Mitsubishi MOTORS CARISMA 1996 Service Bulletin
  1. Manuals
  2. Brands
  3. Mitsubishi MOTORS Manuals
  4. Automobile
  5. CARISMA 1996
  6. Service bulletin
Mitsubishi MOTORS CARISMA 1996 Service Bulletin

Mitsubishi MOTORS CARISMA 1996 Service Bulletin

Hide thumbs
Table of Contents

Advertisement

Quick Links

ww W r s o M
SERVICE BULLETIN
SERVICE BULLETIN
Subject:
OMISSION OF TIGHTENING TORQUE OF A/C
COMPRESSOR TENSION PULLEY FIXING
BOLT
ENGINE
Group:
Correction
1. Description:
This Service Bulletin informs you that omission has been rectified of the tightening torque of
A/C compressor tension pully fixing bolt under Service DRIVE BELT TENSION CHECK AND
ADJUSTMENT in Group 11A of the Workshop Manual.
2. Applicable Manual:
Manual
'96 CARISMA Workshop Manual
Chassis
3. Details:
Please refer to the attached page(s).
SERVICE GROUP, WARRANTY & SERVICE DEP.
No.: ESB-96E11-502
Date
Pub. No.
PWDE9502
PWDS9503
PWDF9504
PWDG9505
PWDD9506
PWDW9507
PWDI96E1
Purchased from www.WorkshopManuals.co.uk
u s o.uk
MITSUBISHI MOTOR SALES EUROPE BV
1997-03-31
:
CARISMA
O. Kai - E.V.P.
After Sales Service
Language
(English) 11A-7
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(Italian)
<Model>
<M/Y>
96-10
Page(s)

Advertisement

Table of Contents
loading

Related Manuals for Mitsubishi MOTORS CARISMA 1996

Summary of Contents for Mitsubishi MOTORS CARISMA 1996

  • Page 1 ww W r s o M u s o.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-96E11-502 Date 1997-03-31 <Model> <M/Y> Subject: OMISSION OF TIGHTENING TORQUE OF A/C CARISMA 96-10 COMPRESSOR TENSION PULLEY FIXING BOLT ENGINE Group:...
  • Page 2 www.WorkshopManuals.co.uk 11A-7 4G9 ENGINE - On vehicle Service 4. Tighten the lock bolt. Tightening torque: 23 Nm 5. Tighten the nut of the alternator pivot bolt. Tightening torque: 44 Nm 6. Tighten the adjusting bolt. Tightening torque: 6 Nm POWER STEERING OIL PUMP AND AIR CONDITIONER <Vehicles without A/C>...
  • Page 3 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV NO.: ESB-96E13-501 SER VI CE BULLET I N DATE: 1996-05-15 <M/Y> <MODEL> (EC,EXP)CARISMA 96-00 SUBJECT: CORRECTION OF FUEL GAUGE UNIT INSTALLATION PROCEDURE GROUP: FUEL INFORMATION: O. Kai -E.V.P. After Sales Service Description This Service Bulletin informs you that the installation procedure for the fuel gauge...
  • Page 4 www.WorkshopManuals.co.uk 13F-3 FUEL SUPPLY - Fuel Tank 13500190046 FUEL TANK REMOVAL AND INSTALLATION Pre-removal Operation Post-Installation Operation Draining the Fuel Installation of Exhaust Pipe (Refer to GROUP 15.) Reduce the Inner Pressure of Fuel Line and Hose Refilling the Fuel (Refer to GROUP 13A - On-vehicle Service.) Checking for Fuel Leaks Removal of the Centre Exhaust Pipe...
  • Page 5 www.WorkshopManuals.co.uk 13F-5 FUEL SUPPLY - Fuel Tank (5) Check to be sure that the fuel tank packing is not damaged (Not good) or deformed, and then securely install the packing. NOTE If the packing is damaged or deformed, replace with new packing.
  • Page 6 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-96E13-506 Date 1997-02-28 <Model> <M/Y> CORRECTION TO PROCEDURE FOR CARISMA 97-10 Subject: EVACUATION OF WATER FROM THE FUEL FILTER Group: FUEL Correction O. Kai - E.V.P. After Sales Service 1.
  • Page 7 www.WorkshopManuals.co.uk 13E-61 DIESEL FUEL - On-vehicle Service EVACUATION OF WATER FROM FUEL FILTER Evacuate water by the following procedures. 1. Remove the air cleaner assembly 2. Remove the fuel filter cap. 3. Use a manual pump to remove any water, and then attach the fuel filter cap.
  • Page 8 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-96E35-001 Date 1997-02-28 <Model> <M/Y> Subject: FRONT BRAKE DISASSEMBLY AND CARISMA 96-10 REASSEMBLY PROCEDURES SERVICE BRAKE Group: Correction O. Kai - E.V.P. After Sales Service 1.
  • Page 9 www.WorkshopManuals.co.uk 35A-11 BASIC BRAKE SYSTEMS - On vehicle Service FRONT DISC BRAKE PAD CHECK AND When new When worn 35100150044 REPLACEMENT NOTE The brake pads have wear indicators that contact the brake disc when the brake pad thickness becomes 2 mm and emit a squealing sound to warn the driver.
  • Page 10 www.WorkshopManuals.co.uk 35A-21 BASIC BRAKE SYSTEMS - Front Disc Brake 2. After installing the caliper support to the knuckle, install the pad clips and the pads to the caliper support. Caution • Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake disc.
  • Page 11 www.WorkshopManuals.co.uk 35A-21A BASIC BRAKE SYSTEM - Front Disc Brake DISASSEMBLY AND REASSEMBLY 14U0109 Brake caliper piston Brake caliper kit Brake pad kit seal kit Grease 14U0111 14U0108 14U0110 Caliper assembly disassembly Pad assembly disassembly steps steps 1. Bolt 1. Bolt 2.
  • Page 12 www.WorkshopManuals.co.uk 35A-21B BASIC BRAKE SYSTEMS - Front Disc Brake LUBRICATION POINTS 14U0102 Grease: Repair kit grease 14U0108 14U0103 Grease : Repair kit grease DISASSEMBLY SERVICE POINTS When disassembling the front disc brakes, disassemble both sides (left and right) as a set. APISTON /PISTON BOOT REMOVAL Protect caliper body with cloth.
  • Page 13 www.WorkshopManuals.co.uk 35A-21C BASIC BRAKE SYSTEM - Front Disc Brake BPISTON SEAL REMOVAL (1) Remove piston seal with finger tip. Caution Do not use a flat-tipped screwdriver or other tool to prevent damage to inner cylinder. (2) Clean piston surface and inner cylinder with trichloroethylene, alcohol or specified brake fluid.
  • Page 14 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV NO.: ESB-96E37-002 SER VI CE BULLET I N <M/Y> DATE: 1996-07-30 <MODEL> CARISMA 96-10 SUBJECT: CHANGE OF POWER STEERING RETURN HOSE AND BOLT TIGHTENING TORQUES GROUP: STEERING INFORMATION: O.
  • Page 15 www.WorkshopManuals.co.uk 37A-20 STEERING - Power Steering Hoses POWER STEERING HOSES 37200570069 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation • • Power Steering Fluid Supplying (Refer to P.37A-8.) Power Steering Fluid Draining (Refer to P.37A-8.) • Power Steering Fluid Line Bleeding (Refer to P.37A-8.) <Old>...
  • Page 16 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 17 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 18 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 19 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV NO.: ESB-96E52-001 SER VI CE BULLET I N <M/Y> DATE: 1996-05-15 <MODEL> (EC,EXP)CARISMA 96-00 SUBJECT: ESTABLISHMENT OF REAR SEATBACK COVER REPLACEMENT PROCEDURE GROUP: INTERIOR INFORMATION: O. Kai -E.V.P. After Sales Service Description This Service Bulletin informs you that the rear seatback cover replacement procedure...
  • Page 20 www.WorkshopManuals.co.uk 52A-13 INTERIOR - Seat REAR SEAT 52200180036 REMOVAL AND INSTALLATION Removal steps 1. Headrestraint 4. Rear seatback assembly 2. Seat cushion 5. Headrestraint guide 3. Side seatback assembly 6. Rear seat striker • REMOVAL SERVICE POINTS REAR SEATBACK COVER REMOVAL (1) Remove the trim clips from the back (7 places) and both Fastener sides (4 places) of the rear seatback cover.
  • Page 21 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 22 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 23 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 24 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-96E54-502 Date 1997-03-31 <Model> <M/Y> ADDITION OF CONTINUITY CHECKING CARISMA 96-10 Subject: PROCEDURE FOR SPEEDOMETER REED SWITCH CHASSIS ELECTRICAL Group: Correction O. Kai - E.V.P. After Sales Service 1.
  • Page 25 www.WorkshopManuals.co.uk 54-25 CHASSIS ELECTRICAL - Combination Meters <Added> REED SWITCH CONTINUITY CHECK Using a circuit tester, check that continuity and discontinuity alternates between terminals 1 and 2 four times at every rotation of the shaft of the speedometer cable connection. A16U0180 INSPECTION 54300300019...
  • Page 26 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB- 96E55-502 Date 1997-02-28 <Model> <M/Y> ADDITION TO AIR PURIFIER TROUBLE- CARISMA 96-10 Subject: SHOOTING SECTION Group: HEATER, A/C & VENTILATION Correction O. Kai - E.V.P. After Sales Service 1.
  • Page 27 www.WorkshopManuals.co.uk 55-49 Heater, air conditioner and ventilation <fully automatic air conditioner> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Troubles Symptom Inspection Reference procedure No. Page Communication with the Communication with all systems is not possible 55-50 MUT-II is not possible Communication with A/C system only is not possible 55-50 Blowing of air does not stop even if blower switch is OFF.
  • Page 28 www.WorkshopManuals.co.uk 55-59 Heater, air conditioner and ventilation <fully automatic air conditioner> - Troubleshooting Inspection procedure 14 Air purifier does not operate Probable cause • The air purifier operates when the ignition switch is at the ON position and the blower Malfunction of ionizer •...
  • Page 29 www.WorkshopManuals.co.uk 55-59-1 Heater, air conditioner and ventilation <fully automatic air conditioner> - Troubleshooting Inspection procedure 16 Air purifier indicator lamp (A/P) flashes. Probable cause (Incorrect output voltages at collector and ionizer sections) • The air purifier indicator lamp (A/P) flashes if the air purifier’s collector and ionizer are Abnormal discharge condition is excessively contaminated or an abnormal current flows to the air purifier.
  • Page 30 www.WorkshopManuals.co.uk 55-59-2 Heater, air conditioner and ventilation <fully automatic air conditioner> - Troubleshooting Inspection procedure 18 Intermittent or continuous sparking sounds Probable cause • Leaks due to water on the collector and ionizer sections or faulty transformer unit are Water on collector and ionizer sections •...
  • Page 31 www.WorkshopManuals.co.uk 55-60 Heater, air conditioner and ventilation <fully automatic air conditioner> - Troubleshooting Inspection procedure 16 19 <CHANGED> A/C compressor (magnetic clutch) circuit inspection Compressor magnetic clutch inspection Refrigerant temperature switch (Refer to P.55-31.) inspection (Refer to P.55-35.) Replace Check the following connector. A-81 Repair Replace the A/C compressor.
  • Page 32 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E00-502 Date 1997-01-15 <Model> <M/Y> CORRECTION TO TIGHTENING TORQUE ECLIPSE (D30) 96-10 Subject: INDICATION CARISMA 96-10 Group: GENERAL Information O. Kai - E.V.P. After Sales Service 1.
  • Page 33 www.WorkshopManuals.co.uk 00-2 GENERAL - How to Use This Manual HOW TO USE THIS MANUAL 00100010081 value to which the part or assembly is corrected and SCOPE OF MAINTENANCE, REPAIR AND adjusted. It is given by tolerance. SERVICING EXPLANATIONS This manual provides explanations, etc. concerning LIMIT procedures for the inspection, maintenance, repair and Shows the standard for judging the quality of a part or...
  • Page 34 www.WorkshopManuals.co.uk 00-2 GENERAL - How to Use This Manual HOW TO USE THIS MANUAL 00100010159 SCOPE OF MAINTENANCE, REPAIR AND value to which the part or assembly is corrected and adjusted. It is given by tolerance. SERVICING EXPLANATIONS This manual provides explanations, etc. concerning LIMIT procedures for the inspection, maintenance, repair and Shows the standard for judging the quality of a part or...
  • Page 35 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E11-503 Date 1997-11-24 <Model> <M/Y> CORRECTING VALVE CLEARANCE & (EC,EXP) 97-10 Subject: INJECTION TIMING INSPECTION & CARISMA ADJUSTMENT PROCEDURE ENGINE Group: CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 36 www.WorkshopManuals.co.uk 11B-6 F8QT ENGINE - Special Tools Tool Number Name Engine lifter Supporting the engine assembly during GENERAL removal and installation of the transmission SERVICE TOOL MZ203827 MMZ203827Z MB996030 Measuring device Adjustment of injection timing adapter MB996030 MB996036 Hexagon socket MB996037 Sprocket adapter MB996037...
  • Page 37 www.WorkshopManuals.co.uk 11B-8 F8QT ENGINE - On vehicle Service VALVE CLEARANCE CHECK AND ADJUSTMENT 1. The valve clearances have to be checked/adjusted in the following sequence: Cylinder at point of Cylinder being balance checked/adjusted Cylinder being Cylinder at point checked/adjusted of balance REN0027 2.
  • Page 38 www.WorkshopManuals.co.uk 11B-9 F8QT ENGINE - On vehicle Service 8. Use a small screwdriver to remove the tappet pad. 9. Select tappet pads which will bring the valve clearance to the standard value. Standard value (cold engine): Intake valve: 0.20 mm Exhaust valve: 0.40 mm Example If the measured valve clearance is 0.25 mm and the...
  • Page 39 www.WorkshopManuals.co.uk 11B-10 F8QT ENGINE - On vehicle Service INJECTION TIMING CHECK AND ADJUSTMENT 1. Turn the cranckshaft clockwise to set the No.1 cylinder to top dead compression centre. 2. Turn the crankshaft 1 ¾ revolutions in its normal direction of rotation 3.
  • Page 40 www.WorkshopManuals.co.uk 11B-11 F8QT ENGINE - On vehicle Service 10. Locate special tool (sprocket stopper) between the pump bracket and the sprocket. Secure the tool with the bolt supplied with the set. 11. Insert special tool (hexagon socket) in the screwed sleeve and nut assembly.
  • Page 41 www.WorkshopManuals.co.uk 11B-12 F8QT ENGINE - On vehicle Service 22. Turn the crackshaft 1¾ revolutions further, locate the clock gauge and make sure that the plunger is pressed in at least 0.2 mm. 23. Check the injection timing. 24. Remove special tool together with the clock gauge and measuring pin.
  • Page 42 www.WorkshopManuals.co.uk INJECTION TIMING CHECK AND AJUSTMENT INJECTION TIMING CHECK 1. Turn the crankschaft clockwise so that the piston of No.1 cylinder (flywheel end) is at TDC, with the following marks in line with each other: • flywheel/clutch housing • timing belt cover/camshaft sprocket 2.
  • Page 43 www.WorkshopManuals.co.uk INJECTION TIMING ADJUSTMENT 1. Turn the crankshaft clockwise so that the piston of No. 1 cylinder (flywheel end) is at TDC, with the following marks in line with each other: • flywheel/clutch housing • timing belt cover/camshaft sprocket REN0148 2.
  • Page 44 www.WorkshopManuals.co.uk 8. Turn the crankshaft (clockwise) 1¾ revolutions. 9. Remove the plug A. 10. Fit measuring device adaptor MB996030: • Locate the guide bush B in the pump. • Slide the measuring pin C, which is part of the measuring tool, into the guideway of the pump. •...
  • Page 45 www.WorkshopManuals.co.uk 17. Turn the crankshaft 1¾ revolutions clockwise. 18. Position the clock gauge and make sure that the plunger is pressed in at least 0.2 mm. Secure the clock gauge and set it at zero. 19. Turn the crankshaft exactly to TDC (clockwise). to achieve this: •...
  • Page 46 www.WorkshopManuals.co.uk 11A-19-3 F8QT ENGINE - Fuel Injection Pump FUEL INJECTION TIMING CHECK MEASURING TOOL INSTALLATION (1) Turn the crankshaft clockwise so that the piston of No. 1 cylinder (flywheel end) is at TDC, with the following marks in line with each other: •...
  • Page 47 www.WorkshopManuals.co.uk 11A-19-5 F8QT ENGINE - Fuel Injection Pump (5) Turn the crankshaft (clockwise) 1¾ revolutions (6) Remove the plug A. (7) Fit the measuring device adaptor MB996030. • Locate the guide bush B in the pump. • Slide the measuring pin C, which is part of the measuring tool, into the guideway of the pump.
  • Page 48 www.WorkshopManuals.co.uk 11A-19-6 F8QT ENGINE - Fuel Injection Pump (11) Locate sprocket stopper MB996043 Fix the bracket with the two bolts supplied with the set. Secure the bracket with bolt F so that it is free from play. Caution The Pump sprocket must not be displaced (the pointer of the micrometer must not move).
  • Page 49 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E13-002 Date 1998-02-28 <Model> <M/Y> Subject: CORRECTION TO ENGINE CONTROL SYSTEM (EC,EXP) 97-10 DESCRIPTIONS CARISMA FUEL Group: INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 50 www.WorkshopManuals.co.uk 13J-3 GDI - General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control condenser fan are controlled in response to Turn the fuel pump relay ON so that current the engine coolant temperature and vehicle is supplied to the fuel pump while the speed.
  • Page 51 www.WorkshopManuals.co.uk 13J-5 GDI - General Information GASOLINE DIRECT INJECTION SYSTEM DIAGRAM ♦ 1 Oxygen (O ) sensor Injector driver (injector) Engine-ECU ♦ 2 Air flow sensor ISC servo ♦ 3 Intake air temperaturesensor EGR control servo (stepper motor) ♦ 4 Throttle position sensor Purge control solenoid valve ♦...
  • Page 52 www.WorkshopManuals.co.uk 13J-9 GDI - Troubleshooting Engine warning lamp Inspection Items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Camshaft position sensor barometric pressure sensor Detonation sensor Injector Abnormal combustion Immobilizer system fuel pressure sensor Excessive intake air amount...
  • Page 53 www.WorkshopManuals.co.uk 13J-11 GDI - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor system 13J - 12 Air flow sensor system 13J - 13 Intake air temperature sensor system 13J - 14 Throttle position sensor system 13J - 15 Engine coolant temperature sensor system 13J - 16...
  • Page 54 www.WorkshopManuals.co.uk 13J-28 GDI - Troubleshooting Code No.66 Brake vacuum sensor system Probable cause • Range of check Malfunction of the brake vacuum sensor • • Ignition switch: ON Improper connector contact, open circuit or short-circuited Set conditions harness wire of the brake vacuum sensor •...
  • Page 55 www.WorkshopManuals.co.uk 13J-37 GDI - Troubleshooting From previous page MUT-II Data list Check the ignition switch-ST and Inhibitor switch system 29 Inhibitor switch (Refer to P.13J-63) (Refer to P.13J-51, INSPECTION PROCEDURE 24.) MUT-II Data list Check the M/T oil temperature sensor system. 48 M/T oil temperature sensor (Refer to P.13J-64.) (Refer to P.13J-59, INSPECTION PROCEDURE 33.) MUT-II Data list...
  • Page 56 www.WorkshopManuals.co.uk 13J-41 GDI - Troubleshooting From previous page MUT-II Data list Check the power steering pressure switch 27 Power steering fluid pressure switch (Refer to P.13J-63) (Refer to P.13J-58, INSPECTION PROCEDURE 31.) MUT-II Data list Check the A/C switch. 28 A/C switch (Refer to P.13J-63.) (Refer to P.13J-58, INSPECTION PROCEDURE 32.) MUT-II Data list Check the ignition switch-ST and inhibitor switch system.
  • Page 57 www.WorkshopManuals.co.uk 13J-60 GDI - Troubleshooting INSPECTION PROCEDURE 35 Small lamp <Correct> <Incorrect> Electrical load switch Probable cause • Improper connector contract, open circuit or During Idling, the ON/OFF condition of switches in equipment which have short-circuited harness wire in the taillamp relay a large electrical load is input to the engine ECU.
  • Page 58 www.WorkshopManuals.co.uk 13J-63 GDI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page • Engine: Cranking Crank angle Compare the engine Accord Code No. 22 13J-17 • Tachometer: sensor speed readings on the tachometer and the Connected MUT-II •...
  • Page 59 www.WorkshopManuals.co.uk 13J-63A GDI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Air flow engine is idling Code No. 12 13J-13 Engine: After having sensor reset warmed up 3,000 r/min signal • Engine coolant Volumetric Engine is idling 15 - 35% efficiency temperature: 80-...
  • Page 60 www.WorkshopManuals.co.uk 13J-69 GDI - Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Engine warning lamp Ignition switch: OFF 0 - 0.1 V System voltage (after several seconds have passed) Steering wheel: Neutral position System voltage Power steering fluid pressure switch Steering wheel: Turned 0 -0.1 V...
  • Page 61 www.WorkshopManuals.co.uk 13J-86 GDI - On-vehicle Service BASIC IDLE SPEED ADJUSTMENT NOTE (1) The standard idling speed has been adjusted by the speed adjusting screw (SAS by the manufacturer, and there should usually be no need for readjustment. (2) If the adjustment has been changed by mistake, the idle speed may become too high or the idle speed may drop too low when loads from components such as the A/C are placed on the engine.
  • Page 62 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E13-501 Date 1997-XX-XX <Model> <M/Y> Subject: CHANGES IN VEHICLE SPEED SENSOR AND (EC, EXP) 97-10 IN ENGINE-ECU TERMINAL VOLTAGE CARISMA FUEL Group: CORRECTION O.
  • Page 63 www.WorkshopManuals.co.uk 13E-51 DIESEL FUEL - Troubleshooting Engine-ECU Connector Terminal Arrangement RFU0003 Caution Do not measure the terminal voltages of the needle lift sensor and crank angle sensor, as this may cause damage to the engine-ECU. NOTE : Varies depending on the engine coolant temperature and altitude when the engine is started. Terminal Check item Check condition (Engine condition)
  • Page 64 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E13-506 Date <Model> <M/Y> 1998-03-31 Subject: CORRECTION TO TIGHTENING TORQUES OF (EC,EXP) 97-10 FUEL TANK BAND NUTS CARISMA Group: FUEL CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 65 www.WorkshopManuals.co.uk 13F-2 FUEL SUPPLY - Fuel Tank FUEL TANK 13500010038 GENERAL INFORMATION (1) The fuel tank is located under the floor of the (3) A plastic fuel tank has been adopted to rear seats to provide increased safety and a reduce wider luggage space.
  • Page 66 www.WorkshopManuals.co.uk 13F-3 FUEL SUPPLY - Fuel Tank FUEL TANK REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation (1) Installation of Exhaust Pipe (Refer to GROUP 15.) (1) Draining the Fuel (2) Refilling the Fuel (2) Reduce the Inner Pressure of Fuel Line and Hose (3) Checking for Fuel Leaks (Refer to GROUP 13A - On-vehicle Service.) (3) Removal of the Center Exhaust Pipe...
  • Page 67 www.WorkshopManuals.co.uk 13F-1 FUEL SUPPLY - General/Fuel Tank GROUP 13F FUEL SUPPLY GENERAL OUTLINE OF CHANGES • The following service procedures have been added to the addition of the diesel-powered vehicle. Applicable models: 1900D 1. Removal and installation of the fuel tank 2.
  • Page 68 www.WorkshopManuals.co.uk 13F-2 FUEL SUPPLY - Fuel Tank FUEL TANK REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation (1) Installation of Exhaust Pipe (1) Draining the Fuel (2) Refilling the Fuel (2) Removal of the Centre Exhaust Pipe (3) Checking for Fuel Leaks <Added>...
  • Page 69 www.WorkshopManuals.co.uk 13F-1 FUEL SUPPLY - General/Fuel Tank GROUP 13F FUEL SUPPLY GENERAL OUTLINE OF CHANGES • Maintenance service procedures have been 1. Removal and installation of the fuel tank 2. Removal and installation of the fuel filler established for items which are different form before correspond following...
  • Page 70 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E17-001 Date 1997-09-26 <Model> <M/Y> Subject: CHANGE IN ERASURE OF CRUISE CONTROL (EC,EXP) 96-10 SYSTEM DIAGNOSTIC TROUBLE CODES CARISMA ENGINE AND EMISSION CONTROL Group: CORRECTION O.
  • Page 71 www.WorkshopManuals.co.uk 3. Interchangeability: : Can be installed. New ECU Old ECU New car : Can be installed if car has a battery back-up wire Old car added on the chassis side harness. • Differentiation between old and new ECU’s The part numbers of the cruise control ECU’s are the same for the old and new ECU’s. Differentiation between the old and new ECU’s should be made by reading the label affixed to an ECU.
  • Page 72 www.WorkshopManuals.co.uk 1-36 ENGINE - Auto-cruise Control System AUTO-CRUISE CONTROL UNIT The control unit consists of the input interface It processes them according to the program in circuit, microprocessor, constant voltage power the microprocessor memory and outputs control supply circuit, microprocessor monitor circuit and signals to the actuator.
  • Page 73 www.WorkshopManuals.co.uk 1-39 ENGINE - Auto-cruise Control System How to erase displayed diagnosis code The diagnosis code is held until the battery power simple operation of the control switch, even is shut off. However, it can also be erased with without disconnecting the battery. <Changed>...
  • Page 74 www.WorkshopManuals.co.uk 17-6 ENGINE AND EMISSION CONTROL - Auto-cruise Control System TROUBLESHOOTING 17200070042 STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION METHOD OF READING THE DIAGNOSIS CODES Auto-cruise control main switch 1.
  • Page 75 www.WorkshopManuals.co.uk 17-11 ENGINE AND EMISSION CONTROL - Auto-cruise Control System Trouble symptom Inspection Reference procedure No. page Auto-cruise control is Even if brake pedal is depressed 17-14 not cancelled Even if clutch pedal is depressed 17-15 Even if select lever is set to N range <A/T> 17-15 Even if CANCEL switch is set to ON 17-16...
  • Page 76 www.WorkshopManuals.co.uk 17-16 ENGINE AND EMISSION CONTROL - Auto-cruise Control System Inspection Procedure 7 Even if auto-cruise control CANCEL switch is set to ON, Probable cause auto-cruise control is not cancelled. The cause is probably an open-circuit in the circuit inside the CANCEL switch. • Malfunction of the auto-cruise control-ECU Replace the auto-cruise control switch Inspection Procedure 8...
  • Page 77 www.WorkshopManuals.co.uk 17-17 ENGINE AND EMISSION CONTROL - Auto-cruise Control System Inspection Procedure 9 Auto-cruise control cannot be set Probable cause • The cause is probably that the fail-safe function is cancelling auto-cruise control. In this Malfunction of the auto-cruise control main switch •...
  • Page 78 www.WorkshopManuals.co.uk 17-21 ENGINE AND EMISSION CONTROL - Auto-cruise Control System CHECK AT THE ECU TERMINALS 03U0031 Terminal Check item Check conditions Normal condition Throttle When accelerator pedal is fully depressed 4.5-5.5V position sen- when accelerator pedal is released 0.3-1.0V sor input Idle switch When accelerator pedal is When idle switch is OFF...
  • Page 79 www.WorkshopManuals.co.uk 4-180 CIRCUIT DIAGRAM AUTO-CRUISE CONTROL SYSTEM ALTERNATOR/ LIGHTING FUSIBLE LINK SWITCH TAIL LAMP RELAY IGNITION SWITCH (IG2) WHITOUT WITH DEDICATED DEDICATED FUSE • FUSE CONDITIONER • COOLING SYSTEM • CLOCK • FULL-AUTO AIR CONDITIONER • TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER AUTO-CRUISE...
  • Page 80 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E22-502 Date 1999-07-15 <Model> <M/Y> Subject: CORRECTION TO TRANSMISSION GEAR (EC, EXP) 96-10 RATIOS AND TO TIGHTENING TORQUES CARISMA Group: MANUAL TRANSAXLE CORRECTION O.
  • Page 81 www.WorkshopManuals.co.uk 22A-1-1 MANUAL TRANSMISSION (E-W) – Specifications 1. SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Model F5MR1, F5MR2 F5MR3 Type Manual, 5-speed, front Manual, 5-speed, front wheel drive wheel drive <Correct> Gear ratio 3.363 3.727 2.047 <Incorrect> 2.074 2.047 1.321 <Correct> 1.321 0.966 <Incorrect>...
  • Page 82 www.WorkshopManuals.co.uk 22A-3-1 MANUAL TRANSMISSION (E-W) - Transmission 3. TRANSMISSION DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2> <Correct> 4     2.25 Nm <Incorrect> Lubricate all internal parts with gear oil during reassembly. <Incorrect> <Correct> 43434 22 Nm Disassembly steps ! ! ! ! "...
  • Page 83 www.WorkshopManuals.co.uk 22A-3-2A MANUAL TRANSMISSION (E-W) – Specifications DISASSEMBLY AND REASSEMBLY <F5MR3> Lubricate all internal parts with gear oil during reassembly. <Correct> 2.25 Nm <Incorrect> <Incorrect> 22 Nm <Correct> RMT0002 Disassembly steps ! ! ! ! " " " " " " " " ! ! ! ! ! ! ! ! "...
  • Page 84 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E22-503 Date 1997-12-05 <Model> <M/Y> Subject: CORRECTION TO GEAR RATIO AND FINAL (EC,EXP) 96-10 REDUCTION RATIO FOR MANUAL CARISMA TRANSMISSION Group: MANUAL TRANSMISSION CORRECTION O.
  • Page 85 www.WorkshopManuals.co.uk 22-2 MANUAL TRANSMISSION - General Information/Lubricants GENERAL INFORMATION 22100010038 The F5MR1 and F5MR2 manual transmissions are designed. Items Specifications Model F5MR1, F5MR2 Type Manual, 5-speed, Front wheel drive Gear ratio 3.363 2.047 2.074 <Incorrect> <Correct> 1.321 0.966 0.967 <Incorrect> <Correct>...
  • Page 86 www.WorkshopManuals.co.uk 22-1 MANUAL TRANSMISSION - General/General Information GROUP 22 MANUAL TRANSMISSION GENERAL OUTLINE OF CHANGES The 4G92 engine equipped cars that have engine output of 73 kW (100 PS) have been added. Accordingly, the F5MR1 manual transmission has been changed from the conventional one in 2nd speed gear ratio and final reduction ratio.
  • Page 87 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E22-504 Date 1997-12-05 <Model> <M/Y> Subject: CORRECTION TO TIGHTENING TORQUES (EC,EXP) 96-10 FOR FILLER AND DRAIN PLUGS CARISMA MANUAL TRANSMISSION Group: CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 88 www.WorkshopManuals.co.uk 22-4 MANUAL TRANSMISSION - On-vehicle Service 22100090049 ON VEHICLE SERVICE TRANSMISSION OIL LEVEL CHECK Transmission Inspect each component for evidence of leakage, and check the oil level by remaining the filler plug. If the oil is Filler plug contaminated, it is necessary to replace it with new oil. 1.
  • Page 89 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E35-006 Date 1998-03-15 <Model> <M/Y> Subject: CHANGE IN LIMIT VALUE FOR FRONT BRAKE (EC,EXP)CARISMA 96-10 DISC RUN-OUT SERVICE BRAKE Group: INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 90 www.WorkshopManuals.co.uk 35A-4 BASIC BRAKE SYSTEMS - General Information/Service Specifications Construction diagram Brake booster Master cylinder Front brake Rear brake Brake pedal A14U0009 SERVICE SPECIFICATIONS 35100030058 Items Standard value Limit Brake pedal height mm L.H. drive vehicles 163.5-166.5 R.H. drive vehicles 162.5-165.5 Brake pedal free play mm Brake pedal to floor board clearance mm...
  • Page 91 www.WorkshopManuals.co.uk 35A-12 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE DISC THICKNESS CHECK 35100160047 1. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and mm in from the outer edge of the disc. Brake disc thickness Standard value: <1600>...
  • Page 92 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E37-501 Date 1997-09-26 <Model> <M/Y> Subject: POWER STEERING OIL PUMP PRESSURE (EC,EXP) 97-10 TEST NEEDED BY AVAILABILITY OF SPECIAL CARISMA TOOLS Group: STEERING CORRECTION O.
  • Page 93 www.WorkshopManuals.co.uk 37A-1 STEERING - General/Power Steering Oil Pump GROUP 37A STEERING GENERAL OUTLINE OF CHANGES • The following service procedures have been added to the addition of the diesel-powered vehicle. Applicable models: 1900D 1. Removal and installation of the power steering oil pump 2.
  • Page 94 www.WorkshopManuals.co.uk OIL PUMP PRESSURE TEST Pressure 1. Put a piece o paper over the alternator to protect it Shut-off gauge valve against the power steering fluid. (MB990662) 2. Disconnect the pressure hose from the oil pump, and Temperature gauge then connect the special tools. Reservoir 3.
  • Page 95 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E51-501 Date 1998-03-15 <Model> <M/Y> Subject: CENTER CONSOLE PANEL AND CUP HOLDER (EC,EXP) 96-10 REMOVAL CARISMA INTERIOR Group: CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 96 www.WorkshopManuals.co.uk 52A-7 INTERIOR - Floor Console REMOVAL SERVICE POINTS CENTER CONSOLE PANEL AND CUP HOLDER ASSEMBLY REMOVAL 1. After removing the center console mounting screws, pull the center console panel towards you to remove it Screw together with the cup holder, inner driver 2.
  • Page 97 www.WorkshopManuals.co.uk SERVICE BULLETIN SERVICE GROUP, WARRANTY & SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-96E52-002 Date <Model> <M/Y> 1997-04-15 Subject: 96-10 ADDITION OF SRS AIR BAG MAINTENANCE ECLIPSE(D30) PROCEDURE CARISMA 96-10 Group: INTERIOR INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 98 www.WorkshopManuals.co.uk 52B-7 SRS - Troubleshooting Code No. Diagnosis item Reference page SRS-ECU non-volatile memory (EEPROM) and A/D converter system 52B-13 51,52 Driver’s side air bag module (squib ignition drive circuit) system 52B-14 54,55 Passenger’s side air bag module (squib ignition drive circuit) system 52B-14 56,57 Driver’s side pre-tensioner (squib ignition drive circuit) system...
  • Page 99 www.WorkshopManuals.co.uk 52B-9 SRS - Troubleshooting Code No. 21, 22, 61 or 62 Driver’s air bag module (squib) system probable cause • These diagnosis codes are output if there is abnormal resistance between the input terminals of the driver’s Malfunction of clock spring •...
  • Page 100 www.WorkshopManuals.co.uk SERVICE BULLETIN PRODUCTION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E52-502 Date 1997-09-26 <Model> <M/Y> Subject: CORRECTION TO CAUTION ON AIR BAG (EC,EXP) ECLIPSE 96-10 MODULE AND CLOCK SPRING (D30) SUPPLEMENTAL RESTRAIN (EC,EXP) L2000 96-10 Group: (K60, K70)
  • Page 101 www.WorkshopManuals.co.uk 52B-22 SRS - SRS-ECU/Air Bag Modules and Clock Spring 52400220031 INSPECTION • Check the SRS-ECU and brackets for dents, cracks or deformation. • Check connectors and lock lever for damage, and terminals for deformation Caution If a dent, crack, deformation or rust is discovered, replace the SRS-ECU with a new one.
  • Page 102 www.WorkshopManuals.co.uk 52B-24 SRS - Air Bag Modules and Clock Spring AIR BAG MODULES AND CLOCK SPRING 52400230010 Caution 1. Disconnect the negative battery cable from 4. The air bag modules should be stored on a the battery and tape the terminal flat surface and placed so that the pad surface is facing upward.
  • Page 103 www.WorkshopManuals.co.uk 52B-28 SRS - SRS Diagnosis Unit (SDU)/Air Bag Modules and Clock Spring 52400220093 INSPECTION • Check the SDU and brackets for dents, cracks or deformation. • Check connector for damage, and terminals for deformation Caution If a dent, crack, deformation or rust is discovered, replace the SDU with a new one.
  • Page 104 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E54-503 Date 1997-09-26 <Model> <M/Y> CLOCK REMOVAL AND INSTALLATION (EC,EXP) 97-10 Subject: CARISMA Group: CHASSIS ELECTRICAL CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 105 www.WorkshopManuals.co.uk 54-46 CHASSIS ELECTRICAL - Cigarette Lighter/Clock 54300570038 INSPECTION • Take out the plug, and check for a worn edge on the Element Spot element spot connection, and for shreds of tobacco or other material on the element. • Using a circuit tester, check the continuity of the element. CAUTIONS FOR USE OF THE CIGARETTE LIGHTER SOCKET AS AUXILIARY POWER SOURCE 1.
  • Page 106 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E55-002 Date <Model> <M/Y> 1998-03-15 Subject: CHANGE IN AIR GAP FOR A/C COMPRESSOR (EC,EXP) ECLIPSE 96-10 (D30) 96-10 Group: (EC,EXP) HEATER, A/C & VENTILATION CARISMA INFORMATION O.
  • Page 107 HEATER, AIR CONDITIONER AND www.WorkshopManuals.co.uk 55-4 VENTILATION <MANUAL AIR CONDITIONERS> - General Information/Service Specifications Caution When metering R-134a into the refrigeration Do not heat R-134a above 40°C system keep the supply tank or cans in an upright position. If the refrigerant containers on its side or upside down, liquid refrigerant will enter the In most instances, moderate heat is required to system and damage the compressor.
  • Page 108 HEATER, AIR CONDITIONER AND www.WorkshopManuals.co.uk 55-34 VENTILATION <MANUAL AIR CONDITIONERS> - Compressor and Tension Pulley Clutch coil C CLUTCH COIL INSTALLATION projection When installing the clutch coil to the A/C compressor body, install so that the pin hole of the A/C compressor body and the clutch coil projection are aligned.
  • Page 109 HEATER, AIR CONDITIONER AND www.WorkshopManuals.co.uk 55-4 VENTILATION - Service Specifications/Lubricants 55200030103 SERVICE SPECIFICATIONS Items Standard value Idle speed r/min 850 ± 50 Idle-up speed r/min 850 in Neutral Resistor (for blower motor) Ω 1.83 0.87 0.31 Refrigerant temperature switch ON (continuity) temperature Approx.
  • Page 110 HEATER, AIR CONDITIONER www.WorkshopManuals.co.uk 55-34 AND VENTILATION - Compressor and Tension Pulley Clutch coil C CLUTCH COIL INSTALLATION projection When installing the clutch coil to the A/C compressor body, install so that the pin hole of the A/C compressor body and the clutch coil projection are aligned.
  • Page 111 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-97E55-003 Date 1998-XX-XX <Model> <M/Y> CORRECTION TO AIR CONDITIONER (EC,EXP) 96-10 Subject: PERFORMANCE TEST PROCEDURE CARISMA Group: HEATER, A/C & VENTILATION INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 112 HEATER, AIR CONDITIONER AND www.WorkshopManuals.co.uk 55-16 VENTILATION <MANUAL AIR CONDITIONERS> - On-vehicle Service 55200140042 PERFORMANCE TEST High pressure valve Low pressure valve 1. The vehicles to be tested should be in a place that is not in direct sunlight. 2. Close the high and low pressure valve of the gauge manifold.
  • Page 113 HEATER, AIR CONDITIONER AND www.WorkshopManuals.co.uk 55-17 VENTILATION <MANUAL AIR CONDITIONERS> - On-vehicle Service Performance Temperature Chart <Incorrect> Garage ambient temperature °C Discharge air temperature °C 2.5 - 4.5 2.5 - 4.5 4.0 - 6.5 6.5 - 9.0 Compressor high pressure kPa 765 - 960 765 - 960 1,325 - 1,420 1,570 - 1,765...
  • Page 114 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E00-014 Date <Model> <M/Y> 30-09-1999 Subject: CHANGE IN TIGHTENING TORQUE FOR (EC,EXP) 96-10 TENSIONER PULLEY MOUNTING NUT CARISMA Group: GENERAL CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 115 www.WorkshopManuals.co.uk 11A-7 4G9 ENGINE – On vehicle Service 4. Tighten the lock bolt. Tighten torque: 23 Nm 5. Tighten the nut of the alternator privot bolt Tighten torque: 44 Nm 6. Tighten the adjusting bolt Tighten torque: 6 Nm POWER STEERING OIL PUMO AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100130035...
  • Page 116 HEATER, AIR CONDITIONER AND www.WorkshopManuals.co.uk 55-29 VENTILATION <MANUAL AIR CONDITIONER> - Compressor and Tension Pulley COMPRESSOR AND TENSION PULLEY 55200410068 REMOVAL AND INSTALLATION Pre removal Operation Post-installation Operation • • Discharging of Refrigerant (Refer to P.55-15) Charging of Refrigerant (Refer to P.55-11.) •...
  • Page 117 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E13-001 Date 1998-05-31 <Model> <M/Y> CORRECTION OF ’98 CARISMA GDI (EC,EXP) 98-10 Subject: WORKSHOP MANUAL GROUP 13J CARISMA Group: FUEL INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 118 www.WorkshopManuals.co.uk 13J-11 GDI - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor system 13J-12 Air flow sensor system 13J-13 Intake air temperature sensor system 13J-14 Throttle position sensor system 13J-15 Engine coolant temperature sensor system 13J-16 Crank angle sensor system 13J-17...
  • Page 119 www.WorkshopManuals.co.uk 13J-25 GDI - Troubleshooting Code No. 56 Fuel pressure sensor system Probable cause • Range of check Malfunction of the fuel pressure sensor • • Ignition switch: ON Open circuit or short-circuited harness wire of the fuel Set conditions pressure sensor •...
  • Page 120 www.WorkshopManuals.co.uk 13J-99 GDI - Fuel Pump (High Pressure) FUEL PUMP (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-Installation Operation • • Engine Coolant Draining an Supplying Throttle Body Removal and Installation • Prevention of fuel discharge <before removal only> (Refer to 13J-105.) •...
  • Page 121 www.WorkshopManuals.co.uk 13J-102 GDI - Fuel Pump (High Pressure) BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION O-ring Back-up ring A Install the back-up rings and the O-ring as shown in the illustration. Caution 1. Install the back-up ring B facing its cutaway surface Cutaway toward the opposite side of the O-ring as shown in surface...
  • Page 122 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E13-001REV Date <Model> <M/Y> 1998-12-15 Subject: CORRECTION OF ’98 CARISMA GDI (EC,EXP)CARISMA 98-10 WORKSHOP MANUAL GROUP 13J Group: FUEL INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 123 www.WorkshopManuals.co.uk 13J-9 GDI - Troubleshooting Engine warning lamp inspection items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector Abnormal combustion <Correct>...
  • Page 124 www.WorkshopManuals.co.uk 13J-10 GDI - Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item Control contents during malfunction Air flow sensor (1) Lean fuel combustion driving and feedback control driving are prevented...
  • Page 125 www.WorkshopManuals.co.uk 13J-11 GDI - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code no. Diagnosis item Reference page Oxygen sensor system 13J-12 Air flow sensor system 13J-13 Intake air temperature sensor system 13J-14 Throttle position sensor system 13J-15 Engine coolant temperature sensor system 13J-16 Crank angle sensor system 13J-17...
  • Page 126 www.WorkshopManuals.co.uk 13J-25 GDI - Troubleshooting [A] on the next page added here. <Correct> Sensor output voltage is 4.8V or more for 4 seconds <Correct> <Correct> Abnormal fuel pressure system Sensor output voltage is 0.2V or more for 4 seconds <Incorrect> Code No.56 Fuel pressure sensor system Probable cause •...
  • Page 127 www.WorkshopManuals.co.uk • Malfunction of the fuel pump (high pressure) Range of check • Following conditions once detected after engine • Malfunction of the fuel pressure regulation is started. (high pressure) (1) Engine speed: 1,000 r/min or more • Clogged high pressure fuel lines (2) Fuel pressure: 2 MPa or more •...
  • Page 128 www.WorkshopManuals.co.uk 13J-35 GDI - Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) Long time to start (Improper starting) • The cause is probably poor ignition due to a malfunction Malfunction of the fuel supply system •...
  • Page 129 www.WorkshopManuals.co.uk 13J-99 GDI - Fuel Pump (High Pressure) FUEL PUMP (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation • • Engine Coolant Draining and Supplying Throttle Body removal and Installation (Refer to 13J- • Prevention of fuel discharge <before removal only> 106.) •...
  • Page 130 www.WorkshopManuals.co.uk 13J-102 GDI - Fuel Pump (High pressure) BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION " Back-up ring A O-ring Install the back-up rings and the O-ring as shown in the illustration. Caution Install the back-up ring B facing its cutaway surface toward the opposite side of the O-ring as shown in the illustration Cutaway Confirm the outer diameter of the back-up ring A.
  • Page 131 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E13-002 Date <Model> <M/Y> 1998-12-15 Subject: CHANGES IN TROUBLESHOOTING (EC,EXP) 98-10 CARISMA Group: FUEL CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept. 1.
  • Page 132 www.WorkshopManuals.co.uk 13J-22 GDI -Troubleshooting CODE NO.41 INJECTOR SYSTEM PROBABLE CAUSE • Range of check Malfunction of the injector • • While engine is cranking or running Malfunction of the injector driver control • Engine speed is 4,000 r/min or less relay •...
  • Page 133 www.WorkshopManuals.co.uk 13J-27 GDI -Troubleshooting CODE NO.64 ALTERNATOR FR TERMINAL SYSTEM PROBABLE CAUSE • Range of check Open circuit in alternator FR terminal • Engine speed is 50 r/min or more. circuit <Incorrect> • Set conditions Malfunction of the engine-ECU • Input voltage from alternator FR terminal is 4.5 V or more for 20 seconds.
  • Page 134 www.WorkshopManuals.co.uk 13J-28 GDI -Troubleshooting CODE NO.66 BRAKE VACUUM SENSOR SYSTEM PROBABLE CAUSE • Range of check Malfunction of the brake vacuum sensor • • Ignition switch: ON. Improper connector contact, open circuit Set conditions or short-circuited harness wire of the •...

  • Page 135: Charging System

    www.WorkshopManuals.co.uk 13J-47 GDI -Troubleshooting LOW ALTERNATOR OUTPUT VOLTAGE (APPROX. 12.3 V) PROBABLE CAUSE • The cause is probably a malfunction of the alternator or one of the problems listed Malfunction of the charging system • at right. Open circuit between the alternator G terminal and he engine-ECU •...
  • Page 136 www.WorkshopManuals.co.uk 13J-65 GDI -Troubleshooting Item Inspection item Inspection contents Normal condition Inspection Reference procedure page A/C relay Engine: After having A/C switch: OFF OFF (Compressor Procedure 13J-58 warmed up/ Engine is clutch is not No.32 idling operating A/C switch: ON ON (Compressor clutch is operating) •...
  • Page 137 www.WorkshopManuals.co.uk 13J-67 GDI -Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART ENGINE-ECU CONNECTOR TERMINAL ARRANGEMENT Terminal Check item Check condition (Engine condition) Normal condition No.1 injector Engine: Idling after having warmed up 10 - 12 V <Correct> No.2 injector Momentarily decreases No.3 injector slightly from 9 - 13 V.
  • Page 138 www.WorkshopManuals.co.uk 13J-68 GDI -Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Power supply Ignition switch: ON System voltage Power supply Earth At all times Earth Air flow sensor reset signal Engine: Idling 0 - 0.1 V Engine: 4,000 r/min 6 - 9 V Air flow sensor Engine: Idling...
  • Page 139 www.WorkshopManuals.co.uk 13J-69 GDI -Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Ignition switch: OFF → ON 0 - 0.1 V → System voltage (after Engine warning lamp several seconds have passed) Power steering fluid Steering wheel: Neutral position System voltage pressure switch Steering wheel: Turned...
  • Page 140 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E16-001 Date <Model> <M/Y> 1998-10-15 Subject: CHANGE OF SPARK PLUG FROM PLATINUM (EC,EXP) 98-10 TO IRIDIUM PLUG CARISMA Group: ENGINE ELECTRICAL INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 141 www.WorkshopManuals.co.uk 16-19 ENGINE ELECTRICAL - Ignition System IGNITION SYSTEM GENERAL INFORMATION This system is equipped with four ignition coils with The Engine -ECU determines which ignition coil should built-in power transistors for each of the cylinders. be controlled by means of the signals from the camshaft Interruption of the primary current flowing in the primary position sensor and the crank angle sensor .

  • Page 142: Service Specifications

    www.WorkshopManuals.co.uk 16-20 ENGINE ELECTRICAL - Ignition System SERVICE SPECIFICATIONS SPARK PLUG Items Specification Limit Spark plug gap mm 0.5 - 0.6 0.75 Spark plug insulation resistance MΩ ON-VEHICULE SERVICE POWER TRANSISTOR CONTINUITY CHECK NOTE 1. An analogue-type circuit tester should be used. 2.
  • Page 143 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E16-501 Date 1999-06-15 <Model> <M/Y> Subject: CORRECTION TO DESCRIPTIONS OF (EC,EXP) 98-10 IGNITION COIL (SECONDARY COIL) CARISMA ENGINE ELECTRICAL Group: CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.

  • Page 144: Table Of Contents

    www.WorkshopManuals.co.uk 16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM....... 2 IGNITION SYSTEM ....... 19 GENERAL INFORMATION ......2 GENERAL INFORMATION ......19 SERVICE SPECIFICATIONS ......3 SERVICE SPECIFICATIONS....... 20 SPECIAL TOOLS ........... 3 ON-VEHICLE SERVICE ......20 <Incorrect> ON-VEHICLE SERVICE ......... 4 Power Transistor Continuity Check ....

  • Page 145: Ignition System

    www.WorkshopManuals.co.uk 16-19 ENGINE ELECTRICAL - Ignition System IGNITION SYSTEM GENERAL INFORMATION This system is equipped with four ignition coils with The Engine -ECU determines which ignition coil should built-in power transistors for each of the cylinders. be controlled by means of the signals from the camshaft Interruption of the primary current flowing in the primary position sensor and the crank angle sensor .
  • Page 146 www.WorkshopManuals.co.uk Ignition switch Battery Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Idle position switch Engine-ECU Camshaft position sensor Ignition coil Crank angle sensor Ignition switch-ST Detonation sensor Vehicle speed sensor Inhibitor switch <A/T> Spark plug Cylinder No.

  • Page 147: Service Specifications

    www.WorkshopManuals.co.uk 16-20 ENGINE ELECTRICAL - Ignition System SERVICE SPECIFICATIONS SPARK PLUG Items Specification Limit Spark plug gap mm 0.5 - 0.6 0.75 Spark plug insulation resistance MΩ <Corrected to on the following page> ON-VEHICLE SERVICE POWER TRANSISTOR CONTINUITY CHECK <Incorrect> NOTE 1.

  • Page 148: Ignition Coil

    www.WorkshopManuals.co.uk <Correct> IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK <Added> SECONDARY COIL CHECK NOTE The ignition coil (secondary coil) circuit has a built-in diode. This makes it difficult to tell whether the secondary coil is good or bad through resistance inspection.
  • Page 149 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E23-501 Date <Model> <M/Y> 1999-06-15 Subject: ADDITION / CORRECTION OF HYDRAULIC (EUR) PRESSURE TEST OF AUTOMATIC CARISMA (DX) 96-10 TRANSMISSION Group: AUTOMATIC TRANSMISSION INFORMATION O.
  • Page 150 www.WorkshopManuals.co.uk 23-56 AUTOMATIC TRANSMISSION – On-vehicle Service TORQUE CONVERTER STALL TEST JUDGEMENT RESULTS a. Stall speed is too high in both D and R ranges • Low line pressure • Low & reverse brake slippage b. Stall speed is too high in D range only •...
  • Page 151 www.WorkshopManuals.co.uk 23-57 AUTOMATIC TRANSMISSION – On-vehicle Service STANDARD HYDRAULIC PRESSURE TEST Measurement condition Standard hydraulic pressure kPa Selector Shift position Engine Under drive Reverse Overdrive Low and Second Torque lever speed (rpm) clutch clutch clutch reverse brake converter position pressure pressure pressure brake...
  • Page 152 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-98E26-001 Date <Model> <M/Y> 1998-02-15 Subject: ADDITION OF DRIVE SHAFT (EC,EXP) 96-10 DISASSEMBLY/REASSEMBLY PROCEDURES CARISMA Group: FRONT AXLE INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 153 <Added> www.WorkshopManuals.co.uk 26-2 FRONT AXLE - General Information/Service Specifications/Sealant /Lubricants GENERAL INFORMATION 26100010036 The wheel bearing and front hub are press-fitted in B.J.-T.J.-type constant velocity joints to improve the axle housing portion of the knuckle to support power transmission efficiency and to reduce the drive shaft.
  • Page 154 www.WorkshopManuals.co.uk 26-4 FRONT AXLE - Special Tools Tool Number Name MB990890 Rear suspension Press-fitting of wheel bearing bushing base Use together with MB990883 <1800> MB991045 Bushing remover Press-fitting of wheel bearing and installer Use together with MB990883 A: MB991050 <1600> MB990847 Rear suspension Press-fitting of the outer oil seal...
  • Page 155 www.WorkshopManuals.co.uk Tool Number Name MB990560 Rear axle shaft • Removal of the TJ boot bearing remover • Removal of the dynamic damper B990560 MD998812 Installer cap Press-fitting the TJ boot MD998814 Installer 200 MD998817 Installer adapter MH062469 Gear puller Removal of the spider assembly <Added>...
  • Page 156 www.WorkshopManuals.co.uk 26-13 FRONT AXLE - Drive Shaft Caution MB991000 Do not apply the vehicle weight to the wheel bearing (MB990998) while loosening the drive shaft nut. If, however, the vehicle weight must be applied to the bearing (because MB991017 of moving the vehicle), temporarily secure the wheel bearing by using the special tool.
  • Page 157 www.WorkshopManuals.co.uk 26-14 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY 26100370134 A11U0093 T.J. boot repair kit <L.H.> T.J. boot repair kit <R.H.> B.J. boot repair kit Disassembly steps 11. T.J. case 11. B.J. assembly " " " " ! ! ! ! ! ! ! ! "...
  • Page 158 www.WorkshopManuals.co.uk 26-15 FRONT AXLE - Drive Shaft DISASSEMBLY SERVICE POINTS T.J. CASE/SPIDER ASSEMBLY REMOVAL " " " " ! ! ! ! (1) Using the water pump pliers, etc., unstake the flange area of T.J. case and T.J. boot (at 3 places). (2) Remove the T.J.
  • Page 159 www.WorkshopManuals.co.uk 26-16 FRONT AXLE - Drive Shaft REASSEMBLY SERVICE POINTS DYNAMIC DAMPER/DAMPER BAND INSTALLATION ! ! ! ! " " " " (1) Install the dynamic damper in the position shown in the illustration. Items 1600-A/T (L.H.), 240±3 mm 1800-A/T (L.H.) 1600 (R.H.), 369±3 mm 1800-A/T (R.H.)
  • Page 160 www.WorkshopManuals.co.uk 26-17 FRONT AXLE - Drive Shaft T.J. CASE INSTALLATION ! ! ! ! " " " " (1) After applying the specified grease to the T.J. case, insert the drive shaft and apply grease one more time. Specified grease: Repair kit grease NOTE The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
  • Page 161 www.WorkshopManuals.co.uk 23-7 AUTOMATIC TRANSMISSION - Troubleshooting SERVICE DATA REFERENCE TABLE The following items have been added to correspond to the addition of vehicles with 4G93-GDI engine. Moreover, item No.57 (engine volumetric efficiency) is not included for vehicles with 4G93-GDI engine. Item No.
  • Page 162 www.WorkshopManuals.co.uk 26-1 FRONT AXLE - General/Service Specifications/Lubricants/Special Tools GROUP 26 FRONT AXLE GENERAL OUTLINE OF CHANGES With adoption of the drive shaft of Mitsubishi make as a drive shaft on the manual transmission car, the service procedures have been established as follows: SERVICE SPECIFICATIONS Items Standard value...
  • Page 163 www.WorkshopManuals.co.uk 26-2 FRONT AXLE - Drive Shaft DRIVE SHAFT DISASSEMBLY AND REASSEMBLY 11I0094 00005700 11I0100 11I0070 11I0101 T.J. repair kit <L.H.> T.J. boot repair kit B.J. boot repair kit Disassembly steps 1. T.J. boot band (large) 10. B.J. assembly ! ! ! ! "...
  • Page 164 www.WorkshopManuals.co.uk 26-4 26-3 FRONT AXLE - Drive Shaft FRONT AXLE - Drive shaft DISASSEMBLY SERVICE POINTS T.J. CASE/SPIDER ASSEMBLY REMOVAL " " " " ! ! ! ! (1) Wipe off grease from the spider assembly and the inside of the T.J. case. (2) Always clean the spider assembly when the grease contains water or foreign material.
  • Page 165 www.WorkshopManuals.co.uk (2) Install the spider assembly to the shaft from the direction of the spline bevelled section. (3) After applying the specified grease to the T.J. case, insert the drive shaft and apply grease one more time. Specified grease: Repair kit grease Amount to use: 120 g NOTE The grease in the repair kit should be divided in half for use,...
  • Page 166 www.WorkshopManuals.co.uk 26-5 FRONT AXLE - Drive shaft (4) Install the B.J. boot with the part with the smallest diameter in a position such that the shaft groove can be seen. 11X0138 11X0142 00003419 (5) Turn the adjusting bolt on the special tool so that the size MB991561 of the opening (W) is at the standard value.
  • Page 167 www.WorkshopManuals.co.uk 26-6 FRONT AXLE - Drive Shaft (8) Check that the crimping amount (B) of the B.J. boot band is at the standard value. Standard value (B): 2.4 - 2.8 mm 11X0140 <If the crimping amount is larger than 2.8 mm> Read just the value of (W) in step (5) according to the following formula, and then repeat the operation in step (7).
  • Page 168 www.WorkshopManuals.co.uk 26-7 FRONT AXLE - Drive shaft (15) Check that the crimping amount (E) of the B.J. boot band is at the standard value. Standard value (E): 2.4 - 2.8 mm <If the crimping amount is larger than 2.8 mm> Read just the value of (W) in step (12) according to the following formula, and then repeat the 11X0134...
  • Page 169 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E21-501 Date <Model> <M/Y> 1999-12-15 Subject: CORRECTION TO CLUTCH PEDAL HEIGHT (EC) CARISMA 96-10 (EC) SPACE STAR Group: CLUTCH (DG1A, DG5A) CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 170 www.WorkshopManuals.co.uk 21-2 CLUTCH - General Information/Service Specifications/Lubricants/On-vehicle Service CLUTCH 21100010031 GENERAL INFORMATION <Correct> The clutch is a dry single-disc diaphragm type; hydraulic pressure is used for the clutch control. 171.2 - 174.2 2100030037 SERVICE SPECIFICATIONS Items Standard value Clutch pedal height mm 163.5 - 166.5 (L.H.
  • Page 171 www.WorkshopManuals.co.uk 21-2 CLUTCH - General Information/Service Specifications/Lubricants/On-vehicle Service GENERAL INFORMATION 21100010031 <Correct> The clutch is a dry single-disc diaphragm type; 173.3 - 176.3 hydraulic pressure is used for the clutch control. 172.8 - 175.8 21100030198 SERVICE SPECIFICATIONS Items Standard value Clutch pedal height mm 163.5 - 166.5 (L.H.
  • Page 172 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E33-501 Date <Model> <M/Y> 1999-11-15 Subject: CORRECTION TO FRONT SUSPENSION (EC,EXP) 96-10 CAMBER AND CASTER VALUES CARISMA Group: FRONT SUSPENSION SPACE STAR CORRECTION O.
  • Page 173 www.WorkshopManuals.co.uk DRIVE CONTROL COMPONENTS – Front Suspension SPECIFICATIONS SUSPENSION SYSTEM Item Specifiactions Suspension method McPherson strut with coil springs and compression rods WHEEL ALIGNMENT Item Specifiactions <Added> Camber 0° 0 0’ ± 3 0’ <Added> ± 30’* Caster 2° 1 2’ Kingpin inclination 1 2°...
  • Page 174 www.WorkshopManuals.co.uk 33A-3 FRONT SUSPENSION – Service Specifications SERVICE SPECIFICATIONS Items Standard value Toe-in At the centre of tyre tread mm 1 ± 2 Toe-angle (per wheel) 0° 03’ ± 06’ Toe-out angle on turns 21.8° (inner wheel when outer wheel at 20°) Steering angle Inner wheel 39°00’...
  • Page 175 www.WorkshopManuals.co.uk 33A-6 FRONT SUSPENSION – On-vehicle Service STEERING ANGLE Standard value: Inner wheel 39°00’ ± 1°30’ Outer wheel 32°00’ <Added> (difference between right and left wheels: less than 30’.) CAMBER, CASTER AND KINGPIN INCLINATION MB991004 Standard value: Camber 0°00’ ± 30’ Caster 2°12’...
  • Page 176 www.WorkshopManuals.co.uk DRIVE-CONTROL COMPONENTS – Front Suspension SPECIFICATIONS SUSPENSION SYSTEM Item Specifiactions Suspension method McPherson strut with coil springs and compression rods WHEEL ALIGNMENT Item Specifiactions <Added> Camber -0°40’ ± 30’ * <Added> ± 30’* Caster 2°54’ Kingpin inclination 13°36’ Toe-In At the centre of tyre tread mm 0 ±...
  • Page 177 www.WorkshopManuals.co.uk 33A-3 FRONT SUSPENSION – Service Specifications SERVICE SPECIFICATIONS Items Standard value Toe-in At the centre of tyre tread mm 0 ± 2 Toe-angle (per wheel) 0° 00’ ± 06’ Toe-out angle on turns 21°39’ (inner wheel when outer wheel at 20°) Steering angle Inner wheel 41°30’...
  • Page 178 www.WorkshopManuals.co.uk 33A-6 FRONT SUSPENSION – On-vehicle Service STEERING ANGLE Standard value: Inner wheel 41°30’ Outer wheel 34°00’ <Added> (difference between right and left wheels: less than 30’.) CAMBER, CASTER AND KINGPIN INCLINATION MB991004 Standard value: Camber 0°40’ ± 30’ Caster 2°54’ Kingpin inclination 13°36’...
  • Page 179 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E35-001 Date <Model> <M/Y> 1999-08-31 Subject: CHANGE TO LIMIT OF FRONT BRAKE DISC (EC) CARISMA 96-10 THICKNESS Group: SERVICE BRAKE CORRECTION O. Kai — E.V.P. & G.M. After Sales Service Dept.
  • Page 180 www.WorkshopManuals.co.uk 35A-4 BASIC BRAKE SYSTEMS – General Information/Service Specifications CONSTRUCTION DIAGRAM Brake booster Master cylinder Rear brake Front brake Brake pedal A14U0009 SERVICE SPECIFICATIONS 35100030058 Items Standard value Limit Brake pedal height mm L.H. drive vehicles 163.5 -166.5 — R.H. drive vehicles 162.5 - 165.5 —...
  • Page 181 www.WorkshopManuals.co.uk 35A-12 BASIC BRAKE SYSTEMS – On-vehicle Service BRAKE DISC THICKNESS CHECK 35100160047 1. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 mm in from the outer edge of the disc. <New> Brake disc thickness 21.5 mm Standard value: <From February 12, 1996>...
  • Page 182 www.WorkshopManuals.co.uk Brake disc 6.4 MIN. (R73.5) Stamped on the backside of brake disc. Purchased from www.WorkshopManuals.co.uk...
  • Page 183 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E35-505 Date 2000-07-15 <Model> <M/Y> Subject: ADDITION OF DIAGNOSTIC TROUBLE CODE (EC) CARISMA 98-10 NO.15 Group: SERVICE BRAKE CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 184 www.WorkshopManuals.co.uk 35B-1 ABS <2WD> - General/Troubleshooting GROUP 35B ANTI-SKID BRAKING SYSTEM (ABS) <2WD> GENERAL OUTLINE OF CHANGES • The hydraulic unit has been changed. • ABS-ECU connectors have been changed. Correspond to this, troubleshooting and inspection procedure for the wheel speed sensor have been changed. TROUBLESHOOTING INSPECTION CHART FOR DIAGNOSIS CODES Inspect according to the inspection chart that is appropriate for the malfunction code.
  • Page 185 www.WorkshopManuals.co.uk 35B-2 ABS <2WD> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code Nos.11, 12, 13 and 14 Wheel speed sensor open circuit Probable cause Code Nos.21, 22, 23 and 24 Wheel speed sensor short circuit • Code Nos.11,12, 13 and 14 are output if the ABS-ECU detects an open circuit in any Malfunction of wheel speed sensor •...
  • Page 186 www.WorkshopManuals.co.uk Code No. 15 Wheel speed sensor (Abnormal output signal) Probable cause • A wheel speed sensor outputs an abnormal signal Tire sizes of four wheels not unified. • (Other than an open short-circuit). Improper installation of wheel speed sensor •...
  • Page 187 www.WorkshopManuals.co.uk 35C-10 TLC - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Inspect according to the inspection chart that is appropriate for the malfunction code. Diagnosis code Inspection item Diagnosis content Reference page Front right wheel speed sensor Open circuit Refer to ‘ 98 CARISMA Workshop Manual –...
  • Page 188 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E35-506 Date 2000-04-15 <Model> <M/Y> Subject: ADDITION OF CAUTION ON READING OF (EC) CARISMA 96-10 DIAGNOSTIC TROUBLE CODES (EC) SPACE STAR Group: SERVICE BRAKE CORRECTION O.
  • Page 189 www.WorkshopManuals.co.uk 35B-7 ABS <2WD> - Troubleshooting Without the MUT-II Use the special tool to earth diagnosis connector terminal No. 1. 00U0018 Turn the ignition switch to ON and then take a reading of th When diagnosis code No. 23 is output diagnosis codes from the flashing of the ABS warning lamp.
  • Page 190 www.WorkshopManuals.co.uk 35B-6 ABS <2WD> - Troubleshooting Without the MUT-II Use the special tool to earth diagnosis connector terminal No. 1. AV0310AJ Turn the ignition switch to ON and then take a reading of th When diagnosis code No. 23 is output diagnosis codes from the flashing of the ABS warning lamp.
  • Page 191 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E37-001 Date <Model> <M/Y> 1999-12-30 Subject: CHANGE TO POWER STEERING OIL PUMP (EC) CARISMA 97-10 Group: STEERING CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 192 www.WorkshopManuals.co.uk 37A-1 STEERING - General/Power Steering Oil Pump GROUP 37A STEERING <Added> GENERAL “SPECIAL TOOLS” on the following page comes here. OUTLINE OF CHANGES • The following service procedures have been added to the addition of the diesel-powered vehicle. Applicable models: 1900D 1.
  • Page 193 www.WorkshopManuals.co.uk STEERING - Special Tools SPECIAL TOOLS Tool Number Name MB991367 Special spanner Removal and installation of the power steering pump pulley B991367 MB991394 Pin set B991394 MB996047 Special bolt Installation of the power steering pump hub MD999574 <Old> <New> MD998815 Adapter, installer Purchased from www.WorkshopManuals.co.uk...
  • Page 194 www.WorkshopManuals.co.uk <Added> STEERING - Power Steering Oil Pump POWER STEERING OIL PUMP <3-SPOKE HUB TYPE> 37200520163 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation • • Power Steering Fluid Draining. Alternator installation • • Hydraulic unit remove <Vehicles with ABS> Hydraulic unit installation. <Vehicles with ABS> •...
  • Page 195 www.WorkshopManuals.co.uk <Added> STEERING - Power Steering Oil Pump POWER STEERING PUMP HUB REMOVAL " " " " Remove the engine mount (RH) to body bolts. Lift the engine on a garage jack, etc. to ensure that the working space is available. Power Steering Measure dimensions A between the power steering pump hub...
  • Page 196 www.WorkshopManuals.co.uk <Added> STEERING - Power Steering Oil Pump 5. Secure the bolt of the special tool to prevent it from Power Steering turning until dimension (A) between the power steering pump hub pump hub and the bracket becomes the same as before removal.
  • Page 197 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E42-504 Date <Model> <M/Y> 1999-11-15 Subject: CORRECTION TO CENTER DOOR LOCK (EC,EXP) 98-10 TROUBLESHOOTING CARISMA Group: BODY CORRECTION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 198 www.WorkshopManuals.co.uk 42-5 BODY - Door Inspection Procedure 13 Probable cause Some doors do not lock or unlock The door lock actuator, a harness or connector may be defective. Malfunction of the door lock actuator Malfunction of the wiring harness or connector Check the following connectors.
  • Page 199 www.WorkshopManuals.co.uk SERVICE BULLETIN PUBLICATION GROUP, AFTER SALES SERVICE DEP. MITSUBISHI MOTOR SALES EUROPE BV SERVICE BULLETIN No.: ESB-99E51-001 Date <Model> <M/Y> 1999-12-15 Subject: ADDITION OF WASHER MOTOR REMOVAL (EC,EXP) 96-10 CARISMA Group: EXTERIOR INFORMATION O. Kai - E.V.P. & G.M. After Sales Service Dept.
  • Page 200 www.WorkshopManuals.co.uk 51-9 EXTERIOR - Windshield Wiper and Washer WINDWHIELD WIPER AND WASHER 51100760032 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation CAUTION: SRS • Before removal of air bag module and clock spring, Relay Box Removal and installation refer to GROUP 52B - SRS Service Precautions and <R.H.
  • Page 201 www.WorkshopManuals.co.uk 51-10 EXTERIOR - Windshield Wiper and Washer REMOVAL SERVICE POINT WIPER MOTOR REMOVAL " " " " Loosen the wiper motor assembly mounting bolts, and then remove the wiper motor assembly. Disconnect the linkage and the motor assembly, and then remove the linkage. Caution Linkage Because the installation angle of the crank arm and the...
  • Page 202 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 203 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 204 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 205 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 206 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 207 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 208 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 209 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 210 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 211 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 212 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 213 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 214 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 215 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 216 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 217 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 218 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 219 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 220 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 221 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 222 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 223 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 224 SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-98E52-502 Date <Model> <M/Y> 1999-10-31 Subject: CORRECTION TO ERASING OF DIAGNOSIS (EX,EXP)ECLIPSE 98-10 (D30) 98-10 CODES (EX,EXP)GALANT 98-10 (E50-80) 98-10 Group: Draft No.: 98AL070710 INTERIOR...
  • Page 225 www.WorkshopManuals.co.uk Manual Pub. No. Language Page(s) ’96 CARISMA PWDE9502 (English) 52B-6 Workshop Manual CHASSIS PWDS9503 (Spanish) PWDF9504 (French) PWDG9505 (German) PWDD9506 (Dutch) PWDW9507 (Swedish) PWDI95E1 (Italian) ’97 L200 PWTE95E1 (English) 52B-6 Workshop Manual CHASSIS PWTS95E1 (Spanish) PWTF95E1 (French) PWTG95E1 (German) ’98 L300 PWWE8608-Q (English) 52B-6...
  • Page 226 www.WorkshopManuals.co.uk 52B-6 SRS – Special Tools/ Test Equipment/Troubleshooting SPECIAL TOOLS 52400070117 Tool Number Name • MB991502 MUT-II sub assembly Reading diagnosis codes • Erasing diagnosis code • Reading trouble period • Reading erase times MB991613 SRS check harness Checking the SRS electrical circuitry 19U0039 MB990803 Steering wheel puller...
  • Page 227 www.WorkshopManuals.co.uk 52B-5 SRS - Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION DIAGNOSIS CODE CHECK Connect the MUT-II to the diagnosis connector (16 –pin) under the instrument under cover, then check diagnosis codes. (Refer to GROUP 00 –...
  • Page 228 www.WorkshopManuals.co.uk 52B-6 SRS –Troubleshooting TROUBLESHOOTING 52400090038 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION DIAGNOSIS CODE CHECK Connect the MUT-II to the diagnosis connector (16 –pin) under the instrument under cover, then check diagnosis codes. (Refer to GROUP 00 –...
  • Page 229 www.WorkshopManuals.co.uk 52B-8 SRS – Test/Equipment/Troubleshooting TEST EQUIPMENT 52400080035 Tool Name Digital multi-meter Checking the SRS electrical circuitry Use a multi-meter for which the maximum test current is 2 mA or less at the minimum range of resistance measurement TROUBLESHOOTING 52400310097 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 –...
  • Page 230 www.WorkshopManuals.co.uk 52B-6 SRS –Troubleshooting DIAGNOSIS FUNCTION DIAGNOSIS CODE CHECK Connect the MUT-II to the diagnosis connector (16 –pin) under the instrument under cover, then check diagnosis codes. (Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.) ERASING DIAGNOSIS CODES <Incorrect>...
  • Page 231 www.WorkshopManuals.co.uk 52B-6 SRS – Sealant/Troubleshooting SEALANT 52400060015 Item Specified sealant Remark Sensor cable 3M ATD Part No. 8625 or equivalent Ribbon sealer TROUBLESHOOTING 52400310097 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. 52400320063 DIAGNOSIS FUNCTION DIAGNOSIS CODE CHECK...
  • Page 232 www.WorkshopManuals.co.uk 52B-6 SRS – Test Equipment/Troubleshooting TEST EQUIPMENT Tool Name Digital multi-meter Checking the SRS electrical circuitry Use a multi-meter for which the maximum test current is 2 mA or less at the minimum range of resistance measurement TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 13 –...

Table of Contents