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Mitsubishi 3000GT 1994, Workshop Manual

The Mitsubishi 3000GT 1994 Workshop Manual is the ultimate guide for enthusiasts and mechanics alike. With step-by-step instructions, diagrams, and in-depth information, this manual allows you to confidently tackle any repair or maintenance task. Download it for free from manualshive.com and enhance your car knowledge today.

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Summary of Contents for 3000GT 1994

Page 1: ...1 File these pages according to the signs ADDED REVISED and DELETED on the list of ef fective pages which are interpreted below ADDED File the pages with this sign additionally in your manual REVISED DELETED Replace the existing pages with the corresponding pages with this sign Missing sheets will be supplied upon request Pub No PWUE9119 D Affi ...

Page 2: ... REVISED REVISED REVISED ADDED D D B B B B B B B D D B D B B D D B B B D D D B B B Mltsbishl Motors Corporation PWUEgltg D REvrsED o Group Page 68 69 thru 70 71 72 73 74 thru75 76 77 78 79 80 B1 82 thru 84 85 86 87 88 thru 89 90 91 thru 92 93 thru 95 96 97 thru 98 99 100 100 1 thru 100 2 101 102 103 104 105 thru 108 109 1 10 thru 1 13 114 1 15 thru 1 18 119 120 thru 121 B B B B D D A B B D B B B D...

Page 3: ...May 1992 May 1992 May 1992 May 1992 Dec 1993 May 1992 July 1994 May 1992 May 1992 July 1994 D D D D PWUEgl19 D Group Page Revision Date code Remarks REVISED REVISED REVISED ADDED REVISED REVISED REVISED REVFED ADDED REVISED REVISED ADDED REVISED REVISED REVISED 2B 3 4B 5 6thru7 B 8 thru 11 July 1993 May 1992 July 1993 May 1992 July 1993 May 1992 4 5thru7 B 8D 9 33B Electronic Control Suspension EG...

Page 4: ... D D Mlt übbhl Moto6 Corportion PWUEgl19 D 52B Supplemental Restraint System SRS 524Interior 1C 3thru4 C 5rhru22 Date Remarks Dec 1993 Dec 1993 May 1992 Dec 1993 July 1994 REVISED Dec 1993 July 199t1 REVISED Dec 1993 July 199tt REVISED Dec 1993 July 199t1 REVISED July l99tl ADDED Dec 1993 Group Page Revision code D c D D c D c D c D c D c D c D c D c D c D c D D c D c D c D lthrug C 10D 11 thru 13...

Page 5: ...July 1994 July 1994 July 1994 May 1992 July 1994 July 1994 July 1994 May 1992 July 1994 May 1992 July 1994 May 1992 July 1994 May 1992 July 1993 May 1992 July 1993 July 1993 May 1992 July 1993 July 1993 July 1994 July 1993 May 1992 July 1993 May 1992 Dec 1993 July 1993 July 1993 May 1992 July 1993 July 1993 July 1993 May 1992 July 1992 May 1992 July 1993 July 1993 July 1993 July 1993 May 1992 July...

Page 6: ...o o o o NOTES ...

Page 7: ...Engine Lubrication Fuel Cooling lntake afid Exhaust Engine Electrical Emissiolr Gontrol Glutch Manual Transmission Propellet Shaft Front A le Rear Axlb Wheel and Tyre Power Plant Mount Front Stispension Electronic Control Suspension EGSI Rear Su pension Service Brakes Parking prakes Steering 4 Wheel Steering System 4WSt Body Exterior Interior Supplenf ental Restraint System sRsl Chassis Elestrical...

Page 8: ...ING lf lmproper service or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to service perconnel from inadvertent firing of the air bagf or to the driver from rendering the SRS inoperative l2l lf at is possible that the SRS components are subjected to heat over 93 C 200 F in baking or in drying after painting remove the SRS components air ba...

Page 9: ...of Circuit Diagrams VEHICLE IDENTIFICATION Vehicle I Models nformation Code Plate Model Code Chassis Number Engine Model Number 3 3 4 6 7 7 7 I 8 9 MAJOR SPECIFICATIONS PRECAUTIONS BEFORE SERVICE SUPPORT ILOCATIONS FOR LIFTING AND JACKING STANDARD PARTS TIGHTENING TOROUE TABLE MAIN SEALANT AND ADHESIVE TABLE 10 11 13 17 18 Mltsubishi Motors Corporation July 199t1 PWUE9l1 D RRISED ...

Page 10: ...00 2 Mltrubbhl MotoE Cotportion M y 1 r9 l ...

Page 11: ...OR 36 PARKING BRAKES PARKING BRAKE BRAKE CABLE LEVER AND PARKING 374 STEERING STEERING WHEEL AND SHAFT POWER STEERING GEAR BOX 42 BODY FENDER 524 INTERIOR INSTRUMENT PANEL FLOOR CONSOLE FRONT SEAT SEAT BELT 54 CHASSIS ELECTRICAL COLUMN SWITCH HORN SWITCH IGNITION SWITCH 55 HEATER AIR CONDITIONER AND VENTILATION AI R CON D ITION ER CONTROL PANEL AND AI R CONDITIONER CONTROL UNIT HEATER UNIT DAMPER ...

Page 12: ...o o o NOTE o ...

Page 13: ...UppORT LOCATTONS FOR LIFTING Model lndications 3 AND JACKING 13 Explanation of Manual Contents a STANDARD PARTS TIGHTENING Explanation of Circuit Diagrams 6 TOROUE TABLE 17 VEHICLE IDENTIFICATION 7 MA1N SEALANT AND ADHESTVE Vehicle Information Code Plate 7 TABLE 18 Models 7 Model Code I Chassis Number 8 Engine Model Number I 10 Mhrublrhl Motor3 Corporttion Mty 1992 PWUE9 t9 ...

Page 14: ...00 2 NOTE Mtu bililotocCorDo rüm iLyt l PWUEgl19 ...

Page 15: ... or assembly on inspection or the value to which the part or assembly is corrected and adjusted lt 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 or in strength lt is a value established outside the range of standard value REFERENCE VALUE In...

Page 16: ...ible in reverse order of disassembly steps Omitted if reassembly is possible in reverse order of disassembly steps Indicates by symbols where lubrication is necessary ln this example multipurpose grease is to applied where indicated to the steering gear box Classifications of Major Maintenancc Scrvice Points When there are major points relative to maintenance and servicing procedures such as essen...

Page 17: ...on for i5int agsGmlily afld t Fffi fr ot rerurd ho e 3 5 f l t treszure hoee ä ocnrbrv 9 Ti rod end dnd knuckl conn6cting nuts 10 Tiorod end br iöints 11 Crogsm6mbä suppon brackel LrrsH8aTw Aa 8 Autac to8gTri il str n l ru fi Operating procedures cau tions etc on removal in stallation disassembly and reassembly are described tfrr M ila n lll0 r rüd d This number corresponds to the number appearing...

Page 18: ...male f ndicates a power supply destination The broken line indicates the same connector lndicates the terminal No The direction of cur rent flow is indicated by the arrow In this instance the current flow is in both directions up or down Indicates that the device side con nector includes the harness Indicates that the connector is the direct insertion type Indicates the branch point of a harness o...

Page 19: ...elseries Vehicle model ENGINE EXT 6G72 cA6 2 3 NOTE 1 From 1995 models 4 TRANS AXLE 5 COLOR INT OPT Jil f 5 r ooFoose I 2 3 4 5 Engine model T Exterior code wsMcl 35 5 L_ R2587V 03V t Rear differential reduction Transmission model Equipment code Interior colour code Body colour code MODELS Modelcode Engine model Transmission model Fuelsupply system Zl6AMNGFL6 6G7212 972 cm3 181 4 cu in WsMG1 MPI Z...

Page 20: ... drive Body style M 2 door hatchback Transmission type N 5 speed manual transmission J 6 speed manual transmission Development order 216 2 972 cc 181 4 cu in Fulltime 4WD Trim code Specified engine feature F Turbocharger with intercooler Steering wheel location L Left hand R Right hand Destination 6 For Europe CHASSIS NUMBER The chassis number is stamped on the toeboard inside the en gine compartm...

Page 21: ... displacement cm3 cu in 6G72 2 972 81 41 2 The engine serial number is stamped near the engine model number and the serial number cycles as shown belows Vehicles built up to May 1993 Engine serial number cycling AA0201 r Ävggöö ÄÄddgi wöest Vehicles built from June 1993 Engine serial number cycling Aoeeeo Aeeeee __ 1T99 t y r üöö Mitsubishi Motors Gorporation July 199t1 ...

Page 22: ... 8 0 72 41 1 285 50 6 2 470 97 21 1 560 61 4 1 580 62 2 145 5 71 1 030 40 6 1 060 41 7 11 2 17 30 4 570 179 9 1 840 72 41 1 285 50 6 2 470 p7 21 1 560 61 4 1 580 62 2 140 5 5 1 030 40 6 1 070 42 11 11 0 17 6 weight kg lbs Kerb weight Gross vehicle weight Max axle weight front rear 1 2 740 3 836 12014 6741 150 2 535 o20 2 2491 1 720 ß 792l 2 120 4 6741 1 150 2 535 1 O20 2 2491 1 730 3 858 2 120 674...

Page 23: ...e car washing equipment or steam car washing equipment is used to wash the vehicle be sure to note the toitowing information in order to avoid damage to plastic components etc o Spraynozzledistance 300 mm 1J 8 in or more o Sbray pressure 4 Mpa a0 kg cnf 569 psi or less o Spraytemperature 82C 18Cl F or less o Time of concentrated spray to one point within 30 sec MULTI USE TESTER 1993 modeb Refer to...

Page 24: ...O O MUT II All models Refer to the MUT tr OPERATING INSTRUCTIONS for instructions on handling the MUT IL Caution Connestion and disconneetion of the MUT II should always be made with the ignition switch in the OFF position trlfröhfri Moton Corporldon July tg t PUYUE91T B ADOED ...

Page 25: ...00 11 2 O NorEs ro Mltlrfibhl Motor Corporutlon July ts l PWUEgTt 8 ...

Page 26: ...cticable before handling them Other precautions Avoid prolonged and repeated contact with oils particular ly used engine oils Wear protective clothing including impervious gloves where practicable o Avoid contaminating clothes particularly underpants with oil o Do not put oily rags in pockets the use of overalls without pockets will avoid this Do not wear heavily soiled clothing and oil impregnate...

Page 27: ...LIFTING AND JACKING Caution Do not support the vehicle at locations other than specified supporting points lf do so this will cause damage etc SUPPORT POSITIONS FOR A GARAGE JACK NOTE O ä Yr r remove the center cover panelto jack up a front part Mh ubl hl MotonCorporrüon Mry 192 ...

Page 28: ...LIFT Caution When service procedures require removing rear suspension fuel tank spare tyre and rcer bump oi placo additional weight on rear end of vehicle or anchor vehicle to hoist to proyent tipping of centre of gravfi changes R dh N v ooE66 h 1 t DOUBLE POST LIFT 00E610 SINGLE POST LIFT Mlfröbhl Motors Corporetlon May l9g2 ...

Page 29: ... the following procedure 1 Place the vehicle on the H bar lift same direction 2 Place attachments on the H bar lift at thÖ designated chassis support positions When making the attachments refer to the section concerning making them Gaution lf support is at any location othsr than thc dclbmtd posiiiöns the body or suspanrlon mlgütt bc dcformcd or otherwise damaged so care should bc takcn to support...

Page 30: ... 57 x 3 74 I Nail 70 12 761 or more 32 Cautlon Thc wood sclccted for thc blockr must be hard For the B blocks and C blocks use a saw and chisel or similar tool to make grooves of the dimensions shown in the figure Make fouT ATTACHMENTS such as shown in the figure nailing B and C blocks so that each B block is sandwiched between C blocks l2l 3 Al 1 800 70 861 mm in Block C 1OO 3 93 Block Bt oqroür ...

Page 31: ...2 1 25 42 14 2 30 83 8 3 60 98 9 8 71 M14 1 5 73 7 3 53 140 14 0 101 160 16 0 116 M16 1 5 113 11 3 821 210 21 0 152 240 124 0 174l M18 1 5 170 17 0 1231 310 31 0 2241 350 35 0 253 M20 1 5 230 23 0 166 420 142 0 304l 490 49 0 354 M22 1 5 310 31 0 2241 570 57 0 412l 660 66 0 477 M24 1 5 400 40 0 289 750 75 0 5421 870 87 0 629 Flange bolt and nut tightening torque Bolt nominal diameter mm Pitch mm To...

Page 32: ...empered glass and weatherstrip o Sealing between body flange and weatherstrip 3M ATD Part No 8513 or equivalent 3M ATD Part No 8509 or equivalent l2l Sealing between laminated glass and weatherstrip 3M ATD Part No 8509 or equivalent Application Recommended brand 3 Adhesion with ribbon sealer o Waterproof film for door r Fender panel o Splash shield o Mud guard r Rear combination lamp 3M ATD Part N...

Page 33: ...elerator arm bracket and toeboard Drying sealant 4 Sealant for drum brake shoe hold down Pin and wheel cylinder 3M ATD Part No 8513 or equivalent 7 Fast bonding adhesive Adhesion of all materials except polyethylene polypropylene fluorocarbon resin or other materials with highly absorbent surface 3M ATD Part No 8155 or equivalent 8 Anaerobic fast bonding adhesives 1 Fixing of bolts and screws r Ti...

Page 34: ...o o o o NOTES ...

Page 35: ...pection ldle Speed Inspection Dashpot Inspection and Adjustment Compression Pressure Inspection Manifold Vacuum Inspection Lash Adjuster Check 5 5 6 7 I 9 10 10 CRANK SHAFT PULI EY 12 CAMSHAFT OIL SEALS 13 OIL PAN 15 CRANKSHAFT FRONT OIL SEAI 17 CRANKSHAFT REAR OIL SEAL 18 CYLINDER HEAD GASKET 20 TIMING BELT A ENGINE ASSEMBLY 28 2 2 2 2 3 Mltsublrhl Motol Cotpolrtlon May 199i PUYUEgT19 ...

Page 36: ...n torque Auto tensioner rod protrusion lgnition timing Engine idle speed Intake manifold vacuum Limit Engine compression pressure r min mmHg in Hg kpa kg m2 psi Engine compression pressure difference between each cylinder kPa kg cm2 psi mm in mm in N kg lbs Nm kgm ft lbs mm in 4 G5 5 0 157 0 216 3 5 4 0 0 138 0 157 4 15 0 0 157 197 9 S13 5 0 3744 531 7 ts9 0 0 29H 354 10 12 5 0 41H 492 251500 2F50...

Page 37: ...91502 MUT II sub assembly Allmodels r ldle speed inspection o Dashpot inspection ROM pack MD998051 Cylinder head bolt wrench Loosening and tightening of rylinder head bolt MD998717 Crankshaft front oil seal installer Installation of crankshaft front oil seal MD998718 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal MD998727 Oilpan remover Removalof oil pan Mltrölrhl Moto...

Page 38: ...holder BB Supporting the crankshaft pulley when crankshaft bolt and pulley are removed or reinstalled Use together with M8990767 MD998767 Socket wrench Adjustment of timing belt M8990968 Torque wrench Adjustment of timing belt MD998769 Crankshaft pulley spacer Used if the crankshaft needs to be rotated to attach the timing belt etc MD998782 Valve lifter set Removal of roller rocker arm ffitrrÖ rhl...

Page 39: ...ndard value Items Check value Adiustment value New beh Used belt For alterna tor and A C compressor Deflection mm in 4 15 5 0 157 2161 3 F4 0 0 13H 157 4 H 0 t0 157 197 For P S pump Deflection mm in 9 5 13 5 0 374 0 531 7 5 9 0 0 295 0 354 10 5 12 5 0 41H 492 Tension N kg lbs 25G 500 2ffio 5S110 50G700 5r70 1 10 1541 350 400 3s 40 77 g 1 DEFTECTION ADJUSTMENT OF THE ALTEß ATOR ATTD AIR CONDITIONER...

Page 40: ...ion and adjustment set vehicle in the follow ing condition Engine coolant temperature SfgboC 176 203 F o Lamps electric cooling fan and all accessories OFF o Transmission Neutral 2 Insert a paper clip into the l pin connector blue as shown in the illustration 4 Set the timing light 5 Start the engine and run at idle 6 Check that engine idle speed is within the standard value Standard valuc 7ü t 1ü...

Page 41: ...ating 2 And it is automatically further advanced by about Sofrom 15 BTDC at higher altitudes IDLE SPEED INSPECTION Ert rct 1 Before inspection and adjustment set vehicles in the follow ing condition o Engine coolant temperature 80 95 C 176 20trF o Lamps electric cooling fan and all accessories OFF o Transmission Neutral 2 Check the basic ignition timing Refer to P 11 Standard valuc 5o BTDC 3 After...

Page 42: ...ntration at idle Standard value CO concentration 0 5 or less HG concentration 1ü ppm or lecs lf the concentrations are outside the standard value check the following items Selfdiagnosis output Feed back control When the feedback control is carried out normally the output signal of the oxygen sensor changes between 0 400mV and 600 1 000mV at idle o Combustion pressure o Injector o lgnition coil spa...

Page 43: ...11 7 2 O NorEs Mltröbhifnoto lcotDorftlon Julyl9 l PUYUCgITSB AD ...

Page 44: ...e valve until the dashpot rod makes a full stroke Close the throttle valve slowly to find a point where the throttle lever contacts the dashpot rod a point where the dashpot starts to contract Hold the throttle valve at this point Check the engine speed at which the dashpot starts to operate Standard value 22 0 0 t 200 r min lf the engine speed is not within the specified limit loosen the lock nut...

Page 45: ...essure Standard value at engine speed of 250 4ül min 1 1oö kPa 111 0 kglcm2 156 psil Limit at engine speed speed of 250 lOO r mjn 810 kPa 8 1 kglcm2 115 Psil 9 Measure the compression pressure for allthe cylinders and check that the pressure differences of the cylinders are be low the limit Limit Max 1ü kPa 1 0 kglcm2 14 pd l 10 lf there is a cylinder with compression or a compression dif ference ...

Page 46: ... the amount of air niixea in the oil increases lf such mixedjn air enters the high pressure chamber in the lash adjuster the air in the high pressure chamber will be compressed while the valüe is opened thJ hsh adjuster will be excessivery compresse d and abnormat rylse will be produced when the valve is closed This is the same phenomenon which oc uri hen the valve clearance is improperly adjusted...

Page 47: ...Refer to GROUP 16 Cam Position Sensor and Crank Angle Sensor EflVA 01il p40 Sealent 3m AfD Part No 8eG0 0r cqulvrlcnt Pre removal Operation r Removal of Air lntake Plenum o Removal of liming Belt Refer to P 11 23 o Removal of Cam Position Sensor Refer to GROUP 16 Cam Position Sensor and Crank Angle Sensor Removal steps 1 Centre cover 2 Spark plug cable 3 PCV hose 4 Blow by hose 5 Rocker cover 6 Ca...

Page 48: ... seal lip and then insert 2 Press fitting the oil seal into the cylinder head INSTALLATION OF CATIISHAFT SPROCKET Hold the hexagonal section of the camshaft with wrench etc and tighten the camshaft sprocket bolt Caution Camshaft l screwdriver 0ttffiiz O Do not apply the wrench to the camrhaft rprockgt ar the sprocket could become damaged INSTALI ATION OF ROCKER COVER Tighten the rocker cover bolts...

Page 49: ...efer to GROUP 51 Bumper o Under Cover r Front Exhaust Pioe Refer to GROUP 15 Exhaust Pipe and Main Muffler o Transfer Assembly Refer to GROUP 22 fransler Assembly 75 Nm b 9 f Hl 75 Nm 7 5 kgm 5 f ft b 9 Nm 0 9 kgm m 7 ft lbs tl O kgm 29 ft lbs 6 F70 Nm 6 0 7 0 kgm ß 1ft bc 7 5 kgm 54 ft lbs 6 0 7 0 kgm 13 51ft bs 3 6 kgm 26ft tb Rcmovd3tcpe 1 Left member 2 Starter 3 Transmission stay 4 Belt housin...

Page 50: ...7 REMOVAT OF OIL PAN After removing the bolt remove the oil pan from the cylinder block with the special tool or a brass bar Caution Perform this carefully to avoid deformation of the oil pan flange E KBB O illtrübhl Moton Coryonüon May 199 PWUEgl19 ...

Page 51: ...RVICE POINTS OF REMOVAL E uBA 5 REMOVAL OF CRANKSHAFT FRONT OIL SEAL 1 Make a notch in the oil seal lip section with ä knife etc 2 Cover the end of a screwdriver with a rag and insert into the notched section of the oil seal and lever out the oil sealto remove it Caution Be careful not to damage the crankshaft and the oil pump Gase SERVICE POINTS OF INSTALLATION Elr rcAD 5 INSTALLATION OF CRANKSHA...

Page 52: ...seal MD998754 0r1ü6a SERVICE POINTS OF REMOVAL 1 REMOVAT OF FTYWHEEL Stop the crankshaft pulley from turning and remove the fly wheel Caution Use only thc specified special toolc othcrwise the crankshaft pulley damper could be damaged 2 REMOVAL OF CRANKSHAFT REAR OIL SEAL 1 Make a notch in the lip section of the oil sealwith a knife etc 2 Cover the end of screwdriver with a rag and insert into the...

Page 53: ...POINTS OF INSTALLATION Erluca 2 INSTALLATION OF CRANKSHAFT REAR OIL SEAL 1 Apply a small amount of engine oil to the oil seal lip and then insert 121 Tap the oil seal into the cylinder block block side Miüublrhl Motorr Cotpontlon May l99il PWUggl19 ...

Page 54: ...ne Coolant Refer to GROUP 14 Service Adjustment Procedures Accelerator Cable Adjustment Refer to GROUP 13 Service Adjustment Procedures Engine Adjustment Refer to P 1l O ring Cold engine 12 F130 Nm 12 13 kgm 87 4ft bs 13 Nm 3f Tff 5 ft lb s cold engine 7 12 F130 Nm r 12 13 kgm 87 04ft tb 24Nm N15 90 Nm 9 0 kgm 65 ft lbs 15N Removal steps Pipe assembly Blow by hose Center cover Front bank Spark plu...

Page 55: ...gasket on the cylinder the identification mark at the front top 14 INSTALLATION OF CYLINDER HEAD ASSEMBL 1 Use a scraper to clean the gasket surface of the head assembly Caution Take care that no foreign material gets cylinder coolaht passages or oil passages 2 Usingi the special tool and a torque wrench tigh bolts to the specified torque in the order shown illustration in two or three cycles Caut...

Page 56: ...ification Gaution Locking the camshaft sprocket with a tool damages the sprocket 5 INSTALIANON OF R rcKER COVER Tighten the rocker cover bolts in the order shown in the illustration NOTE When the rocker cover gasket has been replaced tighten bolts in this order and then re tigllten bolts 1 to 6 to 4 Nm 0 4 kgm 2 9 ft lbs MltröhhltulotorrCorporrdon Mly1992 PWUEgl19 ...

Page 57: ...r assembly 4 Drive belt power steering 5 Crankshaft pulley 6 Brake fluid level sensor 7 Timing belt upper cover 8 Engine mount bracket 9 ldler pulley alternator air conditioner 10 Engine support bracket 11 Cam position sensor and crank angle sensor connector 12 Timing belt lower cover Adjustment of timing belt tension 13 Timing belt 14 Auto tensioner t l ft fl Mitrublrhl Moton Colporrtion Mey 19 S...

Page 58: ...the remoVed timing belt sprocket and tensioner must be free from oil and water These parts should not be washed Replace parts if seriously contamin ated lf there is oil or water on each part check the front case oil seals camshaft oil seal and water pump for leaks SERVICE POINTS OF INSTALIÄTION 13 INSTALLANON OF AUTO TENSIONER 1 lf the auto tensioner rod is in its fully extended position reset it ...

Page 59: ... camshaft sprocket to move the timing mark area closest to the range A Caution In range A the cam lobe on füo the valve through the rocker arm camshaft sprocket is apt to rotate by force of the valve spring Therefore be not to have the finger pinched sprockets Turn the camshaft sprocket for either the exhaust valve to locate the timing mark as the illustration at left Then turn the other to locate...

Page 60: ... 114 turn counterclockwise then rotate it clockwise until the timing marks are aligned 2 Loosen the center bolt on the tensioner pulley Using the special tool and torque wrench apply tensioning torque to the timing belt and at the same time tighten the center bolt to öpecification Specificd torque 10 Nm 1 0 kgm 7 ft lbr l lTiming bclt tensioning torquel Caution When tightcning the ccnter boh make ...

Page 61: ... bracket are different in size depending on location insert them in numbered sequence Gaution When installing the reamer boh tighten it slowly spraying lubricant on the reamsr aret Thread diameter x Length mm in 4 toxog 0 39x2 40 Fo 0 47 x 2 50 Reamer bolt to o q Mltrubirhl Motor Co por tlon Mry 199i1 PWUE9l19 ...

Page 62: ...on of vapour hose 9 Connection of heater hose Adjustment of drive belt tension Refer to P 11 5 Po3t ißtallation Operation o Installation of Radiator Refer to GROUP 14 Radiator o Installation of Cruise Control Pump and Link Assembly Refer to GROUP 13 Cruise Control o Installation of Transmission Assembly Refer to GROUP 22 Transmission Assembly o Installation of Front Exhaust Pipe Refer to GROUP 15 ...

Page 63: ...lant temperature sensor connector Engine coolant temperature gauge unit connector 27 Condenser connector 28 lgnition coil connector 29 Power transistor connector 30 Fuel injector connector 31 Oxygen sensor connector lüFläl Nm 1G12 kgm 72 87 ft lbs r t 35 32 33 34 Engine mounting bracket Rear roll stopper bracket and engine connection bolt Front roll stopper bracket and engine connection bolt Engin...

Page 64: ...ain block or similar arrangement to suspend the engine assembly to the extent thatlhere is no rooöeness of the chain 35 REMOVAL OF ENGINE ASSEMBLY After checking that the cables hoses harness connectors etc are all removed slowly raise the chain block to lift the engine assembly upward out of the engine compartment SERVICE POINTS OF INSTALLATION ErrrDAr 35 INSTALLATION OF ENGINE ASSEMBLY When moun...

Page 65: ...NERAL INFORMATION SPECIFICATIONS Lubricants SERVICE ADJUSTMENT PROCEDURES Engine Oil Inspection Engine Oil Replacement Oil Filter Replacement Oil level sensor insPection 2 ENGINE OIL COOLER o Mlt ublthl Motor Corpor tlon Mey 1992 ...

Page 66: ...able o Avoid contaminating clothes particularly underpants with oil o Do not put oily rags in pockets the use of overalls without pockets will avoid this Do not wear heavily soiled clothing and oil impregnated foot wear Overalls must be cleaned regularly anä kept separate from personal clothing Where there is a risk of eye contäct eye protection should be worn for example chemical goggles or face ...

Page 67: ... has been started stop it and allow for some time before inspection 4 lf below the minimum level supply with specified oil Specified oil APl classiftcltlonl 8G or hlghcr Caution Refilling beyond the maximum level har aörcrlc ctrcct on engine performance Run the engine at idle and stop Then allow some time and check oil level again to make sure it is within the specified range Check to ensure that ...

Page 68: ...vel gauge El2FAAB the filler cap and then Et2rl C cap and then OIL FILTER REPLACEMENT 1 Warm up the engine 2 Drain the engine oil by removing the filler removing the drain plug Use an oil filter wrench to remove the engine oil filter Clean the surface of the filter bracket attachment Lubricate the O ing of the new oil filter with a small amount of engine oil Screw in the oil filter by hand and aft...

Page 69: ...tion switch is turned to ON do not start the en gine check that the oil level warning lamp illuminates NOTE lf the oil level warning lamp does not illuminate the cause is probably a blown lamp or a malfunction in the relay 3 When the engine is started check that the oil level warning lamp turns off NOTE lf the oil level warning indicator does not turn off tho cause is probably malfunction in the o...

Page 70: ...xtension 2 Engine oil feed hose 3 Engine oil return hose 4 Engine oil return tube 5 Engine oil cooler r35 Nm 1 5 kgm 3 t ft tb SERVICE POINTS OF REMOVAL EIA AI 2 REMOVAL OF ENGINE OIL FEED HOSE 4 ENGINE OIL RETURN TUBE Caution Be sure to hold the weld nut of the oil cooler while loosening the eye bolt 30 35 Nm 3 0 3 5 kgm 22 25tj abs in ä h d N N N 4 cr ea Mltr birhi MotoB Corpordon May 1992 PWUEg...

Page 71: ... z66r Aew uollerodroS srolow lqslqnsIw o l rvu9vlo l lllls s ldl ll N O trvultuoJNl vu3il3e J Pl W5r Fz n L äS3 gq o 9 o o o ö c H r o B Hiq 56d g o f o c a I p d g oö o m ö o o o uollBurrolul lBreuac 13nJ z eL ...

Page 72: ...elul rosuas oH J v rolsrsog dtun6 1en3 z ol Äeleg du n6 en3 dutn4 an3 qUeS Jalv od lun pjluo3 eut6u3 gl rlcl rvrs uor1u61 pue Ä1ddng re od 1 p o r6 uorpedsullueuodr uo3 uolleco l luauoduJo3 slNfNodl lroc tdl lt lo Notl3lusu lncH3A No uolpodsul Ued lenpwpul uorlcedsul uelsÄg p luoC ostnlJ Y ilii ijj ä ffiiiä i l luaurace deg 1u61 e6ne9 1en3 luorusceldau Jo1u lonJ osoH lanl alnsse 6 q6r 1 UJoJJ erns...

Page 73: ...ve Rotary contact type Engine control unit ldentification model No sM T Up to 1994 models E2T35679 LHD E2T35680 RHD sM T From 1995 models E2rü478 LHD E2T61479 RHD 6M T E2T35695 LHD E2T35696 RHD Sensors Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Oxygen sensor Vehicle speed sensor Detonation sensor Cam position sensor Crank angle sensor...

Page 74: ...r adjusting voltage Throttle position sensor resistance ldle speed control servo stepper motor coil resistance Intake air temperature sensor resistance Engine coolant temperature sensor resistance 20 c 69 F 80 c 1 76 F Fuel pressure Vacuum hose disconnection Vacuum hose connection I njector coil resistance kPa kg cm2 psi r min r min r min V ko o ko KQ o 5 t 3o BTDC at curb idle 7oo 1oo 900 at neut...

Page 75: ...before ser vrce I M8991502 MUT II sub assembly Allmodels o Reading diagnosis code MPI system inspection Auto cruise control system inspection ROM pack l6xo607 M8998464 Test harness 4 pin square Oxygen sensor inspection MB991348 Test harness set ldle switch and throttle position sensor ad justment I nspection with analyzer MD998706 Injector test set Inspection of injector MD998741 Injector test ada...

Page 76: ...zer MD998709 Adaptor hose Fuel pressure measurement MD998742 Hose adaptor MD991223 Test hamess set for inspection White harness Pin contact pres sure inspection hamess Probe for ordi nary tester con nection for gen eral connector ü Measurement of terminal voltage MD998478 Test harness 3 pin triangle Inspection by osilloscope o liitrubishi Motors Corporatlon July 199 PWUE9119 D ...

Page 77: ...and output signals for the engine control unit are not normal check the body harnesses of the MPI compe nents and rePair as necessary o After repairirig check the input and output signals for the engine iontrol unit again lf they are normalthis time check the input and output signals for the next check item Checking individual MPI components o lf thö body harnesses are normal but the input and otl...

Page 78: ...th ends directly without using a jumper lead to earth one end of the harnes PWUE9I19 AND CAUflONS FOR CtRCUtr o o The connector symbols show the pin arrangement as seen from the direction of the terminal end oi the connector actually mounted in the vehicle o When the standard value when checking the voltage is recorded as SV this is an abbreviation for system voltäge o when checking a waterproof c...

Page 79: ...rth so repair the harness As a rule use an analog type ohmmeter or circuit tester to measure the continuitY lf the harness is normal but the impressed voltage to the sensor is not normal replace the engine control unit and recheck As a rule use a digital type voltmeter or circuit tester to measure the voltage However for checking the power transistor drive voltage use an analog type voltmeter Mitr...

Page 80: ...h is turned on the engine warning lamp is lit for s seconds to indicate tnai the engine warning lamp operates normally TEMS NDICATED BY THE ENGINE WARNING LAMP Ceution Malfunctlon indicator lamp will comc on cv n whcn tcr mlnal for ignition timing adjustment ir thort circuitcd Thcrcforc it is not abnormal that thc lamp comcü on ryon whcn terminll for ignition timing adjurtmcnt ls rhort clrcuhcd at...

Page 81: ...are mem orized even if the ignition key is turned off The malfunction codes will however be erased when the batteryterminalorthe engine control unit connector is disconected Furthermore the malfunction code can also be erased by send ing the malfunction code erase signalfrom the muhi use tester MUT or MUT II to the engine control unit with turning the igni tion switch to ON Caution lf the sensor c...

Page 82: ...position sensor o ldle position switch 6 Engine coolant temperature sensor 21 Retained o Harness and connector r Engine coolant temperature sensor 7 Crank angle sensor 22 Retained r Harness and connector lf hamess and connector are normal replace crank angle sensor assembly I Cam position sensor 23 Retained r Harness and connector lf harness and connector are normal replace crank angle sensor asse...

Page 83: ...nit For No 1 4 cylin ders 44 Retained Harness and connector lgnition coil o Power transistor unit 16 lgnition coil Power transistor unit For No 2 5 cylin ders 52 Retained Harness and connector lgnition coil Power transistor unit 17 lgnition coil Power transistor unit For No 34 cylin ders 53 Retained Harness and connector lgnition coil o Power transistor unit 18 Normal state NOTE 1 Replace the engi...

Page 84: ...air tempera ture sensor signal voltage less than o 27V 1 Defective intake air tempera ture sensor 2 Open or short circuit in intake air temperature sensor circuit or connector in loose contact 3 Defective engine control unit r Somewhat poor driveability o At high temperatures a Poor startability b Unstable idling 14 Throttle position sensor 1 Throttle position sensor signal voltage less than o 2v ...

Page 85: ...V 2 Barometric pressure sensor signalvoltage less than 0 2V 1 t2l 3 Defective barometric pressure sensor Open or short circuit in baro metric pressure sensor circuit or connector in loose contact Defective engine control unit r Unstable idling r Pooracceleration o Poor startability 31 Detonatlon sensor Abnormal detonation sensor signalvoltage 1 l2l 3 Defective detonation sensor Open or short circu...

Page 86: ...ntrol logic provides controls to assure safe operation of the vehicle Trouble item Controls to be provided in the event of trouble Air flow sensor 1 21 Fueliniection timing and ignition timjlg determined on the basis of throttle position sensor TPS signaland engine spee signal crank angle sensor signal ldle speed control servo tlxed at predetermined position and no idling speed controlachieved Int...

Page 87: ...hich belongs to MUT II sub assembly 2 Turn the ignition switch ON 3 Read and record the self diagnosis output 4 Referring to the diagnosis chart repair the faulty part 5 Turn the ignition switch OFF and then turn it ON 6 Erase the malfunction code 7 Recheck the self diagnosis code and make sure that normal code is output NOTE Connect the MUT or MUT II to the white diagnosis connec tor Diagnosis by...

Page 88: ... oosition sensor E OE OE P 1 75 ldle oosition switch B tr OE P 1 78 Cam oosition sensor E OE E E P 1 80 Crank angle sensor tr E tr tr P l3 4 lgnition switch ST OE El P 13 7 Vehicle speed sensor P 13 8 Power steering fluid pressure switch P 1 90 Air conditioner switch and power relay O P l3 92 Detonation sensor Otr P 13 94 Electrical load switch P 1 96 Oxygen sensor P 13 98 Fan motor relay radiator...

Page 89: ...ngine r p m does not increase even when the accelerator pedal is depressed Hesitation sag Hesitation is the delay in response of the vehicle speed engine rpm that occurs when the accelerator is depressed in order to accelerate from the speed st which the vehicle is now traveling or a temporary drop in vehicle speed engine rpm during such accaleration Serious hesitation is called sag E o I A g 9 s ...

Page 90: ...ESHOOTING OUICK REFERENCE CHART Gruise control system is canceled when cancellation not wanted Or the cruise control system cannot be set after an automatic cancellation Check the diagnosis output Refer to P 13 31 Based on the diagnosis output code check the circuit and individual parts Refer to P 13 32 ls the result of diagnosis output check O K Can cruise control be set at the present moment Ref...

Page 91: ... code No 21 does not go away SET switch ON malfunction Replace the control switch P 13 25 Even when RESUME switch is set to OFF code No 22 does not go away RESUME switch ON malfunction Replace control switch P 13 25 Even when CANCEL switch is set to OFF code No 27 does not go away CANCEL switch ON maF f unction Replace control switch P 13 25 Even when brake pedal is depressed code No 23 is not dis...

Page 92: ... the clutch pedal is depressed lt is canceled hows ver when th6 brake pedal is d pressed Damaged or disconnected wiring of clutch switch in put circuit lf the input check code No 26 indi cates I malfunction No 7 Repair the harness or re pair or replace the clutch switch Clutch switch improper installation won t switch oN Malfunction of the ECU Replace the ECU Cannot decelerate by using the SET swi...

Page 93: ...there is no automatic can cellation at that speed Malfunction of the ve hicle speed sensor circuit No 4 Repair the vehicle speed sensor systom or re place the part Malfunction of the ECU Replace the ECU The cruise control indicator lamp of the combination meter does not il luminate But cruise control sys tem is normal Damaged or discon nected bulb of indicator lamp No 3 Repair the hamess or re pla...

Page 94: ...pted This opens the contact of relay Ry1 to stop the power supply to the control unit When the switch is released it automatically returns to the neutral position but relay Ry1 stays in the OFF state When the ignition switch is set to OFF while relay Ry1 in the mairi switch is ON relay Ry1 is forced to the OFF state just like when the main switch is set to OFF Even if the ignition switch is set to...

Page 95: ...ced to less than 40 km h 25 mph the vehicle will not resume cruising at the previously set speed even if the RESUME switch is set to ON lf the RESUME switch is kept at ON during cruise operation the engine accelerates and the vehi cie starts cruising at the speed reached when the RESUME switch was set to OFF However when the vehicle speed is raised to more than 145 km h 90 mph the vehicle cruises ...

Page 96: ...h is set to ON 2 Cruise control CRUISEI indicator lamp During cruise control operation transistor Th in the control unit is kept in the oN state to keep the indicator lamp on TROUBLESHOOTING HNTS EGU terminalvoltage Terminal No Signal name Condition Terminal voltage 23 Cruise control CRUISE indicator lamp When cruise control is active OV When cruise control is inactive System voltage i lltrSbhl Mo...

Page 97: ... of the transmission output g rr u ni le ip eOt to the control unit Four pulse signals generated per rotation of the ortpui gÄar since ine uäÄicte späed sensor is of the electronic iype the power is supplied through the ignition switch lGr TROUBLESHOOTING HINTS Diagnosis No 12 Automatically canccledl ECU terminal voltage Slowly drive forward with shift lever at 1st Speed Vehicle speed sensor Mlt u...

Page 98: ...ly is cut off TROUBTESHOOTING HINTS Diagnosis No 11 Automatically canceledl cRutsE ffils NüIE ll L H ctr ive vehicles 12 R H dr i ve veh i c I es Cruise control operation DC motor ON Current flows OFF No current flows Solenoid valve ON open OFF closed Control valve Release valve Acceleration ON ON ON Hold OFF ON ON Deceleration OFF OFF ON Release OFF OFF OFF EGU terminal vohage Terminal No Signal ...

Page 99: ... No Signal name Condition Terminal voltage 15 Stop lamp switch When brake pedal is depressed System voltage When brake pedal is not depressed 0v Inspection of clutch switch circuit CRUISE CONTROL UNIT CLUTCH PEDAl SllITCH tl l r I ruVH I tYl I e_J nYt ffi l lr 0l rlr2l 3ll I iF sEll l d l DESCRIPTION OF OPERATION When the clutch pedal is depressed during vehicle speed control the contact of the cl...

Page 100: ...or The idle switch inputs the data to the control unit on whether or not the accelerator pedal is operated TROUBTESHOONNG HINTS Diagnosis No 17 ilot automatically cancclcdl ECU terminal vohage UNIT spEg 1 H D R H D llll ß ll 0l lC äffi lbft Terminal No Signal name Condition Terminal voltage 4 ldle switch When accelerator pedal is depressed OV When accelerator pedal is not de pressed 4 5 5 5 5 Thro...

Page 101: ...self diagnosis code 3 Refer to the diagnosis chart and repair the defective point 4 Clear the self diagnosis codes by the following procedure Place the ignition switch in the ON position O With the SET switch in the ON state set the main switch to ON In less than 1 0 second thereafter set the RESUME switch to ON O With the SET switch in the ON state again keep the stop light switch in the ON state...

Page 102: ...s necessary confirm diagno sis code first and conduct input check 2 Input check can be conducted by setting operations Self diagnosis terminal outputs display patters 3 Display codes are displayed only if the circuit is normal ac cording to the conditions shown in the input check table Perform checks using the following procedures 1 Connect a multi use tester MUT or MUT II to the diagnosis inspect...

Page 103: ...erations according to the input check table and read the codes NOTE 1 When two or more input operations are performed simultaneously allthe associated code numbers are output in ascending order 2 lf no code is output by performing any of the input operations the control unit power supply circuit or SET and RESUME switches are probably defective Check the check tables 1 and 2 1P 13 24 251 Set the m...

Page 104: ... 40 km h 25 mph Vehicle speed sensor circuit normal if code Nos 24 and 25 are displayed 25 Vehicle speed less than approx 40 kmlh 25 mph 26 Clutch switch ON clutch pedaldepressed Clutch switch circuit normal 27 CANCEL switch ON CANCEL switch circuit normal 28 TPS output voltage 1 5V or more Accelerator pedal depressed more than half the way Throttle position sensor circuit normal 29 ldle switch OF...

Page 105: ... the bypass passage run the en gine with the throttle valve slightly opened 6 lf the deposit cannot be removed from the throttle valve re peat steps 4 and 5 7 Disconnect the plug from the inlet of the bypass passage 8 Install the air intake hose 9 Use a multi use tester MUT or MUT tr to erase the self diagnosis code 10 Adj ust the basic idle speed speed adjusting screw Refer to P 13 37 NOTE lf the...

Page 106: ... across terminals ang Then tighten the throttle position sensoi mounting bolt securely 7 Connect the throttle position sensor connector 8 When using the multi use tester MUT or MUT tr connect it to the diagnosis connector I9l I r tn the ignition switch ON but do not start the engine 1O when using the MUTor MUT tr select item No t a nd read the throttle position sensor output voltage Stendard value...

Page 107: ...le position switch and throttle position sensor TPS Refer to P 13 35 BASIC IDLE SPEED ADJUSTMENT NOTE 1 The basic idle speed has been factory adiusted with the speed adjusting screw SAS and does not normally require adjustment 2 lf the adjustment is required first check that the ignition plug injector ISC servo and compression pressure are nor mal 1 Before starting the inspection and adjustment pr...

Page 108: ... of the idle switch being moved lf the idle switch seems to have been moved adjust it lf it does not seem to have been moved there may be a leak caused by deteriorated fast idle air valve FIAV In such a case replace the throftle body 8 Turn the ignition switch OFF 9 Remove the jumper wire from the ignition timing adjusting terminal and replace the connector back again 10 Start the engine again and...

Page 109: ... Check for fuel leakages when the fuel is under pressure 6 0l 8 FUEL GAUGE UNIT REP1ÄCEMENT r oa 1 Remove the fuel gauge cover in the luggage compaftment 2 Disconnect the fuel pump harness connector 3 Start the engine and after it stops by itself turn the ignition switch to OFF 4 Disconnect the high pressure fuel hose connection on the body side Gaution The fuel pipe line has somc rccidual prllaur...

Page 110: ...cover FUEL PUMP OPERATION CHECK E F CII 1 Set the ignition switch at OFF 2 Check that when the battery voltage is directly applied to the fuel pump check terminal black the operating sound of the pump can be heard NOTE Since the fuel pump is installed in the fuel tank its operating sound cannot be readily heard Remove the fueltank cap and listen to the operating sound through the filter port 3 Hol...

Page 111: ...ition switch to OFF 5 Check that the accelerator cable cruise control cable and throttle cable are routed without sharp bends 6 Depress the accelerator pedal to check that the throttle lever moves smoothly from the fully closed to fullyopened position 7 Check the free travel state of the inner cables of the accelerator cable cruise control cable and throttle cable 8 lf the inner cables are too loo...

Page 112: ... back off ad justing nut B the specified number of turns Amount adjusting nut B is to be backed off About one turn linner cable free travcl 1to2 mm 0 04 to 0 08 in ll Secure the throttle cable with the lock nut Secure the adjusting bolt of the air intake plenum Turn down adjusting nut A in the direction that the free travel of the inner cable of the cruise control cable is re duced At the position...

Page 113: ...ng speed NOTE Even if during acceleration the vehicle speed reaches or ex ceeds the high limit lapproximately 200 km h 125 mph ac celeration will continue however when the switch is re leased the set speed memorized speed will become the high limit of the vehicle speed SPEED REDUCTION SETTING CHECK 1 Set to the desired speed 2 Operate the control switch downward SET switch ON 3 Check to be sure th...

Page 114: ...switch garnish 3 Operate the main switch and check for continuity across the individual terminals 1 O o denotes continuity across the terminals 2 ILL lllumination lamp 4 Connect a positive lead from the battery to terminal and a negative lead from the batteryto terminal and checkthat battery voltage is available aci oss terminal O and the earth during the period the ON side of the main switch is p...

Page 115: ...n Resistance between terminals When switch is not operated No continuity When switch is operated toward you CANCEL switch ON Approx 0 O When switch is operated upward RESUME switch ON Approx 820 O When switch is operated downward SET switch ON Approx 2 7OO O STOP LAMP SWITCH BRAKE SWITCH INSPECTION 1 Disconnect the connector iZi Cf ect for continuity between the terminals of the switch tEt qffi EE...

Page 116: ...ION For inspection refer to P 13 79 R i lltrSbhl luloto CoDontlon M y 1992 VACUUM PUMP INSPECTION Inspcction of solonoid valves control and Rcrcare vrlvccl 1 Disconnect the connector of the vacuum pump assembly 2 Measure the resistance values across terminals O and and across terminals O and Standard value 50 60 O 3 Check that when the battery voltage is applied across termi nals O and and across ...

Page 117: ...holder portion does not change its position 3 After the actuator has been mounted check and adjust the cruise control cable Refer to P 1341 CRUISE CONTROL RELAY INSPECTION 1 Remove the cruise control relay 2 Apply battery power to terminal and connect terminal D to the earth Check for continuity across the terminals Il When power is supplied Across terminals 1 3 Continuity When no oower is supplie...

Page 118: ...ming adjustment terminal o Injector P Cam position sensor D Oxygen sensor o Control relay E Power steering fluid pressure switch R Crank angle sensor F Purge control solenoid valve S Detonation sensor G Resistor T EGR control solenoid valve H Self diagnosis connector U Engine control unit Throttle position sensor with idle position switch V Engine coolant temperature sensor J Engine warning lamp M...

Page 119: ...13 49 d Air conditroner Air f low sensor li with built in intake arr temperature sensor and barometric Pressure FU1309 Control relay E EGR control solenoid valve I TFUrorl Engine coolant temperature sensor O Mitsubishi Motors Corporation Mty 1992 ...

Page 120: ...50 FUEL On vehicle Inspestion of Mpl Gomponents Y fr r lgnition coil power transistor r n Iei lgnition timing l adlusting terminal Oxygen sensor h 0 solenoid valve TFUloog Mlteübhl Moton Corporrtlon May t9 ...

Page 121: ...FUEL On vehicle Inspection of MPI Components 13 51 Self diagnosis connector oino q ä l r Waste gate solenoid valve Mltsubishi Motoß Corporation July 1994 PWUEgl19 D EVISED ...

Page 122: ...ound check the body harness components etc and repair as necessary 2 After repair check again with the MUT or MUT II to make sure that the input and output signals are now normal 3 Erase the selfdiagnosis trouble code in memory 4 Disconnect the MUT or MUT II 5 Start the engine and perform running test etc to make sure that the troubles have been corrected Mlttr bithl Moto6 Corporation July 1994 PW...

Page 123: ...13 51 2 Mlteubishl Motors Corporatlon July 19910 PWUEgl19 D ...

Page 124: ...he ignition switch to the engine control unit which then turns ON the power transistor to energize the control relay coil This turns ON the control relay switch and the power is supplied from the battery to the engine control unit through the control relay switch INSPECTION Using Multi use Tester MUTI or MUT II Battery lgnition switch ilGl AF d Function Item No Data display Check condition Standar...

Page 125: ...y connector Disconnected Voltage V SV Repair the Battery 8 tr Check for an open circuit or a short ircuit to earth between the enqine control unit and the controlrelay Z lngine control unit connector OK Disconnectea _7 Control relay connector Disconnected harness 6 E 6AF0050 Repair the harness tr m E Measure power voltage to the actuator Control relay connector Connected a Engine control unit conn...

Page 126: ...erminal of control relay to battery O terminal Connecting and disconnecting the jumper wire to battery O terminal check the continuity across terminals and D or and of the control relaY 7 Replace the control relay if any defect is evident CONTROL RELAY INSPECTION 1 Remove the control relaY iZ Cnecf for continuity between control relay terminals 3 4 5 6 TerminalNo Continuity 5 7 Conductive 6 8 Cond...

Page 127: ...ne control unit TROUBLESHOOTING HINTS lf the earth wire of the engine control unit is not connected securely to earth the unit will not operate correctly HARNESS INSPECTION Check for continuity of the earth circuit Engine control unit connector Disconnected Repair the harness 1 ffi Eanh Eanh O Mltrublthl Moto Corporrtlon May t90il ...

Page 128: ...13 56 FUEL On vehicle Inspection of MPI Components Fuel pump check terminal FUEL PUMP fu lrr d reststor uu illlt ubiCri Motoß Corporation May 199i1 ...

Page 129: ...de connector F3ii 13 o olm Equipment side connector D Equipment side connector N rt rAYEYßI Harness side connsctor Fuel pump o pump I ll lol l I t l 4thll Equipment side connector O EF Fuelpump check terminal 7FUt3s2 ö tf l orr Engine control unit connector Ml ublrhlMotoBCo Doraüon ...

Page 130: ...oad is high the engine control unit turns off the power transistor to send drive power directly to the fuel pump without passing through the resistor INSPECTION Using Muhi use Tester MUTI or MUT II Fuel Pump Function Item No Operation Check condition Check item Normal condition Actuator test 07 Fuel pump is driven to cir culate fuel o Engine cranking o Forced drive of fuel pump Check is made for a...

Page 131: ...t to earth between the control relay for fuel pump and the engine control unit o Control relay for fuel pump con nector Disconnected o Engine control unit connector Disconnected Repair the harness tr E 6 Harness side connector Check for continuity between the control relay for fuel pump and the resistor for fuel pump r Control relay for fuel pump con nector Disconnected o Resistor for fuel pump co...

Page 132: ...y and the control relay for fuel pump Control relay connector Disconnected Control relay for fuel pump con nector Disconnected Repair the harness tr E tr E Check for an open circuit or a short circuit to earth between the control relay for fuel pump and the fuel pump o Control relay for fuel pump connector Disconnected Fuel pump connector Discon nected A Repair the harness tr otr CONTROL RELAY INS...

Page 133: ... and bÄt n terminäls 6 and 6 of fuel pump relay No 2 FUEL PUMP RELAY NO 2 INSPECTION 1 Remove fuel PumP relaY No 2 4 Replace fuel pump relay No 2 if it is faulty FUEL PUMP RESISTOR INSPECTION 1 Disconnect the connectors for the fuel pump resistor 2 Measure the resistance between the terminals Standard value 0 6 0 9 O 3 lf the resistance deviates from the standard value replace the fuel PumP resist...

Page 134: ...ontrol ünit andlarth TROUBTESHOOTING HINTS Hint 1 lf the engine stalls occasionally 9 rank the engine and shake the air flow sensor harness lf the engine stalls poor contact of the air flow sensoiconnector is suspäctÄ0 Hint 2 lf the air flow sensor o utput frequency is other than 0 when tdig iti switch is turned on but not s tarting the engine faulty air flow sensor or engine control ünii L suspec...

Page 135: ...ries OFF Transmission Neu tral 700 r min ldle 22 48H2 2 000 r min 60 108 Hz Racing Frequency in creases with racing Function Item No Data display Check condition Engine state Standard value Data list 34 Reset signal condition Engine warm up 700 r min ldle ON 2 000 r min OFF Volumetric Efficiency Function Item No Data display Check condition Engins stato Standerd value Data list 37 Volumetric effic...

Page 136: ... sensor connector Standard waYe pattern Obrcrvation conditions The time rycle time T is reduced when the amount of intake air increases Times Tl andf2 are equal Wave pattern observation points check that cycle time T becomes shorter and the frequency increases when the engine speed is increased Function Special patterns Pattern height Low Pattern selector Display Engine r min ldle r min 700 r min ...

Page 137: ...rn is output even when the en gine is not started o Example 2 Cause of Problem Damaged iectifier or vortex generation column Wave Pattern charasteristics Unstable wave pattern with non uniform frequency How ever when an ignition leak occurs during acceleration the wave patterÄ will be distorted temporarily even if the air flow sensor is normal Mitrubishi Motors Corporation May l9g2 FWUEgl19 ...

Page 138: ...nector Disconnected o lgnition switch ON Voltage V 4 8 5 2 Repair the harness E Check for continuity of the earth crrcurt o Connector Disconnected Repair the harness otr E Engine control unit harness side connector 4 tl lr_ I n I 7 n71s theck for continuity between the air ttow sensor and the engine control unit Air flow sensor connector Dis connected Elgine control unit connector utsconnected Rep...

Page 139: ...ir tem perature sensor resistor has such chäracteristic that its resistance decieases as the intake air temperature rises The intake air temperature sensor terminal voltage increases or decreases as the sensor resistance increases or decreases Therefore the intake air tömperature sensor terminal voltage changes with the intake air temperature decreasing as the temperature rises TROUBLESHOOTING HIN...

Page 140: ...r temperature Standard value Data reading 13 Sensor temperature lgnition switch ON or engrne runnrng At 20 C 4 F 20 c At 0 c 32 F 0 c At 20 C 68 F 20 c At 40 C 104 F 40 c At go c 1 76 F 80 c HARNESS INSPECTION Check for continuity of the earth circuit Connector Disconnected Repair the harness 6E E Measure the power supply voltage Connector Disconnected lgnition switch ON Voltage V 4 5 4 9 A Repair...

Page 141: ...e resistance while heating the sensor using a hair drier Temperature C F Resistance kO Higher Smaller 4 lf the value deviates from the standard value or the resistance remains unchanged replace the air flow sensor assembly Mitsubishl MotoG Coryoration May 1992 ...

Page 142: ...essure into a voltage and inputs it to the engine control unit which then corrects the fuel injection rate etc based on the input signal o The 5 V power in the engine control unit is supplied to the barometric pressure sensor Through the circuit in the sensor it is earthed in the engine control unit o The barometric pressure sensor output voltage which is proportionalto the barometric pressure abs...

Page 143: ...ch ON At0m 0ft 101 kPa F60 mmHgl At 600 m 1 969 ft 95 kPa 710 mmHg At 1 200 m 3 937 ft 88 kPa 660 mmHg At 1 800 m 5 906 ft 81 kPa 610 mmHg HARNESS INSPECNON Repairthe harness oE El Check for continuity of the earth circuit o Connector Disconnected Repairthe hamess M ED Measure the power supply voltage of the barometric pressure sensor o Connector Disconnected o lgnition switch ON Voltage V 4 8 5 2...

Page 144: ...r Through the sensorwhich is a kind of resistor it is earthed in the engine control unit The engine coolant temperature sensor resistor has such characteristic that its resistance decreases as the coolant temperature rises o The engine coolant temperature sensor terminal voltage increases or decreases as the sensor resistance increases or decreases Therefore the engine coolant temperature sensor t...

Page 145: ...e lgnition switch ON or engrne operaüng At 20 C 4 F 20 c At 0 c 32 F 00c At 20 C 68 F 20 c At 40 C 104 F 4 C At 80 C 176 F 80 c HARNESS INSPECTION Repairthe hamess otr El Check for continuitY of the earth circuit o Connector Disconnected Measure the power supply voltage o Connector Disconnected o lgnition switch ON Voltage V 4 5 4 9 Repair the harness tr E Mitsubirhl Moton Corporetlon July 1998 PW...

Page 146: ...the resistance deviates from the standard value greatly replace the sensor INSTALLANON 1 Apply sealant to threaded portion Specified sealant 3M NUT locking part No 4171 ot equivalent 2 Install engine coolant temperature sensor and tighten it to specified torque Sensor tightening torque 30 Nm Zl ft lbs l 3 Fasten harness connectors securely Temperature C F Resistance kO 0 32 5 8 20 68 2 4 40 104 1 ...

Page 147: ...ne control unit o As the throttle valve shaft rotatesTrom the idle position to wide open position the resistanc between the variable resistor terminal of the throttle position sensor and the earth terminal increases As a result the voltage at the throttle position sensor variable resistance terminal also increases TROUBLESHOOTING HINTS Hint 1 The throttle position sensor signal is more important i...

Page 148: ...SS INSPECNON Harness Measure the power supply voltage of the throttle position sensor o Connector Disconnected o lgnition switch ON Voltage V 4 8 5 2 Repairthe harness otr Check for continuity of the earth circuit o Connector Disconnected Repair the harness oE tr Check for an open circuit or a short circuit to earth between the engine control unit and the throttle position sensor o Throttle positi...

Page 149: ... pointer type ohmmeter bewveen terminal sensor earth and terminal O sensor output Operate the throttle valve slowly from the idle position to the full open position and check that the resistance changes smoothly in proportion with the throttle valve opening angle lf the resistance is out of specification or fails to change smoothly replace the throttle position senspr For the idle position switch ...

Page 150: ... terminalvoltage to go low from high TROUBLESHOOTING HINTS lf the idle position switch harness and individual part check results are normal but the idle position switch output is abnormal the following troubles are suspected 1 Poorly adjusted accelerator cable or auto cruise control cable 2 Poorly adjusted fixed SAS INSPECTION Using Multi use Tester MUTI or MUT tr Function Item No Data display Che...

Page 151: ... position sensor after replacement Refer to page 13 35 Measure the power supply voltage of the idle position switch o Connector Disconnected lgnition switch ON Voltage V 4 or more Repairthe harness otr E A sroP Repair the harness E E Check for continuity of the earth circuit o Connector Disconnected 2 Check the continuity between terminal and Accelerator pedal Continuity Depressed Nonconductive oo...

Page 152: ...control relay and is earthed to the body The cam position s nsor generates a pulse signal as it repeatedly connects and disconnects between 5 V voltage supplied from the engine control unit and earth TROUBLESHOOTING HINTS Hint 1 lf the cam position sensor does not function correctly correct sequential injection is not made so that the engine may stall run irregularly at idle or fail to accelerate ...

Page 153: ...cted 2 Connect the special patterns pick up of the analyzer to cam shaft position sensor terminal 3 Disconnect the connector of the crank angle sensor and connect the special tool test harness MD998478 across the disconnected connector terminals 4 Connect the special patterns pick up of the analyzer to crank angle sensor terminal Engine 2 turns camshaft 1 turn The time interval T becomes shorter a...

Page 154: ...t start but the rectangular waveform is I HARNESS INSPECTION Check for continuity between the cam position sensor and control relay Cam position sensor connector Disconnected a Control relay connector Disconnected NOTE Touch ohmmeter probes to both ends of the harness Repair the E E o Example 2 Trouble cause The timing belt is loose The sensor disc is abnormal Waveform feature The waveform fluctua...

Page 155: ...r a short circuit to earth between the cam position sensor and the engine control unit Engine control unit connector Disconnected a Cam position sensor connector Disconnected Repair the harness E E Measure the impressed voltage o Cam position sensor connector Disconnected Engine control unit connector Connected lgnition switch ON Voltage V 4 8 5 2 Replace the engine control unit Mlt ubbhl Motor Co...

Page 156: ...nto a pulse signal and inputs it to the engine control unit which then computes the engine speed and controls the fuel injection timing and ignition timing based on the input signal Pöwer to the crank angle sensor is supplied from the control relay and is earthed to the body The crank angle sensor generates a pulse signal as it repeatedly connects and disconnects between 5 V voltage sup plied from...

Page 157: ...sor reading is out of specification troubles are often in other than the crank angle sensor lExamplesl 1 Faulty engine coolant temperature sensor 21 Faulty idle speed control servo 3 Poorly adjusted reference idle speed INSPECTION Using Muhi use Tester MUTI or MUT II NOTE 1 The tachometer indicates a third of the actual engine speed Therefore 3 times the tachometer indication is the actual engine ...

Page 158: ...uit Crank angle sensor connector Disconnected Repair the harness EF Earth Check for an open ircuit or a shortcircuit to earth between the crank angle sensor and the engine control unit Engine control unit connector Disconnected Crank angle sensor connector Disconnected Repair the harness tr Ä l to l Measure the impressed voltage Crank angle sensor connector Disconnected Engine control unit connect...

Page 159: ...l unit which detects that the engine is öranking INSPECTION Using Multi use Tester MUT or MUT II Engine control unit ä Function Item No Data display Check condition Engine Normal indication Data reading 18 Switch state lgnition switch ON Stop OFF Cranking ON HARNESS INSPECTION Engine control unit harness srde connector Measure the input voltage to the engine control unit o Engine control unit conn...

Page 160: ...n the voltage oi about 5 V applied from the engine control unit and earth using a reed switch TROUBLESHOOTING HINTS lf there is an open or short circuit in the vehicle speed sensor signal circuit the engine may stall when the vehicle is decelerated to stop HARNESS INSPECTION lgnition switch üGl side Engine control module rEv __ l lg Ä 11ro lY lü Equipment connector 9 Eptrl N T o lJ Engine control ...

Page 161: ...nected o lgnition switch ON Move the vehicle o Continuity A tr Measure the power supply voltage of the vehicle speed sensor o Connector Disconnected o lgnition switch ON Voltage V 4 5 4 9 Repair the harness E Check for continuity of the ground circuit Connector Disconnected Repair the harness tr Ground Mitsubishi MotoF Corporation July 19910 FWUEgTl9 D ...

Page 162: ... inputs it to the engine control unit which then controls the idle speed control seryo based on this signal The battery voltage in the engine control unit is applied through a resistor to the power steering fluid pres sure switch Steering operation causes the power steering fluid pressure to increase turning the switch on As a result continuity is produced between the batteryvoltage applied and ea...

Page 163: ...irection OFF Steering wheel half turn ON Checking Fluid Pressure Steering wheel Fluid pump delivery pressure ref value Straight forward 700 1 200 kPa 0 o 12 o kglcm2 100 171 psi Turned 1 500 2 000 kPa 15 0 2O O kglcm2 213 284 psi HARNESS INSPECTION Repairthe harness tr r Measure the power supply voltage o Connector Disconnected r lgnition switch ON Voltage V SV SENSOR INSPECTION Refer to GROUP 37 ...

Page 164: ...ower relay coil is energized to turn ON the relay switch which activates the air compressor magnetic clutch TROUBLESHOOTING HINTS lf the air compressor magnet clutch is not activated when the air conditioner switch is turned ON during idling faulty air conditioner control system is suspected INSPECTION Using Multi use Tester MUT or MUT II AIR CONDITIONER SWITCH Function Item No Data display Check ...

Page 165: ...tch Normal indication Data reading 49 Air condi tioner relay state Engine ldling after warm up OFF OFF compressor clutch non activa tion ON ON compressor clutch activation HARNESS INSPECTION Measure the power supply voltage of the air conditioner circuit o Airconditionerswitch ON o Engine control unit connector Disconnected Voltage V SV Check the air conditioner circuit 7Ft 0695 Mitsubishi Moton C...

Page 166: ...his signal the engine control unit provides retard control of the ignition timing TROUBTESHOOTING HINTS When knocking occurs while driving under high load conditions the following problems are suspected in addition to the detonation sensor itself 1 Inappropriate ignition plug heat range 2 Inappropriate gasoline 3 Incorrectly adjusted reference ignition timing Engine control unit I Engine control u...

Page 167: ...pen circuit or a short circuit to earth between the engine control unit and detonation sensor Detonation sensor connector Disconnected Engine control unit connector Disconnected Repairthe hamess otr Earth Check for continuity of the earth circuit o Connector Disconnected Mltrublrhl Motoru Corporatlon Mry l99ll ...

Page 168: ...e idle speed control servo o When the switch of equipment with a large electrical load is turned ON the battery voltage is applied to the engine control unit to indicate that the equipment switch is turned ON INSPECTION Using Muhi use Tester MUTI or MUT II Function Item No Data display Check condition Equipment state Normal display Data reading 33 Switch state Operation of equipment OFF Lighting s...

Page 169: ... tail lamp relay Check circuit related to de fogger relay Measure the input voltage of engine control unit o Engine control unit connector Disconnected o Defogger switch ON Defogger relay ON Voltage V SV Check circuit related to stop lamp relay Measure the input voltage of engine controlunit o Engine control unit connector Disconnected Brake pedal Depressed Stop lamp switch ON Voltage V SV Mitrubi...

Page 170: ...ätio based on this signal so that ihe air fuel ratio may be kept at the theoretical ratio The battery voltage is supplied to the oxygen sensor through the control relay Therefore the sensor element is heated by the heater so that the oxygen sensor ömains responsive even when thä exhaust temperature is low TROUBLESHOONNG HINTS Hint 1 Poor oleaning of exhaust gas will result if the oxygen sensor fai...

Page 171: ...e airlfuel mixture ratio and also check the condition of control by the engine control unit 700 r min ldling 2 000 r min 400 mVor lower t changes 600 1 000 mV HARNESS INSPECNON Measure the power supply voltage of the oxygen sensor Connector Disconnected o lgnition switch ON Voltage V SV Repair the hamess ER F Check for an open ircuit or a short circuit to earth between the engine control unit and ...

Page 172: ...e jumper wircc are connected corrcctly as wrong connections rssuh in a broken oxygen scn3or Connect a digitalvoltmeter across terminals O black clip of the specialtool and white clip Race the engine repeatedly and measure the output voltage of the oxygen sensor rear bank lf the measurements are not as specified defective oxygen sensor rear bank is suspected check the oxygen sensor front bank in th...

Page 173: ...ADIATOR FAN CONDENSER FANI From 1995 models rU L Condenser fan motor relay lgnition switch lG Condenser fan motor relay Radiator fan motor relay To air conditioner compressor Condenser fan motor Engine control unit connector Mitsubishi Motors Corporation July lg0tl 7 Ul366 ...

Page 174: ...an motor lf the engine control unit turns ON the high speed side power transistor inside the engine control unit the radiator fan motor relay Hi and condenserfan motor relay Hi will operate to send the driving power supply for high speed rotation to the radiator fan motor and condenser fan motor INSPECTION Using Multi use Tester MUTI or MUT II FAN MOTOR RELAY INSPECTION Refer to GROUP 14 Radiator ...

Page 175: ...nspection of MPI Components 13 101 INJECTORS Control relay Injector No 2 7 4____ Iniector 5 5 Iniector Nö 6 T I Iniector I Iniector Engine control unit connector Injection Mit ubichi MotoE Cofpor tlon May 199i1 PWUEgl19 ...

Page 176: ...ter another during idling make following checks about such cylinder 1 Injector and harness check l2l lgnition plug and high tension cable check 3 Compression pressure check Hint 4 lfthe injector harness and individual part checks have resulted normal but the injector drive time is out of specification the following troubles are suspected 1 Poor combustion in the cylinder faulty ignition plug ignit...

Page 177: ...t the special tool test harness M8991348 in between The power side and the engine control unit side terminals should both be connected 2 Connect the analyzer special patterns pickup to the engine control unit test harness clip FOR REAR BANK CYLINDERS No 2 No 4 1tlo 6l 1 Disconnect the injector connector for the rear bank and con nect the specialtool test harness MD998463 2 Connect the analyzer spe...

Page 178: ... Solenoid coil back electromotive force is low or doesn t appear at all Short in the injector solenoid Point B Injector drive time o The injector drive timing will synchronized with the MUT or MUT tr display o When the engine is suddenly raced the drive time will be greatly extended at first but the drive time will soon match the engine speed PWUEgl1 B lütr lthl MotoF Corporttlon July 19 l REVISED...

Page 179: ... Check for continuity between the rear bank side injector and the resistor Injector intermediate harness con nector Disconnected Resistor connector Disconnected Repair the harness trEE EEN Check for an open circuit or a short circuit between the front bank injector and the engine control unit lnjector connector Disconnected Engine control unit connector Disconnected Repairthe hamess ffiF Check for...

Page 180: ...sistance between Rear Bank Terminals 1 Disconnect the injector connector 2 Measure the resistance between terminals Standard value 2 3 O lat 20 C 68 F I 3 Reconnect the injector connector RESISTOR Measurement of Resistance between Terminals 1 Disconnect the resistor connector 2 Measure the resistance between terminals Measuring terminals Resistance 14 24 H il 74 8 4 5 5 6 5 lAt 20 C 68 F I 3 lf th...

Page 181: ...rn hose Clip MD998746 7tuor15 Connect the battery s negative terminal Apply battery voltage to the fuel pump check terminal black and activate the fuel pump 6 Activate the injector and check the atomized spray condition of the fuel The condition can be considered satisfactory unless it is ex tremely poor Stop the actuation of the injector and check for leakage from the injector s nozzle Standard v...

Page 182: ...zed and the motor rotates in normal or reverse direction TROUBLESHOOTING HINTS Hint 1 lf the stepper motor step increases to 100 to 120 steps or decreases to 0 step faulty stepper motor or open circuit in the harness is suspected Hint 2 lf the idle speed control servo harness and individual part checks have resulted normal but the stepper motor steps are out of specification the following faults a...

Page 183: ...Standard wavo pattern Observation conditions Yellow Function Item No Data display Check condition Load state Standard value Data reading 45 Stepper mo tor steps Engine coolant temperature 80 to 95 C 1 76 to 203 F o Lamps electric cooling fan acces sory units All OFF o Transmission Neu tral ldle position switch ON com pressor clutch to be ON if air condi tioner switch is oN Engine ldling Air condit...

Page 184: ...but soon disappears äöäirääb tiue tor u abnormal wave pattern Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small Motor is malfunctioning Point B Height of coil reverse electromotive force Contrast with standard wave pattern Probable cause Coil reverse electromotive force does not appear or is extremely small Short in the coil t orPo...

Page 185: ...otor can be heard after the ignition is switched ON but without starting the motor 2 lf the operation sound cannot be heard check the stepper motor s activation circuit lf the circuit is normal it is probable that there is a malfunction of the stepper motor or of the engine control unit Ghecking the Coil Resistanco 1 Disconnect the idle speed control servo connector and connect the special tool te...

Page 186: ...nd check whether or not a vibrating feeling a feeling of very slight vibration of the stepper motor is generated as a result of the activation of the stepper motor Connect the negative O terminal of the power supply to the red and black clip Connect the negative O terminal of the power supply to the blue and black clip Connect the negative O terminal of the power supply to the blue and yellow clip...

Page 187: ...e is induced in the secondary coil A causing the ignition plugs 91No _1 andNo j cylinders to sparki When the power transistor unit B is turned OFF the ignition plugs of No 2 and No 5 cylinders spait In addition when the power transistor unit C is turned OFF the ignition plugs of No 3 and No 6 cylin ders spark When the engine control unit turns OFF the transistor in the unit the battery voltage in ...

Page 188: ...ine ldling lgnition timing ad justment terminal is earthed ON lgnition timing ad justment terminal is disconnected from earth OFF Standard lgnition Timing Function Item No Drive Check condition Normalcondition Actuator test 17 Set to ignition timing ad justment mode a Engine idling Timing lamp set o 5 BTDC Wavc Pattern Inspection Using an An lyzer o lgnition coil primary signal Refer to GROUP 16 l...

Page 189: ...tterns Pattern height Low Pattern selector Display Engine revolutions Approx 1200 r min i f l t Revolution time corresponding r to a crank angle of 120 lComprossion I Crankshaft angle sensor output wave pattern Reference fi fi ItoP I I r1 ti ll IL l 1 1 I Dwell section Time TFUl2lO Mlbublrhl MotonCorpot tlon Mry 1992 ...

Page 190: ...comes a rectangular wave at power voltage Malfunction of the power transistor Normal wave pattern Normal wave pattern Eramplc of abnormal wavc prtternr o Example 1 Wave pattern during engine cranking Gaur of problem Broken wire in ignition primary circuit Wavc ptttern charastcricticr Topright part of the builGup section cannot be seen and voltage value is approximately 2V too low o Example 2 Wave ...

Page 191: ...r Disconnected o lgnition switch ON Voltage V SV Check for an open circuit or a short circuit to earth between the engine control unit and the power transistor o Engine control unit connector Disconnected o Power transistor connector Dis connected Repair the harness E E a P f iffi_ffii Check for an open circuit or a short circuit to earth between the Power transistor and the ignition coil o lgniti...

Page 192: ...ure the voltage of the control signalcircuit of the power transistor o Connector Disconnected o lgnition switch START Repair the Measure the voltage of the ignition timing adjustment terminal o lgnition switch ON Voltage V 4 0 5 2 Repair the harness tr B ACTUATOR INSPECNON Refer to GROUP 16 lgnition System tllt übl hl Motor Conordon Mry 1992 PWUE9it9 ...

Page 193: ...d to the purge control solenoid valve through the control relay When the engine contöt unit turns ON the power tränsistor in the unit current flows to the coil introducing purge air INSPECTION Using Multi use Tester MUTI or MUT II Engine control unit Control relay Engine control unat connectol Function Item No Drive content Check condition Normal state Actuator test 08 Solenoid valve from OFF to O...

Page 194: ...nds of the harness Repair the harness tr ts E Engine control unit harness side connector Check for an open circuit or a short circuit to earth between the purge control solenoid valve and the engine control unit Purge control solenoid valve connector Disconnected o Engine control unit connector Disconnected harness otr E ACTUATOR INSPECTION Refer to GROUP 17 Evaporative Emission Control System o l...

Page 195: ...l solenoid valve When the engine control unit turns off the power transistor inside the unit current no more flows through the coil and EGR valve operating negative pressure leaks TROUBLESHOOTING HINT lf the results of EGR control solenoid valve on vehicle and off vehicle inspections are normal but the self diagnosis code for EGR system failure is displayed check the EGR valve vacuum hose and EGR ...

Page 196: ...ck for continuity between EGR control solenoid valve and control relay o EGR control solenoid valve connector Disconnected a Control relay connector Disconnected NOTE Touch the ohmmeter probes to both ends of the harness harness otr ts l V l t i L__ilJ Engine control unit harness side connector Check for an open circuit or a short circuit to earth between the EGR control solenoid valve and the eng...

Page 197: ...FF type solenoid valve that switches the pressure introduced to the fuel pressure regulator bewveen either intake manifold pressure or barometric pressure Battery pbwer is supflied to this valve via the control relay When the engine control unit turns ON the internäl bo er transiötor the coil is energized to allow baiometric pressure to be introduced to the fuel pressure regulator i liteöirhl luot...

Page 198: ... between fuel pr ssure control solenoid valve and control relay Fuel pressure control solenoid valve connector Disconnected Control relay connector Disconnected NOTE Touch the ohmmeter probes to both ends of the harnass harness oE 81 Engine control unit harness side connector Check for a n open ircuit or a short circuit to earth between the fuel pressure controlsolenoid valve and Z j illn il j lh ...

Page 199: ...ure to the nipple to which the black väöuüm hole has been connected and check air tightness with and without the battery voltage applied to the solenoid valve terminal Coil Resistance Check 1 Measure the coil resistance with a circuit tester Standard value 36 46 O at 2AC 6fF l i o Battery voltage The other nipple of solenoid valve Normalstate Not applied Open Negative pressure leak Close with fing...

Page 200: ...wer transistor the coil is energized to release part of the boost pressure applied to the waste gate actuator TROUBTESHOOTING HINTS lf the wa ste gate control solenoid valve harness and the unit itself are normal but poor acceleration or other abnormalities are experienced the follwing problems are suspected 1 Faulty boost pressure control system 2 Poor connection of intake air hose 3 Faulty turbo...

Page 201: ...ON harness otit ts1 Check for continuity between waste gate control solenoid valve and control relay Waste gate control solenoid valve connector Disconnected Control relay connector Disconnected NOTE Touch the ohmmeter probes to both ends of the harness harnesg 68 EB Check for an open circuit or a short circuit to earth between the waste gate control solenoid valve and the engine control unit o wa...

Page 202: ...13 128 FUEL On vehicle Inspection of MPI Components BOOST METER Equipment side connector lgnition switch lGr Engine control unit connector tff 5bhl Moton Gorporatlon May 199 PWUEgfi9 ...

Page 203: ...sconnected o lgnition switch ON Voltage V SV Check for an open circuit or a short circuit to earth between the engine control unit and the boost meter r Boost meter connector Discon nected r Engine control unit connector Disconnected Repair the harness otr mt ACTUATOR INSPECTION Refer to GROUP 54 Meters and Gauges Mibubirhi MotoF Corpo taon May 199 ...

Page 204: ... the e ngine control unit controls the idle sp_e_ed control servo to secure effective anti lock braking o When the motor relay is activated the ABS control unit turns ON the power transistor short circuiting the terminal to earth This causes the anti lock braking signal to go from high to low HARNESS INSPECTION Check for an open circuit or a short circuit to earth between the ABS control unit and ...

Page 205: ...leakage from the fuel pressure gauge and the special tool connection part Disconnect the jumper wire from the terminal for activation of the fuel pump to stop the fuel pump Start the engine and let it idle Measure the fuel pressure during idling Standard value Approx 235 kPa 2 35 kg cm2 34 pril at curb idle 3 4 5 6 71 8 e 10 Disconnect the vacuum hose f rom the fuel pressure regula tor and then me...

Page 206: ... pressure in fuel return hose Fuelfilter is clogged Replace the fuel filter Malfunction of the valve seat within the fuel pressure regulator or fuel leakage to return side caused by spring deterioration Replace the fuel pressure regulator Fuel pump low discharge pressure Replace the fuel pump Fuel pressure is too high The valve within the fuel pressure regulator is sticking Replace the fuel pressu...

Page 207: ...the f uel high pressure hose to the delivery pipe tighten the installation bolt rg öÄeöt io be sure that there is no fuel leakage 6 Applv Oattery vottage to the terminal for activation of trid fuet puäp so äs to activate the fuel pupP o witr iuet presiure applied check for leakage of the fuel line Mltrubirhl MotonCorporilion May 19 l nvuEglt9 ...

Page 208: ...out off the order given in the chart Caution Short circuiting the positive l l probe bstnrecn a Gon necter terminal and earth could damage the vehicle wir ing the sonsot engine control unit or all there Use care to prevent thisl lf voltmeter shows any division from standard value check the corresponding sensor actuator and related electricalwir ing then repair or replace After repair or replacemen...

Page 209: ...ture is 20 C 68 F 2 3 2 9V When water temperature is 40 C 104 F 1 3 1 9V When water temperature is 80 C 176 F 0 3 0 9v 64 Throttle oosition sensor lgnition switch Kept in ON state for more than 1 5 seconds Throttle valve placed in idle position 0 3 1 0v Throttle valve placed in fully opened position 4 5 5 5V 67 ldle position switch lgnition switch ON Throttle valve placed in idle position 0 1v Thr...

Page 210: ...lant temperature 95 105 C 203 221 Fll 0 3v 53 Fan motor relay Hi Radiator fan not operating Coolant temperature below 90 C 194 F B 1 995 and later model Radiator fan operating at high speeds Coolant temperature above 105 C 1221 Fll 0 3v 24 Electric load switch Engine Running at idle Lighting switch set to OFF 0 3v Lighting switch set to ON SV 56 55 Oxygen sensor Engine Kept running at 2 000 r min ...

Page 211: ...titude is 1 200 m 3 937 ft 3 2 3 8V 63 water temperature sensor prtion switch When watertemperature is 0 C 32 F 3 2 3 8V When water temperature is 20 C 68 F 2 3 2 9V when water temperature is 40 c 104 F 1 3 1 9V When water temperature is 80 C 176 F 0 3 0 9v 64 Throttle position sensor lgnition switch Kept in ON state for more than 1 5 seconds Throttle valve placed in idle position 0 3 1 0v Throttl...

Page 212: ...ought closer to atmospheric temperature SV 22 Air conditioner relay o Engine Running at idle o Airconditionerswitch OFF ON Air compressor in driven state SVor6Vor more for a moment 0 3V 24 Electric load switch Engine Running at idle Lighting switch set to OFF 0 3v Lighting switch set to ON SV 56 55 Oxygen sensor Engine Kept running at 2 000 r min after warmup Digitalvoltmeterto be used for checkin...

Page 213: ...s idling Falls temporarily from SV 21 Fuel pump relay 2 Engine Depress the accelerator pedal abruptly while the engine is idling Rises temporarily from 0 3V 31 Engine ignition signal Engine 3 000 rpm 0 3 3V 34 lgnition timing adjustment terminal lgnition switch ON lgnition timing adjustment terminal connected to earth 0 1v lgnition timing adjustment terminal disconnected from earth 4 0 5 5V 36 Eng...

Page 214: ... cable Adiustment Refer to P 1341 lflItr 4 lNl 10 Nm 1 0 kgm 7 ft tb R H drive vehicles To cruise control link e 13 Nm 1 3 kgm 9 ft lbs Removal steps 1 Bushing 2 Accelerator cable 3 Accelerator pedal 4 Split pin 5 Accelerator arm 1 3 3 rw 03FOO23 6 7 8 Return spring Accelerator arm bracket Stopper ct HItr Mlt ubl hl Motoru Corporrtlon May 19 t2 Ptt uEgt 19 ...

Page 215: ...nt o lnstallation of Air Intake Plenum o Checking for Fuel Leakage El3JA 12 13 10 1 F13 Nm 1 F1 3 kgm 7 9 ft lbe o3FOO17 10 11 N Removal stops 1 Connection of high pressure fuel hose 2 Connection of fuel return hose 3 Connection of vacuum hose 4 Fuel pressure regulator 5 Connection of control harness 6 Fuel pipe 7 Delivery pipe 8 Insulator 9 Injector support 10 Injector 11 Insulator 12 O ring 13 G...

Page 216: ...and then re insert it intö the delivery pipe and check once again INSTATLANON OF FUEL PRESSURE REGUTATOR When connecting the fuel pressure regulator to the delivery pipe apply light oil or petrol to the O iing and then insert being careful not to damage the O ring CONNECNON OF HIGH PRESSURE FUEL HOSE When connecting the high pressure fuel hose to the delivery pipe apply petrol to the hose union an...

Page 217: ... fuel gauge unit assembly connector 3 High pressure fuel hose connection body side 4 High pressure fuel hose connection fuel pump side 5 Fuel pump and fuel gauge unit assembly SERVICE POINTS OF INSTALLATION 5 INSTAL1ÄTION OF FUEL PUMP AND FUEL GAUGE UN T ASSEMBLY Align the three positioning projections of the packing with thi holes in the fuel pump and fuel gauge unit assembly INSTALLATION OF FUEL...

Page 218: ...cnrtion o Draining of the Fuel o Release of Residual Pressure from High Pressure Hose Refer to P 13 39 Post installation Opcration o Supplying of the Fuel o Checking for Fuel Leakage rc t 35 Nm 3 5 kgm 25ft tb 30 Nm 3 0 kgm Z2it abs 4 fa ta aa fa ae fa 26 Nm 2 6 kgm l9 ft lbs 10 Vapour hose 1 1 Return hose 12 High pressure fuel hose 13 Vapour hose 14 Leveling pipe 15 Self locking nut 1 6 Fuel tank...

Page 219: ...tepped part connect the va pour hose to the pipe securely so that it is the standard value Standard value 25 30 mm 1 0 1 2 in l 17 INSTAL1ÄTION OF TWO WAY VALVE Install so that the twoway valve is facing in the direction shown in the illustration 11 CONNECTION OF RETURN HOSE Connect the return hose to the pipe securely up to the stepped part as shown in the illustration 1 INSTALLATION OF FUEL GAUG...

Page 220: ...ly connection 4 Throttle cable and link assembly connec tion 5 Vacuum pump connector f 6 Vacuum hose and vacuum pump con nection 7 Link assembly and vacuum pump 8 Vacuum pump 9 Pump bracket 10 Link assembly 1 1 Link bracket 12 Accelerator cable and accelerator pedal connection R H drive vehicles 20 19 ß 13 Accelerator cable 14 Throttle cable and throttle body connec tion 15 Throttle cable 16 Cruis...

Page 221: ...ontrol switch Switch garnish Main switch l äs 2s o ooi L J E tt G tt 4 fr r r 2 Nm Upto tsot i g q l e P lmooels 1 t 2 2ft 1bs J 22 23 24 25 26 Gontrol unit and relay removal steps 27 Scuff plate Passenger s side 28 Cowl side trim Passenger s side 29 Cruise control unit 30 Cruise controlrelay 4 J Sensors and switches removal t O Q 31 Throttle oosition sensor 32 Stop lamp switch 33 Clutch switch 34...

Page 222: ...TALLATION 6 CONNECTION OF VACUUM HOSE TO VACUUM PUMP Route the vacuum hose over the throttle cable and connect the hose to the vacuum pump so as to prevent the slackened hose from interfering with other parts Er3sDAc O Mftrublshl Motorc Corporrdon May 1992 ...

Page 223: ...gine Coolant Leak Check Cap Pressure Test Engine Coolant Replacement Concentration Measurement 2 THERMOSTAT WATER PUMP WATER PIPE AND WATER HOSE RADIATOR ENGINE COOLANT TEMPERATURE GAUGE UNIT ENGINE GOO ANT TEMPERATURE SENSOR AND ENGINE COOLANT TEMPERATURE SWITCH 2 2 2 3 3 3 3 4 5 6 7 8 9 Mibublshl Motors Gorporatlon May 1992 PWUEgl19 ...

Page 224: ...concentration 7o Thermostat Valve opening temperature of thermostat C F Fullopening temperature of thermostat C F Opening pressure of cap high pressure valve kPa kg cm2 psi Thermo sensor on radiator operating temperature Up to 1994 models For radiator fan OFF ON C F ON OFF C F For condenser fan OFF ON C F ON OFF C F 30 60 76 5 170 90 194 or more 7S105 0 7S1 05 1 1 1 5 81 89 78 1921 77 7 ll or less...

Page 225: ... or connections Caution Be sure to comptetely clean away any moisture from the places checked Wheh the tester is removed be carefill not to spill any engine coolant from it Be carefut when instalting and removing thetectcrand when testing not to deform the water outlst fitting lf there is leakage repair or replace the appropriate part CAP PRESSURE TEST Er mD 1 Use a adapter to attach the cap to th...

Page 226: ... and also into the reserve tank up to the FULL line Recom mended antffreeze HIGH OUAL TY ETHYLENE GLYCOL ANTIFREEZE COOL ANT Ouantity ams u S qb lmp qts l 8 0 8 5 7 01 NOTE For Norway the non amine type of antifreeze should be used 9 Install the radiator cap securely 10 Start the engine and warm up until the thermostat opens 1 1 Race the engine up to around 3 000 rpm several times then stop the en...

Page 227: ...able concentration HIGH OUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT 30 60 o o Caution ff the concentration of the antifreeze is below 30o o the anti corrosion property will bc dvctr cly affec ed tn addition if the concentration is above 6100 o both the anti freezeing and englnc coollng propordcl will decrease affesting the engine adversely For these reasons be sure to maintaln tfre conccntEtlon lev...

Page 228: ...r Stir to raise water temperature and check that thermostat opening valve tempera ture and the temperature with valve fully open valve lift over 8 mm 0 31 in l are at the standard value 1 2 3 t 4 Connection of radiator lower hose Water inlet fitting Gasket Thermostat Standard value Opening Yalve temperature Full open temperature NOTE Measure valve height when fully closed measuring the height when...

Page 229: ...LATION OF THERMOSTAT Install the thermostat with its jiggle valve lined up with the mark on the thermostat housing 2tl Nm 2 4 kgm 17 ft lba SERVICE POINTS OF INSTALI ATION 3 INSTALLATION OF O RING Insert the O ring to the water inlet pipe and coat the outer circumference of the O ring with water Caution Care must be taken not to pormlt englnc oll or othcr greases to adhere to the O ring 1 INSTALIÄ...

Page 230: ...onnection for water hose A 8 Connection for water hose 9 Connection for radiator lower hose 10 Connection for water hose 1 1 Thermostat housing 12 Gasket It 13 Inlet water pipe e 14 O ring O ring I Inlet water PiPe illtr ölrhl ßlotor Corpol tion Mey 1902 8 SERVICE POINTS OF INSTALIATION Ei rDA 14 INSTALLATION OF O RING l3 INLET WATER PIPE Replace the O rings at both ends of the water inlet pipe wi...

Page 231: ... lower hose 8 Condenser fan motor connector 9 Condenser fan motor assembly 10 Radiator fan motor connector 1 1 Thermo sensor connector For radiator fan Up to 12 Thermo sensor connector I t gg models For condenser fan 13 Radiator fan motor assembly 14 Upper insulator 15 Radiator assembly 16 Lower insulator f 7 ifrermo Jenior For radiator fan I Up to 18 Thermo sensor For condenser fan I t gg models ...

Page 232: ... RESISTOR From 1995 models 1 Measure the resistance between connector terminals O and of the radiator fan motor 2 The resistor is normal if the resistance is within the following range Resistance 0 29 0 35 O THERMO SENSOR INSPECTION up to 1994 models 1 lmmerse the water temperature switch in hot water as shown 2 Change the water temperature and check continuity with a circuit tester lf it is as sp...

Page 233: ...ox located at the right side in the engine compartment 2 Check for continuity between the terminals when the battery power supply is applied to terminal and terminal is grounded When current flows Between terminals 1 3 Continuity When no current flows Between terminals 1 3 No continuity Between terminals 2 4 Continuity Mhsubi l Motoru Corporataon May 1991 PWUEgl19 ...

Page 234: ...e coolant temperature sensor Engine control 5 Engine coolant temperature switch Air conditioner EIaUA Pre romoval and Pogt iffitlllrtion Opcretion o Draining and Supplying of the Engine Coolant Refer to P 14 4 1 r Removal and Installation of Air Intake Hose Refer to GROUP 1 Air Cleaner INSPECTION E rrc g ENGINE COOLANT TEMPERATURE GAUGE UNIT Refer to GROUP 54 Meters and Gauges ENGINE COOTANT TEMPE...

Page 235: ...as stove flame or similar method so as to increase the oil temperature 2 Check to be sure that the engine coolant temperature switch is switched OFF when the oil temperature reaches the standard value itandard value 112 lltrc l2yt 2u Fl Gaution The oil used above should be engine oil and should bo stirred welt white being heated do not holt molo than necessary Mlteubiehi Motorr Corporatlon M Y tgg...

Page 236: ...O o o o NOTES ...

Page 237: ...g Pressure Control System Inspection Supercharging Pressure Relief Solenoid Valve lnspection Air Bypass Valve Inspection Intake Manifold Vacuum lnspection AIR CLEANER INTAKE MANIFOLD TURBOCHARGER FRONTI TURBOCHARGER REARI EXHAUST MANIFOLD EXHAUST PIPE AND MAIN MUFFI ER 18 CATALYTIC CONVERTER REfEr tO GROUP 17 5 7 9 11 14 16 2 2 2 2 3 4 4 4 Mltsubbhi Motors Corporation July 199i1 PWUEgl19D RE TSED ...

Page 238: ...type Dualtype Expansion resonance type Flat coupling insertion type Rubber hangers Exhaust gas turbine type TD04 098S4 Waste gate actuator and solenoid valve Air cooled type Items Standard Limit Intake manifold and air intake plenum Distortion of cylinder head contacting surface mm in Supercharging pressure solenoid valve terminal resistance at 20 C 68 F l O Less than 0 15 0 0059 36 4r 0 2 0 008 T...

Page 239: ... may bc faufi therefore check the following Disconnection or cracks of the waste gatc lc tuatol rubber hose Malfunction of the waste getc actuator Malfunction of the wasto gate valvc SUPERCHARGING PRESSURE CONTROL SYS TEM INSPECTION 1 After the self diagnosis code of MPI system is completely read turn off the ignition switch 2 Disconnect the hose black from the waste gate solenoid valve and connec...

Page 240: ...stance between solenoid valve terminals Standard value 36 tl4 O lat 20 C 6fF l AIR BYPASS VALVE INSPECTION 1 Remove the air bypass valve 2 Connect the hand vacuum pump to the nipple of the air bypass valve 3 Apply a negative pressure of approx 400 mmHg 16 in Hg and check operation of the valve Also check that air tightness is maintained Negative pressure Valve operation About 400 mmHg 16 in Hg It ...

Page 241: ...cover 9 Air flow sensor gasket 10 Air flow sensor assembly NOTE 1 S speed manual transmission 2 6 speed manual transmission Removal stop3 of air intake horc 11 Connection of hose 12 Air hose A 13 Breather hose 14 Connection of vacuum hose 15 Air intake hose A air by pass valve and air by pass hose 16 Connection of purge hose 17 Ai intake hose B 18 Connection of boost hose 19 Air intake hose C 20 A...

Page 242: ...ws insert air intake hoses B and C until seated Insert the turbocharger end of air intake hoses B and C completely 12 INSTALLATION OF AIR HOSE A 1 Connect the air hoses ensuring that alignment marks are aligned with projections lnsert air hoses B and C into pipe all the way to its step Caution Be careful not to allow any foreign matter to get into the hoses pipes or the intercooler itself 2 Connec...

Page 243: ...A 7 Heat orotector F 8 Arr hose B 9 Air hose E 10 Arr prpe B 11 Air pipe C 12 Airhose F 13 Engine orl cooler 14 Intercooler duct LH 15 Intercooler left Pre removal Operation o Removal of Front Bumper Refer to GROUP 51 Front Bumper Post installation Operation o Supplying of Engine Oil When equipped with intercooler left o Installation of Front Bumper Refer to GROUP 51 Front Bumper fa r a NOTE ta e ...

Page 244: ...ger end of air intake hoses B and C completely 15 INSTALLATION OF INTERCOOLER LEFT 12 AIR HOSE F I 9 AIR HOSE E I 8 AIR HOSE B 5 AIR HOSE G 4 INSTALLATION OF INTERCOOLER RIGHT I 2 AIR HOSE D I 1 AIR HOSE C 1 Aligning the marks at the points indicated by the arrows insert securely into the stepped portion of the pipe or un til seated Caution Be careful not to allow any foreign matter to get into th...

Page 245: ...ses 5 Injector connector 6 Delivery pipe with injectors 7 lnsulators 8 Timing belt upper cover ll 9 Intake manifold mounting nut 10 Cone disc spring 1 1 lntake manifold l 12 Intake manifold gasket NOTE 1 Vehicles built up to November 1993 2 Vehicles built from December 1993 Pre removal Operation Installation of Air lntake Plenum o Filling of Engine Coolant o Adjustment of Accelorator Cable Refer t...

Page 246: ...anifold mounting nuts one bank after the other by the following procedure Vehicles built up to November 1993 1 llghten the nuts in the front bank to 3 to 5 Nm 0 3 to 0 5 kgm 2 2 to 3 6 ft lbs 2 Tighten the nuts in the rear bank to 12 to 1 5 Nm 1 2 ro 1 5 kgm I to 11 ft lbs 3 llghten the nuts in the front bank to 12 to 15 Nm 1 2 to 1 5 kgm 9 to 11 ft lbs 4 Repeat steps 2 and 3 one more time respect...

Page 247: ...pe A 14 Water pipe B 15 Oxygen sensor connector 16 Turbocharger fitting assembly 17 Gasket 18 Ring 19 Oxygen sensor 20 Turbocharger stay 21 Exhaust pipe fitting 22 Gasket 23 Oil return pipe t 24 Turbocharger assembly 25 An conditioner compressor 26 Tension pulley bracket 27 Au conditioner compressor bracket 28 Oilpipe t ff ft fl t tf I I wy Ä r47ft ib 26 fir 2s Removal steps 1 Air hose C 2 An inta...

Page 248: ... Clean the alignment surfaces shown in the illustration Supply clean engine oil through the oil pipe installation hole of the turbocharger assembly Caution When cleaning care must be taken so that a piece of the gasket does not enter the oil passage hole INSTALLATION OF AIR HOSE E I 5 AIR HOSE B AIR HOSE D I 1 AIR HOSE C Aligning the marks at the points indicated by the arrows in sert securely int...

Page 249: ... the bolt section of the band upward INSTALLATION OF AIR INTAKE HOSE B Engaging the notches with A marks at the points indicated by the arrows insert until seated Insert the turbocharger end of air intake hose B completely O Ml ubbhl Motoß Corporation July 1994 RETAIED ...

Page 250: ...ccelerator cable engine side 3 Air hose A 4 Air pipe A 5 Heat protector F 6 Clutch booster vacuum hose 7 Connection for accelerator cable pedal side L H drive vehicles B Air intake hose A 9 Air intake hose C 10 Oxygen sensor 11 Heat protector D 12 EGR pipe l t t t t REMOVAL AND INSTALLATION 20 2 O 11 N qst6r ÄLr b ah TM t g 19 Nm x o Ltrl3il3 12 15 Nm 1 2 1 5 kgm o5Fü 41 S11ft lbs 13 Eye bolt 14 O...

Page 251: ...AKE HOSE C I 8 AIR INTAKE HOSE A Engaging the notches with A marks at the points indicated by the arrows insert until seated Insert the turbocharger end of air intake hose C completely 4 INSTALLATION OF AIR PIPE A 3 AIR HOSE A 1 Aligning the marks at the points indicated by the arrows in sert securly into the stepped portion of the pipe Gaution Be careful not to allow any foreign matter to get int...

Page 252: ... to47 53 Nm 4 7 5 3 kgm 34 38ft lbs 3 Back off nuts until torque value of 10 Nm 1 0 kgm 7 ft lbs is achieved 4 Tighten nuts to2S31 Nm 2 9 3 1 kgm 21 22ft lbs NOTE 1 Fit the cone disc spring with the grooved side facing the nut 2 Install the nut cone disc spring and washer in the or der shown in the illustration 3 w t t 5 Heat protector l 6 Exhaust manifold rear 7 Gasket t DO 2 Removal steps of exh...

Page 253: ...t lbs 2 Temporarily tighten the turbocharger to the exhaust manifold 3 Tighten nut to 30 Nm 3 0 kgm 22 ft lbs 4 Tighten nuts and to 47 53 Nm 4 7 5 3 kgm 34 38 ft tbs 5 Back off nuts and until torque value of 10 Nm 1 0 kgm 7 ft lbs is achieved 6 Tlghten nuts and to 29 31 Nm 2 F3 1 kgm 21 22 ft tbs NOTE 1 Fit the cone disc spring with the grooved side facing the nut 2 Installthe nut cone disc spring...

Page 254: ...Rubber hangers 4 Main muffler 5 Gasket 6 Mouldings 7 Hanger brackets 8 Catalytic converter and center exhaust PiPe instal lation nuts 9 Hanger bracket 0 Rubber hangers 11 Center exhaust pipe 12 Gasket 13 Rubber hangers 14 Hanger brackets 1 5 Hanger bracket 16 Rear floor heat protector 17 Catalytic converter and front exhaust pipe instal lation bolts 18 Catalytic converter 19 Gasket 20 SelfJocking ...

Page 255: ...ND EXAUST Exhaust Pipe and Main Muffler 15 19 SERVICE POINTS OF REMOVAL ETSRAAA 2 3 REMOVAL OF RUBBER HANGERS 4 MAIN MUFFLER Support with a transmission jack etc Mitsubishi Motoß Corporation July 199t0 RE I8GD ...

Page 256: ...o o o o NOTES ...

Page 257: ...JUSTMENT PROCEDURES 3 ALTERNATOR 9 STARTING SYSTEM 10 SPECTFTArONS 10 General Specifications 10 IGNITION SYSTEM 10 SPECIFICATIONS 10 General Specifications 10 ServiceSpecifications 11 SPECIAL TOOLS 11 SERVICE ADJUSTMENT PROCEDURES 12 CAM POSITION SENSOR AND CRANK ANGLE SENSOR DETONATION SENSOR ß Mitsubishi Motoß Corporation May 1992 FWUEgl19 ...

Page 258: ...Battery voltage sensing 121110 Electronic built in type Items Specifications Alternator Standard value Regulated voltage Ambient temp at voltage regulator V _20 c 4 F 20 c 68 F 60 c 140 Fl 80 c 176 F 14 2 15 4 13 9 14 9 13 4 14 6 13 1 14 5 Limit Output current A 77 Tool Number Name Use MD998467 Alternator harness connector Checking the alternator S terminal voltage tlltrShhl toto Coryorrtion May 1...

Page 259: ...ING SYSTEM Service Adiustment Procedures 16 3 O sERvrcE ADJUsTMENT PRocEDUREs VOLTAGE DROP TEST OF ALTERNATOR OUTPUT LINE Terminal B Alternator EISAGAG MftrubichiMotorrCorporrtion Julyl90B FWUE9 l9 B EVISCD ...

Page 260: ... terminal and then connect the lead of the voltmeter to the battery cable OUTPUT CURRENT TEST 6 Connect a tachometer For the procedure for connecting the tachometer refer to GROUp 11 Service Adjustment Procedures 7 Reconnect the negative battery cable 8 Leave the hood open 9 Start the engine 1O With the engine running at 2500 r min turn the headlamps and other lamps on and off to adjust the altern...

Page 261: ... lf the voltage is 0 V the cause is probably an open circuit in the wire or fusible link between the al ternator 8 terminal and the battery termi nal 10 After turning the light switch on and turning on the headlamps start the engine 1 1 lmmediately after setting the headlamps to high beam and turning the heater blower switch to the high revolution position increase the engine speed to 2 500 r min ...

Page 262: ...efer to GROUp 11 Ser vice Adjustment Procedures 8 Reconnect the negative battery cable 9 Turn the ignition switch to the ON position and check that the reading on the voltmeter is equal to the battery voltage NOTE 10 Check to be sure that all lamps and accessories are off 1 1 Start the engine 12 lncrease the engine speed to 2 800 r min l3 Read the value displayed on the voltmeter when the current ...

Page 263: ...0 4 0 2 0 0 2 7 ELOI l9 NOTE Furthermore the voltage waveform of the alternator B terminal can undulate as shown at left This waveform is produced when the regülator operates according to fluctua tions in the alternator load current and is normal for the alternator 0 4 FUNCTION SPECIAL PATTERNS PATTERN HEIGHT VARIABLE VARIABLE knob Adjust while viewing the wave oattern PATTERN SELECTOR RASTER Engi...

Page 264: ...ator is not operating Waveforms can be observed when the headlamps are illuminated 3 Check the conditions of the charge lamp illuminated not illuminated also and carry out a total check Abnormal waveforms Problem cause Example o Open diode Example TELOt2l o Short in diode Example 7ELOI22 o Broken wire in stator coil Example 7ELOI23 o Shoft in stator coil Example 5 NOTE At this time the charge lamp...

Page 265: ...elt tension adjustment Refer to GROUP 11 Service Adjustment Procedures 4 Drive belt for alternator and air condi tioner 5 Alternator connector 6 Oxygen sensor connector 7 Alternator and alternator bracket assem blv 8 Alternator bracket 9 Alternator SERVICE POINT OF REMOVAL 3 REMOVAL OF CLAMP NUT On vehicles with an air conditioner remove the clamp nut raise the suction hose and suspend it from the...

Page 266: ...OR Items Specifications Tvpe ldentification No Part No Rated output kW No of pirtion teeth Reduction drive with planetary gear M1T72583 MD172863 1 2t12 8 Items Specifications Tvpe Advance mechanism Contact pointless Electronic IGNITION COIL Items Specifications Type ldentification No Part No Molded 3 coiltype F 536 MD152648 SPARK PLUG Items Specifications NGK NIPPON DENSO PFR6J 1 1 PK2OPR P1 1 O M...

Page 267: ...67 0 81 11 3 15 3 Items Specification Standard value Spark plug gap mm in Limit Spark plug 9ap Platinum plug only mm in 1 0 1 1 0 039 0 043 1 3 0 051 Tool Number Name Use MD998464 Harness connector 4 pin square Inspection of ignition primary voltage ignition coil connection MD998773 Detonation sensor wrench Removallnstallation of detonation sensor Mltrubighl MotoE Corporation May 1992 PWUEgtlg ...

Page 268: ...cylinder side coil Goil B No 2 No 5 cylinder side coil Coil C No 3 No 6 cylinder side coit Standard value 11 3 15 3 kO POWER TRANSISTOR INSPECTION NOTE An analog type circuit tester should be used No 1 No 4coilside 1 Connect the negative terminal of the 1 S V power supply to terminal of the power transistor then check whether there is continuity between terminal and terminal when terminal and the ...

Page 269: ...de 1 Connect the negative terminal of the 1 5 V power supply to terminal of the power transistor then check whether there is continuity between terminal D and terminal when terminalO and the positive terminal are connected and disconnected NOTE Connect the probe of the circuit tester to terminal Terminal 1 and terminal Terminal 11 and terminal4 Connected Continuity Unconnected No continuiV 2 Repla...

Page 270: ...plug cables Caution Whcn pulling off the spark plug cablc from the plug ahrayr hold the cable cap not the cable 4 Remove the spark plugs 5 Check the plug gap and replace if the limit is exceeded Standard value 1 0 1 1 mm 10 039 0 048 in l Limh 1 3 mm 10 051 in l Cautlon 1 Do not sttempt to adjust the gap of the platinum plug 2 Cleaning of the platinum plug may result damage thc platinum tip Theref...

Page 271: ...ylinders in each group appear during wave observation No l cylinder No 4 cylinder No 2 cylinder No S cylinder No 3 cylinder No 6 cylinder However wave observation is carried out for the cylinder with the spark plug cable clamped by the secondary pickup 2 Clamp the spark plug cable with the Trigger pickup NOTE 1 Clamp the spark plug cable for the No l No 2 or No 3 cylinder of the same group with th...

Page 272: ...A lgnition voltage point D l Neutral section Wa te damping reduction section point B Observation Condition Only pattem selcctor bdow ch ngcs from the abovc conditionr Pattern selector I Display Secondary ignition voltage waveform Dwell section No 2 cylinder No 3 cylinder ignition noise ignition noise No 4 cylinder Waveform is disturbed Time 7ELOI17 No 5 cylinder No 6 cylinder ignition noise igniti...

Page 273: ...r to abnormal waveform example 5 Number of vibrations Coil 5 6 or higher Normal Except above Abnormal show the following trends Spark line Plug gap Condition of electrode Compression force Concentration of air mixture lgnition timing Spark plug cable s o i c o Long Small Normal Low Rich Advanced Leak Short Large Large wear High Lean Retarded High resistance c o 6 I High Large Large wear High Lean ...

Page 274: ...distorted This could be a result of mis firing Spark plug gap is too small Example 3 Spark line is low and long and is sloping However there is almost no spark line distortion Spark plug gap is fouled Example 4 Spark line is high and short Difficult to distinguish between this and abnormal wave pattern example 1 Spark plug cable is nearly falling off Causing a dual ignition Example 5 orPo2t9 No wa...

Page 275: ...when observing the No 1 No 4 cylinder group terminal 1 red clip for ifre ruo 2 No 5 cylinder group and terminal 41 white clip for the No 3 No 6 cylinder group 3 Connect the primary pickup earth terminal 4 Clamp the spark plug with the trigger pickup NOTE 1 Clamp the spark plug cable for No l No 2 and No 3 cylinders of the same group with the cylinder that is connected to the Primary PickuP 2 The w...

Page 276: ...ry Pattern height High or Low Pattern selector Raster Engine speed ldle 700 r min STANDARD WAVEFORM ObserYation Conditions rine pointA Zener voltage Point C Approx 40 x 10V Wave damping reduction section point B Dwell section illtrabhl MotonGorporatlon May 1992 PWUEgl19 ...

Page 277: ...estor below changes from the above conditions l Pattern selector Display No 2 or No 5 cylinder ignition noise No 5 or No 2 No 1 cylinder ignition noise No 4 or cylinder I Primary ignition voltage waveform 16 21 No 6 or No 3 cylinder ignition noise Mltarblrhl Motot Cotpor tion Mey l9eil ...

Page 278: ...ve Abnormal Point C Height of Zener voltage Height of Zener voltage Probable cause High Problem in Zener diode Low Abnormal resistance in primary coil circuit Spark line Plug gap Condition of electrode Compression force Concentration of air mixture lgnition timing ligh tension cable c CD c o J Long Small Normal Low Rich Advanced Leak Short Large Large wear High Lean Retarded High resistance s o 6 ...

Page 279: ...second half of the spark line is distorted This could be a result of mis firing Spark plug gap is too small otPo2t2 Spark line is low and long and is sloping However there is almost no spark line distortion Spark plug gap is fouled olPO2tt Spark line is high and short Spark plug cable is nearly falling off Causing a dual ignition Example 5 o1PO21a No waves in wave damping section Rare short in ign...

Page 280: ...CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Pre removal and Post installation Opcration o Removal and Installation of Timing Belt Cover Refer to GROUP 11 Timing Bett 9Nm 0 9 kgm 7 ft tb Removal steps 1 Cam position sensor 2 Crank angle sensor Mltublrhl Motorr Corporrtion Mey 1992 FWUEgl19 ...

Page 281: ... Refer to GROUP 15 Intake Manifold o t 1 Detonation sensor SERVICE POINT OF REMOVAL 1 REMOVAL OF DETONATION SENSOR SERVICE POINT OF INSTALLANON 1 INSTALLATION OF DETONANON SENSOR When the detonation sensor is installed be sure to tighten it precisely to the specified torque as its installation affects the engine control MD998773 4 Mhrublrhl MotorCorpor tlon M y 199i1 n uEgl19 ...

Page 282: ...o o o o NOTES ...

Page 283: ...on Control Device Reference Table Component Layout Vacuum Hose Piping Diagram Vacuum Hose Layout Cautions on Inspection Crankcase Emission Control System Evaporative Emission Control System Exhaust Gas Recirculation EGR System 2 2 2 2 2 3 CATALYTICCONVERTER 15 GAN STER 15 1 TWO WAY VALVE 16 3 4 6 7 7 8 9 12 Mltcubishi Motors Colporataon July 199t0 PWUE9Il9 D E 8GD ...

Page 284: ...feedback type Purpose CO HC NOx reduction Exhaust gas recirculation system EGR valve EGR control solenoid valve Single type Duty cycle type solenoid valve Purpose NOx reduction catalytic converter Monolith type Purpose CO HC NOx reduction Items Specifications Purge control solenoid valve coil resistance lat 20 C 68 F l EGR control solenoid valve coil resistance lat 20 C 68 F I o O 3H4 3H4 Items Sp...

Page 285: ...ontrol system Evapora tive emis sion con trol sys tem Air fuel ra tio control system Catalytic convener Exhaust emission control system Reference page for each part inspection PCV valve X 17 A Purge control solenoid valve X t7 t1 MPI system component X X Fuel Group 13 EGR valve X 17 13 EGR control solenoid valve X 17 14 Catalytic converter X 17 t5 Mftsubishi Motoru Corporatlon May 1992 ...

Page 286: ...dures COMPONENT LAYOUT Name Symbol Name Symbol Canister A EGR valve F Catalytic converter G H PCV valve E EGR control solenoid valve D Purge control solenoid valve C Purge controlvalve B TFUlOO2 ilttltßicri Motors Corporataon July 1 19t0 REVISED o ...

Page 287: ...EMISSION CONTROL Service Adjustment Procedures 17 5 Purge valve d t6 Yfr l Positive crankcase Cataltltic conve rter TEyO25 Mitsublshi Motors Corporation July 1994 PWUE9119 D REVIS D ...

Page 288: ...17 6 EMISSION CONTROL Service Adiustment Procedures VACUUM HOSE PIPING DIAGRAM o o a o oo E a o 5iär59 do Eax 9öJd rlt lD cl f r Mitsubirhl Motors Corporation May 1992 PWUEgl19 ...

Page 289: ...r completing engine ad justment inspect the hoses to make sure there are no disconnections connection errors or damage Make sure there is no hose pipe or port clogging or cracks or damage in the hoses and Pipes When replacing device hoses always mount the replace ment hose in the same position direction as the original When finished check the connections as described in the workshop manual or serv...

Page 290: ... and confirm that negative pressure of the intake manifold is felt Iilfir moment the ptunger in the positive crankcase O ventilation valve moves forward and backward 6 lf negative pressure is not felt clean the positive crank case ventilation valve or replace it 7 Tighten the positive crankcase ventilation valve with the specified torque Tlghtenlng torque 10 Nm 1 0 kgm 7 2 ft lbs l Poritlve Grankc...

Page 291: ... check by apply ing vacuum from a hand vacuum PumP When engine is cold engine coolant temperaturc 4O C 10trF1 or lccs When engine is hot engine coolant temperaturo SO C 176ieFl or higher Engine operating condition Applying vacuum Result 3 000 r min 375 mmHG 14 8 in HG Vacuum is maintained Engine operating condition Applying vacuum Result 3 000 r min with in three minutes after starting engine Try ...

Page 292: ...rge Port Vacuum lnspection Ernre Check Gondition Engine coolant temperature 80 95 C 176 203 F 1 Disconnect the vacuum hose from the throttle body purge hose nipple and connect a hand vacuum pump to the nipple 2 Start the engine and increase the engine speed by racing At this time check to be sure that the purge vacuum in creases in correspondence to the increase in engine speed NOTE lf the vacuum ...

Page 293: ... reconnected to the original position 1 Disconnect the vacuum hoses non stripe and red stripe hose from the solenoid valve 2 Disconnect the harness connector from solenoid valve 3 Connect a hand vacuum pump to the nipple to which the red striped vacuum hose was connected a Apply a vacuum and check for air tightness when voltage ap plied directly to the purge control solenoid valve and when the vol...

Page 294: ...0oC 68 F or lessl and warm condition lcoolant temperature go c 176 F or morel of the engine check the following two points Gold condition of engine Engine operation Normalstate Race the engine by rapidly pressing in the accelerator pedal The negative pressure does not vary Atmospheric pressure Warm condltion of engine Engine operation Normalstate Race the engine by rapidly pressing in the accelera...

Page 295: ... passage of the EGR to check condition as follows Applying vacuum Result 45 mmHg 1 8 in Hg or less Air does not blow through 230 mmHg 9 1 in Hg or more Air blow through Installation lnstall a new gasket and EGR valve tighten bolts to specified torque Specified tightening torque 19 Nm 13 ft lbe l EGR Valve Control Vacuum lnspection Check Gondition Engine coolant temperaiure 80 95 C 176 205 F 1 Disc...

Page 296: ... 3 Connect a hand vacuum pump to the nipple to which the green striped vacuum hose was connected 4 Apply a vacuum and check for air tightness when voltage ap plied directly to the EGR control solenoid valve and when the voltage is discontinued 5 Measure the resistance between the terminals of the sole noid valve Standard value 36 44 O lat 20 C 68PFll 6EMOt88 EGRcontrol solenoidvalve 4 TFUrolr Batt...

Page 297: ... tr 2 1 5 kgm 9 11ft lbs Gatalytic Gonverter Leftl removal steps 1 Self locking nuts 2 Bolts 3 Rubber hanger 4 Center exhaust pipe 5 Gasket f 8 Oxygen sensor connection 9 Heat protector D 10 EGR pipe connection 1 1 Gasket Catalytic convert r Left Heat protector E Gasket Catalytic Convorter removal steps 2 Bolts 15 Nuts 16 Hanger bracket installa tion bolts 17 Catalytic convefter 18 Gasket 12 13 14...

Page 298: ...installation Operation r Removal and Installation of Air Cleaner and Air lntake Hose Refer to GROUP 15 Air Cleaner rtff U Removal steps 1 Purge control valve 2 Fuel vapour hose 3 Canister 4 Canister bracket 5 Vapour pipe 6 Fuel vapour hose o o3FOO27 illtröbhiMotorrCorpo ation July1994 ADDED ...

Page 299: ...17 15 2 O Mltsubirhi Motors Corporation July 19911 PWUE9119 D AOOCD ...

Page 300: ...he stepped part lf the pipe has no stepped part insert so that the inserted portion is 20 25 mm 0 8 1 0 in long G t 5 INSPECTION TWO WAY VALVE Connect a clean rubber hose to the two way valve and check for operation SERVICE POINTS OF INSTALIÄTPN 3 INSTALLATION OF TWO WAY VATVE Install so that the two way valve is facing in the direction shown in the illustration aa ör Rubber hose Inspection proced...

Page 301: ... 17 17 1 INSTALLATION OF FUEL GAUGE UNIT COVER Before installing the fuel gauge unit cover apply the speci fied sealant to the rear floor pan Specified sealant 3M ATD Part No 8509 or equivalent MiSrubirhi Moton Gorporatlon Mry 199i1 ...

Page 302: ...o o o NOTES o ...

Page 303: ...ions cLUTcHcoNTRoL I Lubricants 2 CTUTCH MASTER CYUNDER 12 sealant 2 cturcH vAcuuM L NE SERVICEADJUSTMENTPROCEDURES 3 VACUUMTANK 13 Clutch Pedal Inspection and Adjustment 3 Clutch Booster Operating Inspection 4 CheckValveOperation Check 4 Bleeding 5 Mtrublrhl Moto t Corpor tion Mly 190ül PWUEgtlg ...

Page 304: ... 1 10 N 1 1 kg 24 lbs l Items Specifications Standard value Clutch pedal height mm in Clutch pedalclevis pin play mm in Clutch pedalfree play mm in Distance between the clutch pedaland the firewallwhen the clutch is disengaged mm in Booster push rod to master cylinder piston clearance mm in 183 188 V 20 7 401 1 3 0 04 0j21 12 20 0 49 0 79 5512 2l or more 0 2 t 0 46 0 0082 0 0181 Items Specified lu...

Page 305: ...utch pcdal clcvlr pln play bo careful not to puch the purh rod toward thc mertcr cylinder 3 After completing the adjustments confirm that the clutch pedal free play measured at the face of the pedal pad and the distance between the clutch pedal the face of the pedal pad and the toeboard when the clutch is disen gaged are within the standard value ranges Standard value Gl Standard value Dl 12 20 mm...

Page 306: ...dal moves downward slightly the boosler is in good condition lf there is no changä the booster is faulty 4 With the engine running step on the clutch pedal and then stop the engine Hold the pedal depressed for 30 seconds lf the pedal height does not change the booster is in good condition lf the pedat rises the booster is faulty lf the above three tests are okay the booster performance can be dete...

Page 307: ...tube the clutch hose and or the clutch master cylinder have been removed or if the clutch pedal is spongy bleed the system Specified fluid DOT3 or DOT4 Gaution Use the specified fluid Avoid using a mixture o the specified fluid and other fluid Vacuum pump connection Accept reject criteria Connection at the clutch booster side A negative pressure vacuum is created and held Connection at the intake ...

Page 308: ... o Adjustment of Clutch Pedal Refer to P 21 3 oEFO062 K 3 l l 7 13 15 Removal steps 1 Brake booster Refer to GROUP 35 Brake Booster 2 Connection of clutch master cylinder 3 Connection for vacuum hose 6 Pedal support bracket 7 Clevis pin 8 Clevis pin 9 Clevis pin 10 Yoke 1 1 Clutch pedal shaft 12 Clutch pedal 13 14 15 16 t7 18 19 20 21 22 Bushing Spacer Clutch pedal pad Bolt Lever assembly Bushing ...

Page 309: ... Refer to P 21 A l 30 Nm A 2i2 Yrrn 1 3 kgm 9 ft lbr 6 ä __ 11 13 ilm 1 3lgm I ft lbr 3 0 kgm 22 ft lbs rt öb Romoval stcps 4 Connection for clutch booster 5 Clevis pin 6 Pedal support member 1 1 Pedal shaft 12 Clutch pedal 13 Bushing 15 Pedal pad 22 Clutch switch Mibublrhl Moton Corpontion lllay tgel ...

Page 310: ...4 Clutch release cYlinder 15 Nm PoEt lffit lhtion Opcraüon e Suoolvinq of Clutch Fluid o Bleieidinqbf the clutch Line Refer to P 21 5 r Adiustnientof Clutch Pedal Referto P 21 3 Release cylinder Spociftcd glc 3c MITSUBISHI gcnuine grcase Part No 010101f 15 Nm 1 5 kgm 11 ft lbs Glutch llne rcmoval steP8 1 Brake booster Refer to GROUP 35 Brake Booster 2 An hoseA 3 Air cleaner cover air intake hose A...

Page 311: ...nk 7 Connection for clutch tube A 8 Clutch master cylinder Adiustment of piston to push rod clear ance 9 Sealer Clutch release cylinder removal steps Air hose A Air cleaner cover air intake hose A Vacuum pipe Battery Battery seat washer tank Clutch release cylinder Clutch line removal steps 2 An hoseA 3 Air cleaner cover air intake hose A 4 Vacuum pipe 5 Battery 6 Battery seat washer tank 7 Clutch...

Page 312: ... slots indicated by arrows in air intake hose A with A markings on air intake hoses B and C then insert hoses B and C all the way into air intake hose A lnsert air intake hoses B and C all the way up to the roots on the turbocharger end 2 INSTALLATION OF AIR HOSE A 1 Connect the air hoses ensuring that paint marks on hose end are aligned with protrusions Insert air hoses B and C into pipe all the ...

Page 313: ...e placed on the clutch booster Then subtract the thickness of the square to arrive at D Using the measured values obtained in 1 through 3 obtain the clearance A between the clutch booster push rod and piston Standard value tA A B C Dll O 21 0 6 mm 0 0082 0 0181 in l lAtmosPheric Prcalurcl lWhen the clutch booster negative pressure of 66 7 kPa 0 67 kg cm2 9 7 psi is applied the clearance ß be comes...

Page 314: ...bly 3 Reservoir cap 4 Reservoir band 5 Reservoir 6 Master cylinder body DOT3 or IX T I vdbd Mestcr qllnd kh riuCId P SERVICE POINTS OF DISASSEMBLY 2 REMOVAL OF PISTON ASSEMBLY Gaution 1 Do not damage thc mastor cylindcr body and plrton assembly 2 Do not disassemble piston assembly tlltrrSbhl tilotorc Corporatlon May 1992 PfvuEgl19 ...

Page 315: ...take hose A 11 Vacuum pipe 18 Brake booster Refer to GROUP 35 Brake Booster 19 Vacuum pipe t 20 Vacuum hose NOTE 1 5 speed manual transmission 2 6 speed manual transmission x t t taLotta Sealant 3M ATII Part No 8661 or equivalcnt Vacuum tank assombly romoval ps 21 Right member 22 Vacuum tank assembly 23 Vacuum hose 24 Vacuum pipe Hose clamp 1 0 Nm 0 f kgm 2 9 ft lbs 5 1 8 kgm 1 13ft tb 60 70 Nm 6 ...

Page 316: ... air intake hose A 11 Vacuum pipe 12 Battery e 13 Battery seat washer tank NOTE 1 S soeed manual transmission 2 6 soeed manual transmission 15 18 Nm ii t i g 60 70 Nm 6 0 7 0 kgm ß 51ft bs oSFOO6s taLo2ta Sealant 3M ATD Part No 8661 or equivalent 14 Connection for clutch master cylinder 15 Clevis pin 16 Clutch booster 17 Spacer Vacuum tank removal steps 21 Right member 22 Vacuum tank 23 Vacuum hos...

Page 317: ...he way into air intake hose A Insert air intake hoses B and C all the way up to the roots on the turbocharger end 9 INSTALLATION OF AIR HOSE A 1 Connect the air hoses ensuring that paint marks on hose end are aligned with protrusions Insert air hoses B and C into pipe all the way to its step Caution Be careful not to allow any foreign matter to get into the hoses pipes or the intercooler itself 2 ...

Page 318: ...NOTES ...

Page 319: ...l öis senger from rendering the SRS inoperativef 2 Service or mainterrart 99 9f any SRS component or SRS related component must be performed onty at an authorized MITSUBISH dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP S2B Supplemental Restraint System before böginning any service or maintenance of any componetrt of the SRS or any SRS related comp...

Page 320: ...tems Specified lubricants Quantity Transmission oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 Transfer oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 sM T 0 27 dm3 0 29 U S qts 0 24lmp qts 6M T 0 60 dm3 0 63 U S qts 0 53 lmp qts Sleeve yoke Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 As required Tool...

Page 321: ...e viscosity 3 Tighten filler plug to specified torque Specified torque 27 Nm 2 8 kgm 20 ft lbs l TRANSMISSION OIL REPLACEMENT 1 Remove transmission drain plug 2 Drain oil 3 lighten drain plug to specified torque Specified torque 27 Nm 2 8 kgm 20 ft lbs l 4 Remove filler plug and fill with specified oil till the level comes to the lower portion of filler plug hole Specified oil Hypoid gear oil SAE ...

Page 322: ... 2 Install the oil drain plug and tighten it to the specified torque Specified torque 35 Nm 3 6 kgm 26 ft lbs l 3 Remove the oilfiller plug and oil level plug and fillwith oil until the level reaches the bottom edge of the oil level plug hole Specified transmiqsion oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 Ouantity sM T 0 27 dm3 0 29 U S qts 0 24lmp qts l 6M T...

Page 323: ...n control cable assembly Hose clamp f 0 Nm 12 Nm 1 2 kgm 9 ft lbs o9F0080 Shift lever assembly removal rtcps e 4 Connection for transmission control cable assembly Shitt lever assembly side 7 Shift lever assembly q 2 ff ff f t and Post instdlrtion o Removal and lnstallation of Front Console Assembly Refer to GROUP 52A Floor Console GAUTION SRS When removing and Inüdllryü front conrole arrembly don...

Page 324: ...ever Install the select cable so that the flange side of the plastic bushing at the end of select cable is on the end face side of lever B Turn adjuster on shift cable so that shift cable end is positioned as shown with reference to shift lever on the passenger compartment side Install the shift cable so that the flange side of the plastic bushing at the end of shift cable is on the split pin side...

Page 325: ... on air intake hoses B and C then insert hoses B and C all the wav into air intake hose A 1 CONNECTION OF AIR HOSE A 1 Connect the hoses ensuring that paint marks on hose end are aligned with protrusion Insert air hoses B and C into air hose A all the way or up to the step in hose A Caution Be careful not to allow any foreign matter to get into the hoses pipes or the intercooler itself 2 Connect t...

Page 326: ...embly steps 1 Nut 2 Spring washer 3 Plain washer 4 Shift lever 5 Bushing 6 Plain washer 7 Wave washer 8 Nut 9 Spring washer 10 Plain washer 1 1 Return spring 12 Bushing 13 Pipe 14 Bolt 15 Lever A 16 Bushing 17 Bushing 18 Snap ring 19 Washer 20 Lever B 21 Bushing 22 Cable bracket 23 Bracket assembly Mitrublshl Motor6 Corporation May 19gt PWUEg119 ...

Page 327: ...er Assembly Refer to P 22 14 1 o Supplying of Transmission Oil Refer to P 22 3 o Checking Operation of Shift Lever at Each Position o Checking the Operation of Meters and Gauges Hose clamp 4 0 Nm Removal steps 1 Side under cover 2 Air hose A 3 Air cleaner cover Air intake hose A 4 Vacuum pipe 5 Air cleaner element 6 Air cleaner body 7 Battery 8 Battery seat Washertank 9 Connection for transmission...

Page 328: ...mission assembly lower part coupling bolt 28 Transmission assembly 90 Nm 9 0 kgm 65 ft lbs 6Nm 2 0 6 kgm l ft lbs tq 30 Nm 3 0 kgm 22 ft lbs 10 Connection for clutch tube bracket 1 1 Connection for clutch release cylinder 12 Transmission mount insulator bolt 13 Plug 14 Transmission mount bracket Body side fl 15 Mounting stopper 16 Transmission mount bracket Transmis sion side 17 Transmission assem...

Page 329: ...ECTION OF LOWER ARM BALL JOINT Caution 1 Be sure to tie the cord of the sPocial tool to tho nearby part 2 Loosen the nut but do not remove it 23 REMOVAL OF DRIVE SHAFT LEFT SIDEI INNER SHAFT ASSEMBLY 1 Remove the bearing bracket mounting bolts and insert the pry bar between the bearing bracket and the cylinder block 2 Remove drive shaft left side and inner shaft assembly f rom transmission assembl...

Page 330: ...nsmission assembly with a transmission jack and remove transmission assembly lower part coupling bolt then lower transmission assembly SERVICE POINTS OF INSTALIATION E2a DrL z4 INSTATTANON OF DRIVE SHAFT RIGHT SIDEI Provisionally install the drive shaft right side so that the inboard joint part of the drive shaft right side is straight and not bent relative to the transmission Caution Care must be...

Page 331: ...hose A Insert air intake hoses B and C all the way up to the roots on the turbocharger end 2 INSTALLATION OF AIR HOSE A 1 Connect the air hoses ensuring that paint marks on hose end are aligned with protrusion Insertäir hoses B and C into pipe allthe way to its step Caution Be careful not to allow any foreign matter to get into the hoses pipes or the intercooler itself 2 Connect the hoses with the...

Page 332: ...Pipe and Main Muffler O Mh ubl hl Motors Corporation May 1992 8 5 0 kgm 61 5ft bs Sleeve voke 10GOOO1 Gear oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 SERVICE POINT OF REMOVAL 1 REMOVAL OF TRANSFER ASSEMBLY Caution 1 Be cautious to avoid damaging the transfer oil seal tip 2 Gover the transfer opening with the special tool to prevent transmission oil discharge an...

Page 333: ... PROPELLER SHAFT CONTENTS SPECIFICATIONS 2 2 2 2 3 PROPELLER SHAFT 3 3 General Specif ications Service Specif ications SPECIAL TOOL Lubricants Sealant and Adhesives o Mitsubishi Motors Corporation May 1992 ...

Page 334: ... 52 x 2 56 698 5 x 65 27 50 x 2 56 662 5 x 65 26 08 x 2 56 555 5 x 75 Q1 87 x 2 95 Cross type Cross type Constant velocity type Cross type Pre packed type 17 996 0 7085 99 73 3 93 Items Specifications Limit Propeller shaft runout Dial indicator reading Front mm in Center mm in Rear mm in 0 6 0 024 or less 0 6 0 024 or less 0 6 0 024 or less Items Specified lubricant Ouantity Sleeve yoke surface Lö...

Page 335: ...ES SPECIAL TOOL PROPELLER SHAFT REMOVAL AND INSTALLATION Removalsteps 1 Self locking nut e 2 Insulator e rra 3 Pr opeller shaft e 4 Spacer 10GOOO1 Gear oil Hypoid g er oll SAE 75W 90W or 75WSW conforming to API GL tl or higher qY t so o ru 5 0 0 kgm 36 4il ft lbs W Tool Number Name Use M8991 193 Plug Prevention of entry of foreign objects into the transaxle and transfer Y Mitsubishi MotoF Corporat...

Page 336: ...in the boot 2 Use the special tool provided as a cover to prevent the entry of foreign objects into the transfer 4 REMOVAL OF SPACER The number of spacers necessary may differ from one location to another front rear right left Record the number of spacers used to ensure correct installation INSPECTION PROPELLER SHAFT RUNOUT Limit Front propcller shaft 0 6 mm 0 02 f in l or lcss Center propeller sh...

Page 337: ...ange with the mating marks properly aligned Gaution Tighten inrtallatlon bolr rftrr nmovlng oll end groEso from thrcedt to pnvcnt thrm from foorn ing duc to lubrlcetlon INSTALI ANON OF INSULATOR Install spacers and insulators as indicated in the illustration Caution When installlng the ccntcr bcrilng üaambl th rma spacers a8 rcmoved from lt or now rprorn of tqurl thickncssl Transfer Mlt ubl hl Mot...

Page 338: ...shaft assembly a 2 Self locking nut ef a 3 Companion flange e fa 4 Center bearing assembly af e 5 Center propeller shaft assembly 6 Snap ring f 7 Boot band e fe 8 Löbro joint assembly I 1Of lOOOg Adhesive 3M ATD Part No 8121 or 9 Rubber packing e 10 Löbrotointboot 11 Washer 12 Center propeller shaft f 13 Self locking nut ar a 14 Companion flange af fa 15 Centerbearingassembly 16 Rear propeller sha...

Page 339: ...nge yoke and the companion flange before removing the front propeller shaft assembly 4 REMOVAL OF CENTER BEARING ASSEMBLY First remove the center bearing bracket and then remove the center bearing using a puller commercially available 5 REMOVAL OF CENTER PROPELLER SHAFT ASSEMBLY Put mating marks on the center propeller shaft the Löbro joint assembly and the companion flange before removing the cen...

Page 340: ... the grease on the Löbro joint assembly wipe off the grease and clean the outer and inner races cage and balls 4 lf the outer race cannot be removed remove the complete Löbro joint assembly from the center pro peller shaft by using a puller commercially available 10 REMOVAT OF LÖBRO JOINT BOOT Tape the serration of the center propeller shaft and then remove the Löbro joint boot 14 REMOVAL OF COMPA...

Page 341: ...aft with its dust seal facing the companion flange side 3 lnstall lining up the mating marks on the companion flange and the rear propeller shaft 4 While tightening the selflocking nut install the center bearing assembly with the companion flange 10 INSTALLATION OF LÖBRO JOINT BOOT Tape the serration of the center propeller shaft and then install the Löbro joint boot 8 INSTALI ATION OF LÖBRO JOINT...

Page 342: ...same side Also ensure that the relative positions of the inner and outer races are as shown in the illustration 4 Install the remaining balls in their original positions 5 Check that the outer race rotates on the inner racö smoothly 6 Apply specified grease to the Löbro joint assembly Specified grease Repair kit grease tcs 55 g r sg 1 94 oz ll 7 Apply a small amount of specified adhesive in three ...

Page 343: ...move grease if present fiom around the bosses Grease obstructs the ventilation air passage 5 INSTALLATION OF CENTER PROPELLER SHAFT ASSEMBLY Install lining up the mating marks on the center propeller shaft the Löbro joint assembly and the companion flange 4 INSTALTATION OF CENTER BEARING ASSEMBLY 3 COMPANION FTANGE I 2 SETF LOCKING NUT 1 Install the bearing in the rubber mount groove of the center...

Page 344: ...o o o ilOTES o ...

Page 345: ... SPEC F CATIONS 2 General Specifications 2 ServiceSpecifications 2 Lubricants 2 SPECTALTOOIS 3 SERVICE ADJUSTMENT PR rcEDURES 4 HubAxial Playlnspection 4 HUB AND KNUCKI E 5 DRIVESHAFT 8 Mltrubirhi Motorc Corpor tion Mry t90ll ...

Page 346: ...4 Ert E CD Items Specifications Standard value Setting of T J boot length mm in L H R H 85 3 3 35 0 12 85 3 3 35 0 12 Limit Hub axial play mm in Wheel bearing starting torque Hub starting torque Nm kgcm in lbs 0 05 0 002 1 8 18 16 Items Specified lubricants Ouantity T J boot grease Repair kit grease 160 g 5 64 oz Dust seal inner Dust seal outer Multipurpose grease 1 20 g 0 49 71 oz 12 g 0 284 42 o...

Page 347: ...ess in the hub M8990685 Toroue wrench Measurement of the front hub unil bearing rotation starting torque M8990326 Preload socket M8990890 Rear suspension bushing base Press fitting of the dust seals M8990767 End yoke holdör Removal of the drive shaft M8990241 1M8990242 N tsggoz44 Axle shaft puller Puller bar Puller shaft Puller bar M8991354 Puller body Mitrubi hi Moton Corporation May 1992 PVyUEgl...

Page 348: ... A M8990926 39 1 54 A M8990933 63 5 2 50 M8990927 45 1 77l M8990934 67 5 2 66 MB990928 49 5 1 95 M8990935 71 5 Q 811 M8990929 51 2 01 M8990936 75 5 2 971 M8990930 s4 2 13 M8990937 79 3 1 1 M8990931 57 2 24l B M8990938 M8990932 61 2 40 c M8990939 Mlt ölrtrl Motor Corporutlon May i992 SERVICE ADJUSTMENT PROCEDURES HUB AXIAL PLAY INSPECTION E2OFEAII 1 Jack up the vehicle and remove the front wheels 2...

Page 349: ...the pole piec at thc tip of the speed sensor and the toothed edge of the rotor 80 as nbt to damage them by striking against other parts PWUEgl19 2 3 4 kgm SKr l b 6 F72 Nm 6 F7 2 kgm c3 52 ft lbs Removal steps 1 Front speed sensor connection 2 Split pin 3 Drive shaft nut 4 Caliper assembly 5 Brake disc 6 Front hub unit bearing 7 Dust shield 8 Lower arm balljoint connection 9 Split pin 10 lle rod e...

Page 350: ...OF CALIPER ASSEMBLY Remove the caliper assembly and suspend it with wires DISCONNECTION OF TOWER ARM BALI JOINT Caution 1 Be sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but do not remove it 10 DISCONNECTION OF TIE ROD END Gaution 1 Be sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but do not remove it 11 REMOVAL OF DRIVE SHAFT Gaution ...

Page 351: ...rque of the hub Limit 1 8 Nm 18 kgcm 16 in lbs l or less SERVICE POINT OF INSTALLATION 3 INSTALLATION OF DRIVE SHAFT NUT 2 SPL T PIN 1 Be sure to install the washer and wheel bearing nut in 21 3 the specified direction After installing the wheel lower the vehicle to the ground and finälly tighten the wheel bearing nut if the position of ifrelplit pin holes doe s not match tight en thä nut upto 260...

Page 352: ... connection 6 Center bearing bracket installation bolt 7 Drive shaft anä inner shaft assemOiy ti H t c 8 Drive shaft R H 9 Circtip 2 tl 3 4 ksm 17 25ft tb Inl 2 200 a80 Nm 26kem l1 188ft tbs aj S72 Nm 6 F7 2 ksm rl3 52 ft lbr k SERVICE POINTS OF REMOVAL 2 REMOVAL OF DRIVE SHAFT NUT Gaution Do not pply vehicle load to the whod bearinq loosinq the drive shaft nut lf howeyer vehicle loadhust bä lppli...

Page 353: ...l 1 Using the special tool push out the drive shaft and inner shaft assemblv 1 H or the drive shaft R H from the hub Caution Take care not to dama gc thc rotor for 4 8 8 Inrtrlhd to the B J outer racc 2 lf the inner shaft is hard to remove from thE transmis sion strike the center bearing bracket lightly with a plas tic hammer 3 To remove the drive shaft R H from the transmission pry off the shaft ...

Page 354: ...ut in the specified direction 2 After installing the wheel lower the vehicle to the ground and finally tighten the wheel bearing nut 3 lf the position of the split pin holes does not match tight en the nut up to 260 Nm 26 kgm lgg ft lbs in maxi mum 4 lnstall the split pin in the first matching holes and bend it securely ilftrnbhlllotoncorporadon Mtyl l PWUEgl19 ...

Page 355: ...er bearing 12 Center bearing bracket 13 Circlip 14 Dust shield 15 Snap ring e 16 Spider assembly e e 17 T J boot 18 B J assembly Caution 1 Take care not to damtgc the rotor Inüdbd to ttto B J outer raGe 2 Ncver disassomblc B J acccmbly R H F 2 A i tü s2 I _ o 4 Y reri Y 15 I 1 l 6 qäd I 10lu 13 ffir I 15 16 rg lU 4 T J Boot Repair Kit iF ffu r rLATfr ffi T J Repair Kit k rd ffi Bearing Dust Seal R...

Page 356: ... rd outcr 12 g 0 28 tli oz l Grru Rrprirt ltgrrm 160c 5 0aoz l Grutlon Thr grrrlc in tht rrpelr kit rhould bc dMdtd ln hdlüor ur rupccüvdy at thc iolm tnd InrUc thc boot Sprclel grrer ir urod to lubdcrtc ür h 1t m notmlx oH rnd ncwgrcaroc dlllcnnt typcl ol grcerc llttrÖbhl Motorr Corpordon Mry t99il ...

Page 357: ...sh out the inner shaft underneath 2 Use the special tool to remove the inner shaft from the center bearing bracket 11 REMOVAL OF CENTER BEARING 17 REMOVAL OF T J BOOT 1 Wipe off grease around the shaft spline part izi fo reuse T J boot wrap plastic tape around the shatt spline part so that it is not damaged when removed SERVICE POINTS OF REASSEMBLY 17 INSTALLATION OF T J BOOT tol Wrap plastic tape...

Page 358: ...center bearing bracket 2 Use the special tools to press fit the center bearing into the center bearing bracket 10 9 INSTALTANON OF DUST SEALS 1 Apply multipurpose grease to the rear surfaces of all dust seals Dust seal inner 11F2O g l0 lg O 11 oz l Dust 3eal outsr 8 12 g 10 284 A oz l 2 Press the oil seal into the center bearing bracket using the special tool Caution Take care not to damage the ru...

Page 359: ...ss the seal plate into the T J case 3 Fill the specified grease furnished in the repair kit to the T J case Specified greaso Repair kit grear 160 g 5 64 oz l Gaution 1 The grease in the repail kit should bc dividcd in half for use respectively at the ioint and inside the boot 2 The drive shaft joint uses special grcttt Do not mix old and new or different typc of grcare PWUEglt9 T J case Socket Sea...

Page 360: ...F T J BOOT BANDS Set the T J boot bands at the specified distance in order to adjust the amount of air inside the T J boot and then tighten the T J boot band securely Standard valuc 85 3 mm 3 35 0 12 in l tlltrübhlMotonCorporatlon Mryl9gll PWUE9119 ...

Page 361: ...S SERVICE ADJUSTMENT PROCEDURES Rear Axle Total Backlash Check GearOil Level Check Rear Wheel Bearing Axial Play Check Rear Wheel Bearing Rotary Sliding Resistance Check Limited Slip Differential Check AXLE SHAFT DRIVE SHAFT DIFFERENNAL CARRIER LSD CASE ASSEMBTY 10 13 19 2 2 3 3 3 1 8 I I 9 I I ltltüublrhl Motonr Cotportüon M y 190i1 ...

Page 362: ... type I Outer I Inner I Length joint to joint x diameter mm in I Differential Reduction gear type Reduction ratio Differential gear type and configuration Side gear Pinion gear Number of teeth Drive gear Drive pinion Side gear Pinion gear Bearing O D x l D mm in Side Front Rear Semi floating type 35 1 38 28 1 10 34 5 1 36 245 4 9 71 72x35 2 83x 1 38 58x28 2 28x1 l0l B J T J 395x28 15 6x 1 10 Hypoi...

Page 363: ...gear runout mm in Rearwheelbearing end play mm in N kg lbs mm in 12 1 2 2 6 or less 85 3 ß 3510 12 0 1 1 0 1 6 0 004 0 006 0 03 0 09 0 001 2 0 0035 0 5 0 7 5 0 7 0 4 6 0 35 0 45 3 5 4 5 3 4 0 3 0 5 3 0 5 0 3 4 0 1 5 0 25 5 2 5 1 21 5 0 2 0 05 0 002 0 8 0 031 Items Specified lubricants Ouantity Rear axle gear oil Hypoid Gear Oil SAE No 90 conforming to API classification GL 5 or higher 1 1 dm3 1 16...

Page 364: ... rotor M8990925 Bearing and oil seal installer set M8990938 Driving out of axle shaft inner bearing and oil seal MB990938 M8990928 Pressing in of axle shaft inner bearing M8990938 M8990931 Press fitting of the dr ive pinion rear bear ing outer race M8990936 M8990938 Press fitting of the drive pinion front bear ing outer race M8990934 MB990938 Press fitting of the differential side oil seal M899093...

Page 365: ...ng remover installer base M8990641 Lower arm bushing installer and remover A lnstallation of oil seal M8990685 Torque wrench Measurement of the drive pinion preload M8990326 Preload socket ffi M8990767 End yoke holder Fixing of the hub M8990628 Snap ring pliers To remove and install the snap ring of the drive shaft M8990799 Ball joint dust shield installer Press fitting of rear axle shaft dust shi...

Page 366: ... driving M8990909 Warking base Supporting of the differential carrier MB99ll16 M8991116 Warking adapter base M8990810 Side bearing puller Removal of the side bearing inner race Removal of the companion flange M8990850 End yoke holder Removal and installation of the companion flange M8990339 Bearing puller Removal of the drive pinion rear bearing inner race M8990648 Pinion bearing re mover Mh ubhhl...

Page 367: ...ss fitting of the side bearing inner race M8991168 Drive pinion oil seal installer Press fitting of the drive pinion oil seal M8990813 Tap Removal of sealant M8991294 Side gear holding tool Inspection of the differential gear backlash M8991378 Drive pinion setting gauge set M8991366 M8991379 Measurement of drive pinion height Use only MB991366 instead of M8990901 See above Mltanbirhi ltlotor Corpo...

Page 368: ...r as it will go and make mating marks on the companion flange dust shield and the differential carrier Manually turn the propeller shaft counterclockwise as far as it will go and measure the movement of the mating marks Limlt 5 mm 10 2 in l lf the backlash exceeds the limit remove the differential carrier assembly and adjust the backlash Refer to p 27 26 1 GEAR OIL LEVET CHECK 1 Remove the filler ...

Page 369: ...in the same direction lf it turns in the opposite direction replace the viscous unit PWUEOl19 REAR WHEEL BEARING ROTARY SLIDING RESIS TANCE CHECK E1 flAO 1 Remove the drive shaft from the companion flange 2 Remove the brake pad or caliper assembly 3 Attach a spring balance to the hub bolt then pulling the bal ance at a right angle to the hub bolt measure the rotary slid ing resistance to see wheth...

Page 370: ...er bearing 1 1 Dust shield 12 Dust shield 13 Axle shaft 14 Oilseal 15 Inner bearing F F ca t a F t e l e a aa e aa e SERVICE POINTS OF REMOVAL EzTHarF 1 REMOVAT OF REAR SPEED SENSOR Caution Be cautious to ensure that the tip of the pole piece does not come in contact with othel parts when removing the speed sensor 2 REMOVAL OF BRAKE CALIPER ASSEMBLY Remove the brake caliper assembly and suspend it...

Page 371: ...oo40 Axle housing rlAooSS Mit ubl hl Motort Corpolrtion May 199t1 5 REMOVAL OF SELF LOCKING NUT 8 REMOVAT OF AXLE SHAFT ASSEMBLY 9 REMOVAT OF REAR ROTOR 10 REMOVAL OF OUTER BEARING 11 DUST SHIELD 14 REMOVAT OF OIt SEAL 15 INNER BEARING ...

Page 372: ...ial tool press fit the dust shield until it contacts the axle shaft shoulder NOTE When tapping the oil seal in use a plastic hammer to lightly tap the top and circumference of the special tool press fitting gradually and evenly 11 INSTATLANON OF DUST SHIELD With the special tool install the dust shield so that the depression is facing upward NOTE When tapping the oil seal in use a plastic hammer t...

Page 373: ... fit the rear rotor to the axle shaft with the rear rotor groove surface toward the axle shaft flange Removal stcp3 1 Bolt e fe 2 Drive shaft 3 CircliP 4 Oilseal SERVICE PO NT OF REMOVAL 2 REMOVAL OF DRIVE SHAFT Using a tire lever etc remove the drive shaft differential carrier Ez n D from the 4 l Mihublrhi Moton Cotpontion Mry l0 ll ...

Page 374: ...ne 2 The right drive shaft has a two pail serration Be very carefirl to install each one on the correst sidc NOTE The left and right drive shafts can also be distinguished from each other by the identification colour of B J boot band small Gaution Be sure to thoroughly remove any oil or grease etc from the threaded part of the boh and nut used for installation to the companion flange because any o...

Page 375: ...ng 5 Spider assembly 6 T J boot 7 B J boot band large 8 B J boot band small 9 B J boot 10 B J assembly 11 Circlip W fa r a t aa et te fe a at e e a lfe1 t6ü ffi qp 11UOO77 N NA T J boot repair kit z 7 66 flAO10E 1 q t vo ffi B J boot repair kit 11 4 ac ffiffi r Wr 6t ffi B J repair kit T J repair kit n ruE9119 Mlttublrhl Motorr Corporatlon May 199 l ...

Page 376: ...l grease is used forthe ioint Do not mix old grease with ncw or mix different types 3 6 ___ i _ __l Irr il2 Grclse Repair kit grease Ouantfi to use 125 g 4 41 oz l Gaution Apply all ol the grease from thc repair kit to the joint and boot a half to each as a rule Special groass ia used for the ioint Do not mix old greasewith new ol mix different types ältröbhl itlotorr Corpo rtlon May l l PWUE9119 ...

Page 377: ...shaft ioint use special greaso Do not add another tYPe of grease 6 REMOVAL OF T J BOOT 9 B J BOOT 1 Wipe off grease around the shaft spline part izi ro ieuse iJ boot and B J boot wrap plastic tape around the shaft spline part so that they are not damaged when removed 10 REMOVAL OF GREASE FROM B J Wipe out the grease from the B J Caution Do not disassemble the B J SERVICE POINTS OF REASSEMBLY 9 INS...

Page 378: ...0 joint angle 2 The B J boot band and T J boot band are identified by lhe identification number stamped on the lever lnstall correct ones at cort Gt positions INSTALLANON OF SPIDER ASSEMBTY 1 Apply the specified grease furnished in the repair kit to the spider assembly Specified grease Repair kit grease 2 Install the spider assembly with the chamfered spline end first B J boot band 20 74 8J95 T J ...

Page 379: ... 2 4 kgm 17 ft lbs 30 35 Nm 3 0 3 5 kgm 22 25ft lbs i Removal steps c 1 Drive shaft 2 CircliP af e 3 Propeller shaft connection 4 Differenttal suPPort assemblY 5 Differential support member assembly 6 Rear wheel oil pump installation bolt af a 7 Differentialcarrier 8 O ring 90 Nm r P 90 Nm 9 0 kgm 65ft tb t 90 9 0 65 9 0 kgm üft ib t r I t o E _ 50 Nm 3ö 3 2N Nm kgm ft lbs 55 65 Nm 5 5 6 5 kgm d l...

Page 380: ...e differential carrier and removing the rear wheeloil pump through the mounting hole remove the differential carrier Gaution 1 Use care not to damage the rear wheel oil pump gears 2 Use care not to allow dirt or foreign matter to fall into the differential carrier DIFFERENTIAT SUPPORT BUSHING AND FERENTIAL SUPPORT MEMBER BUSHING PLACEMENT Install or remove the bushing using the special tool Instal...

Page 381: ... vice and attach the differential carrier to the special tool FINAL DRIVE GEAR BACKLASH with the drive pinion locked in place measure the final drive gear backlash with a dial indicator on the drive gear NOTE Measure at four points or more on the circumference of the drive gear Standard value 0 11 0 16 mm 0 004 0 006 in l DRIVE GEAR RUNOUT Measure the drive gear runout at the shoulder on the rever...

Page 382: ...in the re verse direction while applying a load to the drive gear so that the revolution torque approximately 2 b 5 0 Nm 25 30 kgcm 28 33 in lbs l is applied to the drive pinion Caution lf the drive gear is rotated too much the tooth contact pattern will become unclear and difficult to check 3 Check the tooth contact condition of the drive gear and drive pinion Mltröirhl Motorr Corporatlon M y l99...

Page 383: ...ight resulting from insuffi The drive pinion is positioned too close to the centre of the drive gear Decrease the thickness of the pinion height adjust ing shim and position the drive pinion farther from the centre of the drive gear Also for backlash adjustment position the drive gear closer to the drive pinion NOTE 1 Tooth contact pattern is a method for judging the result of the adjustment of dr...

Page 384: ...ve gear for rear wheeloil pump drive 10 Drive gear 11 Spring pin 12 LSD case refer to P 27 34 1 13 Self locking nut 14 Washer M8991367 Mtüubbhl MotoF Corpor üon May fgg2 15 Drive pinion assembly 16 Companion flanoe 17 Drive pinion fron t shim or preload adjustment 18 Drive pinion sdacer 19 Drive pinion rear bearing inner race zv urve ptnton rear shim for pinion height adjustment zt utve ptnton 22 ...

Page 385: ... 39 in wide and 1 to 2 mm 0 04 to 0 08 in l high made of copper sheet or the like to prevent damage to the bearing 8 REMOVAL OF SIDE BEARING INNER RACES g DffVE GEAR FOR REAR WHEEI OIL PUMP DR T EI Pull out the side bearing inner races by using the special tools NOTE 1 Remove tho side bearing inner race on the drive gear for rear wheel oil pump drive side together with the drive gear 2 Use the not...

Page 386: ...g marks should not be made to the contact surfaces of companion flange and propeller shaft 2 Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims 19 REMOVAL OF DRIVE PINION REAR BEARING INNER RACE ZI REMOVAL OF OIL SEAL 23 DRIVE PINION FROIIT BEARING 24 REMOVAL OF DRIVE PINION REAR BEARING OUTER RACE trllrrabltl Motor CoDorttion Mly t99 l PVUUE9 19 ...

Page 387: ...t 10 Drive pinion f ront shim 1 1 Drive pinion assembly 12 Drive pinion front bearing inner race 13 Oil seal 14 Companion flange 15 Washer 16 Self locking nut 17 LSD case Refer to P 27 34 1 18 Drive gear 19 Side bearing inner race 20 Side bearing outer race Final drive gear backlash adiustment 5 21 38 tm 3 6 kem 23ft ba J 80 90 Nmr 8 0 9 0lgmr 58 65 ft lbs r tlFooit2 fa e r a fe te x Ie fa 6 7 8 9...

Page 388: ...N Tap the spring pin into the differential case to the position shown in the illustration before press fitting the rear wheel oil pump drive gear The notch on the spring pin should be in the position shown in the illustration Sqlant 3M ATD Pert No 8661 or cqulvalcnt Adhcsiyc 3M Stud Lockins pert No 4t70orequfuabm MltröLhl Motorr Corporatlon May t99it PWUEgl19 ...

Page 389: ... in the illustration NOTE Apply a thin coat of multipurpose grease to the mating face of the washer of the special tool 2 Tighten the handle of the special tool until the standard value of drive pinion rotation torque is obtained 3 Measure the drive pinion rotation torque without the oil seal Standard value NOTE 1 Gradually tighten the nut of the special tool while checking the drive pinion rotati...

Page 390: ...ront bearing inner race 2 Tighten the companion flange to the specified torque by using the tools NOTE Do not install the oil seal 3 Measure the drive pinion rotation torque without the oil seal by using the special tools Standard value 4 lfthe drive pinion rotation torque is not within the range of the standard value adjust the rotation torque by replacing the drive pinion front shim s or the dri...

Page 391: ...n torque with oil seal to verify that the drive pinion rotation torque complies with the standard value Standard value lf there is a deviation from the standard value check whether or not there is incorrect tightening torque of the companion flange tightening self locking nut or incorrect fitting of the oil seal 18 INSTALLATION OF DRIVE GEAR 1 Clean the drive gear attaching bolts 2 Remove the adhe...

Page 392: ...G OF SIDE BEARING INNER RACE FINAL DRIVE GEAR BACKLASH ADJUSTMENT 1 Using the special tool temporarily tighten the side bearing nut until it is in the state just before preloading of the side bearing 2 Measure the final drive gear backlash Standard value 0 11 0 16 mm 0 0011 0 006 in l NOTE Measure at four or more points around the drive gear circumference 3 Using the special tool M8991367 and M899...

Page 393: ... lf poor contact is evident make adjustment Refer to P 27 23 1 Measure the drive gear runout at the shoulder on the reverse side of the drive gear Limit 0 05 mm 0 X 2 in l lf the drive gear runout exceeds the limit reinstall by changing the phase of the drive gear and differential case and remeasure 24 INSTALLATION OF OIL SEAL 1 Using the special tool install the oil seal flush with the gear carri...

Page 394: ...ooirl Mttrubbhl Motorr Corporation May tg9il I I t fa e e 1 21 IiLi Ä B C s 7 5 I I i 3 2 ü_o o INSPECTION BEFORE DISASSEMBLY E27n A 1 CHECKING THE DIFFERENNAL GEAR BACKLASH Secure the differential case assembly in a vise so that the differential side gear right is facing upward Caution When securing the yise be sure not to hold the differential case assembly too tightly Insert a 0 03 mm O OO12 in...

Page 395: ... the thrust direction of the side gear is not within the standard value range remove differential case A and make the adjustment by adjusting the thickness of the thrust washer left SERVICE POINTS OF DISASSEMBLY EzTtrarl 3 REMOVAL OF THE THRUST WASHER IEFT I 9 THRUST WASHER RIGHT The thrust washers left and right are of different thick ness and so should be discriminated in some way for reference ...

Page 396: ...ial case B 6 Check the side gear left of the viscous unit for unusual wear or damage SERVICE POINTS OF REASSEMBLY EZTN L Io INSTALTATION OF THE DIFFERENTIAL CASE 8 I 2 DIFFERENNAT CASE A Align the mating marks of differential cases B and A and assemble the cases 6 INSTATI ANON OF THE DIFFERENTIAT PINION MATE 5 PINION MATE WASHER With the washer in the position shown in tr e illustration install to...

Page 397: ...he correct side together with the gears viscous unit pinion mate wäsher and pinion shaft to differential cases A and B and then using screws secure them temporarily 3 Secure the differential case assembly in a vise so that the differential side gear right is facing upwaid Caution When securing in the vise be sure not to hold the differential case assembly too tightly 4 Insert a 0 03 mm 0 0012 in t...

Page 398: ... 0 ü 12 0 ü 35 in l NOTE lf the clearance in the thrust direction of the side gäar is within the standard value range the backlash öf tne differential side gear is normal 8 lf the clearance in the thrust direction of the side gear is not within the standard value range remove differential case A and make the adjustment by adjusting the thickness of the thrust washer left Thrust washer right refere...

Page 399: ...ONS General Specifications Service Specifications TROUBLESHOOTING 2 2 2 3 SERVICE ADJUSTME IIT PR EDURES 1 Tyre Inflation Pressure Check Tyre Wear Check Wheel Runout Check WHEEL AND TYRE 4 4 4 1 Mltrublrhl Motor Cotpo ttlon Mry lggüz FWUE9 19 ...

Page 400: ...size Amount of wheel offset mm in Tyrgr inflation pressure kPa kg cm2 psii Front Rear 225150R17 AlumiDum type 17 xTtlzJJ 46 1 8 220 2 2 321 20012 0 291 Items Specifications Limit Wheelrunout Radial mm in Lateral mm in Tread depth of tyre mm in 1 0 or less 0 04 or less 1 0 or less 0 04 or less 1 6 0 06 Mltublrhi MotorrGorpo ttion May t9fil pWuEgtlg ...

Page 401: ...ed treads Under inflation Wear on one side Excessive camber Inspect the camber Refer to GROUP 334 Service Ad justment Proc dures Featherd edge Incorrect toein Adjust the to in Bald spots Unbalanced Adjust the imbalanced wheels Scalloped wear Lack of rotation of tyres or worn or out of alignment suspension Rotate the tyros inspect the front suspension alignment Refer to GROUP 334 Service Ad justmen...

Page 402: ...the tyre NOTE When the tread depth of tyres is reduced to 1 6 mm 0 06 in or less wear indicators will appear WHEEL RUNOUT CHECK ErrFcrA Jack up the vehicle so that the wheels are clear of the floor While slowly turning the wheel measure wheel runout with a dial indicator Umit Radial 1 mm or lecs 0 04 in or lesl Lateral 1 mm or lecs 10 04 in or lcsl lf wheel runout exceeds the limit replace the whe...

Page 403: ...el 21 Service ör maintenanLe of any SRS component or SRS related component must be pcriormcd only tt tn authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 5 28 Supplemental Resträint System before beginning any service or maintenance of tny componürt of the SRS or any SRS related component NOTE The SRS inctudes the following eompo...

Page 404: ...A projection mm in Bushing B projection mm in 7 5 10 5 03H 41 7 2 1A 2 0 2H 40 6 5 9 5 0 26 0 37 Tool Number Name Use M8991113 Steering linkage puller Removal of the lower arm balljoint and tie rod MD991045 Bushing remover and installer Removal and installation of the crossmember bushing M8991193 Plug Prevention of transfer oildischarge and foreign oblect entry O Mh ublthi Moton Corporation äw l9g...

Page 405: ... stopper 6 Dynamic damper 12 Nm 10 F120 Nm rr o 1G12 kgm 12 87 ft tb SERVICE POINT OF REMOVAL Ean 2 REMOVAL OF CRUISE CONTROT PUMP AND UNK ASSEMBLY Remove the actuator mounting nuts and place the actuator where it will not interfere with the work SERVICE POINT OF INSTALLAilON lam 5 INSTALLATION OF MOUNNNG STOPPER Attach the engine mounting bracket so that the arrow mark on the mounting stopper is ...

Page 406: ...ise and Suspend the Transmission to the Elftent Force is not Applied to the Transmission Mount o Removal of the Air Cleaner Refer to GROUP 1S Air Cteaner Port in3tlllrtion Opcration o Lower the Transmission o Installation of Air Cleaner Referto GROUP 15 Air Cteaner SERVICE POINT OF INSTALTANON 5 INSTALLANON OF MOUNNNG STOPPER Attach the transmission mounting bracket so that the arrow mark on the m...

Page 407: ...ose C e 7 Rear roll stopper bracket and engine connection bolt 8 Rear roll stopper bracket installation bolt ef fe 9 Rear roll stopper bracket 10 Heat protector r t g dnry6 r1o 6 5Nm ry li älfl f e h i r 70 l Nm 3ig oTfl 2 J 4 stopper brackel 01 F0042 SERVICE POINT OF REMOVAL 9 REMOVAL OF REAR ROIL STOPPER BRACKET 1 Slightly raise the rear roll stopper bracket 2 Turn the rear roll stopper bracket ...

Page 408: ...acuum tank 7 Front roll stopper installation bolt B No 1 crossmember installation nut 9 Lower plate 10 No 1 crossmember 1 1 Stopper B 12 Bushing B NOTE 1 5 speed manual transmission 2 Gspeed manual transmission Pre removal Operation o Removal of Under Cover Referto GROUP 51 Front Bumper Post installation Operation o lnstallation of Under Cover Refer to GROUP 51 Front Bumper o Air Bleedinq of the P...

Page 409: ... long 16 Clamp 17 Lower arm mounting bolt 18 Stopper 19 Rear roll stopper bracket mounting bolt 20 Self locking nut 21 Lower plate 22 Self locking nut 23 Lower plate 24 Crossmember 25 Stopper B 26 StopperA 27 Bushing B 28 Bushing A NOTE Indicates parts which should be temporarily tightened and then f ully tightened with the vehicle in the unladen condition Press out Press fit 12ß0r t 5 Nm 4 5 kgm ...

Page 410: ... that the projecting amount of the inner sleeve agrees with the standard value Standard value No 1 crossmember Bushing B 7 5 10 5 mm 0 30 0 41 in l Grossmember Bushing A 7 2 1O 2 mm 10 28 0 O in l Bushing B 6 5 9 5 mm 10 26 0 37 in l Caution When pressing in apply a solution of soap and water to the sliding part of the bushings and then press them in without stopping one after the other lf there i...

Page 411: ...NS General Specifications Service Specifications SPECIAL TOOLS SERVICE ADJUSTMENT PROCEDURES Front Wheel Alignment Inspection and Adjustment STRUT ASSEMBTY TOWER ARM STABILIZER BAR 5 8 10 2 2 2 3 4 4 liltlrbirhl ilotor Corporrdon MaV l l PmrEgrr9 ...

Page 412: ...ng force at 0 3m sec 0 984 ft sec Expansion N kg lbs Contraction N kg ibs Hydraulic cylindrical double acting type 150 5 91 Hard 2 650 265 584 Medium 1 650 165 363 soft 650 65 143 Hard 1 200 120 265 Medium 1 150 115 253 soft 1 000 100 220 Stabilizer bar Mounting method O D mm in Pillow balltype 23 0 91 Items Specifications Standard value camber PcaJSLoJZ Caster Moch lo f Kingpin inclination Toe in...

Page 413: ...91 176 Spring seat holder Disassembly assembly of thestrut assembly M8991237 M8991238 Spring compressor body Arm set Compression of the front coil spring M8990799 Balljoint remover and installer lnstallation of the dust shield M8990326 Preload socket Measurement oJ the lower arm balljoint starting torque Measurement of the stabilizer link rota tion stafting torque M8990968 Torque wrench IYlttüöi h...

Page 414: ...an accident or if an accident is presumed it is advisable to check the toe out angle on turns in addition to the wheel alignment Conduct this test on the left turn as well as on the right turn Standard valuo 2iE linnu wheel whcn outer whocl t 2Ol CAMBER CASTER AND KINGPIN INCLINATION Standard vllue Camber 0t30t Gaster 3o55 30 Kingpin inclination 142 lnstall the special tool by tightening it to the...

Page 415: ...Refer to P 3344 I i o Removal steps 1 Brake hose tube clamp mounting bolt 2 Brake hose tube clamp 3 Front speed sensor clamp mounting nut 4 Front speed sensor clamp 5 Strut lower mounting bolt 6 Strut upper mounting bolt 7 ECS connector 8 Cap 9 Strut assemblv sT I 90 105 Nm 9 0 10 5 kgm 65 76 8 i llt bi ha Motor Conofilon Mry 19 2 PUVUE9 19 ...

Page 416: ... 8 Front coil sorino 9 Strut asserhbtf SERVICE POINT OF DISASSEMBTY 2 REMOVAT OF SELF TOCKING NUT l Holding the spring upper seat with the special tool loosen the self ocking nut Carnion 11 The solf locking nut should be loosened only not removed 21 Do not uso an air tool 2 Using the special tools compress the coil spring and then remove the self locking nut Gautlon lll Install thc rpccial toob cv...

Page 417: ...INSTAL1ANON OF SELF LOCKING NUT 1 With the coil spring held compressed by the special tools M8991237 and M89912381 provisionally tighten the self locking nut Gaution Do not use an air tool to tiglrten thc boh of thc lpccial tool 2 Correctly align both ends of the coil spring with the grooves in the spring seat and then loosen the special tools M8991237 and M89912381 3 Using the special tool tighte...

Page 418: ... Stabilizer link mounting nut lower arm side 4 Stabilizer link af 5 Self locking nut connecting lower arm ball joint to knuckle 6 Lower arm mounting nut 7 Lower arm mounting bolt 8 Clamp mounting seltlocking nut Q Clamir mountinö bolt smalli 10 Clamp mountin bolt large fa 1 Lowerarm mounting clamp 12 Lower arm 13 Stopper 14 Dust shield 15 Rod bushing 8N llXl 120 Nm 10 12 kgm 78 87 ft tb NOTE For t...

Page 419: ...HECKING BALL JOINT FOR STARNNG TOROUE Standard value 1 0 22 Nm llOO A2Lkgcm 86 19t In lbr l BALL JOINT DUST SHIELD REPLACEMENT EI OO D 1 Remove the dust shield 2 Apply multipurpose grease to the lip and inside of the dust shield 3 Drive in the dust shield with special tool until it is fully seated SERVICE POINT OF INSTALLATION E cAn 11 INSTALI ATION OF LOWER ARM MOUNNNG CN IMP Install the lower ar...

Page 420: ...ht Member Left Member and Crossmember o Removal and lnstallation of the Transfer Refer to GROUP 22 Transter l tO Nm f 0 kgm 29ft bs Removal steps 1 Stabilizer link 2 Stabilizer bar bracket mountino bolt 3 Stabilizer bar bracket 4 Bushing 5 Stabilizer bar M8990968 ilttrÖbhl llotorr Co porutlon May 1992 INSPECTION t üc l CHECKING STABILIZER IINK BAIL JOINT STARNNG TOROUE Mount two nuts on the balljo...

Page 421: ...ocated at a point 90o 20 with reference to the link axis SERVICE POINT OF INSTALLATION 3 POSITIONING OF STABILIZER BAR BRACIGT 3 4 r2POr56 Clip ring ends Could be on 180 opposite side 12po26 Align end of bushing with marking outer side Align the bushing LH with the stabilizer bar marking end and temporarily tighten the stabilizer bar bracket LH In this condition mount the stabilizer bar bracket RH...

Page 422: ...o o o NOTES o ...

Page 423: ...ance of any Gomponent of the SRS or any SRS relatcd componüü can lcad to peisonat injury or death to service personnel from inadvertent firing of the air bagl or to t lrr drivcr from rendering the SRS inoperative 21 Service or maintenance of any SRS component or SRS related componcnt must bc pcrformcd only rt an authorized MITSUBISHI dealer 31 MITSUBISHI dealer personnel must thoroughly review thi...

Page 424: ...54 1 15 2x 185 2 x 291 5 0 60 x7 29 x 11 48 2 Pink x 2 1 Purple x 1 2 38 2 3 9 218 Shock absorber Type Stroke mm in Damping force lat O 3m sec 0 984 ft sec l Expansion N kg lbs Contraction N kg lbs Hydraulic cylindrical double acting type 150 5 91 Hard 2 650 265 584 Medium 1 650 165 363 Soft 650 65 143 Hard 1 200 120 265 Medium 1 150 1 15 253 Soft 1 000 100 220 Stabilizer bar Mounting method O D m...

Page 425: ...9 3 0 45 x 4 59 x 14 93 2 Blue x 2 1 Brown x 2 2 27 5 2 8 157l Shock absorber Type Stroke mm in Damping force lat 0 3m sec 0 984 ft sec l Expansion N kg lbs contraction N kg lbs Hydraulic cylindrical double acting type 203 8 0 Hard 1 700n71 377l Medium 1 160 116 256 Soft 560 56 123 Hard 1 010 101 223 Medium 880 88 194 soft 670 67 148 Stabilizer bar Mounting method O D mm in Pillow balltype 2210 ff...

Page 426: ...33B 2 2 illtrrS hl MotoB Corporatlon Juty tgo t PUVUE91r9 B ADDCD ...

Page 427: ...o 8 Tool Number Name Use M8991341 Multi use tester sub assembly 1993 models Inspection of electronic control suspension system r Reading and erasing selfdiagnosis codes o Reading service data o Actuator test I ROM pack For the number refer to GROUP 00 Precautions Before Service M8991502 MUT II sub assembly Allmodels lnspection of electronic control suspension system o Reading and erasing selfdiagn...

Page 428: ...domeieränO for the other electronics controlled systems for the engine etc 4 The sensor associated with anti squat control iJ the throttle position sensor The sensor is also used for control of the engine lf the sensor fails therefore the check engine 6 tin tnä öäroi aiiäriäeter witt light and engine selfdiagnosis code No 14 will be output In a situaiion nJr nti squat control only stops therefore ...

Page 429: ... across the following areas l g etween G sensor and ECS control unit I I Between No 1 terminal and No 54 terminal I I Between No 3 terminaland No 57 termina No 1 terminal voltage and continuity between No 3 terminal and earth up to specification Sensor power supply and earth Standards No lterminal 5V No 3 terminal Gontinuity provided Continuity provided between No 2 terminal of G sensor and No 61 ...

Page 430: ...ct harness End Using MUT or MUT II check service data on the steering angular velocity sensor Good Check by entering simulated vehicle speed to samulate anti roll controls Refer to P 338 16 Good Disconnect steering angular velocity sensor connector With ignition switch at ON check harness connector No 2 3 and 4 terminal voltages up to specification Standard 5 V Continuity provided between No 1 ter...

Page 431: ... terminal voltage and continuity between No 2 terminal and earth up to specification Sensor power supply and earth Standards No 1 terminal Battery vohage No 2 terminal Continuity provided Correct harness between No 1 terminal of vehicle speed sensor and battery and between No 2 terminal of vehicle soeed sensor and earth ls continuity provided between No 3 terminal of vehicle speed sensor and No 53...

Page 432: ...hock absorber associated with diagnosis code No disconnect connector di rectly connected to shock absorber and check harness connector with ignition switch at ON Correct harness between No 2 and 4 terminals of shock absorber and earth ls continuity provided between No 2 and 4 terminals and earth ls continuity provided across the following areas of shock absorber associated with diagnosis code No S...

Page 433: ...Standards No l0terminal 5V No 11 terminal Continuity provided Replace ECS switch Check ECS switch Refer to P 338 19 Good Replace ECS indicator lamP bulb Remove combination meter and check ECS indicator lamp for burnt filament Good ls continuity provided across the foJlowing areas I Between combination meter and I ECS control unit I Between No 10 and 2 terminals I Between No 11 and 3 terminals ls c...

Page 434: ...ated vehicle speed from MUT or MUT to simulate antidive control Refer to P 338 16 Good Does stop lamp illuminate when brake pedal is depressed ls continuity provided between No 3 terminal of stop lamp switch and No 58 terminal of ECS control unit No 2 terminal voltage up to specification Standard Baftery vohage Correct harness Between No 2 terminal of stop lamp switch and battery Check stop lamp s...

Page 435: ...fer to P 338 16 Good Does check engine lamp illuminate ls continuity provided between No 2 terminal of throttle position sensor and No 59 terminal of ECS control unit Check throttle position sensor Refer to P 338 20 Good Good No 1 terminalvoltage and continuity between No 4 terminal and earth up to specification Sensor power supply and earth Standards No l terminal 5V No 4terminal Continuity provi...

Page 436: ... the multi use tester MUTI Up to 1993 mod els or MUT II all models 1 Connect MUT or MUT II to the self diagnosis connector When connecting the MUT II to a vehicle up to 1994 model use the adapter harness supplied together with the MUT IL Gaution Gonnest and disconnest either MUT or MUT II with the ignition switch in the OFF position 2 Check the self diagnosis code 3 After the defective portion has...

Page 437: ...r defective 64 R L damping force changeover actuator defective NOTE 1 Control stop warninq indication and fixed damping force return to normal when the ignition switch is set to OFF ü Ää rä tü öBtäüiJääit ää öCöüri it nö iuosequent problem occurs for example when the problem is iäpllln ii noiÄäi opäration witt be restored even if the ilnition switch is not set to OFF Z äüäÄ it cöhtrotstoöIwärning ...

Page 438: ... in a second after actuator drive signal has been output position detection switch output pattern does not change to that of target damping force it is regarded as a problem SERVICE DATA OUTPUT CHECK Using the MUT or MUT tr check the service data SERVICE DATA INSPECTION IIST Item No Check Point Check Condition Soundness Determination Value 11 G sensor Vehicle in stationary condition 2 0 3 0 v Shak...

Page 439: ...ination Value 24 Vehicle speed sensor Check by actually operating vehicle Speedometer indication and MUT or MUT tr indication coincide 26 Stop lamp switch Depress brake pedal ON Do not depress brake pedal OFF 61 F R actuator Tour mode with vehicle stationary SOFT Sport mode with vehicle stationary HARD 62 F L actuator Tour mode with vehicle stationary SOFT Sport mode with vehicle stationary HARD 6...

Page 440: ...k that the original damping force indication SOFT is restored a second later ANTI DIVE CONTROL FUNCTION CHECK 1 Select the Tour mode by the ECS switch 2 Enter a simulated vehicle speed of 100 km h 62 mph from thE MUT Or MUT tr 3 Using the MUT or MUT tr check the indications of service data items No 61 through MUT or MUT tr indication SOFT 4 Depress the brake pedal and simultaneously change the en ...

Page 441: ... Ouickly depress A second later with pedal depressed 30 km h 19 mph HARD MEDlUM 60 km h 37 mph MEDIUM MEDIUM 90 km h 56 mph SOFT MEDIJM 1 21 3 4 5 6 Check that when the accelerator pedal is released the original damping force SOFT is restored in less than a second HIGH SPEED SENSITIVE CONTROT FU TICTIO I CIIECK 1 Select the Tour mode by the ECS switch iz Cnect that when the entered simulated vehic...

Page 442: ...se of the rear shock absorbers remove the trim cover at the top of the shock absorber before bringing your ear near the shock absorber 3 Check that the operating sound of the actuator in the shock absorber can be heard each time the control modes are changed by pressing the ECS switch DAMPING FORCE CHECK 1 Set the ignition switch to ON ECS indicator Tour ON damping force SOFT 2 Check the damping f...

Page 443: ...steering angular velOcity SenSor refer i öcöüt 54 _ cotumn Switch Remove the steering wheel anO ctäcf spring before mounting or removing the sensor CAUTION SRS eätätä t ovai of air bag modute ro er to GR9UP 5 tB SnC Service PrecautionJand Air Bag Module and Glock Spring G SENSOR Ee To mount or remove the G sensor refer to GROUP 52A Front Säat Remove the front seat L H before removing or mounting t...

Page 444: ...r mount the position detection switch and damping force changeover actuator refer to GROUP 33A Strut Assembly and GROUP 34 Shock Absorber Assembly Caution The position dstestion switch and damping force changeover actuator are built into the shock absorber assemblies of frontand rear suspensions Sincethey are of the non disassembly typo remoye or mount them in the form of a strut assembly or shock...

Page 445: ...ELECTRONIC CONTROL SUSPENSION ECSI Ecs control Unit 339 21 E33ZH ECS CONTROL UNIT REMOVAL AND INSTALLATION 1 Cargo floor box R H 2 Lid 3 ECS control unit T D __ Miteubishi Motors Corporation May 1992 ...

Page 446: ...oNTRoL susPENsloN Ecsl circuit Diasram CIRCUIT DIAGRAM Up to 1994 models Taillamp relay nn Combination meter s 8J Iiml 4 Fusible link ECS Control unit 5V 5E ECS switch tffil Mttsubirhi Motor Corporation July 199 l 3 slml ...

Page 447: ...ELEcTRoNIc coNTRoL SUSPENSION Ecsl circuit Diasram 338 23 lgnition switch lG2 5V T ä l r 7 Steering wheel angle speed sensor Mhsublshi MotoE Corporrtion July 19O4 PWUEgl19 D RET IsCD ...

Page 448: ...ECTRONTC CONTROL SUSPENSION ECS Circuit Diasram Front shock absorber L H Rear shock absorber 1 H Rear shock absorber R H Front shock absorber R H t I 2l_ f 5V g 5V f3 dl 5V J Mlt bbhl Motor Co po stlon May 19 12 ...

Page 449: ...SI Gircuit Diasram 338 25 CIRCUIT DIAGRAM From 1995 models Taillamp relay Fusible link O ECS 1 switch llEEi tlol6jl _l llq_LzLs le_11 al I Combination meter ll o n l3 r3313l iB13q3rJ3E H5sfs lsn Mlteublshi Motors Corporatlon July 1994 ...

Page 450: ...338 26 ELECTRONTC CONTROL SUSPENSION ECSI Circuit Diasram lgnition switch lG2 5V T äl r G sensor Mitrubiahi Motoß Corporation July 199t0 AOOED ...

Page 451: ...CONTROL SUSPENSION ECSI circuit Diasram 338 27 Front shock absorber L H Rear shock absorber 1 H Front shock absorber R H Rear shock absorber R H r r 4 tä h rär3 4 j ä Mlt ubishi Motorr Corporation July 1994 ADDED ...

Page 452: ...o o o NOTES o ...

Page 453: ...ions 2 ServiceSpecifications 2 SPECTALTOOLS 3 SERVICE ADJUSTMENT PROCEDURES 5 RearWheelAlignment Inspection 5 REAR SUSPENSION ASSEMBLY 6 UPPER AND LOWER ARM 9 TRAILING ARM 12 SHOCK ABSORBER ASSEMBLY 15 STABIL ZER BAR 17 üftrublrhl Moton Corporrtlon May 19Sl FWUEgl19 ...

Page 454: ...ndrical double acting type 203 8 0 Hard 1 710 171 3771 Medium 1 160 1 16 256 Soft 560 56 123 Hard 1 010 101 233 Medium 880 88 194 Soft 670 67 1 tg Stabilizer bar Mounting method O D mm in Pillow balltype 22 0 86l NOTE Items Specifications Standard value Toe in p r mm in At the centre of tyre tread Toe angle perwheel in q qd camber Roo c ora v Protruding length of stabilizer bar mounting bolt mm in...

Page 455: ...Steering linkage puller Disconnection of the balljoint M8990241 Axle shaft pulter ttaassoz z puler bar M8990244 Puller shaft J Removal of the rear axle shaft M8990211 Sliding hammer M8991354 Puller body M8990847 Base ffjiirä and press fitting of the trailing arm M8990880 Arbor M8991071 nltassr ozz M8991073 Bushing remover and installer Arbor Base Removal and installation of lower arm bushings Mltr...

Page 456: ...ing compressor body Arm set Compression of the coil spring M8990685 Torque wrench Measurement of balljoint starting torque M8990326 Preload socket ffi M8990767 End yoke holder Fixing of the hub M8991387 M8991388 M8990890 Arbor Base Base Removal and installation of the crossmember bushing illt uH H ftotorr Corpor üon tey lSi2 PilrEgttg ...

Page 457: ...m 0 08 to 0 12 in l Toe angle per wheell 5 to 8 To adjust toe turn the trailing arm mounting bolts on the crossmember side on both sides the same amount NOTE Left wheel Clockwise toe out J cF Right wheel Clockwise toe in uettF The difference between right and left wheels should be 3 mm 0 12 in or less One graduation changes toe by about 2 mm 0 08 in Gaution 1 Adjust the eccentric cam bolt within 9...

Page 458: ...ocedures o CheckingWheelAlignment Refer to P 34 5 o Bleeding of 4WS System Refer to GROUP 378 Service Adjustment Procedures o Operation Inspection of the 4WS System Referto GROUP 378 Service Adjustment Procedures o Checking the Parking Brake Lever Stroke Refer to GROUP 36 Service Adjustment Proeedures E34GA Prc rcmoval Opcration o Removal of the Rear Side Trim Absoöer Lid Refer to cROUP 52A Trims ...

Page 459: ...ack requires three persons as the rear suspension assembly is very heavy Assign one person to the differential and one each to the left and right lower arm 3 Apply a wood block to the ball joint of the lower arm to prevent the dust shield from being deformed CROSSMEMBER SUPPORT BUSHING FRONTI REPLACEMENT lr en 1 Using the special tool remove and press fit the crossmem ber support bushing 2 When pr...

Page 460: ...l Dimendon B 2 1 3 7 mm 0 08 0 15 in l CROSSMEMBER BUSHING REAR REPLACE MENT r 1 Using the special tool remove and press fit the bushing 2 When press fitting position the bushing as shown NOTE Ensure that the shift in rotating direction is within 5 3 Make sure that the protrusion of the inner sleeve dimen sion A is up to specification Standard value 6 7 7 3 mm 0 26 0 29 in l 12FOO79 Mltröhhl tloto...

Page 461: ...NOTE 1 Do not remove the nut from the ball joint but just loosen it 2 Suspend the special tool with a rope to prevent it from dropping 3 b Upper arm removal steps 1 Self locking nut 2 Upper arm mounting nut 3 Upper arm mounting bolt 4 Upper arm Lower arm removal steps 5 Lower arm mountino nut 6 Lower arm mounting bolt fa 7 Stabilizer link to lower arm coupling nut cr 8 Self locking nut 9 Lowerarm ...

Page 462: ... with a rope to prevent it from dropping INSPECTION E s D CHECKING OF BALL JOINT FOR STARNNG TOROUE Standard value 2 9 Nm 120 90 kgcm 17 79 in lbr l BALL JOINT DUST COVER REPLACEMENT EsrE 1 Remove the dust cover 2 Apply multipurpose grease to the lip and inside of the dust cover 3 Drive in the dust cover with special tool until it is fully seated LOWER ARM BUSHING REPTACEMENT Removal MB991072 Pres...

Page 463: ... edge SERVIGE POINT OF INSTALI ATION türDA 7 INSTALLATION OF STABILIZER LINK TO LOWER ARM COUPLING NUT Holding the stabilizer link with a wrench tighten the self lociking nut so that the protrusion of the stabilizer link dimensioÄ A indicated in illustration is within the standard value Standard value 5 7 mm 0 197 0 276 in l Hold with wrencn Mttrublrhl Motolt Corpotttion May 199i1 PWUEgl19 ...

Page 464: ... end Parking brake cable clamp bolt Rear speed sensor Rear speed sensor cable and parking brake cable bands Dust shield Self locking nut upper arm Self locking nut lower arm Tie rod end mountino nut Trailing arm mountin g bolt and nut Rear shock absorber mounting bolt Trailing arm NOTE For tightening points marked with first temporarily tighten and then ground the vehicle to torque to specificatio...

Page 465: ... from the knuckle NOTE 1 Do not remove the nut from the ball joint but just loosen it 2 Suspend the special tool with a rope to prevent it from dropping TRAILING ARM BUSHING REPLACEMENT GoNNECTING ROD REPLACEMENT Ero aA Replace the connecting rod using the following procedure 1 Remove the trailing arm bushing 2 Remove the bolt and nut Pressure fitting Removal Trailing arm bushing t2Ao2sB Mftsubirh...

Page 466: ...move the connecting rod 5 Installation of the body special tool should be performed with the screw shaft and guide shaft center lines oriented as shown in the illustration Apply soapy water to the rubber portion of the connecting rod Reverse the removal procedures to press fit 6 71 8 Remove the special tool after aligning the holes in the special tool and trailing arm 9 Tighten the bolts and nuts ...

Page 467: ... Trims Removal steps 1 ECS connector 2 Cap 3 Shock absorber assembly DISASSEMBLY AND REASSEMBLY l t t Disarcembly steps 1 Piston rod tightening nut 2 Washer 3 Upper bushing A 4 Bracket assembly 5 Spring pad 6 Upper bushing B 7 Collar 8 Cup assembly 9 Dust cover 10 Bump rubber 11 Coil spring 12 Shock absorber 78 Nm 7 8 kgm 56 ft lbs n 1 2 3 4 7 5 6 lw Yro Al h flry r 12 t Mltarblrhi Moton Corporatl...

Page 468: ...M8991239 to com press the coil spring and insert it in the shock absorber 2 Align the edge of the coil spring to the position of the shock absorber spring seat as shown 4 INSTALLATION OF BRACKET ASSEMBLY 1 PISTON ROD TIGHTENING NUT 1 With the position of the bracket assembly as shown in the figure tighten the tightening nut to the specified torque 2 Install the coil spring so that the lower edge f...

Page 469: ...shock absorber mounting bolt 13 Power cylinder mounting bolt 1 4 Crossmember bracket 15 Crossmember mounting nut 1 6 Stabilizer bracket 17 Bushing 18 Stabilizer bar lfil Nm 10 kgm 72ft abE rl2 Nm 4 2 kgm 30 ft lbs 12 Nm 110 130 Nm 11 13 kgm 80 9 l ft lbr 78 Nm Iü L 7 _ ql ft R 3rö at af aa 110 130 Nm 11 13 kgm 80 9 l ft lbs 1 2 kgm 30 ft lbs 10 12 Nm 1 2 kgm 9 ft tb 13 10 7 8 kgm 56 ft lbss e a NO...

Page 470: ...d crossmember mounting nut 18 REMOVAT OF STABILIZER BAR 1 Lower the transmission jack a little to obtain a gap between the rear suspension and body 2 Remove the stabilizer bar NSPECnON Eilrc F CIIECKING OF STABITIZER IINK BAIL JOINT FOR START ING TOROUE Standard value 1 7 3 2 Nm 17 32 kgcm t5 2g in lbt l BALL JOINT DUST COVER REPLACEMENT 1 Remove the clip ring and the dust cover M8990968 Mlta6bhl ...

Page 471: ...nce to the link axis 3 4 Tape here Clip ring ends Could be 180 opposite end 1 SERVICE POINTS OF INSTALLATION 6 INSTALLATION OF STABILIZER LINK I LOCKING NUT 1 SELF LOCKING NUT ttao L 2 SEIF 1 Secure the stabilizer link ball stud with a wrench mount the self locking nut and Miuubi l Motor Colpor don Mry 199i1 2 Hold the stabilizer link with a wrench so that its protrusion on the lower arm side dime...

Page 472: ...o o o o NOTES ...

Page 473: ...ed Battery Inspection of Valve Relay and Motor Relay BRAKEPEDAL t MASTER CYLINDER AND BRAKE BOOSTER FRONT DISC BRAKE REAR DISC BRAKE HYDRAUTIC UNIT WHEEL SPEED SENSOR 30 31 32 34 34 34 35 35 35 36 37 2 3 4 4 4 25 26 26 26 27 28 28 30 41 41 42 fil f5 a9 5 f 56 58 G SENSOR 61 ELECTRONTC CONTROL UN T 6 t WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRSI EOUIPPED VEHICI ES WARNING 11 ...

Page 474: ...akes Type Disc effective dia mm in Disc thickness mm in Pad thickness mm in Wheelcylinder l D mm in Clearance adjustment Rigid caliper 4 piston ventilated disc M R762 270 10 6 30 1 18 15 0 59 40 4 1 19ß21x2 42 8 1 11 16 x2 Automatic Rear brakes Type Disc effective dia mm in Disc thickness mm in Pad thickness mm in Wheelcylinder l D mm in Clearance adjustment Rigid caliper 2 piston ventilated disc ...

Page 475: ...r sorvice or maintcnancc of any Gomponont of the SRS or any SR rehtcd componcnt cen lod to p isonal injury or death to scrvice peräonnci from inadvertent ftring of the air bagl or to th drlvcr lfrom rendering the SRS inoperativcl 21 Service ör maintenancd of any Sn component or SRS relatod componcnt murt bc pcrformod only d m authorized MITSUBISHI dealer igf frttiSU3 5Hi Oeatiiporsonniimurt ttroro...

Page 476: ...rakes Type Disc effective dia mm in Disc thickness mm in Pad thickness mm in Wheelcylinder l D mm in l Clearance adjustment Rigid caliper 4 piston ventilated disc M R762 270 10 6 30 1 18 15 0 59 40 4 1 19ß21 x2 42 8 1 t 1 116l x2 Automatic Rear brakes Type Disc effective dia mm in Disc thickness mm in Pad thickness mm in Wheelcylinder l D mm in Clearance adjustment Rigid calipec 2 piston ventilate...

Page 477: ... tooth surface clearance mm in mm in mm in mm in mm in mm in mm in mm in mm in 177 182 17 0 7 21 3 8 0 1 0 3 80 3 1 or more 10 0 0 39 30 0 1 18 20 0 0 79 2 8 0 1 1 168 6 6 3 7 5 4 25 137 5 42 5 533 604 4 68 5 1 8 46 8 51 8 666 737 16 5 65 925 I 0 65 0 85 0 026 0 033 70 17 0 15 4 or less 0 8 1 2 0 8 1 2 28 15 28 45 1 1 1 1 121 Limit LefVright proportioning valve output pressure difference MPa kg cm...

Page 478: ...ant Eüo O Tool Number Name Use M8990964 M8990520 Brake toolset Pressing out of disc brake piston M8991356 A B S check hamess Measurement of A B S control unit terminal voltage M8991223 Check harness set Harness for connector pin contact pressure check Probe for commercial tester for general connector Measurement of terminal voltage M8991341 Multi use tester sub assembly 1993 models For checking of...

Page 479: ...SERVICE Special Tools 35 4 1 Tool Number Name Use M8991502 MUT II sub assembly Allmodels For checking A B S ROM pack Mltrublrhl Motorr Cotporldon July 190i1 FWUEo1t0 B ADOCD ...

Page 480: ...35 4 2 fldr5l litotoncorporatlron Julylggt PWUE9119 B ADOED ...

Page 481: ... tooth surface clearance mm in mm in mm in mm in mm in mm in mm in mm in mm in 177 182 0 O 7 21 3 8 0 1 0 3 80 3 1 or moro 10 0 0 39 30 0 1 18 20 0 0 79 2 8 0 1 1 168 6 6 3 7 5 4 25 i 37 5 42 5 533 604 4 68 5 1 I 46 8 51 8 666 737 16 5 65 925 l 0 65 0 85 0 026 0 033 70 V 0 15 4 or less 0 8 1 2 0 8 1 2 28 t5 28 45 1 1 1 1 121 Limit LefVright proportioning valve output pressure difference MPa kg cm2...

Page 482: ...i drying sealant En O Tool Number Name Use MB9909er M8990520 Brake tool set Pressingout of disc bräke piston M8991356 A B S check harness Measurement of A B S control unit terminal voltage M8991223 Check harness set Harness for connector pin contact pressure check Probe for commercial tester for general connector Measurement of terminal voltage M8991341 Multi use tester assembly For checking of A ...

Page 483: ... the anti lock braking system ABS can be classified into two general categories problems in the electrical system and those in the hydraulic system For problems in the electrical system the self diagnosis function is built into the electronic control unii f C U causing the ABS warning light to illuminate as a warning to the driver In this instance checks can be made by using the multi use tester a...

Page 484: ...self check is made again and then goes out 2 R 1 A05e4 CONTINUED ON NETT PAGE No Trouble condition Major causes Remedy 1 ABS warning lamp does not light up at all ABS warning lamp ON OFF ST ON ACC LOCK lgnition key ABS warning lamp bulb is burnt out Open in ABS warning lamp electrical circuit check for blown fuse Check using flow chart A Refer to P 3 11 2 When the ignition key is turned to the ON ...

Page 485: ...tput check according to trouble code check charts 1 E 7 WHEN USING THE MUT All models 1 With the ignition switch oFE connect the MUT II to 1994 models Use the adapter harness which belongs to MUT II sub assembly Caution Connest and disconnect the MUT II with thc ignition switch in the OFF position Turn the ignition ON and select the ABS system The ABS warning lamp lights up it goes intp the MUT mo...

Page 486: ...codes and check that memory is cleared DIAGNOSIS CODE CHART ACTUATOR TEST FUNCTION The actuator can be forcibly driven in the following way by using the MUT or MUT II NOTE 1 The actuator test cannot be carried out when the ABS ECU system is in failsafe mode 2 When using forced drive using the MUT or MUT II the vehicle must be stopped 3 During forced drive using the MUT or MUT II forced drive opera...

Page 487: ...LAY Vehlcles built Vehlcles bui I 68g November DI ODE HUEEl lHintl lf other warning lamp do not light up either fuse is probably blown IFtrF trFffi ll l8lleItdrilt2 ßlli lltdl lFrr r Fl ä I rt l gl g l3Le l 9 E Il ll rott R H D NOTE iÄih H 31 IVS vSRisiSS ix 6 tt Etrr rc Ä T äÄ Tca A Türl ferr llTl T5r4ll llslrlrl oll R 6 IEEEEEEMI il0te otrürgrstauctül ffi lmm L H D f ril rLEurfll al3lEl lrldll R...

Page 488: ...ector terminal No 29 and earth indicate battery voltage The harness between the combination meter from fuse No 11 is broken ls the ABS warning lamp normal Check for burned bulb Repair or replace combination meter ls there continuity between combination meter No 28 and No 29 terminals Are instrument panel wiring harness and body wiring harness connected properly Connect connectors f irmly Check for...

Page 489: ...on ls valve relay normal Refer to P 3541 Does voltage between the HU harness connector terminal No 8 and earth indicate battery voltage while the ignition key is in the ON position Broken harness wire between ABS warning lamp and HU Broken harness wire between HU and earth ls there continuity between HU harness connector terminal No 9 and earth ls there continuity between HU harness connector term...

Page 490: ...he trouble code and then restart the engine to check if the system is currently in a fault condition ls there diagnosis output ls there communication with MUT or MUT II CONTINUED ON NEXT PAGE Does diagnosis code output display normalcodes Check using the trouble code check chart Refer to P 3 18 Does the ABS warning lamp remain illuminated even with the ECU connector discon nected Short in ECU tran...

Page 491: ...se and replace fuse ls fuse No 3 normal ls power relay normal Refer to P 35 4 1 Replace power relay Repair harness Repair harness With the ignition key in the ON position does voltage between ECU connector terminal No 18 and earth indicate the battery voltage Harness wire between power relay and ECU is broken ls there continuity between body harness terminals No 9 and No 34 and earth ECU earth lin...

Page 492: ...start the engine to check if the system is currently in a fault condition Replace ECU Replace HU or replace valve relay CONTINUED ON NEXT PAGE ls there diagnosis output ls there communication with MUT or MUT II Check using the trouble code check chart Refer to P 3F18 Does diagnosis code output display normalcodes Does the ABS warning lamp remain illuminated even with the ECU connector discon necte...

Page 493: ... u s iY yerieree Kx _ü_i r5 e_ iäi 5i if oil3it i r3 t4 With the ignition key in the ON position does voltage between ECU connector terminal No 18 and earth indicate the battery voltage Harness wire between power relay and ECU is broken ls there continuity between body harness terminals No 9 and No 34 and earth ls there continuity between body harness connector ter minals No 23 and No 24 and diagn...

Page 494: ...g lamp does not illuminate at this time there is trouble in the warning lamp circuit on the valve relay side Remove the hydraulic unit HU connector and junction block No 3 fuse ECU and check them Replace valve relay NOTE When performing the check marked note polarity of the diode refer to the circuit diagram With the ignition key in the ON position does voltage between body connector terminal No 8...

Page 495: ..._Il n F r l 2123F41252612 EBl I i t30t3 1IJ2t33t3 4t35ts6t9 l L H D mn ilJft l llaTsToTz TslEll R H D IffiEMFEEEtrI il r l 2t1 3t 14115t16t1 u8t1et opl e2tl ABS ECU W NOTE läik H 3ilvS vBRl3l33 harness between the ECU and the warning lamp the lamp illuminates only when the valve relay is off in the valve relay test etc Remove ABS ECU connector and hydraulic unit HU connector and check with the har...

Page 496: ...en sensor harness wire is broken Noise interference in sensor signal Sensor output signal is below the standard value or amplitude modulation is over the standard value Using an oscilloscope to measure the wave shape of the wheel speed sensor output signal is very effective Broken sensor harness Poor connection of connector NOTE 1 lf contact is poor check the sensor cable by bending and lightly st...

Page 497: ...ties such as a loose rear speed sensor mounting bolt Replace rear axle shaft or rotor refer to GROUP 27 Axle Shaft ls the rear speed sensor mounting surface to rotor tooth f lank all around distance normalT Standard value 28 15 28 45 mm 1 11 1 12 in l ls the wheel speed sensor rotor normal with no missing or damaged teeth Replace rotor that has missing or damaged teeth Check the output of each whe...

Page 498: ...imately 13 seconds except when the Repair harness vehicle is stopped or when there is stop lamp switch input When there is a broken wire or short circuit in the harness for the G sensor system ls G sensor normal Refer to P 35 1 DEDICATED FI SE NOTE x1 L H drive vehicles X2 R H drive vehicles J lo o o Mitrubirhl Motors Corporation July 1994 With the ignition key ON does the voltage between terminal...

Page 499: ...witch input When there is a broken wire or short circuit in the harness for the G sensor system Repair harness ls G sensor normal Refer to P 35 1 G H D l il ltrl2t t3t4tl E 5 l6l l6l0lrohrDl I l G H D l r lf Jiffi 1f it tl t l G H D IFEFEFffiI ll I 9 lt0lr tltsltslt4ll tF tril ItslzTS lEl ll u t tlts ß n3 ta tc NOTE llik il g ivs vs lsls With the ignition key ON does the voltage between terminal N...

Page 500: ...35 20 2 MlttubLhl Motors Corporation July l99tl PWUE9119 D ADDED ...

Page 501: ...he ABS ECU Check the stop lamp related circuit and repair problem spots Do the stop lamp light up and Disconnect the ABS ECU connector and inspect at the harness side connector When the brake pedal is pressed forcefully does the voltage between connector terminal No 29 and earth indicate battery voltage Harness wire between stop lamp switch and AB9 ECU is broken Connect ABS ECU connector and check...

Page 502: ...the current value of the solenoid valves differs from each other in the same mode solenoid valve drift error is produced and the ABS ECU goes into the failsafe mode Repair harness ffi 4FlnnrtoH ffil dhr ffiffiml G H D EEEffi r ra R H D ilffil CU i iE fi ivs vsnlslss ABS ECU MltaÖbhltotorrCorporrtlon Meylggil In the resistance value for the solenoid valve within the range of the standard values Sta...

Page 503: ...y When battery voltage is applied between terminals No 86 and No 85 No 30 No 87 Continuity No 30 No 87a No continuity Install the valve relay and remove the HU connector With the ignition key ON does the voltage between the connector terminal No 12 and ground indicate battery voltage HU power harness wire is broken ls there continuity between HU No 8 and No 7 terminals Faulty harness in HU Connect...

Page 504: ...g MUT or MUT tr forced drive mode Broken wire or short circuit in motor monitor line the motor relay and check resistance values No 85 No 86 Resistance value 72 88 O No 30 No 87 No continuity Battery voltage is applied between terminals No 85 and No 86 ls pump motor connected normally Does voltage between body connector terminal 11 and earth indicate battery voltage Malfunction of harness in HU ls...

Page 505: ... depress the brake pedal wvo or three times After eliminating the vacuum in the power brake booster press the pedal down by hand and confirm that the amount of movement before resistance is met the free play is within the standard value range Standard value Cl 3 8 mm 0 1 0 3 in l lf the free play is less than the standard value confirm that the clearance between the stop lamp switch and brake peda...

Page 506: ...edal and then stop the engine Hold the pedal depressed for 30 seconds lf the pedal height does not change the booster is in good condition lf the pedal rises the booster is faulty lf the above three tests are okay the booster performance can be determined as good lf one of the above three tests is not okay at last the check valve vacuum hose or booster will be faulty BRAKE FLUID LEVEL SENSOR CHECK...

Page 507: ...essure begins to drop relative to input pressure split point Standard value 3 75 1 25 MPa ß7 5 42 5 kg cm2 533 604 prll 2 Output fluid pressure when input fluid pressure is 6 5 MPa 65 kg cmz 925 Psi Standard value 4 68 5 18 MPa f8 8 51 8 kglcm2 666 737 Pail 3 Output pressure difference between left and right brake lines Limit 0 4 MPa 14 kg cm2 5 Pcil 4 lf the measured pressures are not within the ...

Page 508: ...s 2 to three to four times while fjlling the master cylinder with brake fluid BLEEDING THE BRAKE PIPE IINE Bleed the brake pipe line with the engine running in the order shown in the illustration Gaution When adding brake fluid be sure to fit the fiher to the re sorve tank FRONT DISC BRAKE PAD CHECK AND REPLACE MENT 1 Visually check the brake pad thickness Through the opening in the caliper body S...

Page 509: ...e a spring balance to measure the rotation resistance of the hub in the fonruard direction with the pads removed 5 Clean the piston and then use the specialtoolto push the pis ton into the cylinder 6 Apply repair kit grease to both sides of the inner shims and install the pad Specified grease Brake grease SAE J310 NLGI No 1 Caution 1 Make sure that the friction surfaces of pads and brake discs are...

Page 510: ...tions approximately 45o apart and 10 mm 0 39 in in irom the outer edge of the disc Standard value 30 0 mm 1 18 in l Limh 28 t1mm 1 12 in l NOTE The difference between any thickness measurements should not be more than 0 015 mm 0 0006 in 2 lf the disc is beyond the limits for thickness remove it and install a new one lf thickness variation exceeds the specifications replace the disc or turn rotor w...

Page 511: ...lace a dial gauge as shown in the illustration then move the hub in the axial direction and measure the play Limit 0 05 mm 0 X 2 in l lf the play is equivalent to or exceeds the fimit replace the front hub unit bearing 3 lf the play does not exceed the limit specification and then check the runout of the brake disc once again Mount the brake disc on the position dislocated from the chalk mark 2 lf...

Page 512: ... the pads on right and left wheels as a sst 2 Remove the clip and holding the cross spring with hand re move the pad pins 3 Using a screwdriver remove the pads and shims O Inner pad with wear indicator Outer pad Shim B Shim A 4 To measure the disc brake drag torque after removing the drive shaft and companion flange connection and installing the pads use a spring balance to measure the rotation re...

Page 513: ...m around the shim Start the engine and after depressing the brake pedal hard two or three times stop the engine Turn brake disc forward 10 times Use a spring balance to measure the rotation resistance of the hub in the forward direction 6 7 L 9 10 Calculate the drag torque of the disc brake difference be tween measured values in 9 and 4 Standard vatue 70 N 7 0 kg 15 4lbl l or lccs 11 lf the differ...

Page 514: ...e outer circumference of the brake disc and measure the run out of the disc Limit 0 08 mm 0 m31 in l or lers NOTE Tighten nuts to secure the disc to the hub REAR BRAKE DISC RUN OUT CORRECTION E üara 1 lf the run out of the brake disc is equivalent to or exceeds the limit specification change the phase of the disc and hub and then measure the run out again NOTE The procedures for checking by changi...

Page 515: ...RAKE DISC INSIDE DIAMETER CHECK E orc 1 Remove the rear brake assembly and support it by a wire etc 2 Remove the brake disc 3 Measure the inside diameter of the brake disc at two or more locations Standard value 168 0 mm 6 6 in l Limit 169 0 mm 6 7 in l 4 Replace brake disc and shoe and lining assembly when wear exöeeds the limit value or is badly imbalanced BRAKE LINING AND BRAKE DISC CONNECTION ...

Page 516: ... tester or oscilloscope Output voltage When measured with circuit tester 70 mV or more When measured with oscilloscope max voltage 100 mV or more Probable causes of low output voltage lOeeO sensor pole piece to rotor clearance too large o Faulty speed sensor Then in order to observe the output state of the wheel speed sensors shift into low gear and drive the wheels ob serve the output voltage wav...

Page 517: ...dapter harness which belongs to MUT II sub assembly Gaution Connect and disconnect either MUT or MUT II wfth the ignition switch in the OFF position 4 After confirming that the shift lever is in the neutral position start the engine The ABS warning lamp lights up it goes into the MUT or MUT II mode In the MUT or MUT II mode ABS does not function 5 Operate the MUT or MUT II to force actuator to ope...

Page 518: ...bnormal o4 1 Depress brake pedal to lock wheel 2 Using the MUTor MUT II select the wheel to be checked and force the actuator to operate 3 Turn the selected wheel manually to check the change of brake force Brake force re leased for 6 seconds after locking Wheeldoes not lock when brake pedalis depressed Clogged brake line other than HU Check and clean brake line Clogged hydraulic circuit in HU Rep...

Page 519: ... confirming that the shift lever or selector lever is in the neutral position start the engine The ABS warning lamp lights up it goes into the MUT or MUT II mode ln the MUT or MUT II mode ABS does not function Operate the brake force tester roller Depress the brake pedal until the brake force tester indicates the following value and keep the brake force at this level during the test Front wheels 1...

Page 520: ... o t o_ o E C u o vC io F_9 z o 8ö c o E o o U o f J O o C o o o E E o o o u l r5 q o o_ o E o a f o C o o U o o o_ y s0 o6 la TC E8 F D ä l P f P I LL o E oI v _ sb o c s ruo 9rE ov Öo o o lJ f O eä sc vo Ug oo o eo tr o a o o o o o J C o o q c o o o g o E q o E U E o c o Eog a P d gI täes ö5 E m ö b o I g oF g Eü 9 s öö s 3 e ce Fr oa öHE c tF EägE o E o z G o o o o o Y ä li xE a 68 c äe U J o x...

Page 521: ...t allowing the battery to re cover sufficiently This is because the ABS consumes a great deal of current for its self check In such a case allow the battery to sufficiently charge or perform the following procedures Vehicles built up to Ostober 1993 Remove the ABS power relay in the engine compartment to dis able the ABS Removing the ABS causes the ABS warning lamp to light Afterthe battery is cha...

Page 522: ...nuity of the relays both when they are ener gized and de energized Motor Relay 85 I I 87I 30 I 85 87 lru r I 130 85 When de energized Between terminals and 72 88A Between terminals and No continuity o When energized between terminals and Between terminals 6 and Continuity approx 0O Valve Relay When de energized Between terminals and 60 120 3 iä terminals Continuity approx 0Ol Between terminals and...

Page 523: ...ng Column Assem blv Refer to GROUP 37A Steering Wheel and Shaft o Brake Pedal Adjustment Refer to P 3 25 a Stop lamp switch removal steps 1 Stop lamp switch connector 2 Stop lamp switch Brake pedal removal stepr 1 Stop lamp switch connector l 3 Return spring 5 Split pin 6 Washer 7 Clevis pin 10 Brake pedalshaft bolt 1 1 Brake pedal 4 10 12 12 13 14 173 I e Bushing Spacer Brake pedal support member...

Page 524: ...tion of Cooling Unit Refer to GROUP 55 Cooling Unit o Installation of Blower Case Assembly Refer to GROUP 55 Blower Assembly o lnstallation of Instrument Panel Refer to GROUP 52A Instrument Panel o Brake Pedal Adjustment Refer to P 35 25 21 13 Nm 1 3 kgm 9ft tb 12 Nm 1 2 kgm 9ft 1b8 1 1FOl05 Stop lamp switch removal steps 1 Stop lamp switch connector 2 Stop lamp switch Brake pedal removal steps 1 ...

Page 525: ...l and 2 The stop lamp switch is in good condition if there is no conti nuity when the plunger is pushed in to a depth of within 4 mm 0 16 in from the outer case edge surface and if there is continuity when it is released SERVICE POINT OF INSTALLATION 3 INSTALI ATION OF RETURN SPRING Install the return spring with the shorter hook on the brake pedal Motor Corpo tlon May 1992 PWUEgl19 ...

Page 526: ...Low pressure hose 2 Brake fluid level sensorconnector 3 Brake tube connection 4 Master cylinder o Adjustment of clearance between brake booster push rod and primary piston Brake booster removal stops 4 Master cylinder 5 Vacuum hose 6 Vacuum tube fe 7 Vacuum hose with check valve 8 Fitting 9 Cotter pin 10 Washer 11 Clevis pin 12 Sealer 13 Spacer 14 Brake booster Brekctubcflere nut 15 Nm 1 5 kgm 1r ...

Page 527: ... vacuum hose at the engine should be securely connected until it contacts the hexagonal edge of thä fitting and then should be secured by the hose clip Caution lf the check valve is defective replacc the vacuum hose ADJUSTMENT OF CIEARANGE BETWEET BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON Adjust the clearance A between the brake booster push rod and primary piston as follows 1 Measure the dimensio...

Page 528: ... not within the standard value range adjust by changing the push rod length by turning the adjustable end of the push rod Caution lmproper clearance may ceuse excessive brake drag DISASSEMBLY AND REASSEMBLY Disassembly stePs 1 Reservoir cap assemblY 2 Diaphragm 3 Reservoir cap 4 Filter 5 Brake fluid level sensor 6 Float 7 Reservoir stoPPer bolt B Reservoir 9 Reservoir seal 10 Piston stopper bolt 1...

Page 529: ...SECONDARY PISTON ASSEMBTY NOTE lf it is hard to remove the secondary piston from the cylinder gradually apply compressed air from the outlet port on the secondary end of the master cylinder FRONT DISC BRAKE REMOVAL AND INSTALLATION Pre removal Opcration r Draining of Brake Fluid Post installation Operation o Supplying Brake Fluid o Bleeding Refer to P 3 28 1 5 kgm 11 ft lbs 2 Removal steps 1 Brake...

Page 530: ... in the for ward direction 2 Installthe brake assemblY Start the engine and after depressing the brake pedal hard two or three times stop the engine Turn brake disc forward 10 times Use a spring balance to measure the rotation resistance of the hub in the forward direction Calculate the drag torque of the disc brake difference be wveen measured values in 5 and 1 Standard value 70 N 7 0 kg 15 4lbs ...

Page 531: ...rease SAE J310 NLGI No 1 I Grease Repair kit grease orangel ea ar Disassembly steps 1 Clip 2 Pad pin 3 Cross spring 4 Pad assembly 5 Shim A 6 Shim B 7 Inner pad with wear indicator 8 Outer pad 9 Retaining ring 10 Piston boot 1 1 Piston 12 Piston seal 13 Washer 14 Caliper body Weer 7a W Brake caliper kit tt 14 ffoflt Pad kit Scrl and boot kh öi 4 t4FO119 12 tu tt l t A ft 1 tv A 12 t lt von Jo m og...

Page 532: ... 1 Be careful not to get your fingers to be pinched 2 Use care not to let the brake fluid splash 12 REMOVAL OF PISTON SEAI 1 Remove the piston seal Caution Do not damage the qylinder inner surf ace 2 Clean the piston surfaces and cylinder inner surfaces with trichloroethylene alcohol or the specified brake fluid Specified brake fluid DOT3 or X T4 INSPECTION E IL AF NSPECnON Of PAD WEAR Measure the...

Page 533: ...ation o Draining of Brake Fluid Flarcd brelc llnc nutr tS llm t 5 kgm 11fr bG rr0ffi 50 60 Nm 5 0 6 0 kgm 36 ff1ft lbs INSPECTION BRAKE DISC 1 Check disc for wear Refer to P 3 30 2 Check disc for runout Refer to P 3 30 SERVICE POINT OF INSTAIAflON EriDAo 2 INSTALIATION OF THE REAR BRAKE ASSETTBTY Install the rear brake assembly using the same procedure as that for the front brake assembly Refer to...

Page 534: ...f k lM roU WT 7 6 5 Greace Breke grease SAE J310 ItlLGl No t Greare Repair kit grease orangel Disassembly steps 1 Clip 2 Pad pin 3 Cross spring 4 Padassembly 5 Shim A 6 Shim B 7 Inner pad with wear indicator 8 Outer pad 9 Retaining ring 10 Piston boot 11 Piston 12 Piston seal 13 Caliper body aa L 0 1 a r U 9 tI t t t I UAll 4 I aO vrl J 12 tr t r f t J V trl J Grease LFOt20 trlltröbhl Motor Corpor...

Page 535: ...nched 2 Use care not to let the brake fluid splash 12 REMOVAL OF PISTON SEAI 1 Remove the piston seal Caution Do not damage the cylinder inner rurfacc 2 Clean the piston surfaces and cylinder inner surfaces with trichloroethylene alcohol or the specified brake fluid Specified brake fluid DOT3 or DOT INSPECTION ts INSPECTION OF PAD WEAR Measure the thickness of the pad at a point which wears most R...

Page 536: ...ection 5 Hydraulic unit nut initialtightening 4 Hydraulic unit with bracket 3 Bracket bolt 2 Harness connector connection 1 Brake tube connection 5 Securely tightening of hydraulic unit nut Pre removal Operation o Removal of Splash Shield o Draining of Brake Fluid o Removal of Relay Box o Removal of Air Duct Post ißtrllrtion Operation o Installation of Splash Shield o lnstallation of Air Duct o In...

Page 537: ...rHe SERVICE POINTS OF INSTALLATION 6 CONNECTION OF GROUNDING WIRE Connect the grounding wire at the point illustration EWDAF shown in the Mlteubirhi Moton Corporatlon May 199i1 1 INSTALLATION OF BRAKE TUBE 1 Pull up the relay box with harness attached and inserting a hand under the realy box install the brake tubes using flare nut wrench 2 Connect brake tubes to the hydraulic unit as shown in the ...

Page 538: ...OUP 27 Axle Shaft 4 Rear soeed sensor 5 O ring Pre rcmovel Opcration o Removalof Splash Shield Front Refer to GROUP 42 Fender Post instdlation Opcration Installation of Splash Shield Front Only Refer to GROUP 42 Fender o lnspection of A B S Refer to P 3F5 l NOTE The front rotor is integrated with the drive shaft and is not to be disassembled Mlt ülrff f lototr Corporttlon M Y lg l ...

Page 539: ...oving the speed senrorfrom the knuc rle use care not to strike the tip of the pole picce against the rotor teeth or any other Parß INSPECTION lrnrc RESISTANCE BETWEEN SPEED SENSOR TERMINAI S 1 Check the tip of the speed sensor pole piece for deposits of metal or other foreign matter and clean the pole piece as necessary Also check the pole piece for damage and replace if damaged Caution The speed ...

Page 540: ... and terminal insertion SPEED SENSOR INSUTATION INSPECTION 1 Remove all connections from the speed sensor and then measure the resistance between terminals 1 and 2 and the body of the speed sensor Standard value 100 kf l 2 lf the speed sensor insulation resistance is outside the stan dard value range replace with a new speed sensor NSPECNON OF ROTOR Check the rotor for missing or worn teeth and re...

Page 541: ...the SRS diagnosis unit Removal steps 1 G sensorconnector 2 G sensor 3 G sensorbracket 1440 INSPECTION ErmAA INSPECTION OF G SENSOR 1 Lay the G sensor on a level surface and check for continuity between its terminals Incline the G sensor toward the vehicle front gradually and check that continuity is lost at an angle of 30 or more 3 Incline the G sensor toward the vehicle rear gradually and check t...

Page 542: ...ion o Removal of Rear Seatback R o Removal of Ouarter Trim Post anstdlrtion Opcration o Installation of Ouarter Trim Installation of Rear Seatback R o Installation of Rear Seat Cushion o Inspection of A B S Refer to P 3S5 SERVICE POINT OF REMOVAL Erüzr c 1 REMOVAT OF CONTROT UNIT CONNECTOR Insert a screwdriver into the lock section as illustrated and pull out the connector from below Mltröbhl Moto...

Page 543: ... of the air bagl or to thc drivcr from rendering the SRS inoperativel 21 Service or maintenance of any SRS component or SRS related component must be performed only et an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especially itr GROUP 52B Supplemental Restraint System before beginning any service or maintenance of any componcnt of the SRS or a...

Page 544: ...rake disc l D mm in 3 5 notches 2 8 0 11 168 0 6 6 Limit Brake lining thickness mm in Brake disc LD mm in 1 0 0 039 169 0 6 7 Items Specified lubricant Rear brake shoe and backing plate contact surfaces Contact surface between shoe lining assembly s strut and adjuster Contact surface between shoe lining assembly and shoe adlustment bolt and shoe support piece Brake grease SAE J310 NLGI No 1 Items ...

Page 545: ...umber Name Use M8991354 Puller body Removal of the rear axle shaft assembly M8990241 MBee0242 M8990244 Rear axle shaft puller Puller bar l Puller shaft M8990211 Sliding hammer a M8990767 End yoke holder Fixing of the hub Mitrubbhi MotoBCorpoiltlon Mey 19gl ...

Page 546: ...applied where the disc cannot be turned with both hands approx 2 7 Nm 127 kgcm 23in lbs 1 Then turn the adjuster five notches in the direction opposite the arrow Reference Shoe clearaRce on one side 0 19 mm 10 0075 in l 5 Turn the adjusting nut to obtain specified parking brake lever stroke After the adjustment check that there is no play between the adjusting nut and pin Gaution Do not adjust par...

Page 547: ...ility and pay careful attention to safety 1 Adjust the parking brake stroke to the specified value 2 Hook a spring balance onto the centre of the parking brake lever grip and pull it with a force of 98 147 N in a direction perpendicular to the handle 3 Drive the vehicle at a constant speed of 35 50 kmlh 22 31 mph for 100 metres 4 Release the parking brake and let the brakes coolfor 5 10 minutes 5 ...

Page 548: ...o o o NOTES I ...

Page 549: ...moving the floor console don t allow any imPast ol Shock n3ole don t allow any ll the SRS diagnosis unit Post inctallation Operation o Parking Brake Lever Stroke Adlustment Referto P 3M o installation of Front and Rear Console Refer to GROUP 52A Console Box Parking brake lever removal steps 1 Cable adjuster 2 Parking brake stay 3 Bushing 4 Parking brake switch 5 Parking brake lever x a i dÄ Sfrn l...

Page 550: ...blY 7 Rear brake disc 8 Adjusting wheel sPring a 9 Shoe hold down cup 10 Shoe hold down Pin a 11 Adjuster Brake Gable a 12 Shoe tlanchor sPring 13 Strut 14 Strut return spring 15 Shoe lining assembly 16 Clip 17 parking cable protector 18 Parking brake cable 5 0 6 0 kgm 36 13 ft lbo ültnslrhlMotorrGorpordon Mryl l ...

Page 551: ...iIGS The shoe to anchor spring must be installed in the se quence shown in the illustration Caution Each shoe to anchor spring has a unique spring load and the spring a is painted to prevent erroneous installation NOTE The figure shows the left wheel for the right wheel the position in symmetrical 11 INSTALLATION OF ADJUSTER Install the adjuster facing the left adjusting bolt to the vehicle front ...

Page 552: ... brake disc 5 Self locking nut 6 Companion flange 7 Rear axle shaft 8 Adiusting wheel spring 9 Shoe hold down cup 10 Shoe holddown spring 11 Shoe hold down pin t 12 Adjuster f 13 Shoe to anchorspring 14 Strut 15 Strut return sPring 16 Shoe lining assembly 17 CliP 18 Brake tube connection 19 Backing plate ig 5o 60Nm F I 0 6rQlgm 16 36 ßlft lh Poct installation Operation o Parking Brake Lever Stroke...

Page 553: ... WEAR OF THE BRAKE LINING AND BRAKE DRUM 1 Measure the thickness of the brake lining at several places Standard value 2 8 mm 0 110 in l Limit 1 0 mm 0 039 in l Caution Replace the brake shoes if the thickness of the brake lining is the limit value or less 2 Measure the brake disc drum inner diameter at wvo or more places Standard value 168 0 mm 6 6 in l Limit 169 0 mm 6 7 in l Caution Replace if t...

Page 554: ...Gaution Each shoe to anchor spring has a unique spring load and the spring oa is painted to prevent erroneous installation NOTE The figure shows the left wheel for the right wheel the position in symmetrical 12 INSTALLANON OF ADJUSTER lnstall the adjuster facing the left adjusting bolt to the vehicle front and right adjusting bolt to the vehicle rear lvllt ubllhl MotoE Corporation May 1992 PWUE9I1...

Page 555: ...r maintenance of any component of the SRS or any SRS related componürt crn lced to por sonal iniury or death_to service pe_rsonirel fröm inadvertent firing of ihe air bag or to tlie ddv ind passarigor from rendering the SRS inoperätive 2 Service or maintenance of any SRS componont or SRS related component must be performcd onty at an authorized MITSUBISHI dealer 31 MITSUBISHI dealer personnel must...

Page 556: ...sure MPa kg cm2 psi Pressure gauge valve closed Pressure gauge valve opened Oil pressure switch operating pressure MPa kg cm2 psi Oil pressure switch contacts closed continuity Oil pressure switch contacts opened no continuity Total pinion preload Nm kgcm in lbs Tie od joint swing resistance N kg lbs Tie rod joint swing torque Nm kgcm in lbs Limit Steering wheelfree play when hydraulic operation m...

Page 557: ...luid DEXRON or DEXRON II 0 9 dm3 0 95 U S qt 0 79lmp qt As required SEALANT AND ADHESIVES Items Specified sealant and adhesive Remarks Steering column assembly Cover assembly hole 3M ATD Part No 8661 or equivalent Semidrying sealant Power steering gear box End plug screw Power steering rack support cover screw Dust cover 3M ATD Part No 8661 or equivalent Semidrying sealant O sPEcrALrooLs Tool Numb...

Page 558: ...assembly Measurement of oil pressure M8990993 Power steering oil pressure gauge adapter pump side Measurement of oil pressure M8990994 Power steering oil pressure gauge adapter hose side Measurement of oil pressure M8990826 Torque wrench Removal and installation of the tilt bracket or upper bracket M8990776 Front axle base Installation of the dust cover M8991204 Torque wrench socket Removal and in...

Page 559: ...l seal for the rack M8991199 Oilseal installer To press in the oil seal for the rack M8991099 Oilseal installer attachment Oil seal installer guide M8991202 Oil seal bearing installer Press fitting of rack housing bearing MB991213 Rack installer Rack installation M8991317 Sealring installer Compression of the seal rings after replabement of the pinion seal rings M8991152 Dust cover installer To pr...

Page 560: ...ing wheel play with engine stoppedl 1lmm 0 a3 in l lf the play exceeds the standard value remove steering gear box and check total pinion torque STEERING ANGLE CHECK E E E 1 Set front wheels on turning radius gauge and measure steering angl6 Standard values Inner wheel 33o45 Zo Outer wheel 2821 2 When not within the standard value it is probably a toe problem Adjust toe refer to GROUP 33A Service ...

Page 561: ... and install nut on stud Measure balljoint starting torque with specialtools Standard vatue 1 0 3 0 Nm 10 30 kgcm I 26 in lbc When starting torque exceeds thä st andärd value replace tie rod end When the starting torque is under the standard value check for play or ratcheting in ball joint lf none of these it is still serviceable 2 3 4 Mlt röishi Motorr Corporation Mry 19 l PWUE9I19 ...

Page 562: ...nduct a road test and check as follows l ake both gradual and sudden turns and check the steering feeling to be sure that there is no difference in thä steering force required and the wheel return between left and right turns At a speed of 35 kmlh 22 mph turn the steering wheel 90 and release the steering wheel after 1 or 2 seconds lf the steering wheel then returns 70o or more the return can be j...

Page 563: ... the fluid to approximately 50 60 C 122 140 F 2 With ihe engine running turn the wheel all the way to the left and right several times 3 Cnecf tneituid in the oil reservoir for foaming or milkiness önect the difference of the fluid level when the engine is stopped and while it is running lf the fluid level changes considerably air bleeding should be done FLUID REPLACEMENT ll mr 1 Raise the front w...

Page 564: ...s in the oil reservoir Confirm that the fluid is nöt mitky and that the level is up to the specified position on the level gauge Confirm that there is very little change in the fluid level when the steering wheel is turned left and right Check whether or not the change in the fluid level is within 5 mm 0 2 in when the engine is stopped and when it is run ning Gaution 1 lf the chango of the fluid l...

Page 565: ... the standard value overhaul the oil pump 6 Remove the special töols and then tighten the pressure hose to the specified torque 7 Bleed the system CHECKING THE PRESSURE UNDER NO IOAD CONDI TIONS 1 Disconnect the pressure hose from the oil pump and then connect the special tool 2 Bleed the air and then turn the steering wheel several times while the vehicle is not moving so that the tempera ture of...

Page 566: ...al tools and then tighten the pressure hose to the specified torque 8 Bleed the system OIL PRESSURE SWITCH CHECK e zFoAA 1 Disconnect the pressure hose from the oil pump and then connect the special tools 2 Bleed the air and then turn the steering wheel several times while the vehicle is not moving so that the tempera ture of the fluid rises to approximately 50 60 C i 122 140 F 3 The engine should...

Page 567: ...dule Refer to GROUP 528 Air Baq Module and Clock Sorino a e 2 Stdering wheel 3 Lower column cover 4 Upper column cover 5 Knee protector Referto GROUP 52A lnstrument Panel 6 Lap cooler duct and foot shower duct ßilot2a Sealent 3M ATD Part No 8661 or equlvalcnt 14 12 Nm 1 2 kgm 8 ft lbs V tro 5Nm 0 5 kgm 4 ft lbs 12 Nm 1 2kgt 8 ft lbs 7 a a 8 9 fa 10 11 a a 12 13 14 tSFOOCl Column switch assembly Sp...

Page 568: ... BOLT Before installing the bolt apply specified sealant to the cover assembly attachment hole in the toeboard MltüÖlrhi Motora Corporation May 1992 INSTALIÄTION OF STEERING WHEEL EExoAr Line up the NEUTRAL mark of the clock spring with the mating mark before installing the steering wheel Gaution lf _the clock spring s mating mark is not property aligned the steering wheel may not be completely ro...

Page 569: ... cylinder 8 Steering column assembly Steering lock cYlinder Mitrubbhi Motorc Conoratlon MrY l9O Z a e e c ef a 18 Nm 1 8 kgm 13 ft lbs 13FOO58 SERVIGE POINTS OF DISASSEMBLY En Au 6 REMOVAL OF STEERING LOCK BRACKET 7 STEER ING LOCK CYLINDER lf it is necessary to remove the steering lock cylinder use a hacksaw to cut the special bolts at the steering lock bracket side ...

Page 570: ...ily install thö steering lock in alignment with the column boss 2 After checking that the lock works properly tighten the special bolts until the head twists off Caution The steering lock bracket and bolts must be re placed with new ones when the steering lock cylinder is installed INSTATTANON OF BEARING 1 Fill the inside of the bearing with multipurpose grease 2 Install the bearings to the shaft ...

Page 571: ...traight Ahead o Adjustment of the Front Wheel Alignment Refer to GROUP 33A Service Adjustmenr Procedures 50 Nm 5 0 kgm 36 ft lbs 60 70Nm 6 0 7 0 kgm 43 51 ft lbs 35 Nm 3 5 25ft 60 70 Nm 6 0 7 0 kgm ß 51 ft lbs 7 15Nm 1 5 kgm rl ftlb 12 Nm 1 2 kgm 8 ft lbs 1 8 kgm 13 ft lb RemovalstePs 1 Joint assembly and gear box connecting bolt 2 Cotter pin ef 3 Tie rod end and knuckle connecting nut 4 Left memb...

Page 572: ... then check ihä iöiri öinion Starting torque again lf the total pinion starting iorque cannot be adjusted to within the standard range by adjustiÄg the rack srpp6 r ou i check rne racK support cover rack support spring rack support and replace any parts necessary CHECK THE NE ROD FOR SWING RESISTANCE 1 Give 10 hard swings to the tie rod 2 Measure the tie rod swing resistance with a spring balance ...

Page 573: ...pinion torque 1 1 End plug 12 Self locking nut 13 Locking nut 14 Rack support cover 15 Rack support spring 16 Rack support 17 Valve housing c 18 Oilseal e 19 Pinion and valve assembly st 20 Sealrings n 21 Ball bearing n 22 Oilseal f 23 Circlip 24 Rackstopper st 25 Rack bushing f a 26 Rack 27 O ring e fa 28 Oilseal 29 Sealrings 30 O ing f fe 31 Ballbearing af e 32 Needle roller bearing er t r 33 Oi...

Page 574: ...d DEXROltl or DEXRON ll Sealant 3M ATI Part N0 8661 or equivalent 13iroo22 Fluid Automatic transmission fluid DEXRON or DEXßON ll t I __ b r L l t Yt lY d t Ytca Slalant 3M ATD Part N0 8661 or cquivalent Fluid Automatic transmission fl uid DEXRON or DEXRON ll Fluid Automatic transmission f luid DEXRON or DEXRON ll nvuEgt19 Mitt rbadrl Motor CoDoration May 1992 ...

Page 575: ... similar tool loosen and then remove the boot retaining band 7 REMOVAL OF TAB WASHER Unstake the tab washer which fixes the tie rod and rack with a chisel 11 REMOVAL OF END PLUG Disconnect end plug caulking and remove end plug 14 REMOVAL OF RACK SUPPORT COVER Using the special tool remove the rack support cover from the gear box 1 3K588 Mitsubirhi MotoG Corporatlon May 1902 PWUE9 t9 ...

Page 576: ...opper clockwise until the end of the circlip comes out of the slot in the rack housing 2 Turn the rack stopper anticlockwise to remove the circlip 26 REMOVAL OF RACK Pull out the rack slowly At this time also take out the rack stopper and the rack bushing simultaneously 28 REMOVAL OF OIL SEAI Partially bend oil seal and remove from rack bushing Gaution Do not damage oil seal press fitting surface ...

Page 577: ...the inner surface of the rack cylinder of the gear housing INSPECTION RACK Check the rack tooth surfaces for damage or wear Check the oil seal contact surfaces for uneven wear Check the rack for bends PINION AND VALVE ASSEMBLY Check the pinion gear tooth surfaces for damage or wear Check for worn or defective seal ring BEARING o Check for roughness or abnormal noise during bearing operatron Check ...

Page 578: ... tool 32 INSTALTANON OF NEEDLE ROLLER BEARING 1 Apply specified fluid to housing bearing and oil seal press fitting surface Specifiedfluid Automatic transmission fluid DEXRON or DEXRON ll 2 Use the special tppls to press fit needle roller bearing Caution Press fit straight as valve housing is aluminium 31 INSTALLANON OF BALL BEARING 28 TNSTAIAnON OF OtL SEAI 27 O R NG 1 Apply a coating of the spec...

Page 579: ... stopper Specified fluid Automatic tranlmision fluid DEXRON or DEXRON ll Caution Do not allow oil seal retainer spring to slip out 23 INSTATLATION OF CIRCLIP Insert circlip to rack stopper hole through cylinder hole Turn rack stopper clockwise and insert circlip firmly Caution tnsert circlip to rack stopper hole while turning rack stopper clockwise 20 INSTALLATION OF SEAL RINGS I 19 PINION AND VAL...

Page 580: ...he semidrying sealant to the threaded part of the end plug Specified sealant 3M ATD Part No 8661 or equiva lent 2 Secure the threaded portion of the end plug at two places by using a punch ADJUSTMENT OF TOTAL PINION PRELOAD 1 Position rack at its center With special tool tighten rack support cover to 15 Nm 1 5 kgm 11 ft lbs 2 In neutral position rotate pinion shaft clockwise one turnl4 6 seconds w...

Page 581: ...LTATION OF DUST SHIELD 1 Pack dust shield interior and lip with multipurpose grease 2 Apply semi drying sealant to dust shield Specified sealant 3M ATD Part No 8661 or equiva lent 3 Using the special tool press dust shield to tie rod end 2 INSTALLATION OF TIE ROD END Screw in tie rod end to have its right and left length as illustrated Lock with lock nut o Mitsubirhi Motors Corporation May 1992 PW...

Page 582: ...eding the Power Steerinq Fluid Line Refer to p 37A 1ö Checking of the Oil Pump rressure Refer to P 37A 1 1 t q fi Nm 4 3 kgm 31ft bs Removalsteps 1 Drive belt 2 Suction hose l a 3 Pressure hose 4 O ring 5 Pressure switch connector 6 Oilpump 7 Oilpump bracket 8 Tensioner pulley 2 4 kgm 17 ft lbs 0 1 3 kgm 31ft bs SERVICE POINT OF INSTALLATION e TRD rr 3 INSTALTANON OF PRESSURE HOSE Connect the pres...

Page 583: ... Vanes 4 Rotor 5 Cam ring 6 Side plate 7 O ring B Connector 9 O ring 10 Flow control valve 1 1 Flow control spring 12 Terminal assembly 13 O ring 14 Spring u lffi 1 nI 25 30Nm 2 5 3 0 kgm 18 22 ft lbs 15 ptunoer 16 Pistol rod 17 Snap ring 18 Terminal 19 Washer 20 Insulator st 21 O rinq 22 Plug 23 Clio 24 Suction connector 25 O ring t l 1 e r a fa aa fe te aa R 7E 26 Oil pump body and Pulley assemb...

Page 584: ... thickness gauge Limit 0 06 mm 0 X 24 in l SERVICE POINTS OF REASSEMBLY 25 21 13 9 7 TNSTALLATTON OF O RINGS Apply specified fluid on O rings to install o O a a Mltrublrhl Motoß Corporrtlon May 1992 14 INSTALLATION OF SPRING Fit the spring to the oil pump body with the larger diameter end at the terminal assemblv side Side plate Suction connector mountino oortion 7s2 of orl puöö Oody Connector k I...

Page 585: ...e of the side plate with the dowel pin of the pump body when installing the stde plate 5 INSTALLATION OF CAM RING Install the cam ring with the punch mark facing the side olate 3 INSTALLATION OF VANES Install the vanes on the rotor paying close attention to thÖ installation direction Cutouts for dowel pin 13POr61 Mitsubishi Moto6 Corporation May 1992 PWUEgl19 ...

Page 586: ...t lbs White line 1 3P01 4 Removal steps l Return hose 2 Suction hose 3 Return hose l c 4 Pressure hose 5 O ring 1 5 kgm 11ft lbs 6 Cooler tube 7 Pressure tube 8 Return tube 9 O ring 10 Oil reservoir SERVICE POINT OF INSTALLATION 4 INSTALLATION OF PRESSURE HOSE 1 Connect the pressure hose so that its slit part contacts the oil pump s guide bracket 2 When the pressure hose is installed align the whi...

Page 587: ...rrrE CoNTROLVALVE 10 ServiceSpecifications 2 Lubricants 2 REAROILLINE 11 spEctAL Tools 2 REAR OIL PUMP 12 TROUBLESHOOTING 3 SERVICE ADJUSTMENT PROCEDURES 4 Bleeding 4 FunctionCheck 5 Rear Oil Pump Discharge Flow Volume Check 5 Ball Joint Rotation Starting Torque Check 6 Mitsubishi Motor Corporation May 19O2 PWUE9119 ...

Page 588: ...0 1 0 39 l Items Specifications Standard value Rear oil pump displacement at speedometer readino of 31 mph 50 km h for 30 seöondsl dm3 U S qt lm p qt Power cylinder balljoint rotation starting torque Nm kgcm in lbs Power cylinder tie rod swing torque N kg lbs Nm tgsrn in lbs Approx 1 0 1 06 0 88 0 5 50 4 0 or less 9 55 0 9 5 5 2 121 I0 s 3 0 s 30 4 2611 Items Specified lubricant Ouantity Power ste...

Page 589: ...lve Oil leakage f rom control valve joint Power cylinder Oil leakage from piston rod Oilline Pressure hose breakage Oil reservoir Oil reservoir deformation or oil leakage Rear wheels cannot be steered Poor rear wheels return Hydraulic pressure for rear wheel is constantly high Control valve Stuck control valve spool Power cylinder Stuck power cylinder Rear oil pump Relief valve remains ooen Long r...

Page 590: ... to the bleeder screw Caution Loosen the bleeder s crew about 30 to 45 degrees and secure it with the special tool lrotation prevention metal fixturesl so as not to be loosened more 9 Start the engine and with the front wheels in the straight forward position increase the engine speed temporarily un til the speedometer reading is 70 80 km h 43 50 mphlto operate the rear wheel oil pump Gaution Take...

Page 591: ...0 mph Turn the steering wheel all the way to left and right and turn it swiftly checking to ensure that the rear wheels steer to the same directions as the front wheels REAR OIL PUMP DISCHARGE FLOW VOLUME CHECK estFs c 1 Disconnect the pressure hose from the rear oil pump and install the special tool with a rubber hose 2 Place the other end of the rubber hose in a container which permits measureme...

Page 592: ...ud several times install the stud nut then measure the balljoint rotation starting torque with the special tool Standard value 0 5 Nm 50 kgcm 4 in lbs l or less lf the rotation starting torque exceeds the standard value replace the tie rod end lf the rotation starting torque is less than the standard value check that the ball joint is not loose and operates smoothly lf not it may be reused 21 3 4 ...

Page 593: ...Procedures o Bleeding of 4WS System Refer to P 378 4 o Checking of 4WS System for Operation Refer to P 378 5 o Checking of WheelAlignment Refer to GROUP 34 Service Adjustment Procedures 58Nm 5 8 ksm r trl ft lbs riorso Nm tt_13 kgm 8Ggtft b3 Fluid line flared nut 15 Nm t S lgm lt fi b rü0im qr 1l Fl 1 1 13 80 94 78 Nm 7 8 kgm 56 ft lbs 1 q 30 Nm kgm ft lbs Removal steps 1 Rear shock absorber lower...

Page 594: ...er mounting nut INSPECTION E K AA NR ROD SWING TOROUE INSPECTION l Swing the tie rod ten times hard 2 Point the tie rod end down then attach a spring balance as shown in the illustration to measure swing resistance swing torque Standard value I 55 N 0 9 5 kg 2 12 lbs l t0 5 3 Nm 5 30 kgcm 1 26 in lbs ll 3 lf the swing resistance exceeds the standard value replace the tie rod 4 lf the swing resista...

Page 595: ... clip should be removed for this 3 The difference between the lengths of the left and right tie rods should be less than 1 mm 0 039 in NOTE The threads of the tie rod ends may be used as a guide for this Disassembly steps 1 Nut e 2 Tie rod end assembly 3 Clio 4 Wire fa 5 Dust cover 6 Bleeder caps 7 Bleeder screws 8 Cylinder assembly Mlteubishi Motoru Corpotatlon May 199i1 SERVICE POINTS OF REASSEM...

Page 596: ...er to GROUP 34 Rear Suspension Assembly 12 Nm nH 3äitr 2 4 kgm 17 ft lbs 12 Nm 1 2 kgm sft tbF 3 5 kgm 25ft tbs 3 5 kgm 25ft bE 1 5 kgm l 11ft bs 5Nl 3 1l li tt Y N7 15 Nm 1 5 kgm 11ft lbs Post installation Operation o Installation of Rear Suspension Assembly Refer to GROUP 34 Rear Suspension Assembly o Ref illing and Bleeding of Power Steering System Refer to GROUP 37A Service Adiustment Procedur...

Page 597: ...1 Suctionhose 12 Reserve tank Pre removal Opcration o Cleaning of Pipings with Steam o Draining of Power Steering Fluid Refer to GROUP 37A Service Adjustment Procedures Pct installation Operation o Refilling and Bleeding of Power Steering System Refer to GROUP 37A Service Adjusrment Procedures o Bleeding of 4WS System Refer ro P 3784 o Checking of 4WS System for Operation Refer to P 378 5 12 Nm 1 ...

Page 598: ...System for Operation Refer to P 378 5 2 f ll5l3 o 11G 13oNm 3l 31 t ü lil f 7 z8N 3 1ü Nm 10 kgm n Wh ä I NOTE Do not disassemble the rear wheel oil pump SERVICE POINTS OF REMOVAL E3TRBAL 2 REMOVAL OF CROSSMEMBER BRACKET 3 CROSS MEMBER MOUNTING NUT ON DIFFERENTIAL SIDEI 1 Support the differential case with the transmission jack then remove the crossmember bracket and crossmem ber mounting nut on t...

Page 599: ...e SRS inoperativel 12 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and espccially its GROUP 528 Supplemental Restraint System before beginning any service or maintenance of any componont of the SRS or any SRS related componont NOTE The SRS includes the ...

Page 600: ... 0 21 3 5 0 14 5 0 0 20 3 5 0 14 Powerwindow motor Tvpe Revolutions under no load rpm Revolutions under load rpm At 1 Nm 0 1 kgm 0 72 ft lbs At 2 Nm 0 2 kgm 1 45 ft lbs Bound current A Direction of rotation Permanent magnet type Built in circuit breaker 75 or more 45 75 50 80 34 or less Clockwise and counter clockwise Power window main switch Type Rated load current A Lock switch Power window swit...

Page 601: ...ndle mm in A play 7 0 28l B OPEN 46 9 1 81 r 0 35 C FULL 69 2 721 Clearance of window glass to weatherstrip holder mm in Adjustment of glass inclination amount Front pillar 11 7 1 0 0 46 t 0 O4 Rool 11 8 1 0 0 46 t 0 Ouarter pillar 20 5 1 0 0 80 r 0 04 Adjustment of glass longitudinal inclination Front pillar 7 0 t 0 0 28 0 o4 Roof 7 7 1 0 0 30 r 0 04 Quarter pillar 12 0 1 0 0 47 r 0 04 SEALANTS A...

Page 602: ...90900 or Door adjusting MB991164 wrench Adjustment of door fit M8991341 Multi use tester subassembly 1993 models ETACS input check I ROM Pack For the number refer to GROUP 00 Precautions Before Service M8991502 MUT tr sub assembly Allmodels ETACS input check ROM pack 16XO6 t M8990784 Ornament remover Removal of the window moulding and interior parts ItttaSHilftotol3Corporation July1993 ...

Page 603: ...STORAGE CONNECTOR A 1lX ffi c 04x tffil ROOI I LAMP FOOT LAMP AND IGNITION KEY 9IlülPftAtro r o t5 4Y3 FLUID LEVEL IARNII IG LAIIP r5 ACT E AERO EYETEII mruE o ffi ffi r_ h 24 ffi Yir cotour cooo r sö r n aor Ec Bfr Ai3 l bgöfÄ Bl o 8i96 Sl hIRAH t tTll V V ÄlSi 8B 8rv otuc Mltrubishi Motor3 Corporation July 1994 PWUE9I19 D iEVIAED t 6 ...

Page 604: ...E ffil 16rRorr sroe R CTiTdI5 TIEIEI TET ffi r1 t2 avl 35tt ggta ä o t J lr AC TIVE AERO SYETEII ffi k8rPJ VEL STARTIl G SYSTETI THEFT ALARII SYSTEII n ro rfilR J B VV fll ll lt I J 10 TIMER CIRCUIT pRr veR s srDE I DOOR SW TCH illt ubbhl Motorc Corporation July 1994 x1 Vehicles witnout theft alarm svstem x2 Vehicles with theft alarm system PWUEgl19 D ffi lrafiä m EEEEffi mffi ...

Page 605: ...F E 17 ffi 4 DOOR LOCK ACTUATOR tr enr3 E 5ö o ffi st3 lBto PASSENGER S SIDE c nrt3 E ääo ffi r1 Venictes wi tnout thef t alarm gystem iSiifiBicras with theft atarm system r4 RHD lE FRoü ÄEtouSEBfb f xtt tl taDotl lc Mißubishi Motors Corpo ation 29_ r 14 B13 1g I u D et4 ir 5 I J 19 i i u I J 114 3tg July 199 l PWUEgl19 O REVISED ...

Page 606: ...menon Inspection method One of the door lock actuators fails to operate Check the door actuator which fails to operate The passenger s side door doesn t lock or unlock even if the driver s side door lock knob is operated Check the door lock actuator switch input sig nal Check the door lock actuator switch Refer to P 42 42 1 Check the door lock power relay Refer toP 42 _42 1 The driver s side door ...

Page 607: ... either MUT or MUT IIwith ttre ignition switch in the OFF position 2 Check if the buzzer of the MUT or MUT tr sounds when each switch is operated lf the buzzer sounds the input signals are being input to the ETACS unit so that switch can be considered to be function ing normally lf not the switch or switch input circuit is faulty Check the switch and the switch input circuit when using the MUT X 1...

Page 608: ...g bolts and then adjust the hood by moving it so that the clearance is equal on all sides 2 Turn the bumpers A and B adjust the height of the hood 3 Loosen the hood latch mounting bolts and move the hood latch to adlust the attachment between the hood latch and hood striker Mh ubbhl Motors Corpolation July 1994 PWUEgl19 D ...

Page 609: ...42 9 2 NOTES Mitsubishi Motors Corporation July 1994 PWUE9119 D ADOED ...

Page 610: ...ew and adjust the fuel filler door so that the clearance around the fuel filler door is even without any height differences DOOR ADJUSTMENT E rzn s 1 Use the special tool to loosen the hinge mounting bolts on the body side and then adjust the clearance around the door so that it is uniform on all sides 2 lf the door is not flush with the body remove the spring pin from the door check use the speci...

Page 611: ...line weatherstrip Loosen the bolts and nuts of the following parts o Glass guide front track o Glass guide rear track o Delta sash o Stabilizer inner front Stabilizer inner rear o up stop Door belt line outer weatherstrip NOTE Move the window glass down to the lowest position before removing the delta sash bolt 5 Remove the stabilizer inner front and adjust the adjusting bolt for the dimension sho...

Page 612: ...nward tilt of glass Adjust by turning the adiusting bolts of the glass guide front track and glass guide rear track Caution Turn the trro adiusting bolts of the glass guide rear track same amount Larger dimension Adiusting bolt Smaller dimension 11 7 1 0 t0 46 0 04 11 8 t 1 0 0 46 0 04 20 5 1 0 0 80 0 04 2 Adjust ment of forward or back ward tilt of glass Move the stabilizer inner front and up sto...

Page 613: ...nd tighten in position 1 1 Tighten the glass guide front and rear tracks Caution Do not turn the adjusting bolts of guide tracks 12 Adjust the delta sash so that the window glass end and the delta sash lip end are positioned as illustrated and tighten in position 13 Install the drip line weatherstrip 14 Install the front pillar trim 15 lnstall the door trim and the waterproof film Refer to P 42 37...

Page 614: ...izer inner front o Stabilizer inner rear o Up stop 3 Lift the window glass up to its highest position 4 Tighten the stabilizer inner front so that it presses against the glass guide slider of the window glass assembly 5 Tighten the up stop so that it presses against the glass stop of the window glass assembly 6 Tighten the stabilizer inner rear so that it presses against the window glass assembly ...

Page 615: ...clearance or the position is not at the standard values repeat the procedures in steps 4 and 5 10 Turn the adjusting bolts of the glass guide rear track and the glass guide front track to adjust so that the corner of the window glass touches the weatherstrip when the door is opened by the amount shown in the illustration 11 Install the door trim and the waterproof film Refer to P 42 371 12 Open an...

Page 616: ... about S0 cm 20 in high Pour water over the roof from about 30 cm 12 in above roof for more than 5 minutes While pouring water check for leak around sunroof ln the event of leakage check weatherstrip contact and oth ers 2 lf out of specifications adjust as described below Remove the door trim Refer to P 42 371 Loosen the screw attaching the inside handle and slide the inside handle back and forth ...

Page 617: ... alarm sys tem Engine room inspection lamp Inspection lamp switch Hood hinge removal st6pü o Washer tube Refer to GROUP 51 Windshield Wiper and Washer lB lnspection lamp wiring harness 19 Hood gas spring 20 Hood 21 Hood hinge Caution 1 Never try to disasscmblc thc hood ges sprlng or bum it 2 Always bore a hole in the gas spring to rclcarc t lrc interior gas before the spring is discarded 18FO261 P...

Page 618: ... between the connector terminal and the switch body NOTE O O indicates that there is continuity between the terminals SERVICE POINTS OF INSTALLATION 8 7 6 INSTALI ATION OF BUMPER B A Install the bumpers as illustrated Terminal I 2 Hood switch unpressed o o Hood switch depressed Terminal _ t Switch position 1 Connector terminal 2 Switch body ON OFF Wr r BumPer AtoFo263 17 mm 0 67 in Mltrublrhi Moto...

Page 619: ...moval steps o Tailgate trim Refer to GROUP o Rear side trim I52A Trims 4 Tailgate gas spring 5 Tailgate opening weatherstrip Tailgate and tailgatc hinge removal steps o Washer tube Refer to GROUP 51 Windshield Wiper and Washer a a a 4 6 7 a 8 failgate trim I nete to GROUp Ä lJir fr Itlm LH i äääfi i Tailgate gas spring Connection for tailgate wiring harness Tailgate Headlining Refer to GROUP 52A H...

Page 620: ...Retainer 16 Tailgate lock cylinder Caution 1 Never try to disassemble the tailgtto gas spring or burn it 2 Always bore a hole in the gas spring to release the interior gas before the spring is discardcd INSPECTION TAILGATE LATCH SWITCH VEHICLES W TH THEFT ALARM SYSTEM 1 Unlock the tailgate latch 2 Check the continuity between the terminals Terminal 1 2 Tailgate latch locked Tailgate latch unlocked...

Page 621: ...r to GROUP 52A Trims o Fuel Filler Door Adjustment Refer to P 42 10 1 Pre removal Operation o Removal of Rear Side Trim Ouarter Trim and Scuff Plate Refer to GROUP 52A Trims r I 5 Removal steps 1 Fuel filler door 2 Fuel filler door hook 3 Release handle cover 4 Fuel f iller door lock release handle 5 Fuel filler door lock release cable Mitsubishi Motoß Corporation May 1992 ...

Page 622: ...ATD Part No 8625 or equivalent raFooa2 Section A A Fender panel x a l erl t ffi V t rrooo Sealant 3M ATD Part No 8625 or equivalent 18Fqt O Remova steps 1 Front splash shield o Side airdam Refer to GROUP 51 Aero Parts 2 Front splash shield o Front bumper Refer to GROUP 51 Front Bumper 3 Side turn signal lamp 4 Front fender panel 5 Front fender bracket Mh ubl hi Motors Corporation May 1992 ...

Page 623: ...ing bake it after painting is com pleted Adhesive 3M Super Fast Urethan Auto Glass Sealant Part No 8609 or equivalent Primer 3M Super Fast Urethan Primer Part No 8608 or equivalent Auto Window Sealer Kit TEROSON 127 37V 1 Sealer 10 Gauge 2 Nozzle 1 1 Instruction manual 3 Primer container 4 Primer container cap 5 Piano wire 6 Brush 7 Cleaner 8 Primer 9 Filter 11 5 b t 0 7 üpo ac 4 10 Spacers Dam An...

Page 624: ...or 3 minutes or more Gluing of window dam Glue the window dam to the glass following the standard position all the way around the inside edge of the glass Applioation of primcr Apply sufficient primer evenly to the adhesion surface so that there is no patchiness After application let dry for 3 to 30 minutes Application of adherive Within 30 minutes after applying the primer apply the adhesive even...

Page 625: ... care not to damage the coated surface 2 lf the coated surface is damaged apply paint Cut off the lower portion of a new moulding and install the moulding temporarily to check that it is seated securely Apply primer to the moulding Caution Never touch the primer coated surface 4 5 Moulding C d Wlllgrveor 0 18FO057 6 Apply adhesive to the illustrated moulding before it hardens area and install the ...

Page 626: ...ldings o Removal and Installation of Headlining Refer to GROUP 52A Headlining o Removal and Installation of Front Pillar Trim Refer to GROUP 52A Trims Removal stePs 1 Windshield moulding a 2 Windshield glass 3 Window dam 4 Side spacer ßlt o Cut off nozzle end a 198 ä H 00 8 lFf n Jtl r qryw mm in tsFoooo 7 0 281 Adhesive 12 15 0 47 0 59 3M SUPER FAST URETHAN 8609 orequivalent Primer 3M SUPER FAST ...

Page 627: ...lass Using a sharp knife scoop out existing adhesive f rom the body flange to 2 mm 0 08 in or less thickness all around the window opening Finish smooth the flange surfaces Caution 1 Do not remove the adhesive more than neces sary 2 Use care not to damage the coated surface of the body with the knife lf it is damaged apply retouch paint of anti corrosive lf the glass is reused scoop out existing a...

Page 628: ...overc the surfaces com pletely Note that the primer if applied to thick Gan Gause loss of bonding powel 2 Never touch the primer coated surface 3 Allow 3 to 30 minutes to dry the primer 4 Witnin 30 minutes of primer application apply the adhesive all around the windshield glass uniformly Adhesive 3M SUPER FAST URETHAN 8609 or equivalent NOTE Cutting the nozzle tip of the sealant gun to a V shape w...

Page 629: ...lamp or other means are used for quicker hardening keep the suilace temperature 60 C 140 F1 or lower 9 After about 30 minutes or more following bonding of the windshield glass to the body check for water leaks Caution 1 lf the vehicle is to be moved do so gcntly 2 When checking for water leaks do not apply water with the hose end squeezed Section A 12 15 Adhestve Window dam 0 47 0 59 Primer 7 0 28...

Page 630: ...1ATION l removal and Post installation Operation Removal and Installation of Ouarter lJpper Trim Refer to GROUP 52A Trims Removal and Installation of Center Pillar Garnish Refer to GROUP 51 Garnishes and Center pillar glass Packing Mltanblrhi MotoB Corpor tion May 19 12 ...

Page 631: ...nishes and Mouldings Removal stops af fa 1 Ouarter window moulding and glass 2 Packing 3 Windowdam Section A Adhesive 7 0 281 Primer Adhesive 10 0 39 Section B Cut off nozzle tip 7 0 281 l L E ß it 7 0 281 10 0 39 A Section G Adhesive 5 0 59 2 0 47r 3 mm in 1 8F0060 7 0 28l Adhesive 3M SUPER FAST URETHAN 8609 or equivalent Primer 3M SUPER FAST URETHAN PRIMER 8608 or equivalent 12 15 0 47 0 59 12 1...

Page 632: ...the bolt Caution Hold the window glass with the special tool M89901801to prevent itfrom falling when the adhc sive is cut through Using a sharp knife scoop out existing adhesive from the body flange to 2 mm 0 08 in or less thickness all around the window opening Finish smooth the flange surface Gaution 1 Do not remoye the adhesive more than neces sary 2 Use care not to damage the coated surface of...

Page 633: ...ow er Make sure that it covers the surfacss Gom pletely Note that the primer if applied to thic can cause loss of bonding Powol 2 Never touch the primer coated surface Allow 3 to 30 minutes to dry the primer 3 Within 30 minutes of primer application apply the adhesive all around the windshield glass unifoimly Adhesive 3M SUPER FAST URETHAN 8609 or equivalent NOTE Cutting the nozzle tip of the seal...

Page 634: ...ntil the adhesive hardens Caution lf an infrared lamp or other means are used fol quicker hardening keep the surface temperature 60 C 140 Fl or lower 7 After about 30 minutes or more following bonding of the windshield glass to the body check for water leaks Caution 1 lf the vehicle is to be moved do so gently 2 When checking for water leaks do not squeeze the hose end 12 15 0 47 0 591 10 0 39 Sec...

Page 635: ...ion o Removal and Installation of Rear Wiper Arm Refer to GROUP 51 Windshield Wiper and Washer o Removal and Installation of Tailgate Upper Trim Refer to GROUP 524 Trims o Removal and Installation of Tailgate Trim Refer to GROUP 524 Trims r Removal and Installation of Tailgate Side Trim Refer to GROUP 52A Trims 9N 12 15 0 47 0 59 7 0 281 10 0 39 12 15 0 47 0 59 12 15 0 47 0 59 Adhesive 10 0 39 9 3...

Page 636: ...tion 1 The primer is used to strengthen bonding pow er Make sure that it covers the surfaces com pletely Note that the primer if applied to thick can cause loss of bonding power 2 Never touch the primer coated surface 2 Allow 3 to 30 minutes to dry the primer 3 Within 30 minutes of primer application apply the adhesive all around the liftgate glass uniformly Adhesive 3M SUPER FAST URETHAN 8609 or ...

Page 637: ...n lf an infrared lamp or other means are used for quicker hardening keep the surface temPorature 60 C 140 F1 or lower 7 After about 30 minutes or more following bonding oJ the tailgate glass to the tailgate check for water leaks Caution 1 lf the vehicle is to be moYed do so gently 2 When checking for water leaks do not squeeze the hose end Section A 12 15 Adhestve 0 47 0 59 Window dam Primer Sesti...

Page 638: ...eps 7 Striker 8 Striker shim Door switch removal steps 9 Door switch cap 10 Door switch Door assembly removal steps 1 Connection for door wiring harness connector 2 Spring pin 3 Door assembly 4 Upper hinge 5 Lower hinge Door check strap lemoval steps r Door trim Refer to P 42 37 l o Waterproof film Refer to P 42 37 1 2 Spring pin 6 Doorcheckstrap fe Mltrublrhi Motor Corporation May 1992 PWUEgl19 ...

Page 639: ...RAP Install the door check strap with the identification mark facing up DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION Sealant 3M ATD Part No 8625 or equivalent Removal steps 1 Door lamp 2 lnside handle cover 3 Door trim carpet 4 Door trim 5 Speaker garnish 6 Power window switch 7 Waterproof film Terminal Switch position 1 2 3 Switch Open ON o o Depressed OFF Position ldentification mark D...

Page 640: ...eatherstrip Refer to p 4243 1 3 Up stop 4 Stabilizer inner front 5 Stabilizer inner rear 6 Delta sash 7 Doorwindowqlass 8 Door window iegulator assemblv 9 Door glass guide track front 10 Door glass guide track rear Powerwindow switch assembly removal stcpr o Door trim Refer to P 42 37 l 1 1 Powerwindow switch assembly INSPECTION FOWER WINDOW RETAY 1 Remove the knee protector assembly Refer to GROU...

Page 641: ... check that the slider moves in opposite direction CIRCUIT BREAKER INCORPORATED IN THE POWER WIN DOW MOTORI 1 Press the UP switch to fully close the window glass and continue to press the switch for 10 seconds 2 At the moment that the UP switch is released press the DOWN switch The circuit breaker can be considered good if at this trme the door window glass begins to open within 60 seconds t l a 6...

Page 642: ...ce to the following connection table NOTE O O indicates that there is continuity between the terminals Switch oosition Terminal Power window switch Power window lock switch UP OFF DOWN NORMAL LOCK Driver s side switch 7 31 6 4 ö Y 1 21 ö 3 7 I ö ö ö Passenger s side switch 7 3 4 6 I r Y n Y Ä _ 3 7 I o ö Ä Power window lock switch 7 3 Y 2 tll Ä Switch position Terminal Sub switch UP OFF DOWN Sub s...

Page 643: ...Door outside handle end latch rcmowl stcpc 2 Door key cylinder unlock switch connector 3 Door outside handle 4 Rinq 5 Doör lock key cylinder 6 Door latch assembly 7 Door lock actuator INSPECTION DOOR KEY CYLINDER UNLOCK SWITCH The key cylinder unlock switch is normal if there is not continuity between terminals 1 and 2 when the key is turned approx 20 clockwise or counterclockwise from the neutral...

Page 644: ...placed in the UNLOCK position there is a continuity between the terminals 2 and 4 and that when the rod is placed in the LOCK position there is no continuity DOOR LOCK RELAY 1 Remove the knee Refer to GROUP 2 Remove the door protector assembly 524 Instrument Panel lock relay from indoor relay box 4lsl6l7 I Mltt ülthl llotors Corporation May 1992 3 check for continuity between terminals under the c...

Page 645: ...er Drip line weatherstrip removal steps 6 Drip line weatherstrip 7 Door weatherstrip holder ffil dli SERVICE POINT OF REMOVAL 2 REMOVAL OF DOOR OUTER OPENING WEATHER STRIP Make a tool as shown in the illustration to remove the door opening weatherstrip SERVICE POINT OF INSTALLANOilI 2 INSTALTANON OF D R OUTEß OPENING WEATHER STRIP The clip color identifies the left and right weatherstrips so be su...

Page 646: ...weatherstrip 8 Sunroof female hinge 9 Deflector Sunroof regulator acscmbly re moval steps 1 Sunroof trim assembly 2 Glass assembly 10 Interior temperature sensor 11 Regulator cover 12 Sunroof regulator assembly Adhered portion Mitrubhhi ttlotors Corporation May tSEl 12 11 tr J d ts SERVICE POINTS OF INSTALLATION 7 INSTALLANON OF SUNROOF INNER WEATHERSTRIP 2 I Install so that the adhered portion of...

Page 647: ...PECTALTOOLS rir TROUBLESHOOTING SERVICE ADJUSTMENT PROCEDURES Inspection of Active Aero System FRONTBUMPER 9 1 REAR BUMBPER 12 GARNISHES AND MOULDINGS 14 AEROPARTS 18 WINDSHIELD WIPER AND WASHER 2g REAR WIPER AND WASHER 27 HEADLAMPWASHER 30 DOOR MIRROR Mitsubishi Motors Corporation July 199 t PWUEgl1 D REVISED ...

Page 648: ...7 RHD 90 525120 71 s00 19 7 Rear wiper blade Wiping angle Wiper blade length mm in 870 1 5 550 21 71 Windshield washer motor and pump Motor type Pump type Power consumption A Time of continuous use sec With washer fluid Empty operation Nozzle jet pressurg kPa kg cm2 psi Tank capacity dm3 U S qts lmp qts Direct current ferrite magnet type Centrifugaltype 3 8 or less Max 60 Max 20 120 1 2 17 or more...

Page 649: ...O HI INT Washer switch Voltage drop at 12V and the rated load V Wiper switch Washer switch Headlamp washer switch 4 0 22 0 05 Max 4 0 2 or less 0 5 or less 0 5 0 1 Rear wiper and washer switch Rated load A Wiper switch Washer switch Voltage drop V 5 5 0 1 or less I ntermittent wiper relaY Front incorporated in column switch Intermittentinterval min max sec Variable interval intermittent wiper Dela...

Page 650: ...e air dam 3M ATD Part No 6382 or equivalent Side garnish Cushion Tool Number Name Use M8990449 Window moulding remover Removal of tailgate moulding upper and tailgate moulding lower M8991341 Multi use tester sub assembly 1993 models ETACS input check and active aero system inspection ROM pack O Forthe number referto t359 j oo precautionsJ M8991502 MUT tr sub assembly Allmodels ETACS input check an...

Page 651: ...MN S TCH RHD I LHD J r o J J r d DOOR LAXP LUCiGAGE COMPARTI E LAMP AND TIARNING L 8t8fifEtr 7t1 g12 J 26 12 I 11 I I 9 J 3 il ffi trtrffimTa C TO trEEEtrEE I I m 16 DIAGNOSIS CONNECTOR r nn v tv 14 FRONT SIDE KX35 Al R5t0t tC Mitsublshi Motor3 Corporation July 199t1 t b zd ffi Remarks 1 x 1 Vehicles without theft alarm system lx Venictes wl th tneft atarm gystem 3 x 3 Up to 1994 mode t s 4 r 4 Fr...

Page 652: ... flmf Ähilre c 68 ftFiI Tqs ETfll tcL tguJgrlug gEl D 45 HEffiI l t B t v tffiilfHB ffiF Ä si o oa F 1 COMBINATION METER ltftlTT l E EEEtrEI D HkEryAffi fiÄ IIETER AI D GAUGE r Pt sYsTEll tJINDSHIELD WASHER MOTOR Hiiillil ffion o n gi tst Mltrublshi Motors Corporation July 199 l UINDSHIELD Iffi vrPER n0T0R l l WASHER FLUID LEVEL SENSOR A 15 u ilill t t ll3 sB 8rrv orue PWUEgl19 D 20 H 05 2 I Y G E...

Page 653: ...ch is on for 0 6 second or more when the ignition switch is at ON or ACC with the wiper switch turned off the washer liquid will be poured and the transistor will be turned on 0 6 second later to operate the wipers two or three times Phenomenon lnspecting method Wipers do not operate continuously Washer does not operate o Check the multi purpose fuse No Washer operates o a Check the wiper motor Re...

Page 654: ...s are being input to the ETACS unit so that switch can be considered to be function ing normally lf not the switch or switch input circuit is faulty Check the switch and the switch input circuit SERVICE ADJUSTMENT PROCEDURES INSPECTION OF ACTIVE AERO SYSTEM E IEIAA 1 INSPECTION BY WARNING LAMP Turn the ignition switch from OFF to ON to see if the warning lamp is lit for approx three seconds and th...

Page 655: ... All models Using pseudo vehicle speed input function of the MUT or Mt l I II inspection can be made by means of vehicle speed l Set the MUT or MUT II to the diagnosis connector NOTE When connecting the MUT II to a vehicle up to 1994 model use the adapter harness supplied together with the MUT tr Caution Conneet and disconneet either MUT or MUT tr with ths ignition switch in the OFF position Turn ...

Page 656: ...the clip with a Phillips screwdriver lf however there is enough space to insert a screwdriver or the like behind the clip use the following procedure for ease of work l Removal Using a screwdriver or the like press the screw from the inside of the bumper to remove the clip 2 Installation With the grommet inserted in the hole press the screw in Mitrubishi Motots Corporation July 199 PWUEgl19 D ...

Page 657: ...51 9 2 NOTES Mitsubishi Motors Corporation July 1994 PWUEgl19 D ...

Page 658: ... OF INSTALLATION 1 INSTALLATION OF FRONT UNDER COVER PANEL Install the air dam link assembly in the operative condition for ease of front under cover panel S rz 6 tu 6J g Removal steps 1 Side cover panel 2 Front cover panel 3 Center cover panel t 4 Front under cover panel 5 Front splash shield extension 6 Driving lamp 7 License olate bracket L Front combination lamP garnish 9 Front combination lam...

Page 659: ... 0 5 kgm 32 ft lbs ä 4 w v I I 3 1tF0s75 Removal steps 1 Front splash shield extension 2 License plate bracket 3 Position lamp 4 Front turn signal lamp 5 Headlamp 6 Headlamp washer hose connection 7 Bumper face assembly 8 Center lower bracket 9 Bumper reinforcement assembly Mhsublshi Motors Corporatlon July 1994 ...

Page 660: ...51 10 2 lultt übllhl Motor3 Corpotadon July 190t1 PWUE91 9 D ADOCD o ...

Page 661: ...ing the bumper absorber drill a 3 mm 0 13 in l diameter hole to discharge the gas con tained in the unit Be sure to wear safety goggles while performing this operation as the gas is not harmful but chips may be ejected with it 3 lf the bumper absorber is to be discarded do not burn it SERVICE POINT OF REASSEMBLY 10 INSTALTATION OF BUMPER ABSORBER lf the squareness between the bumper reinforcement ...

Page 662: ...face inner corner plate 6 Bumper face upper front plate 7 Bumper face upper center plate 8 Bumper face protector 9 Side lower plate 10 Pad 11 Clip 12 Headlamp washer nozzle 13 Bumper face 18FO377 Bumper reinforcement disassembly steps 14 Headlamp washer tank lower bracket 15 Front end lower bar assembly 16 Bumper absorber 17 Bumper reinforcement stay 18 Bumper reinforcement l fr MlUrbirhi Moto6Coi...

Page 663: ... hole to discharge the gas con tained in the unit Be sure to wear saf üy goggles while performing this operation as the gas is not harmful but chips may be eieeted with it 3 lf the bumper absorber is to be diccarded do not burn it SERVICE POINT OF REASSEMBLY 16 INSTALLATION OF BUMPER ABSORBER lf the squarness between the bumper reinforcement stay and the bumper absorber is improper adjust it by pu...

Page 664: ...ke press the screw from the inside of the bumper to remove the clip 2 lnstallation With the grommet inserted in the hole press the screw in Pre removal and Post in3tallation Operation o Removal and Installation of Rear End Trim and Rear Side Trim Refer to GROUP 524 Trims 1 0 13 6 t 15 1 1 h 6 3 4 5 6 7 8 Bolts License plate lamp Clios with screw Nuts Tapping screws Bolts 9 Bumper face upper plate ...

Page 665: ...sembly vehiöles buih from July 1993 ru öumper retntorcement rtFoSt3 tl SERVICE POINT OF DISASSEMBLY 8 REMOVAL OF BUMPER ABSORBER Caution 1 Do not attempt to repair a bumper absorber that has been compressed in an accident replace it with a new one 2 Before discarding the bumper absorber drill a 3 mm 0 13 in l diameter hole to discharge the gas con tained in the unit Be sure to wear safsty goggles ...

Page 666: ...e assembly disassembly steps 1 Rear bumper garnish 2 Rear garnish bracket 3 Bumper face Bumper reinforcement assembly disascembly steps 4 Rear bumper harness 5 Rear bumper stay assembly 6 Bumper reinforcement 22 Nm 2 2kgm 16 ft bs 18FO37r O Mtt bbhi Motols Corporation July 199 l ADDED ...

Page 667: ...51 13 2 O NorEs Mltgubishi Motorc Corporatlon July 199t1 ADDCD ...

Page 668: ...eps 3 Drip moulding 5 Windshield moulding Refer to GROUP 42 Windshield Tailgate moulding remova step 6 Tailgate moulding Refer to GROUP 42 Tailgate Glass Ouarter window moulding and glass removal steps 4 Center pillar garnish 7 Ouarter window moulding and glass Refer to GROUP 42 Ouarter Window Glass Rear roof extension removal steps Vehicles with sunroof Headlining Refer to GROUP 524 Headlining 8 ...

Page 669: ... a clip or bolt pull the side garnish toward you to remove the clip or the bolt Gaution 1 To reuse the side garnirh remoyc lt by pnlling the fishing line along the body ro rt not to damage the edges of the side gnrnirh 2 lf it is hard to cut through adhccivo mltsitl heat it to approx 10 C t04 Fl 5 Use an infrared lamp or the like to heat the pressure sensitive double sided tape remaining on the bo...

Page 670: ... 40 to 60 C 104 to 140 F for 5 to 10 minutes Caution Do not overheat the tape until its surface dries to turn white Using a resin spatula or gasket scraper scrape off the pressure sensitive double sided tape lf the pressure sensitive double sided tape remains on the side garnish repeat steps 1 and 2 Use cloth moistened with degreaser 3M ATD Part No 8906 or equivalent to wipe the side garnish clean...

Page 671: ...ips and bolts aligned with the respective holes in the body install the side garnish to the body NOTE lf it is hard to affix the pressure sensitive double sided tape in winter heat the application surface of the body and the adhesive surface of the side garnish before affixing the tape Body 40 60 C 104 140 F Side garnish 20 30 C 68 86 F 3 Apply pressure fully to the side garnish t0 Mitsubishi Moto...

Page 672: ...igh mounted stop lamp L H drive ve hicles Front under cover panel air dam link assembly removal steps 4 Side cover panel 1 H 5 Front cover panel 6 Center cover panel 7 Front under cover panel 8 Lower plate 9 Upper plate f 10 Air dam link assembly 1 1 Under cover bracket Active aero switch removal steps 12 Switch garnish C 13 Active aero switch Active aero control unit removal steps Rear side trim ...

Page 673: ...bed in 1 above check the limit switch for continuity Terminal Spoiler position 3 4 5 FLAT standard position o o During operation o o SLANT operative position o o NOTE O O indicates that there is continuity between the terminals 2 INSPECTION OF AIR DAM IINK ASSEMBTY MOTOR AND LIMIT SWITCH 1 connect the battery see illustration to ensure that the motor and the linkage operate freely 2 While perforrn...

Page 674: ...e air dam link assembly in the operative condition for ease of front under cover panel 1 INSTALLANON OF SIDE AIR DAM Install the side air dam by the same procedure as the side garnish refer to P 51 16 provided that specified adhesive is used Specified adhesive 3M ATD Part No 8609 SUPER FAST URETHAN or equivalent Terminal Switch positö t1 5 1 2 4 6 3 OFF br ILL G rD o bl IND z G AUTO 1 G az AUTO 2 ...

Page 675: ...n of rnotor Gear for limit switch SERVICE POINTS OF REASSEMBLY 5 INSTALLATION OF MOTOR 1 See illustration to ensure that the motor is in the neutral position 2 lf the motor is not in the neutral position use allen wrench to turn the gear for the limit switch until the mo tor is in the neutral position Adhesivetapc 3M ATD Pan No 63 l orcquivelent Mitsubishi Motors Corporation May 1902 PWUEgl19 ...

Page 676: ...sembly the drive gear of the motor may not engage with the cable ln such a case they can be engaged with each other by tightening the motor mounting screw INSTALLANON OF MOTOR AND CABTE ASSEMBTY Affix pressure sensitive adhesive double coated tape to the projection of each cushion and install the cushion in the position shown in the illustration Specified adhesive tape 3M ATD Part No üf82 or equiv...

Page 677: ... removal steps 1 Wiper blade 2 Wiperarm 5 Hole cover 6 Wiper motor Column switch lwiper and washer switchl removal 15 Column switch Refer to GROUP 54 Column Switch 5 5Nm L rli Tf r Washer tank rsmoval rtcPr 8 Battery 9 Battery tray 10 Washertank 1 1 Washer motor 12 Washer fluid level sensor Washer tube rcmovel dcPr 8 Battery 9 Battery tray 13 Washer nozzle 14 Washertube 9Nm 0 9 kgm 7 ft lbs ZA 4 6...

Page 678: ...ect the wiper motor mounted on the vehicle with its connector disconnected Inspection of Wiper Motor Operation at LOW and HIGH Speeds Connect the battery to the wiper motor as shown and check its operation at LOW and HIGH speeds Inspection of Wiper Motor STOP Position 1 Operate the wiper motor at LOW speed and intermediately disconnect the battery to let the wiper motor stop 2 Connect the terminal...

Page 679: ... Switchl 1 Check to ensure that there is continuity between terminals and and between the terminals and and that there is no continuity between terminals and 2 Connect the positive terminal of the battery to terminal and the negative terminal to terminal to check that the battery voltage is available at terminal INSPECTION OF WASHER MOTOR 1 When the washer motor is inspected make sure that it is m...

Page 680: ...he circuit is opened SERVICE POINT OF INSTALLATION 2 INSTAIANON OF WPER ARM 1 The wiper arms right and left are different in shape Check the identification symbol 2 After the wiper blades have been set install them in such a way that the ends of the wiper blades will stop at the specified positions standard values Standardvatue Al t5f mm 0 61 2 in l ldentification mark A ldentification mark D Fron...

Page 681: ...ims 4 Wiper motor e Washer tank removal steps Rear end trim Refer to GROUP 52A Trims 5 Cap 6 Washer tank 7 Washer motor Washer tube ramoval rtcpr Front pillar trim RH I Ouartertrim RH ouarter upper trim RH i ryjg to GRoUP 52A Rear roof rail trim r rrrtrr Rear side trim RH 1 8 Tailgate moulding upper 9 Washer nozzle 10 Tube and grommet assembly 11 Washer tube Mitrubichi Motor Corporstion Mey t9gil ...

Page 682: ...r Wiper Motor Stop Position 1 Operate the wiper motor by the procedure described above and intermediately disconnect the battery to let the wiper motor stop 2 Reconnect the battery as shown and check that the wiper motor stops at the automatically stopped position after operation WIPER WASHER SWITCH 1 Remove switch garnish B from the knee protector 2 Operate the switch to check for continuity betw...

Page 683: ...motor is inspected make sure that it is mounted on the washer tank and that the washer tank is filled with water 2 Connect the battery as shown to check whether water is pumped out SERVICE POINT OF INSTALLATION 2 INSTALLATION OF WIPER ARM After assembling the wiper blade to the wiper arm install the wiper arm with its tip positioned along the ceramic part Condition Standard When wiper is stationar...

Page 684: ...inforcement assembly 3 Headlamp washer hose assembly 4 Headlamp washer tank Headfamp washer nozzle removal steps 5 Headlamp cover 6 Clip 7 Headlamp washer nozzle Golumn switch headlamp washer switchl removal 8 Column switch Refer to GROUP 54 Column switch Headlamp washer relay removal steps Floor console assembly Refer to GROUP 52A Ftoor console 9 Headlamp washer relay Mttrublrhl Motor Corporation...

Page 685: ...t bumper reinforcement assembly 3 Headlamp washer hose assembly 4 Headlamp washer tank Headf amp washer nozzleremoval steps 5 Clip 6 Headlamp washer nozzle Column switch lheadlamp warher switchl removal 7 Column switch Refer to GROUP 54 Column switch Headlamp washr relay removal stcps Floor console assembly Refer to GROUP 52A Floor console 8 Headlamp washer relay O Mitsubishi Motors Corporatlon Ju...

Page 686: ...51 30 2 NOTES Mh ubbhl MotoF Gorporation July 1994 PWUE9119 D ADDED ...

Page 687: ...er fluid level sensor from the washer tank 2 Connect a circuit tester to the connector of washer fluid level sensor 3 Move the float up and down 4 Make sure that when the float is raised there is no continuity and when it is lowered there is continuity HEADIAMP WASHER RELAY 1 Connect battery and test lamp to the relay as illustrated 2 The relay is normal if the lamp lights for approximately 0 5 se...

Page 688: ...en the terminals for each switch GO indicates that there is continuity between the terminals CHECK VALVE Apply pressure to the inlet of the check valve to check its opening pressure Opening pl srure 50 110 kPa 0 5 1 1 kg cm 7 1 15 6 pgil Terminal Switch position 11 14 OFF ON o o NOTE Mlft ublrhl ilotoru Corporation M y 1992 ...

Page 689: ...nt panel switch 5 Electric remote controlled mirror switch SERVICE POINTS OF REMOVAL 1 REMOVAL OF DOOR MIRROR Tilt the door mirror backward and forward to remove the attaching bolts 3 REMOVAL OF MIRROR Tilt the mirror upward and fit a screwdriver blade covered with protective tape in the notch between the mirror and the pivot plate to Pry uP the mirror Gaution Do not fit the screwdriver blade bstu...

Page 690: ...onnected to the battery ELECTRIC REMOTE CONTROL MIRROR SW TCH Iffiil ffi Operate switches and check for continuity betrnreen terminals O NOTE O O indicates that there is continuity between the terminals x Direction Battery Terminal 2 3 4 1 5 UP o O G o DOWN o o r 4 A RIGHT G G r LEFT r G NOTE lnintt Direction Left side Right side 3 4 6 7 8 2 4 6 7 I UP r _ J _ 1J G o DOWN o G o o G o o LEFT G G o ...

Page 691: ...ponent mu3t be performcd only et an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and espcially its GROUP 528 Supplemental Restraint System before beginning any service or maintenance of 8ny Gomponcnt of the SRS or any SRS related component NOTE The SRS includes the following compononts impact sen3ors SRS diagnoeis unit SRS wamlng lanp eh bq module c...

Page 692: ...ber Name Use M8990784 Ornament remover Removal of center air outlet Name Symbol Size mm in DxL Color Shape Tapping SCTEW A 5 x 16 p 20 x 0 63 B 5 x 30 0 20 x 1 21 c 4 x 12 0 16 x 0 47 Black D 5 x 16 0 20 x 0 63 Black E 4 x 16 0 16 x 0 63 Washer assembled screw F 5 x 16 0 20 x 0 63 G 4 x 12 0 16 x 0 47 Washer assembled bolt H 6 x 16 0 24 x 0 63 I 6 x 16 0 24 x 0 63 J 6 x 20 0 24 x 0 79 K 6 x 20 0 2...

Page 693: ... shock to the SRS diagnosis unit 15 rz rum Removal stopc 1 Hood lock release handle 2 Rheostat 3 Switch garnish B 4 Knee protector assembly 5 Column cover 6 Glove box striker 7 Glove box and cross pipe cover 9 Center air outlet assembly 10 Heater control assembly installation screws 1 1 Meter bezel 12 Combination meter 13 Speaker 14 Harness connector 15 Steering shaft mounting bolts 16 lnstument p...

Page 694: ...r bag module and clocks spring t9Fo2Ge br Removal Jtepg 1 Hood lock release handle 2 Rheostat 3 Switch garnish B 4 Knee protector assembly l 5 Column cover 6 Glove box striker 7 Glove box and cross pipe cover 8 Passenger side air bag module Refer to GROUP 52B Air Bag Module and Clock Spring l 9 Center air outlet assembly 10 Heater control assmbly installation screws 11 Meter bezel 12 Combination m...

Page 695: ...o o o o ...

Page 696: ...mbly 3tepc 1 Glove box stopper 2 Cross pipe cover 3 Glove box cover 4 Ratchet assembly 5 Lock cylinder assembly 6 Glove box Instrument panel dirassembly stepc 7 Glove box lower framel Side air outlet I photo sensor I l tgIo GROUP Def roster garnish 55 Ventilators Heater ducts Combination gauge Refer to GROUP 54 Meters and Gauges 8 Instrument panelwiring harness lrrJnorr N w Frat tip I screwdriver ...

Page 697: ...ft lever knob 10 Front console assembly DISASSEMBLY AND REASSEMBLY Front console disassembly steps 1 Shift lever cover 2 Ashtray 3 Cigarette lighter 4 Power seat switch 5 Front console 6 Front console bracket Rear console disassembly steps 7 Plug 8 Console lid 9 Lock lever 10 Spring 11 Rearconsole sRs l removing and lnstalling the console assembly don t allow impact or shock td thc SRS unit rr Mit...

Page 698: ...cross tip screwdriver to push inward the pin at the centre of the trim clip to a depth of about 2 mm 0 08 in 2 Pull the trim clip outward to remove it Caution Do not push the pin inward more than necessary because it may damage the grommet or the pin may fall in if pushed too far INSTALTATION 1 With the pin pulled out inserr the trim clip into the hole in the trim 2 Push the pin inward until the p...

Page 699: ...teps 4 Hangerbracket 5 Sash guide cover mounting bolt 6 Clip 7 Front pillar trim Ouarter upper trim removal steps 3 Ouarter trim Refer to P 52A 8 4 Coat hanger 8 Screw 9 Ouarter upper trim Rear roof rail trim removal rtepr 8 Screw 10 Rear roof rail trim NOTE 1 Location of metallic clip l2l J Location of resin clip 3 indicates trim clip Refer to P 52A 4 Fordoortrim refertoGROUP42 DoorTrim and Water...

Page 700: ...rnish 16 Sash guide cover mounting bolt 17 Front seat belt anchor plate mounting bolt l 8 Retractor cover 19 Rear seat belt anchor plate mounting bolt 20 Screw 21 Ouartertrim 22 Rear side trim Refer to P 524 9 23 Ouarter trim bracket IOTE O Location of resin clip SERVICE POINT OF REMOVAL 11 REMOVAT OF REAR SEAT With the lever pulled forward raise the remove it E5A Ail seat cushion to lulftlubllhlM...

Page 701: ...hion in the hole provided in the floor positively o I Ouarter trlm A A Rear end tnm B B Clip Y Rear side trim rear end trim removal steps 1 Luggage compartment floor box R H 2 Luggage compartment floor box L H 3 Lid R H 4 Lid 1 H 5 Rear end trim 6 Screws 7 Floor mat mounting clip 8 High floor center board 9 Luggage compartment lamp connector connection 10 Rear side trim Location of metallic clip L...

Page 702: ...er trim eFoo D B B Tailgate lower trim c c Tailgate trim removal steps 1 Shelf hook 2 Tailgate lower trim 3 Tailgate upper trim 4 Tailgate side trim NOTE 1 Location of metallic clip 21 I Location of resin clip Mh übiahi Moton Corponüon May 1992 ...

Page 703: ...o Removal and Installation of Front Pif lar Trim Refer to P 52A 7 1 Vehicles with sunroof Removal steps 1 Hanger bracket 2 Sash guide cover mounting bolt 3 Clio 4 Interior temoerature sensor 5 Sunvisor assembly 6 Sunvisor holder 7 Room lamp assembly 8 Regulatorcovar ö Sr öäil wiJiot f cVehicles with sun re 10 Sunroof inner weatherstrio 11 Headlining SERVICE POINT OF INSTALIATION EsiIr oo 10 INSTAL...

Page 704: ...llthe front seat assembly by the following procedure There are two sets of removaland installation points established in accordance with the seät position Position in illustration A Refer to 1 Position in illustration B Refer to 2 1 REMOVAL AND INSTALLANON POINTS WHEN THE SEAT IS STOPPED IN THE FORI I ARD POSMON 1 Remove the bolts underneath the seat cushion shown in the illustration from the rear...

Page 705: ...ont of the seat cushion 2 Remove the slide motor mounting bolts 8 botts in the positions A shown in illustration move the slide motor assembly forward slightly and remove the screw and bracket connections sections C in illustration Depending on the seat position the slide motor may not move if only the bolts shown at A in the illustra tion are removed ln this case remove the motor bracket mounting...

Page 706: ...O o o SPREAD G o r OFF r o OFF F JO RELEASE V o o o cLosE o o o r o NOTE O O indicates that there is continuity between the terminals Outboard Gr SERVICE POINTS OF INSTALLATION 6 INSTALTANON OF FRONT SEAT ASSEMBLY 1 After checking that the seat ad juster is locked at both sides provisionally tighten in the A B C and D sequence the seat installation nuts and the seat installation bolts then fully t...

Page 707: ...ket positively Then rotate the cover in the direction of arrow to install the side tabs in the side holes of the bracket 2 lnsert the rear side seat anchor cover outer side to the front seat rearward installation bracket and then attach each tab of the seat anchor cover to the hole of the bracket 3 lnsert the rear tab of the rear seat anchor cover in the front seat rear mounting bracket positively...

Page 708: ...8 Inner seat belt 9 Seat cushion assembly 10 Memory reclining knob Driver seat 1 1 Sliding adjuster knob 12 Seat back oanel 13 Seat back assembly 14 Seat belt guide 15 Head restraint guide 16 Reclining adjuster lower cover Driver seat 13 FBWE B3l si ls Driver seat 19 Walk in knob 20 Walk in knob garnish Passenger seat 21 Slide adjuster 5 1 3 2 10 1 t 15 Nm tl S kgm 33 ft lbr PASSENGER SEAT 9 45 Nm...

Page 709: ... and each ad iusting mechanism operates in the directions shown in the table below 13 lf there is any abnormality replace the power seat adjustel assembly or seatback assemblY Terminal No Switch oosition 1 2 3 4 E 6 7 8 I 10 t1 12 13 14 Slide switch Forward G o F Backward G o Front height switch Up G G o Down o o o Rear height switch Up G o G Down o o All switches OFF Name of motor Direction of op...

Page 710: ...en the terminals SERVICE POINT OF REASSEMBLY E aKHAE 8 INSTALLATION OF INNER SEAT BELT 1 Route the seat belt switch connector harness on the adjuster bracket 2 Use clips to secure the harness to the adjuster bracket 3 Fit the locking claw of the inner seat belt positively in the locking hole provided in the seat bracket r TerminalNo Switch position 1 2 3 Forward o o Backward o Middle ON G o Front ...

Page 711: ...on REMOVAL Eraxr g SEAT CUSHION raise the seat cushion and remove SERVIGE POINT OF INSTALI ATION 1 INSTALLATION OF REAR SEAT CUSHION 1 Fit the attachment wire of the seat cushion under the seatback positively 2 Pass the rear seat belt buckle through the seat cushion 3 Insert the lock plate of the seat cushion in the respective holes provided in the floor Rear seat belt buckles Lock plate Attachmen...

Page 712: ...steps 1 Ouarter trim Refer to P S2A 2 Outer seat belt Inner teat beh removal steps o Floor console assembly Refer to P 52A 5 3 Shield cover 4 Inner seat belt tl5 Nm f 5 kgm 3 l ft tb 19FO21 7 f5 Nm g l 3ß 5 Outer seet belt removal stepE 1 Ouarter trim refer to P 52A 5 Outer seat belt Inner seat beh removal steps o Rear seat cushion Refer to p 52A 19 6 Inner seat belt 7 Inner seat belt bracket 1gFO...

Page 713: ...ec ipstoSecuretheharnesstotheadiusterbracket iäi f it the locking claw of the inner seat belt positively in the locking hble provided in the seat bracket 2 INSTALLATION OF OUTER SEAT BELT 1 Positively insert the pawl to prevent the retractor from rotating rn the hole provided o n the body tzl 3 Insert the pawl of the belt guide in the hole provided on the body lnstall the final anchor of the front...

Page 714: ...o o o NOTES o ...

Page 715: ...R BAG MODUI E DISPOSAL PROCEDURES Undeployed Air Bag Module Disposal Deployed Air Bag Module Disposal Procedures 59 59 60 dl 65 79 79 85 8 10 10 11 50 55 CAUTION o Carefully read and observer the information in the SRS SER CE PRECAUTIONS P 52841 p ior to any service a For information conceming troubleohooting or maintenance always obsele thc proceduro In thc Troubleshooting P 528 101 or the SRS Ma...

Page 716: ...ent panel which indicates the operational status of the SRS a clock spring interconnection located within the steering column wiring CONSTRUCTION DIAGRAM SRS warning lamp Diagnosis connector The SRS is designed so that the air bag will deploy when the safing sensor plus either or both of the left front and right front impact sensors simultaneously activate while the ignition switch is ON That is d...

Page 717: ...op erational status of the SRS located on the instru ment panel clock spring mounted behind the steer ing wheel and wiring CONSTRUCTION DIAGRAM SRS warning lamp Right front impact sensor Left front impact sensor 13RO708 The SRS is designed so that the air bags will deploy when the safing sensor plus either or both of the left front and right front impact sensors simultaneously activate while the i...

Page 718: ...ace or repair the wiring harness according to the following table VEHICLES WITHOUT FRONT PASSENGER S AIR BAG SDU Terminal No Harness Connector No of Terminals Color Destination of Harness Corrective Action 1 2 pins red Clock spring Air bag module Replace clock spflng 2 3 2 pins yellow Body Front Front wiring wiring t imPact harness harness sensor LH Replace with sensor cable 4 5 2 pins blue B99V F...

Page 719: ... sensor L H To front impact sensor R H To body wiring harness 14 pin To clock spring r9t ot00 2 pin blue connector to right front impact sensor 2 pin yellow connector to left front impact sensor 2 pin red to clock spring 14 pin red connector to t9FOlOa Mttsubbhi Moto6 Cotpotttlon D c 19St PWUEgl19 c EvlSED ...

Page 720: ...ce body wiring harness 6 7 14 pins red I I Diagnosis check pin Correct or replace control wiring instrument panel wiring harness or body wiring harness 10 Control wiring harness lgnition switch ST 11 r General purpose fuse No 11 12 General purpose fuse No 18 13 Instrument panel _ pRS warning wlnng narness amp 14 15 Front wiring Harness Front impact sensor R H positive terminal Correct or replace b...

Page 721: ...cted to heat over 93 C 200 F so remove the front impact sensors SRS diagnosis unit air bag module and clock spring before drying or baking the vehicle after painting Recheck SRS system operability after re installing the components Whenever you finish servicing the SRS check the SRS warning lamp operation to make sure that the system functions properly Refer to P 528 10 Make certain that the ignit...

Page 722: ...se times lRefer to MUT tr OPERATING I LINSTRUCNONS I ROM pack for MUT tr roxoGot Resistor 3 M8991349 3 SRS Check Harness ehicles without front passenger s air bagD I o Cnecmng the SRS electrical öircuitry witi I a dighal multi meter ruore I SRS check harness is used on various I Diagnostic Tests I For details refer to DtAGNosnc sEouENcE I P 52 11 P 528 4s 5 H I n I s l To SDU connector for clock s...

Page 723: ...tor To clock spring To body wiring harness 14 pin 10NO325 To air bag module front passenger s side Digital multi meter l use a mdttimeter for which the I I maximum test current is 2 mA or I I less al th minimum range of I Lresistance measur ment 13RO aC Checking the SRS electrical circuitry with SRS Check Harness M8990803 Steering wheel puller Removal of steering wheel M8686560 SRS AIR BAG ADAPTER...

Page 724: ...e drops In such cases if the battery voltage returns to nor mal the SRS warning lamp will switch off Turn the ignition key to the LOCK position Connect the Multi use Tester 1993 models or MUT II All models to the diagnosis connector NOTE When connecting MUT II to 1994 models use the adapter harness which belongs to MUT II sub assembly Caution Make certain that the ignition switch is OFF when the M...

Page 725: ...sis connector for poor connections Refer to the previous page and perform TEST 3 2 Maximum stored period 9999 minutes approximately 7 days 3 Maximum number of times to be stored 250 Erase in diagnosis codes following the Multi use Tester or MUT II messages Start engine Does SRS warning lamp illuminate for about 7 seconds turn OFF and then remain extinguished for at least 45 seconds lf yes SRS syst...

Page 726: ...ir I I refer to P 528 20 Vehicles with front I I passenger s air bag refer to P 528 24 12 Right or left impact sensor circuit is open or the wire from the sensor to the SDU is open circuit 13 Right and left impact sensor circuits are open or the wires from the sensors to the SDU are open circuit 21 The circuits for the driver s side air bag module squib are shorted together other or the circuit is...

Page 727: ... 1 2 The multi purpose fuse No 18 is blown or the wire from the fuse to the SDU is open circuit or its resistance value is increased or the battery runs short It takes at least 5 seconds that the SDU detects this fault lf the battery voltage is normal perform TEST 10 Referto P 528 39 lf the battery is run down turn the ignition key to the LOCK position disconnect the negative battery cable and wra...

Page 728: ...994 models l Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconneetins the bat lery_cqble before doing any further work Refer to P 52B 7 No 5 1 2 Remove the rear console assembly Refer to GROUP 524 Floor Console COIIBIIIATTON IGTER 8R6 DIAGNOEIS UIIIT üffiüN tÄft ETEcrr or crRcurr llttcublrhi Motoß Co...

Page 729: ...e a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Caution Do not use excessive force to raise the lock lever 4 Disconnect the red 14 pin connector from the SDU Connect the red harness side SDU connector 14 pin to the connector of the SRS Check Harness Check according to the flow chart belo...

Page 730: ...ck for continuity between the earth and terminal No 12 or No 13 of the body wiring harness s connector which is connected to the instrument panel wiring harness The harness between SDU and instrument panel wiring harness is short circuited Repair or replace the wiring harness at the location of the short cir cuit Refer to P 528 4 The instrument panel wiring harness between SRS warning lamp and bod...

Page 731: ... 2 Up to 1994 models n g to mmd 11 SRS DIACil FIE UI IT n 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Gaution Wait at least 60 seconds after disconnecting the bat tery cable before doing any further work Refer to P 52B 7 No 5 1 J B 2 Remove the rear console assembly Refer to GROUP 52A Floor Console rF 20 lo n Mitsubiehl Motorc Corporstlo...

Page 732: ...orce to raise the lock lever 21 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a groove on the lock lever Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Gaution Do not use excessive force to raise the lock lever 4 ...

Page 733: ...nd the No 19 or 20 terminal eart fr1 indicated system voltage Damaged or disconnected wiring of the ignition fuse No 1 1 power supply circuit Damaged or disconnected wiring of the ignition fuse No 18 power supply circuit Does the voltage between the No 12 terminal of SRS Check Harness connec tor Cs and the No 19 or 20 terminal ear h indicated system voltage Replace the SDU Refer to P 528 2 Malfunc...

Page 734: ...be indicated Their relationships are shown in the following table sRS DIAGNOSIS IJNTT FRONT IIIPACT 8E SOR R H Front impact sensors Short circuited One open ircuited Two open circuited Air bag module Squib Short circuited 11 andlor 21 t2 and or 2 1 13 and or 21 Open circuited l l andlor 22 12 andlor 22 13 andlor 22 The numbers in the boxes are diagnosis codes numbers Refer to P 528 12 Mhsbishi Mot...

Page 735: ...lever and the lock spdng ln case that there is a groove on the lock lever tType 2l Place a screwdriver against the lock spring rnetal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Caution Do not use excessive force to raise the lock lever Disconnect each connector other than 14 pin connector from the SDU Locate the blue and yellow...

Page 736: ...lue Disital 2 q 0 t 49 Replace the left front impact sensor Refer to P 528 0 ls there continuity bewveen the No 3 or No 4 terminal of SRS Check Harness connector and the body earth ls there continuity between the terminalof left front im pact sensor and the sensor bracket The harness between left front impact sensor and SRS diagnosis unit is short cir cuited CONTINUED ON NEXT PAGE Front wiring har...

Page 737: ...t impact sensor normal Standard value Disital 2 000 t Pg ls there continuity between the No 5 or No 6 terminalof SRS Check Har ness connector and the body earth ls there continuity between the terminal of right front impact sensor and the sen sor bracket The harness between right front impact sensor and SRS diagnosis unit is short cir cuited CONTINUED ON NEXT PAGE Replace the sensor cables Refer t...

Page 738: ...528 22 2 Mt6ubl iMotoruCorporatlon July1994 PIYIr 9I1 D ADOED ...

Page 739: ... ieääing to the front impact sensors to the SDU and double lock them NOTE l lf double locking cannot bc madc t tr cennrctor Hö octly or incomplctclv inraald ru chcdt 6 ft rt iträ connecoi corbctlv and rocunly M8991 349 Connector of SRS Check Harness red 2 pin 19FO093 CONTINUED ON P 528 29 TEST 6 Vehicles without front passenger s air bag NOTE _ IMPORTANT 1 After repairing the SRS reconnect the bat...

Page 740: ... 12 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Waft at least 60 seconds after dirconnecting the bat tery cable before doing any further work Refer to P 52B 7 No 5 1 2 Remove the rear console assembly Refer to GROUP 52A Floor Console tlterbhhl llotorr Gorporrtlon D c 19Sl BRE DIAGI osI6 UNIT FROI f IIIPAC T sEl soR R H ffi FROIIT...

Page 741: ...ver and the lock spring In case that there is a groove on the lock lever TVpe 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Gaution Do not use excessive force to raise the lock lever 4 Disconnect the red 14 pin connector from the SDU Connect the now disconnected red harness side...

Page 742: ...ont impact sensor Refer to P 528 0 ls there continuity between the No 16 or 17 terminal of SRS Check Harness connector and the body earth ls there continuity between the terminalof left front im pact sensor and the sensor bracket The harness b6tween left front impact sensor and SRS diagnosis unit is short cir cuited Repair or replace the harness CONTINUED ON NEXT PAGE Front wiring harness is earth...

Page 743: ...S Check Har ness connector and the body earth Yes l ls there continuity between the terminal of right front impact sensor and the sen sor bracket Yes Replace the right front impact sensor No No The harness between right front impact sensor and SRS diagnosis unit is shortcir cuited Repair or replace the harness o Check the driver s side air bag module squib system TEST 6 Vehicles with front passeng...

Page 744: ...52B 26 2 o MltrubishlMotorscorporation Julyl9ott PWUE911 D ...

Page 745: ...mpact sensor and air bag module squib failure m9de9 simultaneously occur in two places the preconditions for lhe respective detection circuits will go out of order For thid reason boih diagnosis codes may not be stored but only one of them may be indicated Their relationships are shown in the following table Perform Front impact sensors Short circuited One open circuited Two open ircuited Air bag ...

Page 746: ...nsort the screwdriver into the gap between the lock lener and the lock spring In case that there is a groove on the lock lever Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Caution Do not use excessiw force to raise the lock lewr Disconnect the red 2 pin connector from the ...

Page 747: ...to MUT II sub assem blv Gaution Gonnest and disconnect either Muhi ure Tester or MUT II with the ignition switch in the OFF pori tion Turn the ignition key to the ON position Using the Multi use Tester or MUT tr erase the diag nosis code memory Refer to TEST 1 Return the ignition key from the ON to the LOCK position and then back to the ON position 3 41 When using th6 MUT When Up t 1tA ll ll tr a ...

Page 748: ...nition key to the LOCK position dis connect the negative banery cable and tape the terminal Gaution Wait at least 60 seconds after disconnec ing the battery cable before doing any further work Refer to P 528 7 No 5 1 2 Disconnect the red 2 pin connector 1 of the SRS Check Harness from the SDU Connector of SRS Check Harness 19FoO93 CONTINUED ON NEXT PAGE Mhubishi Moton Corporation JulV 199f PWUE9l1...

Page 749: ...52B 29 2 NOTES Mitcubighi Motors Corporation July 1994 PWUE9119 D ADOED ...

Page 750: ...hod Hrmoss No 7 connector of the clock sPrtng U lr Clock spring No 2 connector of the clock sPring 1gl cml rirw A SRS Chod Harnes Connecor 191flIt68 il Lö t i Replace the air bag mod ule Refer to P 52B 5 Replace the clock spring Refer to P 528 5 Caution ltlever attompt to measure the circuit resistance of the alr bag module squibl even it you al using the specified tester lf thö circuit resistance...

Page 751: ... bag module squib failure modes simultaneously occur in wvo places the preconditions for the respective detection circuits will go out of order For this reason both diagnosis codes may not be stored but only one of them may be indicated Their relationships are shown in the following table Perform lFs r if it does not become proper even through ITESTE is executed Front impact sensors Short circuite...

Page 752: ...d the lock spring ln case that there is a groove on the lock lever Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Caution Do not use excessive force to raise the lock lever Disconnect the red 2 pin connector from the SDU Connect the red connector O of the SRS Check Har ness ...

Page 753: ... diagnosis code memory Refer to TEST 1 Return the ignition key f rom the ON to the LOCK position and then back to the ON position 3 4 No ls the SRS warning lamp operation normal I f l Replace the SDU Refer to P 528 2 Yes 1 Turn the ignition key to the LOCK position discon nect the negative battery cable and tape the ter minal Gaution Wait at least 60 seconds after disconnccting thc battery cable b...

Page 754: ...of SRS Check Harness con nector normal Standard value less than O rK 3 Malfunction of the driver s side air bag module Replace the clock spring Refer toP 528 72 Replace the driver s side air bag module Refer to P 528 72 1 Ceution Never lttempt to mearurc the circuit resistancc of thc air bas module squibl oyon it you are using the spccificd tcrtcr lf thö circuit resistance is measured with a testc...

Page 755: ... the LOCK position disoonnect the negative battery cable and tape the teiininal Caution Wait at least 60 seconds after dicconnectlngtho battery cable before doing any further work Rcfer to P 528 7 No 5 l 2 Remove the rear console assembly Refer to GROUP 524 Floor Console IGNITION S ITCH ST J 8 rrs il rt O e iET ED CPANKING SIGNAL DETECTION CIRCUIT IT u L H D 1 m ra R H D m 10 SRS DIAGNOSIS UNIT Mh...

Page 756: ...sxcessive force to raise the lock lever 21 Do not insert the screwdriver into the gap betr teen the lock lever and the lock spring In case that there is a groone on the lock lever Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Caution Do not use excessive force to raise the ...

Page 757: ...ry cable and tape the terminal 2 After waiting at least 6O seconds repah or replacc the body wiring hamess Refer to P 528 4 Short qircuit of cranking signal detection circuit wiring harness and power source NOTE _ IMPORTANT 11 lf more than 45 seconds of cranking is required to start up the engine the diagnosis code will be stored in memory but if there is no problem the diagnosis code will be clea...

Page 758: ...any further work lRefer to P 52B 7 No 5 1 2 Remove the rear console assembly Refer to GROUP 524 Floor Console i j i L___l ffiHP8T F ut t tla E lm t EmilFS _ _ T I Jrr ls the SDU lock lever securely locked Insert the all four SDU con nectors correctly and securely to lock the lock lever Malfunction of the SDU Replace the SDU Refer to P 528 2 NOTE IMPORTANT 11 After repairing the SRS reconnegt the b...

Page 759: ...95 models 2 Up to 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Gaution Wait at least 60 seconds after disconnecting the bat tery cable before doing any further work Refer to P 52B 7 No 5 1 2 Remove the rear console assembly Refer to GROUP 52A Floor Console r E D EEEffiM o Wile3 ffiffi H r ffi coNNEcroR EM I B Battery cable r M...

Page 760: ... th gap between the lock lever and the lock spring In case that there is a groove on the lock lever Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Caution Do not use excessive force to raise the lock lever 4 Disconnect the red 14 pin connector from the SDU 5 Connect the now ...

Page 761: ...RS Check Harness con nector Damaged or disconnected wiring of fuse No 18 or damaged of disconnected body wiring harness Malfunction of the SDU Replace the SDU Refer to P 52B 2 1 Turn the ignition keY to the LOCK Po sition disconnect the negative battery cable and tape the terminal 2 After waiting at least 60seconds repair or replace the body widng hamess Refer to P 528 4 ls there a voltage of 9V o...

Page 762: ...TION ffi ffi ffiffi rl FROIfi 8I DE t2 FrcilT SI DE REAR SIDE r 6ns DtAcilosrs lriltT ctRcul rgl ll ml lg J B 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnesting the bat tery cable before doing any further work Refer to P 52B 7 No 5 1 Remove the rear console assembly Refer to GROUP 52A Floor C...

Page 763: ... Caution Do not use excessive force to raise the lock lever 4 Disconnect the red 14 pin connector from the SDU 5 Reconnect negative terminal of battery and turn the ignition key to the ON position 6 Check according to the flow chart below Does the SRS warning lamp remain illuminated when the red 14 pin con nector of the SDU is disconnected Malfunction of the SDU Replace the SDU Refer to P 528 2 Bo...

Page 764: ...the LOCK position disconnect the negative battery cable and tape the terminal Gaution Wait at least 60 seconds after disconnecting the bat tery cable before doing any further work Refer to P 52B 7 No 5l 2 Remove the rear console assembly Refer to GROUP 52A Floor Console J B ffim w EEEq COIIBINATION METER rt FROM SIDE a2 FROI T SIDE REAR SIDE SRS DIAGNOSIS I NIT TARNIT G LIGHT XALFI IICtr I OI DETE...

Page 765: ...sert the screwdriver into the gap btw en the lock lever and the lock spring In case that there is a groove on the lock lener Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustration and push it toward the inside of the unit Caution Do not use excessive force to raise the lock lever 4 Disconnect the red 14 pin connector from t...

Page 766: ...odY wir ino harness or instru mänt panel wiring har ness Refer to P 528 4 Burn out SRS warning lamp bulbs or damaged or disconnected body wir ing harness or instrument panel wiring harness ls there system voltage between the No 19 or 20 terminal earth and the No 14 terminal and No 13 terminal of the SRS Check Harness connector Replace the SDU Refer to P 52B 2 NOTE _ IMPORTANT 11 After repairing th...

Page 767: ...t impact sensor and air bag module squib failure modes simultaneously occur in tvvo places the preconditions for ihe respective detection circuits will go out of order For thid reason boih diagnosis codes may not be stored but only one of them may be rndicated Their relationships are shown rn the following table Perform ITES1_B if it does not become propör even through lTtrS q is executed CONTINUE...

Page 768: ... ohm resistor that corresponds to the resistance of the air bag module isquib and the wiring resistance is cbnnected b etween the terminals of the connector 1 of the SRS Check Harness Reconnect ngga ve terminal of battery Connect the MUT tr NOTE When connecting MUT tr to 1994 models use the adapter harness which belongs to MUT tr suFassem blv Gaution Gonnect and disconnec t the MUT II with the ign...

Page 769: ... Malfunction of front passen ger s side the air bag module Replace the front passen ger s side air bag module Refer to P 528 5 Caution Never attempt to mearuÖ the circuit ruirtance of üc air beg module squibl even if you a uring the rpccified brtcr lf the circuit resistance is measuFd with a tos or apcidental air NorE TM RTANT deploymont will rosult in serious personal injury 11 After repairing th...

Page 770: ...OUP 52A Floor Console 3 Release the lock of SDU connector in accordance with the following procedure In case that there is no groove on the lock lever Tvpe 1l Place a screwdriver against the lock spring metal section of the connector lock lever as shown in the illustration and push the spring horizontally toward the inside of the unit Caution 11 Do not use excessive force to raise the lock lever 2...

Page 771: ...ing harness forfront impact sensor for binds connector for damage and terminals for deformities Replace sensor and or wiring harness if it fails visual check Refer to P 528 0 and P 52B4 2 2 SRS Diagnosis Unit SDUI 1 Check SDU case and brackets for dents cracks deformities or rust Caution The SRS may not activato if SRS diagnoris unit is not installed properly which could rtsuft in serious injury o...

Page 772: ...28 5 Caution The removed air bag modules should be stored in a clean dry place with the pad cover face up 2 Check pad cover for dents cracks of deformities 3 Check hooks and connectors for damage terminals defor mities and harness for binds 4 Check air bag inflator case for dents cracks or deformities 5 Check harness and connectors for damage and terminals for deformities 6 Check clock spring conn...

Page 773: ...k spring may be sevcrcd obstruGting normal opora tion of the SRS and possibly leading to rrious iniury to the vehicle s driver and passenger 9 Install the steering column covers steering wheeland the air bag module 1O Check steering wheel for noise binds or difficult opera tion 1 1 Check steering wheel for excessive free play REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION Refer to...

Page 774: ...er to P 52B4 Gaution The SRS may not activate if SRS harnesses or con nestorc are damaged or improperly connected which could resuh in serious injury or death to the vehicle s driver and passenger 3 FOST INSTAIT AnON NSPECTIOil Reconnect the negative battery terminal Turn the ignition keytothe ON position Doesthe SRS warning lamp illu minate for about 7 seconds and then remain extinguished for at ...

Page 775: ... body wiring harness before proceeding further 3 Read the service data fault duration and how many times memories are erased using the Multi use Tester or MUT II NOTE Maximum stored period 9999 minutes approxi mately 7 daYs Maximum number of times to be stored 250 4 Erase the diagnosis codes and after waiting 45 seconds or more read and write down all displayed diagnosis codes Refer to P 52B 12 2 ...

Page 776: ... and cautionary points for working refer to appropriate INDIVIDUAL COMPONENT SERVtCE P 528 59 Frcrt lmpoqt Sensors 1 Check front upper frame lower for deformities or rust 2 Check front impact sensor for dents cracks deformities or rust 3 Check sensor harnesses for binds connectors for damage and terminals for deformities SRS Diagnois Unit SDUI 1 Check SDU case and brackets for dents cracks or defo...

Page 777: ... pad cover for dents cracks or deformities 2 Check hooks and connectors for damage terminals deformities and harness for binds 3 Check air bag inflator case for dents cracks or deforml ties 4 Install air bag module to steering wheel to check fit or alignment with the wheel Glock Spring 1 Check clock spring connectors and protective tube for damage and terminals for deformities PWUEgl19 c AODCD ...

Page 778: ...d connectors for damage and terminals for deformities 2 lnstall air bag module to check fit or alignment with steering wheel 3 Check iteering wheelfor noise binds or difficult operation and excessive free play Hamess Connec or Body and Front wiring hamcsrl Check harnesses for binding connectors for damage poor connections and terminals for deformities Refer to P 52B 4 o Mit blCri MotoF Corpontaon ...

Page 779: ...g or baking the vehicle after painting Recheck SRS system operability after re installing them 2 lf the SRS components are removed for the purpose of check sheet metal repair painting etc they should be stored in a clean dry place unitl they are reinstalled WARNING CAUTION LABELS A number of caution labels relating to the SRS are found in the vehicle as shown in the following illustration Follow l...

Page 780: ...llation inspection aa 1 Connection of the negative battery cable to the battery 2 Front splash shield extension aa 3 Front impact sensor f l o Pre installation inspection be dented cracked deformed or rusted replace it with a new one 3 Replace sensors with new ones after the air bag has deployed SERVICE POINTS OF REMOVAL 1 DISCONNECTION OF THE NEGATIVE I BATTERY CABTE FROM THE BATTERY Disconnect t...

Page 781: ...RVICE POINT OF INSTALIATION PRE INSTALIÄTION INSPECNON To mount the new front impact sensor visually check it and measure the resistance between the terminals Refer to the previous item INSPECTION 3 INSTALIATION OF FRONT IMPACT SENSOR 1 Bend the wiring harness slightly to the extent that there is no slack and clip securely by using the clip of the front impact sensor 2 Install the front impact sen...

Page 782: ...e special test equipment described on P 52B 3 4 Pre removal Operation Iä irlj isniiion key to the LocK f f f Removal steps o Post installation inspection 1 Connection of the negative _ Qattqry cable to the battery 2 Cup holder 3 Console plug 4 Rear console assembly 5 Connection of the SRS diagnosis unit and each harness connector 6 SRS diagnosis unit SDU Lock lever 2 pin yellow connector to left f...

Page 783: ...wn in the illustration and push the spring horizontally toward the inside of the unit Caution 11 Do not use excessive force to raise the lock lever 21 Do not insert the screwdriver into the gap bctween the lock lever and the lock spring In case that there is a groove on the lock levtr TVpo 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in t...

Page 784: ...erious injury or death to the vehicle s driwr and passengel 5 CONNECTION OF THE SDU AND EACH HARNESS CONNECTOR After connecting each harness connector securely and correctly to the SDU be sure to press down the lock lever of the sDU POST INSTAI LANON INSPECTION Reconnectthe negative batteryterminal Turn the ignition keyto the ON position Does the SRS warning lamp illuminated for about 7 seconds an...

Page 785: ...nce with the ptoedutes lP 52B 79 P 52B 85 1 2 6 tm 4 5 6 7 025llm 1 8ft fr Vehicles without front passenger s air bag Pre removal Operation After setting the steering wheel and the front wheels to the straight ahead position remove the ignition key Air bag module removal stepo a Post installation inspection ar 1 Connection of the negative battery cable to the battery arp ft 2 Air bag module 3 Cove...

Page 786: ...om the back side 2 When disconnecting the connector of the olbck spring from the air bag module press the air bag s lock toward the outer side to spread it open Use a screwdriver as shown in the figure at the left to pry so as to remove the connector gently Cautirn 1 When disconnesting the air bag module ölock rpriq Gonnocdor tdre care not to apply exoosiue iorco b it 2 Tho snorrcd air bog module ...

Page 787: ...there is a groove on the tock lever Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groo as shown in the illustration and push it toward the inside of the unit Gaution Do not use excessive force to rdite the lock level l2l Disconnect the clock spring connector red 2 pin frorrt the SRS diagnosis unit INSPECTION AIR BAG MODULE lf any improper part is fou...

Page 788: ...s cracks or deformities 5 lnstall the air bag module to steering wheel to check fit or alignment with the wheel CLOCK SPRING lf as result of following checks even one abnormal point is discovered replace the clock spring with a new one 1 Check connectors and protective tube for damage and terminals for deformities 2 Visuafly check the case and the gears for damage To air bag module To SRS diagnosi...

Page 789: ...inuity between terminal 1 and terminal 21 and terminal 2 and terminal 22 of SRS Check Harness connector using a digital multi meter Standad value less than O 4O No 1 connector No 3 connec IOr No 4 connec tor No 5 connec tor No 6 connector Termi nal 1 Termi nal2 Termi nal 3 Termi nal 4 Termi nal 1 Termi nal2 G o o o c o o G_ To crurse control unit To ACC power To horn relay To radio To horn switch ...

Page 790: ...tion Make oertain that the ignition switch is OFF when the Muhi use Tester or MUT II is connested or dis connested 3 Reconnect negative terminal of battery and turn the ignition key to the ON position 4 Conduct self diagnosis using Multi use Tester or MUT II to ensure entire SRS operates properly except open cir cuit of air bag module Diagnosis code No 22 Refer to P 528 12 1 5 Turn the ignition ke...

Page 791: ...wheel Fay not f9 completely rot ational during a iurn or the flat cable within the clock spring mäy be seYered obstructing normal operation oi the SRS and possibly leading to serious injury to the vehicle s driver 9 CONNECTOR OF SRS DIAGNOSIS UNIT AND CLOCK SPRING HARNESS CONNECTOR After connecting the harness connector securely and correctly to the SRS diagnosis ünit be sure to press down the loc...

Page 792: ...528 70 2 MltlublthiMotoEcorporrtion Julylgo4 pWUEgttg D ...

Page 793: ...normal 2 INSTALTANON OF AIR BAG MODUTE 1 Arrange the wiring of the horn switch as shown in the figure at the left and hook up in place 2 Install the air bag module taking care that no wiring is caught by it POST INSTALIATION INSPECTION After installing the clock spring the steering wheel the column covers and the air bag module check steering wheel of noise binds or difficult operation Reconnect t...

Page 794: ... 52A Floor Console 1 9 Clock spring and SRS diagnosis unit connection 10 Clock spring and body wiring harness connection c 11 Clock spring r a o Pre installation inspection tO Nm 4 0 kgm 29ft bs 5Nm 0 5 ksm f ft fu 1eFo274 Air bag module driver s sidel removal steps a o Post installation inspection 1 Connection of the negative battery cable to the battery t a 2 Air bag module 3 Cover 4 Horn contac...

Page 795: ...m the back side 2 When disconnecting the connector of the clock spring from the air bag module driver s side press the air bag s lock toward the outer side to spread it open Use a screwdriver as shown in the figure at the left to pry so as to remove the connector gently Caution 1 When dieconnesting the air bcA modub clodr rying oonnector taks caru not to eely mtdn for b it 2 The nmqred dr brg modu...

Page 796: ...e to raise the lock lever 21 Do not insert the screwdriver into the gap be tween the lock lever and the lock spring In case that there is a groove on the lodt lever Type 2l Place a screwdriver against the lock spring metal section of the connector lock lever groove as shown in the illustra tion and push it toward the inside of the unit Gaution Do not use excessive force to raise the lock lever 2 D...

Page 797: ...asurcd with a teütor accidentalair bag deployment will result in seriour perconal injury 1 Check pad cover for dents cracks or deformities 2 Check the air bag module for denting cracking or defor mation 3 Check hooks and connectors for damage terminals for deformities and harness for binds 4 Check air bag inflator case for dents cracks or deformities 5 Install the air bag module driver s side to s...

Page 798: ...r continuity between terminal 1 and terminal 21 and terminal 2 and terminal 22 of SRS Check Harness connector using a digital multi meter Standard value less than 0 rK ADDGD No 1 connector No 3 connec tor No 4 connector Termi nal 1 Termi nal 2 Termi nal 3 Termi nal 4 Termi nal 1 Termi nal 2 o o G o o o To cruise control unit To ACC power To horn relay To radio To horn switch To cruise control swit...

Page 799: ...s properly except open circuit of air bag module Diagnosis code No 22 and 25 Refer to P 528 12 5 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the battery cable before doing any fufther work Refer to P 52B 7 No S 11 INSTALLATION OF CLOCK SPRING Align the mating mark and NEUTRAL position in...

Page 800: ...heel all the way in both directions to confirm that steering is normal 2 TNSTAUÄnON OF AIR BAG MODULE DRtVER S S DEI 1 Arrange the wiring of the horn switch as shown in the figure at the left and hook up in place 2 Install the air bag module taking care that no wiring is caught by it 7 SRS warning lamP POST INSTALLATION INSPECTION 1 After installing the clock spring the steering wheel the column c...

Page 801: ...be wom by personnel performing these procedures or by people in the sur rounding area 1 DEPLOYMENT INSIDE THE VEHICTE lwhen disposing a vehiclel 1 Open all windows and doörs of the vehicle Move the vehicle to an isolated spot 2 Disconnect the negative H and positive battery cables from the battery terminals and then remove the battery from the vehicle Gaution Wait at least 60 ceconds aftcr dbconnc...

Page 802: ... front passenger s side connector red 2 pin and the body wiring harness connector 6 Connect two wires each six meters 20 feet long or more to the two leads of SRS AIR BAG ADAPTER HARNESS A and cover the connections with insulation tape The other ends of the two wires should be connected to each other short circuited to prevent sudden unexpected deployment of the air bag 7 When the air bag driver s...

Page 803: ...neal the vehicle Wear safety glasses 2 The inflator will be quite hot immediately following the deployment so wait at leact 30 minutes to allow it to cool before attempting to handle it Although not poiconouf do not inhalc gar from air bag deployment See Deployed Air Bag Module Dbpoc l ProF dures P 528 851 for post deploymert handling h structions 3 lf the air bag module failr to deploy whon thc p...

Page 804: ...ape The other ends of the two wires should be connected to each other short circuited to prevent sudden unexpected deployment of the air bag 4 lristall nuts that are no longer needed to the four bolts on the rear side of the air bag module and tie on some thick wire to secure to the wheel 5 Take the SRS air bag adaptor harness B that is connected to the wires pass it beneath the old tyre that is a...

Page 805: ...eploy the air bag Caution 1 Before deployment check carcfillly to bc rurc that no one is nearby 2 The inflator will be quitc hot lmmcdiatoly fol lowing deployment 30 wait 8t least 30 minutes to allow it to cool bsfore attempting to handle it Ahhough not poironour do not inhale gas from air bag deployment See Deployed Air Bag Module Dirpoul Procedurer refer to P 528 51 for poctdegloymcat han dling ...

Page 806: ...ER HARNESS A and cover the connections with insulation tape The other ends of the two wires should be connected to each other short circuited to prevent sudden unexpected deployment of the air bag 4 Connect the deployment wires to the SRS air bag adapter harness A Pass it beneath the tyre and wheel assembly and connect it to the air bag module 5 Pass the thick wires into the hole of the air bag mo...

Page 807: ...edures above are followed do not go near the module Contact your local disttibutor DEPLOYED AIR BAG MODULE DISPOSAL PROCE DURES After deployment the air bag module should be disposed of in the same manner as any other scrap parts except that the following points should be carefully noted during disposal 1 The inflator will be quite hot immediately following deploy ment so wait at least 30 minutes ...

Page 808: ...NOTES Mlt ubishi ltbto t CorpoEtlon D c l l PUY rEgfi9 AOOED ...

Page 809: ...t3 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 528 Supplemental Restraint System before beginning any service or maintenance of eny component of the SRS or any SRS related component NOTE The SRS includes the following components impact sensors SRS diagnosis unit SRS warning lamp air bag module clock spring and interconnecting wiring Other SRS related com...

Page 810: ... FAN MOTOR Refer to GROUP 14 ELECTRONIC CONTROL SUSPENSION ECSI Refer to GROUP 33B ELECTRONIC CONTROL susPENsloN Ecsl Refer to GROUp 33B ANTI LOCK BRAKE SYSTEM ABSI Refer to GROUP 35 DOOR GLASS AND REGUI ATOR POWER WINDOWSI Referto cRoup 42 DOOR HANDLE AND LATCH DOOR LOCKINGI Refer to GROUP 42 WINDSHIELD WIPER ANDWASHER RefertoGROUP5t REAR WIPER AND WASHER RefertoGROUP5l HEADLAMP WASHER REfET tO G...

Page 811: ...has been installed in the 3000GT iZi fne ÖÄS includes the followang components impact sensors SRS diagnosis unit SRS warning light air bag modute clock spring intercönneciing wiring Other SRS related comPonsnts that may have to be removed installeä in äonnection with SRS service or maintenance are indicated in the table of contents by an asterisk WARNING 1 lmproper service or maintenance of any co...

Page 812: ...TOR REfEr tO GROUP 14 ELECTRONIC CONTROL SUSPENSION ECS REfEr tO GROUP 33B ELECTRONIC CONTROL susPENstoN Ecsl Refer to cRoup 338 ANTI LOCK BRAKE SYSTEM ABSI Refer to GROUp 35 D X R GI ASS AND REGUI ATOR POWER W NDOWSI Referto GROUp 42 DOOR HANDTE AND LATCH DOOR LOCKINGI Refer to GROUp rt2 WINDSHIELD WIPER ANDWASHER RsfertoGROUp5t REAR WIPER AND WASHER Rsfcrto GROUP 5l HEADLAMP WASHER Refer to GROU...

Page 813: ...d reaches 1 250 1 290 and remains constant for at least one hour 2 f the voltage of each cell reaches 2 5 2 8 V and remains constant for at least one hour Caution 11 Take care gince the battcry f uid lcvel may rise during charging 21 Keep all sources of ftrp awty wttilc charging because there ir dangor of explosion 31 Take care not to do anything that could generate sparks while charging 41 When c...

Page 814: ...headlamps on for 15 seconds o Turn headlamps off for 2 minutes to allow battery voltage to stabilize o Disconnect cables o Read open circuit voltage A4 i LOAD TEST o Connect a load tester to the battery r Load the battery at the recommended discharge rate See LOAD TEST RATE CHART for 15 seconds e Read voltage after 15 seconds then remove load REPLACE battery VOLTAGE IS LESS THAN I MINIMUM LISTED I...

Page 815: ...Tool Number Name Use M8990803 Steering puller wheel Removal of steering wheel LH drive vehicles only taDl CAUTION SRS eoiöreiemövat of air bag modulc rcfcr to QIOUP sie SiS Service Preceütions and Air Bq Modulc and Clock Spring t üal e a Steering lock cVlindcr tcmovll stcps 1 Air bao module 1 Refer to GROUP 528 Air Ba Module qnd Clock Spring 2 Steering wheel l 3 Knee protector Aefei to GROUP 52A l...

Page 816: ... down with a Phillips head screwdriver small size one to remove the steering lock cylinder INSPEGTION E q Aa IGNITION SWITCH INSPECTION 1 Remove the knee protector the column cover lower and the column cover upper Refer to GROUp S2A Instru ment Panel Disconnect the wiring connector from the ignition switch and key reminder switch and connect an ohmmeter to the switch side connector Operate the swi...

Page 817: ...n ribbon cable in the clock spring orthe like could occur As a result they might hinder propel operation of the SRS resulting in serious iniury METERS AND GAUGES SPECIFICATIONS GENERAL SPECIFICATIONS Items Specif ications Speedometer Type Tachometer Type Fuel gauge Type Fuelgauge unit Type Engine coolant temperature gauge Type Engine coolant temperature gauge unit Type Oil pressure gauge Type Boos...

Page 818: ...58 F l Fuelgauge resistance O Between A B Between A C Between B C Engine coolant temperature gauge resistance o Between A B Between A C Between B C Oil pressure gauge resistance O Boost meter resistance O 18 6 21 6 0 73 85 193 4 196 4 7 61 7 73 104 13 5 Approx 254 Approx 101 Approx 153 Approx 51 Approx 139 Approx 190 Approx 42 Approx 72 4G48 Q F 25l 8192 WHTI 121136 6H9 160 180 80 91 10r114 t 100 ...

Page 819: ...ed on a jack 6 Attach anchoring bars on the tie down brackets and secure their ends to the anchor Plates 7 Make sure the tension on the right and left bars is the same Also be sure there is enough tension on each bar 8 Attach a chain or wire to the rear tie down hole Make sure the end of the wire or chain is secured firmly 9 Take all other necessary precautions 1O Use a speedometer tester to measu...

Page 820: ... the engine tachometer and tachometer readings Replace tachometer if difference is excessive Standard value 1 000 rpm 100 rpm 3 000 rpm 150 rpm 5 000 rpm 250 rpm 6 000 rpm 300 rpm Caution The engine speed signal output from the engine is one third of the actual speed When the engine speed is measured make sure that the engine tachometer is placed in the 2 cylinder range The real speed is indicated...

Page 821: ...ges smoothly when float moves slowly between point F highest and point E lowest Fuel Gauge Unit Float Height Move float and measure the height at point F highest and point E lowest with float arm touching stopper Standard value Point F 18 6 21 6 mm 0 73 0 85 in l Point E 193 4 196 4 mm 7 61 7 73 in FUEL SENSOR INSPECTION Connect f uel gauge unit to battery via test lamp 12V 3 4W lm merse in watör ...

Page 822: ...ine coolant temperature gauge unit Test lamp is not illuminated Pointer of gauge does not swing ENGINE COOLANT TEMPERATURE GAUGE UNIT INSPEC TION To check remove engine coolant temperature gauge unit from the thermostat housing Engine Coolant Temperature Gauge Unit Resistance 1 lmmerse unit in 70 C 158 F water to measure resistance Standard value 104 13 5 O 2 After checking apply the specified sea...

Page 823: ...IMPLE INSPECTION Check the test lamp and gauge conditions C Test lamp is illuminated Pointer of gauge does not swing Test lamp is illuminated Pointer of gauge swings 3 Test lamp is not illuminated Pointer of gauge does not swing Miteubishi MotoF Corporation May 1902 PWUEgl19 ...

Page 824: ...ver upper 4 Meter bezel 5 Combination meter 6 Vehicles speed sensor SERVICE POINTS OF REMOVAL 2 REMOVAL OF COTUMN COVER LOWER 3 COLUMN COVER UPPER After the screws have been removed remove the covers while making sure not to break the grippers INSPEGTION Ee A x VEHICLES SPEED SENSOR INSPECTION 1 Remove the vehicles speed sensor and connect as shown in the illustration using a 3 10 k resistance 2 u...

Page 825: ...ASSEMBLY AND REASSEMBLY Disassembly steps 1 Trip counter reset knob 2 Meter glass 3 Window plate 4 Speedometer 5 Fuel gauge 6 Tachometer 7 Printed circuit board 8 Meter case COMBINATION GAUGES REMOVAL AND INSTALLATION Removalsteps 1 Instrument panel Refer to GROUP 52A Instrument Panel Distribution duct IRefer to GROUP 55 Ventrlators lnstrument Panel 1 2 Combination gauge Mitsubishi Motors Gorporat...

Page 826: ...terminals with circuit tester Standard value Approx 42 0 ENGINE COOTANT TEMPERATURE GAUGE INSPECTION 1 Remove the lG terminal screw from area A 2 Measure resistance between terminals with circuit tester Caution For inspection use a circuit tester which uses a measurement current of 4mA or less Standard value A B Approx 51 O A C Approx 139 O B C Approx 190 O 1 6F0143 I 6F01 4l o Mltrublrhl Motorc C...

Page 827: ...SSEMBLY AND REASSEMBLY Disassembly steps 1 Gauge bracket 2 Gauge glass 3 Window plate 4 Oil pressure gauge 5 Engine coolant temperature gauge and boost meter 6 Clock 7 Printed ircuit board 8 Gauge case Mitsubishi Motors Corporallon May 1992 PWUEgl19 ...

Page 828: ...ng lamp Oil pressure warning lamp Door ajar warning lamp Brake warning lamp Low fuelwarning lamp Engine coolant temperature warning lamp Check engine warning lamp Supplemental restraint system warning lamp Anti lock braking system warning lamp 4 wheel steering oil level warning lamp Active aero system warning lamp 3 0 1 4 1 4 1 4 1 4 1 12 1 4 1 4 1 4 1 4 1 4 t 4 1 4 3 4 1 4 1 4 1 4 x2 1 4 1 4 1 4 ...

Page 829: ...cal direction Horizontal direction Driving lamp aiming Up to 1994 models Vertical direction Horizontal direction Resistance between resistor terminals R H drive vehicles with dimdip lamp Limit Headlamp intensity 60 mm 2 36 in below horizontal H Position where the 15 sloping section intersects the vertical line V 140 mm 5 5 in below horizontal H Deviation of light beam axis is within 394 mm 15 5 in...

Page 830: ...54 19 1 LIGHTING SYSTEM Special Toots Tool Number Name Use M8991502 MUTLI sub assembly Allmodels ETACS input checking ROM pack Mltsubishi Motors Corporation July 1993 PWUE9119 B ...

Page 831: ...54 19 2 O t Mitsublshi MotoB Corporation July 1993 PWUEglr9 B ...

Page 832: ...p lamp Up to 1994 modelsl CIRCUIT DIAGRAM FUSIBLE LINK LAMP RELAY DRIVING LAMP RELAY A 03X HEN LATP kttFLi Vire colour code xnsr Ac Ro8or Ec Bi Ä 3 bgällflls o 8i96 Sl k Rlä Mlt ubitha Moton Corporation July 1 l9rl PWUE91 D DEDI CATED FUEE HEADLAMP RELAY A 01X ffi Y tlhlte YrYel tovr BB Sky blue P Pl nk V Vlolst trvt8ED ...

Page 833: ...LIGHTING SYSTEM Troubleshooting 54 21 HEADLAMP RELAY HEADLAMP RELAY DRIVING DRIVINC kBtf häilä DEDICATED FUSE J I E c I 9 t Btfffi sYslEtl D 46 lffiffiffi 3e sa e za Mhsubishl MotoB Corporation May 1992 ...

Page 834: ... I PASSING I swrTcH 6 I J ffil o C J mc B Yl rs colour cocle B Black LG Llght oreen G Groen L Btua tttg lC R080IA EC BR Brown 0 0ranee GR Grav R Reo r c 65 E c 67 1 A llx 2 A ltX a I a i E I u I J 4 r lz gtt i u r oFF _ oFF l ni f ffiff f 1a lrenrrNc swrrcH I 1 7 C 75 Mhrublrhi Motorc Colpor tion MaY 1992 FWUE9lt9 t BI l ü ü jisi 8B 8kv b uo ...

Page 835: ...LAI R 88 fiffitEffii on ff ilufiIkÄffi8fi Hä ffiÄl88iEÄon THEFT ALARII 6YSTEII I lrl DEFOGIEN I J frffimYffi csilRq I J I J L R D 33 EH IUMPER coNNECf o ffi o ro b sd l r D 45 ffil PtBÄ duo ffi c 78 E c 66 EEEEil cLocK DEFüi ER EbE8lffiÄfi SffiF r ffiättffi bqir sr LEvELrMi IIETER AflD GAIreS REAR FE LATF REAR VIPER AT D YA EN ACf IVE AEßO 8YEIEI Sbrtrr E ffiilPÄig tt0ft ffi st6 tEr XETER AT D GAI...

Page 836: ...fOR RH A 1 lrl E 15rl 17r2 l1 Vehlcles wlth theft alarm system x2 Vehlctes wlthout theft alarm sygtem Vl re co lour cocte P Erack tGiLlght gresn x 35 Ac R0a0rB EcER Brown u uranoe ETACS CONTROL UNIT C 55 z ffi rl ffi m ssyffiffi Er6f ffiffi W Xhlt6 I Ietlow S8 Skyblur P Plnk V Vlolet G Green GR Gray ktRiH q ä ot v Mit3ubichi Motors Corporatlon May 1992 PWUE9119 ...

Page 837: ...igYEANAT r 0N smÄ n 2R B ffiklffir D f e c 03 FEml ffi c 3 c 78 ftfrtrT ll It6ldrfsll D 46 rfi FRffiTET6 I F Tfl nffiifrilr5lläfiElI ßx3ä AC ROEtlo EC Mitsubishi Motors Corporation July 1994 ADOED 14 1 i i t 26i I II I il I Dl I l I ll I li CJI I I I I I 4R I y___J 1 A 54 d G HEADLAMP 2 GH l l tttn I A 74 tr HEADLAMP 2 LH 1 A 91 PWUE9119 D ...

Page 838: ...cH I l r r rüt i LIGHTING sulrcH i c 09 jm 7c slffiffil mc 8 Wire colour cocle B Brack LG Light BR Br own 0 0range Mltrublchl Motors Cotporatlon July 199t0 ö 0 8en G Green L B t ue GR Gray R RBo PWUEgl19 D U Yni te Y Ye r row SBrgky bt u P Pink V Violet ADO D ...

Page 839: ...LAMP RELAY A OlX rr35 AC R0E0S EC Mitrubishi Motoru Corporation July 19911 mhtm JUMPER CONNECTOR A 83 B d8tfiE8 o c 03 ffi D 04 n Elr ErEeE3e4tSC6grEtl t l BoFrßeß3ßaB6 tr l ffi DED I CATED FUSE HEADLAMP LEVEL I NG SYSTE T HEADLAMP TIASHER COMBINATION METER A HI 10 A 74 A 92 1 HEADLAMP LH L0 Hr A 91 A il 1 m m ffiffiffi ADOCD ...

Page 840: ...40 AT TI LOCK BRAKE SYSTEI NO CONNECTI ON A 42 NO CONNECTION NO CONNECTION DIODE A 41 EB r A 43 A 43 B E c 24 I EEIEEEI llsl lEl9lrdrlrär l l 17 c ot I LIGHTING i swtTcH l COLUMN SWITCH I D MMER I PASSING I SWITCH l ire colour B Bracr BR Br own G Green GR Gray L Btue V Viotet SB Sxy otue LG Lisht gr 0 0r ange P Pink R Rec Y Yet tow Y Uhite Mltlubl hi Motors Corporetlon July 199t1 ADDED ...

Page 841: ...adlamps in the UP position When the lighting switch is placed in the TAIL or OFF position current flows through the multi purpose fuse to the lighting switch and the ETACS control unit Then the DOWN timercircuit in the ETACS control unit is operated and current flows from the ETACS control unit to the DOWN contacts of the pop up motor U D UP DOWN switch the coil of the pop up motor relay and earth...

Page 842: ...mp doesn t illuminate Check the bulb Can t switch from low to high beam or vice versa check the dimmer switch Refer to P 54 4 The high beam indicator lamp doesn t illuminate The high beam of the headlamps is normal o Check dedicated fuse No Check the bulb a Headlamps do not rise Up to 1994 models They rise only when the lighting switch is operated Check the pop up switch input signal Refer to P 5 ...

Page 843: ...pter harness which belongs to MUT II sub assembly Gaution Connest and disconnect either MUT or MUT II with the ignition twitch in the OFF position 2 Check if the buzzer of the MUT or MUT II operates when each switch is operated lf the buzzer operates the input signals are being sent to the ETACS unit so that switch can be considered to be function ing normally lf not the switch or switch input cir...

Page 844: ...9ütLi Ui ro colour code B Black LG Ltoht oreen G Green L Btue ßngü rc n0S0g lg 8R Brown O 0ransc CR cray R f d Mftsubishi Motorc Corporation July 1994 PWUE9119 D LAMP A 05X ffi DED I CATED DRIVING LAMP RELAY A 03X tTtfl ll rll tLat TAIL LAMP POSITION LAIP AND LICEITCE PLATE LAMP HEADLAMP RELAY U lhl te y Yelt0lr 8B 81y plru P Plnk V Vlotot REVISED ...

Page 845: ... LAMP RELAY RELAY DEDICATED FUSE LE0Bttffi SYSTEI HEADLAIIP VAEHER I I I I I I I I I I I I I I I I I I I I I I I L REAR FOG LAilP ü I J I v ot tr DRIVII IG LA P GM R I 2 A 56 A 0 COMBINATION METER D 46 ffitrffi ffiEn IEtrItrE trEE a A 54 A 74 Mhsubirhi Motor3 Corporatlon May 1992 PWUEgl19 ...

Page 846: ...RUNNING LAMP RELAY 1 A 36 A 35 ffi trt I u lr c J EfiF E cH A I äÄ c 78 J B 6 c ooT ffi G R TAIL LAMP RELAY äffiAi ffF DAYTI IE RUNNING LAMP RELAY 2 DRL CONTROL UNIT A 3 ffi J I u EI roreü rc RoooaA Ec Bn A 8I b9ö iH n 8i Ps k RiH lvi re colour cods Mitsubishi Motors Corporation May 1992 PWUEgl19 t iliÄl t Y llBt sB sky bruo ...

Page 847: ...ELAY 1 HEADLAMP 1 IYR i H r uuE c 03 1 ffi d c 6 ffi ffi A 1lX ffi ffi c 6 CONNECf OR COLUMN SWITCH LIGTfIING swrTcH I mm oruunn I PASS NG I swrTCH J ts 6 I J c 75 ffi n o rtp illtatJra v I v ilDtot rtol ca cu E r ra D 24Ä l QFF l FF L oru olI H Mitsubishi Motors Corporation May 1902 ...

Page 848: ...R EbEffiAsiÄfi 89SEF ffit EFt t ffi Bgsofr LEvELrilc TETER AIID GAI GB REAR FOG LATP REAR UIPER AND WASHER ffifütFH hff ACTIVE AFTO sYBTEil AIR CONDITIü ER 8ffi 8 uÄVg iE0Bttffi sysrEr II TER AIiID CAUGE REAR I OG LA IP REAfuilTPER Atü DEFTX GER I J HEADLAIIP POP UP SWITCH D 0 I tffi I J L R POF UP RELAY D 33 tffil l o colour code r0rss rc R0ooso Ec EÄlA 8 bgölif o 8R96 l L 81uo R Red CONNECTION i...

Page 849: ...X ffiffi HEADLAMP POP UP IIOTOR ßH A 1 HEADLAMP POP UP MOTOR LH A 58 ffi a E 16 1 72s2 15r1 1 1 2 ETACS coI TRoL UNIT C 55 z l tl ffiffi EE EEEtrI IAGNOSIS 1 Venlctes wlth theft alarm system x2 Vehicles without theft alarm syst m ffiffi ffi Mltsubishi Motors Corporation May 1992 REAR SIDE ...

Page 850: ...bublrhi Motoru Corporrtion July 1994 ETSS tu ffi8ftfi TAIL LAMP RELAY PüBÄCATED ACTIVE AERO SIEIEI AUTO CRUISE CON ROL sY8TBI glgtrütrE CL EK DEFIGGER ELECTRO IC CONTROL EUSPENSIOI EYETE I GLOVE BOX LATP AT D INSPESTIü LAUP HEADLAIIP LEVEL I I G SYSTEI ffiffiE IPI SYST il F lopfl n REAR FOG LNIP REAR TIPER AND WASMR TAIL LAIIP Rgf rIlru h0rP ll Xal i iilX rLäIA Lffi i Ht A 54 2 RH f fir A 4 PWUE91...

Page 851: ...IL LAMP RELAY PTBAWO EÄbrrro 89ghau 0ilIÄEtS6 I v 46 c 8 c 66 ffi 88hrnor UNIT A 3 btttren Wi re colour cocte ö biaöl LöI Isnt srsen G Green t Blue V hite Y Yet low SB 8t v Dlue BnTöiöin ö 07änriö GRIGiäv R Reo P Pink v vioret Mltrubishi Motors Corporation July 1994 PWUEgtlg D ADOCD ...

Page 852: ...ing DRL CONTROL UNIT DAYTIME RUNNING LAMP RELAY 72 c 01 UMN TCH HTING TCH I ml c 8 H l 6 8 o r E fl f rs6_ c Rorco c EnTö öün öTö7äfl8 0 n 8Ä96 sl k FiH F Fiil ü v Älsl Mitrublshi Motors Corporation July 1994 PWUE9119 D SB 8xy orue ADOED ...

Page 853: ...54 33 4 O NorEs Mitsublshi Motors Corporation July 1994 PWUEgl19 D ...

Page 854: ...it switch ON and OFF respectively the tail lamps illuminate without the headlamps illuminating o lf the lighting switch is set to the HEAD posi tion the headlamp relay switches ON and the headlamps illuminate Pop up operation Operation by lighting switch lUp to 199t1modelsl o In vehicles with daytime running lamps when the ignition switch is turned to ON the popup relay normally switches on indepe...

Page 855: ...minate The upper beam of head lamos is normal a Check dedicated fuse No check the bulb a Headlamps do not rise Up to 1994 models They rise only when the ignition switch is OFF and lighting switch is set to the HEAD Dosition Check the potrup switch Refer to P 54 59 Check the pop up switch input signal Refer to P 54 27 l Check the popup relay Refer to P 54 57 They rise only when the ignition switch ...

Page 856: ...IRCUIT DIAGRAM FUSIBLE LINK TAIL LAMP RELAY A 05X H DEDICATED HEADLATP kruft l Wi re co I our codo n Jtack l G Light oreen XltOS tC nOOO4 lC BR Rrowrr 0 Jranse Miteublshl MotoB Corpor tlon July l9grt G Green L Blue CR Gray R Reo PWUEgl19 D HEADLAMP RELAY f f hl te Y Yer row 68 8ky blue P Plnk V Vit tet ...

Page 857: ... SYSTEII HEADLAI P VAS IER REAR FOG LAMP COMBINAT ON METER HEADLAMP RELAY 14 I IEADLAMP RELAY DRIVING DRIVING LAMP LAMP RELAY RELAY J t u c I J I w C I tr l J I u CU d tL ä ä il1 Lia iatJ KtÄgtgJt I v t A 54 A 74 D 46 Mltsubishi MotoB Corpontion May 1992 PWUEgl19 ...

Page 858: ...IODE A 38 bttto RESI DIODE A 40 1 A 43 B STOR A 42 IGEI DIIT DI LAI P R A 81 m ELAY 1 J I 9 J I u tf crr o I g rr a co I w DIODE A 39 DI ODE A 41 l l re co lour cocle B Black LG Llsht srBen tl l lc l080tu lc BR Brown 0 oranse ä l Uhits P Pink DIM DTP LAIIP RELAY 2 A 82 I I u ro c I Mifgblshl Motors Corporatlon May 1992 PWUEgl19 vlv Äi3t BB 8ky bru ...

Page 859: ...DE RELAY rJ DIODE J DIME T RÄh r PÄbDIP RELAY 3 J I u ro 1 c 65 El 2 A 111 ffi 17 dbil c 81 DI ODE c 24 c 24 r ffif Fffi l IEEEEEEE I COI UMN T swrTCH I rruuun t PASSING I swrTCH E1 lu o o ml ton_ I 3 C 73 la lrenrtnc st lrcH I 7 6 I J c 74 Mitsubishi Motors Corporation M8y 1 192 ...

Page 860: ...N HEADLA P POP UP STIITCH D 0 1 rffiffi CLWK DEFOGGER 8ffiT trä hfffi LAIIP sscf LEYELT G ISTER AilD GAI GE REAR FM LAP REAR YIPER AND YABHER URN SIGNAL LAIP AND HAZARD LAYP ACTIVE ASRO SYSTEY AIR COI DITIONER 8 Ah88uAFE tEilBttffi sYsrEx I ETER AND GAT GE REAR FOG LI TIP R3fuHrPER AlrD I J NO OONNECTI ON rh trl D 34 b od ffi üc Effiffiffi DEF OGGER ELECTRONIC c0ltTR0L BUSPEI 8ION SYATET XETER AND...

Page 861: ...OR RELAY A 08X HEADLAI IP POP I P MOTOR GII A 71 ETACS CONTROL UNlT C 55 z lffi tl ffil l1 Venlcles wlth theft atarm system e vehictos without thett erlarm system ETEH ffiffi or t I J o1 l oFF Mltsubiehi Motors Corporatlon May 1992 PWUE9lr9 ö8ffiffiI ...

Page 862: ...C RoA3t EC Mitrubishi Motors Corporation July 1994 E PWUE9119 D ffikfffie HEADLAMP RELAY A O1 II4II EJ D 04 F W B0ß rlttß3l3aB6F8Btl 1 25R tJ DED I CATED FUSE HEADLAIIP LEVEL I NG SYSTE I HEADLA IP YASHER COMB NATION METER A v 1 n za A 92 HEADLAMP LH 10 HI A 91 A 54 ffilffil ATX ED ...

Page 863: ...DIODE A 41 DI ODE A 40 DIM LAMP RELA A 81 ffi DIP Y1 COLUMN SWITCH t D MMER I PASSING I S I ITCH J B lVire colour B Black BR Br own G Gr een GR Gray L Btue V Violet SB St y otue LG Liont 9r 0 0r ange P Pink R Reo Y Yer tow U White 5 C B llrFf T ll lt5t6r l8tl E July 199t1 c 24 Il tl L lcl cl9l I l 6 l lE lS rdr thärol tE J Mitsubishi Motor Corporation code ...

Page 864: ...illuminate dimmer than normally Pop up operation Operation by lighting switch Up to 1994 modelsl o In vehicles with dim dip lamps when the ignition switch is turned to ON the popup relay nor mallyturns on independent of the lighting switch and the ETACS up timer circuit operates setting the headlamps to the UP position NOTE For other operation than the up timer circuit in side the ETACS refer to P...

Page 865: ... illuminate check the bulb Can t switch from low to upper beam or vice versa Check the dimmer switch Refer to P 54 4 The upper beam indicator lamp doesn t illuminate The upper beam of the headlamps is normal a Check dedicated fuse No check the bulb a Headlamps do not rise Up to 1994 models They rise only when the ignition switch is OFF and lighting switch is set to the HEAD position Check the potr...

Page 866: ...c0NNECroR A rtl ffi c 6 m c 72 EE KEY ION ALTIVE AERO SYETBI DMR LAXP LT GGAGE COXPAIilIENT LAI P AIÜ tnOR YARN INS LAP ACTIVE AERO nsteu CENTRAL DO n LMN II G 8Y8TEX cnAKin G SYSTET 4fS FLUID LEVEL WARNING LATP HPI S 6TEI STARTING SYSTEY i äf stztl c 72 IEEEffi N xrtS tc PoEt2 lc Mlbubishi Motoß Corporation May 1992 c 56 C 28 PWUEgl19 ...

Page 867: ...lN t ffihtffi fiIEFT ALARX s ETEX C 61 rs C 27 413 S 4 9 I tv L t E E 16 J EI 9 u c 70 l I E DIAGNOSIS CONNECTOR l1 Vehicltss trithout theft älarm 5y5l em t2 Vehicles with th ft alarm svst em 13 LH rrr lve vohiclos 14 Rll clr lvB vshlcles p4ppEncnn s rP8ÄyER s SIDE iJlDE L y J DOOR SW ITCH l1 g c 541 r1 c 5s dffi GI D v REAR SIDE rffil E Mltsubirhl Motort Corporation May 1992 PWUEgl19 mlffi ...

Page 868: ... in the oFF position open any door and all lamp will come on o With all lamps turned on with the ignition switch in the OFF position close all doors and the timer circuit inside the ETACS unit will operate in the same manner as the room lamp to dim all lamps When the ignition switch is placed in the ON position with all lamps turned on with the timer in operation the same opöration as the room lam...

Page 869: ...y Caution Connect and disconnect either MUT or MUT II with the ignition switch in the OFF position 2 Check if the buzzer of the MUT or MUT II operates when each switch is operated lf the buzzer operates the input signals are being sent to the ETACS unit so that switch can be considered to be function ing normally lf not switch or switch input circuit is faulty Check the switch and the switch input...

Page 870: ...ssures and remove the load from the vehicle except a driver Set the distance between the screen and the centre of the headlamps as shown in the illustration With the engine running at 2 000 r min 5 Check if the beam shining onto the screen is at the standard value Standard value For lower beam adjustment Vertical directionl 60mm 2 36 in l below horizontal Hl Horizontal direction Position where the...

Page 871: ...ter DRIVING LAMP AIMING Up to 1994 modeb 1 Measure the centre of the driving lamps as shown in the il lustration 2 Inflate the tyres to the specified pressures and remove the load from the vehicle except a driver 3 Set the distance between the screen and the centre of the driving lamps at 5 m 16 4 ft Refer to P 54 48 4 Set the headlamp at the uppqr beam and turn on the driving lamp 5 With the engi...

Page 872: ...ing it thoroughly 3 Be sure to attach the cap NOTE Be sure to installthe cap securely because if it is not an in secure installation could cause such problems as clouding of the lens or intrusion of moisture to inside the lamp unit Headlamp Bulb From 1995 modelsl 1 Disconnect the connector 2 Turn the valve socket counterclockwise and remove the valve Caution 1 Never hold the halogen lamp bulb with...

Page 873: ...achment spring and pull out the bulb Caution Do not touch the surface of the bulb with hands or dirty gloves lf the surface does become dirty clean it with al cohol or thinner and let it dry thoroughly before instal ling lnstall the socket cover securely NOTE Be sure to install the socket cover securely because if it is not an insecure installation could cause such problems as clouding of the lend...

Page 874: ...54 50 2 Mitubishi MotoB Corporatlon July l9gtl PWUEgl19 D ADDSD ...

Page 875: ... upper 2 Headlamp bezel lower 3 Headlamp 4 Socket cover 5 Bulb 6 Mounting ring 7 Spring Up to 199t0 modds 1 8 Headlamp leveling unit Vehicles with headlamp leveling 9 Adjuster assembly Vehicles without headlamp leveling 10 Rod assembly 11 Headlamp hood 12 Link assembly 13 Boot 14 Pop up motor Headlamp leveling switct removal 15 Headlamp leveling switch 11 10 e Mitsubishi Motoß Corporation July 199...

Page 876: ... negative battery terminal 2 Remove the headlamp bezel upper 5 REMOVAL OF BULB Remove the bulb mounting spring and take out the bulb Caution Do not touch the surface of the headlamp bulb with hands or dirty gloves lf the surface does become dirty 16FO430 91J f 1 fi n or thinner and let it drv thoroushlv O Mltsubishi Motor3 Corporation July 19 14 PWUEgIl9 D ...

Page 877: ...54 51 2 NOTES Mitsubishi Motors Corporetion July 1994 PWUEgl19 D ...

Page 878: ...OP UP MOTOR Rotate the manual knob of the popup motor clockwise by hand to check continuity between terminals Terminal Continuity range When the terminalof the ohmmeter is connected to O and the terminal is connected to B When the terminalof the ohmmeter is connected to O and the H terminal is connected to A rcaoa3S Headlamp upper stop position Manual knob B Conductivity is observed Headlamp lower...

Page 879: ...ver 2 Remove the bulb mounting spring and remove the bulb Caution Do not touch the surface of the headlamp bulb with bare hands or dirty gloves lf there are deposits on the surface loosen and re move the deposits with a cloth dipped in alcohol or thinner and let the surface dry before mounting the bulb q___ _ 2 Jr 1 9 P äJ g E 3i9 t i i g r ö iBr A Spring ü r O N Mitsubishi Motors Corporation July...

Page 880: ...osition Lamp FRONT COMBINATION LAMP Up to 1994 models REMOVAL AND INSTALLATION Removal steps 1 Front combination lamp garnish 2 Front combination lamp FRONTTURN SIGNAL LAMP AND POSffiON LAMP From 1995 models REMOVAL AND INSTALIATION Mlteubisha Motors Corporetion July 199t0 ...

Page 881: ...BINATION LAMP AND LICENSE PLATE LAMP RE MOVAL AN D INSTALLATION 2 Rear combination lamp removal 1 Rear combination lamp unit 2 Bulb Rear side trim Refer to GROUP Trims 3 Socket assembly License plate lamp removal 4 License plate lamp Mltrubishi Motor3 Corporatlon July 1994 ADOCD ...

Page 882: ...54 54 2 ADOED Mitsublchl Motoß Corporatloo July 1994 PWUEgttg D ...

Page 883: ...ke out the headlamp relay taillamp relay or driving lamp relay from the engine compartment relay box Connect battery to terminal 1 and check continuity between terminals with terminal3 earthed FOG LAMP REISY Remove rear fog lamp relay from the instrument panel relay box t v t l Driving lamp relay Up to 1994 models r rerozor Mftrublrhi Motors Corporstion July 1994 t l a r 6 re L___i l6F0122 PWUEgl1...

Page 884: ... shield R H and take lamp relay 1 2 and3 qr Aaä ä J l L J Power is supplied 4 5 terminals Continuity Power is not supplied 4 5 terminals No continuity 1 3 terminals Continuity Power is supplied 1 3 terminals Continuity Power is not supplied 1 3 terminals No continuity 2 4 terminals Continuity Dimdip lamp relay 1 2 3 tcro4cz out the dimdip O 2 Connea battery to terminal 2 and check continuity betwe...

Page 885: ...ip lamp Up to 1994 modelsl 1 Remove the radio panel and radio Refer to P 54 90 2 Take out the pop up relay from relay bracket 3 Connect battery to terminal 1 and check continuity between terminals with terminal3 earthed Terminal Battery voltage 1 2 3 4 5 7 I Voltage applied o 1J G o o G o No voltage applied o o E o Vehicles yl t f f Te running lagrn Vehicles with dim dip lamp Power is supplied 4 5...

Page 886: ...dard value Approx 1 Q LIGHTING MONITOR BUZZER INSPECTION 1 Remove the radio panel and radio Refer to p 54 90 2 Take out the lighting monitor buzzer 16co324 Mitsubishi MotoF Corporation May 1992 Check to be sure that the buzzer sounds when battery volt age is applied to terminal and terminal O is earthed Check to be sure that the buzzer stops sounding when bat tery voltage is applied to terminal 1 ...

Page 887: ... upper 4 Meter bezel 5 Popup switch and rear fog lamp switch 6 Rear window defogger switch SERVICE POINTS OF REMOVAL 2 REMOVAL OF COLUMN COVER LOWER 3 COLUMN COVER UPPER After the screws have been removed remove the covers while making sure not to break the grippers INSPECTION Operate the switch to check for continuity between terminals O O indicates that there is continuity between the terminals ...

Page 888: ...hly without flashing or flicker ing when the rheostat is operated 21 3 HAZARD IAMP SWITCH INSPECTION 1 Remove the center air outlet assembly from panel Refer to GROUP 55 Ventilators Panel 1 EIICYA instrument lnstrument rcAO33E 2 Operate the switch to check for continuity between terminals NOTE O O indicates that there is continuity between the terminals ffi P a erminal Switch positioA 1 5 6 7 8 I ...

Page 889: ...H E GYAI 1 Remove the instrument panel switch R H from the knee orotector 2 Connect the ohmmeter to headlamp levelling switch con nector terminals O and 3 Operate the Switch and check the resistance values in each switch position Standard value Switch position 0 1 2 3 4 Resistance O 120 300 620 1 100 2 000 ...

Page 890: ...Rated load A Voltage drop V Dimmer passing lamp Rated load A High beam Low beam Passing Voltage drop V O 22 0 O5 0 2 or less 6 6 0 5 0 2 or less 10 7 0 8 9 8 r 0 7 20 5 1 5 0 2 or less NOTE For the wiper and washer switch refer to GROUP 51 Windshield Wiper and Washer SPECIAL TOOL Tool Number Name Use M8990803 Steering wheel puller Removal of steering wheel MitrubirhlMotorcCorporation May1992 PWUEg...

Page 891: ... wheel Knee protector Refer to GROUP 52A Instrument Panel Column cover lower Column cover upper Lap cooler duct and foot shower duct Column switch left For lighting switch dimmer passing switch and turn signal lamp switch Column switch right For wiper and washer switch t fl SERVICE POINTS OF REMOVAL 2 REMOVAL OF STEERING WHEEL Gaution Do not hammer on the steering wheel Doing so may damage the col...

Page 892: ... and check the continuity between the terminals NOTE GO indicates that there is continuity between the terminals T IMMER PASSING SWITCH Operate the switch and check the continuity between the terminals O O indicates that there is continuity between the terminals WIPER AND WASHER SWITCH Refer to GROUP 51 Windshield wiper and washer HEADLAMP WASHER SWITCH Refer to GROUP 51 Headlamp Washer _ Terminal...

Page 893: ...lf the clock spring s mating mark is not properly aligned the steering wheel may not be completely rotational during a turn or the flat cable within the clock spring may be severed obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle s driver GAUTION SRS Before removal of the alr bag modulo rcf r to GROUP 528 SRS Scrvicr Proceutlonr lrd Alr Bag Module and G...

Page 894: ...e theft alarm horn relay from junction block 2 Connect battery to terminal 2 and check continuity between terminals with terminal 4 earthed Power is supplied 4 5 terminals Continuity Power is not supplied 4 5 terminals No continuity 1 3 terminals Continuity t l wL ö w L__ i r 6F0061 Power is supplied 1 3 terminals Continuity Power is not supplied 1 3 terminals No continuity 2 4 terminals Continuit...

Page 895: ...sing an ohmmeter check the continuity of the element CAUTIONS FOR USE OFTHE CIGARETTE JGHTER SOCKET AS AUXILIARY POWER SOURCE 1 When using a plug in type of acccronl b not urc anything with a load of more than lälW 2 lt is recommended that only the liglrter be inrertcd in füe receptacle Use of plug in type accessoriec may damago thr re ceptacle and result in poor rstentlon of the llglrter 3 The sp...

Page 896: ...N no power is available B 1 No sound from one speaker B 2 There is noise but no reception for both AM and FM or no sound from AM or no sound from FM B 3 Insuff icient sensitivity B4 Distortion on AM or on both AM and FM B 5 Distortion on FM only B 6 Too few automatic select stations B 7 Insufficient memory preset stations are erased B 8 Tape player Cassette tape will not insert c 1 No sound c 2 No...

Page 897: ...3 Name and frequency of stations affected by noise lf due to external noise lf due to vehicle noise In almost all cases prevention on the receiver side is impossible Weak signals especially are susceptible to i nterf erence It may not be possible to prevent noise if the signal is weak lf there is more noise than other radios find out the noise conditions and the name and frequency of the receiving...

Page 898: ...m 12 16 miles for stereo reception and 30 40 km 19 25 miles for monaural reception 2 The signal becomes weak when an area of shadow from the transmitting antenna places where there are obstructions such as mountains or buildings between the antenna and the car FM Broadcast Good RecePtion Areas and noise willappear This is called first fading and gives a steady buzzing noise lf a direct signal hits...

Page 899: ...a beating ls the noise still obvious even with the lamps OFF sound mav occur Beat sound Two signals close in frequency interfere with each other creating a repetitious high pitched sound This sound is generated not only by sound signals but by electricalwaves as well 2 Factors due to vehicle noise Alternator noise mav be a cause Do the following measures eliminate the noise ö Tune to a station wit...

Page 900: ...nna plug and No ls the antenna mounted tself in good condition or is it properly ealrn wrrg mgunun9 area Mount the antenna securely Check the antenna itself Refer to D 1 2 Yes lf there is more noise than other radios consult a service center NOTE About noise encountered during FM reception only noise interference first fading and multipath Refer Due to differences in FM and AM systems FM is to A 2...

Page 901: ...rical noise Noise prevention on the radio side is difficult lf the problem is particularly worse than other radios consult a servrce center Continue to check for static when static is detected check for the conditions listed above lf the problem is particularly worse than other radios consult a service center 2 There is much noise only on FM Due to differences in FM and AM systems FM is not as sus...

Page 902: ...em is not eliminated by a single response to one area are common due to several body parts being imper fectly earthed Caution 1 Gonnesting a high tension cable to the noiso capacitor may destroy the noise capacitor and should never be done 2 Check that there is no external noise Since failure due this may result in misdiagnosas due to inability to identify the noise source this operation must be p...

Page 903: ...RADIO AND TAPE PLAYER Troubleshooting 54 75 NOISE SUPPRESSION PARTS MOUNTING POSITIONS Mitsublshi MotoB Corporation May 1992 ...

Page 904: ...shings used to prevent vibration tires etc occurs because of separation from the earth causing a buzzing noise Srnce no measures can be taken on the radio side steps should be taken to discharge the static electricity of the vehicle body ls the radio correctly earthed ls the mounting screw tightened securely Tighten the screw securely ls the antenna correctly earthed lf noise appears when the ante...

Page 905: ...away from a station ls the radio body correctly earthed ls the mountind screw tightened securely Tighten the screw securelY lf rust is present of the antenna earth screw clean and tighten the earth securelY ls the antenna correctly earthed lf noise appears when the antenna is moved this means thä earth is not securely connected Yes About multipath noise and fading noise Because the frequency of FM...

Page 906: ... a service center No power is supplied when the switch is set to ON ls multi purpose fuse No 4 blown or is the circuit open Replace fuse or repair harness ls the connector at the back of the radio connected properly Disconnect and check the connector at the rear of the radio ls the ACC power 12V being supplied to the radio Repair or replace radio No sound from one speaker Check to see if there is ...

Page 907: ...nderground garage or rnside a building ls proper performance obtained when the vehicle is moved Check the antenna itself Refer to D 1 2 ls the antenna completely extended Does tuning solve the Problem Are the antenna plug and radio unit properly connected Repair or replace radio Does the problem disappear if connected to another radioT Repair or replace the antenna Refer to D 1 2 MitgubirhiMotoBGo...

Page 908: ...moved Yes OK No ts tne antenna completely extended Check the antenna itself Refer to D 1 2 Yes Yes Does tuning solve the problem7 OK No ls the problem limited to the reception of a specific radio station from a specific position Yes Electrical f ield condition related multipath noise or fading noise No No ts tne antenna plug properly connected to the unit Ensure proper connection Yes Does the prob...

Page 909: ...ontact with the cone paper Remove the speakers and check for torn cone paper or foreign objects Check for deformation with speaker installed Repair or replace radio Distortion on FM only Due to weak electrical field of radio station Does the distortion persist when the radio is tuned to another station Does distortion increase or decrease when the vehicle rs movedT Repair or replace radio Mitsubir...

Page 910: ...ended Yes Check the antenna itself Refer to D l 2 No Yes ts tne antenna plug properly connected to the equipment Ensure proper connectton Yes Oo s the equipment work properly if the radio is changed Repair or replace radio lnsufficient memory preset stations are erasedl ls multi purpose fuse No 19 blown or is the circuit open Disconnect and check the connector at the rear of the radio ls the memor...

Page 911: ...hat the tape is tightly wound Also tape of C 120 or greater length often get caught in the mechanism and should not be used Are there any foreign objects in the tape player Remove the object s Does the tape player work if another tape is inserted Repair or replace tape player C 2 No sound even after a tape has been insertedl ls multi purpose fuse No 4 blown or is the circuit open ls connector at r...

Page 912: ...ck again Repair or replace tape player Remove the connector on the back of the radio and check the speaker harness for conductance It conducts electricity but is shorted out Repair speaker harness and ensure proper connection ol relav connectors Repair or replace speaker Check the speaker for conductance lllrrnbff Moton Gorpordon llay 1992 PWUEgl19 ...

Page 913: ... properly tightened or of a malfunction of the tape player itself Malfunctions involving the tape becoming caught in the mechanism and ruining the case are ätsö possible and attempting to force the tape out of the player can cause damage to the mechanism The player should be taken to a service dealer for repair ls proper operation obtained when the tape player is replaced C 5 Cassette tape will no...

Page 914: ...irty Head Repair or replace tape player e7 Automatic search does not work r1 o Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound Also tapes of C 12O or greater length often get caught in the mechanism and should not be used Does the player play OK if the tape 1 is changed Tape used is bad Repair or replace the tape player fftrübhlilotoc...

Page 915: ...sm and should not be used Tape gets caught in mechanism r1 When the tape is caught in the mechanism the case may not eject When this occurs äo not try1o force the tape out as this may damage the tape player mechanism Take the cassette to a servlce dealer Tor repalr 2 Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound Also tapes of C 120 ...

Page 916: ...lish the surface of the antenna rod ls the radio power switch ON7 ls voltage approx 12V emitted to the radio s motor antenna terminal Repair or replace the radio ls the antenna bent Repair the bend or replace the antenna mast ls the antenna relay OK ls the motor OK illtüöLhl Motor Corporrtlon May 1992 PWUE9I19 ...

Page 917: ... OK ls operation normalwhen a new antenna assembly is directlv installed to the radio A B Checking the antenna Ohmmeter measurement locations Result Circuits from F to A B C D and E Continuity Circuit between G and H Continuity Circuits from H to A B C D and E No continuitY Mftrubirhi Motor3 Corporatlon May 199i1 PWUE9It9 ...

Page 918: ... AND INSTALLATION Removal steps 1 Radio panel la4io and tape ptayer 3 Radio bracktit A irpl _c_olsole assembly Refer to GROUP b2A Consote tioi t Removal steps 1 Doortrim Referto GROUP42 _ DoorTrim and Waterproof Film 2 Speaker qarnish 3 Speaker 4 Speakercover Ä llitnrbbhl iloton Gorporation May l9g2 v Xt ...

Page 919: ...nsole Box Radio and tape plaYer Refer to P 54 90 4 Motor antenna connection 6 Rear seat cushion 7 Rearseatback 8 Inner seat belt 9 Console side cover LH 1 0 Antenna feeder cable Motor antenna removal steps Rear side trim LH Refer to GROUP 52A Trims 1 Ring nut 2 Base 3 Antenna pole 4 Motor antenna connection 5 Motor antenna Antenna feeder cabte removalsteps Rear side trim LH l Refer to GROUP ouarte...

Page 920: ...Body harness 2 Disconnect the antenna motor connector 3 with the ignition switch in the ACC or oN position operate the radio switch and check the voltage between the ter minals during the period when the antehna is going up or going down SERVICE POINT OF INSTALLATION 6 INSTALLANON OF REAR SEAT CUSHION 1 Securely fit the attachment wire of the seat cushion under the seatback 2 Pass the inner seat b...

Page 921: ...th side of rack 5 Turn the tooth side of the rack cable toward the rear of the vehicle 90 clockwise to bring the rack cable into mesh 6 71 with the motor gear f lghtly pull the rack cable lf it comes out without reäistänöe it means that the rack cable is not in mesh with if ä rätot gear Recheck that the rack cable end is not bent ü iot repäating the above mentioned steps tzl an e With the antenna ...

Page 922: ...Number Name Use M8991341 Multi use tester sub assembly 1993 models ETACS input checking I For the number ROM pack I refer to I I GROUP 0o I Precautions I Before Service M8991502 MUT II suF assembly Allmodels ETACS input checking ROM pack mhrubbhlMotor Colporaüon Julytgg t FWUEgttg B ...

Page 923: ...PENSION HEMLAilP YASHER PffER VII DW il m11 oxra EEEEEEE V1 tffi c 55 mm 2 C 55 t2 v t rQ D ETACS coI TR0L t NIT 89ilfu Effi 12 tl grP mm J I Gt DIAGNOSIS CONNECTOR x1 Vehicles without theft alarm system x2 Vehicles with theft alarm svstem EfB ffi ffiffiffiffi Ul re colour B Black BR Brown c0de LG L I oht 0 0rano6 reon 8i96 sl hlRiH t H ll ü ü il3 88 8kv bru CIRCUIT DIAGRAM 154 mmo F tropf n ffi l...

Page 924: ...ffi ct ocK G tv DEFOGGER GLWE Bü LAXP AXD IIAPECTIOil LAIP IßADLAUP HEADLA IP LEVELII G SYSTEI IETER AI D GAWE REAR FO3 LAIIP REAR YIPER AI D VAEHER N RN 8IGT AL LAIP AIID II IZART LAIP AIR COIü ITIOI ER äs ffi E ffffi 8flÄffinr HEADLTIIP I EADI AIP LEVELIrc SY8 ITI IISIER AIID GArc8 REAR FOG LAP R8AR TIPBR AIID flA8HER 1 F 31 EE fu cEt c r D 4 Irlell F 02 F 05 X 1 LHD X2 RHD ElER GAI lllbubirhi M...

Page 925: ...ivated the timer is activated they will also stop activating even if the defogger switch is set at ON again TROUBLESHOOTING HINTS Phenomenon Checking method Mirror heater operates but defogger does not operate check the defogger Refer to P 54 98 Defogger operates but mirror heater does not operate Check the dedicated fuse No Check the mirror heater Refer to GROUP 51 Door Minor Neither defogger nor...

Page 926: ...r sub assembly Gaution Gonnect and disconnest either MUT or MUT II with the ignition switch in the OFF position 2 Check if the buzzer of the MUT or MUT tr operates when each switch is operated lfe luzzer operates the input signals are being sent to the ETACS unit so that switch can be considered tobe function ing normally lf not the switch or switch input circuit is faulty Check the switch and the...

Page 927: ...54 97 2 FWUE9 tt B ...

Page 928: ...tage changes suddenly 12 V with the same method described PRINTED HEATER LINES REPAIR REOUIRED MATERIALS o Thinner o Lead free gasoline Tape o Fine brush o Conductive paint 1 Clean disconnected area with lead free gasoline Tape along both sides of heater element 2 Mix conductive paint thoroughly Thin the required amount of paint in a separate container with a small amount of thinner and paint brea...

Page 929: ...9 DEFOGGER RELAY INSPECTION 1 Remove defogger relay from the instrument panel relay box 2 Connect battery power source to terminal 5 check circuit UJt tn termiÄats with terminal3 earthed lCFO20C Mltrublrhl Motot Cotpor tion Mry 1991 Pw EfiIE ...

Page 930: ...s Troubreshooting THEFT ALARM SYSTEM SPECIAL TOOLS o Number Name N MBee1341 1993 models ETACS input checking For the number I refer to I I GROUP OO I I Precautions I Before Service w MltrrrbLhl Motorr Corporation July i993 PWT EflT9B nsylE ...

Page 931: ...54 100 1 O NorEs Mltrublrhl Moto Corporatlon July 1998 PWUE T9 8 ADED ...

Page 932: ...i ffir 8öftffi8F0 A tlX c 68 ffi q d D 45 ffi rr_rrEm fiSHANArr0N D 04 F TgiF c EgÄ l tt AER0 gga F AERo ffihffigffir nrf rc ssr lc HiiilFil ffi r 0 n Eig6 s0 krRaH YFHEIEVED fffiffim HEilr or SWITCH c 51 tilff n D 43 O ilhrrbl hl Moton Corporrüon Juty t99E PWUEgl19 B c 55 t t Äls 8B 8ky bruc ...

Page 933: ... Ro UNIT DOOR LOCK ACTUATOR 15E 01ffi DRIVER SIDE m E 1 cq C I IEEEEEEIC 6 Ega ün o HEAD AI P FäßÄop0lll n ffihlflM Ä c 54 I ON IG1 DOOR KEY OYLINDER UNLOCK stl tTcH DRIVER S SI DE E 18 tfiflnHF RBlE h8fi n oo gp E osEH 154 I llltlrrbi hl Motor CotpoEtlon JulY lSß PWUEgfl 8 F ...

Page 934: ...M CONTINUEDI FEfIT 11 C 01 l A ogx ffi c 0 ffil ffiffi 0sts CTOR EtSU Ef6E DIAGN CONNE m ffiFlffiffi Iru tffi 8 c oa 2 trt I J I J IPt EttsTEtl STARTER MOTOR xIS3 tC RtSitrA c HOOD SWITCH A 9 DOOR SYITCH Emo ro B Hlbfirffif em ru illtl öbhl MotoE Corporutton July i99it ADCD ...

Page 935: ...H c 48 5 A 61 HORN Sh I TCH a sr THEFT ALARM HORN lffil A 32 TAILGATE Sl ITCH F 23 IEEtrI Wire colour code B Btack SB Sky blue BR Brown LG Lignt green G Green P Pi nk f lÄ 8 3t V Violet l hlte 0 0ranqe TAILGATE CYL I NDER LOCK Sl ITCH F 22 ü July 1993 v HoRN b 1 1 tcl THEFT ALARM HORN RELAY c 69 5V äs Mitsubishi Motors Corporation ...

Page 936: ...995 models Y_2 Name Symbol Name Symbol Selfdiagnosis connector Up to 1994 models E Horn relay A Self diagnosis connector From 1 995 models F Starter relay A ETACS unit c Theft alarm horn relay B Headlamp relay A Theft alarm starter relay D connector Mitrublrhi Motorc Corporatlon July 1994 ...

Page 937: ...UT or MUT tr oper ates one time when each switch noted below is operated lf the buzzer operates the input signals are being sent to the electronic control unit so that switch can be considered to be f unctioning normallY lf there is a mälfunction there is an abnormality in the switch or in the switch input circuit so they should be inspected Driver and front passenger door switches Driver and fron...

Page 938: ...o o o o NOTES ...

Page 939: ... door or the tailgate is unlocked by using the key Damaged or disconnected wiring of a door key cylin der and the tailgate cylin der lock switch input cir curt lf input checks P 54 100 indicate a malfunction check by using check chart P 54 106 and 107 Repair the harness or rs place a door key rylinder and the tailgate cylinder lock switch Malfunction of a door key cylinder and the tailgate cylinde...

Page 940: ...ring an alarm test in which the alarm is intentionally activated the door or tailgate is unlocked by using the key The system also cannot be dis armed Damaged or disconnected wiring of door key cylinder and tailgate cylinder lock switch input circuit lf input checks P il 100 indicate a malfunction check by using check chart P 54 106 and 107 Repair the harness Replace the key cylinder switch or the...

Page 941: ... the igiition key cylinder when tl 9 key is 19 1ov9d the key öminder switön is switched ON and LOWlevel signals are Description of oPeration The battery supplies a stabilized 5V powersupplytothe ECU via tnäconstairt vbitage circuit and terminal 1 which is directly con nected to the battery ECU terminalvoltage ffhe ECU connector connected ECU terminal No Signal Condition Terminal voltage 1 ECU powe...

Page 942: ...ng the hood switch circuit Disconnect the ECU connec tor and check the wiring harness side Deccription of operation When the door is closed the door switch is switched OFF HIGH level signals are sent to the ECU When the door is opened the door switch is switched ON LOW level signals are sent to the ECU ECU terminalvoltage The ECU connector connected Measurement is not possible by using a voltmeter...

Page 943: ...l voltage 33 Door lock actuator switch driver dood Door lock actuator switch Lock OFF 5V Jnlock ON OV 34 Door lock actuator switch passenger door Door lock actuator switch Lock OFF 5V Jnlock ON OV Measurement is not possible by using a voltmeter but is possible by using an oscilloscope Checking the earth circuit Disconnect the ECU connector and check the wiring harness side tffil ffil LH ECU terml...

Page 944: ...eck the wiring har ness ffil Junction block Multi purposo fuse Door key cylrnder untoct switch ETACS unit ECU Tailgate cylinder lock switch I EEI LH Door key cylinder unlock switch ECU termanal No Connected to measured parl Measuremen Tester connectron Check conditions Standard 39 Door key cylinder unlock swrlch Resistance 39 earth Door key cylinder LH Not rotate No continuity Rotate Contrnurty Do...

Page 945: ...Junction block Multi purpose fuse tffil ßfl lj E lali tlli l I ll_c19 u LL4L il 61 l Hl llltPtst4lstst t8tl ll e lroNrilrellslt4ll6lrdl ETACS unit ECU Measurement is not possible by using a voltmeter but is possible by using an oscilloscope lg the tailgate latch switch circuit Disconnect the ECU tör and check the wiring harness Condition I Terminal ECU terminal No Connected to measured part Measur...

Page 946: ...e harness 2 Combination meter connector terminal voltag6 System voltage OV Damaged or disconnectod wiring of SECURITY lamp bulb Replace the bulb larness damaged r dtsconnected Repair the harness ECU terminal voltage 7 System voltage OV larness damaged r disconnected r short circuit Bepair the narness CIRCUIT Description of operation Power voltage is always supplied to the horn relay Checking the h...

Page 947: ...ector No I and activate the horn relay Step Check obiect Judgement Cause Remedy Normal Mal function 1 Horn relay terminalvoltage 4 Earth System voltage OV Malfunction of the horn relay Check the horn rolay Refer to P 54 6 2 Horn terminal voltage LH RH 1 Earth System vo tag OV Harness damaged or disconnected Repair the harness Horn terminal voltage LH RH 1 Earth Horn sounds 0v Horn doesn t sounct 0...

Page 948: ...rthl Horn sounds 0v Horn doesn t sound ovl Malfunction of the norn Replace the horn Battery voltage Damaged or disconnected wiring of earth circuit lepair the larness CIRCUIT Description of operation The ECU transistor is switched oN if the vehicle door etc are opened without use of the key This turns oFF the starter relay and power ceases to be suplied to the starter magnet switch checking the st...

Page 949: ...intenanäe of any SRS Gomponent or SRS related component mu3t bc porformod only et an authorized MITSUBISHI dealer t3l MITSUBISHI dealer perconnet must thoroughly review this manual and especially ft3 GROUP 5i2B Supplemental Resträint System before b ginning any service or maintenance of tnV Gomponcnt of the SRS or any SRS related component NOTE The SRS inctudes the following components impact sens...

Page 950: ...2 700 27 38 l OFF 210 2 1 30 ON 2 100 Q 299l ON 235 2 35 33 OFF 3 200 ß2 455 ON 2 600 e6 370 OFF 200 Q 0 28l ON 225 2 25 321 Air temperature thermostat OFF 2 28 41 ON 2 35 6 R 1 2 CFC I 21 770 870 27 1 6 30 69 R 1 34a HFC 1 34a 7 4O 79O 126 10 27 87l Items Specifications Standard value ldle speed when air conditioner on rpm Resister resistance value O Thermostat ON temperature C fF OFF temperature...

Page 951: ...olant temperature switch threaded part 3M Nut Locking Part No 4171 or equivalent SPECIAL TOOLS Tool Number Name Use MD991367 Specialspanner Removal and installation of armature mounting nut of compressor M8991386 Pin bb M8991341 Multi use tester sub assembly Up to 1993 models Inspection of full auto air conditioner ROM pack I ror tn number refer to I e nOue 0o Precautions Before I I Service M89915...

Page 952: ...cuum gauge Vacuum check M8991403 For high pressure M8991404 For low pressure Adaptor valve Supplying refrigerant gas Replenishing refrigerant gas Draining refrigerant gas Function test M8990784 Ornament remover Removalof air outlet grille ttlhrytfdrl Motor Corpor tlon Jüly tgo t pWUEgttg B Am ...

Page 953: ...O NorE o o o ...

Page 954: ...i E o c o c I E c ö o c E c I c o G c e o o g o g o o o G o 9 c I U g E o F o L I E o F I p c_ o o o E c 8 o e D 8 a c J F L o p o 6 ö o E F c o E o a o o 5 E g E o I E c o 6 0 E E o o o 6 e o I 6 E 6 6 E b o E o 3 o 6 b Y E I E e I o ö o F o E t R E o o o ö g a g c G B c I o o o o a o o t o 1 Air conditioner does not operate when the ignition switch in the ON position o o 2 Interior temperature d...

Page 955: ...5 17 Defective air mix damper potentioreter input circuil Defective air mix damper drive motor Replace air mix damper drive motor 5S37 Incorrect engagement of air mix damper drive motor lever and air mix damoer Engage correctly Sticking air mix damper Correct air mix damper Opencircuited harness between air mix damp er drive motor and air cönditioner control unit Correct harness Defective control ...

Page 956: ...l Replace control panel 5 34 Defective air conditioner control unit Replace air conditioner control unit 5 34 4 Blower motor does not rotate Defective blower motor Replace blower motor Blown thermal fuse inside power transistor Replace power transistor 5 35 Defective blower motor relay Replace blower motor relay Open circuited harnesss between fuse and blower motor relay Correct harness Opencircui...

Page 957: ...ntrol unit Reolace air conditioner control unit 5 34 8 Condenser fan does not operate when the air condi tioner is activated Defective condenser fan motor relay Replace power relay Defective condenser fan motor Replace condenser fan motor 5S51 Air conditioner graphic dis play does not function cor rectly Ooen ircuited harness between control panel and air conditioner control unit Correct harness D...

Page 958: ...l at 1 5 C 59 F 1 No 21 22 Fix air thermo sensor input signal at 2 C F35 6 F 1 o Air conditioner control unit terminal voltages LJt IJt Air inlet sensor Connectors are keyed by terminal numbers Indicates the diagnosis output code number and system condition when the code is output Indicates the terminal number to be checked Temperature at sensor 25 C 77 F 4 kO Temperature at sensor 25 C 77 F 4 kO ...

Page 959: ...link 1m Junction block MultFpurpose fuse Air conditioner control unit Troubleshooting Hints Air conditioner control unit terminal voltage Terminal No Signal name Condition Terminal voltage 23 Backup power source Normally System voltage 48 56 Air conditioner control unit power source lgnition switch ON system voltage 47 55 Air conditioner control unit earth Normally OV e t902 ...

Page 960: ...ion or at FACE position when it is at FACE position Air conditioner control unit terminal voltages Terminal No Signal name Condition Terminal voltage 26 il rilf da mPer Potentiometer Air mix damper at MAX COOL position 0 1 0 3v Air mix damper at MAX HOT position 4 7 5 0 V 27 Air selection damper potentiometer input Air selection damper at FACE position 0 1 0 3v Air selection damper at DEF position...

Page 961: ...59 F 1 No 21 22IFix air thermo sensor input signal at 2 C 35 6 F 1 Air conditioner control unit terminal voltages Air inle sensor Air conditioner comprsssor command arithmstic circuit lr Ay D conversion i Terminal No Signal name Condition Terminal voltage 25 Air inlet temDerature sensor Temperature at sensor 25 C 77 F 4 kO 2 2 2 8V 30 Sensor power source Normally 4 8 5 2V 36 Interior temperature s...

Page 962: ...shooting Hints Air conditioner control unit terminal voltages Each sensor Aircontrol panel Terminal No Signal name Condition Terminal voltage 39 Photo sensor O llluminance 100 000lux or more 0 1 to 0 2 v llluminance less than 0 lux OV 40 Photo sensor Normally OV 29 Engine coolant temperature sensor Switch OFF IEngine coolant temperature less than 50 C 122 F l System voltage Switch ON Engine coolan...

Page 963: ... 13 5 tnspection of belt lock controller circuit Air conditioner control panel Troubleshooting Hints Air conditioner control unit terminal voltages Compressor relay Revolution pickuP sensor 10 V to system voltage Mltrubbhi MotoFCorporttlon MaY 199i2 PWUEglT9 ...

Page 964: ...on damper control motor circuits Air mix damper control moto Air conditioner control panel Air inlet sensor Air mix damper control motor 20FOt37 Mode selection damper control moto Air conditioner control unit Air conditioner control panel Mode selection damper control motor Poten tiometer Mtttubbhi Motoru Corporrüon May 1992 ...

Page 965: ... damper control motor O lnside air switch ON Output turns OFF 40 seconds after inside air has been activated 10v Outside air switch ON Output turns OFF 40 seconds after outside air has been activated 0 5v 45 Air mix damper control motor E Temoerature is set at 17 C 62 6 F Outbut turns OFF 40 seconds after the damper movbd to MAX COOL position 0 5v Temoerature is set at 32 5 C 90 5 F Outbut turns O...

Page 966: ...tages Terminal No Signal name Condition Terminal voltage 21 Power transistor collector Switch is turned OFF System voltage Switch is placed in LO Approx 7 V Switch is placed in Hl OV 22 Power transistor base Blower switch is turned OFF OV Blower switch is placed in LO Approx 1 3 V Blowerswitch is placed in Hl Approx 1 2 V 41 Blower motor Hl relay Fan switch Hl is ON 1 5 V or less Fan switch in ME ...

Page 967: ...USE TESTER IMUTI OR MUT tr Inspection ltem Inspection Probable cause of malfunction or remedy Inspection conditions Normal diagnosis val ue Interior temperature sensor MUT or MUT u 11 lgnition switch ON Interior temPerature and MUT or MUT II display temperature are the same Interior temperatufe Sengor or re lated circuitry is defective Air inlet MUT or MUT 13 lgnition switch ON Atmospheric temper ...

Page 968: ... pornt Method Criteria Probable cause Remeü Normal Abnormal 11 lnterior tem perSture sensor Measure resistance of sen sor when r m tempera ture is 25 C 77 F1 Approx 4kO Largely deviates from approx 4kO Defective interior tern perature sensor Replace interior tern oerature sensor Measure voltage across terminal 16 of air condition er control unit and earth when interior temperature is 25 C 07oFl In...

Page 969: ...sor and air condition er control unit Corrgct hame Outside aPProx 2 3 2 9V range Poor connection of air conditioner control unit connector or defective air conditioner control unit Correct connector con nection or rePlace air conditioner contrctl unit 31 Air mix damper potentio meter Ref r to P 55 38 Defective air mix demP er potentiometer Replrac air n drmPer potontiomoter Measure voltage across ...

Page 970: ...oil handy when working on the refrigeration system Should any liquid refrigerant get into the eyes use a few drops of mineral oil to wash them out R 12 is rapidly absorbed by the oil Next splash the eyes with plenty of cold water Call your doctor immediately even though irritation has ceased after treatment Caution Do not heat R 12 above 4 fC t04Tl In most instances moderate heat is required to br...

Page 971: ...g on the refrig eration system Should any liquid refrigerant get into the eyes use a few drops of mineraloilto wash them out R l34a is rapidly absorbed bythe oil Next splash the eyes with plenty of cold water Callyour doctor immediately even though irritation has ceased after treatment Caution Do not heat R 134a above 40 C 104 F1 ln most instances moderate heat is required to bring the pressure of...

Page 972: ...o o o o NOTE ...

Page 973: ... 2 Connect battery voltage directly to the wiring for the magnetic clutch 3 lf the magnetic clutch is normal there will be a click lf the pulley and armature do not make contact click there is a malfunction RECEIVER DRIER To Test the Receiver Drier 1 Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet 2 lf there is a difference in the temperatures the ...

Page 974: ...ressure or open arr 200 500 kPa 2 0 5 0 kgcm2 28 4 71 1psi I ou zuu Kra 1 5 2 0 kgcm2 21 3 28 4 osi Acceptable Proper 100 kPa or less 1 0 kgcm2 or less 14 2 psi or less Acceptable Abnormal The magnet clutch is frequently turned on and off Faulty compressor t Replace compressor Case 2 Case 3 early saturated pressure of open air Relected The difference between the hioh and low pressuie is not observ...

Page 975: ... ohmmeter measure the resistance lf the resistance is within 1jo o of value of the characteris tic curve the sensor is functioning normally 2 lf the sensor is normal there is a malfunction of the air conditioner control unit and it should be replaced COMPRESSOR DRIVE BELT ADJUSTMENT Refer to GROUP 11 Service Adjustment Procedures t rt 0 Tspa at6a Mitrubirhi MotoB Coryor tion May 19911 PWUE9 t9 ...

Page 976: ...e service valve to the discharge port of discharge hose and the low pressure service valve tothe suction port of compressor 2 Tighten the handle of the specialtoolO and valve open 3 Connect the charging hose to the speciat tool O anä 4 With the handle of the special tool tightened valve open install the special tool to the low pressure side charging hose Installthe vacuum gauge M8991402 to the spe...

Page 977: ...he handle of the special tool valve open to charge refrigerant 16 When refrigerant is no longer drawn in turn back the handle of the special tool O all the way vavle close 17 Check for gas leaks using a leak detector 18 Start the engine 19 Operate the air conditioner and set at the lowest tempera ture MAX COOL 20 Fix the engine speed at 1 500 r min 21 Tighten thä handle of the special tool O valve...

Page 978: ...Close the hitgh and low pressure valves of the gauge manifold 3 Connect the charging hoses to the special tools O and 4 Tighten the handles of the special tools O and valves opened Refrigerant charge 5 Start up the vacuum pump Gaution 1 Do not use the comprossor for evacuation 2 Do not opetate the compressor in the vecuum condltion damage mly oocur 6 Evacuate to a vacuum reading of 10Q kPa 1 Okg c...

Page 979: ...leak detector 15 Start the engine 16 Operate the air conditioner and set at the lowest tempera ture MAX COOL 17 Fix the engine speed at 1 500 r min 18 Tighten the handle of the special tool O valve open and charge refrigerant up to the specified quantity Caution lf the service can is invertod liquid rcfrigcrant mey bc drawn into the compressor damaging it by liquid compression Keep the service can...

Page 980: ...use refrigerant to flow back resulting rupture of thoservice ean or the charging hose 8 State the engine 9 Operate the air conditionenr and set at the lowest tempera ture MAX COOL 10 Fix the engine speed at 1 500 r min 11 Tighten the handle of the special tool valve open and replenish refrigerant checking the quantity through the sight glass 12 After replenishing is completed turn the handle of th...

Page 981: ...ure When a FX 1Q5VS compressor is installed at the factory it con tains 160 cm3 9 8 cu in of refrigerant oil While the aii condi tioning system is in operation the oil is carried through the entire system by the refrigerant Some of this oil will be trapped and retained in various parts of the system When the following system components are charged it is nec essary to add oil to the system to repla...

Page 982: ...w to the R 134a connec tion port of the vacuum pump adaptor 9 Tighten the adaptor valve handle valve open 1O Open the low pressure valve of the gauge manifold 1 1 Turn the power switch of the vacuum pump to the ON posi tion NOTE Even if the vacuum pump power switch is turned ON the vacuum pump will not operate because of the power supply connection is step 7 12 Turn the vacuum adaptor switch to st...

Page 983: ...f the adap tor valve back all the way valve closed 21 Check for gas leaks using a leak detector lf a gas leak is detected re tighten the connections and then repeat the charging procedure from evacuation in step 12 Gaution The leak detestor for R 134a should be uced 21 Start the engine 22lOperate the A C and set to the lowest temperature MAX coou Z4lFixthe engine speed at 1 500 r min 25 Tighten th...

Page 984: ... NOTE The low pressure service valve is on the suction hose A LEVEL tN cAsE rHE o 8 s Start the engine Operate the air conditioner and set at the ture MAX COOL 10 Fix the engine speed at 1 500 r min 1 1 Tighten the handle of the adaptor valve valve open and re plenish refrigerant checking the quantity through the sight glass Gaution lf the servics can is inverted liquid refrigerant may bc draw int...

Page 985: ... adaptor valve inside the container and discharge the refrigerant by opening the handle gradually so that oil does not gush out NOTE Any oil remaining in the container should be returned to the A C system REFILLING OF OIL IN THE A C SJSTEM Too little oil will provide inadeguate compressor lubrication and cause a compressorfailure Too much oilwill increase discharge air temperature When a compresso...

Page 986: ...position Temperature control Max cooling position Air selection Recirculation position Blower switch Hl Fast position 8 Adjust engine speed to 1 000 r min with air conditioner clutch engaged 9 Engine should be warmed up with doors windows closed and bonnet opened 10 lnsert a thermometer in the left center air conditioner outlet and operate the engine tor 20 minutes 11 Note the discharge air temper...

Page 987: ...he A C as follows A C switch A C ON position Mode selection Face position Temperature control Max cooling position Air selection Recirculation position Blower switch Hl Fast position Adjust engine speed to 1 000 r min with A C clutch engaged Engine should be warmed up with doors and windows closed 1O lnsert a thermometer in the left center A C outlet and oper ate the engine lor 20 minutes 1 1 Note...

Page 988: ...o o o NOTE o ...

Page 989: ...g or sharp bends in the refrigerant hose lines will greatly reduce the capac ity 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 mois ture can enter the system when it is opened for repair or replacement of lines or components The following precautions must be observed T...

Page 990: ...ine speeds and depending upon belt tension belts can develop unusual noises that are often mistaken for mechanical problems within the com pressor ADJUSTMENT PROCEDURES 1 Select a quiet area for testing Duplicate condi tions as much as possible Switch compressor on and off several times to clearly identify compressor noise To duplicate high ambient conditions high head pressure restrict air flow t...

Page 991: ...elays Hl and LOlfrom the relay box on the right of the engine compartment Remove the radiator fan motor relay air conditioner con denser fan motor relays Hl and LO and magnetic clutch relay from the relay box on the left of the engine compart ment Remove the blower motor relay from the junction box Remove the blower motor Hl relay from the blower case assembly Check the continuity between terminal...

Page 992: ...le GAUTION SRS When installing or removing the floor console don t allow any impact or shock to the SRS diagnosis unit Removal staps 1 Center air outlet assembly 2 Air conditioner control panel 3 Air conditioner control unit SERVICE POINT OF REMOVAL E66GEA I 1 REMOVAL OF CENTER AIR OUTTET ASSEMBTY Disengaging the clips 2 positions of the center air outlet assembly with a flat tip screwdriver remov...

Page 993: ...r BertLockcontrotrer 55 35 POWER TRANSISTOR BELT LOCK CONTROLLER REMOVAL AND INSTALLATION 34 Power transistor temoval stePs 1 Stopper 2 Glove box outer case assembly 3 Power transistor Belt lock controller removal 3tops 4 Undercover 5 Belt lock controller ...

Page 994: ...ment Panel Refer to GROUP 52A Floor Console and lnstrument Panel CAUTION SRS When installing or removing thefloor console and instrument panel don t allow any impact or shock to the SRS diagnosis unit Removal steps 1 Connection of water noses 2 Center reirrforcement 3 Undercover 4 Distribution duct foot 5 Footshowerduct 6 Lap cooler duct 7 Evaporator mounting bolt and nut 8 Centerduct 9 Heater uni...

Page 995: ...removal steps 4 Floor console Refer to GROUP 52A Floor Console 5 Air conditioner control unit 6 Center outlet assembly 7 Air conditioner control panel 8 Air mix damper motor assembli Modo ccfestion dampcr motor rrlcmbly removal steps 9 knee protector 10 Side console cover 1 1 Shower duct and lap cooler duct 12 Mode selection damper motor assembly SERVICE POINTS OF REMOVAL E 6orAp2 6 REMOVAL OF CEN...

Page 996: ...n when polarity is changed Gaution 1 Gut off the voltage when the damper is in the MAX HOT or MAX COOL Position 2 Cut off the vohage if the motor does not turn when battery voltage is aPPlied NSPECNON OF AIR MIX DAMPER POTENTIOMETER Connect a circuit tester across terminals and of the motor assembly connector and check that resistance gradually changes as the damper is moved from MAX HOT to MAX CO...

Page 997: ...rd value DEF position Approx 0 2 kQ FACE position Approx 4 8 kO SENSORS REMOVAL AND INSTALLATION 1 Interior temperature sensor Photo sensor removal steps 2 Stopper 3 Glove box outer case 4 Photo sensor connector connection 5 Photo sensor Engine coolant temperature sensol removal steps 2 Stopper 3 Glove box outer case assemblv 6 Plate 7 Engine coolant temperature sensor Air inlet sensor removalstep...

Page 998: ...ches the specif ied temperatu re Standard value 26 5 4 C 179 7 7 tFl AIR INI ET SENSOR The condition can be considered normal if the resistances are measured within the ranges of 3 98 4 12 kilohms and 2 21 2 35 kilohms respectively when the air inlet sensor is sub merged in warm water of 25 C l77 Fl and 40 C 104 F for one minute or longer each NOTE The relationship between the ambient temperature ...

Page 999: ...r case assembly 1 Stopper 2 Glove box 3 Glove box outer case assembly 4 Undercover 5 Lower frame 6 Evaporator mounting bok and nut 7 Side frame L Blower assembly 9 Air selection damper motor 10 Air inlet sensor 1 1 Blower motor assembly 12 Blower case assembly Removal steps of blower motor assembly 4 Under cover 11 Blower motor assembly t ...

Page 1000: ...eration of the air selection dämper and for damage BLOWER MOTOR ASSEMBLY CHECK When battery voltage is applied between the terminals check to be sure that the motor operates Also check to be sure that there is no abnormal noise SERVICE POINTS OF INSTALLANON E O F 11 INSTALTATION OF BLOWER MOTOR ASSEMBLY Before installing the blower motor assembly carefully clean away any dust dirt etc adhering to ...

Page 1001: ...Pre removal and Post imtallrdon Oporetion o Discharge and Charging of Refrigerant Refer to P 55 24 29 1 o Removal and Installation of Battery NOTE 1 L H drive vehicles 2 R H drive vehicles SERVIGE POINTS OF REMOVAL Erö lar 1 DISCONNECITON OF LIOUID PIPE AND SUCTION HOSE B lf the hoses or pipes are disconnected cap the hoses or pipes with a blank plug to prevent entry of dust dirt and water INSPECT...

Page 1002: ...VAPORATOR When replacing the evaporator fill it with the specified vol ume of the compressor oil and install it Compresror oil Vehiclcs uring R 12 rcfrigerrnb Frcol S 83 or SUNISO sGS Vchidco uring R 134a refrigcranb SUN PAG 56 Ouantity 60 cm3 13 66 cu in l Mltuöhhl Motor Corporldon July 1993 PWUE91 l9 B ADE ...

Page 1003: ...O NorE o o o ...

Page 1004: ... upper 3 Air thermo sensor 4 Evaporator case lower 5 Evaporator assembly 6 Grommet 7 lnsulator 8 Rubber insulator 9 Clip 10 Expansion valve SERVICE FOINTS OF DISASSEMBLY 1 REMOVAT OF CUPS Remove the clips with a flat blade screwdriver covered with a shop towelto prevent damage to case surfaces 10 REMOVAL OF EXPANSION VALVE Loosen the flare nut by using two wrenches for both the inlet and outlet Ml...

Page 1005: ... 5 3 t 4 2 kgm 30ft bü Nm d6 5 7 MSC105 Removal steps e 1 Air hose B X 2 Air pipe 3 Compressor drive belt 4 Condenser fan motor assembly 5 Connection of suction hose A and dis charge hose f 6 Alternator Refer to GROUP 16 Alternator t 7 Compressor 8 ldler pulley 9 Compressor bracket 10 Tension pulley assembly 11 Bolt 12 Tension pulley 13 Bolt 14 Adjustment plate 15 Tension pulley bracket tf tf t t ...

Page 1006: ...ion of the air conditioner belt OPERANON CHECK OF THE COMPRESSOR S MAGNEnC CTUTCH 1 Connect terminal at the compressor side to the positive terminal of the battery and ground the negative J terminal of the battery to the compressor 2 The condition of the compressor s magnetic clutch can be considered satisfactory if the operation sound a click sound of the magnetic clutch can be heard when this ch...

Page 1007: ...ame time as the compressor subtract the rated oil amount of the each part from Y cm3 y cu in and discharge from the new compres sor Ouantity Evaporator Condenser Sustion hose Receiver 6o cm3 3 66 cu in l 15 cm3 0 92 cu in l 1o cm3 10 61 cu in l 1o cm3 10 61 cu in l Mitrubi i Motorr Corporation July 1993 ...

Page 1008: ...o o o o NOTE ...

Page 1009: ... Gaution Be careful not to allow any foreign matter to get into the hoses pipes or the intercooler itself 15 14 lP llfo AI 72 E N Magnetic clutch disassembly steps 1 Bolts 2 Pulley e 3 Nut a 4 Armature plate 5 Snap ring 6 Rotor fe 7 Snap ring f 8 Clutch coil 9 Shims High pressure relief valve disassembly steps 10 Cover 1 1 Dust cover 12 High pressure relief valve toFooot Control valve dlrasrembly ...

Page 1010: ...Bolts 2 Pulley 3 Nut 4 Armature plate 5 Snap ring 6 Rotor 7 Snap ring 8 Clutch coil 9 Shims High pressure relief valvc dlraumbly 12 High pressure relief valve Thermoctrt and revolution pick rip scn sor dirarccmbly 16 Thermostat and revolution pick up sen sor 16 W 20FOrCt t e e t ft O mft r bkhl Motorr Corporrdon July 199i1 ...

Page 1011: ...O NorE o o o ...

Page 1012: ... the high pressure relief valve closes thusallow ing continued operation 1 lf a leak is detected at section A replace the high pressure relief valve The valve can be used unless there is a leak from that section 21 lf a leak is detected at section B retighten the valve lf the leak still persists after retightening the valve replace the packing THERMOSTAT CHECK 1 Dip the thermostat in engine oil 2 ...

Page 1013: ... speed increases until a pressure of 180 kPa 1 8 kg cm2 25 ös i R 1 2 1 50 200 kPa 1 2 0 kg cm2 2f30 psi R 134a is reached at which point the pressure temporarily ceases to drop Then the pressure again starts dropping as the engine speed further increases lf the valve is abnormal the low pressure drops in direct pro portion to the increase in engine speed without a temporarily leveling off at the ...

Page 1014: ... mark of the armature plate and then fit them together 3 INSTALTANON OF NUT 1 Use the special tool to tighten the nut 2 Check whether or not the air gap of the clutch is within the standard value Standard value 0 4 0 6 mm 10 01 0 02 in l NOTE lf there is a deviation of the air gap from the standard value make the necessary adjustment by adiusting the number of shims D M Y 1992 PWUEgl19 ...

Page 1015: ...4 Fan 5 Motor assembly 6 Shroud lf ll 7 Radiator fan motor assembly Refer to GROUP 14 Radiator lnsulator installation bolts Liquid pipe A Discharge pipe Condenser Bushings Gorryanorot bhld6 ulhg R 12 t lgctrtU Frül S 3 c r ro5GS bhkjec udn R 13L slflmG50 1F13l m 1 F1 3 kgm 74ft b ryoo g 1 ft fl _____ SERVICE POINTS OF REMOVAL Efl Ar 9 REMOVAL OF TIOUID PIPE A 10 DISCHARGE PIPE 1 Loosen the flare n...

Page 1016: ...ATION OF CONDENSER When replacing the codenser fill it with the specified amout of the compressor oil and install it Compressor oil Vehicles using R 12 refrigorant Freol S Xf or SUNISO sGS Vehicles using R l 34a refrigerant Ouantity SUN PAG 56 15cm3 0 92 cu in l 2 INSTALLATION OF AIR PIPE 1 AIR HOSE B When installing the air hoses make sure that the alignment marks at places indicated by arrows ar...

Page 1017: ...3 2 Vehicles buit from February 1993 1 1 5 kgm 9ft lbG I 12 15 Nm 1 2 1 5 kgm 9 11ft bl Piping connection O ring Compressor oil Vehicles using R 12 rcfrlgcranO Ftrol S f or Suniso 5GS Vehicles using R 134a rcfrlgranb SUN PAG 56 2 3 kgm 17 ft lbs 1 r v9 10 Removal steps 1 Air hose B 2 Air pipe 3 Discharge hose 4 Discharge pipe 5 Liquid pipe A 6 Liquid pipe B 7 Liquid pipe C 8 Suction hose B 9 Sucti...

Page 1018: ...pipe A 6 Liquid pipe B 8 Suction hose B 9 Suction hose A 10 Receiver bracket 11 Receiver 1 2 Dual pressure switch 20FO1 r ft X c fc Gomprcrlor oil Vchidcs uring R 12 rdrlgcranb Frcol S lor Suniro 5GS _ Vqhtdq uein g R 1 3tle rcfri gorenO Rcmoval3topi 1 Air hose B 2 Air pipe Gro NOTE 1 Vehicles buit up to Jauuary 1993 2 Vehicles buit from February 1993 SERVICE POINTS OF REMOVAL EESA A 3 REMOVAL OF ...

Page 1019: ... of these with the specif ied volume of the compressor oil and installthem Comprcssor oil Vehiclec ucing R 12 rcfcigcrnlb Frcol S t or Sumiso 5GS Vehiclcs using R 134a rcfrlgcreno SUN PAG 56 Ouantfi Suciön hose 10 cm3 0 61 cu ln l Recciver 10 cm3 0 61 cu in l 6 INSTALLATION OF LIOUID PIPE B First install the receiver side of the liquid pipe B Mlt r bl hl Motor Corporstlon July lStl PWUE9Ir9 B ADOC...

Page 1020: ...o o o NOTE o ...

Page 1021: ...into the hoses pipes or the intercoolel itself 14 13 E65il4 GAUTION SRS When installing or removing the instrument panel don t allow any impec t or rhock to the SRS diagnosis unit 20F 55 1 1 Distribution duct center 12 Defroster duct 13 Side defroster hoses B 14 Defroster garnishes 15 Photo sensor 16 Center air outlet assembly 17 Side air outlet assembly 18 Distribution duct foot 6 6P EE g Removal...

Page 1022: ...OVAL 14 REMOVAL OF DEFROSTER GARNISHES 15 REMOVAL OF PHOTO SENSOR 16 REMOVAL OF CENTER AIR OUTLET ASSEMBLY Disengaging the clips 2 positions of the center air outlet assembly with a flat tip screwdriver remove the center air outlet assembly with the special tool M8990784 M8990784 Jl f lrT l ter I o ...

Page 1023: ...STALLATION 13 Nm 1 3 kgm 9 4 ft lbs o Inlet garnishcs removll stops 1 Windshieldwiperarm 2 Frontdeck garnish 3 Inlet garnish RH 4 Inlet garnish LH Rear ventilation dust removal steps 5 Rear ventilation duct A ef e 6 Side air dam side sill Refer to GROUP 51 Aero Parts 7 Rear ventilation duct B ü Mitsubi il lotors Corporation May lgg2 ...

Page 1024: ... the engine coolant temperature switch in oil and heat by a gas stove or similar method so as to increase the oil temperature 2 Check to be sure that the engine coolant temperature switch is switched OFF when the oil temperature reaches the standard value l Standard yalue 112 118 C 1233 244 Fl Caution t fu 35 Nm 3 5 kgm 25 ft lbs I j ft t 666666 Air intake hose A Air intake hose B SERVICE POINTS O...

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