Mitsubishi MOTORS Lancer Evolution VIII 2003 Technical document

GROUP INDEX

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

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

Lubrication . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Engine and Emission Control . . . . .

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

Manual Transaxle . . . . . . . . . . . . . . .

Propeller Shaft . . . . . . . . . . . . . . . . .

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

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

Wheel and Tire . . . . . . . . . . . . . . . . .

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

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

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

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

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

Steering . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2003

MITSUBISHI

LANCER

EVOLUTION VIII

TECHNICAL

INFORMATION

MANUAL

FOREWORD

This manual has been prepared as an introduction to

the specifications, features, construction, functions,

and other areas of the new 2003 LANCER EVOLU-

TION VIII. It includes Technical Information and Body

Repair Service. The Body Repair sections immediate-

ly follow Group 55 - Heater, Air Conditioning and Ven-

tilation.

Please read this manual carefully so that it will be of

assistance for your service and sales activities. Please

note the following service manuals are also available

and should be used in conjunction with this manual.

SERVICE MANUAL MSSP-206B-2003

PARTS CATALOG BUM6K103A

No part of this publication may be reproduced, stored in any retrieval

system of transmitted, in any form or by any means, including but not

limited to electronic, mechanical photocopying, recording or otherwise,

without the prior written permission of Mitsubishi Motors Corporation.

!2003 Mitsubishi Motors Corporation

All Rights, Reserved

Printed in USA

MSSP-260B-2003

Interior and Supplemental

Restraint System (SRS) . . . . . . . . . .

Heater, Air Conditioning

and Ventilation . . . . . . . . . . . . . . . . .

52B-1

GROUP 52B

SUPPLEMENTAL

RESTRAINT

SYSTEM (SRS)

CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 52B-2

SYSTEM OPERATION. . . . . . . . . . . . 52B-7

SRS-ECU . . . . . . . . . . . . . . . . . . . . . . 52B-10

GENERAL DESCRIPTION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

52B-2

GENERAL DESCRIPTION

M2521000100132

CAUTION

•Driver and front passenger air bags and seat belt pre-tensioners deploy and operate in all head-on

collisions that exceed the threshold to activate the SRS system.

•The specific value is the equivalent impact when a vehicle collides against a concrete (fixed) wall

at approximately 25 km/h (16 mph) or more.

•The SRS and pre-tensioner may not work under the following conditions:

•A head-on collision is less than the specific value.

•A vehicle collides on its rear end.

•A vehicle rolls over or is in a similar position.

Driverís and front passengerís air bags and seat

belts with pre-tensioner are standard, increasing the

passive safety level.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

The SRS is designed to supplement the front seat

belts. It eliminates or reduces or injury to the front

passenger(s) by deploying air bag(s) in case of a

head-on collision.

SEAT BELT WITH PRE-TENSIONER

The seat belts with pre-tensioner work simulta-

neously with the SRS. The pre-tensioner takes up

seat belt slack immediately when a collision takes

place by that restraining the front passengers sooner

than the SRS. This prevents the passengers from

moving forwards.

AC211587AB

PASSENGER'S

(FRONT) AIR BAG

DRIVER'S AIR BAG

SEAT BELT PRE-TENSIONER

GENERAL DESCRIPTION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-3

CONSTRUCTION DIAGRAM

The SRS and seat belt tightening systems consist of

driverís/passenger air bag modules, SRS-ECU, two

front impact sensors, SRS warning light, clock

spring, and seat belt pre-tensioner. Air bags are

located in the center of the steering wheel and above

the glove box. Each air bag has a safing folded air

bag and an inflators the system and has a safing G

sensor and an analogue G sensor. On all air bag

modules, the inflator does not contain sodium azide.

The front impact sensor is assembled on the head-

light support panel to monitor collision upon frontal

impact. The warning light on the instrument panel

indicates the operational status of the SRS. A clock

spring is installed in the steering column.

The SRS-ECU detects the impact produced at the

time of a collision from the safing and analog G sen-

sors and supplies squib ignition current to the air bag

modules.

The SRS-ECU has the following functions:

This triggers the air bag modules.

•Power supply backup function (backup con-

denser) that deploys or operates the air bag mod-

ule and seat belt pretensioner within specific

period, in case of power failure upon impact.

•Voltage raising function (DC-DC converter cir-

cuit).

•Diagnostic test mode to improve safety and reli-

ability.

AC211592

VEHICLES

IDENTIFICATION

CODE CHART

PLATE

SRS WARNING LIGHT

DRIVER'S AIR

BAG MODULE

CLOCK SPRING

DATA LINK

CONNECTOR

(FOR SCAN

TOOL) SRS-ECU

PASSENGER'S (FRONT)

AIR BAG MODULE

SEAT BELT WITH

PRE-TENSIONER

RADIATOR

FRONT IMPACT SENSOR

GENERAL DESCRIPTION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

52B-4

SRS SYSTEM CIRCUIT DIAGRAM

AC211582

MICRO

PROCESSOR

FRONT AIR

BAG

ANALOG

G-SENSOR

CONNECTOR

LOCK

DETECTION

CIRCUIT

CONNECTOR

LOCK

DETECTION

CIRCUIT

SCAN TOOL

INTERFACE

CIRCUIT

BACK UP

CAPACITOR

DC-DC

CONVERTER

POWER

SOURCE

CIRCUIT FOR

SIDE-AIRBAG

FRONT AIR BAG

SAFING

G-SENSOR

WARNING

LIGHT

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

AIR BAG

DRIVE

CIRCUIT

FRONT

IMPACT

SENSOR

INTERFACE

CIRCUIT

DATA LINK

CONNECTOR

(FOR SCAN

TOOL)

OFF

CONNECTOR

LOCK SWITCH*

IGNITION SWITCH (IG1)

No.2

7.5A

No.3

7.5A

COMBINATION

METER (SRS

WARNING LIGHT)

OFF

CONNECTOR LOCK

SWITCH*

DRIVER'S

AIR BAG

MODULE

CLOCK SPRING

OFF

ON ON

PASSENGER'S

(FRONT) AIR BAG

MODULE OFF

OFF

CONNECTOR

LOCK SWITCH*

OFF

CONNECTOR

LOCK SWITCH*

SEAT BELT

PRE-TENSIONER

(LH)

SEAT BELT

PRE-TENSIONER

(RH) OFF

OFF CONNECTOR

LOCK SWITCH*

(LH) (RH)

FRONT IMPACT

SENSOR

CONNCTOR LOCK

SWITCH*

OFF

NOTE

*: CONNECTOR LOCKED: ON

CONNECTOR UNLOCKED: OFF

GENERAL DESCRIPTION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-5

CAUTION LABELS

Labels to indicate cautions regarding the handling

and the services of SRS air bag air attached on the

position shown in the following illustration.

AC211604AB

COVER CLOCK SPRING

PASSENGER'S (FRONT)

AIR BAG MODULE

SRS-ECU

SUN VISOR

STEERING JOINT COVER

GLOVE BOX

SEAT BELT WITH

PRE-TENSIONER

(DRIVER'S AND FRONT

PASSENGER'S SEATBELT)

FRONT IMPACT SENSOR

GENERAL DESCRIPTION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

52B-6

LABEL CONTENTS

A WARNING: SRS

BEFORE REPLACING STEERING WHEEL, READ SERVICE MANUAL. THIS AIR BAG

MODULE CANNOT BE REPAIRED.

DO NOT DISASSEMBLE OR TAMPER.

B CAUTION: SRS CLOCK SPRING

THIS IS NOT A REPAIRABLE PART. IF DEFECTIVE, REPLACE ENTIRE UNIT

ACCORDING TO THE SERVICE MANUAL INSTRUCTIONS. TO RE-CENTER: ROTATE

CLOCKWISE UNTIL TIGHT. THEN ROTATE IN OPPOSITE DIRECTION ROUGHLY 3

TURNS AND ALIGN ARROWS >><<.

C WARNING FLAMMABLE/EXPLOSIVE SRS AIR BAG MODULE

TO AVOID SERIOUS INJURY:

•DO NOT REPAIR, DISASSEMBLE OR TAMPER.

•AVOID CONTACT WITH FLAME OR ELECTRICITY.

•DO NOT DIAGNOSIS/USE NO TEST EQUIPMENT OR PROBES.

•STORE BELOW 200°F (93°C).

•BEFORE DOING ANY WORK INVOLVING MODULE, READ SERVICE MANUAL

FOR IMPORTANT FURTHER DATA.

DCAUTION:

DO NOT DISASSEMBLE OR DROP. IF DEFECT REFER TO SERVICE MANUAL.

E WARNING

DEATH or SERIOUS INJURY can occur

•Children 12 and under can be killed by the air bag.

•The BACK SEAT is the SAFEST place for children.

•NEVER put a rear-facing child seat in the front.

•Sit as far back as possible from the air bag.

•ALWAYS use SEAT BELTS and CHILD RESTRAINTS.

F AIR BAG SYSTEM INFORMATION

THIS VEHICLE HAS AN AIR BAG SYSTEM WHICH WILL SUPPLEMENT THE SEAT

BELT IN CERTAIN FRONTAL COLLISIONS. THE AIR BAG IS NOT A SUBSTITUTE FOR

THE SEAT BELT IN ANY TYPE OF COLLISION. THE DRIVER AND ALL OTHER

OCCUPANTS SHOULD WEAR SEAT BELTS AT ALL TIME.

WARNING!

IF THE "SRS" WARNING LIGHT DOES NOT ILLUMINATE FOR SEVERAL SECONDS

WHEN IGNITION KEY IS TURNED TO "ON" OR THE ENGINE IS STARTED, OR IF THE

WARNING LIGHT STAYS ON WHILE DRIVING, TAKE THE VEHICLE TO YOUR

NEAREST AUTHORIZED DEALER IMMEDIATELY. ALSO, IF VEHICLE'S FRONT END

IS DAMAGED OR IF THE AIR BAG HAS DEPLOYED, TAKE THE VEHICLE FOR

SERVICE IMMEDIATELY.

THE AIR BAG SYSTEM MUST BE INSPECTED BY AN AUTHORIZED DEALER TEN

YEARS AFTER THE VEHICLE MANUFACTURE DATE SHOWN ON THE

CERTIFICATION LABEL LOCATED ON THE LEFT FRONT DOOR-LATCH POST OR

DOOR FRAME.

READ THE "SRS" SECTION OF YOUR OWNER'S MANUAL BEFORE DRIVING FOR

IMPORTANT INFORMATION ABOUT OPERATION AND SERVICE OF THE AIR BAG

SYSTEM.

WHEN YOU ARE GOING TO DISCARD YOUR GAS GENERATOR OR VEHICLE,

PLEASE SEE YOUR DEALER.

SYSTEM OPERATION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-7

SYSTEM OPERATION

M2521001000116

A passengerís (front) air bag module and clock

spring are the same as OUTLANDER.

DRIVERíS AIR BAG MODULE

CAUTION

Never disassemble the air bag module.

The driverís air bag module is incorporated into the

3-spoke steering wheel. The driverís air bag module

is an assembly part consisting of air bag, module

cover, inflator, and its their fasteners. It is installed

into the steering wheel. The air bag is made from

nylon and inflates by the gas generating from the

inflator. As a driver is being pressed to the air bag, it

deflates discharging gas from two vents at the rear of

the air bag to reduce the shock from the impact. An

inflator that does not contain sodium azide is used.

G WARNING

CHILDREN CAN BE KILLED OR INJURED BY PASSENGER AIR BAG. THE BACK

SEAT IS THE SAFEST PLACE FOR CHILDREN 12 AND UNDER. MAKE SURE ALL

CHILDREN USE SEAT BELTS OR CHILD SEAT. NOT TO BE REMOVED EXCEPT BY

OWNER.

H CAUTION: SRS

FIX STRG. WHEEL AT TIRES STRAIGHT AHEAD BEFORE GEARBOX REMOVAL.

OTHERWISE, MAY DAMAGE SRS CLOCK SPRING MAKING SRS SYSTEM IN

OPERATIVE. RISKING SERIOUS DRIVER INJURY.

I DANGER SEAT BELT PRETENSIONER

CAUTION THIS ASSEMBLY CONTAINS AN EXPLOSIVE INITIATOR

FLAMMABLE MATERIAL

TO PREVENT PERSONAL INJURY

•DO NOT IMPACT, DISMANTLE OR INSTALL IT INTO ANOTHER VEHICLE.

•SERVICE OR DISPOSE OF IT AS DIRECTED IN THE REPAIR MANUAL.

JCAUTION:

DO NOT DISASSEMBLE OR DROP.

LABEL CONTENTS

AC211615AB

AIR BAG MODULE

SECTION A - A

INFLATOR

AIR BAG

MODULE COVER

SYSTEM OPERATION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

52B-8

FRONT IMPACT SENSOR

CAUTION

Never disassemble the front impact sensor.

The front impact sensor is installed in the radiator support

panel. In a collision, the contact in the front impact sensor turns

ON and an output signal is send to the SRS-ECU. A resistor is

connected to the front impact sensor in parallel with the contact

for fault diagnosis.

SEAT BELT WITH PRE-TENSIONER

CAUTION

Never disassemble the seat belt with pre-ten-

sioner.

The seatbelt incorporating the pretensioner automat-

ically winds the seatbelt upon front impact to reduce

forward shifting of the passenger.

The seat belt pre-tensioner is built into the driver's

and passenger's front seat belt retractor.

Upon front impact the pretensioner ignites the gas

generator and emits gas with the SRS-ECU signal

when the front impact sensor, attached to the front of

the body, detects an impact that exceeds the permis-

sible limit. The gas pressure shifts the ball in the pipe

and the balls comes in contact with the protrusion of

the ring gear, The ball is inserted in the ring gear and

then interlocked with the pinion. The ring gear rota-

tion forces the pinion to turn the spool toward the belt

wind direction to wind the webbing.

AC206958AC

SENSOR INTERNAL CIRCUIT

AC101663AE

GAS GENERANT

SPOOL

PINION

RING GEAR

PIPE

BALL

SYSTEM OPERATION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-9

SRS AIR BAG SPECIAL CONNECTOR

To enhance the Systemís reliability, a connector lock

switch is integrated into the SRS-ECU connector, the

air bag module connectors, the clock spring connec-

tor, the seat belt pretensioner connectors (black con-

nector "A" shown in the illustration above).

SQUIB CIRCUIT CONNECTOR LOCK SWITCH

AC103223

SRS-ECU

SEAT BELT WITH

PRE-TENSIONER

(DRIVER'S SIDE)

CLOCK

SPRING

DRIVER'S AIR BAG MODULE

PASSENGER'S (FRONT)

AIR BAG MODULE

SEAT BELT WITH

PRE-TENSIONER

(FRONT PASSENGER'S

SIDE)

AC006197

OFF

SQUIB SRS-ECU SQUIB

SRS-ECU

OFF

CONNECTOR DISCONNECTED

ECU-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR

TERMINAL

(MALE)

PARTITION

PANEL

PARTITION

PANEL

BSHORT SPRING

SHORT SPRING

SECTION B - B

SHORT

SPRING

SECTION A - A

CONNECTOR CONNECTED

TERMINAL

(MALE)

TERMINAL

(MALE)

PARTITION

PANEL

TERMINAL

(FEMALE)

TERMINAL

(FEMALE)

TERMINAL

(FEMALE)

CONNECTOR CONNECTED

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