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Mitsubishi 1993 Galant Manuals
Manuals and User Guides for Mitsubishi 1993 Galant. We have
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Mitsubishi 1993 Galant manual available for free PDF download: Service Manual
Mitsubishi 1993 Galant Service Manual (1274 pages)
Brand:
Mitsubishi
| Category:
Automobile
| Size: 39.44 MB
Table of Contents
Group Index
1
Rear Suspension
1
Table of Contents
3
HOW to USE this MANUAL Definition of Terms
5
Explanation of Manual Contents
6
Explanation of the Troubleshooting Guide
8
Explanation of Circuit Diagrams
9
Vehicle Identification Number List
10
Vehicle Information Code Plate
13
Chssis Number
13
Vehicle Safety Certification Label
14
Engine Model Stamping
14
Theft Protection Label
14
Cautions Regarding Panel Repairs
14
Labels Locations
15
Precautions before Service
17
Servicing Electrical System
17
Vehicle Washing Precaution
18
Scan Tool
18
Towing and Hoisting
19
Front Towing Pickup
19
Rear Towing Pickup
19
Towing When Keys Are Not Available
19
Safety Precautions When Towing
20
Hoisting
20
Floor Jack
20
Lifting, Jacking Support Location
21
Special Handling Instructions for AWD Models
22
Speedometer Test (AWD)
23
Brake Test (AWD)
23
Wheel Balance
24
Front Wheel Measurement
24
Rear Wheel Measurement
24
General Data and Specifications
25
Dimensions
25
Engine Specifications
28
Tightening Torque
29
Master Troubleshooting
30
Vehicle Pulls to One Side
34
Lubrication and Maintenance
36
Server Service
36
Engine Oil
36
Recommended Lubricants and Lubricant Capacities Table
37
Materials Added to Fuel
37
Automatic Transaxle
37
Recommended Lubricants and Lubricant Capacities Table
38
Selection of Coolant
39
Scheduled Maintenance Table
40
Maintenance Service
41
Fuel Hoses
41
Spark Plugs Replacement
42
Timing Belt Replacement
42
Drive Belt Inspection
43
Engine Oil Change
43
Engine Oil Filter Change
43
Drive Belt (for Water Pump and Generator)
43
Engine Oil Filter Selection
44
Manual Transaxle - Inspect Oil Level
44
Automatic Transaxle - Inspect Fluid Level
45
Automatic Transaxle - Change Fluid
45
Engine Coolant Change
46
Disc Brake Pads Inspection
46
Rear Drum Brake Linings and Rear Wheel Cylinders Inspection
46
Brake Hoses Check
47
Ball Joint and Steering Linkage Seals Inspection
47
Drive Shaft Boot Inspection
47
Exhaust System Check
47
Table of Main Sealants and Adhesives
48
Engine
51
Engine (SOHC) Specifications
52
General Specifications
52
Engine (SOHC) - Selants and Adhesives
55
Engine (SOHC) - Special Tools
55
Engine (SOHC) Troubleshooting
56
Engine (SOHC) Service Adjustment Procedures
57
Engine (SOHC) Oil Check
57
Engine (SOHC) Lash Adjusters Check
57
Engine (SOHC) - Compression Pressure Check
58
Engine (SOHC) Manifold Vacuum Inspection
59
Engine (SOHC) Timing Belt Tension Adjustment
60
Engine (SOHC) Drive Belts Tension Adjustment
62
Tension Adjustment of the Generator Drive Belt
63
Deflection Adjustment of Power Steering Oil Pump Drive Belt
63
Tension Adjustment of the Air Conditioning Compressor Drive Belt
63
Engine Assembly (8 Valve) Removal and Installation
64
Removal of Power Steering Oil Pump
66
Removal of Air Conditioning Compressor
66
Removal of Engine Mount Bracket
66
Removal/Installation of Engine Assembly
66
Engine Asssembly (16 Valve) Removal and Installation
67
Engine Assembly
67
Camshaft and Camshaft Oil Seal (8 Valve) Removal and Installation
69
Removal of Rocker Arm and Shaft Assembly
70
Installation of Camshaft
70
Installation of Oil Seal
70
Removal of Camshaft Sprocket
72
Removal of Rocker Arms and Rocker Arm Shaft Assembly
72
Installation of Rocker Arms and Rocker Arms Shaft Assembly
72
Installation of Camshaft Oil Seal
72
Oil Pan and Oil Screen Removal and Installation
73
Cylinder Head Gasket (8 Valve) Removal and Installation
75
Cylinder Head Gasket (16 Valve) Removal and Installation
80
Removal of Cylinder Head Assembly
82
Installation of Cylinder Head Gasket
82
Installation of Cylinder Head Assembly/Cylinder Head Bolt
83
Installation of Water Inlet Fitting, Thermostat and Case Assembly
83
Timing Belt (8 Valve) Removal and Installation
84
Removal of Timing Belt
86
Removal of Oil Pump Sprocket
87
Removal of Timing Belt "B"
87
Timing Belts Inspection
87
Tensioner Pulley
88
Installation of Crankshaft Sprocket "B"
88
Installation of Spacer
88
Installation of Timing Belt "B"
88
Adjustment of Timing Belt "B" Tension
89
Installation of Timing Belt Tensioner/Tensioner Spring/Spacer
89
Timing Belt Installation
90
Timing Belt Tension Adjustment
90
Timing Belt Front Lower Cover Installation
91
Timing Belt (16 Valve) Removal and Installation
92
Removal of Auto Tensioner
94
Engine (DOHC) Specifications
103
Troubleshooting
106
Engine (DOHC) Service Adjustment Procedures
107
Engine Oil Check (DOHC)
107
Lash Adjusters Check (DOHC)
107
Dash Pot Inspection and Adjustment (Non-Turbo-M/T)
108
Compression Pressure Check (DOHC)
109
Manifold Vacuum Inspection (DOHC)
110
Drive Belts Tension Adjustment (DOHC)
111
Tension Adjustment of the Generator Drive Belt (DOHC)
112
Deflection Adjustment of Power Steering Oil Pump Drive Belt (DOHC)
112
Adjusting of the Air Conditioning Compressor Drive Belt (DOHC)
112
Engine Assembly Removal (DOHC)
113
Service Points of Removal (DOHC Engine)
117
Camshaft and Camshaft Oil Seals Removal and Installation (DOHC)
118
Oil Pan and Oil Screen Removal and Installation (DOHC)
121
Cylinder Head Gasket Removal and Installation (DOHC)
123
Timing Belt Removal and Installation (DOHC)
130
Auto Tensioner (DOHC)
135
Installation of Engine Support Bracket (DOHC)
135
Installation of Crankshaft Sprocket "B" (DOHC)
136
Installation of Spacer (DOHC)
136
Installation of Timing Belt "B" (DOHC)
136
Adjustment of Timing Belt "B" Tension (DOHC)
136
Installation of Flange (DOHC)
137
Installation of Crankshaft Sprocket (DOHC)
137
Installation of Oil Pump Sprocket (DOHC)
137
Installation of Camshaft Sprockets (DOHC)
137
Installation of Auto Tensioner (DOHC)
138
Installation of Tensioner Pulley (DOHC)
138
Installation of Timing Belt (DOHC)
139
Adjustment of Timing Belt Tension (DOHC)
141
Installation of Timing Belt Lower Cover/Timing Belt Upper Cover
142
Fuel
143
Fuel System (SOHC 8 Valve)
145
General Information
145
Fuel System (SOHC 8 Valve) Specifications
147
Torque Specifications
148
Fuel System - Special Tools
149
Fuel System (SOHC 8 Valve) Troubleshooting
150
Explanation and Precaution Related to Harness Checking
151
Check Engine/Malfunction Indicator Lamp
152
Fuel System (SOHC 8 Valve) On-Board Diagnostics
153
Fuel System (SOHC 8 Valve) Troubleshooting Table
155
Fuel System (SOHC 8 Valve) - Failsafe/Back-Up Functions List
158
Fuel System (SOHC 8 Valve) - Read out of Diagnostic Trouble Code
158
Clear Memory of Diagnostic Trouble Code
159
Fuel System - Check Chart Classified by Problem Symptoms
160
Fuel System (SOHC 8 Valve) Problem Symptoms Table
161
Fuel System (SOHC 8 Valve) Circuit Diagram
162
Circuit Diagram
166
Fuel Tank and Fuel Line Troubleshooting
174
Curb Idle Speed Inspection
174
Basic Idle Speed Adjustment
175
Throttle Body (Throttle Valve Area) Cleaning
177
Throttle Position Sensor Adjustment
177
On-Vehicle Inspection of MFI Components
180
Components Inspection Procedure Using the Scan Tool (Fuel System)
183
Fuel System - Harness Inspection
185
Multipoint Fuel Injection Relay Inspection
186
Engine Control Module Power Ground
187
Fuel Pump
188
Fuel System
188
Volume Air Flow Sensor
191
Intake Air Temperature Sensor
193
Barometric Pressure Sensor
195
Engine Coolant Temperature Sensor
197
Throttle Position Sensor
199
Closed Throttle Position Switch
203
Closed Throttle Position Switch (from 1990 Models)
205
Idle Speed Control Motor Position Sensor (1989 Models)
206
Idle Speed Control Motor Posistion Sensor (from 1990 Models)
209
Camshaft Position Sensor (up to 1990 Models)
211
Camshaft Position Sensor (from 1991 Models)
213
Crankshaft Position Sensor (up to 1990 Models)
215
Crankshaft Position Sensor (from 1991 Models)
217
Ignition Switch - ST and Park/Neutral Position Switch (A/T)
220
Vehicle Speed Sensor
222
Power Steering Pressure Switch
223
Air Conditioning Switch and A/C Compressor Clutch Relay
225
EGR Temperature Sensor (Calif.)
227
Oxygen Sensor
229
Injectors
232
Measuring Resistance between Terminals
234
Idle Speed Control Motor (DC Motor)
235
Actuator Inspection
236
Idle Speed Control Motor (DC Motor) (from 1990 Models)
236
Ignition Coil and Ignition Power Transistor
238
Evaporative Emission Purge Solenoid
241
EGR Solenoid (Calif.)
243
Fuel Pressure Test
245
Inspection of Engine Control Module Terminal Voltage
247
Terminal Voltage Check Chart
248
Fuel Tank Removal
251
Fuel Tank Inspection
252
Installation of Fuel Tank Pressure Control Valve
252
Fuel Pump Replacement
253
Connection of Vapor Hose/Filler Hose
253
Connection of High Pressure Hose to Fuel Pump
253
Fuel Line and Vapor Line Removal and Installation
255
Removal of Eye Bolt
256
Removal of Fuel Filter
256
Fuel Line and Vapor Line Inspection
256
Installation of Fuel Filter
256
Installation of High Pressure Fuel Hose
257
Fuel System (SOHC 16 Valve) General Information
258
Fuel System (SOHC 16 Valve) Specifications
260
Explanation of Troubleshooting Procedures
261
Fuel System (SOHC 16 Valve) Troubleshooting
262
Check Engine/Malfunction Indicator Lamp (SOHC 16 Valve)
262
Fuel System (SOHC 16 Valve) On-Board Diagnostics
263
Fuel System (SOHC 16 Valve) Diagnostic Chart (Fault Tree)
263
Fuel System (SOHC 16 Valve) Troubleshooting Table
265
Fuel System (SOHC 16 Valve) Failsafe/Back-Up Functions List
268
Fuel System (SOHC 16 Valve) Check Chart Classified by Problem Symptoms
269
Fuel System (SOHC 16 Valve) Circuit Diagram
270
Fuel System (SOHC 16 Valve) Service Adjustment Procedures
275
Fuel Tank and Fuel Line (SOHC 16 Valve) Troubles
275
Curb Idle Speed Inspection (SOHC 16 Valve)
275
Basic Idle Speed Adjustment (SOHC 16 Valve)
276
Throttle Body (Throttle Valve Area) Cleaning (SOHC 16 Valve)
278
Closed Throttle Position Switch and Sensor Adjustment
278
Fixed SAS Adjustment (SOHC 16 Valve)
280
On-Vehicle Inspection of MFI Components (SOHC 16 Valve)
281
Component Location
281
Power Supply - MFI (SOHC 16 Valve)
285
Multiport (SOHC 16 Valve)
287
Engine Control Module Power Ground (SOHC 16 Valve)
288
Fuel Pump (SOHC 16 Valve)
289
Volume Air Flow Sensor (SOHC 16 Valve)
292
Intake Air Temperature Sensor (SOHC 16 Valve)
294
Barometric Pressure Sensor (SOHC 16 Valve)
296
Engine Coolant Temperature Sensor (SOHC 16 Valve)
297
Throttle Position Sensor (SOHC 16 Valve)
299
Closed Throttle Position Switch (SOHC 16 Valve)
302
IAC Valve Position Sensor (SOHC 16 Valve)
304
Camshaft Position Sensor (SOHC 16 Valve)
307
Crankshaft Position Sensor (SOHC 16 Valve)
309
Ignition Switch-ST (M/T) (SOHC 16 Valve)
313
Ignition Switch-ST and Park/Neutral Position Switch (A/T)
314
Vehicle Speed Sensor (SOHC 16 Valve)
315
Power Steering Pressure Switch (SOHC 16 Valve)
317
Air Conditioning Switch and A/C Compressor Clutch Relay (SOHC 16 V)
318
EGR Temperature Sensor (SOHC 16 Valve)
319
Egr Temperature Sensor <California
319
Oxygen Sensor (SOHC 16 Valve)
321
Injectors (SOHC 16 Valve)
323
Idle Air Control Motor (DC Motor) (SOHC 16 Valve)
326
Ignition Coil and Ignition Power Transistor (SOHC 16 Valve)
328
Evaporative Emission Purge Solenoid (SOHC 16 Valve)
331
EGR Solenoid (SOHC 16 Valve)
333
Inspection of Engine Control Module Terminal Voltage (SOHC 16 Valve)
334
Fuel Filter
337
Fuel System (DOHC) General Information
338
Fuel System (DOHC) Specifications
343
Fuel System (DOHC) Troubleshooting
347
Check Engine/Malfunction Indicator Lamp (DOHC)
347
Fuel System (DOHC) Diagnostic Chart (Fault Tree)
348
Fuel System (DOHC) Troubleshooting Table
350
Failsafe/Back-Up Functions List - Fuel System (DOHC)
353
Clear Memory of Diagnostic Trouble Code
353
Check Chart Classified by Problem Symptoms - Fuel System (DOHC)
354
Fuel System (DOHC) Problem Symptoms Table
355
Fuel System (DOHC) Circuit Diagram
356
Fuel Tank and Fuel Line Troubles (DOHC)
386
Fuel System (DOHC) Service Adjustment Procedures
387
Curb Idle Speed Inspection (DOHC)
387
Basic Idle Speed Adjustment (DOHC)
387
Throttle Body (Throttle Valve Area) Cleaning (DOHC)
390
Throttle Position Sensor Adjustment (DOHC)
390
Closed Throttle Position Switch (Fixed SAS) Adjustment (DOHC)
392
On Vehicle Inspection of MFI Components (DOHC)
393
Power Supply and Ignition Switch-IG (DOHC)
397
Multiport (DOHC)
399
Fuel Pump (DOHC)
400
Volume Air Flow Sensor (DOHC)
403
Intake Air Temperature Sensor (DOHC)
405
Barometric Pressure Sensor (DOHC)
408
Engine Coolant Temperature Sensor (DOHC)
410
Throttle Position Sensor (1989 Models) (DOHC)
412
Throttle Position Sensor (from 1990 Models) (DOHC)
414
Closed Throttle Position Switch (DOHC)
416
Camshaft Position Sensor (DOHC)
419
Crankshaft Position Sensor (DOHC)
425
Ignition Switch-St
426
Ignition Switch-St and Park/Neutral Position Switch
426
Air Conditioning Switch and A/C Compressor Clutch Relay (DOHC)
427
Knock Sensor (DOHC)
429
EGR Temperature Sensor (DOHC)
430
Heated Oxygen Sensor (DOHC)
432
Injectors (DOHC)
437
Actuator Inspection (DOHC)
439
Measuring Resistance between Terminals (DOHC)
439
Resistor (Turbo) (DOHC)
440
Idle Air Control Motor (Stepper Motor) (DOHC)
440
Ignition Coil and Ignition Power Transistor (DOHC)
444
Fuel Pressure Solenoid <Turbo
449
Turbocharger Waste Gate Solenoid (DOHC)
451
Boost Meter (DOHC)
453
Boost Meter <Turbo
453
Fuel Pressure Test (DOHC)
454
Terminal Voltage Check Chart - Fuel System (DOHC)
457
Fuel Tank Removal and Installation (DOHC)
460
Fuel Tank Pressure Control Valve (DOHC)
461
Installation of Fuel Tank Pressure Control Valve (DOHC)
461
Fuel Pump Replacement (DOHC)
462
Connection of Vapor Hose/Fillter Hose (DOHC)
462
Connection of High Pressure Hose to Fuel Pump (DOHC)
462
Fuel Tank (AWD) Removal and Installation
464
Fuel Pump and Gauge Assembly Replacement (DOHC)
465
Fuel Line and Vapor Line (FWD) Removal and Installation
466
Removal of Eye Bolt (DOHC)
467
Removal of Fuel Filter (DOHC)
467
Installation of Fuel Vapor Hose/Fuel Return Hose (DOHC)
467
Installation of Fuel Filter (DOHC)
467
Fuel Line and Vapor Line (AWD) Removal and Installation
468
Fuel Filter Removal and Installation (DOHC)
469
Engine Control Specifications
470
Engine Control Troubleshooting
470
Accelerator Cable and Accelerator Pedal Troubles
470
Accelerator Cable Inspection and Adjustment
471
Accelerator Switch Inspection and Adjustment
471
Engine Control Removal and Installation
472
Removal of Accelerator Pedal
472
Application of Sealant to Accelerator Arm Bracket
473
Application of Grease to Accelerator Arm Side Inner Cables/Bushing
473
Auto-Cruise Control System Specifications
474
Auto-Cruise Control System - Special Tools
475
Auto-Cruise Control System Troubleshooting
476
Checking the Control Unit Power Supply Circuit
481
Checking the Set Switch Circuit
482
Checking the Resume Switch Circuit
483
Checking the Vehicle-Speed Sensor Circuit
484
Checking the Actuator Circuit
485
Checking the Stop Light Switch Circuit
487
Checking the Park/Neutral Position Switch Control Circuit (A/T)
488
Checking the Clutch Pedal Position Switch Circuit (M/T)
489
Checking the Circuits Related to the Accelerator Switch off Function
490
Checking the Circuits Related to the Overdrive Cancellation Function
491
Auto-Cruise Control System Troubleshooting Quick-Reference Chart
492
Check the Control Unit Power Supply Circuit
496
Checking the Set Switch
496
Check the Resume Switch Circuit
497
Checking the Vehicle Speed Sensor Circuit
497
Checking the Auto-Cruise Control Vacuum Pump
498
Check the Stop Light Switch Circuit
499
Checking the Park/Neutral Position Switch Circuit (A/T)
499
Check the Clutch Pedal Position Switch Circuit (M/T)
500
Check the Circuits Related to the Accelerator Switch off Function
500
Check the Circuits Related to the Overdvie Cancel Function (A/T)
501
Auto-Cruise Control
501
Check Throttle Position Sensor and Closed Position Switch Circuit
502
Auto-Cruise Control System On-Board Diagnostic Check
503
Auto-Cruise Control System - Diagnostic Display Patterns/Trouble Codes
504
Input Check Table
506
Auto-Cruise Control Related Harnesses
507
Location of Control Unit
509
Auto-Cruise Control Components Location
510
Auto-Cruise Control System Circuit Diagrams
513
Control System
516
Auto-Cruise Control System Service Adjustment Procedures
539
Auto-Cruise Control System Inspection
539
Auto-Cruise Control Main Switch Check
539
Speed Reduction Setting Check
539
Auto-Cruise Control Cancellation Check
540
Check of Return to the Set Speed before Cancellation
540
Accelerator Cables Inspection and Adjustment
540
Auto-Cruise Control Switch Inspection
543
Stop Light Switch/Brake Switch Inspection
543
Clutch Pedal Position Switch Inspection
543
Park/Neutral Position Switch ("N" and "P" Positions) Inspection
544
Actuator Inspection and Operation Check
544
Electronic Control Unit (ECU) Signal Circuit Check
547
Auto-Cruise Control Vacuum Pump Inspection
549
Auto-Cruise Control Removal and Installation
550
Removal Steps of Actuator
551
Removal Steps of Sensor and Switches
551
Installation of Vacuum Hose
552
Cooling
553
Cooling Specifications
554
Cooling System Troubleshooting
557
Special Tool
557
Cooling System Circuit Diagram
558
Cooling System Service Adjustment Procedures
560
Engine Coolant Leak Check
560
Radiator Cap Pressure Test
560
Radiator Removal and Installation
561
Removal of Radiator Upper Hose/Lose Hose
562
Disconnection of Automatic Transaxle Oil Cooler Hoses
562
Radiator Inspection
562
Radiator Fan Motor Inspection
562
Thermo Sensor Inspection
563
Resistor Inspection
563
Radiator Fan Motor Relay Inspection
563
Radiator Fan Motor Assembly Disassembly and Reassembly
564
Installation of Radiator Lower Hose/Radiator Upper Hose
564
Thermostat Removal and Installation
565
Thermostat Inspection
565
Water Pump (SOHC) Removal and Installation
567
V-Ribbed Belt Inspection
570
Water Pump Inspection
570
Installation of O-Ring
570
Water Pump (SOHC) Installation
571
Water Pump (DOHC) Removal and Installation
572
Water Pump (DOHC) Inspection
574
Water Pump (DOHC) Installation
574
Water Hose and Water Pipe (SOHC) Removal and Installation
575
Engine Coolant Temp. Gauge Unit/Coolant Sensor Removal/Installation
583
Engine Coolant Temperature Gauge Unit Inspection
584
Engine Coolant Temperature Sensor Inspection
584
Air Conditioning Engine Coolant Temperature Switch Inspection
584
Engine Coolant Temperature Switch
585
Intake and Exhaust
587
Intake and Exhaust Specifications
588
Exhaust System
588
Intake and Exhaust Troubleshooting
591
Intake and Exhaust Service Adjustment Procedures
592
Air Cleaner Element Inspection and Replacement
592
Intake Charge Pressure Control System Inspection
593
Turbocharger Supercharging Pressure Inspection
593
Turbocharger Waste Gate Solenoid Inspection
594
Turbocharger Bypass Valve Inspection
594
Air Cleaner Removal and Installation
595
Charge Air Cooler Removal and Installation
598
Intake and Exhaust
598
Charge Air Cooler Inspection
599
Intake Manifold (SOHC 8) Removal and Installation
600
Disconnection of Radiator Upper Hose
602
Disconnection of Fuel High Pressure Hose
602
Removal of Fuel Rail, Fuel Injection and Pressure Regulator
602
Intake Manifold Plenum Check
602
Intake Manifold Check
603
Installation of Fuel Rail, Fuel Injector and Pressure Regulator
603
Connection of Radiator Upper Hose
603
Intake Manifold (SOHC 16) Removal and Installation
604
Intake Manifold (DOHC) Removal and Installation
607
Turbocharger Removal and Installation
610
Removal of Oxygen Sensor
611
Removal of Turbocharger Assembly
612
Removal of Oil Pipe
612
Turbocharger Assembly Check
612
Installation of Turbocharger Assembly
612
Exhaust Manifold (SOHC 8) Removal and Installation
613
Exhaust Manifold (SOHC 16 Valve) Removal and Installation
614
Exhaust Manifold (DOHC Non-Turbo) Removal and Installation
616
Exhaust Manifold (DOHC Turbo) Removal and Installation
617
Exhaust Pipe and Main Muffler (SOHC) Removal and Installation
618
Exhaust Pipe and Main Muffler (DOHC) Removal and Installation
619
Emission Control Systems
621
Emission Control Systems Specifications
622
Emission Control Systems Troubleshooting
623
Vacuum Hoses Routing
624
Vacuum Circuit Diagram
629
Positive Crankcase Ventilation System
633
Crankcase Ventilation System Inspection
634
Positive Crankcase Ventilation (PCV) Valve Inspection
634
Evaporative Emission Control System
635
Component Location
635
Evaporative Emission Canister
636
Evaporative Emission Purge Solenoid
636
Purge Control System Inspection
637
Purge Control System Inspection <Turbo
638
Purge Port Vacuum
639
Purge Control Valve Inspection
640
Evaporative Emission Purge Solenoid Inspection
641
Volume Air Flow Sensor, Engine Coolant Temperature Sensor and Intake Air Temperature Sensor
641
Air Conditioning Switch
641
Exhaust Gas Recirculation (EGR) System
642
Component Location
642
EGR System Inspection <California
645
EGR Valve Control Vacuum Inspection
646
EGR Valve Inspection
647
Thermal Vacuum Valve Inspection
647
EGR Temperature Sensor Inspection
648
EGR Solenoid Inspection
648
Catalytic Converter Inspection
649
Clutch
651
Clutch Specifications
652
General Specifications
652
Clutch Lubricants
653
Torque Specifications
653
Clutch Troubleshooting
654
Clutch Service Adjustment Procedures
655
Clutch Pedal Inspection and Adjustment
655
Clutch Bleeding
656
Clutch Pedal Removal and Installation
657
Clutch Pedal Inspection
659
Interlock Switch Inspection (Clutch)
659
Clutch Control Removal and Installation
660
Disconnection of Hose Clips/Clutch
661
Installation of Clutch Hose/Tube
661
Clutch Master Cylinder Disassembly and Reassembly
662
Clutch Release Cylinder Removal and Installation
663
Manual Transaxle
665
Manual Transaxle Specifications
666
Manual Transaxle Troubleshooting
667
Manual Transaxle (FWD) Service Adjustment Procedures
668
Transaxle Oil Replacement
668
Drive Shaft Oil Seals Replacement
668
Speedometer Cable Replacement
669
Transaxle Control Removal and Installation
670
Installation of Select Cable
671
Installation of Shift Cable
671
Shift Lever Assembly Disassembly and Reassembly
673
Installation of Return Spring
673
Transaxle (FWD) Removal and Installation
674
Disconnection of Compressor Assembly from Transaxle Assembly
676
Disconnection of Tie Rod End from Knuckle
676
Disconnection of Lower Arm Ball Joint
676
Disconnection of Drive Shaft
676
Removal of Transaxle Assembly
677
Installation of Drive Shaft
677
Installation of Front Height Sensor Rod
677
Installation of Starter
678
Manual Transaxle (AWD) Specifications
679
Transaxle Oil Replacement (AWD)
682
Drive Shaft Oil Seals Replacement (AWD)
682
Transfer Oil Seal Replacement (AWD)
683
Transaxle Control
683
Transaxle (AWD) Removal and Installation
684
Disconnection of Drive Shaft (AWD)
686
Transfer Removal and Installation (AWD)
687
Automatic Transaxle
689
Troubleshooting
689
Speedometer Cable Replacement
689
Specifications
689
General Specifications
689
Lubricants
689
Torque Specifications
689
Transaxle Control
689
Hydraulic Circuit - Neutral
691
Hydraulic Circuit - Parking
693
Hydraulic Circuit - Drive First
695
Hydraulic Circuit - Drive Second
697
Hydraulic Circuit - Drive Third
699
Hydraulic Circuit - Drive Fourth
701
Hydraulic Circuit - Lock-Up
703
Hydraulic Circuit - Reverse
705
Hydraulic Circuit - Neutral for 1990.5, 1991, 1992 and 1993 Model
707
Hydraulic Circuit - Parking for 1990.5, 1991, 1992 and 1993 Model
709
Hydraulic Circuit - Drive Stopping for 1990.5, 1991, 1992, 1993 Model
711
Hydraulic Circuit - Drive First for 1990.5, 1991, 1992 and 1993 Model
713
Hydraulic Circuit - Drive Second for 1990.5, 1991, 1992 and 1993 Model
715
Hydraulic Circuit - Drive Third for 1990.5, 1991, 1992 and 1993 Model
717
Hydraulic Circuit - Drive Fourth for 1990.5, 1991, 1992 and 1993 Model
719
Hydraulic Circuit - Lock-Up for 1990.5, 1991, 1992 and 1993 Model
721
Hydraulic Circuit - Reverse for 1990.5, 1991, 1992 and 1993 Model
723
Automatic Transaxle Specifications
725
Automatic Transaxle - Special Tools
727
Automatic Transaxle Troubleshooting
728
Troubleshooting Guide
730
Automatic Transaxle - Data Link and Test
732
Fluid Level and Condition (Automatic Transaxle)
732
Control Cable
732
Automatic Transaxle - Read out of Fault Codes
733
Checking the Control System (When Scan Tool Is Used)
740
Element in Use at each Position of Selector Lever
743
Automatic Transaxle - Shift Patterns
743
Inspection of Electronic Control System Components
750
Oil Pressure Tests
758
Standard Oil Pressure Table
759
Remedial Steps if Oil Pressure Is Not Normal
761
Converter Stall Test
765
Transaxle Control
765
Automatic Transaxle Circuit Diagram
766
ELC 4-Speed Automatic Transaxle Control Component Layout
786
Automatic Transaxle Service Adjustment Procedures
788
Transaxle Fluid Level Inspection
788
Transaxle Fluid Replacement
788
Transfer Oil Replacement
788
Selector Lever Operation Check
789
Key Interlock Mechanism Check
789
Shift Lock Mechanism Check
790
Park/Neutral Position Switch Adjustment
790
Kickdown Servo Adjustment
792
Line Pressure Adjustment
794
Reducing Pressure Adjustment
797
Drive Shaft Oil Seals Replacement (Automatic Transaxle)
798
Speedometer Cable Replacement (Automatic Transaxle)
799
Automatic Transaxle Control Removal and Installation
800
Power (PWR) Economy (ECO) Switch
802
Overdrive Control Switch
802
Installation of Transacle Control Cable
802
Installation of Shift Lock Cable
803
Installation of Slide Lever/Key Interlock Cable
803
Automatic Transaxle Control Disassembly and Reassembly
804
Removal of Overdrive Control Switch Connector
805
Removal of Overdrive Control Switch
805
Installation of Sleeve
805
Transaxle Oil Cooler Hoses Removal and Installation
806
Transaxle Assembly (FWD) Removal and Installation
807
Disconnection of Tie Rod End
810
Transaxle Assembly (AWD) Removal and Installation
811
Automatic Transaxle Transfer Removal and Installation
814
Propeller Shaft
815
Propeller Shaft Specifications
816
Propeller Shaft Removal and Installation
818
Propeller Shaft Disassembly and Reassembly
820
Propeller Shaft
827
Front Axle
831
Front Axle Specifications
832
Front Axle Troubleshooting and Service Adjustment Procedures
835
Hub End Play Inspection
835
Hub and Knuckle Removal and Installation
836
Hub and Knuckle Disassembly and Reassembly
839
Drive Shaft (FWD)
842
Drive Shaft (FWD) Removal and Installation
843
Drive Shaft (TJ-RJ Type) Disassembly and Reassembly
845
Installation of Boot Band
848
Drive Shaft (TJ-BJ Type) Disassembly and Reassembly
849
Drive Shaft (AWD - up to 1992 Models)
852
Drive Shaft Grease Points
856
Rear Axle
861
Rear Axle (FWD) Specifications
862
Rear Axle (FWD) Troubleshooting
862
Wheel Bearing End Play Adjustment
863
Rear Hub Rotary-Sliding Resistance (Torque) Adjustment
865
Rear Axle Hub Removal and Installation
866
Rear Axle Hub Disassembly and Reassembly
867
Rear Axle (AWD - up to 1992 Models) Specifications
870
Rear Axle (AWD - up to 1992 Models) Troubleshooting
874
Rear Axle Total Backlash Check
875
Gear Oil Level Check
875
Rear Wheel Bearing Rotation Sliding Resistance Check
876
Axle Shaft Removal and Installation
877
Drive Shaft Parts Distinction
880
Rear Axle (AWD) Drive Shaft Removal and Installation
881
Rear Axle (AWD) Drive Shaft Disassembly and Assembly
882
Differential Carrier Removal and Installation
886
Differential Support Member Bushing Replacement
887
Final Drive Gear Backlash
887
Drive Gear Runout
887
Differential Gear Backlash
887
Final Drive Gear Tooth Contact
888
Differential Carrier Disassembly
890
Removal of Differential Case Assembly
891
Removal of Drive Gear
891
Removal of Lock Pin
891
Removal of Self-Locking Nut
891
Removal of Drive Pinion
892
Removal of Drive Pinion Rear Bearing Inner Race
892
Removal of Oil Seal/Drive Pinion Front Bearing
892
Removal of Drive Pinion Rear Bearing Outer Race
892
Differential Carrier Reassembly
893
Adjustment of Drive Pinion Preload
896
Adjustment of Differential Gear Backlash
897
Installation of Drive Gear/Spring Pin
898
Installation of Lock Pin
898
Installation of Drive Gear
898
Adjustment of Final Drive Gear Backlash
899
Wheel and Tire
900
Wheel and Tire Specifications
901
Wheel and Tire Troubleshooting
902
Tire Inflation Pressure Check
903
Tire Wear Check
903
Wheel Runout Check
903
Wheel and Tire Removal and Installation
904
Power Plant Mount
906
Power Plant Mount Specifications
907
Power Plant Mount Troubleshooting
909
Engine Mounting Removal and Installation
909
Transaxle Mounting Removal and Installation
910
Power Plant Mount
910
Engine Roll Stopper Removal and Installation
911
Centermember and Crossmember (FWD) Removal and Installation
913
Power Plant
915
Bushing Replacement
916
Centermember/Crossmember (AWD up to 1992 Models) Removal/Installation
917
Front Suspension
922
Front Suspension Specifications
923
Front Suspension
924
Front Suspension Troubleshooting
925
Front Suspension Service Adjustment Procedures
926
Front Wheel Alignment
926
Strut Assembly Removal and Installation
927
Strut Assembly Disassembly and Reassembly
928
Lower Arm Removal and Installation
931
Stabilizer Bar (FWD) Removal and Installation
934
Removal of Front Exhaust Pipe
935
Removal of Stabilizer Link Mounting Nut
935
Checking of Stabilizer Link Ball Joint for Starting Torque
936
Ball Joint Dust Cover Replacement
936
Installation of Stabilizer Bar Bracket
937
Installation of Stabilizer Link Mounting Nut
937
Installation of Stabilizer Bar Mounting Nut
937
Stabilizer Bar (AWD up to 1992 Models) Removal and Installation
938
Active Electronic Control Suspension
940
Active Electronic Control Suspension Specifications
941
Active Electronic Control Suspension - Special Tools
946
Active Electronic Control Suspension Troubleshooting
949
G-Sensor Circuit Troubles
961
Generator "L" Terminal Circuit Troubles
963
Low-Pressure Switch Circuit Troubles
965
Throttle Position Sensor Circuit Troubles
967
High-Pressure Switch Circuit Troubles
969
Active-ECS Power Source Circuit Troubles
971
Active-ECS Indicators Circuit Troubles
973
Headlight Switch Circuit Troubles
977
Steering Angular-Velocity Sensor Circuit Troubles
979
Front-Height Sensor Circuit Troubles
981
Rear-Height Sensor Circuit Troubles
983
Vehicle Speed Sensor Circuit Troubles
985
Rear Pressure Sensor Circuit Troubles
987
Stop Light Switch Circuit Troubles
989
Back-Up Light Switch Circuit Troubles
991
Door Switch Circuit Troubles
992
Damping Force Switching Actuator Drive Circuit Troubles
993
Compressor Drive Circuit Troubles
995
Return Pump Drive Circuit Troubles
997
Exhaust Valve Activation Circuit Troubles
999
Flow-Rate Switchover Valve Activation Circuit Troubles
1001
Front Rear Exhaust Valve Activation Circuit Troubles
1003
Front Air Supply Valve Activation Circuit Troubles
1005
Rear Air Supply Valve Activation Circuit Troubles
1007
Left Front Right Front Valve Activation Circuit Troubles
1009
Left Rear/Right Rear Valve Activation Circuit Troubles
1011
Active-ECS Related Diagnostic/Service Data Output Circuit Troubles
1013
Configuration Diagram - Engine Room
1015
Concentrated Junction Diagram
1017
Engine and Transaxle Diagram
1017
Dashboard Panel Diagram
1018
Interior Diagram
1021
Instrument Panel Diagram
1023
Luggage Compartment Diagram
1024
Rear under Floor Diagram
1025
Toe-In
1026
Wheel Bearing Adjustment
1026
Alarm Light Check
1026
System Checking by Using Alarm Light
1026
Checking by On-Board Diagnostic
1027
Normal Vehicle Height Check and Adjustment
1027
Rolling Diaphragm Check
1028
Active Electronic Control Suspension System Operation Check
1029
Checking the Active-ECS Indicator Lights
1030
Checking the Damping Force
1031
Checking the Anti-Rolling Function
1031
Checking the Anti-Dive Function
1032
Checking the Anti-Squat Function
1032
Checking the Vehicle-Speed Response Function
1032
High Pressure Switch Actuation Pressure Check
1033
Low Pressure Switch Actuation Pressure Check
1034
G-Sensor Output Voltage Check
1035
Strut Assembly Removal/Installation
1036
Checking for Strut Assembly Air Leakage
1037
Strut Assembly Disassembly and Assembly
1039
Lower Arm Removal/Installation
1042
Removal of Front Height Sensor Rod
1043
Removal of Lower Arm Ball Joint
1043
Ball Joint Checking for Starting Torque
1044
Installation of Stabilizer Link Mounting
1044
Stabilizer Bar Removal and Installation
1045
Shock Absorber Assembly Removal and Installation
1049
Shock Absorber Assembly Disassembly and Reassembly
1051
Rear Suspension Assembly Removal and Installation
1053
Lateral Rod Removal and Installation
1056
Torsion Axle and Arm Assembly Removal
1058
Trailing Arm Bushing Replacement
1060
Reserve Tank Removal and Installation
1061
Reserve Tank Disassembly and Reassembly
1063
Air Compressor Removal and Installation
1064
Solenoid Valve and Dryer Removal and Installation
1066
Air Tube Removal and Installation
1072
Height Sensor Removal and Installation
1074
Active-ECS Sensor Removal and Installation
1077
Indicator Assembly Removal and Inspection
1079
Control Unit Removal and Inspection
1079
Active-ECS Relay Removal and Installation
1080
Rear Suspension
1082
Rear Suspension Specifications
1083
Rear Suspension Troubleshooting
1086
Rear Suspension Assembly Removal/Installation
1087
Rear Suspension Assembly Lubrication Points
1088
Shock Absorber Assembly Removal and Installation (Rear)
1092
Shock Absorber Assembly Disassembly and Reassembly (Rear)
1093
Lateral Rod Removal and Installation (Rear)
1095
Torsion Axle and Arm Assembly Removal and Installation (Rear)
1096
Rear Suspension Specifications (AWD - up to 1992 Models)
1100
Rear Suspension Troubleshooting (AWD - up to 1992 Models)
1103
Rear Wheel Alignment Inspection
1104
Upper and Lower Arm Removal and Installation
1109
Trailing Arm Removal and Installation
1112
Stabilizer Bar
1118
Service Brakes
1122
Service Brakes Specifications
1123
Service Brakes
1128
Service Brakes Troubleshooting
1133
Anti-Lock Braking System Troubleshooting
1136
Anti-Lock Braking System - Diagnostic Trouble Code Chart
1140
Method of Clearing Diagnostic Trouble Code Memory
1141
Actuator Test Function
1141
ABS Warning Light Does Not Light at All
1142
ABS Warning Light Illuminated after the Engine Started and Remains on
1145
ABS Light Doesn't Illuminate When Ignition Key in “START” Position
1147
Troubleshooting (ABS-AWD)
1155
Brake Pedal Inspection and Adjustment
1174
Brake Fluid Level Sensor Check
1175
Brake Booster Operating Inspection
1175
Check Valve Operation Check
1175
Proportioning Valve Function Test
1177
Service Brakes Bleeding
1178
Front Disc Brake Pad Check and Replacement
1180
Front Disc Brake Rotor Inspection
1184
Brake Disc Run-Out Correction
1185
Brake Disc Thickness Check
1185
Rear Disc Brake Pad Check and Replacement
1186
Rear Brake Disc Thickness Check
1187
Rear Brake Disc Runout Check
1187
Rear Brake Disc Run-Out Correction
1187
Brake Lining Thickness Check
1188
Brake Drum Inside Diameter Check
1188
Brake Lining and Brake Drum Connection Check
1188
Anti-Lock Braking System (ABS) Check
1189
Wheel Speed Sensor Output Voltage Check
1189
Inspection of Hydraulic Unit
1191
ABS Power Relay Check
1195
Delay Valve Check
1195
Flat Battery Remedy
1196
Brake Fluid Pressure Switch Check
1196
Brake Pedal Removal and Installation
1197
Brake Pedal Lubrication Points
1200
Brake Pedal Inspection
1201
Master Cylinder Removal and Installation
1202
Master Cylindre Disassembly and Reassembly
1204
Brake Booster Removal and Installation
1206
Brake Line Removal and Installation
1208
Front Disc Brake Removal and Installation
1215
Front Disc Brake Disassembly and Reassembly
1217
Lubrication Points
1218
Pad Wear Check
1220
Application of Brake Grease to Outer Shim/Shim Holder
1220
Rear Drum Brake Removal and Installation
1229
Adjustment of Shoe Outside Diameter
1231
Rear Brake Wheel Cylinder Removal and Installation
1232
Rear Brake Wheel Cylinder Disassembly and Reassembly
1233
Rear Disc Brake Removal
1235
Rear Disc Brake Disassembly and Reassembly
1238
Rear Disc Brake Inspection
1240
Hidraulic Unit Removal (Vehicles with ABS)
1242
Wheel Speed Sensor Removal and Installation (Vehicles with ABS)
1247
Removal of the Front Toothed Rotor
1249
Removal of Front Speed Sensor
1249
Removal of Rear Toothed Rotor
1249
Speed Sensor Inspection
1249
Installation of Rear Speed Sensor Bracket
1250
Installation of Rear Speed Sensor
1251
Installation of Front Speed Sensor
1252
G-Sensor Removal and Installation (AWD-ABS)
1253
Brake Fluid Pressure Switch Removal and Installation
1254
Electronic Control Unit Removal and Installation
1255
Parking Brakes
1256
Parking Brakes Specifications
1257
Parking Brakes Troubleshooting
1257
Service Specification
1257
Parking Brake Lever Stroke Check
1257
Parking Brake Switch Check
1258
Parking Brake Lever Removal and Installation
1259
Parking Brake Cable Removal and Installation
1260
Alphabetical Index
1262
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