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Mitsubishi MOTORS CARISMA 1996, Service Bulletin

The Mitsubishi MOTORS CARISMA 1996 is a reliable and stylish vehicle that offers exceptional performance. To ensure you have all the information you need for proper maintenance, we provide a free Service Bulletin manual. Download it from manualshive.com to access essential instructions and recommendations, keeping your car in top shape.

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15

(4)  Install the B.J. boot with the part with the smallest

diameter in a position such that the shaft groove can be
seen.

(5)  Turn the adjusting bolt on the special tool so that the size

of the opening (W) is at the standard value.

 

Standard value (W): 2.9 mm

 

<If it is larger than 2.9 mm>

 

Tighten the adjusting bolt.

 

<If it is smaller than 2.9 mm)>

 

Loosen the adjusting bolt.

 

NOTE

(1) The value of W will change by approximately 0.7 mm

for each turn of the adjusting bolt.

(2) The adjusting bolt should not be turned more than

once.

(6) Place the B.J. boot band (small against the projection at

the edge of the boot, and then secure it so that there is a
clearance left as shown by (A) in the illustration.

(7) Use the special tool to crimp the B.J. boot band (small).

 

Caution

1.  Secure the drive shaft in an upright position and

clamp the part of the B.J. boot band to be crimped
securely in the jaws of the special tool.

2.  Crimp the B.J. boot band until the special tool

touches the stopper.

FRONT AXLE - Drive shaft

26-5

<Added>

11X0138

11X0142

00003419

Adjusting bolt

Stopper

MB991561

11X0131

11X0141

00003420

Projection

B.J. boot

band (small)

B.J. boot

A11S0170

MB991561

00003421

11X0137

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Summary of Contents for CARISMA 1996

Page 1: ...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 Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 11A 7 Chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedis...

Page 2: ...s installed When a new belt is installed Tension N 392 588 441 539 637 833 Deflection mm 10 0 12 0 10 0 11 0 7 0 9 0 2 If the tension or deflection is outside the standard value adjust by the following procedure 1 Loosen tension pulley fixing bolt A 2 Adjust the amount of belt deflection using adjusting bolt B 3 Tighten fixing bolt A 4 Check the belt deflection amount and tension and readjust if n...

Page 3: ...orms you that the installation procedure for the fuel gauge Unit pump assembly or the fuel gauge unit pipe assembly has been corrected 2 Effective Date 3 Applicable Manual Manual Pub No Page s 96 CARISMA Workshop PWDE9502 English 13F 3 13F 5 Manual PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 4 Details Please refer to the attached pages O Kai E ...

Page 4: ...assembly 11 Fuel rubber drain 5 Fuel main hose 12 Filler neck assembly 6 Fuel return hose 13 Leveling hose 7 Cap 14 Filler hose Added 4A3 INSTALLATION SERVICE POINT 4 4A3 3CAP INSTALLATION Using a special tool tighten the cap to the specified torque so that the alignment mark of the fuel tank and that of the fuel pump module are in alignment Caution When the cap is tightened use care to prevent th...

Page 5: ...is tightened use care to prevent the fuel pump module from turning with the cap If alignment marks are out of alignment the float will be positioned incorrectly resulting in improper operation of the fuel remainder warning lamp 8 Check for leaks from the installation section of the fuel pump module by the following procedure 1 Apply soapy water to the circumference of the cap 2 Choke the vapor hos...

Page 6: ...Service 1 Description This Service Bulletin informs you that the procedure has been corrected for evacuation of water from the fuel filter 2 Applicable Manual Manual Pub No Language Page s 97 CARISMA Workshop PWDE9502 A English 13E 61 Manual chassis SUPPLEMENT PWDS9503 A Spanish PWDF9504 A French PWDG9505 A German PWDD9506 A Dutch PWDW9507 A Swedish PWDI96E1 A Italian 3 Details Please refer to the...

Page 7: ... after refilling the fuel When the fuel is drained for service When fuel filter is replaced When main fuel line is removed 1 Connect a long piece of tubing to the bleedscrew of the fuel injection pump with its open end in a drip tray 2 Open the bleedscrew and operate the pump on the fuel filter until clear fuel flows out of the bleedscrew 3 Close the bleedscrew and remove the tubing 4 Turn the ign...

Page 8: ...ice 1 Description Procedures for disassembling and reassembling the front disc brake caliper assemblies Have been established as shown in this Service Bulletin 2 Applicable Manual Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 35A 11 35A 21 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Details Please refer to the atta...

Page 9: ...k pin Lift caliper assembly and retain with wires Caution do not wipe off the special grease that is on the lock pin or allow it to contaminate the lock pin 3 Remove the following parts from caliper support 1 Pad wear indicator assembly 2 Pad assembly 3 Outer shim 4 In order to measure the brake drag torque after pad installation measure the rotary sliding resistance of the hub A with the pads rem...

Page 10: ...lock pin 5 Check brake drag torque as follows 1 Start the engine and then depress the brake pedal 2 3 times 2 Stop engine 3 Turn brake disc forward 10 times 6 Check hub torque B with spring balance 7 Calculate the drag torque of the disc brake difference between hub torque B and hub torque A Standard value 40 N or less 8 If the difference between brake drag torque and hub torque exceeds the standa...

Page 11: ...n boot 8 Piston seal 9 Caliper body 10 Caliper bleeder cap 11 Caliper bleeder 1 Bolt 12 Pad and wear indicator assembly 13 Pad assembly 14 Outer shim 35A 21A BASIC BRAKE SYSTEM Front Disc Brake Added Brake caliper kit Brake pad kit Brake caliper piston seal kit Grease 14U0108 14U0110 14U0111 14U0109 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 12: ...BOOT REMOVAL Protect caliper body with cloth Blow compressed air through brake hose to remove piston and piston boot Caution Blow compressed air gently Added BASIC BRAKE SYSTEMS Front Disc Brake 35A 21B 14U0108 Grease Repair kit grease Grease Repair kit grease 14U0102 14U0103 14N0139 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 13: ...ethylene alcohol or specified brake fluid Specified brake fluid DOT3 or DOT4 INSPECTION Check cylinder for wear damage or rust Check piston surface for wear damage or rust Check caliper body or sleeve for wear Check pad for damage or adhesion of grease check backing metal for damage 35A 21C BASIC BRAKE SYSTEM Front Disc Brake 35100630081 Added www WorkshopManuals co uk Purchased from www WorkshopM...

Page 14: ...on the tightening torque specifications for pressure hose attaching bolts and Eye bolts have been changed 2 Effective Date Return hose From September 21 1995 Pressure hose attaching bolt and eye bolt torques From July 12 1995 3 Applicable Manual Manual Pub No Page s 96 CARISMA Workshop PWDE9502 English 37A 20 Manual PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish P...

Page 15: ...er to P 37A 8 Old New Old New Old New R H drive vehicles L H drive vehicles 6 Eye bolt 7 Washer 8 Pressure hose 9 O ring Removal steps 4 4A3 3 1 Suction hose 2 Oil reservoir 4 4A3 3 3 Return hose 4 O ring 5 Pressure switch connector INSTALLATION SERVICE POINT 4 4A3 3RETURN HOSE SUCTION HOSE INSTALLATION Connect the hose so that the marking is facing upwards Return hose Suction hose Facing upward F...

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Page 19: ...scription This Service Bulletin informs you that the rear seatback cover replacement procedure Has been established 2 Effective Date 3 Applicable Manual Manual Pub No Page s 96 CARISMA Workshop PWDE9502 English 52A 13 Manual PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 4 Details Please refer to the attached pages O Kai E V P After Sales Service ...

Page 20: ...EAR SEATBACK COVER INSTALLATION 1 While laying the rear seatback cover over the rear seatback frame pad assembly install the hog ring on the front of the rear seatback Use hog ring pliers to install the hog ring 2 Install the lock assembly 3 Install the trim clips 4 Using hog ring pliers install the hog ring on the back of the rear seatback INTERIOR Seat 52A 13 52200180036 Knob Lock assembly Lever...

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Page 24: ...he manual indicated below concerning speedometer reed switch Continuity checking It is requested that the manual is complemented by adding the Instruction shown in this Service Bulletin to the appropriate location in the manual 2 Applicable Manual Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 54 25 Chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch ...

Page 25: ...GINE COOLANT TEMPERATURE GAUGE RESISTANCE CHECK 1 Remove the power supply tightening screw 2 Use a circuit tester to measure the resistance value between the terminals NOTE The terminal positions are indicated by T and Standard value Power supply Earth 185 227 Ω Power supply Engine coolant temperature gauge T 54 58 Ω Engine coolant temperature gauge T Earth 239 285 Ω Caution When inserting the tes...

Page 26: ... Service 1 Description Supplementary information needs to be added to the air purifier troubleshooting section in accordance with this Service Bulletin 2 Applicable Manual Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 55 49 55 59 55 60 Chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 4 Details Please refer to the ...

Page 27: ...5 55 Window glass becomes cloudy although operation is in AUTO mode 11 55 56 Outside air temperature display does not change from 20ºC 12 55 57 Condenser fan does not operate 13 55 57 Air purifier does not operate 14 55 59 Air purifier indicator lamp A P does not illuminate 15 55 59 Air purifier indicator lamp A P flashes Output voltages at collector and ionizer sections are not correct Output vol...

Page 28: ...G Ionizer and collector voltage inspection refer to P 55 69 NG Replace OK Check the harness between the air purifier and the earth and repair if necessary Inspection procedure 15 Air purifier indicator lamp A P does not illuminate however air purifier is operating Probable cause The cause is probably an open circuit in the harness between the air purifier and the A C ECU or a defective air purifie...

Page 29: ...er sections No Remove water dry Yes Collector and ionizer cleaning Inspection procedure 17 Air purifier indicator lamp A P flashes Collect output voltages at collector and ionizer sections Probable cause Correct output voltages show that the purifier is operating Faulty air purifier indicator lamp A P related circuit is probable Malfunction of transformer unit Malfunction of air conditioner contro...

Page 30: ...r Malfunction of connector Malfunction of transformer Leaks due to water on collector and ionizer sections No Remove water from dry collector and ionizer Yes Check high tension wires in collector and ionizer NG Replace the collector or ionizer OK Replace the transformer unit Heater air conditioner and ventilation fully automatic air conditioner Troubleshooting 55 59 2 Added www WorkshopManuals co ...

Page 31: ...Outside air temperature and temperature displayed on the MUT II are identical 15 Heater water temperature switch Ignition switch ON ON when heater core wall temperature is 30ºC or higher 21 Air thermo sensor Ignition switch ON Temperature of blow air from evaporator and temperature displayed on the MUT II are identical 25 Photo sensor Ignition switch ON Amount of incident light is proportional to ...

Page 32: ...ENING TORQUE INDICATION under Section GENERAL How to Use This Manual of the Service Manual 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual chassis PWDE9502 English 00 2 PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian ECLIPSE Workshop Manual chassis PWUE95E1 English 00 2 PWUS95E1 Spanish PWUF95E1 French PWUG95E1 German PWUD95E1 Dutch PW...

Page 33: ...ERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted It is given by tolerance LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally o...

Page 34: ...ERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted It is given by tolerance LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally o...

Page 35: ...adjustment procedure for valve clearance and injection timing 2 Applicable Manuals Manual Pub No Language Page s 97 CARISMA Workshop Manual chassis PWDE9502 A English 11B 6 SUPPLEMENT PWDS9503 A Spanish 11B 8 11B 9 PWDF9504 A French 11B 10 11B 12 PWDG9505 A German PWDD9506 A Dutch PWDW9507 A Swedish PWDI96E1 A Italian ENGINE F8QT Workshop Manual PWEE9602 English 11A 19 3 PWES9603 Spanish 11A 19 5 ...

Page 36: ...njection timing MB996036 Hexagon socket MB996037 Sprocket adapter MB996043 Sprocket stopper MB996035 Valve lifter Adjustment of valve clearance MB996041 Special socket Removal of fuel injector MB996045 Tension gauge Checking of drive belt tension 11B 6 F8QT ENGINE Special Tools Deleted MMZ203827Z MB996030 MB996037 MB996035 MB996045 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 37: ...the measurements 5 Based on the measurements select a tappet pad that will bring the valve clearance within the standard value Thickness of adjusting tappet pad Thickness of tappet pad installed at inspection Measured value Standard value NOTE 1 Measure the thickness of the tappet pad with a micrometer 2 Always use new tappet pads 3 Tappet pads are available in thickness from 3 25 mm to 4 25 mm In...

Page 38: ...a new pad which is 0 15 mm thinner NOTE 1 Measure the thickness of the tapped pad with a micrometer 2 Always use new tappet pads 3 Tappet pads are available in thicknesses from 3 25 mm to 4 25 mm increasing by increments of 0 05 mm and in thicknesses from 4 30 to 4 50 mm increasing by increments of 0 10 mm 10 The tappet pad must be lubricated with oil and installed with the projection facing towar...

Page 39: ...at zero NOTE The measuring pin and guide bush can only be supplied and used as a set 5 Turn the crankshaft in its normal direction of rotation until the clock gauge indicates approximately 5 00 mm 6 Apply pressure on the locking pin and turn the crankshaft in its normal direction of rotation until the locking pin engages the recess in the crankshaft web 7 Read off the value on the clock gauge 8 Th...

Page 40: ... of the tool engage the three internal recesses of the sprocket 16 Turn the tool with the flange clockwise until the backlash in the pump is eliminated and than turn it to 0 5 mm below the adjustment reference value 17 Now turn the tool with the flange counter clockwise until the adjustment reference value is obtained as shown on the pump 0 02 mm 18 Locate special tool sprocket stopper and secure ...

Page 41: ... r min 4 If the idle speed is outside the standard value range adjust by the following procedure 5 Loosen the lock nut and then turn the idle adjustment screw to adjust the idle speed to the standard value 6 tighten the lock nut to secure the idle adjustment screw 7 Insert a feeler guage with a thickness of 4 mm between the throttle elver and the stopper screw 8 Check that the idle speed is at 1 2...

Page 42: ... gauge it may damage the clock gauge The measuring pin and guide bush can only be supplied and used as a set 6 Turn the crankshaft exactly to TDC clockwise To achieve this Insert an 8 mm diameter locking pin in the hole of torxbolt Apply pressure just before TDC on this pin until it engages the recess in the crankshaft 7 Read off the value on the clock gauge This value should not differ more the 0...

Page 43: ... the set Bolt F is not needed now 4 Insert Hexagon socket spanner MB996036 in the nut assembly Loosen nut assembly approx of turn clock wise until it is possible to move the flange 2 5 Remove sprocket stopper MB996043 6 Fit sprocket adaptor MB996037 in the three holes of the flange Turn the tool with the flange until the jaws of the tool engage the three internal recesses of the sprocket 7 Turn th...

Page 44: ...8 mm diameter locking pin in the hole of torxbolt Apply pressure just before TDC on this pin until it engages the recess in the crankshaft 13 Now turn the flange with sprocket adaptor MB996037 counterclockwise until the adjustment value is obtained as shown on the pump 0 02 mm 14 Locate sprocket stopper MB996043 Fix the bracket with the two bolts supplied with the set Secure the bracket with bolt ...

Page 45: ...shaft 20 Read off the value on the clock gauge This value should not differ more the 0 02 mm as the set value shown on the pump control arm If the value is not obtained the pump has to be adjusted 21 Remove measuring divice adaptor MB996030 with the clock gauge Fit the plug with a new O ring 22 Tighten the plug to the specified torque Specified torque 10 Nm 23 Remove the locking pin and fit the pl...

Page 46: ...an only be supplied and used as a set CHECKING THE INJECTION TIMING 1 Turn the crankshaft exactly to TDC clockwise To achieve this Insert an 8 mm diameter locking pin in the hol e of torxbolt Apply pressure just before TDC on this pin until it engages the recess in the crankshaft 2 Read off the value on the clock gauge This value should not differ more the 0 02 mm as the set value shown on the pum...

Page 47: ...with the gauge installed you might damage the clock gauge NOTE The measuring pin and guide bush can only be supplied and used as a set 9 Turn the crankshaft exactly to TDC clockwise To achieve this Insert an 8 mm diameter locking pin in the hole of torxbolt Apply pressure just before TDC on this pin until it engages the recess in the crankshaft 10 Now turn the flange with sprocket adaptor MB996037...

Page 48: ... the crankshaft exactly to TDC clockwise To achieve this Insert an 8 mm diameter locking pin in the hole of torxbolt Apply pressure just before TDC on this pin until it engages the recess in the crankshaft 4 Read off the value on the clock gauge This value should not differ more the 0 02 mm as the set value shown on the pump control arm If the value is not obtained the pump has to be adjusted MEAS...

Page 49: ...e Dept 1 Description This Service Bulletin informs you of correction to the CARISMA GDI engine control system descriptions 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA PWDE9502 C English 13J 3 13J 5 Workshop Manual chassis PWDS9503 C Spanish 13J 9 13J 11 PWDF9504 C French 13J 28 13J 37 PWDG9505 C German 13J 41 13J 60 PWDD9506 C Dutch 13J 63 13J 69 PWDW9507 C Swedish 13J 86 PWDI96E...

Page 50: ...rottle body Idle position switch Rotary contact type within throttle position sensor Engine ECU Identification model No E2T68374 Air flow sensor Kaman vortex type Barometric pressure sensor Semiconductor type Intake air temperature sensor Thermistor type Engine coolant temperature sensor Thermistor type Oxygen sensor Zirconia type Vehicle speed sensor Magnetic resistive element type Inhibitor swit...

Page 51: ...Air bypass control solenoid valve ON OFF Air bypass control solenoid valve DUTY Control relay Fuel pump relay Injector driver control relay A C relay Ignition coil Engine warning lamp Diagnosis output Alternator G terminal A T ECU Engine ECU Small lamp switch Incorrect Correct From fuel pump low pressure 3 Intake air temperature sensor Fuel pump high pressure 9FU0867 To fuel tank 11Fuel pressure s...

Page 52: ...00 How to Use Troubleshooting Inspection Service Points INSPECTION USING MUT II DATA LIST AND ACTUATOR TESTING 1 Carry out inspection by means of the data list and the actuator test function If there is an abnormality check and repair the chassis harnesses and components 2 After repairing re check using the MUT II and check that the abnormal input and output have returned to normal as a result of ...

Page 53: ...r system 13J 18 24 Vehicle speed sensor system 13J 19 25 Barometric pressure sensor system 13J 20 31 Detonation sensor system 13J 21 41 Injector system 13J 22 44 abnormal combustion 13J 23 54 Immobilizer system 13J 24 56 Fuel pressure sensor system 13J 25 58 Excessive intake air amount 13J 26 61 communication wire A T ECU system 13J 26 64 Alternator FR terminal system 13J 27 66 Brake vacuum sensor...

Page 54: ...ECU and the brake vacuum sen sor and repair if necessary Voltage between 42 and earth Engine Idling OK 0 9 1 5 V Repair Check the vacuum hose between the brake vacuum sensor and the air intake plenum Check the following connectors A 121 B 20 B 22 Repair Repair Check trouble symptom Replace the brake vacuum sensor Replace the engine ECU 13J 28 GDI Troubleshooting NG Code No 89 Abnormal fuel system ...

Page 55: ...r by pass control solenoid valve system Refer to P 13J 54 INSPECTION PROCEDURE 27 MUT II Actuator test 18 Air by pass control solenoid valve ON OFF 32 Air by pass control solenoid valve DUTY Refer to P 13J 66 OK Check the ignition timing Refer to GROUP 11A On vehicle Service OK NG Check that the crank angle sensor and timing bell cover are installed property OK Clean the throttle body Refer to P 1...

Page 56: ...UT II Data list 68 EGR control servo Refer to P 13J 65 NG Check the EGR control servo system Refer to P 13J 56 INSPECTION PROCEDURE 29 OK OK Check the air by pass control solenoid valve system Refer to P 13J 54 INSPECTION PROCEDURE 27 MUT II Actuator test 18 Air by pass control solenoid valve ON OFF Refer to P 13J 66 32 Air by pass control solenoid valve DUTY Refer to P 13J 66 OK Does the engine s...

Page 57: ...p relay circuit Refer to ELECTRICAL WIRING Measure at the engine ECU connector B 20 Disconnect the connector and measure at the harness side Voltage between 52 and earth Lighting switch ON OK System voltage OK Check the following connector B 20 Repair OK Check the trouble symptoms NG Replace the engine ECU 13J 60 GDI Troubleshooting NG NG Incorrect Small lamp Correct The ON OFF condition of the sm...

Page 58: ...sor Ignition switch ON At altitude of 1 800 m 81 kPa Code No 25 13J 20 Throttle valve Set to idle position ON 26 Idle position switch Ignition switch ON check by operating accelerator pedal repeatedly Throttle valve Slightly open OFF 2 Procedure No 25 13J 52 Steering wheel stationary OFF 27 Power steering fluid pressure switch Engine Idling Steering wheel turning ON Procedure No 31 13J 58 A C swit...

Page 59: ...efficiency Engine coolant temperature 80 95 C Lights electric cooling fan and accessories OFF Transmission Neutral A T P range Engine is suddenly raced volumetric efficiency increases in response to racing 38 Crank angle sensor Engine Cranking reading is possible at 2 000 r min or less Tachometer Connected Engine speeds dis played on the MUT II and tachometer are identical 13J 63A GDI Troubleshoot...

Page 60: ...ctric load switch Engine Idling Turn on the lighting switch System voltage Radiator fan is not operating Engine coolant temperature is 90 C or less system voltage 54 Fan motor relay HI Radiator fan is operating Engine coolant temperature is 105 C or more 0 3 V 56 Diagnosis control terminal 62 Diagnosis output terminal Ignition switch ON At normal condition no diagnosis output 4 5 V Engine Stopped ...

Page 61: ...e 750 50 r min NOTE 1 The engine speed may be 20 to 100 r min lower than indicated above for a new vehicle driven approximately 500 km or less but no adjustment is necessary 2 If the engine stalls or the engine speed is low even though the vehicle has been driven approximately 500 km or more it is probable that deposits are adhered to the throttle valve so clean it Refer to P 13J 84 6 If not withi...

Page 62: ... normal condition has been changed in inspection of the engine ECU terminal voltage NOTE With the above change the part number of the engine ECU has been changed from MD341682 to MD345712 2 Effective Period From the end of September 1996 3 Interchangeability The new engine ECU is used for both the old and new cars 4 Applicable Manuals Manual Pub No Language Page s Engine Model 97 CARISMA Workshop ...

Page 63: ...FF ON 0 3 V System voltage after 2 20 seconds have passed 1 8 Timing control solenoid valve Ignition switch ON Engine Idle speed System voltage 8 12 9 EGR solenoid valve Ignition switch ON Engine Started idle speed System voltage From system voltage drops after approx 3 seconds have passed 10 Lever position sensor power supply Ignition switch ON 4 5 5 5 V 13 Power supply Ignition switch ON System ...

Page 64: ...DE9502 English 13F 2 3 chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 97 CARISMA Workshop Manual PWDE9502 A English 13F 1 2 chassis PWDS9503 A Spanish PWDF9504 A French PWDG9505 A German PWDD9506 A Dutch PWDW9507A Swedish PWDI96E1 A Italian 98 CARISMA GDI Workshop Manual PWDE9502 C English 13F 1 chassis PWDS9503 C Spanish PWDF9504 C French...

Page 65: ...t in the event of a collision 3 A plastic fuel tank has been adopted to reduce weight and improve anti corrosion effective ness SPECIAL TOOL Tool Number Name Use MB996009 Tank cap wrench Installation of tank cap SEALANTS Items Specified sealant Remarks Fuel tank Loctite 222 or 242 or equivalent 13F 2 FUEL SUPPLY Fuel Tank 13500010038 13500060026 Added www WorkshopManuals co uk Purchased from www W...

Page 66: ...k 13F 3 Pre removal Operation 1 Draining the Fuel 2 Reduce the Inner Pressure of Fuel Line and Hose Refer to GROUP 13A On vehicle Service 3 Removal of the Center Exhaust Pipe Refer to GROUP 15 Post installation Operation 1 Installation of Exhaust Pipe Refer to GROUP 15 2 Refilling the Fuel 3 Checking for Fuel Leaks Sealant Loctite 222 or 242 or equivalent Correct Added Incorrect 30 Nm Correct 30 N...

Page 67: ...Removal and installation of the fuel tank 2 Removal and installation of the fuel filter FUEL TANK SPECIAL TOOL Tool Number Name Use MB996009 Tank cap wrench Installation of tank cap SEALANTS Items Specified sealant Remarks Fuel tank Loctite 222 or 242 or equivalent 13F 1 FUEL SUPPLY General Fuel Tank Added www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 68: ...turn hose 13 Filler neck assembly A 7 Cap 14 Filler hose Pre removal Operation 1 Draining the Fuel 2 Removal of the Centre Exhaust Pipe Post installation Operation 1 Installation of Exhaust Pipe 2 Refilling the Fuel 3 Checking for Fuel Leaks Sealant Loctite 222 or 242 or equivalent Added Incorrect 30 Nm Correct 30 Nm Correct Correct Incorrect Incorrect 11 Nm flange nut 14 Nm Self locking nut A03U0...

Page 69: ...1 Installation of Exhaust Pipe Refer to GROUP 15 2 Refilling the Fuel 3 Checking for Fuel Leaks Sealant Loctite 222 or 242 or equivalent Added 11 Nm Flange nut 14 Nm Self locking nut 30 Nm 30 Nm 0510033 00007141 03U0063 Correct Incorrect Incorrect Correct Incorrect Removal steps 1 Hose connection 10 Fuel vapour hose 2 Fuel return pipe 11 Fuel filler cap 3 Band 12 Fuel rubber drain 4 Protector 13 F...

Page 70: ... This resulted in change of the erasing method for diagnostic trouble codes 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Technical Information Manual PYGE95E1 English 1 36 1 39 96 CARISMA Workshop Manual chassis PWDE9502 English 17 6 17 11 PWDS9503 Spanish 17 16 17 17 PWDF9504 French 17 21 PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 96 97 CARISMA Workshop Manu...

Page 71: ...tween the old and new ECU s should be made by reading the label affixed to an ECU New ECU Old ECU New car Old car Can be installed Can be installed if car has a battery back up wire added on the chassis side harness New ECU Old ECU Bar codes Part numbers 4 Effective Date From the middle of March 1997 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 72: ... speed sensor Control switch SET COAST RESUME ACCEL CANCEL Vehicle speed set signal input circuit Cancel signal input circuit Stop lamp switch Inhibitor switch A T Clutch switch M T Constant voltage power supply circuit battery back up Deleted Microprocessor monitor circuit Output interface circuit Actuator output monitor circuit Actuator drive circuit Cancel conditions hold circuit Cancel system ...

Page 73: ... 24 is present 25 Drive at under 40 km h Vehicle speed sensor circuit is normal if code No 25 is present 26 Turn on the inhibitor switch A T or clutch switch M T inhibitor switch circuit 27 Turn on the CANCEL switch CANCEL switch circuit 28 Operate TPS APS TPS APS circuit 29 Turn off the idle position switch idle position circuit NOTE If two more actions are taken at the same time codes are output...

Page 74: ... direction of arrow A 3 After pushing the auto cruise control switch once more in the direction of arrow A in the illustration and keeping it in this position press the stop lamp switch to the ON position for 5 seconds or more INPUT SWITCH CODE CHECK METHOD 1 Connect the MUT II to the diagnosis connector 16 pin under the instrument under cover 2 Turn the ignition switch to ON 3 After pushing the a...

Page 75: ...trol is normal 13 17 19 INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Communication with MUT I is not possible Communica tion with all system is not possible Probable cause The reason is probably a defect in the power supply system including earth for the diagnosis line Malfunction of the connector Malfunction of the harness Measure at the diagnosis connector B 41 Check the foll...

Page 76: ... memorised and displayed even though auto cruise control is cancelled Malfunction of the connector Malfunction of the harness Malfunction of the auto cruise control ECU Measure at auto cruise control ECU connector B 35 Check the following connectors B 83 B 89 B 17 Repair Disconnect the connector and measure at the harness side Voltage between terminal 6 and earth OK OK System Voltage Check trouble...

Page 77: ...UT II Check for each trouble symptom Yes Refer to inspection procedure No 2 on P 17 12 Is the diagnosis system diagnosis displayed on the MUT II normal Check for each trouble symptom Refer to inspection procedure No 8 on P 17 16 No Are any of MUT II diagnosis code Nos 11 12 14 15 16 or 17 Check for each diagnosis code Refer to P 17 7 output No Is input switch inspection possible with the MUT II Ch...

Page 78: ...witch is ON When stop lamp switch is OFF System voltage 0V 5 diagnosis control input When ignition switch is ON 4V or more 6 ECU backup power supply At any time System voltage 7 8 7 8 Motor driven vacuum pump release valve and control valve input When decelerating with the SET switch while driving at constant speed When cancelling constant speed driving with the CANCEL switch Release valve closed ...

Page 79: ...SE AUTO CRUISE CONTROL MAIN SWITCH CIGARETTE LIGHTER DEFOGGER AND DOOR MIRROR HEATER TURN SIGNAL LAMP AND HAZARD WARNING LAMP CLOCK FULL AUTO AIR CONDITIONER TAIL LAMP POSITION LAMP LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER TURN SIGNAL LAMP AND HAZARD WARNING LAMP RHEOSTAT BATTERY BACK UP POWER SOURCE Deleted AUTO CRUISE ECU HT15E13AA www WorkshopManuals co uk Purchased from www WorkshopManua...

Page 80: ... G M After Sales Service Dept 1 Description This Service Bulletin informs you of correction to the transmission gear ratios and to tightening torques of the drain plug and the filler level plug 2 Applicable Manuals Manual Pub No Language Page s TRANSMISSION Workshop Manual PWEE9508 English 22A 1 1 PWES9509 Spanish 22A 3 1 PWEF9510 French 22A 3 2a PWEG9511 German PWED9512 Dutch PWEW9513 Swedish PWE...

Page 81: ...uction ratio 4 067 4 066 3 294 3 437 TORQUE SPECIFICATIONS Items Specifications Nm Bearing housing bolts 25 Input shaft lock nut 135 Output shaft bolt 80 Cover bolts 25 Locating pin 24 Back up lamp switch 22 Drain plug 38 22 Filler level plug 22 2 25 Sealing plugs 25 Guide bushing bolts F5MR3 25 Differential nut F5MR3 130 MANUAL TRANSMISSION E W Specifications 22A 1 1 Incorrect Incorrect Correct C...

Page 82: ... Bearing sleeve A Y 07 Rear cover D T 20 Retaining ring A Y 08 O ring E U 21 5th gear wheel B W 09 Bolt F S 22 Locating pin B W 10 Shim G R 23 Cover plate B W 11 Lock nut G R 24 Poppet spring C X 12 Spring pin G R 25 Poppet ball C V 13 5th speed shift fork MANUAL TRANSMISSION E W Transmission 22A 3 1 xxx 43434 Incorrect Lubricate all internal parts with gear oil during reassembly Correct 22 Nm Inc...

Page 83: ...leeve A Y 07 Rear cover D T 20 Retaining ring A Y 08 O ring E U 21 5th gear wheel B W 09 Bolt F S 22 Locating pin B W 10 Shim G R 23 Cover plate B W 11 Lock nut G R 24 Poppet spring C X 12 Spring pin G R 25 Poppet ball C V 13 5th speed shift fork MANUAL TRANSMISSION E W Specifications 22A 3 2A RMT0002 Incorrect Lubricate all internal parts with gear oil during reassembly Correct 22 Nm Incorrect Co...

Page 84: ...n to gear ratio and final reduction ratio for the manual transmission 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual chassis PWDE9502 English 22 2 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 98 CARISMA except GDI PWDE9502 B English Newly added Workshop Manual chassis PWDS9503 B Spanish PWDF9504 B French PWDG9505 B...

Page 85: ... 705 Reverse 3 550 Final reduction ratio 4 067 LUBRICANTS Item Specified lubricant Quantity Transmission oil Elf Tranself TRX 75W 80W XT3556 3 4 22 2 MANUAL TRANSMISSION General Information Lubricants 22100010038 Incorrect Incorrect Incorrect Incorrect Incorrect Correct Correct Correct Correct Correct 2 047 0 966 0 794 3 545 4 066 22100040037 www WorkshopManuals co uk Purchased from www WorkshopMa...

Page 86: ...s the same as for the conventional F5MR1 manual transmission GENERAL INFORMATION specifications for the F5MR1 manual transmission installed on the 4G92 engine equipped car that has engine output of 73 kW 100 PS are as listed below Items Specifications Model F5MR1 Type Manual 5 speed Front wheel drive Gear ratio 1st 3 363 2nd 1 864 3rd 1 321 4th 0 966 5th 0 794 Reverse 3 545 Final reduction ratio 3...

Page 87: ...RRECTION O Kai E V P G M After Sales Service Dept 1 Description This Service Bulletin informs you of correction to the tightening torques for the manual transmission filler and drain plugs 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 22 4 chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Det...

Page 88: ...CEMENT 1 Remove transmission drain plug 2 Drain oil 3 Tighten drain plug to specified torque Specified torque 38 Nm 4 Remove filler plug and fill with specified oil till the level comes to the lower portion of filler plug hole Specified oil Elf Tranself TRX 75W 80W XT3556 Quantity 3 4 5 Tighten filler plug to specified torque Specified torque 22 Nm 22 4 MANUAL TRANSMISSION On vehicle Service 22100...

Page 89: ...ce Bulletin informs you of change in the limit value for the front brake disc run out 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 35A 4 35A 12 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Effective Date Applicable vehicle Limit value Effective date New Old CARISMA 0 06 mm or less 0 07 mm or le...

Page 90: ...ut pressure difference between left and right MPa 0 8 Brake booster push rod to master cylinder piston clearance mm 0 6 0 8 Front disc brake Pad thickness mm 10 0 2 0 Disc thickness mm 1600 18 0 16 4 1800 24 0 22 4 Disc runout mm 0 07 Old Drag force tangential force of wheel mounting bolts N 40 or less 35A 4 BASIC BRAKE SYSTEMS General Information Service Specifications Brake booster Master cylind...

Page 91: ...r turn rotor with on the car type brake lathe MAD DL 8700PF or equivalent BRAKE DISC RUN OUT CHECK 1 Remove the calliper support then raise the calliper assembly upward and secure by using wire 2 Inspect the disc surface for grooves cracks and rust Clean the disc thoroughly and remove all rust 3 Place a dial gauge approximately 5 mm from the outer circumference of the brake disc and measure the ru...

Page 92: ...vailability of the special tools for measurement of oil pressure of the power steering oil pump on the F8QT engine equipped car descriptions of the power steering oil pump pressure test have been added 2 Applicable Manuals Manual Pub No Language Page s 97 CARISMA Workshop Manual Chassis PWDE9502 A English 37A 1 SUPPLEMENT PWDS9503 A Spanish PWDF9504 A French PWDG9505 A German PWDD9506 A Dutch PWDW...

Page 93: ...ower Cover Removal Refer to GROUP 11 Crankshaft Pulley Post installation Operation 1 Power Steering Fluid Supplying 2 Drive Belt Tension Adjusting 3 Power Steering Fluid Line Bleeding 4 Oil Pump Pressure Check 5 Timing Belt Lower Cover Installation Refer to GROUP11 Crankshaft Pulley Next page comes here Removal steps 1 Drive belt 2 Power steering pump pulley 3 Suction hose connection 4 Pressure ho...

Page 94: ...Check whether or not the hydraulic pressure is the standard value when no load conditions are created by fully opening the shut off valve of the pressure gauge Standard value 0 2 0 5 Mpa 8 If it is not within the standard value the probable cause is a malfunction of the oil line or steering gear box 9 Fully open the shut off valve of the pressure gauge 10 Turn the steering wheel all the way to the...

Page 95: ...i E V P G M After Sales Service Dept 1 Description This Service Bulletin informs you of addition of a removal procedure for the center console panel and cup holder assembly 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual chassis PWDE9502 English 52A 7 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Details www Worksh...

Page 96: ...he cup holder inner INSTALLATION SERVICE POINT A CENTER AIR OUTLET ASSEMBLY INSTALLATION 1 Turn the cool air bypass lever of the center air outlet assembly fully upward 2 Turn the cool air bypass damper at the heater unit side fully downward and install the cool air bypass lever cable 1 Affix a tape to the front floor console assembly to prevent it from being damaged INTERIOR Floor Console 52A 7 S...

Page 97: ...nspection procedure for each diagnostic trouble code have been added 2 Applicable Manuals Manual Pub No Language Page s 96 ECLIPSE Workshop Manual chassis PWUE96E1 English 52B 9 PWUS95E1 Spanish PWUF95E1 French PWUG95E1 German PWUD95E1 Dutch PWUI95E1 Italian 96 CARISMA Workshop Manual chassis PWUE9502 English 52B 7 PWUS9503 Spanish PWUF9504 French PWUG9505 German PWUD9506 Dutch PWUW9507 Swedish PW...

Page 98: ...ECU Replace the SRS ECU Code No 15 Safing G sensor system Probable cause This code is output when there is a short circuit between the terminals of the safing G sensor The cause of the problem is probably a short circuit in the safing G sensor Malfunction of SRS ECU Replace the SRS ECU Code No 21 or 22 Driver s side air bag module squib system Probable cause These diagnosis codes are output if the...

Page 99: ...n the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Malfunction of connector contact 61 The harness wire of the driver s air bag module squib is grounded to the power supply 62 The harness wire of the driver s air bag module squib is grounded MUT II DIAGNOSIS CODE Disconnect clock spring connector B 41 Connect SRS check harness connector 1 Er...

Page 100: ...corrected 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 52B 22 chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 96 ECLIPSE Workshop Manual PWUE95E1 English 52B 24 chassis PWUS95E1 Spanish PWUF95E1 French PWUG95E1 German PWUD95E1 Dutch 52B 25 PWUI95E1 Italian 97 L200 Workshop Manual PWTE96E1 En...

Page 101: ...t 3 do not drop the air bag modules or clock spring or allow contact with water grease or oil Replace it if a dent crack deformation or rust is detected 4 The air bag modules should be stored on a flat surface and placed so that the pad surface is facing upward Do not place anything on top of it 5 Do not expose the air bag modules to temperatures over 93 C 6 After deployment of an air bag replace ...

Page 102: ...yed 8 An undeployed air bag module should only be disposed of in accordance with the specified procedures Refer to P 52B 30 REMOVAL AND INSTALLATION Air bag module Driver s side Clock spring 52B 24 SRS Air Bag Modules and Clock Spring 52400230010 After deployment of an air bag replace the air bag modules Check the clock spring and if faulty replace it with a new part Incorrect Correct 52400240105 ...

Page 103: ... modules or clock spring or allow contact with water grease or oil 4 Replace it if a dent crack deformation or rust is detected 4 The air bag modules should be stored on a flat surface and placed so that the pad surface is facing upward Do not place anything on top of it 5 Do not expose the air bag modules to temperatures over 93 C 6 After deployment of an air bag replace the clock spring with a n...

Page 104: ... G M After Sales Service Dept 1 Description This Service Bulletin informs you of addition of TROUBLESHOOTING under CLOCK and of 2 Bulb under Removal steps in the Workshop Manual 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 54 46 Chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Details www W...

Page 105: ... receptacle and result in poor retention of the lighter 3 The specified load should be strictly observed because overloaded cord burns the ignition switch and harness CLOCK REMOVAL AND INSTALLATION TROUBLESHOOTING 54 46 CHASSIS ELECTRICAL Cigarette Lighter Clock Symptom Probable cause Remedy Does not indicate time Connector improperly connected Repair Harness broken Repair or replace Bulb burnt Re...

Page 106: ...gap of the clutch for the A C compressor 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 55 4 34 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 96 ECLIPSE Workshop Manual PWDE95E1 English 55 4 34 PWDS95E1 Spanish PWDF95E1 French PWDG95E1 German PWDD95E1 Dutch PWDI95E1 Italian 3 Effective Date CARISMA ...

Page 107: ...pside down liquid refrigerant will enter the system and damage the compressor Caution 1 The leak detector for R 134a should be used to check for refrigerant gas leaks 2 Do not allow liquid refrigerant to touch bright metal Refrigerant will tarnish bright metal and chrome surfaces and in combination with moisture can severely corrode all metal surfaces SERVICE SPECIFICATIONS Items Standard value Id...

Page 108: ...P ADJUSTMENT Check whether or not the air gap of the clutch is within the standard value Standard value 0 4 0 65 mm NOTE If there is a deviation of the air gap from the standard value make the necessary adjustment by adjusting the number of shims 55 34 HEATER AIR CONDITIONER AND VENTILATION MANUAL AIR CONDITIONERS Compressor and Tension Pulley A20S0112 A20A0157 A20A0213 A20N0087 A20N0028 Clutch co...

Page 109: ... more until the temperature drops to approx 125 C when OFF Air gap Magnetic clutch mm 0 4 0 65 LUBRICANTS Items Specified lubricants Quantity Each connection of refrigerant line Lip seal of the compressor SUN PAG 56 As required Compressor refrigerant unit lubricant lubricant m SUN PAG 56 170 190 55 4 HEATER AIR CONDITIONER AND VENTILATION Service Specifications Lubricants 55200030103 Old New 55200...

Page 110: ...ION G AIR GAP ADJUSTMENT Check whether or not the air gap of the clutch is within the standard value Standard value 0 4 0 65 mm NOTE If there is a deviation of the air gap from the standard value make the necessary adjustment by adjusting the number of shims 55 34 HEATER AIR CONDITIONER AND VENTILATION Compressor and Tension Pulley A20S0112 A20A0157 A20A0213 A20N0087 A20N0028 Clutch coil projectio...

Page 111: ...TILATION INFORMATION O Kai E V P G M After Sales Service Dept 1 Description This Service Bulletin informs you of correction to the air conditioner performance test procedure 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual chassis PWDE9502 English 55 16 17 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Details www Wo...

Page 112: ...e hose while pressing to ensure that there are no bends in the hose 6 Start the engine 7 Set the controls to the A C as follows AC switch A C ON position Mode selection Face position Temperature control Max cooling position Air selection Recirculation position Blower switch HI Fast position 8 Adjust engine speed to 1 000 r min with A C clutch engaged 9 Engine should be warmed up with doors and win...

Page 113: ... lines will greatly reduce the capacity of the entire system High pressures are produced in the system when it is operating Extreme care must be exercised to make sure that all connections are pressure tight Dirt and moisture can enter the system when it is opened for repair replacement of lines or components The following precautions must be observed The system must be completely discharged befor...

Page 114: ...CTION O Kai E V P G M After Sales Service Dept 1 Description This Service Bulletin informs you of change in tightening torque for the mounting nut of the tensioner pulley of Volvo make 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA PWDE9502 English 11A 7 55 29 Workshop Manual chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian ww...

Page 115: ...n tension pulley fixing bolt A 2 Adjust amount of belt deflection using adjusting bolt B 3 Tighten fixing bolt A 4 Check the belt deflection amount and tension and readjust if necessary Caution Check after turning the crankshaft once or more clockwise right up Added Tighten torque 25 Nm for flange nut with flange O D of 19 5 mm 38 Nm for flange nut with flange O D of 21 8 mm 4G9 ENGINE On vehicle ...

Page 116: ...ervice Removal steps A 1 A C compressor drive belt A 2 Tension pulley B 3 Suction hose connection B 4 Discharge pipe connection C A 5 Compressor NOTE A 6 Compressor bracket 1 1 indicates flange bolt A 7 Power steering oil pump bracket 2 2 indicates flange bolt 3 3 indicates flange nut with flange O D of 19 5 mm 4 4 indicates flange nut with flange O D of 21 8 mm Added 55 29 55200410068 HEATER AIR ...

Page 117: ...t 1 Description In the Group 13J of the 98 CARISMA GDI Workshop Manual additions have been made to the GDI Troubleshooting and to the GDI Fuel Pump Hight Pressure Removal Installation procedures 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA GDI Workshop Manual PWDE9502 C English 13J 11 25 99 102 PWDS9503 C Spanish PWDF9504 C French PWDG9505 C German PWDD9506 C Dutch PWDW9507 C Swed...

Page 118: ...r system 13J 19 25 Barometric pressure sensor system 13J 20 31 Detonation sensor system 13J 21 41 Injector system 13J 22 44 Abnormal combustion 13J 23 54 Immobilizer system 13J 24 56 Fuel pressure sensor system 13J 25 58 Excessive intake air amount 13J 26 61 Communication wire with A T ECU system 13J 26 64 alternator FR terminal system 13J 27 66 Brake vacuum sensor system 13J 28 NOTE Code No 56 ma...

Page 119: ...e following connectors A 122 B 22 the engine ECU and the fuel pressure sensor OK NG OK NG Repair NG Repair Check trouble symptom Check the harness wire between NG the engine ECU and the fuel pres sure sensor Measure at the engine ECU con Check the harness wire between OK NG nector B 22 the engine ECU and the fuel pres Connect the connector sure sensor and repair if necessary Repair Voltage between...

Page 120: ...bleeding of high pressure fuel pump Removal steps 01 Fuel pressure sensor connector F 11 Fuel return lower pipe assembly I 02 High pressure fuel hose connection 12 Fuel pressure regulator high pressure 03 Fuel return hose connection assembly 04 Clamp A E 13 Flange H 05 Fuel return pipe assembly E 14 Fuel pressure sensor H 06 Fuel feed pipe assembly D 15 O ring G 07 Back up ring A D 16 Back up ring...

Page 121: ...t inside the fuel pump high pressure 2 While being careful not to damage the O ring turn the high pressure fuel hose tot he left and right and connect in to the fuel pump high pressure After connecting check that the hose turns smoothly 3 If the hose does not turn smoothly the cause may be that the O ring is getting caught Disconnect the hose check the O ring for damage and re connect the hose to ...

Page 122: ...rs in the 98 CARISMA GDI troubleshooting section The previous S B MSB 98E13 001 should be discarded 1 Description In the group 13J of the 98 CARISMA GDI Workshop Manual additions have been made to the GDI Troubleshooting and the GDI Fuel Pump High Pressure Removal Installation procedures 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA PWDE9502 C English 13J 9 10 11 25 Workshop Manual...

Page 123: ... Inspection Service Points INSPECTION USING MUT II DATA LIST AND ACTUATOR TESTING 1 Carry out inspection by means of the data list and the actuator test function If there is an abnormality check and repair the chassis harnesses and components 2 After repairing re check using the MUT II and check that the abnormal input and output have returned to normal as a result of the repairs 3 Erase the diagn...

Page 124: ...gine speed is continuously at 1 500 r min or more for a certain length of time 2 Lean fuel combustion during idle is prevented Barometric pressure sensor Control is carried out as if the barometric pressure is 101 kPa 760 mmHg Detonation sensor Ignition timing is fixed to the timing for standard petrol Injector 1 Lean fuel combustion driving is prevented 2 EGR operation is cut Abnormal combustion ...

Page 125: ...etric pressure sensor system 13J 20 31 Detonation sensor system 13J 21 41 Injector system 13J 22 44 Abnormal combustion 13J 23 54 Immobilizer system 13J 24 56 Fuel pressure sensor system 13J 25 58 Excessive intake air mount 13J 26 61 Communication wire with A T ECU system 13J 26 64 Alternator FR terminal system 13J 27 66 Brake vacuum sensor system 13J 28 NOTE Code No 56 may be output when air ente...

Page 126: ...rness wire between the engine ECU and the fuel pressure sensor OK NG Replace the engine ECU Check trouble symptom Check the harness wire between the engine ECU and the fuel pressure sensor Check the harness wire between the engine ECUY and the fuel pressure sensor and repair if necessary OK NG Measure at the engine ECU connector B 22 Connect the connector Voltage between 74 an earth Engine idling ...

Page 127: ...e high pressure regulator Regulator stuck Replace the high Pressure return pipe Pipe clogged OK MUT II Data list 74 Fuel pressure sensor Engine Run at idle for 3 minutes or more OK 4 MPa or more NG OK Replace the fuel pump high pressure Pump delivery pressure insufficient Replace the high pressure regulator Fuel leakage at return side Erase diagnosis code No 56 The cause is in entry of air into th...

Page 128: ...K Check the air by pass control solenoid valve system Refer to P 13J 54 INSPECTION PROCEDURE 27 MUT II Actuator test 18 Air by pass control solenoid valve ON OFF Refer to P 13J 66 32 Air by pass control solenoid valve DUTY Refer to P 13J 66 OK Can the sound of the injectors operating be heard while the engine is cranking Using a soundscope Check the injector system Refer to P 13J 22 Code No 41 OK ...

Page 129: ... sensor connector F 11 Fuel return lower pipe assembly I 2 High pressure fuel hose connection 12 Fuel pressure regulator high 3 Fuel return hose connection pressure assembly 4 Clamp A E 13 Flange H 5 Fuel return pipe assembly E 14 Fuel pressure sensor H 6 Fuel feed pipe assembly D 15 O ring G 7 Back up ring A D 16 Back up ring G 8 O ring C 17 Fuel nipple ring G 9 Back up ring B B 18 Fuel pump high...

Page 130: ...uel pump high pressure or the delivery pipe assembly 2 While being careful not to damage the O ring turn the high pressure fuel hose to the left and right and connect it to the fuel pump high pressure After connecting check that the hose turns smoothly 3 If the hose does not turn smoothly the cause may be that the O ring is getting caught Disconnect the hose check the O ring for damage and re conn...

Page 131: ...t 1 Description This Service Bulletin informs you of changes in GDI Troubleshooting described in each of the following Workshop Manuals 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA PWDE9502 C English 13J 22 27 28 Workshop Manual PWDS9503 C Spanish 47 65 67 68 69 Chassis SUPPLEMENT GDI PWDF9504 C French PWDG9505 C German PWDD9506 C Dutch PWDW9507 C Swedish PWDI96E1 C Italian 3 Deta...

Page 132: ...age between 12 and earth Voltage between 21 and earth Ignition switch ON OK System Voltage 2 Continuity between 13 and earth Continuity between 22 and earth OK Continuity 3 Continuity between 17 and 26 Continuity between 16 and 25 Continuity between 15 and 24 Continuity between 14 and 23 OK 13 16 Ω Repair OK NG OK Repair Check the harness wire between the injector driver and the intermediate con n...

Page 133: ...connector A 86 Connect the connector Use test harness M991519 Voltage between 4 blue clip and earth Engine Idling Radiator fan Not operating Headlamp OFF ON OK 2 0 3 0 1 0 5 0 V OK Check the following connector A 86 OK NG Check the harness wire between the engine ECU and the alternator Replace the engine ECU OK NG Repair Repair Check trouble symptom NG Replace the engine ECU Check the harness wire...

Page 134: ...e Idling OK 0 9 1 5 V Voltage between 1 and earth OK When the accelerator pedal is suddenly depressed while the engine is idling the voltage momentarily rises from 0 9 1 5 V OK NG OK Repair Replace the engine ECU Check trouble symptom NG Check the harness wire between the engine ECU and the brake vacuum sensor NG OK NG Check the harness wire between the engine ECU and the brake vacuum sensor and r...

Page 135: ...isconnect the engine ECU connector Continuity between 1 and earth OK No continuity Measure at the alternator connector A 86 Connect the connector Use test harness M991519 Voltage between 1 black clip and earth Engine Idling Radiator fan Not operating Headlamps OFF ON OK 4 5 5 5 6 5 7 5 V OK OK Check the following connectors A 23 A 86 B 20 Check the alternator Refer to GROUP 16 Charging System OK N...

Page 136: ... 13J 59 Stop lamp switch Brake pedal Released OFF 68 Engine is idling 5 15 STEP 2 500 r min 0 5 STEP EGR control servo Engine coolant temperature 80 95 C Lamps Electric cooling fan and all accessories OFF Transmission Neutral A T P range When engine is suddenly raced 0 5 STEP Procedure No 29 13J 56 74 Fuel pressure sensor Engine coolant temperature 80 95 C Lamps Electric cooling fan and all access...

Page 137: ...e speed control servo B 5 Idle speed control servo C 18 Idle speed control servo D Engine Immediately after the warm engine has been started System voltage 0 0 5 V changes repeatedly 7 A T ECU communication output Other than 0 V 59 A T ECU communication input Engine Idling Selector lever position D range 8 A C switch OFF 0 0 1 V A C relay Engine Idling A C switch ON Momentarily system voltage or m...

Page 138: ...itch ON Engine Stopped System voltage Engine Idling 0 1 V 39 EGR control servo A 40 EGR control servo B 31 EGR control servo C 32 EGR control servo D Engine Immediately after the warm engine has been started System voltage 0 0 5 V changes repeatedly 33 Alternator G terminal Engine Idling after having warmed up Radiator fan Not operating Headlamp OFF ON Stop lamp OFF ON Rear defogger switch OFF ON ...

Page 139: ...r fan and condenser fan are not operating Engine coolant temperature is 90 C or less System voltage Radiator fan and is operating Engine coolant temperature is 105 C or more 0 3 V 56 Diagnosis control terminal 62 Diagnosis output terminal Ignition switch ON At normal condition no diagnosis output 4 5 V 57 Purge control solenoid valve Ignition switch ON Engine Stopped System voltage Engine Running ...

Page 140: ... iridium plug applicable description in the Workshop Manual have been changed 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA GDI PWDE9502 C English 16 19 20 Workshop Manual chassis PWDS9503 C Spanish PWDF9504 C French PWDG9505 C German PWDD9506 C Dutch PWDW9507 C Swedish PWDI96E1 C Italian 3 Effective Date From December 3 1997 4 Interchangeability Not interchangeable except that the...

Page 141: ...It also detects the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions When the engine is cold or running at high altitudes the ignition timing is slightly advanced to provide optimum performance Furthermore if knocking occurs the ignition timing is gradually retarded until knocking ceases SYSTEM DIAGRAM IGNITION COIL SPEC...

Page 142: ...ning platinum plugs may result in damage to the platinum tip Therefore if cleaning is necessary because the plug is sooty use a plug cleaner and do not clean the plug for more than 20 seconds in order to preserve the electrodes A wire brush should never be used 3 The spark plugs in GDI engines are special platinum plugs in which the electrodes can become black even when the plugs are working norma...

Page 143: ... G M After Sales Service Dept 1 Description This Service Bulletin informs you of correction to descriptions of the ignition coil secondary coil given in each of the following Workshop Manuals 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA GDI PWDE9502 C English 16 1 19 20 Workshop Manual chassis PWDS9503 C Spanish PWDF9504 C French PWDG9505 C German PWDD9506 C Dutch PWDW9507 C Swedi...

Page 144: ...SITION SENSOR 22 CHARGING SYSTEM 2 GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 3 SPECIAL TOOLS 3 ON VEHICLE SERVICE 4 Alternator Output Line Voltage Drop Test 4 Output Current Test 5 Regulated Voltage Test 7 Waveform Check Using An Analyzer 9 Alternator Relay Continuity Check 10 STARTING SYSTEM 11 GENERAL INFORMATION 11 SERVICE SPECIFICATIONS 11 STARTER MOTOR 12 Ignition Coil With Built in Power ...

Page 145: ...ts the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions When the engine is cold or running at high altitudes the ignition timing is slightly advanced to provide optimum performance Furthermore if knocking occurs the ignition timing is gradually retarded until knocking ceases SYSTEM DIAGRAM IGNITION COIL SPECIFICATION Ite...

Page 146: ...coolant temperature sensor Idle position switch Camshaft position sensor Crank angle sensor Ignition switch ST Detonation sensor Vehicle speed sensor Inhibitor switch A T Cylinder No Spark plug Ignition coil Engine ECU To tachometer 9FU0931 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 147: ... result in damage to the iridium tip Therefore if cleaning is necessary because the plug is sooty use a plug cleaner and do not clean the plug for more than 20 seconds in order to preserve the electrodes A wire brush should never be used 3 The spark plugs in GDI engines are special iridium plugs in which the electrodes can become black even when the plugs are working normally Carbon which may beco...

Page 148: ... the ignition coil 2 Ground the spark plug outer electrode body and crank the engine 3 Check to ensure that the spark plug creates a spark 4 If the spark plug creates no spark a defective secondary coil is suspected In this event use a new ignition coil and a new spark plug to check whether a spark is created or not When the new ignition coil and the new spark plug are used if a spark is created t...

Page 149: ...NFORMATION O Kai E V P G M After Sales Service Dept 1 Description This service bulletin informs you concerning addition and correction of the hydraulic pressure test of the automatic transmission 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA PWDE9502 English 23 56 23 57 Workshop Manual chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1...

Page 150: ...ssure gauge MD998330 and joints MD998332 MD998900 to each pressure discharge port 4 Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table and check that the measured values are within the standard value ranges 5 If a value is outside the standard range correct the problem while referring to the hydraulic pressure test diagnosis table 23 56 ...

Page 151: ...590 690 590 690 450 650 D 4th gear 2 500 590 690 590 690 450 650 HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE Trouble symptom Probable cause Incorrect transmission control cable adjustment All hydraulic pressures are high Malfunction of the regulator valve Incorrect transmission control cable adjustment Malfunction of the oil pump Clogged internal oil filter Clogged external oil filter Clogged oil cool...

Page 152: ...res have been added do be included in the GROUP 26 FRONT AXLE of the Carisma Workshop Manual 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA PWDE9502 English 26 2 4 13 Workshop Manual Chassis Basic PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 96 CARISMA GDI PWDE9502 C English 23 7 Workshop Manual Chassis PWDS9503 C Spanish SUPPLEME...

Page 153: ... 05 Wheel bearing starting torque Nm 1 8 or less SEALANT Items Specified sealant Remarks Drive shaft lock pin MITSUBISHI GENUINE PART MD997110 or equivalent Semi drying sealant LUBRICANTS Items Specified lubricant Quantity g T J boot grease Repair kit grease 200 B J boot grease Repair kit grease 200 26 2 FRONT AXLE General Information Service Specifications Sealant Lubricants 26100010036 Added Dyn...

Page 154: ...er oil seal 1800 MB990947 Lower arm bushing arbor MB991387 Bushing remover and installer Press fitting of the outer oil seal 1600 MB990685 Torque wrench Measurement of the wheel bearing starting torque MB990326 Preload socket Measurement of the wheel bearing starting torque MB991389 Bushing remover base Press fitting of the inner oil seal 1600 MB991618 Hub bolt remover Removal of the hub bolt Foll...

Page 155: ...f the TJ boot Removal of the dynamic damper MD998812 Installer cap Press fitting the TJ boot MD998814 Installer 200 MD998817 Installer adapter MH062469 Gear puller Removal of the spider assembly B990560 Added www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 156: ...80 and then install it again NOTE Because there are an odd number of splines on the drive shaft the pin hole will be off line by half the width of the hole if the drive shaft is turned 180 2 Apply specified sealant to the spring pin and then insert it into the drive shaft After inserting the pin apply sealant to both ends of the pin hole to fully seal the hole Specified sealant MITSUBISHI GENUINE ...

Page 157: ...e C 14 T J boot band 14 B J boot 15 Dust cover B B 16 T J boot Caution A 17 Damper band 1 Never disassemble the B J assembly except C A 18 Dynamic damper when replacing the B J boot A 19 Damper band 2 On vehicle with ABS be sure not to damage C A 10 Dynamic damper the rotor attached to the B J outer race 26 14 FRONT AXLE Drive Shaft 26100370134 A11U0093 Added www WorkshopManuals co uk Purchased fr...

Page 158: ...en the grease contains water or foreign material Caution 1 Do not disassemble the spider assembly 2 Use care in handling so as not to damage the drive shaft B T J BOOT REMOVAL 1 Wipe off grease from the shaft spline 2 When reusing the T J boot wrap plastic tape around the shaft spline to avoid damaging the boot 3 Using the special tool remove the T J boot C DYNAMIC DAMPER REMOVAL FRONT AXLE Drive ...

Page 159: ...bly between the spider axle and the roller Specified grease Repair kit grease Caution 1 The drive shaft joint uses special grease Do not mix old and new or different types of grease 2 If the spider assembly has been cleaned take special care to apply the specified grease 2 Using the socket of 24 mm width across flats install the spider assembly 26 16 FRONT AXLE Drive Shaft Added Items A B 1600 A T...

Page 160: ...area of T J case and T J boot at 3 places INSPECTION Check the drive shaft for damage bending or corrosion Check the drive shaft spline part for wear or damage Check the spider assembly for roller rotation wear or corrosion Check the groove inside T J case for wear or corrosion Check the dynamic damper for damage or cracking Check the boots for deterioration damage or cracking B J BOOT REPLACEMENT...

Page 161: ... fully closed depressed Data changes CHECK AT THE A T ECU TERMINALS Inspection procedures are basically the same as those for 97 and prior vehicle models except that the input terminal No for the vehicle speed sensor has been changed from terminal No 46 to terminal No 69 Terminal No Check item Check requirement Normal value 69 Vehicle speed sensor When stopped 0 V Move forward slowly 0 5 V alterna...

Page 162: ...ecial tool MB991561 mm When the B J boot band large is crimped 3 2 Crimped width of the B J boot band mm 2 4 2 8 Clearance between the B J boot large diameter side and the stepped phase of the B J housing mm 0 1 1 5 LUBRICANTS Items Specified lubricant Quantity g T J Repair kit grease 120 B J Repair kit grease 120 SPECIAL TOOLS Tool Number Name Use MB991561 Boot band crimping tool B J boot band in...

Page 163: ... boot band large 4 Circlip 13 B J boot 5 Snap ring Caution A B 6 Spider assembly 1 Never disassemble the B J assembly except B A 7 T J boot when replacing the B J boot A 8 Damper band 2 On vehicle with ABS be sure not to damage A 9 Dynamic damper the rotor attached to the B J outer race 26 2 FRONT AXLE Drive Shaft Added 11I0094 00005700 11I0070 11I0100 11I0101 www WorkshopManuals co uk Purchased f...

Page 164: ...n in the figure Caution There should be no grease adhered to the rubber part of the dynamic damper NOTE The damper band and the T J boot band small are the same parts 2 Wrap plastic tape around the shaft spline and then install the T J boot band small and TJ boot B SPIDER ASSEMBLY T J CASE INSTALLATION 1 Apply the specified grease furnished in the repair kit to the spider assembly between the spid...

Page 165: ...er to adjust the amount of air inside the T J boot and then tighten the T J boot bands sercurely Standard value A 82 mm INSPECTION Check the drive shaft for damage bending or corrosion Check the drive shaft spline part for wear or damage Check the spider assembly for roller rotation wear or corrosion Check the groove inside T J case for wear or corrosion Check the dynamic damper for damage or crac...

Page 166: ... once 6 Place the B J boot band small against the projection at the edge of the boot and then secure it so that there is a clearance left as shown by A in the illustration 7 Use the special tool to crimp the B J boot band small Caution 1 Secure the drive shaft in an upright position and clamp the part of the B J boot band to be crimped securely in the jaws of the special tool 2 Crimp the B J boot ...

Page 167: ...the inside of the B J boot with the specified amount of the specified grease Specified grease Repair kit grease Amount to use 120 g Caution The driver shaft joint uses special grease Do not mix old and new or different types of grease 11 Install the B J boot band large so that there is the clearance C between it and the B J housing is at the standard value Standard value C 0 1 1 5 mm 12 Follow the...

Page 168: ... Remove the B J boot band read just the value of W in step 12 according to the following formula and then repeat the operations in steps 13 and 14 using a new B J boot band W 5 8 mm E Example If E 2 3 then W 3 5 mm 16 Check that the B J boot band is not sticking out past the place where it has been installed If the B J boot band is sticking out remove it and then repeat the operations in steps 13 ...

Page 169: ...height has been rectified 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual chassis PWDE9502 English 21 2 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 99 SPACE STAR Workshop Manual CMXE99E1 English 21 2 chassis CMXS99E1 Spanish CMXF99E1 French CMXG99E1 German CMXD99E1 Dutch CMXW99E1 Swedish CMXI99E1 Italian 3 Details ...

Page 170: ...d DOT 3 or DOT 4 Push rod assembly Boot Rubber grease Release cylinder push rod MITSUBISHI genuine grease Part No 0101011 As required ON VEHICLE SERVICE CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1 Measure the clutch pedal height and the clutch pedal clevis pin relay Standard value A 163 5 166 5 mm L H drive vehicles 162 5 165 5 mm R H drive vehicles 21 2 CLUTCH General Information Service Specificati...

Page 171: ...embly Boot Rubber grease Release cylinder push rod MITSUBISHI genuine grease Part No 0101011 As required ON VEHICLE SERVICE CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1 Turn up carpet etc under the clutch pedal 2 Measure the clutch pedal height and the clutch pedal clevis pin relay Standard value A 163 5 166 5 mm L H drive vehicles 162 5 165 5 mm R H drive vehicles Standard value B 1 3 mm 21 2 CLUTCH ...

Page 172: ...Technical Information Manual PYGE95E1 English 3 4 PWDE9502 English 33A 3 6 PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish 96 CARISMA Workshop Manual chassis PWDI96E1 Italian 99 SPACE STAR Technical Information Manual 1MXE99E1 English 3 4 CMXE99E1 English 33A 3 6 CMXS99E1 Spanish CMXF99E1 French CMXG99E1 German CMXD99E1 Dutch CMXW99E1 Swedish 99 SPACE STAR Workshop...

Page 173: ... 0 3 0 Added Caster 2 1 2 Added Kingpin inclination 1 2 4 1 At the centre of tyre tread mm 1 2 Toe In Toe angle per wheel 0 0 6 1 2 Toe out angle on turns inner wheel when outer wheel at 20 2 1 8 NOTE difference between right and left wheels less than 30 Added 3 4 DRIVE CONTROL COMPONENTS Front Suspension 30 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 174: ...e Outer wheel 32 00 Camber 0 00 30 Added Caster 2 12 Added Kingping inclination 12 41 Lower arm ball joint starting torque Nm 1 0 6 5 Lower arm ball joint turning torque Nm 1 0 3 9 Stabilizer link ball joint turning torque Nm 1 7 3 1 NOTE difference between right and left wheels less than 30 Added FRONT SUSPENSION Service Specifications 33A 3 30 www WorkshopManuals co uk Purchased from www Worksho...

Page 175: ...vehicles with aluminium type wheels attache the camber caster kingpin gauge to drive shaft by using the special tool Tighten the special tool to the same torque 200 260 Nm as the drive shaft nut Caution Never subject the wheel bearings to the vehicle load when the drive shaft nuts are loosended 33A 6 FRONT SUSPENSION On vehicle Service difference between right and left wheels less than 30 Added 30...

Page 176: ...s in the vehicle lateral direction for steering stability and riding comfort Front supporting point lower arm front bushing section positioned near the front wheel axis line to provide higher literal rigidity and reduce lateral force steering Lower arm ball joint using polyacetal resin bearing which changes the rotating torque according to applied vibration frequency LOWER ARM FRONT BUSHING Lower ...

Page 177: ...Outer wheel 34 00 Camber 0 40 30 Added Caster 2 54 30 Added Kingping inclination 13 36 Lower arm ball joint starting torque Nm 1 0 6 4 Lower arm ball joint turning torque Nm 1 0 2 5 Protruding lenght of stabilizer bar mounting bolt mm 22 NOTE difference between right and left wheels less than 30 Added FRONT SUSPENSION Service Specifications 33A 3 www WorkshopManuals co uk Purchased from www Worksh...

Page 178: ...special tool to the same torque 216 255 Nm as the drive shaft nut Caution Never subject the wheel bearings to the vehicle load when the drive shaft nuts are loosended BALL JOINT DUST COVER CHECK 1 Check the dust cover for cracks or damage by pushing it with finger 2 If the dust cover is cracks or damaged replace the lower arm assembly NOTE Cracks or damage of dust cover may cause damage of the bal...

Page 179: ... 8 liter engine equipped car limit of the front brake disc thickness has been changed The standard value remains unchanged 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA PWDE9502 English 35A 4 35A 12 Workshop Manual Chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Interchangebility Not interchangeable 4 Effective Date From F...

Page 180: ...ut fluid pressure difference between left and right Mpa 0 8 Brake booster push rod to master cylinder piston clearance mm 0 6 0 8 Pad thickness mm 10 0 2 0 1600 18 0 16 4 Disc thickness mm 1800 24 0 22 4 Disc runout mm 0 07 Front disc brake Drag force tangential force of wheel mounting bolts N 40 or less 35A 4 BASIC BRAKE SYSTEMS General Information Service Specifications 35100030058 A14U0009 21 5...

Page 181: ...e disc or turn rotor with on the car type brake lathe MAD DL 8700PF or equivalent BRAKE DISC RUN OUT CHECK 1 Remove the caliper support then raise the caliper assembly upward and secure by using wire 2 Inspect the disc surface for grooves cracks and rust Clean the disc thoroughly and remove all rust 3 Place a dial gauge approximately 5 mm from the outer circumference of the brake disc and measure ...

Page 182: ...4 Stamped on the backside of brake disc 6 4 MIN R73 5 Brake disc www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 183: ...s been added 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA PWDE9502 B English 35B 1 and 2 Workshop Manual PWDS9503 B Spanish except GDI Chassis PWDF9504 B French PWDG9505 B German PWDD9506 B Dutch PWDW9507 B Swedish PWDI96E1 B Italian 00 CARISMA PWDE9502 D English 35C 10 Workshop Manual PWDS9503 D Spanish Chassis PWDF9504 D French PWDG9505 D German PWDD9506 D Dutch PWDW9507 D Swedi...

Page 184: ... 15 Wheel speed sensor Abnormal output signal See page 4 of this S B 16 Power supply system 35B 2 21 Front right wheel speed sensor 22 Front left wheel speed sensor 23 Rear right wheel speed sensor 24 Rear left wheel speed sensor Short circuit 35B 2 38 Stop lamp switch system 35B 3 41 Front right inlet solenoid valve 42 Front left inlet solenoid valve 43 Rear right inlet solenoid valve 44 Rear lef...

Page 185: ...speed sensor inspection Replace the wheel speed sensor Wheel speed sensor output voltage inspection Refer to P 35B 8 OK NG OK Rotor inspection NG Replace the rotor Check the following connector A 48 Repair OK NG Wheel bearing inspection Replace the hydraulic unit assembly NG NG Code No Power supply system Probable cause The voltage of the ABS ECU power supply drops lower or rises higher than the s...

Page 186: ...ame size i each of four wheels Check trouble symptoms NG NO Wheel speed sensor installation inspection OK NG Repair Wheel speed sensor inspection NG Replace wheel speed sensor Wheel speed sensor output voltage inspection Refer to P 35C 17 OK OK ABS rotor inspection NG Replace the ABS rotor Check the following connector A 48 Repair OK OK Check trouble symptoms NG Replace the ABS ECU NG NG Wheel bar...

Page 187: ...eed sensor 24 Rear left wheel speed sensor Short circuit Refer to 98 CARISMA Workshop Manual GROUP 35B Troubleshooting 25 Engine speed 31 TLC solenoid valve inlet 32 TLC solenoid valve outlet 33 TLC solenoid valve inlet 34 TLC solenoid valve outlet 35C 10 38 Stop lamp switch system Refer to 98 CARRISMA Workshop Manual GROUP 35B Troubleshooting 41 Front right inlet solenoid valve 42 Front left inle...

Page 188: ...gnostic trouble codes by use of the ABS warning light 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA PWDE9502 English 35B 7 Workshop Manual Chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 99 SPACE STAR CMXE99E1 English 35B 6 Workshop Manual Chassis CMXS99E1 Spanish CMXF99E1 French CMXG99E1 German CMXD99E1 Dutch CMXW99E1 Swedi...

Page 189: ...ooting 35B 7 Caution After placing the ignition switch in the ON position do not press the brake pedal When an ABS fault occurs if the brake pedal is depresse with the ignition switch in the ON position the ABS warning light will remain illuminated This makes it impossible for the diagnostic trouble codes to be read Added Warning lamp 1 5 secs 0 5 secs 0 5 secs Pause time 3 secs Tens signal Place ...

Page 190: ...ubleshooting Caution After placing the ignition switch in the ON position do not press the brake pedal When an ABS fault occurs if the brake pedal is depresse with the ignition switch in the ON position the ABS warning light will remain illuminated This makes it impossible for the diagnostic trouble codes to be read Added Warning lamp 1 5 secs 0 5 secs 0 5 secs Pause time 3 secs Tens signal Place ...

Page 191: ... steering oil pump has been changed in the shape of hub from the round type to a three spoke type Accordingly removal and installation procedures of the power steering oil pump have been changed 2 Applicable Manuals Manual Pub No Language Page s 97 CARISMA PWDE9502 A English 37A 1 Workshop Manual Chassis PWDS9503 A Spanish Supplement PWDF9504 A French PWDG9505 A German PWDD9506 A Dutch PWDW9507 A ...

Page 192: ...n Operation 1 Power Steering Fluid Supplying 2 Drive belt Tension Adjusting 3 Power Steering Fluid Line Bleeding 4 Oil Pump Pressure Check 5 Timing Belt Lower Cover Installation Refer to GROUP 11 Crankshaft Pulley Removal steps 6 Oil pump 1 Drive belt 2 Power steering pump pulley 3 Suction hose connection 4 Pressure hose connection 5 O ring NOTE 1 Vehicles with A C 2 Vehicles without A C STEERING ...

Page 193: ...t Removal and installation of the power steering pump pulley MB996047 Special bolt MD999574 Installation of the power steering pump hub MD998815 Adapter installer STEERING Special Tools B991367 B991394 Old New www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 194: ...upplying Drive Belt Tension Check Power steering Fluid Line Bleeding Oil Pump Pressure Check Removal steps A B B A 1 Drive belt 2 Power steering pump pulley 3 Power steering pump hub 4 Suction hose connection 5 Pressure hose connection 6 O ring 7 Oill Pump NOTE 1 Vehicles with A C 2 Vehicles without A C REMOVAL SERVICE POINT A POWER STEERING PUMP PULLEY REMOVAL STEERING Power Steering Oil Pump Add...

Page 195: ...t of the special tool to the oil pump 2 Holding the bolt of the special tool from turning install the power steering pump hub while turning the nut 3 When the nut of the special tool no longer turns remove the special tool 4 Combine special tool MB996047 and special tool MD998815 and again install the bolt of the special tool on the power steering pump STEERING Power Steering Oil Pump X0116BN Powe...

Page 196: ...becomes the same as before removal Then turn the nut to install the power steering pump hub 6 Install the engine mount to body bolts B POWER STEERING PUMP PULLEY INSTALLATION STEERING Power Steering Oil Pump Added X0116BN AX0111BN Oil pump Bracket Power Steering pump hub www WorkshopManuals co uk Purchased from www WorkshopManuals co uk ...

Page 197: ...P G M After Sales Service Dept 1 Description This Service Bulletin informs you that typographical errors in the center door lock troubleshooting have been rectified 2 Applicable Manuals Manual Pub No Language Page s 98 CARISMA PWDE9502 B English 42 5 Workshop Manual chassis PWDS9503 B Spanish PWDF9504 B French PWDG9505 B German PWDD9506 B Dutch PWDW9507 B Swedish PWDI96E1 B Italian 3 Details www W...

Page 198: ...re between front continuity check Sedan Refer to P 42 5 2 door lock actuator and joint connector and repair if necessary 3 OK NG Check the following connectors Replace L H B 76X D 14 E 07 R H B 76X D 04 E 15 NG Repair OK Check the following connectors NG Repair B 76X D 11 F 02 F 19 1 Check trouble symptoms or F 31 2 NG OK Check the harness wire between rear door lock actuator and joint connector C...

Page 199: ...10 Group EXTERIOR INFORMATION O Kai E V P G M After Sales Service Dept 1 Description The washer motor removal procedure has been added 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA PWDE9502 English 51 9 10 Workshop Manual PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 3 Details www WorkshopManuals co uk Purchased from www WorkshopM...

Page 200: ...r relay Refer to GROUP 37A Steering wheel and shaft 2 Washer hose 3 Washer nozzle Washer tank removal steps Draining of washer fluid Front bumper Refer to P 51 3 8 Washer hose 9 Washer tank 10 Washer motor 11 Washer fluid level switch Wiper motor an linkage removal steps A A 4 Wiper arm and blade assembly 5 Front deck garnish 6 Wiper motor 7 Linkage B Washer motor removal 10 Washer motor EXTERIOR ...

Page 201: ...SEMBLY INSTALLATION 1 The movements of the left and right wiper arms are different so check the identification marks 2 Install the wiper blade in the specified position standard value as shown in the illustration Standard value Passenger s side A 20 5 mm Driver s side B 25 5 mm INSPECTION COLUMN SWITCH CHECK Wiper and Washer Switch Intermittent Wiper Relay Intermittent Operation Inspection 1 Conne...

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Page 224: ...orms you of correction to erasing of the diagnosis codes 2 Applicable Manuals Manual Pub No Language Page s 96 COLT LANCER PWME9511 English 52B 6 Workshop Manual CHASSIS PWMS9512 Spanish PWMF9513 French PWMG9514 German PWMD9515 Dutch PWMW9516 Swedish 98 COLT LANCER PWME9511 A English 52B 5 Workshop Manual CHASSIS PWMS9512 A Spanish PWMF9513 A French PWMG9514 A German PWMD9515 A Dutch PWMW9516 A Sw...

Page 225: ...08 Q English 52B 6 Workshop Manual CHASSIS PWWS8613 Q Spanish PWWF8612 Q French PWWG8609 Q German PWWD8610 Q Dutch PWWW8611 Q Swedish 3 Details 96 COLT LANCER Workshop Manual CHASSIS page 3 98 COLT LANCER Workshop Manual CHASSIS page 4 96 ECLIPSE Workshop Manual CHASSIS page 5 97 GALANT Workshop Manual CHASSIS page 6 96 CARISMA Workshop Manual CHASSIS page 7 97 L200 Workshop Manual CHASSIS page 8 ...

Page 226: ...hich 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 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 How t...

Page 227: ... 34 Connector lock system 52B 9 35 SRS ECU deployed air bag system 52B 9 41 IG1 A power circuit system 52B 9 42 IG1 B power circuit system 52B 9 Lamp does not illuminate 52B 10 43 SRS warning lamp driver circuit system Lamp does not switch off 52B 10 44 SRS warning lamp drive circuit system 52B 10 45 Internal circuit system of non volatile memory EEPROM inside SRS ECU 52B 11 51 52 Driver s side ai...

Page 228: ...shooting Inspection Service Points SRS WARNING LAMP INSPECTION 1 Check that the SRS warning lamp illuminates when teh ignition switch is in the ON position 2 Check that it illuminates for approximately 7 seconds and then switches off 3 If the above is not the case check the diagnosis codes 52B 6 SRS Troubleshooting Incorrect WHEN USING THE MUT II Connect the MUT II to the diagnosis connector and e...

Page 229: ...n the SRS ECU 52B 9 15 16 Front impact safing G sensor system inside SRS ECU 52B 9 17 Side impact safing G senosr system insided SRS ECU 52B 10 21 22 61 62 Driver s side air bag module squib system 52B 10 24 25 64 65 Front passenger s side air bag module squib system 52B 11 31 32 SRS ECU capacitor system 52B 11 34 Connector lock system 52B 12 35 SRS ECU deployed air bag system 52B 12 41 IG1 A powe...

Page 230: ... 7 15 Safing G sensor system 52B 7 21 22 Driver s side air bag module squib system 52B 7 24 1 25 1 Front passenger s side air bag module squib system 52B 8 26 27 Driver s side pre tensioner squib system 52B 9 28 29 Front passenger s side pre tensioner squib system 52B 9 31 32 SRS ECU capacitor system 52B 10 35 SRS ECU system ignition of the air bag or activation of the seat belt pre tensioner comp...

Page 231: ... 33 Cranking signal system 52B 10 34 Connector lock system 52B 11 41 IG1 A power circuit system 52B 11 42 IG1 B power circuit system 52B 12 43 SRS warning lamp drive circuit system Lamp does not illuminate 52B 13 SRS warning lamp drive circuit system Lamp does not switch off 52B 14 44 SRS warning lamp drive circuit system 52B 14 45 SDU non volatile memory EEPROM and A D converter system 52B 14 NOT...

Page 232: ... the malfunction code Code No Diagnosis Item Reference Page 14 Analog G sensor system in the SRS ECU 52B 7 15 16 Safing G sensor system inside SRS ECU 52B 7 21 22 51 54 1 61 64 1 Driver s side air bag module squib system 52B 8 24 25 51 54 61 64 Front passenger s side air bag module squib system 52B 9 31 32 SRS ECU capacitor system 52B 19 34 2 Connector lock system 52B 10 35 SRS ECU deployed air ba...

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