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 00-1

GROUP 00

GENERAL
CONTENTS

HOW TO USE THIS MANUAL. . . . . . 00-2 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 00-6

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 00-8
TARGETS OF DEVELOPMENT . . . . 00-2 ACTIVE SAFETY. . . . . . . . . . . . . . . . . . . . . 00-9
PASSIVE SAFETY . . . . . . . . . . . . . . . . . . . 00-10
PRODUCT FEATURES . . . . . . . . . . . 00-2 ENVIRONMENTAL PROTECTION . . . . . . . 00-12
SERVICEABILITY AND RELIABILITY . . . . 00-12
TECHNICAL FEATURES. . . . . . . . . . 00-3
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 VEHICLE IDENTIFICATION . . . . . . . . 00-13
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4
BODY DIMENSIONS AND SPACIOUS GENERAL DATA AND
CABIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5 SPECIFICATIONS . . . . . . . . . . . . . . . 00-15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5
00-2 GENERAL
HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

M2000029000758

ABBREVIATIONS M/T:Indicates manual transaxle, or models equipped

The following abbreviations are used in this manual with manual transaxle.
for classification of model types. CVT: Indicates the continuously variable transmis-
2.0 L Engine:1.998 liter <4B11> engine, or a model sion.
equipped with such an engine. FWD: 2-wheel drive vehicles.
MFI: Multiport fuel injection, or engines equipped SWS: Simplified wiring system
with multiport fuel injection. A/C: Air conditioning.
PCM: Powertrain control module

TARGETS OF DEVELOPMENT
M2000004001215
Since first launched in 1973, the LANCER has
always been acknowledged as a motor sport based
vehicle in the sporty sedan market. Keeping with the
tradition of these LANCERS, the new LANCER has
been developed aiming at acquiring additional
LANCER users, and even more, Mitsubishi custom-
ers.

PRODUCT FEATURES
M2000005000594

STYLING COMFORT
The global standard body size has been adopted to • The Rockford Fosgate premium sound system
match the market trend. has been installed.
• The comfort equipment such as keyless opera-
DRIVING PERFORMANCE tion system (KOS)*1, HDD navigation, handsfree
• The newly-developed aluminum block engine phone for Bluetooth*2 has been adopted.
and CVT have been adopted to achieve excellent
NOTE: .
power and performance.
1. The power and performance greatly exceeds • *1: In this manual, F.A.S.T.-key (Free-hand
that of the previous LANCER. Advanced Security Transmitter) is described
as Keyless Operation System (KOS). Refer to
2. The fuel efficiency in cruising range has been
greatly improved from the previous LANCER, P.42B-2.
both for M/T and CVT. • *2: Refer to P.54A-29.
• High rigidity of body and suspension has been
achieved. SAFETY
• With fine tuning of suspension, sporty steering, • The impact safety body aiming at high score in
flat cornaring and superior driving comfort have New Car Assessment Program (NCAP) has been
been achieved. developed.
• The paddle shift has been adopted to achieve • With consideration of Insurance Institute for High-
"Fun to Drive." way Safety (IIHS), going ahead of competitors,
the knee air bag has been equipped as a stan-
dard feature in addition to the driver's and pas-
senger's (front) air bags, side-air bag, and curtain
air bag.
 GENERAL
TECHNICAL FEATURES
00-3
TECHNICAL FEATURES
EXTERIOR
M2000017000966

DESIGN FEATURES
The robust styling to create the image of LANCER
EVOLUTION, the symbol of Mitsubishi Motors sport
DNA, has been established.

12
10, 11
1

3, 8

6 5

2,7

9
AC607908AC
. .

BETTER APPEARANCE BETTER USER-FRIENDLINESS

1. Radiator grille integrated front bumper 10. Electric remote-controlled door mirrors
2. Side air dams 11. Heated door mirrors
3. Rear spoiler .

5. Air dam skirt panels BETTER PRODUCT PACKAGE

.
12. Vehicle speed sensitive intermittent time variable
BETTER AERODYNAMIC windshield wiper
CHARACTERISTICS .

4. Aerodynamic front bumper SUPPORT RECYCLING OF RESOURCES

5. Air dam skirt panels Uses PP (polypropylene) materials that are easy to
6. Engine room under cover with bulges at left and recycle and easy to stamp material symbols on the
right (Refer to P.51-3) plastic (resin) parts.
7. Side air dams
8. Rear spoiler
9. Aerodynamic rear bumper
00-4 GENERAL
TECHNICAL FEATURES

INTERIOR
M2000018000969

DESIGN FEATURES
Functionality, interior comfort, and safety have been
emphasized, giving interior design for elegance and
relaxation. Various measures have been taken to
protect the environment and recycle resources.

AC609922

Quality improvement • Side-airbag

• Two-tone interior • Curtain air bag
• Full interior trim • ELR 3-point seat belt (driver side)
• ELR/ALR 3-point seat belt (front passenger side)
Usability improvement
• ELR/ALR 3-point seat belt (rear)
• Armrest (floor console, rear seat, front door trim,
• Seat belt retractor with a driver's side preten-
rear door trim)
sioner and variable force limiter
• Cup holder (floor console, rear seat armrest)
• Seat belt retractor with a passenger’s side pre-
• Bottle holder (front door trim)
tensioner and force limiter
Convenient storage • Headliner energy absorption rib
• Glove box
Consideration for the optimum driving position
• Card holder (Glove box)
• Seat height adjustment (driver’s seat)
• Seatback pocket [front seat (driver side)]
• Headrestraint with height adjustment (front, rear)
• Floor console box
• Seat slide adjustment (front)
• Door pocket (front door trim, rear door trim)
• Tissue paper holder (floor console) Measures for resource recycling
• Aggressively use PP materials that are easy to
Safety improvement
recycle and easy to stamp material symbols on
• Front and rear collision protection seat mecha-
the plastic (resin) parts.
nism (front seat)
• ISO-FIX lower anchor (rear seat outside) • Reduction of chemical material (formaldehyde*,
• Upper tether anchor (rear shelf) organic solvent)
• deiver’s and passenger’s (front) air bags NOTE: *: Clear and colourless, toxic, irritating odour
• Knee air bag
 GENERAL
TECHNICAL FEATURES
00-5
BODY DIMENSIONS AND SPACIOUS CABIN
M2000019000285

8 9 10

2 3 4 7

1 6

AC609780 AB

No. Item Dimension

1 Overall length mm (in) 4,570 (180.0)
2 Front overhang mm (in) 955 (37.6)
3 Wheel base mm (in) 2,635 (103.7)
4 Rear overhang mm (in) 980 (38.7)
5 Overall height mm (in) 1,490 (58.7)
6 Overall width mm (in) 1,760 (69.4)
7 Tread mm (in) 1,530 (60.2)
8 Front head room mm (in) 1,005 (39.6)
9 Rear head room mm (in) 935 (36.9)
10 Interior width mm (in) 1,390 (54.7)

ENGINE
M2000020000717
The newly-developed 4B11 MIVEC engine has been
adopted. For the 4B11 engine, the aluminum die-cast
cylinder block has been adopted to achieve the top
level of this class in high performance, good fuel effi-
ciency, while being compact and lightweight.

Technology and purpose for 4B11 engine adoption

Item High Compact and Low exhaust Low vibration Reliability
performance lightweight gas improvement
/good fuel
efficiency

Aluminum die-cast cylinder block X

Cylinder head cover made of resin X
Direct injection DOHC valve drive X X X
Intake/exhaust continuously variable valve X X X
timing (MIVEC)
Timing chain cam drive X X
Serpentine auxiliary drive X
00-6 GENERAL
TECHNICAL FEATURES

Item High Compact and Low exhaust Low vibration Reliability

performance lightweight gas improvement
/good fuel
efficiency
Isometric long port intake manifold made of X X
resin
Exhaust manifold made of stainless steel X X X
(double structure)
Rear exhaust engine layout X X
Ultra fine injection X
EGR system <California only> X X
Water pump with shroud-integrated resin X
impeller
Returnless fuel system X
Iridium spark plug X X

TRANSAXLE
M2000021000732

MANUAL TRANSAXLE saxle mechanism by steel belt & pulley" to achieve

F5MBB type (5M/T) has been adopted. "high driving performance" and "better fuel econ-
omy." Depending on the driving conditions, the com-
CONTINUOUSLY VARIABLE TRANSAXLE fortable gear ratio is automatically and continuously
selected from low to overdrive, ensuring
(CVT)
driver-intended smooth driving without shift shocks
The new CVT has been developed to achieve excel- related to acceleration pedal operation.
lent fuel economy, driving ease, and fun. This CVT
achieves quick and smooth acceleration suitable for
LANCER from any speeds. The CVT combines
"torque converter" and "continuously variable tran-
 GENERAL
TECHNICAL FEATURES
00-7
PADDLE SHIFT <Vehicle with sports mode (CVT) >

Down shift lever

AC609992

Up shift lever
Down shift

Up shift
(operate it for 2 seconds or more to return to D range.)

AC611129AB

For some models, the paddle-shaped up shift/down

shift lever has been fitted just behind the steering
wheel to allow the driver to operate up shift or down
shift with his/her hands kept on the steering wheel.
00-8 GENERAL
TECHNICAL FEATURES

SUSPENSION
M2000023000590

<REAR SUSPENSION>
Shock absorber
Upper arm

Coil spring
Stabilizer bar <GTS, ES>
<FRONT SUSPENSION>

Coil spring

Stabilizer link
Toe control arm
Stabilizer bar Rear crossmember

Stay

Front Trailing arm

suspension strut

Lower arm

Front axle crossmember

AC609418AD

• A MacPherson strut type suspension is adopted • Flexible steering stability is achieved, along with
for the front suspension. comfortable driving, secure handling, and flat cor-
• A trailing arm type multi-link suspension is nering.
adopted for the rear suspension.
 GENERAL
TECHNICAL FEATURES
00-9
ACTIVE SAFETY
M2000031000700

BRAKING SYSTEM <VEHICLES WITH ABS>

ABS warning light ABS warning light <Vehicles for rear drum brake>
Brake warning light Wheel speed sensor

SERVICE
REQUIRED

Brake warning light

Magnetic encoder for

Data link connector wheel speed detection

CHECK Stoplight switch

Hydraulic unit,
ABS control unit (ABS-ECU)

Wheel speed sensor

Magnetic encoder for
Wheel speed sensor wheel speed detection
Magnetic encoder for
wheel speed detection <Vehicles with rear disc brake> AC608518AC

The ABS that ensures directional stability and con- • The magnetic encoder for detecting the wheel
trollability during hard braking. ABS is standard speed has been installed instead of the rotor as
equippment on the ES and GTS models but is the wheel speed sensor.
optional. • For wiring harness simplification and secure data
This ABS uses a 4-sensor system that controls all communication, CAN *2 bus has been adopted as
four wheels independently of each other, and has the a tool of communication with another ECU.
following features:
NOTE: .
• EBD *1 (Electronic Brake-force Distribution sys-
• *1: EBD (Electronic Brake-force Distribution)
tem) control that can obtain ideal rear wheel
brake force has been employed. • *2: For more information about CAN (Controller
Area Network), refer to GROUP 54C P.54C-2.
00-10 GENERAL
TECHNICAL FEATURES

PASSIVE SAFETY
M2000032000769

SRS AIR BAGS

Driver's air bag module Passenger's (front)
Seat belt with air bag module
pre-tensioner

Side-airbag module

Curtain air bag module

Knee air bag module

AC609360 AB

• Driver's and passenger's (front) air bags, side-air • The curtain air bag is activated simultaneously
bags, knee air bag, curtain air bags and seat with the side-air bag upon a side collision to pro-
belts with pre-tensioner are installed on all the tect the heads of the front seat and second seat
vehicles as standard. passengers.
• The SRS is a system that is effective with the • All the air bag modules are equipped with the
seat belt fastened, and it is designed as a supple- inflator that does not contain toxic sodium azide.
mental system of the seat belt. • The seat belt pre-tensioner is activated simulta-
• The advanced air bag system is adopted to the neously with the deployment of driver's and pas-
driver's and passenger's (front) sides. When a senger's (front) air bags in case of a frontal
frontal impact exceeds the threshold upon a fron- collision. Seat belts are pulled in to eliminate the
tal collision, or depending on the seat position slack upon a collision, thus improving the initial
(driver's seat side), the air bag inflates the cush- occupant restraint, and reducing the travel dis-
ion air bag in two stages, improving the protection tance of the occupants. For the driver's seat, in
for the front seat passengers. When a frontal addition to the seat belt pre-tensioner for the
impact exceeds the threshold, the knee air bag is shoulder side, the lap pre-tensioner has been
instantaneously inflated to protect the passen- installed on the outer seat belt lower anchor side
ger's feet (knee and leg). in order to improve the restraining performance in
• The side-air bag is activated when an impact the waist and the chest areas.
exceeds the threshold upon a side collision, and
the cushion air bag is instantaneously inflated to
protect the chest area of the front seat passen-
gers.
 GENERAL
TECHNICAL FEATURES
00-11
BODY CONSTRUCTION
4 Section A - A
6
5
Crush box

A
2
1 3
AB609784AB

The front and rear structures to absorb high energy, 6. The roof bow and roof rail and the side outer
and the strong and sturdy cabin structure is adopted panel have been jointed by the brace to improve
to reduce the risk of passenger injuries at front-, driving stability.
rear-, and side-impact collisions, secure the space
for life protection, and facilitate rescuing passengers. SAFETY-ENHANCED FRONT SEATS
The structures also have the following features: The front seats are designed to minimize the risk of
1. The crush box structure is adopted for the front whiplash in a collision from the rear.
end of the sidemember to reduce the vehicle The head restraints have been ideally angled for-
repair cost in a low speed collision. ward, while the seat frame was moved toward the
2. An annular construction is used for the side struc- rear.
ture reinforcement to improve collision safety and
vehicle body rigidity. OTHER SAFETY FEATURES
3. The front frame structure is supported in three • Brake pedal recede-control device
directions by the dash crossmember center, dash • Collapsible steering column
crossmember lower, and front sidemember rear • Child-protection rear door locks
in order to improve the frontal collision character- • Front fog lamps
istics, and increase the vehicle body rigidity. • Passenger’s seat weight sensor system
4. The crush box structure has been changed to • 3-point ELR seat belts <Driver’s seat, rear seat
straight type with an octagon cross-section so on each side>
that the structure can effectively absorb energy • 3-point ELR/ALR seat belts <Passenger's seat,
from the impact at the time of collision. rear seat center>
5. The closed section structure has been adopted • Tire pressure monitoring system (TPMS)
for the roof bow and roof rail to improve driving
stability and reduce vibration and noise.
00-12 GENERAL
TECHNICAL FEATURES

ENVIRONMENTAL PROTECTION
M2000027000473
Mitsubishi has given careful consideration to protec-
tion of natural resources and the environment in the
vehicle. Environmentally friendly features are shown
below.
Items Dealing with Environmental Protection
Prevention of Parts name Features
atmospheric
pollution
Adoption of easy Bumper, Instrument panel, Door trim, Interior Adoption of thermoplastic resin
recycling material trim and soon
Expansion of Bumper, Instrument panel, Door trim, Radiator Re-use of material discarded in plant
recycled material grille
Sound absorbing material in dash panel and Re-use of discarded material in other
roof, Oil level gauge industry
Reduction of Fuel tank, Radiator, Heater core, Battery cable Adoption of lead free material
hazardous terminal, Balance weight for wheel, Pressure
substances hose for power steering, Glass ceramics print,
Harness, Electrostatic coating, Intake valve
sheet, Crank bearing metal, Connecting rod
bearing metal, Connecting rod

SERVICEABILITY AND RELIABILITY

M2000028000647

ENHANCED DIAGNOSIS SYSTEM • ETACS

Diagnosis functions have been included for the fol- • Radio and CD player and visual information
lowing systems, so that it is possible to use the scan equipment etc.
tool to read the diagnosis codes and service data • Heater and air conditioning
and to carry out actuator tests. In addition, it is also
possible to read the diagnosis codes by the flashing ADAPTATION OF BOLTS AND NUTS
of the warning light in some systems. WITH STABILIZER FOR COEFFICIENT OF
• MFI
• Auto-cruise control system
FRICTION *
• CVT The bolts and nuts with stabilizer for coefficient of
• ABS friction are used for the connections such as the sus-
• Power window pension arm and crossmember in order to stabilize
• Keyless operation system (KOS) the axial force and to ensure the high axial force at
bolt/nut connections, resulting in improved reliability.
NOTE: In this manual, F.A.S.T.-key (Free-hand
Advanced Security Transmitter) is described as NOTE: *: The bolts and nuts with stabilizer for coeffi-
Keyless Operation System (KOS). cient of friction mean that the bolts and nuts with sur-
• SRS air bag face treatment to stabilize and reduce the coefficient
• Immobilizer of friction, allowing to achieve the stable axial force
• Combination meter and to secure the high axial force with low tightening
• Headlight auto leveling device torque.
 GENERAL
VEHICLE IDENTIFICATION
00-13
VEHICLE IDENTIFICATION
M2000001002662
.

VEHICLE IDENTIFICATION NUMBER LOCATION

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

AC611242

VEHICLE IDENTIFICATION CODE CHART PLATE

All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
No. Item Content
1 Country J: Japan
J A 3 AU 2 6 U _ 8 U 0 0 0 0 0 1
2 Make A: Mitsubishi
12 3 Vehicle type 3: Passenger car
1 2 3 4 5 6 7 8 9 10 11 4 Others Restraint system
AC609472AB A: Driver and passenger air bags
5 Line U: LANCER
6 Price class 1: Economy
2: Low
8: Sports
7 Body 6: 4-door sedan
8 Engine U: 2.0 L (4B11) MIVEC
9 Check digits* 0, 1, 2, 3, -----------9, X
10 Model year 8: 2008 year
11 Plant U: Mizushima
12 Serial number 000001 to 999999

NOTE: *: Check digit means a single number, or letter X, used

to verify the accuracy of transcription of vehicle identification
number.
00-14 GENERAL
VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER LIST

.

VEHICLES FOR USA

(VEHICLES FOR FEDERAL EMISSION REGULATION)

VIN Brand Engine Model code
(Except sequence number) displacement
JA3AU16U_8U MITSUBISHI 2.0L CY4ASNLHL2M
LANCER CY4ASTLHL2M
JA3AU26U_8U CY4ASNSHL2M
CY4ASTSHL2M
JA3AU86U_8U CY4ASNXHL2M
CY4ASTXHL2M

(VEHICLES FOR CALIFORNIA EMISSION REGULATION)

VIN Brand Engine Model code
(Except sequence number) displacement
JA3AU16U_8U MITSUBISHI 2.0L CY4ASNLHL7M
LANCER CY4ASTLHL7M
JA3AU26U_8U CY4ASNSHL7M
CY4ASTSHL7M
JA3AU86U_8U CY4ASNXHL7M
CY4ASTXHL7M
.

VEHICLES FOR PUERTO RICO

VIN Brand Engine Model code
(Except sequence number) displacement
JA3AU16U_8U MITSUBISHI 2.0L CY4ASNLHL2M
LANCER CY4ASTLHL2M
JA3AU26U_8U CY4ASNSHL2M
CY4ASTSHL2M
JA3AU86U_8U CY4ASNXHL2M
CY4ASTXHL2M
.

VEHICLES FOR CANADA

VIN Brand Engine Model code
(Except sequence number) displacement
JA3AU16U_8U MITSUBISHI 2.0L CY4ASNLHL3M
LANCER CY4ASTLHL3M
JA3AU26U_8U CY4ASNSHL3M
CY4ASTSHL3M
JA3AU86U_8U CY4ASNXHL3M
CY4ASTXHL3M
 GENERAL
GENERAL DATA AND SPECIFICATIONS
00-15
GENERAL DATA AND SPECIFICATIONS
M2000030001034
.

GENERAL SPECIFICATIONS

2 4 7 5 6 9
1 3

AC608677AB

Item CY4ASNLHL2M/ CY4ASTLHL2M/ CY4ASNSHL2M/

3M/7M 3M/7M 3M/7M
Vehicle Overall width 1 1,760 (69.4) 1,760 (69.4) 1,760 (69.4)
dimension mm Tread-front 2 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
(in)
Overall length 3 4,570 (180.0) 4,570 (180.0) 4,570 (180.0)
Overhang-front 4 955 (37.6) 955 (37.6) 955 (37.6)
Wheelbase 5 2,635 (103.7) 2,635 (103.7) 2,635 (103.7)
Overhang-rear 6 980 (38.7) 980 (38.7) 980 (38.7)
Ground clearance 7 147 (5.8) 147 (5.8) 147 (5.8)
Overall height (unladen) 8 1,490 (58.7) 1,490 (58.7) 1,490 (58.7)
Tread-rear 9 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
Vehicle weight Curb weight 1,325 (2,922) 1,360 (2,999) 1,335 (2,944)
kg (lb) Gross vehicle weight rating 1,850 (4,079) 1,850 (4,079) 1,850 (4,079)
Gross axle weight rating-front 1,010 (2,227) 1,010 (2,227) 1,010 (2,227)
Gross axle weight rating-rear 910 (2,007) 910 (2,007) 910 (2,007)
Seating capacity 5 5 5
Engine Model No. 4B11 4B11 4B11
Piston displacement cm3 (cu in) 1,998 (121.9) 1,998 (121.9) 1,998 (121.9)
Maximum output kW/r/min 113/6,000 (152/6,000) <Except California>,
(HP/r/min) 107/6,000 (143/6,000) <California>
Maximum torque N⋅ m/r/min 198/4,250 (146/4,250) <Except California>,
(ft-lb/r/min) 194/4,250 (143/4,250) <California>
Fuel system Fuel supply system Electronic controlled multiport fuel injection
Transaxle Model No. F5MBB F1CJA F5MBB
Type 5-speed manual CVT 5-speed manual
Turning radius m (ft) 5.0 (16.4) 5.0 (16.4) 5.0 (16.4)
00-16 GENERAL
GENERAL DATA AND SPECIFICATIONS

2 4 7 5 6 9
1 3

AC608677AB

ITEM CY4ASTSHL2M/ CY4ASNXHL2M/ CY4ASTXHL2M/

3M/7M 3M/7M 3M/7M
Vehicle Overall width 1 1,760 (69.4) 1,760 (69.4) 1,760 (69.4)
dimension mm Tread-front 2 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
(in)
Overall length 3 4,570 (180.0) 4,570 (180.0) 4,570 (180.0)
Overhang-front 4 955 (37.6) 955 (37.6) 955 (37.6)
Wheelbase 5 2,635 (103.7) 2,635 (103.7) 2,635 (103.7)
Overhang-rear 6 980 (38.7) 980 (38.7) 980 (38.7)
Ground clearance 7 147 (5.8) 147 (5.8) 147 (5.8)
Overall height (unladen) 8 1,490 (58.7) 1,490 (58.7) 1,490 (58.7)
Tread-rear 9 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
Vehicle weight Curb weight 1,370 (3,021) 1,375 (3,032) 1,410 (3,109)
kg (lb) Gross vehicle weight rating 1,850 (4,079) 1,850 (4,079) 1,850 (4,079)
Gross axle weight rating-front 1,010 (2,227) 1,010 (2,227) 1,010 (2,227)
Gross axle weight rating-rear 910 (2,007) 910 (2,007) 910 (2,007)
Seating capacity 5 5 5
Engine Model No. 4B11 4B11 4B11
Piston displacement cm3 (cu in) 1,998 (121.9) 1,998 (121.9) 1,998 (121.9)
Maximum output kW/r/min 113/6,000 (152/6,000) <Except California>,
(HP/r/min) 107/6,000 (143/6,000) <California>
Maximum torque N⋅ m/r/min 198/4,250 (146/4,250) <Except California>,
(ft-lb/r/min) 194/4,250 (143/4,250) <California>
Fuel system Fuel supply system Electronic controlled multiport fuel injection
Transaxle Model No. F1CJA F5MBB F1CJA
Type CVT 5-speed manual CVT
with sport mode
Turning radius m (ft) 5.0 (16.4) 5.0 (16.4) 5.0 (16.4)
 00E-1

GROUP 00E

GENERAL
<ELECTRICAL>
CONTENTS

HARNESS CONNECTOR INSPECTION INSTRUMENTS . . . . . . . . . . 00E-8

INSPECTION . . . . . . . . . . . . . . . . . . . 00E-2 CHECKING FUSES. . . . . . . . . . . . . . . . . . . 00E-9
CHECKING SWITCHES . . . . . . . . . . . . . . . 00E-10
HOW TO DIAGNOSE. . . . . . . . . . . . . 00E-6 CHECKING RELAYS . . . . . . . . . . . . . . . . . 00E-11
HOW TO DIAGNOSE . . . . . . . . . . . . . . . . . 00E-6 CABLE AND WIRE CHECK . . . . . . . . . . . . 00E-12
TROUBLESHOOTING STEPS . . . . . . . . . . 00E-6 BATTERY HANDLING . . . . . . . . . . . . . . . . 00E-12
INFORMATION FOR DIAGNOSIS . . . . . . . 00E-6 GENERAL ELECTRICAL SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 00E-7 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E-13
00E-2 GENERAL <ELECTRICAL>
HARNESS CONNECTOR INSPECTION

HARNESS CONNECTOR INSPECTION

M1001003900201

CONNECTOR CONTINUITY AND VOLTAGE TEST

Required Special Tools:
•MB991219: Test Harness Set
•MD998459: Test Harness
Follow the steps below to avoid causing poor connector contact
and/or reduced waterproof performance of connectors when
checking continuity and/or voltage at waterproof connectors.
CAUTION
MD998459
Never backprobe a waterproof connector. Backprobing a
connector may cause the terminals to corrode, deteriorat-
ing circuit performance.
1. If the circuit to be checked is a closed state, use a special
tool like MD998459.

AC000014 AB
CAUTION
Forcing the probe into the terminal may open the terminal,
causing intermittent or poor contact and creating an open
circuit.
2. If the connector is disconnected for checking and the facing
part is the female pin side, use an appropriate male terminal
for checking the contact pressure of connector pins (like
MB991219 MB991219).
CAUTION
Do not simultaneously contact more than one terminal
AC000015 AB with the probe. Contacting two or more terminals at the
same time may damage a circuit, possibly to the point of
starting an electrical fire.
3. If the facing part is the male pin side, either carefully touch
the probe to the pin so it does not accidently contact other
pins, or use an appropriate female terminal.

IMPROPER TERMINAL ENGAGEMENT CHECK

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

AC000016

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 GENERAL <ELECTRICAL>
HARNESS CONNECTOR INSPECTION
00E-3
CONNECTOR TERMINAL ENGAGEMENT AND
DISENGAGEMENT
Loosely engaged terminals can be repaired by removing the
female terminal from the connector housing and raising its
lance to establish better engagement. Removal of the connec-
tor terminal used for MFI and INVECS-II A/T control circuit can
be done in the following manner.
.

COMPUTER CONNECTOR
1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in
the figure, disengage the front holder, and remove it.

FRONT
HOLDER
FRONT HOLDER
ACX00904AB

2. Push the harness wire of the terminal to be repaired deep

into the connector from the harness side and hold it there.

ACX00905

3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width]

HOUSING LANCE
into the connector as shown in the figure, gently push the
housing lance down with the tip, and pull out the terminal.

AC310118AB

4. Insert a needle through the hole provided on the terminal

and raise the contact point. Lightly squeeze the outer edge
NEEDLE so the flats are parallel with the bottom.

NEEDLE

ACX00907 AB

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00E-4 GENERAL <ELECTRICAL>
HARNESS CONNECTOR INSPECTION

ROUND WATERPROOF CONNECTOR

1. Remove the waterproof cap by using a screwdriver.
2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0
mm (0.08 inch) width] into the connector as shown in the
figure, raise the housing lance slightly with the tip, and pull
out the terminal.

HOUSING LANCE

ACX00908 AB

3. Insert a screwdriver through the hole provided on the

terminal and raise the contact point. Lightly squeeze the
outer edge so the flats are parallel with the bottom.

ACX00909

RECTANGULAR WATERPROOF CONNECTOR

1. Disengage the front holder with a screwdriver and remove it.

FRONT
HOLDER
FRONT HOLDER
ACX00910AB

2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into

the connector as shown in the figure, push it lightly to raise
the housing lance, and pull out the terminal.

HOUSING LANCE
ACX00911AB

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 GENERAL <ELECTRICAL>
HARNESS CONNECTOR INSPECTION
00E-5
3. Press the contact point to the male terminal down by holding
a screwdriver [1.4 mm (0.06 inch) width] as shown in the
figure. Lightly squeeze the outer edge so the flats are
parallel with the bottom.

ACX00912

INJECTOR CONNECTOR
1. Remove the waterproof cap.
WATERPROOF
CAP

ACX00913AB

2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into

TERMINAL LANCE the connector as shown in the figure, press in the terminal
lance, and pull out the terminal.

AC310304AB
CAUTION
Make sure the lance is pressed in before the terminal is
inserted into the connector.
3. Press the contact point to the male terminal down by holding
a screwdriver [1.4 mm (0.06 inch) width] as shown in the
figure.

AC310313

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00E-6 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE

HOW TO DIAGNOSE
HOW TO DIAGNOSE
M1001004300086
The most important point in troubleshooting is to
determine "Probable Cause." Once the probable
causes are determined, parts to be checked can be
limited to those associated with such probable
causes. The determination of the probable causes
must be based on a theory and be supported by facts
and must not be based on intuition only.
TROUBLESHOOTING STEPS
M1001004400049
If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symp-
toms could become more complicated, resulting in failure to determine the causes correctly and making
incorrect repairs. The four steps below should be followed in troubleshooting.

Observe the symptom carefully. Check if there are also

1 Observation of Problem Symptoms other problems.

In determining the probable causes, it is necessary to

study the wiring diagram to understand the circuit as a
2 Determination of Probable Causes system. Knowledge of switches, relays and other parts is
necessary for accurate analysis. The causes of similar
problems in the past must be taken into account.

Troubleshooting is carried out by making step-by-step

Checking of Parts Associated with checks until the cause is found.
3 Probable Causes and Determination
of Faulty Parts

After the problems are corrected, be sure to check that the

system operates correctly. Also check that new problems
4 Repair and Confirmation have not been caused by the repair.
ACX00915 AC

INFORMATION FOR DIAGNOSIS

M1001004500132
This manual contains the harness diagrams as well as the individual circuit drawings, operational explana-
tions, and troubleshooting hints for each component. The information is presented in the following manner:
1. Connector diagrams show the connector 3. Operational explanations include circuit drawings
positions, etc., on the actual vehicle as well as the of current flow when the switch is operated and
harness path. how the component reacts.
2. Circuit diagrams show the configuration of the
circuit with all switches in their normal positions.

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 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE
00E-7
4. Troubleshooting hints include numerous
examples of problems which might occur, traced
backward in a common-sense manner to the
origin of the trouble. Problems whose origins may
not be found in this manner are pursued through
the various system circuits.
NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer
to a relevant group which includes details of these components.

INSPECTION
M1001004600139
1. Sight and sound checks
Check relay operation, blower motor rotation, light
CLICK illumination, etc. Listen for a "click" when some relay covers
are pushed down.

ACX00936 AB

2. Simple checks
For example, if a headlight does not come on and a faulty
fuse or poor grounding is suspected, replace the fuse with a
new one. Or use a jumper wire to ground the light to the
body. Determine which part(s) is/are responsible for the
problem.

ACX00937

3. Checking with instruments

Use an appropriate instrument in an adequate range and
POINTER
read the indication correctly.

SELECTOR KNOB ACX00938AB

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00E-8 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE

INSPECTION INSTRUMENTS
M1001004700040
For inspection, use the following instruments:
CAUTION
Never use a test light for checking ECU-related circuits or
ECUs.
1. Test light
A test light consists of a 12V bulb and lead wires. It is used
to check voltages or short circuits.

ACX00939

2. Self-powered test light

A self-powered test light consists of a bulb, battery and lead
wires connected in series. It is used to check continuity or
grounding.

ACX00940
CAUTION
Never use a jumper wire to connect a power supply
directly to a load.
3. Jumper wire
A jumper wire is used to close an open circuit.

ACX00941

4. Voltmeter
POWER LINE A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) probe is applied to the point of voltage
BLACK LEAD WIRE measurement and the negative (black lead) probe to the
body ground. Use a digital voltmeter to check for voltage
drop before or after a component.
RED LEAD WIRE

GROUND
ACX00942AB

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 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE
00E-9
5. Ohmmeter
An ohmmeter is used to check continuity or measure
resistance of a switch or coil. If the measuring range has
been changed, the zero point must be adjusted before
measurement.

ACX00943

CHECKING FUSES
M1001005000141
A blade type fuse has test taps provided to allow checking of
the fuse itself without removing it from the fuse block. The fuse
FUSE BLOCK is okay if the test light comes on when its one lead is connected
to the test taps (one at a time) and the other lead is grounded.
Remember to turn the ignition switch to ON to ensure all cir-
cuits are live.

TEST TAPS
ACX00951AB

CAUTIONS IN EVENT OF BLOWN FUSE

When a fuse is blown, there are two probable causes. One is
that it is blown due to flow of current exceeding its rating. The
other is that it is blown due to repeated on/off current flowing
through it. Which of the two causes is responsible can be easily
determined by visual check as described below.
1. Fuse blown due to current exceeding rating
STATE OF FUSE BLOWN DUE TO The illustration shows the state of a fuse blown due to this
OVERCURRENT cause. In this case, do not replace the fuse with a new one
hastily since a current heavy enough to blow the fuse has
flowed through it. First, check the circuit for shorts and check
for abnormal electric parts. After correcting shorts or
replacing parts, use only a fuse of the same capacity as a
replacement. Never use a fuse of larger capacity than the
original fuse. If a larger capacity fuse is used, electric parts
ACX00952 AB or wiring could be damaged, or could start a fire.
2. Fuse blown due to repeated turning current on and off
STATE OF FUSE BLOWN DUE TO The illustration shows the state of a fuse blown due to
THERMAL FATIGUE
repeated current on/off. Normally, this type of problem
occurs after a fairly long period of use and is less frequent
than above. In this case, simply replace with a new fuse of
the same capacity.

ACX00953 AB

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00E-10 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE

CHECKING SWITCHES
M1001004800177
In a circuit diagram, a switch is shown in the idle state.
1. Normally open or normally closed switch
NORMALLY OPEN (NO) TYPE
Switches are classified into those which open the circuit and
OFF ON those which close the circuit when off.
Switches are shown in their normal state unless specified
otherwise.

CURRENT DOES CURRENT FLOWS

NOT FLOW

NORMALLY CLOSED (NC) TYPE

OFF ON

CURRENT CURRENT DOES

FLOWS NOT FLOW
ACX00944AC

2. Switch connection
6 This figure illustrates a complex switch. The continuity
between terminals at each position is as indicated in the
table below.
SWITCH TESTER SPECIFIED
POSITION CONNECTION CONDITION
OFF 1ST 2ND 3RD 4TH STAGE
OFF − −
1st stage 1−5−6 Continuity
5 4 3 2 1
2nd stage 1−4−6 Continuity
3rd stage 1−3−6 Continuity
4th stage 1−2−6 Continuity

ACX00945 AB

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 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE
00E-11
CHECKING RELAYS
M1001004900152

POWER SUPPLY 1. By using a relay, a heavy current can be turned on and off by
a switch using much less current. For example, in the circuit
shown here, when the switch is turned on (closed), current
RELAY flows to the coil of the relay. Then, its contact is turned on
ON
(closed) and the light comes on. The current flowing through
OFF
the switch is much less than that for the light.
FUSE
SWITCH
LIGHT ON
OFF
ACX00948 AB

NORMALLY OPEN (NO) TYPE 2. When current flows through the coil of a relay, its core is
ENERGIZED STATE magnetized to attract the iron piece, closing (ON) the
COVER contact at the tip of the iron piece. When the coil current is
SPRING
turned off, the iron piece returns to its original position by a
COIL spring, opening the contact (OFF).
IRON
CORE
IRON
PIECE
CONTACT

AC308621 AB

NORMALLY OPEN (NO) TYPE 3. Relays may be classified as the normally open-type or the
DEENERGIZED STATE ENERGIZED STATE normally closed-type, depending on their contact
construction.
3 1 3 1 NOTE: The deenergized state means that no current is flow-
ing through the coil. The energized state means that current
is flowing through the coil.
(1) The normally open-type
4 2 4 2
CURRENT DOES CURRENT FLOWS When a normally open relay as illustrated here is
NOT FLOW checked, there should be no continuity between terminals
AC310636AB 3 and 4 when the relay is deenergized. There should be
continuity between terminals 3 and 4 when battery
NORMALLY CLOSED (NC) TYPE
voltage and ground are applied to terminals 1 and 2. The
DEENERGIZED STATE ENERGIZED STATE
relay condition is determined by this check.
NOTE: Check the relay in both situation which is ener-
3 1 3 1
gized and is not energized.
(2) The normally closed-type
When a normally closed relay as illustrated here is
4 2 4 2 checked, there should be continuity between terminals 3
CURRENT FLOWS CURRENT DOES
NOT FLOW and 4 when the relay is deenergized. There should be no
AC310637 AB continuity between terminals 3 and 4 when battery
voltage and ground are applied to terminals 1 and 2. The
relay condition is determined by this check.
NOTE: Check the relay in both situation which is ener-
gized and is not energized.

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00E-12 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE

CABLES AND WIRES CHECK

M1001005100041
1. Check connections for looseness, rust, and stains.
2. Check terminals and wires for corrosion.
3. Check terminals and wires for open circuit or impending
open circuit.
4. Check wire insulation and coating for damage, cracks, and
wear.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
ACX00954 AB
6. Check grounding parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with
sharp edges and corners or hot parts (exhaust manifold,
pipe, etc.).
9. Check that harnesses are secured firmly to provide enough
clearance from the fan pulley, fan belt, and other rotating or
moving parts.
10.Check that the harnesses between fixed parts (such as the
ACX00955AB
vehicle body) and vibrating parts (such as the engine) are
long enough to allow for vibration and movement.

BATTERY HANDLING
M1001005200048

WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When checking or servicing does not require power from the
vehicle battery, be sure to disconnect the cable from the battery
(−) terminal. This will prevent problems that could be caused by
a short circuit. Disconnect the (−) battery terminal first and
reconnect it last.

AC000017

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 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE
00E-13
GENERAL ELECTRICAL SYSTEM CHECK
M1001005300045
A circuit consists of the power supply, switch, relay, load,
ground, etc. There are various methods to check a circuit
including an overall check, voltage check, short-circuit check,
and continuity check. Each of the methods briefly described
below applies only to circuits similar to the illustration.
1. VOLTAGE CHECK
POWER SUPPLY (1) Ground one lead wire of the test light. If a voltmeter is
used instead of the test light, ground the grounding side
lead wire.
FUSE
(2) Connect the other lead wire of the test light to the power
side terminal of the switch connector. The test light
ON (2) should come on or the voltmeter should indicate a
voltage.
SWITCH
(3) Then, connect the test light or voltmeter to the motor
connector. The test light should not come on, or the
voltmeter should indicate no voltage. When the switch is
turned ON in this state, the test light should come on, or
OFF the voltmeter should indicate a voltage, with the motor
(3)
starting to run.
MOTOR (4) The circuit illustrated here is normal. If there is any
problem, such as the motor failing to run, check voltages
TEST LIGHT beginning at the connector nearest to the motor until the
(OR faulty part is identified.
VOLTMETER)
(1) 2. SHORT-CIRCUIT CHECK
Because the fuse has blown, it is probable that there is a
ACX00956AB
short circuit. Follow the procedures below to narrow down
the short-circuit location.

STEP 1. Remove the blown fuse and connect the test light
across the fuse terminals (Circuit switch: OFF).
Q: Does the test light illuminate?
YES : Short-circuit exists between the fuse block and the
POWER SUPPLY
switch. Repair the harness between the fuse block
and the switch.
FUSE BLOCK
(REMOVE NO : Go to Step 2.
THE FUSE)

SHORT-CIRCUIT
TEST
LOCATION
LIGHT

SWITCH
OFF

ILLUMINATION
LIGHT

ACX00957 AB

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00E-14 GENERAL <ELECTRICAL>
HOW TO DIAGNOSE

STEP 2. Turn the switch ON and disconnect the

illumination light connector.
Q: Does the test light illuminate?
YES : Short-circuit exists between the switch and the
POWER SUPPLY connector. Repair the harness between the switch
and the connector.
FUSE BLOCK NO : Short-circuit exists between the connector and the
(REMOVE
THE FUSE) illumination light. Repair the harness between the
connector and the illumination light.
TEST
LIGHT
SWITCH

ON

SHORT-CIRCUIT
LOCATION
DISCONNECT
THE LOAD

ILLUMINATION
LIGHT

ACX00958AB

POWER SUPPLY

FUSE BLOCK
(REMOVE
THE FUSE)

TEST
LIGHT
SWITCH

ON

DISCONNECT
THE LOAD

SHORT-CIRCUIT
LOCATION

ILLUMINATION
LIGHT

ACX00959AB

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