Mitsubishi 3000GT 1991 Service Manual

Table of Contents

Quick Links

Volume lm

I ' k

Engine, Chassis & Body

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Mitsubishi 3000GT 1991

Page 1 Volume lm I ‘ k Engine, Chassis & Body...
Page 3 MITSUBISHI Interior ..*....*..*....... MOTOR SALES OF AMERICA. Inc. Mitsubishi Motors Corporation reserves the right to make changes in design or to make addltlons to or tmprovements in Its products without Heater, Air Conditioner Imposing any obligations upon Itself to install them on its products previously manufactured.
Page 4 (3) Service or maintenance of any SRS component or SRS-related component must be perfarmed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B component of the SRS or any SRS-related component.
Page 5: Table Of Contents
GENERAL CONTENTS MOOOA- GENERAL DATA AND SPECIFICATIONS ..21 Fuel System ............Manual Transaxle .
Page 7: How To Use This Manual
GENERAL HOW TO USE THIS MANUAL MOOBAAF SCOPE OF MAINTENANCE, REPAIR AND DEFINITION OF TERMS SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection or the and servicing of the subject model.
Page 8: Explanation Of Manual Contents
GENERAL - How to Use This Manual EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures Classifications of Major Maintenance/Service Points Symbols for Lubrication, Sealants and Adhesives TSB Revision...
Page 9 GENERAL - How to Use This Manual STEERING - Power Steering Gear Box POWER STEERING GEAR BOX REMOVAL AND INSTAUATION 2. Connection for return tube for press.ure hose 4. cotter pm 3. maI,% ,v*, ,tu&w.,. *.-._ 10. Center member rear mourha WR SERVICE POINTS OF REMOVALJ- 6.
Page 10: Explanation Of The Troubleshooting Guide
GENERAL EXPLANATION OF THE TROUBLESHOOTING GUIDE 3. Cheddng the psssenger compartment-tempwsturs sensor, o&de-sir sensor, sir- A negatkcharactensw fhemwor IS employed for each sensor nn order 10 convert the smbnen, temperature of rhe SB”SOf pan to ,es,s,ance. The sensor power-supply l2.W) of the air-condaioner control unit 1s applied to each sensor. and the voltages of terminals 1161.
Page 11: Explanation Of Circuit Diagrams
GENERAL 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 Volume 2 - Circuit Dia- grams. TSB Revision...
Page 12: Vehicle Identification Code Chart Plate
GENERAL VEHICLE IDENTIFICATION MOOCA- VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number (V.I.N.) is located on a plate 1 J attached to the left top s3e 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 13: Vehicle Identification Number List
GENERAL VEHICLE IDENTIFICATION NUMBER LIST MOOCC- VEHICLES FOR FEDERAL Mitsubishi 3000GT 3.0 liters (181.4 cu.in.) [DOHC-MPI] Mitsubishi 3000GT 3.0 liters (181.4 cu.in.) [DOHC-MPI-Turbo] VEHICLES FOR CALIFORNIA Engine displacement Models code Mitsubishi 3000GT 3.0 liters (181.4 cu.in.1 [DOHC-MPI] Mitsubishi 3000GT 3.0 liters (181.4 cu.in.1...
Page 14: Chassis Number
GENERAL VEHICLE INFORMATION CODE PLATE MOOCD- . 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. 1. MODEL 0060046 2. ENGINE / E n g i n e m o d e l 3.
Page 15: Engine Model Stamping
GENERAL - Vehicle Identification ENGINE MODEL STAMPING MOOCG- the top edge of the cylinder block as shown in the following: Engine displacement 3.0 liters (181.4 cu.in.1 2. The engine serial number is stamped near the engine model number, and the serial number cycles, as shown below Engine serial number N u m b e r c y c l i n g...
Page 16 GENERAL Automatic transaxle The illustration indicates left hand side, outer. Right hand side is symmetrically opposite.
Page 17 GENERAL - Vehicle Identification The illustration indicates right hand side, outer. Left hand side is symmetrically opposite. The illustration indicates left hand side, outer. Right hand side is symmetrically opposite. TSB Revision...
Page 18 GENERAL - Vehicle Identification Part Target area Front bummer OOFO013 OOFO047 TSB Revision...
Page 19 GENERAL PRECAUTIONS BEFORE SERWCE MOOOAAO SYSTEM SERVICING ELECTRICAL 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 20: Towing And Hoisting
GENERAL TOWING AND HOISTING Sling type MOOGAAC WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP Caution This vehicle cannot be towed by a wrecker using sling-type Wheel lift type equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equip- ment.
Page 21 GENERAL SAFETY PRECAUTIONS The following precautions should be taken when towing the vehicle. 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 prior to moving the vehicle.
Page 22 GENERAL HOISTING support Frame contact 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 L) proper adapters in order to support the vehicle at the proper locations.
Page 23 GENERAL LIFTING, JACKING SUPPORT LOCATION OOFO019 EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack supplied with the vehicle for emergency road service. Always block opposite wheels and jack on level surface. TSB Revision...
Page 24: For Awd Models
GENERAL SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS MOOUAAC 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 25: General Data And Specifications
GENERAL GENERAL DATA AND SPECIFICATIONS OOFO015 GENERAL SPECIFICATIONS 3000GT 3000GT SL 3000GT VR-4 <DOHC> <DOHC> <DOHC> (Non-Turbo) (Non-Turbo) (Turbo) Vehicle dimensions mm (in.) Overall length 4,545 (178.9) 4,545 (178.9) 4,545 (I 78.9) Overall width 1,840 (72.4) 1,840 (72.4) 1,840 (72.4) Overall height 1,285 (50.6) 1,285 (50.6)
Page 26 GENERAL 3000GT 3000GT SL 3000GT VR-4 <DOHC> <DOHC> <DOHC> (Non-Turbo) (Non-Turbo) (Turbo) Transaxle Model No. -Type Manual transaxle Automatic transaxle automatic automatic Fuel system Fuel supply system Electronic Electronic Electronic control control control multi-point multi-point multi-point injection injection injection ENGINE SPECIFICATIONS Items Front Transverse Front Transverse...
Page 27: Tightening Torque
GENERAL - Tightening Torque 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 nuts are all in dry condition.
Page 28: Master Troubleshooting
GENERAL - Master Troubleshooting MASTER TROUBLESHOOTING ENGINE OVERHEATS Symptom Probable cause Reference page faulty Engine overheats 14-3 Cooling system , incorrect ignition timing ENGINE WILL NOT CRANK OR CRANKS SLOWLY Probable cause Symptom Reference page Starting system faulty Engine will not crank 16-15 or cranks slowly ENGINE WILL NOT START OR HARD TO START (CRANKS OK)
Page 29 GENERAL - Master Troubleshooting ROUGH IDLE OR ENGINE STALLS Reference page or remedy Symptom Probable cause Rough idle or engine stalls Vacuum leaks Purge control valve hose Vacuum hoses Intake manifold Air intake plenum Throttle body EGR valve Ignition system problems 16-25 Check idle speed control Idle speed set too low...
Page 30 GENERAL ENGINE DIESELING Symptom Probable cause Reference page Engine dieseling (runs after Incorrect ignition timing 11-13 ignition switch is turned off) EXCESSIVE OIL CONSUMPTION Probable cause Symptom Excessive oil consumption Oil leak Repair as necessary Positive crankcase ventilation line clogged 17-5 11-34 Valve stem seal worn or damaged...
Page 31 GENERAL 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 Excessive turning resistance of lower arm ball joint Excessively tightened steering gear box rack support cover 33A-4 Improper front wheel alignment...
Page 32 GENERAL POOR RIDING 34-5. 13.23, 33 Broken or worn ABNORMAL TIRE WEAR Reference page Probable cause Symptom Abnormal tire wear Improper tire pressure lmbalanced wheels 34-6 Loose wheel bearings Malfunctioning shock absorber 34-l 3.33 ROAD WANDER Reference page Probable cause Symptom Road wander Improper front or rear wheel alignment...
Page 33: Vehicle Pulls To One Side
GENERAL VEHICLE PULLS TO ONE SIDE Symptom Probable cause Reference page or remedy Vehicle pulls to one side Improper front or rear wheel alignment lmbalanced or worn tires 31-3 Uneven tire pressure Excessive turning resistance of lower arm ball Wheel beanng serzure Replace Broken or worn coil spring r ~~~~~~...
Page 34 GENERAL 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 End of bearing life The surface peels because of uneven rotation of the race and bearing surfaces Improper bearing assembly Cracking Chipping or cracking of cage or roller edges...
Page 35: Lubrication And Maintenance
GENERAL LUBRICATION AND MAINTE- engine protection. Both the SAE grade and the API designation can be found on the container. NANCE Caution Maintenance and lubrication service recommenda- Test results submitted to EPA have shown that tions have been compiled to provide maximum laboratory animals develop skin cancer after protection for the vehicle owner’s investment prolonged contact with used engine oil.
Page 36: Lubricant Capacities Table
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS DIA-QUEEN LONG-LIFE COOLANT (Part No. 0103044) or LUBRICANT CAPACITIES TABLE U.S. measure Description Metric measure Engine oil 4.2 qts. Crankcase 4.0 liters (excluding oil filter and oil cooler) Oil filter 0.3 liter 112 qt.
Page 37 GENERAL SELECTION OF LUBRICANTS ENGINE OIL Engine oil should be used which conform to the requirements of the API classification “For Service SG” or “For Service expected temperature range. Caution Nondetergent or straight mineral oil must never be used. Energy Conserving Oil In order to improve fuel economy and conserve energy new, lower friction engine oils have been developed.
Page 38 SELECTION OF COOLANT COOLANT Relation between Antifreeze Concentration and Specific Gravity Example The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at the coolant temperature of 20°C (68°F). Caution 1. If the concentration of the coolant is below the anti-corrosion property will be adversely affected.
Page 39: Scheduled Maintenance Table
GENERAL SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER 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. GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE TSB Revision...
Page 40: Maintenance Service
GENERAL - Scheduled Maintenance Table / Maintenance Service SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS The maintenance items should be performed according to the following table: MAINTENANCE SERVICE 1. FUEL SYSTEM (TANK, LINES, CONNECTIONS AND FUEL FILLER CAP) (Check for leaks) / 2. FUEL HOSES (Check for leaks or damage) 1.
Page 41: Air Cleaner Element
GENERAL 3. AIR CLEANER ELEMENT (Replace) MOOSAKH The air cleaner element will become dirty and loaded with dust during use, and the filtering effect will be substantially reduced. Replace it with a new one. <Non-Turbo> (1) Disconnect the air-flow sensor connector. (2) Remove the air intake hose from the air-flow sensor.
Page 42: Drive Belt (For Alternator)
GENERAL 6. DRIVE BELT (For Alternator) <Vehicles without air conditioner> (Inspect tension) (1) Measure the deflection with a force of 100 N (22 Ibs.) applied to belt mid-point between pulleys shown in the illustration. If the standard value is not obtained, make adjustment.
Page 43: Engine Oil Filter
The following is a highquality filter and is strongly recommended for use on this vehicle: Mitsubishi Engine Oil Filter P/N MD136790. Any replacement oil filter should be installed in accordance with the oil filter manufacturer’s installation instructions.
Page 44 GENERAL - Maintenance Service (2) Check that the transaxle oil level is at the lower portion of the filler plug hole. For AWD-vehicles, check that the transfer oil level is at the portion shown in the illustration. (3) Check to be sure that the transmission oil is not noticeably ‘d dirty, and that it has a suitable viscosity.
Page 45: Engine Coolant
(7.9 qts.). Actually however, approx. 4.5 liters (4.8 qts.) of fluid can be replaced because rest of fluid remains in torque converter.] Specified fluid: Dia ATF SP or MITSUBISHI PLUS ATF or equivalent (9) Start engine and allow to idle for at least two minutes.
Page 46: Ball Joint And Steering Linkage Seals
GENERAL 9. Install the radiator cap securely. 10. Start’the engine and warm up until the thermostat opens. 11. Race the engine up to around 3,000 rpm several times, then stop the engine. 12. When the enkine has cooled down, remove the radiator cap and add coolant up to the brim.
Page 47: Drive Shaft Boots
GENERAL 15. 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. Inspect the boots for proper sealing, leakage and damage.
Page 48: Main Sealant And Adhesive Table
Part No. 8660 or equivalent 6. Chassis sealant Sealing of flange surfaces 3M ATD and threaded portions Part No. 8659 MITSUBISHI Fuel gauge unit packing or equivalent (except 4G5 engine) GENUINE Part No. MD9971 10 3M ATD or equivalent threaded portions, packing Part No.8663...
Page 49 GENERAL - Main Sealant and Adhesive Table Recommended Application brand 7. Fast bonding adhesive Adhesion of all materials 3M ATD except polyethylene, poly- Part No. 8155 propylene, fluorocarbon resin or equivalent or other materials with highly absorbent surface 8. Anaerobic fast bonding adhesives 3M Stud locking Tightening of drive gear...
Page 51 ENGINE CONTENTS CAMSHAFT OIL SEALS ........PISTON AND CONNECTING ROD ....CRANKSHAFT, FLYWHEEL AND ROCKER ARM AND CAMSHAFT ....DRIVE PLATE ............SERVICE ADJUSTMENT PROCEDURES ..CYLINDER BLOCK ..........Compression Pressure Check ......Curb Idle Speed Inspection ......CYLINDER HEAD AND VALVE ......Drive Belts Tension Adjustment ....
Page 52 E N G I N E - General Information GENERAL INFORMATION SECTIONAL VIEW TSB Revision...
Page 53 ENGINE TSB Revision...
Page 54 ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS Items Non-Turbo Turbo V-type, DOHC V-type, DOHC Number of cylinders Bore mm (in.) 91 .I (3.587) 91 .I (3.587) Stroke mm (in.) 76.0 (2.992) 76.0 (2.992) Piston displacement cc (win.) 2,972 (181.4) 2,972 (181.4) Compression ratio Firing order 1-2-3-4-5-6 1-2-3-4-5-6...
Page 55 ENGINE - Specifications Items Standard value Limit Cylinder head Overall height mm (in.) 132 (5.20) -0.2 (-,008)’ Flatness of gasket surface mm (in.) Max. 0.03 l.0012) 0.2 (.008) Oversize rework dimension of valve seat hole mm (in.) Intake 0.3 f.012) O.S. 36.300 - 36.325 (1.4291 - 1.4301) 0.6 l.024) O.S.
Page 56 ENGINE Standard value Limit Items Valve guide Length mm (in.) 45.5 (1.791) Intake 50.5 (1.988) Exhaust mm (in.) 0.05 f.002). 0.25 (.OlO), Service size 0.50 f.020) Oversize Valve seat mm (in.) 0.9 - 1.3 (.035 - ,051) Width of seat contact 44 - 44.5”...
Page 57 ENGINE Items Standard value Limit Connecting rod bearing Oil clearance mm (in.) 0.1 (.004) Crankshaft main bearing Oil clearance mm (in.) 0.1 (.004) Crankshaft Pin O.D. mm (in.) 49.9 (I ,965) Journal O.D. mm (in.) 59.9 (2.358) Out-of-roundness of journal and pin Less than 0.003 (.00012) mm (in.) Taper of journal and pin...
Page 58 ENGINE - Specifications / Special Tools SEALANTS Items Specified sealant Oil pan MITSUBISHI GENUINE Part No. MD9971 10 or equivalent Oil seal case Oil pressure switch Oil pressure gauge unit 3M ATD Part No.8660 or equivalent Rocker cover SPECIAL TOOLS...
Page 59 ENGINE - Special Tools Use with MD998765 Removal and installation of piston pin Use with MD998764 Supporting the cran crankshaft bolt and pulley are removed or reinstalled. Use together with MB990767-01 Tensioner pulley Adjustment of timing belt socket wrench TSB Revision...
Page 60 ENGINE TROUBLESHOOTING Symptom Probable cause Remedy Compression too low Piston ring worn or damage Replace rings Piston or cylinder worn Repair or replace piston and/or cylinder block Valve seat worn or damage Repair or replace valve and/or seat ring Engine oil level too low Check engine oil level Oil pressure switch faulty Replace oil pressure switch...
Page 61 ENGINE SERVICE ADJUSTMENT PROCEDURES DRIVE BELTS TENSION ADJUSTMENT Caution 1. When installing the V-ribbed belt, check that the V-ribs are properly fit without misalignment. 2. If creaking or slippage is observed, check the belt for wear, damage, or breakage on the pulley contact surface, check the pulley for scoring, in addition to sag inspection.
Page 62 ENGINE TENSION ADJUSTMENT OF THE ALTERNATOR DRIVE BELT <Vehicle without air conditioner> (1) Remove front under cover panel <Vehicle with active (3) Loosen tension pulley fixing nut. (4) Adjust belt deflection with adjusting bolt. (5) Tighten fixing bolt. (6) Run the engine one time or more. (7) Check the belt tension.
Page 63 ENGINE - Service Adiustment Procedures IGNITION TIMING ADJUSTMENT inspection and adjustment. Engine coolant temperature: 80 - 95°C (176 - 205°F) Lights, electric cooling fan and accessories: OFF Transaxle: neutral (P for A/T) Steering wheel: neutral position (2) Insert a paper clip to the connector, and connect a tachometer to the paper clip.
Page 64 ENGINE (15)Check to be sure that the idling ignition timing is the correct timing. Actual ignition timing: Approx. 15” BTDC NOTE (2) And it is automatically advanced at higher altitudes. CURB IDLE SPEED INSPECTION (1) The vehicle should be prepared as follows before the inspection.
Page 65 ENGINE - Service Adjustment Procedures COMPRESSION PRESSURE CHECK (1) Before checking compression, ensure that engine oil, the starter motor, and battery are all in normal operating condition. (2) Start the engine and wait until engine coolant temperature has risen to 80 - 95°C (176 - 205°F). (3) Remove the all spark plugs.
Page 66 ENGINE MANIFOLD VACUUM INSPECTION inspection. Engine coolant temperature: 80 - 95°C (176 - 205°F) ‘d Lights, electric cooling fan, and accessories: OFF Transaxle: Neutral (P for A/T) Steering wheel: neutral position (3) Disconnect the vacuum hose from the nipple for taking off fuel pressure regulator vacuum from the air intake plenum.
Page 67: Engine Assembly
ENGINE - Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation 29 - 33 fklbs. Removal steps 11. Drive belt (Alternator and air conditioner) 1. Connection of accelerator cable 2. Connection of brake booster vacuum hose (Refer to P.l l-l 1.) 3.
Page 68 ENGINE 19. ISC servo connector 20. TPS connector 21. Oil pressure switch and oil pressure gauge unit connector 22. Fuel injector harness connector 23. Knock sensor connector 24. Crankshaft angle sensor connector 25. Engine coolant temperature switch connector (Air conditioner) 26.
Page 69 ENGINE - Enaine Assemblv SERVICE POINTS OF REMOVAL 15. DISCONNECTION OF Ail? CONDITIONER COMPRES- SOR / 16. POWER STEERING OIL PUMP Disconnect air conditioner compressor and power steering oil pump (with the hose). NOTE The removed air conditioner compressor and power steer- ing 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 70: Camshaft Oil Seals
ENGINE - Camshaft Oil Seals CAMSHAFT OIL SEALS Pre-removal and Post-installation Operation (Refer to GROUP 90 Nm Removal steps 2. Connection for spark plug cables 3. Connection for breather hose 4. Connection for PCV hose 5. Rocker cover 6. Camshaft sprocket Sealant: 3M ATD Part No.
Page 71 ENGINE - Camshaft Oil Seals 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 72: Oil Pan And Oil Screen
ENGINE - Oil Pan and Oil Screen OIL PAN AND OIL SCREEN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Refilling Removal and Installation MITSUBISHI GENUINE Part Sealant: No. MD9971 10 or equivalent 13 Nm 7 ft.lbs. 26 ft.lbs.
Page 73: Cylinder Head Gasket
ENGINE - Winder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying Removal-and Installation 10 Nm 7 ft.lbs. 10 Nm 7 ft.lbs. 2.2 klbs. 01 LO21 7 1.4 in.) Sealant: 3M ATD Part No. 8660 or equivalent <Cold engine>...
Page 74 ENGINE SERVICE POINTS OF REMOVAL 6. REMOVAL OF INTAKE CAMSHAFT SPROCKET (1) Using a wrench, hold the camshaft at its hexagon and remove the camshaft sprocket bolt. Caution Locking the camshaft sprocket with a tool damages the sprocket. (2) Remove the camshaft sprockets. 14.
Page 75 ENGINE - Cylinder Head Gasket 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. INSTALLATION OF ROCKER COVER Tighten the rocker cover bolts in the order shown in the illustration.
Page 76: Timing Belt
ENGINE TIMING BELT REMOVAL AND INSTALLATION Pre-removal Operation 7 - 9 ft.lbs. Cruise Control Pump and IO-12Nm OSFOO03 72 - 87 ft.lbs. 25 ft.l$. Removal steps 130 - 137 ft.lbs. 2. Air pipe m --@ 3. Tensioner assembly Drive belt (power steering) Post-installation Operation 6.
Page 77 ENGINE - Timinn Belt 10. REMOVAL OF ENGINE SUPPORT BRACKET 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 78 ENGINE - Timing Belt 12. INSTALLATION OF TIMING BELT In case of the camshaft sprockets in the front bank, I 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 79 E N G I N E - Timing Belt (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 80 ENGINE - Timing Belt 11. INSTALLATION OF TIMING BELT FRONT COVER (LOW- Since the mounting bolts of timing cover are different in size depending on location, insert them with care. 10. INSTALLATION OF ENGINE SUPPORT BRACKET Since the mounting bolts of engine support bracket are different in size depending on location, insert them in numbered sequence.
Page 81 ENGINE - Rocker Arm and Camshaft ROCKER ARM AND CAMSHAFT REMOVAL AND INSTALLATION 11 Nm 8 ftlbs. Installation steps Removal steps 10. Rocker arm * 9. Camshaft 3. Oil seal 4. Bearing cap rear * 7. Bearing cap No. 4 5.
Page 82 ENGINE INSPECTION CAMSHAFT Measure cam height (longer diameter of the cam). If it exceeds the limit, replace the camshaft. Standard value: Intake side 35.49 mm (1.3972 in.) Exhaust side mm (1.3858 in.) 35.20 Limit: Intake side 34.99 mm (1.3776 in.) Exhaust side mm (1.3661 in.) 34.70...
Page 83 ENGINE - Rocker Arm and Camshaft (2) Tighten gradually in two or three steps and finally tighten to specified torque. (3) Measure the camshaft end play. Replace if the limit is exceeded. Standard value: 0.1 - 0.2 mm (.004 - .008 in.) Limit: 0.4 mm (.016 in.) NOTE If the bearing cap is installed with the cylinder cap...
Page 84 ENGINE - Cylinder Head and Valve CYLINDER HEAD AND VALVE REMOVAL AND INSTALLATION 125 Nm 90 ftlbs. 7E NO254 Removal steps * 11. Valve spring 2. Washer 12. Exhaust valve 3. Cylinder head assembly 4 13. Valve stem seal + 4. Cylinder head gasket 14.
Page 85 ENGINE SERVICE POINTS OF REMOVAL 1. REMOVAL OF CYLINDER HEAD BOLT bolts. Using the special tool, remove the cylinder head 5. 9. REMOVAL OF RETAINER LOCK Using the special tool, remove the retainer lock. INSPECTION CYLINDER HEAD flatness of the cylinder head gasket surface. Standard value: 0.03 mm (0012 in.) or less Limit: 0.2 mm (008 in.) (2) If the measured flatness exceeds the limit, grind and repair...
Page 86 ENGINE VALVE SPRINGS necessary. Standard value: 46.9 mm (1.846 in.) Limit: 45.9 mm (1.807 in.) (2) Using a square, test squareness of each valve spring. If spring is excessively out of square, replace it. Standard value: Less than 2” Limit: 4 1 EN035 VALVE GUIDES Check the valve stem-to-guide clearance.
Page 87 ENGINE (2) Rebore the valve seat hole in cylinder head to a selected oversize valve seat diameter. Oversize I.D. Valve Seat Insert Oversizes Seat insEt(,ke;ght H Cylinder head I.D. Description Size mm (in.) mm (in.) Intake valve 0.3 i.012) 0,s. 7.5 - 7.7 (.295 - ,303) 36.300-36.325 (1.4291-1.4301) 0.6 (.024) O.S.
Page 88 ENGINE 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. Caution 1. Incorrect installation of the seal without using the special tool will result in poor sealing and cause oil leakage down valve guide.
Page 89 ENGINE 1. INSTALLATION OF CYLINDER HEAD BOLT (1) Using the special tool, tighten the bolts in two to three stages in the illustrated sequence. (2) Back off the bolts once and tighten them to the specified torque as shown in step (1). TSB Revision...
Page 90 ENGINE OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION 19 Nm 14 ft.lbs. 0110156 0110156 Sealant: 3M ATD Part No. 8660 or No. MD9971 10 or equivalen equivalent Revision...
Page 91 ENGINE Removal steps 1. Transaxle stay (front) 16. Relief plug 2. Transaxle stay (rear) 17. Relief spring 3. Oil pressure switch 18. Relief plunger Oil pressure gauge unit Oil filter 20. Oil pump case Oil cooler by-pass valve <Turbo> 21. Oil pump gasket Oil filter bracket stay 22.
Page 92 Knock it as far as the surface. 13. APPLICATION OF SEALANT TO OIL PAN 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 93 ENGINE - Oil Pan and Oil Pump 12. TIGHTENING SEQUENCE OF OIL PAN BOLT Tighten the flange bolts in the sequence shown in the illustration. 11. INSTALLATION OF DRAIN PLUG GASKET Install the drain plug gasket in the direction shown in the TSB Revision...
Page 94 ENGINE REMOVAL AND INSTALLATION Removal steps * I)* 2. Connecting rod cap 3. Connecting rod bearing (lower) 4. Piston, connecting rod assembly * ** 7. Piston ring No. 2 l * ._ - -’ 52 ihn 38 fklbs. 11. Connecting rod 12.
Page 95 ENGINE 9. REMOVAL OF PISTON PIN (1) Insert the special tool, Pushrod from the front mark side of the piston top and install the guide B. (2) With the piston top facing the front mark side of the special tool, Piston Pin Setting Base and the piston front mark facing up, set the piston and connecting rod assembly.
Page 96 ENGINE BEARING Measure the inner diameter of the connecting rod bearing and the outer diameter of the crankshaft pin. If the oil clearance exceeds the limit, replace the bearing, and crankshaft if necessary. Standard value: 0.016 - 0.046 mm (.OOOS - .0018 in.) Limit: 0.1 mm (.004 in.) NOTE For the method by which the oil clearance is measured using a...
Page 97 ENGINE (7) Check that the piston moves smoothly. 8. INSTALLATION OF OIL RING NOTE On the side rail and the spacer, no difference exists between the upper and the lower surfaces. the side rail, engage one side of the side rail with the piston groove.
Page 98 ENGINE 4. INSTALLATION OF PISTON, CONNECTING ROD ASSEMBLY piston, piston ring, and oil ring. spacer) as shown in the illustration. (3) Rotate crankshaft so that crank pin is on center of cylinder bore. before inserting piston and connecting rod assembly into cylinder block.
Page 99 ENGINE CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 75 Nm 55 ft.lbs. 11 Nm 8 ft.lbs. Removal steps 3. Drive plate QVT> 4. Rear plate 5. Bell housing cover 6. Oil seal case 13. Crankshaft 80 Nm ‘58 ft.lbs. 48Nm 35 ft.lbs.
Page 100 ENGINE I N S P E C T I O N FLYWHEEL (engine with a manual transaxle) streaking, or seizure are apparent, replace it. (2) If flywheel run out exceeds the limit, replace it. Limit: 0.13 mm t.0051 in.) RING GEAR (engine with a manual transaxle) When there is wear, cracks, or other damage to the ring gear teeth, replace the ring gear by the following procedure.
Page 101 ENGINE Plastigage may be used to measure the clearance. journals. (2) Cut plastigage to the same length as the width of the bearing and place it in parallel with the journal, off oil holes. (3) Install the crankshaft, bearings and caps and tighten them to the specified torques.
Page 102 ENGINE - Crankshaft, Flywheel and Drive Plate 9. INSTALLATION OF BEARING CAP the illustration. (2) Tighten the bearing cap bolts to the specified torque in ‘I the sequence shown in the illustration. (3) Check that the crankshaft rotates smoothly. Bearing cap bolt Front of engine (4) Check the end plate.
Page 103: Cylinder Block
ENGINE - Crankshaft, Flywheel and Drive Plate / Cylinder Block 7. INSTALLATION OF CRANKSHAFT REAR OIL SEAL Using the special tool, press-fit a new crankshaft rear oil seal into the oil seal case. CYLINDER BLOCK REMOVAL AND INSTALLATION 42 Nm stopper 1.
Page 104 ENGINE - Cylinder Block (2) Using a cylinder gauge, measure the inside diameter and roundness of the cylinder. If excessively worn, repair (over size) the cylinder and replace the piston and piston rings. The measurement points are shown in the illustration. I t+ ‘: ;I 2 Center - BORING THE CYLINDER sized piston to be used.
Page 105 ENGINE ENGINE OIL COOLER REMOVAL AND INSTALLATION 2.9 ft.lbs. 40-45 Nrh 29 - 33 ft.lbs. Removal steps 1. Front splash shield extension 12 Nm 9 ft.lbs. 2. Engine oil feed hose 3. Engine oil return hose 4. Engine oil return tube 5.
Page 107 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 108 Boost Meter <Turbo> ............128 Purge Control Solenord Valve ..........1 19 Components Inspection Procedure ........40 Release of Residual Pressure from High ............36 Components Location ............137 Pressure Fuel Hose ............72 Crank Angle Sensor Throttle Position Sensor ............
Page 109 FUEL SYSTEM - General Information MPI SYSTEM DIAGRAM <Federal - Non Turbo> TSB Revision...
Page 110 13-4 FUEL SYSTEM <California - Non Turbo> TSB Revision...
Page 111 1 3 - 5 FUEL SYSTEM <Turbo> a.5 239 TSB Revision...
Page 112 FUEL SYSTEM GENERAL SPECIFICATIONS Tank capacity liter (gal.) Return system High pressure type Filter Electrical, in-tank type Driven by Variable resistor type Throttle position sensor Stepper motor type The stepper motor type by-pass air control system with the first idle air valve Engine control unit Identification model No.
Page 113 FUEL SYSTEM Items Specifications Actuators Control relay type Contact switch type Injector type and number Electromagnetic, 6 Injector identification mark <Non Turbo> <Turbo> BDL360 Variable induction control servo <Non Turbo> Electric motor Purge control solenoid valve ON/OFF type solenoid valve EGR control solenoid valve Duty cycle solenoid valve <California - Non Turbo, Turbo>...
Page 114 13-8 FUEL SYSTEM SPECIAL TOOLS Reading diagnosis code MB991359 MPI system inspection Detonation sensor...
Page 115 13-9 FUEL SYSTEM START EXPLANATION OF TROUBLESHOOTING PROCE- DURES Effective troubleshooting procedures for MPI 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.
Page 116 FUEL SYSTEM EXPLANATION AND CAUTIONS ABOUT HAR- Equipment side NESS CHECK The connector symbol shown is as viewed from the terminal end of the connector inside the vehicle. “SV” used as the standard value in voltage check stands for system voltage. When checking a waterproof connector for circuit continui- Test harness ty, be sure to use the special tool, Test Harness.
Page 117 FUEL SYSTEM If the sensor impressed voltage is abnormal, check the wire Sensor side for an open circuit or short-circuit to ground and repair as necessary. If the wire is normal, replace the engine control unit and check again. To check the voltage, use a digital voltmeter (or circuit tester) as a rule.
Page 118 FUEL SYSTEM MALFUNCTION INDICATOR LIGHT INSPECTION (1) Check that when the ignition switch is turned on, the light illuminates for about 5 seconds and then goes out. (2) If the light does not illuminate, check for open circuit in d harness, blown fuse and blown bulb.
Page 119 FUEL SYSTEM - Troubleshootinn DIAGNOSIS CHART (FAULT TREE) output Diagnosis code Diagnosis item Check item (Remedy) order Output signal pattern Memory Engine control (Replace engine control unit unit) Oxygen sensor Retained Harness and connector (Turbo: Rear bank) Fuel pressure Injectors (Replace if defective.) Intake air leaks Air flow sensor...
Page 120 13-14 FUEL SYSTEM output Diagnosis code preference Diannosis item order Output signal pattern adjustment signal Oxygen sensor Retained Harness and connector (Turbo: Front bank) Oxygen sensor Fuel pressure Injectors (Replace if defective) Intake air leaks Injector Retained Harness and connector Injector coil resistance Retained Harness and connector...
Page 121 FUEL SYSTEM READ OUT OF MALFUNCTION CODE Precautions for Operation possible. Be sure to check the battery for voltage and other conditions before starting the test. (2) Diagnosis item is erased if the battery or the engine control unit connector is disconnected. Do not disconnect the battery before the diagnosis result is completely read.
Page 122 FUEL SYSTEM CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS TSB Revision...
Page 123 FUEL SYSTEM PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Won’t start The starter is used to crank the engine, but there is no combustion within the (no initial combustion) cylinders, and the engine won’t start. There is combustion within the cylinders, but then the engine soon stalls. (Starting takes a long Engine won’t start quickly.
Page 124 FUEL SYSTEM CIRCUIT DIAGRAM < N o n T u r b o > STARTER 'ION FUSIBLE LINK@ WITH WITHOUT ALARM INHIBITOR 4 D-15 I c-29 "9 B-26 i ENGINE CONTROL RELAY c-44 ON'-OFF "6 M/T A/T TSB Revision...
Page 125 FUEL SYSTEM IGNITI 7 C-62 6 C-71 6 D-44 4 c-30 A-17 [ 9 c-34 CONNECTOR D-04 COMBINATION METER D-03 ITCH) FUEL F-16 F-14 ENGINE CONTROL UNIT TSB Revision...
Page 126 FUEL SYSTEM CRANK ANGLE AND TOP DEAD z CENTER SENSOR $j SENSOR FLOW SENSOR B-29 "1 “ 7 “ 5 “ 6 “2 “4 “l --- --- --. ENGINE CONTROL UNIT ENGINE CONTROL RELAY ENGINE THROTTLE B-05 COOLANT c - 5 5 c&m B-02 @J...
Page 127 13-21 FUEL SYSTEM ENGINE CONTROL RELAY IDLE SPEED s 3-13 CONTROL SERVO B-35 ----------------- ----------------- VARIABLE INDUCTION SERVO MOTOR TSB Revision...
Page 128 13-22 FUEL SYSTEM MULTI-PURPOSE TAIL LIGHT RELAY 8 A-36 C-69 DIODE 6 A-67 C-52 r----- ENGINE COOLANT POWER TRANSISTOR TEMPERATURE (FOR AIR CONDITIONER) UNIT TSB Revision...
Page 129 FUEL SYSTEM - Troubleshootina ENGINE CONTROL RELAY . - - - - - - - B-06 c-79 B-36 CONNECTOR ADJUSTMENT POWER STEERIK?
Page 130 FUEL SYSTEM FUSIBLE LINK@ BATTERY c-71 3 A-67 FLOW SENSOR' i ENGINE CONTROL RELAY c-44 OFF-*ON 71 ,----- TSB Revision...
Page 131 13-25 FUEL SYSTEM - Troubleshootinn IGNI ENGINE SWIT CONTROL RELAY 1234 FUEL PUMP RESISTOR A-51 D-04 COMBINATION CONNECTOR D-03 1 C-14 5 F-14...
Page 132 13-26 FUEL SYSTEM CRANK ANGLE AND TOP DEAD z CENTER SENSOR m FLOW SENSOR FLOW SENSOR B-29 “1 “7 “5 “6 “2 “4 “3 ENGINE CONTROL RELAY TSB Revision...
Page 133 FUEL SYSTEM ENGINE CONTROL RELAY STOR IDLE SPEED /\2 CONTROL SERVO B-35 A-67 ,,2-,,8--,,1-,,?_--,,lO OXYGEN TEMPERATURE T S B R e v i s i o n...
Page 134 13-28 FUEL SYSTEM - Troubleshooting MULTI-PURPOSE TAIL LIGHT RELAY CONTR STOP LIGHT ITCH C-61 C-69 c-29 DIODE I - - - - - 6 ------- A-33 ACTIVE UNIT CONTROL POWER TRANSISTOR UNIT RELAY TSB Revision...
Page 135 1 3 - 2 9 FUEL SYSTEM ENGINE CONTROL RELAY c - - - - WASTE PRESSURE GATE SOLENOID SOLENOID VALVE VALVE A-20 1 A-70 ENGINE COOLANT 1 A-18 FOR AIR CONDITIONER OFF --xOlJ CONNECTOR ADJUSTMENT CONNECTOR POWER STEERING TSB Revision...
Page 136 FUEL SYSTEM FUEL TANK AND FUEL LINE Symptom Engine malfunctions due to insufficient fuel supply tank and fuel line Evaporative emission malfunctions (When tank cap is removed, pressure releasing noise is heard)
Page 137 FUEL SYSTEM SERVICE ADJUSTMENT PROCEDURES BASIC IDLE SPEED ADJUSTMENT NOTE (1) The basic idle speed has been factory-adjusted with the speed adjusting screw (SAS) and does not normally require adjustment. (2) If the adjustment is required, first check that the ignition plug, injector, ISC servo, and compression pressure are normal.
Page 138 13-32 FUEL SYSTEM - S ervice Adjustment Procedures transmission selector terminal (terminal @) of the diagnosis connector (white). Self-diagnosis/ y data transmission (4) Remove the waterproof female connector from the ignition timing adjusting connector (brawn). (5) Using a jumper wire, ground the ignition timing adjusting terminal.
Page 139 FUEL SYSTEM 13-33 THROTTLE BODY (THROTrLE VALVE AREA) CLEANING (1) Start the engine, warm it up until engine coolant tempera- 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 140 FUEL SYSTEM (3) Insert a 0.65-mm-thick feeler gauge between the fixed SAS and throttle lever. (4) Loosen the throttle position sensor mounting bolts and turn the TPS body fully counterclockwise. (5) In this condition, check that there is continuity across terminals @ and @.
Page 141 13-35 FUEL SYSTEM ADJUSTMENT OF FIXED SAS NOTE move it. the procedure given below. (2) Loosen the lock nut on the fixed SAS. wise to fully close the throttle valve. (4) Tighten the fixed SAS slowly to find a point at which it contacts the throttle lever (where the throttle valve starts opening).
Page 142 13-36 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components ON-VEHICLE INSPECTION OF MPI COMPONENTS COMPONENTS LOCATION EGR control solenoid valve temperature sensor <California> Engine control unit Self-diagnosis output terminal and self-diagnosis/ data transmission selector terminal Engine coolant temperature sensor TDC sensor and crank angle sensor Engine warning light Throttle position sensor (with built-in idle switch)
Page 143 1 3 - 3 7 FUEL SYSTEM (with built-in intake I (reed switch) TSB Revision...
Page 144 13-38 FUEL SYSTEM Engine warning and self-dlagnosisi data transmission selector terminal T3 unit TSB Revision...
Page 145 FUEL SYSTEM 1 3 - 3 9 <California - N&Turbo, Turbo> i/ EGR control solenoid valve TSB Revision...
Page 146 FUEL SYSTEM - On-vehicle Inspection of MPI Components COMPONENTS INSPECTION PROCEDURE USING MULTI-USE TESTER (1) Check by the service data and actuator test function. If any ij abnormality is found, check the body harness, components, etc. and repair as necessary. (2) After repair, check again with the multi-use tester to make sure that the input and output signals are now normal.
Page 147 FUEL SYSTEM POWER SUPPLY AND IGNITION SWITCH-IG Engine control unit Engine control unit Engine control unit connector OPERATION While the ignition switch is on, battery power is supplied to the engine control unit, the injector, the air flow sensor, etc. When the ignition switch is turned on, the battery voltage is applied from the ignition switch to the engine control unit, which then turns ON the power transistor to energize the control relay coil.
Page 148 FUEL SYSTEM HARNESS INSPECTION Measure the ignition switch terminal input voltage. Engine control unit connector: Disconnected Ignition switch: ON Voltage (V) Repair the harness. (Ignition switch -@I Measure the power supply voltage of the control relay. Connector: Disconnected Voltage (V) Repair the harness.
Page 149 FUEL SYSTEM 13-43 CONTROL RELAY INSPECTION Caution When applying battery voltage directly, make sure that it is applied to correct terminal. Otherwise, the relay could be (2) Using jumper wires, connect terminal @ of control relay to battery 0 terminal and terminal @ of control relay to battery 0 terminal.
Page 150 13-44 FUEL SYSTEM ENGINE CONTROL UNIT POWER GROUND Engine control unit Engine control unit connector OPERATION Grounds the engine control unit TROUBLESHOOTING HINTS If the ground wire of the engine control unit is not connected securely to ground, the unit will not operate correctly.
Page 151 13-45 FUEL SYSTEM - On-vehicle Inspection of MPI Components FUEL PUMP <Non Turbo> Fuel pump connector connector Equipment side connector connector connector Engine control unit connector OPERATION Drives the fuel pump during cranking and engine operation. When the ignition switch is set to START, current flows from the ignition switch through the control relay coil to ground.
Page 152 13-46 FUEL SYSTEM - On-vehicle Inspection of Components INSPECTION Using Multi-use Tester 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 driven to cir-...
Page 153 FUEL SYSTEM - On-vehicle inspection of MPI Components Measure th& power supply voltage of connector the control relay. Connector: Disconnected Ignition switch: START (when Repair the @@checked) harness. Ignition switch: ON (when @@ (Ignition checked) (Ignition switch-[ST] Check for an open-circuit, or a short- circuit to ground between the control relay and the engine control unit.
Page 154 13-48 FUEL SYSTEM CONTROL RELAY INSPECTION Refer to P.13-43. FUEL PUMP <Turbo> TSB Revision...
Page 155 13-49 FUEL SYSTEM Ignition switch [IG] Ignition switch [ST] Control reta) connector side connector connector connector Fuel Equipment side connector Resistor (for fuel pump) Equipment side connector Fuel pump A 8 A21 Enaine control unit check terminal Engine control unit connector TSB Revision...
Page 156 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components OPERATION Control Relay Operation Drives the fuel pump during cranking and engine operation. When the ignition switch is set to START, current flows from the ignition switch through the control relay coil to ground.
Page 157 13-51 FUEL SYSTEM Check for continuity between the fuel pump and the checking terminal. Connector: Disconnected Repair the harness. connector Check for continuity between the Harness side connector checking terminal and the control re- lay (for fuel pump), and between the resistor (for fuel pump).
Page 158 13-52 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components Check for an open-circuit, or a short- circuit to ground, between the control relay and the engine control unit. connector Control relay connector: Discon- nected Engine control unit connector: Disconnected Engine control unit harness side connector...
Page 159 FUEL SYSTEM FUEL PUMP RELAY NO. 2 INSPECTION (1) Remove fuel pump relay No. 2. (2) Use a jumper wire to connect terminal @ of fuel pump relay No. 2 and the positive terminal of the battery and use another jumper wire to connect terminal @ and the negative terminal of the battery.
Page 160 0 n-vehicle Inspection of MPI Components FUEL SYSTEM - AIR FLOW SENSOR Control relay Air flow sensor J II Air flow sensor connector connector Engine control unit connector OPERATION The 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 unit, which then computes the fuel injection rate, etc.
Page 161 FUEL SYSTEM INSPECTION Using Multi-use Tester <Air Flow Sensor> Function tern No. Data display Check condition Engine state Standard value Data reading Sensor air Engine coolant tem- 700 rpm (Idle) 25-50 Hz volume perature: 80 to 95°C (frequency) (176 to 205°F) 2,000 rpm Lights and accessories: Racing...
Page 162 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage. arness side Connector: Disconnected connector Ignition switch: ON Voltage (V) check the control relay. Measure the terminal voltage. Connector: Disconnected Ignition switch: ON Check for continuity of the ground connector circuit.
Page 163 FUEL SYSTEM - On-vehicle Inspection of MPI Components 13-57 INTAKE ACR TEMPERATURE SENSOR Air flow sensor (with built-in intake arr -temperature sensor and barometric pressure sensor) Temperature Temperature connector Air flow sensor Intake air connector temperature sensor connector “ 6 temperature sensor OPERATION The intake air temperature sensor converts the engine intake air temperature into a voltage and inputs it to...
Page 164 13-58 FUEL SYSTEM INSPECTION Using Multi-use Tester 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) 0°C At 20°C (68°F) 20°C At 40°C (104°F) 40°C...
Page 165 13-59 FUEL SYSTEM (3) Measure resistance while heating the sensor using a hair Intake air drier. Resistance (kR) Temperature 1°C (“F)] Smaller Higher resistance remains unchanged, replace the air flow sensor assembly.
Page 166 FUEL SYSTEM BAROMETRIC PRESSURE SENSOR Barometric pressure sensor Air flow sensor connector connector Barometric pressure sensor Engine control unit A6 I Output voltage (VI Engine control unit connector Barometric pressure (30) OPERATION The barometric pressure sensor converts the barometric pressure into a voltage and inputs it to the engine control unit, which then corrects the fuel injection rate, etc.
Page 167 FUEL SYSTEM - On-vehicle Inspection of MPI 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 168: Engine Coolant Temperature Sensor
13-62 FUEL SYSTEM ENGINE COOLANT TEMPERATURE SENSOR Coolant temperature Coolant temperature Coolant temperature sensor connector Engine control unit ), 72 OPERATION The engine coolant temperature sensor converts the engine coolant temperature into a voltage and inputs it to the engine control unit, which then controls the fuel injection rate and fast idle speed when the engine is cold based on the input signal.
Page 169 13-63 FUEL SYSTEM INSPECTION Using Multi-use Tester Function Item No. Data display Check condition Coolant temperature Standard value Data reading Sensor Ignition switch: ON or At -20°C (-4°F) -20°C temperature engine operating At 0°C (32°F) 0°C HARNESS INSPECTION Check for continuity of the ground circuit.
Page 170 13-64 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components SENSOR INSPECTION intake manifold. (2) With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resis- tance. Temperature “C (“F) Resistance 20 (68) 40 (104) 80 (176) (3) If the resistance deviates from the standard value greatly, replace the sensor.
Page 171: Automatic Transaxle
13-65 FUEL SYSTEM THROTTLE POSITION SENSOR Equipment side Throttle positron sensor connector connector Engine control unit , Engine control unit 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 unit, which then controls the fuel injection based on the input signal.
Page 172 13-66 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components INSPECTION Using Multi-use Tester Function Item No. Data display Check condition Throttle valve Standard value Data reading Sensor Ignition switch: left ON At idle position voltage for 15 seconds or more Open slowly Increases with valve opening...
Page 173 FUEL SYSTEM 13-67 SENSOR INSPECTION (1) Disconnect the throttle position sensor connector (sensor side, front view (2) Measure resistance between terminal @ (sensor ground) and terminal @ (sensor power). Standard value: 3.5 - 6.5 kR (3) Connect a pointer type ohmmeter between terminal @ (sensor ground) and terminal @ (sensor output).
Page 174 13-68 FUEL SYSTEM IDLE POSITION SWITCH Engine control unit Throttle position se (Idle position switch Idle position connector connector Throttle position sensor connector Throttle shaft turning angle D’20g2 OPERATION The idle 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 unit, which then controls the idle speed control servo based on the input signal.
Page 175 13-69 FUEL SYSTEM HARNESS INSPECTION Measure the power supply voltage of arness side the idle position switch. connector Connector: Disconnected Ignition switch: ON Check for continuity of the ground circuit. Connector: Disconnected STOP Repair the harness. SENSOR INSPECTION (1) With the accelerator pedal released, check to be sure that the throttle valve lever or the fixed SAS is pushed.
Page 176 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components TOP DEAD CENTER SENSOR Control relay Crank angle sensor connector Top dead center sensor Time Normal waveform OPERATION The top dead center sensor senses the top dead center on compression stroke of the No. 1, No. 3 and No. 5 cylinders, converts it into a pulse signal and inputs it to the engine control unit, which then computes the fuel injection sequence, etc.
Page 177 FUEL SYSTEM INSPECTION Using Oscilloscope (1) Run the engine at an idle speed. (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 Voltage (VI...
Page 178 FUEL SYSTEM CRANK ANGLE SENSOR Control relay Crank angle sensor Crank angle sensor Output characteristic Engine control Time OPERATION The crank angle sensor senses the crank angle (piston position) of each cylinder, converts it into a pulse signal and inputs it to the engine control unit, which then computes the engine speed and controls the fuel injection timing and ignition timing based on the input signal.
Page 179 FUEL SYSTEM INSPECTION Using Multi-use Tester Function Item No. Data display Check condition Check content Normal state Data reading Cranking Engine cranking Compare cranking speed Indicated speed speed Tachometer connected and multi-use tester to agree (check on and off of reading primary current of ignition coil by...
Page 180 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage. connector Repair the harness. trol relay) Check for continuity of the ground @ Harness side Connector: Disconnected connector Repair the harness. Check the voltage of the output cir- cuit.
Page 181 FUEL SYSTEM IGNITION SWITCH-ST <M/T> Enaine control unit connector Engine control unit FU0638 OPERATION The ignition switch-ST inputs a high signal to the engine control unit while the engine is cranking. The engine control unit provides fuel injection control, etc., at engine startup based on this signal. When the ignition switch is set to START, the battery voltage at cranking is applied through the ignition switch to the engine control unit, which detects that the engine is cranking.
Page 182 13-76 FUEL SYSTEM IGNITION SWITCH-ST AND INHIBITOR SWITCH <A/T> connector connector Starter S Control terminal relay Engine control unit Engine control unit connector OPERATION The ignition switch-ST inputs a high signal to the engine control unit while the engine is cranking. The engine control unit provides fuel injection control, etc., at engine startup based on this signal.
Page 183 13-77 FUEL SYSTEM INSPECTION Using Multi-use Tester IGNITION SWITCH-ST Function Item No. Data display Check condition Engine Normal rndrcation Data reading Switch state Ignition switch: ON stop Cranking INHIBITOR SWITCH Function Check condition Item No. Data display Select lever position Normal indication Shift Data...
Page 184 13-78 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components VEHICLE SPEED SENSOR Engine control unit (reed switch\) Speedometer Terminal voltage (V) Engine control unit connector Vehicle speed [km/h (mph)] 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 unit, which then provides the idle speed control, etc.
Page 185 FUEL SYSTEM - On-vehicle lnwection of MPI ComDonents Measure the power supply voltage of the vehicle speed sensor. Connector: Dlsconnected Ignition switch: ON Connector: Disconnected SENSOR INSPECTION Refer to GROUP 54 - Meters and Gauges. TSB Revision...
Page 186 FUEL SYSTEM - n-vehicle Inspection of MPI Components POWER STEERING OIL PRESSURE SWITCH Engine control unit connector Power steering oil Pressure switch Pressure [kPa (psi)] OPERATION The power steering oil pressure switch converts presence/absence of power steering load into low/high voltage and inputs it to the engine control unit, which then controls the idle speed control servo based on this signal.
Page 187 13-81 FUEL SYSTEM INSPECTION Using Multi-use Tester Normal indication Function Check condition Steering wheel Item No. Data display Switch state Engine: Idling Steering wheel neutral Data reading position (wheels straight-ahead direction) Steering wheel half turn Checking Oil Pressure Oil pump delivery pressure (ref. value) Steering wheel 700 - 1,200 kPa (100 - 171 psi) Straight forward...
Page 188 13-82 FUEL SYSTEM AIR CONDITIONER SWITCH AND POWER RELAY Air conditioner compressor lock Air conditioner controller control unit Dual pressure Air conditroner switch Air conditioner compressor Engine control unit Engine control unit connector OPERATION The air conditioner switch applies the battery voltage to the engine control unit when the air conditioner is turned on.
Page 189 FUEL SYSTEM AIR CONDITIONER POWER RELAY Function Item No. Data display Check condition Air conditioner switch Normal indication Air condi- Data reading Engine: Idling after OFF (compressor tioner relay warm-up clutch non-activa- state tion) ON (compressor clutch activation) HARNESS INSPECTION Measure the power supply voltage of the air conditioner circuit.
Page 190 FUEL SYSTEM - n-vehicle Inspection of MPI Components DETONATION SENSOR Engine control unit connector connector Engine control unit connector OPERATION The detonation sensor generates a voltage proportional to the magnitude of cylinder block vibration due to knocking and inputs it to the engine control unit. Based on this signal, the engine control unit provides retard control of the ignition timing.
Page 191 FUEL SYSTEM HARNESS INSPECTION Check for continuity of the ground circuit. Connector: Disconnected Repair the harness.
Page 192: Electrical Load Switch
13-86 FUEL SYSTEM ELECTRICAL LOAD SWITCH Defog. stop light light relay relay switch Engine control unit 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 unit. Based on this signal, the engine control unit controls the idle-speed control servo.
Page 193 FUEL SYSTEM HARNESS INSPECTION Measure the input voltage of engine control unit. Engine control unit connector: Disconnected Lighting switch: ON (Tail light relay ON) Engine control unit harness side connector Measure the input voltage of engine control unit. Engine control unit connector: Disconnected Defogger switch: ON (Defogger relay ON)
Page 194 13-88 FUEL SYSTEM MUFFLER MODE CHANGEOVER SWITCH <Turbo> connector Muffler mode switch OPERATION If the operator turns the muffler mode changeover switch to ON or OFF position, this is converted to high/low voltage to be sent to the engine control unit. Receiving this signal, the engine control unit performs the dual mode (TOUR/SPORT mode) muffler control.
Page 195 0 n-vehicle Inspection of MPI Components 13-89 FUEL SYSTEM - HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Voltage (V) connector Repair the harness. Check for continuity of the ground circuit. Connector: Disconnected...
Page 196 FUEL SYSTEM INDUCTION CONTROL VALVE POSITION SENSOR <Non Turbo> [Induction control valve connector Variable induction control se (DC motor)(with built-In induction Variable inductlon control valve position sensor) control servo connector 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 unit, which provides valve opening and closing control based on this signal.
Page 197 FUEL SYSTEM - On-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage of the air intake control valve position sensor. Connector: Disconnected Ignition switch: ON Check for continuity of the ground circuit. Connector: Disconnected nnector Measure the terminal voltage. Connector: Disconnected Ignition switch: ON Repair the...
Page 198 FUEL SYSTEM EGR TEMPERATURE SENSOR <California> connector EGR tem0erature senso control unit Temperature 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 unit. The engine control unit judges the condition of the EGR by this signal.
Page 199 13-93 FUEL SYSTEM INSPECTION Using Multi-Use Tester Standard value Function Item No. Data display Check condition Engine state Data reading Sensor Engine: Warmed up 700 rpm (Idle) 100°C or less (212°F) temperature Engine is maintained in a constant state for 3,500 rpm or more 120°C (248°F)
Page 200 FUEL SYSTEM OXYGEN SENSOR <Non Turbo> connector C o n t r o l r e l a y 2 dI 1: Theoretical A/F Engine control unit Engine control unit connector OPERATION The oxygen sensor senses the oxygen concentration in exhaustgas, converts it into a voltage and inputs it to the engine control unit.
Page 201 FUEL SYSTEM - 0n-vehicle Inspection of MPI Components TROUBLESHOOTING HINTS Hint 1: Poor cleaning of exhaust gas will result if the oxygen sensor fails. Hint 2: If the oxygen sensor check has resulted normal but the sensor output voltage is out of specification, troubles of parts related to air fuel ratio control system are suspected.
Page 202 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage of the oxygen sensor. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the harness. trol relay) e oxygen sensor. Disconnected Connector: Disconnected connector Revision...
Page 203 FUEL SYSTEM SENSOR INSPECTION (2) Check that there is continuity [approx. 20 IR at 20°C (68”F)j across terminals @and @of the oxygen sensor connector. (3) If there is no continuity, replace the oxygen sensor. (4) Warm up the engine until the engine coolant temperature becomes 80°C (176°F) or higher.
Page 204 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components OXYGEN SENSOR <Turbo> Oxygen sensor Oxygen sensor (front) (rear) Equipment side Equipment side Connector connector - C o n t r o l r e l a y Theoretical A/F Engine control unit 56 Connector connector EC1007...
Page 205 FUEL SYSTEM - On-vehicle InsDection of MPI ComDonents HARNESS INSPECTION Connector: Disconnected Ignition switch: ON Engine control Check for an open-circuit, or a short- circuit to ground, between the engine control unit and the oxygen sensor. Oxygen sensor connector: Dis- connected Engine control unit connector: Disconnected...
Page 206 FUEL SYSTEM - 0n-vehicle Inspection of MPI Components SENSOR INSPECTION the special tool, Test Harness, to the oxygen sensor (rear) connector. (2) Check that there is continuity [approx. 20 R at 20°C (68”F)I across terminals @ and @ of the oxygen sensor (rear) connector.
Page 207 FUEL SYSTEM - On-vehicle Inspection of MPI Components INJECTORS <Non Turbo> Injector Connector for rear bank Engine control unit Fuel Engine control unit connector Filter Injection OPERATION The injector is an injection nozzle with a solenoid valve which injects fuel according to the injection signal coming from the engine control unit.
Page 208 FUEL SYSTEM 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 when the engine that is hard to start is cranked, the following as well as the injector itself may be responsible.
Page 209 FUEL SYSTEM Using Oscilloscope (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram, and check the waveform at the drive side of each injector. Normal waveform HARNESS INSPECTION Measure the power supply voltage of the front bank injector.
Page 210 FUEL SYSTEM Check for an open-circuit, or a short- circuit between the rear bank injector Harness side and the engine control unit. connector Connector: Disconnected Engine control unit connector: Disconnected ACTUATOR INSPECTION Measurement of Resistance between Front Bank Termi- nals (1) Remove the injector connector.
Page 211 FUEL SYSTEM - On-vehicle Inspection of MPI Components INJECTORS <Turbo> connector Control relay (Front bank connector) 4 - - - - 5 ----_ Rear bank connector Injector - - - - - Injector Injector Injector No. 1 N o . 5 Engine control unit...
Page 212 FUEL SYSTEM INSPECTION Tester Using Multi-use value Item No. Check condition Coolant temperature Standard Function Data display Drive time*’ Engine: Cranking 0°C (32’F)*’ Approx. 53 ms Data reading 20°C (68°F) Approx. 29 ms 80°C (176°F) Approx. 7 ms Standard value Function Item No.
Page 213 FUEL SYSTEM - On-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage of the resistor. Resistor connector: Discon- nected Ignition switch: ON connector Measure the power supply voltage of the front bank injector. Resistor connector: Connected connector Repair the Ignition switch: ON harness.
Page 214 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components Check for an open-circuit, or a short- circuit between the rear bank injector and the engine control unit. Connector: Disconnected STOP Engine control unit connector: Disconnected Repair the harness. ACTUATOR INSPECTION INJECTORS Measurement of Resistance between Front Bank Termi- nals...
Page 215 FUEL SYSTEM RESISTOR Measurement of Resistance between Terminals (1) Disconnect the resistor connector. (2) Measure the resistance between terminals. Measuring terminals Resistance 5.5 - 6.5 R (3) If the resistance is out of specification, replace the resistor. TSB Revision...
Page 216 FUEL SYSTEM - On-vehicle Inspection of MPI Components IDLE SPEED CONTROL SERVO (STEPPER MOTOR TYPE) connector Control relay ‘9 Ball beam “3 “4 “6 control servo Engine control unit 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 217 FUEL SYSTEM INSPECTION Using Multi-use Tester Function Item No. Data display Check condition Load state Standard value 2 - 12 stp Data reading Stepper Engine coolant tem- motor steps perature: 80 to 95°C (176 to 205°F) 25 - 65 stp &conditioner switch: fan, accessory units: All OFF...
Page 218 FUEL SYSTEM - 0 n-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage of idle speed control servo. Idle speed control servo connec- tor: Disconnected Ignition switch: ON Connector Check for an open-circuit, or a short- circuit to ground between the engine connector control unit and the idle speed control servo.
Page 219 FUEL SYSTEM - On-vehicle Inspection of MPI Components Checking the Coil Resistance (1) Disconnect the idle speed control servo connector and connect the special tool (test harness). the special tool) and either terminal @ (red clip) or terminal servo side. Standard value: 28 - 33 Measure the resistance between terminal @ (green clip of the special tool) and either terminal @ (yellow clip) or...
Page 220 FUEL SYSTEM - On-vehicle Inspection of MPI Components 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 221 FUEL SYSTEM - On-vehicle Inspection of MPI Components IGNITION COIL AND POWER TRANSISTOR Battery connector Equipment side connector No. 2 No. 3 “ 8 “ 6 No 5 No. 6 Tachometer -1 adjust- ment Engine control unit Engine control unit connector OPERATION When the power transistor unit A is turned on by the signal from the engine control unit, primary current flows to the ignition coil A.
Page 222 FUEL SYSTEM - n-vehicle Inspection of MPI Components INSPECTION Using Multi-use Tester <Spark Advance> Function Item No. Data display Check condition Engine state Standard value Data reading Ignition Engine: Warming up 750 rpm (Idle) 7 - 23”BTDC advance Timing light: Set (set timing light to check 2,000 rpm 30 - 40”BTDC <Non Turbo>...
Page 223 FUEL SYSTEM - On-vehicle Inspection of MPI Components HARNESS INSPECTION Connector: Disconnected connector Ignition switch: ON Check for an open-circuit, or a short- circuit to ground between the engine control unit and the power transistor. Engine control unit connector: Disconnected Power transistor connector: Dis- connected Repair the...
Page 224 FUEL SYSTEM - On-vehicle Inspection of MPI Components Check for continuity of the ground circuit. Connector: Disconnected connector Repair the harness. Ground) Measure the voltage of the control Connector: Disconnected Voltage (VI Repair the 0.5 - 4.0 harness. Measure the voltage of the ignition timinq adiustment terminal.
Page 225 FUEL SYSTEM - On-vehicle Inspection of MPI Components PURGE CONTROL SOLENOID VALVE Control relay connector connector connector unit Engine control unit connector O P E R A T I O N The purge control solenoid valve is an ON-OFF type one which controls introduction of purge air from the canister into the intake air plenum.
Page 226 FUEL SYSTEM - On-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected connector Check for an open-circuit, or a short- circuit to ground between the purge control solenoid valve and the engine control unit, Engine control unit connector: Disconnected Purge control solenoid valve con- Repair the...
Page 227 FUEL SYSTEM - On-vehicle lnwection of MPI ComDonents EGR CONTROL SOLENOID VALVE <California - Non Turbo, Turbo> Control relav connector EGR control solenoid valve Engine control unit OPERATION The EGR control solenoid valve is a duty control type solenoid valve. It makes control by leaking EGR valve operating negative pressure to the throttle body A port.
Page 228 FUEL SYSTEM INSPECTION Using Multi-use Tester Function Item No. Drive content Check condition Normal state Actuator test Change solenoid valve Ignition switch: ON Operating sound is heard from OFF to ON state when driven HARNESS INSPECTION Measure the power supply voltage. connector Control relay) Engine control unit...
Page 229 FUEL SYSTEM - On-vehicle Inspection of MPI ComDonents FUEL PRESSURE CONTROL VALVE <Turbo> Control relay Equipment side connector Fuel pressure control valve Enaine control unit connector OPERATION The fuel pressure control valve 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 230 FUEL SYSTEM - On-vehicle Inspection of MPI Components INSPECTION Using Multi-use tester Drive content Check condition Normal state Function Item No. Actuator test Turn solenoid valve from Ignition switch: ON OFF to ON HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON connector...
Page 231 FUEL SYSTEM - On-vehicle Inspection of MPI Components ACTUATOR INSPECTION Operation Check NOTE Before disconnecting the vacuum hose, mark it to ensure reconnection at the correct position. solenoid valve. (3) Apply a negative pressure to the nipple to which the black vacuum hose has been connected and check air-tightness with and without the battery voltage applied to the solenoid valve terminal.
Page 232 FUEL SYSTEM - On-vehicle Inspection of MPI Components WASTE GATE CONTROL SOLENOID VALVE <Turbo> Control relav Waste gate control solenoid valve connector unit 0110324 OPERATION The waste gate control solenoid valve is an ON-OFF type solenoid valve that controls the boost pressure that is introduced to the waste gate actuator.
Page 233 FUEL SYSTEM INSPECTION Using Multi-use tester Drive content Check condition Normal state Function Item No. Turn solenoid valve from Ignition switch: ON Actuator test OFF to ON HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON trol relay) Check for an open-circuit, or a short- circuit to ground, between the waste gate control solenoid valve and the...
Page 234 FUEL SYSTEM - On-vehicle Inspection of MPI Components BOOST METER <Turbo> Ignition switch (IG,) connector Boost meter Engine control unit Engine control unit connector T S B R e v i s i o n...
Page 235 FUEL SYSTEM - On-vehicle Inspection of MPI Components HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the harness. tion coil 9 IG]) Engine control unit Check for an open-circuit or a short- harness side connect0 r circuit to ground, between the engine control unit and the boost meter.
Page 236 FUEL SYSTEM ACTIVE EXHAUST CONTROL UNIT <Turbo> valve drive Active connector exhaust control unit Engine control unit 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. The DC motor is driven in the normal or reverse direction by changing the direction of power flow by the motor driving IC in the active exhaust control unit.
Page 237 FUEL SYSTEM - On-vehicle lnwection of MPI ComDonents VARIABLE INDUCTION CONTROL SERVO (DC MOTOR) <Non Turbo> Engine control unit (DC motor)(with built-in induction /- control valve oosition sensor) Close Open connector , , I Variable induction control servo DC motor 1 FU0646 Engine control unit connector OPERATION...
Page 238 FUEL SYSTEM - 0n-vehicle Inspection of MPI Components HARNESS INSPECTION Engine control unit Check for an open-circuit or a short- harness side connector circuit to ground, between the engine control unit and the variable induction control servo connector. Variable induction control servo connector: Disconnected Engine control unit connector: Repair the...
Page 239 FUEL SYSTEM - On-vehicle Inspection of MPI Components ANTI-LOCK BRAKE SIGNAL <Turbo> ABS ECU equipment side connector ABS HU Engine control unit Engine control unit connector OPERATION The anti-lock brake signal is input to the engine control unit from the anti-lock brake system (ABS) control unit as a signal to indicate whether or not the motor relay is activated.
Page 240 FUEL SYSTEM INSPECTION Using Multi-use Tester Function Item No. Data display Check condition . Driving condition Standard value Data reading Stepper Engine warmed up Apply fairly sharp To reach tempo- motor step braking at 50 km/h rarily 70 to (4th speed) to stop vehicle NOTE Select a place where a rear-end collision is unlikely.
Page 241 FUEL SYSTEM - On-vehicle lnwection of MPI ComDonents ENGINE AND TRANSAXLE TOTAL CONTROL SIGNAL <A/T> Transaxle control unit Engine control unit Engine control unit Engine control unit connector OPERATION Three communication lines are connected between the engine control unit and the transaxle control unit to send and receive the engine and transaxle total control signal.
Page 242 FUEL SYSTEM - On-vehicle Inspection of MPI Components HARNESS INSPECTION Engine control Check for an open-circuit, or a short- unit harness circuit to ground between the transax-’ unit, connector Transaxle control unit connector: Disconnected Engine control unit connector: Repair the Disconnected harness.
Page 243 FUEL SYSTEM - Orwehicle lnwection of MPI 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. (3) Start the engine and after it stops by itself, turn the ignition switch to OFF.
Page 244 FUEL SYSTEM - On-vehicle Inspection of MPI Components FUEL PRESSURE TEST (1) Reduce the internal pressure of the fuel pipes and hoses. (2) Disconnect the fuel high pressure hose at the delivery pipe 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 245 FUEL SYSTEM regulator, and then measure the fuel pressure while using a finger to plug the end of the hose. Standard value: <Non Turbo> 330 - 350 kPa (47 - 50 psi) at curb idle <Turbo> 295 - 315 kPa (43 - 45 psi) at curb idle (11 )Check to be sure that the fuel pressure during idling does not decrease even after the engine is raced a few times.
Page 246 FUEL SYSTEM - On-vehicle Inspection of MPI 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 :d speed of the decrease, and, referring to the table below, determine the cause of the problem and make the appropriate repair.
Page 247 FUEL SYSTEM - Injector REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Draining of the Coolant Supplying of Coolant (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 00- Maintenance Service.) Removal of Air Intake Plenum Installation of Air intake Plenum (Refer to GROUP 15-Air Intake Plenum,) (Refer to GROUP 15 -Air Intake Plenum.) Release of Residual Pressure from High...
Page 248 FUEL SYSTEM - Injector SERVICE POINT OF REMOVAL 1. DISCONNECTION OF HIGH PRESSURE FUEL HOSE Bleed the residual pressure within the fuel pipe line so as to LA; 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 249 FUEL SYSTEM REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying of Engine Coolant (Refer to GROUP 00 -Maintenance Service.) <DOHC (Turbo)> <DOHC (Non Turbo) - California> Removal sl 1. Connection of accelerator cable 2. Connection of air intake hose 3.
Page 250 FUEL SYSTEM - Throttle- Body DISASSEMBLY AND REASSEMBLY 2.0 Nni Disassembly steps 2. Hose <Turbo only> 3. Vacuum valve > * 4. Throttle position sensor (within idle position switch) 5. Idle speed control servo assembly 6. Throttle body SERVICE POINT OF DISASSEMBLY Caution 1.
Page 251 FUEL SYSTEM (5) Disconnect the hand vacuum pump and connect it to the Orifice other nipple. (6) Make sure that the negative pressure leaks out as soon as it is applied. CLEANING THROTTLE BODY PARTS (1) Clean all throttle body parts. Do not use solvent to clean the following parts: Throttle position sensor (Idle position switch) Idle speed control servo...
Page 252 FUEL SYSTEM - Fuel Tank REMOVAL AND INSTALLATION Pre-removal Operation Draining of the Fuel High Pressure Hose. 25 ft.lbs. 22 ftlbs. 12 Nm 8 ft.lbs. W 26 Nm 19 ft.lbs. Removal steps * IO. Vapor hose 11. Return hose 2. Fuel pump and fuel gauge unit assembly * 12.
Page 253 FUEL SYSTEM - 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 254 FUEL SYSTEM - Fuel Tank 17. INSTALLATION OF OVERFILL LIMITER (TWO-WAY VALVE) Install so that the overfill limiter is facing in the direction shown in the illustration. Canist 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 fuel hose does not become twisted.
Page 255 Fuel Pump and Fuel Gauge Unit Assembly FUEL SYSTEM REMOVAL AND INSTALLATION Removal steps 1. Fuel gauge cover 2. Fuel pump and fuel gauge unit assembly connector 3. Overfill limiter (Two-way valve) side) 5. High pressure fuel hose connection 6. Fuel pump and fuel gauge unit assembly SERVICE POINTS OF REMOVAL 4.
Page 256 Fuel Pump and Fuel Gauge Unit Assembly FUEL SYSTEM INSPECTION OVERFILL LIMITER (TWO-WAY VALVE) Connect a clean rubber hose to the overfill limiter and check for operation. Inspection procedure Normal condition Lightly blow from the inlet Air passes through after a slight resistance (fuel tank) side Rubber hose...
Page 257 FUEL SYSTEM - Fuel Line and Vapor Line REMOVAL AND INSTALLATION <Turbo> Removal steps 2. Battery 3. Battery tray with washer tank assembly 4. Purge control valve 6. Canister 7. Vapor pipe assembly + 8. Fuel return hose 9. Eye bolt 11.
Page 258 FUEL SYSTEM 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 of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 259 FUEL SYSTEM REMOVAL AND INSTALLATION Removal of Residual Pressure from Post-installation Operation Removal steps 1. Battery 2. Battery tray with washer tank assembly 3. Eye bolt 4. Gasket 5. High pressure fuel hose 6. Connection of fuel main pipe 7. Mounting bolt 8.
Page 260 FUEL SYSTEM REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Release and Installation of the Air Intake Plenum (Refer to GROUP 15-Air Intake Plenum.) Removal and Installation of the Intake Manifold (Refer to GROUP 15 - Intake Manifold.) l * +* SERVICE POINT OF REMOVAL 1.
Page 261 ENGINE CONTROL - Specifications / Troubleshooting SERVICE SPECIFICATIONS Items Specifications Standard value mm (in.) Accelerator cable play 1 - 2 (.04 - .08) mm (in.) Accelerator switch switching point 2 - 6 (08 - .24) ACCELERATOR CABLE AND ACCELERATOR PEDAL Remedy Symptom Probable cause...
Page 262 ENGINE CONTROL A C C E L E R A T O R C A B L E I N S P E C T I O N A N D a ’ ADJUSTMENT For models equipped with the cruise control system, refer to (1) Turn air conditioner and lights OFF.
Page 263: Engine Control
ENGINE CONTROL REMOVAL AND INSTALLATION 5 N m Post-installation Operation 4 ftlbs. Accelerator Cable Adjustment (Refer to P. 13-156.) Accelerator Switch Adjustment <A/T; (Refer to P.13.156.) Removal steps 2. Connection of throttle body side inner cable 3. Bushing 4. Accelerator cable 5.
Page 264 CRUISE CONTROL SYSTEM - Specifications GENERAL SPECIFICATIONS Rated load A Voltage drop V Auto-cruise control switch Rated load A Stop light switch (for cruise control) Rated load A Clutch switch Rated load A Vacuum pump Rated load A Control valve, release valve SERVICE SPECIFICATIONS I Specifications Items...
Page 265 CRUISE CONTROL SYSTEM - S Decial Tools / Troubleshootina Tool Number Name MB991341 Multi-use tester Checking of the self-diagnosis output assembly MB991 359 ROM pack PRELIMINARY INSPECTION Check the following points and repair defective points, if any, before troubleshooting. properly installed and that the cables and vacuum hoses are correctly routed. (3).
Page 266 CRUISE CONTROL SYSTEM - Troubleshooting NOTE This chart contains troubleshooting procedures to perform when a problem cannot be detected by self diagnosis. Check input. (Refer to P. 13-l 73.) Is the result of input check O.K.? (Refer to P. 13-l 67.) NOTE If the results of checks on the vacuum pump indicate that they are good, replace the control unit...
Page 267 CRUISE CONTROL SYSTEM - Troubleshootina Trouble symptom Probable cause Check chart No. Remedy The set vehicle speed varies Malfunction of the vehicle No. 4 Repair the vehicle speed greatly upward or downward. speed sensor circuit sensor system, or replace “Hunching” (repeated alter- the part.
Page 268 CRUISE CONTROL SYSTEM - Troubleshooting Trouble symptom Probable cause Check chart No. Remedy 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 269 CRUISE CONTROL SYSTEM - Troubleshooting CHECK CHART Inspection of control unit power supply circuit DESCRIPTION OF OPERATION The power is supplied through the ignition switch unit. 1. 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 270 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 271 CRUISE CONTROL SYSTEM Inspection of indicator light circuit IGNITION MAIN CRUISE CONTROL UNIT 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.
Page 272 CRUISE CONTROL SYSTEM Inspection of vehicle speed sensor circuit <TURBO> <NON-TURBO> IGNITION CRUISE CONTROL UNIT COMBINATION METER VEHICLE SPEED SENSOR DESCRIPTION OF OPERATION The vehicle speed sensor, mounted in the transmission, 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 273 CRUISE CONTROL SYSTEM Inspection of vacuum pump assemblv drive circuit DESCRIPTION OF OPERATION CRUISE CONTROL The vacuum pump assembly consists of a di- MAIN SWITCH aphragm type negative pressure pump that is driven by a DC motor, and two solenoid valves (control valve and relief valve) and is controlled by the.
Page 274 CRUISE CONTROL SYSTEM Inspection of stop light switch circuit FUSIBLE LINK@ 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 275: Cruise Control System
CRUISE CONTROL SYSTEM Inspection of inhibitor switch circuit <A/T> DESCRIPTION OF OPERATION The inhibitor 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 vacuum pump assembly drive circuit for cancellation of vehicle speed.
Page 276 CRUISE CONTROL SYSTEM Inspection of circuit associated with accelerator pedal switch OFF function <A/T> DESCRIPTION OF OPERATION The accelerator pedal switch is used to detect the operating state of the accelerator pedal. It is one of the sensors of the ELC4A/T automatic transmis- sion.
Page 277 CRUISE CONTROL SYSTEM Inspection of circuits associated with overdrive cancel <A/T> 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, the cruise control unit forces transistor Tr, into the OFF state.
Page 278 CRUISE CONTROL SYSTEM SELF-DIAGNOSIS CHECKING Self-diagnosis checking is performed when there has been an automatic cancellation without cancel switch operation. NOTE Even when the ignition key is placed in the OFF position, all diagnosis 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 279 CRUISE CONTROL SYSTEM - Troubleshooting DIAGNOSIS DISPLAY PATTERNS AND CODES Code Display patterns (output codes) Probable cause Check chart No. (Use with voltmeter) Vacuum pump assembly drive out of order same pattern repeatedly displayed Vehicle speed signal system of order Control switch out of order (When SET or RESUME switch is kept in ON state continuously for more than 60 seconds)
Page 280 CRUISE CONTROL SYSTEM - Troubleshooting (2) Calling up a code Control switch switch to ON. In less than 1 .O second thereafter, set the I,/ SUME itch: ON 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 281 CRUISE CONTROL SYSTEM - Troubleshooting INPUT CHECK TABLE Input operation Check results Display patterns (output codes) (use with voltmeter) SET switch ON SET switch circuit normal RESUME switch.ON RESUME switch normal Stop light switch circuit normal Stop light switch ON (brake pedal depressed) Vehicle speed sensor circuit Vehicle speed more than approx.
Page 282 CRUISE CONTROL SYSTEM HARNESS AND COMPONENTS LAYOUT ENGINE COMPARTMENT Engine front view Engine rear view 01 Jumper connector 02 Vacuum pump 03 Throttle position sensor 04 Inhibitor switch <A/T> 05 VeTkFo;peed sensor INSTRUMENT PANEL AND FLOOR CONSOLE Combination meter Main switch TSB Revision...
Page 283 CRUISE CONTROL .SYSTEM - Troubleshooting DASH PANEL Junction block JUNCTION BLOCK Front side 14 Over drive switch <A/T> 15 Cruise control unit Front wiring harness and junction 19 Adapter wiring harness and junction block combination 11 Stop light switch Body wiring harness (LH) and junction block 12 Clock spring 13 Accelerator pedal switch <A/T>...
Page 284 CRUISE CONTROL SYSTEM - Service Adjustment Procedures CRUISE CONTROL CABLES INSPECTION AND ADJUSTMENT Cruise control actuator Cruise control assembly Adjusting nut A Link B - L i n k A Cruise control cable Adjusting nut C Accelerator cable Throttle valve (1) Set the air conditioner, lights and other switches to OFF for inspection at no load.
Page 285 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 to move.
Page 286 CRUISE CONTROL SYSTEM - Service Adjustment Procedures CRUISE CONTROL SETTING CHECK (1) Switch ON the main switch. (2) Drive at the desired speed within the range of approximate- ly 40 - 145 km/h (25 - 90 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 287 ‘CRUISE CONTROL SYSTEM - Service Adjustment Procedures Control switch 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. switch is set to OFF, the normal drive mode is restored and the vehicle coasts smoothly.
Page 288 CRUISE CONTROL SYSTEM CRUISE CONTROL SWITCH INSPECTION (1) Remove the air bag module using the following procedure. for more than 30 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.
Page 289 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 Brake switch Stop light switch When brake pedal depressed. When brake pedal not depressed. CLUTCH SWITCH INSPECTION <M/T> the clutch pedal is depressed, and that there is no continuity when the pedal is released.
Page 290 CRUISE CONTROL SYSTEM For inspection, refer to P.13-65. IDLE POSITION SWITCH INSPECTION For inspection, refer to P.13-68. VACUUM PUMP INSPECTION Inspection of Solenoid Valves (Control and Relief Valves) (1) Disconnect the connector of the vacuum pump assembly. (2) Measure the resistance values across terminals @ and @ and across terminals @ and 0.
Page 291 CRUISE CONTROL SYSTEM - Cruise Control System REMOVAL AND INSTALLATION 5 N m 4 ft.lbs. 5 N m 4 ft.lbs. Post-installation Operation Cruise Control Cables (Refer to Removal steps of actuator 1. Link protector 2. Connection of accelerator cable and link assembly 3.
Page 292 CRUISE CONTROL SYSTEM - Cruise Control System 1.6 - 2.2 ft.lbs. Removal steps of control switches 20. Air bag module 21. Air bag module bracket 22. Cruise control switch 23. Switch garnish 24. Main switch Removal steps of control unit 25.
Page 293 CRUISE CONTROL SYSTEM - Cruise Control Svstem SERVICE POINT OF REMOVAL 20. REMOVAL OF AIR BAG MODULE for more than 30 seconds. Caution The capacitor in the SRS diagnosis unit retains enough voltage to deploy the air bag for a given battery.
Page 295 CONTENTS ENGINE COOLANT TEMPERATURE GAUGE SPECIFICATIONS ...._......... UNIT, ENGINE COOLANT TEMPERATURE . ..___..___._...___.__.... General Specifications SENSOR AND ENGINE COOLANT Lubricant ........_...._..TEMPERATURE SWITCH .
Page 296 COOLING - SDecifications 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 76.5 (Stamped on flange) Identification mark SERVICE SPECIFICATIONS Specifications...
Page 297 COOLING - Specifications / Troubleshooting SEALANT AND ADHESIVE Items Specified sealants and adhesive Engine coolant temperature gauge unit Engine coolant temperature sensor (Engine control) 3M Nut Locking Part No. 4171 Engine coolant temperature sensor (Air conditioner) Remedy Symptom Probable cause Replenish Insufficient engine coolant Overheat...
Page 298 COOLING - Troubleshooting CIRCUIT DIAGRAM IGNITION FUSIBL RADIATOR FAN ASSEMBLY RADIATOR FAN MOTOR > r A-04X ,--- RADIATOR FAN ASSEMBLY TSB Revision...
Page 299 COOLING - Troubleshootina RADIATOR AIR CONDITIONER FUSIBLE FAN MOTOR COMPRESSOR LOCK LINK@ CONTROLLER A-36 A-45 TSB Revision...
Page 300 COOLING - Troubleshooting TROUBLESHOOTING HINTS Check the radiator fan motor relay (LO) and condenser fan motor relay (LO). 1. Neither the radiator fan nor condenser fan Check the therm0 sensor (for radiator rotate at all. fan). Check fusible link No. 5. 2.
Page 301 COOLING - Service Adiustment Procedures. ENGINE COOLANT LEAK CHECK 2. Confirm that the engine coolant level is up to the filler neck. Install an adapter to the water outlet fitting and apply 160 checking for leakage from the radiator, hose or connec- tions.
Page 302 COOLING - Radiator REMOVAL AND INSTALLATION Removal steps of radiator 1. Drain plug 2. Cap 3. Overflow tube 4. Water level sensor connector 5. Reserve tank 6. Radiator upper hose 7. Radiator lower hose 8. Automatic transaxle oil cooler hoses <Vehicles with A/T>...
Page 303 COOLING - Radiator 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 304 COOLING - Radiator 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 305 COOLING - Thermostat REMOVAL AND INSTALLATION Draining and Supplying of the (Refer to GROUP 00 - Maintenance Removal steps 1. Air hose A <Turbo> 3. Air intake hose <Non-Turbo> 4. Connection of radiator lower hose 5. Water inlet fitting 6. Gasket a 7.
Page 306 COOLING - Thermostat SERVICE POINTS OF INSTALLATION 7. INSTALLATION OF THERMOSTAT Install the thermostat with its jiggle valve lined up with the , mark on the thermostat housing. 2. INSTALLATION OF AIR INTAKE HOSE A Assemble the air intake hose A with its notches (arrow- marked) lined up with the L marks on the air intake hoses B and C.
Page 307 COOLING - Water Pump, Water Pipe and Water Hose REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying of the Engine Coolant (Refer to GROUP 00 - Maintenance Service.) Removal and Installation of Power Transistor 17-20 Nm Unit and Ignition Coil (Refer to GROUP 16 - Engine Electrical) Removal and lnstallatlon of Timing Belt (Refer to GROUP 11 -Timing Belt)
Page 308 COOLING - Water Pump, Water Pipe and Water Hose INSPECTION WATER PUMP If any of the following irregularities are observed, replace the LJ 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 309 Engine Coolant Temperature Gauge Unit, Engine Coolant COOLING REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying of the Engine Coolant (Refer to GROUP 00 - Maintenance Service.) 30 Nm Removal steps 1. Air hose A <Turbo> + 2. Air intake hose A <Turbo> 4.
Page 310 Engine Coolant Temperature Gauge Unit, Engine Coolant COOLING ENGINE COOLANT TEMPERATURE SWITCH (Air condition- then heat (by using a gas stove flame or similar method) so as to increase the oil temperature. (2) Check to be sure that the engine coolant temperature switch is switched OFF when the oil temperature reaches the standard value.
Page 311 INTAKE E X H A U S T = CONTENTS ACTIVE EXHAUST SYSTEM ......Supercharging Pressure Relief Solenoid Valve Inspection .
Page 312 INTAKE AND EXHAUST - Specifications / Special Tool GENERAL SPECIFICATIONS Specifications Items Air cleaner Unwoven cloth type Element Exhaust system Dual type Front exhaust pipe Expansion resonance type Muffler Flat coupling, insertion type Coupling Rubber hangers Suspension system Turbocharger Exhaust gas turbine type identification No.
Page 313 INTAKE AND EXHAUST - Troubleshooting Remedy Symptom Probable cause gas leakage Retighten Exhaust Loose joints Broken pipe or muffler Repair or replace Abnormal noise Broken separator in muffler Replace Broken rubber hangers Correct Interference of pipe or muffler with vehicle body Repair or replace Broken pipe or muffler...
Page 314 INTAKE AND EXHAUST - Troubleshooting (Active Exhaust System) TROUBLESHOOTING PROCEDURE (1) Make sure that the valve operating cable is not dislocated. (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 315 INTAKE AND EXHAUST - Troubleshooting (Active Exhaust.System) ACTIVE EXHAUST SYSTEM CIRCUIT CHECK TROUBLESHOOTING HINTS Checking Active Exhaust Control Unit Terminal Status SPORT MODE signal SPORT MODE Not less than IOV TOUR MODE signal TOUR MODE Not less than IOV Full open posrtion detection srgnal SPORT MODE (Not lesi’than 5V) Engine control unit output signal...
Page 316 INTAKE AND EXHAUST VARIABLE INDUCTION CONTROL SYSTEM IN- d SYSTEM INSPECTION Adjustment.) the idle speed to 5,000 rpm, the induction control valve shaft turns. VARIABLE INDUCTION CONTROL SERVO INSPECTION (2) Teck the vanable induction control servo coil for continui- Standard value control servo connectors Measured terminal...
Page 317 INTAKE AND EXHAUST valve, and connect the pressure gauge to the hose. Plug the nipple of the solenoid valve from which the hose (black) has been disconnected. (2) Drive the vehicle with full throttle and accelerate the engine to a speed of more than 3,500 rpm at 2nd gear. Measure the supercharging pressure when the pointer is stabilized.
Page 318 INTAKE AND EXHAUST SUPERCHARGING PRESSURE RELIEF SOLENOID VALVE INSPECTION (Turbo) OPERATION INSPECTION terminal and battery terminal. battery negative terminal to apply a negative pressure, check tightness. Jumper wire Normal condition condition Open Negative pressure leaks. Connected Close Negative pressure is held. Disconnected Open Negative pressure is held.
Page 319 INTAKE AND EXHAUST REMOVAL AND INSTALLATION T u r b o > < T u r b o > 15 Hose clamp Removal steps of air intake hose Removal steps of air cleaner 1. Connection of air flow sensor connector <Turbo>...
Page 320 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 321 INTAKE AND EXHAUST REMOVAL AND INSTALLATION 24Nm 7 - 9 ft.lbs. IO-13Nm . .-... 2.9 ft.lbs. lo-13Nm 7 - 9 ft.lbs. b-ring 7 - 9 ft.lbs. Turbocharger Removal steps of intercooler right * 2. Air hose D (When equipped with intercooler left) 3.
Page 322 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 intercooler fins for bending, damage, or foreign matter. Check the intercooler hoses for cracking, damage, or wear. SERVICE POINTS OF INSTALLATION 21.
Page 323 INTAKE AND EXHAUST REMOVAL AND INSTALLATIQN I Post-installation ODeration Adjustment of Accelerator Cable (Refer to GROUP 13 - Engine Control.) Removal steps 2. Connection of accelerator cable 3. Throttle body assembly * 4. Throttle body gasket 8 6 0 N m 5.
Page 324 INTAKE AND EXHAUST REMOVAL AND INSTALLATION (Refer to GROUP 13 - Engine Control.) 18 Nm Turbocharger 19 Nm 13 ft.lbs. Removal steps 11. EGR valve 12. EGR valve gasket 2. Connection of accelerator cable 13. EGR pipe installation bolts 3. Throttle body assembly * 4.
Page 325 INTAKE AND EXHAUST INSPECTION Check the following points; replace the part if a problem is found. AIR INTAKE PLENUM (1) Check air intake plenum for defect or cracks. Replace if defective or cracked. (2) Check load (negative pressure) of drain port. Clean if required.
Page 326 INTAKE AND EXHAUST - Intake Manifold REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Release of Residual Pressure from Installation of Air Intake Plenum High Pressure Fuel Hose (Refer to P.1.5-13. 14.) (Refer to GROUP 13-Service Filling of Engine Coolant Adjustment Procedures.) (Refer to GROUP 00 - Maintenance Draining of Engine Coolant (Refer Service.)
Page 327 INTAKE AND EXHAUST INSPECTION Check the following replace the part if a problem is points; found. INTAKE MANIFOLD (1) Check for damage or cracking of any part. (2) Clogging of the negative pressure (vacuum) outlet port, or clogging of the gas passages. (3) Check deflection of installation surface with straight edge and thickness gauge.
Page 328 INTAKE AND EXHAUST - Turbocharger (Front) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Radiator (Refer to GROUP 14 - Radiator.) Removal and Installation of Transmission Pipe (Refer to P.15-31.) - 1 3 N m 40 - 47 ft.lbs. ‘...
Page 329 INTAKE AND EXHAUST - Turbocharger (Front) SERVICE POINTS OF REMOVAL 19. REMOVAL OF OXYGEN SENSOR Disconnect the connector of the oxygen sensor, and install the special tool to the oxygen sensor. 25. DISCONNECTION OF AIR CONDITIONER COMPRES- Disconnect air conditioner compressor with hoses from the bracket.
Page 330 INTAKE AND EXHAUST - Turbocharger (Front) 19. INSTALLATION OF OXYGEN SENSOR Use the special tool to install the 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 331 INTAKE AND EXHAUST - Turbocharger (Rear) REMOVAL AND INSTALLATION Post-installation ODeration Installation of Front Exhaust Pipe Refilling of the Engine Coolant (Refer to GROUP 00 - Maintenance Adjustment of Accelerator Cable 7 - 9 ft.lbs. 1 8 N m ’ d 13 ft.lbs.
Page 332 INTAKE AND EXHAUST SERVICE POINT OF REMOVAL Disconnect the connector of the oxygen sensor, and install the special tool to the 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 333 INTAKE AND EXHAUST 9. INSTALLATION OF AIR INTAKE HOSE C / 8. AIR INTAKE HOSE A Engaging the notches with n marks at the points indicated by the arrows insert until seated. Insert the turbocharger end of air intake hose C completely. Air intake hose A Air intake hose B 4.
Page 334 INTAKE AND EXHAUST - Turbocharger DISASSEMBLY AND REASSEMBLY 12 Nm Disassembly steps 2. Waste gate actuator 3. Coupling 6. Cartridge assembly O-ring * 7. 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 335 INTAKE AND EXHAUST INSPECTION TURBOCHARGER it operates freely. 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. SERVICE POINTS OF REASSEMBLY 7.
Page 336 INTAKE AND EXHAUST TEST OF 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 actuator. Otherwise, diaphragm may be damaged.
Page 337 INTAKE AND EXHAUST - Exhaust Manifold <Non Turbo> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Front Exhaust Pipe Removal and Installation of Condenser Fan Motor Assembly <Vehicles with Air Conditioner> (Refer to GROUP 14 - Radiator.) 9 - 11 ft.lbs.
Page 338 INTAKE AND EXHAUST REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Turbocharger Assembly (Refer to P.15-18, 21.) 9 - 11 ft.lbs. Removal steps of exhaust manifold (front) 4. Gasket Removal steps of exhaust manifold (rear) 5. Heat protector 7.
Page 339 INTAKE AND EXHAUST 3. INSTALLATION OF EXHAUST MANIFOLD STAY With the exhaust manifold stay resting on the exhaust Exhaust manifold, fit it along with the exhaust manifold over the manifold studs. stay Exhaust manifold INSTALLATION OF EXHAUST MANIFOLD (FRONT) Tighten the nuts in the following order. (2) Temporarily tighten the turbocharger to the exhaust manifold.
Page 340 INTAKE AND EXHAUST - Exhaust Pipe, Main Muffler and Catalytic Converter <Non Turbo> REMOVAL AND INSTALLATION 3. Rubber hangers 50 Nm 4. Rubber nanger 5. Main muffler 6. Mouldings 7. Hanger brackets 8. Catalytic converter and center exhaust pipe installation bolts 9.
Page 341 INTAKE AND EXHAUST - Exhaust Pipe, Main Muffler and Catalytic Converter <Turbo> 13 Nm 9 ft.lbs. 13 Nm - - - - 9 ft.lbs. 13 Nm 9 ft.lbs. Removal steps 1. Main muffler and center 13. Center exhaust pipe 25. Gaskets exhaust pipe installation 14.
Page 342 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. 30. REMOVAL OF OXYGEN SENSOR Disconnect the connector of the oxygen sensor, and install the special tool to the oxygen sensor.
Page 343 INTAKE AND EXHAUST REMOVAL AND INSTALLATION 5 ft.lbs. Removal steps Pre-removal and Post-installation Active exhaust system control unit Removal and Installation of Rear Side Trim (LH) (Refer to GROUP 52A-Trims.) 3. Actuator 4. Protector + 5. Connection of cable (Muffler side) 6.
Page 344 INTAKE AND EXHAUST - Active Exhaust System I N S P E C T I O N ACTIVE EXHAUST SWITCH (2) Operate the switch and check the continuity between the terminals. NOTE O-O indicates that there is continuity between the terminals. TSB Revision...
Page 345 EMISSION C O N T R O L .~ CONTENTS ......: ... EXHAUST GAS RECIRCULATION (EGR) CATALYTIC CONVERTER SYSTEM ..____._.._..__.._____......Inspection ............Air-Fuel Ratio Control (MPI) System ........
Page 346: Catalytic Converter
EMISSION CONTROL - Specifications / Troubleshooting GENERAL SPECIFICATIONS Items Specifications Crankcase emission control system Closed type with positive crankcase ventilation valve Evaporative emission control system Canister storage type Canister Charcoal type Purge control solenoid valve ON/OFF solenoid valve Exhaust emission control system Exhaust gas recirculation system EGR valve Vacuum-activated diaphragm type...
Page 347: Vacuum Hoses Routing
EMISSION CONTROL - Vacuum Hoses VACUUM HOSES ROUTING Fuel pressure regulator Vehicle front L: Light blue R: Red B: Black <California - Non Turbo> EGR control solenoid valve Canister Fuel pressure regulator Vehicle front G: Green Y: Yellow L: Light blue R: Red B: Black Revision...
Page 348 EMISSION CONTROL - Vacuum Hoses < T u r b o > Waste gate control EGR control solenoid valve Fuel pressure control solenoid valve solenoid valve aste gate actuator Purge control solenoid valve Bypass valve Fuel pressure regulator G: Green Purge control valve Y: Yellow L: Light blue...
Page 349 EMISSION CONTROL - Crankcase Emission Control System COMPONENTS LOCATION J I r--‘-l Name Symbol Positive crankcase ventilation valve CRANKCASE VENTILATION SYSTEM INSPEC- TION (1) After disconnecting the ventilation hose from the positive crankcase ventilation valve, disconnect the positive crank- case ventilation valve from the rocker cover, and reconnect the positive crankcase ventilation valve to the ventilation hose.
Page 350 EMISSION CONTROL - Evaporative Emission Control System COMPONENTS LOCATION Name Symbol Canister Purge control solenoid valve TSB Revision...
Page 351 EMISSION CONTROL PURGE CONTROL SYSTEM INSPECTION <Non Turbo> Barometric pressure sensor (2) Plug the nipple from which the vacuum hose is discon- nected. (3) Under the engine conditions shown below, check by applying vacuum from a hand vacuum pump. When engine is cold - engine coolant temperature: - - - - I \ When engine is hot - engine coolant temperature: 70°C (158°F) or higher...
Page 352 EMISSION CONTROL PURGE CONTROL SYSTEM INSPECTION <Turbo> Canister PI IrnQ rnntrnl Purge control valve relay Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Air flow sensor Engine control unit (1) Disconnect the purge air hose from the air intake hose, and plug the air intake hose.
Page 353 EMISSION CONTROL - Evaporative Emission Control System PURGE PORT VACUUM CHECK Purge h o s e - - - - - Check Condition Engine coolant temperature: 80 - 95°C (176 - 205°F) (1) Disconnect the vacuum hose from the throttle body purge hose nipple and connect a hand vacuum pump to the nipple.
Page 354: Air Conditioner Switch
EMISSION CONTROL (4) Apply a vacuum and check for airtightness when voltage applied directly to the purge control solenoid valve and when the voltage is discontinued. Battery voltage Result Non-Turbo When applied Vacuum leaks Vacuum is maintained When discontinued Turbo When applied Vacuum is maintained When discontinued...
Page 355: Exhaust Gas Recirculation (Egr) System
EMISSION CONTROL - Exhaust Gas Recirculation (EGR) System COMPONENTS LOCATION Symbol Name <California - Non Turbo, Turbo> EGR temperature sensor <Cahfornla> TSB Revision...
Page 356 EMISSION CONTROL - Exhaust Gas Recirculation (EGR) System EGR SYSTEM INSPECTION <California - No, Turbo, Turbo> valve, and connect a hand vacuum pump through the three-way terminal. (2) Regarding cold condition [coolant temperature: 20°C (68°F) or less] and warm condition [coolant temperature: 70°C (158°F) or more] of the engine, check the following two points: <Cold condition of engine>...
Page 357: Egr Control Solenoid Valve
EMISSION CONTROL EGR VALVE <California - Non Turbo, Turbo> INSPECTION (1) Remove the EGR valve and check it for sticking, deposit of carbon, etc. If such condition exists, clean with adequate solvent to ensure tight valve seat contact. (2) Connect a hand vacuum pump to the EGR valve. (3) Apply a vacuum of 500 mmHg (19.8 in.Hg.) and check airtightness.

Page 358 EMISSION CONTROL - Exhaust Gas Recirculation (EGR) System / Catalytic Converter (4) Apply a vacuum and check for air-tightness when voltage applied directly to the EGR control solenoid valve and when the voltage is discontinued. Battery voltage Result When applied Vacuum is maintained When discontinued Vacuum leaks...
Page 359 CLUTCH CONTENTS CLUTCH CONTROL .._.._......_... SPECIFICATIONS ..........
Page 360: Specifications
CLUTCH GENERAL SPECIFICATIONS Single dry disc type Single dry disc type Facing diameter Diaphragm spring strap SERVICE SPECIFICATIONS Specifications terns Standard value mm (in.) 177 - 182 (6.97 - 7.17) Clutch pedal height mm (in.) Clutch pedal stroke Amount of clutch pedal return from full pedal stroke position to where operating sound of interlock switch is produced mm (in.)
Page 361: Troubleshooting
CLUTCH LUBRICANTS Items Specified lubricants Contact surface of release bearing and fulcrum of MITSUBISHI genuine grease clutch release fork Part No.0101 011 or equivalent Inner surface of clutch release bearing Inner surface of clutch disc spline Contact portion of release fork to release cylinder push rod...
Page 362 CLUTCH - Troubleshooting Clutch release fork not operating...
Page 363 CLUTCH 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: 177 - 182 mm (6.97 - 7.17 in.) If the clutch pedal height is not within the standard value range, adjust as follows: For vehicles without auto-cruise control system, turn and auto-cruise control...
Page 364: Vacuum Hoses
CLUTCH 4. Measure pedal play. In the case of AWD vehicles, depress 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: 6 - 13 mm (.24 - 51 in.) Measure the clearance to the toe board (or pedal stopper) Distance between the clutch pedal...
Page 365 CLUTCH - Service Adiustment Procedures 2. Check the operation of the check valve by using a vacuum Accept/reject criteria Vacuum pump connection Connection at the clutch A negative pressure (vacuum) is booster side @ created and held. A negative pressure (vacuum) is not Connection at the intake Valve Intake...
Page 366 CLUTCH REMOVAL AND INSTALLATION 30 Nm 22 ftlbs. 9 ft.lbs. 13 Nm 9 ft.lbs. 13. Clutch pedal Removal steps 14. Bushing 1. Connection of brake booster 15. Spacer Adjustment of brake pedal 16. Clutch pedal pad (Refer to GROUP 35 - Service 17.
Page 367 CLUTCH Removal steps 23. Brake booster 33. Bushing (Refer to GROUP 35 - Brake Booster.) 34. Spacer 24. Connection of clutch master cylinder 25. Connection for vacuum hose 26. Pedal support bracket 37. Lever assembly 27. Clevis pin 38. Bushing 28.
Page 368 CLUTCH REMOVAL AND INSTALLATION Pre-removal Operation Draining of the Clutch Fluid Bleeding of the Clutch Line (Refer to P.21-7.) Adjustment of Clutch Pedal (Refer to P.21-5.) Clutch master cylinder removal step 1. Brake booster (Refer to GROUP 35 - Brake Booster.) 2.
Page 369 CLUTCH Release cylinder push rod 15 Nm 11 ftlbs. Clutch release cylinder removal steps 4 5. Air hose A <AWD> 6. Air cleaner cover, air intake hose <FWD> * 7. Air cleaner cover, air intake hose A <AWD> * 8. Vacuum pipe cAWD> 9.
Page 370 CLUTCH 14. 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. HOSE SIDE) / 16. CLUTCH TUBE B <AWD> (CLUTCH HOSE SIDE) While holding the clutch hose side nut, loosen the clutch tube flare nut.
Page 371 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’...
Page 372 CLUTCH DISASSEMBLY AND REASSEMBLY Disassembly steps Master cvlinder kit 1. Piston stop bolt <FWD> 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 6.0 Nm 9.
Page 373 CLUTCH DISASSEMBLY AND REASSEMBLY Lubricant: Conforming to DOT3 Disassembly steps 2. Spring 3. Push rod Boots 5. Piston and cup 6. Conical spring 8. Bleeder plug 9. Release cylinder SERVICE POINTS OF DISASSEMBLY 5. DISASSEMBLY OF PISTON AND CUP (1) Remove the corrosion from the piston-removal port of the release cylinder.
Page 374 CLUTCH INSPECTION es or irregular wear. (2) Replace if the piston cup outer circumference is scratched or shows signs of fatigue, or if there is excessive wear of the lip where indicated in the figure. SERVICE POINTS OF REASSEMBLY 5. APPLICATION OF FLUID TO PISTON AND CUP Apply specified brake fluid to the release cylinder inside and outer surface of the piston and piston cup and push the piston cup assembly in the cylinder.
Page 375 CLUTCH - Clutch Vacuum Line, Vacuum Tank <AWD> REMOVAL AND INSTALLATION Hose clamp 4.0 Nm 4. Fitting Vacuum pipe A removal steps Vacuum tank assembly, vacuum hose E, * 5. Air hose A vacuum pipe C removal steps 7. Vacuum pipe A 11.
Page 376 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 Check valve 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 377 CLUTCH - Clutch Cover and Disc REMOVAL AND INSTALLATION Removal of the Transaxle Assembly 15-21 Nm 11 - 15 klbs. Removal steps 1. Clutch cover assembly 3. Return clip 6. Fulcrum 7. Release fork boot TSB Revision...
Page 378 CLUTCH Lubricant: MITSUBISHI genuine grease Part No. 0101011 or equivalent Lubricant: MITSUBISHI genuine grease Part No. 0101011 or eauivalent Lubricant: MITSUBISHI genuine grease Part No. 0101011 or equivalent SERVICE POINTS OF REMOVAL 1. REMOVAL OF CLUTCH COVER ASSEMBLY / 2. CLUTCH...
Page 379 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 380 (1) Apply a coating of the specified grease to the point of contact with the fulcrum and the point of contact with the release bearing. Specified grease: MITSUBISHI genuine grease Part No. 0101011 or equivalent Caution When installing the clutch, apply grease to each part, but be careful not to apply excessive grease;...
Page 381 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 382 MANUAL TRANSAXLE <FWD> - General Information 2nd speed gear Bearing retainer 1 st weed speed synchronizer assembly Input shaft 5th speed gear 5th speed 1 st-2nd synchronizer speed assembly Spacer synchro- nizer assembly noise-prevention Filter 5th speed inter- mediate gear Differential drive gear TSB Revision...
Page 383: Specifications
MANUAL TRANSAXLE <FWD> - Specifications GENERAL SPECIFICATIONS items Specifications Model Applicable engine Gear ratio 1 st 1.833 1.217 Reverse Final reduction ratio 4.153 Speedometer gear ratio (driven/drive) Oil quantity liters (qts.) 2.3 (2.4) SERVICE SPECIFICATIONS mm (in.) Items Specifications Standard value Transaxle Input shaft end play 0 - 0.05 (0 - ,002)
Page 384 MANUAL TRANSAXLE <FWD> - Specifications Identification Part name Thickness mm (in.) Part No. symbol Spacer 0.95 l.0374) MD720941 MD720942 0.98 t.0386) 1 .Ol t.0398) M D720943 MD720944 MD720945 MD71 0454 1.13 l.0445) MD700270 1.16 i.0457) MD710455 1.19 (.0468) MD710456 MD700271 1.25 i.0492) MD710457 1.28 t.0504)
Page 385 MANUAL TRANSAXLE <FWD> - Specifications Identification Part name Thickness mm (in.) Part No. symbol MD720937 Spacer 0.83 (.0327) (For adjustment of output shaft preload) 0.86 (0338) MD720938 0.89 (.0350) MD720939 0.92 (.0362) MD720940 0.95 (.0374) MD720941 0.98 (.0386) MD720942 1 .Ol t.0398) MD720943 MD720944 MD729945...
Page 386: 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 3M Stud Locking part No. 4170 or equivalent...
Page 387 MANUAL TRANSAXLE <FWD> - Special Tools Bearing remover Removal of gears and bearings of input shaft, intermediate gear and output shaft and intermediate shaft lock nut M D998808-01 Snap ring installer Installation of input shaft rear snap ring installer adapter Installation of differential case bearings MD998822 TSB Revision...
Page 388 MANUAL TRANSAXLE <FWD> - 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 e.
Page 389 MANUAL TRANSAXLE <FWD> - Service Adiustment Procedures TRANSMISSION OIL LEVEL INSPECTION Refer to GROUP 00 - Maintenance Service. TRANSMISSION OIL REPLACEMENT (1) Position vehicle on a flat level. (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 390 MANUAL TRANSAXLE <FWD> - Service Adjustment Procedures DRIVE SHAFT OIL SEALS REPLACEMENT (Refer to GROUP 26 - Drive Shaft.) (3) Using the special tool, tap the drive shaft oil seal into the transaxle. The drive shaft oil seal must be installed in the direction shown.
Page 391 MANUAL TRANSAXLE <FWD> - Transaxle. Control REMOVAL AND INSTALLATION Pre-removal and Post-installation (Refer to GROUP 52A-Floor Console.) 12 Nm 9 ft.lbs. Shift lever assembly removal steps Transaxle control cable assembly removal steps 1. Air cleaner, Air intake hose 1. Air cleaner, Air intake hose a 3.
Page 392 MANUAL TRANSAXLE <FWD> 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 action, and damage. 3. CONNECTION OF TRANSAXLE CONTROL CABLE ASSEMBLY (SHIFT LEVER ASSEMBLY SIDE) NOTE The select lever will be set to the neutral position when the transaxle shift lever is moved to the neutral position.
Page 393 MANUAL TRANSAXLE <FWD> DISASSEMBLY AND REASSEMBLY 24Nm Disassembly steps 1. Nut 2. Spring washer 3. Plain washer 4. Shift lever 5. Bushing 6. Plain washer 7. Wave washer 8. Nut 9. Spring washer 11. Return spring 12. Bushing 13. Pipe 14.
Page 394 MANUAL TRANSAXLE <FWD> REMOVAL AND INSTALLATION (Refer to GROUP 51 -Front Bumper.) 4.0 Nm 19 Nm 13 ft.lbs. Removal steps 2. Battery 3. Battery seat, Washer tank Air cleaner cover, Air intake hose 5. Connection for clutch release cylinder 6. Connection for clutch tube bracket and clutch damper assembly 7.
Page 395 MANUAL TRANSAXLE <FWD> Post-installation Operation Installation of Front Under Cover Supplying of Transmission Oil (Refer to P.22-9.) 70 Nm Filling of Engine Coolant (Refer to GROUP 14- Service Adjustment Procedures.) Checking Operation of Shift Lever at Each Position Checking the Operation of the Meters and Gauges 26 ft.lbs.
Page 396 MANUAL TRANSAXLE <FWD> 9. 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 397 MANUAL TRANSAXLE <FWD> REMOVAL OF DRIVE SHAFT (RIGHT SIDE) assembly, apply pry bar to the protrusion. NOTE Remove drive shaft (right side) as an assemb’ly 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 398 MANUAL TRANSAXLE <FWD> - Transaxle Assemblv DISASSEMBLY AND REASSEMBLY 11 - 15 ftlbs. 4.0 - 5.5 Nm 30-35 Nm -42 Nm 2.9 - 3.9 ftlbs. 22 - 25 ft.lbs. 140 - 160 Nm 102 - 115 ftlbs. 2.5 - 3.5 ftlbs. Disassembly steps * 15.
Page 399 MANUAL TRANSAXLE <FWD> - Transaxle Assemblv Adhesive: 3M Stud Locking Part No. 4170 T F M 0 0 1 6 M ATD Part No. 8001...
Page 400 MANUAL TRANSAXLE <FWD> 35-42 Nm 22 - 25 ftlbs. 26 - 30 ft.lbs. 32 - 39 ft.lbs. Sealant: MITSUBISHI Genuine Part No. 997740 or equivalent Disassembly steps 23. Reverse idler gear shaft bolt Gasket 41. Bearing outer race Bolt * 42. Spacer * 26.
Page 401 MANUAL TRANSAXLE <FWD> I 53 -22Nm -15 ftlbs. 51. Screw 52. Bolt 53. Bearing retainer 54. Intermediate gear assembly 55. Input shaft assembly 56. Output shaft assembly 57. Differential gear assembly 58. Bearing outer race 59. Bearing outer race 60. Oil guide 61.
Page 402 MANUAL TRANSAXLE <FWD> SERVICE POINTS OF DISASSEMBLY 14. REMOVAL OF SPRING PIN Remove the spring pin using a pin punch. NOTE If the spring pin interferes with the synchronizer ring or cone gear, rotate the gear for dislocation and remove the spring pin.
Page 403 MANUAL TRANSAXLE <FWD> 22-23 50. REMOVAL OF SHIFT RAIL ASSEMBLY (3) Remove the shift rail assembly. INSPECTION BACKUP LIGHT SWITCH Operate the backup light switch to check continuity with a circuit tester. If without continuity, replace the switch. SERVICE POINTS OF REASSEMBLY 54.
Page 404 22-24 MANUAL TRANSAXLE <FWD> 63. INSTALLATION OF OIL SEAL Install the input shaft front oil seal using the special tool. Oil seal 2010041 50. INSTALLATION OF SHIFT RAIL ASSEMBLY (3) Fit the shift forks of shift rail assembly to groove of sleeves.
Page 405 MANUAL TRANSAXLE <FWD> 22-25 (2) When installing, make sure that the slit of the spring pin is aligned with the shift rail center line. Slit Spring pin Shift rail 201034 46. INSTALLATION OF REVERSE IDLER GEAR SHAFT Install in the direction illustrated. 35.37.
Page 406 Amount l-2 mm transaxle case is installed. (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 407 22-27 MANUAL TRANSAXLE <FWD> (3) Shift the transaxle in reverse using control lever and select lever. (4) Tighten the lock nut to specified torque, while using the bolt attached in the above step as a spinner handle stopper. (5) Loosen the lock nuts. (6) Retighten the lock nuts to the specified torque.
Page 408 22-28 MANUAL TRANSAXLE <FWD> - 5th Speed Synchronizer Assembly 5TH SPEED SYNCHRONIZER ASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Synchronizer spring 3. Synchronizer sleeve 5. Synchronizer hub INSPECTION SYNCHRONIZER SLEEVE AND HUB Combine the synchronizer sleeve and hub and check that they slide smoothly.
Page 409 2 2 - 2 9 MANUAL TRANSAXLE <FWD> - 5th Speed Synchronizer Assembly SERVICE POINTS OF REASSEMBLY Oil groove 5. INSTALLATION OF SYNCHRONIZER HUB / 4. SYN- CHRONIZER KEY / 2. SYNCHRONIZER SPRING direction. (2) Assemble the synchronizer spring so that its projection may be engaged in the groove of the synchronizer key.
Page 410 MANUAL TRANSAXLE <FWD> INPUT SHAFT ASSEMBLY DISASSEMBLY AND REASSEMBLY 2150009 Disassembly steps 1. Taper roller bearing 14. Synchronizer sleeve * *a 2. Bearing sleeve 15. Synchronizer key 16. Synchronizer hub a 4. Taper roller bearing 17. Synchronizer ring 4 5. Snap ring 3rd speed gear 19.
Page 411 22-31 MANUAL TRANSAXLE <FWD> SERVICE POINTS OF DISASSEMBLY REMOVAL OF TAPER ROLLER BEARING Remove the front bearing using the special tool as illustrated. 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 412 22-32 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. Check the needle bearing cage for deformation 20105' SYNCHRONIZER RING Check the clutch gear teeth for damage and breakage. Check paper lining on cone I.D.
Page 413 22-33 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 414 22-34 MANUAL TRANSAXLE <FWD> 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 415 22-35 MANUAL TRANSAXLE <FWD> 2. REASSEMBLY OF BEARING SLEEVE shaft. Caution After fitting, check that the sleeve flange is closely fit to the bearing. 1. INSTALLATION OF TAPER ROLLER BEARING Install the taper roller bearing over the input shaft using the special tool.
Page 416 22-36 MANUAL TRANSAXLE <FWD> - Intermediate Gear Assembly INTERMEDIATE GEAR ASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly steps * ** 2. Taper roller bearing st speed gear 4. 1 5. Needle bearing a 6. Synchronizer ring 7. Synchronizer spring 8. 1 st-2nd speed synchronizer sleeve * 11.
Page 417 22-37 MANUAL TRANSAXLE <FWD> - Intermediate Gear Assemblv 10. REMOVAL OF lST-ZND SPEED SYNCHRONIZER HUB / 12. 2ND SPEED GEAR Remove the 1 st-2nd speed synchronizer assembly and 2nd speed gear together using the special tool as illustrated. 14. REMOVAL OF TAPER ROLLER BEARING Use the special tool as illustrated.
Page 418 22-38 MANUAL TRANSAXLE <FWD> - Intermediate Gear Assembly SYNCHRONIZER RING Check the clutch gear teeth for damage and breakage. Damage and breakage Check paper lining on cone I.D. for damage, wear, and flaking. Force the synchronizer ring toward the clutch gear and check clearance “A”.
Page 419 22-39 MANUAL TRANSAXLE <FWD> - Intermediate Gear Assembly SERVICE POINTS OF REASSEMBLY 14. INSTALLATION OF TAPER ROLLER BEARING Install the taper roller bearing over the intermediate gear using the special tool. Caution When installing the bearing, push the inner race only. The 1 st speed synchronizer ring has an identification mark.
Page 420 MANUAL TRANSAXLE <FWD> - Intermediate Gear Assembly the intermediate gear using the special tool. Caution 1. When installing the synchronizer assembly, L/: make sure that three synchronizer keys are 1 st-2nd seated correctly in respective grooves of the speed synchronizer ring. synchronizer assembly 2.
Page 421 MANUAL TRANSAXLE <FWD> DISASSEMBLY AND REASSEMBLY Disassembly steps * I. Taper roller bearing 3. Output shaft 210028 SERVICE POINTS OF DISASSEMBLY Press 1. 2. REMOVAL OF TAPER ROLLER BEARINGS Remove the taper roller bearing using the special tool as illustrated. Caution 1.
Page 422 MANUAL TRANSAXLE <FWD> DISASSEMBLY AND REASSEMBLY Disassembly steps 1. 1 st-2nd speed shift fork 2. 1 st-2nd speed shift rail 3. 3rd4th speed shift fork 4. 5th-reverse speed shift rail 5. Interlock plunger 6. 3rd-4th speed shift rail 7. Reverse shift lug 201073 SERVICE POINT OF REASSEMBLY Reverse shift lug...
Page 423 MANUAL TRANSAXLE <FWD> DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Differential drive gear 3. Taper roller bearing + 4. Lock pin * 5. Pinion shaft * 6. Pinion * 7. Washer Side gear * 9. Spacer (Select) Adhesive: 3M Stud Locking SERVICE POINTS OF DISASSEMBLY Press 3.
Page 424 MANUAL TRANSAXLE <FWD> REMOVAL OF LOCK PIN Lock pin Drive out the lock pin from the hole A using a punch. Pinion shaft 150020 SERVICE POINTS OF REASSEMBLY 9. INSTALLATION OF SPACER / 8. SIDE GEAR / 7. WASHER / 6. PINION / 5. PINION SHAFT install the gear in the differential case.
Page 425 Differential Assembly / Speed- MANUAL TRANSAXLE <FWD> - ometer Driven Gear Assembly 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.
Page 426 MANUAL TRANSAXLE <FWD> DISASSEMBLY AND REASSEMELY 1 5 - 2100019 Disassembly steps 1. Bolt * 16. Needle bearing 2. Select lever assembly 4. Interlock plate bolt 5. Gasket 20. Return spring a 6. Lock pin 22. Spring pin 8. Neutral return spring 9.
Page 427 MANUAL TRANSAXLE <FWD> SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF LOCK PIN Drive out the lock pin from the control finger using the pin punch. Caution When removing the lock pin, turn the control lever to such position that the lock pin will not contact the clutch housing.
Page 428 MANUAL TRANSAXLE <AWD> - General Information Ist-2nd speed synchronizer assembly Transaxle case Input shaft 5th speed gear Center shaft Viscous coupling Center differentral Reverse idler ‘gear Front differential TSB Revision...
Page 429 MANUAL TRANSAXLE <AWD> - Specifications GENERAL SPECIFICATIONS Items Specifications Model Applicable engine Gear ratio 1 St 1.739 0.659 Reverse 3.076 Reduction ratio 1.375 Primary Front differential 2.888 Transfer 0.814 Speedometer gear ratio (driven/drive) Oil quantity liters (qts.) 2.4 (2.5) Transaxle 0.27 (.29) Transfer L U B R I C A N T S...
Page 430 MANUAL TRANSAXLE <AWD> foreign object entry TSB Revision...
Page 431 22-51 MANUAL TRANSAXLE <AWD> SERVICE ADJUSTMENT PROCEDURES TRANSMISSION OIL LEVEL INSPECTION Refer to GROUP 00 - Maintenance Service. TRANSMISSION OIL REPLACEiVlENT plugs to drain transmission oil. (2) Pour in fresh transmission oil through filler port. Transmission oil: Hypoid gear oil, SAE 75W-85W con- forming to API classification GL-4 or higher Transaxle: 2.4 liters (2.5 qts.)
Page 432 22-52 MANUAL TRANSAXLE <AWD> DRIVE SHAFT OIL SEALS REPLACEMENT (Refer to GROUP 26 - Drive Shaft.) (2) Remove the transfer assembly. (3) Using a flat-tip (-) screwdriver, remove the oil seal. L.H. side (4) Install the oil seals using the following procedure: For R.H.
Page 433 MANUAL TRANSAXLE <AWD> - Service Adjustment Procedures / Shift Lever Assembly22-53 TRANSFER OIL SEAL REPLACEMENT GROUP 25 - Propeller Shaft.) Front exhaust p6eU transfer. seal. Transmission oil: Hypoid gear oil, SAE 75W-90 or SPEEDOMETER CABLE REPLACEMENT Refer to P.22-9. SHIFT LEVER ASSEMBLY Refer to P.22-13.
Page 434 22-54 MANUAL TRANSAXLE <AWD> TRANSAXLE CONT.ROL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Front Console Assembly (Refer to GROUP 52A-Floor Console.) Transaxle control cable assembly removal steps Shift lever assembly removal steps * 1. AirhoseA * 1. AirhoseA 3.
Page 435 22-55 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 action, and damage. SERVICE POINTS OF INSTALLATION 5. CdNNECTlON OF TRANSAXLE CONTROL CABLE ASSEMBLY (SHIFT LEVER ASSEMBLY SIDE) Refer to P.22-12.
Page 436 22-56 MANUAL TRANSAXLE <AWD> REMOVAL AND INSTALLATION Post-installation Operation Installation of Transfer Assembly (Refer to P.22-59.) Supplying of Transmission Oil (Refer to P.2351,) Checking Operation of Shift Lever at Each Position Checking the Operation of Meters and Gauges 19 Nm 13 f;t.lbs.
Page 437 MANUAL TRANSAXLE <AWD> 22-57 45 Nm 31 Nm 22 ftlbs. 43 - 52 ft.lbs. 4.0 ftlbs. 20. Right member 21. Starter cover 12. Connection for transaxle mount 22. Starter 13. Plug 23. Drive shaft (Left side), 14. Transaxle mount bracket (Body side) Inner shaft assembly * 24.
Page 438 22-58 MANUAL TRANSAXLE <AWD> SERVICE POINTS OF REMOVAL 11. REMOVAL OF CLUTCH RELEASE CYLINDER / 12. CONNECTION OF TRANSAXLE MOUNT Refer to PZ-15. 18. DISCONNECTION OF TIE ROD END / 19. LOWER ARM BALL JOINT Refer to P.22-16. 23. REMOVAL OF DRIVE SHAFT (LEFT SIDE), INNER SHAFT ASSEMBLY / 24.
Page 439 MANUAL TRANSAXLE <AWD> 22-59 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Supplying of Transfer Oil (Refer to P.22-51.) Removal and Installation of Active Front Venturi Skirt (Refer to GROUP 51 -Front Bumper.) Removal and Installation of Front Exhaust Pioe (defer to GROUP 15 - Exhaust Pipe and Main Muffler.)
Page 440 MANUAL TRANSAXLE <dWD> TRANSAXLE ASSEMBLY The W5MGl transaxle cannot be disassembled. If any parts other than describes below are defective, replace the transaxle assembly. REPLACEABLE PART Transaxle to transfer connecting bolt Transfer case oil seal * 2. Transfer oil seal guide Input shaft rear seal cap 4 5.
Page 441 22-61 MANUAL TRANSAXLE <AWD> Install the input shaft rear seal .cap. TSB Revision...
Page 443 SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MlTSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 444 23-2 AUTOMATIC TRANSAXLE - General Information GENERAL INFORMATION CROSS-SECTIONAL VIEW TFA0540 TSB Revision...
Page 445 AUTOMATIC TRANSAXLE - General Information HYDRAULIC CONTROL SYSTEM Low-reverse Damper cluG control solenoid valve To lubncatlon valve (front) To lubncatlon ,-= (rear) valve Torque solenoid valve “6” valve filter Oil pump suction pressure Damper clutch control solenoid valve pressure sure valve pressure T F A 0 0 7 0 TSB Revision...
Page 447 AUTOMATIC TRANSAXLE - General information Low-reverse brake Front clutch Rear clutch End clutch To lubrrcatron c (front) To lubrrcatton c Reducing valve (rear) solenoid valve “B” Pressure control Pressure control N-R control valve Damper clutch control solenoid Torque converter and lubrication valve pressure pressure Pressure control solenoid...
Page 449 AUTOMATIC T Torque converter Low-reverse brake Front clutch End clutch Rear clutch - Damper clutch control solenc To lubrmtl (front) Torque converter control valve Pressure control Pressure valve Oil filter Oil pan Damper clutch pressure Line pressure Damper clutch control solenoid and lubrication Torque converter valve pressure...
Page 451 End clutch , j p Ja Damper Cll To lubrlcdtlon + control Torque cnnvertar and lubrication Damper clutch co Pressure contrcJ snlerloid TSB Revision...
Page 453 AUTOMATIC TRANSAXLE - General Information Damper clutch F Damper clutch c Drive (Second) 1 T F A 0 0 7 3 TSB Revision...
Page 455 AUTOMATIC TRANSAXLE - General Information valve “Es” Damper clutch F Damper clutch c ( T h i r d ) 1...
Page 457 AUTOMATIC TRANSAXLE - General Information Low !e?rise To lubricd!iw + Damper clutch pressure L ‘I$ pir-w!w Damper clutch cnntrol snleno~d valve pressure...
Page 459 AUTOMATIC TRANSAXLE - General Information brake To lubncatinn s Damper clutc’l control soleno;d T F A 0 0 7 6...
Page 461 AUTOMATIC TRANSAXLE - General lnformatisn Torque converter Low-reverse Front clutch End clutch hift valve Hear clutch exhaust valve Damper clutct control soleno valve To lubrlcatlon c (front) Torque converter control Shift control valve Pressure control Pressure N-R control -7 Oil filter Damper clutch I solenoid Damper clutch...
Page 464: Service Specifications
AUTOMATIC TRANSAXLE - Specifications GENERAL SPECIFICATIONS M23CA.C Items Specifications Model Full automatic 4 speed transaxle Torque converter 3 element with damper clutch Engine stall speed Stall torque ratio Transaxle Electronically controlled Gear ratio First 2.551 Second 1.488 Third Fourth Reverse 2.176 Final gear ratio 3.958...
Page 465 AUTOMATIC TRANSAXLE VALVE BODY SPRING IDENTIFICATION CHART mm (in.) Part name Wire diameter Outside diameter Length No. of turns Regulator valve spring 1.4 (.055) 15 (59) 52 (2.05) 11.5 l-2 shift valve spring 0.6 (024) 7.6 (.299) 26.6 (1.047) 13.5 Pressure control valve spring 0.45 (.0177) 7.6 f.299)
Page 466 AUTOMATIC TRANSAXLE - Specifications Identification Part name Thickness mm (in.) Part No. symbol 5.9 l.232) MD731 736 Pressure plate (for adjustment of low-reverse brake end play) 6.0 f.236) MD731 737 MD731738 6.1 i.240) MD731 739 6.2 (.244) MD731 740 6.3 (.248) MD731 588 6.4 (.252) MD731 741...
Page 467 (for adjustment of end clutch end play) Yellow MD71 5801 1.55 (.0610) None MD71 5802 Green MD71 5803 Pink MD720849 2.05 (.0807) LUBRICANTS Items Transaxle fluid liters (qts.) Dia ATF SP or MITSUBISHI PLUS ATF or equivalent Drive shaft oil seal lip TSB Revision...
Page 468 AUTOMATIC TRANSAXLE Reassembly of valve body...
Page 469 AUTOMATIC TRANSAXLE Installer adapter Driving of bearing MD998829 TSB Revision...
Page 470 AUTOMATIC TRANSAXLE Removal and installation of low/reverse wrench adapter TSB Revision...
Page 471: Troubleshooting
AUTOMATIC TRANSAXLE Based upon use of the troubleshooting Functional malfunctions of the ELC4A/T can lead to other problems, such as those described below: Checks should be made of fluid levels and (3) Malfunctions of mechanical functions the condition of the ATF, as well as the condition of the manual control cables;...
Page 472 AUTOMATIC TRANSAXLE TROUBLESHOOTING GUIDE ‘resumed cause of transaxle control untt SCSV = Shift control solenoid valve NOTE- @ indicates items of prlortty during Inspection. PSCV = Pressure control solenoid valve DCCSV = Damper clutch control solenoid valve OD = Overdwe...
Page 473 AUTOMATIC TRANSAXLE TSB Revision...
Page 474 AUTOMATIC TRANSAXLE DIAGNOSIS AND TEST FLUID LEVEL AND CONDITION Drive until the fluid temperature reaches the usual tempera- 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 475 AUTOMATIC TRANSAXLE - Troubleshootina OBTAINING FAULT CODES (1) Connect the voltmeter or multi-use tester to the connector for diagnosis. (2) Read the output fault codes. Then follow the remedy procedures according to the “FAULT CODE DESCRIPTION” on the following page. NOTE As many as a maximum of ten fault codes, in the sequence of occurrence, can be stored in the Random...
Page 476 AUTOMATIC TRANSAXLE 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. Check accelerator switch Excessively small throttle (whether code number 24 is being position sensor output output).
Page 477 AUTOMATIC TRANSAXLE Display Pattern Item Remedial Action Open-circuited pulse generator A Check pulse generator A or B on bench. Check vehicle-speed reed switch (chattering). Open-circuited pulse generator B Open-circuited shift control Check solenoid valve connector. solenoid valve A Check shift control solenoid valve A on bench.
Page 478 AUTOMATIC TRANSAXLE Item Remedial Action Code Display Pattern 1 st speed shift not finish Check connectors of pulse generators A and B. Check pulse generators A and B on bench. Rear clutch slipping 2nd speed shift not finish Check connectors of pulse generators A and B.
Page 479 AUTOMATIC TRANSAXLE FAIL-SAFE CODE DESCRIPTION Display Pattern Item Fail-safe Related Self-Diagnosis Open-circuited pulse Fixed at 3rd (D) generator A or 2nd (2, L) Fixed at 3rd (D) generator B or 2nd (2, L) Open- or short-circuited Fixed at 3rd shift control solenoid valve A Open- or short-circuited Fixed at 3rd shift control solenoid...
Page 480 AUTOMATIC TRANSAXLE INSPECTION OF CONTROL SYSTEM Check the control system by using the multi-use tester and following the procedure given below. CONTROL SYSTEM INSPECTION TABLE Check Item Cold engine (before start) sensor Data list Item No. 15 Data list Item No. 23 or circuit harness Item No.
Page 481 AUTOMATIC TRANSAXLE Check Item Defective pulse generator B shielded wire External noise interference Data list Item No. 36 output where vehicle is stationary. Data list Otherwise, vehicle-speed reed switch Item No. 38 or circuit harness is defective. Damper clutch D range, 3rd speed, 1,500 rpm Defective damper clutch Defective ignition signal line or slip...
Page 482 AUTOMATIC TRANSAXLE TRANSMISSION CONTROL UNIT T h e c o n n e c t o r h a s 4 2 p i n s t o a c c o m m o d a t e t h e i n c r e a s e d n u m b e r o f senso.r i n p u t s . H e r e a r e t h e p i n a s s i g n m e n t s .
Page 483 AUTOMATIC TRANSAXLE ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER NOTE Cl Front clutch C2 . Rear clutch C3 End clutch B2 . . Kickdown brake OWC One way clutch SHIFT PATTERNS Two shift patterns are pre-stored in the control unit of this transaxle.
Page 484 AUTOMATIC TRANSAXLE INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS Based on the wiring diagram. connector, damaged or 1. Wiring check whether the continuity and disconnected harness, grounding of each harness is OK. or incorrect wiring con- nection. Continuity Reconnect the connec- tor;...
Page 485 AUTOMATIC TRANSAXLE Check the resistance between 4. Pulse generator aged or disconnected terminals 1 and 2 or 3 and Pulse generator terminals l-2: pulse generator A pulse generator B 1750338 Connect the pulse generator and front wheels raised. With the selector lever at the “L” position and the engine running at 1,000 rpm, check the voltage waveform between terminals 1...
Page 486 AUTOMATIC TRANSAXLE - Troubleshooting 6. Pressure- Check the resistance between Short-circuit, or dam- control sole- too low or too aged or disconnected terminal 1 of the solenoid valve wiring connector and the transaxle case. 2.9 + 0.3Q/20°C (68°F) Connect 12V between the trans- Foreign material caught axle case and terminal 2;...
Page 487 AUTOMATIC TRANSAXLE - Troubleshooting P u l l t h e p a r k i n g b r a k e set it securely. With the engine idling, de- press the foot brake firmly. Set the selector Stop the Improper adjustment engine.
Page 488 AUTOMATIC TRANSAXLE - Troubleshootina Check the resistance between Short-circuit, or dam- 9. Damper clutch terminal 2 of the solenoid valve too low or too aged or disconnected control solenoid connector and the transmission wiring valve (DCCSV) case. Replace the DCCSV. Solenoid valve Foreign terminal...
Page 489 AUTOMATIC TRANSAXLE - Troubleshooting Continuity exists In the “R” range, check for con- tinuity between terminals 4 and 7, and terminals 10 and 11. Continuity exists tinuity between termrnals 2 and 4, Continuity exists No continuity In the ti D“ range, check for con- tinuity between terminals 4 and 6.
Page 490 AUTOMATIC TRANSAXLE - Troubleshooting Poor contact, or dam- Check for continuity between the 12. Kickdown aged or disconnected (K/D) servo wiring and the transaxle case. switch Replace the K/D servo Continuity exists switch. Start the engine, set to the “L” range, and let the engine idle;...
Page 491 AUTOMATIC TRANSAXLE OIL PRESSURE TESTS 1. Completely warm up the transaxle. Raise the vehicle by using a jack so that the front wheels can be rotated. 3. Connect an engine tachometer and place it in a position where it’s easy to see. 4.
Page 492 AUTOMATIC TRANSAXLE - Troubleshooting INADEQUATE OIL PRESSURE Symptom Possible cause Remedy a. Plugged oil filter a. Visually check oil filter and replace it if plugged. are low (or high). b. Improperly adjusted regulator (KID brake pres- valve line pressure sure) and readjust line pressure if it is NOTE: out of specifications.
Page 493 AUTOMATIC TRANSAXLE @Seal ring ring @Seal rmg @Seal rmg Front clutch Low-reverse brake @Seal ring TFA0362 TSB Revision...
Page 494 AUTOMATIC TRANSAXLE SHIFT PATTERNS P range n 6 0 2 413 (2, L) 5000 6000 2000 3000 4000 1000 90 100 130 140 TFA0570 Vehiclespeed (km/h) E range 3 e-4 (DA 4000 2000 3000 6000 5000 Transferdrivegearspeed (rpm) 170 180 Vehiclespeed (km/h) T FA0571 Revision...
Page 495 AUTOMATIC TRANSAXLE CONVERTER STALL TEST 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 “I?” Stall Speed Above Specification in “D” positions.
Page 496 AUTOMATIC TRANSAXLE - Troubleshootina A/T SAFETY-LOCK SYSTEM TROUBLESHOOTING n or sagging outer cable (shift lot be selected into R from P by depressing brake pedal with ignition key in position other than LOCK. eck and adjust slide lever ide lever and ca Selector lever TSB Revision...
Page 497 AUTOMATIC TRANSAXLE Symptom Probable cause Remedy Ref. page Selector lever cannot Defective selector lever assembly Check and replace selector 23-54 be shifted from R to P. lever assembly. Improperly adjusted transaxle control cable Adjust transaxle control 23-56 cable. Ignition key cannot Foreign matter wedged in lock cams A and B Check and replace lock cams 23-58...
Page 498 5. Check to see if fluid level is in “HOT” range on dipstick. If fluid level is low, add automatic transmission fluid until level reaches “HOT” range. Transmission fluid: MITSUBISHI PLUS ATF/Automatic transmission fluid “DEXRON” abr “DEXRON II” Low fluid level can cause a variety of conditions because it allows pump to take in air along with fluid.
Page 499 AUTOMATIC TRANSAXLE (1) Remove dust, dirt, and other contaminants completely from (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 500 AUTOMATIC TRANSAXLE (8) Tighten lock nut by hand until it contacts piston. Then, using torque wrench, tighten to specification. Lock nut: 29 Nm (21 ftlbs.) 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 501 23-49 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 502 AUTOMATIC TRANSAXLE - s ACCELERATOR SWITCH INSPECTION AND ADJUSTMENT Check that current flows between terminals of accelerator switch when accelerator pedal is in free state and that no d current flows when the pedal is depressed and the specified stroke A is obtained. Standard value: 2 - 6 mm (.079 - .24 in.) ‘If stroke A is out of specification, adjust with adjusting bolt.
Page 503 23-51 AUTOMATIC TRANSAXLE Check to be sure that, under the following conditions, the selector lever can be moved from the “P” position to any other position. Press the button a few times and check to be sure that the selector lever moves smoothly. Ignition key position: “ACC”...
Page 504 23-52 AUTOMATIC TRANSAXLE INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT Manual control lever 1. Place selector lever in “N” (Neutral) position. 2. Place manual control lever in “N” (Neutral) position. For adjustment, turn inhibitor switch body so that the end (section A-A in illustration on left) of manual control lever is aligned with the hole In inhibitor switch body flange.
Page 505 Note in illustration the direction of installation of drive shaft oil seal. (4) Apply a coating of the transaxle fluid to the lip of the oil seal. Transaxle fluid: Dia ATF SP or MITSUBISHI PLUS ATF or equivalent Transaxle side...
Page 506 23-54 AUTOMATIC TRANSAXLE TRANSAXLE CONTROL REMOVAL AND INSTALLATION Pre-removal and Post-installation (Refer to GROUP 52A-Floor Console.) 7 ft.lbs. Selector lever assembly removal steps Transaxle control cable removal steps + 3. Connection for key-interlock cable 2. CD amp. (Vehicles with CD player) (Selector lever assembly side) 5.
Page 507 AUTOMATIC TRANSAXLE 23-55 9 ft.lbs. Key-interlock cable removal steps Shift-lock cable removal steps 2. CD amp. (Vehicles with CD player) 2. CD amp. (Selector lever assembly side) (Selector lever assembly side) 11. Knee protector (Refer to GROUP 52A- Instrument Panel) 20.
Page 508 23-56 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 509 AUTOMATIC TRANSAXLE 23-57 (5) Connect the shift lock cable to lock cam B and temporarily tighten the nut. At this time, install the spring and washer, vvhich 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 510 23-58 AUTOMATIC TRANSAXLE SELECTOR LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly steps Overdrive control switch, position light and Power (PWRVEconomy (ECO)/Hold (HOLD) changeover switch connector Cover Selector knob 1.6 ftlbs. Overdrive control switch button Overdrive control switch Pushbutton Spring Indicator panel Power (PWRVEconomy (ECOVHold (HOLD) Indicator panel lower Socket assembly...
Page 511 23-59 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- TON / 5.
Page 512 AUTOMATIC TRANSAXLE - Transaxle Oil Cooler, Hoses, Tubes TRANSAXLE OIL COOLER, HOSES, TUBES REMOVAL AND INSTALLATION Pre-removal and Post-installation <Vehicles without oil cooler> <Vehicles with oil cooler> 9 ft.lbs. 2. Tube assembly 3. Feed hose 4. Return hose Hose assembly removal steps 5.
Page 513 23-61 AUTOMATIC TRANSAXLE - Hoses, T ransaxle Oil Cooler, Tubes SERVICE POINTS OF REMOVAL 1. REMOVAL OF HOSE / 2. TUBE ASSEMBLY J 3. FEED HOSE / 4. RETURN HOSE Caution Take care not to spill the transaxlefluid when removing components.
Page 514 23-62 AUTOMATIC TRANSAXLE - Transaxle Assembly 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 00 - Maintenance Service.) Removal of Front Under Cover 70 Nm 51 ft.lbs.
Page 515 AUTOMATIC TRANSAXLE 23-63 60 - 72 43 - 52 31 Nm 15’ 14. Transaxle assembly upper part Post-installation Operation coupling bolt Installation of Front Under Cover 15. Connection for tie rod end (Refer to GROUP 51 -Front Bumper.) 16. Connection for lower arm ball joint Supplying of Transaxle Fluid (Refer to 17.
Page 516 23-64 AUTOMATIC, TRANSAXLE can be applied to the transaxle mount bracket mounting bolt; then, remove the transaxle mount bracket mount- ing bolt. 15. DISCONNECTION OF TIE ROD END / 16. LOWER ARM BALL JOINT Refer to GROUP 22 - Manual Transaxle. 19.
Page 517 AUTOMATIC TRANSAXLE - Transaxle Assembly DISASSEMBLY AND REASSEMBLY 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. Center support 44. Oil temperature sensor 18.
Page 518 23-66 AUTOMATIC TRANSAXLE 68. Gasket 63. Idler gear cover 69. Differential cover 64. Differential bearing retainer 70. Output bearing retainer 65. Outer race 71. Transfer shaft 66. Differential front bearing cap 72. Transaxle case 67. Differential assembly TFA0410...
Page 519 23-67 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 520 23-68 AUTOMATIC TRANSAXLE Remove the oil pan, magnet, and gasket. (11 IRemove 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. TSB Revision...
Page 521 AUTOMATIC TRANSAXLE 23-69 remove the manual control shaft assembly. the differential cover and gasket. the differential front bearing cap. race. remove the end clutch cover.
Page 522 AUTOMATIC TRANSAXLE 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. the idler gear cover and gasket.
Page 523 23-71 AUTOMATIC TRANSAXLE (28)Straighten the lock where it forms over the bolt and remove the bolt. inner race.
Page 524 23-72 AUTOMATIC TRANSAXLE assembly and rear clutch assembly together. NOTE The thrust race may be sticking to the clutch hub. TSB Revision...
Page 525 AUTOMATIC TRANSAXLE 23-73 switch. snap off the snap ring. TSB Revision...
Page 526 23-74 AUTOMATIC TRANSAXLE TSB Revision...
Page 527 AUTOMATIC TRANSAXLE 2 3 - 7 5 the planetary carrier assembly. (49)Remove the wave spring, return spring, reaction plate, brake disc, and brake plate. (50)Remove the screw and remove the rear bearing retainer. (51)Snap off the snap ring and remove the output flange assemblv.
Page 528 AUTOMATIC TRANSAXLE TFA0478 TSB Revision...
Page 529 AUTOMATIC TRANSAXLE 23-77 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 530 23-78 AUTOMATIC TRANSAXLE the locations shown of the output bearing retainer and install the outer race. specification. TFA0149 (7) Remove the outer race from the output bearing retainer and remove the solders. If the solders are not crushed, use larger dia. (3 mm or .12 in.) solders to repeat steps (4) to (6). Measure the thickness of the solders crushed with a micrometer and select a spacer to obtain the specified preload.
Page 531 23-79 AUTOMATIC TRANSAXLE (13)Stake the heads of the bolts. Thrust earing #lO bearing to the planetary carrier. TSB Revision...
Page 532 AUTOMATIC TRANSAXLE IDENTIFICATION OF THRUST BEARINGS, THRUST RACES AND THRUST WASHERS LOCATION mm (in.) I.D. Thickness Part No. Code O.D. I.D. Thickness Part No. Code 55.7 48.9 MD997852 (included *4) 48.9 MD997853 (included *4) 48.1 34.4 M D 7 0 7 2 7 1 #4 (1.874) (1.354) 4 2 .
Page 533 AUTOMATIC TRANSAXLE 23-81 bearing #8, and reverse sun gear. 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 534 23-82 AUTOMATIC TRANSAXLE (at two places), and press the center support into the transaxle case. Caution 1. Coat the O-rings with ATF and align oil holes. 2. Install with care not to allow the wave spring to shift its position. brake.
Page 535 23-83 AUTOMATIC TRANSAXLE C a u t i o n Make sure that the ends of seal ring on the kickdown servo piston are not located at the oil supply port (indicated by arrows). and sleeve into position and fit the snap ring. (28)Fit the kickdown band.
Page 536 23-84 AUTOMATIC TRANSAXLE - Transaxle Assembly hub. Thrust race #6 TSB Revision...
Page 537 AUTOMATIC TRANSAXLE 23-85 transaxle case at the same time. [Thrust race #3 pump assembly. 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.j shaft.
Page 538 23-86 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. Thrust washer TSB Revision...
Page 539 23-87 AUTOMATIC TRANSAXLE hub. 1750205 tion.
Page 540 23-88 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 (.I2 in.)] solders to repeat steps (51) to (53).
Page 541 AUTOMATIC TRANSAXLE - Transaxle Assembly 23-89 ATF, and insert it into the transaxle case. hole and install the set screw. valve body assembly. TSB Revision...
Page 542 AUTOMATIC TRANSAXLE new one. case from the inside. hole. temporarily secure the valve body. Then, install the oil temperature sensor and holder and tighten bolts to speci- fication. Bolt A = 18 mm (.71 in.) Bolt B = 25 mm (.98 in.) Bolt C = 40 mm (1.57 in.) Caution Secure the solenoid valve and oil temperature sensor...
Page 543 AUTOMATIC TRANSAXLE 23-91 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. (75)Adjust the kickdown servo. snap ring. converter, and push converter into position so that dimen- sion A is up to specification.
Page 544 AUTOMATIC TRANSAXLE - Transaxle Assembly / Transfer Shaft GENERAL REASSEMBLY PRECAUTIONS sliding surfaces with ATF before installation. 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 Bearing...
Page 545: Oil Pump
23-93 AUTOMATIC TRANSAXLE SERVICE POINTS OF REASSEMBLY Front side 3. INSTALLATION OF BEARING Using the special tool, install the bearings to the transfer shaft. TFAo324 Rear side MD998825 OIL PUMP DISASSEMBLY AND REASSEMBLY Disassembly steps * 3. Steel ball + 4. Drive gear * 5.
Page 546 23-94 AUTOMATIC TRANSAXLE - Oil Pump SERVICE POINTS OF REASSEMBLY 9. INSTALLATION OF OIL SEAL 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 547 AUTOMATIC TRANSAXLE 23-95 FRONT CLUTCH ASSEMBLY MWLHAH DISASSEMBLY AND REASSEMBLY 1 2 3 5 1. Snap ring 2. Clutch reaction plate * 3. Clutch plate 4. Clutch disc * 5. Clutch pressure plate * 6. Snap ring 7. Return spring 8.
Page 548 23-96 AUTOMATIC TRANSAXLE SERVICE POINT OF DISASSEMBLY 6. REMOVAL OF SNAP RING 1750264 SERVICE POINTS OF REASSEMBLY 6. INSTALLATION OF SNAP RING (2) Install the snap ring. 1750264 5. INSTALLATION OF CLUTCH PRESSURE PLATE / 3. CLUTCH PLATE / 2. CLUTCH REACTION PLATE and clutch reaction plate, align the areas where one tooth is missing [indicated by @I.
Page 549 23-97 AUTOMATIC TRANSAXLE REAR CLUTCH ASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Seal ring + 2. Input shaft TFA0490 3. O-ring 4. Snap ring 5. Thrust race 6. Seal ring * 7. Snap ring 9. Clutch disc + 10. Clutch plate 11.
Page 550 23-98 AUTOMATIC TRANSAXLE SERVICE POINT OF DISASSEMBLY 12. REMOVAL OF SNAP RING Using the special tool, compress the return spring. (2) Using the snap ring pliers, remove the snap ring. SERVICE POINTS OF REASSEMBLY 12. INSTALLATION OF SNAP RING (2) Using the snap ring pliers, install the snap ring. TION PLATE Install the clutch plate and reaction plate so that the areas where one tooth is missing [indicated by @] are aligned...
Page 551 AUTOMATIC TRANSAXLE 23-99 END CLUTCH ASSEMBLY DISASSEMBLY AND REASSEMBLY T F A 0 6 0 7 Disassembly steps 3. Clutch reaction plate 4. Clutch disc 5. Clutch plate l 6. Snap ring 7. Washer TFA0608 8. Return spring 9. End clutch piston 11.
Page 552 23-100 AUTOMATIC TRANSAXLE 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. When measuring the clearance, press the entire periphery of the clutch reaction plate with a force of 50 N (1 1 Ibs.).
Page 553 AUTOMATIC TRANSAXLE 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 554 AUTOMATIC TRANSAXLE - DISASSEMBLY AND REASSEMBLY TFA0262 Disassembly steps 1. Snap ring 2. Stopper plate * I)* 3. Bearing 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 555 AUTOMATIC TRANSAXLE - SERVICE POINTS OF REASSEMBLY 5. INSTALLATION OF TRANSFER DRIVE GEAR / 4. 3. BEARING sides of the transfer drive gear. TFA0226 (2) Using the special tool, install the transfer drive gear to the output flange. 1.. SELECTION. OF SNAP RING Measure the snap ring groove clearance and select appropriate spacer to obtain the specified end play.
Page 556 AUTOMATIC TRANSAXLE - Differential DIFFERENTIAL DISASSEMBLY AND REASSEMBLY 163025 Disassembly steps 2. Differential drive gear a 7. Washer * 8. Sidegear SERVICE POINTS OF DISASSEMBLY 3. REMOVAL OF BEARING Using the special tool; remove the bearing. 4. REMOVAL OF LOCK PIN Using a pin punch, drive 6ut the lock pin.
Page 557 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. the same time into position to mesh with the side gear. (3) Insert the pinion shaft Pinion gear Pinion, shaft...
Page 558 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. SPEEDOMETER DRIVEN GEAR ASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly steps 2.
Page 559 AUTOMATIC TRANSAXLE DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Kickdown servo 3. D-ring 1750299 4. Seal ring Lock 6. Kickdown servo rod 7. Kickdown servo piston LOW-REVERSE BRAKE DISASSEMBLY AND REASSEMBLY Disassembly steps 2. D-ring 3. D-ring 4. Center support TSB Revision...
Page 560 AUTOMATIC TRANSAXLE - Valve Body VALVE BODY Viewed from A DISASSEMBLY AND REASSEMBLY TFA0523 * 2. Pressure control solenoid valve * 4. Shift control solenoid valve “A” a 5. Shift control solenoid valve “B” 6. Clamp 7. Valve stopper 8. N-D control sleeve 9.
Page 561 AUTOMATIC TRANSAXLE - Valve Bodv Viewed from B 24. Front end cover 25. Pressure control spring 40. Rear end cover 26. Pressure control valve 41. Shift control plug B 27. Torque converter control spring * 42. Stopper plate 28. Torque converter control valve 43.
Page 562 AUTOMATIC TRANSAXLE - Valve Body 47. Pin 48. Stopper 50. End clutch spring T F A 0 5 4 1 51. End clutch valve 52. End cover 53. Damper clutch control sleeve 54. Damper clutch control valve 55. Damper clutch control spring 56.
Page 563 23-111 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 564 23-112 AUTOMATIC TRANSAXLE (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 the solenoid valves as shown. Wire color Solenoid valve Orange Shift control solenoid valve A Yellow Shift control solenoid valve B Damper clutch control solenoid valve...
Page 565 P R O P E L L E R ~ SHAFT CONTENTS Lubricants ..............2 PROPELLER SHAFT ..................2 Service Specifications ............SPECIAL TOOL ..........TROUBLESHOOTING ............ SPECIFICATIONS Noise and Vibration at High Speed ........2 General Specifications Noise at Start...
Page 566: Propeller Shaft
PROPELLER SHAFT - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Propeller shaft 4 joint propeller shaft mm (In.) Length x O.D. 673.5 x 65 (26.52 x 2.56) Front Center 662.5 x 65 (26.08 x 2.56) Rear 555.5 x 75 (21.87 x 2.95) Universal joint Cross type No.
Page 567: Troubleshooting
PROPELLER SHAFT - Special Tool / Troubleshooting / Propeller Shaft SPECIAL TOOL Number Name I Use Plug MB991 193 Prevention of entry of forergn objects into the transaxle and transfer TROUBLESHOOTING Probable cause Remedy Symptom Replace Noise at start Worn journal bearing Worn sleeve yoke spline Retighten Loose propeller shaft installation...
Page 568 25-4 PROPELLER SHAFT SERVICE POINTS OF REMOVAL 3. REMOVAL OF PROPELLER SHAFT flange and flange yoke. Caution Propeller Remove the propeller shaft in a straight and level assembly shaft manner so as to ensure that the boot is not damaged through pinching. NOTE Damage to the boot can be avoided, and the work will be easier, if a piece of cloth or similar material is...
Page 569 25-5 PROPELLER SHAFT 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 570 25-6 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY AND REASSEMBLY Rubber mount (outer race) (inner race)loxools Grease: Repair kit grease 3M ATD Part No. 8155 or equivalent Disassembly steps 9. Rubber packing 11. Washer * 4. Center bearing assembly 12. Center propeller shaft + 5.
Page 571 25-7 PROPELLER SHAFT SERVICE POINTS OF DISASSEMBLY 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. REMOVAL OF COMPANION FLANGE Mating marks Put mating marks on the companion flange and the center propeller shaft before removing the companion flange.
Page 572 25-8 PROPELLER SHAFT Shaft (2) Put mating marks on the outer race, cage and inner race Outer 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 573 25-9 PROPELLER SHAFT 15. REMOVAL OF CENTER BEARING ASSEMBLY Puller First remove the center bearing bracket and then remove [commercially available) 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 wear, damage or rust.
Page 574 PROPELLER SkIAFT (2) Put the cage on the inner race with the mating marks inner race 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 575 PROPELLER SHAFT (9) Using the center propeller shaft bolt, align the bolt holes Mounting bolts of the Lobro joint boot and the Lobro joint assembly and install the Lobro joint boot to the Lobro joint assembly. (10)Check that the Lobro joint assembly moves smoothly. 7.
Page 577 FRONT AXLE CONTENTS DRIVE SHAFT .........._ ... S P E C I F I C A T I O N S _..._...........
Page 578 26-2 FRONT AXLE - Specifications GENERAL SPECIFICATIONS Items Wheel bearing Unit ball bearing Double-row angular-contact ball bearing O.D. x I.D. mm (in.) 84 x 45 (3.31 x 1.77) Drive shaft Joint type B.J. B.J. Outer T.J. T.J. Inner Length mm (in.) 417 (I 6.4) 419 (16.5) L.H.
Page 579 FRONT AXLE - Special Tools Front hub remover Removal or press-in the front hub <FWD> and installer Measurement of front hub unit bearing rotation starting torque <AWD> of the hub <FWD> M B990955-01 Oil seal installer M B990883-01 Rear suspension...
Page 580 26-4 FRONT AXLE - Special Tools Tool Number Name MB991 248 or Inner shaft remover Removal of the inner shaft MD998801 Bearing and oil seal Removal of wheel bearing installer set M 8990932-01 M B990938-01 Removal and installation of center bearing M 8990938-01 Handle Tool number...
Page 581 FRONT AXLE - Troubleshooting / Service Adjustment Procedures Symptom Probable cause Remedy Vehicle pulls to one Seizure of drive shaft ball joint Replace side Abnormal wear, play or seizure of wheel bearing Replace Malfunction of front suspension or steering Adjust or replace Vibration Bend, damage or abnormal wear of drive shaft Replace...
Page 582 FRONT AXLE REMOVAL AND INSTALLATION 90 - 105 Nm 43 - 52 ft.‘bs. 145 - 188 ftlbs. 2 9 N m 200 - 260 Nm l l F O 0 2 6 Removal steps 1. Front speed sensor connection 9. Cotter pin <Vehicles with A.B.S.*>...
Page 583 26-7 FRONT AXLE SERVICE POINTS OF REMOVAL 1. DISCONNECTION OF FRONT SPEED SENSOR Remove the mounting bolts which hold the speed sensor 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 584 26-8 FRONT AXLE 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 knuckle, or of the wheel bearing inner race and the hub, is loose, replace the bearing or damaged parts.
Page 585 26-9 FRONT AXLE 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. Wheel bearing 9.
Page 586 FRONT AXLE (3) Remove the snap ring from the knuckle. (4) Remove the bearing by using the special tools. 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 587 FRONT AXLE (5) Measure to determine whether the end play of the hub is within the specified limit or not. MB99 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 588 FRONT AXLE SERVICE POINTS OF REMOVAL 2. 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, 3.
Page 589 FRONT AXLE - Drive Shaft (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.
Page 590 FRONT AXLE - Drive Shaft ISASSEMBLY AND REASSEMBLY T.J. Boot Repair Kit 0 0 2 8 T.J. Repair Kit l l A 0 3 1 5 Bearing Dust Seal Repair Kit Bracket Assembly Repair Kit B.J. Repair Kit B.J. Boot Repair Kit Disassembly steps 14.
Page 591 FRONT AXLE - Drive Shaft Grease: Multipurpose grease Dust seal inner Dust seal outer 8 - 12 g (.28- .42 oz.) Grease: Repair kit grease 160 g (5.64 oz.) Caution The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
Page 592 FRONT AXLE SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF INNER SHAFT (1) Using the special tool, remove the inner shaft assem- 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 593 FRONT AXLE 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 594 FRONT AXLE 16. INSTALLATION OF SPIDER ASSEMBLY and rollers of the spider assembly. Specified grease: Repair kit grease Caution Special grease is used to lubricate the joint. Do not mix old and new grease or different types of grease. (2) To install the spider assembly to the shaft, insert the shaft from the chamfered end of the spider.
Page 595 FRONT AXLE - Drive Shaft Dust seal outer r -j 6. INSTALLATION OF INNER SHAFT Use the pipe 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.
Page 596 FRONT AXLE 2. 1. INSTALLATION OF T.J. BOOT BANDS Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot band securely. Standard value: 85 + 3 mm (3.35 k .12 in.)
Page 597 REAR AXLE CONTENTS REAR AXLE <AWD> ..... . . _ . _ . . Differential (Limited Slip Differential) Abnormal noise during driving or AXLE SHAFT .
Page 598 27-2 REAR AXLE <FWD> SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Wheel bearing Unit ball bearina SERVICE SPECIFICATIONS Specifications Items Limit mm (in.) 0.05 l.002) or less Wheel bearing end play N (Ibs.) 31 (7) or less Rear hub rotary-sliding resistance Nm (ft.lbs.) 1.8 (1.30) or less Rear hub rotary-sliding torque TROUBLESHOOTING...
Page 599 27-3 REAR AXLE <FWD> WHEEL BEARING END PLAY INSPECTION 1. Inspect the play of the bearings while the vehicle is jacked 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. Check the bearing’s end play.
Page 600: Rear Axle Hub
27-4 REAR AXLE <FWD> REAR AXLE HUB REMOVAL AND INSTALLATION 36 - 43 ftlbs. 145 - 188 ftibs. Removal steps 2. Calioer assemblv 3. Brake disc 4. Hubcap 4 ’ 5. Wheel bearing nut 6. Tongued washer 7. Rear hub assembly 8.
Page 601 REAR AXLE 27-5 SERVICE POINT OF INSTALLATION 5. INSTALLATION OF WHEEL BEARING NUT After tightening the wheel bearing nut, align with the spindle’s indentation and crimp. Revision...
Page 602: Rear Axle
27-6 REAR AXLE tAWD> SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Axle shaft Semi-floating type Shaft dimensions mm (in.) Outer bearing portion dia. 35 (1.38) inner bearing portion dia. Center portion dia. 34.5 (1.36) Overall length 245.4 (9.7) Bearing O.D. x I.D. mm (in.) Outer 72 x 35 (2.83 x 1.38)

Page 603 27-7 REAR AXLE <AWD> - Specifications SERVICE SPECIFICATIONS Items Specifications Standard value Rear wheel bearing rotation torque N (Ibs.) [Nm (in.lbs.)l 12 (2.6) lo.7 (6)] or less Setting of T.J. boot length mm (in.) 85 +_ 3 (3.35 f .12) Final drive gear backlash mm (in.) 0.11 -0.16(.004-.006)
Page 604 27-8 REAR AXLE <AWD> - Special Tools SPECIAL TOOLS TSB Revision...
Page 605 27-9 REAR AXLE <AWD> Removal of the drive pinion rear bearing inner remover step plate MB99081 O-01 Side bearing puller Removal of the drive pinion TSB Revision...
Page 606 REAR AXLE <AWD> Tool Number Name M B990890 Rear suspension Press-fitting of drive gear (for 4WS) bushing .base M B990802-01 Bearing installer Pressing of drive pinion rear bearing inner ract Pressing of side bearing inner race Press-fitting of the drive pinion oil seal Bearing and oil seal Installation of drive pinion rear bearing outer installer set...
Page 607 REAR AXLE <AWD> - Troubleshootinn TROUBLESHOOTING Symptom Probable cause Remedy 4XLE SHAFT Noise while wheels Brake drag Replace 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 Noise Wear, play or seizure of ball joint...
Page 608 27-12 REAR AXLE <AWD> - Troubleshooting 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...
Page 609: Rear Wheel Bearing End Play Check
REAR AXLE <AWD> PROCEDURES 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.
Page 610: Rear Wheel Bearing Rotation Torque
27-14 REAR AXLE <AWD> REAR WHEEL BEARING ROTATION TORQUE CHECK 1. Remove the drive shaft from the companion flange. 2. Remove the brake pad or caliper assembly. 3. Attach a spring balance to the hub bolt, then, pulling the balance at a right angle to the hub bolt, measure the rotation torque (rotation starting torque) to see whether it is within the standard value.
Page 611 REAR AXLE <AWD> - Axle Shaft AXLE SHAFT REMOVAL AND INSTALLATION 55-65 Nm 12 Nm 9 ft.lbs. 190 Nm 137 ft.lbs. 260 - 300 Nm l l N 0 0 2 1 Removal steps 1. Rear speed sensor <Vehicles with A.B.S.> 2.
Page 612 REAR AXLE <AWD> - Axle Shaft 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 ASSEMBLY With the special tool, remove the axle shaft from the axle housing.
Page 613 REAR AXLE <AWD> - Axle Shaft SERVICE POINTS OF INSTALLATION Axle housing 15. INSTALLATION OF INNER BEARING With the special tool, press fit the inner bearing onto the axle housing. 14. INSTALLATION OF OIL SEAL MB990641 (1) With the special tool, press the oil seal onto the axle housing with the depression in the oil seal facing upward, and until it contacts the shoulder on the inside of the axle housing.
Page 614 REAR AXLE <AWD> 9. INSTALLATION OF REAR ROTOR <VEHICLES WITH 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 615 REAR AXLE <AWD> 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 616 REAR AXLE <AWD> DISASSEMBLY AND REASSEMBLY T.J. boot repair kit B.J. boot repair kit 11 NO024 T.J. repair kit B.J. repair kit Disassembly steps + 7. B.J. boot band (large) 2. T.J. boot band (small) * 9. B.J. boot 3. T.J. case 4.
Page 617 27-21 REAR AXLE <AWD> Lubrication Points l l A 0 0 8 4 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.
Page 618 27-22 REAR AXLE <AWD> SERVICE POINTS OF DISASSEMBLY 4. REMOVAL OF SNAP RING / 5. SPIDER ASSEMBLY snap ring pliers. (3) Clean the spider assembly. Caution 1. Do not disassemble the spider assembly. joint may be damaged. Use care in handling the drive shaft.
Page 619 27-23 REAR AXLE <AWD> - Drive Shaft (3) Fill the inside of the B.J. and B.J. boot with the specified grease. Specified grease: Repair kit grease 125 g (4.4102.) Caution The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
Page 620 27-24 REAR AXLE <AWD> DIFFERENTIAL CARRIER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining and Filling of Differential Gear Oil (Refer to Group 00 - Maintenance Service.) Removal and Installation of Main Muffler (Refer to Group 15 - Exhaust Pipe and Muffler.) 24Nm 17 ft.lbs.
Page 621 27-25 REAR AXLE <AWD> 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 622 27-26 REAR AXLE <AWD> SERVICE POINTS OF INSTALLATION 7. INSTALLATION OF DIFFERENTIAL CARRIER Install the rear wheel oil pump by inserting it through the mounting hole and install the differential carrier securely. \yi Caution Use care not to damage the rear wheel oil pump gears. 3.
Page 623 REAR AXLE <AWD> - Differential Carrier (2) Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear, so that the revolution torque [approximately 2.5 - 3.0 Nm (28 - 33 in.lbs.)] is applied to the drive pinion.
Page 624 27-28 REAR AXLE <AWD> 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) Problem Solution 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 625 27-29 REAR AXLE <AWD> DISASSEMBLY inspection Before Disassembly Final Drive Gear Backlash (Refer to P.27-26.) Drive Gear Runout (Refer to P.27-26.) Final Drive Gear Tooth Contact (Refer to P.27-26.) 11 FO032 Disassembly steps 15. Drive pinion assembly 1. Differential cover assembly 16.
Page 626 REAR AXLE <AWD> 6. REMOVAL OF SIDE BEARING OUTER RACE Using a press, push the differential case until it is 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 627: Special Tools
REAR AXLE <AWD> 15. REMOVAL OF DRIVE PINION ASSEMBLY (1) Make the mating marks to the drive pinion and 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 628 27-32 REAR AXLE <AWD> REASSEMBLY Reassembly steps 15. Washer * 2. Drive gear (for 4WS) 16. Self-locking nut 3. Differential carrier 17. LSD case (Refer to P.27-39.) * 4. Drive pinion rear bearing outer race 5. Drive pinion front bearing outer race Drive pinion height adjustment 20.
Page 629 REAR AXLE <AWD> 27-33 Lubrication, Sealing and Adhesion Points Sealant: 3M AID Part No. 8663 or equivalent l l F O 0 3 2 Adhesive: 3M Stud Locking Part No. 4170 or equivalent SERVICE POINTS OF REASSEMBLY Spring pin 1. INSTALLATION OF SPRING PIN (FOR 4WS) Tap the spring pin into the differential case to the position shown in the illustration before press fitting the rear wheel oil pump drive gear.
Page 630 27-34 REAR AXLE <AWD> 2. PRESS-IN OF THE DRIVE GEAR (FOR 4WS) drive gear at the inner side, press in the drive gear (by using the special tool) until the drive gear contacts the end surface of the .differential case. (2) Check to ensure that the drive gear and the spring pin are flush.
Page 631 27-35 REAR AXLE <AWD> (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 632 27-36 REAR AXLE <AWD> (5) Remove the companion flange and drive pinion once again. Drive the oil seal into the qear carrier front lip by using the special tool. Apply multipurpose grease to the oil seal lip. (6) Apply a thin coat of multipurpose grease to the companion flange contacting surface of the washer before installing drive pinion assembly.
Page 633 27-37 REAR AXLE <AWD> (3) Apply multipurpose adhesive to the threaded holes of the drive gear. Specified adhesive: 3M Stud Locking Part No. 4170 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 634 27-38 REAR AXLE <AWD> 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 Snap ring side bearing nut. (6) Check the drive gear and drive pinion for tooth contact. If poor contact is evident, make adjustment.
Page 635: Lsd Case Assembly
27-39 REAR AXLE <AWD> Case Assembly LSD CASE ASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Screw + 2. Differential case A 1 lFOO33 4. Viscous unit 7. Differential pinion shaft 8. Differential side gear 9. Thrust washer (R.H.) INSPECTION BEFORE DISASSEMBLY 1.
Page 636 REAR AXLE <AWD> (3) Insert the special tool at the spline part of differential case B (right) and check to be sure the side gear (right) rotates. replace a 0.03 mm (.0012 in.) gauge. differential side gear (right) and check to be sure the side gear (right) does not rotate.
Page 637 REAR AXLE <AWD> - 27-41 LSD Case Assembly (5) Check the spline part of the viscous unit for stepped wear or damage, and check the contact surface with differential case B. (6) Check the side gear (left) of the viscous unit for unusual wear or damage.
Page 638 27-42 REAR AXLE <AWD> gear (right) and check to be sure the side gear (right) rotates. Feeler gauge 0.03 mm i.0012 in.) gauge. side gear (right) and check to be sure the side gear (right) does not rotate. Differential gear backlash Standard value (clearance in thrust direction of side gear): 0.03 - 0.09 mm (.0012 - .0035 in.) NOTE...
Page 639 WHEEL. AND TIRE CONTENTS SERVICE ADJUSTMENT PROCEDURES .... 4 TROUBLESHOOTING Tire Inflation Pressure Check ........ 4 Bald Spots Tire Wear Check ............ Cracked Treads Wheel Runout Check ..........Feathered Edge Rapid Wear at Center SPECIFICATIONS ............ Rapid Wear at Shoulders General Specifications ........
Page 640: Specifications
31-2 WHEEL AND TIRE - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items DOHC-T/C Wheel Tire size Wheel type Aluminum type Aluminum type Wheel size 17 x 8.5J Amount of wheel offset mm (in.) 46 (1.8) 46 (1.8) Tire inflation pressure Front 220 (32) 220 (32) Rear 200 (29)
Page 641: Troubleshooting
WHEEL AND TIRE - Troubleshooting TROUBLESHOOTING Over-inflation or lack of rotation at center Inspect the camber Adjust the unbalanced wheels e front suspension wear TSB Revision...
Page 642: Service Adjustment Procedures
WHEEL AND TIRE SERVICE ADJUSTMENT PROCEDURES TIRE INFLATION PRESSURE CHECK Check the inflation pressure of the tires. If it is not within the standard value, make the necessary adjustment. TIRE WEAR CHECK Measure the tread depth of tires. L i m i t : 1 . 6 m m (.06 in.) Wear indicator If the remaining tread depth is less than the limit, replace the tire.
Page 643 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 644: Specifications
32-2 POWER PLANT MOUNT - Specifications / Special Tools / Troubleshooting SPECIFICATIONS SERVICE SPECIFICATIONS Items Specifications Standard value No. 1 crossmember Bushing (B) projection mm (in.) 7.5 - 10.5 (.30 - .41) Crossmember Bushing (A) projection mm (in.) 7.2 - 10.2 (.28 - .40) Bushing (B) projection mm (in.) 6.5 - 9.5 (.26 - .37)
Page 645: Engine Mounting
32-3 POWER PLANT MOUNT ENGINE MOUNTING REMOVAL AND INSTALLATION 12 Nm Raise and Suspend the Engine to the 9 ftlbs. 2. Cruise control pump and link assembly <Vehicles with Cruise Control> 3. Engine mount bracket and body connection bolt 4. Engine mount bracket * 5.
Page 646 32-4 POWER PLANT MOUNT TRANSAXLE MOUNTING REMOVAL AND INSTALLATION 45 Nm 33 ft.lbs. (Refer to GROUP 15 -Air Cleaner.) (Refer to GROUP 15 -Air Cleaner.) 70 Nm 51 ftlbs. Removal steps 1. Transaxle mount bracket and transaxle connection bolt 2. Cap 3.
Page 647 32-5 POWER PLANT MOUNT ENGINE ROLL STOPPER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Condenser Fan Motor Assembly <Turbo> (Refer to GROUP 55 - Condenser and Condenser Fan Motor.) Removal and installation of Catalytic Converter (Left) <Turbo> 45 Nm (Refer to GROUP 15 -Turbocharger <Rear>.)
Page 648 32-6 POWER PLANT MOUNT - Right Member, Left Member and Crossmember RIGHT MEMBER, LEFT MEMBER AND CROSSMEMBER REMOVAL AND INSTALLATION Post-installation Operation Installation of Under Cover Air Bleeding of the Power-steering Fluid (Refer to GROUP 37A- No. 1 crossmember, Left member, Service Adjustment Procedures.) R i g h t m e m b e r Adjustment of the Front Wheel...
Page 649 32-7 POWER PLANT MOUNT - Right Member, Left Member and Crossmember 45 Nm 33 ftlbs. Crossmember Front exhaust pipe (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter.) Transfer <AWD> Stabilizer bar (Refer to GROUP 33A-Stabilizer Bar.) Steering gear box to GROUP 37A- Power Steering Gear 13.
Page 650 32-8 POWER PLANT MOUNT - 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 1k5”...
Page 651 FRONT SUSPENSION CONTENTS SPECIFICATIONS ..........LOWER ARM ............General Specifications ........SERVICE ADJUSTMENT PROCEDURES ..Service Specifications ........Front Wheel Alignment ........STABILIZER BAR, ..........Wheel Bearing Adjustment ......STRUT ASSEMBLY ..........SPECIAL TOOLS ............ TROUBLESHOOTING ........
Page 652: General Specifications
FRONT SUSPENSION SPECIFICATIONS GENERAL SPECIFICATIONS Items Coil spring identification color M/T: Orange x 1 Shock absorber Hydraulic, cylindrical Hydraulic, cylindrical double acting type double acting type Maximum length 485 + 3 (19.09 f .12) 485 k 3 (19.09 + .12) Compressed length 335 I 3 (13.19 + .12) 335 2 3 (13.19 + .12)
Page 653: Troubleshooting
FRONT SUSPENSION SPECIAL TOOLS Removal of the lower arm ball joint and Wheel alignment Measurement of the wheel alignment gauge attachment Compression of the front coil spring Spring compressor Ball joint remover Installation of the dust shield and installer TROUBLESHOOTING Probable cause Remedy Symptom...
Page 654 FRONT SUSPENSION SERVICE ADJUSTMENT PROCEDURES FRONT WHEEL ALIGNMENT TOE-IN Standard value: 0 2 3 mm (0 + .12 in.) 1. Adjust the toe-in by undoing the clips and turning the left and right tie rod turnbuckles by the same amount (in opposite directions).
Page 655 FRONT SUSPENSION STRUT ASSEMBLY REMOVAL AND INSTALLATION Adjustment of Wheel 45 Nm 33 ft.lbs. I - - ‘ - / ’ Removal steps 2. Brake hose tube clam; 3. Fr;;tSs;eed sensor clamp mountmg nut 4. Front speed sensor clamp tABS> 5.
Page 656 FRONT SUSPENSION DISASSEMBLY AND REASSEMBLY 78 Nm 56 ftlbs. Caution When applying the grease, take care that grease does not adhere to the insulator’s rubber part. Disassembly steps * 2. Self-lockrng nut 3. Strut insulator assembly 4. Spring upper seat assembly 5.
Page 657 FRONT SUSPENSION INSPECTION Check the strut insulator bearing- for wear or rust. Check the rubber parts for damage or deterioration. Check the spring for deformation, deterioration or damage. Check the shock absorber for deformation, Strut msulatkx bearing SERVICE POINTS OF REASSEMBLY 4.
Page 658 FRONT SUSPENSION LOWER ARM REMOVAL AND INSTALLATION 100 Nm 40 Nm 29 ft.lbs. Removal steps 1. Stabilizer link mounting nut (stabilizer bar side) 2. Stabilizer link mounting nut (lower arm side) 3. Stabilizer link 4. Self-lockrng nut connecting lower arm ball joint to knuckle 5.
Page 659 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 660: Stabilizer Bar
FRONT SUSPENSION STABILIZER BAR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and installation of the Front Exhaust Pipe (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.) Removal and Installation of the Under Cover Removal and installation of the Left Member and Right Member (Refer to GROUP 32 - Right Member, Left Member and Crossmember.) 26 ft.lbs.
Page 661 FRONT SUSPENSION CHECKING STABILIZER LINK BALL JOINT STARTING TORQUE Mount two nuts on the ball joint, and then measure the ball joint starting torque. Standard value: 1.7 - 3.2 Nm (15 - 28 in.lbs.) BALL JOINT DUST SHIELD REPLACEMENT (1) Remove the clip ring and the dust shield. (2) Apply multipurpose grease to the lip and inside of the dust shield.
Page 663 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP Ei2B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 664 ELECTRONIC CONTROL SUSPENSION (ECS) SPECIFICATIONS GENERAL SPECIFICATIONS FRONT SUSPENSION Coil spring 15.7 x 170 x 301.5 15.0 x 170 x 331.0 14.8 x 170 x 322.5 Effective No. of coils Shock absorber Hydraulic, cylindrical double-acting type 485 (19.1) 335 (13.2) Expansion 2,650 (584) Hard...
Page 665 ELECTRONIC CONTROL SUSPENSION (ECS) Items Shock absorber Hydraulic, cylindrical double-acting type Max. length mm (in.) 610 (24.0) 515 (20.3) Min. length mm (in.) (16.0) 356 (14.0) Stroke mm (in.) 203 (8.0) (6.3) Damping force at 0.3 m/see N (Ibs Expansion 1,800 (397) Hard 1,200 (265)
Page 666 ELECTRONIC CONTROL SUSPENSION (ECS) TROUBLESHOOTING QUICK REFERENCE CHART FOR TROUBLESHOOTING Symptoms TROUBLESHOOTING HINTS fails, therefore, ride control stops. internally detects the voltages of the two sensor output lines connected to the ECS control unit to detect an open circuit in the signal line. When the signal line is short-circuited or when the power line is open-circuited, however, it cannot be detected.
Page 667 ELECTRONIC CONTROL SUSPENSION (ECS) - Troubleshooting is output When diagnosis code No. 11 Disconnect G sensor connector. Is continuity provided across the following No. 1 terminal voltage and continuity areas? between No. 3 terminal and ground Between G sensor and ECS control unit up to specification? Between No.
Page 668 ELECTRONIC CONTROL SUSPENSION (ECS) When diagnosis code No. 21 is output, or when anti-roil control only stops. Using MUT, check service data on Check by entering simulated vehicle speed to the steering angular velocity sensor. simulate anti-roll controls. (Refer to P.33B-16.) No.
Page 669 ELECTRONIC CONTROL SUSPENSION (ECS) When diagnosis code No. 24 is output <Turbo> Using MUT, check service data on Check by entering simulated vehicle speed from MUT vehicle speed sensor. Good? late high speed-sensitive control. (Refer to P.338-17.) Disconnect vehicle speed sensor con- Replace ECS control unit.
Page 670 ELECTRONIC CONTROL SUSPENSION (ECS) Using MUT, check actuator. (Refer to P.33B-15.) Good? Remove cap at top of shock absorber associated with diagnosis code No., disconnect connector directly connected to shock absorber, and check harness connector with ignition switch at ON. No.
Page 671 ELECTRONIC CONTROL SUSPENSION (ECS) Read diagnosis code and check area associated with dralgnosrs Does ECS indicator light flash? code. Disconnect ECS switch connector and check harness connector with No. 10 terminal voltage and continuity between No. 11 terminal and ground up to specification? Standards: No.
Page 672 ELECTRONIC CONTROL SUSPENSION (ECS) Anti-dive control only stops. Using MUT, check service data on Check by entering simulated vehicle speed from MUT to stop light switch. Good? simulate anti-dive control. (Refer to P.33B-16.) Good? Disconnect stop light switch con- nector and check harness connector. (Between No.
Page 673 ELECTRONIC CONTROL SUSPENSION (ECS) Anti-squat control only stops. Using MUT, check service data on Check by entering simulated vehicle speed from MUT to throttle position sensor. Good? simulate anti-squat control. (Refer to P.33B-16.) Good? Does check engine light illuminate? Is continuity provided between No. 2 terminal of throttle position sensor and No.
Page 674 ELECTRONIC CONTROL SUSPENSION (EC9 - i?:~~u:‘?s*men* SERVICE ADJUSTMENT PROCEDURES ON-VEHICLE INSPECTION 1. 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 self-diagnosis code associated with the problem is output to the diagnosis connector.
Page 675 Service Adjustment ELECTRONIC CONTROL SUSPENSION (ECS) Fail Safe and Diagnosis List Output Code Diagnosis Item Fail Safe Code No. Indication Pattern [Good] [Good] G sensor defective* Ride controls (pinching and bouncing control, bad road detection control) Steering angular Anti-roll control stops. velocity sensor open- circuited* Vehicle speed sensor...
Page 676 ELECTRONIC CONTROL SUSPENSION (ECS) - ~;:i%?tment Self-Diagnosis Determination Conditions Code No. What is Defective Self-Diagnosis 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 677 ELECTRONIC CONTROL SUSPENSION (ECS) - Item No. Check Check Condition Soundness Determination Value Point Vehicle Check by actually operating Speedometer indication and speed vehicle. MUT indication coincide. sensor stop Depress brake pedal. light switch Do not depress brake pedal. F.R. Tour mode with vehicle stationary SOFT actuator...
Page 678 ELECTRONIC CONTROL SUSPENSION (ECS) - 5. CONTROL FUNCTION SIMULATION CHECK Using the MUT, check all control functions during operation with the vehicle in stationary condition. (1) Raise the front wheels on a jack and have them supported by rigid racks. (2) Place the steering wheel in straight ahead position.
Page 679 ELECTRONIC CONTROL SUSPENSION (ECS) - :;:~u:~men* (4) Check that when the accelerator dedal is operated, the indications of service data items No. 61 through 64 on the MUT 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 MUT indications change over.
Page 680 ELECTRONIC CONTROL SUSPENSION (EC9 - ~::::u:?‘s*men* 6. ACTUATOR OPERATION CHECK 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. (Front) (Rear) absorber can be heard each time the control modes are changed by pressing the ECS switch.
Page 681: Ecs Switch
ECS Switch I Steering Angular Velocity ECS SWITCH To mount or remove the ECS switch, refer to GROUP 54 - Meters and Gauges. Remove the meter bezel before rnounting or removing the ECS switch. INSPECTION Operate the switch to check for continuity between the individual terminals.
Page 682: Throttle Position Sensor
THROTTLE POSITION SENSOR INSPECTION AND ADJUSTMENT Refer to GROUP 13 - Fuel System. STOP LIGHT SWITCH To remove or mount the stop light switch, refer to GROUP 35 - Brake Pedal. INSPECTION Refer to GROUP 35 - Brake Pedal. POSITION DETECTION SWITCH and DAMPING FORCE CHANGEOVER ACTUATOR To remove or mount the position detection switch and damping...
Page 683 ELECTRONIC CONTROL SUSPENSION (ECS) ECS CONTROL UNIT REMOVAL AND INSTALLATION Removal steps 2. Lid 3. ECS control unit TSB Revision...
Page 684 ELECTRONIC CONTROL SUSPENSION (ECS) - Circuit Diagram CIRCUIT DIAGRAM FUSIBLE LINK@ CONNECTOR ELECTROMIC CONTROL 62 -------____ 12 - - - 1 ------.-- . ET- JN 10 - SELF-DIAGNOSIS TSB Revision...
Page 685 ELECTRONIC CONTROL SUSPENSION (ECS) IGN: ENGINE THROTTLE -- - 54 55 ------ IGNITION TURBO \ G SENSOR STEERING WHEEL ANGLE SPEED SENSOR TSB Revision...
Page 686 ELECTRONIC CONTROL SUSPENSION (ECS) FRONT SHOCK ABSORBERtLH) FRONT SHOCK ABSORBERCRH) - - - i fj y - - - - - - 4 3! 1 - i i - 1 2 TSB Revision...
Page 687 REAR CONTENTS REAR SUSPENSION ASSEMBLY ..._.. REAR AXLE HUB ..........SERVICE ADJUSTMENT PROCEDURES . . 23 REAR SUSPENSION ASSEMBLY ....Rear Wheel Alignment Inspection ..23 SERVICE ADJUSTMENT PROCEDURES ..
Page 688 34-2 REAR SUSPENSION <FWD> 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 1 Orange x 1 Spring constant N/mm (Ibs./in.) Shock absorber Hydraulic cylindrical...
Page 689 34-3 REAR SUSPENSION <FWD> SPECIAL TOOLS member...
Page 690 34-4 REAR SUSPENSION <FWD> - Troubleshooting TROUBLESHOOTING Symptom Probable cause Remedy Squeaks or other Loose rear suspension installation bolts and nuts abnormal noise Malfunction of shock absorber Replace Worn bushings Upper arms and/or lower arms and/or assist link deformed or damaged Trailing arms deformed or damaged Crossmember deformed or damaged Poor ride...
Page 691: Service Adjustment Procedures
REAR SUSPENSION <FWD> 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. (2) The difference between the right and left wheels should be 30’...
Page 692 34-6 REAR SUSPENSION <FWD> WHEEL BEARING END PLAY INSPECTION 1. Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. 2. Remove the hub cap and then release the parking brake. s& 3. Remove the caliper assembly and the brake disc. 4.
Page 693 REAR SUSPENSION <FWD> 34-7 REMOVAL AND INSTALLATION Removal steps 1. Shock absorber mounting nuts (upper) 2. ECS connector (ECS) 4. Brake line clamp bolt 5. Brake caliper mounting bolt 6. Brake caliper assembly (Refer to GROUP 15 - Exhaust Pipe and 7.
Page 694 34-8 REAR SUSPENSION <FWD> INSPECTION Check the crossmember for cracks or deformation. Check the bushings for cracks or deterioration. CROSSMEMBER BUSHING REPLACEMENT Press fit Press out (2) When press-fitting the bushing, apply soapsuds to it and position the arrows as shown. sleeve is up to specification.
Page 695: Lower Arm
34-9 REAR SUSPENSION <FWD> - Upper Arm, Lower Arm and Assist Link UPPER ARM, LOWER ARM AND ASSIST LINK REMOVAL AND INSTALLATION 140 - 160 Nm* Pre-removal Operation Removal of the Shock Absorber (Refer to P.34-13.) Post-installation Operation Check of Wheel Alignment (Refer to P.34-5.) Installation of the Shock Absorber (Refer to P.34-13.)
Page 696 REAR SUSPENSION <FWD> - Upper Arm, Lower Arm and Assist Link INSPECTION Check the bushing for wear and deterioration. Check the upper, lower arm or assist link for bend or breakage. Check the ball joint dust cover for cracks. Check all bolts for condition and straightness. CHECKING OF BALL JOINT FOR STARTING TORQUE Mount two nuts on the ball .joint, and then measure the ball joint starting torque.
Page 697 REAR SUSPENSION <FWD> 34-11 TRAILING ARM REMOVAL AND INSTALLATION Post-installation Operation Check of Wheel Alignment ‘Refer to P.34-5.) (Refer to GROUP 35 -Service Adjustment 36 - 43 36 - 43 12FOlll Removal steps 12. Backing plate 1. Brake caliper mounting bolt l I) 14.
Page 698 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 699 REAR SUSPENSION <FWD> SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of the Rear Side Trim Removal steps 2. ECS connector (ECS) 3. Cap 4. Brake line clamp bolt 5. Shock absorber lower mounting bolt 6.
Page 700 34-14 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 701 REAR SUSPENSION <FWD> REMOVAL AND INSTALLATION Removal steps * 2. Stabilizer bar bracket 3. Bushing * 4. Self-locking nut 5. Joint cup (A) 6. Stabilizer rubber 7. Joint cup (B) * 8. Self-locking nut * 9. Stabilizer link 11. Stabilizer rubber 12.
Page 702 REAR SUSPENSION <FWD> BALL JOINT DUST COVER REPLACEMENT cover. Multipurpose grease illustration, and then install the dust cover to the stabilizer link. SERVICE POINTS OF INSTALLATION 9 . I N S T A L L A T I O N O F S T A B I L I Z E R L I N K / 8. SELF- Hold with wrench LOCKING NUT / 4.
Page 703 REAR SUSPENSION <FWD> REMOVAL AND INSTALLATION 36 - 43 ftlbs. 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. Rear hub unit bearing C a u t i o n Rear hub unit bearing cannot be disassembled.
Page 704 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 705: Specifications
REAR SUSPENSION <AWD> - Specifications GENERAL SPECIFICATIONS Items Specifications Suspension system Double wishbone suspension type Coil spring Wire dia. x O.D. x free length mm (in.) Coil spring identification color Blue x 2 N/mm (Ibs./in.) Spring constant 28.0 2 1.4 (I 57 -t 8) Shock absorber Hydraulic, cylindrical, double-acting type mm (in.)
Page 706: Special Tools
REAR SUSPENSION <AWD> - Special Tools,. remover an TSB Revision...
Page 707 REAR SUSPENSION <AWD> - Special Tools TSB Revision...
Page 708: Troubleshooting
REAR SUSPENSION <AWD> - Troubleshooting Trailing arms deformed or damaged Crossmember deformed or damaged TSB Revision...
Page 709 REAR SUSPENSION <AWD> - Service Adjustment Procedures REAR WHEEL ALIGNMENT INSPECTION CAMBER Standard value: -0”lO’ + 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 shoiuld be 30’...
Page 710 REMOVAL AND INSTALLATION Pre-removal Operation 1. Shock absorber mounting nuts (upper)* Removal of the Rear Side Trim Absorber Lid 2. ECS connector <ECS>* Removal of the Center Exhaust Pipe and Main Muffler (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.) 5.
Page 711 REAR SUSPENSION <AWD> SERVICE POINTS OF REMOVAL 17. REMOVAL OF CROSSMEMBER BRACKET / 18. CROSS- MEMBER MOUNTING NUT (ON DIFFERENTIAL SIDE) / 19. 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...
Page 712: Specifications
REAR SUSPENSION <AWD> sion A and B) are up to specifications. Standard value Dimension A: 15.5 mm (.59 in.) Dimension B: 2.1 - 3.7 mm (.08 - .15 in.) CROSSMEMBER BUSHING (REAR) REPLACE- I Press out MENT (1) Using the special tool, remove and press-fit the bushing. M B990958-01 NOTE Ensure that the shift in rotating direction is within t- 5”.
Page 713 REAR SUSPENSION <AWD> REMOVAL AND INSTALLATION Post-installation Operation Dust cover Upper arm removal steps 2. Upper arm mounting nut 3. Upper arm mounting.bolt 4. Upper arm Lower arm removal steps 5. Lower arm mounting nut 6. Lower arm mounting bolt Stabilizer link to lower arm Self-locking nut 9.
Page 714 REAR SUSPENSION <AWD> INSPECTION Check the bushing for wear and deterioration. Check the upper arm or lower arm for bend or breakage. Check the ball joint dust cover for cracks. Check all bolts for condition and straightness. CHECKING OF BALL JOINT FOR STARTING TORQUE Mount two nuts on the ball joint, and then measure the ball joint starting torque.
Page 715 REAR SUSPENSION <AWD> (2) Press-fit the lower arm bushing until the bushing outer pipe edge flush with the lower arm pipe edge. (lower (bushing) arm) SERVICE POINT OF INSTALLATION 7. INSTALLATION OF STABILIZER LINK TO LOWER ARM COUPLING NUT Holding the stabilizer link with a wrench, tighten the self-locking nut so that the protrusion of thG stabilizer link (dimension A indicated in illustration) is within the standard value.
Page 716 REAR SUSPENSION <AWD> - Trailing Arm REMOVAL AND INSTALLATION N/A $icJ 14 ft.lbs. T/C vehicles 36 - 43 ftlbs. 72 ft.lbs. 40 - 47 ft.lbs. 200 - 240 Nm* ‘ 7 58 Nm 42 ft.lbs. Removal steps Post-installation Operation Check of Wheel Alignment 2.
Page 717 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 718 REAR SUSPENSION <AWD> - Trailing Arm (3) Set the special tool onto the trailing arm as shown in the Bolt B illustration. (at the arrow marked “A” in the illustration). (2) Install bolt B to the trailing arm, at the point shown in the figure.
Page 719: Shock Absorber Assembly
REAR SUSPENSION <AWD> - Shock Absorber Assembly REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of the Rear Side Trim Absorber Lid (Refer to GROUP 52A-Trims.) Removal steps 1. Shock absorber upper mounting nut 2. ECS connector (ECS) 3.
Page 720 REAR SUSPENSION <AWD> - Stabilizer Bar REMOVAL AND INSTALLATION 80 - 94 ftlbs. Removal steps 1. Self-locking nut* 2. Self-locking nut* 3. Joint cup A* 4. Stabilizer rubber* 5. Joint cup B” 7. Joint cup A* 8. Stabilizer rubber* 9. Tie rod end mounting nut* 11.
Page 721 REAR SUSPENSION <AWD> SERVICE POINTS OF REMOVAL 14. REMOVAL OF CROSSMEMBER BRACKET / 15. CROSS- MEMBER MOUNTING NUT (1) Support the rear suspension assembly with the trans- mission jack. (2) Remove the crossmember bracket and crossmember mounting nut. 18. REMOVAL OF STABILIZER BAR between the rear suspension and body.
Page 722 REAR SUSPENSION <AWD> cover. install the dust cover. (4) Secure the dust cover with the clip ring. At this time, make sure that the clip ring ends are located at a point 90” f 20” with reference to the link axis. Clip ring ends (Could be 180”...
Page 723 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 724 SERVICE BRAKES - Specifications GENERAL SPECIFICATIONS Items Master cylinder Tandem type Tandem type (with level sensor) (with level sensor) I.D. mm (in.) 25.4 (1) or 26.9 (1 %s)* 26.9 (1 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)”...
Page 725 SERVICE BRAKES - Specifications andard value Brake pedal height mm (in.) 177 - 182 (7.0 - 7.2) 177 - 182 (7.0 - 7.2) Brake pedal free play mm (in.) Brake pedal to floorboard clearance mm (in.) 80 (3.1) or more 80 (3.1) or more Pad thickness mm (in.)
Page 726: Special Tools
SERVICE BRAKES - Specifications / Special Tools LUBRICANTS Specified lubricant Items Conforming to DOT3 Brake fluid Inside of shim A and shim B, or inside of inner shim A, Brake grease SAE J310, inner shim B, and outer shim Guide pin and lock pin sliding part Repair kit grease Piston boot inner surface Pin boot inner surface...
Page 727 SERVICE BRAKES - Special Tools / Troubleshooting Symptom Probable cause Remedy Vehicle pulls to one Grease or oil on pad or lining surface Replace side when brakes are Inadequate contact of pad applied Correct Auto adjuster malfunction Adjust Low or deteriorated brake fluid Add or refill Insufficient braking power...
Page 728 SERVICE BRAKES - Troubleshooting Symptom Probable cause Remedy Insufficient parking Worn brake pad Replace brake function Excessive parking brake lever stroke Adjust the parking brake lever stroke or check the parking brake cable routing Grease or oil on pad surface Replace Parking brake cable sticking Replace...
Page 729 SERVICE BRAKES - PARTICULAR PHENOMENA OF THE For problems in the electrical system, the self- ANTI-LOCK BRAKING SYSTEM diagnosis function is built into the electronic control unit (E.C.U.) causing the ABS warning light to Models equipped with the anti-lock braking system illuminate as a warning to the driver.
Page 730 SERVICE 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 ABS warning light remains lit because the valve position, the ABS ECU causes the ABS warning...
Page 731 SERVICE 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 illuminates when it is turned to the Malfunction of ECU “START”...
Page 732 SERVICE BRAKES - After a test drive, use self-diagnosis to No trouble codes output and normal Trouble codes are output codes are displayed? put terminals and the di- Y e s agnosis check connector. If trouble does not re- appear, watch vehicle movements until it reap- pears.
Page 733 35-11 SERVICE BRAKES - CHECK USING SELF DIAGNOSIS FUNCTION adapter harness (MB9913771, turn the ignition ON and select the ABS system. (The ABS warning light lights up, it goes into the MUT mode. In the MUT mode, ABS does not function.) If it does not go into the MUT mode, check the ECU power circuit and the harness between the ECU and diagnosis check terminals.
Page 734 SERVICE BRAKES - METHOD OF CLEARING DIAGNOSIS ACTUATOR TEST FUNCTION CODE MEMORY The actuator can be forcibly driven in the following way by using the MUT. Caution When servicing is finished, clear the diagno- NOTE The actuator test cannot be carried out when the ABS ECU system is in fail safe.
Page 735 SERVICE BRAKES - A ABS warning light does not light at all. [Hint] [Explanation] If other warning lights do not light up either, fuse is When it does not light up at all, there is a strong probably blown. possibility that there is trouble with ABS warning light or with power to the light.
Page 736 SERVICE BRAKES Does voltage between harness connector terminal combination meter from No. 14 and ground indicate fuse No. 11 is broken. battery voltage? Circuit in combination meter is broken. Turn the ignition switch OFF and check. Is there continuity between combination meter No.
Page 737 SERVICE 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 voltage while the ignition key is in the “ON” position? ABS ECU malfunction Is valve relay normal? (Refer to P.35-62.) install the valve relay, remove the HU...
Page 738 SERVICE BRAKES - ABS warning light stays on when the ignition key is in the “ON” position. [Explanation] [Hint] This is the symptom when the ABS ECU does not Check the diagnosis output and if there is no output power up due to broken ECU power circuit, etc., voltage or if the MUT and ABS ECU cannot when the fail safe function operates and isolates the communicate, there is a good possibility that power...
Page 739 SERVICE BRAKES - CONTINUED FROM PREVIOUS PAGE Is power relay normal? (Refer to P.35-62.) POSER RELAY Replace power relay. DIODE With the ignition key in the Harness wire between “ON” position, does voltage power relay and ECU between ECU connector is broken terminal No.
Page 740 SERVICE BRAKES - ABS warning light does not illuminate when the ignition key is in the “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 IG, power source which is is trouble in the warning light circuit on the valve...
Page 741 SERVICE 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] harness between the ECU and the warning light, the When power flows, the ABS ECU turns on the light illuminates only when the valve relay is off in warning light for approximately 1 sec.
Page 742 SERVICE BRAKES - the following diagnosis codes are displayed “11 FR SNSR. OPEN” “12 FL SNSR. OPEN” “13 RR SNSR. OPEN” “14 RL SNSR. OPEN” [Hint] [Explanation] In addition to a broken wire/short circuit in the wheel The ABS ECU detects breaks in the wheel speed sensor wire.
Page 743 SERVICE BRAKES - Check flow connected with wheel speed sensor When checking with an oscilloscope, first measure voltage variations in the wheel speed sensor output. (Refer to P.35-57.) sensor speed sensor part normal? Standard value: Front 1.4 - 2.2 kR Rear 1.3 - 2.1 kSZ Is the standard value for the gap between the wheel...
Page 744 SERVICE BRAKES - When diagnosis code “22 STOP LAMP SW” is displayed [Hint] [Explanation] If the stop light operates normal, the harness for the The ABS ECU outputs this trouble code in the stop light switch input circuit is broken or there is a following cases.
Page 745 SERVICE BRAKES - When diagnosis codes “41 FR SOL. VALVE”, “42 FL 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 trouble...
Page 746 SERVICE BRAKES - When diagnosis code “51 VALVE RELAY” is displayed [Explanation] When the ignition switch is turned ON, the ABS normal. In addition, normally it monitors whether or ECU switches the valve relay OFF and ON for an not there is power in the valve power monitor line initial check, compares the voltage of the signal to since the valve relay is normally ON.
Page 747 SERVICE BRAKES - E 6 When diagnosis code “52 MOTOR RELAY” is displayed [Explanation] When the motor continues to revolve The ABS ECU outputs this trouble code for the [Hint] motor relay and motor in the following cases. If there is motor operation noise during MUT forced When the motor relay does not function drive mode, there is a broken or short circuited When there is trouble with the motor itself and it...
Page 748 SERVICE 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...
Page 749 SERVICE 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 750 SERVICE BRAKES - After a test drive, use self diagnosis to check (Refer to P.35-29.). No diagnosis output No trouble codes output and normal Trouble codes are output codes are displayed? All ABS functions are normal. (Nor are there stored memory of past trouble code.) TSB Revision...
Page 751 SERVICE BRAKES - CHECK USING SELF DIAGNOSIS FUNCTION adapter harness (MB991377). turn the ignition ON and select the ABS system. (The ABS warning light lights up, it goes into the MUT mode. In the MUT mode, ABS does not function.) If it does not go into the MUT mode, check the ECU power circuit and the harness between the ECU and diagnosis check terminals.
Page 752 SERVICE BRAKES - METHOD OF CLEARING DIAGNOSIS ACTUATOR TEST FUNCTION CODE MEMORY The actuator can be forcibly driven in the following way by using the MUT. Caution When servicing is finished, clear the diagno- NOTE sis code memory The actuator test cannot be carried out when the ABS ECU system is in fail safe mode.
Page 753 SERVICE BRAKES - A ABS warning light does not light at all. [Hint] [Explanation] If other warning lights do not light up either, fuse is When it does not light up at all, there is a strong probably blown. possibility that there is trouble with ABS warning light or with power to the light.
Page 754 SERVICE BRAKES - With the ignition key in the “ON” posi- Check fuse No. 11. If it is blown, correct the cause of the blown fuse and then replace the fuse. harness connector terminal No. 59 and ground indicate battery voltage? Repair harness.
Page 755 SERVICE 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 voltage while the ignition key is in the “ON” position? Remove valve relay and check. Install the valve relay, remove the HU connector and check.
Page 756 SERVICE BRAKES - [Explanation] [Hint] This is the symptom when the ABS ECU does not Check the diagnosis output and if there is no output power up due to broken ECU power circuit, etc., voltage or if the MUT and ABS ECU cannot when the fail safe function operates and isolates the communicate, there is a good possibility that power system or when the warning light drive circuit is...
Page 757 35-35 SERVICE BRAKES - PREVIOUS PAGE IGNITION RELAY DIODE With the ignition key in the “ON” position, does voltage between ECU connector terminal No. 18 and ground indicate the battery voltage? Is there continuity between body harness terminals No. 9 and No.
Page 758 SERVICE BRAKES - ABS warning light does not illuminate when the ignition key is in the “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 IG, power source which is is trouble in the warning light circuit on the valve...
Page 759 SERVICE 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] harness between the ECU and the warning light, the 1 sec.
Page 760 SERVICE BRAKES - When the following diagnosis codes are displayed “11 FR SNSR. OPEN” “12 FL SNSR. OPEN” “13 RR SNSR. OPEN” “14 RL SNSR. OPEN” [Hint] [Explanation] In addition to a broken wire/short circuit in the wheel The ABS ECU detects breaks in the wheel speed speed sensor, also check whether the sensor gap is sensor wire.
Page 761 SERVICE BRAKES - Check flow connected with wheel NOTE speed sensor Check speed sensor harness and connector connection and then observe with oscilloscope. (Refer to P.35-57.) Is the resistance value of the wheel speed sensor part normal? sensor Standard value: 0.8 - 1.2 kR Check the output of each wheel speed sensor with an oscilloscope, including the...
Page 762 SERVICE BRAKES - When diagnosis code “21 G SNSR.” is displayed [Explanation] The ABS-ECU outputs this trouble code in the vehicle is stopped or when there is stop light 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 763 SERVICE BRAKES - E-4 When diagnosis code “22 STOP LAMP SW” is displayed [Hint] If the stop light operates normal, the harness for the The ABS-ECU outputs this trouble code in the stop light switch input circuit is broken or there is a following cases.
Page 764 SERVICE BRAKES - When diagnosis codes “41 FR SOL. VALVE”, “42 FL SOL. VALVE” or “43 VALVE DRIFT” are displayed. [Explanation] The ABS-ECU normally monitors the solenoid valve solenoid coil wire is broken/short-circuited or the drive circuit. harness is broken/short-circuited, and then these If no current flows in the solenoid even if the ECU trouble codes are output.
Page 765 SERVICE. BRAKES - When diagnosis code “51 VALVE RELAY” is displayed [Explanation] When the ignition switch is turned ON, the ABS normal. In addition, normally it monitors whether or ECU switches the valve relay OFF and ON for an not there is power in the valve power monitor line initial check, compares the voltage of the signal to since the valve relay is normally ON.
Page 766 SERVICE BRAKES - When diagnosis code “52 MOTOR RELAY” is displayed [Explanation] The ABS ECU outputs this trouble code for the When the motor ground is disconnected and the motor relay and motor in the following cases. 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 767 SERVICE BRAKES - S et-vice Adiustment Procedures BRAKE PEDAL INSPECTION AND ADJUSTMENT 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 768 SERVICE BRAKES 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. 3. The brake fluid level sensor is in good condition if there is ‘k&J no continuity when the float surface is above “A”, and if there is continuity when the float surface is below “A”.
Page 769 SERVICE BRAKES Check the operation of the check valve by using a vacuum Valve Spring Vacuum pump connection Connection at the brake created and held. booster side @ Connection at intake created. manifold side @ Caution If the check valve is defective, replace it as an assembly unit together with the vacuum hose.
Page 770 SERVICE BRAKES - Service Adjustment Procedures BLEEDING Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. Specified brake fluid: Conforming to DOT3 BLEEDING THE MASTER CYLINDER If the master cylinder is empty of brake fluid, bleed the cylinder as follows.
Page 771 SERVICE BRAKES 1. Visually check the brake pad thickness through the inspec- tion hole in the caliper body. Standard value: IO.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.
Page 772 SERVICE BRAKES - S 6. Clean the piston and, using the special tool, push the piston into the cylinder. 7. With care not to allow the piston boot to be wedged, lower the caliper assembly and fit the lock pin. 8.
Page 773 SERVICE BRAKES 3. Using a screwdriver, remove the pads and shims. 4. Measure the rotating torque qf the hub with the pads removed to determine brake drag torque after pads are installed. 5. Clean the piston and then push the piston into the cylinder. 6.
Page 774 SERVICE BRAKES 7. Using the following procedure, check the brake drag torque. for five seconds. [Approx. 200 N (44 Ibs.)] 8. If the difference between the brake drag force and hub rotating force exceeds the standard value, disassemble the piston and check the piston sliding surfaces for dirt and rust, piston seal for deterioration, and lock pin and guide pin for sliding motion.
Page 775 SERVICE BRAKES - Service Adjustment Procedures 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. wheel stud on the side at which run-out is greatest.
Page 776 SERVICE BRAKES 4. Remove the following parts from caliper support. 5. Measure hub torque with pad removed to measure brake drag torque after pad installation. On vehicles with VCU-equipped LSD, disengage the drive shaft and companion flange. NOTE Secure the disc to the hub with wheel nuts. 6.
Page 777 SERVICE BRAKES - Service Adjustment Procedures 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>...
Page 778 SERVICE BRAKES BRAKE LINING THICKNESS CHECK Remove the rear brake assembly, and support it by a wire, etc. 2. Remove the brake disc. 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 brake lining thickness is less than the limit and/or if it is not worn evenly.
Page 779 SERVICE BRAKES MEASUREMENT OF WHEEL SPEED SENSOR OUTPUT VOLTAGE 9 18 I 7 16 I 5 14 13 12 1 1 1 2. Disconnect the ECU harness connector and measure with Check connector the adapter harness (MB991 356) connected to the harness side connector.
Page 780 SERVICE BRAKES POINTS IN WAVEFORM MEASUREMENT Symptom Probable causes Remedy Too small or zero waveform Faulty wheel speed sensor Replace sensor amplitude Incorrect pole piece-to-rotor clearance Adjust clearance Waveform amplitude fluctuates Axle hub eccentric or with large runout Replace hub excessively (this is no problem if the minimum amplitude is 100 mV or more)
Page 781 SERVICE BRAKES MUT actuator test start 3 sec. 3 sec. Pressure decrease Pedal operation Pedal operation pattern @ pattern @ Release - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 6 sec.
Page 782 SERVICE BRAKES INSPECTION BY USING BRAKE FORCE TESTER NOTE test. when testing the rear brakes, apply chocks to the front wheels to lock them. roller. (2) Set the MUT through the adapter harness (MB9913771 as illustrated. (3) After confirming that the shift lever or selector lever is in the neutral position, start the engine.
Page 784 SERVICE BRAKES - Service Adjustment Procedures INSPECTION OF POWER RELAY 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 ‘L-J continuity between the following terminals when the terminal @ is short-circuited to ground.
Page 785 SERVICE BRAKES - Service Adjustment Procedures 3. Check continuity of the relays both when they are ener- gized and de-energized. Motor Relay When de-energized Between termrnals @ o contrnurty Between termrnals @ and @ When energized Between terminals @ Continuity (approx.
Page 786 SERVICE BRAKES - Brake Pedal REMOVAL AND INSTALLATION Post-installation Operation Installation of Steering Column Assembly 9 ft.lbs. (Refer to GROUP 37A-Steering Wheel and Shaft.) Clutch Pedal Adjustment (Refer to GROUP 21 -Clutch Pedal.) Brake Pedal Adjustment (Refer to P.3545.) Stop switch removal steps light 2.
Page 787 SERVICE BRAKES 9 ftlbs. Stop light switch removal steps 9 ft.lbs. 1. Stop light switch connector 10 klbs. 2. Stop light switch Brake pedal removal steps 12 Nlm 3. Return spring 9 ftllbs. 4. Cotter pin 5. Washer 6. Clevis pin 7.
Page 788 SERVICE BRAKES 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 stolj light switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within mm (.16 in.) from the outer case edge surface, and...
Page 789 SERVICE BRAKES - Master Cylinder and Brake Booster REMOVAL AND INSTALLATION Brake tube flare nut 1 5 N m 11 ft.lbs. Post-installation Operation Supplying Brake Fluid Bleeding (Refer to P.35-48.) Adjustment of Brake Pedal (Refer to P.35-45.) Sealant: 3M ATD Part No. 8663 or equivalent 14 Nm 7 ft.lbs.
Page 790 SERVICE BRAKES SERVICE POINT 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 791 SERVICE BRAKES - Master Cylinder and Brake Booster (3) Measure the dimension (D) 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- light scale push rod and primary piston.
Page 792 SERVICE BRAKES SERVICE POINTS OF DISASSEMBLY 10. DISASSEMBLY OF PISTON STOPPER BOLT 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 793 SERVICE BRAKES BRAKE LINE REMOVAL AND INSTALLATION <Vehicles without ABS> Pre-removal Operation Draining of Brake Fluid Post-installation Operation Supplying Brake Fluid Bleeding (Refer to P.35-48.) Flared brake line nuts 15 Nm 11 ft.lbs. 1. Brake hose 2. Brake tube (strut) 3.
Page 794 SERVICE BRAKES - Brake Line <Vehicles with ABS> Flared brake line nuts 15Nm 1 AFO38 1. Brake hose 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.
Page 795 SERVICE 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. Check the flared brake line nuts for damage and leakage. SERVICE POINT OF INSTALLATION 13.
Page 796 SERVICE BRAKES INSPECTION Check disc for wear. (Refer to P.35-52.) Check disc for runout. (Refer to P.35-52, 53.) Check disc for damage. SERVICE POINTS OF lNS?ALLATlON 2. INSTALLATION OF FRONT BRAKE ASSEMBLY (1) Measure hub torque with pad removed to measure brake drag torque after pad installation.
Page 797 SERVICE BRAKES - Front Disc Brake SASSEMBLY AND REASSEMBLY 75 Nm 54 ftlbs. Brake caliper kit Caliper assembly disassembly steps 2. Lock pin 3. Bushing 4. Caliper support (pad. clip, shim) 5. Pin boot 6. Boot ring 7. Piston boot 8.
Page 798 SERVICE BRAKES - Front Disc Brake Lubrication points Grease: Repair kit grease (orange) Brake fluid: Conforming to DOT3 Grease: Repair kit grease (orange) Grease: Repair kit grease (orange) TSB Revision...
Page 799 SERVICE 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 800 SERVICE BRAKES SERVICE POINTS OF REASSEMBLY ldenti fication 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 801 SERVICE BRAKES - Front Disc Brake Caution The piston seal contained in the seal and boot kit is coated with special grease. Do not wipe off the grease. Brake fluid: Conforming to DOT3 Brake caliper kit Grease: Brake grease SAE 5310, Pad kit Seal and boot kit 1.
Page 802 SERVICE BRAKES SERVICE POINTS OF DISASSEMBLY 2. REMOVAL OF PAD PIN Holding the cross spring with hand, remove the pad pin. 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 803: Rear Disc Brake
SERVICE BRAKES - Rear Disc Brake REAR DISC BRAKE REMOVAL AND INSTALLATION Flared brake line nuts 15 Nm 11 ft.lbs. (Refer to P.35-48.1 36 - 43 ft.lbs. 36 - 43 ftlbs. Removal steps 3. Brake disc INSPECTION INSPECTING THE BRAKE DISC Check disc for wear.
Page 804 35-82 SERVICE BRAKES - Rear Disc Brake 44Nm 32 ft.lbs. Brake caliper kit Caliper assembly disassembly steps 1. Lock pin * 2. Guide pin 3. Bushing Caliper support (pad, clip, shim) 5. Pin boot 9. Boot ring Pad kit Seal and boot kit 12.
Page 805 SERVICE BRAKES - Rear Disc Brake 27 Nm 20 ft.lbs. Brake caliper kit Grease: Br3rt;ty SAE J310, Caliper disassembly steps 1. Lock pin 4. Caliper support (pad, clip, shim) Sleeve 7. Lock pin boot 8. Guide pin boot 9. Boot ring Seal and boot kit Pad kit 11.
Page 806 35-84 SERVICE 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. Brake fluid: Conforming to DOT3 Grease: Repair kit grease (orange) Grease: Repair kit grease (orange) TSB Revision...
Page 807 35-85 SERVICE BRAKES SERVICE POINTS OF DISASSEMBLY 10. REMOVAL OF PISTON BOOT / 11. PISTON Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston. Caution Blow compressed air gently. 12. REMOVAL OF PISTON SEAL Remove piston seal with finger tip.
Page 808 35-86 SERVICE BRAKES - Hydraulic Unit (ABS) HYDRAULIC UNIT (ABS) REMOVAL AND INSTALLATION Flared brake line nuts 15 Nm Removal steps Pre-removal Operation Removal of Splash Shield 2. Harness connector connection Draining of Brake Fluid Removal of Relay Box 3. Bracket bolt Removal of Air Duct 4.
Page 809 SERVICE BRAKES - Hvdraulic Unit (ABS) SERVICE POINTS OF REMOVAL 1. REMOVAL OF BRAKE TUBES Pull up the relay box with harness attached and inserting a hand under the relay box, remove the brake tubes using the flare nut wrench. 4.
Page 810 SERVICE BRAKES - Wheel Speed Sensor (ABS) WHEEL SPEED SENSOR (ABS) REMOVAL AND INSTALLATION 1. Front rotor Front speed sensor removal steps (Refer to Group 42 - Fender.) 2. Clip Post-installation Operation 5. Rear rotor Installation of Splash Shield (Front Only) (Refer to Group 42 - Fender.) Rear speed sensor removal steps Inspection of A.B.S.
Page 811 SERVICE BRAKES - Wheel Speed Sensor (ABS) 35-89 12 Nm 9 ft.lbs. 12 Nm Pre-removal Operation Removal of Splash Shield (Front Only) Front speed sensor removal steps (Refer to Group 42 - Fender.) 2. Clip * I)* 3. Front speed sensor 5.
Page 812 SERVICE BRAKES - Wheel Speed Sensor (ABS) SERVICE POINTS OF REMOVAL 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 813 35-91 SERVICE BRAKES - Wheel SDeed Sensor lABSI 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. INSPECTION OF ROTOR Check the rotor for missing or worn teeth and replace if faulty. SERVICE POINTS OF INSTALLATION 8.
Page 814 35-92 SERVICE BRAKES G SENSOR (AWD - ABS) INSTALLATION REMOVAL Pre-removal and Post-installation Operation Removal and installation of Front (Refer to Group 52A - Console Box.) 4 ft.lbs. Removal steps 1. G sensor connector 2. G sensor 3. G sensor bracket INSPECTION 1.
Page 815 35-93 SERVICE BRAKES ELECTRONIC CONTROL UNIT (ABS) REMOVAL AND INSTALLATION Post-installation Operation Installation of Quarter Trim Installation of Rear Seatback (R) Installation of Rear Seat Cushion inspection of A.B.S. (Refer to P.35-7.) Removal steps 2. Electronic control unit SERVICE POINT OF REMOVAL 1.
Page 817 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 818: Specifications
36-2 PARKING BRAKES - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Parking brakes Mechanical brake acting on rear wheels Brake lever type Lever type Cable arrangement V-type SERVICE SPECIFICATIONS Items Specifications Standard value Parking brake lever stroke 3 - 5 notches Brake lining thickness mm (in.) Brake drum I.D.
Page 819: Troubleshooting
PARKING BRAKES - Special Tools / Troubleshooting SPECIAL TOOLS Number Tool Name End yoke holder Removal of the rear axle shaft assembly Axle puller MB99021 I-01 TROUBLESHOOTING Probable cause Remedy Symptom Brake drag Incomplete release of parking brake Correct Adjust Insufficient parking Worn brake pad Replace...
Page 820: Parking Brake
36-4 PARKING BRAKES SERVICE ADJUSTMENT PROCEDURES PARKING BRAKE LEVER STROKE CHECK Caution The 200 N be strictly observed. Standard value: 3 - 5 notches If the parking brake lever stroke is not the standard value, adjust as described below. adjustment nut to the cable end so that the cable becomes free.
Page 821 36-5 PARKING BRAKES - Parking Brake Lever and Parking Brake Cable PARKING BRAKE LEVER AND PARKING BRAKE CABLE REMOVAL AND INSTALLATION Removal of Front and Rear Console (Refer to GROUP 52A-Console Box.) Post-installation Operation Parking Brake Lever Stroke Adjustment (Refer to P.36-4.) Installation of Front and Rear Console (Refer to GROUP 52A-Console Box.) Parking brake lever removal steps...
Page 822 36-6 PARKING BRAKES - Parking Brake Lever and Parking Brake Cable 50-60 Nm 36 - 43 ft.lbs. a 13. Shoe-to-anchor spring l * l Rear speed sensor 14. Strut (Refer to GROUP 35 -Speed Sensor.) 15. Strut return spring 7. Rear brake assembly 16.
Page 823 36-7 PARKING BRAKES - Parking Brake Lever and Parking Brake Cable SERVICE POINTS OF REMOVAL 10. REMOVAL OF SHOE HOLD DOWN CUP 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 se- quence shown in the illustration.
Page 824 36-8 PARKING BRAKES - Parking Brake PARKING BRAKE REMOVAL AND INSTALLATION Adjustment (Refer to 83 Nm Sealant: 3M ATD Part No. 8513 or equivalent 36 - 43 ft.lbs. 1 ’ 1. Rear speed sensor 3. Rear brake assembly 4. Rear brake disc 5.
Page 825 PARKING BRAKES - Parking Brake 36-9 83 Nm 12 Nm 60 ft.lbs. 9 ft.lbs. 190 Nm 50-60 Nm 137 ft.lbs. 36 43 Removal steps 2. O-ring 3. Rear brake assembly 4. Rear brake disc 43 ft.lbs. * 9. Self-locking nut 12.
Page 826 PARKING BRAKES SERVICE POINTS OF REMOVAL I. REMOVAL OF REAR SPEED SENSOR Caution When removing the speed sensor from the knuckle, use i&J care not to hit the pole piece at its tip against the rotor teeth or other parts. 9.
Page 827 PARKING BRAKES SERVICE POINTS OF INSTALLATION 17. INSTALLATION OF SHOE-TO-ANCHOR SPRING The shoe-to-anchor spring must be installed in the se- quence 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 829 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 830 STEERING - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Steering wheel Steering wheel O.D. mm (in.) 390 (15.4) Gear box Steering gear type Rack and pinion Power steering oil pump Oil pump type Vane type 9.6 t.59) Displacement Relief set pressure SERVICE SPECIFICATIONS Specifications Steering wheel free play (with engine stopped)
Page 831: Special Tools
STEERING - Specifications / Special Tools LUBRICANTS Specified lubricant Quantity Items Power steering gear box MITSUBISHI PLUS ATF/Automatic trans- Bearing As required mission fluid “DEXRON” or “DEXRON II” As required O-ring mission fluid “DEXRON” or “DEXRON II” Oil seal MITSUBISHI PLUS ATF/Automatic trans- As required mission fluid “DEXRON”...
Page 832 STEERING - Special Tools easuremen Power steering oil Measurement of oil pressure pressure gauge adapter (pump side) MB991 204 Removal of rack housing needle bearing TSB Revision...
Page 833 STEERING 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.) 13FOOOi shaft connection and steering linkage. Correct or replace. 4.
Page 834 STEERING TIE ROD END. BALL JOINT STARTING TORQUE CHECK 2. Move ball joint stud several times and install nut on stud. Measure ball joint starting torque. Standard value: 0.5 - 3.0 Nm (4 - 26 in.lbs.1 3. When starting torque exceeds the standard value, replace tie rod end.
Page 835 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 make tie rods to the front wheels steer toward the left, and vice...
Page 836 STEERING - Service Adjustment 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 + 100 rpm. Caution After checking the engine speed, there must be a return to the standard idling speed.
Page 837: Fluid Replacement
5. Connect the return hoses securely, and then secure it with the clip. 6. Fill the oil reservoir with the specified fluid up to the lower position of the filter, and then bleed the air. Specified fluid: MITSUBISHI PLUS ATF/Automatic transmission fluid “DEXRON” or “DEXRON II”...
Page 838 STEERING - Service Adjustment Procedures BLEEDING stand. 2. Manually turn the oil pump pulley a few times. 3. Turn the steering wheel all the way to the left and to the right several times. 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 (for 15 to 20 seconds).
Page 839 STEERING OIL PUMP PRESSURE TEST Shut-off valve Pressure gauge (FuW dose) CHECKING THE OIL PUMP RELIEF PRESSURE 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 840 STEERING CHECKING THE STEERING GEAR RETENTION HYDRAULIC Shut-off valve PRESSURE open) 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- ture of the fluid rises to approximately 50 - 60°C (122 - 140°F).
Page 841 STEERING - Steering Wheel and Shaft STEERING WHEEL AND SHAFT REMOVAL AND INSTALLATION Post-installation Operation Checking of Steering Wheel Positlon with Wheels Straight Ahead 40 Nm 29 ftlbs. 4 ft.lbs. 12 Nn Removal steps a 2. Steering wheel <Automatic transaxle vehicles> 3.
Page 842 STEERING SERVICE POINTS OF REMOVAL 1. REMOVAL OF AIR BAG MODULE socket wrench from the back side. (2) To remove the clock spring connector (squib connector) from the air bag module, force the lock outward and pry it with a standard screwdriver, as shown in the illustration at the left, to make sure that no undue force is exerted to the connector when it is removed.
Page 843 STEERING DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Cover assembly 4. Joint assembly 6. Steering lock bracket 8. Steering column assembly SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF STEERING LOCK BRACKET / 7. STEER- ING LOCK CYLINDER If it is necessary to remove the steering lock cylinder, use a hacksaw to cut the special bolts at the steering lock bracket side.
Page 844 STEERING - Steering Wheel and Shaft INSPECTION Check the steering shaft for play and round movement. Check the joints for play, damage, or rough movement. Check the joint bearing for wear and damage. Check the dust shield for damage. SERVICE POINTS OF REASSEMBLY 7.
Page 845 STEERING POWER STEERING GEAR BOX REMOVAL AND INSTALLATION 40 Nm Pre-removal ODeration 29 ftlbs. Draining of the Power Steering Fluid (Refer to P.37A-9.) Removal of Front Exhaust Pipe (Refer to GROUP 15 - Exhaust Pipe Removal of Transfer Assembly (Refer to GROUP 22 -Transfer.) Post-installation Operation Installation of Transfer Assembly (Refer to GROUP 22 -Transfer.)
Page 846 STEERING 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 (1) Move the rack completely to the right and then remove the gear box from the crossmember.
Page 847: Gear Box
STEERING Gear Box SASSEMBLY AND REASSEMBLY <Vehicles with 4WS> Steering gear seal kit <Vehicles without 4WS> 22 Nm 16 ft.lbs. 15 Nm 11 ft.lbs 36 - 40 ft.lbs. 65 ftlbs. Disassembly steps 4 18. Oil seal assembly a I 9. Pinion and valve Tie rod ends Bellows clips Oil seal...
Page 848 STEERING Automatic transmission fluid Fluid: MITSUBISHI PLUS ATF/ Automatic transmission fluid “DEXRON” or “DEXRON II” Sealant: equivalent MITSUBISHI PLUS ATF/ Automatic transmission fluid “DEXRON” or “DEXRON II” Grease: Silicone grease Fluid: MITSUBISHI PLUS ATF/ Automatic transmission fluid “DEXRON” or “DEXRON II”...
Page 849 STEERING 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. REMOVAL OF TAB WASHER Unstake the tab washer which fixes the tie rod and rack with a chisel.
Page 850 STEERING 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. Socket 23.
Page 851 STEERING Gear 31. REMOVAL OF BALL BEARING Use a brass bar to remove the ball bearing from the gear housing. 32. REMOVAL OF NEEDLE ROLLER BEARING Use the special tool to remove the needle roller bearing from the rack housing. Caution Do not open special tool excessively to prevent damag- ing housing interior.
Page 852 34. INSTALLATION OF BACK-UP WASHER / 33. OIL SEAL (1) Apply a coating of the specified fluid to the outside of the oil seal. Specified fluid: MITSUBISHI PLUS ATF/Automatic transmission fluid “DEXRON” or “DEXRON II” into the rack housing to the specified position (where...
Page 853 STEERING (3) Apply specified fluid on special tool. Specified fluid: MITSUBISHI PLUS ATFIAutomatic transmission fluid “DEXRON” or “DEXRON II” (4) Match oil seal center with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.
Page 854 STEERING bearing. (3) Wrap vinyl tape around the serrated part so that the oil Apply grease seal won’t be damaged when the pinion and valve assembly is installed to the valve housing. (4) Mount the pinion and valve assembly to the valve housing.
Page 855 STEERING 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 (1) Pack dust shield interior and lip with multipurpose grease. (2) Apply semi-drying sealant to dust shield. Specified sealant: 3M ART Part No.
Page 856: Power Steering Oil Pump
STEERING POWER STEERING OIL PUMP REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation Supplying of the Power Steering Fluid Adjusting V-belt Tension (Refer to P.37A-8.) 22 Nm Bleeding the Power Steering 16 ft.lbs. Fluid Line (Refer to P.37A-10.) Checking of the Oil Pump Pressure (Refer to P.37A-11.) 31 ft.lbs.
Page 857 STEERING DISASSEMBLY AND REASSEMBLY Oil pump seal kit nission fluid “DEXRON” or “DEXRON II” 20 Nm 14 ft.lbs. 6 ft.lbs. 25-30 Nm 18 - 22 ft.lbs. Disassembly steps 15. Plunger Pump cover Snap ring O-ring Terminal Vanes Washer Rotor Insulator Cam ring O-ring Side plate...
Page 858 STEERING 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 for “stepped” wear. Check the vanes for breakage.
Page 859 STEERING 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. Dowel pin 5. INSTALLATION OF CAM RING Install the cam ring with the punch mark facing the side plate.
Page 860 STEERING - P ower Steering Hoses POWER STEERING HOSES REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Draining, Supplying, and Bleeding of the Power Steerina Fluid (Refer to P.37A-9,‘iO.) 12 Nm <Vehicles with 4WS> <Vehicles without 4WS> 24 Nm 35 Nm 22 Nm 17 f-tlbs 12 Nm...
Page 861 CONTENTS CONTROL VALVE ..........SPECIAL TOOLS ............ POWER CYLINDER ..........SPECIFICATIONS ..........General Specifications ..................REAR OIL LINE Lubricants ..........:.... REAR OIL PUMP ............ Service Specifications ........TROUBLESHOOTING ........_ . _ . _ SERVICE ADJUSTMENT PROCEDURES .
Page 862: Specifications
Power cylinder slide resistance LUBRICANTS Quantity Specified lubricant Items 1.45 liter (1.53 qts.) Power steering fluid MITSUBISHI PLUS ATFiAutomatic Trans- mission fluid “DEXRON” or “DEXRON II” As required ‘Silicone grease Dust cover SPECIAL TOOLS Measurement of fluid flow volume Power steering oil...
Page 863: Control Valve
TROUBLESHOOTING Before inspecting, check the following items: Oil pump drive belt tension Ensure that the suspension has not been mod- Power steering fluid level, and air in the system ified Engine Idle soeed and even idle Tire and wheel size, specifications, air pressure, Oil leakage balance and amount of wear Steering wheel type...
Page 864 Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES BLEEDING (1) Bleed air from power steering system (Refer to GROUP 37A - Service Adjustment Procedures.) (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 the special tool to the bleeder screw.
Page 865: Ball Joint Rotation Starting Torque Check
Service Adjustment Procedures 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 866 POWER CYLINDER REMOVAL AND INSTALLATION Installation of Main Muffler Assembly Refilling and Bleeding of Power Steering System (Refer to GROUP 37A-Service Adjustment Removal of Main Muffler Assembly Procedures.) Bleeding of 4WS System (Refer to P.37B-4.) Checking of 4WS System for Operation (Refer to P.37B-5.) (Refer to GROUP 34 -Service Adiustment 78 Nm...
Page 867 SERVICE POINTS OF REMOVAL 3. REMOVAL OF CROSSMEMBER MOUNTING NUT 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. INSPECTION (2) Point the tie rod end down, then attach a spring balance as shown in the illustration to measure swing resistance...
Page 868 (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’ Lj tie rods should be less than 1 mm ( ,039 in.).
Page 869 IQ-WHEEL STEERING SYSTEM (4WS) - Control Valve CONTROL VALVE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Cleaning of Pipings with Steam Installation of Rear Suspension Assembly (Refer to GROUP 34 - Rear Suspension Assembly.) (Refer to GROUP 37A - Service Adjustment Procedures.) (Refer to GROUP 37A-Service Adjustment Removal of Rear Suspension Assembly...
Page 870 REAR OIL LINE REMOVAL AND INSTALLATION 35 Nm 25 ftlbs. 12 Nm 9 ftlbs. Removal steps 2. Suction hose Cleaning of Pipings with Steam 3. Protector 4. Pipe assembly to pressure tube connection 5. Pipe assembly 6. Suction hose 7. Rubber hose Post-installation Operation 8.
Page 871 REAR OIL PUMP REMOVAL AND INSTALLATION Draining of Power Steering Fluid (Refer to GROUP 37A- Service Adjustment Removal of Main Muffler Assembly (Refer to GROUP 15 - Exhaust Pipe and Muffler.) Post-installation Operation Installation of Main Muffler Assembly (Refer to GROUP 15 - Exhaust Pipe and Muffler.) Refilling and Bleeding of Power Steering System (Refer to GROUP 37A- Service Adjustment Procedures.)
Page 873 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the...
Page 874 BODY - SDecifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Hood Rear hinged, front opening type (with gas damper) Door Front-hinged, sashless Construction Wire type Regulator system Pin-fork type Locking system Inner-hinged, with gas damper Glass installation method Adhesive type Windshield glass Adhesive type Quarter window glass Adhesive type...
Page 875: Sealants And Adhesives
BODY - SDecifications Item Specifications Door lock power relay Range of voltage used 8 - 1 6 Rated load current (at 13.5 VI Rated coil current 0.2 or less Voltage drop between terminals 0.2 or less Door lock actuator Bound current (at 12 V) 2.5 - 4.5 Operating voltage range 9 - 1 5...
Page 876: Special Tools
42-4 BODY - SDecial Tools SPECIAL TOOLS remover TSB Revision...
Page 877: Troubleshooting
BODY - Troubleshooting 42-5 TROUBLESHOOTING HOOD, LIFTGATE, GLASS AND DOORS Symptom Probable cause Remedy Improper closure Striker and latch not properly aligned Adjust the alignment Difficult locking and Striker and latch not properly aligned Adjust the alignment unlocking Uneven body Incorrectly installed hood or liftgate Adjust the installation of clearance...
Page 878 42-6 BODY - Troubleshooting HOW TO LOCATE WIND NOISES the source of wind noise, such as panel seams, projections, moulding seams, glass and body seams, etc. not covered by tape are not sources of wind noise. (3) Then remove the strips of tape one by one, making a road test after each is removed, until a wind noise source is discovered.
Page 879: Power Window
42-7 BODY POWER WINDOW FUSIBLE CIRCUIT DIAGRAM LINK@ POWER WINDOWS "4 E-34 POWER WINDOW MAIN SWITCH ------ POWER WINDOW MOTOR TSB Revision...
Page 880 42-8 BODY POWER WINDOWS RELAY JUMPER CONNECTOR ----- 5 /\ c-34 __ SELF-DIAGNOSIS CHECK C01'6NZCTOR E-21 TSB Revision...
Page 881 42-9 BODY OPERATION TROUBLESHOOTING HINTS When, with the ignition switch at the ON 1. All door windows cannot be opened or closed. position, a power-window (main or sub) switch Check sub-fusible link No. 8. (“UP” side or “DOWN” side) is pressed, current Check the power-window relay.
Page 882 BODY CENTRAL DOOR LOCKING SYSTEM CIRCUIT DIAGRAM DOOR LOCK POWER RELAY E-22 2 If E-13 TSB Revision...
Page 883 42-11 BODY - Troubleshooting DOOR LOCK POWER RELAY 51 CONNECTOR C-66 ____ ---- ETACS UNIT WITH c - 3 4 4-- DOOR TSB Revision...
Page 884 42-12 BODY OPERATION When the door lock switch is set to the LOCK side (or UNLOCK side), the LOCK side (or UNLOCK side) of the door lock relay is turned ON and the door actuators of alIsa doors operate. If the driver seat side door (or assistant seat side door) is opened and the driver seat side inside lock knob (or assistant seat side inside lock knob) is locked with the key inserted in the ignition switch, the ETACS unit grounds the...
Page 885 42-13 BODY SERVICE ADJUSTMENT PROCEDURES HOOD ADJUSTMENT Loosen the hood mounting bolts, and then adjust the hood by moving it so that the clearance is equal on all sides. 2. Turn the bumpers A and B, adjust the height of the hood. Loosen the hood latch mounting bolts, and move the hood latch to adjust the attachment between the hood latch and hood striker.
Page 886 42-14 BODY - Service Rdiustment Procedures FUEL FILLER DOOR ADJUSTMENT Loosen the fuel filler door mounting screw and adjust the fuel filler door so that the clearance around the fuel filler door is even without any height differences. DOOR ADJUSTMENT Use the special tool to loosen the hinge mounting bolts on the body side, and then adjust the clearance around the door so that it is uniform on all sides.
Page 887 42-15 BODY 5. Remove the stabilizer inner front and adjust the adjusting bolt for the dimension shown here. 5 mm (20 in.) 6. Adjust the adjusting bolt for the stabilizer inner rear 14.5 mm (.57 in.) dimension shown here. 7. Raise door window glass. Push glass against the outer stabilizer of the door belt line outer weatherstrip and insert cloth or the like between the door inner panel and glass.
Page 888 42-16 BODY NOTE Adjust both inward tilt and forward or backward tilt of glass at the same time. Force the stabilizer inner front onto the glass guide slider of the window glass assembly and tighten in position. 10. Force the up stop onto the glass stop of the window glass assembly and tighten in position.
Page 889 42-17 BODY 2. If out of specifications, adjust as described below. the inside handle back and forth to adjust the inside handle play. FLOOR PAN INSPECTION Front floor pan A common result of body leaks is a soaked floor mat pad or carpet, and it’s not unusual to find that the water is getting in through the floor pan to some other low point jn the body.
Page 890: Engine Hood
42-18 BODY ENGINE HOOD REMOVAL AND INSTALLATION 12 Nm 7 ft.lbs. 8 ft.lbs. 2. Hood lock release handle Hood lock release cable 4. Hood weatherstrip (Front) Hood hinge removal steps 5. Hood weatherstrip (Rear) Washer tube (Refer to GROUP 51 -Wind- a 6.
Page 891 BODY - Engine Hood INSPECTION HOOD SWITCH Check the continuity between the terminal. Terminal Lid switch unpressed Lid switch depressed NOTE INSPECTION LIGHT SWITCH Turn the switch ON/OFF and check continuity between terminals (between the connector terminal and the switch body).
Page 892 BODY REMOVAL AND INSTALLATION 12 Nm 12 Nm 8 ft.lbs. 7 ftlbs. + 1. Bumper 2. Liftgate damper (upper) Washer tube (Refer to GROUP 51 -Wind- 3. Liftgate damper (lower) removal steps (Refer to GROUP Rear side trim > 4. Liftgate gas spring 6.
Page 893 42-21 BODY Scuff plate (driver’s side) Rear end trim (Refer to GROUP 52A-Trims.) (Refer to GROUP 52A-Trims.) 9. Release handle cover Rear combination light Rear panel garnish Quarter trim Mouldings.) Rear side trim (Refer to GROUP 14. Liftgate lock cylinder switch Rear end trim I 52A -Trims.) 15.
Page 894 42-22 BODY FUEL TANK FILLER DOOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Rear Side Trim, Quarter Trim and Scuff Plate Removal steps 1. Fuel filler door 2. Fuel filler door hook 3. Release handle cover 4.
Page 895 42-23 BODY - Fender FENDER REMOVAL AND INSTALLATION Sealant: 3M ATD Part No. 8625 or equivalent Removal steps 1. Front splash shield Side airdam (Refer to GROUP 51 -Aero Parts.) 2. Front splash shield Front bumper Sealant: (Refer to GROUP 51 - Front Bumper.) 3M ATD Part No.
Page 896 42-24 BODY - Loose Panel LOOSE PANEL REMOVAL AND INSTALLATION support crossmember Deck crossmember TSB Revision...
Page 897: Window Glass
42-25 BODY WINDOW GLASS GENERAL For bonding of the windshield and liftgate glass, a single-liquid urethane adhesive is used. ADHESIVE AND RESERVE ITEMS Adhesive and Reserve Items Applications Quantity Adhesive 3M SUPER FAST URETHAN 8609 One cartridge 3M SUPER FAST URETHAN PRIMER 8608 As required Reserve items Wire (dia.
Page 898 42-26 BODY WINDSHIELD AND LIFTGATE GLASS INSTALLATION PROCEDURE Removal of moutding (wire) Body side Cleaning bonding surface Cleaning bonding surface Cleaning bonding surface Scoop out existing adhesive to less than Scoop out existing adhesive com- Clean the bonding surface and dry 2 mm (.08 in) thick and clean bonding 3 minutes or more.
Page 899 42-27 BODY - Window Glass REPLACEMENT OF MOULDING (BONDING TYPE) Recommended tool Make the tool by 2. To cut the existing adhesive, make a tool such as the one shown. Sharpen the edge here 3. Using the tool, scoop out the existing adhesive. Caution 1.
Page 900 42-28 BODY WINDSHIELD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and lnstallatron of Deck Garnish (Refer to GROUP 51 - Garnrshes and Mouldrngs.; Removal and lnstallatron of Roof Drop Mouldrng (Refer to GROUP 51 -Garnishes and Mouldings.] Removal and lnstallatron of Headlrnrng (Refer to GROUP 52A- Headlrning.) Removal and lnstallatron of Front Pillar Removal steps...
Page 901 42-29 BODY - Windshield SERVICE POINTS OF REMOVAL 2. REMOVAL OF WINDSHIELD GLASS Remove windshield using the following procedure. tape to all around the body where the glass is installed. (2) Using a drill of sharp bit, drill a hole through the adhesive fixing the windshield glass.
Page 902 BODY (2) Apply a uniform coat of primer to the illustrated areas of the body and glass making sure it is applied without breaks or thin spots. Adhesive: 3M SUPER FAST URETHAN PRIMER 8608 ‘& or equivalent Caution 1. The primer is used to strengthen bonding pow- er.
Page 903 42-31 BODY (6) After application of the adhesive, line up the match- marks on the glass and body and force the glass lightly and evenly onto the body for complete fitting. (7) Remove adhesive from around and on the glass and body surfaces using a spatula and wipe the surfaces clean.
Page 904 42-32 BODY - Center Pillar Glass REMOVAL AND INSTALLATION Removal and Installation of Quarter Upper Trim (Refer to GROUP 52A-Trims.) Removal and Installation of Center Pillar Garnish (Refer to GROUP 51 -Garnishes and Mouldings.) 1. Center pillar glass 2. Packing TSB Revision...
Page 905 42-33 BODY - Quarter Window Glass QUARTER WINDOW GLASS REMOVAL AND INSTALLATION Trim (RefertoGROUP52A-Trims.) Removal and Installation of Center Pillar Garnish (Refer to GROUP 51 -Garnishes and Removal steps * I)* 2. Packing 3. Window dam Section A Adhesive Cut off nozzle tip mm (in.) Adhesive: 3M SUPER FAST URETHAN 8609 or equivalent...
Page 906 42-34 BODY - Quarter Window Glass SERVICE POINT OF REMOVAL 1. REMOVAL OF QUARTER WINDOW MOULDING AND GLASS tape to all around the body where the glass is installed. (2) Using a cutter knife, cut off the quarter window moulding along its edge. (3) Run a wire between the glass and the body at the upper portion of the quarter window and pull it back and forth along the glass to cut through the adhesive.
Page 907 BODY SERVICE POINT OF INSTALLATION 1. INSTALLATION OF QUARTER WINDOW MOULDING AND GLASS the body and glass making sure it is applied without breaks or thin spots. Caution 1. The primer is used to strengthen bonding pow- er. Make sure that it covers the surfaces com- pletely.
Page 908 BODY - Quarter Window Glass (4) After application of the adhesive, line up the match- marks on the glass and body and force the glass lightly and evenly onto the body for complete fitting. (5) Remove adhesive from around and on the glass and \Lj body surfaces using a spatula and wipe the surfaces clean.
Page 909 BODY - Liftgate Glass REMOVAL AND INSTALLATION Removal steps 2. Liftgate moulding upper 3. Liftgate moulding upper clip Removal and Installation of Rear Wiper Arm 4. Liftgate moulding lower (Refer to GROUP 51 -Windshield Wiper and Washer 5. Liftgate moulding lower clip Removal and Installation of Liftgate Upper 6.
Page 910 BODY - Liftgate Glass MB990449 2. REMOVAL OF LIFTGATE MOULDING UPPER / 4. LIFT- GATE MOULDING LOWER Usina the special tool, pry up the clipped portions to remove the liftgate moulding upper and lower. 7. REMOVAL OF LIFTGATE GLASS Remove the same way as the windshield glass. (Refer to SERVICE POINT OF INSTALLATION 7.
Page 911 BODY Glass (4) After application of the adhesive, line up the match- marks on the glass and liftgate and force the glass lightly and evenly for complete fitting. (5) Remove adhesive from around and on the glass and body surfaces using a spatula and wipe the surfaces clean.
Page 912: Door Assembly
BODY - Door Assembly DOOR ASSEMBLY REMOVAL AND INSTALLATION 22Nm Door assembly removal steps Striker removal steps 1. Connection for door wiring harness 7. Striker connector 8. Striker shim 2. Spring pin Door switch removal steps 3. Door assembly 9. Door switch cap 4.
Page 913 42-41 B O D Y INSPECTION DOOR SWITCH Operate the switch, and check the continuity between the terminals. Open (ON) Switch Depressed (OFF) NOTE O-O indicates that there is continuity between the terminals SERVICE POINT OF INSTALLATION 6. INSTALLATION OF DOOR CHECK STRAP Install the door check strap with the identification mark facing up.
Page 914: Door Glass And Regulator
42-42 BODY - Door Trim and Waterproof Film / Door Glass and Regulator SERVICE POINT OF REMOVAL 1 . R E M O V A L O F C L I P Use a shop towel to remove the clip; and remove door window regulator handle.
Page 915 BODY TROUBLESHOOTING GUIDE INPUT CHECK Using the multi-use tester or voltmeter, check whether or not the input signals from each switch are being input to the ETACS unit. connector located at the right side of the junction block or connect the voltmeter between the ETACS terminal and the ground terminal.
Page 916 42-44 B O D Y - P o w e r W i n d o w Problem Probable cause Check method Remedy The power windows can be opened Damaged or discon- If a malfunction is in- Repair the wiring har- and closed immediately after the front door switch ignition switch is switched “OFF”, but...
Page 917 B O D Y - P o w e r W i n d o w CHECKING INDIVIDUAL PART AND CIRCUIT 1. ETACS POWER-SUPPLY AND GROUND CIRCUITS Battery Junction block Jumper connector ETACS unrt “2: Vehicles with theft-alarm system Description of operation The battery supplies a stabilized 5V power supply to the electronic control unit, via the constant-voltage circuit and terminal (51) directly connected to the battery.
Page 918 42-46 B O D Y - P o w e r W i n d o w 2. IGNITION SWITCH INPUT CIRCUITS Battery Fusible link 1 2 3 4 5 6 Junction block ETACS unit “1 : Vehicles without theft-alarm system Description of operation A condition for operation of this system is the sending of HIGH-level signals to the electronic control unit when the ignition switch is switched to the “ON”...
Page 919 B O D Y - P o w e r W i n d o w Fusible link @ Power window One-touch Power window sub-switch TSB Revision...
Page 920 42-48 BODY Description of operation When the ignition switch is switched to the “ON” position, and also for a period of 30 seconds after the ignition switch is switched to the “OFF” position, the transistor of the electronic control unit is switched ON, and battery voltage is supplied from the battery (through fusible link No.
Page 921 42-49 BODY 4. DOOR SWITCH INPUT CIRCUIT ETACS unit Passenger door “2: Vehicles with theft-alarm system switch switch Description of operation When the front door is closed (the door switch is switched OFF), HIGH-level signals are sent to the electronic control unit;...
Page 922 BODY Checking the driver door switch circuit (Disconnect the connector of the electronic control unit’and check the wiring harness side.) ECU Terminal Connected to/ Check conditions Standard Measurement ~~~~e~rion measured part 14”’ Driver door switch Resistance Closed No continuity Open Continuity No continuity 16”’...
Page 923 42-51 B O D Y - P o w e r W i n d o w R E M O V A L A N D I N S T A L L A T I O N Door Wlndow Glass Adjustment Door window regulator assembly removal steps 6.
Page 924 42-52 BODY (3) Apply battery voltage to terminal 1, and check for continuity when terminal 3 is grounded. Continuity no voltage Continuity with voltage NOTE O-O indicates that there is continuity between the terminals. POWER WINDOW MOTOR (1) Connect the battery directly to the motor terminal and check that the slider moves smoothly.
Page 925 42-53 BODY POWER WINDOW MAIN SWITCH Power window passenger’s Check for continuity in accordance to the following connection table. View A side switch ock switch Driver’s side switch NOTE O-O indicates that there is continuity between the terminals POWER WINDOW SUB SWITCH Check for continuity in accordance to the following connection table.
Page 926 42-54 BODY REMOVAL AND INSTALLATION Door inside handle removal Door Inside Handle Play Check (Refer to 1. Door inside handle Door outside handle and latch removal steps 2. Door key cylinder unlock switch connector (Vehicles with theft-alarm system) 3. Door outside handle 4.
Page 927 42-55 BODY - Central Door Locking System CENTRAL DOOR LOCKING SYSTEM IGNITION KEY REMINDER TROUBLESHOOTING GUIDE INPUT CHECK Using the multi-use tester or voltmeter, check whether or not t h e i n p u t s i g n a l s f r o m e a c h s w i t c h a r e b e i n g i n p u t t o t h e ETACS unit.
Page 928 42-56 BODY CHECKING INDIVIDUAL PART AND CIRCUIT (IGNITION KEY REMINDER SYSTEM) 1. ETACS POWER-SUPPLY AND GROUND CIRCUITS Junction block (Multi -purpose fuse) Jumper connector ETACS unit (ECU) “2: Vehicles with theft-alarm system Description of operation The battery supplies a stabilized 5V power supply to the electronic control unit, via the constant-voltage circuit and terminal (51) directly connected to the battery.
Page 929 42-57 BODY - Central Door Locking System 2. DOOR LOCK ACTUATOR INPUT CIRCUIT Fusible link @ Junction block (Multi-purpose fuse) ETACS unit (ECU) “2: Vehicles with theft-alarm system Description of operation If the door is opened with the ignition key inserted and then locking is made by means of inside lock knob, the door lock actuator is brought to the OFF position, sending H signal to the electronic control unit.
Page 930 42-58 BODY 3. DOOR LOCK POWER RELAY ACTIVATION CIRCUIT Fusible link 0 Door lock Door lock actuator actuator Description of operation If the door is opened with the ignition key inserted and then door locking is made, transistor Tr of the electronic control unit is turned ON to operate the door lock power relay (unlock side) and the door lock actuator is unlocked.
Page 931 42-59 BODY 4. KEY REMINDER SWITCH INPUT CIRCUIT <Vehicles with theft-alarm system> <Vehicles without theft-alarm system> Fusible ETACS unit Junction block (Multi-purpose fuse) Key reminder switch ETACS unit Description of operation Insert the key in the ignition key cylinder, and the key reminder switch will be turned OFF, sending H signal to the electronic control unit.
Page 932 BODY 5. DOOR SWITCH INPUT CIRCUIT ETACS (ECU) switch switch Description of operation When the front door is closed (the door switch is switched OFF), HIGH-level signals are sent to the electronic control unit; when the front door is opened (the door switch is switched ON), LOW-level signals are sent to the electronic control unit.
Page 933 42-61 BODY Checking the driver door switch circuit (Disconnect the connector of the electronic control unit and check the wiring harness side.) Connected to/ Standard Measurement -ff~~e~rion Check conditions measured part Closed No continuity Driver door Continuity Open Passenger Closed No continuity door Open...
Page 934 BODY - Central Door Locking System REMOVAL AND INSTALLATION Door lock actuator removal Door lock switch removal Door trim and waterproof film (Refer to Door trim (Refer to 2. Door lock switch Door lock actuator INSPECTION <Driver’s side> DOOR LOCK ACTUATOR (1) Place the rod in the LOCK position, apply the battery power to the terminal L(3) for driver’s side or (1) for passenger’s driver’s side or (3) for passenger’s side] is grounded, the rod...
Page 935 BODY - Central Door Lockina Svstem DOOR LOCK SWITCH Check for continuity in accordance to the following connection Dower window main switch side table. with power window> <Vehicles Power window main switch side LOCK o - - + - - Q I Power window sub switch side UNLOCK NOTE...
Page 936 BODY - Central Door Locking System (3) Check for continuity between terminals under the condi- tions described below. NOTE that there is continuity between the terminals.
Page 937 B O D Y - Drir, Line Weatherstrir, REMOVAL AND INSTALLATION Removal steps Delta cover inner (Refer to Delta cover outer P.42-42.51.) Door trim (Refer to P.4241.) 1. Door belt line outer weatherstrip 2. Door outer opening weatherstrip 3. Door inner opening weatherstrip front 4.
Page 939 CONTENTS AERO PARTS ............20 SERVICE ADJUSTMENT PROCEDURES ..Inspection of Active Aero System ....DOOR MIRROR ........... . SPECIAL TOOLS .
Page 940 51-2 EXTERIOR GENERAL SPECIFICATIONS Items Specifications Windshield wiper motor Ferrite-magnet type Speed control system Third brush system Braking system Dynamic brake system rpm at load of 1 Nm (0.72 ft.lbs.) Low speed 48 _+ 4 High speed 70 2 7 Nominal torque Nm (ft.lbs.) Rear wiper motor...
Page 941: Door Mirror
EXTERIOR Items Specifications Wiper and washer switch Rated load A Wiper switch LO, HI 0.22 f 0.05 Washer switch Max. 4 Voltage drop (at 12V and the rated load) 0.2 or less Wiper switch Washer switch 0.5 or less Rear wiper and washer switch Rated load A Wiper switch Washer switch...
Page 942 EXTERIOR - SDecial Tools system inspectlon MB991 359 TSB Revision...
Page 943 EXTERIOR WINDSHIELD WIPER AND WASHER IGNITION : CIRCUIT DIAGRAM FRONT JUMPER CONNECTOR - - - - -l--r COLUMN MITTENT FRONT WIPER RELAY WIPER SWITCII VARIABLE WIPER CONTROL SWITCH C-79 CONNECTOR...
Page 944 51-6 EXTERIOR FRONT WIPER IGNITION SWITCH WIPER RELAY SWITCH(ACC) - - - - - - - r ‘( FRONT A-19 MOTOR A-15 TSB Revision...
Page 945 51-7 EXTERIOR OPERATION TROUBLESHOOTING HINTS <Low-speed (and high-speed) wiper operation> 1. Wipers do not operate. When the wiper switch is placed in the LO Check multi-purpose fuse No. 0. position with the ignition switch in the ACC or Check ground. ON position, wipers operate continuously at low speed.
Page 946 51-8 EXTERIOR CIRCUIT DIAGRAM IGNITION I iITCH(ACC) T RELAY C-82 DEDICATED FUSE REAR INTERMITTENT WIPER RELAY E-18 8 C-71 8 D-44 REAR D-42 RHEOSTAT REAR F-34 2 D-41 F-15 REAR WIPER MOTOR F-03 TSB Revision...
Page 947 EXTERIOR ELECTRIC REMOTE CONTROLLED MIRROR CIRCUIT DIAGRAM IGNITION C-82 REMOTE D-43 ‘1'8 REMOTE TROUBLESHOOTING HINTS OPERATION Neither right nor left mirror operates When the remote controlled mirror switch is operated while the ignition key is in “ACC” or 1) Also cigarette lighter does not operate “ON”...
Page 948 EXTERIOR SERVICE ADJUSTMENT PROCEDURES INSPECTION OF ACTIVE AERO SYSTEM 1. INSPECTION BY WARNING LIGHT Turn the ignition switch from “OFF” to “ON” to see if the warning light is lit for approx. three seconds and then goes out. If not, replace the control unit. NOTE which is designed as follows: Turn the ignition switch from “OFF”...
Page 949: Front Bumper
EXTERIOR FRONT BUMPER REMOVAL AND INSTALLATION OF CLIP WITH Grommet SCREW Normally, remove the clip with a Phillips screwdriver. If, however, there is enough space to insert a screwdriver or the like behind the clip, use the following procedure for ease of work.
Page 950 EXTERIOR REMOVAL ,AND INSTALLATION <Vehicles with active aero system> <Vehicles without active aero system> Removal steps 1. Front under cover side panel (Vehicles without 2. Front under cover center panel active aero system) 11. Optical horn lens 12. Clips with screw 3.
Page 951 EXTERIOR DISASSEMBLY AND REASSEMBLY Bumper face disassembly steps Bumper reinforcement disassembly steps 1. Bumper face side plate 9. Fog light bracket corner 2. Bumper face plate * IO. Bumper absorber 3. Bumper face upper front plate 11. Bumper reinforcement stay 4.
Page 952: Rear Bumper
EXTERIOR REAR BUMPER Grommet REMOVAL AND INSTALLATION OF CLIP WITH SCREW Normally, remove the clip with a Phillips screwdriver. If, however, there is enough space to insert a screwdriver or the like behind the clip, use the following procedure for ease of work.
Page 953 EXTERIOR DISASSEMBLY AND REASSEMBLY Bumper face assembly disassembly steps 2. License plate light bracket 3. Bumper muffler plate 4. Bumper face Bumper reinforcement assembly disassembly steps 5. Rear bumper harness 6. Bumper absorber 7. Bumper reinforcement SERVICE POINT OF DISASSEMBLY 6.
Page 954 EXTERIOR - Garnishes and Mouldings GARNISHES AND MOULDINGS REMOVAL AND INSTALLATION Windshield moulding removal steps Front deck garnish removal steps 3. Drip moulding 1. Wiper arm assembly 5. Windshield moulding (Refer to 2. Front deck garnish GROUP 42 -Windshield.) Drip moulding and center pillar garnish removal steps (Refer to GROUP 42 - 6.
Page 955 EXTERIOR - Garnishes and Mouldings SERVICE POINT OF REMOVAL 8. REMOVAL OF SIDE GARNISH (1) Remove the side garnish mounting nuts. (2) Affix protective tape to the periphery of the side garnish. Protective tape (3) Insert a fishing line [@0.8 mm (03 in.)] between the body and the side garnish and grip each end of the fishing line.
Page 956 EXTERIOR - Garnishes and Mouldings (7) Wipe off application surface of body with clean cloth dampened with degreaser (3M ATD Part No. 8906 or equivalent). NOTE After wiping surface, leave surface as it is to volatilize degreaser. SERVICE POINT OF INSTALLATION 8.
Page 957 EXTERIOR - Garnishes and Mouldings Installation of Side Garnish (1) Remove strip paper from the pressure sensitive double- sided tape. NOTE Affix adhesive tape to the end of strip paper for ease of strip paper removal. (2) With its clips and bolts aligned with the respective holes in the body, install the side garnish to the body.
Page 958: Aero Parts
EXTERIOR - Aero Parts AERO PARTS REMOVAL AND INSTALLATION Side air dam removal steps Front splash shield (Refer to GROUP 42 - Fender.) Quarter trim (Refer to GROUP 52A-Trims.) * ** 1. Side air dam Rear spoiler removal steps Trims.) 2.
Page 959 51-21 EXTERIOR - Aero Parts <Vehicles with active aero system> Side air dam removal steps Front splash shield (Refer to GROUP 42 - Fender.) 1. Side airdam Rear spoiler removal steps (Refer to GROUP 52A-Trims.) 2. Rear spoiler assembly 4. High mounted stop light Front under cover panel, air dam link assembly Active aero switch removal steps removal steps...
Page 960 51-22 EXTERIOR - Aero Parts SERVICE POINT OF REMOVAL 1. REMOVAL OF SIDE AIR DAM Remove the side air dam by the same procedure as the side ‘ I J garnish. (Refer to P.51-17.) INSPECTION 1. INSPECTION OF REAR SPOILER MOTOR AND LIMIT SWITCH (1) Connect the battery as shown in the illustration to make sure that the motor and spoiler operate freely.
Page 961 EXTERIOR - Aero Parts 3. INSPECTION OF ACTIVE AERO SWITCH Operate the switch to check the continuity between the terminals. (Automatic reset type) NOTE SERVICE POINTS OF INSTALLATION 11. INSTALLATION OF AIR DAM LINK ASSEMBLY Install the air dam link assembly in the operative condition for ease of front under cover panel.
Page 962 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER TROUBLESHOOTING GUIDE INPUT CHECK Using the multi-use tester or voltmeter, check whether or not the input signals from each switch are being input to the ETACS unit. (1) Connect the multi-use tester to the diagnosis check connector located at the right side of the junction block or connect the voltmeter between the ETACS terminal and block...
Page 963 51-25 INTERMITTENT WIPERS Problem Probable cause(s) Checking procedure Remedy The wipers don’t operate when Damage or disconnection If a malfunction is discov- Repair the wiring har- the wiper switch is set to the of the wiring of the wiper ered as a result of the ness, or replace the “INT”...
Page 964 MIST WIPERS/WASHER-INTERLOCKED WIPERS Problem Probable cause(s) Checking procedure Remedy Repair the wiring har- The wipers do not function when Damage or disconnection If a malfunction is discov- the washer switch is switched ON of the wiring of the ered as a result of the ness, or replace the for 0.6 second or longer.
Page 965 EXTERIOR CHECKING INDIVIDUAL PART AND CIRCUIT 1. IGNITION SWITCH INPUT CIRCUIT Battery Junction block Jumper connector “2: Vehicles with theft-alarm system Operation Description As the condition for operation of the system, HIGH-level signals are sent to the electronic control unit when “ACC”...
Page 966 51-28 EXTERIOR 2. WIPER SWITCH ‘ANT” INPUT CIRCUIT ETACS unrt Operation Description When the wiper switch is set to the “INT” position, LOW-level signals are input to the electronic control unit; the intermittent time interval detection circuit is then activated, and the wipers operate at the intermittent time interval according to the setting of the intermittent variable volume switch.
Page 967 51-29 EXTERIOR - Windshield Wiper and Washer 3. INTERMITTENT VARIABLE VOLUME SWITCH INPUT CIRCUIT ETACS unit (ECU) “2: Vehicles with theft-alarm system Operation Description This circuit functions to input (to the intermittent time interval detection circuit of the electronic control unit) the set value of the intermittent variable volume switch.
Page 968 E X T E R I O R 4. WIPER RELAY ACTIVATION CIRCUIT Junction block Column switch ETACS untt A *’ Wiper motor Operation Description W ith the wiper switch at the “INT” position, switch ON the transistor (by the intermittent activation from the electronic control unit) in order to activate the wiper relay.
Page 969 EXTERIOR 5. WASHER SWITCH INPUT CIRCUIT Junction block Column switch ETACS unit (ECU) “2: Vehicles with theft-alarm system Operation Description While the washer switch is ON, HIGH-level signals are sent to the washer switch ON-time detection circuit simultaneous with the activation of the washer motor, thus causing the transistor to be switched ON and the wipers to be activated for a certain fixed time.
Page 970 EXTERIOR - Windshield Wiper and Washer MOVAL AND INSTALLATION 3. Front deck garnish 4. Air inlet garnish (RH) 5. Hole cover 6. Wiper motor 7. Linkage Removal steps of washer tank 8. Battery Removal steps of wiper motor 9. Battery tray 1.
Page 971 51-33 EXTERIOR SERVICE POINT OF REMOVAL 6. REMOVAL OF WIPER MOTOR (2) Using a plain screwdriver, detach the crank arm of the wiper motor from the linkage to remove the wiper motor. Caution Do not remove the crank arm from the wiper motor except when necessary, as the auto stop angle has been preset.
Page 972 51-34 EXTERIOR Inspection of Wiper Relay (Built-in Column Switch) Connector B (1) Check to ensure that there is continuity between terminals there is no continuity between terminals @ and @. and the negative terminal to terminal @ to check that the battery voltage is available at terminal @.
Page 973: Rear Wiper And Washer
51-35 EXTERIOR - Rear Wber and Washer REAR WIPER AND WASHER REMOVAL AND INSTALLATION Removal steps of washer tube Removal steps of wiper motor Front pillar trim (RH) 1. Wiper blade 2. Wiper arm Quarter trim (RH) Quarter upper trim (RH) 3.
Page 974 51-36 EXTERIOR SERVICE POINT OF REMOVAL 8. REMOVAL OF LIFTGATE MOULDING, UPPER Using a special tool, pry the clip portion to remove the upper liftgate moulding. INSPECTION WIPER MOTOR Check the wiper motor with it mounted on the vehicle and with its harness connector disconnected.
Page 975 51-37 EXTERIOR INTERMITTENT WIPER RELAY (1) Remove the quarter trim. (Refer to GROUP 52A - Trims.) (2) With the intermittent wiper relay connected to the wiring harness connector, let the wiper operate intermittently and check the voltage at terminal 0. WASHER MOTOR (1) When the washer motor is inspected, make sure that it is mounted on the washer tank and that the washer tank is...
Page 976 51-38 EXTERIOR DOOR MIRROR REMOVAL AND INSTALLATION Door mirror removal steps 2. Harness connector 3. Mirror Electric remote controlled mirror switch removal 4. Instrument panel switch 5. Electric remote controlled mirror switch SERVICE POINTS OF REMOVAL 1. REMOVAL OF DOOR MIRROR Tilt the door mirror backward and forward to remove the attaching bolts.
Page 977 51-39 EXTERIOR - Door Mirror INSPECTION <Vehicles witpout heater> DOOR MIRROR table when each terminal is connected to the battery. (2) Check to see that there is continuity between terminals 1 and 5. RIGHT LEFT NOTE O-O indicates that each terminal is connected to the battery ELECTRIC REMOTE CONTROL MIRROR SWITCH Operate switches and check for continuity between terminals.
Page 979 CONTENTS FLOOR CONSOLE* ____.._..__._..._.._..._..11 REAR SEAT . .._._____..______..____.._.._._..___.._._____..___..FRONT SEAT* ......... 18 SEAT BELT* .
Page 980 INTERIOR ‘OWER SEAT CIRCUIT DIAGRAM FUSIB E IGNI' LINK C-82...
Page 981 INTERIOR POWER WINDOWS RELAY SWITCH D-21 ----- SIDE LUMBAR S U P P O R T SUPPORT MOTOR MOTOR IQ 2 1 ROWER SEAT ASSEMBLY C-82 5 f 1 9 C-78...
Page 982 INTERIOR TENSION-REDUCER TYPE SEAT BELT CIRCUIT DIAGRAM FUSIBLE LiNK@ C-68 C-Slm 3 F-19 $6 FRONT SEAT E-26 FRONT SEAT E-20 BELT SOLENOID E-14 - - - - - - - - - - - - - - - C-65 SELF-DIAGNOSIS m CHECK CONNECTORa DOOR SWITCH TSB Revision...
Page 983 INTERIOR - Troubleshootinn OPERATION TROUBLESHOOTING HINTS If the driver fastens the seat belt with the The seat belt solenoid does not function ignition switch placed in the “ON” position, the seat belt switch in the seat belt buckle is turned Check the ETACS unit.
Page 984 INTERIOR BUZZER D-43 9 r - - - - COMBINATION METER D-05 BUZZER I----- DIODE E-2112 ETACS UNIT DOOR c-79 'THEFT-ALARM SYSTEM TSB Revision...
Page 985 INTERIOR OPERATION TROUBLESHOOTING HINTS Key-reminder warning Key-reminder warning The key-reminder warning doesn’t sound. fusible link No. 6 to the key-reminder switch. When the driver’s seat is opened while the Check the door switch. ignition key is still in the key cylinder, the door switch is switched ON, electricity flows to Check the buzzer.
Page 986 INTERIOR - Instrument Panel For installation of the instrument panel, the bolts and screws described below are used. They are indicated by symbols in the illustration. 4 x 16 (.I6 x .63) 5 x 16 (.20 x .63) 4 x 12 (.I6 x .47) 6 x 16 (.24 x .63) 6 x 25 (.24 x .98) NOTE...
Page 987 INTERIOR REMOVAL AND INSTALLATION Removal and Installation of Floor Console (Refer to P.52A-11.) Removal steps 1. Hood lock release handle 2. Rheostat 3. Switch garnish B 4. Knee protector assembly 5. Column cover 6. Glove box striker 7. Glove box and cross pipe cover 8.
Page 988 INTERIOR 8. REMOVAL OF CENTER AIR OUTLET ASSEMBLY Disengaging the clips of the center air outlet assembly with a flat tip (-1 screwdriver, remove the center air outlet assembly with the trim stick. screwdriver REMOVAL OF SPEEDOMETER CABLE ADAPTER (MECHANICAL TYPE SPEEDOMETER) of the cable.
Page 989 INTERIOR - Floor Console FLOOR CONSOLE REMOVAL AND INSTALLATION Removal steps 1. Cup holder 2. Console plug 3. Rear console assembly 4. Radio panel 5. Radio 6. Switch garnish C 7. Console side cover 8. Front console garnish 9. Manual transaxle shift lever knob DISASSEMBLY AND REASSEMBLY Front console disassembly steps 2.
Page 990 INTERIOR TRIMS Trim TRIM CLIP REMOVAL/INSTALLATION PROCE- DURES The type of clip shown in the illustration, which is used for the installation of instrument panel, should be removed and installed by the following procedures described below. REMOVAL in.) (1) Use a cross-tip (+) screwdriver to push inward the pin (at the center of the trim clip) to a depth of about 2 mm (.08 in.).
Page 991 INTERIOR <Interior> c - c Scuff plate Front piiar trim Rear roof rail trim removal steps Cowl side trim removal steps 8. Screw 1. Scuff plate 2. Cowl side trim Front pillar trim removal steps 4. Hanger bracket 5. Sash guide cover mounting bolt 6.
Page 992 INTERIOR Scuff plate Quarter trim removal steps 19. Rear seat belt anchor plate mounting bolt 12. Shelf cover assembly Screw 13. Shelf catcher 21. Quarter trim 14. Cover 22. Rear side trim (Refer to P.52A-15.) 15. Garnish 23. Quarter trim bracket 16.
Page 993 INTERIOR SERVICE POINT OF INSTALLATION INSTALLATION OF REAR SEAT back positively. cushion. in the floor positively. <Luggage compartment> B - B Rear end trim Rear side trim, rear end trim removal steps Luggage compartment light connector con- nection 2. Luggage compartment floor box (L.H.) 10.
Page 994 INTERIOR Clip D - D 1. Shelf hook 2. Liftgate lower trim 3. Liftgate upper trim 4. Liftgate side trim NOTE (1) @...
Page 995 INTERIOR - Headlining HEADLINING Removal and Installation of Rear Roof Rail Trim (Refer to P52A-13.) Removal and lnstallatron of Front Removal steps 1. Hanger bracket 2. Sash guide cover mounting bolt 3. Clip 4. Passenger compartment temperature sensor (Vehicles with full automatic air conditioner) 5.
Page 996: Front Seat
INTERIOR - Front Seat FRONT SEAT REMOVAL AND INSTALLATION <Sporty type> Front seat removal steps 2. Seat anchor covers 3. Seat mounting nut 4. Seat mounting bolt 5. Harness connector 6. Front seat assembly Power seat switch removal steps 7. Front console assembly (Refer to...
Page 997 INTERIOR - Front Seat INSPECTION POWER SEAT SWITCH A INSPECTION Operate the power seat switch A to check for continuity. Lumbar support Side support PUSH (A, SPREAD (4D) RELEASE(O) CLOSE (D 4) NOTE O-O indicates that there is continuity between the terminals. SERVICE POINTS OF INSTALLATION 6.
Page 998 INTERIOR 2. INSTALLATION OF SEAT ANCHOR COVERS (1) Install the forward tab of the front seat anchor cover to the front seat forward mounting bracket positively. Then rotate the cover in the drrection of arrow to install d ont seat forward the side tabs in the side holes of the bracket.
Page 999 INTERIOR DRIVER SEAT <Standard seat> <Sporty seat> FRONTPASSENGER SEAT Removal steps 2. Plug 3. Cap 4. Height adiuster lever I v~““~‘” L switch B 6. Adjuster cover 7. Side shield cover (L.H.) 8. Side shield cover (R.H.) 9. Inner seat belt 12.
Page 1000 INTERIOR INSPECTION INSPECTION OF POWER SEAT SWITCH B Operate the power seat switch B to check for continuity. , NOTE O-O indicates that there continuity between the terminals INSPECTION OF FRONT HEIGHT MOTOR AND REAR HEIGHT MOTOR (2) Connect the battery directly to the terminal of the motor and check to see that the power seat adjuster rotates smoothly until it strikes the limit switch.
Page 1001 INTERIOR - Front Seat continuity between terminals. Highest Medium Lowest NOTE O-O indicates that there is continurty between the terminals, with the selector gear. SERVICE POINT OF REASSEMBLY 9. INSTALLATION OF INNER SEAT BELT (1) Route the seat belt switch connector harness on the adjuster bracket.
Page 1002: Rear Seat
INTERIOR - Rear Seat REAR SEAT REMOVAL AND INSTALLATION Rear seat removal steps * I)* 1. Rear seat cushion 2. Rear seat back Striker removal steps 3. Quarter trim (Refer to P.52A-14.) 4. Striker SERVICE POINT OF REMOVAL 1. REMOVAL OF REAR SEAT CUSHION With the lever pulled, raise the seat cushion, and remove the seat cushion.
Page 1003: Seat Belt
INTERIOR - Seat Belt SEAT BELT TROUBLESHOOTING GUIDE INPUT CHECK Using the multi-use tester or voltmeter, check whether or not the input signals from each switch are being input to the ETACS unit. (1) Connect the multi-use tester to the diagnosis check connector located at the right side of the junction block or Diagnosis connector”...
Page 1004 INTERIOR - Seat Belt Problem Probable cause Check method Remedy The warning light flashes, but Damaged or discon- Repair the wiring Check by following in- the warning buzzer does not dividual part and the harness, sound. seat belt warning circuit check No. 2 buzzer activation procedures (P.52A-28).
Page 1005 INTERIOR - Seat Belt CHECKING INDIVIDUAL PART AND CIRCUIT IGNITION SWITCH INPUT CIRCUIT Battery Fusible link Junction block Description of operation A condition for operation of this system is the sending of HIGH-level signals to the electronic control unit when the ignition switch is switched to the “ON” position. Electronic control unit terminal voltage (Disconnect the connector of the electronic control unit and check the wiring harness side.) Condition...
Page 1006 INTERIOR - Seat Belt 2. SEAT BELT WARNING LIGHT AND BUZZER ACTIVATION CIRCUIT Fusible link @ ETACS unit (ECU) Description of operation Place the ignition switch in the ON position, and the transistor will be turned on, blinking the warning light and sounding the buzzer four times.
Page 1007 INTERIOR - Seat Belt REMOVAL AND INSTALLATION <Front Seat Belt> Outer seat belt removal steps 1. Quarter trim (Refer to P.52A-14 + 2. Outer seat belt Inner seat belt removal steps Floor console assembly (Refer to P.52A-11 .I 3. Shield cover a 4.
Page 1008 INTERIOR - Seat Belt INSPECTION BUCKLE SWITCH (1) Disconnect the buckle switch connector. (2) Check the continuity between the terminals. Terminal Buckle unlock Buckle lock NOTE O-O indicates that there is continuity between the terminals. BUZZER Check that buzzer sounds when battery voltage is applied to the buzzer terminal.
Page 1009 INTERIOR - Seat Belt (3) Insert the pawl of the belt guide in the hole provided on the body. TSB Revision...
Page 1011 RESTRAINT SYSTEM (SRS) CONTENTS INDIVIDUAL COMPONENT GENERAL INFORMATION ........ SERVICE ...._........ 56 Component Location ........AIR BAG MODULE AND CLOCK Construction Diagram ........S P R I N G ._..._......._.._....Introduction ............
Page 1012 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General information GENERAL INFORMATION INTRODUCTION The Supplemental Restraint System (SRS) is de- under the steering column. signed to supplement the driver’s seat belt to help The SRS is designed so that the air bag will deploy reduce the risk or severity of injury to the driver by when the safing sensor, plus either or both of the activating and deploying a driver’s-side air bag in...
Page 1013 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General information Right front Impact sensor Left front impact sensor SRS diagnosis unit (Incorporated safing impact sensor) ‘EHICLE ‘LATE module NOTE This construction diagram displays the general view of the SRS components. For details, refer to “SRS Schematic” (P.52B-6). “Configuration Diagrams” (P.52B-7) and “SRS Circuit Diagram”(P.52B-11). TSB Revision...
Page 1014 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General lnform=*ion WARNING/CAUTION LABELS A number of caution labels relating to the SRS are SRS. found in the vehicle, as shown in the following If labels are dirty or damaged, replace them with illustration. Follow label instructions when servicing new ones.
Page 1015 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General lnform=*ion Driver’s air bag information WARNING: SRS This vehicle ha% an air bag which will supple- This air bag module cannot be repaired. Do not ment the driver’s seatbelt in certain frontal disassemble or tamper. collisions.
Page 1016 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General Information STARTER RELAY IGNITION SWITCH <ST> IGNITION SWITCH <IGI> Multi -purpose fuses Connector lock switch - - - - Warning light malfunction Crank signal detection circuit detection circuit Connector lock detection circuit Safing impact sensor Multi-use Tester...
Page 1017 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General Information Engine compartment A-38 Engine and transaxle (Front view) B-23 Starter motor B-26 Inhibitor switch...
Page 1018 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General Information C-57 Clock spring C-59 Ignition switch C-79 Self-diagnosis check connector (For Multi-use Tester) D-03 D-04 Combination meter D-05 D-23 to body wiring harness D-26 D-24 Z-pin blue connector to Connector to right front impact sensor SRS Diagnosis D-25 Unit...
Page 1019 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General Information SRS CONNECTOR CONSTRUCTION The connector of the SRS diagnosis unit has a double lock mechanism, fit verification mechanism and connector shorting mechanism. DOUBLE LOCK MECHANISM The double lock mechanism comprises a mechanism for locking the connector of the SRS diagnosis unit and the connector of the harness, and a mechanism for locking the locked connectors by the lock secondary lever mounted to the...
Page 1020 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General Information FIT VERIFICATION MECHANISM Secondary The mechanism electrically verifies that the connectors of the lock lever SRS diagnosis unit have been fitted. The operating principle is described below. connectors and press the secondary lock lever down to lock the connectors.
Page 1021 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General information SRS CIRCUIT DIAGRAM IGNITION SWITCH(IG1) COMBINATION METER WITHOUT INHIBITOR MICROCOMPUTER SELF-DIAGNOSIS CHECK CONNECTOR TSB Revision...
Page 1022 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General Information CAUTION not repair, splice or modify SRS wiring (except for specific repairs to the body wiring harness shown on replace wiring if necessary, after reading and following all precautions and procedures in this manual. not use an analogue ohmmeter to check SRS wiring or components;...
Page 1023 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - General Information COMPONENT LOCATION TSB Revision...
Page 1024 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - SRS Service Precautions SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others from Never Attempt to Repair the Following Com- ponents: accidental deployment of the air bag during SRS servicing, read and carefully follow all the pre- Front Impact Sensors cautions and procedures described in this manu- SRS Diagnosis Unit (SDU)
Page 1025 SRS Service Precautions / SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Z-pin blue connector to right front impact sensor Z-pin yellow connector to left front impact sen to clock spring View A To front impact sensor (L.H.) To front impact sensor (R.H.) To body wiring harness (14-pin) To clock spring SRS diagnosis unit and air bag module and clock spring before drying or baking the vehicle after painting.

Mitsubishi 3000GT 1991 Service Manual

General

Emission

Clutch

P R O P E L L E R ~ Shaft

Rear Axle

Wheel. and Tire

Front Suspension

Electronic Control Suspension (Ecs)

Table of Contents

Table of Contents

Table of Contents

Quick Links

Chapters

Troubleshooting

Related Manuals for Mitsubishi 3000GT 1991

Summary of Contents for Mitsubishi 3000GT 1991

Table of Contents