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Mitsubishi Eclipse 1990, Service Manual

The Mitsubishi Eclipse 1990 Service Manual is a comprehensive manual detailing the maintenance and repair procedures for this iconic vehicle. Download this manual for free from manualshive.com, ensuring you have access to the information you need to keep your Mitsubishi Eclipse running at its best.

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11

 ENGINE OVERHAUL 

(9) Install 

 head cover assembly to head and tighten

fasteners  in  sequence  shown  in  the  figure.  Using  the
3 step torque method:

Step  1  Tighten  all  fasteners  to  4.5  Nm  (3.3 
Step  2  Tighten  all  fasteners  to  9.0  Nm  (6.5 
Step  3  Tighten  all  fasteners  to  12  Nm  (9 

Spark  plug  well  gaskets

TSB  Revision

Summary of Contents for Eclipse 1990

Page 1: ......

Page 2: ...are heat over baklng or in drying after painting remove the SRS components air bag module beforehand 3 Service or maintenance of any SRS component or SRS related component be performed only at an auth...

Page 3: ...e Seals 50 Brake Hoses 50 Disc Brake Pads 49 Drive Belt For Generator Water Pump Power Steering Pump 40 Drive Shaft Boots 50 Engine Coolant 48 Engine Oil 42 Engine Oil Filter 43 Evaporative Emission C...

Page 4: ...NOTES...

Page 5: ...he work presented in order to facilitate assembly and adjustment procedures and so they can be com pleted in a shorter time CAUTION Indicates the presentation of information particularly vital to the...

Page 6: ...NERAL How to Use This Manual EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures l l Classifications of Major Maintenance Service points Symbols for Lubrication Sealants and Adhesives...

Page 7: ...r TIE ROD END Operating procedures etc on removal assembly 1 sun tie the cord of the special tool described 2 Loosen the nut but do not FOG LIGHT RELAY CHECK I indicates that there is 1 3 4 continuity...

Page 8: ...o diagnostic inspection procedures for each trouble symptom will be found by means of this chart 7 INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Indicates the inspection procedures corresponding to each t...

Page 9: ...be carried out in the order given in the chart Cautlon If resistance and continuity checks are performed the wrong terminals damage vehicle wiring sensors ECU and or ohmmeter may occur Use care to pre...

Page 10: ...harness and check HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to the connector measurements Carry out this inspection whil...

Page 11: ...inserting the test probe from the harness side Note that if the connector control unit etc is too small to permit insertion of the test probe it should not be forced use a special tool the extra thin...

Page 12: ...to rusted terminals or foreign matter lodged in terminals CONNECTOR PIN INSPECTION If the connector pin stopper is damaged the terminal connec tions male and female pins will not be perfect even when...

Page 13: ...Determine the most likely circuit s and perform tion tests on the connectors and parts of that circuit s Be sure to use the inspection proce dures provided for trouble codes and trouble symptoms For...

Page 14: ...the resistance is almost this time there Battery is a short somewhere switches I If the resistance is not 0 there is no short present time but a momentary short has fuse to blow fuse The main causes o...

Page 15: ...vehicle etc 3 7 11 Items Contents Country 4 USA Make A Mitsubishi I Vehicle type Others A Drive Line L ECLIPSE X ECLIPSE SPYDER Price class 2 Low I TSB Revision 3 Medium 4 High Body hatchback 5 conve...

Page 16: ...0 122 0 DOHC MFI Turbo Mitsubishi Eclipse Mitsubishi Eclipse 2 0 122 0 Spyder DOHC MFI Turbo 2 4 146 5 SOHC MFI VEHICLES FOR CALIFORNIA V I N except sequence number Brand Engine displacement Model cod...

Page 17: ...o face of left door pillar 2 This label indicates Gross Vehicle Weight Rating G V W R Gross Axle Weight Rating front rear and Vehicle Identification Number V I N ENGINE MODEL STAMPING 1 The engine mod...

Page 18: ...r ter panel Hood Liftgate Trunk lid Bumpers In addition a theft protection label is attached to replacement parts for the body outer panel main and the same data are stamped into replacement parts for...

Page 19: ...or original equipment parts B for replacement parts Engine Engine Non turbo Engine Turbo Manual transaxle Engine Non turbo Engine Turbo and Engine A 00003676 Automatic transaxle Engine Non turbo Engin...

Page 20: ...r The illustration indicates left hand side outer Right hand side is symmetrically opposite Quarter panel The label is attached at the inner side of the parts shown in the figure TSB Revision The ill...

Page 21: ...GENERAL Vehicle Target area A for original equipment parts B for replacement parts Front bumper Rear bumper Trunk lid A TSB Revision...

Page 22: ...d placed so that the pad surface is facing upward Do not place anything on top of it 7 Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an a...

Page 23: ...axle Neutral position A T models N or P Steering neutral center position mm in Scan tool ROM pack VEHICLE WASHING If high pressure car washing equipment or steam car washing equipment is used to wash...

Page 24: ...hat vehicles be towed using the front pickup whenev er possible REAR TOWING PICKUP Caution 1 This vehicle cannot be towed by a wrecker using equipment to prevent the from de formation if this vehicle...

Page 25: ...cle 3 Operator should refrain going under a vehicle while it is lifted by the towing unless the vehicle is adequately supported by safety stands 4 Never allow passengers to ride in a towed vehicle 5 S...

Page 26: ...GENERAL Towing and Hoisting LIFTING JACKING SUPPORT FLOOR JACK nember Piece wood 1 Rear Caution Never support any point other than the specified one or it will be deformed TSB Revision...

Page 27: ...care should be taken when raising the vehicle on a frame contact type The be equipped with the proper adapters in order to support the vehicle at the Caution When service procedures require removing...

Page 28: ...cified the cause may be the effect of the viscous dragging force so jack up the front and check the rotation condition of the wheels in this state for no effect by the viscous coupling s dragging forc...

Page 29: ...manually and check to be sure that there is no dragging 3 Use the engine to drive the tyres and then make the measurement Caution 1 If an error is indicated in the state of engine drive motor drive c...

Page 30: ...ground 9 145 5 7 145 5 7 145 5 7 145 5 7 clearance mm in Angle of approach 10 11 8 11 8 11 8 11 8 degrees Angle of departure 11 15 8 15 8 15 8 15 8 degrees Curb weight 1 236 2 725 1 266 2 791 1 245 2...

Page 31: ...rance mm in Angle of approach 10 11 8 11 8 11 8 degrees Angle of departure 11 15 8 15 8 1 5 8 degrees Curb weight 1 285 2 833 1 315 2 899 322 1 357 2 992 Gross vehicle weight rating 1 750 3 858 1 750...

Page 32: ...cle weight rating Gross axle weight rating Front Gross axle weight rating Rear 1 2 3 4 5 6 7 8 9 10 11 Seating capacity Engine Model No Piston displacement 4 1 740 68 5 1 310 51 6 98 8 1 515 59 6 1 51...

Page 33: ...round 9 160 6 3 160 6 3 160 6 3 1 6 0 6 3 clearance mm in Angle of approach 10 12 2 12 2 12 2 12 2 degrees Angle of departure 11 15 8 15 8 15 8 1 5 6 degrees Curb weight 3 053 1 425 3 142 1 305 2 877...

Page 34: ...of bolts and nuts are all in condition The values in the table applicable 1 If toothed washers are inserted 2 If plastic parts are fastened If bolts to plastic or die cast in nuts 4 If self tapping s...

Page 35: ...the following engine oils should be used 1 Engine oil displaying EOLCS certification mark 2 Engine oil conforming to the API classification SH or ECII For further details refer to LUBRICANTS SELEC TIO...

Page 36: ...ar Fuel containing MTBE over 15 vol may cause reduced engine perfor mance and produce vapor lock or hard starting MATERIALS TO FUEL Indiscriminate use of fuel system cleaning should be avoided Many of...

Page 37: ...ant reserve system 7 0 7 4 qts Manual transaxle FWD 2 0 2 1 qts AWD 2 3 2 4 Automatic transaxle Engine Non turbo 8 6 9 1 Engine Turbo 6 7 7 1 qts 2 41 Engine 6 1 6 4 qts Transfer 0 5 qt Differential r...

Page 38: ...afe operating Engine coolant temperature temperature concentration Specific volume 16 3 2 11 12 2 30 20 4 15 5 35 25 13 20 4 1 079 1 074 1 069 1 064 1 058 30 13 25 1 087 1 082 1 076 1 070 1 064 36 32...

Page 39: ...00140124 MAIN T E NA NC E VEHICLE PERFORMANCE Inspection and services be performed any time a is observed or suspected Retain receipts for all vehicle emission services to protect your emission warran...

Page 40: ...iving in sandy areas Driving in salty areas More than 50 operation in traffic or at sustained high speeds during hot weather above Driving on off road MAINTENANCE SERVICE 1 FUEL SYSTEM Tank Pipe and F...

Page 41: ...sed 4 EVAPORATIVE EMISSION CONTROL SYSTEM Check for leaks and clogging except evapo rative emission canister 1 If the fuel vapor vent line is clogged or damaged a fuel vapor mixture escapes into the a...

Page 42: ...odically with new ones After replacing make sure that the ignition cables are routed properly and fully seated NOTE When disconnecting an ignition cable be sure to hold the cable boot If the cable is...

Page 43: ...9 0 11 5 Engine Non turbo Check the belt tension with the tension gauge at the middle point of the belt or check the belt deflection by pressing the belt point by a force of 98 22 Ibs Standard value...

Page 44: ...on Never use nondetergent or straight mineral oil 1 After warming up the engine remove the oil filler cap 2 Remove the drain plug to allow the engine oil to drain 3 Replace the drain plug gasket with...

Page 45: ...ement filter for this vehicle It is possible in cold weather that this vehicle may develop high for a short duration You should be sure that replacement filter used on this vehicle is a high quality f...

Page 46: ...l level by removing filler plug If is contaminated it is necessary to replace it with new 1 With the vehicle parked at a level the filler plug and check that the oil level 2 The level must be up to th...

Page 47: ...o not overfill automatic transaxle leakage or damage can result 6 Remove dipstick with handle above tip take fluid level reading If the vehicle has been driven for at feast 15 minutes before inspectin...

Page 48: ...has too much fluid gears churn up foam and cause same conditions which occur with low fluid level resulting in accelerated deterioration of ATF In either case air bubbles can cause overheating fluid o...

Page 49: ...amination has been corrected 1 Remove drain plugs to let fluid drain 2 Remove the oil pan 3 Check the oil filter for clogging and damage and replace if necessary 4 Clean the inside of oil pan and magn...

Page 50: ...t it has a suitable viscosity Change oil 1 Remove transfer drain plug 2 Drain oil 3 Tighten drain plug to specified torque Specified torque 32 Nm 24 4 Remove filler plug and fill with specified oil ti...

Page 51: ...r hose with your hand to check that warm water is flowing 11 After the thermostat opens race the engine at 3 000 3 times 12 After the engine is stopped wait until the engine has cooled down and then r...

Page 52: ...ay occur with possible bursting failure 2 Faulty installation casing twisting or interference wheel tire or chassis 18 BALL JOINT AND STEERING SEALS Check for grease leaks damage 1 These components wh...

Page 53: ...ds If yes SRS system is functioning properly If not refer to GROUP Troubleshooting SRS COMPONENTS VISUAL CHECK 1 Turn the ignition key to position disconnect the negative battery cable and tape the te...

Page 54: ...th to the driver and AIR BAG MODULE STEERING CLOCK SPRING CHECK 1 Remove the air bag module and clock spring Refer to GROUP and Clock Spring Caution The removed air bag be In a clean dry place with th...

Page 55: ...le s driver and passenger 9 Install the steering column covers steering wheel and the air bag module 10 Check steering wheel for noise binds of difficult operation 11 Check steering wheel for excessiv...

Page 56: ...T SYSTEM CONNECTION OF MUFFLER PIPINGS AND CONVERTER HEAT SHIELDS Check as required 1 Check for holes and gas leaks dwe to damage etc 2 Check the joints and connections for looseness and gas leaks 3 C...

Page 57: ...rstrip Sealing between body flange and weatherstrip Sealing between laminated glass and weatherstrip Recommended brand ATD Part No 8513 or equivalent ATD Part No 8509 or equivalent ADHESION WITH RIBBO...

Page 58: ...um brake shoe hold down pin and wheel cylinder ATD Part No 8513 or equivalent FAST BONDING ADHESIVE Application Recommended brand Adhesion of all materials except polyethylene polypropylene Part 8155...

Page 59: ...ENGINE CONTENTS ENGINE ENGINE OVERHAUL ENGINE ENGINE OVERHAUL ENGINE ENGINE OVERHAUL...

Page 60: ...11 2...

Page 61: ...Mixture Check 10 Ignition Timing Check Lash Adjuster Check CYLINDER HEAD GASKET 31 ENGINE ASSEMBLY 16 GENERAL INFORMATION 2 OIL PAN AND OIL SCREEN 26 ON VEHICLE SERVICE 7 Basic Idle Speed Adjustment...

Page 62: ...isplacement Compression ratio Firing order Counterbalance shaft 8 5 Equipped Valve timing Intake valve Exhaust valve Opens Closes Opens Closes 21 BTDC Lubrication system I Pressure feed full flow I Oi...

Page 63: ...d belt is installed Deflection Whenchecked mm in When a new belt is installed When a used belt is installed ignition timing at idle ignition timing at idle idle speed contents contents ppm pressure at...

Page 64: ...nt rear and cylinder head Specified sealant ATD Part No 8860 or equivalent pan cylinder block and thermostat case assembly MITSUBISHI GENUINE PART or equivalent Flywheel bolt or drive plate bolt Stud...

Page 65: ...ket Lash adjuster removal Valve lifter set End yoke holder Crankshaft sprocket 193 General service tool Preventing foreign substances from entering transfer Plug 654 Cylinder head bolt wrench 12 Remov...

Page 66: ...Thin or diluted engine oil Change engine oil Excessive bearing clearance Replace bearings belt noise Incorrect belt tension Adjust belt tension and or replace tim ing belt engine Loose engine roll st...

Page 67: ...n GENERATOR DRIVE BELT TENSION ADJUSTMENT 1 Loosen the nut of the generator pivot bolt 2 Loosen the lock bolt 3 Turn the adjusting bolt to adjust the belt tension or deflec tion to the standard value...

Page 68: ...items Tension tbs Deflection mm in When a new belt is When a used belt is installed 3 Tighten fixing bolt A Tightening torque 28 Nm 21 4 Tighten the remaining fixing bolts and Tightening torque Bolt a...

Page 69: ...F l Transaxle Neutral P range on vehicles with 2 Turn the ignition switch to OFF and connect the scan tool to the data link connector 3 Set up a timing light 4 Start the engine and run at idle 5 Selec...

Page 70: ...le for 2 minutes 6 Select No 22 of the SCAN TOOL DATA LIST 7 Check the curb idle speed Standard value 750 100 NOTE The idle speed is controlled automatically by the idle air control system 8 If the id...

Page 71: ...ndard value even though the result of the inspection is all items COMPRESSION CHECK 1 Before inspection check that the engine oil starter battery are normal Also set the to the condition l Engine cool...

Page 72: ...e limit Limit max 100 14 psi 9 If there is a cylinder with compression or a compression difference that is outside the limit pour a small amount of engine oil through the spark plug hole and repeat th...

Page 73: ...sh adjusters is heard and the noise does not as follows as follows 1 Check the engine oil and if required refuel or replace it NOTE l If the amount of the engine oil is insufficient air will be sucked...

Page 74: ...pression top dead center 3 Push the rocker arm indicated by the white arrow mark as shown in the illustration at left and check whether or not the arm lock goes down 4 Turn slowly the crankshaft 5 Che...

Page 75: ...remove the roller rocker 2 Remove the lash adjuster from the cylinder head 3 Install a new lash adjuster air has been bled to the 4 Use the special tool to push down the valve and install the roller r...

Page 76: ...16 Operation l Radiator Installation Refer to GROUP 14 Radiator l Transaxle Assembly Removal Refer to GROUP Assembly Refer to GROUP Transaxle Refer to GROUP Transaxle Refer to GROUP Transaxle l Engine...

Page 77: ...on sensor connector 21 Crankshaft position sensor connector 22 Air conditioning compressor connector 23 Control wiring harness 24 Brake booster vacuum hose 14 Ignition power transistor connector 15 Th...

Page 78: ...mount bracket assembly 33 Engine assembly REMOVAL SERVICE POINTS POWER STEERING PUMP Remove the power steering pump from with the hose attached NOTE Place the removed power steering pump in a place wh...

Page 79: ...ck up the engine so that the weight of the engine is no longer being applied to the engine mount bracket and then remove the engine mount bracket ENGINE ASSEMBLY REMOVAL After checking that all cables...

Page 80: ...th the arrow mark facing toward the shown direction Then the stopper HIGH PRESSURE FUEL HOSE CONNECTION When connecting the high pressure the fuel rail apply a small amount of clean oil to the hose th...

Page 81: ...CRANKSHAFT PULLEY REMOVAL AND INSTALLATION l Under Cover Removal Refer to GROUP 42 Under Cover Refer to Under Removal steps 1 Drive belt Generator 2 Drive belt Power steering 3 Drive belt A C 4 Crank...

Page 82: ...ON Operation l Timing Belt Front Upper Cover Removal Refer to Post installation Operation l Timing Belt Front Cover Refer to l Engine 2 9 Nm 2 2 3 4 Nm 2 5 Nm Enaine oil TSB Revision 2 in Sealant MITS...

Page 83: ...shaft bearing cap 15 Camshaft bearing cap 16 Rear camshaft bearing cap R H 17 Rear camshaft bearing cap L H 18 Exhaust camshaft 19 Intake camshaft 20 Camshaft oil seal 21 Semi circular packing Install...

Page 84: ...ng cap NOTE If the bearing cap is difficult to remove use a plastic hammer to gently tap the rear part of the camshaft and then remove INSTALLATION SERVICE POINTS INTAKE CAMSHAFT EXHAUST CAMSHAFT INST...

Page 85: ...special tool to drive the camshaft oil seal into position carefully CAMSHAFT POSITION SENSING CYLINDER CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION 1 Install the camshaft position sensing cylinder t...

Page 86: ...el Gauge Removal and Installation l Front Exhaust Pipe Removal and Installation GROUP 15 Exhaust Pipe and Muffler Refer to GROUP 15 Exhaust Pipe and Muffler Nm 1 I 6 9 Nm 5 1 29 I 6 6 6 5 Removal step...

Page 87: ...ing the transfer assembly insert the special tool to prevent the oil from leaking out 5 Suspend the shaft from the vehicle chassis with wire etc PAN After removing the oil pan mounting bolts oil pan w...

Page 88: ...Post installation Operation l Timing Belt Removal and installation Refer to Removal steps 1 Crankshaft sprocket front oil seal INSTALLATION SERVICE FRONT OIL SEAL 1 Apply engine oil to the entire ins...

Page 89: ...val and Installation Refer to GROUP Transaxle Assembly l and and Refer to GROUP Transaxle Assembl Refer to GROUP Transaxle Assembly Refer to GROUP Transaxle Assembly Nm Engine oil Removal steps 1 Flyw...

Page 90: ...tration PLATE BOLT BOLT M T 1 Clean off all sealant oil and other substances which are adhering to the threaded bolts crankshaft thread holes and the flywheel or drive plate 2 Apply oil to the bearing...

Page 91: ...6 Engine coolant temperature gauge unit connector 7 Engine coolant temperature sensor connector 8 Ignition power transistor connector 9 Throttle position sensor connector 10 Capacitor connector 11 Man...

Page 92: ...ase assembly 37 O ring 38 Flange bolts and flange nut Refer to GROUP 39 Cylinder head 40 Cylinder head assembly 41 Ring 42 A Cylinder head gasket l Timing belt Refer to 28 Power steering pump 29 Rocke...

Page 93: ...illustration in 2 or 3 stages and then the cylinder head assembly INSTALLATION SERVICE CYLINDER HEAD GASKET INSTALLATION 1 all oil and grease from the gasket mounting 2 Install the gasket to the cyli...

Page 94: ...n the illustration Mark of the cylinder head bolt and cylinder head by paint 5 Tighten of a turn shown in the Check that the painted of lined the Caution 1 Always make a tightening If than the head bo...

Page 95: ...mounting bolts 5 Tighten the water inlet pipe bolts RADIATOR LOWER HOSE RADIATOR UPPER HOSE CONNECTION 1 Insert each hose as far as the projection of the water outlet fitting or water inlet fitting 2...

Page 96: ...o GROUP 32 Engine Mounting 48 17 6 8 6 5 2 25 Removal steps l Drive Belt Tension Adjustment 1 Drive belt Generator 2 Drive belt Power steering 3 Tensioner pulley bracket 4 Drive belt A C 5 Water pump...

Page 97: ...ion only 2 Loosen the tension pulley center bolt 3 Move the tension pulley to the water pump side and then remove the timing belt Caution If the timing belt is to be reused use chalk to mark on its fl...

Page 98: ...new part the pin will be in the auto tensioner 5 Install the auto tensioner to the engine TIMING BELT INSTALLATION 1 Align the timing marks on the camshaft sprocket crank shaft sprocket and oil pump...

Page 99: ...e belt at indicated position by another bulldog clip 4 Install the timing belt around the the oil pump sprocket the crankshaft and the ten sioner pulleys in the order 5 Remove the two bulldog clips 4...

Page 100: ...bolt do pulley turn with the bolt 3 Turn the crankshaft two revolutions clockwise so that the timing marks are aligned After it for 15 min utes measure the amount of of the auto ten sioner Standard v...

Page 101: ...ng belt Refer to 2 Crankshaft sprocket 3 Crankshaft sensing blade l Timing belt tension adjustment 4 Timing belt tensioner 5 Timing belt __ REMOVAL SERVICE POINTS CRANKSHAFT SPROCKET 1 Use the special...

Page 102: ...lack in the belt BELT TENSION ADJUSTMENT Adjust the tension of timing belt by the following procedure 1 Temporarily fix the timing belt B tensioner such that the center of the tensioner pulley is to t...

Page 103: ...nstalling make sure the direction is correct See figure CRANKSHAFT SPROCKET INSTALLATION Use the special tool to install the crankshaft sprocket and bolt NOTE Apply the minimum amount of engine oil to...

Page 104: ...NOTES...

Page 105: ...NTERBALANCE SHAFT AND OIL PAN 42 FUEL AND EMISSION CONTROL PARTS 25 GENERAL INFORMATION 2 General Specifications 2 GENERATOR IGNITION SYSTEM 11 INTAKE MANIFOLD PISTON AND CONNECTING ROD 51 ROCKER ARMS...

Page 106: ...ntake valve Opens BTDC 2 1 Exhaust valve Closes ABDC 51 Opens BBDC 57 Closes ATDC Lubrication system Pressure feed full flow filtration I Oil pump type Cooling system Water pump type EGR type I Involu...

Page 107: ...t 199 70 4 3189 Valve thickness to valve guide clearance mm Intake 0 10 in Exhaust 0 15 Valve face angle mm in Valve spring free length mm in 47 0 1 85 46 0 1 83 Valve spring load installed height N m...

Page 108: ...0 05 0 1 block grinding limit of gasket surface mm in l 0 2 Total resurfacing depth of both cylinder head and cylinder block block overall height mm in 283 9 284 1 11 177 11 185 block I D mm in 85 0 3...

Page 109: ...ley bolt Oil sprocket nut pump Crankshaft bolt Tensioner bolt Counterbalance shaft sprocket bolt Camshaft sprocket bolt Engine support bracket bolt Fuel and emission parts EGR valve bolt Throttle body...

Page 110: ...E N G I N E O V E R H A U L TSB Revision...

Page 111: ...43 36 SEALANT Items Specified sealant I Camshaft position sensor support Mitsubishi Genuine Part No or equivalent Rocker cover Semi circular packing Enaine bracket bolt ATD Part No 8660 or equivalent...

Page 112: ...OOLS Tool Tool number and name Supersession Application Installation of Handle seal Crankshaft rear oil seal installer 62 Removal and installation Plug wrench case cap Crankshaft front oil seal instal...

Page 113: ...ENGINE OVERHAUL Use with TSB Revision...

Page 114: ...ENGINE OVERHAUL Special Tools Cylinder head bolt TSB Revision...

Page 115: ...steps 1 Drive belt 2 Water pump pulley 3 Power steering pump pulley 4 Generator brace 5 Generator 6 Crankshaft pulley 7 Center cover 8 Spark plug cable 9 Spark plug 10 Ignition power transistor 11 Ign...

Page 116: ...L Generator and INSTALLATION SERVICE POINTS POSITION I N S T A L L A T I O N Apply a 3 mm bead of form in place gasket FIPG to the area shown Specified sealant Mitsubishi Genuine Part No or equivalent...

Page 117: ...6 Tensioner pulley 7 Tensioner arm 8 Auto tensioner 9 Idler pulley 10 Oil pump sprocket 11 Crankshaft bolt 12 Crankshaft sprocket 13 Crankshaft sensing blade 55 Nm 40 14 Tensioner 15 Timing belt 16 C...

Page 118: ...its life drastically so the removed timing belt sprocket and tensioner must be free from oil and water These parts should not be washed Replace parts if seriously contami nated 2 If there is oil or wa...

Page 119: ...from oil and water These should not be washed Replace parts if seriously 2 If there is oil or water on each part check front case oil seals camshaft oil seal and water pump for COUNTERBALANCE SHAFT S...

Page 120: ...gon between the No 2 and No 3 journals and tighten the bolt to the specification Caution Locking the camshaft sprocket with a tool damages the sprocket ENGINE SUPPORT BRACKET INSTALLATION 1 Coat the b...

Page 121: ...rcular Cylinder head SEALANT APPLICATION ON ROCKER COVER Apply the specified sealant to areas in the illustration Specified sealant ATD Part No 8660 in SPACER INSTALLATION 1 Install the spacer with th...

Page 122: ...e tensioner pulley center and the bolt center is as shown in the illustration 4 Move the tensioner B in the direction of arrow while lifting with a finger to give a sufficient tension to the tension s...

Page 123: ...uts 4 Tighten the nuts to the specified torque AUTO TENSIONER INSTALLATION 1 If the auto tensioner rod is in its fully extended position reset it as follows 2 Clamp the auto tensioner in the vise jaws...

Page 124: ...camshaft it will rotate one tooth counterclockwise This should be taken into account when installing the timing belt on the sprockets NOTE The same camshaft sprocket is used for the intake and exhaust...

Page 125: ...inserted 60 mm 2 4 in or more Keep the screwdriver inserted the installation of the timing belt is finished NOTE Step 4 is performed to ensure that the oil pump sprocket is correctly positioned with r...

Page 126: ...al tools Socket Wrench and Torque Wrench on the tensioner pulley and loosen the tensioner pulley center bolt NOTE If the special tool is not available use a commercially available torque wrench that i...

Page 127: ...fingernail 2 Cracks on rubber back 3 Cracks or peeling of canvas 4 Cracks on rib root 5 Cracks on belt sides 6 Abnormal wear of belt sides The sides are normal if they are sharp as if cut by a knife 7...

Page 128: ...NGINE OVERHAUL Timing 4 Press the rod with a force of 98 to 196 22 to 44 ft and measure its protrusion 5 If the measured value is mm 0 39 in or more shorter than the value obtained in step replace the...

Page 129: ...9 Nm 7 Removal steps 1 Air fitting 2 Air fitting gasket 3 Throttle body 4 Throttle body gasket 5 EGR valve 6 EGR valve gasket 7 Injectors and fuel rail 12 Nm 9 19 Nm 14 8 Insulator 9 Fuel pressure 10...

Page 130: ...drop of clean engine oil to aid in installation 2 Install injector top end into fuel rail Be careful not to damage the O ring during installation FUEL PRESSURE REGULATOR INSTALLATION 1 Before install...

Page 131: ...8 20 Nm 14 31 Nm 22 Removal steps 1 Water hose 2 Water hose 3 Engine coolant temperature gauge unit 4 Engine coolant temperature sensor 5 Water inlet fitting 6 Thermostat case 7 Water outlet fitting...

Page 132: ...ant for hour SEALANT APPLICATION TO WATER OUTLET Specified sealant Mitsubishi Genuine Part No or equiva lent NOTE 1 Be sure to install the housing quickly while the is wet within 15 minutes 2 After in...

Page 133: ...18 Turbocharger 3 O ring 19 Engine hanger 4 Heat protector A 20 Exhaust manifold 5 Heat protector 21 Gasket 6 Heated oxygen sensor 22 Water hose 7 Exhaust fitting 23 Water pipe 8 Gasket 24 Water pipe...

Page 134: ...ERVICE WATER PIPE O RING Wet the O ring with water to facilitate assembly Caution Keep the O ring free of oil or grease TURBOCHARGER 1 the cone disc spring in shown direction 2 Tighten the turbocharge...

Page 135: ...FT REMOVAL AND INSTALLATION 20 14 8 I Removal steps 1 Bearing cap rear 2 Bearing cap front 3 Camshaft oil seal 4 Bearing cap No 5 5 Bearing cap No 2 6 Bearing cap No 4 7 cap No 3 8 Camshaft 9 Rocker a...

Page 136: ...d for driving the crankshaft position sensor 3 Install the crankshaft sprocket or spacer and flange to an end of the crankshaft and turn the until the timing marks are lined up setting No cylinder to...

Page 137: ...ENGINE OVERHAUL Rocker OIL INSTALLATION SEAL PACKING TSB Revision...

Page 138: ...and other foreign matter 2 Do not disassemble lash adjuster 3 When lash adjuster use diesel fuel 1 Immerse the lash adjuster in clean diesel fuel 2 While lightly pushing down inner steel ball using t...

Page 139: ...4 After air bleeding place lash adjuster on the Leak down tester 5 After plunger has down measure time taken for it to go down 1 mm Replace if measured time is out of specification Standard seconds mm...

Page 140: ...y Retainer lock 5 Valve spring retainer 6 Valve spring 7 Intake valve 8 Retainer lock 9 Valve spring retainer 10 Valve spring TSB Revision 11 Exhaust valve 12 Valve stem seal 13 Valve spring seat 14 V...

Page 141: ...d valves springs and other parts tagged to indicate their cylinder No and location for reassembly STEM SEAL REMOVAL 1 Do not reuse valve stem seal INSTALLATION SERVICE POINTS VALVE STEM SEAL INSTALLAT...

Page 142: ...to the tightening sequence tighten the bolts to the specified torque 78 Nm t o o l 4 Loosen bolts completely 5 Retighten the loosened bolts to Nm in the specified tightening sequence 6 Make a paint m...

Page 143: ...ned with cylinder grinding Cylinder head height Specification when 131 9 132 1 mm in VALVE 1 Check the valve face for correct contact I incorrect reface using valve Valve seat contact should be main t...

Page 144: ...etween the end of the valve stem and the spring seating surface If the measurement the specified limit replace the valve seat VALVE SEAT RECONDITIONING PROCEDURE 1 Before correcting the valve seat che...

Page 145: ...Using a valve seat cutter correct the valve seat to the specified width and angle See VALVE SEAT RECONDITIONING PROCEDURE VALVE GUIDE REPLACEMENT PROCEDURE 1 Using the push rod and a press remove the...

Page 146: ...te 10 Plug 11 O ring 12 Flange bolt 13 Oil pressure switch 14 Oil pressure gauge unit 15 Relief plug 16 Gasket 17 Relief spring 18 Relief plunger TSB Revision 19 Oil filter bracket 20 Oil filter brack...

Page 147: ...t hit the plug head with a hammer two to three times and the plug will be easily loosened FLANGE BOLT REMOVAL 1 Remove the plug on the side of cylinder block 2 Insert a Phillips screwdriver shank diam...

Page 148: ...INSTALLATION SERVICE POINTS RIGHT COUNTERBALANCE REAR BEARING INSTALLATION 1 Apply engine oil to the outer surface of bearing 2 Using special tools install right rear bearing that oil hole of bearing...

Page 149: ...CASE 1 Place the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer of the special tool to install the front 2 Install the front case assembly through a new f...

Page 150: ...nt marks SEALANT APPLICATION TO OIL GAUGE UNIT 1 Coat the threads of switch with sealant and the switch using the special Specified sealant ATD Part No 8660 or equivalent Caution 1 Keep the end of thr...

Page 151: ...the cylinder block to lock the counterbalance shaft 2 Secure the oil pump driven gear onto the left counterbal ance shaft by tightening the flange bolt to specified torque PLUG INSTALLATION 1 Install...

Page 152: ...INE or equivalent NOTE Be sure to install the oil pan quickly the sealant is wet within 15 minutes 2 After installation keep the sealed area from the oil and coolant for approx hour 3 Note the differe...

Page 153: ...tallation surface of the filter bracket 2 Apply engine oil to the O ring of the oil filter 3 Screw the oil filter in until the O ring contacts the bracket Then tighten turn tightening torque Nm 12 NOT...

Page 154: ...y 2 Check the oil seal lip for deterioration Replace oil seal if necessary I COUNTERBALANCE SHAFT 1 Check oil holes for clogging 2 Check journal for seizure damage and contact with bear ing If there i...

Page 155: ...REMOVAL AND INSTALLATION 4 Removal steps 1 Nut Connecting rod cap 3 Connecting rod bearing 4 Piston and connecting rod assembly 5 Connecting rod bearing 6 Piston ring No 1 7 Piston ring No 2 8 Oil ri...

Page 156: ...I 1 Remove the stop screw from the base 2 Select the correct piston support for your application See above Fit the piston support onto the base Place the base on press support blocks TSB Revision 3 In...

Page 157: ...ions on the tool 3 Place the base on press support blocks 4 Slide the piston pin over the threaded end of the press pin and thread the correct guide pin it 5 Coat the piston pin with oil and connectin...

Page 158: ...it one the rail into the piston groove then press the remaining portion position by finger See illustration Caution Do not use piston ring expander side rail 3 Install the lower side rail in the as de...

Page 159: ...e the crankshaft pin diameter and confirm its classi fication from the following table In the case of a crankshaft supplied as a service part identification colors of its pins are painted at the posit...

Page 160: ...h fingers to the full length of the bolt threads the nut does not run down the bolt should be replaced 2 Before installation of each nut apply engine oil to the threaded portion and bearing surface of...

Page 161: ...d with a one the piston also be replaced with new ones 2 Check for the clearance the piston ring and ring groove If the limit is exceeded replace the or piston or both Item No 1 ring ring Limit 0 1 mm...

Page 162: ...me length as the width of bearing and place it on crankshaft pin in parallel with its axis 3 Install the connecting rod cap tighten the nuts to specified torque 4 Carefully remove the connecting rod c...

Page 163: ...ALLATION I Removal steps 1 Flywheel bolt 2 Flywheel 3 Drive plate bolt 4 Adapter plate 5 Drive plate 6 Crankshaft bushing 7 Rear plate 8 Bell housing cover 9 Oil seal case 10 Oil seal 11 Bearing cap 1...

Page 164: ...he crankshaft journal diameter and confirm its classification from the following table In the case of a crankshaft supplied as a service part identification colors of its journals are painted at the p...

Page 165: ...s so that their arrows directed to the timing belt side 2 Before installing the bearing cap bolts check that the shank length of each bolt meets the limit limit is exceeded replace the bolt A Max 71 1...

Page 166: ...nd play exceeds the bearings Standard value Limit 0 25 mm OIL SEAL INSTALLATION Revision SEALANT TO sealant Mitsubishi Genuine No lent NOTE 1 Be sure to install the case the is wet within 15 minutes 2...

Page 167: ...the check If defects are evident correct or replace 2 Using a straightedge and feeler gauge check the block top surface for Make sure that the surface is free from gasket chips and other foreign matt...

Page 168: ...d piston O D calculate boring dimension Boring finish dimension Piston O D clearance between piston O D and cylinder 0 02 mm in honing margin 4 Bore all cylinders to calculated boring finish dimension...

Page 169: ...7 Removal steps 1 Roll stopper bracket front 2 Engine support bracket front 3 Exhaust pipe support bracket 4 Roll stopper bracket rear BRACKET ENGINE OVERHAUL Bracket REMOVAL AND INSTALLATION TSB Revi...

Page 170: ...11 NOTES...

Page 171: ...SSEMBLY 14 GENERAL INFORMATION 2 OIL PAN AND OIL SCREEN 24 ON VEHICLE SERVICE 8 Basic idle Speed Adjustment Refer to GROUP Compression Pressure Check Curb Speed Check Drive Tension Adjustment Mixture...

Page 172: ...45 Stroke mm in 8 3 0 3 2 8 7 Piston displacement 1 996 121 8 Compression ratio 9 6 Firing order Valve timing Intake Opens 1 3 BTDC Measured at 0 5 mm Closes 39 7 ABDC Exhaust Opens 36 BBDC Closes 1 1...

Page 173: ...is installed When a used belt is installed Drive belt Tension Whenchecked For power When a new belt is installed steering oil and A C When a used belt is installed Deflection Whenchecked mm in When a...

Page 174: ...Scan tool MUT II ROM Pack MUT II Interface cartridge 545 Adapter harness Remover crankshaft damper sprocket Remover puller damper Remover crankshaft sprocket Supersession 502 544 545 TSB Revision 102...

Page 175: ...Special Took Oil seal installer seal SERVICE TOOL Revision...

Page 176: ...ol Tool number Supersession and name 0991453 453 Engine hanger assembly the engine assembly removal and of the seal installation Oil seal pilot installer 6995059 6926 2 Crankshaft oil seal installer R...

Page 177: ...rings pressure too high Oil relief valve stuck closed Repair relief valve valves Incorrect lash adjuster Bleed air or replace lash adjuster Thin or diluted engine oil low oil pressure Change engine oi...

Page 178: ...he generator pivot nut 3 Loosen the lock nut 4 Turn the adjusting screw to adjust belt tension or deflection to the standard NOTE When installing a new belt apply 310 70 ibs of tension for 5 minutes o...

Page 179: ...nd adjust tension Standard value When a new belt is when a used belt is installed installed Tension 489 712 I Deflection 6 5 9 5 mm in I Tighten the fixing bolt A Tightening torque 39 Nm 29 4 Tighten...

Page 180: ...ming using a timing light because the crankshaft position is detected directly and ignition timing is controlled electronically CURB IDLE SPEED CHECK 1 Before inspection and adjustment set vehicles in...

Page 181: ...loop control is carried out normally the output signal of the heated oxygen sensor repeats between and 000 at idle l Fuel pressure Injector l Ignition coil spark plug cable spark plug l EGR system an...

Page 182: ...he cylinders are below the limit Limit NOTE The limit value can be derived by calculating the difference between the maximum and minimum values for the compression pressure and dividing this value by...

Page 183: ...adjusters and cause them to be spongy 2 Insufficient running time after rebuilding the cylinder head Low speed running up to 1 hour may be required 3 Low oil pressure 4 The oil restrictor pressed in t...

Page 184: ...4 Radiator l Transaxle Assembly Installation Refer to GROUP Transaxle Assembly Refer to GROUP Assembly l Engine Coolant Supplying Refer to GROUP 00 Maintenance Service l Hood Installation l Accelerato...

Page 185: ...15 Generator harness connector 16 Ignition coil connector 17 Camshaft position sensor connector 18 EGR solenoid valve connector 19 Generator connector 20 Crankshaft position sensor connector 21 Knock...

Page 186: ...30 Engine mount bracket assembly 31 Engine assembly REMOVAL SERVICE POINTS POWER STEERING Remove the power pump from the bracket with the hose attached NOTE Place the removed power steering pump in wh...

Page 187: ...ort the engine with a garage jack 2 Remove the special tool which was attached when the transaxle assembly was removed 3 Hold the engine assembly with a chain block or similar 4 a garage jack against...

Page 188: ...e mount bracket while adjusting the position of the engine 2 Support the engine with the garage jack 3 Remove the chain block and support the engine assembly with the special tool 4 Align the notches...

Page 189: ...emoval Refer to GROUP 42 Under Cover Post installation l Drive Belt Tension l Under Cover Installation Refer to GROUP 42 Under Cover Removal steps 1 Drive belt Power steering and 2 Drive belt Generato...

Page 190: ...E N G I N E I INSTALLATION SERVICE POINTS CRANKSHAFT PULLEY INSTALLATION CRANKSHAFT BOLT TSB Revision...

Page 191: ...or equivalent Camshaft removal steps 1 Ignition coil pack 2 PCV hose 3 Breather hose 4 Air hose 5 Vapor hose and pipe assembly connection 6 Cylinder head cover Semi circular packing 8 Camshaft positio...

Page 192: ...REMOVAL Identify the camshafts before removing from the head The camshafts are not interchangeable INSTALLATION SERVICE POINTS CAMSHAFT OIL SEAL 1 a piece of wood between a garage jack and the engine...

Page 193: ...stall the intake camshaft sprockets CYLINDER HEAD COVER INSTALLATION Install the cylinder head cover assembly to the head and tighten fasteners in sequence shown in figure Tighten all fasteners accord...

Page 194: ...Engine Oil Draining and Supplying Oil Level Gauge Removal and l Front Exhaust Pipe Removal and Installation Refer to GROUP 15 Exhaust Pipe and Muffler Specified sealant 5699 or equivalent TSB Revisio...

Page 195: ...Installation Refer to Removal steps 1 Crankshaft sprocket 2 Crankshaft front oil seal REMOVAL SERVICE POINTS CRANKSHAFT SPROCKET REMOVAL Caution Do not nick the shaft seal surface or seal bore FRONT O...

Page 196: ...ENGINE Crankshaft Front Oil Seal I INSTALLATION SERVICE CRANKSHAFT FRONT OIL SEAL Use the special tool to align the oil seal witti the CRANKSHAFT SPROCKET INSTALLATION TSB...

Page 197: ...r oil seal INSTALLATION SERVICE POINT CRANKSHAFT REAR OIL SEAL INSTALLATION Caution If burr or scratch is present on the crankshaft edge chamfer cleanup with 400 grit sand paper to prevent seal damage...

Page 198: ...ENGINE Crankshaft Rear Oil 3 Drive the seal into the using and handle until the tool bottoms the block If the seal is driven into block may an oil leak TSB Revision...

Page 199: ...l Air Cleaner Removal 6 Post installation Operation l Air Cleaner Installation l Engine Oil Refer to GROU 00 Maintenance Service l Engine Coolant Supplying Refer to GROUP 00 Maintenance Service l Acc...

Page 200: ...Injector harness connector 12 Ignition coil connector 13 Camshaft position sensor connector 14 EGR solenoid valve connector 15 Heater hose connection 16 High pressure fuel hose connection 17 Purge air...

Page 201: ...t camshafts Refer to 23 Front exhaust pipe connection 24 Gasket 25 Cylinder head bolt 26 Cylinder head 27 Cylinder head gasket REMOVAL SERVICE POINT A RADIATOR UPPER HOSE DISCONNECTION Place mating on...

Page 202: ...4 step torque method tighten according to the following values 1 Tighten center fasteners 1 thru 6 to 33 Nm 25 Then outer fasteners 7 thru 10 to 27 Nm 20 2 Tighten center fasteners thru 6 to 67 Nm 50...

Page 203: ...E FUEL HOSE CONNECTION When connecting the high pressure fuel to the fuel rail apply a small amount of clean engine oil to the and then insert being careful not to the O ring Caution Do not let the en...

Page 204: ...n l Crankshaft Pulley Installation Refer to l Engine Adjustment 88 Nm 84 Nm 8 9 TSB Revision Removal steps 1 Power steering oil pump tion 2 Power steering oil pump bracket 3 Engine mount bracket assem...

Page 205: ...AL Align timing marks Loosen the timing belt remove timing belt Caution Do not rotate the camshaft or crankshaft after removing the timing belt or valve components may be Always align timing marks bef...

Page 206: ...kshaft sprocket to to take belt slack Install the tensioner to block but do not tighten fasteners 6 Using a torque wrench on the tensioner pulley apply 28 Nm 21 of torque to tensioner 7 With torque be...

Page 207: ...UST MANIFOLD 27 FUEL AND EMISSION CONTROL PARTS GENERAL INFORMATION 2 General Specifications 2 GENERATOR 11 IGNITION SYSTEM 12 INTAKE MANIFOLD OIL PAN AND PUMP OIL PUMP PISTON CONNECTING ROD AND CYLIN...

Page 208: ...Piston stroke mm in Compression ratio Valve timing Intake valve Measured at 0 5 mm in lift Exhaust valve Lubrication system Water pump type EGR type Injector type and number 4 87 5 3 445 83 0 3 267 Op...

Page 209: ...Camshaft end play mm in Camshaft bearing journal diameter mm in 0 15 Camshaft lift mm in Hydraulic lash adjuster mm in head and valve Intake Exhaust Body diameter Plunger travel minimum dry 8 22 7 00...

Page 210: ...gth mm in spring tension valve closed N mm 0 076 0 101 46 1 811 spring tension valve open N mm spring number of coils mm in spring wire diameter mm in installed spring height mm in pump pump clearance...

Page 211: ...ng ring Piston pin clearance in piston mm in Piston pin in rod interference mm in 63 82 pin diameter mm in pin length mm in 74 75 75 25 ring gap mm Top upper compression ring 0 8 in Intermediate compr...

Page 212: ...rod journal diameter mm in Crankshaft out of round mm in Crankshaft tape mm in Crankshaft main bearing diameter clearance mm in 0 0035 0 0038 Crankshaft end play mm in TORQUE SPECIFICATIONS Items Gen...

Page 213: ...Oil filter Adapter Oil Oil pick up tube Oil pump Oil pump Relief valve retaining cap Long bolt 87 Short bolt 28 20 21 12 2 8 23 54 Oil pump cover Piston connecting rod and cylinder block Connecting ro...

Page 214: ...ing a form in place gasket requires care but it s easier than using precut gaskets Gasket material should be applied sparingly 1 mm inch diameter or less to one surface Be certain the material surroun...

Page 215: ...er Removal puller damper Installer damper sprocket Installation of crankshaft damper and crankshaft End yoke holder Holding camshaft sprocket when loosening or 9 Pin 2 6792 Installation of crankshaft...

Page 216: ...ENGINE OVERHAUL Special crankshaft seal Installation of crankshaft oil seal 6926 2 8995060 TSB Revision...

Page 217: ...drive belt 5 Loosen the generator pivot nut 6 Loosen the lock nut 7 Turn the adjusting screw to adjust the belt tension to the standard value NOTE When installing a new belt apply 310 70 of tension fo...

Page 218: ...il pack 2 Remove coil pack mounting nuts 3 Remove coil 4 Remove spark plug cables 5 Remove the spark plug using a socket with a rubber or foam insert 6 Inspect the spark plug condition Refer to Spark...

Page 219: ...ENGINE OVERHAUL Ignition Remove crankshaft position sensor mounting screw Re move sensor Revision...

Page 220: ...Install camshaft position sensor Tighten sensor mounting screws to 9 Nm 6 5 torque 4 To avoid cross threading the spark plug into the cylinder head by hand 5 Tighten spark plugs to 28 Nm 20 torque 6...

Page 221: ...he primary of each At the coil connect an ohmmeter between the and the pin corresponding to the in Resistance on the primary side of 0 51 ohm Replace the coil if resistance is 2 Remove ignition cables...

Page 222: ...belt Special Tensioner pulley Timing belt tensioner 1 Remove crankshaft damper bolt Remove damper using Special Tool and insert or equiva lent 2 Remove engine mount bracket 3 Remove front half of tim...

Page 223: ...ioner the it installed on the engine This is to proper pin orientation when is installed on the engine ll When plunger is compressed into the tensioner body install a pin through the body and plunger...

Page 224: ...ten fasteners to 9 6 Nm 6 9 3 Install support bracket 4 Install camshaft sprockets and tighten attaching to 101 Nm 73 5 Install idler pulley 6 Install tensioner arm bracket 7 I n s t a l l t i m i n g...

Page 225: ...g applied to the tensioner pulley move the tensioner up against the tensioner pulley tighten fasteners to 31 Nm 22 tensioner plunger pin Pretension is correct when pin can be removed and installed cra...

Page 226: ...ENGINE OVERHAUL Belt engine mount Tighten bolts to 41 Nm 30 crankshaft damper using Using Special Tools and to hold damper tighten crankshaft bolt to 62 Nm 45 Revision...

Page 227: ...at Thermostat Gasket 2 Remove level gauge 3 Remove exhaust manifold cover 4 Remove water hose 5 Remove water pipe 6 Remove O ring 7 Remove thermostat housing bolts and housing 8 Remove thermostat disc...

Page 228: ...oil level gauge 9 Install new O ring gasket in water pump body O ring groove Caution Make sure O ring is properly seated in water pump groove before tightening screws An improperly located O ring may...

Page 229: ...body mounting bolts Remove throffle body I 5 Remove gaskets Clean gasket 6 Release fuel system pressure Refer to Fuel Pressure Release procedure in this section 7 Remove fuel rail mounting screws Acce...

Page 230: ...tor nozzle into openings in manifold Seat the injectors in place rail screws 6 Connect fuel supply tube to fuel rail 7 Install throttle body and new gasket on intake manifold Tighten mounting bolts TS...

Page 231: ...MAP sensor mount ing screws 3 Remove manifold absolute pressure MAP sensor 4 Remove intake manifold stay 5 Remove EGR tube fasteners from the and valve Remove tube from engine Remove vacuum hose and...

Page 232: ...tube gaskets at valve 5 Install EGR tube and tighten fasteners to 8 6 6 Install intake manifold stay 7 Insert sensor into manifold making to damage O ring seals 8 Tighten mounting screws to 2 Nm torqu...

Page 233: ...at center and in both directions to 23 procedure until all fasteners are specified 3 Install exhaust manifold heat shield 4 Install oil level gauge CLEANING AND INSPECTION 1 Discard gasket and clean...

Page 234: ...one camshaft at a time Caution Camshafts are not interchangeable The exhaust cam number 6 bearing journal 5 Identify the before removing The cams are not 6 Remove cam follower assemblies cylinder hea...

Page 235: ...and cams with clean oil and install the camshafts Install right and left camshaft bearing caps No 2 thru No 5 and right Tighten fasteners to 12 Nm 9 in sequence shown in the figure 4 Apply Loctite 518...

Page 236: ...head and tighten fasteners in sequence shown in the figure Using the 3 step torque method Step 1 Tighten all fasteners to 4 5 Nm 3 3 Step 2 Tighten all fasteners to 9 0 Nm 6 5 Step 3 Tighten all faste...

Page 237: ...t diameter Take first reading with micrometer area at edge of the lobe Take second reading in where cam follower contacts the from the first The is wear ENGINE OVERHAUL Camshaft and Cam Follower INSPE...

Page 238: ...g seat Spe cial Tool or 5 Before removing valves remove from valve stem lock grooves to prevent damage to the valve guides Identify valves to insure original location CLEANING CYLINDER HEAD Caution Be...

Page 239: ...measurements from cylinder head 3 Install valve seal spring seat assembly over valve guides to the top of valve stem on all valve stems Ensure garter intact around the top of the rubber seal Install v...

Page 240: ...he following values Step Tighten center fasteners 1 thru 6 to 33 Nm 24 then outer fasteners 7 thru 10 to 26 20 2 Tighten center fasteners to 67 Nm 46 then outer fasteners 7 to 28 Nm 20 Step 3 Tighten...

Page 241: ...liable guide cleaner 2 Using a small hole gauge and a measure valve guides in 3 places top middle and bottom Replace guides if they are not within specification Standard value Intake mm Exhaust mm in...

Page 242: ...2 inspect each valve spring for squareness with a steel square and surface plate test springs from both ends If the spring is more than 1 5 mm in out of square install a new spring REFACING VALVES AND...

Page 243: ...lue to determine where the valve contacts the seat To do this coat valve face LIGHTLY with Prussian blue then set valve in place Rotate the valve with light pressure If the blue is transferred to the...

Page 244: ...91 in for intake valve over spring seat when installed in the head The valve tip chamfer may need to be reground to prevent seal damage when the valve is installed 8 the valve spring installed height...

Page 245: ...late Remove oil filter 4 Remove adapter 5 Drain engine oil and remove oil pan 6 Clean oil pan and all gasket surfaces 7 Remove oil pick up tube 8 Remove crankshaft using Tool Caution Do not nick shaft...

Page 246: ...charge passage 2 oil pump slowly onto crankshaft until seated to engine block Tighten fasteners to 23 Nm 17 3 Install new seal by using Tool 4 Place seal into opening with seal spring toward the insid...

Page 247: ...apter Align roll pin into engine block and tighten assembly to 55 Nm 40 Caution When servicing the oil filter avoid deforming the filter can by installing the remove install tool band strap against th...

Page 248: ...in the figure or serious damage may occur b Remove spring and relief valve Remove oil pump cover screws and lift off cover Remove pump rotors REASSEMBLY 1 Assemble pump using new parts as required In...

Page 249: ...over should be replaced Limit 0 076 mm in 4 Measure thickness and diameter of outer rotor If outer rotor thickness measures 7 64 mm in or less or if the diameter is 79 95 mm 3 148 in or less replace o...

Page 250: ...ore can be inserted and straightedge replace pump Limit 0 102 mm 9 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with wet or dry sandp...

Page 251: ...res with a reliable ridge reamer before removing pistons from cylinder block Be sure to keep tops of pistons covered during this opera tion Mark piston with matching cylinder number 3 Ensure connectin...

Page 252: ...piston from rod by removing piston pin 2 a suitable ring expander remove and inter mediate piston rings 3 Remove the upper oil ring side rail lower oil ring side rail and then oil ring expander from p...

Page 253: ...il d No 2 intermediate piston ring e No 1 upper piston ring 2 Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly and press down the portion to be...

Page 254: ...Piston ENGINE OVERHAUL and Cylinder 6 Position ring expander at 45 the side gaps but on the pin canter on the thrust direction Staggering important for control TSB Revision...

Page 255: ...re butted and the rail as shown in the figure 3 Immerse the piston head and rings in clean engine oil slide the ring compressor over the piston Be sure that position of rings does not change during th...

Page 256: ...own in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal 7 Install connecting rod bearings selected based obtained connecting rod bearin...

Page 257: ...r or scratch is present on the edge chamfer cleanup with 400 grit paper to prevent seal damage during new NOTE When installing seal no lube on seal is needed 11 Place Special Tool on crankshaft This i...

Page 258: ...d be closely with the fitting of pistons and rings so that specified clear ances may be maintained 2 the cylinder bore at three levels in directions A and B Top measurement should be 10 mm in down and...

Page 259: ...ring mm in Oil ring mm Limit Upper ring 0 8 mm in Intermediate ring 1 0 mm in Oil control ring 1 0 mm in 2 Check piston ring to groove side clearance Standard in Limit 0 10 mm CRANKSHAFT MAIN BEARINGS...

Page 260: ...rotate the crankshaft while assembling the cap or the Plastigage may be smeared giving inaccurate re sults 3 Remove the bearing cap and compare the width of the flattened Plastigage with the metric s...

Page 261: ...al Be careful not to damage the seal surface of cover 2 out rear seal with screwdriver Be careful not to nick or damage crankshaft flange seal surface or retainer bore 3 Remove main bearing cap 4 Remo...

Page 262: ...main bearing shells by referring to CRANKSHAFT BEARING CLEARANCE NOTE Upper and lower No 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchange able with any other b...

Page 263: ...6 Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the tab slots 7 Oil the bearings and journals and install crankshaft Caution Do get oil on If may effect th...

Page 264: ...to engine block bolts thru finger tight then torque main bearing bolts to 75 Nm 55 in sequence shown in the figure main bearing to engine block bolts A thru finger tight then torque each bolt to 28 N...

Page 265: ...mage during of new seal NOTE When installing seal no lube on seal is needed Tool on crankshaft This is a pilot tool with a magnetic base seal over pilot tool Make sure you can read the words THIS SIDE...

Page 266: ...o mm in Journal grinding should not exceed 0 305 mm in under the standard Do NOT grind thrust faces of 3 journal Do NOT nick crank pin or journal fillets After grinding remove rough edges from cranksh...

Page 267: ...ard value mm in Stretched bolt Threads are straight on line Unstretched bolt MAIN BEARING BOLTS 1 Since the main bearing bolts are torqued using a new procedure they should be examined BEFORE reuse If...

Page 268: ...rear of its travel using a lever inserted between a main bearing cap and a crank shaft cheek using care not to damage any bearing sur face Do not loosen main bearing cap 2 Use a feeler gauge between...

Page 269: ...ixture Check CRANKSHAFT PULLEY 20 Ignition Timing Check 13 CRANKSHAFT REAR OIL SEAL 27 Lash Adjuster Check Manifold Vacuum Check 12 CYLINDER HEAD GASKET 29 SEALANTS 3 ENGINE ASSEMBLY 15 SERVICE GENERA...

Page 270: ...ston displacement Compression ratio 9 5 Firing order Counterbalance shaft Valve timing Intake valve Opens Closes Exhaust valve Opens Closes Equipped 18 BTDC 58 ABDC 58 BBDC 18 ATDC Lubrication system...

Page 271: ...lled ignition timing at idle ignition timing at idle idle speed contents contents ppm pressure at 250 400 psi pressure difference of all cylinder psi ntake manifold vacuum in Hg head bolt length mm in...

Page 272: ...pack 8991325 Supporting of the lash adjuster Lash adjuster holder to prevent it from falling when rocker shaft assembly is moved or installed 3 Camshaft oil seal installation oil seal Oil pan gasket c...

Page 273: ...andle GENERAL SERVICE TOOL Engine lifter engine assembly when removing and installing transaxle Auto tensioner installation Tensioner pulley wrench I General service tool Crankshaft sprocket removal C...

Page 274: ...n g s Oil pressure too high Oil relief valve stuck closed Repair relief valve Noisy valves Incorrect lash adjuster Bleed air or replace lash adjuster Thin or diluted engine oil low oil pressure Change...

Page 275: ...eflection Reference 9 0 11 5 mm GENERATOR DRIVE BELT TENSION ADJUSTMENT 1 Loosen the nut of the generator pivot bolt 2 Loosen the lock bolt 3 Turn the adjusting bolt to adjust the belt tension or defl...

Page 276: ...ard value Items Tension Deflection mm in When a new belt is When a used is installed 3 Tighten fixing bolt A Tightening torque 28 Nm 21 4 Tighten the remaining fixing bolts and Tightening torque Bolt...

Page 277: ...K 1 Before inspection and adjustment set vehicle in the follow ing condition l Engine coolant temperature l Lights electric cooling fan and all accessories OFF Transaxle Neutral P range on vehicles wi...

Page 278: ...on switch to OFF and connect the scan tool to the data link connector 3 Select No 17 of the SCAN TOOL ACTUATOR TEST 4 Check the basic ignition timing Standard value BTDC 5 Run the engine at idle for 2...

Page 279: ...l Evaporative emission Compression NOTE Replace the three way CO and HC contents do not the value even though the of the on all items PRESSURE CHECK 1 Before inspection check that the engine oil star...

Page 280: ...ifference that is outside the limit pour a small amount of engine oil through the spark plug hole and repeat the operations in steps 7 and 8 1 If the compression increases after oil is added the cause...

Page 281: ...il l If the oil is deteriorated it will not easily from air and the amount of air mixed in the oil will increase If the air which has mixed in the oil due to the above causes enters the high pressure...

Page 282: ...e crankshaft clockwise 5 Check the rocker arm indicated by the black arrow mark as shown in the illustration at left same as above 3 6 If the rocker arm can be lowered easily when the part of the rock...

Page 283: ...lation Refer to GROUP 14 Radiator l Transaxle Assembly Installation Refer to GROUP Transaxle Assembly Refer to GROUP Transaxle Assembly l Engine Coolant Supplying Refer to GROUP 00 Maintenance Service...

Page 284: ...acitor connector 16 Manifold differential pressure 20 Crankshaft position sensor connector 21 Air conditioning compressor connector 22 Evaporative emission purge sole noid valve 23 Control wiring harn...

Page 285: ...Engine 67 Nm 49 Nm 28 30 Front exhaust pipe connection 31 Gasket 32 Engine mount bracket assembly 33 Engine assembly...

Page 286: ...ngine assembly and tie it with a cord Do not bend the joint between hose and the A C pipe force ENGINE A SS EM B LY REMOVAL 1 Support the a garage 2 Remove the special tool which was attached when the...

Page 287: ...the garage jack 3 Remove the chain block and support the engine assembly with the special tool Engine side Engine Arro Engine mount bracket 4 Align the notches on the stopper with the engine mount br...

Page 288: ...REMOVAL AND INSTALLATION Pre removal Operation l Under Cover Removal Refer to GROUP 42 Under Refer to GROUP 42 Under Cover TSB Revision Removal steps 1 Drive belt Generator 2 Drive belt Power steerin...

Page 289: ...PART or equivalent Removal steps 1 Accelerator cable connection 2 Air Intake nose 3 Connection for breather hose 4 Connection for PCV hose 5 Spark plug cable 6 Rocker cover 7 Camshaft position sensor...

Page 290: ...o the timing belt 3 the special tool to remove the camshaft sprocket with the timing belt attached Caution After removing the camshaft sprocket be sure to rotate the crankshaft ARM AND ASSEMBLY REMOVA...

Page 291: ...nstalling Remove the the 4 Confirm that the rocker shaft notch is in the direction shown in the diagram OIL SEAL INSTALLATION 1 Apply engine oil to the camshaft oil seal lip 2 Use the special tool to...

Page 292: ...g Refer to GROUP 00 Maintenance service l Oil Level Gauge Removal and Installation l Front Exhaust Pipe Removal and Installation Refer to GROUP 15 Exhaust Pipe and Main Muffler TSB Revision 5 Specifie...

Page 293: ...with the special tool and a brass Caution Do it slowly to avoid deformation of oil flange INSTALLATION SERVICE POINTS OIL PAN INSTALLATION Caution After cleaning the oil bolt holes the seal case the o...

Page 294: ...Removal and Installation Refer to TSB Revision Engine oil 0 0 0 0 3 9 1 7 Removal steps 1 Crankshaft sprocket front oil seal INSTALLATION SERVICE POINT CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Apply...

Page 295: ...tallation Operation l Transaxle Assembly Removal and Installation Refer to GROUP Assembly Refer to GROUP Assembly l Clutch Cover and Clutch Disc Removal and Installation 127 137 Nm 101 Crankshaft Engi...

Page 296: ...nd other substances which are adhering to the threaded bolts crankshaft thread holes and the flywheel or drive plate 2 Apply oil to the bearing surface of the flywheel or drive plate bolt 3 Apply oil...

Page 297: ...ENGINE Cvlinder Head REMOVAL AND INSTALLATION Operation l l l Post installation Operation l Refer to l Refer to 21 Removal steps 24 Breather hose connection TSB Revision...

Page 298: ...ENGINE Cylinder Head Gasket 3 4 2 5 24 Nm 18 30 7 8 Nm 7 9 34 25 00004208 32 Specified PART 25 26 TSB Revision...

Page 299: ...tion only 2 Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket not with respect to the timing belt 3 Use the special tool to remove the sprocket with t...

Page 300: ...them selves be careful not to damage or deform the when removing the cylinder head bolts INSTALLATION SERVICE CYLINDER HEAD GASKET INSTALLATION 1 Wipe off all oil and grease from the gasket mounting...

Page 301: ...et pipe assembly 1 Caution 1 make a tightening angle just 90 it is than the head bolt will be loosened If it is more than remove the head bolt and repeat the procedure from step 1 O RING INSTALLATION...

Page 302: ...en the thermostat case assembly mounting bolts 5 Tighten the water inlet pipe bolts RADIATOR LOWER UPPER HOSE CONNECTION 1 Insert each hose as the projection water outlet fitting or water inlet fittin...

Page 303: ...l Engine Mount Bracket Removal Refer to GROUP 32 Engine Mounting l Under Cover Installation Refer to GROUP 42 Under Cover l Engine Adjustment l Engine Mount Bracket Refer to GROUP 32 Engine Mounting 8...

Page 304: ...ce to the push rod of the auto tensioner by against a metal cylinder and measure the movement of the push rod Standard value Within 1 mm in A Length when it is free not pressed B Length when it is A B...

Page 305: ...ming mark and check that the screwdriver goes in 60 mm 2 36 in or more Do not take out the screwdriver until the timing belt is installed 3 Install the timing belt so as not to be the sprockets by the...

Page 306: ...the tension pulley turn with the bolt 3 Turn the crankshaft two revolutions clockwise so that the timing marks are aligned leaving it for 15 min utes measure the amount of protrusion of the auto ten s...

Page 307: ...ENGINE Timing belt REMOVAL AND INSTALLATION Nm R e m o v a l s t e p s 2 l REMOVAL SERVICE SPROCKET 1 Use the special tool to remove bolt Use the special tool to remove crankshaft sprocket...

Page 308: ...ADJUSTMENT Adjust the tension of timing belt by the following procedure 1 Temporarily fix the timing belt tensioner such that the center of the tensioner pulley is to the left and above the center of...

Page 309: ...haft sprocket I CRANKSHAFT SENSING BLADE When installing make sure the direction is correct See figure CRANKSHAFT SPROCKET INSTALLATION Use the special tool to install the crankshaft sprocket and bolt...

Page 310: ......

Page 311: ...UST MANIFOLD AND WATER PUMP 27 FRONT CASE COUNTERBALANCE SHAFT AND OIL PAN 40 FUEL AND EMISSION CONTROL PARTS 23 GENERAL INFORMATION 2 GENERATOR AND IGNITION SYSTEM 11 INTAKE MANIFOLD 25 PISTON AND CO...

Page 312: ...ENGINE OVERHAUL General Information GENERAL SPECIFICATIONS TSB Revision...

Page 313: ...OVERHAUL Specifications SERVICE SPECIFICATIONS Timing belt Rocker arms and camshaft 36 97 1 4555 Cvlinder head and valves TSB Revision...

Page 314: ...OVERHAUL Crankshaft flywheel and drive plate Cylinder block REWORK DIMENSIONS Cylinder head and valve Crankshaft flywheel and drive plate TORQUE SPECIFICATIONS Generator and ignition system I TSB Rev...

Page 315: ...7 __ Fuel and emission parts Intake manifold Exhaust manifold and water pump 3 1 13 9 31 10 Rocker arms and camshaft 10 TSB Revision...

Page 316: ...ENGINE OVERHAUL Cylinder head and valves 14 5 Front case counterbalance shaft and oil pan 14 Piston and connecting rod Crankshaft flywheel and drive plate case 1 TSB Revision...

Page 317: ...ENGINE OVERHAUL SEALANTS TSB Revision...

Page 318: ...ENGINE OVERHAUL Special Tools TSB Revision...

Page 319: ...ENGINE OVERHAUL TSB Revision...

Page 320: ...ENGINE OVERHAUL Tools 6991654 bolt TSB Revision...

Page 321: ...ENGINE Generator and Ignition System REMOVAL AND INSTALLATION 23 Nm 17 5 10 25 Nm 18 q 14 Nm 10 22 Nm 18 5 Nm 3 8 Removal steps 24 Nm 17 11 Nm TSB Revision...

Page 322: ...11 ENGINE OVERHAUL Generator and TSB Revision 1 Apply a 3 mm bead of form in place gasket FIPG to the area shown Specified sealant Mitsubishi Genuine Part No or equivalent...

Page 323: ...ENGINE OVERHAUL Timing Belt REMOVAL AND INSTALLATION 45 33 I 45 Nm 33 I 24 Nm 17 55 Nm 40 120 Nm 6 14 Nm 10 8 35 25 9 Nm 7 Removal steps 10 Crankshaft bolt 2 1 T i m i n g b e l t r e a r Revision...

Page 324: ...is oil or water on each part check front case oil seals camshaft oil seal and water pump for leaks OIL PUMP SPROCKET REMOVAL CRANKSHAFT BOLT LOOSENING CRANKSHAFT SPROCKET REMOVAL BELT B 1 Make a mark...

Page 325: ...oil or water on each part check front case oil seals camshaft oil seal and water pump leaks COUNTERBALANCE SHAFT SPROCKET REMOVAL SPROCKET B REMOVAL CAMSHAFT SPROCKET BOLT LOOSENING INSTALLATION SERVI...

Page 326: ...ered end oil seal S P R O C K E T INSTALLATION BELT B INSTALLATION 1 Align timing marks on the crankshaft sprocket counterbalance shaft sprocket with front case respectively 2 Install the timing belt...

Page 327: ...ent 6 Press with index finger the center of span on tension side of timing belt The bolt must deflect mm in CRANKSHAFT BOLT TIGHTENING PUMP SPROCKET INSTALLATION 1 Insert a Phillips screwdriver shank...

Page 328: ...n to the specified torque Caution Leave the wire the TENSIONER PULLEY INSTALLATION Install the tensioner pulley in such that its small holes are arranged vertically TIMING BELT INSTALLATION 1 Check th...

Page 329: ...rankshaft sprocket idler pulley camshaft sprocket and tensioner pulley in that order 7 Lift up the tensioner pulley in the direction of arrow and tighten the center bolt 8 Check that all timing marks...

Page 330: ...prox 15 make sure that the auto tensioner setting wire moves freely NOTE If the wire does not move freely step 10 above until it moves freely the auto tensioner setting wire TSB Revision the distance...

Page 331: ...aves no indent when pressed fingernail 2 Cracks on rubber back 3 Cracks or peeling of canvas 4 Cracks on rib root 5 Cracks on belt sides 6 Abnormal wear of belt sides The sides are normal if they are...

Page 332: ...11 ENGINE TSB Revision...

Page 333: ...Fuel and Emission Parts FUEL AND EMISSION CONTROL PARTS Removal steps TSB Revision I...

Page 334: ...ith a drop of clean engine oil to aid in installa tion 2 Install injector top end into fuel rail Be careful not to damage O ring during installation FUEL PRESSURE REGULATOR INSTALLATION Before the pre...

Page 335: ...ENGINE OVERHAUL Intake Manifold REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION 30 24 IA I 13 18 Nm 13 13 10 31 Nm 22 Removal steps 7 TSB Revision...

Page 336: ...one hour SEALANT APPLICATION TO WATER FITTING Specified sealant Mitsubishi Genuine Part No or equivalent NOTE 1 Be sure to install the housing quickly while the sealant is wet within 15 minutes 2 Aft...

Page 337: ...ENGINE OVERHAUL Exhaust Manifold REMOVAL AND INSTALLATION 30 22 14 10 28 14 Removal steps TSB Revision...

Page 338: ...ENGINE OVERHAUL Exhaust Manifold and WATER 1 Wet the O ring with Caution Keep the O ring free of oil or grease TSB Revision...

Page 339: ...ENGINE OVERHAUL Rocker Arms REMOVAL AND INSTALLATION 3 3 2 4 6 2 Removal steps 2 4 6 7 TSB Revision...

Page 340: ...e lash adjuster to rocker arm being careful not to spill the diesel fuel Then use the special tool to prevent adjuster from falling while installing it ARMS AND ROCKER ARM SHAFT 1 Temporarily tighten...

Page 341: ...ENGINE OVERHAUL Rocker Arms CAMSHAFT OIL TSB Revision...

Page 342: ...ker arm LASH ADJUSTER LEAK DOWN TEST Caution 1 The lash adjuster is a precision part Keep it free from dust and other foreign matter 2 Do not disassemble lash adjuster 3 When cleaning lash adjuster us...

Page 343: ...ght to prevent inside diesel 4 After air bleeding set lash adjuster on the special tool Leak down tester 5 After plunger has gone down somewhat mm measure time taken for it to go down 1 Replace if mea...

Page 344: ...nder head gasket 4 Retainer lock 5 Valve spring retainer 6 Valve spring 7 Intake valve 8 Retainer lock 9 Valve spring retainer 10 Valve spring ii Exhaust valve 12 Valve stem seal 13 Valve spring seat...

Page 345: ...gs and other parts tagged to indicate their cylinder No and location for reassembly STEM SEAL REMOVAL Do not reuse valve stem seal INSTALLATION SERVICE POINTS VALVE STEM SEAL INSTALLATION 1 Install th...

Page 346: ...g tighten the bolts to the specified torque 78 58 using the special tool 654 4 Loosen bolts completely 5 Retighten the loosened bolts to 20 in the specified tightening sequence 6 Make a paint mark acr...

Page 347: ...1 Check the valve face for correct contact If incorrect reface using valve Valve seat contact be main tained uniform at the center of valve face 2 If the margin exceeds the service limit valve Standar...

Page 348: ...the end of the valve stem and the spring seating surface If the measurement exceeds the specified limit replace the valve seat Standard value 49 30 mm 1 9409 in Limit 49 80 mm 1 9606 in VALVE SEAT REC...

Page 349: ...cutter correct the valve seat to the specified width and angle See SEAT RECONDITIONING PROCEDURE VALVE GUIDE REPLACEMENT PROCEDURE 1 Using the push rod and a press remove the valve guide toward cylind...

Page 350: ...Flange bolt 10 Oil pressure switch 11 Relief plug 12 Gasket 13 Relief spring 14 Relief plunger 15 Oil filter bracket 16 Oil filter bracket gasket 19 14 I lb 7 7 5 17 Oil pump cover 18 Oil pump driven...

Page 351: ...ead with a hammer two to three times and the plug will be easily loosened FLANGE BOLT REMOVAL 1 Remove the plug on the side of block 2 Insert a Phillips screwdriver shank diameter 8 mm in into the plu...

Page 352: ...U N T E R B A L A NC E RE A R BEARING INSTALLATION 1 Apply engine oil to the outer surface of bearing 2 Using special tools install right rear bearing Make sure that oil hole of bearing is aligned wi...

Page 353: ...special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case 2 Install the front case assembly new front gas...

Page 354: ...PUMP GEAR INSTALLATION Apply engine oil to the gears and line up the marks SEALANT APPLICATION TO OIL PRESSURE S W I T C H Coat the threads of switch with sealant and using the special tool Specified...

Page 355: ...and tighten to speci fied torque OIL PAN INSTALLATION 1 Clean both mating surfaces of oil pan and cylinder block 2 Apply a 4 mm in wide bead of sealant to the entire circumference of the oil pan flan...

Page 356: ...tall the drain plug gasket in I OIL INSTALLATION 1 Clean the installation of bracket Apply engine oil to the O ring of the oil filter 3 Screw the oil filter in until the the bracket Then tighten torqu...

Page 357: ...ry 2 Check the seal lip for deterioration Replace oil seal if necessary COUNTERBALANCE SHAFT 1 Check oil holes for clogging 2 Check journal for seizure damage and contact with bear ing If there is any...

Page 358: ...OVAL AND INSTALLATION Lubricate all I Removal steps 1 Nut 2 Connecting rod cap 3 Connecting rod bearing 4 Piston and connecting rod assembly 5 Connecting rod bearing 6 Piston ring No 1 7 Piston ring N...

Page 359: ...cting rods caps and bearings in order according to the cylinder PISTON PIN REMOVAL 1 2 I Connecting Pin 4 5 Rod Piston Support 7 Connecting Pin 8 Piston Support 9 43 Press Pin 10 216943 Stop Screw 11...

Page 360: ...t of the assembly IMPORTANT To avoid piston damage l The piston support must seat against the piston l Verify that the piston pin will slide hole in the piston support 6 Remove the piston pin from the...

Page 361: ...the stop screw 7 Remove the piston assembly from the base Remove the guide pin and press pin from the assembly IMPORTANT Due to production tolerance variations it is necessary to visually inspect the...

Page 362: ...Make sure that the side rails move smoothly in either direction PISTON RING NO 2 PISTON NO 1 INSTALLATION Using piston ring expander fit No 2 and then 1 piston ring into position NOTE 1 The ring end i...

Page 363: ...bearing identification mark is stamped at the position shown in the illustration None Yellow 1 2 None None 2 1 491 1 495 1 7711 1 7715 3 None White 3 Connecting I D mm in 3 Select a bearing from the...

Page 364: ...e checked by running a nut with fingers to the full length of the bolt threads If the nut does not run down smoothly the bolt should be replaced 2 Before installation of each nut apply engine oil to t...

Page 365: ...he piston ring into the cylinder bore Force it down with a piston its crown being in contact with the ring to correctly position it at right angles to the cylinder wall Then measure the end gap with a...

Page 366: ...l the connecting rod cap carefully and tighten nuts to specified torque 4 Carefully remove the 5 Measure the width of the its widest part by using a scale printed on the package Standard value mm in L...

Page 367: ...moval steps 1 Flywheel bolt 2 Flywheel 3 Drive plate bolt 4 Adapter plate 5 Drive plate 6 Crankshaft bushing 7 Rear plate 8 Bell housing cover 9 Oil seal case 10 Oil seal 11 Bearing cap bolt 12 Bearin...

Page 368: ...None None None Identifica tion color for service Yellow White None 1 2 3 0 2 1 3 2 4 0 3 1 4 2 5 3 Select a proper bearing from above table on the basis of the identification data confirmed under Item...

Page 369: ...the bolt in the direction of tightening the bolt 7 According to the specified tightening sequence give a to turn to each bolt and make sure that the paint mark on the bolt and that on the cap are in a...

Page 370: ...OIL SEAL Specified sealant Mitsubishi Genuine Part No or equivalent 1 Be sure to install the case quickly while the sealant wet within 15 minutes 2 After installation keep the sealed area from the oil...

Page 371: ...re evident correct or replace 2 Using a straightedge and feeler gauge check the block top for Make sure that the surface is free from gasket chips and other foreign matter Standard value 0 05 mm in Li...

Page 372: ...lculate boring Boring finish dimension between piston O D 0 02 mm in honing margin 4 Bore all cylinders to calculated boring finish dimension Caution To prevent distortion that may result from tempera...

Page 373: ...ENGINE CONTENTS ENGINE OIL COOLER ON VEHICLE SERVICE 3 GENERAL INFORMATION 2 Engine Oil Engine Oil Replacement 3 LUBRICANTS 2 Oil Filter Replacement 4...

Page 374: ...eparate from personal clothing LUBRICANTS harmful contaminants which may cause skin cancer Adequate means of skin protection and washing facilities must provided Where there is a risk of eye contact e...

Page 375: ...owly and check that the oil is within the marks on the oil dipstick 2 Check that the oil is dirty that there is no coolant or gasoline mixed in and that it has sufficient viscosity ENGINE OIL REPLACEM...

Page 376: ...oil filler cap 2 Remove the engine oil drain plug and drain out the engine o i l 3 Remove the engine oil filter by using the oil filter wrench 4 Clean the oil filter mounting surface of the oil filte...

Page 377: ...nce Engine oil Engine Oil Checking and Supplying 2 Removal steps 1 Oil filter 2 Water hose connection 3 Oil cooler bolt 4 Engine oil cooler Oil filter bracket Stopper Engine oil cooler INSTALLATION SE...

Page 378: ...12 6 ENGINE LUBRICATION Engine Oil Cooler INSPECTION l Check the water for cracks clogging or deterioration l Check the oil cooler bolt clogging deformation Revision...

Page 379: ...FUEL CONTENTS FUEL INJECTION FUEL SUPPLY AUTO CRUISE CONTROL SYSTEM Refer to GROUP 17 NOTE Groups that have been shaded are not contained in this manual...

Page 380: ...13 2...

Page 381: ...tric EGR Transducer Solenoid Check 133 Engine Coolant Temperature Sensor Check 129 Evaporative Emission Purge Solenoid C h e c k 1 3 3 Heated Oxygen Sensor Check 130 Idle Air Control Motor Stepper Mot...

Page 382: ...287 Idle Air Control Motor Stepper Motor Check Engine Turbo 285 Injector Check 283 Intake Air Temperature Sensor Check 280 Fuel Injection MFI Relay and Fuel Pump Relay Check 280 Resistor Check Engine...

Page 383: ...e IGNITION TIMING CONTROL The ignition power transistor is built into the PCM It turns the ignition primary circuit on and off to respectively supply and cut off primary current flow to the ignition c...

Page 384: ...eter or Tachometer Control Sends a pulse signal which corresponds to the engine speed to the speedometer unit 6 Evaporative Emission Purge C o n t r o l Refer to GROUP 17 7 Electric EGR Transducer Sol...

Page 385: ...en l ignition sor sense Engine coolant tempera l Brake switch ture sensor relay relay Knock sensor Heated oxygen sensor Rear Injector l Fuel Evaporative l fuel purge solenoid Idle air control motor EE...

Page 386: ...ature sensor resistance Engine coolant temperature sensor Heated oxygen sensor output voltage Fuel pressure psi Injector coil resistance Electric EGR transducer solenoid coil resistance 3 5 8 5 9 1 1...

Page 387: ...ENGINE NON TURBO SPECIAL TOOLS Scan tool Interface Fuel pressure gauge Use with TSB Revision...

Page 388: ...on from customer Verify complaint Reoccurs Read the diagnostic trouble code Refer to I Does not reoccur Read the diagnostic trouble code Refer to I Diagnostic trouble trouble Recheck trouble symptom R...

Page 389: ...ircuit Injector control circuit 20 Injector control circuit 21 Injector control circuit 25 Idle air control motor circuit 26 Throttle position sensor voltage low 27 Throttle position sensor voltage hi...

Page 390: ...P or CKP EVAP leak monitor small leak detected EVAP leak monitor large leak detected Evaporative emission ventilation solenoid circuit Evaporative emission ventilation solenoid switch or mechanical fa...

Page 391: ...is to cycle the ignition switch On Off On Off On within 5 Then count the number of times the malfunction indicator lamp check engine lamp on the instrument panel flashes on and off The number of flas...

Page 392: ...ly be checked in General Scan Tool mode SENSOR READ TEST l term fuel trim l Calculated load vlaue FREEZ FRAME DATA READINESS TESTS 3 When diagnostic trouble codes DTC are erased the freeze frame data...

Page 393: ...the trouble code There is a slight pause between the flashes representing the first and second digits of the code Longer pauses approx 4 seconds separate individual trouble codes 3 Repair the malfunc...

Page 394: ...t Mode The solenoid is energized with a fixed duration pulse Subsequent fixed pulses occur when the diaphragm reaches the Switch closure point The spring in the pump is set so that the system will ach...

Page 395: ...of the repairs 3 Erase the diagnostic trouble code from memory 4 Remove the scan tool 5 Start the engine again and carry out a road test to confirm that the problem disappeared NOTE Refer to for Sens...

Page 396: ...PCM carries out open loop control center No vehicle speed sensor The PCM controls the engine as if the vehicle speed were 0 mph signal MAP sensor voltage too low The PCM uses the value calculated fro...

Page 397: ...sensor signal only to control timing etc Accordingly normal sequential fuel injection may not be carried out The PCM uses the value calculated from the throttle position sensor and the engine speed si...

Page 398: ...ASD relay Generator field not l Harness and connector Retained switching properly l Generator A C clutch relay circuit l Harness and connector Retained l clutch relay 32 31 27 27 27 25 24 24 EGR solen...

Page 399: ...P sensor No in MAP l Harness and connector from start to run If harness and connec tor are defective replace MAP sensor No crankshaft l Harness and connector reference signal at If harness and tor are...

Page 400: ...am shorted to voltage PCM failure communications l Harness and connector Retained l Injector Harness and connector Retained l Upstream l Replace the PCM Retained 71 44 Battery temperature volts out of...

Page 401: ...ained Injector Compression pressure l Air intake 109 43 Cylinder misfire l Spark plug Retained Injector Compression pressure l Air 110 43 Cylinder misfire Spark plug Retained l Injector Compression pr...

Page 402: ...sensor l Thermostat 21 24 11 Downstream l Harness and connector Retained stays at center Downstream Throttle position sensor l Harness and connector Retained voltage does not agree l Throttle position...

Page 403: ...m l Harness and connector Retained voltage grounded l Downstream Intermittent loss of CMP or CKP l Crankshaft position Retained and camshaft posi tion sensor connector EVAP leak monitor small leak det...

Page 404: ...h ON l Crankshaft position sensor signal High or low is input Engine Cranking Set Condition l Camshaft position sensor signal High or low isn t input for 2 seconds Check that the camshaft position NG...

Page 405: ...voltage between the generator terminal and the battery positive terminal Engine 1600 Headlight High beam ON OK Less than Check the harness wire and terminal generator terminal and battery necessary NG...

Page 406: ...approx one minute Set Condition l Battery positive voltage is at least higher than target charging voltage for approx 12 seconds SCAN TOOL SENSOR READ TEST Data list 36 Charging system goal OK or more...

Page 407: ...ry voltage or more l Ignition switch ON Set Condition l Open or short circuit is detected in the relay ASD relay for 3 seconds l Relay coil open or shorted l relay shorted l circuit in Check the relay...

Page 408: ...rating sound can be heard OK Measure at the generator connector l Disconnect the connector and measure at the harness side SCAN TOOL Actuator test 10 relay ASD relay relay is turned on 1 l Voltage bet...

Page 409: ...Battery voltage or more l 30 seconds or more after starting engine Set Condition l Open or short circuit is detected in the A C clutch relay control circuit for 3 seconds NG relay Replace 55 On vehic...

Page 410: ...ssion Control System OK Measure at the electric transducer solenoid connector l Disconnect the connector and measure a the harness side l Voltage between 2 and ground switch ON Battery positive voltag...

Page 411: ...or solenoid l Check the evaporative emission NG Replace Refer to GROUP 17 Emission Control System OK NG Check the following connectors Measure at the evaporative purge solenoid connector l Disconnect...

Page 412: ...ectors OK NG Measure at the injector connector Check the following connectors l Disconnect the connector and measure at the harness side SCAN TOOL Actuator test 10 relay ASD relay relay ASD relay is t...

Page 413: ...r injectors Measure at the injector connector l Disconnect the connector and measure at the harness side SCAN TOOL Actuator test 10 relay ASD relay l Voltage between 2 and ground Measure with the rela...

Page 414: ...it OK The reiav sound can be heard NG Check the injector Refer to Replace OK Measure at the injector connector l Disconnect the connector and measure at the harness side SCAN TOOL Actuator test 10 rel...

Page 415: ...tall or run rough l As the PCM anticipates load it operates the motor opening the throttle bypass passage and allowing more air into the intake manifold l Malfunction of this system cause rough idle a...

Page 416: ...eck l ignition switch ON Set Condition l Throttle position sensor output remains less than for 1 second NG Check the position Replace OK Measure at the throttle position sensor connector l Disconnect...

Page 417: ...d measure at the harness side l Continuity between 1 and ground OK Continuity OK Scan tool 30 Code General scan tool Engine Coolant Temperature No Sensor Voltage Too 22 Comment l Sensor shorted to Bac...

Page 418: ...ween 1 and ground OK Continuity OK OK NG NG Check the harness wire between the PCM and the engine coolant temperature sensor connector Repair if Repair Check the harness wire between the coolant tempe...

Page 419: ...iled l that the engine coolant rises the specified value within a sufficient period after the Engine coolant temperature engine is started improperly connected l PCM failed Range of Check l Vehicle sp...

Page 420: ...ant temperature or more Transaxle Other than or range only 31 seconds after starting engine Brakes not applied Throffle valve Open Engine 1600 or more Difference between the atmospheric pressure and i...

Page 421: ...tion above the estimates MAP value to allow the engine to run Range of Check l Engine l position sensor output voltage Less than Set Condition l MAP sensor output voltage remains less than for 2 secon...

Page 422: ...ed to voltage l PCM l Engine 1500 l Throttle position sensor output voltage Less than Set Condition l MAP sensor output voltage remains less than 4 7 for 2 seconds Measure at the MAP sensor connector...

Page 423: ...l Diagnostic trouble code DTC memory is not deleted even after the ignition switch is turned off l The difference between the two following MAP values is small The value immediately after the ignition...

Page 424: ...l Open or shorted supply circuit l Open sensor ground l Open or shorted signal circuit l Excessive clearance between the sensor and rotor Sensor failed l PCM failed Check the position sensor OK Measur...

Page 425: ...pair relay ASD relay related OK Measure at the ignition coil connector l Disconnect the connector and measure at the harness side SCAN TOOL Actuator test 10 relay ASD relay relay ASD relay is turned o...

Page 426: ...ay ASD relay related OK Relay operating sound can be heard Measure at the ignition coil connector l Disconnect the connector and measure at the harness side SCAN TOOL Actuator test 10 relay ASD relay...

Page 427: ...nge of Check l Battery voltage or more l switch ON l Unless the engine is cranking Set Condition l The relay voltage is low for 1 second NG Replace Measure at the relay ASD relay connector l Disconnec...

Page 428: ...ratio closed loop control Condition The measured change in the short term fuel compensation value shift during the test is less than 7 4 or greater than 20 5 Check the idle running l Idle running afte...

Page 429: ...injector pulse width calculation l In this instance the system uses information on air mass to determine the correct width necessary to achieve the proper air fuel ratio l Because air mass is related...

Page 430: ...l Ignition switch ON Set Condition l air temperature sensor output voltage is more than for 3 Check the intake air temperature sensor Refer to Replace Measure at the intake air temperature sensor con...

Page 431: ...ndition l Knock sensor signal below minimum acceptable threshold voltage Knock sensor output voltage is above 5 0 volts l Knock sensor l Open or shorted knock sensor l I Measure at the knock sensor co...

Page 432: ...easure at the injector connector l Disconnect the connector and measure at the harness side SCAN TOOL Actuator test 10 relay ASD relay istumedonandoff l Voltage between 2 and ground Measure with the r...

Page 433: ...more Set Condition l Heated oxygen sensor output voltage is more than 1 2 for 3 seconds OK OK NG Repair Check trouble symptom NG NG Check the harness wire between the PCM and the heated oxygen Repair...

Page 434: ...M l l The PCM grounds the relay control circuit depending on engine coolant temperature etc Range of Check l Battery voltage 10 or more l Ignition switch ON Set Condition l An open or short circuit co...

Page 435: ...er conditions Range of Check l Battery voltage or more Ignition switch ON Set Condition An open or shorted condition is detected in the high speed condenser fan relay control circuit for 3 seconds l R...

Page 436: ...l Disconnect the PCM connector l Voltage between 27 and ground Ignition switch ON O K l Voltage between and ground Ignition switch ON O K l Resistance between 27 and 28 O K OK Measure at the data link...

Page 437: ...Battery voltage 10 or more l Ignition switch ON Set Condition l Open or short circuit is detected in fuel pump relay control circuit for 3 seconds NG Check the fuel pump Replace OK Measure at the fue...

Page 438: ...e coolant temperature greater than l Approximately three minutes elapsed time after start up l Vehicle has operated at more than for 75 seconds with engine coolant temperature at l Power steering pres...

Page 439: ...he output line voltage is less than 1 57 V Set Condition Heated oxygen sensor s circuit does not show the appropriate decrease of voltage the test l Heated oxygen sensor heater open l harness and conn...

Page 440: ...al of the output line voltage is less than 1 57 V Set Condition Heated oxygen sensor s circuit does not show the appropriate decrease of voltage the test 1 NG Measure at the heated oxygen sensor rear...

Page 441: ...n piston rings valves l Head gasket failed l C r a c k e d l Fuel lines and filter failed l Fuel failed l failed l Wiring and connectors failed l Engine coolant l Timing belt tooth broken l EGR SCAN T...

Page 442: ...c trouble code and causes the l Injector failed l to either flash or illuminate continuously during active misfire Range of Check l MAP voltage is less than l Engine speed is between 2200 and l Engine...

Page 443: ...ar heated oxygen sensor reaches 70 of the front sensors switch rate Check the exhaust system l Check for cracks or exhaust leaks Replace the exhaust manifold OK SCAN TOOL SENSOR READ TESTS Data list 6...

Page 444: ...s fuel injection compensation value is less than 5 shift injector pulse width when the evaporative purge solenoid is turned on and off Engine speed less than 2048 l MAP sensor output voltage MAP senso...

Page 445: ...position sensor l MAP is greater than 66 of barometric pressure Set Condition l Transaxle range sensor output voltage Low Range of Check l relay ASD relay ON l Engine is cranking Set condition l Trans...

Page 446: ...igh steering pump pressure Range of Check l Vehicle speed 90 56 mph Set Condition l PSP switch output voltage High for 30 seconds N G Measure at the the PSP Disconnect the connector and measure at the...

Page 447: ...ke air temperature sensor Refer to NG SCAN TOOL SENSOR READ TESTS Data list 11 MAP sensor reading Refer to OK Check the engine coolant temperature circuit INSPECTION PROCEDURE 38 Check the intake air...

Page 448: ...temperature sensor Refer to SCAN TOOL SENSOR READ 27 Intake air temperature sensor to SCAN TOOL SENSOR READ 11 MAP sensor reading Refer to I NG Check the engine coolant temperature circuit Refer to I...

Page 449: ...to R e p l a c e OK NG Check the following Repair OK Check trouble symptom NG Check the harness wire between the PCM and the heated NG sensor rear connector OK Replace the PCM Scan tool 128 Code Gener...

Page 450: ...ffle position Range of Check l Engine speed less than 1 500 l Subtract MAP value from atmospheric pressure more than 13 19 psi when atmospheric pressure is more than 77 11 psi more than 6 0 9 psi when...

Page 451: ...does not exist the misalignment between the camshaft and crankshaft one of the following have been serviced is monitored Set Condition camshaft timing ten When the camshaft position sensor is offset f...

Page 452: ...e and immediately after stopping engine Set Condition The output of MAP sensor is lower than the specified Measure at the MAP sensor connector l Disconnect the connector and measure at the harness sid...

Page 453: ...tor Check the following connectors l Disconnect the connector and measure at the harness side OK Check trouble symptom U K Check the following connectors OK NG Check the wire between the PCM Repair if...

Page 454: ...rcuit is completed when the other side of the relay coil is grounded by the PCM l The PCM grounds the relay control circuit depending on engine coolant temperature and or A C compressor condition etc...

Page 455: ...ed circuit drops below 4 volts for over four seconds l supply circuit grounded l PCM failed Check harness wire between the PCM the MAP sensor connector Repair if necessary N G Measure at the position...

Page 456: ...Check trouble symptom Check the harness wire between the PCM and fuel level sensor Scan tool 150 Code General scan tool Fuel Level Sending Unit Volts Too No High 42 Comment l Sensor is grounded Backgr...

Page 457: ...k the fuel gauge unit and its circuit Refer to GROUP 54 Combination Meters OK NG Check the following connectors A l 06 Repair OK Check trouble symptom NG NG Check the harness wire between the PCM and...

Page 458: ...ature is low the sensor has the same electrical characteristics as an insulator l The heated oxygen sensor output signal line is restricted to That is why the line voltage is approx when the heated ox...

Page 459: ...Replace the PCM 11 Comment Background connected l After the engine has been started the PCM maintains an expected camshaft port l position Scan tool 157 General scan tool Intermittent Loss of CMP CKP...

Page 460: ...ace Refer to GROUP 17 Emission Control System OK Check the fuel tank and purge line for leakage Scan tool 161 Code General scan tool EVAP Leak Monitor Large Leak No Detected TSB Revision Comment l The...

Page 461: ...seconds NG Measure at the evaporative emission ventilation solenoid connector Check the following connectors l Disconnect the connector and measure at the harness side l Voltage between 2 and ground I...

Page 462: ...Monitor Pinched NO Hose Found 31 Background l The PCM monitors that the fuel tank purge lines etc are sealed well l When monitoring the PCM byactivatingtheevaporativeemission ventilation solenoid with...

Page 463: ...ted and never goes 4 Cranks won t start 5 Starting Fires up and dies 6 Hard starting 7 Idling stability Unstable idle Rough idle hunting 6 Improper Idle speed is high Improper idle speed 9 idling Idle...

Page 464: ...n Hesitation is the delay in response of the vehicle speed engine speed that occurs accelerator is depressed in order to accelerate from the speed at which the vehicle is temporary drop in vehicle spe...

Page 465: ...scan tool INSPECTION PROCEDURE 2 Scan tool communication with PCM is not possible P r o b a b l e Comment One of the following causes may be suspected l No power supply to PCM Defective ground circui...

Page 466: ...alfunctions listed at right probably occurred NG 10 Battery voltage Refer to Check the power supply and ignition circuit Refer to INSPECTION Measure at the PCM connector OK The check engine malfunctio...

Page 467: ...Probable cause Comment l Malfunction of the ignition system In cases such as the above the cause is probably that a spark plugs are fouled defective l Malfunction of the fuel pump system or that the...

Page 468: ...plug cables l Clean the injectors l Check the compression pressure l Check fuel lines for l Check if foreign water alcohol etc got into fuel TSB Revision INSPECTION PROCEDURE 7 Hard starting I Probab...

Page 469: ...ntly SCAN TOOL DTC Are diagnostic trouble codes output NO Refer to INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES YES Inspection when hunting occurs Refer to INSPECTION PROCEDURE 31 SCAN TOOL Actuator...

Page 470: ...elay to INSPECTION PROCEDURE 26 Check the throttle body minimum air flow Refer to INSPECTION PROCEDURE 10 Idle speed is low Improper idle speed Probable cause Comment l control motor In cases such as...

Page 471: ...ut TROUBLE CODES N O I Does the engine stall right after the accelerator pedal is Check the throffle body minimum air Refer to released NO NO Check for unstable idle Rough hunting Is engine idling sta...

Page 472: ...the engine stall right released NO Does the engine stall easily again YES Scan tool Inspection when engine stalls when the engine is warm and idling Refer to INSPECTION PROCEDURE 33 OK Check the throt...

Page 473: ...ottle body minimum air flow INSPECTION PROCEDURE 15 Hesitation sag or stumble Comment In cases such as the above the cause is probably that ignition system air fuel mixture or compression pressure is...

Page 474: ...spark plug cables l Check for occurrence of ignition leak l Check the torque reduction link wire between the PCM and TCM INSPECTION PROCEDURE 17 Deceleration shock Probable cause Comment Malfunction o...

Page 475: ...k the compression pressure l Check the fuel filter or fuel line for clogging l Clogged air cleaner l Clogged exhaust system INSPECTION PROCEDURE 19 Surge Comment Defective ignition system abnormal air...

Page 476: ...S Are diagnostic trouble codes Refer to INSPECTION CHART FOR DIAGNOSTIC output TROUBLE CODES NO SCAN TOOL SENSOR NG 09 Knock sensor volts Refer to Check the knock sensor circuit Refer to INSPECTION PR...

Page 477: ...83 sensor volts rear Refer to l Transaxle gear range l Driving with the throttle wide open OK OK SCAN TOOL SENSOR READ TESTS Data list 02 sensor volts front Refer to OK 1 when suddenlv NG Check the h...

Page 478: ...voltage Check trouble symptoms NG Check the and connector Repair if necessary Check the harness wire ground if necessary Check trouble symptoms N G the PCM TSB INSPECTION PROCEDURE 24 Fuel pump syste...

Page 479: ...ECTION PROCEDURE 26 A C switch and A C compressor clutch relay system motor and also operates the A C compressor magnetic clutch Probable cause l Malfunction of A C control l Malfunction of A C switch...

Page 480: ...nition switch ON OK Check symptom 1 Replace the OK Radiator fan runs at low speed l Check the radiator fan circuit Refer to ELEC TRICAL WIRING Refer to ELECTRICAL WIRING l Check the A C condenser fan...

Page 481: ...fuel pump system 51 Fuel pump relay Refer to Refer to INSPECTION 24 SCAN TOOL SENSOR Check the engine coolant temperature Sensor Refer to INSPECTION PROCEDURE 38 INSPECTION PROCEDURE 30 Scan tool Ins...

Page 482: ...TOOL SENSOR READ TESTS Data list 63 sensor volts rear Refer to l Transaxle gear Check the heated oxygen sensor rear Refer to P INSPECTION range l Drive with wide open throttle OK 1 000 SCAN TOOL SENSO...

Page 483: ...TESTS Data list 02 sensor volts front Refer to OK Changes between 1 000 during sudden racing OK Check the heated oxygen sensor rear circuit Refer to INSPECTION SCAN TOOL SENSOR READ TESTS Data list 02...

Page 484: ...to Check the position sensor Refer to INSPECTION 43 I SCAN TOOL Actuator test NG INSPECTION 16 EGR solenoid Refer to OK SCAN TOOL SENSOR READ TESTS Data list 63 sensor rear Refer to Transaxle gear ran...

Page 485: ...TIC TROUBLE CODE SCAN TOOL SENSOR READ TESTS Data list 63 sensor volts rear Refer to l Transaxle gear range l with wide open throttle OK NG Refer to INSPECTION PROCEDURE 41 SCAN TOOL SENSOR READ TESTS...

Page 486: ...the ignition switch to Check the following Check trouble symptom Check the harness wire between the battery fuel pump relay connector Repair if necessary Measure at the PCM connector NG Check the foll...

Page 487: ...wing connector OK OK NG Replace the PCM NG Repair Check trouble symptom NG Replace the PCM INSPECTION PROCEDURE 39 1 Check the intake air temperature sensor circuit NG Check the intake air temperature...

Page 488: ...ce OK Check trouble symptom R e p a i r Replace the MAP sensor INSPECTION PROCEDURE 41 Check the heated oxygen sensor rear circuit NG Check the heated oxygen sensor rear Refer to Replace TSB Revision...

Page 489: ...nd heated oxygen sensor front connector Repair if Check the following connector OK NG Check trouble symptom NG NG Check the harness wire between the PCM and the heated oxygen Repair sensor front conne...

Page 490: ...le symptom NG NG Check the harness wire between the PCM and the speed sensor Repair connector SCAN TOOL SENSOR Data list 65 Vehicle speed l Is actual vehicle soeed indicated durina drivina I No Check...

Page 491: ...ON TURBO Troubleshooting INSPECTION PROCEDURE 45 Check the speedometer A l A l 07 OK Check trouble symptom NG Check the harness wire between the PCM and the combination meter Repair if necessary TSB R...

Page 492: ...r oxygen sensor Engine Idle front signal is used to 400 or less to check the air fuel 1 000 mixture ratio and Changes control condition is also checked Engine 2000 by the PCM When engine coolant tempe...

Page 493: ...air tern perature is When intake air Intake air Ignition switch ON engine run is temperature When intake air tem perature is 36 Charging system goal When intake air tem perature is Code No Engine 2 5...

Page 494: ...e 2 000 by the PCM MAP l Engine Warm idle The same l Use a vacuum gauge to measure the indication as the reading plenum vacuum vacuum gauge Procedure Procedure Total spark advance Engine Warm idle App...

Page 495: ...Warm idle When steering wheel ON is turned Transaxle or range Ignition switch ON Other than or range Brake Depress the brake pedal ON switch Do not depress the brake pedal ASD voltage OFF sense Igniti...

Page 496: ...ngine Warm idle ON EGR sole OFF Slight racing Engine 2 000 or more m o m e n t a r i l y Radiator fan Not activated Engine coolant Radiator temperature Less than approx 176 F fan low Radiator operates...

Page 497: ...tch ON Engine display reads 2300 nin switch ON switch ON I I 0 sound be heard Item No 01 02 04 05 06 6 Inspection Code Code Code Code Procedure Procedure Code No 1 Code Procedure Code No 35 Inspection...

Page 498: ...excessive amounts of fuel to be deposited in manifold Hydrostatic lock may result Inspection item High speed condenser fan relay Fuel pump relay Drive contents Fanspeedchanges between off and high eve...

Page 499: ...le speed is within the range shown in the Specification chart throttle body minimum airflow is set correctly Standard value Less than 1 000 miles More than 1 000 miles If idle speed is not within the...

Page 500: ...deposits d Use compressed air to dry the throttle body e Inspect throttle body for foreign material f Install throttle body on manifold g Repeat steps 1 through 14 If the minimum air flow is still not...

Page 501: ...ove protective cover from service valve on the fuel rail Connect Pressure Gauge to rail service valve Caution When using the scan tool Fuel System Test fuel pump relay will remain energized for 7 minu...

Page 502: ...uel return hose or pipe Clean or replace or pipe 7 the scan tool with the position the Fuel System 8 Turn the ignition switch off and gauge reading Normal does within 2 minutes it does observe the rat...

Page 503: ...the following operation so as to release fuel pressure in the line and running out 1 2 3 4 5 Remove the rear seat cushion Refer to Seat Remove the protector to the fuel pump connector Start the engine...

Page 504: ...on ventilation solenoid Fuel pump relay Heated oxygen sensor Front Heated sensor Rear Park Neutral position switch Transaxle range switch Power steering pressure switch Powertrain control module 0 Thr...

Page 505: ...On vehicle Inspection of ENGINE NON TURBO TSB Revision...

Page 506: ...of ENGINE Evaporative TSB Revision...

Page 507: ...TSB Revision...

Page 508: ...connected Continuity No continuity 4 If there is a defect replace the ASD relay or fuel pump relay INTAKE AIR TEMPERATURE SENSOR CHECK 1 Disconnect the intake air temperature sensor connector 2 Measur...

Page 509: ...ten harness connectors securely THROTTLE POSITION SENSOR CHECK 1 the throttle position sensor connector 2 Measure the resistance between the throttle position sensor side connector terminal 1 and term...

Page 510: ...en terminal 1 terminal 2 7 While repeatedly racing the engine heated oxygen sensor output voltage Standard value Engine TSB Revision If you make ratio rich by racing the engine repeatedly a normal hea...

Page 511: ...On vehicle Inspection of ENGINE NON TURBO 1 2 removal and installation of the oxygen sensor refer to GROUP 15 Exhaust Pipe Main TSB Revision...

Page 512: ...if the injector you are checking is not operating you will hear the operating sound of the other injectors NOTE If no operating sound is heard from the injector that is being checked check the injecto...

Page 513: ...On vehicle Inspection of ENGINE NON TURBO EVAPORATIVE EMISSION PURGE CHECK 1 7 ELECTRIC EGR Refer to GROUP 17 Emission Control TSB Revision...

Page 514: ...eration Battery and Air Hose Removal l Battery and Air Intake Hose Installation l Fuel Leakage Inspection Engine oil I 2 5 Nm I 6 TSB Revision 00003911 Removal steps 1 High pressure fuel hose connecti...

Page 515: ...e injector to the left and right install it to the fuel rail 3 Check to be sure that the injector turns smoothly If it does not turn smoothly the O ring may be trapped remove the injector and then rei...

Page 516: ...ATION Pm removal l Battery Removal Refer to GROUP 17 On vehicle 3 9 Nm 5 2 9 Removal steps 1 Air intake hose 2 Accelerator cable connection 3 Vacuum hose connection 4 TPS connector 5 motor connector 6...

Page 517: ...SEMBLY SERVICE POINT MOTOR REMOVAL Do not disassemble the motor 2 Do not immerse solvent to clean the sensor and motor Clean them with shop towel THROTTLE BODY REMOVAL 1 Do not remove the throttle val...

Page 518: ...wer transistor located in the igni tion primary circuit turns ON and OFF to control the primary current flow to the ignition coil This controls the ignition timing in order to pro vide the optimum ign...

Page 519: ...ntrol Supplies current to fuel pressure solenoid coil to raise the fuel pressure so that the fuel does not vaporize when the engine is started while it is warm trouble code the normality is output l T...

Page 520: ...sensor Idle air control motor Variable resistor type Stepper motor type Stepper type by pass air control system the air Closed throttle position switch model No Rotary contact type Knock sensor Piezoe...

Page 521: ...ir temperature sensor Thermistor type Engine coolant temperature sensor Thermistor type Heated oxygen sensor Zircon type Vehicle speed sensor Electromagnetic resistance element type Park neutral posit...

Page 522: ...tch l Park neutral position switch Power steering pressure switch Ignition switch ST Enginecontrol Injector Fuel pump Evaporative emission l injection purge relay Idle air control motor l A C compress...

Page 523: ...or valve position sensor Heated oxygen sensor rear Manifold differential pres sure sensor tank differential pres sure sensor Engine control Injector l Fuel pump relay Evaporative emission l Fuel pump...

Page 524: ...0 26 0 36 Heated oxygen sensor output voltage 0 6 1 Fuel pressure psi Vacuum hose disconnected 289 309 42 45 at curb idle Engine Turbo 330 350 47 50 at curb idle Engine Injector coil resistance soleno...

Page 525: ...ENGINE TURBO AND ENGINE Scan tool Test harness set Inspection using an analyze Tool not available Revision I...

Page 526: ...ify complaint Does not reoccur Read the diagnostic trouble code Refer to Read the diagnostic trouble code Refer to TSB Revision Refer to the INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES Refer to MALF...

Page 527: ...ensor circuit malfunction bank 1 sensor 2 sensor heater circuit malfunction bank 1 sensor 1 sensor circuit bank 1 sensor 2 sensor heater circuit malfunction 1 Fuel trim malfunction bank 1 Injector cir...

Page 528: ...ECM detects function three times and detected no a malfunction the check engine malfunction indicator lamp illuminates when the engine is In this case one time indicates from next turned on and the s...

Page 529: ...from the scan tool to the engine control module Caution If the sensor connector is disconnected wlth the ignition switch turned on the diagnostic trouble code is In send the diagnostic trouble code er...

Page 530: ...y out one trip monitoring according to the following drive pattern from starting until ignition is turned off Takes approximately 20 minutes the engine and quickly accelerate to a speed of 72 km h 45...

Page 531: ...cceleration deceleration and braking can be carried period Drive for 60 seconds or more while maintaining the vehicle speed 55 60 mph Braking and throttle operations can be carried out this as the veh...

Page 532: ...d up turn the ignition switch to OFF Start the engine and accelerate to a speed of between 56 64 km h 35 mph Monitoring period drive for 120 seconds or more while maintaining the throttle opening angl...

Page 533: ...throttle and let the vehicle decelerate to an engine speed of 900 without applying the brakes The steering wheel should not be turned and no lights or accessories be turned on or off during this time...

Page 534: ...med up turn the ignition switch to OFF the engine and accelerate to a speed of between 89 97 km h 55 60 Monitoring period drive for 30 minutes or more while maintaining the speed at 89 97 km h 55 60 m...

Page 535: ...r higher 3 condition l Selector lever position range l Overdrive switch ON l Power economy changeover switch Power 2 Carry out one trip monitoring according to the following drive pattern from startin...

Page 536: ...codes 2 Repair the malfunction while the CHART FOR DIAGNOSTIC CODES 3 Turn the ignition switch to OFF and then back to ON again 4 Erase the diagnostic trouble codes using the scan tool 5 Check that th...

Page 537: ...ve been completed are both made easier Once mode II has been selected it is necessary ignition switch to OFF or to use the MUT II to I once more before mode I operation can resumed However all readine...

Page 538: ...the signal of the heated oxygen sensor front installed on the front side of the catalytic converter The ECM stops supplying fuel to the cylinder with the highest misfiring rate if a misfiring that cou...

Page 539: ...ensor front Retained Loop Fuel Control l sensor harness and connector Injector sensor circuit malfunction Bank l Harness and connector Retained 1 Sensor 1 If harness and connector are not defective re...

Page 540: ...replace camshaft position sensor 0400 0420 Exhaust gas recirculation flow function Exhaust gas recirculation solenoid malfunction Catalyst system efficiency below threshold Bankl l Harness and connect...

Page 541: ...aste gate solenoid Engine Turbo Fuel pressure solenoid malfunction l Harness and connector Retained Engine Turbo l Fuel pressure solenoid Manifold differential pressure MDP l Harness and connector Ret...

Page 542: ...eauencv has continued to be 1000 Hz or hiaher for 4 sec Engine l Sensor output frequency has continued to be 800 Hz or higher for 4 sec Engine 3 Check Area l Throttle position sensor voltage is 1 5 or...

Page 543: ...be 1 95 or lower a barometric pressure of 50 7 4 psi or lower for 4 sec the ECM and the barometric NG Measure at the volume air flow sensor connector l Disconnect the connector and measure at the har...

Page 544: ...l Sensor output voltage has continued to be 4 6 or higher corresponding to an intake air temperature of or lower for 4 sec or l Sensor output voltage has continued to be 0 2 or lower corresponding to...

Page 545: ...or lower corresponding to an engine coolant temperature of or higher for 4 sec 2 Check Area Judgement Criteria l Sensor output voltage increased from a value lower than 1 6 to a value higher than 1 6...

Page 546: ...higher for 4 sec or I l Sensor output has continued to be 0 2 or lower for 4 sec 2 Check Area l Engine speed is at between 500 and 3000 Volumetric efficiency is 30 or lower Judgement Criteria l Senso...

Page 547: ...l Engine control module l Engine speed is at between about 1800 and 3500 l Volumetric efficiency is 16 62 l Running within air fuel mixture ratio feedback zone l Monitoring time 128 Judgement Criteri...

Page 548: ...than 25 l intake air temperature is or higher l Barometric pressure is 76 11 psi or higher Judgement Criteria l Input voltage supplied to the engine control module interface circuit is not lower than...

Page 549: ...nk 1 Sensor 1 has continued to be not higher than 0 2 A or not lower than 3 5 A for 6 sec l Monitored only once per trip NG Refer to I OK Measure at the oxygen sensor front connector l Disconnectthe c...

Page 550: ...Engine coolant temperature is not lower than l Engine speed is higher than 1200 l Volumetric efficiency is not lower than 25 l Intake air temperature is or higher l Barometric pressure is 76 11 psi o...

Page 551: ...A for sec l Monitored once trio NG Replace Refer to Measure at the heated oxygen sensor rear connector l Disconnect the connector heated oxygen sensor rear and the relay connector Repair if sure at th...

Page 552: ...CODE NG SCAN TOOL Data list Check the engine coolant malfunction Refer 21 Engine coolant temperature sensor Refer to to INSPECTION PROCEDURE OK TROUBLE CODE SCAN TOOL Data list 25 Barometric pressure...

Page 553: ...fer to NG Measure at the resistor connector l Disconnect the connector and measure at the harness side Check harness wire between the relay and the l Voltage between 3 and ground Ignition switch ON to...

Page 554: ...e crankshaft is used for misfire detection l Misfire has occurred more frequently than allowed during the last 200 revolutions when the catalyst temperature is higher than or l Misfire has occurred in...

Page 555: ...emission standard l l Low compression l Injector failed l Engine Check the injector Refer OK Replace Check the following connectors __ Repair OK Check the harness wire between the ECM and the injecto...

Page 556: ...l The engine control module checks whether the pulse signal is input while the engine is cranking Check Area Judgement Criteria 1 Check Area l Engine is being changed Judgement Criteria l Sensor outpu...

Page 557: ...etween the crankshaft poition sensor and Disconnect the connector and measure at the harness the relay connector Repair if necessary side 1 Voltage between 3 and ground Ignition switch ON OK Battery p...

Page 558: ...the connector Voltage between 2 and ground Engine cranking OK l Voltage between 2 and ground Engine idling OK NG Measure at the camshaft position sensor connector l Disconnect the connector and measu...

Page 559: ...perature is or higher l Barometric pressure is 76 11 psi or higher l Closed throttle position switch ON l Volumetric efficiency is 15 or 27 or lower engine l Volumetric efficiency is 15 or 20 or lower...

Page 560: ...surge voltage system voltage V is not detected when the EGR solenoid is turned on off NG Check the EGR solenoid Refer to GROUP Emission Control System Engine Turbo Refer to GROUP 17 Emission Control...

Page 561: ...Turbo l Volume air flow sensor output frequency is between 50 and 240 Hz l Intake air temperature is or higher l Barometric pressure is 76 11 psi or higher l Closed throffle position switch OFF l Unde...

Page 562: ...his change l Check Area l Engine control module l 3 min or more have passed after the sequence was completed l Engine coolant temperature is higher than l Power steering switch OFF l Under the closed...

Page 563: ...and the check engine malfunction indicator lamp illuminates Check Area l Engine coolant is not lower than Engine speed is at between 1600 3500 l Power steering pressure switch OFF Ambient pressure is...

Page 564: ...s turned on off l Evaporative emission purge l Open or shorted solenoid or Engine control module failed Measure at the ECM Check the evaporative l NG Disconnect the connector and measure at the harnes...

Page 565: ...n V Judgement Criteria l Solenoid coil surge voltage system voltage is not detected when the Evaporative emission vent solenoid is turned on off Check the evaporative emission ventilation solenoid Ref...

Page 566: ...driven at 100 duty or l The sensor output voltage is 0 5 or lower for 10 seconds even though the intake air temperature is 41 or higher and the evaporative emission purge solenoid is not being driven...

Page 567: ...ement Criteria l Sensor output voltage has not changed no pulse signal is input for 4 sec speed sensor l Open or shorted vehicle speed or loose l Engine module Check the vehicle speed tion Meters Repa...

Page 568: ...e during the last operation was or more l Engine coolant temperature is approximately or higher l System voltage is 10 or higher l Intake air temperature is or higher l Barometric pressure is 76 11 ps...

Page 569: ...nition switch is turned to the ON position OK changes from 1 5 4 0 momentary to 0 1 or 4 5 5 5 l Voltage between 4 and ground right ignition switch is turned to the ON position OK changes from 1 5 4 0...

Page 570: ...l Closed throttle position switch is on 2 Check Area I l Driving 1 and stopping 2 are repeated 15 times or more 1 driving Engine speed is 1 500 or higher air flow sensor output frequency is 100 Hz or...

Page 571: ...place the ECM Code No Transmission Range Sensor Circuit Malfunction RPNDL Input Comment Background l When a malfunction of the park neutral position switch is detected the transaxle control module out...

Page 572: ...arger waste gate solenoid is turned on off Check the turbocharger NG Refer to GROUP 15 On vehicle Service Replace OK Measure at the turbocharger waste gate pressure solenoid connector l Disconnect the...

Page 573: ...ge voltage system voltage 2 V is not detected when the fuel pressure solenoid is turned on off Probable cause l Fuel pressure solenoid l Open or shorted fuel pressure or loose connector l E n g i n e...

Page 574: ...sor output voltage has continued to be not higher than 0 1 corresponding to an absolute pressure of 2 4 0 3 psi or lower for 4 sec 2 Check Area 8 min or more have passed engine Started However this is...

Page 575: ...e NG OK Measure at the ECM connector Connect the connector Voltage between 73 and ground O K Check the following connector Replace the ECM Measure at the MDP sensor con nector Disconnect the connector...

Page 576: ...le cause l Open circuit in generator terminal circuit l Engine control module failed Replace the ECM Check trouble symptom NG NG Repair between the ECM and the OK connector NG Repair OK Check trouble...

Page 577: ...lenoids has failed the transaxle control module inputs these failure signals to the engine control module Check Area Judgement Criteria l Torque converter clutch solenoid shift control solenoid or pre...

Page 578: ...ENGINE TURBO AND ENGINE Check the following connectors Repair OK Check trouble symptom module connector Replace the OK Repair __ Revision...

Page 579: ...dling stability Unstable idle Rough idle hunting 8 Improper idling dling stability Idle speed is high Improper idle speed 9 idling Idle speed is low Improper idle speed dling stability When the engine...

Page 580: ...the accelerator pedal is depressed or being used Hesitation is the delay in response of the vehicle speed engine speed that occurs when the accelerator is depressed in order to accelerate from the spe...

Page 581: ...ata link connector and ground Repair if necessary Replace the scan tool INSPECTION PROCEDURE 2 Scan tool communication with ECM is not possible P r o b a b l e Comment One of the following causes may...

Page 582: ...listed at right has probably occurred SCAN TOOL Date list 16 ECM power supply voltage Refer to OK Measure at the ECM Check the power supply ignitiori system Refer to INSPECTION PROCEDURE 27 Check the...

Page 583: ...cases such as the above the cause is probably that the spark plugs are fouled defective or l Malfunction of the fuel pump system that the supply of fuel to the combustion chamber is defective Malfunc...

Page 584: ...OCEDURE 38 OK Yes INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE Is starting good if the engine Yes pedal depressed No Check idle air control motor for operation sound Check the idle control malfunction...

Page 585: ...or Check battery positive OK 8 or higher Check the battery Refer to GROUP 54 Battery Scan tool Inspection when incomplete combustion occurs Refer to INSPECTION PROCEDURE 38 OK Can any sound be heard R...

Page 586: ...ion of the evaporative purge system l Poor compression l Drawing air exhaust system Check the idle control system malfunction Refer to INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODE Checktheinjector...

Page 587: ...to OK Check the idle control system malfunction Refer INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODE NG SCAN TOOL Data list Check the closed throttle position 26 Closed throttle position switch Refe...

Page 588: ...ntrol motor for operation sound Refer to OK SCAN TOOL Data list NG 26 Closed position switch Refer to Check the idle control system to INSPECTION PROCEDURE FOR DIAGNOSTIC Check the closed position swi...

Page 589: ...idle air control motor for operation sound NG Engine Turbo Refer to Check the idle air control motor for operation sound Refer to Checktheinjectorforope OK Check the idle control system malfunction to...

Page 590: ...STIC TROUBLE CODE Check the idle air control motor for operation sound Refer to Checktheinjectorforoperati OK PROCEDURE FOR DIAGNOSTIC I Does the engine stall NO While carrying out an intermittent mal...

Page 591: ...he intake air volume is insufficient due to a defective idle air control motor system Were the battery terminals disconnected recently NO After warming up let the engine at idling for 10 SCAN TOOL DTC...

Page 592: ...sitation sag stumble or poor acceleration occurs Refer to INSPECTION PROCEDURE 42 I OK Check the fuel pressure Refer to O K Check the following items l Check the ignition coil spark plugs spark plug c...

Page 593: ...pressure etc are l Malfunction of the Ignition system Malfunction of air fuel ratio control l Malfunction of the fuel supply system Poor acceleration l Clogged exhaust system l Malfunction of turbocha...

Page 594: ...lugs spark plug cables l Check the EGR system l Check the waste actuator INSPECTION PROCEDURE 20 Knocking Probable cause Comment l Defective knock sensor In cases such as the above the cause is probab...

Page 595: ...pressure sensor Refer to OK Check the pressure circuit malfunction INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODE SCAN TOOL Data list NG Check the oxygen sensor circuit malfunction bank sensor 2 Ref...

Page 596: ...lfunction of charging system l Short harness between t e r m i n a l l Malfunction of the ECM OK Check the generator 1 Measure at the generator connector l Connect the connector l Voltage between and...

Page 597: ...of the feedback control from the oxygen sensor signal if the EGR flow volume is insufficient or if the catalyst has deteriorated Probable cause 1 NOTE If the temperature of the three way catalyst is...

Page 598: ...the barometric pressure sensor circuit Refer to INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODE N G SCAN TOOL Data list Check the oxygen sensor circuit malfunction bank 1 sensor 2 59 Heated oxygen se...

Page 599: ...RT FOR DIAGNOSTIC TROUBLE CODE Refer to GROUP 17 Emission Control System INSPECTION PROCEDURE 26 Pressure test of the evaporative system failed Probable Comment The test is if there is a leak in the f...

Page 600: ...ssary side l between 3 4 and around OK Battery positive voltage OK Check the ECM power and around circuit Refer PR O C E D U R E 44 INSPECTION PROCEDURE 28 Fuel pump system Engine Turbo Probable cause...

Page 601: ...and ground switch ON OK Battery positive voltage Check the fuel pump drive circuit 46 NG Repair l Disconnect the connector and measure at the harness side connector 1 Voltage between 1 and ground Ign...

Page 602: ...cranking Improper connector The ECM controls fuel injection etc during starting based on this input l t h e Measure at the ECM connector l Disconnect the connector and measure at the harness side 1 Vo...

Page 603: ...lace On vehicle Service park neutral position switch and ignition switch connector OK Check the ignition switch Refer to GROUP 54 Switch 1 NG Measure at the position switch connector l Disconnect the...

Page 604: ...e compressor magnetic clutch l Improper connector open circuit or harness NG Refer to GROUP 55 On vehicle Service Replace OK Measure at the ECM connectors l Disconnect the connector and measure at the...

Page 605: ...r open shortclrcuited l Malfunction of the ECM Disconnect the connector and measure at the harness Voltage between 20 and ground and 21 and ground l Shortcircuit between 20 and ground Ignition switch...

Page 606: ...harness side l Continuity between 3 and ground OK Continuitv Check trouble symptom Check the ignition switch Refer to Ignition Switch NG Check the harness wire between ignition connector and ground R...

Page 607: ...URE 36 Scan tool Inspection when no initial combustion occurs SCAN TOOL Data list NG Check the power and ignition 16 Voltage of ECM power source Refer to Refer to I PROCEDURE 27 When oil filler cap is...

Page 608: ...on circuit system Refer to INSPECTION PROCEDURE 34 OK NG Check that the crankshaft position sensor are properly installed INSPECTION PROCEDURE 38 Scan tool Inspection when incomplete combustion occurs...

Page 609: ...th wide open throttle OK 1 000 OK SCAN TOOL Date list 11 Heated oxygen sensor front Refer to OK during sudden racing Check the oxygen sensor circuit malfunction bank Refer to P INSPECTION PROCEDURE FO...

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Page 617: ...the power transistor unit INSPECTION PROCEDURE 51 Check the boost meter circuit Engine Turbo I Measure at the ECM connector l Disconnect the connector and mea sure at the harness side l Voltage betwee...

Page 618: ...21 22 Inspection item Heated oxygen sensor Front Volume air flow sensor Intake air temperature sensor Throttle position sensor Power supply voltage Cranking signal Ignition switch ST Engine coolant t...

Page 619: ...osed throttle position switch turns from on to off at this time the sensors are normal If the throttle position sensor voltage rises 100 from the voltage when the engine is at idle the throttle valve...

Page 620: ...on to throttle opening angle Open fully Power Ignition switch ON Battery voltage No 27 8 Cranking Ignition switch ON Engine Stopped OFF s i g n a l No tion Engine Cranking ON 30 Engine Ignition switch...

Page 621: ...At 600 95 1 969 ft 3 937 ft At 1800 81 5 906 ft 26 Closed l Ignition switch ON Throttle valve Set ON Code No throttle l Depress accelera to idle position tion switch tor pedal Throttle valve Slightly...

Page 622: ...arm Engine is idling and ignition l Timing light is set Engine power The timing light sistor is set in order to Turbo check actual __ tion timing 2 500 Idle air con e Engine coolant A C switch OFF 2 2...

Page 623: ...ould be operating 59 Heated l Transaxle 3 500 1 000 Code No gen sensor gear Rear range l Drive with wide open throttle 31 Long term fuel pensation Engine Warm 2 500 without any load 12 5 12 5 Code No...

Page 624: ...el is recirculated Pulse is felt Procedure No 28 En gine Tur bo Typical pump whine when valve is Procedure 29 En gine Code when valve is when valve Code No Code No when valve is No BTDC Fan motor oper...

Page 625: ...onvenient to pull out the ECM to make it easier to reach the connector terminals 3 Checks don t have to be carried out in the order given in the chart Caution Short circuiting the positive probe betwe...

Page 626: ...r Ignition switch Immediately after or more turning ON tartly O l Idle air control motor Ignition switch Immediately after Momentarily valve position sensor turning ON O l or 4 5 5 5 Idle air control...

Page 627: ...gh Radiator fan is not operating Engine coolant 20 20 21 22 33 Radiator fan is operating at high speed Engine i s Fan motor relay Low Radiator fan is not operating Engine temperature Radiator fan is o...

Page 628: ...h OFF switch ON A C compressor is operating Engine Idle at the coolant b l ture of or lower Engine Warm idle Engine Warm idle Engine 5 000 the at a constant speed Engine 3 000 Warm idle Engine 5 000 E...

Page 629: ...e Ignition switch ON 4 5 5 5 92 Ignition Ignition switch ON 33 83 Engine coolant Ignition switch When engine 3 2 3 8 ture sensor ON coolant tempera _ ture is When engine 2 3 2 9 coolant tempera ture i...

Page 630: ...t throttle O l switch ON to idle position Slightly open 4 or more throttle valve 88 88 Camshaft position sensor Engine Cranking 89 89 90 90 91 91 Engine Idle Crankshaft position Engine Cranking sor En...

Page 631: ...may occur Use care to prevent this 4 If the ohmmeter shows from the normal condition check the corresponding sensor actuator and related electrical wiring and then repair or replace 5 After repair or...

Page 632: ...lenoid Approx 12 At 36 44 At Heated oxygen sensor heater front Approx 12 At Intake air temperature sensor 5 3 6 7 intake air temperature is When intake air temperature is 1 1 5 intake air temperature...

Page 633: ...onnected 2 Connect the analyzer special patterns pickup to volume air flow sensor connector terminal 3 Alternate method lest harness not available 1 Connect the analyzer special pickup to ECM terminal...

Page 634: ...al wave patterns l Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started l Example 2 Cause of prob...

Page 635: ...tion sensor signal wave pattern 2 Connect the analyzer special patterns pickup to ECM terminal 89 When checking the crankshaft position sen sor signal wave pattern Standard Wave Pattern Observation co...

Page 636: ...t method 1 Disconnect the injector connector and connect the special tool test harness 348 in between Both on the engine control module side and the terminal on the power supply side should be connect...

Page 637: ...ern observation points Point A Height of injector coil induced voltage Contrast with standard wave pattern Injector coil induced voltage is low or doesn t appear at all Probable cause Short in the inj...

Page 638: ...M terminal 4 connection terminal 5 connection terminal 17 and connection terminal 18 respectively Standard Wave Pattern Observation conditions Function Special patterns Pattern height Pattern selector...

Page 639: ...cause Induced voltage does not appear or is extremely small Motor is malfunctioning Point Height of coil reverse voltage Contrast with standard wave pattern Probable cause Coil reverse voltage does n...

Page 640: ...ct the analyzer special patterns pickup to tion power transistor connector terminal 2 No 3 and terminal 7 No 1 No 4 Alternate method Test 1 Connect the analyzer special pickup to ECM terminal and conn...

Page 641: ...ectangular wave at power voltage Ignition power transistor malfunction Normal wave pattern Normal wave pattern Examples of abnormal wave l Example 1 Wave pattern during engine cranking of problem Open...

Page 642: ...eral times and idle it for about 1 minute If the idling speed becomes unstable or if the engine stalls due to the bypass passage being plugged slightly open the throttle valve to keep the If the throt...

Page 643: ...sert a feeler gauge with a thickness of 0 45 mm in between the fixed SAS and the throttle lever 4 Loosen the throttle position sensor mounting bolt then turn the throttle position sensor body fully co...

Page 644: ...connectors 2 Connect a digital voltmeter throttle tion sensor terminal 2 sensor output and 4 sensor ground 10 Turn the ignition switch ON but do not start the engine 11 Check the throttle position se...

Page 645: ...erclockwise until it is sufficiently backed out and fully close the throttle valve 4 Turn the fixed SAS clockwise until the throttle lever is touched i e the point at which the throttle valve begins t...

Page 646: ...T E When the scan tool is connected the diagnostic test mode control terminal should be grounded 3 Start the engine and run at idle 4 Select the item No 30 of the SCAN TOOL MUT II Actuator test NOTE...

Page 647: ...s been moved the fixed SAS If there are no indications that it has been moved it possible that there is leakage as a result of the fast idle air valve FIAV and if so the throttle body should be replac...

Page 648: ...the fuel pressure gauge and the special tool so as to seal in order to prevent fuel leakage at this time 5 Install the special tool which was assembled in steps 3 and 4 between the fuel rail and the...

Page 649: ...bleshoot and repair according to the table below Symptom Probable cause Remedy l Fuel pressure too low Clogged fuel filter Replace fuel filter l Fuel pressure drops after racing l No fuel pressure in...

Page 650: ...ual pressure from the fuel pipe line Refer 16 Remove the fuel pressure gauge and special tool from the fuel rail Caution Cover the hose connection with a shop towel to pre vent splash of fuel that cou...

Page 651: ...o install the 5 the rear seat cushion FUEL PUMP OPERATION CHECK 1 Check the operation of the fuel pump by tool to force drive the fuel pump 2 If the fuel pump will not operate check by using following...

Page 652: ...k terminal Fuel pump relay Heated oxygen sensor Front Heated oxygen sensor Rear Idle air control motor Ignition coil Ignition power transistor NOTE Symbol Name Symbol A Injector Knock sensor Manifold...

Page 653: ...Fuel check built in intake air temperature...

Page 654: ...Inject Turbocharger waste solenoid...

Page 655: ...Data...

Page 656: ...olenoid fuel relav I I Engine control module ECM Engine coolant temperature sensor Park Neutral position switch Power steering pressure switch Evaporative emission purge solenoid Fuel check terminal T...

Page 657: ...Volume air flow sensor with built in intake air tem perature and baro metric pressure sensor...

Page 658: ...Throttle sensor built in closed on coil temperature sensor...

Page 659: ...neutral position switch I Check engine malfunction indicator lamp Data connector o x v a e n front...

Page 660: ...1 3 while connecting and disconnecting the at bat tery terminal Jumper lead Continuity 3 Connected Continuity Disconnected No continuity If there is a defect replace relay INTAKE AIR TEMPERATURE SENSO...

Page 661: ...ture sensor immersed in hot water check resistance Temperature 32 20 66 40 104 60 176 Resistance 2 1 2 7 3 If the resistance deviates from the standard value greatly replace the sensor 4 Apply sealant...

Page 662: ...hanges in pro fully open from the idle portion to of 4 If the resistance is outside the or if doesn t change smoothly replace the sensor NOTE Always adjust the throttle position sensor after replace m...

Page 663: ...e the jumper wires to connect terminal 1 red clip of the heated oxygen sensor connector to the battery terminal and terminal 3 blue clip to the battery terminal Caution Be very careful when connecting...

Page 664: ...rement of Resistance between Terminals 1 Remove the injector connector 2 Measure the resistance between terminals Standard value 2 3 at Engine Turbo 13 16 at Engine 3 Install the injector connector Ch...

Page 665: ...rature is or below NOTE Disconnecting the engine coolant temperature sensor connector and connecting the harness side of the connec tor to another engine coolant temperature sensor that is at or below...

Page 666: ...x to the white clip and the green clip 5 With the idle air control motor as shown in connect the negative terminal of the power supply to each clip as described in the following steps and check whethe...

Page 667: ...ignition switch is turned to NOTE If the motor operation cannot be heard check the motor drive circuit and the idle air control motor FUEL PRESSURE SOLENOID CHECK Engine Turbo NOTE When disconnecting...

Page 668: ...s Vacuum maintained Vacuum maintained Measure the resistance between the terminals of the sole noid valve Standard value 36 44 at 3 4 5 EVAPORATIVE EMISSION PURGE SOLENOID CHECK Refer to GROUP 17 Emis...

Page 669: ...installation Operation Spark Plug Cable Installation l Fuel Leakage Inspection Engine Engine Turbo I Engine Engine fuel hose connection Fuel return hose connection 4 Vacuum hose connection regulator...

Page 670: ...ve the injector and then re insert it into the fuel rail and check once again FUEL PRESSURE REGULATOR 1 Apply a small amount of clean engine oil to a new and insert it to the fuel rail carefully Do no...

Page 671: ...nnector 5 motor connector 6 Vacuum hose connection 7 Heater hose connection 8 Charge air cooler fitting Engine Gasket Engine 10 Throttle body 11 Throttle body gasket INSTALLATION SERVICE POINT BODY GA...

Page 672: ...DISASSEMBLY AND REASSEMBLY Englne Turbo 4 1 4 I 1 Throttle position Sensor with in closed position switch 2 air control motor 3 O ring 4 Throttle body...

Page 673: ...semble the sensor and motor 2 Do not immerse solvent to clean the sensor and motor Clean then with shop towel REMOVAL 1 Do not remove the throttle valve 2 Check if the vacuum port or passage is clogge...

Page 674: ...ion sensor clockwise tighten screws 3 Check for continuity between terminals No 3 closed throttle position switch and No 4 ground If not continuity with the throttle valve fully closed turn the thrott...

Page 675: ...REMOVAL AND INSTALLATION NOTE Resin clip position 1 Console side cover Harness connector 3 pump relay module...

Page 676: ...NOTES a...

Page 677: ...CONTENTS FUEL FILTER 12 SERVICE FUEL TANK 2 SPECIAL TOOL 2 FUEL TANK 4 3 GENERAL INFORMATION 2...

Page 678: ...polyethylene material and 2 A fuel cut off valve has been adopted to prevent blow formed an tank fuel from leaking out in the event of a collision Specifications Fuel tank capacity gals Fuel pump type...

Page 679: ...ed fuel tank interior Replace Replace the fuel filter or clean the fuel tank and fuel line Clean or replace Malfunctioning fuel pump Clogged filter in the pump Evaporative emission Mispiping of vapor...

Page 680: ...el cut off valve assembly 7 Vapor hose 8 Fuel tank filler tube cap 9 Filler hose 10 Vapor hose TSB Revision 11 Fuel tank filler tube protector 12 Reinforcement 13 Fuel tank filler tube assembly 14 Pac...

Page 681: ...h pressure fuel hose 4 Return hose 12 Fuel tank filler protector 14 Fuel tank assembly Packing 5 Fuel pump 6 Fuel gauge unit 7 Fuel cut off valve assembly 6 Vapor hose NOTE When replacing the fuel or...

Page 682: ...e sensor 6 Fuel pump assembly 7 Fuel gauge unit 8 Fuel cut off valve assembly 9 Vapor hose lo Fuel tank filler cap 11 Filler hose 1 13 Fuel tank filler tube protector 14 Reinforcement 15 tank tube ass...

Page 683: ...ressure fuel hose 7 Return hose 8 Suction hose 9 Pipe 10 Cap 11 Fuel gauge unit and pump assembly gauge unit and pipe assembly 14 hose TSB Revision Shaft 15 Fuel cut off valve assembly 16 Fuel tank fi...

Page 684: ...pipe assembly are aligned Caution Make sure that the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly does not turn together with the cap when tightening the cap If the mati...

Page 685: ...flow out of the port B FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK Engine 1 Disconnect the fuel tank differential connector and connect the special tool terminals of the disconnected connector 2 Turn...

Page 686: ...fuel to prevent the fuel from spraying Refer to GROUP On vehicle Service 4 Disconnect the hose and connector connections and then remove the fuel and pump assembly 5 or the fuel gauge unit and pipe C...

Page 687: ...el gauge unit and or the fuel gauge unit and does not turn together with the cap when cap If the marks the of the float will light and the fuel Caution The packing should be as in the illustration 8 C...

Page 688: ...Post installation Operation l Air Intake Hose Installation and l Battery Engine l Pressure Measurement Engine Non turbo Refer to GROUP On vehicle Service Turbo and Engine Refer to GROUP Service Engin...

Page 689: ...er and remove the eye bolt Caution As there will be some pressure remaining in the fuel pipe line cover it with a shop towel to prevent fuel from spraying out FUEL MAIN PIPE DISCONNECTION Hold the fue...

Page 690: ...NOTES...

Page 691: ...ICLE SERVICE 7 TROUBLESHOOTING 4 Engine Coolant Concentration Test 7 Engine Coolant Leak Check 7 WATER HOSE AND PIPE Engine Coolant Replacement 7 AND Radiator Cap Valve Opening Pressure Check ENGINE 2...

Page 692: ...water pump is of the centrifugal type and is driven by the the forced circulation type in which the water pump crankshaft pressurizes coolant and circulates it throughout the engine If the coolant tem...

Page 693: ...t Engine Turbo and Engine 82 180 Full opening temperature of Engine Non turbo 102 216 thermostat Engine Turbo and Engine 95 203 Radiator cap valve opening pressure psi Engine Non turbo 94 122 14 18 En...

Page 694: ...s or leaking gasket in water inlet fitting Torque bolts again or replace gasket Faulty Loose water pump mounting bolts or leaking gasket Loose thermostat housing bolts or gasket automatic transaxle oi...

Page 695: ...fan and condenser fan do not operate in the low speed mode but operate otherwise 4 The radiator fan and condenser fan do not operate in the high speed mode but otherwise l Check the radiator fan motor...

Page 696: ...enser fan do not operate in the low speed mode but operate otherwise l Check the radiator fan motor relay LO and condenser fan motor relay LO l Check the engine control module Refer to GROUP Troublesh...

Page 697: ...ent repair or replace the appropriate part RADIATOR CAP VALVE OPENING CHECK 1 Use a cap adapter to attach the radiator cap to the tester 2 Increase the pressure until the indicator of the gauge stops...

Page 698: ...racket 6 upper hose 7 h o s e 8 Transaxle cooler hose tion Vehicles with Upper insulator 10 Radiator assembly 11 Transaxle fluid cooler hose and pipe assembly Vehicles with 12 Lower insulator 13 Conde...

Page 699: ...e 8 7 10 6 Radiator removal steps 1 Drain plug 2 Radiator cap 3 Overflow tube 4 Reserve tank 5 Reserve tank bracket upper hose 8 Radiator lower hose 9 Transaxle cooler hose and assembly Vehicles with...

Page 700: ...ntenance 12 Nm 8 7 Radiator removal steps 1 Drain plug 2 Radiator cap 3 Overflow tube 4 Reserve tank 5 Reserve tank bracket 8 Radiator upper hose 7 Radiator lower hose 8 Transaxle fluid cooler hose an...

Page 701: ...he radiator plug the hose and the radiator nipple to dust or from getting in INSTALLATION SERVICE POINT RADIATOR LOWER HOSE RADIATOR UPPER HOSE CONNECTION 1 each hose as the projection of the water ou...

Page 702: ...ENGINE Engine Non Turbo Engine Turbo FAN RELAY CONTINUITY TSB Revision...

Page 703: ...ir Hose C Removal and Installation Engine Turbo Refer to GROUP 15 Charge Cooler I I Engine Turbo Ermine 16 Engine 9 4 0 0 0 0 4 0 4 2 Removal steps 1 Radiator upper hose connection Engine Non turbo or...

Page 704: ...t so that the jiggle valve is facing straight up and is aligned with the mark on the thermostat case as shown in the illustration Caution Make absolutely sure that no oil is adhering to the rubber rin...

Page 705: ...that the thermostat valve opening temperature and the water temperature with valve fully open valve lift 8 mm in are at the standard value Standard value Valve opening temperature Engine Non turbo En...

Page 706: ...URBO REMOVAL AND INSTALLATION and Post Installation l Engine Coolant Draining and Supplying Refer to GROUP 00 Maintenance Service l Timing Belt Rear Cover Removal and Installation Refer to GROUP Timin...

Page 707: ...to the and of the O ring with water or coolant By with water or engine coolant the insertion the will become easier Caution 1 Do not allow engine oil or othei grease to to the O ring 2 When inserting...

Page 708: ...al and Post installation l Engine Coolant Draining and Supplying Refer to GROUP 00 Maintenance Service l For Timinig Belt Removal and Installation Refer to the Following GROUP Timing Belt GROUP Timing...

Page 709: ...ring to the water inlet pipe and coat the outer of the O ring with or coating Water or engine coolant the insertion to the water pump will become easier Caution 1 Do not allow engine other grease to t...

Page 710: ...g Refer to GROUP 00 Service l Under Cover Removal and Installation Refer to GROUP 42 Under Cover I I 3 9 2 9 7 33 Removal steps 1 Air intake hose 2 Air hose connection 7 Radiator fan motor assembly 8...

Page 711: ...diator hose and the hose clamp disconnect the radiator hose I N S T A L L A T I O N P O I N T S Insert the O ring to the water inlet pipe and coat circumference of the water or engine Do not allow or...

Page 712: ...rge Air Cooler l Turbocharger Removal and Installation Refer to GROUP 15 Exhaust Manifold 11 24 17 24 Nm 17 48 Nm 35 3 Specified Sealant or equivalent 58 Removal steps 1 Radiator upper hose connection...

Page 713: ...rvice 2 Air Cleaner Removal and Installation 3 Exhaust Manifold Removal and Refer to GROUP 15 Exhaust Manifold Specified Sealant Mitsubishi Genuine Part No or equivalent Removal steps 1 Radiator upper...

Page 714: ...or engine coolant Caution Do not allow engine oil or other grease to adhere to the O ring THERMOSTAT CASE ASSEMBLY INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there...

Page 715: ...E NON TURBO 7 ENGINE TURBO 11 ENGINE 14 ON VEHICLE SERVICE 3 C O N T E N T S 15166666676 Intake Charge Pressure Control System Check Turbo 4 Intake Manifold Vacuum Check Turbocharger Bypass Valve Chec...

Page 716: ...e actuator and solenoid valve Charge air cooler Air cooled type SERVICE SPECIFICATIONS Items Standard value Limit Intake manifold and Distortion of the installation surface mm in 0 15 or less air inta...

Page 717: ...m the gate solenoid and connect the pressure gauge to the hose Plug the nipple of the solenoid valve which the hose black has been 2 Drive the vehicle with and to a speed of more than at gear the supe...

Page 718: ...is idling Engine state Normal state Ignition switch ON Negative pressure is I maintained I after warmup Negative pressure leaks NOTE If this check indicates an abnormal condition the turbocharger wast...

Page 719: ...TURBOCHARGER Turbo 2 Connect the to the turbocharger 3 Apply a negative pressure and check of the valve Also check that air tightness is maintained Negative pressure Valve operation I Approx 53 16 It...

Page 720: ...aner assembly 2 Air duct assembly B 3 Relay box 4 Air bypass hose 5 Air intake hose 6 Air hose C 7 Turbocharger bypass valve 8 Air hose B 9 Charge air cooler duct 10 Charge air cooler 11 Air hose A NO...

Page 721: ...ystem l Engine Coolant Supplying Refer to GROUP Service l Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service 3 9 2 9 O ring Engine oil Removal steps 1 Air intake hose 2 Breather hose 3...

Page 722: ...oil 17 Intake manifold stay 18 Engine hanger 19 Injector connector 20 Throttle body 21 intake manifold plenum 22 Intake manifold plenum gasket 23 Fuel rail injector and pressure regulator 24 O ring 2...

Page 723: ...AND PRESSURE REGULATOR ASSEMBLY REMOVAL Remove fuel rail with fuel injector and pressure regulator on Caution Do not drop fuel injector when removing fuel rail INSTALLATION SERVICE POINTS RAIL FUEL I...

Page 724: ...NTAKE MANIFOLD CHECK 1 Check for damage or cracking of any part Check for of the negative pressure vacuum outlet port and for obstruction of the water passage or gas passage Using a straight edge and...

Page 725: ...r 5 Ignition power transistor connector 6 Manifold pressure sen sor connector 14 Air conditioning compressor con 7 Capacitor connector TPS connector 9 Knock sensor connector 10 Engine coolant temperat...

Page 726: ...rail fuel injector and pressure regulator assembly 28 Insulator 29 Insulator 30 Ignition power transistor 31 Ignition coil 32 EGR valve assembly 33 Intake manifold Engine hanger 35 Intake 38 Intake m...

Page 727: ...HOSE When connecting the high pressure hose to the fuel rail apply a small amount of new engine oil to the hose union and then insert beihg careful not to O ring Caution Do not let engine oil get into...

Page 728: ...onnector 6 Manifold differential pressure sen sor connector 7 Capacitor connector 8 TPS connector 9 motor connector 10 Heated oxygen sensor connector 11 Crankshaft position sensor connector 12 Air con...

Page 729: ...ulator assembly 25 Insulator 26 Insulator 27 Manifold erential pressure sensor 26 Ignition power transistor 29 Spark plug cable connection TSB Revision 30 Ignition coil 31 Intake manifold stay 32 Inta...

Page 730: ...STALLATION POINT HIGH PRESSURE FUEL HOSE When connecting the hose to the fuel rail apply a small amount of new engine the hose union and then insert being careful not to damage the O ring C a u t i o...

Page 731: ...raining and Refer to GROUP 3 9 Nm 2 9 6 Removal steps 1 Air intake hose 2 Radiator upper hose connection 3 Air hose connection 4 Control wiring harness connection 5 Water pipe assembly 6 Engine oil le...

Page 732: ...oval steps 1 Condenser fan motor assembly with air conditioning 2 Heated oxygen sensor front 3 Engine oil level gauge guide 4 Air cleaner and air intake hose assembly 5 Air hose A connection 6 Water h...

Page 733: ...Ghsket REMOVAL SERVICE HEATED OXYGEN SENSOR FRONT REMOVAL TSB Revision TURBOCHARGER ASSEMBLY Remove the turbocharger assembly with the exhaust fitting water pipe assembly A water pipe assembly B and t...

Page 734: ...ll the coned disc spring the shown direction 2 Tighten the flange nuts and bolts to 27 31 Nm 20 23 3 Use the special tool to further tighten by INSPECTION TURBOCHARGER ASSEMBLY CHECK 1 Visually check...

Page 735: ...Manifold EXHAUST MANIFOLD ENGINE REMOVAL AND INSTALLATION 12 15 Nm 29 Nm 21 49 Nm 36 Removal steps 1 Front exhaust connection 2 Gasket 3 Heat protector 4 Engine hanger 5 Exhaust manifold 6 Exhaust man...

Page 736: ...ic converter removal steps 1 Main muffler assembly 2 Gasket 13 Catalytic 14 Gasket 3 Hanger 4 Tail hanger 15 Catalytic converter bracket 5 Rear hanger 16 Hanger protector 6 Rear floor heat protector p...

Page 737: ...sket 3 Muffler cutter 4 Hanger 5 Tail hanger 6 Rear hanger 7 Rear floor heat protector panel Center exhaust pipe removal steps 8 Heated oxygen sensor connection 9 Center exhaust pipe 10 Gasket 11 Hang...

Page 738: ...bly 2 Gasket 3 Muffler cutter 4 Hanger 5 Tail hanger 6 Rear hanger 7 Rear floor heat protector panel Center exhaust pipe removal steps 6 Heated oxygen sensor connection rear 9 Center exhaust pipe 10 G...

Page 739: ...nger 6 Rear floor heat protector panel Center exhaust pipe removal steps 7 Heated oxygen sensor connection rear exhaust pipe Hanger protector 11 Hanger 12 Hanger bracket 9 4 9 4 1 Catalytic converter...

Page 740: ...turbo the exhaust threabs must be cleaned with an 18 mm in 1 5 the heated oxygen sensor has been disconnected INSTALLATION SERVICE HEATED OXYGEN SENSOR OXYGEN SENSER REAR If reusing the original senso...

Page 741: ...NG OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED WARNING 1 Improper service or maintenance of any component of the or any SRS related can to injuryorcleathtoservicepersonnel from inadvertentfiring the...

Page 742: ...n Engine Turbo 69 Component Location Engine Turbo 70 Evaporative Emission Canister Fuel Tank Pressure Relief Valve Purge Control Valve 78 Evaporative Emission Purge Solenoid Check 76 General Informati...

Page 743: ...BLESHOOTING Symptom Probable cause Remedy Throttle valve will not Misadjusted accelerator cable Adjust fully open or close Misadjusted auto cruise control cable Adjust Broken return spring Replace Thr...

Page 744: ...s too much the following procedures 1 Turn the ignition switch to ON position without starting the in that condition motor 4 9 3 6 TSB Revision 2 Loosen the adjusting bolt release the cable 3 After mo...

Page 745: ...ator cable Accelerator pedal removal steps 4 Accelerator cable connection Accelerator pedal pin 11 13 Nm 9 4 4 9 Nm 8 Bushing 9 Spring 10 Accelerator pedal arm Accelerator pedal bracket 12 Accelerator...

Page 746: ...17 6 ENGINE AND EMISSION Engine ACCELERATOR Clamp the accelerator so that its as I TSB Revision...

Page 747: ...e Engine Non turbo Powertrain Non turbo km h 25 124 mph Engine Turbo and Engine without ing the accelerator pedal assemblv sensor Input speed sensor sensor Control switch Reservoir assembly Transaxle...

Page 748: ...ON CONTROL SERVICE Items Accelerator cable play mm in 2 3 Throttle cable play mm in Auto cruise control cable play Engine Turbo and Engine mm in SPECIAL TOOLS MUT II Diagnostic trouble code check harn...

Page 749: ...dard value DIAGNOSTIC FUNCTION HOW TO READ THE DIAGNOSTIC TROUBLE When using the scan tool Connect the scan tool to the data link connector and then read the diagnostic trouble codes the ignition swit...

Page 750: ...Auto cruise control switch 17 11 87 15 34 34 Auto cruise control switch 1 7 1 1 Speed control servo solenoid valve system 02 53 Powertrain control module PCM I 17 12 82 77 Auto cruise control relay s...

Page 751: ...cruise control switch Scan tool 15 Code General scan Speed control servo solenoid No system I I Comment l Malfunction of the speed control An open or shorted condition is detected in either the speed...

Page 752: ...ector l Malfunction of the l Malfunction of the PCM Speed control servo check Refer to Replace l Voltage between the terminal l Voltage between terminal and ground OK Battery positive voltage l Discon...

Page 753: ...5 instrument panel does not illuminate However auto cruise control is normal Auto cruise control main switch illumination light does not illuminate 9 17 16 Auto cruise control indicator light inside...

Page 754: ...ground positive voltage following connectors NG 63 and NG Check trouble NG symp Check the light and PCM Repair OK Check trouble symptom Replace the PCM light switch and the ground INSPECTION PROCEDUR...

Page 755: ...eed Comment A malfunction of a speed sensor the speed control servo or the vacuum supply may be present For vehicle speed sensor check For input speed sensor or output speed sensor check Refer to GROU...

Page 756: ...ol main switch connector l Disconnect the connector and mea sure at the harness side l Voltage between terminal 2 and ground OK Battery positive voltage I I OK Check trouble symptom NG power supply Re...

Page 757: ...Is the vacuum hose correctly installed and undamaged 2 Are the auto cruise accelerator and throttle cables routed correctly 3 Do the link assembly and cables move smoothly 4 Is the play of each cable...

Page 758: ...codes can erased by disconnecting the cable from the battery for 10 seconds or more and then reconnecting it or by the following procedure 1 Turn the ignition switch to ON 2 With the SET switch at the...

Page 759: ...cruise control ECU judges that clutch ON when clutch pedal depressed Park neutral position switch switch or park neutral position ON l ON when selector lever in range 27 CANCEL switch ON Auto cruise c...

Page 760: ...at the harness side l Voltage between terminal 12 and ground for driving release valve l Voltage between terminal 13 and ground for driving control valve l Voltage between terminal 26 and ground for d...

Page 761: ...d 3 NG OK Continuity OK Check trouble symptom NG Check the harness between the speed sensor Check the following OK NG Check trouble symptom NG Check the harness between the auto cruise ECU and the veh...

Page 762: ...e auto cruise control ECU Replace the auto cruise Code Throttle position sensor system Probable cause Comment l Malfunction of the throttle position sensor This diagnostic trouble code is output if a...

Page 763: ...ch is set to ON 5 17 26 I 7 17 27 Trouble symptom Inspection procedure No Reference page The diagnosis result displayed on the scan tool is normal even though auto cruise control cannot be set Auto cr...

Page 764: ...switch circuit malfunction Auto cruise control main switch check NG Repair to OK NG Measure at auto cruise control main switch connector l Disconnect the connector and mea sure at the harness side l...

Page 765: ...between terminal 2 and ground OK Battery positive voltage OK Check trouble symptom Check trouble spring and auto cruise INSPECTION PROCEDURE 4 When brake pedal is depressed auto cruise control does n...

Page 766: ...nd NG Replace the auto cruise control ECU INSPECTION PROCEDURE 6 When select lever is set to range auto cruise control does not cancel Probable cause Comment The cause is probably an open circuit in t...

Page 767: ...ment Because of an open circuit in the battery backup circuit system the fail safe function prevents diagnostic trouble codes from being memorized and displayed even though auto cruise control is canc...

Page 768: ...on procedure No 2 on Yes Is input switch inspection possible with the scan tool Yes Inspection for trouble symptom Refer to inspection procedure No 3 on Dose the input switch code or 27 remain output...

Page 769: ...main switch INSPECTION PROCEDURE 12 Auto cruise control main switch illumination light does not illuminate Probable cause Comment A malfunction of auto cruise control main switch harness or connector...

Page 770: ...en the combination meter and auto cruise control ECU if INSPECTION PROCEDURE 14 Stop light switch input circuit system check Code No 23 I I Stoplight switch check Refer to Check the harness between ju...

Page 771: ...witch is Battery positive voltage Battery positive voltage When ignition switch is ON Battery positive When ignition switch is ON When accelerator pedal is When closed throttle position depressed swit...

Page 772: ...When sensor is ON Vehicle speed and backwards sensor input sensor turns ON and OFF repeatedly When sensor is OFF 4 5 or more 20 ACC power supply When ignition switch is in ACC position Battery positiv...

Page 773: ...AUTO CRUISE CONTROL CABLE CHECK AND ADJUSTMENT Engine Non turbo Link assembly Accelerator cable Adjusting bolts To intake manifold assembly Speed control assembly Engine Turbo and Engine Actuator Lin...

Page 774: ...k A Engine Turbo and nut Accelerator cable Link A Engine Non turbo cable Engine Turbo and Engine Throttle cable CABLE 1 Adjust with the adjusting nut A so when the hits the stopper the accelerator cab...

Page 775: ...CONTROL SYSTEM OPERATION CHECK 17200160048 AUTO CRUISE CONTROL MAIN SWITCH INDICATOR LIGHT 1 Turn the ignition key to ON 2 Check that the indicator within the switch illuminates when the main switch i...

Page 776: ...low limit approximately 40 km h 25 mph during deceleration the auto cruise control will be canceled RETURN TO THE SET SPEED BEFORE CANCELLATION AND AUTO CRUISE CONTROL CANCELLATION 1 Set the auto crui...

Page 777: ...and Engine Measurement conditions When clutch pedal depressed Terminal No 1 2 0 When clutch pedal not depressed PARK NEUTRAL POSITION SWITCH POSITION Engine Turbo and Engine Measurement Terminal No I...

Page 778: ...2 Apply negative pressure to the actuator with the vacuum pump and check that the holder moves more than 35 mm 1 38 in In addition check that there is no change in the position of the holder when neg...

Page 779: ...ervo pins 1 2 5 Connect a hand held vacuum pump to the servo vacuum nipple and apply 10 to 15 inches of vacuum 6 The cable should pull in and hold for as long as vacuum is applied VACUUM SUPPLY Engine...

Page 780: ...11 Vacuum hose connection 4 Accelerator cable 12 13 control assembly 14 Actuator upper bracket Vacuum pump and actuator 15 Actuator lower bracket Link assembly removal steps 1 Link protector l Auto cr...

Page 781: ...removal steps Engine Non turbo l Air cleaner 22 Powertrain control module bracket 23 Powertrain control module Auto cruise removal steps Engine Turbo and Engine l side Auto cruise control main switch...

Page 782: ...trol 29 Steering wheel 30 Steering column upper cover 31 Steering column lower cover l under cover Refer to GROUP Panel 32 Clock spring Refer to GROUP Bag Modules and Clock Spring 3 8 Sensor removal s...

Page 783: ...re the resistance between the terminals when each of the SET RESUME and CANCEL switches is pressed If the values measured at this time correspond to those in the table below then there is no problem S...

Page 784: ...d 16 If there is no continuity replace the auto cruise control indicator CLOCK SPRING CHECK Refer to GROUP Air Bag Module and Clock Spring THROTTLE POSITION SENSOR CHECK Engine Turbo and Engine 172002...

Page 785: ...not replace Malfunction of the evaporative emission purge or solenoid Rough idle or engine The EGR valve is not closed Repair or replace stalls Vacuum hose disconnected or damaged Repair or replace M...

Page 786: ...D EMISSION CONTROL VACUUM HOSES VACUUM HOSE Two way valve I I To heater and control EVAP canister Vent EVAP solenoid To engine block EVAP emission Back pressure EGR and electric EGR transducer sole as...

Page 787: ...P purge solenoid ON open V A C U U M H O S E C H E C K 1 Using the VACUUM HOSE ROUTING as a guide check that the vacuum hoses are correctly that there are no bends or damage to the hoses VACUUM HOSE 1...

Page 788: ...nto the intake manifold through positive crank case ventilation valve The plunger inside the positive crankcase tion valve is designed to lift according to intake manifold vacuum regulating the flow o...

Page 789: ...manifold is felt NOTE At this time the plunger in the positive crankcase ventila tion valve moves forward and backward 4 If vacuum is not felt replace the PCV valve POSITIVE CRANKCASE VALVE CHECK 1 I...

Page 790: ...ATION Evaporative emission purge solenoid purge solenoid the power train control module PCM allows intake manifold vacuum to draw va pors into the combustion chambers during certain engine operating c...

Page 791: ...urge port may be clogged EVAPORATIVE PURGE SOLENOID CHECK NOTE When disconnecting the vacuum hose place an identification mark on it for reconnection 1 2 3 4 5 Disconnect the vacuum hose from the sole...

Page 792: ...LANT TEMPERATURE SENSOR AND INTAKE AIR TEMPERATURE SENSOR To check these parts refer to GROUP Troubleshooting AIR CONDITIONING SWITCH 17300200031 To check the air conditioning switch refer to GROUP 55...

Page 793: ...al steps 1 Suction hose fixing bolts 2 Pressure tube fixing bolt 3 Air filter 4 Air filter bracket Evaporative emission canister and evaporative emission ventilation solenoid assembly 6 Vent hose 7 Va...

Page 794: ...Vacuum only flows to the transducer when the PCM energizes the solenoid When exhaust system back pressure becomes high enough a bleed valve in the transducer closes The PCM energizes the solenoid and...

Page 795: ...is ing normally 6 Remove the vacuum hose from the EGR valve and plug the hose end 7 Connect a hand vacuum pump directly to the EGR valve 8 Check whether the engine stalls or if the idle is unstable wh...

Page 796: ...ng the vacuum hose place an identification mark on it for proper re connection 1 Disconnect the vacuum hose from the electric EGR trans ducer 2 Disconnect the harness connector 3 Plug nipple A 4 Conne...

Page 797: ...al oxidizes carbon monoxides CO and hydrocarbons HC and reduces nitrogen oxides REMOVAL AND INSTALLATION and Post installation Operation Under Cover Removal and Installation Refer to GROUP Cover When...

Page 798: ...sfiring occurs otherwise an abnormally hot exhaust system will damage the catalytic converter or other underbody parts 2 Correct and repair the ignition or fuel system if there are malfunctions otherw...

Page 799: ...GR valve is not closed Repair or replace Malfunction of the evaporative emission purge Repair or replace solenoid Rough idle or engine stalls The EGR valve is not closed Vacuum hose disconnected or da...

Page 800: ...ative emission EVAP canister EGR solenoid Evaporative emission Fuel pressure EVAP purge solenoid solenoid I Purge control valve By pass valve Fuel pressure regulator Revision Turbocharger waste gate s...

Page 801: ...Evaporative emission EVAP canister solenoid Vacuum control valve EGR Evaporative EVAP purge Front Turbo and Engine Blue B Black G Green Y Yellow White Revision...

Page 802: ...IAGRAM Engine Turbo intake air Throttle body L Light Blue Red B Black G Green Yellow W White To combustion chamber Check EVAP ON open EVAP canister TSB Revision Air Turbocharger waste gate Turbocharge...

Page 803: ...closed EGR VACUUM HOSE CHECK Using the VACUUM HOSE ROUTING as a guide check that the vacuum hoses are correctly connected and that there are no bends or damage to the hoses VACUUM HOSE INSTALLATION 1...

Page 804: ...inside the crankcase The blow by gas inside the is drawn into the intake manifold through the positive crank case ventilation valve The plunger inside the positive crankcase tion valve is designed to...

Page 805: ...ENGINE AND EMISSION CONTROL Emission Control and __ Ventilation hose Breather hose COMPONENT LOCATION Positive crankcase ventilation valve TSB Revision...

Page 806: ...ger on the open end of the PCV valve and check for negative pressure vacuum with finger NOTE At this time the plunger in the PCV valve should move back and forth as the open end is covered and uncover...

Page 807: ...with the vacuum side Using light pressure depress the PCV valve spring the thin stick mm Release pressure on stick to see if the PCV valve spring will lift stick to its original position 2 If the stic...

Page 808: ...ors from the fuel tank flow through the When driving with a high load on the engine the fuel tank pressure control valve and vapor pipe hose purge control valve opens and the fuel vapor to be stored t...

Page 809: ...w to the intake manifold plenum This does not only insure the when the cold or running under low load but also stabilize the emission level Furthermore an EVAP ventilation solenoid is locate between t...

Page 810: ...icator 700 1 Disconnect the purge hose from the evaporative emission EVAP canister and connect the special tool purge flow indicator between the EVAP canister and the purge hose 2 The vehicle should b...

Page 811: ...standard value check it again with the vacuum hose disconnected from the EVAP canister If the purge flow volume is below the standard values check for blockages in the vacuum port and vacuum hose and...

Page 812: ...ter Disconnect the purge hose from the evaporative emission EVAP canister and connect the special tool purge flow indicator between the EVAP canister and the purge hose 2 The vehicle should be prepare...

Page 813: ...__ 5 If the purge flow volume is than the value check it again with the hose from the EVAP canister If the purge flow volume the check for blockages in the vacuum and also check the evaporative and t...

Page 814: ...ple 2 Vacuum is kept constant despite the increased engine speed NOTE If no vacuum is generated the throttle body purge port may be clogged Engine Turbo 1 Disconnect the vacuum hose from the intake ma...

Page 815: ...sconnect the harness connector 3 Connect a hand vacuum pump to nipple A of the solenoid valve refer to the at left 4 Check air tightness by applying a vacuum with voltage applied directly from the bat...

Page 816: ...e and check conditions as follows Hand vacuum pump vacu um Normal condition 0 0 No vacuum Air does not blow through is applied 27 8 0 or more Air blow through 5 Connect a hand vacuum pump to the posit...

Page 817: ...nstallation Operation Battery Removal and Installation Removal steps 1 Battery bracket 2 Shift and con nection 3 Vapor hose 4 Connector 5 Vapor hose 6 Fuel tank pressure relief 7 Vapor hose 8 Vapor ho...

Page 818: ...lation Re fer to GROUP 42 Fender TSB Revision Removal steps 1 Evaporative emission 2 Vent hose 3 Vent hose 4 Connector 5 Vent hose 6 Vapor hose 7 Connector 8 Evaporative emission purge hose 9 Vapor ho...

Page 819: ...re Lightly blow from inlet Air passes fuel tank side slight feeling of Lightly blow from outlet side Air resistance EVAPORATIVE EMISSION VENTILATION SOLENOID CHECK 1 Connect a hand vacuum pump to nipp...

Page 820: ...um This sensor detects variations in the manifold pressure when the EGR solenoid is momentarily operated If the manifold negative pressure the EGR sys tem is normal SYSTEM DIAGRAM Engine Turbo EGR SYS...

Page 821: ...ENGINE AND EMISSION CONTROL Engine Turbo end Engine COMPONENT LOCATION Engine Turbo EGR solenoid Manifold differential pressure sensor relay Engine module EGR valve...

Page 822: ...Engine Turbo and Engine Engine EGR solenoid EGR valve Manifold differential pressure TSB Revision...

Page 823: ...as barometric pressure I When engine is hot Engine coolant or Throttle valve vacuum condition Open quickly It will momentarily rise over 3 9 3 Disconnect the three way terminal 4 Connect the hand vac...

Page 824: ...valve 3 Apply 67 20 of vacuum and check to be sure that the vacuum is maintained 4 Apply vacuum according to the below and check the passage of air by blowing through either side of the EG passages Va...

Page 825: ...ipe Engine Turbo green stripe Engine from the throttle body EGR vacuum nipple Connect a hand vacuum pump to the nipple 2 Start the engine and gradually raise the speed The vacu um reading on the pump...

Page 826: ...connect the harness connector Connect a hand vacuum pump to the nipple to which the white striped vacuum hose was connected Check air tightness by applying a vacuum voltage applied directly from the b...

Page 827: ...ipe stripe 1 2 3 4 5 from the solenoid valve Disconnect the harness connector Connect a hand vacuum to Check air tightness by applying vacuum directly from the battery to the solenoid without applying...

Page 828: ...ation against CO HC and and Post installation Operation Under Cover Removal and Refer to GROUP Cover 13 Nm 9 4 13 Nm I 36 Revision 36 Removal steps 1 Front exhaust pipe 2 Gasket 3 Catalytic converter...

Page 829: ...CLUTCH CONTENTS CLUTCH CLUTCHOVERHAUL...

Page 830: ...NOTES...

Page 831: ...ER CYLINDER 13 Bleeding 7 Clutch Pedal Check and Interlock Switch Check and Adjustment 6 CLUTCH PEDAL 8 Interlock Switch Operating Check 6 GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 3 LUBRICANTS 3 T...

Page 832: ...m in Clutch cover type Clutch cover setting load Clutch release cylinder I D mm in Engine Non turbo Turbo Hydraulic type Hydraulic type Single dry disc type Single dry disc type 225 150 8 9 5 9 Diaphr...

Page 833: ...andard value 6 13 70 2 76 or more Items Clutch fluid Push rod assembly Boot Specified lubricants Brake Fluid DOT 3 or DOT 4 Rubber grease Q u a n t i t y As required As required Release cylinder push...

Page 834: ...parts noise clutch pedal play Adjust Improper installation of clutch cover assembly Repair or replace parts Excessive wear of clutch disc facing Replace Clutch release fork catching Repair or replace...

Page 835: ...t the pin Standard value B mm in If the clutch pedal play is outside the adjust with the push rod Caution Do not push in the master cylinder at this time After completing the adjustments confirm that...

Page 836: ...n disconnected while the clutch pedal is depressed with the ignition switch turned to START position If the engine should start before the clutch pedal is disconnected or the engine does not start eve...

Page 837: ...gine Turbo and BLEEDING Whenever the clutch tube the clutch clutch master cylinder have or the clutch pedal is spongy bleed the system Specified brake fluid DOT 3 or 4 Caution Use only the specified b...

Page 838: ...on Refer to GROUP Trims I I Nm 7 9 29 Nm 21 5 Removal steps 1 Instrument under Refer to GROUP Panel 2 Master cylinder installation nuts 3 Clutch pedal return spring gine Non turbo Engine 4 Clevis pin...

Page 839: ...CLUTCH Clutch INSPECTION l Check the pedal shaft for wear l Check the clutch for l Check the return spring for or l Check the turnover spring for l Check the pedal pad for damage or wear TSB Revision...

Page 840: ...genuine grease Part No 0101011 or equivalent I Nm 11 11 TSB Revision Clutch master removal steps 1 Clevis pin 2 Clutch pipe 3 Clutch master cylinder 4 Sealer 5 Reservoir bracket 4 9 00003520 Clutch r...

Page 841: ...1 pin 2 Clutch pipe connection master cylinder Reservoir bracket Clutch release cylinder removal steps 6 Clutch pipe connection 7 Clutch release cylinder Clutch line removal steps 8 Clutch pipe 9 Clu...

Page 842: ...nd and then tighten it to the specified being careful that the clutch hose does not become twisted 2 After tightening the clutch pipe flare nut check to be sure there is no leakage of the clutch fluid...

Page 843: ...7 Reservoir cap 8 Reservoir tank 9 Reservoir band 10 Nipple 11 Clutch master cylinder body INSTALLATION SERVICE POINT PUSH ROD ASSEMBLY INSTALLATION NOTE Set the length of the push rod assembly to the...

Page 844: ...NOTES...

Page 845: ...OVERHAUL CONTENTS CLUTCH 4 SPECIFICATIONS 2 CLUTCH RELEASE CYLINDER Engine Turbo and Engine 3 Lubricants Service Specifications Engine Turbo and Engine 2 Torque Specifications 2...

Page 846: ...TORQUE SPECIFICATIONS Engine Turbo and Engine Clutch cover bolt Release cylinder mounting bolt Release cylinder union bolt Release cylinder bleeder plug Release fork fulcrum Clutch chamber bracket mou...

Page 847: ...ivalent Clutch release fork to release cylinder contact surface Clutch release bearing inside Clutch disc spline Clutch release bearing to release fork contact surface Engine Non turbo Items Clutch fl...

Page 848: ...ch release lever 3 Clutch flywheel 6 Clutch control equip stud 7 Boot 4 Clutch release bearing NOTE The modular clutch assembly flywheel assembly used in this vehicle consists of a single dry type clu...

Page 849: ...steps 1 Clutch oil tube A 2 Clutch tube 3 Clutch oil fluid chamber 4 Union bolt 5 Gasket 6 Union 7 Valve plate 8 Valve plate spring 9 Clutch release cylinder 10 Clutch cover 11 Clutch disc 12 Return c...

Page 850: ...rk Be careful not to cause damage to clip by pushing release fork in the direction other than that of arrow and removing it with force INSTALLATION SERVICE POINTS GREASE APPLICATION TO RELEASE Specifi...

Page 851: ...ne grease No 0101011 or equivalent 2 Using clutch disc guide to position clutch disc on flywheel GREASE APPLICATION TO CLUTCH RELEASE LEVER Specified grease MITSUBISHI genuine grease Part No 0101011 o...

Page 852: ...SC l Check the facing for loose rivets uneven contact deterio ration due to seizure adhesion of oil or grease and re place the clutch disc if defective l Measure the rivet sink and replace the clutch...

Page 853: ...o CLUTCH FLYWHEEL ASSEMBLY l Check clutch assembly for contamination dirt oil Replace clutch assembly if required l Check to see if the clutch disc hub are damaged Replace with new clutch assembly if...

Page 854: ...Turbo and Engine DISASSEMBLY AND REASSEMBLY 21200150057 Brake fluid or 8 0 TSB Revision Disassembly steps 1 Push rod 2 Boot 3 Piston cup 4 Piston 4 q3 1 2 5 Piston I Brake fluid or 5 Conical spring 6...

Page 855: ...e cylinder using compressed air Caution 1 Cover with shop towel to prevent the piston from popping out 2 Apply compressed air slowly to prevent brake fluid from splashing INSPECTION Check the inner of...

Page 856: ...NOTES...

Page 857: ...CONTENTS MANUAL TRANSAXLE MANUAL TRANSAXLE OVERHAUL MANUAL TRANSAXLE OVERHAUL...

Page 858: ...NOTES...

Page 859: ...TAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the or any component can lead to personal injury or death to service personnel from inadvertent...

Page 860: ...cable engine floor shift Gear ratio 3 166 1 833 1 240 0 896 0 731 Reverse 3 166 Final gear ratio 3 625 gear Engine Turbo floor shift 3 090 1 833 1 217 0 888 0 741 3 166 4 153 Specifications Model Appl...

Page 861: ...ANUAL TRANSAXLE ENGINE TURBO AND ENGINE SECTIONAL VIEW Bearing retainer Input shaft 1 st speed gear peed gear 3 peed synchronizer speed Intermediate Transaxle case D r a i n p l u g TSB Revision shaft...

Page 862: ...MANUAL E N G I N E speed Bearing retainer speed speed gear I speed gear Rear cover TSB Revision brake device Spacer Spacer Drain plug...

Page 863: ...hh Input shaft Drive bevel gear Driven bevel gear ousing speed synchronizer gear assembly speed gear Sub gear speed gear speed synchronizer I I gear differential coupling Front output shaft gear Cent...

Page 864: ...SPECIFICATIONS Standard value of front roll stopper bracket 43 3 1 69 LUBRICANTS Items lubricant Quantity Transaxle oil API classification SAE or 2 3 2 4 Transfer oil API classification SAE or 0 5 qt...

Page 865: ...rvice Tool TSB Revision Application l Tie rod end ball joint knuckle l Lateral lower arm ball join and knuckle disconnection l Compression lower arm ba joint and knuckle tion Supporting the engine ass...

Page 866: ...control cable Replace the control cable Poor contact or wear of synchronizer ring and Correct or replace gear cone Weakenecl synchronizer spring Replace synchronizer spring Use of grade of oil Replac...

Page 867: ...ter panel 4 Cupholder assembly 5 Floor console assembly 6 Shift lever cover 7 Console side cover 8 Nut 9 Clip passenger compartment side 10 Clip transaxle side 11 Shift cable and select cable con nect...

Page 868: ...ide in the direction of the arrow in the illustration to set it to gear NOTE If the shift lever does not move easily depress and hold the clutch pedal CABLE AND SELECT CABLE CONNECTION PASSENGER COMPA...

Page 869: ...SEMBLY 15 14 Disassembly steps 1 Nut 2 Spring washer 3 Plain washer 4 Shift lever Spring washer 8 Plain washer 9 Return spring 10 Bushing 11 Pipe 00000099 12 Bolt 1 3 L e v e r A 14 Bushing 15 Collar...

Page 870: ...r Installation Refer to GROUP 42 Under Cover l Battery installation 56 69 42 Engine Turbo 51 32 6 Removal steps 1 Air cleaner cover and air intake hose assembly 2 Air cleaner element 3 Air hose Turbo...

Page 871: ...nt and kunckle connection 21 Drive shaft connection 22 Clutch release cylinder connection 23 Bell housing cover 24 Stay 27 Transaxle mounting 28 Transaxle assembly 25 Center member assembly 26 mountin...

Page 872: ...Using the special tool loosen the tie rod end mountlng nut Only loosen the nut do not remove it from the ball joint 2 Support the special tool with a cold etc to prevent it from coming off DRIVE DISCO...

Page 873: ...ansaxle mount bracket with the arrow mark facing toward the shown direction Then install the stopper CENTER MEMBER If the dimension shown in the outside the standard value when the weight of the engin...

Page 874: ...eck Transfer Assembly Installation Refer to l Under Cover Installation Refer to GROUP 42 Under Cover l Installation 69 Nm 51 56 Nm 42 15 51 Removal steps Air cleaner cover and air intake hose assembly...

Page 875: ...nting 30 Transaxle assembly knuckle connection 20 Compression lower arm ball joint and knuckle connection 21 Drive shaft nut 22 Drive shaft 23 Drive shaft with inner shaft connection 24 Clutch release...

Page 876: ...ROD END BALL JOINT AND KNUCKLE LATERAL LOWER ARM BALL JOINT AND KNUCKLE COMPRESSION LOWER ARM BALL JOINT AND KNUCKLE DISCONNECTION Caution 1 Using the special tool loosen the tie rod end mounting nut...

Page 877: ...saxle case not to let foreign materials get into the transaxle case DRIVE SHAFT WITH INNER SHAFT DISCONNECTION Lightly tap the center bearing bracket plastic hammer or similar tool to remove the inner...

Page 878: ...place the front roll stopper bracket assembly Standard A 43 3 mm 1 69 in SHAFT WITH INNER SHAFT CONNECTION DRIVE SHAFT INSTALLATION Temporarily install the drive shaft so that the inner shaft or T J c...

Page 879: ...Exhaust Pipe Muffler Gear oil API classification SAE or 1 Transfer assembly 54 59 Nm REMOVAL SERVICE POINT A TRANSFER ASSEMBLY REMOVAL Caution 1 Do not damage the oil seal lip of the transfer 2 Use t...

Page 880: ...ion 22110010022 GENERAL The manual transaxle comes in one model namely Items Specifications Model Applicable engine floor shift Gear ratio 3 54 2 13 1 36 1 03 0 81 Reverse 3 42 Final gear ratio 3 94 S...

Page 881: ...MANUAL TRANSAXLE NON TURBO General SECTIONAL VIEW synchronizer I speed gear speed gear idler speed gear synchronizer 1 st synchronizer 1 st speed clear Differential TSB Revision I...

Page 882: ...kage puller Application l Tie rod end ball joint knuckle disconnection l Lateral lower arm ball join and knuckle disconnection l Compression lower arm ba joint and knuckle tion Supporting the engine a...

Page 883: ...y stay 3 Shift lever knob 4 Center panel 5 Cup holder assembly 6 Floor console assembly 7 Shift lever cover 8 Console side cover 9 Nut 10 Clips passenger compartment side 11 Clips transaxle side 14 Sh...

Page 884: ...the passenger compartment in the neutral position install the select cable to the passenger compartment side of the shift lever 2 Install the select cable so that the flange side of resin bushing is...

Page 885: ...Y Disassembly steps 1 Nut 2 Spring washer 3 Plain washer 4 Shift lever 5 Bushing 6 Nut 7 Spring washer 8 Plain washer 9 Return spring 10 Bushing 11 Pipe 00000098 12 Bolt 13 Lever A 14 Bushing 15 Colla...

Page 886: ...ver Check l Speedometer Operation Check l Under Cover Installation Refer to GROUP 42 Under Cover Installation 8 54 Nm Removal steps 1 Air cleaner cover and air intake hose assembly 2 Air cleaner eleme...

Page 887: ...connection 17 Center member assembly 18 Clutch release cylinder connection Front plate 20 Rear 21 Transaxle case lower cover 22 Flex plate connecting bolts Revision 23 Transaxle assembly mounting bol...

Page 888: ...special tool loosen the tie mounting nut Only loosen the nut do not remove it from the ball joint 2 Support the special tool with a cord etc to prevent it from coming off DRIVE SHAFT DISCONNECTION 1 a...

Page 889: ...a transaxle jack 2 Remove the connection bolts while turning the crankshaft 3 Chalk mating marks on the flex plate and clutch pressure plate for easier installation 4 Press the clutch pressure plate i...

Page 890: ...ard value when the weight of the engine is on the body replace the front roll stopper bracket assembly Standard value A 43 3 mm 1 69 in SHAFT CONNECTION Temporarily install the drive shaft so that the...

Page 891: ...ENERAL INFORMATION 2 INPUT SHAFT 38 INTERMEDIATE GEAR 48 OUTPUT SHAFT 55 SHIFT 3 SPECIAL TOOLS 13 SPECIFICATIONS Gear Ratio Table 5 Sealants and Adhesives 13 Service Specifications 6 Service Specifica...

Page 892: ...L Clutch Bearing retainer Input shaft speed synchro nizer 1 speed gear 22200010055 ed gear speed gear I speed gear Rear cover Reverse brake device speed intermediate gear Intermediate gear spacer Outp...

Page 893: ...VIEW Clutch housing Bearing retainer speed gear speed gear 1 speed gear I speed synchronizer assembly Input shaft 1 I Rear cover Reverse brake gear gear Spacer Output Differential drive gear Spacer D...

Page 894: ...speed gear I speed synchronizer assembly speed gear Bearing retainer I Sub gear Intermediate gear Revision speed gear speed synchronizer assembly speed gear speed gear speed synchronizer Center differ...

Page 895: ...ATIONS Transaxle model Gear ratio Speedometer gear ratio A Final gear ratio 3 625 Vehicle model model 4 153 Items 3 166 3 090 1 833 1 833 1 240 1 217 0 896 0 888 0 731 0 741 0 666 Reverse Transfer 3 1...

Page 896: ...e Center differential case end play mm in Center differential side gear end play mm in Front differential case end play mm in Front differential pinion backlash mm in Front output shaft preload mm in...

Page 897: ...m in Identification symbol 0 80 80 0 83 83 0 86 86 0 89 89 0 92 92 0 95 95 0 98 98 1 1 04 04 1 07 07 1 1 13 Part No 0454 Thickness mm in 1 16 1 19 1 22 1 25 1 28 1 31 1 34 1 37 1 40 1 43 Identificatio...

Page 898: ...For adjustment of intermediate gear preload Thickness mm in Identification syrnbol Part No Thickness mm in Identification symbol Part No 0 80 80 1 13 13 0 83 83 1 16 16 0 86 86 1 19 19 0 89 89 1 22 2...

Page 899: ...Thickness mm in 0 80 80 0 92 0 83 83 0 95 0 86 86 0 98 0 89 89 1 1 04 04 1 1 07 07 1 19 1 0454 1 22 1 13 1 25 Part No Part No 80675 92 95 98 01 Spacer For adjustment of front differential pinion backl...

Page 900: ...0 409 2 59 2 66 2 67 2 74 2 75 2 82 4 3 2 408 407 405 Spacer For adjustment of center differential case preload Thickness mm in Identification symbol 1 13 13 1 16 16 1 19 19 1 22 2 2 1 25 25 1 28 28 1...

Page 901: ...73 1 46 1 76 1 49 I 1 55 1 85 Spacer For adjustment of drive bevel gear mount Thickness mm in Identification symbol 0 13 0 16 0 19 19 0 22 22 0 25 25 0 28 IO 28 0 31 31 Part No Thickness mm in Identi...

Page 902: ...ck nut 33 24 33 24 Output gear mounting bolt Poppet plug Rear cover bolt Rear cover bolt Restrict ball Reverse brake cone machine screw Reverse idler gear shaft bolt Reverse shift lever assembly Selec...

Page 903: ...e clutch housing mating surfaces Adapter transaxle case mating surfaces Adapter rear cover mating surfaces Output gear bolt STUD Locking 70 or equivalent Differential drive gear bolts Bearing retainer...

Page 904: ...aft Installation and removal of inpu shaft and intermediate gear nut General service tool Installation of differential oil seal Adjustment of tooth contact and inspection of turning drive torque Insta...

Page 905: ...MANUAL TRANSAXLE OVERHAUL Special Tools Installer adapter 30 Installer adapter 38 Installer adapter 46 TSB Revision I...

Page 906: ...ring Oil seal installer Installation of transfer case oil seal Handle Special spanner Installation and removal of driver gear lock nut 7 Bearing remover of intermediate Claw of bearing outer race Gene...

Page 907: ...ve spring 5 Machine screw 6 Backup light switch 7 Gasket 8 Poppet plug 9 Poppet spring 10 Poppet ball 11 Bolt Lubricate all internal oil 12 Speedometer driven gear assembly 13 Air breather 14 Spring 1...

Page 908: ...Transaxle case 27 Oil guide 28 Bolt 29 Spring washer 30 Stopper bracket 31 Restrict ball assembly 32 Gasket 33 Oil seal 34 Bearing outer race 35 Spacer 2210010 36 Bearing outer race 37 Spacer 38 Beari...

Page 909: ...assembly steps Bearing retainer 51 Intermediate gear assembly 52 Input shaft assembly 53 Output shaft assembly 54 Differential gear assembly 55 Bearing outer race 56 Oil guide 57 Bearing outer race 58...

Page 910: ...ear cover 3 Reverse brake cone 4 Wave spring 5 Machine switch Poppet plug 9 10 Poppet spring Poppet ball 11 Bolt Revision 12 Speedometer driven gear assembly 13 Air breather 14 Spring pin 15 Lock nut...

Page 911: ...Bolt 26 Transaxle case 27 Oil guide 28 Bolt 29 Spring washer 30 Stopper bracket 31 Restrict ball assembly 32 Gasket 33 Oil seal 34 Bearing outer race 35 Spacer 36 Bearing outer race 14 37 Spacer 38 F...

Page 912: ...Bearing retainer 54 Intermediate gear assembly 55 Input shaft assembly 56 Output shaft assembly 57 Differential gear assembly 58 Bearing outer race 59 Bearing outer race 60 Oil guide 61 Bearing outer...

Page 913: ...1 Rear cover 2 Reverse bracket cone 3 Wave spring 4 Machine screw assembly Poppet plug 10 Poppet spring 11 Poppet ball 12 Speedometer gear assembly 13 Air breather 14 Spring 15 Lock nut 16 Lock nut 1...

Page 914: ...teps Snap ring 24 Viscous coupling 25 Steel ball 26 Center shaft 27 Transaxle case adapter 28 Outer case 29 Spacer 30 Outer race 31 Spacer 32 Outer race 33 Spacer 34 Center differential 35 Outer race...

Page 915: ...guide 41 Oil guide 42 Outer race 43 Spacer 44 Spacer 45 Stopper bracket 46 Oil seal 47 Reverse shift lever assembly 48 Reverse shift lever shoe 49 Reverse idler gear 50 Reverse idler gear 51 Front ou...

Page 916: ...ing pin 55 Spring pin 56 Shift rail assembly 57 Bolt 58 Bearing retainer 59 Intermediate gear assembly 60 Input shaft assembly 61 Outer race 62 Outer race Oil 64 race 65 Oil seal O i l s e a l 68 Magn...

Page 917: ...stall the special tool onto the input shaft 4 Screw a bolt mm in into the bolt clutch housing and attach a spinner handle to special 5 Remove the lock nut while using the bolt as a spinner handle stop...

Page 918: ...up the input shaft assembly and remove intermediate gear assembly BEARING OUTER RACE REMOVAL REASSEMBLY SERVICE SEAL FOR DRIVE SHAFT SE A L I N P U T INSTALLATION G E A R SHAFT ASSEMBLY Lifting up the...

Page 919: ...eve at speed 2 Set the speed shift sleeve at 3 Install the shift fdrks respective sleeves 4 the shift rail into the shift fork hole while turning so as to prevent the shift lug from interfering with t...

Page 920: ...ter to carry out the operations in 1 and 2 4 Measure the thickness of the crushed and select and a of that gives standard end play Standard value Input shaft end play 0 0 Intermediate gear preload mm...

Page 921: ...OCK NUTS FOR INPUT SHAFT INTERMEDIATE GEAR INSTALLATION 1 Install the special tool onto the input shaft 2 Screw a bolt IO mm in into the hole around clutch housing and attach a handle to the 3 Shift t...

Page 922: ...ALANT APPLICATION TO AIR sealant SUPER WEATHERSTRIP or equivalent APPLICATION TO REAR COVER Specified sealant Mitsubishi genuine sealant or equivalent APPLICATION TO Specified sealant STUD Locking or...

Page 923: ...ted locations on the transaxle and install each outer 2 Place two of solder measuring about mm in in length and 3 mm 2 in in diameter on the beanng outer race as shown in 3 install the transaxle case...

Page 924: ...micrometer and select and install a spacer of thickness that gives standard end play and preload S t a n d a r d v a l u e Intermediate gear preload mm in Center differential case mm in Input shaft e...

Page 925: ...MANUAL TRANSAXLE OVERHAUL Transaxle 0 0 0 0 WAVE SPRING INSTALLATION Install the wave spring so that to the position in the TSB Revision...

Page 926: ...Synchronizer spring 3 Synchronizer sleeve 72 4 Synchronizer key 5 Synchronizer hub REASSEMBLY SERVICE POINTS SYNCHRONIZER HUB SYNCHRONIZER SLEEVE INSTALLATION SYNCHRONIZER SPRING INSTALLATION When in...

Page 927: ...side front and rear ends 3 Check for wear of the hub front end surface in contact with the speed gear Caution When replacing replace the synchronizer hub and as a set SYNCHRONIZER KEY AND SPRING 1 Che...

Page 928: ...Dd 7 Snap ring 8 Cone spring 9 Sub gear 10 speed gear 11 Needle bearing 8 9 2 Bearing sleeve 3 Synchronizer ring 4 Synchronizer spring 5 speed synchronizer sleeve 6 Synchronizer key 7 speed synchroni...

Page 929: ...sleeve 3 Snap ring 4 Taper roller bearing 5 Snap ring 6 Cone spring 7 Sub gear 8 speed gear 9 Needle bearing 10 Bearing sleeve 11 Synchronizer ring 12 Synchronizer spring 13 synchronizer 14 Synchroni...

Page 930: ...p ring 4 Taper roller bearing 5 speed gear 6 Needle bearing 7 Bearing sleeve 8 Synchronizer ring 9 Synchronizer spring 10 speed synchronizer sleeve 11 Synchronizer speed synchronizer Synchronizer ring...

Page 931: ...MANUAL TRANSAXLE OVERHAUL Input D I S A S S E M B L Y BALL BEARING TAPER ROLLER BEARING REMOVAL I speed gear SLEEVE FOR SPEED GEAR BALL BEARING TAPER ROLLER BEARING SPEED TSB Revision...

Page 932: ...ee gear side Identification mark Spring stepped SPEED SYNCHRONIZER HUB SPEED INSTALLATION SYNCHRONIZER SPRING INSTALLATION When installing the be sure position each spring with respect to the keys ill...

Page 933: ...MANUAL TRANSAXLE OVERHAUL Input Snap ring Sub speed gear side 210019 GEAR CONE INSTALLATION SPACER INSTALLATION REAR BALL TSB Revision...

Page 934: ...ring groove Standard value Input shaft rear bearing mm in Caution l Do not reuse the snap l The snap ring by pliers resulting in improper the SLEEVE FOR SPEED GEAR INSTALLATION Caution When press fit...

Page 935: ...B A LL BEARING INSTALLATION SNAP RING INSTALLATION Snap rings are available in three Select the thickest one that fits in the snap ring Standard value input shaft front end play mm in Caution Do not d...

Page 936: ...needle bearing cage for SYNCHRONIZER RING 1 Check the clutch gear teeth for and breakage 2 Check the internal surface for damage and broken threads 3 Force the synchronizer ring toward the clutch gea...

Page 937: ...r Da SYNCHRONIZER KEY AND 1 for wear of key 2 the spring for deform i age SPEED GEARS 1 Check the synchronizer cone for rough surface damage and wear 2 Check the gear bore and front and rear ends for...

Page 938: ...during reassembly Disassembly steps 1 Snap ring 2 Taper roller bearing 9 Synchronizer key 3 Bearing sleeve 10 speed synchronizer hub 4 speed gear 11 Synchronizer ring 12 5 speed 13 N e e d l e g e a r...

Page 939: ...nap ring 2 Taper roller bearing Bearing sleeve 4 speed gear 5 Needle bearing 6 Synchronizer ring 7 Synchronizer spring 8 speed synchronizer 9 Synchronizer key TSB Revision speed 11 12 Synchronizer con...

Page 940: ...eplace the inner and outer races of the taper roller bearing as a set SPEED SYNCHRONIZER HUB SPEED GEAR REMOVAL TAPER ROLLER BEARING REMOVAL Caution l Do not reuse the bearing removed from the shaft R...

Page 941: ...SYNCHRONIZER KEY SLEEVE 1 the speed as 2 The synchronizer sleeve has tooth missing at six portions Assemble the hub to the sleeve in such a way that the center tooth between two missing teeth will tou...

Page 942: ...Gear TAPER ROLLER BEARING Caution When installing the bearing push the race only RING INSTALLATION Select and install the snap that gives intermediate gear bearing end play Standard value Intermediat...

Page 943: ...gear and check it rotates Smoothly without abnormal noise or play 2 Check the needle bearing for SYNCHRONIZER RING 1 Check the clutch gear teeth for damage breakage 2 Check the internal surface for d...

Page 944: ...hub and check that they slide smoothly 2 Check that the sleeve is free from damage its front and rear ends 3 Check for wear of the end contact each speed gear Caution Replace the synchronizer hub and...

Page 945: ...g 2 shaft Press 2210025 I I DISASSEMBLY SERVICE POINT TAPER ROLLER BEARINGS REMOVAL Caution l Do not reuse the bearings removed from the shaft l Replace the inner and outer races of the taper roller b...

Page 946: ...roller bearings using the special tool NOTE 1 Do not reuse the bearing removed the 2 Replace the inner and outer the taper roller bearing as a set REASSEMBLY SERVICE ROLLER BEARINGS Install the taper...

Page 947: ...REASSEMBLY 2160119 Disassembly steps 1 Bolt 2 Differential drive gear 3 Ball bearing 4 5 Lock pin 6 Pinion shaft 7 8 Washer 9 Side gear 10 Spacer 11 Differential Do not reuse the bearing removed from...

Page 948: ...er bearing as a set LOCK PIN REMOVAL Drive out the lock pin from the hole A using a punch REASSEMBLY SERVICE POINTS LOCK PIN INSTALLATION Align the pinion shaft lock pin hole the case lock pin hole an...

Page 949: ...nt 2 Tighten to the specified torque while following the order given in the illustration ADJUSTMENT OF PINION BACKLASH Measure the backlash between the side gears and pinions Adjust for same backlash...

Page 950: ...R DIFFERENTIAL DISASSEMBLY AND REASSEMBLY 22250015 Disassembly steps 1 Taper roller bearing 2 Bolt 3 Taper roller bearing 4 Output gear 5 Spacer 6 Side gear 7 Pinion shaft 8 Washer 9 Pinion Side gear...

Page 951: ...side gear pinion gear and pinion shaft to the center differential 2 Holding down the pinion shaft select the of maxi mum thickness that allows the pinion gear to and install it to the shaft 3 Install...

Page 952: ...Revision 1 Apply the specified sealant the threads Specified sealant Stud Locking or equivalent Tighten to the specified torque following order given in the illustration TAPER ROLLER BEARINGS NOTE App...

Page 953: ...EASSEMBLY 1 Disassembly steps 1 speed shift fork 2 speed shift fork 3 speed shift rail 4 speed shift rail Reverse shift lug 0 speed shift rail 2201088 5 Interlock plunger 6 speed shift rail 7 Reverse...

Page 954: ...ISASSEMBLY AND REASSEMBLY Lubricate all internal parts with engine oil during reassembly Disassembly steps 1 e clip driven gear Sleeve S E R V I C E SPEEDOMETER DRIVEN GEAR Apply gear oil sparingly to...

Page 955: ...00019 Disassembly steps 1 Bolt 2 Select lever assembly 3 Select lever shoe 4 Interlock plate bolt 5 Gasket 6 Lock pin 7 Spring pin 8 Neutral return spring 9 Stopper body 10 Control finger 1 Interlock...

Page 956: ...ition that the lock pin will not contact the clutch housing SPRING PIN REMOVAL Caution When spring pin pull control shaft the direction illustrated so that the pin will not contact the clutch housing...

Page 957: ...ina bar socket wrench Extension bar socket wrench SEAL INSTALLATION PIN LOCK PIN Caution l Do not reuse the spring pin and lock pin l Install the spring pin In such a way its will at right angle to th...

Page 958: ...BLY I 39 Nm 28 I Lubricate all internal with engine oil during reassembly Disassembly steps 1 Cover 2 Cover gasket 3 Extension housing assembly 4 Transfer case sub assembly 5 Spacer 6 O ring 7 Transfe...

Page 959: ...tall the spacer that has 3 Align the transfer drive bevel gear mating 4 Align the transfer case adapter and drive bevel gear mating marks 5 Assemble the transfer case and transfer case adapter and tig...

Page 960: ...E Refer to the TOOTH CONTACT PROCE DURES on page for the standard tooth contact 9 Check to see if the drive bevel gear and driven bevel backlash is as specified Standard value Bevel gear set mm O RING...

Page 961: ...t side tooth face Side on which force acts when reversing 2 Tooth contact pattern produced when drive gear height is too large Cause The driven bevel is too close to the drive bevei gear Remedy Use th...

Page 962: ...gear mount and then adjust l When the driven bevel gear height is too small if the thinnest driven bevel gear mount adjusting spacer 0 13 mm in is used Replace the drive bevel gear mount adjusting spa...

Page 963: ...D REASSEMBLY Disassembly steps 1 Air bleeder 2 Dust seal guard 3 Oii seal 4 Extention housing REASSEMBLY SERVICE POINTS OIL SEAL INSTALLATION AIR BLEEDER Install the air bleeder Specified sealant SUPE...

Page 964: ...LE OVERHAUL TRANSFER CASE DISASSEMBLY AND REASSEMBLY Nm 29 Disassembly steps 1 Transfer cover 2 O ring 3 Spacer 4 Outer race 5 Drive bevel gear assembly 6 Outer race 7 Spacer 6 Oil seal 9 Transfer cas...

Page 965: ...rotating drive torque is within the standard value Standard value 3 If the rotating drive torque is outside of the standard value adjust using adjusting spacers NOTE For adjustment use two spacers of...

Page 966: ...Y AND REASSEMBLY 8 Disassembly steps 1 Lock nut 2 Driven bevel gear assembly 3 Taper roller bearing 4 Spacer 22210133 5 Collar 6 Outer race 7 Outer race 6 Transfer case assembly DISASSEMBLY SERVICE PO...

Page 967: ...g the special tool check that the bevel gear rotating drive torque is within standard value Standard value Nm 3 If the rotating drive torque is outside of the standard value adjust using adjusting spa...

Page 968: ...HAUL Drive DRIVE BEVEL GEAR DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Taper roller bearing 2 Taper roller bearing 3 Drive bevel gear 4 Drive bevel gear shaft 22210142 DISASSEMBLY SERVICE POINTS R...

Page 969: ...OVERHAUL Drive Bevel Gear DRIVE REASSEMBLY SERVICE TRANSFER DRIVE BEVEL GEAR INSTALLATION Install the drive bevel gear and drive bevel gear shaft with the mating marks aligned TAPER ROLLER BEARING IN...

Page 970: ...BLY AND REASSEMBLY Lubricate all internal parts with engine oil during reassembly Disassembly steps 1 Driven bevel gear 2 Taper roller bearing 14 3 DISASSEMBLY ROLLER BEARING REASSEMBLY SERVICE POINT...

Page 971: ...R CASE OVERHAUL 22 GENERAL INFORMATION 2 GENERAL SPECIFICATIONS 4 INPUT SHAFT DISASSEMBLY 13 INPUT SHAFT REASSEMBLY 28 OUTPUT GEAR DISASSEMBLY 16 SEALANTS 4 SERVICE SPECIFICATIONS 4 SHIFTER RAILS OVER...

Page 972: ...2210010018 The transaxle internal components can only be serviced by separating the gear case from the case The transaxle output shaft is as a unit no disassembly and reassembly is possible Damage to...

Page 973: ...MANUAL TRANSAXLE General Information SECTIONAL VIEW speed gear speed gear synchronizer I Reverse idler gear l 1 synchronizer Differential TSB Revision...

Page 974: ...QUE SPECIFICATIONS 22210040017 Items N m Back up light switch 24 18 Differential ring bolt gear 81 End cover bolt 29 21 Output bearing race retaining strap 9 6 Reverse idler bolt gear 26 19 Reverse fo...

Page 975: ...dapter Installer adapter Installer bar Bearing remover installer Bearing remover installer Bearing remover installer Puller press Puller blocks adapter Dial indicator set Removal of input and sleeve w...

Page 976: ...bearing torque tool ing torque Removal of differential bearing Adapter Adjustment of differential side gear end play 6786 Removal of shifter bushing Bushing remover shifter selector shaft Removal of...

Page 977: ...Installation and of Installer 100 tool TSB Revision...

Page 978: ...ve shift levers bolts 3 Place two screwdrivers in the slots provided in the case halves near the dowels the case halves 4 Remove bell housing case half from 5 Remove output shaft roller bearing from o...

Page 979: ...Selector shaft spacer Plastic 7 Remove reverse idler shaft Remove reverse idler gear 8 Remove two screws retaining fork bracket Remove reverse fork bracket and reverse cam assembly 9 Using snap ring...

Page 980: ...elector up out of the 11 Remove transaxle end cover two snap rings retaining the output shaft and the input shaft to the bearing bench fixture and shims provided transaxle over Install trans axle onto...

Page 981: ...d while pressing if the bearing fixture is not used transaxle gear case and bench fixture press Press output and assemblies out transaxle from press remove transaxle case from the shaft assemblies and...

Page 982: ...t the output input and output shaft assemblies from f i x t u r e Caution The output shaft assembly is Do not try to repair any component on the shaft If the synchronizer gear fails it is to replace t...

Page 983: ...m m m i n 1 37 1 93 mm 1 41 1 97 mm 1 37 1 93 mm If a stop ring gap does not fall within the it must be insepcted for wear and If or synchronizer stop ring is worn the plete output shaft assembly mus...

Page 984: ...put shaft Input shaft gear Caged needle bearing 4 Remove 4 5 gears split thrust washer 5 Remove split thrust washer 6 Remove split thrust washer separation pin 7 Remove gear 8 Remove gear caged needle...

Page 985: ...cking input shaft in shop press Using to remove synchronizer and gear 11 Remove gear caged needle bearing Check the caged needle bearing for a broken retention spring the input shaft for worn or damag...

Page 986: ...feeder shifter mechanism gear case and with solvent Dry all parts except the bearings with compressed air Allow the bearings to either air dry or wipe them dry with clean shop towels Inspect the gear...

Page 987: ...ometer Pinion shaft Differential 1 Remove differential bearing 2 Remove ring gear bolts and ring gear 3 Pry the drive gear off using a flat blade NOTE drive gear differential case in order 4 Remove pi...

Page 988: ...s thrust washers rotating side gears to case REASSEMBLY 1 Assemble the differential side gears gears and pinion gears with the pinion gears 2 Install pinion shaft 3 Stake pinion shaft solid pin with a...

Page 989: ...r side gear should be checked using the same procedure Side gear end play must be within 0 25 mm in to 0 33 mm in Five select thrust washers are available 0 69 mm in 0 61 mm in 0 94 mm in 1 07 mm in a...

Page 990: ...nner hub Carefully open up shop towel and remove springs balls keys hub and sleeve CLEAN Do not attempt to clean the blocking rings in solvent The friction material will become contaminated Place sync...

Page 991: ...key balls into each key 5 Slide sleeve over the hub and depress balls as you careful ly slip the sleeve into position 6 Line up stop ring tang over the keys in the hub Install stop rings Center the k...

Page 992: ...place parts as necessary GEAR CASE The sealant used to seal the transaxle case halves is Loctite 51817 or equivalent The sealant used for the bearing end plate cover is Loctite or equivalent The compo...

Page 993: ...Input shaft b e a r i n g REMOVAL 1 Note the position of the output shaft The bearing is not identical to end Remove caged roller bearing from output bearing race 2 Remove screws at output bearing st...

Page 994: ...and sleeve The sleeve is the slide point for the clutch release bearing and lever __ REMOVAL tool over input bearing on the gear case side of the transaxle clutch housing 2 Tap the input bearing out h...

Page 995: ...tion the bearing cup into case 2 Install the bearing cup onto 3 Using driver install differential bearing cup into the transaxle REMOVAL 1 Thread tool into shifter rail bushing 2 Install onto tool 3 R...

Page 996: ...ize deep well socket REMOVAL 1 With the transaxle disassembled remove the selector shaft by pushing on the shaft from the outside and pulling shaft out from the inside Reverse removal procedure to ins...

Page 997: ...emove the crossover shaft bush ing INSTALLATION 1 Position the replacement crossover shaft bushing over the crossover shaft bushing bore 2 Using an appropriate size deep socket install the crossover s...

Page 998: ...lace input shaft into shop press 2 Install gear caged needle on input shaft 3 Install gear and synchronizer onto input shaft Install 3 shaft and press on synchronizer hub gear The nizer hub has the le...

Page 999: ...ll split thrust washer onto input shaft 9 Install split thrust washer retaining ring gear caged needle bearing 11 Using 2 install speed gear and synchronizer The gear synchronizer hub has the letter s...

Page 1000: ...MANUAL TRANSAXLE Shaft Reassembly gear synchronizer snap ririg TSB Revision...

Page 1001: ...Loctite 18718 or equivalent 1 Verify bench fixture shims are removed from bench Install output and input gear pallet 2 Install shift rails and forks into bench fixture 3 Install shift blocker assembl...

Page 1002: ...ply 18718 or equivalent to end cover outer edge and around bolt holes Install end cover onto gear case Tighten end cover bolts to torque 9 Remove gear case from bench fixture gear case in a holding fi...

Page 1003: ...MANUAL TRANSAXLE Case Reverse idler Screws 2 A TSB Revision reverse fork bracket and reverse cam lockout as sembly Tighten screws to 11 Nm 9 6 torque differential into gear case...

Page 1004: ...signs of pitting or heat distress If distress seen on either the cup or bearing rollers both cone must be replaced Bearing preload and drag torque specifications maintained to avoid premature origina...

Page 1005: ...n the downward direction Roll differential assembly back and forth many times This will settle the bearings Zero dial indicator To obtain end play readings apply a medium load in the upward direction...

Page 1006: ......

Page 1007: ...AUTOMATIC TRANSAXLE CONTENTS AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE OVERHAUL AUTOMATIC TRANSAXLE OVERHAUL AUTOMATIC TRANSAXLE OVERHAUL...

Page 1008: ...23 2 NOTES...

Page 1009: ...RANSAXLE ASSEMBLY TRANSAXLE CONTROL 187 Selector Lever Assembly 189 Key Interlock Mechanism Check 186 CONTINUED ON NEXT PAGE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL EQUIPPED VEHICLES WARNING 1 Im...

Page 1010: ...Servo Adjustment 84 Line Pressure Adjustment 67 Park Neutral Position Switch and Control Cable Adjustment 57 Park Neutral Position Switch Continuity Check 56 Selector Lever Operation Check 91 Lock Me...

Page 1011: ...erse Final ratio gear Speedometer gear ratio driven drive AWD Model Applicable engine Torque converter Type Engine stall speed Gear ratio Reverse Reduction ratio Primary Front differential Transfer Sp...

Page 1012: ...r Gear Gear Engine Parking Front Rear lever drive position switch ratio start mechanism clutch clutch clutch way down clutch Neutral OK Re 2 176 l verse Neutral OK ON 2 551 ON 1 488 I I I O N 1 000 ON...

Page 1013: ...ND ENGINE General tnformation SECTIONAL VIEW Torque converter Oil pump I Front clutch I Low reverse Rear clutch Planetary gear I brake Torque clutch TSB Revision I End Transfer driven gear drive gear...

Page 1014: ...AUTOMATIC TRANSAXLE ENGINE TURBO AND ENGINE General Torque converter Oil pump I brake Planetary gear Transfer Front clutch Low reverst I Rear clutch brak idler gear I TSB Revision...

Page 1015: ...O AND ENGINE General Information SECTIONAL VIEW Torque converter Rear output shaft Transfer Oil pump gear Rear reverse Transfer drive brake clutch brake gear I I TSB Revision differential output shaft...

Page 1016: ...oid valves A and coils at Approx 22 Line pressure Line pressure psi 126 129 Oil pressure change for each turn of adjusting screw psi 38 5 5 Reducing pressure Reducing pressure psi Oil pressure change...

Page 1017: ...AND ENGINE Special SPECIAL TOOLS Scan tool MUT II I ROM pack for scan tool pressure gauge 3 000 400 psi 5 servo wrench adapter To measure oil pressure Oil pressure servo adjustment 6 servo wrench ada...

Page 1018: ...uckle disconnection Lateral lower arm ball joir and l Compression lower arm ba joint and tion To prevent foreign substances from entering transaxle case l Use shop towel To support the engine assembly...

Page 1019: ...Record the diagnostic trouble code and fail safe code Refer to trouble code trouble Basic Abnormality exists no diagnostic trouble code Abnormality exists diagnostic trouble code present No abnormalit...

Page 1020: ...switch 2 OFF Data list No 35 2 OD OFF Data list No 37 3 4 Data list No 28 ON OFF should be possible Overdrive switch Selector position 4 2 Park Neutral switch Brake pedal 1 Depressed Released light po...

Page 1021: ...not move forward or reverse Engine Idling switch Data list No 26 A C load signal A C load signal vehicle stopped system Selector lever 2 OFF position Accelerator pedal Data list No 45 Pressure Code N...

Page 1022: ...sensor sensor system mph with 2 10 km h selector lever in 3 50 range 4 40 Selector Engine Data list No 31 lever Pulse generator Code Nos tion 1 Idling vehicle 3 rpm A PG A Pulse generator A stopped sy...

Page 1023: ...hocks and flare shifts position data list Nos 27 3 should match when shifting Overdrive and 32 the specified ON 1 Accelerate to shaft Displaced All points gear at speed vehicle shifting points TPS out...

Page 1024: ...utput of speed and 1 5 opening there should be angle 30 no abnormal Code Nos 1 2 Slowly shocks gear incorrect ratio erate to a standstill For 5 and 3 downshifting gear at TPS output of immediately aft...

Page 1025: ...link connector at the lower right of the instrument under cover and then read the diagnostic trouble codes Caution Always turn the ignition switch off before connecting or disconnecting the scan tool...

Page 1026: ...TO ERASE THE DIAGNOSTIC TROUBLE CODES When using the scan tool 1 Turn the ignition switch to OFF and then back to ON again 2 Erase the diagnostic trouble codes 3 Check to be sure that no diagnostic t...

Page 1027: ...r system servo switch system servo switch system Ignition signal system Open circuit Short circuit Open circuit Short circuit Open circuit 22 22 22 28 31 32 36 Stop light switch system Pulse generator...

Page 1028: ...Code Diagnostic item 63 Torque reduction execution signal lines Short circuit...

Page 1029: ...ng connectors l OK NG Repair Check trouble symptom NG Replace the TCM Code No 15 16 Oil temperature sensor system Comment If the oil temperature sensor output is 4 4 or higher oil temperature does not...

Page 1030: ...and I sure at the harness side OK servo switch and TCM Check trouble Replace the TCM NG Check the harness wire between the servo switch and TCM con nectors if TSB Revision Code No 23 Ignition signal P...

Page 1031: ...e while driving at 3 km h 2 more l of connector there is a short circuit in the stop light switch and diagnostic trouble code No 28 is output l of SCAN TOOL DTC Yes Is TCL diagnostic trouble code No 2...

Page 1032: ...output and the vehicle is locked in gear D or l Noise generated gear 2 L as a fail safe measure Refer to Automatic P u l s e g e n e r a t o r Refer to Replace OK Measure output from pulse generator...

Page 1033: ...a fail safe l Noise generated measure Refer to Automatic Transaxle Overhaul Pulse generator check Refer to NG Replace OK Measure output waveform from pulse generator connector using an oscilloscope l...

Page 1034: ...and diagnostic trouble code No 36 is output Malfunction of ignition switch When the position switch signal is not input to a single place for a continuous l Malfunction of TCM period of 30 seconds or...

Page 1035: ...rs NG Repair l NG Repair of TCM and SCSV A OK Replace shift control solenoid valve A SCSV A Check trouble symptom NG Replace the TCM Code No 84 Shift control solenoid valve SCSV B Probable cause syste...

Page 1036: ...stem Comment TSB Revision If the resistance value of the torque converter clutch solenoid is high there is an open circuit in the torque converter clutch solenoid and diagnostic trouble code No 47 is...

Page 1037: ...31 Code Nos 31 Pulse generator A system check Refer to No SCAN TOOL DTC Yes Code Nos 32 82 Pulse generator Is diagnostic trouble code No 32 system check Refer to output No NG Pulse generator A and w...

Page 1038: ...Nos 51 52 53 and 54 are output 4 times there is an incorrect gear ratio fail safe code No 86 is output and the vehicle is locked in gear D or gear 2 L as a fail safe measure SCAN TOOL DTC Yes Code No...

Page 1039: ...tion request signal is being output there is a short circuit in the l Malfunction of connector torque reduction request signal line or an open circuit in the torque reduction execution signal line and...

Page 1040: ...time Shocks and flare shift late shift All points Some points not shift while No fail safe codes 13 42 Poor acceleration 14 Vibration switch system 16 throttle position switch system 17 load signal sy...

Page 1041: ...ness wire between the TCM and ground Repair if nec INSPECTION PROCEDURE 2 l Starting impossible will not crank Probable cause Comment l Malfunction of engine system Starting is not possible when the s...

Page 1042: ...e rear clutch pressure when shifting from to range S t a n d a r d psi OK Rear clutch system check l Remove the oil pan and valve body l Pistons should operate and pres sure should also be maintained...

Page 1043: ...low reverse brake pressure in range at 2 500 Standard value 233 319 psi Front l Remove the oil pan and body l Pistons operate and pres sure should also be maintained when air is blown through the fron...

Page 1044: ...cause is probably a defective engine system or damper l Malfunction of torque solenoid clutch control solenoid valve Malfunction of body l Malfunction of torque converter Refer to Automatic Transaxle...

Page 1045: ...from to Rear clutch system check l Remove the transaxle oil pan and valve body When starting off Shocks sometimes occur Pistons should and should also be maintained when air is blown through the rear...

Page 1046: ...range at 2 500 Standard value 1 640 2 240 OK Hydraulic pressure test Refer to l Measure the low reverse brake pressure in range at 2 500 Standard value 1 640 NG l Remove the transaxle oil pan and l Pi...

Page 1047: ...tion of the selector lever is shifted from to range and also from to range In such cases Malfunction the cause is probably abnormal reducing pressure or a defective oil pump Refer to Automatic Transax...

Page 1048: ...d position After completion Closed position switch check l Check the closed throttle position switch system according to inspec tion procedures 17 Refer to Valve body disassembly cleaning and reassemb...

Page 1049: ...d brakes l Malfunction of valve body Refer to Automatic Transaxle Overhaul OK SCAN TOOL Data list l 32 Pulse generator PG B OK Increases in proportion to vehicle speed NG Code Nos 32 82 Pulse generato...

Page 1050: ...cause Comment l Malfunction of overdrive switch Shifting does not occur while driving and no fail safe codes are output In such cases the l cause is probably a defective overdrive switch or Park Neut...

Page 1051: ...r or replace the engine system After completion Clutch and brake check l Check each end play and if they exceed the standard l Check for burning and wear in each facing INSPECTION PROCEDURE 15 l Vibra...

Page 1052: ...trouble svmotom Check the l OK NG Repair ignition switch and overdrive switch NG NG Repair overdrive switch and TCM connectors OK TSB Revision the TCM INSPECTION PROCEDURE 17 l Closed throttle positio...

Page 1053: ...eplace GROUP 55 On vehicle Service OK Measure at TCM connector l connector and mea sure at the harness side l Ignition switch ON l switch ON l Voltage between terminals 8 and ground OK Battery positiv...

Page 1054: ...harness side 1 Voltage between 1 and ground Ignition switch ON OK Battery positive voltage 2 Voltage between 3 and ground Ignition switch ON OK 2 NG 3 Continuity between 2 and ground O K NG Check the...

Page 1055: ...al Closed throttle position switch Selector lever position 2 range Selector lever position range Overdrive OFF Selector lever position range Overdrive ON Selector lever position range Selector lever p...

Page 1056: ...onstant speed of 40 seconds 2 or more Released Driving at 5 km h 3 1 mph Driving at constant speed of 50 mph 20 seconds 3 or more Driving at constant speed of 50 mph 20 seconds 4 or more Depressed OFF...

Page 1057: ...solenoid Amount of torque converter clutch slippage Torque converter clutch solenoid duty Selector lever position range Overdrive OFF Selector lever position range Overdrive OFF Driving at constant s...

Page 1058: ...fe codes lock the transaxle in or gear Fail safe will be if the ignition switch is turned to OFF The diagnostic trouble codes will remain Code No Item Fail safe Related sis code No 81 82 83 Open circu...

Page 1059: ...Selector lever range o v ECM Engine Idling Selector lever position range 7 servo switch Selector lever position range Battery positive Transaxle condition gear voltage Battery positive 8 compressor A...

Page 1060: ...ition Out of range 0 Park Neutral position Selector lever position range Battery positive switch R voltage Selector lever position Out of range 0 Park Neutral position Selector lever position range Ba...

Page 1061: ...lector lever position range Transaxle condition gear Measure between terminals 41 and 42 Pulse generator 42 PG B Engine 3 000 Selector lever position range Transaxle condition gear 43 Pulse generator...

Page 1062: ...tion range Overdrive OFF Vehicle speed Selector lever position range sensor Overdrive OFF at constant speed of 50 mph 20 seconds or Waveform more Driving at constant speed of 50 mph 20 seconds or Wave...

Page 1063: ...UID LEVEL CHECK Refer to GROUP 00 Maintenance Service TRANSAXLE FLUID REPLACEMENT 23100100176 Refer to GROUP 00 Maintenance Service TRANSFER OIL LEVEL CHECK 23100110025 Refer to GROUP 00 Maintenance S...

Page 1064: ...AUTOMATIC TRANSAXLE ENGINE TURBO AND On vehicle Service Manual Terminal No I I I I 2 TSB Revision Terminal I No I I I 2 I I I 10 11 12...

Page 1065: ...osition switch body Then the hole in the end of the manual control lever and the hole in the flange of the park neutral switch body must be aligned 5 Tighten the park neutral position switch body moun...

Page 1066: ...AUTOMATIC TRANSAXLE ENGINE AND On vehicle Service switch Name Data link connector servo switch OD OFF switch Oil temperature sensor Oil temperature sensor Park neutral position switch Revision I...

Page 1067: ...AUTOMATIC TRANSAXLE I ENGINE TURBO AND On vehicle Service I Pulse gene rator Pulse gene rator A Throttle position sensor with closed throttle position switch Vehicle sensor CC Solenoid Revision...

Page 1068: ...TRANSAXLE ENGINE TURBO AND On vehicle Service TSB Revision...

Page 1069: ...ECK 1 Disconnect the pulse generator connector 2 Measure the resistance between the generator side connector terminals 3 and 4 Standard at 3 If the resistance is outside the standard replace the pulse...

Page 1070: ...h OIL TEMPERATURE SENSOR CHECK 1 Disconnect the oil temperature sensor connector 2 Measure the resistance between the oil temperature sen sor side connector terminals 1 and 2 and check that the values...

Page 1071: ...nd the body ground Standard value Approx 3 at 3 If the resistance is outside the standard value replace the solenoid valve assembly CONTROL SOLENOID VALVE A SCSV A CHECK 23100520033 1 Disconnect the S...

Page 1072: ...than is necessary to obtain maximum engine rpm reading and never longer 5 seconds at a time If more than one stall test is required operate at approximately 1 000 in neutral for 2 minutes to cool tra...

Page 1073: ...ge and the adapter to oil pres sure outlet port When the reverse position pressure is be 3 000 435 psi type of gauge should used Measure each hydraulic under the conditions in the standard hydraulic a...

Page 1074: ...dling Neutral 2 Idling gear l using scan tool 3 Approx gear 2 500 64 92 4 Approx gear 900 2 500 I 64 92 I 5 2 Approx gear 2 500 I I 64 92 6 Approx 1 st gear 1 000 4 3 6 4 7 Approx 2 500 2 240 2 240 23...

Page 1075: ...wn brake apply pressure is abnormal No 3 hydraulic pressure kickdown brake release pressure and No 4 hydraulic pressure front clutch abnormal No 5 hydraulic pressure rear clutch pressure is abnormal N...

Page 1076: ...OMATIC TRANSAXLE ENGINE TURBO AND ENGINE On vehicle Seal ring D ring I Seal ring I Seal ring D ring b r a k e O ring Seal ring 0 ring I Rear clutch D ring clutch A Seal ring D ring brake O ring Revisi...

Page 1077: ...AUTOMATIC TRANSAXLE ENGINE TURBO AND ENGINE Service ring I D ring Seal O ring Oil seal D ring 0 Seal ring Rear Low reverse I Front clutch D ring A Seal ring D ring brake O ring TSB Revision...

Page 1078: ...AUTOMATIC TRANSAXLE ENGINE AND ENGINE Hole 6 Hole A Revision 1 Hole 2 I 3 Hole 6 hole A 00000394...

Page 1079: ...ic pressure changed Retest Overhaul the valve Regulator valve sticking line relief ball contact surface regulator spring CASE 2 No 1 hydraulic pressure reducing pressure is abnormal Refer to Automatic...

Page 1080: ...e scan tool to check the PCSV control operation sound and check No 2 hy draulic pressure also NG OK Overhaul the valve Pressurecontrolvalve pressurecontrolspring shift valve I Check the PCSV part Refe...

Page 1081: ...l Refer to Automatic Transaxle Overhaul Are other hydraulic pressures No 2 3 5 7 hydraulic pressures normal clutch retainer rina and clutch cover rina CASE 7 No 7 hydraulic pressure low reverse brake...

Page 1082: ...lenoid Refer to NG I OK Replace the TCC solenoid the v a l v e converter clutch control valve and spring control valve and Replace seal 0 of the input shaft Check Retest for cracks and breaks on the o...

Page 1083: ...er 2 Front 3 near 4 Low reverse brake 5 End clutch 6 7 Transaxle control 8 Torque converter clutch 14 15 9 Rear exhaust valve 10 valve Torque converter solenoide valve shift valve End clutch Torque co...

Page 1084: ...essure shift valve 15 End valve 16 Converter control 17 solenoid valve 18 Shift 19 N D valve 20 21 Manual valve 22 Pressure control 23 N R 24 Oil 25 Oil pan 26 Oil pump 27 Line relief valve 28 Pressur...

Page 1085: ...clutch 6 7 Transaxle control 8 Torque converter clutch valve Rear clutch exhaust Torque converter clutch valve 14 shift valve End clutch valve Torque converter control 7 Shift control valve Shift N D...

Page 1086: ...ssure 1 Torque 2 Front clutch 3 Rear clutch 4 Low reverse brake 5 End clutch 6 Servo 7 Transaxle control module 8 converter clutch control 9 Rear clutch exhaust valve valve Torque clutch control valve...

Page 1087: ...ransaxle 8 Torque converter clutch valve valve End clutch Torque Converter control valve control solenoid control valve N D control 9 Rear clutch exhaust 10 valve il Torque converter clutch 12 Reducin...

Page 1088: ...rse brake 5 End clutch 6 Servo 7 Transaxle control module 8 converter clutch control 9 Rear clutch exhaust valve 10 valve Torque converter clutch control valve 12 valve control valve A 14 shift valve...

Page 1089: ...lutch 3 Rear clutch 4 Low reverse brake 5 End clutch 6 Servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve shift valve 11 Torque converter clutch valve 12 Redu...

Page 1090: ...brake 5 End clutch 6 Servo 7 Transaxle control 8 clutch control 9 Rear clutch exhaust valve 10 shifl valve Torque converter clutch solenoide valve 12 Reducing valve 13 control solenoide 14 valve 15 En...

Page 1091: ...4 Low reverse brake 5 End clutch 6 7 Transaxle control module 8 Torque converter clutch control valve 9 Rear clutch exhaust valve valve Torque converter clutch control Valve valve Revision End clutch...

Page 1092: ...ion of the piston engage the of the special tool into the notch of the piston and using the adapter secure the piston as shown to the left Caution 1 Don t press in the piston with the special tool 2 W...

Page 1093: ...que wrench to the special tool inner and tighten to a torque of 10 Nm 7 2 and repeating Tighten and Loosen two times then torque to 5 Nm 3 6 After that back off the special tool inner 2 to turns 8 Eng...

Page 1094: ...iston Then using the torque wrench tighten to the specified torque Lock nut 21 Caution If it is rapidly tightened with the socket wrench or torque wrench the lock nut and adjusting rod may rotate toge...

Page 1095: ...n 3 Remove the oil filter 4 Remove the oil temperature sensor 5 Press the solenoid valve harness grommet and connector into the transaxle case 6 Press the catches of the solenoid valve harness grommet...

Page 1096: ...ned clockwise the line pressure decreases when it is turned to counterclockwise it increases Standard value psi Oil pressure change for each turn of adjustment screw 38 5 5 psi 9 Check that the O ring...

Page 1097: ...rid holder and tighten bolts with the specified torque A bolt 18 mm long bolt 25 mm in long bolt 40 mm 1 57 long body assembly mounting 11 Nm 8 0 13 Install oil filter 14 Install a new oil pan gasket...

Page 1098: ...crew 45 6 5 psi 3 Install the oil filter and oil in the same way as for adjustment of the line pressure 4 Perform the oil pressure test Readjust if necessary WHEN SCAN TOOL IS USED 1 Use the scan tool...

Page 1099: ...at under the the lever cannot be moved from the position other position Also check at the same time that the button be pressed Ignition key position or Brake pedal Depressed 2 Check that under the fol...

Page 1100: ...Pressed Check that under the following conditions the selector lever can be moved smoothly from the position to any other position Ignition key position ACC Brake pedal Depressed Button Pressed I Che...

Page 1101: ...bly 5 Console side cover L H 6 Console side cover R H 7 TCM bracket 8 Transaxle control module TCM 9 Nut 10 Clip 11 Clip 12 Transaxle control cable connection 13 Nut 14 Transaxle control cable assembl...

Page 1102: ...GINE TURBO AND ENGINE Transaxle INSTALLATION SERVICE POINT 1 Put the selector lever in the posit on 2 Loosen the adjusting nut gently pull the transaxle control cable in the direction of the arrow tig...

Page 1103: ...Pin 13 Sleeve 14 Bolt 15 Lever assembly 16 Detent spring assembly 17 Bushing 18 Pipe 19 Cotter pin 20 Washer 21 Lock cam 22 Bracket assembly 9 1 5 2 Nm 7 Push button 8 Spring 9 Indicator panel upper 1...

Page 1104: ...AS S EM BLY Shift the selector lever to the neutral N position and then install the detent spring assembly so that the roller is in the detent plate groove SELECTOR KNOB INSTALLATION 1 Put the selecto...

Page 1105: ...TURBO AND ENGINE l Check the wear l Check the spring for OVERDRIVE SWITCH CONTINUITY Terminal No Switch position 3 OD is operating ON OD is not operating OFF TSB Revision...

Page 1106: ...strument panel under cover 5 Steering column lower cover 6 Center panel 7 Cup holder assembly 8 Floor console assembly 9 Console side cover L H 10 Cover Cam and lever 12 Key interlock cable connection...

Page 1107: ...ATION 1 Place the selector fever in position 2 Fasten the shift lock cable at the position where the end of the shift lock cable is above the red marking LEVER I N S T A L L A T I O N 1 Install the ke...

Page 1108: ...mbly 2 Air cleaner element 3 Air hose 4 Air hose A 5 Battery tray 6 Evaporative emission canister 7 Evaporative emission canister holder 8 Battery tray stay 9 Transaxle control cable connection 10 Oil...

Page 1109: ...ball joint and knuckle connection 27 Drive shaft connection 28 Bell housing cover 29 Stay R H 30 Centermember assembly 69 78 Nm 31 plate bolts 32 mounting bolts 33 bracket 34 Transaxle assembly Cauti...

Page 1110: ...or Lever Operation Check 30 Nm 59 15 44 Nm TSB Revision Removal steps 1 Air cleaner cover and air intake hose assembly 2 Air cleaner element 3 Battery tray 4 Battery tray stay 5 Transaxle control cabl...

Page 1111: ...and knuckle connection 23 Drive shaft connection 24 Bell housing cover 25 Stay R H 26 Centermember assembly 27 Drive connecting bolts 28 Transaxle assembly mounting bolts 29 Transaxle mounting 30 Tra...

Page 1112: ...ing the special tool loosen the tie rod end mounting nut Only loosen the nut do not remove it from the ball joint 2 Support the special tool with a cord etc to prevent it from coming off DRIVE SHAFT D...

Page 1113: ...E TRANSAXLE ASSEMBLY After securely inserting the torque converter the transaxle so that the shown in the becomes the refer ence value install the assembly the engine value A mm 12 0 ASSEMBLY If the d...

Page 1114: ...tion l Transaxle Fluid Supplying Refer to GROUP 00 Maintenance Service 30 Nm 22 23 17 69 Nm 51 Removal steps 1 Air cleaner cover and air intake hose assembly 2 Air cleaner element 3 Air hose 4 Air hos...

Page 1115: ...27 Drive shaft nut 28 Drive shaft 29 Drive shaft with inner shaft connec tion 30 Bell housing cover 31 Stay N m 32 Centermember assembly 33 Drive plate connecting 34 Transaxle assembly mounting bolts...

Page 1116: ...bly ROD END BALL JOINT AND KNUCKLE LATERAL LOWER ARM BALL JOINT AND KNUCKLE COMPRESSION LOWER ARM BALL JOINT AND KNUCKLE DISCONNECTION Caution 1 Using the special tool loosen the tie rod end mounting...

Page 1117: ...gn get into the transaxle case DRIVE SHAFT WITH INNER SHAFT DISCONNECTION 1 Lightly tap the center bracket with ham mer or similar tool to remove shaft from the transaxle 2 Suspend the removed drive s...

Page 1118: ...omes the refer ence value install the transaxle assembly to the engine Reference value A Approx 16 3 mm CENTERMEMBER ASSEMBLY INSTALLATION If the shown in the illustration is outside the standard valu...

Page 1119: ...X L E ENGINE TURBO AND ENGINE Transaxle Assembly 2 Use the special to Caution Before securely sure there is no on the 3 If the position of the cotter pin tighten the nut up to 255 4 Install the pin in...

Page 1120: ...ce l Front Exhaust Pipe Removal and installation Refer to GROUP 42 Exhaust Pipe and Main Muffler Gear oil classification SAE 1 Transfer assembly 69 Nm 51 REMOVAL SERVICE POINT ASSEMBLY REMOVAL Caution...

Page 1121: ...INSTALLATION Engine Engine Turbo 9 8 Nm 7 2 Engine Turbo 6 9 8 7 2 Nm 2 9 29199710119 Removal steps 1 Air cleaner cover and air intake hose 2 Feed hose 3 Return hose 4 Hose assembly Pipe assembly 6 Oi...

Page 1122: ...INE TURBO AND ENGINE Transaxle Oil Cooler INSPECTION 231 l Check the hose for cracks damage l Check for rusted or clogged transaxle oil cooler l Check oil cooler fins for damage and clogged with forei...

Page 1123: ...lled full automatic Torque converter Engine stall speed with torque Gear ratio 2 8 4 2 I 1 5 7 3 1 0 0 0 Reverse Final gear ratio FUNCTION ELEMENT TABLE 0 689 2 214 3 9 0 9 Shift Lever Position PARK R...

Page 1124: ...ON TURBO General SECTIONAL VIEW Case Input speed Overdrive clutch Reverse clutch sensor 2 4 clutch Underdrive clutch L o w R e v e r s e clutch converter Torque converter sensor Oil pump TSB Revision...

Page 1125: ...x 1 Resistance of UD solenoid coil at Distance between detent pin and detent plate mm in Installation dimension of front roll stopper bracket assembly mm in Item Specified lubricant Quantity qts Trans...

Page 1126: ...AUTOMATIC TRANSAXLE Oil pressure gauge TSB Revision...

Page 1127: ...ble code output No diagnostic trouble Erase the diagnostic trouble code code displayed Refer to Basic inspection item adjustment Refer to Abnormality exists no diagnostic trouble code Road test Refer...

Page 1128: ...rises to sensor transmission fluid temperature becomes 3 Engine Engine Data list Transaxle control 45 Selector lever 1 for at least 1 2 0 module position 30 seconds Check diagnos CCD Bus 19 tic troubl...

Page 1129: ...r Engine Data list position 1 Driving in 21 tor lever in ON gear with selec 2 4 OFF tor lever in 2 4 Driving in gear with lever in range Overdrive switch ON 2 4 OFF OD OFF 5 Driving in Re verse gear w...

Page 1130: ...a downshift occurs Do this at least 3 times ingine 1 Driving at constant speed of 80 km h 50 mph with selec tor lever in range Overdrive switch ON Judgment value Data list and 1 Check the UD and clut...

Page 1131: ...T O M A T I C T R A N S A X L E ENGINE de 3 I 20 I 0 0 1000 2000 3000 4 0 0 0 6 0 0 0 Transfer drive 0 Vehicle speed km h LOCK UP Throttle opening 40 I I I I 20 0 I 1000 I I 2000 I 3000 4000 Transfer...

Page 1132: ...ockout switch ON OFF 24 Transaxle range sensor 1 ON OFF 25 Transaxle range sensor 2 ON OFF 26 Transaxle range sensor 43 ON OFF 27 Transaxle range sensor 41 ON OFF 43 Engine speed 44 Transaxle input sp...

Page 1133: ...OM flag register 68 Output teeth count Status Teeth 69 Wheel speed coefficient in EEPROM Coefficient Current production MY application MY Model Year ACTUATOR RE FERENCE TABL E Item No Check item Drive...

Page 1134: ...rded 3 1 2 3 4 5 6 Turn the ignition switch off before connecting or disconnecting the scan tool Install the interface cartridge cartridge to the scan tool Use the cartridge adapter harness to connect...

Page 1135: ...AUTOMATIC TRANSAXLE ENGINE INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES TSB Revision...

Page 1136: ...TCM l Replace TCM Code Scan tool 12 No Battery power was disconnected Probable cause General scan tool since last power down Battery disconnected or first installation l Battery disconnected A batter...

Page 1137: ...Measure at the EATX relay connector Repair the harness Continuity between terminal 6 and 2 g r o u n d I Repair Measure at the TCM connector l Disconnect the connector and measure at the harness side...

Page 1138: ...ontinuity when system voltageisapplied minals 4 and no conti nuity when system voltage is not applied OK Measure at the EATX relay connector l Disconnect the connector and measure at the harness side...

Page 1139: ...or l of TCM OK Measure at the TCM connector l Disconnect the connector and measure at the harness side l Voltage between 46 and ground Start the engine OK C h e c k t h e l OK Road test Refer to Repla...

Page 1140: ...OK Measure at PCM connector A l 07 and data link connector l Disconnect the connector and measure at the harness side l Resistance value between 59 and 27 OK Less than OK Measure at TCM connector and...

Page 1141: ...ssure switch assembly connector l Disconnect the connector and measure at the harness side l Voltage between 5 and ground l Ignition switch ON OK OV OK Measure at the TCM connector l Disconnect the co...

Page 1142: ...and pressure switch Check trouble symptom NG Possible cause Internal transaxle failure Refer to Adjust the fluid level P r o b a b l e c a u s e fluid level in transaxle l Malfunction of pressure swi...

Page 1143: ...the 2 4 clutch tap l Move selector lever to the 2 position Increase throttle opening to achieve an indicated vehicle speed of 48 km h 30 mph Take a reading of the clutch pressure OK 1000 115 145 psi...

Page 1144: ...crease speed to 1 5 0 0 1 Take a reading of the clutch pressure O K psi 2 SCAN TOOL list 20 L R pressure switch OK ON Replace the TCM OK INTERMITTENT MALFUNCTION l Study the DTC information back groun...

Page 1145: ...nsaxle problem l Carry out the inspection procedure for code No 22 Refer to l Carry out the inspection procedure for code No 24 Refer to Pressure switch circuit ALL A mismatch has occurred between the...

Page 1146: ...setting data error flag since start up SCAN TOOL Data list 26 Transaxle range sensor 43 l Ignition switch ON OK Shift lever position 2 L ON Otherthan OFF NG OK SCAN TOOL Data list Check the transaxle...

Page 1147: ...e following connector l Engine ground connection l l Ignition switch ON I OK More than OK A b n o r m a l i t y no diagnostic trouble connector Abnormality exists trouble code present To INSPECTION CH...

Page 1148: ...ne speed slightly Standard 75 95 psi every 3 seconds Check the transmission fluid level NG Repair l Solenoid and pressure switch assembly Internal transaxle failure Refer to Code Scan tool 32 Hydrauli...

Page 1149: ...ter a l Internal transaxle problem Refer to Speed errors I Code Scan tool 37 Solenoid switch valve latched in No General scan tool the LU position Three unsuccessful attempts shift gear Probable l Int...

Page 1150: ...tor l Disconnect the connector and measure at the harness side l Resistance value between and switch assembly connector ground OK Less than NG l Resistance value between 4 and ground OK Less than NG C...

Page 1151: ...t the connector and measure at the harness side l Resistance value between 56 and OK 1 of pressure switch l Harness or connector between open or l ground open circuited l Resistance value between 59 a...

Page 1152: ...een 20 and NG Replace the solenoid and pressure switch assembly Check the wire between the Replace the TCM Measure at the TCM connector l Disconnect the connector and measure at the harness side l Res...

Page 1153: ...ess side l Resistance value between 19 and around Less than OK Measure at the TCM connector value between 19 and Replace the switch assembly Check trouble symptom Replace the TCM Measure at the TCM Me...

Page 1154: ...r second time l Internal problem l lnspectlon matrlxfoidiagnostictrouble code transaxle problem Code Scan tool 48 No General scan tool TRD link communication error The code sets when There is an incor...

Page 1155: ...hard fault is considered to exist when the fault counter has matured to a value of Malfunction of output speed sensor An intermittent fault is considered present when the fault counter is greater than...

Page 1156: ...the throttle to 30 Caution Do not test any gear range for longer than 5 seconds l Use the scan tool to monitor the input RPM Allow the engne to return to idle OK 0 rpm l The reverse clutch or low reve...

Page 1157: ...measure at the harness side l Resistance value between 12 and ground OK Less than OK Replace the input speed sensor Measure at the TCM connector l Disconnect the connector and measure at the harness...

Page 1158: ...around Measure at the TCM conenctor l Disconnect the connector and and then measure at the harness side l Resistance value between 54 and ground Less than Measure at the TCM connector l Disconnect th...

Page 1159: ...ments are continuously monitored and learned for adaptive controls As the friction material wears the volume Of code Internal transaxle problem fluid needed to apply the element increases The followin...

Page 1160: ...r between transaxle range sensor and TCM open or short circuited l Malfunction of TCM Oil temperature sensor check Refer to NG Replace N G Measure at the transaxle range sensor Check connector A l 08...

Page 1161: ...ailure 37 Solenoid switch valve stuck in X X the LU position 38 Partial lockup control out of x x x x x x range 46 UD clutch not lowering x x x x pressure 47 Solenoid switch valve stuck in x x the pos...

Page 1162: ...ailed reverse clutch 9 Damaged or failed 2 4 clutch 10 Damaged or failed low reverse clutch 11 Damaged clutch seal 12 Worn or damaged accumulator sealing 13 Plugged filter 14 Stuck sticky valves 15 So...

Page 1163: ...5 Worn or faulty 2 4 clutch 6 Worn or faulty low reverse clutch 7 dragging 8 Insufficient clutch plate clearance 9 Damaged clutch seal 10 Worn or damaged accumulator sealing s 11 Faulty cooling system...

Page 1164: ...sealing 20 Worn or damaged input shaft sealing 21 Valve body malfunction or leakage 22 Hydraulic pressure too low 23 Hydraulic pressure too high 24 Faulty oil pump 25 Oil filter clogged 26 Low fluid...

Page 1165: ...tion gear ov Transaxle condition other gears Battery positive voltage 9 Overdrive switch Overdrive switch ON Battery positive voltage Overdrive switch OFF o v pressure switch Transaxle condition and g...

Page 1166: ...positive voltage Selector lever position P o v Transaxle condition Battetv positive voltaae 49 Transaxle condition other I ov I 51 Ignition Feed Ignition switch ON Battery positive voltage Ignition s...

Page 1167: ...he scan tool screen Then input the clutch volume index into the PINION FACTOR WRITING PROCEDURE REPLACEMENT OR TIRE SIZE NOTE With transmissions the TCM uses the rotation speed of the transaxle output...

Page 1168: ...and body ground and terminals should be as shown in the table below Lever Terminal No Body TSB Revision 3 If there is a defect replace the transaxle range sensor OIL TEMPERATURE SENSOR CONTINUITY CHE...

Page 1169: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO AUTOMATIC TRANSAXLE CONTROL COMPONENT LAYOUT Output speed sensor Transaxle TSB Revision...

Page 1170: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle Service Transaxle range sensor with built in oil temperature sensor TSB Revision...

Page 1171: ...sor connector 2 Measure the resistance between the input speed side connector terminals 1 2 Standard value 3 If the resistance is outside the standard value replace the output speed sensor TRANSAXLE R...

Page 1172: ...K Refer to GROUP On vehicle Service SOLENOID CHECK 1 Disconnect the solenoid and pressure switch assembly connector 2 Measure the resistance between the solenoid and pressure switch assembly side conn...

Page 1173: ...als 6 and Standard value Approx at 3 If the resistance is outside replace the solenoid and pressure switch assembly 1 Disconnect the solenoid and pressure assembly c o n n e c t o r 2 Measure the resi...

Page 1174: ...ay be ac ceptable but a high throttle is required to maintain vehicle speed The vehicle may seem like it has a loss of power With either type of failure poor fuel economy and transaxle fluid over hear...

Page 1175: ...for COOLER AND If there has been a mechanical failure within the torque con verter or in the transaxle itself the fluid becomes contaminated and circulates throughout the hydraulic system This include...

Page 1176: ...n the air pressure is removed CLUTCH Apply air pressure to the feed hole located on the clutch retainer Look in the area where the piston contacts the first separator plate and watch carefully for the...

Page 1177: ...orque converter weld leaks at the out side peripheral weld Torque converter hub weld 3 Hub inside and not visible Do not attempt to repair Replace torque converter If the torque converter must be repl...

Page 1178: ...cle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 48 km h 30 4 Underdrive clutch pressure should read 758 to 1 000 110 to 145 psi 5 This test checks the underdr...

Page 1179: ...circuit TEST SIX SELECTOR IN REVERSE 1 Attach pressure gauge to the reverse clutch tap 2 Move selector lever to the reverse position 3 Read reverse clutch pressure with output stationary foot on brak...

Page 1180: ...on Gear PARK PARK 0 km h 0 mph REVERSE 0 km h 0 mph VERSE NEUTRAL NEUTRAL 0 km h 0 mph FIRST 32 km h 48 km h SECOND 72 km h 45 DIRECT 48 km h 30 DRIVE 80 km h 50 DRIVE WITH TCC Drive Clutch 1 000 Clut...

Page 1181: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle Service HYDRAULIC CIRCUIT Park Neutral REVERSE 24 CLUTCH C L AC ITCH TSB Revision...

Page 1182: ...AUTOMATIC TRANSAXLE ENGINE On vehicle Service TSB Revision...

Page 1183: ...Reverse AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle REVERSE c c I Revision...

Page 1184: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle Service Block REVERSE BLOCK REV W SPEED OVER MPH LR REVERSE AC PT TSB Revision OFF ON I...

Page 1185: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle Service First Gear FIRST GEAR LR REVERSE Revision...

Page 1186: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle Service Second SECOND GEAR n O F F II PT TSB Revision SOLENOIDS EM RPM...

Page 1187: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle Service Direct Gear Electronically Modulated Converter Clutch DIRECT GEAR EMCC LR REVERSE 24 CLUTCH AC P T VENT RESERVOIR TSB Revision...

Page 1188: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO On vehicle Service Direct Gear Converter Clutch ON DIRECT GEAR CC ON 4 LR REVERSE 24 CLUTCH I SW SWITCH P I PT I 2 02 n l TSB Revision RESERVOIR AC...

Page 1189: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO Overdrive OVERDRIVE REVERSE 24 CLUTCH C L OFF ON SW 0 2 CHAIN LUBE CHAIN LUBE TSB Revision...

Page 1190: ...AUTOMATIC TRANSAXLE ENGINE NON TURBO Service Overdrive Electronically Modulated Converter Clutch OVERDRIVE REVERSE 24 CLUTCH AC CL P T II II I II I AC TSB Revision...

Page 1191: ...AUTOMATIC TRANSAXLE ENGINE On vehicle Service Overdrive Converter Clutch ON OVERDRIVE CHAIN LUBE O N SW 1 TSB Revision...

Page 1192: ...AUTOMATIC TRANSAXLE ENGINE On vehicle Service Refer to Refer to Refer to TSB Revision...

Page 1193: ...embly 5 Console side cover L H 6 Console side cover R H 7 Nut 8 Clip 9 Clip 10 Transaxle control cable connection Nut 12 EATX ECM 13 Transaxle control cable assembly Selector lever assembly removal st...

Page 1194: ...GINE Transaxle Control NUT INSTALLATION al control lever 1 Put the selector lever in the N position 2 Loosen the adjusting nut gently pull the transaxle control cable in the direction of the arrow tig...

Page 1195: ...indicator light connector case 2 Cover 3 Selector knob 4 Overdrive switch button 5 Overdrive switch 6 Pin 7 Push button 8 Spring 9 Indicator panel upper 10 Slider 11 Indicator panel 11 Nm 22 8 3 12 P...

Page 1196: ...screw 3 Pressing the switch remove the overdrive switch REASSEMBLY SERVICE POINTS DETENT SPRING ASSEMBLY Shift the selector lever to the neutral position and then install the detent spring assembly s...

Page 1197: ...ENGINE l l Check the bushing wear l OVERDRIVE SWITCH CONTINUITY Switch position Terminal 3 OD is operating ON OD is not operating OFF 0 Revision...

Page 1198: ...lever 4 Instrument panel under cover 5 Steering column lower cover 6 Center panel 7 Cup holder assembly 8 Floor console assembly 9 Console side cover L H 10 Cover 11 Cam and lever 12 Key interlock cab...

Page 1199: ...E R INSTALLATION 1 Place the lever in 2 Fasten the shift lock cable at the end of the shift lock is positioned the KEY INTERLOCK CABLE SELECTOR LEVER 1 Install the key interlock cable cam 2 Install th...

Page 1200: ...e Fluid Supplying Refer to GROUP 00 Maintenance Service l Selector Lever Operation Check 9 2 6 51 40 69 Nm 51 I 42 51 Removal steps 1 Air cleaner cover and air intake hose assembly 2 Air cleaner eleme...

Page 1201: ...nnection 17 Stabilizer link connection 16 Damper fork 19 Lateral lower ball joint and knuckle connection 20 Compression lower arm ball joint l 1 parts which and then and knuckle connection 21 Drive sh...

Page 1202: ...he tool loosen the tie rod end mounting nut Only loosen the nut do not remove from the joint 2 Support the tool with a cord prevent it from coming off DRIVE SHAFT DISCONNECTION 1 insert a pry bar betw...

Page 1203: ...the torque converter into the for easier 5 the transaxle assembly and lower the transaxle ASSEMBLY INSTALLATION If the dimension shown in the illustration is outside the standard value when the weight...

Page 1204: ...Draining and Refer to GROUP 00 Maintenance 2 3 9 Nm 2 9 Removal steps 1 Air cleaner cover and air intake hose 2 Hose 3 Pipe assembly l Check the hose for cracks damage and clogs l Check for rusted or...

Page 1205: ......

Page 1206: ......

Page 1207: ...ERSE BRAKE 67 OIL PUMP 49 PLANETARY GEAR 59 REAR CLUTCH 54 SPECIAL SPECIFICATIONS Gear Ratio Table Pressure Plates Snap Rings and Spacers for Adjustment 6 Service Specifications 5 Torque Specification...

Page 1208: ...be cleaned with ordinary detergents but must be thoroughly air dried Clean the clutch disc resin thrust plate and rubber parts by using transmission fluid being very careful that dust dirt etc do not...

Page 1209: ...AUTOMATIC TRANSAXLE OVERHAUL Information Torque converter Front clutch Rear clutch Oil pump brake I TSB Revision Transfer drive Transfer driven gear Differential...

Page 1210: ...onverter clutch solenoid 10 Rear clutch exhaust valve 11 shift valve 12 Reducing valve 13 Shift control solenoid valve 14 shift valve 15 End clutch valve 16 Torque converter control valve 17 Shift con...

Page 1211: ...rake end play mm in Differential case preload mm in End clutch snap ring clearance mm in Oil pump gear side clearance mm in Front clutch snap ring clearance mm in Rear clutch snap ring clearance mm in...

Page 1212: ...2 5 7 7 0 6 2 Number of loops 11 9 5 8 12 15 15 5 13 9 8 22 10 9 5 Wire diameter 1 4 1 3 0 45 0 7 0 6 0 6 1 39 0 5 1 0 7 PRESSURE PLATES SNAP RINGS AND SPACERS FOR ADJUSTMENT TSB Revision hrust washe...

Page 1213: ...ss Identification Part No mm in s y m b o l 1 20 Purple 1 1 40 Brown 1 55 None 1 65 Gray 1 80 Green 1 95 Red 67 ring of output flange bearing end play Thickness Identification Part No Thickness Identi...

Page 1214: ...c c 5956 1 25 0457 1 97 DD 1 28 2 00 EE 5958 1 31 2 03 FF 1 34 0 2 06 GG 5960 1 37 0460 2 09 HH 1 40 None 2 12 2 15 JJ I 0462 2 18 KK I 2 21 LL I 0463 2 24 MM 5966 I 0464 2 27 NN 5967 I 2 30 0 0 5968...

Page 1215: ...nut 19 Manual control shaft set screw 9 7 Oil filter bolts Oil pan bolts Oil pump assembly mounting bolts One way clutch outer race lock plate bolts Park neutral position switch bolts Pressure check p...

Page 1216: ...AUTOMATIC TRANSAXLE OVERHAUL Special Tools SPECIAL TOOLS Oil seal installer TSB Revision...

Page 1217: ...l numberand name Guide pin Spring compressor Spring compressor servo set 01 adapter puller ring nstaller 10998812 nstaller cap service Use Disassembly clutch installation of servo Removal and installa...

Page 1218: ...AUTOMATIC TRANSAXLE OVERHAUL Tools Tool of each bearing TSB Revision...

Page 1219: ...AUTOMATIC OVERHAUL __ TSB Revision...

Page 1220: ...12 Rear clutch assembly 13 Spacer 14 Outer race Differential 16 Thrust bearing 17 Clutch hub 18 Thrust race 19 Thrust bearing 20 band 21 drum 22 Snap ring 23 Center support 24 O ring 25 Wave spring 2...

Page 1221: ...g End clutch Thrust washer End clutch hub Thrust bearing End clutch shaft Bearing retainer Snap ring Lock plate 54 Idler gear shaft 55 Bearing inner race 56 Idler gear 57 Bearing inner race 58 Spacer...

Page 1222: ...orque converter 4 Measuring input shaft end play will usually indicate when a thrust is required except when major parts are replaced Thrust washers are located between the shaft support and rear clut...

Page 1223: ...filter the oil temperature sensor bracket mounting bolts and remove the oil temperature sensor from brack et Using a screwdriver push out the rubber plug from inside the case and remove the oil temper...

Page 1224: ...R A N S A X L E OVERHAUL Transaxle the valve body mounting bolts indicated by aiid the valve body from the transaxle the end clutch the end clutch thrust washer from the end the end clutch hub and th...

Page 1225: ...end 14 the housing and the six arrows the special the bolt the oil remove the gasket the the case...

Page 1226: ...AUTOMATIC OVERHAUL T r a n s a x l e fiber thrust washer input shaft to remove the and clutch assemblies 25 Remove thrust the clutch hub race and thrust...

Page 1227: ...AUTOMATIC OVERHAUL Transaxle the drum 29 Remove the special tools push in the and remove the snap ring the special tools remove the servo piston sleeve and the anchor rod TSB Revision...

Page 1228: ...pecial tool on the center support and remove the center support from the case reverse sun gear thrust bearing thrust race and forward sun gear together the gear set and thrust bearing the wave spring...

Page 1229: ...n the bearing retainer Tap the heads so can be easily loosened an impact driver loosen the and remove the bearing retained the idler shaft lock plate the transfer idler shaft with the transfer idler g...

Page 1230: ...TRANSAXLE AUL Transaxle the spacer the snap ring from the flange bearing the output flange from the the transfer shaft cover the locking tab the transfer lock nut where it is bent TSB Revision I...

Page 1231: ...lock nut Caution The lock nut is a left handed screw out the transfer shaft toward the converter housing end and remove the transfer shaft and transfer driven gear the outer races from the transfer s...

Page 1232: ...pressed air b Install the appropriate pressure and the return spring Make return spring in the correct c Apply petrolatum jelly to the spring and attach the wave spring on the center support the two O...

Page 1233: ...he transfer the brake reaction i Using a hand pump feed air through the shown and at the time read the dial and select a pressure plate to the end play Standard mm After a pressure plate of the approp...

Page 1234: ...t the transfer shaft in the case 4 Mount the special tool on the transaxle to the transfer shaft 5 Install the thickest spacer in 8 Install the transfer driven gear on the shaft 7 Remove the tool and...

Page 1235: ...liding the transfer shaft in and out and select a spacer to obtain the specified end Standard value mm in lO Bend the locking tab of the 11 Place the transaxle case on the oil pan mounting surface up...

Page 1236: ...races in the transfer idler gear the transfer idler gear in the case insert and screw the idler shaft into position in and tighten the idler shaft by the special the special tool into the output flan...

Page 1237: ...he lock plate bolt to the Tightening torque t h e b e a r i n g the screw to specified torque Caution The screw not Tightening torque __ the screw head in place using a chisel petrolatum jelly to thru...

Page 1238: ...A U T O M A T I C T R A N S A X L E OVERHAUL Transaxle thrust race sun gear Then assemble sun gear the sun gear assembled in in the carrier TSB Revision...

Page 1239: ...ENTIFICATION OF THRUST BEARINGS THRUST RACES AND THRUST WASHERS I identification marking O D I 48 9 1 925 I I 46 1 1 906 42 6 1 677 I I I 52 0 2 047 55 7 2 193 37 0 1 457 34 4 1 354 21 0 28 0 1 102 38...

Page 1240: ...ss Part No 41 0 1 614 1 102 39 0 1 102 1 2 42 4 1 669 22 2 54 0 2 126 36 4 1 433 9846 2 283 44 0 1 732 Oil pump side plate Brake reaction plate Brake disc Pressure plate Return spring the brake disc a...

Page 1241: ...automatic transmission fluid to the O rings the special tool to the center support Install the center support slowly in transaxle case the special tool Caution 1 During installation take the wave spri...

Page 1242: ...ng the servo piston with the sleeve the spring on the servo piston and sleeve assembly and insert them together in the making sure that the end gap of the teflon seal of the servo piston does not inte...

Page 1243: ...he drum and tighten servo adjusting screw to keep the band in jetty to thrust and attach the thrust bearing to drum jelly to thrust race thrust race to the rear clutch splines hub engaging it with sun...

Page 1244: ...Rear Front clutch 21750201 to thrust washer and thrust bear ing and attach the bearing to the assembly the the front the clutch assembly race rear face of the oil TSB Revision...

Page 1245: ...of the input shaft If the measure ment is out of the standard value replace thrust race and thrust washer to meet the standard value Standard value mm in two pieces of in long and in dia the on the c...

Page 1246: ...whose thickness falls the range determined by the formulas below T 0 38 mm in 0 13 mm in to T 0 38 mm in 0 08 mm in the spacer which was selected 60 and the outer race on the silicone grease to all ga...

Page 1247: ...asher clutch end clutch hub on the end clutch assembly thrust bearing to the end clutch hub jelly the end clutch assembly a new O ring in the groove of the end Check bearing for smooth it if defects a...

Page 1248: ...n the illustration In doing this work do not O ring in the O ring groove installing a new O ring on the assembly draw the shaft back into the case the set screw and gasket Tighten the detent plate mou...

Page 1249: ...m __ the oil tighten the five the five depressions the oil pan sure to remove metal from the clean the inside the oil pan the gasket surfaces of the transaxle case and oil pan Install a new oil pan ga...

Page 1250: ...the lock nut until it is reach the V groove in the adjusting special tool inner until it the c Fit the special outer to the lock the outer cylinder counterclockwise and the inner cylinder clockwise to...

Page 1251: ...e lock nut to the specified torque Tightening torque 29 Nm Caution The lock nut may turn adjusting rod if tightened quickly with or torque wrench g Remove the special tool for securing the piston Inst...

Page 1252: ...ntrol lever aligns with the in in the body c Tighten the attaching bolts to specified torque taking care that switch body is not displaced Tightening torque 11 Nm 8 the continuity between terminals wi...

Page 1253: ...l pump side cylindrical portion of the torque converter install the torque converter carefully so as not to give damage to the oil seal lip the torque converter is in mesh with the gear the distance b...

Page 1254: ...ther case replace the pulse generator assembly SOLENOID VALVES 1 Measure the resistance the terminals body of each solenoid valve Stgndard value at TSB Revision Pressure control solenoid valve Shift c...

Page 1255: ...embly steps 1 O ring 2 Reaction shaft support 3 Steel ball 4 Drive gear 5 Driven gear 6 Seal ring 7 Oil seal 6 Oil pump housing 9 Snap ring 10 Oil seal DISASSEMBLY SERVICE POINT GEAR DRIVEN GEAR REMOV...

Page 1256: ...e the reaction shaft hous ing and tighten the five 2 Insert the special tool Guide pump bolt hole and tighten the and housing with the special tool to locate the support and housing 3 Tighten the five...

Page 1257: ...Front Clutch FRONT CLUTCH DISASSEMBLY AND REASSEMBLY __ Disassembly steps Snap ring 2 Clutch reaction plate 3 Clutch disc 4 Snap ring 5 Return spring 6 Front clutch piston 7 D ring 6 D ring 9 Front c...

Page 1258: ...tall the snap ring CLUTCH REACTION PLATE 1 Install the clutch reaction plate with missing tooth portions A in the illustration in alignment NOTE This design is to facilitate escape of automatic transm...

Page 1259: ...ance snap ring and plate To of the clutch reaction plate down with 11 Ibs force If clearance is out of standard value select a snap ring to obtain the standard value Standard value mm in NOTE To insta...

Page 1260: ...__ 13 9 8 Disassembly steps 1 Seal ring Snap ring 5 Thrust race 6 Seal ring 7 Snap ring 8 Clutch reaction plate 9 Clutch disc 10 Clutch plate 11 Clutch pressure plate 12 Wave spring 13 Return spring...

Page 1261: ...utch pressure plate clutch plates and clutch reaction plate with their missing tooth portions A in the illustration in alignment NOTE This design is to facilitate escape of automatic transmis sion flu...

Page 1262: ...AUTOMATIC TRANSAXLE OVERHAUL Install the input shaft with one of its groove the punch mark on the rear clutch Revision...

Page 1263: ...ND CLUTCH DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Seal ring 2 Snap ring 3 Clutch reaction plate 4 Clutch disc 5 Clutch plate 6 8 Return Spring 9 End clutch piston 10 Oil seal 11 D ring 12 End c...

Page 1264: ...g to the lowest possible portion of the Guide Put the Installer over the Guide and use a press to install the snap ring in the groove If the snap ring is installed in the groove stop using the press D...

Page 1265: ...ETARY GEAR DISASSEMBLY AND REASSEMBLY 29 6 Disassembly steps 1 Bolt 2 Lock plate 3 One way clutch outer race 4 End plate 5 One way clutch 6 End plate 7 Pinion shaft Front thrust washer Spacer bushing...

Page 1266: ...ICE POINTS THRUST BEARING INSTALLATION 1 Install a new thrust bearing on the carrier Make sure that it fits correctly in the spot faced of the carrier 2 Apply unsparingly to the inside surface of the...

Page 1267: ...NSTALLATION the one way clutch into the outer race Make sure that arrow on the outside circumference of cage is directed upward as shown in illustration when the one way clutch is pushed in BOLT INSTA...

Page 1268: ...R AND TRANSFER DRIVE GEAR SET DISASSEMBLY AND Disassembly steps 1 Snap ring 2 Bearing 3 Transfer drive gear 4 Bearing 5 Snap ring 6 Output flange 7 gear DISASSEMBLY SERVICE POINTS BEARING REMOVAL TRAN...

Page 1269: ...ap ring be one that can be installed in groove Standard value mm in TSB Revision REASSEMBLY SERVICE POINTS BEARING T R A N S F E R Install the transfer drive gear in proper can be identified by the gr...

Page 1270: ...ubricate all internal parts with automatic transmission fluid during Disassembly steps 1 Bolt 2 Differential drive gear 3 Taper roller bearing 4 Lock pin 5 Pinion shaft Differential case 9 7 6 Pinion...

Page 1271: ...ing new dif ferential side gears install spacers of medium thickness 0 93 to 1 00 mm to in 2 Install the washers to the back of the pinion gears install the gears in the differential case and then ins...

Page 1272: ...AUTOMATIC TRANSAXLE OVERHAUL Apply automatic transmission fluid to the bolts and tighten the to the specified torque sequence shown in the illustration TSB Revision...

Page 1273: ...AUTOMATIC TRANSAXLE OVERHAUL Brake LOW REVERSE BRAKE DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Low reverse brake piston 2 D ring 3 D ring 4 Center support Revision...

Page 1274: ...UTOMATIC TRANSAXLE OVERHAUL Servo SERVO DISASSEMBLY AND REASSEMBLY 3 parts with automatic 1 7 TSB Revision Disassembly steps 1 O ring 2 servo sleeve 3 D ring 4 Seal ring 5 Lock nut 6 servo rod 7 pisto...

Page 1275: ...A T I C T R A N S A X L E OVERHAUL Gear SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Disassembly steps driven gear Sleeve REASSEMBLY SERVICE A Apply gear oil sparingly to shaft and insert the shaft TSB...

Page 1276: ...IC TRANSAXLE OVERHAUL Drive Shaft DRIVE SHAFT OIL SEAL DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Converter housing 2 Transaxle case 3 Oil seal REASSEMBLY SERVICE POINT OIL SEAL INSTALLATION TSB R...

Page 1277: ...TRANSAXLE AUL TRANSFER SHAFT DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Bearing 2 Transfer shaft 4 DISASSEMBLY SERVICE BEARING REMOVAL REASSEMBLY SERVICE BEARING INSTALLATION TSB Revision...

Page 1278: ...AUL Transfer Driven Gear TRANSFER DRIVEN GEAR DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Bearing 2 Transfer driven gear DISASSEMBLY SERVICE POINT BEARING REMOVAL REASSEMBLY SERVICE POINT BEARING I...

Page 1279: ...ontrol solenoid valve 3 Shift control solenoid valve A 4 Shift control converter clutch Valve stopper 8 N D control sleeve 9 N D control valve 10 Lower valve body sub assembly 11 Lower separating plat...

Page 1280: ...que converter control valve 30 Adjusting screw 31 Regulator spring 32 Regulator valve 33 Shift control spriig A 34 Stopper plate 35 Shift control plug 36 Rear clutch exhaust valve A 5 Nm 4 37 Rear clu...

Page 1281: ...tch plug 51 End clutch spring 52 End clutch valve 53 End cover 54 Torque converter clutch control sleeve 55 Torque converter clutch control valve 56 Torque spring 57 N R control valve 58 N R control 5...

Page 1282: ...ODY SUB ASSEMBLY INSTALLATION Mount the special tools and secure the upper separating plate and intermediate plate with the eight mounting bolts Then demount the special tools I STEEL BALL RELIEF SPRI...

Page 1283: ...s SOLENOID VALVE ASSEMBLY INSTALLATION Install each solenoid valve in the position shown in the figure Solenoid valve Wiring color Shift control solenoid valve A Orange SCSV A Shift control solenoid v...

Page 1284: ...NOTES...

Page 1285: ...L PUMP 76 PLANETARY GEAR 85 REAR CLUTCH 80 SPECIAL TOOLS 13 6 Gear Ratio Table 6 Pressure Plates Snap Rings and Spacers for Adjustment 8 Sealants and Adhesives 12 Service Specifications 7 Torque Speci...

Page 1286: ...leaned with ordinary but must thoroughly air dried Clean the clutch disc resin thrust plate and rubber parts by using ATF automatic transmission fluid being very careful that dust dirt etc do not adhe...

Page 1287: ...AUTOMATIC TRANSAXLE OVERHAUL General SECTIONAL VIEW Kick Torque converter clutch Oil pump do bra Torque Front clutch Rear clutch gear Transfer drive gear End TSB Revision D i f f e r e n t i a l...

Page 1288: ...RHAUL General Information SECTIONAL VIEW Torque converter Oil pump Front R e a r clutch brake clutch Torque Transfer Planetary gear Transfer idler gear reverse brake End clutch TSB Revision coupling F...

Page 1289: ...e converter clutch solenoid 10 Rear clutch exhaust valve 11 shift valve 12 Reducing valve 13 Shift control solenoid valve A 14 shift valve 15 End clutch valve 16 Torque converter 17 Shift control sole...

Page 1290: ...ATIC TRANSAXLE OVERHAUL TRANSAXLE MODEL TABLE Transaxle model Gear ratio type Speedometer Final gear ratio Engine model gear ratio A 4 376 T C A 4 361 T C GEAR RATIO TABLE Reverse A 2 551 1 488 1 0 68...

Page 1291: ...sh mm in Oil pump side clearance mm in Output flange bearing end play mm in Front clutch end play mm in Rear clutch end play mm in End clutch end play mm in Transfer drive gear end play mm in Front ou...

Page 1292: ...n e Blue 1 5 Brown None 1 7 Blue 1 8 Brown No 747 748 749 750 751 752 Thickness mm in 1 9 Spacer For adjustment of transfer driven gear preload Thickness Identification mm in symbol 82 65 88 0 71 71...

Page 1293: ...No 0454 Thickness mm in 1 1 28 Identification symbol Spacer For adjustment of differential gear and pinion backlash Thickness Identification mm in symbol Part No Thickness Identification mm in symbol...

Page 1294: ...3 1 76 1 79 1 82 Identification Spacer For adjustment of driven bevel gear train preload Thickness Identification mm in symbol 1 19 19 1 22 22 1 25 25 1 28 28 1 31 31 1 34 34 1 37 37 1 40 40 1 43 43 1...

Page 1295: ...itch PNP switch bolt 11 8 servo lock nut 29 21 Manual control lever nut 19 14 Manual control shaft set screw 9 7 Oil drain bolt 33 24 Oil filter bolt 6 5 Oil dipstick guide bolt 24 18 Oil bolt pan 11...

Page 1296: ...g mounting bolt Oil drain plug Oil filler plug Transfer case adapter mounting bolt Transfer cover mounting bolt Nm __ 5 4 1 5 0 19 1 4 33 33 39 4 39 28 SEALANTS AND ADHESIVES Items Transfer extension...

Page 1297: ...__ __ TSB Revision...

Page 1298: ...Oil seal installer TSB Revision...

Page 1299: ...TSB...

Page 1300: ...ol number and name Special spanner Application Removal and installation of transfer driven bevel gear lock nut 50 Bolt Pull out idler shaft Handle installation of center support Disassembly and reasse...

Page 1301: ...rust race 7 Thrust bearing 8 Thrust washer 9 Rear clutch assembly 10 Thrust bearing 11 Rear clutch hub 12 Thrust bearing 13 Thrust race 14 band 15 drum 16 Snap ring 17 Center support 18 Wave spring 19...

Page 1302: ...31 Oil dipstick 32 Oil filler tube 33 Snap ring 34 servo switch 35 Snap ring 36 servo piston 37 Spring 38 Anchor rod 39 Detent plate 40 Manual control shaft 59 60 66 70 Nm 51 41 Parking roller support...

Page 1303: ...haft 60 Idler gear 61 Spacer 64 bearing 65 Outer 66 Diff 67 I front assembly 68 69 cover 7 0 72 1 Clean away any sand the transaxle 2 Place the transaxle assembly oil pan down 3 Remove the torque conv...

Page 1304: ...temperature sensor holder and oil temperature sensor clamp the finger of the solenoid valve harness grommet push the grommet into and remove the valve body assembly out the oil temperature sensor the...

Page 1305: ...ANSAXLE OVERHAUL Transaxle the differential cover the differential the differential outer race the differential assembly out the end clutch installation move the cover holder and end the end assembly...

Page 1306: ...e thrust plate the end clutch hub t h r u s t b e a r i n g NOTE It may be stuck to the and clutch out the end clutch shaft the idler gear cover mounting then the idler gear cover and gasket the bolt...

Page 1307: ...AUTOMATIC TRANSAXLE OVERHAUL the special tool pull out the shaft and remove the idler gear and race the spacer the oil pump bolts the special tool to remove the pump thrust washer TSB Revision...

Page 1308: ...RANSAXLE OVERHAUL Transaxle the input shaft and remove the front and rear clutch assembly together thrust bearing the clutch hub NOTE The thrust race may be to the clutch hub thrust bearing the drum T...

Page 1309: ...TSB t h e the servo cover cover t h e t h e special tool push in the remove the snap t h e...

Page 1310: ...Transaxle plug then remove the the snap ring the special tool remove the support TSB Revision the sun gear forward to gether the carrier assembly...

Page 1311: ...n brake discs and brake plates the screws and rear bearing retainer the snap ring and the output a s s e m b l y the output bearing retainer mounting then remove the output bearing retainer and outer...

Page 1312: ...oil seals to the differential bearing retainer and transaxle case 2 Use the special tool to press fit the into the transaxle case 3 Install the transfer shaft 4 Place solder with a length of approxim...

Page 1313: ...the thickness of the solder with a micrometer and select a thickness that will provide standard for Standard value m m i n 8 Install the spacer selected in the and the outer race on the output bearin...

Page 1314: ...heads of the bolts a coating of to bearing attach to the planetary carrier the planetary carrier the forward sun gear thrust race thrust bearing and reverse sun gear both sun gears assembled in the p...

Page 1315: ...AUTOMATIC TRANSAXLE OVERHAUL the reaction plate brake disc and brake plate TSB Revision...

Page 1316: ...ss marking Part No mm in 70 0 2 756 55 7 1 4 l 1 1 8 l 2 2 2 0 87 2 6 86 0 2 598 54 7 2 126 1 8 48 9 1 925 37 0 1 457 1 1 2 1 4 1 6 1 8 2 0 2 2 2 4 48 1 1 906 34 4 1 354 42 6 1 677 28 0 1 102 54 0 2 1...

Page 1317: ...jeliy to the wave and attach it to center support the special tool on the center support new O rings and push into the transaxle case Caution 1 Coat the O rings with and align the holes 2 Do not move...

Page 1318: ...m 24 the anchor rod TSB Revision the servo spring piston and sleeve Caution The seal ring alignment hole of piston must not the oil filler port by the arrow in the the special tool to push in the serv...

Page 1319: ...RHAUL Transaxle thrust bearing and washer the rear clutch Thrust bearing race TSB Revision the rear clutch assembly front assembly thrust bearing the rear clutch hub the rear clutch hub the thrust rac...

Page 1320: ...drum the clutch assembly in the drum the clutch assembly and drum into the transaxle case at the same time thrust race and washer to back of the oil pump with the special tool to install a oil pump g...

Page 1321: ...rd value the idler shaft lock bolt lock to the specified torque of the lock plate prevent Idler shaft lock bolt the idler cover new Idler gear cover 8 spacer idler gear arid the idler shaft Caution As...

Page 1322: ...T R A N S A X L E OVERHAUL Transaxle Thrust bearina the thrust washer on the the clutch the end clutch hub on end clutch assembly thrust bearing with petrolatum a new to the end clutch assembly to th...

Page 1323: ...position shown the diagram and install the outer race the differential rear the to the specified torque the bolts remove the differential remove the if solder is repeat steps 51 using the solder with...

Page 1324: ...cified torque Differential front bearing cap mounting bolts 70 Nm 51 the differential cover and a new gasket Differential cover mounting bolts 11 Nm 8 the detent plate Detent plate mounting bolt 11 Nm...

Page 1325: ...e detent plate pin in the manual groove Temporarily install the valve body the oil tempera ture sensor and holder then tighten the to the specified torque A 1 8 bolt 40 mm 1 58 in body assembly mounti...

Page 1326: ...sition switch mounting bolts 11 Nm 8 Manual control bolt 19 Nm 14 the speedometer gear assembly Speedometer gear locking plate mounting bolt 5 Nm 4 the pulse generator A and B generator mounting bolts...

Page 1327: ...c Fit the special tool to the nut Turn outer cylinder the inner clockwise to lock the lock nut tool inner d Fit torque wrench to tighten it to a torque 10 Repeat this sequence special tool inner to 5...

Page 1328: ...with the tightened quickly or tightened quickly or wrench wrench g Remove the special tool for securing the piston the plug to the pressure outlet and tight en to the specified torque ring the servo...

Page 1329: ...6 Thrust race 7 Thrust bearing 8 Thrust washer 9 Rear clutch assembly 10 Thrust bearing 11 Rear clutch hub 12 Thrust bearing 13 Thrust race 14 band 15 drum 16 Snap ring 17 Center support s p r i n g...

Page 1330: ...ol lever 48 position switch PNP switch End clutch shaft 50 Bearing retainer 51 Thrust bearing 52 End clutch 53 Thrust washer 54 End clutch assembly 55 O ring 31 Oil dipstick 32 Oil filler tube 33 Snap...

Page 1331: ...al assembly 72 Center bearing retainer 73 Stopper ring 74 unit 75 Center bearing retainer 7 6 F r o n t 77 Rear output shaft 78 Transaxle case DISASSEMBLY 1 Clean away any sand mud etc adhered the tra...

Page 1332: ...older and remove the oil temperature sensor harness from the clamp the finger of the solenoid valve grommet push the grommet into the case and remove the valve body assembly out the oil temperature se...

Page 1333: ...AUTOMATIC OVERHAUL the cover the cover the differential the differential the differential bearing retainer differential end clutch cover holder and end the end clutch a...

Page 1334: ...SAXLE OVERHAUL Transaxle the thrust the end ditch hub thrust bearing NOTE It may be stuck to out the end the idler gear mounting bolts then the idler gear cover and gasket the bolt stopper and the bol...

Page 1335: ...AUTOMATIC TRANSAXLE OVERHAUL Transaxle the tool pull the idler remove the idler gear and inner the spacer the oil pump installation the special tool remove the oil thrust washer TSB Revision...

Page 1336: ...Transaxle Thrust bearina the input shaft and remove the front clutch assembly and rear clutch assembly together thrust bearing the clutch hub NOTE The thrust race may be stuck to clutch hub thrust be...

Page 1337: ...AUTOMATIC TRANSAXLE O VERHAUL the band the servo coyer snap ring Then the servo switch the special tool push in the remove the snap ring the servo piston the anchor rod TSB Revision...

Page 1338: ...AUTOMATIC TRANSAXLE OVERHAUL Transaxle the plug then remove the exhaust plug the snap ring the special tool remove the center the reverse sun gear forward gear to gether the assembly TSB Revision...

Page 1339: ...ake discs and brake plates the and the rear bearing __ 49 the snap ring and then remove output flange assembly the output bearing then remove the output bearing retainer and outer a rod 8 mm in in dia...

Page 1340: ...ainer and race the center bearing remove the ring and put a puller or similar tool in the viscous pull out the viscous the front bearing retainer bolt Then screw a bolt into the threaded hole the fron...

Page 1341: ...AUL Transaxle 59 I I I front I a sliding or tool remove race the oil REASSEMBLY 1 Using the special tool install the oil differential bearing retainer and transaxle case 2 Using the special tool insta...

Page 1342: ...emove the front bearing retainer 8 Remove the outer race from the front bearing and remove the solder If the solder does not break per form the work in steps 5 8 with large solder Measure the thicknes...

Page 1343: ...l install the outer race in the bearing retainer the center bearing retainer stopper bearing retainer stopper bolt 5 Nm 4 the center bearing retainer so the projection of the stopper bolt fits in the...

Page 1344: ...d remove the solder If the solder is repeat steps using with of 3 mm in Measure the thickness of the crushed with a micrometer and select a spacer with thickness that will provide the standard value f...

Page 1345: ...VERHAUL I the retainer 15 the heads the I i i _ I a coating of petrolatum to thrust bearing and attach to the carrier the planetary carrier the forward sun gear thrust race thrust bearing and reverse...

Page 1346: ...AUTOMATIC TRANSAXLE OVERHAUL both sun assembled in the previous into the planetary carrier the reaction brake and brake TSB Revision...

Page 1347: ...0 2 596 54 7 2 126 1 8 48 9 1 925 37 0 1 457 1 1 2 1 4 2 2 2 4 48 1 1 906 34 4 1 354 42 6 1 677 28 0 1 102 54 0 2 126 38 7 1 524 1 6 52 0 2 047 36 4 1 433 45 0 1 772 28 0 1 46 0 1 811 31 1 220 0 8 52...

Page 1348: ...t to the center support the special tool on the center support install 2 new O rings and push into the transaxle case Caution Coat the O rings with automatic and align the oil holes 2 Do not move the...

Page 1349: ...od the servo piston and sleeve Caution The seal ring alignment hole of the servo piston must not overlap the oil filler port indicated by the arrow in the diagram the special tool to push in the servo...

Page 1350: ...AUL Transaxle thrust bearing and thrust rear clutch the rear clutch assembly and the front assembly thrust bearing on the rear clutch hub I the rear clutch hub on the thrust race on the end of the rea...

Page 1351: ...aring in the the clutch assembly in the __ the clutch assembly and drum into transaxle case at the same time I thrust race and thrust washer of the oil pump with petrolatum the special tool to new and...

Page 1352: ...mm in the spacer idler and then insert the idler shaft Caution Assemble so that the groove on idler gear faces backward the idler shaft lock together lock to the specified torque Bend the three finge...

Page 1353: ...ATIC TRANSAXLE the thrust washer on the return spring clutch the end clutch hub on the thrust bearing to the end of the hub with petrolatum the end clutch assembly a new O ring the end clutch TSB Revi...

Page 1354: ...r race the differential rear bearing retainer and tighten the bolts to the specified torque the bolts remove the differential bearing retainer and remove the solder If the crushed repeat steps using t...

Page 1355: ...hten the the specified torque Differential front bearing cap mounting 70 Nm 51 the differential cover and a new gasket Differential the detent Detent plate mounting bolt 11 Nm 8 a new O ring on the ma...

Page 1356: ...late pin in the manual valve groove Temporarily install the valve body the oil ture sensor and holder then tighten mounting bolts to the specified torque A bolt 18 mm in bolt 25 mm in bolt 40 mm 1 57...

Page 1357: ...utral position switch mounting bolts Nm 8 Manual control lever 19 the speedometer gear Speedometer gear N m 4 the servo the pulse A and generator mounting bolts Caution Install the black on the output...

Page 1358: ...case do not apply en by hand TSB Revision b Loosen the lock nut until it reach the V groove in the the special tool inner nut c Fit the special tool outer to lock nut Turn the outer cylinder and the...

Page 1359: ...t may turn with the adjusting rod tightened quickly with a socket wrench or torque wrench g Remove the special tool for securing the piston Install the plug to the Low Reverse pressure outlet and tigh...

Page 1360: ...g reassembly 2 N m I 8 I Disassembly steps 1 O ring 2 Reaction shaft support 3 Steel ball 4 Drive gear 5 Driven gear 3 6 Seal ring 7 Oil seal 8 pump housing 9 Snap ring 10 Oil seal DISASSEMBLY SERVICE...

Page 1361: ...the five bolts by fingers 2 Insert the special tool Guide Pin oil pump bolt hole and tighten the peripheries of the and housing with the special tool Band to locate the support and housing 3 Tighten...

Page 1362: ...ps 1 Snap ring 2 Clutch reaction plate 3 Clutch disc 4 Clutch plate 5 Clutch pressure plate 8 Snap ring 7 Return spring 8 Front clutch piston 9 10 D ring D ring 11 Front clutch retainer TSB Revision L...

Page 1363: ...the cooling efficiency of the plate and disc Plate No 4 Plate No 2 ring Clutch discs 2 Install the innermost plate droops directed as shown in the Plate No Thickness mm in 1 5 0 2 2 3 2 2 Position the...

Page 1364: ...TRANSAXLE Rear DISASSEMBLY AND Disassembly steps 1 Seal ring 2 input shaft 3 4 5 Snap ring Thrust race 6 7 Seal ring 8 Snap ring Clutch disc plate 10 Clutch Clutch 12 13 Snap 14 15 piston 1 6 1 7 TSB...

Page 1365: ...ir missing tooth portions A in the illustration in alignment NOTE This design helps automatic transmission fluid escape and improve the cooling efficiency of the plates and disc 2 Install the clutch r...

Page 1366: ...AUTOMATIC TRANSAXLE Rear INPUT SHAFT INSTALLATION 1 Install the input shaft with one of oil aligned with the punch mark on the rear TSB Revision...

Page 1367: ...CLUTCH DISASSEMBLY AND REASSEMBLY 11 8 Disassembly steps 1 Seal ring 2 Snap ring 3 Clutch reaction plate 4 Clutch disc 5 Clutch plate 8 Return Spring 9 End clutch 10 Oil seal 11 D ring 12 End clutch...

Page 1368: ...CE POINTS SNAP RING INSTALLATION 1 Using the special tool fit the snap ring Caution Make sure that the snap ring is fitted in position in the groove SNAP RING SELECTION 1 Check clearance between the s...

Page 1369: ...parts with automatic 6 I Disassembly steps 1 Thrust bearing 2 Rivet 3 Wave washer 4 One way clutch outer race End Planetary carrier POINTS B E A R I N G 1 the only one short not and lose the 17 rolle...

Page 1370: ...he stopper plate claw is not at the groove in the one way clutch outer race 2 Using a pin punch drive out the REASSEMBLY SERVICE B E A R I N G 1 Install a new thrust bearing car r sure that it fits co...

Page 1371: ...tted in the hole of the rear thrust plate when the pinion shafts is inserted ONE WAY CLUTCH INSTALLATION 1 Push the one way clutch into the sure that arrow on the outside inside diameter of cage is di...

Page 1372: ...p ring 2 Stopper plate 3 Bearing 4 Bearing 5 drive 6 Snap ring 7 Output flange 8 gear DISASSEMBLY SERVICE POINT TRANSFER DRIVE GEAR REMOVAL 1 Using the special tool remove the transfer drive gear toge...

Page 1373: ...GEAR BEARING INSTALLATION 1 Using the special tool press fit the bearings into both sides of the transfer gear 2 Using the special tool install the transfer drive gear to the output flange SNAP SELECT...

Page 1374: ...s with automatic Disassembly steps 1 Bolt 2 Differential drive gear 3 Ball bearing 4 Taper roller bearing 5 Lock pin 6 Pinion shaft Pinion 8 Washer 9 Side gear 10 Spacer 11 Differential case DISASSEMB...

Page 1375: ...1 Fit the spacer to the back face of gear then install the gear into the differential case 2 Fit a washer to back of the pinion two pinions at the same time into position to gear pinion shaft 4 Measur...

Page 1376: ...k pin lower than the the differential case flange 3 Press fitting load is over ROLLER BEARING INSTALLATION Using the special tool the into both sides of the differential case BEARING INSTALLATION BOLT...

Page 1377: ...AUTOMATIC TRANSAXLE S E R V O I DISASSEMBLY AND REASSEMBLY Disassembly steps 1 O ring 2 servo sleeve 3 D ring 4 Seal ring 5 Lock nut 6 servo rod 7 servo piston Revision...

Page 1378: ...AUTOMATIC TRANSAXLE Low reverse Brake LOW REVERSE BRAKE DISASSEMBLY AND REASSEMBLY 1 TSB Revision Disassembly steps 1 Low reverse brake piston 2 D ring 3 D ring 4 Center support...

Page 1379: ...EAR DISASSEMBLY AND REASSEMBLY Disassembly steps 1 E clip driven gear Sleeve I REASSEMBLY SERVICE POINT SPEEDOMETER DRIVEN GEAR INSTALLATION Apply gear oil sparingly to the speedometer driven gear sha...

Page 1380: ...RANSAXLE Transfer Shaft TRANSFER SHAFT DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Taper roller bearing 2 Transfer shaft 3 Taper roller bearing Revision DISASSEMBLY SERVICE POINT TAPER ROLLER BEARI...

Page 1381: ...AUTOMATIC TRANSAXLE Transfer REASSEMBLY SERVICE I I INSTALLATION TSB Revision...

Page 1382: ...rter clutch solenoid 4 control valve control valve Valve stopper 8 N D control sleeve 9 N D control valve 10 Lower valve body sub assembly 11 Lower separating plate 12 Nut 16 5 5 Nm 4 13 Jet 14 Relief...

Page 1383: ...onverter control spring 29 Torque converter control valve 30 Adjusting screw 31 Regulator spring 32 Regulator valve 33 Shift control spring 34 Stopper plate 35 Shift control plug 36 Rear clutch exhaus...

Page 1384: ...d clutch spring 52 End clutch valve 53 End cover 54 converter clutch control 55 Torque converter clutch control 56 Torque converter clutch control spring 57 N R control valve 58 N R control spring 59...

Page 1385: ...Y INSTALLATION 1 the special tool the upper separating plate and intermediate plate with eight bolts Then remove the special FILTER STEEL BALL RELIEF SPRING INSTALLATION 1 Install the oil filter two s...

Page 1386: ...then remove the special tool SOLENOID VALVE 1 Install the solenoid valves as shown Solenoid valve Shift control solenoid valve A SCSV A Wire color Orange Shift control solenoid valve Yellow Torque co...

Page 1387: ...sembly 1 Transfer driven gear 2 Taper roller bearing 3 Taper roller bearing 4 Bolt 5 Center differential flange 6 Spacer 7 Side gear front __ 10 Washer 11 Side gear 12 Clip 13 Spacer Center DISASSEMBL...

Page 1388: ...n the center differential case 2 While pressing the pinion shaft select the thickest to gently rotate the pinion 3 Install the side gear front spacer and center differential flange and tighten the bol...

Page 1389: ...AUTOMATIC TRANSAXLE Cent 1 Using the special the center flarige INSTALLATION 1 Using the special the taper roller bearing on the transfer driven gear TSB Revision...

Page 1390: ...3 Front output shaft 2 3 2 DISASSEMBLY SERVICE POINT TAPER ROLLER BEARINGS REMOVAL 1 Using the special tool remove the taper roller bearings on both ends of the front output shaft REASSEMBLY SERVICE P...

Page 1391: ...l during reassembly Disassemblv 1 Cover 2 Cover gasket 3 Extension housing assembly 4 Oil guide 5 Transfer case sub assembly 6 case sub REASSEMBLY SERVICE POINTS CASE ADAPTER ASSEMBLY INSTALLATION App...

Page 1392: ...ssembly to the transfer case sub assembly and tighten the mounting bolts to specified torque Transfer case adapter mounting bolt 39 3 Using the special tool turn the drive bevel gear shaft one turn in...

Page 1393: ...e drive gear driven is as specified Standard value Bevel gear m m to the adapter surface and install the housing Mitsubishi or equivalent NOTE Squeeze out sealant from the tube uniformly and ously in...

Page 1394: ...contact pattern gear height is too large Cause The driven bevel is too close to the drive bevel gear Remedy Use thicker gear mount to separate the driven bevel gear more drive bevel gear 3 Tooth prod...

Page 1395: ...spacer that is in use with one that is one rank thicker and replace the drive bevel preload adjusting spacer that is in use with one that is one rank thinner l When the driven bevel gear height is too...

Page 1396: ...ut 2 Driven bevel gear 3 Taper roller bearing 6 Outer race 7 Outer race 8 Transfer case adapter Taper roller bearing DISASSEMBLY SERVICE POINTS LOCK NUT REMOVAL 1 Unlock the lock nut Straighten the be...

Page 1397: ...dapter 2 4 DRIVEN GEAR ASSEMBLY Using a press the bevel gear OUTER RACE REMOVAL 1 Remove the outer race lightly with a screwdriver etc TAPER ROLLER BEARING REMOVAL REASSEMBLY SERVICE POINTS TAPER ROLL...

Page 1398: ...ard value Nm 3 If the rotating drive torque is outside standard range adjust using adjusting spacers TAPER ROLLER BEARING DRIVEN BEVEL GEAR 1 Attach the driven bevel gear to the transfer and then alig...

Page 1399: ...A U T O M A T I C T R A N S A X L E TRANSFER CASE DISASSEMBLY AND 39 Nm 2 9 Disassembly steps 1 Transfer cover 2 O ring 3 Spacer 4 race 5 Drive bevel gear shaft 6 Outer race 11 roller 12 TSB...

Page 1400: ...AUTOMATIC TRANSAXLE Case 1 II I 8 REASSEMBLY SERVICE ROLLER BEARING INSTALLATION DRIVE BEVEL GEAR 1 Install the drive bevel gear to the shaft with their matching marks in TSB Revision...

Page 1401: ...vel gear shaft SPACER SELECTION 1 Use the existing spacer to assemble the transfer case 2 Using the special tool check that the bevel gear rotating drive torque is within standard range Standard value...

Page 1402: ...1 Air breather 2 Dust seal guard 3 Oil seal 4 Extension housing 2 REASSEMBLY SERVICE POINTS OIL SEAL INSTALLATION AIR BLEEDER INSTALLATION 1 Apply sealant to the outer diameter of the air bleeder and...

Page 1403: ...TS DIFFERENTIAL 77 SPECIFICATIONS 4 2 General Specifications 4 GENERAL INFORMATION 5 INPUT CLUTCHES 49 Service Specifications 4 Torque Specifications 5 OIL PUMP 73 TRANSAXLE 13 OIL PUMP SEAL 72 VALVE...

Page 1404: ...adaptive Adaptive are those which perform their functions based on real time feedback sensor The t axle uses hydraulically applied clutches to shift a planetary gear train SECTIONAL VIEW Case c l u t...

Page 1405: ...lutch 3 2 4 clutch 4 clutch 5 Overdrive clutch 6 Reverse clutch 7 Torque converter Bypass 11 Torque converter 12 Torque clutch control 13 Switch valve 14 Low reverse converter solenoid 15 2 4 clutch l...

Page 1406: ...NS pump gear Output gear bearing preload mm in Output gear turning drive torque Nm Input shaft end play mm in Transfer shaft bearing end play mm in Differential bearing preload mm in I Differential si...

Page 1407: ...20 14 16 200 3 6 SEALANTS Oil pan Rear cover Rear cover bolts Differential cover Differential bearing retainer Differential bearing retainer bolts Extension S p e c i f i e d s e a l a n t Loctite 187...

Page 1408: ...ap ring For adjustment of reverse clutch clearance Thickness mm in Thickness mm in Thickness mm in Thickness mm in 1 56 1 80 2 05 2 30 Shim For adjustment of output gear bearing preload transfer shaft...

Page 1409: ...AUTOMATIC TRANSAXLE OVERHAUL SPECIAL TOOLS output bearing cup Installation and removal TSB Revision...

Page 1410: ...AUTOMATIC TRANSAXLE OVERHAUL Special Installation and removal of shaft ring output bearing cup T S B R e v i s i o n...

Page 1411: ...AUTOMATIC TRANSAXLE OVERHAUL T C clutch switch valve overdrive clutch TSB Revision...

Page 1412: ...gear remover TSB Revision...

Page 1413: ...AUTOMATIC TRANSAXLE Took Tool Removal of differential bearing bearing cup Adjustment of differential bearing Removal of transfer shaft bearing cone TSB Revision...

Page 1414: ...AUTOMATIC TRANSAXLE OVERHAUL Special Tool cone output bearing cone TSB Revision...

Page 1415: ...C TRANSAXLE OVERHAUL DISASSEMBLY Caution Do not intermix clutch discs or plates or might fall 1 Remove oil pan bolts 2 Remove oil pan 3 Remove oil filter 4 Remove valve body attaching bolts 18 TSB Rev...

Page 1416: ...valve body 7 Remove underdrive clutch clutch accumulator with and seal rings 8 Remove return spring and two rings from the and underdrive clutch accumulator 9 Remove the snap ring holding the accumula...

Page 1417: ...put shaft end play before disassembly Will usually indicate when a No 4 thrust plate is required except when major parts are No 4 thrust plate is the overdrive hub Attach a dial indicator to transaxle...

Page 1418: ...the weights of the pullers against the of the tools to loosen the pump on input while loosening pump o i l p u m p oil pump gasket TSB Revision...

Page 1419: ...needle bearing washer cooler No 1 caged needle input clutches assembly No 4 thrust plate and front sun gear and pull to carrier and rear assembly Remove No 6 needle bearing...

Page 1420: ...d No 7 needle bearing spring compressor Using the special tool compress the clutch retainer just enough to remove the snap ring Using a screwdriver remove the clutch retainer snap ring up clutch retai...

Page 1421: ...ck NOTE Tag clutch pack for reassembly identification tapered ring by prying with a as shown low reverse reaction plate one disc from low reverse clutch a screwdriver out the low reverse reaction flat...

Page 1422: ...ack NOTE Tag low reverse clutch pack for identification A U T O M A T I C T R A N S A X L E rear bolts rear cover holding transfer shaft gear with Holder loosen transfer shaft nut transfer shaft gear...

Page 1423: ...gear Using the appropriate wrench turn the center clockwise to remove gear transfer shaft gear and shim 42 Remove bearing cap retainer Bearing Puller and Button on transfer shaft gear bearing to remov...

Page 1424: ...TRANSAXLE OVERHAUL Transaxle Transfer shaft transfer shaft bearing snap Pliers transfer shaft with oil baffle and bearing cup from transfer shaft Bearing holding output gear with output gear bolt TSB...

Page 1425: ...lock washer Gear Puller with Bolts and Thrust Button to output gear Turn puller center bolt clockwise to remove gear output gear and shim Bearing and Gear Puller Button on output gear bearing to remo...

Page 1426: ...utton center bolt of Spring Compressor Spring Compressor Disc 0 to assemble low reverse spring compressor tool compressor tool as shown Compress low reverse piston assembly Position Spring Compressor...

Page 1427: ...out park rod bracket anchor shaft with hammer and drift Drift Park rod bracket anchor shaft guide bracket shaft and plug out guide bracket pivot with pliers pivot shaft bracket l Guide bracket assemb...

Page 1428: ...leeve Spacer I Stepped spacer spring Low reverse piston Lip seal Low reverse Screwdriver retainer screws l Guide bracket disassembled low reverse clutch piston screws low reverse piston retainer low r...

Page 1429: ...AUTOMATIC TRANSAXLE OVERHAUL out output a steel h a m m e r Drift bearing cup all the way Remover 1 TSB Revision...

Page 1430: ...l both output bearing Bearing and wrenches 2 Install low reverse clutch Be sure to align gasket holes 3 Install low reverse clutch piston retainer 4 install screws attaching low reverse clutch piston...

Page 1431: ...Install pivot shaft and guide bracket Caution Be sure that guide bracket split touch the rear of the case l Guide bracket disassembled l Guide bracket assembled 7 Install guide bracket anchor shaft an...

Page 1432: ...ol to transaxle as shown to compress low reverse piston assembly AUTOMATIC TRANSAXLE OVERHAUL 9 Install low reverse piston return spring snap ring with snap ring pliers NOTE Be sure to place the openi...

Page 1433: ...er 48 a 4 50 mm in test shim on the rear carrier assembly hub using grease to hold the shim in place output gear using Gear Installer and two output gear bolt to 271 Nm 200 while holding output gear w...

Page 1434: ...r e and Special Bolts and pull the gear while rotating back forth to ensure seating of the bearing output gear end play bearing end play has been determined refer to the Output Gear Bearing Shim for t...

Page 1435: ...3 54 0 97 3 50 holding output gear with Holder loosen output gear bolt and washer Gear Puller with Bolts and Thrust Button to output gear Turn putter center bolt clockwise to remove gear the test shi...

Page 1436: ...se a new retaining bolt when reassembling torque wrench check the turning torque should be between to 0 90 3 If the turning torque is too mm in thicker shim If the torque low install a 0 04 mm in thin...

Page 1437: ...4 New bearing output bolt to 271 Nm 200 holding output gear with Caution Always use new must not be reused transfer bearing press transfer using Installer Cap and Installer Adapter 44 oil baffle and...

Page 1438: ...ing 2 Transfer transfer shaft with transfer shaft bearing snap ring Snap Pliers transfer shaft gear bearing use Adapter and Installer Bar bearing press in using Installer Cap and Installer Adapter 48...

Page 1439: ...ng nut when reassembling Dial Indicator Set with Fixture and Special Bolts and pull the gear while rotating back and forth to ensure seating of the bearing rollers transfer shaft gear end play bearing...

Page 1440: ...0 33 I 0 36 4 34 0 38 I 0 41 0 43 4 26 0 46 4 22 0 48 4 22 A I 0 53 4 18 0 58 4 14 0 58 4 10 0 81 0 64 I 0 71 3 98 0 74 3 94 3 94 I I 3 79 3 81 3 84 3 86 I 3 91 3 78 3 94 3 74 3 97 3 74 3 99 3 70 1 0...

Page 1441: ...AUTOMATIC End play installed m m 1 1 7 1 19 3 50 1 22 3 46 1 24 3 46 1 27 1 30 3 38 iransfer shaft proper shim tranbfer and two wrenches I shaft nut and TSB Revision...

Page 1442: ...shaft gear with Holder Caution Always use new retaining nut Never reuse old retaining nut 52 Install rear cover NOTE Apply a inch wide bead of Loctite 18718 or equivalent as shown rear cover bolts lo...

Page 1443: ...ger and zero dial indicator Raise one clutch disc with a hook tool Read the dial indicator the proper low reverse reaction plate to achieve specification Low reverse clutch pack clearance is 1 04 to 1...

Page 1444: ...ll Note clutch retainer tab NOTE l Do not reuse the old snap ring l When installing a new position the snap ring ends as shown l Follow A sequence for best results clutch pack correct position of clut...

Page 1445: ...ess down on the clutch pack with finger and zero dial indicator Raise one clutch disc with a hook tool Read the dial indicator clutch pack clearance is 0 76 to 2 64 mm to inch If not within specificat...

Page 1446: ...completely seated Caution if view through input speed sensor hole is not as shown above the input assembly is not seated the oil pump O ring You can install and remove the oil pump and gasket very eas...

Page 1447: ...m to select proper if end play reading is 1 40 mm subtract end play specifications mm inch to 0 64 mm inch mm to 0 76 mm inch to inch test shim 0 76 mm to 1 27 mm to inch 0 81 mm inch 1 75 mm to 2 08...

Page 1448: ...AUTOMATIC cooler Caution cooler must If has clean old When end toward rear oil pump gasket o i l Caution Be sure oil pump Is attaching r e t u r n TSB Revision...

Page 1449: ...he snap the low reverse plug cover in place return spring and two seal rings from the overdrive and clutch accumulator pistons clutch accumulator and accumulator with springs and Seal rings detent as...

Page 1450: ...oil filter oil pan NOTE Apply a inch wide bead of 8718 oil pan bolts NOTE Use 18718 or equivalent TSB Revision...

Page 1451: ...cilitate disassembly and reassembly 1 Tap down reverse clutch reaction plate to or install snap ring 2 Using a screwdriver remove the reverse snap ring 3 Loosen reverse clutch reaction plate by prying...

Page 1452: ...rive shaft assembly and OD clutch pack assembly Overdrive shaft 7 R e m o v e 8 Remove overdrive reverse clutch snap with a screwdriver 9 overdrive shaft assembly overdrive clutch Tie plates and toget...

Page 1453: ...No 3 thrust washer 5 tabs not I clutches reaction plate tapered snap ring clutch reaction ll Remove No 3 and 4 thrust plates shaft assembly shaft N o 2 n e e d l e I tapered snap ring Do not scratch...

Page 1454: ...ewdriver clutch clutch plates and discs Tie together so plates and location 19 Remove snap ring with return spring with Spring press ram Caution Compress return spring just to snap ring nap ring Pisto...

Page 1455: ...aft and assembly Input clutches retainer Overdrive reverse Overdrive reverse piston input hub ring with snap ring pliers on input and hub assembly with a plastic hammer input shaft hub assembly overdr...

Page 1456: ...am compress return spring just enough to remove snap ring Snap ring Return spring I snap ring with a screwdriver while compressing return spring with Disc press ram snap ring and return spring TSB Rev...

Page 1457: ...put shaft snap ring Replace lip seals and O rings Do not scratch bearing surface 3 Install return spring and snap ring Replace O ring and lip seal of piston While compressing return spring with Disc a...

Page 1458: ...haft hub to align overdrive reverse piston and push down by hand 7 Install input hub tapered with snap ring pliers 8 Install underdrive clutch piston 9 Install piston return spring Installer Coat Inst...

Page 1459: ...ive clutch disc I spring with Spring and arbor press ram install snap ring pliers Caution Compress return spring install snap ring underdrive clutch pack excluding one clutch disc underdrive clutch re...

Page 1460: ...within one finger of input clutch hub sure seated by pushing with into all the way around Caution Do not scratch reaction plate dial indicator set and steel as shown for checking clutch pack with fin...

Page 1461: ...down pressure down overdrive reverse pressure plate with Spring and arbor press ram install flat snap ring Caution Press down just enough to expose snap ring groove overdrive clutch pack clearance The...

Page 1462: ...e down reverse clutch snap ring with a screwdriver reverse clutch reaction plate by prying up at two locations with screwdrivers to seat snap ring reverse clutch pack clearance by ifting clutch reacti...

Page 1463: ...m in I All clutch clearances in the input clutch retainer have now been checked and approved To complete the of the input clutch retainer the reverse clutch and the overdrive clutch must be removed fr...

Page 1464: ...note 3 tabsj underdrive shaft assembly No 3 thrust washer No 3 thrust plate onto overdrive shaft assembly with dabs of petrolatum overdrive shaft assembly Now that both shaft assemblies and thrust wa...

Page 1465: ...AUTOMATIC OVERHAUL Input Clutches of input clutch assembly is now complete TSB Revision...

Page 1466: ...hen each part should be washed suitable dried by compressed air Do not All mating surfaces in the transaxles are accurately machined therefore careful of all parts must be to avoid nicks or burrs all...

Page 1467: ...e body attaching bolts 18 I Manual shaft seal 5 Using a screwdriver push park sprag rollers away from guide bracket 6 Remove valve body 7 Remove transaxle range sensor screw 8 Remove manual shaft seal...

Page 1468: ...sensor up the manual shaft and remove lO Remove accumulator retaining plate screws 2 Remove the upper valve body ll Remove separator plate from transfer plate Remove O D clutch check ball and oil scre...

Page 1469: ...T C control valve spring plug Regulator valve spring 76 retainer plate with 6 Remove torque converter control valve and torque converter clutch valve retainer plate using Installer Remover 17 15 Remo...

Page 1470: ...SPRINGS AND VALVES IDENTIFICATION Roostercomb Manual shaft Retainer 4 Rivet Solenoid switch valve Retainer T C control valve Torque clutch valve Manual valve Insulator check ball accumulator Valves r...

Page 1471: ...plate using 7 2 Install torque converter control valve and torque converter clutch valve Install dual retainer plate with Installer Remover 6 3 Install check balls and retainers 4 Install thermal val...

Page 1472: ...AUTOMATIC TRANSAXLE OVERHAUL Body accumulator plate 2 Manual shaft seal 7 Slide transaxle range down the manual shaft 8 Install manual shaft seal Install transaxle range screw detent as shown...

Page 1473: ...I 11 Install valve body a screwdriver push guide bracket away to park sprag rollers valve body attaching bolts 18 oil filter oil pan NOTE Apply a inch bead of 18718 or equivalent TSB Revision...

Page 1474: ...oil pan bolts NOTE Use Loctite or equivalent bolt 233101800 6 DISASSEMBLY 1 Remove oil pump seal with Seal Remover REASSEMBLY Install new oil pump seal with 3 and Adapter 52 TSB Revision...

Page 1475: ...Oil Pump DISASSEMBLY Remove pump 2 Installer Puller Set on bolts holes 3 Strike the weights of the pullers against bolt heads of the tools to loosen the in on shaft while loosening pump 4 Remove oil p...

Page 1476: ...nd reaction shaft 8 Remove the oil pump outer gear and oil pump inner gear from the pump housing If the gears are to be reused place mark on the to ensure that the mounting direction will be correct g...

Page 1477: ...mp inner If is than the standard the pump Standard value Side between outer oil pump inner 3 Measure the pump outer gear and the pump housing pocket If the than the standard value replace oil pump Sta...

Page 1478: ...AUTOMATIC TRANSAXLE OVERHAUL Oil Pump 6 Install the oil pump O ring 7 Install pump gasket 8 Install oil pump 9 Install pump attaching bolts TSB Revision...

Page 1479: ...rential cover DISASSEMBLY Remove oil seal from housing 2 Remove differential cover 3 Remove differential cover 4 Remove differential retainer bolts 5 Loosen differential bearing retainer with Walk ret...

Page 1480: ...ring 7 Remove bolts from extension housing 8 Loosen extension housing with Remover Walk housing out of transaxle case using special tool 9 Remove extension housing differential from differential case...

Page 1481: ...l from ring gear side Bearing and Gear remover and ring gear bolts pinion shaft roll pin by tapping out with a hammer and steel punch pinion shaft pinion gears side gears and tabbed thrust washers by...

Page 1482: ...AUTOMATIC TRANSAXLE OVERHAUL Differential oil seal from differential bearing with a small chisel and hammer bearing cup with Cup Remover TSB Revision...

Page 1483: ...the and to 28 Nm 20 Position transaxle assembly with oil facing Rotate ring gear one revolution to seal differential bearings I 4 a dial indicator set to and the dial indicator Place a large screwdriv...

Page 1484: ...AUTOMATIC TRANSAXLE DIFFERENTIAL BEARING SHIM CHART 7 Remove bolts from extension TSB Revision...

Page 1485: ...transaxle using special tool 9 Remove extension housing differential retainer bolts differential bearing retainer Remover Walk retainer out of transaxle using special differential bearing retainer be...

Page 1486: ...Checking Tool and a torque wrench to check differential bearings turning torque The turning torque should be 0 56 to 2 03 5 to 18 in If the turning torque is too high install a 0 05 mm in thinner shi...

Page 1487: ...Adapter check side gear end play at ring gear side and differential case side NOTE Side gear end play each side must be 0 025 to 0 330 mm to inch Four select thrust are available 0 81 0 93 1 07 mm and...

Page 1488: ...asher Pinion Hammer case tc Torque wench pinion gears by rotating pinion gears to opening in case must properly pinion shaft Steel punch pinion shaft roll pin by tapping and steel punch ring gear bolt...

Page 1489: ...l bearing and then using Cap and Adapter 44 extension NOTE Apply an inch wide bead of Loctite 18718 or equivalent bolts to extension housing differential bearing retainer NOTE Apply an inch wide bead...

Page 1490: ...VERHAUL Differential inch bead Differential cove differential retainer bolts differential cover NOTE Apply an inch wide 1 equivalent differential cover _ new oil seal using Installer arid Installer Ad...

Page 1491: ...PROPELLER SHAFT CONTENTS ADHESIVE 2 SERVICE 2 GENERAL INFORMATION 2 SPECIAL 3 LUBRICANTS 2 TROUBLESHOOTING 3...

Page 1492: ...tween center points of each joint SERVICE SPECIFICATIONS Items Standard value Limit Journal end play mm in Propeller shaft Front 0 6 or less Dial indicator reading mm in Center 0 6 or less Rear 0 6 or...

Page 1493: ...bjects from getting into the transfer Inner shaft remover Inner shaft and seal plate removal and installation 25100070020 Symptom Noise at start Noise and vibration at high speed Probable cause Remedy...

Page 1494: ...PROPELLER Propeller PROPELLER SHAFT REMOVAL AND INSTALLATION 2 22 6 22 11 Nm 8 TSB Revision Removal steps 1 Self locking nut 2 Insulator 3 Spacer shaft assembly Heat protector...

Page 1495: ...ure that the boot is not through pinching NOTE Damage to the boot can be and the Work will be easier if a piece of cloth or material is inserted in the boot 2 Use special tool a to let objects SPACER...

Page 1496: ...amage or cracks l Check the propeller shaft for damage or cracks l Check the propeller for or l the universal joints operation in all directions l Check the center bearing for movement l Check the cen...

Page 1497: ...Journal bearing 3 Journal 4 Flange yoke 5 Sleeve yoke assembly 6 Front propeller shaft 7 Self locking nut 8 Center yoke assembly Snap ring 12 Boot band 13 Lobro joint assembly 14 Rubber packing 15 Lo...

Page 1498: ...POINTS not apply excessive grease otherwise fitting of bearing caps and errors the selection of snap rings may result Rubber mount joint assembly Grease Repair kit grease Grease Repair kit grease 1 5...

Page 1499: ...L Use the special tool to force out the journal bearings from the yoke and propeller shaft Caution Do not tap the journal bearings or the propeller shaft won t function well CENTER YOKE REMOVAL 1 Plac...

Page 1500: ...al positions 4 Remove the inner race with cage from the center propeller shaft by using a puller commercially available NOTE When changing the grease on the Lobro joint assembly wipe off the grease an...

Page 1501: ...ration 3 Align the mating marks on the companion flange rear propeller shaft 4 Press fit the center bearing assembly with the companion flange while tightening the self locking nut JOINT INSTALLATION...

Page 1502: ...sitions of inner as shown in the illustration 4 Install the remaining balls in their positibns 5 Check outer race rotates on the inner race smooth I 6 Apply the specified grease to the Lobro joint ass...

Page 1503: ...e center bearing assembly to the center propeller shaft as shown in the illustration 3 Align the mating marks on the center yoke and center propeller shaft 4 Press fit the center bearing assembly with...

Page 1504: ...oove wall of the yoke with a feeler If the clear ance exceeds the standard value the snap rings should be replaced Standard value A mm Snap ring thickness mm in color 1 28 1 3 1 Yellow 1 34 1 37 1 4 0...

Page 1505: ...IVE SHAFT 10 ON VEHICLE SERVICE 5 Hub Replacement 5 DRIVE SHAFT 19 Wheel Bearing End Play Check 5 FRONT HUB ASSEMBLY 6 SERVICE SPECIFICATIONS 2 GENERAL INFORMATION 2 SPECIAL TOOLS 3 KNUCKLE 8 TROUBLES...

Page 1506: ...ve shaft hub Standard value Limit Setting of boot length mm in Opening dimension of the When the band small is 2 9 special tool mm crimped in When the band big is crimped 3 2 Crimped width of the band...

Page 1507: ...SPECIAL TOOLS FRONT AXLE Special Steering linkage puller Front hub remover and torque measureme 460 TSB Revision...

Page 1508: ...26 4 FRONT AXLE Special Shimmy or abnormal wear of drive shaft unction of front suspension and steering TSB Revision...

Page 1509: ...the axial direction Limit 0 05 mm in 4 If end play exceeds the replace the front hub assem bly HUB BOLT REPLACEMENT 1 Remove the caliper assembly and secure it with wire so that it does not fall 2 Re...

Page 1510: ...n 6 Upper 7 Front hub The front hub assembly not be disassembled REMOVAL SERVICE POINTS DRIVE SHAFT REMOVAL CALIPER ASSEMBLY REMOVAL Secure the removed caliper so that it does not fall ARM BALL JOINT...

Page 1511: ...he hub rotation breakaway torque should be within the limit value range and there should be no engagement or feeling of roughness Nm 0 0 0 0 0 3 2 0 FRONT HUB ASSEMBLY REMOVAL Shift the knuckle to the...

Page 1512: ...d Refer to All Removal steps 1 Dust shield 2 Cotter pin 6 Connecting bolt fork and 3 Tie rod end ball joint and lateral lower 7 Knuckle connection 4 Compression lower arm ball joint Caution and knuckl...

Page 1513: ...AL LOWER ARM BALL JOINT AND KNUCKLE DISCONNECTION Caution 1 Use the special tool to loosen the tie rod end mounting nut Only the nut do not remove it from the ball joint 2 Support with a cord etc to p...

Page 1514: ...and knuckle connection 4 Stabilizer link ball joint and damper fork connection 7 Caution Compression lower arm ball joint and connection Drive shaft 5 Damper fork l Indicates parts which should be tem...

Page 1515: ...ONNECTION Caution 1 Use the special tool to loosen the tie rod end mounting nut Only loosen the nut do not remove it from the ball joint 2 Support the special tool with a cord etc to prevent it from c...

Page 1516: ...the drive shaft nuts make sure there is no load on the wheel bearings 3 If the position of the cotter pin holes not match tighten the nut up to 255 Nm in maximum 4 Install the cotter pin in the first...

Page 1517: ...sassembly steps 1 T J boot band large 2 T J boot band small 3 T J case 4 5 ring band 9 Dynamic damper T J repair kit boot repair kit 10 assembly 11 band small 12 band large 1 3 b o o t Caution Do not...

Page 1518: ...LE Drive Shaft LUBRICANT POINTS TSB Revision Grease Repair kit grease Engine Non turbo 110 3 88 oz Engine Turbo and Engine 130 4 59 oz shaft joint uses special grease Do mix old and new or different t...

Page 1519: ...2 Use care in handling so as not damage the drive shaft BOOT REMOVAL 1 Wipe the grease off of the spline portion 2 Remove the boot NOTE If the boot is reused wrap plastic tape around the shaft spline...

Page 1520: ...long the protruding and install it so that there is some A the other side 5 Use the special tool to crimp the B J boot Caution 1 Hold the drive shaft perpendicularly and use the special tool to crimp...

Page 1521: ...rotruding portion and install it so that there is clearance D along the other side the special tool to crimp the B J boot band large in the same way as the step 5 that the crimped width E is within th...

Page 1522: ...use respectively at the joint and inside the boot Caution The drive shaft joint uses special Do not mix old and new or different types of T J BOOT BAND BOOT LARGE INSTALLATION Set the T J boot bands...

Page 1523: ...ion 4 Stabilizer link ball joint and damper fork connection 5 Damper fork 6 Lateral lower arm ball joint and knuckle connection 7 Compression lower arm ball joint and knuckle connection 8 9 Drive shaf...

Page 1524: ...1 Use the special tool to loosen the tie rod etid nut Only loosen the nut do not remove it from the ball joint 2 Support the special tool with a cord etc prevent it from coming off DRIVE SHAFT AND INN...

Page 1525: ...shaft Caution Before securely tightening the drive shaft nuts sure there is no load on the wheel bearings 3 If the position of the cotter pin holes does not match tighten the nut up to 255 Nm 188 in...

Page 1526: ...large 2 T J boot shaft assembly Seal plate 6 Inner 7 Bracket assembly 8 Dust seal outer 9 Dust seal inner 10 Center bearing 11 Center bearing bracket 12 Bracket assembly repair kit 13 ring 14 assembly...

Page 1527: ...seal inner oz Dust seal outer oz grease 105 3 70 oz The drive shaft joint uses grease Do not mix old new different Grease Repair kit grease 95 3 35 oz Caution The drive shaft joint uses special grease...

Page 1528: ...y together with the seal plate from the T J case 2 Use the special tools to remove the inner shaft from the bracket CENTER BEARING REMOVAL SNAP RING SPIDER ASSEMBLY REMOVAL 1 Remove the snap ring from...

Page 1529: ...ine part on the drive shaft and then install the B J boot band small and 2 smaller side of the B J boot band so that one shaft groove can be seen 3 Turn the adjusting bolt of the special tool to adjus...

Page 1530: ...2 9 mm in is 2 6 mm in When less than 2 4 in Remove the B J boot dimension W of step calculated by the following a new B J boot band to to 5 5 5 mm in Example If is 2 3 is 3 2 mm in 7 Check that the B...

Page 1531: ...0 to the value calculated equation and repeat step 12 5 8 mm in Example If E is 2 9 mm in is 2 9 mm in When less than 2 4 mm in Remove the B J boot band readjust the dimension W of step 10 to the valu...

Page 1532: ...eal so that its surface runs even with that of the bracket 3 Apply multi purpose grease to the lip of each dust NOTE When applying grease make to anything outside the INNER SHAFT INSTALLATION CASE INS...

Page 1533: ...inside the boot and then tighten the T J boot band securely Standard value A 80 3 mm 3 15 in INSPECTION 26100280076 l Check the drive shaft for damage bending or corrosion l Check the inner shaft for...

Page 1534: ...NOTES...

Page 1535: ...Level Check 16 Hub Bolt Replacement 17 Limited Slip Differenital Condition Check VCU type 17 Rear Axle Total Backlash Check 16 Wheel Bearing End Play Check 17 SERVICE SPECIFICATIONS 10 SPECIAL TOOLS 1...

Page 1536: ...e same type of double row angular contact ball bearing as does the front axle On ABS a ABS rotor for detecting the speed is located on the and sensor is located on the knuckle Rear rotor Unit Oil seal...

Page 1537: ...he play exceeds the limit value replace the hub assembly REAR HUB ROTARY SLIDING RESISTANCE CHECK 27100110061 1 Release the parking brake 2 Remove the brake drum 3 For vehicles with rear disc brake re...

Page 1538: ...sc 3 For vehicles with disc brakes assembly 4 Pull the hub bolt using the special NOTE For vehicles with drum near the retainer in order to maintain C a u t i o n Be sure to tie the cord of a nearby p...

Page 1539: ...oval steps 1 Rear wheel speed sensor Vehicles with Refer to GROUP Wheel Speed Sensor 2 Caliper assembly 3 Brake drum 4 Brake disc 5 Clip mounting bolt 6 Shoe and lining assembly Refer GROUP 36 Parking...

Page 1540: ...ICE CALIPER ASSEMBLY Remove the caliper assembly it Socket ABS ROTOR TSB Revision INSTALLATION SERVICE POINT ROTOR INSTALLATION INSPECTION l Check the oil seal for crack or damage l Check the ABS roto...

Page 1541: ...al and Installation Refer to P 27 5 85 99 71 2 Removal steps 1 Trailing arm connection 2 Lower arm connection 3 Toe control arm ball joint and knuckle connection 4 Shock absorber connection 5 Upper ar...

Page 1542: ...REAR AXLE Knuckle REMOVAL SERVICE POINT TOE CONTROL BALL AND Caution 1 Use the special to nut Only loosen the do the ball joint 2 the special tool with a it from coming off TSB Revision...

Page 1543: ...l differ Limited slip Limited slip differ ential ential ential VCU type Reduction gear type Hypoid gear Hypoid gear Hypoid gear Hypoid gear Reduction ratio 3 545 3 307 Differential Side gear Straight...

Page 1544: ...a n t API classification or higher T J assembly B J assembly 95 3 35 oz Conventional differential 105 3 70 oz Limited slip differential 75 2 65 oz SAE SAE Repair kit grease Items Threaded holes of the...

Page 1545: ...REAR AXLE Special Tools Preload socket General service tool Prevention of entry of foreign objects into the differential General service tool Working base adapter TSB Revision...

Page 1546: ...REAR AXLE Tools seal installer set l Differential side oil press fitting Use Side bearing puller race removal Oil seal installer TSB Revision...

Page 1547: ...REAR AXLE Special Tools eanng Side gear holding tool Side gear holding tool TSB Revision...

Page 1548: ...place Replace TSB Revision Gear Insufficient gear oil quantity Improper drive gear tooth contact adjustment Replenish Adjust or replace Incorrect drive gear backlash Adjust I I I I Improper drive pini...

Page 1549: ...bable cause Remedy Damaged broken and or seized of Replace the drive gear and drive pinion Damaged broken and or seized drive pinion bear ings Damaged broken and or seized side bearings Damaged differ...

Page 1550: ...Manually turn the propeller shaft as far as it will go and make mating marks flange dust cover and the differential carrier 3 Manually turn the propeller shaft counterclockwise as far as it will go an...

Page 1551: ...s of the side sills 4 Disconnect the propeller shaft from the differential 5 While turning one wheel slowly and make sure that opposite wheel turns in the same direction 6 If the opposite wheel turns...

Page 1552: ...wheel speed sensor Vehicles with Refer to GROUP Wheel Speed Sensor 2 Brake drum 3 Shoe and lever assembly 4 Caliper assembly Refer to 5 Brake disc 6 Shoe and lining assembly Refer to GROUP 36 Parking...

Page 1553: ...b rotation starting torque Limit 1 0 Nm 9 or less 3 The hub rotation starting torque should be within the limit value range and there should be no engagement or feel ing of roughness WHEEL BEARING END...

Page 1554: ...d installation Refer to 98 71 98 118 137 85 99 TSB Revision 98 71 Removal steps 1 Trailing arm connection 2 Lower arm connection 3 Toe control arm ball joint and knuckle connection Refer to 4 Shock ab...

Page 1555: ...OUP 36 Parking Brake Drum in disc brakes 6 Shoe and lever assembly 7 Clip 8 Parking brake cable 9 Brake pipe connection 10 Shock absorber connection Trailing arm connection 12 Lower arm connection 13...

Page 1556: ...1 Push the lower part of the knuckle the of the vehicle and then separate the differen tial carrier At fhis time use a tire or similar to separate the drive shaft connection 2 Use the special tool as...

Page 1557: ...ft R H Boot band B J side Green identification color DRIVE SHAFT NUT INSTALLATION 1 Install the washer and drive shaft nut in the direction 2 Use the special tool to tighten the shaft nut 3 If the pos...

Page 1558: ...pair kit repair kit Disassembly steps 1 T J boot band large 2 T J boot band small __ 3 T J case 4 Snap ring 5 Spider assembly 6 T J boot 7 B J boot band large Do not disassemble the B J assembly 6 TSB...

Page 1559: ...new or different types of grease Grease Repair kit grease Conventional differential 95 3 35 oz Limited slip differential 105 3 70 oz Caution drive shaft joint uses special grease not mix old and new o...

Page 1560: ...REMOVAL 1 Wipe the grease off of the spline portion 2 Remove the boot and N O T E If the boots are reused around the drive shaft spline so that the boots when they are removed __ REASSEMBLY SERVICE B...

Page 1561: ...Install the spider assembly to the shaft from the direction of the section 3 After applying specified grease to the T J case insert the drive shaft and apply grease one more time Specified grease Rep...

Page 1562: ...ed slip differential 84 3 mm in Caution Always check the identification numbers on the band levers Never confuse the bands Items Identification number I T J boot band large I T J boot band small INSPE...

Page 1563: ...teps 1 Rear wheel speed sensor with 2 Caliper assembly Refer to 3 Brake disc 4 Brake drum 5 Shoe and lining assembly Refer to GROUP 36 Parking Brake Drum in disc brakes 6 Shoe and lever assembly 7 Cli...

Page 1564: ...hen separate the drive shaft from the differen tial carrier At this time use a tire lever similar to separate the drive shaft connection 2 Support the separated drive shaft wire or similar so as not t...

Page 1565: ...t using the side bearing spacer NOTE After adjustment inspect the contact of the drive gear DRIVE GEAR CHECK 1 Measure the drive gear at the shoulder on the reverse side of the drive gear Limit 0 05 m...

Page 1566: ...f adjustment is impossible gear and pinion gear as a set DRIVE GEAR TOOTH CONTACT CHECK Check the drive gear tooth contact by following the steps below 1 Apply a thin uniform coat of machine blue to b...

Page 1567: ...contact resulting from insufficient pinion height Decrease the thickness of pinion height adjusting Shim position the drive pinion farther from the The drive positioned center of the drive gear close...

Page 1568: ...nal differential 12 Pinion washer Conventional differential 13 Side gear differentials 14 Side gear spacer Conventional differential Differential case Conventional differential 16 Limited slip differe...

Page 1569: ...INNER RACE REMOVAL Place the nut on top of the differential case and then use the special tool to remove the side bearing inner race NOTE Attach the prongs of the special tool to the inner race of the...

Page 1570: ...nd drive pinion PINION REAR BEARING REMOVAL OIL RACE DRIVE PINION FRONT OUTER RACE REMOVAL TSB Revision REAR BEARING REMOVAL INSPECTION l Check the companion flange for wear or damage l Check the bear...

Page 1571: ...inion assembly 11 Drive pinion front bearing inner race 12 Oil 13 Companion flange 14 Washer 15 Self locking nut 16 Differential case 17 Limited slip differential case assem bly Refer to l Differentia...

Page 1572: ...Conventional differential 2 3 mm in Limited slip differential Adhesive Locking No or equivalent TSB Revision...

Page 1573: ...ve front and rear bearing inner races on the gear carrier in the sequence shown in the illustration NOTE Apply a thin coat of the multipurpose grease to the mating face of the washer of the special to...

Page 1574: ...al tools 9 Install the bearing cap and then use a gage and the micrometer to measure the of the bearing cap as shown in the the thickness E of the drive rear shim from the following equation and selec...

Page 1575: ...front shims if the number of shims is large reduce the number of shims to a minimum by selecting the drive pinion spacers 5 Remove the companion flange and drive pinion once again Drive the oil into...

Page 1576: ...e side gears side gear spacers pinion gears and pinion washers into the differential case 2 Temporarily install the pinion shaft NOTE Do not drive in the lock pin yet 3 While locking the side gear wit...

Page 1577: ...cified adhesive to the threaded holes of the drive gear Specified adhesive Stud Locking Part No 4170 or equivalent 4 Install the drive gear onto the differential case with the mating marks properly al...

Page 1578: ...which correspond to that thickness plus one half of the clearance plus 0 05 mm and then install one pair each to the drive pinion side and the drive gear side 4 Install side bearing spacers and differ...

Page 1579: ...hen adjust the drive gear backlash between the drive gear and the drive pinion NOTE When increasing the number of bearing spacers use the same number for each and as few 9 Check the drive gear and dri...

Page 1580: ...H and make the side gear R H turns the feeler gauges with in feeler gauges the special tool in the gear R H and make gear R H does not turn Standard value mm in NOTE The differential gear backlash is...

Page 1581: ...o Differential case A 3 Thrust washer L H 4 Viscous coupling with differential side gear L H 5 Pinion mate washer 6 Differential pinion mate 7 Differential pinion shaft 8 Differential side gear 9 Thru...

Page 1582: ...case B THRUST WASHER L H SELECTION When the differential side gear and pinion mate gear have been replaced select the thrust washer L H by the following procedure 1 Wash the differential side gear an...

Page 1583: ...the thrust washer and pinion mate washer for wear seizure and damage 4 Check the sliding surfaces of the differential cases A and B for wear seizure and damage A Surface in sliding contact with VCU B...

Page 1584: ...NOTES...

Page 1585: ...CONTENTS GENERAL INFORMATION 2 ON VEHICLE SERVICE 5 Tire Inflation Pressure Check Tire Wear Check 5 Wheel Check 5 SERVICE SPECIFICATIONS TROUBLESHOOTING WHEEL AND TIRE...

Page 1586: ...minum Premium price Aluminum Aluminum type 17 mm 46 1 6 46 46 1 8 Pitch diameter mm in 114 3 4 5 114 3 4 5 114 3 4 5 Tire Size Steel Steell wheel Size circle diameter mm in mm 46 1 8 46 1 8 46 1 8 4 5...

Page 1587: ...WHEEL AND TIRE Service Specifications Limit Tread depth of tire Wheel Radial Lateral Steel wheel 1 6 1 2 or less Aluminum wheel Steel wheel or less 1 2 or less Aluminum wheel 1 or I TSB Revision...

Page 1588: ...treads Under inflation Adjust the tire Refer to pressure Wear on one side Excessive ber Check the camber Refer to GROUP On vehicle Service Feathered edge Incorrect toe in Adjust the toe in Bald spots...

Page 1589: ...ad depth of tires is reduced to 1 6 mm or less wear indicators will appear WHEEL CHECK Jack up the vehicle so that the wheels are clear of the floor While slowly turning the wheel measure wheel with a...

Page 1590: ...NOTES...

Page 1591: ...MOUNT CONTENTS CROSSMEMBER 9 SERVICE SPECIFICATIONS 3 ENGINE MOUNTING 4 SPECIAL TOOLS 3 ENGINE ROLL STOPPER TRANSAXLE CENTERMEMBER 7 TROUBLESHOOTING 3 GENERAL INFORMATION 2...

Page 1592: ...lent features have the rear upper part of the transaxle at the rear ready been proven in many Mitsubishi vehicles This arrangement effectively suppresses the engine The inertial supporting type mount...

Page 1593: ...in Bushing A projection mm in Crossmember Bushing B projection mm in Bushing projection mm in TOOL Symptom Probable cause Excessive engine Cracked rubber parts of insulator Remedy Replace wobble or v...

Page 1594: ...insulator mounting 2 Engine mount bracket 3 Engine mount stopper Engine side Engine mount Engine mount stopper ______ bracket Engine Turbo and Engine 87 98 71 85 INSTALLATION POINT ENGINE MOUNT Align...

Page 1595: ...and Engine 69 Nm 3 NOTE l 1 Battery bracket 2 Evaporative emission canister Engine Turbo Refer to GROUP 17 Evaporative Emission Control System 3 Evaporative emission canister hold er assembly Engine...

Page 1596: ...Transaxle side l TRANSAXLE MOUNT Align the notches on the stopper with the transaxle mount bracket with the arrow mark facing toward the Then install the stopper INSPECTION l Check each insulator for...

Page 1597: ...2 88 Nm 64 1 Rear roll stopper bracket assembly 2 Front roll stopper bracket assembly Centermember removal steps 3 Bolts 4 Stay Engine Turbo and Engine 5 Centermember assembly Indicates parts should b...

Page 1598: ...ve the centermember assembly INSTALLATION POINT FRONT If the dimension shown in the illustration the standard value when the weight of the engine is the body replace the front roll stopper bracket Sta...

Page 1599: ...g Gear Box Removal and Installation Refer to GROUP Power Steering Gear Box Engine Non turbo 44 Nm 32 Engine Turbo and Engine 44 Nm 3 2 88 Nm 84 88 00003506 Crossmember removal steps 1 Lateral lower ar...

Page 1600: ...ush 2 The bush should be press fitted that the inner projection is at the standard length S t a n d a r d Bushing A mm in Bushing B mm in 1 Use the special tool to drive out and press fit the member b...

Page 1601: ...HOCK ABSORBER ASSEMBLY 8 LATERAL LOWER ARM ASSEMBLIES 11 SPECIAL TOOLS 3 GENERAL INFORMATION 2 STABILIZER BAR 14 ON VEHICLE SERVICE 4 Front Wheel Alignment Check TROUBLESHOOTING 4 and Adjustment 4 UPP...

Page 1602: ...nsion Ibs 1255 1667 1432 1902 322 528 absorber 1167 1579 267 355 1481 1952 333 439 damping force Contraction 471 706 106 520 0 9 Premium price AWD Coil spring Wire diameter 13 3 84 6 124 6 312 0 13 5...

Page 1603: ...s with wheels AWD Caster Upper arm ball joint breakaway torque Nm 0 3 2 5 3 22 Compression lower arm ball joint breakaway torque Nm 0 5 2 5 4 22 Lateral lower arm ball joint breakaway torque Nm Stabil...

Page 1604: ...vehicle rolling Broken or deteriorated stabilizer Shock absorber malfunction Replace Improper tire inflation pressure Noise Lack of lubrication Looseness and wear of each part Broken coil spring Shoc...

Page 1605: ...el FWD AWD CAMBER Standard value Vehicles with lbinch wheels Vehicles with wheels AWD CASTER Standard value NOTE 1 Camber and caster are preset at the factory and cannot be adjusted 2 If camber is not...

Page 1606: ...assembly Nut Upper arm shaft REMOVAL SERVICE POINT ARM BALL AND Caution 1 Use the special tool to loosen the loosen the nut do not from the 2 the special tool with cord etc to prevent it from coming I...

Page 1607: ...oint stud times install the nut to the stud and use the special tool to measure the breakaway torque of the ball joint Standard value Nm 3 22 2 When the measured value exceeds the standard value repla...

Page 1608: ...ol until it is fully SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION I Post installation Operation Front Wheel Alignment Adjustment Refer to 88 65 44 32 65 Removal steps 1 Stabilizer link mounting nu...

Page 1609: ...r 12 Shock DISASSEMBLY SERVICE POINT SELF LOCKING NUT REMOVAL 1 the coil spring using the special tools Caution 1 Install the special tools evenly so that the maximum length will be attained the insta...

Page 1610: ...bsorber Caution Do not use an impact wrench to tighten the bolt of the special tool 2 Align the edge of the coil spring to the stepped part of the shock spring seat UPPER BRACKET ASSEMBLY so that the...

Page 1611: ...pression lower arm bail joint and knuckle connection 2 Compression lower arm mounting bolts 3 Compression lower arm assembly Lateral lower arm assembly removal steps 4 Stay 5 absorber lower mounting 6...

Page 1612: ...1 After shaking the ball joint stud several times install the nut to the stud and use the special tool to measure the breakaway torque of the ball joint Compression lower arm ball joint Standard value...

Page 1613: ...he dust cover by the following procedure only if the dust cover has become damaged by accident during servicing 1 Remove the dust cover 2 Apply multipurpose grease to the lip and inside of the dust co...

Page 1614: ...ABILIZER BAR BRACKET INSTALLATION Position the stabilizer bar so that the marking on the stabilizer bar and the edge of the bracket becomes the reference value and then tighten the stabilizer bar brac...

Page 1615: ...possible to use that ball joint BALL JOINT DUST COVER CHECK If there are any cracks in or damage to the dust cover replace the stabilizer link STABILIZER LINK BALL JOINT DUST COVER REPLACEMENT Replace...

Page 1616: ...6 NOTES I...

Page 1617: ...K ABSORBER ASSEMBLY LOWER ARM AND TOE CONTROL ARM SPECIAL TOOLS 4 ASSEMBLIES 12 STABILIZER BAR REAR SUSPENSION ASSEMBLY 7 TRAILING ARM 11 ON VEHICLE SERVICE 6 Rear Wheel Alignment Check 6 and Adjustme...

Page 1618: ...Wire diameterx 75 2 117 2 length 2 953 4 606 2 953 360 5 2 961 1 1 9 2 9 11 929 11 830 Identification Purple 2 Purple 2 color Spring constant 26 5 151 26 5 151 Shock absorber stroke mm in 154 6 1 154...

Page 1619: ...REAR SUSPENSION General Information Shock absorber U p p e r a r m control with aero arm Trailing arm Differential support arm 00003694 TSB Revision...

Page 1620: ...er Vehicles with 1 wheels FWD Vehicles with wheels Dimension for positioning upper arm bracket Thrust angle Toe control arm ball joint breakaway torque Stabilizer link ball joint breakaway torque SPEC...

Page 1621: ...or damaged Crossmember deformed or damaged Poor ride Excessive tire inflation pressure Adjust the pressure Malfunction of shock absorber Replace Weak or broken springs Stabilizer bar and or stabilizer...

Page 1622: ...Turn the toe control arm bolt to the left or right by equal amounts to adjust L H Turning clockwise toe out direction R H Turning clockwise toe in Furthermore toe adjustment can be made at graduation...

Page 1623: ...fer GROUP Service 6 Check and Adjustment 6 137 157 99 114 l 3 Removal steps 11 1 Propeller shaft connection 2 Brake caliper assembly with disc brakes 3 Brake disc with disc brakes or brake drum Vehicl...

Page 1624: ...may damage the joint CROSSMEMBER MOUNTING SELF LOCKING NUTS REMOVAL After supporting the crossmember in FWD vehicles or the differential case in AWD vehicles with a garage jack or trans mission jack...

Page 1625: ...heck and Adjustment Refer to 4 57 Nm 57 Nm 41 39 Nm Removal steps 1 Upper arm and knuckle connecting bolt 2 arm assembly mounting 3 Upper arm assembly 4 Upper arm bracket Caution Indicates parts which...

Page 1626: ...rd value A 37 2 2 mm 1 46 in Upper arm bracket installation nut and bolt NOTE If the upper arm bracket is with standard value the dimensibn is follows B 213 5 mm 8 4 in C 289 2 mm 10 6 in Upper end of...

Page 1627: ...7 157 118 137 85 99 steps 1 Knuckle and trailing arm assembly connecting bolt 2 Grommet 3 Trailing arm assembly mounting bolt 4 Stopper 5 Trailing arm assembly Indicates parts which should be and then...

Page 1628: ...heel speed sensor clamp bolts with 4 Lower arm assembly and knuckle connecting bolt 5 Lower arm assembly mounting bolt 6 Lower arm assembly Toe control arm assembly removal steps 7 Toe control arm bal...

Page 1629: ...he ball joint Standard value Nm When the measured value exceeds the standard value replace the toe control arm assembly 3 When the measured value is lower than the standard value check that the ball j...

Page 1630: ...d Post installation Operation 1 Service Lid Removal and Installation Refer to 2 Luggage compartment side trim 98 Nm Removal steps 1 Cap 2 Flange nuts 3 Bolt 4 Shock absorber INSPECTION l Check the rub...

Page 1631: ...Collar 8 Cup assembly 9 Dust cover 10 Bump rubber 11 Coil spring 12 Shock absorber assembly DISASSEMBLY SERVICE POINTS SELF LOCKING NUT REMOVAL 1 the coil spring using the special tools Caution 1 Inst...

Page 1632: ...to compress the coil spring and install it to the shock absorber Caution not use an wrench to tighten the special tool bolt 2 Align the edge of the coil spring to the stepped part of the shock absorbe...

Page 1633: ...BILIZER BAR REMOVAL AND INSTALLATION Pre removal and Post installation Operation l Lower Arm Cover Removal and Installation Vehicles with aero Refer to 9 14 39 2 8 Removal steps 1 Stabilizer link moun...

Page 1634: ...ss STABILIZER LINK BALL JOINT BREAKAWAY TORQUE CHECK 1 After shaking the ball joint stud several times install the nut to the stud and use the tool to measure the breakaway torque of the ball joint St...

Page 1635: ...the dust cover Clip ring Al Clip ring ends on opposite side also possible 2 Apply multi purpose grease to the inside of the dust cover 3 Use plastic tape on the stabilizer link threads as shown in the...

Page 1636: ...NOTES...

Page 1637: ...SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ANTI LOCK BRAKING SYSTEM ABS 358 ANTI LOCK BRAKING SYSTEM ABS...

Page 1638: ...NOTES...

Page 1639: ...rake Pedal Check and Adjustment 8 Check Valve Operation Check 11 Front Brake Disc Run out Check 18 Front Brake Disc Run out Correction 18 Front Brake Disc Thickness Check 19 Front Disc Brake Pad Check...

Page 1640: ...main features are as follows Floating caliper double piston and l A dual type master cylinder is equipped on disc all models l Both a single type and a tandem type caliper single piston and disc boos...

Page 1641: ...ure difference psi 0 4 I Front disc brake pad thickness mm in 10 Front disc brake drag force tangential force of wheel mounting bolts 69 15 4 or less tbs Front brake disc run out mm in Front hub end p...

Page 1642: ...act surfaces Brake grease 1 Shoe and lining assembly and auto adjuster assembly con tact surfaces Shoe and lever assembly and auto adjuster assembly con tact surfaces SEALANT Items Thread part fitting...

Page 1643: ...unction Clogged brake line pedal Reduced to floorboard drag Grease or oil on pad or lining surface Proportioning valve malfunction Auto adjuster malfunction Air in brake system Worn lining or pad Brok...

Page 1644: ...r brake disc Squealing groaning chattering noise brakes are Missing or damaged brake pad anti squeak shim Replace Brake drums and linings discs and pads worn or Correct or replace scored Incorrect par...

Page 1645: ...replace Worn damaged or insufficiently lubricated wheel bearings Incorrect brake pedal or booster push rod setting Adjust Groaning clicking or Stones or foreign material trapped inside wheel Remove s...

Page 1646: ...is caused to move Back off the stop light switch to turn and secure by tightening the lock nut d Connect the the stop light switch e Check to be sure that the stop light is not with the brake 4 For ve...

Page 1647: ...ack the carpet No continuity Continuity 4 with auto cruise control system a STOP LIGHT SWITCH Connect a circuit tester to the stop light switch and check whether or not there is continuity when the pl...

Page 1648: ...remains unchanged the booster is defective 2 With the engine stopped step on the brake pedal several times Then step on the brake pedal and start the engine If the pedal moves downward slightly the b...

Page 1649: ...s fitted inside the vacuum hose 2 Check the operation of the check valve by using a vacuum Vacuum pump connection Accept reject criteria Connection at the brake A negative pressure booster side A is c...

Page 1650: ...re within the allowable Output pressure begins to drop to input p r e s s u r e s p l i t p o i n t Standard value 2 Check that the output at the standard value when the input fluid pressure increases...

Page 1651: ...cified brake fluid CYLINDER BLEEDING The master cylinder has no so if bleeding is carried out by the following procedure bleeding of air from the brake line will become easier 1 Fill the reserve tank...

Page 1652: ...heck brake pad port Standard 10 mm Limit 2 0 mm in Caution When the limit is pads on both the left and be replaced as a set 2 If there is a significant in the thicknesses of the pads on the left and r...

Page 1653: ...Take out the drive shaft Refer to GROUP 26 Drive Shaft to GROUP 26 Drive Shaft Set the special tool to the front hub assembly as shown in the illustration Measure hub torque A with pads removed to mea...

Page 1654: ...ot catch and as the caliper assembly and lock pin are installed 11 Check brake drag torque as 1 Start engine and hold brake pedal Pedal depression force approx 196 44 Ibs 2 Stop engine 3 Turn brake di...

Page 1655: ...with lining will become rusty causing noise and shudderin l If grooves resulting rom excessive disc wear and scratches are not removed prior to installing a new pad assembly there will tarily be inap...

Page 1656: ...chalk both sides of the wheel stud on the side at which run out is greatest 2 Remove the brake disc and then place a dial gauge as shown in the illustration then move the hub in the axial direction an...

Page 1657: ...pe brake lathe or equivalent Be sure to follow the exact lathe manufacturer instructions BRAKE LINING THICKNESS CHECK 1 Remove the brake drum 2 Measure the wear of the brake lining at the place worn t...

Page 1658: ...shoe and when wear exceeds the limit value or is badly out of balance BRAKE LINING AND BRAKE DRUM CONTACT CHECK 1 Remove the brake drum 2 Remove the shoe and lining assembly Refer to 3 Chalk inner sur...

Page 1659: ...s exceeded the brake pads on both the left and right wheels must be replaced as a set 2 If there is a significant difference the thicknesses of the pads on the left and right check the condition of th...

Page 1660: ...s the caliper assembly and lock are installed 8 Check brake drag torque as follows 1 Start engine and hold brake pedal down for 5 seconds Pedal depression force approx 196 44 Ibs 2 Stop engine 3 Turn...

Page 1661: ...08 mm in NOTE To secure the disc to the hub tighten the nuts REAR BRAKE DISC RUN OUT CORRECTION 1 If the run out of the brake disc is equivalent to or exceeds the limit specification change the phase...

Page 1662: ...r to M T 30 22 7 10 6 3 2 4 Removal steps 1 Brake return spring pin 5 Shift lock cable connection Brake pedal assembly 7 Cotter pin 8 Link assembly 35100340103 30 Nm 22 TSB Revision 8 9 Brake pedal sh...

Page 1663: ...to GROUP Power Hoses l Air Conditioning High Pressure Hose Clamp Mounting Bolts Engine and Engine l Air Conditioning Compressor Installation Engine Turbo and ngines Refer to GROUP 55 Compressor and Te...

Page 1664: ...Cvlinder Brake Booster Grease points Fitting ATD Part No 8861 o r e q u i v a l e n t 1 4 1 0 2 4 9 SERVICE POINT BOOSTER REMOVAL Engine Turbo and Engine Slide the engine forward and remove the brake...

Page 1665: ...ntact each other 2 Connect so that the marking faces upwards 2 Install the other end of the vacuum hose fully onto its port on the engine Secure the hose using the hose clip CLEARANCE ADJUSTMENT BETWE...

Page 1666: ...BASIC BRAKE SYSTEM Master Brake Booster If the clearance is not within the standard turn the screw to achieve desired length I TSB Revision...

Page 1667: ...level sensor 7 Float 8 Reservoir 9 Pin 10 Retainer Master cylinder kit Brake fluid or 11 Connector 12 Grommet 13 Piston stopper ring 14 Primary piston assembly 15 Secondary piston assembly 16 Master...

Page 1668: ...IC BRAKE SYSTEM Master Cvlinder and INSPECTION Check the inner or pitting Check the primary and secondary pistons for rust scoring wear damage or wear Check the diaphragm for cracks and wear TSB Revis...

Page 1669: ...l Brake Fluid Supplying l Brake Line Bleeding Refer to I 88 Nm 6 5 Removal steps 1 Brake hose connection 2 Gasket assembly INSTALLATION SERVICE FRONT BRAKE ASSEMBLY INSTALLATION Install the front brak...

Page 1670: ...bly disassembly steps steps 1 Guide pin 1 Guide pin 2 Lock pin 2 Lock pin 3 Bushing 3 Bushing 4 Caliper support pad clip shim 4 Caliper support pad clip shim 11 Pad and wear indicator assembly 5 Boot...

Page 1671: ...RICATION POINTS Caution The piston seal inside the seal and boot kit is coated with special grease Do not wipe this grease off Brake fluid or Grease Repair kit grease Inner shi Grease grease SAE Greas...

Page 1672: ...nger tip Caution Do not use a flat tipped screwdriver or other tool to prevent damage to inner cylinder 2 Clean piston surface and inner cylinder with trichloro ethylene alcohol or specified brake flu...

Page 1673: ...e thickness at the thinnest and worn area of the pad Replace pad assembly when pad thickness is less than the limit value Standard value 10 mm in Limit value 2 0 m m in Caution 1 When the limit is exc...

Page 1674: ...Seal and boots repair kit Caliper assembly disassembly steps 1 Guide pin 2 Lock pin 3 Bushing 4 Caliper support pad 5 Boot 6 Boot ring 7 Piston boot 8 Piston 9 Piston seal 10 Caliper body clip shim P...

Page 1675: ...SYSTEM Front Brake LUBRICATION POINTS Inner ter Grease Brake grease SAE Cautiqn The piston seal inside the seal and boot kit is coated with special grease so do not wipe this grease Brake fluid or TS...

Page 1676: ...hile pumping in air protrude evenly Do not remove one piston before trying to remove the other piston because will impossible to remove the second become _ REMOVAL 1 Remove piston with fingertip Cauti...

Page 1677: ...K Measure thickness at the thinnest and worn area of the pad Replace pad assembly when pad thickness is less than the limit value Standard value 10 mm in Limit value 2 0 mm in Caution 1 When the limit...

Page 1678: ...ecified grease Brake grease SAE No 1 Removal steps 1 Brake drum 2 Lever return spring 3 Shoe to lever spring 4 Adjuster lever 5 Auto adjuster assembly 6 Retainer spring 7 Shoe hold down cup 8 Shoe hol...

Page 1679: ...ike to up the retainer joint and remove the retainer Retainer INSTALLATION SERVICE POINTS WAVE WASHER INSTALLATION Install the washer in the direction shown in the illustration Parking lever Pin of sh...

Page 1680: ...M BRAKE WHEEL CYLINDER REMOVAL AND INSTALLATION Operation l Brake Fluid Draining Removal steps 1 Brake drum 2 spring 3 Shoe to shoe spring 4 Auto adjuster assembly 5 Brake pipe connection 6 Wheel cyli...

Page 1681: ...rum Brake DISASSEMBLY AND REASSEMBLY Grease Repair kit grease orange Brake fluid or Disassembly steps 1 Boots 2 Piston assembly 3 Pistons 4 Piston cups 5 Wheel cylinder body Wheel cylinder repair kit...

Page 1682: ...ke fluid or 3 Set the piston cup on the tool with the lip of the cup facing up Fit the cup onto the special tool and then slide it down the outside of the into the piston groove In order to keep the p...

Page 1683: ...Refer to l Parking Brake Lever Adjustment Refer to GROUP 36 On vehicle Service 49 59 36 43 3 Removal steps 1 Brake hose connection 2 Rear brake assembly 3 Brake disc INSTALLATION SERVICE POINT REAR BR...

Page 1684: ...it TSB Revision C per assembly disassembly 10 Caliper body steps 1 Guide pin 2 Lock pin 3 Bushing support Boot ring 7 Piston boot 8 Piston 9 Piston seal pad clip shim Pad assembly disassembly steps 1...

Page 1685: ...brakes disassemble both sides left and right as a set PISTON BOOT PISTON REMOVAL Protect caliper body with cloth Blow compressed air through brake hose to remove piston boot and piston Caution Blow co...

Page 1686: ...amage or rust l Check piston surface for wear damage or l Check caliper body or sleeve for wear l Check pad for damage or adhesion of grease check backing metal for damage PAD WEAR CHECK Measure thick...

Page 1687: ...ngine Turbo and Engine Brake Line fer l Link Assembly Bolts Installation Refer to GROUP Control Engine l Intake Manifold Refer to Engine Non turbo Intake Manifold Refer to Manifold Engine R e f e r G...

Page 1688: ...BASIC BRAKE Connect the pipes to the the 1 Proportioning valve Rear brake 2 Proportioning 3 Proportioning valve 4 Proportioning valve 5 Proportioning valve 6 valve Master TSB Revision...

Page 1689: ...rake Booster Operating Test Brake Drum inside Diameter Check Vehicles with Rear Drum Brakes Brake Fluid Level Sensor Check Brake Lining and Brake Drum Contact Check Brake Lining Thickness Check Brake...

Page 1690: ...gnostic trouble code will not be erased even if the ignition switch is turned to OFF In addition reading of diagnostic trouble codes service testing are possible using the scan Items Wheel speed senso...

Page 1691: ...lenoid valve internal resistance Wheel speed sensor internal resistance I Clearance between the wheel speed sensor mounting surface and the ABS rotor mm in 2 8 2 2 8 5 1 1 1 1 1 2 Wheel speed sensor i...

Page 1692: ...this is because the system operatioh check is being performed This is considered normal ABS operation sound ABS operation Long braking distance 1 Sound of the motor inside the ABS hydraulic unit oper...

Page 1693: ...e code from the flashing of the ABS warning Diagnostic trouble code No 24 is output 0 5 sec No diagnostic trouble code is output 0 5 s e c Illuminated Illuminated Switched off Pause Tens digit Digit F...

Page 1694: ...is on 10 times in succession according to the timing given below C a u t i o n The memory cannot be erased under the following conditions 1 When the stop light switch is not turned on and off accordi...

Page 1695: ...peed sensor 23 Right rear wheel speed sensor 24 Left rear wheel speed sensor 38 Stop light switch system Right front solenoid valve system 42 Left front solenoid valve system 43 Rear solenoid valve sy...

Page 1696: ...of ABS ECU NG Repair Refer to OK Measure at ABS ECU connector l Disconnect the connector and mea sure at the harness side l Resistance value between terminals NG Check the following connectors NG Rep...

Page 1697: ...or output l Malfunction of wheel malfunction l Malfunction of ABS ECU l Distortion of rotor teeth missing l Low frequency noise interference when sensor harness wire is broken l Noise interference in...

Page 1698: ...owing connector OK Check trouble symptoms Replace ABS ECU Code No Wheel speed sensor gap or short circuit Comment l Improper installation of wheel speed sensor These diagnostic trouble codes are outpu...

Page 1699: ...ircuited If the stop light operates normally there is an open circuit in the harness for the stop light switch input circuit or there is a malfunction in the ABS ECU Yes Stop light switch check Refer...

Page 1700: ...uited or the harness is broken short circuited and then these diagnostic trouble codes are output Measure at hydraulic unit connector l Disconnect the connector and Replace the hydraulic unit sure at...

Page 1701: ...er in the valve power monitor line since the valve relay is normally ON If the supply of power to the valve power monitor line is interrupted this diagnostic trouble code will be output ABS valve rela...

Page 1702: ...5 seconds or more when motor continues operating etc l When the motor relay does not function ABS motor relay check Refer to Inspect the harness between fusible link No 8 and the hydraulic unit Measu...

Page 1703: ...that the ABS warning light as 1 When the ignition switch is turned warning light illuminates 2 When the ignition switch is turned to START to the engine the ABS warning light 1 second 3 If the is oth...

Page 1704: ...ht flashes once and then switches off Faulty ABS operation Unequal braking power on both sides 7 Insufficient braking power ABS operates under normal braking conditions ABS operates before vehicle sto...

Page 1705: ...ctor l Malfunction of ABS ECU circuit NG Measure at data link connector Repair and ABS ECU connector 1 l Disconnect the connector and mea sure at the side Continuity between the following terminals OK...

Page 1706: ...l Ignition Switch ON l Voltage between terminal 10 and body OK Battery positive voltage Check trouble symptoms Measure at combination meter connector sure at the combination meter side l Continuitv be...

Page 1707: ...d bodv v o l t a g e trouble symptom Replace the hydraulic unit INSPECTION PROCEDURE 6 The ABS warning light flashes once after the ignition key Probable cause is turned to ON The light when is turned...

Page 1708: ...epair Refer to Wheel speed sensor output voltage check R e p l a c e t h e w h e e l Hydraulic unit check Refer to 1 NG ABS rotor check Refer to Replace the rotor O K NG Wheel bearing end play check R...

Page 1709: ...s 3 Checks don t have to be the order in the chart Caution Short circuiting the positive probe between a connector terminal and could damage the vehicle wiring the sensor ABS ECU or three care to prev...

Page 1710: ...ltage 18 19 Ignition switch Input F R solenoid valve Output Ignition switch ON Ignition switch START Ignition switch OFF Ignition switch ON Battery voltage o v o v Battery voltage positive positive 22...

Page 1711: ...a test probe 2 Checks do not have to be carried out in the order given this chart Caution or continuity checks are performed on the damage to the and or ohmmeter may occur care to prevent this If the...

Page 1712: ...ris may damage the HU OPERATION CHECK 35200130101 WHEEL SPEED SENSOR OUTPUT VOLTAGE 1 Lift up the vehicle and the brake 2 Disconnect the ECU harness connector and measure from the harness side connect...

Page 1713: ...e follows l Faulty wheel sensor Inspecting Wave Forms With An Oscilloscope Use the following method to observe the output voltage wave form from each wheel sensor with an oscilloscope l Start the engi...

Page 1714: ...ircuit in sensor R e p l a c e s e n s o r Open circuit in harness Correct harness Incorrectly mounted wheel speed sensor Mount correctly rotor with missing or damaged teeth Replace ABS rotor NOTE The...

Page 1715: ...ke and when testing the rear brakes stop the front by chocking them 2 Release the parking brake and feel the drag force drag torque on each road wheel __ When using the braking force tester take a rea...

Page 1716: ...i I Scan tool actuator test Item Nos 04 05 start C y L Diagnosis Table No 04 Operation 1 Depress brake pedal to lock wheel 2 Using the scan tool select the wheel to be checked and force the actuator...

Page 1717: ...ABS __ battery and check to be sure that the sound hydraulic unit motor can be heard power not than 1 second TSB Revision...

Page 1718: ...x the continuity between the terminals power is not supplied and when power Motor Relay When no current Between terminals flows Between terminals No continuity When current flows Between terminals Con...

Page 1719: ...ficult 1 This happens because ABS consumes a great amount current for its self check function The remedy is to either allow the battery to recharge or to remove the fusible link for circuit thus disab...

Page 1720: ...aster cylinder kit Brake fluid steps Reservoir bracket 2 Reservoir hose 3 Reservoir cap assembly 4 Diaphragm 5 Reservoir cap 6 Filter 7 Brake fluid level sensor 8 Float 9 Reservoir 10 Pin Retainer 12...

Page 1721: ...per while depressing the piston PISTON STOPPER RING DISASSEMBLY Remove the piston stopper ring while depressing the piston INSPECTION l Check the inner surface of master cylinder body for corrosion l...

Page 1722: ...Cruise Control l Manifold Removal Engine Non turbo Refer to GROUP 15 Intake Manifold Flared brake line nuts 15 Nm Post installation l Brake Fluid ing l Brake l Link Engine Turbo and bolts Installatio...

Page 1723: ...ABS the pipes to the shown in the illustration 1 Proportioning valve Rear 4 2 Proportioning valve 3 Proportioning valve 4 Proportioning valve...

Page 1724: ...Control Module ECM Installation Engine Non turbo l Air Cleaner Assembly Installation Engine Non turbo l Power Steering Oil Reservoir Mounting Bolts Removal Engine Turbo and Refer to GROUP Power Steeri...

Page 1725: ...ropped or otherwise subjected to impact shocks 4 The hydraulic unit must not be turned upside down or laid on its side INSTALLATION POINT PIPE Connect the pipes to the shown in the illustration 1 Hydr...

Page 1726: ...sensor removal steps 1 Clip 2 Front wheel speed sensor Front ABS rotor removal 3 Drive shaft Front ABS Refer to GROUP 26 Drive Shaft Rear wheel speed sensor removal 4 Rear wheel speed sensor Rear ABS...

Page 1727: ...el speed sensor terminals Standard value If the internal resistance of the wheel speed sensor is not within the standard value replace with a new wheel speed sensor 3 Check the wheel speed sensor cabl...

Page 1728: ...ABS Wheel Speed ABS ROTOR CHECK Check whether ABS rotor teeth are or deformed if so replace the TSB Revision...

Page 1729: ...ABS ECU and Post installation Operation Cowl Side Trim R H and Front Scuff Plate Removal steps 1 Control unit cover 2 ABS ECU INSPECTION ABS ECU CHECK Refer to...

Page 1730: ......

Page 1731: ...Check with Rear Drum Brakes Brake Fluid Level Sensor Check Brake Lining and Brake Drum Contact Check Brake Lining Thickness Check Brake Pedal Check and Adjustment Check Valve Operation Check Front Br...

Page 1732: ...be identified by means of the diagnostic In addition reading of diagnostic trouble codes function and the trouble symptom memory will not and service data actuator testing are possible using the scan...

Page 1733: ...l speed sensor 1 11 1 12 mounting surface and the ABS rotor mm in G sensor output voltage In laden stationary 2 4 2 8 With FRONT mark downward 3 3 3 7 Wheel speed sensor insulation resistance or more...

Page 1734: ...lanation of condition System check sound TSB Revision ABS operation sound Sound of the motor inside the ABS hydraulic unit operating whine 2 Sound is generated along with vibration of the scraping 3 W...

Page 1735: ...a voltmeter Use the special tool to connect a the output terminal and the terminal the link connector Then take a reading of the diagnostic codes from the movement of the of the ERASING DIAGNOSTIC TR...

Page 1736: ...pen circuit or ON malfunction Left front solenoid valve system No response to Right front solenoid valve system drive signal 43 51 52 Rear solenoid valve system Valve relay system Motor relay or motor...

Page 1737: ...onnect the connector and mea sure at the harness side l Resistance value between terminals and O K Check trouble symptom each wheel speed sensor and the Wheel speed sensor check Refer to GROUP Wheel S...

Page 1738: ...r connection of connector I NG Wheel speed sensor insulation check Repair Refer to OK Refer to Refer to GROUP Wheel Speed Refer to 28 On vehicle Service Refer to GROUP 27 On vehicle wheel speed sensor...

Page 1739: ...circuit is broken or there is a malfunction in the ABS ECU l Malfunction of stop light switch of harness or connector l Malfunction of Does the stop light illuminate and switch off Yes Refer to GROUP...

Page 1740: ...he ECU determines the solenoid coil wire is broken short circuited or the harness is broken short circuited and then these diagnostic trouble codes are output l Disconnect the connector and mea sure a...

Page 1741: ...stic trouble code be output NG OK Replace the valve Measure at unit connector NG l Disconnect the connector and mea sure at the harness side l Voltage between terminal 12 and body Measure at ABS ECU c...

Page 1742: ...Refer to OK Replace the ABS motor relay the harness between fusible link NO 8 and the hydraulic unit Measure at ABS ECU connector l Disconnect the connector and l Resistance value between terminals si...

Page 1743: ...ce procedure page No Communication with all systems is not possible Communication with ABS only is not possible When the ignition key is turned to ON engine stopped the ABS warning light does 3 not il...

Page 1744: ...ness Refer to GROUP Troubleshooting INSPECTION PROCEDURE 2 Communication with scan tool is not possible Communication with ABS only is not Probable cause Comment l Blown fuse When communication with t...

Page 1745: ...ter connector Check l and l Disconnect the connector and mea l Disconnect the connector and mea sure at the combination meter side l Continuitv between terminals OK Continuity OK Not Replace combinati...

Page 1746: ...e hydraulic The ABS warning light flashes once after the ignition key is turned to ON The light illuminates when the ignition Probable cause key is turned to START and when the key is returned to ON i...

Page 1747: ...d sensor check Refer to GROUP Wheel Speed Replace the wheel speed sensor OK Sensor Check OK Hydraulic unit check Refer to NG ABS rotor check Refer to Replace the rotor OK Wheel bearing end play check...

Page 1748: ...oblem Connector terminal arrangement for troubleshooting Terminal arrangement shown on the tool connector 0 0 0 0 0 0 7 6 ABS ECU Connector Terminal Arrangement Use the special tool to check the ABS E...

Page 1749: ...Input switch ON Battery positive voltage 22 Valve relay monitor Input Ignition switch START o v ignition switch OFF o v Ignition switch ON voltage Diagnostic communication Input Output Scan tool conne...

Page 1750: ...h as harness ABS ECU ohmmeter will damaged If the ohmmeter shows any deviation from the condition check the corresponding sensor actuator related electrical wiring and repair or replace After repair o...

Page 1751: ...Front right left Output When with a voltmeter 70 or more When measuring with an 200 or more Connector terminal arrangement Terminal arrangement shown on the special tool connector 0 0 0 0 0 0 7 6 Cau...

Page 1752: ...eed Points In Waveform Measurement Symptom Probable causes Remedy Too small or zero waveform amplitude Waveform amplitude fluctuates ex cessively this is no problem if the minimum amplitude is 100 or...

Page 1753: ...orce tester take a brake drag Turn the ignition key to the scan tool as the lever is in neutral start 1 At this time the ABS 2 mode and the When the ABS has function the scan tool actuator testing can...

Page 1754: ...locking Abnormal Probable cause Remedy does not Clogged brake Check and clean lock when brake line other than brake line pedal is HU pressed Clogged hydrau Replace HU circuit in HU assembly force is r...

Page 1755: ...he splash shield to 42 Fender 2 Remove the relay box mounting bolts 3 Insert the tip of a screwdriver into the space the hydraulic unit and the relay box to open the tab at then 4 Take out all of the...

Page 1756: ...ompletely flat and then the vehicle is driven without waiting for the battery to some extent the engine may misfire and driving not be possible This happens because ABS consumes a great of current for...

Page 1757: ...nsor removal steps 1 Clip 2 Front wheel speed sensor Front rotor removal 3 Drive shaft ABS rotoo Refer to GROUP 26 Drive Shaft wheel speed sensor removal 4 Rear wheel sensor Rear ABS rotor removal ste...

Page 1758: ...ace Standard value 28 2 28 5 mm 1 11 1 12 in INSPECTION WHEEL SPEED SENSOR CHECK Refer to GROUP Wheel Speed Sensor Check WHEEL SPEED SENSOR INSULATION 1 Remove all the wheel sensor and then between 1...

Page 1759: ...G SENSOR REMOVAL AND INSTALLATION Caution Do not drop the G sensor or subject it to shocks TSB Revision...

Page 1760: ...3 Standard value 2 4 2 6 3 With the special tool still connected secure the G sensor so that the FRONT mark on the sensor mounting surface is facing straight down take a reading of the following outp...

Page 1761: ...ON Pre removal and Post installation Operation l Cowl Side Trim R H Front Scuff Plate Removal and Installation Refer to GROUP Trims Removal steps Control unit cover 2 ABS ECU INSPECTION ABS ECU CHECK...

Page 1762: ...NOTES...

Page 1763: ...t of the or any component can lead to inadvertent firingofthealr rendering the inoperative 2 Service or maintenance of any component or component must be performed only at an authorized dealer MITSUBI...

Page 1764: ...f a mechanical rear wheel The operation method utilizes a parking brake lever brake construction in all vehicles Drum type or drum in disc type brakes are employed depending which is in an offset posi...

Page 1765: ...eter mm in 188 0 6 8 169 0 6 7 LUBRICANTS Items Specified lubricant Backing plate Brake grease SAE No 1 Shoe and lining assembly Adjuster TROUBLESHOOTING Symptom Probable cause Brake drag lnsuff parki...

Page 1766: ...us freeing the parking brake cable Vehicles with With the engine idling forcefully depress pedal five of six times and confirm that the pedal stroke stops changing N O T E If the pedal stroke stops ch...

Page 1767: ...itch installation bolt 2 The parking brake switch is good if there is continuity when the parking brake lever is pulled and there is no continuity when it is returned LINING RUNNING IN 99199119949 Veh...

Page 1768: ...talling the floor console do not let it bump against the SRS ECU or other components 2 Before removal of to GROUP SRS ECU Post installation l Parking Brake Lever Stroke Refer to P 36 4 l Floor Console...

Page 1769: ...r to GROUP Floor Console CAUTION SRS 1 When removing and installing the floor console do not let it bump against the SRS ECU or other components 2 Before removal of SRS ECU refer to GROUP SRS ECU Remo...

Page 1770: ...RS 1 When removing and the floor console do not let it bump against the SRS ECU or other components 2 Before removal of SRS ECU refer to GROUP SRS ECU I I l 13 49 59 Nm 36 43 Removal steps 1 Rear brak...

Page 1771: ...l d d o w n c u p INSTALLATION ADJUSTER Install the adjuster so that the shoe adjusting bolt of left hand wheel is attached towards the front the vehicle and the shoe adjusting bolt of right hand whe...

Page 1772: ...teps 1 Rear brake assembly 2 Rear brake disc 9 Shoe hold down cup 10 Shoe hold down spring 3 Shoe to anchor spring rear 4 Shoe to anchor spring front 11 Shoe hold down pin 5 Adjusting wheel spring 12...

Page 1773: ...STER INSTALLATION the adjuster so that the shoe adjusting bolt of left hand wheel is attached towards the front of the vehicle and the shoe adjusting bolt of right hand wheel is towards the rear of th...

Page 1774: ...m in Caution Replace the brake shoes if the thickness of brake lining is the limit value or 2 Using a dial gauge caliper or for measure the brake disc drum inner at two or more places Standard value 1...

Page 1775: ...CIAL TOOLS 4 STEERING WHEEL AND 14 WARNINGS REGARDING SERVICING OF SUPPLEMENTAL SRS EQUIPPED WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead...

Page 1776: ...steering column in all vehicles has a shock absorber mechanism and a tilt steering mechanism Four spoke steering wheel has been adopted In A vane type oil pump a fluid flow control system addition Sup...

Page 1777: ...ering gear retention pressure Power steering pressure switch operating pressure psi Total pinion torque Nm Tie rod swing resistance Ibs ON OFF OFF ON 2 1 3 2 8 4 7 8 27 rod swina toraue Nm 1 5 4 9 bet...

Page 1778: ...ol 0 Tool number and name or Steering linkage puller socket Oil pressure gauge assembly 548 Engine Non turbo Power steering oil gauge adapter side Engine Non turbo steering oil gauge adapter side or E...

Page 1779: ...ilable roller bearing removal __ 197 Bar long type General service tool and oil seal installation Oil 199 Oil seal installer General service tool General service tool Oil seal installer attach ment Ge...

Page 1780: ...installation 317 Tool not available Seal ring installation Seal ring installer 152 General service tool Oil seal installation Dust cover installer Dust cover installation Front axle base Drive pulley...

Page 1781: ...g gear box and check total pinion torque STEERING ANGLE CHECK 37200110131 1 Locate front wheels on turning and measure steering angle Standard Inside wheel FWD AWD Outside wheel FWD AWD 2 the angle is...

Page 1782: ...rd value refer to the troubleshooting and and adjust ments described there CHECKING STEERING WHEEL TO CENTER To make this test conduct a road test and check follows 1 Make both gradual and sudden turn...

Page 1783: ...ile operat ing the starting motor intermittently turn the steering wheel all the way to the left and right several times to drain all of the fluid Caution careful not to position the or the fuel rail...

Page 1784: ...control valve and condition the life of the pump etc PRESSURE TEST PUMP RELIEF PRESSURE CHECK Disconnect the pressure hose from the oil pump and then connect the special tools 2 the air and then turn...

Page 1785: ...nd then turn the steering several times the vehicle is not moving so that the tempera ture the fluid rises to approximately 3 the and idle it 100 4 Check whether or not the hydraulic pressure is dard...

Page 1786: ...teering wheel several times while the vehicle is moving so that ture of the fluid rises approximately 3 Start the engine and it at 1 000 100 4 Fully open the shut off valve of the pressure gauge 5 Tur...

Page 1787: ...he pressure gauge and increase the hydraulic pressure then check or not the hydraulic pressure that activates the switch is the standard value Standard value 213 284 psi 6 Gradually open the shut off...

Page 1788: ...Refer to GROUP Air Bag Module and Clock Spring 2 Steering wheel 3 Lower column cover 4 Column pad 5 Upper column cover 6 Clock spring and column switch assembly Refer to GROUP Air Bag Module and Cloc...

Page 1789: ...Steering Wheel REMOVAL SERVICE POINT WHEEL REMOVAL DISASSEMBLY AND REASSEMBLY 1 D i s a s s e m b l y s t e p s 1 Joint assembly 2 B o o t 3 Outer cover 4 Retainer 5 Bearing 6 Inner cover TSB Revision...

Page 1790: ...STEERING LOCK LOCK CYLINDER REMOVAL If it is necessary to remove the steering lock cylinder use a hacksaw to cut the special steering lock bracket side REASSEMBLY SERVICE POINTS STEERING LOCK CYLINDE...

Page 1791: ...3 Wrap plastic tape approximately and one half times around the the and then press fit the bearings into the cover assembly BOOT INSTALLATION Apply grease to the inside of the lip section of the boot...

Page 1792: ...connection 3 Cotter pin 4 Tie rod end and knuckle connec tion 5 Stay L H 6 Stay R H Post installation l Stabilizer Bar Installation Refer to GROUP Stabilizer Bar l Washer Tank Refer to GROUP Windshiel...

Page 1793: ...ry Post installation l Stabilizer Bar Installation Refer to GROUP Stabilizer Bar l Drive belt Tension Adjustment Engine Turbo On vehicle Engine Refer to On vehicle l Fluid Supplying l Fluid Refer to l...

Page 1794: ...connect the brake fluid level sensor connector and remove the brake fluid reservoir assembly from the dash panel with the hose still attached NOTE Place the removed reservoir where it will not be a hi...

Page 1795: ...on lower arm should be suspended that undue force is not applied to the ball joint 2 Remove the connection between the gear box assembly and joint assembly and remove the gear box assembly from the cr...

Page 1796: ...n starting torque al If the pinion torque be the standard range by the rack support cover rack and any parts if ROD SWING RESISTANCE CHECK 1 hard swings to the tie rod 2 Measure the tie rod swing resi...

Page 1797: ...band 7 Bellows 8 T i e r o d 9 Tab washer l Total pinion torque adjustment 10 Locking nut 11 Rack support cover 12 Rack support spring 13 Rack support 14 End plug 15 Self locking nut 16 Valve housing...

Page 1798: ...NG POINTS Fluid Automatic Transmission Fluid II Grease Silicone grease Fluid Automatic Transmission Fluid DEXRON II Sealant ATD Part No 6663 or equivalent Sealant ATD Part No 6663 equivalent Fluid Aut...

Page 1799: ...from the gear box OIL REMOVAL Using a plastic hammer gently tap the pinion to remove it RING REMOVAL Cut the seal ring and remove it from the and valve assembly and the rack Caution When cutting the s...

Page 1800: ...topper will turn R E M O V A L Pull out the rack At this time also take the rack stopper and bushing simultaneously S E A L R E M O V A L oil seal and remove from rack bushing C a u t i o n Do not dam...

Page 1801: ...the specified fluid to the outside of the oil seal f l u i d Automatic transmission II 2 Using the special tools press the washer and the oil seal into the rack housing position where the upper press...

Page 1802: ...ool Specified fluid Automatic transmission Fluid DEXRON II 4 Match oil seal centre with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side Plastic tape Rack...

Page 1803: ...omatic Fluid II SEAL RING INSTALLATION Because the seal rings expand at the time of installation after by using the tool to compress the rings or press down by hand I S E A L Using the special the oil...

Page 1804: ...nds to the total pinion torque Standard value 6 12 Change in torque 0 4 Nm 3 Caution 1 When adjusting set standard value at high est value 2 Assure no ratcheting or operating rack towards the shaft di...

Page 1805: ...worn or defective seal ring BEARING l Check for roughness or during bearing operation l Check the bearing for play l Check the needle roller for roller slip off OTHERS l Check the cylinder inner of th...

Page 1806: ...er Fluid Line Bleeding Refer to l Oil Pump Pressure Check to 39 Nm 29 57 Nm 39 Nm 29 Removal steps 1 Drive belt 2 Suction hose 3 Pressure hose 4 Gasket uc ion ose 5 Pressure switch connector 6 Oil pum...

Page 1807: ...e with air conditioning install the oil pump assembly to the bracket so that it faces toward vehicle front Then use the air coriditioning tension adjust the belt tension 37300530043 l Check the drive...

Page 1808: ...P u l l e y 2 Pump bracket 3 Pump cover 4 Pump housing gasket 5 Side plate 6 Wave washer 7 O ring 8 9 Cam ring 10 Snap ring Connector 0 0 0 0 3 7 6 5 14 O ring 15 Flow control valve 16 Flow control sp...

Page 1809: ...DISASSEMBLY SERVICE PULLEY REMOVAL the special tool to pulley the pulley mounting R I N G Remove the snap ring from the shaft with snap and separate the rotor from the shaft REASSEMBLY SERVICE SEAL IN...

Page 1810: ...cover side SNAP RING INSTALLATION 1 Install the snap ring with the snap ring plier 2 After installation of snap ring lift the rotor and check that the snap ring has entered the countersunk part CAM R...

Page 1811: ...te PLATE up the pin hole of the side plate with the dowel pin the oil pump body PUMP HOUSING GASKET INSTALLATION Fit protrusions of the pump housing gasket in concavities of the oil pump body to insta...

Page 1812: ...and vane for stepped wear l Check the contact surface of cam ring and vanes for stepped wear l Check the vanes for damage CLEARANCE BETWEEN SHAFT AND OIL PUMP BODY Use a caliper gauge and a micrometer...

Page 1813: ...Pump TURBO AND ENGINE Operation Power Steering Fluid Draining Refer to 13 16 28 Nm 21 21 Removal steps 1 Drive belt 2 Suction hose h o s e 5 Pressure switch connector 6 Oil pump 7 Oil pump bracket TSB...

Page 1814: ...ution Generator is below the oil pump with a shop towel before removing of the hoses INSTALLATION SERVICE POINT PRESSURE HOSE INSTALLATION Connect the pressure hose so that its notch part contacts the...

Page 1815: ...al kit 61 Nm 12 Disassembly steps 1 D r i v e 2 Snap ring 3 Pump cover 4 Lock pin 5 Seal washer 6 Vanes 7 Cam ring 6 Rotor 9 Side plate 10 O ring 11 Connector 12 O ring 13 Flow valve 14 control spring...

Page 1816: ...o secure the drive pulley and then remove the drive pulley mounting nuts REASSEMBLY SERVICE POINTS SEAL INSTALLATION DRIVE ASSEMBLY INSTALLATION Use the special tool to press fit the drive shaft assem...

Page 1817: ...INSTALLATION Install the rotor to the pulley assembly so that the rotor s punch mark is at the pump cover side CAM RING INSTALLATION Install the cam ring with the punch mark facing the side plate VAN...

Page 1818: ...INSPECTION l Check the flow control valve for Check the pulley assembly for wear or damage l Check the groove of rotor and vane for stepped wear l Check the contact surface of cam ring and vanes for...

Page 1819: ...moval Refer to GROUP 51 Windshield Wiper and POWER STEERING HOSES ENGINE REMOVAL AND 11 Nm 11 3 9 Nm 2 9 Removal steps 1 Oil reservoir h o s e Suction hose 5 Return hose 6 Return hose 7 Pressure tube...

Page 1820: ...sor is below the oil pump so cover the compressor with a shop towel before removing any INSTALLATION SERVICE POINT PRESSURE HOSE INSTALLATION When the pressure hose is installed align the white line o...

Page 1821: ...Engine Refer to GROUP 11 E On vehicle Service l Power Steering Fluid Supplying l Power Steering Fluid Line Bleeding Refer to 23 26 Nm 34 Nm 25 11 Nm 11 Nm 8 8 11 8 Removal steps 1 Brake fluid reservo...

Page 1822: ...embly in a place where it will not be a hindrance when removing and installing the power steering hoses and tie it with a cord A C COMPRESSOR REMOVAL Disconnect the A C compressor connector remove the...

Page 1823: ...er Steering Hoses Engine Turbo and White line 2 When the pressure hose is installed align the on the pressure hose with the white line on the pressure tube so that together they form a straight line T...

Page 1824: ...NOTES...

Page 1825: ...ols 91 Drive Motor 99 Driven Gear 96 Rail Weatherstrip and Top Cover Retainer 101 Troubleshooting 91 FENDER 5 Fender 5 Sealants 5 FUEL FILLER DOOR 6 HOOD 2 Hood 3 Troubleshooting 2 ENTRY SYSTEM 72 Ent...

Page 1826: ...aligned Remedy Adjust the alignment Difficult locking and unlocking Striker and latch not properly aligned Adjust the alignment Uneven body clearance Incorrectly installed hood Adjust the installatio...

Page 1827: ...Hood silencer 9 Hood switch Vehicles with alarm system Hood and hood hinge removal steps l Front deck garnish Refer to GROUP 51 Windshield and Washer hose Hood hinge Hood lock release cable removal s...

Page 1828: ...BODY Hood Bumper small mm in Bumper 00000130 00000129 INSTALLATION SERVICE POINT BUMPER INSTALLATION INSPECTION HOOD SWITCH CONTINUITY CHECK Switch position 2 0 TSB Revision...

Page 1829: ...nt FENDER REMOVAL AND INSTALLATION and post installation Operation Front Bumper Removal and Installation Refer to GROUP 51 Front Bumper Sealant ATD Part No or equivalent Sealant ATD Part 8531 No 8848...

Page 1830: ...eration l Removal and Installation of Rear Side Trim Quarter Trim and Scuff Plate Refer to GROUP fuel filler door Removal steps 1 Fuel filler door 2 Fuel filler door hook 3 Release handle cover 4 Fuel...

Page 1831: ...and between quarter window glass and glass quarter belt line outer weatherstrip flushness mm in Rear of quarter window glass 9 0 2 0 Quarter window glass tilt mm in 3 0 2 0 SEALANTS AND ADHESIVES Item...

Page 1832: ...ulty l Power window motor is faulty l Convertible top control module is faulty When the power windows are not l Broken wire in power window up Check according to Flow Chart lowered fully the power win...

Page 1833: ...I NG NG window main switch and power window motor and between the power window motor and convertible top control mod ule and between the power window main switch and convertible top control module Rep...

Page 1834: ...S ADJUSTMENT Door in order to ensure that cross section A A and are correct 1 Remove the quarter trim Refer to GROUP Trims 2 Check that the quarter window glass moves up and down smoothly Non smooth o...

Page 1835: ...b Loosen one adjusting stud bolt nut at a time 6 Lower the quarter window slightly loosen the up stop installation bolt s 7 Adjust using the up stop installation bolts so that the difference in the qu...

Page 1836: ...2 0 mm in NOTE If dimensions of section A and A A are adjusted the height of the quarter window glass may be changed Confirm the height of the quarter window glass again Refer to view A in the illustr...

Page 1837: ...flushness and between the window glass and the quarter standard value B B Quarter window Quarter belt mouldi Quarter belt line outer small S t a n d a r d v a l u e C 7 0 2 0 mm 9 0 2 0 mm _ _ _ A Lo...

Page 1838: ...n the standard value additional adjustment to the upper adjusting studs may be necessary Standard value D 3 0 in E Tighten the 2 upper adjusting stud nuts to the specified torque value Tighten the low...

Page 1839: ...the window frame This adhesive not only improved glass holding and sealing but also permits use of body openings having a greater structural strength ADHESIVE Adhesive kit Quantity I ATD Part No 8609...

Page 1840: ...ive Apply it to the body evenly after 30 min utes of primer application I Reusing the glass Replace the glass I Cleaning of adhesion surface Completely cut off all of the residual adhesive Cleaning of...

Page 1841: ...es l Front Pillar Trim Refer to GROUP Trims l Headlining Refer to GROUP Headlining Section A A molding mm in Section B B Section C C mm in Adhesive ATD Part No 8609 Super Fast Urethane ATD Super Fast...

Page 1842: ...Use the special tool to remove the 8 Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm in around the entire circumference of the body flange 9 Finish the flange surf...

Page 1843: ...e windshield section to clean it and grease etc 2 Attach the dual lock fastener in the places shown the illustration so that there are no or wrinkles windshield or the body WINDOW SPACER INSTALLATION...

Page 1844: ...er evenly around the entire circum ference because it strengthens the adhesive Otherwise a too thick application cause lower ing of the adhesive strength 2 Do not touch the coated 2 After applying the...

Page 1845: ...plied with an infra red light to shorten the setting time keep the surface temperature of the adhesive 6 After attaching the windshield to the body let it stand far 30 minutes or more then test for wa...

Page 1846: ...OVAL AND INSTALLATION 00003800 Section A A Section B B Section C C TSB Revision Adhesive ATD Part No 8609 Super Fast Urethane and ATD Part No 8608 Super Fast Urethane Primer equivalent Removal steps 4...

Page 1847: ...adhesive cut through 4 Using a sharp knife scoop out existing adhesive from the body flange to 2 mm in or less thickness all around the window opening 5 Finish smooth the flange surface Caution 1 Do...

Page 1848: ...rengthen bonding pow er Make sure that it covers the surfaces complete Note that the primer if applied too thick cause loss of bonding power 2 Never touch the primer coated surface 2 Allow 3 to 30 min...

Page 1849: ...o n When using an infrared lamp or other means for quick er hardening keep the surface temperature or lower 7 After about 30 minutes or more following bonding of the quarter glass to the body check f...

Page 1850: ...Power window switch Quarter window glass removal steps l Quarter trim lower Refer to GROUP Trims Quarter belt moulding Refer to GROUP 3 Quarter trim bracket 4 Quarter belt line inner weatherstrip and...

Page 1851: ...OINT QUARTER WINDOW GLASS ASSEMBLY INSTALLATION Set the length of the adjusting stud to the dimension shown in the illustration to make adjustment of the quarter window glass easier INSPECTION POWER W...

Page 1852: ...Glass Power window switch Quarter window Power window Connector A Connector POWER WINDOW SWITCH CONTINUITY CHECK Main switch Quarter Window Glass Switch position OFF Terminal No of connector A 2 0 Te...

Page 1853: ...Lower Trim and Side Trim Refer to GROUP Trims l High mounted Stop Light without rear spoiler Refer to GROUP 54 High mounted Stop Light Adhesive tape or equivalent Section C C 24 Section Section D D m...

Page 1854: ...FASTENER INSTALLATION After making sure that there are no bends or raised sections in the dual lock fasteners attach the dual lock fasteners to the notches in the body as shown in the illustration MO...

Page 1855: ...the entire circum ference because it strengthens the adhesive Otherwise a too thick application will cause lower ing of the adhesive strength 2 not touch the coated surface 2 After applying the prime...

Page 1856: ...e it disturbed until the adhesive sets Caution When using an infrared or other for quick er hardening keep the surface temperature or lower After attaching the glass to the body let it stand for 30 mi...

Page 1857: ...n Distance between door window glass and weatherstrip step line mm in 4 4 more Front pillar 37 0 Roof or convertible 3 1 Front pillar 1 6 Roof or convertible 1 Quarter pillar ECLIPSE 13 0 1 0 Front pi...

Page 1858: ...Tool 1 Connect the scan tool to the data link connector Caution Always turn the ignition switch OFF before discon necting or connecting the scan tool 2 If buzzer of the scan tool sounds once when a s...

Page 1859: ...l Power window main switch driver s side door Check according to Flow Chart operated by means of is faulty the power window sub R e f e r t o switches passengers side but can not by means of the powe...

Page 1860: ...between terminal 5 and ground OK Battery positive voltage Check trouble symptom Check the harness between the power relay and the ETACS ECU Check the harness between the power relay and the power main...

Page 1861: ...e at the power window l Disconnect the connector and measure at the harness side ground OK positive voltage NG Check trouble window main switch and window motor and between the convertible top power w...

Page 1862: ...witch Power windows can be operated by means of the power window sub switches passengers side but can not by means of the power main switch driver s side NG Refer to Replace OK NG Repair and ECLIPSE E...

Page 1863: ...e top control module Repair if necessary When the power windows are not lowered fully and the power window main lock switch is OFF the passenger s side power window does not lower automatically if the...

Page 1864: ...harness TROUBLE SYMPTOM INSPECTION CHART A When the central door lock switch is operated all doors are not locked or unlocked I without entry system NG l Central door lock switch continuity check Refe...

Page 1865: ...ock power 1 the ground and the door relay ground Repair if necessary Measure at the door lock switch connector L H and Check the harness between the door R H Disconnect the connector and measure at ha...

Page 1866: ...ator switch driver s side and the ground Repair if necessary When the driver s side door lock is turned with key another door is not unlocked OK Check the scan tool input signal Check the harness betw...

Page 1867: ...input circuit in door locked under the following conditions the switch Chart A door can not be locked l Door switch is faulty l The key is inserted in the ignition key l cylinder l The driver s side...

Page 1868: ...Replace the ETACS ECU If the driver s side inside lock knob is locked under the following conditions the door will be locked l The key is inserted in the ignition key cylinder l The driver s side door...

Page 1869: ...ditions the door can not locked l The key is removed from the ignition key cylinder l The driver s side door is opened and minder switch and the ETACS ECU Replace the ETACS ECU OK NG Check the connect...

Page 1870: ...lm contact or damage Correct or replace Door hard to open Incorrect latch or striker adjustment Adjust Door does not open Incorrect door installation Adjust position close completely Defective door ch...

Page 1871: ...d i s c o v e r e d 4 When such a place is found cover it again and repeat the procedure to check if there are any other noise source 5 If no others are found the last tape the only source 6 Cut the...

Page 1872: ...ADJUSTMENT 423001001 0 1 Remove the door trim and waterproof film Refer to 2 Remove the drip line weatherstrip ECLIPSE Refer to 3 Loosen the bolts and nuts of parts l Delta sash l Equalizer arm bracke...

Page 1873: ...rear adjustment track forward or backward Refer to a 37 0 31 0 1 46 1 22 I I 1 6 I I 1 9 NOTE Glass longitudinal adjustments should be carried out at the same time bracket Lii arm bracket 6 Push the u...

Page 1874: ...clear ance is too large wind noise may be generated at high vehicle speeds because the glass is not hooked onto the glass 2 The amount of catch of the door catch on the door glass and the amount of s...

Page 1875: ...and the trim INSIDE HANDLE PLAY ADJUSTMENT 1 Remove the door trim and waterproof Refer to 2 Move the door inside handle installation position back and forth to adjust so that the inside handle play a...

Page 1876: ...Spring pin 3 Door assembly 4 Door upper hinge 5 Door lower hinge Door check removal steps l Door trim Refer to l Waterproof film Refer to 2 Spring pin 6 Door Nm 16 Adjustment of the door stepping ari...

Page 1877: ...BODY Door SERVICE POINT DOOR CHECK Install the door check so that identification mark upwards INSPECTION DOOR SWITCH CONTINUITY CHECK TSB Revision...

Page 1878: ...INSTALLATION NOTE Indicates the clip positions TSB Revision Removal steps 1 Clip 2 Regulator handle 3 Escutcheon 4 Pull handle box 5 6 Cover Door trim 7 Pull handle bracket 8 Door inside handle 9 Doo...

Page 1879: ...ing it toward the front of the vehicle to remove the clamp section from the door inside handle DOOR TRIM REMOVAL After removing the trim mounting screws and clips push the trim to remove it from the d...

Page 1880: ...olding Installation Refer l Door Trim and Waterproof Film Installation Refer to TSB Revision 8 00003676 Power window switch removal steps 1 Pull handle box 2 Power window switch Door glass and regulat...

Page 1881: ...HECK 1 Check that the motor runs smoothly the battery is connected directly to the terminals 2 Furthermore check that the operates in reverse when the terminal connections switched POWER WINDOW RELAY...

Page 1882: ...r window Connector A Connector Power window switch Door lock switch Main switch Switch position Connector A Connector terminal No No 2 1 3 1 6 1 7 1 8 1 9 5 Driver s Side Switch Passenger s Side Switc...

Page 1883: ...lation Refer to l Door Fit Adjustment Refer to 7 9 Nm 7 Central door lock switch removal steps 1 Pull handle box 2 Central door lock switch 6 00000150 Door handle and latch removal 3 Door inside handl...

Page 1884: ...al 2 and when the rod is set to the LOCK position check that there is no continuity side 1 After setting the rod to the LOCK position apply battery voltage to terminal 4 and check if the rod moves as...

Page 1885: ...0 side Switch position Terminal No 7 LOCK 0 Neutral OFF UNLOCK 0 0 DOOR LOCK POWER RELAY 1 CONTINUITY CHECK 1 Removal the radio tape player and CD player Refer to GROUP 54 Radio Tape Player CD Player...

Page 1886: ...Removal the quarter trim L H Refer to GROUP Trims ECLIPSE Removal the rear seat Refer to GROUP Rear seat 2 Check for continuity between under the conditions described below Battery voltage I Terminal...

Page 1887: ...ip removal steps l Door trim Refer to l Delta sash Refer to 1 Belt line molding 2 Door outer opening weatherstrip 3 Door window inner weatherstrip Door inner opening weatherstrip removal steps 4 Drip...

Page 1888: ...removal steps l Scuff plate Refer to GROUP Trims 1 Door inner front opening weatherstrip 2 Door inner rear opening weatherstrip TSB Revision REMOVAL SERVICE POINT DOOR OUTER OPENING WEATHERSTRIP REMOV...

Page 1889: ...even body clearance Uneven Probable cause Remedy Striker and latch not properly aligned Adjust the alignment Striker and latch not properly aligned Adjust the alignment Incorrectly installed Adjust th...

Page 1890: ...m and rear end trim Refer to GROUP Trims 10 latch 11 lock release cable of clearance around iftgate Adjustment of step and striker linkage latch removal steps l Rear end trim Refer to GROUP Trims 10 l...

Page 1891: ...GGAGE COMPARTMENT LIGHT SWITCH CONTINUITY CHECK INCLUDING LATCH Switch position Terminal No 1 2 Ground ON Latch open 0 0 OFF Latch shut LOCK CYLINDER SWITCH CONTINUITY CHECK Switch position Terminal N...

Page 1892: ...closure Striker and latch not properly aligned Adjust the alignment Difficult locking and unlocking Uneven body clearance Incorrectly installed trunk lid Adjust the installation of trunk lid Uneven h...

Page 1893: ...s l Rear end trim Refer to GROUP Trims 4 Trunk lid latch Caution 1 Never try to disassemble the gas spring or burn it 2 Always bore a hole in the gas spring to release the interior gas before the spri...

Page 1894: ...RVICE POINTS TRUNK LID OPENING WEATHERSTRIP INSTALLATION 1 Install the trunk lid opening weatherstrip so that the marked part is at the position shown in the illustration 2 Install so that the notch o...

Page 1895: ...ide Refer to GROUP Front seat 4 Trunk lid lock release handle Adjustment of trunk lid step frunk lid striker linkage Trunk lid lock cable removal steps 1 Release handle cover l Scuff plate Driver s si...

Page 1896: ...sh or illuminate Check according to the dome light operation is normal when a door is opened Flow Chart and closed Refer to No secret code can be registered l Malfunction of receiver Malfunction of sc...

Page 1897: ...heck Refer to Check the following OK and 549 Check the following connectors and NOTE l Carry when or or the code has been programmed Not all of the doors can be locked or unlocked I Door lock actuator...

Page 1898: ...sible l Voltage between terminal 16 and and Yes ground OK Battery positive supply and the data link connector Measure at the data link connector and the receiver connector l Disconnect the connector a...

Page 1899: ...d the headlights do not flash and the horns do not sound However the theft alarm functions normally with theft alarm system Comment When the PANIC switch is pressed the receiver sends a PANIC signal t...

Page 1900: ...iver power source Scan tool connected Scan tool disconnected Ignition switch ACC or ON Ignition switch OFF System voltage Battery voltage o v TSB Revision Receiver power source Always Battery positive...

Page 1901: ...BODY Entry System ENTRY SYSTEM REMOVAL AND Pre removal and Post installation Operation l Quarter trim L H Refer to GROUP Trims Removal steps 1 Door lock power relay 2 2 Receiver assembly TSB Revision...

Page 1902: ...BODY Entry System REMOVAL AND INSTALLATION ECLIPSE I Removal steps l 1 2 Rear seat Refer to GROUP Rear Seat Door lock power relay 2 for entry system Receiver assembly TSB Revision...

Page 1903: ...Then take the battery out of the transmitter 2 Install a new battery with its positive side down Replacement battery Coin type battery 2 3 Firmly close the transmitter case 4 Check that the entry sys...

Page 1904: ...a code registration Caution Turn the ignition switch to OFF before connecting or disconnecting the scan tool 3 Close all doors 4 Turn the ignition switch to ACC and return it to OFF NOTE This locks a...

Page 1905: ...N Part No 8825 or equivalent 00003746 1 Front center under cover panel 2 Lower front bumper plate 3 Front splash shield 4 Under cover side panel 5 Rear seat under cover panel 6 Rear crossmember under...

Page 1906: ...Black Toughened Instant Adhesive or equivalent in Hose ON VEHICLE SERVICE WATER TEST 1 Close the roof lid tightly 2 Hold the hose upward and adjust water fountain to about 50 cm 20 in high 3 Pour wate...

Page 1907: ...switch ON Sunroof switch Close Block the sunroof at 200 mm 7 9 in before the sunroof is fully closed I Sunroof moves until the blocking force reaches 98 22 0 Ibs gnition switch ON Sunroof switch Close...

Page 1908: ...en 2 Sunroof stops before tilt up finishes 2 Sunroof switch Release the open 12 Tilt up Ignition switch ON 1 Sunroof switch Open 2 Ignition switch OFF before the sunroof is fully open 1 Sunroof moves...

Page 1909: ...sunshade 5 Sunshade slide block motor steps 6 Refer to Headlining 7 Bracket 10 Sunroof motor Sunroof 6 Headlining Refer to GROUP Headlining guide assembly removal steps 1 Sunroof glass 3 Rear sunroof...

Page 1910: ...crew Threadlocker 222 or equivalent REMOVAL SERVICE POINTS SUNROOF GLASS REMOVAL 1 Tilt the sunroof 2 Remove the screws attaching sunroof glass to the guide assemblies and then lift the glass out of r...

Page 1911: ...r fingers on inboard end of the slide block to allow the slide block to slide out channel and then remove the slide block and spring CONTROL UNIT REMOVAL 1 Close the sunroof glass 2 a flat tipped scre...

Page 1912: ...nd pull the drain hose out into the wheel house INSTALLATION SERVICE POINTS DRAIN HOSE INSTALLATION 1 the cord that was used during removal the end of the drain hose and wind the plastic tape around i...

Page 1913: ...ide the sunshade back and forth to check that it functions smoothly SUNROOF CONTROL UNIT INSTALLATION 1 Look into the viewing windows while turning the rotating wheel Turn the rotating until the white...

Page 1914: ...oof glass onto the guide assemblies and align the mounting holes 2 Apply the specified sealant to the sunroof glass attaching screws and install them going to the next step before tightening Specified...

Page 1915: ...sing with the convert ible top switch is not possible Operation takes place when the convertible top switch is set to open or close during travel Probable cause l Convertible top switch is faulty l Co...

Page 1916: ...ct the connector and measure at the harness side l Voltage between terminal 12 and ground OK Battery positive voltage OK link 3 and convertible top control module Repair if necessary Measure at the co...

Page 1917: ...vertible top module and Operation takes place when the convertible top switch is set to open or close during travel NG Simulated vehicle speed of 4 km h and 2 mph or more OK Convertible too does not o...

Page 1918: ...TION Pre removal Operation Completely open the convertible top Post installation Operation Convertible top fit adjustment 8 View A 18 View A 7 6 7 5 Removal steps 3 Strip l Quarter belt moulding Refer...

Page 1919: ...ain trough during top removal CONVERTIBLE TOP ASSEMBLY REMOVAL Pty one side back at a time Caution Use care not to rip the drain trough durlng convertible top removal TSB Revision SERVICE POINT CONVER...

Page 1920: ...pivot and support with 102 mm 366 mm 279 mm 4 in 14 in 11 in block of wood or equivalent INSTALLATION SERVICE POINTS DRIVEN GEAR BUSHING INSTALLATION 1 Position the driven gear and insert the main pi...

Page 1921: ...vot bolt and washer driven gear BUSHING INSTALLATION bushing to balance link shown orientation 2 Install balance link into main pivot complete bracket 3 Insert balance link installation screw then tig...

Page 1922: ...INER ATTACHING STRAP REMOVAL From a completely closed position open the convertible top half way HEADLINER REMOVAL Mark the bows lightly at the end of each retainer then pry the retainer from the bow...

Page 1923: ...54 Speaker 1 Rear speaker bracket 2 Spacer 3 drive motor NOTE This illustration shows the right side The left side is symmetrical to the right side REMOVAL SERVICE MOTOR Remove lower bolts with space...

Page 1924: ...BODY Electric Convertible FRONT ROOF WEATHERSTRIP REMOVAL AND INSTALLATION Removal steps 1 Clip 2 Front roof weatherstrip 3 Front pillar weatherstrip holder 4 Front roof weatherstrip holder Revision...

Page 1925: ...IL WEATHERSTRIP AND TOP REMOVAL AND INSTALLATION Adhesive tape ATD Part or equivalent 00004748 1 Top cover retainer rail weatherstrip removal steps 2 front 3 front 4 center 5 center weatherstrip 6 rea...

Page 1926: ...nt healiner attaching strap 2 Center headliner attaching strap 3 Bushing 4 Balance link NOTE This illustration shows the left side The right side is symmetrical to the side REMOVAL SERVICE POINT FRONT...

Page 1927: ...SSEMBLY REMOVAL Using the pry tool carefully pry the assembly out of the INSTALLATION SERVICE POINT CENTER AIR OUTLET ASSEMBLY INSTALLATION 1 Turn the cool air bypass lever of the center air outlet fu...

Page 1928: ...0 0 CLOSE 0 0 CONVERTIBLE TOP BYPASS SWITCH REMOVAL AND INSTALLATION Removal steps 1 Convertible top bypass switch Lid REMOVAL SERVICE POINT TOP BYPASS REMOVAL 1 Slide the lock knob of the lid in the...

Page 1929: ...lower clip push the lower front of the switch past the lower clip 5 mm in 4 Depress upper clip 5 While holding upper clip jiggle and slide switch out INSPECTION Switch position Terminal No 1 2 3 OFF 0...

Page 1930: ...NOTES...

Page 1931: ...ent of the SRS or any SRS related component can lead to personal injury or death to personnel from inadvertent firing of the air bag the the SRS inoperative Service or maintenance of any SRS component...

Page 1932: ...emoval and Post installation Operation Splash shield Removal and Installation Refer to GROUP 42 Under Cover 6 1 Removal steps 1 Front side marker light 2 Front bumper center plate 3 Front bumper assem...

Page 1933: ...D REASSEMBLY 8 Disassembly 1 Front fog light bezel 2 Air intake cover 3 Front license plate bracket 4 Bolt plate 5 Front bumper side plate 6 Front bumper 7 Front bumper core 8 Front bumper stay assemb...

Page 1934: ...ation Rear End Trim and Rear Side Trim Removal and Installation Refer to GROUP Trims 5 Removal steps 1 Rear panel garnish 2 Rear combination light 3 Rear bumper upper plate A 4 Rear bumper upper plate...

Page 1935: ...REASSEMBLY 6 8 3 Disassembly steps 1 License plate light 2 Back up light 3 Rear bumper lower plate 4 Rear bumper reinforcement 5 Rear bumper core 6 Rear bumper stay assembly 7 License plate light brac...

Page 1936: ...RNISHES REMOVAL AND INSTALLATION 13 Nm 9 1 9 3 Front deck garnish removal steps 1 Wiper arm assembly 2 Front deck garnish Rear panel garnish removal steps l Rear end trim Refer to GROUP Trims 3 Rear p...

Page 1937: ...dhesive tape ATD Part No 6382 or equivalent 15 mm in wide and 1 2 mm in thick Adhesive ATD Part No 8608 Super Fast Urethane Primer or equivalent Windshield molding Refer to GROUP 42 Windshield 2 Belt...

Page 1938: ...alent 1 Windshield moulding Refer to GROUP 42 Windshield 2 Belt line moulding Refer to GROUP 42 Door Opening Weatherstrip 3 Side protector moulding Drip moulding removal steps l Front roof weatherstri...

Page 1939: ...g the side molding the fishing line the edge of the body so not to damage the edge of the side protector molding 2 If the adhesive is difficult to remove heat it to 3 Scrape off the double sided tape...

Page 1940: ...touch the coated surface 5 After applying the primer let it dry for 3 to 30 minutes 6 the specified double sided tape to the side protector molding adhesive tape ATD Part No 6382 or equivalent 15 mm...

Page 1941: ...ied sealant and adhesive I Door garnish Side air dam ATD Part No 6382 or equivalent and ATD Part No 8608 Super Fast Urethane Primer or equivalent AERO PARTS REMOVAL AND INSTALLATION Door garnish remov...

Page 1942: ...spoiler 5 Bracket REMOVAL SERVICE POINT I Adhesive tape ATD Part No 6383 or equivalent 0 2 mm in thick DOOR GARNISH FRONT SIDE AIR DAM REAR SIDE AIR DAM REMOVAL Carry out the same procedure as side pr...

Page 1943: ...or ON position the intermittent wiper relay is energized causing the intermittent wiper relay contacts to close and open repeatedly l When the contacts are closed motor is energized l When the wiper...

Page 1944: ...n switch with a built in intermittent wiper relay with the intermittent wiper relay energezed 5 The length of pause for intermittent operation cannot be varied l Check variable intermittent wiper cont...

Page 1945: ...otor and assembly removal steps Wiper arm and blade assembly 2 Front deck garnish 3 Wiper motor and link assembly l Brake bolt Refer Cylinder Booster 6 7 Washer motor Washer Washer nozzle and washer h...

Page 1946: ...d link assembly removal steps 1 Wiper arm and blade assembly 2 Front deck garnish 3 Wiper motor and link assembly Washer nozzle and washer hose removal steps 4 Washer hose connection 5 Washer nozzle T...

Page 1947: ...bag module Refer to GROUP Air Bag Module and Clock Spring l Steering wheel Refer to GROUP Steering Wheel and Shaft 9 Column cover lower 10 Column cover upper 11 Column switch assembly with built in wi...

Page 1948: ...k with water 2 When the battery is connected as shown in the figure check that the water squirts out strongly WIPER MOTOR CHECK Do not remove the motor and link assembly when checking Wiper Motor at L...

Page 1949: ...tch Intermittent Wiper Relay Intermittent Check 1 Connect the column switch connector 2 Turn the ignition switch to ACC 3 Inspect the intermittent wiper switch is turned to Vehicles with variable inte...

Page 1950: ...er the cam contacts keep the wiper motor energized until the wiper blades return to their stop position SERVICE SPECIFICATION I Standard value I Rear wiper blade installation position mm in I TROUBLES...

Page 1951: ...Wiper and washer switch Wiper motor removal steps 2 Wiper blade 3 Wiper arm 4 Spacer assembly lower Refer to GROUP Trims 5 Wiper motor 5 7 4 5 4 8 Washer tank and hose removal steps l Quarter upper t...

Page 1952: ...removal steps 2 Wiper blade 3 Wiper arm 4 Spacer assembly lower trim Refer to GROUP Trims 5 Wiper motor TSB Revision Washer tank and hose removal steps l Quarter upper trim L H quarter lower trim L H...

Page 1953: ...er INSTALLATION SERVICE POINT ARM WIPER BLADE INSTALLATION Adjust the wiper arm so that the clearance the wiper blade edge and the ceramic portion is at the value Standard value A 130 mm 5 18 in T S B...

Page 1954: ...wiper motor as shown in the illustration and inspect motor operation at low speed and high speed Wiper Motor at Stop Position Operation 1 Run the wiper motor at low speed disconnect the battery and st...

Page 1955: ...REMOVAL INSTALLATION Electrically controlled controlled mirror 1 Door mirror removal steps l Door trim Refer to GROUP 42 Door Trim and Waterproof Film 1 Knob 2 Delta cover inner 3 Boot Door mirror co...

Page 1956: ...with masking tape into the notched section and lever out the mirror to remove it INSPECTION ELECTRICALLY CONTROLLED Check that the mirror moves as described the each terminal is connected to the Batte...

Page 1957: ...INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM CONTENTS INTERIOR SUPPLEMENTAL RESTRAINT SYSTEM SRS...

Page 1958: ...52 2 NOTES...

Page 1959: ...omponent of the SRS or any component can lead to personal injuryordeath the inoperative 2 Service or maintenance of any component or component must be performed only at an authorized MITSUBISHI dealer...

Page 1960: ...eneral Service tool Ornament remover Application Removal of switch trim etc INSTRUMENT PANEL 52100170154 For installation of the instrument panel the bolts and screws described below are used They are...

Page 1961: ...ide air bag module removal installation always observe the proce dures of GROUP Air Bag Modules and Clock Spring 14 5 NOTE 1 Metal clip position 2 Resin clip position Removal steps 1 Meter bezel 2 Com...

Page 1962: ...ory but not needed for service work INSTALLATION SERVICE POINTS HEATER CONTROL ASSEMBLY INSTALLATION 1 Always snap the boss and clamp before installing a new heater control assembly to the instrument...

Page 1963: ...osition 9 Set the air changeover damper lever of the blower unit to inside recirculation position while the inside outside air changeover lever touches the stopper of the blower case and install the c...

Page 1964: ...eps 1 Glove box under frame 2 Glove box light switch 3 Glove box light bracket 4 Glove box striker 5 Defroster garnish 6 R h e o s t a t 7 Striker 8 Side face garnish 9 wiring harness DISASSEMBLY AND...

Page 1965: ...c FLOOR CONSOLE REMOVAL AND INSTALLATION CAUTION When removing and installing the floor console as sembly do not let it bump against the NOTE Metal clip position Removal steps 1 Center console panel 2...

Page 1966: ...Cup holder 2 Inner box 3 Floor console lid sub assembly Shift lever cover assembly 5 Hinge assembly 6 Inner lid 7 Lock lever 8 Spring 9 Stopper 10 Floor console lid 11 Floor console NOTE 1 Vehicles w...

Page 1967: ...on Resin clip position 00003812 B B Clip lip I I Cowl side trim removal steps 1 Scuff plate 2 Cowl side trim Front pillar trim removal steps 3 Assist grip 4 Front pillar trim c c Clip Quarter trim upp...

Page 1968: ...8 Rear shelf trim 9 Rear end trim 10 Luggage compartment floor box 11 Absorber lid 12 Rear side trim NOTE Metal clip position Resin clip position compartment floor board 13 Luggage floor board trim r...

Page 1969: ...ear view mirror stay cover 7 Inside rear view mirror 8 Front roof rail trim Metal clip position Resin clip position 00004754 Quarter steps l Door Refer to ening weatherstrip 42 Door Opening Weatherstr...

Page 1970: ...ction G G Rear end trim Luggage compartment side trim removal steps 16 Luggage compartment floor board 17 Partition trim 18 Rear end trim 19 Luggage compartment side trim Partition trim removal steps...

Page 1971: ...Remove the six upper clips of the rear end trim and then pull up the trim INSTALLATION SERVICE POINT OUTER SEAT BELT ANCHOR PLATE INSTALLATION Install the anchor along bead of the BELT GUIDE COVER INS...

Page 1972: ...ING ECLIPSE REMOVAL AND INSTALLATION 52100140178 and Post installation Operation l Front Pillar Trim and Quarter Trim Upper Removal and Installation Refer to Vehicles without sunroof NOTE Metal clip p...

Page 1973: ...itch cover 6 Sunroof switch panel 7 Headlining Tab REMOVAL SERVICE POINT DOME LIGHT ASSEMBLY REMOVAL Press and pull the tab downward to remove the dome light assembly INSTALLATION SERVICE POINT SUNROO...

Page 1974: ...EMOVAL AND INSTALLATION Vehicles without sunroof with sunrooh 1 1 00003741 Removal steps 1 Harness cover 2 Inside rear view mirror ECLIPSE REMOVAL AND INSTALLATION Removal steps 1 Inside rear view mir...

Page 1975: ...REMOVAL a narrow flat tip into rear view mirror bracket keep the spring pushed in and remove the inside rear view mirror in the direction of the arrow in the illustration NOTE While the spring is push...

Page 1976: ...IS A MALFUNCTION IN THE POWER SEAT SLIDE MECHANISM If the seat will not slide due to a malfunction of the slide motor or the slide switch and the seat mounting nuts and bolts consequently cannot be r...

Page 1977: ...SEAT ANCHOR COVER INSTALLATION the rear tab of the seat anchor cover in the front seat rear mounting bracket Then rotate the cover in the direction of arrow to install the side tabs in the side holes...

Page 1978: ...shield cover 8 Front seat hinge cover 9 Front inner seat belt 10 Power seat switch 11 Front seat cushion assembly 12 Front seat cushion cover 13 Front seat cushion pad 14 Front seat cushion frame 15 S...

Page 1979: ...terminals of each motor directly to the battery and check that the motor turns freely and each adjusting mechanism operates in the directions shown in the table below 3 If there is any malfunction re...

Page 1980: ...LATION ECLIPSE ECLIPSE Bench Seat 4 9 Nm 5 3 6 Split Seat 4 9 Nm ECLIPSE Removal steps 1 Rear seat cushion 2 Rear seat hook 3 Rear seat back Nm N O T E Metal clip position Striker removal steps 3 Quar...

Page 1981: ...POINTS SEAT BACK INSTALLATION Push the rear seat back in the direction indicated in the illustration then securely attach the attachment wire to the body hook and install the rear seat back REAR SEAT...

Page 1982: ...MBLY AND REASSEMBLY ECLIPSE Bench 9 4 Revision Disassembly steps Rear seat cushion cover 2 Rear seat cushion pad 3 Knob 4 Garnish 5 Rear seat back hinge 6 Rear seat back cover Rear seat back pad 8 Rea...

Page 1983: ...ECLIPSE SPYDER INTERIOR Rear Seat 4 Disassembly steps 1 Rear seat cushion cover 2 Rear seat cushion pad 3 Rear seat back cover 4 Rear seat back pad TSB Revision I...

Page 1984: ...r flashes four times for 6 seconds l The decision circuit output makes the seat belt warning buzzer sound intermittently for 6 se conds to indicate unfastening of the seat belt SPECIAL TOOLS l When th...

Page 1985: ...he scan sounds once when the front seat belt buckle switch L H is operated ON OFF the ETACS ECU input signal for that switch circuit system is normal When Using a Voltmeter 1 Use the special tool a vo...

Page 1986: ...buzzer does not stop sounding for six seconds even though the seat belt is buckled immediately INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 I n s p e c t i o n R e f e r e n c e pr...

Page 1987: ...It is possible that there is a malfunction of the power supply circuit including of l Malfunction of harness grounding of ETACS ECU l Malfunction of ETACS ECU Disconnect the junction and measure at t...

Page 1988: ...the seat belt warning buzzer sounds but the seat belt warning light does not il luminate nor flash Comment l Malfunction of bulb It is possible that there is a malfunction of the seat belt warning li...

Page 1989: ...check Frontsaatbelt buckle switch input circuit Front seat belt buckle switch system check OK When the front seat belt buckle Refer to switch is turned on the scan tool sounds once OK Replace the ETAC...

Page 1990: ...Rear seat belt anchor plate 5 Front seat belt sash guide cover 6 Front seat belt anchor plate 7 Quarter trim upper Refer to 8 Adjustable seat belt anchor 9 Fuel harness protector Front Inner seat remo...

Page 1991: ...l Quarter trim lower Refer to 1 Front outer seat belt Front inner seat belt removal steps l assembly Refer to 2 Harness connector Driver s seat 3 Front seat hinge cover 4 Front inner seat belt 000053...

Page 1992: ...seat adjuster FRONT OUTER SEAT BELT INSTALLATION ECLIPSE the to prevent the retractor from rotating in the hole on the body 1 Accurately insert the anchor claws into the holes on the body 2 Accurately...

Page 1993: ...elt INSPECTION FRONT SEAT BELT BUCKLE SWITCH CHECK I Switch position 2 ON 0 OFF REAR SEAT BELT SPECIAL TOOL Tool Tool number and name S u p e r s e s s i o n Application General service tool Removal o...

Page 1994: ...INSTALLATION 44 NOTE Metal clip position Revision Rear outer seat belt removal steps l Rear seat cushion Refer to 2 Rear seat belt sash guide cover 3 Rear outer seat belt Rear inner seat belt removal...

Page 1995: ...l seat cushion Refer to 1 Rear outer seat belt 2 Rear inner seat belt INSTALLATION SERVICE POINTS INNER SEAT BELT INSTALLATION ECLIPSE Install the anchor plate along the bead of the body OUTER SEAT B...

Page 1996: ...ear Seat Belt 1 Accurately insert the retractor pins into the on the body 2 Accurately insert the anchor plate claws into the holes on the body 3 Install the anchor plate along the bead of the body TS...

Page 1997: ...28 SPECIAL TOOLS 13 SERVICE PRECAUTIONS 11 SERVICE SPECIFICATIONS 12 SRS AIR BAG UNIT SRS ECU 32 TEST EQUIPMENT 13 TROUBLESHOOTING 14 CAUTION l Carefully read and observe the information in the SERVI...

Page 1998: ...the SRS deploys the air bag Only authorized service personnel should do work on or around SRS components Those service per sonnel should read this manual carefully before starting any such work Extre...

Page 1999: ...CHART PLATE Air module SRS warning light SRS ECU incorporated safing sensor and analog sensor NOTE This construction diagram displays the general view of the SRS components For details refer to Schem...

Page 2000: ...ION LABELS A number of caution labels related to the SRS are found in the vehicle as shown in the following lustration Follow label instructions when servicing SRS If labels are dirty or damaged repla...

Page 2001: ...s WARNING driver injury If the warning light does not illuminate for several seconds when ignition key is turned to or the engine is started or if the warning light stays on while driving take the veh...

Page 2002: ...nector coupled LOCK Connector uncoupled UNLOCK I I Analog Warning 3 sensor light drive circuit Microprocessor TSB Revision Clock spring I air Passenger s air bag drive circuit I Air bag module Driver...

Page 2003: ...ag module front passenger s side Data link connector For scan tool Data link connector For scan tool Instrument panel Clock spring Air bag module driver s side 18 Combination meter For warning light C...

Page 2004: ...multi meter refer to IGNITION 23 I 25 13 CONDITIONING AUTO CRUISE CONTROL SYSTEM CHARGING SYSTEM COOLING SYSTEM IGNIT METER MFI ELC AUTOMATIC TRANSAXLE ION SYSTEM AND GAUGES 14 COMBINATION METER AUTO...

Page 2005: ...J B 1 R E MICROPROCESSOR I S E N S O R I SCAN TOOL INTERFACE CIRCUIT J C 6 SRS General Information J C Y G R t 4 5 12 a A DATA LINK CONNECTOR FRONT SIDE TSB Revision...

Page 2006: ...SRS General Information COMPONENT LOCATION TSB Revision...

Page 2007: ...ng harness connectors of the SRS any of the connectors are diagnosed as faulty replace the harness If the wires are diagnosed as faulty replace or repair the wiring harness according to the following...

Page 2008: ...ts should not be subjected to heat over so remove the SRS ECU air bag module and clock spring before drying or baking the vehicle after painting Whenever you finish servicing the SRS check the SRS war...

Page 2009: ...a digital multi mete Steering wheel puller ADAPTER HARNESS TEST EQUIPMENT Tool Tool name Use Digital multi meter Checking the electrical Use a multi meter for which the maximum test circuitry with SRS...

Page 2010: ...eck trouble codes Refer Inspection chart for diagnostic trouble Refer to I codes Refer to I I TSB Revision No trouble code Intermittent malfunction Refer to How to Cope with Inter mittent Malfunctions...

Page 2011: ...t illuminate Light does off 44 SRS light drive circuit system 45 SRS ECU non volatile memory and A D converter system Driver s air bag module squib ignition drive circuit system Front passenger s air...

Page 2012: ...ble before doing any further work Refer to Replace the SRS ECU Code No 15 or 16 Safing sensor system Probable l Malfunction of SRS ECU These codes are output when the resistance value between the safi...

Page 2013: ...ss Open circuit in Malfunction of connector contact 61 The harness wire of the driver s air bag module squib is grounded to the power supply 62 The harness wire of the driver s air bag module squib is...

Page 2014: ...s l Malfunction of connector contact The harness wire of the front passenger s air bag module squib is grounded to the power supply 65 The harness wire of the front passenger s air bag module squib is...

Page 2015: ...nnecting the battery cable before doing any further work Refer to Battery cable Replace the SRS ECU Code No 34 Connector lock system Probable cause Comment l Malfunction of connectors This diagnostic...

Page 2016: ...bag this code is output If this code is output before deployment of the air bag a trouble in the SRS ECU is suspected Insulating tape Battery cable Caution Turn the ignition key to the LOCK the negati...

Page 2017: ...e light will switch off Insulating tape cable I Caution Turn the ignition key to the LOCK position the negative battery cable and tape terminal Wait at least 60 seconds after battery cable before doin...

Page 2018: ...the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Wait at least 60 seconds after disconnecting the battery cable before doing any further work Refer to...

Page 2019: ...and the SRS light will switch off Battery cable SRS check harness OK Probable cause of harnesses or connectors l bulb l Malfunction of l Malfunction of combination meter Caution Turn the ignition key...

Page 2020: ...ry cable before doing any further work Refer to P Battery cable Does light switch off when SRS ECU connector Replace the SRS ECU Check trouble symptom N G Repair Probable cause Code No 44 warning ligh...

Page 2021: ...battery cable before doing any further work Refer to P Replace the SRS ECU I Code or 52 Drivers s air bag module Squib ianition drive circuit svstem Probable cause Comment l Malfunction of SRS ECU Th...

Page 2022: ...ry cable Caution Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Wait at least 60 seconds after disconnecting the battery cable before doing any...

Page 2023: ...is not possible Probable cause Comment l of connectors The cause is probably in the power supply system including ground circuit of the l Malfunction of harness diagnostic line Refer to GROUP Troubles...

Page 2024: ...etween the terminal 13 and ground OK 9 or more l Voltage between the terminal 14 and ground OK 9 or more Check trouble symptom NG OK Check the harness R e p a i r connector OK Replace the SRS ECU MAIN...

Page 2025: ...es l SRS air bag control unit SRS ECU Refer l Air bag modules Refer to 2 Check the following parts and replace if any malfunctions are present l Clock spring Refer to l Steering wheel steering column...

Page 2026: ...d terminals for deformation Driver s side Front passenger s 0 0 0 0 0 0 5 4 side Inflator case Air Bag Module 1 Check pad cover for dents cracks or deformation 2 Check for connector damage deformed te...

Page 2027: ...y and Front Wiring Harness Check for binding harness connector damage poor connections and deformed terminals Refer to 52400290070 If the SRS components are to be removed or replaced as a result of ma...

Page 2028: ...it with a new SRS ECU Discard the old one 3 After deployment of air bags replace the with a 4 Never use an on or near ECU and use only the special test equip ment described on REMOVAL AND INSTALLATIO...

Page 2029: ...properly in a collision POST INSTALLATION INSPECTION Reconnect the negative battery terminal Turn the ignition key to the ON position Does the warning light illumi nate for about 7 seconds turn OFF an...

Page 2030: ...ring 6 Wear gloves and safety goggles handling an air bag that has 7 An undeployed air bag module should only be disposed of in accordance with the specified procedures Refer to REMOVAL AND INSTALLATI...

Page 2031: ...e negative battery cable from the battery and tape the terminal Caution Wait at least 60 seconds after disconnecting the battery cable before doing any further work Refer to BAG MODULE DRIVER S REMOVA...

Page 2032: ...place with the pad cover facing up INSTALLATION SERVICE POINTS PRE INSTALLATION INSPECTION 1 When installing the new air bag clock spring refer to INSPECTION Caution Dispose of an air bag module only...

Page 2033: ...to align the mating marks Caution If the clock spring s mating marks are not aligned the steering wheel may not be completely a turn or the flat cable within the clock spring may be severed obstructin...

Page 2034: ...efer to Caution Never attempt to measure the circuit resistance of the air bag module squib even if you are using the specified tester If the circuit resistance is measured with accidental air bag dep...

Page 2035: ...To cruise control unit To ACC power To horn relay To horn To auto cruise control switch switch 4 Check resistance between the terminals a Align the paint mark of the SRS check harness con nector No 4...

Page 2036: ...s nearby give warning of the impending noise 4 Suitable ear protection be worn by personnel performing these procedures or by people in the im mediate area DEPLOYMENT INSIDE THE VEHICLE when disposing...

Page 2037: ...leads of SRS AIR BAG ADAPTER HAR NESS 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 unex pected...

Page 2038: ...Do not perform deployment outside if a strong wind is blowing and if there is even a air bag module be placed and deployed down wind from the battery 1 Disconnect the negative and positive battery ca...

Page 2039: ...uld damage the adaptor harness 4 Place three old tires without wheels on top of the tire secured to the air bag module Front passenger s side 1 Connect the deployment wires to the SRS air bag adaptor...

Page 2040: ...ch Line 5 Dispose of the air bag module after according to the Deployed Air Bag Module Disposal Procedures Refer to DEPLOYED AIR BAG DISPOSAL After deployment the air bag module should be of in the sa...

Page 2041: ...PAGE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 improper service or maintenance of any component of the SRS or any SRS related component can lead to...

Page 2042: ...55 2 REFRIGERANT LINE 44 OUTLET SERVICE SPECIFICATIONS VENTILATORS FLOOR SPECIAL TOOLS 5 INSTRUMENT PANEL TROUBLESHOOTING 6...

Page 2043: ...ressor control l When the air conditioning switch is pushed in A C switch ON or the air outlet changeover control knob is moved to the DEF or position defroster switch ON the air conditioning system o...

Page 2044: ...le mineral 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 is rapidly absorbed by the oil Next splash...

Page 2045: ...until the temperature drops to approx when OFF Air gap Magnetic clutch mm in Engine Turbo and Engine Engine Non turbo I LUBRICANTS Items Specified lubricants Quantity Each connection of refrigerant li...

Page 2046: ...ing of refrigerant Remedy Reference Reference page page Engine Engine Non turbo Turbo Engine Replace A C compressor clutch 55 18 55 18 relay Replace the armature plate rotor 55 34 or clutch coil Reple...

Page 2047: ...Blower switch is defective Replace the blower switch 55 22 55 22 Blower fan and Short circuit of the harness Repair the harness motor keeps between the blower fan and ning motor and the blower switch...

Page 2048: ...switch is ON Battery positive voltage Engine Turbo and Engine I O N V E H I C L E S E R V I C E SIGHT GLASS REFRIGERANT LEVEL TEST The sight glass is a refrigerant level indicator To check the refrig...

Page 2049: ...er is restricted Replace the receiver drier DUAL PRESSURE SWITCH 1 Remove the dual pressure switch connector and connect the high low pressure side terminals located on the har ness side as shown in t...

Page 2050: ...the hose while pressing to ensure that there are no bends in the hose 5 Close the high and low pressure valves of the gauge manifold 6 Install the vacuum pump adaptor to the vacuum pump 7 Connect the...

Page 2051: ...20 Check for gas leaks using a leak detector If a gas leak is detected re tighten the connections and then repeat the charging procedure from evacuation in step 12 Caution A leak detector designed fo...

Page 2052: ...tall the quick joint for low pressure to the low pressure service valve NOTE The low pressure service valve should be connected to the suction hose 7 a 9 10 Start the engine Operate the air conditione...

Page 2053: ...use a compressor failure Too much oil will increase discharge air temperature When a compressor is installed at the factory it contains 170 5 7 Engine Turbo and 100 3 4 Engine Non turbo of refrigerant...

Page 2054: ...ct the quick joint press section A firmly against the service valve until a click is heard When connecting run your hand along the hose while pressing to ensure that there are no bends in the hose 6 S...

Page 2055: ...p bends in the refrigerant hose lines will greatly reduce the capacity of the entire system High pressures are produced in the system when it is operating Extreme care must be exercised to make sure t...

Page 2056: ...engine speeds and depending upon belt tension belts can develop unusual noises that are often mistaken for mechanical problems within the compressor ADJUSTMENT 1 Select a quiet area for testing Duplic...

Page 2057: ...ine Non turbo 3 When the is running after turning the A C switch to ON and the blower switch to the MH or HI position check to be sure that the idle speed is at the standard value Standard value in Ne...

Page 2058: ...ervice A C COMPRESSOR CLUTCH RELAY CONDENSER FAN RELAY LO AND HI CONTINUITY CHECK Battery voltage Terminal No 1 3 4 5 Power is not supplied 0 Engine Non turbo Condenser fan relay LO Engine NC clutch r...

Page 2059: ...and the floor console as let it orthecomponents NOTE metal clip positions Removal steps 1 Center panel 2 Floor console Refer to GROUP Floor Console 3 Radio tape player and CD player Refer to GROUP Ra...

Page 2060: ...lamp are needed for assembly line at the factory but not needed for service work 2 Set the temperature control knob on the heater control assembly to MAX HOT 3 Set the air mix lever at the upper part...

Page 2061: ...case and install the cable to the lever the outer cable in the direction of the arrow so that there is no looseness and then secure it with the clip INSPECTION Check each knob and lever for proper op...

Page 2062: ...ca ble 8 Air mix damper cable 9 Inside outside air changeover 10 Control base assembly 11 Knob assembly A 12 Panel case 13 Nut 14 Control base 15 Blower switch NOTE Parts from No 11 to No 14 are not...

Page 2063: ...ision INSTALLATION POINT CENTER AIR OUTLET INSTALLATION 1 Turn the cool air bypass lever of the center air outlet fully downward 2 Pull the cool air bypass damper lever on the heater unit side all the...

Page 2064: ...the floor console from vehicles equipped with SRS do not let it bump against the ECU or the components TSB Revision Removal steps l Instrument panel Refer to GROUP Instrument Panel 1 Heater hose conn...

Page 2065: ...pin at the center of the clip to a depth of about in 2 the clip outward to remove it Caution Do not push the pin inward more than be cause it may damage the grommet or the may fall in if pushed too f...

Page 2066: ...Resistor removal steps 1 Stopper 2 Resistor Blower fan and motor removal steps 3 Automatic compressor ECM with A C for non turbo 4 Blower fan and motor Vehicles with 8 Blower unit removal steps 5 Ins...

Page 2067: ...ON 1 With the pin pulled out insert the clip into the hole 2 Push the pin inward until the pin s head is flush with the grommet I INSPECTION 55100320016 BLOWER FAN AND MOTOR CHECK When battery voltage...

Page 2068: ...when disconnecting them Compressor oil SUN PAG 56 Turbo 6 Non turbo 00003634 Removal steps 1 Drain hose 2 Suction pipe Engine turbo or suction hose gine Turbo and Engine connection 3 Liquid pipe conne...

Page 2069: ...an necessary be cause it may damage the or the pin may fall in if pushed too far INSTALLATION U N I T When replacing the cooling unit with new refill evapo rator with a specified amount of compressor...

Page 2070: ...ing 8 Evaporator Resis tance 10 20 30 40 14 50 68 86 Temperature INSPECTION FIN SENSOR RESISTANCE CHECK When the resistance value between the sensor terminals is measured under two or more temperature...

Page 2071: ...es to prevent air from when disconnecting them I I 23 26 Nm Hose connection Compressor SUN FAG 56 23 26 Nm 23 26 Nm Tension pulley and tension pulley bracket removal steps 1 Brake fluid reservoir 2 Co...

Page 2072: ...mpressor oil amount 170 1 y indicates the amount of oil in the refrigerant line the condenser the evaporator REMOVAL SERVICE POINTS FLUID Disconnect the brake fluid level sensor connector and remove t...

Page 2073: ...Quantity Evaporator 60 2 03 Condenser 15 Suction hose 10 Receiver 10 INSPECTION 55200420047 l Checking for heat damage of the tension pulley l Check for excessive play or deflection of the tension pu...

Page 2074: ...re switch 2 Pulley l Air gap adjustment 3 N u t 4 Armature plate 5 Snap ring 6 Rotor 7 Snap ring O ring 11 High pressure relief valve DISASSEMBLY SERVICE POINTS REFRIGERANT TEMPERATURE SWITCH REMOVAL...

Page 2075: ...n installing the clutch coil to the A C compressor body install so that the pin hole of the A C compressor body and the clutch coil projection are aligned SNAP RING INSTALLATION Install the snap ring...

Page 2076: ...r for scoring or bluing l Check the sealing surfaces for cracks scratches and deformation l Check the front housing for cracks or scoring on the sealing surfaces l Check the compressor shaft for scori...

Page 2077: ...the psi during air conditioning operation Once the pressure inside the system has bean reduced to 2 940 psi or lower the valve closes thus allowing continued If a leak is detected at section A relief...

Page 2078: ...P On vehicle Service CAUTION Plug refrigerant lines to prevent from when disconnecting them I Hose connection Compressor oil ND OIL 8 Tension pulley and tension pulley bracket removal steps 1 Compress...

Page 2079: ...m the new compressor the amount of oil calcu lated according to the following formula and then install then new compressor New compressor oil amount 3 4 NOTE 1 y indicates the amount of oil in the ref...

Page 2080: ...0003640 l Air gap adjustment 1 Clutch hub 2 Shim 3 Snap ring 4 Rotor assembly 5 Snap ring 6 Clutch coil 7 Front housing holder Snap ring High pressure relief valve 14 O ring 15 Revolution pickup senso...

Page 2081: ...the O ring assembly side is facing the front housing FELT FELT HOLDER INSTALLATION After installing the felt in the felt holder them to the front housing using a 14 mm deep socket FRONT HOUSING INSTA...

Page 2082: ...lue adjust with a shim Standard value mm in NOTE If there is a deviation of the air gap from the value adjust the number of shims 55266476659 l Check the surface of the armature for scoring or bluing...

Page 2083: ...ration Once the pressure inside the system has been reduced to 2 940 psi or lower the relief valve closes thus allowing continued operation 1 If a leak is detected at section A replace the high pressu...

Page 2084: ...gerant Discharging and Charging Refer to Piping or hose connection 1 Liquid pipe A 2 Liquid pipe 3 Liquid pipe 4 Receiver assembly 5 Dual pressure switch 6 0 0 0 0 3 6 4 1 6 Receiver bracket 7 Dischar...

Page 2085: ...on 0 0 0 0 4 0 6 9 1 Liquid pipe A Liquid pipe Dual pressure switch 6 Discharge hose 7 Suction hose 8 Suction pipe 9 O ring INSTALLATION SERVICE POINT SUCTION HOSE RECEIVER ASSEMBLY INSTALLATION When...

Page 2086: ...n SUN PAG 56 1 Radiator fan motor assembly Refer to GROUP 14 Radiator Engine Turbo Refer to GROUP 14 Radiator Engine 2 Condenser fan motor and shroud assembly 6 Reserve tank 7 Upper insulator installa...

Page 2087: ...assembly Refer to GROUP 14 Radiator 2 Condenser fan motor and shroud assembly Upper insulator installation bolts 8 Liquid pipe A 9 Discharge hose 10 O ring 11 Condenser 1 Radiator fan motor assembly...

Page 2088: ...denser with a specified amount of compressor oil Engine Turbo and Compressor oil SUN PAG 56 Quantity 15 Engine Non turbo Compressor oil ND OIL 8 Quantity 40 1 35 INSPECTION CONDENSER FAN MOTOR CHECK...

Page 2089: ...r outlet 6 Floor console Refer to GROUP Floor Console 7 Radio tape player and CD Player Refer to GROUP 54 Radio Tape Player CD Player Amplifer Speaker and Antenna 8 Relay bracket 9 Semi rear heater du...

Page 2090: ...air bypass lever of the center air outlet fully downward 2 Pull the unit side all the way toward you and connect the to the lever pin 3 Push the outer cable in the direction of the arrow so that there...

Page 2091: ...lling the floor console as sembly from vehicles equipped with SRS do not let it bump against the SRS ECU or other compo nents Removal steps 1 Instrument panel Refer to GROUP Instrument Panel 2 Center...

Page 2092: ...VENTILATORS AIR OUTLET 1 Rear bumper Refer to GROUP 51 Rear Bum 2 Rear ventilation duct NOTE For the front deck garnish refer to GROUP 51 nishes...

Page 2093: ...MS ENGINE NON TURBO ENGINE TURBO AND ENGINE AXLE Rear Total Backlash Check AXLE OIL Rear Maintenance BACK UP LIGHT BALL JOINT Tie Rod End Breakaway Torque Check BALL JOINT SEALS Maintenance BAR Stabil...

Page 2094: ...End Rear CLUTCH AIR PRESSURE Tests ENGINE NON TURBO CLUTCH CONTROL CLUTCH HOUSING CLUTCH MASTER CYLINDER CLUTCH PEDAL Check and Adjustment CLUTCH RELEASE CYLINDER CLUTCHES Input COIL Ignition Check C...

Page 2095: ...n EGR SYSTEM Check ENGINE NON TURBO AND EGR VALVE Check ENGINE TURBO AND ENGINE CONTROL COMPONENT Check ENGINE TURBO AND ENGINE Layout ENGINE TURBO AND ELECTRIC CONVERTIBLE TOP BALANCE LINK BYPASS SWI...

Page 2096: ...R Condenser FENDER SYNCHRONIZER FILLER DOOR Fuel FILTER Air Engine Oil Maintenance Fuel FIXED Adjustment ENGINE TURBO AND ENGINE FLOOR CONSOLE FLUID LEAKAGE TORQUE CONVERTER HOUSING AREA ENGINE NON TU...

Page 2097: ...NTROL MOTOR Stepper Motor Check On vehicle Inspection ENGINE NON TURBO ENGINE TURBO AND Check IDLE SPEED Basic Adjustment ENGINE TURBO AND ENGINE Curb Check IDLE UP OPERATION Check IGNITION CABLES Mai...

Page 2098: ...rake Rear Maintenance Running in LOWER ARM LOW REVERSE BRAKE LSD CASE LUMINOUS INTENSITY Measurement MAGNETIC CLUTCH Test MAIN MUFFLER MAINTENANCE MANIFOLD ENGINE NON TURBO 11 ENGINE TURBO ENGINE Inta...

Page 2099: ...KE CABLE DRUM BRAKES DRUM IN DISC BRAKES PARKING BRAKE DRUM PARKING BRAKE LEVER PARKING BRAKE LEVER Stroke Check PARKING BRAKE SWITCH Check PEDAL Accelerator Brake Brake Check and Adjustment Clutch Cl...

Page 2100: ...R DRIER Test REDUCING PRESSURE Adjustment ENGINE TURBO AND ENGINE REFRIGERANT LINE REFRIGERANT Leak Repair REGULATED VOLTAGE Test ENGINE NON TURBO ENGINE TURBO AND ENGINE RELAY ASD On vehicle Inspecti...

Page 2101: ...RBO SPARK PLUG Check ENGINE NON TURBO ENGINE TURBO AND ENGINE Gleaning ENGINE NON TURBO ENGINE TURBO AND ENGINE Test ENGINE NON TURBO ENGINE TURBO AND ENGINE SPARK PLUG CABLE Resistance Check ENGINE S...

Page 2102: ...NSAXLECASE Disassembly Reassembly TRANSAXLE CONTROL ENGINE NON TURBO ENGINE TURBO AND ENGINE A T ENGINE NON TURBO ENGINE TURBO AND TRANSAXLE FLUID Automatic Maintenance Replacement ENGINE NON TURBO EN...

Page 2103: ...ATORS Air outlet Instrument panel 55 51 VOLUME AIR FLOW SENSOR ENGINE TURBO AND ENGINE WARNING CAUTION LABELS WASHER Rear Windshield WATER HOSE ENGINE NON TURBO ENGINE TURBO AND ENGINE WATER PIPE ENGI...

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