General Information - Lancer Evolution: Other Mitsubishi Lancer X рестайлинг

ON-VEHICLE SERVICE

The "ON-VEHICLE SERVICE" information 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 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.

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

1. 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!
2. Insert the needle-nosed wire probe into each of the ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE: Measure voltage with the ECU connectors connected. You may find it convenient to pull out the ECU to make it easier to reach the connector terminals. Checks don't have to be carried out in the order given in the chart.
3. If voltage readings differ from normal condition values, check related sensors, actuators, and wiring. Replace or repair as needed.
4. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem.

TERMINAL RESISTANCE AND CONTINUITY CHECKS

1. Turn the ignition switch to the "LOCK" (OFF) position.
2. Disconnect the ECU connector. 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!
3. Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart. NOTE: Checks don't have to be carried out in the order given in the chart.
4. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace.
5. After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem.

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.

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.

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 155

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-592584-S02750277482014011000000) .
3. Shake the part or sensor.

VEHICLES FOR USA (VEHICLES FOR 50 STATES)

VEHICLE IDENTIFICATION REFERENCE

(VEHICLES FOR PUERTO RICO)

VEHICLE IDENTIFICATION REFERENCE

VEHICLES FOR CANADA

VEHICLE IDENTIFICATION REFERENCE

CHASSIS NUMBER

The chassis number is stamped on the front floor pan.

CODE CHART

CODE CHART

Scheme 156

TIRE AND LOADING INFORMATION PLACARD

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

Scheme 157

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.

The engine model number is as shown as follows.

ENGINE MODEL NUMBERS REFERENCE

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

ENGINE SERIAL NUMBER REFERENCE

Scheme 158

CAUTIONS FOR WORKING IN ENGINE COMPARTMENT

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

1. Items to review when servicing SRS: For safe operation, please follow the directions and heed all warnings. Refer to «SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - LANCER EVOLUTION»(ref-592595) . 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) 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-592595-S07717067222014011000000) ).
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 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

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 166

Scheme 167

Scheme 168

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-592599-S39644025762014011000000) or «ID CODE REGISTRATION JUDGMENT TABLE»(ref-592600-S42106495682014011000000) .)

CODING LIST

Before troubleshooting, check that the coding data written into the engine control module, TC-SST-ECU and ETACS-ECU are normal. If they are not the same as the initial settings, various 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-ECU 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-592621-S08804776802014011000000) . For replacement of the TC-SST-ECU*, refer to «TRANSAXLE ASSEMBLY»(ref-592623-S11618165432014011000000) . For replacement of the ETACS-ECU, refer to «ETACS»(ref-592588-S15835176932014011000000) . 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 «VARIANT CODING»(ref-592586-S26261254372014011000000) . 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 "MP/GDI/DIESEL" or "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. Refer to «VARIANT CODING»(ref-592586-S26261254372014011000000) . 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 "MP/GDI/DIESEL" or "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 LIST Item name Cruise Control LIST ITEM LIST Item name Number of speaker Seat material Auto light CNTL AUDIO (CAN) AND HFM (hands free-ECU) Rain Light Sensor Front fog light Rear fog light Horn type Remote engine starter Wiper washer check bulb Compressor type Satellite Radio Keyless Door Unlock Mode Customize AUDIO/S.RADIO type Manner switch DRL function Front wiper

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

1. After the ignition switch is in "LOCK" (OFF) position, connect scan tool MB991958 to the data link connector.
2. Turn the ignition switch to the "ON" position.
3. Select "MFI" from System select Screen of scan tool MB991958.
4. Select "Special Function" from MFI Screen.
5. Select "Learned value reset" from Special Function Screen.
6. Select "All learned value" from Learned value reset Screen
7. Initialize the learning value by pressing the "OK" button.
8. After initializing the learning value, the learning value of MFI engine idling is necessary. (Refer to «LEARNING PROCEDURE FOR IDLING IN MFI ENGINE»(ref-592586-S17410518942014011000000) ).

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 169

If the vehicle equipped with 2.0 L turbocharged 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 above. 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 initial learning value when the timing chain is installed. The ECM stores the amount of elongation of the timing chain in the EEPROM as the current learning value, compared with the initial learning value. The ECM judges that the visual check of the elongation of the timing chain is necessary when the current learning value exceeds the specified value. Thus, use the scan tool MB991958 to always carry out the maintenance of the initial learning value related to the timing chain that is stored by the ECM after the following service.

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

SERVICING ELECTRICAL SYSTEM

Scheme 170

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.

HOW TO SHIFT LOCK FORCED RELEASE

If the shift lever cannot be moved from the P position due to discharged battery or similar reasons, release the shift lock by observing the procedure below.

< TC-SST>

Scheme 171

Scheme 172

1. Remove the floor console box cup holder and the floor console panel assembly (Refer to «FLOOR CONSOLE ASSEMBLY»(ref-592589-S06407524462014011000000) ).
2. Turn the ignition switch to the position other than the LOCK (OFF) position.
3. Insert a screwdriver or a similar tool from the section "A" shown in the illustration below. While pressing the shift lock forced release switch, move the shift lever.

Scheme 173

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

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.

FORM-IN-PLACE GASKET (FIPG)

The engine has several parts to which the form-in-place gasket (FIPG) is used. To sufficiently achieve the aims of this gasket, it is necessary to pay attention to the application amount, procedure, and surface status.

If the application amount is too small, a leakage will occur. If the application amount is excessive, the FIPG will overflow and cause a clogging or narrowing of water and oil paths. Therefore, to eliminate the leak from the joint, it is indispensable that the FIPG be applied with a correct amount and without any gap.

Because the FIPG used for the engine parts becomes hardened by the reaction with the atmospheric moisture, it is normally used for the metal flange section.

GASKET SURFACE CLEANING

Use a gasket scraper or wire brush to completely remove all the foreign materials adhering to the gasket surface. Check that the FIPG application surface is smooth. There must be no grease or foreign material adhesion to the gasket surface. Do not forget to remove the old FIPG remaining in the mounting hole and tapped hole.

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.

FLOOR JACK AND RIGID RACK

FLOOR JACK

Scheme 174

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 175

Scheme 176

VEHICLE DIMENSION SPECIFICATION

VEHICLE DIMENSION SPECIFICATION

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

LUBRICANTS SPECIFICATION

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

Scheme 177

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

Scheme 178

OIL VISCOSITY

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.

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 179

Scheme 180

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-592644-S24529768612014011000000) )
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 below, and then tighten the drain plug to the specified torque. Tightening torque: 39 ± 5 N.m (29 ± 3 ft-lb) CAUTION: Select engine oil of the proper SAE viscosity number according to the atmospheric temperature.
6. Refill the specified quantity of oil. Specified Engine Oil: Engine oils displaying ILSAC certification symbol ("Starburst" symbol) or conforming to the API classification SN or higher Total quantity: 5.6 dm 3 (5.85 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-592644-S24529768612014011000000) )

TRANSAXLE OIL CHANGE

1. Remove the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-592644-S24529768612014011000000) .)
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. Brand name: DiaQueen NEW MULTI GEAR OIL API classification GL-3, SAE 75W-80 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-592644-S24529768612014011000000) .)

13. TWIN CLUTCH SPORT-SHIFT TRANSMISSION OIL FILTER (CHANGE)

For information concerning the replacement procedures, refer to OIL FILTER .

Scheme 181

Scheme 182

Scheme 183

1. Remove the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-592644-S24529768612014011000000) .)
2. Remove the filler plug and gasket.
3. Check that the oil level is not 14 mm (0.6 inch) below the bottom of the oil filler plug hole.
4. Check that the oil is not excessively foul and has moderate viscosity.
5. If the oil level is not in between the upper limit and the lower limit, refill the specified oil to the bottom of the oil filler plug hole. Brand name: DiaQueen LSD gear oil
6. Install the filler plug and new gasket, then tighten them to the specified torque. Tightening torque: 32 ± 2 N.m (24 ± 1 ft-lb)
7. Install the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-592644-S24529768612014011000000) .)

Scheme 184

1. Remove the engine room under cover front B assembly. (Refer to «UNDER COVER»(ref-592644-S24529768612014011000000) .)
2. Remove the drain plug and gasket to drain the oil.
3. Install the 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 filler plug and gasket, then fill the oil up to the lower edge of the filler plug hole. Brand name: DiaQueen LSD gear oil Quantity: 0.8 dm 3 (0.85 quarts)
5. Install the 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-592644-S24529768612014011000000) .)

16. ENGINE COOLANT (CHANGE)

Required Special Tool

1. MB991871: LLC changer

Scheme 185

Scheme 186

1. Remove the engine room under cover front A (RH). (Refer to «UNDER COVER»(ref-592644-S24529768612014011000000) ) 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. Remove the engine room under cover front B. (Refer to «UNDER COVER»(ref-592644-S24529768612014011000000) )
4. Remove the air cleaner intake hose. (Refer to «AIR CLEANER»(ref-592677-S03266293052014011000000) )
5. Remove the turbocharger compressor bracket. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-592677-S09727143592014011000000) )
6. Disconnect the turbocharger water return hose and drain the coolant in the water jacket.
7. Remove the exhaust manifold cover. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-592677-S09727143592014011000000) )
8. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.
9. Remove the radiator condenser tank and drain the coolant.
10. Connect the turbocharger water return hose.
11. Replace the cylinder block drain plug gasket, and tighten the drain plug to the specified torque. Tightening torque: 39 ± 3 N.m (29 ± 2 ft-lb)
12. Install the exhaust manifold cover. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-592677-S09727143592014011000000) ).
13. Securely tighten the drain plug of the radiator.
14. Reinstall the radiator condenser tank. CAUTION: Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminum components.
15. Use special tool MB991871 to refill the engine coolant up to the top of the radiator port. Recommended antifreeze: DiaQueen Super Long Life Coolant Premium or equivalent* Quantity: 7.5 dm 3 (7.9 quarts) NOTE: *similar high quality ethylene glycol based non-silicate, non-amine, non-nitrate and non-borate coolant with long life hybrid organic acid technology. NOTE: For how to use special tool (MB991871), refer to its manufacturer's instructions.
16. Tighten the radiator cap securely.
17. Remove the radiator condenser tank cap, and add the engine coolant up to the "FULL" line.
18. Turn the A/C switch to OFF position to start the engine and warm up until the cooling fan operates. NOTE: This step opens the thermostat fully.
19. Rev the engine several times and then stop it. Check that there are no coolant leaks.
20. Remove the radiator cap with the engine cool, and then refill the engine coolant up to the top of the radiator port.
21. Tighten the radiator cap securely. CAUTION: Do not overfill the radiator condenser tank.
22. Remove the radiator condenser tank cap, and add the engine coolant up to the "FULL" line.
23. Install the turbocharger compressor bracket. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-592677-S09727143592014011000000) )
24. Install the air cleaner intake hose. (Refer to «AIR CLEANER»(ref-592677-S03266293052014011000000) )
25. Remove the engine room under cover front A and engine room under cover front A (RH). (Refer to «UNDER COVER»(ref-592644-S24529768612014011000000) )

DISK BRAKE PAD CHECK

Scheme 187

Scheme 188

1. Visually check the thickness of brake pad from the inspection hole of the caliper body. Standard value: 9.85 mm (0.39 inch) 9.0 mm (0.35 inch) Limit: 2.0 mm (0.08 inch) 2.0 mm (0.08 inch)
2. When the thickness is lower than the limit value, replace both brake pads (right and left) as a set (Refer to «BRAKE PAD CHECK»(ref-592663-S41356544592014011000000) ).

Scheme 189

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) 22.0 mm (0.87 inch) Limit: 30.0 mm (1.18 inch) 20.0 mm (0.79 inch) NOTE: Thickness variation (at least 8 positions) should not be more than 0.015 mm (0.0006 inch).

FRONT BRAKE DISK RUN-OUT CHECK AND CORRECTION

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

1. 0.06 mm (0.0024 inch)
2. 0.08 mm (0.0032 inch)

19. 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 190

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 191

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 192

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.

25. 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 193

Scheme 194

1. Remove the glove box (Refer to «GLOVE BOX»(ref-592589-S03921592372014011000000) ).
2. Loosen the two lugs as shown in the illustration below to replace the clean air filter.
3. Install the glove box.

MAIN SEALANT AND ADHESIVE TABLE

MAIN SEALANT AND ADHESIVE SPECIFICATION