Mitsubishi MUT-II How To Use Manual Download Page 3

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GENERAL -

How to Use This Manual

00-3

MODEL INDICATIONS

The following abbreviations are used in this manual for classification of model types.

2000: Indicates models equipped with the 2,000 mL <4G63> petrol engine.

2500: Indicates models equipped with the 2,500 mL <6A13> petrol engine.

2000D: Indicates models equipped with the 2,000 mL <4D68> diesel engine.

MPI: Indicates the multi-point injection, or engine equipped with the multi-point injection.

SOHC: Indicates an engine with the single overhead camshaft, or models equipped with such an

engine.

M/T: Indicates the manual transmission, or models equipped with the manual transmission.

A/T: Indicates the automatic transmission, or models equipped with the automatic transmission.

A/C: Indicates the air conditioner.

Summary of Contents for MUT-II

Page 1: ...Inspection 11 Inspection Service Points for a Blown Fuse 12 Points to Note for Intermittent Malfunctions 12 VEHICLE IDENTIFICATION 13 Vehicle Information Code Plate 13 Models 13 Model Code 15 Chassis Number 16 Engine Model Number 17 MAJOR SPECIFICATIONS 18 PRECAUTIONS BEFORE SERVICE 20 SUPPLEMENTAL RESTRAINT SYSTEM SRS AND SEAT BELT WITH PRE TENSIONER 24 SUPPORT LOCATIONS FOR LIFTING AND JACKING 2...

Page 2: ...d servicing procedures visual inspections should always be performed as well DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted It is given by tolerance LIMIT Shows the standard for judging the quality of a part or assembly on inspection and mean...

Page 3: ...gine 2000D Indicates models equipped with the 2 000 mL 4D68 diesel engine MPI Indicates the multi point injection or engine equipped with the multi point injection SOHC Indicates an engine with the single overhead camshaft or models equipped with such an engine M T Indicates the manual transmission or models equipped with the manual transmission A T Indicates the automatic transmission or models e...

Page 4: ...lassifications of Major Maintenance Service Points When there are major points relative to maintenance and servicing procedures such as essential maintenance and service points maintenance and service stan dard values information regarding the use of special tools etc these are ar ranged together as major maintenance and service points and explained in detail AA Indicates that there are essential ...

Page 5: ... is applied Indicates the section title Indicates the group num ber Indicates the page number Indicates the group title Denotes non reus able part Repair kit or set parts are shown Only very frequently used parts are shown Operating procedures cau tions etc on removal installa tion disassembly and reas sembly are described The title of the page following the page on which the diagram of component ...

Page 6: ...rmation from the customer Check trouble symptom Reoccurs Does not reoccur Read the diagnosis code No diagnosis code or communication with MUT II not possible Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS Refer to applicable group Diagnosis code displayed Read the diagnosis code Diagnosis code displayed No diagnosis code After taking note of the malfunction code erase the diagnosis code memory...

Page 7: ...ding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms Refer to P 00 9 for how to read the inspection procedures 8 SERVICE DATA REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference information 9 CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors inspection items and standard values have been provided i...

Page 8: ...n of diagnosis code by warning lamp When the diagnosis code No 24 is output When no diagnosis code is output On Off 1 5 secs 0 5 sec 0 5 sec Pause time 3 secs Tens signal Place division 2 secs Units signal On Off 0 5 sec MPI A T 0 25 sec ABS NOTE Even if the ABS system is normal removing the valve relay causes the diagnosis code No 52 to be output METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE M...

Page 9: ...that there are trouble symptoms If trouble symptoms have disappeared the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection If it seems that trouble symptoms still remain proceed to the next page of instructions 7 If trouble symptoms still remain up to this stage there is a possibility that there is an open or short circuit in the harness be...

Page 10: ...te that if the connector control unit etc is too small to permit insertion of the test bar it should not be forced use a special tool the extra thin probe in the harness set for checking for this purpose IF INSPECTING WITH THE CONNECTOR DISCONNECTED When Inspecting a Female Pin Use the special tool inspection harness for connector pin contact pressure in the harness set for inspection The inspecti...

Page 11: ...ed the terminal connections male and female pins will not be perfect even if the connector body is connected and the pins may pull out of the reverse side of the connector Therefore gently pull the harnesses one by one to make sure that no pins pull out of the connector CONNECTOR ENGAGEMENT INSPECTION Use the special tool connector pin connection pressure inspection harness of the inspection harne...

Page 12: ...e becomes simple In order to ascertain the conditions under which an intermittent malfunction occurs first ask the customer for details about the driving conditions weather conditions frequency of occurrence and trouble symptoms and then try to recreate the trouble symptoms Next ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration temperature or ...

Page 13: ...OR B60 41H 03V B60 Body colour code INT OPT 41H Interior code 03V Equipment code For monotone colour vehicles the body colour code shall be indicated For two tone or three way two tone colour vehicles each colour code only shall be indicated in series MODELS 00100030223 SEDAN Model code Engine model Transmission model Fuel supply system EA2A SNJEQL6 4G63 SOHC 1 997 mL F5M42 2WD 5M T MPI SNHEQL6 SR...

Page 14: ... Fuel supply system EA2W LNJEQL6 4G63 SOHC 1 997 mL F5M42 2WD 5M T MPI LNHEQL6 LRHEQL6 F4A42 2WD 4A T EA5W LNGEQL6 6A13 SOHC 2 497 mL F5M42 2WD 5M T MPI LRGEQL6 F4A42 2WD 4A T EA6W LNHFQL6 4D68 SOHC 1 998 mL F5M42 2WD 5M T Electronically controlled injection pump EA2W LNJEQL6C 4G63 SOHC 1 997 mL F5M42 2WD 5M T MPI LNHEQL6C LRHEQL6C F4A42 2WD 4A T EA5W LNGEQL6C 6A13 SOHC 2 497 mL F5M42 2WD 5M T MPI...

Page 15: ...style S 4 door sedan L 4 door station wagon 5 Transmission type N 5 speed manual transmission R 4 speed automatic transmission 6 Trim level J GLX H GLS G V6 24 7 Specification engine feature E MPI SOHC F Turbocharger with intercooler 8 Exhaust system specification Q With catalytic converter None Without catalytic converter 9 Steering wheel location L Left hand R Right hand 10 Destination 6 For Eur...

Page 16: ...nnel 3 Destination A For Europe right hand drive B For Europe left hand drive 4 Body style S 4 door sedan L 4 door station wagon 5 Transmission type N 5 speed manual transmission R 4 speed automatic transmission 6 Development order EA GALANT 7 Engine 2 4G63 1 997 mL petrol engine 5 6A13 2 498 mL petrol engine 6 4D68 1 998 mL diesel engine 8 Sort A Passenger car 9 Model year V 1997 10 Plant Z Okaza...

Page 17: ...s stamped at the cylinder block as shown in the following Engine model Engine displacement mL 4G63 6A13 4D68 1 997 2 498 1 998 2 The engine serial number is stamped near the engine model number Engine serial number AA0201 to YY9999 4G63 Front of vehicle Front of vehicle 6A13 4D68 Front of vehicle ...

Page 18: ...10 1 510 Track rear 6 1 505 1 505 1 505 1 505 1 505 1 505 Overhang front 7 930 930 930 930 930 930 Overhang rear 8 1 065 1 065 1 065 1 065 1 065 1 065 Ground clear ance unladen 9 150 150 150 150 150 150 Vehicle Kerb weight 1 260 1 280 1 290 1 310 1 300 weight kg Max gross vehicle weight 1 775 1 805 1 795 Max axle weight rating front 925 955 955 Max axle weight rating rear 850 850 840 Seating capac...

Page 19: ...ar 6 1 505 1 505 1 505 1 505 1 505 1 505 Overhang front 7 930 930 930 930 930 930 Overhang rear 8 1 115 1 115 1 115 1 115 1 115 1 115 Ground clear ance unladen 9 150 150 150 150 150 150 Vehicle Kerb weight 1 310 1 310 1 330 1 340 1 360 1 350 weight kg Max gross vehicle weight 1 830 1 860 1 850 Max axle weight rating front 920 950 Max axle weight rating rear 910 910 900 Seating capacity 5 Engine Mo...

Page 20: ...t surface and placed so that the pad surface is facing upward Do not place anything on top of it 6 Never attempt to disassemble or repair the SRS components SRS air bag control unit air bag module clock spring and side impact sensor and seat belt with pre tensioner 7 Whenever you finish servicing the SRS and seat belt with pre tensioner check the SRS warning lamp operation to make sure that the sy...

Page 21: ...r the oxygen sensor with a protective cover when applying anti corrosion agents and undercoats PRE INSPECTION CONDITION Pre inspection condition refers to the condition that the vehicle must be in before proper engine inspection can be carried out If you see the words Set the vehicle to the pre inspection condition in this manual it means to set the vehicle to the following condition D Engine cool...

Page 22: ...ut which involve the electrical or fuel systems MUST be carried out in accordance with MMC s information Instructions ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin leading to dryness irritation and dermatitits In addition used engine oil contains potentially harmful contaminants which may cause skin cancer Adequa...

Page 23: ...is a risk of eye contact eye protection should be worn for example chemical goggles or face shields in addition an eye wash facility should be provided D Obtain First Aid treatment immediately for open cuts and wounds D Wash regularly with soap and water to ensure all oil is removed especially before meals skin cleansers and nail brushes will help After cleaning the application of preparations con...

Page 24: ...ing from the side of the vehicle The warning lamp on the instrument panel indicates the operational status of the SRS The clock spring is installed in the steering column The SRS side air bag deploys if an impact received at the side of the vehicle is stronger than a certain set value in order to protect the upper bodies of front seat passengers in the event of a collision The seat belt pre tensio...

Page 25: ...t The safety mechanism operates automatically when the retractor top mounting screw is removed during removal of the seat belt When the retractor top mounting screw is removed the force of the spring plate causes the tab at the lower edge of plate A to push in the pin of the G sensor which prevents the weight inside the G sensor from moving At the same time the retractor bracket and the top of pla...

Page 26: ...hese components are diagnosed as faulty they should only be replaced in accordance with the INDIVIDUAL COM PONENTS SERVICE procedures in this manual starting at page GROUP 52B 4 After disconnecting the battery cable wait 60 seconds or more before proceeding with the following work The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has ...

Page 27: ...ing harness Earth Correct or replace the dash wring harness Vehicles with SRS side air bag SRS ECU Terminal No Destination of harness Corrective action 1 2 3 Dash wiring harness Earth Correct or replace the dash wiring harness 4 Dash wiring harness Instrument panel wiring harness SRS warning lamp Correct or replace each wiring harness 5 6 Dash wiring harness Air bag module Front Passenger s side C...

Page 28: ...als are plated to increase their conductivity so that if they are touched directly by the probe the plating may break which will cause drops in reliability MB991222 SRS ECU harness connector SRS ECU harness connector rear side 7 SRS components and seat belt with pre tensioner should not be subjected to heat so remove the SRS ECU air bag module driver s side and front passenger s side clock spring ...

Page 29: ...the vehicles at locations other than specified supporting points If do so this will cause damage etc SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK Caution Never support any point other than the specified one or it will be deformed Notch Caution Never support the rear floor crossmember AXLE STANDS Notch Rubber Rubber ...

Page 30: ...POST LIFT OR DOUBLE POST LIFT Caution When service procedures require removing rear suspension spare tyre and rear bumper place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes DOUBLE POST LIFT SINGLE POST LIFT Notch Notch ...

Page 31: ...edure 1 Place the vehicle on the H bar lift same direction 2 Place attachments on the H bar lift at the designated chassis support positions When making the attachments refer to the section concerning making them Caution If support is at any location other than the designated positions the body or suspension might be deformed or otherwise damaged so care should be taken to support only at the corr...

Page 32: ...he wood selected for the blocks must be hard 2 For the B blocks and C blocks use a saw and chisel or similar tool to make grooves of the dimensions shown in the figure 3 Make four ATTACHMENTS such as shown in the figure nailing B and C blocks so that each B blocks is sandwiches between C blocks Block A mm 1 800 90 95 Block B Block C 15 40 60 100 40 20 15 40 140 40 20 40 Block C 140 100 Block C Nai...

Page 33: ...ened to plastic or die cast inserted nuts 4 If self tapping screws or self locking nuts are used Standard bolt and nut tightening torque Thread size Torque Nm Bolt nominal diameter mm Pitch mm Head mark 4 Head mark 7 Head mark 8 M5 0 8 2 5 4 9 5 9 M6 1 0 4 9 8 8 9 8 M8 1 25 12 22 25 M10 1 25 24 44 52 M12 1 25 41 81 96 M14 1 5 72 137 157 M16 1 5 111 206 235 M18 1 5 167 304 343 M20 1 5 226 412 481 M...

Page 34: ...NOTES ...

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