Mitsubishi Stealth 1994 Import Service Manual

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IMPORT SERVICE

MANUAL

ENGINE, CHASSIS & BODY

Volume - I

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Troubleshooting

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Page 1 IMPORT SERVICE MANUAL ENGINE, CHASSIS & BODY Volume - I...
Page 2: Safety Notice
SAFETY NOTICE CAUTION ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies in non-automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product.
Page 3 BackupServiceManual GROUP INDEX Introduction and Stealth Master Troubleshooting *****..***.**.***.*. Lubrication and Maintenance ..Front Suspension ....... . 1994 .
Page 4 INTRODUCTION AND MASTER TROUBLESHOOTING WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering the SRS inoperative).
Page 5: How To Use This Manual
(3) Special tightening methods are used. SPECIAL TOOLS Only Mitsubishi special tool numbers are called out in the repair section of this manual. Please refer to the special tool cross reference chart, located at the beginning of each group for a cross reference from Mitsubishi special tool numbers to Miller special tool numbers.
Page 6: Explanation Of Manual Contents
INTRODUCTION AND MASTER TROUBLESHOOTING - “0~ to “se this Manual EXPLANATION OF MANUAL CONTENTS Indicates procedures to be per- Maintenance and Servicing Procedures Removal steps: The part designation number corresponds to the number in the illustration to indicate removal near the front of each section in order to give the steps.
Page 7 INTRODUCTION AND MASTER TROUBLESHOOTING - “0~ to “se This Manua’ This number corresponds to the The title of the page (following the page on which the diagram of component parts is pre- sented) indicating the locations of lubrication and sealing proce- dures.
Page 8: Explanation Of The Troubleshooting Guide
INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual EXPLANATION OF THE TROUBLESHOOTING GUIDE Indicates the circuit diagram for checking (including the inter- face of the ato;Foi ditioning unit). Indicates connec- tor’s terminal num- ber. Indicates the con- nector number. Numbers are used in the operation de- scriptions only as...
Page 9: Explanation Of Circuit Diagrams
INTRODUCTION AND MASTER TROUBLESHOOTING EXPLANATION OF CIRCUIT DIAGRAMS The symbols used in circuit diagrams are used as NOTE described below. For detailed information concerning the reading of circuit diagrams, refer to GROUP 8 - Wiring Harness. The input/output (direction of cur- rent flow) relative to the electro- nic control unit is indicated by symbols (A, V).
Page 10: Vehicle Identification
INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number (V.I.N.) is located on a plate attached to the left top side of the instrument panel. VEHICLE IDENTIFICATION CODE CHART PLATE All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.
Page 11: Vehicle Identification Number List
INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle lden*ifica*ion VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR FEDERAL V.I.N. (except sequence number) Brand Engine displacement Models code Dodge Stealth 3.0 dm3 (181.4 cu.in.1 [SOHC-MFII Dodge Stealth 3.0 dm” (181.4 cu.in.) [DOHC-MFI-Turbo] VEHICLES FOR CALIFORNIA Brand Models code V.I.N.
Page 12 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle lden*ifica*ion VEHICLE INFORMATION CODE PLATE Vehicle information code plate is riveted onto the bulkhead in the engine compartment. The place shows model code, engine model, transaxle model, and body color code. Vehicle model 2. ENGINE 3.
Page 13 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle identification ENGINE MODEL STAMPING 1. The engine model number is stamped at the front side on the top edge of the cylinder block as shown in the following: Engine model Engine displacement 3.0 dm3 (181.4 cu.in.1 2.
Page 14 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification LOCATIONS DOHC Manual transaxle Automatic transaxle...
Page 15 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification The replacement part label is attached to the inner side of the part shown in the illustration. The illustration indicates left hand side, outer. Right hand side is symmetrically opposite.
Page 16 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle identification Rear of vehicle...
Page 17: Precautions Before Service
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to follow when servicing SRS System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Always use the designated special tools and test equipment.
Page 18 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service SERVICING ELECTRICAL SYSTEM 1. Note the following before proceeding with work on the electrical system. Note that the following must never be done: Unauthorized modifications of any electrical device or wiring, because such modifications might lead to a vehicle malfunction, over-capacity or short-circuit that could result in a fire in the vehicle.
Page 19 INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting TOWING AND HOISTING ing type WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP Caution This vehicle cannot be towed by a wrecker using sling-type heel lift type equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equip- ment.
Page 20 INTRODUCTION AND MASTER SAFETY PRECAUTIONS The following precautions should be taken when towing the vehicle. 1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER. 2. Any loose or protruding parts of damaged vehicle such as hoods, doors, fenders, trim, etc., should be secured or removed prior to moving the vehicle.
Page 21 INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting HOISTING Frame contact support location POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations.
Page 22 INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting LIFTING, JACKING SUPPORT LOCATION Approximate center of gravity Frame contact hoist, twin post hoist or scissors lack (emergency) locations EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack supplied with the vehicle for emergency road service.
Page 23: For Awd Models
Special Handling Instructions INTRODUCTION AND MASTER TROUBLESHOOTING Models SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS BRAKE TEST In order to stabilize the viscous coupling’s dragging force, the brake test should always be conducted after the speedometer test. FRONT WHEEL MEASUREMENTS 1. Place the front wheels on the brake tester. 2.
Page 24: General Data And Specifications
INTRODUCTION AND MASTER TROUBLESHOOTING - General Data and Specifications GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS STEALTH STEALTH R/T STEALTH R/T STEALTH ES <SOHC> <DOHC> <DOHC> <DOHC> (Turbo) (Non-Turbo) (Non-Turbo) Vehicle dimensions mm (in.) Overall length 4,560 (179.5) 4,565 (179.7) 4,565 (179.7) 4,565 (179.7) Overall width 1,840 (72.4)
Page 25: Engine Specifications
INTRODUCTION AND MASTER TROUBLESHOOTING - General Data and Specifications 23 Models STEALTH STEALTH ES STEALTH R/T STEALTH R/T <SOHC> <DOHC> <DOHC> <DOHC> (Non-Turbo) (Non-Turbo) (Turbo) Transaxle Model No. -Type Manual transaxle Automatic transaxle automatic automatic automatic Fuel system Fuel system Fuel supply system Fuel supply system Multiport...
Page 26: Tightening Torque
INTRODUCTION AND MASTER TROUBLESHOOTING - Tiahtenincl Toraue TIGHTENING TORQUE Each torque value in the table is a standard value for tightening under the following conditions. (1) Bolts, nuts and washers are all mode of steel and plated with zinc. (2) The threads and bearing surface of bolts and nuts are all in dry condition. The values in the table are not applicable: (1) If toothed washers are inserted.
Page 27: Master Troubleshooting
INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting MASTER TROUBLESHOOTING ENGINE OVERHEATS Symptom Probable cause Reference page Engine overheats Cooling system faulty Incorrect ignition timing 9-l 8 ENGINE WILL NOT CRANK OR CRANKS SLOWLY Symptom Probable cause Reference page Engine will not crank Starting system faulty 8-l 87 or cranks slowly...
Page 28 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troub’eshootiw ROUGH IDLE OR ENGINE STALLS Symptom Probable cause Reference page or remedy Rough idle or engine stalls Vacuum leaks 25-3 Purge control valve hose Vacuum hoses Intake manifold Intake manifold plenum Throttle body EGR valve Ignition system problems 8-199...
Page 29 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting ENGINE DIESELING Probable cause Reference page Engine dieseling (runs after Incorrect ignition timing 9-18 ignition switch is turned off) EXCESSIVE OIL CONSUMPTION Symptom Probable cause Reference page or remedy Oil leak Repair as necessary Excessive oil consumption Positive crankcase ventilation line clogged 25-9...
Page 30 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting HARD STEERING Reference page or remedy Symptom Probable cause Hard steering Loose power steering oil pump belt Low fluid level Replenish Air in power steering system Low tire pressure 22-3 Excessive turning resistance of lower arm ball joint Excessively tightened steering gear box rack support cover...
Page 31 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troub’eshooting POOR RIDING Reference page or remedy Probable cause Symptom 22-3 Poor riding Improper tire pressure Repair lmbalanced wheels Improper front or rear wheel alignment Malfunctioning shock absorber Broken or worn stabilizer Broken or worn coil spring Loose suspension securing bolt(s) Retighten Worn lower arm bushing...
Page 32: Vehicle Pulls To One Side
INTRODUCTION AND MASTER TROUBLESHOOTlNG VEHICLE PULLS TO ONE SIDE Probable cause Reference page or remedy Improper front or rear wheel alignment 17-5.22 lmbalanced or worn tires 22-3 Uneven tire pressure Excessive turning resistance of lower arm ball joint Wheel bearing seizure Replace Broken or worn coil spring , Bent front axle drive shaft...
Page 33 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting WHEEL BEARING TROUBLESHOOTING Trouble Symptom Probable cause Pitting Pitting occurs because of uneven rotation of race Excessive bearing preload and bearing surfaces Excessive load Flaking The surface peels because of uneven rotation of End of bearing life the race and bearing surfaces Improper bearing assembly...
Page 35: Table Of Contents
LUBRICATION i MAINTENANCE CONTENTS GENERAL INFORMATION ..t..... Evaporative Emission Control System . MAINTENANCE SERVICE ....... Exhaust System .
Page 36: General Information
LUBRICATION AND MAINTENANCE - General Information GENERAL INFORMATION Caution Test results submitted to EPA have shown that Maintenance and lubrication service recommenda- laboratory animals develop skin cancer after tions have been compiled to provide maximum prolonged contact with used engine oil. Accor- protection for the vehicle owner’s investment dingly, the potential exists for humans to de- against all reasonable types of driving conditions.
Page 37 LUBRICATION AND MAINTENANCE - General Information MATERIALS ADDED TO FUEL Cars equipped with DOHC engines Your car is designed to operate on premium Indiscriminate use of fuel system cleaning agents unleaded gasoline having a minimum octane rating should be avoided. Many of these materials in- of 91 or 95 RON (Research Octane Number).
Page 38: Scheduled Maintenance Table
LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE Inspection and services should be performed any time a malfunction is observed or suspected. Retain receipts for all vehicle emission services to protect your emission warranty. Kilometers in thousands 96 120 Emission control system...
Page 39: Ball Joint And Steering Linkage Seals
LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table Kilometers in thousands Service to be performed Mileage in thousands 16 Brake hoses Check deterioration leaks Every year Ball fount and steering linkage Inspect for grease leaks and damage seals Every 2 years Inspect for grease leaks and damage 18 Drive shaft boots Every year...
Page 40: Engine Coolant
Recommended Lubricants and LUBRICATION AND MAINTENANCE RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS Items Recommended lubricants Engine oil API classification SG ECII or SG/CD ECll (For further details, refer to SAE viscosity number) Manual transaxle MOPAR Hypoid Gear Oil/API classification GL-4, SAE 75W-90 or 75w - 85W Transfer Automatic transaxle...
Page 41 Recommended Lubricants and LUBRICATION AND MAINTENANCE LUBRICANT CAPACITIES TABLE Description Metric measure U.S. measure Engine oil 4.0 dm” 4.2 qts. Crankcase Oil filter 0.3 dm3 0.3 dm” 112 qt. Oil cooler (Turbo) Total 4.5 qts. <Non-Turbo> 4.3 dm3 <Turbo> 4.6 dm” 4.9 qts.
Page 42: Rear Axle
Recommended Lubricants and LUBRICATION AND MAINTENANCE Oil Identification Symbol A standard symbol appears on the top of oil containers and has three district areas for identifying various aspects of the oil. The top portion will indicate the quality of the oil. The center d portion will show the SAE viscosity grade, such as SAE indicates that the oil has fuel-saving capabilities.
Page 43: Maintenance Service
LUBRICATION AND MAlNTENANCE - Maintenance Service MAINTENANCE SERVICE 1. FUEL SYSTEM (TANK, PIPE LINE, CONNEC- TIONS AND FUEL TANK FILLER TUBE CAP) (Check for leak) / 2. FUEL HOSES (Check condition) 1. Check for damage or leakage in the fuel lines and connections and looseness of the fuel tank filler tube cap.
Page 44: Spark Plugs
LUBRICATION AND MAINTENANCE - Maintenance Service 4. EVAPORATIVE EMISSION CONTROL SYSTEM (Check for leaks and clogging) 1. If the fuel-vapor vent line is clogged or damaged, a fuel vapor mixture escapes into the atmosphere causing exces- sive emissions. Disconnect the line at both ends, and blow it clean with compressed air.
Page 45 LUBRICATION AND MAINTENANCE - Maintenance Service 8. TIMING BELT (Replace) Replace the belt with a new one periodically to assure proper engine performance. For removal and installation procedures, refer to GROUP 9 - Timing Belt. 9. DRIVE BELT (For Generator) (Check condition) Check the tension of the drive belt.
Page 46 256 psi (1,765 kPa) (manufacturer’s specifications) to avoid filter and engine damage. The following is a high-quality filter and is strongly recommended for use on this vehicle: Mitsubishi Engine Oil Filter P/N MD136790.
Page 47 o-13 LUBRICATION AND MAINTENANCE - Maintenance Service Any replacement oil filter should be installed in accordance with the oil filter manufacturer’s installation instructions. (2) Clean the oil filter mounting surface of the oil filter bracket. (3) Coat engine oil to the O-ring of new oil filter. (4) Screw in the oil filter by hand, and after the O-ring contacts the flange surface, tighten it another 3/4 turns with a filter wrench, etc.
Page 48 o-14 LUBRICATION AND MAINTENANCE 13. AUTOMATIC TRANSAXLE (Inspect fluid level) 1. Drive until the fluid temperature reaches the usual tempera- 1 ture [70 - 80°C (160 - 18O”F)]. 2. Place vehicle on level floor. 3. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid, then place lever in “N”...
Page 49 LUBRICATION AND MAINTENANCE (8) Pour 4.5 dm3 (4.8 qts.) of specified ATF into case through dipstick hole. [Total quantity of ATF required is approx. 7.5 of fluid can be replaced because rest of fluid remains in torque converter.] Specified fluid: MOPAR ATF PLUS (Automatic Trans- mission Fluid Type 7176) / Dia ATF SP or equivalent (9) Start engine and allow to idle for at least two minutes.
Page 50 O-16 LUBRICATION AND MAINTENANCE - Maintenance Service 9. Install the radiator cap securely. 11. Race the engine up to around 3,000 rpm several times, then stop the engine. 12. When the engine has cooled down, remove the radiator cap and add coolant up to the brim. Add coolant to the reserve tank up to the FULL line.
Page 51 o-17 LUBRICATION AND MAINTENANCE - Maintenance Service 18. DRIVE SHAFT BOOTS (Inspect for grease leaks and damage) 1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged boots should be replaced to prevent leakage or contamina- tion of the grease.
Page 52 O-18 LUBRICATION AND MAINTENANCE - Maintenance ‘Service Maintenance Items SRS warning light “SRS” WARNING LIGHT CHECK When the ignition key is turned to “ON” or engine started, the “SRS” warning light will illuminate for about 7 seconds and then turn off. This means that the system is functioning properly.
Page 53 LUBRICATION AND MAINTENANCE - Maintenance Service o-19 Check sensors to ensure the arrow marks face the front of the vehicle. (2) Check front upper frame lowers and sensor brackets for deformities or rust. Caution The SRS may not activate properly if a front impact sensor is not installed properly, which could result in serious injury or death to the vehicles driver and passenger.
Page 54 LUBRICATION AND MAINTENANCE 2-3 Air Bag Module, Clock Spring Rotor Ring gear Screw Air bag module <Driver’s side> Steering shaft <Passenger’s side>...
Page 55 o-21 LUBRICATION AND MAINTENANCE - Maintenance Service GROUP 23B - Air Bag Module and Clock Spring.) Caution When disconnecting the air bag module-clock spring connector, take care not to apply excessive force to it. (2) Check pad cover for dents, cracks or deformities. <Driver’s side>...
Page 56 o-22 LUBRICATION AND MAINTENANCE - Maintenance Service (6) Remove the steering wheel by using the special tool. Caution Do not hammer on the steering wheel. Doing so may a damage the collapsible column mechanism. (7) Remove the steering column covers. (Refer to GROUP 23A Instrument Panel.) (8) Remove the clock spring.
Page 57 O-23 LUBRICATION AND MAINTENANCE 2-4 Front Wiring Harness and Body Wiring Harness (2) Check harnesses for binds, connectors for damage, and terminals for deformities. REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION. (Refer to GROUP 23B - SRS Service Precautions.) Caution The SRS may not activate properly if SRS harnesses or connectors are damaged or improperly connected, which...
Page 59 FRONT SUSPENSION CONTENTS ....................2A FRONT SUSPENSION .
Page 61 FRONT SUSPENSION CONTENTS DRIVE SHAFT ............SPECIFICATIONS .
Page 62 FRONT SUSPENSION SPECIFICATIONS GENERAL SPECIFICATIONS Items DOHC SOHC Vehicles Vehicles without ECS with ECS Wheel bearing Double-row angular-contact ball bearing Unit ball bearing mm (in.) 84 x 45 (3.31 x 1.77) Drive shaft Joint type Outer B.J. Inner T.J. T.J. T.J.
Page 63 FRONT SUSPENSION SERVICE SPECIFICATIONS Specifications Standard value Setting of T.J. boot length mm (in.) L.H. 85 + 3 (3.35 k .12) 85 + 3(3.35 + .12) No. 1 crossmember Bushing (B) projection mm (in.) Crossmember Bushing (A) projection mm (in.) Bushing (B) projection mm (in.) Camber...
Page 64 FRONT SUSPENSION LUBRICANTS Quantity Items Specified lubricants T.J. boot grease Repair kit grease Dust seal inner MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent 8 - 12 g (.28 - .42 oz) Dust seal outer As required MOPAR Multi-mileage Lubricant Spider assembly Part No.
Page 65 FRONT SUSPENSION - SPECIAL TOOLS the knuckle and tie rod M B990767 remover and M B990326 General service tool Measurement of the wheel bearing starting Preload socket of the lower arm ball joint of the stabilizer link rotation- gauge attachment...
Page 66 FRONT SUSPENSION Press-fitting of the dust seal inner Press-fitting of the wheel bearing Press-fitting of the oil-seal (drive shaft side)
Page 67 FRONT SUSPENSION Oil seal installer remover...
Page 68 FRONT SUSPENSION TROUBLESHOOTING Symptom Probable cause Remedy Steering wheel is heavy, Suspension malfunction Adjust or replace vibrates or pulls to Ball joint one side Coil spring Wheel alignment Unbalanced or worn tires Adjust or replace Excessive vehicle Broken or deteriorated stabilizer Replace rolling Shock absorber malfunction...
Page 69 FRONT SUSPENSION SERVICE ADJUSTMENT PROCEDURES HUB END PLAY INSPECTION 1. Jack up the vehicle and remove the front wheels. 2. Remove the disc brake caliper and suspend it with a wire. (Refer to GROUP 5 - Service Adjustment Procedures.) 3. Attach a dial indicator as shown in the illustration, and then measure the axial play while moving the hub back and forth.
Page 70 FRONT SUSPENSION - Right Member, Left Member and Crossmember RIGHT MEMBER, LEFT MEMBER AND CROSSMEMBER REMOVAL AND INSTALLATION CAUTION: SRS Before removal of steering gear box, Pre-removal Operation refer to GROUP 23B - SRS, center front Removal of Under Cover wheels and remove ignition key.
Page 71 FRONT SUSPENSION - Right Member, Left Member and Crossmember Crossmember 45 Nm 33 ft.lbs. Removal steps of crossmember 13. Self-locking nut 14. Clamp installation bolt (short) 15. Clamp installation bolt (long) 16. Clamp 17. Lower arm mounting bolt 18. Stopper 19.
Page 72 FRONT SUSPENSION - Right Member, Left Member and Crossmember Press in bushings A and B so that the arrows on their bottom Front surfaces may be directed in the crosswise direction (except those on No. 1 crossmember of FWD vehicles). Caution Shifting of the arrow in the direction of rotation shall be within k5”...
Page 73: 11. Drive Shaft
FRONT SUSPENSION HUB AND KNUCKLE REMOVAL AND INSTALLATION 65 - 76 ftlbs. 43 - 52 ft.lbs. 166 ft.lbs. 5 - 76 ft.lbs. 11 NO029 Removal steps 9. Cotter pin <Vehicles with A.B.S.> 2. Cotter pin 3. Drive shaft nut 12. Front strut mounting bolt 13.
Page 74 FRONT SUSPENSION SERVICE POINTS OF REMOVAL 1. DISCONNECTION OF FRONT SPEED SENSOR Remove the mounting bolts which hold the speed sensor ‘{J bracket to the knuckle, and then remove the speed sensor. Caution Be careful when handling the pole piece at the tip of the speed sensor and the toothed edge of the rotor so as not to damage them by striking against other parts.
Page 75 FRONT SUSPENSION INSPECTION Check the hub for cracks and spline for wear. Check the oil seal for damage. Check the knuckle for cracks. Check for defective bearing. NOTE If the meshing of the wheel bearing outer race and the knuckle, or of the wheel bearing inner race and the hub, is loose, replace the bearing or damaged parts.
Page 76 FRONT SUSPENSION - Hub and Knuckle DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Hub and rotor Adjustment of wheel bearing starting torque 3. Hub 4. Rotor <Vehicles with A.B.S.> 5. Dust shield 6. Oil seal (hub side) 7 ftlbs. 7. Snap ring 8.
Page 77 FRONT SUSPENSION (3) Remove the snap ring from the knuckle. M B990938 (4) Remove the bearing by using the special tools. M B 9 9 0 9 3 2 / ‘NOTE Removal is easier if the outer side inner race removed from the hub is placed on the bearing and the wheel bearing is then removed.
Page 78 FRONT SUSPENSION (5) Measure to determine whether the end play of the hub is within the specified limit or not. MB990998 Limit: 0.05 mm (.002 in.) (6) If the starting torque and hub end play are not within the limit range while the nut is tightened to 200 - 260 Nm (145 - 188 ft.lbs.), the bearing, hub and/or knuckle have probably not been installed correctly.
Page 79 FRONT SUSPENSION SERVICE POINTS OF REMOVAL REMOVAL OF DRIVE SHAFT NUT Loosen the drive shaft nut while the vehicle is on the floor with the brakes applied. Caution Do not apply vehicle load to the wheel bearing loosing the drive shaft nut. If, however, vehicle load must be applied to the bearing in moving the vehicle, temporari- ly secure the wheel bearing by using the special tools, DISCONNECTION OF LOWER ARM BALL JOINT...
Page 80 FRONT SUSPENSION (3) To remove the drive shaft (R.H.) from the transaxle, pry off the shaft using a lever against the protrusion of the drive shaft. Caution Pulling the drive shaft can cause damage to the T.J. Be sure to use a lever. INSPECTION Check the drive shaft boot for damage or deterioration.
Page 81 FRONT SUSPENSION <Left side> T.J. Boot Repair Kit Bearing Dust Seal Repair Kit Bracket Assembly Repair Kit T.J. Repair Kit Disassembly steps 12. Center bearing bracket 2. T.J. boot band (small) 13. Circlip 3. T.J. case and inner shaft assembly 14.
Page 82 FRONT SUSPENSION Grease: Multipurpose greas- g (.49 - .71 oz.) Dust seal outer 160 g (5.64 oz.) The grease in the repair kit should be the joint and inside the boot. joint. Do not mix old and new grease o different types of grease.
Page 83 FRONT SUSPENSION SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF INNER SHAFT bly, together with the seal plate, from the T.J. case. NOTE Press the tool directly against the seal plate. The tool under pressure will puncture and deform the seal plate, and push out the inner shaft underneath.
Page 84 FRONT SUSPENSION INSPECTION Check the drive shaft for damage, bending or corrosion. Check the inner shaft for damage, bending or corrosion. Check the drive shaft splines for wear or damage. Check the inner shaft splines for wear or damage. Check for entry of water and/or foreign material into B.J. Check the spider assembly for roller rotation, wear or corrosion.
Page 85 FRONT SUSPENSION 11. INSTALLATION OF CENTER BEARING (1) Apply multipurpose grease to the center bearing and inside the center bearing bracket. Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent llLO064 (2) Use the special tools to press-fit the center bearing into the center bearing bracket.
Page 86 FRONT SUSPENSION 6. INSTALLATION OF INNER SHAFT Use the special tool to hold the inner race of the center bearing and force the inner shaft into place. 3. INSTALLATION OF T.J. CASE AND INNER SHAFT ASSEMBLY then press fit it into the T.J. case. Grease: MOPAR Multi-mileage Lubricant Part No.
Page 87 FRONT SUSPENSION STRUT ASSEMBLY REMOVAL AND INSTALLATION 33 ft.lbs. Removal steps clamp mounting bolt 2. Brake hose tube clamp 3. Front speed sen sor clamp mounting nut 5. Strut lower mounting bolt 6. Strut upper mounting bolt 7. ECS connector <ECS> 8.
Page 88 FRONT SUSPENSION DISASSEMBLY AND REASSEMBLY 78Nm 56 ftlbs. Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent Caution When applying the grease, take care that grease does not adhere to the insulator’s rubber part. Disassembly steps 1. Dust shield 2. Self-locking nut 3.
Page 89 FRONT SUSPENSION SERVICE POlNiS OF REASSEMBLY 4. INSTALLATION OF SPRING UPPER SEAT ASSEMBLY the notch in the rod to the shaped hole in spring seat. (2) Using a pipe, line up the holes in the strut assembly spring lower seat with the hole in the spring upper seat. NOTE’...
Page 90: Lower Arm
FRONT SUSPENSION LOWER ARM REMOVAL AND INSTALLATION - 7 2 100 Nm 40 Nm 40 Nm 29 ft.lbs. 72 - 87 ftlbs. Adjustment of Wheel Alignment shield Removal steps 1. Stabilizer link mounting nut (stabilizer bar side) 2. Stabilizer link mounting nut (lower arm side) 3.
Page 91 FRONT SUSPENSION SERVICE POINT OF REMOVAL 4. REMOVAL OF LOWER ARM BALL JOINT Using the special tool, disconnect the knuckle from the lower arm ball joint. NOTE loosen it. (2) Suspend the special tool with a rope to prevent it from dropping.
Page 92 FRONT SUSPENSION STABILIZER BAR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of the Front Exhaust Pipe (Refer to GROUP 11 - Exhaust Pipe and Main Muffler.) Removal and Installation of the Under Cover Removal and Installation of the Left Member and Right Member (Refer to P.2A-IO.) 40 Nm 29 ftlbs.
Page 93 FRONT SUSPENSION CHECKING STABILIZER LINK BALL JOINT BREAKAWAY TORQUE Install the nut to the stud, and use the special tool to measure the ball joint breakaway torque. Standard value: 1.7 - 3.2 Nm (15 - 28 in.lbs.) BALL JOINT DUST SHIELD REPLACEMENT Clip ring (2) Apply multipurpose grease to the lip and inside of shield.
Page 95: Service Adjustment Procedures
ELECTRONIC CONTROL SUSPENSION (ECS) CONTENTS CIRCUIT DIAGRAM ..............SPECIAL TOOLS ................ DAMPING FORCE CHANGEOVER SPECIFICATIONS ..............ACTUATOR ................General Specifications ........................ Service Specifications ECS CONTROL UNIT ..............ECS INDICATOR LIGHT ............STEERING ANGULAR VELOCITY ................................ECS SWITCH STOP LIGHT SWITCH ............
Page 96: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS FRONT SUSPENSION Items SOHC DOHC Suspension system McPherson strut type 15.2 x 170 x 301.6 Wire dia. x center dia. x 14.2 x 170 x 316 14.4 x 170 x 322.7 14.5 x 170 x 329.3 free length mm (in.) Brown x 1 Coil spring identification...
Page 97 REAR SUSPENSION Items SOHC DOHC Suspension system Multi-link type Double-wishbone type Coil spring Wire dia. x center dia. x 11.6 x 105 x 350.0 11.5 x 105 x 379.3 free length mm (in.) Coil spring identification Green x 1 Brown color Spring constant 34 (190)
Page 98: Troubleshooting
Tool number and tool name Replaced by Miller Application tool number MB991 529 MB991 529 Inspection of electronic control suspension system using a voltmeter Diagnostic trouble code check harness TROUBLESHOOTING QUICK REFERENCE CHART FOR TROUBLESHOOTING Associated components Pages to refer to Symptoms When diagnostic trouble code No.
Page 99 ECS - Troubleshootincl When diagnostic trouble code No. 11 is output Check by entering simulated vehicle speed from scan tool to simulate pitching and bouncing controls. (Refer to P.2B-16.) Good? Disconnect G sensor connector. No. 1 terminal voltage and continuity between No.
Page 100 When diagnostic trouble code No. 21 is output, or when anti-roll control only stops. Using scan tool, check service Check by entering simulated vehicle speed to simulate anti-roll controls. (Refer to P.2B-17.) Disconnect steering angular velocity Replace ECS control unit. sensor connector.
Page 101 ECS - Troubleshooting When diagnostic trouble code No. 24 is output Check by entering simulated vehicle speed from scan tool to data on vehicle ‘speed sensor. Good? simulate high speed-sensitive control. (Refer to P.2B-17.) Good? Disconnect vehicle speed sensor con- Replace ECS control unit.
Page 102 ECS - Troubleshootina Using scan tool, check actuator. (Refer to P.2B-15.) Good? Remove cap at top of shock absorber associated with diagnostic trouble connected to shock absorber, and No. 1 and 3 terminal voltages up Is continuity provided across the following areas of shock to specification? absorber associated with diagnostic trouble code No.? Standard: 5 V...
Page 103 ECS - Troubleshooting Does ECS indicator light flash? Read diagnostic trouble code and check area associated with diagnostic trouble code. Disconnect ECS switch connector and check harness connector with (ignition switch at 0,N. Is continuity provided betwen No. 10 terminal of ECS switch No.
Page 104 6 Anti-dive control only stops. Using scan tool, check service Check by entering simulated vehicle speed from scan tool data on stop light switch. Good? to simulate anti-dive control. (Refer to P.2B-16.) Good? Replace ECS control unit Is continuity provided between No. 3 terminal of stop light switch and No.
Page 105 Anti-squat control only stops. Using scan tool, check service data Check by entering simulated vehicle speed from scan tool on throttle position sensor. Good? to simulate anti-squat control. (Refer to P.2B-16.) Good? Replace ECS control unit. Does check engine/malfunction Is continuity provided between No. 2 terminal of throttle indicator lamp illuminate? position sensor and No.
Page 106 ON-VEHICLE INSPECTION WARNING INDICATION BY ECS INDICATOR LIGHT If a problem associated with the following items occurs, the ECS indicator light (Tour Sport) in the combination light flashes at intervals of 0.5 sec. At the same time, the diagnostic trouble code associated with the problem is output to the data link connector.
Page 107 Fail Safe and Diagnosis List Output Code Fail Safe Diagnostic Item Indication Pattern [Good] [Good] Ride controls (pinching and bouncing G sensor defective* control, bad road detection control) stop. Anti-roll control stops. Steering angular velocity sensor open- circuited* Vehicle speed sensor open-circuited* speed sensitive controls) and attitude controls (anti-dive, anti-squat) stop.
Page 108 On-board Diagnostic Determination Conditions Code No. What is defective On-board diagnostic determination conditions G sensor defective When sensor input of 0.5 or less or 4.5 V or more lasts for more than 10 seconds. Steering angular velocity Open circuit detected on the basis of difference in voltage level of sensor open-circuited sensor signal.
Page 109 ECS - Service Adiustment Procedures Item No. Check Check Condition Soundness Determination Value Point Vehicle Check by actually operating Speedometer indication and speed vehicle. scan tool indication coincide. sensor stop Depress brake pedal. light switch Do not depress brake pedal. F.R.
Page 110 ECS - Service Adjustment Procedures CONTROL FUNCTION SIMULATION CHECK Using the scan tool, check all control functions during operation with the vehicle in stationary condition. Anti-Roll Control Function Check (1) Raise the front wheels on a jack and have them supported by rigid racks.
Page 111 ECS - Service Adjustment Procedures (4) Check that when the accelerator pedal is operated, the indications of service data items No. 61 through 64 on the scan tool change as shown in the following table. (5) With the simulated vehicle speed at 60 km/h (37 mph) and 90 km/h (56 mph), similarly operate the accelerator pedal and check that the scan tool indications change over.
Page 112 Service Adjustment Procedures I ECS Switch I ECS - s ACTUATOR OPERA ON CHECK ACTUATOR OPERATING SOUND CHECK (1) Set the ignition switch (2) Bring your ear near the top of the shock absorber. NOTE In the case of the rear shock absorbers, remove the trim cover at the top of the shock absorber before bringing your ear near the shock absorber.
Page 113: Damping Force Changeover Actuator
G Sensor I Vehicle Speed Sensor I Throttle Position Sensor I Stop Light Switch I To mount or remove the G sensor, refer to the section on front seats in GROUP 23A - Body. Remove the front seat (L.H.) before removing or mounting the sensor. To mount or remove the vehicle speed sensor, refer to the section on meters and gauges in GROUP 8 -Chassis Electrical.
Page 114: Ecs Control Unit
To remove or mount the ECS indicator lights, refer to the \ section on meters and gauges in GROUP 8 - Chassis Electrical. vi REMOVAL AND INSTALLATION Removal steps 1. Cargo floor box (R.H.) 2. Lid 3. ECS control unit...
Page 115: Ecs Switch
FUSIBLE LINK@ TAILLIG 1 C-68 * c-70 ‘5 2 c-77 IOD OR C - 6 9 STORAGE CONNECTOR 1 2 9 4 ELECTRONIC CONTROL SUSPENSION F-13 62 ----------- CONTROL UNIT 1 F-12 SWITCH D-03 D-41 DATA LINK CONNECTOR c-79 NOTE...
Page 116: G Sensor
CIRCUIT DIAGRAM (CONTINUED) THROTTLE B-05 STOP LIGHT SWITCH ---------- ~ - - - - - - - - - - - - - - - - - - - - - 54 5 C-60 G SENSOR STEERING SPEED SENSOR...
Page 117 FRONT SHOCK ABSORBERtL FRONT Sl-iOCK ABSORBER(I; 1 ‘1 4 L-- 1 --- _ --- -- 4 --- SUSPENSION CONTROL UN11 14 F-20 F-07...
Page 119 CONTENTS AXLE SHAFT ............TROUBLESHOOTING .
Page 120 REAR AXLE - Specifications GENERAL SPECIFICATIONS Specifications Semi-floating type mm (in.) 35 (1.38) Outer bearing portion dia. Inner bearing portion dia. 34.5 (1.36) Center portion dia. 245.4 (9.7) Overall length Bearing mm (in.) O.D. x I.D. 72 x 35 (2.83 x 1.38) Outer Inner Drive shaft...
Page 121 REAR AXLE SERVICE SPECIFICATIONS Items Specifications Standard value Setting of T.J. boot length mm (in.) 85 + 3 (3.35 + .I 2) Final drive gear backlash mm (in.) 0.11 -0.16(.004-,006) Differential gear backlash (Limited slip differential) mm (in.) 0.03 - 0.09 LOO1 2 -.0035) Drive pinion rotation torque Nm (in.lbs.) With oil seal...
Page 122 REAR AXLE Rear axle shaft Removal of axle shaft inner bearing (Use universal driver Installation of axle shaft inner bearing Installation of drive pinion rear bearing Installation of drive pinion front bearing Installation of differential side oil seal MB990938 (Use in conjunction with Removal of drive pinion front bearing and drive pinion rear bearing outer race Adjustment of differential final gear tooth...
Page 123 REAR AXLE - Special Tools and remover A Removal of the side bearing inner race, drive pinion rear bearing inner race and companion flange M B990339 C-293PA Removal of drive pinion rear bearing inner race...
Page 124 REAR AXLE - Special Tools junction with MB991366) Preload socket Oil seal installer M B990728 Oil seal installer...
Page 125: Troubleshooting
REAR AXLE Symptom Probable cause Remedy AXLE SHAFT Brake drag Replace Noise while wheels are rotating Bent axle shaft Worn or scarred axle shaft bearing Grease leakage Worn or damaged oil seal Replace Malfunction of bearing seal DRIVE SHAFT Replace Noise Wear, play or seizure of ball joint Excessive drive shaft spline looseness...
Page 126 REAR AXLE - Troubleshootina Symptom Probable cause Remedy Gear oil leakage Worn or damaged front oil seal, or an improperly Replace installed oil seal Damaged gasket Loose companion flange self-locking nut Retighten or replace Loose filler or drain plug Retighten or apply adhesive Clogged or damaged vent plug Clean or replace Seizure...
Page 127 REAR AXLE REAR AXLE TOTAL BACKLASH CHECK If the vehicle vibrates and produces a booming sound due to an imbalance of the driving system, measure the rear axle total backlash by the following procedures to see if the differential carrier assembly required removal. parking brake and jack up the vehicle.
Page 128 REAR AXLE - Service Adjustment Procedures R E A R W H E E L B E A R I N G R O T A R Y - S L I D I N G RESISTANCE CHECK 1. Remove the drive shaft from the companion flange. 2.
Page 129: Axle Shaft
REAR AXLE - Axle Shaft REMOVAL AND INSTALLATION 12 Nm 40 - 47 ftlbs. 9 ftlbs. 36 - 43 I ft.lbs. 260 - 3’00 Nm Removal steps 1. Rear speed sensor <Vehicles with A.B.S.> 2. Brake caliper assembly 3. Brake disc 4.
Page 130 REAR AXLE 5. REMOVAL OF SELF-LOCKING NUT With the special tool, secure the axle shaft and remove the companion flange self-locking nut. 8. REMOVAL OF AXLE SHAFT ASSEM.pLY With the special tool, remove the axle shaft from the axle housing. MB990242 (use three puller) l l N 0 0 4 0...
Page 131 REAR AXLE SERVICE POINTS OF INSTALLATION Axle housing 15. INSTALLATION OF INNER BEARING MB990938 With the tool, press fit the inner bearing onto the axle housing. MB990931 14. INSTALLATION OF OIL SEAL housing with the depression in the oil seal facing upward, and until it contacts the shoulder on the inside of the axle housing.
Page 132: Differential Carrier
REAR AXLE 9. INSTALLATION OF REAR ROTOR <VEHICLES WITH With the special tool, press fit the rear rotor to the axle shaft \ with the rear rotor groove surface toward the axle shaft flange. 5. INSTALLATION OF SELF-LOCKING NUT With the special tool, secure the axle shaft and tighten the companion flange self-locking nut.
Page 133 REAR AXLE - Drive Shaft INSPECTION Check the drive shaft boots for damage or deterioration. Check the ball joints for excessive play or check operation. Check the drive shaft spline for wear or damage. SERVICE POINTS OF INSTALLATION 4. INSTALLATION OF OIL SEAL it in by using the special tool.
Page 134 REAR AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY T.J. boot repair kit B.J. boot repair kit T.J. repair kit B.J. repair kit Disassembly steps 7. B.J. boot band (large) 8. B.J. boot band (small) 2. T.J. boot band (small) l * l 9.
Page 135 REAR ,AXLE - Drive Shaft Lubrication Points Grease: Repair kit grease Quantity to use: 135 g (4.76 oz.) Caution Apply all of the grease from the repair kit to the joint and boot, a half to each as a rule. Special grease is used for the joint.
Page 136 REAR AXLE SERVICE POINTS OF DISASSEMBLY 4. REMOVAL OF SNAP RING / 5. SPIDER ASSEMBLY (1) Remove the snap ring from the drive shaft with the d snap ring pliers. (2) Take out the spider assembly from the drive shaft. (3) Clean the spider assembly.
Page 137 REAR AXLE - Drive Shaft grease. 125 g (4.4102.) Specified grease: Repair kit grease Caution The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. A special type of grease is used on the joint. Be cautious to ensure that not other grease is allowed to come in contact with the joint.
Page 138 REAR AXLE - Differential Carrier REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Filling of Differential Gear Oil (Refer to Group O- Maintenance Service.) Removal and Installation of Main Muffler (Refer to Group 11 - Exhaust Pipe and Muffler.) 24 Nm 17 ftlbs.
Page 139 REAR AXLE - Differential Carrier SERVICE POINTS OF REMOVAL 1. REMOVAL OF DRIVE SHAFT With a tire lever, etc., remove the drive shaft from the differential carrier. NOTE Be cautious to ensure that the differential carrier oil seal is not damaged by the drive shaft spline. 3.
Page 140 REAR AXLE FINAL DRIVE GEAR BACKLASH With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear. NOTE Measure at four points or more on the circumference of the drive gear. Standard value: 0.11 - 0.16 mm (.004 - .006 in.) DRIVE GEAR RUNOUT t at the shoulder on the reverse...
Page 141 REAR AXLE Standard tooth contact pattern 1 Narrow tooth side 2 Drive-side tooth surface (the side applying power during forward movement) 3 Wide tooth side 4 Coast-side tooth surface (the side applying power during reverse movement) Solution Problem Tooth contact pattern resulting from exces- sive pinion height The drive pinion is positioned too far from the center of Increase the thickness of the pinion height adjusting...
Page 142 REAR AXLE DISASSEMBLY Inspection Before Disassembly Final Drive Gear Backlash (Refer to P.3-2’2.) Drive Gear Runout (Refer to P.3-22.) Final Drive Gear Tooth Contact (Refer to P.3-22.) Disassembly steps 15. Drive pinion assembly 16. Companion flange 2. Vent plug 17. Drive pinion front shim 3.
Page 143 REAR AXLE 6. REMOVAL OF SIDE BEARING OUTER RACE pressed against the carrier. (2) Remove the differential case from the press. Insert two spacers in diagonally opposed positions between the side bearing outer race to be removed and the inner race.
Page 144 REAR AXLE 15. REMOVAL OF DRIVE PINION ASSEMBLY Mating marks companion flange. NOTE Mating marks should not be made to the contact surfaces of companion flange and propeller shaft. (2) Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims.
Page 145 REAR AXLE REASSEMBLY 36 Nm 26 ft.lbs. 137 ft.lbs. 58 - 65 ft.lbs.* 22 23 Reassembly steps 1. Spring pin 15. Washer + 2. Drivegear 16. Self-locking nut 3. Differential carrier LSD case (Refer to P.3-34.) 4. Drive pinion rear bearing outer race 18.
Page 146 REAR AXLE Lubrication, Sealing and Adhesion Points Sealant: Semi-drying sealant Part No. 2525035 or equivalent l l F O 0 3 2 Grease: MOPAR Multi-Mileage Lubricant Adhesive: MOPAR Part No. 4318031 or Part No. 2525035 or equivalent 4318032, or equivalent SERVICE POINTS OF REASSEMBLY 1.
Page 147 REAR AXLE 2. PRESS-IN OF THE DRIVE GEAR drive gear at the inner side, press in the drive gear (by using the special tool) until the drive gear contacts the M B990890 end surface of the differential case. (2) Check to ensure that the drive gear and the spring pin are flush.
Page 148 REAR AXLE (4) Position the special tool in the side bearing seat of the gear carrier, and then select a drive pinion rear shim of a thickness which corresponds to the gap between the special tools. NOTE Clean the side bearing seat thoroughly. When selecting the drive pinion rear shims, keep the number of shims to a minimum.
Page 149 REAR AXLE (5) Remove the companion flange and drive pinion once again. Drive the oil seal into the gear carrier front lip by using the special tool. Apply multipurpose grease to the oil seal lip. Specified grease: MOPAR Multi-Mileage Lubricant Part No.
Page 150 REAR AXLE (3) Apply multipurpose adhesive to the threaded holes of the drive gear. Specified adhesive: MOPAR Part No. 4318031 or ‘d ~ 4318032, or equivalent (4) Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence.
Page 151 REAR AXLE (4) Using the special tool, to apply the preload, turn down both right and left side bearing nuts on half the distance between centers of two neighboring holes. (5) Fit the snap ring at either position shown to lock the side bearing nut.
Page 152: Lsd Case Assembly
REAR AXLE DISASSEMBLY AND REASSEMBLY Disassembly steps l l F O 0 3 3 * I)+ 3. Thrustwasher(L.H.) 4. Viscous unit 7. Differential pinion shaft 8. Differential side gear (R.H.) 9. Thrust washer (R.H.) INSPECTION BEFORE DISASSEMBLY Feeler gauge 1. CHECKING THE DIFFERENTIAL GEAR BACKLASH the differential side gear (right) is facing upward.
Page 153 REAR AXLE (3) Insert the special tool at the spline part of differential case B (right) and check to be sure the side gear (right) rotates. Feeler gauge (4) Then insert a 0.09 mm (.0035 in.) feeler gauge to replace a 0.03 mm (.0012 in.) gauge. (5) Insert the special tool at the spline part of the differential side gear (right) and check to be sure the side gear (right) does not rotate.
Page 154 REAR AXLE - LSD Case Assembly (5) Check the spline part of the viscous unit for stepped wear Contact surface or damage, and check the contact surface with differential case B. (6) Check the side gear (left) of the viscous unit for unusual Id wear or damage.
Page 155 REAR AXLE (5) Insert the special tool at the spline part of differential side gear (right) and check to be sure the side gear (right) rotates. Feeler gauge (6) Then insert a 0.09 mm (.0035 in.) feeler gauge to replace a 0.03 mm (.0012 in.) gauge.
Page 157: Service Adjustment Procedures
CONTENTS ANTI-LOCK BRAKING SYSTEM TROUBLESHOOTING ..7 Brake Fluid Level Sensor Check ........46 Brake Lining and Brake Drum Connection Check .... Actuator Test Function ............ 12, 30 Brake Lining Thickness Check ..........Check Using On-board Diagnostic ........ 1 1, 29 Brake Pedal Inspection and Adjustment ......
Page 158: Specifications
BRAKES GENERAL SPECIFICATIONS Items Master cylinder Tandem type Tandem type (with level sensor) (with level sensor) I.D. mm (in.) 25.4 (I) or 26.9 26.9 (1 l/16) Brake booster Vacuum type, tandem Vacuum type, tandem Effective dia. of power cylinder mm (in.) 203 (8.0) + 230 (9.0) 203 (8.0) + 230 (9.0)* Boosting ratio...
Page 159 BRAKES - Specifications SPECIFICATIONS lter ndard value 3rake pedal height mm (in.) 177 - 182 (7.0 - 7.2) 3rake pedal free play mm (in.) 3 - 8 (.I - .3) 3rake pedal to floorboard clearance mm (in.) 80 (3.1) or more 80 (3.1) or more mm (in.) mm (in.)
Page 160: Lubricants
BRAKES LUBRICANTS Items Specified lubricant Brake fluid MOPAR Brake Fluid/Conforming to DOT3 or DOT4 Brake pedal bushing inner surface MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent Clevis pin and washer Inside of shim A and shim B, or inside of inner shim A, MOPAR Multi-Purpose Grease inner shim B, and outer shim Part No.
Page 161: Troubleshooting
BRAKES - Special Tools / Troubleshootinn power Bleed air from system Increased pedal stroke Air in brake system (Reduced pedal to floorboard clearance) Worn pad Replace Replace Broken vacuum hose Brake fluid leaks Correct Excessive push rod to master cylinder clearance Adjust Faulty master cylinder Replace...
Page 162 BRAKES - Troubleshootina Probable cause Remedy Symptom Brake drag Incomplete release of parking brake Correct Incorrect parking brake adjustment Adjust Worn brake pedal return spring Replace Adjust Incorrect push rod to master cylinder clearance Replace Defective master cylinder piston return spring Correct Clogged master cylinder return port Worn brake pad...
Page 163 BRAKES - Anti-lock Brakina Svstem Troubleshootina ‘PARTICULAR P H E N O M E N A O F T H E For problems in the electrical system, the on-board diagnostic is built into the electronic control unit ANTI-LOCK BRAKING SYSTEM (E.C.U.) causing the ABS warning light to illuminate Models equipped with the anti-lock braking system as a warning to the driver.
Page 164 BRAKES TROUBLESHOOTING (ABS - FWD) Confirm condition in the following way and diagnosis accordingly, Does the ABS warning light illuminate as described (2) With the ignition key in the “START” position, below up to the time the engine starts? power to the ABS ECU is interrupted and the (1) When the ignition key is turned to the “ON”...
Page 165 BRAKES Trouble condition Major causes Remedy After the ignition key is turned to the Break in harness for ECU warning Check, using flow “ON” position, it blinks once and then light drive circuit chart D (Refer to illuminates when it is turned to the Malfunction of ECU “START”...
Page 166 BRAKES NOTE more than 30 seconds. diagnostic to check (Refer to P.5-13.). No on-board diagnostic output Check and repair the har- No diagnostic trouble codes output Diagnostic trouble codes are output ness between the ABS and normal codes are displayed? ECU serial/on-board diag- nostic output terminals and the diagnosis check...
Page 167 BRAKES - Anti-lock Braking System Troubleshooting CHECK USING ON-BOARD DIAGNOSTIC Caution Turn off the ignition switch beforehand whenever the scan tool is connected or disconnected. Turn the ignition ON and select the ABS system. (The ABS warning light lights up, it goes into the scan tool mode. the scan tool mode, ABS does not function.) If it does not go into the scan tool mode, check the ECU power circuit and the harness between the ECU and...
Page 168 BRAKES METHOD OF CLEARING DIAGNOSTIC ACTUATOR TEST FUNCTION TROUBLE CODE MEMORY The actuator can be forcibly driven in the following Caution way by using the scan tool. When servicing is finished, clear the diagnos- NOTE tic trouble code memory. The actuator test cannot be carried out when the ABS ECU system is in fail safe.
Page 169 BRAKES A ABS warning light does not light at all. [Explanation] [Hint] When it does not light up at all, there is a strong if other warning lights do not light up either, fuse is possibility that there is trouble with ABS warning IGNITION i&R RELAY COMBINATION...
Page 170 BRAKES Does voltage between harness connector terminal combination meter from No. 14 and ground indicate fuse No. 11 is broken. battery positive voltage? Repair harness. Circuit in combination meter is broken. combination meter. Turn the ignition switch OFF and meter No. 58 and No. 59 terminals? Broken wire in ECU, valve relay or both drive circuits.
Page 171 BRAKES Remove the ECU connector and check. Does the voltage between ECU harness connector terminal No. 25 and ground warning light and ECU indicate battery positive voltage while the ignition key is in the “ON” position? Check valve relay. Remove valve relay and check. Is valve relay normal? (Refer to P.5-58.) Valve relay malfunction Replace valve relay.
Page 172 BRAKES warning light stays on when the ignition key is in the “ON” position. [ H i n t ] [Explanation] Check the on-board diagnostic output and if there is This is the symptom when the ABS ECU does not no output voltage or if the scan tool and ABS ECU power up due to broken ECU power circuit, etc., cannot communicate, there is a good possibility that...
Page 173 CONTINUED FROM PREVIOUS PAGE Is power relay normal? (Refer to P.5-69.) Replace power relay. With the ignition key in the power relay and ECU “ON” position, does voltage between ECU connector terminal No. 18 and ground indicate the battery positive voltage? Is there continuity between body harness terminals No.
Page 174 BRAKES ABS warning light does not illuminate when ignition key is in “START” position. [Explanation] The ABS ECU uses the IG2 power source which is and the ECU turns the valve relay OFF. If the turned off in the “START” position. The ABS warning light does not illuminate at this time, there warning light uses the IG1 power source which is is trouble in the warning light circuit on the valve...
Page 175 BRAKES ABS warning light blinks once after the ignition key is turned to the “ON” position. It illuminates in the “START” position and blinks once again when turned to the “ON” position. [Explanation] When power flows, the ABS ECU turns on the harness between the ECU and the warning light, the warning light for approximately 1 sec.
Page 176 BRAKES When the following diagnostic trouble codes are displayed “11 FL SNSR. OPEN” “12 FR SNSR. OPEN” “13 RL SNSR. OPEN” “14 RR SNSR. OPEN” [Hint] [Explanation] The ABS ECU detects breaks in the wheel speed In addition to a broken wire/short circuit in the wheel speed sensor, also check whether the sensor gap is sensor wire.
Page 177 BRAKES Check flow connected with wheel NOTE speedsensor When checking with an oscilloscope, first measure voltage variations in the wheel speed sensor output. (Refer to P.5-58.) o ~- Is the resistance value of the wheel speed sensor part normal? sensor Standard value: Front 0.8 - 1.2 k0 Rear 0.6 - 0.8 kR...
Page 178 BRAKES When diagnostic trouble code “22 STOP LAMP SW” is displayed [Explanation] [Hint] The ABS ECU outputs this diagnostic trouble code If the stop light operates normal, the harness for the in the following cases. stop light switch input circuit is broken or there is a Stop light switch may remain on for more than malfunction in the ABS ECU.
Page 179 BRAKES When diagnostic trouble codes “41 FL SOL. VALVE”, “42 FR SOL. VALVE” or “43 REAR SOL. V.” are displayed. [Explanation] The ABS ECU normally monitors the solenoid valve when turned OFF, the ECU determines the solenoid drive circuit. coil wire is broken/short-circuited or the harness is If no current flows in the solenoid even if the ECU broken/short-circuited, and then these diagnostic turns the solenoid ON or if it continues to flow even...
Page 180 BRAKES When diagnostic trouble code “51 VALVE RELAY” is displayed [Explanation] When the ignition switch is turned ON, the ABS not there is power in the valve power monitor line ECU switches the valve relay OFF and ON for an since the valve relay is normally ON.
Page 181 BRAKES When diagnostic trouble code “52 MOTOR RELAY” is displayed [Explanation] The ABS ECU outputs this diagnostic trouble code When the motor continues to revolve for the motor relay and motor in the following cases. [Hint] When the motor relay does not function If there is motor operation noise during scan tool When there is trouble with the motor itself and it forced drive mode, there is a broken or short...
Page 182 BRAKES TROUBLESHOOTING (ABS - AWD) Confirm condition in the following way and diagnosis accordingly. Does the ABS warning light illuminate as described (2) With the ignition key in the “START” position, below up to the time the engine starts? power to the ABS ECU is interrupted and the ABS warning light remains lit because the valve position, the ABS ECU causes the ABS warning relay is OFF.
Page 183 BRAKES Trouble condition Major causes Remedy After the ignition key is turned to the Break in harness for ECU warning Check, using flow “ON” position, it blinks once and then light drive circuit chart D (Refer to illuminates when it is turned to the Malfunction of ECU “START”...
Page 184 BRAKES CONTINUED FROM PREVIOUS PAGE After a test drive, use on-board diagnostic to check (Refer to P.5-33.). No on-board diagnostic output No diagnostic trouble codes output Check and repair the har- Diagnostic trouble codes are output and normal codes are displayed? ness between the ABS There was trouble in Referring to the diagnostic...
Page 185 BRAKES CHECK USING ON-BOARD DIAGNOSTIC Caution Turn off the ignition switch beforehand whenever the scan tool is connected or disconnected. Turn the ignition ON and select the ABS system. (The ABS warning light lights up, it goes into the scan tool mode. the scan tool mode, ABS does not function.) If it does not go into the scan tool mode, check the ECU tool...
Page 186 BRAKES METHOD OF CLEARING DIAGNOSTIC ACTUATOR TEST FUNCTION TROUBLE CODE MEMORY The actuator can be forcibly driven in the following way by using the scan tool. Caution When servicing is finished, clear the diagnos- NOTE tic trouble code memory The actuator test cannot be carried out when the ABS ECU system is in fail safe mode.
Page 187 BRAKES warning A ABS light does not light at all. [Explanation] [Hint] When it does not light up at all, there is a strong If other warning lights do not light up either, fuse is possibility that there is trouble with ABS warning probably blown.
Page 188 BRAKES With the ignition key in the “ON” posi- Check fuse No. 1 I. If it is tion, do other warning lights (except blown, correct the cause of door-ajar warning light, seat belt warning the blown fuse and then light) illuminate? replace the fuse.
Page 189 BRAKES Check ABS ECU. Remove the ECU connector and check. Does the voltage between ECU harness connector terminal No. 25 and ground warning light and ECU indicate battery positive voltage while the ignition key is in the “ON” position? Check valve relay. Remove valve relay and check.
Page 190 BRAKES ABS warning light stays on when the ignition key in the “ON” position. [Explanation] [Hint] This is the symptom when the ABS ECU does not Check the on-board diagnostic output and if there is power up due to broken ECU power circuit, etc., no output voltage or if the scan tool and ABS ECU when the fail safe function operates and isolates the cannot communicate, there is a good possibility that...
Page 191 BRAKES CONTINUED FROM PREVIOUS PAGE IGNITION POWER RELAY Is power relay normal? "3 (Refer to P.35-63.) Replace power relay. DIODE ABS-ECU With the ignition key in the “ON” position, does voltage power relay and ECU between ECU connector G N D GND terminal No.
Page 192 BRAKES ABS warning light does not illuminate when ignition key is in “START” position. [Explanation] The ABS ECU uses the IG2 power source which is and the ECU turns the valve relay OFF. If the turned off in the “START” position. The ABS warning light does not illuminate at this time, there warning light uses the IG1 power source which is is trouble in the warning light circuit on the valve...
Page 193 BRAKES - Anti-lock Braking System Troubleshooting ABS warning light blinks once after the ignition key is turned to the “ON” position. It illuminates in the “START” position and blinks once again when turned to the “ON” position. [Explanation] When power flows, the ABS ECU turns on the harness between the ECU and the warning light, the warning light for approximately 1 sec.
Page 194 BRAKES When the following diagnostic trouble codes are displayed “11 FL SNSR. OPEN” “12 FR SNSR. OPEN” “13 RL SNSR. OPEN” “14 RR SNSR. OPEN” [Explanation] [Hint] The ABS ECU detects breaks in the wheel speed In addition to a broken wire/short circuit in the wheel sensor wire.
Page 195 BRAKES When checking with an oscilloscope, first check the connections of the speed sensor harnesses and connectors. speed sensor part normal? sensor Standard value: 0.8 - 1.2 kfl connector normal? Standard value: 0.8 - 1.2 kfl I Yes Is the front wheel speed sensor-to-rotor clearance normal? Standard value:...
Page 196 BRAKES When diagnostic trouble code “21 G SNSR.” is displayed [Explanation] The ABS ECU outputs this diagnostic trouble code vehicle is stopped or when there is stop light in the following cases. switch input. G sensor OFF trouble (It is judged that the G When there is a broken wire or short circuit in sensor continues to be OFF for more than the harness for the G sensor system.
Page 197 BRAKES When diagnostic trouble code “22 STOP LAMP SW” is displayed [Explanation] [Hint] The ABS ECU outputs this diagnostic trouble code If the stop light operates normal, the harness for the in the following cases. stop light switch input circuit is broken or there is a Stop light switch may remain on for more than 15 minutes without ABS operation.
Page 198 BRAKES When diagnostic trouble codes “41 FL SOL. VALVE”, “42 FR SOL. VALVE” “43 VALVE DRIFT” are displayed. [Explanation] The ABS ECU normally monitors the solenoid valve coil wire is broken/short-circuited or the harness is drive circuit. broken/short-circuited, and then these diagnostic If no current flows in the solenoid even if the ECU trouble codes are output.
Page 199 BRAKES When diagnostic trouble code “51 VALVE RELAY” is displayed [Explanation] When the ignition switch is turned ON, the ABS not there is power in the valve power monitor line ECU switches the valve relay OFF and ON for an since the valve relay is normally ON.
Page 200 BRAKES When diagnostic trouble code “52 MOTOR RELAY” is displayed [Explanation] The ABS ECU outputs this diagnostic trouble code When the motor ground line is disconnected and for the motor relay and motor in the following cases. the motor does not revolve When the motor relay does not function When the motor continues to revolve When there is trouble with the motor itself and it...
Page 201 5-45 BRAKES - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES BRAKE PEDAL INSPECTION AND ADJUSTMENT 1. Measure the brake pedal height as illustrated. If the brake pedal height is not within the standard value, adjust as follows. Standard value (A): 177 - 182 mm (7.0 - 7.2 in.) lock nut, and move the stop light switch to a position Pedal where it does not contact the brake pedal arm.
Page 202 5-46 BRAKES - Service Adjustment Procedures BRAKE FLUID LEVEL SENSOR CHECK 1. Connect a circuit tester to the brake fluid level sensor. 2. Move the float from top to bottom and check for continuity. ‘d 3. The brake fluid level sensor is in good condition if there is no continuity when the float surface is above “A”, and if there is continuity when the float surface is below “A“.
Page 203 5-47 BRAKES PARKING BRAKE SWITCH CHECK 1. Disconnect the connector of the parking brake switch, and connect an ohmmeter to the parking brake switch and the switch installation bolt. 2. The parking brake switch is good if there is continuity when the parking brake lever is pulled and there is no continuity when it is returned.
Page 204 5-48 BRAKES Check the operation of the check valve by using a vacuum Valve Spring Vacuum pump connection Accept/reject criteria Connection at the brake A negative pressure (vacuum) is booster side @ created and held. Connection at the intake A negative pressure (vacuum) is not manifold side @ created.
Page 205 5-49 BRAKES BLEEDING Caution Use the specified brake fluid. Don’t use a mixture of the specified brake fluid and another non-specified fluid. Specified brake fluid: MOPAR Brake Fluid/ Conforming to DOT3 or DOT4 BLEEDING THE MASTER CYLINDER If the master cylinder is empty of brake fluid, bleed the cylinder as follows.
Page 206 BRAKES - Service Adjustment Procedures tion hole in the caliper body. Standard value: 10.0 mm (.39 in.) Limit: 2.0 mm (.08 in.) Caution Replace the pad if worn beyond the limit. At this time, replace the pads on right and left wheels as a set. 2.
Page 207 5-51 BRAKES - Service Adjustment Procedures 6. Clean the piston and, using the special tool, push the piston into the cylinder (caliper). 7. With care not to allow the piston boot to be wedged, lower the caliper assembly and fit the lock pin. 8.
Page 208 5-52 BRAKES - Service Adiustment Procedures 3. Using a screwdriver, remove the pads and shims. Using the following method, measure the drag force of the disc brake after installation of the brake assembly. 4. With the brake assembly removed, use a spring scale to measure the rotary sliding resistance of the hub in the forward direction.
Page 209 5-53 BRAKES - Service Adiustment Procedures 7. Start the engine, depress the brake pedal firmly two to three times and stop the engine. 8. Give the brake disc ten turns in the forward direction. 9. Using a spring scale, measure the rotary sliding resistance of the hub in the forward direction.
Page 210 5-54 BRAKES FRONT BRAKE DISC RUN-OUT CORRECTION 1. If the run-out of the brake disc is equivalent to or exceeds the limit specification, change the phase of the disc and hub, and then measure the run-out again. (1) Before removing the brake disc, chalk both sides of the wheel stud on the side at which run-out is greatest.
Page 211 5-55 BRAKES - Service Adjustment Procedures 4. Remove the following parts from caliper support Using the following method, measure the drag force of the disc brake after installation of the brake assembly. 5. With the brake assembly removed, use a spring scale to measure the rotary sliding resistance of the hub in the forward direction.
Page 212 5-56 BRAKES REAR BRAKE DISC THICKNESS CHECK 1. Remove dirt and rust from brake disc surface. 2. Measure disc thickness at 4 locations or more. Standard value: <FWD> 18.0 mm (.71 in.) 20.0 mm (.79 in.) Limit: <FWD> 16.4 mm (.65 in.) 18.4 mm (.72 in.) Replace the discs and pad assembly for both sides left and right of the vehicle if they are worn beyond the specified...
Page 213 5-57 BRAKES BRAKE LINING THICKNESS CHECK 1. Remove the rear brake assembly, and support it by a wire, etc. 2. Remove the brake disc. 3. Measure the wear of the brake lining at the place worn the most. Standard value: 2.8 mm (.I1 in.) Limit: 1.0 mm (.04 in.) Replace the shoe and lining assembly if any location of the brake lining thickness is less than the limit.
Page 214 5-58 BRAKES - Service Adjustment Procedures 3. Drive the vehicle at a constant speed of 35 - 50 km/h (22 - 31 mph) for 100 m (328 ft.) 4. Release the parking brake and let the brakes cool for 5 - 10 minutes.
Page 215 5-59 BRAKES - Service Adjustment Procedures POINTS IN WAVEFORM MEASUREMENT Symptom Probable causes Remedy Replace sensor Too small or zero waveform Faulty wheel speed sensor amplitude Adjust clearance Incorrect pole piece-to-rotor clearance Replace hub Waveform amplitude fluctuates Axle hub eccentric or with large runout excessively (this is no problem if the minimum amplitude is 100 mV or more)
Page 216 BRAKES - Service Adjustment Procedures Scan tool actuator test start 3 sec. 3 sec. Pressure decrease Pedal operation Pedal operation pattern @ pattern @ Release 6 sec. Drag force when - - - - - --_- - - - - - - - - - - - - - - - - - - - - - - - - pedal is released (7) If any abnormality is found in the check, take corrective action according to the following “Judgement in Inspection...
Page 217 5-61 BRAKES - Service Adiustment Procedures INSPECTION BY USING BRAKE FORCE TESTER NOTE (1) The brake force tester roller and tire must be dry during the test. (2) When testing the front brakes, apply the parking brake and when testing the rear brakes, apply chocks to the front wheels to lock them.
Page 218 Judgement in Inspection by Using Brake Force Tester Scan tool Judgement (reading of brake force tester) display Operation Probable cause Remedy Normal Abnormal After brake force When the actuator is driven by scan Brake force in Incorrect HU Connect tester indication tool, brake force changes as shown Step 1 shows brake tube...
Page 219 5-63 BRAKES - Service Adjustment Procedures INSPECTION OF POWER RELAY 1. Remove the relay box cover in the engine compartment and remove the power relay. 2. Apply the battery voltage to the terminal @ and check for continuity between the following terminals when the terminal @ is short-circuited to ground.
Page 220 5-64 BRAKES - Service Adjustment Procedures INSPECTION OF VALVE RELAY AND MOTOR RELAY (ABS) cover by inserting a screwdriver between the hydraulic unit and cover to pry off the lock. 2. Remove the relays. The one closest to you (larger one) is the motor relay and the one farthest from you (smaller one) is the valve relay.
Page 221: Brake Pedal
5-65 BRAKES - Brake Pedal BRAKE PEDAL Pre-removal Operation Assembly (Refer to GROUP 19AASteering Wheel and Shaft.) Post-installation Operation Assembly (Refer to GROUP 19A-Steering Wheel and Shaft.) Clutch Pedal Adjustment (Refer to GROUP 6-Clutch Pedal.) Brake Pedal Adjustment (Refer to P.5-45.) 9 ft.lbs.
Page 222 BRAKES - Brake Pedal 5-66 30 Nm 22 ft.lbs. 13 Nm 9 ft.lbs. 22 ftlbs. Grease: MOPAR Multi-Mileage Lubricant Part No. 2525035 or equivalent 13 Nm Stop light switch removal steps 9 ft.lbs. 1. Stop light switch connector 2. Stop light switch 30 Nm 22 ftlbs.
Page 223 BRAKES - Brake Pedal INSPECTION Check the bushing for wear. Check the brake pedal for bend or twisting. Check the brake pedal return spring for damage. STOP LIGHT SWITCH (2) The stop light switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm (.I 6 in.) from the outer case edge surface, and if there is continuity when it is released.
Page 224: Master Cylinder And Brake Booster
5-68 BRAKES - Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER REMOVAL AND INSTALLATION Pre-removal Operation Brake tube flare nut Draining Brake Fluid 15 Nm 11 ft.lbs. Post-installation Operation Supplying Brake Fluid Bleeding (Refer to P.5-49.) Adjustment of Brake Pedal (Refer to P.5-45.) 11 - 13 ft.lbs.
Page 225 BRAKES - Master Cylinder and Brake Booster SERVICE POINTS OF REMOVAL 1. MOVING LOW-PRESSURE HOSE Remove the nuts and bolts securing low-pressure hose shown in the illustration, and using a wire, suspend the hose from the hood to a position where it does not hamper the removal and installation of the brake booster.
Page 226 BRAKES - Master Cylinder and Brake Booster (3) Measure the dimension (D) between the master cylin- der mounting surface on brake booster and the push rod end. NOTE To obtain (D), first take measurement with a square placed on the brake booster. Then, subtract the thick- ness of the square to arrive at (D).
Page 227 5-71 BRAKES - Master Cylinder and Brake Booster SERVICE POINTS OF DISASSEMBLY Remove the piston stopper bolt, while depressing the piston. 12. DISASSEMBLY OF PISTON STOPPER RING Remove the piston stopper ring, while depressing the piston. 14. DISASSEMBLY OF SECONDARY PISTON ASSEMBLY NOTE If it is hard to remove the secondary piston from the cylinder, gradually apply compressed air from the outlet...
Page 228 5-72 BRAKES - Brake Line BRAKE LINE REMOVAL AND INSTALLATION <Vehicles without ABS> 2. Brake tube (strut) 3. Brake tube (A) 4. Brake tube (B) 5. Brake tube (front, R.H.) 6. Brake tube (front, L.H.) 7. Brake tube (main, R.H.) 8.
Page 229 BRAKES - Brake Line <Vehicles with ABS> Post-installation Operation Supplying Brake Fluid Bleeding (Refer to P.5-49.1 Flared brake line nuts 15 Nm 11 ftlbs. Connecting part of hydraulic unit 1. Brake hose 2. Brake tube 3. Brake tube (A) 4. Brake tube (B) 5.
Page 230: Front Disc Brake
BRAKES - Brake Line / Front Disc Brake INSPECTION Check the brake tubes for cracks, crimps and corrosion. Check the brake hoses for cracks, damage and leakage. s& Check the flared brake line nuts for damage and leakage. SERVICE POINT OF INSTALLATION Connect the tubes to the hydraulic unit as shown in the i l l u s t r a t i o n .
Page 231 5-75 BRAKES - Front Disc Brake INSPECTION Check disc for wear. (Refer to P.5-53.) Check disc for runout. (Refer to P.5-53, 54.) Check disc for damage. SERVICE POINTS OF INSTALLATION 2. INSTALLATION OF FRONT BRAKE ASSEMBLY Using the following method, measure the drag force of the disc brake after installation of the brake assembly.
Page 232 BRAKES - Front Disc Brake 5-76 DISASSEMBLY AND REASSEMBLY Brake caliper kit Caliper assembly disassembly steps 1. Guide pin 3. Bushing 4. Caliper support (pad, clip, shim) 5. Pin boot 6. Boot ring 7. Piston boot 8. Piston 9. Piston seal Pad assembly disassembly steps 2.
Page 233 BRAKES - Front Disc Brake Lubrication points Grease: Repair kit grease (orange) Brake fluid. MOPAR Brake Fluid/ Grease: Repair kit grease (orange) Grease: Repair kit grease (orange)
Page 234 5-78 BRAKES - Front Disc Brake SERVICE POINTS OF DISASSEMBLY When disassembling the front disc brakes, disassemble both sides (left and right) as a set. 7. REMOVAL OF PISTON BOOT / 8. PISTON Send compressed air from the port to which brake hose is installed and remove the pistons and piston boots.
Page 235 5-79 BRAKES - Front Disc Brake SERVICE POINTS OF REASSEMBLY Identification. 2. INSTALLATION OF LOCK PIN / 1. GUIDE PIN Install the guide pin and lock pin mating the head markings on the guide and lock pins with the identification markings on the caliper body.
Page 236 BRAKES - Front Disc Brake DISASSEMBLY AND REASSEMBLY Caution The piston seal contained in the seal and boot kit is coated with special grease. Do not wipe off the grease. Brake fluid: MOPAR Brake Fluid/ Conforming to DOT3 or DOT4 Brake caliper kit Grease: MOPAR Multi-Purpose Grease Grease: Repair kit grease (orange)
Page 237 5-81 BRAKES - Front Disc Brake SERVICE POINTS OF DISASSEMBLY 2. REMOVAL OF PAD PIN Holding the cross spring with hand, remove the pad pin. spring 4. REMOVAL OF PAD ASSEMBLY Using a screwdriver, remove the pad assembly 11. REMOVAL OF PISTONS Install a wood block as shown and send compressed air through the port, to which brake hose is attached, to remove the pistons.
Page 238: Rear Disc Brake
5-82 BRAKES REAR DISC BRAKE REMOVAL AND INSTALLATION Flared brake line nuts 15 Nm 11 ft.lbs. 50-60 Nm 36 - 43 ft.lbs. Removal steps 1. Brake hose 2. Rear brake assembly 3. Brake disc INSPECTION INSPECTING THE BRAKE DISC Check disc for wear. (Refer to P.5-56.) Check disc for runout.
Page 239 5-83 BRAKES - Rear Disc Brake Grease: MOPAR Multi-Purpose Grease Part No. 2932524 or equivalent Brake caliper kit Caliper assembly disassembly steps 6. Pad pin 7. Retaining ring. 8. Piston boot Seal and boot kit Pad kit 9. Piston 11. Caliper body Pad assembly disassembly steps 6.
Page 240 BRAKES - Rear Disc Brake 5-84 27 Nm 20 ft.lbs. Brake caliper kit Part No. 2932524 or equivaleni Caliper disassembly steps 1. Lock pin 2. Caliper support (pad, clip, shim) 3. Sleeve Lock pin boot 5. Guide pin boot 6. Boot ring 8.
Page 241 BRAKES - Rear Disc Brake Lubrication Points Grease: Repair kit grease (orange) Caution The piston seal contained in the seal and boot kit is coated with special grease. Do not wipe off the grease. Grease: Repair kit grease (orange) Brake fluid: Conforming to DOT3 or DOT4 Grease: Repair kit grease (orange) Caution...
Page 242 5-86 BRAKES SERVICE POINTS OF DISASSEMBLY 8. REMOVAL OF PISTON BOOT / 9. PISTON Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston. Caution Blow compressed air gently. Insert a piece of wooden plate as shown and blow compressed air through the brake hose connecting hole to remove the pistons.
Page 243 5-87 BRAKES - Hydraulic Unit (ABS) HYDRAULIC UNIT (ABS) REMOVAL AND INSTALLATION Flared brake line nuts 15 Nm 11 ftlbs. 14FO38 Removal steps Pre-removal Operation Removal of Splash Shield Draining of Brake Fluid 2. Harness connector connection Removal of Relay Box 3.
Page 244 BRAKES - Hydraulic Unit (ABS) SERVICE POINTS OF REMOVAL 1. REMOVAL OF BRAKE LINE Pull up the relay box with harness attached and inserting a ‘d hand under the relay box, remove the brake tubes using the flare nut wrench. 4.
Page 245 5-89 BRAKES - Wheel Speed Sensor (ABS) WHEEL SPEED SENSOR (ABS) REMOVAL AND INSTALLATION 12 Nm 9 ft.lbs. Pre-removal Operation Removal of Splash Shield Front speed sensor removal steps (Refer to Group 23A - Fender.) Clip 3. Front speed sensor 4.
Page 246 BRAKES - Wheel Speed Sensor (ABS) 12 Nm - z @ - - - 9 ft.lbs. 1. Front rotor Removal of Splash Shield (Front Only) Front speed sensor removal steps 2. Clip. 3. Front speed sensor 5. Rear rotor Installation of Splash Shield (Front Only) Rear speed sensor removal steps 6.
Page 247 5-91 BRAKES - Wheel Speed Sensor (ABS) SERVICE POINTS OF REMOVAL 1. REMOVAL OF FRONT ROTOR / 5. REMOVAL OF REAR ROTOR Caution Do not damage rotor teeth and never drop the rotor. If the rotor has missing teeth or is deformed, accurate wheel speed detection cannot be expected and the system may fail to function normally.
Page 248 5-92 BRAKES - Wheel Speed Sensor (ABS) (3) Check the speed sensor cable for open circuit and replace if faulty. NOTE Remove the cable clamp from the body and, while flexing the cable near the clamp, check for temporary open circuit. Also check connector connection and terminal insertion.
Page 249 BRAKES G SENSOR (AWD - ABS) REMOVAL AND INSTALLATION Pre-removal/Post-installation Operation Removal/Installation of Front and Rear Console Assemblies (Refer to Group 23A-Console Box.) CAUTION: SRS When installing or removing the instrument panel, don’t allow any impact or shock to the SRS diagnosis unit. 4 ft.lbs.
Page 250 5-94 BRAKES - Electronic Control Unit (ABS) ELECTRONIC CONTROL UNIT (ABS) REMOVAL AND INSTALLATION Post-installation Operation Installation of Quarter Trim Installation of Rear Seatback (R) Removal steps 1. Control unit connector connection 2. Electronic control unit SERVICE POINT OF REMOVAL 1.
Page 251 BRAKES - Parking Brake Lever and Parking Brake Cable PARKING BRAKE LEVER AND PARKING BRAKE CABLE REMOVAL AND INSTALLATION Pre-removal Operation Removal of Front and Rear Console (Refer to GROUP 23A-Console Box.) CAUTION: SRS When installing or removing the floor console, don’t allow any impact or shock to the SRS diagnosis unit.
Page 252 5-96 BRAKES - Parking Brake Lever and Parking Brake Cable Parking brake cable removal steps 11. Shoe hold-down pin + 12. Adjuster 1. Cable adjuster 6. Rear speed sensor 14. Strut (Refer to P.5-89.) 15. Strut return spring 7. Rear brake assembly 16.
Page 253 5-97 BRAKES SERVICE POINTS OF REMOVAL Expand the shoe & lining assembly and remove the shoe hold down cup. SERVICE POINTS OF INSTALLATION 13. INSTALLATION OF SHOE TO ANCHOR SPRINGS The shoe-to-anchor spring must be installed in the sequ- ence shown in the illustration. Caution Each shoe-to-anchor spring has a unique spring load and the spring “a”...
Page 254: Parking Brake
5-98 BRAKES - Parking Brake PARKING BRAKE REMOVAL AND INSTALLATION Adjustment (Refer to P.5-46.) 83 Nm Part No. 2299314 . \” . : ; 3. Rear brake assembly 4. Rear brake disc 5. Hubcap 6. Flange nut 7. Washer 8. Rear hub unit bearing 12.
Page 255 5-99 BRAKES 12 Nm 83 Nm 9 ft.lbs. 60 ft.lbs. 260-300 Nm Removal steps 1. Rear speed sensor 2. 0-rins 3. Rear-brake assembly 4. Rear brake disc 36 - 43 ft.lbs. + 9. Self-locking nut 12. Adjusting wheel spring 13. Shoe hold-down cup 14.
Page 256 BRAKES SERVICE POINTS OF REMOVAL 1. REMOVAL OF REAR SPEED SENSOR Caution When removing the speed sensor from the knuckle, use care not to hit the pole piece at its tip against the rotor teeth or other parts. 9. REMOVAL OF SELF-LOCKING NUT companion flange self-locking nut.
Page 257 BRAKES SERVICE POINTS OF INSTALLATION 17. INSTALLATION OF SHOE-TO-ANCHOR SPRING The shoe-to-anchor spring must be installed in the sequ- ence shown in the illustration. Caution Each shoe-to-anchor spring has a unique spring load and the spring “a” is painted to prevent erroneous installation.
Page 259 CLUTCH CONTENTS SPECIAL TOOL ........... CLUTCH CONTROL .
Page 260 CLUTCH SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Hydraulic type Hydraulic type Clutch operating method Clutch disc Single dry disc type Single dry disc type Facing diameter O.D. x I.D. mm (in.) 225 x 150 (8.9 x 5.9) 250 x 160 (9.8 x 6.3) Clutch cover assembly Diaphragm spring strap Diaphragm spring strap...
Page 261 CLUTCH - Specifications / Special Tool / Troubleshootina LUBRICANTS Specified lubricants Items Contact surface of release bearing and fulcrum of MOPAR Multi-mileage Lubricant part clutch release fork No.2525035 or equivalent Inner surface of clutch release bearing Inner surface of clutch disc spline Contact portion of release fork to release cylinder push rod Clutch pedal bushing Brake pedal bushing...
Page 262 CLUTCH Symptom Probable cause Remedy Gear shifting Clutch pedal play too large Adjust failure Large clutch disc distortion or runout Replace Worn clutch cover assembly Replace Worn or corroded clutch disc splines Replace Separated clutch disc facing Replace Worn clutch release bearing Replace Damaged pressure plate or flywheel Replace...
Page 263: Clutch Pedal
CLUTCH SERVICE ADJUSTMENT PROCEDURES Clutch pedal height CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1. Measure the clutch pedal height (from the face of the pedal pad to the firewall). Standard value (A): 177 - 182 mm (6.97 - 7.17 in.) 183 - 188 mm (7.20 - 7.40 in.) 2.
Page 264 CLUTCH 4. Measure pedal play. In the case of AWD vehicles, depress Clutch pedal free play the pedal 2 or 3 times to eliminate booster negative pressure with the engine stopped and then push the pedal with a finger to measure the play. Clutch pedal play (including play of clevis pin) Standard value: 5.
Page 265 CLUTCH - Service Adiustment Procedures Check the operation of the check valve by using a vacuum Accept/reject criteria Vacuum pump connection Connection at the ciutch A negative pressure (vacuum) is booster side 0 created and held. A negative pressure (vacuum) is not Valve Intake created.
Page 266 CLUTCH CLUTCH PEDAL REMOVAL AND INSTALLATION Adjustment Pre-removal and Post-installation Adjustment of Brake Pedal (Refer to GROUP 5 ~ Service Adjustment Procedures.) Adjustment of Clutch Pedal (Refer to P.6-5.) 30 Nm 22 ft.lbs. 25 71 12 Nm Removal steps 15. Clutch pedal shaft 1.
Page 267 CLUTCH 13Nm MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent 36. Clutch pedal shaft Removal steps 37. Clutch pedal 38. Bushing 26. Brake booster 39. Spacer (Refer to GROUP 5 - Brake Booster.) 40. Clutch pedal pad 27. Connection of clutch master cylinder 41.
Page 268: Clutch Control
CLUTCH CLUTCH CONTROL Pre-removal Operation Draining of the Clutch Fluid 11 ftlbs. MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent Clutch master cylinder removal ste (Refer to GROUP 5 - Brake Booster.) Connection for clutch tube (Clutch master cylinder side) Clutch master cylinder Adjustment of piston to push rod clearance <AWD>...
Page 269 6-11 CLUTCH push rod MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent 11 ftlbs. 19 Nm 13 ftlbs. Clutch release cylinder removal steps 6. Air hose A <AWD> 7. Harness connector 8 Air cleaner cover, air intake hose <FWD> 11 ftlbs. 9 Air cleaner cover, air intake hose A <AWD>...
Page 270 6 - 1 2 CLUTCH 21. REMOVAL OF CLUTCH HOSE To disconnect clutch hose from the clutch tube, proceed as follows: nut on the clutch tube. (2) Remove the clip from the clutch hose to remove clutch hose from bracket. 23.
Page 271 6-13 CLUTCH . ADJUSTMENT OF CLEARANCE BETWEEN CLUTCH BOOSTER PUSH ROD AND PISTON <AWD> Adjust the clearance (A) between the clutch booster push rod and piston as follows: (1) Measure the dimension (B) between the master cylin- der end face and piston. NOTE To obtain (B), first take measurement with a square placed on the master cylinder end face.
Page 272: Clutch Master Cylinder
6-14 CLUTCH CLUTCH MASTER CYLINDER DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Gasket <FWD> 3. Piston stop ring <FWD> 4. Snap ring <AWD> 5. Push rod <FWD> 6. Boot <FWD> 7. Piston assembly 8. Reservoir cap 9. Reservoir band 4.0 ft.lbs 13 Nm 9.0 ft.lbs.
Page 273: Clutch Release Cylinder
6-15 CLUTCH CLUTCH RELEASE CYLINDER DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Valve plate 2. Spring 3. Push rod 4. Boots 5. Piston and CUT) 6. Conical sprini 7. Cap 8. Bleeder plug 9. Release cylinder SERVICE POINTS OF DISASSEMBLY 5. DISASSEMBLY OF PISTON AND CUP the release cylinder.
Page 274 6-16 CLUTCH CLUTCH VACUUM LINE, VACUUM TANK <AWD> REMOVAL AND INSTALLATION Hose clamp 4.0 Nm , 2.9 ft.lbs. 3. Vacuum hose C with check valve 4. Fitting Sealant: Semi-drying sealant Vacuum pipe A removal steps 5. Air hose A Vacuum tank assembly, vacuum hose E, 6.
Page 275 6-17 CLUTCH SERVICE POINTS OF REMOVAL 3. REMOVAL OF VACUUM HOSE C WITH CHECK VALVE NOTE Since the check valve is fit to the vacuum hose C, replace the check valve as an assembly unit together with the vacuum hose C if the check valve is defective. INSPECTION Check the hose and pipes for cracks, bend, deformation and clogging.
Page 276 6-18 CLUTCH CLUTCH COVER AND DISC REMOVAL AND INSTALLATION Removal of the Transaxle Assembly 36 Nm 18Nm 13 ftlbs. Removal steps 1. Clutch cover assembly 2. Clutch disc 3. Return clip 5. Release fork 6. Fulcrum 7. Release fork boot SERVICE POINTS OF REMOVAL 1.
Page 277 6-19 CLUTCH INSPECTION CLUTCH COVER ASSEMBLY Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit. Limit : 0.5 mm (.02 in.) Check the pressure plate surface for wear, cracks and color change.
Page 278 CLUTCH SERVICE POINTS OF INSTALLATION 5. APPLICATION OF GREASE TO RELEASE FORK contact with the fulcrum and the point of contact with the release bearing. Specified grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent Caution When installing the clutch, apply grease to each part, but be careful not to apply excessive grease;...
Page 279 COOLING CONTENTS ENGINE COOLANT TEMPERATURE GAUGE THERMOSTAT ... . . UNIT AND ENGINE COOLANT .._....._._ TEMPERATURE SENSOR ........TROUBLESHOOTING No Rise in Temperature RADIATOR .
Page 280: Specifications
COOLING - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Water-cooled, pressurized, forced circulation Cooling method with electrical fan Radiator Pressurized corrugated fin type Radiator fan motor Direct current ferrite type Water pump Centrifugal impeller type Thermostat Wax type with jiggle valve 82 (Stamped on flange) Identification mark <SOHC>...
Page 281: Troubleshooting
COOLING - Specifications / Troubleshootincr SEALANT AND ADHESIVE Specified sealants and adhesive Items Engine coolant temperature gauge unit MOPAR Part No. 4318034 or equivalent Engine coolant temperature sensor (Engine control) TROUBLESHOOTING Remedy Symptom Probable cause Replenish Overheat Insufficient engine coolant Correct anti-freeze concentration Too high an anti-freeze concentration Inoperative electric cooling fan...
Page 282 COOLING - Troubleshooting CIRCUIT DIAGRAM <SOHC, DOHC NON-TURBO (FEDERAL AND CANADA)> IGNIT SWITC --------- -------- D-45 , 11 - - - - - - - - - - - - _ - - - - - - - - - - - - - A-56 ENGINE SENSOR...
Page 283 COOLING AIR CONDITIONING COMPRESSOR LOCK CONDENSER A-36 A-45 j...
Page 284: Radiator
COOLING <DOHC (CALIFORNIA)> IGNITION IGNITION RADIATOR c-71 RADIATOR FAN MOTOR 1 A-07X RADIATOR 11 ---__----____~~--_________ A-56 ENGINE SENSOR ENGINE COOLANT SENSOR ASSEMBLY (RESISTOR)
Page 285 COOLING AIR CONDITIONING COMPRESSOR LOCK CONTROLLER 2 0 A...
Page 286 COOLING OPERATION NOTE In the event of faulty water temperature sensor, the The engine control unit controls the power transis- engine control unit commands the fan motors (for I ~ tors (high speed and low speed) in the unit to both radiator and condenser) to rotate at high LJ provide radiator fan motor and condenser fan motor speeds.
Page 287: Service Adjustment Procedures
COOLING SERVICE ADJUSTMENT PROCEDURES ENGINE COOLANT LEAK CHECK 1. Loosen cap. 2. Confirm that the engine coolant level is up to the filler neck. 3. Install an adapter to the water outlet fitting and apply 160 checking for leakage from the radiator, hose or connec- tions.
Page 288 COOLING RADIATOR REMOVAL AND INSTALLATION Draining of the Engine Coolant Checking Automatic Transaxle Fluid Level and Refilling If Necessary 8 ftlbs. I S - - Removal steps of radiator 1. Drain plug 3. Overflow tube 4. Water level sensor connector 5.
Page 289 COOLING SERVICE POINT OF REMOVAL 8. DISCONNECTION OF AUTOMATIC TRANSAXLE OIL COOLER HOSES Use a plug or otherwise cover the hose and nipple part of the radiator so that dust, dirt, foreign materials, etc. do not enter after the hose has been disconnected from the radiator.
Page 290 COOLING RADIATOR FAN MOTOR RELAY INSPECTION at the right side in the engine compartment. (2) Check for continuity between the terminals when the battery power-supply is applied to terminal 0, and terminal When current Between Continuity flows terminals 1 - 3 When no Between No continuity...
Page 291: Thermostat
7-13 COOLING THERMOSTAT REMOVAL AND INSTALLATION 17-20 Nm 12 - 14 ftlbs. <SOHC> Pre-removal and Post-installation Operation Engine Coolant (Refer to GROUP 0 - Maintenance Service.) <DOHC> Removal steps 01 FOO37 2. Air intake hose A <Turbo> 3. Air Intake hose <Non-Turbo> 4.
Page 292 7-14 COOLING Standard value: <SOHC> Opening valve temperature 82°C (180°F) 8 ’ . <SOHC> <DOHC> Full-open temperature 95°C (203°F) <SOHC> <DOHC> NOTE Measure valve height when fully closed. Calculate lift by measuring the height when fully open. SERVICE POINTS OF INSTALLATION <SOHC>...
Page 293 7-15 COOLING - Water Pump, Water Pipe and Water Hose <SOHC> WATER PUMP, WATER PIPE AND WATER HOSE <SOHC> REMOVAL AND INSTALLATION Pre-removal and Post-installation Draining and Supplying of the 24 Nm 17 ft.lbs. 9 - 11 ftlbs. 17 its. 01 FO036 Installation steps Removal steps...
Page 294 7-16 COOLING - Water Pump, Water Pipe and Water Hose <SOHC> INSPECTION WATER PUMP If any of the following irregularities are observed, replace the d water pump as an assembly. (2) Water leakage. With improper sealing, a water leakage mark may be observed around hole @. SERVICE POINTS OF INSTALLATION 14.
Page 295: Hose
COOLING - Water Pump, Water Pipe and Water Hose <DOHC> WATER PUMP, WATER PIPE AND WATER HOSE <DOHC> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying of the Engine Coolant (Refer to GROUP 0 - Maintenance Service.) Removal and Installation of Ignition Power 17-20 Nm Transistor Unit and Ignition Coil (Refer to GROUP 8 - Engine Electrical)

Page 296 COOLING - Water Pump, Water Pipe and Water Hose <DOHC> INSPECTION WATER PUMP If any of the following irregularities are observed, replace the d’ water pump as an assembly. (1) Damage or crack on the water pump body (2) Water leakage. With improper sealing, a water leakage mark may be observed around hole @.
Page 297 7-19 COOLING - Engine Coolant Temperature Gauge Unit and ETC Sensor ENGINE COOLANT TEMPERATURE GAUGE UNIT AND ENGINE COOLANT TEMPERATURE SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation <SOHC> Draining and Supplying of the (Refer to GROUP 0- Maintenance I O - 1 2 N m 30Nm 7 - 8 ft.lbs.
Page 298 COOLING - Engine Coolant Temperature Gauge Unit and ETC Sensor SERVICE POINTS OF INSTALLATION 3. INSTALLATION OF AIR INTAKE HOSE B / 2. AIR INTAKE hose C HOSE A Assemble the air intake hose A with its notches (arrow- marked) lined up with the n marks on the air intake hoses Air Intake hose A B and C.
Page 299 ENGINE CONTENTS CAMSHAFT <DOHC> ........PISTON AND CONNECTING ROD ....CAMSHAFT <SOHC> ........SERVICE ADJUSTMENT PROCEDURES ..Compression Pressure Check ......CAMSHAFT OIL SEALS <DOHC> ..........Curb Idle Speed Inspection CAMSHAFT OIL SEALS <SOHC> ........ CRANKSHAFT, FLYWHEEL AND Drive Belt Tension Adjustment ......
Page 300 ENGINE GENERAL INFORMATION SECTIONAL VIEW...
Page 301 ENGINE - General Information DOHC>...
Page 302 ENGINE - General Information <SOHC> <DOHC> Lash adjuster Lash adjuster To oil cooler (turbocharged engine) (turbocharged engine)
Page 303 ENGINE - SDecifications SPECIFICATIONS GENERAL SPECIFICATIONS Items SOHC DOHC - Non-Turbo DOHC -Turbo V-type, SOHC V-type, DOHC V-type, DOHC Number of cylinders Bore mm (in.) 91 .I (3.587) 91 .I (3.587) 91 .I (3.587) Stroke mm (in.) 76.0 (2.992) 76.0 (2.992) 76.0 (2.992) Piston displacement 2,972 (181.4)
Page 304 ENGINE ‘- Specifications Items Standard value Limit Cylinder head-SOHC Overall height mm (in.) 84 (3.31) - 0 . 2 (-.008)* Flatness of gasket surface mm (in.) max. 0.05 (0019) 0.2 (.008) seat hole mm (in.) Intake 0.3 (.012) O.S. 0.6 (.024) O.S. Exhaust 0.3 (.012) O.S.
Page 305 ENGINE - Specifications Items Standard value Limit Camshaft - SOHC Cam height mm (in.) Intake 41.25 (1.6240) 40.75 (1.6430) Exhaust 41.25 (1.6240) 40.75 (1.6430) Journal O.D. mm (in.) 34 (1.34) Bearing oil clearance mm (in.) 0.05 ~ 0.09 (.0020 ~ .0035) Camshaft - DOHC Cam height mm (in.)
Page 306 ENGINE - Specifications Items Standard value Limit Valve ~ DOHC Valve length mm (in.) Intake 106.3 (4.185) Exhaust 105.4 (4.150) Stem O.D. mm (in.) Intake 6.6 (.260) Exhaust Face angle 45 ~ 45.5” Intake 1 .o l.039) 0.5 (.019) Exhaust 1.5 i.059) 1 .o (.039) Clearance (Valve stem to guide)
Page 307 ENGINE - Specifications Items Standard value Limit Piston 91 .I0 (3.5866) Clearance (Piston to cylinder) mm (in.) 0.03 - 0.05 (.0012 - .0020) Ring groove width mm (in.) No. 1 1.2 (.047) No. 2 1.5 (.059) 3.0 (.I 18) Service size mm (in.) 0.25 (.OlO), 0.50 (.020), 0.75 (.030), 1 .oo f.039)
Page 308 ENGINE - Specifications Items Standard value Limit Crankshaft Pin O.D. mm (in.) 49.9 Journal O.D. mm (in.) 59.9 (2.358) SOHC Less than 0.005 (0002) D O H C Less than 0.003 (.00012) Taper of journal and pin mm (in.) Less than 0.005 (0002) mm (in.) End play 0.05 - 0.25 (0020 - .0098)
Page 309 Timing belt <DOHC> (distance between the tensioner arm and auto tensioner body) SEALANTS Recommended sealant Items MITSUBISHI GENUINE Part No. MD9971 10 or equivalent Oil pan Oil seal case MOPAR Part No. 4318034 or equivalent Oil pressure switch Oil pressure gauge unit MOPAR Part No.
Page 310 9-12 ENGINE - Special Tools SPECIAL TOOLS Leak-down tester Bleeding of air inside the adjuster For SOHC engine only Air bleed wire Installation of camshaft oil seal < S O H C > Installation of circular packing <SOHC> Camshaft oil seal Crankshaft front oil seal installer Crankshaft rear...
Page 311 ENGINE - SDecial Tools remover Camshaft oil seal Valve stem seal Supporting the crankshaft pulley when crankshaft bolt and pulley are removed or e large nut included in , together with the crankshaft...
Page 312 9-14 ENGINE - Special Tools Tool number and tool name...
Page 313 ENGINE - Troubleshootina 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 and/or cylinder block Valve seat worn or damaged Repair or replace valve and/or seat ring Oil pressure drop Engine oil level too low...
Page 314 9-16 ENGINE - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES <SOHC> DRIVE BELTS TENSION ADJUSTMENT Power steering Apply 100 N (22 Ibs.) force to the belt back midway between pump pulley the pulleys as shown in the illustration, measure the deflection or by using a belt-tension gauge, check the belt’s tension.
Page 315 9-17 ENGINE TENSION ADJUSTMENT OF THE GENERATOR AND POW- Adjusting bolt ER STEERING PUMP DRIVE BELT <SOHC> (2) Adjust belt deflection with adjusting bolt. Caution Put the adjusting bolt into the recess at the far depth of the elongated hole on the tension bracket. (3) Tighten the fixing nut.
Page 316 ENGINE - Service Adjustment Procedures DEFLECTION ADJUSTMENT OF POWER STEERING PUMP DRIVE BELT <DOHC> (2) Place the power steering hose under the oil reservoir. (3) Insert an extension bar (insertion depth 12.7 mm), etc. into the opening at the end of the tension pulley bracket. (4) Use straight handle box wrench to loosen the tension pulley fixing bolts in the order of A and B.
Page 317 ENGINE - Service Adjustment Procedures (3) Set the timing light. (4) Start the engine and run at idle. (5) Check curb idle speed. Curb idle speed: 700 31 100 rpm (6) Turn OFF the ignition switch. (7) Remove the water-proof female connector from the ignition timing adjustment connector (brown).
Page 318 ENGINE - Service Adjustment Procedures (2) Insert a paper clip to the engine speed detection connector (blue), and connect a tachometer to the paper clip. NOTE Do not use the scan tool. If tested with the scan tool connected to the data link connector, the ignition timing will not be the basic timing but be ordinary timing.
Page 319 9-21 ENGINE (2) Connect a tachometer. (Refer to P.9-18) (3) Set a timing light. (4) Using a jumper wire, ground the ignition timing adjusting terminal. (5) Start the engine and let it idle. (6) Check whether or not the ignition timing is the standard value;...
Page 320 9-22 ENGINE Leaks in EGR system and EGR valve Evaporative emission control system NOTE If CO and HC concentrations exceed the respective standard values despite the fact that the results of the inspection made on all items are normal, replace the three-way catalyst.
Page 321 9-23 ENGINE COMPRESSION PRESSURE CHECK (1) Prior to inspection, check to ensure that the engine oil, starter motor and battery are in proper condition. Place the vehicle in the following conditions. Engine coolant temperature: 80 - 95°C (176 - 205°F) Lights, electric cooling fan and accessories: OFF Transaxle: Neutral (P for A/T) (2) Remove the spark plug cables.
Page 322 9-24 ENGINE (9) If there is a cylinder in which the compression pressure or pressure difference is beyond the limit value, pour in a small amount of engine oil through the spark plug mounting hole, and repeat Steps (7) through (8). compression pressure to rise, then it is likely that either the piston ring or cylinder wall surface is worn or damaged.
Page 323 9-25 ENGINE - Service Adiustment Procedures TIMING BELT TENSION ADJUSTMENT <SOHC> Access cover (2) Loosen the timing belt tensioner mounting bolt 1 or 2 turns. (3) Turn the crankshaft two turns in the clockwise direction. (4) Tighten the timing belt tensioner mounting bolt. (5) Attach the access cover.
Page 324 9-26 ENGINE (2) Start the engine and race* it several times (less than 10 times) at moderate speeds. If racing the engine causes the noise to die away, it means, that the air has escaped from the high pressure chamber of d the lash adjuster and that the lash adjuster has regained its normal functions.
Page 325 9-27 ENGINE above the lash adjuster. If the rocker arm goes down readily, the lash adjuster is defective. Replace it with a new one. On DOHC engines, replace in accordance with step (4). In addition, when replacing the lash adjuster, be sure to remove air positively from the lash adjuster before installation.
Page 326: Engine Mounting
9-28 ENGINE ENGINE MOUNTING REMOVAL AND INSTALLATION 72 - 87 ft.lbs. Pre-removal Operation Raise and Suspend the Engine to the Extent Force is not Applied to the Engine Mount 70 Nm 51 i=t.lbs. Removal steps 2. Cruise control pump and link assembly <Vehicles with Cruise Control>...
Page 327 9-29 ENGINE TRANSAXLE MOUNTING REMOVAL AND INSTALLATION 45 Nm Raise and Suspend the Transaxle to 33 ftlbs. the Extent Force is not Applied to (Refer to GROUP 11 -Air Cleaner.) Post-installation Operation (Refer to GROUP 11 -Air Cleaner.) 70 Nm 51 ft.lbs.
Page 328 ENGINE - Engine Roll Stopper ENGINE ROLL STOPPER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Condenser Fan Motor Assembly <Turbo> (Refer to GROUP 24-Condenser and Condenser Fan Motor.) Removal and Installation of Left Bank Warm Up Three-Way Catalytic Converter <Turbo>...
Page 329 9-31 ENGINE ENGINE ASSEMBLY <SOHC> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Eliminating Fuel Pressure in Fuel Line Installation of Radiator (Refer to GROUP 14 - Servrce Adjustment (Refer to GROUP 7 - Radiator.) Procedures.) Installation of Cruise Control Pump and Link Removal of Hood Assembly Removal of Cruise Control Pump and...
Page 330 9-32 ENGINE - Engine Assembly <SOHC> 13. Connection of idle air control motor 14. Connection of TPS 15. Connection of injector harness 16. Connection of engine coolant temperature sensor 17. Connection of engine coolant temperature gauge unit 18. Connection of fuel injectors 19.
Page 331 9-33 ENGINE < S O H C > SERVICE POINTS OF REMOVAL 11. DISCONNECTION OF POWER STEERING OIL PUMP / 12. AIR CONDITIONING COMPRESSOR Disconnect power steering oil pump and air conditioning compressor with hoses from the bracket. NOTE The removed power steering oil pump and air conditioning compressor should be fastened (by using rope, etc.) in a position that will not interfere with the removal/installation of the engine assembly.
Page 332 ENGINE - Engine Assembly <DOHC> ENGINE ASSEMBLY <DOHC> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Release of Residual Pressure from High Installation of Radiator Pressure Fuel Hose (Refer to GROUP 7 - Radiator.) (Refer to GROUP 14-Service Adjustment Installation of Cruise Control Pump and Procedures.) Link Assembly Control.)
Page 333 9-35 ENGINE - Enaine Assemblv <DOHC> 19. Connection of idle air control motor 20. Connection of TPS 21. Connection of oil pressure switch and oil pressure gauge unit 22. Connection of fuel injector harness 23. Connection of knock sensor 24. Connection of crankshaft position sensor 25.
Page 334 9-36 ENGINE SERVICE POINTS OF REMOVAL 15. DISCONNECTION OF AIR CONDITIONING COMPRES- SOR / 16. POWER STEERING OIL PUMP Disconnect air conditioning compressor and power steering oil pump (with the hose). NOTE The removed air conditioning compressor and power steering oil pump should be fastened (by using rope, etc.) in a position that will not interfere with the removal/installation of the engine assembly.
Page 335 9-37 ENGINE CAMSHAFT OIL SEALS <SOHC> Pre-removal and Post-installation Operation (Kete 90 Nm Removal steps 65 ftlbs. 2. Timing belt rear cover 3. Camshaft oil seals SERVICE POINTS OF REMOVAL 1. REMOVAL OF CAMSHAFT SPROCKET Using the special tools, lock the camshaft and remove the camshaft sprocket.
Page 336 9-38 ENGINE CAMSHAFT OIL SEALS <DOHC> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Timing Belt (Refer to P.9-56.) Removal and Installation of Intake Manifold (Refer to GROUP 8 -Camshaft Position Sensor and Crankshaft Position Sensor.) (Refer to GROUP 8 -Camshaft Position Sensor and Crankshaft Position Sensor.) 2.2 ft.lbs.
Page 337 9-39 ENGINE SERVICE POINTS OF REMOVAL 6. REMOVAL OF CAMSHAFT SPROCKET Using a wrench at the hexagonal part of the camshaft (to prevent the crankshaft from turning), loosen the camshaft sprocket bolt. Caution Do not hold the camshaft sprocket with a tool, or a damaged sprocket could result.
Page 338: Oil Pan And Oil Screen
Under Cover Front Exhaust Pipe (Refer to GROUP 11 - Exhaust Pipe and Main Muffler.) Transfer Assembly <AWD> (Refer to GROUP 21 -Transfer Assembly.) Sealant: MITSUBISHI GENUINE Pari No. MD9971 10 or equivalent 13 N 9 ft.1 14 ft.lbs. 7 ftlbs.
Page 339 9-41 ENGINE SERVICE POINT OF REMOVAL 7. REMOVAL OF OIL PAN After removing the bolts, use the special tool and a brass bar to remove the oil pan from the cylinder block. Caution Remove the oil pan gradually since the flange of the oil pan is easy to deform.
Page 340 9-42 ENGINE CRANKSHAFT FRONT OIL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Timing Belt (Refer to P.9-56.) Removal and Installation of Crankshaft Position Sensor (Refer to GROUP 16 - Camshaft Position Sensor and Crankshaft Position.) Removal steps 2.
Page 341: Crankshaft Rear Oil Seal
9-43 ENGINE - Crankshaft Rear Oil Seal CRANKSHAFT REAR OIL SEAL R E M O V A L A N D I N S T A L L A T I O N Pre-removal and Post-installation Operation Removal and Installation of Transaxle Assembly (Refer to GROUP 21 -Transaxle assembly.)
Page 342 9-44 ENGINE - Crankshaft Rear Oil Seal SERVICE POINTS OF INSTALLATION 2. INSTALLATION OF CRANKSHAFT REAR OIL SEAL then insert. (2) Tap the oil seal into the cylinder block.
Page 343 ENGINE CYLINDER HEAD GASKET <SOHC> , REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Rocker cover Removal and Installation gasket Exhaust Manifold (Refer to GROUP 11 - Exhaust Manifold.) Air Intake Manifold (Refer to GROUP 11 -Air Intake Manifold.) Timing Belt (Refer to P.9-52.) Adjustment Engine Adjustment (Refer to P.9-16.) Sealant: MOPAR Part No.
Page 344 9-46 ENGINE - Cylinder Head Gasket <SOHC> Rear bank 13 Nm 9 ftlbs. <Cold engine> 76 - 83 ftlbs. Rocker cover gasket Sealant: MOPAR Part No. 4318034 or equivalent 19 Nm 13 klbs. 90 Nm I O - 1 2 N m 65 ft.lbs.
Page 345 9-47 ENGINE - Cylinder Head Gasket <SOHC> SERVICE POINTS OF REMOVAL 1. REMOVAL OF CAMSHAFT SPROCKET Using special tools, remove the camshaft sprocket from the camshaft. 8. REMOVAL OF CYLINDER HEAD ASSEMBLY Using a 10 mm hex wrench, remove the cylinder head assembly.
Page 346 9-48 ENGINE 1. INSTALLATION OF CAMSHAFT SPROCKET Using the special tool, attach the camshaft sprocket to the camshaft.
Page 347 9-49 <DOHC> ENGINE - Cylinder Head Gasket CYLINDER HEAD GASKET <DOHC> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying Engine Coolant (Refer to GROUP 14- Engine Control.) (Refer to GROUP 0 - Maintenance Service.) Air Intake Manifold Turbocharger <Turbo> (Refer to GROUP 11 -Turbocharger.) Exhaust Manifold Timing Belt...
Page 348 ENGINE - ~Cylinder Head Gasket <DOHC> SERVICE POINTS OF REMOVAL 6. REMOVAL OF INTAKE CAMSHAFT SPROCKET remove the camshaft sprocket bolt. Caution Locking the camshaft sprocket with a tool damages the sprocket. (2) Remove the camshaft sprockets. 14. REMOVAL CYLINDER HEAD ASSEMBLY Using a IO mm hex wrench, remove the cylinder head assembly.
Page 349 9-51 ENGINE 6. INSTALLATION OF INTAKE CAMSHAFT SPROCKET Using a wrench, hold the camshaft at its hexagon and tighten the bolt to specification. Caution Locking the camshaft sprocket with a tool damages the sprocket. 5. IN+\TALLATION OF ROCKER COVER Rear bank Tighten the rocker cover bolts in the order shown in the illustration.
Page 350 9-52 ENGINE TIMING BELT <SOHC> REMOVAL AND INSTALLATION Pre-removal Operation Removal of the Under Cover (Front LH, Side LH, Removal of Cruise Control Actuator <Vehicle with Cruise Control> (Refer to GROUP 14 ~ Cruise Control.) Raise and Suspend the Engine to the Extent Force is not Applied to the Engine Mount 29 ftlbs.
Page 351 ENGINE SERVICE POINTS OF REMOVAL 7. DISCONNECTION OF POWER STEERING OIL PUMP Disconnect the oil pump (with the hose attached). NOTE Suspend the removed oil pump (by using wire or similar material) at a place where no damage will be caused during removal/installation of the engine assembly.
Page 352 ENGINE - Timing Belt <SOHC> SERVICE POINT OF INSTALLATION 15. INSTALLATION OF TIMING BELT (1) Align the timing marks of the camshaft sprockets (on “3 the front and rear sides) and the crankshaft sprocket. (At the top dead point of the No. 1 cylinder compression Camshaft stroke.) sprocket...
Page 353 ENGINE 9. INSTALLATION OF CRANKSHAFT PULLEY Using the special tool, attach the crankshaft pulley to the crankshaft. 8. INSTALLATION OF ENGINE SUPPORT BRACKET Since the mounting bolts of engine support bracket are different in size depending on location, insert them in (Reamer bolt) numbered sequence.
Page 354 ENGINE TIMING BELT <DOHC> REMOVAL AND INSTALLATION I O - 1 2 N m Pre-removal Operation 7 - 9 ft.lbs. Removal of the Under Cover (Front L.H., side L.H.) I O - 1 2 N m Removal of Cruise Control Pump and 7 - 9 fklbs.
Page 355 9 - 5 7 ENGINE - Timina Belt <DOHC> Remove the engine support bracket in the numbered sequence shown in the illustration. Spraying lubricant, slowly remove the bolt (reamer bolt) indicated by the arrow. Caution Keep in mind that the reamer bolt is sometimes heat seized on the engine support bracket.
Page 356 9-58 ENGINE 13. INSTALLATION OF TIMING BELT In case of the camshaft sprockets in the front bank, a proceed as follows: on the crankshaft sprocket by three teeth to lower the piston in No. 1 cylinder slightly from the top dead center on compression stroke.
Page 357 9-59 ENGINE (2) Using paper clips, install the timing belt in the following order with care not to allow the belt to slack. Intake camshaft sprocket (front bank side) --+ @ Water pump pulley + @ Intake camshaft sprocket (rear bank side) + @ Exhaust camshaft sprocket -+ @ Idler pulley NOTE Since the camshaft sprockets turn easily, secure them...
Page 358 ENGINE 12. INSTALLATION OF TIMING BELT FRONT COVER (LOW- Thread diameter x Since the mounting bolts of timing cover are different in size depending on lo.cation, insert them with care. mm (in.) Since the mounting bolts of engine support bracket are Reamer bolt different in size depending on location, insert them in numbered sequence.
Page 359 ENGINE - Camshaft <SOHC> 9-61 CAMSHAFT <SOHC> REMOVAL AND INSTALLATION during reassembly 14 Nm 11 ftlbs., Sealant: MOPAR Part No. 4318034 or equivalent...
Page 360 9-62 ENGINE Installation steps Removal steps 30. Bearing cap No. 1 1. Distributor adaptor 2. O-ring * 29. Rocker arm shaft (A) * 28. Rocker arm shaft (B) 3. Camshaft oil seal 27. Spring 4. Rocker arm and shaft assembly (rear) 5.
Page 361 9-63 ENGINE SERVICE POINTS OF REMOVAL 4. 8. REMOVAL OF ROCKER ARM AND SHAFT ASSEMBLY Use the special tool to ensure that the lash adjuster doesn’t fall out. INSPECTION CAMSHAFT Measure cam height (longer diameter of the cam). If it exceeds the limit, replace- the camshaft.
Page 362 9-64 ENGINE (4) After air bleeding, set lash adjuster on the special tool (Leak Division = 1 mm (.04 in.) down tester M D998440). (5) After plunger has gone down somewhat 0.2 - 0.5 mm (.008 in.). Replace if measured time is out of specification. Standard value: 4 - 20 seconds / 1 mm (.04 in.) [Diesel fuel at 15 - 20°C (50 - 68”F)] SERVICE POINTS OF INSTALLATION...
Page 363 9-65 ENGINE - Camshaft <SOHC> 12.7. INSTALLATION OF LASH ADJUSTER (1) Immerse the lash adjuster in clean diesel fuel. (2) Using a small wire, move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air.
Page 364 9-66 ENGINE (4) Remove the special tool (lash adjuster holders). (5) Check the camshaft end play. If the end play is excessive, replace the camshaft and/or the cylinder head assembly. Standard value: 0.1 - 0.2 mm (.004 - .008 in.) Limit: 0.4 mm (.016 in.) 9.
Page 365 9-67 ENGINE - Camshaft <DOHC> CAMSHAFT <DOHC> , REMOVAL AND INSTALLATION 11 Nm 8 ft.lbs. 20Nm 15 ft.lbs. Removal steps 1. Bearing cap front 2. Oil seal 3. Bearing cap rear 4. Circular packing 5. Bearing cap No. 2 6. Bearing cap No. 4 7.
Page 366 9-68 ENGINE INSPECTION CAMSHAFT Measure cam height (longer diameter of the cam). If it exceeds d the limit, replace the camshaft. Standard value: Intake side 34.91 mm (1.3744 in.) Exhaust side 34.91 mm (1.3744 in.) Limit: Intake side 34.41 mm (1.3547 in.) Exhaust side 34.41 mm (1.3547 in.) LEAK DOWN TEST OF LASH ADJUSTER...
Page 367 9-69 ENGINE <DOHC> 7. 6. 5. 3. 1. INSTALLATION OF BEARING CAPS (1) Install noting the identification mark and cap No. No.2,3 and 4 bearing caps bear the front mark. Install these Cap No caps with the mark lined up with the front mark on the cylinder head.
Page 368 ENGINE 4. INSTALLATION OF CIRCULAR PACKING Using the special tool, insert the circular packing. 2. INSTALLATION OF OIL SEAL Using the special tool, insert the oil seal.
Page 369 9-71 ENGINE - Cylinder Head and Valve CYLINDER HEAD AND VALVE REMOVAL AND INSTALLATION - SOHC 110 Nm 80 ft.lbs. Removal steps 12. Exhaust valve Valve stem seal 2 . W a s h e r 3. Cylinder head assembly C 15.
Page 370 ENGINE - Cylinder Head and Valve <Non-Turbo> 80 ft.lbs. <Turbo> - 1 7 125 Nm 125Nm 90 ft.lbs. - Back Off ---) 90 ft.lbs. 7E NO254 Removal steps 1. Cylinder head bolt 12. Exhaust valve 2. Washer 3. Cylinder head assembl 14.
Page 371 9-73 ENGINE - Cylinder Head and Valve SERVICE POINTS OF REMOVAL 1. REMOVAL OF CYLINDER HEAD BOLT Remove the cylinder head bolts. 5. 9. REMOVAL .OF RETAINER LOCK Using the special tool, remove the retainer lock. INSPECTION CYLINDER HEAD (1) Using a straight edge and feeler gauge, measure the flatness of the cylinder head gasket surface.
Page 372 9-74 ENGINE VALVES Replace the valve if the margin (thickness of the valve head) exceeds the limit. Contact area Standard value: <SOHC> the center of Intake side 1.2 mm (.047 in.) Exhaust side 2.0 mm (.079 in.) <DOHC> Intake side 1 .O mm (.039 in.) Exhaust side 1.5 mm (.059 in.)
Page 373 9-75 ENGINE Limit: <SOHC> 0.10 mm (.0039 in.) Intake Exhaust 0.15 mm (.0059 in.) <DOHC> 0.10 mm (.0039 in.) Intake 0.12 mm (.0047 in.) Exhaust SERVICE POINTS OF INSTALLATION 15.13. INSTALLATION OF VALVE STEM SEAL Install the spring seat, then using the special tool, install the stem seal by lightly tapping the tool.
Page 374 9-76 ENGINE 4. INSTALLATION OF CYLINDER HEAD GASKET Identification mark: <SOHC> <DOHC - Non-Turbo> I de <DOHC-Turbo> 1. INSTALLATION OF CYLINDER HEAD BOLT <Non-Turbo engine> Tighten two-three times in illustrated sequence until snug finally tightened to the specified torque. <Turbo engine> (1) Tighten the bolts in two to three stages in the illustrated sequence.
Page 375 ENGINE - Oil Pan and Oil Pump OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION <SOHC> 14 Nm 11 ft.lbs. 75 ‘Nm 55 ftlbs. 19 Nm 8 ft.lbs. 40 him 29 ftlbs. 14 Nm 7E NO304 11 ftlbs. with engine oil during reassembly...
Page 376 ENGINE 23 Nm 75 Nm 55 ft.lbs. 17 ft.lbs. 13 Nm B-18 19 Nm 14 Nm 11 ftlbs. ‘45 Nm 33 ftlbs. 5 ft.lbs. with engine oil during reassembly...
Page 377 9-79 ENGINE Bolt hole 0110156 portion portion Sealant: MITSUBISHI GENUINE Part Sealant: MOPAR Part No. 4318034 or No. MD9971 10 or equivaleni equivalent Removal steps 16. Relief plug 1. Transaxle stay (front) 17. Relief spring 2. Transaxle stay (rear) 18. Relief plunger + 19.
Page 378 ENGINE - Oil Pan and Oil Pump INSPECTION OIL PUMP Standard value: 0.03 - 0.08 mm (.0012 - .0031 in.) (2) Check the side clearance. Standard value: 0.04 - 0.10 mm (.0016 - .0039 in.) (3) Check the body clearance. Standard value: 0.10 - 0.18 mm (.0040 - .0070 in.) Limit: 0.35 mm (.0138 in.) OIL COOLER BY-PASS VALVE <Turbo>...
Page 379 13. APPLICATION OF SEALANT TO OIL PAN (1) Apply specified sealant all around the oil pan flange to a diameter of 4 mm (.I6 in.). Specified sealant: MITSUBISHI Genuine Part No. MD9971 10 or equivalent (2) Install the oil pan within 15 mins. after applying the liquid gasket.
Page 380 ENGINE 12. TIGHTENING SEQUENCE OF OIL PAN BOLT Tightening sequence of flange bolts Tighten the flange bolts in the sequence shown in the (bottom view) illustration. Timing belt 11. INSTALLATION OF DRAIN PLUG GASKET Install the drain plug gasket in the direction shown in the illustration.
Page 381: Piston And Connecting Rod
9-83 ENGINE - Piston and Connectina Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Removal steps 1. Nut 3. Connecting rod bearing (lower) a 4. Piston and connecting rod assembly 5. Connecting rod bearing (upper) + 6. Piston ring No. 1 52 Nm 38 ftlbs.
Page 382 9-84 ENGINE - Piston and Connectinrr Rod INSPECTION PISTON RING groove. When it exceeds the limit, replace the rings, the piston, or both. Standard value: No.1 0.03 - 0.07 mm (.0012 - .0028 in.) No.2 0.02 - 0.06 mm (.OOOS - .0024 in.) Limit: No.1 0.1 mm (.004 in.) No.2...
Page 383 9-85 ENGINE NOTE For the method by which the oil clearance is measured using a plastigauge, refer to the item on the crankshaft. SERVICE POINTS OF INSTALLATION 8. INSTALLATION OF OIL RING (1) Fit the oil ring spacer into the piston ring groove. NOTE On the side rail and the spacer, no difference exists between the upper and the lower surfaces.
Page 384 9-86 ENGINE 4. INSTALLATION OF PISTON, CONNECTING ROD Side rail ASSEMBLY No.1 (1) Liberally coat engine oil on the circumference of the { , piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration.
Page 385 9-87 ENGINE CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 75 Nm 55 ft.lbs. with engine oil during reassembly Sealant: MOPAR Part No. 4318034 or equivalent 57 ft.lbs. Removal steps 2. Ball bearing 67 ft.lbs. 3. Adaptor plate <A/T> 4. Drive plate <A/T> 5.
Page 386 9-88 ENGINE INSPECTION CRANKSHAFT Inspect out-of-roundness and taper of crankshaft journal and \ pin. Limit: Out-of-roundness of journal and pin: <SOHC> 0.005 mm (.00020 in.) <DOHC> 0.003 mm (.00012 in.) Taper of journal and pin: 0.005 mm (.00020 in.) OIL CLEARANCE MEASUREMENT (1) To check the oil clearance, measure the outside diameter of the crankshaft journal and the crank pin and the inside diameter of the bearing.
Page 387 9-89 ENGINE - Crankshaft. Flvwheel and Drive Plate SERVICE POINTS OF INSTALLATION 16. INSTALLATION OF CRANKSHAFT BEARING (UPPER) / 15.10. THRUST BEARING A / 14.11. THRUST BEARING B / 12. CRANKSHAFT BEARING (LOWER) whether there is an oil groove or not. Then, assemble as shown in the illustration.
Page 388 ENGINE 8. 9. INSTALLATION OF BEARING CAP the illustration. (2) Tighten the bearing cap bolts to the specified torque in :Lj the sequence shown in the illustration. (3) Check that the crankshaft rotates smoothly. Bearing cap bolt <SOHC, DOHC - Non Turbo> <DOHC-Turbo>...
Page 389: Cylinder Block
9-91 ENGINE CYLINDER BLOCK REMOVAL AND INSTALLATION 42 Nm 31 ftlbs. 75 Nm 55 f-tlbs. 2. Roll stopper bracket rear 3. Cylinder block...
Page 390 9-92 ENGINE <DOHC> 23 Nm 17 ft.lbs. 29 Nm 4 2 N m -- 31 ft.lbs.-@%I@ 75 Nm 55 ftlbs. 45 Nm 33 ftlbs. 1. Roll stopper bracket front 2. Roll stopper bracket front (AWD only) 3. Roll stopper bracket rear 4.
Page 391 9-93 BORING THE CYLINDER sized piston to be used. (2) Measure with the outside diameter of the piston as the datum measurement points. NOTE Thrust There are four sizes of oversize piston -0.25 mm (.OlO in.), direction 0.50 mm (.020 in.), 0.75 mm (.030 in.), 1.00 mm (.039 in.). (3) Calculate the reground bore size based on the measured measurement value of the outside piston diameter.
Page 392: Oil Cooler
9-94 ENGINE Oil Cooler ENGINE OIL COOLER REMOVAL AND INSTALLATION 22 - 25 fklbs. Post-installation Operation (Refer to GROUP 0- Maintenance 4 N m 2.9 ft.lbs. Removal steps 1. Front spla 2. Eye bolt 3. Gasket 1 2 N m ’ 4.
Page 393 I I - I CONTENTS ACTIVE EXHAUST SYSTEM ..,.... SERVICE ADJUSTMENT PROCEDURES . . . Intake Charge Pressure Control AIR CLEANER ..........System Inspection .
Page 394 INTAKE AND EXHAUST SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Air cleaner Unwoven cloth type Element Exhaust system Dual type Front exhaust pipe Expansion resonance type Muffler Coupling Flat coupling, insertion type Rubber hangers Suspension system Turbocharger Exhaust gas turbine type Identification No. Turbocharger waste gate actuator and Supercharging pressure control solenoid valve...
Page 395 INTAKE AND EXHAUST SPECIAL TOOLS Application Tool number and tool name Replaced by Miller tool number M D998770 Removal and installation of oxygen General service sensor <Non-Turbo> Oxygen sensor wrench or open end wrench Removal and installation of oxygen General service sensor <Turbo, front pipe>...
Page 396 INTAKE AND EXHAUST - Troubleshooting (Active Exhaust System) TROUBLESHOOTING (ACTIVE EXHAUST SYSTEM) TROUBLESHOOTING PROCEDURE (2) Make sure that the connectors of each component are positively connected and that no fuse has blown. (3) Have an overall understanding of the substance and procedure of checking by reference to the Troubleshooting Quick-Reference Table and perform check in the proper sequence.
Page 397: Active Exhaust System
INTAKE AND EXHAUST - Troubleshooting (Active Exhaust System) ACTIVE EXHAUST SYSTEM CIRCUIT CHECK POWER OFF‘ O N c-14 C-29 D-44 ACTIVE F-26 D-38 “4 RHEOSTAT TROUBLESHOOTING HINTS Checking Active Exhaust Control Module Terminal voltage Status Signal Not less than IOV SPORT MODE SPORT MODE signal Not less than IOV...
Page 398 INTAKE AND EXHAUST SERVICE ADJUSTMENT PROCEDURES VARIABLE INDUCTION CONTROL SYSTEM IN-1 SYSTEM INSPECTION connector. (2) Connect the special tool (test harness set) between the disconnected connectors. (All terminals should be con- nected.) (3) Connect a circuit tester between terminal @ and terminal measure the voltage.
Page 399 INTAKE AND EXHAUST - Service Adiustment Procedures TURBOCHARGER SUPERCHARGING PRESSURE INSPECTION (Turbo) Caution Perform running inspection with two passengers in the vehicle and where full throttle acceleration can be safely made. The pressure gauge reading is taken by a front seat passenger.
Page 400 INTAKE AND EXHAUST Engine Hose Normal state state (with its end painted red) stop Opened Negative pressure leaks. (Ignition switch: Closed by finger Negative pressure is maintained. Idling Closed by finger Negative pressure leaks. (After warm-up) NOTE If this check indicates an abnormal condition, the turbochar- ger waste gate actuator, turbocharger waste gate solenoid or hose is broken.
Page 401 INTAKE AND EXHAUST TURBOCHARGER BYPASS VALVE INSPECTION (Turbo) (2) Connect the hand vacuum pump to the nipple of the turbocharger bypass valve. (3) Apply a negative pressure of approx. 400 mmHg (16 in.Hg), and check operation of the valve. Also check that air tightness is maintained.
Page 402: Air Cleaner
INTAKE AND EXHAUST REMOVAL AND INSTALLATION < N o n T u r b o > < T u r b o > 15 Hose clamn Removal steps of air cleaner Removal steps of air intake hose 1. Connection of volume air flow sensor con- <Turbo>...
Page 403 INTAKE AND EXHAUST INSPECTION Check the air cleaner body, cover or packing for deforma- tion, corrosion or damage. Check the air duct for damage. Check the air cleaner element for clogging, contamination or damage. If element is slightly clogged, remove dust by blowing air from inside of element.
Page 404: Charge Air Cooler
INTAKE AND EXHAUST REMOVAL AND INSTALLATION Removal steps of charge air cooler right 2. Air hose D 3. Charge air cooler duct (RH) 4. Charge air cooler right Removal steps of charge air cooler left Removal steps of air intake hose 5.
Page 405 INTAKE AND EXHAUST SERVICE POINT OF REMOVAL 13. REMOVAL OF ENGINE OIL COOLER Disconnect the hose from the engine oil cooler and remove the engine oil cooler only. INSPECTION Check the charge air cooler fins for bending, damage, or foreign matter. Check the charge air cooler hoses for cracking, damage, or wear.
Page 406 INTAKE AND EXHAUST REMOVAL AND INSTALLATION Removal steps 2. Connection of accelerator cable <Vehicles for 11. EGR pipe installation bolts California> 3. Throttle body assembly + 4. Throttle body gasket 12. EGR pipe gasket 5. Connection of vacuum hose 13. Connection of intake manifold plenum stay 6.
Page 407 INTAKE AND EXHAUST REMOVAL AND INSTALLATIOIN Adjustment ot Acceler Removal steps 1. Connection air intake hose 2. Connection of accelerator cable 3. Throttle body assembly 4. Throttle body gasket 5. Connection of brake booster v’xuum hose 6. Harness connecters 7. Connection of VIC motor 3.
Page 408 INTAKE AND EXHAUST REMOVAL AND INSTALLATION 11. EGR valve 12. EGR valve gasket 2. Connection of accelerator cable 3. Throttle body assembly 14. EGR pipe gasket 4. Throttle body gasket 15. Connection of intake manifold plenum stay 5. Air pipe A 16.
Page 409 INTAKE AND EXHAUST INSPECTION Check the following points; replace the part if a problem is found. INTAKE MANIFOLD PLENUM if defective or cracked. (2) Check load (negative pressure) of drain port. Clean if required. SERVICE POINTS OF INSTALLATION 4. INSTALLATION OF THROTTLE BODY GASKET Install with the gasket protrusion positioned as shown.
Page 410 INTAKE AND EXHAUST REMOVAL AND INSTALLATION Release of Residual Pressure Installation of Intake Manifold from High Pressure Hose Plenum (Refer to P.ll-14.) (Refer to GROUP 11 -Service Filling of Engine Coolant Adjustment Procedure.) (Refer to GROUP 0 - Coolant Replacement.) (Refer to GROUP 0 - Coolant Adjustment of Accelerator Cable Replacement.)
Page 411 INTAKE AND EXHAUST SERVICE POINTS OF REMOVAL 6. REMOVAL OF FUEL RAIL (WITH INJECTORS) Disconnect the fuel rail with the injector attached to the fuel rail. Caution 1. Be careful not to drop the injector when removing the fuel rail. 2.
Page 412 INTAKE AND EXHAUST REMOVAL AND INSTALLATION Installation of intake Manifold Plenum (Referto P.ll-15, 16.) Release of Residual Pressure from High Pressure Fuel Hose Filling of Engine Coolant (Refer to GROUP 14 - Service Adjustment Procedures.) Service.) Draining of Engine Coolant (Refer Adjustment of Accelerator Cable to GROUP 0 - Maintenance Service.) (Refer to GROUP 14- Engine...
Page 413 INTAKE AND EXHAUST INSPECTION Check the following points; replace I found. INTAKE MANIFOLD any part. (2) Clogging of the negative pressure vacuum) outlet port, or (3) Check deflection of installation surface with straight edge and thickness gauge. Standard value : 0.15 mm (.0059 in.) or less Limit : 0.2 mm (.008 in.) SERVICE POINTS OF INSTALLATION 12.
Page 414 INTAKE AND EXHAUST REMOVAL AND INSTALLATION Removal steps 13. Water pipe A 1. Air hose C 14. Water pipe B Air intake hose B 15. Connection of heated oxygen sensor 3. Air hose D 16. Turbocharger &fitting assembly 4. Air hose A 17.
Page 415 INTAKE AND1 EXHAUST SERVICE POINTS OF REMOVAL 19. REMOVAL OF HEATED OXYGEN SENSOR Disconnect the connector of the heated oxygen sensor, and install the special tool to the heated oxygen sensor. 25. DISCONNECTION OF AIR CONDITIONING COMPRES- Disconnect air conditioning compressor with hoses from the bracket.
Page 416 INTAKE AND EXHAUST - Turbocharger (Front) 19. INSTALLATION OF HEATED OXYGEN SENSOR Use the special tool to install the heated oxygen sensor. 7. INSTALLATION OF AIR HOSE E / 5. AIR HOSE B Aligning the marks at the points indicated by the arrows, insert securely into the stepped portion of the pipe or until seated.
Page 417 INTAKE AND EXHAUST REMOVAL AND INSTALLATION Removal steps 13. Eye bolt 1. Battery l a 14. 2. Connection of accelerator cable EGR valve 16. Water pipe A 17. Water pipe B 4. Air pipeA 18. Exhaust fitting 5. Heat protector F 19.
Page 418 INTAKE AND EXHAUST SERVICE POINT OF REMOVAL Disconnect the connector of the heated oxygen sensor, and install the special tool to the heated oxygen sensor. INSPECTION TURBOCHARGER ASSEMBLY CHECK Visually check the turbine wheel and the compressor wheel for cracking or other damage. Check whether the turbine wheel and the compressor wheel can be easily turned by hand.
Page 419 INTAKE AND EXHAUST 9. INSTALLATION OF AIR INTAKE HOSE C / 8. AIR INTAKE HOSE A Engaging the notches with LI marks at the points indicated by the arrows insert until seated. Insert the turbocharger end of air intake hose C completely. 4.
Page 420 INTAKE AND EXHAUST DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Snap pin 2. Turbocharger waste gate actuator 3. Coupling * I)* 5. Snap ring 6. Cartridge assembly 8. Compressor cover SERVICE POINTS OF DISASSEMBLY 5. REMOVAL OF SNAP RING Place the compressor cover assembly on the floor with its end surface down and remove the snap ring with pliers.
Page 421 INTAKE AND EXHAUST INSPECTION TURBOCHARGER to make sure it operates freely. (2) Inspect the oil passage in the cartridge for signs of deposits or blockage. (3) Clean the inlet section of the compressor cover with a rag. Inspect it for signs of contact with the compressor turbine. If worn, replace it.
Page 422 INTAKE AND EXHAU$T TEST OF TURBOCHARGER WASTE GATE ACTUATOR OPERATION Using a tester, apply a pressure of approx. 48 kPa (6.8 psi) to the actuator and make sure that the rod moves. Caution Do not apply a pressure of more than 61 kPa (8.7 psi) to the actuator.
Page 423: Exhaust Manifold
INTAKE AND EIXHAUST REMOVAL AND INSTALLATION <‘VEHICLE FOR FEDERAL> Removal steps of exhaust manifold (rear) Removal steps of exhaust manifold (front) 5. Heat protector 1. Heat protector 6. Exhaust manifold (rear) 2. Exhaust manifold (front) 7. Gasket 3. Oil level gauge guide 4.

Page 424 INTAKE AND EXHAUST REMOVAL AND INSTALLATION <VEHICLE FOR CALIFORNIA> Removal steps of exhaust manifold (rear) Removal steps of exhaust manifold (front) 5. EGR pipe 1. Heat protector 6. EGR gasket 2. Exhaust manifold (front) 7. Exhaust manifold (rear) 3. Oil level gauge guide 8.
Page 425 INTAKE AND EXHAU!ST REMOVAL AND INSTALLATION <VEHICLE FOR FEDERAL> Removal steps of exhaust manifold ([front) Removal steps of exhaust manifold (rear) 7. Stud 8. Heat protector 9. Exhaust manifold (rear) Service Adjustment procedures) 2. Generator assembly 3. Oil level gauge guide 4.
Page 426 INTAKE AND EXHAUST REMOVAL AND INSTALLATION <VEHICLE FOR CALIFORNIA> Removal steps of exhaust manifold (front) Removal steps of exhaust manifold (rear) belt (Generator) 9. Exhaust manifold (rear) Service Adjustment procedures) 2. Generator assembly 3. Oil level gauge guide 4. Heat protector 5.
Page 427 INTAKE AND EXHAUST - Exhaust Manifold <DOHC (Turbo)> REMOVAL AND INSTALLATION 1. Heat protector 4. Gasket 5. Heat protector * 6. Exhaust manifold (rear) 7. Gasket INSPECTION Check the following points; replace the part if a problem is found. Check for damage of cracking of any part. SERVICE POINTS OF INSTALLATION 6.
Page 428 INTAKE AND EXHAUST 3. INSTALLATION OF EXHAUST MANIFOLD STAY With the exhaust manifoid stay resting on the exhaust manifold, fit it along with the exhaust manifold over the a studs. 2. INSTALLATION OF EXHAUST MANIFOLD (FRONT) Tighten the nuts in the following order. (1) Tighten four nuts @ to 30 Nm (22 ft.lbs.).
Page 429: Exhaust Pipe, Main Muffler And
INTAKE AND EXHAUST - Exhaust Pipe, Main Muffler and Catalytic Converter <Non Turbo> 1 I-37 REMOVAL AND INSTALLATION 50 Nm 36 ftlbs. Removal steps 1. Main muffler and center exhaust pipe installation bolts Gasket Rubber Rubber Main muffler Mouldinas Hanger bracket Catalytic converter and center exhaust pipe installation bolts Hanger bracket...
Page 430 INTAKE AND EXHAUST - Exhaust Pipe, Main Muffler and Catalytic Converter <Non-Turbo> REMOVAL AND INSTALLATION <VEHICLE FOR CALIFORNIA> 27. Self- locking nuts 15. Hanger bracket 28. Catalytic converter (front) 2. Gasket 16. Hanger brackets 29. Gasket 3. Rubber hangers 17. Rear floor heat protector 30.
Page 431: Exhaust Pipe, Main Muffler And Catalytic Converter
INTAKE AND EXHAUST - Exhaust Pipe, Main Muffler and Catalytic Converter <Turbo> Pre-removal and Post-installation Operation REMOVAL AND INSTALLATION 33 ftlbs. 9 - 11 ft.lbs. 6.5 ft.lbs. 18 Nm 13 ft.lbs. 45 Nm 33 ft.lbs.& 50 Nm 13 r(rm 36 ft.lbs. 8 ft.lbs.

Page 432 INTAKE AND EXHAUST - Exhaust Pipe, Main Muffler and Catalytic Converter <Turbo> SERVICE POINTS OF REMOVAL 4. 5. REMOVAL OF RUBBER HANGER / 6. MAIN MUFFLER Support with a transmission jack, etc. 32. REMOVAL OF HEATED OXYGEN SENSOR Disconnect the connector of the heated oxygen sensor, and install the special tool to the heated oxygen sensor.
Page 433 INTAKE AND EXHAUST REMOVAL AND INSTALLATION Removal and Installation of Rear Side Trim (LH) (Refer to GROUP 23A-TRIMS.) Removal steps 1. Active exhaust system control module 2. Connection of cable (Actuator side) 3. Actuator 4. Protector 5. Connection of cable (Muffler :side) 6.
Page 434 INTAKE AND EXHAUST INSPECTION ACTIVE EXHAUST SWITCH (1) Remove switch garnish B from the knee protector. (2) Operate the switch and check the continuity between the terminals. TOUR SPORT NOTE...
Page 435 CONTENTS MULTIPORT FUEL INJECTION (MFI) ..............‘VARIABLE VENTURI TYPE CARBURETt3R .
Page 437 CONTENTS...
Page 439 MULTIPORT FlJEL INJECTION...
Page 440 MULTIPORT FUEL INJECTION - General Information <California SOHC>...
Page 441 throttle powon switch) control valve EVAP canister Engine control module Crankshaft p;sbtion Catalytic Camshaft DOS,+,• ~ <ensor sensor Crankshaft posWon sensor Heated oxygen sensor Knock sensor Throttle po%Uon sensor, Closed throttle powon switch Intake air temp. sensor Volume air flow sensor. Barometric pressure sensor...
Page 442 MULTIPORT FUEL INJECTION <California DOHC-Non Turbo>...
Page 443 Intake a,r temp. sensor...
Page 444: Dohc (Turbo)
MULTIPORT FUEL INJECTION GENERAL SPECIFICATIONS terns mm (in.) Throttle bore <SOHC> <DOHC> Throttle position sensor Idle air control motor Stepper motor type by-pass air control system with the first idle air valve iotary contact type Closed throttle position switch Engine control module Identification model No.
Page 445 MULTIPORT FUEL INJECTION - Specifications Items Specifications Actuators Multiport fuel injection (MFI) relay type Contact switch type Injector type and number Electromagnetic, 6 Injector identification mark <SOHC> S21 OH <DOHC - Non Turbo> <DOHC -Turbo> BDL360 Variable induction control motor <DOHC - Non Turbo> Direct current motor type Evaporative emission purge solenoid ON/OFF type solenoid valve...
Page 446: Inspection
MULTIPORT FUEL INJECTION - Special Tools Test harness set Checking the diagnostic trouble code Tool not necessary if Basic idle speed adjustment Test harness Inspection by oscilloscope Test harness Measurement of fuel pressure...
Page 447 MULTIPORT FUEL INJECTION Tool number and tool name of knock...
Page 448: Troubleshooting
MULTIPORT FUEL INJECTION EXPLANATION OF TROUBLESHOOTING PROCEDURES Effective troubleshooting procedures for MFI system problems are given below. 1. Verification of trouble symptom Reproduce trouble symptom and verify the characteris- tics of the trouble and the conditions (engine condition, driving conditions, etc.) under which it is produced. 2.
Page 449 MULTIPORT FUEL INJECTION EXPLANATION AND CAUTIONS ABOUT HARNESS CHECK The connector symbol shown is as viewed from the terminal end of the connector inside the vehicle. system voltage. When checking a waterproof connector for circuit continui- ty, be sure to use the special tool, Test Harness. Never insert the test probe from the harness side as this causes loss of waterproof characteristics and corrosion may result.
Page 450 MULTIPORT FUEL INJECTION If the sensor impressed voltage is abnormal, check the wire for an open circuit or short-circuit to ground and repair as necessary. If the wire is normal, replace the engine control module and check again. To check the voltage, use a digital voltmeter (or circuit tester) as a rule.
Page 451 MULTIPORT FUEL INJECTION CHECK ENGINE MALFUNCTION INDICATOR LAMP IN- SPECTION illuminates for about 5 seconds and then goes out. (2) If the lamp does not illuminate, check for open circuit in harness, blown fuse and blown bulb. ON-BOARD DIAGNOSTIC The engine control module monitors the input/output signals (some signals at all times and the others under specified conditions) of the engine control module.
Page 452: Troubleshooting
MULTIPORT FUEL INJECTION DIAGNOSTIC CHART (FAULT TREE) l Harness and connector l Throttle posrtron sensor l Vehrcle speed sensor l Harness and connector...
Page 453 MULTIPORT IFUEL INJECTION coil...
Page 454 MULTIPORT FUEL INJECTION...
Page 455 MULTIPORT FUEL INJECTION TROUBLE DIAGNOSIS QUICK REFERENCE CHART Diagnostic Description Major cause Remarks item (Symptoms, etc.) trouble Engine control Trouble in engine Engine stalls. module control module itself Engine cannot be started. Heated oxygen Despite air-fuel ratio (1) Defective heated oxygen sensor Poor exhaust sensor <Except feedback control (2) Open or short circuit in heated...
Page 456 MULTIPORT FUEL INJECTION Description Major cause Remarks trouble (Symptoms, etc.) code No. Crankshaft (1 )Cranking the engine (1) Defective crank angle sensor Engine stalls. position for more than four (2) Open or short circuit in crank- @ Engine cannot be sensor seconds does not shaft position sensor circuit, or...
Page 457 MULTIPORT FUEL INJECTION Diagnos- Diagnostic item Description Major cause Remarks (Symptoms, etc.) trouble code No. EGR <California With the engine Poor exhaust -Non Turbo, running after warmup, (2) EGR valve control negative Turbo> EGR amount too small pressure too low performance* (3) Defective EGR control solenoid (EGR temperature sensor...
Page 458 MULTIPORT FUEL INJECTION Diagnos- Diagnostic item Description Major cause Remarks (Symptoms, etc.) trouble code No. Right bank Engine warm-up has been (1) Failure of oxygen sensor Decrease of exhaust heated oxygen completed, but oxygen (2) A break or short in oxygen gas purification sensor (Rear) sensor signal voltage does...
Page 459 MULTIPORT FUEL INJECTION READ OUT OF DIAGNOSTIC TROUBLE CODE Precautions for Operation (1) When battery voltage is low, no detection of failure is possible. Be sure to check the battery for voltage and other conditions before starting the test. (2) Diagnostic item is erased if the battery or the engine control module connector is disconnected.
Page 460 MULTIPORT FUEL INJECTION Diagnostic result indication method when check engine/malfunction indicator lamp is used Typical blinking, made while diagnostic Blinking when condition is trouble code is output normal In case of diagnostic trouble NOTE Other diagnostic items are also output by lamp blinking corresponding to the same code number as when scan tool is used.
Page 461 MULTIPORT FWEL INJECTION CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS...
Page 462 MULTIPORT FUEL INJECTION PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
Page 463 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <SOHC> (FEDERAL AND CANADA) IGNITION BATTERY FUSIBLE LINK@ WITH ALARM 4 Dl15 VOLUME AIR Pp FLOW SENSOR M/T A/T 7x---...
Page 464 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <SOHC> (CONTINUED) j C-71 'D-44 CONNECTOR COMBINATION METER :: 0 ENGINE CONTROL MODULE...
Page 465 MULTIPORT FUEL INJECTION CRP iNKSHAFT AND CAMSHAFT POSITION SENSOR% I VOLUME AIR FLOW SENSOR B-29 ‘7 -5 I \I ENGINE CONTROL -5 MODULE I I I I I I II THROTTLE ENGINE COOLANT C-55 pl%rq B-05 1-1 B-02 i@'...
Page 466 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <SOHC> (CONTINUED) RELAY IDLE SPEED ” 3-11 B-35 I 18 -__---___...
Page 467 MULTIPORT FUEL INJECTION - Troubleshooting A-36 IGNITION CONDITIONING POWER TRANSISTOR CONTROL UNIT RADIATOR FAN RADIATOR FAN...
Page 468 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <SOHC> (CONTINUED) AUTMATIC TRANSP LE CONI SOLENOID VALVE A-21 c-29 DATA LINK CONNECTOR c-79 POWER STEERING...
Page 469 MULTIPORT IFUEL INJECTION CIRCUIT DIAGRAM <SOHC> (CALIFORNIA) STARTER IGNITION FUSIBLE ATTE "5 4 D-15 7 B-26 g 1 i f s c u ;...
Page 470 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <SOHC> (CONTINUED) RELAY CONNECTOR SPEED (REED i ------- :---...
Page 471 MULTIPORT FUEL INJECTION CRANKSHAFT POSITION SENSOR AND CAMSHAFT POSITION SENSORg, VOLUME AIR FLOW SENSOR B-29 4 > - - - - - - - - - - - - - - - - - - ’ CONTROL MODULE THROTTLE ENGINE COOLANT B-05 4-j' B-02 a...
Page 472 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <SOHC> (CONTINUED) RELAY IDLE SPEED v B-35 105 & RIGHT BANK HEATED LEFT BANK HEATED RIGHT BANK HEATED A-22 @iI...
Page 473 MULTIPORT FUEL INJECTION CLUTCH A-36 C-52 IGNITION POWER CONDITIONING TRANS I STOR CONTROL UNIT RADIATOR FAN RADIATOR FAN...
Page 474 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <SOHC> (CONTINUED) AUTMATIC TRANSAXLE CO1 MODULE EVAP SOLENOID PURGE VALVE SOLENOID A-21 A-20 I s - - - - - - - DATA LINK IGNITION CONNECTOR TIMING c-79 POWER STEER...
Page 475 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Non-Turbo> (FEDERAL AND CANADA) IGNITION FUSIBLE LINK@ 4 D-15 VOLUME AIR g FLOW SENSOR RELAY c-44 M/T A/T...
Page 476 MULTIPORT FUEL INJECTION - Troubleshooting CIRCUIT DIAGRAM <Non-Turbo> (CONTINUED) IGNI 4 c-30 A-17 [ 3 c-34 CONNECTOR D-04 SPEE ITCH) FUEL PUMP 6 C-14 : - - - 5 F-14 ENGINE...
Page 477 MULTIPORT FUEL INJECTION FLOW SENSOR SENSOR B-29 "3 2 B-41 1 B-40 1 65 .------. 13 Ii3 ENGINE THROTTLE B-05 COOLANT B-02 m...
Page 478 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Non-Turbo> (CONTINUED) RELAY IDLE SPEED v B-35 I--j+--- VARIABLE INDUCTION CONTROL MOTOR SENSOR...
Page 479 MULTIPORT FUEL INJECTION - Troubleshootina MULTI-PURPOSE WITH DIODE E-31 6 A-67 19 c-29 C-52 '115 c-29 1 MAGNETIC CLUTCH IGNITION POWER TRANSISTOR RADIATOR FAN[ MOTOR RELAY...
Page 480 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Non-Turbo> (CONTINUED) RELAY AUTMAT: E CO. EVAP PURGE SOLENOID A-21 1 - - - - - - - - - - - - - - - - - 104 c-54 B-38 DATA LINK CONNECTOR c-79 POWER STEER...
Page 481 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Non-Turbo> (CALIFORNIA) IGNITION FUSIBLE LINK 6) BATTERY VOLUME AIR m FLOW SENSOR ' RELAY c-44 M/T A/T...
Page 482 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Non-Turbo> (CONTINUED) SWITC A-17 CONNECTOR COMBINATION METER SPEED SENSOR (REED SWITCH) FUEL PUMP F-16 ENGINE...
Page 483 MULTIPORT FUEL INJECTION - Troubleshooting V UME SENSOR B-29 L - . B-05 EN= RIGHT BANK HEATED THROTTLE SENSOR B-44 B-02 @J (FRONT)
Page 484 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Non-Turbo> (CONTINUED) IDLE SPEED " B-35 i - - - LEFT BANK HEATED OXYGEN SENSORtREAR) VARIABLE INDUCTION CONTROL MOTOR B-45...
Page 485 MULTIPORT IFUEL INJECTION MULTI-PURPOSE C-69 c-03 DIODE E-31 c-53 7 ---: MAGNETIC CLUTCH IGNITION POWER TRANSISTOR RADIATOR FAN MOTOR RELAY...
Page 486 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Non-Turbo> (CONTINUED) LE CON'I EVAP PURGE SOLENOID "2 A-20 ENGINE CONTROL MODULE B-06 B-38 DATA LINK CONNECTOR TION...
Page 487 MULTIPORT FUEL INJECTION (FEDERAL) 5 D-44 A-67 IOD OR STORAGE CONNECTOR 1 2 3 4...
Page 488 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Turbo> (CONTINUED) RELAY D-04 C-34 COMBINATION g METER " 6 D-03 F-16 1 2 3 c-14 4 5 6 F-14...
Page 489 MULTIPORT FUEL INJECTION VOLUME FLOW SENSOR B-40 r - - - - - - - - - - I 19 ENGINE THROTTLE B-05...
Page 490 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Turbo> (CONTINUED) RESISTOR IDLE SPEED ..2 B-35 C-88 A-22 2 HEATED B-19 OXYGEN SENSOR...
Page 491 MULTIPORT FUEL INJECTION MULTI-PURPOSE UNIT STOP LIGHT SWITCH C-61 c-29 11 _------ 6 -__---- ----- 8 C-14 ACTIVE UNIT CONTROL IGNITION POWER TRANSISTOR UNIT RADIATOR FAN RELAY...
Page 492 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Turbo> (CONTINUED) SOLENOID ENGINE CONTROL MODULE B-38 IGNI C-79 DATA LINK CONNECTOR SWITCH...
Page 493 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Turbo> (CALIFORNIA) FUSIBLE LINK@ BAT: 3 A-67 IOD OR STORAGE CONNECTOR m cu 4 D-15 A I R RELAY c-44 - - - - -...
Page 494 MULTIPORT FUEL INJECTION - Troubleshooting CIRCUIT DIAGRAM <Turbo> (CONTINUED) SWITC RELAY 7 C-82 6 D-44 D-04 COMB GAUGE c-34 D-09 D-03 I cu 7 .---_---_---------_ MODULE...
Page 495 MULTIPORT FUEL INJECTION . (F>O.85R $ VOLUME FLOW SENSOR FLOW SENSOR B-40 "6 "1 ---------- RIGHT BANK HEATED ENGINE THROTTLE B-05 OXYGEN SENSOR SENSOR B-44 (FRONT) =...
Page 496 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Turbo> (CONTINUED) RESISTOR A-69 IDLE SPE B-35 ------------------------ LEFT BANK HEATED OXYGEN SENSOR SENSOR...
Page 497 MULTIPORT fWEL INJECTION MULTI-PURPOSE FUSE@ UNIT STOP LIGHT SWITCH C-61 c-29 32 -5 11 .------ A-36 ACTIVE UNIT RADIATOR FAN TRANSISTOR RADIATOR FAN RELAY...
Page 498 MULTIPORT FUEL INJECTION CIRCUIT DIAGRAM <Turbo> (CONTINUED) EVAP PURGE SOLENOID SOLENOID 1 A-71 A-20 A-21 A-70 3 ~-----------___ ENGINE CONTROL MODULE MAGNET CLUTCH 1 ml A-18 1 B-38 TIMING DATA LINK CONNECTOR ADJUSTMENT CONNECTOR SWITCH...
Page 499 MULTIPORT FUEL INJECTION - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES BASIC IDLE SPEED ADJUSTMENT NOTE engine speed adjusting screw and does not normally require adjustment. (2) If adjustment has been disturbed, or if the idle speed is too high or it drops owing to application of air conditioning load to the engine, perform the following step to make adjust- ment.
Page 500 MULTIPORT FUEL INJECTION - Service Adjustment Procedures Harness) to ground the diagnostic test mode control terminal (terminal 0) of the data link connector (16-pin). (4) Remove the waterproof female connector from the ignition timing adjusting connector (brown). (5) Using a jumper wire, ground the ignition timing adjusting terminal.
Page 501 MULTIPORT FUEL INJECTION - Service Adjustment Procedures THROTTLE BODY (THROTTLE VALVE AREA) CLEANING ture rises to 80°C (176”F), and stop the engine. (2) Disconnect the air intake hose at the throttle body side. (3) Put a plug in the inlet of bypass passage in the throttle body.
Page 502 MULTIPORT FUEL INJECTION - Service Adjustment Procedures (3) Insert a 0.65-mm (.025 in.)-thick feeler gauge between the fixed SAS and throttle lever. (4) Loosen the throttle position sensor mounting bolts and turn the throttle position sensor body fully counterclockwise. (5) In this condition, check that there is continuity across terminals @ and @.
Page 503 MULTIPORT FUEL INJECTION - Service Adjustment Procedures ADJUSTMENT OF FIXED SAS NOTE (1) The fixed SAS has been factory-adjusted. Never attempt to move it. (2) Should it be out of proper adjustment, adjust by following the procedure given below. (1) Sufficiently slacken the accelerator cable. (2) Loosen the lock nut on the fixed SAS.
Page 504 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ON-VEHICLE INSPECTION OF MFI COMPONENTS <SOHC, Federal- Non Turbo, Canada-Non Turbo> COMPONENT LOCATION <SOHC> Name Symbol Name Symbol Air conditioning relay Ignition coil (ignition power transistor) Air conditioning switch Ignition timing adjusting terminal Camshaft ,position sensor and crankshaft Injector position sensor...
Page 505 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components r and e sensor) Throttle position ’ sensor (with built-in closed Vehicle speed sensor (reed switch)
Page 506 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Idle air control motor (stepper motor) Check engine/malfunction indicator lamp control terminal...
Page 507 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components nperature...
Page 508 MULTIPORT FUEL INJECTION - On Vehicle Inspection of MFI Components <DOHC> NOTE The “Name” column is in alphabetical order...
Page 509 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Engine coolant temperature sense Heated oxvqenl Vehicle speed sensor s e n s o r ‘- (reed switch,) DC motor) (with built-in air intake /...
Page 510 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Injector (Ignition power transistor) Air conditioning Check engine/malfunction indicator lamp Diagnostic output terminal and diagnostic test mode control terminal Engine control module...
Page 511 MULTIPORT FUEL IINJECTION Camshaft position sensor...
Page 512 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components COMPONENTS INSPECTION PROCEDURE USING SCAN TOOL abnormality is found, check the body harness, components, etc. and repair as necessary. (2) After repair, check again-with the scan tool to make sure that the input and output signals are now normal. (3) Erase the diagnostic trouble code in memory.
Page 513 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components POWER SUPPLY (MFI relay) AIND IGNITION SWITCH-IG Battery connector relay connector “ 3 “2 “6 Engine control module Engine control module connector OPERATION While the ignition switch is on, battery power is supplied to the engine control module, the injector, the volume air flow sensor, etc.
Page 514 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the ignition switch (IG) ter- Engine control minal input voltage. module harness side connector Engine control module connector: Disconnected Repair the Ignition switch I Voltage (V) harness. Measure the power supply voltage of the MFI relay.
Page 515 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components (1) Remove the MFI relay. (2) Check for continuity between MFI relay terminals. Terminal No. Continuity 5 - 7 Conductive (approx. 90 fi) 6 - 8 Conductive (only one direction) (3) Using jumper wires, connect terminal @ of MFI relay to battery 0 terminal and terminal @of MFI relay to battery 0 terminal.
Page 516 MULTIPORT FUEL NJECTION - On-Vehicle Inspection of MFI Components Engine control module connector OPERATION Grounds the engine control module TROUBLESHOOTING HINTS If the ground wire of the engine control module is not connected securely to ground, the module will not d operate correctly.
Page 517: Fuel Pump
MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components FUEL PUMP Ignition switch [IG] connector , MFI r e l a y connector connector connector Engine control check terminal module Engine control rnodule connector OPERATION The fuel pump is driven when the engine is cranking and while the engine is running. When the engine is cranking and whlile the engine is running, the engine control module turns the power transistor ON to supply power to thie MFI relay coil.
Page 518 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function Item No. Drive Check condition Check content Normal state A c t u a t o r t e s t 0 7 Fuel pump is Engine cranking Hold return hose with Pulsation is felt...
Page 519 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components Measure the power supply voltage of the MFI relay. Control relay connector: Discon- nected connector Check for an open-circuit, or a short- circuit to ground between the MFI relay and the engine control module. connector Engine control module connector: Disconnected...
Page 520 MULTIPORT FUEL INJECTION - On-Vehicle inspection of MFI Components VOLUME AIR FLOW SENSOR Volume air flow sensor Volume air flow sensor connector connector Engine control module Engine control module connector OPERATION The volume air flow sensor located in the air cleaner converts the engine intake air volume into a pulse signal of frequency proportional to the air volume and inputs it to the engine control module, which then computes the fuel injection rate, etc.
Page 521 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool <Volume Air Flow Sensor> Function Item No. m Check condition Engine state Standard value Data reading 700 rpm (Idle) 21-47 Hz <SOHC> perature: 80 to 95°C 22-48 Hz <DOHC> (176 to 205°F) 57 - 97 Hz <SOHC>...
Page 522 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. trol relay) or check the control relay. Measure the terminal voltage. Connector: Disconnected Ignition switch: ON Check for continuity,of the ground circuit. connector Connector: Disconnected Repair the Check for continuity between the volume air flow sensor and the engine...
Page 523 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INTAKE AIR TEMPERATURE SENSOR Volume air flow sensor (with built in intake air - t e m p e r a t u r e sensor and Temperature Temperature 1 6 2 4 5 5 162100 connector Volume air flow...
Page 524 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Function Item No. Data display Check condition Intake air temperature Standard value Data reading Sensor Ignition switch: ON or At -20°C (-4°F) -20°C temperature engine running At 0°C (32°F) (At 40°C (104°F) At 80°C (176°F) 80°C HARNESS INSPECTION...
Page 525 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components (3) Measure resistance while heating the sensor using a hair Intake air drier. Temperature [“C (“F)] Resistance (klR) Higher Smaller (4) If resistance does not decrease as heat increases or the resistance remains unchanged, replace the volume air flow sensor assembly.
Page 526 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components BAROMETRIC PRESSURE SENSOR connector Barometric pressure sensor Volume air flow sensor connector connector pressure se1 nsor Engine module A fj I Engine control module connector 0 ii - 760 Barometric pressure [mmHg (in.Hg)] (30) OPERATION The barometric pressure sensor converts the barometric pressure into a voltage and inputs it to the engine control module, which then corrects the fuel injection rate, etc.
Page 527 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components TROUBLESHOOTING HINTS Hint 1 : If the barometric pressure sensor is faulty, poor driveability is caused at high altitude, in particular. ‘Hint 2: If the pressure indication of the barometric pressure sensor drops significantly during high speed driving, check the air cleaner for clogging.
Page 528 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ENGINE COOLANT TEMPERATURE SENSOR Coolant temperature Coolant temperature 1621008 Engine coolant temperature sensor connector OPERATION The engine coolant temperature sensor converts the engine coolant temperature into a voltage and inputs it to the engine control module, which then controls the fuel injection rate and fast idle speed when the engine is cold based on the input signal.
Page 529 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function Item No. Data display Check condition Coolant temperature Standard value Data reading Sensor Ignition switch: ON or At -20°C (-4°F) temperature engine operating At 0°C (32°F) 20°C At 20°C (68°F) At 40°C (104°F)
Page 530 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components SENSOR INSPECTION intake manifold. (2) With temperature sensing portion of engine coolant d temperature sensor immersed in hot water, check resis- tance. Temperature “C (“F) Resistance (kR) 40 (104) 80 (176) 'b.3 (3) If the resistance deviates from the standard value greatly, replace the sensor.
Page 531 MULTIPORT FUEi INJECTION - On-Vehicle Inspection of MFI Components THROTTLE POSITION SENSOR Throttle position sensor connector connector Engine control module, Engine control module connector Throttle shaft turning angle OPERATION The throttle position sensor converts the throttle position opening into a voltage and inputs it to the engine control module, which then controls the fuel injection based on the input signal.
Page 532 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Item No. Data display Standard value Function Check condition Throttle valve 300 - 1,000 mV Data reading Sensor Ignition switch: left ON At idle position voltage for 15 seconds or more Increases with Open slowly valve opening...
Page 533 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components SENSOR INSPECTION Throttle position (1) Disconnect the throttle position sensor connector. sensor connector (2) Measure resistance between terminal @ (sensor ground) and terminal @ (sensor power). Standard value: 3.5 - 6.5 kin (3) Connect a pointer type ohmmeter between terminal @ (sensor ground) and terminal @ (sensor output).
Page 534 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components CLOSED THROTTLE POSITION SWITCH Engine control module Throttle position sensor (Closed throttle position switch mounted) ‘Y Closed throttle position connector connector Throttle shaft turning angle o’20g2 OPERATION The closed throttle position switch senses whether the accelerator pedal is depressed or not, converts it into high/low voltage and inputs the voltage to the engine control module, which then controls the idle air control motor based on the input signal.
Page 535 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the closed throttle position switch. Check for continuity of the ground circuit. Connector: Disconnected connector 6FU 1242 SENSOR INSPECTION the throttle valve lever or the fixed SAS is pushed. NOTE If it is not pushed, adjust the fixed SAS (Refer to P.l4A-67.) (2) Disconnect the throttle position sensor connector.
Page 536 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components CAMSHAFT POSITION SENSOR <SOHC> Distributor (with built-in camshaft position sensor) connector Engine control module Time OPERATION The camshaft position sensor senses the top dead center on compression stroke of the No. 1, converts it into a pulse signal and inputs it to the engine control module, which then controls the fuel injection sequence, etc.
Page 537 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Using Oscilloscope (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram, and check the waveform. Normal waveform HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Harness side Voltage (V)
Page 538 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Camshaft position sensor Camshaft position sensor connector Engine control module, Time Engine control module connector OPERATION The camshaft position sensor senses the top dead center on compression stroke, converts it into a pulse signal and inputs it to the engine control module, which then controls the fuel injection sequence, etc.
Page 539 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON connector Voltage (V) Repair the harness. relay Check for continuity of the ground circuit. Connector: Disconnected connector Repair the harness.
Page 540 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of CRANKSHAFT POSITION SENSOR <SOHC> MFI relav Output characteristic OPERATION The crankshaft position sensor senses the crank angle (piston position) of each cylinder, converts it into a pulse signal and inputs it to the engine control module, which then controls the engine speed and controls the fuel injection timing and ignition timing based on the input signal.
Page 541 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function tern No. Data display Check condition Check content Normal state Cranking Indicated speed Data reading Compare cranking speed to agree speed and scan tool reading (check on and off of primary current of ignition coil by tachometer)
Page 542 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected connector Voltage (V) Repair the relay Check for continuity of the ground circuit. Connector: Disconnected Check the voltage of the output cir- cuit.
Page 543 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components CRANKSHAFT POSITION SENSOR <DOHC> Crankshaft position sensor connector connector Engine control module Output characteristic Time Engine control module connector OPERATION Refer to P.l4A-104 Refer to P.l4A-104 INSPECTION Using Scan Tool Check content Normal state Check condition Function...
Page 544 MULTIPORT FUEL INJECTION - On-Vehicle inspection of MFI Components unction Item No. Data display 1 Check condition Data reading Idle speed Engine: Running at Closed throttle (At 40°C (104°F) (600 - 800 rpm Measure the power supply voltage. Connector: Disconnected connector Ignition switch: ON Voltage (V)
Page 545 MULTIPORT FUEL INJECTION - On-Vehicle .Inspection of MFI Components Ignition switch (ST) Engine control module connector Engine control module 1 FU0638 OPERATION The ignition switch-ST inputs a high signal to the engine control module while the engine is cranking. The engine control module provides fuel injection control, etc., at engine startup based on this signal.
Page 546 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Ignition switch (ST) connector relay terminal Engine control module Engine control module connector OPERATION The ignition switch-ST inputs a high signal to the engine control module while the engine is cranking. The engine control module provides fuel injection control, etc., at engine startup based on this signal.
Page 547 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components INSPECTION PARK/NEUTRAL POSITION SWITCH HARNESS INSPECTION Measure the power supply voltage. Engine control module connector: connector PNP switch connector: Discon- nected Ignition switch: START Check for continuity between the PNP switch and engine control module. Engine control module connector: Disconnected PNP switch connector: Discon-...
Page 548: Vehicle Speed Sensor
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components VEHICLE SPEED SENSOR Engine control module (reed switch) Speedometer connector Vehicle speed sensor voltage (V) Terminal connector module connector Engine control Vehicle speed [km/h (mph)] 1 6 2 4 5 1 OPERATION The vehicle speed sensor which is located in the speedometer converts the vehicle speed into a pulse signal and inputs it to the engine control module, which then provides the idle speed control, etc.
Page 549 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components . : “ ” ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ i ~ ~ ~ ~ ~ ~ c ted Measure the power supply voltage of Voltage (V) 4.5 - 4.9 Check for continuity of the ground Repair the...
Page 550 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Engine control module connector ON .- Pressure [kPa (psi)] OPERATION The power steering pressure switch converts presence/absence of power steering load into low/high voltage and inputs it to the engine control module, which then controls the idle air control motor based on this signal.
Page 551 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function Item No. Data display Check condition Steering wheel Normal’ indication Data reading Switch state Steering wheel neutral position (wheels straight-ahead direction) Steering wheel half turn Checking Oil Pressure Oil pump delivery pressure (ref.
Page 552 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components A I R CONDITIONING SWITCH AND Battery Air conditioning Air conditioning compressor lock control unit controller Dual pressure switch /compressor relav Air conditioning Engine control module compressor Engine control module connector NOTE DOHC “2:...
Page 553 MULTIPORT FUEL INJECTION - Components On-Vehicle Inspection of MFl AIR CONDITIONING POWER RELAY Function Air conditioning switch Normal indication Item No. Data display Check condition Data reading Air condi- Eingine: Idling after OFF (compressor tioning relay clutch non-activa- warm-up tion) state ON (compressor clutch activation)
Page 554 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components KNOCK SENSOR <DOHC> Engine control module connector Knock sensor connector Engine control module connector OPERATION The knock sensor generates a voltage proportional to the magnitude of cylinder block vibration due to knocking and inputs it to the engine control module.
Page 555 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Engine control Check for an open-circuit or a short- module harness circuit to ground, between the engine side connector control module and knock sensor. Knock sensor connector: Discon- Enaine control module connector: Repair the harness.
Page 556 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ELECTRICAL LOAD SWITCH <DOHC> Engine control module connector OPERATION The electrical load switch inputs ON/OFF state of the switch of equipment that consumes much power during idling, namely, equipment with a large electrical load, to the engine control module. Based on this signal, the engine control module controls the idle air control motor.
Page 557 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the input voltage of engine control module. Engine control module connector: Disconnected Lighting switch: ON (Tail light relay ON) Measure the input voltage of engine control module. Engine control module connector: Disconnected Defogger switch: ON (Defogger relay ON)
Page 558 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components FAN MOTOR RELAY (RADIATOR, AIR CONDITIONING CONDENSER) ‘condense; fan motor relay Ignition switch (IG) Air conditioner compressor lock controller Compressor NOTE E C M F Engine control module connector...
Page 559 MULTIPORT FUEL IINJECTION - On Vehicle Inspection of MFI Components OPERATION The engine control module controls the radiator fan motor and condenser fan motor according to the engine coolant temperature and vehicle speed via the power transistors (low speed side and high speed side) in the module.
Page 560 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INDUCTION CONTROL VALVE POSITION SENSOR <DOHC> Variable induction control motor (DC motor) connector (DC motor)(with built-in induction,/ Variable induction control valve position sensor) control motor connector Engine control OPERATION The induction control valve position sensor detects the induction control valve opening degree and converts it into a pulse signal to be input into the engine control module, which provides valve opening and closing control based on this signal.
Page 561 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the air intake control valve position sensor. Connector: Disconnected connector Ignition switch: ON Check for continuity of the ground circuit. Connector: Disconnected Harness side connector Repair the harness.
Page 562 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components EGR temperature sensor connector connector Engine control module T e m p e r a t u r e OPERATION The EGR temperature sensor converts the temperature of EGR gas downstream from the EGR valve to voltage and inputs it to the engine control module.
Page 563 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Item No. Data display Check condition Engine state Standard value Sensor Engine: Warmed up 700 rpm (Idle) 100°C (212°F) or less temperature Engine is maintained in a constant state for 3,500 rpm 120°C (248°F) or more 2 minutes or more...
Page 564 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HEATED OXYGEN SENSOR <Except California - SOHC> Heated oxvuen s e n s o r ‘- connector relay --I Theoretical A/F Engine control Engine control module connector OPERATION The heated oxygen sensor senses the oxygen concentration in exhaust gas, converts it into a voltage and inputs it to the engine control module.
Page 565 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components TROUBLESHOOTING HINTS Hint 1: Poor cleaning of exhaust gas will result if the heated oxygen sensor fails. troubles of parts related to air-fuel ratio control system are suspected. [Examples] (1) Faulty injector (2) Air leaking into the intake manifold through gasket gap, etc.
Page 566 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the heated oxygen sensor. Connector: Disconnected Ignition switch: ON tor: Disconnected Engine control module connector: Disconnected Connector: Disconnected...
Page 567 MULTIPORT FUEL IiNJECTION - On-Vehicle Inspection of MFI Components SENSOR VNSPECTION (2) Check that there is continuity [approx. 20 R at 20°C (68”F)l across terminals @ and @ of the heated oxygen sensor connector. (3) If there is no continuity, replace the heated oxygen sensor. (4) Warm up the engine until the engine coolant temperature becomes 80°C (176°F) or higher.
Page 568 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HEATED OXYGEN SENSOR <California - SOHC> Heated oxygen sensor Equipment side connector Harness side connector eoretical A/F Engine control module connector OPERATION Refer to P.l4A-128. TROUBLESHOOTING Refer to P.l4A-129.
Page 569 On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function tern No. Data display Check condition Engine condition Standard value Data reading When sudden 200 mV or lower (Make the mixture lean by engine deceleration speed reduction, and rich by from 4,000 rpm racing) 600 - 1 .OOO mV...
Page 570 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION connector connector Heated oxygen sensor connector: Disconnected Engine control module connector: Disconnected control module and the heated ox- Heated oxygen sensor connector: Disconnected Engine control module connector: Disconnected Check for continuity of the ground circuit.
Page 571 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components SENSOR INSPECTION connect the special tool, Test Harness, to the heated oxygen sensor connector. (2) Check that there is continuity [approx. 20 0 at 20°C (68”F)l across terminals @ and @ of the heated oxygen sensor connector.
Page 572 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components MFI relay Injector Nb.4 N o . 6 - for rear bank < S O H C > Injector for rear bank < S O H C > (for rear bank) (for r:ar bank)Y&,,a{ Engine control module Fuel...
Page 573 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components TROUBLESHOOTING HINTS Hint 1 : If the engine is hard to start when hot, check fuel pressure and check the injector for leaks. Hint 2: If the injector does not operate when the engine that is hard to start is cranked, the following as well as the injector itself may be responsible.
Page 574 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Function Item No. Drive content Check condition Normal state Actuator test No. 1 injector shut off Idle state to change Engine: Idling after warm-up further (becoming less No. 2 injector shut off (Shut off the injectors stable or stalling) in sequence during idling...
Page 575 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Check for an open-circuit, or a short- circuit between the front bank injector and the engine control module. Injector connector: Disconnected Engine control module connector: Disconnected Repair the Harness connector Check for an open-circuit, or a short- circuit between the rear bank injector and the engine control module.
Page 576 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components <DOHC> <DOHC> Measuring terminals Resistance Injector No. 13 - 16 R 1 - 2 No. 2 [ A t 20°C (68”F)] 1 - 3 No. 4 (3) Connect the injector intermediate connector.
Page 577 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components IDLE AIR CONTROL MOTOR (STEPPER MOTOR TYPE) connector connector Ball beanng -fTbMagnetlc rotor Ball bearing control module Throttle bodv seat Engine control module connector OPERATION The intake air volume during idling is, controlled by opening or closing the servo valve provided in the air path that bypasses the throttle valve.
Page 578 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function Item No. Data display Check condition Load state Standard value Data reading Stepper Engine coolant tem- 2 - 25 step motor steps perature: 80 to 95°C 205°F) .
Page 579 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of idle air control motor. Idle air control motor connector: Disconnected Ignition switch: ON connector 01 LO395 Engine control Check for an open-circuit, or a short- module harness circuit to ground between the engine connector...
Page 580 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Checking the Coil Resistance (1) Disconnect the idle air control motor connector and connect the special tool (test harness). (2) Measure the resistance between terminal @ (white clip of Id the special tool) and either terminal @ (red clip) or terminal Standard value: 28 - 33 IR at 20°C (68°F) (3) Measure the resistance between terminal @ (green clip of the special tool) and either terminal @ (yellow clip) or...
Page 581 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components (5) With the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.
Page 582 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components IGNITION COIL AND IGNITION POWER TRANSISTOR <SOHC> Ignition switch [IG] Ignition coil ,, 2 Equipment Distributor connector Spark No.1 No.4 No.2 No.5 No.3 No.6 terminal Engine control module Engine control module connector OPERATION When the ignition power transistor unit is switched ON by the signals from the engine control module, the primary current of the ignition coil will flow.
Page 583 MULTIPORT FUEL INJECTION - On-Vehicle inspection of MFI Components <Ignition timing adjustment mode> Function Item No. Data display Check Engine state Normal condition display Ground ignition timing Data list Existence of continuity Engine: Idling to ground if ignition adjustment terminal. timing adjustment Remove ground from terminal...
Page 584 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Check for continuity of the ground circuit of the ignition power transistor. connector Ignition power transistor connec- tor: Disconnected Engine control module connector: Disconnected Repair the Ground) 2.0 - 6.0 timing adjusting terminal. ACTUATOR INSPECTION Refer to Group 8 - Ignition System...
Page 585 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components IGNITION COIL AND IGNITION POWER TRANSISTOR <DOHC> Battery Ignition switch connector connector Spark Tachometer ment connector Engine control module 5 v- Engine control module connector OPERATION When the ignition power transistor unit A is turned on by the signal from the engine control module, primary current flows to the ignition coil A.
Page 586 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function Check condition Standard value Data reading Ignition Engine: Warming up 700 rpm (Idle) 7 - 23”BTDC advance Timing light: Set (set timing light to check 2,000 rpm 30 - 50”BTDC actual ignition timing) <Ignition Timing Adjustment Mode>...
Page 587 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the ignition coil. Connector: Disconnected Ignition switch: ON Repair the harness. tion switch) Measure the power supply voltage of the ignition coil. connector Connector: Disconnected Ignition switch: ON Voltage (V)
Page 588 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Check for continuity of the ground circuit. connector Connector: Disconnected Repair the harness. Ground) Measure the voltage of the control signal circuit of the ignition power transistor. Connector: Disconnected Ignition switch: START ACTUATOR INSPECTION Refer to GROUP 8 - Ignition System.
Page 589 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components EVAPORATIVE EMISSION PURGE SOLENOID connector Engine control module Engine control module connector OPERATION The evaporative emission purge solenoid is an ON-OFF type one which controls introduction of purge air from the canister into the intake ailr plenum. The battery power is supplied to the evaporative emission purge solenoid through the MFI relay.
Page 590 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Voltage (V) harness. Check for an open-circuit, or a short- circuit to ground between the eva- porative emission purge solenoid and the engine control module.
Page 591 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components EGR SOLENOID <California> MFI relay connector EGR solenoid Engine control module Engine control module connector OPERATION The EGR solenoid is a duty control type solenoid valve. It makes control by leaking EGR valve operating negative pressure to the throttle blody A port.
Page 592 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan tool Function Item No. Check condition Normal state Drive content Operating sound is heard Actuator test Change solenoid valve Ignition switch: ON when driven from OFF to ON state HARNESS INSPECTION Measure the power supply voltage.
Page 593 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components VARIABLE INDUCTION CONTROL MOTOR (DC MOTOR) <DOHC> Engine control module (DC motor)(with built-in induction ‘/ control valve position sensor) connector Variable induction control motor Engine control module connector OPERATION the DC motor is driven clockwise or counterclockwise by the signal from the engine control module, the variable induction valve opens or closes.
Page 594 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Engine control module Check for an open-circuit,or a short- harness side connector circuit to ground, between the engine control module and the variable induc- Variable induction control motor connector: Disconnected Engine control module connector: Disconnected connector...
Page 595 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ENGINE AND TRANSAXLE TOTAL CONTROL SIGNAL <A/T> Transaxle control module module Engine control Engine control module connector OPERATION Three communication lines are connected between the engine control module and the transaxle control module to send and receive the engine and transaxle total control signal.
Page 596 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Check for an open-circuit, or a short- module harness circuit to ground between the trans- OK -+ ‘axle control module and the engine module harness side control module. Transaxle control module connec- 0 tor: Disconnected Engine control module connector: Repair the...
Page 597 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components RELEASE OF RESIDUAL PRESSURE FROM HIGH Fuel gauge cover PRESSURE FUEL HOSE Make the following operations to release the pressure remain- ing in fuel pipe line so that fuel will not flow out. (2) Disconnect the fuel pump harness connector.
Page 598 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components FUEL PRESSURE TEST (2) Disconnect the fuel high pressure hose at the fuel rail side. of fuel that could be caused by some residual pressure in the fuel pipe line. (3) Set a fuel pressure gauge on the special tool, placing an adequate O-ring or gasket between the gauge and special tool prevent fuel leaks.
Page 599 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components regulator, and then measure the fuel pressure while using a finger to plug the end of the hose. Standard value: 330 - 350 kPa (47 - 50 psi) at curb idle not decrease even after the engine is raced a few times.
Page 600 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components indicated by the fuel pressure gauge. The condition is normal if there is no decrease of the indicated value within two minutes. If there is a decrease of the indicated value, monitor the , speed of the decrease, and, referring to the table below, d determine the cause of the problem and make the appropriate repair.
Page 601 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components ENGINE CONTROL MODULE (ECM) TERMINAL VOLTAGES INSPECTION (1) Connect a very thin wire probe (such as a paper clip) to the probe of the voltmeter. (2) Insert the very thin probe from the wire side into contact with each of the terminals of the ECM connector and check the voltage, while referring to the check chart.
Page 602 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Engine: Idle Volume air flow sensor Engine: 2,000 rpm Volume air flow sensor Engine: idle O - I V reset signal Engine: 3,000 rpm Intake air tempera- Ignition switch: When intake temperature...
Page 603 MULTIPORT FUEL INJECTION - On Vehicle Inspection of MFI Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Vehicle speed sensor (Changes repeated) Power steering Engine: Steering wheel placed in neutral pressure switch Idle, (straight ahead) position warm Steering wheel turned half a turn 0 ~ 3V...
Page 604 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Stepper motor coil Engine: warm < A l > Check immediately after hot restart. Stepper motor coil (Changed repeated) Stepper motor coil Stepper motor coil Ignition power Engine: 3,000 rpm...
Page 605 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Induction control valve Ignition switch: ON DOHC position sensor No. 2 4.5 - 5.5v Engine: Slowly accelerated from idling 0 - IVor speed to 5,000 rpm 4.5 - 5.5v (for a moment)
Page 606 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ON-VEHICLE INSPECTION OF MFI COMPONENTS <California - DOHC Non Turbo, Turbo> COMPONENT LOCATION NOTE The “Name” column is in alphabetical order.
Page 607 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Volume air flow sensor (with built-in intake air bardmetric pressure sensor)1 temperature sensor Non Turbo%!! I?!& Vehicle speed sensor (reed switch) Air conditioninq switch...
Page 608 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components DC motor) (with built-in air intake Injector Check engine/malfunction indicator lamp...
Page 609 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Engine control / D i a g n o s t i c o u t p u t t e r m i n a l a n d module diagnostic test mode control .terminal Camshaft position sensor...
Page 610: Components Inspection Procedure
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components COMPONENTS INSPECTION PROCEDURE USING SCAN TOOL . Refer to P.l4A-76. I ‘OWER SUPPLY (MFI RELAY) AND IGNITION SWITCH-IG Battery , I g n i t i o n s w i t c h llG1 connector relay Engine control module...
Page 611 MULTIPORT FUEL INJECTION - On-Vehicle inspection of MFI Components HARNESS INSPECTION Measure the ignition switch (IG) ter- Engine control minal input voltage. module harness side connector Engine control module connector: Disconnected Repair the Ignition switch Voltage (V) harness. switch 01 LO427 Measure the power supply voltage of the MFI relay.
Page 612 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Measure power voltage to the actuator. MFI relay connector: Connected Engine control module connector: Connected Racing MFI RELAY INSPECTION Refer to P.l4A-79...
Page 613 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ENGINE CONTROL MODULE POWER GROUND Engine control module Engine control module connector OPERATION Refer to 14A-80. TROUBLESHOOTING HINTS Refer to 14A-80. HARNESS INSPECTION Refer to 14A-80.
Page 614 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components FUEL PUMP <Non Turbo> Fuel pump connector Ignition swtich [IG] connector side connector connector Engine control module connector OPERATION Refer to 14A-81. INSPECTION Refer to 14A-82. HARNESS INSPECTION Refer to 14A-82. MFI RELAY INSPECTION Refer to 14A-79.
Page 615 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components FUEL PUMP <Turbo> Ignition switch [IG] Equipment side connector Equipment side connector connector Fuel pump relay II Fuel pump I I,‘I- check terminal Engine control Engine control module connector module...
Page 616 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components OPERATION Refer to 14A-81. INSPECTION Refer to 14A-82. HARNESS INSPECTION Check the fuel pump. Apply battery voltage to the checking terminal and operate the Check the ground circuit of the fuel Fuel pump connector: Discon- nected Repair the...
Page 617 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Engine control Check for an open-circuit, or a short- module harness circuit to ground, between the fuel side connector pump relay II and the engine control module. Fuel pump relay II connector: Disconnected Engine control module connector: Disconnected...
Page 618 MULTIPORT FUEL INJECTlON - On-Vehicle Inspection of MFI Components Check for an open-circuit, or a short- circuit to ground, between the fuel pump relay II and the fuel pump. Fuel pump relay II connector: Disconnected Fuel pump connector: Discon- nected Repair the harness.
Page 619 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components (2) Measure the resistance between the terminals. Standard value: 0.6 - 0.9 IR (3) If the resistance deviates from the standard value, replace the fuel pump circuit resistor. VOLUME AIR FLOW SENSOR Volume air flow sensor Volume air flow sensor connector...
Page 620 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool <Volume Air Flow Sensor> Function Item No. Data display Check condition Engine state Standard value Data reading Sensor air Engine coolant tem- 700 rpm (Idle) 22-48 perature: 80 to 95°C’ [frequency) (176 to 205°F) 2,000 rpm...
Page 621 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the harness trol relay) or check the control relay. Measure the terminal voltage. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the 4.8 - 5.2...
Page 622 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INTAKE AIR TEMPERATURE SENSOR Volume air flow sensor ith built in intake air Temperature Temperature - connector Volume air flow Intake air sensor connector temperature sensor connector OPERATION Refer to P.l4A-87. TROUBLESHOOTING HINTS Refer to P.l4A-87.
Page 623 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Check for continuity of the ground Connector: Disconnected Repair the harness. Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Voltage (V) 4.5 - 4.9 Repair the harness. SENSOR INSPECTION Refer to P.l4A-88.
Page 624 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components BAROMETRIC PRESSURE SENSOR Volume air flow sensor (with built-in intake air temperature sensor connector Barometric pressure sensor Volume air flow sensor connector connector pressure sensor Engine control module A Output voltage (VI Engine control module connector Barometric pressure [mmHg (in.Hg)] (30) OPERATION...
Page 625 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION connector Connector: Disconnected Repair the harness. Measure the power supply voltage of the barometric pressure sensor. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the 4.8 - 5.2 harness. 7FU066.5 Engine control Check for an open-circuit, or a short-...
Page 626: Engine Coolant Temperature Sensor
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ENGINE COOLANT TEMPERATURE SENSOR Coolant temperature Coolant temperature oolant temperature sensor side connector Engine control module OPERATION Refer to P.l4A-92. TROUBLESHOOTING HINTS Refer to P.l4A-92. INSPECTION Refer to P.l4A-93.
Page 627 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Check for continuity of the ground circuit. Engine coolant temperature sen- sor connector: Disconnected Repair the Measure the impressed voltage. Engine coolant temperature sen- sor connector: Disconnected Engine control module connector: Connected Ignition switch: ON Repair the...
Page 628: Throttle Position Sensor
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components THROTTLE POSITION SENSOR Throttle position sensor connector connector “ “ 2 Engine control module,, 92 Engine control module connector Throttle shaft turning angle 162461 OPERATION Refer to P.l4A-95. TROUBLESHOOTING HINTS Refer to P.l4A-95. INSPECTION Refer to P.l4A-96.
Page 629 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the throttle position sensor. Connector: Disconnected Ignition switch: ON Connector: Disconnected Check for an open-circuit, or a short- circuit to ground between the engine control module and the throttle posi- tion sensor.
Page 630 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components CLOSED THROTTLE POSITION SWITCH Engine control module Throttle position se (Closed throttle position switchzunted) Closed throttle position connector Throttle shaft turning angle o’20s2 OPERATION Refer to P.l4A-98. TROUBLESHOOTING HINTS Refer to P.l4A-98. INSPECTION Refer to P.l4A-98.
Page 631 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the closed throttle position switch. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the 4 or more harness. Check for continuity of the ground circuit.
Page 632: Camshaft Position Sensor
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components CAMSHAFT POSITION SENSOR Camshaft position sensor MFI relay Camshaft position sensor connector sensor connector Engine control module 5 ” Engine control module connector OPERATION Refer to P.l4A-100. TROUBLESHOOTING HINTS Refer to P.l4A-100. INSPECTION Refer to P.l4A-101...
Page 633 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON side connector Voltage (V) circuit. Connector: Disconnected connector Repair the harness. Measure the impressed voltage. Connector: Disconnected connector Ignition switch: ON Voltage (V) 4.8 - 5.2 Repair the...
Page 634: Crankshaft Position Sensor
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components CRANKSHAFT POSITION SENSOR Crankshaft position sensor connector connector I [“It Output characteristic Engine control module connector OPERATION Refer to P.l4A-104. TROUBLESHOOTING HINTS Refer to P.l4A-104.
Page 635 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Normal state Item No. Data display Check content Function Check condition Cranking Compare cranking speed Indicated speed Data reading to agree speed (check on and off of primary current of ignition coil by tachometer)
Page 636 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Check for continuity of the ground circuit. Connector: Disconnected Repair the Ground) Measure the impressed voltage. Connector: Disconnected Ignition switch: ON Voltage (V) 4.8 - 5.2 Repair the...
Page 637 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Ignition switch (ST) IGNITION SWITCH-ST <M/T> Engine control module connector 1 FU0638 OPERATION Refer to P.l4A-109. INSPECTION Refer to P.l4A-109. HARNESS INSPECTION control Engine Measure the input voltage to the engine control module. Engine control module connector: Disconnected Ignition switch: START...
Page 638 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH (PNP SWITCH) <A/T> Ignition switch (ST) connector Engine control module Engine control module connector OPERATION Refer to P.l4A-110. TROUBLESHOOTING HINTS Refer to P.l4A-110.
Page 639 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Refer to P.l4A-111. HARNESS INSPECTION Measure the power supply voltage. Engine control module connector: Disconnected PNP switch connector: Discon- Ignition switch: START Check the circuit. Check for continuity between the PNP switch and engine control module.
Page 640 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components VEHICLE SPEED SENSOR <Non Turbo> Vehicle sDeed sensor Engine control module Terminal voltage (V) Engine control module connector 162451 OPERATION Refer to P.l4A-112. TROUBLESHOOTING HINTS Refer to P.l4A-112.
Page 641 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the vehicle speed sensor. Connector: Disconnected Ignition switch: ON Check for continuity of the ground circuit. Connector: Disconnected Repair the Ground) SENSOR INSPECTION Refer to GROUP 8 - Meters and Gauges.
Page 642 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components VEHICLE SPEED SENSOR <Turbo> Ignition switch [IG] Engine control module Vehicle speed sensor Terminal voltage (V) Engine control module connector Vehicle speed [km/h (mph)] 162451 OPERATION The vehicle speed sensor is directly attached to the speedometer driven gear in the transmission. It detects the vehicle speed and sends it to the engine control module after converting to pulse signals, based on which the engine control module controls the idle speed control motor.
Page 643 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure line voltage applied to vehi- cle speed sensor. Connector: Disconnected Harness side Ignition switch: ON connector Voltage (V) Check the vehicle speed sensor out- Engine control module connector: Disconnected Ignition switch: ON Move the vehicle...
Page 644: Power Steering Pressure Switch
MULTIPORT FUEL INJECTION - On Vehicle Inspection of MFI Components POWER STEERING PRESSURE SWITCH Engine control module connector OFF , Pressure [kPa (PSI)] OPERATION Refer to P.l4A-114. INSPECTION Refer to P.l4A-115 HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected connector SENSOR INSPECTION Refer to GROUP 19 - Service Adjustment Procedures.
Page 645 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components AIR CONDITIONING SWITCH AND COMPRESSER CLUTCH RELAY Battery Air conditioning Air conditioning compressor lock control unit controller Air conditioning compressor Engine control module Engine control module connector OPERATION Refer to P.l4A-116. TROUBLESHOOTING HINTS Refer to P.l4A-116.
Page 646 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components KNOCK SENSOR Engine control module connector Knock sensor connector Engine control module connector OPERATION Refer to P.l4A-118. TROUBLESHOOTING HINTS Refer to P.l4A-118.
Page 647 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Check for an open-circuit or a short- circuit to ground, between the engine side connector control module and knock sensor. Knock sensor connector: Discon- Engine control module connector: Engine control module connector: Disconnected Disconnected Repair the...
Page 648: Electrical Load Switch
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ELECTRICAL LOAD SWITCH Engine control module connector Engine control module OPERATION Refer to P.l4A-120. INSPECTION Refer to P.l4A-120. HARNESS INSPECTION Refer to P.l4A-121.
Page 649 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components FAN MOTOR RELAY (RADIATOR, AIR CONDITIONER CONDENSER) Ignition switch - IG Battery Air conditioner compressor lock controller compressor elay Resistor Condenser fan motor 21 - Engine control module connector...
Page 650 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components OPERATION Refer to P.l4A-123. INSPECTION Refer to P.l4A-123. HARNESS INSPECTION Measure input voltage applied to ECM. ECM connector: Disconnected Ignition switch: ON STOP Check the fan motor re- lay circuit. FAN MOTOR RELAY INSPECTION Refer to Radiator Check in GROUP 7 and Power Relay Check in GROUP 24.
Page 651 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Normal display Muffler mode changeove Check condition Function Item No. Data display switch condition Turn to TOUR mode Ignition switch: ON Turn to SPORT mode HARNESS INSPECTION Measure the power supply voltage.
Page 652 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INDUCTION CONTROL VALVE POSITION SENSOR <Non Turbo> Variable induction control motor (DC motor) Induction control valve connector Variable induction control motor connector OPERATION Refer to P.l4A-124.
Page 653 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the air intake control valve position sensor. connector Connector: Disconnected Ignition switch: ON Voltage (V) Repair the harness. Check for continuity of the ground circuit.
Page 654 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components EGR TEMPERATURE SENSOR EGR temperature sensor connector ature sensor connector Engine control module Temperature OPERATION Refer to P.l4A-126. INSPECTION Refer to P.l4A-127.
Page 655 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the Check for continuity of the ground circuit. Connector: Disconnected Repair the SENSOR INSPECTION Refer to GROUP 25 - Exhaust Gas Recirculation (EGR) System.
Page 656 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HEATED OXYGEN SENSOR <California - Non Turbo> Heated oxyqen sensor Equipment side ‘connector Harness side connector Theoretical A/F 60 7 Engine control module connector OPERATION Refer to P.l4A-128. TROUBLESHOOTING Refer to P.l4A-129. INSPECTION Refer to P.l4A-129.
Page 657 On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the heated oxygen sensor. Connector: Disconnected connector Ignition switch: ON Repair the harness. MFI relay) Check for an open-circuit, or a short- circuit to ground, between the engine control module and the heated ox- ygen sensor.
Page 658 On-Vehicle Inspection of MFI Components connector Theoretical A/F connector connector Engine control module connector OPERATION Refer to P.l4A-128. TROUBLESHOOTING Refer to P.l4A-129. INSPECTION Refer to P.l4A-129.
Page 659 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the heated oxygen sensor. Ignition switch: ON Voltage (V) Repair the Check for an open-circuit, or a short- circuit to ground, between the engine control module and the heated ox- ygen sensor.
Page 660 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HEATED OXYGEN SENSOR <California - Turbo> Equipment side connector Harness side connector Theoretical A/F Engine control module connector OPERATION Refer to P.l4A-128. TROUBLESHOOTING Refer to P.l4A-129. INSPECTION Using Scan Tool <Heated Oxygen Sensor (front)> Function Item No.
Page 661 MULTIPORT FUEL INJECTION - On Vehicle Inspection of MFI Components <Heated Oxygen Sensor (iear)> Engine state Standard value 3,500 rpm Measure the power supply voltage of the heated oxygen sensor. Harness side Connector: Disconnected connector Ignition switch: ON Voltage (V) Check for an open-circuit, or a short- module harnes: circuit to ground, between the engine...
Page 662 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Check for continuity of the ground circuit. Connector: Disconnected Repair the harness. Ground) SENSOR INSPECTION Refer to P.l4A-135. INSTALLATION Refer to P.l4A-135.
Page 663 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INJECTORS <Non Turbo> Injector for rear bank Connector for Engine control module Fuel Engine control module connector OPERATION Refer to P.l4A-136. TROUBLESHOOTING HINTS Refer to P.l4A-137.
Page 664 MULTIPORT FUEL INJECTION - On Vehicle Inspection of MFI Components INSPECTION Using Scan Tool Function Item No. Data display Check condition Standard value Coolant temperature Data reading Drive time*’ Engine: Cranking 0°C (32”F)*’ 40 - 48.8 ms 20°C (68°F) 8.6 - 10.6 ms 80°C (176°F) Engine state Standard value...
Page 665 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INJECTORS <Turbo> connector MFI relav Resistor I - - - - Rear bank connector Injector No. 2 Injector Injector No. 1 No.5 Engine control module connector Fuel Filter Injection OPERATION Refer to P.l4A-136. TROUBLESHOOTING HINTS Refer to P.l4A-137.
Page 666 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INSPECTION I Jsing Scan Tool Function Item No. Data display Check condition Standard value Coolant temperature Data Drive time*’ Engine: Cranking 8.8 - 10.8 reading 20°C (68°F) 25.6-31.2 ms 80°C (176°F) 5.5 - 6.7 ms Function Item No.
Page 667 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ACTUATOR INSPECTION INJECTORS Measurement of Resistance between Front Bank Termi- nals (2) Measure the resistance between terminals. Standard value: 2 - 3 fl [at 20°C (68”F)] (3) Reconnect the injector connector. Measurement of Resistance between Rear Bank Terminals (2) Measure the resistance between terminals.
Page 668 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components IDLE AIR CONTROL MOTOR (STEPPER MOTOR TYPE) connector connector Ball bearlna Throttle body seat Enaine control module connector OPERATION Refer to P.l4A-141. TROUBLESHOOTING HINTS Refer to P.l4A-141. INSPECTION Refer to P.l4A-142 HARNESS INSPECTION Refer to P.l4A-143.
Page 669: Ignition Coil And Ignition Power Transistor
MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components IGNITION COIL AND IGNITION POWER TRANSISTOR Battery Ignition switch Ignition coil connector Engine speed check control Equipment side connector Spark No. 2 No. 3 No 6 Tachonieter adjust- ment connector Engine control Enaine control module connector OPERATION Refer to P.l4A-149.
Page 670 MULTIPORT FUEL INJECTION - On Vehicle Inspection of MFI Components I N S P E C T I O N Using Scan Tool <Spark Advance> Function Item No. Data display Check condition Engine state Standard value Data reading Ignition Engine: Warming up 700 rpm (Idle) 7 - 23”BTDC advance...
Page 671 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the ignition coil. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the harness. tion switch) 01 LO4,ll Measure the power supply voltage of the ignition coil.
Page 672 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Check for continuity of the ground circuit, Connector: Disconnected connector Repair the harness. Ground) Measure the voltage of the control signal circuit of the ignition power transistor. Connector: Disconnected Ignition switch: START Measure the voltage of the ignition adjustment timing adjustment terminal.
Page 673 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components EVAPORATIVE EMISSION PURGE SOLENOID MFI relay connector Connector Engine control module Engine control module connector OPERATION Refer to P.l4A-153. INSPECTION Refer to P.l4A-153. HARNESS INSPECTION Refer to P.l4A-154. ACTUATOR INSPECTION Refer to GROUP 25 - Evaporative Emission Control System.
Page 674: Egr Solenoid
MULTIPORT FUEL INJECTION - On-Vehicle inspection of MFI Components EGR SOLENOID connector EGR solenoid Engine control module Engine control module connector OPERATION Refer to P.l4A-155. TROUBLESHOOTING HINT Refer to P.l4A-155. INSPECTION Refer to P.l4A-156. HARNESS INSPECTION Refer to P.l4A-156. ACTUATOR INSPECTION Refer to GROUP 25 - Exhaust Gas Recirculation (EGR) System.
Page 675 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components FUEL PRESSURE SOLENOID <Turbo> Fuel pressure solenoid Engine control module Engine control module connector OPERATION The fuel pressure solenoid is an ON-OFF type solenoid valve that switches the pressure introduced to the fuel pressure regulator between either intake manifold pressure or barometric pressure.
Page 676 MULTIPORT FUEL INJECTION - On Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON connector Check for an open-circuit, or a short- harness side connector Fuel pressure solenoid connector: Repair the Disconnected ACTUATOR INSPECTION Operation Check NOTE...
Page 677 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Coil Resistance Check Standard value: 36 - 46 R [at 20°C (68”F)] TURBOCHARGER WASTE GATE SOLENOID <Turbo> MFI relav Turbocharger waste 1 gate solenoid connector Engine control module Engine control module connector OPERATION The turbocharger waste gate solenoid is an ON-OFF type solenoid valve that controls the boost pressure that is introduced to the turbocharger waste gate actuator.
Page 678 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components TROUBLESHOOTING HINTS If the turbocharger waste gate solenoid harness and the unit itself are normal, but poor acceleration or other abnormalities are experienced, the follwing problems are suspected. (1) Faulty boost pressure control system (2) Poor connection of intake air hose (3) Faulty turbocharger or turbocharger waste gate actuator (4) Clogged exhaust system...
Page 679 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components BOOST METER <Turbo> Ignition switch (IG,) connector Boost meter Engine control module connector...
Page 680 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON tion coil [IGI) Engine control module Check for an open-circuit or a short- harness side connector circuit to ground, between the engine control module and the boost meter.
Page 681 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components ACTIVE EXHAUST CONTROL 1JNlT <Turbo> DC motor for valve drive Active connector exhaust control unit DC motor Engine control module connector OPERATION Muffler noise is controlled by opening and closing the valve provided inside the main muffler. The valve is opened or closed by turning the DC motor in the normal or reverse direction.
Page 682 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components VARIABLE INDUCTION CONTROL MOTOR (DC MOTOR) <Non Turbo> Engine control module (DC motor)(with built-in induction ‘/ control valve position sensor) Close Open connector Variable induction control motor OPERATION Refer to P.l4A-157. INSPECTION Refer to P.l4A-157.
Page 683 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components ANTI-LOCK BRAKING SIGNAL <Turbo> ABS ECU equipment side connector Engine control module connector OPERATION The anti-lock braking signal is input to the engine control module from the anti-lock braking system (ABS) control module as a signal to indicate whether or not the motor relay is activated.
Page 684 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ENGINE AND TRANSAXLE TOTAL CONTROL SIGNAL <A/T> Engine control module ‘Engine control module connector OPERATION Three communication lines are connected between the engine control module and the transaxle control module to send and receive the engine and transaxle total control signal. If the transistor inside the engine control module changes from OFF to ON by the command of the engine control module, the terminal having a voltage of 5 V applied to it from the transaxle control module is grounded in the engine control module.
Page 685 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Check for an open-circuit, or a short- circuit to ground between the trans- axle control module and the engine control module. Transaxle control module connec- , tor: Disconnected Engine control module connector: Repair the Disconnected Check for an open-circuit, or a short-...
Page 686: Fuel Pump Operation Check
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components RELEASE OF RESIDUAL PRESSURE FROM HIGH Fuel qauqe cover PRESSURE FUEL HOSE Make the following operations to release the pressure remain- ing in fuel pipe line so that fuel will not flow out. (2) Disconnect the fuel pump harness connector.
Page 687: Fuel Pressure Test
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components FUEL PRESSURE TEST (2) Disconnect the fuel high pressure hose at the fuel rail side. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 688 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components (9) Disconnect the vacuum hose from the fuel pressure regulator, and then measure the fuel pressure while using a finger to plug the end of the hose. Standard value: 295 - 315 kPa (43 - 45 psi) at curb idle not decrease even after the engine is raced a few times.
Page 689 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components (13)Stop the engine and check for a change of the value indicated by the fuel pressure gauge. The condition is normal if there is no decrease of the indicated value within two minutes.
Page 690 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components ENGINE CONTROL MODULE (ECM) TERMINAL VOLTAGES INSPECTION (1) Connect a very thin wire probe (such as a paper clip) to the probe of the voltmeter. (2) Insert the very thin probe from the wire side into contact with each of the terminals of the ECM connector and check the voltage, while referring to the check chart.
Page 691 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components Terminal No. Check point Volume air flow sensor Volume air flow sensor reset signal Intake air tempera- hen intake temperature ture sensor Barometric pressure sensor Water temperature sensor Throttle position sensor Closed throttle position switch Camshaft position...
Page 692 On-Vehicle lnsoection of MFI Comoonents Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Vehicle speed sensor Ignition switch: ON Move the vehicle slowly forward (Changes repeated) Power steering Engine: Steering wheel placed in neutral pressure switch Idle, (straight ahead) position warm 0 - 3V...
Page 693 MULTIPORT FUEL IINJECTION - On-Vehicle Inspection of MFI Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Stepper motor coil Engine: Warm <Al > Check immediately after hot restart. Stepper motor coil (Changed repeated) Stepper motor coil Stepper motor coil Ignition power Engine speed: 3,000 rpm...
Page 694 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Check engine/malfunc- Ignition switch: OFF + ON o - 3 v tion indicator lamp (Several seconds later) EGR solenoid Ignition switch: ON Engine: Idle.
Page 695 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components Check point Check conditions (Engine conditions) Standard value Remarks Total control Engine: Idle O - I V “Reduce torque” request signal 2 Engine: Running at idle after warmup and 1 - 5.5v changing speeds Total control Engine: Running at idle with coolant tempera- 0 - IV...
Page 696 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components INJECTOR REMOVAL AND INSTALLATION I O - 1 3 N m <SOHC> Pre-removal Operation Draining of the Coolant (Refer to GROUP 0 - Maintenance Service.) Removal of Air Intake Manifold Plenum Release of Residual Pressure from High Pressure Hose.
Page 697 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components SERVICE POINT OF REMOVAL 1. DISCONNECTION OF HIGH PRESSURE FUEL HOSE Bleed the residual pressure within the fuel pipe line so as to prevent the flow of fuel. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 698: Throttle Body
MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying of Engine Coolant (Refer to GROUP 0 - Maintenance Service.) <SOHC-California> <DOHC (Non Turbo) - Federal, <DOHC (Non Turbo) -California> Canada>...
Page 699 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components DISASSEMBLY AND REASSEMBLY 3.5 Nm 2.5 ft.lbs. Disassembly steps 2. Throttle position sensor (within closed throttle position switch) 3. Idle air control motor assembly 4. Throttle body SERVICE POINTS OF DISASSEMBLY Caution 1.
Page 700 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components CLEANING THROTTLE BODY PARTS (1) Clean all throttle body parts. Do not use solvent to clean the following parts: Throttle position sensor (closed throttle position switch) Idle air control motor If these parts are immersed in solvent, their insulation will deteriorate.
Page 701 MULTIPORT FUEL INJECTION - On-Vehicle Inspection of MFI Components KNOCK SENSOR REMOVAL AND INSTALLATION Removal and Installation of the Intake Manifold Plenum Removal and Installation of the Intake Manifold Removal steps Knock sensor SERVICE POINT OF REMOVAL 1. REMOVAL OF KNOCK SENSOR SERVICE POINT OF INSTALLATION 1.
Page 703 FUEL SUPPLY ENGINE CONTROL CONTENTS ..........12 SERVICE ADJUSTMENT PROCEDURES .
Page 704 Specifications / FUEL SUPPLY AND ENGINE CONTROL SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Fuel Tank capacity 75 (19.8) Return system Equipped Filter High pressure type SERVICE SPECIFICATIONS Items Specifications Standard value mm (in.) Accelerator cable play <M/T> 1 - 2 (.04 - .08) 3 - 5 (.
Page 705 Troubleshooting I FUEL SUPPLY AND ENGINE CONTROL FUEL TANK AND FUEL LINE Probable cause Remedy Symptom Bent or kinked fuel pipe or hose Repair or replace Engine malfunctions due to insufficient Clean or replace fuel supply Clogged fuel pipe or hose Clogged fuel filter or in-tank fuel filter Replace Water in fuel filter...
Page 706: Fuel Tank
FUEL SUPPLY AND ENGINE CONTROL - Fuel Tank FUEL TANK REMOVAL AND INSTALLATION Release of Residual Pressure from 8 ft.lbs. -----@a 26 Nm 19 ftlbs. Removal steps 1. Fuel gauge cover 2. Fuel pump and fuel gauge unit assembly connector 3.
Page 707 FUEL SUPPLY AND ENGINE CONTROL - Fuel Tank SERVICE POINT OF REMOVAL 12. DISCONNECTION OF HIGH PRESSURE FUEL HOSE Disconnect the hose from body main pipe first and then from fuel pump. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 708 FUEL SUPPLY AND ENGINE CONTROL - Fuel Tank 17. INSTALLATION OF FUEL TANK PRESSURE CONTROL VALVE Install so that the fuel tank pressure control valve is facing in the direction shown in the illustration. Evaporative e canister side DO3041 12. CONNECTION OF HIGH PRESSURE FUEL HOSE Temporarily tighten the flare nut by hand, and then tighten it Flare nut to the specified torque, being careful that the high pressure...
Page 709 FUEL SUPPLY AND ENGINE CONTROL FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY AND FUEL TANK PRESSURE CONTROL VALVE REMOVAL AND INSTALLATION Post-installation Operation 30 Pirn Removal steps 1. Fuel gauge cover 2. Fuel pump and fuel gauge unit assembly connector W I)4 4.
Page 710 Fuel Pump and Fuel Gauge Unit Assembly AND ENGINE CONTROL FUEL TANK PRESSURE CONTROL VALVE REPLACEMENT Connect a clean rubber hose to the fuel tank pressure control Fuel tank txessure valve and check for operation. Inspection procedure Normal condition Lightly blow from the inlet Air passes through after a (fuel tank) side slight resistance...
Page 711: Fuel Line And Vapor Line
FUEL SUPPLY AND ENGINE CONTROL - Fuel Line and Vapor Line FUEL LINE AND VAPOR LINE REMOVAL AND INSTALLATION Pre-removal Operation Release of Residual Pressure from High Pressure Hose. Removal of the Air Cleaner and Air Intake Hose (Refer to GROUP 11 -Air Cleaner.) Checking for Fuel Leakage 30 Nm Removal steps...
Page 712 FUEL SUPPLY AND ENGINE CONTROL SERVICE POINTS OF REMOVAL 9. 13. REMOVAL OF EYE BOLT Remove the eye bolt while holding the fuel filter nut securely. Caution Cover the hose connection with rags to prevent splash in the fuel pipe line. INSPECTION Check the hoses and pipes for cracks, bend, deformation and clogging.
Page 713: Fuel Filter
FUEL SUPPLY AND ENGINE CONTROL - Fuel Filter FUEL FILTER REMOVAL AND INSTALLATION Release of Residual Pressure from Post-installation Operation Checking for Fuel Leakage Removal steps 1. Battery Eye bolt 4. Gasket 5. High pressure fuel hose 6. Connection of fuel main pipe 7.
Page 714: Engine Control
FUEL SUPPLY AND ENGINE CONTROL - Engine Control ENGINE CONTROL REMOVAL AND INSTALLATION Grease: MOPAR Multi-mileage Lubricant Pat-t No. 2525035 or equivalent 7 ft.lbs. Removal steps 2. Connection of throttle body side inner cable 3. Bushing 4. Accelerator cable 5. Accelerator pedal 6.
Page 715 SPECIAL TOOL ........... . CRUISE CONTROL SYSTEM* .
Page 716: Specifications
CRUISE CONTROL SYSTEM - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Main switch Rated load A 0.1 or less Voltage drop V Auto-cruise control switch Rated load mA RESUME CANCEL Stop light switch (for cruise control) 0.1 -0.9 Rated load A 0.15 or less Voltage drop (at rated load) Clutch switch...
Page 717: Troubleshooting
CRUISE CONTROL SYSTEM - Special Tool / Troubleshooting SPECIAL TOOL Tool number and tool name Checking of the diagnostic output Inspection of cruise control system using MB991 529 MB99 1529 a voltmeter Diagnostic trouble code check harness TROUBLESHOOTING PRELIMINARY INSPECTION and repair defective points, if any, before troubleshooting.
Page 718 CRUISE CONTROL SYSTEM NOTE Cruise control system cannot be set. This chart contains troubleshooting procedures to perform when a problem cannot be detected by on-board diagnostic. Check input. (Refer to P.l4G-16.) Is the result of input check O.K.? (Refer to P.l4G-11.) NOTE If the results of checks on the vacuum pump assembly circuit and actuator parts (refer to P.l4G-24.)
Page 719 CRUISE CONTROL SYSTEM Remedy Probable cause Check chart No. Trouble symptom Repair the vehicle speed Malfunction of the vehicle No. 4 The set vehicle speed varies sensor system, or replace speed sensor circuit greatly upward or downward. “Hunting” (repeated alter- Repair the actuator Vacuum pump assembly No.
Page 720 CRUISE CONTROL SYSTEM Trouble symptom Probable cause Remedy Check chart No. Open or short circuit in Cannot accelerate or resume speed No. 2 Replace the control switch by using the RESUME switch. RESUME switch circuit in control switch Vacuum pump assembly No.
Page 721 CRUISE CONTROL SYSTEM CHECK CHART Inspection of control unit power supply circuit DESCRIPTION OF OPERATION The power is supplied through the ignition switch When the cruise control main switch is set to ON with the ignition switch at ON, the current from switch S, flows through relay Ry, in the switch.
Page 722 CRUISE CONTROL SYSTEM Inspection of control switch circuit DESCRIPTION OF OPERATION The control switch is a switch in which the SET, RESUME and CANCEL switches are integrated. Therefore, different resistance values are used for the individual switches to change the outputs (voltages) to the control unit.
Page 723 CRUISE CONTROL SYSTEM Inspection of indicator light circuit CRUISE DESCRIPTION OF OPERATION 1. Cruise control ON (ASC ON) indicator light Located in the combination meter, it lights as soon as the main switch is set to ON. 2. Cruise control (CRUISE) indicator light During cruise control operation, transistor TrI in the control unit is kept in the ON state to keep the indicator light on.
Page 724 CRUISE CONTROL SYSTEM Inspection of vehicle speed sensor circuit IGNITION SENSOR DESCRIPTION OF OPERATION The vehicle speed sensor, mounted in the transmissi,on, delivers pulse signals proportional to the rotational speed of the transmission output gear (vehicle speed) to the control unit. (Four pulse signals generated per rotation of the output gear) Since the vehicle speed sensor is of the electronic type, the power is supplied through the ignition switch (IG,).
Page 725 CRUISE CONTROL SYSTEM Inspection of vacuum pump assembly drive circuit DESCRIPTION OF OPERATION The input signal from the control switch causes transistor Tr to be ON. Accordingly, the cruise control relay is placed in the ON state to supply power to the vacuum pump assembly. J/B @ The vacuum pump assembly consists of a di- aphragm type negative pressure pump that is driven...
Page 726 CRUISE CONTROL SYSTEM Inspection of stop light switch circuit DESCRIPTION OF OPERATION When the brake pedal is depressed during vehicle \& speed control, the cruise control (NC) contact of the stop light switch is opened to interrupt the power supply to the vacuum pump assembly for cancella- tion of vehicle speed control.
Page 727 CRUISE CONTROL SYSTEM Inspection of park/neutral position switch circuit <A/T> DESCRIPTION OF OPERATION The park/neutral position switch is interlocked with the starter switch.When the gear selector lever is placed in the “N” position during vehicle speed control, a cancel signal is input to the control unit which internally interrupts the power supply to the 4 5 6 vacuum pump assembly drive circuit for cancellation...
Page 728 CRUISE CONTROL SYSTEM Inspection of circuits associated with overdrive cancel <A/T> IGNITION CONTROL MODULE OVER DRIVE SWITCH CRUISE DESCRIPTION OF OPERATION On a vehicle with cruise control, the OD switch ON signal is input through the cruise control unit to the When the vehicle speed control is in the overdrive mode, if the actual vehicle speed falls more than about 7 km/h (4 mph) below the set vehicle speed or the RESUME switch is turned ON, the cruise control unit forces transistor Tr, into the OFF state.
Page 729 CRUISE CONTROL SYSTEM - Troubleshootina ON-BOARD DIAGNOSTIC CHECKING On-board diagnostic checking is performed when there has been an automatic cancellation, without cancel switch opera- tion. NOTE Even when the ignition key is placed in the OFF position, all diagnostic trouble codes are stored and retained, until the battery cable is disconnected, to make sure that the problems encountered in the past can be checked.
Page 730 CRUISE CONTROL SYSTEM DIAGNOSIS DISPLAY PATTERNS AND CODES Code Display patterns (output codes) Probable cause Check chart No. (Use with voltmeter) Vacuum pump assembly drive output system out of order The same pattern repeatedly displayed Vehicle speed signal system out of order Control switch out of order (When SET or RESUME switch is kept in ON state continuously for more than 60 seconds)
Page 731 CRUISE CONTROL SYSTEM - Troubleshootina (2) Calling up a code Control switch switch to ON. In less than 1 .O second thereafter, set the RESUME switch to ON. Then the input check results can be displayed. SET switch: (3) Reading a code input check table and read the codes.
Page 732 CRUISE CONTROL SYSTEM - Troubleshooting INPUT CHECK TABLE Code Display patterns (output codes) Input operation Check results (use with voltmeter) SET switch ON SET switch circuit normal RESUME switch ON RESUME switch normal Stop light switch ON Stop light switch circuit normal (brake pedal depressed) Vehicle speed more than approx.
Page 733 CRUISE CONTROL SYSTEM HARNESS AND COMPONENT LAYOUT ENGINE COMPARTMENT Engine rear view Engine front view 01 Jumper connector 02 Vacuum pump 03 Throttle position sensor 04 Park/neutral position switch <A/T> 05 Vehicle speed sensor INSTRUMENT PANEL AND FLOOR CONSOLE 07 Combination meter 08 >...
Page 734 CRUISE CONTROL SYSTEM - Troubleshooting. DASH PANEL JUNCTION BLOCK Front side 14 Over drive switch <A/T> 15 Cruise control unit 19 Adapter wiring harness and junction block combina- tion 10 Clutch pedal position switch <M/T> 11 Stop light switch Body wiring harness (LH) and junction block 12 Clock spring combination LOCATION OF CONTROL UNIT AND RELAY...
Page 735: Service Adjustment Procedures
CRUISE CONTROL SYSTEM SERVICE ADJUSTMENT PROCEDURES CRUISE CONTROL CABLES INSPECTION AND ADJUSTMENT Cruise control assembly Cruise control actuator Adjusting nut A Link B Adjusting nut B Throttle cable Accelerator cable Throttle valve for inspection at no load. (2) Let the engine warm up until it runs at idle. (3) Check that the idle speed is within the specified range.
Page 736 CRUISE CONTROL SYSTEM is blocked by the stopper, turn down adjusting nut C in the direction that the free travel of the inner cable is reduced, and back off adjusting nut C the specified number of turns just before intermediate link C begins ’ h .J to move.
Page 737 CRUISE CONTROL SYSTEM CRUISE CONTROL SETTING CHECK (1) Switch ON the main switch. (2) Drive at the desired speed within the range of approximate- ly 40 - 200 km/h (25 - 124 mph). (3) Operate the control switch downward. (SET switch: ON) (4) Check to be sure that the speed is the desired constant speed when the switch is released, and also check to be sure that the CRUISE indicator light (within the combination...
Page 738: Individual Parts Inspection
CRUISE CONTROL SYSTEM (3) With the vehicle at a speed of more than about 40 km/h (25 mph), check that when the control switch is moved upward (RESUME switch: ON), the vehicle resumes cruising at the speed held before cancellation of the cruise control mode. (4) In the cruise control mode, check that when the main switch is set to OFF, the normal drive mode is restored and d the vehicle coasts smoothly.
Page 739 CRUISE CONTROL SYSTEM CRUISE CONTROL SWITCH INSPECTION for more than 60 seconds. Caution The capacitor in the SRS diagnosis unit retains enough voltage to deploy the air bag for a given period even after disconnection of the battery. If an operation is performed during that given period, unintended deployment of the air bag could result and cause serious injury.
Page 740 CRUISE CONTROL SYSTEM STOP LIGHT SWITCH/BRAKE SWITCH INSPECTION (1) Disconnect the connector. 2) Check for continuity between the terminals of the switch. O-O: Continuity ‘ I When brake pedal depressed. When brake pedal not depressed. CLUTCH PEDAL POSITION SWITCH INSPECTION <M/T> (1) Disconnect the connector.
Page 741 CRUISE CONTROL SYSTEM THROTTLE POSITION SENSOR INSPECTION For inspection, refer to P.l4A-95. CLOSED THROTTLE POSITION SWITCH INSPECTION For inspection, refer to P.l4A-98. VACUUM PUMP INSPECTION Inspection of Solenoid Valves (Control and Relief Valves) (2) Measure the resistance values across terminals @ and @ and across terminals @ and 0.
Page 742 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM REMOVAL AND INSTALLATION 5 N m 4 ftlbs. Removal steps of actuator 1. Link protector 2. Connection of accelerator cable and link assembly 3. Connection of cruise control cable and link assembly 4. Connection of throttle cable and link assembly 5.
Page 743 CRUISE CONTROL SYSTEM CAUTION: SRS Before removal of air bag module, refer to GROUP 23B - SRS Service Precautions and Air Bag Module and Clock Spring. Removal steps of control switches 20. Air bag module (Refer to GROUP 23B -Air Bag Module Clock Spring.) 21.
Page 744 CRUISE CONTROL SYSTEM INSPECTION Check the inner and outer cable for damage. Check the cable for smooth movement. Check the link protector for damage. INSPECTION OF INDIVIDUAL PARTS Refer to Service Adjustment Procedures - Individual Parts Inspection (P. 146-24). SERVICE POINT OF INSTALLATION Vacuum hose \ Throttle cable 6.
Page 745 PROPELLER SHAFT AND UNIVERSAL JOINTS CONTENTS PROPELLER SHAFT ..........4 SPECIAL TOOL ............3 TROUBLESHOOTING ..........3 SPECIFICATIONS ............ 2 ........2 Noise and Vibration at High Speed General Specifications Lubricants ..............2 Noise at Start Service Specifications ........2...
Page 746: Specifications
16-2 PROPELLER SHAFT AND UNIVERSAL JOINTS SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Propeller shaft 4 joint propeller shaft Length x O.D. mm (in.) Front 698.5 x 65 (27.50 x 2.56) Center 662.5 x 65 (26.08 x 2.56) Rear 555.5 x 65 (21.87x 2.56) Universal joint No.
Page 747: Troubleshooting
Special Tool / PROPELLER SHAFT AND UNIVERSAL JOINTS SPECIAL TOOL Replaced by Miller Application Tool number and tool name tool number General service tool Prevention of entry of foreign MB991 193 objects into the transaxle and Plug transfer TROUBLESHOOTING Symptom Probable cause Worn journal bearing Noise at start...
Page 748 16-4 PROPELLER SHAFT AND UNIVERSAL JOINTS PROPELLER SHAFT REMOVAL AND INSTALLATION 22 ft.lbs. Removal steps 1. Self-locking nut 3. Propeller shaft 4. Spacer I O N 0 0 1 3...
Page 749 16-5 PROPELLER SHAFT AND UNIVERSAL JOINTS SERVICE POINTS OF REMOVAL 3. REMOVAL OF PROPELLER SHAFT (1) Make mating marks on the differential companion flange and flange yoke. Caution Remove the propeller shaft in a straight and level manner so as to ensure that the boot is not damaged through pinching.
Page 750 16-6 PROPELLER SHAFT AND UNIVERSAL JOINTS Check the universal joints for smooth operation in all directions. Check the center bearing for smooth movement. Check the center bearing mounting rubber for damage or deterioration. SERVICE POINTS OF INSTALLATION 3. INSTALLATION OF PROPELLER SHAFT Caution Be cautious to avoid damage to the oil seal lip of the transfer.
Page 751 PROPELLER SHAFT AND UNIVERSAL JOINTS 16-7 DISASSEMBLY AND REASSEMBLY 55 Nm 137 ft.lbs. Rubber mount (outer race) (Inner Grease: Repair kit grease 1.94 Adhesive: Quick fix adhesive Disassembly steps 9. Rubber packing 3. Companion flange 4. Center bearing assembly 12. Center propeller shaft 5.
Page 752 16-8 PROPELLER SHAFT AND UNIVERSAL JOINTS SERVICE POINTS OF DISASSEMBLY 1. REMOVAL OF FRONT PROPELLER SHAFT ASSEMBLY Mating marks Put mating marks on the front propeller shaft flange yoke and the companion flange before removing the front propeller shaft assembly. 3.
Page 753 16-9 PROPELLER SHAFT AND UNIVERSAL JOINTS (2) Put mating marks on the outer race, cage and inner race with a scriber before removing the outer race and balls. Caution Note the positions of balls so that they can be reinstalled in their original positions. (3) Remove the inner race with cage from the center Inner race Cage...
Page 754 PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller Shaft 15. REMOVAL OF CENTER BEARING ASSEMBLY First remove the center bearing bracket and then remove the center bearing using a puller (commercially available). INSPECTION Check the propeller shaft splines for wear or damage. Check the ball grooves in inner or outer race for uneven Check ball surface for rust, wear or other damage.
Page 755 PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller Shaft (2) Put the cage on the inner race with the mating marks aligned and install two balls, one in a groove and the other in the groove opposite to that groove. Both balls should be placed in the grooves where they were before disassembly.
Page 756 16-12 PROPELLER SHAFT AND UNIVERSAL JOINTS (9) Using the center propeller shaft bolt, align the bolt holes Mounting bolts of the LCjbro joint boot and the LCibro joint assembly and install the Liibro joint boot to the Lijbro joint assembly. 7.
Page 757 REAR SUSPENSION CONTENTS REAR SUSPENSION ASSEMBLY ....23 REAR AXLE HUB ..... 17 SERVICE ADJUSTMENT PROCEDURES .
Page 758 17-2 REAR SUSPENSION <FWD> - Specifications SPECIFICATIONS <FWD> GENERAL SPECIFICATIONS Items Vehicles without ECS Vehicles with ECS Suspension system Multi-link Coil spring Wire dia. x O.D. x free length mm (in.) Coil spring identification color Pink x 2 Green x 1 Spring constant N/mm (Ibsiin.) 34 (190)
Page 759 17-3 REAR SUSPENSION <FWD> - Special Tools SPECIAL TOOLS Preload socket Installation of the dust cover Compression of the coil spring...
Page 760 REAR SUSPENSION <FWD> - Troubleshootinn TROUBLESHOOTING Remedy Symptom Probable cause Squeaks or other Loose rear suspension installation bolts and nuts Retighten abnormal noise Malfunction of shock absorber Replace Worn bushings Upper arms and/or lower arms and/or assist Trailing arms deformed or damaged Crossmember deformed or damaged Adjust the pressure Excessive tire inflation pressure...
Page 761 17-5 REAR SUSPENSION <FWD> - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES REAR WHEEL ALIGNMENT INSPECTION CAMBER Standard value: 0” + 30’ To adjust camber, turn the lower arm mounting bolt (cross- member side). NOTE (1) Make the adjustment with the assist link mounting bolt (crossmember side) loosened.
Page 762 1 7 - 6 REAR SUSPENSION <FWD> WHEEL BEARING END PLAY INSPECTION up and resting on floor jack. 2. Remove the hub cap and then release the parking brake. 3. Remove the caliper assembly and the brake disc. 4. Check the bearing’s end play. Place a dial gauge against the hub surface;...
Page 763 17-7 REAR SUSPENSION <FWD> - Rear Suspension Assembly REAR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION 45 Nm 33 ftlbs. ‘ 7 2. ECS connector (ECS) Pre-removal Operation Removal of the Absorber Lid from Rear Side Trim 4. Brake line clamp bolt (Refer to GROUP 23A-Trims.) 5.
Page 764 REAR SUSPENSION <FWD> INSPECTION Check the bushings for cracks or deterioration. CROSSMEMBER BUSHING REPLACEMENT Press out Press fit B o l t (2) When press-fitting the bushing, apply soapsuds to it and position the arrows as shown. (3) Make sure that the protrusion (dimension A) of the inner sleeve is up to specification.
Page 765 17-9 REAR SUSPENSION <FWD> - Upper Arm, Lower Arm and Assist Link UPPER ARM, LOWER ARM AND ASSIST LINK REMOVAL AND INSTALLATION Pre-removal Operation 1 4 0 - 0 Removal of the Shock Absorber (Refer to P.17-I 3.) Post-installation Operation Check of Wheel Alignment (Refer to P.
Page 766 REAR SUSPENSION <FWD> - Upper Arm, Lower Arm and Assist Link INSPECTION Check the bushing for wear and deterioration. Check the upper arm, lower arm or assist link for bend or breakage. Check the ball joint dust cover for cracks. Check all bolts for condition and straightness.
Page 767 REAR SUSPENSION <FWD> TRAILING ARM REMOVAL AND INSTALLATION Post-installation Operation Check of Wheel Alignment (Refer to P. 17-5.) Check of Parking Brake Lever Stroke (Refer to GROUP 5 - Service Adjustment Procedures.) Rear Brake Disc Run-out Check (Refer to GROUP 5 ~ Service Adjustment Procedures.) 75 - 89 Nm 36 - 43 ft.lbs.
Page 768 REAR SUSPENSION <FWD> SERVICE POINTS OF REMOVAL 14.16. 17. REMOVAL OF SELF-LOCKING NUT Using the special tool, remove the knuckle from the lower arm, upper arm, and assist link. NOTE loosen it. (2) Suspend the special tool with a rope to prevent it from dropping.
Page 769 REAR SUSPENSION <FWD> SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION 45 Nm Pre-removal and Post-installation Operation Removal and Installation of the Rear Side Trim Removal steps Shock absorber upper mounting nut 2. ECS connector (ECS) 4. Brake line clamp bolt 5. Shock absorber lower mounting bolt 6.
Page 770 REAR SUSPENSION <FWD> SERVICE POINT OF DISASSEMBLY 1. REMOVAL OF PISTON ROD TIGHTENING NUT press the coil spring using the special tool. (2) While holding the piston rod, remove the piston rod tightening nut. INSPECTION Check the rubber parts for damage. Check the coil springs for crack, damage or deterioration.
Page 771 REAR SUSPENSION <FWD> STABILIZER BAR REMOVAL AND INSTALLATION Removal steps 3. Bushing 5. Joint cup (A) 6. Stabilizer rubber 7. Joint cup (B) 8. Self-locking nut 9. Stabilizer link 12. Stabilizer bar INSPECTION for wear and deterioration. Check the bushing Check the stabilizer bar for deterioration or damage.
Page 772 REAR SUSPENSION <FWD> BALL JOINT DUST COVER REPLACEMENT (1) Remove the clip ring and the dust cover. (2) Apply multipurpose grease to the lip and inside of the dust cover. Grease : MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent grease (3) Use vinyl tape to tape the stabilizer link where shown in the illustration, and then install the dust cover to the stabilizer...
Page 773: Rear Axle Hub
REAR AXLE HUB REMOVAL AND INSTALLATION 5 0 - 6 0 N m 36 - 43 ft.lbs. Removal steps 2. Caliper assembly 3. Brake disc 4. Hubcap 5. Wheel bearing nut 6. Tongued washer 7. Rear hub assembly 8. Rear rotor <Vehicles with ABS> 9.
Page 774 REAR SUSPENSION <FWD> SERVICE POINT OF INSTALLATION 5. INSTALLATION OF WHEEL BEARING NUT After tightening the wheel bearing nut, align with the spindle’s indentation and crimp. Spindle...
Page 775 REAR SUSPENSION <AWD> - SDecifications SPECIFICATIONS <AWD> GENERAL SPECIFICATIONS Items Specifications Suspension system Double wishbone suspension type Coil spring Wire dia. x O.D. x free length mm (in.) 11.5x 105x379.3 (45 x4.13x 14.93) Coil spring identification color Light brown x 2 Spring constant N/mm (lbs./in.) 28.0 (157)
Page 776 REAR SUSPENSION <AWD> - SPecial Tools SPECIAL TOOLS General service Preload socket M B990767 C-3281 To stop axle shaft turning End yoke holder CT-1 003 For removal of the axle shaft Axle shaft puller MB990242 Puller bar MB990242 MB990244 Puller shaft MB990244 C-637 MB99021 1...
Page 777 17-21 REAR SUSPENSION <AWD> - Special Tools / Troubleshooting Replace by Miller Application Tool number and tool name tool number MB991354 CT-1 003 For removal of the axle shaft Puller body MB991 237 C-4838 Compression of the coil spring Spring compres- sor body MB991 239 Arm set...
Page 778 REAR SUSPENSION <AWD> Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES REAR WHEEL ALIGNMENT INSPECTION CAMBER Standard value: -0”lO’ f 30’ To adjust camber, turn the lower arm mounting bolt on the crossmember side. NOTE Left wheel: Clockwise (0 camber) Right wheel: Clockwise (0 camber) The difference between the right and left wheels should be 30’...
Page 779 17-23 REAR SUSPENSION <AWD> REAR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION 45 Nm Removal steps Pre-removal Operation Removal of the Rear Side Trim Absorber Lid 2. ECS connector <EC.%* 3. Cap” Removal of the Center Exhaust Pipe and Main 4. Brake tube to brake hose connection* Muffler (Refer to GROUP 5 - Brake Line.) 5.
Page 780 17-24 REAR SUSPENSION <AWD> SERVICE POINTS OF REMOVAL REMOVAL OF CROSSMEMBER BRACKET / MEMBER MOUNTING NUT (ON DIFFERENTIAL SIDE) / REAR SUSPENSION ASSEMBLY differential case with the transmission jack. (2) Remove the crossmember mounting bolt and nut. NOTE Lowering the rear suspension assembly down from the transmission jack requires three persons, as the rear suspension assembly is very heavy.
Page 781 Rear Suspension Assembly I REAR SUSPENSION <AWD> (2) When press-fitting, position the bushing as shown. NOTE Ensure that the shift in rotating direction is within k 5”. (3) Make sure that the protrusion of the inner sleeve (dimen- sion A) is up to specification. Standard value: 6.7 - 7.3 mm (.26 - .29 in.) UPPER AND LOWER ARM REMOVAL AND INSTALLATION...
Page 782 17-26 REAR SUSPENSION <AWD> SERVICE POINTS OF REMOVAL 1. REMOVAL OF SELF-LOCKING NUT Using the special tool, disconnect the upper arm ball joint from the knuckle. NOTE (1) Do not remove the nut from the ball joint, but just loosen it. (2) Suspend the special tool with a rope to prevent it from dropping.
Page 783 17-27 REAR SUSPENSION <AWD> LOWER ARM BUSHING REPLACEMENT Removal Press-fit MB991 073 (2) Press-fit the lower arm bushing until the bushing outer pipe edge is flush with the lower arm pipe edge. Pipe (lower (bushing) arm) SERVICE POINT OF INSTALLATION 7.
Page 784 17-28 REAR SUSPENSION <AWD> - Trailing Arm TRAILING ARM REMOVAL AND INSTALLATION 5 0 - 6 0 N m 300 Nm 36 - 43 ftlbs. Removal steps Post-installation Operation 1. Rear brake caliper assembly Check of Wheel Alignment 2. Rear brake disc 3.
Page 785 REAR SUSPENSION <AWD> SERVICE POINTS OF REMOVAL 4. REMOVAL OF SELF-LOCKING NUT With the special tool, secure the rear axle shaft, then remove the self-locking nut. 6. REMOVAL OF REAR AXLE SHAFT With the,special tool, remove the rear axle shaft. 12.
Page 786 REAR SUSPENSION <AWD> SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION 72 ft.lbs. Pre-removal and Post-installation Operation Removal and Installation of the Rear Side Trim Absorber Lid (Refer to GROUP 23A-Trims.) Removal steps 2. ECS connector (ECS) 3. Cap 4. Shock absorber lower mounting bolt 5.
Page 787 REAR SUSPENSION <AWD> STABILIZER BAR REMOVAL AND INSTALLATION 72 ftlbs. 42 Nm 42 Nm 5% Nm 51 - 61 ft.lbs. Removal steps * 2. Self-locking nut* 3. Joint cup A* 4. Stabilizer rubber* 5. Joint cup B” 6. Stabilizer link* 7.
Page 788 REAR SUSPENSION <AWD> SERVICE POINTS OF REMOVAL 14. REMOVAL OF CROSSMEMBER BRACKET / 15. CROSS- MEMBER MOUNTING NUT mission jack. (2) Remove the crossmember bracket and crossmember mounting nut. 18. REMOVAL OF STABILIZER BAR (1) Lower the transmission jack a little to obtain a gap between the rear suspension and body.
Page 789 REAR SUSPENSION <AWD> (2) Apply multipurpose grease to the lip and inside of the dust cover. Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent (3) Wind tape around the threads of the stabilizer link stud and install the dust cover. (4) Secure the dust cover with the clip ring.
Page 791 STEERING CONTENTS STEERING ....................... . .
Page 793 STEERING CONTENTS POWER STEERING GEAR BOX* ...._ _. . Steering Wheel Free Play Check ....Steering Wheel Return to Center POWER STEERING HOSES .
Page 794 STEERING - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Steering wheel Steering wheel O.D. mm (in.) 386 (15.2) Gear box Steering gear type Rack and pinion Power steering oil pump Oil pump type Vane type Displacement 9.6 f.59) Relief set pressure SERVICE SPECIFICATIONS Items Specifications...
Page 795 Items Specifications Limit Steering wheel free play (when hydraulic operation) mm (in.) 30 (1.2) Variation of tie rod end ball joint shaft direction mm (in.) 1.5 (.059) Oil pump pressure Pressure gauge valve opened M Pa (psi) 1.5 (213) Space between vane and rotor mm (in.) 0.06 (.0024) LUBRICANTS...
Page 796 STEERING - Special Tools SPECIAL TOOLS Preload socket easurement 0 e pinion shaft preload Preload socket General service or other suitable...
Page 797 STEERING - SDecial Tools Tool number and tool name Replaced by Miller Application tool number MB991 199 General service To press in the oil seal for the rack Oil seal installer MB991 197 General service To press in the oil seal for the rack MB991 202 General servie Press-fitting of rack housing bearing...
Page 798 STEERING - s ervice Adiustment Procedures SERVICE ADJUSTMENT PROCEDURES STEERING WHEEL FREE PLAY CHECK straight ahead. 2. Measure the play on steering wheel circumference before wheels start to move when slightly moving steering wheel in both directions. Limit: 30 mm (1.2 in.) 3.
Page 799 STEERING ,- Service Adjustment Procedures 2. Move ball joint stud several times and install nut on stud. Use the special tool to measure ball joint starting torque. Standard value: 0.5 - 3.0 Nm (4 - 26 in.lbs.) 3. When starting torque exceeds the standard value, replace tie rod end.
Page 800 STEERING PRECISION STEERING WHEEL CENTERING In general, the tie rods are adjusted to steer the front wheels in the same direction that the steering wheel is off center. If the steering wheel is off center to the left, center it by adjusting the tie rods to make the front wheels steer toward the left, and vice versa.
Page 801 STEERING -- Service Adiustment Procedures STATIONARY STEERING EFFORT CHECK 1. With the vehicle stopped on a flat, paved surface, turn the steering wheel to the straight ahead position. 2. Start the engine and set it to 1,000 IL 100 rpm. After checking the engine speed, there must be a return the standard idling speed.
Page 802 STEERING <SOHC Engine> 1. Press in drive belt at the illustrated position with about 100 pulley N (22 Ibs.) and measure deflection. Brace bolt S t a n d a r d v a l u e pulley nut 6.0 - 9.0 mm (.24- .35 in.) When belt tension is inspected When new belt is installed 2.
Page 803 STEERING -- Service Adiustment Procedures 4. Disconnect the high-tension cable, and then while operat- ing the starting motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid. Caution Be careful not to position the high-tension cable near the carburetor or the delivery pipe.
Page 804 STEERING OIL PUMP PRESSURE TEST Shut-oif valve Pressure gauge (Fully CHECKING THE OIL PUMP RELIEF PRESSURE 1. Disconnect the pressure hose from the oil pump, and then Temperature connect the special tools. 2. Bleed the air, and then turn the steering wheel several ‘& times while the vehicle is not moving so that the tempera- ture of the fluid rises to approximately 50 - 60°C (122 - 140°F).
Page 805 STEERING -- Service Adjustment Procedures CHECKING THE STEERING GEAR RETENTION HYDRAULIC Shut-off valve PRESSURE Disconnect the pressure hose from the oil pump, and then connect the special tools. Bleed the air, and then turn the steering wheel several times while the vehicle is not moving so that the tempera- Pressure hoses ture of the fluid rises to approximately 50 - 60°C (122 - 140°F).
Page 806 STEERING - Steering Wheel and Shaft STEERING WHEEL AND SHAFT REMOVAL AND INSTALLATION Post-installation Operation Checking of Steering Wheel PosItIon with Wheels Straight Ahead and Air Bag Module and Clock Spring. 40‘Nm 29 ft.lbs. Removal steps <Automatic transaxle vehicles> (Refer to GROUP 23B -Air Bag Module and GROUP Clock Spring.) 3.
Page 807 STEERING SERVICE POINTS OF REMOVAL 2. REMOVAL OF STEERING WHEEL Remove the steering wheel by using the special tool. Caution Do not hammer on the steering wheel to remove it; doing so may damage the collapsible mechanism. SERVICE POINT OF INSTALLATION 2.
Page 808 STEERING DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Cover assembly 4. Joint assembly 8. Steering column assembly Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF STEERING LOCK BRACKET / 7. STEER- ING LOCK CYLINDER it is necessary to remove the steering lock cylinder, use a hacksaw to cut the special bolts at the steering lock bracket side.
Page 809 STEERING - Steering Wheel and Shaft INSPECTION Check the steering shaft for play and round movement. Check the joint bearing for wear and damage. Check the dust shield for damage. SERVICE POINTS OF REASSEMBLY 7. INSTALLATION OF STEERING LOCK CYLINDER / 6. STEERING LOCK BRACKET / 5.
Page 810: Front Wheel Alignment 9
STEERING - ’ ower Steering Gear Box POWER STEERING GEAR BOX REMOVAL AND INSTALLATION 4 u Nrn CAUTION: SRS 29 ftlbs. Before removal of steering gear box, refer to GROUP 23B - SRS, center front wheels and remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.
Page 811 STEERING - Power Steering Gear Box SERVICE POINTS OF REMOVAL 3. DISCONNECTION OF TIE-ROD END Using the special tool, disconnect the tie rod from the knuckle. 9. REMOVAL OF GEAR BOX ASSEMBLY the gear box from the crossmember. (2) While tilting the gear box downward, remove it to the left.
Page 812 STEERING - Power Steering Gear SASSEMBLY AND REASSEMBLY <Vehicles with 4WS> Steering gear seal kit <Vehicles without 4WS> 22 Nm 16 ft.lbs. 15 Nm 11 ft.lbs 50-55 Nm 36 - 40 ft.lbs. Disassembly steps * +a 18. Oil seal 1. Tie rod end locking nuts 3.
Page 813 STEERING - Power Steering Gear Box Fluid: MOPAR ATF PLUS (Automatic transmission fluid type 7176)/ Automatic Transmission F “DEXRON” or “DEXRON II” Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent Fluid: MOPAR ATF PLUS (Automatic transmission fluid type 7176)/ Automatic Transmission Fluid “DEXRON”...
Page 814 STEERING - Power Steering Gear Box SERVICE POINTS OF DISASSEMBLY 3. REMOVAL OF DUST SHIELD Remove the dust shield from the tie rod end. 5. REMOVAL OF BELLOWS BANDS Using a screwdriver or similar tool, loosen and then remove the boot retaining band. 7.
Page 815 STEERING - Power Steering Gear Box 18. REMOVAL OF OIL SEAL Using a plastic hammer, gently tap the pinion to remove it. 21. REMOVAL OF BALL BEARING / 22. OIL SEAL Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.
Page 816 S T E E R I N G - P ower Steering Gear Box 31. REMOVAL OF BALL BEARING Use the spatial tool to remove the ball bearing from the gear housing. (Brass bar) 32. REMOVAL OF NEEDLE ROLLER BEARING Using the special tool, remove the needle roller bearing from the rack housing.
Page 817 STEERING - Power Steerina Gear Box SERVICE POINTS OF REASSEMBLY MB991 197 34. INSTALLATION OF BACK-UP WASHER / 33. OIL SEAL Guide Installer MB991 199 the oil seal. Specified fluid: MOPAR ATF PLUS (Automatic transmission fluid type 7176)/ Automatic Transmission Fluid “DEXRON”...
Page 818 STEERING (2) Cover rack serrations with special tool. Apply specified fluid on special tool. Oil seal MB991213 Specified fluid: MOPAR ATF PLUS (Automatic transmission fluid type 7176)/ Automatic Transmission Fluid, “DEXRON” or “DEXRON II Match oil seal center with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.
Page 819 STEERING 20. INSTALLATION OF SEAL RING Tapered side (2) Apply the specified fluid to the seal ring, and install to the rack groove. Specified fluid: MOPAR ATF PLUS (Automatic transmission fluid type 7176)/ Automatic transmission Fluid DE- XRON or DEXRON II Pinion gear (3) Insert the tapered side of the special tool from the...
Page 820 STEERING - Power Steering Gear Box 8. INSTALLATION OF TIE ROD After installing tie rod to rack, fold tab washer end (2 locations) to tie rod notch. 3. INSTALLATION OF DUST SHIELD M B990776 grease. Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent (2) Apply semi-drying sealant to dust shield.
Page 821: Power Steering Oil Pump
STEERING POWER STEERING OIL PUMP REMOVAL AND INSTALLATION <SOHC Engine> Post-installation Operation Supplying of the Power Steering Fluid 24 Nm 17 ftlbs. 22 Nm 16 ft.lbs. 22 Nm IO- 12 Nm Removal steps 1. Drive belt 2. Suction hose 3. Pressure hose 4.
Page 822 STEERING - P ower Steerina Oil Pumo <DOHC Engine> 22 Nm 16 ftlbs. Removal steps 2. Suction hose 3. Pressure hose 43 Nm 4. O-ring 31 ft.lbs. 5. Pressure switch connector 6. Oil pump 13. Oil pump bracket 14. Tensioner pulley SERVICE POINT OF REMOVAL 6.
Page 823 STEERING - Power Steering Oil Pump ISASSEMBLY AND REASSEMBLY Fluid: MOPAR ATF PLUS (Automatic transmission fluid type 7176VAutomatic Transmissidn Fluid “DEXRON” or “DEXRON II” 60 Nm 43 ft.lbs. 20 Nm 14 ftlbs. 25-30 Nm 18 - 22 ft.lbs. 15. Plunger Disassembly steps 16.
Page 824 STEERING Pump INSPECTION Check the flow control spring for wear. Check the shaft of the pulley for play and round movement. Check the groove of rotor vane for ,“stepped” wear. Check the contact surface of cam ring and vanes ford “stepped”...
Page 825 STEERING - Power Steering Oil Pump 6. INSTALLATION OF SIDE PLATE Line up the dowel pin hole of the side plate with the dowel pin of the pump body when installing the side plate. 5. INSTALLATION OF CAM RING Install the cam ring with the punch mark facing the side plate.
Page 826 STEERING - Power Steering Hoses POWER STEERING HOSES REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation <DOHC Engine> 12 Nm <Vehicles without 4 24Nm <Vehicles with 4WS 8 ft.1 Removal steps Cooler tube 2. Suction hose 7. Pressure tube 3. Return hose 8.
Page 827 STEERING - Power Steering Hoses SERVICE POINT OF INSTALLATION 4. INSTALLATION OF PRESSURE HOSE (1) Connect the pressure hose so that its slit part contacts the oil pump’s guide bracket. (2) When the pressure hose is installed, align the white line on the pressure hose with the white line on the pressure tube so that together they form a straight line.
Page 829 CONTENTS CONTROL VALVE ....SPECIAL TOOL ........... . SPECIFICATIONS .
Page 830 4WS - Specifications / Special Tool SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Power steering gear box Rack and pinion Oil pump Vane type Displacement 9.6 (0.59) Relief set pressure 8 (1,138) Rear oil pump Vane type Displacement 3.3 (0.20) Relief set pressure 4 (569) Power cylinder Hydraulic double action type...
Page 831: Control Valve
4WS - Troubleshooting TROUBLESHOOTING Oil pump drive belt tension Before inspecting, check the following items: Ensure that the suspension has not been mod- Power steering fluid level, and air in the system ified Engine idle speed and even idle Oil leakaae Tire and wheel size, specifications, air pressure, balance and amount of wear Steering wheel type...
Page 832: Service Adjustment Procedures
Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES BLEEDING (1) Bleed air from power steering system (Refer to GROUP (2) Lift up the vehicle. (3) Start the engine and let it idle. (4) Loosen the bleeder screw on the left side of the control valve and set a plastic tube to the bleeder screw.
Page 833: Ball Joint Rotation Starting Torque Check
4WS - Service Adiustment Procedure FUNCTION CHECK (2) Start the engine, running the vehicle at an indicated speed of about 80 km/h (50 mph). (3) Turn the steering wheel all the way to left and right and turn it swiftly, checking to ensure that the rear wheels steer to the same directions as the front wheels.
Page 834 POWER CYLINDER REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Cleaning of Pipings with Steam Installation of Main Muffler Assembly Draining of Power Steering Fluid (Refer to GROUP 11 -Exhaust Pipe and Muffler.) (Refer to GROUP 19A-Service Adjustment Refilling and Bleeding of Power Steering System Procedures.) (Refer to GROUP 19A-Service Adjustment Removal of Main Muffler Assembly...
Page 835 4 w s - Power Winder SERVICE POINTS OF REMOVAL 3. REMOVAL OF CROSSMEMBER MOUNTING NUT (1) Before removing the self-locking nuts, support the differential case with a transaxle jack. (2) Remove the self-locking nuts. 9. REMOVAL OF TIE ROD END NUT Secure the power cylinder on the tie rod side with a spanner and remove the power cylinder mounting nut.
Page 836 4 w s - Power Cylinder (4) When the tie rod ends and the installation holes at the trailing arm do not meet, loosen the tie rod end securing nut, then adjust the length. The dust cover fastener clip should be removed for this. (5) The difference between the lengths of the left and right tie rods should be less than 1 mm ( ,039 in.).
Page 837 4WS - Control Valve CONTROL VALVE REMOVAL AND INSTALLATION Post-installation Operation Installation of Rear Suspension Assembly (Refer to GROUP 17 - Rear Suspension Assembly.) Refilling and Bleeding of Power Steering System (Refer to GROUP 19A-Service Adjustment Procedures.) Bleeding of 4WS System (Refer to GROUP 17 -Rear Suspension Assembly.) (Refer to P.
Page 838 4 w s - Rear Oil Line REAR OIL LINE REMOVAL AND IklSTALLATlON 35 Nm 25 ftlbs. 12 Nm 9 ft.lbs. Removal steps 2. Suction hose 3. Protector 4. Pipe assembly to pressure (Refer to GROUP 19A-Service Adjustment tube connection 5.
Page 839 4 w s - Rear Oil Puma REAR OIL PUMP REMOVAL AND INSTALLATION Draining of Power Steering Fluid (Refer to GROUP 19A - Service Adjustment Removal of Main Muffler Assembly (Refer to GROUP 11 -Exhaust Pipe and Muffler.) Post-installation Operation Installation of Main Muffler Assembly (Refer to GROUP 11 - Exhaust Pipe and Muffler.) Refilling and Bleeding of Power Steering System...
Page 841 CONTENTS AUTOMATIC TRANSAXLE ........ 63 Selector Lever Operation Check ........1 13 Shift Lock Mechanism Check ..........114 ........ 109 SET ....................164 Transmission Fluid Replacement ........109 DIFFERENTIAL ................ 166 SPECIAL TOOLS ................ END CLUTCH ASSEMBLY ............ 161 ..............SPECIFICATIONS FRONT CLUTCH ASSEMBLY ..........
Page 842 21-2 Element in Use at Each Position of Selector Lever ..5TH SPEED SYNCHRONIZER ASSEMBLY ......Hydraulic Pressure Tests ............ 103 GENERAL INFORMATION ............ Inspection of Electronic Control System Components ._,, Shift Patterns ................ INPUT SHAFT ASSEMBLY ............ Troubleshooting Guide ............INTERMEDIATE GEAR ASSEMBLY ........
Page 843 21-3 MANUAL TRANSAXLE <FWD> - General Information GENERAL INFORMATION 2nd speed gear retainer 1 st speed gear 5th speed gear 5th speed 1 st-2nd synchronizer speed assembly Spacer synchro- nizer assembly Rear cover Reverse gear device (Vehicles with DOHC-engine) 5th soeed rnter- mediate gear Intermediate gear - - - - - - O u t p u t s h a f t...
Page 844: Specifications
21-4 MANUAL TRANSAXLE <FWD> - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Model Applicable engine floor shift floor shift Gear ratio 1 st 1.833 1.833 1.217 1.217 0.741 Reverse 3.166 3.166 Final reduction ratio 4.153 Speedometer gear ratio (driven/drive) Oil quantity 2.0 (2.1) 2.0 (2.1) SERVICE SPECIFICATIONS...
Page 845 21-5 MANUAL TRANSAXLE <FWD> - SDecifications SNAP RING (FOR ADJUSTMENT) AND SPACER Identification Thickness mm (in.) Part No. Part name symbol Blue M D723276 Snap ring (For adjustment of input shaft rear bearing end play) 1.45 (.0571) Purple M D730889 M D723277 1.55 (.0610) White...
Page 846 21-6 MANUAL TRANSAXLE <FWD> - Specificatiork Identification Part name Thickness mm (in.) Part No. symbol Spacer 0.92 (.0362) MD7241 46 (For adjustment of intermediate gear preload) MD7241 47 0.95 (.0374) MD7241 48 0.98 (.0386) MD7241 49 1 .Ol l.0398) MD7241 50 MD7241 51 MD7241 52 1 .I 0 (.0433)
Page 847: Lubricants
SEALANTS AND ADHESIVES Items Specified sealants and adhesives Transaxle case-clutch housing mating surfaces Mitsubishi genuine part No. 997740 or equivalent Transaxle case - rear cover mating surfaces Differential drive gear bolts MOPAR part No. 4318031 or MOPAR part No. 4318032 or equivalent...
Page 848 21-8 MANUAL TRANSAXLE <FWD> - Special Tools SPECIAL TOOLS Oil seal installer Differential oil intermediate shaft lock nut Input shaft holder Snap ring installer...
Page 849 21-9 MANUAL TRANSAXLE <FWD> - Special Tools Application Replaced by Miller Tool number and tool name tool numer MD998813 Use with installer cap and installer adapter Installer-l 00 M D998816 L-4965 Installation of input shaft front bearing Installer adapter MD99881 7 L-441 1 Installation of input shaft bearing sleeve Installer adapter...
Page 850 MANUAL TRANSAXLE <FWD> - Troubleshooting TROUBLESHOOTING Symptom Probable cause Remedy Vibration, noise a. Loose or damaged transaxle and a. Tighten or replace mounts engine mounts b. Inadequate shaft end play b. Correct end play c. Worn of damaged gears c. Replace gears d.
Page 851 MANUAL TRANSAXLE <FWD> SERVICE ADJUSTMENT PROCEDURES TRANSMISSION OIL LEVEL INSPECTION Refer to GROUP 0 - Maintenance Service. TRANSMISSION OIL REPLACEMENT (2) Remove filler and drain plugs and allow the transmission oil to drain. (3) Refill the transaxle to the proper level with specified transmission oil.
Page 852 21-12 MANUAL TRANSAXLE <FWD> - Service Adjustment Procedures transaxle. The drive shaft oil seal must be installed in the direction shown. (4) Apply a coating of the transmission oil to the lip of the oil, seal. Transmission oil: MOPAR Hypoid gear oil or equivalent, API classification GL-4, SAE 75W-90 or 75W-85W 2200037...
Page 853 MANUAL TRANSAXLE <FWD> - Transaxle Control TRANSAXLE CONTROL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Front Console Assembly (Refer to GROUP 23A- Floor Console.) CAUTION: SRS When installing or removing the front console, don’t allow any impact or shock to the SRS diagnosis unit.
Page 854 21-14 MANUAL TRANSAXLE <FWD> - Transaxle Control INSPECTION Check the transaxle control cable assembly for function and for damage. Check the boot for damage. Check each bushing for wear or abrasion, sticking, impededd action, and damage. SERVICE POINTS OF INSTALLATION 4.
Page 855 MANUAL TRANSAXLE <FWD> - Shift Lever Assembly SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 24 Nm Disassembly steps 1. Nut 2. Spring washer 3. Plain washer 4. Shift lever 5. Bushing 6. Plain washer 7. Wave washer 9. Spring washer 11. Return spring 12.
Page 856 MANUAL TRANSAXLE <FWD> - Transaxle Assemblv TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Removal of Front Under Cover (Refer to GROUP 23A- Front Bumper.) Draining of Engine Coolant <SOHC> (Refer to GROUP 7 -Service Adjustment Procedures.) 19 Nm Removal steps 8.
Page 857 MANUAL TRANSAXLE <FWD> Post-installation Operation Installation of Front Under Cover (Refer to GROUP 23A- Front Bumper.) Supplying of Transmission Oil (Refer to P.21-II.) 70 Nm Filling of Engine Coolant (Refer to GROUP 7 - Service Adjustment Procedures.) Checking Operation of Shift Lever at Each Position Checking the Operation of the Meters and Gauges 60-72 Nm 43 - 52 ftlbs.
Page 858 MANUAL TRANSAXLE <FWD> 14. DISCONNECTION OF TRANSAXLE MOUNT Raise transaxle assembly with a jack up to a level where mount bracket no longer receives its weight and remove transaxle mount insulator bolt. Caution Support the transaxle assembly with the jack so that no localized force is applied to the assembly.
Page 859 MANUAL TRANSAXLE <FWD> 24. REMOVAL OF DRIVE SHAFT (RIGHT SIDE) assembly, apply pry bar to the protrusion. NOTE Remove drive shaft (right side) as an assembly together with hub, knuckle, and other parts. (2) Suspend the removed drive shaft (right side) with wire or something similar to prevent it from sharply bending or turning at each joint.
Page 860 MANUAL TRANSAXLE <FWD> - Transaxle Assembly TRANSAXLE ASSEMBLY DISASSEMBLY AND REASSEMBLY 19 Nm 30-35 Nm 22 - 25 6.8 Nm 4 N m Lubricate all Disassembly steps 12. Speedometer driven gear assembly 2. Rear cover 3. Wave spring + 15. Lock nut 5.
Page 861 21-21 MANUAL TRANSAXLE <FWD> - Transaxle Assembly 3 0 - 3 5 Nm 3 5 - 4 2 Nm 22 - 25 ft.lbs. 26 - 30 ft.lbs. 49 Nm 35 ft.lbs. Disassembly steps * 40. Spacer 23. Reverse idler gear shaft bolt 41.
Page 862 21-22 MANUAL TRANSAXLE <FWD> - Transaxle Assembly 19 Nm * 51. Screw 52. Bolt 53. Bearing retainer internal parts 54. Intermediate gear assembly with gear oil 55. Input shaft assembly during reassembly. 56. Output shaft assembly 57. Differential gear assembly 58.
Page 863 21-23 MANUAL TRANSAXLE <FWD> - Transaxle Assembly SERVICE POINTS OF DISASSEMBLY 14. REMOVAL OF SPRING PIN Remove the spring pin. NOTE If the spring pin interferes with the synchronizer ring or cone gear, rotate the gear for dislocation and remove the spring pin.
Page 864 21-24 MANUAL TRANSAXLE <FWD> 50. REMOVAL OF SHIFT RAIL ASSEMBLY (2) Shift the 3rd-4th speed shift fork to the 4th speed. (3) Remove the shift rail assembly. INSPECTION BACKUP LIGHT SWITCH Operate the backup light switch to check continuity with a circuit tester.
Page 865 21-25 MANUAL TRANSAXLE <FWD> 63. INSTALLATION OF OIL SEAL Install the input shaft front oil seal using the special tool. 51. APPLICATION OF ADHESIVE TO BOLT Apply specified adhesive to the bolt threads. Caution Do not apply to the bolt head. Specified adhesive: MOPAR part No.
Page 866 21-26 MANUAL TRANSAXLE <FWD> 48.49. INSTALLATION OF SPRING PINS punch. Caution Do not reuse the spring pins. (2) When installing, make sure that the slit of the spring pin is aligned with the shift rail center line. Slit 46. INSTALLATION OF REVERSE IDLER GEAR SHAFT Install in the direction illustrated.
Page 867 (3) Apply specified sealant to the clutch housing side of the transaxle case. Specified sealant: MITSUBISHI genuine Part No. MD997740 or equiva- lent Caution Squeeze out sealant from the tube uniformly with- out excess or discontinuity.
Page 868 21-28 MANUAL TRANSAXLE <FWD> - Transaxle Assembly (2) Screw a bolt [IO mm (.40 in.)] into the hole on the periphery of clutch housing and attach a spinner handle to the special tool. (3) Shift the transaxle in reverse using control lever and select lever.
Page 869 MOPAR Part No. 4318032 or equivalent TFM0041 2. APPLICATION OF SEALANT TO THE REAR COVER Apply specified sealant to the rear cover. Specified sealant: MITSUBISHI genuine Part No. MD997740 or equivalent in.) Caution Squeeze out sealant from the tube uniformly without Amount of excess or discontinuity.
Page 870 MANUAL TRANSAXLE <FWD> - INSPECTION SYNCHRONIZER SLEEVE AND HUB Combine the synchronizer sleeve and hub and check that they slide smoothly. Check that the sleeve is free from damage at its inside frontd and rear ends. Check for wear of the hub front end (surface in contact with the 5th speed gear).
Page 871 - - - - _ _ _ _ _ ----_- MANUAL TRANSAXLE <FWD> INPUT SHAFT ASSEMBLY DISASSEMBLY AND REASSEMBLY Internal Darts 1’1 T F MO262 Disassembly steps 14. Synchronrzer sleeve 1. Taper roller bearing 2. Bearing sleeve 15. Synchronrzer key 16.
Page 872 MANUAL TRANSAXLE <FWD> SERVICE POINTS OF DISASSEMBLY 1. REMOVAL OF TAPER ROLLER BEARING Remove the front bearing using the special tool as 2. REMOVAL OF BEARING SLEEVE Remove the bearing sleeve using the special tool as illustrated. 4. REMOVAL OF TAPER ROLLER BEARING Remove the taper roller bearing together using the special tool as illustrated.
Page 873 21-33 MANUAL TRANSAXLE <FWD> NEEDLE BEARING Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play. SYNCHRONIZER RING Check the clutch gear teeth for damage and breakage. Check paper lining on cone I.D.
Page 874 21-34 MANUAL TRANSAXLE <FWD> SPEED GEARS Check the bevel gear and clutch gear teeth for damage and wear. Check the synchronizer cone for rough surface, damage and wear. Check the gear bore and front and rear ends for damage and wear. SERVICE POINTS OF REASSEMBLY 13.
Page 875 21-35 MANUAL TRANSAXLE <FWD> - Input Shaft Assembly 7. INSTALLATION OF SUB GEAR / 6. CONE SPRING / 5. SNAP RING Install the sub gear and cone spring to 4th gear, and then install the snap ring. NOTE Be sure that the cone spring is installed so that it is facing in the correct direction.
Page 876 21-36 MANUAL TRANSAXLE <FWD> 2. REASSEMBLY OF BEARING SLEEVE MD99881 2 shaft. Caution MD99881 7 After fitting, check that the sleeve flange is closely i fit to the bearing. 1. INSTALLATION OF TAPER ROLLER BEARING MD998812 Install the taper roller bearing over the input shaft using the special tool.
Page 877 MANUAL TRANSAXLE <FWD> INTERMEDIATE GEAd ASSEMBLY DISASSEMBLY AND REASSEMBLY 9. Synchronizer key Disassembly steps a 10. 1 st-2nd speed synchronizer hub 1. Snap ring 12. Synchronizer inner ring 13. Synchronizer cone 3. Bearing sleeve 2nd speed gear 1 st speed gear 5.
Page 878 21-38 MANUAL TRANSAXLE <FWp> 14. 2ND SPEED GEAR Remove the 1 st-2nd speed synchronizer assembly and 2nd speed gear together using the special tool as illustrated. 20106: 16. REMOVAL OF TAPER ROLLER BEARING Use the special tool as illustrated. Caution 1.
Page 879 21-39 MANUAL TRANSAXLE <FWD> SYNCHRONIZER RING Damage and wear Check the clutch gear teeth for damage and breakage. Check paper lining on synchronizer outer ring I.D. and synchronizer inner ring O.D. for damage, wear, and flaking. Force the synchronizer outer ring toward the clutch gear Synchronizer and check clearance “A”.
Page 880 MANUAL TRANSAXLE <FWD> SERVICE POINTS OF REASSEMBLY MD99881 2 16. INSTALLATION OF TAPER ROLLER BEARING Install the taper roller bearing over the intermediate gear using the special tool. MD99881 3 Caution When installing the bearing, push the inner race only. MD99881 8 Clutch housing + HUB / 9.
Page 881 21-41 MANUAL TRANSAXLE <FWD> 3. INSTALLATION OF BEARING SLEEVE Install the 1st speed gear and bearing sleeve together over the intermediate gear using the special tool. 2. INSTALLATION OF TAPER ROLLER BEARING Install the taper roller bearing over the intermediate using the special tool.
Page 882 21-42 MANUAL TRANSAXLE <FWD> OUTPUT SHAFT ASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly steps Lubricate all internal parts with gear oil during reassembly. 3. Output shaft SERVICE POINTS OF DISASSEMBLY Press 2. REMOVAL OF TAPER ROLLER BEARINGS Remove the taper roller bearing using the special tool as illustrated.
Page 883 MANUAL TRANSAXLE <FWD> SHIFT RAILS AND FORKS DISASSEMBLY AND REASSEMBLY Disassembly steps 1. 1 st-2nd speed shift fork 2. 1 st-2nd speed shift rail 3. 3rd-4th speed shift fork internal parts 4. 5th-reverse speed shift rail with gear oil 5. Interlock plunger during reassembly.
Page 884 MANUAL TRANSAXLE <FWD> DIFFERENTIAL ASSEMBLY DISASSEMBLY AND REASSEMBLY 94 - 101 ftlbs. Disassembly steps + I. Bolt 2. Differential drive gear 3. Taper roller bearing 5. Pinion shaft + 6. Pinion + 7. Washer 8. Side gear 9. Spacer (Select) SERVICE POINTS OF DISASSEMBLY 3.
Page 885 2 1 - 4 5 MANUAL TRANSAXLE <FWD> 4. REMOVAL OF LOCK PIN Lock pin Drive out the lock pin from the hole A using a punch. Pinion shaft SERVICE POINTS OF REASSEMBLY 9. INSTALLATION OF SPACER / 8. SIDE GEAR / 7. WASHER / 6.
Page 886 21-46 MANUAL TRANSAXLE <FWD> 3. INSTALLATION OF TAPER ROLLER BEARING Install the taper roller bearings on both sides of the differential case. Caution When press-fitting the bearings, push the inner race only. 1. INSTALLATION OF BOLTS Apply specified adhesive to the entire threads of the bolts and quickly tighten in the order shown to specified torque.
Page 887 MANUAL TRANSAXLE <FWD> 21-47 CLUTCH HOUSING ASSEMBLY DISASSEMBLY AND REASSEMBLY l 6 4 17 ftlbs. 2100019 Disassembly steps 1. Bolt 2. Select lever assembly Select lever shoe 18. Clutch housing 19. Pin 4. Interlock plate bolt 5. Gasket 20. Return spring 21.
Page 888 21-48 MANUAL TRANSAXLE <FWD> SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF LOCK PIN Drive out the lock pin from the control finger. Caution When removing the lock pin, turn the control lever to d such position that the lock pin will not contact the clutch housing.
Page 889 21-49 MANUAL TRANSAXLE <AWD> GENERAL INFORMATION 1 st-2nd speed synchronizer assembly Transaxle case Clutch housing Input shaft Reverse Front output shaft Transfer case 6th gear Intermediate shaft Center differential Center differential Center differential case Reverse idler gear Front differential gear...
Page 890 MANUAL TRANSAXLE <AWD> SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Model Applicable engine Gear ratio 1 st 3.266 1.241 Reverse Reduction ratio Primary 1.222 Front differential 3.166 Transfer Speedometer gear ratio (driven/drive) 28136 Oil quantity Transaxle 2.4 (2.5) Transfer 0.6 (63) LUBRICANTS Items Specified lubricants Quantity dm3 (qts.)
Page 891 R A N S A X L E SPECIAL TOOLS Use with MB990930 Oil seal installer Differential oil Installation of differential oil seal M D998803 Differential oil M D998824 Installation of transfer case oil seal...
Page 892 MANUAL TRANSAXLE <AWD> - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES TRANSMISSION OIL LEVEL INSPECTION Refer to GROUP 0 - Maintenance Service. TRANSMISSION OIL REPLACEMENT plugs to drain transmission oil. (2) Pour in fresh transmission oil through filler port. Transmission oil: MOPAR Hypoid gear oil or equivalent, API classification GL-4, SAE 75W-90 or 75W-85W Transaxle: 2.4 dm3 (2.5 qts.)
Page 893 MANUAL TRANSAXLE <AWD> - Service Adjustment Procedures 21-53 DRIVE SHAFT OIL SEALS REPLACEMENT (Refer to GROUP 2A - Drive Shaft.) (2) Remove the transfer assembly. (3) Using a flat-tip (-) screwdriver, remove the oil seal. (4) Install the oil seals using the following procedure: For R.H.
Page 894 21-54 MANUAL TRANSAXLE <AWD> TRANSFER OIL SEAL REPLACEMENT (1) Pull out the propeller shaft from the transfer. (Refer to GROUP 16 - Propeller Shaft.) (2) Using a flat-tip (-) screwdriver, remove the oil seal. (3) Using the special tool, tap the drive shaft oil seal into the transfer.
Page 895 21-55 MANUAL TRANSAXLE <AWD> TRANSAXLE CONTROL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Front Console Assembly (Refer to GROUP 23A- Floor Console.) 12 Nm 9 ft.lbs. Transaxle control cable assembly removal steps Shift lever assembly removal steps 1.
Page 896 MANUAL TRANSAXLE <AWD> INSPECTION Check the transaxle control cable assembly for function and for damage. Check the boot for damage. Check each bushing for wear or abrasion, sticking, impeded L/j action, and damage. SERVICE POINTS OF INSTALLATION 6. CONNECTION OF TRANSAXLE CONTROL CABLE ASSEMBLY (SHIFT LEVER ASSEMBLY SIDE) Refer to P.21-14.
Page 897 21-57 MANUAL TRANSAXLE <AWD> TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Draining of Transmission Oil Installation of Transfer Assembly (Refer to P.21-52.) (Refer to P.21-60.) Removal of Transfer Assembly Supplying of Transmission Oil (Refer to P.21-60.) (Refer to P.21-52.) at Each Position Checking the Operation of Meters and Gauges...
Page 898 21-58 MANUAL TRANSAXLE <AWD> 45 Nm 70 Nm 19 Nm 51 ft.lbs. 13 ft.lbs. 75 Nm 75 NI 20 \ 75 Nm 31 Nm 22 ft.lbs. 43 - 52 t=t.lbs. 90 Nm 4.0 ftlbs. 60-72 Nm 36 ftlbs. 43 - 51 ftlbs. 26 ftlbs.
Page 899 MANUAL TRANSAXLE <AWD> SERVICE POINTS OF REMOVAL CONNECTION OF TRANSAXLE MOUNT Refer to P.21-16. 22. DISCONNECTION OF TIE ROD END / 23. LOWER ARM BALL JOINT Refer to P.21-17. 27. REMOVAL OF DRIVE SHAFT (LEFT SIDE), INNER SHAFT ASSEMBLY / 28. DRIVE SHAFT (RIGHT SIDE) / 31. TRANSAXLE ASSEMBLY LOWER COUPLING BOLT / 32.
Page 900: Transfer Assembly
MANUAL TRANSAXLE <AWD> TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying of Transfer Oil (Refer to P.21-52.) Removal and installation of Active Front Venturi Skirt Removal and Installation of Front Exhaust Pipe (Refer to GROUP 11 - Exhaust Pipe and Main Muffler.) 2 5 - 29 Nm...
Page 902 MANUAL TRANSAXLE <AWD> 20102:...
Page 904 brake Front clutch Rear clutch End clutch Torque cow clutch solema To lubrication (front) To lubrlcatlon c 3 clutch v a l v e Torque Shift control valve Oil pan Line pressure Torque converter and lubrlcatlon pressure solenoid pressure Pressure control solemd valve pressure TFA0070...
Page 905 Torque converter Low-reverse brake Front clutch To lubrication C-e ( f r o n t ) To lubrlcatton c (rear) Torque converter control Torque converter clutch pressure Torque converter clutch Torque converter and lubrication solenoid pressure pressure Pressure control solenoid valve pressure TFA0071...
Page 906 Low-reverse brake Front clutch Rear clutch clutch solenoid To lubrrcatron +: (front) To lubricatron c (rear) Pressure control filter I..; 011 p u m p suctron p r e s s u r e Line pressure Torque converter and lubrrcatron pressure Pressure control solenoid valve pressure...
Page 907 AUTOMATIC TRANSAXLE - General Information Low-reverse Front clutch Rear clutch - End clutch Torque converter clutch valve Torque converter I( clutch solenoid To lubrication (front) N-D control Shift control valve valve “B” valve Pressure control solenoid valve Line relief valve Oil oan Torque converter clutch pressure pressure...
Page 908 AUTOMATIC TRANSAXLE - General Information Torque converter Front clutch Rear clutch bra’n u End clutch Torque converte- clutch valve To lubrication (front) To lubrication (rear) Torque Regulator valve Pressure control control module Line pressure Torque converter and lubrication Torque converter clutch pressure solenoid pressure Pressure control solenoid...
Page 909 AUTOMATIC TRANSAXLE - General Information Low-reverse Front clutch Rear clutch End clutch Torque converter clutch solenoid To lubrication (front) To lubrlcatlon += (rear) valve “B” valve valve Torque converter clutch pressure Torque converter clutch Torque converter and lubrication solenoid pressure pressure Pressure control solenoid valve pressure...
Page 910 AUTOMATIC TRANSAXLE - General Information Torque converter Low-reverse brake Front clutch End clutch Torque converter clutch valve ( Torque conver clutch solenoid To lubrrcatron c_ (front) To lubncatron cz (rear) valve Oil pan Torque converter clutch pressure Torque converter clutch Torque converter and lubrrcatron pressure Pressure control solenord...
Page 911 AUTOMATIC TRANSAXLE End clutch Front clutch Rear clutch oraKe \: Torque converter clutch solenoid To lubricatior (front) To lubrication += Torque converter control valve Shift control Pressure control Pressure control Duty N R control m Torque converter clutch pressure Torque converter clutch solenoid pressure Pressure control solenoid valve pressure...
Page 912 AUTOMATIC TRANSAXLE Low reverse brake Front clutch Rear clutch End clutch Rear clutch exhaust valve Torque conve clutch solenol To lubrication c (front) valve Pressure control Oil filter Torque converter and lubrication pressure Pressure control solenoid valve pressure TFA0077...
Page 913: Service Specifications
21-73 AUTOMATIC TRANSAXLE - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items SOHC engine DOHC engine Model Full automatic Full automatic 4 speed transaxle 4 speed transaxle Torque converter 3 element with torque 3 element with torque converter clutch converter clutch 1,800 - 2,800 rpm 2,200 - 3,200 rpm Engine stall speed 2.00...
Page 914 21-74 AUTOMATIC TRANSAXLE - Specifications VALVE BODY SPRING IDENTIFICATION CHART ( i n . ) Part name Wire diameter Outside diameter Length No. of turns Regulator valve spring 1.4 (.055) 15 1.59) 52 (2.05) 11.5 0.6 (.024) 7.6 (.299) 13.5 26.6 (1.047) Pressure control valve spring 0.45 (.0177)
Page 915 21-75 AUTOMATIC TRANSAXLE - Specifications Identification ‘art name Thickness mm (in.) Part No. symbol MD731 736 5.9 (.232) 6.0 (236) MD731 737 6.1 (.240) MD731 738 6.2 (244) MD731 739 6.3 (248) MD731 740 6.4 (.252) MD731 588 MD731741 6.5 (.256) 6.6 (260) MD731 742 6.7 (264)
Page 916 21-76 AUTOMATIC TRANSAXLE - Specifications Identification Part name Thickness mm (in.) Part No. symbol Spacer 0.75 - 0.82 MD722986 (for adjustment of differential gear and pinion backlash) 0.83 - 0.92 MD722985 0.93 - 1 .oo MD722984 1 .Ol - 1.08 M D722982 1 .
Page 917 21-77 AUTOMATIC TRANSAXLE - Special Tools SPECIAL TOOLS Tool number and tool name Replaced by Miller Application tool number MB990635 MB990635 Disconnection of the coupling of the knuckle and lower arm ball joint Steering linkage Disconnection of the coupling of the puller knuckle and tie-rod end ball joint M 8990934...
Page 918 21-78 AUTOMATIC TRANSAXLE - Special Tools Oil seal installer Reassembly of oil pump Oil seal installer B e a r i n g r e m o v e r Installation of each bearing...
Page 919 21-79 AUTOMATIC TRANSAXLE - Special Tools Tool number and tool name Replaced by Miller Application tool number MD998825 Installation of each bearing Installer adapter MD998829 Installation of each bearing Installer adapter M D998830 Installation of each bearing Removal and installation of Installer adapter kick down servo M D998905...
Page 920 AUTOMATIC TRANSAXLE - Special Tools Snap ring installer...
Page 921: Troubleshooting
AUTOMATIC TRANSAXLE - Troubleshootina TROUBLESHOOTING Based upon use of the troubleshooting guide, the probable location of the problem F u n c t i o n a l m a l f u n c t i o n s o f t h e ELC-4A/T c a n l e a d t o o t h e r should be estimated.
Page 922: Troubleshooting Guide
21-82 AUTOMATIC TRANSAXLE TROUBLESHOOTING GUIDE Problem Drivin ‘resumed cause Abnormal idling rpm 2 Performance malfunction Improper adjustment of manual linkage Malfunction of torque convertor Operation malfunction of oil pump Malfunction of one-way clutch Damaged ~rworn gear or other rotating part, or improper Cracked drive plate.
Page 923 Won’t shift from 2nd to 3rd Won’t shift to 4th Overdrive control switch doesn’t function Doesn’t shift according to shift pattern (shifting is possible) Improper start-off (starts off from 2nd. etc.) Excessive vibrato-shock when shift l-2 or 34 Excessive vibration-shock when shift 2-3 or 4-3 Excessive vibration-shock during upshift...
Page 924 21-84 AUTOMATIC TRANSAXLE - Troubleshooting DIAGNOSIS AND TEST FLUID LEVEL AND CONDITION ture [70 - 80°C (158 - 176”F)]. 2. Place vehicle on level floor. 3. Move selector lever sequentially to every position to fill ’ torque converter and hydraulic circuit with fluid, then place lever in “N”...
Page 925 21-85 AUTOMATIC TRANSAXLE DIAGNOSIS FUNCTION METHOD OF READING THE DIAGNOSTIC TROUBLE CODES When using the scan tool Caution Connection and disconnection of the scan tool should always be made with the ignition switch in the OFF position. (2) Take a reading of the diagnostic output. (3) Repair the problem location, referring to the diagnostic chart.
Page 926 21-86 AUTOMATIC TRANSAXLE - Troubleshooting METHOD OF ERASE THE DIAGNOSTIC TROUBLE CODES When using the scan tool (1) Turn the ignition switch to OFF and then back to ON again. (2) Erase the diagnostic trouble codes. (3) Check to be sure that no diagnostic trouble codes exist. When using the voltmeter (1) Turn the ignition switch to the OFF.
Page 927 21-87 AUTOMATIC TRANSAXLE - Troubleshootina FAULT CODE DESCRIPTION Code Display Pattern Item Remedial Action Excessively large throttle Check throttle position sensor position sensor output connector. Check throttle position sensor on bench. Adjust throttle position sensor. Excessively small throttle position sensor output Defective or improperly adjusted throttle position sensor...
Page 928 21-88 AUTOMATIC TRANSAXLE Code Display Pattern Item Remedial Action Open-circuited shift control Check solenoid valve connector. solenoid valve B Check shift control solenoid valve B on bench. Short-circuited shift control solenoid valve B Open-circuited pressure control Check solenoid valve connector. solenoid valve Check pressure control solenoid valve on bench.
Page 929 21-89 AUTOMATIC TRANSAXLE - Troubleshootina Code Display Pattern Item Remedial Action Occurrence of abnormal Check connector of pulse vibration generator A. Check generator A on bench. Replace automatic transmission fluid Short-circuited torque Check torque reduction request reduction request signal line signal line.
Page 930 AUTOMATIC TRANSAXLE - Troubleshooting INSPECTION OF CONTROL SYSTEM Check the control system by using the scan tool and following the procedure given below. CONTROL SYSTEM INSPECTION TABLE Check Item Data list Item No. 11 TPS or circuit harness is defective if there is no change.
Page 931 AUTOMATIC TRANSAXLE - Troubleshootincl al control cable Vehicle-speed reed switch is Duty should become 100% when acceler- PCSV duty Data list Item No. 45 from D range idle conditions. Defective TCM D range, gear being shifted Torque converter D range, 3rd speed, 1,500 rpm clutch slip pulse generator B circ Data list...
Page 932 AUTOMATIC TRANSAXLE TRANSAXLE CONTROL UNIT The connector has 42 pins to accommodate the increased number of sensor inputs. Here are the pin assignments TFA0744 Torque converter clutch solenoid Shift control solenoid valve A (SCSV-A) Engine communication signal Air conditioning relay signal On-board diagnostic output terminal Pulse generator B (PG-B) output Diagnostic test mode control terminal...
Page 933 AUTOMATIC TRANSAXLE ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER 1 st 2.551 1.488 1 st 2.551 1.488 1 st 2.551 NOTE Cl ,_, Front clutch C2 Rear clutch C3 End clutch B 2 Kickdown b r a k e OWC One way clutch SHIFT PATTERNS Two shift patterns are pre-stored in the control unit of this...
Page 934 AUTOMATIC TRANSAXLE <Vehicles with DOHC engine> Transferdrivegearspeed (rpm) 120 130 140 Vehiclespeed (km/h) TFA0817 E range 5000 6000 150 160 170 Vehiclespeed (km/h)
Page 935 AUTOMATIC TRANSAXLE <Vehicles with SOHC engine> P range 2000 3000 4000 5000 6000 Transfer drive gear speed (rpm) Vehicle speed (km/h) TFA0819 20 20 2000 3000 4000 5000 6000 Transfer drive gear speed (rpm) Vehicle speed (km/h) TFA0820...
Page 936 21-96 AUTOMATIC TRANSAXL,E INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS Based on the wiring diagram, check whether the continuity and grounding of each harness is OK. Vary the thermo-sensitive part temperature and check the resist- ance between the terminals Replace the oil- Changes of the resistance con- temperature sensor tinuous and smooth.
Page 937 21-97 AUTOMATIC TRANSAXLE Short-circuit, or dam- Check the resistance between 4. Pulse generator aged or disconnected terminals 1 and 2 or 3 and 4. A or B wiring 215-275 52/2O”C (68°F) Replace the pulse generator A generator. 3-4 pulse Normal generator B 1750338 Connect the pulse generator and...
Page 938 AUTOMATIC TRANSAXLE 6. Pressure- Short-circuit, or dam- Check the resistance between control sole- terminal 1 of the solenoid valve aged or disconnected noid valve wiring connector and the transaxle case. 2.9 f 0.3S2/20°C (68°F) Replace the PCSV. Solenoid valve connector terminals 1 : PCSV 2: TCC solenoid...
Page 939 AUTOMATIC TRANSAXLE Set the selector lever to “P” or “N”, and start the engine. Set the selector lever to the Readjust the idling. Normal Replace the torque converter clutch solenoid. , ;;$i;go”&ty clutch Overhaul the valve body.
Page 940 21-100 AUTOMATIC TRANSAXLE Solenoid valve connector terminals Connect 12 V between the trans- 3: scsu-A 4: SCSU-B mission case and terminal 2; switch ON and OFF and check 1750338 for operation noise. Normal...
Page 941 AUTOMATIC TRANSAXLE In the “P” range, check for con- Continuity exists Continuity exists In the “N” range, check for con- tinuity between terminals 3 and 12. and terminals 7 and 8. Continuity exists No continuity In the “D” range, check for con- tinuity between terminals 3 and 10.
Page 942 AUTOMATIC TRANSAXLE Check for continuity between the Start the engine, set to the “D” range, and let the engine idle; check for continuity between the and the transaxle case. NOTE: Be sure the brakes are pplied during this check. No continuity Normal Disconnect the harness (both A and B connectors) from the vehi-...
Page 943 AUTOMATIC TRANSAXLE - Troubleshooting HYDRAULIC PRESSURE TESTS Completely warm up the transaxle. Raise the vehicle by using a jack so that the front wheels can be rotated. Connect an engine tachometer and place it in a position where it’s easy to see. Attach the special oil-pressure gauge (MD998330 or clutch @Front...
Page 944 21-104 AUTOMATIC TRANSAXLE REMEDIAL ACTION TO TAKE FOR INADEQUATE HYDRAULIC PRESSURE Symptom Possible cause Remedy 1. All line pressures a. Plugged oil filter a. Visually check oil filter and replace it if plugged. are low (or high). b. Measure line pressure @ (K/D brake pres- valve line pressure sure) and readjust line pressure if it is Remarks:...
Page 945 AUTOMATIC TRANSAXLE ring ring End clutch Front clutch Low-reverse brake TFA0641 @Seal ring brake TFA0362...
Page 946 AUTOMATIC TRANSAXLE CONVERTER STALL TEST 7. Place selector lever to “R” position and perform stall test by the same procedure as in foregoing Stall test consist of determining maximum engine item. speed obtained at full throttle in “D” and “R” Stall Speed Above Specification in “D”...
Page 947 AUTOMATIC TRANSAXLE - Troubleshootinn A/T SAFETY-LOCK SYSTEM TROUBLESHOOTING Symptom Probable cause Remedy Ref. page Selector lever can be Damaged lock cam B Check and replace lock cam B. 21-120 selected into R from P without depressing Improperly adjusted shift lock cable, Check, adjust or replace 21-118 brake pedal with...
Page 948 AUTOMATIC TRANSAXLE Improperly adjusted transaxle control cable position even with selector lever in position other than P. lever is placed in R...
Page 949 AUTOMATIC TRANSAXLE SERVICE ADJUSTMENT PROCEDURES TRANSMISSION FLUID LEVEL INSPECTION 1. Drive until the fluid temperature reaches the usual tempera- ture [70 - 80°C (158 - 176”F)I. 2. Place vehicle on level floor. 3. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid, then place lever in “N”...
Page 950 21-110 AUTOMATIC TRANSAXLE - s (2) Snap off the snap ring and remove K/D servo switch. (3) Fit claw of special tool into cutout in piston to prevent ~ piston from turning and use adapter to fix the piston into position.
Page 951 21-111 AUTOMATIC TRANSAXLE (8) Tighten lock nut by hand until it contacts piston. Then, using torque wrench, tighten to specification. Lock nut: 29 Nm (21 ft.lbs.) Caution Use of socket wrench or torque wrench could result in lock nut being turned with adjust rod. (9) Remove the special tool to secure the piston and torque plug to specification at L/R brake pressure take-up port.
Page 952 21-112 AUTOMATIC TRANSAXLE (9) Install valve body and oil temperature sensor. Bolt A = Length 18 mm (.709 in.) Bolt B = Length 25 mm (.984 in.) Bolt C = Length 40 mm (1.575 in.) Caution Secure solenoid valve and oil temperature sensor harness at locations shown.
Page 953 21-113 AUTOMATIC TRANSAXLE SELECTOR LEVER OPERATION CHECK 1. Shift selector lever to each range and check that lever moves smoothly and clicks into position. Check that position indicator is correct. 2. Check to be sure the selector lever can be shifted to each position (by button operation as shown in the illustration).
Page 954 21-114 AUTOMATIC TRANSAXLE - s ervice Adjustment Procedures (4) Loosen nut that secure key interlock cable. (5) Lightly pressing lock cam A in the direction of arrow, lightly push key interlock cable to take up slack and tighten nut to secure key interlock cable. (6) Reinstall front console assembly.
Page 955 AUTOMATIC TRANSAXLE 5. Loosen the nut shown in the figure, and lightly pull the end of the transaxle control cable in the direction of arrow by hand. 6. Tighten the nut to the specified torque. Specified torque: 13 Nm (9.0 ft.lbs.) 7.
Page 956 AUTOMATIC TRANSAXLE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Front Console Assembly CAUTION: SRS When installing or removing the front console, don’t allow any impact or shock to the SRS diagnosis unit. 13 Nm 9 ft.lbs. 4.0 N/m 2.9 ftlbs.
Page 957 AUTOMATIC TRANSAXLE MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent 12 Nm 9 ft.lbs. Key-interlock cable removal steps Shift-lock cable removal steps 3. Connection for key-interlock cable 4. Connection for shift-lock cable (Selector lever assembly side) (Selector lever assembly side) 13.
Page 958 21-118 AUTOMATIC TRANSAXLE INSPECTION Check the control cable for function and for damage. Check the outer cable (key interlock cable, shift lock cable) for damage and spring for breakage and tension. Check the inner cable (key interlock cable, shift lock cable)‘& for extension.
Page 959 21-119 AUTOMATIC TRANSAXLE (5) Connect the shift lock cable to lock cam B and temporarily tighten the nut. At this time, install the spring and washer, which have been fitted to the shift lock cable, as shown. (6) Pressing the set lever to prevent lock cam B from moving, lightly pull the shift lock cable to take up slack and tighten the nut to secure the shift lock cable into position.
Page 960 AUTOMATIC TRANSAXLE SELECTOR LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY MOPAR Multi-mileage Lubricant Part No. 2525035 or eauivalent Disassembly steps Overdrive control switch, position light and Power (PWR)/Economv (ECOVHold (HOLD) changeover switch connector Cover Selector knob 2.0 Nm 1.6 ft.lbs. Overdrive control switch button Overdrive control switch Pushbutton Spring...
Page 961 AUTOMATIC TRANSAXLE SERVICE POINTS OF DISASSEMBLY 1. REMOVAL OF OVERDRIVE CONTROL SWITCH CON- NECTOR Terminal Disconnect the overdrive control switch connector and then remove the terminal from the overdrive control switch connector. 4. REMOVAL OF OVERDRIVE CONTROL SWITCH BUT- Screwdriver TON / 5.
Page 962 AUTOMATIC TRANSAXLE REMOVAL AND INSTALLATION Pre-removal and Post-installation <Vehicles without oil cooler> Operation Drainage and Filling of Automatic Transaxle Fluid (Refer to GROUP 0 -Maintenance Service.) . Removal and Installation of Front Under Cover (Refer to GROUP 23A- Front Bumper.) 12Nm <Vehicles with oil cooler>...
Page 963 21-123 AUTOMATIC TRANSAXLE SERVICE POINTS OF REMOVAL 1. REMOVAL OF HOSE / 2. TUBE ASSEMBLY / 3. FEED HOSE / 4. RETURN HOSE Caution Take care not to spill the transaxle fluid when removing components. 7. REMOVAL OF HOSE ASSEMBLY Caution 1.
Page 964 21-124 AUTOMATIC TRANSAXLE TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Place Selector Lever in “N” Position and Stop the Engine. Draining of Transaxle Fluid (Refer to GROUP 0- Maintenance Service.) Removal of Front Under Cover (Refer to GROUP 23A- Front Bumper.) 70 Nm 51 ftlbs.
Page 965 21-125 AUTOMATIC TRANSAXLE 75 Nm 75 Nm 60-72 Nm 54 ft.lbs. 43 - 52 ftlbs. 33 - 38 ft.lbs. 60-72 Nm 43 - 52 fklbs. 75 Nm 54 ftlbs. 3 4 lt.IDS. 60-70 Nm 43 - 51 ft.lbs. 26 fklbs. 15.
Page 966 21-126 AUTOMATIC TRANSAXLE (2) Remove the nut and move the bolt so that a spanner can be applied to the transaxle mount bracket mounting bolt; then, remove the transaxle mount bracket mount- ing bolt. 16. DISCONNECTION OF TIE ROD END / 17. LOWER ARM’\Lj BALL JOINT Refer to P.21-18.
Page 967 AUTOMATIC TRANSAXLE DISASSEMBLY AND REASSEMBLY When assembling, apply automatic transmission fluid to all sliding surfaces. 36. Kickdown servo piston 37. Spring 38. Anchor rod 39. Detent assembly 40. Manual control shaft 41. Parking roller support 42. Oil pan 43. Gasket 17.
Page 968 21-128 AUTOMATIC TRANSAXLE 63. Idler gear cover 68. Gasket 64. Differential bearing retainer 69. Differential cover 65. Outer race 70. Output bearing retainer 66. Differential front bearing cap 71. Transfer shaft 67. Differential assembly 72. Transaxle case...
Page 969 21-129 AUTOMATIC TRANSAXLE DISASSEMBLY Caution 1. The automatic transaxle consists of high-precision parts and utmost care must be exercised during disassembly and reassembly to prevent damage to the parts. 2. Place a rubber mat on the workbench and keep it clean at all times.
Page 970 AUTOMATIC TRANSAXLE (9) Remove the oil screen. (1 l)Remove the oil temperature sensor holder and remove the oil temperature sensor harness from the clamp. grommet into the case; then, remove the valve body assembly.
Page 971 21-131 AUTOMATIC TRANSAXLE (15)Remove the set screw from the manual control shaft and screw remove the manual control shaft assembly. (16)Remove the detent assembly. (17)Remove the differential cover and gasket. (18)Remove the differential front bearing cap. (19)Remove the differential bearing retainer, spacer and outer race.
Page 972 AUTOMATIC TRANSAXLE (22)Remove the end clutch assembly. (23)Remove the thrust plate. (24)Remove the end clutch hub. (25)Remove the thrust bearing. NOTE The bearing may be adhering to the end clutch hub. (27)Remove the idler gear cover mounting bolts and remove the idler gear cover and gasket.
Page 973 21-133 AUTOMATIC TRANSAXLE (28)Straighten the lock where it forms over the bolt and remove the bolt. inner race. (30)Remove the spacer...
Page 974 AUTOMATIC TRANSAXLE (33)Remove the thrust washer and thrust race assembly and rear clutch assembly together. (35)Remove the thrust bearing. (36)Remove the rear clutch hub. NOTE The thrust race may be sticking to the clutch hub. (37)Remove the thrust bearing.
Page 975 AUTOMATIC TRANSAXLE (38)Remove the kickdown drum. (39)Remove the kickdown band. switch. TFA0137 (41)Using previously released drivers or deep well socket, push in the kickdown servo piston to snap off the snap ring. (42)Remove the kickdown servo piston.
Page 976 AUTOMATIC TRANSAXLE (43)Remove the anchor rod. (45)Remove the snap ring. (46)Using the special tool, remove the center support.
Page 977 2 1 - 1 3 7 AUTOMATIC TRANSAXLE (48)Remove the planetary carrier assembly. brake disc, and brake plate. (50)Remove the screw and remove the rear bearing retainer. assembly. (52)Remove the output bearing retainer mounting bolts and remove the’ output bearing retainer and outer race.
Page 978 21-138 AUTOMATIC TRANSAXLE (55)Remove oil seals. TFA0478...
Page 979 21-139 AUTOMATIC TRANSAXLE REASSEMBLY Caution 1. The gasket, O-ring, and oil seal should never be reused. Whenever they have been removed, they must be replaced with new ones. (Note: The rubber used in the oil level gauge does not require replacement.) 2.
Page 980 AUTOMATIC TRANSAXLE (4) Place 10 mm-long (.39 in.), 1.6 mm-dia. (.06 in.) solders at the locations shown of the output bearing retainer and install the outer race. TFA0167 (5) Install the output bearing retainer and tighten bolts to specification. (6) Loosen the bolts and remove the output bearing retainer. TFA0149 (7) Remove the outer race from the output bearing retainer and remove the solders.
Page 981 21-141 AUTOMATIC TRANSAXLE Thrust earing #IO bearing to the planetary carrier.
Page 982 21-142 AUTOMATIC TRANSAXLE IDENTIFICATION OF THRUST BEARINGS, THRUST RACES AND THRUST WASHERS LOCATION mm (in.) O.D. I.D. Thickness Part No. Code O.D. I.D. Thickness Part No. Code 55.7 48.9 MD997852 (2.193) (1.925) (included *4) 55.7 48.9 MD997853 (2.193) (included “4) 55.7 48.1 34.4...
Page 983 21-143 AUTOMATIC TRANSAXLE - Transaxle Assemblv bearing #8, and reverse sun gear. 1770066 into the planetary carrier. Caution If a new brake disc is to be used, it should be dipped in ATF for more than two hours. Caution Make sure the return spring is installed in the correct direction.
Page 984 21-144 AUTOMATIC TRANSAXLE (21 )Install the special tool to the center support, fit new O-rings (at two places), and press the center support into the transaxle case. Caution 2. Install with care not to allow the wave spring to d shift its position.
Page 985 21-145 AUTOMATIC TRANSAXLE Caution Make sure that the ends of seal ring on the kickdown servo piston are not located at the oil supply port (indicated by arrows). (27)Using previously released drivers or deep well socket, press the kickdown servo piston and sleeve into position and fit the snap ring.
Page 986 21-146 AUTOMATIC TRANSAXLE (31)Mount thrust bearing #5 to the rear clutch hub. Thrust’ bearing #5 TFA0271 TFA0274...
Page 987 21-147 AUTOMATIC TRANSAXLE transaxle case at the same time. pump assembly. (39)Measure the end play in input shaft. If the measurement is out of specification, replace thrust race #3 and thrust washer #I to obtain the specified end play. Standard value: 0.3 - 1.0 mm (.012 - .039 in.) shaft.
Page 988 21-148 AUTOMATIC TRANSAXLE (41)Tighten the idler shaft lock bolt to specification and raise the new lock plate for locking. (43)lnsert the end clutch shaft with its longer splines facing front. (44)Fit the thrust washer onto the end clutch return spring.
Page 989 21-149 AUTOMATIC TRANSAXLE hub. tion.
Page 990 21-150 AUTOMATIC TRANSAXLE the locations shown of the differential rear bearing retainer and install the outer race. to specification. (53)Loosen the bolts, remove the differential rear bearing retainer, and remove the solders. If the solders are not crushed, use larger dia. (3 mm or .I2 in.) solders to repeat steps (51) to (53).
Page 991 21-151 AUTOMATIC TRANSAXLE (59)Fit a new O-ring to the manual control shaft assembly, apply ATF, and insert it into the transaxle case. hole and install the set screw. (61)Mount the parking roller support. (63)Fit the O-ring into the O-ring groove in the top surface of valve body assembly.
Page 992 AUTOMATIC TRANSAXLE - Transaxle Assembly case from the inside. (66)Press the solenoid valve harness grommet into the case a hole. (67)Fitting the detent plate pin into the groove in manual valve, Detent plate temporarily secure the valve body. Then, install the oil temperature sensor and holder and tighten bolts to speci- fication.
Page 993 AUTOMATIC TRANSAXLE 21-153 Caution Install the black tube to the output gear side and transparent tube to end clutch side. (73)Mount the oil filler tube and insert the level gauge. tube TFA0757 t with the snap ring. converter, and push converter into position so that dimen- sion A is up to specification.
Page 994 21-154 AUTOMATIC TRANSAXLE GENERAL REASSEMBLY PRECAUTIONS (1) Coat the seal rings, clutch disc, clutch plate, and rotary and sliding surfaces with ATF before installation. (2) Replace all gaskets and O-rings with new parts. They should not be reused. (3) Use petrolatum to secure parts in position. TRANSFER SHAFT DISASSEMBLY AND REASSEMBLY Disassembly steps...
Page 995: Oil Pump
AUTOMATIC TRANSAXLE SERVICE POINTS OF REASSEMBLY Front side 1. 3. INSTALLATION OF BEARING U s i n g p r e v i o u s l y r e l e a s e d d r i v e r s o r d e e p w e l l s o c k e t , i n s t a l l t h e b e a r i n g s t o t h e t r a n s f e r s h a f t .
Page 996 21-156 AUTOMATIC TRANSAXLE - Oil Puma, SERVICE POINTS OF REASSEMBLY 9. INSTALLATION OF OIL SEAL housing Using the special tool, install the oil seal to the pump housing. 5. MEASUREMENT SIDE CLEARANCE OF DRIVEN GEAR / 4. DRIVE GEAR Measure the side clearance of the oil pump gear and, if the specification is exceeded, replace the gear or oil pump assembly.
Page 997 AUTOMATIC TRANSAXLE FRONT CLUTCH ASSEMBLY DISASSEMBLY AND REASSEMBLY Lubricate all internal parts with automatic Clutch reaction plate Clutch plate Clutch disc Clutch pressure plate Snap ring l * .C Return spring Front clutch piston D-ring D-ring Front clutch retainer...
Page 998 21-158 AUTOMATIC TRANSAXLE SERVICE POINT OF DISASSEMBLY 6. REMOVAL OF SNAP RING (2) Remove the snap ring. 1750264 SERVICE POINTS OF REASSEMBLY MD998337 6. INSTALLATION OF SNAP RING (1) Compress the return spring with the special tool. (2) Install the snap ring. 1750264 5.
Page 999 AUTOMATIC TRANSAXLE REAR CLUTCH ASSEMBLY DISASSEMBLY AND REASSEMBLY TFA1075 Disassembly steps 1. Seal ring 2. Input shaft 3. O-ring 4. Snap ring 5. Thrust race 6. Seal ring 7. Snap ring 8. Clutch reaction plate 9. Clutch disc TFA1076 11. Clutch pressure plate 12.
Page 1000 AUTOMATIC TRANSAXLE - Rear Clutch Assembly SERVICE POINT OF DISASSEMBLY MD998337 12. REMOVAL OF SNAP RING (2) Using the snap ring pliers, remove the snap ring. SERVICE POINTS OF REASSEMBLY MD998337 12. INSTALLATION OF SNAP RING (1) Using the special tool, compress the return spring. (2) Using the snap ring pliers, install the snap ring.
Page 1001 AUTOMATIC TRANSAXLE DISASSEMBLY AND REASSEMBLY T F A 0 6 0 7 Disassembly steps 1. Seal ring 2. Snap ring 3. Clutch reaction plate 4. Clutch disc 5. Clutch plate 6. Snap ring 7. Washer TFA0608 8. Return spring Lubricate all internal 9.
Page 1002 AUTOMATIC TRANSAXLE SERVICE POINTS OF REASSEMBLY 6. INSTALLATION OF SNAP RING Using the special tool, fit the snap ring. Caution Make sure that the snap ring is fitted in position in the d groove. 2. SELECTION OF SNAP RING After the snap ring has been installed, check to see if the clearance between the snap ring and clutch reaction plate is up to specification.
Page 1003 AUTOMATIC TRANSAXLE (2) Using a pin punch, drive out the rivet. SERVICE POINTS OF REASSEMBLY 6. INSTALLATION OF ONE-WAY CLUTCH Push the one-way clutch into position so that the arrow on its gauge points at a direction as shown. 3. INSTALLATION OF WAVED WASHER Install the waved washer to the rivet so that its indentation is placed on the outer race side.
Page 1004 AUTOMATIC TRANSAXLE - DISASSEMBLY AND REASSEMBLY TFA0262 Disassembly steps 1. Snap ring 2. Stopper plate * 4. Bearing + 5. Transferdrivegear 6. Snap ring 7. Output flange 8. Annulus gear SERVICE POINTS OF DISASSEMBLY 3. 4. REMOVAL OF BEARING / 5. TRANSFER DRIVE GEAR together with two bearings from the output flange.
Page 1005 AUTOMATIC TRANSAXLE - SERVICE POINTS OF REASSEMBLY 5. INSTALLATION OF TRANSFER DRIVE GEAR / 4. 3. BEARING (1) Using previously released drivers or deep well socket, , I/ press-fit the bearings into both sides of the transfer drive gear. (2) Using previously released drivers or deep well socket, install the transfer drive gear to the output flange.
Page 1006 AUTOMATIC TRANSAXLE DISASSEMBLY AND REASSEMBLY 163025 Disassembly steps 2. Differential drive gear + 3. Bearing + 4. Lock pin 5. Pinion shaft Lubricate all internal + 6. Pinion parts with automatic C 7. Washer transmission fluid * 8. Sidegear during reassembly. * 9.
Page 1007 AUTOMATIC TRANSAXLE SERVICE POINTS OF DISASSEMBLY 9. INSTALLATION OF SPACER / 8. SIDE GEAR / 7. WASHER / 6. PINION / 5. PINION SHAFT install the gear into the differential case. (2) Fit washer to back of pinion and rotate two pinions at the same time into position to mesh with the side gear.
Page 1008 AUTOMATIC TRANSAXLE - Differential / Speedometer Driven Gear Assembly 1. INSTALLATION OF BOLTS Coat the differential drive gear bolts with ATF and tighten them to specification in the numerical order shown. DISASSEMBLY AND REASSEMBLY 201078 Disassembly steps 2. Spring pin Speedometer driven gear Oil seal Sleeve...
Page 1009 AUTOMATIC TRANSAXLE DISASSEMBLY AND REASSEMBLY Disassembly steps 1. O-ring 2. Kickdown servo 3. D-ring 1750299 4. Seal ring 5. Locknut 6. Kickdown servo rod 7. Kickdown servo piston DISASSEMBLY AND REASSEMBLY Lubricate all internal parts with automatic transmission fluid during reassembly. Disassembly steps 2.
Page 1010 AUTOMATIC TRANSAXLE - Valve Body Viewed from A DISASSEMBLY AND REASSEMBLY Lubricate all internal parts with automatic during reassembly. TFA0523 Disassembly steps 1. Manual valve 2. Pressure control solenoid valve 3. Torque converter clutch solenoid + 4. Shift control solenoid valve “A” + 5.
Page 1011 AUTOMATIC TRANSAXLE - Valve Bodv Viewed from B 38. 2-3/4-3 shift spring 24. Front end cover 39. 2-314-3 shift valve 25. Pressure control spring 40. Rear end cover 26. Pressure control valve 27. Torque converter control spring 41. Shift control plug B 28.
Page 1012 AUTOMATIC TRANSAXLE - Valve Body 47. Pin 48. Stopper 49. End clutch plug 50. End clutch spring 51. End clutch valve 52. End cover 53. Torque converter clutch control sleeve 54. Torque converter clutch control valve 55. Torque converter clutch control spring Lubricate all internal 56.
Page 1013 AUTOMATIC TRANSAXLE - Valve Body 42.33. LOCATION OF STOPPER PLATE / 20. N-D PLATE / 19. TEFLON BALL / 18. STEEL BALL Install the stopper plates, N-D plate, teflon ball, and steel balls into the upper valve body as shown. 17.
Page 1014 AUTOMATIC TRANSAXLE - Valve Body (3) Secure the lower valve body with mounting bolts and then remove the special tool. 5. 4. 3.2. INSTALLATION OF SOLENOID VALVE ASSEM- install solenoid valves as shown. Solenoid valve Wire color Orange Shift control solenoid valve A Yellow Shift control solenoid valve B SCSV-A...
Page 1015 CONTENTS TROUBLESHOOTING ..........3 SERVICE ADJUSTMENT PROCEDURES .
Page 1016: Wheels And Tires
WHEELS AND TIRES GENERAL SPECIFICATIONS Items SOHC DOHC <Non-Turbo> DOHC <Turbo> Wheel Tire size Wheel type Polycast steel Aluminum type Aluminum type Aluminum type* Wheel size 17 x 8.5J 15 x 6.5JJ” Amount of wheel offset mm (in.) 46 (1.8) 46 (1.8) 46 (1.8) Tire inflation pressure...

Mitsubishi Stealth 1994 Import Service Manual

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