Page 2 (3) Service or maintenance of any SRS component or SRS-related component be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and Its GROUP Supplemental Restraint System (SRS), before beginning any service or maintenance of any compo- nent of the SRS or any SRS-related component.
Page 3: Table Of Contents
CONTENTS Evaporative Emission Control System ..GENERAL DATA AND SPECIFICATIONS .. Exhaust System ......HOW TO USE THIS MANUAL .
Page 4 NOTES...
Page 5: How To Use This Manual
GENERAL How to Use This HOW TO USE THIS MANUAL MAINTENANCE, REPAIR AND functional. This value is established outside the standard value range. SERVICING EXPLANATIONS This manual provides explanations, etc. concerning REFERENCE VALUE procedures for the inspection, maintenance, repair Indicates the adjustment value prior to starting the and servicing of the subject model.
Page 6 GENERAL How to Use This Manual EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures Classifications of Major Maintenance Service points Symbols for Lubrication, Sealants and Adhesives...
Page 7 GENERAL How to Use This Manual STEERING Power Steering Gear B POWER STEERING GEAR BOX gear . Operating procedures, etc. on removal, TIE-ROD END assembly described. tie the cord of the special tool Loosen the nut but do not FOG LIGHT RELAY CHECK indicates that there is continuity’...
Page 8: How To Use Troubleshooting/ Inspection Service Points
GENERAL How to Use Troubleshooting/Inspection Service Points Troubleshooting of electronic control systems for which the scan tool the basic outline described below. Furthermore, even in systems for which the scan tool cannot be used, part of these systems still follow this outline. TROUBLESHOOTING CONTENTS 1.
Page 9 GENERAL How to Use Troubleshooting/Inspection Service Points 4. After repair or replacement, recheck the voltmeter to confirm the repair the problem. Terminal Resistance and Continuity Checks 1. Turn the ignition switch to off. 2. Disconnect the ECU connector. Measure the resistance and check for continuity between the terminals of the ECU connector while referring to the check chart.
Page 10 GENERAL How to Use Service HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally components, the ECU and the harnesses between in that These follow this order, and they first try to discover a problem with a connector or a Check trouble Caution After carrying out connector inspection, always be sure to...
Page 11 GENERAL How to Use Troubleshooting/Inspection Service ‘Points CONNECTOR Turn the ignition switch to when connecting and discon- necting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to the contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED (WITH CIRCUIT IN A CONDITION OF Waterproof Connectors Be sure to use the special tool (harness connector).
Page 12: Connector Inspection Service Points
GENERAL How to Use CONNECTOR INSPECTION SERVICE POINTS Connector disconnected or improperly connected VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Harness wire breakage due to harness tension at terminal section between male and female terminals contact pressure Low connection pressure due to rusted terminals or foreign matter lodged in terminals...
Page 13 G E N E R A L How to Use HOW TO COPE WITH INTERMITTENT Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be easier to find. TO COPE WITH INTERMITTENT MALFUNCTION; duplicate the customer’s complaint.
Page 14 GENERAL How to Use Troubleshooting/Inspection SERVICE POINTS FOR A Remove the fuse and measure the resistance load side of the fuse and ground. Set the of all, this circuits which are connected time, there continuity. If the resistance is almost this Battery is a short somewhere...
Page 15 Body hatchback “convertible” digits* 1 2 3 4 5 6 7 8 9 year 1997 E: Mitsubishi Motor Manufacturing of America, Inc. number 000001 to 999999 NOTE “Check digit” means a single number or letter used to verify the accuracy of transcription of vehicle number.
Page 16 GENERAL Vehicle VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR FEDERAL V.I.N. (except sequence number) Brand Engine displacement Mitsubishi Eclipse (122.0 [DOHC-MFI (122.0 [DOHC-MFI-Turbo Mitsubishi Eclipse Mitsubishi Eclipse (122.0 Spyder [DOHC-MFI-Turbo (146.5 [SOHC-MFI VEHICLES FOR CALIFORNIA V.I.N. (except sequence number) Brand Engine displacement...
Page 17 GENERAL Vehicle VEHICLE INFORMATION Vehicle information plate is riveted onto the in the engine compartment. The place shows model code, transaxle model, and body color code. No. Item MODEL Engine Exterior code Equipment code VEHICLE SAFETY CERTIFICATION LABEL 1. The vehicle safety certification label is attached to face of left door pillar.
Page 18 MITSUBISHI Engine cylinder block, Transaxle housing. Door, Quar- ter panel, Hood, Liftgate, Trunk lid, Bumpers In addition, a theft-protection label is attached to replacement...
Page 19 GENERAL Vehicle LOCATIONS Target area (A: for original equipment parts, B: for replacement parts) Engine Engine (Turbo)> Engine (Non-turbo)> Manual transaxle Engine (Turbo) and Engine> Engine (Non-turbo)> 00003676 Automatic transaxle Engine> . Engine (Turbo) and Engine (Non-turbo)> 0 0 0 0 3 6 7 9 TSB Revision...
Page 20 GENERAL Vehicle Target area (A: for original equipment parts, B: for replacement parts) Fender D o o r The illustration indicates left hand side, outer. Right hand side is symmetrically opposite. The label is attached at the inner Quarter panel side of the parts shown in the figure.
Page 21 GENERAL Vehicle Target area (A: for original equipment parts, B: for replacement parts) Rear bumper Front bumper Trunk lid TSB Revision...
Page 22 GENERAL before Service PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM to follow when servicing SRS (1) Be sure to read GROUP Supplemental Restraint System For safe operations, please follow the directions and heed all (2) Always use the designated special tools and test equipment. (3) Wait at least 60 seconds after disconnecting the battery cable before”...
Page 23 GENERAL Precautions before Service Caution Before connecting or disconnecting the negative be sure to turn off the ignition the lighting switch. semi- (if this is not done, the possibility conductor parts being damaged.) 2. After completion of the work steps [when the bat- warm tery’s negative terminal is connected],...
Page 24 GENERAL Towing and Hoisting type WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP Caution Wheel lift type This vehicle cannot be towed by a wrecker using sling type equipment to prevent the bumper from deformation. if this vehicle is towed, use lift type, fiat bed type type equipment.
Page 25 GENERAL Towing and Hoisting TOWING WHEN KEYS ARE, NOT, AVAILABLE When a locked vehicle must be towed and able, the vehicle may be lifted and towed from the front; provided the parking brake is released. If not released,. the rear wheels should be placed on a tow dolly. SAFETY PRECAUTIONS The following precautions should be towing the...
Page 26 GENERAL Towing and Hoisting LIFTING, JACKING SUPPORT FLOOR JACK nember Rear Piece wood Caution Never support any point other than the specified one, or it will be deformed. TSB Revision...
Page 27 G E N E R A L Towing and RIGID RACK For lifting, put rubber or similar between the side sill and rigid rack, or the side sill area be damaged. POST TYPE Special care should be taken when raising the vehicle on a frame contact type be equipped with the proper adapters in order to support the vehicle at the Caution When service procedures require removing rear suspension, fuel tank and spare tire, place...
Page 28 GENERAL AWD Models Special Handling 0 0 1 0 0 7 4 0 0 1 0 Speedometer tests, brake tests and wheel balance measure- ment for full-time AWD vehicles should be carried out accord- ing to the following procedures. SPEEDOMETER TEST Refer to GROUP 54 Combination Meter.
Page 29 GENERAL Special Handling Instructions for Models W H E E L B A L A N C E FRONT WHEEL MEASUREMENTS 1. Jack up the rear wheels, and place an axle the designated part of the side sill. 2. Jack up the front wheels and set, a pick-up stand and balancing machine in place.
Page 30 GENERAL General Data and Specifications“ 00199999191 ECLIPSE ‘: MD GENERAL SPECIFICATIONS Vehicle Overall length mm (in.) 1 4,380 (172.4) 4,380 (172.4) 4,380 4,380 (172.4) Overall width (68.3) 1,735 (68.3) 1,735 (68.3) 1,735 (68.3) 1,735 sions Overall height (unladen) 3 (in.) 1,295 (51 1,295 (51 1,295 (51...
Page 31 GENERAL General Data and Specifications Items Vehicle Overall length mm (in.) 1 (172.4) 4,380 (172.4) 4,380 (172.4) 4,380 (172.4) Overall width mm (in.) 2 1,735 (68.3) 1,735 (68.3) 1,740 (68.5) 1,740 (68.5) sions 1,740 1,740 (unladen) 3 1,295 (51 1,295 (51 1,295 (51 1,295 (51 Wheelbase mm (in.) 4...
Page 32 GENERAL General 4,380 (172.4) Vehicle dimensions Overall length mm (in.) 1,740 (68.5) Overall width mm (in.) 1 ,740 (68.5) 1 ,310 (51.6) 1,310 (51.6) Overall height (unladen) mm (in.) 2,510 Wheelbase mm (in.) (98.8) 1 ,515 (59.6) 1,515 (59.6) Tread Front mm (in.) 1 ,510 (59.4) Tread...
Page 33 GENERAL General Data and Specifications ECLIPSE SPYDER GENERAL SPECIFICATIONS Items Vehicle Overall length mm (in.) 1 4,380 (172.4) 4,380 (172.4) 4,360 (172.4) 4,380 (172.4) 1,740 (68.5) 1,740 (68.5) Overall width mm (in.) 2 1,735 (68.3) 1,735 (68.3) sions 1,740 1,740 Overall height (unladen) 3 1,340 (52.8) 1,340 (52.8)
Page 34 GENERAL The values in the table applicable: Each torque value in the table is a standard value (1) If toothed washers are ‘inserted. for tightening the following conditions. Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened. . and plated with zinc.
Page 35 GENERAL Lubrication arid Maintenance, 00100120067 Maintenance and lubrication service recommenda- Caution tions have been compiled to provide maximum Test to EPA have shown protection for the vehicle owner’s investment laboratory animals develop skin after against all reasonable types of driving conditions. prolonged contact with used engine oil.
Page 36: Lubrication And Maintenance
Lubrication and GENERAL Lubricants and Lubricant Capacities Table Use of fuels containing alcohol is not recommended Gasolines containing unless the nature of the blend can be determined Ether) as being satisfactory. Unleaded gasoline containing 15% or Gasohol A mixture of 10% ethanol (grain alcohol) may be used in car.
Page 37 GENERAL Recommended Lubricants and Lubricant Table LUBRICANT CAPACITIES Description Metric measure U.S. measure 4 qts. Engine oil Crankcase Engine (Non-turbo) (excluding oil filter) 4.2 qts. Engine (Turbo) and Engine Oil filter Engine (Non-turbo) Engine (Turbo) and Engine Oil cooler Engine (Turbo)> Cooling system (including heater and engine coolant reserve system) 7.4 qts.
Page 38 GENERAL Recommended Lubricants and Capacities Oil Viscosity Non-turbo The SAE grade number indicates the viscosity Of the A proper SAE grade number should be selected to ambient temperature. NOTE may be used for operation in very cold weather areas where the lowest ambient temperature is below Engine PREFERRED Turbo...
Page 39 GENERAL Scheduled Maintenance Table SCHEDULED MAINTENANCE TABLE 00100140124 M A I VEHICLE PERFORMANCE Inspection and services be performed any time a is observed or suspected. Retain receipts for all vehicle emission services to protect your emission warranty. GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE, TSB Revision...
Page 40: Maintenance Service
GENERAL Scheduled Maintenance Table/Maintenance Service SCHEDULED MAINTENANCE UNDER SEVERE USAGE The maintenance items should be performed according to the following table: Severe usage conditions Driving in dusty conditions Driving in sandy areas Driving in salty areas Trailer towing or police, taxi, or commercial type More than 50% operation in traffic or at operation...
Page 41: Air Cleaner Element
GENERAL Maintenance Service AIR CLEANER ELEMENT (Replace) Engine (Non-turbo)> 00100180058 The air cleaner element become dirty and loaded with dust during use, and the filtering effect will be reduced. Replace it with a new one. (1) Unclamp the air cleaner cover. (2) Take out the air cleaner element, install a new one.
Page 42 GENERAL Maintenance 5. SPARK PLUGS Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission Therefore, they should be periodically with new ones. 2. The new plugs should be checked gap. , . . Spark plug gap: Engine (Turbo)>’...
Page 43 GENERAL Maintenance GENERATOR AND WATER PUMP DRIVE CHECK Engine (Turbo) and Engine> Check the belt tension with the tension gauge, or check the belt deflection by pressing. the middle point of belt by force of 98 (22 Ibs.). Standard value: Tension (Ibs.) 490 (55.1...
Page 44 Service GENERAL Maintenance Engine (Non-turbo)> 1. Pull push at the mid point of the belt with a force of 98 (22 Ibs.) to measure dirve belt deflection. Standard value: in.) 2. Use a tension gauge to measure belt Standard value: 9.
Page 45 1,765 (256 psi). These high’ quality filters are highly recommended. The followings part are available as follows. Oil Filter Part No. Engine (Turbo) and Mitsubishi Genuine Parts: 35737, 36466, Engine (Non-turbo)>: Chrysler Genuine Parts: ENGINE OIL FILTER SELECTION Engine (Turbo) and Engine>...
Page 46 GENERAL (5) Coat engine oil to the O-ring filter: (6) Screw on the oil filter by hand until it touches the of the flange and then tighten it with the filter wrench: . . . etc. Engine (Turbo) and One full or 14 or 17 , Engine...
Page 47: Automatic Transaxle Fluid
GENERAL Maintenance, Service 5. Tighten filler plug to specified torque. Specified torque: 30 Nm (22 Engine (Non-turbo)> Engine (Turbo) and Engine> 32 Nm (24 12. AUTOMATIC TRANSAXLE FLUID (Check ‘fluid level) Engine (Non-turbo)> 1. Position the vehicle on a level surface. 2.
Page 48 GENERAL Maintenance Before removing dipstick, wipe all dirt from area around dipstick. Then take out the dipstick and check the condition of the fluid. Further investigation of the transaxle is necessary if, the fluid smells burnt. the fluid color is brown or black. metal particles can be seen or felt on the dipstick.
Page 49 GENERAL Maintenance Service 5. Add 3.8 (4.0 qts.) of the specified transmission fluid through the filler tube. Specified fluid: DIAMOND ATF SP or equivalent 6. Start the engine and allow it to run at idle for at least one minute. Then, with parking and service brake applied, move the selector lever momentarily to each position, ending in the park or neutral position.
Page 50 GENERAL Maintenance Service 13. TRANSFER OIL (Check oil level) Check each component for evidence of leakage, and-check the oil level by removing the filler the oil it is necessary to replace it with new oil. 1. With the vehicle parked at a level place, remove filler, portion 2.
Page 51: Disc Brake Pads
GENERAL Maintenance from For non-turbo, remove the ‘drain plug Engine (Non-turbo)> block to drain engine coolant. For turbo, remove the water hose from the water pipe assembly (C) to do so. Remove the reserve tank to drain the coolant. When the engine coolant has drained, pour in water from the cap to clean the engine coolant line.
Page 52: Drive Shaft Boots
GENERAL Maintenance Service 2. Check the wheel cylinder boots for evidence, a’ brake boots for tears or fluid leak. Visually check the may not cracks. (A slight amount of fluid on the boot preservative assembly.) be a leak, but may be Caution The shoes for the right and left replaced at the same time.
Page 53 GENERAL Maintenance SYSTEM component damage, to wiring, harness, etc.) The SRS must be inspected by an after the manufacture date the certification label located on left center Manufacture date Certification label “SRS” WARNING LIGHT CHECK Turn the ignition key to the “ON” position. warning light illuminate for about 7 seconds, turn “OFF”...
Page 54 GENERAL Maintenance Service CHECK Check SRS-ECU case and brackets for dents, cracks, deformities or rust. Caution The SRS may not activate if a front impact sensor not installed properly, which could result serious injury or death to the driver and AIR BAG MODULE, STEERING CLOCK <Driver’s side>...
Page 55 GENERAL Maintenance 6. Check clock spring connectors and protective tube for damage, and terminals for deformities. 7. Visually check the clock spring case for damage. 8. Align the mating mark of the clock spring and, after turning the vehicle’s front wheels to position, install the clock spring to the column switch.
Page 56: Exhaust System
GENERAL Maintenance Service; 22. EXHAUST SYSTEM (CONNECTION OF MUFFLER, PIPINGS AND, CONVERTER HEAT SHIELDS) (Check as’ required) 1. Check for holes and gas leaks’dwe to damage; etc. 2. Check the joints and connections for looseness and gas’ leaks. 3. Check the hanger rubber and brackets for damage. Revision...
Page 57 (large size) Engine coolant temperature gauge unit (small size, only) ATD Part No. 8660 or equivalent Oil pan (except engine) MITSUBISHI GENUINE ‘Part 0 or equivalent SEALING BETWEEN GLASS AND WEATHERSTRIP Application Recommended brand Sealing between tempered glass and weatherstrip ATD Part No.
Page 58 GENERAL Main Sealant and Adhesive Table Application Sealing of flange threaded portions ATD Part No. 8659 or Fuel gauge unit packing Sealing of flange surfaces, threaded portions, packing and dust cover ATD Part No. 8663 or equivalent Differential carrier packing Dust covers for ball joint and linkage Steering gear box packing and shims Steering gear housing rack support cover and top cover...
Page 59 ENGINE CONTENTS ENGINE ..........ENGINE OVERHAUL .
Page 60 11-2...
Page 61 ENGINE CONTENTS Speed Check ....10 Curb CAMSHAFT AND CAMSHAFT OIL SEAL ........22 Drive Belt Tension Check and Adjustment .
Page 62 ENGINE General Information GENERAL INFORMATION Items Specifications In-line DOHC Number of cylinders Bore mm (in.) 85.0 Stroke mm (in.) (3.28) Piston displacement Compression ratio Firing order Counterbalance shaft Equipped Valve timing Intake valve Opens 21 “BTDC Closes Exhaust valve Opens Closes Lubrication system I Pressure feed-full flow...
Page 63 Service Specifications ENGINE SERVICE SPECIFICATIONS Standard value Limit Items Tension When checked 245 -490 (55.1 110.2) Drive belt (For generator) When a new belt is installed 886 (110.2 154.3) When a used belt is installed Deflection Whenchecked ‘9.0 mm (in.) When a new belt is installed When a used belt is installed 10.0...
Page 64 Semi-circular packing and rocker cover ATD Part No. 8860 or equivalent Bearing cap (front, rear) and cylinder head pan, cylinder block and thermostat case assembly MITSUBISHI GENUINE PART or equivalent Flywheel bolt or drive plate bolt Stud locking 4170 or...
Page 65 ENGINE Special Tools of the transaxle Crankshaft sprocket Lash adjuster removal Valve lifter set Crankshaft sprocket End yoke holder General service tool Preventing foreign substances from entering transfer Plug Removal and installation of cylinder head bolt Cylinder head bolt wrench (12) Revision...
Page 66 ENGINE TROUBLESHOOTING Symptom Probable cause Remedy Compression too low Cylinder head gasket blown Replace gasket Piston ring worn or damaged Replace rings Piston or cylinder worn cylinder Repair or replace piston block Valve seat worn or damaged valve and/or Repair or replace Oil pressure drop Engine oil level too low Check engine oil level...
Page 67 ENGINE On-vehicle ON-VEHICLE DRIVE BELT TENSION CHECK’ AND ADJUSTMENT GENERATOR DRIVE BELT Use the belt tension gauge to check belt the shown point or deflection by applying 98 (22 tbs.) to shown point. Standard value: Tension: 245 (55.1 110.2 Deflection <Reference 9 .
Page 68: Tightening Torque
ENGINE On-vehicle Service POWER STEERING PUMP DRIVE BELT TENSION” 11100110114 Use the belt tension gauge to check belt tension the shown point or check deflection by applying to the shown point. Standard value: Tension: 245 110.2 Ibs.) Deflection: 5.5 8.0 mm in.) pump pulley POWER STEERING PUMP DRIVE BELT...
Page 69 ENGINE On-vehicle A/C COMPRESSOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen tension pulley fixing bolt A. 2. Adjust belt tension with adjusting bolt B. Standard value: Items When a new belt is When a used belt is installed installed 382-411 Tension 255-333 (Ibs.) Deflection...
Page 70 ENGINE Service On-vehicle NOTE Ignition timing is variable within about even under operating. 2. And it is automatically further advanced by about from BTDC at higher altitudes. CURB IDLE SPEED CHECK 1. Before inspection and adjustment, set vehicles in the following condition.
Page 71 ENGINE On-vehicle 8. If the standard value is exceeded, check the following items: Diagnostic output Closed-loop control (When the closed-loop control is carried out normally, the output signal of the heated oxygen sensor repeats between ,000 at idle.) Fuel pressure Injector Ignition coil, spark plug cable, spark plug EGR system and the EGR valve leak...
Page 72 ENGINE On-vehicle Caution Keep away from the spark plug hole when crank- ing. 2. If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous. Set compression gauge to one of the spark plug holes.
Page 73 ENGINE On-vehicle Service MANIFOLD VACUUM CHECK 11100270200 Before inspection, set vehicles in the following condition: Engine coolant temperature: Lights, electric cooling fan, and accessories: OFF Transaxle: Neutral (P range on vehicles with 2. Set up the tachometer or connect the scan tool to the data link connector.
Page 74 ENGINE On-vehicle Service 2. Start the engine and perform gentle racing* several times (less than times.) If the abnormal noise stops by racing, the air is bled of the lash adjusters from the high pressure chamber normalized. and the function of the lash adjusters is After raising the engine speed from idling to 3000 gradually (in 30 seconds), drop the ally (in 30 seconds) to idling.
Page 75 ENGINE On-vehicle Lash adjuster replacement Caution In the cylinder ‘are will touch the pistons when the valves are down, so the piston positions. In addition, places by the cams cannot be crankshaft should be are not lifted. ) Use the special tool to push remove the roller rocker (2) Remove.
Page 76 ENGINE Engine ENGINE ASSEMBLY REMOVAL AND INSTALLATION Operation Operation Radiator Installation Fuel Line Pressure Releasing (Refer to GROUP 14 Radiator.) (Refer to GROUP On-vehicle Service.) Transaxle Assembly Removal ‘Hood Removal Refer to GROUP Engine Coolant Draining Assembly.) Refer to GROUP 00 Maintenance Service.) Refer to GROUP Transaxle...
Page 77 ENGINE Engine Assembly Engine oil 00005320 ‘ c o i l c o n n e c t o r ’ 8. Accelerator cable connection 20. Camshaft position sensor connector air control motor connector 21. Crankshaft position sensor 10. Knock sensor connector 11.
Page 78 ENGINE Assemblv 72-67 49 Nm 30. Front exhaust pipe connection 31. Gasket 32. Engine mount bracket assembly 33. Engine assembly REMOVAL SERVICE POINTS POWER STEERING PUMP Remove the power steering pump from with the hose attached. NOTE Place the removed power steering pump in a ‘place where it will not be a hindrance when and installing the and tie it...
Page 79 ENGINE -‘Engine Assembly COMPRESSOR Disconnect the compressor connector and remove the compressor from the compressor bracket the hose attached. NOTE Place the removed A/C compressor in a where it will not be a hindrance when removing ‘and installing the engine assembly, and tie it with a cord: Caution Do not bend the joint...
Page 80 ENGINE Engine (4) Align the notches on the stopper with the Engine side bracket with the arrow mark facing, toward the shown topper direction. Then the stopper. Arrow bracket HIGH-PRESSURE FUEL HOSE CONNECTION When connecting the high-pressure the fuel rail, apply a small amount of clean oil, to the hose then insert, being careful not to damage the O-ring.
Page 81 ENGINE Crankshaft CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Under Cover Removal (Refer to GROUP 42 Under Cover.) (Refer to Under Removal steps 1. Drive belt (Generator) 2. Drive belt (Power steering) 3. Drive belt (A/C) 4. Crankshaft pulley...
Page 82 Post-installation Operation Timing Belt Front Upper Cover Removal Timing Belt Front Cover (Refer to (Refer to Engine 2.9 Nm 3.4 Nm Enaine oil 2 in.) Sealant: MITSUBISHI GENUINE PART or equivalent Cylinder head sealant: No. 8660 or equivalent TSB Revision...
Page 83 Camshaft and Camshaft ‘Oil -Seal ENGINE Removal steps Installation steps 19. Intake camshaft 1. Accelerator cable connection 18. Exhaust camshaft 2. Center cover (R.H.) 3. Spark plug cable Rear 4. Breather hose 16. Rear bearing cap (L.H.) 5. PCV bearing cap 6.
Page 84: Camshaft And Camshaft Oil
ENGINE Camshaft and Camshaft REMOVAL SERVICE POINTS . CAMSHAFT SPROCKET Use a wrench at the hexagonal part of the camshaft (to prevent the crankshaft from turning) to loosen the camshaft sprocket bolt. (2) Remove the camshaft sprockets. FRONT CAMSHAFT BEARING FRONT CAMSHAFT BEARING Plastic hammer BEARING...
Page 85: Seal
Camshaft and Oil Seal ENGINE CAMSHAFT C A M S H A F T BEARING INSTALLATION Tighten the bearing cap installation bolts to the torque in two or three steps. C a u t i o n arms Tighten uniformly, otherwise the rocker straight.
Page 86 E N G I N E Oil fan and Oil OIL PAN AND OIL SCREEN REMOVAL AND INSTALLATION and Post-installation Operation Engine Oil Draining and Supplying Oil Level Gauge Removal and Installation Front Exhaust Pipe Removal and Installation GROUP 15 Exhaust Pipe and Muffler.) (Refer to GROUP 15 Exhaust Pipe and Muffler.)
Page 87 ENGINE R E M O V A L (1) Remove the transfer shaft still installed.. (2) Insert a flat-tipped screwdriver or similar the transfer and transaxle, and remove transfer the center shaft (3) Remove the transfer from the propeller shaft. Caution Do not tilt the transfer assembly to the rear, or transfer oil will leak out.
Page 88: Crankshaft Front Oil Seal
ENGINE Crankshaft Front Oil’ CRANKSHAFT FRONT OIL SEAL 11333343133 REMOVAL AND INSTALLATION and Post-installation Operation Timing Belt Removal and installation (Refer to Removal steps 1. Crankshaft sprocket front oil seal INSTALLATION SERVICE FRONT OIL SEAL (1) Apply engine oil to the entire inside diameter of the oil seal lip.
Page 89: Crankshaft Rear Oil Seal
ENGINE Crankshaft Rear Oil CRANKSHAFT REAR OIL SEAL REMOVAL AND INSTALLATION and Post-installation Transaxle Assembly Removal and Installation Refer to GROUP Transaxle Assembly.) Refer to GROUP Transaxle Assembl Refer to GROUP Transaxle Assembly.) Refer to GROUP Transaxle Assembly.) Engine oil Removal steps 5.
Page 90 ENGINE Crankshaft pear Oil BOLT PLATE BOLT <AK> R E M O V A L or drive plate, Use the special tool to secure. and remove the bolt. INSTALLATION SERVICE REAR OIL SEAL INSTALLATION CRANKSHAFT (1) Apply a small amount of engine oil to the entire inside diameter of the oil seal lip.
Page 91: Cylinder Head Gasket
Cylinder Head ENGINE CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal Operation Fuel Line Inner Pressure Release (Refer to GROUP On-vehicle Engine Coolant Draining (Refer to GROUP 00 Maintenance Service.) Engine Oil Draining (Refer to GROUP 00 Maintenance Service.) 2.9 Nm 4.9 Nm Engine oil Removal steps...
Page 92 ENGINE Head Gasket’ engine> Cylinder head Specified sealant: Sealant: ATD Part No. 8880 or equivalent MITSUBISHI GENUINE PART or equivalent Timing belt 36. Thermostat case assembly (Refer to 37. O-ring 28. Power steering pump flange 38. Flange bolts and 29. Rocker cover (Refer to GROUP 30.
Page 93 Gasket, ENGINE Cylinder Head REMOVAL SERVICE POINTS UPPER HOSE/RADIATOR HOSE Place mating marks on the radiator hose and the hose clamp, and then disconnect the radiator hose. HEAD BOLT REMOVAL Using the special tool, loosen the bolts in the order shown in the illustration (in 2 or 3 stages), and then cylinder head assembly.
Page 94 ENGINE H e a d bolts by the following I n t a k e s i d e Front of Remarks Step enaine In the in the Tighten to order of that Loosen Tighten to 20 Nm (15 Exhaust side Tighten of a turn.
Page 95 (2) Apply specified sealant to the thermostat case in the places shown in the illustration. i n . ) Specified equiva- MITSUBISHI GENUINE PART lent (3) Apply a small amount of water to the O-ring water inlet pipe, and then press the thermostat case into the water inlet pipe.
Page 96 ENGINE Timing Belt TIMING BELT REMOVAL AND INSTALLATION Post-installation Operation Under Cover Installation (Refer to GROUP 42 Under Cover.) Engine Adjustment Engine Mount Bracket Removal Engine Mount Bracket (Refer to GROUP 32 Engine Mounting.) (Refer to GROUP 32 Engine Mounting.) Removal steps 7.
Page 97 ENGINE Timing REMOVAL SERVICE POINTS BELT FRONT CENTER COVER Remove the stud bolt of the engine support bracket, and remove the timing belt front center cover. TIMING BELT REMOVAL marks Cylinder head surface (1) Turn the crankshaft in the forward direction (to the right) to align the camshaft sprocket timing marks.
Page 98 ENGINE Timing Belt (3) Use a press or vise to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole of the tensioner cylinder are aligned. C a u t i o n If the compression speed is too fast, the rod opera- become damaged, so be sure to carry out this...
Page 99 E N G I N E (3) Install the timing belt so as not to be’ the sprockets, by the Cautidn to be that If the timing belt is the mark indicates the 1) Install the timing belt around the intake side camshaft sprocket and fix it at indicated position by a bulldog clip.
Page 100: Adjustment
ENGINE Belt TIMING BELT TENSION ADJUSTMENT (1) After turning the crankshaft of a revolution in the counterclockwise direction, turn it in the clockwise direction . until the timing marks are aligned. (2) Loosen the tension pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the timing belt.
Page 101 ENGINE Timing TIMING BELT REMOVAL AND INSTALLATION (Engine oil) Removal steps 1. Timing belt (Refer to Crankshaft sprocket 3. Crankshaft sensing blade Timing belt tension adjustment 4. Timing belt tensioner 5. Timing belt REMOVAL SERVICE POINTS CRANKSHAFT SPROCKET (1) Use special tool to remove the bolt, (2) Use the special tool to remove the crankshaft TSB Revision...
Page 102 ENGINE Timing Belt BELT REMOVAL Caution If timing belt is ‘to be use chalk to it with an arrow on its flat side indicating the turning direction (to the right). INSTALLATION SERVICE POINTS Counterbalance BELT INSTALLATION Belt tension side Install’ timing belt “B” by the following procedure. (1) Ensure that crankshaft sprocket “B”...
Page 103 ENGINE Timing Belt CRANKSHAFT SENSING BLADE INSTALLATION When installing, make sure the direction is correct. See figure. CRANKSHAFT SPROCKET INSTALLATION Use the special tool to install the crankshaft sprocket and bolt. NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt.
Page 104 NOTES...
Page 105: Sealants
CONTENTS IGNITION SYSTEM ..11 BRACKET GENERATOR INTAKE MANIFOLD ..... . CRANKSHAFT, FLYWHEEL AND DRIVE PLATE ......59 PISTON AND CONNECTING ROD..
Page 106 ENGINE OVERHAUL General Information GENERAL INFORMATION GENERAL SPECIFICATIONS Descriptions . . . Specifications “in-line DOHC Number of cylinders Combustion chamber type Total displacement 1,997 (121.9) Cylinder bore mm (in.) (3.35) Piston stroke mm (in.) 88.0 (3.46) Compression ratio Valve, timing Intake valve 2 1 ”...
Page 107: Service Specifications
ENGINE OVERHAUL ‘Specifications SPECIFICATIONS SERVICE SPECIFICATIONS Standard value Limit Rocker arms and camshaft cam height mm (in.) Intake 34.91 (1.37) 34.41 Exhaust 34.91 (1.37) 34.41 Camshaft journal O.D. mm (in.) 25.96 (1.02) Cylinder head and valve Cylinder head flatness of gasket surface mm (in.) Less than 0.05 Cylinder head grinding limit of gasket surface mm (in.) *Total resurfacing depth of both cylinder head and cylinder block...
Page 108 ENGINE OVERHAUL Items Standard value Piston ring end gap mm (in.) 0 . 8 Piston pin O.D. mm (in.) Piston pin press-in load (Ibs.) 17,500 [Room temperature] Crankshaft pin oil clearance mm (in.) Connecting rod big end side clearance mm (in.) Crankshaft, flywheel and drive plate Bearing cap bolt shank length mm (in.) Crankshaft end play mm (in.)
Page 109 ENGINE OVERHAUL TORQUE SPECIFICATIONS Items Generator and ignition system W a t e r p u l l e y b o l t 8” pump Generator mounting bolt Generator brace bolt Generator pivot nut Crankshaft pulley bolt Spark plug Ignition coil bolt Center cover bolt Ignition power transistor bolt...
Page 110 E N G I N E O V E R H A U L TSB Revision...
Page 111 Rear roll stopper bracket bolt Front engine support bracket bolt Exhaust pipe support bracket bolt SEALANT Specified sealant Items Mitsubishi Genuine Part No. or equivalent Camshaft position sensor support ATD Part No. 8660 or equivalent Rocker cover ATD Part No. 8660 or equivalent Semi-circular packing ATD Part No.
Page 112: Special Tools
ENGINE OVERHAUL SPECIAL TOOLS Application Tool Tool number and name Supersession Installation of seal Handle Crankshaft rear oil seal installer Removal and installation case cap Plug wrench Crankshaft front oil seal installer Use with Revision...
Page 113 ENGINE OVERHAUL Use with TSB Revision...
Page 114 ENGINE OVERHAUL Special Tools Cylinder head bolt TSB Revision...
Page 115: Belt
ENGINE OVERHAUL GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 25 Nm 10 Nm Removal steps 9. Spark plug 1. Drive belt 10. Ignition power transistor 2. Water pump pulley 11. Ignition coil 3. Power steering pump pulley 12. Plate 4. Generator brace 13.
Page 116 Generator and INSTALLATION SERVICE POINTS, POSITION I N S T A L L A T I O N Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine Part No. equivalent. TSB Revision...
Page 117: Timing Belt
ENGINE OVERHAUL TIMING BELT REMOVAL AND INSTALLATION 90 Nm 24 Nm 9 Nm 55 Nm 36 Nm 120 Nm Removal steps 14. Tensioner 1. Timing belt front upper cover 15. Timing belt 2. Timing belt front center cover 16. Counterbalance shaft’ sprocket 3.
Page 118 OVERHAUL Timing. Belt REMOVAL SERVICE POINTS B E L T R E M O V A L (1) Mark the belt running direction for reference in t i o n . NOTE (1) Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water.
Page 119 OVERHAUL Timing BELT “B” REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the’ same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water.
Page 120 ENGINE OVERHAUL Timing Belt INSTALLATION SERVICE POINTS CAMSHAFT SPROCKETS TIGHTENING (1) Using a wrench, hold the camshaft at its hexagon (between the No. 2 and No. 3 journals) and tighten the bolt to the specification. Caution Locking the camshaft sprocket with a tool damages the sprocket.
Page 121 ENGINE OVERHAUL Timing Belt Semi-circular Cylinder head SEALANT APPLICATION ON ROCKER COVER Apply the specified sealant to areas in the, illustration. Specified sealant: ATD Part No. 8660 in.) SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal.
Page 122 ENGINE OVERHAUL Timing’ COUNTERBALANCE SHAFT INSTALLATION BELT “B” INSTALLATION (1) Align timing marks on the crankshaft sprocket counterbalance shaft sprocket with the marks on the front case respectively. (2) Install the timing belt on the crankshaft sprocket and counterbalance shaft sprocket. There should be no slack on the tension side.
Page 123 ENGINE OVERHAUL Belt BOLT O I L S P R O C K E T a Phillips screwdriver [shank diameter 8 mm in.) shaft] through the plug hole on the cylinder block to block the left counterbalance shaft. the oil pump sprocket. (3) Apply a proper amount of engine oil-to the bearing of the nuts.
Page 124 ENGINE OVERHAUL TENSIONER PULLEY INSTALLATION (1) Install the tensioner pulley in such direction that its two small holes are arranged vertically. TIMING BELT INSTALLATION (1) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with the top surface of the cylinder head.
Page 125 ENGINE OVERHAUL Belt a Phillips screwdriver [shank diameter 8 mm in.)] through the hole. If it can be inserted as deep as 60 mm (2.4 or more; the timing ‘marks are correctly aligned. If the inserted depth is only in.), turn the oil’ pump sprocket one turn and marks.
Page 126 ENGINE OVERHAUL Timing (8) Thread the timing belt over the idler pulley, the oil pump sprocket, the crankshaft sprocket and the tensioner pulley in the order shown. (9) Remove the two clips. (lO)Lift up the tensioner pulley in the direction of arrow and tighten the center bolt.
Page 127 ENGINE OVERHAUL Timing INSPECTION TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail. (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on rib root.
Page 128 ENGINE OVERHAUL Timing (4) Press the rod with a force of 98 to 196 (22 to 44 98 to 196 (22 to 44 ft.) ft.) and measure its protrusion. (5) If the measured value is mm (0.39 in) or more shorter than the value obtained in step replace the tensioner.
Page 129 ENGINE OVERHAUL FUEL AND CONTROL PARTS REMOVAL AND INSTALLATION 12 Nm 19 Nm 9 Nm 8. Insulator Removal steps 9. Fuel pressure 1. Air fitting 10. O-ring 2. Air fitting gasket 11. Insulator 3. Throttle body 4. Throttle body gasket 5.
Page 130 ENGINE OVERHAUL Fuel and INJECTOR (1) Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector top end into fuel rail. Be careful not to damage the O-ring during installation. FUEL PRESSURE REGULATOR INSTALLATION (1) Before installing’...
Page 131 ENGINE OVERHAUL Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION 13 Nm (To oil cooler) 20 Nm Removal steps 1. Water hose 7. Water outlet fitting 2. Water hose 8. Thermostat housing 3. Engine coolant temperature gauge 9. Intake manifold stay unit 10.
Page 132 SEALANT APPLICATION TO THERMOSTAT diameter HOUSING bead Specified sealant: or equiva- Mitsubishi Genuine Part No. lent NOTE (1) Be sure to install the housing quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for hour.
Page 133 ENGINE OVERHAUL Exhaust Manifold EXHAUST MANIFOLD AND WATER PUMP 11300490108 REMOVAL AND INSTALLATION ‘ - 2 3 14 Nm Removal steps 1. Oil dipstick 17. Water pipe 2. Oil dipstick guide 18. Turbocharger 3. O-ring 19. Engine hanger 4. Heat protector “A” 20.
Page 134 ENGINE OVERHAUL Exhaust Manifold and INSTALLATION SERVICE O-ring WATER PIPE/O-RING Wet the O-ring (with water) to facilitate assembly. Caution Keep the O-ring free of oil or grease. TURBOCHARGER the cone disc spring in shown direction. Identification (2) Tighten the turbocharger mounting bolts and hole 31 Nm Exhaust...
Page 135 ENGINE OVERHAUL Rocker Arms and ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION Removal steps 1. Bearing cap rear cap No. 3 8. Camshaft 2. Bearing cap front 3. Camshaft oil seal 9. Rocker arm 10. Lash adjuster 4. Bearing cap No. 5 11.
Page 136 OVERHAUL ENGINE Rocker, Arms I N S T A L L A T I O N S E R V I C E L A S H A D J U S T E R the lash adjuster in clean diesel fuel. and down (2) Using a special tool, move the plunger up 4 or 5 times while pushing down lightly on the check...
Page 137 ENGINE OVERHAUL R o c k e r SEAL PACKING INSTALLATION TSB Revision...
Page 138 ENGINE OVERHAUL Rocker INSPECTION CAMSHAFT (1) Measure the cam height. Limit mm (in.) Standard value mm (in.) 34.91 (1.37) 34.41 (1.36) Intake 34.41 Exhaust 34.91 (1.37) ROCKER ARM Roller (1) Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm.
Page 139 ENGINE OVERHAUL Rocker Arms and on the (4) After air bleeding, place lash adjuster (Leak down tester). (5) After plunger has down Replace measure time taken for it to go down if measured time is out of specification. Standard seconds in.) [Diesel fuel at TSB Revision...
Page 140 E N G I N E O V E R H A U L 11300690201 CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION Removal steps 11. Exhaust valve 1. Cylinder head bolt 12. Valve stem seal head assembly 13. Valve spring seat 14.
Page 141 ENGINE OVERHAUL Cylinder Head and Valves REMOVAL PRECAUTION FOR PARTS (1) Keep removed parts in order according to the cylinder, number and intake/exhaust. H E A D B O L T S R E M O V A L (1) Using the special tool, the cylinder bolts.
Page 142 ENGINE OVERHAUL Cylinder Head RETAINER LOCK The ‘valve if excessively, compressed, causes the spring, bottom end of retainer to be in contact with, and damage,: the stem seal. HEAD GASKET Identification mark I d e n t i f i c a t i o n m a r k : HEAD BOLT INSTALLATION (1) When installing the cylinder bolts,...
Page 143 ENGINE OVERHAUL Cylinder Head and INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and feeler gauge. Standard value: 0.05 mm in.) Limit: 0.2 mm in.) (2) If the service limit is exceeded, correct to meet specifica- tion.
Page 144 ENGINE OVERHAUL Head and (2) Measure the squareness of the spring and, is exceeded, replace. Standard value: or less Limit: Max. GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.
Page 145 ENGINE OVERHAUL Cylinder Head and Valves, (2) Rebore the valve seat hole in the cylinder to’ selected oversize valve seat diameter. Intake seat ring hole’ 0.3 O.S. 35.30 35.33 mm (1.3989 1.3909 in.) 0.6 OS. 35.60 35.63 mm (1.4018 Exhaust seat ring hole diameters 0.3 O.S.
Page 146 ENGINE OVERHAUL. FRONT CASE, COUNTERBALANCE SHAFT AND OIL REMOVAL AND INSTALLATION 1 3 1 24 Nm 10 Nm 17 Nm 45 Nm 19 Nm 10 Nm 40 Nm Removal steps Oil filter 19. Oil filter bracket 2. Oil cooler bolt 20.
Page 147 Front Case, ENGINE OVERHAUL REMOVAL SERVICE POINTS PAN REMOVAL (1) Remove all oil pan bolts. (2) Drive in the special tool between the and. oil pan. NOTE Never use a screwdriver or chisel, instead of tool, as a deformed oil pan flange result in oil leakage.
Page 148 Front Case, ENGINE OVERHAUL Shaft and COUNTERBALANCE SHAFT REAR BEARING REMOVAL Using the special tool, remove the counterbalance shaft . rear bearing from the cylinder block. NOTE When removing the left counterbalance shaft, install the special tool to the front of the cylinder block. INSTALLATION SERVICE POINTS RIGHT COUNTERBALANCE REAR...
Page 149 Front Case, Counterbalance ENGINE OVERHAUL Shaft and COUNTERBALANCE INSTALLATION (1) Using special tools, install front bearing. C y l i n d e r block FRONT CASE (1) Place the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer of the special tool to install the front (2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other...
Page 150 Front Case, ENGINE OVERHAUL Shaft and OIL PUMP OIL SEAL INSTALLATION Socket FRONT OIL SEAL INSTALLATION (1) Using the special tool, install the crankshaft front seal into the front case. Oil seal case PUMP DRIVEN GEAR OIL PUMP DRIVE GEAR INSTALLATION Apply engine oil amply to the gears’...
Page 151 Front Case,, ENGINE OVERHAUL Shaft and ‘Pan Phillips screwdriver hole in the left side of the cylinder block to lock the counterbalance shaft. Phillips screwdriver (2) Secure the oil pump driven gear onto the left counterbal- ance shaft by tightening the flange bolt to specified torque. PLUG INSTALLATION (1) Install a new O-ring to the front case.
Page 152 (2) Apply a 4 mm in.) wide bead of to the entire circumference of the oil pan flange. Specified sealant: MITSUBISHI GENUINE equivalent NOTE Be sure to install the oil pan quickly the sealant’ is wet (within 15 minutes);...
Page 153 Front Case, ENGINE OVERHAUL Shaft and OIL FILTER INSTALLATION Bracket side (1) Clean the installation surface of the filter bracket. (2) Apply engine oil to the O-ring of the oil filter. (3) Screw the oil filter in until the O-ring contacts the bracket. Then tighten turn [tightening torque: Nm (12...
Page 154 Front Case, Counterbalance ENGINE Shaft and INSPECTION FRONT CASE (1) Check oil holes for clogging and if necessary. (2)’ Check left counterbalance shaft front bearing Wear, damage and seizure. If there is anything wrong’ with the section, replace the front (3) Check the front case for cracks and other damage.
Page 155 Piston and Connecting ENGINE OVERHAUL PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Removal steps 1. Nut 7. Piston ring No. 2 Connecting rod cap 8. Oil ring Connecting rod bearing 9. Piston pin 4. Piston and connecting rod assembly Piston 11.
Page 156 ENGINE OVERHAUL Piston and R E M O V A L S E R V I C E ROD CAP (1) Mark the cylinder number on the side of connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, ‘and bearings in order according to the cylinder number.
Page 157 Piston and Connecting Rod ENGINE OVERHAUL INSTALLATION SERVICE PIN INSTALLATION (1) Thread the stop screw and lock nut into the base. Fit the correct piston support on top of the base, the press pin, threaded end up, into hole in the piston support until the pin touches the stop Base...
Page 158 ENGINE OVERHAUL Piston and OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. NOTE (1) The side rails and spacer may be installed in either direction. (2) New spacer and side rails are colored for of their sizes.
Page 159 ENGINE OVERHAUL PISTON AND CONNECTING ROD Upper side (1) Liberally coat engine oil on the of the piston,’ piston ring, and oil ring. (2) Arrange the piston ring and. oil ring gaps rail and Crankshaft spacer) as shown in the ‘figure. (3) Rotate crankshaft so that crank cylinder side...
Page 160 ENGINE OVERHAUL Piston and CONNECTING ROD CAP (1) Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make that. the bearing locking notches come on the same side as shown. Notch (2) Make sure that the connecting rod big end side clearance meets the specification.
Page 161 ENGINE OVERHAUL 11300850104 (1) Replace piston ii or seizure is evident its surfaces (especially surface). Replace the piston if it is cracked. PISTON PIN the piston pin pin hole You should feel a slight resistance. pin if it can be easily inserted or there ‘is (2) The piston and piston pin must be replaced bly.
Page 162 ENGINE OVERHAUL Piston PIN OIL CLEARANCE (PLASTIGAGE METHOD) (1) Remove oil from crankshaft pin and connecting rod bearing. (2) Cut the Plastigage to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.
Page 163 E N G I N E O V E R H A U L CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION Removal steps 10. Oil seal 1. Flywheel bolt 11. Bearing cap 2. Flywheel 12. Bearing 3. Drive plate bolt 13.
Page 164 Crankshaft, ENGINE OVERHAUL Drive Plate REMOVAL POINT Use an appropriate metal bar to press the out. (1) Be careful not to damage the cylinder (2) Never reuse the removed oil INSTALLATION SERVICE POINTS JET INSTALLATION Use a pin punch of 4 5 mm in.) diameter to press the oil jet in from the crank journal until the oil jet bottoms...
Page 165 E N G I N E O V E R H A U L [Example] (1) If the measured value of a crankshaft diameter is between 56.994 mm (2.2439 2.2441 in.), the journal is in the’ case the is also replaced by a (for No.
Page 166 Standard value: Limit: 0.25 mm OIL SEAL INSTALLATION S E A L A N T sealant: Mitsubishi Genuine lent NOTE (1) Be sure to install the case is wet (within, 15 minutes). (2) After installation, keep the sealed area away from oil and coolant for approx.
Page 167 ENGINE OVERHAUL INSPECTION O I L C L E A R A N C E (1) Remove oil from the crankshaft journal ‘and crankshaft bearing. (2) Install the crankshaft. (3) Cut the Plastigage to the same length as the width of bearing and place it on journal in parallel with its axis.
Page 168 , Flywheel ENGINE OVERHAUL and Drive Plate BORING CYLINDER (1) Oversize pistons to be used should be determined the basis of the largest bore cylinder. Piston size identification Identification mark Size Thrust direction 0.50 1.00 NOTE Size mark is stamped on piston top, (2) Measure outside diameter of piston to be used.
Page 169 ENGINE OVERHAUL Bracket BRACKET REMOVAL AND INSTALLATION Removal steps 1. Roll stopper bracket, front 2. Engine support bracket, front 3. Exhaust pipe support bracket 4. Roll stopper bracket, rear Revision...
Page 170 NOTES...
Page 171 CONTENTS Compression Pressure Check ..CAMSHAFT AND CAMSHAFT OIL SEAL ........Curb Speed Check .
Page 172 ENGINE General Information GENERAL items Specifications OHV, DOHC Number of cylinder Bore mm (in.) 87.5 (3.445) Stroke mm (in.) 8 3 . 0 ( 3 . 2 8 7 ) Piston displacement 1,996 (121.8) Compression ratio Firing order Intake Valve timing Opens 1.3”...
Page 173 ENGINE ‘Service SERVICE SPECIFICATIONS Items Standard value Limit Drive belt Tension When checked (For (Ibs.) When a new belt is installed generator) When a used belt is installed 110) Deflection Whenchecked mm (in.) When a new belt is installed 10.5 <Reference When a used belt is installed 12.0...
Page 174 ENGINE Special SPECIAL TOOLS Tool number Supersession Application Tool and name speed inspection Scan tool (MUT-II) ROM Pack MUT-II Interface cartridge Adapter harness Crankshaft sprocket removal Remover crankshaft damper/sprocket 1026 Remover puller damper Remover crankshaft sprocket Revision...
Page 175 Special Took Oil seal installer seal SERVICE TOOL Revision...
Page 176 E N G I N E Tools Tool number Supersession Tool and name the engine assembly removal and of the Engine hanger assembly 0991453 seal installation Oil seal pilot installer 6995059 6926-2 Crankshaft oil seal installer R e v i s i o n...
Page 177 ENGINE Troubleshooting, TROUBLESHOOTING Symptom Probable cause Remedy Compression too low Cylinder head gasket blown Replace gasket Piston ring worn or damaged Replace rings Piston or cylinder worn Repair or replace piston cylinder block Valve seat worn or damaged Repair or replace valve seat ring Oil pressure drop Engine oil level too low...
Page 178 B E L T ADJUSTMENT Check the belt tension with the tension gauge, or check the belt deflection by pressing the middle point of the belt by a force of 98 (22 ibs.). Standard value: Tension: 400 Deflection <Reference 12.0 mm Crankshaft GENERATOR BELT...
Page 179 ENGINE On-vehicle POWER STEERING OIL PUMP DRIVE BELT Power CHECK <Vehicle Use the belt tension gauge to check belt tension at the shown point or check deflection by applying 98 to the shown point. Standard value: Tension: 400 Deflection: 11 14.0 mm in.) POWER STEERING OIL PUMP DRIVE BELT TENSION...
Page 180 ENGINE On-vehicle Service POWER STEERING OIL PUMP AND A/C DRIVE BELT TENSION ADJUSTMENT Tension 1. Loosen the tension pulley nut. pulley nut 2.. Adjust the belt deflection amount using the adjusting bolt. Tension pulley Standard value: Adjusting bolt Items When a new belt is When a used belt is installed installed...
Page 181 ENGINE On-vehicle Service IDLE MIXTURE CHECK 11100210081 Before inspection, set vehicles in the following condition: Engine coolant temperature: Lights, electric cooling fan and all accessories: OFF Transaxle: Neutral (P range on vehicles with 2. After turning the ignition switch to OFF, connect the scan tool to the data link connector.
Page 182 ENGINE On-vehicle Service’ 5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. . Caution Keep away from the spark plug hole when crank- ing.
Page 183 ENGINE On-vehicle.’ MANIFOLD VACUUM Before inspection, set vehicles. in the condition: Engine coolant Lights, electric cooling Transaxle: Neutral (P 2. Connect the scan tool to the data link connector. 3. Attach a three-way joint to the vacuum the fuel pressure regulator and the intake manifold, and connect a vacuum gauge.
Page 184 ENGINE Engine ENGINE ASSEMBLY REMOVAL AND INSTALLATION Pm-removal Operation Post-installation Operation GROUP 14 Fuel Line Pressure Releasing Radiator Installation (Refer to (Refer to GROUP On-vehicle Service.) Radiator.) Hood Removal Transaxle Assembly Installation Engine Coolant Draining Refer to GROUP Transaxle Assembly.) (Refer to GROUP 00 Maintenance Service.) Refer to GROUP...
Page 185 ENGINE Fuel rail Engine oil 2.5 Nm 10. Accelerator cable connection 19. Generator connector 11. Throttle position sensor connector 20. Crankshaft position sensor control motor connector connector speed sensor connector 21. Knock sensor connector 22. Oil pressure switch connector 14. injector harness connector 23.
Page 186 E N G I N E 66 Nm 72-67 27. Vapor hose connection 28. Front exhaust pipe connection 29. Gasket 30. Engine mount bracket assembly 31. Engine assembly REMOVAL SERVICE POINTS POWER STEERING Remove the power pump from the bracket with the hose attached.
Page 187 ENGINE Engine A/C COMPRESSOR REMOVAL the A/C compressor connector and remove compressor from the compressor bracket with the attached. NOTE Place the removed A/C compressor in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 188 ENGINE Enaine INSTALLATION SERVICE POINTS ENGINE ASSEMBLY INSTALLATION Install the engine assembly while checking that the cables, hoses, and harness connectors are not clamped. ENGINE MOUNT BRACKET ASSEMBLY INSTALLATION (1) Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.
Page 189 ENGINE Crankshaft CRANKSHAFT PULLEY INSTALLATION REMOVAL AND Post-installation Operation Drive Belt Tension Under Cover Removal Under Cover Installation (Refer to GROUP 42 Under Cover.) (Refer to GROUP 42 Under Cover.), Removal steps 3. Crankshaft bolt 1. Drive belt (Power steering and 4.
Page 190 E N G I N E INSTALLATION SERVICE POINTS CRANKSHAFT PULLEY INSTALLATION CRANKSHAFT BOLT TSB Revision...
Page 191: Camshaft And Camshaft Oil
Camshaft and Camshaft Seal ENGINE CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Post-installation Operation Engine Adjustment 28 Nm Specified sealant: Loctlte 5699 or equivalent Specified sealant: 518 or equivalent Camshaft removal steps 14. Outside bearing Cad 1. Ignition coil pack 2.
Page 192 ENGINE Camshaft and INTAKE CAMSHAFT SPROCKET/EXHAUST CAMSHAFT Use the special tool not to let the. camshaft sprockets CAMSHAFT BEARING Loosen the camshaft bearing cap attaching fasteners in sequence shown in the figure (one at a time). INTAKE CAMSHAFT/EXHAUST CAMSHAFT REMOVAL Identify the camshafts before removing from the head.
Page 193 Camshaft and ENGINE EXHAUST CAMSHAFT CAMSHAFT Use the special tool to the camshaft turning, and then install the intake camshaft, sprockets. CYLINDER HEAD COVER INSTALLATION Install the cylinder head cover assembly to the head and tighten fasteners in sequence shown in figure. Tighten all fasteners according to the torque method.
Page 194 ENGINE Oil Pan and Oil Screen OIL PAN AND OIL SCREEN REMOVAL AND INSTALLATION and Post-installation Operation Engine Oil Draining and Supplying Oil Level Gauge Removal and Front Exhaust Pipe Removal and Installation (Refer to GROUP 15 Exhaust Pipe and Muffler.) Specified sealant: 5699 or equivalent...
Page 195: Crankshaft Front Oil Seal
ENGINE Crankshaft Front CRANKSHAFT FRONT OIL SEAL REMOVAL AND INSTALLATION and Post-installation Operatidn Timing Belt Removal and Installation (Refer to Removal steps 1. Crankshaft sprocket 2. Crankshaft front oil seal REMOVAL SERVICE POINTS CRANKSHAFT SPROCKET REMOVAL Caution Do not nick the shaft seal surface or seal bore. FRONT OIL SEAL Use the special tool to remove the crankshaft front oil seal.
Page 196 ENGINE Crankshaft Front Oil Seal INSTALLATION SERVICE CRANKSHAFT FRONT OIL SEAL Use the special tool to align the oil seal witti the’ CRANKSHAFT SPROCKET INSTALLATION...
Page 197: Crankshaft Rear Oil Seal
ENGINE Crankshaft Rear Oil Seal CRANKSHAFT REAR OIL SEAL REMOVAL AND INSTALLATION and Post-installation Operatidn Transaxle Assembly Removal and Refer to GROUP Transaxle Assembly.) Refer to GROUP -Transaxle Assembly.) Clutch Cover and Clutch Disc Removal and Installation Removal steps 1. Flywheel 2.
Page 198 ENGINE Crankshaft Rear Oil (3) Drive the seal into the using and handle until the tool bottoms the block. If the seal is driven into block an oil leak. TSB Revision...
Page 199: Cylinder Head Gasket
Cylinder Head CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Operation Post-installation Operation Fuel Line Pressure Releasing (Refer to GROUP Air Cleaner Installation On-vehicle Service.) Engine Oil Engine Coolant Draining (Refer to GROU Maintenance Service.) (Refer to GROUP 00 Maintenance Service.) Engine Coolant Supplying Engine Oil Draining (Refer to GROUP 00 Maintenance Service.)
Page 200 Cylinder Head ENGINE 4.9 Nm Engine oil 16. High-pressure fuel hose connection 8. Accelerator cable connection 17. Purge air hose connection 9. Throttle position sensor connector Brake booster. vacuum hose motor connector connection 11. Injector harness connector 19. Overflow tube connection 12.
Page 201 ENGINE Head Gasket <Long <Short bolts> Intake and exhaust camshafts (Refer to 23. Front exhaust pipe connection 24. Gasket 25. Cylinder head bolt 26. Cylinder head 27. Cylinder head gasket REMOVAL SERVICE POINT (A, RADIATOR UPPER HOSE DISCONNECTION Place mating on the radiator hose hose clamp, and then disconnect the radiator hose.
Page 202 E N G I N E Cylinder Head INSTALLATION SERVICE POINTS CYLINDER HEAD (1) Cylinder head bolts should be carefully before reuse. If the threads are necked bolts should be replaced. Necking can be checked by holding a edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.
Page 203 ENGINE Cylinder Head Gasket HIGH-PRESSURE FUEL HOSE CONNECTION When connecting the high-pressure fuel to the fuel rail, apply a small amount of clean engine oil to the and then insert, being careful not to the O-ring. Caution Do not let the engine oil get into the fuel rail. Revision...
Page 204 ENGINE Timing Belt TIMING BELT REMOVAL AND INSTALLATION Post-installation Operation Operation Crankshaft Pulley Installation (Refer to Pulley Removal Engine Adjustment (Refer to 88 Nm Removal steps 5. Front timing belt cover 1. Power steering oil pump 6. Timing belt tion 7.
Page 205 ENGINE Timing Belt REMOVAL SERVICE POINTS POWER STEERING OIL PUMP Remove the power steering oil pump from the bracket with the hose attached. Place the removed power pump in a place where it will not be a hindrance when removing and installing ‘the timing belt, and tie it with a cord.
Page 206 ENGINE Belt INSTALLATION SERVICE POINT T.D.C. Reference mark TIMING BELT BELT INSTALLATION (1) Set the crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. (2) Set the camshafts timing marks together by aligning notches on sprockets.
Page 207: Sealants
CONTENTS INTAKE MANIFOLD CAMSHAFT AND CAM FOLLOWER .... 28 PUMP . . , ......OIL PAN AND COOLING SYSTEM COMPONENTS .....
Page 208 ENGINE OVERHAUL General Information GENERAL INFORMATION GENERAL SPECIFICATIONS Descriptions Specifications In-line DOHC Number of cylinders Cylinder bore mm (in.) 87.5 (3.445) 83.0 (3.267) Piston stroke mm (in.) Compression ratio Valve timing Intake valve Opens (BTDC) 1.3” [Measured at 0.5 Closes (ABDC) 39.7”...
Page 209: Service Specifications
ENGINE OVERHAUL SPECIFICATIONS SERVICE SPECIFICATIONS Standard value Limit Ignition coil system Spark plug cable 12000 Ignition coil Primary Secondary Camshaft and cam follower Cam wear amount mm (in.) 0 . 0 2 5 4 0.254 Camshaft bearing bore diameter mm (in.) Camshaft diameter bearing clearance mm (in.) Camshaft end play mm (in.) 0.15...
Page 210 ENGINE OVERHAUL ..-- ----- ---- Items Standard value Valve margin mm (in.) Exhaust Valve length (Overall) mm (in.) Intake Exhaust (4.314-4.334) Valve stem tip height mm (in.) Intake 48.04 (1.891) Exhaust 47.99 (1.889) Valve stem diameter mm (in.) Intake 5.934-5.952 Exhaust...
Page 211 ENGINE OVERHAUL Specifications Items Standard value Limit Piston, connecting rod and cylinder block Piston standard piston size mm (in.) 87.463-87.481 Piston to bore clearance mm (in.) From bottom of skirt mm (in.) Land clearance (Diametrical) mm (in.) Piston length mm (in.) 63.82 Piston ring groove Top upper compression ring...
Page 212 ENGINE OVERHAUL Specifications Items Standard value Limit Connecting rod bearing oil clearance mm (in.) Connecting rod piston pin bore diameter mm (in.) Connecting rod large end bore diameter mm (in.) Connecting rod side clearance mm (in.) 0.37 Main bearing journal diameter mm (in.) Main bearing journal out-of-round mm (in.) 0.0035 Main bearing journal taper mm (in.)
Page 213 ENGINE OVERHAUL Items Engine coolant temperature sensor Fuel and emission control parts EGR tube EGR valve Intake manifold Intake manifold air temperature sensor Manifold absolute pressure sensor 1 . 4 Intake manifold Exhaust manifold Exhaust manifold Camshaft and cam follower Cvlinder head cover Bearing head cover No.
Page 214 ENGINE OVERHAUL FORM-IN-PLACE GASKETS There are numerous places where form-in-place gaskets are used on the engine. Care must be when applying form-in-place gaskets to assure obtaining the desired results. size, continuity, ‘and location are of great importance. Too thin a bead can result in leakage too much can result’...
Page 215: Special Tools
ENGINE OVERHAUL SPECIAL TOOLS Tool number and name Application Tool Removal Removal crankshaft damper/sprocket 8995057 1026 Removal of damper. Removal puller damper Installation of crankshaft damper ‘and crankshaft Installer damper/sprocket Holding camshaft sprocket when loosening or End yoke holder Pin (2) Installation of crankshaft 6792 sprocket.
Page 216 ENGINE OVERHAUL Special crankshaft seal Installation of crankshaft oil seal 6926-2 8995060 TSB Revision...
Page 217 ENGINE OVERHAUL Generator GENERATOR REMOVAL (1) Remove drive belt. (2) Remove generator. (3) Remove generator (4) Remove bracket. INSTALLATION (1) Install bracket. (2) Install generator brace. (3) Install generator. (4) Install drive belt. (5) Loosen the generator pivot nut. (6) Loosen the lock nut. (7) Turn the adjusting screw to adjust the belt tension to the standard value.
Page 218 ENGINE OVERHAUL SYSTEM 11301840018 Ignition coil fasteners REMOVAL The electronic ignition coil pack attaches to the cylinder head cover. (1) Disconnect electrical connector from coil pack. (2) Remove coil pack mounting nuts. (3) Remove coil. (4) Remove spark plug cables. (5) ‘Remove the spark plug using a socket with ‘a rubber or foam insert.
Page 219 ENGINE OVERHAUL Ignition Remove crankshaft position sensor mounting screw. Re- move sensor Revision...
Page 220 ENGINE OVERHAUL INSTALLATION (1) Install crankshaft position sensor. (2) The target magnet has locating dowels that fit into off-set Target machined locating holes in end of the camshaft. install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (2.2 torque.
Page 221 ENGINE OVERHAUL Ignition INSPECTION SPARK PLUG CABLE must be between 3,000 to 12,000 ohms per foot of cable. Replace any cable not within tolerance. IGNITION COIL (1) Measure the primary of each ‘At the coil, connect an ohmmeter between the and the pin corresponding to the Resistance...
Page 222: Timing Belt
E N G I N E O V E R H A U L TIMING BELT 11301860021 REMOVAL Caution Camshaft or crankshaft should not be rotate after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timlng belt. (1) Remove crankshaft damper bolt.
Page 223 ENGINE OVERHAUL Belt (9) When tensioner is removed from it is necessary Tensioner to compress the plunger into the tensioner body. the tensioner into a vise slowly compress the plunger. Caution Index the tensioner installed on the engine. This is to proper pin orientation when ‘is installed on the...
Page 224 ENGINE OVERHAUL Timing INSTALLATION 11301870017 (1) Install camshaft seal into cylinder head using Tool until flush with the head. NOTE Shaft seal lip surface must be free of varnish, nicks. Polish with 400 grit paper if necessary. (2) Install rear timing belt cover. Tighten fasteners to 9.6 Nm (6.9 (3) Install support bracket.
Page 225 ENGINE OVERHAUL Belt belt. Starting at the crankshaft, go around the water pump sprocket, ‘idler pulley, and then around the tensioner pulley. crankshaft sprocket to up belt slack. Install tensioner to block but do not tighten fasteners. a torque wrench on the tensioner pulley, apply 28 Nm (20 of torque to tensioner.
Page 226 ENGINE OVERHAUL Belt engine mount Tighten bolts to 41 Nm (30 crankshaft damper using Using Special Tools to hold damper, tighten crankshaft bolt to 62 Nm (45 Revision...
Page 227 Cooling System ENGINE OVERHAUL COOLING SYSTEM COMPONENTS REMOVAL (1) Remove water pump attaching screws to engine. (2) Remove level gauge. (3) Remove exhaust manifold cover. (4) Remove water hose. (5) Remove water pipe. (6) Remove O-ring. (7) Remove thermostat housing bolts and housing. (8) Remove thermostat, discard gasket and clean both gasket sealing surfaces.
Page 228 ENGINE OVERHAUL Cooling System (1) Install switch. (2) Install engine coolant lighten sensor to 7 Nm (5 torque. clean water) on water (3) Place a new gasket (dipped in Pressure cap Overflow water gasket. box surface, center thermostat in nipple Place housing over gasket and thermostat;...
Page 229 ENGINE OVERHAUL Fuel FUEL AND EMISSION CONTROL PARTS Intake manifold REMOVAL (1) Remove screws attaching EGR tube to intake manifold. (2) Remove EGR valve mounting screws. Remove EGR valve and transducer. (3) Disconnect purge hose from throttle. body. (4) Remove throttle body mounting bolts. Remove throffle body.
Page 230 ENGINE, OVERHAUL Fuel and Emission Control,, INSTALLATION (1) Apply a light coating of clean engine,, oil to the upper O-ring. (2) Install injector in cup on fuel (3) Install retaining clip. (4) Apply a light coating of clean engine oil to ‘the -O-ring on the nozzle end of each Insert fuel injector nozzle into openings in manifold.
Page 231 ENGINE OVERHAUL Manifold INTAKE MANIFOLD (1) Remove intake air temperature sensor. (2) Remove manifold absolute pressure (MAP) sensor mount- ing screws. (3) Remove manifold absolute pressure (MAP) sensor. (4) Remove intake manifold stay. EGR tube (5) Remove EGR tube fasteners from the and valve.
Page 232 ENGINE OVERHAUL INSTALLATION EGR tube 11661966616 (1) Install new manifold gasket. DO NOT APPLY SEALER. (2) Set manifold in place. Tighten retaining fasteners, starting at center and progressing outward in both directions to 23 Nm (17 Repeat this procedure until all fasteners are at specified torque.
Page 233 ENGINE OVERHAUL Exhaust EXHAUST MANIFOLD REMOVAL (1) Remove oil level gauge. (2) Remove exhaust manifold. heat shield, (3) Remove 8 exhaust manifold retaining move exhaust manifold. (1) Install new manifold gasket. DO NOT APPLY-SEALER. (2) Set exhaust manifold in Tighten nuts and bolt, starting at center and both directions to 23...
Page 234 OVERHAUL and Cam Camshaft CAMSHAFT AND CAM FOLLOWER 11301990010 REMOVAL (1) Remove the cylinder head cover fasteners. cylinder head. (2) Remove cylinder head cover from askets (3) Bearing caps are identified for outside bearing caps first. (4) Loosen the camshaft bearing cap attaching fasteners in sequence shown in one camshaft at a time.
Page 235 Camshaft ENGINE OVERHAUL INSTALLATION (1) Install hydraulic lash adjuster making. that adjusters are at least by little or no plunger travel the lash adjuster is depressed. (2) Lubricate with clean oil and install cam follower assemblies in their original position on the hydraulic adjuster and valve stem.
Page 236 ENGINE OVERHAUL (9) Install head cover assembly to head and tighten fasteners in sequence shown in the figure. Using the 3 step torque method: Step 1 Tighten all fasteners to 4.5 Nm (3.3 Step 2 Tighten all fasteners to 9.0 Nm (6.5 Step 3 Tighten all fasteners to 12 Nm (9 Spark plug well gaskets TSB Revision...
Page 237 Follower ENGINE OVERHAUL Camshaft and Cam INSPECTION CAMSHAFT and bind- (1) Inspect camshaft bearing journals for damage ing. head bear- If journals are binding, also check the cylinder ing surface for damage, and check the camshaft bearing oil feed holes in the cylinder head for clogging. and damage.
Page 238 ENGINE OVERHAUL C Y L I N D E R A N D REMOVAL Remove cylinder head bolts. (2) With cylinder head removed, compress valve springs using Special Tool or equivalent. retaining locks, valve retainers and valve- spring. (4) Remove valve stem seal/valve spring seat Spe- cial Tool (5) Before removing valves, remove...
Page 239 ENGINE OVERHAUL Cylinder and Valve INSTALLATION (1) Coat valve stems with clean engine oil and in cylinder head: (2) If valves or seats have been reground,! valve tip Valve retaining locks height (A). Make sure of measurements from cylinder head to the top of valve stem.
Page 240 ENGINE OVERHAUL Cylinder (6) Tighten the cylinder head bolts in the sequence shown in the figure. Using the 4 step torque turn method, tighten according to the following values: Step Tighten center fasteners 1 thru 6 to 33 Nm (24 then outer fasteners 7 thru 10 to 26 Tighten center fasteners to 67.
Page 241 ENGINE OVERHAUL Cylinder INSPECTION 11390790119 CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and feeler gauge. Limit: 0.1 mm in.) VALVE (1) Clean valves thoroughly and discard burned, warped and cracked valves. (2) Measure valve stems for wear. (3) If valve stems are worn more than 0.05 mm in.), replace valve.
Page 242 E N G I N E O V E R H A U L Head and This wrench at this instant. Multiply this reading by will give the spring load at test length. Fractional measure- ments are indicated on the table for finer adjustments. Refer to specifications to obtain specified and allow- that...
Page 243 (Overall) Intake 111.49-111.99 mm (4.389-4.499 in.) Exhaust in.) Stem Diameter Intake 5.934-5.952 mm in.) Exhaust in.) Valve Margin Intake 1.285-1.615 mm in.) Exhaust in.) (3) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating true and complete surface must Measure the concentricity of valve seat using a valve seat dial indicator.
Page 244 ENGINE OVERHAUL Cylinder Head seat is properly positioned, the width of intake and exhaust seats should be 0.9 to 1.3 mm in.). (7) Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip until A is equal to 47.99 mm (1.889 in.) for exhaust valve and 48.04 mm (1.891 in.) for intake valve over spring seat when installed in the head.
Page 245 ENGINE OVERHAUL Oil Pan REMOVAL (1) Remove flywheel or drive plate: (2) Remove rear plate. ‘Remove oil filter. (4) Remove adapter. (5) Drain engine oil and remove oil pan. (6) Clean oil pan and all gasket surfaces. (7) Remove oil pick-up tube. (8) Remove crankshaft using Tool,...
Page 246 ENGINE OVERHAUL Oil Pan and Oil’ (1) Apply Loctite 51817 to oil pump as shown in the figure. Install oil-ring into the counter bore on the oil pump body discharge passage. oil pump slowly onto crankshaft until seated to engine ‘block. Tighten fasteners to 23 Nm (17 (3) Install new seal by using Tool (4) Place seal into opening with seal spring toward the inside engine.
Page 247 E N G I N E O V E R H A U L Oil ‘Pan and Oil Pump (7) Apply Loctite 18716 or equivalent at the bed plate parting line. (8) Install the oil pan gasket to the plate. Mopar Silicone Rubber Adhesive Sealant or equivalent to hold in place.
Page 248 ENGINE OVERHAUL Oil Pump PUMP Gasket DISASSEMBLY Sprin (1) To remove the relief valve,’ proceed as (a) Remove the threaded and gasket from the oil Caution Install oil pump pressure relief valve as shown in the figure, or serious damage may occur. (b) Remove spring and relief valve.
Page 249 ENGINE OVERHAUL INSPECTION (1) Wash all parts in a suitable solvent and for damage or wear. (2) Mating surface of the oil pump should be smooth. Replace pump cover if scratched or (3) Lay a straightedge across the pump cover surface. a feeler gauge of 0.076 mm ‘in.) or more can be inserted between cover and straightedge, cover should...
Page 250 E N G I N E -‘Oil (7) Install inner rotor into pump housing. If clearance between inner and outer rotors exceeds the limit, replace both rotors. Limit: in.) Feeler Outer rotor (8) Place a straightedge across the face pump between bolt holes.
Page 251 Piston, ENGINE and Cylinder PISTON, CONNECTING ROD Rear Engine block crankshaft seal CYLINDER BLOCK Engine metal case crankshaft seal REMOVAL (1) insert a flat ‘screwdriver between the dust lip and the metal case of the seal. the dust lip metal Angle the screwdriver through case of the seal.
Page 252 Piston, ENGINE OVERHAUL DISASSEMBLY (1) Separate piston from rod by removing piston pin. a suitable ring expander,, remove and inter- mediate piston rings. (3) Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. ring grooves of any carbon deposits.
Page 253 ENGINE and Cylinder REASSEMBLY (1) Install rings with manufacturer’s mark facing up, to- ward the top of the piston. Caution Install piston rings in the following order: (a) Oil ring expander. (b) Upper oil ring side rail. (c) Lower oil ring side rail. (d) No.
Page 254 Piston, ENGINE OVERHAUL and Cylinder (6) Position ring expander the side gaps but ‘on the pin canter on the thrust direction. Staggering important control. TSB Revision...
Page 255 piston, ENGINE (1) Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. (2) Before installing the ring compressor, make sure the ring expander ends are butted and the rail as shown in the figure.
Page 256 Piston, Connecting ENGINE OVERHAUL (6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. (7) Install connecting rod bearings selected based obtained connecting rod bearing (Refer to CONNECTING ROD BEARING CLEARANCE.) TSB Revision...
Page 257 a n d (8) Install each bolt finger tight then alternately torque each nut to. assemble the cap properly. (9) Tighten the bolts to 27.0 Nm PLUS turn (20 PLUS turn). Do not use a torque wrench for last step. (lO)Using a feeler gauge, check connecting rod’...
Page 258 Piston, Connecting Rod ENGINE OVERHAUL INSPECTION BLOCK (1) Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. (2) Examine block and cylinder bores for cracks or fractures. CYLINDER BORE (1) The cylinder walls should be checked for out-of-round and taper with Tool or equivalent cylinder...
Page 259 Piston, E N G I N E PISTON RING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least in.) from bottom of bore.
Page 260 piston, ENGINE OVERHAUL Cylinder Block CONNECTING BEARING (1) Place a piece of Plastigage across the, width of bearing in the 6.35 mm off center and away -from the hole. suspect areas can be checked, by placing the suspect area. (2) Before assembling the rod with in place;...
Page 261 OVERHAUL CRANKSHAFT REMOVAL Procedures after removing crankshaft sprocket, oil pan, pis- tons and connecting rods. (1) Using Tool remove front crankshaft oil seal. Be careful not to damage the seal surface of cover. out rear seal with screwdriver. careful not to nick or damage crankshaft flange seal surface or retainer bore.
Page 262 ENGINE Crankshaft I N S T A L L A T I O N (1) Install oil level gauge (dipstick). (2) Install oil pressure switch. (3) Install knock sensor. Tighten knock sensor to 10 Nm torque. Over or under tightening effects knock sensor performance, possibly causing improper spark con- t r o l .
Page 263 ENGINE OVERHAUL NOTE All upper bearing in the crankcase have oil grooves. All lower bearing shells installed in the (bedplate) main bearing caps are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal.
Page 264 ENGINE installing the bolts, the threads should be oiled with engine oil. main bearing to engine block bolts thru finger tight, then torque main bearing bolts to 75 Nm (55 in sequence shown in the figure. main bearing to engine block bolts (A thru finger tight, then torque each bolt to 28 Nm (20 in sequence shown in the figure.
Page 265 ENGINE OVERHAUL new front seal into opening with seal spring towards the inside of engine. seal by using Tool until flush with oil pump cover. Caution if burr or scratch is present on the crankshaft edge (chamfer), with 400 grit sand paper to prevent seal damage during of new seal.
Page 266 E N G I N E INSPECTION CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or on any crankshaft journals should be held. to in.). Journal grinding should not exceed 0.305 mm in.) under the standard Do NOT grind thrust faces of...
Page 267 ENGINE BEARING CLEARANCE (1) The. total: clearance of the main bearings can only be determined by removing the weight of the crankshaft. This is accomplished by having the engine turned upside down on the engine stand. This will remove all the crank- weight off the bearing surface.
Page 268 ENGINE OVERHAUL OPTIONAL CRANKSHAFT END PLAY CHECK (1) Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crank- shaft cheek, using care not to damage any bearing sur- face.
Page 269 CONTENTS Compression Pressure Check ... CAMSHAFT AND CAMSHAFT OIL Curb Speed Check ....SEAL ........Drive Belt Tension Check and .
Page 270 ENGINE General Information GENERAL INFORMATION Specifications In-line OHV, SOHC Number of cylinders Bore Stroke Piston displacement Compression ratio Firing order Counterbalance shaft Equipped Valve timing Intake valve Opens 18” BTDC Closes 58” ABDC Exhaust valve Opens 58” BBDC Closes 18” ATDC Lubrication system Pressure feed-full flow filtration LUBRICATION SYSTEM...
Page 271 S E A L A N T S S p e c i f i e d s e a l a n t Items MITSUBISHI GENUINE PART or equivalent Oil pan, cylinder block and thermostat case assembly Stud locking 4170 or...
Page 272: Crankshaft Pulley
ENGINE Special Tools SPECIAL TOOLS Tool Tool number and name Supersession Application Idle tool (MUT-II) ROM pack 8991325 Supporting of the lash adjuster to prevent it from falling when Lash adjuster holder rocker shaft assembly is moved or installed Camshaft oil seal installation oil seal Oil pan gasket cutter are removed or reinstalled.
Page 273: Crankshaft Rear Oil Seal
Tools Tool Tool number and name Supersession Crankshaft rear oil seal tion Crankshaft rear oil seal installer Handle GENERAL SERVICE engine assembly TOOL when removing and installing transaxle Engine lifter Auto tensioner installation Tensioner pulley wrench Crankshaft sprocket removal General service tool Crankshaft sprocket Removal and installation of cylinder head bolt...
Page 274 ENGINE Troubleshooting TROUBLESHOOTING Probable cause Remedy Symptom Compression too low Cylinder head gasket blown Replace gasket Piston ring worn or damaged Replace rings Piston or cylinder worn Repair or replace piston and/or cylinder block Repair or replace valve and/or seat ring Valve seat worn or damaged Oil pressure drop Engine oil level too low...
Page 275 ENGINE On-vehicle Service DRIVE BELT TENSION CHECK AND A D J U S T M E N T GENERATOR DRIVE BELT TENSION Use the belt tension gauge to check belt tension the shown point or check deflection by applying to the shown point.
Page 276 ENGINE O n - v e h i c l e S e r v i c e POWER STEERING PUMP DRIVE BELT TENSION CHECK Use the belt tension gauge to check belt tension at the shown point or check deflection by applying 98 to the shown point.
Page 277 On-vehicle Service A/C COMPRESSOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen tension pulley fixing nut A. 2. Adjust belt tension with adjusting bolt B. Standard value: When a new belt is When a used belt is installed installed Tension 382-411 255-333 (Ibs.) 8.5-7.5 Deflection...
Page 278 ENGINE On-vehicle Press the scan tool clear key (select forced driving cancel mode) to release the ACTUATOR TEST NOTE If the test is not a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. Check that the actual ignition timing is at the standard value.
Page 279 On-vehicle Run the engine. 8. Set CO, HC tester. 7. Check the CO contents and the HC contents at idle. Standard value: CO contents: 0.5% or less HC contents: 100 ppm or less the standard value is exceeded, check the following items: Diagnostic output Closed-loop control (When the closed-loop control...
Page 280 ENGINE On-vehicle 5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution Keep away from the spark plug hole when crank- ing.
Page 281 ENGINE On-vehicle Service’ 3. Attach a three-way joint to the vacuum hose connected between the intake manifold plenum and the fuel pressure solenoid valve and connect a vacuum gauge. 4. Start the engine, and check that the curb idle speed is within the standard value range.
Page 282 ENGINE On-vehicle NOTE If the vehicle is parked on a slope for long, in the lash adjusters will and ‘air may enter the high-pressure’ chamber when the vehicle i s s t a r t e d . After the vehicle is parked for long, air may enter the high-pressure because, the oil in the oil passage will be gone...
Page 283: Engine Assembly
Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Pm-removal Operation Post-installation Operation Fuel Line Pressure Releasing Radiator Installation (Refer to GROUP On-vehicle Service.) (Refer to GROUP 14 Radiator.) Hood Removal Transaxle Assembly Installation Refer to GROUP Transaxle Assembly.) Engine Coolant Draining (Refer to GROUP 00 Maintenance Refer to GROUP...
Page 284 4 . 9 N m \ / X L - - 8. Accelerator cable connection 20. Crankshaft position sensor air control motor connector connector Heated oxygen sensor connector 21. Air conditioning compressor 11. Engine coolant temperature gauge connector 22. Evaporative emission purge sole- unit connector 12.
Page 285 Engine 30. Front exhaust pipe connection 31. Gasket 32. Engine mount bracket assembly 33. Engine assembly...
Page 286 REMOVAL SERVICE POINTS POWER STEERING PUMP REMOVAL power steering pump from the bracket with the hose attached. NOTE Place the removed power steering pump in a place where will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. A/C COMPRESSOR REMOVAL Disconnect the compressor connector and remove the...
Page 287 Engine Assembly INSTALLATION ENGINE INSTALLATION Install the engine while checking hoses, and harness connectors are not clamped. MOUNT BRACKET ASSEMBLY INSTALLATION (1) Place a garage jack against the engine oil pan piece of wood in between, and install the engine mount bracket assembly while adjusting the position of the gine.
Page 288 ENGINE Crankshaft CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal’ Operation Under Cover Removal to GROUP 42 Under (Refer (Refer to GROUP 42 Under Cover.) Removal steps 1. Drive belt (Generator) 2. Drive belt (Power steering) 3. Drive belt (NC) 4. Crankshaft pulley TSB Revision...
Page 289 REMOVAL AND INSTALLATION Pm-removal Operation Post-installation Battery Removal Battery Installation Engine Adjustment 00005324 Sealant: MITSUBISHI GENUINE PART Engine oil or equivalent Removal steps 1. Accelerator cable connection 9. Timing belt upper cover ..2. Air Intake nose 10.
Page 290 ENGINE and Camshaft Oil ‘Seat REMOVAL SERVICE SPROCKET (1) Rotate the crankshaft (right) direction and align the timing marks. cylinder the compression stroke top dead center position.) Caution forward The crankshaft must always be rotated in the direction only. sprocket (2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket will not move with respect to the timing belt.
Page 291 Camshaft ENGINE Install the rocker spring installing, Remove the (4) Confirm that the rocker shaft notch is in the direction shown in the diagram. OIL SEAL INSTALLATION (1) Apply engine oil to the camshaft oil seal lip. Use the special tool to the camshaft oil seal.
Page 292: Oil Pan And Oil Screen
Maintenance service.) Oil Level Gauge Removal and Installation Front Exhaust Pipe Removal and Installation Exhaust Pipe and Main (Refer to GROUP 15 Muffler.) Specified sealant: MITSUBISHI PART or equivalent 39 Nm 00000245 Removal steps 1. Bell housing cover 2. Drain plug 3.
Page 293 ENGINE Oil Pan and OIL PAN REMOVAL After removing the oil pan remove the oil pan with the special tool and brass Caution Do it slowly to avoid deformation of flange. INSTALLATION SERVICE POINTS OIL PAN INSTALLATION Caution After cleaning the oil bolt holes seal case, the oil’...
Page 294 ENGINE Crankshaft Front Oil Seal CRANKSHAFT FRONT OIL SEAL REMOVAL AND INSTALLATION and Post-installation Operation Timing and Installation Removal (Refer to Engine oil 0 0 0 0 3 9 1 7 Removal steps 1. Crankshaft sprocket front oil seal INSTALLATION SERVICE POINT CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Apply engine oil to the entire inside diameter of the oil seal lip.
Page 295 ENGINE Crankshaft Rear Oil Seal REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Transaxle Assembly Removal and Installation Refer to GROUP Assembly.) Refer to GROUP Assembly.) Clutch Cover and Clutch Disc Removal and Installation 127-137 Nm -101 Crankshaft Specified sealant: Stud locking 4170 or equiv- Engine oil alent Removal steps...
Page 296 INSTALLATION SERVICE POINTS CRANKSHAFT REAR OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the entire inside diameter of the oil seal lip. (2) Tap in the oil seal as shown in the illustration. DRIVE PLATE BOLT BOLT <M/T>...
Page 297 ENGINE Cvlinder Head REMOVAL AND INSTALLATION Operation Post-installation Operation (Refer to (Refer to steps Removal 24. Breather hose connection TSB Revision...
Page 298 Cylinder ENGINE Head Gasket 24 Nm 00004208 S p e c i f i e d PART Revision...
Page 299 ENGINE Cylinder Head REMOVAL SERVICE POINTS CAMSHAFT SPROCKET REMOVAL (1) Rotate the crankshaft in the forward (right) ‘and, align the timing marks. is the stroke top dead position.) Caution The crankshaft must always be in the sprocket direction only. (2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket with respect to the timing belt.
Page 300 ENGINE Cylinder Head Gasket CYLINDER HEAD BOLT Using the special tool, the bolts in the order shown in the illustration (in 2 or 3 stages), and then remove the cylinder head assembly. Caution Because the plug guides cannot, be replaced by them- selves, be careful not to damage or deform the when removing the cylinder head bolts.
Page 301 Cylinder Head Gasket ENGINE Painted marks Painted marks Caution make a tightening angle just 90”. it is than the head bolt will be loosened. and repeat If it is more than remove the head bolt the ‘procedure from step 1. O-RING INSTALLATION Thermostat case assembly or water pump...
Page 302 Cvlinder (2) Apply specified sealant to the thermostat case assembly in the places shown in the Specified sealant: MITSUBISHI GENUINE lent (3) Apply a small amount of the O-ring of the water inlet pipe, and then press the thermostat case assembly into the water inlet pipe.
Page 303 ENGINE Timing Belt REMOVAL AND INSTALLATION Pre-removal Operation Under Cover Removal Under Cover Installation (Refer to GROUP 42 Under Cover.) (Refer to GROUP 42 Under Cover.) Engine Mount Bracket Removal Engine Adjustment (Refer to GROUP 32 Engine Mounting.) Engine Mount Bracket (Refer to GROUP 32 Engine Mounting.) 7.2-8.7...
Page 304 ENGINE marks TIMING BELT, REMOVAL (1) Turn the crankshaft in the forward direction (to the to align the camshaft sprocket timing marks. Caution Always turn the crankshaft in the o n l y . (2) Loosen the tension pulley center bolt. (3) Move the tension pulley to the water pump side, and then remove the timing belt.
Page 305 ENGINE Timing Belt BELT INSTALLATION Timing marks (1) Align the timing marks on the camshaft sprocket; crank- shaft sprocket and oil pump sprocket. sprocket (2) After aligning the timing mark on the oil pump sprocket,’ (2.36 in.) remove the cylinder block plug and insert a Phillips screw- more driver with a diameter of 8 mm in.), and check...
Page 306 ENGINE Belt BELT TENSION ADJUSTMENT (1) After turning the crankshaft of a revolution counter- clockwise, turn it clockwise until the timing marks are aligned. (2) Loosen the tension pulley fixing bolt, and then use the special tool and a torque wrench to the fixing bolt to the specified torque while applying tension to the timing belt.
Page 307 E N G I N E Timing belt REMOVAL AND INSTALLATION R e m o v a l s t e p s REMOVAL SERVICE SPROCKET (1) Use the special tool to remove bolt. Use the special tool to remove crankshaft sprocket.
Page 308 ENGINE Timing Belt TIMING BELT REMOVAL,, Caution If timing belt “B” is to be reused, use it with an arrow on its flat side indicating the turning direction (to the right). INSTALLATION SERVICE POINTS Counterbalance TIMING BELT INSTALLATION Install timing belt by the procedure.
Page 309 E N G I N E Timing CRANKSHAFT SENSING BLADE Crankshaft Crankshaft sprocket When installing, make sure the direction is correct. See figure. Crankshaft sprocket Crankshaft blade CRANKSHAFT SPROCKET INSTALLATION Use the special tool to install the crankshaft sprocket and bolt.
Page 311: Special Tools
ENGINE OVERHAUL. CONTENTS CRANKSHAFT, FLYWHEEL AND INTAKE MANIFOLD ..... . . 25 DRIVE PLATE ......57 .
Page 312 ENGINE OVERHAUL General Information GENERAL SPECIFICATIONS TSB Revision...
Page 313: Timing Belt
OVERHAUL Specifications SERVICE SPECIFICATIONS Timing belt Rocker arms and camshaft 36.97 (1.4555) Cvlinder head and valves TSB Revision...
Page 314 ENGINE OVERHAUL Crankshaft, flywheel and drive plate Cylinder block REWORK DIMENSIONS Cylinder head and valve Crankshaft, flywheel and drive plate TORQUE SPECIFICATIONS Generator and ignition system I‘ TSB Revision...
Page 315 ’ Fuel and emission parts Intake manifold Exhaust manifold and water pump Rocker arms and camshaft TSB Revision...
Page 316 ENGINE OVERHAUL Cylinder head and valves 14.5 Front case, counterbalance shaft and oil pan Piston and connecting rod Crankshaft, flywheel and drive plate case Revision...
Page 317 ENGINE OVERHAUL SEALANTS TSB Revision...
Page 318 ENGINE OVERHAUL Special Tools, TSB Revision...
Page 319 ENGINE OVERHAUL TSB Revision...
Page 320 ENGINE OVERHAUL Tools bolt 6991654 TSB Revision...
Page 321 Generator and Ignition System ENGINE REMOVAL AND INSTALLATION . . . 23 Nm 14 Nm 5 Nm 24 Nm 11 Nm Removal steps TSB Revision...
Page 322 ENGINE OVERHAUL Generator and (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine Part No. equivalent. Revision...
Page 323 ENGINE OVERHAUL Timing Belt REMOVAL AND INSTALLATION 45 Nm 9 Nm 14 Nm 55 Nm 24’ Nm 120 Nm Removal steps 2 1 . T i m i n g b e l t r e a r , 10. Crankshaft bolt Revision...
Page 324 ENGINE OVERHAUL Timing Belt REMOVAL SERVICE POINTS TIMING BELT REMOVAL Mark belt running direction for reinstallation. NOTE (1) Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated.
Page 325 ENGINE OVERHAUL Timing Belt (2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump leaks.’ COUNTERBALANCE SHAFT SPROCKET REMOVAL SPROCKET “B” REMOVAL CAMSHAFT SPROCKET BOLT LOOSENING INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET TSB Revision...
Page 326 ENGINE OVERHAUL Timing, ENGINE SUPPORT BRACKET INSTALLATION Coat the bolts illustrated with sealant before tightening. Specified sealant: ATD Part No. 8660 or equivalent SPACER INSTALLATION Spacer Install the spacer with the chamfered end oil seal. S P R O C K E T INSTALLATION BELT “B”...
Page 327 ENGINE OVERHAUL Belt Timing (4) Move the tensioner “B” in the of arrow while lifting with a finger to give a sufficient tension to the tension side timing belt. In this condition, tighten bolt to secure tensioner “B”. When the bolt is tightened, use care to prevent shaft from turning together.
Page 328 ENGINE OVERHAUL Belt (3) Push in the rod little by little with the until the set hole A in the rod is the hole cylinder. a wire mm’ in.) the set holes. Unclamp the auto tensioner vise. (6) Install the auto tensioner to front case tighten to the specified torque.
Page 329 ENGINE OVERHAUL Belt (4) Align the timing mark on oil pump sprocket with its mating mark. (5) Remove the plug on cylinder block and insert a Phillips, screwdriver [shank diameter 8 mm. in.)] through the’ hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm (2.4 in.) or more, the timing marks are correctly aligned.
Page 330 ENGINE OVERHAUL giving two clockwise turns the crankshaft, ‘let it alone for approx. 15 make sure that the auto tensioner setting wire moves freely. NOTE If the wire does not move freely, step (10) above until it moves freely. the auto tensioner setting wire. the distance “A”...
Page 331 ENGINE OVERHAUL Timing INSPECTION TIMING BELT Replace belt if any of the following exist. (1) Hardening of back Back side is glossy without resilience, and leaves no indent when pressed fingernail.:’ (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on rib root.
Page 332 ENGINE TSB Revision...
Page 333 Fuel and Emission Parts FUEL AND EMISSION CONTROL PARTS Removal steps Revision...
Page 334 ENGINE OVERHAUL Fuel and INJECTORS (1) Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installa- tion. (2) Install injector top end into fuel rail. Be careful not to damage O-ring during installation.
Page 335 ENGINE OVERHAUL Intake Manifold REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION 18 Nm 31 Nm Removal steps TSB Revision...
Page 336 ENGINE OVERHAUL intake Manifold INSTALLATION SERVICE SEALANT HOUSING Specified sealant: Mitsubishi Genuine Part No. or equivalent NOTE (1) Be sure to install the housing quickly while sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the sealant oil and coolant for approx.
Page 337 Exhaust Manifold ENGINE OVERHAUL REMOVAL AND INSTALLATION Removal steps TSB Revision...
Page 338 ENGINE OVERHAUL Exhaust Manifold and. WATER (1) Wet the O-ring (with Caution Keep the O-ring free of oil or grease. TSB Revision...
Page 339 ENGINE OVERHAUL Rocker Arms REMOVAL AND INSTALLATION Removal steps TSB Revision...
Page 340 ENGINE OVERHAUL Arms and Camshaft Rocker REMOVAL SERVICE ARMS AND REMOVAL Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. INSTALLATION SERVICE POINTS LASH ADJUSTER INSTALLATION (1) Immerse the’ lash adjuster in clean diesel fuel. (2) Using a special tool, move the plunger up and down 4 or 5 times while pushing down lightly on the check bail in order to bleed out the air.
Page 341 ENGINE OVERHAUL Rocker Arms CAMSHAFT OIL Revision...
Page 342 ENGINE OVERHAUL Arms Camshaft Rocker INSPECTION CAMSHAFT (1) Measure the cam height. Standard Intake 37.39 mm (1.4720 Exhaust 37.47 mm (1.4752 Limit: Intake 36.69 mm (1.4524 in.) Exhaust 36.97 mm (1.4655 in.) NOTE The camshaft identification mark is stamped on the opposite end of the camshaft sprocket side.
Page 343 ENGINE OVERHAUL Rocker and Camshaft Caution Upon completion of air bleeding’ upright to prevent inside’ diesel (4) After air bleeding, set lash adjuster on the special tool (Leak down tester). (5) After plunger has gone down somewhat mm), measure time taken for it to go down 1. Replace if measured time is out of Standard value:...
Page 344 ENGINE OVERHAUL Cylinder Head CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION Removal steps ii. Exhaust valve 1. Cylinder head bolt 12. Valve stem seal 2. Cylinder head assembly 13. Valve spring seat 3. Cylinder head gasket 4. Retainer lock 14. Valve stem Seal 15.
Page 345 ENGINE OVERHAUL Cylinder Head and Valves REMOVAL SERVICE PRECAUTION FOR PARTS Keep removed parts in order according to cylinder and intake/exhaust. CYLINDER HEAD BOLTS Using the special tool, loosen head bolts. Loosen evenly, little by little. LOCK REMOVAL Store removed valves, springs and other parts, tagged to indicate their cylinder No.
Page 346 ENGINE OVERHAUL Cylinder Head RETAINER LOCK INSTALLATION valve spring, if excessively compressed, causes the bottom end of retainer to be, in contact, the stem seal. CYLINDER HEAD GASKET Identification mark Identification mark: HEAD INSTALLATION (1) When installing the cylinder head bolts, check that the’ shank length of each bolt meets the limit.
Page 347 ENGINE OVERHAUL Cylinder Head and INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.05 mm in.) Limit: 0.2 mm in.) (2) If the service limit is exceeded, correct to meet specifica- tion.
Page 348 ENGINE OVERHAUL Cylinder Head and (2) Measure the squareness of the spring and, if the limit is exceeded, replace. Standard value: or less Limit: Max. VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.
Page 349 ENGINE OVERHAUL Cylinder Head and Valves (2) Rebore the valve seat hole in the selected oversize valve seat diameter. Intake seat ring hole diameters’ in.) mm (1.3622-1.3634 in.) Exhaust seat ring hole in.) 0.6 O.S. in.) (3) Before fitting the valve seat, either heat the cylinder head up to approximately cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from...
Page 350 Front Case, ENGINE OVERHAUL Shaft and FRONT CASE, COUNTERBALANCE SHAFT AND OIL REMOVAL AND INSTALLATION during reassembly. Removal steps 17. Oil pump cover 1. Oil filter 18. Oil pump driven gear 2. Drain plug 3. Drain plug gasket 19. Oil drive gear 20.
Page 351 Front Case, ENGINE Shaft REMOVAL SERVICE POINTS PAN REMOVAL (1) Remove all oil pan bolts. (2) Drive in the special tool the cylinder, block and oil pan. NOTE Never use a screwdriver or chisel, instead service tool, as a deformed oil pan will result in oil leakage.
Page 352 Front Case, ENGINE OVERHAUL Shaft and COUNTERBALANCE SHAFT REAR BEARING REMOVAL Using the special tool, remove the left counterbalance shaft rear bearing from the cylinder block. NOTE When removing the left counterbalance shaft rear bearing, install the special tool in front of the block.
Page 353 Front Case, ENGINE OVERHAUL Shaft and I N S T A L L A T I O N Using special tools, front bearing, FRONT CASE (1) Set the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
Page 354 Front Case, Counterbalance ENGINE OVERHAUL Shaft and OIL PUMP OIL SEAL INSTALLATION Socket FRONT OIL SEAL INSTALLATION Using the special tool, install the crankshaft front oil into the front case. OIL PUMP DRIVEN GEAR PUMP GEAR INSTALLATION Apply engine oil to the gears and line up the gnment marks.
Page 355 (2) Apply a 4 mm in.) wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: MITSUBISHI GENUINE PART No. equivalent NOTE (1) Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
Page 356 Front Case, ENGINE OVERHAUL Shaft DRAIN PLUG GASKET Install the drain plug gasket in Drain pi gasket INSTALLATION side (1) Clean the installation bracket. Apply engine oil to the O-ring of, the oil filter. (3) Screw the oil filter in until the the bracket.
Page 357 Front ENGINE OVERHAUL Shaft and I N S P E C T I O N FRONT CASE (1) Check oil holes for clogging and -clean if necessary. (2) Check left counterbalance shaft front bearing wear, damage and seizure. If there is anything ‘wrong with the section, replace the front case.
Page 358 ENGINE OVERHAUL Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Lubricate all Removal steps 1. Nut 7. Piston ring No. 2 8. Oil ring 2. Connecting rod cap 9. Piston pin 3. Connecting rod bearing 10. Piston 4.
Page 359 ENGINE OVERHAUL Piston and REMOVAL SERVICE POINTS ROD CAP REMOVAL Mark the cylinder number on the side of number rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder PISTON PIN REMOVAL Piston Din tool...
Page 360 ENGINE OVERHAUL Piston and (3) Insert the press pin through the piston! pin Select the correct connecting rod guide pin Thread the guide pin onto the threaded portion of the press pin. (4) Position the piston assembly on the piston., support in the press.
Page 361 ENGINE OVERHAUL Piston Place the base on Slide the piston pin over the of the press Piston pin pin, and thread the correct Coat the piston pin with oil, aiid with the held in position, slide the guide pin through the piston Piston pin and connecting rod.
Page 362 ENGINE OVERHAUL Piston and Connecting the upper side rail. Side rail gap To install the side rail, first fit one the rail into the piston groove, then press the remaining portion into position by finger. See illustration. Use of ring expander to the side rail end gap can break the side rail, unlike other rings.
Page 363 ENGINE OVERHAUL Piston thread protectors on the connecting Timing belt side before inserting piston and assembly into the. block. Care’ must be taken not to nick crank Using a suitable piston. piston and connecting rod block. CONNECTING ROD When the bearing needs replacing, select and a, proper bearing by the following procedure.
Page 364 ENGINE OVERHAUL Piston CONNECTING ROD CAP INSTALLATION (1) Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing ylinder No. locking notches come on the same side as shown. (2) Make sure that the connecting rod big end side clearance meets the specification.
Page 365 ENGINE OVERHAUL Piston and INSPECTION PISTON RING (1) Check the piston ring for excessive breakage and replace if defects. If the’ piston has been replaced with ,a new one, the piston rings must also be replaced with, new. ones. (2) Check for the clearance between the piston ring and ring groove.
Page 366 ENGINE OVERHAUL (3) Install the connecting rod cap carefully and tighten’ nuts to specified torque. (4) Carefully remove the (5) Measure the width of the its widest part by using a scale printed on the package. Standard value: in.) Limit: 0.1 mm in.) TSB Revision...
Page 367 Crankshaft, Flywheel and Plate ENGINE OVERHAUL CRANKSHAFT, FLYWHEEL AND PLATE 11300870193 REMOVAL AND Removal steps 9. Oil seal case 1. Flywheel bolt 10. Oil seal 2. Flywheel 11. Bearing cap bolt 3. Drive plate bolt 12. Bearing cap 4. Adapter plate 13.
Page 368 ENGINE OVERHAUL Crankshaft, SERVICE CRANKSHAFT BEARING When the bearing needs replacing, select and install a proper bearing by the following procedure. (1) Measure the crankshaft journal diameter and confirm its classification from the following In the case of a crankshaft supplied as part, identification colors of its journals are painted at the positions shown in the illustration.
Page 369 ENGINE OVERHAUL Flywheel BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so that points to the timing belt side. (2) Before installing the bearing cap bolts, check that the, shank length of each bolt “meets the limit., If, the limit’ is exceeded, replace the bolt.
Page 370 ENGINE OVERHAUL Crankshaft. Drive APPLICATION TO OIL SEAL Specified sealant: Mitsubishi Genuine Part No. or equivalent (1) Be sure to install the case quickly while the sealant wet (within 15 minutes). (2) After installation, keep the sealed area from the oil and coolant for approx.
Page 371 ENGINE OVERHAUL Crankshaft, Flywheel and, INSPECTION 11300880103 CRANKSHAFT OIL CLEARANCE (1) Remove oil from the crankshaft bearing. (2) Install the crankshaft. (3) Cut the to the same length as the bearing and place it on -with axis; (4) Install the crankshaft bearing cap carefully and tighten the bolts the specified torque.
Page 372 Crankshaft, Flywheel ‘and ‘Drive Plate ENGINE OVERHAUL BORING CYLINDER (1) Oversize pistons to be used should determined on the basis of the largest bore Piston size identification mark Size Thrust 0.50 direction NOTE Size mark is stamped on piston top. outside diameter of piston to be used.
Page 373 ENGINE CONTENTS ENGINE OIL COOLER..... . ON-VEHICLE SERVICE ....
Page 374 ENGINE LUBRICATION General Information/Lubricants G E N E R A L I N F O R M A T I O N The lubrication method is a fully force-fed, full-flow filtration type. ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil harmful contaminants which may cause skin cancer.
Page 375 ENGINE LUBRICATION Service If these oils are not available, an API classification can be used.’ ON-VEHICLE ENGINE OIL Pull out the oil dipstick slowly and check that the oil is within the marks on the oil dipstick. 2. Check that the oil is dirty, that there is no coolant or gasoline mixed in, ‘and that it has, sufficient viscosity.
Page 376 12-4 L U B R I C A T I O N 4. Supply new engine oil through the oil filler. Engine oil total quantity: [including oil filter and oil cooler] Engine (Non-turbo) arid 4 . 3 q t s . ) Engine (Turbo)>...
Page 377 ENGINE LUBRICATION Oil Cooler ENGINE OIL COOLER 12100130117 REMOVAL AND INSTALLATION Operation Engine Coolant Draining (Refer to GROUP 00 Maintenance Checking and Supplying Engine Oil Engine oil Removal steps 1. Oil filter 2. Water hose connection 3. Oil cooler bolt 4.
Page 378 12-6 ENGINE LUBRICATION Engine Oil Cooler INSPECTION Check the water for cracks, clogging, or deterioration. Check the oil cooler bolt clogging deformation. Revision...
Page 379 FUEL CONTENTS FUEL INJECTION ......FUEL SUPPLY ..........AUTO-CRUISE CONTROL SYSTEM .
Page 380 13-2...
Page 381 FUEL INJECTION CONTENTS ‘Relay Relay (ASD Relay) and Fuel FUEL INJECTION (MFI) Check......, . .
Page 382 Resistor Check Engine (Turbo)>..285 MULTIPORT FUEL INJECTION (MFI) (TURBO) AND’ Throttle Position Sensor ..282 GINE> ......Turbocharger Waste Gate, Check .
Page 383 ENGINE (NON-TURBO)> General FUEL INJECTION ENGINE (NON-TURBO)> GENERAL INFORMATION Fuel Injection System consists The PCM carries activities such fuel of sensors which detect the engine conditions, injection control, idle air control and ignition the POWERTRAIN CONTROL MODULE timing control. (PCM) which controls the system based on In addition, the signals from these sensors, and actuators diagnostic...
Page 384 ENGINE (NON-TURBO)> DIAGNOSTIC TEST MODE When an abnormality is detected in one t r o u b l e c o d e of the sensors or actuators related to abnormality is output. emission control, the CHECK The RAM data inside the PCM that is MALFUNCTION INDICATOR LAMP to the sensors and nates as a warning to the driver.
Page 385 ENGINE (NON-TURBO)> MULTIPORT FUEL INJECTION SYSTEM Heated oxygen sensor Power supply Injector F u e l (Front) Vehicle speed sensor Evaporative fuel Manifold absolute switch purge solenoid sure sensor position Idle air control motor Intake air temperature switch (transaxle range sensor switch) position sensor...
Page 386 Service ENGINE (NON-TURBO)> Sealants SERVICE SPECIFICATIONS Standard value Ignition timing BTDC. at curb idle (Nonadjustable)- Curb idle Idle speed when is ON in Neutral Throttle position sensor resistance, 3 . 5 8 . 5 Idle air control motor coil resistance Intake air temperature sensor resistance Engine coolant temperature sensor 9-11...
Page 387 ENGINE (NON-TURBO)> SPECIAL TOOLS Scan tool Interface Use with Fuel pressure gauge TSB Revision...
Page 388 ENGINE (NON-TURBO)> Troubleshooting TROUBLESHOOTING DIAGNOSTIC TROUBLESHOOTING FLOW Gather information from customer. Verify complaint Reoccurs Does not reoccur. Read the diagnostic trouble code (Refer to Read the diagnostic trouble code (Refer to Diagnostic trouble trouble Recheck trouble symptom. Refer to the INSPECTION CHART FOR DIAGNOSTIC How to Cope with TROUBLE CODES (Refer to TSB Revision...
Page 389 (NON-TURBO)> ENGINE TEST MODE LAMP CHECK ENGINE/MALFUNCTION INDICATOR As a functional test, the Malfunction Indicator Lamp illuminates at key-on before engine cranking. Whenever the Power-train Control Module (PCM) sets a diagnostic trouble code that effects vehicle emissions, it illuminates the The PCM illuminates the diagnostic trouble codes that effect vehicle emissions.
Page 390 ENGINE (NON-TURBO)> Troubleshooting DTC No. Items Cylinder misfire Cylinder misfire Cylinder misfire misfire Catalytic efficiency failure EVAP purge flow monitor failure Park/neutral position switch (transaxle range switch) failure Fuel system rich Fuel system lean Downstream shorted to Closed loop temperature not reached Downstream at center TPS voltage does not agree with MAP...
Page 391 ENGINE (NON-TURBO)> Troubleshooting ON-BOARD DIAGNOSTICS Control Module (PCM) monitors The first is to cycle the ignition switch many different circuits in the fuel injection system. On-Off-On-Off-On within 5 Then count If the PCM senses a problem with a monitored the number of times the malfunction indicator lamp circuit often enough to indicate an actual problem, (check engine lamp) on the instrument panel flashes it stores a diagnostic trouble code in the...
Page 392 ENGINE (NON-TURBO)> Troubleshooting HOW TO READ AND ERASE DIAGNOSTIC CODES Caution 1. If battery voltage is diagnostic codes. may not be output. Be sure to check the, and charging system before 2. If the battery is disconnected or if the connector is disconnected, the diagnostic trouble code will be erased.
Page 393 ENGINE (NON-TURBO)> Troubleshooting If scan tool not available 1. Cycle the ignition key On-Off-On-Off-On within seconds. 2. Count the number of times the malfunction indicator lamp (check engine lamp) on the instrument panel flashes on and off. The number flashes represents the trouble code.
Page 394 ENGINE (NON-TURBO)> LEAK DETECTION PUMP MONITOR Related diagnosis trouble codes (DTC) EVAP leak monitor small leak detected EVAP leak monitor large leak detected EVAP leak monitor pinched hose found Operation The leak detection assembly incorporates two primary functions: it must detect a system and seal the evaporative system so the leak detection test can be run.
Page 395 ENGINE (NON-TURBO)> INSPECTION USING TOOL SENSOR TEST, INPUT STATE TEST,, OUTPUT T E S T 1. Carry out inspection by means:’ of the data list ‘and the actuator test function. If there is a malfunction, check and repair the chassis harnesses and components.
Page 396 ENGINE (NON-TURBO)> Troubleshooting FAIL-SAFE-BACUP FUNKTION Mode) TABLE When the PCM detects the following malfunction (s), the PCM carries out’ fail safe/back-up addition, the corresponding DTC number (s) can be identified by using the scan tool. Diagnostic item Control during malfunction No cam signal at PCM The PCM uses the crankshaft position sensor signal control fuel...
Page 397 ENGINE (NON-TURBO)> Troubleshooting Control during malfunction Diagnostic item TPS voltage does not agree The PCM uses the value calculated from the MAP sensor signal instead of the throttle with MAP valve opening angle (voltage)> Timing belt skipped 1 tooth or The PCM uses the crankshaft position sensor signal only to control more timing, etc.
Page 398 ENGINE (NON-TURBO)> Troubleshooting INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES NOTE Diagnostic trouble code (DTC) memory is not deleted even after the ignition DTC No. DTC No. DTC No. Diagnostic items Check items, (Remedy) tool <General Page (MUT-II) scan tool pulses mode>...
Page 399 ENGINE (NON-TURBO)> Memory DTC No. DTC No. DTC N Diagnostic items Check items (Remedy) tool (MUT-II) scan tool pulses mode> mode> mode> Engine coolant Harness and Retained temperature sensor Engine coolant temper voltage too low ature sensor Engine coolant Harness temperature sensor Engirie coolant temper voltage too high...
Page 400 E N G I N E ( N O N - T U R B O ) > DTC No. DTC No. DTC No. Diagnostic items Check items (Remedy) M e m o r y tool (MUT-II) scan tool pulses mode>...
Page 401: Injector
ENGINE (NON-TURBO)> Check items (Remedy) M e m o r y DTC No. DTC No. DTC No. Diagnostic items tool <General (MUT-II) scan tool pulses mode> mode> Downstream Harness and connector heater failure Downstream Retained Multiple cylinder Ignition coil misfire* Spark plug Ignition circuit Injector...
Page 402 ENGINE (NON-TURBO)> Troubleshooting DTC No. DTC No. DTC No. Diagnostic items Check items (Remedy) Memory tool <General (MUT-II) scan tool pulses mode> mode> mode> Power steering pres- Harness and connector Retained sure (PSP) switch fail- Power steering pressure switch Fuel system rich* MAP sensor output Retained Injector...
Page 403 ENGINE Memory DTC No. Diagnostic items Check items (Remedy) tool P a g e (MUT-II) Harness and connector Retained’ High speed radiator fan control relay circuit High speed radiator fan relay 5 volt supply output Harness and connector too low Fuel level sending unit Harness and connector Retained volts too low...
Page 404 ENGINE (NON-TURBO)> Troubleshooting CODES INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE Scan tool 01 Code General scan tool No Cam Sync Signal at PCM Probable cause [Comment] Open supply circuit Background Open sensor ground The PCM uses information from both the camshaft position sensor and crankshaft position Open or shorted signal circuit sensor to determine ignition timing.
Page 405 ENGINE (NON-TURBO)> C h a r g i n g T o o [Comment] Defects in generator or adjustment Background High resistance The PCM tries to maintain charging system voltage of between and 15 volts. generator This code indicates: High between battery The battery voltage input is below the target charging voltage during engine generator ground...
Page 406 ENGINE (NON-TURBO)> Troubleshooting Scan tool 06 Charging System Voltage Too General scan tool High [Comment] Generator internal shorted Background Generator field driver shorted to ‘ground The PCM tries to maintain charging system voltage of between 13.2 and 15 volts. PCM failed This code indicates that the battery voltage input is above the target charging voltage during engine operation and PCM efforts to regulate the generator field do not prevent the voltage from rising.
Page 407 Scan tool 10 Code relay relay) General scan tool [Comment] Relay coil open or shorted Background relay relay (ASD relay) controls the battery voltage supplied to the fuel injectors, ignition shorted coils, and generator. circuit The PCM provides a ground path for the relay (ASD relay).
Page 408 (NON-TURBO)> Troubleshooting Scan tool 11 Generator Field Not Switching General scan tool Properly [Comment] Field driver circuit open or Background Generator internal o p en The PCM receives generator field input. failed Battery voltage is supplied to the generator through the relay relay).
Page 409 Scan tool 16 General scan tool A/C Clutch Relay Circuit [Comment] Coinpressor clutch relay shorted Background control circuit defective The PCM provides a switched ground to the clutch relay. circuit driver in PCM The PCM can prevent operation of the clutch in selected situations such as during wide-open or for a...
Page 410 Scan tool 17 Code General scan [Comment] Open short Background Open output The PCM provides a switched ground path to the solenoid. or shorted This DTC indicates an open or short-circuit condition in the control circuit. Range of Check Battery voltage: or more Ignition switch: ON Set Condition...
Page 411 Scan tool 18 Code General Circuit [Comment] Open or short control circuit Background Open fused output It is operated as a PCM output providing a switched ground path once the vehicle enters Open or solenoid closed loop operation..This DTC indicates a short or condition in the circuit.
Page 412 ENGINE Scan tool 19 Injector Control Circuit Probable cause MIL 27 [Comment] Open or shorted injector control Background injector Grounds for the injector circuits are provided by the PCM. Open (ASD) supply Battery power is provided through the relay (ASD relay) Driver in PCM failed This DTC is set if an open or short-circuit condition is detected in the control circuit for the individual injector.
Page 413 ENGINE (NON-TURBO)> Scan tool 20 Injector Circuit Open or shorted injector control [Comment] Background Open injector Grounds for the injector circuits are provided by the PCM. (ASD) supply Battery power is provided through the relay (ASD relay). Driver tailed This DTC is set if an open or short-circuit condition is detected in the control circuit the individual injector.
Page 414 (NON-TURBO)> Scan tool 21 Injector Control Circuit Probable cause [Comment] Open or shorted injector control Background O p e n i n j e c t o r Grounds for the injector circuits are provided by the PCM. voitage supply at injector Battery power is provided through the relay (ASD ’...
Page 415 ENGINE (NON-TURBO)> Scan tool 25 Code General scan tool Air Control Motor Circuits [Comment] Driver circuit shorted to ground Background Driver circuit shorted to battery The idle air stepper motor is used to prevent the engine from shorted to together idle.
Page 416 ENGINE (NON-TURBO)> Scan tool 26 Code scan tool Position Sensor [Comment] Sensor circuit shorted to Background position The sensor consists of a resistor that provides a signal to the PCM based on the position of the throffle blade. The PCM uses throffle body position information to adjust fuel injector width.
Page 417 ENGINE (NON-TURBO)> Scan tool 27 Code scan tool Throttle Position Sensor Voltage High [Comment] Sensor circuit open Background position sensor failed The sensor consists of a resistor that provides a to the PCM based S e n s o r g r o u n d c i r c u i t on the position of the throttle blade.
Page 418 ENGINE Scan tool 31 Code General scan tool Engine Coolant Temperature Sensor Voltage Too High [Comment] Sensor signal circuit open Background Sensor internally open Data from the engine coolant temperature sensor is used in most fuel and spark related control functions. PCM failed When DTC is set, the PCM uses a default value as the engine coolant temperature, and the vehicle enters the limp-in mode.
Page 419 ENGINE (NON-TURBO)> Scan tool 33 General scan tool Too Long P r o b a b l e [Comment] Thermostat fully Background Engine temperature sensor failed When the engine is started, the engine coolant temperature The PCM checks Engine coolant temperature that the engine coolant rises the specified value within a sufficient period after the improperly connected...
Page 420 ENGINE I Scan tool 35 Code General scan tool No Vehicle Speed Sensor Signal [Comment] Open or shorted. circuit Background S p e e d o m e t e r d a m a g e d speed sensor serves as a PCM input switching voltage between 0 and 5 Open supply circuit volts.
Page 421 ENGINE (NON-TURBO)> R e p l a c e t h e P C M . SCAN SENSOR READ TEST list) 65 Vehicle speed sensor Is vehicle speed displayed during driving? Check the following Repair Check trouble symptom. Repair harness wire module connector.
Page 422 ENGINE Scan tool 37 Code General scan tool MAP Sensor Voltage Too High Probable cause [Comment] Signal circuit open Background Sensor open This code is generated when the MAP sensor voltage exceeds maximum voltage Sensor ground circuit open of 4.7 volts. Sensor circuit shorted to voltage Range of Check...
Page 423 ENGINE Troubleshooting General scan tool No Change in MAP From Start to [Comment] Ice in sensor Background Sensor failed The MAP sensor is mounted to intake manifold vacuum. failed This information provides an important PCM input for determining fuel injector pulse wide. The sensor should measure a difference in manifold pressure between key ON and after the engine is running.
Page 424 ENGINE (NON-TURBO)> Scan tool 40 Code General scan tool No Crank Reference Probable cause [Comment] Open or shorted supply circuit Background Open sensor ground The crankshaft position sensor is a Hall-effect sensor that provides a voltage signal to Open or shorted signal circuit the PCM.
Page 425 ENGINE (NON-TURBO)> Scan tool 42 Code General scan tool Ignition Coil Circuit Probable [Comment] Ignition coil wiring harness or connector Background failed The PCM provides the ground control circuit for the side of ignition coil. Open circuit in coil Battery voltage is through the relay (ASD relay).
Page 426 ENGINE (NON-TURBO)> Scan tool 43 Code General scan tool Ignition Coil Primary Circuit Probable [Comment] Ignition coil wiring harness or Background failed The PCM provides the ground control circuit for the primary side of ignition coil. Open circuit in ignition Battery voltage is supplied through the relay relay).
Page 427 ENGINE (NON-TURBO)> Troubleshooting Scan tool 44 C o d e relay) output General scan tool Voltage at PCM [Comment] relay (ASD output open Background Fused circuit open The PCM senses operation of the relay (ASD relay) by measuring relay voltage. relay (ASD reiay) failed (If relay turns to ON, voltage is high).
Page 428 ENGINE Scan tool 46 Code General scan tool EGR System Failure cause [Comment] EGR valve Background t u b e Once per vehicle trip the PCM monitors the EGR system fiow rate. harness and If the flow rate is above or below the acceptable limits, the PCM stores a’ diagnostic Vacuum hoses’...
Page 429 ENGINE , Troubleshooting Probable EEPROM Write Denied [Comment) Unsuccessful attempt to write to an EEPROM location by the control module. Replace the PCM. Scan tool 57 Code General scan Intake Air Temperature Voltage Low [Comment] Sensor Background Sensor internally shorted When the fuel system is in the open loop mode, the heated oxygen sensor cannot be PCM failed used for injector pulse width calculation.
Page 430 Scan tool 58 Code General scan tool Air Temperature Senspr Voltage High [Comment] Sensor signal circuit open Background Sensor internally open When the fuel system is in the open mode, the heated oxygen sensor cannot be Sensor ground circuit open used for injector pulse width calculation.
Page 431 ENGINE Scan tool 59 Knock Sensor Circuit [Comment] Knock sensor Background Open or shorted knock sensor The sensor consists of a material that constantly vibrates, sending a signal to the PCM when the engine is operating. When the signal exceeds a threshold, the PCM retards engine ignition timing to reduce Set Condition Knock sensor signal below minimum acceptable threshold voltage.
Page 432 ENGINE Scan tool 61 Code General scan tool Injector Control Circuit c a u s e [Comment] Open or shorted injector control Background Open injector Grounds for the injector circuits are provided by the PCM. O p e n Battery power is provided through the relay.
Page 433 ENGINE (NON-TURBO)> Scan tool 62 Code General scan tool Upstream Shorted to Volt; [Comment] Heated oxygen sensor failed Background W i r i n g Upstream heated oxygen sensor requires a heater circuit for proper operation. The heater circuit is supplied with battery voltage through the relay relay): A failure in the sensors heater circuit prevents it from providing accurate data to the PCM.
Page 434 ENGINE Scan tool 92 C o d e G e n e r a l s c a n t o o l L o w S p e e d F a n Circuit [Comment] Relay coil open or shorted Background Ignition switch output circuit open The low speed radiator fan relay controls the low...
Page 435 ENGINE Scan tool 93 Code General scan tool High Speed Control Relay Circuit [Comment] Relay, coil open, shorted Background The high speed condenser fan relay controls the high speed operation of the condenser High speed condenser fan relay control circuit fan.
Page 436 ENGINE Scan tool 96 [Comment] Communication line between The TCM outputs no messages. failed PCM failed CHECK BY SCAN TOOL Can the scan tool communicate with the TCM? Disconnect the PCM connector. Can the scan tool communicate with the TCM? Replace PCM.
Page 437 ENGINE (NON-TURBO)> Scan tool 101 Code General scan tool Fuel Pump Relay Control Circuit Relay open or shorted [Comment] Background Fuel pump relay control open The fuel pump relay control the battery voltage supplied to the fuel pump. I n o p e r a t i v e P C M , The PCM provides a ground path for the fuel pump relay.
Page 438 ENGINE (NON-TURBO)> Scan tool 102 Code General scan tool Response [Comment] Heated oxygen sensor failed Background Exhaust system failed During closed-loop operation the PCM monitors the heated oxygen sensor response rate -Pipes for proper operation. Response rate is the time required for the heated oxygen sensor to switch from - s e a l s once the sensor is exposed to a richer than the ideal air fuel mixture.
Page 439 ENGINE (NON-TURBO)> Scan tool 103 Code General scan tool Upstream Failure [Comment] Heated oxygen sensor heater open Background harness and connectors The PCM continues to monitor this system after the key is OFF. The PCM waits some periods to allow the heated oxygen sensors to cool. Once the PCM calculates that the heated oxygen sensor is cooled, it energizes the relay (ASD relay) and tests for the heated oxygen sensor operation.
Page 440 ENGINE [Comment] Heated oxygen sensor heater Background harness and The PCM continues to monitor this system after the key is OFF. The PCM waits some periods to allow the heated oxygen sensors to cool. Once the PCM calculates that the heated oxygen sensor is cooled, it energizes the relay relay) and tests for the heated oxygen sensor operation.
Page 441 ENGINE (NON-TURBO)> Scan tool 106 Code General scan tool Multiple Cylinder Mlsfire [Comment] Spark plugs or wires failed Background Ignition coil failed Excessive engine misfire results in increased catalyst temperature. Crankshaft position Severe misfire could cause catalyst damage. piston rings To prevent catalytic converter damage, the PCM monitors engine misfire.
Page 442 ENGINE Scan tool Cylinder Misfire Code General scan tool Cylinder Misfire Probable cause Cylinder Misfire Cylinder Misfire [Comment] Spark plugs or Background Excessive engine misfire results in increased catalyst temperature. valves Severe misfire could cause catalyst damage. Head gasket failed To prevent catalytic converter damage, the PCM monitors engine’...
Page 443 ENGINE (NON-TURBO)> Scan tool 112 Code General scan tool Catalytic Converter Efficiency Failure [Comment] Catalytic converter Background Heated oxygen sensor failed During normal closed-loop operation, the PCM monitors the catalytic converter for hydrocar- E x h a u s t bon conversion (HC) efficiency.
Page 444 ENGINE (NON-TURBO)> Troubleshooting’ Scan tool 113 Code General scan tool Evaporative Purge Flow Monitor Failure Purge line clogged Background Vacuum hose failed This is a functionality test. Evaporative purge solenoid failed If the fuel control doesn’t sense purge vapor flow from the canister, this code will be Evaporative emission clogged set.
Page 445 ENGINE (NON-TURBO)> Scan tool 114 Park/Neutral Position (PNP) Code General scan tool Switch (transaxle range cause Failure [Comment] range sensor failed Background Transaxle range sensor The diagnostics for the transaxle range sensor are divided into two categories. failed’ The first is trying to identify if the transaxle range sensor is indicating park or neutral while driving.
Page 446 ENGINE (NON-TURBO)> Troubleshooting Scan tool 115 scan tool Power Pressure Probable [Comment] PSP switch failed Background Wiring harness and connectors failed Data from the PSP switch allows the PCM to compensate for the additional load put on the engine during steering maneuvers that require high steering pump pressure. Range of Check Vehicle speed: 90 (56 mph)
Page 447 ENGINE (NON-TURBO)> Scan tool 118 C o d e [Comment] Engine coolant temperature Background Intake air temperature sensor The PCM monitors the fuel system for compliance with emission standards:’ Head gasket ‘failed Range of Check Exhaust manifold cracked , Engine coolant temperature is greater than , Injectors failed Closed loop operation MAP sensor failed...
Page 448 ENGINE (NON-TURBO)> Troubleshooting Scan tool 119 Code General scan tool Fuel System Lean Probable [Comment] Engine coolant temperature sensor Background Intake air temperature sensor failed- The PCM monitors the fuel system for compliance with emission standards. Head gasket Range of Check Exhaust manifold cracked Engine coolant temperature is greater than Injectors failed...
Page 449 (NON-TURBO)> Scan tool 126 Code General scan tool Downstream Shorted to Voltage [Comment] Heated oxygen sensor failed Background harness and connectors Downstream heated oxygen sensor requires a heater circuit for proper operation. The heater circuit is supplied with battery voltage through the relay relay).
Page 450 ENGINE (NON-TURBO)> Scan tool 129 C o d e G e n e r a l s c a n t o o l D o w n s t r e a m Stays at [Comment] Heated oxygen sensor (rear) Background Sensor signal circuit open Sensor output voltage is checked.
Page 451 (NON-TURBO)> Scan tool 133 Code General scan tool Timing Belt Skipped 1 Tooth or More Timing belt improperly [Comment] Background C r a n k s h a f t sensor The PCM uses voltage signals generated by the camshaft position sensor and position sensors to determine engine synchronization.
Page 452 ENGINE (NON-TURBO)> Scan tool 135 No 5 Volts to MAP [Comment] Open circuit Background Signal circuit grounded of 5 volts is to the MAP sensor. if this is extremely the MAP sensor output deviates from standard Range of Check Before starting engine and immediately after stopping engine Set Condition The output of MAP sensor is lower than the specified...
Page 453 ENGINE Scan tool 136 Code General scan tool No 5 Volts to Throttle Sensor [Comment] Sensor circuit grounded Background position sensor of 5 volts is to the TPS. if voltage is extremely low, this . Loss of output deviates from standard Range of Check Vehicle speed: More than 20 mph Engine speed: 1500...
Page 454 ENGINE Troubleshooting Scan tool 138 Code General scan tool [Comment] Idle air control motor failed Range of Check motor related circuit Engine: Vehicle at rest and the brake applied Set Condition speed differs from target idle by 200 for 12 seconds. SCAN TOOL SENSOR READ TESTS (Data list) Check the air control motor.
Page 455 ENGINE (NON-TURBO)> Scan tool 146 Code General scan too! 5 Volts Supply output Low‘ [Comment) supply circuit grounded PCM failed The PCM supplies a regulated B-volts to the and MAP sensor. This DTC is set when both the and MAP sensors have the sensing too low of voltage.
Page 456 ENGINE Scan tool 149 Code General scan tool Fuel Level Sending Unit Volts Too [Comment] Sensor signal line is grounded. . Background Fuel level sensor failed The fuel level sensor, which is installed in the fuel tank, informs the PCM of fuel level Loss of supply (amount).
Page 457 ENGINE Troubleshooting Probable cause [Comment] Fuel level sensor failed Background PCM failed The fuel level sensor, which is installed in the fuel tank, informs the PCM of fuel level (amount). The PCM does not carry out a specific monitor when the fuel amount is small or large.
Page 458 ENGINE Scan tool 154 Code General scan tool Temperature Sensor Voltage Too High [Comment] Battery temperature sensor Background PCM failed Battery temperature input is used to adjust the generator charging rate based upon the ambient temperature around the battery. Range of Check Ignition switch: ON Set Conditions The sensor voltage remains more than 4.9...
Page 459 Scan tool 156 Code General scan tool Downstream G r o u n d [Comment] Downstream heated oxygen Background harness and connectors When the heated oxygen sensor temperature is low, the sensor has the same electrical failed characteristics as an insulator. The heated oxygen sensor output signal line is That is is approx.
Page 460 ENGINE (NON-TURBO)> Scan tool 160 Code General scan tool EVAP Leak Monitor ‘ P r o b a b l e Detected [Comment] Fuel tank cap screwed on Background tank and purge lines, The PCM monitors that the fuel tank, purge lines, etc. are well.
Page 461 ENGINE (NON-TURBO)> Scan tool 183 Code General scan tool Evaporative Emission tion Solenoid Circuit [Comment] Open or short control drcuit Background Open fused ignition The PCM provides a switched ground path to the solenoid. Open or shorted solenoid This DTC indicates an open or short-circuit condition in the evaporative emission PCM failed solenoid control circuit.
Page 462 E N G I N E ( N O N - T U R B O ) > Scan tool 184 C o d e G e n e r a l s c a n t o o l E v a p o r a t i v e E m i s s i o n V e n t i l a - tion Switch or Mechanical Fault [Comment] Evaporative emission...
Page 463 ENGINE (NON-TURBO)> Troubleshooting’ INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Communication with all systems is not possible. tion with scan tool is Communication with PCM only is not possible. The check engine/malfunction indicator lamp does not illuminate right after the ignition malfunction switch is turned to the ON position.
Page 464 E N G I N E PROBLEM SYMPTOMS TABLE (FOR YOUR Items Symptom Starting Won’t The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine Fires up and dies There is combustion within the cylinders, but then the stalls.
Page 465 ENGINE (NON-TURBO)> INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with scan tool is not possible. (Communication with all systems is not possible.) The cause is probably a defect in the power supply system (including ground) for the on-board Measure at the data link connector .
Page 466 INSPECTION PROCEDURE 3 T h e c h e c k i n d i c a t o r . l a m p n o t illuminate right after the ignition switch is turned to the position. [Comment] bulb The PCM causes the check engine/malfunction indicator lamp to illuminate for three seconds, Defective check engine/malfunction...
Page 467 ENGINE Troubleshooting INSPECTION PROCEDURE 4 Probable cause The check engine/malfunction indicator lamp remains illuminated and never goes out. [Comment] Short-circuit between the check In cases such as the above, the cause is probably that the PCM is indicator lamp and detecting a problem in a sensor or actuator, or that one of the malfunctions listed at right has Malfunction of the PCM occurred.
Page 468 ENGINE (NON-TURBO)=, INSPECTION PROCEDURE 6 Fires up and dies. P r o b a b l e [Comment] of the ignition system In such cases as the above, the cause is probably that the spark plugs are generating sparks Malfunction of the injector system but the sparks are weak, or the initial mixture for starting is not appropriate.
Page 469 ENGINE (NON-TURBO)> Troubleshooting INSPECTION PROCEDURE 8 Unstable idle (Rough idle, hunting) Probable cause [Comment] Malfunction of the ignition system In cases such as the above, the cause is probably that the ignition system, Malfunction of air-fuel ratio system idle air control motor or compression pressure is defective. Malfunction of the system Because the range of possible causes is broad, inspection is narrowed down to simple items.
Page 470 ENGINE INSPECTION PROCEDURE 9 Idle speed is high. (Improper idle speed) [Comment] In such cases as the above, the cause is probably that the intake air volume during idle is’ Intake manifold vacuum leak too great. b o d y SCAN TOOL DTC Refer to INSPECTION CHART FOR DIAGNOSTIC...
Page 471 ENGINE, INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idle. (Die out) [Comment] Malfunction of the idle air control In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate when Malfunction of the fhroffle body the engine is cold, or that the intake air volume is insufficient.
Page 472 ENGINE INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idle. (Die out) [Comment] Malfunction of the ignition In cases such as the above, the cause is probably that ignition system, mixture, idle Malfunction control air control motor or compression pressure is defective. Malfunction of the system In addition, if the engine...
Page 473 ENGINE (NON-TURBO)> INSPECTION PROCEDURE 14 The engine stalls when decelerating. Probable cause [Comment] Malfunction of the system In cases such as the above, the cause is probably that the intake air volume is insufficient due to a defective idle air control motor system. Were the battery terminals disconnected recently? After warming-up, let the engine run at idling for SCAN TOOL DTC...
Page 474 ENGINE INSPECTION PROCEDURE 16 Acceleration shock [Comment] Malfunction of the ignition system In cases such as the above, the cause is probably that there is an ignition leak accompanying Improper control of reduction the increase in the spark plug demand voltage during acceleration. stiifting Refer to INSPECTION CHART...
Page 475 E N G I N E ( N O N - T U R B O ) > INSPECTION PROCEDURE 18 Poor acceleration Probable cause [Comment] Malfunction of the ignition system Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. are suspected. Malfunction of air-fuel ratio of the fuel supply...
Page 476 ENGINE Troubleshooting INSPECTION PROCEDURE 20 Knocking [Comment] Defective knock sensor In cases such as the above, the cause is probably that the detonation control is defective or Inappropriate value of the the heat value of the spark plug is inappropriate. Refer to INSPECTION CHART FOR DIAGNOSTIC Are diagnostic trouble codes...
Page 477 ENGINE INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling cause [Comment] of the air-fuel ratio control system. Abnormal air-fuel ratio is suspected. Deteriorated catalyst SCAN TOOL DTC Refer to INSPECTION CHART FOR DIAGNOSTIC Are diagnostic trouble codes output TROUBLE CODES.
Page 478 INSPECTION PROCEDURE 23 Power supply system and ignition [Comment] Malfunction When an ignition switch turns ON, battery positive voltage is supplied to the PCM. Improper connector contact, open short-circuited harness Disconnected ground wire Malfunction of the Measure at the PCM connectors Disconnect the connector and at the measure...
Page 479 (NON-TURBO)> ENGINE INSPECTION PROCEDURE 25 Transaxle range sensor circuit [Comment] The transaxle range sensor inputs the condition of the selector lever, i.e. whether it is in Improper connector contact, open circuit range or in some other range, to the PCM. The PCM controls the idle air control motor based on this input.
Page 480 ENGINE (NON-TURBO)> INSPECTION PROCEDURE 27 Fan motor relay system (Radiator fan, condenser fan) [Comment] Malfunction of fan motor relay The fan motor relay is controlled by the power transistor inside the PCM turning ON and OFF Malfunction of fan motor improper connector contact, open short-circuited wire...
Page 481 ENGINE (NON-TURBO)> INSPECTION PROCEDURE 29 S c a n t o o l : I n s p e c t i o n w h e n n o i n i t i a l c o m b u s t i o n o c c u r s . SCAN TOOL SENSOR READ TESTS list) Check the power supply system and...
Page 482 ENGINE (NON-TURBO)> INSPECTION PROCEDURE 32 Scan tool: Inspection when idle speed is unstable. SCAN TOOL SENSOR READ TESTS (Data list) air temperature (Refer to SCAN TOOL SENSOR Check MAP sensor circuit. 11 MAP sensor reading (Refer to ( R e f e r t o I N S P E C T I O N SCAN TOOL SENSOR Check the engine coolant temperature sensor...
Page 483 (NON-TURBO)> INSPECTION PROCEDURE 33 Scan tool: Inspection when engine. stalls when, engine warm SCAN TOOL SENSOR READ TESTS (Data list) air temperature sensor (Refer to N G ’ SCAN TOOL SENSOR Check the MAP sensor circuit 11 MAP sensor reading (Refer to (Refer to INSPECTION SCAN TOOL SENSOR...
Page 484 (NON-TURBO)> ENGINE Troubleshooting INSPECTION PROCEDURE 34 Scan tool: Inspection when hesitation, sag, stumble or poor acceleration occurs.’ Check the intake air 27 Intake air temperature (Refer to (Refer to PROCEDURE 39.) SCAN TOOL SENSOR Check the MAP sensor 11 MAP sensor reading. (Refer to (Refer to INSPECTION PROCEDURE 40.) Check the engine...
Page 485 ENGINE INSPECTION PROCEDURE 35 Scan tool: Inspection when surge occurs. SCAN TOOL SENSOR READ TESTS (Data list) Check the intake air’ 27 Intake air temperature sensor (Refer to (Refer to INSPECTION. PROCEDURE 39.) SCAN TOOL SENSOR Check the MAP sensor 11 MAP sensor reading (Refer to (Refer to INSPECTION PROCEDURE 40.)
Page 486 ENGINE (NON-TURBO)> Troubleshooting INSPECTION PROCEDURE 37 Check the fuel pump drive control circuit. Measure at the fuel pump relay connector Disconnect the connector and measure at the harness side. 1. Voltage between 6 and ground switch: ON) OK: Battery positive voltage 2.
Page 487 E N G I N E INSPECTION PROCEDURE 38 Check the temperature sensor circuit. engine coolant Checktheenginecool Replace Measure at the engine coolant temperature sensor connector Check the following connectors: Disconnect the connector, and measure at the harness side. Voltage between 2 and ground (Ignition switch: ON) OK: 4.7-5.2 Repair Continuity between 1 and ground...
Page 488 INSPECTION PROCEDURE 40 Check the MAP sensor circuit. Measure at the MAP sensor connector the following Disconnect the connector, and measure at the harness side. Voltage between 2 and ground (Ignition switch: ON) OK: 4.7-5.2 Continuity between 1 and ground OK: Continuity Check the harness between the PCM...
Page 489 ENGINE (NON-TURBO)> Troubleshooting INSPECTION PROCEDURE 42 Check the heated oxygen sensor (front) circuit. Replace Measure at the heated (front) connector Check the following connector: Disconnect the connector and measure at the harness side. Continuity between 2 and ground OK: Continuity Check trouble symptom.
Page 490 ENGINE (NON-TURBO)> INSPECTION PROCEDURE 44 Check the vehicle-speed sensor and speedometer. Measure at the speed sensor connector C h e c k t h e Disconnect the connector and measure at the harness side. Voltage between 1 and ground (Ignition switch: ON) OK: 8.5-9.5 Continuity between 2 and ground OK: Continuity...
Page 491 ENGINE (NON-TURBO)> Troubleshooting INSPECTION PROCEDURE 45 Check the speedometer. A-l 07, Check trouble symptom. Check the harness wire between the PCM and the combination meter. Repair, if necessary. TSB Revision...
Page 492 ENGINE (NON-TURBO)> Troubleshooting SENSOR READ TESTS (DATA LIST) REFERENCE TABLE Caution 1. When shifting the select lever to range, the brakes should be applied so that the does not move forward. 2. When checking while driving the vehicle, always be sure to have two vehicle.
Page 493 ENGINE (NON-TURBO)> Inspection procedure Normalcondition Inspection contents item Engine: Idle Step value A/C switch: OFF increases. position (A/C compressor activated) Increases Adaptive Engine: Warm, 2,500 fuel factor Disconnect any injector connector. gradually Altitude: Om (0 ft.) Barometric Ignition switch: ON pressure Altitude: (3,937 ft.)
Page 494 ENGINE (NON-TURBO)> Troubleshooting inspection Inspection Normal condition Inspection contents p a g e item Engine: Warm When at 4,000 Air/fuel mixture engine is suddenly L e a n made leaner decelerated. when decelerating, and When engine is is made richer Rich sensor suddenly raced.
Page 495 ENGINE INPUT STATE TESTS (DATA LIST) REFERENCE TABLE Item Inspection N o r m a l c o n d i t i o n p r o c e d u r e Inspection contents item When steering wheel Power is stationary steering...
Page 496 ENGINE (NON-TURBO)> OUTPUT STATE TESTS (DATA LIST) REFERENCE TABLE Item Inspection Inspection contents Normal condition item Torque When running at constant speed reduction link When shifting UP, DOWN A/C switch: OFF A/C clutch Engine: Idle A/C switch: ON (A/C ON relay compressor activated) Ignition switch: ON...
Page 497 ACTUATOR TEST REFERENCE TABLE Inspection Item Inspection Drive contents Inspection contents item Ignition coi Ground the spar Ignites every 1.4 Spark plugs Ignition switch: seconds ignite Ignition Connect new spar plugs to the Code Injector Injector Operating sound Injects every 1.4 Ignition switch: ON can be heard.
Page 498 ENGINE Inspection Drive contents Inspection contents Normal condition procedure item Fanspeedchanges When energized, High speed between off and condenser Ignition switch: ON high every 0.7 fan relay seconds. f a n o p e r a t e s Fuel pump Turned on and off Ignition switch: ON every 1.4 seconds.
Page 499 ENGINE (NON-TURBO)> ON-VEHICLE SERVICE THROTTLE BODY MINIMUM AIR FLOW CHECK 1. Start the engine and warm it up until the engine coolant is heated to or higher and then stop the engine. Disconnect the PCV valve hose from the intake manifold PCV valve hose nipple.
Page 500 (NON-TURBO)> (c) Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of, ‘the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits.
Page 501 E N G I N E FUEL PRESSURE TEST FUEL SYSTEM PRESSURE MUST BE RELEASED BEFORE A FUEL SYSTEM HOSE OR COMPONENT’ “IS DISCONNECTED. The specifications listed in the Fuel System Pressure Chart are determined without vacuum applied to the fuel ‘pressure, regurator.
Page 502 ENGINE 6. If is not correct, troubleshoot and repair to the table Symptom Probable cause Remedy Fuel pressure too low Clogged fuel filter Replace fuel filter No fuel pressure in fuel return hose Fuel leaking return side due to poor Replace fuel pressure regulator fuel regulator valve seating or settled spring...
Page 503 ENGINE (NON-TURBO)> On-vehicle FUEL PUMP (HOW TO REDUCE FUEL LINE PRESSURE) When removing the fuel pipe, hose., etc., since fuel in the fuel pipe line is high, do the following operation so as to release fuel pressure in the line and running out.
Page 504: Component Location
ENGINE (NON-TURBO)> 13100210139 COMPONENT LOCATION Park/Neutral position switch Evaporative emission purge solenoid (Transaxle range switch) Evaporative emission ventilation solenoid Power steering pressure switch Powertrain control module Fuel pump relay Throttle position sensor Heated oxygen sensor (Front) Heated sensor (Rear) Vehicle speed sensor NOTE The “Name”...
Page 505 On-vehicle Inspection of ENGINE (NON-TURBO)> Revision...
Page 506 E N G I N E , Evaporative TSB Revision...
Page 507 TSB Revision...
Page 508 ( N O N - T U R B O ) > RELAY RELAY) RELAY CHE 1. Remove the relay. Check that there is (4) , and (6) terminals. Standard value: Bottom view of relay Use jumper leads to connect battery terminal and terminal .
Page 509: Engine (Turbo)
On-vehicle Inspection of ENGINE TEMPERATURE SENSOR CHECK 1. Disconnect the engine coolant temperature sensor connector. 2. Measure the resistance between the sensor terminals. INSTALLATION 1. Apply sealant to threaded Specified sealant: Loctite 24200 or equivalent engine coolant sensor tighten it to specified torque. Sensor tightening torque: 7 3.
Page 510 On-vehicle (NON-TURBO)> ENGINE o x y g e n s e n s o r 1. Disconnect the heated oxygen 2. Check that there is continuity between terminal 3 and terminal 4 on the heated oxygen sensor connector. If there is no continuity, replace the heated oxygen sensor. Warm up the engine until engine coolant is or higher.
Page 511 On-vehicle Inspection of ENGINE (NON-TURBO)> removal and installation of the oxygen sensor, refer to GROUP 15 Exhaust Pipe, Main TSB Revision...
Page 512 On-vehicle, Inspection of (NON-TURBO)> INJECTOR CHECK Measurement of Resistance between Terminals 1. Remove the injector connector. 2. Measure the resistance between terminals. Standard value: 3. Install the injector connector Checking operation sound Using a stethoscope or long blade screwdriver, check the operation sound (“tick-tick-tick”) of injectors during idling or during cranking Check that as the engine speed increases, the frequency...
Page 513 On-vehicle Inspection of ENGINE (NON-TURBO)> EVAPORATIVE EMISSION PURGE CHECK 1 7 ’ ELECTRIC EGR Refer to GROUP 17 Emission Control TSB Revision...
Page 514 REMOVAL AND INSTALLATION Post-Installation Operation Fuel Line Pressure Reduction (Refer to P. Battery and Air Intake Hose Installation Battery and Air Hose Removal Fuel Leakage Inspection Engine oil 00003911 Removal steps 1. High-pressure fuel hose connection 6. Retainers 2. O-ring 3.
Page 515 ENGINE (NON-TURBO)> REMOVAL SERVICE POINT F U E L Remove the fuel rail attached’ Do not drop the injector. INSTALLATION SERVICE POINTS INJECTORS INSTALLATION (1) Apply a small amount of clean engine oil to the O-ring. Caution Do not let the engine oil get into the fuel rail. (2) While turning the injector to the left and right, install it to the fuel rail.
Page 516 ENGINE (NON-TURBO)> THROTTLE BODY REMOVAL AND INSTALLATION Pm-removal Battery Removal (Refer to GROUP 17 On-vehicle 3.9 Nm Removal steps 1. Air intake hose motor connector 2. Accelerator cable connection 6. Throttle 3. Vacuum hose connection 7. Throttle body body gasket 4.
Page 517 ENGINE (NON-TURBO)> Throttle Body DISASSEMBLY AND REASSEMBLY steps motor assembly 2. Throttle body DISASSEMBLY SERVICE POINT MOTOR REMOVAL Do not disassemble the motor. Do not immerse solvent to clean the sensor and motor. Clean them with shop towel. THROTTLE BODY REMOVAL 1.
Page 518 ENGINE ENGINE> G e n e r a l ENGINE (TURBO) AND ENGINE> 13199910319 GENERAL INFORMATION Fuel Injection System consists The ECM carries out activities such as fuel of sensors which detect the engine conditions, injection control, idle air control and ignition the ENGINE CONTROL MODULE (ECM) which timing control.
Page 519 ENGINE (TURBO) ENGINE> DIAGNOSTIC TEST MODE When an abnormality is detected in one trouble code ‘the,, of the sensors or actuators related to emis- normality is output. sion control, the CHECK The RAM data inside the that FUNCTION INDICATOR LAMP illuminates to the sensors and actuators can be read’...
Page 520 E N G I N E ( T U R B O ) Engine (Turbo)> Item Throttle bore mm (in.) Throttle body Variable resistor type Throttle position sensor Idle air control motor Stepper motor type [Stepper. type ‘by-pass’ air control system Closed throttle position switch Rotary contact type, Engine control...
Page 521 ENGINE (TURBO) ENGINE> General Engine> Item Specifications Throttle bore mm (in.) Throttle body 54 (2.13) Throttle position sensor Variable resistor type Idle air control motor DC motor type [DC by-pass air control system with the fast idle air Closed throttle position switch Rotary contact type, within throttle position sensor Idle air control valve position sensor Hall element type...
Page 522 E N G I N E ( T U R B O ) ENGINE> General MULTI-PORT FUEL INJECTION SYSTEM DIAGRAM Engine (Turbo)> Enginecontrol Heated oxygen sensor Power supply Injector Fuel pump Vehicle speed sensor Evaporative emission (front) injection relay switch purge Volume air flow sensor Intake air temperature...
Page 523 ENGINE (TURBO) General lnformaiton ENGINE> Engine> Engine control Injector Fuel pump relay Heated oxygen sensor Power supply Evaporative emission Fuel pump relay Vehicle speed sensor (front) purge solenoid switch Volume air flow sensor air control motor injection Park/neutral position Intake air temperature EGR solenoid relay sensor...
Page 524 ENGINE (TURBO) S e r v i c e ENGINE> S t a n d a r d v a l u e at curb idle Basic Curb idle 100 in Neutral speed when A/C is ON Basic idle speed Throttle position sensor adjusting voltage 1,000 Throttle position sensor resistance...
Page 525 E N G I N E ( T U R B O ) ENGINE> Scan tool Test harness set an analyze Inspection using Tool available Revision...
Page 526 (TURBO) TROUBLESHOOTING . ? ’ D I A G N O S T I C FLOW CHART I:-- Verify complaint. Does not reoccur. Read the diagnostic trouble code (Refer to Read the diagnostic trouble code (Refer to ‘Refer to the INSPECTION CHART FOR DIAGNOSTIC MALFUNCTIONS to GROUP 00 TROUBLE CODES (Refer to...
Page 527 E N G I N E ( T U R B O ) ENGINE> DIAGNOSTIC TEST MODE CHECK Among the on-board diagnostic a check function indicator lamp notify the emission control items ‘a malfunction is detected. an ‘irregular signal to normal engine control judges, has returned to...
Page 528 ENGINE (TURBO) Troubleshooting ENGINE> DTC No. Closed throttle position switch malfunction Power steering pressure sensorcircuit range/performance Transaxle range sensor circuit malfunction (RPNDL Input) Transaxle fluid temperature sensor circuit malfunction Turbocharger waste gate actuator malfunction Engine (Turbo)> Turbocharger waste gate solenoid malfunction Engine Fuel pressure solenoid malfunction Engine (Turbo)>...
Page 529 E N G I N E ENGINE> ON-BOARD DIAGNOSTICS The engine control module monitors the input/out- Caution put signals (some signals at all times and the others If the sensor connector ‘is disconnected wlth under specified conditions) of the engine control the’...
Page 530 ENGINE (TURBO) Troubleshooting ENGINE> OBD-II DRIVE CYCLE All kinds of diagnostic trouble code can be monitored by carrying out a drive test in with the following six drive cycle patterns. In other words, carrying out such a drive test to reproduce any kind of which involves causing the check indicator to illuminate and to check that the repair procedure has eliminated the trouble...
Page 531 ENGINE (TURBO) ENGINE> 2. Evaporative emission control system leak monitor , . . Test conditions/procedure 1. All of the following conditions should be satisfied ‘when the drive test is carried out. (1) Engine coolant temperature: or lower engine is stopped) (2) Outside air temperature: or higher, or lower...
Page 532 ENGINE (TURBO) Troubleshooting ENGINE> 3. Heated oxygen sensor monitor Test conditions/procedure 1. All of the following conditions should be satisfied when the drive test is out. (1) Engine coolant temperature: or higher (when engine is fully warmed up) (2) Outside air temperature: or higher condition: Selector lever position:...
Page 533 ENGINE (TURBO) ENGINE> Troubleshooting 4. Exhaust gas recirculation (EGR) system monitor Test conditions/procedure All of the following conditions should be satisfied when the drive test is carried out. (1) Engine coolant temperature: or higher (when engine is (2) Outside air temperature: or higher (3) A/T condition: Selector lever position:...
Page 534 ENGINE (TURBO) Troubleshooting ENGINE> 5. Fuel trim monitor Test conditions/procedure 1. All of the following conditions should be satisfied when the drive test is out. (1) Engine coolant temperature: (when engine is fully warmed up) (2) Outside air temperature: or higher, or lower (3) A/T condition: Selector lever position:...
Page 535 ENGINE (TURBO) ENGINE> Troubleshooting 6. Other monitoring Misfire Engine coolant temperature sensor Evaporative emission control system Closed throttle position switch Idle air control system Generator terminal circuit Manifold differential pressure sensor sensor circuit Excessive time to enter closed loop fuel control sensor heater circuit Turbocharger waste gate solenoid Throttle position sensor...
Page 536 ENGINE (TURBO) T r o u b l e s h o o t i n g ENGINE> HOW TO READ AND ERASE DIAGNOSTIC TROUBLE CODES Caution 1. If battery voltage is ‘low, diagnostic trouble ‘codes Be sure to check the’ battery may not be output, and charging system before continuing.
Page 537 ENGINE (TURBO) ENGINE> Troubleshooting DIAGNOSTIC BY TEST (INCREASED SENSITIVITY) When mode II is selected using the MUT-II, the check engine/malfunction indicator lamp illuminates at the point when the ECM detects a problem (except if the related to emissions), and at the same time the corresponding diagnostic trouble codes are stored.
Page 538: Throttle Position Sensor
ENGINE ENGINE> . FAIL-SAFE/BACKUP FUNCTION TABLE When the main sensor malfunctions are by the diagnostic test mode, the vehicle is controlled by means of the following defaults. Malfunctioning item Control contents during malfunction Volume air flow sensor 1. Uses the throttle position sensor signal and engine speed signal (crankshaft position sensor signal) for basic injector drive timing and basic ignition timing from the motor in the appointed position so idle air control is not performed.
Page 539 ENGINE (TURBO) Troubleshooting ENGINE> (FAULT TREE) INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES Diagnostic items Check items (Remedy) Refer- DTC No. Memory Volume air flow circuit malfunction Harness and connector Retained (If harness and connector are not defective, replace volume air flow sensor assembly.) Barometric pressure Harness and connector...
Page 540 ENGINE (TURBO) Troubleshooting ENGINE> Diagnostic items Check items (Remedy} DTC No. page Retained Random misfire Ignition coil Ignition power transistor detected* Spark plug Retained Cylinder 1 misfire Ignition circuit detected* Injector S e n s o r Cylinder 2 misfire Compression pressure detected* Timing belt...
Page 541 ENGINE (TURBO) Troubleshooting ENGINE> Diagnostic items Refer- DTC No. Check items (Remedy) Memory Evaporative emission control system Harness and connector Retained pressure sensor malfunction F u e l t a n k d i f f e r e n t i a l p r e s s u r e Engine>...
Page 542 ENGINE (TURBO) ENGINE> Troubleshooting Code No. Volume Air Flow Circuit Malfunction Probable cause [Comment] Volume air, flow Background Open or shorted sensor While the engine is running, the volume air flow sensor outputs a signal which or loose connector corresponds to the volume of air flow. Engine control module failed The engine control module checks whether the frequency of this signal output by the volume air flow sensor while the engine is running is at or above the set value.
Page 543 (TURBO) ENGINE ENGINE> Troubleshooting Code No. Barometric Pressure Malfunction Probable cause [ C o m m e n t ] Barometric pressure sensor failed Background Open or shorted barometric The barometric pressure sensor outputs a voltage which corresponds to the barometric or loose connector pressure.
Page 544 ENGINE (TURBO) Troubleshooting ENGINE> Code No. Intake Air Temperature Circuit [Comment] Intake air temperature Background Open or shorted intake The intake air temperature sensor converts the intake air temperature to a voltage and circuit, or loose outputs it. Engine control The engine control module checks whether the voltage is within a specified range.
Page 545 ENGINE (TURBO) ENGINE> Code No. 5 Engine Coolant Temperature Circuit Probable Malfunction [Comment] Engine coolant temperature Background Open shorted engine theenginecoolanttemperature sensor circuit, or and outputs it. Engine control module The engine control module checks whether the voltage is within a specified range. In addition, it checks that the engine coolant temperature (signal) does not drop while the engine is warming up.
Page 546 ENGINE (TURBO) Troubleshooting ENGINE> Code No. Throttle Position Circuit Malfunction Probable cause’ Throttle position sensor failed or [Comment] Background The throttle position sensor outputs a voltage which corresponds to the throttle valve or loose connector opening angle. Closed switch The engine control module checks whether the voltage is within a specified range. In Closed throttle position switch addition, it checks that the voltage output does not become too large while the engine shorted...
Page 547 ENGINE (TURBO) Troubleshooting ENGINE> Code No. Excessive to Enter Closed Loop Fuel Control [Comment] Heated oxygen failed Background Injector failed system reduces exhaust emissions by means of closed-loop fuel control. Fuel pressure regulator failed The engine control module checks the time taken until closed-loop fuel control commences. Fuel pump failed Fuel filter blocked, Check Area...
Page 548 ENGINE (TURBO) ENGINE> Troubleshooting Code No. (Heated Oxygen) Sensor Circuit Malfunction (Bank Sensor 1) [Comment] Heated oxygen sensor deteriorated Background Open circuit in heated oxygen When the heated oxygen sensor begins to sensor signal response becomes poor. Engine control module failed The engine control module forcibly mixture to make it leaner and richer, and checks the response speed of the heated oxygen sensor.
Page 549 ENGINE (TURBO) Troubleshooting ENGINE> Code No. (Heated Oxygen) Sensor Heater Circuit Probable cause Malfunction (Bank 1 Sensor 1) [Comment] Open or shorted oxygen sensor Background Open circuit in oxygen sensor The engine control module checks whether the heater current Is within a specified range Engine module when the heater is energized.
Page 550 ENGINE ENGINE> Troubleshooting Code No. (Heated Oxygen) Sensor Circuit Malfunction (Bank 1 Sensor 2) [Comment] Heated oxygen sensor Background Open circuit in The engine control module checks for an open circuit in the heated oxygen sensor output line. Check Area Coolant temperature sensor: normal .
Page 551 ENGINE (TURBO) ENGINE> Code No. (Heated Oxygen) Sensor Heater Circuit cause Malfunction (Bank 1 Sensor 2) Open or shorted oxygen sensor [Comment] Background in oxygen sensor heater’ The engine control module checks whether the heater current is within a specified range Engine control module failed when the is energized.
Page 552 ENGINE (TURBO) Troubleshooting ENGINE> Code No. Fuel Trim Malfunction (Bank 1) Probable [Comment] V o l u m e ‘ a i r Background Injector failed If a malfunction occurs in the fuel system, the fuel compensation value becomes too large Incorrect fuel pressure or too small.
Page 553 ENGINE Troubleshootina ENGINE> Code No. Injector Circuit P r o b a b l e c a u s e function (Cylinder-l, Injector failed [Comment] Background con- A surge voltage is generated when the injectors are driven and the current flowing to the injector coil is shut off.
Page 554 E N G I N E ( T U R B O ) . ENGINE> Code No. Random Misfire Detected [Comment] Ignition system related part(s) Background Poor crankshaft sensor If a misfiring occurs while the engine is running, the engine speed suddenly changes. Incorrect air/fuel ratio The engine control module checks for changes in the engine speed.
Page 555 ENGINE (TURBO) ENGINE> Code No. Misfire Detected (Cylin- der-l, [Comment] Background compression if a misfiring occurs while the engine is running, the engine speed suddenly changes. Injector failed The engine control module checks for changes in the engine speed. Engine Check Area or more have passed after the engine was started.
Page 556 E N G I N E Check the harness wire between the ECM and the Repair sensor connector. Replace the knock sensor. Check trouble Replace the ECM. Code No. Crankshaft Position Sensor Circuit Malfunction [Comment] Background Open or crankshaft When the engine is running, the crankshaft position sensor outputs a pulse signal. circuit, or connector The engine control module checks whether the pulse signal is input while the engine...
Page 557 Measure at the crankshaft poition sensor connector Replace the ECM. Connect the connector. (Use the test harness: Voltage between 2 (black clip) and ground (Engine: Voltage between 2 (black clip) and ground (Engine: idling) OK: 1.5-2.5 1. NG Measure at the crankshaft poition sensor connector Check the harness wire between the crankshaft poition sensor and Disconnect the connector, and measure at the harness relay connector.
Page 558 ENGINE (TURBO) ENGINE> Code No. Camshaft Position Sensor Circuit Probable cause Malfunction [Comment] Camshaft position sensor Background Open or position cir- When the engine is running, the camshaft position sensor outputs a pulse signal. cuit or loose connector The engine control module checks whether the pulse signal is input. Engine control module failed Check Area, Criteria...
Page 559 ENGINE (TURBO) ENGINE> Troubleshooting Code No. Exhaust Gas Recirculation Flow Malfunction Probable [Comment] EGR valve does not open Background EGR control vacuum is too low When the EGR solenoid switches from OFF to ON while the engine is running, EGR EGR solenoid failed gas flows.
Page 560 ENGINE (TURBO) Troubleshooting ENGINE> Code No. Exhaust Gas Recirculation Solenoid cause Malfunction [Comment] EGR solenoid Background Open or shorted The engine control module checks current flows in the EGR solenoid circuit when connector. the solenoid is on and off. Engine control module failed. Check Area Battery voltage is not lower than 10 V.
Page 561 ENGINE ENGINE> Troubleshooting. Code No. Catalyst System Efficiency Below Threshold (Bank 1) [Comment] Catalytic converter deteriorated Background Heated oxygen sensor failed The signal from the heated oxygen sensor which follows the catalytic’ converter differs Engine control from that which precedes the converter.
Page 562 ENGINE (TURBO) ENGINE> Troubleshooting Code No. Evaporative Emission Control System Probable cause Malfunction Engine (Turbo)> [Comment] purge Background Open or shorted evaporative The evaporative emission purge solenoid opens and while the engine is idling. loose Then the fuel compensation value changes according to whether the evaporative emission connection canister emits purge air or not.
Page 563 ENGINE (TURBO) ENGINE> Troubleshooting Code No. Evaporative Emission System Probable cause Detected Malfunction Engine> [Comment] Improper tightening of fuel tank filler tube cap Background Fuel vent valve failed The engine control module turns the evaporative emission ventilation solenoid on in order Purge line or to shut off the outside air of the evaporative emission canister.
Page 564 ENGINE (TURBO) ENGINE> Troubleshooting Code No. Evaporative Emission Control System Purge Probable Control Valve Circuit Malfunction [Comment] Evaporative emission purge Background Open or shorted The engine control module checks whether current flows in the evaporative emission purge solenoid solenoid drive circuit when the solenoid is driven. Engine control module failed Check Area Battery voltage is not lower than 10...
Page 565: Check
ENGINE (TURBO) Troubleshooting ENGINE> Code No. Evaporative Emission Control System Vent Probable cause Control Malfunction Engine> [Comment] Evaporative emission vent Background Open or shorted evaporative The engine control module checks current flows in the evaporative emission ventilation solenoid circuit, or loose connector. solenoid drive circuit when the solenoid is ON and OFF Engine control module failed.
Page 566 ENGINE (TURBO) ENGINE> Troubleshooting Code No. Evaporative Emission Pressure Sensor Malfunction Engine> [Comment] Fuel tank differential pressure or shorted fuel Background Open The fuel tank differential pressure sensor outputs the voltage in proportion to the pressure in the fuel tank. (differential pressure against the barometric pressure) Engine control module The engine control module checks whether the output voltage of the fuel tank differential pressure sensor is within the specified range...
Page 567 E N G I N E ( T U R B O ) ENGINE> Troubleshooting Code No. Vehicle Speed Sensor Malfunction [Comment] speed sensor Background Open or shorted vehicle-speed The vehicle speed sensor outputs a pulse signal while the vehicle is driven. or loose The engine module checks whether the pulse signal is output.
Page 568 ENGINE (TURBO) Troubleshooting AND. ENGINE> Code No. Idle Control System Malfunction [Comment] Idle air control motor failed Background Open or shorted idle-air control If there is a malfunction of the system, the actual engine speed will not be identical to the target engine speed. , Engine control The engine control module checks the difference between the actual engine speed and the target engine speed.
Page 569 ENGINE Troubleshooting ENGINE> Engine> Cantheoperation sound be heard Check the idle air control motor system. (Refer to after the ignition switch is turned INSPECTION PROCEDURE 35.) to the ON position? Check the Measure at the idle air control mo- Measure at the idle air control mo- tor connector tor connector Disconnect the connector, and...
Page 570 ENGINE (TURBO) ENGINE> T r o u b l e s h o o t i n g Code No. Closed Throttle Position Switch Malfunction Probable cause [Comment] Closed throttle position switch failed. Background Open or shorted While the engine is idling without pressing the accelerator pedal, “ON” signal can be input circuit, or loose connector.
Page 571 ENGINE (TURBO) Troubleshooting ENGINE> Probable cause Code No. Power Steering Pressure Sensor Circuit [Comment] Power pressure switch Background Open or shorted power steering pressure When the steering wheel is kept in the position during driving, the power switch steering pressure switch will be momentarily turned off. Engine control failed’...
Page 572 ENGINE (TURBO) Code No. Turbocharger Waste Gate Solenoid Probable cause Malfunction Engine (Turbo)> [Comment] Turbocharger waste gate solenoid Background The engine control module checks current flows in the turbocharger waste gate solenoid loose connector. drive circuit when the solenoid is ON and OFF. Engine control module failed.
Page 573 ENGINE (TURBO) cause Probable Code No. Fuel Pressure Solenoid Malfunction Engine Fuel pressure solenoid Open or shorted fuel pressure Background or loose connector The engine control module checks current flows in the fuel pressure solenoid drive circuit E n g i n e when the solenoid is on and off.
Page 574 E N G I N E Code No. Differential Malfunction [Comment] Manifold differential Background o r l o o s e pressure in the intake manifold. Engine control. The engine control module checks whether the voltage output by manifold differential sure sensor is within a specified range.
Page 575 ENGINE (TURBO), ENGINE> Measure at the MDP sensor con- Measure at the MDP sensor con- Check the Repair nector nector Disconnect the connector, and test harness: measure at the harness side. Voltage between 1 and ground Voltage between 3 and ground Check trouble symptom.
Page 576 (TURBO) Troubleshooting ENGINE> Code No. Generator Terminal Circuit Malfunction Probable cause [Comment] Open circuit in generator terminal circuit Background Engine control module failed When the generator field coil is controlled, the generator terminal inputs a signal to the engine control module. The engine control module detects the generator output with the input signal, and controls the idle air control motor according to the generator output.
Page 577 ENGINE Troubleshooting ENGINE> Check the following connectors: Repair Check trouble symptom. Check the harness wire between the the transaxle control Repair module connector. There is probably a problem in automatic transaxle control system. Carry out automatic transaxle troubleshooting. (Refer to GROUP Troubleshooting) Replace the ECM.
Page 578 ENGINE (TURBO) ENGINE> Check the following connectors: Repair Check trouble symptom. Repair module connector. Replace the Revision...
Page 579 E N G I N E ( T U R B O ) ENGINE> INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Communication with Communication with all systems is not possible. scan tool is impossi- Communication with ECM only is not possible. ble.
Page 580 ENGINE (TURBO) Troubleshooting Items Symptom used Starting The starter is to crank the engine, but there is no combustion within the Won’t start cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine Hard starting Engine starts after cranking a while.
Page 581 ENGINE (TURBO) ENGINE> INSPECTION PROCEDURE 1 Communication with scan tool is not possible. tion with all systems is not possible.) [Comment] M a l f u n c t i o n c o n n e c t o r The cause is probably defect in the power supply system [including ground) for the on-board diagnostic test mode line.
Page 582 ( T U R B O ) ENGINE ENGINE> INSPECTION PROCEDURE 3 The check engine/malfunction indicator lamp nate right after the is turned to the, ON position. [Comment] Defective The ECM causes the check engine/malfunction indicator lamp to illuminate for five seconds lamp circuit immediately after the ignition switch is turned to ON.
Page 583 ENGINE (TURBO) INSPECTION PROCEDURE 4 The check engine/malfunction indicator lamp remains Probable cause and never goes out. [Comment] check indicator lamp and ECM In cases such as the above, the cause is probably that the ECM is detecting a problem in a Malfunction of the ECM sensor or actuator, or that one of the malfunctions listed at right has occurred.
Page 584 ENGINE (TURBO) ENGINE> INSPECTION PROCEDURE 6 Fires up and dies. Probable cause [Comment] Malfunction of system Malfunction of the injector system In such cases as the above, the cause is probably that the spark plugs are generating sparks Foreign materials in fuel but the sparks are weak, or the initial mixture for starting is not appropriate.
Page 585 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 7 cause Probable Malfunction of the ignition system Malfunction of the system In cases such as the above, the cause is probably that the spark is weak and ignition is difficult, Inappropriate gasoline use the initial mixture for starting is not appropriate, or sufficient compression pressure is not being Poor Check battery positive...
Page 586 E N G I N E ( T U R B O ) ENGINE> INSPECTION PROCEDURE 8 Unstable Rough Probable cause [Comment] Malfunction of the ignition system In cases such as the above, the cause is probably that the ignition system, air/fuel mixture, idle M a l f u n c t i o n s y s t e m air control motor or compression pressure is defective.
Page 587 ENGINE (TURBO) Troubleshooting INSPECTION PROCEDURE 9 speed is high. (Improper idle speed) [Comment] In such cases as the above, the cause is probably that the intake air volume during idle is too great. Refer to INSPECTION CHART FOR Are diagnostic trouble codes output TROUBLE CODES.
Page 588 ENGINE (TURBO) ENGINE> Troubleshooting INSPECTION PROCEDURE 10 Idle speed is low. (Improper idle speed) “Probable cause [Commentj Malfunction of the system In cases such as the the cause is probably that the intake air volume during idling is throttle small. SCAN TOOL DTC Refer to INSPECTION CHART...
Page 589 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idle. (Die out) P r o b a b l e c a u s e [Comment] Malfunction of the system In such cases as the above, the cause is probably that the mixture is inappropriate when body Malfunction of the injector system...
Page 590 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idle. (Die out) Probable cause Malfunction of the ignition system Malfunction control system In cases such as the above, the cause is probably that ignition system, air/fuel mixture, idle air Malfunction of system control motor or compression pressure is defective.
Page 591 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 13 Probable The engine stalls when accelerating. (Pass out) Drawing air into intake system [Comment] Malfunction of system In cases such as the above, the cause is probably misfiring due to a weak spark, or an air/fuel mixture when the accelerator pedal is depressed.
Page 592 ENGINE (TURBO) T r o u b l e s h o o t i n g ENGINE> INSPECTION PROCEDURE 15 Hesitation, sag or stumble Probable [Comment] Malfunction of the ignition system In cases such as the above, the cause is probably that ignition system, air/fuel of the fuel pressure is defective.
Page 593 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 17 Probable cause [Comment] Malfunction of the system Malfunction of the system is suspected. Refer to INSPECTION FOR DIAGNOSTIC Are diagnostic trouble codes output TROUBLE CODES. Check the idle air control motor for operation sound Check the idle control system malfunction (Refer to Engine (Refer to...
Page 594 ENGINE (TURBO) ENGINE> Troubleshootina INSPECTION PROCEDURE 19 Surge Malfunction of ignition system Malfunction of’ ‘ratio ‘control system Defective ignition system, abnormal air-fuel are suspected. Malfunction of the EGR solenoid system Refer to INSPECTION CHART FOR DIAGNOSTIC Are diagnostic trouble codes output TROUBLE CODES.
Page 595 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling [Comment] Malfunction of the ratio Abnormal air-fuel ratio is suspected. SCAN TOOL Refer to INSPECTION CHART FOR DIAGNOSTIC Are diagnostic trouble codes output TROUBLE CODES. Check the ignition timing.
Page 596 ENGINE (‘TURBO) ENGINE> INSPECTION PROCEDURE 23 Generator output voltage is low (approx. [Comment] Malfunction of charging system. The cause may be a malfunction of the generator or one of the problems listed at right. Short harness between t e r m i n a l Malfunction of the ECM.
Page 597 ENGINE (TURBO) Troubleshoot&j ENGINE> INSPECTION PROCEDURE 24 Probable cause Transient, mass emission tailpipe test test failed [Comment] The test is failed if the air/fuel ratio is not controlled to the theoretical air/fuel ratio by means of the feedback control from the oxygen sensor signal, if the EGR flow volume is insufficient, or if the catalyst has deteriorated.
Page 598 ENGINE (TURBO) Troubleshooting ENGINE> Has the engine warmed up sufficiently when the exhaust gas is Let the engine warm up sufficiently before testing the exhaust gas. tested? (Check with owner.) Check all vacuum hoses and connectors. Repair Check electrical wires and connectors for obvious problems. Check the exhaust system for missing Refer to INSPECTION CHART...
Page 599 ENGINE Troubleshooting ENGINE> INSPECTION PROCEDURE 25 Purge flow test of the evaporative canister test failed [Comment] Blocked purge line or purge port emission The test is failed if there is a blockage in the purge line or purge port, or a malfunction of the solenoid evaporative emission purge solenoid.
Page 600 (TURBO) ENGINE ENGINE> INSPECTION PROCEDURE 27 Power supply system and ignition system P r o b a b l e [Comment] Malfunction of the ignition switch Malfunction of the relay When an ignition switch ON signal is input to the ECM, the ECM turns the relay ON.
Page 601 ENGINE (TURBO) ENGINE> INSPECTION PROCEDURE 29 Fuel pump system Engine> [Comment] of the fuel pump The ECM judges the engine (Low, Middle, High), and outputs the result of this judgement to Malfunction fuel the fuel pump relay module. The fuel pump relay module controls the operation of the fuel pump Malfunction, of the fuel pump module in accordance with the engine...
Page 602 ENGINE (TURBO) ENGINE> INSPECTION PROCEDURE 30 Ignition switch-ST system Malfunction, of ignition switch [Comment] Improper connector The ignition switch ST inputs a HIGH signal to the while the engine is cranking. The ECM controls fuel injection, etc. during starting based on this input. t h e 1.
Page 603 ENGINE (TURBO) ENGINE> INSPECTION PROCEDURE 31 Ignition switch-ST and park/neutral position system [Comment] Malfunction of switch park/neutral switch The ignition switch ST inputs a HIGH signal to the ECM while the engine is cranking. Improper connector contact, open circuit or The ECM controls fuel injection, etc.
Page 604 E N G I N E ‘ENGINE> Troubleshooting INSPECTION PROCEDURE 32 switch and compressor clutch relay system (Comment] Malfunction of control Malfunction of When an A/C ON signal is input to the the ECM carries out control of the idle air control motor, and also operates the compressor magnetic clutch.
Page 605 ENGINE (TURBO) INSPECTION PROCEDURE 33 Probable cause Fan motor relay system (Radiator fan, A/C condenser fan) Malfunction of fan motor relay [Comment] Malfunction of fan motor The fan motor relay is controlled by the power transistor inside the ECM turning ON and OFF. Improper connector open shortclrcuited...
Page 606 ENGINE (TURBO) Troubleshooting INSPECTION PROCEDURE 34 Ignition circuit system cause’ [Comment] Malfunction of ignition interrupts the ignition coil current by turning the transistor in- Improper connector contact, open circuit or, side the ECM ON and OFF. shortcircuited harness wire Malfunction the ECM Engine (Turbo)>...
Page 607 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 35 Idle air control motor (DC motor) Engine> Probable cause [Comment] Malfunction of idle air control motor The ECM controls the intake air volume during idling by opening and closing the Improper connector open “circuit’ servo valve located in the bypass passage.
Page 608 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE 37 Ignition system: Inspection when no initial occurs Engine (Turbo)> Measure at the ignition coil connector Check ignition circuit system. Connect the connector. (Use the test harness: (Refer to INSPECTION PROCEDURE 34.) To inspect, connect the primary voltage detection-type tachometer to the terminal 1 (red clip) and terminal 2 (black clip).
Page 609 ENGINE (TURBO) Troubleshooting . AND. ENGINE> ‘A, . INSPECTION PROCEDURE 40 Scan tool: Inspection when idle speed is unstable. SCAN TOOL Data list 26 Closed throttle position switch (Refer to TROUBLE CODE SCAN TOOL Data list Check the intake air temperature circuit (Refer 13 Intake air temperature sensor (Refer to INSPECTION’...
Page 617 ENGINE (TURBO) ENGINE> Troubleshooting INSPECTION PROCEDURE 50 Check the ignition signal circuit. Disconnect the connector and measure at the harness side. Check trouble symptom. sistor unit and ignition switch connector. Voltage between 58 and ground (engine: 3000 Check the ignition switch. (Refer to GROUP 54 Switch.) Replace the ECM.
Page 618 ENGINE (TURBO) ENGINE> DATA LIST REFERENCE TABLE Item No. Inspection item General- scan tool Heated oxygen sensor (Front) Volume air flow sensor Intake air temperature sensor Throttle position sensor Power supply voltage Cranking signal (Ignition switch-ST) Engine coolant temperature sensor Crankshaft position sensor TSB Revision...
Page 619 ENGINE (TURBO) ENGINE> Caution 1. Always apply the brakes when shifting the selector lever to ran&, or vehicle will forward. 2. Driving tests always need another personnel. NOTE In a new vehicle [driven approximately 500 km (300 mile) or less], the volume air sensor output is sometimes 10 higher than the standard frequency.
Page 620 E N G I N E ENGINE> Troubleshooting Item Inspection Inspection contents Normal contents Inspection item ‘procedure Intake air Ignition switch: ON or Intake Code No. temperature with engine running air tern- sensor ture Throttle Ignition switch: ON Set to idle position ,000 position Gradually open...
Page 621 ENGINE (TURBO) ENGINE> Inspection Inspection contents Normal contents Inspection item p r o c e d u r e p a g e Crankshaft Engine: Idle Engine At Code No. Closed position throttle coolant position switch: ON ature Vehicle Drive at 40 (25 miles/h) Approx.
Page 622 E N G I N E ENGINE> . Item Inspection Inspection contents procedure item Engine: Cranking When engine Injectors** a n t t e m p e r a t u r e Engine> When engine cool- ant temperature is Engine (Turbo)? 7.2-11...
Page 623 ENGINE (TURBO) ENGINE> Inspection contents Inspection item A/C switch: OFF Increases Engine coolant motor position temperature: (176 Engine> Lights, electric cooling fan and A/C switch: from Increases all accessories: OFF to ON 50 steps Transaxle: Neutral range) Closed throttle Increases by A/C switch: position switch: steps...
Page 624 ENGINE (TURBO) ACTUATOR TEST REFERENCE TABLE iter Inspection Drive contents inspection contents Normal condition inspection item Injectors Cut fuel to Engine: Warm, idle Idle speed drops Code injector equally for each (Cut the fuel supply to injector each injector in turn and Cut fuel to No.
Page 625 ENGINE (TURBO) Troubleshooting CHECK AT THE ENGINE TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (paper etc.) to probe. 2. insert the needle-nosed wire probe into each of the ECM connector terminals from the wire side, and measure the voltage referring to the check chart.
Page 626 E N G I N E ENGINE> ECM Connector Terminal Arrangement Terminal (Engine Normal condition Terminal Check item Engine Engine> No. 1 injector Engine: Warm, idle From Suddenly depress the accelerator mentarily drops slightly No. 2 injector pedal. No. 3 No.
Page 627 ENGINE (TURBO) ENGINE> Check (Engine Normal Terminal Terminal Check item Engine Engine> Engine: 3,000 Ignition power transistor Ignition power transistor Turbocharger waste gate Ignition switch: ON solenoid Engine: Idle premium gasoline is used) Ignition switch: ON Power supply Boost meter Ignition switch: ON Engine: Idle From...
Page 628 ENGINE (TURBO) ENGINE> Troubleshooting Terminal Terminal Check item Check condition (Engine condition) c o n d i t i o n Engine Engine> Generator Terminal Engine: idle after warm-up (radia- tor fan: OFF) Headlight: OFF switch: OFF Stop lamp: OFF A/C refrigerant A/C refrigerant 1 , 3 7 3...
Page 629 ENGINE (TURBO) ENGINE> Check condition (Engine Terminal Terminal Check item Engine Engine> Manifold differential Engine: Idle sure sensor Engine: Idle ‘rises from Suddenly depress the accelerator suddenly pedal Heated oxygen sensor Transaxle: range (Rear) Driving with the throttle widely 3,500 or more Heated oxygen sensor Engine: Warm, 2,500...
Page 630 ENGINE (TURBO) Troubleshooting ENGINE> Terminal Terminal Check item Check condition (Engine condition) Normal Engine Engine> Ignition switch: Set throttle Closed throttle position switch to idle position Slightly open or more throttle valve Camshaft position sensor Engine: Cranking Engine: Idle Engine: Cranking Crankshaft position Engine: Idle 2 .
Page 631 (TURBO) ENGINE ENGINE> TERMINAL RESISTANCE 1. Turn the ignition switch off. 2. Disconnect the ECM connector. Measure the resistance and check for continuity between the terminals of referring to the check NOTE When measuring resistance and checking continuity’ a harness for checking contact pin pressure should’ be used instead of inserting a test probe.
Page 632 ENGINE (TURBO) Troubleshooting ENGINE> Normal condition (Check condition) Terminal’ No. Inspection item 6-12 EGR solenoid 36-44 9-12 Evaporative emission purge solenoid 36-44 11-12 Turbocharger waste gate solenoid 36-44 Engine (Turbo)> E C M g r o u n d Continuity ground ECM ground ground...
Page 633 ENGINE (TURBO) Troubleshooting ENGINE> INSPECTION PROCEDURE USING AN ANALYZER VOLUME AIR FLOW SENSOR Measurement method 1. Disconnect the volume air flow sensor connector, in be- connect the special tool (test harness: tween. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to volume air flow sensor connector terminal 3.
Page 634 ENGINE (TURBO) ENGINE> Troubleshooting Observation conditions (pattern changes with engine changes.) Time Wave pattern observation points Check to be sure that cycle time becomes shorter and the frequency increases when speed is increased. Examples of abnormal wave patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics...
Page 635 ENGINE (TURBO) ENGINE> SENSOR AND CAMSHAFT POSITION Camshaft position sensor POSITION SENSOR Measurement method Connect the analyzer special patterns pickup to position sensor terminal 2. Disconnect the crankshaft position sensor connect the special tool (test harness: between. 3. Connect the analyzer special patterns pickup to crankshaft position sensor terminal 2.
Page 636 ENGINE (TURBO) ENGINE> Troubleshooting Examples of abnormal wave Example 1 Cause problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern jumps to the left or right.
Page 637 ENGINE (TURBO) Troubleshooting ENGINE> Standard Wave Pattern Observation conditions Special patterns Function Pattern height Variable Adjust while viewing Variable knob Display Pattern selector Engine Standard wave pattern Drive signal: ON Drive signal: OFF 27 FU 1202 Wave pattern observation points Point A: Height of injector coil induced voltage Probable cause Contrast with standard wave pattern...
Page 638 STEPPER MOTOR Engine (Turbo)> Analyzer Measurement method 1. Disconnect the stepper motor connector, and connect the special tool (test harness: in between. 2. Connect the analyzer special patterns pickup to the step- per motor-side connector terminal (red clip on the special tool), terminal 3 (blue clip), terminal 4 (black clip) and terminal 6 (yellow clip) respectively.
Page 639 Wave pattern observation points Check that the standard wave pattern appears when the stepper operating. Point A: Presence or absence of induced voltage from the motor turning. (Refer to the pattern.) Contrast with standard wave pattern Probable cause Induced voltage does not appear or is extremely small. Motor is malfunctioning Point Height of coil reverse voltage...
Page 640 ENGINE (TURBO) ENGINE> IGNITION COIL AND IGNITION Analyzer Ignition coil primary Refer to GROUP 16 Ignition System. Ignition power transistor control signal. Measurement method 1. Disconnect the ignition power transistor connector, connect the special tool (test harness:. tween. (All terminals should be connected.) 2.
Page 641 Wave pattern observation points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Probable cause Condition of wave pattern build-up section and maximum voltage Rises from approx. approx. at the top-right Normal rectangular wave Open-circuit in ignition primary circuit...
Page 642 THROTTLE BODY CLEANING Start the engine and warm it up the coolant is higher and then stop the Remove the air intake hose from the Plug the bypass passage inlet Caution Do not allow cleaning solvent to enter the bypass passage.
Page 643 CLOSED THROTTLE SWITCH THROTTLE POSITION SENSOR ADJUSTMENT NOTE When using the scan tool, service item 26 and observe the ON/OFF changes posi- tion switch instead of performing If the scan tool is not available, follow the steps bellow. Disconnect the connector the throttle position sensor.
Page 644 9. When not using the scan tool, proceed as follows: Terminal 4 Terminal 2 (1) Disconnect the throttle position connectors and connect the special tool. set, be- tween the disconnected connectors. (2) Connect a digital voltmeter throttle tion sensor terminal 2 (sensor output) and 4 (sensor ground.) 10.
Page 645 FIXED SAS ADJUSTMENT NOTE 1. The fixed SAS should not be moved unnecessarily; it has been precisely adjusted by the manufacturer. If the adjustment is disturbed for any reason, readjust as follows. 1. Loosen the tension of the accelerator cable sufficiently. 2.
Page 646 SPEED NOTE 1. The standard idle speed engine speed and there should usually for readjustment. 2. The adjustment, after first: confirming that the spark plugs; air control servo, the compression pressure, all normal. 1.. The vehicle should be prepared as follows before the i n s p e c t i o n a n d a d j u s t m e n t .
Page 647 If not within the standard value range, turn the engine speed adjusting screw to make the necessary adjustment. NOTE If the idling speed is higher standard value even when the engine speed adjusting screw’ fully closed, check whether or not there is any indication that the fixed SAS has been moved.
Page 648 FUEL PRESSURE TEST 1. Release residual the fuel line. (Refer to Disconnect the high-pressure,, fuel. hose -at the fuel rail’ side. Caution Cover the hose with a shop to let fuel gush out. 3. Remove the union joint and bolt from the special tool Fuel pressure (adapter hose and instead attach the special...
Page 649 On-vehicle 10. Disconnect and plug the vacuum hose from the fuel sure regulator and measure fuel pressure with the hose end closed by a finger. Standard value: ( 4 2 - 4 5 a t c u r b (Turbo)> idle 11.
Page 650 14. Stop the engine and Normal if the reading does observe repair according to “the table, Symptom Probable Fuel pressure drops gradually after Leaky injector inject& engine is stopped Leaky fuel regulator valve seat Fuel pressure drops Check is held mediately after engine is stopped open 15.
Page 651 FUEL PUMP CONNECTOR” (HOW TO REDUCE FUEL When removing the fuel pipe, hose, etc., in the fuel pipe line is high, do the as to release fuel pressure in the line and from running out. Remove the rear seat cushion. (Refer to GROUP Seat.) Remove the protector to disconnect the fuel...
Page 652 COMPONENT LOCATION Engine (Turbo)> Symbol Symbol Name Name Air conditioning compressor clutch relay Injector Air conditioning switch Knock sensor Camshaft position sensor Manifold differential pressure (MDP) sensor Check engine/Malfunction indicator lamp Crankshaft position sensor Data link connector fuel injection (MFI) relay Park/Neutral position switch EGR solenoid Power steering pressure switch...
Page 653 built-in intake air temperature Fuel check...
Page 654 . Inject@ Turbocharger waste solenoid...
Page 655 Data...
Page 656 Name Symbol Name Air conditioning compressor clutch relay air control motor Air conditioning switch coil power transistor) Camshaft position sensor Ignition power transistor Check engine/Malfunction indicator lamp Crankshaft position sensor injector Data link connector Manifold differential pressure sensor EGR solenoid fuel relav Engine control module (ECM)
Page 657 Volume air flow sensor (with built-in intake air tem- perature and baro- metric pressure sensor)
Page 658 -Throttle sensor closed built-in on coil temperature sensor...
Page 659 neutral position switch Check engine/malfunction indicator lamp Data connector o x v a e n (front)
Page 660 FUEL INJECTION AND FUEL PUMP RELAY Remove the relay. Check the continuity between the Inspection terminals Continuity 2 - 4 Use the jumper leads to connect relay terminal 4 to battery terminal and terminal termi- nal. Check the continuity between relay 3 while connecting and disconnecting the ‘at...
Page 661 COOLANT SENSOR Caution Be careful not to touch the tool against the (resin section) when Remove engine coolant temperature sensor from the in-, take manifold. 2. With temperature sensing portion of engine tem- perature sensor immersed in hot water, check resistance. Resistance Temperature (32)
Page 662 THROTTLE, POSITION SENSOR CHECK 1. Disconnect the throttle position sensor connector. Throttle position sensor connector Measure the resistance between the throttle position sen- sor side connector terminal 1 and terminal 4. Standard value: 3.5-6.5 3. Measure the resistance between throttle sen- sor side connector terminal 2 and terminal 4.
Page 663 HEATED OXYGEN SENSOR CHECK <Heated oxygen sensor (front)> and con- 1. Disconnect the heated sensor the special tool harness) to the sensor equipment the heated oxygen sensor side connector Make sure that there is continuity [Approx. 12 between terminal 1 (red clip special tool) and terminal 3 (blue clip of special tool) on the heated oxygen sensor connector.
Page 664 ENGINE (TURBO) ENGINE> Components’ <Heated oxygen sensor 1. Disconnect the heated oxygen sensor connector. Make sure that there is continuity [approx. 12 between terminal 3 and terminal oxygen sensor connector. If there is no continuity, replace the heated oxygen sensor. NOTE the scan tool dose not display ‘the standard although no abnormality is found by the above men-...
Page 665 RESISTOR CHECK Engine (Turbo)>; Terminals 1. Disconnect the resistor connector. 2. Measure the resistance between terminals. Resistance Measuring terminals If the resistance is out of specification, replace the resistor. IDLE AIR O T O R CHECK Engine (Turbo ai r 1.
Page 666 Checking the Coil Resistance Disconnect the idle air control motor connector and con- nect the special tool (test harness). 2. Measure the resistance between terminal 2 (white, clip of the special tool) and either terminal (red clip) or terminal 3 (blue clip) of the connector at the idle control motor side.
Page 667 IDLE AIR CONTROL (DC: MOTOR) CHECK Engine> Use a stethoscope or long blade screwdriver to check if the operating sound of the idle air control’ motor can immediately after the ignition switch is turned to NOTE If the motor operation cannot be heard, check the motor drive circuit and the idle air control motor.
Page 668 Connect a hand vacuum pump to the nipple. Connect a battery to the solenoid valve and apply a vacu- um to check air-tightness. Battery voltage nipple Normal condition Not applied Open Vacuum leaks Closed Vacuum maintained Applied Open Vacuum maintained Measure the resistance between the terminals of the sole- noid valve.
Page 669 REMOVAL AND INSTALLATION Post-installation Operation Operation Spark Plug Cable Installation Fuel Line Pressure Reduction (Refer to Fuel Leakage Inspection Spark Plug Cable Removal Engine> Engine (Turbo)> Engine Engine> 8. Injector connectors fuel hose connection 9. Fuel rail Fuel return hose connection 10.
Page 670 ( T U R B O ) Remove the fuel rail (with the attached it.) Caution Do not drop the injector. INSTALLATION SERVICE POINTS INJECTORS INSTALLATION (1) Apply a small amount of clean engine oil to the O-ring. Caution Do not let the engine oil get into the fuel rail. (2) While injector to the left and right, install it to the fuel rail.
Page 671 ( T U R B O ) E N G I N E ENGINE> REMOVAL AND INSTALLATION Service.) (Refer to Engine (Turbo)> Removal steps 7. Heater hose connection 1. Accelerator cable connection cooler fitting 2. Air hose 8. Charge air Engine Engine (Turbo)>...
Page 672 DISASSEMBLY AND REASSEMBLY Englne (Turbo)> 1. Throttle position Sensor (with in closed position switch) air control motor 3. O-ring 4. Throttle body...
Page 673 steps 1. Throttle position sensor (with in closed throttle position switch) 2. Idle air control motor 3. Gasket 4. Throttle body DISASSEMBLY SERVICE POINTS POSITION SENSOR AND IDLE All? CONTROL MOTOR REMOVAL 1. Do not disassemble the sensor and motor. Do not immerse solvent to clean the sensor and motor.
Page 674 (2) Turn throttle position sensor clockwise tighten screws. (3) Check for continuity between terminals No. 3 (closed Throttle throttle position switch) and No. 4 (ground). sensor power not continuity with the throttle valve fully closed, sensor output turn the throttle position sensor counterclockwise, and then check again.
Page 675 REMOVAL AND INSTALLATION NOTE Resin clip position 1. Console side cover Harness connector pump relay module...
Page 676 NOTES...
Page 677 CONTENTS SERVICE ..FUEL FILTER ..... . 12 SPECIAL TOOL .., .., ..‘2 FUEL TANK .
Page 678 FUEL SUPPLY Fuel Tank 13500010032 (1) The fuel tank is located under the floor of the The fuel tank from a high rear seats to provide increased safety. density: polyethylene material and blow-formed ‘tank. (2) A fuel cut-off valve has been’adopted to prevent fuel from leaking out in the event of a collision.
Page 679 FUEL SUPPLY -‘Fuel Tank Probable cause Symptom Repair or replace Engine malfunctions Bent or kinked fuel pipe or hose due to insufficient fuel Clean or replace Clogged fuel pipe or hose Replace Clogged fuel filter or in-tank fuel filter Water in fuel filter Replace the fuel filter or clean the fuel tank and fuel line Dirty or rusted fuel tank interior...
Page 680 FUEL SUPPLY Tank FUEL TANK REMOVAL AND INSTALLATION Engine (Non-turbo)> 2.5 Nm 2.5 Nm Removal steps 1. Fuel tank 11. Fuel tank filler tube protector 2. High-pressure fuel hose 12. Reinforcement 3. Return hose 13. Fuel tank filler tube assembly 4.
Page 681 SUPPLY ‘Fuel Tank Enaine (Refer to GROUP On-vehicle Service.) 2.5 Nm Removal steps 12. Fuel tank filler protector 1. Fuel tank 2. Vapor hose 14. Fuel tank’ assembly 3. High-pressure fuel hose Packing 4. Return hose 5. Fuel pump NOTE 6.
Page 682 FUEL SUPPLY Fuel Engine> (Refer to GROUP On-vehicle Service.) 25 Nm Removal steps Fuel tank 13. Fuel tank filler tube protector 2. Vapor hose 14. Reinforcement 3. High-pressure fuel hose tank tube assembly 4. Return hose 16. Packing 5. Fuel tank differential pressure sensor 6.
Page 683 FUEL SUPPLY Fuel Tank Post-installation Operation Pre-removal Operation Installation Propeller Shaft.) to GROUP 25 Propeller and Hose. Pressure of Fuel (Refer to GROUP On-vehicle Service.) ..Fuel Leaks Propeller Shaft.) Removal Steps valve assembly 15. Fuel cut-off connection 1.
Page 684 FUEL SUPPLY Fuel Tank INSTALLATION SERVICE POINT INSTALLATION Use the special tool to tighten the so that the marks on the fuel tank the, unit and pump assembly (or the fuel gauge and pipe assembly) are aligned. Caution Make sure that the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) does not turn together with the cap when tightening the cap.
Page 685 FUEL SUPPLY Fuel Tank INSPECTION FUEL TANK FILLER TUBE Engine (Non-turbo) (1) Connect a clean rubber hose to the port tank filler tube assembly. (2) Blow air into the hose. Check that the air flows out of the port B. (3) Use a screwdriver or tool to close the valve.
Page 686 FUEL SUPPLY Fuel Tank FUEL GAUGE UNIT AND PUMP ASSEMBLY REPLACEMENT (1) Remove the rear seat cushion. (Refer to, GROUP Seat.) (2) Remove the protector. (3) Disconnect the hoses and connectors to remove the fuel pump assembly or fuel gauge unit. (4) Align the packing positioning projections with.
Page 687 FUEL SUPPLY Fuel (7) After applying soapy water fuel tank. Use the special tool to specified torque so fuel the fuel gauge unit and pump assembly (or unit and pipe assembly) are aligned. Caution Make sure that the fuel gauge unit and (or the fuel gauge unit and does not turn together with the cap ‘when...
Page 688 FUEL SUPPLY Filter REMOVAL AND INSTALLATION Operation Post-installation Operation Residual Pressure from High Pressure Air Intake Hose Installation Engine (Non-turbo)> Battery Engine (Refer to GROUP On-vehicle Service.) Engine (Turbo) and Engine> Pressure Measurement (Refer to GROUP On-vehicle Service.) Engine (Non-turbo)> Removal Engine (Turbo) and (Refer to GROUP...
Page 689 FUEL SUPPLY Fuel Filter POINTS REMOVAL SERVICE EYE BOLT REMOVAL Hold the fuel filter with a spanner and remove the eye bolt. Caution As there will be some pressure remaining in the fuel pipe line, cover it with a shop towel to prevent fuel from spraying out.
Page 690 NOTES...
Page 691 CONTENTS GENERAL INFORMATION ....2 SERVICE SPECIFICATIONS ....3 THERMOSTAT .
Page 692: General Information
14-2 ENGINE COOLING General Information GENERAL INFORMATION The cooling system is designed to keep every part that the heat absorbed by the coolant may be of the engine at appropriate temperature in diated into the air. er condition the engine may be operated. The water pump is of the centrifugal type and is The cooling of the water-cooled, pressure...
Page 693 (psi) 94-122 (14-18) Engine (Non-turbo) Engine (Turbo) and Engine LUBRICANT Item Quantity Engine coolant HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT 7.0 (7.4) SEALANT Item Specified sealant Thermostat case Engine (Turbo) and Engine> Mitsubishi Genuine Parts No. or equivalent: TSB Revision...
Page 694 E N G I N E C O O L I N G TROUBLESHOOTING OVERHEAT Probable cause Remedy Inoperative electric cooling fan Faulty electrical motor , Replace R e p l a c e Faulty radiator fan Water leaks Damaged radiator core joint Replace Corroded or cracked hoses Replace...
Page 695 ENGINE COOLING Troubleshooting TROUBLESHOOTING HINTS Engine (Non-turbo)> 1. Only the radiator fan does not operate. 4. The radiator fan and condenser fan do not Check fusible link No. 7. operate in the high speed mode, ‘but 2. Only the condenser fan does not operate. otherwise.
Page 696 14-6 ENGINE COOLING Engine (Turbo) and Engine> 1. Only the radiator fan does not operate. 4. The radiator fan and fan do not Check fusible link No. 7. operate in the high speed mode, but 2. Only the condenser fan does not operate. Check dedicated fuse No.
Page 697: On-Vehicle Service
ENGINE COOLING On-vehicle Service ON-VEHICLE SERVICE ENGINE COOLANT LEAK CHECK 1. Confirm that the coolant level is. up to the filter Install a radiator cap tester and apply 160 (23 psi) pressure, and then check for leakage from radiator hose or connections. Caution seepage 1.
Page 698 14-8 ENGINE COOLING, Radiator RADIATOR REMOVAL AND INSTALLATION Engine (Non-turbo)> Operation Engine Coolant Draining (Refer to GROUP 00 Maintenance Service.) 12 Nm Radiator removal steps 13. Condenser fan motor assembly 1. Drain plug 2. Radiator cap <Vehicles with 3. Overflow tube 14.
Page 699 ENGINE Engine (Turbo)> Post-installation Pre-removal Operation Engine Coolant Supplying and Engine Coolant Draining (Refer to GROUP 00 GROUP 00 Maintenance Service.) A/T Fluid Checking and Refilling if with (Refer to GROUP 00 Maintenance Radiator fan motor removal steps Radiator removal steps 1.
Page 700 ENGINE Radiator Pm-removal Operation Post-installation Operation Engine Coolant Draining Engine Coolant Supplying and (Refer to GROUP 00 Maintenance Service.) GROUP 00 Maintenance Fluid Checking -and Refilling Necessary with (Refer to GROUP 00 Maintenance 12 Nm steps Radiator removal steps Radiator fan 1.
Page 701 ENGINE COOLING Radiator REMOVAL SERVICE POINTS RADIATOR UPPER LOWER HOSE DISCONNECTION After making mating marks on the hose and the hose clamp, disconnect the radiator hose. TRANSAXLE FLUID COOLER FLUID COOLER HOSE AND PIPE REMOVAL After removing the hose from the radiator, plug the hose and the radiator nipple to dust or from getting in.
Page 702 ENGINE FAN RELAY CONTINUITY Engine (Non-Turbo)> Engine (Turbo)> TSB Revision...
Page 703: Thermostat
ENGINE COOLING T H E R M O S T A T REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 00 Maintenance Service.) and Installation Engine Air Hose(C) Removal (Turbo)> (Refer to GROUP 15 -Charge Cooler.) Ermine Engine (Turbo)>...
Page 704 ENGINE Thermostat R E M O V A L S E R V I C E P O I N T UPPER HOSE (Non-turbo)> OR ROSE Engine and. D I S C O N N E C T I O N Place a mating mark on the and the clamp.
Page 705 ENGINE COOLING Thermostat” INSPECTION . . . T H E R M O S T A T Check that the valve closes ‘tightly-at temperature. Check for defects or damage. Check for rust or other Remove, if any. Immerse thermostat in container of Stir to raise water temperature and check that the thermostat valve opening temperature and the water temperature with valve...
Page 706 ENGINE COOLING Water Pump Engine (Non-turbo)> WATER PUMP ENGINE (NON-TURBO)> REMOVAL AND INSTALLATION and Post-Installation Engine Coolant Draining and Supplying (Refer to GROUP 00 Maintenance Service.) Timing Belt Rear Cover Removal and Installation (Refer to GROUP Timing Belt.) 12 Nm Removal steps Water pump 2.
Page 707 ENGINE COOLING Water Pump Engine P O I N T O-RING INSTALLATION Insert the O-ring to the of the O-ring with water or coolant. By with water or engine coolant, the insertion will become easier. Caution Do not allow engine oil or othei grease to to the O-ring.
Page 708 Water Pump Engine (Turbo) and. ENGINE COOLING WATER PUMP ENGINE (TURBO) AND 14100270155, REMOVAL AND INSTALLATION Pm-removal and Post-installation Engine Coolant Draining and Supplying (Refer to GROUP 00 Maintenance Service.) For Timinig Belt Removal and Installation, Refer to the Following GROUP Timing Belt.
Page 709 Water Pump Engine (Turbo) ENGINE COOLING I N S T A L L A T I O N S E R V I C E P O I N T O-RING INSTALLATION Insert the O-ring to the water inlet pipe, and coat the outer of the O-ring with coating Water...
Page 710 Water: Hose and Water Pipe Engine E N G I N E C O O L I N G ( N o n - t u r b o ) > WATER HOSE AND WATER PIPE ~ 4 1 0 0 5 5 0 1 1 5 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to...
Page 711: Engine
Water Engine Hose and Water Pipe ENGINE COOLING (Non-turbo)> REMOVAL POINTS. HEATER HOSE Caution cover the before a heater hose, the- below the hoses. RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. I N S T A L L A T I O N P O I N T S Cylinder block...
Page 712: Engine (Non-Turbo)
Water Hose and ENGINE COOLING Engine> WATER HOSE AND WATER PIPE ENGINE (TURBO) AND ENGINE> 14100330245 REMOVAL AND INSTALLATION Engine (Turbo)> Pre-removal and Post-installation Operation Turbocharger Removal and Installation (Refer to Engine Coolant Draining and Supplying (Refer to GROUP 15 Exhaust Manifold.) GROUP 00 Maintenance Service.)
Page 713 Installation (2) Air Cleaner Removal (3) Exhaust Manifold Removal and (Refer to GROUP 15 Exhaust Manifold.) Specified Sealant: Mitsubishi Genuine Part No. or equivalent Removal steps 6. Water hose 1. Radiator upper hose connection 7. Heater hose connection 2. Radiator lower hose 8.
Page 714 Engine> Squeeze out the sealant from the tube evenly and apply it so that there is not too much places without sealant. Specified Sealant: Mitsubishi Genuine Parts No. or equivalent in.) RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION Projection (1) Insert each hose as far as the projection of the water outlet fitting or water inlet fitting.
Page 715 INTAKE EXHAUST, C O N T E N T S 15166666676 Intake Charge Pressure Control System CHARGE AIR COOLER ....6 Check <Turbo>...
Page 716 General Information/Service Specifications/ INTAKE AND EXHAUST Special Tools/Troubleshooting GENERAL The intake manifold is made of an alloy, The exhaust pipe is divided into three parts: the and the shape provides an increased intake inertia front pipe, the center pipe, and the main muffler. effect and has a good volumetric efficiency.
Page 717 Service INTAKE AND EXHAUST ON-VEHICLE SERVICE INTAKE MANIFOLD VACUUM Engine (Turbo)> Refer to GROUP 11 A On-vehicle Engine (Non-turbo)> Refer to GROUP 11 On-vehicle Service. Engine>’ Refer to GROUP 11 On-vehicle Service. TURBOCHARGER SUPERCHARGING PRESSURE CHECK <Turbo> Caution Do a test drive with two passengers in the where full throttle acceleration can be safely made.
Page 718 INTAKE CHARGE PRESSURE CONTROL CHECK <Turbo> (1) After the diagnostic trouble code of system is com- pletely read, turn off the ignition switch. (2) Disconnect the hose (black) from the turbocharger waste gate solenoid and plug this hose. (3) Connect a hand vacuum pump to the turbocharger waste gate solenoid nipple to which the hose (black) was con- n e c t e d .
Page 719 INTAKE AND EXHAUST On-vehicle TURBOCHARGER <Turbo> (2) Connect the to,, turbocharger (3) Apply a negative pressure and check of the valve. Also check that air tightness is maintained. Negative pressure Valve operation Approx. 53 It starts opening TSB Revision...
Page 720: Charge Air Cooler
INTAKE AND EXHAUST CHARGE AIR COOLER REMOVAL AND INSTALLATION and Post-installation Operation Front Bumper Removal and Installation (Refer to GROUP Bumper.) Hose 7.2-9.4 Removal steps 1. Air cleaner assembly 9. Charge air cooler duct 2. Air duct assembly (B) 10. Charge air cooler 3.
Page 721 Intake Manifold Engine INTAKE AND EXHAUST REMOVAL AND INSTALLATION Post-installation Operation Operation Reservoir Assembly Installation Residual Fuel Pressure Releasing <Vehicles with Auto-Cruise System> (Refer to GROUP Service.) Engine Coolant Draining (Refer to GROUP Service.) Engine Coolant Supplying (Refer to GROUP Service.) Reservoir Assembly Removal with Auto-Cruise...
Page 722 INTAKE AND EXHAUST Intake Manifold Engine. 17. Intake manifold stay 18. Engine hanger 19. Injector connector 20. Throttle body 21. intake manifold plenum 22. Intake manifold plenum gasket 23. Fuel rail, injector and pressure regulator 24. O-ring 25. Intake manifold 26.
Page 723 INTAKE AND EXHAUST Intake Manifold Engine REMOVAL SERVICE POINTS HIGH-PRESSURE FUEL HOSE DISCONNECTION Relieve pressure in the fuel pipe line to prevent fuel outflow. (Refer to GROUP On-vehicle Service.) Caution Cover fuel pipe line with shop towel after relieving pres- sure as certain pressure may still remain.
Page 724 INTAKE AND EXHAUST Intake Manifold . . . INSPECTION 15100310123 Check the following points; replace the part if a problem is found. INTAKE MANIFOLD CHECK Check for damage or cracking of any part. Check for of the negative pressure (vacuum) outlet port, and for obstruction of the water passage or gas passage.
Page 725 Intake Manifold Engine INTAKE AND EXHAUST INTAKE MANIFOLD ENGINE (TURBO)> 15100300298 REMOVAL AND INSTALLATION Post-installation Operation Battery Installation Residual Fuel Pressure Releasing Engine Coolant Supplying GROUP Service.) (Refer to Accelerator Cable Adjustment (Refer to GROUP Service.) (Refer to GROUP Service.) 3.9 Nm 9.8 Nm IEngine oil...
Page 726 INTAKE AND EXHAUST Intake Manifold, Engine 12-15 27-34 Nm 27. Fuel rail, fuel injector and pressure 33. Intake manifold regulator assembly Engine hanger 28. Insulator 35. Intake 29. Insulator 38. Intake manifold gasket 30. Ignition power transistor 37. Manifold sensor 39.
Page 727 AND EXHAUST Intake Manifold FUEL HOSE Relieve pressure in line to prevent fuel outflow. (Refer to GROUP On-vehicle Service.) Cautlon Cover fuel pipe line with shop after sure as certain pressure may still FUEL INJECTOR AND PRESSURE ASSEMBLY REMOVAL Remove fuel rail with fuel injector and pressure regulator attached.
Page 728 INTAKE AND EXHAUST Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION Residual Fuel Pressure Releasing (Refer to GROUP Service.) (Refer to GROUP Service.) Accelerator Cable Adjustment (Refer to GROUP Service.) 4.9 Nm 3.6’ O-ring 10 Nm Engine oil Removal 1. Accelerator cable connection 13.
Page 729 12 Nm 9.8 Nm 30. Ignition coil 24. Fuel rail, fuel injector and pressure 31. Intake manifold stay regulator assembly 32. Intake manifold 25. Insulator 33. Intake manifold gasket 26. Insulator 34. Throttle body 27. Manifold erential pressure sensor 35. EGR valve assembly 26.
Page 730 INTAKE AND EXHAUST Intake Manifold REMOVAL SERVICE POINTS HIGH-PRESSURE FUEL HOSE DISCONNECTION Relieve pressure in the fuel pipe line to prevent fuel outflow. (Refer to GROUP On-vehicle Service.) Caution Cover fuel pipe line with shop towel after relieving pres- sure as certain pressure may remain.
Page 731: Exhaust Manifold
INTAKE, AND EXHAUST Exhaust Manifold Engine EXHAUST MANIFOLD ENGINE (NON-TURBO)>’ REMOVAL AND INSTALLATION and Post-installation Operation Engine Coolant Draining and (Refer to GROUP 3.9 Nm 44 Nm Removal steps 1. Air intake hose 7. Heat protector 2. Radiator upper hose connection 6.
Page 732: Engine (Turbo)
INTAKE AND EXHAUST Exhaust Manifold E X H A U S T M A N I F O L D E N G I N E ( T U R B O ) > REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling Engine Oil Draining and Refilling (Refer to GROUP 00...
Page 733 INTAKE AND EXHAUST Exhaust Manifold 54-64 Nm 24. Oil pipe 20. Vacuum hose assembly 21. Turbocharger assembly 25. Water pipe assembly (A) manifold fitting 22. Oil return pipe 27. Ghsket 23. Water pipe assembly (B) REMOVAL SERVICE REMOVAL HEATED OXYGEN SENSOR <FRONT> TURBOCHARGER ASSEMBLY assembly with the exhaust fitting, Remove the turbocharger...
Page 734 INTAKE AND EXHAUST Exhaust Manifold ENGINE (Turbo)> INSTALLATION SERVICE POINTS TURBOCHARGER ASSEMBLY (1) Clean the alignment surfaces shown in the illustration. (2) Supply clean engine oil through the oil pipe installation hole of the turbocharger assembly. Caution When cleaning, take care that no foreign material gets into the engine coolant or oil passages hole.
Page 735 Exhaust Manifold INTAKE AND EXHAUST EXHAUST MANIFOLD ENGINE> INSTALLATION REMOVAL AND 12-15 Nm 29 Nm 49 Nm Removal steps 1. Front exhaust connection 2. Gasket 3. Heat protector 4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold gasket TSB Revision...
Page 736: Engine
INTAKE AND EXHAUST Exhaust Pipe and Main Muffler EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION Engine (Non-turbo)> and Post-installation Under Cover Removal and Installation (Refer to GROUP Cover.) Main muffler removal steps Catalytic converter removal steps 1. Main muffler assembly 13.
Page 737 Exhaust Pipe and Main INTAKE AND EXHAUST Engine and Post-installation Operation steps Main muffler steps converter 1. Main muffler assembly 15. Gasket 2. Gasket 16. Catalytic converter bracket 3. Muffler cutter 1 7 . 4. Hanger 18. Hanger 5. Tail hanger Front 6.
Page 738 15-24 INTAKE AND EXHAUST Exhaust Pipe Main Engine Pre-removal and Post-installation Under Cover Removal and Installation (Refer to GROUP Cover.) Main muffler removal steps steps 1. Main muffler assembly 14. Catalytic converter 2. Gasket 15. Gasket 3. Muffler cutter 16. Front floor. heat protector panel 4.
Page 739 INTAKE AND EXHAUST Exhaust Pipe Engine> Post-installation Operation Under Cover Removal and Installation (Refer to GROUP Cover.) 49 Nm -59 Nm 44 N m Main muffler removal steps Catalytic converter removal steps 1. Main muffler assembly 13. Catalytic 2. Gasket 14.
Page 740 INTAKE AND Pipe and Main REMOVAL SERVICE POINT Engine (Non-turbo)> HEATED OXYGEN OXYGEN SENSER <REAR> Engine (Non-turbo), ‘the’ exhaust threabs must be cleaned with an 18 mm in.) the heated oxygen sensor has been disconnected. Engine (Turbo) and INSTALLATION SERVICE HEATED OXYGEN SENSOR OXYGEN SENSER <REAR;...
Page 741 SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP Restraint System (SRS) and GROUP 00 Maintenance Service, before...
Page 742 17-2 Evaporative Emission Canister/Air Filter/ G e n e r a l I n f o r m a t i o n Evaporative Emission Ventilation Solenoid ......... 70 .
Page 743: General Information
ENGINE AND EMISSION CONTROL Engine Control System GENERAL INFORMATION A c a b l e - t y p e a c c e l e r a t o r m e c h a n i s m a n d a suspended-type pedal have been adopted.
Page 744 ENGINE AND EMISSION CONTROL Engine Control ADJUSTMENT For models equipped with the auto-cruise refer to 1. Turn and lights OFF. Inspect and adjust” no load. 2. Warm engine until stabilized at 3. Confirm idle 4. Stop engine (ignition switch OFF). 5.
Page 745 ENGINE AND EMISSION CONTROL ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION 4.9 Nm 13 Nm 4.9 Nm 8. Bushing Accelerator cable removal steps 9. Spring 1. Clip 10. Accelerator pedal arm 2. Adjusting bolts Accelerator pedal bracket 3. Accelerator cable 12.
Page 746 17-6 ENGINE ‘AND EMISSION Engine ACCELERATOR Clamp the accelerator so that its Revision...
Page 747 AND EMISSION CONTROL Auto-cruise Control System GENERAL INFORMATION (Non-turbo)>, km/h (25-124 mph) By using the auto-cruise control, the driver can Engine (Turbo) and Engine>] without drive at the speed he/she likes [in a range of ing the accelerator pedal. mately km/h (25-84 mph) Engine Engine...
Page 748 ENGINE AND EMISSION CONTROL SERVICE Items Accelerator cable play mm (in.) Throttle cable play mm (in.) Auto-cruise control cable play Engine (Turbo) and Engine> mm (in.) SPECIAL TOOLS MUT-II Diagnostic trouble code check harness TSB Revision...
Page 749: Engine (Non-Turbo)
ENGINE AND EMISSION CONTROL Auto-cruise Control TROUBLESHOOTING ENGINE (NON-TURBO)> DIAGNOSTIC TROUBLESHOOTING FLOW not reoccur Reoccurs No diagnostic Diagnostic trouble No diagnostic trouble code displayed code or can’t with scan tool NOTE Before carrying out trouble diagnosis, check all the following items. Is the vacuum hose correctly installed and undamaged? 2.
Page 750 ENGINE AND EMISSION CONTROL Auto-cruise ERASING DIAGNOSTIC TROUBLE CODES the scan tool Connect the scan tool to the data link connector, then, erase the diagnostic trouble codes according to scan tool instruction. the scan tool 1. Remove the battery cable from the battery terminal for 10 seconds or more, then, reconnect the cable.
Page 751 ENGINE AND EMISSION CONTROL Auto-Cruise Scan tool Code General scan control switch Probable cause [Comment] Malfunction of the auto-cruise Speed control switch input above maximum acceptable voltage. Replace the auto-cruise control switch. Scan tool Code General scan control switch Probable [Comment] Malfunction of the auto-cruise control Speed control switch input below minimum acceptable voltage.
Page 752 17-12 ENGINE AND EMISSION CONTROL Auto-cruise Control I Scan tool control module [Comment] Malfunction of the PCM. Internal control module fault is detected. control Malfunction of the speed control [Comment] servo. Malfunction of the auto-cruise control relay. An open or shorted condition is detected in the speed control servo power relay control circuit. Malfunction of the connector.
Page 753 ENGINE AND EMISSION CONTROL Auto-cruise INSPECTION CHART FOR TROUBLE SYMPTOMS Inspection R e f e r e n c e Trouble symptom procedure No. page Communication with scan tool is not possible. Auto-cruise control does When engine speed rises suddenly 17-13 not cancel.
Page 754 ENGINE AND EMISSION CONTROL Auto-cruise Control System INSPECTION PROCEDURE 3 When brake pedal is depressed,, auto-cruise control does not Probable cause cancel. Malfunction of the stop light switch. [Comment] A malfunction of the stop light switch or stop light circuit may exist. Malfunction of the connector.
Page 755 ENGINE AND EMISSION CONTROL Auto-cruise System INSPECTION PROCEDURE 6 Auto-cruise control cannot be set. cause [Comment] Malfunction of the auto-cruise control switch A malfunction of the auto-cruise control switch circuit may exist. Malfunction of spring. Malfunction of the connector. Auto-cruise control switch check Measure at clock spring connector Disconnect the connector and mea- * Voltage between terminal (3) and...
Page 756 17-16 ENGINE AND EMISSION CONTROL Auto-cruise Control System INSPECTION PROCEDURE 9 Auto-cruise control main switch illumination light does not Probable cause illuminate. Malfunction of the auto-cruise control main A malfunction of the auto-cruise control main switch, or connector may exist. switch.
Page 757: Engine (Turbo)
ENGINE AND EMISSION CONTROL Auto-cruise System TROUBLESHOOTING ENGINE (TURBO) AND ENGINE> DIAGNOSTIC TROUBLESHOOTING FLOW Does not (Refer to (Refer to No diagnostic trouble Diagnostic trouble No diagnostic trouble code code displayed code or can’t with scan tool (Refer to NOTE Before carrying out trouble diagnosis, check to be sure that all of the following items are normal.
Page 758 ENGINE AND EMISSION CONTROL Auto-cruise Control When using a voltmeter Use the special tool to connect a voltmeter between the ground terminal and the diagnostic output terminal of d a t a l i n k c o n n e c t o r . In the same way as when using the scan tool, turn the ignition switch to ON and turn on the auto-cruise control main switch.
Page 759 CONTROL Input Inspection Table Input operation Operation Code No. SET switch ON Auto-cruise control-ECU judges that SET switch is ON RESUME switch ON Auto-cruisecontrol-ECU judges that Stop light switch Auto-cruise control-ECU judges that stop light switch is ON (ON when brake pedal depressed) Auto-cruise control-ECU judges that vehicle speed is 40 km/h (25 mph) or higher Vehicle speed signal...
Page 760 ENGINE AND EMISSION CONTROL Auto-cruise INSPECTION PROCEDURE: FOR DIAGNOSTIC TROUBLE CODES Code Auto-cruise vacuum pump drive system Malfunction of the auto-cruise vacuum pump [Comment] This diagnostic trouble code is output if the release valve, control valve and motor drive signals from the auto-cruise vacuum pump are not input to the auto-cruise control-ECU.
Page 761 ENGINE AND EMISSION CONTROL Auto-cruise Control’ Code 2 Vehicle speed signal system [Comment] Malfunction of the vehicle This diagnostic trouble code is output if the vehicle speed signals from the vehicle speed sensor connector are not input to the auto-cruise control-ECU when the vehicle speed is 40 km/h (25 mph) Malfunction of the harness or more.
Page 762 17-22 ENGINE AND EMISSION CONTROL Auto-cruise Control System Code Auto-cruise switch Probable cause Malfunction of the auto-cruise control switch This diagnostic trouble code is output if the RESUME switch or SET switch remains ON. Replace the auto-cruise control Code 6 Auto-cruise control-ECU Probable cause [Comment] Malfunction of the auto-cruise control-ECU...
Page 763 ENGINE AND EMISSION CONTROL Auto-cruise Control INSPECTION CHART FOR SYMPTOMS Inspection Trouble symptom Reference page procedure No. Communication with Communication with systems is not possible. scan tool is not Communication with auto-cruise control-ECU only possible. is not possible. Input switch inspection using the scan tool is not possible. (However, diagnostic inspection is possible.) Auto-cruise control When brake pedal is depressed...
Page 764 17-24 ENGINE AND EMISSION CONTROL Auto-cruise Control System INSPECTION PROCEDURE: FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with scan tool is not possible. (Communication with all systems is not possible.) [Comment] Malfunction of the connector. A defect in the power supply system (including ground) for the diagnostic line may be present. Malfunction of the harness.
Page 765 ENGINE AND EMISSION System INSPECTION PROCEDURE 3 Input switch inspection using the scan tool is pdssible. (However, diagnostic inspection is possible.) Malfunction of the auto-cruise control [Comment] A malfunction of auto-cruise control switch circuit system may be present. Malfunction of the clock spring . of the connector.
Page 766 17-26 ENGINE AND EMISSION CONTROL Auto-cruise Control System INSPECTION PROCEDURE 5 When clutch pedal is depressed, auto-cruise control does not Probable cause cancel. Malfunction of the clutch pedal position switch. Malfunction of the connector. or clutch circuit may be present. Malfunction of the Malfunction of the auto-cruise control-ECU.
Page 767 ENGINE AND EMISSION CONTROL Control. System INSPECTION PROCEDURE 7 When auto-cruise control CANCEL switch is set to ON, auto-cruise control does not cancel. [Comment] An open-circuit in the circuit inside the CANCEL switch may be present. Replace the auto-cruise control switch. INSPECTION PROCEDURE 8 The diagnostic result displayed on the scan tool is normal Probable cause...
Page 768 17-28 ENGINE AND CONTROL Auto-cruise Control System INSPECTION PROCEDURE 9 Auto-cruise control cannot be set. cause [Comment] Malfunction of the auto-cruise control main A malfunction of switches or that the fail-safe function auto-cruise control may be switch. present. Malfunction of the auto-cruise control Malfunction of the clock Malfunction of the harnesses or connectors.
Page 769 ENGINE AND EMISSION CONTROL Auto-cruise INSPECTION PROCEDURE 11 When the auto-cruise control main switch is ON, the switch indicator on the instrument panel does not illuminate. Probable cause (However, auto-cruise control is normal.) [Comment] auto-cruise control main Blown bulb in auto-cruise control main switch. switch.
Page 770 ENGINE AND EMISSION CONTROL Auto-cruise Control INSPECTION PROCEDURE 13 Auto-cruise control indicator inside combination meter does Probable cause not illuminate. (However, auto-cruise control is normal.) [Comment] Malfunction of the bulb. A malfunction of the bulb, the connector harness may be present. Malfunction of the harness.
Page 771 ENGINE AND EMISSION CONTROL CHECK AT THE ECU TERMINALS Termi- Normal Check item Check conditions nal No. When pedal is not depressed When clutch pedal position positive Clutch pedal switch is OFF voltage position switch When pedal is depressed When clutch pedal position input is ON When selector lever is in a...
Page 772 ENGINE EMISSION CONTROL Auto-cruise Control Normal Check item Check conditions condition Continuity Ground A? all times When brake pedal is When stop light switch voltage depressed Stop light switch input When stop light switch is When brake pedal is not depressed Al all times Battery...
Page 773 ENGINE AND EMISSION CONTROL Auto-cruise ON-VEHICLE SERVICE AUTO-CRUISE CONTROL CABLE CHECK AND ADJUSTMENT Engine Link assembly (Non-turbo)> Accelerator cable Adjusting bolts To intake manifold assembly Speed control assembly Engine (Turbo) Engine> Actuator Link assembly Accelerator cable Auto-cruise vacuum Revision...
Page 774 Auto-cruise Control System Remove the link protector. (Refer to Check the slack in each of the inner cables in the accelerator cable, auto-cruise control cable and throttle cable. If the slack in an inner cable is excessive, or if there is no play, loosen the adjusting bolts and the nuts in the throttle lever and each link, to release the throttle lever and each link.
Page 775 ENGINE AND EMISSION CONTROL Auto-cruise Control System AUTO-CRUISE CONTROL (Turbo) Engine> Adjusting nut(C) 1. Adjust with the adjusting nut so when the lever stopper hits the link B, the auto-cruise control cable play (inner cable play) reaches the standard value. Standard value: in.) 2.
Page 776 17-36 ENGINE AND EMISSION CONTROL Auto-cruise Control System SPEED-INCREASE RESUME switch: ON 1. Set to the desired speed. 2. Switch ON the RESUME switch. 3. Check to be sure that acceleration continues while the switch is hold, and that when it is released the constant speed at the time when it was becomes the driving speed.
Page 777: (Turbo)
ENGINE AND EMISSION CONTROL Auto-cruise Control System CONTROL COMPONENT STOP LIGHT SWITCH Measurement For stop light conditions circuit control circuit terminal No. terminal When brake pedal depressed. When brake pedal not depressed. CLUTCH PEDAL POSITION SWITCH Engine (Turbo) Engine Terminal No. Measurement conditions When clutch pedal depressed.
Page 778 17-38 ENGINE AND EMISSION CONTROL Auto-cruise’ Control 3. Connect terminal (1) to the battery terminal, and <Release valve closed, control valve connect terminals (2) and (3) to the battery terminal. closed> 4. Check to be sure that the vacuum gauge shows a reading of 53 (15.7 or more when...
Page 779 Control (3) Connect a jumper wire servo connector of the main harness and pin 3 of the speed control servo. The other three pins should show battery voltage. If not, replace the servo. (4) Using an ohmmeter, connect one lead to ground.
Page 780 ENGINE AND EMISSION CONTROL Auto-cruise Control AUTO-CRUISE CONTROL REMOVAL AND INSTALLATION Engine (Non-turbo)> Engine (Turbo) Engine> 00003900 10. Link bracket Engine Auto-cruise control cable, throttle turbo)> cable and accelerator cable removal steps Reservoir assembly and speed 1. Link protector control assembly removal steps Auto-cruise control cable adjustment Engine (Non-turbo)>...
Page 781 ENGINE AND EMISSION CONTROL Engine (Non-turbo)> (Turbo) and Auto-cruise removal Powertrain control module removal steps Engine (Non-turbo)> steps Engine (Turbo) and Engine> Air cleaner 22. Powertrain control module bracket side 23. Powertrain control module Auto-cruise control main switch removat steps 25.
Page 782 17-42 ENGINE AND EMISSION CONTROL Auto-cruise Control System CAUTION: Before removal of air bag module and clock spring, refer to the following sections: GROUP SRS Service Precautions. GROUP Air Bag Modules Clock Spring. 5.9 Nm Sensor removal steps Auto-cruise control switch and clock spring steps 33.
Page 783 Control ENGINE AND EMISSION CONTROL INSPECTION AUTO-CRUISE CONTROL MAIN SWITCH CHECK Terminal No. Switch AUTO-CRUISE CONTROL SWITCH CHECK 17200120082 Measure the resistance between the terminals when each of the SET, RESUME and CANCEL switches is pressed. If the values measured at this time correspond to those in the table below, then there is no problem.
Page 784 ENGINE AND EMISSION CONTROL Auto-cruise System’, AUTO-CRUISE CONTROL INDICATOR CHECK 17200190052 (1) Remove the combination meter. (Refer to GROUP 54 Combination meter.) (2) Check the continuity between terminals (10) and (16). If there is no continuity, replace the auto-cruise control indicator.
Page 785: Service Specifications
Emission ENGINE AND EMISSION CONTROL GENERAL INFORMATION The emission control system consists of the following sub-systems: Positive crankcase ventilation system Evaporative emission control system Exhaust emission control system SERVICE SPECIFICATIONS Standard value Evaporative emission purge solenoid coil resistance 25-35 Electric EGR transducer solenoid coil resistance 25-35 TROUBLESHOOTING 17300070052...
Page 786 17-46 ENGINE AND EMISSION CONTROL VACUUM HOSES VACUUM HOSE To heater and control Two way valve Vent EVAP solenoid EVAP canister To engine block EVAP Back pressure EGR and emission electric EGR transducer assembly sole Revision...
Page 787 Emission ENGINE AND EMISSION VACUUM CIRCUIT DIAGRAM intake air plenum b o d y To combustion Electric EGR transducer EGR valve EVAP canister purge solenoid EVAP (ON: open) V A C U U M H O S E C H E C K as a guide, check that Using the VACUUM HOSE ROUTING the vacuum hoses are correctly...
Page 788 Emission Control System ENGINE AND EMISSION CONTROL Engine POSITIVE CRANKCASE VENTILATION SYSTEM GENERAL INFORMATION The positive crankcase system (PCV) The plunger inside the positive crankcase prevents the escape of blow-by from inside tion valve is designed to lift according to intake the crankcase into the atmosphere.
Page 789 Emission ENGINE AND EMISSION CONTROL (Non-turbo)> CRANKCASE, CHECK’ of the PCV Remove the rocker cover side’ 2. Start the engine and run at idle. positive Place a finger at the opening Positive Positive of the ventilation valve and crankcase manifold is felt. ventilation NOTE At this time, the plunger in the positive crankcase ventila-...
Page 790 ENGINE AND EMISSION CONTROL EVAPORATIVE EMISSION CONTROL SYSTEM 17300510271 GENERAL INFORMATION The evaporative emission control system prevents purge solenoid, the power-train control module the emission of fuel tank vapors into the atmo- (PCM) allows intake manifold vacuum to draw va- sphere.
Page 791 Emission ENGINE AND CONTROL PURGE PORT VACUUM CHECK Disconnect the vacuum hose from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and raise the speed. Vacuum should Vacuum be kept constant regardless of the increased engine speed.
Page 792 ENGINE AND EMISSION CONTROL ENGINE COOLANT TEMPERATURE SENSOR AND INTAKE AIR TEMPERATURE SENSOR To check these parts, refer to GROUP Troubleshooting. AIR CONDITIONING SWITCH 17300200031 To check the air conditioning switch, refer to GROUP 55 Air Conditioning Switch. TSB Revision...
Page 793 Emission ENGINE AND EMISSION CONTROL EVAPORATIVE EMISSION CANISTER/AIR VENTILATION SOLENOID REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Splash Shield (R.H.) Removal and Installation fer to GROUP Removal steps 1. Suction hose fixing bolts 6. Vapor hose 2. Pressure tube fixing bolt 9.
Page 794 ENGINE AND EMISSION CONTROL EXHAUST GAS (EGR) SYSTEM 17309520059 GENERAL INFORMATION The EGR system reduces oxides in engine The EGR system contents: exhaust and helps prevent detonation (engine EGR tube knock). The system allows a predetermined amount EGR valve of hot exhaust gas to recirculate and dilute the Electronic EGR Transducer incoming air/fuel mixture.
Page 795 Emission Control Engine system, all To ensure proper operation of and moving parts must be free of plugging or sticking. Ensure that the system’ hoses do not leak. Replace leaking components. 1. Check the EGR valve with engine fully warmed up and running coolant perature over 2.
Page 796 Emission Control System ENGINE AND Disconnect the vacuum hose from the throttle body EGR vacuum nipple. Connect a hand vacuum pump to the nipple. Start the engine and gradually raise the speed. The vacu- Vacuum um reading on the pump should remain constant. Engine speed ELECTRIC EGR TRANSDUCER SOLENOID CHECK...
Page 797 Emission Control AND EMISSION CONTROL 8. Measure the resistance between the solenoid terminals. Standard value: CATALYTIC CONVERTER GENERAL INFORMATION When the mixture is controlled at stoichiometric The three-way catalytic converter, together with the closed loop air-fuel ratio control (based on the air-fuel ratio, the three-way catalytic converter pro- oxygen sensor signal) oxidizes carbon monoxides vides the highest purification against CO, HC, and...
Page 798 ENGINE AND EMISSION CONTROL INSPECTION Check for damage, cracking or deterioration. Replace if faulty. Caution 1. Stop the engine immediately if engine misfiring occurs, otherwise an abnormally hot exhaust system will damage the catalytic converter or other underbody parts. 2. Correct and repair the ignition or fuel system if there are malfunctions, otherwise engine misfiring may occur which will damage the catalytic converter.
Page 799: Special Tools
(Turbo) 2.41 Engines GENERAL INFORMATION The emission control system consists of the following sub-systems: Positive crankcase ventilation system Evaporative emission control system Exhaust emission control system SERVICE SPECIFICATIONS Standard value Evaporative emission purge solenoid coil resistance 36-44 EGR solenoid coil resistance [at 36-44 SPECIAL TOOL Tool...
Page 800 (Turbo) and Engine> VACUUM HOSES VACUUM HOSE ROUTING Engine (Turbo)> To evaporative emission EGR solenoid Evaporative emission Fuel pressure (EVAP) canister (EVAP) purge solenoid solenoid Purge control valve Fuel pressure regulator By-pass valve Turbocharger waste gate actuator gate solenoid Front L: Light Blue Black G: Green...
Page 801 (Turbo) and Engine> Evaporative emission solenoid (EVAP) canister Vacuum control valve E v a p o r a t i v e (EVAP) purge Front Blue B: Black G: Green Y: Yellow White Revision...
Page 802 Engine VACUUM CIRCUIT DIAGRAM Engine (Turbo)> Blue L: Light intake air Throttle body B: Black G: Green Yellow W: White To combustion chamber Check EVAP canister EVAP (ON: open) Turbocharger waste gate Turbochargerwaste ate solenoid ON: open) TSB Revision...
Page 803 Engine Engine> G: Green Yellow White intake air Throttle body To combustion chamber paint mark (ON: closed) EVAP purge (ON: open) Fuel pressure regulator EVAP canister VACUUM HOSE CHECK Using the VACUUM HOSE ROUTING as a guide, check that the vacuum hoses are correctly connected, and that there are no bends or damage to the hoses.
Page 804 (Turbo) and Engine> POSITIVE CRANKCASE VENTILATION SYSTEM 17300500070 GENERAL INFORMATION The plunger inside the positive crankcase The positive crankcase ventilation system (PCV) tion valve is designed to lift according to intake prevents the escape of blow-by from inside manifold vacuum, regulating the flow of blow-by. the crankcase into the atmosphere.
Page 805 Emission Control ENGINE AND EMISSION CONTROL Ventilation hose Breather hose COMPONENT LOCATION Positive crankcase ventilation valve TSB Revision...
Page 806 17-66 (Turbo) and CRANKCASE VENTILATION SYSTEM CHECK Engine (Turbo)> 17900110198 Remove the positive crankcase ventilation (PCV) valve from the rocker cover, then reconnect the PCV valve to the vacuum supply hose (ventilation hose). With the engine idling, put finger on the open end of the PCV valve, and check for negative pressure (vacuum) with finger.
Page 807 (Turbo) and POSITIVE VENTILATION VALVE” Engine (Turbo)> CHECK Hold the PCV valve with the vacuum side Thin stick Using light pressure depress the PCV valve spring (Extremely light) the thin stick mm. Release pressure on stick to see if the PCV valve spring will lift stick to its original position.
Page 808 17-68 AND EMISSION CONTROL ENGINE (Turbo) and EVAPORATIVE EMISSION CONTROL, SYSTEM GENERAL INFORMATION Engine (Turbo)> When driving with a low to medium load on the The evaporative emission control system prevents engine, the fuel vapor absorbed by the EVAP fuel vapors generated in the fuel tank from escaping ter is drawn into the port of the throttle body.
Page 809 (Turbo) and GENERAL INFORMATION Engine> The evaporative emission control system prevents module brings the purge OFF state to shut off the fuel vapor flow to the fuel vapors generated in the fuel tank from escaping intake manifold plenum. This does not only insure into the atmosphere.
Page 810 CONTROL 17-70 (Turbo) and Engine> PURGE CONTROL SYSTEM CHECK (PURGE FLOW CHECK) ENGINE (TURBO)> Intake manifold plenum EVAP purge solenoid (ON: OPEN) Nipple Purge control valve Air cleaner Check valve Air intake hose Purge flow indicator 700) Disconnect the purge hose from the evaporative emission (EVAP) canister, and connect the special tool (purge flow indicator) between the EVAP canister and the purge hose.
Page 811 ENGINE AND EMISSION CONTROL 4. Check the purge when carried out several times. Standard value: Momentarily 20 (2.5 SCFH) or more If the purge flow volume is less thah the standard value, check it again with the vacuum hose disconnected from the EVAP canister.
Page 812 (Turbo) and Engine> PURGE CONTROL CHECK (PURGE FLOW CHECK) ENGINE> 17300140272 Intake plenum Throttle body From air cleaner EVAP purge solenoid (ON: OPEN) Purge flow hose indicator EVAP canister Disconnect the purge hose from the evaporative emission (EVAP) canister, and connect the special tool (purge flow indicator) between the EVAP canister and the purge hose.
Page 813 ENGINE AND EMISSION 4. Check the purge when sudden carried out several’ value: (2.5 SCFH) , __ more 5. If the purge flow, volume ‘is than the value, hose from check it again with the the EVAP canister. If the purge flow volume check for blockages in the vacuum and also check the evaporative and the purge control...
Page 814 Engine (Turbo) Engine> PURGE VACUUM CHECK (Turbo)> Disconnect the vacuum hose from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Vacuum is kept constant despite the increased engine Vacuum speed. NOTE If no vacuum is generated, the throttle body purge port may be clogged.
Page 815 EVAPORATIVE EMISSION PURGE --SOLENOID Engine (Turbo)> CHECK NOTE When disconnecting the vacuum hose, place an mark on it proper reconnection. 1. Disconnect the vacuum hose from the valve. 2. Disconnect the harness connector. Connect a hand vacuum pump to nipple (A) of the solenoid’ valve (refer to the at left).
Page 816: Troubleshooting
CONTROL (Turbo) and Engine> PURGE CONTROL VALVE Engine 1. Remove the purge control valve. 2. Connect a hand vacuum pump to the vacuum nipple of the purge control valve. 3. Apply a vacuum of 53 and check Valve ness. Blow in air lightly from the evaporative emission canister side nipple and check conditions as follows.
Page 817 EVAPORATIVE EMISSION CANISTER/FUEL TANK PRESSURE RELIEF VALVE/PURGE CONTROL VALVE REMOVAL AND INSTALLATION Engine (Turbo)> Pre-removal and Post-installation Operation Battery Removal and Installation Removal steps Battery bracket 8. Vapor hose 2. Shift con- 9. Check valve nection 1 0 . C l a m p ’ 3.
Page 818 ENGINE AND EMISSION CONTROL Engine (Turbo) and Engine> Engine> and Post-installation Operation Splash Shield (R.H.) Removal and installation (Re- fer to GROUP 42 Fender) Removal steps 1. Evaporative emission 10. Vent hose 2. Vent hose Filter bracket 12. Air filter 3.
Page 819 FUEL TANK INSTALLATION Install the fuel relief Evaporative on the left. emission canister side I..- I N S P E C T I O N FUEL TANK PRESSURE RELIEF VALVE SIMPLE WARNING To avoid bodily injury, do not breathe fuel Attach a clean hose and tank Inspection procedure...
Page 820 (Turbo) Engine> EXHAUST GAS RECIRCULATION (EGR) SYSTEM 17300520205 GENERAL INFORMATION The exhaust gas recirculation (EG system lowers chamber through the intake manifold to decrease the nitrogen oxide emission level. When the mixture combustion temperature, result- air/fuel mixture combustion temperature is high, ing in reduction of a large quantity of nitrogen oxides is gener-...
Page 821 ENGINE AND EMISSION CONTROL Engine (Turbo) end Engine> Engine module relay COMPONENT LOCATION Engine (Turbo)> EGR valve EGR solenoid Manifold differential pressure sensor...
Page 822 Engine (Turbo) and Engine> Engine> EGR valve EGR solenoid Manifold differential pressure TSB Revision...
Page 823 Emission Control ENGINE AND EMISSION CONTROL Engine EGR SYSTEM CHECK 17300260220 the vacuum hose (green stripe Engine (Turbo)>, white stripe Engine>) from the sole- noid, and then connect a hand vacuum pump via the three-way terminal. Regarding the engine in cold and hot conditions, check the condition of vacuum when a rapid racing has been performed by opening the throttle valve quickly.
Page 824 (Turbo) and Engine> EGR VALVE CHECK Remove the EGR valve and inspect for sticking, carbon deposits, etc. If contaminants are found, clean the valve with a suitable solvent so it will seat correctly. 2. Connect a hand vacuum pump to the EGR valve. 3.
Page 825 EGR PORT VACUUM CHECK Engine Disconnect the vacuum hose (white stripe Engine (Turbo)>, green stripe Engine>) from the throttle body EGR vacuum nipple. Connect a hand vacuum pump to the nipple. Engine> 2. Start the engine and gradually raise the speed.’ The vacu- Vacuum um reading on the pump should remain NOTE...
Page 826 ENGINE AND EMISSION CONTROL (Turbo) EGR SOLENOID CHECK Engine (Turbo)> 17300310032 NOTE identification When disconnecting the vacuum’ hose, mark on it p r o p e r r e c o n n e c t i o n . Disconnect the vacuum hose (yellow stripe, stripe, green stripe) from the solenoid valve.
Page 827 Emission Engine AND EMISSION CONTROL SOLENOID CHECK NOTE When disconnecting the vacuum mark on it for proper re-connection. Disconnect the vacuum hose (yellow stripe; stripe) from the solenoid valve; Disconnect the harness connector. Connect a hand vacuum Check air tightness by applying vacuum directly from the battery to the solenoid...
Page 828 Emission Control System ENGINE AND EMISSION CONTROL Engine (Turbo) and CATALYTIC CONVERTER 17399939993 GENERAL INFORMATION When the mixture is controlled at stoichiometric The three-way catalytic converter, together with the closed loop air-fuel ratio control (based on the air-fuel ratio, the three-way catalytic converter pro- oxygen sensor signal) oxidizes carbon monoxides vides the highest purification against CO, HC, and (CO) and hydrocarbons (HC), and reduces nitrogen...
Page 829 CLUTCH CONTENTS CLUTCH ............CLUTCHOVERHAUL .
Page 830 NOTES...
Page 831 C O N T E N T S Bleeding ........‘7 CLUTCH CONTROL .
Page 832: Clutch Control
CLUTCH General Information GENERAL INFORMATION The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control. Items Engine (Non-turbo) (Turbo) Engine Clutch operating method Hydraulic type Hydraulic type Clutch disc type Single dry disc type Single dry disc type Clutch disc facing diameter 150 (8.9...
Page 833: Clutch Pedal
Clutch fluid Brake Fluid DOT 3 or DOT 4 Rubber grease As required Push rod assembly Boot MITSUBISHI genuine grease As required Release cylinder push rod Part No. 0101011 or equivalent As required Clutch pedal shaft, bushings and end of the Brake grease SAE No.
Page 834 CLUTCH 21199979939 Symptom Probable cause Remedy Clutch slips Insufficient clutch pedal play Adjust Excessive wear of clutch disc facing Replace Hardening of clutch disc facing, or adhesion of oil Replace Clutch release fork catching Repair or replace parts Weak or damaged diaphragm spring Replace Clogging of hydraulic system Repair or replace parts...
Page 835: On-Vehicle Service
CLUTCH -On-vehicle Service ON-VEHICLE SERVICE Pedal height 21199999999 CLUTCH PEDAL CHECK AND ADJUSTMENT 1. Turn up the carpet, etc. under the clutch pedal. Measure the clutch pedal height as shown in the figure. Clutch pedal height Standard value (A): Adjusting bolt or clutch pedal If the pedal height is not within the standard value, loosen position...
Page 836: Interlock Switch Operating Check
CLUTCH On-vehicle Service INTERLOCK SWITCH OPERATING CHECK Lock the front wheels, apply the parking brake and put the shift lever in the gear. After normally adjusting the clutch pedal, check the inter- lock switch operation as follows: (1) The engine should not start even if the ignition switch is turned to “START”...
Page 837 CLUTCH On-vehicle Service BLEEDING Engine (Non-turbo)> Whenever the clutch tube, the clutch clutch master cylinder have the clutch pedal is spongy, bleed the system. Specified brake fluid: DOT 3 or Caution with Use only the specified brake fluid. Do not mix fluid.
Page 838 CLUTCH Clutch Pedal CLUTCH PEDAL REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Scuff Plate Removal GROUP Clutch Pedal Adjustment (Refer to Cowl Side Trim Removal Junction Block Installation (Refer to GROUP Trims.) Cowl Side Trim Installation Junction Block Installation Boll: Removal (Refer to GROUP Trims.) Scuff Plate Installation...
Page 839 CLUTCH Clutch INSPECTION Check the pedal shaft for, wear. Check the clutch ‘for Check the return spring for Check the turnover spring for Check the pedal pad for damage or wear. Revision...
Page 840 CLUTCH Clutch Control CLUTCH CONTROL REMOVAL AND INSTALLATION Operation Clutch Fluid Draining Clutch Pedal Adjustment (Refer to Specified grease: MITSUBISHI genuine grease Part No. 0101011 or equivalent I Engine (Non-turbo)> 00003520 Clutch master removal Clutch release cylinder removal steps steps 1.
Page 841 CLUTCH Clutch Engine (Turbo)> removal Clutch master cylinder removal Clutch release cylinder steps steps 6. Clutch pipe connection 2. Clutch pipe connection 7. Clutch release cylinder master cylinder Clutch line removal steps 8. Clutch pipe Reservoir bracket 9. Clutch pipe 10.
Page 842 CLUTCH Clutch Control REMOVAL SERVICE POINT CLUTCH HOSE REMOVAL Holding the nut at the clutch hose side, loosen the flare nut on the clutch pipe. INSTALLATION SERVICE POINT CLUTCH HOSE/CLUTCH PIPE INSTALLATION 1. Temporarily tighten the clutch pipe flare nut by hand, and then tighten it to the specified being careful that the clutch hose does not become twisted.
Page 843 CLUTCH Clutch Master Cylinder CLUTCH MASTER CYLINDER DISASSEMBLY AND REASSEMBLY Brake fluid DOT 3 Piston repair kit DOT 4 Rubber Grease: (Non-turbo) Engine (Turbo)> Disassembly steps Reservoir cap 1. Piston stopper ring 8. Reservoir tank rod assembly 9. Reservoir band 10.
Page 844 NOTES...
Page 845 OVERHAUL CONTENTS CLUTCH .......*... 4 SPECIFICATIONS ... . . Lubricants .
Page 846 CLUTCH OVERHAUL Specifications SPECIFICATIONS 21200030047 SERVICE SPECIFICATION Engine (Turbo) and Engine> Diaphragm spring end height difference TORQUE SPECIFICATIONS Engine (Turbo) and Engine> Clutch cover bolt Release cylinder mounting bolt Release cylinder union bolt Release cylinder bleeder plug Release fork fulcrum Clutch chamber bracket mounting bolt Clutch line tube flare nut Engine (Non-turbo)>...
Page 847 Clutch release bearing to release fork contact surface Engine (Non-turbo)> Items Specified lubricants Clutch flywheel assembly spline Mitsubishi genuine grease Part As required or equivalent Clutch release release cylinder contact surface Clutch release lever to release bearing contact surface TSB Revision...
Page 848 CLUTCH OVERHAUL Clutch CLUTCH REMOVAL AND INSTALLATION Engine Removal steps 5. Clutch release lever 1. Oil tube 6. Clutch control equip stud 2. Clutch release cylinder 7. Boot 3. Clutch flywheel 4. Clutch release bearing NOTE The modular clutch assembly flywheel assembly) used in this vehicle consists of a single, dry-type clutch disc and a diaphragm style clutch cover.
Page 849 CLUTCH OVERHAUL Clutch REMOVAL AND INSTALLATION Engine (Turbo) and 15 Nm 19 Nm 19 Nm Removal steps 10. Clutch cover 1. Clutch oil tube (A) 11. Clutch disc 2. Clutch tube 12. Return clip 3. Clutch oil fluid chamber 13. Clutch release bearing 4.
Page 850 INSTALLATION SERVICE POINTS GREASE APPLICATION TO RELEASE Specified grease: MITSUBISHI genuine grease Part No. 01010 1 or equivalent CLUTCH RELEASE GREASE APPLICATION...
Page 851 (2) Using clutch disc guide to position clutch disc on flywheel. Clutch cover assembly GREASE APPLICATION TO CLUTCH RELEASE LEVER Specified grease: MITSUBISHI genuine grease Part No. 0101011 or equivalent CLUTCH FLYWHEEL ASSEMBLY INSTALLATION (1) Apply specified grease to clutch disc splines and squeeze it in place with a brush.
Page 852 CLUTCH OVERHAUL Clutch INSPECTION 21200110043 Engine (Turbo) and Engine> CLUTCH COVER ASSEMBLY Check the diaphragm spring end for wear and uneven height. if wear is evident ‘or height difference exceeds limit. Limit: in.) Check the pressure plate surface for wear, cracks and seizure.
Page 853 CLUTCH OVERHAUL Clutch CLUTCH RELEASE Caution Release bearing is packed with grease. wash it in cleaning solvent the like. Check bearing for seizure, damage, noise, or improper rotation. Check also diaphragm spring contact surface for wear. Replace bearing if its release fork contact surface is abnor- mally worn.
Page 854 (Turbo) CLUTCH RELEASE CYLINDER Engine (Turbo) and Engine> 21200150057 DISASSEMBLY AND REASSEMBLY Brake fluid Piston Brake fluid Disassembly steps 1. Push rod 5. Conical spring 2. Boot 6. Cap 3. Piston cup 7. Bleeder plug 4. Piston 8. Release cylinder TSB Revision...
Page 855 Clutch Release Cylinder CLUTCH Engine (Turbo) and Engine> DISASSEMBLY SERVICE POINT AND PISTON CAP REMOVAL Remove the piston from the release cylinder using compressed air. Caution 1. Cover with shop towel to prevent the piston from popping out. 2. Apply compressed air slowly to prevent brake fluid from splashing.
Page 856 NOTES...
Page 857 CONTENTS MANUAL TRANSAXLE ....‘....... MANUAL TRANSAXLE OVERHAUL ........
Page 858 NOTES...
Page 859 Service or maintenance of any component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP Maintenance Service, before beginning any or maintenance of Restraint System and GROUP 00...
Page 860: General Information
MANUAL TRANSAXLE ENGINE (TURBO) AND General Information GENERAL The manual transaxles come in three models, axles are essentially the same as the previous namely, These els. Engine (Turbo) Engine Model Applicable engine floor shift floor shift Gear ratio 3.090 3.166 1.833 1.833 1.240...
Page 861 MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> SECTIONAL VIEW Bearing retainer ‘peed gear shaft Input peed 1 st speed gear synchronizer speed Intermediate shaft Transaxle case . D r a i n p l u g Revision...
Page 862 MANUAL E N G I N E Bearing retainer speed speed speed gear speed gear Rear cover brake device Spacer Spacer Drain plug Revision...
Page 863 MANUAL TRANSAXLE ENGINE (TURBO) Information ousing speed synchronizer gear assembly speed gear Sub gear speed gear speed synchronizer gear Input shaft Drive bevel gear gear Center shaft Driven bevel coupling gear differential Front output shaft Front differential TSB Revision...
Page 864: Service Specifications
MANUAL TRANSAXLE Service Specifications/ ENGINE ENGINE> Lubricants SERVICE SPECIFICATIONS Standard value of front roll stopper bracket 3 (1.69 LUBRICANTS Items lubricant Quantity Transaxle oil API classification (2.4 Transfer oil API classification qt.) Propeller shaft sleeve yoke API classification As required Revision...
Page 865 MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> Special Tools SPECIAL TOOLS Tool number and name Application Tool Tie rod end ball joint knuckle Steering linkage puller Lateral lower arm ball join and knuckle disconnection Compression lower arm ba joint and knuckle tion GENERAL SERVICE Supporting the engine assembly...
Page 866: Troubleshooting
Troubleshooting! MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> On-vehicle Service TROUBLESHOOTING Probable Remedy Symptom Tighten or replace mounts Loose or damaged transaxle and engine mounts Vibration, noise Inadequate shaft end play Correct the end play Worn or damaged gears Replace gears Replace with specified oil Use of inadequate grade of oil Refill...
Page 867 MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> TRANSAXLE CONTROL REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the transaxle control cable and shift lever assembly. Engine> 3.9 Nm Engine (Turbo)> NOTE Resin clip position Shift lever...
Page 868 MANUAL TRANSAXLE (TURBO) AND ENGINE> Transaxle INSTALLATION SERVICE CABLE AND SELECT CONNECTION (TRANSAXLE SIDE) SELECT CABLE (1) Connect the select cable to the transaxle side select lever. (2) Set the shift lever of the transaxle side at the neutral position. NOTE When the shift lever of the transaxle side is set at the Neutral position...
Page 869 MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 0 0 0 0 0 0 9 9 Disassembly steps 12. Bolt 1. Nut 1 3 . L e v e r A 2. Spring washer 14. Bushing 3.
Page 870 MANUAL TRANSAXLE ENGINE ENGINE> Transaxle TRANSAXLE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Transaxle Oil Draining (Refer to GROUP 00 Supplying Transaxle Oil (Refer to GROUP 00 Maintenance Service.) Maintenance Service.) Removal Shift Lever Operation Check Under Cover Removal Speedometer Operation Check (Refer to GROUP 42 Under Cover.) Under Cover Installation...
Page 871 MANUAL TRANSAXLE -ENGINE (TURBO) AND ENGINE> Transaxle Engine> Engine> 22-25 51-58 Lifiting up of the vehicle 16. Tie rod end ball joint and kunckle 27. Transaxle mounting connection 28. Transaxle assembly 17. Stabilizer link connection 18. Damper fork Caution 19. Lateral lower arm ball joint and Indicates parts which should be temporarily kunckle connection tightened, and then fully...
Page 872 MANUAL TRANSAXLE ENGINE ENGINE> Transaxle Assembly REMOVAL SERVICE POINTS TRANSAXLE MOUNTING BRACKET MOUNTING NUTS REMOVAL Jack up the transaxle assembly gently with a garage jack, and then remove the transaxle mounting bracket nuts. Caution Be sure not to tilt the transaxle assembly. SUPPORTING ENGINE ASSEMBLY Set the special tool to the vehicle to support the engine assembly.
Page 873 MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> Transaxle Assembly CLUTCH. Remove the clutch release cylinder without disconnecting the oil line, and suspend a nearby “a etc. INSTALLATION SERVICE POINT Transaxle Transaxle side mount TRANSAXLE MOUNTING stopper Align the notches on the stopper with the transaxle mount bracket with the arrow mark facing toward the shown direction.
Page 874 MANUAL ENGINE Transaxle Assembly TRANSAXLE ASSEMBLY 22100270092 REMOVAL INSTALLATION Pre-removal Operation Post-installation Operation Transaxle Oil Draining to GROUP 00 Supplying Transaxle Oil (Refer to GROUP 00 Maintenance Service.) Maintenance Service.) Battery Removal Shift Lever Operation Check Under Cover Removal Speedometer Operation Check (Refer to GROUP 42 Under Cover.) Transfer Assembly Installation (Refer to...
Page 875 MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> Transaxle Assembly 34 Nm 2 4 ’ 59-71 Nm 8.8 Nm 44-52 Lifting up of the vehicle 27. Center member assembly 16. Tie rod end ball joint and knuckle 28. Transaxle assembly mounting bolt connection 29.
Page 876 MANUAL TRANSAXLE ENGINE ENGINE> Transaxle Assembly REMOVAL SERVICE POINTS TRANSAXLE MOUNTING BRACKET MOUNTING NUTS REMOVAL Jack up the transaxle assembly gently with a garage jack, and then remove the transaxle mounting bracket nuts. Caution Be sure not the transaxle assembly. to tilt SUPPORTING ENGINE ASSEMBLY Set the special tool to the vehicle to support the engine...
Page 877 MANUAL TRANSAXLE Assembly ENGINE (TURBO) AND ENGINE> Transaxle DRIVE SHAFT REMOVAL a pry bar between the transaxle case and the drive shaft, and then pry the drive shaft from the transaxle. Caution Use a pry bar to remove drive shaft from the assembly, or the T.J.
Page 878 MANUAL TRANSAXLE ENGINE (TURBO) AND ENGINE> Transaxle Assembly INSTALLATION SERVICE POINT Transaxle Transaxle side mount TRANSAXLE MOUNTING INSTALLATION s t o p p e r , Arrow Align the notches on the stopper with the transaxle mount bracket with the arrow mark facing toward the shown direction. Then install the stopper.
Page 879 MANUAL TRANSAXLE ENGINE (TURBO) AND Assembly TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (Refer to GROUP 15 Exhaust Pipe, Muffler.) 54-59 Nm Gear oil: API classification 1. Transfer assembly REMOVAL SERVICE POINT (A, TRANSFER ASSEMBLY REMOVAL Caution (1) Do not damage the oil seal lip of the transfer. (2) Use the special tool to cover the transaxle case to prevent oil from gushing out or foreign materials from getting into the transaxle case.
Page 880 MANUAL TRANSAXLE (NON-TURBO)> General Information 22110010022 GENERAL The manual transaxle comes in one model, namely Items Specifications Model Applicable engine floor shift Gear ratio 3.54 2.13 1.36 1.03 0.81 3.42 Reverse Final gear ratio 3.94 Speedmeter gear ratio (driven/drive) Revision...
Page 881 MANUAL TRANSAXLE (NON-TURBO)> General SECTIONAL VIEW speed gear synchronizer speed gear idler speed gear synchronizer 1 st synchronizer 1 st speed clear Differential TSB Revision...
Page 882: Transaxle Oil Level Check
MANUAL Service Specifications/Lubricants/ Special Tools/Troubleshooting/On-vehicle Service ENGINE (NON-TURBO)> SERVICE SPECIFICATIONS 22100020010 Items Standard value Installation dimension of front roll stopper bracket 43 3 (1.69 LUBRICANTS 22110020025 Items Specified lubricant Quantity (qts.) Transaxle oil TEXACO MTX FLUID FM SPECIAL TOOLS 22110020028 nber and name Application Tie rod end ball joint...
Page 883 MANUAL TRANSAXLE ENGINE (NON-TURBO)> Transaxle TRANSAXLE CONTROL REMOVAL AND INSTALLATION Caution: SRS Pre-removal and Post-installation Be careful not Operation of the shocks during removal Removal and Installation assembly. transaxle control cable 3.9 Nm NOTE Resin clip 14. Shift cable. select cable Transaxle control cable assembly assembly removal steps...
Page 884 MANUAL TRANSAXLE ENGINE (NON-TURBO)> Transaxle Control INSTALLATION SERVICE POINTS Select cable (1) Connect the select cable to the transaxle side select lever. (2) Set the select lever of the transaxle side at the neutral position. (1) Connect the shift cable to the transaxle side shift lever. (2) Set the shift lever of the transaxle side at the neutral position.
Page 885 MANUAL TRANSAXLE ENGINE Transaxle SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 00000098 Disassembly steps 1. Nut 12. Bolt 2. Spring washer Lever 14. Bushing 3. Plain washer 4. Shift lever 15. Collar 5. Bushing 16. Bushing 6. Nut 17. Snap ring 7.
Page 886 MANUAL TRANSAXLE ENGINE (NON-TURBO)> Transaxle Control TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Transaxle Oil Draining (Refer to GROUP 00 Supplying Transaxle Oil (Refer to GROUP 00 Maintenance Service.) Shift Lever Check Speedometer ‘Operation Check (Refer to GROUP 42 Under Cover.) Under Cover Installation (Refer to GROUP 42 Under Cover.)
Page 887 MANUAL TRANSAXLE ENGINE (NON-TURBO)> Transaxle 59-71 Nm Lifting up of the vehicle 11. Tie rod end ball joint and 23. Transaxle assembly mounting bolts connection 24. Transaxle mounting 12. Stabilizer link connection 25. Transaxle assembly 13. Damper fork 14. Lateral lower arm ball joint and Caution connection l: Indicates parts which...
Page 888 MANUAL TRANSAXLE (NON-TURBO)> Transaxle Control REMOVAL SERVICE POINTS TRANSAXLE MOUNTING BRACKET MOUNTING NUTS REMOVAL Jack up the transaxle assembly gently with a garage jack, and then remove the transaxle mounting bracket nuts. Caution Be sure not to tilt the transaxle assembly. SUPPORTING ENGINE ASSEMBLY Set the special tool to the vehicle to support the engine assembly.
Page 889 MANUAL TRANSAXLE ENGINE (NON-TURBO)> CLUTCH RELEASE CYLINDER Remove the clutch release cylinder disconnecting the oil line connection, and fix it to the vehicle chassis. FLEX PLATE CONNECTING ASSEMBLY MOUNTING BOLTS/TRANSAXLE ASSEMBLY REMOVAL (1) Support the transaxle a transaxle jack. (2) Remove the connection bolts while turning the crankshaft. (3) Chalk mating marks on the flex plate and clutch pressure plate for easier installation.
Page 890 MANUAL. TRANSAXLE ENGINE (NON-TURBO)> Transaxle Control ASSEMBLY INSTALLATION If the dimension shown in the illustration is outside the standard value when the’ weight of the engine is on the body, replace Front the front roll stopper bracket assembly. stopper bracket Standard value (A): 43 3 mm (1.69 in.)
Page 891 T R A N S A X L E CONTENTS SPECIAL TOOLS ......13 ..60 CENTER DIFFERENTIAL SPECIFICATIONS .
Page 892 MANUAL. TRANSAXLE OVERHAUL General GENERAL 22200010055 Bearing retainer Clutch ed gear Input shaft speed gear speed gear speed synchro- speed gear nizer Rear cover Reverse brake device speed intermediate gear Intermediate gear spacer Output shaft S p a c e r Drain plug Revision...
Page 893 MANUAL TRANSAXLE OVERHAUL Information SECTIONAL VIEW Clutch housing speed gear Bearing retainer speed gear speed synchronizer assembly speed gear Input shaft Rear cover Reverse brake gear gear Spacer Output Spacer case Differential drive gear Spacer Drain plug Differential TSB Revision...
Page 894 MANUAL TRANSAXLE OVERHAUL Information speed gear Clutch housing speed synchronizer assembly speed gear Sub gear Bearing retainer speed gear speed synchronizer assembly speed gear speed gear speed synchronizer Intermediate gear coupling Center differential Front output shaft Front differential Revision...
Page 895 MANUAL TRANSAXLE OVERHAUL SPECIFICATIONS Transaxle model Gear ratio Speedometer Final gear ratio Vehicle model model” gear ratio 3.625 4.153 Items 3.166 3.090 1.833 1.833 1.240 1.217 0.896 0.888 0.731 0.741 0.666 Reverse 3.166 3.166 3.166 Transfer 1.090 Revision...
Page 896 MANUAL, TRANSAXLE OVERHAUL Standard value Items Differential case preload mm (in.) Differential pinion backlash mm (in.) Input shaft front bearing end play mm (in.) Input shaft end play mm (in.) Input shaft rear bearing end play mm (in.) Intermediate gear bearing end play mm (in.) Intermediate gear bearing end play mm (in.)
Page 897 MANUAL TRANSAXLE OVERHAUL Snap ring (For adjustment of input shaft front bearing end play) Thickness mm (in.) identification symbol Part No. Thickness mm (in.) Identification symbol Part No. 2.24 None 2 . 3 8 Brown 2.31 Blue Snap ring (For adjustment of input shaft rear bearing end play) Thickness mm (in.) Identification symbol Part No.
Page 898 MANUAL TRANSAXLE OVERHAUL Spacer: (For adjustment of intermediate gear end play) Identification symbol Part No. Thickness mm (in.) Part Thickness mm (in.) 1.01 0.62 1.04 0.65 1.07 0.68 1.10 0.71 1.13 0.74 1.16 0.77 1.19 0.80 1.22 0.83 1.25 0.86 1.28 0.89 1.31...
Page 899 MANUALTRANSAXLE OVERHAUL Spacer: (For adjustment of fron differential case end play) Thickness mm (in.) Identification symbol Part No. Thickness mm (in.) Identification symbol Part No. 0.56 0.65 1 . 1 0 0.74 0.83 1 . 2 8 0458 0.92 1 . 3 7 0460 Spacer: (For adjustment of front differential case end play)
Page 900 MANUAL TRANSAXLE OVERHAUL Snap ring: [For adjustment of viscous coupling end play (with VCU)] Thickness mm (in.) Identification symbol Part No. Thickness mm (in.) Identification symbol Part No. Orange White Yellow Blue Green None Spacer: (For adjustment of center differential pinion backlash front side) Thickness mm (in.) Identification symbol Part No.
Page 901 MANUAL TRANSAXLE OVERHAUL Spacer: (For adjustment of drive bevel gear mount) Thickness mm (in.) Identification symbol Part No. Thickness mm (in.) Identification symbol Part No. 1.34 1.52 1.37 1.55 1.40 1.58 1.43 1.61 0575) 1.49 Spacer: (For adjustment of drive bevel gear preload) Thickness mm (in.) symbol Thickness mm (in.)
Page 902 MANUAL TRANSAXLE OVERHAUL Items Transaxle Backup light switch Bearing retainer bolt Bell housing cover mounting bolt Center differential lock actuator mou Center differential lock indicator Center differential shift lever Differential drive gear bolt Input shaft lock nut Interlock plate bolt Intermediate gear lock nut Output gear mounting bolt Poppet plug...
Page 903: Special Tools
Transfer cover mounting bolt Transfer mounting bolt SEALANTS AND ADHESIVES Items Specified sealants and adhesives Quantity Transaxle case rear cover mating surfaces Mitsubishi genuine sealant As required Part or equivalent Transaxle case clutch housing mating surfaces Adapter-transaxle case mating surfaces Adapter...
Page 904 MANUAL TRANSAXLE OVERHAUL Special Tools Application nber and name Installation of input shaft General service tool Installation of differential oil seal Differential oil seal Removal of gears and of input shaft, intermediate and output shaft Installation and removal of inpu shaft and intermediate gear General service tool Installation of differential oil seal...
Page 905 MANUAL TRANSAXLE OVERHAUL -Special Tools Installer adapter (30) Installer adapter (38) Installer adapter (46) TSB Revision...
Page 906 MANUAL TRANSAXLE OVERHAUL Special Tools Tool Application Installation of each bearing Installer adapter (56) Installation of transfer case oil Oil seal installer seal Handle Installation and removal of driver Special spanner gear lock nut of intermediate Bearing remover General service tool of bearing outer race Claw service tool...
Page 907 TRANSAXLE OVERHAUL MANUAL Transaxle TRANSAXLE DISASSEMBLY AND REASSEMBLY 19 Nm Lubricate all internal Disassembly steps 12. Speedometer. driven gear assembly 1. Bolt 13. Air breather Rear cover 14. Spring 3. Reverse brake cone 15. Lock nut 41 Wave spring 16. Lock nut 5.
Page 908 MANUAL TRANSAXLE OVERHAUL Transaxle 39 Nm 33 Nm 49 Nm 2210010 Disassembly steps 23. Reverse idler gear shaft bolt 36. Bearing outer race 24. Gasket 37. Spacer 25. Bolt 38. Bearing outer race 26. Transaxle case 27. Oil guide Bolt Reverse shift lever 29.
Page 909 MANUAL TRANSAXLE OVERHAUL Transaxle 19 Nm Lubricate all internal parts with during reassembly. Disassembly steps 56. Oil guide 57. Bearing outer race 58. Bearing outer race’ Bearing retainer 51. Intermediate gear assembly 59. Oil seal 60. Oil seal 52. Input shaft assembly 61.
Page 910 MANUAL TRANSAXLE 19 Nm Disassembly steps 1. Bolt 12. Speedometer driven gear assembly 2. Rear cover 13. Air breather 3. Reverse brake cone 14. Spring pin 4. Wave spring 15. Lock nut 5. Machine 16. Lock nut switch synchronizer assembly 1.8.
Page 911 MANUAL TRANSAXLE. OVERHAUL Transaxle 39 Nm Disassembly steps 37. Spacer 23. Reverse idler gear shaft bolt 38. Filter 24. Gasket 39. Bearing outer race 25. Bolt 40. Spacer 26. Transaxle case race 27. Oil guide 28. Bolt 29. Spring washer 44.
Page 912 MANUAL TRANSAXLE Transaxle Lubricate all internal parts with engine oil during reassembly. Disassembly steps 60. Oil guide 61. Bearing outer race 62. Bearing outer race Bearing retainer Oil seal 54. Intermediate gear assembly Oil seal 55. Input shaft assembly Magnet 56.
Page 913 MANUAL TRANSAXLE OVERHAUL 39 Nm 4 Nm Disassembly steps 1. Rear cover 12. Speedometer gear assembly 2. Reverse bracket cone 13. Air breather 3. Wave spring Spring 4. Machine screw . 15. Lock nut Lock speed assembly assembly 19. Synchronizer ring Poppet plug speed 10.
Page 914 MANUAL TRANSAXLE OVERHAUL Transaxle Disassembly steps Snap ring 24. Viscous coupling 25. Steel ball 26. Center shaft 27. Transaxle case adapter 28. Outer case 29. Spacer 30. Outer race 31. Spacer 32. Outer race 33. Spacer 34. Center differential 35. Outer race 36.
Page 915 Disassembly steps 38. Clutch oil line bracket 39. Transaxle case 40. Oil guide 41. Oil guide 42. Outer race 43. Spacer 44. Spacer 45. Stopper bracket Oil seal 47. Reverse shift lever assembly Reverse shift lever shoe 49. Reverse idler gear 50.
Page 916 MANUAL TRANSAXLE OVERHAUL Disassembly steps 54. Spring pin race’ 55. Spring pin Oil seal 56. Shift rail assembly 57. Bolt O i l ‘ s e a l 58. Bearing retainer 68. Magnet 59. Intermediate gear assembly Magnet 60. Input shaft assembly 70.
Page 917 MANUAL TRANSAXLE OVERHAUL Transaxle NUTS FOR INPUT INTERMEDIATE GEAR (1) Unstake nuts of the input shaft and gear. the transaxle in reverse using control lever and select lever. (3) Install the special tool onto the input shaft. (4) Screw a bolt in.)] into the bolt clutch housing and attach a spinner handle to special...
Page 918 MANUAL TRANSAXLE OVERHAUL Transaxle INTERMEDIATE GEAR INPUT SHAFT ASSEMBLY REMOVAL Lift up the input shaft assembly and remove intermediate gear assembly. RACE REMOVAL BEARING OUTER REASSEMBLY SERVICE SEAL FOR DRIVE SHAFT I N P U T INSTALLATION G E A R SHAFT ASSEMBLY Lifting up the input shaft assembly, it simultaneously...
Page 919 TRANSAXLE OVERHAUL MANUAL Transaxle APPLICATION TO RETAINER MOUNTING BOLT s e a l a n t : STUD Locking or equivalent SHIFT RAIL ASSEMBLY (1) Set the speed shift sleeve at speed. (2) Set the speed shift sleeve at (3) Install the shift fdrks respective sleeves.
Page 920 OIL SEAL FOR DRIVE SHAFT INSTALLATION SEALANT APPLICATION TO TRANSAXLE’ Squeeze out sealant from the tube uniformly without or discontinuity. S p e c i f i e d s e a l a n t : Mitsubishi genuine sealant part equivalent TSB Revision...
Page 921 MANUAL TRANSAXLE OVERHAUL Transaxle GEAR SHAFT BOLT IDLER INSTALLATION (1) Center the shaft with a Phillips screwdriver [shaft diameter 8 mm in.)] or the like. (2) Tighten the reverse idler gear shaft bolt to the specified torque. LOCK NUTS FOR INPUT SHAFT INTERMEDIATE GEAR INSTALLATION (1) Install the special tool onto the input shaft.
Page 922 MANUAL TRANSAXLE OVERHAUL Transaxle SEALANT APPLICATION TO AIR’ sealant: SUPER WEATHERSTRIP ‘or equivalent APPLICATION TO REAR COVER Specified sealant: Mitsubishi genuine sealant equivalent 22210033 APPLICATION TO Specified sealant: STUD Locking equivalent OIL SEAL INSTALLATION I- . . TSB Revision...
Page 923 MANUAL OVERHAUL Transaxle OIL SEAL INSTALLATION Install the oil seal flange part so hole faces the bottom of the transaxle. Caution Apply transmission oil to the oil Oil seal INSTALLATION (1) Place two pieces of solder measuring about in.) in length and 3 mm in.) in at illustrated locations on the transaxle and install each outer...
Page 924 TRANSAXLE CASE INSTALLATION Apply the specified sealant (liquid gasket) to the transaxle case side of the transaxle case adapter, assembly. Specified sealant: Mitsubishi genuine sealant Part equivalent Caution S q u e e z e out sealant from the tube excess or discontinuity.
Page 925 MANUAL TRANSAXLE OVERHAUL Transaxle WAVE SPRING INSTALLATION Install the wave spring so that to the position in the TSB Revision...
Page 926 MANUAL TRANSAXLE OVERHAUL Synchronizer SYNCHRONIZER DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Reverse brake ring 4. Synchronizer key 2. Synchronizer spring 5. Synchronizer hub 3. Synchronizer sleeve REASSEMBLY SERVICE POINTS SLEEVE SYNCHRONIZER HUB SYNCHRONIZER INSTALLATION INSTALLATION SYNCHRONIZER SPRING When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.
Page 927 MANUAL TRANSAXLE OVERHAUL Synchronizer that they slide smoothly. (2) Check that the sleeve is free from damage at its inside front and rear ends. (3) Check for wear of the hub front end (surface in contact with the speed gear). Caution 201044 When replacing, replace the synchronizer hub and...
Page 928 MANUAL TRANSAXLE OVERHAUL Input Shaft INPUT SHAFT Lubricate all internal parts with engine oil during reassembly. Disassembly steps 1. Snap ring 2. Bearing sleeve 2. Ball bearing 3. Synchronizer ring 3. Bearing sleeve 4. Synchronizer spring speed synchronizer sleeve 4. Snap ring 5.
Page 929 MANUAL TRANSAXLE OVERHAUL Input Shaft Disassembly steps 1. Taper roller bearing 11. Synchronizer ring 2. Bearing sleeve 12. Synchronizer spring 3. Snap ring synchronizer 4. Taper roller bearing 14. Synchronizer key 5. Snap ring Cone spring 16. Synchronizer ring Sub gear gear speed gear 18.
Page 930 MANUAL TRANSAXLE OVERHAUL Input Shaft Disassembly 1. Taper roller bearing Synchronizer 2. Bearing sleeve speed synchronizer 3. Snap ring Synchronizer ring 4. Taper roller bearing speed speed gear S n a p r i n g 6. Needle bearing Cone spring 7.
Page 931 MANUAL TRANSAXLE OVERHAUL: Input D I S A S S E M B L Y BALL BEARING TAPER ROLLER BEARING, REMOVAL SLEEVE FOR SPEED GEAR BALL BEARING TAPER ROLLER BEARING SPEED speed gear TSB Revision...
Page 932 MANUAL TRANSAXLE OVERHAUL Input Shaft gear SPEED SYNCHRONIZER HUB spee SPEED gear side INSTALLATION Identification mark SYNCHRONIZER SPRING INSTALLATION When installing the be sure position each spring with respect to the keys illustrated. Spring stepped SLEEVE FOR INSTALLATION TSB Revision...
Page 933 MANUAL TRANSAXLE’ OVERHAUL Input GEAR CONE INSTALLATION Snap ring SPACER INSTALLATION speed gear side 210019 REAR BALL TSB Revision...
Page 934 MANUAL TRANSAXLE OVERHAUL Input Shaft Select the thickest snap ring that the snap ring groove. Standard value: Input shaft rear bearing in.) Caution Do not reuse the snap The snap ring by pliers, resulting in improper 22100024 SLEEVE FOR SPEED GEAR INSTALLATION Caution When press-fitting the sleeve to the input shaft, make...
Page 935 M A N U A L Input Shaft 65133, F R O N T B A L BEARING INSTALLATION SNAP RING INSTALLATION’ Snap rings are available in three, Select the thickest one that fits in the snap ring Standard value: input shaft front end play in.)
Page 936 MANUAL TRANSAXLE’OVERHAUL Shaft INSPECTION INPUT SHAFT (1) Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A]. (2) Check the for damage and wear. NEEDLE BEARING Combine the needle bearing with the shaft or sleeve and gear and check that it rotates smoothly without’...
Page 937 MANUAL TRANSAXLE OVERHAUL S Y N C H R O N I Z E R K E Y A N D for wear of the spring for deform&i& age. SPEED GEARS wear (1) Check the synchronizer cone for rough surface, damage and wear.
Page 938 MANUAL TRANSAXLE OVERHAUL Intermediate Gear INTERMEDIATE GEAR 2220018004~ DISASSEMBLY AND REASSEMBLY ‘I Lubricate all internal parts with engine oil during reassembly. Disassembly steps 1. Snap ring 9. Synchronizer key 2. Taper roller bearing speed synchronizer hub Bearing sleeve 11. Synchronizer ring speed gear Needle bearing 13.
Page 939 MANUAL TRANSAXLE.: OVERHAUL Gear DISASSEMBLY AND REASSEMBLY Disassembly steps speed 1. Snap ring 2. Taper roller bearing 12. Synchronizer cone Bearing sleeve 13. Synchronizer inner speed gear speed gear 5. Needle bearing 15. Needle 6. Synchronizer ring 16. Taper roller bearing 7.
Page 940 MANUAL TRANSAXLE OVERHAUL Intermediate Gear DISASSEMBLY SERVICE POINTS ROLLER BEARING SPEED GEAR REMOVAL Caution Do not reuse the bearing removed from the shaft. Replace the inner and outer races of the taper roller bearing as a set. SPEED SYNCHRONIZER HUB SPEED GEAR REMOVAL 2201053 TAPER ROLLER BEARING REMOVAL...
Page 941 MANUAL TRANSAXLE OVERHAUL bear RINGS Identification mark GEAR INSTALLATION . speed gear and rings have an identification mark. SPEED Clutch housing SYNCHRONIZER KEY SLEEVE speed Identification mark (2) The synchronizer sleeve has tooth missing at six portions. Assemble the hub to the sleeve in such a way that the Tooth missing here center tooth between two missing teeth will touch...
Page 942 MANUAL TRANSAXLE OVERHAUL Intermediate Gear TAPER ROLLER BEARING Caution When installing the bearing, push the. race only. RING INSTALLATION Select and install the snap that gives intermediate gear bearing end play. Standard, value: Intermediate gear bearing end in.) TSB Revision...
Page 943 MANUAL TRANSAXLE OVERHAUL Gear I N S P E C T I O N INTERMEDIATE GEAR (1) Check the outer surface of the the needle bearing is mounted’ abnormal wear and seizure (2) Check the splines for NEEDLE BEARING (1) Combine the bearing or bearing’...
Page 944 MANUAL TRANSAXLE OVERHAUL Intermediate Gear the outer ring, inner ring and cone, and press them onto the clutch gear. Check clearance and replace is below the limit value. Limit: 0.5 mm in.) Replace the outer ring, inner ring cone, as SYNCHRONIZER SLEEVE AND HUB (1) Combine the synchronizer and hub and check...
Page 945 MANUAL TRANSAXLE OVERHAUL Output Shaft OUTPUT SHAFT 22200220052 DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Taper roller bearing shaft DISASSEMBLY SERVICE POINT Press TAPER ROLLER BEARINGS REMOVAL Caution Do not reuse the bearings removed from the shaft. Replace the inner and outer races of the taper roller bearing as a set.
Page 946 . . . MANUAL TRANSAXLE OVERHAUL Front Output , __ DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Taper roller bearing 2. Taper roller bearing 3. Front output shaft DISASSEMBLY Press ROLLER BEARINGS REMOVAL Remove the taper roller bearings using the special tool. N O T E (1) Do not reuse the bearing removed’...
Page 947 MANUAL TRANSAXLE OVERHAUL Differential DIFFERENTIAL DISASSEMBLY REASSEMBLY 2160119 Disassembly steps 2. Differential drive gear 1. Bolt 6. Pinion shaft’ 3. Ball bearing 8. Washer 9. Side gear 10. Spacer, 5. Lock pin 11. Differential DISASSEMBLY SERVICE POINTS BALL BEARINGS REMOVAL Do not reuse the bearing ‘removed ‘from TSB Revision...
Page 948 MANUAL TRANSAXLE OVERHAUL Differential TAPER ROLLER BEARING Caution Bearing Do not reuse the bearing removed from the Replace the inner and outer races of the taper roller bearing as a set. Differential case LOCK PIN REMOVAL Lock pin Drive out the lock pin from the hole A using a punch. REASSEMBLY SERVICE POINTS Lock pin Differential case...
Page 949 MANUAL TRANSAXLE OVERHAUL Differential JNSTALLATION (1) Apply the specified sealant to the bolt threads. Specified sealant: Stud Locking or equivalent (2) Tighten to the specified torque while following the order given in the illustration. 160030 ADJUSTMENT OF PINION BACKLASH Measure the backlash between the side gears and pinions. Adjust for same backlash of both side gears.
Page 950 MANUAL TRANSAXLE OVERHAUL Center Differential CENTER DIFFERENTIAL DISASSEMBLY AND REASSEMBLY 22250015 Disassembly steps 1. Taper roller bearing 2. Bolt 3. Taper roller bearing 4. Output gear 5. Spacer 6. Side gear 7. Pinion shaft 8. Washer 9. Pinion Side gear 11.
Page 951 MANUAL TRANSAXLE OVERHAUL, Center DISASSEMBLY SERVICE ROLLER REMOVAL Remove-the taper roller bearings ‘using the special NOTE (1) Do not reuse the bearing removed from shaft. the taper roller (2) Replace the inner and races bearing as a set. REASSEMBLY SERVICE POINTS (1) Install the spacer, side gear, pinion gear, pinion shaft to the center differential (2) Holding down the pinion shaft, select the...
Page 952 MANUAL TRANSAXLE OVERHAUL Center Differential (1) Apply the specified sealant threads. Specified sealant: Stud Locking or equivalent Tighten to the specified torque following order given in the illustration. TAPER ROLLER BEARINGS NOTE Apply the special tool to the inner race the bearing.
Page 953 MANUAL TRANSAXLE OVERHAUL Shift Fork SHIFT FORK DISASSEMBLY AND REASSEMBLY Disassembly steps 5. Interlock plunger speed shift fork speed shift rail speed shift fork speed shift rail 7. Reverse shift lug speed shift rail REASSEMBLY SERVICE POINT Reverse shift lug INTERLOCK PLUNGER INSTALLATION speed shift rail 2201088...
Page 954 MANUAL TRANSAXLE OVERHAUL Speedometer Gear SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Lubricate all internal parts with engine oil during reassembly. Disassembly steps 1. e-clip driven gear Sleeve S E R V I C E SPEEDOMETER DRIVEN GEAR Apply gear oil sparingly to the speedometer gear shaft and insert the shaft.
Page 955 MANUAL TRANSAXLE OVERHAUL Housing CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY 19 Nm 24 Nm Lubricate all internal parts with engine oil during reassembly. 22100019 Disassembly steps 12. Neutral return spring assembly 1. Bolt 13. Control shaft 2. Select lever assembly 14. Control shaft boot 3.
Page 956 MANUAL TRANSAXLE OVERHAUL Clutch Housing DISASSEMBLY SERVICE Caution When removing the lock pin, turn the control lever to such position that the lock pin will not contact the clutch housing. 2200064 SPRING PIN REMOVAL Caution When spring pin, pull control shaft the direction illustrated so that the pin will not contact the clutch housing.
Page 957 MANUAL TRANSAXLE OVERHAUL Clutch Housina socket wrench Extension bar INSTALLATION SEAL socket wrench LOCK PIN Caution Do not reuse the spring pin and lock pin. Install the spring pin In such a way its will at right angle to the control shaft center. TSB Revision...
Page 958 MANUAL TRANSAXLE TRANSFER DISASSEMBLY AND REASSEMBLY Lubricate all internal with engine oil during reassembly. Disassembly steps 1. Cover 2. Cover gasket 3. Extension housing assembly 4. Transfer case sub assembly 5. Spacer 6. O-ring 7. Transfer case adapter sub-assembly T S B R e v i s i o n...
Page 959 MANUAL TRANSAXLE OVERHAUL R E A S S E M B L Y BACKLASH ADJUSTMENT, a light and uniform coat lead to the driven bevel gear teeth using. brush. (2) install the spacer that has (3) Align the transfer drive bevel gear mating (4) Align the transfer case adapter and drive bevel gear mating marks.
Page 960 Q-ring, Apply H O U S I N G Apply sealant to the adapter flange surface and extension housing. Specified sealant: Mitsubishi genuine Sealant equivalent NOTE Squeeze out sealant from the ‘tube uniformly and continuously in adequate amount. TSB Revision...
Page 961 MANUAL TRANSAXLE OVERHAUL SEALANT APPLICATION TO COVER Specified sealant: A T D P a r t (both sides) TOOTH CONTACT PROCEDURES 1. Standard tooth contact pattern A ..Small end side ..Drive side tooth face (Side on which force acts running forward) .
Page 962 MANUAL TRANSAXLE OVERHAUL Transfer R e m e d y Use thinner driven bevel gear mount adjusting spacer, to briiig the driven bevel gear closer to the drive bevel gear. NOTE (1) If’ correct tooth contact cannot Drive bevel gear change of the driven mount adjusting Drive bevel gear...
Page 963 DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Air bleeder 2. Dust seal guard 3. Oii seal 4. Extention housing REASSEMBLY SERVICE POINTS OIL SEAL INSTALLATION AIR BLEEDER Install the air bleeder Specified sealant: SUPER WEATHERSTRIP...
Page 964 MANUAL TRANSAXLE OVERHAUL TRANSFER CASE DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Transfer cover 2. O-ring 3. Spacer Outer race 5. Drive bevel gear assembly 6. Outer race 7. Spacer Oil seal 9. Transfer case TSB Revision...
Page 965 MANUAL TRANSAXLE OVERHAUL,. Case“ SPACER (1) Use the existing spacer assemble the transfer case. (2) Using the special that the rotating drive torque is within the standard value. Standard value: (3) If the rotating drive torque is outside of the standard value, adjust using adjusting spacers.
Page 966 MANUAL TRANSAXLE OVERHAUL Transfer Case Adapter TRANSFER CASE ADAPTER DISASSEMBLY AND REASSEMBLY 22210133 Disassembly steps 1. Lock nut 5. Collar 2. Driven bevel gear assembly 6. Outer race 3. Taper roller bearing 7. Outer race 4. Spacer 6. Transfer case assembly DISASSEMBLY SERVICE POINTS LOCK NUT REMOVAL (1) Unlock the lock nut.
Page 967 MANUAL TRANSAXLE OVERHAUL Transfer Case Adapter (2) Holding gear, in vise special tool, remove the lock nut. REASSEMBLY POINTS SPACER (1) Use the exisfing spacer to assemble the transfer case adapter. (2) Using the special tool, check that the bevel gear rotating drive torque is within standard value.
Page 968 MANUAL TRANSAXLE OVERHAUL Drive DRIVE BEVEL GEAR DISASSEMBLY AND REASSEMBLY 22210142 Disassembly steps 1. Taper roller bearing Taper roller bearing Drive bevel gear 4. Drive bevel gear shaft DISASSEMBLY SERVICE POINTS‘. ROLLER BEARING REMOVAL...
Page 969 MANUAL TRANSAXLE OVERHAUL Drive Bevel Gear DRIVE REASSEMBLY SERVICE TRANSFER DRIVE BEVEL GEAR INSTALLATION Install the drive bevel gear and drive bevel gear shaft with the mating marks aligned. TAPER ROLLER BEARING INSTALLATION...
Page 970 MANUAL TRANSAXLE OVERHAUL Driven Bevel DISASSEMBLY AND REASSEMBLY Lubricate all internal parts with engine oil during reassembly. Disassembly steps 1. Driven bevel gear 2. Taper roller bearing DISASSEMBLY ROLLER BEARING REASSEMBLY SERVICE POINT TAPER ROLLER BEARING INSTALLATION TSB Revision.
Page 971 CONTENTS OUTPUT GEAR DISASSEMBLY ..16 CASE DISASSEMBLY ....8 SEALANTS ......4 CASE REASSEMBLY .
Page 972 MANUAL TRANSAXLE General Information 22210010018 transaxle internal components can only as a unit, no, disassembly and reassembly be serviced by separating the gear case from the is possible. Damage to the transaxle may results. case. The transaxle output shaft is TSB Revision...
Page 973 MANUAL TRANSAXLE General Information SECTIONAL VIEW speed gear synchronizer speed gear Reverse idler gear synchronizer Differential TSB Revision...
Page 974 MANUAL TRANSAXLE Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Model Applicable engine floor shift floor shift Gear ratio 3.54 3.54 2.13 2.13 1.36 1.36 Reverse 3.94 Final gear ratio 3.55 Speedometer gear ratio (driven/drive) SERVICE SPECIFICATIONS Specifications Differential side gear end play mm (in.) Differential case preload mm (in.) .
Page 975 MANUAL TRANSAXLE SPECIAL TOOLS Tool number and name Tool Removal of input. and sleeve. Installer adapter Installer adapter with Installer bar Installation and input bear- Bearing remover ing. installer Bearing remover installer Bearing remover installer Removal of Puller press Puller blocks adapter side Dial indicator set TSB Revision...
Page 976 MANUAL TRANSAXLE Tool Tool number and name Removal of shifter rail bushing, Puller set shifter crossover bushing, selector shaft. Installation of input shaft bearing Seal installer and sleeve. Checking of different/al bearing Differential bearing end play, differential bearing torque tool ing torque.
Page 977 Installation and tool Installer 100 TSB Revision...
Page 978 MANUAL TRANSAXLE Case (1) Place transaxle on bench. (2) Remove shift levers. bolts.’ (3) Place two screwdrivers in the slots provided in the case halves near the dowels. the case halves.’ (4) Remove bell housing case half, from (5) Remove output shaft roller bearing from output shaft. (6) Remove differential assembly.
Page 979 MANUAL TRANSAXLE (7) Remove reverse idler shaft Remove reverse idler gear. (8) Remove two screws retaining fork bracket. Remove reverse fork bracket and reverse cam assembly. (9) Using snap ring pliers, remove shaft blocker assembly Selector shaft spacer (Plastic) TSB Revision...
Page 980 Case MANUAL TRANSAXLE the selector shaft shift blocker, assembly. Turn selector out of the (11) Remove transaxle end cover. Case two snap rings retaining the output shaft and’ the input shaft to the bearing. bench fixture and shims provided transaxle over., Install trans- axle onto bench fixture.
Page 981 MANUAL TRANSAXLE bearing fixture bearings. Verify tool is property shaft. dams in the input and can be damaged while pressing if the bearing fixture is not used. transaxle gear case and bench fixture press. Press output and assemblies out transaxle from press. remove transaxle case from the shaft assemblies and bench fixture.
Page 982 MANUAL TRANSAXLE Case Disassembly shift the output input and output shaft assemblies from f i x t u r e . Caution The output shaft assembly is Do not try to repair any component on ‘the shaft. If the synchronizer gear fails, it is to replace the complete output shaft assembly.
Page 983 MANUAL TRANSAXLE INPUT SHAFT speed Before disassembly of the input shaft, it the synchronizer stop ring gap. Use a to measure the gaps between the stop rings and the speed gears. The correct gaps are listed below:, , Sleeve i n . ) speed speed 1.37-1.93 mm...
Page 984 MANUAL TRANSAXLE Shaft Disassembly (4) Remove 4-5 gears split thrust washer Thrust washer (5) Remove split thrust washer. Input shaft (6) Remove split thrust washer separation pin. Input shaft Separation pin (7) Remove gear. Input shaft gear (8) Remove gear caged needle bearing. Check the Caged needle needle bearing for a broken retention spring.
Page 985 MANUAL TRANSAXLE (9) Remove blocking Snap ring . pliers input shaft in shop press. Using remove synchronizer and gear. (11) Remove gear caged needle bearing. Check the caged needle bearing for a broken retention spring. shaft the input shaft for worn or damaged bearing races or chipped gear teeth.
Page 986 Output Disassembly/ MANUAL TRANSAXLE speed Stop ring It is necessary to check the gap. Use gear a feeler gauge to measure the gaps the stop rings Reverse gear and the speed gears. The correct gaps are listed below: 1.37-1.93 mm If a stop ring gap does not fall specifications it must be inspected for wear and...
Page 987 (1) Remove differential bearing Differential assembly (2) Remove ring gear bolts and ring gear. (3) Pry the drive gear off using a flat blade NOTE drive gear differential case in order gear bolts (4) Remove pinion shaft solid pin. Soeedometer Remove pinion shaft.
Page 988 MANUAL TRANSAXLE Rotate side gears to opening in differential. Differential Side (7) Remove pinion gears, side gears’ thrust washers assembly rotating side gears to case. Pinion Pinion wash Ring gear REASSEMBLY (1) Assemble the differential side gears, gears and pinion gears with the pinion gears thrust washer (2) Install pinion shaft.
Page 989 MANUAL TRANSAXLE (6) Using the smallest end play record, shim that side gear to within 0.25 mm in.) to 0.33 mm in.). (9) The other side gear should be checked using the same Move side g e a r u p procedure.
Page 990 MANUAL TRANSAXLE Synchronizer DISASSEMBLY Place synchronizer in a clean shop,, towel Wrap. Press on inner hub. Carefully open up shop. towel and remove springs, balls, keys, hub, and sleeve. CLEAN Do not attempt to clean the blocking rings in solvent. The friction material will become contaminated.
Page 991 MANUAL TRANSAXLE ASSEMBLY Sleeve (1) Position synchronizer hub onto a suitable holding fixture (input shaft). The synchronizer hubs are directional. The hubs must be installed with the facing upward. (2) Install springs into hub slot (3) Insert key into hub and spring. (4) Apply petroleum jelly to the hole in the key.
Page 992 Shifter Rails Overhaul/ MANUAL SHIFTER Disassemble the transaxle case using the procedures’ provided in this group. (2) Remove shifter rails from the (3) To service the shift rail, remove the retaining the reverse shift lever arm. Remove the “shift fork roll pin and remove the shift fork.
Page 993 MANUAL TRANSAXLE Case Overhaul REMOVAL (1) Note the position of the output shaft The bearing is not identical to end. Remove caged roller bearing from output bearing “race. output bearing (2) Remove screws at output bearing strap. Bearing Input shaft b e a r i n g .
Page 994 MANUAL TRANSAXLE Case (1) Line up bearing race race bore. tool into output bearing race. Tap race into bore. Tighten bolts to’ 11 Nm INPUT BEARING AND SLEEVE Differential The input bearing is a one-piece bearing and sleeve The sleeve is the slide point for the clutch release bearing and lever.
Page 995 MANUAL TRANSAXLE Case Gear case REMOVAL (1) Install into the differential bearing cup. (2) Install the tool cup over the tool. (3) Tighten the tool until the race is removed from the case. INSTALLATION (1) Position the bearing cup into case.
Page 996 MANUAL TRANSAXLE Gear Case SHAFT SEALS It is not necessary to remove the shifter the trans- axle to service the shifter shaft seals. REMOVAL (1) Using a pick tool, pry up the shifter seal and remove seal from bore. INSTALLATION (1) Position new shifter shaft seal in bore.
Page 997 MANUAL TRANSAXLE Gear Case Overhaul SHIFTER SELECTOR SHAFT REMOVAL (1) Thread into bushing. (2) Install onto tool and remove bushing using slide hammer. INSTALLATION (1) Position replacement over selector shaft bore. (2) Using an appropriate size deep well socket, install bushing in selector shaft bore.
Page 998 MANUAL TRANSAXLE Shaft Reassembly INPUT SHAFT REASSEMBLY Input shaft The snap rings that are used the input available in select fit sizes. Use the thicknest that will fit in each ‘snap ring groove. (1) Place input shaft into shop press. gear caged needle bearing (2) Install...
Page 999 split thrust washer pin. Input shaft Separation pin (8) Install split thrust washer onto input shaft. Input shaft (9) Install split thrust washer retaining ring. gear caged needle bearing. Input Caged needle bearing (11) Using install speed gear and synchronizer. The gear synchronizer hub has the letter stamped on the top face of the hub.
Page 1000 MANUAL TRANSAXLE Shaft Reassembly gear synchronizer snap ririg. TSB Revision...
Page 1001 MANUAL TRANSAXLE Case CASE REASSEMBLY The sealant used to seal the transaxle case halves is Loctite 51617 or equivalent. The sealant used for the bearing end plate cover is Loctite 18718 or equivalent. (1) Verify bench fixture shims are removed from bench Install output and input gear pallet (2) Install shift rails and forks.
Page 1002 MANUAL TRANSAXLE Case (6) Position input and output bearings on the shafts. Using press input and bearings until’ they bottom into the case and shafts:’ (7) Install shaft snap rings at input and output bearings. (8) Apply 18718 or equivalent to end cover outer edge and around bolt holes.
Page 1003 MANUAL TRANSAXLE Case- Reverse idler reverse fork bracket and reverse cam lockout as- sembly. Tighten screws to 11 Nm (9.6 torque. Screws (2) differential into gear case. Revision...
Page 1004 TRANSAXLE G E N E R A L R U L E S O N Take extreme care when removing, and installing bearing cups and cones. Use only arbor for installation, as a hammer may not properly* align the or cone. Burrs or nicks on the bearing give a play reading while gauging.
Page 1005 Differential Bearing MANUAL TRANSAXLE Preload Adjustment DIFFERENTIAL BEARING ADJUSTMENT True bearing turning torque readings can only be obtained with the gear train removed from the case. (1) Remove bearing cup and existing shim from clutch housing case. (2) Press in new bearing cup into bell housing case (or use a cup that has been ground down on the outer edge for ease of measurement).
Page 1007 AUTOMATIC TRANSAXLE CONTENTS AUTOMATIC TRANSAXLE ........
Page 1008 23-2 NOTES...
Page 1009 SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service before beginning any service or maintenance of any com-...
Page 1010 TRANSAXLE OIL COOLER ....198 Selector Lever Operation Check ... . . 91 TROUBLESHOOTING ..... Lock Mechanism Check .

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Mitsubishi Eclipse 1990 Service Manual

Table of Contents

Inspection Service Points

Lubrication and Maintenance

Main Sealant and Adhesive Table

Maintenance Service

Engine

Special Handling Instructions for

Awd Models

Tightening Torque

Cylinder Head Gasket

Sealants

Service Specifications

Special Tools

. Notes

Table of Contents

Multiport Fuel Injection (Mfi) (Turbo) And' En-

General Information/On-Vehicle Service

On-Vehicle Service

Thermostat

Engine (Non-Turbo)

Intake Exhaust

Table of Contents

Clutch Master Cylinder

Clutch Pedal

Lubricants

On-Vehicle Service

Table of Contents

On-Vehicle Service

Troubleshooting

Service Specifications

Special Tools

Troubleshooting

Transfer Assembly

Special

Gear and Transfer Drive

Center Differential

Extension Housing

Transfer

Transaxle Overhaul

Brake Pedal/Lubricants

Basic Brake

Brake Lining and Brake Drum Contact

Bleeding

Table of Contents

Compressor and Tension Pulley

Condenser and Condenser Fan Motor

Cooling Unit

Compressor Drive Belt Adjustment

Performance Test

Receiver Drier Test

Refrigerant Leak Repair

Sight Glass Refrigerant Level Test

Quick Links

Chapters

Troubleshooting

Related Manuals for Mitsubishi Eclipse 1990

Summary of Contents for Mitsubishi Eclipse 1990

This manual is also suitable for:

Table of Contents