General -- Lancer Evolution: Other Mitsubishi Lancer X

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.

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 article 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 article 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 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

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.

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.

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.

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.

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.

Scheme 35

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»(ref-289377-S30386868932008063000000) .
3. Shake the part or sensor.

CODE CHART

CODE CHART

VEHICLES FOR USA

TRANSAXLE MODEL REFERENCE (VEHICLES FOR USA)

VEHICLES FOR CANADA

TRANSAXLE MODEL REFERENCE (VEHICLES FOR CANADA)

CHASSIS NUMBER

The chassis number is stamped on the front floor pan.

CODE CHART

Scheme 36

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.

The engine model number is as shown as follow.

ENGINE MODEL SPECIFICATION

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

Scheme 37

ENGINE MODEL SPECIFICATION

CODE CHART

Scheme 38

TIRE AND LOADING INFORMATION PLACARD

The tire and loading information placard is located on the inside sill of the driver's door.

Scheme 39

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 40

NATIONAL SAFETY MARK < CANADA >

The tire and loading information placard is located on the inside sill of the driver's door.

Scheme 41

THEFT PROTECTION LABEL

In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts of the engine, transaxle and main outer panels: Engine cylinder block, Transaxle housing, Front fender, Hood, Trunk lid, Bumpers, Side outer panel, Doors. In addition, a theft-protection label is attached to replacement parts for main outer panels. The same data is stamped into replacement parts for the engine and the transaxle.

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

CAUTIONS FOR WORKING IN ENGINE COMPARTMENT

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

1. Items to review when servicing SRS: Be sure to read «SUPPLEMENTAL RESTRAINT SYSTEM (SRS)»(ref-289381) . 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. Air bag module (Driver's or front passenger's) Clock spring SRS-ECU Knee air bag module Sun visor Seat belt pre-tensioner Side-airbag module (Driver's side and front passenger's side) Curtain air bag module (Driver's side and front passenger's side) Center pillar (Driver's side and front passenger's side) Glove box 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 and clock spring). 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 «AIR BAG MODULE DISPOSAL PROCEDURES»(ref-289381-S29720027942008063000000) ).
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-ECU, the air bag module, clock spring, the front impact sensor, the side impact sensor, and the seat belt pre-tensioner. SRS-ECU, air bag module, clock spring, front impact sensor, the side impact sensor: 93 °C (200 °F) or more Seat belt pre-tensioner: 90 °C (194 °F) or more

WRITING PROCEDURE

Required Special Tools

1. MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: V.C.I. MB991827: M.U.T.-III USB Cable MB991910: M.U.T.-III Main Harness A

Connect scan tool MB991958 to the 16-pin data link connector as follows.

Note. For details on how to use scan tool MB991958, refer to the "M.U.T.-III Owner's Manual".

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824 and the personal computer.
4. Connect special tool MB991910 to the special tool MB991824.
5. Connect special tool MB991910 to the data link connector of the vehicle.
6. Turn the special tool MB991824 power switch to the "ON" position. NOTE: When the special tool MB991824 is energized, the special tool MB991824 indicator light will be illuminated in a green color.
7. Start the "M.U.T.-III system" on the personal computer and turn the ignition switch to the "ON" position.
8. Select "F.A.S.T./IMMO/Keyless/TPMS" button from the "System Select" screen. Then, select the applicable option code item and push the OK button.
9. Select "Special Function" on the next screen.
10. Select "ENG key code & VIN Reg." from the "Special Function" screen.
11. Push the OK button after "ENG key code & VIN Reg." is displayed.
12. Push the OK button after "Completed. Press the OK button and move to VIN writing function." is displayed.
13. Enter the VIN of registering vehicle and push the OK button.
14. Push the OK button after "VIN Writing will start. Are you sure?" is displayed.
15. Return to the previous screen and "In Progress" is displayed at the lower-left corner on the screen.
16. Push the OK button after "Completed." is displayed.
17. VIN writing result is displayed.
18. Complete the scan tool MB991958.
19. Disconnecting the scan tool MB991958 is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF).
20. Push the OK button after "Completed." is displayed.
21. Terminate the scan tool MB991958.
22. Turn the ignition switch to the "LOCK" (OFF) position and then disconnect scan tool MB991958.

VIN WRITING STEPS FOR WCM AND KOS-ECU

Connect scan tool MB991958 to the 16-pin data link connector as follows.

Note. For details on how to use scan tool MB991958, refer to the "M.U.T.-III Owner's Manual".

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824 and the personal computer.
4. Connect special tool MB991910 to the special tool MB991824.
5. Connect special tool MB991910 to the data link connector of the vehicle.
6. Turn the special tool MB991824 power switch to the "ON" position. NOTE: When the special tool MB991824 is energized, the special tool MB991824 indicator light will be illuminated in a green color.
7. Start the "M.U.T.-III system" on the personal computer and turn the ignition switch to the "ON" position.
8. Select "F.A.S.T./IMMO/Keyless/TPMS" button from the "System Select" screen. Then, select the applicable option code item and push the OK button.
9. Select "Coding" on the next screen.
10. Select "VIN Writing" on "Coding" screen.
11. Push the OK button after the VIN written in the engine control module is displayed.
12. Push the OK button after "VIN Writing will start. Are you sure?" is displayed.
13. Push the OK button after "Completed." is displayed.
14. Result of VIN writing is displayed.
15. Resister the other ID code. (Refer to «ID CODE REGISTRATION JUDGMENT TABLE»(ref-289389-S15626519462008063000000) < Vehicles with KOS > or «ID CODE REGISTRATION JUDGMENT TABLE»(ref-289390-S00543095272008063000000) < Vehicles with WCM >.)

INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE

When the following service is performed, initialize the learning value.

1. At replacing engine assembly
2. At replacing throttle body and at cleaning
3. At replacing knock sensor

INITIALIZATION PROCEDURE

Required Special Tools

1. MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: V. C.I. MB991827: M.U.T.-III USB Cable MB991910: M.U.T.-III Main Harness A

Note. When the engine ASSY is replaced, the timing chain is simultaneously replaced. Thus, it is not necessary to perform Step 3 and 9 .

1. After the ignition switch is in "LOCK" (OFF) position, connect scan tool MB991958 to the diagnosis connector.
2. Turn the ignition switch to the "ON" position.
3. The initial learning value for timing chain elongation must be stored in scan tool MB991958 (Refer to «TIMING CHAIN MAINTENANCE»(ref-289379-S11700470332008063000000) ).
4. Select "MFI" from System select Screen of scan tool MB991958.
5. Select "Special Function" from MFI Screen.
6. Select "Learned value reset" from Special Function Screen.
7. Select "All learned value" from Learned value reset Screen
8. Initialize the learning value by pressing the "OK" button.
9. The stored initial learning value for timing chain elongation during Step 3 must be written into the ECM (Refer to «TIMING CHAIN MAINTENANCE»(ref-289379-S11700470332008063000000) ).
10. After initializing the learning value, the learning value of MFI engine idling is necessary. (Refer to «ENGINE IDLING LEARNING PROCEDURE»(ref-289379-S24490223962008063000000) ).

ENGINE IDLING LEARNING PROCEDURE

PURPOSE

When the ECM is replaced, or when the learned value is initialized, the idle may not be stabilized. Carry out the learning method by following the procedures below.

LEARNING PROCEDURE

1. Start the engine and warm to reach 80°C (176°F) or more. NOTE: When the engine coolant temperature is 80°C (176°F) or more, the warm-up is not needed if the ignition switch is in "ON" position once.
2. Turn the ignition switch to "LOCK" (OFF) position.
3. After 10 seconds or more, start the engine again.
4. For 10 minutes, carry out the idling under the condition shown below and then confirm the engine idles normally. Transaxle: Neutral (P range on vehicles with TC-SST) Operation in ignition-related, fan and attachments: Not to be operated Engine coolant temperature: 80°C (176°F) or more NOTE: If the engine stalls while idling, check for a dirty (on the throttle valve) of the throttle body and clean if needed. Then perform the service from Procedure 1 again.

INITIALIZATION PROCEDURE FOR THROTTLE ACTUATOR CONTROL MOTOR

When the battery cable is disconnected and reconnected, throttle actuator control motor valve (Fully closed position) is eliminated, so that the throttle valve opening angle control would not be performed correctly. When the battery cable is disconnected and reconnected, initialize the throttle actuator control motor using the following procedure.

1. Turn the ignition switch to the "ON" position then, turn the ignition switch to "LOCK" (OFF) position.
2. For 10 seconds or more, keep the ignition switch in "LOCK" (OFF) position.

Scheme 56

If the vehicle equipped with 4B11-T/C engine continues the rough driving like competitive running *1 , the amount of carbon mixed into the engine oil tends to increase. This can possibly cause the timing chain to gradually elongate. To prevent this, the function or logic monitoring the amount of elongation of the timing chain is integrated into the ECM. When the ECM detects the elongation of the timing chain, the warning is shown on the multi-information display of combination meter as shown in the illustration. This gives the driver the information that the visual check of the elongation of the timing chain is necessary. If this warning is continuously neglected, the timing chain can possibly interfere with the other engine components, resulting in the engine damaged.

Note. *1: The competitive running means the running that constantly repeats the cycle of the full opened position of the accelerator pedal and the full closed position of the accelerator pedal.

The ECM stores the timing chain conditions as the learning value when the timing chain is installed. The ECM stores the amount of elongation of the timing chain in the EEPROM as the current learning value, compared with the learning value. The ECM judges that the visual check of the elongation of the timing chain is necessary when the current learning value exceeds the specified value. Thus, use the scan tool MB991958 to always carry out the maintenance of the learning value related to the timing chain that is stored by the ECM after the following service.

SERVICE AND MAINTENANCE CHART

LEARNED VALUE READ&SAVE AND WRITE LEARNED VALUE (CHANGED ECU)

Required Special Tools

1. MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: V. C.I. MB991827: M.U.T.-III USB Cable MB991910: M.U.T.-III Main Harness A

1. After the ignition switch is in "LOCK" (OFF) position, connect scan tool MB991958 to the diagnosis connector.
2. Turn the ignition switch to the "ON" position.
3. Select "MFI" from System select Screen of scan tool MB991958.
4. Select "Special Function" from MFI Screen.
5. Select "Timing chain maintenance" from Special Function Screen.
6. Select "Learned value Read&Save" from Timing chain maintenance Screen.
7. Press "OK" to store the learning value file. NOTE: When the learning value file is appropriately stored, "Learned value Save Complete" is shown on the screen of the scan tool MB991958. NOTE: Calculating the amount of elongation of the timing chain by the ECM takes the time. Thus, the file cannot be stored for a while after the ECM initialization or replacement.
8. Replace the ECM.
9. Select "Learned value reset" from Timing chain maintenance Screen.
10. Select the learning value file stored during Step 3 to write the learning value. NOTE: Use only the learning value file stored during Step 3 without using any other files. NOTE: When the learning value is appropriately written, "Learned value writing Completed." is shown on the screen of the scan tool MB991958.

SERVICING ELECTRICAL SYSTEM

Scheme 57

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: "P" position Steering wheel: straight-forward position
2. When servicing the electrical system, disconnect the negative cable terminal from the battery.

Scheme 58

1. 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 40cm (16 in.) from any plastic parts and all opening parts (doors, luggage compartment, etc.).
2. If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to observe the following instructions to prevent damages to the plastic parts. Spray nozzle distance: Approximately 40 cm (16 in.) or more Spray pressure: 3,900 kPa or less Spray temperature: 82 °C (180°F) or less Time of intensive spraying to one point: Within 30 seconds

CODING LIST

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

VARIANT CODING

Required Special Tools

1. MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: Vehicle Communication Interface (V. C.I.) MB991827: M.U.T.-III USB Cable MB991910: M.U.T.-III Main Harness A (Vehicles with CAN communication system)

The coding data can be checked by operating scan tool MB991958.

Note. For details on how to use the scan tool MB991958, refer to the "M.U.T.-III Owner's manual".

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824 and the personal computer.
4. Connect special tool MB991910 to special tool MB991824.
5. Connect special tool MB991910 to the data link connector.
6. Turn the power switch of special tool MB991824 to the "ON" position. NOTE: When special tool MB991824 is energized, special tool MB991824 indicator light will be illuminated in a green color.
7. Start the "M.U.T.-III system" on the personal computer.
8. Turn the ignition switch to the "ON" position.
9. Select "System select" from the start-up screen.
10. Select "From 2006 MY" under "Model Year". Check that "Vehicle Information" contents are correct.
11. On the system list screen, select "MPI/GDI/DIESEL" to check the engine control module data, "AT/CVT/A-MT/TC-SST" to check the TC-SST data, and "ETACS" to check the ETACS-ECU data. NOTE: If "Loading Option Setup" list is shown, click appropriate box.
12. Select "Coding".
13. Select "Coding information & copy".
14. If the displayed coding information is different from the corresponding initial setting in the list, replace the ECU with a correctly coded one. For replacement of the engine control module, refer to «ENGINE CONTROL MODULE»(ref-289380-S19421569532008063000000) . For replacement of the TC-SST-ECU*, refer to «TRANSAXLE ASSEMBLY»(ref-289384-S42777275452008063000000) . For replacement of the ETACS-ECU, refer to «ETACS»(ref-289392-S22124280732008063000000) . NOTE: *: TC-SST-ECU cannot be disassembled. Thus, replace the transaxle assembly.

ENGINE CONTROL MODULE CODING DATA LIST

ENGINE CONTROL MODULE CODING DATA LIST

TC-SST-ECU CODING DATA LIST

TC-SST-ECU CODING DATA LIST

ETACS-ECU CODING DATA LIST

ETACS-ECU CODING DATA LIST

OPTION CODING

The ETACS-ECU option coding data can be checked or changed by operating scan tool MB991958.

1. How to check option coding data Connect the scan tool MB991958. Refer to «CODING LIST»(ref-289379-S27431265632008063000000) . Turn the ignition switch to the "ON" position. Select "System select" from the start-up screen. Select "From 2006 MY" under "Model Year". Check that "Vehicle Information" contents are correct. Select "ETACS" from "System List", and then press "OK" button. NOTE: If "Loading Option Setup" list is shown, click appropriate box. Select "Coding". Select "Option Coding Information". Check the displayed option coding information.
2. How to change option coding data Connect the scan tool MB991958. Turn the ignition switch to the "ON" position. Select "System select" from the start-up screen. Select "From 2006 MY" under "Model Year". Check that "Vehicle Information" contents are correct. Select "ETACS" from "System List", and then press "OK" button. NOTE: If "Loading Option Setup" list is shown, click appropriate box. Select "Coding". Select "Option Coding". Change to correct option coding data.

LIST

Item name

1. Number of speaker
2. Seat material
3. Auto light control
4. AUDIO (CAN)
5. AND
6. HFM (hands free-ECU)
7. Rain Light Sensor
8. Front fog light
9. Rear fog light
10. Horn type
11. Manner switch
12. Remote engine starter
13. Wiper washer check bulb
14. Compressor type
15. Satellite Radio
16. DRL function
17. Keyless

BOLTS AND NUTS WITH STABILIZER FOR COEFFICIENT OF FRICTION

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

Note. The bolts and nuts with stabilizer for coefficient of friction mean that the bolts and nuts with surface treatment to stabilize and reduce the coefficient of friction, allowing to achieve the stable axial force and to secure the high axial force with low tightening torque.

Scheme 59

Scheme 60

TOWING WHEN KEYS ARE NOT AVAILABLE

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

SAFETY PRECAUTIONS

The following precautions should be taken when towing the vehicle

1. Do not lift or tow the vehicle by attaching to or wrapping around the bumper.
2. Any loose, protruding, or damaged parts such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle.
3. Refrain from going under a vehicle when it is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed when towing a vehicle.

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 61

Scheme 62

GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS

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: Engine oils displaying ILSAC certification symbol or conforming to the API classification SM.

For further details, refer to "LUBRICANTS SELECTION".

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.

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

LUBRICATION CHART

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

Scheme 63

If these oils are not available, an API classification SM or higher can be used.

Scheme 64

OIL VISCOSITY

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

Note. SAE 5W-30 engine oil is strongly recommended for optimum fuel economy and cold starting. If engine oil other than 5W-30 is used, the engine may be seized by poor lubrication.

COOLANT

Relationship between Coolant Concentration and Specific Gravity

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)

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.

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

If the fuel-vapor vent line is clogged or damaged, fuel vapor will escape into the atmosphere causing excessive emissions. 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.

8. EXHAUST SYSTEM (CONNECTIONS PORTION OF MUFFLER, MUFFLER PIPES AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE)

Check for holes and exhaust gas leaks due to damage, corrosion, etc.

1. Check the joints and connections for looseness and exhaust gas leaks.
2. Check the rubber hangers and brackets for damage.

Scheme 65

Scheme 66

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 - 90°C (176 - 194°F). WARNING: Use care as oil could be hot.
2. Remove the engine oil filler cap.
3. Remove the engine room under cover extension. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) )
4. Remove the drain plug to drain oil.
5. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque. Tightening torque: 39 ± 5 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. If engine oil other than 5W-30 is used, the engine may be seized by poor lubrication.
6. Refill the specified quantity of oil. Specified Engine Oil: Engine oils displaying ILSAC certification symbol ("Starburst" symbol) or conforming to the API classification SM or higher Total quantity: 5.6 dm 3 (5.9 quarts)
7. Install the engine oil filler cap.
8. Let the engine run for a few minutes.
9. Stop the engine, and then check the oil level using the oil dipstick after a few minutes.
10. Install the engine room under cover extension. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) )

Scheme 67

Scheme 68

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 - 90°C (176 - 194°F) WARNING: Use care as oil could be hot.
2. Remove the engine oil filler cap.
3. Remove the engine room under cover extension (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) ).
4. Remove the drain plug to drain oil.
5. Use the respective tool in the following table to remove the engine oil filter. SPECIAL TOOL REFERENCE Number Special tool MD356000 Oil filter wrench (MB991610) or equivalent
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. Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with an oil filter wrench. TIGHTENING TORQUE SPECIFICATION Number Special tool Tightening torque MD356000 MB991610 or equivalent Approximately 3/4 turn [14 ± 2 N.m (124 ± 17 in-lb)]
9. Install the drain plug and refill engine oil (Refer to «ENGINE OIL FILTER REPLACEMENT»(ref-289386-S34502935612008063000000) ).
10. Rev the engine a few times, and check to be sure that no engine oil leaks at the oil filter.
11. Install the engine room under cover extension (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) ).

Scheme 69

Scheme 70

1. Remove the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)
2. Remove the oil filler plug and gasket.
3. Check that the oil level is just below the lower edge of the oil filler plug hole.
4. Check that the oil is not excessively foul and has moderate viscosity.
5. Install the oil filler plug and new gasket, then tighten them to the specified torque. Tightening torque: 32 ± 2 N.m (24 ± 1 ft-lb)
6. Install the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)

TRANSAXLE OIL CHANGE

1. Remove the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)
2. Remove the oil drain plug and gasket to drain the oil.
3. Install the oil drain plug and new gasket, then tighten them to the specified torque. Tightening torque: 32 ± 2 N.m (24 ± 2 ft-lb)
4. Remove the oil filler plug and gasket, then fill the oil up to the lower edge of the oil filler plug. Brand name: Mitsubishi genuine Dia-Queen New Multi Gear Oil SAE 75W-80 API GL-3 Quantity: 2.5 dm 3 (2.6 quarts)
5. Install the oil filler plug and new gasket, then tighten them to the specified torque. Tightening torque: 32 ± 2 N.m (24 ± 1 ft-lb)
6. Install the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)

TC-SST OIL LEVEL CHECK

1. After cleaning the outer surface of transaxle, visually check that there is no oil oozing or oil leaking from the transaxle.
2. If an oil oozing or leaking is present, replace the transaxle assembly.

Scheme 71

Scheme 72

1. Remove the engine compartment under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)
2. Remove the oil drain plug to drain the oil. NOTE: Because the oil in the oil cooler and oil filter cannot be drained, the amount of drained oil will be approximately 5.5 dm 3 .
3. Tighten the oil drain plug to the specified torque. Tightening torque: 25 N.m
4. Remove the air cleaner element, air cleaner intake duct, and air cleaner body. (Refer to «AIR CLEANER»(ref-289375-S31240850732008063000000) .)
5. Remove the oil filler plug, then fill the oil. Brand name: Mitsubishi genuine Dia-Queen SSTF-I Filling amount: Approximately 5.5 dm 3
6. Tighten the oil filler plug to the specified torque. Tightening torque: 25 N.m
7. Install the air cleaner element, air cleaner intake duct, and air cleaner body. (Refer to «AIR CLEANER»(ref-289375-S31240850732008063000000) .)
8. Start the engine, then let it idle for 1 to 2 minutes.
9. Move the shift lever to every position, and then move it to the P or N range.
10. Stop the engine, then perform Steps 2 to 5 again.
11. Check the oil level and oil fouling. (Refer to «TRANSMISSION OIL LEVEL CHECK»(ref-289383-S42325830642008063000000) .) If fouling is found, repeat Steps 2 to 5 until the fouling is eliminated.
12. Install the engine compartment under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)

Scheme 73

1. Remove the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)
2. Remove the oil filler plug and gasket.
3. Check that the oil level is just below the lower edge of the oil filler plug hole.
4. Check that the oil is not excessively foul and has moderate viscosity.
5. Install the oil filler plug and new gasket, then tighten them to the specified torque. Tightening torque: 32 ± 2 N.m (24 ± 1 ft-lb)
6. Install the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)

TRANSFER OIL CHANGE

1. Remove the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)
2. Remove the oil drain plug and gasket to drain the oil.
3. Install the oil drain plug and new gasket, then tighten them to the specified torque. Tightening torque: 32 ± 2 N.m (24 ± 1 ft-lb)
4. Remove the oil filler plug and gasket, then fill the oil up to the lower edge of the oil filler plug hole. Brand name: Mitsubishi genuine Dia-Queen LSD Gear Oil Quantity: 0.9 dm 3 (1.0 quarts)
5. Install the oil filler plug and new gasket, then tighten them to the specified torque. Tightening torque: 32 ± 2 N.m (24 ± 1 ft-lb)
6. Install the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) .)

Scheme 74

1. Remove the trunk room side trim lid on the right of the trunk room.
2. If the vehicle has been run, leave it for 90 min. or more in an ordinary temperature {10 - 30°C (50 - 86°F)} to allow the accumulator internal pressure to drop. NOTE: If the ambient temperature is 10°C (50°F) or less, allow more time to leave the vehicle to stand idle.
3. Check that the oil reservoir fluid level is in between MAX and MIN.
4. If the fluid level is not in between MAX and MIN, fill the specified fluid. Specified fluid: DIAMOND ATF-SP III
5. Install the trunk room side trim lid.

DISK BRAKE PAD CHECK

Scheme 75

Scheme 76

1. Visually check the thickness of brake pad from the inspection hole of the caliper body. Standard value: 9.85 mm (0.39 inch) < Front > 9.0 mm (0.35 inch) < Rear > Limit: 2.0 mm (0.08 inch) < Front > 2.0 mm (0.08 inch) < Rear >
2. When the thickness is lower than the limit value, replace both brake pads (right and left) as a set (Refer to «BRAKE PAD REPLACEMENT»(ref-289400-S37795878612008063000000) ).

DISK BRAKE ROTOR CHECK

Before turning the brake disk, the following conditions should be checked.

DISK BRAKE ROTOR SPECIFICATION

Scheme 77

Scheme 78

1. Using a micrometer, measure disk thickness at eight positions, approximately 45 degrees apart and 10 mm (0.4 inch) in from the outer edge of the disk. Standard value: 32.0 mm (1.26 inch) < Front > 22.0 mm (0.87 inch) < Rear > Limit: 30.0 mm (1.18 inch) < Front > 20.0 mm (0.79 inch) < Rear > NOTE: Thickness variation (at least 8 positions) should not be more than 0.015 mm (0.0006 inch). CAUTION: After a new brake disk is installed, always grind the brake disk with on-the-car type brake lathe. If this step is not carried out, the brake disk run-out exceeds the specified value, resulting in judder. When the on-the-car type lathe is used, first install M12 flat washer on the stud bolt in the brake disk side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disk rotor may be deformed, resulting in inaccurate grinding. Grind the brake disk with all wheel nuts diagonally and equally tightened to the specified torque 100 N.m (74 ft-lb). When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disk rotor or drum may be deformed, resulting in judder.
2. If the disk thickness is less than the limits, replace it with a new one. If thickness variation exceeds the specification, turn rotor with an on-the-car type brake lathe ("MAD, DL-8700PF" or equivalent). If the calculated final thickness after turning the rotor is less than the standard value, replace the disk.

Scheme 79

Scheme 80

1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disk with the hub nut.
3. Place a dial gauge approximately 5 mm (0.2 inch) from the outer circumference of the brake disk, and measure the run-out of the disk. Limit: 0.06 mm (0.0024 inch) < Front > 0.08 mm (0.0032 inch) < Rear >
4. When the brake disk runout exceeds the limit value, correct the brake disk runout according to the following procedure. Before removing the brake disk, make marks using a chalk to the stud bolt on the side with the greater runout and to both sides of the stud bolt. Check the wheel bearing axial looseness. (Refer to «WHEEL BEARING END PLAY CHECK»(ref-289401-S19854450872008063000000) < Front > or «WHEEL BEARING END PLAY CHECK»(ref-289399-S02395837622008063000000) < Rear >.) When the looseness is within the limit value, install the brake disk after changing the phase between the hub and the brake disk, then check the runout of the brake disk again. CAUTION: After a new brake disk is installed, always grind the brake disk with on-the-car type brake lathe. If this step is not carried out, the brake disk run-out exceeds the specified value, resulting in judder. When the on-the-car type lathe is used, first install M12 flat washer on the stud bolt in the brake disk side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disk rotor may be deformed, resulting in inaccurate grinding. Grind the brake disk with all wheel nuts diagonally and equally tightened to the specified torque 100 N.m (74 ft-lb). When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disk rotor or drum may be deformed, resulting in judder.
5. If the run-out cannot be corrected by changing the phase of the brake disk, replace the brake disk or grind it with the on-the-car type brake lathe ("MAD, DL-8700PF" or equivalent).

18. 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

Scheme 81

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 82

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

Scheme 83

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.

24. 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).

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 84

Scheme 85

1. Remove the glove box (Refer to «GLOVE BOX»(ref-289397-S14824251762008063000000) ).
2. Loosen the two lugs as shown to replace the clean air filter.
3. Install the glove box.

MAIN SEALANT AND ADHESIVE TABLE

MAIN SEALANT AND ADHESIVE REFERENCE CHART