General - Evolution Mitsubishi Lancer Evolution VIII

MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This information 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 information under " VEHICLE IDENTIFICATION ."

ON-VEHICLE SERVICE

The "ON-VEHICLE SERVICE" section 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.

Attention to be paid in performing vehicle service are described in detail in SERVICE POINTS.

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

1. If a DANGER is not followed, the result is severe bodily harm or even death.
2. If a WARNING is not followed, the result could be bodily injury.
3. 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 TIGHTENING TORQUE .

SPECIAL TOOL NOTE

Only MMC special tool part numbers are called out in the repair sections of the articles. Please refer to the special tool cross-reference chart in each article for the special tool number that is available in your market.

ABBREVIATIONS

The following abbreviations are used in this information for classification of model types

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

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

AWD: 4-wheel drive vehicles.

A/C: Air conditioning.

2.0L Engine: 2.0 liter < 4G63> engine, or a model equipped with such an engine.

ECM: Engine control module

SWS: Simplified Wiring System

Scheme 233

Scheme 234

VERIFY THE COMPLAINT

1. Make sure the customer's complaint and the service writer's work order description are understood before starting work.
2. Make sure the correct operation of the system is understood. Read the service information description to verify normal system operation.
3. 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.

1. Analyze the system diagrams and list all possible causes for the problem symptoms.
2. 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 in the service 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 service information 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

1. General to specific.
2. Most-likely to least-likely.
3. 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

1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Troubleshooting strategy is shown in each group.
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown.
3. DIAGNOSTIC FUNCTION The following diagnostic trouble code diagnosis are shown. How to read diagnostic trouble codes. How to erase diagnostic trouble codes. Input inspection service points.
4. DIAGNOSTIC TROUBLE CODE CHART If the scan tool displays a diagnostic trouble code, find the applicable inspection procedure according to this chart.
5. SYMPTOM CHART If there are symptoms, even though the scan tools show that no DTCs are set, inspection procedures for each symptom will be found by using this chart.
6. DIAGNOSTIC TROUBLE CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to.)
7. SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart. (Refer to.)
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, 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.
10. 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 235

Scheme 236

CURRENT TROUBLE

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

PAST TROUBLE

Indicates that the trouble is historic, but normal operation has been restored. Observe the applicable inspection procedure with particular emphasis on connector(s) and wiring harness.

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 . 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 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 237

Check by inserting the multimeter 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 238

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

Required Special Tool

Scheme 239

1. MB991219: Inspection Harness (Included in MB991223, Harness Set)
2. 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.
3. From back side of the connector (SRS-ECU harness side connector)
4. Since the SRS-ECU harness connector is plated to improve conductivity, observe the warning below when checking this connector.

Scheme 240

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

Touch the pin directly with the test probe.

Scheme 241

VISUAL INSPECTION

1. Connector is disconnected or improperly connected
2. Connector pins are pulled out.
3. Stretched an broken wires at terminal section.
4. Low contact pressure between male and female terminals.
5. Low connection pressure due to rusted terminals or foreign matter lodged in terminals.

Scheme 242

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 243

CONNECTOR ENGAGEMENT INSPECTION

Required Special Tool

1. 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 244

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

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 conditions like vibration, temperature and/or moisture change, poor connections. From the customer's responses, it should be reasoned which condition is most likely.
3. 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.
4. 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.

1. Shake the connector up-and-down, and right-and-left.
2. Shake the wiring harness up-and-down, and right-and-left. Especially, check the splice points of wiring harnesses carefully. Refer to «HARNESS CONNECTOR INSPECTION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/oem-general-information/#general-evolution) .
3. Shake the part or sensor.

Scheme 245

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.

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

Scheme 246

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 247

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.

Scheme 248

VEHICLE IDENTIFICATION CODE CHART

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

VEHICLES FOR FEDERAL EMISSION REGULATION

VEHICLE IDENTIFICATION NUMBER LIST

VEHICLE INFORMATION 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.

VEHICLE INFORMATION CODE

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

Scheme 249

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 250

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.

These engine model number are as shown as follows.

ENGINE MODEL STAMPING

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

Scheme 251

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.

Scheme 252

Scheme 253

Scheme 254

Scheme 255

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

1. Items to review when servicing SRS Be sure to refer to 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. Front impact sensor Sun visor Glove box SRS-ECU Steering wheel Clock spring Joint cover Air bag module (Driver's or front passenger's) Seat belt pretensioner 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, clock spring and seat belt pretensioner). 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-except-sportback__disposal-procedures) .)
2. 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 reinstalling them, check the SRS warning light operation to make sure that the system functions properly. SRS-ECU, air bag module, clock spring: 93°C (200°F) or more Seat belt pretensioner: 90°C (194°F) or more

SERVICING ELECTRICAL SYSTEM

Scheme 256

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. 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. Engine coolant temperature: 85 - 95°C (185 - 203°F) Lights and all accessories: OFF Transaxle: "N" position Steering wheel: straight-forward position
2. When servicing the electrical system, disconnect the negative cable terminal from the battery.

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 257

APPLYING ANTI-CORROSION AGENT OR OTHER UNDERCOAT AGENTS

Be careful 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)

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

Scheme 258

FRONT TOWING PICKUP

Scheme 259

REAR TOWING PICKUP

Scheme 260

SAFETY PRECAUTIONS

The following precautions should be taken when towing the vehicle

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

FLOOR JACK

Scheme 261

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.

Scheme 262

Scheme 263

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TIGHTENING TORQUE

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

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

The values in the table are not applicable

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

STANDARD BOLT AND NUT TIGHTENING TORQUE

STANDARD BOLT AND NUT TIGHTENING TORQUES

FLANGE BOLT AND NUT TIGHTENING TORQUE

FLANGE BOLT AND NUT TIGHTENING TORQUES

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 the " 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 section 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

1. Trailer towing or police, taxi or commercial type operation.
2. 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

Either of the following engine oils should be used

1. Engine oil displaying ILSAC certification mark.
2. Engine oil conforming to the API classification SL or SL/CF. For further details, refer to «LUBRICANTS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/oem-general-information/#general-evolution__scheduled-maintenance-service-for-emission-control) .

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

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 premium grade unleaded gasoline having a minimum octane rating of 93 [(MON + RON)/2], or 98 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

RECOMMENDED LUBRICANTS SPECIFICATION

LUBRICANT CAPACITY TABLE

LUBRICANT CAPACITY

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

Scheme 264

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

Scheme 265

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 266

COOLANT

Relationship between Coolant Concentration and Specific Gravity

COOLANT SPECIFICATION

Example

The safe operating temperature is -15°C (5°F) when the specific gravity is 1.058 at the engine coolant temperature of 20°C (68°F)

SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE

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

SCHEDULED MAINTENANCE

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

Note. *1: For California, Massachusetts, Vermont and Maine, this maintenance is recommended but not required to maintain the emissions warranty. *2: This maintenance is not required if previously replaced. *3: This maintenance is recommended but is not required to maintain the emissions warranty. *4: In case of replaced at 60miles/60months.

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS

Maintenance should be carried out according to the following table

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS

Severe usage conditions

1. Driving on dusty, rough, muddy or salt-spread roads
2. Towing or police, taxi or commercial operation
3. Extensive idling and/or low speed operation
4. Repeated short-trip operation at freezing temperatures (engine not thoroughly warmed up)
5. Extended use of brakes while driving
6. Driving in sandy areas

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)

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

Scheme 267

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

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)

Scheme 268

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 SPARK PLUG SPECIFICATION MAKER IDENTIFICATION NO. NGK IGR7A-G
2. The new plugs should be checked for the proper gap. Spark plug gap: 0.7 - 0.8 mm (0.028 - 0.031 inch)
3. Install the spark plugs and tighten to 25+/-5 N.m (18+/-4 ft-lb).

6. IGNITION CABLES (REPLACE)

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 269

7. TIMING BELT (REPLACE)

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

For removal and installation procedures, refer to TIMING BELT .

< WHEN USING SCAN TOOL MB991958>

Required Special Tools

1. MB991668: Belt Tension Meter Set
2. MB991958: Scan Tool (MUT-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991911: Main Harness B

Scheme 270

Scheme 271

1. Check the drive belt tension. (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution__drive-belt-tension-check).)
2. Measure the drive belt tension vibration frequency by the following procedures: CAUTION: To prevent damage to scan tool MB991824, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991824. 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 Measurement" from the menu scan tool MB991824 screen. CAUTION: The temperature of the surface of the belt should be as close to normal temperature as possible. Do not allow any contaminants such as water or oil to 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. Hold special tool MB991668 to the middle of the drive belt between the pulleys (at the place indicated by arrow), approximately 10-20 mm (0.40 - 0.78 inch) away from the rear surface of the belt so that it is perpendicular to the belt (within an angle of +/- 15 degree). Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger (Scheme 271), and measure that the vibration frequency of the belt is within the standard value. Standard value: 110 - 144 Hz
3. If not within the standard value, replace the auto-tensioner. (Refer to «AUTO-TENSIONER CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution).)

< WHEN USING A TENSION GAUGE>

1. Check the drive belt tension. (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution__drive-belt-tension-check) .)
2. Use a belt tension gauge in the middle of the belt between the pulleys (at the place indicated by the arrow) to measure that the belt tension is within the standard value. Standard value: 245 - 412 N
3. If not within the standard value, replace the auto-tensioner. (Refer to «AUTO-TENSIONER CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .)

Scheme 272

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

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

Scheme 273

Scheme 274

Scheme 275

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80°C (176°F) to 90°C (194°F). WARNING: Use care as oil could be hot.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque. Tightening torque: 39 +/- 5 N.m (29 +/- 3 ft-lb) CAUTION: Do not use conventional petroleum based motor oil. Using conventional motor oil may cause engine or turbocharger damage. Do not used "blends" of conventional oil and synthetic oil.
5. Refill the specified quantity of oil. Specified Engine Oil: Fully synthetic engine oils displaying ILSAC GF-3 certification symbol ("Starburst" symbol) or conforming to the API classification SL or SL/CF Total quantity (Includes volume inside oil filter and oil cooler): 5.1 dm 3 (5.4 quarts) NOTE: SAE 5W-30 fully synthetic engine oil can be used to improve engine startability in very cold weather areas where the lowest atmospheric temperature is below -18°C (0°F).
6. Install the engine oil filler cap.
7. Start the engine and run it at idle for a few minutes.
8. Stop the engine and check to ensure that the engine oil level is within the level range indicated on the dip stick.

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 1,800 kPa (261 psi) are high quality filters and are recommended as follows

Mitsubishi Oil Filter Part Number: MD356000 or equivalent

ENGINE OIL FILTER SELECTION

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 1,800 kPa (261 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 MD356000. Any replacement oil filter should be installed in accordance with the oil filter manufacturer's installation instructions.

Scheme 276

Scheme 277

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80°C (176°F) to 90°C (194°F). WARNING: Use care as oil could be hot
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
4. Remove the side cover.
5. Use the commercially-available tool to remove the engine oil filter.
6. Clean the filter bracket side mounting surface and ensure 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. Where the oil filter O-ring touches the oil pan flange, tighten the oil filter to the specified torque using the commercially-available tool. Tightening torque: Approximately 3/4 turn [14 +/- 2 N.m (124 +/- 18 in-lb)]
9. Install the side cover.
10. Install the drain plug and refill engine oil. (Refer to «ENGINE OIL REPLACEMENT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/lubrication-system/#lubrication-evolution) .)
11. Rev the engine a few times, and check to be sure that no engine oil leaks from the installation section of the oil filter.

CHECK OIL LEVEL

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

1. Remove the filler plug.
2. Check that the oil level is up to the lower edge of the filler plug hole.
3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque.

Tightening torque: 32 +/- 2 N.m (23 +/- 2 ft-lb)

Scheme 278

CHANGE OIL

1. Remove the filler plug.
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque. Tightening torque: 32 +/- 2 N.m (23 +/- 2 ft-lb)
4. Fill with gear oil API classification GL-4 SAE 75W-85W or 75W-90 until the level comes to the lower portion of filler plug hole. Quantity: 2.8 dm 3 (2.9 quarts)
5. Tighten the filler plug to the specified torque.

Tightening torque: 32 +/- 2 N.m (23 +/- 2 ft-lb)

Scheme 279

TRANSFER OIL LEVEL CHECK

1. Remove the filler plug.
2. Check that the oil level is up to the lower edge of the filler plug hole.
3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque.

Tightening torque: 32 +/- 2 N.m (23 +/- 2 ft-lb)

Scheme 280

Scheme 281

1. Remove the filler plug.
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque. Tightening torque: 32 +/- 2 N.m (23 +/- 2 ft-lb) CAUTION: Cover the heat protector of the front exhaust pipe with cardboard or something similar when refilling transfer oil so that transfer oil does not enter the area between the front exhaust pipe and heat protector.
4. Fill with hypoid gear oil API classification GL-5 SAE90 until the level comes to the lower portion of filler plug hole. Quantity: 0.55 dm 3 (0.58 quart)
5. Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N.m (23 +/- 2 ft-lb)

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.

CHANGING COOLANT

Required Special Tool

1. MB991871: LLC Changer

Scheme 282

Scheme 283

1. Remove the under cover. 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.
2. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.
3. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.
4. Remove the reserve tank and drain the coolant.
5. Drain the cooling water then clean the path of the cooling water by injecting water into the radiator from the radiator cap area.
6. 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: 44 +/- 5 N.m (33 +/- 3 ft-lb)
7. Securely tighten the drain plug of the radiator.
8. Assemble the reserve 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.
9. 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 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: Mitsubishi Genuine Coolant or equivalent Quantity: 6.0 dm 3 (6.3 quarts) NOTE: For how to use special tool MB991871, refer to the manufacturer's instructions.
10. Reinstall the radiator cap.
11. Start the engine and let it warm up until the thermostat opens.
12. After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.
13. 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.
14. Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary.
15. Install the under cover.

15. COOLANT HOSES (RADIATOR HOSE, HEATER HOSE) (INSPECT)

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

DISC BRAKE PADS CHECK

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)

Scheme 284

ROTORS CHECK

Check whether the ABS rotor teeth are broken or deformed.

Replace the Eight Ball Fixed Joint (EBJ) assembly of the driveshaft, respectively, if the teeth are damaged or deformed.

Scheme 285

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

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.

Scheme 286

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

1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or grease contamination.
2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

Scheme 287

19. SUSPENSION SYSTEM (INSPECT FOR LOOSENESS AND DAMAGE)

Visually inspect the front/rear suspension components for deterioration and damage. Retighten the front/rear suspension components retaining bolts to specified torque.

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

1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or grease contamination.
2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

Scheme 288

21. REAR AXLE OIL (CHANGE)

Before the changing the rear axle oil, check that there is no oil leakage from the rear axle housing.

1. Remove the filler plug.
2. Remove the drain plug and drain out the oil.
3. Replace the packing for drain plug and tighten the drain plug to the specified torque. Tightening torque: 64 +/- 4 N.m (47 +/- 3 ft-lb)
4. Refill engine oil via the filler hole. Specified gear oil: Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No. 8149630 EX or equivalent Quantity: 0.55 dm 3 (0.58 quart)
5. Replace the gasket for drain plug and tighten the drain plug to the specified torque.

Tightening torque: 49 +/- 9 N.m (37 +/- 6 ft-lb)

22. SRS AIR BAG (INSPECT THE 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 289

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 DIAGNOSTICS .

Scheme 290

SRS COMPONENT VISUAL CHECK

DANGER

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.

Scheme 291

1. Turn the ignition switch to the "LOCK" (OFF) position, disconnect the negative battery cable and tape the terminal.
2. Remove the floor console assembly. (Refer to «FRONT FLOOR CONSOLE ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/exteriorinterior-trim/#front-floor-console-assembly-evolution) .)
3. Disconnect a connector from the SRS-ECU.

Scheme 292

1. Check that the arrows on the sensors face toward the front of the vehicle. WARNING: The SRS may not activate if a front impact sensor is not installed properly, which could result in serious injury or death to the vehicle's driver and passenger. If a dent, crack, deformation or rust is detected, replace with a new sensor.
2. Check the front side member and front impact sensor for deformation or rust.
3. Check the front impact sensor wiring harness for binding; Check the connector for damage; and check the terminals for deformation. Replace the sensor and/or wiring harness if they fail the visual check (Refer to «AIR BAG SAFETY PRECAUTIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback__air-bag-safety-precautions) and «FRONT IMPACT SENSOR (LANCER EVOLUTION)»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) ).

SRS AIR BAG CONTROL UNIT (SRS-ECU)

1. Check the SRS-ECU case and brackets for dents, cracks, deformation or rust.
2. 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 293

AIR BAG MODULE, STEERING WHEEL AND CLOCK SPRING

Scheme 294

Scheme 295

Scheme 296

Scheme 297

1. Remove the steering wheel-driver's air bag module assembly 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) .)
2. Check the pad cover for dents, cracks or deformation.
3. Check the connector for damage and deformed terminals, and check the harness for binding.
4. Check the air bag inflator case for dents, cracks or deformation.
5. Check the harness (built into the steering wheel) and connectors for damage, and check the terminals for deformation.
6. Check the clock spring connectors and protective tube for damage, and terminals for deformities.
7. 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.
8. 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.
9. Install the steering column covers and steering wheel-driver's air bag module assembly. (Refer to «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) .)
10. Check the steering wheel for noise, binding or difficult operation. DANGER 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.
11. 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) ).

SEAT BELT WITH PRE-TENSIONER

1. Check the seat belt pre-tensioner for dents or deformation.
2. Check that the seat belt pre-tensioner is installed correctly to the vehicle body. Replace the seat belt pre-tensioner if it fails the visual checks above (Refer to «SEAT BELT PRETENSIONER»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/airbag/#air-bag-restraint-systems-except-sportback) ).

Scheme 298

1. Check the connector for poor connection. DANGER 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.
2. Check the harness for binds, 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) ).

23. TIRES (ROTATE)

Rotate tires regularly to equalize tire wear and help extend tire life. Recommended tire rotation is every 8,000 km (5,000 miles) under normal driving conditions and every 6,000 km (3,750 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 299

MAIN SEALANT AND ADHESIVE TABLE

SEALANT AND ADHESIVE SPECIFICATIONS

CONNECTOR CONTINUITY AND VOLTAGE TEST

Required Special Tools

1. MB991219: Test Harness Set
2. MD998459: Test Harness

Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at waterproof connectors.

Scheme 300

Scheme 301

1. If the circuit to be checked is a closed state, use a special tool like MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit.
2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (like MB991219). CAUTION: Do not simultaneously contact more than one terminal with the probe. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire.
3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal.

IMPROPER TERMINAL ENGAGEMENT CHECK

Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector.

Scheme 302

CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT

Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuit can be done in the following manner.

Scheme 303

Scheme 304

Scheme 305

1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it.
2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there.
3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, gently push the housing lance down with the tip, and pull out the terminal.
4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom.

Scheme 306

Scheme 307

1. Remove the waterproof cap by using a screwdriver.
2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal.
3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom.

Scheme 308

Scheme 309

Scheme 310

1. Disengage the front holder with a screwdriver and remove it.
2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal.
3. Press the contact point to the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom.

Scheme 311

Scheme 312

Scheme 313

1. Remove the waterproof cap.
2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector.
3. Press the contact point to the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure.

Scheme 314

HOW TO DIAGNOSE

The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only.

TROUBLESHOOTING STEPS

If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making, incorrect repairs. The four steps below should be followed in troubleshooting.

Scheme 315

INFORMATION FOR DIAGNOSIS

This information contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner

1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path.
2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions.
3. Operational explanations include circuit drawings of current flow when the switch is operated and how the component reacts.
4. Troubleshooting hints include numerous examples of problems which might occur, traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits.

Note. Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to an article which includes details of these components.

Scheme 316

Scheme 317

1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when some relay covers are pushed down.
2. Simple checks For example, if a headlight does not come on and a faulty fuse or poor grounding is suspected, replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem.
3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly.

Scheme 318

INSPECTION INSTRUMENTS

For inspection, use the following instruments

Scheme 319

Scheme 320

Scheme 321

Scheme 322

1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits.
2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. CAUTION: Never use a jumper wire to connect a power supply directly to a load.
3. Jumper wire A jumper wire is used to close an open circuit.
4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop before or after a component.
5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or coil. If the measuring range has been changed, the zero point must be adjusted before measurement.

Scheme 323

CHECKING FUSES

A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live.

Scheme 324

CAUTIONS IN EVENT OF BLOWN FUSE

When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown, due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below.

Scheme 325

1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire.
2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity.

Scheme 326

CHECKING SWITCHES

In a circuit diagram, a switch is shown in the idle state.

Scheme 327

1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise.
2. Switch connection

This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below.

SPECIFIED CONNECTION

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Scheme 332

1. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light.
2. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF).
3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. NOTE: The de-energized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. The normally open-type When a normally open relay as illustrated here is checked, there should be no continuity between terminals 3 and 4 when the relay is de-energized. There should be continuity between terminals 3 and 4 when battery voltage and ground are applied to terminals 1 and 2. The relay condition is determined by this check. NOTE: Check the relay in both situation which is energized and is not energized. The normally closed-type When a normally closed relay as illustrated here is checked, there should be continuity between terminals 3 and 4 when the relay is de-energized. There should be continuity between terminals 3 and 4 when battery voltage and ground are applied to terminals 1 and 2. The relay condition is determined by this check. NOTE: Check the relay in both situation which is energized and is not energized.

Scheme 333

1. Check connections for looseness, rust, and stains.
2. Check terminals and wires for corrosion.
3. Check terminals and wires for open circuit or impending open circuit.
4. Check wire insulation and coating for damage, cracks, and wear.
5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.).
9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts.
10. Check that the harnesses between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement.

Scheme 334

BATTERY HANDLING

When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last.

Scheme 335

GENERAL ELECTRICAL SYSTEM CHECK

A circuit consists of the power supply, switch, relay, load, ground, etc. There are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below applies only to circuits similar to the illustration.

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

1. VOLTAGE CHECK Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. Then, connect the test light or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified.
2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to narrow down the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES : Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. NO : Go to Step 2. STEP 2. Turn thee switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES : Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO : Short-circuit exists between the connector and the illumination light. Repair the harness between the connector and the illumination light.
3. CONTINUITY CHECK When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm.

See also:
• DISPOSAL PROCEDURES
• TIMING BELT
• DRIVE BELT TENSION CHECK
• ENGINE OIL REPLACEMENT
• DIAGNOSTICS
• FRONT FLOOR CONSOLE ASSEMBLY
• AIR BAG SAFETY PRECAUTIONS
• VEHICLE IDENTIFICATION
• TIGHTENING TORQUE
• INSPECTION SERVICE POINTS FOR A BLOWN FUSE
• MAINTENANCE SERVICE