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Mitsubishi 3000GT Service Manual

Mitsubishi 3000GT Service Manual

Chassis and body

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Joel Copper

April 13, 2025

need torque specs for a head gasket job on my 1995 - vr-4

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Mr. Anderson

April 13, 2025

For a 1995 Mitsubishi 3000GT VR-4 using ARP head studs, torque the head studs in three steps: first to 30 ft/lbs, then 60 ft/lbs, and finally 90 ft/lbs. After reaching 90 ft/lbs, back each stud out about 1/6 turn and re-tighten to 90 ft/lbs again, following the correct sequence. This ensures even clamping and proper head seating.

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Summary of Contents for Mitsubishi 3000GT

Page 3: Manual Transaxle
... . . Alphabetical Index Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products...
Page 4 (3) Service or maintenance of any SRS component or SRS-related component must’be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) and GROUP 00 - Maintenance Service, before beginning any service or maintenance of any component of the SRS or any SRS-related compo- nent.
Page 5: Table Of Contents
GENERAL CONTENTS GENERAL DATA AND SPECIFICATIONS . . . 26 Fuel Hoses ....... . . 45 Fuel System (Tank, Pipe Line, Connections HOW TO USE THIS MANUAL .
Page 6: How To Use This Manual
GENERAL HOW TO USE THIS MANUAL MAINTENANCE, REPAIR AND or the value to which the part or assembly is cor- SERVICING EXPLANATIONS rected and adjusted. It is given by tolerance. LIMIT This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair Shows the standard for judging the quality of a and servicing of the subject model.
Page 7: Explanation Of Circuit Diagrams
GENERAL EXPLANATION OF CIRCUIT DIAGRAMS NOTE The symbols used in circuit diagrams are used as described below. For detailed information concerning the reading of circuit diagrams, refer to Volume 2 - Circuit D i a g r a m s . - The input/output (direction of cur- rent flow) relative to the electronic control unit is indicated by sym-...
Page 8: Explanation Of Manual Contents
GENERAL EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and proce- dures to be performed after the work in that section is finished. Component Diagram A diagram of the component parts is pro- vided near the front of each section in order to give the reader a better understanding of the installed condition of component parts.
Page 9 GENERAL - How to Use This Manual STEERING - Power Steering Gear Box POWER STEERtNG GEAR BOX tightening Denotes Repair kit or set parts are shown. 2. s&mid v&e OLxIlieEmr <VeNc!es wiU~ EPS> FOG lJGl+l RELAY coNnNulTY CHECX continuity between the termi- nals.
Page 10: Explanation Of The Troubleshooting Guide
GENERAL - How to Use This Manual EXPLANATION OF THE TROUBLESHOOTING GUIDE diagram for checking (including the inter- face of the air condi- tioning control unit). Indicates the con- nector number. the operation de- scriptions only as necessary, these numbers cor- respond to the num- bers used in harness is mYwed f o r &...
Page 11: How To Use Troubleshooting/ Inspection Service Points
GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINT Troubleshooting of electronic control systems for which the scan tool can be used follows the basic outline described below. Furthermore, even in systems for which the scan tool cannot be used, part of these systems still follow this outline.
Page 12 GENERAL Terminal Resistance and Continuity Checks 1. Turn off the ignition switch. 2. Disconnect the ECU connector. Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart. NOTE Checks don’t have to be carried out in the order given in the chart. Caution If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur.
Page 13: How To Use The Inspection Procedures
GENERAL - to Use Troubleshooting/inspection Service Point HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component.
Page 14 GENERAL Service Point HOW TO COPE WITH INTERMITTENT MALFUNCTIONS Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be easier to find. TO COPE WITH INTERMIITENT MALFUNCTION; 1. Ask the customer about the malfunction duplicate the customer’s complaint.
Page 15: Vehicle Identification
B: (1993 models) A: (From 1994 Driver and Passenger Air 1234567891011 12 models) Line <From 1994 modek- Convertible models W: 3000GT AWD 1234567891011 12 1234567891011 12 Convertible Price 4: High class 5: Sports (1994 models only), Premium 0 0 2 0 0 0 9 t...
Page 16: Vehicle Identification Number List
GENERAL VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR FEDERAL Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) ZltAMNXML2M Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) Z15AMNGFL2M [DOHC-MFI-Turbo] VEHICLES FOR CALIFORNIA V.I.N. (except sequence number) Brand Engine displacement Models code Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) ZllAMNXML7M [DOHC-MFI] Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) Z15AMNGFL7M...
Page 17: Vehicle Information Code Plate
GENERAL - Vehicle Identification cl996 MODELS> VEHICLES FOR FEDERAL V.I.N. (except sequence number) Brand Engine displacement Models code Mitsubishi 3.0 dm3 (181.4 cu.in.) f~:~~~~~~~~ 3000GT [DOHC-MFI] 3.0 dm3 (181.4 cu.in.) ZlGAMJGFL2M [DOHC-MFI-Turbo] VEHICLES FOR CALIFORNIA V.I.N. (except sequence number) Brand Models code Mitsubishi Hatch- 3.0 dm3 (181.4 cu.in.)
Page 18: Chassis Number
GENERAL CHASSIS NUMBER STAMPING LOCATION The chassis number is stamped on the top center of the CHASSIS NUMBER CODE CHART Chassis number code Contents A RYOOOOOl Refer to 10th thru 17th digits of V.I.N. plate. VEHICLE SAFETY CERTIFICATION LABEL The vehicle safety certification label is attached to the face of left door pillar.
Page 19: Theft Protection
GENERAL THEFT PROTECTION Theft protection label In order to protect against theft, a Vehicle Identification Number (VIN) is stamped in, or attached as a label to, the following For original parts major parts of the engine and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Door, Quar- ter panel, Hood, Liftgate, Bumpers...
Page 20 GENERAL - Vehicle Identification LOCATIONS Target area (A: for original equipment parts, B: for replacement parts) Engine Automatic transaxle Manual transaxle Manual transaxle Door Fender The illustration indicates right hand side, outer. Right hand side is symmetrically opposite. Left hand side is symmetrically opposite. TSB Revision...
Page 21 GENERAL - Vehicle Identification Target area (A: for original equipment parts, B: for replacement parts) Quarter panel Hood replacement part label is at- tached to inner side of the part shown in the illustration. The illustration indicates left hand side, outer. Right hand side is symmetrically opposite.
Page 22 GENERAL - Precautions before Service PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to follow when servicing SRS (1) Be sure to be read GROUP 528 - Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Always use the designated special tools and test equipment.
Page 23 GENERAL SERVICING ELECTRICAL SYSTEM 1. Note the following before proceeding with work on the electrical system. Note that the following must never be done: Unauthorized modifications of any electrical device or wiring, because such modifications might lead to a vehicle malfunction, over-capacity or short-circuit that could result in a fire in the vehicle.
Page 24 GENERAL - Precautions before Service SCAN TOOL (MUT) <Up to 1993 models> Scan tool (Multi-Use Tester <MUT>) (1) To operate the scan tool, refer to the“MULTI-USE TESTER OPERATION INSTRUCTIONS”. Caution Connection and disconnection of the scan tool should always be made with the ignition switch in the OFF position.
Page 25: Towing And Hoisting
GENERAL - Towing and Hoisting TOWING AND HOISTING WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP Caution This vehicle cannot be towed by a wrecker using sling- type equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equipment. The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released.
Page 26 GENERAL SAFETY PRECAUTIONS The following precautions should be taken when towing the , ’ vehicle. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER. 2. Any loose or protruding parts of damaged vehicle’such as hoods, doors, fenders, trim, etc., should be secured or removed prior to moving the vehicle.
Page 27 GENERAL - Towing and Hoisting HOISTING support Frame contact location POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations.
Page 28 GENERAL - Towing and Hoisting ‘LIFTING, JACKING SUPPORT LOCATION 0 0 0 0 2 2 8 5 EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack supplied with the vehicle for emergency road service. Always block opposite wheels and jack on level sur- face.
Page 29: For Awd Models
GENERAL SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS BRAKE TEST In order to stabilize the viscous coupling’s dragging force, the brake test should always be conducted after the speedom- eter test. FRONT WHEEL MEASUREMENTS 1. Place the front wheels on the brake tester. 2.
Page 30: General Data And Specifications
GENERAL GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS NOTE l 1: l 5: l 7: l 2: 1992 model 1995 model <Hatchback> <Hatchback> 1993 model 1994 model 1996 model l 6: l 8: 1995 model <Convertible> 1996 model <Convertible> Revision...
Page 31: Engine Specifications
GENERAL items 3000GT 3000GT SL 3000GT VR-4 <DOHC> <DOHC> <DOHC> (Non-Turbo) (Non-Turbo) (Turbo) Engine Model No. Piston displacement 2,972 (181.4) 2,972 (181.4) 2,972 (181.4) Transaxle Model No.-Type (Manual transaxle) Model No.-Type Automatic transaxle automatic automatic Fuel Fuel supply system Multiport fuel...
Page 32 GENERAL TIGHTENING TORQUE Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
Page 33: Master Troubleshooting
GENERAL - Master Troubleshooting MASTER TROUBLESHOOTING ENGINE OVERHEATS Reference page Symptom Probable cause 14-3 Engine overheats Cooling system faulty 11-9 Incorrect ignition timing ENGINE WILL NOT CRANK OR CRANKS SLOWLY Reference page Probable cause Symptom 16-19 Starting system faulty Engine will not crank or cranks slowly ENGINE WILL NOT START OR HARD TO START (CRANKS OK) Reference page...
Page 34 GENERAL - Master Troubleshooting ROUGH IDLE OR ENGINE STALLS rative emission purge control valve ENGINE HESITATES OR POOR ACCELERATION vaporative emission purge control valve Vacuum hoses TSB Revision...
Page 35 GENERAL - Master Troubleshooting ENGINE DIESELING Probable cause Reference page Symptom 11-9 Engine dieseling (runs after Incorrect ignition timing ignition switch is turned off) EXCESSIVE OIL CONSUMPTION Reference page or remedy Symptom Probable cause Repair as necessary Excessive oil consumption Oil leak 17-56 Positive crankcase ventilation line clogged...
Page 36 GENERAL - Master Troubleshooting HARD STEERING Symptom Probable cause Reference page or remedy Hard steering Loose power steering oil pump belt Low fluid level Replenish Air in power steering system Low tire pressure Excessive turning resistance of lower arm ball joint Excessively tightened steering gear box rack support cover...
Page 37 GENERAL - Master Troubleshootina POOR RIDING Reference page or remedy Symptom Probable cause Poor riding Improper tire pressure 31-3 lmbalanced wheels Repair Improper front or rear wheel alignment Malfunctioning shock absorber Broken or worn stabilizer 34-13, 16, 36, 38 Broken or worn coil spring Loose suspension securing bolt(s) Retighten Worn lower arm bushing...
Page 38 GENERAL - Master Troubleshooting VEHICLE PULLS TO ONE SIDE Symptom Probable cause Reference page or remedy Vehicle pulls to one side Improper front or rear wheel alignment lmbalanced or worn tires 31-3 Uneven tire pressure Excessive turning resistance of lower arm ball joint Wheel bearing seizure Replace...
Page 39 GENERAL - Master Troubleshootina WHEEL BEARING TROUBLESHOOTING Trouble Symptom Probable cause Pitting Pitting occurs because of uneven rotation of race Excessive bearing preload and bearing surfaces Excessive load Flaking The surface peels because of uneven rotation of End of bearing life the race and bearing surfaces Improper bearing assembly Cracking...
Page 40: Lubrication And Maintenance
GENERAL LUBRICATION AND Caution Test results submitted to EPA have shown that MAINTENANCE laboratory animals develop skin cancer after prolonged contact with used engine oil. Accord- Maintenance and lubrication service recommenda- ingly, the potential exists for humans to develop tions have been compiled to provide maximum a number of skin disorders, including cancer, protection for the vehicle owner’s investment from such exposure to used engine oil.
Page 41 GENERAL MATERIALS ADDED TO FUEL Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials in- tended for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts.
Page 42: Recommended Lubricants And Lubricant Capacities Table
necommenaea Lubrtcams ana LuDrlcant GENERAL RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS Differential (rear axle) Hypoid Gear Oil API classification GL-5 or high Above -23°C (-10°F) SAESO, 85W-90,8OW From -34°C (-30°F) to -23°C (-10°F) SAE 8OW, 8OW-90 LUBRICANT CAPACITIES TABLE U.S.
Page 43: Rear Axle
GENERAL LUBRICANTS SELECTION EOLCS certification mark ENGINE OIL Caution Never use nondetergent or straight mineral oil. Oil Identification Symbol Use only engine oils displaying the EOLCS certification mark on the container. If these oils are not available, an API classification SH ECII, Oil Viscosity The SAE grade number indicates the viscosity of the oil.
Page 44 necommenaea LuDrlcants ana LuDricant GENERAL SELECTION OF COOLANT COOLANT Relation between Antifreeze Concentration and Specific Gravity Freezing Safe operating Engine coolant temperature temperature concentration Engine coolant temperature “C (OF) and specific gravity (Specific volume) Example The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at the coolant temperature of 20°C (68°F).
Page 45: Air Cleaner Element
GENERAL - Scheduled Maintenance Table SCHEDULED MAINTENANCE TABLE <Up to 1994 models> SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER Inspection and services should be performed any time a malfunction is observed or suspected. Retain receipts for all vehicle emission services to protect your emission warranty. Service to be Kilometers in thousands 120 144 168...
Page 46: Brake Hoses
GENERAL - Scheduled Maintenance Table Kilometers in thousands 120 144 168 General maintenance Service to be performed Mileage in thousands Check for deterioration or leaks Every year Brake hoses ‘Ball joint and steering link- Inspect for grease leaks and damage Every 2 years or age seals Drive shaft boots...
Page 47 GENERAL. - Scheduled Maintenance Table SCHEDULED MAINTENANCE TABLE <From 1995 models> SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER Inspection and services should be performed any time a malfunction is observed or suspected. Retain receipts for all vehicle emission services to protect your emission warranty. Service to be Kilometers in thousands 120 144 168...
Page 48: Disc Brake Pads
GENERAL Disc brake pads Inspect for wear Every year or 16 Brake hoses Check deterioration leaks Every year Ball joint and steering link- Inspect for grease leaks and damage age seals Every 2 years or Drive shaft boots Inspect for grease leaks and damage Every year or Rear axle oil cAWD>...
Page 49: Maintenance Service
GENERAL - Maintenance Service MAINTENANCE SERVICE 1. FUEL SYSTEM (TANK, PIPE LINE, CONNECTIONS AND FUEL TANK FILLER TUBE CAP) (Check for leak) Check for damage or leakage in the fuel lines and connections and looseness of the fuel tank filler tube cap. 2.
Page 50: Ignition Cables
GENERAL 4. EVAPORATIVE EMISSION CONTROL SYSTEM (Check for leaks and clogging) 1. If the fuel-vapor vent line is clogged or damaged, a fuel vapor mixture escapes into the atmosphere causing ex- cessive emissions. Disconnect the line at both ends, and blow it clean with compressed air.
Page 51: Drive Belt
GENERAL 8. DRIVE BELT (For Generator, Water Pump, Power Steering Pump) (Check condition) Check the tension of the drive belt. Inspect the drive belt Generator Tension pulley for evidence of cuts and cracks, and replace it if defective. Idler pulley (1) Measure the deflection with a force of 100 N (22 Ibs.) applied to belt mid-point between pulleys shown in the...
Page 52: Manual Transmission Oil
256 psi and are strongly recommended for use on this vehicle. Oil Filter Part No. MITSUBISHI Genuine Parts: MD136790 or equivalent. Any replacement oil filter should be installed in accordance with the oil filter manufacturer’s installation instructions.
Page 53: Transfer Oil
GENERAL (2) Check that the transaxle oil level is at the lower portion of the filler plug hole. For AWD-vehicles, check that the transfer oil level is at the portion shown in the illustration. (3) Check to be sure that the transmission oil is not noticeably dirty, and that it has a suitable viscosity.
Page 54 GENERAL - Maintenance Service 5. Check to see if fluid level is in “HOT’ range on dipstick. If fluid level is low, add ATF until level reaches “HOT range. Low fluid level can cause a variety of conditions because it allows pump to take in air along with fluid. Air trapped in hydraulic circuit forms bubbles which make fluid spongy.
Page 55 GENERAL (lO)Add sufficient ATF to bring fluid level to lower mark. Re- check fluid level after transaxle is at normal operating temperature. Fluid level should be between upper and lower marks of “HOT’ range. Insert dipstick fully to prevent dirt from entering transaxle. Inspect each components for evidence of leakage, and check the oil level by removing the filler plug.
Page 56: Rear Axle Oil
GENERAL Check for fluid contamination and wear. Replace complete set of pads if defective. Caution The pads for the right and left wheels should be replaced at the same time. Never “split” or intermix brake pad sets. All four pads must be replaced as a complete set. Thickness of lining: Limit 2.0 mm (.08 in.) 16.
Page 57: Srs Maintenance
GENERAL 20. SRS MAINTENANCE (SRS component check: damage, function, connection to wiring harness, etc.) The SRS must be inspected by an authorized dealer 10 years after the car manufacture date shown on the certification label located on left front door latch post. Manufacture date Certification label...
Page 58 GENERAL - Maintenance Service In case that there is a notch on the lock lever (Type Place a flat tip screwdriver against the lock spring (metal section) at the lock lever notch as shown in the illustration, and push the spring toward the unit. Caution Do not use excessive force to raise the lock lever.
Page 59 GENERAL 2-3 Air Bag Module, Steering Wheel and Clock Spring Screw Ring gear Rotor <Driver’s side> Caution label To cruis mote control itch (radio) remote control switch To air bag module <From 1994 models> SRS diagnosis unit Rotor Screw Ring gear Air bag module Flat c <Driver’s side>...
Page 60 GENERAL <From 1994 models> <Passenger’s side> Air bag module Glove b& assembly (1) Remove air bag module from steering wheel. (Refer to GROUP 52Ei3 - Air Bag Module and Clock Spring.) C a u t i o n When disconnecting the air bag module-clock spring connector, take care not to apply excessive force to (2) Check pad cover for dents, cracks or deformities.
Page 61 GENERAL - Maintenance Service Pad cover Pad cover 00002291 (3) Check hooks and connectors for damage, terminals defor- mities, and harness for binds. (4) Check air bag inflator case for dents, cracks or deformities. (5) Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
Page 62 GENERAL (6) Remove the steering wheel by using special tool. Caution Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism. (7) Remove the steering column covers. (Refer to GROUP 52A - Instrument Panel.) (8) Remove the clock spring. (Refer to GROUP 52B - Air Bag Module and Clock Spring.) (9) Check clock spring connectors and protective tube for To air bag module...
Page 63 GENERAL - Maintenance Service the air bag module. REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION. (Refer to GROUP 52B - Air Bag Module and Clock Spring.) Caution The SRS may not activate properly if any of the above components is not installed properly, which could result in serious injury or death to the vehicle’s driver and pas- senger.
Page 64 GENERAL 21. EXHAUST SYSTEM (CONNECTION PORTION OF MUFFLER, PIPINGS AND CONVERTER HEAT SHIELDS) (Check and service as required) 1. Check for holes and gas leaks due to damage, corrqsion, etc. 2. Check the joints and connections for looseness and gas leaks.
Page 65: Main Sealant And Adhesive Table
Engine coolant temperature gauge unit (small size, MD091056 only) 3M ATD Part No. 8660 or equivalent Oil pan (except 4G5,4G9 engine) MITSUBISHI GENUINE Part No. MD970389 or equivalent Oil pan, Water pump, Thermostat case (4G9, 4G6, 6Al engine only) SEALING BETWEEN GLASS AND WEATHERSTRIP...
Page 66 GENERAL - Main Sealant and Adhesive Table CHASSIS SEALANT ball joint and linkage ox packing and shims ousing rack support cover and top cover of knuckle arm flange FAST BONDING ADHESIVE Recommended brand Application 3M ATD Part No. 8155 or equivalent Adhesion of all materials except polyethylene, polypropylene, fluorocarbon resin or other materials with highly absorbent surface ANAEROBIC FAST BONDING ADHESIVE...
Page 67 ENGINE CONTENTS CAMSHAFT OIL SEALS ....21 SPECIAL TOOLS ......4 CRANKSHAFT FRONT OIL SEAL .
Page 68: Specifications
ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS Items Non-Turbo Turbo V-type, DOHC V-type, DOHC Number of cylinders Bore mm (in.) 91 .l (3.587) 91 .l (3.587) Stroke mm (in.) 76.0 (2.992) 76.0 (2.992) Piston displacement cc (cu.in.) 2,972 (181.4) 2,972 (181.4) SERVICE SPECIFICATIONS HC concentration ppm 100 or less NOTE...
Page 69: Timing Belt
Amount of projection of auto tensioner rod mm (in.) 3.8-4.5 (.149-.177) (distance between the tensioner arm and auto tensioner body) SEALANTS Items Specified sealant Oil pan MITSUBISHI GENUINE Part No. MD970389 or equivalent Rocker cover 3M ATD Part No. 8660 or equivalent TSB Revision...
Page 70: Precautions Before Service
ENGINE - Special Tools SPECIAL TOOLS Tool number Tool Supersession Application and name MB991341 MB991 341 Up to 1993 models Idle speed check Scan tool (Multi-use tester cMUT>) ROM pack (For the number, refer to GROUP 00 - Precau- tions before ser- vice.) MB991 502 MB991502...
Page 71 ENGINE - Special Tools Tool number Tool Supersession Application and name MB990767 Supporting the sprocket and shaft pulley when attaching or detaching them End yoke holder Supporting the crankshaft pulley when crank- bolt shaft and pulley are removed or reinstalled. MD998754 Crank pulley holder...
Page 72: Troubleshooting
ENGINE - Troubleshooting TROUBLESHOOTING Oil relief valve stuck (opened) Repair relief valve Excessive bearing clearance Replace bearings Oil pressure too high Oil relief valve stuck (closed) Repair relief valve Incorrect lash adjuster Noisy valves Replace lash adjuster Connecting rod noise/ main bearing noise TSB Revision...
Page 73 ENGINE Service ON-VEHICLE SERVICE DRIVE BELTS TENSION ADJUSTMENT (1) Check that the belts are not damaged and are properly fit into the pulley grooves. Caution 1. When installing the V-ribbed belt, check that the V-ribs are properly fit without misalignment. 2.
Page 74: Tightening Torque
ENGINE - On-vehicle Service GENERATOR DRIVE BELT TENSION ADJUSTMENT (1) Remove front under cover panel <Vehicle with active (2) Remove under covers (front L.H., side L.H.). (3) Loosen tension pulley fixing nut. Adju bolt (4) Adjust belt deflection with adjusting bolt. (5) Tighten fixing bolt.
Page 75 11-9 ENGINE - On-vehicle Service IGNITION TIMING CHECK 4 9 9 2 m o d e l s > (1) The vehicle should be prepared as follows before the inspection and adjustment. Engine coolant temperature: 80-95°C (176-203°F) Lights, electric cooling fan and accessories: OFF Transaxle: neutral (P for AIT) (2) Insert a paper clip to the engine speed detection connector (blue), and connect a tachometer to the paper clip.
Page 76 ENGINE correct timing. Actual ignition timing: Approx. 15” BTDC NOTE (1) Ignition timing is variable within about +7”, even-under normal operation. (2) And it is automatically further advanced by about 5 from 15” BTDC at higher altitudes. IGNITION TIMING CHECK (1) The vehicle should be prepared as follows before the inspection and adjustment.
Page 77 I I - I I ENGINE - On-vehicle Service check the crankshaft position sensor by reference to GROUP 13A - On-vehicle Inspection of MFI Components. (12)Disconnect the jumper wire connected at step (8). (13)Check to be sure that the idling ignition timing is the correct timing.
Page 78 ENGINE IDLE MIXTURE CHECK (1) Before inspection, set the vehicle in the following condi- tion. Engine coolant temperature: 80-95°C (176-203°F) Lights, electric cooling fan and accessories: OFF Transaxle: P range (2) Make sure that the basic ignition timing is of a standard value.
Page 79 ENGINE for California> (1) Inspect the idle speed before inspection and adjustment of the dashpot. (2) Set the vehicle in the following conditions before dashpot inspection and adjustment. Engine coolant temperature: 80-95°C (176-203°F) Lights, electrical cooling fan and accessories: OFF Transaxle: neutral (3) Set the tachometer or connect the scan tool to the data link connector (white).
Page 80 ENGINE COMPRESSION PRESSURE CHECK (1) Prior to inspection, check to ensure that the engine oil, starter motor and battery are in proper condition. Place the vehicle in the following conditions. Engine coolant temperature: 80-95°C (176-203°F) Lights, electric cooling fan and accessories: OFF Transaxle: Neutral (P for A/T) (2) Remove the spark plug cables.
Page 81 ENGINE (9) If there is a cylinder in which the compression pressure or pressure difference is beyond the limit value, pour in a small amount of engine oil through the spark plug mounting hole, and repeat Steps (7) through (8). 1) If the small amount of oil poured in causes the com- pression pressure to rise, then it is likely that either the piston ring, cylinder wall surface or both are worn...
Page 82 ENGINE - On-vehicle Service (2) If the engine oil level is higher than the specified level, agitation of the oil by the crankshaft could cause a large amount of air to enter the oil. (3) A deteriorated oil contains a large amount of air, be- cause the air, once trapped, is not readily separated from the oil.
Page 83 ENGINE NOTE (1) If the leak-down test is performed, the lash adjust- er can be judged accurately to be defective or not. (2) For the leak-down test procedure or the procedure for removing air from the lash adjuster, refer to the Engine Service Manual.
Page 84: Engine Assembly
ENGINE ENGINE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation High Pressure Fuel Hose Release of Residual Radiator installation (RefertoGROUP 14-Radiator.) Procedures.) (Refer to GROUP 13G - Cruise Control.) Cruise Control Pump and Link Assembly Removal Transaxle Assembly Installation (Refer to GROUP 13G - Cruise Control.) Hood Removal (Refer to GROUP 42 - Hood.) Air Hose and Air Pipe <Turbo>...
Page 85 ENGINE 70 Nm 51 ft.lb;s. 0 0 0 0 2 1 1 8 Idle air control motor connector 31. Ignition power transistor connector 20. TPS connector 32. Fuel injector connector 21. Oil pressure switch and oil 33. Variable induction motor connector pressure gauge unit connector <Non-Turbo>...
Page 86 ENGINE - Engine Assembly REMOVAL SERVICE POINTS STEERING OIL PUMP DISCONNECTION Disconnect air conditioning compressor and power steering oil pump (with the hose). NOTE The removed air conditioning compressor and power steering oil pump should be fastened (by using rope, etc.) in a position that will not interfere with the removal/installation of the engine assembly.
Page 87: Camshaft Oil Seals
ENGINE CAMSHAFT OIL SEALS REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Timing Belt Removal (Refer to P.ll-31.) Camshaft Position Sensor installation Intake Manifold Removal (Refer to GROUP 16 - Cam Position Sensor and (Refer to GROUP 15 - Intake Manifold.) Crankshaft Position Sensor.) Camshaft Position Sensor Removal Intake Manifold Installation...
Page 88 ENGINE REMOVAL SERVICE POINTS Using a wrench at the hexagonal part of the camshaft (to prevent the crankshaft from turning), loosen the camshaft sprocket bolt. Caution Do not hold the camshaft sprocket with a tool, or a dam- aged sprocket could result. Oil seal (1) Cut out a portion in the camshaft oil seal lip.
Page 89: Oil Pan And Oil Screen
Front Air Dam Removal and Installation <Active Aero> (Refer to GROUP 51 - Aero Parts.) (Refer to GROUP 22 - Transfer Assembly.) Under Cover Removal and installation Sealant: MITSUBISHI GENUINE Part No. MD970389 or equivalent ..w-. 9 Nm...
Page 90 ENGINE - Oil Pan and Oil Screen REMOVAL SERVICE POINT MD998727 -..---- MD998727 .------y 1 After removing the bolts, use the special tool and a brass bar to remove the oil pan from the cylinder block. Caution /-i: Remove the oil pan gradually since the flange of the oil pan is easy to deform.
Page 91: Crankshaft Front Oil Seal
ENGINE CRANKSHAFT FRONT OIL SEAL Pre-removal and Post-installation Operation Timing Belt Removal and Installation Crankshaft Position Sensor Removal and Installation (Refer to GROUP 16 - Camshaft Position Sensor and Crankshaft Position Sensor.) Removal steps ä 2. Crankshaft sensing blade 3. Crankshaft spacer REMOVAL SERVICE POINT (1) Make a notch in the oil seal lip section with knife, etc.
Page 92: Crankshaft Rear Oil Seal
ENGINE - Crankshaft Rear Oil Seal CRANKSHAFT REAR OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Transaxle Assembly Removal and Installation Clutch Cover and Clutch Disc Removal and Installa- tion 73-77 Nm Removal steps 1. Flywheel R E M O V A L S E R V I C E P O I N T S Stop the crankshaft pulley from turning, and remove the fly- wheel.
Page 93 ENGINE - Crankshaft Rear Oil Seal INSTALLATION SERVICE POINT Cylinder side (1) Apply a small amount of engine oil to the oil seal lip and then insert. (2) Tap the oil seal into the cylinder block.
Page 94: Cylinder Head Gasket
ENGINE - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Timing Belt Installation (Refer to P.li-31.) (Refer to GROUP 00 - Maintenance Service.) Exhaust Manifold Installation Air Intake Manifold Removal (Refer to GROUP 15 - Exhaust Manifold.) (Refer to GROUP 15 - Air Intake Manifold.) Turbocharger Installation <Turbo>...
Page 95 ENGINE - Cylinder Head Gasket REMOVAL SERVICE POINTS (A, INTAKE CAMSHAFT SPROCKET REMOVAL remove the camshaft sprocket bolt. Caution Locking the camshaft sprocket with a tool damages the sprocket. (2) Remove the camshaft sprockets. Using the special tool, remove the cylinder head assembly. NOTE Use of commercially available cylinder head bolt wrench is recommended.
Page 96 ENGINE Using a wrench, hold the camshaft at its hexagon and tighten the bolt to specification. Caution Locking the camshaft sprocket with a tool damages the sprocket. Rear bank Tighten the rocker cover bolts in the order shown in the illustra- tion.
Page 97: Timing Belt
ENGINE - Timing Belt TIMING BELT REMOVAL AtiD INSTALLATION Post-installation Operation Pre-removal Operation Generator Assembly installation Under Cover (Front L.H., Side L.H.) Removal (Refer to GROUP 16 - Generator.) Front Under Cover Panel Removal Under Cover (Front L.H., Side L.H.) Installation Front Under Cover Panel Installation (Refer to GROUP 51 - Aero Parts.) Cruise Control Pump and Link Assembly Removal...
Page 98 ENGINE REMOVAL SERVICE POINTS Using special tools, remove the crankshaft pulley from the crankshaft. Caution Use only the specified special tools, or a damaged pulley damper could result. Remove the engine support bracket in the numbered se- quence shown in the illustration. Spraying lubricant, slowly remove the bolt (reamer bolt) indi- cated by the arrow.
Page 99 ENGINE - Timing Belt Caution Push in the rod slowly to prevent the push rod from being damaged. 3) Insert a wire [I.4 mm (.055 in.) in diameter] into the set holes. 4) Unclamp the auto tensioner from the vise.’ (2) Install the auto tensioner.
Page 100 ENGINE -. Timing Belt 5) Align the timing mark of the crankshaft sprocket. NOTE Shift the timing mark of the crankshaft sprocket one tooth in counterclockwise direction to facilitate belt installation. (2) Using bulldog clips, install the timing belt in the following order with care not to allow the belt to slack.
Page 101 ENGINE Belt NOTE Even if the set pin cannot be easily inserted, the auto tensioner is normal if its rod protrusion is within specifica- tion. Standard value (A): 3.8-4.5 mm (.149-.177 in.) If the protrusion is out of specification, repeat steps (1) to (4).
Page 102: Removal And Installation
ENGINE - Engine Oil Cooler ENGINE OIL COOLER REMOVAL AND INSTALLATION Preremoval and Post-installation Operation Engine Oil Draining and Supplying (Refer to GROUP 00 - Maintenance Service.) 9 ft.lbs. Removal steps oil return tube 1. Front splash shield extension 4. Engine 2.
Page 103 CONTENTS MULTIPORT FUEL INJECTION (MFI) ......13A ELECTRONIC CONTROL TYPE CARBURETOR ....13B CONVENTIONAL TYPE CARBURETOR .
Page 104 13-2...
Page 105 CONTENTS GENERAL INFORMATION ......3 Induction Control Valve Position Sensor ... 242 Injectors .
Page 106 Fuel Pressure Solenoid., ..... ON-VEHICLE SERVICE ......Fuel Pressure Test .
Page 107: General Information
MULTIPORT FUEL INJECTION - General Information GENERAL INFORMATION MULTIPORT FUEL INJECTION (MFI) SYSTEM DIAGRAM Intake air temp. sensor tank EVAP canister Electric load switch module NOTE ‘1: EVAP purge solenoid ‘ 2 : lniector ‘6: Fuel pump relay ‘7: Ignition coil ‘8: Check engine/malfunction indicator lamp ‘9: Engine/transaxle total control TSB Revision...
Page 108 MULTIPORT FUEL INJECTION - General Information <California Non Turbo - Up to 1993 models> , TPS (with closed throttle position switch) 6 ‘7 ‘t Heated oxygen sensor Knock sensor Enoine coolant temo. sensor ) Induction control valve position sensor Throttle position sensor, Closed throttle position switch lntake air temp.
Page 109 MULTIPORT FUEL INJECTION <California Non Turbo - 1994 and 1995 models> Intake air temp. sen~nr Fuel tank * Heated Intake arr temp. sensor NOTE ‘1 : . f%/AP purge solenoid ‘2: Injector ‘4: Idle air control motor ‘5: Variable induction control motor ‘6: Heater control ‘11: tngme/trfLnsaxle total control...
Page 110 Intake air temperature sensor module Induction control valve position sensor _ Throttle position sensor, Closed throttle cosition switch NOTE l l : EVAP purge solenoid ‘2: Injector ‘3: EGR solenoid ‘4: Idle air control motor ‘5: Variable induction contorl motor ‘6: Heater control ‘7: A/C compressor clutch relay l 8: Fuel pump relay...
Page 111 MULTIPORT FUEL INJECTION - General Information <Turbo - 1992 models> intake air NOTE ‘1: injector ‘2: EGR solenoid ‘3: IAC motor ‘4: Fuel pressure solenoid ‘5: Evaporative emission purge solenoid ‘6: Turbocharger waste gate solenoid ‘7: AC compressor clutch relay “8: Fuel pump relay ‘9: Ignition coil “10: Check engine/malfunction indicator lamp...
Page 112 <Turbo - From 1993 Up to 1995 models> Intake air temp. senso NOTE ‘1: Injector ‘2: EGR solenoid ‘3: Evaporative emission purge solenoid ‘4: IAC motor ‘5: Fuel pressure solenoid ‘6: Turbocharger waste gate solenoid “7: AK compressor clutch relay ‘8: Fuel pump relay ‘9: Ignition coil ‘10: Check engine/malfunction indicator lamp...
Page 113 MULTIPORT FUEL INJECTION - General Information Intake air temperature senso NC switch _ Check enaine~ Iam TSB Revision...
Page 114 MULTIPORT FUEL INJECTION SPECIFICATIONS GENERAL SPECIFICATIONS California <Non Turbo> emperature sensor c NOTE l: 1992 models 2: 1993 models Except 1992 models From 1996 models TSB Revision...
Page 115 MULTIPORT FUEL INJECTION - Specifications Specifications terns Power steering pressure switch Contact switch type Sensors Contact switch type Injector type and number Electromagnetic, 6 Injector identification mark <Non Turbo> BDH21 O*‘? Injector identification mark <Turbo> BDL360 Variable induction control motor Direct current motor type ON/OFF type solenoid valve*4 Evaporative emission purge solenoid...
Page 116 MULTIPORT FUEL INJECTION SERVICE SPECIFICATIONS e speed when air conditi gine coolant temperatu SEALANT Specified sealant Items 3M NUT Locking Part No. 4171 or equivalent Engine coolant temperature sensor threaded portion TSB Revision...
Page 117 MULTIPORT FUEL INJECTION - Special Tools SPECIAL TOOLS Reading diagnostic trouble code MFI system inspection tester cMUT> Test harness set Basic idle speed adjustment Inspection by oscilloscop TSB Revision...
Page 118 MULTIPORT FUEL INJECTION - Special Tools TSB Revision...
Page 119: Explanation Of Troubleshooting Procedures
MULTIPORT FUEL INJECTION - Troubleshooting TROUBLESHOOTING EXPLANATION OF TROUBLESHOOTING START PROCEDURES Effective troubleshooting procedures for MFI system problems are given below. Reproduce trouble symptom and verify the character- istics of the trouble and the conditions (engine condi- tion, driving conditions, etc.) under which it is pro- duced.
Page 120: Explanation And Cautions About Harness Check
MULTIPORT FUEL INJECTION - Troubleshooting EXPLANATION AND CAUTIONS ABOUT HARNESS CHECK The connector symbol shown is as viewed from the termi- nal end of the connector inside the vehicle. for system voltage. When checking a waterproof connector for circuit continu- ity, be sure to use the special tool, Test Harness.
Page 121 MULTIPORT FUEL INJECTION - Troubleshooting If the sensor impressed voltage is abnormal, check the wire for an open circuit or short-circuit to ground and repair as necessary. If the wire is normal, replace the engine control module and check again. To check the voltage, use a digital voltmeter (or circuit tester) as a rule.
Page 122 MULTIPORT FUEL INJECTION - Troubleshooting ITEMS INDICATED BY THE CHECK ENGINE/MALFUNCTION INDICATOR LAMP <From 1996 models> TSB Revision...
Page 123 MULTIPORT FUEL INJECTION - Troubleshooting NOTE When the ECM monitored the powertrain malfunction three times* and detected no 1. After the Engine Control Module (ECM) detects a malfunction, the check engine/malfunction malfunction. indicator lamp illuminates when the engine is In this case, one time indicates from engine next turned on and the same malfunction is start to stop.
Page 124 MULTIPORT FUEL INJECTION - Troubleshooting Caution If the sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code is memo- rized. In this case, send the diagnostic trouble code erase signal from the scan tool to the engine control module or disconnect the battery terminal (-) for 10 seconds or more, and the diagnostic memory will be erased.
Page 125 MULTIPORT FUEL INJECTION - Troubleshooting Code No. Output signal pattern Diagnostic item Check item (Remedy) Memory Enginecoolanttemperaturesensor Harness and connector Retained Engine coolant temperature sensor Crankshaft position sensor Harness and connector Retained (If harness and connector are normal, replace crankshaft position sensor assembly.) Camshaft position sensor Harness and connector...
Page 126 MULTIPORT FUEL INJECTION - Troubleshooting Code No. Output signal pattern Diagnostic item Check item (Remedy) Memory Ignition coil, ignition powertransis- Harness and connector Retained tor unit Ignition coil (No. l-4 cylinder) Ignition power transistor unit Ignition coil, Ignition power transis- Harness and connector Retained tor unit...
Page 127 MULTIPORT FUEL INJECTION - Troubleshooting DIAGNOSTIC DETECTION LOGIC Fault ID Title Heated Oxygen Sensor (front) <Except Effect Probable causes 1994 and Later California model> / Left Bank Heated Oxygen Sensor (front) cl994 and Later California model> Limp-in Oxygen sensor deteriorated. Background Open or shorted oxygen The oxygen sensor converts the oxygen density in the exhaust...
Page 128 MULTIPORT FUEL INJECTION Fault ID Title Effect Probable causes Intake Air Temperature Sensor Background Limp-in Intake air temperature sensor failed. temperature to a voltage and outputs it. air temperature is 25°C temperature sensor circuit, or The engine control module checks whether the voltage is within (77°F).
Page 129 MULTIPORT FUEL INJECTION - Troubleshooting Fault ID Title Probable causes Effect Engine Coolant Temperature Sensor Engine coolant temperature Background Limp-in sensor failed. Controls as if the engine The engine coolant temperature sensor converts the engine Open or shorted the engine coolant temperature to a voltage and outputs it.
Page 130 MULTIPORT FUEL INJECTION - Troubleshootina Fault ID Title Effect Probable causes Camshaft Position Sensor Background Limp-in Camshaft position sensor failed. (a) Injects fuel into all When the engine is running, the camshaft position sensor outputs Open or shorted camshaft a pulse signal. cylinders simulta- position sensor circuit, or loose neously.
Page 131 MULTIPORT FUEL INJECTION - Troubleshootina Fault ID Title Probable causes Effect Barometric Pressure Sensor Limp-in Barometric pressure sensor Background failed. The barometric pressure sensor outputs a voltage which Controls as if the baro- Open or shorted barometric corresponds to the barometric pressure. metric pressure is 101 pressure sensor circuit, or The engine control module checks whether this voltage is within...
Page 132 MULTIPORT FUEL INJECTION oxygen sensor Probable causes xygen sensor deteriorated. or shorted oxygen Incorrect fuel pressure. Injector failed. Range of Check Engine control module failed. 3 minutes have passed after engine was started. Engine coolant temperature is approx. 80% (176OF) or more. Intake air temperature is 20-50°C (68-122°F).
Page 133 MULTIPORT FUEL INJECTION - Troubleshooting Fault ID Title Effect Probable causes EGR System Non Turbo, EGR valve does not open. No limp-in Backaround EGR control vacuum istoo low. EGR temperature sensor converts the EGR gas temperature EGR solenoid failed. to a voltage and outputs it. EGR temperature sensor Engine control module checks whether an output voltage of...
Page 134 MULTIPORT FUEL INJECTION - Troubleshooting Probable causes nverts the oxygen density in the exhaust odule checks an output voltage of the the oxygen volume in the exhaust gas Range of Check Approx. 3 minutes or more have passed after engine was started. Engine coolant temperature is approx.
Page 135 MULTIPORT FUEL INJECTION Fault ID Title Effect Probable causes 62 <Non Induction Control Valve Position Turbo> Sensor Limp-in Background sensor failed. The induction control valve position sensor outputs a pulse signal The induction control Open or shorted induction valve is driven under according to a change of the valve opening.
Page 136 LIST OF FAIL-SAFE/BACK-UP FUNCTIONS When the failure of a major sensor is detected by the on-board diagnostics, the preset control logic provides controls to assure safe operation of the vehicle. Trouble item Controls to be provided in the event of trouble Volume air flow Based on throttle position sensor (TPS) signal and engine speed signal (crank angle sensor sensor...
Page 137 MULTIPORT FUEL INJECTION - Troubleshooting ON-BOARD DIAGNOSTICS <From 1996 models> Caution The engine control module monitors the If the sensor connector is disconnected with input/output signals (some signals at all times and the ignition switch turned on, the diagnostic the others under specified conditions) of the engine trouble code is memorized.
Page 138 MULTIPORT FUEL INJECTION - Troubleshooting OBD-II DRIVE CYCLE All kinds of diagnostic trouble code can be monitored by carrying out a short drive in accordance with the following drive cycle pattern. In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the check engine/malfunction indicator lamp and to check if the repair procedure has eliminated the trouble (the check engine/malfunction indicator lamp is no more illumir$ed).
Page 139 MULTIPORT FUEL INJECTION DIAGNOSTIC CHART (FAULT TREE) DTC No. DTC No. Check item (Remedy) Diagnostic item Memory (MUT-II) scan tool mode> mode> PO100 Volume Air Flow Circuit Harness and connector Retained Malfunction (If harness and connector are normal, replace volume air flow sensor assembly.) Barometric Pressure Circuit Harness and connector Retained...
Page 140 Diagnostic item Check item (Remedy) Injector Circuit Malfunction - position sensor circuit and (If harness and connector are normal, replace Circuit Malfunction PO340 PO340 Camshaft Position Sensor Harness and connector Retained Circuit Malfunction (If harness and connector are normal, replace camshaft position sensor.) Exhaust Gas Recirculation Flow Retained...
Page 141 MULTIPORT FUEL INJECTION - Troubleshooting DTC No. DTC No. <General Diagnostic item Check item (Remedy) Memory scan tool (MUT-II) mode> mode> Vehicle Speed Sensor Malfunc- Retained PO500 PO500 Harness and connector tion Vehicle speed sensor PO505 Idle Control System Malfunction Harness and connector Retained PO505...
Page 142 MULTIPORT FUEL INJECTION - Troubleshootinn DIAGNOSTIC DETECTION LOGIC DTC No. Title Probable causes Volume Air Flow Circuit Malfunction Background Volume air flow sensor failed. While the engine is running, the volume air flow sensor outputs a pulse signal which Open or shorted volume air flow corresponds to the volume of air flow.
Page 143 MULTIPORT FUEL INJECTION - Troubleshooting Title DTC No. Probable causes PO115 Engine Coolant Temperature Circuit Malfunction Engine coolant temperature sensor failed. Open or shorted the engine and outputs it. coolant temperature sensor circuit, or loose connector. addition, it checks the engine coolant temperature (signal) does not drop while the engine is warming up.
Page 144 MULTIPORT FUEL INJECTION - Troubleshootina DTC No. Title Probable causes PO1 25 Excessive Time to Enter Closed Loop Fuel Control Background Heated oxygen sensor failed. The MFI system reduces exhaust emissions by means of closed-loop fuel control. Injector failed. The engine control module checks the time taken until closed-loop fuel control commences. Engine control module failed.
Page 145 MULTIPORT FUEL INJECTION - Troubleshooting DTC No. Title Probable causes Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) Background Open or shorted oxygen sensor The engine control module checks whether the heater current is within a specified range when heater circuit.
Page 146 MULTIPORT FUEL INJECTION - Troubleshooting DTC No. Title Probable causes Fuel Trim Malfunction (Bank 1) Background Volume air flow sensor failed. If a malfunction occurs in the fuel system, the fuel compensation value bacomes too large Injector failed. or too small. Air drawn in from gaps in gasket The engine control module checks whether the fuel compensation value is within a specified range.
Page 147 MULTIPORT FUEL INJECTION - Troubleshooting Title DTC No. Probable causes PO301 - Cylinder-l - Cylinder-6 Misfire Detected P O 3 0 6 Ignition system related part(s) Background failed. If a misfiring occurs while the engine is running, the engine speed suddenly changes. Engine control module failed.
Page 148 MULTIPORT FUEL INJECTION - Troubleshooting DTC No. Title Probable causes PO400 Exhaust Gas Recirculation Flow Malfunction Background When the EGR solenoid switches from OFF to ON while the engine is running, EGR gas EGR control vacuum is too low. flows. EGR solenoid failed.
Page 149 MULTIPORT FUEL INJECTION - Troubleshooting Title DTC No. Probable causes PO440 Evaporative Emission Control System Malfunction Evaporative emission purge Background solenoid failed. Open or shorted evaporative Then the fuel compensation value change according to whether the evaporative emission emission purge solenoid circuit, canister emits purge air or not.
Page 150 MULTIPORT FUEL INJECTION - Troubleshooting Title DTC No. Probable causes PO51 0 Closed Throttle Position Switch Malfunction Background Closed throttle position switch While the engine is idling without pressing the accelerator pedal, “ON” signal can be input failed. from the closed throttle position switch to the engine control module. Open or shorted closed throttle The engine control module is used for checking the input signal during the engine idling.
Page 151 MULTIPORT FUEL INJECTION - Troubleshooting DTC No. Title Turbocharger waste gate sole- Background The engine control module checks current flows in the turbocharger waste gate solenoid drive noid failed. Open or shorted turbocharger circuit when the solenoid is ON and OFF. waste gate solenoid circuit, or Range of Check, Set Conditions loose connector.
Page 152 MULTIPORT FUEL INJECTION - Troubleshooting DTC No. Title Probable causes Background Pulse generator failed. The transaxle control module monitors the pulse signals of the pulse generator “A” and Engine control module failed. When the pulse generators “A” and “B” are failed, the transaxle control module inputs the pulse generator failed signal to the engine control module.
Page 153 MULTIPORT FUEL INJECTION - Troubleshooting LIST OF FAIL-SAFE/BACK-UP FUNCTIONS When the failure of a major sensor is detected by the on-board diagnostics, the preset control logic provides controls to assure safe operation of the vehicle. Trouble item Controls to be provided in the event of trouble Volume air flow (1) Based on throttle position sensor (TPS) signal and engine speed signal (crank angle sensor sensor...
Page 154: Read Out Of Diagnostic Trouble Code
READ OUT OF DIAGNOSTIC TROUBLE CODE Caution (1) When battery voltage is low, no detection of failure is possible. Be sure to check the battery for voltage and other conditions before starting the test. (2) Diagnostic item is erased if the battery or the engine control module connector is disconnected.
Page 155 MULTIPORT FUEL INJECTION - Troubleshooting WHEN USING THE CHECK ENGINE/MALFUNCTION INDICATOR LAMP <1994 AND 1995 MODELS> (1) Using the special tool, Diagnostic Trouble Code Check Harness, ground the diagnostic test mode control terminal (terminal 1) of the data link connector. (2) Turn the ignition switch to ON.
Page 156: Check Chart Classified By Problem Symptoms
MULTIPORT FUEL INJECTION - Troubleshooting CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS items Starting Starting idling Idling idling Reference stability stability stability page (13A-) Will not Fires up Idling Incorrect Engine start and dies instability idle speed stall Hard (rough starting idling) Power supply and ignition switch-IG Engine control module power around...
Page 157 MULTIPORT FUEL INJECTION - Troubleshootina Items Driving Driving Driving Driving Driving Driving Reference page (13A-) Poor Shock Surge Run-on tion eration Power supply and ignition switch-IG Engine control module power ground / I 1 (1) I Fuel pump 1 (1) Volume air flow sensor I 5 (5) I 5 (5)
Page 158: Problem Symptoms Table (For Your Information)
MULTIPORT FUEL INJECTION - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Won’t star-l The starter is used to crank the engine, but there is no combustion within (no initial combustion) the cylinders, and the engine won’t start. Starting Fires up and dies There is combustion within the cylinders, then the engine soon stalls.
Page 159: Basic Idle Speed Adjustment
MULTIPORT FUEL INJECTION - On-vehicle Service ON-VEHICLE SERVICE BASIC IDLE SPEED ADJUSTMENT NOTE (1) The basic idle speed has been factory-adjusted with the engine speed adjusting screw and does not normally re- quire adjustment. (2) If adjustment has been disturbed, or if the idle speed is too high or it drops owing to application of air conditioning load to the engine, perform the following step to make adjustment.
Page 160 MULTIPORT FUEL IbiJECTlON - On-vehicle Service From 1994 models: 3) Use the special tool (Diagnostic Trouble Code Check Harness) to ground the diagnostic test mode control terminal (terminal (1)) of the data link connector WFU1466 (4) Remove the waterproof female connector from the ignition timing adjusting connector (brown).
Page 161: Throttle Body (Throttle Valve Area) Cleaning
MULTIPORT FUEL INJECTION - On-vehicle Service THROTTLE BODY (THROTTLE VALVE AREA) CLEANING (1) Start the engine, warm it up until engine coolant tempera- ture rises to 80°C (176”F), and stop the engine. (2) Disconnect the air intake hose at the throttle body side. (3) Put a plug in the inlet of bypass passage in the throttle b o d y .
Page 162 MULTIPORT FUEL INJECTION - On-vehicle Service (2) Insert a 0.65-mm (.025 in.)-thick feeler gauge between the fixed SAS and throttle lever. Engine speed adjusting (3) If the MUT-II is used, turn the ignition switch to ON position. (Do not start the engine.) (4) Loosen the throttle position sensor mounting bolts and turn the throttle position sensor body fully counterclock- wise.
Page 163: Fixed Sas Adjustment
MULTIPORT FUEL INJECTION - On-vehicle Service FIXED SAS ADJUSTMENT NOTE (1) The fixed SAS has been factory-adjusted. Never attempt to move it. (2) Should it be out of proper adjustment, adjust by following the procedure given below. (1) Sufficiently slacken the accelerator cable. (2) Loosen the lock nut on the fixed SAS.
Page 164: Component Location
FUEL INJECTION Components ON-VEHICLE INSPECTION OF MFI COMPONENTS Models> COMPONENT LOCATION Throttle position sensor (with built-in closed throttle Engine control module , position switch) Turbocharger waste gate solenoid <Turbo> Engine coolant temperature sensor Variable induction control motor (DC motor) (with Evaporative emission purge solenoid built-in induction control valve position sensor) Vehicle speed sensor...
Page 165 FUEL INJECTION Components Volume air flow sensor (with built-in intake air <Mechanical Speedometer Type> Vehicle speed sensor (reed switch) Revision...
Page 166 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents Injector control valG position sensor) Idle air control TSB Revision...
Page 167 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Check engine/malfunction indicator lamp <From 1994 models> and diagnostic test mode control terminal control terminal TSB Revision...
Page 168: Components Inspection Procedure
MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Camshaft position sensor COMPONENTS INSPECTION PROCEDURE USING SCAN TOOL (1) Check by the data reading and actuator test function. If any abnormality is found, check the body harness, corn- ponents, etc. and repair as necessary. (2) After repair, check again with the scan tool to make sure that the input and output signals are now normal.
Page 169 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components POWER SUPPLY (MFI relay) AND IGNITION SWITCH-IG <Up to 1993 model& lanition switch IIG1 4 Equipment side connector A Equipment MFI relay side connectc Engine control module Engine control module connector OPERATION While the ignition switch is on, battery power is supplied to the engine control module, the injector, the volume air flow sensor, etc.
Page 170 MULTIPORT FUEL INJECTION Components INSPECTION HARNESS Measure the ignition switch termi- @ Engine control module con- Ignition switch: ON Battery voltage Repair the harness. (Ignition module harness side connector switch - 62) age of the MFI relay. MFI relay connector: Discon- A Harness side connector Engine control module con-...
Page 171 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components MULTIPORT FUEL INJECTION (MFI) RELAY INSPECTION Caution When applying battery voltage directly, make sure that it is applied to correct terminal. Otherwise, the relay could be damaged. (1) Remove the MFI relay. 01 LO220 0 0 0 0 2 5 3 1 (2) Using jumper wires, connect terminal (10) of MFI relay...
Page 172 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components POWER SUPPLY (MFI relay) AND IGNITION SWITCH IG <From 1994 models> Battery Ignition 1 itch [IG] A Equipment side connector relay A Harness side Engine control module connector “3 “2 Engine control module connector OPERATION Refer to P.l3A-65.
Page 173 MULTIPORT FUEL INJECTION Components HARNESS INSPECTION Engine control module Measure the ignition switch (IG) harness side connector terminal input voltage. Engine control module con- nector: Disconnected Ignition switch OFF: O-l V Ignition switch ON: Battery voltage Measure the power supply volt- - Ignition switch: OFF MFI relay connector: Discon- nected...
Page 174 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components MFI RELAY INSPECTION (1) Remove the MFI relay. (2) Check for continuity between MFI relay terminals. (3) Using jumper wires, connect terminal (7) of MFI relay to battery (+) terminal and terminal (5) of MFI relay to battery (-) terminal.
Page 175 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components ENGINE CONTROL MODULE POWER GROUND Engine control module Engine control module connector OPERATION Grounds the engine control module TROUBLESHOOTING HINTS If the ground wire of the engine control module is not connected securely to ground, the module will not operate correctly.
Page 176 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FUEL PUMP <Up to 1993 Models - Non Turbo> A Equipment side connector Ignition switch (IG,) Ignition switch (ST) B Equipment side connector A Harness side connector Fuel Equipment side connector 6 7 ”...
Page 177 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Function Item No. Drive Check condition Check content Normal state Actuator test 07 Fuel pump is Engine cranking Hold return hose with Pulsation is felt driven to cir- Forced drive of fuel fingers to feel pulsation indicating fuel flow...
Page 178 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for continuity between the and the MFI relay tetminals. MFI relay connector: Discon- nected F u e l p u m p c o n n e c t o r : D i s - - 1 connected Repair the harness.
Page 179 On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for an open-circuit, or a short-circuit to ground between the MFI relay and the fuel pump. nected Fuel pump connector: Dis- connected Repair the harness. INSPECTION RELAY Refer to P.l3A-67. TSB Revision...
Page 180 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comraonents FUEL PUMP <From 1994 Model - Non Turbo> A Harness side connector B Equipment side A Equipment side B Equipment side connector connector Engine control module connector i7FU06.53 OPERATION The fuel pump is driven when the engine is cranking and while the engine is running. When the engine is cranking and while the engine is running, the engine control module turns the power transistor ON to the MFI relay coil.
Page 181 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Refer to P.l3A-73. HARNESS INSPECTION Check the fuel pump. Apply battery voltage to the checking terminal and oper- ate the pump. Check the ground circuit of the fuel pump. Fuel pump connector: Dis- connected Repair the B Harness side...
Page 182 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Measure the power SUDDIV volt- age of the MF’I relay. Control relay connector: Dis- connected Ignition switch OFF: O-l V Ignition switch ON: Battery voltage or check the connector ignition switch. Engine control Check for an open-circuit, or a module harness...
Page 183 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FUEL PUMP <Turbo> TSB &vision...
Page 184 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components i g n i t i o n sw,itch [IG] ignition sivitch [STji A Equipment side B Equipment connector side B Harness side connector connector A Harness side Fuel Fuel pump connector Fuel pump Engine control module...
Page 185 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components OPERATION Drives the fuel pump during cranking and engine operation. relay coil to ground. This turns on the MFI relay switch and drive power is supplied from the battery through the MFI relay switch to the fuel pump. While the engine is running, the engine control module keeps the power transistor on and energizes the MFI relay coil so that drive power is supplied to the fuel pump.
Page 186 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for continuity between the fuel pump and the checking termi- nal. Fuel pump connector: Dis- connected Repair the harness Check for continuity between the E Harness side connector checking terminal and the fuel Resistor (for fuel pump) con- Repair nector: Disconnected...
Page 187 On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for an open-circuit, or a short-circuit to ground, between A Harness side the MFI relay and the engine con- Engine control module con- Repair the nector: Disconnected harness. harness side D Harness side Check for continuity between the MFI relay and the fuel pump relay A Harness side...
Page 188 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comaonents FUEL PUMP RELAY II INSPECTION (1) Remove fuel pump relay II. (2) Use a jumper wire to connect terminal (3) of fuel pump relay II and the positive terminal of the battery and use another jumper wire to connect terminal (1) and the nega- tive terminal of the battery.
Page 189 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components VOLUME AIR FLOW SENSOR Volume air flow sensor (with built in intake air temperature sensor and Volume air flow sensor A Equipment side connector A Harness side Output frequency (Hz) connector Engine control module...
Page 190 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool <Volume Air Flow Sensor> Data display Check condition Engine state Standard value 22-48 Hz Sensor air Engine coolant 700 rpm (Idle) volume temperature: 80 to 95°C (176 to (frequency) 203”...
Page 191 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Combonents HARNESS INSPECTION Measure the power supply volt- age. A Harness side connector Connector: Disconnected Ignition switch: ON Battery voltage Repair the harness (A4 - Con- trol relay) or check control relay. Connector: Disconnected Ignition switch: ON Check for continuity of the ground...
Page 192: Intake Air Temperature Sensor
MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INTAKE AIR TEMPERATURE SENSOR Volume air flow sensor Resistance (with built in intake air ---- temperature sensor and barometric pressure sensor) Temperature A Equipment side connector Intake air Volume air flow temperature sensor connector sensor...
Page 193 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Function Item No. Data display Check condition Intake air temperature Standard value Data reading 13 Sensor tem- Ignition switch: ON or At -20°C (-4°F) -20°C perature engine running At 0°C (32°F) 0°C At 20°C (68°F)
Page 194 On-Vehicle inspection of MFI FUEL INJECTION - Components (3) Measure resistance while heating the sensor using a hair drier. Temperature [“C (OF)] Resistance (kL2) Higher Smaller (4) If resistance does not decrease as heat increases or the resistance remains unchanged, replace the volume air flow sensor assembly.
Page 195 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components BAROMETRIC PRESSURE SENSOR A Equipment side connector Barometric pressure sensor Volume air flow sensor connector A Harness side ’ connector Barometric pressure sensor Engine control unit connector Barometric pressure [mmHg (in.Hg)] OPERATION The barometric pressure sensor converts the barometric pressure into a voltage and inputs it to the engine control module, which then corrects the fuel injection, rate, etc.
Page 196 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components TROUBLESHOOTING HINTS Hint 1: If the barometric pressure sensor is faulty, poor driveability is caused at high altitude, in particular. Hint 2: If the pressure indication of the barometric pressure sensor drops significantly during high speed driving, check the air cleaner for clogging.
Page 197 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components ENGINE COOLANT TEMPERATURE SENSOR <Up to 1993 models> Resistance Output voltage Coolant temperature Coolant temperature 152455 1621008 teniperaturesensor A Equipment side connector OPERATION The engine coolant temperature sensor converts the engine coolant temperature into a voltage and inputs it to the engine control module, which then controls the fuel injection rate and fast idle speed when the engine is cold based on the input signal.
Page 198 On-Vehicle Inspection of MFI 1 3A-94 FUEL INJECTION - Comraonents INSPECTION Using Scan Tool Standard value Check condition Coolant temperature Data display Function -20°C Sensor Ignition switch: ON or At -20°C (-4°F) Data reading 21 temperature engine operating At 0°C (32°F) 0°C At 20°C (68°F) 20°C...
Page 199 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components SENSOR INSPECTION (1) Remove engine coolant temperature sensor from the in- take manifold. (2) With temperature sensing portion of engine coolant tem- perature sensor immersed in hot water, check resistance. Temperature “C (OF) Resistance (Wz) 5 .
Page 200 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components ENGINE COOLANT TEMPERATURE SENSOR <From 1994 models> Resistance output voltage Engine coolant temperature , Engine coolant temperature sensor Engine coolant temperature 1621006 Engine coolant temperature sensor A Equipment side connector Engine control module OPERATION...
Page 201 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Measure the impressed voltage. Engine coolant temperature sensor connector: Discon- nected Engine control module con- Ignition switch: ON Repair the harness. (Al -63) SENSOR INSPECTION Refer to 13A-95. INSTALLATION Refer to 13A-95. Revision...
Page 202 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components A Equipment side Throttle position sensor connector A Harness side connector Engine control module , Terminal voltage (V) Engine control module connector Minimum Maximum Throttle shaft turning angle 162461 OPERATION The throttle position sensor converts the throttle position opening into a voltage and inputs it to the The 5 V power in the engine control module is supplied to the throttle position sensor.
Page 203 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents INSPECTION Using Scan Tool Function Item No. Data display Check condition Data reading Sensor Ignition switch: left ON voltage for 15 seconds or more Open widely HARNESS INSPECTION Measure the power supply volt- - Connector: disconnected Ignition switch: ON 4.8-5.2...
Page 204 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components SENSOR INSPECTION (1) Disconnect the throttle position sensor connector. connector (sensor side, front view) (2) Measure resistance between terminal (4) (sensor ground) and terminal (sensor power). Standard value: 3.5-6.5 kQ (3) Connect a pointer type ohmmeter between terminal (4) (sensor ground) and terminal (2) (sensor output).
Page 205 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components CLOSED THROTTLE POSITION SWITCH Engine control module (Closed throttle position switch mounted) Closed A Harness side throttle . . . connector Terminal voltage (V) Throttle shaft turning angle o, zogl OPERATION The closed throttle position switch senses whether the accelerator pedal is depressed or not, converts it into high/low voltage and inputs the voltage to the engine control module, which then controls the idle air control motor based on the input signal.
Page 206 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- A Harness side age of the closed throttle position connector switch. Connector: Disconnected Ignition switch: ON 4 V or more Repair the harness. Check for continuity of the ground circuit.
Page 207 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components CAMSHAFT POSITION SENSOR 4 992 models> MFI relay Crankshaft position sensor (with built-in Equipment side connector Output characteristic No.1 No.4 Engine control module Time OPERATION The camshaft position sensor senses the top dead center on compression stroke of the No.1, No.3 and No.5 cylinders, converts it into a pulse signal and inputs it to the engine control module, which then controls the fuel injection sequence, etc.
Page 208 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Oscilloscope (1) Run the engine at an idle speed. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram, and check the waveform. Normal waveform HARNESS INSPECTION Connector: Disconnected Connector: Disconnected...
Page 209 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components CAMSHAFT POSITION SENSOR <From 1993 models> Camshaft position sensor A Equipment side connector Engine control module Engine control module connector OPERATION The camshaft position sensor senses the top dead center on compression stroke, converts it into a pulse signal and inputs it to the engine control module, which then controls the fuel injection sequence, etc.
Page 210 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age. Connector: Disconnected A Harness side connector Ignition switch: ON Battery voltage relay) Check for continuity of the ground circuit. Connector: Disconnected connector Measure the impressed voltage. A Harness side Connector: Disconnected connector...
Page 211 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components CRANKSHAFT POSITION SENSOR 4 992 models> Crankshaft position sensor A Equipmer Crankshaft position sensor A Output characteristic Time OPERATION The crankshaft position sensor senses the crank angle (piston position) of each cylinder, converts it into a pulse signal and inputs it to the engine control module, which then controls the engine speed and controls the fuel injection timing and ignition timing based on the input signal.
Page 212 On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Check content current of ignition NOTE (1) The tachometer indicates a third of the actual engine speed. Therefore, 3 times the tachometer indication is the actual engine speed. (2) When the tachometer is set to the 2-cylinder range, it indicates actual engine speed.
Page 213 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age. A Harness side connector Battery voltage relay) Check for continuity of the ground circuit. A Harness side connector Connector Disconnected Repair the harness. (A4 - Ground) Check the voltage of the output...
Page 214 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION T Components CRANKSHAFT POSITION SENSOR <From 1993 models> A Equipment side connector A Harness side connector Output characteristic Time _ Engine control module connector OPERATION Refer to P.l3A-107. TROUBLESHOOTING HINTS Refer to P.l3A-107. INSPECTION Refer to P.i3A-108.
Page 215 On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents Check for continuity of the ground A Harness side circuit. connector Connector: Disconnected Repair the harness. (Al - Ground) A Harness side...
Page 216 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components IGNITION SWITCH-ST <M/T> Ignition switch (ST) Engine control module connector Engine control module OPERATION The ignition switch-ST inputs a high signal to the engine control module while the engine is cranking. The engine control module provides fuel injection control, etc., at engine startup based on this signal.
Page 217 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH (PNP SWITCH) Ignition switch (ST) A Harness side connector Park/Neutral 1 position A Equipment switch side connector Starter S Control terminal relay c o n t r o l m o d u l e / Engine control module connector OPERATION...
Page 218 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool IGNITION SWITCH-ST Function Item No. Engine Data display Check condition Normal indication Data reading 18 Switch state Ignition switch: ON stop Cranking PARK/NEUTRAL POSITION SWITCH Function Item No. Data display Check condition Select lever position...
Page 219 On-Vehicle Inspection of MFI FUEL INJECTION - Components IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH (PNP SWITCH) A Equipment side connector switch Starter S MFI terminal relay Engine control module Engine control module connector OPERATION Refer to P.l3A-113. TROUBLESHOOTING HINTS Refer to P.l3A-113. TSB Revision...
Page 220 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Refer to P.l3A-114. HARNESS INSPECTION Measure the power supply volt- age. A Harness side Engine control module con- n connector PNP switch connector: Dis- ’ connected Check Battery voltage the power circuit.
Page 221 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components VEHICLE SPEED SENSOR (Mechanical Speedometer Type) Vehicle speed sensor (reed switch) Enginecontrol module , Speedometer A Equipment side connector Vehicle speed sensor Terminal voltage (V) B Equipment side connector Frequency (Hz) Vehiclespeed [km/h (mph)] OPERATION The vehicle speed sensor which is located in the speedometer converts the vehicle speed into a...
Page 222 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components A Harness side Connector: Disconnected Ignition switch: ON SENSOR INSPECTION Refer to GROUP 54 - Meters and Gauges. Revision...
Page 223 MULTIPORT On-Vehicle Inspection of MFI VEHICLE SPEED SENSOR (Electrical Speedometer Type) Ignition switch [IG] Engine control module A Equipment side connector Terminal voltage (V) Vehicle speed sensor Engine control module connector Vehicle speed [km/h (mph)] 162451 OPERATION The vehicle speed sensor, mounted directly to the speedometer driven gear of the transmission, converts the vehicle speed to the pulse signal to be input to the engine control module.
Page 224 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the line voltaae of the vehicle steed sensor. - A Harness side Connector: Disconnected connector Ignition switch: ON Battery voltage Check the vehicle speed sensor output circuit for continuity. Engine control module con- f-\ 1 Ignition switch: ON Move the vehicle...
Page 225 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents POWER STEERING PRESSURE SWITCH Engine control module A Harness side connector Power steering pressure switch Pressure [kPa (psi)] (100-284) OPERATION The power steering pressure switch converts presence/absence of power steering load into low/high voltage and inputs it to the engine control module, which then controls the idle air control motor based on this signal.
Page 226 MULTIPORT Components FUEL INJECTION INSPECTION Using Scan Tool Checking Oil Pressure Oil pump delivery pressure (ref. value) Steering wheel Straight forward Turned HARNESS INSPECTION Measure the power supply volt- age. A Harness side Ignition switch: ON connector B a t t e r y v o l t a g e . (Al - 107) SENSOR INSPECTION Refer to GROUP 37A - On-vehicle Service.
Page 227 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comtaonents AIR CONDITIONING SWITCH AND COMPRESSOR CLUTCH RELAY Air conditioning Air conditioning compressor lock control unit controller Engine control module Engine control module connector OPERATION The air conditioning switch applies the battery voltage to the engine control module when the air conditioning is turned on.
Page 228 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components AIR CONDITIONING POWER RELAY Function Item No. Data display Check condition Air conditioning switch Normal indication Data reading 49 Air condition- Engine: Idling after OFF OFF (compressor I/ relay warm-up clutch non-activa- state tion) ON (compressor...
Page 229 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comnonents KNOCKSENSOR Engine control module A Equipment side connector Knock sensor A Harness side Engine control module connector OPERATION The knock sensor generates a voltage proportional to the magnitude of cylinder block vibration due to knocking and inputs it to the engine control module.
Page 230 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION harness side short-circuit to TSB Revision...
Page 231 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comoonents ELECTRICAL LOAD SWITCH Engine control module connector Engine control module OPERATION The electrical load switch inputs ON/OFF state of the switch of equipment that consumes much power during idling, namely, equipment with a large electrical load, to the engine control module. Based on this signal, the engine control module controls the idle air control motor.
Page 232 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the input voltage of en- Battery voltage Check circuit related to tail Engine control module harness light relay side connector Measure the input voltage of en- gine control module. Engine control module con- nector: Disconnected Defogger switch: ON...
Page 233 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FAN MOTOR RELAY (RADIATOR, AIR CONDITIONING CONDENSER) <From 1994 models> Ignitionswitch (IG) Air conditioner compressor lock controller To air conditioner compressor Condenser fan motor Engine control module connector Revision...
Page 234 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components OPERATION The engine control module controls the radiator fan motor and condenser fan motor according to the engine coolant temperature and vehicle speed via the power transistors (low speed side and high speed side) in the module.
Page 235 On-Vehicle Inspection of MFI FUEL INJECTION - Components MUFFLER MODE CHANGEOVER SWITCH <Turbo> Engine control module A Equipment side connector Muffler mode changeover switch OPERATION If the operator turns the muffler mode changeover switch to ON or OFF position, this is converted to high/low voltage to be sent to the engine control module.
Page 236 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age. Connector: Disconnected Ignition switch: ON Battery voltage connector Repair the harness. A Harness side Connector: Disconnected Revision...
Page 237 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INDUCTION CONTROL VALVE POSITION SENSOR <Non Turbo> Variable induction control motor (DC motor) A Equipment side connector Variable induction control motor’ (DC motor) (with built-in induction _ control valve position sensor) Variable induction control motor connector...
Page 238 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age of the air intake control valve 4.8-5.2 V Repair the harness. (Al -61) Check for continuity of the ground A Harness side circuit. connector Connector: Disconnected Repair the...
Page 239 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components EGR TEMPERATURE SENSOR <California> EGR temperature sensor A Equipment side connector A Harness side connector Engine control module output voltage Temperature OPERATION The EGR temperature sensor converts the temperature of EGR gas downstream from the EGR valve to voltage and inputs it to the engine control module.
Page 240 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Data display Check condition Engine state Standard value Sensor Engine: Warmed up 700 rpm (Idle) 100°C (212°F) or less temperature Engine is maintained in a constant state for 2 minutes or more Disconnect vacuum hose (green stripe) from...
Page 241 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Comoonents HEATED OXYGEN SENSOR <Non Turbo> Heated oxygen Heated oxygen sensor A Equipment side connector Electromotive Theoretical A/F force (V) Engine control module r\5&72 Engine control module connector OPERATION The heated oxygen sensor senses the oxygen concentration in exhaust gas, converts it into a voltage and inputs it to the engine control module.
Page 242 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components TROUBLESHOOTING HINTS Hint 1: Poor cleaning of exhaust gas will result if the heated oxygen sensor fails. Hint 2: If the heated oxygen sensor checked good but the sensor output voltage is out of specification, troubles of parts related to air-fuel ratio control system are suspected.
Page 243 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age of the heated oxygen sensor. A Harness side Connector: Disconnected connector Ignition switch: ON Battery voltage Repair the harness. (A3 - MFI relay) module harness short-circuit to ground between the engine control module and the heated oxygen sensor.
Page 244 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components SENSOR INSPECTION (1) Disconnect the heated oxygen sensor connector. (2) Check that there is continuity [approx. 20 fiat 20°C (SS’F)] across terminals (3) and (4) of the heated oxygen sensor LJ connector.
Page 245 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HEATED OXYGEN SENSOR <Turbo> Heated ‘d&en , sensor (right) Heated oxygen Heated oxygen B Equipment side sensor (right) t Equipment side connector connector Heated ‘oxygen sensor (left) MFI relay Electromotive Theoretical A/F force (V) A Harness side B Harness side...
Page 246 On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age of the heated oxygen sensor. Connector: Disconnected Ignition switch: ON Battery voltage relay) Check for an open-circuit, or a short-circuit to ground, between the engine control module and the heated oxygen sensor.
Page 247 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components SENSOR INSPECTION (1) Disconnect the heated oxygen sensor connector and con- nect the special tool, Test Harness, to the heated oxygen sensor connector. (2) Check that there is continuity [approx. 20 Q at 20% (SSOF)] across terminals (1) and (3) of the heated oxygen sensor connector.
Page 248 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INJECTORS <Non Turbo> Engine control module Filter Engine control module connector injection OPERATION The injector is an injection nozzle with a solenoid valve which injects fuel according to the injection signal coming from the engine control module. The injector has a fixed nozzle opening area and the fuel pressure against manifold inside pressure is regulated to a fixed level.
Page 249 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components TROUBLESHOOTING HINTS Hint 1: If the engine is hard to start when hot, check fuel pressure and check the injector for leaks. Hint 2: If the injector does not operate when the engine that is hard to start is cranked, the following as well as the injector itself may be responsible.
Page 250 On-Vehicle Inspection of MFI FUEL INJECTION - Components Using Oscilloscope (1) Run the engine at idle speed. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram, and check the waveform d at the drive side of each injector. Normal waveform HARNESS INSPECTION Measure the power supply volt-...
Page 251 On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for an open-circuit, or a short-circuit between the rear Harness side bank injector and the engine con- connector trol module. Connector: Disconnected Engine control module con- nector: Disconnected ACTUATOR INSPECTION Measurement of Resistance between Front Bank Terminals (1) Remove the injector connector.
Page 252 On-Vehicle Inspection of MFI FUEL INJECTION - Components INJECTORS <Turbo> A Equipment side connector MFI relay Injector (Front bank connector) 7F,,0SOR 4 - - - - 5 - - - - - Rear bank connector Injector Inject0 Inject0 No.2 . No.6 - - - - - No.3...
Page 253 MULTIPORT On-Vehicle Inspection of MFI INSPECTION Tool Using Scan item No. Data display Check condition Coolant temperature Standard value Data Drive time” Engine: Cranking 0°C (32”F)** reading (Rear bank) 20°C (68°F) 26.1-31.9 (Front bank) 80°C (176°F) 6.3-7.7 Item Data display Check condition Engine state Function...
Page 254 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- - Resistor connector: Discon- nected Ignition switch: ON Battery voltage _ Repair the harness. (A4 - MFI relay) Measure the power supply volt- age of the front bank injector. Resistor connector: Con- necteu Repair the...
Page 255 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components short-circuit between the rear bank injector and the engine con- trol module. Connector: Disconnected Engine control module con- nector: Disconnected ACTUATOR INSPECTION INJECTORS Measurement of Resistance between Front Bank Terminals (1) Disconnect the injector connector. (2) Measure the resistance between terminals.
Page 256 MULTIPORT On-Vehicle inspection of MFI FUEL INJECTION - Components RESISTOR Measurement of Resistance between Terminals (1) Disconnect the resistor connector. (2) Measure the resistance between terminals. Measuring terminals Resistance (3) If the resistance is out of specification, replace the resistor. TSB Revision...
Page 257 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components IDLE AIR CONTROL MOTOR (STEPPER MOTOR TYPE) A Harness side “3 Engine control module connector OPERATION The intake air volume during idling is controlled by opening or closing the servo valve provided in the air path that bypasses the throttle valve.
Page 258 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Item No. Data display Check condition Load state Standard value Function Data Stepper mo- Engine coolant temper- Air conditioning switch: tor steps ature: 80 to 95°C (176 to 203°F) Lights, electric cooling fan, accessory units: Increase by...
Page 259 On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents HARNESS INSPECTION Measure the power supply volt- aae of idle air control ,motor. Idle air control motor connec- tor: Disconnected Ignition switch: ON Repair the Battery voltage A Harness side connector Engine control Check for an open-circuit, or a A Harness side harness...
Page 260 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Checking the Coil Resistance Disconnect the idle air control motor connector and con- nect the special tool (test harness). (2) Measure the resistance between terminal (2) (white clip of the special tool) and either terminal (1) (red clip) or terminal (3) (blue clip) of the connector at the idle air control motor side.
Page 261 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components (5) With the idle air control motor as shown in the illustration, connect the negative (-) terminal of the power supply to each clip as described in the following steps, check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.
Page 262 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components IGNITION COIL AND IGNITION POWER TRANSISTOR Battery A Harness side A Harness side connector connector side connector Spark iransistor Engine control module 101 OPERATION When the ignition power transistor unit A is turned on by the signat from the engine control module, primary current flows to the ignition coil A.
Page 263 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Item Function Data display Check condition Engine state Standard value Ignition Data reading Engine: Warming up 700 rpm (Idle) 7-23”BTDC advance Timing light: Set (set timing light to check actual ignition timing) <Ignition Timing Adjustmernt Mode>...
Page 264 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age of the ignition coil. A Harness side Connector: Disconnected Ignition switch: ON Battery voltage Repair the harness. (A3 - Igni- tion switch) Ignition power transistor con- nector: Disconnected Ignition power transistor con- nector: Disconnected...
Page 265 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Checkforcontinuity of the ground circuit. B-2 Harness side connector Connector: Disconnected Measure the voltage of the control signal circuit of the ignition power B-2 Harness side transistor. connector Connector: Disconnected 0.5-4.0 Repair the harness.
Page 266 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comtaonents EVAPORATIVE EMISSION PURGE SOLENOID A Equipment side connector A Harness side connector Engine control module Sm.1206 OPERATION The evaporative emission purge solenoid is an ON-OFF type one which controls introduction of purge air from the canister into the intake air plenum.
Page 267 On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age. Connector: Disconnected Ignition switch: ON Battery voltage connector Repair the (MFI relay - A l ) Check for an open-circuit, or a short-circuit to ground between the evaporative emission purge solenoid and the engine control module.
Page 268 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - ComDonents EGR SOLENOID <California - Non Turbo, Turbo> A Equipment side connector EGR solenoid Engine control module Engine control module connector OPERATION The EGR solenoid is a duty control type solenoid valve. It makes control by leaking EGR valve operating negative pressure to the throttle body A port.
Page 269 On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan tool HARNESS INSPECTION Measure the power supply volt- - Connector: Disconnected Ignition switch: ON Battery voltage relay) Engine control module Check for an open-circuit, or a harness side connector short-circuit to ground between the EGR the engine...
Page 270 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FUEL PRESSURE SOLENOID <Turbo> MFI relay side connector Fuel pressure solenoid Engine control module Engine control module connector OPERATION The fuel pressure solenoid is an ON-OFF type solenoid valve that switches the pressure introduced to the fuel pressure regulator between either intake manifold pressure or barometric pressure.
Page 271 MULTIPORT On-Vehicle Inspection of MFI INSPECTION Using Scan Tool Item No. Drive content Check condition Function Normal state Ignition switch: ON Click heard when driven Actuator test Turn solenoid valve from HARNESS INSPECTION Measure the power supply volt- age. Connector: Disconnected A Harness side connector Repair the...
Page 272 On-Vehicle Inspection of MFI FUEL INJECTION - Components ACTUATOR INSPECTION Operation Check NOTE Before disconnecting the vacuum hose, mark it to ensure reconnection at the correct position. (1) Remove the vacuum hose (blue stripe on black) from the solenoid valve. (2) Disconnect the harness connector.
Page 273 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components TURBOCHARGER WASTE GATE SOLENOID <Turbo> A Equipment side connector Engine control module Engine control module connector OPERATION The turbocharger waste gate solenoid is an ON-OFF type solenoid valve that controls the boost pressure that is introduced to the turbocharger waste gate actuator.
Page 274 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Function Item No. Drive content Check condition Normal State Actuator test Turn solenoid valve from Ignition switch: ON Click heard when driven OFF to ON HARNESS INSPECTION Measure the power supply volt- A Harness side age.
Page 275 On-Vehicle Inspection of MFI BOOST METER <Turbo> Ignition switch (IG,) A Equipment side connector Boost meter Engine control module connector Revision...
Page 276 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age. Connector: Disconnected Ignition switch: ON Battery voltage Repair the harness. (A2 - Igni- tion coil [IG]) short-circuit to ground, between the engine control module and the boost meter.
Page 277 On-Vehicle Inspection of MFI ACTIVE EXHAUST COIWTROL UNIT <Turbo> DC motor for valve drive A Equipment side Active connector exhaust control unit Engine control module connector OPERATION Muffler noise is controlled1 by opening and closing the valve provided inside the main muffler. The valve is opened or closed by turning the DC motor in the normal or reverse direction.
Page 278 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components VARIABLE INDUCTION CONTROL MOTOR (DC MOTOR) <Non Turbo> Engine control module Variable induction control motor (DC motor) (with built-in induction _ control valve position sensor) Close Open A Equipment side connector Variable induction control...
Page 279 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components 700 rpm (Idle) NOTE HARNESS INSPECTION Engine control module Check for an open-circuit or a short-circuit to ground, between the engine control module and the variable induction control motor connector. Variable induction control mo- tor connector: Disconnected Repair the Engine control module con-...
Page 280 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comnonents ANTI-LOCK BRAKING SIGNAL <Turbo> ABS ECU A ABS control unit equipment side connector Engine control module Engine control module connector OPERATION The anti-lock braking signal is input to the engine control module from the anti-lock braking system (ABS) control module as a signal to indicate whether or not the motor relay is activated.
Page 281 On-Vehicle Inspection of MFI FUEL INJECTION - Components ENGINE AND TRANSAXLE TOTAL CONTROL SIGNAL <AK> Transaxle control module Engine control module A Transaxle control module connector Engine control module connector OPERATION Three communication lines are connected between the engine control module and the transaxle control module to send and receive the engine and transaxle total control signal.
Page 282 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents HARNESS INSPECTION Engine control Check for an open-circuit, or a side connector short-circuit to ground between A Transaxle control the transaxle control module and module harness side connector the engine control module. Transaxle control module connector: Disconnected Engine control module con-...
Page 283 On-Vehicle Inspection of MFI FUEL INJECTION - Components RELEASE OF RESIDUAL PRESSURE FROM Fuel gauge cover HIGH PRESSURE FUEL HOSE Make the following operations to release the pressure remain- ing in fuel pipe line so that fuel will not flow out. (1) Remove the fuel gauge cover in the luggage compartment.
Page 284 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Combonents FUEL PRESSURE TEST (1) Reduce the internal pressure of the fuel pipes and hoses. (2) Disconnect the fuel high pressure hose at the fuel rail side. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 285 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComPonents (9) Disconnect the vacuum hose from the fuel pressure regu- lator, and then measure the fuel pressure while using a finger to plug the end of the hose. Standard value: <Turbo> 295-315 kPa (43-45 psi) at curb idle not decrease even after the engine is raced a few times.
Page 286 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents (13)Stop the engine and check for a change of the value indicated by the fuel pressure gauge. The condition is normal if there is no decrease of the indicated value within two minutes.
Page 287 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comuonents ENGINE CONTROL MODULE (ECM) TERMINAL VOLTAGES INSPECTION (1) Connect a very thin wire probe (such as a paper clip) to the probe of the voltmeter. (2) Insert the very thin probe from the wire side into contact with each of the terminals of the ECM connector and check the voltage, while referring to the check chart.
Page 288 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comtaonents Camshaft position sen-...
Page 289 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Vehicle speed sensor Ignition switch: ON Move the vehicle slowly forward (Changes repeated) Power steering pres- .Engine: Steering wheel placed in neutral sure switch Idle, (straight ahead) position...
Page 290 MULTIPORT FUEL INJECTION - Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Stepper motor coil Engine: Warm <Al> Check immediately after hot restart (Changed repeated) Stepper motor coil Stepper motor coil Stepper motor coil Ignition power transis- Engine speed: 3,000 rpm 0.3-3 v tor unit A...
Page 291 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Terminal No. Check poi EGR solenoid EGR temperatu Induction control valve position sensor No. 1 Engine: Slowly accelerated from idling speed to 5,000 rpm Induction contrc position sensor I Engine: Slowly accelerated from idling O-l V or speed to 5,000 rpm 4.5-5.5 v + 1.5-4 v...
Page 292 On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents ON-VEHICLE INSPECTION OF MFI COMPONENTS Federal> COMPONENT LOCATION terminal Federal - Non Turbo> Engine coolant temperature sensor Variable induction control motor (DC motor) (with built-in in- Evaporative emission purge solenoid Fuel pressure solenoid <Turbo> Vehicle speed sensor Volume air flow sensor (with built-in intake air temperature Heated oxygen sensor...
Page 293 On-Vehicle Inspection of MFI FUEL INJECTION - Components Volume airflow sensor (with built-in intake air temperature sensor and barometric pressure sensoc sensor, left bank heated oxygen <Mechanical Speedometer Type> and Federal - Turbo sensor (fro1 from 1996~ Vehicle speed sensor (reed switch) <Electrical Speedometer Type>...
Page 294 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Variable air intake control s Injector (DC motor) (with built-in air intak...
Page 295 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components <California up to 1995 Imodels, _ Federal -Turbo up to 1995 models>...
Page 296 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Camshaft position sensor Manifolddifferential Manifolddifferential pressure sensor pressure sensor TSB Revision...
Page 297 On-Vehicle Inspection of MFI COMPONENTS INSPECTION PROCEDURE USING SCAN TOOL Refer to P.l3A-64. POWER SUPPLY (MFI RELAY) AND IGNITION SWITCH - IG <Up to 1995 models> Ignition switch [IG] A Equipment side connector MFI - relay A Harness side connector Engine control module connector OPERATION Refer to P.l3A-65.
Page 298 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Engine control Measure the ignition switch (IG) module harness terminal input voltage. side connector Engine control module con- Ignition switch OFF: O-l V Repair the Ignition switch ON: Battery harness: voltage switch - 82)
Page 299 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Measure power voltage to the ac- tuator. connector nected Engine control module con- nector: Connected Engine cranking: 8 V or higher Engine racing: Battery voltage engine con- trol module Refer to P.i3A-70. Revision...
Page 300 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components POWER SUPPLY (MFI RELAY) AND IGNITION SWITCH-IG <From 1996 models> Battery A Equipment side connector Engi relay Engine control module Engine control module connector OPERATION Refer to P.l3A-65. INSPECTION Refer to P.l3A-65. TSB Revision...
Page 301 On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the ignition switch (IG) terminal input voltage. Engine control module con- nector: Disconnected Ignition switch OFF: 0- 1 V Ignition switch ON: Battery harness. voltage (Ignition switch - 82) or check the ignition switch...
Page 302 On-Vehicle Inspection of MFI FUEL INJECTION - Components MULTIPORT FUEL INJECTION (MFI) RELAY AND FUEL PUMP RELAY INSPECTION (1) Remove the relay. (2) Check for continuity between the relay terminals. Inspection terminals / Continuity (3) Use the jumper leads to connect relay terminal 4 to the battery (+) terminal and terminal 2 to the battery (-) termi- nal.
Page 303 On-Vehicle Inspection of MFI FUEL INJECTION - Components ENGINE CONTROL MODULE POWER GROUND Engine control module Engine control module connector OPERATION Refer to 13A-71. TROUBLESHOOTING HINTS Refer to 13A-71. HARNESS INSPECTION Refer to 13A-71. TSB Revision...
Page 304 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FUEL PUMP <Non Turbo - Up to 1995 models> Fuel pump connector Ignition switch [IG] MFI relay A Harness side B Equipment side connector connector A Equipment side connector B Harness side connector - .7 C Fuel pump .
Page 305 On-Vehicle Inspection of MFI FUEL INJECTION - Components FUEL PUMP <Non Turbo - From 1996 models> Fuel pump check terminal Fuel pump connector Ignition switch [IG] A Equipment side connector B Equipment B Harness side connector Fuel C Fuel pump Engine control check terminal module...
Page 306 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Check the fuel pump. Apply battery voltage to the checking terminal and oper- ate the pump. Check the ground circuit of the fuel pump. connected bround) Check for continuity between the fuel pump and the checking termi- nal.
Page 307 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comwnents Measure the power supply volt- A Harness side aae of the MFI relav. connected Ignition switch OFF: 0- 1 V Ignition switch ON: Battery voltage switch - A3, A4) or check ignition switch.
Page 308 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FUEL PUMP <Turbo - Up to 1995 models> Ignition switch [IG] Equipment side connector B Harness side connector A Harness side connector E Equipment sidl C Fuel pump check Engine control module connector TSB Revision...
Page 309 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components OPERATION Refer to 13A-81. INSPECTION Refer to 13A-81. HARNESS INSPECTION Check the ground circuit of the B Harness side Repair the connector harness. (B2 - Ground) Check for continuity between the fuel pump and the checking termi- nal.
Page 310 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Engine control Check for an open-circuit, or a short-circuit to ground, between the fuel pump r&ay II and the en- gine control module. Fuel pump relay II connector: Disconnected Engine control module con- Repair the nector: Disconnected D Harness side...
Page 311 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comraonents short-circuit to Fuel pump relay II connector: Disconnected Fuel pump connector: Dis- D Harness side MFI RELAY INSPECTION Refer to P.l3A-70.
Page 312 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents FUEL PUMP <Turbo - From 1996 models> Fuel pump connector Ignition switch [IG] Equipment side connector A connector B Harness side connector Fuel pump relay II D Equipment side Fuel pump connector Fuel pump circuit...
Page 313 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comuonents OPERATION Refer to P.l3A-81. INSPECTION Refer to P.l3A-81. HARNESS INSPECTION Fuel pump connector: Dis- connector continuity between the Check for Harness side checking terminal and the fuel pump relay II, and between the re- sistor (for fuel pump).
Page 314 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Engine control Check for an open-circuit, or a module harness short-circuit to ground, between side connector the fuel pump relay II and the en- gine control module. Fuel pump relay II connector: Disconnected Engine control module con- Repair the...
Page 315 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for an open-circuit, or a short-circuit to ground, between the fuel pump relay II and the fuel Fuel pump relay II connector: Disconnected Fuel pump connector: Dis- Repair the connected harness.
Page 316 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - ComDonents VOLUME AIR FLOW SENSOR Volume air flow sensor (with built in intake air mperature sensor and Volume air flow sensor A Equipment side connector A Harness side Output frequency (Hz) connector Engine control module...
Page 317 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents Function Item No. Data display Check conditions Engine state Standard value Data reading Sensor air Engine coolant tem- Idling 3.6-7.5 g/s volume (Air- perature: 80 to 95°C (176 to 203°F) models> flow volume) 3.9-7.7 g/s Lights, electric cool-...
Page 318 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Connector: Disconnected Ignition switch: ON Connector: Disconnected volume air flow sensor and the engine control unit. Volume air flow sensor con- nector: Disconnected Engine control module con- nector: Disconnected...
Page 319 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components INTAKE AIR TEMPERATURE SENSOR Output voltage Volume air flow sensor Resistance barometric pressure sensor) Temperature Temperature A Equipment side connector intake air Volume air flow temperature sensor connector sensor A Harness side connector intake air temperature sensor...
Page 320 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Connector: Disconnected Repair the harness. A Harness side Measure the power supply volt- age. Ignition switch: ON 4.5-4.9 v SENSOR INSPECTION Refer to P.l3A-89. TSB Revision...
Page 321 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components BAROMETRIC PRESSURE SENSOR A EQuiDment side Barometric pressure sensor Volume air flow sensor connector A Harness side connector pressure - 5ELl803, Engine conf’ol module Output voltage (V) OPERATION Refer to P.l3A-91. TROUBLESHOOTING HINTS Refer to P.l3A-92.
Page 322 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION A Harness side Check for continuity of the ground Connector: Disconnected Repair the harness. Measure the power supply volt- age of the barometric pressure sensor. Connector: Disconnected A Harness side Ignition switch: ON connector Repair the...
Page 323: Engine Coolant Temperature Sensor
MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components ENGINE COOLANT TEMPERATURE SENSOR Resistance I\___: %$~\) Coolant temperature sensor Coolant temperature Engine coolant temperature sensor A Equipment connector Engine control module connector Engine control module OPERATION Refer to P.l3A-93. TROUBLESHOOTING HINTS Refer to P.l3A-93.
Page 324 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Check for continuity of the ground circuit A Harness side Engine coolant temperature connector sensor connector: Discon- Repair the harness. Measure the impressed voltage. Engine coolant temperature A Harness side sensor connector: Discon- connector nected...
Page 325: Throttle Position Sensor
MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components THROTTLE POSITION SENSOR sensor A Equipment side connector Throttle position sensor A Harness side connector Engine control module Terminal voltage (V) Engine control module connector Minimum Maximum Throttle shaft turning angle 2 1 6 2 4 6 1 OPERATION Refer to P.l3A-98.
Page 326 MULTIPORT FUEL INJECTION Components HARNESS INSPECTION A Harness side Connector: Disconnected connector Throttle position sensor con- nector: Disconnected Engine control module con- nector: Disconnected nals like ECM: Discon- SENSOR INSPECTION Refer to P.l3A-100. TSB Revision...
Page 327: Closed Throttle Position Switch
On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components CLOSED THROTTLE POSITION SWITCH Throttle position sensor (Closed throttle position switch mounted) Engine control module Closed Closed A Harness side throttle throttle connector position position A Equipment side switch switch connector Terminal voltage (V) Throttle shaft turning anglezo;t002 OPERATION...
Page 328 On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- A Harness side age of the closed throttle position connector switch. Connector: Disconnected Ignition switch: ON 4 V or more Repair thl harness. Check for continuity of the ground Repair the harness.
Page 329: Camshaft Position Sensor
MULTIPORT On-Vehicle lixspection of MFI FUEL INJECTION - Components CAMSHAFT POSITION SENSOR Camshaft position sensor A Equipment side connector Engine control module , Output characteristic No.1 No.4 Engine control module connector OPERATION Refer to P.l3A-103. TROUBLESHOOTING HINTS Refer to P.l3A-103. INSPECTION Refer to P.l3A-104.
Page 330 On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents HARNESS INSPECTION Measure the power supply volt- age. Connector: Disconnected Ignition switch: ON Battery voltage Repair the harness. (A3 - MFI relay) A Harness side Connector: Disconnected Connector: Disconnected Ignition switch: ON...
Page 331 MULTIPORT FUEL INJECTION Components A Equipment side A Harness side connector put characteristic OPERATION Refer to P.l3A-107. TROUBLESHOOTING HINTS Refer to P.l3A-107. INSPECTION Using Scan Tool Check condition Data display Check content Normal state Cranking Engine cranking Compare cranking Indicated speed to Tachometer connected speed speed and scan tool...
Page 332 MULTIPORT FUEL INJECTION Components Function Item No. Data display Check condition Coolant temperature Standard value Data reading 22 Idle speed Engine: Running at idle At -20°C (4°F) Closed throttle position 1,300-l ,500 rpm*2 switch: ON At 0°C (32°F) 1,300-l ,500 rpm*2 At 2O”C(68”F) 1,300-l ,500 rpm*2 At 4O”C(104”F)
Page 333 FUEL INJECTION Components Ignition switch: ON IGNITION SWITCH-ST <M/T> Ignition switch (ST) Engine control module connector OPERATION Refer to P.l3A-112. INSPECTION Refer to P.l3A-112. HARNESS INSPECTION Engine control Measure the input voltage to the side connector Engine control module con- Ignition switch: START V or more Repair the...
Page 334 MULTIPORT FUEL INJECTION IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH (PNP SWITCH) Ignition switch (ST) A Equipment side connector Starter S MFI terminal relay A 91 Engine control module Engine control module connector OPERATION Refer to P.i3A-113. TROUBLESHOOTING HINTS Refer to P.l3A-113. INSPECTION Refer to P.l3A-114.
Page 335 MULTIPORT of MFI FUEL INJECTION Check for continuity between the PNP switch and enaine control module. Engine control module con- PNP switch connector: Dis- connected Repair the NOTE harness harness. Insert the probes of the circuit tes- side ter into both ends of the harness. Measure the impressed voltage to the PNP switch.
Page 336 MULTIPORT FUEL INJECTION Components OPERATION Refer to P.l3A-117. TROUBLESHOOTING HINTS Refer to P.l3A-117. HARNESS INSPECTION SENSOR INSPECTION Refer to GROUP 54 - Meters and Gauges. Revision...
Page 337 MULTIPORT FUEL INJECTION Components Engine control module A Equipment side connector Vehicle r- speed sensor Frequency (Hz) Engine control module connector Vehicle speed [km/h (mph)] OPERATION Refer to P.l3A-119. TROUBLESHOOTING HINTS Refer to P.l3A-117. TSB Revision...
Page 338 MULTIPORT FUEL INJECTION Components HARNESS INSPECTION Measure line voltage applied to vehicle speed sensor. Connector: Disconnected A Harness side connector Ignition switch: ON Battery voltage Repair the harness. (Al - Igni- tion switch) Check the vehicle speed sensor output circuit for continuity. Engine control module con- nector: Disconnected Ignition switch: ON...
Page 339: Power Steering Pressure Switch
MULTIPORT FUEL INJECTION Components POWER STEERING PRESSURE SWITCH Engine control module A Harness side connector Power steering pressure switch,, 1 Pressure [kPa (psi)] OPERATION Refer to P.l3A-121. INSPECTION Refer to P.l3A-122. HARNESS INSPECTION Measure the power supply volt- age. A Harness side connector Ignition switch: ON Battery voltage...
Page 340 On-Vehicle Inspection of MFI FUEL INJECTION - Components AIR CONDITIONING SWITCH AND COMPRESSOR CLUTCH RELAY Battery Air conditioning Air conditioning compressor lock control unit controller Air conditioning Engine control module compressor Engine control module connector NOTE OPERATION Refer to P.l3A-123. TROUBLESHOOTING HINTS Refer to P.l3A-123.
Page 341 MULTIPORT On-Vehicle Inspection of MFI FUEL ‘INJECTION - Components AIR CONDITIONING INSPECTION Refer to GROUP 55 - On-vehicle Service. Engine control module A Equipment side connector Knock sensor A Harness side Engine control module connector OPERATION Refer to P.l3A-125. TROUBLESHOOTING HINTS Refer to P.l3A-125.
Page 342: Electrical Load Switch
On-Vehicle Inspection of MFI FUEL INJECTION - Comtsonents Check for continuity of the ground STOP ELECTRICAL LOAD SWITCH Defog relay NOTE 1995 models 1996 models Engine Engine control module connector control module OPERATION Refer to P.l3A-127. INSPECTION Refer to P.l3A-127.
Page 343 On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the input voltage of en- gine control module. Engine control module con- Lighting switch: ON (Tail light relay ON) Battery voltage Check circuit related to tail Engine control light relay module harness side connector Measure the input voltage of en-...
Page 344 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FAN MOTOR RELAY (RADIATOR, AIR CONDITIONING CONDENSER) Ignition switch-IG Battery z Air conditioning compressor lock controller Radiato compressor 1 r 1I ( L o ) fan mote relay Condenser fan motor ECM - Engine control module connector Revision...
Page 345 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components OPERATION Refer to P.l3A-130. , INSPECTION Refer to P.l3A-130. INSPECTION HARNESS Measure input voltage applied to ECM. ECM connector: Discon- Ignition switch: ON Battery voltage Check the motor relay circuit. ECM harness FAN MOTOR RELAY INSPECTION Refer to Radiator Check in GROUP 14 and Power Relay Check in GROUP 55.
Page 346 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age. Connector: Disconnected A Harness side Battery voltage connector Repair the harness. Checkforcontinuity of the ground circuit. A Harness side connector Connector: Disconnected Repair the harness.
Page 347 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components OPERATION Refer to P.l3A-133. Refer to P.l3A-133. HARNESS INSPECTION Measure the power supply volt- age of the air intake control valve A Harness side connector Check for continuity of the ground circuit.
Page 348: Manifold Differential Pressure (Mdp) Sensor
MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components MANIFOLD DIFFERENTIAL PRESSURE (MDP) SENSOR <Turbo> Manifold differential pressure sensor Manifold differential Manifold differential pressure sensor pressure sensor A Equipment side connector output Engine voltage control module Intake manifold plenum pressure 16z45 l Engine control module connector OPERATION and inputs to the engine control module.
Page 349 On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Item No. Data display Check condition Standard value Function Engine state Data reading 95 intake manifold Engine: Warm-up Idling 25.5-38.9 plenum sure 29.0-42.4 HARNESS INSPECTION Check for continuity of the ground A Harness side circuit.
Page 350 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components EGR TEMPERATURE SENSOR <California Up to 1995 models, Federal - Turbo Up to 1995 models> A Equipment side connector A Harness side output voltage Temperature OPERATION Refer to P.l3A-135. INSPECTION Refer to P.l3A-136. HARNESS INSPECTION A Harness side Connector: Disconnected...
Page 351 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for continuity of the ground circuit. A Harness side connector Connector: Disconnected Repair the harness. (Al -92) SENSOR INSPECTION Refer to GROUP 17 - Exhaust Gas Recirculation (EGR) System. HEATED OXYGEN SENSOR <California - Non Turbo Up to 1995 models> A B C D Equipment side connector...
Page 352 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components OPERATION Refer to P.l3A-137. TROUBLESHOOTING Refer to P.l3A-138. INSPECTION Using Scan Tool Function Item No. Data display Check condition Engine state Standard value Engine: Warm-up Data reading Sensor When sudden 200 mV or lower deceleration detection (Make the mixture lean by engine...
Page 353 On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- ABCD age of the heated oxygen sensor. Harness side Connector: Disconnected connector Ignition switch ON Battery voltage Repair the harness. C l , Dl - Engine control Check for an open-circuit, or a module harness...
Page 354 On-Vehicle Inspection of MFI FUEL INJECTION - Components HEATED OXYGEN SENSOR <Federal - Turbo Up to 1995 models> Heated oxygen B Heated oxygen Equipment Equipment side connector connector Electromotive Engine con B Harness side A Harness side connector Engine control module connector OPERATION Refer to P.l3A-137.
Page 355 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age of the heated oxygen sensor. A B Harness side Connector: Disconnected Ignition switch: ON Battery voltage Repair the harness. ( A l , Bl - Check for an open-circuit, or a short-circuit to ground, between the enginecontrol module and the...
Page 356 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents HEATED OXYGEN SENSOR <California - Turbo Up to 1995 models> A B C D Equipment side connector Harness side connector force Engine control module connector OPERATION Refer to P.l3A-137. TROUBLESHOOTING Refer to P.l3A-138. INSPECTION Using Scan Tool Check condition...
Page 357 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components <Heated Oxygen Sensor (rear)> Function Item No. Data display Check condition Engine state Standard value Data reading 59 Sensor Transaxle: 2nd gear 3,500 rpm voltage Drive with wide open throttle HARNESS INSPECTION Measure the power supply volt- A B C D age of the heated oxygen sensor.
Page 358 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components SENSOR INSPECTION Refer to P.l3A-143. INSTALLATION Refer to P.l3A-143. HEATED OXYGEN SENSOR <From 1996 models> A B C D Harness side connector Theoretical A/F Electromotive Engine control module connector OPERATION The heated oxygen sensor senses the oxygen concentration in exhaust gas, converts it into a voltage and inputs it to the engine control module.
Page 359 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components TROUBLESHOOTING HINTS Hint 1: Poor cleaning of exhaust gas will result if the heated oxygen sensor fails. Hint 2: If the heated oxygen sensor checked good but the sensor output voltage is out of specification, troubles of parts related to air-fuel raito control system are suspected.
Page 360 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power volt- A B C D age of be heated oxygen’ sensor. Harness side Connector: Disconnected connector Ignition switch: ON Battery voltage MFI relay) Engine control Check for an open-circuit, or a module harness short-circuit to ground, between side connector...
Page 361 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components INJECTORS <Non Turbo> 1 Injector MFI relay Injector Injector D Connector rear bank rear bank Fuel Engine control module Filter Connector Solenoid coil Plunger 3 Engine control module connector Needle valve - Y Injection OPERATION Refer to P.l3A-144.
Page 362 On-Vehicle Inspection of MFI FUEL INJECTION - Components INSPECTION Using Scan Tool Function Item No. Data display Check condition Coolant temperature Standard value Data reading 41 Drive time*’ Engine: Cranking 0°C (32”F)*2 20°C (68°F) 80°C (176°F) 8.2-i 2.4 ms Function Data display Check condition Engine state...
Page 363 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Function Item No. Drive content Check condition Normal state Actuator test No. 1 injector shut off Engine: Idling after Idle state to change fur- warm-up ther (becoming less No. 2 injector shut off (Shut off the injectors in stable or stalling) sequence during idling...
Page 364 On-Vehicle Inspection of MFI FUEL INJECTION - Components INJECTORS <Turbo> A Equipment side connector Resistor (Front bank connector) lnjectc inject0 No. 1. Engine control module Fuel Filter Engine control module connector Connector Solenoid coil Plunger Needle valv- Injection OPERATION Refer to P.l3A-144. TROUBLESHOOTING HINTS Refer to P.l3A-145.
Page 365 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Comtaonents INSPECTION Using Scan Tool Check condition Coolant temperature Standard value Function Item No. Data display Engine: Cranking 0°C (32”F)** 8.4-l 2.6 ms Data Drive time*’ reading (Rear bank) 20°C (68°F) 23.3-34.9 ms (Front bank) 5.4-8.2 ms Function...
Page 366 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Function Item No. Drive content Check condition Actuator test No. 1 injector shut off Engine: Idling after Idle state to change fur- warm-up ther (becoming less No. 2 injector shut off stable or stalling) (Shut off the injectors in sequence during idling...
Page 367: Idle Air Control Motor (Stepper Motor Type)
On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components IDLE AIR CONTROL MOTOR (STEPPER MOTOR TYPE) A Harness side connector connector Magnetic rotor Coil IAC motor Oscillo Oscillo Oscillo Oscillo Ball bearing Engine control module Throttle body seat Engine control module connector OPERATION Refer to P.l3A-153.
Page 368: Ignition Coil And Ignition Power Transistor
MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components IGNITION COIL AND IGNITION POWER TRANSISTOR Batterv Ignition coil A Harness side connector Engine speed check control terminal Equipment side connector B Harness side connector Spark iransistor Tachometer __ ignition timing , adjustment connector Engine control module...
Page 369 MULTIPORT FUEL INJECTION Components INSPECTION Using Scan Tool Data display Check condition Engine state Standard value Ignition Engine: Warming up 700 rpm 7-23” BTDC Data reading 44 Timing light: Set (set (Idle) advance timing light to check actual ignition tim- 2,000 23-43”...
Page 370 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION Measure the power supply volt- age of the ignition coil. A Harness side Connector: Disconnected connector Ignition switch: ON Battery voltage Repair the harness. (A3 - Igni- tion switch) Measure the power supply volt- Harness side age of the ignition coil.
Page 371 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Check for continuity of the ground circuit. B-2 Harness side connector Repair the harness. (B4 - Ground) Measure the voltage of the control signal circuit of the ignition power transistor. Connector: Disconnected Ignition switch: START 0.5-4.0 v Repair the...
Page 372 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components EVAPORATIVE EMISSION PURGE SOLENOID EVAP purge solenoid side Engine control module Engine control module connector OPERATION Refer to P.l3A-162. INSPECTION Refer to P.l3A-162. HARNESS INSPECTION Refer to P.l3A-163. ACTUATOR INSPECTION Refer to GROUP 17 - Evaporative Emission Control System. Revision...
Page 373: Egr Solenoid
On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components EGR SOLENOID EGR solenoid EGR solenoid Engine control module Engine control module connector OPERATION Refer to P.l3A-164. TROUBLESHOOTING HINT Refer to P.l3A-164. INSPECTION Refer to P.l3A-165. HARNESS INSPECTION Refer to P.l3A-165.
Page 374 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components FUEL PRESSURE SOLENOID <Turbo> MFI relay ‘: Up to 1995 models Engine control module connector OPERATION Refer to P.l3A-166. INSPECTION Refer to P.l3A-167. HARNESS INSPECTION Measure the power supply Connector: Disconnected A Harness side Ignition switch: ON connector...
Page 375 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Engine control module Check for an open-circuit, or a harness side connector short-circuit to ground, between A Harness side the fuel oressure solenoid and the connector engine control module. Engine control module con- Fuel pressure solenoid con- Repair the nector: Disconnected...
Page 376 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components OPERATION Refer to P.l3A-169. TROUBLESHOOTING HINTS Refer to P.l3A-169. INSPECTION Refer to P.l3A-170. HARNESS INSPECTION Measure the power supply volt- age. Ignition switch: ON Battery voltage relay) Check for an open-circuit, or a short-circuit to ground, between the turbocharger waste gate sole- ule.
Page 377 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components BOOST METER <Turbo> - - - - - ignition switch (IG,) A Equipment side connector - - - - - - - - y I = = - - - - NOTE Engine control...
Page 378 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Engine control module bar ess side connector short-circuit to ground, between A Harness side the engine control module and the Engine control module con- Repair the nector: Disconnected harness. NOTE ACTUATOR INSPECTION Refer to GROUP 54.
Page 379 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comr>onents OPERATION Refer to P.l3A-173. HARNESS INSPECTION Measure the input voltage of en- 35” gine control module. Engine control module con- nector: Disconnected Ignition switch: ON Battery voltage Repair the harness. Engine control module harness side connector NOTE...
Page 380 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components VARIABLE INDUCTION CONTROL MOTOR (DC MOTOR) <Non Turbo> Engine control module Variable induction control motor r (DC motor) (with built-in induction /- control valve position sensor) A Equipment connector Variable induction control motor OPERATION...
Page 381 On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents ANTI-LOCK BRAKING SIGNAL <Turbo> ABS ECU A ABS control unit equipment side connector Engine control module Engine control module connector OPERATION Refer to P.l3A-176. HARNESS INSPECTION Engine control module Check for an open-circuit or a short-circuit to ground, between the ABS control unit and the en-...
Page 382 On-Vehicle Inspection of MFI 7 314-278 FUEL INJECTION - Components ENGINE AND TRANSAXLE TOTAL CONTROL SIGNAL <A/T> Transaxle control module NOTE Engine control module A Transaxle control module connector Engine control module connector OPERATION Refer to P.l3A-177 TSB Revision...
Page 383: Fuel Pump Operation Check
MULTIPORT On-Vehicle Inspection of MFI 7 344-279 FUEL INJECTION - Components INSPECTION HARNESS Engine control Engine control Check for an open-circuit, or a module harness module harness short-circuit to ground between side corms A Transaxle control the transaxle control module and module harness side the engine control module.
Page 384 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components ENGINE CONTROL MODULE (ECM) TERMINAL VOLTAGE INSPECTION (1) Connect a very thin wire probe (such as a paper clip) to the probe of the voltmeter. (2) Insert the very thin probe from the wire side into contact with each of the terminals of the ECM connector and check the voltage, while referring to the check chart.
Page 385 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Engine: Idle Volume air flow sensor 2.2-3.2 Engine: 2,000 rpm Volume air flow sensor Engine: Idle o-1 v reset signal Engine: 3,000 rpm 6-9 V ignition...
Page 386 MULTIPORT Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Vehicle speed sensor Move the vehicle slowly forward (Changes repeated) Power steering Engine: Steering wheel placed in B+ pressure switch Idle, neutral (straight ahead) posi- warm tion O-3 V Steering wheel turned half a turn...
Page 387 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Heated oxygen sensor Transaxle: 2nd gear <M/T>, L range 0.6-l .O V nia, Drive with wide open throttle models> Federal - Engine 3,500 rpm or more from 1996...
Page 388 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Engine: 4,500 rpm Muffler mode change- Ignition Changeover switch set to ON O-3 V Turbo over switch switch: (TOUR) models> Changeover switch set to B+ OFF (SPORT) models> Ignition timing adjust- Ignition Ignition timing adjustment O-l V switch: ment terminal...
Page 389 On-Vehicle Inspection of MFI FUEL INJECTION - Components Terminal No. Check point Check conditions (Engine conditions) Standard value Remarks Induction control valve Ignition switch: ON O-l V or position sensor No. 1 4.5-5.5 v Turbo models> Engine: Slowly accelerated from idling O-l V or speed to 5,000 rpm 4.5-5.5 v + models>...
Page 390 MULTIPORT FUEL INJECTION INJECTOR REMOVAL AND INSTALLATION (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 15 - Intake Manifold Plenum.) Residual Pressure from High Pressure Hose Release O-ring O-ring Engine oil 00002423 Removal steps 8.
Page 391 MULTIPORT FUEL INJECTION REMOVAL SERVICE POINT (A, HIGH PRESSURE FUEL HOSE DISCONNECTION Bleed the residual pressure within the fuel pipe line so as to prevent the flow of fuel. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 392: Throttle Body
MULTIPORT FUEL INJECTION THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 00 - Maintenance Service.) <DOHC (Turbo)> 18 Nm 13 ft.lbs. Removal steps Accelerator cable adjustment 7. Vacuum pipe assembly 1. Accelerator cable connection 8.
Page 393: Knock Sensor
MULTIPORT FUEL INJECTION KNOCK SENSOR R jMOVAL A N D I N S T A L L A T I O N Pre-removal and Post-installation Operation Intake Manifold Plenum Release and Installation Plenum.) (Refer to GROUP 15 - Intake Manifold Intake Manifold Removal and Installation (Refer to GROUP 15 - Intake Manifold.) 20-25 Nm...
Page 394 NOTES...
Page 395 FUEL SUPPLY FUEL FILTER ......10 SPECIFICATIONS ..*....2 General Specifications .
Page 396 SPECIFICATIONS Specified sealant Items Fuel tank hole cover TROUBLESHOOTING Water in fuel filter functions (When tank cap is re- moved, pressure re- leasing noise is heard)
Page 397: Fuel Tank
FUEL SUPPLY FUEL TANK REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation Fuel Supplying Fuel Draining Residual Pressure from High Pressure Hose Release Fuel Leakage Checking (Refer to GROUP 13A - On-Vehicle Inspection of 5-6 Nm 3.6-4.3 fLIta. 25 Ribs. 8 ft.lbs. 26 Nm 19 ft.lbs.
Page 398 FUEL SUPPLY REMOVAL SERVICE POINT (A, HIGH PRESSURE FUEL HOSE DISCONNECTION Disconnect the hose from body main pipe first and then from fuel pump. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 399: Fuel Supply
FUEL SUPPLY Connect the return hose to the pipe securely, up to the stepped part, as shown in the illustration. Before installing the fuel gauge cover, apply the specified sealant to the rear floor pan. Specified sealant: 3M ATD Part No. 8509 or equivalent INSPECTION Check the hoses and the pipes for crack or damage.
Page 400 FUEL SUPPLY - and Fuel Tank Pressure Control Valve FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY AND FUEL TANK PRESSURE CONTROL VALVE REMOVAL AND INSTALLATION Removal steps 1. Fuel gauge cover 2. Fuel pump and fuel gauge unit (fuel pump side) assembly connector assembly (body side)
Page 401 FUEL SUPPLY - and Fuel Tank Pressure Control Valve INSTALLATION SERVICE POINTS ASSEMBLY INSTALLATION Align the three positioning projections of the packing with the holes in the fuel pump and fuel gauge unit assembly. Temporarily tighten the flare nut by hand, and then tighten Flare nut it to the specified torque, being careful that the high pressure fuel hose does not become twisted.
Page 402 FUEL SUPPLY FUEL LINE AND VAPOR LINE REMOVAL AND INSTALLATION Residual Pressure from High Pressure Hose Release Air Cleaner and iir Intake Hose Removal (Refer to GROUP 15 - Air Cleaner.) 30 Nm 2 2 ft.lbs. _ 35 Nm 8 ft.lbs. Fuel rail 0 0 0 0 2 4 2 7...
Page 403 FUEL SUPPLY REMOVAL SERVICE POINTS (A, EYE BOLT REMOVAL Remove the eye bolt while holding the fuel filter nut securely. Caution Cover the hose connection with rags to prevent splash h pressure of fuel that could be caused by some residual pressure hose in the fuel pipe line.
Page 404: Fuel Filter
FUEL SUPPLY FUEL FILTER REMOVAL AND INSTALLATION 25 ft.lbs. Removal steps 1. Battery 6. Fuel main pipe connection 2. Battery tray with washer tank 7. Mounting bolt 8. Fuel filter 3. Eye bolt 9. Eye bolt 4. Gasket 10. Gasket 5.
Page 405 ENGINE COOLING CONTENTS ENGINE COOLANT TEMPERATURE GAUGE SPECIFICATIONS ......UNIT, ENGINE COOLANT TEMPERATURE General Specifications ......2 SENSOR AND AIR CONDITIONING Lubricant..
Page 406 ENGINE COOLING - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Cooling method Water-cooled, pressurized, forced circulation with electrical fan Radiator Pressurized corrugated fin type Radiator fan motor Direct current ferrite type Water pump Centrifugal impeller type Thermostat Wax type with jiggle valve Identification mark 76.5 (Stamped on flange) SERVICE SPECIFICATIONS...
Page 407 ENGINE COOLING - Specifications / Troubleshooting SEALANT Items Specified sealants Engine coolant temperature gauge unit 3M Nut Locking Part No. 4171 Engine coolant temperature sensor (Engine control) Engine coolant temperature sensor (Air conditioning) TROUBLESHOOTING Symptom Probable cause Remedy Replenish Overheat Insufficient engine coolant Correct anti-freeze Too high an anti-freeze concentration...
Page 408 ENGINE COOLING ON-VEHICLE SERVICE ENGINE COOLANT LEAK CHECK 1. Loosen cap. 2. Confirm that the engine coolant level is up to the filler neck. 3. Install an adapter and cap adapter to the water outlet fitting and apply 160 kPa (23 psi) pressure. Hold pressure for two minutes, while checking for leakage from the radia- tor, hose or connections.
Page 409 ENGINE COOLING - Radiator RADIATOR REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Engine Coolant Refilling (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 00 - Maintenance Service.) Checking Automatic Transaxle Fluid Level and Refilling If Necessary 12 Nm 0 0 0 0 2 2 2 6 Radiator removal...
Page 410: Engine Cooling
14-6 ENGINE COOLING <From 1994 models> 13 Nm 9 ft.lbs. 0 0 0 0 2 2 2 7 Radiator fan motor assembly removal steps 1. Drain plug 13. Therm0 sensor connection* (For condenser fan) 6. Radiator upper hose <Vehicles with air conditioning> 9.
Page 411 14-7 ENGINE COOLING REMOVAL SERVICE POINT DISCONNECTION Use a plug or otherwise cover the hose and nipple part of the radiator so that dust, dirt, foreign materials, etc. do not enter after the hose has been disconnected from the radiator. INSTALLATION SERVICE POINT CONNECTION Connect the radiator fan motor connector to the body harness.
Page 412 14-8 ENGINE COOLING RESISTOR CHECK 1993 models> (1) Measure the resistance between connector terminals (1) and (4) of the radiator fan motor. (2) The resistor is normal if the resistance is within the follow- ing range. Resistance: 0.29-0.35 Q RESISTOR CHECK <From 1994 models>...
Page 413 14-9 ENGINE COOLING THERMOSTAT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 00 - Maintenance Service.) Removal steps 1. Air hose A <Turbo> 3. Air intake hose <Non-Turbo> 4. Radiator lower hose connection 5.
Page 414 ENGINE COOLING INSPECTION Check that valve closes tightly at room temperature. Check for defects or damage. Check for rust or encrustation on valve. Remove if any. Immerse thermostat in container of water. Stir to raise water temperature and check that thermostat opening valve temperature and the temperature with valve fully open [valve lift-over 8 mm (.31 in.)] are at the standard value.
Page 415 14-11 ENGINE COOLING - Water Pump, Water Pipe and Water Hose WATER PUMP, WATER PIPE AND WATER HOSE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Timing Belt Removal and Installation (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 11 - Timing Belt.) Ignition PowerTransistor Unit and Ignition Coil Removal and Installation...
Page 416 14-12 ENGINE COOLING - Water Pump, Water Pipe and Water Hose (1) Clean both gasket surfaces of water pump body and cylinder block. (2) Install new water pump gasket and water pump assembly and tighten the bolts. (3) Water pump installation bolt size are different and caution must be paid to ensure that they are properly installed.
Page 417 14-13 ENGINE COOLING - s ENGINE COOLANT TEMPERATURE GAUGE UNIT, ENGINE COOLANT TEMPERATURE SENSOR AND AIR CONDITIONING ENGINE COOLANT TEMPERATURE SWITCH REMOVAL AND INSTALLATION Pre-removal and Post-installation operation Engine Coolant Draining and Supplying (Refer to GROUP 00 - Maintenance Service.) 0 0 0 0 2 2 2 9 Removal steps 1.
Page 418 ENGINE COOLING - s INSTALLATION SERVICE POINTS INSTALLATION Assemble the air intake hose A with its notches (arrow-marked) lined up with the marks on the air intake hoses B and Insert the hoses into the air intake hose A until they are bottomed.
Page 419: Intake And Exhaust
INTAKE AND EXHAUST CONTENTS Intake Charge Pressure Control System ACTIVE EXHAUST SYSTEM ... . Check ........7 AIR CLEANER .
Page 420: Special Tool
INTAKE AND EXHAUST - Specifications / Special Tool SPECIFICATIONS GENERAL SPECIFICATIONS xpansron resonance SERVICE SPECIFICATIONS Items Standard value Limit 0.2 (.008) Less than 0.15 (0059) Intake manifolds Distortion of cylinder head contacting surface mm (in.) 36-44 Turbocharger waste gate solenoid terminal resistance [at 20°C (68”...
Page 421 15-3 INTAKE AND EXHAUST - Troubleshooting TROUBLESHOOTING Probable cause Remedy Symptom Retighten Loose joints Exhaust gas leakage Repair or replace Broken pipe or muffler Broken separator in muffler Replace Abnormal noise Replace Broken rubber hangers Interference of pipe or muffler with vehicle body Correct Repair or replace Broken pipe or muffler...
Page 422: Exhaust System
INTAKE AND EXHAUST - Troubleshooting (Active Exhaust System) EXHAUST SYSTEM) TROUBLESHOOTING PROCEDURE (1) Make sure that the valve operating cable is not dislocated. (2) Make sure that the connectors of each component are positively connected and that no fuse has blown.
Page 423 15-5 INTAKE AND EXHAUST - On-vehicle Service ON-VEHICLE SERVICE VARIABLE INDUCTION CONTROL SYSTEM CHECK (Non Turbo) cl 992 models> SYSTEM CHECK (1) Warm up the engine. (2) Connect the tachometer. (Refer to GROUP 11 - Engine Adjustment.) (3) Make sure that when the engine speed is increased from the idle speed to 5,000 rpm, the induction control valve shaft turns.
Page 424 15-6 INTAKE AND EXHAUST Standard value Engine condition Voltage [V] Idle O-l or 4.5-5.5 Engine speed gradually 1 Z-4.0 (momentarily) Increases to 5,000 rpm 5,000 rpm O-l or 4.5-5.5 (4) If the voltages are outside the standard values, inspect the induction control valve position sensor, variable induc- tion control motor and the related harnesses.
Page 425 15-7 INTAKE AND EXHAUST Disconnect the hose (black) from the turbocharger waste gate solenoid, and connect the pressure gauge to the hose. Plug the nipple of the solenoid valve from which the hose (black) has been disconnected. (2) Drive the vehicle with full throttle and accelerate the engine to a speed of more than 3,500 rpm at 2nd gear.
Page 426 15-8 INTAKE AND EXHAUST - On-vehicle Service TURBOCHARGER WASTE GATE SOLENOID CHECK (Turbo) OPERATION CHECK (1) Connect a hand vacuum pump to the solenoid valve nipple (A) (see the illustration to the left). (2) Using a jumper wire, connect between the solenoid valve terminal and battery terminal.
Page 427 INTAKE AND EXHAUST - Air Cleaner AIR CLEANER REMOVAL AND INSTALLATION Air cleaner removal steps Air intake hose removal steps 1. Volume airflow sensor connector <Turbo> 2. Air cleaner cover and volume airflow 14. Boost hose connection sensor assembly 15. Air hose A 3.
Page 428 INTAKE AND EXHAUST - Air Cleaner INSTALLATION SERVICE POINTS AIR INTAKE HOSE A, TURBOCHARGER BY-PASS VALVE AND AIR BY-PASS HOSE INSTALLATION Air intake hose A Engaging the notch with the A mark at points indicated by the arrows, insert air intake hoses B and C until seated. Insert the turbocharger end of air intake hoses B and C com- Air intake hose B pletely.
Page 429: Charge Air Cooler
INTAKE AND EXHAUST - Charge Air Cooler CHARGE AIR COOLER REMOVAL AND INSTALLATION Pre-removal Operation Front Bumper Removal (Refer to GROUP 51 - Front Bumper.) (When equipped with charge air cooler left) (Refer to GROUP 51 - Front Bumper.) 7 - 9 ft.lbs. 2.9 ft.lbs.
Page 430 INTAKE AND EXHAUST REMOVAL SERVICE POINT Disconnect the hose from the engine oil cooler and remove the engine oil cooler only. INSTALLATION SERVICE POINTS AIR INTAKE HOSE A INSTALLATION Engaging the notch with the A mark at points indicated by the arrows, insert air intake hoses B and C until seated.
Page 431 INTAKE AND EXHAUST INTAKE MANIFOLD PLENUM <Non Turbo> REMOVAL AND INSTALLATION Post-installation operation Accelerator Cable Adjustment (Refer to GROUP 13F - Engine Control.) 5 Nm 18 Nm 13 ft.lbs. 60 Nm 43 ft.lbs. Removal steps 1. Air intake hose connection 12.
Page 432 INTAKE AND EXHAUST REMOVAL SERVICE POINT (A, THROTTLE BODY ASSEMBLY REMOVAL Leaving the water hoses and vacuum hoses in their installed positions, remove from the intake manifold plenum. INSTALLATION SERVICE POINT Install with the gasket protrusion positioned as shown. Caution If installed in an incorrect direction, idling failure or other problems may occur.
Page 433 INTAKE AND EXHAUST - Intake Manifold Plenum <Turbo> INTAKE MANIFOLD PLENUM <Turbo> REMOVAL AND INSTALLATION Post-installation Operation Accelerator Cable Adjustment (Refer to GROUP 13F - Engine Control.) 4-6 Nm 3-4 ft.lbs. 18 Nm Turbocharger O-ring osFooo3 0 0 0 0 4 1 5 0 7-9 ft.lbs.
Page 434 INTAKE AND EXHAUST - Intake Manifold Plenum <Turbo> INSTALLATION SERVICE POINT Throttle body Caution If installed in an incorrect direction, idling failure or other problems may occur. INSPECTION Check the following points; replace the part if a problem is found. INTAKE MANIFOLD PLENUM CHECK (1) Check intake manifold plenum for defect or cracks.
Page 435: Intake Manifold
INTAKE AND EXHAUST - Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Residual Pressure Release (Refer to GROUP 13A - On-vehicle Service.) (Refer to P.1513. 15.) Engine Coolant Draining Engine Coolant Filling’ (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 00 - Maintenance Service.) Intake Manifold Plenum Removal (Refer to P.1513, 15.)
Page 436 INTAKE AND EXHAUST INSTALLATION SERVICE POINTS Install with gasket protrusions in the position illustrated. FRONT INSTALLATION Tighten the intake manifold mounting nuts one bank after the other by the following procedure. (1) Tighten the nuts in the front bank to 3 to 5 Nm (2.2 to 3.6 ftlbs.).
Page 437 INTAKE AND EXHAUST - Intake Manifold INSPECTION Check the following points; replace the part if a problem is found. INTAKE MANIFOLD CHECK (1) Check for damage or cracking of any part. (2) Clogging of the negative pressure (vacuum) outlet port, or clogging of the gas passages.
Page 438 INTAKE AND EXHAUST TURBOCHARGER (FRONT) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Radiator Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to P.l5-33, 35, 37.) (Refer to GROUP 14 - Radiator.) Transmission Stay (Right) Removal and Installation 7-S ft.lbs. 31 Nm I( 22 ft.lbs.
Page 439 INTAKE AND EXHAUST - Turbocharger (Front) REMOVAL SERVICE POINTS Disconnect the connector of the heated oxygen sensor, and install the special tool to the heated oxygen sensor. DISCONNECTION Disconnect air conditioning compressor with hoses from the bracket. NOTE The removed air conditioning compressor should be fastened (by using rope, etc.) in a position that will not interfere with the removal/installation of the turbocharger assembly.
Page 440 15-22 INTAKE AND EXHAUST - Turbocharger (Front) Hose end . . . paint Aligning the marks at the points indicated by the arrows, Pipe end . . . protrusion insert securely into the stepped portion of the pipe. Caution Be careful not to allow any foreign matter to get into the hoses or pipes.
Page 441 INTAKE AND EXHAUST TURBOCHARGER (REAR) Post-installation ODeration Front Exhaust Pipe Installation (Refer to GROUP 00 - Maintenance Service.) (Refer to P.15-33, 35. 37.1 7-9 ft.lbs. d-ring . - l7 1 8 ' 55-65 Nm 13 ft.lbs. 33 ft.lbs. 9-11 ft.lbs. Removal steps 13.
Page 442 15-24 INTAKE AND EXHAUST - Turbocharger (Rear) REMOVAL SERVICE POINT Disconnect the connector of the heated oxygen sensor, and install the special tool to the heated oxygen sensor. INSTALLATION SERVICE POINTS Clean the alignment surfaces shown in the Illustration. Caution When cleaning, care must be taken so that a piece of the gasket does not enter the oil passage hole.
Page 443 15-25 INTAKE AND EXHAUST INSPECTION TURBOCHARGER ASSEMBLY CHECK Visually check the turbine wheel and the compressor wheel for cracking or other damage. Check whether the turbine wheel and the compressor wheel can be easily turned by hand. Check for oil leakage from the turbocharger assembly. Check whether or not the turbocharger waste gate valve Compressor remains open.
Page 444 15-26 INTAKE AND EXHAUST EXHAUST MANIFOLD <Non Turbo> REMOVAL AND INSTALLATION <Vehicles for Federal> Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and Installation Condenser Fan Motor Assembly Removal and Installa- (Refer to P.l5-30, 31.) tion <Vehicles with Air Conditioning> (Refer to GROUP 14 - Radiator.) 12-15 Nm 9-11 ft.lbs.
Page 445 INTAKE AND EXHAUST 15-27 Pre-removal and Post-installation Operation Catalytic Converter Removal and Installation Condenser Fan Motor Assembly Removal and Installa- tion <Vehicles with Air Conditioning> (Refer to GROUP 14 - Radiator.) 60 Nm 43 ft.lbs. 60 Nm 43 ft.lbs. 12-15 Nm 33 ft.lbs.
Page 446 15-28 INTAKE AND EXHAUST EXHAUST MANIFOLD <Turbo> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Turbocharger Assembly Removal and Installation (Refer to P.1520, 23.) 12-15 Nm 9-11 ft.lbs. 9-11 ft.lbs. Exhaust manifold removal steps removal steps Exhaust manifold (rear) (front) 5. Heat protector 1.
Page 447 15-29 INTAKE AND EXHAUST INSTALLATION SERVICE POINTS Tighten the nuts in the following order. (1) Tighten five nuts (A) to 30 Nm (22 ftlbs.). (2) lIghten nuts (B) to 47-53 Nm (34-38 ftlbs.). (3) Back off nuts (B) until torque value of 10 Nm (7 ftlbs.) is achieved.
Page 448 Exhaust Pipe Main Muffler and Catalytic Converter INTAKE AND EXHAUST - EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER j REMOVAL AND INSTALLATION 50 Nm 36 ft.lbs. 13 Nm 13 Nm 9 ft.lbs. 9 ft.lbs. 13 N m 9 ft.lbs. 9 ft.lbs. 13 Nm 13 Nm 9 ft.lbs.
Page 449 Exhaust Pipe, Main Muffler and Catalytic Converter INTAKE AND EXHAUST 7 N m 75 Nm 5 ft.lbs. 7-9 ftlbs. 54 ft.lbs 13 Nm 9 ft.lbs. 45 Nm 33 ftlbs. 13 Nm 9 ft.lbs. Removal steps 20. Gasket 1. Main muffler and center exhaust pipe installation bolts 21.
Page 450 Exhaust Pipe, Main Muffler and Catalytic Converter REMOVAL SERVICE POINTS Support with a transmission jack, etc. INSPECTION Check the mufflers and pipes for corrosion or damage. Check the rubber hangers for deterioration or damage. Check for gas leakage from mufflers and pipes. TSB Revision...
Page 451 Exhaust Pipe, Main Muffler and Catalytic Converter INTAKE AND EXHAUST EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER REMOVAL AND INSTALLATION 9 ft.lbs. - - - - - - - - 36 ftlbs. 4 ft.lbs. 13 Nm 9 ft.lbs. 13 Nm 9 ftlbs.
Page 452 catalytic Converter INTAKE AND EXHAUST 19. Catalytic converter and front exhaust 28. Gasket pipe installation bolts 29. Hanger bracket 20. Catalytic converter 21. Gasket 31. Heat protector D 22. Self-locking nuts 32. EGR pipe connection 23. Rubber hanger 33. Gasket 24.
Page 453 Exhaust Pipe, Main Muffler and Catalytic Converter INTAKE AND EXHAUST cl 994 models> Pre-removal and Post-installation Operation Air Conditioning Low-Pressure Hose and Liquid Pipe Clutch Booster Vacuum Pipe Removal and Installation B Clamp Removal and Installation (Refer to GROUP 21 - Clutch Control.) (Refer to GROUP 55 - Refrigerant Line.) Drive Shaft (Left Side), Inner Shaft Assembly Removal Brake Booster VacuumTube Clamp Removal and Instal-...
Page 454 Exhaust Pipe, Main Muffler and Catalytic Converter INTAKE AND EXHAUST - 12-15 Nm 6.5 ft.lbs. 11 Nm - - - - - - - - - - 50 Nm 36 ft.lbs. 19. Catalytic converter and front exhaust 30. Gasket pipe installation bolts 31.
Page 455 Exhaust Pipe, Main Muffler and Catalytic Converter INTAKE AND EXHAUST - <Turbo> Preremoval and Post-installation Operation Air Conditioning Low-Pressure Hose and Liquid Pipe Clutch Booster Vacuum Pipe Removal and Installation B Clamp Removal and installation (Refer to GROUP 21 - Clutch Control.) (Refer to GROUP 55 - Refrigerant Line.) Drive Shaft (Left Side), Inner Shaft Assembly Removal Brake Booster VacuumTube Clamp Removal and Instal-...
Page 456 Exhaust Pipe, Main Muffler and Catalytic Converter 18 Nm 7-9 ftlbs. 13 ft.lbs. 40-47 ft.lbs. 13 -Nm 15. Hanger bracket Right bank warm up three-way 16. Rear floor heat protector catalytic converter 17. Catalytic converter and front exhaust Gasket pipe installation bolts Hanger bracket 18.
Page 457 Exhaust Pipe, Main Muffler and Catalytic Converter 15-39 INTAKE AND EXHAUST REMOVAL SERVICE POINTS Support with a transmission jack, etc. Disconnect the connector of the heated oxygen sensor, and install the special tool to the heated oxygen. INSTALLATION SERVICE POINTS Use the special tool to install the heated oxygen sensor.
Page 458 INTAKE AND EXHAUST ACTIVE EXHAUST SYSTEM <Up to 1994 models> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Rear Side Trim (LH) Removal and installation (Refer to GROUP 52A - Trims.) 7 Nm 5 ft.lbs. Removal steps 1. Active exhaust system control module 4.
Page 459 INTAKE AND EXHAUST - Active Exhaust System INSPECTION ACTIVE EXHAUST SWITCH CHECK (1) Remove switch garnish B from the knee protector. (2) Operate the switch and check the continuity between the terminals. Switch position Terminal No. TOUR II I SPORT TSB Revision...
Page 460 NOTES...
Page 461 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service, before beginning any service or maintenance of anycom- ponent of the SRS or any SRS-related component.
Page 462 17-2 EXHAUST GAS RECIRCULATION (EGR) ENGINE CONTROL SYSTEM ..; . . 3 SYSTEM ....... ENGINE CONTROL .
Page 463 ENGINE AND EMISSION CONTROL SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Accelerator cable play mm (in.) TROUBLESHOOTING ACCELERATOR CABLE AND ACCELERATOR PEDAL Symptom Remedy Misadjusted accelerator cable Throttle valve will not Adjust fully open or close Misadjusted automatic speed-control cable Adjust Broken return spring Replace Throttle lever malfunction...
Page 464 17-4 ENGINE AND EMISSION CONTROL - Engine Control System ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT For models equipped with the cruise control system, refer to P.17-31. (1) Check the accelerator cable for sharp bends. (2) Check to ensure that the throttle lever is in contact with the engine speed adjusting screw.
Page 465: Engine Control
17-5 ENGINE AND EMISSION CONTROL - Engine Control System ENGINE CONTROL REMOVAL AND INSTALLATION Post-installation Operation Accelerator Cable Adiustment (Refer to P.li’-4.1 Accelerator Switch Adjustment ‘<AA> (Refer to f?17-4.) 5 Nm 5 Nm 10 Nm 0 0 0 0 2 4 2 8 Removal steps 1.
Page 466 17-6 ENGINE AND EMISSION CONTROL - Cruise Control System SPECIFICATIONS GENERAL SPECIFICATIONS NOTE SERVICE SPECIFICATIONS TSB Revision...
Page 467 ENGINE AND EMISSION CONTROL - Cruise Control System SPECIAL TOOLS Up to 1993 models Checking of the diagnostic output Checking of the diagnostic trouble code Checking of the diagnostic trouble code check harness TSB Revision...
Page 468 ENGINE AND EMISSION CONTROL - Cruise Control System TROUBLESHOOTING P R E L I M I N A R Y I N S P E C T I O N Check the following points and repair defective points, if any, before troubleshooting. (1) Check that the vacuum pump assembly, link assembly, actuator and all cables and vacuum hoses are properly installed and that the cables and vacuum hoses are correctly routed.
Page 469 17-9 ENGINE AND EMISSION CONTROL - Cruise Control System NOTE This chart contains troubleshooting procedures to perform when a problem cannot be detected by on- Check input. (Refer to P.l7-26.) board diagnostic. Is the result of input check O.K.? Check vacuum pump assembly circuit. NOTE If the results of checks on the vacuum pump assembly circuit and actuator parts (refer to F!17-37.) indicate...
Page 470 ENGINE AND EMISSION CONTROL - Cruise Control System Trouble symptom Probable cause Check chart No. Remedy No.4 The set vehicle speed varies Malfunction of the vehicle Repair the vehicle speed greatly upward or downward. speed sensor circuit sensor system, or replace “Hunting”...
Page 471 ENGINE AND EMISSION CONTROL - Cruise Control Svstem Trouble symptom Probable cause Check chart No. Remedy Cannot accelerate or resume Open or shot-t circuit in No. Replace control speed by using the RESUME RESUME switch circuit in switch. switch. control switch Vacuum pump assembly No.5 Repair the harness or re- circuit poor contact...
Page 472 ENGINE AND EMISSION CONTROL - Cruise Control System CHECK CHART inspection of control unit power supply circuit IGNITION SW ITCH DESCRIPTION OF OPERATION tact of relay Ryt to stop the power supply to the control unit. When the switch is released, The power is supplied through the ignition switch it automatically returns to the neutral position, but relay Ryl stays in the OFF state.
Page 473 ENGINE AND EMISSION CONTROL - Cruise Control @stem TROUBLESHOOTING HINTS terminal voltage Terminal Signal name Condition Terminal voltage Battery positive Control unit power supply Main switch ON and neutral position there- after voltage Main switch OFF and neutral position 0 V thereafter Control unit ground At all times...
Page 474 17-14 ENGINE AND EMISSION CONTROL - Cruise Control System DESCRIPTION OF OPERATION to OFF and when the vehicle speed is reduced to less than 40 km/h (25 mph), the vehicle The control switch is a switch in which the SET, will not resume cruising at the previously set RESUME and CANCEL switches are integrated.
Page 475 ENGINE AND EMISSION CONTROL Inspection of indicator light circuit CRUISE DESCRIPTION OF OPERATION 1. Cruise control ON (ASC ON) indicator 2. Cruise control (CRUISE) indicator light light During cruise control operation, transistor Trl Located in the combination meter, it lights as in the control unit is kept in the ON state to soon as the main switch is set to ON.
Page 476 ENGINE AND EMISSION CONTROL Inspection of vehicle speed sensor circuit IGNITION CRUISE DESCRIPTION OF OPERATION 1994 models> The vehicle speed sensor is a reed switch type The vehicle speed sensor, mounted in the transmis- and is mounted in the speedometer. It sends pulse sion, delivers pulse signals proportional to the rota- signals proportional to the rotational speed of the tional speed of the transmission output gear (vehicle...
Page 477 ENGINE AND EMISSION CONTROL - Cruise Control System Inspection of vacuum pump assembly drive circuit TSB Revision...
Page 478 ENGINE AND EMISSION CONTROL -‘Cruise Control System DESCRIPTION OF OPERATION The input signal from the control switch causes by a DC motor, and two solenoid valves (control transistor Trt to be ON. Accordingly, the cruise valve and relief valve) and is controlled by the con- control relay is placed in the ON state to supply trol unit as shown in the following table.
Page 479 ENGINE AND EMISSION CONTROL Inspection of stop light switch circuit DESCRIPTION OF OPERATION FUSIBLE LINK@ When the brake pedal is depressed during vehicle speed control, the cruise control (NC) contact of the stop light switch is opened to interrupt the power supply to the vacuum pump assembly for cancellation of vehicle speed control.
Page 480 ENGINE AND EMISSION CONTROL Inspection of park/neutral position switch circuit <A/T> DESCRIPTION OF OPERATION The park/neutral position switch is interlocked with which internally interrupts the power supply to the the starter switch. When the gear selector lever vacuum pump assembly drive circuit for cancellation is placed in the “N”...
Page 481 17-21 ENGINE AND EMISSION CONTROL - Cruise Control System Inspection of throttle position sensor circuit NOTE (NON TURBO - FEDERAL) l 2: 1994, 1995 MODELS (TURBO, NON TURBO - CALIFORNIA) AND 1996 MODELS DESCRIPTION OF OPERATION unit, regarding the opening of the accelerator. The The throttle position sensor (with built-in closed closed throttle position switch inputs the data to throttle position switch) is used for engine control...
Page 482 17-22 ENGINE AND EMISSION CONTROL - Cruise Control System Inspection of circuit associated with accelerator pedal switch OFF function <A/T> (1992 models) IGNITION 'CH (I G2) -TV-- "2 9 -. DESCRIPTION OF OPERATION The accelerator pedal switch is used to detect the during vehicle speed control, the cruise control unit operating state of the accelerator pedal.
Page 483 17-23 ENGINE AND EMISSION CONTROL Inspection of circuits associated with overdrive cancel <A/T> CRUISE CONTROL DESCRIPTION OF OPERATION On a vehicle with cruise control, the OD switch or the RESUME switch is turned ON, the cruise ON signal is input through the cruise control unit control unit forces transistor Tr, into the OFF state.
Page 484 17-24 ENGINE AND EMISSION CONTROL ON-BOARD DIAGNOSTIC CHECKING On-board diagnostic checking is performed when there has been an automatic cancellation, without cancel switch opera- tion. NOTE Even when the ignition key is placed in the OFF position, all diagnostic trouble codes are stored and retained, until the battery cable is disconnected, to make sure that the prob- lems encountered in the past can be checked.
Page 485 17-25 ENGINE AND EMISSION CONTROL - Cruise Control System WHEN USING THE VOLTMETER (1) Connect an analog voltmeter across the diagnostic output terminal and ground terminal of the data link connector. (2) Place the ignition switch in the ON position. (3) Read the diagnostic trouble code on the basis of the deflection of the pointer of the voltmeter.
Page 486 17-26 ENGINE AND EMISSION CONTROL NOTE Normal code three latest code numbers are displayed in the order of lowest code number first. 2. Even if the problem represented by the code number marked * occurs during cruise control operation, the cruise control mode will not be canceled.
Page 487 17-27 ENGINE AND EMISSION CONTROL - Cruise Control System INPUT CHECK TABLE Code Display patterns (output codes) Input operation Check results (use with voltmeter) SET switch ON SET switch circuit normal RESUME switch ON RESUME switch normal Stop light switch ON Stop light switch circuit normal (brake pedal depressed) Vehicle speed more than approx.
Page 488 ENGINE AND EMISSION CONTROL - Cruise Control System HARNESS AND COMPONENT LAYOUT HARNESS AND COMPONENT LAYOUT ENGINE COMPARTMENT ENGINE COMPARTMENT Engine front view Engine rear view INSTRUMENT PANEL AND FLOOR CONSOLE Jumper connector Vacuum pump Throttle position sensor Park/neutral position switch <A/T> Vehicle speed sensor Combination meter Combination meter...
Page 489 ENGINE AND EMISSION CONTROL - Cruise Control System DASH PANEL Junction block JUNCTION BLOCK Front side Rear side 16’ 0 0 0 0 2 4 3 5 10. Clutch pedal position switch <M/T> 20. Adapter wiring harness and junction 11. Stop light switch block combination 12.
Page 490 ENGINE AND EMISSION CONTROL - Cruise Control System LOCATION OF CONTROL UNIT AND RELAY Engine control module control unit GROUND POINT...
Page 491 ENGINE AND EMISSION CONTROL ON-VEHICLE SERVICE CRUISE CONTROL CABLES CHECK AND ADJUSTMENT Cruise control assembly Cruise control actuator Adjusting nut A Adjusting nut B , LA; Link A Adjusting nut C Throttle cable Accelerator cable -- (1) Set the air conditioning, lights and other switches to OFF for inspection at no load.
Page 492 17-32 ENGINE AND EMISSION CONTROL Set the ignition switch to ON (do not start the engine). Rotate intermediate link C in the direction shown until it is blocked by the stopper, turn down adjusting nut C in the direction that the free travel of the inner cable is reduced, and back off adjusting nut C the specified number of turns just before intermediate link C begins to move.
Page 493 17-33 ENGINE AND EMISSION CONTROL - Cruise Control System CRUISE CONTROL SETTING CHECK (1) Switch ON the main switch. (2) Drive at the desired speed within the range of approximate- ly 40-145 km/h (25-90 mph)*‘, 40-200 km/h (25-124 (3) Operate the control switch downward. (SET switch: ON) (4) Check to be sure that the speed is the desired constant speed when the switch is released, and also check to be sure that the CRUISE indicator light (within the com-...
Page 494 17-34 ENGINE AND EMISSION CONTROL (3) With the vehicle at a speed of more than about 40 km/h (25 mph), check that when the control switch is moved upward (RESUME switch: ON), the vehicle resumes cruis- ing at the speed held before cancellation of the cruise control mode.
Page 495 ENGINE AND EMISSION CONTROL - Cruise Control System (1) Remove the air bag module using the following procedure. 1) Remove the negative terminal of the battery and wait for more than 60 seconds. Caution The capacitor in the SRS diagnosis unit retains enough voltage to deploy the air bag for a given period even after disconnection of the battery.
Page 496 17-36 ENGINE AND EMISSION CONTROL - Cruise Control System STOP LIGHT SWITCH/BRAKE SWITCH CHECK (1) Disconnect the connector. (2) Check for continuity between the terminals of the switch. For brake switch For stop light Measurement terminal switch terminal conditions When brake pedal depressed.
Page 497 17-37 ENGINE AND EMISSION CONTROL THROTTLE POSITION SENSOR INSPECTION For inspection, refer to GROUP 13A - On-Vehicle Inspection of MFI Components. CLOSED THROlTLE POSITION SWITCH INSPECTION For inspection, refer to GROUP 13A - On-Vehicle Inspection of MFI Components. VACUUM PUMP INSPECTION Inspection of Solenoid Valves (Control and Relief Valves) (1) Disconnect the connector of the vacuum pump assembly.
Page 498: Cruise Control System
17-38 ENGINE AND EMISSION CONTROL - Cruise Control System CRUISE CONTROL SYSTEM REMOVAL AND INSTALLATION Post-installation Operation (Refer to R.17-31.) Actuator removal steps 10. Link assembly 1. Link protector 11. Link bracket 2. Accelerator cable and link assembly 12. Accelerator cable and accelerator connection pedal connection 3.
Page 499 ENGINE AND EMISSION CONTROL - Cruise Control System 17-39 0 0 0 0 2 4 4 5 Control switches removal steps Control unit and relay removal steps 20. Air bag module (Refer to GROUP 52B - Air Bag 25. Scuff plate (R.H.) Module and Clock Spring.) 26.
Page 500 ENGINE AND EMISSION CONTROL - Cruise Control System 0 0 0 0 2 4 4 6 Sensors and switches removal Equipped on 1992 models only steps Up to 1993 models 29. Throttle position sensor models (Turbo) and From 1993 1994 models 30.
Page 501 ENGINE AND EMISSION CONTROL - Emission Control Svstem GENERAL SPECIFICATIONS Items Positive crankcase ventilation system Closed type with positive crankcase ventilation valve Evaporative emission control system Evaporative emission cEVAP> canister Evaporative emission cEVAP> purge solenoid ON/OFF solenoid valve Evaporative emission cEVAP> purge solenoid Duty cycle type Vacuum-activated diaphragm type Exhaust gas...
Page 502: Vacuum Hoses Routing
ENGINE AND EMISSION CONTROL VACUUM HOSES ROUTING purge solenoid Fuel pressure regulator L: Light blue Vehicle front B: Black Evaporative emission purge solenoid Evaporative emission canister Fuel pressure regulator Vehicle front L: Light blue B: Black...
Page 503 EGR solenoid purge solenoid Evaporative emission canister Fuel prkssure regulator G: Green Vehicle front Y: Yellow L: Light blue EGR solenoid I LliLlI- E v a p o r a t i v e v emission purge solenoid Evaporative emission canister Throttle body...
Page 504 ENGINE AND EMISSION CONTROL Evaporative emission EGR solenoid purge solenoid valve Evaporative emission canister Throttle body Fuel pressure regulator G: Green 7F Ul815 Vehicle front L: Light blue R: Red B: Black...
Page 505 ENGINE AND EMISSION CONTROL - Emission Control System Turbocharger waste Fuel pressure solenoid Turbocharger waste solenoid Bypass valve Fuel pressure regulator Vehicle front G Green Purge control valve T u r b o c h a r g e r w a s t e ’ L: Light blue Turbocharger gate actuator...
Page 506 ENGINE AND EMISSION CONTROL - Emission Control System EVAP purge solenoid C waste gate solenoid TC waste gate Turbocharger Vehicle front Check valve actuator G: Green Y: Yellow L: Light blue R: Red B: Black W: White...
Page 507 ENGINE AND EMISSION CONTROL - Emission Control System VACUUM CIRCUIT DIAGRAM To combustion chamber From air cleaner Fuel pressure regulator = EVAP purge solenoid (ON: open) EVAP canister B: Black L: Light blue...
Page 508 ENGINE AND EMISSION CONTROL - Emission Control System Intake manifold plenum EVAP canister B: Black L: Light blue...
Page 509 ENGINE AND EMISSION CONTROL Intake manifold plenum Throttle body To combustion chamber From air cleaner Fuel pressure regulator - EGR solenoid (ON: close) EGR valve B: Black G: Green L: Light blue EVAP canister...
Page 510 ENGINE AND EMISSION CONTROL - Emission Control Svstem Throttle body To combustion chamber Fuel pressure regulator EVAP purge solenoid (ON: open) EGR solenoid (ON: close) EGR valve EVAP canister B: Black G: Green L: Light blue...
Page 511 ENGINE AND EMISSION CONTROL Throttle body To combustion chamber From Fuel pressure regulator EGR valve G: Green Y: Yellow L: Light blue B: Black W: White...
Page 512 1 7 - 5 2 ENGINE AND EMISSION CONTROL Throttle body To combustion chamber Fuel pressure regulator TC waste gate solenoid (ON: open) Air cleaner Turbocharger bypass vah EGR valve Air intake hose EGR solenoid close) EVAP canister EVAP purge solenoid (ON: close)
Page 513 ENGINE AND EMISSION CONTROL Intake manifold plenum Throttle body To combustion chamber Fuel pressure regulator Turbocharger bypass valve Air cleaner EVAP purge solenoid (ON: close) Air intake hose EVAP canister...
Page 514 ENGINE AND EMISSION CONTROL Throttle body To combustion chamber Check valve EVAP canister Fuel pressure Air cleaner regulator EGR valve TC waste gate a c t u a t o r TC waste gate actuator G: Green L: Light blue R: Red W: White...
Page 515 ENGINE AND EMISSION CONTROL INSPECTION (1) Referring to the VACUUM HOSES ROUTING, confirm that the vacuum hoses are properly connected. (2) Check the hoses for irregularities (disconnection, loose- ness, etc.) and confirm that there is no breakage or dam- age. INSTALLATION (1) When connecting a hose, firmly press it onto the nipple.
Page 516 ENGINE AND EMISSION CONTROL COMPONENT LOCATION Name Symbol Positive crankcase ventilation valve CRANKCASE VENTILATION SYSTEM INSPECTION (1) After disconnecting the ventilation hose from the positive crankcase ventilation valve, disconnect the positive crank- case ventilation valve from the rocker cover, and reconnect the positive crankcase ventilation valve to the ventilation hose.
Page 517 ENGINE AND EMISSION CONTROL - Emission Control System COMPONENT LOCATION Name Symbol Name Symbol Evaporative emission (EVAP) canister Purge control valve <Turbo> Evaporative emission (EVAP) purge sole- Revision...
Page 518 ENGINE AND EMISSION CONTROL - Emission Control System PURGE CONTROL SYSTEM INSPECTION body EVAP purge solenoid EVAP canister Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Engine control Volume air flow sensor module Barometric pressure sensor intake air temperature sensor Engine coolant temperature sensor Volume air flow sensor Engine...
Page 519 ENGINE AND EMISSION CONTROL - Emission Control Svstem Throttle body Evaporative emission Engine control module Volume air flow sensor relay Barometric pressure sensor Disconnect the vacuum hose (red stripes) from the throttle body and connect it to a hand vacuum pump. Plug the nipple from which the vacuum hose is discon- nected.
Page 520 ENGINE AND EMISSION CONTROL - Emission Control System PURGE CONTROL SYSTEM INSPECTION <Turbo - 1992 models> EVAP canister Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Volume flow sensor Engine control module (1) Disconnect the purge air hose from the air intake hose, and plug the air intake hose.
Page 521 ENGINE AND EMISSION CONTROL - Emission Control System PURGE CONTROL SYSTEM INSPECTION <Turbo - From 1993 up to 1995 models> Purge control Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Volume air flow sensor Enginecontrolmodule (1) Disconnect the vacuum hos (red stripes) from the throttle body and connect it to a hana vacuum pump.
Page 522 ENGINE AND EMISSION CONTROL - Emission Control Svstem (4) Connect the vacuum hose (red stripes) removed in (1) above to P nipple of the throttle body as before. (5) Disconnect the purge air hose from the air intake hose, and plug the air intake hose. Then, connect the hand vacuum pump to the purge air hose.
Page 523 ENGINE AND EMISSION CONTROL - Emission Control System Engine operating Applying vacuum Result condition 3,000 rpm 375 mmHg Vacuum is maintained (14.8 in.Hg) Engine operating Applying vacuum Result condition 3,000 rpm within Try applying Vacuum leaks three minutes af- vacuum ter starting engine (4) Connect the vacuum hose (red stripes) removed in (1) above to P nipple of the throttle body as before.
Page 524 ENGINE AND EMISSION CONTROL Vacuum is kept constant regardless of the increased en- gine speed. Vacu- NOTE If there is no vacuum created, it is possible that the throttle body purge port may be clogged and require cleaning. Engine speed (rpm) PURGE CONTROL VALVE <Turbo>...
Page 525 ENGINE AND EMISSION CONTROL (4) Apply a vacuum and check for air tightness when voltage applied directly to the evaporative emission purge solenoid and when the voltage is discontinued. Battery voltage Result Non-Turbo, When applied Vacuum leaks Turbo - From - When discontinued Vacuum is maintained 1993 models...
Page 526 ENGINE AND EMISSION CONTROL COMPONENT LOCATION Name Symbol Name Symbol EGR valve <California - Non Turbo, Turbo, EGR solenoid <California - Non Turbo, Turbo, Federal - Non Turbo from 1996 model> Federal - Non Turbo from 1996 model> EGR temperature sensor <California - up to 1995, Federal -Turbo 1994 and 1995 model>...
Page 527 ENGINE AND EMISSION CONTROL - Emission Control System EGR SYSTEM INSPECTION <California - Non Turbo, Turbo, Federal - Non Turbo from 1996 model> (1) Disconnect the vacuum hose (green stripe) from the EGR valve, and connect a hand vacuum pump through the three-way terminal.
Page 528 ENGINE AND EMISSION CONTROL Vacuum Vacuum remains fairly constant. NOTE If there is a problem with the change in vacuum, it is possible that the throttle body port may be clogged and require cleaning. Engine speed (rpm) EGR VALVE <California - Non Turbo, Turbo, Federal - Non Turbo from 1996 models>...
Page 529 ENGINE AND EMISSION CONTROL VACUUM CONTROL VALVE <Non Turbo> Plug (1) Disconnect the vacuum hose (white stripe) from the vacu- um control valve and connect the hand vacuum pump to the vacuum control valve. (2) Put the blind plug to the removed vacuum hose. (3) Start the engine and run at idle.
Page 530 ENGINE AND EMISSION CONTROL (5) Measure the resistance between the terminals of the sole- noid. EGR SOLENOID <Turbo> NOTE When disconnecting the vacuum hose, place an identification mark on it for proper re-connection. (1) Disconnect the vacuum hose (yellow stripe, green stripe, white stripe) from the solenoid valve.
Page 531 ENGINE AND EMISSION CONTROL - Emission Control Svstem REMOVAL AND INSTALLATION Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter. INSPECTION Inspect for damage, cracking or deterioration. Replace if faulty.
Page 533 CLUTCH CONTENTS General Specifications ......2 Lubricants........3 Sealant .
Page 534 CLUTCH GENERAL SPECIFICATIONS 225 x 150 (8.86 x 5.91) 250 x 160 (9.84 x 6.30) Clutch booster Boosting ratio [Clutch pedal 1.7 [at 110 N (24 Ibs.)] depressing force] SERVICE SPECIFICATIONS...
Page 535 CLUTCH LUBRICANTS Items Specified lubricants Contact surface of release bearilng and fulcrum of clutch release MITSUBISHI genuine grease Part No. 0101011 or fork equivalent Inner surface of clutch release bearing Inner surface of clutch disc spline Contact portion of release fork to release cylinder push rod...
Page 536 Excessive wear of clutch disc facin...
Page 537 CLUTCH CLUTCH PEDAL CHECK AND ADJUSTMENT 1. Take off the carpet at under the clutch pedal. Measure the clutch pedal height (from the face of the pedal pad to the firewall). If the clutch pedal height is not within the standard value range, adjust as follows: Vehicles wiiho&...
Page 538 CLUTCH 4. Measure the clutch pedal clevis pin play. Clutch pedal clevis pin play and clutch pedal free play If the clutch pedal clevis pin play is outside the standard value, adjust with the push rod. 5. Measure pedal play. In the case of AWD vehicles, depress the pedal 2 or 3 times to eliminate booster negative pres- sure with the engine stopped and then push the pedal with a finger to measure the play.
Page 539 CLUTCH (4) With the engine running, step on the clutch pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition. If the pedal rises, the booster is faulty. If the above three tests are okay, the booster performance can be determined as good.
Page 540 CLUTCH - Clutch Pedal REMOVAL AND INSTALLATION 1 ’ Pre-removal and Post-installation Operation Adjustment Clutch Pedal Adjustment (Refer to F?21-5.) (Refer to GROUP 37A - Steering Wheel and Shaft.) 30 Nm 13 Nm 9 ft.lbs. 00002218 Removal steps 12. Clutch pedal shaft Brake pedal adjustment 13.
Page 541 CLUTCH 13 Nm 0 0 0 0 2 2 1 9 Removal steps 23. Brake booster 33. Bushing (Refer to GROUP 35- Brake Booster.) 34. Spacer 24. Clutch master cylinder connection 35. Clutch pedal pad 25. Vacuum hose connection 36. Bolt 26.
Page 542 CLUTCH REMOVAL AND INSTALLATION Pre-removal Operation Draining of the Clutch Fluid 15 Nm 4 1 ftlhr 11 ft.lbs. 11 ft.lbs. Clutch master cylinder removal Clutch tube removal steps steps 1. Brake booster 1. Brake booster (Refer to GROUP 35- Brake Booster.) (Refer to GROUP 35 - Brake Booster.) 2.
Page 543 CLUTCH 15 Nm 11 ft.lbs. 19 Nm 13 ft.lbs. 15 Nm 11 ft.lbs. 00002215 15 Nm 11 ft.lbs. Clutch release cylinder removal steps 5. Air hose A cAWD> 6. Air&e,aner cover, air intake hose Clutch tube A, tube B, tube C, damper removal steps 6.
Page 544 CLUTCH To disconnect clutch hose from the clutch tube, proceed as follows: (1) Secure the nut on the clutch hose and loosen the flare nut on the clutch tube. (2) Remove the clip from the clutch hose to remove clutch hose from bracket.
Page 545 CLUTCH Adjust the clearance (A) between the clutch booster push rod and piston as follows: (1) Measure the dimension (B) between the master cylinder end face and piston. NOTE To obtain (B), first take measurement with a square placed on the master cylinder end face. Then, subtract the thick- ness of the square to arrive at (B).
Page 546 C L U T C H (5) If the clearance is not within the standard value range, adjust by changing the push rod length by turning the adjustable end of the push rod. INSPECTION Check the clutch hose or tube for cracks or clogging. DISASSEMBLY AND REASSEMBLY Master cylinder kit 9.0 ft.lbs.
Page 547 C L U T C H Remove the piston stop ring or snap ring, while depressing the piston. REASSEMBLY SERVICE POINT NOTE Set the push rod length to the dimension shown in the illustration before installation. This can facilitate the clutch pedal adjustment.
Page 548 CLUTCH DISASSEMBLY AND REASSEMBLY 6C LO003 ATFM0576 Lubricant: Conforming to DOT3 or DOT4 Lubricant: Conforming to DOT3 or DOT4 Disassembly steps 1. Valve plate 6. Conical smina 2. Spring 3. Push rod 8. Bleeder plug Boots 9. Release cylinder (1) Remove the corrosion from the piston-removal port of the release cylinder.
Page 549 C L U T C H REASSEMBLY SERVICE POINT Apply specified brake fluid to the release cylinder inside and outer surface of the piston and piston cup and push the piston cup assembly in the cylinder. INSPECTION (1) Check the inner surface of the release cylinder for scratches or irregular wear.
Page 550 C L U T C H REMOVAL AND INSTALLATION Sealant: 3M ATD Part No. 8663 or equivalent Vacuum tank assembly, vacuum hose E, vacuum pipe C removal steps 4. Fitting Vacuum pipe A removal steps Crossmember.) 12. Vacuum tank assembly 14.
Page 551 C L U T C H REMOVAL SERVICE POINT NOTE Since the check valve is fit to the vacuum hose C, replace the check valve as an assembly unit together with the vacuum hose C if the check valve is defective. INSTALLATION SERVICE POINTS If a hose is connected to a pipe with a stepped part, insert the hose up to the stepped part.
Page 552 CLUTCH Disc REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Transaxle Assembly Removal Transaxle Assembly Installation (Refer to GROUP 22 - Transaxle Assembly.) (Refer to GROUP 22 - Transaxle Assembly.) 30-42 Nm 15-21 Nm 3. Return clip 6. Fulcrum 7. Release fork boot...
Page 553 C L U T C H Lubricant: MITSUBISHI genuine grease Part No. 0101011 or equivalent Lubricant: MITSUBISHI genuine grease Part No. 0101011 or equivalent Lubricant: MITSUBISHI genuine grease Part No. 0101011 or eauivalent ATFM0857 REMOVAL SERVICE POINT Diagonally loosen bolts which attach clutch cover to flywheel.
Page 554 CLUTCH - Clutch Cover and Disc INSTALLATION SERVICE POINTS (1) Apply a coating of the specified grease to the point of contact with the fulcrum and the point of contact with the release bearing. (2) Apply a coating of the specified grease to the end of the release cylinder’s push rod and to the push rod hole in the release fork.
Page 555 C L U T C H INSPECTION Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit. Check the pressure plate surface for wear, cracks and color change. Check the strap plate rivets for looseness and replace the clutch cover assembly if loose.
Page 557 (2) Service or maintenance of any SRS component or SK-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 -Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 558 As required SEALANTS AND ADHESIVES Items Transaxle case - clutch housing mating surfaces Mitsubishi genuine part No. 997740 or equivalent Transaxle case - rear cover mating surfaces Differential drive gear bolts 3M STUD Locking part No. 4170 or equivalent Bearing retainer screw (flush head screw)
Page 559 MANUAL TRANSAXLE <FWD> - Special Tools / Troubleshooting Tool number and Tool Supersession Application name knuckle and lower arm ball joint Steering linkage Disconnection of the coupling of the puller knuckle and tie-rod end ball joint Installation of differential oil seal seal installer Symptom Probable cause...
Page 560 MANUAL TRANSAXLE cFWD> - On-vehicle Service TRANSMISSION OIL LEVEL CHECK Refer to GROUP 00 - Maintenance Service. TRANSMISSION OIL REPLACEMENT Refer to GROUP 00 - Maintenance Service. SPEEDOMETER CABLE REPLACEMENT 1. Correctly insert the adapter into the instrument panel, and fasten the new speedometer cable. 2.
Page 561 MANUAL TRANSAXLE cFWD> - On-vehicle Service DRIVE SHAFT OIL SEALS REPLACEMENT R.H. side (1) Disconnect the drive shaft from the transaxle. (Refer to GROUP 26 - Drive Shaft.) (2) Using a flat-tip (-) screwdriver, remove the oil seal. (3) Using the special tool, tap the drive shaft oil seal into the transaxle.
Page 562 MANUAL TRANSAXLE <FWD> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Console Assembly Removal and Installation (Refer to GROUP 52A - Floor Console.) 4.0 Nm 2.9 ft.lbs. 12 Nm 9 ft.lbs. Shift lever assembly removal steps Transaxle control cable assembly removal steps 1.
Page 563 MANUAL TRANSAXLE <FWD> INSTALLATION SERVICE POINTS (1) Move the transaxle shift lever to the neutral position. NOTE The select lever will be set to the neutral position when the transaxle shift lever is moved to the neutral position. (2) With the shift lever on the passenger compartment side Neutral position in the neutral position, turn adjuster on select cable so Shift lever...
Page 564 MANUAL TRANSAXLE <FWD> DISASSEMBLY AND REASSEMBLY 24 Nm 17 ft.lbs. 23 ’ - 00001531 Disassembly steps 1. Nut 13. Pipe 2. Spring washer 14. Bolt 3. Plain washer 15. Lever (A) Shift lever 16. Bushing 5. Bushing 17. Bushing 6. Plain washer 18.
Page 565 MANUAL TRANSAXLE <FWD> REMOVAL AND INSTALLATION Post-installation Operation Front Under Cover Installation (Refer to GROUP 51 - Front Bumper.) (Refer to GROUP 51 - Front Bumper.) Transmission Oil Supplying (Refer to P.22-4.) Engine Coolant Filling (Refer to GROUP 14- Service Adjustment Procedures.) Shift Lever at Each Position Checking Operation Meters and Gauges Checking Operation...
Page 566 MANUAL TRANSAXLE 4WD> 70 Nm 60-72 Nm 60-70 Nm 43-51 ft.lbs. 26 ftlbs. 17. Drive shaft (Left side), Inner shaft 9. Transaxle mount connection 10. Transaxle mount bracket assembly 12. Transaxle assembly upper part 19. Transaxle stay (Front bank side) coupling bolt 20.
Page 567 MANUAL TRANSAXLE cNVD> Raise transaxle assembly with a jack up to a level where mount bracket no longer receives its weight and remove trans- axle mount insulator bolt. Using the special tool, disconnect the tie rod end from the knuckle. Using the special tool, disconnect the lower arm ball joint from the knuckle.
Page 568 MANUAL TRANSAXLE cFWD> - Transaxle Assemblv (1) To remove drive shaft (right side) from transaxle assembly, apply pry bar to the protrusion. NOTE Remove drive shaft (right side) as an assembly together with hub, knuckle, and other parts. (2) Suspend the removed drive shaft (right side) with wire or something similar to prevent it from sharply bending or turning at each joint.
Page 569: Automatic Transaxle
AUTOMATIC TRANSAXLE Tool number and Tool Application name MD998330 Measuring oil pressure Oil pressure MD999563 Oil pressure (10 kg/cm2) MD998332 Connection of the oil pressure gauge Adapter A: MD99891 5 MD99891 6-01 Adjustment of kickdown servo MD99891 6-l-01 wrench adapter MD99891 6-2-01 B: MD99891 6 MD99891 6-3-01...
Page 570 MANUAL TRANSAXLE <AWD> Oil seal installer...
Page 571 MANUAL TRANSAXLE <AWD> TRANSMISSION OIL LEVEL CHECK Refer to GROUP 00 - Maintenance Service. TRANSMISSION OIL REPLACEMENT Refer to GROUP 00 - Maintenance Service. TRANSFER OIL LEVEL CHECK Refer to GROUP 00 - Maintenance Service. TRANSFER OIL REPLACEMENT Refer to GROUP 00 - Maintenance Service. DRIVE SHAFT OIL SEALS REPLACEMENT R.H.
Page 572 (5) Drive shaft oil seal must be installed in the direction shown. (6) Apply a coating of the transmission oil to the lip of the oil seal. TRANSFER OIL SEAL REPLACEMENT (1) Pull out the propeller shaft from the transfer. (Refer to GROUP 25 - Propeller Shaft.) (2) Using a flat-tip (-) screwdriver, remove the oil seal.
Page 573 MANUAL TRANSAXLE <AWD> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Console Assembly Removal and Installation (Refer to GROUP 52A - Floor Console.) 9 ft.lbs. 0 0 0 0 1 5 3 6 Shift lever assembly removal steps Transaxle controll cable assembly removal steps 1.
Page 574 MANUAL TRANSAXLE <AWD> - Transaxle Control INSTALLATION SERVICE POINTS Refer to P.22-7. If the vacuum pipe has a stepped part, connect the vacuum hose to the pipe securely, up to the stepped part, as shown in the figure. Align slots indicated by arrows in air intake hose A with markings on air intake hoses B and C;...
Page 575 MANUAL TRANSAXLE <AWLI> REMOVAL AND INSTALLATION Post-installation Operation Transfer Assembly installation (Refer to P.22-22.) Transmission Oil Supplying (Refer to l?22-15.) Transfer Assembly Removal1 (Refer to P.22-22.) Shift Lever at Each Position Checking Operation Meters and Gauges Checking the Operation Hose clamp 4.0 Nm Removal steps 1.
Page 576 MANUAL T R A N S A X L E <AWD> 45 Nm 22 lt.lbs. 6.0 Nm 4.0 ft.lbs. 60-70 Nm 43-51 ft.lbs. 00001538 10. Clutch tube bracket connection 21. Starter cover 11. Clutch release cylinder connection 22. Starter 12. Transaxle mount connection 23.
Page 577 MANUAL TRANSAXLE cAWD> REMOVAL SERVICE POINTS Refer to P.22-10. Refer to P.22-11. Refer to P.22-il. INSTALLATION SERVICE POINTS Refer to P.22-12. If the vacuum pipe has a stepped part, connect the vacuum hose to the pipe securely, up to the stepped part, as shown in the figure.
Page 578 MANUAL TRANSAXLE <AWD> Pre-removal and Post-installation Operation Transfer Oil Draining and Supplying Active Front Venturi Skirt Removal and Installation (Refer to !?22-15.) (Refer to GROUP 51 - Front Bumper.) 6 1 - 6 5 25-29 Nm*2 18-22 ft.lbs. Sleeve yoke Gear oil: Hypoid gear oil, SAE 75W-90 or 75W-85W conforming to API classifi 09 FOO08...
Page 579 MANUAL TRANSAXLE <AWD> The transaxle cannot be disassembled. If any parts other than describes below are defective, replace the transaxle assembly. 1. Transfer mounting bolts 4. Transfer oil seal guide INSTALLATION SERVICE POINTS Using the special tool, install the drive shaft oil seal.
Page 580 MANUAL TRANSAXLE <AWD> - Transaxle Assembly Using the special tool, install the drive shaft oil seal. MD998325 2201029 Using a pipe shown in the illustration, drive the oil seal until it is flush with the case. Do not drive the oil seal more than necessary.
Page 581 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 -Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 583 To lubrlcatlon (front) To lutmcatm (rear) - mx.. Line pressure pressure solenoid pressure solenoid valve pressure 15. End clutch valve 16. Torque converter control valve 2. Front clutch 3. Rear clutch 18. Shift control valve 4. Low-reverse brake 5. End clutch 6.
Page 585 Parking To lubncation (front) .-E? To lubrication (rear) -= que converter clutch ssure que converter clutch lubrication pressure valve pressure 15. End clutch valve 1. Torque converter 16. Torque converter control valve 2. Front clutch 17. Shift control solenoid valve “B” Rear clutch 18.
Page 587 AUTOMATIC TRANSAXLE - General ln~~r~~ti~m Drive (Stop) To lubrication (front) .-= To lubrication (rear) -I Line pressure pressure solenoid pressure valve pressure 15. End clutch valve Torque converter 16. Torque converter control valve Front clutch Rear clutch 18. Shift control valve Low-reverse brake 19.
Page 589 AUTOMATIC TRANSA LE - General h-d Drive (First) To lubrication (front) -3 To lubrication (rear) C= Line pressure brque converter clutch Reducing pressure valve pressure End clutch valve Torque converter control valve 2. Front clutch Shift control solenoid valve “B” 3.
Page 591 To lubrication (front) - To lubrication (rear) -Z Line pressure pressure Reducing pressure valve pressuie 15. End clutch valve 2. Front clutch 16. Torque converter control valve 3. Rear clutch 17. Shift control solenoid valve ‘33” 4. Low-reverse brake 5. End clutch 6.
Page 593 To lubrication (fror.., _~_ To lubrication (rear) +Z ssure lubrication pressure valve pressure 2. Front clutch 16. Torque converter control valve 3. Rear clutch 17. Shift control solenoid valve “B” 4. Low-reverse brake 18. Shift control valve 5. End clutch 19.
Page 595 AUTOMATIC TRANSAXLE - General Information rive (Fourth) To lubrrc To lubric (rear) + pressure solenoid pressure valve pressure TFA0075 15. End clutch valve 16. Torque converter control valve 2. Front clutch 17. Shift control solenoid valve “B” 3. Rear clutch 18.
Page 597 AUTOMATIC TRANSAXLE - General Information To lubrrcatron (front) .-=/ To lubrication (rear) -= rque converter clutch rque converter clutch lubrication pressure valve pressure 1. Torque converter 15. End clutch valve 2. Front clutch 16. Torque converter control valve 3. Rear clutch 17.
Page 599 AUTOMATIC TRANSAXLE - General Information Reverse To lubrication (front) .-= To lubrication (rearj +Z - Line pressure pressure solenoid pressure valve pressure TFA0077 End clutch valve Torque converter control valve 2. Front clutch 3. Rear clutch Shift control solenoid valve “B” Shift 4.
Page 601: General Specifications
AUTOMATIC TRANSAXLE - SPecifications GENERAL SPECIFICATIONS Items Specifications Model Electronically controlled Torque 3 element with torque converter clutch converter Gear ratio First Fourth 0.685 Reverse 2.176 Final gear ratio 3.958 Speedometer gear ratio (Drive/Driven) SERVICE SPECIFICATIONS Specifications Items Approx. 3 Resistance of torque converter clutch solenoid valve coil [at 20°C (68”F)] Approx.
Page 602 AUTOMATIC TRANSAXLE - Specifications / Special Tools LUBRICANTS Quantity Specified lubricants Items 7.5 (7.9) Transmission fluid dm3 (qts.) DIAMOND ATF SP or equivalent As required Drive shaft oil seal lip and lower arm ball joint Disconnection of thecoupling of the knuckle and tie-rod end ball joint Checking of the diagnostic trouble code check harness...
Page 603 MANUAL TRANSAXLE cAWD> - Specifications MANUAL TRANSAXLE cAWD> GENERAL SPECIFICATIONS Items From 1994 model Up to 1993 model Model Sear ratio 0.589 3.076 3.153 Reverse Reduction ratio Primary 1.375 3.166 2.888 Front differential 0.958 0.814 Transfer Speedometer gear ratio (driven/drive) 2.4 (2.5) 2.4 (2.5) Oil quantity dm3 (qts.) / Transaxle...
Page 604 AUTOMATIC TRANSAXLE - Troubleshooting Functional malfunctions of the ELC-4A/T can lead to other Based upon use of the troubleshooting guide, the prob- able location of the problem should be estimated. problems, such as those described below: (1) Improper maintenance and/or adjustments (2) Malfunctions of the electronic control functions Checks should be made of fluid levels and the condition (3) Malfunctions of mechanical functions...
Page 605: Troubleshooting Guide
AUTOMATIC TRANSAXLE TROUBLESHOOTING GUIDE Driving impossible or abnormal (before start-off) Forward/ Starter Forward Backward terns backward motor won’t movement movement movement impossible impossible function impossible Abnormal idling rpm Engine 2 I Performancemalfunction Improper adjustmentof manual linkage Malfunction of torque convertor Operation malfunction of oil pump Malfunction of one-way clutch Transaxle...
Page 606 AUTOMATIC TRANSAXLE - Troubleshooting Driving impossible or abnormal (before start-off) Abnormal Engine stalls Clutch slips at Clutch slips at Vehicle Parking or vehicle Stall rpm vibration-shock when D (stall rpm too R (stall rpm too moves moves, doesn’t too low when shift to high) high)
Page 607 AUTOMATIC TRANSAXLE - Troubleshooting Won’t shift from Won’t shift to 4th TSB Revision...
Page 608 AUTOMATIC TRANSAXLE - Troubleshooting Excessive vibration- shock during upshift TSB Revision...
Page 609 AUTOMATIC TRANSAXLE - Troubleshooting...
Page 610 AUTOMATIC TRANSAXLE DIAGNOSIS AND TEST FLUID LEVEL AND CONDITION Drive until the fluid temperature reaches the usual temper- ature [70-80°C (158-176”F)j. 2. Place vehicle on level floor. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid, then place lever in “N”...
Page 611 AUTOMATIC TRANSAXLE DIAGNOSIS FUNCTION 1993 model> %. METHOD OF READING THE DIAGNOSTIC TROUBLE CODES When using the scan tool [Multi-use tester (MUT) Caution Connection and disconnection of the scan tool should always be made with the ignition switch in the OFF posi- tion.
Page 612 AUTOMATIC TRANSAXLE Diagnostic result indication by voltmeter Waveform when normal Waveform for diagnostic trouble code No. 24 digit delimiter digit signal 2 sec. signal NOTE Other diagnostic items are also indicated by the voltage waveforms corresponding to the code numbers obtainea when the scan tool is used.
Page 613 AUTOMATIC TRANSAXLE FAULT CODE’ DESCRIPTION Code Item Remedial Action Excessively large throttle position sensor output Check throttle position sensor connector. Check throttle position sensor on bench. Excessively small throttle position sensor output Adjust throttle position sensor. Check accelerator switch Defective or improperly adjusted throttle position sen- (whether code number 24 is being output).
Page 614 AUTOMATIC TRANSAXLE Code Item Remedial Action 1 st gear incorrect ratio Check connectors of pulse generators A and B. Check pulse generators A and B on bench. Rear clutch slipping Check connectors of pulse generators A and B. 2nd gear incorrect ratio Check pulse generators A and B on bench.
Page 615 AUTOMATIC TRANSAXLE INSPECTION OF CONTROL SYSTEM Check the control system by using the scan tool and following the procedure given below. CONTROL SYSTEM INSPECTION TABLE Check Item Condition Criteria Possible Cause of Trouble (or Remedy) Accelerator pedal fully Throttle position TPS is improperly adjusted if voltage sensor (TPS) released...
Page 616 AUTOMATIC TRANSAXLE e pulse generator A shieldec rnal noise interference Item No. 32 External noise interference Overdrive switch Overdrive switch in ON tion switch or circuit harness Defective manual control cable If selector lever does not move, check shift lock mechanism. Vehicle-speed reed Item No.
Page 617 AUTOMATIC TRANSAXLE - Troubleshooting TRANSAXLE CONTROL MODULE The connector has 42 pins accommodate the increased number of sensor inputs. Here are the pin , assignments. cl 992 models> 101. Torque converter clutch solenoid 13. - 102. Shift control solenoid valve A 14.
Page 618 AUTOMATIC TRANSAXLE - Troubleshooting <From 1993 models> 1. Torque converter clutch solenoid 2. Shift control solenoid valve A (SCSV-A) 24. Sensor ground 3. - 25. Power source 4. Engine communication signal 26. Ground 31. Park/neutral position switch (P) 32. Park/neutral position switch (R) 7.
Page 619 AUTOMATIC TRANSAXLE ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER Selector. Overdrive Clutch Brake Shifting Gear Engine Parking lever control gear ratio start position switch Neutral Possible Reverse 2.176 Neutral Possible 2.551 1.488 1.000 0.685 2.551 1.488 1.000 2.551 1.488 2.551 NOTE...
Page 620 AUTOMATIC TRANSAXLE - Troubleshooting cl 992 model> P range Throttle 3000 6000 2000 5000 1000 4000 Transfer drive gearspeed(rpm) 100 110 120 130 140 150 160 170 180 E range Throttle 4000 6000 3000 5000 1000 2000 90 100 110 120 130 140 150 160 170 180 Vehicle speed (km/h) Vehicle speed (km/h) TSB Revision...
Page 621 AUTOMATIC TRANSAXLE - Troubleshooting range 80 L 4000 5000 6000 1000 2000 3000 100 110 160 170 130 140 150 Vehicle speed (km/h) 5000 6000 1000 2000 3000 4000 120 130 140 150 170 180 Vehicle speed (km/h) TSB Revision...
Page 622 AUTOMATIC TRANSAXLE - Troubleshooting INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS Based on the wiring diagram check whether the lmproperconnectionof connec- continuity and grounding of each harness is OK. Continuity Reconnecttheconnector; repair or replace the harness. Normal 1: Low temperature side 2: Ground 3: High temperature side Damaged or disconnected wir-...
Page 623 AUTOMATIC TRANSAXLE - Troubleshooting Check the resistance between terminals 1 and Resistance: highorin- Damaged or disconnected wir- sensor 4 of the TPS. finite TPS terminal Replace the TPS. Check the resistance between terminals 4 and --w Resistance: more or less than 0.4 kW2O”C 2 with the engine idling after throttle-valve open- ing warm-up.
Page 624 AUTOMATIC TRANSAXLE 2 or 3 and 4. connected wiring Pulse generator terminals Replace the pulse generator, generator A 3-4: pulse Normal generator B 6. Pulse generator Connect the pulse generator and body harness, A or B (checking by and connect an oscilloscope. Check with the an oscilloscope) chassis on a dynamo or with the front wheels raised.
Page 625 AUTOMATIC TRANSAXLE - Troubleshooting 7. Pressure-control so- too high connected wiring - solenoidvalveconnectorandthetransaxlecase. 2.9 f 0.3W2O”C (68°F) Replace the PCSV. Connect 12 V between the transaxle case and - No operation noise. Foreign material caught be- Solenoid valve tween the valve and guide terminal 1;...
Page 626 AUTOMATIC TRANSAXLE - Troubleshooting Pull the parking brake to set it securely. clutch system Set the selector lever to ” P” or “N”, and start With the engine idling, depress the foot brake firmly. Improper adjustment of idling Let the engine continue idling. Readjust the idling.
Page 627 AUTOMATIC TRANSAXLE 10. Torque converter clutch solenoid solenoid valve connector and the transmission connected wiring. case. Solenoid valve Replace the TCC solenoid. connector terminals Standard value: 3 fY2O”C (68°F) <1992,1993 models> 13 .M?O”C (68°F) <From 1994 mod- 1: PCS” els> 2: TCC solenoid 3: SCSV-A...
Page 628 AUTOMATIC TRANSAXLE - Troubleshooting 12. Park/neutral position In the “P” range, check for continuity between switch terminals 3 and 4, and terminals 8 and 9. In the “R” range, check for continuity between terminals 4 and 7, and terminals 10 and 11. In the “N”...
Page 629 AUTOMATIC TRANSAXLE - Troubleshooting In the “P” range, check for continuity between terminals 3 and 4, and terminals 7 and 8. In the “R” range, check for continuity between teninals 2 and 3, and terminals 5 and 6. ZTFA0802 In the “R” range, check for continuity between terminals 2 and 3.
Page 630 AUTOMATIC TRANSAXLE Poor contact, or damaged or servo switch switch terminal and the transaxle case. disconnected wiring Continuity exists Replace the K/D servo switch. Start the engine, set to the “D” range, and let Continuity exists the engine idle: check for continuity between the kickdown servo switch terminal and the Replace the K/D servo switch.
Page 631 AUTOMATIC TRANSAXLE HYDRAULIC PRESSURE TESTS 1. Completely warm up the transaxle. Raise the vehicle by using a jack so that the front wheels can be rotated. 3. Connect an engine tachometer and place it in a position where it’s easy to see. 4.
Page 632 AUTOMATIC TRANSAXLE REMEDIAL ACTION TO TAKE FOR INADEQUATE HYDRAULIC PRESSURE Symptom Possible cause Remedy 1. All line pressures Plugged oil filter Visually check oil filter and replace it if plugged. are low (or high). Improperly adjusted regulator valve line Measure line pressure (b) (K/D brake pressure) and NOTE: pressure readjust line pressure if it is out of specifications.
Page 633 AUTOMATIC TRANSAXLE - Troubleshootina (7) Seal ring (5) Seal ring (14) O-ring (12) Oil seal (4) D-ring\ (6) D-ring D-ring (8) Seal ring (15) Seal ring / Front clutch Low-reverse brake (1) Seal ring --- (2) Seal ring brake...
Page 634 AUTOMATIC TRANSAXLE - Troubleshooting CONVERTER STALL TEST Stall test consist of determining maximum engine Place selector lever to “R” position and perform speed obtained at full throttle in “D” and “R” posi- stall test by the same procedure as in foregoing tions.
Page 635 AUTOMATIC TRANSAXLE A/T SAFETY-LOCK SYSTEM TROUBLESHOOTING Symptom Probable cause Remedy Ref. page Damaged lock cam B Selector lever can be Check and replace lock cam B. 23-59 selected into R from P without depressing Improperly adjusted shift lock cable, broken Check, adjust or replace the shift inner cable, loose or off connections brake pedal with igni-...
Page 636 AUTOMATIC TRANSAXLE Symptom Probable cause Remedy Ref. page Defective selector lever assembly Selector lever cannot Check and replace selector lever 23-55 be shifted from R to P. assembly. adjusted Improperly transaxle control cable Adjust transaxle control cable. 23-57 Ignition key cannot be Foreign matter wedged in lock cams A and Check and replace lock cams A 23-59...
Page 637 AUTOMATIC TRANSAXLE TRANSMISSION FLUID LEVEL CHECK Refer to GROUP 00 - Maintenance Service. TRANSMISSION FLUID REPLACEMENT Refer to GROUP 00 - Maintenance Service. (1) Remove dust, dirt, and other contaminants completely from kickdown (K/D) servo cover and surrounding areas. (2) Snap off the snap ring and remove K/D servo switch. (3) Fit claw of special tool into cutout in piston to prevent piston from turning and use adapter to fix the piston into position.
Page 638 AUTOMATIC TRANSAXLE - On-vehicle Service (7) Fit special tool (Outer Wrench) to lock nut. Turn Outer Wrench clockwise and Inner Wrench counter- clockwise to unlock the lock nut from special tool (Inner Wrench). Caution Be sure to apply even torque to the two special tools when unlocking.
Page 639 AUTOMATIC TRANSAXLE (7) Check that an O-ring is fitted at the location shown on top of valve body. (8) Replace O-ring of solenoid valve intermediate grommet with a new one and then fit the O-ring into case. (9) Install valve body and oil temperature sensor. 4992 model>...
Page 640 AUTOMATIC TRANSAXLE REDUCING PRESSURE ADJUSTMENT When scan tool is not used (1) Following the same steps as those in line pressure adjust- ment, remove parts up to oil filter. There is no need to remove valve body. (2) Turn adjusting screw of lower valve body to obtain the specified reducing pressure.
Page 641 AUTOMATIC TRANSAXLE - On-vehicle Service ACCELERATOR SWITCH CHECK AND ADJUSTMENT (1992 model) Check that current flows between terminals of accelerator switch when accelerator pedal is in free state and that no current flows when the pedal is depressed and the specified stroke A is obtained.
Page 642 AUTOMATIC TRANSAXLE - On-vehicle Service 2. Check to be sure that, under the following conditions, the selector lever can be moved from the “P” position to any other position. Press the button a few times and check to be sure that the selector lever moves smoothly.
Page 643 AUTOMATIC TRANSAXLE - On-vehicle Service Manual PARK/NEUTRAL POSITION SWITCH AND control lever CONTROL CABLE ADJUSTMENT 1. Place selector lever in “N” (Neutral) position. Loosen transaxle control cable to manual control coupling adjusting nut to set cable and lever free. 3. Place manual control lever in “N” (Neutral) position. 4.
Page 644 AUTOMATIC TRANSAXLE - On-vehicle Service (3) Using the special tool, tap the drive shaft oil seal into the transaxle. Note in illustration the direction of installation of drive shaft oil seal. (4) Apply a coating of the transmission fluid to the lip of the oil seal.
Page 645 AUTOMATIC TRANSAXLE - Transaxle Control REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Console Assembly Removal and Installation When re;oving and installing the front con (Refer to GROUP 52A - Floor Console.) shock to the SRS diagnosis unit. 12 Nm 7 ft.lbs.
Page 646 AUTOMATIC TRANSAXLE - Transaxle Control 12 Nm 9 ft.lbs. Key-interlock cable removal steps Shift-lock cable removal steps (Selector lever assembly side) (Selector lever assembly side) 9. Transaxle control module connection 9. Transaxle control module connection 10. Knee protector (Refer to GROUP 52A 19.
Page 647 AUTOMATIC TRANSAXLE - Transaxle Control INSTALLATION SERVICE POINTS PEDAL SIDE) Connect the shift lock cable so that its threads measure about 4 mm (.16 in.). Caution Do not change the routing of shift lock cable to the selector lever assembly. (STEERING LOCK ASSEMBLY SIDE) / CAM LEVER INSTALLATION (1) Place the ignition key at the “LOCK”...
Page 648 AUTOMATIC TRANSAXLE (7) Connect the key interlock cable to lock cam A and Lock cam A temporarily tighten the nut. At this time, install the spring and washer, which have been fitted to the key interlock cable, as shown. (8) Lightly pressing lock- cam A in the direction of arrow, lightly push the key interlock cable to take up slack and tighten the nut to secure the key interlock cable in position.
Page 649 AUTOMATIC TRANSAXLE DISASSEMBLY AND REASSEMBLY 12 Nm Disassembly steps 13. Socket assembly 1. Overdrive control switch, position light and Power (PWR)/Economy switch connector 17. Bushing 2. Cover 18. Pipe 3. Selector knob 19. Cotter pin 4. Overdrive control switch button 20.
Page 650 AUTOMATIC TRANSAXLE DISASSEMBLY SERVICE POINTS Terminal REMOVAL Disconnect the overdrive control switch connector and then remove the terminal from the overdrive control switch connector. Screwdriver OVERDRIVE CONTROL SWITCH REMOVAL (1) Using the flat-tip screwdriver, remove the overdrive control switch button. (2) Remove the overdrive control switch mounting screw.
Page 651 AUTOMATIC TRANSAXLE OVERDRIVE CONTROL SWITCH CHECK Check for continuity between terminals when the switch is OFF and when ON. 6 (RW) ’ (Bw) Terminal No. OFF (Overdrive non-activa- tion) TSB Revision...
Page 652 AUTOMATIC TRANSAXLE - Transaxle Oil Cooler, Hoses, Tubes REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Automatic Transmission Fluid Drainage and Filling Front Under Cover Removal and Installation (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 51 - Front Bumper.) 12 Nm 9 ft.lbs.
Page 653 AUTOMATIC TRANSAXLE REMOVAL SERVICE POINTS RETURN HOSE REMOVAL Caution Be careful not to spill the transmission fluid when removing components. Caution 1. When removing the hose assembly; be careful not to allow the transmission fluid to spill. 2. After removing the hose assembly, plug so that foreign materials cannot enter the transaxle.
Page 654 AUTOMATIC TRANSAXLE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Place Selector Lever in “N” Position and Stop the Front Under Cover Installation (Refer to GROUP 51 - Front Bumper.) Engine. Transaxle Fluid Supplying Transaxle Fluid Draining (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 00 - Maintenance Service.) Selector Lever Operation Check Front Under Cover Removal...
Page 655 AUTOMATIC TRANSAXLE 75 Nm 75 Nm 60-70 Nm 43-51 ft.lbs. 26 ft.lbs. 14. Transaxle assembly upper part coupling bolt 21. Transaxle stay (front bank side) 15. Tie rod end connection 22. Transaxle stay (rear bank side) 16. Lower arm ball joint connection 23.
Page 656 AUTOMATIC TRANSAXLE (2) Remove the nut and move the bolt so that a spanner can be applied to the transaxle mount bracket mounting bolt; then, remove the transaxle mount bracket mounting bolt. DISCONNECTION Refer to GROUP 22 - Manual Transaxle. bracket installation ASSEMBLY / DRIVE SHAFT (RIGHT SIDE) REMOVAL...
Page 657 PROPELLER SHAFT CONTENTS PROPELLER SHAFT ..... . . 3 General Specifications ......2 Lubricants..
Page 658 PROPELLER SHAFT - Specifications GENERAL SPECIFICATIONS PROPELLER SHAFT Items Specifications 4 joint propeller shaft Length x O.D. mm (in.) Front 673.5 x 65 (26.52 x 2.56) 662.5 x 65 (26.08 x 2.56) Center Rear 555.5 x 75 (21.87 x 2.95) Length x O.D.
Page 659 Special tool / Troubleshooting / PROPELLER SHAFT Tool number and T o o l A p p l i c a t i o n name MB991193 General service Prevention of entry of foreign objects into the transaxle and transfer Plug Remedy Symptom...
Page 660 PROPELLER SHAFT REMOVAL SERVICE POINTS Mating marks (1) Make mating marks on the differential companion flange and flange yoke. Caution , zL .-..-.-. . . Remove the propeller shaft in a straight and level manner so as to ensure that the boot is not damaged through pinching.
Page 661 PROPELLER SHAFT Install spacers and insulators as indicated in the illustration. Caution When installing the center bearing, assemble the same spacers as removed from it (or new spacers of equal thickness). INSPECTION Check the sleeve yoke, center yoke and flange yoke for wear, damage or cracks.
Page 662 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY AND REASSEMBLY 55 Nm 40 ft.lbs. [outer race) (inner race) 1oxoo1e 0 6 0 0 1 0 2 6 Grease: Repair kit grease Adhesive: 3M ATD Part No. 8155 or equivalent Disassembly steps 1. Front propeller shaft assembly 9.
Page 663 PROPELLER SHAFT DISASSEMBLY SERVICE POINTS Mating marks REMOVAL Put mating marks on the front propeller shaft flange yoke and the companion flange before removing the front propeller shaft assembly. Mating marks Put mating marks on the companion flange and the center propeller shaft before removing the companion flange.
Page 664 PROPELLER SHAFT Shaft (2) Put mating marks on the outer race, cage and inner race with a scriber before removing the outer race and balls. Caution Note the positions of balls so that they can be reinstalled in their original positions. Cage Inner race (3) Remove the inner race with cage from the center propeller...
Page 665 PROPELLER SHAFT First remove the center bearing bracket and then remove the center bearing using a puller (commercially available). REASSEMBLY SERVICE POINTS Companion flange Rubber mount Dust seal FLANGE / SELF-LOCKING NUT INSTALLATION (1) Install the bearing in the rubber mount groove of the center bearing bracket.
Page 666 PROPELLER SHAFT (4) Install the remaining balls in their original positions. Install these balls first (5) Check that the outer race rotates on the inner race smoothly. (6) Apply specified grease to the Lobro joint assembly. Specified grease: Repair kit grease [45-55 g (1.59-1.94 oz.)] (7) Apply quick fix adhesive at three locations illustrated to Rubber prevent displacement of the rubber packing and fix it...
Page 667 PROPELLER SHAFT (10)Check that the Lobro joint assembly moves smoothly. Caution Clamp the boot band by folding down the lever at a position nearly opposite to the vent groove provided in the sure to remove grease, if present, from around the vent groove.
Page 668 NOTES...
Page 669 FRONT AXLE CONTENTS DRIVE SHAFT ......12 SPECIFICATIONS ......2 General Specifications .
Page 670 FRONT AXLE - Specifications GENERAL SPECIFICATIONS WHEEL BEARING Items Double-row angular-contact Unit ball bearing ball bearing O.D. x I.D. mm (in.) 84 x 45 (3.31 x 1.77) DRIVE SHAFT Items Joint type Outer B.J. B.J. Inner T.J. T.J. L.H. shaft Length 417 (16.4) 419 (16.5)
Page 671 FRONT AXLE - SDecial Tools A: MB990244 rement of the lower arm ball joint starting Preload socket ment of the stabilizer link rotation Press-out of the center bearing Press-fitting of the center bearing Press-fitting of the dust seal outer TSB Revision...
Page 672 FRONT AXLE - Special Tools Tool number and Tool Application name MB990890 Press-fitting of the dust seal Press-fitting of the wheel bearing, oil-seal (drive shaft side) Rear suspension bushing base MB990883 MB990947 Press-fitting of the oil seal (hub side) MB990955 Oil seal installer...
Page 673 FRONT AXLE Symptom Probable cause Remedy Vehicle pulls to one Seizure of drive shaft ball joint Replace side Abnormal wear, play or seizure of wheel bearing Replace Adjust or replace Malfunction of front suspension or steering Replace Vibration Bend, damage or abnormal wear of drive shaft Replace Play in drive shaft and hub serration Replace...
Page 674 FRONT AXLE - Hub and Knuckle REMOVAL AND INSTALLATION 230 Nm 166 ft.lbs. 50 Nm 12 Nm 230 Nm 166 ft.lbs. Removal steps 10. Tie rod end connection Front speed sensor connection 11. Drive shaft 12. Front strut mounting bolt 13.
Page 675 FRONT AXLE REMOVAL SERVICE POINTS Front speed Remove the mounting bolts which hold the speed sensor bracket to the knuckle, and then remove the speed sensor. Caution Be careful when handling the pole piece at the tip of the speed sensor and the toothed edge of the rotor so as not to damage them by striking against other parts.
Page 676 FRONT AXLE INSTALLATION SERVICE POINT INSTALLATION (1) Be sure to install the washer and wheel bearing nut in the specified direction. (2) After installing the wheel, lower the vehicle to the ground and finally tighten the wheel bearing nut. (3) If the position of the cotter pin holes does not match, tighten the nut up to 260 Nm (188 ftlbs.) in maximum.
Page 677 FRONT AXLE - Hub and Knuckle DISASSEMBLY AND REASSEMBLY cFWD> 9 Nm 0 0 0 0 0 6 3 0 Disassembly steps 5. Dust shield 2. Hub and rotor Adjustment of wheel bearing starting 7. Snap ring torque 3. Hub 9.
Page 678 FRONT AXLE (2) Remove the wheel bearing inner race from the hub by using the special tool: Caution Be careful that the hub will not fall down as the wheel bearing inner race (outer side) is removed from the hub. (3) Remove the snap ring from the knuckle.
Page 679 FRONT AXLE (4) Measure the wheel bearing starting torque (hub starting MB990998 torque) by using the special tools. Limit: 1.8 Nm (16 in.lbs.) or less 990326 NOTE The starting torque must be within the limit and, in addition, the bearing must not feel rough when rotated. (5) Measure to determine whether the end play of the hub is within the specified limit or not.
Page 680: Front Axle
FRONT AXLE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation 29 Nm 21 ft.lbs. 43-52 ft.1 bs 50 Nm 230 ‘Nm 166 ft.lbs. Removal steps Cotter 3. Lower arm ball joint connection Cotter 5. Tie rod end connection 6.
Page 681 FRONT AXLE Using the special tool, disconnect the lower arm ball joint from the knuckle. Caution 1. Be sure to tie the cord of the special tool to the nearby 2. Loosen the nut but do not remove it. Using the special tool, disconnect the tie rod end from the knuckle.
Page 682 FRONT AXLE - Drive Shaft INSTALLATION SERVICE POINT (1) Be sure to install the washer and wheel bearing nut in the specified direction. (2) After installing the wheel, lower the vehicle to the ground and finally tighten the wheel bearing nut. (3) If the position of the cotter pin holes does not match, tighten the nut up to 260 Nm (188 ftlbs.) in maximum.
Page 683 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY 992 models> T.J. Boot Repair Kit 15 ‘6 17 T.J. Repair Kit Bearing Dust Seal Bracket Assemblv B.J. Boot Repair Kit B.J. Repair Kit Disassembly steps T.J. boot band (large) 14. Dust shield T.J.
Page 684 FRONT AXLE Shaft Lubrication Points Dust seal inner 14-20 g (.49-.71 oz.) Grease: Repair kit grease Caution The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. Special grease used lubricate the joint.
Page 685 FRONT AXLE DISASSEMBLY SERVICE POINTS (1) Using the special tool, remove the inner shaft assembly, together with the seal plate, from the T.J. case. NOTE Press the tool directly against the seal plate. The tool under oressure will ouncture and deform the seal plate, and push out the inner shaft underneath.
Page 686 FRONT AXLE REASSEMBLY SERVICE POINTS INSTALLATION (1) Wrap vinyl tape around the splines on the drive shaft, and then install the R.J. boots and T.J. boots, in that order. (2) Fill the inside of the B.J. and B.J. boot with the specified grease.
Page 687 FRONT AXLE - Drive Shaft (1) Apply multipurpose grease to the center bearing and inside the center bearing bracket. (2) Use the special tools to press-fit the center bearing into the center bearing bracket. (1) Apply multipurpose grease to the rear surfaces of all dust seals.
Page 688 FRONT AXLE Shaft Use the special tool to hold the inner race of the center bearing and force the inner shaft into place. MB991172 INSTALLATION (1) Apply multipurpose grease to the inner shaft spline, then Inner shaft press fit it into the T.J. case. assembly (2) Using the special tool, press the seal plate into the T.J.
Page 689 FRONT AXLE INSPECTION Check the drive shaft for damage, bending or corrosion. Check the inner shaft for damage, bending or corrosion. Check the drive shaft splines for wear or damage. Check the inner shaft splines for wear or damage. Check for entry of water and/or foreign material into B.J. Check the spider assembly for roller rotation, wear or corrosion.
Page 690 FRONT AXLE (5) Install the boot band (small) against the projection at the boot end to provide clearance A as shown in the illustration. B.J. boot band (6) Using the special tool, crimp the boot band. Caution 1. With the drive shaft secured vertically, pinch positively the portion to be crimped of the band between the tips of the special tool.
Page 691 FRONT AXLE Shaft provided between the large diameter end of the boot and the shoulder of B.J. housing. Standard value (C): 0.1 - 1.55 mm (.004 - .061 in.) (ll)Adjust the width of opening in the special tool (W) to standard value in the same manner as described in (4).
Page 692 NOTES...
Page 693 REAR AXLE CONTENTS REAR AXLE cFWD> ....2 REAR AXLE <AWD> ....6 ON-VEHICLE SERVICE .
Page 694 27-2 REAR AXLE <FW& - Specifications / Troubleshooting REAR AXLE <FWD> SPECIFICATIONS GENERAL SPECIFICATIONS Item Specification Wheel bearing Unit ball bearing SERVICE SPECIFICATIONS Items Limit Wheel bearing end play mm (in.) 0.05 (.002) or less Rear hub rotary-sliding resistance N (Ibs.) 31 (7) or less TROUBLESHOOTING Revision...
Page 695 27-3 REAR AXLE cFWD> - On-vehicle Service ON-VEHICLE SERVICE WHEEL BEARING END PLAY CHECK 1. Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. 2. Remove the hub cap and then release the parking brake. 3.
Page 696: Rear Axle Cfwd
27-4 REAR AXLE cFWD> REAR AXLE HUB REMOVAL AND INSTALLATION 36-43 ft.lbs. R e m o v a l s t e p s 1. Rear speed sensor 7. Rear hub assembly 8. Rear rotor <Vehicles with ABS> 2. Caliper assembly 9.
Page 697 27-5 REAR AXLE eFWD> Caution Care must be taken not to scratch or scar the rotor’s toothed surface, and not to drop it. If the rotor’s toothed surface is chipped or the rotor is deformed, it might not be able to accurately sense the wheel rotation speed and the system as a result might not perform normally.
Page 698 REAR AXLE cAWD> REAR AXLE <AWD> GENERAL SPECIFICATIONS AXLE SHAFT DRIVE SHAFT items Specifications Joint type Outer B.J. Inner T.J. Length (joint to joint) x diameter mm (in.) 395x28 (15.6x 1.10) B.J.: Bit-field Joint T.J.: Tripod Joint DIFFERENTIAL items Specifications Reduction gear type Hypoid gear Reduction ratio...
Page 699 REAR AXLE <AWD> - Specifications SERVICE SPECIFICATIONS Items Setting of T.J. boot length mm (in.) Final drive gear backlash mm (in.) Differential gear backlash (Limited slip differential) mm (in.) 0.03-0.09 Drive pinion With oil seal (4-6) New part rotation torque (with rust-prevention oil) Nm (in.lbs.) N e w parVreusable part 0.35-0.45 ( 3 - 4 )
Page 700 27-8 REAR AXLE’ eAWD> SPECIAL TOOLS MB990560 General service Removal of the axle shaft dust shield, outer bearing and rear rotor Press-in the outer wheel bearing and rear Bearing rotor remover MB990925 MB990925 or Removal of axle shaft inner bearing General service Installation of axle shaft inner bearing Bearing and oil tool...
Page 701 27-9 Tool number and Tool Supersession Application name Drive pinion height adjustment MB990901 MB990901 -01 (Use in conjunction with MB991 366) Drive pinion set- Drive pinion assembly B: MB990552 Cylinder MB991 378 Drive pinion set- ting gauge set A: MB991 366 Head B: MB991 365 Cylinder...
Page 702 REAR AXLE eAWD> - Special Tools Tool number and Supersession Application name MB991153 Driving-out and press-fitting of differential support bushing and differential support member bushing Bushing remov- er & installer ar- MB990831 Bushing remov- er & installer ring MB990847 Bushing remov- er &...
Page 703 REAR AXLE cAWD+ - Tool number and Supersession Application name MB990339 General service Removal of drive pinion rear bearing inner race Taper roller bear- tool ing puller MB990648 General service Bearing remover tool MB990890 Press-fitting of drive gear (for 4WS) Rear suspension bushing base...
Page 704 REAR AXLE eAWD> AXLE SHAFT DRIVE SHAFT Symptom Probable cause Remedy Noise Wear, play or seizure of ball joint Replace Excessive drive shaft spline looseness DIFFERENTIAL (LIMITED SLIP DIFFERENTIAL) driving or gear changing* when cornering Damaged, broken, and/or seized drive pinion bearings Damaged, broken, and/or seized side bearings Damaged differential case Inferior gear oil...
Page 705 REAR AXLE <AWD> - Traubleshootina Remedy Symptom Probable cause Replace Gear oil leakage Worn or damaged front oil seal, or an improperly installed oil seal Damaged gasket Retighten or replace Loose companion flange self-locking nut Retighten or apply Loose filler or drain plug adhesive Clean or replace Clogged or damaged vent plug...
Page 706: Rear Axle Total Backlash Check
REAR AXLE cAWD> REAR AXLE TOTAL BACKLASH CHECK If the vehicle vibrates and produces a booming sound due to an imbalance of the driving system, measure the rear axle total backlash by the following procedures to see if the differen- tial carrier assembly required removal.
Page 707: Limited-Slip Differential Check
REAR AXLE <AWD> REAR WHEEL BEARING ROTARY-SLIDING RESISTANCE CHECK 1. Remove the drive shaft from the companion flange. 2. Remove the brake pad or caliper assembly. 3. Attach a spring balance to the hub bolt, then, pulling the balance at a right angle to the hub bolt, measure the rotary-sliding resistance to see whether it is within the limit value.
Page 708 REAR AXLE cAWD> - Axle Shaft A X L E S H A F T REMOVAL AND INSTALLATION 12 Nm 40-47 ft.lbs. 9 ft.lbs. 36-43 ft.lbs. 0 0 0 0 1 0 4 0 Removal steps 1. Rear speed sensor <Vehicles with ABS>...
Page 709 REAR AXLE eAWD> - Shaft Axle With the special tool, secure the axle shaft and remove the companion flange self-locking nut. MB99 With the special tool, remove the axle shaft from the axle housing. <VEHICLES WITH ABS> Using the special tool, remove the rear rotor from the axle MB990560 shaft.
Page 710 REAR AXLE cAWD> - Axle Shaft INSTALLATION SERVICE POINTS Axle housing MB990938 With the special tool, press fit the inner bearing onto the axle housing. MB990931 (1) With the special tool, press the oil seal onto the axle housing with the depression in the oil seal facing upward, and until it contacts the shoulder on the inside of the axle housing.
Page 711 REAR AXLE <AWD> - Axle Shaft / Drive Shaft Using the special tool, press fit the rear rotor to the axle shaft with the rear rotor groove surface toward the axle shaft flange. With the special tool, secure the axle shaft and tighten the companion flange self-locking nut.
Page 712 REAR AXLE <AWD> Shaft REMOVAL SERVICE POINT Using a tire lever, etc. remove the drive shaft from the differential carrier. INSTALLATION SERVICE POINTS (1) If the oil seal is to be replaced because of damage, drive it in by using the special tool. (2) Apply the specified grease to the oil seal lip.
Page 713 REAR AXLE <AWD> DISASSEMBLY AND REASSEMBLY T.J. boot repair kit B.J. boot repair kit 1 lN0023 l l N O 0 2 4 0 0 0 0 1 0 4 6 B.J. repair kit Disassembly steps 3. T.J. case 10. B.J. assembly 4.
Page 714 REAR AXLE cAWD> Shaft Lubrication Points l l A 0 0 8 4 Grease: Repair kit grease Quantity to use: 135 g (4.76 oz.) Caution Apply all of the grease from the repair kit to the joint and boot, a half to each as a rule. Special grease is used for the joint.
Page 715 REAR AXLE cAWD> - Drive Shaft DISASSEMBLY SERVICE POINTS (1) Remove the snap ring from the drive shaft with the snap ring pliers. (2) Take out the spider assembly from the drive shaft. (3) Clean the spider assembly. Caution 1. Do not disassemble the spider assembly. 2.
Page 716 27-24 REAR AXLE <AWD> (4) Secure the boot bands. Caution 1. The boot bands should be tightened with the drive shaft at a 0” joint angle. 2. The B.J. boot band and T.J. boot band are identified by the identification number stamped on the lever. Install correct ones at correct positions.
Page 717 REAR AXLE cAWD> - Differential Carrier REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Differential Gear Oil Draining and Filling Main Muffler Removal and Installation (Refer to Group 00 - Maintenance Service.) (Refer to Group 15 - Exhaust Pipe and Muffler.) 24 Nm 17 ft.lbs.
Page 718 REAR AXLE cAWD> REMOVAL SERVICE POINTS With atire lever, etc., remove the drive shaft from the differential carrier. NOTE Be cautious to ensure that the differential carrier oil seal is not damaged by the drive shaft spline. Mating marks (1) Make mating marks on the differential companion flange and the propeller shaft flange yoke for reference during reassembly.
Page 719 REAR AXLE cAWD> INSTALLATION SERVICE POINTS Install the rear wheel oil pump by inserting it through the mounting hole and install the differential carrier securely. Caution Use care not to damage the rear wheel oil pump gears. Align the mating marks on the flange yoke and the companion flange to install the propeller shaft.
Page 720 27-28 REAR AXLE eAWD> (2) Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear, so that the revolution torque [approximately 2.5-3.0 Nm (28-33 in.lbs.)] is applied to the drive pinion.
Page 721 27-29 REAR AXLE eAWD> Standard tooth contact pattern 1 Narrow tooth side 2 Drive-side tooth surface (the side applying power during forward movement) 4 Coast-side tooth surface (the side applying power during reverse movement) Problem Solution Tooth contact pattern resulting from excessive pinion height The drive pinion is positioned too far from the center Increase the thickness of the pinion height adjusting...
Page 722 REAR AXLE cAWD> DISASSEMBLY Inspection Before Disassembly Final Drive Gear Backlash (Refer to P.27-27.) Final Drive Gear Tooth Contact (Refer to P.27-27.) Drive Gear Runout (Refer to P.27-27.) Disassembly steps Differential cover assembly 15. Drive pinion assembly 2. Vent plug 16.
Page 723 REAR AXLE eAWD> (1) Using a press, push the differential case until it is pressed against the carrier. (2) Remove the differential case from the press. Insert two spacers in diagonally opposed positions between the side bearing outer race to be removed and the inner race. Using the press again, remove the outer race.
Page 724 REAR AXLE cAWD> MB99081 0 G/ (1) Make the mating marks to the drive pinion and companion Mating marks flange. NOTE Mating marks should not be made to the contact surfaces of companion flange and propeller shaft. (2) Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims.
Page 725 REAR AXLE cAWD> REASSEMBLY Reassembly steps Spring pin (for 4WS) 15. Washer Drive gear (for 4WS) 16. Self-locking nut Differential carrier 17. LSD case (Refer to P.27-40.) Drive pinion rear bearing outer race Drive pinion front bearing outer race ä 4 ;‘ Drive pinion height adjustment 20.
Page 726 REAR AXLE eAWD> Lubrication, Sealing and Adhesion Points Sealant: 3M ATD Part No. 8663 or equivalent l l F O 0 1 9 - 0 0 0 0 1 5 1 9 Adhesive: 3M Stud Locking Part No. 4170 or equivalent REASSEMBLY SERVICE POINTS Tap the spring pin into the differential case to the position shown in the illustration before press fitting the rear wheel...
Page 727 27-35 REAR AXLE eAWD> (1) With the beveled (large) part of the rear wheel oil pump drive gear at the inner side, press in the drive gear (by using the special tool) until the drive gear contacts the Beveled end surface of the differential case. (2) Check to ensure that the drive gear and the spring pin are flush.
Page 728 REAR AXLE <AWD> (4) Position the special tool in the side bearing seat of the gear carrier, and then select a drive pinion rear shim of a thickness which corresponds to the gap between the special tools. NOTE Clean the side bearing seat thoroughly. When selecting the drive pinion rear shims, keep the number of shims to a minimum.
Page 729 27-37 REAR AXLE cAWD> (5) Remove the companion flange and drive pinion once again. Drive the oil seal into the gear carrier front lip by using the special tool. Apply multipurpose grease to the oil seal lip. (6) Apply a thin coat of multipurpose grease to the companion flange contacting surface of the washer before installing drive pinion assembly.
Page 730 REAR AXLE eAWD> (3) Apply multipurpose adhesive to the threaded holes of the drive gear. Specified adhesive: 3M Stud Locking Part No. 4170 or equivalent (4) Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence.
Page 731 27-39 REAR AXLE cAWD> (4) Using the special tool, to apply the preload, turn down MB991 367 both right and left side bearing nuts on half the distance between centers of two neighboring holes. (5) Fit the snap ring at either position shown to lock the side bearing nut.
Page 732: Lsd Case Assembly
REAR AXLE <AWD> LSD Case Assembly DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Screw 6. Differential pinion mate 2. Differential case A 7. Differential pinion shaft 8. Differential side gear (R.H.) 4. Viscous unit ’ ’ 9. Thrust washer (R.H.) 5. Pinion mate washer 10.
Page 733 REAR AXLE <AWD> LSD Case Assembly (3) insert the special tool at the spline part of differential case B (right) and check to be sure the side gear (right) rotates. eeler gauge f (4) Then insert a 0.09 mm (.0035 in.) feeler gauge to replace a 0.03 mm (.0012 in.) gauge.
Page 734 REAR AXLE <AWD> If the differential side gear and pinion mate gear have been replaced, select the thrust washer (left) by following the steps below. (1) Wash the differential side gear and pinion mate gear in unleaded gasoline to remove all oil, grease, etc. (2) Install the previously used thrust washers (being careful the left and right ones are used at the correct side), together with the gears, viscous unit, pinion mate washer and pinion...
Page 735 REAR AXLE <AWD> Thrust washer (left) Part No. Thickness mm (in.) 0.8 (.031) 0.9 (.035) 1 .o (.039) 1.1 (.043) 1.15 (.045) MB83746 1 1.2 (.047) 1.25 (.049) 1.3 (.051) 1.35 (.053) 1.4 (.055) 1.5 (.059) Thickness mm (in.) M B837522 0.8 (.031) NOTE Select one thrust washer (left) from the eleven types in the kit.
Page 736 27-44 REAR AXLE cAWD> (4) Check differential cases A and B for unusual wear of Differential case B Differential contact surfaces, heat damage or other damage. 1: Contact surface with the viscous unit 2: Contact surface with the pinion mate washer 3 and 4: Contact surfaces with thrust washer (5) Check the spline part of the viscous unit for stepped Contact surface...
Page 737 WHEEL AND TIRE CONTENTS ON-VEHICLE SERVICE ....4 TROUBLESHOOTING ..... . . 3 Tire Inflation Pressure Check .
Page 738: Wheel And Tire
WHEEL AND TIRE GENERAL SPECIFICATIONS Items except spare wheel) except spare tire) Size 16 x 4T 16 x 4T*‘, 17 x 4-r 17 x 4T*2 Amount of wheel 14 (55) 14 (.55)*’ 14 III 1 .o (55 zk .04) offset mm (in.) 14 * 1 .o (.55 + .04)‘2 Pitch circle diameter 114.3 (4.50)
Page 739 WHEEL AND TIRE Symptom Probable cause Remedy Rapid wear Under-inflation or Adjust the tire pressure. at shoulders lack of rotation Rapid wear Over-inflation or at center lack of rotation Cracked Under-inflation Adjust the tire pressure. treads Wear on Excessive Inspect the camber. one side camber Feathered...
Page 740 WHEEL AND TIRE TIRE INFLATION PRESSURE CHECK Check the inflation pressure of the tires. If it is not within the standard value, make the necessary adjustment. TIRE WEAR CHECK Measure the tread depth of tires. Limit: 1.6 mm (.06 in.) Wear indicator If the remaining tread depth is less than the limit, replace the tire.
Page 741: Power Plant Mount
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 -Supplemental Re- straint System (SRS) and GROUP 00- Maintenance Service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 742 POWER PLANT MOUNT SERVICE SPECIFICATIONS Items Standard value No. 1 crossmember Bushing (B) projection mm (in.) Crossmember Bushing (A) projection mm (in.) 7.2-10.2 (.28-.40) Bushing (B) projection mm (in.) 6.5-9.5 Tool Remedy Probable cause Symptom Replace Excessive engine Cracked rubber parts of insulator wobble or vibration (with engine in normal Retighten...
Page 743 POWER PLANT MOUNT Raise and Suspend the Engine to the Extent Force is not Applied to the Engine Mount <From 1994 models> 72-87 ft.lbs. 9 ft.lbs. 72-87 ft.lbs. h31 25 ft.lbs.,-&//,i ‘I Removal steps 4. Engine mount bracket <Turbo> 1. Air hose G connection 2.
Page 744 POWER PLANT MOUNT - Engine Mounting INSTALLATION SERVICE POINT Attach the engine mounting bracket so that the arrow mark on the mounting stopper is in the direction as shown in the illustration. Engine mount bracket INSPECTION Check each insulator for cracks or damage. Check each bracket for deformation or damage.
Page 745 POWER PLANT MOUNT (Refer to GROUP 15 - Air Cleaner.) 45 Nm 33 ft.lbs. mount Removal steps 3. Transaxle mount bracket installation bolt 1. Transaxle mount bracket and 4. Transaxle mount bracket transaxle connection bolt 5. Mounting stopper INSTALLATION SERVICE POINT Transaxle mount bracket Attach the transaxle mounting bracket so that the arrow mark on the mounting stopper is in the direction as shown in the...
Page 746 POWER PLANT MOUNT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Condenser Fan Motor Assembly Removal and Installation <Turbo> (Refer to GROUP 55 - Condenser and Condenser Fan Motor.) Left Bank Warm Up Three-Way Catalytic Converter Removal and Installation <Turbo> (Refer to GROUP 15 - Turbocharger <Rear>.) 36-43 ft.lbs.
Page 747 POWER PLANT MOUNT INSTALLATION SERVICE POINTS Install the rear roll stopper bracket as shown in the illustration. CONNECTION BOLT INSTALLATION Install the bolt as shown in the illustration. INSPECTION Check each insulator for cracks or damage. Check each bracket for deformation or damage. TSB Revision...
Page 748 POWER PLANT MOUNT REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Under Cover Installation (Refer to GROUP 51 - Front Bumper.) (Refer to GROUP 51 - Front Bumper.) Power-steering Fluid Air Bleeding (Refer to GROUP 37A - Service Adjustment Procedures.) CAUTION: SRS Front Wheel Alignment Adjustment...
Page 749 POWER PLANT MOUNT Crossmember 45 Nm 33 ft.lbs. 90 Nm 78 ft.lbs.* 40 Nm 29 ft.lbs. Crossmember removal steps 18. Stopper Front exhaust pipe 19. Rear roll stopper bracket mounting bolt (Refer to GROUP 15 - Exhaust Pipe, 20. Self-locking nut Main Muffler and Catalytic Convener.) Transfer cAWD>...
Page 750 POWER PLANT MOUNT - Crossmember INSPECTION Check the crossmember for cracks or deformation. Check the bushings for cracks or deterioration. Check the right member for cracks or deformation. Check the left member for cracks or deformation. BUSHING A AND B REPLACEMENT Press fit Press out Use the special tool to remove and press in bushings A and...
Page 751 FRONT S U S P E N S I O N ~ CONTENTS FRONT SUSPENSION ......... . . 33A ELECTRONIC CONTROL SUSPENSION (ECS)* .
Page 752 NOTES...
Page 753 FRONT SUSPENSION CONTENTS LOWER ARM ......10 SPECIFICATIONS ..s....2 General SpecificationS .
Page 754: Front Suspension
FRONT SUSPENSION GENERAL SPECIFICATIONS SUSPENSION SYSTEM Items Specification Suspension type McPherson strut with coil spring and compression rod type COIL SPRING (Hatchback) Items Wire dia. x O.D. x free length 15.7x170x301.5 mm (in.) (.58x 6.69 x 12.70) Coil spring identification color Blue x 1 Spring constant N/mm (Ibs./in.) 30 (168)
Page 755 FRONT SUSPENSION SHOCK ABSORBER Vehicles with ECS Items Vehicles without ECS (up to 1995 models) Maximum length mm (in.) Compressed length mm (in.) Stroke mm (in.) (5.91) Damping force Expansion Hard: 2,530 (558) 1,080 (238) [at 0.3 m/set. (0.984 ft./ Medium: 1,580 (348) Soft: 620 (137) sec.)]...
Page 756 FRONT SUSPENSION - Special Tools Tool A: MB991 237 Compression of the front coil spring B: MB991 238 Measurement of the ball joint and stabilizer link MB990326 General service ball joint starting torque...
Page 757 FRONT SUSPENSION Remedy Symptom Probable cause Suspension malfunction Adjust or replace Steering wheel is heavy, vibrates or Ball joint pulls to one side Coil spring Wheel alignment Unbalanced or worn tires Replace Excessive vehicle Broken or deteriorated stabilizer rolling Shock absorber malfunction Adjust Poor riding Improper tire inflation pressure...
Page 758 FRONT SUSPENSION - On-vehicle Service FRONT WHEEL ALIGNMENT TOE-IN Standard value: 0 + 3 mm (0 f .12 in.) 1. Adjust the toe-in by undoing the clips and turning the left and right tie rod turnbuckles by the same amount (in opposite directions).
Page 759 FRONT SUSPENSION - Strut Assemblv Wheel Alignment Adjustment (Refer to P.33A-6.) Removal steps 1. Brake hose tube clamp mounting bolt 5. Strut lower mounting bolt 6. Strut upper mounting bolt 2. Brake hose tube clamp 7. ECS connector <EC&- 3. Front speed sensor clamp mounting 8.
Page 760 FRONT SUSPENSION - Strut Assembly DISASSEMBLY AND REASSEMBLY 78 Nm 00000616 Caution When applying the grease, take care that grease does not adhere to the insulator’s rubber part. Disassembly steps 1. Dust shield 3. Strut insulator assembly 5. Upper spring pad 6.
Page 761 FRONT SUSPENSION REASSEMBLY SERVICE POINTS INSTALLATION (1) Assemble the spring upper seat to the piston.rod, fitting the notch in the rod to the shaped hole in spring seat. (2) Using a pipe, line up the holes in the strut assembly spring lower seat with the hole in the spring upper seat.
Page 762 FRONT SUSPENSION REMOVAL AND INSTALLATION Post-installation Operation Wheel Alignment- Adjustment (Refer to P.33A-6.) 00000619 shield Removal steps 1. Stabilizer link mounting nut (stabilizer 10. Logw;:rarm clamp mounting self-lock- bar side) 2. Stabilizer link mounting nut (lower arm 11. Lower arm mounting clamp side) 12.
Page 763 FRONT SUSPENSION REMOVAL SERVICE POINT Using the special tool, disconnect the knuckle from the lower arm ball joint. Caution 1. Be sure to tie the cord of the special tool to a nearby 2. Loosen the nut but do not remove it. INSTALLATION SERVICE POINT A R M L A M P...
Page 764 FRONT SUSPENSION REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and installation Left Member and Right Member Removal and (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.) Installation (Refer to GROUP 32 - Right Member, Left Member and Crossmember.) Under Cover Removal and Installation 36 Nm...
Page 765 FRONT SUSPENSION INSPECTION Check the bushing for wear and deterioration. Check the stabilizer bar for deterioration or damage. Check the stabilizer link ball joint dust cover for cracks. Check all bolts for condition and straightness. CHECKING STABILIZER LINK BALL JOINT BREAKAWAY TORQUE Install the nut to each stud.
Page 766 NOTES...
Page 767 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 -Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 768 ECS - Specifications GENERAL SPECIFICATIONS FRONT SUSPENSION item Suspension system McPherson strut type COIL SPRING (Hatchback) Items FWD - M/l 15.2 x 170 x 301.6 Wire dia. x center dia. x free 14.5 x 170 x 329.3 14.4 x 170 x 322.7 length mm (in.) Green x 1 Brown x 1...
Page 769 ECS - Sl>ecifications STABILIZER BAR Items Mounting method Pillow ball type Pillow ball type Outside dia. mm (in.) 23 t.91) 22 i.86) REAR SUSPENSION Items Suspension system Multi-link type Double-wishbone type COIL SPRING (Hatchback) Items 12.2 x 105 x 350.0 Wire dia.
Page 770 ECS - SDecifications / SDecial Tools STABILIZER BAR Items Mounting method Pillow ball type Pillow ball type Outside dia. mm (in.) 10 (.37) 22 (.86) SERVICE SPECIFICATIONS Rear suspension- AWD Items Rear suspension - FWD Front suspension Standard value Camber 0”...
Page 771 Symptoms When diagnostic trouble code No. When diagnostic trouble code No. 21 is output. *2 When diagnostic trouble code N ECS indicator light does not switch is operated. ECS control unit Steering angular velocity sensor *2 Anti-roll control only stops. *2 ECS control unit Anti-dive control only stops.
Page 772 When diagnostic trouble code No. 11 is output Using scan tool, check Check by entering simulated vehicle speed from scan tool to simu- sensor. Good? late pitching and bouncing controls. (Refer to P.33B-17.) Good? Disconnect G sensor connector. With ignition switch at ON, check harness connector.
Page 773 When diagnostic trouble code No. 24 is output Using scan tool, check service data on vehicle p Check by entering simulated vehicle speed from scan tool to simu- late high speed-sensitive control. (Refer to P.33B-16.) Good? speed sensor. Good? Disconnect vehicle speed sensor Replace ECS control unit.
Page 774 ECS - Troubleshooting When diagnostic trouble code Nos. 61, 62, 63 and 64 are output. Using scan tool, check actuator. (Refer to with diagnostic trouble code No., disconnect con- nector directly connected to shock absorber, and Is continuity provided across the following areas of shock ab- Standard: 5 V sorber associated with diagnostic trouble code No.? ECS control unit terminal...
Page 775 ECS - Troubleshootina ECS indicator light does not switch when ECS switch is operated. Does ECS indicator light flash? code. Disconnect ECS switch connector and check har- ness connector with ignition switch at ON. No. 10 terminal voltage and continuity between Is continuity provided between No.
Page 776 ECS - Troubleshooting Anti-squat control only stops. Check by entering simulated vehicle speed from scan tool to simulate anti-squat control. (Refer to P.33B-16.) Good? Does check engine/malfunction indicator lamp illu- Is continuity provided between No. 2 terminal of throttle position sensor and No. minate? 59 terminal of ECS control unit? Correct harness.
Page 777 ON-VEHICLE INSPECTION 1. WARNING INDICATION BY ECS INDICATOR LIGHT If a problem associated with the following items occurs, the ECS indicator light (Tour Sport) in the combination light flashes at intervals of 0.5 sec. At the same time, the diagnostic trouble code associated with the problem is output to the data link connector.
Page 778 ECS - Service Adjustment Procedures When using the voltmeter <Up to 1993 models> (1) Set the ignition switch to OFF. (2) Connect the positive (+) terminal of the voltmeter to the No. 3 terminal of the data link connector beside the junction d block and connect the negative (-) terminal of the voltme- ter to the No.
Page 779 Fail Safe and Diagnosis List output Output Code Diagnostic Item Fail Safe Code No. indication Pattern [Good] [Good] G sensor defective* Ride controls (pinching and bouncing control, bad road detection control) stop. Steering angular Anti-roll control stops. Vehicle speed sensor Steering stability controls (anti-roil, high speed sensitive controls) and attitude controls (anti-dive, anti-squat) stop.
Page 780 ECS - Service Adjustment Procedures On-board Diagnostic Determination Conditions Code No. What is Defective On-board Diagnostic Determination Conditions G sensor defective When sensor input of 0.5 or less or 4.5 V or more lasts for more than 10 seconds. Steering angular velocity sen- Open circuit detected on the basis of difference in voltage level of sen- sor open-circuited sor signal.
Page 781 ECS - Service Adjustment Procedures 4. ACTUATOR CHECK (1) Using the scan tool, force-drive the actuator and fix the damping force changeover. (2) Check service data (Item No. 61 through 64) to verify that the actuator has been force-driven. NOTE All of the four actuators in the shock absorbers are simultaneously changed over by forced drive.
Page 782 (4) Depress the brake pedal and simultaneously change the entered simulated vehicle speed by the scan tool. (Change the speed in 0.4 seconds after depressing the brake ped- al.) (5) Using the scan tool, check that the indications of service data items No.
Page 783 Select the Tour mode by the ECS switch. (2) Using the scan tool, check the indications of service data items No. 61 through 64. Scan tool indication: SOFT (3) Remove the G sensor, slowly shake it up and down through a space of about 5 cm (1.9 in.) with the connector con- nected, and check that the indications of service data items No.
Page 784 To mount or remove the ECS switch, refer to GROUP 54 ing or removing the ECS switch. INSPECTION Operate the switch to check for continuity between the individu- al terminals. Switch position Terminal No. ECS switch To mount or remove the steering angular velocity sensor, refer to GROUP 54 - Column Switch.
Page 785 Throttle Position Sensor I Stop Light Switch / Position Detection Switch / INSPECTION AND ADJUSTMENT Refer to GROUP 13A - Fuel System. To remove or mount the stoplight switch, refer to GROUP 35 - Brake Pedal. INSPECTION Refer to GROUP 35 - Brake Pedal. To remove or mount the position detection switch and damping force changeover actuator, refer to GROUP 33A - Strut As- sembly and GROUP 34 - Shock Absorber Assembly.
Page 786 ECS - ECS Control Unit REMOVAL AND INSTALLATION Removal steps 1. Cargo floor box (R.H.) 2. Lid 3. ECS control unit...
Page 787 REAR SUSPENSION CONTENTS REAR SUSPENSION cFWD> REAR SUSPENSION <AWD> ASSIST LINK ......35 ON-VEHICLE SERVICE .
Page 788 REAR SUSPENSION <FWD> REAR SUSPENSION <FWD> GENERAL SPECIFICATIONS SUSPENSION SYSTEM Item Specification Suspension system Multi-link COIL SPRING (Hatchback) Items Vehicles without ECS Vehicles with ECS Wire dia. x O.D. x free length mm (in.) (.48x 4.13 x 13.78) Coil spring identification color Pink x 1 Orange x 1 Spring constant N/mm (IbsAn.)
Page 789 REAR SUSPENSION <FWD> Tools WHEEL BEARING I Soecification I Item Unit ball bearing SERVICE SPECIFICATIONS Limit Standard value Items 0.5 + 2.5 (.Ol + .09) Toe-in (Left-right difference) mm (in.) 0” f 30’ Camber 1.7-3.2 (15-28) Stabilizer link ball joint breakaway torque Nm (inlbs.) 2-9 (17-78) Ball joint rotation breakaway torque Nm (in.lbs.) Stabilizer link protrusion mm (in.)
Page 790 REAR SUSPENSION <FWD> Tool number and Tool Supersession Application name A: MB991 237 MIT62220 Compression of the coil spring Spring compressor body B: MB991 239 Arm set MB991 045 Removal and installation of the crossmember bushing Bushing remov- er and installer MB990880 MB991 005-01 Removal and installation of trailing...
Page 791 REAR SUSPENSION <FWD> REAR WHEEL ALIGNMENT CHECK CAMBER Standard value: 0” f 30’ To adjust camber, turn the lower arm mounting bolt (cross- member side). NOTE (1) Make the adjustment with the assist link mounting bolt (crossmember side) loosened. (2) The difference between the right and left wheels should be 30’...
Page 792: Wheel Bearing End Play Check
REAR SUSPENSION <FWD> - On-vehicle Service WHEEL BEARING END PLAY CHECK 1. Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. Remove the hub cap and then release the parking brake. 3. Remove the caliper assembly and the brake disc. 4.
Page 793 REAR SUSPENSION <FWD> - Rear Suspension Assembly RI MOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Absorber Lid Removal from Rear Side Trim Main Muffler Installation (Refer to GROUP 15 - Ex- (Refer to GROUP 52A - Trims.) haust Pipe and Main Muffler.) Pipe and Main Muffler.) Parking Brake Lever Stroke Check (Refer to GROUP 36 - On-vehicle Service.)
Page 794 REAR SUSPENSION eFWD> REMOVAL SERVICE POINT SUSPENSION ASSEMBLY REMOVAL Support the crossmember with a transmission jack, then remove the crossmember mounting nut and rear suspension assembly. INSPECTION Check the crossmember for cracks or deformation. Check the bushings for cracks or deterioration. CROSSMEMBER BUSHING REPLACEMENT Press fit Press out...
Page 795 upper nrm, Lower nrm ano REAR SUSPENSION <FWD> Post-installation Operation Shock Absorber Removal (Refer to P.34-13.) Wheel Alignment Check (Refer to P.34-5.) Shock Absorber Installation (Refer to P.34-13.) 140-160 Nm* 0 0 0 0 1 0 3 2 link removal steps Upper arm removal steps Assist 8.
Page 796 upper Arm, Lower Hrm anu REAR SUSPENSION cFWD> INSPECTION Check the bushing for wear and deterioration. Check the upper, lower arm or assist link for bend or breakage. Check the ball joint dust cover for cracks. Check all bolts for condition and straightness. BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool, measure the ball joint breakaway torque.
Page 797 REAR SUSPENSION cFWD> - Trailing Arm Rear Brake Disc Run-out Check (Refer to GROUP 35 - On-vehicle Service.) Parking Brake Lever Stroke Check (Refer to GROUP 36 - On-vehicle Service.) 83 Nm 60 ft.lbs. 160 Nm* 2 13< 140- 116 ft.lbs.* 101- 36-43 ft.lbs.
Page 798 REAR SUSPENSION cFWD> REMOVAL SERVICE POINTS Caution Replace the rear hub assembly with a new one if the bearing inner race is left on the spindle when removing the rear hub assembly. If the removed rear hub assembly is reinstalled with the inner race attached on the spindle, it can be caused that the oil seal lip is pushed in the reverse direction, resulting in oil leaks or loose mounting.
Page 799 REAR SUSPENSION cFWD> Removal steps 1. Shock absorber upper mounting nut 3 l=clc nnnnnrtnr “CCC. NOTE 4. Brake tube clamp bolt Indicates parts which should be temporarily tightened, and 5. Shock absorber lower mounting bolt then fully tightened with the vehicle on the ground in the 6.
Page 800 REAR SUSPENSION <FWD> DISASSEMBLY AND REASSEMBLY Disassembly steps 7. Collar 2. Washer 8. Cup assembly 3. Upper bushing (A) 9. Dust cover 4. Bracket assembly 10. Bump rubber 5. Upper spring pad 6. Upper bushing (B) 12. Shock absorber DISASSEMBLY SERVICE POINT the piston rod tightening nut, compress (1) Before removing the coil spring using the special tool.
Page 801 REAR SUSPENSION <FWD> REASSEMBLY SERVICE POINTS (1) Use the special tool (MB991237 and MB991239) to compress the coil spring and insert it in the shock absorber. (2) Align the edge of the coil spring to the position of the shock absorber spring seat as shown. Coil sprin TIGHTENING NUT INSTALLATION (1) With the position of the bracket assembly as shown in...
Page 802 REAR SUSPENSION cFWD> REMOVAL AND INSTALLATION Removal steps 1. Stabilizer bracket mountina bolt 7. Joint 3. Bushing 10. Joint cup (A) 5. Joint cup (A) 11. Stabilizer rubber 6. Stabilizer rubber 12. Stabilizer bar INSTALLATION SERVICE POINTS Hold with wrench SELF-LOCKING NUT INSTALLATION (1) Hold the stabilizer link ball studs with a wrench and install the self-locking nut (A).
Page 803 REAR SUSPENSION <FWD> (1) Align the bushing (L.H.) with the stabilizer bar marking end and temporarily tighten the stabilizer bar bracket (L.H.). (2) In this condition, mount the stabilizer bar bracket (R.H.) and temporarily tighten it. (3) Temporarily fix the both ends of the stabilizer bar to the link and tighten the stabilizer bar bracket mounting bolts to specification.
Page 804 REAR SUSPENSION <FWD> - Rear Axle Hub REMOVAL AND INSTALLATION 50-60 Nm 36-43 ft.lbs. Removal steps 8. Rear rotor CABS> 1. Rear speed sensor CABS> 9. Rear hub unit bearing 2. Caliper assembly 3. Brake disc 4. Hub cap Caution 5.
Page 805 REAR SUSPENSION <FWD> - Rear Axle Hub Caution Replace the rear hub assembly with a new one if the bearing inner race is left on the spindle when removing assembly. the rear hub If the removed rear hub assembly is reinstalled with the inner race attached on the spindle, it can be caused that the oil seal lip is pushed in the reverse direction, resulting in oil leaks or loose mounting.
Page 806 REAR SUSPENSION cAWD> GENERAL SPECIFICATIONS SUSPENSION SYSTEM Item Specification Suspension system COIL SPRING (Hatchback) Specifications Items Wire dia. x O.D. x free length mm (in.) 12.2 x 105 x 379.3 (.48x 4.13 x 14.93) Blue x 2 Coil spring identification color Spring constant N/mm (Ibs./in.) 28.0 (157) items...
Page 807 REAR SUSPENSION <AWD> SHOCK ABSORBER to 1995 models> Specifications Items Hydraulic, cylindrical, double-acting type Max. length mm (in.) 610 (24.0) Min. length mm (in.) 407 (16.0) Stroke mm (in.) 203 (8.0) Damping force [at 0.3 m/set. (0.9 ft./set.)] Expansion Hard: 1,710 (377) N (Ibs.) Medium: 1 ,160 (256) Soft: 560 (123)
Page 808 REAR SUSPENSION <AWD> - Special Tools Tool numberand Tool Supersession Application name A: MB991 387 Removal and installation of the crossmember Arbor bushing B: MB991 388 Base C: MB990890 Base MB990958 Removal and installation of crossmember bushings Arbor MB991113 Disconnection of the ball joint Steering linkage puller MB990326...
Page 809 REAR SUSPENSION <AWD> - Special Tools B: lMB990244 TSB Revision...
Page 810 REAR SUSPENSION <AWD> - Troubleshooting TSB Revision...
Page 811 REAR SUSPENSION <AWD> REAR WHEEL ALIGNMENT CHECK Standard value: -0”lO’ + 30’ To adjust camber, turn the lower arm mounting bolt on the crossmember side. Left wheel: Clockwise ((-) camber) Right wheel: Clockwise ((+) camber) The difference between the right and left wheels should be One graduation changes camber by about 12’.
Page 812 REAR SUSPENSION <AWD> - Rear Suspension Assembly REMOVAL AND INSTALLATION Pre-removal Operation Rear Side Trim Absorber Center Exhaust Pipe and Main Muffler Removal (Refer Lid Removal to GROUP 52A - Trims.) (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.) Post-installation Operation Center Exhaust Pipe and Main Muffler Installation Wheel Alignment Checking (Refer to P.34-25.)
Page 813 REAR SUSU’ENSION cAWD> - Rear Suspension Assembly REMOVAL SERVICE POINTS MOUNTING NUT (ON DIFFERENTIAL SIDE) / REAR SUSPENSION ASSEMBLY REMOVAL (1) Before removing the crossmember bracket, support the differential case with the transmission jack. (2) Remove the crossmember mounting bolt and nut. NOTE Lowering the rear suspension assembly down from the transmission jack requires three persons, as the rear...
Page 814 REAR SUSPENSION <AWD> (3) Make sure that the protrusion of the inner sleeve (dimen- sion A and B) are up to specifications. Standard value Dimension A: 15.5 mm (59 in.) Dimension B: 2.1-3.7 mm (.08-.15 in.) CROSSMEMBER BUSHING (REAR) Press out REPLACEMENT (1) Using the special tool, remove and press-fit the bushing.
Page 815 REAR SUSPENSION cAWD> REMOVAL AND INSTALLATION Post-installation Operation 1 0 1 - 1 1 6 ft.lbs. Dust cover 140-160 Nm* 1 0 1 - 1 1 6 ft.lbs.* g E 00001036 Upper arm removal steps Lower arm removal steps 1. Self-locking nut 5.
Page 816 REAR SUSPENSION cAWD> Lower down the lower arm on the crossmember side. Then, install the special tool and disconnect the lower arm ball joint from the knuckle. Caution 1. Be sure to tie the cord of the special tool to a nearby part.
Page 817 REAR SUSPENSION cAWD> - Upper and Lower Removal MI3991 072 (1) Use the special tool to remove and press-fit the bushing. MB991 073 Press-fit (2) Press-fit the lower arm bushing until the bushing outer pipe edge flush with the lower arm pipe edge. Pipe (lower (bushing)
Page 818 REAR SUSPENSION cAWD> REMOVAL AND INSTALLATION Post-installation Operation Wheel Alignment Check (Refer to P.34-25.) Rear Brake Disc Run-out Check (Refer to GROUP 35 - On-vehicle Service.) (Refer to GROUP 36 - On-vehicle Service.) 36-43 ft.lbs. 260-300 Nm 188-217 ft.lbs. 55-6 40-4 200-240 Nm* 145-174 ft.lbs.*...
Page 819 REAR SUSPENSION <AWD> REMOVAL SERVICE POINTS With the special tool, secure the rear axle shaft, then remove the self-locking nut. With the special tool, remove the rear axle shaft. SELF-LOCKING NUT (LOWER ARM) REMOVAL Using the special tool, disconnect the ball joint from the knuckle.
Page 820 REAR SUSPENSION cAWD> (3) Set the special tool onto the trailing arm as shown in Bolt B the illustration. NOTE (1) Apply lubricant to the sliding portion of the special tool (at the arrow marked “A” in the illustration). (2) Install bolt B to the trailing arm, at the point shown in the figure.
Page 821 REAR SUSPENSION cAWD> - Assist Link Wheel Alignment Check (Refer to P.34-25.) 40 Nm 29 ft.lbs. 58 Nm 42 ft.lbs. 1. Assist link NOTE L.H. side shown. INSTALLATION SERVICE POINT Bolt If the ball studs of the assist link does not align with their mounting holes, loosen the lock nuts and turn the adjusting bolt to adjust the length of the assist link.
Page 822 REAR SUSPENSION <AWD> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (Refer to GROUP 52A - Trims.) 1. Shock absorber upper mounting nut 2. ECS connector <EC&- Shock absorber lower mounting bolt 5. Shock absorber assembly...
Page 823 REAR SUSPENSION <AWD> DISASSEMBLY AND REASSEMBLY 14-18 Disassembly steps 1. Cap 2. Piston rod tightening nut (Refer to P.34-14.) 10. Dust cover 3. Washer 11. Bump rubber 4. Upper bushing (A) 12. Coil spring (Refer to P.34-15.) 5. Bracket assembly (Refer to P.34-15.) 13.
Page 824 REAR SUSPENSION cAWD> - Stabilizer REMOVAL AND INSTALLATION 2 9 f t . l b s . s -) 0 0 0 0 1 0 3 7 Removal steps 11. 4WS piping fixing bolt <4WS> 12. Rear shock absorber mounting bolt 3.
Page 825 REAR SUSPENSION cAWD> REMOVAL SERVICE POINTS MOUNTING NUT REMOVAL (1) Support the rear suspension assembly with the transmission jack. (2) Remove the crossmember bracket and crossmember mounting nut. (1) Lower the transmission jack a little to obtain a gap between the rear suspension and body.
Page 826 REAR SUSPENSION <AWD> - Stabilizer INSPECTION Check the bushing for wear and deterioration. Check the stabilizer bar for deterioration or damage. Check the stabilizer link ball joint dust cover for cracks. Check all bolts for condition and straightness. STABILIZER LINK BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool, measure the ball joint breakaway torque.
Page 827 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 -Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 828: Service Brakes
SERVICE BRAKES GENERAL SPECIFICATIONS MASTER CYLINDER Items FWD without ABS FWD with ABS Tandem type Tandem type Tandem type (with level sensor) (with level sensor) (with level sensor) I.D. mm (in.) 25.4 (1) or 26.9 (1 ‘/,s) 26.9 (1 ‘/,s) 26.9 (1 1/,6) BRAKE BOOSTER Items...
Page 829 SERVICE BRAKES - Specifications SERVICE SPECIFICATIONS Items Front disc thickness mm (in.) Rear disc thickness mm.(in.) to master cylinder Disc brake drag force (tangenti mounting bolts) N (Ibs.) Speed sensor’s internal resistance CABS> kQ Solenoid valve (HU) resistance R Hydraulic unit solenoid valve inte nal resistance R G-sensor output voltage V clearance cAWD>...
Page 830 SERVICE BRAKES - Specifications / Special Tools Limit Standard value Items 1 .o (.04) Rear brake lining thickness mm (in.) 2.8 (.ll) 0.05 (.002) Front hub end play mm (in.) 0.08 (.0031) or less Rear disc run-out mm (in.) 0.05 (.002) Rear hub end play mm (in.) 0.8 (.031) LUBRICANTS...
Page 831 SERVICE BRAKES - Special Tools / Troubleshootincl refer to GROUP For checking of ABS check harness Symptom Probable cause Remedy Replace Grease or oil on pad or lining surface Vehicle pulls to one side when brakes are Inadequate contact of pad Correct applied Auto ad,juster malfunction...
Page 832 SERVICE BRAKES - Troubleshootina Insufficient parking brake function the parking brake lever stroke Excessive parking brake lever stroke ck the parking brake cable rout- Scraping or grinding noise when brakes are applied when brakes are ap- TSB Revision...
Page 833 SERVICE BRAKES Symptom Probable cause Remedy Squealing noise when Disc brakes - rusted, stuck Lubricate or replace brakes are not applied Loose or extra brake parts Retighten Improper positioning of pads in caliper Correct Improper installation of support mounting to caliper Correct body Poor return of brake booster or master cylinder...
Page 834 SERVICE BRAKES - Anti-lock Braking System Troubleshooting TROUBLESHOOTING (ABS-FWD) Confirm condition in the following way and diagnosis accordingly. Does the ABS warning light illuminate as described (2) With the ignition key in the “START” position, below up to the time the engine starts? power to the ABS ECU is interrupted and the (1) When the ignition key is turned to the “ON”...
Page 835 SERVICE BRAKES - Anti-lock Braking Svstem Troubleshooting Trouble condition Remedy Major causes Break in harness for ECU warning light Check, using flow After the ignition key is turned to the “ON” drive circuit chart D (Refer to position, it blinks once and then illumi- Malfunction of ECU nates when it is turned to the “START’...
Page 836 SERVICE BRAKES NOTE After a test drive*, use on-board diag- Drive at 19 mph or higher for more than 30 seconds. No diagnostic trouble codes output and normal codes are displayed? on-board diagnostic output ter- minals and the diagnosis check intermittent or other trouble.
Page 837 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ACTUATOR TEST FUNCTION METHOD OF CLEARING DIAGNOSTIC The actuator can be forcibly driven in the following way by using the scan tool. Caution When servicing is finished, clear the diag- NOTE nostic trouble code memory. The actuator test cannot be carried out when the ABS ECU System is in fail safe.
Page 838 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ABS warning light does not light at all. [Explanation] [Hint] When it does not light up at all, there is a strong If other warning lights do not light up either, fuse possibility that there is trouble with ABS warning is probably blown.
Page 839 SERVICE BRAKES - Anti-lock Braking System Troubleshooting With the ignition key in the “ON” position, Check fuse No. 11. If it is do other warning lights (except door-ajar blown, correct the cause of warning light, seat belt warning light) illu- the blown fuse and then re- minate? Remove the combination me-...
Page 840 SERVICE BRAKES - Anti-lock Braking System Troubleshooting Repair harness. connector terminal No. 25 and ground the ignition key is in the “ON” position? ABS ECU malfun Replace ABS ECU. Remove valve relay and check. Replace valve relay. Install the valve relay, remove the HU connector and check.
Page 841 SERVICE BRAKES ABS warning light stays on when the ignition key is in the “ON” position. [Explanation] [Hint] This is the symptom when the ABS ECU does not Check the on-board diagnostic output if there power up due to broken ECU power circuit, etc., is no output voltage or if the scan tool and ABS when the fail safe function operates and isolates ECU cannot communicate, there is a good possibil-...
Page 842 SERVICE BRAKES - Anti-lock Braking System Troubleshooting <Models produced up to Oct. 1994> CONTINUED FROM PREVIOUS PAGE SWITCH (lG2) Can other electronic control systems communicate with function. Repair and re- scan tool? check. RELAY Disconnect ECU connector and check harness connector I 18 ABS ECU Is there continuity between...
Page 843 SERVICE BRAKES - Anti-lock Braking System Troubleshooting <Models produced from Nov. 1994> CONTINUED FROM PREVIOUS PAGE IGNITION SWITCH (IG2) Can other electronic control systems communicate with function. Repair and re- scan tool? check. Correct cause of blown fuse and replace fuse. Disconnect ECU connector and check harness connector ABS ECU...
Page 844 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ABS warning light does not illuminate when the ignition key is in the “START” position. [Explanation] sequently, in the “START” position power is off and The ABS ECU uses the IGz power source which is turned off in the “START”...
Page 845 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When power flows, the ABS ECU turns on the harness between the ECU and the warning light, warning light for approximately 1 sec. while it per- the light illuminates only when the valve relay is forms a valve relay test.
Page 846 SERVICE BRAKES - Anti-lock Braking System Troubleshooting CHECK USING ON-BOARD DIAGNOSTIC When using the MUT When using the scan tool [Multi-use tester (MUT) <Up to 1993 models> or MUT-II <All models>] (1) With the ignition switch OFF, connect the scan tool. When connecting the scan tool (MUT-II) to a 1993 model vehicle, use the adapter harness supplied together.
Page 847 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When the following diagnostic trouble codes are displayed “11 FL SNSR. OPEN” “12 FR SNSR. OPEN” “13 RL SNSR. OPEN” “14 RR SNSR. OPEN” [Explanation] [Hint] The ABS ECU detects breaks in the wheel speed In addition to a broken wire/short circuit in the wheel sensor wire.
Page 848 SERVICE BRAKES - Anti-lock Braking System Troubleshooting Check flow connected with wheel NOTE speed sensor When checking with an oscilloscope, first measure voltage varia- tions in the wheel speed sensor output. (Refer to P.35-75.) Is the resistance value of the wheel speed sensor Repair harness.
Page 849 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When diagnostic trouble code “22 STOP LAMP SW” is displayed [Explanation] [Hint] The ABS ECU outputs this diagnostic trouble code If the stop light operates normal, the harness for in the following cases. the stop light switch input circuit is broken or there Stop light switch may remain on for more than is a malfunction in the ABS ECU.
Page 850 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When diagnostic trouble codes “41 FL SOL. VALVE “, “42 FR SOL. VALVE” or “43 REAR SOL. V.” are displayed. [Explanation] The ABS ECU normally monitors the solenoid valve when turned OFF, the ECU determines the solenoid drive circuit.
Page 851 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When diagnostic trouble code “51 VALVE RELAY” is displayed [Explanation] When the ignition switch is turned ON, the ABS or not there is power in the valve power monitor ECU switches the valve relay OFF and ON for line since the valve relay is normally ON.
Page 852 SERVICE. BRAKES - Anti-lock Braking System Troubleshooting When diagnostic trouble code “52 MOTOR RELAY” is displayed [Explanation] When the motor continues to revolve The ABS ECU outputs this diagnostic trouble code [Hint] for the motor relay and motor in the following cases. If there is motor operation noise during scan tool When the motor relay does not function forced drive mode, there is a broken or short cir-...
Page 853 SERVICE BRAKES - Anti-lock Braking Svstem Troubleshootina TROUBLESHOOTING (ABS-AWD) Confirm condition in the following way and diagnosis accordingly. (2) With the ignition key in the “START” position, power to the ABS ECU is interrupted and the ABS warning light remains lit because the valve position, the ABS ECU causes the ABS warn- relay is OFF.
Page 854 SERVICE BRAKES - Anti-lock Braking System Troubleshooting Trouble condition Major causes Remedy Break in harness for ECU warning Check, using flow After the ignition key is turned to the “ON” light drive circuit chart D (Refer to position, it blinks once and then illumi- Malfunction of ECU nates when it is turned to the “START’...
Page 855 SERVICE BRAKES After a test drive, use on-board tic to check (Refer to P.35-39.). No on-board diagnostic output No diagnostic trouble codes out Diagnostic trouble codes are normal codes are displayed? on-board diagnostic output ter- minals and the diagnosis check connector.
Page 856 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ACTUATOR TEST FUNCTION METHOD OF CLEARING DIAGNOSTIC TROUBLE CODE MEMORY The actuator can be forcibly driven in the following way by using the scan tool. Caution When servicing is finished, clear the diag- NOTE nostic trouble code memory The actuator test cannot be carried out when...
Page 857 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ABS warning light does not light at all. [Explanation] When it does not light up at all, there is a strong If other. warning lights do not light up either, fuse possibility that there is trouble with ABS warning is probably blown.
Page 858 SERVICE BRAKES - Anti-lock Braking System Troubleshooting door-ajar warning light, seat belt warn- ing light) illuminate? Repair or replace com- bination meter. Turn the ignition switch OFF and check. bulb. burned. (Check for burned bulb.) Repair or replace com- Faulty combination meter Is there continuity between combination bination meter meter No.
Page 859 SERVICE BRAKES - Anti-lock Brakina Svstem Troubleshooting Check ABS ECU. Remove the ECU connector and check. Does the voltage between ECU harness Repair harness. connector terminal No. 25 and ground in- warning light and ECU ianition kev is in the “ON” oosition? ABS ECU malfunction Replace ABS ECU.
Page 860 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ABS warning light stays on when the ignition key is in the “ON” position. [Explanation] [Hint] This is the symptom when the ABS ECU does not Check the on-board diagnostic output and if there power up due to broken ECU power circuit, etc., is no output voltage or if the scan tool and ABS when the fail safe function operates and isolates...
Page 861 SERVICE BRAKES - Anti-lock Braking System Troubleshooting IGNITION Can other electronic control systems communicate with scan tool? is fuse No. 3 normal? Is power relay normal? (Refer to P.3565.) Replace power relay. Disconnect ECU connector / and check harness connector 1 With the ignition key in the Harness wire between “ON”...
Page 862 SERVICE BRAKES - Anti-lock Braking System Troubleshooting <Models produced from Nov. 1994> IGNITION Can other electronic control - systems communicate with tion. Repair and recheck. scan tool? Disconnect ECU connector DIODE and check harness connector Is there continuity between body harness terminals No. 9 and No.
Page 863 SERVICE BRAKES - Anti-lock Braking System -Troubleshooting ABS warning light does not illuminate when the ignition key is in the “START” position. The ABS ECU uses the IG2 power source which and the ECU turns the valve relay OFF. If the warn- is turned off in the “START”...
Page 864 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ABS warning light blinks once after the ignition key is turned to the “ON” position. It illuminates in the “START” position and blinks once again when turned to the “ON” position. [Explanation] When power flows, the ABS ECU turns on the harness between the ECU and the warning light, warning light for approximately 1 sec.
Page 865 SERVICE BRAKES - Anti-lock Braking System Troubleshooting CHECK USING ON-BOARD DIAGNOSTIC When using the MUT When using the scan tool [Multi-use tester (MUT) (1) With the ignition switch OFF, connect the scan tool. When connecting the scan tool (MUT-II) to a 1993 model vehicle, use the adapter harness supplied together.
Page 866 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When the following diagnostic trouble codes are displayed “11 FL SNSR. OPEN” “12 FR SNSR. OPEN” “13 RL SNSR. OPEN” “14 RR SNSR. OPEN” [Explanation] [Hint] The ABS ECU detects breaks in the wheel speed In addition to a broken wire/short circuit in the wheel sensor wire.
Page 867 SERVICE BRAKES - Anti-lock Braking System Troubleshooting NOTE Check flow connected with Check speed sensor harness and connector connection speed sensor and then observe with oscilloscope. (Refer to P.3575.) Is the resistance value of the Malfunction of wheel speed sensor part normal? Standard value: 0.8-1.2 k~2 Is the resistance value at the ECU Harness wire for wheel speed...
Page 868 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When diagnostic trouble code “21 G SNSR.” is displayed [Explanation] The ABS-ECU outputs this diagnostic trouble code vehicle is stopped or when there is stop light switch input.) in the following cases. G sensor OFF trouble (It is judged that the When there is a broken wire or short circuit in the harness for the G sensor system.
Page 869 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When diagnostic trouble code “22 STOP LAMP SW” is displayed [Hint] The ABS-ECU outputs this diagnostic trouble code If the stop light operates normal, the harness for in the following cases. the stop light switch input circuit is broken or there Stop light switch remains on for more than 15 is a malfunction in the ABS-ECU.
Page 870 SERVICE BRAKES - Anti-lock Braking System Troubleshooting Do the stop lights light up and go out normally? Is resistor resistance 780 to Replace resistor. 860 !a? Is there continuity Repair harness. 2 terminal and ground? tween resistor and ground. I Yes Replace ABS-ECU.
Page 871 SERVICE BRAKES - Anti-lock Braking System Troubleshooting When diagnostic trouble codes “41 FL SOL. VALVE [Explanation] The ABS-ECU normally monitors the solenoid valve is broken/short-circuited, and then these diagnostic drive circuit. trouble codes are output. ABS-ECU controls the If no current flows in the solenoid even if the ECU solenoid valve current and if the current value of turns the solenoid ON or if it continues to flow even the solenoid valves differs from each other in the...
Page 872 SERVICE BRAKES When diagnostic trouble code “51 VALVE RELAY” is displayed [Explanation] When the ignition switch is turned ON, the ABS or not there is power in the valve power monitor ECU switches the valve relay OFF and ON for line since the valve relay is normally ON.
Page 873 SERVICE BRAKES When diagnostic trouble code “52 MOTOR RELAY” is displayed When the motor ground is disconnected and the motor does not revolve The ABS ECU outputs this diagnostic trouble code When the motor continues to revolve for the motor relay and motor in the following cases. When the motor relay does not function [Hint] When there is trouble with the motor itself and...
Page 874 SERVICE BRAKES - Anti-lock Braking System Troubleshooting DIAGNOSTIC TROUBLESHOOTING FLOW Reoccurs Does not reoccur Diagnostic trouble Diagnostic trouble Nodiagnostic No diagnostic code displayed code displayed trouble code trouble code or can’t communicate with scan tool No diagnostic trouble code Diagnostic trouble NOTES WITH REGARD TO DIAGNOSIS The condition listed in the following table are considered normal.
Page 875 SERVICE BRAKES DIAGNOSTIC FUNCTION DIAGNOSTIC TROUBLE CODES CHECK With the Scan Tool Connect the scan tool to the data link connector, then check diagnostic trouble codes. Caution Always turn the ignition switch to connect or disconnect the scan tool. NOTE Diagnostic trouble code No.
Page 876 SERVICE BRAKES - Anti-lock Braking System Troubleshooting ERASING DIAGNOSTIC TROUBLE CODES With the Scan Tool Connect the scan tool to the data link connector (l&pin), then erase the diagnostic trouble codes. With the ABS Warning Light When the ignition switch is turned on while the stop light switch is on, the stop light switch will operate 10 times in succession according to the timing given below.
Page 877 SERVICE BRAKES - Anti-lock Braking System Troubleshooting INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES Code No. Diagnostic Item Reference Page F.R. wheel speed sensor system (open-circuited) F.L. wheel speed sensor system (open-circuited) 35-52 35-52 R.L. wheel speed sensor system (open-circuited) 35-52 Wheel speed sensor system (output signal abnormal) 35-52 ABS-ECU power supply system (voltage abnormally low or high)
Page 878 SERVICE BRAKES - Anti-lock Brakina Svstem Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES Code Nos. 11, 12, 13, 14 Wheel speed sensor system (open-circuited) Output is provided when signal is not input due to breakage of the (+) or (-) wire Wheel speed sensor defective of one or more of the four wheel speed sensors.
Page 879 SERVICE BRAKES - Anti-lock Braking System Troubleshooting Code No. 16 ABS-ECU power supply system (voltage Probab,e cauSe abnormally low or high) Output is provided when ABS-ECU power supply voltage drops below or rises above Harness and connector defective if power supply voltage returns to normal ABS-ECU defective Caution If battery voltage drops or rises while making this check, this code is output as an existing trouble,...
Page 880 SERVICE BRAKES Code No. 26 G-sensor system (open-, short-circuited or signal abnormal) Output is provided in the following cases. G-sensor defective G-sensor output drops below 0.W or rises above 4.W Harness and connector defective ABS-ECU defective G-sensor svstem harness is broken or shorted Replace G-sensor.
Page 881 SERVICE BRAKES Code Nos. 41,42,43,44,45,46,47 and 48 Solenoid valve systems HU defective ABS-ECU monitors solenoid valve drive circuit at all times. When solenoid is not Harness, connector defective energized with solenoid valve turned ON by ABS-ECU or when it is kept energized * ABS-ECU defective with solenoid valve turned OFF by ABS-ECU, solenoid coil is judged to be open- or short-circuited or harness is judged to be broken or shorted and output is provided.
Page 882 SERVICE BRAKES Code No. 51 ABS valve relay system Probable cause ABS-ECU monitors solenoid valve drive circuit at all times. When 5 or more solenoids are not energized with solenoid valve turned ON by ABS-ECU or when 5 or more Harness, connector defective solenoids are kept energized with solenoid valve turned OFF by ABS-ECU, ABS HU defective...
Page 883 SERVICE BRAKES Output is provided in the following cases. ABS motor relay defective. No signal is received by motor monitor line with ABS motor relay turned ON. Harness, connector defective (HU pump motor does not run.) HU defective Signal is received by motor monitor line for 5 seconds or more with ABS motor ABS-ECU defective relay turned OFF.
Page 884 SERVICE BRAKES INSPECTION CHART FOR TROUBLE SYMPTOMS Caution Under certain driving conditions such as going on a low p road surface, high speed turning and passing over projection, ABS may operate even if no sudden brake is applied. When making diagnosis by questioning the user, therefore, be sure to check if the trouble occurred under such driving conditions.
Page 885: Inspection Procedure
SERVICE BRAKES - Anti-lock Braking System Troubleshooting Inspection Procedure 2 No communication is possible between scan tool and ABS-ECU. output circuit is probably open-circuited. Fuse blown Harness, connector defective ABS-ECU defective Measure at data Iinkconnector C-79 and ABS-ECU E-12. Disconnect connectors and make measurements on har- ness side.
Page 886 SERVICE BRAKES Inspection Procedure 3 ABS warning light is not lighted with the ignition key Probablecause turned ON (stationary engine). Probably light power supply circuit is open-circuited, light bulb has burned out or Fuse blown circuit between warning light and ABS-ECU is open-circuited. ABS warning light bulb burned out.
Page 887 SERVICE BRAKES - Anti-lock Braking System Troubleshooting inspection Procedure 5 Brakes operate abnormally,. Probable cause Troubles are hard to be judged since they differ according to the driving conditions Wheel speed sensor installation defective Harness, connector defective and the state of road surface, when the diagnostic trouble code is normal code, perform the following check.
Page 888 SERVICE BRAKES - Anti-lock Braking System Troubleshooting SERVICE DATA CHART Of all ECU input data, the following items can be read by the scan tool. Check Item Checking Condition Criterion for normality F.R. sensor Perform actual running. Agreement of speedometer reading with scan tool display F.L.
Page 889 SERVICE BRAKES - On-vehicle Service BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1. Turn off the carpet etc. at under the brake pedal. 2. Measure the brake pedal height as illustrated. If the brake Operat pedal height is not within the standard value, adjust as rod lot follows.
Page 890 SERVICE BRAKES CLEARANCE BETWEEN ;RAKE PEDAL AND FLOOR BOARD 1. Turn off the carpet etc. at under the brake pedal. 2. Start the engine, depress the brake pedal with approxi- mately 500 N (110 Ibs.) of force, and measure the clear- ance between the brake pedal and the floorboard.
Page 891 SERVICE BRAKES CHECK VALVE OPERATION CHECK When checking the check valve, keep the check valve fit in the vacuum hose. 1. Remove the vacuum hose. Caution The check valve is press-fit inside the vacuum hose and do not remove the check valve from the vacuum hose.
Page 892 SERVICE BRAKES - On-vehicle Service BLEEDING C a u t i o n Use the specified brake fluid. Don’t use a mixture of the specified brake fluid and another non-specified fluid. Specified brake fluid: Conforming to DOT3 or DOT 4 BLEEDING THE MASTER CYLINDER If the master cylinder is empty of brake fluid, bleed the cylinder as follows.
Page 893 SERVICE BRAKES - On-vehicle Service 1. Visually check the brake pad thickness through the inspec- tion hole in the caliper body. Standard value: 10.0 mm (.39 in.) Limit: 2.0 mm (.08 in.) Caution 1. Replace the pad if worn beyond the limit. At this time, replace the pads on right and left wheels as a set.
Page 894 SERVICE BRAKES 10. Using a spring scale, measure the rotary sliding resistance of the hub in the forward direction. 11. Obtain the drag force of the disc brake (the difference between the values measured in 10 and 4). Standard value: 70 N (15.4 Ibs.) or less ’ 12.
Page 895 Using the following method, measure the drag force of the disc brake after installation of the brake assembly. 4. With the brake assembly removed, use a spring scale to measure the rotary sliding resistance of the hub in the forward direction. 5.
Page 896 SERVICE BRAKES FRONT BRAKE DISC THICKNESS CHECK Using a micrometer, measure disc thickness at eight posi- tions, approximately 45” apart and 10 mm (.39 in.) in from the outer edge of the disc. Standard value: Limit: Thickness variation (At least 8 positions) The difference between any thickness measure- ment should not be more than .015 mm (.OOOS in.).
Page 897 SERVICE BRAKES - On-vehicle Service (2) Remove the brake disc, and then place a dial gauge as shown in the illustration; then move the hub in the axial direction and measure the play. Limit: 0.05 mm (.002 in.) If the play is equivalent to or exceeds the limit, replace the front hub unit bearing.
Page 898 SERVICE BRAKES - On-vehicle Service 4. Remove the following parts from caliper support, (1) Outer shim (2) Pad assembly (3) Pad & wear indicator assembly (4) Clip (5) Inner shim A (6) Inner shim B (7) Outer shim A (8) Outer shim B (Up to 1993 models) (From 1994 models) c 0 0 0 0 2 1 5 ~...
Page 899 SERVICE BRAKES - On-vehicle Service REAR BRAKE DISC THICKNESS CHECK 1. Remove dirt and rust from brake disc surface. 2. Measure disc thickness at 4 locations or more. Standard value: Limit: Replace the discs and pad assembly for both sides left and right of the vehicle if they are worn beyond the speci- fied limit.
Page 900 SERVICE BRAKES - On-vehicle Service If the problem cannot be corrected by changing the phase of the brake disc, replace the disc or turn rotor using an on the car type brake lathe. Be sure to follow the exact brake lathe manufacturer instructions. Rotors turned on the vehicle will often have a lower run-out than a new brake disc.
Page 901 SERVICE BRAKES - On-vehicle Service Replace shoe and lining assembly or brake disc if very irregular contact area is observed. NOTE Clean off chalk after check. WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT 1. Lift up the vehicle and release the parking brake. 2.
Page 902 SERVICE BRAKES POINTS IN WAVEFORM MEASUREMENT tude Waveform amplitude fluctuates ex- Axle hub eccentric or with large runout (this is no problem if the amplitude is 100 mV or NOTE The wheel speed sensor cable moves following motion of the front or rear suspension. Therefore, it is likely that it has an open circuit only when driving on rough roads and it functions normally on ordinary roads.
Page 903 SERVICE BRAKES Scan tool actuator Pressure increase 3 sec. Pressure decrease Pedal operation Pedal operation pattern 1 pattern 2 Release 6 sec. pedal is released (7) If any abnormality is found in the check, take corrective action according to the following “Judgement in Inspection by Feel”...
Page 904 SERVICE BRAKES - On-vehicle Service BY USING BRAKE FORCE TESTER INSPECTION When using the scan tool [Multi-use tester (MUT) <Up to 1993 models> or MUT-II <All models>] NOTE (1) The brake force tester roller and tire must be dry during the test.
Page 905 SERVICE BRAKES - On-vehicle Service Judgement in Inspection by Using Brake Force Tester Normal Abnormal Scan tool Probable Operation Remedy display condition condition cause 1) Brake force Brake force in After brake force Incorrect HU Connect tester indication changes as Step 1 shows very brake tube correctly...
Page 906 SERVICE BRAKES Caution Turn the ignition switch off before connecting or discon- 1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points or place the wheels which are checked on the rollers of the braking force tester.
Page 907 SERVICE BRAKES - On-vehicle Service Depressed Released Scan tool actuator test Pressure increase Pressure hold Pressure decrease Lock 3 sec. Drag force when the pedal is free If the result of inspection is abnormal, correct according to the “Diagnosis Table.” Diagnosis Table Scan tool Operation...
Page 908 SERVICE BRAKES POWER RELAY CHECK <up to Oct. 1994> Remove the relay box cover in the engine compartment and remove the power relay. 2. Apply the battery voltage to the terminal (1) and check for continuity between the following terminals when the terminal (3) is short-circuited to ground.
Page 909 SERVICE BRAKES - On-vehicle Service VALVE RELAY AND MOTOR RELAY CHECK 1. Remove the splash shield (FR) and remove the relay box cover by inserting a screwdriver between the hydraulic unit and cover to pry off the lock. Remove the relays. The one closest to you (larger one) is the motor relay and the one farthest from you (smaller one) is the valve relay.
Page 910: Brake Pedal
SERVICE BRAKES - Brake Pedal BRAKE PEDAL REMOVAL AND INSTALLATION Pre-removal Operation Steering Column Assembly Installation Steering Column Assembly Removal (Refer to GROUP 37A - Steering Wheel and Shaft:) (Refer to GROUP 37A - Steering Wheel and Shaft.) (Refer to GROUP 21 - Clutch Pedal.) 0 0 0 0 2 1 2 9 Stop light switch removal steps 1.
Page 911 SERVICE BRAKES 30 Nm 22 ft.lbs. ‘12 Nm 00002130 Stop light switch removal steps 1. Stop light switch connector 2. Stop light switch Brake pedal removal steps 12. Lever assembly 4. Cotter pin 13. Brake assembly 5. Washer 14. Bushing 6.
Page 912 SERVICE BRAKES INSTALLATION SERVICE POINT Install the return spring with the shorter hook on the brake pedal. column racket Return spring INSPECTION Check the bushing for wear. Check the brake pedal for bend or twisting. Check the brake pedal return spring for damage. STOP LIGHT SWITCH CHECK (1) Connect a circuit tester to the stop light switch.
Page 913: Master Cylinder And Brake Booster
35-87 SERVICE BRAKES MASTER CYLINDER AND BRAKE BOOSTER Brake Pedal Adjustment (defer to I?3563.) 15-18 Nm 11-13 ft.1b.s. 10 ft.lbs. 00002132 Brake booster removal steps Master cylinder removal steps 4. Master cylinder 1. Low-pressure hose 5. Vacuum hose 2. Brake fluid level sensor connector 6.
Page 914 SERVICE BRAKES REMOVAL SERVICE POINT Remove the nuts and bolts securing low-pressure hose shown in the illustration, and using a wire, suspend the hose from the hood to a position where it does not hamper the removal and installation of the brake booster. Caution Move the hose slowly with care not ‘to bend it.
Page 915 SERVICE BRAKES Measure the dimension (D) between the master cylinder mounting surface on brake booster and the push rod end. NOTE To obtain (D), first take measurement with a square placed on the brake booster. Then, subtract the thickness of the square to arrive at (D).
Page 916 SERVICE BRAKES - Master Cylinder and Brake Booster DISASSEMBLY SERVICE POINTS Remove the piston stopper bolt, while depressing the piston. Remove the piston stopper ring, while depressing the piston. NOTE If it is hard to remove the secondary piston from the cylinder, gradually apply compressed air from the outlet port on the secondary end of the master cylinder.
Page 917 SERVICE BRAKES Line BRAKE LINE REMOVAL AND INSTALLATION Post-installation Operation Brake Fluid Supplying Bleeding (Refer to P.35-66.) Caution 1. Brake hose Do not disassemble the proportioning valve because its 2. Brake tube (strut) performance depends on the set load of the spring. 3.
Page 918 SERVICE BRAKES - Brake Line <Vehicles with ABS> Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Bleeding (Refer to P.3566.) Flared brake line nuts 11 ft.lbs. ,4F038 00003717 Connecting part of hydraulic unit <From 1996 models> 1480167 1. Brake hose 8.
Page 919: Front Disc Brake
SERVICE BRAKES INSTALLATION SERVICE POINT Connect the tubes to the HU as shown in the illustration. 1. HU - front brake (L.H.) 2. HU - rear brake (R.H.) 3. HU - front brake (R.H.) 4. HU - rear brake (L.H.) 5.
Page 920 SERVICE BRAKES - Front Disc Brake INSTALLATION SERVICE POINT Using the following method, measure the drag force of the disc brake after installation of the brake assembly. (1) With the brake assembly removed, use a spring scale to measure the rotary sliding resistance of the hub in the forward direction.
Page 921 DISASSEMBLY AND REASSEMBLY <FWD> Brake caliper kit Pad kit Pad assembly disassembly steps Caliper assembly disassembly steps 4. Caliper support (pad, clip, shim) 3. Bushing 11. Pad & wear indicator 4. Caliper support (pad, clip, shim) 12. Pad assembly 5. Pin boot 13.
Page 922 SERVICE BRAKES - Front Disc Brake Lubrication points Grease: Repair kit grease (orange) Brake fluid: Conforming to DOT3 or DOT4 Grease: Repair kit grease (orange) Grease: Repair kit grease (orange) TSB Revision...
Page 923 SERVICE BRAKES - Front Disc Brake DISASSEMBLY SERVICE POINTS When disassembling the front disc brakes, disassemble both sides (left and right) as a set. Send compressed air from the port to which brake hose is installed and remove the pistons and piston boots. Caution Send the air gradually, and using the handle of a plastic hammer etc., keep the protrusions of the two pistons...
Page 924 SERVICE BRAKES - Front Disc Brake PAD WEAR CHECK 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: 10.0 mm (.39 in.) Limit value: 2.0 mm (.08 in.) Caution 1.
Page 925 SERVICE BRAKES - Front Disc Brake DISASSEMBLY AND REASSEMBLY cAWD> Seal and boot kit 00002144 Pad kit Brake caliper kit Disassembly steps 1. Clip 8. Outer pad 2. Pad pin 9. Retaining ring 3. Cross spring 10. Piston boot 12. 11. Piston Piston seal 6.
Page 926 SERVICE BRAKES seal and boot kit is coated with Brake fluid: Conforming to DOT3 or DOT4 00002145 Grease: Brake grease SAE J310, NLGI No. 1 Revision...
Page 927 SERVICE BRAKES DISASSEMBLY SERVICE POINTS Holding the cross spring with hand, remove the pad pin. Using a screwdriver, remove the pad assembly. Install a wood block as shown and send compressed air through the port, to which brake hose is attached, to remove the pistons.
Page 928 SERVICE BRAKES - Front Disc Brake PAD WEAR CHECK Measure the thickness at the thinnest and worn area of the pad. Replace pad assembly when pad thickness is less than the limit value. Standard value: 10.0 mm (.39 in.) Limit: 2.0 mm (08 in.) Caution 1.
Page 929: Rear Disc Brake
SERVICE BRAKES - Rear Disc Brake REAR DISC BRAKE Post-installation Operation Brake Fluid Filling Brake Line Bleeding (Refer to P.3566.) Flared brake line nuts 11 ft.lbs. 50-60 Nm 36-43 ft.lbs. 36-43 ft.lbs. 0 0 0 0 2 1 4 6 Removal steps 1.
Page 930 35-104 SERVICE BRAKES - Rear Disc Brake DISASSEMBLY AND REASSEMBLY (Up to 1993 models) 23 21 18 . 00002163 Grease: Brake grease SAE J310, Seal and boot kit Pad kit Brake caliper kit Grease Pad assembly disassembly steps Caliper assembly disassembly steps 3.
Page 931 SERVICE BRAKES - Rear Disc Brake (From 1994 models) 23 21 18 Grease: Brake grease SAE 5310, NLGI No. 1 00002148 Pad kit Seal and boot kit Brake caliper kit Grease Pad assembly disassembly steps Caliper assembly disassembly steps 9. Pad pin 9.
Page 932 SERVICE BRAKES - Rear Disc Brake 27 Nm 20 ft.lbs. 00002147 Grease: Brake grease SAE 5310, NLGI No. 1 Seal and boot kit Pad kit Brake caliper kit ‘4 Grease Pad assembly disassembly steps Caliper disassembly steps 1. Lock pin 1.
Page 933 SERVICE BRAKES - Rear Disc Brake Lubrication Points , <FWD> ‘he piston seal contained in Grease: boot kit is coated Repair kit grease (orange) rith special grease. Do noi 3rake fluid: Grease: Repair kit grease (orange) 00002164 Caution The piston seal contained in the seal and boot kit is coated with special grease.
Page 934 SERVICE BRAKES - Rear Disc Brake DISASSEMBLY SERVICE POINTS BOOT / PISTON REMOVAL Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston. Caution Blow compressed air gently. air through the brake hose connecting hole to remove the pistons.
Page 935 SERVICE BRAKES PAD WEAR CHECK Measure the thickness at the thinnest worn area of the pad. Replace pad assembly when pad thickness is less than the limit value. Standard value: 10.0 mm (.39 in.) Limit: 2.0 mm (.08 in.) Caution 1.
Page 936 SERVICE BRAKES - Hydraulic Unit (HU), Relay CABS> HYDRAULIC UNIT (HU), RELAY CABS> REMOVAL AND INSTALLATION Post-installation Operation (Refer to Group 42 - Fender.) Splash Shield Installation (Refer to Group 42 - Fender.) Air Duct installation Relay Box Installation Brake Fluid Filling Flared brake line nuts 15 Nm 11 ft.lbs.
Page 937 35-111 SERVICE BRAKES - Hvdraulic Unit (Huh Relav CABS> REMOVAL SERVICE POINTS Pull. up the relay box with harness attached and inserting a hand under the relay box, remove the brake tube using the flare nut wrench. Remove the hydraulic unit together with the bracket from the wheel house.
Page 938 35412 SERVICE BRAKES - Hydraulic Unit (HU), Relay CABS> <From 1996 models> <From 1996 Connect the tubes to the HU as shown in the illustration. 2. HU - rear brake (R.H.) 3. HU - rear brake (L.H.) 4. HU - front brake (R.H.) 5.
Page 939 SERVICE BRAKES - Wheel Speed Sensor CABS> WHEEL SPEED SENSOR CABS> REMOVAL AND INSTALsLATION 12 Nm 9 ft.lbs. 9 ft.lbs. Rear speed sensor removal steps 1. Front rotor 2. Rear rotor 6. Clip 8. Rear speed sensor Front speed sensor removal steps 3.
Page 940 Pre-removal Operation Splash Shield Removal (Front Only) (Refer to Group 42 - Fender.) ABS Inspection (Refer to P.35-7.) 12 Nm 9 ft.lbs. Rear speed sensor removal steps 1. Front rotor 2. Rear rotor 6. Clip 7. Cable band Front speed sensor removal steps 3.
Page 941 SERVICE BRAKES - Wheel Speed Sensor CABS> SENSOR REMOVAL Caution When removing the speed sensor from the knuckle, be careful not to strike the tip of the pole piece against the rotor teeth or any other parts. INSTALLATION SERVICE POINTS Insert a feeler gauge between the speed sensor pole piece and the rotor tooth surface and tighten the speed sensor to specified torque where the clearance is as specified all...
Page 942 SERVICE BRAKES - Wheel Speed Sensor CABS> INSPECTION Front Rear SPEED SENSOR CHECK (1) Check the tip of the speed sensor pole piece for deposits of metal or other foreign matter and clean the pole piece as necessary. Also check the pole piece for damage and replace if damaged.
Page 943 SERVICE BRAKES - G Sensor <AWD-ABS> G SENSOR <AMID-ABS> 5 Nm 4 ft.lbs. Removal steps 1. G sensor connector 2. G sensor 3. G sensor bracket INSPECTION G SENSOR CHECK (1) Lay the G sensor on a level surface and check for continu- ity between its terminals.
Page 944 SERVICE BRAKES - G Sensor cAWD-ABS> (3) Incline the G sensor toward the vehicle rear gradually and check that continuity is lost at an angle of 30” or more. (1) Disconnect G-sensor connector and connect special tool between terminals of the disconnected connector. (2) With the ignition switch turned ON, read output voltage between terminals No.
Page 945 SERVICE BRAKES - Electronic Control Unit (ABS-ECU) CABS> ELECTRONIC CONTROL UNIT (ABS-ECU) <ABS> Rear Seatback (RH) installation Rear Seat Cushion Installation ABS Inspection (Refer to P.357.) 00003719 Removal steps 1. Control unit connector connection 2. Electronic control unit 3. ABS-ECU bracket REMOVAL SERVICE POINT Insert a screwdriver into the lock section as illustrated and pull out the connector from below.
Page 946 NOTES...
Page 947: Parking Brakes
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B -Suppiemental Re- straint System (SRS) and GROUP 00 -Maintenance service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 948 36-2 PARKING BRAKES - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS items Specifications Parking brakes Mechanical brake acting on rear wheels Brake lever type Lever type Cable arrangement SERVICE SPECIFICATIONS LUBRICANTS Items Specified lubricant Rear brake shoe and backing plate contact surfaces Brake grease SAE J310, NLGI No. 1 Contact surface between shoe &...
Page 949 36-3 PARKING BRAKES - Special Tools / Troubleshooting SPECIAL TOOLS Tool number and Application Tool Supersession name Removal of the rear axle shaft assembly MB990767 End yoke holder MB990241 General service Axle shaft puller A: N1B990244 Puller bar MB990211 MB990211 -01 Sliding hammer MB991 354 General service...
Page 950 36-4 PARKING BRAKES - On-vehicle Service ON-VEHICLE SERVICE PARKING BRAKE LEVER STROKE CHECK Pull the parking brake lever with a force of approx. 200 N (45 Ibs.), and count the number of notches. Caution The 200 N (45 Ibs.) force of the parking brake lever must be strictly observed.
Page 951 On-vehicle Service / Parking Brake 36-5 PARKING BRAKES LINING RUNNING-IN Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when brake performance is insufficient. 1. Adjust the parking brake stroke to the specified value. 2.
Page 952 36-6 PARKING BRAKES - Parking Brake Lever and Parking Brake Cable 36-43 ftlbs. Parking brake cable removal steps 1. Cable adjuster 12. Adjuster 6. Rear speed sensor (Refer to GROUP 35Speed Sensor.) 7. Rear brake assembly 8. Rear brake disc 16.
Page 953 36-7 PARKING BRAKES - Parking Brake Lever and Parking Brake Cable REMOVAL SERVICE POINT Expand the shoe & lining assembly and remove the shoe hold down cup. INSTALLATION SERVICE POINTS The shoe-to-anchor spring must be installed in the sequence shown in the illustration. Caution Each shoe-to-anchor spring has a unique spring load and the spring “a”...
Page 954: Parking Brake
36-8 PARKING BRAKES - Parking Brake PARKING BRAKE REMOVAL AND INSTALLATION Post-installation Operation Parking Brake Lever Stroke Adjustment (Refer to Grease: Brake grease SAE 5310, NLGI No. 1 Removal steps 14. Shoe hold-down spring 15. Shoe hold-down pin 3. Rear brake assembly 4.
Page 955 36-9 PARKING BRAKES 12 Nm 98 Nm 9 ft.lbs. 260-300 Nm 36-43 ft.lbs. 55-65 Nm 40-47 ft.lbs. 00002157 36-43 ftlbs. Grease: Brake grease SAE 5310, NLGI No. 1 Removal steps 1. Rear speed sensor 15. Shoe hold-down 2. O-ring 3. Rear brake assembly 4.
Page 956 PARKING BRAKES REMOVAL SERVICE POINTS Caution When removing the speed sensor from the knuckle, use care not to hit the pole piece at its tip against the rotor teeth or other parts. With the special tool, secure the axle shaft and remove the companion flange self-locking nut.
Page 957 PARKING BRAKES With the special tool, secure the axle shaft and tighten the companion flange self-locking nut. MB990 After tightening the flange nut, align with the spindle’s indentation and crimp. Spindle Insert a filler gauge between the speed sensor pole piece and rotor teeth and tighten the speed sensor at such position where the gap is as specified below over the entire circumference.
Page 958 NOTES...
Page 959 STEERING CONTENTS STEERING ............37A CWHEEL STEERING SYSTEM (ACTIVE 4WS) .
Page 960 37-2...
Page 961 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 962 STEERING - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS NOTE SERVICE SPECIFICATIONS Items 11 (.43) Steering wheel free play (with engine stopped) mm (in.) Steering angle Inner wheel FWD, AWD*’ Outer wheel Inner wheel Outer wheel Nm (in.lbs.) 1 .O-3.0 (9-26) 35 (8) or less Stationary steering effort N (Ibs.) When belt tension is inspected Drive belt deflection mm (in.)
Page 963 STEERING - Specifications LUBRICANTS Items Specified lubricant Quantity Gear box Bearing Automatic transmission fluid “DEXRON II” As required O-ring Oil seal Special tool (MB991213) Pinion and valve assembly seal ring part Bellows Silicone grease As required Oil pump Power steering fluid Automatic transmission fluid’“DEXRON II”...
Page 964 STEERING - Snecial Tools SPECIAL TOOLS Preload socket General service TSB Revision...
Page 965 STEERING - Special Tools Tool number and Tool Supersession Application name MB991199 General service To press in the oil seal for the rack Oil seal installer MB991197 General service To press in the oil seal for the rack MB991 202 General service Press-fitting of rack housing bearing Oil seal and...
Page 966 STEERING - On-vehicle Service ON-VEHICLE SERVICE STEERING WHEEL FREE PLAY CHECK With engine running (hydraulic operation), set front wheels straight ahead. Measure the play on steering wheel circumference before wheels start to move when slightly moving steering wheel in both directions. Limit: 30 mm (1.2 in.) When the play exceeds the limit, check for play on steering shaft connection and steering linkage.
Page 967 STEERING If the measured displacement exceeds the limit, replace the tie-rod end. Caution Even if the variation is within the limit, check ball joint starting torque. TIE ROD END BALL JOINT STARTING TORQUE CHECK 1. Disconnect tie rod and knuckle with special tool. Move ball joint stud several times and install nut on stud.
Page 968 STEERING - On-vehicle Service Indexing Steering Wheel to Center It The steering wheel shaft has 36 splines, a lowing the steering wheel to be indexed in ten-degree increments. 1. Remove the steering wheel. Without disturbing the position of the steering wheel shaft, re-install the wheel as near on-center as possible.
Page 969 STEERING - On-vehicle Service STATIONARY STEERING EFFORT CHECK 1. With the vehicle stopped on a flat, paved surface, turn the steering wheel to the straight ahead position. 2. Start the engine and set it to 1,000 + 100 rpm. Caution After checking the engine speed, there must be a return to the standard idling speed.
Page 970 STEERING FLUID LEVEL CHECK Fluid fluctuation Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50-60°C - - - - - 2.
Page 971 STEERING - On-vehicle Service BLEEDING 1. Jack up the front wheels and support them by using a floor stand. 2. Manually turn the oil pump pulley a few times. 3. Turn the steering wheel all the way to the left and to the right several times.
Page 972 STEERING OIL PUMP PRESSURE TEST Shut-off valve Pressure gauge (Fully close) CHECKING THE OIL PUMP RELIEF PRESSURE 1. Disconnect the pressure hose from the oil pump, and then connect the special tools. 2. Bleed the air, and then turn the steering wheel several times while the vehicle is not moving so that the tempera- ture of the fluid rises to approximately 50-60°C 3.
Page 973 STEERING CHECKING THE STEERING GEAR RETENTION Shut-off valve HYDRAULIC PRESSURE (Fully open) Pressure gauge Temperature (MB990662 1. Disconnect the pressure hose from the oil pump, and then connect the special tools. 2. Bleed the air, and then turn the steering wheel several times while the vehicle is not moving so that the tempera- ture of the fluid rises to approximately 50-60°C 3.
Page 974 STEERING - Steering Wheel and Shaft STEERING WHEEL AND SHAF REMOVAL AND INSTALLATION Post-installation Operation Checking Steering Wheel Position with Wheels Straight Ahead 29 ft.lbs. 8 ft.lbs. 12 Nm 8 ft.lbs. 18 N 13 ft.lbs. Removal steps 9. Key interlock cable* (Refer to GROUP 1.
Page 975 STEERING - Steering Wheel and Shaft REMOVAL SERVICE POINT (A, STEERING WHEEL REMOVAL Remove the steering wheel by using the special tool. Caution Do not hammer on the steering wheel to remove it; doing so may damage the collapsible mechanism. INSTALLATION SERVICE POINT ,A( STEERING WHEEL INSTALLATION Line up the “NEUTRAL”...
Page 976 STEERING - Steering Wheel and Shaft DISASSEMBLY AND REASSEMBLY 18 Nm 00002169 Disassembly steps 1. Boot 2. Cover assembly 8. Steering column assembly 4. Joint assembly DISASSEMBLY SERVICE POINT CYLINDER REMOVAL If it is necessary to remove the steering lock cylinder, use a hacksaw to cut the special bolts at the steering lock bracket side.
Page 977 STEERING - Steering Wheel and Shaft REASSEMBLY SERVICE POINTS BRACKET / SPECIAL BOLT INSTALLATION (1) When installing the steering lock cylinder and steering lock bracket to the column tube, temporarily install the steering lock in alignment with the column boss. (2) After checking that the lock works properly, tighten the special bolts until the head twists off.
Page 978 STEERING - Power Steering Gear Box POWER STEERING GEAR BOX REMOVAL AND INSTALLATION Post-installation Operation Transfer Assemblv installation (Refer to GROUP 22 - Transfer.) Front Exhaust Pioe Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.) Power Steering Fluid Supplying (Refer to P.37A-10.) Power Steering Fluid Line Bleeding (Refer to P.37A-1 I .) Steering Wheel Position with Wheels Straight Ahead...
Page 979 STEERING REMOVAL SERVICE POINTS Using the special tool, disconnect the tie rod from the knuckle. (1) Move the rack completely to the right and then remove the gear box from the crossmember. (2) While tilting the gear box downward, remove it to the left.
Page 980 STEERING - Power Steering Gear Box DISASSEMBLY AND REASSEMBLY <Vehicles with 4WS> Steering gear seal 22 Nm 16 ft.lbs. 15 Nm 9 ‘1 ft.lbs ’ 50-55 Nm 36-40 ft.lbs. 0 0 0 0 2 1 7 2 Disassembly steps 1. Tie rod end locking nuts Oil seal rod ends 19.
Page 981 STEERING - Power Steering Gear Box LUBRICATION AND SEALING POINTS Fluid: Automatic transmission fluid “DEXRON II” Sealant: 3M ATD, Part No. 8663 or equivalent Fluid: Automatic transmission fluid “DEXRON II” Grease: Silicone grease Fluid: Automatic transmission fluid “DEXRON II” 21310564 Sealant: Fluid: 3M ATD, Part No.
Page 982 STEERING - Power Steering Gear DISASSEMBLY SERVICE POINTS Remove the dust shield from the tie rod end. Using a screwdriver or similar tool, loosen and then remove the boot retaining band. Unstake the tab washer which fixes the tie rod and rack with a chisel.
Page 983 STEERING - Power Steering Gear Box Using a plastic hammer, gently tap the pinion to remove it. Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously. Rack stopper (1) Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.
Page 984 STEERING Use a brass bar to remove the ball bearing from the gear MB990939 or brass bar housing. Ball bearing Use the special tool to remove the needle roller bearing from the rack housing. Caution Do not open special tool excessively to prevent damaging housing interior.
Page 985 STEERING - Power Steering Gear Box Use the special tools to press fit ball bearing. (1) Apply ‘a coating of the specified fluid to the outside of the oil seal and O-ring. MB990927 Specified fluid: Automatic transmission fluid “DEXRON II” (2) Using the special tool, press fit oil seal until it touches -ring rack bush end.
Page 986 STEERING - Power Steerina Gear Box Insert circlip to rack stopper hole through cylinder hole. Turn rack stopper clockwise and insert circlip firmly. Caution Insert circlip to rack stopper hole while turning rack stopper clockwise. 2 1 3 6 0 1 4 8 0 0 0 0 2 1 7 5 Apply a coating of the specified fluid to the outside of the MB990938...
Page 987 STEERING - Power Steerina Gear (1) Apply the semi-drying sealant to the threaded part of End plug the end plug. Specified sealant: 3M ATD Part No. 8663 or equivalent (2) Secure the threaded portion of the end plug at two places by using a punch.
Page 988 STEERING - Power Steering Gear Box End of insertion Screw in tie rod end to have its right and left length as Lock nut illustrated. Lock with lock nut. INSPECTION RACK CHECK Check the rack tooth surfaces for damage or wear. Check the oil seal contact surfaces for uneven wear.
Page 989: Power Steering Oil Pump
STEERING POWER STEERING OIL PUMP Operation Power Steering Fluid Draining Power Steering Fluid Supplying Drive Belt Tension Adjusting (Refer to P.37A-9.) Power Steering Fluid Line Bleeding (Refer to P.37A-11.) Oil Pump Pressure Checking (Refer to P.37A-12.) 22 Nm 43 N’m 31 ft.lbs.
Page 990 STEERING - Power Steering Oil Pump DISASSEMBLY AND REASSEMBLY Oil pump seal kit Fluid: Automatic transmission fluid “DEXRON II” 60 Nm 43 ftlbs. 20 Nm 14 fi.1b.s. 00002179 16-22 ft.lbs. Disassembly steps 16. Piston rod 1. Pump cover 17. Snap 18.
Page 991 STEERING REASSEMBLY SERVICE POINTS Side plate Apply specified fluid on O-rings to install. I.D. x Width mm (in.) 11 x 1.9 13x 1.9 (.512x .075) Suction connector mounting portion of oil pump body 17.8 x 2.4 13.5 x 1.5 Terminal assembly 3.8 x 1.9 16.8 x 2.4 0 0 0 0 2 1 8 0...
Page 992 STEERING - Power Steering Oil Pump Direct round edge Install the vanes on the rotor, paying close attention to the installation direction. INSPECTION Check the flow control spring for wear. Check the shaft of the pulley for play and round movement. Check the groove of rotor vane for “stepped”...
Page 993 STEERING - Power Steering Hoses POWER STEERING HOSES REMOVAL AND INSTALLATION Pm-removal and Post-installation Operation Power Steering Fluid Draining, Supplying, and Bleeding (Refer to P37A-10,ll.) 12 Nm <Vehicles without 4WS> 8 ft.lbs. <Vehicles with 4WS> 24 Nm 22 Nm 35 Nm 17 ft.lbs.
Page 994 NOTES...
Page 995 STEERING SYSTEM (4WS) CONTENTS REAR OIL PUMP ......11 CONTROL VALVE ....*..9 SPECIAL TOOLS .
Page 996 SPECIFICATIONS GENERAL SPECIFICATIONS SERVICE SPECIFICATIONS Standard value Items Approx. 1 .O (1.06) Rear oil pump displacement [at speedometer reading of 31 mph (50 km/h) for 30 seconds] dm3 (qts.) LUBRICANTS Items 1.45 dm3 (1.53 qts.) Power steering fluid Automatic Transmission fluid “DEXRON II” As required Dust cover Silicone grease...
Page 997 4WS - Troubleshootina TROUBLESHOOTING Wheel alignment Before inspecting, check the following items: Oil pump drive belt tension Ensure that the suspension has not been modi- Power steering fluid level, and air in the system fied ‘Tire and wheel size, specifications, air pressure, Engine idle speed and even idle balance and amount of wear Oil leakage...
Page 998 ON-VEHICLE SERVICE BLEEDING (1) Bleed air from power steering system. (Refer to GROUP 37A - On-vehicle Service.) (2) Lift up the vehicle. (3) Start the engine and let it idle. (4) Loosen the bleeder screw on the left side of the control valve and set the special tool to the bleeder screw.
Page 999 FUNCTION CHECK (1) Raise the vehicle so that all four wheels may turn freely. (2) Start the engine, running the vehicle at an indicated speed of about 80 km/h (50 mph). (3) Turn the steering wheel all the way to left and right and turn it swiftly, checking to ensure that the rear wheels steer to the same directions as the front wheels.
Page 1000 POWER CYLINDER REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation Cleaning of Pipings with Steam (Refer to GROUP 15 - Exhaust Pipe and Muffler.) Power Steering Fluid Draining Power Steering System Refilling and Bleeding (Refer to GROUP 37A - On-vehicle Service.) (Refer to GROUP 37A - On-vehicle Service.) Main Muffler Assembly Removal 4WS System Bleeding (Refer to P.37B-4.)
Page 1001 4WS - Power Cvlinder REMOVAL SERVICE POINTS (A, CROSSMEMBER MOUNTING NUT REMOVAL (1) Before removing the self-locking nuts, support the differential case with a transaxle jack. (2) Remove the self-locking nuts. Secure the power cylinder on the tie rod side with a spanner and remove the power cylinder mounting nut.
Page 1002 (3) If the swing resistance exceeds the standard value, re- place the tie rod. (4) If the swing resistance is less than the standard value, the ball joint may be reused as long as it is not loose and operates smoothly. POWER CYLINDER SLIDE RESISTANCE CHECK (1) Place the piston in a neutral position.
Page 1003: Control Valve
Power Temporarily attach the tie rod end assembly to the cylinder assembly at the place of dimension as illustrated. NOTE To adjust the assembly dimensions of the tie rod end assembly, remove the dust cover clip and rotate the rod. CONTROL VALVE REMOVAL AND INSTALLATION Post-installation Operation...
Page 1004 4WS - Rear Oil Line REAR OIL LINE REMOVAL AND INSTALLATION Post-installation Operation Power Steering System Refilling and Bleeding (Refer to GROUP 37A - On-vehicle Service.) (Refer to GROUP 37A - On-vehicle Service.) 4WS System Bleeding (Refer to P.378-4.) 4WS System Operation Checking (Refer to P.378~5.) 35 Nm 25 ft.lbs.
Page 1005 REAR OIL PUMP ‘REMOVAL AND INSTALLATION Post-installation Operation Power Steering Fluid Draining Main Muffler Assembly Installation (Refer to GROUP 15 - Exhaust Pipe and Muffler.) Power Steering System Refilling and Bleeding Main Muffler Assembly Removal (Refer to GROUP 37A - On-vehicle Service.) (Refer to GROUP 15 - Exhaust Pipe and Muffler.) 4WS System Bleeding (Refer to P.37B-4.) 4WS System Operation Checking...
Page 1006 NOTES...
Page 1007 (2) Service or maintenance of,any SRS component or SF&related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Re- straint System (SRS) and GROUP 00 -Maintenance Service, before beginning any service or maintenance of any com- ponent of the SRS or any SRS-related component.
Page 1008 BODY - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS HOOD, DOOR, LIFTGATE Items Specifications Hood Rear hinged, front opening type (with gas damper) Door Construction Front-hinged, sashless Regulator system Wire type Locking system Pin-fork type Inner-hinged, with gas damper GLASS POWER WINDOW Power window motor Specifications Items Permanent magnet type (Built-in circuit breaker)
Page 1009 BODY - Specifications Power window relay Items Specifications Maximum contact current A Rated coil current A Max. 0.2 Voltage drop between terminals V 0.2 or less (At 12 V and the rated load current) CENTRAL DOOR LOCKING SYSTEM Items Specifications Door lock power 8-16 relay...
Page 1010 42-4 BODY - Specifications / Special Tools Items Specified sealant Remarks Quarter window glass 3M SUPER FAST URETHAN PRIMER 8608 or equivalent SPECIAL TOOLS Tool number and Tool Application name MB990834 Adjustment of door fit MB990449 Removal of window moulding MB991 341 Checking the power-windows system and the Scan tool...
Page 1011 42-5 BODY - Troubleshooting TROUBLESHOOTING HOOD, LIFTGATE, GLASS AND DOORS Symptom Hood/ Improper closure Difficult locking and unlocking Incorrectly installed hood or liftgate Uneven body clearance Uneven height Window Water leak through glass windshield Water leak through door window glass Water leak through Door window mal- function...
Page 1012 BODY HOW TO LOCATE WIND NOISES (1) Attach cloth tape to every place which might conceivably be the source of wind noise, such as panel seams, projec- tions, moulding seams, glass and body seams, etc. (2) Then make a road test in order to determine that the places not covered by tape are not sources of wind noise.
Page 1013 42-7 BODY - Troubleshootina POWER WINDOW AND CENTRAL DOOR LOCKING SYSTEM With voltmeter Data link connector INPUT SIGNAL When using the scan tool (MUT) or voltmeter connector - Using the scan tool or voltmeter, check whether or not the input signals from each switch are being input to the ETACS unit.
Page 1014 42-8 BODY Disconnect the amplifier and inspect the connector on the wire harness side as shown in the chart below. 18X0820 Terminal No. Signal Conditions Terminal voltage Key reminder switch ON (Key removed) Battery positive (vehicles with theft alarm) voltage OFF (Key installed) Door switch All doors close...

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