00-1

GENERAL
CONTENTS

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Scope of Maintenance, Repair and Servicing Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Destination . . . . . . . . . . . . . . . . . . . . . . 2 Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 16
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Indication of Tightening Torque . . . . . . . . . . . . . . . . 2 MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . . 17
Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PRECAUTIONS BEFORE SERVICE . . . . . . . . . 18
Explanation of Manual Contents . . . . . . . . . . . . . . . 4
SUPPLEMENTAL RESTRAINT SYSTEM
HOW TO USE (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING/INSPECTION SERVICE
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SRS SERVICE PRECAUTIONS . . . . . . . . . . . . . 22
Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . 6
SUPPORT LOCATIONS FOR LIFTING AND
Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
How to Use the Inspection Procedures . . . . . . . . 10
Support Positions for a Garage Jack and Axle
Connector Measurement Service Points . . . . . . . 11 Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 12 Support Positions for a Single-Post Lift or
Inspection Service Points for a Blown Fuse . . . 13 Double-Post Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Points to Note for Intermittent Malfunctions . . . . 13 Support Positions and Support Method for an
H-Bar Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . 14
STANDARD PART/TIGHTENING-TORQUE
Vehicle Information Code Plate . . . . . . . . . . . . . . . 14 TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
00-2 GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS
AND SERVICING EXPLANATIONS STANDARD VALUE
This manual provides explanations, etc. concerning Indicates the value used as the standard for judging
procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection
and servicing of the subject model. Note, however, or the value to which the part or assembly is
that for engine and transmission-related component corrected and adjusted. It is given by tolerance.
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and LIMIT
installation procedures for major components.
For detailed information concerning the inspection, Shows the standard for judging the quality of a
checking, adjustment, disassembly and reassembly part or assembly on inspection and means the
of the engine, transmission and major components maximum or minimum value within which the part
after they have been removed from the vehicle, or assembly must be kept functionally or in strength.
please refer to separate manuals covering the It is a value established outside the range of
engine and the transmission. standard value.

ON-VEHICLE SERVICE REFERENCE VALUE

“On-vehicle Service” is procedures for performing Indicates the adjustment value prior to starting the
inspections and adjustments of particularly work (presented in order to facilitate assembly and
important locations with regard to the construction adjustment procedures, and so they can be
and for maintenance and servicing, but other completed in a shorter time).
inspection (for looseness, play, cracking, damage,
etc.) must also be performed. CAUTION
Indicates the presentation of information particularly
INSPECTION vital to the worker during the performance of
Under this title are presented inspection and maintenance and servicing procedures in order to
checking procedures to be performed by using avoid the possibility of injury to the worker, or
special tools and measuring instruments and by damage to component parts, or a reduction of
feeling, but, for actual maintenance and servicing component or vehicle function or performance, etc.
procedures, visual inspections should always be
performed as well. INDICATION OF TIGHTENING TORQUE
Tightening torques (units: N·m) are set to take into
INDICATION OF DESTINATION account the central value and the allowable
General Export and GCC are used for convenience tolerance. The central value is the target value,
to indicate destination. and the allowable tolerance provides the checking
NOTE
range for tightening torques. If bolts and nuts are
(1) “General Export” means territories other than
Europe, GCC, Australia, New Zealand, the not provided with tightening torques, refer to
U.S.A. and Canada. P.00-28.
(2) “GCC” indicates countries that are members
of the (Persian) Gulf Cooperation Council of
nations.
(3) In some instances, vehicles with other
specifications may be shipped to some
countries.
 GENERAL - How to Use This Manual 00-3

MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.

MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection.
DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an
engine.
M/T: Indicates the manual transmission, or models equipped with the manual transmission.
A/C: Indicates the air conditioner.
00-4 GENERAL - How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed

before the work in that section is started,
and procedures to be performed after
the work in that section is finished.

Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better under-
standing of the installed condition of
component parts.

Indicates (by symbols) where lubrica-

tion is necessary.

Maintenance and Servicing Procedures

The numbers provided within the diagram indi- D Installation steps:
cate the sequence for maintenance and servic- Specified in case installation is impossible
ing procedures. in reverse order of removal steps. Omitted
D Removal steps: if installation is possible in reverse order of
The part designation number corresponds removal steps.
to the number in the illustration to indicate D Reassembly steps:
removal steps. Specified in case reassembly is impossible
D Disassembly steps: in reverse order of disassembly steps.
The part designation number corresponds Omitted if reassembly is possible in reverse
to the number in the illustration to indicate order of disassembly steps.
disassembly steps.

Classifications of Major Maintenance/Service Points

When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for lubrica- : Grease

tion and for application of sealants and adhe- (multipurpose grease unless there is
sives is provided, by using symbols, in the dia- a brand or type specified)
gram of component parts or on the page follow-
ing the component parts page, and explained. : Sealant or adhesive

: Brake fluid or automatic transmission fluid

: Engine oil, gear oil or air conditioner

compressor oil

: Adhesive tape or butyl rubber tape

 GENERAL - How to Use This Manual 00-5

Indicates the Indicates the Indicates the Indicates the

group title. section title. group num- page number.
ber.

denotes non-re-
usable part.

Denotes tightening torque.

For bolts and nuts which do not
have a tightening torque listed,
refer to the “Standard Parts-
tightening-torque Table”.

Repair kit or set parts

are shown. (Only very
frequently used parts
are shown.)

Operating procedures, cau-

tions, etc. on removal, installa-
tion, disassembly and reas-
sembly are described.

indicates that there is

a continuity between the termi-
nals.
indicates terminals to
which battery voltage is applied.

The title of the page (following

the page on which the diagram
of component parts is pres-
ented) indicating the locations of
lubrication and sealing proce-
dures.
00-6 GENERAL - How to Use Troubleshooting/Inspection Service Points

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline
described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems
still follow this outline.

TROUBLESHOOTING CONTENTS
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis
flow is different from that given below, or if additional explanation is required, the details of such
differences or additions will also be listed.

Diagnosis method

Gathering information
from the customer.

Check trouble symptom.

Reoccurs Does not reoccur.

Read the diagnosis code Read the diagnosis code

No diagnosis code
or communication Diagnosis code Diagnosis code No diagnosis
with MUT-II not displayed. displayed. code
possible

Refer to the INSPECTION After taking note of the

CHART FOR TROUBLE malfunction code, erase
SYMPTOMS (Refer to the diagnosis code
applicable group.) memory

Recheck trouble symptom.

Read the diagnosis codes.

Diagnosis code No diagnosis
displayed. code

Refer to the INSPECTION CHART FOR DIAGNOSIS INTERMITTENT MALFUNCTIONS (Refer to P.00-13.)
CODES (Refer to applicable group.)

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the trouble symptoms is difficult, procedures for checking operation and verifying
trouble symptoms are shown.

3. DIAGNOSIS FUNCTION
Details which are different from those in the “Diagnosis Function” section on the next page are listed.
 GENERAL - How to Use Troubleshooting/Inspection Service Points 00-7
4. INSPECTION CHART FOR DIAGNOSIS CODES
5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-10 for how
to use the inspection procedures.)

6. INSPECTION CHART FOR TROUBLE SYMPTOMS

If there are trouble symptoms even though the results of inspection using the MUT-II show that all
diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means
of this chart.

7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM

Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection
Chart for Trouble Symptoms. (Refer to P.00-10 for how to use the inspection procedures.)

8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgement 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.

10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE

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

MUT- Ⅱ DIAGNOSIS FUNCTION

METHOD OF READING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and take a
reading of the diagnosis codes.
Caution
Turn the ignition switch to “LOCK”(OFF) position before
connecting or disconnecting the MUT-II.
00-8 GENERAL - How to Use Troubleshooting/Inspection Service Points

MB991529 WHEN USING THE WARNING LAMP

1. Use the special tool to earth No.1 terminal (diagnosis
control terminal) of the diagnosis connector.
2. Turn the ignition switch to “ON” position.
3. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems

System name Warning lamp name

ACD, AYC ACD mode indicator lamp

ABS ABS warning lamp

Indication of diagnosis code by warning lamp

When the diagnosis code No.24 is output When no diagnosis code is output*

0.5 sec.
1.5 secs. 0.5 sec. 0.25 sec.
On
Off On
Pause Tens Place Units Off
time 3 signal division signal
secs. 2 secs.

METHOD OF ERASING DIAGNOSIS CODES

WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and erase the diagnosis code.
Caution
Turn the ignition switch to “LOCK”(OFF) position before connecting or disconnecting the MUT-II.
WHEN NOT USING THE MUT-II
1. Turn the ignition switch to “LOCK”(OFF) position.
2. After disconnecting the battery cable from the battery ( - ) terminal for 10 seconds or more, reconnect
the cable.
3. After the engine has warmed up, run it at idle for about 15 minutes.
GENERAL - How to Use Troubleshooting/Inspection Service Points 00-9
MUT- Ⅱ INPUT SIGNAL CHECK <SWS>
WHEN USING THE MUT-II
1. Connect the MUT-II to the diagnosis connector and erase
the diagnosis code.
Caution
Turn the ignition switch to “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
2. If the MUT-II buzzer sounds once when each switch is
operated (ON/OFF), the input signal for that switch circuit
system is normal.

MB991529 WHEN USING A VOLTMETER

1. Use the special tool to connect the ETACS terminal
(terminal 9) and the earth terminals (terminals 4 and 5)
of the diagnosis connector to the voltage meter.
2. If the needle of the voltage meter flickers once when
each switch is operated (ON/OFF), the input signal for
that switch circuit system is normal.
00-10 GENERAL - How to Use Troubleshooting/Inspection Service Points

HOW TO USE THE INSPECTION PROCEDURES

The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. These inspection procedures
follow this order, and they first try to discover a problem with a connector or a defective component.

1. Comments on the diagnosis code or trouble

symptom above.
CHECKING PROCEDURE 4

D Indicator does not turn on or off even if control Probable cause

mode switch is pressed. 2. Indicates inspection carried out using the
D Indicator switch should not be illuminated is MUT-II.
illuminated. Indicates the operation and inspection proce-
dures.
In the above cases, the ECS switch circuit is defective or the indicator Indicates the OK judgement conditions.
circuit is defective.

3. Detailed inspection procedures (methods)

such as component inspection and circuit
inspection are listed on a separate page, and
OK are given here for reference.
MUT-II Data list
17 Control mode selection switch
OK: Voltage changes between approx. 0V → approx.
2.5V → approx. 5V when the switch is operated.
NG
4. Indicates voltage and resistance to be measured at a particular
ECU switch component inspection (Refer to P.33-44.) NG connector.
(Refer to Connector Measurement Service Points.)
OK The connector position can be located in the wiring diagram in the
Measure at switch connector A-44 OK electrical wiring manual by means of this symbol.
D Disconnect the connector, and measure at the harness Indicates operation and inspection procedures, inspection terminals
side. and inspection conditions.
D Voltage between terminal 6 - earth and terminal 8 - Indicates the OK judgement conditions.
earth
OK: Approx. 5V
OK
Check the following connector. A-44 NG Repair
OK
5. Inspect the contact condition at each connector terminal.
Check trouble symptom. (Refer to Connector Inspection Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Caution
Replace the ECS-ECU.
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.

6. Confirm that there are trouble symptoms. If trouble symptoms have

disappeared, the connector may have been inserted incorrectly and the
trouble symptom may have disappeared during inspection.
If it seems that trouble symptoms still remain, proceed to the next page of
instructions.

7. If trouble symptoms still remain up to this stage, there is a possibility that there is an
open or short circuit in the harness between the connectors, so check the harness.
Alternatively, the cause may be a defective ECU, so try replacing the ECU and check
if the trouble symptom disappears.

HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses.
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.
 GENERAL - How to Use Troubleshooting/Inspection Service Points 00-11
CONNECTOR MEASUREMENT SERVICE POINTS
Turn the ignition switch to OFF when connecting disconnecting
the connectors, and turn the ignition switch to ON when
measuring if there are no instructions to be contrary.

Harness connector IF INSPECTING WITH THE CONNECTOR CONNECTED

(WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Waterproof Connectors
Be sure to use the special tool (harness connector). Never
insert a test bar from the harness side, because to do so
will reduce the waterproof performance and result in corrosion.

Ordinary (non-waterproof) Connectors

Extra-thin probe
Check by inserting the test bar from the harness side. Note
that if the connector (control unit, etc.) is too small to permit
insertion of the test bar, it should not be forced; use a special
tool (the extra-thin probe in the harness set for checking
for this purpose.
Test bar

Connector

IF INSPECTING WITH THE CONNECTOR DISCONNECTED

<When Inspecting a Female Pin>
Use the special tool (inspection harness for connector pin
contact pressure in the harness set for inspection).
The inspection harness for connector pin contact pressure
Inspection harness should be used. the test bar should never be forcibly inserted,
for connector pin
contact pressure as it may cause a defective contact.

<When Inspecting a Male Pin>

Touch the pin directly with the test bar.
Caution
At this time, be careful not to short the connector pins
with the test bars. To do so may damage the circuits
inside the ECU.
00-12 GENERAL - How to Use Troubleshooting/Inspection Service Points

Connector disconnected or improperly CONNECTOR INSPECTION

connected
VISUAL INSPECTION
D Connector is disconnected or improperly connected
D Connector pins are pulled out
D Due to harness tension at terminal section
D Low contact pressure between male and female terminals
D Low connection pressure due to rusted terminals or foreign
matter lodged in terminals

Defective connector contact

Harness wire breakage

at terminal section

Low contact pressure

Good

Bad

CONNECTOR PIN INSPECTION

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

CONNECTOR ENGAGEMENT INSPECTION

Use the special tool (connector pin connection pressure
MB991219
inspection harness of the inspection harness set) to inspect
the engagement of the male pins and females pins. (Pin
drawing force : 1 N or more)
 GENERAL - How to Use Troubleshooting/Inspection Service Points 00-13
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 earth. Set the switches
Battery of all circuits which are connected to this fuse to a condition
of continuity. If the resistance is almost 0 Ω at this time,
there is a short somewhere between these switches and the
load. If the resistance is not 0 Ω, there is no short at the
present time, but a momentary short has probably caused
Fuse the fuse to blow.
The main causes of a short circuit are the following.
D Harness being clamped by the vehicle body
Short circuit
Load D Damage to the outer casing of the harness due to wear
occurrence
switch or heat
section
D Water getting into the connector or circuitry
D Human error (mistakenly shorting a circuit, etc.)

Load

POINTS TO NOTE FOR INTERMITTENT

MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some
other factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and components
to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
D Gently shake the connector up, down and to the left and
right.
D Gently shake the wiring harness up, down and to the
left and right. Check the branch point of wiring harness
connector closely.
D Gently rock each sensor and relay, etc. by hand.
D Gently shake the wiring harness at suspensions and other
moving parts.
NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.
00-14 GENERAL - Vehicle Identification

VEHICLE IDENTIFICATION
VEHICLE INFORMATION CODE PLATE
LOCATION
Vehicle information code plate is riveted on the toeboard
inside the engine compartment.

CODE PLATE DESCRIPTION

The plate shows model code, engine model, transmission
model, and body colour code.
1
2 No. Item Contents Contents
3
4 1 MODEL CT9A CT9A: Vehicle model
5 SNDFZL
SNDFZL: Model series

2 ENGINE 4G63-DOHC Engine model

3 EXT A37B Exterior code

4 TRANS W5M51 W5M51: Transmission code

AXLE

5 COLOR A37 A37: Body colour code

INT OPT 14H
R11 14H: Interior code

R11: Equipment code

For monotone colour vehicles, the body colour code shall

be indicated. For two-tone or three-way two-tone colour
vehicles, each colour code only shall be indicated in series.
MODELS
Model code Class code Grade Engine model Transmission model Fuel supply
system

CT9A SNDFZL/R RS 4G63 (1,997 mL-DOHC- W5M51 <4WD-5M/T> MPI

16 valves-intercooler
valves intercooler turbo)
SNGFZL/R RS-II
 GENERAL - Vehicle Identification 00-15
MODEL CODE

CT 9 A S N D F Z L No. Items Contents

1 Development CT: MITSUBISHI LANCER

EVOLUTION-VII

2 Engine type 9: 1,997 mL petrol engine

1 2 3 4 5 6 7 8 9
3 Sort A: Passenger car

4 Body style S: 4-door sedan

5 Transmission type N: 5-speed manual

transmission

6 Trim level D: RS
G: RS-II or GSR

7 Specification engine F: MPI-DOHC-intercooler

feature turbo

8 Special feature Z: 4WD

9 Steering wheel location L: Left hand

R: Right hand
00-16 GENERAL - Vehicle Identification

CHASSIS NUMBER
The chassis number is stamped on the toeboard inside the
engine compartment.

1 2 3 4 5 6 7 8 9 10 11

No. Items Contents

1 Fixed figure J Asia

2 Distribution channel M Japan channel

3 Destination Y For Europe and General Export

4 Body style S 4-door sedan

5 Transmission type N 5-speed manual transmission

6 Development order CT MITSUBISHI LANCER EVOLUTION-VII

7 Engine 9 4G63: 1,997 mL petrol engine

8 Sort A Passenger car

9 Model year 2 2002

10 Plant U MIZUSHIMA-1

11 Serial number - -

ENGINE MODEL NUMBER

1. The engine model number is stamped on the cylinder
block as shown below.
Engine model Engine displacement mL
4G63 1,997
2. The engine serial number is stamped near the engine
model number.
Engine serial number AA0201 to YY9999
 GENERAL - Major Specifications 00-17
MAJOR SPECIFICATIONS

1 7 9
2 3 4 5
6

Items CT9A
SNDFZL/R SNGFZL/R
Vehicle Front track 1 1,500, 1,515 *1
di
dimensions
i
Overall width 2 1,770
mm
Front overhang 3 895
Wheel base 4 2,625
Rear overhang 5 935
Overall length 6 4,455
Ground clearance 7 140
(unladen)
Overall height (unladen) 8 1,450
Rear track 9 1,500, 1,515 *1
Vehicle Kerb weight 1,320 1,380
weight
i ht kg
k
Max. gross vehicle weight 1,655 1,695
Max. axle weight 950 970
rating-front
Max. axle weight 705 725
rating-rear
Seating capacity 5
Engine
g Model No. 4G63
Total displacement mL 1,997
Transmis- Model No. W5M51
sion
i
Type 5-speed manual
Fuel system Fuel supply system MPI

NOTE
*1: Vehicles with 17 inch wheels.
00-18 GENERAL - Precautions Before Service

PRECAUTIONS BEFORE SERVICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(3) Warning labels must be heeded when servicing or handling SRS components. Warning labels
are located in the following locations.
D Sun visor
D Glove box
D SRS-ECU
D Steering wheel
D Steering Joint Cover
D Air bag module (driver’s side and front passenger’s side)
D Clock spring
D Seat belt with pre-tensioner
(4) Always use the designated special tools and test equipment.
(5) 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.
Do not place anything on top of it.
(6) Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module, clock
spring and seat belt with pre-tensioner).
(7) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
(8) Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle
equipped with an air bag. (Refer to GROUP 52B - Air Bag Module 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.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat, so remove the SRS components before drying
or baking the vehicle after painting.
D SRS-ECU, air bag module, clock spring: 93_C or more
D Seat belt with pre-tensioner: 90_C or more
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.
 GENERAL - Precautions Before Service 00-19
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
( - ) cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connecting or disconnecting the negative ( - ) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)

APPLICATION OF ANTI-CORROSION AGENTS

AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover when applying
anti-corrosion agents and undercoats.

PRE-INSPECTION CONDITION
“Pre-inspection condition” refers to the condition that the
vehicle must be in before proper engine inspection can be
carried out. If you see the words “Set the vehicle to the
pre-inspection condition”. in this manual, it means to set the
vehicle to the following condition.
D Engine coolant temperature: 80 to 90_C
D Lamps, electric cooling fan and all accessories: OFF
D M/T: Neutral
D A/T: P range

VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
Approx. equipment is used to wash the vehicle, be sure to note the
40 cm following information in order to avoid damage to plastic
components, etc.
D Spray nozzle distance: Approx. 40 cm or more
D Spray pressure: 3,900 kPa or less
D Spray temperature: 82_C or less
D Time of concentrated spray to one point: within 30 sec.
00-20 GENERAL - Precautions Before Service

MUT-II
MUT-II
sub-assembly Refer to the “MUT-II REFERENCE MANUAL” or “MUT-II
OPERATING INSTRUCTIONS” for instructions on handling
the MUT-II.

ROM pack

MUT- Ⅱ Connect the MUT-II to the diagnosis connector as shown

in the illustration.
Caution
Turn the ignition switch to the LOCK (OFF) position before
connecting or disconnecting the MUT-II.

IN ORDER TO PREVENT VEHICLES FROM FIRE

“Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high
quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/repairs
that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance
with MMC’s information/Instructions”.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities
must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine
oil and by degreasing components, where practicable, before handling them.
Other precautions:
D Avoid prolonged and repeated contact with oils, particularly used engine oils.
D Wear protective clothing, including impervious gloves where practicable.
D Avoid contaminating clothes, particularly underpants, with oil.
D Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
D Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly
and kept separately from personal clothing.
D Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles
or face shields; in addition an eye wash facility should be provided.
D Obtain First Aid treatment immediately for open cuts and wounds.
D Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers
and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace
the natural skin oils is advised.
D Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.
D Use barrier creams, applying them before each work period, to help the removal of oil from the skin
after work.
D If skin disorders develop, obtain medical advice without delay.
 GENERAL - Supplemental Restraint System (SRS) 00-21
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
To improve safety, the SRS and seat belts with instrument panel indicates the operational status
pre-tensioner. These systems enhance collision of the SRS. The clock spring is installed in the
safety by restraining the front passengers in case steering column. The seat belt pre-tensioner is built
of an accident. The SRS works with the into the front seat belt retractor. Only authorized
pre-tensioner simultaneously when a collision is service personnel should do work on or around
detected. the SRS components and seat belt with
The SRS consists of two air bag modules, SRS pre-tensioner. Those service personnel should read
air bag control unit (SRS-ECU), SRS warning lamp this manual carefully before starting any such work.
and clock spring. The air bags are located in the Extreme care must be used when servicing the
center of the steering wheel, above the glove box. SRS to avoid injury to the service personnel (by
Each air bag has a folded air bag and an inflator inadvertent deployment of the air bags or
unit. The SRS-ECU under the floor console monitors inadvertent operation of the seat belt with
the system and has a safing G-sensor and an pre-tensioner) or the driver (by rendering the SRS
analog G-sensor. The warning lamp on the or the seat belt with pre-tensioner inoperative).

Driver’s air bag Front

passenger’s
air bag

SRS warning lamp

Driver’s air bag Front passenger’s

module air bag module

Clock spring
Seat belt with
pre-tensioner
Diagnosis
connector

SRS-ECU
00-22 GENERAL - Supplemental Restraint System (SRS)

SRS SERVICE PRECAUTIONS

1. In order to avoid injury to yourself or others NOTE
from accidental deployment of the air bag and If any of these components are diagnosed as
accidental operation of the seat belt with faulty, they should only be replaced, in
pre-tensioner during servicing, read and accordance with the INDIVIDUAL COM-
carefully follow all the precautions and PONENTS SERVICE procedures in this
procedures described in this manual. manual. (Refer to P.52B-49.)
2. Do not use any electrical test equipment on
or near SRS components, except those
specified on P.52B-6.
3. Never Attempt to Repair the Following
Components:
D SRS air bag control unit (SRS-ECU)
D Clock spring
D Driver’s and front passenger’s air bag
modules
D Seat belt with pre-tensioner

4. After disconnecting the negative (–) battery cable,

Insulating tape Battery wait 60 seconds at least before any service and
insulate the disconnected cable with tape. The SRS
retain enough voltage to deploy the air bags for a
short time even after the disconnection of the battery.
So, serious injury may result by accidental air bag
deployment if a work is done on the SRS just after
the disconnection of the battery.

5. Do not attempt to repair the wiring harness connectors

SRS-ECU connector
of the SRS. If the connector(s) are diagnosed as defective,
replace the wiring harness(es). If the harness(es) are
diagnosed as faulty, replace or repair the wiring
harness(es) according to the table that follows.
 GENERAL - Supplemental Restraint System (SRS) 00-23

SRS-ECU Destination of harness Corrective action

Terminal No.

7 Instrument panel wiring harness → Earth Repair or replace each wiring

harness
8 Instrument panel wiring harness → Combination meter
(SRS warning lamp)

9, 10 Instrument panel wiring harness → Front passenger’s air bag

module

11, 12 Instrument panel wiring harness → Clock spring → Driver’s air bag Repair or replace the dash wiring
module) harness. Replace clock spring.

13 Instrument panel wiring harness → Junction block (fuse No.3) Repair or replace each wiring
harness
harness.
16 Instrument panel wiring harness → Junction block (fuse No.2)

20 Instrument panel wiring harness → Diagnosis connector

29, 30 Floor wiring harness → Driver’s seat belt pre-tensioner

27, 28 Floor wiring harness → Front passenger’s seat belt pre-tensioner

6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
Insert the special tool (probe, MB991222, in the harness set) into the connector from harness side
(rear side), and connect the tester to this probe. If any tool than specified is used, damage to the
harness and other components will result. Furthermore, measurement should not be carried out by
touching the probe directly against the terminals from the front of the connector. The terminals are
plated to increase their conductivity, so that if they are touched directly by the probe, the plating
may break, which will cause drops in reliability.
SRS-ECU harness connector

SRS-ECU harness connector (rear view)

MB991222

7. SRS components and seat belt with pre-tensioner should not be subjected to hart, so remove the
SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, and seat belt with pre-tensioner
before drying or baking the vehicle after painting.
D SRS - ECU, air bag module, clock spring : 93℃ or more
D Seat belt with pre-tensioner : 90℃ or more
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-6.)
9. Make certain that the ignition switch is LOCK (OFF) position when the MUT-II is connected or
disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
00-24 GENERAL - Support Locations for Lifting and Jacking

SUPPORT LOCATIONS FOR LIFTING AND JACKING

Caution
Do not support the vehicles at locations other than specified supporting points. Doing so will
cause damage, etc.

SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

GARAGE JACK
Caution
Never support any point other than the specified ones, or deformation will result.
 GENERAL - Support Locations for Lifting and Jacking 00-25
SUPPORT POSITIONS FOR AXLE STANDS AND A SINGLE-POST LIFT OR
DOUBLE-POST LIFT
Caution
1. If rubber attachments with grooves that are too thick are used at the front support positions,
the front fender may become bent, so be sure to use rubber attachments with groove thicknesses
of 18 mm or less.
2. If attachments which are not high enough are used, they may damage areas such as the side
step. Be sure to use attachments which are high enough, or remove the side step if not using
attachments.
AXLE STANDS
Side sill rear end
Bolts

Rubber
Rubber

SINGLE-POST
LIFT OR DOUBLE-
POST LIFT

Bolts Side sill rear end

Attachment Attachment
00-26 GENERAL - Support Locations for Lifting and Jacking

PLATE TYPE LIFT

To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
NOTE
The wooden block should be 100 mm wide and 50 mm high.

H-bar lift SUPPORT POSITIONS AND SUPPORT METHOD

FOR AN H-BAR LIFT
H-bar lift Caution
When service procedures require removing the rear
suspension, fuel tank, spare tyre and rear bumper, place
additional weight on rear end of vehicle or anchor vehicle
to hoist to prevent tipping of centre of gravity changes.
When H-bar lift is used to lift up vehicles, use of metallic
attachment attached to the H-bar lift may cause damage
to the suspension arm etc. Therefore, lift up the vehicle by
the following procedure.

Chassis-sup- 1. Place the vehicle on the H-bar lift (same direction).

port position 2. Place attachments on the H-bar lift at the designated
(side sill) Attachment chassis-support positions. When making the attachments,
refer to the section concerning making them.
Section A - A Caution
Side sill If support is at any location other than the designated
positions, the body or suspension might be deformed
or otherwise damaged, so care should be taken to
support only at the correct (designated) positions.
H-bar lift
H-bar lift 3. Raise the H-bar lift to the height at which the vehicle
Attachment
is slightly raised and check to be sure that the vehicle
is correctly and sufficiently secured; then raise the vehicle.

A
 GENERAL - Support Locations for Lifting and Jacking 00-27
PREPARATION OF “ATTACHMENTS”
Block (A) mm
1. Prepare the blocks (wooden) and nails as shown in the
1,800 figure.
Item Dimensions mm Quantity
90 Block (A) 90 × 95 × 1,800 2
Block (B) 60 × 100 × 95 4
95
Block (C) 140 × 40 × 95 8
Block (B) Block (C) Nail 70 or more 32

15
15 Caution
40 20 40 The wood selected for the blocks must be hard.
40 20
40 2. For the (B) blocks and (C) blocks, use a saw and chisel
60 140
or similar tool to make grooves of the dimensions shown
in the figure.
3. Make four “ATTACHMENTS” such as shown in the figure
100 40 nailing (B) and (C) blocks so that each (B) blocks is
sandwiches between (C) blocks.

Block (C)
100

Block (C)

140 Nail

Block (B)

Finished attachment

Movable according
to vehicle width
00-28 GENERAL - Standard Part/Tightening-Torque Table

STANDARD PART/TIGHTENING-TORQUE TABLE

Each torque value in the table is a standard value The values in the table are not applicable:
for tightening under the following conditions. (1) If toothed washers are inserted.
(1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
and plated with zinc. (3) If bolts are tightened to plastic or die-cast
(2) The threads and bearing surface of bolts and inserted nuts.
nuts are all in dry condition. (4) If self-tapping screws or self-locking nuts are
used.

Standard bolt and nut tightening torque

Thread size Torque N·m

Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)

M5 0.8 2.50.5 5.01.0 6.01.0

M6 1.0 5.01.0 9.02.0 102

M8 1.25 122 224 254

M10 1.25 244 4410 537

M12 1.25 418 8312 9812

M14 1.5 7312 14020 15525

M16 1.5 11020 21030 23535

M18 1.5 16525 30040 34050

M20 1.5 22535 41060 48070

M22 1.5 30040 55585 64595

M24 1.5 39555 735105 855125

Flange bolt and nut tightening torque

Thread size Torque N·m

Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)

M6 1.0 5.01.0 102 122

M8 1.25 132 244 275

M10 1.25 264 499 587

M10 1.5 244 458 5510

M12 1.25 468 9515 10515

M12 1.75 438 8312 9812

NOTE
1. Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
2. Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the
greater the bolt strength.