Eagle Talon (1995), Talon (1996) Service Manual

Part ia 1’ 13A~CeKUP

Servicq ~Manual

::L

.’

This Service Manual
latest service

‘has

informatlon

been prepared with the

available at the time
of publication. It t is subdivided into various group
categories
disassembly, repair,” and
along with complete
references. Use of thismanual

andeach

section contains diagnostic,

instatjation

specificatiohs

procedures

and tightening

will aid-,in properly!?

performing any servicing necessary to,maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.

This

BACKUP DSM

WHOLE SECTIONS. This

a GENUINE
manual was

Please See

manual IS

to be used

DSM MANUAL. It

lost or

README.N

BACKUP

destroyed.)

or

README.HTML for additional Information.

Thank you. Glm~[e-mail]

ONLY

was

solq to you

CANNOT,,~$onsidered a

.k

as a BACKUP. Please DO

under the fact that

REPLACEMENT

‘-.$‘,

NOT REDISTRIBUTE

you do

indeed OWN

(Unless your original

Engine . . .

Rear

Steering

Suspen@n-

........ ....... .. .......

.:I

......

” -.

“,,, ,I IN’

w..

.:‘i

...

I

:

I

ION

Chrysler Motors Co

design

or to make a
imposing any obligations upon itself to install them on its products
previously manufactured.

@

lW!5 Mitsubishi Motors

ration reserves the right to make changes in

27.

ions

to or

improvemqnts

in its products without

Emission Cont@Systems

. . . . . .

.-

VEHICLE IDENTIFICATION

l//i 1 /

12 3456 7 8 91011

\\\\\I*

*OOLOOOQ

VEHICLE IDENTIFICATION

The vehicle identification number
attached to the left top side of the instrument panel.

VEHICLE

All vehicle identification numbers
number is a code which tells country, make, vehicle type,

IDENTIFICATION C0b~ .&HART

NUMBER--LOCATION

(V.1.N)

is

located

contain 17 di$iti. Thti

on a plate

PLATE

vehicle

!tc.
No.

1
2
3
4
5

Items

Country
Make
Vehicle type
Others
Line

Contents
4: USA

E: EAGLE
3: Passenger car
A: Drive and passenger air hags
K: TALON

L:

TALON <AWD,

<FWD>

I

I

7
8

9

10
11

12

NOTE

*

“Check digit” means a single number or letter X used to
verify the accuracy of transcription of Vehicle identification
number.

VEHICLE IDENTIFICATION NUMBER LIST

VEHICLES FOR FEDERAL

V.I.N. (except sequence

4E3AK44Y*TE

4E3AK54F*TE

4E3AL54F*TE

number)

Brand
Eagle Talon

Eagle Talon

Eagle Talon

<FWD>

cFWD>

<AWD>

.

Engine

2.0

[DOHC-MFI (42OA)l

2.0

[DOHC-MFI-Turbo (4683)] D32AMHGFL4E

dm3

dms

(122.0

(122.0

displ&ement

cu.in.)

cuin.)

Modelcode
D31AMNHML4E

D31 AMRHML4E
D32AMNGFL4E

I

14

-~ -

INTRODUCTION -. Vehicle,

"

jdentifictitjcjti

VEHICLES FOR

V.I.N. (except sequence number)

4E3AK44Y’TE

4E3AK54F*TE

4E3AL54F*TE

VEHICLES FOR CANADA

V.I.N.

(except sequence number)

4E3AK44YTE

4E3AK54F*TE

4E3AL54F’TE

CALIFORNIA

Brand Engine Displacement
Eagle Talon

Eagle Talon

Eagle Talon

Brand
Eagle Talon

Eagle Talon

Eagle Talon

<MID>

<FWD>

d\Wb

-SVD>

+WD>

<AWD>

2.0

dm3

(122.0

[DOHC-MFI

2.0

dm3

(122.0

[DOHC-MFI-Turbo (4G63)]

Engine Displacement

2.0

dms

(122.0

[DOHC-MFI

2.0

dm3

(122.0

[DOHC-MFI-Turbo (4663)]

cu.in.)

(420A)]

cuin.)

cu.in.)

(420A)]

cu.in.)

VEHICLE INFORMATION CODE PLATE

Vehicle information code plate is riveted onto the bulkhead

in the engine compartment.

The

place

shows model code, engine model, transaxle model,

and body color code.

Model code

D31AMNHMLSE
D31 AMRHMLSE

D32AMNGFLSE
D32AMRGFLSE
D33AMNGFLSE
D33AMRGFLSE

Model code

D3l

AMNHM.4!&

D31 AMRHMtiE ::

D32AMNGFLS’
D32AMRGFLSE
D33AMNGFLSE ’ ­D33AMRGFLSE

.

/_

-

VEHICLE SAFETY CERTIFICATION LABEL

1. The vehicle safety certification label is attached to face
of left door pillar.

2. This label indicates Gross Vehicle Weight Rating
(G.V.W.R.), Gross Axle Weight Rating (G.A.W.R.) front,
rear and Vehicle Identification Number (V.I.N.).

ENGIN~E

1. The engine model number is stamped at the front side

MODEL STAMPING

on the top edge of the cylinder block as shown in the
following.

Theft

pro&ion

For original parts

mF!!!w! .iii2uiw

.label

!se!!!EE

rrbnnmrrbnn

OOAO212

For replacement parts

[-i!zszEl

OOAO213

(10000222

Engine model

420A
4G63

The 4G63 or

2.
the engine model number, and the serial number cycles,
as shown below.

1

Engine serial number

420A

Engine displacement

2.0

dm3

(122.0

2.0

dm3

(122.0

engine serial number is stamped near

1 AA0201

to

cu.@.)
cu.in.1

W9999

1

THEFT PROTECTION

In order to protect against theft, a Vehicle Identification Number
(VIN) is stamped in, or attached as a label to, the following

-major parts of the engine and
outer panels:

Engine

ter panel, Hood, Liftgate, Bumpers

In addition, a theft-protection label is attached to replacement

parts for the body outer panel main components, and the
same data are stamped into replacement parts for the engine
and the transaxle.

cylinder block, Transaxle housing. Fender, Door, Quar-

Cautions regarding panel repairs:

When repainting original

1.
ing the theft-protection label, and, after
sure to peel off the masking tape.
The theft-protection label for replacement parts is cov-

2.
ered by masking tape,
as is. The masking tape should be removed after

lng

is finished.

The theft-protection label should not be removed from

3.
original parts or replacement parts.

transaxle,

parts,

do so after first

so.such

parts can be

as well as main

mask-

painting,

be

painted

palnt-

16

INTfiQDt~JJCTION’

r

,Vbhicie 4dentification

LOCATIONS

Target area (A: for original equipment parts, B: for replacement parts)

Engine

<Non-turbo>

Manual transaxle

eNdi%turbot

<Turbo>

<Turbo>

A

Automatic transaxle

<Non-turbo>

6

00x0092

<Turbo>

100 mm

oO”oo1.

ooA0.t~

00003678

WOO3679

Target area (A: for original equipment parts,

B:

for replacement parts)

Fender

31x0521

The

illustraticn~indic&s !qfl-

hand side, outer.

Right hand side is symmetrically opposite.

Quarter panel

\’

t

The label is attached at the inner
side of the parts shown in the figure.

Door

‘. 3

,. /

., ,5

”

,i’.,

“. .. i

‘-,.

;,

i

00003660

,’

I’

i I

:

The illustration indicates right hand side, outer.
Left hand side is symmetrically opposite.

Hood Liftgate

6

,:

A

00003661

31xo4ra

INTRODUCTION.+y

Vehicle

I&#tification/Ptie,@autipw

Target area (A: for original equipment parts, B: for replacement parts)

before Service

~~ t:

’

Front bumper

Rear bumper

00003662

00X0016

PRECAUTIONS BEFORE SERVICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

1. Items to follow when servicing SRS

-

(1) Be sure to read GROUP 238

For safe operations, please follow the directions and heed all warnings.

(2) Always

r&e

the

<designated

(3) Wait at least 80 seconds after disconnecting the battery cable before doing any further work.

The SRS system is designed to retain enough voltage to deploy the air bag even after the battery

has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system

(4) Never attempt to disassemble or repair the SRS components (SRS- ECU air bag module and

clock spring). If faulty, replace it.

(5) Warning labels must be heeded when servicing or handling SRS components. Warning labels

are located in the following locations.

0

Sun visor

l Glove box
l SRS
l Steering wheel
l Air bag module
l Clock spring
l Steering gear and linkage clamp

-

ECU

(6) Store components removed from the SRS in a clean and dry place.

The air bag module should be stored on a flat surface and placed so that the pad surface is

facing upward.
Do not place anything on top of it.

(7) Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle

equipped with an air bag. (Refer to GROUP 238 - Air Bag Module Disposal Procedures.)

(8) Whenever you finish servicing the SRS, check the SRS warning light operation to make sure

that the system functions properly.

2.

Observe the following when carrying out operations on places where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93°C

nents before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning light operation to make sure that the system
functions properly.

Supplemental Restraint System (SRS).

special tools and test equipment.

.immediately

after the battery cable is disconnected.

(200°F),

so remove the

SRS compo-

26

INTRODUCTION - General Data and Specifications

”

GENERAL

GENERAL

<FWD>

SPECIFICATIONS

DATA

AND

SPECIFICATIONS

1073

00x0

_

-,

I

Fuel

system

Fuel supply system

Electronically Electronically
controlled multi- controlled
port fuel
tion

injec- port

fuel injection port fuel

multi-

Electronically

controlled multi- controlled

injec-

tion

Electronically
port fuel injection

multi-

<AWD>

INTRODUCTION - General Data

atl;d”Spe&fkations

27

Items

Vehicle dimensions Overall length mm (in.)

Overall width mm (in.)
Overall height (unladen) mm (in.)
Wheelbase mm (in.)

Tread - Front mm (in.)
Tread - Rear mm (in.)
Overhang - Front mm (in.)
Overhang - Rear mm (in.)
Minimum running ground clearance 9

mm (in.)

Angle of approach degrees

i.”

Vehicle weight kg
(Ibs.)

’

Angle of departure degrees

Curb weights 1,420 (3,130)
Gross vehicle weight rating
Gross axle weight rating

-,Front

D33AMNGFL4E
D33AMNGFLSE
D33AMNGFL5E

1

4,375 (172.2)
2 1,745 (68.7)
3 1,310 (51.6)
4

2,510

7

5

-~-~-~T ~~

1,5 15

6

1,510 (59.4)

930 (36.6)

8 935 (36.8)

145 (5.7)

10 12.2
11 16.2

1,850 (4,079)

1,050 (2,315)

(98.8)

(59.6)

D33AMRGFL4E
D33AMRGFLSE

D33AMRGFLSE

4,375 (172.2)

1,745 (68.7)

1,31 O-(51.6)
2,510

(98.8)
1,515 (59.6)

i ,a

0 (59.4)

930 (36.6)

935 (36.8)

145 (5.7)

12.2

16.2

1,455 (3,208)
1,850 (4,079)

1,050 (2,315)

._

“-

.I-.

;

”

Seating capacity
Engine

Transaxle

Fuel system

Gross axle weight rating - Rear 850 (1,874)

4

4663

Model No.

Piston displacement

Model No.

Type

Fuel supply system

ems (cuin.)

(DOHC)
1997 (121.9)

W5M33
5-speed

Electronically controlled

multiport

manual

fuel injection

850 (1,874)
4

4G63

(DOHC)

1997 (121.9)

W4A33
4-speed

Electronically controlled

multiport

automatic

fuel injection

28

INTRODUCTION - Tightening Torque

TIGHTENING TORQUE

Each torque value in the table is a standard value
for tightening under the following conditions.

(1)

Bolts, nuts and washers are all made of steel

and plated with zinc.

(2) The threads and bearing surface of bolts and

nuts are all in

dry

condition.

Standard bolt and nut tightening torque

Bolt nominal diameter

(mm)
M5

M6

Ml0
Ml2

Ml4
Ml6

q 1
Ml8
M20
M22
M24

Pitch (mm)

0.8

I

1.0

1.25

1.25

1.5

I I

1.5
'1.5

1.5

1.5

1.5

Torque Nm
Head mark

2.5 (1.8) 4.9 (3.6) 5.9 (4.3)

I

4.9 (3.6)

1 12(8.7)

24
41 (30)
72
111 (82)

167(123)

226 (166) 412
304
392

The

values,

in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or

serted nuts.

(4) If self-tapping screws or self-locking nuts are

used.

(ft.lbs.)

“4”

(17)

(53)

Head mark ‘7” Head mark

I

1 8.8(6.5)

1

22

(16)

44 (33)

8i'

(60)

137(101)

I

206 (152)
304

(224)

I

9.8 (7.2)

1

25

(18)

52 (38)

96(71)

157(116)

235 (174)
343

(253)

(304) 481 (354)

(.224)

(289)

'.

.'

559(412)

:

735(542)

647
853

(477)
(629)

diecast

“8”

in-

Flange bolt and nut tightening torque

Bolt nominal diameter

Pitch (mm)

(mm)

I

M6
M8
Ml0
Ml0
Ml2

Ml2

1.0

1.25

1.25

1.5

1.25

1

1.75

Torque Nm
Head mark “4

I I

(ft.lbs.)

4.9 (3.6)
13 (9.4)

26

(19)

24

(17)

46

(34)

1 42(31)

1

Head mark

9.8 (7.2)

24(17)

49 (36)
44

(33)

93

(69)

)

81 (60)

“7”

Head mark

L

12 (8.7)

28

(20)
57 (42)
54 (40)

103 (76)

I96(71)

‘8’

I

-t

2.OL

<TURBO>

ENGINE

CONTENiS

CAMSHAFT AND CAMSHAFT OIL
SEAL

CAMSHAFT

CRANKSHAFT, FLYWHEEL, DRIVE
PLATE AND CYLINDER BLOCK

CRANKSHAFT FRONT OIL

CRANKYAFT

CRANKSHAFT: REAR OIL SEAL
CYLINDER HEAD AND VALVE

CYLINDER HEAD GASKET

ENGINE ASSEMBLY
ENGINE MOUNTING
ENGINE ROLL STOPPER

ENGINE OIL COOLER
GENERAL INFORMATION
OIL PAN AND OIL SCREEN
OIL PAN, OIL PUMP AND

COUNTERBALANCE SHAFT

.................................

AND ROCKER ARMS

SEAL

PULLEY

................

............

...................

...................

..............

.................

...............

......

........

......

.......

.........

...........

...........

29
50

73
34
28
35

54
37
23
19
22
79

.2

32

59

PISTON
S~AtiNkS
ON-VEHICLE

.:

lash Adjuster Check

SERVICE SPECIFICATIONS
SPECIAL TOOLS
TIMING BELT

TIMING BELT
TRANSAXLE MOUNTING
TROUBLESHOOTING

AND CONNECTING ROD

..............................

SERVICE

Basic Idle

.....

Compression Pressure Check
Curb Idle Speed Check
Drive Belt Tension Check and

Adjustment
Idle Mixture Check
Ignition ‘Timing Check

Manifold Vacuum Check

Speed Adjustment

.

................

..............................

.......................

.........................

.......................

B

...............

Refer to GROUP

...................

.......................

.....................

.....................

..................

.............

..............

...................

......

.............

87

5

10

14A

14
13

10
14
12
16
16

.3
.5

42
47
20

.9

9Am2

2.OL

ENGINE

<TURBO> -

General Information

GENERAL

Items

Type

Number of cylinders

Bore mm (in.)
Stroke mm (in.)
Piston displacement
Compression ratio
Firing order
Counterbalance shaft
Valve timing

Lubrication system

Oil pump type

INFORMAtION

cm3 (cu.in.)

Intake valve

Exhaust valve

i’

c

LUBRICATION SYSTEM

Opens
Closes
Opens
Closes

Specifications
In-line

OHV,

DOHC

4

85.0 (3.35)

88.0 (3.46)
1,997 (121.9)

8.5

l-3-4-2

Equipped
21 “BTDC
51 “ABDC

57”BBDC

15”ATDC

Pressure feed-full
Involute gear type

”

.

y I;,.

- ,, ;

floGr

filtration

Camshaft

Counte~alance

shaft

Oil jet

w

2.OL

ENGINE <TURBO, L

SERVICE SPECIFICATIONS

Items

Tension N (Ibs.)

Drive belt
(For generator)

Drive belt
(For power
steering pump)

Drive belt
(For A/C

compressor)

Tension N

Deflection

mm (in.)
<Reference

value>

(tbs.)

When checkedWhen checked
When a new belt is installedWhen a new belt is installed
When a used belt is installedWhen a used belt is installed

1

When checked

When a new belt is installed

When a used belt is installed

.Setiice Specifications

1

Standard value

Standard value
245 - 490 (55.1 - 110.2)245 - 490 (55.1 - 110.2)

490-686

490-686

392 (88.2)392 (88.2)

I 9.0-11.5(.35-&j)

(110.2 -154.3)

(110.2 -154.3)

Limit

1

Limit I

--

-

-

( -

When a used belt is installed1 6.5-7.5 (.26-.30)

asic

ignition timing at idle

ctual

ianition timina at idle

CIU liui llGll13 -70

HC

contents ppm

Compression pressure (at 250 - 400
Compression pressure difference of all cylinder
Intake
Installation dimension of front roll
Auto tensioner

____ ._.._ - - ,~

Timing belt tension torque Nm
Auto tensioner

Timingbell ~~

Camshaft

Cylinder head 1 Flatness of gasket surface mm (in.)

manifold

vacuum

oush

r

rod mm

6

tension mm (in.)

. .

Cam height (Intake) mm (in.)
Cam height (Exhaust) mm (in.)

I Journal diameter mm (in.)

I

Grinding limit of gasket surface

l

(in.)
Overall height mm (in.)

Oversize valve guide hole (both intake and exhaust)

0.05 O.S. mm (in.)
Oversize valve guide hole (both intake and exhaust)

0.25 O.S. mm (in.)
Oversize valve guide hole (both intake and exhaust)

0.50 O.S. mm (in.)

rod movement mm (in.)

protrusion

Includes/combined with cylinder block grinding mm

:

kPa (in.Hg)

stoboer

(ft.lbs)

(in.)

1

kPa

r/min:

bracket assemblv mm (in.)

. ,

.

(psi)

kPa

(psi)

’

1 5”BTDC f

1

Approx. 8:

(750flf

0.5

1

.--

lw orless

1250 (178)

43f3(1.69&.12)

Mthin

I\r

-------- \-- #

1 3.5(2.6)
1

3.8

1

5-7

34.91 (1.3744)

34.91 p79f.

-5.96 (1 .oiioi

12
1

0.05

131.9-132.1

(5.91 - 5.20)

12.05 - 12.97

(.4744-.4752)

12.25 - 12.27

(.4823-

12.50 - 12.52

(.4921 - &?9)

3”’

E

3TQc

IO

.

or

less+: I- .- 31’i.

.

1

1.041

-

50--177)

4.5

(.l.

(.20-A

- ,~-- .i~ ,

(,902a;>T\

..” ::!*;,

,

‘:f

::.I-,.:

!8).

:

. .

4831)

-1 -

-

-

-

-

min. 935 (133)

max.

min. 60 (18)

-

-

-

34.41 (1.3547)

34.41

,

1

0.2

-

-

-

1

1OP 1141

(1.3547)

(.008)

- _ .-_

I \r.,

3)

I

I

Items

Cylinder head

Oversize

fl3r-r n ,S -mm-h \

exiiaust valve &at &g

.

,L ..,.

. ..I...

”

hole

35JO i

35.60 -~35.63 (MI1

35.33 (1.3898 - 1.3909) -;
6 --

33.30-.33,33 (1.3110-

1.4028)

1.3122)

.I, I

.’

.“’ .:’

1

­!

I

-

I,

.‘,. ‘:

:,

.Cytjnder

Val\ie

head bolt

”

Valve sprini!.+

Valve seat
Valve guide

. .

.,

:

Oij +I@.

:I

(It%:)/

iini.

(in.)

245

(54)/4-0.0

(1.57)

I ” “*

,

Prbje&@r+dr

s-.~i-.~.-ti.~ii

Side

clearance

9.96N39.!4 (9031

0.06 - 0.12
78

(11.4).or

LO024

more

Piston
Piston ring

Connecting rod

Crankshaft

‘.

?l)

0.4

(.016)

. 0.25

LOO98)

Cyljnder bl&

Flatness of

l

Includes/combined with cylinder

arindina
Cverallheight

gasket

mm (in.)

mm (in.)

surface

mm~(iri?)~~!i:~!~AI~

Inner diameter mm (in.)

- Cylindricity mm,(in.)

,F’-‘i ,,1,1

;I

block: I’/, ‘d

/I
j

283.9-284.1

85.0

, T

o.oq (.qQ12 - .0020)

;O.OS (.0020) i

‘.,,’

.I

(3.348)

J

I

(11.177-11.185)‘ i,

-

0.1

l

0.2
,

A’

(.004)

(408)

;_

SerIiici6%ifai

packing and rocker cover
Bearing cap (front, rear) and cylinder head
Oil pressure gauge unit

;s

(.. r;$sp-,‘&y .’ :.:.> ,,.,

Oil pressure switch
Oil pan,

cyliper bloc$

and thermostat case

assembly

_.. _

t&w oil.Seal
Flywheel

bolt or

iPEClAL

TooI

_.

case :

:

dV&e~pt,ate.bo;a !.. i

TOOLS

:-

Tool number and

MB991

502

_

-'I i$

nan@

Scan tool
(MUT-II)

MD998713

...

‘;t

MCPAfj~Par$oX31803+or equivalent

:

.MITSUBISHI

‘l

.

j

i$.; ; ;- y$: ,, .:: ,

GENUINE PART

MD970389

It

,.,._ 4 _--

.,__;

. . .

-‘I

I

431803!,~~~~~~~~~r,equiv~l~~t_~,

.!,

;""l'$y:“i f

I'

‘

$%@a&d

by Miller

*j

Application

toothumber

idle speed inspection’

I

;;;-

::

I L

DRB-III

Scan tool

.’

or equivalent

.._

.,,,

;?;‘&&.r”~

; ii;

" 1

TV., ..__

‘..,

;:?.

,

A

:

. .

~

,.

f $

i’

._

..-

”

f

. ^ ..-,. I__.-__:..

Camshaft oil seal

-in

ajler--

.._ _ .._. .--.-.:w

t:.:$qi

MD998727

Oil pan gasket cutter

: .‘.

.-

_... .._--__.,

. _ .

.I.,^

$;a

1

._c- -._.

_

@iT?e 1 i

,$

,r’l-‘i-

1.,

.I

. .

,,

,General

(Use scraper

excerci$e
*i* ^...

service tool

care)

-&-...i -.... I.

. .

.._.__._.. .._

and

$$&.:IJ ,i ,.

,

,_

_

:.*-,

/

,?

,..

I/

““’ “’

,; ;: 3. :?I

: A’­I

..,. .-._” ____,,, *...

I

_

.-,. _. - --..-y--“, .I_ .I

Tool number and nami

MD998781

Flywheel stopper

MD998778

Crankshaft rear oil
seal installer

MB990938

~-----

Handle

GENERAL SERVICE

TOOL

MZ203827

Engine

litter

MB991

453

‘En$&th;anger

assembly

MD998767

Tensioner pulley

wrench

MD998778

Crankshaft sprocket

puller

MD998782
Valve

I+:.?

litter set

:<

Ii

,,

: :,

MB990767

.

-.

MD998767 I : -:~&~~~~~~ ,+to ;tensioner

..- _

_

. .

installation

,I.

b._

,... . . . _. “.

End yoke holder

Tool’number

_di.L_ /-

and name

I

Ml$9:j193

Plug

(,.,,.

.,

Replaced by Miller
tool number

General service tool
(Use shop towel)

$@vehting

fro’m;

riteri$transfer

6

~$vJl ,j ,;,

for&in substances

‘MD9981

PI&

62

wrench

,_

lM~9$8;05

,:

.., i,._

Silent shaft bearing
installer

(for front and rear

bearihgs) !
MB991

603

‘,.’
&l&it

shaft bearing

,stopper

MD998375

Crankshaft front oil
seal installer

MD998371

;;X$

shaft bearing

MD9981 62

MD998285

MD998373

MB991

603

C-3095-A

MD998371

,‘i

i-”

:3

-.

,/

‘. :

‘1

,..,. *

--.-x~toppetifo~ use

I / *

. .

:.

Crankshaft front oil seal installa­tion

:

.

: y. 4, ,:, *

“. ._

‘Zotiirterbalanceshaft

,itig

removal

,.

.d

iti iemoval

,

front

bear-

MD998372

Silent shaft bearing
puller

MD998440

Leak-down tester

MD998372

I-

-)

‘Counterbalance shaft rear bear-

ing removal

,’

(U&d with

.. Leakdown ted

MB991

603)

of lash adjuster

Application

ioifi

Air bleeding of auto

lasl’~ adj@W

/ .I

.

.>:,2, ,I

!

..-

,,,...

.

.-..

‘,.,.,! t

,i. r _

.

‘I ,-. ., :

!

i

, ’

_

/

II

.

2.OL

SW-28

ENGINE

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

<TURBO> - CrankdibfttPirlf@

s

l

Pre-removal

Under Cover Removal

(Refer to GROUP

Operation

23A -

Under Cover.)

Removal steps

1. Drive belt

2. Drive belt (Power steering)

3.

Drive belt

4. Crankshaft pulley

(Generator)

(A/C)

AOlX0179

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pm-removal Operation

l

Timing

Belt

(Refer to

Front Upper Cover Removal

P.QA-42.)

Timing Belt Front Upper Cover Installation

h

2.9 Nm

2.2

Fibs.

3

bs.

16

4.9 Nm

3.6

ft.lbs.

Engine

oil

6

OlNOO42

Specified sealant:

Removal steps

1. Accelerator cable connection

2. Center cover

3. Spark plug cable

4. Breather hose

5. PCV hose

6.

Rocker cover

7. Timing belt (Refer to

8. Exhaust camshaft sprocket

9. Intake camshaft sprocket

10. Front camshaft bearing cap

11. Camshaft bearing cap

12. Rear camshaft bearing cap

13. Rear camshaft bearing cap (L.H.)

14. Exhaust camshaft

15.

Intake

16. Camshaft oil seal

17. Semicircular packing

OJAOO46

MOPAR

camshaft

Part No.

4318034

P.9A-42.)

(R.H.)

or equivalent

Cylinder head

Installation steps

.A+

15. Intake camshaft

,A+

14. Exhaust camshaft

FBI

13. Rear camshaft bearing cap (R.H.)

.B+

12. Rear camshaft bearing cap

FBI

11. Camshaft beating cap

bB+

10. Front camshaft bearing cap

bC+

16. Camshaft oil seal

9. Intake camshaft sprocket

8. Exhaust camshaft sprocket

7. Timing belt (Refer to

17. Semi-circular packing

6. Rocker cover

5.

PCV hose

4. Breather hose

3.

Spark plug cable

2. Center cover

1.

Accelerator

(Refer to GROUP

tiicle

Service.),

cat?@ cqn

14P‘II On-ve-

,_, -I

(L.H.)

P.9A-42.)

ection

9A-30

2.0L ENGINE

GURBO~ + Camshaft and

Uimshaft ‘Oil S&l:

r

Intake

Plastic hammer

side

if

Exhaust side

REMOVAL SERVICE POINTS

dA,

EXHAUST CAMSHAFT SPROCKET/INTAKE

CAMSHAFT SPROCKET REMOVAL

(1) Use a wrench at the hexagonal part of the camshaft

(to prevent the crankshaft from turning) to loosen the
camshaft sprocket bolt.

(2) Remove the camshaft sprockets.

46,

FRONT CAMSHAFT BEARING CAP/CAMSHAFT

BEARING CAP/REAR CAMSHAFT BEARING

(R.H.)/REAR

(1) Loosen the bearing cap installati& bolts in two or three

steps.

(2) Remove the bearing cap.

NOTE

If the bearing cap is difficult to remove, use a plastic
hammer to gently tap the rear part of the camshaft, and
then remove.

INSTALLATION SERVICE POINTS

I

.A+

INTAKE CAMSHAFT/EXHAUST CAMSHAFT

INSTALLATION

(1) Install the camshafts on the cylinder head.

Caution
Do not confuse the

CAMSHAFT FEARING (L.H.) REMOVAL

..

Intake

side and the exhaust side.

--

Slits

Dowel tins

Exhaust side

intake

01 A0048

side

*ol*oow

I

NOTE
Install new camshafts using the following procedure.

(1) Remove the rocker arms.
(2) Lay the camshafts on the cylinder head and install

the bearing caps.

(3) Check that the camshaft can be easily turned by

hand.

(4) After checking, remove the bearing caps and the

camshafts, and install the rocker arms.

(2) The camshaft’s dowel pins should be at the positions

shown in the figure.

2.OL

ENGINE <TURBO* -

i=amsf&Wand Camtihtift

,Bq

REAR CAMSHAFT BEARING CAP

CAMSHAFT BEARING CAP
BEARING CAP/FROM CAMSHAFT BEARING CAP
INSTALLATION

Tighten the bearing cap installation bolts to the specified torque
in two or three steps.

Caution
Tighten uniformly, otherwise the rocker arms will not
straight.

,C+

CAMSHAFT OIL SEAL INSTALLATION

Use the special tool to drive the camshaft oil seal into position

carefully.

Oil

&al

(R.H$REAR

(L&.)/CAMSHAFT

be

2.OL

ENGINE .4tIJRBO~ i

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

Pm-removal Operation

l

Fuel Line inner Pressure Release

(Refer to GROUP

l

Engine Coolant Draining

(Refer to GROUP O-Maintenance Service.)

l

Engine Oil Draining

(Refer to GROUP O-Maintenance Service.)

14A-On-vehicle

Service.)

2.9

Nm

1

J

-CjjlffiZfer !Hi%d

I

Post-installation Operation

l

Engine Oil Refilling

(Refer to GROUP

l Engine

(Refer to GROUP 0-

I

I

4.9

Nm

- - -.

. .

Gasket

Coolant Refillin

18

,

?w

12

O-Maintenance

9

aintenance

-r65/

Service.)

Service.)

8

-2

I

1

ii!%-

Removal steps

1. Accelerator cable connection

$Iyfi;ot;

2. Air

3. Idle air control motor connector

4. Knock sensor connector

5. Heated oxygen sensor connector

6. Engine
unit connector

7. Engine coolant temperature sensor

connector

8. Ignition power transistor connector

9. Throttle. position

GROUP 14F-On-vehicle

hose C

coolant temperature gauge

10. Capacitor connector

11. Manifold’ differential pressure
sensor

12.

Injector;,connectors

13.

tgnition icoil

connector

connector

”

sensor

connector

25

01x0199

21'

&ing

OJAOO70

Engine oil

14. Camshaft position sensor connector

15. Crankshaft position sensor
connector

16. Air conditioning compressor

connector

17. Control wiring harness

18. Center cover

19. Spark plug cable

20. Brake booster vacuum hose
connection

FE+

21.

High-pressure fuel hose connection

22. Fuel return hose connection

23.

B

-pass valve hose connection

24.

ater

hose connection

VY

25. Vacuum “hoses connection

26.

27:. RX

Breather;hose

,., .,!, a’:., < :; /,

hose

connection

.connection

‘,,.,

2.OL-

ENGINE

<TURBO> -

Cylinder Head Gasket

<Cold

en

ine>

76

Nm-,, Nm+20

8

Nm

++90” -++90”

(58

ft.lbs.+O Ribs.+15 ft.lbs.

++90” ++90”)

12-15 Nm

8-7-11ftA

\

38.(

q

11 A

I

a

“-

-

I/

/34

36

-34 Nm

-25

ft.lbs.

Sealant:

4A,

,Ed

qA, ,Ed

Cylinder head

MOPAR

Part No.

0

Timing belt
(Refer to

28. Power steering pump

29.

Rocker cover

30.

Semicircular packing

31. Heat protector (A)

32.

Water hose connection

33. Water hose A connection

34. Radiator upper hose ‘connection

35. Radiator lower hose connection

4318034

P.9A-42.)

or equivalent

&eclfled sealant:

MITSUBISHI GENUINE PART

MD970389

LM ;I. ;h,enx$ostat

38:

Flange

.B+

39.

t. $$der

42:

.A4

Gasket (A) .-

43. Cylinder

or equivalent

case assembly

(Refer to GROUP
Manifold and Turbocharger.)

Cylinder

bolts

head bolt

head assembly

head,Qask;et

01x0174

and flange nut

ll-Exhaust

1:. :

Crankshaft

.C(

CRANKSHAFT SENSING BLADE INSTALLATION

When installing, make sure the direction is correct. See figure.

sensing blade

AOlXO201

AllAOllO

.D+

CRANKSHAFT SPROCKET INSTALLATION

Use the special tool to install the crankshaft sprocket and

bolt.

NOTE
Apply the minimum amount of-engine oil to the bearing surface
and thread of the crankshaft bolt.

9A950

2.0L

ENGINE

;clTlJRBO,~ 3Mishaft

and

Rock& Arms

CAMSHAFT AND

REMOVAL AND

INSTALLATION

&

Lubricate all

internal parts
with engine oil
during reassembly.

I

t ’

ROCKER ARMS

Removal steps

1.

FE+

.D+

bC+
W+
Wq

bCi4

Plate

2. Camshaft oil seal

3. Circular packing

4. Bearing cap front

5. Bearing cap rear

6.

Bearing

7.

Bearing

cap

cap

No. 2
No. 5

11 I

12

,C+
.C+

,B+

.A+

6ENl079

8.

Bearing cap No.

9.

Bearing cap No.

10.

Camshaft

11.

Rocker arm

12.

Lash adjuster

13. Oil delivery body

.

3
4

C

Camshaft sprocket side

atNO

INSTALLATION SERVICE POINTS

,A4

LASH ADJUSTER INSTALLATION

(1) Immerse the lash adjuster in clean diesel fuel.
(2) Using the special tool

up and down 4 or 5 times while pushing down lightly
on the check ball to bleed out the air.

.Bq

CAMSHAFT INSTALLATION

(1) Apply engine oil to journals and cams of the camshafts.
(2) Install the camshafts on the

Do not confuse the intake’
one. The intake camshaft has a
driving the crankshaft position sensor.

(MD998442),

cylfnder.head.

camshaft’:with

slit

move the plunger

the exhaust

on its rear end for

W’

intake side

t’

Dowel pin

04

Lu

LF

S’it

Capnumber

Symbol identifying
intake or exhaust

(3) Install the crankshaft sprocket B or spacer and flange

to an end of the crankshaft. Then
until the timing marks are lined up to set No.? cylinder
to the TDC.

(4) Set the camshafts so that their

at top.

.Cq

BEARING CAPS

(1) According to the identification mark stamped on top of

each bearing cap, install the caps to the cylinder head.
Only

“L”

or

“R”

No. is stamped on No. 2 to No. 5 bearing caps, No.
6 bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side

INSTALLATION

is stamped on No. 1 bearing cap. Cap

turn

the crankshaft

dowel.

pins are positioned

:

W

Camshaft sprocket side

11

9

53 12 48

7 8

6EN0464

10 12

6EN0192

(2) Tighten the bearing caps in the order shown two to three

times. Tighten to specification in the final sequence.

(3) Check that the rocker arm is held in position on the lash

adjuster and valve stem end.

2.OL

ENGINE

MD99871 3

<TURBO>-- CamshMtiatid Robket Arms’

,D+

I

CIRCULAR PACKING INSTALLATION

r

.E+

CAMSHAFT OIL SEAL INSTALLATION

INSPECTION

CAMSHAFT

(1) Measure the cam height.

9ENOO58

Standard value: 34.91 mm (1.37 in.)
Limit’: 34.51 mm (1.35 in.)

ROCKER ARM

(1) Check the roller surface. If any dents, damage or seizure

is evident, replace the rocker arm.

(2) Check rotation of the roller. If it does not rotate smoothly

or if looseness is evident,

(3)

Check the inside diameter. If damage or seizure
replace the rocker arm.

replace

the rocker arm.

.,

,is

evident,

6ENOl85

LASH ADJUSTER LEAK DOWN TEST

Caution

1. The lash adjuster is a precision part. Keep
from dust and other foreign matter.

2. Do not disassemble lash adjuster.

3. When
only.

cleaning

lash adjuster, use clean

dies+

‘it free

fuel

2.OL,

ENGINE

<TURBGs - CatidhMt?iih&RBcker Mms

(1) Immerse the lash adjuster in clean diesel fuel.
(2)

While

lightly pushing down inner

tool

6ENO421

(MD998442),

or five times to bleed air.
Use of the retainer helps the air bleeding of the rocker
arm mounted type lash adjuster.

(3) Remove the small wire and press the plunger. If the

plunger is hard to be pushed in, the lash adjuster is normal.
If the plunger can be pushed in all the way readily, bleed

the lash adjuster again and test again. If the plunger

is still loose, replace the lash adjuster.

Caution
Immediately after air bleeding, hold lash adjuster up
right to prevent fuel from spilling.

move the plunger up and down four

steel

ball

using the special

S&!ifs

MD99

MD9W40

1’

Division = 1 mm LO39

7ENO438

Soale = 1

1,l-l

mm

(.039

Lash
adjuster

in.)

in.1

(4) After air bleeding, set lash adjuster on the special tool

(Leak down tester

(5) After plunger has gone down 0.2 to 0.5 mm

.020

in.), measure time taken for it to go

L (.039

in.). Replace if measured time is out of specification.

Standard value:
[Diesel fuel at

MD998440).

4-20

seconds/l mm

M-20’% (59~68”F)j

(908

down 1 mm

(.04

in.)

to

2.OL

-ENGINE

<TURBO>

- CylintW He& ti&$Val\ie -

CYLINDER

HEAD AND VALVE

REMOVAL AND INSTALLATION

:m

a, .C+

.B+ 4:

4W

.B+

I

’

Lubricate all internal

parts with engine oil

1

during reassembly.

Removal steps

1.

Cyljnder

;. C&knkrn

Retainer lock

5. Valve spring retainer

6. Valve spring

7. Intake valve

8. Retainer lock

9. Valve spring retainer

IO.

Valve spring

head bolt

head assembly

I

1::

,A+

+C, .A+

6EN0948

11. Exhaust valve

12. Valve stem seal

13. Valve spring seat

14. Valve stem seal

15. Valve

16. Intake valve guide

17. Exhaust valve guide

18. Intake valve seat

19. Exhaust valve seat

20. Cylinder head

sprin,g

r _‘,

. . .

seat

ON-VEHICLE INSPECTION OF

COMPONENT LOCATION

Name

Air conditioning compressor clutch relay
Air conditioning switch
Camshaft position sensor

Check

engine/Malfunction indicator lamp
Crankshaft position sensor
Data link connector
EGR solenoid
Engine control module (ECM)
Engine coolant temperature sensor

Evaporative emission purge solenoid

Fuel pressure solenoid

Fuel pump check terminal
Fuel pump relay
Heated oxygen sensor (Front)
Heated oxygen sensor (Rear)
Idle air control motor
Ignition coil

NOTE
The “Name” column is in alphabetical order.

(IgnitiQh powentransistor)

\>ylll”“l

MFI

COMPONENTS

,“a I

Ici

A Ignition timing adjustment connector

W

N

U

0

V

J
X Power steering pressure switch

D

J
M

E
Y
Q
2

F
K

Injector
Knock sensor
Manifold differential pressure (MDP) sensor

Multiport

Park/Neutral position switch

Resistor

Throttle position sensor (with built-in closed
throttle position switch)

Turbocharger waste gate
Vehicle

Volume air flow sensor (with built-in intake air

temperature sensor and barometric pressure

sensor)

fuel injection (MFI) relay

sol8noid

speed sensor

“J”‘LN’

E
R

L
H
Y

T
P

I

G
S

C

B

6FU2077

6FU2078

6FU248o

MFI, <TURBO>.“L

On-vehicle

Inspectbn

of

MFI C&ii~ier;i@i ’

‘f’#sesg

.

*

-I

Idle air control motor-

//L

,

(stepper motor)

14A-240

MFI <TURBO>. 9’. On-vehici~~;In’specti~n of MFI ;CiirQYdneri& ”

Intake side
camshaft
sprocket

MFI <TURBO> -

On-vehicle:

ins@dtik;~6f

.-MFi

Components

l&j#3&l

14F-10

FUEL

SUPPLY AND ENGINE CONTROL

-

Accelerator Cable And P&M

ACCELERATOR CABLE AND ~-PEDAL

GENERAL INFORMATION

A cable-type accelerator mechanism and a
suspended-type pedal have been adopted.

SERVICE SPECIFICATION

;

Item

Accelerator cable play mm (in.)

LUBRICANT

Item

Accelerator pedal
accelerator cable end

TROUBLESHOOTING

Symptom Probable cause

Throttle valve will not

fully open or close

Accelerator pedal op­eration not smooth

(over acceleration)

pin, spring

21

3

Misadjusted accelerator cable Adjust
Misadjusted auto-cruise control cable
Broken return spring
Throttle lever malfunction

Accelerator pedal wrongly tightened

Misinstalled accelerator cable

Standard value

l-2 (.04-.08)

Specified lubricant

MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent

Quantity
As required

Remedy

Adjust
Replace
Replace

Repair

Repair

Accelerator cable requires lubrication

Lubricate or replace

ON4EHICLE

SERVICE

4.9 Nm

3.6

Ribs.

dlate

AOlA0021

ACCELERiTOR

CABLE CHECK AND

ADJUSTMENT

For models
refer to GROUP

1.

Turn AIC

inspect and adjust at no load.

2. Warm engine until stabilized at idle.

3.

Confirm

4. Stop engine (ignition switch OFF).

5. Confirm there are no sharp bends in accelerator cable.

6. Check inner cable for correct slack.

7. If there is too much slack or no slack, adjust play by
the following procedures.

(13:Turn

(2) Loosen the adjusting bolt to release the cable.
(3) After moving the plate to the position

(4) Tighten the adjusting bolts to the specified torque.

equjpped

and lights OFF.

idle speed is at prescribed

the ignition switch to the ON position

starting the engine) and leave in that condition for

.approximately

IAC

motor.

before the throttle lever
plate back towards the throttle body by the

value amount only to bring the accelerator cable

to’ the standard value.

Standard value:

with the auto-cruise control system,

14G -

On-vehicle Service.

rpm.

15 seconds in order to initialize the

immediately

starts

to move, move the

:

l-2

mm (.04-.08 in.)

(without

standard

play

8. Adjust accelerator cable play and confirm throttle lever
stopper touches the fixed SAS.

i:

(,/.

14F-12

FUEL SUPPLY AND ENGINE CONTROL

ACCELERATOR CABLE AND PEDAL

REMOVAL AND INSTALLATION

‘- iGcelerator &6i’iiCA8d,@&@

Post-Installation

;I$ator*CaMe

to GROU

I-

upped

“s

14G -

Operation

Adjustment, (Refer to

with auto-cruise

On-vehicle Service.)

control system, refer

P.l4F-10;

for

<Turbo>

4.9

3.6

<Non-turbo>

4.9 Nm

3.6ftlbs.

1

4.9

Nm

3.6hlbs.l

k-

I

4.9 Nm

3.6ft.lbs.

2

Grease:

MOPAR Multi-Mileage

Lubricant

Part No. 2525035 or equivalent

Accelerator cable removal

1. Clip

2. Adjusting bolts

,A+

3. Accelerator cable

Accelerator pedal removal steps

4. Accelerator cable connection

5. Cotter pin

6. Washer

7. Accelerator pedal pin

steps

11

13 Nm

9.4

ft.lbs.

4.;

/

Nm

3.6ft.lbs.

8. Bushing

9. Spring

10. Accelerator pedal arm

11. Accelerator pedal bracket

12. Accelerator pedal stopper

NOTE
For models equipped with auto-cruise control system, the
accelerator
referred to GROUP

cabfe removaVinstallation

14G -

Auto-cruise control system.

procedures are

FUEL SUPPLY AND ENGINE CONTROL

INSTALLATION SERVICE POINT

,A(ACCELERATOR

Clamp the accelerator cable so that its

-

Accelerator Cable And

CABLE INSTALLATION <Turbo>

Pedal

marking

14b!'f3

is as shown.

BODY - Hood

Bumper
(small)

mm (in.)

18X0721

Bumper

(large)

00000130

18X0831

00000129

r

17 mm

10x0722

INSTALLATION SERVICE POINT

,A4

BUMPER INSTALLATION

Install the bumper as shown in the diagram.

,’

t**.

“I

INSPECTION

HOOD SWITCH CONTINUITY CHECK

_,

_ ,;x.,

:

FENDER

SEALANTS

Items

Fender to body panel

Splash shield to fender

I

FENDER

REMOVAL AND INSTALLATION

Prwemoval

Front Bumger
(Refer to

and post-installation Operation

Removal and Installation

.23A-71.)

Specified sealants
MOPAR Silicone Rubber Sealer Part
MOPAR Silicone Rubber Sealer Part No. 4026070 or Auto Glass

Adhesive and Sealer Part No. 2298825 or equivalent

No. 4026070 or equivalent

I

Removal steps

1. Splash

l

S@e

i. Front fend&

air

shield :

cjam

(Refer to

panel

18X0736

P.23A-79)

10x0734

Sealant:

MOPAR Silicon Rubber Sealer Part No.

4026070 or Auto Glass Adhesive and Sealer

Part

No.2298825

Sealant:
MOPAR Silicon Rubber Sealer Part No.
4026070 or equivalent

or equivalent

18X0729

00000131

,,,-

FENDER

SEALANTS

eODY

-

Fend&

Items
Fender to body panel

I

Splash shield to fender

I

FENDER

REMOVAL AND INSTALLATION

Preremoval

Front

(Refer to

and post-installation Operation

Bum

r

Renioval and installation

.23A-71.)

B”

Specified sealants
MOPAR Silicone Rubber Sealer Part No. 4026070 or equivalent

I

MOPAR Silicone Rubber Sealer Part No. 4026070 or Auto Glass

Adhesive and Sealer Part No. 2298825 or equivalent

I

Removal steps

1. Splash shield

l

Side air dam (Refer to

2. Front fender panel

18X0736

P.23A-79)

18X0734

Sealant:
MOPAR Silicon Rubber Sealer Part No.

4026070 or Auto Glass Adhesive and Sealer

Part

No.2298825

Sealant:

MOPAR Silicon Rubber Sealer Part No.
4026070 or equivalent

or equivalent

18X0729

00000131

BODY i Front Bumper

FRONT BUMPER

REMOVAL AND INSTALLATION

g?&p:

*

’

‘!$

Prs-removal

S

lash shield Removal and Installation

&efer

and

to GROUP

Post-installation

23A-61.)

Operation

Removal steps

1. Fog light

2. Front side-marker light

3. Front bumper center plate

4. Front bumper assembly

;. Fc$t

7:

bumper corner plate

Front fascia bracket

23A-72

BODY -

DISASSEMBLY AND REASSEMBLY

Pro’nt Biimper-

Disassembly steps

1. Fog light hole cover

2. Front license plate bracket

3. Bolt plate

4. Front bumper side plate

5. Front bumper reinforcement

6. Front bumper core

7. Front bumper stay assembly

8. Front bumper face

REAR BUMPER

REMOVAL AND INSTALLATION

6

Removal steps

1. Rear panel garnish

2. Rear combination light

3. Rear bumper upper plate (A)

4. Rear bumper upper plate

(B)

~16x0676

5. Connector harness

6. Rear bumper assembly

7. Rear bumper side plate

BODY<- Rear

Burnber

DISASSEMBLY

AND REASSEMBLY

Disassembly steps

1. Rear bumper lower plate

2. Rear bumper reinforcement

3. Rear bumper core

Alox1oos

4. Rear bumper stay assembly

5. Rear bumper face

GARNISHES

REMOVAL AND INSTALLATION

BODY

-;

~GarnisheS

13Nm

Front deck garnish removal steps

1. Wiper arm

assembly

2. Front deck garnish

18X0675

00003740

Rear panel garnish removal steps

l

Rear end trim

(Refq to

3. Rea? ,-panel

P.$JA-90)

garnish

23A-76

MOLDINGS

BODY,

‘-

Moldings

SEALANT

Items

Side protector molding

AND ADHESIVE

MOLDINGS

REMOVAL AND INSTALLATION

Specified sealant and adhesive

3M

ATD Part No. 6382 or equivalent and

3M

ATD Part No. 8608 Super Fast Urethane Primer or equivalent

+A, .A+

Adhesive tape:

3M

ATD

Part

15 mm

Adhesive:

3M

ATD Part No.

1. Windshield molding
(Refer to

2. Belt line molding
(Refer to

3. Side protector molding

4.

Liftgate

molding

(Refer to

No. 6382 or equivalent

(59

in.) wide and 1.2 mm

8606

P.23A-10)

P.23A-50)

P.23A-18)

(.047

in.) thick

Super Fast Urethane Primer or equivalent

l

Drip line weatherstrip

(Refer to

s Door

(Refer to

5. Drip molding

P.23A-50)

weatherstri

P.23AJO)

holder

BODY -

Moldings

Masking tape

Fishing line

REMOVAL

+A,

SIDE PROTECTOR MOLDING REMOVAL

(1) Apply masking tape to the outside circumference of the

side protector molding.

(2) Insert fishing line

and the side protector molding, pull both ends alternately

\

I

to cut the adhesive section and remove the side protector
molding.

SERV’ICE

[0O.8

POINT

mm

(.03

in.)] in between the body

Caution

1.

When reusing the

side

protector

Molding,

pull the
fishing line along the edge of the body so as not
to damage the edge of the

side

protector Molding.

2. If the adhesive Is difficult to remove, heat it to

40°C (104°F).

(3) Scrape off the double-sided tape with a resin spatula.

Double-sided tape

.

\

Adhesive

I

(4) Tear off the masking tape;
(5) Scrape off a small amount of the adhesive with a cutter

knife.

Aesin

spatula

(6) Use a shop towel moistened with degreaser (MOPAR

SUPER KLEEN or equivalent) to wipe the body surface.

INSTALLATION SERVICE POINT

,A+

SIDE PROTECTOR MOLDING INSTALLATION

Double-sided
(when reusing)

(1) Scrape off the double-sided tape with a resin spatula

or gasket scraper.

tap6

affixing to the

side protector

Molding

Primer

BfJDV -

(2) Use a shop towel moistened with degreaser (MOPAR
(3) Remove a small portion of the residual adhesive.

MotdtnQs-

SUPER KLEEN or equivalent) to wipe the

moldingsurface.

Caution
Do not remove all of the residual adhesive.

(4) Soak a sponge in the primer, and apply evenly to the

side protector molding in the places shown in the illustra­tion.

Specified primer: 3M ATD Part No. 8608

Urethane

Prim*

di’&@G!l~nt

Caution

i.

Always apply it on the

entiie’

I&x%+-because

Super

?j ‘!.: 6.

,‘j ,.:: ‘,

.r.

a lot or little will reduce its strength,

2. Do not touch the coated surface.

(5) After applying the primer, let it dry for 3 to

3g.

minutes.

Fast

Al8XO607

(6) Affix the specified double-sided tape to the side protector

molding.

Specified adhesive tape:

3M

ATD Part No. 6382 or equivalenf

15 mm

(59

in.) wide

and %+~mrn.?#J47&L)~

.* ‘., * ?.& :i.&$ ”

II .“‘<p+“:,+>

’ ( ,_ :.

thick

Side protector molding installation

(1) Tear off the double-sided tape backing paper.

NOTE

If you attach the adhesive tape to the edge of the backing

paper, it will be easy to tear off.

(2) Install the side protector molding.

NOTE
If the double-sided tape is difficult to
etc., warm the bonding surfaces of the body and the

side protector molding to about

before affixing the tape.

(3) Firmly press in the side protector

40-6O”C

-molding.

-

affix

during winter,

(104-140°F)

AERO PARTS

SEALANT AND ADHESIVE

I

Items

BODY - Aero

Specified sealant and adhesive

Patts

Door garnish, Side air dam

AERO PARTS

REMOVAL AND INSTALLATION

3M

ATD Part No. 6382 or equivalent and

3MATD

Part No. 8608 Super Fast Urethane Primer or equivalent

+A,

Adhesive tape:

Adhesive:

Door garnish removal

,A1

1. Door garnish

3M ATD

4 mm

3M

Part No. 6382 or equivalent

(.15

in.) wide and 1.5 mm

ATD Part No. 8608 Super Fast Urethane Primer or equivalent

(.059

in.) thick

Side air dam removal steps

BODY *

:

Awe Paits

18X0673

00003751

nm (in.)

-

Rear spoiler removal steps

l

Liftgate

1.

2. Rear spoiler assembly

lower trim (Refer to

Connector harness

10x0133

P.23A-90)

3. High mounted stop light

4.

Dua!-!oc\

5. Dual-lock fastener (large)

REMOVAL SERVICE POINT

+A,

DOOR GARNISH/FRONT SIDE-AIR DAM/REAR

SIDE-AIR DAM REMOVAL

Carry

out..@b

ings. (Refer to

same procedure as for the side protector mold-

P.23A-76.)

INSTALLATION SERVICE POINT

.A+ DOOR

SIDELAIR

Carry out the same procedure as for
ings. (Refer to

GARNISH/FRONT SIDE-AIR DAM/REAR

DAM INSTALLATION

P.23A-76.)

fastener

the

(small)

side protector mold-