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GROUP INDEX

LANCER /

LANCER WAGON

WORKSHOP MANUAL

FOREWORD

This Workshop manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.

General . . . . . . . . . . . . . . . . . . . . . . . .

Engine. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . . .

Engine and Emission Control . . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . . .

Automatic Transmission. . . . . . . . . .

Front Axle. . . . . . . . . . . . . . . . . . . . . .

00

11

12

13

14

15

16

17

21

22

23

26

TECHNICAL INFORMATION MANUAL

PYME0302
PYME0302-A

WORKSHOP MANUAL

CHASSIS GROUP PWME0302
BODY REPAIR MANUAL

PBME0302
PBME0302-A

PARTS CATALOGUE

B606K005A_

All information, illustrations and product descriptions
contained in this manual are current as at the time of
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation.

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tyre . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . . .

Service Brakes. . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Power Steering . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

. . . . . . . . . .

Restraint System (SRS)

Chassis Electrical . . . . . . . . . . . . . . .

Heater, Air Conditioner and

. . . . . . .

Ventilation

Component Locations. . . . . . . . . . . .

27

31

32

33

34

35

36

37

42

51

52

54

55

70

Mitsubishi Motors Corporation May 2004

Configration Diagrams . . . . . . . . . . .

Circuit Diagrams . . . . . . . . . . . . . . . .

80

90

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WARNINGS REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

(1) Improper service or maintenance of any component of the SRS or any SRS-related component,

can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).

(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so

remove the SRS-ECU, driverís and front passengerís air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.

ï SRS-ECU, air bag module and clock spring 93°C or more
ï Seat belt with pre-tensioner: 90°C or more

(3) Service or maintenance of any SRS component or SRS-related component must be performed

only at an authorized MITSUBISHI dealer.

(4) MITSUBISHI dealer personnel must thoroughly review this Manual, and especially its GROUP

52B — Supplemental Restraint System (SRS), before beginning any service or maintenance of
any component of the SRS or any SRS-related component.

NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

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GROUP 17

ENGINE AND

EMISSION

CONTROL

CONTENTS

17-1

ENGINE CONTROL. . . . . . . . . .

GENERAL INFORMATION . . . . . . 17-2

SERVICE SPECIFICATIONS. . . . . 17-2

ON-VEHICLE SERVICE. . . . . . . . . 17-2

ACCEL CABLE CHECK AND

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 17-2

ACCELERATOR CABLE AND

PEDAL . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . 17-3

17-2

17-3

EMISSION CONTROL MPI . . . . 17-5

GENERAL INFORMATION . . . . . .

EMISSION CONTROL DEVICE

REFERENCE TABLE . . . . . . . . . .

SERVICE SPECIFICATION(S) . . . 17-5

VACUUM HOSE. . . . . . . . . . . . . . . 17-6

VACUUM HOSE PIPING DIAGRAM . . . 17-6

VACUUM CIRCUIT DIAGRAM . . . . . . . 17-7

VACUUM HOSE CHECK. . . . . . . . . . . . 17-8

VACUUM HOSE INSTALLATION . . . . . 17-8

CRANKCASE EMISSION CONTROL

SYSTEM. . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . . 17-8

17-5

17-5

17-8

COMPONENT LOCATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . . 17-9

POSITIVE CRANKCASE VENTILATION

SYSTEM CHECK . . . . . . . . . . . . . . . . . . 17-9

POSITIVE CRANKCASE VENTILATION

(PCV) VALVE CHECK . . . . . . . . . . . . . . 17-9

EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-9

GENERAL INFORMATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . . 17-9

COMPONENT LOCATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . . 17-10

PURGE CONTROL SYSTEM CHECK. . 17-10

PURGE PORT VACUUM CHECK . . . . . 17-11

PURGE CONTROL SOLENOID VALVE

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11

FUEL VAPOUR CANISTER REMOVAL

AND INSTALLATION . . . . . . . . . . . . . . . 17-12

EXHAUST GAS RECIRCULATION

(EGR) SYSTEM . . . . . . . . . . . . . . .

GENERAL INFORMATION

(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-13

COMPONENT LOCATION

(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-14

EGR SYSTEM CHECK . . . . . . . . . . . . . 17-15

EGR VALVE CHECK . . . . . . . . . . . . . . . 17-15

EGR PORT VACUUM CHECK <4G1>. . 17-16
EGR CONTROL SOLENOID VALVE

CHECK <4G1> . . . . . . . . . . . . . . . . . . . . 17-16

EGR CONTROL SOLENOID VALVE

CHECK <4G6> . . . . . . . . . . . . . . . . . . . . 17-17

EXHAUST GAS RECIRCULATION (EGR)
VALVE REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . 17-18

CATALYTIC CONVERTER . . . . . . 17-18

REMOVAL AND INSTALLATION . . . . . . 17-18

17-13

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17-2

ENGINE AND EMISSION CONTROL

ENGINE CONTROL

ENGINE CONTROL

GENERAL INFORMATION

M1171000100277

A cable-type accelerator mechanical
suspended-type pedal has been adopted.

SERVICE SPECIFICATIONS

M1171000300088

Item Standard value

Accel cable play mm 1.0 − 2.0

Engine idle speed r/min 4G1 750 ± 50

4G6 750 ± 100

ON-VEHICLE SERVICE

ACCEL CABLE CHECK AND

<4G1>

Adjusting bolts

Plate

ADJUSTMENT

M1171000900314

1. Turn A/C and lights OFF. Inspect and adjust at no
load.

2. Warm engine until stabilized at idle.

3. Confirm idle speed is at standard value.

Standard value:
750 ± 50 r/min <4G1>
750 ± 100 r/min <4G6>

Accel cable

<4G6>

Adjusting bolts

AC207966

AC

4. Stop engine. [ignition switch: LOCK (OFF)
position].

5. Confirm there are no sharp bends in the
accelerator cable.

6. Check the inner cable for correct slack.

Standard value: 1.0 − 2.0 mm

7. If there is too much slack or no slack, adjust play
by the following procedures.

Plate

Accel cable

AC301055

AC

(1) Loosen the adjusting bolts to release the

cable.

(2) Move the plate until the inner cable play is at

the standard value, and then tighten the
adjusting bolts.

(3) After adjusting, check that the throttle lever is

touching the stopper.

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ENGINE AND EMISSION CONTROL

ENGINE CONTROL

ACCELERATOR CABLE AND PEDAL

17-3

REMOVAL AND INSTALLATION

Post-installation Operation

Adjusting the Accelerator Cable (Refer to P.17-2).

<L.H. drive vehicles>

3

M1171001200341

2

5.0 ± 1.0 N·m

12 ± 2 N·m

10

1

7

9

7

N

5

4

<R.H. drive vehicles>

5.0 ± 1.0 N·m

2

Accelerator cable assembly
removal steps

1. Inner cable connection (Accelerator
pedal side)

2. Inner cable connection (Throttle body
side)

3. Accelerator cable assembly

8

13

N

12

6

Y1060AU

11

3

1

12 ± 2 N·m

9

7

13

11

12

6

N

Y1059AU

AC304070

AB

10

N

5

4

7

8

Accelerator pedal assembly
removal steps

1. Inner cable connection (Accelerator
pedal side)

4. Accelerator pedal assembly

5. Accelerator control equip nut

6. Accelerator pedal arm and
accelerator pedal pad assembly

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17-4

ENGINE AND EMISSION CONTROL

ENGINE CONTROL

Accelerator pedal assembly
removal steps (Continued)

7. Accelerator control equip bushing

8. Accelerator pedal arm return spring

9. Accelerator pedal arm stopper

INSTALLATION SERVICE POINT
>>A<< ACCEL PEDAL PAD

INSTALLATION

CAUTION

To p reve nt damag es to the ac c eler ator pe dal pad,
warm the thumb area of the accelerator pedal
pad with a dryer, etc. prior to assembling it.

NOTE: If it is difficult to assemble, apply soapy water
to the thumb area to enhance the assembling
process.

>>A<<

Accelerator pedal assembly
removal steps (Continued)

10. Accelerator pedal arm bracket

11. Ac c e l erator p edal a rm

12. Accelerator pedal pad

13. Accelerator pedal arm stopper

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ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

EMISSION CONTROL <MPI>

17-5

GENERAL INFORMATION

M1173000100370

The emission control system consists of the following
subsystems:

Items Name Specification

Crankcase emission control
system

Evaporative emission control
system

Exhaust emission control system Air-fuel ratio control device — MPI

Positive crankcase ventilation
(PCV) valve

Canister
Purge control solenoid valve

system

Exhaust gas recirculation system

• EGR valve

• EGR control solenoid valve

Catalytic converter Monolith type

• Crankcase emission control system

• Evaporative emission control system

• Exhaust emission control system

Varia b le flo w t yp e
(Purpose: HC reduction)

Equipped
Duty cycle type solenoid valve
(Purpose: HC reduction)

Oxygen sensor feedback type
(Purpose: CO, HC, NOx reduction)

Equipped
Single type
Duty cycle type solenoid valve
(Purpose: NOx reduction)

(Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE
REFERENCE TABLE

M1173006600135

Related parts Crankcase

emission
control
system

Evaporative
emission
control
system

Air/fuel ratio
control
system

Catalytic
converter

Exhaust gas
recirculation
system

PCV valve

Purge control solenoid valve

MPI system component

Catalytic converter

EGR valve

EGR control solenoid valve

×

×

××

SERVICE SPECIFICATION(S)

M1173000300288

Items Standard value

Purge control solenoid valve coil resistance (at 20°C) Ω 30 − 34

EGR control solenoid valve coil resistance (at 20°C) Ω 29 − 35

×

×

×

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17-6

VACUUM HOSE

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

VACUUM HOSE PIPING DIAGRAM

M1173000900417

<4G1>

To
fuel tank

Oxygen sensor
(front)

Catalytic
converter

Fuel pressure
regulator

Oxygen sensor (rear)

From
fuel pump

EGR valve

EGR control
solenoid valve

Air cleaner

Air

Canister

Purge control
solenoid valve

<4G6>

To
fuel tank

Oxygen sensor
(front)

Catalytic
converter

PCV valve

Fuel pressure
regulator

Catalytic
converter

From
fuel pump

EGR valve

Oxygen sensor (rear)

Catalytic
converter

EGR control
solenoid valve

Purge control
solenoid valve

Air cleaner

Canister

AK300964

AB

Air

AK204364

AC

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ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-7

VACUUM CIRC UIT DIA GRAM

<4G1>

To
combustion
chamber

L

Fuel
pressure
regulator

Vacuum hose colour

B: Black
G: Green
R: Red
Y: Yellow
L: Blue

EGR
valve

G

M1173007100263

Intake manifold

G

EGR
control
solenoid
valve

Throttle body

From
air
cleaner

G

R

Y

R

Purge
control
solenoid
valve

Canister

B

AK300765

AB

<4G6>

To
combustion
chamber

Fuel
pressure
regulator

Vacuum hose colour

B: Black
G: Green
R: Red
W: White
Y: Yellow
L: Blue

Intake manifold

L

G

EGR
control
solenoid

EGR
valve

valve

W

R

Throttle body

Y

B

B

Purge
control
solenoid
valve

From
air
cleaner

Canister

B

AK300766

AB

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17-8

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

VACUUM HOSE CHECK

M1173007300159

1. Using the piping diagram as a guide, check to be
sure that the vacuum hoses are correctly
connected.

2. Check the connection condition of the vacuum
hoses, (removed, loose, etc.) and check to be
sure that there are no bends or damage.

VACUUM HOSE INSTALLATION

M1173007200107

1. When connecting the vacuum hoses, they should
be securely inserted onto the nipples.

2. Connect the hoses correctly, using the vacuum
hose piping diagram as a guide.

CRANKCASE EMISSION CONTROL
SYSTEM

GENERAL INFORMATION (CRANKCASE
EMISSION CONTROL SYSTEM)

M1173005000237

The crankcase emission control system prevents
blow-by gases from escaping inside the crankcase
into the atmosphere.
Fresh air is sent from the air cleaner into the
crankcase through the breather hose.
The air becomes mixed with the blow-by gases
inside the crankcase.
The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
ventilation (PCV) valve.
The PCV valve lifts the plunger according to the
intake manifold vacuum so as to regulate the flow of
blow-by gas properly.
In other words, the blow-by gas flow is regulated
during low load engine operation to maintain engine
stability, while the flow is increased during high load
operation to improve the ventilation performance.

SYSTEM DIAGRAM

Ventilation hose

PCV valve

Breather hose

Air cleaner

AK204365

Air

AB

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ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-9

COMPONENT LOCATION (CRANKCASE
EMISSION CONTROL SYSTEM)

M1173007400208

<4G1>

PCV valve

AK300767

<4G6>

PCV valve

AK204366

AB

AC

POSITIVE CRANKCASE VENTILATION
(PCV) VALVE CHECK

M1173001200187

PCV valve

AK100010

AC

1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
side), and move the rod back and forth to check
that the plunger moves.

2. If the plunger does not move, there is a clogging
in the PCV valve. In this case, clean or replace
the PCV valve.

EVAPORATIVE EMISSION CONTROL
SYSTEM

POSITIVE CRANKCASE VENTILATION
SYSTEM CHECK

M1173001100179

1. Remove the ventilation hose from the PCV valve.

2. Remove the PCV valve from the rocker cover.

3. Reinstall the PCV valve at the ventilation hose.

4. Start the engine and run at idle.

PCV valve

AKX00336

5. Place a finger at the opening of the PCV valve
and check that vacuum of the intake manifold is
felt.

NOTE: At this moment, the plunger in the PCV
valve moves back and forth.

6. If vacuum is not felt, clean the PCV valve or
replace it.

AD

GENERAL INFORMATION (EVAPORATIVE
EMISSION CONTROL SYSTEM)

M1173005100405

The evaporative emission control system prevents
fuel vapours generated in the fuel tank from escaping
into the atmosphere.
Fuel vapours from the fuel tank flow through the fuel
tank pressure control valve and vapour pipe/hose to
be stored temporarily in the canister.
When driving the vehicle, fuel vapours stored in the
canister flow through the purge solenoid and purge
port and go into the intake manifold to be sent to the
combustion chamber.
When the engine coolant temperature is low or when
the intake air quantity is small (when the engine is at
idle, for example), the engine control unit turns the
purge solenoid off to shut off the fuel vapour flow to
the intake manifold.
This does not only insure the driveability when the
engine is cold or running under low load but also
stabilize the emission level.

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17-10

SYSTEM DIAGRAM

From
fuel
tank

Canister

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

Throttle body

Engine-ECU <4G1-M/T, 4G6>,
Engine-A/T-ECU <4G1-A/T>

OFF

Purge
control

ON

solenoid
valve

Battery

Control
relay

Manifold absolute pressure
(MAP) sensor <4G1>

Air flow sensor <4G6>

Engine coolant
temperature sensor

Intake air
temperature sensor

Barometric pressure
sensor <4G6>

COMPONENT LOCATION (EVAPORATIVE
EMISSION CONTROL SYSTEM)

M1173007500216

<4G1>

Purge control
solenoid valve

<4G6>

AK300769

AB

AK204367

PURGE CONTROL SYSTEM CHECK

M1173001400299

<4G1>

Vacuum hose

Plug

<4G6>

AK300771

Vacuum hose

Plug

AB

AC

Purge control
solenoid valve

AK300770

AB

AK300772

AB

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ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

1. Disconnect the vacuum hose (red stripe) from
throttle body and connect it to a hand vacuum
pump.

2. Plug the nipple from which the vacuum hose was
removed.

3. When the engine is cold or hot, apply a vacuum of
53 kPa, and check the condition of the vacuum.

17-11

Vac­uum

When engine is cold
(Engine coolant temperature: 40°C or less)

Engine condition Normal condition

At idle Vacuum is maintained.

3,000 r/min

When engine is hot
(Engine coolant temperature: 80°C or higher)

Engine condition Normal condition

At idle Vacuum is maintained.

3,000 r/min (within 3

Vacuum will leak.
minutes after engine
starts)

PURGE PORT VACUUM CHECK

M1173001500177

<4G1>

Vacuum hose

Plug

Engine speed (r/min)

AK100011

AC

3. Start the engine.

4. Check that a fairly constant negative pressure is
generated regardless of the engine speed.

5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.

PURGE CONTROL SOLENOID VALVE
CHECK

M1173001700193

NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.

A

AK300773

<4G6>

Vacuum hose

Plug

AK300774

AB

AB

1. Disconnect the vacuum hose (red stripe) from the
throttle body and connect a hand vacuum pump to
the nipple.

2. Plug the vacuum hose (red stripe).

Battery

AK100012

AC

AK100013

1. Disconnect the vacuum hose from the solenoid
valve.

2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).

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17-12

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

4. Check airtightness by applying a vacuum with
voltage applied directly from the battery to the
purge control solenoid valve and without applying
voltage.

FUEL VAPOUR CANISTER REMOVAL
AND INSTALLATION

M1173004200153

Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).

3

2

6

4

5

1

Battery voltage Normal condition

Applied Vacuum leaks

Not applied Vacuum maintained

5. Measure the resistance between the terminals of
the solenoid valve.

Standard value: 30 − 34 Ω (at 20°C)

8

7

Removal steps

1. Emission vacuum hose connection

2. Fuel vapour control line hose

3. Fuel vapour control check valve

4. Fuel vapour control line hose

AC208253

Removal steps (Continued)

5. Fuel vapour control line clamp

6. Fuel vapour canister

7. Fuel high-pressure hose clamp

8. Fuel vapour canister bracket

AD

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ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-13

EXHAUST GAS RECIRCULATION
(EGR) SYSTEM

GENERAL INFORMATION (EGR SYSTEM)

M1173005200327

The exhaust gas recirculation (EGR) system lowers
the nitrogen oxide (NOx) emission level.
When the air/fuel mixture combustion temperature is
high, a large quantity of nitrogen oxides (NOx) is
generated in the combustion chamber.
Therefore, this system recirculates part of emission
gas from the exhaust port of the cylinder head to the
combustion chamber through the intake manifold to
decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.

SYSTEM DIAGRAM

<4G1>

The EGR flow rate is controlled by the EGR valve so
as not to decrease the driveability.

OPERATION

The EGR valve is being closed and does not
recirculate exhaust gases under one of the following
conditions.
Otherwise, the EGR valve is opened and recirculates
exhaust gases.

• The engine coolant temperature is low.

• The engine is at idle.

• The throttle valve is widely opened.

EGR valve

OFF

ON

Battery

EGR
control
solenoid
valve

Control
relay

Engine-ECU <M/T>,
Engine-A/T-ECU <A/T>

Manifold absolute
pressure (MAP) sensor

Engine coolant
temperature sensor

Crank angle sensor

AK300775

AB

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17-14

<4G6>

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

EGR
control
Solenoid
valve

OFF

EGR valve

ON

Battery

COMPONENT LOCATION (EGR SYSTEM)

M1173007600224

<4G1>

EGR control
solenoid valve

Control
relay

<4G1>

Engine-ECU

Barometric pressure
sensor

Air flow sensor

Engine coolant
temperature sensor

Crank angle sensor

AK302349

EGR valve

AB

<4G6>

AK300776

EGR control
solenoid valve

AK300778

AB

AB

<4G6>

AK300777

EGR valve

AK300779

AB

AB

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ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-15

EGR SYSTEM CHECK

M1173002600348

<4G1>

Green stripe

Three-way
terminal

<4G6>

EGR valve

Three-way
terminal

Green stripe

AK300780

EGR valve

AK300781

1. Disconnect the vacuum hose (Green stripe) from
the EGR valve, and then connect a hand vacuum
pump via the three-way terminal.

2. When the engine is hot or cold, check the
condition of vacuum by racing the engine.

When engine is cold
(Engine coolant temperature: 20°C or less)

Throttle valve Normal vacuum condition

Open quickly No vacuum will generate (the

same as barometric pressure.)

When engine is hot
(Engine coolant temperature: 80°C or higher)

Throttle valve Normal vacuum condition

AB

AB

<4G1>

Green stripe

EGR valve

AK300782

<4G6>

Green stripe

EGR valve

AK300783

AB

AB

4. Connect the hand vacuum pump to the EGR
valve nipple.

5. Check whether the engine stalls or the idling is
unstable when a vacuum of 30 kPa or higher is
applied during idling.

EGR VALVE CHECK

M1173002800223

1. Remove the EGR valve and inspect for sticking,
carbon deposits, etc. If found, clean with a
suitable solvent so that the valve seats correctly.

2. Connect a hand vacuum pump to the EGR valve.

3. Apply 67 kPa of vacuum, and check that the
vacuum is maintained.

Open quickly It will momentarily rise over 13

kPa

3. Disconnect the three-way terminal.

AKX00348

4. Apply a vacuum and check the passage of air by
blowing through one side of the EGR passage.

Vacuum Passage of air

5.3 kPa or less Air is not blown out

27 kPa or more Air is blown out

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17-16

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

5. Replace the gasket, and tighten to the specified
torque.

Tightening torque:
<4G1> 21 ± 4 N⋅m
<4G6> 20 ± 2 N⋅m

EGR PORT VACUUM CHECK <4G1>

M1173002900167

Green strip

AK300784

1. Disconnect the vacuum hose (Green stripe) from
the throttle body EGR vacuum nipple and connect
a hand vacuum pump to the nipple.

2. Plug the vacuum hose (Green stripe).

Vac­uum

AB

1. Disconnect the vacuum hose (White stripe) from
the throttle body EGR vacuum nipple and connect
a hand vacuum pump to the nipple.

2. Plug the vacuum hose (White stripe).

Vac­uum

Engine speed (r/min)

AK100011

AC

3. Start the engine.

4. Check that a fairly constant negative is generated
regardless of the engine speed.

5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.

EGR CONTROL SOLENOID VALVE
CHECK <4G1>

M1173003100238

NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.

A

Engine speed (r/min)

AK201224AB

3. Start the engine and check that, after raising the
engine speed by racing the engine, purge vacuum
raises according to engine speed.

NOTE: If there is a problem with change in
vacuum, the throttle body purge port may be
clogged and require cleaning.

EGR PORT VACUUM CHECK <4G6>

M1173002900156

White stripe

AK300786

AB

B

Battery

AKX00351

AE

1. Disconnect the vacuum hose from the solenoid
valve.

2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).

4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the
EGR control solenoid valve and without applying
voltage.

Battery voltage Normal condition

Applied Vacuum leaks

Not applied Vacuum maintained

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ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

AKX00352

5. Measure the resistance between the terminals of
the solenoid valve.

Standard value: 29 − 35 Ω (at 20°C)

EGR CONTROL SOLENOID VALVE
CHECK <4G6>

M1173003100249

NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.

17-17

1. Disconnect the vacuum hose from the solenoid
valve.

2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).

4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the
EGR control solenoid valve and without applying
voltage.

Battery
voltage

Not applied Open Vacuum

Applied Open Vacuum leaks

B nipple

Normal condition

condition

maintained

Closed Vacuum

maintained

A

B

C

Battery

AK201251AB

5. Measure the resistance between the terminals of
the solenoid valve.

AK100016

Standard value: 29 − 35 Ω (at 20°C)

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17-18

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

EXHAUST GAS RECIRCULATION (EGR)
VALVE REMOVAL AND INSTALLATION

M1173010500175

Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).

<4G1>

<4G6>

21 ± 4 N·m

N

3

1

2

AC208130

AC

1

2

19 ± 3 N·m

Removal steps

1. Emission vacuum hose connection

CATALYTIC CONVERTER

REMOVAL AND INSTALLATION

M1173003900386

Refer to GROUP 15 — Exhaust Pipe and Main Muffler P.15-11.

N

3

Removal steps (Continued)

2. EGR valve

3. EGR valve gasket

AC301219

AC

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GROUP 13

FUEL

CONTENTS

MULTIPORT FUEL INJECTION (MPI) <4G1> . . . . . . . . . . . . . . 13A

MULTIPORT FUEL INJECTION (MPI) <4G6> . . . . . . . . . . . . . . 13B

13-1

FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C

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NOTES

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GROUP 32

POWER PLANT

MOUNT

CONTENTS

32-1

GENERAL INFORMATION . . . . . . . . 32-2

SERVICE SPECIFICATION . . . . . . . . 32-3

SPECIAL TOOL . . . . . . . . . . . . . . . . . 32-3

ENGINE MOUNTING . . . . . . . . . . . . . 32-4

REMOVAL AND INSTALLATION . . . . . . . . 32-4

TRANSMISSION MOUNTING . . . . . . 32-5

REMOVAL AND INSTALLATION . . . . . . . . 32-5

ENGINE ROLL STOPPER,

CENTERMEMBER . . . . . . . . . . . . . . . 32-7

REMOVAL AND INSTALLATION . . . . . . . . 32-7

CROSSMEMBER . . . . . . . . . . . . . . . . 32-8

REMOVAL AND INSTALLATION . . . . . . . . 32-8

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32-2

POWER PLANT MOUNT

GENERAL INFORMATION

GENERAL INFORMATION

The engine mounting system employs the inertial
axis four-point suspension method, which is field
proven.

• The optimised locations of the front and rear roll
mounts well distribute their loads thereby
reducing engine idling vibrations.

CONSTRUCTION DIAGRAM

Engine front
mounting bracket

• The fore-and-aft, liquid-filled engine mount of

M1321000100340

cylinder type is adopted to reduce engine shake
for improved riding comfort.

Transmission mounting
body side bracket

Engine front roll stopper bracket

Engine rear roll stopper bracket

Y0290AU

AC107318

AC303563

AB

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POWER PLANT MOUNT

SERVICE SPECIFICATION

SERVICE SPECIFICATION

Item Standard value

Protruding length of stabilizer link thread part mm 22 ± 1.5

SPECIAL TOOL

Tool Numb er Name Use

MB991897 Ball joint remover Knuckle and tie rod end ball joint

disconnection

NOTE: Steering linkage puller
(MB990635 or MB991113) is also

AC106827

available to disconnect knuckle and
tie rod end ball joint.

32-3

M1321000300333

M1321000600378

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32-4

POWER PLANT MOUNT

ENGINE MOUNTING

ENGINE MOUNTING

REMOVAL AND INSTALLATION

M1321001100440

CAUTION

*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal Operation

Raise the engine and transmission assembly until its weight
is not applied to the insulator, and support it securely.

<4G1> <4G6>

44 ± 10 N·m*

67 ± 7 N·m*

N

2

44 ± 10 N·m*

3

12 ± 2 N·m

1

67 ± 7 N·m*

N

2

3

AC303999 AC303968

Removal steps

1. Pressure hose clamp <4G6>

AC304304

Removal steps (Continued)

2. Self-locking nuts

3. Engine front mounting bracket

AB

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POWER PLANT MOUNT

TRANSMISSION MOUNTING

TRANSMISSION MOUNTING

32-5

REMOVAL AND INSTALLATION

M1321001400430

CAUTION

*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal Operation

• Raise the engine and transmission assembly until its
weight is not applied to the insulator, and support it
securely.

• Battery and Battery tray Removal

• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner

P.15-3).

• Engine Rear Roll Stopper Bracket Removal (Refer to

P.32-7).

<M/T> <A/T>

80 ± 7 N·m*

Post-installation Operation

• Engine Rear Roll Stopper Bracket Installation (Refer to

P.32-7).

• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner

P.15-3).

• Battery and Battery tray Installation

80 ± 7 N·m*

2

>>A<<

1

Removal steps

1. Transmission mounting body side
bracket

2. Transmission mounting stopper

47 ± 7 N·m*

2

AC303988

47 ± 7 N·m*

2

2

1

AC303989

AC304258

AB

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32-6

POWER PLANT MOUNT

TRANSMISSION MOUNTING

INSTALLATION SERVICE POINT
>>A<< TRANSMISSION MOUNTING

STOPPER INSTALLATION

Engine side

Transmission
mounting body
side bracket

Transmission
mounting
stopper

AC200645

AB

Install the transmission mounting stopper so that its
arrow points upward.

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POWER PLANT MOUNT

ENGINE ROLL STOPPER, CENTERMEMBER

ENGINE ROLL STOPPER, CENTERMEMBER

32-7

REMOVAL AND INSTALLATION

M1321002300287

CAUTION

*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal and Post-installation Operation

Under Cover Removal and Installation

45 ± 5 N·m*

7

<4G1> <4G6>

45 ± 5 N·m*

1

3

2

45 ± 5 N·m*

5

52 ± 7 N·m*

11 ± 1 N·m

69 ± 10 N·m

6

52 ± 7 N·m*

3

>>B<<

>>A<<

52 ± 7 N·m*

4

69 ± 10 N·m

Engine front roll stopper bracket
and centermember removal
steps

1. Engine front roll stopper bracket
connecting bolt
Centermember and engine front roll

•

stopper bracket assembly

2. Engine mounting cushion stopper
<4G6>

3. Engine front roll stopper bracket

4. Centermember

1

69 ± 10 N·m

5. Engine rear roll stopper bracket

6. Transmission case rear roll stopper

7. Engine rear roll stopper bracket

AC303978

AC304309

Engine rear roll stopper bracket
removal steps

connecting bolt

bracket

AB

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32-8

POWER PLANT MOUNT

CROSSMEMBER

INSTALLATION SERVICE POINTS
>>A<< ENGINE FRONT ROLL STOPPER

BRACKET INSTALLATION

Hole

>>B<< ENGINE MOUNTING CUSHION
STOPPER INSTALLATION <4G6>

Engine mounting
cushion stopper

Hole

Front of vehicle

AC005918

AC

Install the engine front roll stopper bracket so that its
hole points towards the front side of the vehicle.

Install the engine mounting cushion stopper as
shown.

Front of vehicle

AC304315

AB

CROSSMEMBER

REMOVAL AND INSTALLATION

CAUTION

• Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B ­Service Precautions P.52B-5, Air bag Module and Clock Spring P.52B-210. Also, set the front
wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this,
the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.

1

: Indicates parts which should be initially tightened, and then fully tightened after placing the

• *
vehicle horizontally and loading the full weight of the engine on the vehicle body.

2

: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle

• *
on the earth in the unladen condition.

Pre-removal Operation

• Centermember Removal (Refer to P.32-7).

• Front Exhaust Pipe Removal (Refer to GROUP 15,

Exhaust Pipe and Main Muffler P.15-11).

• Stee ring Wheel Air Bag Module Assembly Removal
(Refer to GROUP 37, Steering Wheel P.37-17).

• Power Steering Fluid Draining (Refer to GROUP 37,
On-vehicle Service P.37-13).

M1321003200368

Post-installation Operation

• Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-11).

• Centermember Installation (Refer to P.32-7).

• Clock Spring Centring (Refer to GROUP 52B, Air Bag

Modules and Clock Spring P.52B-210).

• Steering Wheel Air Bag Module Assembly Installation
(Refer to GROUP 37, Steering Wheel P.37-17).

• Power Steering Fluid Supplying (Refer to GROUP 37,
On-vehicle Service P.37-13).

• Power Steering Fluid Line Bleeding (Refer to GROUP 37,
On-vehicle Service P.37-13).

• Press the dust cover with a finger to check whether the
dust cover cracked or damaged.

• Checking Steering Wheel Position with Wheels Straight
Ahead.

• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service P.33-5).