00-1

GENERAL
CONTENTS

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 3 Points to Note for Intermittent Malfunctions . . . . 13

Scope of Maintenance, Repair and Servicing
Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PRECAUTIONS BEFORE SERVICE . . . . . . . 15
Indication of Tightening Torque . . . . . . . . . . . . . . . . 3
Explanation of Manual Contents . . . . . . . . . . . . . . . 4 SUPPORT LOCATIONS FOR LIFTING AND
JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HOW TO USE Garage Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING/INSPECTION SERVICE Axle Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Single-post and Double-post Lift . . . . . . . . . . . . . . 19
Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . 6
Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPECIAL HANDLING INSTRUMENTS FOR
How to Use the Inspection Procedures . . . . . . . 10 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connector Measurement Service Points . . . . . . . 11
BRAKE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection Service Points for a Blown Fuse . . . 13 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . 22
00-2
NOTES
 GENERAL – How to Use This Manual 00-3
HOW TO USE THIS MANUAL
SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS
AND SERVICING EXPLANATIONS STANDARD VALUE
This manual provides explanations, etc. concerning Indicates the value used as the standard for judging
procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection
and servicing of the subject model. Note, however, or the value to which the part or assembly is
that for engine and transmission-related component corrected and adjusted. It is given by tolerance.
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and LIMIT
installation procedures for major components. Shows the standard for judging the quality of a
For detailed information concerning the inspection, part or assembly on inspection and means the
checking, adjustment, disassembly and reassembly maximum or minimum value within which the part
of the engine, transmission and major components or assembly must be kept functionally or in strength.
after they have been removed from the vehicle, It is a value established outside the range of
please refer to separate manuals covering the standard value.
engine and the transmission.
REFERENCE VALUE
ON-VEHICLE SERVICE
Indicates the adjustment value prior to starting the
“On-vehicle Service” is procedures for performing work (presented in order to facilitate assembly and
inspections and adjustments of particularly adjustment procedures, and so they can be
important locations with regard to the construction completed in a shorter time).
and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage, CAUTION
etc.) must also be performed. Indicates the presentation of information particularly
INSPECTION vital to the worker during the performance of
maintenance and servicing procedures in order to
Under this title are presented inspection and avoid the possibility of injury to the worker, or
checking procedures to be performed by using damage to component parts, or a reduction of
special tools and measuring instruments and by component or vehicle function or performance, etc.
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be INDICATION OF TIGHTENING TORQUE
performed as well. The tightening torque shown in this manual is a
basic value with a tolerance of ±10% except the
following cases when the upper and lower limits
of tightening torque are given.
(1) The tolerance of the basic value is within ±10%.
(2) Special bolts or the like are in use.
(3) Special tightening methods are used.
00-4 GENERAL – How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed

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

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

Indicates (by symbols) where lubrica-

tion is necessary.

Maintenance and Servicing Procedures

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

Classifications of Major Maintenance/Service Points

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

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for lubrica- : Grease

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

: Brake fluid or automatic transmission fluid

: Engine oil, gear oil or air conditioner com-

pressor oil

: Adhesive tape or butyl rubber tape

 GENERAL – How to Use This Manual 00-5

Indicates the Indicates the Indicates the Indicates the

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

Denotes non-reus-
able part.

Denotes tightening torque.

For bolts and nuts which do not
have a tightening torque listed,
refer to the “Tightening torque”.

Repair kit or set parts

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

Operating procedures, cau-

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

indicates that there is

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

The title of the page (following

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

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

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

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

Diagnosis method

Gathering information
from the customer.

Check trouble symptom.

Reoccurs Does not reoccur.

Read the diagnosis code Read the diagnosis code

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

Refer to the INSPECTION After taking note of the

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

Recheck trouble symptom.

Read the diagnosis codes.

Diagnosis code No diagnosis
displayed. code

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

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

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

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

6. INSPECTION CHART FOR TROUBLE SYMPTOMS

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

7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM

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

8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgement values have been provided in this chart as reference information.

9. CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspection items and standard values have been provided
in this chart as reference information.

10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE

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

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

WHEN USING THE WARNING LAMP

1. Use the special tool to earth No.1 terminal (diagnosis
Diagnosis connector
control terminal) of the diagnosis connector.
2. To check ABS system, remove the valve relay.
NOTE
That is because the valve relay is off and the warning
lamp remains illuminated if there is a fault in the ABS
system.
MB991529 3. Turn on the ignition switch.
4. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems
System name Warning lamp name

MPI Engine warning lamp

AYC AYC warning lamp

ABS ABS warning lamp

Indication of diagnosis code by warning lamp
When the diagnosis code No.24 is output When no diagnosis code is output*

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

NOTE
*: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to
be output.

Earth terminal WHEN USING THE VOLTMETER

Use the special tool to connect the diagnosis output terminals
and the earth terminal of the diagnosis connector to a voltmeter
and take a reading of the diagnosis codes from the movement
Full-auto air con- of the needle.
ditioner terminal
Voltmeter connection terminals

System name Positive connection Negative connec-

terminal tion terminal
MB991529
Full-auto air 11 4 or 5
conditioner
 GENERAL – How to Use Troubleshooting/Inspection Service Points 00-9
Diagnosis result display method when using a voltmeter
Example of diagnosis code voltage wave pattern for Normal voltage wave pattern
diagnosis code No. 24

0.5 sec.
1.5 secs. 0.5 sec. 0.5 sec.
12V
0V 12 V
Tens Place Units 0V
Pause
time 3 signal division signal
secs. 2 secs.

METHOD OF ERASING DIAGNOSIS CODES

WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and erase the diagnosis code.
Caution
Turn off the ignition switch before connecting or disconnecting the MUT-II.
WHEN NOT USING THE MUT-II
(1) Turn the ignition switch to OFF.
(2) After disconnecting the battery cable from the battery (–) terminal for 10 seconds or more, reconnect
the cable.
(3) After the engine has warmed up, run it at idle for about 15 minutes.
INPUT SIGNAL INSPECTION POINTS <VEHICLES
WITH ETACS-ECU>
MUT-II
WHEN USING THE MUT-II
1. Connect the MUT-II to the diagnosis connector.
Caution
The MUT-II should be connected or disconnected after
turning the ignition switch to the OFF position.
2. If buzzer of the MUT-II sounds once when the each switch
is operated (ON/OFF), the ETACS-ECU input signal for
that switch circuit system is normal.

Earth terminal WHEN USING VOLTMETER

1. Use the special tool to connect a voltmeter between
the earth terminal (No. 4 or 5) and the ETACS terminal
(No. 9) of the diagnosis connector.
ETACS terminal 2. If the voltmeter indicator deflects once when the each
switch is operated (ON/OFF), the ETACS-ECU input signal
for that switch circuit system is normal.

MB991529
00-10 GENERAL – How to Use Troubleshooting/Inspection Service Points

HOW TO USE THE INSPECTION PROCEDURES

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

1. Comments on the diagnosis code or trouble

symptom above.
CHECKING PROCEDURE 4

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

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

3. Detailed inspection procedures (methods)

such as component inspection and circuit
inspection are listed on a separate page, and
OK are given here for reference.
MUT-II Data list
17 Control mode selection switch
OK: Voltage changes between approx. 0V → approx.
2.5V → approx. 5V when the switch is operated.
NG
4. Indicates voltage and resistance to be measured at a particular
ECU switch component inspection (Refer to P.3-44.) NG connector.
(Refer to Connector Measurement Service Points.)
OK The connector position can be located in the wiring diagram in the
Measure at switch connector A-44
OK electrical wiring manual by means of this symbol.
D Disconnect the connector, and measure at the harness Indicates operation and inspection procedures, inspection terminals
side. and inspection conditions.
D Voltage between terminal 6 – earth and terminal 8 – Indicates the OK judgement conditions.
earth
OK: Approx. 5V
OK
Check the following connector. A-44
NG
Repair
OK
5. Inspect the contact condition at each connector terminal.
Check trouble symptom. (Refer to Connector Inspection Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Caution
Replace the ECS-ECU.
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.

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

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

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

HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses.
For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown
Fuse.”
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure
from the beginning.
 GENERAL – How to Use Troubleshooting/Inspection Service Points 00-11
CONNECTOR MEASUREMENT SERVICE POINTS
Turn the ignition switch to OFF when connecting disconnecting
the connectors, and turn the ignition switch to ON when
measuring if there are no instructions to be contrary.

Harness connector IF INSPECTING WITH THE CONNECTOR CONNECTED

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

Ordinary (non-waterproof) Connectors

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

Connector

IF INSPECTING WITH THE CONNECTOR DISCONNECTED

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

<When Inspecting a Male Pin>

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

Connector disconnected or improperly CONNECTOR INSPECTION

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

Defective connector contact

Harness wire breakage

at terminal section

Low contact pressure

CONNECTOR PIN INSPECTION

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

CONNECTOR ENGAGEMENT INSPECTION

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

POINTS TO NOTE FOR INTERMITTENT

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

MODELS
<LANCER EVOLUTION-IV>
Model Class Model Grade Engine model Transmission Fuel supply
code code year model system

E-CN9A SNDF ’97 RS 4G63 (2,000-DOHC – W5M51 Electronically

16 valves-intercooler (4WD-5M/T) controlled fuel
SRGF ’97 GSR turbo) injection (MPI)

Applicable serial numbers

E-CN9A: CN9A – 0000001 Y

<LANCER EVOLUTION-V>
Model Class Model Grade Engine model Transmission Fuel supply
code code year model system

GF-CP9A SNDF ’98 EVOLUTION-V RS 4G63 (2,000-DOHC – W5M51 MPI

16 valves-intercooler
valves intercooler (4WD 5M/T)
(4WD-5M/T)
SNGF ’98 EVOLUTION-V turbo)
GSR

Applicable serial numbers

GF-CP9A: CP9A – 0000001 Y
<LANCER EVOLUTION-VI>
Model Class Model Grade Engine model Transmission Fuel supply
code code year model system

GF-CP9A SNDF ’99 EVOLUTION-VI 4G63 (2,000-DOHC – W5M51 MPI

RS 16 valves-intercooler (4WD-5M/T)
turbo)
SNGF ’99 EVOLUTION-VI
GSR

Applicable serial numbers

GF-CP9A: CP9A – 0100001 Y
 GENERAL – Precautions Before Service 00-15
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Always use the designated special tools and test equipment.
(3) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(4) Never attempt to disassemble or repair the SRS components. (SRS air bag control unit, air bag
module and clock spring.) If faulty, replace it.
(5) Warnings labels must be needed when servicing and handling SRS components. Warning labels
are located in the following locations.
D Sun visor
D Glove box
D SRS air bag control unit
D Steering wheel
D Steering gear and linkage
D Air bag module
D Clock spring
(6) Store components removed from the SRS in a clean and dry place.
The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upwards.
(7) Be sure to deploy the air bag before disposing of air bag module or disposing of a vehicle equipped
with an air bag. (Refer to GROUP 52B – Air Bag Module Disposal Procedures.)
(8) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
2. Observe the following when carrying out operations on place where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93_C, so remove the SRS components
before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.
00-16 GENERAL – Precautions Before Service

SERVICING THE ELECTRICAL SYSTEM

Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
(–) cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connecting or disconnecting the negative (–) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)

APPLICATION OF ANTI-CORROSION AGENTS

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

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

VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
Approx. equipment is used to wash the vehicle, be sure to note the
40 cm following information in order to avoid damage to plastic
components, etc.
D Spray nozzle distance: Approx. 40 cm or more
D Spray pressure: 3,900 kPa or less
D Spray temperature: 82_C or less
D Time of concentrated spray to one point: within 30 sec.
 GENERAL – Precautions Before Service 00-17

MUT-II
MUT-II
sub-assembly Refer to the MUT-II INSTRUCTION MANUAL for instructions
on handling the MUT-II.

ROM pack

Connect the MUT-II to the diagnosis connector as shown

in the illustration.
Caution
Connection and disconnection of the MUT-II should
always be made with the ignition switch in the OFF
position.
00-18 GENERAL – Support Locations for Lifting and Jacking

SUPPORT LOCATIONS FOR LIFTING AND JACKING

GARAGE JACK
Caution
Do not support the vehicles at locations other than specified supporting points. Neglecting this
will cause damage, etc.

Caution
Never support the rear floor
crossmember.
 GENERAL – Support Locations for Lifting and Jacking 00-19
AXLE STANDS

Notch
Notch

Rubber
Rubber

SINGLE-POST AND
DOUBLE-POST LIFT

Notch Notch
00-20 GENERAL – Special Handling Instruments for Towing

SPECIAL HANDLING INSTRUMENTS FOR TOWING

Towing methods Remarks

If a tow truck is used D For 4WD models, the basic principle is that all
Lifting method for 4 wheels – Good four wheels are to be raised before towing.
D The shift lever should be set to 1st gear and
the parking brake should be applied.

Front wheels lifted – No good D The vehicle must not be towed by placing only
its front wheels or only the rear wheels on a
rolling dolly, because to do so will result in
deterioration of the viscous coupling and result
in the viscous coupling causing the vehicle to
jump forward suddenly.

D If only the front wheels or only the rear wheels

Front wheels lifted – No good
are lifted for towing, the bumper will be damaged.
In addition, lifting of the rear wheels causes
the oil to flow forward, and may result in heat
damage to the rear bushing of the transfer, and
so should never be done.

Rear wheels lifted – No good

D The front and rear wheels must rotate normally.

Towing by rope or cable – Good D Both running and driving systems must function
normally.
D The shift lever must be set to the neutral position
and the ignition key must be set to “ACC”.
 GENERAL – Brake Test 00-21
BRAKE TEST
In order to stabilize the viscous coupling’s dragging force,
the brake test should always be conducted after the
speedometer test.
FRONT WHEEL MEASUREMENTS
1. Place the front wheels on the brake tester.
2. Perform the brake test.
Brake tester Caution
The rear wheels should remain on the ground.
3. If the brake dragging force exceeds the specified value,
jack up the vehicle and manually rotate each wheel to
check the rotation condition of each wheel.
NOTE
If the brake dragging force exceeds the specified value,
the cause may be the effect of the viscous coupling’s
dragging force, so jack up the front wheels and check
the rotation condition of the wheels in this state for no
effect by the viscous coupling’s dragging force.
REAR WHEEL MEASUREMENTS
After placing the rear wheels on the brake tester, follow the
same procedures as for the front wheel measurements.
00-22 GENERAL – Tightening Torque

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

Standard bolt and nut tightening torque

Thread size Torque Nm

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

M5 0.8 2.5 4.9 5.9

M6 1.0 4.9 8.8 9.8

M8 1.25 12 22 25

M10 1.25 24 44 52

M12 1.25 41 81 96

M14 1.5 72 137 157

M16 1.5 111 206 235

M18 1.5 167 304 343

M20 1.5 226 412 481

M22 1.5 304 559 647

M24 1.5 392 735 853

Flange bolt and nut tightening torque

Thread size Torque Nm

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

M6 1.0 4.9 9.8 12

M8 1.25 13 24 28

M10 1.25 26 49 57

M10 1.5 24 44 54

M12 1.25 46 93 103

M12 1.75 42 81 96