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TECHNICAL INFORMATION MANUAL

EVOLUTION-VII

Pub. No. N0104CT9A

 GROUP INDEX

GENERAL . . . . . . . . . . . . . . . . . . . . . . .
0
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . .
1
TECHNICAL
INFORMATION POWER TRAIN . . . . . . . . . . . . . . . . . .
2
MANUAL DRIVE-CONTROL

FOREWORD
COMPONENTS . . . . . . . . . . . . . . . . . .
3
This manual has been prepared as an introduction
to the specifications, features, construction, func-
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
tions, etc. of the newly developed LANCER EVOLU-
TION-VII. Please read this manual carefully so that
it will be of assistance for your service activities.
Please note that the following service manuals are
also available and should be used in conjunction
EXTERIOR . . . . . . . . . . . . . . . . . . . . . .
5
with this manual.
WORKSHOP MANUAL S0105CT9A
All information, illustrations and product descrip-
INTERIOR . . . . . . . . . . . . . . . . . . . . . . .
6
tions contained in this manual are current as of the
time of publication. We, however, reserve the right
to make changes at any time without prior notice or
obligation.
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 7
The EVOLUTION-VII is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VII is a rally-
based model, it will not be warranted and will not be
homologated for general production. Therefore, any
service matters on the EVOLUTION-VII should be
inquired to RALLIART Inc. as usual.

E Mitsubishi Motors Corporation April 2001

NOTES
 0-1

GENERAL
CONTENTS

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2 Active Center Differential (ACD), Active Yaw
Control (AYC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TARGETS OF DEVELOPMENT . . . . . . . . . . . . . . 2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
All-wheel Independent Suspensions . . . . . . . . . . . . 8
PRODUCTS FEATURES . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . 4 Equipments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Serviceability and Reliability . . . . . . . . . . . . . . . . . . 13
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . 14
Body Dimensions and Spacious Cabin . . . . . . . . . 6
Aerodynamic Performance . . . . . . . . . . . . . . . . . . . . 6 MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . . 15
0-2 GENERAL - How to Use This Manual/Targets of Development/Product Features

HOW TO USE THIS MANUAL

MODEL INDICATIONS
The following abbreviations are used in this manual for identification 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 models equipped with such an engine.
M/T: Indicates the manual transmission, or models equipped with the manual transmission.
A/C: Indicates the air conditioner.

TARGETS OF DEVELOPMENT
A new competitive device in addition to technology established in the previous motor sport events to
improve potential performance as well as outward and inward appearance with a sophisticated view to
represent a high performance sedan of the next generation has been featured to improve the image
of Mitsubishi brand.
Furthermore, enhancement of competitiveness as well as driving performance in various motor sport
events has been sought.

PRODUCT FEATURES
Outward and in- (1) Exterior with sophisticated and fearless expression
ward appearance D Multi - lighted headlamp and rear combination lamp exclusively used
to represent a for EVOLUTION-VII
high perfor- D Front bumper with large cooling air inlet
mance sedan of D Incorporate blister fender and overwhelming large - sized tyre
the next genera- D Large - sized and light weight rear spoiler with variable elevation angle
tion that can be adjusted at 4 points
D Front bumper extension and side sill extension
D Large - sized under cover equipped (for improvement of aerodynamic
and cooling performance in drive system)
(2) Interiors with athletic feeling
D Light weight backet newly designed by RECARO seat (adoption of
silk waving cloth with functionality)
D Steering wheel newly designed by MOMO
D Multi - functional sports meter (with permanent illumination to be visible
in the day light)

The most out- (1) Fine tuned engine that provides improved output at all ranges:Maximum
standing engine output 280 PS (206 kW) and maximum torque 39 kgfSm (383 NSm)
and power per- D mprovement of turbo charger
formance in the D Enlarged Intercooler and oil cooler
class D Automatic injection control 3 - nozzle intercooler spray
(2) Drive system with high reliability to deal with increased engine torque
D Reinforcement of transfer, propeller shaft, and drive shaft
 GENERAL - Product Features 0-3
Further improve- (1) Mitsubishi original revolutionary technology with all wheel control
ment in handling D Newly developed active center differential system (ACD) (to be
performance compatible with steering response to cornering and rising traction
made by en- performance)
hancement of the D Improvement of marginal performance in cornering made by integrated
marginal perfor- control of ACD{active yawing control (AYC)
mance (2) Optimally tuned suspension to be adjusted to the new dimensions has
improved cornering performance.
D Extended length of wheel base (+115 mm), enlarged width of treads
(front: +5 mm, rear: +10 mm)
D Increased suspension stroke in the compression side
(front:+15 mm, rear: +5 mm)
D 235/45ZR17 tyres adopting half - radial structure and newly developed
high performance high grip compounds
NOTE
Figures in the parentheses indicate the numbers compared with those
of EVOLUION-VI.
(3) High rigidity body to sustain high marginal performance
(bend rigidity: increased by 50 %, torsion rigidity: equal to that of
EVOLUTION-VII)
D Suspension mounting, fortification of body frame connections, addition
of reinforcements (approximately 20 locations), and addition of welding
spots
D High rigidity 3 - point mounting strut tower bar
D Rear end cross bar<RS>
D Aluminum hood and fender attached

Revolutionary (1) Sporty type 4ABS (improved braking stability derived from braking control
braking system in both sides at driving in sports mode)
to correspond (2) EBD system for EVOLUTION-VII (improvement in deceleration
with high margin- performance)
al performance (3) Featuring Brenvo made front 17 - inch ventilated disc (opposite differential
diameter 4 - piston type) and rear 16 - inch ventilated disc (opposite
2 - piston type)
0-4 GENERAL - Technical Features

TECHNICAL FEATURES
EXTERIOR
DESIGN FEATURES
The 7th generation EVOLUTION has acquired the (3) Exclusive blister fender to appeal good road
image of “high performance sports sedan” equipped hanging (traction characteristics) and brisk
with guaranteed quality and fearless determination driving capability
as “high quality driving sedan” in addition to the (4) Front - side sill extension and wing - type rear
rally image of the previous generations. spoiler to emphasize the high aerodynamic
(1) Aggressive and overwhelming front mask with performance
multi - lighted headlamps, large - sized inlet (5) Clear type rear combination lamp to appeal
bumper grill, and side outlet sporty feeling and guaranteed quality
(2) Improved maneuvering capability of the vehicle (6) Attaching the newly designed “EVOLUTION
at the corners by cutting a large portion of the VII” emblem with sharp and sporty image
front corner

(4)

(3)

(4)

(1) (4) (2)

(3)
(6)

(5)
 GENERAL - Technical Features 0-5
INTERIOR
DESIGN FEATURES
High performance interior to provide an impression (2) The Mitsubishi original design made by MOMO
of sports minded vehicle as the 7th generation used for the steering has the same design used
EVOLUTION for horn pad as the shift lever to express
(1) Combination meter exclusively for EVOLU- integration of the image and high performance
TION-VII with a configuration of a circular interior.
tachometer in the center and thick bezels (3) The Mitsubishi original design made by Recaro
(partitions between meters) with discreet design used for the front seat has a sewing line
create appeal for fearless determination and surrounding circumference of the sides to
sporty feelings. emphasize the good holding.
(1)

(3)

(2) (2)
0-6 GENERAL - Technical Features

BODY DIMENSIONS AND SPACIOUS CABIN

Body Dimensions
The dimensions of the EVOLUTION-VII except for the overall width have been altered in comparison
with those of EVOLUTION-VI.

5 4 6
7
2 1

No. Item Dimensions mm No. Item Dimensions mm

1 Overall length 4 455 (+105) 6 Rear overhang 935 ( - 15)
2 Overall width 1 770 (±0) 7 Tred Front 1 515 (+5)
<Vehicles with
3 Overall height 1 450 (+45) 235/45ZR17tyres> Rear 1 515 (+10)
4 Wheel base 2 625 (+115) Tred Front 1 500 (+5)
<Vehicles with
5 Front overhang 895 (+5) 205/65R15tyres> Rear 1 500 (+10)

NOTE
Figures in the parentheses indicate the values in comparison with those of EVOLUTION-VI.
AERODYNAMIC PERFORMANCE
Deterioration of aerodynamic performance accompanied with enlargement of the body size has been
suppressed by attaching a large - sized under cover on the lower part of the engine compartment, optimizing
elevation angle setting of rear spoiler.
(1) Under cover
A large - sized under cover is designed for compatibility of reduction of air resistance and reduction
of lift.
(2) Rear spoiler
Lift control by attaching elevation angle adjustable rear spoiler and optimizing attached position of
the spoiler are designed for reduction of air resistance.

(2)

(1)
 GENERAL - Technical Features 0-7
ACTIVE CENTER DIFFERENTIAL (ACD), ACTIVE YAW CONTROL (AYC)
ACD, which is designed for improving drive characteristics by electronically controlling center
differential movement, and AYC, which has been adopted since EVOLUTION-IV are featured by
combing two systems for integrated control so that further improvements in driving performance can
be achieved.

ACD mode indicator lamp

AYC torque transfer

differential
Parking brake switch
Steering wheel
sensor

Throttle position sensor (TPS)

Reserve tank

ABS-ECU

Hydraulic unit
assembly
Lateral G sensor
Wheel speed sensor
Longitudinal
ACD transfer G sensor

Engine - ECU
ACD mode switch
4WD-ECU
Stop lamp switch

Wheel speed sensor

0-8 GENERAL - Technical Features

ENGINE
The turbo charger specifications have been Since adoption of magnesium diecasting rocker
optimized by reducing the size of the turbine nozzle cover and hollow camshaft is intended for light
diameter to increase the engine torque at weight of the upper part of the engine, vibration
low - middle speed range as well as high speed of engine - transmission at acceleration can be
range. reduced to improve the response of the body.

TRANSMISSION
Implementation of fortifying each part to deal with
the increased engine torque and revision of the gear
ratio of the standard transmission are intended for
further improvement in power performance.

ALL-WHEEL INDEPENDENT SUSPENSIONS

While the popular and rally-proven McPherson strut The steering gear’s optimal position ensures
front and multi-link rear suspension systems have predictably linear toe-in changes.
basically been retained, they were optimized for Each arm of the rear multi-links with trailing arms,
the new model. as well as its linkage point and length, was
The improvements to the front include adding a reevaluated to achieve optimal alignment.
crossmember brace to the lower arm mount for Combined with the wider tracks, higher body rigidity,
more rigidity, flattening the chassis crossmember, and improved damping characteristics of the
and realigning the roll center to an ideal height. bushings and bump rubbers, the suspensions
As a result, the suspension delivers enhanced deliver a supple ride with superb handling stability
handling and straight-line stability, ride comfort, for relaxing, effortless control.
grounding characteristics, and roll feel, as well as
less vibrations and noise.
 GENERAL - Technical Features 0-9

Strut insulator
Lower arm bushing
(Pillow ball bushing with rubber)
Coil spring
Stabilizer bar
Crossmember

Strut assembly
(shock absorber)
Stabilizer link

Lower arm

Crossmember bar
<RS (option), RS-II>

Coil spring
Shock absorber

Stabilizer bar
Upper arm
Crossmember

Toe control arm Differential

support arm

Trailing arm Lower arm

Differential support
member Toe control bar <RS>
0-10 GENERAL - Technical Features

SAFETY
ACTIVE SAFETY
BRAKING SYSTEM
All models feature fade-resistant 14-inch ventilated New for the Lancer, EBD works with the ABS
discs up front and rear 8-inch drums for sure, linear computer to evenly modulate each channel’s
stopping power. braking pressure for ideal braking force regardless
A 4-sensor, 3-channel ABS (Anti-lock Braking of load or surface conditions at all times.
System) with EBD (Electronic Brake-force
Distribution) is available. ABS adjusts the braking
pressure of the front wheels independently and
rear wheels together for controlled emergency
braking.

Parking brake switch

Steering wheel sensor

ABS warning lamp

Hydraulic unit
(integrated in
ABS-ECU)

Lateral G sensor Wheel speed sensor

Diagnosis connector Longitudinal G sensor
Stop lamp switch Wheel speed sensor
 GENERAL - Technical Features 0-11
PASSIVE SAFETY
SRS AIR BAGS
Dual SRS (Supplemental Restraint System) front Seat belt with pretensioner featured for the driver’s
airbags deploy only upon detection of frontal impact. and front passenger’s seats is designed for instantly
When used in combination with the 3-point ELR taking up the slack in the seat belt at the time
seatbelts, they significantly mitigate head and upper of impact to improve restraint effect on a passenger.
torso injury to front-seat occupants. It is activated approximately at the same time as
SRS airbag is activated to improve protection effect
on a passenger.

Seat belt with pretensioner

SRS warning lamp

Driver’s side air bag module

Front passenger’s side air bag module

Clock spring

Diagnosis connector

SRS - ECU

Driver’s side Passenger’s side

0-12 GENERAL - Technical Features

BODY CONSTRUCTION
The EVOLUTION-VII safety-enhanced body Adding to all-round occupant protection is a
structure comprises front and rear crushable zones deformation-resistant, highly rigid cabin structure
that effectively absorb the impact energy of front that features strategic reinforcements plus large
and rear collisions. side-door impact bars.

Enlarged impact bars

Enlarged cross-section of roof bow

Thicher dash panel lower

Reinforced center pillar

Enlarged cross-section and

minimised vertical offset of
front floor side member
Enlarged cross-section
of side sill

Reinforced front pillar

Enlarged cross-section and
Added dash crossmember extended front side member
 GENERAL - Technical Features 0-13
SAFETY-ENHANCED FRONT SEATS
The front seats are designed to minimise the risk In-house tests show a roughly 40% improvement
of whiplash in a collision from the rear. in occupant injury figures.
The headrestraints have been ideally angled
forward, while the seat frame was moved toward
the rear.
OTHER SAFETY FEATURES
D 3-point ELR seatbelts D Child-protection rear door locks
D Front fog lamps

EQUIPMENTS
IMMOBILIZER SYSTEM
This system lets the engine be started only when recorded in the immobilizer-ECU. Immobilizer
an encrypted code that is recorded in the ignition system is equipped as an option.
key is the same as an encrypted code that is
Integrated immobilizer-ECU and antenna
Start
permission
Ignition key signal
Power
Engine-ECU
Transponder or
Engine A/T-ECU

Encrypted code
MUT - II
Registration
Steering lock key of ignition
cylinder and immobilizer - ECU key

SERVICEABILITY AND RELIABILITY

MAINTENANCE-FREE FEATURES
D Adoption of an auto-tensioner eliminates the D Adoption of auto lash adjusters eliminates the
need for timing belt adjustment need for valve clearance adjustment

ENHANCED DIAGNOSIS SYSTEM

Diagnosis functions have been included for the D MPI
following systems, so that it is possible to use the D ACD
MUT-II to read the diagnosis codes and service D AYC
data and to carry out actuator tests. In addition, D 4ABS
it is also possible to read the diagnosis codes by D SRS air bag
the flashing of the warning lamp in some systems. D Simplified Wiring System (SWS)

IMPROVED SERVICEABILITY AND HANDLING

D A one-touch joint type plastic tube has been D A small wiper module, which includes wiper
adopted for fuel main lines, which makes motor and linkage, has been adopted to
removal and installation easier. facilitate removal and installation.
0-14 GENERAL - Vehicle Identification

VEHICLE IDENTIFICATION
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

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

7 Specification engine F: MPI-DOHC

feature

8 Special feature Z: 4WD

9 Steering wheel location L: Left hand

R: Right hand
 GENERAL - Major Specifications 0-15
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 3 855
Wheel base 4 2,625
Rear overhang 5 975
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 1,380 1,420
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.
NOTES
 1-1

ENGINE
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2 System Block Diagram . . . . . . . . . . . . . . . . . . . . 14

Major Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 Control System Diagram . . . . . . . . . . . . . . . . . . 15
List of Component Functions . . . . . . . . . . . . . . 16
BASE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Injection Control . . . . . . . . . . . . . . . . . . . . . . 19
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Idle Speed Control . . . . . . . . . . . . . . . . . . . . . . . 19
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ignition Timing and Distribution Control . . . . . 20
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . 4 Radiator Fan Motor Control . . . . . . . . . . . . . . . 20
Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power Supply and A/C Condenser Fan Relay
Control, Oxygen Senser Heater Control, Air Flow
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5 Senser Filter Reset Control, Alternator Control,
Fuel Pressure Control, Supercharging Pressure
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control, Secondary Air Control . . . . . . . . . . . . . 20
Construction Diagram . . . . . . . . . . . . . . . . . . . . . . 5 Fuel Pump Relay Control . . . . . . . . . . . . . . . . . . 21
EGR Control and Purge Control . . . . . . . . . . . . 22
INTAKE AND EXHAUST . . . . . . . . . . . . . . . . . 6
Diagnosis System . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 EMISSION CONTROL SYSTEM . . . . . . . . . . 23
Emission Control System Diagram . . . . . . . . . 23
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Construction Diagram . . . . . . . . . . . . . . . . . . . . . 11 Construction Diagram . . . . . . . . . . . . . . . . . . . . . 24
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ACCELERATOR SYSTEM . . . . . . . . . . . . . . . 26
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 13 Construction Diagram . . . . . . . . . . . . . . . . . . . . . 26
1-2 ENGINE - General Information

GENERAL INFORMATION
This engine has the same basic structure as the previous 4G63-T/C engine, however, the following
enhancements have been added in order to provide improved performance.
D The piston shape has been changed.
D The width of the piston rings has been reduced in order to reduce engine friction.
D The turbocharger type has been changed.
D An EGR valve has been added.

MAJOR SPECIFICATIONS
Items 4G63-T/C

Total displacement mL 1,997

Bore × stroke mm 85.0 × 88.0

Compression ratio 8.8

Combustion chamber Pentroof type

Camshaft arrangement DOHC

Valve timing Intake opening BTDC 21_

Intake closing ABDC 59_

Exhaust opening BBDC 58_

Exhaust closing ATDC 18_

Maximum output kW/r/min 206/6500

Maximum torque N·m/r/min 383/3500

Fuel system Electronic controlled multipoint fuel injection

Rocker arm Roller type

Auto-lash adjuster Equipped

 ENGINE - Base Engine 1-3
BASE ENGINE
PISTON
The top land height has been changed from 5 mm to 6 mm, and the second land height has been
changed from 4.5 mm to 5 mm.

<NEW> <OLD>
6 mm 5 mm
5 mm 4.5 mm

PISTON RING
The tension of the rings has been changed as shown in the table below, and the thicknesses of the
No. 2 ring and the oil ring have been reduced in order to provide reduced engine friction.

NEW OLD

PISTON RING No. 1 9.5 N 8.34 N

PISTON RING No. 2 7.0 N 10.49 N

OIL RING 25.0 N 33.34 N

PISTON RING No. 1 PISTON RING No. 2 OIL RING

0.20 ∼ 0.30 mm (New models) 0.35 ∼ 0.50 mm (New models) 0.10 ∼ 0.40 mm
0.25 ∼ 0.35 mm (Old models) 0.40 ∼ 0.55 mm (Old models)

2.0 mm (New
1.2 mm (New models) models)
1.2 mm 1.5 mm (Old models) 2.8 mm (Old
models)

3.1 mm 3.5 mm (New models) 2.2 mm (New models)

3.8 mm (Old models) 2.5 mm (Old models)
1-4 ENGINE - Lubrication System

LUBRICATION SYSTEM
ENGINE OIL COOLER
The drawn cup air-cooled type engine oil cooler has been adopted. The engine oil cooler is installed
below the right head lamp assembly and brings in the air through the oil cooler duct of the front bumper
to cool the engine oil.
SPECIFICATIONS
Items Specifications

Type Drawn cup type

Core size mm (Width × Hight × Thickness) 160 × 200 × 49

Engine oil cooler oil amount L 0.35

Performance kJ/h 29,900

CONSTRUCTION DIAGRAM

Engine oil cooler

return hose

Engine oil cooler

Engine oil cooler

feed hose
 ENGINE - Cooling System 1-5
COOLING SYSTEM
The cooling system is a water-cooled pressurized, forced circulation type which offers the following features.
D To improve the reliability of cavitation at a high engine speed and to increase the amount of engine
coolant, output control system in which a thermostat is installed at the outlet of engine coolant from
the engine to the radiator has been adopted.
D To improve the engine cooling performance and save weight, a plastic tank and an aluminium radiator
fins have been introduced.
D The speed of electric cooling fan is optimally controlled by a radiator fan controller and the engine-ECU
according to driving conditions so that the fan operating noise is minimized and the fuel efficiency
is improved.
SPECIFICATIONS
Items Specifications

Cooling method Water-cooled pressurized, forced circulation with electrical fan

Radiator Type Pressurized corrugate type

Performance kJ/h 216,700

Water pump Type Impeller of centrifugal type

Drive method Drive belt

Thermostat Type Wax pellet type with jiggle valve

Valve open temperature _C 80 ± 1.5

CONSTRUCTION DIAGRAM

Radiator fan
motor

Radiator fan
controller Reserve tank

Radiator
Shroud
1-6 ENGINE - Intake and Exhaust

INTAKE AND EXHAUST

AIR INTAKE SYSTEM
AIR DUCT, AIR CLEANER
D By introducing fresh cool air from the top of the radiator efficiently, the engine performance has been
enhanced and intake air noise has been reduced.
D Burnable used paper mixed with plastic materials have been adopted in consideration for reduction
of industrial wastes and protection of global environment.
AIR INTAKE HOSE
Unleaded rubber materials have been adopted for air intake hose in consideration for protection of global
environment.
CONSTRUCTION DIAGRAM
Air duct
Air cleaner assembly

Air intake hose

INTER COOLER
By mounting an air cooled intercooler to reduce the intake air temperature after boosting, engine output
has been improved. The features of the air cooled intercooler are as follows.
D Large intercooler (Core size: 289.5×490×65 mm)
D Air guides are mounted to the bottom of the intercooler.
CONSTRUCTION DIAGRAM

Inter cooler assembly

490 mm

Air guide
 ENGINE - Intake and Exhaust 1-7
INTER COOLER WATER SPRAY
To complement the intercooler efficiency in ranges where the cooling efficiency of the air cooled intercooler
is insufficient, and attain high performance in various operating environments, a system which cools by
spraying water from a special washer tank for the intercooler to the front of the intercooler has been
adopted.
The features of the intercooler water spray system is as follows.
D Sprays water when the water spray switch on the floor console is operated.
D Adopts a system which enables switching between the auto mode which automatically sprays water
at the optimum operating conditions by signals from the ECU according to the engine state, and
the manual mode which is operated by the driver.
D Three water spray nozzles are located at optimum positions to enhance the intercooler efficiency.
CONSTRUCTION DIAGRAM
<Water Spray Nozzle/Water Spray Hose/Washer Tank>

Water spray nozzle Water spray hose

Inter cooler

Water spray nozzle

Washer tank

<Water Spray Switch>

Water spray switch

1-8 ENGINE - Intake and Exhaust

SYSTEM DIAGRAM

Ignition switch (IG2) Ignition switch (IG1)

Fuse 7.5A J/B 7.5A

20A

Front-ECU
(Tail lamp relay)

J/B Water spray relay Combination

meter Fuse
OFF ON 7.5A

Water spray M
motor
Engine-ECU J/C

Water spray switch

MANUAL AUTO

J/C
 ENGINE - Exhaust System 1-9
EXHAUST SYSTEM
EXHAUST FITTING BRACKET
An exhaust fitting bracket has been added in order to provide
greater rigidity.
Exhaust fitting

Exhaust manifold
heat protector

Exhaust fitting bracket

TURBOCHARGER
The turbocharger type TD05HR-16G6-9.8T and TD05HRA-16G6-9.8T have been adopted.
Compared to previous types of turbocharger, these new types have a smaller turbine housing nozzle
area which improves response at medium to low speeds.

A
A

Nozzle area
Section A - A
1-10 ENGINE - Intake and Exhaust

EXHAUST PIPE AND MUFFLER

Exhaust pipe consisting of 3 separation system: front exhaust pipe, center exhaust pipe, and exhaust
main muffler, has the following features:
D The adoption of a seal ring has reduced vibrations during idling and driving noise.
D A main muffler incorporating a back pressure variable valve is adopted.
D Straight layout of exhaust piping has reduced vibration and exhaust pressure in exhaust system.
D The adoption of hanger rubber with lower spring constant and the decreased number of hangers
have reduced vibration in exhaust piping.
D The adoption of all stainless exhaust piping has enhanced resistance to corrosion and heat.
D Installation of thermal insulating cover and materials on front pipe has improved emission control
performance.
CONSTRUCTION DIAGRAM

When valve
is open

Back
pressure
variable
valve

Flow of exhaust gas

Seal ring

Oxygen sensor

Main muffler
Pre-muffler (sub)

Pre-muffler
Catalytic converter
Center exhaust pipe
Front exhaust pipe
 ENGINE - Fuel System 1-11
FUEL SYSTEM
The fuel system consists of parts such as electromagnetic-type fuel injectors, a delivery pipe and a fuel
pressure regulator. In addition, a fuel pressure control solenoid valve has been provided in order to maintain
idling stability after the engine is re-started when it is hot. This system is basically the same as the
previous system used in the 4G63-DOHC-Turbocharger engine for the EVOLUTION-VI.
SPECIFICATIONS
Items Specification
Fuel tank capacity L 48
Fuel pump type Electric
Fuel filter type Cartridge (filter-paper type)
Fuel return system Fuel pressure regulator return
Fuel pressure regulator control pressure kPa 294
Injectors
j Type Electromagnetic
Quantity 4
Evaporative emission control system Canister type

CONSTRUCTION DIAGRAM

Fuel tank
Fuel pump resistor
Injector resistor

Delivery pipe
Fuel pressure regulator

Injector

Fuel cut-off valve assembly

Fuel pump and gauge assembly
Pipe and gauge assembly
Evaporative canister Fuel pump relay
1-12 ENGINE - Fuel System

FUEL TANK
A steel fuel tank is located under the floor of the D For better serviceability, the fuel tank has been
rear seats to provide increased safety and increase coupled with the main line by a one-touch joint
the amount of luggage compartment space. method, not the conventional double flare nut
D The fuel tank has been equipped with a valve method.
assembly which incorporates a fuel cut-off valve
to prevent fuel from leaking out in the event
of a collision for adjusting the pressure inside
the fuel tank.

CONSTRUCTION DIAGRAM
Fuel high-pressure hose
Suction hose

Fuel pump and gauge assembly

Fuel cut-off valve assembly

Pipe and gauge assembly

Fuel high-pressure hose Fuel tank

 ENGINE - Control System 1-13
CONTROL SYSTEM
The control system is based on the system for 4G63-DOHC-Tubocharger which has been installed in
the EVOLUTION-VI, with the following improvements added.
Improvements/Additions Remarks

Adoption of compact throttle position sensor D Smaller size and light weight
D Higher resistance to vibration
D Idle position switch disused
D Basically the same as that used in the SPACE
WAGON

Adoption of compact stepper motor for idle speed control D Improved ignition performance
servo D Basically the same as that used in the LANCER

Adoption of PWM (pulse width modulation) method of D Reduced fuel consumption

radiator fan motor control D Reduced fan noise
D Basically the same as that used in the LANCER

Adoption of dual oxygen sensor D Higher reliability of air fuel ratio control
D Basically the same as that used in the GALANT

Adoption of intercooler water spray control D Improved intercooler cooling efficiency

1-14 ENGINE - Control System

SYSTEM BLOCK DIAGRAM

Engine-ECU No.1 injector
Air flow sensor
No.2 injector
Fuel injection control
Intake air temperature sensor No.3 injector
Idle speed control No.4 injector
Barometric pressure sensor
Idle speed control servo
Ignition timing control (stepper motor)
Engine coolant temperature sensor
No.1, No.4 ignition coil
Engine control relay control
No.2, No.3 ignition coil
Throttle position sensor
Fuel pump relay control
Engine control relay
A/C switch Fuel pump relay 2
A/C relay control
Fuel pump relay 3
A/C load signal
Fan motor control
(radiator) Tachometer
Camshaft position sensor A/C relay
Fan relay control
(A/C condenser) Fan controller
Crank angle sensor (radiator)

Alternator control Fan motor relay (HI, LOW)

Vehicle speed sensor (A/C condenser)
Air flow sensor filter reset control Alternator G terminal
Power steering fluid pressure switch
Air flow sensor
Fuel pressure control
Detonation sensor
Fuel pressure control solenoid valve
Turbochanger control
Intercooler water spray (auto) Waste gate solenoid valve

Intercooler water spray (manual) Secondary air control Secondary air control solenoid valve

Intercooler water spray relay

Oxygen sensor (front) Intercooler water spray control
Intercooler water spray lamp
Oxygen sensor (rear) Engine warning lamp control Engine warning lamp
(check engine lamp)
Oxygen sensor heater control Oxygen sensor heater (front)
Ignition switch-IG

EGR control Oxygen sensor heater (rear)

Ignition switch-ST

Purge control EGR control solenoid valve

Alternator FR terminal
Purge control solenoid valve
Diagnosis output
Power supply
Diagnosis output terminal
RAM data transmission
Diagnosis control terminal Diagnosis output terminal
(for MUT-II)
 ENGINE - Control System 1-15
CONTROL SYSTEM DIAGRAM
L1 Oxygen sensor (front) l1 Injector
L2 Oxygen sensor (rear) l2 Idle speed control servo
L3 Air flow sensor l3 Fuel pressure control solenoid valve
L4 Intake air temperature sensor Engine-ECU l4 Waste gate solenoid valve
L5 Throttle position sensor l5 EGR control solenoid valve
L6 Camshaft position sensor l6 Purge control solenoid valve
L7 Crank angle sensor l7 Secondary air control solenoid valve
L8 Barometric pressure sensor
L9 Engine coolant temperature sensor
L10 Detonation sensor D Engine control relay
D Fuel pump relay 2, 3
D A/C relay
D Ignition coil
D Fan controller
D Power supply D Condenser fan relay (HI)
D Ignition switch-IG D Condenser fan relay (LOW)
D Ignition switch-ST D Engine warning lamp
D Vehicle speed sensor D Diagnosis output
D A/C switch D Alternator G terminal
D A/C load signal
D Power steering fluid pressure switch
D Alternator FR terminal

From
fuel tank l2 Idle
speed Vacuum
Canister L5 Throttle control
By-pass tank
Check position servo
valve valve sensor
l7 Secondary
air control
solenoid
valve

l5 EGR control
l3 Fuel pressure solenoid valve
control
solenoid valve
Secondary l1 Injector
air valve
Fuel L6 Camshaft
l6 Purge pressure position sensor
L8 Barometric control regurator From
pressure solenoid To fuel tank fuel pump
sensor valve
PCV valve EGR
L3 Air flow L1 Oxygen valve
Air sensor sensor
inlet (front)

L9 Engine coolant
temperature sensor

L4 Intake air L7 Crank angle sensor

temperature L10 Detonation sensor
sensor Waste gate
actuator L2 Oxygen sensor (rear)

l4 Waste gate Three-way

solenoid valve catalytic converter
1-16 ENGINE - Control System

LIST OF COMPONENT FUNCTIONS

Name Function

ECU Engine-ECU Uses the signals input from the various sensors to control operation of
actuators in accordance with the driving conditions.

Sensors Ignition switch-IG Detects the ON/OFF position of the ignition switch. When this signal
is input to the engine-ECU, power is supplied to components such as
the injectors, air flow sensor, idle speed control servo and crank angle
sensor.

Ignition switch-ST Detects whether the engine is cranking. The engine-ECU controls the
fuel injection, throttle valve opening angle and ignition timing to the
appropriate settings based on this signal.

Air flow sensor Detects the amount of intake air (volumetric capacity) by means of a
Karman vortex meter. The engine-ECU controls the basic injector drive
time based on this signal and on the engine speed.

Barometric pressure sensor Detects the barometric pressure by means of a semiconductor

diffusion-type pressure sensor. The engine-ECU detects the vehicle’s
altitude based on this signal, and uses this to correct the fuel injection
amount so that the optimum air/fuel mixture ratio is obtained for that
altitude.

Oxygen sensor Detects the concentration of oxygen in the exhaust gas by means of
zirconia and platinum electrodes. The engine-ECU judges whether the
air/fuel mixture ratio is at the optimum theoretical ratio based on this
concentration.

Intake air temperature sensor Detects the temperature of the intake air by means of a thermistor. The
engine-ECU corrects the fuel injection amount to the correct amount
corresponding to the intake air temperature based on the voltage
output from this sensor.

Engine coolant temperature Detects the temperature of the engine coolant by means of a
sensor thermistor. The engine-ECU detects how warm the engine is based on
the signal from this sensor, and uses this to control the fuel injection
amount, idle speed and ignition timing.

Throttle position sensor Detects the throttle valve opening angle by means of a potentiometer.
The engine-ECU controls the throttle valve and also determines the
optimum fuel injection for the vehicle’s degree of acceleration based
on the voltage output from this sensor.

Vehicle speed sensor Detects the vehicle speed by means of a magnetic rheostatic element.

Camshaft position sensor Detects the No. 1 cylinder compression top dead centre position by
means of a hall element.

Crank angle sensor Detects the crank angle by means of a hall element. The engine-ECU
controls the injectors based on the signal from this sensor.

Alternator FR terminal Detects the energising duty ratio of the alternator field coil.

Power steering fluid pressure Detects whether there is a power steering load present by means of a
switch contact switch.

A/C switch Detects the ON/OFF condition of the A/C.

 ENGINE - Control System 1-17

Name Function

Sensors A/C load signal Inputs the compressor drive state (low load/high load) to the
engine-ECU. The engine-ECU controls the A/C idle-up revolution
speed using this signal.

Intercooler water spray switch Sprays water when certain driving conditions are satisfied.
(automatic)

Intercooler water spray switch Sprays water while the switch is being pressed by the driver.
(manual)

Diagnosis control terminal Notifies the engine-ECU that the MUT-II has been connected to the
diagnosis connector, and enables communication between the MUT-II
and the engine-ECU.

Actuators Engine control relay Turns the engine-ECU power circuit on and off.

Injector Drives the fuel injection by means of drive signals from the
engine-ECU.

Ignition coil Interrupts the ignition coil primary current in accordance with the
(integrated power transistor) ignition signals from the engine-ECU, in order to generate a high
voltage for ignition.

Idle speed control servo The throttle valve bypass air amount during idling and deceleration is
controlled with the signal from the engine-ECU.

Fuel pump relay 1 Supplies power to the fuel pump when the ignition switch is at the ON
position.

Fuel pump relay 2 Controls the supply of power to the fuel pump in accordance with the
signal from the engine-ECU.

Fuel pump relay 3 Controls the supply of power to the fuel pump when driving at low loads
and when driving at high loads, in accordance with the signal from the
engine-ECU.

Fan controller Controls the smooth operation of the radiator fan in accordance with
the signal from the engine-ECU.

Condenser fan relay (HI) Controls the condenser fan operation (high speed) in accordance with
the signal from the engine-ECU.

Condenser fan relay (LOW) Controls the condenser fan operation (low speed) in accordance with
the signal from the engine-ECU.

Intercooler water spray relay Controls the driving of the intercooler spray motor in accordance with
the signal from the engine-ECU.

Waste gate solenoid valve Controls the supercharging pressure which acts on the waste gate
actuator in accordance with the signal from the engine-ECU.

Purge control solenoid valve Controls the purge air flow amount which is introduced into the surge
tank in accordance with the signal from the engine-ECU.

EGR control solenoid valve Controls the negative pressure which operates the EGR valve in
accordance with the signal from the engine-ECU.

Secondary air control solenoid Controls the pressure which is introduced into the secondary air valve
valve in accordance with the signal from the engine-ECU.

Fuel pressure control solenoid Controls the fuel pressure in accordance with the signal from the
valve engine-ECU.
1-18 ENGINE - Control System

Name Function

Actuators Alternator G terminal Controls the current generated by the alternator in accordance with the
signal from the engine-ECU.

A/C relay Controls the A/C compressor operation.

Engine warning lamp Illuminates when a sensor malfunction is detected to warn the driver
(check engine lamp) of the problem.

Intercooler water spray lamp Illuminates when the intercooler is being sprayed in accordance with
the signal from the engine-ECU.
 ENGINE - Control System 1-19
FUEL INJECTION CONTROL
The fuel injection control system is basically the same as the control system for the 4G63-DOHC-Turbocharger
engine installed in the Evolution-VI.
SYSTEM CONFIGURATION DIAGRAM

Air flow sensor

Barometric pressure sensor

Intake air temperature sensor

Engine coolant temperature sensor

Fuel pressure control Throttle position sensor

solenoid valve
Engine-ECU Camshaft position sensor
From
fuel Crank angle sensor
Fuelpressure
To fuel regulator pump
tank Ignition switch-ST
Injector
Oxygen sensor

Vehicle speed sensor

Detonation sensor

IDLE SPEED CONTROL

The idle speed control system is basically the same as the control system for the 4G63-DOHC-Turbocharger
engine installed in the Evolution-VI.
SYSTEM CONFIGURATION DIAGRAM

Air flow sensor

Barometric pressure sensor

Intake air temperature sensor

Bimetal type limiter Engine coolant temperature sensor

Idle speed con-
trol servo Throttle position sensor
(Stepper motor)
Crank angle sensor

Engine-ECU A/C switch

A/C load signal
To intake From air Vehicle speed sensor
manifold cleaner
Power steering fluid pressure switch
Alternator FR terminal
Ignition switch-IG
Ignition switch-ST
Diagnosis control terminal
Speed adjusting screw
1-20 ENGINE - Control System

IGNITION TIMING AND DISTRIBUTION CONTROL

The ignition timing and distribution control system is basically the same as the control system for the
4G63 - DOHC-Turbocharger engine installed in the Evolution-VI.
SYSTEM CONFIGURATION DIAGRAM

Ignition switch Battery

Air flow sensor

Barometric pressure sensor

Intake air temperature sensor

Engine coolant temperature sensor

Engine- Ignition Ignition
Camshaft position sensor ECU coil A coil B

Crank angle sensor

Detonation sensor

Ignition switch-ST

Vehicle speed sensor

Spark plug
To tachometer
Cylinder No. 4 1 2 3

RADIATOR FAN MOTOR CONTROL

The radiator fan motor control system is basically the same as the control system for 4G6-MPI engine
installed in the GALANT.

POWER SUPPLY AND A/C CONDENSER FAN RELAY CONTROL, OXYGEN

SENSOR HEATER CONTROL, AIR FLOW SENSOR FILTER RESET CONTROL,
ALTERNATOR CONTROL, FUEL PRESSURE CONTROL, SUPERCHARGING
PRESSURE CONTROL, SECONDARY AIR CONTROL
These control systems are basically the same as those for 4G63-DOHC-Turbocharger engine installed
in the EVOLUTION-VI.
 ENGINE - Control System 1-21
FUEL PUMP RELAY CONTROL
D The fuel injection amount is controlled by the fuel pump relay 3 in order to reduce the amount of
return fuel when the engine is running at low speeds and fuel consumption is low, and also to reduce
noise.
Battery

Ignition switch

Fuel pump relay 1

Fuel pump relay 2

Fuel
pump Fuel pump resistor
relay 3

To fuel pump

Engine-ECU
1-22 ENGINE - Control System

EGR CONTROL AND PURGE CONTROL

Refer to the EMISSION CONTROL SYSTEM.

DIAGNOSIS SYSTEM
The engine-ECU is prvided with the following functions to make system inspection easier.
D Engine warning lamp control
D Diagnosis function
D Service data output
D Actuator test
NOTE
Refer to the Workshop Manual for details on each item.
 ENGINE - Emission Control System 1-23
EMISSION CONTROL SYSTEM
The following improvements in the control details have been made to the system, which is basically
the same as the previous system used in the 4G63-DOHC-Turbocharger engine for the EVOLUTION-VI.
D An electronically-controlled EGR system utilizing an EGR control solenoid valve has been adopted.
D An electronically-controlled purge control system utilizing purge control solenoid valve has been adopted.

System Remarks

Evaporative emission control system Electronic control type

(Duty cycle type purge control solenoid valve)

Exaust gas recirculation (EGR) system Electronic control type

(Duty cycle type EGR control solenoid valve)

EMISSION CONTROL SYSTEM DIAGRAM

From
fuel
Canister tank
Check
valve

EGR control
Fuel pressure solenoid valve
control
solenoid valve
Injector
Fuel
Purge pressure
control regurator From fuel
solenoid To fuel pump
valve tank
PCV valve EGR
Oxygen valve
Air sensor
inlet (front)

Oxygen sensor (rear)

Three-way
catalytic converter
1-24 ENGINE - Mount

MOUNT
The inertia axial system based on the past achievements in COLT/LANCER has been adopted for the
engine mount system.
D Longitudinal installation type of cylindrical liquid-filled engine mount has been adopted for reduction
of idle vibration and improvement of ride feeling.
D The liquid-filled mount system has been adopted for transmission mount to improve ride feeling by
optimizing the insulator.
D Installation of roll mount in the upper area has reduced engine rolling. Furthermore, enlargement
of insulator diameter has reduced idle vibration.
CONSTRUCTION DIAGRAM
<Engine mount/Transmission mount>

Engine mount

Transmission mount
 ENGINE - Mount 1-25
<Engine roll stopper/Crossmember/Centermember : L.H. drive vehicles>

Rear roll mount bracket

Rear roll rod assembly

Rear roll rod bracket

Crossmember
Front roll mount bracket

Front roll stopper

Crossmember bar
Centermember

<Engine roll stopper/Crossmember/Centermember : R.H. drive vehicles>

Rear roll mount bracket

Rear roll stopper

Crossmember

Front roll mount bracket

Front roll stopper

Crossmember bar

Centermember
1-26 ENGINE - Accelerator System

ACCELERATOR SYSTEM
The accelerator system is a cable and suspended vent noise and vibration when the cable and accel-
pedal combination. erator arm contact.
Plastic bushing and rubber damper have been at-
tached to the end of the accelerator cable, to pre-

CONSTRUCTION DIAGRAM

Plastic bushing
Rubber
dumper

Accelerator
cable

Accelerator arm

<L.H. drive vehicles> <R.H. drive vehicles>

Accelerator cable Accelerator cable

Accelerator arm
Accelerator Accelerator
pedal bracket pedal bracket

Accelerator arm
 2-1

POWER TRAIN

CONTENTS

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System Structure . . . . . . . . . . . . . . . . . . . . . . . . . 16

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Oil Pressure Unit . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electronic Control System . . . . . . . . . . . . . . . . . 20
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 27
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4WD System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transmission Control . . . . . . . . . . . . . . . . . . . . . 11
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 30
ACTIVE CENTER DIFFERENTIAL (ACD)
AND ACTIVE YAW CONTROL (AYC) . . . . . . . . 12 DIFFERENTIAL MOUNT . . . . . . . . . . . . . . . . . 33
Description of Structure and Operations . . . . 16
2-2 POWER TRAIN - Clutch

CLUTCH
SPECIFICATIONS
Items Specifications

Engine model 4G63-DOHC-Intercooler Turbocharger

Clutch disc type Dry single plate type

Clutch disc facing diameter O.D.×I.D. mm 240×160

Clutch cover type Diaphragm spring pull type

Clutch cover set load N 9,320 ± 750

Control system Hydraulic type

Release cylinder I.D. mm 20.64

Master cylinder I.D. mm 15.87

Clutch fluid Brake fluid DOT 3 or DOT 4

CLUTCH CONTROL CONFIGURATION

<L.H.drive vehicles> Reservoir hose Master cylinder member assembly

Clutch hose

Clutch pipe

Clutch master cylinder

Clutch pedal

Reservoir hose Master cylinder member assembly

Clutch release
cylinger Clutch pipe

<R.H.drive vehicles> Clutch master cylinder

Clutch pipe Clutch pedal

Clutch hose

Clutch release cylinger

 POWER TRAIN - Manual Transmission 2-3
MANUAL TRANSMISSION
The manual transmission is a W5M5 transmission. This transmission incorporates the following changes
from the F5M4 type transmission mounted to GALANT.
D With the incorporation of 4WD, the center differential has been positioned at the front differential
of the 2WD, and the front differential has been positioned inside the transfer.
D The kinetic performance has been improved by setting a helical gear LSD for the front differential.
<RS, RS II: Option>
D With the adoption of the active center differential (ACD), an hydraulic multi plate clutch has been
adopted for the transfer limited slip differential. <RS, RS II: Option> (Refer to P.2-17 for details
of the hydraulic multi plate clutch.)
SPECIFICATIONS
Item Specifications
Classification RS, RS II RS, RS II (Super cross gear specifications)
Transmission type W5M51
Engine type 4G63-DOHC-T/C
Transmission type 5 steps forward, 1 step reverce, always in contact)
Gear ratio 1st 2.785 ←
2nd 1.950 ←
3rd 1.407 1.444
4th 1.031 1.096
5th 0.720 0.825
Reverse 3.416 ←
Final deceleration ratio 4.529 ←
Helical gear LSD (Front differential) No Yes
Transfer Deceleration ratio 3.307 ←
Limited slip differential VCU or hydraulic multi ←
plate clutch (ACD)
2-4 POWER TRAIN - Manual Transmission

SECTIONAL VIEW
W5M51 <Vehicle with VCU>

4 5

1 2 3
6

19 18 17 16 15 14

20
10
11
13

12

1. 4th gear 11. Transfer cover

2. 3rd - 4th synchronizer 12. Hypoid pinion
3. 3rd gear 13. Center differential
4. Transmission case 14. 1st gear
5. Clutch housing 15. 1st - 2nd synchronizer
6. Clutch release bearing retainer 16. 2nd gear
7. Input shaft 17. 5th gear
8. Output shaft 18. 5th - reverse synchronizer
9. Front differential 19. Reverse gear
10. Viscous coupling unit (VCU) 20. Reverse idler gear
 POWER TRAIN - Manual Transmission 2-5
W5M51 <Vehicle with ACD>

4 5

1 2 3

21 20 19 18 17 16

22
10

11
15 13 12

14

1. 4th gear 12. Piston

2. 3rd - 4th synchronizer 13. Transfer hydraulic case
3. 3rd gear 14. Hypoid pinion
4. Transmission case 15. Center differential
5. Clutch housing 16. 1st gear
6. Clutch release bearing retainer 17. 1st - 2nd synchronizer
7. Input shaft 18. 2nd gear
8. Output shaft 19. 5th gear
9. Front differential 20. 5th - reverse synchronizer
10. Clutch housing 21. Reverse gear
11. Transfer cover 22. Reverse idler gear
2-6 POWER TRAIN - Manual Transmission

W5M51 <Vehicle with Helical Gear LSD and VCU>

4 5

1 2 3
6

19 18 17 16 15 14

20
10
13 11

12

1. 4th gear 11. Transfer cover

2. 3rd - 4th sychronizer 12. Hypoid pinion
3. 3rd gear 13. Center differential
4. Transmission case 14. 1st gear
5. Clutch housing 15. 1st - 2nd sychronizer
6. Clutch release bearing retainer 16. 2nd gear
7. Input shaft 17. 5th gear
8. Output shaft 18. 5th - reverse synchronizer
9. Front differential (Helical gear LSD) 19. Reverse gear
10. Viscous coupling unit (VCU) 20. Reverse idler gear
 POWER TRAIN - Manual Transmission 2-7
W5M51 <Vehicle with Helical Gear LSD and ACD>

4 5

1 2 3
6

21 20 19 18 17 16

22
10
11
15 13 12

14

1. 4th gear 12. Piston

2. 3rd - 4th sychronizer 13. Transfer hydraulic case
3. 3rd gear 14. Hypoid pinion
4. Transmission case 15. Center differential
5. Clutch housing 16. 1st gear
6. Clutch release bearing retainer 17. 1st - 2nd sychronizer
7. Input shaft 18. 2nd gear
8. Output shaft 19. 5th gear
9. Front differential (Helical gear LSD) 20. 5th - reverse synchronizer
10. Clutch housing 21. Reverse gear
11. Transfer cover 22. Reverse idler gear
2-8 POWER TRAIN - Manual Transmission

4WD SYSTEM
The 4WD system is a center differential full-time 4WD with limited slip differential.
The center differential has been positioned at the front differential of the 2WD transmission, and the
front differential has been positioned inside the transfer. The limited slip differential of the center differential
has been positioned at the back of the front differential in the transfer.
For the limited slip differential of the center differential, a viscous coupling unit (VCU) or active center
differential (ACD) has been adopted.

Engine

Transfer

Limited slip
differential
Center differential

Front differential

Rear differential
 POWER TRAIN - Manual Transmission 2-9
POWER TRAIN
Helical Gear LSD
The helical gear LSD is composed of four long pinions, four short pinions, three thrust washers, side
gears A and B, and cases A and B.
The long pinions are in contact with the side gear B and short pinions, while the short pinions are in
contact with the side gear A and long pinions.

Case B
Short pinion
Thrust washer

Side gear B

Long pinion
Side gear A

Case A

Power Flow
Operations in forward driving
During forward driving, as the differential case and and drive shaft rotate at the same speed, they
rotate at the assembly without the inside of the differential moving.
The driving force at this time will be transmitted as follows.
Differential case → Long and short pinions → Side gears A and B → Drive shaft

Driving power
Differential case Side gear B

Short pinion

Long pinion

Side gear A
2-10 POWER TRAIN - Manual Transmission

Operations during differential (when there is rotational difference between the left and right
wheels)
When the frictional coefficient of the left and right wheels are more or less equal, and a slight rotational
difference occurs at the left and right wheels (normal turning), rotational difference will also occur
between side gears A and B. In this case, while the long pinions and short pinions mutually rotate
in the reverse direction, the vicinity of side gears A and B revolves and absorbs the speed difference.
In this way, like normal differential, the high speed side accelerates for the revolved amount in respect
to the revolution speed of the differential case,while the low speed side rotates in the decelerated
state and performs differential.

Differential case Driving power

Side gear B

Revolution

Low speed
side
Autorotation

High speed side

Long pinion

Side gear A Short pinion

Autorotation

Operations during Limited Slip Differential

When the loads of the left and right wheels become unbalanced due to changes in road surface
conditions and sudden turning, the driving torque of side gears A and B will differ.
As mentioned earlier, because side gears A and B are in contact via the respective long and short
pinions, the gears influence each other, resulting in contact reaction force (F and f) between the
long pinion and side gear B, and the short pinion and side gear A.
The separating force (Ft and ft) in the axial direction of the contact reaction force causes side gears
A and B to be pushed and extended. From this force, side gears A and B are pushed against the
thrust washer (case) and friction occurs.
The separating force (Fr and fr) in the radial direction of the contact reaction force causes the long
pinion and short pinion to be pushed against the differential case (cases A and B). This force generates
a large friction between the long pinion, short pinion, and differential case (cases A and B).
Friction also occurs on the gear with the generation of contact reaction force (F and f) of the four
gears (pinions).
These frictional forces cause the generation of frictional torque at each section according to the
size of the driving torque input to the differential case, and the generation of limited slip differential
torque proportionate to the input torque.
 POWER TRAIN - Manual Transmission 2-11

Driving power Forward direction

Thrust washer
Torque F Fr fr f

High speed Ft ft
side
Low speed
side

Long pinion

Thrust washer
Differential case Short pinion
Side gear A Side gear B

TRANSMISSION CONTROL
D The shift lever construction adopted the D The shift and select cable securing portions
spherical rotary shaft fulcrum type to assure have been elastically supported to reduce
a non-rickety. contained sound.
D The base bracket material adopted a synthetic D A mass-filled shift knob has been adopted to
resin for the weight reduction. minimize the binding touch at the time of a
shift.

CONSTRUCTION DIAGRAM

Select cable

Shift lever assembly

Shift cable

Base bracket
2-12 POWER TRAIN - ACD and AYC

ACTIVE CENTER DIFFERENTIAL (ACD) AND ACTIVE YAW

CONTROL (AYC)
The LANCER EVOLUTION-VII adopts the newly developed active center differential (ACD).
The driving performance of the ACD has been improved by varying the center differential drive by electronic
control.
The yaw moment is directly controlled by the active yaw control (AYC) adopted from EVOLUTION-V
onwards to improve the turning performance.
By combining and integratedly controlling these two systems, the driving performance has been further
improved.
RS, RS II
ACD Option
ACD and AYC Option

OUTLINE OF CONTROL
The following effects are obtained by equipping the ACD or ACD and AYC.
State of vehicle ACD AYC Integrated control effects
1. During de- Similar to the direct engagement [When decelerated during Stability against various
celeration 4WD by increasing the center turning] external influences such as
(Before differential during sharp decelera- The driving power is moved to poor road conditions and
corners) tion to improve stability in decelera- the inside turning wheel to driver operations have been
tion. reduce the tack in. improved.
2. First half of The center differential restriction is The driving power is moved to The response to steering
turning reduced according to the steering the outside turning wheel operations (brisk move-
(Corner en- angle and operation speed to set according to the steering ment) is improved as much
trance) the center differential as close as angle and operation speed to as possible.
possible to the free state and improve the turning perfor-
improve turning performance. mance.
3. Latter half The center differential restriction is The driving power is moved to Two elements (acceleration
of turning enhanced according to the amount the outside turning wheel and turning) have been
(Corner the acceleration is stepped to set according to the amount the improved simultaneously.
exit) similar effects as the direct engage- acceleration is stepped to
ment 4WD and improve the accel- decrease the acceleration
eration performance. understeer and improve turn-
ing performance.

2. First half of turning

3. Latter half of turning
AYC: Under steer deceleration
AYC: Turning

ACD: Direct engagement

ACD: Free

1. During deceleration
ACD: Direct
engagement
AYC: Tack in deceleration
(During deceleration when turning)
 POWER TRAIN - ACD and AYC 2-13
COMPONENT VIEW

ACD mode indicator lamp

AYC torque transfer

differential
Parking brake switch
Steering
wheel sensor

Throttle position sensor (TPS)

Reserve tank

ABS-ECU

Hydraulic unit
assembly
Lateral G sensor
Wheel speed sensor
Longitudinal
ACD transfer G sensor

Engine-ECU
ACD mode switch
4WD-ECU
Stop lamp switch

Wheel speed sensor

2-14 POWER TRAIN - ACD and AYC

LIST OF MAIN COMPONENTS

Components Outline of function

ACD transfer Controls the transmission torque of the hydraulic multi plate clutch by the
hydraulic unit, and adjusts the center differential.
4WD-ECU Processes information of various sensors and switches, calculates the hydraulic
multi plate clutch transmission torque and amount of AYC torque movement and
direction, and controls the hydraulic unit on the basis of them.
Engine-ECU Sends the engine idling state to the 4WD-ECU.
ABS-ECU Outputs the ABS monitor signal to the 4WD-ECU.
Throttle position sensor (TPS) Sends the throttle valve opening angle to the 4WD-ECU.
Longitudinal G sensor Sends the acceleration in the front and rear directions of the vehicle to the
4WD-ECU.
Lateral G sensor Sends the acceleration along the side of the vehicle to the 4WD-ECU.
Steering wheel sensor Sends the steering angle and neutral position to the 4WD-ECU.
Wheel speed sensor Sends the wheel speed to the 4WD-ECU.
Stop lamp switch Sends the brake operating state to the 4WD-ECU.
Parking brake switch Sends the operating state of the parking brake to the 4WD-ECU.
ACD mode indicator lamp
p Displays the ACD control mode (TARMAC, GRAVEL, SNOW).
Lights the all mode lamp during fail. (Lights for about 1.5 seconds after the ignition
switch is turned ON)
ACD mode switch Switches the ACD control mode (TARMAC, GRAVEL, SNOW).
Hydraulic
y Pressure sensor Sends the pressure of the accumulator to the 4WD-ECU.
unitit Electric pump Generates oil pressure for clutch operations.
Directional valve Controls whether to supply the oil pressure to the left or right AYC clutch.
Proportional valve Controls hydraulic supplied to hydraulic multi plate clutch of the ACD.
<ACD>
Proportional valve Controls oil pressure supplied to the AYC clutch.
<AYC>
Electric pump relay Supplies the power to the electric pump.
AYC torque transfer differential Controls the transmission torque of the left and right clutches according to the
oil pressure from the hydraulic unit, and adjusts the left and right driving power
difference of the rear wheels.
 POWER TRAIN - ACD and AYC 2-15
OUTLINE OF ACD AND AYC

Idling information
Engine-ECU
<ACD and AYC
Equipped Vehicle>
ACD mode switch
ABS monitor signal
Parking brake switch
Wheel speed sensor <FL>
ABS- Wheel speed sensor <RL> ACD mode indicator lamp
ECU Wheel speed sensor <RR>
Wheel speed sensor <FR>
Diagnostic connector

Wheel speed sensor <FL>*1

Wheel speed sensor <RL>*1 Direction valve*2
4WD-ECU
Wheel speed sensor <RR>*1
Wheel speed sensor <FR>*1 Proportional valve*2 (AYC)
Longitudinal G sensor
Lateral G sensor Proportional valve (ACD)
Stop lamp
Steering wheel sensor
Pressure sensor
Throttle position sensor
ECU power supply

Electric
pump
Steering wheel sensor

Stop lamp switch

Wheel speed Reservoir
sensor <FR> Wheel speed sensor <RR> tank relay

Pressure
sensor

Lateral G sensor
Longitudinal G sensor Right clutch*2
ACD transfer Proportional Accu-
Left clutch*2 valve mulator
(ACD)
Hydraulic
multi
Electric
plate clutch
Proportional pump
valve*2
(AYC)
Center
differential Directional
valve*2

Hydraulic unit
AYC torque transfer
differential *2
Wheel speed sensor <FL> Wheel speed sensor <RL>
NOTE
1. *1 indicates equipped with only ACD.
2. *2 indicates equipped with ACD and AYC.
2-16 POWER TRAIN - ACD and AYC

DESCRIPTION OF STRUCTURE AND OPERATIONS

The ACD system adopts a transfer limited slip differential as the hydraulic multi plate clutch, and electronically
controls it using sensors, 4WD-ECU, and hydraulic unit.
NOTE
Refer to P.2-30 for details on the AYC structure and operations.
SYSTEM STRUCTURE

AYC torque transfer

differential
ACD transfer

Hydraulic unit
(Electric pump with
accumulator)

Engine

4WD-ECU

T/M
Steering wheel sensor

TPS

Wheel speed sensor

Longitudinal G sensor

Lateral G sensor

Sensors
 POWER TRAIN - ACD and AYC 2-17
TRANSFER LIMITED SLIP DIFFERENTIAL
During acceleration and deceleration, the piston is moved in the right direction according to the oil pressure
from the hydraulic unit to connect the hydraulic multi plate clutch (friction plate and disc) and set the
center differential to the direct engagement state as much as possible. This improves the acceleration
performance and stability during deceleration.
During turning, the oil pressure from the hydraulic unit stops, the piston operates in the left direction
to release the hydraulic multi plate clutch and free the center differential to improve the turning performance.
If the parking brake is pulled while driving at a vehicle speed above 5 km/h, the hydraulic multi plate
clutch will also be released and the center differential set as close as possible to the free state.

Hydraulic unit
assembly

ACD transfer

Section A - A

Piston <During acceleration

and deceleration>
Thrust bearing

Transfer hydraulic case Hydraulic multi plate clutch

(Friction plate and disk)

<During turning>
2-18 POWER TRAIN - ACD and AYC

HYDRAULIC UNIT
The hydreaulic unit is composed of the accumulator (electric pump, pressure sensor, accumulator) and
pressure controller (proportional valve, directional valve).
The pressure accumulator intermittently operates the pump, and accumulates the control pressure required
in the accumulator.
The pressure controller operates the proportional valve and directional valve, and supplies the appropriate
oil pressure to the ACD transfer or AYC torque transfer differential according to the signals from the
4WD-ECU.
SPECIFICATIONS
Specifications Specifications
Electric pump Trochoidal type
Operating oil ATF SP III
Proportional valve Current proportional control type
Directional valve 3 position electromagnetic switching method

TPS

Stop lamp switch Hydraulic unit assembly

Wheel speed sensor Pressure sensor

Electric pump relay
Longitudinal G sensor
Electric Accu-
pump mulator
Lateral G sensor
4WD-ECU ACD transfer
Steering wheel sensor
Proportional Proportional
valve (AYC) valve (ACD) Hydraulic multi
Engine-ECU plate clutch
Directional
ABS-ECU valve

ACD mode switch

Parking brake switch

Electronic control system ACD mode

indicator lamp Left Right
Oil pressure control system
AYC clutch

Proportional valve
Supplies the oil pressure required for ACD or AYC control
according to the instructions of the 4WD-ECU.
Proportional
valve <ACD>

Proportional
valve <AYC>
 POWER TRAIN - ACD and AYC 2-19
When the proportional valve is OFF, the oil pressure from
Proportional
From electric pump the electric pump will be cut off by the proportional valve.
valve (OFF) For this reason, oil pressure will be supplied to the ACD
or AYC and each system will be set into the non-operating
state.

Proportional When the proportional valve turns ON, the proportional valve
From electric pump
valve (ON) opens, and the oil pressure from the electric pump will be
supplied to the ACD hydraulic multi plate clutch or AYC
directional valve.

Return

To ACD hydraulic multi plate

clutch or AYC directional valve

Directional valve
Supplies the oil pressure required for controlling the AYC
clutch according to the instructions of the 4WD-ECU.

Directional
valve

From proportional When the directional valve is OFF, the oil pressure from the
Directional valve <AYC> proportional valve <AYC> will be cut off by the directional
valve (OFF) valve. For this reason, the clutch will set into the non-operating
state without oil pressure supplied to each clutch of the AYC.

To clutch To clutch
<Left side> <Right side>

Directional valve From proportional valve When oil pressure supply signal for the AYC clutch <Right
(Right side: ON) <AYC> side> is sent to the directional valve from the 4WD-ECU,
the directional valve will move to the right. As a result, the
oil pressure from the proportional valve <AYC> will be supplied
to the AYC clutch <Right side>.
If the oil pressure supply signal to the AYC clutch <Left side>
is sent to the directional valve, the directional valve will move
to the left.
To clutch
<Left side> To clutch
<Right side>
2-20 POWER TRAIN - ACD and AYC

ELECTRONIC CONTROL SYSTEM

THROTTLE POSITION SENSOR
For detecting the throttle valve opening angle. Also used as throttle position sensor for engine control.

LONGITUDINAL G SENSOR/LATERAL G SENSOR

The longitudinal G sensor are sensors detecting the acceleration in the longitudinal directions of the
vehicle, and are basically the same as those used conventionally.
The lateral G sensor is used for detecting the acceleration along the sides of the vehicle by changing
the installing direction by 90° . The same sensor as the longitudinal G sensor is used.
G-sensor output characteristics
Parking brake lever
Output voltage (V)
Lateral G sensor
4.0
3.5

2.5
Longitudinal
G sensor 1.5
1.0

1.5 1.0 0 1.0 1.5

Acceleration speed Deceleration speed
(G) (G)

STEERING WHEEL SENSOR

The steering wheel sensor is installed at the steering column, and is used to output steer angles to
the 4WD-ECU as signals.
It is composed of the slit plate which rotates according to the movements of the handle and a three-set
photointerruptor. The slit plate and photointerruptor have a sealed integrated structure to prevent the
invasion of foreign particles as well as misoperations by external light. To detect malfunctions of the
sensor output circuit, it is equipped with a zener diode for detecting disconnections parallel to the
phototransistor.
The ECU calculates the steering angle by reading the signals of the steering wheel sensor after every
certain period of time and calculating the total of the ST-1 signal and ST-2 signal.
The steering angle is obtained by taking the neutral position (ST-N output is L center) as 0° , and if
there are changes, the steering angle is added with 2° for right and - 2° for left. The output of the
photointerruptor becomes L (low) when light passes through and H (high) when obstructed.
 POWER TRAIN - ACD and AYC 2-21
Output waveform of each sensor
N (Neutral point)
2°
Steering wheel sensor
V H
4° 4°
ST-1
L
θ

V
H
4° 4°
ST-2
L
θ

V H
Slit 11°
ST-N
L
θ
Slit plate

Slit plate

Photointerruptor Neutral position

(ST-2) detection slit

Zener diode
for disconnec-
tion detection
Photointerruptor
(ST-N)
Photointerruptor
(ST-1)

Light-emitting diode Photo-transistor

<Front> WHEEL SPEED SENSOR

Sensor for detecting each wheel speed. It is the same as
that conventionally adopted for the ABS. For vehicle with
ACD and AYC, the wheel speed sensor signal
waveform-shaped by the ABS-ECU is input to the 4WD-ECU.

Wheel speed sensor

<Rear>
Wheel speed sensor
2-22 POWER TRAIN - ACD and AYC

ACD MODE SWITCH

When the ACD mode switch is pressed, the mode switches
to TARMAC, GRAVEL, or SNOW.
ACD mode TARMAC GRAVEL SNOW
Good condi- Dry paved Wet roads, Snowy roads
tion roads roads gravel roads

ACD mode switch

ACD MODE INDICATOR LAMP

ACD mode indicator lamp
For about 1.5 seconds after the Ignition switch is turned ON,
all ACD mode indicator lamps will light up. When the ACD
mode switch is pressed, each mode (TARMAC, GRAVEL,
SNOW) will light up alternately.
When the ACD or AYC malfunctions, all mode indicators will
light up (until the ignition switch goes OFF*).
NOTE
*: When the vehicle is determined as having returned to normal
according to the malfunction, the lamps will also be returned
to their normal states.
PRESSURE SENSOR
Detects the pressure of the accumulator, and sends the signal
Pressure to the 4WD-ECU. The 4WD-ECU controls the operations of
sensor
the electric pump on the basis of this signal.

Hydraulic unit
assembly

ELECTRIC PUMP RELAY

Supplies power to the electric pump according to the signal
from the 4WD-ECU.

Electric pump relay

4WD-ECU
4WD-ECU
Determines the driving state, vehicle state, and road state
according to the inputs of each sensor, idling information
from the engine-ECU, and ABS monitor signal from the
ABS-ECU to control the hydraulic unit.
The 4WD-ECU also has a diagnosis function which lights
up all the ACD mode indicator lamps during malfunctions.

Door check
 POWER TRAIN - ACD and AYC 2-23
The terminals of the 4WD-ECU are arranged as follows.

1. Proportional valve <ACD> 25. -

2. - 26. ECU earth
3. Proportional valve <AYC>*1 31. ECU backup power supply
4. - 32. Pressure sensor
5. - 33. Steering wheel sensor <ST-1>
6. Wheel speed sensor <FL> 34. Steering wheel sensor <ST-2>
7. Wheel speed sensor <RR> 35. Diagnosis data input/output
8. Wheel speed sensor <RL> 36. Idle switch
9. Wheel speed sensor <FR> 37. Parking brake switch
10. Pressure sensor earth 38. Stop lamp switch
11. Lateral G sensor 39. TPS
12. - 40. ACD mode indicator lamp <TARMAC>
13. 4WD-ECU power supply 41. -
14. Directional valve <Right>*1 42. ECU earth
15. Directional valve <Left>*1 43. Pressure sensor power supply
16. Electric pump relay power supply 44. Steering wheel sensor <ST-N>
17. - 45. -
18. - 46. Diagnostic control
19. Wheel speed sensor earth <FL>*2 47. ACD mode switch
20. Wheel speed sensor earth <RR>*2 48. -
21. Wheel speed sensor earth <RL>*2 49. ABS monitor *1
22. Wheel speed sensor earth <FR>*2 50. Earth*2
23. Longitudinal G sensor 51. ACD mode indicator lamp <SNOW>
24. Longitudinal G sensor and lateral 52. ACD mode indicator lamp <GRAVEL>
G sensor earth *2

NOTE
1. *1 indicates that the terminal is omitted if only ACD is equipped.
2. *2 indicates that the terminal is added if only ACD is equipped.

DIAGNOSIS ITEMS
Code Diagnosis Item Mode indica- Main diagnosis details
No. tor lamp (f: all
lit, – : normally
displayed)
12 Power supply voltage f Open-circuit, short-circuit of power supply voltage system, or
(Valve power supply) drop in voltage
13 Fail save relay f Open-circuit or short-circuit of ECU equipped fail save relay
21 Wheel speed sensor f Open-circuit or short-circuit of wheel speed sensor <FR>
<FR> system
22 Wheel speed sensor <FL> f Open-circuit or short-circuit of wheel speed sensor <FL>
system
23 Wheel speed sensor f Open-circuit or short-circuit of wheel speed sensor <RR>
<RR> system
24 Wheel speed sensor f Open-circuit or short-circuit of wheel speed sensor <RL>
<RL> system
25 Wheel speed
p sensor - Equipped with step-bore tire
26 f Wheel speed sensor defect
31 Steering wheel sensor f Steering wheel sensor <ST-N,ST-1,ST-2> system
opened or short-circuit
2-24 POWER TRAIN - ACD and AYC

Code Diagnosis Item Mode indica- Main diagnosis details

No. tor lamp (f: all
lit, – : normally
displayed)
32 Steering
g wheel sensor f Steering wheel sensor <ST-N> system short-circuit
33 <ST-N>
ST N f Fixing of steering wheel sensor <ST-N> system
34 Steering wheel sensor f Short-circuit or fixing of output of steering wheel sensor <ST-1,
<ST-1, ST-2> ST-2> system
41 TPS f Open-circuit or grounding of TPS system
42 f Short-circuit of TPS system
45 Pressure sensor f Open-circuit or short-circuit of pressure sensor system
46 f Earth open-circuit of pressure sensor system
47 f Power supply defect of pressure sensor system
51 Longitudinal
g G sensor f Open-circuit and short-circuit of longitudinal G sensor system
52 f Longitudinal G sensor defect
56 Lateral G sensor f Open-circuit or short-circuit of lateral G sensor
57 f Lateral G sensor defect
61 Stop lamp switch f Open circuit of stop lamp switch system
62 ACD mode switch f ACD mode switch is stuck
63 Parking brake switch f Short-circuit of parking brake switch or it has not been returned
to designated position
65 ABS f Open-circuit of ABS monitor system or malfunction of ABS
71 Proportional valve <AYC> f Open-circuit or short-circuit of proportional valve <AYC>
system
72 Directional valve <Right> f Open-circuit or short-circuit of directional valve <right> system
73 Directional valve <Left> f Open-circuit or short-circuit of directional valve <left> system
74 Proportional valve <ACD> f Open-circuit or short-circuit of proportional valve <ACD>
system
81 Electric pump
p p relayy f Open-circuit or short-circuit of electric pump relay system
82 f Electric pump malfunction or pressure sensor defect
84 AYC control f AYC control defect
85 ACD control f ACD control defect
 POWER TRAIN - ACD and AYC 2-25
SERVICE DATA
Item No. Item Unit
01 Wheel speed sensor <FR> km/h (Displayed for every 1 km/h)
02 Wheel speed sensor <FL> km/h (Displayed for every 1 km/h)
03 Wheel speed sensor <RR> km/h (Displayed for every 1 km/h)
04 Wheel speed sensor <RL> km/h (Displayed for every 1 km/h)
05 Wheel speed sensor <FR> (0.2 km/h) km/h (Displayed for every 0.2 km/h)
06 Wheel speed sensor <FL> (0.2 km/h) km/h (Displayed for every 0.2 km/h)
07 Wheel speed sensor <RR> (0.2 km/h) km/h (Displayed for every 0.2 km/h)
08 Wheel speed sensor <RL> (0.2 km/h) km/h (Displayed for every 0.2 km/h)
09 Vehicle speed km/h
10 Battery voltage V
11 Proportional valve current<ACD> mA
12 Proportional valve current <AYC> mA
13 TPS voltage mV
14 Longitudinal G sensor voltage V
15 Lateral G sensor voltage V
16 Steering angle deg
17 Steering angle speed deg/s
18 Pressure sensor MPa
19 Pressure sensor power supply V
20 Valve power supply V
21 Steering wheel sensor voltage <ST-1> V
22 Steering wheel sensor voltage <ST-2> V
23 Steering wheel sensor voltage <ST-N> V
51 Idle switch ON/OFF
52 Steering wheel sensor <ST-N> ON/OFF
53 Steering wheel sensor <ST-1> ON/OFF
54 Steering wheel sensor <ST-2> ON/OFF
55 Steering wheel sensor learning <ST-N> ON/OFF
56 Stop lamp switch ON/OFF
57 Motor monitor ON/OFF
58 Oil pressure state HIGH/LOW
59 Directional valve <Right> ON/OFF
60 Directional valve <Left> ON/OFF
61 ABS monitor ON/OFF
62 Parking brake switch ON/OFF
63 ACD mode switch ON/OFF
2-26 POWER TRAIN - ACD and AYC

ACTUATOR TEST
Item No. Content Drive Specifications Driving Check
time
01 Bleeding Outputs current to the 5 minutes Check that no air is discharged from the
<ACD> proportional valve accord- bleeder screw installed on the ACD
ing to the steering angle. transfer.
02 Bleeding Outputs current to the 5 minutes Check that no air is discharged from the
<AYC> proportional valve accord- bleeder screw installed on the AYC torque
ing to the steering angle to transfer differential.
operate the direction
valve.
03 Oil amount Operates the directional 20 sec- Check the oil amount of the reservoir tank.
check valve to the left and right. onds
04 Electric pump Operates the electric To end of Check the operating state from the
drive pump for 5 seconds. operations operation sound of the electric pump.
05 ACD clutch op- Operates the proportional 1 minute With the vehicle lifted up, check the
eration check valve <ACD> to supply operating state according to the speed
maximum oil pressure to difference between the front and rear
the multi plate clutch. wheels.
06 AYC clutch op- Operates the directional 1 minute With the vehicle lifted up, check the
eration check valve, and supplies maxi- operating state according to the speed
<Left side> mum oil pressure to the difference between the front and rear
left side clutch. wheels.
07 AYC clutch op- Operates the directional 1 minute With the vehicle lifted up, check the
eration check valve, and supplies maxi- operating state from the speed difference
<Right side> mum oil pressure to the between the left and right rear wheels.
right side clutch.
08 Control OFF Turns OFF the electric - Check the difference between control ON
pump relay, and ACD and OFF in actual driving.
control and AYC control.
 POWER TRAIN - Propeller Shaft 2-27
PROPELLER SHAFT
3 way split 4-joint type propeller shaft with center bearing is adopted.
SPECIFICATIONS
Item Vehicles without AYC Vehicles with AYC

Propeller Type 3 way split 4-joint type propeller shaft

shaft
Length × Outside Front 608.5 × 65
diameter mm
Center 551 × 65

Rear 750.5 × 65 768.5 × 65

Universal Type No.1 Cross type (caulking method)

joint
No.2 Cross type (caulking method)

No.3 Constant velocity type (LJ)

No.4 Cross type (caulking method)

Bearing Lubricationless type needle roller bearing

Journal diameter mm 16.3

NOTE
The propeller shaft length indicates the length between the centre points of each joint.
CONSTRUCTION DIAGRAM

Center bearing Rear propeller shaft

No.2 joint
Front propeller shaft

Sleeve yoke

No.4 joint
No.3 joint
(LJ)
Center propeller shaft

No.1 joint
2-28 DRIVETRAIN - Front Axle

FRONT AXLE
The front axle consists of front hubs, knuckles, D The drive shaft incorporates B.J.-T.J. type
wheel bearings and drive shafts, and it has the constant velocity joints with high transmission
following features. efficiency and low vibration and noise.
D The wheel bearing is unit bearing (Double-row D ABS rotors for detecting the wheel speeds are
angular contact ball bearing) which is integrated press-fitted to the B.J. outer wheels in vehicles
with hub. with ACD or ABS.

NOTE
1. B.J.: Birfield Joint
2. T.J.: Tripod Joint
SPECIFICATIONS
Item Specifications
Wheel Wheel bearing type Hub unit bearing (Double-row angular
g
bearings contact ball bearing)
Bearing (outside diameter) mm 87*1
Drive Joint type Outside B.J.
shaft
Inside T.J.
Shaft length*2 × Shaft diameter mm Left 350 × 26
Right 427 × 26

NOTE
*1: The wheel bearing is integrated with hub,only the outer diameter is shown.
*2: The shaft length indicates the length between the center points of each joint.
STRUCTURAL DIAGRAM

Strut assembly Output shaft

T.J.(L.H.)

Knuckle

Front hub T.J.

Drive shaft
T.J.(R.H.)

B.J. Output shaft

Wheel bearing
 DRIVETRAIN - Rear Axle 2-29
REAR AXLE
The rear axle consists of rear hubs, wheel bearings, D The drive shaft incorporates B.J.-T.J. type
drive shafts, and rear differentialand, it has the constant velocity joints with high transmission
following features. efficiency and low vibration and noise.
D The wheel bearing is a unit bearing (double-row D ABS rotors for detecting the wheel speeds are
angular contact ball bearing). press-fitted to the B.J. outer wheels in vehicles
with ACD or ABS.

NOTE
1. B.J.: Birfield Joint
2. T.J.: Tripod Joint
SPECIFICATIONS
Item Vehicles without AYC Vehicles with AYC
Wheel Wheel bearing type Unit bearing (Double-row angular contact ball
g
bearings bearing)
Bearing (outside diameter × inside diameter) mm 78 × 40
Drive Joint type Outside B.J.
shaft
Inside T.J.
Shaft length*1 × Shaft diameter Left 483 × 25 426 × 25
mm
Right 573 × 25 446 × 25

NOTE
*1: The shaft length indicates the length between the center points of each joint.
STRUCTURAL DIAGRAM

Differential carrier
T.J.
B.J.
Oil seal Rear hub

Drive shaft
2-30 DRIVETRAIN - Differential

DIFFERENTIAL
Mechanical type Limited Slip Differential <Vehicles without AYC> or Torque transfer differential <Vehicles
with AYC> is adopted. About the structure of AYC, refer to P.2-3, manual transmission.
MECHANICAL LIMITED SLIP DIFFERENTIAL
SPECIFICATIONS
Item Mechanical LSD
Reduction gear type Hypoid gear
Reduction ratio 3.312
Differential g
gear type
yp ((Type
yp × Side gear Straight bevel gear × 2
number
b off gears)) Pinion gear Straight bevel gear × 4
Number of teeth Drive gear 43
Drive pinion 13
Side gear 14
Pinion gear 10
Bearings
g (Outside
( diameter × Side 72.0 × 35.0
I id diameter)
Inside di t ) mm Front 62.0 × 25.0
Rear 72.0 × 35.0

CONSTRUCTION DIAGRAM
<Mechanical LSD>

Differential carrier
 DRIVETRAIN - Differential 2-31
TORQUE TRANSFER DIFFERENTIAL
The torque transfer differential consists of differential mechanism,acceleration/decelation gear and two
pairs of wet multi-plate clutch. The hipoid gear oil is used to lublicate differential part, ATF-SP III is used
to lublicate torque movement part (acceleration/decelation gear and clutch).

L.H. clutch
Differential Wet multi-plate clutch
mechanism R.H. clutch

Reductiongear
Input gear Overdrive gear

Acceleration/decelation gear

DIFFERENTIAL MECHANISM
When the vehicle turns, admits the revolution difference between inner race and outer race.
ACCELERATION/DECELATION GEAR
Have the revolution speed of right and left wet multi-plate clutch to accelerate or decelate as oposed
to the revolution speed of right wheel.
WET MULTI-PLATE CLUTCH
Have the torque to move from high speed wheel to low speed wheel.
L.H. clutch operate: decelation geer have the torque to move R.H. wheel to L.H. wheel.
R.H. clutch operate: accelelation geer have the torque to move L.H. wheel to R.H. wheel.
The movement of torque is dependence on pushing force of the clutch.
2-32 DRIVETRAIN - Differential

TORQUE TRANSFER DIFFERENTIAL MECHANISM

High Low
speed speed When high speed clutch is pushed, the driving power always
side side moves from high speed side to low speed side, and controls
the driving power with the aid of the property which the
movement of driving power is proportional to the pushing
Pushing Pushing force of clutch.
force force In torque transfer differential, acceleration/decelation gear
always engages, and towerd to input speed from the
Driving differential case, L.H. clutch engaging decelation gear is
power
moves revolutes in low speed, R.H. clutch engaging accelelation
gear is revolutes in high speed.
In the other hand, the housing side of R.H/L.H. clutch is
Differential L.H. R.H. integlated to rear R.H. axle, if R.H. or L.H. clutch is opelated,
case Clutch Clutch the driving power can be moved to right or left.

Decelation
gear Acceleration
gear

Turning Yaw THE FLOW OF DRIVING POWER

direction moment L.H.clutch (1) L.H.CLUTCH OPERATE
In order to boost the driving power of L.H. wheel, when
L.H.clutch is operated,a part of the driving power of R.H.
Driving Driving
power power wheel flows to the differential case, the driving power
(large) (small) of L.H. wheel is boosted.
The result of this, the yaw moment occures in a right
to the vehicle.

Yaw Turning (2) R.H.CLUTCH OPERATE

moment direction In order to boost the driving power of R.H. wheel,when
R.H.
clutch
R.H.clutch is operated, a part of the driving power of
L.H. wheel flows to the differential case, the driving power
Driving
Driving of R.H. wheel is boosted.
power The result of this, the yaw moment occures in a left to
power (large)
(small) the vehicle.
 DRIVETRAIN - Differential Mount 2-33
DIFFERENTIAL MOUNT
The front of differential carrier is suported with the The front of torque transfer differential is supported
differential support member via the differential with the differential support member with insulator
mount bracket with insulator,and the rear is via the differential mount bracket,and the rear is
suported with the differential support arm. supported with the differential mount bracket and
<Mechanical LSD> the differential support arm. <AYC>
<Mechanical LSD>
Toe control bar

Differential support member

Differential support arm

Differential mount bracket

Insulator

<AYC> Differential support arm

Differential support member

Differential mount bracket

Differential mount
bracket (R.H.)

Insulator

Differential mount
bracket (L.H.)
NOTES
 3-1

DRIVE-CONTROL
COMPONENTS
CONTENTS

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . 2 Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . 2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Construction Diagram . . . . . . . . . . . . . . . . . . . . 15
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Construction Diagram . . . . . . . . . . . . . . . . . . . . 3 SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . 16
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lower Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . 5 Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Construction Diagram . . . . . . . . . . . . . . . . . . . . 5 4-WHEEL ANTI-SKID BRAKING SYSTEM
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 (4ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

WHEEL AND TYRE . . . . . . . . . . . . . . . . . . . . . 7 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Construction Diagram . . . . . . . . . . . . . . . . . . . . 21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Configuration Diagram . . . . . . . . . . . . . 22
POWER STEERING . . . . . . . . . . . . . . . . . . . . 8 ABS Electrical Circuit Diagram . . . . . . . . . . . . . 23
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ABS-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Construction Diagram . . . . . . . . . . . . . . . . . . . . 9
System Operation . . . . . . . . . . . . . . . . . . . . . . . . 27
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering Shaft and Column . . . . . . . . . . . . . . . . 10 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . 27
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power Steering Fluid Cooler Tube . . . . . . . . . . 12
Construction Diagram . . . . . . . . . . . . . . . . . . . . 27
3-2 DRIVE-CONTROL COMPONENTS - Suspension/Front Suspension

SUSPENSION
The suspension which has been adjusted to new A McPherson strut-type suspension has been used
body dimension with the optimal tuning has im- at the front, and a multi-link suspension has been
proved its cornering ability. used at the rear.
FEATURES
High Steering 1. Suspension geometry optimized by linearisation of toe change, etc.
Stability 2. Wider tread
3. Optimized the roll center height
4. Increased the suspension stroke of the compressed side
5. Increased the lateral rigidity equipped with crossmember bars and flatted
crossmember
6. Damping forces of front struts and rear shock absorbers as well as
their coil springs’ characteristics optimized
7. Optimized suspension bushings
Enhanced Riding 1. Increased the suspension stroke of the compressed side
Comfort 2. Damping forces of front struts and rear shock absorbers as well as
their coil springs’ characteristics optimized
3. Spring characteristics of bump rubber optimized
4. Characteristics of suspension bushings optimized
Reduced road 1. Increased the volume of stabilizer bushings
noise 2. Adoption of two mounting bolts to the stabilizer bracket

FRONT SUSPENSION
FEATURES
A McPherson strut independent suspension-type D Improved reliability by making the size of
suspension has been adopted as the front mounting bolts larger at the front and rear
suspension. It has improved its limitation of bushing installation parts of lower arm.
capacity as well as securing the sufficient lateral D Improved the stroke feeling by replacing the
rigidity and rolling rigidity as a high performance rear bushings of the lower arm with the pillow
vehicle. ball bushing with rubber.
D With widened tread and optimized roll center D Restricted the useless movement of lower arm
height, the cornering performance from initial equipped with stopper rubber at the front and
responce to limited performance has been rear bushing mounting parts of the lower arm.
improved. D Improved the reliability and steering feeling by
D Adopted the two - stage selectable structuare reducing friction as well as making the ball size
of camber angle according to driving mode like of lower arm ball joint larger.
EVOLUTION-VI. D Improved the camber rigidity by adopting an
D Stabilized the vehicle behavior during cornering inverted strut like EVOLUTION-VI.
by lowering the installation position of the D Improved the steering stability by optimizing
steering gear box with linear toe change. the damping force of shock absorbers and
D Increased the horizontal strength, improved the spring constants of coil springs.
steering feeling and the rigidness at the time D Adopted a strut insulaor with previous results
of cornering by making the cross member flat like EVOLUTION-VI.
and connecting two reinforced bars D Prevented the occurance of unusual noise by
(crossmember bar) at the installation part of increasing the volume of stabilizer bushing.
the both right and left lower arms. D Prevented the occurance of unusual noise
D Improved the cornering limitation with improved caused by lateral sliding of brackets with
adhesion at the time of rolling by increasing installation of two mounting bolts to the
bump strokes. stabilizer bracket.
D Achieved the weight reduction being equipped
with aluminium lower arm like EVOLUTION-VI.
 DRIVE-CONTROL COMPONENTS - Front Suspension 3-3
CONSTRUCTION DIAGRAM

Strut insulator
Lower arm bushing
(Pillow ball bushing with rubber)
Coil spring
Stabilizer bar
Crossmember

Strut assembly
(shock absorber)
Stabilizer link

Lower arm

Crossmember bar
<RS (option), RS-II>

SPECIFICATIONS
SUSPENSION SYSTEM
Items Lancer EVOLUTION-VII Lancer EVOLUTION-VI
Tommi Makinen Edition

Suspension method McPherson strut with coil springs McPherson strut with coil springs

WHEEL ALIGNMENT
Items Lancer EVOLUTION-VII Lancer EVOLUTION-VI Tommi Makinen Edition

Tarmac suspension Normal suspension

Camber - 1_00’* or - 2_00’ - 1_10’* or - 2_10’ - 1_00’* or - 2_00’

(selectable from 2 options)

Caster 3_55’ 4_24’ 3_54’

Kingpin inclination 13_45’ 14_48’ 14_18’

Toe-in 0 0 0

NOTE
*: The factory shipped camber value is indicated.
3-4 DRIVE-CONTROL COMPONENTS - Front Suspension

COIL SPRING
Item Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen Edition

RS (standard), RS-II RS (option) Tarmac suspension Normal suspension

Wire diameter mm 14 14 14 14

Average diameter mm 155 155 155 155

Free length mm 281 275 273 296

LOWER ARM
Like Lancer EVOLUTION-VI Tommi Makinen D Improved the reliability and steering feeling by
Edition, an aluminium forged lower arm has been reducing friction as well as making the ball size
adopted and the followings are improved. of the ball joint larger.
D Enlarging the size of mounting bolts at the front D Restricted the useless movement of lower arm
and rear sides of crossmember mounting equipped with stopper rubber at the front
section on lower arm has increased reliability. bushing mounting parts of the lower arm.
D Improved the stroke feeling by installing a pillow
ball bushing with rubber at the rear bushing.

Pillow ball bushing Rubber part

Lower arm

Lower arm

Stopper rubber

Enlarged ball
diameter

Lower arm
Front of vehicle
 DRIVE-CONTROL COMPONENTS - Front Suspension/Rear Suspension 3-5
STABILIZER BAR
Following modifications have been made to Lancer D Prevents the occurance of unusual noise
EVOLUTION-VI Tommi Makinen Edition. caused by lateral sliding of brackets with
D Prevents the occurance of unusual noise by installation of two mounting bolts to the
increasing the volume of stabilizer bushing. stabilizer bracket.

Increased
Stabilizer bar volume

Stabilizer bar bushing

Front of vehicle

Mounting bolt

REAR SUSPENSION
FEATURES
A multi - link suspension which is developed with D By increasing bump strokes (10 mm) adhesion
intention of performance improvement for racing at the time of rolling and cornering limitation
use has been adopted. Yet this suspension is has been improved.
basically the same type as current Lancer D By optimizing the damping force of shock
EVOLUTION-VI Tommi Makinen Edition, but the absorbers, spring constants of coil springs and
following points have been improved. bushing characteristics, the cornering
D By widening tread (10 mm) and optimizing roll performance from initial responce upto limited
center height, the cornering performance from performance has been improved.
initial responce to limited performance has been
improved.
CONSTRUCTION DIAGRAM

Coil spring
Shock absorber

Stabilizer bar
Upper arm
Crossmember

Toe control arm Differential

support arm

Trailing arm Lower arm

Differential support
member Toe control bar <RS>
3-6 DRIVE-CONTROL COMPONENTS - Rear Suspension

SPECIFICATIONS
SUSPENSION SYSTEM
Item Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ
Tommi Makinen Edition

Suspension method Multi-link Multi-link

WHEEL ALIGNMENT
Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ
Tommi Makinen Edition

Camber - 1_00’ - 1_00’

Toe-in 3 3

COIL SPRING
Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen
Edition

Vehicles without AYC Vehicles with AYC Vehicles without AYC Vehicles with AYC

RS (standard) RS RS-II RS RS-II RS-II (option)

(option) (standard)

Wire diameter mm 9 - 12 12 12 9 - 12 10 - 12 10 - 12

Average diameter mm 88 88 88 88 88 88

Free length mm 287 281 284 284 274 279

 DRIVE-CONTROL COMPONENTS - Wheel and Tyre 3-7
WHEEL AND TYRE
FEATURES
Following modifications have been made to Lancer D Equipped with 205/65R15 94H tyre <RS
EVOLUTION-VI Tommi Makinen Edition to improve (standard)>
the vehicle performance. D Exclusively to EVOLUTION-VII 17-inch
D Exclusively to EVOLUTION-VII 17 - inch tyre aluminium wheel has been newly deeveloped
has been newly developed by widening the by widening rim width from 7 1/2JJ to 8JJ <RS
tyre width from 225mm to 235mm and the limit (option), RS-II>
performance has been improved by getting D Equipped with a strong type steel wheel with
better grip at the time of high G cornering. <RS previous results <RS (standard)>
(option), RS-II>
17 - inch Aluminium Wheel (17×8JJ) Steel Wheel (15×6JJ)
<RS (option), RS-II> <RS (standard)>

SPECIFICATIONS
Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ
Tommi Makinen Edition
RS (standard) RS (option), RS- Standard Option
II
Wheel Type Steel type Aluminium type Steel type Aluminium type
Size 15 × 6JJ 17 × 8JJ 15 × 6JJ 17 × 7 1/2JJ
Amount of wheel 46 38 46 38
offset mm
Pitch circle 114.3 114.3 114.3 114.3
diameter
(P.C.D.) mm

Tyre Size 205/65R15 94H 235/45ZR17 205/60R15 91H 225/45ZR17

Spare
p wheel Type Steel type Steel type Steel type Steel type
Size 16 × 4T 17 × 4T 16 × 4T 16 × 4T
Amount of wheel 40 30 40 40
offset mm
Pitch circle 114.3 114.3 114.3 114.3
diameter
(P.C.D.) mm

Spare tyre Size T125/70D16 T125/70D17 T125/70D16 T125/70D16

(High pressure)
3-8 DRIVE CONTROL COMPONENTS - Power Steering

POWER STEERING
FEATURES
To improve steering feeling and response of the D A variable capacity pump has been adopted to
steering system, the following steering system has reduce power losses and improve fuel
been adopted. consumption. When the engine speed increases,
D The system has been equipped with the MOMO the pump chamber capacity is reduced
leather 3 - spoke - type steering wheel with proportionally so that only the necessary amount
built - in SRS airbag. of power steering fluid is discharged.
D A steering column with a shock absorbing D Improved the cooling efficiency of power steering
mechanism and a tilt steering mechanism has fluid by adopting a cooler tube to the fluid line.
been adopted.
D Integral-type rack and pinion gear with high rigidity
and excellent response has been adopted.

SPECIFICATIONS
Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi
Makinen Edition
Steering
g wheel Type MOMO 3-spoke type MOMO 3-spoke type
Outside diameter mm 380 <RS (standard)>, 365 <RS>, 380 <RS-II>
365 <RS(option), RS-II>
Maximum number of turns 2.1 2.1 <RS>, 2.3 <RS-II>
Steering column Column mechanism Tilt steering Tilt steering
Power steering type Integral type Integral type
Oil pump Type Variable capacity type (vane Variable capacity type (vane
pump) pump)
Basic discharge amount 9.6 7.2
cm3/rev.
Relief pressure MPa 8.3 - 9.0 8.3 - 9.0
Reservoir type Separate type Separate type
Pressure switch Equipped Equipped
Steering
g g gear Type Rack and pinion Rack and pinion
and
d linkage
li k Stroke ratio (Rack stroke/ 68.61 62.89
Steering wheel Maximum
turning radius)
Rack stroke mm 146 136
Steering
g angle
g Inner wheel 32° 33°
Outer wheel 27° 28°
<for reference>
Power steering Specified lubricants Automatic transmission fluid Automatic transmission fluid
fluid DEXRON II DEXRON II
Quantity dm3 Approximately 1.0 Approximately 1.0
 DRIVE CONTROL COMPONENTS - Power Steering 3-9
CONSTRUCTION DIAGRAM
<L.H. drive vehicles>
Steering wheel

Steering column and shaft

Reservoir tank
Return hose
Suction hose
Pressure hose

Oil pump
Assembly

Steering gear
Cooler tube and linkage

<R.H. drive vehicles>

Steering wheel

Steering column and shaft

Reservoir tank
Return hose
Suction hose Pressure hose

Oil pump Steering gear and linkage

Assembly

Cooler tube
3-10 DRIVE CONTROL COMPONENTS - Power Steering

STEERING WHEEL
There are two types of MOMO leather 3-spoke-type
steering wheels (built-in SRS air bag) with different
desigins.
<RS (standard)> <RS(option), RS-II>

STEERING SHAFT AND COLUMN

For the steering column, an impact absorbing
mechanism which absorbs impact energy in the
event of a collision as well as a tilt steering
mechanism which enables the driver to obtain an
optimum driving position have been adopted.

Tilt bracket (B) Tilt bracket (A)

Shaft sub assembly Pipe sub assembly Steering shaft

Tilt lever
 DRIVE CONTROL COMPONENTS - Power Steering 3-11
SHOCK ABSORBING MECHANISM
BEFORE COLLISION
1. Primary impact
When the vehicle collides with something and there is a load
added to the shaft sub assembly from the gearbox, the shaft
sub assembly slides above the pipe sub assembly to absorb
the shock load. This prevents the steering column from
Shaft sub assembly Pipe sub assembly moving backwards during the impact.

AFTER COLLISION

BEFORE COLLISION 2. Secondary impact

Polyacetal resin
(1) When the driver falls against the developed air bag, the
Tilt bracket(A) Steering
column tilt bracket(A) moves forwards by shearing the polyacetal
mounting resin, causing the steering column assembly to move
bolt forward.

A A Steering
column
Section A – A assembly

AFTER COLLISION

Impact
load

B B

Section B – B
3-12 DRIVE CONTROL COMPONENTS - Power Steering

BEFORE COLLISION (2) At the same time that tilt bracket (A) separates, the clevis
U - section pin comes out of the U - section groove in the tilt plate,
groove
Clevis pin allowing the steering column assembly to move forward.

Tilt plate
Tilt bracket (B)
Steering column
assembly
AFTER COLLISION

OIL PUMP
The oil pump is a vane type with a fluid flow control D By increasing the basic discharge amount from
system which functions so that the steering wheel 7.2 cm3/rev. to 9.6 cm3/rev., the assist shortage
turning effort will be reduced at low engine speeds at idle has been improved.
and it will be appropriately increased at higher D By increasing the diameter of the pully shaft
speeds. bearing and the pump body rigidity , the pump
The following modifications have been made to noise has been relieved reducing vibration
Lancer EVOLUTION-VI Tommi Makinen Edition. occurance.

POWER STEERING FLUID COOLER TUBE

The cooling efficiency of power steering fluid has been
improved by adopting a cooler tube to the fluid line.

Cooler tube
 DRIVE CONTROL COMPONENTS - Power Steering 3-13
STEERING GEAR
D Using the following parts have contributed to D The installation accuracy, rigidity and steering
save weight; an aluminium steering gear and stability have been improved by using an eye
linkage valve housing, a plastic tie-rod bellows, bushing, which secures the steering gear to
and the hollow-type tie-rod stud. the crossmember.

Steering gear and linkage Gear housing

Valve housing

Tierod bellows

Hollow

Gear housing
Bushing
Crossmember

Inner pipe Crossmember

3-14 DRIVE-CONTROL COMPONENTS - Brakes

BRAKES
The brake system has been designed to give
greater reliability and durability and to provide
excellent braking performance.

FEATURES
Improved braking perfor- 1. A 8+9-inch brake booster has been adopted to provide
mance large braking force with a small pedal depression force.
2. 15-inch ventilate disc brakes have been adopted to provide
stable braking force and improved braking feel. <Vehicles
without brembo braking system>
3. 17-inch front ventilate disc brakes have been adopted to
provide stable braking force and improved braking feel.
<Vehicles with brembo braking system>
4. 16-inch rear ventilate disc brakes have been adopted to
provide stable braking force and improved braking feel.
<Vehicles with brembo braking system>
Improved stability 1. A 4-wheel anti-skid braking system (4ABS) has been
adopted to prevent slipping caused by the vehicle wheels
locking up in order to maintain an appropriate braking
distance, and also to maintain a stable vehicle posture
and steering performance. <Vehicles with ABS>
2. Adoption of an electronic brake-force distribution(EBD)
which makes it possible to maintain the maximum amount
of braking force even when the vehicle’s load is unevenly
distributed. <Vehicles with ABS>
3. A rear wheel early lock-prevention proportioning valve has
been adopted. <Vehicles without ABS>
4. Front- and rear-wheel X-type brake line layout has been
adopted.
5. Ventilated discs have been adopted in order to improve
anti-fading performance.
Improved serviceability 1. A diagnosis function has been adopted for the ABS system
in order to make inspection easier. <Vehicles with ABS>
2. An outer disc method separated hub and rotor has been
adopted to make removal and installation easier.
3. The master cylinder reservoir tank cap has been coloured
white to make identification easier.
4. The ABS-ECU and hydraulic unit have been integrated
to make them more compact and lightweight.
 DRIVE-CONTROL COMPONENTS - Brakes 3-15
CONSTRUCTION DIAGRAM

<Vehicles with ABS>

Brake booster*

Hydraulic unit*

Rear disc brake

Parking brake
Master cylinder*
Front disc brake

<Vehicles without ABS>

Brake booster*

Master cylinder and

proportioning valves*

Rear disc brake

Parking brake

Front disc brake

NOTE
For R.H. drive vehicles, only the position indicated by the * is symmetrical.
3-16 DRIVE-CONTROL COMPONENTS - Service Brakes

SERVICE BRAKES
SPECIFICATIONS
Lancer EVOLUTION-VI Tommi
Items Lancer EVOLUTION-VII
Makinen Edition
Master Type Tandem type Tandem type
cylinder
I.D. mm 26.9 26.9
Brake Type Vacuum type, tandem Vacuum type, tandem
booster
Effective dia. of power 205 + 230 180 + 205
cylinder mm
Boosting ratio 4.5 (Pedal depressing force: 230 4.5 (Pedal depressing force: 230
N) N)
Rear wheel hydraulic control method Electronic brake-force Proportioning valves
distribution (EBD) <Vehicles with
ABS (RS, RS-II)> or
Proportioning valves <Vehicles
without ABS (RS)>
Front brakes Type Floating caliper, 2 piston, Floating caliper, 2 piston,
<RS (standard)> ventilated disc ventilated disc
Disc effective dia. ¢ 227 ¢ 24 227 ¢ 24
thickness mm
Wheel cylinder I.D. mm 42.9 (¢2) 42.9 (¢2)
Pad thickness mm 10.0 10.0
Clearance adjustment Automatic Automatic
Front brakes Type 4 opposed piston, ventilated disc 4 opposed piston, ventilated disc
<RS (option), <Brembo braking system> <Brembo braking system>
RS II
RS-II>
Disc effective dia. ¢ 263 ¢ 32 263 ¢ 32
thickness mm
Wheel cylinder I.D. mm 40.0 (¢2), 46.0 (¢2) 40.0 (¢2), 46.0 (¢2)
Pad thickness mm 10.0 10.0
Clearance adjustment Automatic Automatic
Rear brakes Type Floating caliper, 1 piston, Floating caliper, 1 piston,
<RS (standard)> ventilated disc ventilated disc
Disc effective dia. ¢ 237 ¢ 20 237 ¢ 20
thickness mm
Wheel cylinder I.D. mm 34.9 34.9
Pad thickness mm 10.0 10.0
Clearance adjustment Automatic Automatic
Rear brakes Type 2 opposed piston, ventilated disc 2 opposed piston, ventilated disc
<RS (option), <Brembo braking system> <Brembo braking system>
RS II
RS-II>
Disc effective dia. ¢ 252 ¢ 22 252 ¢ 22
thickness mm
Wheel cylinder I.D. mm 40.0 (¢2) 40.0 (¢2)
Pad thickness mm 9.0 9.0
Clearance adjustment Automatic Automatic
Brake fluid DOT3 or DOT4 DOT3 or DOT4
 DRIVE-CONTROL COMPONENTS - Service Brakes 3-17
MASTER CYLINDER
The master cylinder is a tandem-type, with a
structure that emphasises safety.

Reserve tank

Master cylinder body

Primary piston assembly

Piston retainer

Secondary piston assembly

BRAKE BOOSTER
A 8+9-inch tandem-type brake booster has been
adopted.
Front diaphragm
Rear diaphragm

Booster return spring

Reaction disc

Operating rod

Push rod

Barometricpressure
chambers
3-18 DRIVE-CONTROL COMPONENTS - Service Brakes

DISC BRAKES
Brakes with the following specifications have been D The brake pads are equipped with
adopted. mechanical-type audible wear indicators to
D V5-W43 2-piston ventilate discs for front brakes notify the driver when the usage limit (2 mm)
<RS (standard)> has been reached.
D V5-S35 1-piston ventilate discs for rear brakes D Split fins adopted as the disc fins to improve
<RS (standard)> cooling performance
D Brembo V7-Z4046 4-opposed-piston ventilate NOTE
discs for front brakes <RS (option), RS-II> Brembo is an italian component maker whose name
D Brembo V6-X40 2-opposed-piston ventilate and products are well known in the motorsports
discs for rear brakes <RS (option), RS-II> world.
D An outer disc method in which the wheels and
discs are tightened together has been adopted
to improve the ease of brake disc removal and
installation.
DISC BRAKES <Brembo braking system>

<Front> <Rear>

Front of
vehicle B
A

Front of vehicle

View A View B

Pads

Pads
 DRIVE-CONTROL COMPONENTS - Service Brakes 3-19
DISC BRAKE NOMENCLATURE

No. Item Contents

V 7 – Z 40 46 1 Brake disc type V: Ventilated

2 Brake size 5: 15-inch

1 2 3 4 (Minimum applicable 6: 16-inch
disc wheel) 7: 17-inch

3 No. of pistons S: 1 piston (floating type)

W: 2 piston (floating type)
X: 2 piston (opposed type)
Z: 4 piston (opposed type)

4 Piston size 35: φ35 mm

(rounded to nearest 40: φ40 mm
integer) 43: φ43 mm
46: φ46 mm

BRAKE LINE
PROPORTIONING VALVE <Vehicles without ABS (RS)>
A proportioning valve has been adopted to prevent
early locking of the rear wheels, in order to provide
improved stability during braking.
NOTE
In terms of structure and operation, the
proportioning valve is basically the same as that
of the 1999 SPACE RUNNER/SPACE WAGON.

From master cylinder

rear brake system

Valve
Sleeve
Plate U-packing

Spring
O-ring

Seal

Guide

To rear brake
3-20 DRIVE-CONTROL COMPONENTS - 4ABS

4-WHEEL ANTI-SKID BRAKING SYSTEM (4ABS)

FEATURES
ABS has been adopted as optional equipment in D By adding lateral G sensor, longitudinal G
RS- II to maintain directional stability and steering sensor and steering wheel sensor, optimized
performance during sudden braking or braking on ABS control at the time of cornering.
slippery road surfaces. D By inputting parking brake switch signal to
The ABS control method is a 4-sensor, 4-channel ABS-ECU with pulling parking brake lever, ABS
method which provides independent control for all control has been optimized.
wheels. D ABS-ECU outputs ABS signal to 4WD-ECU.
Following system for Lancer EVOLUTION-VII has D G sensor (lateral), steering wheel sensor and
been modified from Lancer EVOLUTION-VI Tommi parking brake switch have been added to the
Makinen Edition. diagnosis and service data.
D ABS-ECU connector has been changed.

EBD CONTROL
In ABS, electronic control method is used by which laden condition and the condition of the road
the rear wheel brake hydraulic pressure during surface, the system reduces the required pedal
braking is regulated by rear wheel control solenoid depression force, particularly when the vehicle
valves in accordance with the vehicle’s rate of is heavily laden or driving on road surfaces
deceleration and the front and rear wheel slippage with high frictional coefficients.
which are calculated from the each wheel speed D Because the duty placed on the front brakes
sensor’s signal. EBD control is a control system has been reduced, the increases in pad
which provides a high level of control for both vehicle temperature can be controlled to improve the
braking force and vehicle stability. The system has wear resistance characteristics of the pad, dur-
the following features: ing front brakes applying.
D Because the system provides the optimum rear D Control valves such as the proportioning valve
wheel braking force regardless of the vehicle are no longer required.

SPECIFICATIONS
Items Lancer EVOLUTION-VII Lancer EVOLUTION-VI Tommi Makinen Edition
ABS control method 4-sensor, 4-channel 4-sensor, 4-channel
No. of Front 43 43
ABS
rotor Rear 43 43
teeth
ABS Type Magnet coil type Magnet coil type
speed
d Gap 0.85 <front (non-adjustable type)> 0.9 <front (non-adjustable type)>
sensor
between 0.60 <rear (non-adjustable type)> 0.9 <rear (non-adjustable type)>
sensor
and rotor
mm
 DRIVE-CONTROL COMPONENTS - 4ABS 3-21
CONSTRUCTION DIAGRAM

4*

8*

7*, 10*

2 1

9* 3
5* 1

NOTE
For R.H. drive vehicles, only the position indicated by the * is symmetrical.
Name of part Number Outline of functions
Sensor Wheel speed sensor 1 Send alternating current signals at frequencies which are
proportional to the rotation speeds of each wheel to the
ABS-ECU
Lateral G sensor 2 Sends data on vehicle’s rate of lateral acceleration to the
ABS-ECU
Longitudinal G sensor 3 Sends data on vehicle’s rate of longitudinal acceleration to the
ABS-ECU
Steering
g wheel sensor 4 Sends data on steering wheel angle to the ABS-ECU
Informs the ABS-ECU when steering wheel is in straight-ahead
position
Stop lamp switch 5 Sends a signal to the ABS-ECU to inform whether the
brake pedal is depressed or not
Parking brake switch 6 Sends a signal to the ABS-ECU to inform whether the
parking brake lever is pulled or not
Actuator Hydraulic unit 7 Drives the solenoid valves according to signals from the
ABS-ECU in order to control the brake hydraulic pressure
for each wheel
ABS warning lamp 8 Illuminates in response to signals from the ABS-ECU
when a problem happens in the system
Diagnosis connector 9 Outputs the diagnosis codes and allows communication
with the MUT-II
ABS control unit (ABS-ECU) 10 Controls actuators (described above) based on the signals
coming from each sensor
Controls the self-diagnosis and fail-safe functions
Controls the diagnosis function (MUT-II compatible)
3-22 DRIVE-CONTROL COMPONENTS - 4ABS

SYSTEM CONFIGURATION DIAGRAM

Motor

Wheel speed sensor (FL) FR solenoid valve (OUT)

Wheel speed sensor (RL) FR solenoid valve (IN)

Wheel speed sensor (RR) FL solenoid valve (OUT)

Wheel speed sensor (FR) FL solenoid valve (IN)

Longitudinal G sensor RR solenoid valve (OUT)

Lateral G sensor RR solenoid valve (IN)

ABS-ECU
Stop lamp switch RL solenoid valve (OUT)

Parking brake switch RL solenoid valve (IN)

Steering wheel sensor

ABS warning lamp
ECU power supply
Diagnosis connector

Steering wheel
sensor

Parking brake
switch

Front- right Rear- right

wheel (FR) wheel (RR)
Stop lamp
switch

Wheel speed Wheel speed

sensor sensor

Hydraulic unit

Lateral G sensor

Longitudinal G sensor
Wheel speed
Wheel speed
sensor
sensor

Front- left wheel (FL) Rear- left wheel (RL)

 DRIVE-CONTROL COMPONENTS - 4ABS 3-23
ABS ELECTRICAL CIRCUIT DIAGRAM

Fusible link Ignition Switch Ignition Switch Fusible link

No. 3 Battery (IG2) (IG1) No. 1
Junction block (Multi- purpose fuse)
Dedicated
5 fuse 12 5 2 15
15A 7.5A 7.5A 7.5A 15A

Stop lamp
switch

Combination meter
(ABS warning lamp)

Longitudinal ABS
Lateral G sensor
G sensor
Stop lamp

Steering wheel
sensor

4WD-ECU

Hydraulic unit
Motor

Solenoid valves

ABS-ECU
Wheel speed
sensor output
Motor power Lateral
supply G sensor Steering wheel
ABS input sensor input
signal output

Solenoid valve Stop lamp Longitudinal

ECU power
power supply switch monitor G sensor
supply
input Communication
Parking brake
switch monitor line

Control line

Diagnosis
connector

FL FR RL RR Parking brake
switch

Wheel speed sensor

3-24 DRIVE-CONTROL COMPONENTS - 4ABS

SENSORS
WHEEL SPEED SENSOR
The wheel speed sensors consist of fixed ABS D The ABS rotors (43 teeth) are installed to the
speed sensors and the ABS rotors that rotate at drive shafts, and the ABS speed sensors are
the same speed as the wheels, and output installed to knuckles.
alternating current signals at frequencies which are D The gap between the ABS rotors and the ABS
proportional to the wheel speed. speed sensors are non-adjustable at both the
front and rear to improve serviceability.

Front Rear

ABS speed
sensor ABS rotor
Drive shaft

Drive shaft
ABS rotor
ABS speed
sensor

Parking brake lever

LATERAL G SENSOR/LONGITUDINAL G SENSOR
Refer to GROUP 2 - ACD and AYC.

Lateral G sensor Longitudinal G sensor

STEERING WHEEL SENSOR

Steering wheel sensor Refer to GROUP 2 - ACD and AYC.
 DRIVE-CONTROL COMPONENTS - 4ABS 3-25
STOP LAMP SWITCH
This switch turns on when the brake pedal is stop lamp switch is on or off by means of fluctuations
depressed, and turns off when the brake pedal in voltage (ON: system voltage; OFF: Approximately
is released. The ABS-ECU detects whether the 0 V). This data is used for ABS control.

PARKING BRAKE SWITCH

This switch turns on when the parking brake lever the parking brake switch is on or off by means
is pulled, and turns off when the parking brake of fluctuations in voltage (ON: less than 1V; OFF:
lever is released. The ABS-ECU detects whether system voltage). This data is used for ABS control.

ACTUATORS
ABS WARNING LAMP
The ABS-ECU controls the power transistor in ABS-ECU to
turn on and causes the ABS warning lamp to illuminate in
the following cases:
D During initial check when the ignition switch is at the
“ON” position (for approximately 3 seconds)
D When a problem happens in the ABS/EBD system
D Poor ABS-ECU connector connection
ABS warning lamp

HYDRAULIC UNIT
The hydraulic unit is basically the same as that of the 1999
PAJERO io <General Export>/2000 PAJERO PININ
<Europe>.
3-26 DRIVE-CONTROL COMPONENTS - 4ABS

ABS-ECU
The ABS-ECU is basically the same as that of the PININ <Europe> except for the followings:
1999 PAJERO io <General Export>/2000 PAJERO
FAIL-SAFE FUNCTION
Diagnosis code No.
No Item
11 Open circuit or short-circuit in wheel speed sensor (FR)
12 Open circuit or short-circuit in wheel speed sensor (FL)
13 Open circuit or short-circuit in wheel speed sensor (RR)
14 Open circuit or short-circuit in wheel speed sensor (RL)
16 Abnormal drop or rise in ABS-ECU power supply voltage
21 Wheel speed sensor (FR) system
22 Wheel speed sensor (FL) system
23 Wheel speed sensor (RR) system
24 Wheel speed sensor (RL) system
32 Longitudinal G sensor system
41 Solenoid valve (FR) system
42 Solenoid valve (FL) system
43 Solenoid valve (RR) system
44 Solenoid valve (RL) system
51 Valve relay ON problem
52 Valve relay OFF problem
53 Motor relay OFF problem
54 Motor relay ON problem
55 Motor system
63 ABS-ECU abnormality
71 Lateral G sensor system
81 Steering wheel sensor (ST-1) system
82 Steering wheel sensor (ST-2) system
83 Steering wheel sensor (ST-N) system

DATA LIST REFERENCE TABLE

Item No. Check item Display unit or words

11 Front-right wheel speed sensor km/h

12 Front-left wheel speed sensor

13 Rear-right wheel speed sensor

14 Rear-left wheel speed sensor

21 Power supply voltage V

29 Parking brake switch ON/OFF

36 Stop lamp switch ON/OFF

37 Steering wheel sensor straight ahead position memory ON/OFF

 DRIVE-CONTROL COMPONENTS - 4ABS/Parking Brake 3-27

Item No. Check item Display unit or words

71 Lateral G sensor V

74 Steering wheel sensor (ST-N) ON/OFF

75 Steering wheel sensor (ST-1)

76 Steering wheel sensor (ST-2)

86 Steering angle _ or OFF (When the steering angle is

straight ahead position)

SYSTEM OPERATION
In terms of operation, the system is basically the
same as that of the 1996 Colt/Lancer.

PARKING BRAKE
FEATURES
The parking brakes are a mechanical rear wheel
brake design and controlled by a lever.

CONSTRUCTION DIAGRAM
NOTES
 4-1

BODY
CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . 2 STRUT TOWER BAR . . . . . . . . . . . . . . . . . . . . . . . 9

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR END CROSS BAR <RS> . . . . . . . . . . . . 10
MAIN BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Body Paneling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Door Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Body Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Window Glass Regulator . . . . . . . . . . . . . . . . . . . . . 12
Body Colour Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 8
New Colour Number . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HOOD AND FENDER . . . . . . . . . . . . . . . . . . . . . . . 9 WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-2 BODY - General Description

GENERAL DESCRIPTION
FEATURES
Weight reduction 1. Use of high-tensile steel panels and steel plate with uneven
thickness
2. Use of aluminum for fender and hood

High rigidity 1. Use of high-tensile steel panels and steel plate with uneven
thickness
2. Equipped with 3-point installing strut tower bar and rear end
cross bar<RS>

Reduction of vibration, Effective layout of acoustic materials and sound proof

noise, and materials
aerodynamic noise

Improvements in 1. Unbreakable resin materials at the door trim on the occasion

safety of impact have been adopted to protect passengers from
the side impact of the vehicle.
2. One-touch power windows with safety mechanism (with the
function to be enabled after the ignition key is turned to
the OFF position) have been installed. <RS: option, RS-II:
standard>
3. Inside lock cables have been adopted at the front doors
to improve safety on the occasion of impact.
4. Side door beams have been adopted to improve safety on
the occasion of impact.

Improvements in 1. The central door lock system to lock/unlock all doors has
operation quality been installed. <RS: option, RS-II: standard>
2. High rigidity in the suspension mounting part

Improvements in 1. Hinge protrusion to the loading space has been reduced by

convenience reducing the size of the trunk lid hinge.
2. Adoption of larger front door pockets
 BODY - Main Body 4-3
MAIN BODY
BODY PANELING
The body has been given enhanced impact safety performance. It has been made lighter by adopting
aluminum alloy panels for the hood panel and front fender.

: Anti-corrosion steel panels

: High-tensile steel panels
 4-4 BODY - Main Body

BODY SHELL
IMPACT SAFETY BODY
The following structure ensures survival space during impact and facilitaty to rescue passengers.
1. Application of enlarged and linear cross section of front side member
2. Addition of dash panel cross member
3. Application of thicker dash panel lower
4. Application of enlarged cross section of front floor side member
5. Application of enlarged cross section of side sill outer reinforcement
6. Application of thicker front pillar reinforcement and center pillar reinforcement
7. Application of enlarged cross section of roof bow

6
2 1
 BODY - Main Body 4-5
STEEL PLATE WITH UNEVEN THICKNESS
Due to the adoption of steel plate with uneven thickness* for the following parts, the incorporate structure
of uneven thickness has improved impact safety and has reduced weight.
1. The thickness of the front end crossmember outer applied at the right side of the vehicle has been
increased.
2. The thickness of the front side member inner applied at the rear has been increased.
3. The thickness of the center pillar reinforcement applied at the upper has been increased.
NOTE
*: Steel plates with different thickness welded together to make one steel plate

The thickness of the center pillar reinforcement

applied above this part has been increased.

The thickness of the front side member

inner applied behind this part has been
increased.

(With the side outer panel removed)

The thickness of the front end crossmember outer

applied at the right side of the vehicle from this part has
been increased.
 4-6 BODY - Main Body

OPERATIONAL STABILITY
The adoption of the following structure to increase rigidity of the suspension mounting part has improved
driving stability and has reduced noise from the road.
1. By directly joining a spring house bracket with increased thickness to the cowl top lower panel, and
adding an upper frame to the front pillar brace, the rigidity of the top, bottom, left, and right sides
of the front suspension has been improved.
2. The roof rail front, front pillar reinforcement upper, and side outer panel have been joined with each
other to increase torsion rigidity.
3. A closed surface structure is given by adding a rear shelf extension to the front of the rear shelf,
and the top of the rear shelf and rear wheel house have been additionally joined with a rear pillar
reinforcement, and the rear shelf and rear floor with a seat back plate to improve twisting rigidity.
4. Additional welded position of the door opening improves twisting rigidity.
Section A – A Section B – B
Front pillar reinforce-
ment upper
Cowl top lower panel

Roof rail front Side outer panel

Spring house bracket

Section C – C
B
B C Rear shelf panel

Rear shelf extension

Upper frame to front

pillar brace

Seat back plate

Rear pillar
reinforcement

(With the side outer panel removed)

 BODY - Main Body 4-7
QUIETNESS
The adoption of the following items has improved quietness.
1. Foaming sound absorption materials have been filled into the front pillar, the roof side rail, the center
pillar, the rear pillar, and the inside the wheel house arch to prevent noise getting inside the vehicle.
2. Steel plate restricted anti-vibration materials (silencer sandwiched inside the panel) has been adopted
to suppress operating sound and the vibration from the engine.
3. Urethane foam has been inserted into the center pillar to prevent noise getting into the vehicle.
1 <RS-II>

A
1 <RS-II>

1 <RS-II>
Section A – A

Dash silencer

2
<RS-II> Dash panel
1
1 <RS-II>

1
<RS-II>
3 <RS-II>
4-8 BODY - Main Body

BODY COLOUR CHARTS

Colour Body Colour number Body colour name Composition Engine compartment and
colour of film luggage compartment colour
code
d Colour number Colour name
SILVER A69 AC11169 Satellite Silver Metallic AC10595 GRAY
BRIGHT T10 CMT10010 French Blue Solid CMB17004 BRIGHT
BLUE BLUE
BLACK X42 AC11342 Amethyst Black Interference AC10903 BLACK
Pearl
WHITE W83 AC10983 Scotia White Solid AC10863 WHITE
RED P85 AC11185 Palma Red Solid AC10795 RED
YELLOW Y01 CMY10001 Dandelion Yellow Solid AC10911 YELLOW

NEW COLOUR NUMBER

Example C M T 10 010 (Body colour code T10)

1 2 3 4 5

No. Item Content

1 Identification code C: The colour number is indicated.
2 Manufacture center code M: Japan (Automobile Engineering Center)
T: Japan (Truck and Bus Engineering Center)
3 System colour code W (N): White
H (A, U): Silver/Gray
X (J): Black
R (P): Red
Y (C, S, E, M, K): Brown/Yellow (including Orange, Maroon, and Gold)
G (F, L): Green/Olive
B (T, D): Blue
V: Purple
( ) Codes within the parenthesis can be also used.
4 Colour classification code From 10 to 16: The body colour is indicated.
17: The body inner panel colour is indicated.
5 Specific number Serial number numbering management
 BODY - Hood and Fender/Strut Tower Bar 4-9
HOOD AND FENDER
The body has been made lightweight with the use of aluminum hood and fender. The hood has also
been equipped with the air outlet and air inlet garnish.

Hood

Air inlet garnish

Air outlet garnish

Fender

STRUT TOWER BAR

The strut installing portion has been equipped with a 3-point installing strut tower bar to improve body
rigidity.

Strut tower bar

4-10 BODY - Rear End Cross Bar <RS>

REAR END CROSS BAR <RS>

The rear floor pan has been equipped with a rear end cross bar to improve body rigidity.

Rear end cross bar

 BODY - Door 4-11
DOOR
DOOR LOCK
The central door lock to lock/unlock all doors with a key cylinder at the driver’s door has been installed.
<RS: option, RS- II: standard>
CONSTRUCTION DIAGRAM
<Front>

Section A – A

Inside lock cable

Clip
Inside lock cable

Inside handle Outside handle

A

A Door latch assembly Door inner panel

Inside handle rod
Door lock actuator

Inside handle rod

<Rear>

Section B – B
Inside lock rod
Inside lock rod

Inside handle Outside handle

B
Door latch assembly Clip

B
Door lock actuator

Door inner panel

Inside handle rod

Inside handle rod

4-12 BODY - Door

WINDOW GLASS REGULATOR

1. Small-size and lightweight wire winding style has been adopted for the window glass regulator.
2. The power window with the safety function to activate the descending movement of the door window
glass for 150 mm when jammed hand or neck is detected during the ascending movement of the
door window glass has been adopted to increase safety.
3. The operation method of the power window switch in which the switch knob is pressed to activate
the descending movement of the door window glass and the pulled up to activate the ascending
movement has been adopted to increase safety.
4. The one-touch mechanism to fully open and close windows has been adopted for the power window
switch located at the driver’s seat side. Furthermore, the lock switch to prevent the opening and
closing operations of the door window glasses by the power window switches located at the passenger’s
seat side and rear seats has been featured.
5. Smart wiring system (SWS) has been adopted for signal transmission to the main switch at the power
window. (Refer to GROUP 7 – SWS.)
6. After the ignition switch is turned to the LOCK (OFF) position, window glasses can be opened and
closed with the timer function (30 seconds) of the power window. (If the driver’s door is open during
that particular time, window glasses can be opened and closed for another 30 seconds. However,
as soon as the door is closed, the key off operation function is disabled.)
CONSTRUCTION DIAGRAM
<Front> <Rear>
Stationary window glass
Door window glass
Door window glass

Manual window glass Manual window glass

regulator assembly regulator assembly
<RS: standard> <RS: standard>

Power window glass

regulator assembly
Power window glass <RS: option, RS - II:
regulator assembly standard>
<RS: option, RS - II:
standard>

Power window switch (driver’s side)

Lock switch

Power window switch

 BODY - Trunk Lid/Window Glass 4-13
TRUNK LID
Downsizing of the trunk lid hinge and reduction of the hinge protrusion has increased practicality.

Trunk lid hinge

Approximately 128 mm

Trunk lid hinge (the previous LANCER EVOLUTION-VII)

WINDOW GLASS
Laminated glasses for the windshield and tempered glasses for other areas have been used.
5

1
4

No. Name Type Thickness Coloration Visible ray trans-

(mm) missivity rate (%)
1 Windshield Laminated 4.3 Green 80.5
glass
2 Front door window glass Tempered 3.1 Green (UV 82.0
g
glass shade glass)
3 Rear door window glass 3.1 Green 82.0
4 Rear stationary window glass 3.1 Green 82.0
5 Rear window glass 3.1 Green 82.3

NOTE
D The figure at the visible ray transmissivity is a reference value. There could be marginal errors.
NOTES
 5-1

EXTERIOR
CONTENTS

SUMMARY OF EXTERIOR PARTS . . . . . . . 2 WIPER AND WASHER . . . . . . . . . . . . . . . . . . 6

Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . 6
Windshield Washer . . . . . . . . . . . . . . . . . . . . . . 7
AERO PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Elevation-ajustable Large Rear Spoiler . . . . . 4

OUTSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . 5
5-2 EXTERIOR - Summary of Exterior Parts

SUMMARY OF EXTERIOR PARTS

Sophisticated and bold exterior designs have been given to every detail.
FEATURE
Improvements in 1. A radiator grill integrated front bumper has been
appearance equipped.
2. An air dam integrated rear bumper has been equipped.
3. Air dams have been installed to the front, and side areas.
4. An elevation-adjustable large rear spoiler has been
adopted.
Improvements in 5. Air dams have been installed to the front, and side areas.
aerodynamic 6. An elevation-adjustable large rear spoiler has been
characteristics adopted.

Improvements in 7. A power remote control type <RS-II>, or manual type

usability <RS> outside mirror has been installed.

Measures for 8. Material identification mark engraving to resin parts and

resource recycle materials (PP) for easy recycling have been actively
used.
Weight reduction 9. PP has been used for bumper faces.

4, 6
7

3, 5

1, 9

2, 9
3, 5
 EXTERIOR - Aero Parts 5-3
AERO PARTS
Installation of airdams and elevation-adjustable large rear spoilers have improved aerodynamic characteris-
tics and appearance.
CONSTRUCTION DIAGRAM

Front air dam

Rear spoiler

Side air dam

5-4 EXTERIOR - Aero Parts

ELEVATION-ADJUSTABLE LARGE REAR SPOILER

Remove the cap of the rear spoiler, loosen the elevation fulcrum nut, and change the four installing
holes of the adjustment bolts to adjust the elevation of the spoiler wing according to the driving conditions.

Rear spoiler

Cap
Wing

View A <Adjustment Bolt Installing Hole

Positions> Elevation fulcrum nut
Step 2 installing
hole

Step 1 installing hole

Step 4 installing hole Step 3 installing hole

View A <Movable Angle>

Elevation fulcrum nut
Down force (Small) Step 1

Step 2

Step 3

Down force (Large)

Step 4
 EXTERIOR - Outside Mirror 5-5
OUTSIDE MIRROR
A power remote control type <RS-II>, or manual type <RS> outside mirror has been installed.
CONSTRUCTION DIAGRAM

Power remote control mirror switch

5-6 EXTERIOR - Wiper and Washer

WIPER AND WASHER

WINDSHIELD WIPER
D Two-speed type windshield wipers to be operable in a low or high speed have been adopted.
D Intermittent wipers with the variable intermittent time have been adopted.
D Due to the installation of wiper link assembly with frames, higher rigidity of link assembly has achieved
reduction of incomplete cleaning by smoother wiper operation and improvements in quiet wiper operation.
D The adoption of mist wiper function to turn the mist switch in the opposite direction of the wiper
switch movement has improved easiness-to-use. The wipers operate in a high speed while the mist
switch is turned to the ON position. When the mist switch is turned to the OFF position, the speed
of wiper operation becomes slow and the wipers move to the stop position. When the mist switch
is turned to the ON position for a moment, the wipers operate once in a low speed.
CONSTRUCTION DIAGRAM

Wiper blade

Wiper motor

Wiper arm

Wiper link assembly

Frame
 EXTERIOR - Wiper and Washer 5-7
WINDSHIELD WASHER
D 2-nozzle and 4-jet type indoor shield washers have been installed. Furthermore, the wiper related
to washers function has been adopted.
D A washer tank has been installed in the trunk room.
CONSTRUCTION DIAGRAM
Trunk lid hinge

Washer tank

Washer tank

Washer nozzle

Washer hose
NOTES
 6-1

INTERIOR
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . 2 INTERIOR TRIMS . . . . . . . . . . . . . . . . . . . . . . 8

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Construction Diagram . . . . . . . . . . . . . . . . . . . . 8

INSTRUMENT PANEL AND FLOOR SUPPLEMENTAL RESTRAINT SYSTEM

CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Construction Diagram . . . . . . . . . . . . . . . . . . . . 3 Construction Diagram . . . . . . . . . . . . . . . . . . . . 9
SRS System Circuit Diagram . . . . . . . . . . . . . 10
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . 4
Caution Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Construction and Operation . . . . . . . . . . . . . . 13
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SRS-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Seat Belt Retractor with Force Limiter . . . . . 7
6-2 INTERIOR – General Information

GENERAL INFORMATION
The interiors to value functionality, habitation, and safety brings a new sense of good quality and security.
Furthermore, it is also intended for getting actively involved with global environmental protection and
natural resource recycling.
FEATURES

Improvements in quality Fully trim-covered interior

Consideration for the most 1. The adjustable seat belt anchor has been installed to
suitable riding posture the front seat belt.
2. RECARO seat have been equipped. <RS-II>

Improvements in safety 1. SRS air bags (driver’s/front passenger’s) are equipped

as standard.
2. Installation of ELR 3-point seat belt (front seat)
3. ELR 3-point seat belt/seat belt with child seat fixing
mechanism (ALR) switching function have been
equipped (rear seat).
4. Seat belts with pretensioner force limiter mechanism
have been equipped to the front seats.
5. Head impact reduction pillar trim
6. Folding assistant grip
7. Inflammable materials are used for instrumental panel,
floor console, and trims.
Improvements in usability Vanity mirror <RS-II>

Convenient storage 1. Glove box

2. Center panel box <RS-II>
3. Cup holder
Dealing with resource Display of material codes to resin parts
recycling
 INTERIOR – Instrument Panel and Floor Console 6-3
INSTRUMENT PANEL AND FLOOR CONSOLE
The instrument panel and the floor console have the D A pad incorporating the front passenger’s air
following features: bag door has improved appearance.
D The center panel with a new sense of design D A glove compartment convenient for
incorporate the instrument panel has been accessories has been installed.
adopted. D A cup holder has been installed to the floor
D The considerably tilted center panel has console.
enhanced a sense of emancipation and D Ashtrays have been installed to the front and
operability. the rear console. <Rear console: RS-II>
D A center panel box convenient for storing Inflammable materials are used for the instrument
accessories has been installed. panel and the floor console to increase safety as
<RS-II> interiors.
D The push-to-open type lid to the center panel Also, material codes are indicated to deal with
box has been installed. <RS-II> recycling easily.
D Hair transplant has been done inside the center
panel box to prevent the stored goods from
being damaged. <RS-II>
CONSTRUCTION DIAGRAM

Air bag door

Front seat ashtray

Cup holder
Glove box

Center panel box

Ashtray for the rear seat

<Rear console: RS-II>
6-4 INTERIOR – Accessories

ACCESSORIES
D A vanity mirror has been installed to improve D A folding assistant grip has been installed to
usability. <RS-II> improve safety.

Vanity mirror
Folding assistant grip
 INTERIOR – Seat 6-5
SEAT
FRONT SEAT
D The most suitable driving position can be set D RECARO seat adopting non-step adjustment
by the sliding and reclining mechanism. <RS> slide and reclining mechanism have been
D Height adjustment function to secure the most equipped. <RS-II>
suitable driving posture has been adopted at
the driver’s seat. <RS>

Head restraint
vertical adjustment
RECARO seat

Height adjustment

Reclining adjustment
Reclining adjustment

Sliding adjustment Sliding adjustment

REAR SEAT
D The rear seats have been set with the low back
bench seat.

<Low back bench seat>

6-6 INTERIOR – Seat Belt

SEAT BELT
FRONT SEAT BELT
D The adoption of 3-point seat belt with ELR which D The seat belt retractor with the pre-tensioner
has belt adjustment device for height and the and the force limiter for the driver’s seat and
buckle fixed at the seat have secured the most the front passenger’s seat has been adopted
suitable fitting for the wearer. to improve safety.

REAR SEAT BELT

D 3-point seat belts with ALR/ELR (L.H./R.H./cen-
ter) have been installed.
CONSTRUCTION DIAGRAM

Seat belt retractor (L.H./R.H./center)

Belt adjustment device (L.H./R.H.)

3-point seat belt

with ELR
(L.H./R.H.)
3-point seat belt with
ALR/ELR (L.H./R.H./center)

Buckle (L.H./R.H.)

Seat belt retractor with the pre-tensioner and

the force limiter (L.H./R.H.)
 INTERIOR – Seat Belt 6-7
SEAT BELT RETRACTOR WITH FORCE LIMITER
The driver’s/front passenger’s seat belt retractor
has been equipped with a force limiter. The force lim-
iter is a device which operates when a predeter-
mined force is applied, and limits the force.

Seat belt retractor with

force limiter

Torsion bar OPERATION

(1) If a collision energy is transmitted to the seat belt, the
Belt ELR mechanism will operate to lock the seat belt.
(2) Then, if the energy increases to a predetermined value,
the torsion bar will be distorted. As the spool rotates
together with the torsion bar, the seat belt webbing is
pulled out, reducing impact on the occupants.

Spool
6-8 INTERIOR – Interior Trims

INTERIOR TRIMS
D The interiors are fully covered by trims to D Use of inflammable materials for the trims has
enhance product value. increased safety as outstanding interiors. Also,
D The adoption of the energy absorption rib mold material codes are indicated to deal with
located in the rear of the front pillar trim and recycling easily.
the rear pillar trim to protect head from the
side impact and the resin materials for the trims
as unbreakable materials has increased safety
as outstanding interiors.
CONSTRUCTION DIAGRAM

Energy absorption rib

Front pillar trim

(back side)

Rear pillar trim

Center pillar upper trim
Rear shelf trim
Front pillar trim
Retractor trim

Cowl side trim

Partition board
Rear scuff plate
Center pillar lower trim
Front scuff plate
 INTERIOR – Supplemental Restraint System (SRS) 6-9
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
D SRS air bag is a system to be effective once D Seat belt with pre - tensioner featured for the
the seat belt is worn. The system is designed driver’s and front passenger’s seats is designed
to be a supplemental system of the seat belt. for instantly taking up the slack in the seat
The system protects head and chest of a front belt at the time of impact to improve restraint
seat passenger from the frontal collision by effect on a passenger. It is activated
inflating the air bag to soften the impact when approximately at the same time as SRS airbag
the impact applied from the front of the vehicle is activated to improve protection effect on a
is greater than the set value. passenger.
D To enhance impact safety, all models are Caution
equipped with driver’s/front passenger’s SRS Never disassemble the SRS air bag compo-
air bag as standard. nents. And never subject the SRS air bag com-
D An inflator that does not contain sodium azide ponents to impact.
has been adopted for all types of the air bag
modules.
CONSTRUCTION DIAGRAM

Seat belt with pretensioner

SRS warning lamp

Front passenger’s side air bag

Driver’s side air bag module module

Clock spring

Diagnosis connector

SRS-ECU
6-10 INTERIOR – Supplemental Restraint System (SRS)

SRS SYSTEM CIRCUIT DIAGRAM

Ignition switch (IG1)

SRS-ECU

J/B N_2 N_23

(multi-purpose fuse) 7.5A 7.5A

16

13

Combination meter
OFF

Connector lock switch* ON 8

OFF
7

ON

Connector short-circuit system*

Connector short-circuit system*
OFF OFF
11
Driver’s side
air bag module ON
ON
(squib) OFF
OFF
12
C-207 ON C-22
ON
Clock spring
C-204 20

Connector short-circuit system*

Diagnosis connector
OFF
10
P a s s e n ge r ’ s
side air bag ON
module(squib) OFF
9
OFF
C-109 ON
ON

Connector short-circuit system*

OFF
30
OFF
Seatbelt with ON
pre-tensioner OFF
(L.H.) 29 ON

D-28 ON
Connector lock switch*

Connector short-circuit system*

OFF
28
Seatbelt with
pre-tensioner ON
(R.H.) OFF
27
D-26 ON

NOTE:
When the connector is installed: ON
SRS-ECU connector When the connector is removed: OFF
 INTERIOR – Supplemental Restraint System (SRS) 6-11
CAUTION LABELS
Labels to indicate cautions regarding the handling
and the services of SRS air bag are attached on the
position shown in the following illustration.
<TYPE 1> <TYPE 2>
Steering wheel Driver’s side bag module Cover

A
B
A
Clock spring Front passenger’s side air bag module SRS-ECU

Sun visor Steering joint cover Glove box

F
G
F H

Seat belt with pretensioner

NOTE
(1) Type 1 : Steering wheel/air bag module separation type
(2) Type 2 : Steering wheel/air bag module integrated type
6-12 INTERIOR – Supplemental Restraint System (SRS)

A. CAUTION: SRS G. WARNING: SRS

BEFORE REPLACING STEERING WHEEL, FIX STRG. WHEEL AT TIRES STRAIGHT
READ SERVICE MANUAL,THIS AIR BAG AHEAD BEFORE GEARBOX REMOVAL.
MODULE CANNOT BE REPAIRED. DO NOT OTHER WISE, MAY DAMAGE SRS CLOCK
DISASSEMBLE OR TAMPER. SPRING MAKING SRS SYSTEM INOPERA-
TIVE, RISKING SERIOUS DRIVER INJURY.
B. DANGER
CONTENTS ARE EXTREMELY FLAMMABLE. H. AIR BAG SYSTEM INFORMATION
DO NOT PROBE WITH ELECTRICAL DE- THIS VEHICLE HAS AN AIR BAG SYSTEM
VICES OR OTHER WISE TEMPER WITH IN WHICH WILL SUPPLEMENT THE SEAT BELT
ANY WAY. IN CERTAIN FRONTAL COLLISIONS. THE
AIR BAG IS NOT A SUBSTITUTE FOR THE
C. CAUTION: SRS CLOCK SPRING SEAT BELT IN ANY TYPE OF COLLISION.
THIS IS NOT A REPAIRABLE PART. IF DE- THE DRIVER AND ALL OTHER OCCUPANTS
FECTIVE, REPLACE ENTIRE UNIT ACCORD- SHOULD WEAR SEAT BELTS AT ALL TIME.
ING TO THE SERVICE MANUAL IN-
STRUCTIONS. TO RE-CENTER: ROTATE WARNING!
CLOCKWISE UNTIL TIGHT. THEN ROTATE IF THE “SRS” WARNING LIGHT DOES NOT
IN OPPOSITE DIRECTION ROUGHLY 3 ILLUMINATE FOR SEVERAL SECONDS
TURNS AND ALIGN ARROWS "A. WHEN THE IGNITION KEY IS TURNED TO
“ON” OR THE ENGINE IS STARTED, OR IF
D. WARNING: FLAMMABLE/EXPLOSIVE SRS THE WARNING LIGHT STAYS ON WHILE
AIR BAG MODULE TO AVOID SERIOUS INJU- DRIVING, TAKE THE VEHICLE TO YOUR
RY: NEAREST AUTHORIZED DEALER IMMEDI-
D DO NOT REPAIR, DISASSEMBLE OR ATELY. ALSO, IF VEHICLE FOR SERVICE
TAMPER. IMMEDIATELY.
D AVOID CONTACT WITH FLAME OR THE AIR BAG SYSTEM MUST BE IN-
ELECTRICITY. SPECTED BY AN AUTHORIZED DEALER
D DO NOT DIAGNOSE/USE NO TEST TEN YEARS AFTER THE VEHICLE
EQPT OR PROBES. MANUFACTURE DATE SHOWN ON THE
D STORE BELOW 200°F (93°C). CERTIFICATION LABEL LOCATED ON THE
D BEFORE DOING ANY WORK INVOLVING LEFT FRONT DOOR-LATCH POST OR DOOR
MODULE, READ SERVICE MANUAL FOR FRAME.
IMPORTANT FURTHER DATA. READ THE “SRS” SECTION OF YOUR OWN-
ER’S MANUAL BEFORE DRIVING FOR IM-
E. CAUTION: PORTANT INFORMATION ABOUT OPERA-
DO NOT DISASSEMBLE OR DROP. IF DE- TION AND SERVICE OF THE AIR BAG SYS-
FECT, REFER TO SERVICE MANUAL. TEM.
WHEN YOU ARE GOING TO DISCARD YOUR
GAS GENERATOR OR VEHICLE, PLEASE
F. WARNING TO AVOID SERIOUS INJURY: SEE YOUR DEALER.
D THE AIR BAG DOES NOT SAFETY BELT.
D FOR MAXIMUM SAFETY PROTECTION I. DANGER: SEAT BELT PRETENSIONER
IN ALL TYPES OF CRASHES,YOU MUST D DO NOT IMPACT. DISMANTLE OR
ALWAYS WEAR YOUR SAFETY BELT. INSTALL IT INTO ANOTHER VEHICLE.
D DO NOT INSTALL REARWARD-FACING D SERVICE OR DISPOSE OF IT AS DI-
CHILD SEATS IN ANY FRONT PAS- RECTED IN THE REPAIR MANUAL.
SENGER SEAT POSITION.
D DO NOT SIT OR LEAN UNNECESSARILY
CLOSE TO THE AIR BAG.
D DO NOT PLACE ANY OBJECTS OVER
THE AIR BAG OR BETWEEN THE AIR
BAG AND YOURSELF.
D SEE THE OWNER’S MANUAL FOR FUR-
THER INFORMATION AND EXPLANA-
TIONS.
 INTERIOR – Supplemental Restraint System (SRS) 6-13
CONSTRUCTION AND OPERATION
NOTE for more information regarding the inflator and the
Refer to ’99 PAJERO in Technical Information clock spring of the front passenger’s side air bag
Manual (Pub. No. PYJE9805) or ’00 PAJERO PININ module.
Technical Information Manual (Pub. No. IKRE00E1)
DRIVER’S SIDE AIR BAG MODULE
Both the type 1 and type 2 3-spokes (MOMO) 1are comes into contact with the air bag, the air bag starts
equipped. The driver’s air bag module is an assem- to deflate while gas is discharged from the two vents
bly part composed of an air bag, module cover, in- at the back to ease the impact.
flator, and their fixing parts. It is mounted to the The inflator contains no sodium azide.
steering wheel. Caution
The air bag is made of nylon, and is inflated by gas Never disassemble the air bag module. And nev-
generated from the inflator. As the passenger er subject it to impact.

<TYPE 1> Section A - A

A Air bag module

Inflator
Module cover

Air bag

<TYPE 2> Air bag module

A Section A - A

Inflator
Module cover

Air bag

A
6-14 INTERIOR – Supplemental Restraint System (SRS)
FRONT PASSENGER’S SIDE AIR BAG MODULE
The front passenger’s side air bag module consists gas from two bores at the rear of the air bag to re-
of air bag, inflator, module cover (incorporating the duce the shock from the impact.
instrument panel pad), and the fixing gear related to An inflator that does not contain sodium azide has
those parts. been adopted for all types of the air bag modules.
The air bag is made from nylon and inflates by the Caution
gas generating from the inflator. As a passenger is Never disassemble the air bag module. And nev-
being pressed to the air bag, it deflates discharging er subject it to impact.
Section A - A
Air bag module Module cover
A

Air bag

Inflator

SEAT BELT WITH PRETENSIONER

Seat belt with pre-tensioner is designed for instantly outwards by the gas pressure. As the strip wound
taking up the seat belt at the time of impact to around the clutch sleeve is pulled out, the clutch
improve restraint on a passenger. When the G sleeve rotates at high speed. The clutch sleeve
sensor in the SRS-ECU detects impact above a rotates to wind the waving.
certain level, the heater for ignition heats up Caution
according to the signal from the SRS-ECU to ignite Never disassemble the seat belt with preten-
the igniter and generate gas. The strip is pushed sioner. And never subject it to impact.
Strip

Clutch sleeve
 INTERIOR – Supplemental Restraint System (SRS) 6-15
SRS-ECU
The SRS-ECU incorporates an analog G sensor D Backup power supply in case of power failure
and safing G sensor for frontal collisions. in collisions
In frontal collisions, the driver’s and front passen- D Boosting function in case of battery voltage
ger’s air bags deploy only when both the analog drop
and safing G sensors detect simultaneously a colli- D Self-diagnosis function to avoid system’s opera-
sion-induced G of a level exceeding the threshold tion errors and improve its reliability
as in the case with the conventional system. Caution
Like the conventional system, the SRS-ECU is pro- Never disassemble the SRS-ECU. And never
vided with the following capabilities: subject it to impact.

DIAGNOSIS FUNCTION
The SRS-ECU has the following functions to make D Service data output
system checking using MUT-II easy.
D Diagnosis code output

DIAGNOSIS CODE OUTPUT

The SRS-ECU diagnoses the following items and Therefore, the memory is not deleted after a battery
stores a diagnosis code in the non-volatile memory terminal is disconnected. (The diagnosis code
(EEPROM*1) when a problem is detected. memory can be deleted by the MUT-II.)

Code Major Contents of Diagnosis

No.
14 Frontal collision analog G sensor failure
15 Frontal collision safing G sensor short-circuited
16 Frontal collision safing G sensor open-circuited
21*3 Driver’s side front air bag squib short-circuited
22*3 Driver’s side front air bag squib open-circuited
24*3 Front passenger’s side front air bag squib short-circuited
25*3 Front passenger’s side front air bag squib open-circuited
26*3 Driver’s side front seat belt pretensioner short-circuited
27*3 Driver’s side front seat belt pretensioner open-circuited
28*3 Front passenger’s side front seat belt pretensioner short-circuited
29*3 Front passenger’s side front seat belt pretensioner open-circuited
31 Capacitor voltage rises
32 Capacitor voltage drops
34*2 Connector locking mechanism malfunction
35 Ignition of the air bag completed
41*2 Power supply voltage (IG1 voltage) drops abnormally.
42*2 Power supply voltage (IG1 voltage) drops abnormally.
43*2 SRS warning lamp circuit open-circuited
44*2 Defective SRS warning lamp circuit
45 Defective SRS-ECU
49 Air bag fully deployed
51 Driver’s side front air bag squib activating circuit short-circuited
6-16 INTERIOR – Supplemental Restraint System (SRS)

Code
No. Major Contents of Diagnosis

52 Driver’s side front air bag squib activating circuit open-circuited

54 Front passenger’s side front air bag squib activating circuit short-circuited
55 Front passenger’s side front air bag squib activating circuit open-circuited
56 Driver’s side front seat belt pretensioner activating circuit short-circuited
57 Driver’s side front seat belt pretensioner activating circuit open-circuited
58 Front passenger’s side front seat belt pretensioner activating circuit short-circuited
59 Front passenger’s side front seat belt pretensioner activating circuit open-circuited
61 Driver’s side front air bag squib drive circuit (power supply side) short-circuited
62 Driver’s side front air bag squib drive circuit (earth side) short-circuited
64 Front passenger’s side front air bag squib drive circuit (power supply side) short-circuited
65 Front passenger’s side front air bag squib drive circuit (earth side) short-circuited
66 Driver’s side front seat belt pretensioner drive circuit (power supply side) short-circuited
67 Driver’s side front seat belt pretensioner drive circuit (earth side) short-circuited
68 Front passenger’s side front seat belt pretensioner drive circuit (power supply side) short-circuited
69 Front passenger’s side front seat belt pretensioner drive circuit (earth side) short-circuited

NOTE
*1: Electrically Erasable Programmable ROM
*2: This diagnosis code memory will be automatically cleared from the memory and the SRS warning
lamp will be switched off when the system returns to normal condition.
*3: The diagnosis codes will remain in memory and the SRS warning lamp will be switched off if the
system returns to normal.

SERVICE DATA OUTPUT

When the SRS-ECU detects a problem, it stores by the MUT-II are stored in the non-volatile memory
a diagnosis code and the duration of the problem as a reference for service work. The data which
has lasted in the non-volatile memory. In addition, is stored can be read by the MUT-II.
how often a diagnosis code and duration are cleared

No. Service Data Item Applicability

92 Number indicating how often the memory is cleared Maximum time to be stored:
250
93 How long a problem has lasted (How long takes from the occur- Maximum time to be stored:
rence of the problem till the first air bag squid Igniting signal) 9999 minutes (approximately
( pp y
7days)
94 How long a problem has lasted (How long it takes from the first
air bag squib igniting signal signal till now)
 7-1

EQUIPMENT
CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . 2 COMBINATION METER . . . . . . . . . . . . . . . . . . . . . 9

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SMART WIRING SYSTEM (SWS) . . . . . . . . . . . 10
DIAGNOSTIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 3 Communication Method . . . . . . . . . . . . . . . . . . . . . . 11
Diagnosis Connector . . . . . . . . . . . . . . . . . . . . . . . . . 3 Multi-distribution Input/output by Circuit . . . . . . . . 11
Diagnostic Function . . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Functions and Control of SWS ECUs . . . . . . . . . 14
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . . . . 4
HEATER AND AIR CONDITIONER . . . . . . . . . 20
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exterior Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Heater and Air Conditoner System . . . . . . . . . . . . 22
Interior Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-2 EQUIPMENT – General Description

GENERAL DESCRIPTION
The adoption of new accessories and functions has enhanced a lineup of equipment.

FEATURES
Enhanced reliability 1. Adoption of waterproof connector in the engine compartment
2. Installation of fuse box and relay box

Enhanced visibility and 1. Adoption of headlamp with leveling function

safety 2. Installation of front turn signal lamp with outstanding visibility
Enhanced ease-of-use using an aluminum metal evaporated reflector
and convenience 3. Installation of rear combination lamps with large tail and stop
lamp emitter blending with the body design
4. Installation of high mount stop lamps
5. Installation of rear fog lamps with outstanding visibility
6. Equipped with an immobilizer system

Improvements in service 1. Installation of diagnostic connectors (two) for MUT-II inspection

quality 2. Addition of ignition timing inspection function to the MUT-II
3. Adoption of Smart Wiring System (SWS) to reduce weight and
complexity of harnesses

Improvements in com- Installation of Smart Wiring System (SWS) with new functions
mercial value such as headlamp auto-cut and lamp on reminder function,
ETACS-ECU, and front-ECU

NOTE
Refer to P.7-20 for general information and features of the heater and air conditioner.
 EQUIPMENT – Diagnostic System 7-3
DIAGNOSTIC SYSTEM
Service quality has been improved by fitting diagnostic connectors for MUT-II inspection near the left
knee area of the driver’s seat on the instrument panel.
Diagnostic
g function MPI ABS Immobilizer SRS SWS
air
i bbag ETACS Column Front
switch ECU
Diagnosis code output D D – D D D D
Diagnosis code output by volt- – – – – D D D
meter
Output of service data D D – D – – –
Actuator test D D – – – – –
Diagnostic output by warning – D (ABS warn- – – – – –
lamp and indicator lamp ing lamp)
Diagnosis record storage D D D D – – –
Erasure of diagnosis code by D D D D – – –
MUT-II
Pulse check by MUT-II – – – – D D D
Pulse check by sounding buzzer – – – – D D D

DIAGNOSIS CONNECTOR
Diagnosis connector (Black)
1 Diagnosis control
2, 3 –
4 Grounding
5 Grounding
6 –
7 MPI, ABS, immobilizer and SRS air bag
8 –
9 ETACS
10 –
11
12-pin connector 16-pin connector
(white) (black) 12 –
13 –
14 –
15 –
7-4 EQUIPMENT – Diagnostic System/Battery/Immobilizer

Diagnosis connector (Black)

16 Battery
Diagnostic connector (White)
21 - 25 –
26 MPI
27 - 32 –

BATTERY
Light and compact batteries have been adopted.
Item Specifications
44B20L
Voltage V 12
Capacity (5-hour rate Ah) 34
Electrolytic fluid specific gravity 1.280
(fully charged state at 20_C)

IMMOBILIZER SYSTEM
The immobilizer system consists of the ignition key, immobilizer system. If the ignition key is lost or
the key ring antenna, the immobilizer-ECU, and another ignition key is added, all the keys must
the engine-ECU. be registered again by using the scan tool
The ignition key has a built-in transponder as the MB991502 (MUT-II) for security reasons.
oscillator. The key ring antenna is installed on the
steering lock key cylinder. Only the registered igni-
tion key permits the engine to start, therefore, the
engine can never be started by means of a forged
key or by connecting the ignition wiring directly.
The system is significantly safe and reliable against
theft. In addition, the driver has only to turn the
ignition switch to the “ON” position to activate the

CONSTRUCTION DIAGRAM
The system prevents the engine from being started 3. The immobilizer-ECU judges the encrypted
deviously to protect the vehicle from theft. The op- code with its code logic in itself. If they are
eration is as follows. identical, the immobilizer-ECU sends the
1. When the ignition switch is turned “ON” encrypted code to the engine-ECU.
position,the engine-ECU sends a requirement 4. If the engine-ECU can not receive the encrypted
for the encrypted code to the immobilizer-ECU code, the engine will be immobilized.
(at this time, the engine is remobilized).
2. When the immobilizer-ECU receives the
requirement from the engine-ECU transponder
inside the ignition key via the antenna. The
energized transponder sends the encrypted
code back to the immobilizer-ECU via the
antenna.
 EQUIPMENT – Immobilizer System 7-5
DISPOSITION WHEN REPLACING IMMOBILIZER SYSTEM RELATED PARTS
To replace immobilizer related parts, observe the table below. When the ignition key is re-registered with
the MUT-II, the originally registered ignition key registration information will be lost.
Engine-ECU Immobilizer-ECU Ignition key
When replacing engine-ECU – Replacement required Replacement and re-registration
are required.
When rewriting engine-ECU – Replacement not required Replacement not required, re-
registration not required
ECU Replacement not re- – Replacement not required, regis-
quired tration are required
When adding ignition key Replacement not re- Replacement not required Register an additional ignition key
newly quired and re-register all other ignition keys.
When ignition key is lost Replacement not re- Replacement not required re-register all other ignition keys
quired except the lost one.

Integrated immobilizer-ECU and antenna

Ignition key Start of permis-
sion signal
Engine-ECU
Power
Transponder

Encrypted code
MUT-II
Registration
Steering lock key cylinder and of ignition key
immobilizer-ECU
7-6 EQUIPMENT – Lighting

LIGHTING
EXTERIOR LAMPS
D The large lens adjusted to the exclusive body has been equipped with model specific 4 bulb type
headlamp incorporating front turn signal lamp, position lamp. The low beam is a projector type used
as a compact but efficient wide light distributor.
D The front turn signal lamp adopts an aluminum metal evaporated reflector to improve visibility.
D The tail lamp and stop lamp make use of complementary colors to emit white color from the red lens
to improve visibility.
D The inner lens of the tail lamp has been set with a reflex reflector to improve appearance.
D Rear fog lamps with outstanding visibility have been installed.
D A high mount stop lamp has been installed to the rear shelf.
D The lighting system is provided with headlamp auto-cut.
SPECIFICATIONS
Item Specifications
Headlamp
p assemblyy High beam (Halogen bulb) W 60 (HB3)
Low beam (Halogen bulb) W 51 (HB4)
Headlamp
p assemblyy Position lamp W 5
Front turn signal lamp W 21
Side turn signal lamp W 5
Rear combination lamp
p Tail/stop lamp W 5/21
Turn signal lamp W 21
Backup lamp W 21
Rear fog lamp W 21
High mount stop lamp W 21
License plate lamp W × number 5×2

NOTE
The brackets ( ) show the bulb type.
 EQUIPMENT – Lighting 7-7
CONSTRUCTION DIAGRAM

Headlamp (High beam)

Headlamp
assembly

Headlamp (Low beam)

Side turn signal lamp
Position lamp

Front turn signal lamp

Back-up lamp or
rear fog lamp ∗

Tail lamp

Rear combination
lamp Tail / stop lamp

Rear turn signal lamp

High mount stop lamp

NOTE
*: The driver’s side is installed with a rear fog lamp, while the passenger’s side is installed with a back-up
lamp.
7-8 EQUIPMENT – Lighting

INTERIOR LAMPS
D A map lamp serving also as front room lamp which can be used at both the driver’s seat and passenger
sea is provided.
D A rear room lamp to light the backseat and trunk lamp to light the trunk are provided.
SPECIFICATIONS
Item Specifications
Map lamp W × quantity 7.5 × 2
Front room lamp W 7.5
Rear room lamp W 8
Trunk lamp W 5

CONSTRUCTION DIAGRAM

Rear room lamp Map lamp and front room lamp

Trunk lamp
 EQUIPMENT – Combination Meter 7-9
COMBINATION METER
The combination meter is an easy-to-read pointer type meter. At the center is a tachometer, on the left side
a speedometer, on the right side a fuel meter, engine coolant thermometer, and indicator lamp. It has a sport
and efficient design to allow the driver to read the meters clearly.
D The tachometer displays the conditions of the current road using three indicators TARMAC, SNOW,
and GRAVEL. [Refer to GROUP 2-Active Center Differential (Active Control System.)]
D A water spray indicator which lights up when the water splay switch is set to AUTO has been adopted.
D The speedometer is an electronic type speedometer which operates by the pulse signal generated
by the speed sensor.
D A large and clear LCD type odo-tripmeter is provided. The odometer continuously displays values
while the tripmeter adopts a twin-trip (trip A, trip B) function which is switched by a reset button.
(Standard meter)
D The fuel gauge is provided with a triangular mark indicating the location of the fuel filler door to
show clearly that the fuel filler door is on the left side of the car.
CONSTRUCTION DIAGRAM
Rear fog lamp
Speedometer Tachometer indicator Coolant temperature
gauge

Water splay
indicator

Mode indicator lamp Reset button Fuel gauge

7-10 EQUIPMENT – Smart Wiring System (SWS)

SMART WIRING SYSTEM (SWS)

SWS is a minimal line system which transmits numerous signals using one wiring to control against
increased weight and complication of harnesses which result from the increase in electronic accessories.
Basically the same as the new SPACE RUNNER.
To transmit numerous signals, the ETACS-ECU*, column switch, front ECU, power window main switch
(power window switch of the driver’s seat side) incorporate multi-distribution circuits to carry out
communication between control units.
NOTE
*: ETACS (Electronic Time and Alarm Control System)
CONSTRUCTION DIAGRAM

Power window switch

Column switch

ETACS-ECU

Front ECU
 EQUIPMENT – Smart Wiring System (SWS) 7-11
COMMUNICATION METHOD
The exclusive signal lines for transmitting the multi-distribution data are connected as follows between
the ETACS-ECU, column switch (incorporated inside the column ECU), front ECU, power window main
switch (incorporated inside the power window ECU) and power window motor assemblies (incorporated
inside the power window motor ECU) for internal communication.

Power window Power window

ETACS-ECU motor assem- motor assem-
bly (Front RH) bly (Rear RH)

Power window
Column main switch
switch

Front ECU Power window Power window

motor assembly motor assembly
(Front LH) (Rear LH)

Single-direction communication
Bidirectional communication

MULTI-DISTRIBUTION INPUT/OUTPUT BY CIRCUIT

Multi-distribution is employed by the following circuits. The relation of the input switches, sensors, ECUs
connected by multi-distribution lines, and outputs are also shown below.
Circuit and input switch and sensor ECUs and switches con- Output side
nected by multi-distribution
1. Buzzer
D Lamp still ON reminder warning function
D Ignition switch (IG1) ETACS-ECU Buzzer (built-in ETACS-
D Driver’s seat door switch ECU)
Column switch
(Lighting switch)

2. Power window
D Power window timer function

D Ignition switch (IG1) ETACS-ECU Power window relay

D Driver’s seat door switch
Power window
main switch
Power window
motors
7-12 EQUIPMENT – Smart Wiring System (SWS)

Circuit and input switch and sensor ECUs and switches con- Output side
nected by multi-distribution
3. Windshield wiper washer
D Windshield mist wiper
D Windshield low speed wiper
D Windshield high speed wiper
D Windshield washer

Column switch ETACS-ECU

Column switch)

Windshield wiper motor

Ignition switch (ACC) Front ECU Windshield washer motor

4. Lighting
D Headlamp, tail lamp
D Headlamp auto-cut function
D Rear fog lamp

Ignition switch (IG1) ETACS-ECU Combination meter (High

Driver’s seat door switch beam or rear fog lamp
Vehicle speed signal indicator) Illumination lamps
Rear fog lamp switch Rear fog lamp
Column switch
(Lighting switch)

Headlamp
Ignition switch (IG2) Front ECU Taillamps
Rear fog lamp

5. Flasher
D Turn signal lamp
D Hazard warning lamp

D Ignition switch (IG1) ETACS-ECU Combination meter (Turn

D Hazard warning lamp switch signal indicator)
Column switch Turn signal lamps
(Turn signal lamp
switch)
 EQUIPMENT – Smart Wiring System (SWS) 7-13
DIAGNOSTIC FUNCTION
DIAGNOSIS CODE SET
The ETACS-ECU sends diagnosis codes if the communication
line is faulty when the MUT-ll is connected.
NOTE Refer to the Workshop Manual for details of the
diagnostic items.
SWS INPUT SIGNAL CHECK BY MUT-II
When the MUT-II is connected to the diagnostic connector,
and switches input for the SWS are operated, the buzzer
in the MUT-II sounds, indicating whether the operations of
the switches are satisfactory or not.
INPUT SIGNALS THAT CAN BE CHECKED
Input signal Conditions for sounding buzzer
Ignition switch (ACC) When the switch is turned from the LOCK (OFF) position to ACC
Ignition switch (IG1) When the switch is turned from ACC to the ON position
Hazard warning lamp switch When the switch is turned from the OFF to the ON position
Rear fog lamp switch When the switch is turned from the OFF to the ON position
Driver’s seat door switch When the driver’s seat door is opened from the closed state
Various door switches When one of the closed doors is opened
Driver’s seat door lock actuator When the key cylinder or door lock knob of the driver seat is turned
from LOCK to UNLOCK position, or from UNLOCK to LOCK
position
Speed signal When the speed changes from less than 10 km/h to more than
10 km/h
Column Tail lamp switch When the lighting switch is turned from one position to the tail lamp
switch position
Headlamp switch When the lighting switch is turned from one position to the
headlamp position
Dimmer switch When the switch is turned from the OFF to the ON position
p
Passing switch
Turn signal lamp LH switch
Turn signal lamp RH switch
Windshield mist wiper switch
Windshield intermittent wiper switch
Windshield low speed wiper switch
Windshield high speed wiper switch
Windshield washer switch
Multi-purpose fuse No.17 load When the multi-purpose fuse No. 17 is used as the power supply
load
7-14 EQUIPMENT – Smart Wiring System (SWS)

FUNCTIONS AND CONTROL OF SWS ECUS

The following functions are controlled by the SWS ECUs:
No. Functions Control ECU
1 Lamp still ON reminder warning function ETACS-ECU, column switch
2 Central door lock control function ETACS-ECU
3 Power window timer function ETACS-ECU, power window main switch
4 Windshield wiper washer control function ETACS-ECU, front ECU, column switch
5 Headlamp auto-cut function ETACS-ECU, front ECU, column switch
6 Flasher timer function ETACS-ECU, column switch
7 Rear fog lamp function ETACS-ECU
8 Dimmer type room lamp control function ETACS-ECU

Tail lamp, fog lamp, or ON

LAMP STILL ON REMINDER WARNING FUNCTION
headlamp
OFF When the tail lamp, fog lamp, or headlamp is ON, if the ignition
Ignition
switch OFF
switch is in “OFF” position and the driver’s door is opened,
position
ON (ACC)
a buzzer will sound continuously to warn that the lamp is
illuminated. However, if the tail lamp or headlamp has been
Driver’s (Open) ON
seat door turned off by the headlamp auto-cut function, the buzzer will
(Closed) OFF
switch not sound.
(Sounds) ON
Buzzer
output (Does not sound)
OFF

CENTRAL DOOR LOCK CONTROL FUNCTION

ON
Lock switch
OFF When the driver’s seat door is locked (after the unlock switch
in the driver’s seat door lock actuator is turned OFF, the
ON
Unlock switch lock switch is turned ON), the ETACS-ECU activates the lock
OFF
relay output for 0.25 seconds and locks all doors. Next, when
Lock relay output
ON the driver’s seat door is unlocked (after the lock switch in
OFF
t the driver’s seat unlock actuator is turned OFF, the unlock
Unlock relay output ON switch is turned ON), the ETACS-ECU activates the unlock
OFF
t
relay output for 0.25 seconds and unlocks all doors.
t: 0.25 seconds
 EQUIPMENT – Smart Wiring System (SWS) 7-15
Ignition ON POWER WINDOW TIMER FUNCTION
switch (IG) OFF
When the ignition switch is turned to the ON position, the
Driver’s
seat door
(Open) ON power window relay and power window switch reception
(Closed) OFF
switch
(Permitted)
permission signals (SWS signal sent from the ETACS) are
Power window ON turned ON. After the ignition switch is turned OFF, the system
switch reception
permission sig- (Prohibited)
OFF t
continues to turn ON the power window switch reception
nal t t
permission signal for about 30 seconds and to enable the
Power window
relay
ON
opening and closing of the door window by the power window
OFF
switch. The power window relay goes OFF about 30 seconds
t t t after the reception permission signal goes OFF. When the
t: 30 seconds
driver’s seat door is opened while the timer is in operation,
the reception permission signal will be turned ON for about
30 seconds from this point. However, if the driver’s seat door
is closed, the reception permission signal will be turned OFF.
The power window relay goes OFF about 30 seconds after
the reception permission signal goes OFF.
WINDSHIELD WIPER WASHER CONTROL FUNCTION
1. Mist wiper control
When the ignition switch is at the ACC or ON position, if the windshield mist wiper switch of the column
switch is turned ON, the front ECU turns ON the windshield wiper drive signal. At the same time, the
wiper speed switching relay is turned ON (HI), and while the windshield mist wiper switch is ON, the
windshield wiper will operate at high speed. At the point the windshield mist switch is turned ON, if the
windshield wiper has been operating intermittently, the same operations as the above will be performed
while the windshield mist wiper switch is ON. After the windshield mist wiper switch goes OFF, the intermittent
operations will be set again TI seconds after the windshield wiper auto-stop signal is turned ON last.
Windshield mist wiper switch ON
OFF

Windshield wiper auto-stop signal ON

OFF

Windshield wiper drive signal ON

OFF

TI TI
Windshield wiper speed (HI) ON
switching relay (LO) OFF

When windshield wiper When windshield intermittent

switch is OFF wiper is operating

TI: Intermittent wiper intermittent time

7-16 EQUIPMENT – Smart Wiring System (SWS)
2. Low Speed Wiper, High Speed Wiper Control
When the ignition switch is at the ACC or ON position, if the windshield low speed wiper switch of the
column switch is turned ON, the front ECU turns ON the windshield wiper drive signal, turns OFF (LO)
the windshield wiper speed relay, and operates the windshield wiper at low speed. Next, when the windshield
high speed wiper switch is turned ON, the windshield wiper drive signal is turned ON, the windshield
wiper speed switching relay is turned ON (HI), and the windshield wiper is operated at high speed.
Windshield low speed ON
wiper switch
OFF

Windshield high speed ON

wiper switch
OFF

Windshield wiper auto-stop ON

signal
OFF

Windshield wiper ON
drive signal
OFF

Windshield wiper (HI) ON

speed switching relay
(LO) OFF

Low speed operations High speed operations

3. Washer control
When the ignition switch is at the ACC or ON position, if the windshield washer switch of the column
switch is turned ON, the front ECU turns ON the windshield washer relay. The windshield wiper drive
signal is turned ON in 0.3 seconds until 3 seconds after the windshield washer switch goes OFF (The
wiper drive signal output time varies according to the conditions. Refer to the following table for details)
to operate the windshield wiper continuously. When the windshield washer switch is turned ON, if the
windshield wiper is operating intermittently, intermittent operations will be continued after continuous
operations.

Windshield washer switch ON t

t
OFF

Windshield washer relay ON

OFF

Windshield wiper auto-stop ON

signal OFF
TI
Windshield wiper drive ON
signal T T
OFF

TI TI

When windshield wiper When windshield intermittent wiper

switch is OFF is operating
TI: Intermittent wiper intermittent time

When wiper switch is OFF When wiper switch is INT When wiper switch
is LO or HI
t 0.3 0.3 - 0.5 0.5 - 0.7 0.7 Less 0.3 - 0.5 0.5 - 0.7 0.7 -
seconds seconds seconds seconds than 0.2 seconds seconds seconds
or less seconds
T 0 1 2 3 0 1 2 3 3 seconds
second second seconds seconds second second seconds seconds
 EQUIPMENT – Smart Wiring System (SWS) 7-17
HEADLAMP AUTO-CUT FUNCTION
Even if the headlamp switch is ON, the head lamp will automatically go off in the following conditions
to prevent the battery from discharging as a result of forgetting to turn off lights.
(1) When the ignition key is turned from ON to OFF with the headlamp switch turned ON, and this
state continues for 3 minutes, the headlamp will automatically be turned off. If the driver’s seat door
is opened during these 3 minutes, the lamp will go off 1 second later. (During the one second until
it goes off, the light still ON reminder warning buzzer will sound. However, if the driver’s seat door
is opened with the ignition key inserted, the key inserted reminder warning buzzer will function first.)
(2) When the tail lamp switch is turned ON with the ignition switch and lighting switch OFF, the lamp
will not go off automatically.
The headlamp auto-cut function is cancelled by turning ON the lighting switch (tail or headlamp switch)
or ignition switch.

Ignition switch(IG) ON
OFF

Driver’s seat door (Open) ON

switch
(Closed) OFF
Lighting switch Headlamp

Tail lamp
OFF

Tail lamp output ON

OFF

Headlamp output ON
OFF

3 minutes 1 second

Ignition switch
FLASHER TIMER FUNCTION
ON
(IG)
OFF (1) The turn signal lamp output (flashing signal) is turned
Turn signal lamp ON ON when the turn signal lamp ignition switch is ON and
switch RH
OFF the turn signal lamp switch is ON (LH or RH). If the front
Turn signal lamp ON turn signal lamp or rear turn signal lamp bulb has burned
switch LH OFF out, the flashing speed increases to indicate that the
Turn signal lamp ON bulb has burned out.
output RH OFF
Turn signal lamp ON
output LH OFF
7-18 EQUIPMENT – Smart Wiring System (SWS)

(2) Detects the signal where the hazard warning lamp switch
input changes from OFF to ON, and reverse the flashing
Hazard warn-
ing lamp
ON state according to this signal. (Flashes when the hazard
switch OFF lamp is not flashing and turns off when flashing.)
Turn signal lamp ON NOTE
output RH OFF The hazard warning lamp switch is a push-return switch.
Turn signal lamp ON
output LH OFF

REAR FOG LAMP CONTROL FUNCTION

Headlamp or ON
front fog lamp
If the rear fog lamp switch is turned ON when the headlamp
OFF is turned ON, the rear fog lamp is switched ON and OFF
alternatively.
ON
Rear fog lamp If the headlamp is turned OFF during lighting of the rear
switch OFF fog lamp, the rear fog lamp is turned OFF at the same time.
ON
Rear fog lamps
OFF
 EQUIPMENT – Smart Wiring System (SWS) 7-19
DIMMER TYPE ROOM LAMP CONTROL FUNCTION
When the room lamp switch is at the door position, the ETACS-ECU controls the lighting of the room
lamp as follows.
(1) When a door is opened to get on or get off the vehicle (when the ignition switch is OFF), the lamp
lights up (100%), when closed, the lamp dims (65%), and goes off 15 seconds later. However if
the ignition switch is turned ON while the timer illuminates or if door is locked, the lamp will go off
at that point.
(2) When a door is opened with the ignition switch ON, the lamp illuminates (100%), and goes off when
closed.
(3) When the ignition key is removed with all doors closed
When the ignition key is removed with all doors closed, the lamp illuminates (65%) and goes off
after 15 seconds. When the ignition key is inserted again while the lamp illuminates or when door
is locked, the lamp goes off.
NOTE
The delay time until the room lamp goes off can be adjusted by the adjustment function. (Refer to P.7-29.)
ON
Ignition switch ACC
OFF
Key removed

(Any one open) ON

Door switch
(All closed) OFF

Driver’s seat door lock (LOCK) ON

actuator switch (lock
switch) (UNLOCK) OFF

LOCK
Lock/unlock signal by
keyless entry OFF
UNLOCK

100 %
65 %
Room lamp brightness

0%

15 seconds 15 seconds

NOTE
The dotted lines indicate that lighting mode when the ignition switch is turned ON, door is locked, or
any door is opened during the timer illumination time.
7-20 EQUIPMENT – Heater and Air Conditioner

HEATER AND AIR CONDITIONER

The heater and air conditioner system incorporating the heater and cleaning unit has reduced ventilation
resistance to increase air volume and reduce noise.
FEATURES
Improvements in comfort 1. Installation of two-ray blow full air mix heater
2. Adoption of low noise, large air volume heater and air conditioner
system
3. Improvement of heater performance using an in-air mixing
dumper

Improvements in opera- 1. Installation of dial type control with excellent operation

tion performance performance on the heater and air conditioner control panel
2. Incorporation of rear defogger switch with timer into the control
panel
3. Increase in panel display size
Reliable visual field 1. Achievement of ventilation system to defog windows by increasing
(improvement in safety) the outside air intake duct area on the front deck and adopting
a large air outlet
2. Windshield defogging speed improvement derived from increase
in air volume and wind speed by adopting a blower type defroster
and high performance heater
Improvements in fuel 1. Optimization of idle rotation speed according to air conditioner
economy load
2. Installation of sub-cooling type condenser
Global environment Adoption of a new refrigerant system
protection

Improvements in service 1. Improvement in service performance and reliability by adopting

quality an O-ring dropout prevention structure for the refrigerant lines.
2. Reduction of gas leakage and improvement in service
performance by incorporating condenser and receiver
3. Enhancement of the MUT-II compatible diagnostic function
SPECIFICATIONS
Item Specifications
Heater unit type Two-ray blow full air mix method
Heater control method Dial type
Air conditioner switch type Push button type
Compressor type MSC90C
Refrigerant
g Type R134a (HFC-134a)
Filled air volume g 550 ± 20
 EQUIPMENT – Heater and Air Conditioner 7-21
CONSTRUCTION DIAGRAM
Blower assembly

Liquid pipe B

Liquid pipe A

Suction flexible hose

Heater unit
Compressor

Suction pipe

Condenser fun

Condenser
Discharge flexible hose
7-22 EQUIPMENT – Heater And Air Conditioner

HEATER AND AIR CONDITIONER SYSTEM

CONSTRUCTION AND DESCRIPTION
BLOWER ASSEMBLY AND HEATER UNIT
The following blower assembly and heater unit has been adopted to increase air volume, reduce noise,
improve air-conditioning performance, as well as improve the car interior air environment.
D Installation of two-ray blow full air mix heater
D Incorporation of heater and cleaning unit
D Increase in the outside air intake duct area size of the blower assembly and optimization of the
shape
D Improvement of heater performance using an in-air mixing dumper

Outlet air changeover damper Motor for inside/outside

air changeover damper

Intake duct
Heater unit

Heater core

Air mix door Blower assembly

Evaporator
(Cooling unit)

Air thermometer sensor Inside and outside air

changeover damper
Resistor
In-air mixing
dumper Blower motor
 EQUIPMENT – Heater And Air Conditioner 7-23
Two-Ray Blow Full Air Mix Heater
Air flow passing
through heater In the heater unit, there are two rays of air;one which passes
core Air flow not
passing through the heater core, and air which does not pass through
through the core. One air mix door is used for temperature control.
heater core The two-ray blow full mix heater with low ventilation resistance
has increased air volume and has reduced noise.
Heater core
Air mix door

Evaporator

CONDENSER
The heat exchange efficiency has been improved with the
adoption of a sub-cooling type condenser added with a
sub-cooled section. The reduction of line unions by
incorporating the condenser and receiver has reduced a
Con-
denser possibility of gas leakage and has increased service
performance.
Su b- co o le d
s e cti o n

Vapor fluid separation device

COMPRESSOR CLUTCH WITH TEMPERATURE FUSE

When the compressor is locked, friction heat generated by
the contact of the compressor and the rotor melts the
temperature fuse incorporated into the field core and causes
the compressor clutch to be disengaged so that the
compressor clutch with temperature fuse can prevent the
drive belt from being damaged.
7-24 EQUIPMENT – Heater And Air Conditioner
HEATER AND AIR CONDITIONER CONTROL
Adoption of the following heater and air conditioner control has improved operation performance and
visual observation.
D Installation of dial type switch
D Incorporation of rear window defogger switch with timer
D Improved appearance by incorporating the center panel

Temperature
Outlet changeover Blower switch adjustment switch
switch

Rear window defogger Inside/outside air

switch changeover switch
Air-conditioner switch

VENTILATION SYSTEM
DESCRIPTION OF STRUCTURE AND OPERATION
The adoption of the following mechanism has increased air volume for ventilation and has achieved
a ventilation system for defogging windows.
D Increasing the outside air intake duct area
D Increasing the size of air outlet on the back of the rear bumper
D Installation of blower type defroster

To windshield
(Defroster) Blower type defroster
To front door window
(Side defroster)

Side ventilator Centre ventilator

To front door window
(Side defroster)

To driver seat
footwell Side ventilator

To passenger
seat footwell
 EQUIPMENT – Heater And Air Conditioner 7-25

Air outlet

RJST104003 - 170
NOTES