General <body & Chassis> - Except Evolution & Sportback — General Information — Oem General Information — Mitsubishi Lancer Evolution VIII (2003-2005)

MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This article 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 models are identified by the model codes, or similar designation (engine type, transaxle type, etc.). A description of these designations is covered in this article under VEHICLE IDENTIFICATION .

ON-VEHICLE SERVICE

On-Vehicle Service has procedures for performing inspections and adjustments of particularly important components. These procedures are done with regard to maintenance and servicing, but other inspections (looseness, play, cracking, damage, etc.) must also be performed.

SERVICE PROCEDURES

The service steps are arranged in numerical order.

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 completed in a shorter time).

DANGER, WARNING, AND CAUTION

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

If a DANGER is not followed, the result is severe bodily harm or even death.
If a WARNING is not followed, the result could be bodily injury.
If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

TIGHTENING TORQUE INDICATION

The tightening torque indicates a median and its tolerance by a unit of N.m (in-lb) or N.m (ft-lb). For fasteners with no assigned torque value, refer to GENERAL SPECIFICATIONS < VEHICLES FOR PUERTO RICO> .

SPECIAL TOOL NOTE

Only MMC special tool part numbers are 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 article for classification of model types

M/T: Manual transaxle, or models equipped with manual transaxle.

A/T: Automatic transaxle, or models equipped with automatic transaxle.

MFI: Multiport fuel injection, or engines equipped with multiport fuel injection.

A/C: Air conditioning.

2.0L Engine: 2.0 liter < 4G94 > engine, or a model equipped with such an engine.

2.4L Engine: 2.4 liter < 4G69> engine, or a model equipped with such an engine.

PCM: Powertrain control module

ECM: Engine control module

SWS: Simplified Wiring System

Scheme 109

Scheme 109: EXPLANATION OF CONTENTS

VERIFY THE COMPLAINT

Make sure the customer's complaint and the service writer's work order description are understood before starting work.
Make sure the correct operation of the system is understood.
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 procedure.

If the confirmed symptoms cannot be found on any symptom index, determine other possible causes.

Analyze the system diagrams and list all possible causes for the problem symptoms.
Rank all these possible causes in order of probability, 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.

FIND THE PROBLEM

After the symptoms have been confirmed, and probable 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 information whenever possible. Follow these procedures carefully to avoid missing an important step in the diagnosis sequence. It might be the skipped step that leads to the solution of the problem.

If the article doesn't have step-by-step procedures 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

general to specific
most-likely to least-likely
easy-to-check to hard-to-check

REPAIR THE PROBLEM

When the step-by-step troubleshooting checks find a fault, perform the proper repairs. Make sure to fix the root cause of the problem, not just the symptom. Just fixing the symptom, without fixing the root cause, will cause the symptom to eventually return.

VERIFY THE REPAIR

After repairs are made, recheck the operation of the system to confirm that the problem is eliminated. Be sure to check the system thoroughly. Sometimes new problems are revealed after repairs have been made.

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Troubleshooting of electronic control systems for which the scan tool can be used follows the basic outline described below. Even in systems for which the scan tool cannot be used, part of these systems still follow this outline.

TROUBLESHOOTING CONTENTS

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Troubleshooting strategy is shown in each group.
SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown.
DIAGNOSTIC FUNCTION The following trouble code diagnosis are shown. How to read diagnostic trouble codes How to erase diagnostic trouble codes Input inspection service points
DIAGNOSTIC TROUBLE CODE CHART If the scan tool displays a diagnostic trouble code, find the applicable inspection procedure according to this chart.
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.
DIAGNOSTIC TROUBLE CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to.)
SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart.
SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this chart as reference information.
CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items, and standard values have been provided in this chart as reference information. Terminal Voltage Checks Connect a needle-nosed wire probe to a voltmeter probe. CAUTION: Short-circuiting the positive (+) probe between a connector terminal and ground could damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this! 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. If voltage readings differ from normal condition values, check related sensors, actuators, and wiring. Replace or repair as needed. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem. Terminal Resistance and Continuity Checks Turn the ignition switch to "LOCK" (OFF) position. Disconnect the ECU connector. CAUTION: If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this! 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. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem.
INSPECTION PROCEDURES USING AN OSCILLOSCOPE

When there are inspection procedures using an oscilloscope, these are listed.

HOW TO USE THE INSPECTION PROCEDURES

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.

Scheme 110

Scheme 110: HOW TO USE THE INSPECTION PROCEDURES

Scheme 111

HARNESS INSPECTION

Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements. Carry out this inspection while referring to HARNESS CONNECTOR INSPECTION . "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 " Inspection Service Points for a Blown Fuse ."

MEASURES TO TAKE AFTER REPLACING THE ECU

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

CONNECTOR MEASUREMENT SERVICE POINTS

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.

Scheme 112

Scheme 112: IF INSPECTING WITH THE CONNECTOR CONNECTED < WATERPROOF CONNECTORS>

IF INSPECTING WITH THE CONNECTOR CONNECTED < ORDINARY (NON-WATERPROOF) CONNECTORS>

Check by inserting the multi-meter test probe from the harness side. Note that if the connector (control unit, etc.) is too small to permit insertion of the test probe, it should not be forced; use the backprobing tool for this purpose.

Scheme 113

Scheme 113: IF INSPECTING WITH THE CONNECTOR CONNECTED < ORDINARY (NON-WATERPROOF) CONNECTORS>

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

Required Special Tool

Scheme 114

Scheme 114: IF INSPECTING WITH THE CONNECTOR DISCONNECTED < WHEN INSPECTING A FEMALE PIN>

MB991219: Inspection Harness (Included in MB991223, Harness Set)
The special tool MB991219 for connector pin contact pressure should be used. The test probe should never be forcibly inserted, as it may cause a defective contact.
From back side of the connector (SRS-ECU harness side connector)
Since the SRS-ECU harness connector is plated to improve conductivity, observe the warning below when checking this connector.

WARNING

Insert the backprobing tool into the connector from the harness side, and connect the tester to the backprobing 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 backprobing tool directly against the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the backprobing tool, the plating may break, which will decrease reliability.

Scheme 115

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

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.

Scheme 116

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

Scheme 117

CONNECTOR PIN INSPECTION

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even when the connector body is connected, because the pins may pull out of the back side of the connector. Therefore, gently pull the wires one by one to make sure that no pins pull out of the connector.

Scheme 118

Scheme 118: CONNECTOR PIN INSPECTION

CONNECTOR ENGAGEMENT INSPECTION

Required Special Tool

MB991219: Inspection Harness (contained in MB991223 Test Harness)

Use special tool, MB991219 to inspect the engagement of the male pins and female pins. [Pin drawing force: 1 N (0.2 pound) or more]

Scheme 119

Scheme 119: CONNECTOR ENGAGEMENT INSPECTION

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

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

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.
Determine the conditions from the customer's responses Typically, almost all intermittent malfunctions occur from conditions like vibration, temperature and/or moisture change, poor connections. From the customer's responses, it should be reasoned which condition is most likely.
Use simulation test Use the simulation tests below to attempt to duplicate the customer's complaint. Determine the most likely circuit(s) and perform 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 circuit components, then use the simulation tests below.
Verify the intermittent malfunction is eliminated Repair the malfunctioning part and try to duplicate the condition(s) again to verify the intermittent malfunction has been eliminated.

SIMULATION TESTS

Note. In case of difficulty in finding the cause of the intermittent 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 intermittent malfunction.

Shake the connector up-and-down, and right-and-left.
Shake the wiring harness up-and-down, and right-and-left. Especially, check the splice points of wiring harnesses carefully. Refer to «SPLICES»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/electrical-component-locations/#electrical-component-locator-except-evolution__splices) .
Shake the part or sensor.

Scheme 120

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

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 ohm at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 ohm, there is no short at the present time, but a momentary short has probably caused the fuse to blow.

The main causes of a short circuit are the following.

Harness being clamped by the vehicle body
Damage to the outer casing of the harness due to wear or heat
Water getting into the connector or circuitry
Human error (mistakenly shorting a circuit, etc.)

Scheme 121

VEHICLES IDENTIFICATION NUMBER LOCATION

The vehicle identification number (VIN) is located on a plate attached to the left top side of the instrument panel.

Scheme 122

Scheme 122: VEHICLES IDENTIFICATION NUMBER LOCATION

VEHICLE IDENTIFICATION CODE CHART PLATE

All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.

NO.	ITEM	CONTENT
1	Country	J: Japan
2	Make	A: Mitsubishi
3	Vehicle type	3: Passenger car
4	Others	A: Driver and passenger air bags
5	Line	J: LANCER
6	Price class	1: Economy
		2: Low
		3: Medium
		6: Special
		8: Sports
7	Body	6: 4-door sedan
8	Engine	E: 2.0L
8	Engine	F: 2.4L
9	Check digits*	0, 1, 2, 3,---9, X
10	Model year	4: 2004 year
11	Plant	U: Mizushima
12	Serial number	000001 to 999999

VEHICLE IDENTIFICATION CODE CHART

Note. *: Check digit means a single number, or letter X, used to verify the accuracy of transcription of vehicle identification number.

Scheme 123

VEHICLES FOR USA

VIN (EXCEPT SEQUENCE NUMBER)	BRAND	ENGINE DISPLACEMENT	MODEL CODE
JA3AJ26E_4U	MITSUBISHI LANCER	2.0L	CS6ASNMEL2M
JA3AJ26E_4U			CS6ASRMEL2M
JA3AJ36E_4U			CS6ASRDEL2M
JA3AJ86E_4U			CS6ASNHEL2M
JA3AJ86E_4U			CS6ASRHEL2M
JA3AJ66F_4U	MITSUBISHI LANCER	2.4L	CS7ASNPYL2M
JA3AJ66F_4U	MITSUBISHI LANCER	2.4L	CS7ASRPYL2M

VEHICLE IDENTIFICATION NUMBER LIST - VEHICLES FOR USA

VEHICLES FOR CANADA

VIN (EXCEPT SEQUENCE NUMBER)	BRAND	ENGINE DISPLACEMENT	MODEL CODE
JA3AJ16E_4U	MITSUBISHI LANCER	2.0L	CS6ASNSEL3M
JA3AJ16E_4U			CS6ASRSEL3M
JA3AJ26E_4U			CS6ASNMEL3M
JA3AJ26E_4U			CS6ASRMEL3M
JA3AJ36E_4U			CS6ASRDEL3M
JA3AJ86E_4U			CS6ASNHEL3M
JA3AJ86E_4U			CS6ASRHEL3M
JA3AJ66F_4U	MITSUBISHI LANCER	2.4L	CS7ASNPYL3M
JA3AJ66F_4U	MITSUBISHI LANCER	2.4L	CS7ASRPYL3M

VEHICLE IDENTIFICATION NUMBER LIST - VEHICLES FOR CANADA

VEHICLES FOR PUERTO RICO

VIN (EXCEPT SEQUENCE NUMBER)	BRAND	ENGINE DISPLACEMENT	MODEL CODE
JA3AJ16E_4U	MITSUBISHI LANCER	2.0L	CS6ASRSEL2M

VEHICLE IDENTIFICATION NUMBER LIST - VEHICLES FOR PUERTO RICO

VEHICLE IDENTIFICATION CODE PLATE

The vehicle information code plate is riveted onto the cowl top outer panel in the engine compartment.

The plate shows model code, engine model, transaxle model and body color code.

NO.	ITEM	CONTENT
1	MODEL	CS6ASRSE L2M	CS6AS: Vehicle model
1	MODEL	CS6ASRSE L2M	RSEL2M: Model series
2	ENGINE	4G94	4G94: Engine model
2	ENGINE	4G69	4G69: Engine model
3	EXT	ZZZ	Exterior code
4	TRANS AXLE	F5M42	F5M42:Transaxle model
4	TRANS AXLE	F4A4B	F4A4B:Transaxle model
5	COLOR	W83	W83: Body color code
6	INT	62E	62E: Interior code
7	OPT	ZT7	ZT7: Equipment code

VEHICLE IDENTIFICATION CODE

Scheme 124

For monotone color vehicles, the body color code shall be indicated.

VEHICLE SAFETY CERTIFICATION LABEL

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).

Scheme 125

Scheme 125: VEHICLE SAFETY CERTIFICATION LABEL

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.

These engine model numbers are as shown as follows.

ENGINE MODEL	ENGINE DISPLACEMENT
4G94	2.0L
4G69	2.4L

ENGINE MODEL

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

Scheme 126

THEFT PROTECTION

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 and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Doors, Trunk lid, Quarter panel, Hood, Bumpers

In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data is stamped into replacement parts for the engine and the transaxle.

CAUTION

Cautions regarding panel repairs

When repainting original parts, do so after first masking the theft-protection label. After painting, be sure to peel off the masking tape.
The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as 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.

Scheme 127

Scheme 128

Scheme 128: LOCATIONS

Scheme 129

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Items to review when servicing SRS Be sure to read «AIR BAG RESTRAINT SYSTEMS - EXCEPT SPORTBACK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) Supplemental Restraint System (SRS). For safe operation, please follow the directions and heed all warnings. 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. Warning labels must be heeded when servicing or handling SRS components. Warning labels can be found in the following locations. Sun visor Glove box Center pillar SRS-ECU Steering wheel Clock spring Joint cover Air bag module (Driver's or front passenger's) Side-airbag module (Driver's side or front passenger's side) Side impact sensor Seat belt pre-tensioner Always use the designated special tools and test equipment. Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module, side impact sensor, clock spring and seat belt pre-tensioner). If there is a defect, replace the defective part. Whenever you finish servicing the SRS, check the SRS warning light operation to make sure that the system functions properly. 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 «DISPOSAL PROCEDURES»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-sportback__disposal-procedures) .)
Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag. When removing or installing parts, do not allow any impact or shock to occur to the SRS components. If heat damage may occur during paint work, remove the SRS components. After re-installing them, check the SRS warning light operation to make sure that the system functions properly. SRS-ECU, air bag module, clock spring, side impact sensor: 93°C (200°F) or more Seat belt pre-tensioner: 90°C (194°F) or more

SERVICING ELECTRICAL SYSTEM

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

Scheme 130

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. CAUTION: Before connecting or disconnecting the negative battery cable, be sure to turn the ignition switch to the "LOCK" (OFF) position and turn off the lights. (If this is not done, there is the possibility of semiconductor parts being damaged.) After completion of the work (and the negative battery terminals is connected), warm up the engine and allow it to idle for approximately 10 minutes under the conditions described below in order to stabilize engine control conditions, and then check to be sure that the idle is satisfactory.
When servicing the electrical system, disconnect the negative cable terminal from the battery. Engine coolant temperature: 85 - 95°C (185 - 203°F) Lights and all accessories: OFF Transaxle: "N" or "P" position Steering wheel: straight-forward position

VEHICLE WASHING

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to maintain the spray nozzle at a distance of at least approximately 40 cm (16 inches) from any plastic parts and all opening parts (doors, luggage compartment, etc.).

Scheme 131

Scheme 131: VEHICLE WASHING

APPLYING ANTI-CORROSION AGENT OR OTHER UNDERCOAT AGENTS

Do not to apply oil or grease to the heated oxygen sensor. If applied, the sensor may malfunction. Protect the heated oxygen sensor with a cover before applying anti-corrosion agent, etc.

SCAN TOOL (MUT-III Sub Assembly)

CAUTION

Turn the ignition switch to the "LOCK" (OFF) position before disconnecting or connecting the scan tool.

Note. MB991826 MUT-III Trigger Harness is not necessary when pushing V.C.I. ENTER key.

Scheme 132

FRONT TOWING PICKUP

CAUTION

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

The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible.

Scheme 133

REAR TOWING PICKUP

CAUTION

This vehicle cannot be towed by a wrecker using sling-type equipment; otherwise the lower arm may become deformed. If this vehicle is towed, use a wheel lift or flat bed equipment. Do not use the steering column lock to secure the front wheels for towing. Make sure the transaxle is in Neutral if vehicle will have drive wheels on the ground. If these requirements cannot be met, the front wheels must be placed on a tow dolly.

Automatic transmission vehicle may be towed on the front wheels at speeds not to exceed 50 km/h (30 mph) for distances not to exceed 30 km (18 miles).

TOWING WHEN KEYS ARE NOT AVAILABLE

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

Scheme 134

SAFETY PRECAUTIONS

The following precautions should be taken when towing the vehicle

DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER.
Any loose, protruding, or damaged parts such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle.
Refrain from going under a vehicle when it is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands.
Never allow passengers to ride in a towed vehicle.
State and local rules and regulations must be followed when towing a vehicle.

FLOOR JACK

CAUTION

Never support any point other than the specified one, or that point will be deformed. For lifting, put rubber or similar material between the side sill and rigid rack, or the side sill area will be damaged.

Scheme 135

POST TYPE

Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations.

CAUTION

When service procedures require removing rear suspension, fuel tank and spare tire, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping when the location of the center of gravity changes.

Scheme 136

Scheme 137

Scheme 137: GENERAL DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS < VEHICLES FOR USA>

ITEM			CS6A
ITEM			SNMEL2M	SRMEL2M	SRDEL2M	SNHEL2M
Vehicle dimension mm (in)	Overall length	1	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)
	Overall width	2	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)
	Overall height (unladen)	3	1,430 (56.3)	1,430 (56.3)	1,450 (57.1)	1,450 (57.1)
	Wheelbase	4	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)
	Tread-front	5	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Tread-rear	6	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Overhang-front	7	955 (37.6)	955 (37.6)	955 (37.6)	955 (37.6)
	Overhang-rear	8	1,030 (40.6)	1,030 (40.6)	1,030(40.6)	1,030 (40.6)
	Minimum running ground clearance	9	150 (5.9)	150 (5.9)	165 (6.5)	165 (6.5)
Vehicle weight kg (lb)	Curb Weight		1,205 (2,656)	1,225 (2,700)	1,268 (2,795)	1,225 (2,700)
	Gross vehicle weight rating		1,670 (3,681)	1,670 (3,681)	1,670 (3,681)	1,670 (3,681)
	Gross axle weight rating-front		920 (2,028)	920 (2,028)	920 (2,028)	920 (2,028)
	Gross axle weight rating-rear		780 (1,719)	780 (1,719)	780(1,719)	780 (1,719)
Seating capacity			5
Engine	Model No.		4G94
Engine	Displacement		2.0L
Transaxle	Model No.		F5M42	F4A4B		F5M42
Transaxle	Type		5-speed manual	4-speed automatic		5-speed manual
Fuef system	Fuel supply system		Electronic controlled multiport fuel injection

GENERAL SPECIFICATIONS - VEHICLES FOR USA

ITEM			CS6A	CS7A
ITEM			SRHEL2M	SNPYL2M	SRPYL2M
Vehicle dimension mm (in)	Overall length	1	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)
	Overall width	2	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)
	Overall height (unladen)	3	1,450 (57.1)	1,420 (55.9)	1,420 (55.9)
	Wheelbase	4	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)
	Tread-front	5	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Tread-rear	6	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Overhang-front	7	955 (37.6)	955 (37.6)	955 (37.6)
	Overhang-rear	8	1,030 (40.6)	1,030 (40.6)	1,030 (40.6)
	Minimum running ground clearance	9	165 (6.5)	140 (5.5)	140 (5.5)
Vehicle weight kg (lb)	Curb weight		1,245 (2,744)	1,290 (2,843)	1,310 (2,888)
	Gross vehicle weight rating		1,670 (3,681)	1,780 (3,924)	1,780 (3,924)
	Gross axle weight rating-front		920 (2,028)	960 (2,116)	960 (2,116)
	Gross axle weight rating-rear		780 (1,719)	840 (1,851)	840 (1,851)
Seating capacity			5
Engine	Model No.		4G94	4G69
Engine	Displacement		2.0L	2.4L
Transaxle	Model No.	F4A4B	F5M42	F4A4B
Transaxle	Type		4-speed automatic	5-speed manual	4-speed automatic
Fuel system	Fuel supply system		Electronic controlled multiport fuel injection

GENERAL SPECIFICATIONS - VEHICLES FOR USA

GENERAL SPECIFICATIONS < VEHICLES FOR CANADA>

ITEM			CS6A
ITEM			SNSEL3M	SRSEL3M	SNMEL3M	SRMEL3M	SRDEL3M
Vehicle dimension mm (in)	Overall length	1	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)
	Overall width	2	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)
	Overall height (unladen)	3	1,430 (56.3)	1,430 (56.3)	1,430 (56.3)	1,430 (56.3)	1,430 (56.3)
	Wheelbase	4	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)
	Tread-front	5	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Tread-rear	6	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Overhang-front	7	955 (37.6)	955 (37.6)	955 (37.6)	955 (37.6)	955 (37.6)
	Overhang-rear	8	1,030 (40.6)	1,030 (40.6)	1,030 (40.6)	1,030 (40.6)	1,030 (40.6)
	Minimum running ground clearance	9	150 (5.9)	150 (5.9)	150 (5.9)	150(5.9)	150 (5.9)
Vehicle weight kg (lb)	Curb weight		1,180 (2,604)	1,200 (2,716)	1,205 (2,656)	1,225 (2,700)	1,270 (2,799)
	Gross vehicle weight rating		1,670 (3,681)	1,670 (3,681)	1,670 (3,681)	1,670 (3,681)	1,670 (3,681)
	Gross axle weight rating-front		920 (2,028)	920 (2,028)	920 (2,028)	920 (2,028)	920 (2,028)
	Gross axle weight rating-rear		780 (1,719)	780 (1,719)	780 (1,719)	780 (1,719)	780 (1,719)
Seating capacity			5
Engine	Model No.		4G94
Engine	Displacement		2.0L
Transaxle	Model No.		F5M42	F4A4B	F5M42	F4A4B
Transaxle	Type		5-speed manual	4-speed automatic	5-speed manual	4-speed automatic
Fuel system	Fuel supply system		Electronic controlled multiport fuel injection

GENERAL SPECIFICATIONS - VEHICLES FOR CANADA

ITEM			CS6A		CS7A
ITEM			SNHEL3M	SRHEL3M	SNPYL3M	SRPYL3M
Vehicle dimension mm (in)	Overall length	1	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)	4,585 (180.5)
	Overall width	2	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)	1,695 (66.7)
	Overall height (unladen)	3	1,450 (57.1)	1,450 (57.1)	1,420 (55.9)	1,420 (55.9)
	Wheelbase	4	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)	2,600 (102.4)
	Tread-front	5	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Tread-rear	6	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)	1,470 (57.9)
	Overhang-front	7	955 (37.6)	955 (37.6)	955 (37.6)	955 (37.6)
	Overhang-rear	8	1,030 (40.6)	1,030 (40.6)	1,030 (40.6)	1,030 (40.6)
	Minimum running ground clearance	9	165 (6.5)	165.(6.5)	140 (5.5)	140 (5.5)
Vehicle weight kg (lb)	Curb weight		1,225 (2,700)	1,245 (2,744)	1,290 (2,843)	1,310 (2,888)
	Gross vehicle weight rating		1,670 (3,681)	1,670 (3,681)	1,780 (3,924)	1,780 (3,924)
	Gross axle weight rating-front		920 (2,028)	920 (2,028)	960 (2,116)	960 (2,116)
	Gross axle weight rating-rear		780 (1,720)	780 (1,719)	840 (1,851)	840 (1,851)
Seating capacity			5
Engine	Model No.	4G94			4G69
Engine	Displacement		2.0L		2.4L
Transaxle	Model No.		F5M42	F4A4B	F5M42	F4A4B
Transaxle	Type		5-speed manual	4-speed automatic	5-speed manual	4-speed automatic
Fuel system	Fuel supply system		Electronic controlled multiport fuel injection

GENERAL SPECIFICATIONS - VEHICLES FOR CANADA

GENERAL SPECIFICATIONS < VEHICLES FOR PUERTO RICO>

ITEM			CS6A
ITEM			SNSEL3M
Vehicle dimension mm (in)	Overall length	1	4,585 (180.5)
	Overall width	2	1,695 (66.7)
	Overall height (unladen)	3	1,430 (56.3)
	Wheelbase	4	2,600 (102.4)
	Tread-front	5	1,470 (57.9)
	Tread-rear	6	1,470 (57.9)
	Overhang-front	7	955 (37.6)
	Overhang-rear	8	1,030 (40.6)
	Minimum running ground clearance	9	150 (5.9)
Vehicle weight kg (lb)	Curb weight		1,215 (2,678)
	Gross vehicle weight rating		1,670 (3,681)
	Gross axle weight rating-front		920 (2,028)
	Gross axle weight rating-rear		780 (1,720)
Seating capacity			5
Engine	Model No.		4G94
Engine	Displacement		2.0L
Transaxle	Model No.		F4A4B
Transaxle	Type		4-speed automatic
Fuel system	Fuel supply system		Electronic controlled multiport fuel injection

GENERAL SPECIFICATIONS - VEHICLES FOR PUERTO RICO

TIGHTENING TORQUE

Each torque value in the table is a standard value for tightening under the following conditions.

Bolts, nuts and washers are all made of steel and plated with zinc.
The threads and bearing surface of bolts and nuts are all in dry condition.

The values in the table are not applicable

If toothed washers are inserted.
If plastic parts are fastened.
If bolts are tightened to plastic or die-cast inserted nuts.
If self-tapping screws or self-locking nuts are used

STANDARD BOLT AND NUT TIGHTENING TORQUE

THREAD SIZE		STANDARD TIGHTENING TORQUE
NOMINAL BOLT DIAMETER (mm)	PITCH (mm)	HEAD MARK "4"	HEAD MARK "7"	HEAD MARK "8"
M5	0.8	2.5 +/- 0.5 N.m (23 +/- 4 in-lb)	5.0 +/- 1.0 N.m (44 +/- 9 in-lb)	6.0 +/- 1.0 N.m (53 +/- 9 in-lb)
M6	1.0	5.0 +/- 1.0 N.m (44 +/- 9 in-lb)	9.0 +/- 2.0 N.m (79 +/- 18 in-lb)	10 +/- 2 N.m (89 +/- 17 in-lb)
M8	1.25	12 +/- 2 N.m (107 +/- 17 in-lb)	22 +/- 4 N.m (16 +/- 3 ft-lb)	25 +/- 4 N.m (18 +/- 3 ft-lb)
M10	1.25	24 +/- 4 N.m (18 +/- 3 ft-lb)	44 +/- 10 N.m (33 +/- 7 ft-lb)	53 +/- 7 N.m (39 +/- 5 ft-lb)
M12	1.25	41 +/- 8 N.m (30 +/- 6 ft-lb)	83 +/- 12 N.m (61 +/- 9 ft-lb)	98 +/- 12 N.m (72 +/- 9 ft-lb)
M14	1.5	73 +/- 12 N.m (54 +/- 9 ft-lb)	140 +/- 20 N.m (104 +/- 14 ft-lb)	155 +/- 25 N.m (115 +/- 18 ft-lb)
M16	1.5	110 +/- 20 N.m (81 +/- 15 ft-lb)	210 +/- 30 N.m (155 +/- 22 ft-lb)	235 +/- 35 N.m (174 +/- 25 ft-lb)
M18	1.5	165 +/- 125 N.m (122 +/- 18 ft-lb)	300 +/- 40 N.m (222 +/- 29 ft-lb)	340 +/- 50 N.m (251 +/- 37 ft-lb)
M20	1.5	225 +/- 35 N.m (166 +/- 26 ft-lb)	410 +/- 60 N.m (303 +/- 44 ft-lb)	480 +/- 70 N.m (354 +/- 52 ft-lb)
M22	1.5	300 +/- 40 N.m (222 +/- 29 ft-lb)	555 +/- 85 N.m (410 +/- 62 ft-lb)	645 +/- 95 N.m (476 +/- 70 ft-lb)
M24	1.5	395 +/- 55 N.m (292 +/- 40 ft-lb)	735 +/- 105 N.m (543 +/- 77 ft-lb)	855 +/- 125 N.m (631 +/- 92 ft-lb)

STANDARD BOLT AND NUT TIGHTENING TORQUE

FLANGE BOLT AND NUT TIGHTENING TORQUE

THREAD SIZE		STANDARD TIGHTENING TORQUE
NOMINAL BOLT DIAMETER (mm)	PITCH (mm)	HEAD MARK "4"	HEAD MARK "7"	HEAD MARK "8"
M6	1.0	5.0 +/- 1.0 N.m (44 +/- 9 in-ib)	10 +/- 2 N.m (89 +/- 17 in-lb)	12 +/- 2 N.m (107 +/- 17 in-lb)
M8	1.25	13 +/- 2 N-m (111 +/- 22 in-lb)	24 +/- 4 N.m (18 +/- 3 ft-lb)	27 +/- 5 N.m (20 +/- 4 ft-lb)
M10	1.25	26 +/- 4 N.m (19 +/- 3 ft-lb)	49 +/- 9 N.m (36 +/- 7 ft-lb)	58 +/- 7 N.m (43 +/- 5 ft-lb)
M10	1.5	24 +/- 4 N.m (18 +/- 3 ft-lb)	45 +/- 8 N.m (33 +/- 6 ft-lb)	55 +/- 10 N.m (41 +/- 7 ft-lb)
M12	1.25	46 +/- 8 N.m (34 +/- 6 ft-lb)	95 +/- 15 N.m (70 +/- 11 ft-lb)	105 +/- 15 N.m (78 +/- 11 ft-lb)
M12	1.75	43 +/- 8 N.m (32 +/- 6 ft-lb)	83 +/- 12 N.m (61 +/- 9 ft-lb)	98 +/- 12 N.m (72 +/- 9 ft-lb)

FLANGE BOLT AND NUT TIGHTENING TORQUE

LUBRICATION AND MAINTENANCE

Maintenance and lubrication service recommendations have been compiled to provide maximum protection 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 operated and the type of driving to which the vehicle is subjected, it is necessary to prescribe lubrication and maintenance service on a time frequency as well as mileage interval basis.

Oils, lubricants and greases are classified and graded according to standards recommended by the Society of Automotive Engineers (SAE), the American Petroleum Institute (API) and the National Lubricating Grease Institute (NLGI).

MAINTENANCE SCHEDULES

Information for service maintenance is provided in SCHEDULED MAINTENANCE TABLE . Three schedules are provided; one for "Required Maintenance." one for "General Maintenance" and one for "Severe Usage Service."

The item numbers in "SCHEDULED MAINTENANCE TABLE" correspond to the numbers in " MAINTENANCE SERVICE ."

SEVERE SERVICE

Vehicles operating under severe service conditions will require more frequent service.

Component service information is included for vehicles operating under one or more of the following conditions

Trailer towing or police, taxi or commercial type operation.
Operation of Vehicle Short-trip operation at freezing temperature (engine not thoroughly warmed up) More than 50% operation in heavy city traffic during hot weather above 32°C (90°F) Extensive idling Driving in sandy areas Driving in salty areas Driving in dusty conditions Driving off-road

ENGINE OIL

CAUTION

Test results submitted to EPA have shown that laboratory animals develop skin cancer after prolonged contact with used engine oil. Accordingly, the potential exists for humans to develop a number of skin disorders, including cancer, from such exposure to used engine oil. Therefore, when changing engine oil, be careful not to touch it as much as possible. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. The skin should be thoroughly washed with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.

Either oil the following engine oils should be used

Engine oil displaying ILSAC certification mark.
Engine oil conforming to the API classification SJ EC or SJ/CD EC.

For further details, refer to " RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE ."

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, Multipurpose Grease, NLGI grade Number 2, should be used.

FUEL USAGE STATEMENT

CAUTION

Using leaded gasoline in this car will damage the catalytic converters and heated oxygen sensors, 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.

The 2.0L model is designed to operate on unleaded gasoline having a minimum octane rating of 87 [(MON + RON)/2], or 91 RON.

Note. MON: Motor Octane Number RON: Research Octane Number

GASOLINE CONTAINING ALCOHOL

Some gasoline sold at service stations contain alcohol although they may not be so identified.

Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory.

Gasohol: A mixture of 10% ethanol (grain alcohol) and 90% 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 methanol (wood alcohol). Using this type of alcohol can result in vehicle performance deterioration and damage 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 15% or less MTBE may be used in your vehicle. (Fuel containing MTBE over 15% in volume may cause reduced engine performance 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

LUBRICANT	SPECIFICATION	REMARK
Engine oil	Engine oil displaying ILSAC certification mark ("Starburst" symbol) conforming to API classification SL or SL/CF	For further details, refer to " RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE ."
Manual transaxle	API classification GL-4	SAE grade number: SAE75W-90 or 75W/85W
Automatic transaxle	MITSUBISHI genuine ATF SP III
Power steering fluid	GENUINE MITSUBISHI POWER STEERING FLUID
Brakes	Conforming to DOT 3 or DOT 4
Engine coolant	Long Life Antifreeze Coolant or an equivalent
Door hinges, back door hinges	Engine oil

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES

LUBRICANT CAPACITY TABLE

DESCRIPTION			SPECIFICATION
Engine oil dm 3 (qt)	Oil pan (excluding oil filter)	2.0L Engine	3.5 (3.7)
	Oil pan (excluding oil filter)	2.4L Engine	4.0 (4.2)
	Oil filter		0.3 (0.32)
Engine coolant dm 3 (qt)		2.0L Engine	6.0 (6.3)
Engine coolant dm 3 (qt)		2.4L Engine	7.0 (7.4)
Manual transaxle dm 3 (qt)			2.2 (2.3)
Automatic transaxle dm 3 (qt)			7.7 (8.1)
Power steering dm 3 (qt)			1.2 (1.3)
Fuel tank dm 3 (gal)			50 (13.2)

LUBRICANT CAPACITY

CAUTION

CAUTION Never use nondetergent or straight mineral oil. Oil Identification Symbol

Use only engine oils displaying the ILSAC certification mark ("Starburst" symbol) on the container.

Scheme 138

If these oils are not available, an API classification SL or SL/CF can be used.

Scheme 139

Oil Viscosity

The SAE grade number indicates the viscosity of the oil. A proper SAE grade number should be selected according to ambient temperature.

Scheme 140

Scheme 140: Oil Viscosity

COOLANT

Relationship between Coolant Concentration and Specific Gravity

CAUTION

If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 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. Do not use a mixture of different brands of anti-freeze.

COOLANT TEMPERATURE °C (°F) AND SPECIFIC GRAVITY					FREEZING TEMPERATURE	SAFE OPERATING TEMPERATURE	COOLANT CONCENTRATION (SPECIFIC VOLUME)
10 (50)	20 (68)	30 (86)	40 (104)	50 (122)	°C (°F)	°C (°F)	%
1.054	1.050	1.046	1.042	1.036	16 (3.2)	11 (12.2)	30
1.063	1.058	1.054	1.049	1.044	20 (-4)	15 (5)	35
1.071	1.067	1.062	1.057	1.052	25 (-13)	20 (-4)	40
1.079	1.074	1.069	1.064	1.058	30 (-22)	25 (-13)	45
1.087	1.082	1.076	1.070	1.064	36 (-32.8)	31 (-23.8)	50
1.095	1.090	1.084	1.077	1.070	42 (-44)	37 (-35)	55
1.103	1.098	1.092	1.084	1.076	50 (-58)	45 (-49)	60

COOLANT TEMPERATURE SPECIFICATION

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)

SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE

Inspection and service should be performed any time a malfunction is observed or suspected.

NO.	EMISSION CONTROL SYSTEM MAINTENANCE	SERVICE INTERVALS	KILOMETERS IN THOUSANDS	24	48	72	96	120	144	168
NO.	EMISSION CONTROL SYSTEM MAINTENANCE	SERVICE INTERVALS	MILEAGE IN THOUSANDS	15	30	45	60	75	90	105
1	Fuel system (tank, pipe line and connection, and fuel tank filler tube cap)	Check for leaks every 5 years or					X
2	Fuel hoses	Check condition every 2 years or			X		X		X
3	Air cleaner element	Replace at			X		X		X
4	Evaporative emission control system (except evaporative emission canister)	Check for leaks and clogging every 5 years or					X
5	Spark plugs	Replace at								X
6	Intake and exhaust valve clearance	Inspect and adjust If valve noise increases, adjust valve clearance			X		X		X
7	Ignition cables	Replace every 5 years or					X

SCHEDULED MAINTENANCE

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

NO.	GENERAL MAINTENANCE	SERVICE INTERVALS	KILOMETERS IN THOUSANDS	24	48	72	96	120	144	168
NO.	GENERAL MAINTENANCE	SERVICE INTERVALS	MILEAGE IN THOUSANDS	15	30	45	60	75	90	105
8	Timing belt	Replace at					X (1) .		At 160,000 km (2) (100,000 miles)
9	Drive belt (for generator, water pump, power steering oil pump and A/C compressor)	Check condition at			X		X		X
10	Engine oil	Change oil every 12 months or		Every 12,000 km (7,500 miles)
11	Engine oil filter	Replace every 12 months or (3)		X	X	X	X	X	X	X
12	Manual transaxle oil	Check oil level every 24 months or			X		X		X
(1) 1: For California, Massachusetts, Vermont and Maine, this maintenance is recommended but not required. (2) 2: Not required if belt was previously changed. (3) *3: If the mileage is less than 12,000 km (7,500 miles) each year, the oil filter should be replaced at every oil change.

(1)	*1: For California, Massachusetts, Vermont and Maine, this maintenance is recommended but not required.

(2)	*2: Not required if belt was previously changed.

(3)	*3: If the mileage is less than 12,000 km (7,500 miles) each year, the oil filter should be replaced at every oil change.

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

NO.	GENERAL MAINTENANCE	SERVICE INTERVALS	KILOMETERS IN THOUSANDS	24	48	72	96	120	144	168
NO.	GENERAL MAINTENANCE	SERVICE INTERVALS	MILEAGE IN THOUSANDS	15	30	45	60	75	90	105
13	Automatic transaxle fluid (1)	Check A/T fluid level every 12 months or		X	X	X	X	X	X	X
14	Engine coolant	Change	At first 4 years or				X
14	Engine coolant	Change	After that every 2 years or				Every 48,000 km (30,000 miles)		X
15	Disc brake pads	Inspect for wear every 12 months or		X	X	X	X	X	X
16	Rear drum brake linings and rear wheel cylinders	Inspect for wear and leaks every 2 years or			X		X		X
17	Brake hoses	Check for deterioration or leaks every 12 months or		X	X	X	X	X	X	X
18	Ball joint and steering linkage seals	Inspect for grease leaks and damage every 2 years or			X		X		X
19	Drive shaft boots	Inspect for grease leaks and damage every 12 months or		X	X	X	X	X	X	X
20	SRS air bag	Inspect the SRS system at		10 years
21	Exhaust system (connections, pipes and converter heat shields)	Check and service as required every 2 years or			X		X		X
22	Tires	Rotate every 12 months or		Every 12,000 km (7,500 miles)
(1) *4: Change fluid under severe usage conditions only.

(1)	*4: Change fluid under severe usage conditions only.

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS

Maintenance should be carried out according to the following table

NO.	MAINTENANCE ITEM	SERVICE INTERVALS	KILOMETERS IN THOUSANDS	24	48	72	96	120	144	168	SEVERE USAGE CONDITIONS
NO.	MAINTENANCE ITEM	SERVICE INTERVALS	MILEAGE IN THOUSANDS	15	30	45	60	75	90	105	SEVERE USAGE CONDITIONS
3	Air cleaner element	Replace at		X	X	X	X	X	X	X	A and E
5	Spark plugs	Replace at		X	X	X	X	X	X	X	B and D
10	Engine oil	Change every 3 months or		Every 4,800 km (3,000 miles)							A, B, C, D and G
11	Engine oil filter	Replace every 6 months or		Every 9,600 km (6,000 miles)							A, B, C, D and G
12	Manual transaxle oil	Change oil at			X		X		X		B, G and H
13	Automatic transaxle fluid	Change A/T fluid at			X		X		X		B, G and H
15	Disc brake pads	Inspect for wear every 6 months or		Every 9,600 km (6,000 miles)							A and F
16	Rear drum brake linings and rear wheel cylinders	Inspect for wear every 12 months or		Every 2,400 km (15,000 miles)							A and F
22	Tires	Rotate every 6 months or		Every 9,600 km (6,000 miles)							B, C, E, G and H

SCHEDULED MAINTENANCE SPECIFICATION

Severe usage conditions

A: Driving in dusty conditions

B: Trailer towing, or police, taxi, or commercial type operation

C: Extensive idling, driving in stop and go traffic

D: Short-trip operation at freezing temperatures (engine not thoroughly warmed up)

E: Driving in sandy areas

F: Driving in salty areas

G: More than 50% operation in heavy city traffic or at sustained high speeds during hot weather above 32°C (90°F)

H: Driving off-road

1. FUEL SYSTEM (TANK, PIPE LINE AND CONNECTION, AND FUEL TANK FILLER TUBE CAP) (CHECK FOR LEAKS)

Check for damage or leakage in the fuel lines and connections.

2. FUEL HOSES (CHECK CONDITION)

Inspect the surface of fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.
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)

The air cleaner element will become dirty during use, reducing its effectiveness. Replace it with a new one.

REPLACEMENT OF AIR CLEANER ELEMENT

Unclamp the air cleaner cover.
Remove the air cleaner element and install a new one.
When clamping the air cleaner cover in place, be sure that the cover is completed closed.

Scheme 141

4. EVAPORATIVE EMISSION CONTROL SYSTEM (EXCEPT EVAPORATIVE EMISSION CANISTER) (CHECK FOR CLOGGING)

If the fuel-vapor vent line is clogged or damaged, fuel vapor will escape into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean with compressed 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.

5. SPARK PLUGS (REPLACE)

CAUTION

Iridium plugs are used on 2.4L engine. Use care not to damage the iridium tips of the iridium plugs. Do not attempt to adjust the gap on these plugs.

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 SPARK PLUG SPECIFICATION MAKER 2.0L ENGINE 2.4L ENGINE NGK BKR5E-11 LZFR6AI DENSO K16PR-U11 - CHAMPION RC10YC4
The new plugs should be checked for the proper gap. Spark plug gap: < 2.0L Engine >1.0 - 1.1 mm (0.039 - 0.043 inch) < 2.4L Engine >0.7 - 0.8 mm (0.028 - 0.031 inch)
Install the spark plugs and tighten to 25 +/- 4 N m (18 +/- 3 ft-lb)

Scheme 142

Scheme 143

Scheme 143: 6. INTAKE AND EXHAUST VALVE CLEARANCE (INSPECT AND ADJUST)

Before checks, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: Engine coolant temperature: 80 - 95°C (176- 203°F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T) NOTE: Vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks and adjustment.
Remove all of the ignition coils.
Remove the rocker cover.
Turn the crankshaft clockwise until the notch on the pulley is lined up with "T" mark on the timing indicator.
Move the rocker arms on the No.1 and No.4 cylinders up and down by hand to determine which cylinder has its piston at the top dead center on the compression stroke. If both intake and exhaust valve rocker arms have a valve lash, the piston in the cylinder corresponding to these rocker arms is at the top dead center on the compression stroke.
Valve clearance inspection and adjustment can be performed on rocker arms indicated by white arrow mark when the No.1 cylinder piston is at the top dead center on the compression stroke, and on rocker arms indicated by black arrow mark when the No.4 cylinder piston is at the top dead center on the compression stroke.
Measure the valve clearance. If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance using a thickness gauge while turning the adjusting screw. Standard value (hot engine): Intake valve: 0.20 mm (0.008 inch) Exhaust valve: 0.30 mm (0.012 inch)
While holding the adjusting screw with a screwdriver to prevent it from turning, tighten the lock nut to the specified torque. Tightening torque: 9 +/- 1 N m (80 +/- 9 in-lb)
Turn the crankshaft through 360 degree angle to line up the notch on the crankshaft pulley with the "T" mark on the timing indicator.
Repeat steps 7 and 8 on other valves for clearance adjustment.
Install the rocker cover.
Install the ignition coils.

< 2.0L ENGINE >

CAUTION

When disconnecting an ignition cable, be sure to hold the cable boot. If the cable is disconnected by pulling on the cable alone, you might break the cable.

The ignition cables should be replaced periodically with new ones. After replacing, make sure that the ignition cables are routed properly and fully seated.

Scheme 144

8. TIMING BELT (REPLACE)

Replace the belt with a new one according to the maintenance schedule on SCHEDULED MAINTENANCE TABLE to assure proper engine performance.

For removal and installation procedures, refer to REMOVAL AND INSTALLATION .

< 2.4L ENGINE >

For removal and installation procedures, refer to REMOVAL AND INSTALLATION .

< WHEN USING SCAN TOOL MB991958>

Required Special Tools

MB991668: Belt Tension Meter Set
MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991911: MUT-III Main Harness B

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.

Scheme 145

Scheme 146

Connect special tool MB991668 to scan tool MB991958.
Connect scan tool MB991958 to the data link connector.
Turn the ignition switch to the "ON" position and select scan tool MB991958 "Belt Tension Measurement" from the menu screen.
Hold special tool MB991668 (microphone) near the center of the drive belt between the pulleys (at the place indicated by the arrow), about 10-20 mm (0.4 - 0.8 inch) away from the rear surface of the belt and perpendicular to the belt (within an angle of +/- 15 degree angle). CAUTION: The temperature of the surface of the belt should be as close as possible to underhood temperature. Do not let any contaminants such as water or oil get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running.
Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value. Standard value: STANDARD VALUE ITEMS WHEN CHECKED DURING ADJUSTMENT DURING REPLACEMENT Vibration frequency Hz 151 - 195 163 - 185 213 - 246

Required Special Tools

MB991668: Belt Tension Meter Set
MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991911: MUT-III Main Harness B

CAUTION

To prevent damage to scan tool MB991824, always turn t ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991824.

Scheme 147

Scheme 148

Connect special tool MB991668 to scan tool MB991824.
Connect scan tool MB991911 to scan tool MB991824.
Connect scan tool MB991911 to the data link connector.
Turn the ignition switch to the "ON" position and select "Belt Tension" from the menu scan tool MB991824 screen.
Hold special tool MB991668 (microphone) near the center of the drive belt between the pulleys (at the place indicated by the arrow), about 10-20 mm (0.4 - 0.8 inch) away from the rear surface of the belt and perpendicular to the belt (within an angle of +/- 15 degree angle). CAUTION: The temperature of the surface of the belt should be as close as possible to underhood temperature. Do not let any contaminants such as water or oil get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running.
Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

ITEMS	WHEN CHECKED	DURING ADJUSTMENT	DURING REPLACEMENT
Vibration frequency Hz	151 - 195	163 - 185	213 - 246

STANDARD VALUE

< WHEN USING THE TENSION GAUGE>

Use a belt tension gauge to check that the belt tension is within the standard value.

Scheme 149

Scheme 149: < WHEN USING THE TENSION GAUGE>

ITEMS	WHEN CHECKED	DURING ADJUSTMENT	DURING REPLACEMENT
Tension N (lb)	294 - 490 (66 - 110)	343 - 441 (77 - 99)	588 - 784 (132 - 176)

STANDARD VALUE

< BELT DEFLECTION CHECK>

Apply approximately 100 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Scheme 150

Scheme 150: < BELT DEFLECTION CHECK>

ITEMS	WHEN CHECKED	DURING ADJUSTMENT	DURING REPLACEMENT
Deflection (Reference value) mm (in)	9.7 - 12.7 (0.38 - 0.50)	10.3 - 11.8 (0.41 - 0.47)	6.7 - 8.5 (0.26 - 0.34)

BELT DEFLECTION STANDARD VALUE

Scheme 151

Scheme 151: GENERATOR DRIVE BELT TENSION ADJUSTMENT < 2.0L ENGINE >

Loosen the nut of the generator pivot bolt.
Loosen the lock bolt.
Turn the adjusting bolt to adjust the belt vibration frequency, belt tension or deflection to the standard value. CAUTION: Check after turning the crankshaft one or more rotations clockwise. GENERATOR DRIVE BELT TENSION STANDARD VALUE ITEMS WHEN CHECKED DURING ADJUSTMENT DURING REPLACEMENT Vibration frequency Hz 151 - 195 163 - 185 213 - 246 Tension N (Ib) 294 - 490 (66-110) 343 - 441 (77 -99) 588 - 784 (132-176) Deflection (Reference value) mm (in) 9.7 - 12.7 (0.38 - 0.50) 10.3 - 11.8 (0.41 - 0.47) 6.7 - 8.5 (0.26 - 0.34)
Tighten the lock bolt. Tightening torque: 23 +/- 2 N.m (16 +/- 2 ft-lb)
Tighten the nut of the generator pivot bolt. Tightening torque: 44 +/- 10 N m (33 +/- 7 ft-lb)
Tighten the adjusting bolt. Tightening torque: 5.0 +/- 1.0 N.m (44 +/- 8 in-lb)

POWER STEERING OIL PUMP AND A/C COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT < 2.0L ENGINE>

Check the drive belt tension by the following procedure.

Required Special Tools

MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991911: MUT-III Main Harness B
MB991668: Belt Tension Meter Set

Gently tap the middle of the belt between the pulleys (the location indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

Note. Refer to DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP AND A/C COMPRESSOR) (CHECK CONDITION) for details on the method of measuring the vibration frequency using the scan tool.

Scheme 152

< When using a tension gauge>

Use a belt tension gauge to check that the belt tension is within the standard value.

Scheme 153

Scheme 153: < Belt deflection check>

ITEMS	WHEN CHECKED	DURING ADJUSTMENT	DURING REPLACEMENT
Vibration frequency Hz	151 - 195	163 - 185	213 - 246
Tension N (Ib)	294 - 490 (66 - 110)	343 - 441 (77 - 99)	588 - 784 (132-176)
Deflection (Reference value) mm (in)	9.7 - 12.7 (0.38 - 0.50)	10.3 - 11.8 (0.41 - 0.46)	6.7 - 8.5 (0.26 - 0.33)

BELT DEFLECTION STANDARD VALUE

If the tension or deflection is outside the standard value, adjust by the following procedure

Loosen the tension pulley fixing nut A behind the tension pulley.
Adjust the belt deflection amount using the adjusting bolt B.
Tighten the fixing nut A. Tightening torque: 26 +/- 4 N.m (19 +/- 3 ft-lb) CAUTION: Check after turning the crankshaft one or more rotations clockwise.
Check the belt deflection amount and tension, and readjust if necessary.

DRIVE BELT TENSION CHECK < 2.4L ENGINE

CAUTION

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

Scheme 154

Make sure that the indicator mark is within the area marked with A in the illustration.
If the mark is out of the area, replace the drive belt. (Refer to CRANKSHAFT PULLEY ). NOTE: The drive belt tension adjustment is not necessary as auto-tensioner is adopted.

10. ENGINE OIL (CHANGE)

Use the specified oil. (Refer to RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE .)

Scheme 155

Scheme 155: 10. ENGINE OIL (CHANGE)

Scheme 156

After warming up the engine, remove the oil filler cap. WARNING: Use care, oil could be hot
Remove the drain plug to allow the engine oil to drain.
Replace the drain plug gasket with a new one, and then tighten the drain plug to the specified torque. Tightening torque: 39 +/- 5 N.m (29 +/- 4 ft-lb) NOTE: Install the drain plug gasket so it faces in the direction shown in the illustration.
Pour new engine oil in through the oil filler tube. Engine oil capacity: < 2.0L Engine> 3.8 dm 3 (4.0 quarts) < 2.4L Engine> 4.3 dm 3 (4.5 quarts)
Start the engine and run it at idle for a few minutes.
Stop the engine and check to ensure that the engine oil level is within the level range indicated on the dip stick.

Scheme 157

Scheme 158

11. ENGINE OIL FILTER (REPLACE)

The quality of replacement filters varies considerably. Only high quality filters should be used to assure most efficient service. Genuine oil filters require that the filter is capable of withstanding a pressure of 1,765 kPa (256 psi) are high quality filters and are recommended as follows

Mitsubishi Oil Filter Part Number

< 2.0L Engine>

MD136456, MD322508, MD325714, MD332687, MD360935 or MO365876

< 2.4L Engine>

MD136466, MD322508 or MD356000

ENGINE OIL FILTER SELECTION

This vehicle is equipped with a full-flow, throw-away oil filter. The same type of filter is recommended as a replacement filter for this vehicle. It is possible, particularly in cold weather, that this vehicle may develop high oil pressure for a short duration. Make sure that any replacement filter used on this vehicle is a high-quality filter. The filter must withstand a pressure of 1,765 kPa (256 psi) [manufacturer's specifications] to avoid filter and ultimately engine damage. The following is a high-quality filter and is strongly recommended for use on this vehicle: Mitsubishi Engine Oil Filter Part number MD136466, MD322508, MD325714, MD332687, MD360935 and MD365876. Any replacement oil filter should be installed in accordance with the oil filter manufacturer's installation instructions.

Scheme 159

Scheme 159: OIL FILTER REPLACEMENT

Scheme 160

Drain the engine oil by removing the oil drain plug.
Use an oil filter wrench to remove the engine oil filter.
Clean the contact surface of the filter bracket.
Lubricate the O-ring of the new oil filter with a small amount of new engine oil.
Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with an oil filter wrench. SPECIAL TOOL SPECIFICATION ENGINE NUMBER SPECIAL TOOL TIGHTENING TORQUE 2.0L MD360935 MB991396 or equivalent Approximately one turn [14 +/- 2 N.m (124 +/- 18 in-lb)] MD365876 MB991828 or equivalent Approximately 3/4 turn [16 +/- 4 N.m (12 +/- 3 ft-lb)] MD325714. MD332687 General service tool Approximately 3/4 turn [16 +/- 4 N.m (12 +/- 3 ft-lb)] MD136466 MD322508 General service tool Approximately 3/4 turn [17 +/- 3 N.m (13 +/- 2 ft-lb)] 2.4L MD136466, MD322508 General service tool Approximately 3/4 turn [17 + 3 N.m (13 + 2 ft-lb)] MD356000 MB991610 or equivalent Approximately 3/4 turn [14 +/- 2 N.m (124 +/- 18 in-lb)]
Add new engine oil through the oil filler.

CHECK OIL LEVEL

Inspect each component for evidence of leakage. Check the oil level by removing the filler plug.

Remove the filler plug.
Check that the oil is not noticeably dirty, and that it has a suitable viscosity.
Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)

Scheme 161

Scheme 162

Scheme 162: CHANGE OIL

Remove the filler plug.
Remove the drain plug and drain the oil.
Tighten the drain plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)
Fill with Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4 until the level comes to the lower portion of filler plug hole. Quantity: 2.2 dm 3 (2.3 quarts)
Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)

Scheme 163

Scheme 163: CHECKING A/T FLUID LEVEL

Scheme 164

Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 - 80°C (158 - 176°F)]. NOTE: The A/T fluid temperature is measured with MUT-II. NOTE: If its takes some amount of time until the A/T fluid reaches its normal operating temperature [70 - 80°C (158 - 176°F)], check the A/T fluid level by referring to the left diagram.
Park the vehicle on a level surface.
Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with A/T fluid, and then move the selector lever to the "N" position.
After wiping off any dirt from around the dipstick, remove the dipstick and check the condition of the A/T fluid. NOTE: If the fluid smells as if it is burnt, it means that the A/T fluid has been contaminated by fine particles from the bushings and friction materials. A transaxle overhaul and cooler line flushing may be necessary.
Check that the A/T fluid level is at the "HOT" mark on the dipstick. If the A/T fluid level is lower than this, pour in more MITSUBISHI genuine ATF SP-III or equivalent until the level reaches the "HOT" mark. NOTE: If the A/T fluid level is too low, the oil pump will draw in air along with the A/T fluid, which will cause bubbles to form. If the A/T fluid level is too high, rotating components inside the transaxle will churn the fluid and air into a foamy liquid. Both conditions (level too low or too high) will cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. In either case, air bubbles can interfere with normal valve, clutch, and brake operation. Also, foaming can cause A/T fluid to escape from the transaxle vent where it may be mistaken for a leak.
Securely insert the dipstick. NOTE: The A/T fluid should always be replaced when: When overhauling the transaxle When the oil is noticeably dirty or burnt (vehicle was driven under severe conditions)

CHANGE A/T FLUID

If you have an A/T fluid changer, use this changer to replace the A/T fluid. If you do not have an A/T fluid changer, replace the A/T fluid by the following procedure

Scheme 165

Scheme 165: CHANGE A/T FLUID

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Disconnect the hose shown in the illustration which connects the transaxle and the oil cooler (inside the radiator). Place a container under the hose to collect the A/T fluid. CAUTION: The engine should be stopped within one minute after it is started. If all the A/T fluid has drained out before then, the engine should be stopped at that point.
Start the engine and let the A/T fluid drain out. (Running conditions: "N" range with engine idling) Approximately 3.5 dm 3 (3.7 quarts) of A/T fluid should be removed.
Remove the drain plug from the bottom of the transaxle case to drain the A/T fluid. Approximately 2.0 dm 3 (2.1 quarts) of A/T fluid should be removed.
Install the drain plug with a new gasket, and tighten it to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb) CAUTION: Stop pouring if the full volume of A/T fluid can not be added.
Add new A/T fluid (DIAMOND ATF SP III or equivalent) through the oil filter tube. Approximately 5.5 dm 3 (5.8 quarts) of A/T fluid should be added.
Repeat the procedure in Step 2 (to pump out the rest of the contaminated A/T fluid)
Add new A/T fluid (DIAMOND ATF SP III or equivalent) through the oil filter tube. Approximately 3.5 dm 3 (3.7 quarts) of A/T fluid should be added. NOTE: Check for contamination or a burnt odor. If the A/T fluid is still contaminated or burnt, repeat Steps 6 and 7 before proceeding to Step 8.
Reconnect the hose which was disconnected in step 1 above, and firmly replace the dipstick.
Start the engine and run it at idle for 1 - 2 minutes.
Move the selector lever through all positions, and then move it to the "N" position.
Check that the A/T fluid level is at the "COLD" mark on the dipstick. If the level is lower than this, pour in more A/T fluid.
Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 - 80°C (158 - 176°F)], and then check the A/T fluid level again. The A/T fluid level must be at the "HOT" mark. NOTE: The A/T fluid temperature is measured with scan tool (MUT-II). The "COLD" level is for reference only; the "HOT" level should be regarded as the standard level. NOTE: If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 - 80°C (158 -176°F)], check the A/T fluid level by referring to the left diagram.
If the A/T fluid is under the specified level, pour in more A/T fluid. If the A/T fluid is over the specified level, drain the excessive A/T fluid from the drain plug to adjust A/T fluid level to the specified level.
Firmly insert the dipstick into the oil filler tube.

14. ENGINE COOLANT (CHANGE)

Check the cooling system parts such as the radiator, heater and oil cooler hoses, thermostat and their connections for leakage and damage.

Scheme 170

Scheme 170: CHANGING COOLANT

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Set the temperature control knob to the "HOT" position.
Run the engine until the engine coolant warms, and then stop the engine. 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 little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise.
Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.
Drain the water in the water jacket by unplugging the drain plug of the cylinder block.
Remove the radiator condenser tank and drain the coolant.
Drain the cooling water then clean the path of the cooling water by injecting water into the radiator from the radiator cap area.
Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten to the standard torque. Specified sealant: 3M TM AAD Part No.8731 or equivalent Tightening torque: < 2.0L Engine> 40 +/- 5 N.m (30 +/- 3 ft-lb) < 2.4L Engine> 44 +/- 5 N.m (33 +/- 3 ft-lb)
Securely tighten the drain plug of the radiator.
Assemble the radiator condenser tank. 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.
By referring to the information on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60 %. Use special tool MB991871 to refill the coolant. A convenient mixture is a 50 % water and 50 % antifreeze solution [freezing point: -31°C (-32.8°F)]. Recommended antifreeze: Long Life Antifreeze Coolant or an equivalent Quantity: < 2.4L Engine> 6.0 dm 3 (6.3 quarts) < 2.4L Engine> 7.0 dm 3 (7.4 quarts) NOTE: For how to use special tool MB991871, refer to its manufacturer's instructions.
Reinstall the radiator cap.
Start the engine and let it warm up until the thermostat opens.
After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.
Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap. CAUTION: Do not overfill the reserve tank.
Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary.

15. DISC BRAKE PADS (INSPECT FOR WEAR)

Check for fluid contamination and wear. Replace the complete set of pads if any one pad is defective.

Thickness of lining

Minimum limit: 2.0 mm (0.08 inch)

CAUTION

The pads for the right and left wheels should be replaced at the same time. Never split or intermix brake pad sets. All four pads must be replaced as a complete set.

Scheme 175

16. REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS (INSPECT FOR WEAR AND LEAKS)

Remove the brake drum and check the thickness of brake shoe lining for wear. Check the automatic brake adjusting system by hand to see if it operates smoothly. Also see if the gears are in proper mesh with each other. To assure smooth operation, apply a very thin coat of multipurpose grease to the friction surface of the adjuster and link shaft. CAUTION: The shoes for the right and left wheels should be replaced at the same time. Never split or intermix brake shoe sets. All four shoes must be replaced as a complete set.
Inspect the wheel cylinder boot for evidence of a brake fluid leak. Visually check the boot for cuts, tears or heat cracks. (A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at assembly.) Check the brake shoes for wear. Thickness of lining Minimum limit: 1.0 mm (0.04 inch)

Scheme 176

17. BRAKE HOSES (CHECK FOR DETERIORATION OR LEAKS)

Inspection of brake hoses should be included in all brake service operations.

The hoses should be checked for

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.)
Incorrect installation, twisting or interference with wheel, tire or chassis.

Scheme 177

18. BALL JOINT AND STEERING LINKAGE SEALS (INSPECT FOR GREASE LEAKS AND DAMAGE)

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.
Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

Scheme 178

19. DRIVE SHAFT BOOTS (INSPECT FOR GREASE LEAKS AND DAMAGE)

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.
Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

Scheme 179

20. SRS AIR BAG (INSPECT FOR SRS SYSTEM)

The SRS must be inspected by an authorized dealer 10 years after the car manufacture date shown on the certification label located on the left center sill.

Scheme 180

Scheme 180: 20. SRS AIR BAG (INSPECT FOR SRS SYSTEM)

SRS WARNING LIGHT CHECK

Turn the ignition key to the "ON" position. Does the "SRS" warning light illuminate for about seven seconds, and then remain off for at least five seconds after turning OFF? If yes, the SRS system is functioning properly. If no, refer to AIR BAG RESTRAINT SYSTEMS - EXCEPT SPORTBACK .

Scheme 181

Scheme 181: SRS WARNING LIGHT CHECK

SRS COMPONENT VISUAL CHECK

WARNING

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 for a short time 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.

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

Scheme 182

Turn the ignition switch to the "LOCK" (OFF) position, disconnect the negative battery cable and tape the terminal.
Remove the floor console assembly. (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/exteriorinterior-trim/#front-floor-console-assembly-except-evolution-sportback) .)
Disconnect a connector from the SRS-ECU.

SIDE IMPACT SENSORS

WARNING

If the side impact sensor is not installed securely and correctly, the side-airbag may not operate normally. If a dent, crack, deformation or rust is detected, replace with a new sensor.

Check the side impact sensor and bracket for dents, cracks or deformation. The side impact sensors are located inside the center pillars (LH/RH).
Check the connector for damage, and terminal for deformation.
Check that there is no bending or corrosion in the center pillars (LH/RH).

Note. The illustration at left shows the left side impact sensor (LH). The position of the side impact sensor (RH) is symmetrical to this.

Scheme 183

REPLACE THE SIDE IMPACT SENSOR IF IT FAILS THE VISUAL CHECK

Refer to SIDE IMPACT SENSOR .

SRS AIR BAG CONTROL UNIT (SRS-ECU)

WARNING

The SRS may not activate if the SRS-ECU (with built-in safing G-sensor and analog G-sensor) is not installed properly, which could result in serious injury or death to the vehicle's driver and front passenger.

Check the SRS-ECU case and brackets for dents, cracks, deformation or rust.
Check the connector for damage, and check the terminals for deformation or rust. Replace the SRS-ECU if it fails the visual checks above. (Refer to «SRS ELECTRONIC CONTROL UNIT (ECU)»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) .)

Scheme 184

AIR BAG MODULE, STEERING WHEEL AND CLOCK SPRING

WARNING

The removed air bag module should be stored in a clean, dry place with the pad cover face up.

Scheme 185

Scheme 186

Scheme 187

Remove the air bag module, steering wheel and clock spring. (Refer to «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) .)
Check the pad cover for dents, cracks or deformation.
Check the connector for damage and deformed terminals, and check the harness for binding.
Check the air bag inflator case for dents, cracks or deformation.
Check the harness (built into the steering wheel) and connectors for damage, and check the terminals for deformation.
Check the clock spring connectors and protective tube for damage, and terminals for deformities.
Visually check the case for damage. WARNING: If the clock spring's mating mark is not properly aligned, the steering wheel may not completely rotate during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle's driver and front passenger.
Align the mating marks of the clock spring first. After turning the front wheels to the straight-ahead position, install the clock spring to the column. Mating Marks Alignment; After turning the clock spring fully clockwise, turn it approximately 3-3/4 turns counterclockwise until the mating marks are aligned.
Install the steering column covers, steering wheel and air bag module. (Refer to «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) .)
Check the steering wheel for noise, binding or difficult operation. WARNING: The SRS may not activate if any of the above components are not installed properly, which could result in serious injury or death to the vehicle's driver and front passenger.
Check the steering wheel for excessive free play. REPLACE ANY PART IF IT FAILS VISUAL INSPECTION. (Refer to «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) .)

Scheme 188

FRONT SEATBACK ASSEMBLY WITH SIDE-AIRBAG MODULE

WARNING

If any improper part is found during the following inspection, replace the front seatback assembly with a new one. Dispose of the old one according to the specified procedure. (Refer to DISPOSAL PROCEDURES .) Never attempt to measure the circuit resistance of the air bag module (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental air bag deployment will result in serious personal injury.

Scheme 189

Check the air bag module deployment section for dents or deformation.
Check the connector for damage; check the terminals for deformation; and check the harness for binding.

SEAT BELT WITH PRE-TENSIONER

WARNING

If the seat belt pre-tensioner is not installed securely and correctly, the seat belt pre-tensioner may not operate normally. If a dent, crack, deformation or rust is detected, replace with a new seat belt pre-tensioner.

Check the seat belt pre-tensioner for dents or deformation.
Check that the seat belt pre-tensioner is installed correctly to the vehicle body.

Scheme 190

Scheme 190: WIRING HARNESS

Check the connector for poor connection. WARNING: The SRS system may not operate if SRS harnesses or connectors are damaged or improperly connected, which could result in serious injury or death to the vehicle's driver and front passenger.
Check the harness for binding; check the connectors for damage; and the terminals for deformation. REPLACE ANY CONNECTOR OR HARNESS THAT FAILS THE VISUAL INSPECTION. (Refer to «AIR BAG SAFETY PRECAUTIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback__air-bag-safety-precautions) .)

21. EXHAUST SYSTEM (CONNECTIONS, PIPES AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE AS REQUIRED)

Check for holes and exhaust gas leaks due to damage, corrosion, etc.
Check the joints and connections for looseness and exhaust gas leaks.
Check the rubber hangers and brackets for damage.

22. TIRES (ROTATE)

Rotate tires regularly to equalize tire wear and help extend tire life. Recommended tire rotation is every 12,000 km (7,500 miles) under normal driving conditions and every 9,600 km (6,000 miles) in severe driving conditions.

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.

Scheme 191

Scheme 191: 22. TIRES (ROTATE)

MAIN SEALANT AND ADHESIVE TABLE

APPLICATION		3M TM NO.	LOCTITE(R)/PERMATEX(R) NO.
ENGINE AND DRIVETRAIN	Between rocker cover and camshaft bearing cap. Between rocker cover, semicircular packing and cylinder head. Between oil pressure switch and engine.	3M TM AAD Part No. 8660 Ultrapro High Temp. Silicone Gasket or 3M TM AAD Part No. 8679 Black/8678 Black Press-In-Place Silicone gasket strips	Permatex(R) Ultra Black 598, No.82180
	Between engine coolant temperature switch, engine coolant temperature sensor, thermo valve, thermo switch, joint, engine coolant temperature gauge unit (large-size) and engine	3M TM AAD Part No. 8731 Medium Strength Blue Threadlocker	Loctite(R)242 Blue Service Tool Removable 24200
	Between oil pan and engine block	3M TM AAD Part No. 8672, 3M TM AAD Part No. 8704 or 3M TM AAD Part No. 8679/ 3M TM AAD Part No. 8678	Permatex(R) Ultra Gray 599, No.82194
WEATHER-STRIPPING FOR GLASS	Between tempered glass, body flanges, and weatherstrip	3M TM AAD Part No. 8509 Auto Bedding and Glazing Compound or 3M TM AAD Part No. 8633 Windo-weld Resealant
INTERIOR	Adhesive of vinyl chloride cloth	3M(tm) AAD Part No.8088 General Trim Adhesive or 3M(tm) AAD Part No.8064 Vinyl Trim Adhesive	PERMATEX(R) Vinyl Repair Kit No.81786
	Adhesion of door weatherstrip	3M(tm) AAD Part No.8001 (yellow) or 3M(tm) AAD Part No.8008 (black) Super Weatherstrip Adhesive or 3M(tm) AAD Part No.8011 Black Weatherstrip Adhesive	PERMATEX(R) Super Black Weatherstrip Adhesive No.82, 81850
	Sealing of various grommets and packing	3M(tm) AAD Part No.8509 or 3M(tm) AAD Part No.8678
	Adhesion of headliners and various interior decorative materials	3M(tm) AAD Part No.8088 General Trim Adhesive or 3M(tm) AAD Part No.8090 Super Trim Adhesive	PERMATEX(R) Spray Adhesive No.82019
BODY SEALANTS	Sealing of sheet metal joints	3M(tm) AAD Part No.8531 Heavy Drip-Check Sealer (gray) or 3M(tm) AAD Part No.8302 Ultrapro Autobody Sealant (clear) or 3M(tm) AAD Part No.8361 Urethane A/B Sealant (gray or white)
	Miscellaneous body sealants (originally mounted w/adhesive tape) Waterproof door film Fender panel Mud guard Rear combination lamp	3M(tm) AAD Part No.8633 Windo-weld Resealant
	Fuel Tank and Pad	3M(tm) AAD Part No.8088 General Trim Adhesive or 3M(tm) AAD Part No.8090 Super Trim Adhesive	PERMATEX(R) Spray Adhesive No.82019
CHASSIS SEALANT	Sealing of various flange faces and threaded parts. Packing of fuel gauge unit	3M(tm) AAD Part No.8730 High Strength Red Thread lock or 3M(tm) AAD Part No.8731 Medium Strength Blue Threadlocker	LOCTITE(R)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(tm) AAD Part No.8672 Ultrapro High Temp. Silicone Gasket or 3M(tm) AAD Part No.8679 (black) or 3M(tm) AAD Part No.8678 (black) Press-In-Place Silicone gasket strips 3M(tm) AAD Part No.8661 or 3M(tm) AAD Part No.8663 Super Silicone sealant	PERMATEX(R) The Right Stuff No.25223
	Seal of brake shoe hold-down pin and wheel cylinder of drum brakes	3M(tm) AAD Part No.8633 Windo-weld Resealant
QUICK FIX ADHESIVE	3M(tm) AAD Part No.8155 Quick Fix Adhesive	LOCTITE(R) Quicktite Super Glue 21309
ANAEROBIC STRONG SEALING AGENT	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(tm) AAD Part No.8730 High Strength Threadlocker or 3M(tm) AAD Part No.8731 Medium Strength Threadlocker	LOCTITE (R)271, High-Strength Threadlocker 27100 or 27200
UNDERCOATING AGENT		3M(tm) AAD Part No.8883 Rubberized Undercoating Aerosol or 3M(tm) AAD Part No.8864 Body Schutz Undercoating (qt)	PERMATEX(R) Heavy-Duty Undercoating 81833

MAIN SEALANT AND ADHESIVE

General <body & Chassis> - Except Evolution & Sportback Mitsubishi Lancer Evolution VIII

MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

ON-VEHICLE SERVICE

SERVICE PROCEDURES

STANDARD VALUE

LIMIT

REFERENCE VALUE

DANGER, WARNING, AND CAUTION

TIGHTENING TORQUE INDICATION

SPECIAL TOOL NOTE

ABBREVIATIONS

Scheme 109

VERIFY THE COMPLAINT

DETERMINE POSSIBLE CAUSES

FIND THE PROBLEM

REPAIR THE PROBLEM

VERIFY THE REPAIR

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

TROUBLESHOOTING CONTENTS

HOW TO USE THE INSPECTION PROCEDURES

Scheme 110

Scheme 111

HARNESS INSPECTION

MEASURES TO TAKE AFTER REPLACING THE ECU

CONNECTOR MEASUREMENT SERVICE POINTS

IF INSPECTING WITH THE CONNECTOR CONNECTED < WATERPROOF CONNECTORS>

Scheme 112

IF INSPECTING WITH THE CONNECTOR CONNECTED < ORDINARY (NON-WATERPROOF) CONNECTORS>

Scheme 113

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

Scheme 114

Scheme 115

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

Scheme 116

VISUAL INSPECTION

Scheme 117

CONNECTOR PIN INSPECTION

Scheme 118

CONNECTOR ENGAGEMENT INSPECTION

Scheme 119

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

TO COPE WITH INTERMITTENT MALFUNCTION

SIMULATION TESTS

Scheme 120

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

Scheme 121

VEHICLES IDENTIFICATION NUMBER LOCATION

Scheme 122

VEHICLE IDENTIFICATION CODE CHART PLATE

Scheme 123

VEHICLES FOR USA

VEHICLES FOR CANADA

VEHICLES FOR PUERTO RICO

VEHICLE IDENTIFICATION CODE PLATE

Scheme 124

VEHICLE SAFETY CERTIFICATION LABEL

Scheme 125

ENGINE MODEL STAMPING

Scheme 126

THEFT PROTECTION

Scheme 127

Scheme 128

Scheme 129

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SERVICING ELECTRICAL SYSTEM

Scheme 130

VEHICLE WASHING

Scheme 131

APPLYING ANTI-CORROSION AGENT OR OTHER UNDERCOAT AGENTS

SCAN TOOL (MUT-III Sub Assembly)

Scheme 132

FRONT TOWING PICKUP

Scheme 133

REAR TOWING PICKUP

Scheme 134

SAFETY PRECAUTIONS

FLOOR JACK

Scheme 135

POST TYPE

Scheme 136