Mitsubishi Delica User Manual

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Users manual: Mitsubishi

Delica SpaceGear

Dr D John Pons

The following data have

been collected from

various sources,

including verbal

discussions and

opinions of others. The

author makes no claim

for the accuracy of the

data nor accepts any

liability in connection

with their use. Most of

the data are for the

1997 2.8 turbo diesel

model.

This manual may be freely reproduced.

Contact me at

rhino@pons.ws

to provide feedback, corrections, and any additional information.

Edition E12 December 2005

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Summary of Contents for Mitsubishi Delica

Page 1 Users manual: Mitsubishi Delica SpaceGear Dr D John Pons The following data have been collected from various sources, including verbal discussions and opinions of others. The author makes no claim for the accuracy of the data nor accepts any liability in connection with their use.
Page 2 0 Vehicle details Useful details when you buy spare parts Year Configuration Registration number Engine type Engine number Model Chassis number Transaxle number Color int opt...
Page 3 1 Getting started This is a quick driving tutorial. Driving the Delica Gearbox must be in park mode (P). Turn ignition key until instrument lights are illuminated (see Figure 1). Wait until glow plug light (see Figure 1) is extinguished. This usually happens very fast, or even instantly if the engine is already warm.
Page 4 2 Instruments and gears This section describes the main driver controls. Instrument panel Delica 1997 Figure 1 Instrument panel See Figure 1 for the layout. Gearbox: Shows gear position for automatic gearbox. Also an ‘O/D off’ indicator if overdrive has been deselected by the driver.
Page 5 <unknown> Glow plug status (coil symbol)- usually on momentarily when ignition is energised. Wait for this light to extinguish before turning the engine. Engine revolutions per minute (revs). The information is of no real value if you have an automatic gearbox and mainly use drive (D). But if you are heavily laden, then it’s useful to check that the revs are not too low - low revs under high load will generate more heat in the gearbox.
Page 6 The driver has to manually engage and disengage four wheel drive (4WD) using the "Super Select" selection lever. This is typical of a full 4WD vehicle, and gives the Delica full 4WD capability (the same capability as the Mitsubishi Pajero for...
Page 7 By comparison some other vehicles (e.g. Mitsubishi RVR SportsGear) have permanently engaged 4WD over which the driver has no control. For driving in town and on sealed roads (bitumen or concrete), two wheel drive is adequate. The 4WD selection lever is floor mounted, see Figure 2.
Page 8 Stop completely before engaging or disengaging this gear. Same warning applies as for 4HLc, i.e don’t use on high-grip surfaces. The low range ‘L’ always has locked central differential ‘Lc’. You can’t have low range on its own with the Mitsubishi design. Additional controls 2.3.1 Door controls Controls located on the driver’s door are shown in Figure 3.
Page 9 driver height. 2.3.3 Windscreen wiper controls The controls are shown in Figure 5. Rear wiper - twist anticlockwise to activate. Water squirt at the end of the range in both directions. Water fill bottle is at left rear of vehicle, see Figure 6. Front wipers - rotate downwards to Figure 5: Windscreen wiper controls...
Page 10 3 Solving simple problems Changing a wheel The spare wheel is underneath at the rear. The tools are inside at the rear right, see Figure 7. Figure 7: Jack and tools for changing tyre. Extra socket for 12 V power also visible (round black cap) - takes cigarette lighter type fitting.
Page 11 Once the bolt has been unscrewed sufficiently, it lowers the cage holding the spare wheel. The spare wheel can now be removed, see Figure 9. Figure 9: Releasing the spare wheel. Slide it out backwards. Remove the plastic wheel cap (if fitted) with the tool provided, or a flat screwdriver, see Figure 10.
Page 12 Delica, and only for high-top models from 1996 onwards. (A similar part, 425, is for a low top Delica). Available in NZ from Hampco for NZ$430 for a set (4 feet plus two bars). In Australia the price is AU$250.
Page 13 Tow-bar Tow bars are readily available for the Delica. However, the factory rear chrome bars usually have to be taken off. The standard electrical wiring in Australia and New Zealand is a 7-pin flat plug. The wiring of the pins is shown in Figure 12.
Page 14 The Delica is unusual in having the engine at the front, whereas other coaches (e.g. Toyota) tend to have it under the driver seat. The Delica layout is a consequence of the design philosophy that adopts the Pajero layout. As a result, the bonnet for the Delica engine bay is short, and the firewall...
Page 15 Hose and clamp for compressed air flowing from turbo-charger through inter- cooler, and into engine. Intercooler - cools down hot air ex turbo-charger. Fill cap for power steering. Battery terminal. There are two Figure 15: Left side of engine bay. batteries in parallel in this model.
Page 16 This section is a basic introduction for new users. Delica manoeuvrability For town driving, the Delica behaves much as a normal sedan. It's light to steer (requires no special physical strength) due to the power steering. The engine is powerful so it accelerates reasonably well.
Page 17 Figures 16-19. Roll-over Stability The Delica, like any full 4WD, has a greater risk of rolling sideways than a sedan. This is because the centre of gravity is higher though the width is comparable. In normal town driving there are few, if any, circumstances where the slope of the land is so steep that the vehicle can roll when stationary.
Page 18 6 Off-road Many if not most Delica owners are families who expect to do only minor off-road activities. Consequently they are at risk of being under-prepared and inexperienced when they do occasionally venture off-road. This section provides basic guidance to reduce this risk.
Page 19 Also, reduce tyre pressure - this gives a bigger ground footprint, hence lower pressure on the soft surface. A pressure of 140 - 70 kPa (1.4 - 0.7 bar or 20-10 psi) has been reported as fine for Delica in soft sand [7]. Generally inner tubes would be recommended at these low pressures.
Page 20 Use 4H Drive a straight course [18] In general, deflate the tyres to 140 kPa (20 psi) [20]. For Delica the range seems to be 140 - 70 kPa (1.4 - 0.7 bar or 20-10 psi) [7] Drive straight up slopes (not along the contour)
Page 21 4WD, or driving uphill or towing then the chains should go on the driving wheels, which for Delica are the rear [25]. (For front-wheel drive cars, the chains should always go on the front wheels, as this is where the propulsion and the steering takes place.)
Page 22 Towing ropes/straps should be firmly attached, preferably with a shackle. Spectators should stand well aside in case the rope breaks or the mounting points pull out. Do not tow using the factory fitted chrome bars, as these can rip off [12].
Page 23 7 Service Service intervals Service 5 000 20 000 40 000 100 000 Comment Change engine oil and Filter RZ372 and 6.5 litre of oil 15W40 oil filter CF/B2-96 or better Fuel tank - drain 2 at change of ownership litres and check amount of dirt Check brake pads...
Page 24 Purchasers of a used vehicle might consider doing all the items in the 40 000 km column and before, as the previous owner might not have done them. Changing engine oil The best thing you can do to prolong the life of your diesel engine is to replace the engine oil frequently.
Page 25 Oil filter and sump drain plug should now be visible, see Figure 25. Undo sump drain plug with 17 mm socket and collect oil in container. Replace sump drain plug. Loosen oil filter, using oil filter wrench if necessary. Place a pan underneath as some oil will spill out.
Page 26 How to do it: Open the engine compartment and find the housing for the air filter. Release the four clamps, Figure 27. Lift out the old air filter. Remove any loose dust, insects, or plant fragments from the housing. Inspect it. You do not need to automatically replace it. To make a decision, look at the colour difference between inside and outside.
Page 27 You will need: Socket or spanner 10mm, 12mm, 14mm Screwdrivers Gloves (recommended) And remember this: only turn the engine crankshaft clockwise, the natural direction of rotation, to prevent any risk of the timing chain tensioner becoming misaligned. How to do it: Remove intercooler (see above).
Page 28 very cramped in there! Tension fan belt by prising alternator outwards again, then tighten (clockwise) the hex screws in the reverse order. Tension values in Section 8. See Figure 30. Replace air conditioner belt, tension at ‘second loosen’ in Figure 29, then lock into position a ‘first loosen’.
Page 29 Loosen the screw in the usual anti- clockwise direction. This screw is very tight (e.g. 200 Nm). There are several options for doing this: (a) purchase the special tool from Mitsubishi, (b) make up your own tool with two dowels (or bolts) of D8-D10mm protruding about...
Page 30 or more times around the pulley - it will self lock and grip the pulley, see Figure 33 for application to the tightening stage. Remove the pulley - it slides off in the forward direction. Check that shaft and keys are still fine. (10) Fit new pulley - align with key and slide on.
Page 31 These data are from various sources: information provided from discussion with those in the trade, feedback from other Delica owners, and comments on the internet. In some cases the various sources differ, and I leave it to the reader to decide which values to use.
Page 32 'S' oils. The second letter (A, B, C...) gives the performance of the oil, the further into the alphabet the better. Example: an oil like 'CH-4/SJ' is suitable in a diesel engine like Delica, and is superior to a 'CF' oil. The '4' denotes a high performance oil suitable for clean burning engines that use high compression ratios and exhaust gas re-circulation: these oils have more detergents and additives to cope with the additional combustion by-products that get into the oil.
Page 33 2 x 12V in parallel 64 Ahr Starting current 173-211 A Cold cranking amps (CCA) unknown capacity recommended by Mitsubishi Candidate battery ‘Exide’ N70ZZ or N70EX (see below) [30] Number of batteries required One or two. Probably two if used in cold...
Page 34 Delica 1.4, 1.6, 1.8, 79-95 N310P E360DP 2.0 - Petrol Delica 2.3, 2.4 diesel 89-95 N50Z GS3478N NS70 NS70EX Delica 2.5, 2.8 - Diesel 82-95 N70ZZ N70EX Delica Space Gear N70ZZ N70EX Data for particular Exide batteries [31]: Exide Code N70ZZ N70EX...
Page 35 Transfer case 75W85 or 75W90 grade GL4 [1] Oil Grade Capacity 2.5-3.7 litre [1] Comments Remove plug in oil pan to drain [3]. Fill to ‘Full’ mark on dipstick. No adjustment required. Front differential Oil Grade 80W90 grade GL5 [1] Capacity 1.2 litre Comments...
Page 36 Suspension and brakes Brakes Discs at front, drum at rear Type Replace disc pads when only 2 mm lining left Replacement Bleeding sequence RR, LF, RF [1] 20.4 mm [1] or 22.4 mm front and 16.4 mm Disc thickness - minimum rear [2] Brake fluid replacement 50 000 km [1] or 24 months [4]...
Page 37 Front 180 kPa, Rear 200 kPa Inflation Pressure laden Front 210 kPa, Rear 240 kPa Lowest permissible unknown, maybe 70-100 kPa? pressure (e.g. on sand) Overall dimensions of Delica [16] Total length (mm) 4685 Full-width (mm) 1695 Total height (mm)
Page 38 9 Fault diagnosis Diagnosing Delica vehicle problems can be difficult since the vehicles are imported outside of Mitsubishi dealer networks, and workshop manuals are difficult to obtain. This section provides some basic help. Starting faults Will not start battery flat - recharge...
Page 39 Rubber hose failed Rubber hose perished (e.g. by solvent or time) Rubber hose ruptured Rubber hose rubbed through (check fan cowl on Delica) Hose clamp failed or loose Cylinder head gasket failed (e.g. partially) extreme operating conditions...
Page 40 hot weather heavy load or steep terrain handbrake on Cylinder head gasket failed engine oil failure lack of oil Damaged sump drain plug absent oil pump failure Automatic Gearbox overheats too high a gear for terrain or load (try switching overdrive off) lack of automatic transmission fluid Noises Engine squeal, only when accelerating: fan belt or air conditioner belt too lose,...
Page 41 (NOx) and thus reducing smog. Figure 35: Location of EGR value on Delica (circled). If the valve has to be blanked off, do so by inserting a plate at the arrow point. 10.2...
Page 42 engine. The inert gas (exhaust) has of course been generated by the engine. The Engine responds to inert gas. Oxygen concentration is decreased by addition of inert gas, resulting in lower combustion temperature, and thus less NOx. The accompanying IDEF0 diagram shows how the system works.
Page 44 10.3 Operating modes for the EGR system There are three operating modes for the EGR system as a whole. These are listed below with some of the failure causes. If the EGR valve is not working as expected, then the first solution is to try and clean it. The list below gives other possible causes if this does not work.
Page 45 A simple set of test of voltage outputs across various terminals will determine whether the control unit is working. However they are not practical to describe here and require the Mitsubishi manual. The EGR control unit senses engine speed, accelerator position, and engine temperature. Therefore a faulty sensor in any of these locations could also affect EGR operation.
Page 46 (several mm would be necessary). Aluminium, tin can, plastic, silicone or gasket materials would be inappropriate. Mitsubishi recommend replacing rather than disabling the EGR valve, for both technical and environmental reasons.
Page 47 If the EGR system fails in the shut position, or is actively disabled by blanking it off, then near-normal engine performance is restored, although there is the risk, presumably slight, of deceasing engine life. Mitsubishi recommend replacing rather than disabling a faulty EGR valve. In some countries it...
Page 48 2003, Offroad essentials, http://www.delicaclub.com/viewtopic.php?t=174 beyondallken, 2004, 2.8 Turbo Diesel - Users manual and Technical data, http://www.delicaclub.com/viewtopic.php?t=311 deandownunder2, 2003, Delica - Mitsubishi Recalls, http://www.delicaclub.com/viewtopic.php?t=28&highlight=recall Babel Fish, http://world.altavista.com/ (To translate Japanese web pages to English) Spec Album, 1994, Delica Space Gear, http://babelfish.altavista.com/babelfish/urltrurl?lp=ja_en&url=http%3A%2F%2Fsirius.mitsubishi...

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