Mitsubishi Lancer 2005 User Manual

GROUP INDEX

LANCER /

LANCER WAGON

WORKSHOP MANUAL

FOREWORD

This Workshop manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required.

General . . . . . . . . . . . . . . . . . . . . . . . .

Engine. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . . .

Engine and Emission Control . . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . . .

Automatic Transmission. . . . . . . . . .

Front Axle. . . . . . . . . . . . . . . . . . . . . .

TECHNICAL INFORMATION MANUAL

PYME0302 PYME0302-A

WORKSHOP MANUAL

CHASSIS GROUP PWME0302 BODY REPAIR MANUAL

PBME0302 PBME0302-A

PARTS CATALOGUE

B606K005A_

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tyre . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . . .

Service Brakes. . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Power Steering . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

. . . . . . . . . .

Restraint System (SRS)

Chassis Electrical . . . . . . . . . . . . . . .

Heater, Air Conditioner and

. . . . . . .

Ventilation

Component Locations. . . . . . . . . . . .

Mitsubishi Motors Corporation May 2004

Configration Diagrams . . . . . . . . . . .

Circuit Diagrams . . . . . . . . . . . . . . . .

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

(1) Improper service or maintenance of any component of the SRS or any SRS-related component,

can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative).

(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so

remove the SRS-ECU, driverís and front passengerís air bag modules, clock spring, side air bag modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.

ï SRS-ECU, air bag module and clock spring 93°C or more ï Seat belt with pre-tensioner: 90°C or more

(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), before beginning any service or maintenance of any component of the SRS or any SRS-related component.

NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

GROUP 17

ENGINE AND

EMISSION

CONTROL

CONTENTS

17-1

ENGINE CONTROL. . . . . . . . . .

GENERAL INFORMATION . . . . . . 17-2

SERVICE SPECIFICATIONS. . . . . 17-2

ON-VEHICLE SERVICE. . . . . . . . . 17-2

ACCEL CABLE CHECK AND

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 17-2

ACCELERATOR CABLE AND

PEDAL . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . 17-3

17-2

17-3

EMISSION CONTROL MPI . . . . 17-5

GENERAL INFORMATION . . . . . .

EMISSION CONTROL DEVICE

REFERENCE TABLE . . . . . . . . . .

SERVICE SPECIFICATION(S) . . . 17-5

VACUUM HOSE. . . . . . . . . . . . . . . 17-6

VACUUM HOSE PIPING DIAGRAM . . . 17-6

VACUUM CIRCUIT DIAGRAM . . . . . . . 17-7

VACUUM HOSE CHECK. . . . . . . . . . . . 17-8

VACUUM HOSE INSTALLATION . . . . . 17-8

CRANKCASE EMISSION CONTROL

SYSTEM. . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . . 17-8

17-5

17-8

COMPONENT LOCATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . . 17-9

POSITIVE CRANKCASE VENTILATION

SYSTEM CHECK . . . . . . . . . . . . . . . . . . 17-9

POSITIVE CRANKCASE VENTILATION

(PCV) VALVE CHECK . . . . . . . . . . . . . . 17-9

EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-9

GENERAL INFORMATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . . 17-9

COMPONENT LOCATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . . 17-10

PURGE CONTROL SYSTEM CHECK. . 17-10

PURGE PORT VACUUM CHECK . . . . . 17-11

PURGE CONTROL SOLENOID VALVE

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11

FUEL VAPOUR CANISTER REMOVAL

AND INSTALLATION . . . . . . . . . . . . . . . 17-12

EXHAUST GAS RECIRCULATION

(EGR) SYSTEM . . . . . . . . . . . . . . .

GENERAL INFORMATION

(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-13

COMPONENT LOCATION

(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-14

EGR SYSTEM CHECK . . . . . . . . . . . . . 17-15

EGR VALVE CHECK . . . . . . . . . . . . . . . 17-15

EGR PORT VACUUM CHECK <4G1>. . 17-16 EGR CONTROL SOLENOID VALVE

CHECK <4G1> . . . . . . . . . . . . . . . . . . . . 17-16

EGR CONTROL SOLENOID VALVE

CHECK <4G6> . . . . . . . . . . . . . . . . . . . . 17-17

EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . 17-18

CATALYTIC CONVERTER . . . . . . 17-18

REMOVAL AND INSTALLATION . . . . . . 17-18

17-13

17-2

ENGINE AND EMISSION CONTROL

ENGINE CONTROL

GENERAL INFORMATION

M1171000100277

A cable-type accelerator mechanical suspended-type pedal has been adopted.

SERVICE SPECIFICATIONS

M1171000300088

Item Standard value

Accel cable play mm 1.0 − 2.0

Engine idle speed r/min 4G1 750 ± 50

4G6 750 ± 100

ON-VEHICLE SERVICE

ACCEL CABLE CHECK AND

<4G1>

Adjusting bolts

Plate

ADJUSTMENT

M1171000900314

1. Turn A/C and lights OFF. Inspect and adjust at no load.

2. Warm engine until stabilized at idle.

3. Confirm idle speed is at standard value.

Standard value: 750 ± 50 r/min <4G1> 750 ± 100 r/min <4G6>

Accel cable

<4G6>

Adjusting bolts

AC207966

4. Stop engine. [ignition switch: LOCK (OFF) position].

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

6. Check the inner cable for correct slack.

Standard value: 1.0 − 2.0 mm

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

Plate

Accel cable

AC301055

(1) Loosen the adjusting bolts to release the

cable.

(2) Move the plate until the inner cable play is at

the standard value, and then tighten the adjusting bolts.

(3) After adjusting, check that the throttle lever is

touching the stopper.

ENGINE AND EMISSION CONTROL

ENGINE CONTROL

ACCELERATOR CABLE AND PEDAL

17-3

REMOVAL AND INSTALLATION

Post-installation Operation

Adjusting the Accelerator Cable (Refer to P.17-2).

<L.H. drive vehicles>

M1171001200341

5.0 ± 1.0 N·m

12 ± 2 N·m

<R.H. drive vehicles>

5.0 ± 1.0 N·m

Accelerator cable assembly removal steps

1. Inner cable connection (Accelerator pedal side)

2. Inner cable connection (Throttle body side)

3. Accelerator cable assembly

Y1060AU

12 ± 2 N·m

Y1059AU

AC304070

Accelerator pedal assembly removal steps

1. Inner cable connection (Accelerator pedal side)

4. Accelerator pedal assembly

5. Accelerator control equip nut

6. Accelerator pedal arm and accelerator pedal pad assembly

17-4

ENGINE AND EMISSION CONTROL

ENGINE CONTROL

Accelerator pedal assembly removal steps (Continued)

7. Accelerator control equip bushing

8. Accelerator pedal arm return spring

9. Accelerator pedal arm stopper

INSTALLATION SERVICE POINT >>A<< ACCEL PEDAL PAD

INSTALLATION

CAUTION

To p reve nt damag es to the ac c eler ator pe dal pad, warm the thumb area of the accelerator pedal pad with a dryer, etc. prior to assembling it.

NOTE: If it is difficult to assemble, apply soapy water to the thumb area to enhance the assembling process.

>>A<<

Accelerator pedal assembly removal steps (Continued)

10. Accelerator pedal arm bracket

11. Ac c e l erator p edal a rm

12. Accelerator pedal pad

13. Accelerator pedal arm stopper

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-5

GENERAL INFORMATION

M1173000100370

The emission control system consists of the following subsystems:

Items Name Specification

Crankcase emission control system

Evaporative emission control system

Exhaust emission control system Air-fuel ratio control device - MPI

Positive crankcase ventilation (PCV) valve

Canister Purge control solenoid valve

system

Exhaust gas recirculation system

• EGR valve

• EGR control solenoid valve

Catalytic converter Monolith type

• Crankcase emission control system

• Evaporative emission control system

• Exhaust emission control system

Varia b le flo w t yp e (Purpose: HC reduction)

Equipped Duty cycle type solenoid valve (Purpose: HC reduction)

Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction)

Equipped Single type Duty cycle type solenoid valve (Purpose: NOx reduction)

(Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE REFERENCE TABLE

M1173006600135

Related parts Crankcase

emission control system

Evaporative emission control system

Air/fuel ratio control system

Catalytic converter

Exhaust gas recirculation system

PCV valve

Purge control solenoid valve

MPI system component

Catalytic converter

EGR valve

EGR control solenoid valve

××

SERVICE SPECIFICATION(S)

M1173000300288

Items Standard value

Purge control solenoid valve coil resistance (at 20°C) Ω 30 − 34

EGR control solenoid valve coil resistance (at 20°C) Ω 29 − 35

17-6

VACUUM HOSE

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

VACUUM HOSE PIPING DIAGRAM

M1173000900417

<4G1>

To fuel tank

Oxygen sensor (front)

Catalytic converter

Fuel pressure regulator

Oxygen sensor (rear)

From fuel pump

EGR valve

EGR control solenoid valve

Air cleaner

Air

Canister

Purge control solenoid valve

<4G6>

To fuel tank

Oxygen sensor (front)

Catalytic converter

PCV valve

Fuel pressure regulator

Catalytic converter

From fuel pump

EGR valve

Oxygen sensor (rear)

Catalytic converter

EGR control solenoid valve

Purge control solenoid valve

Air cleaner

Canister

AK300964

Air

AK204364

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-7

VACUUM CIRC UIT DIA GRAM

<4G1>

To combustion chamber

Fuel pressure regulator

Vacuum hose colour

B: Black G: Green R: Red Y: Yellow L: Blue

EGR valve

M1173007100263

Intake manifold

EGR control solenoid valve

Throttle body

From air cleaner

Purge control solenoid valve

Canister

AK300765

<4G6>

To combustion chamber

Fuel pressure regulator

Vacuum hose colour

B: Black G: Green R: Red W: White Y: Yellow L: Blue

Intake manifold

EGR control solenoid

EGR valve

valve

Throttle body

Purge control solenoid valve

From air cleaner

Canister

AK300766

17-8

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

VACUUM HOSE CHECK

M1173007300159

1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected.

2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage.

VACUUM HOSE INSTALLATION

M1173007200107

1. When connecting the vacuum hoses, they should be securely inserted onto the nipples.

2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.

CRANKCASE EMISSION CONTROL SYSTEM

GENERAL INFORMATION (CRANKCASE EMISSION CONTROL SYSTEM)

M1173005000237

The crankcase emission control system prevents blow-by gases from escaping inside the crankcase into the atmosphere. Fresh air is sent from the air cleaner into the crankcase through the breather hose. The air becomes mixed with the blow-by gases inside the crankcase. The blow-by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation (PCV) valve. The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow of blow-by gas properly. In other words, the blow-by gas flow is regulated during low load engine operation to maintain engine stability, while the flow is increased during high load operation to improve the ventilation performance.

SYSTEM DIAGRAM

Ventilation hose

PCV valve

Breather hose

Air cleaner

AK204365

Air

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-9

COMPONENT LOCATION (CRANKCASE EMISSION CONTROL SYSTEM)

M1173007400208

<4G1>

PCV valve

AK300767

<4G6>

PCV valve

AK204366

POSITIVE CRANKCASE VENTILATION (PCV) VALVE CHECK

M1173001200187

PCV valve

AK100010

1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation side), and move the rod back and forth to check that the plunger moves.

2. If the plunger does not move, there is a clogging in the PCV valve. In this case, clean or replace the PCV valve.

EVAPORATIVE EMISSION CONTROL SYSTEM

POSITIVE CRANKCASE VENTILATION SYSTEM CHECK

M1173001100179

1. Remove the ventilation hose from the PCV valve.

2. Remove the PCV valve from the rocker cover.

3. Reinstall the PCV valve at the ventilation hose.

4. Start the engine and run at idle.

PCV valve

AKX00336

5. Place a finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt.

NOTE: At this moment, the plunger in the PCV valve moves back and forth.

6. If vacuum is not felt, clean the PCV valve or replace it.

GENERAL INFORMATION (EVAPORATIVE EMISSION CONTROL SYSTEM)

M1173005100405

The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level.

17-10

SYSTEM DIAGRAM

From fuel tank

Canister

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

Throttle body

Engine-ECU <4G1-M/T, 4G6>, Engine-A/T-ECU <4G1-A/T>

OFF

Purge control

solenoid valve

Battery

Control relay

Manifold absolute pressure (MAP) sensor <4G1>

Air flow sensor <4G6>

Engine coolant temperature sensor

Intake air temperature sensor

Barometric pressure sensor <4G6>

COMPONENT LOCATION (EVAPORATIVE EMISSION CONTROL SYSTEM)

M1173007500216

<4G1>

Purge control solenoid valve

<4G6>

AK300769

AK204367

PURGE CONTROL SYSTEM CHECK

M1173001400299

<4G1>

Vacuum hose

Plug

<4G6>

AK300771

Vacuum hose

Plug

Purge control solenoid valve

AK300770

AK300772

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

1. Disconnect the vacuum hose (red stripe) from throttle body and connect it to a hand vacuum pump.

2. Plug the nipple from which the vacuum hose was removed.

3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum.

17-11

Vacuum

When engine is cold (Engine coolant temperature: 40°C or less)

Engine condition Normal condition

At idle Vacuum is maintained.

3,000 r/min

When engine is hot (Engine coolant temperature: 80°C or higher)

Engine condition Normal condition

At idle Vacuum is maintained.

3,000 r/min (within 3

Vacuum will leak. minutes after engine starts)

PURGE PORT VACUUM CHECK

M1173001500177

<4G1>

Vacuum hose

Plug

Engine speed (r/min)

AK100011

3. Start the engine.

4. Check that a fairly constant negative pressure is generated regardless of the engine speed.

5. If no negative pressure is generated, the port is probably blocked and should be cleaned.

PURGE CONTROL SOLENOID VALVE CHECK

M1173001700193

NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position.

AK300773

<4G6>

Vacuum hose

Plug

AK300774

1. Disconnect the vacuum hose (red stripe) from the throttle body and connect a hand vacuum pump to the nipple.

2. Plug the vacuum hose (red stripe).

Battery

AK100012

AK100013

1. Disconnect the vacuum hose from the solenoid valve.

2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left).

17-12

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage.

FUEL VAPOUR CANISTER REMOVAL AND INSTALLATION

M1173004200153

Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3).

Battery voltage Normal condition

Applied Vacuum leaks

Not applied Vacuum maintained

5. Measure the resistance between the terminals of the solenoid valve.

Standard value: 30 − 34 Ω (at 20°C)

Removal steps

1. Emission vacuum hose connection

2. Fuel vapour control line hose

3. Fuel vapour control check valve

4. Fuel vapour control line hose

AC208253

Removal steps (Continued)

5. Fuel vapour control line clamp

6. Fuel vapour canister

7. Fuel high-pressure hose clamp

8. Fuel vapour canister bracket

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-13

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

GENERAL INFORMATION (EGR SYSTEM)

M1173005200327

The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx.

SYSTEM DIAGRAM

<4G1>

The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability.

OPERATION

The EGR valve is being closed and does not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculates exhaust gases.

• The engine coolant temperature is low.

• The engine is at idle.

• The throttle valve is widely opened.

EGR valve

OFF

Battery

EGR control solenoid valve

Control relay

Engine-ECU <M/T>, Engine-A/T-ECU <A/T>

Manifold absolute pressure (MAP) sensor

Engine coolant temperature sensor

Crank angle sensor

AK300775

17-14

<4G6>

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

EGR control Solenoid valve

OFF

EGR valve

Battery

COMPONENT LOCATION (EGR SYSTEM)

M1173007600224

<4G1>

EGR control solenoid valve

Control relay

<4G1>

Engine-ECU

Barometric pressure sensor

Air flow sensor

Engine coolant temperature sensor

Crank angle sensor

AK302349

EGR valve

<4G6>

AK300776

EGR control solenoid valve

AK300778

<4G6>

AK300777

EGR valve

AK300779

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

17-15

EGR SYSTEM CHECK

M1173002600348

<4G1>

Green stripe

Three-way terminal

<4G6>

EGR valve

Three-way terminal

Green stripe

AK300780

EGR valve

AK300781

1. Disconnect the vacuum hose (Green stripe) from the EGR valve, and then connect a hand vacuum pump via the three-way terminal.

2. When the engine is hot or cold, check the condition of vacuum by racing the engine.

When engine is cold (Engine coolant temperature: 20°C or less)

Throttle valve Normal vacuum condition

Open quickly No vacuum will generate (the

same as barometric pressure.)

When engine is hot (Engine coolant temperature: 80°C or higher)

Throttle valve Normal vacuum condition

<4G1>

Green stripe

EGR valve

AK300782

<4G6>

Green stripe

EGR valve

AK300783

4. Connect the hand vacuum pump to the EGR valve nipple.

5. Check whether the engine stalls or the idling is unstable when a vacuum of 30 kPa or higher is applied during idling.

EGR VALVE CHECK

M1173002800223

1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly.

2. Connect a hand vacuum pump to the EGR valve.

3. Apply 67 kPa of vacuum, and check that the vacuum is maintained.

Open quickly It will momentarily rise over 13

kPa

3. Disconnect the three-way terminal.

AKX00348

4. Apply a vacuum and check the passage of air by blowing through one side of the EGR passage.

Vacuum Passage of air

5.3 kPa or less Air is not blown out

27 kPa or more Air is blown out

17-16

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

5. Replace the gasket, and tighten to the specified torque.

Tightening torque: <4G1> 21 ± 4 N⋅m <4G6> 20 ± 2 N⋅m

EGR PORT VACUUM CHECK <4G1>

M1173002900167

Green strip

AK300784

1. Disconnect the vacuum hose (Green stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple.

2. Plug the vacuum hose (Green stripe).

Vacuum

1. Disconnect the vacuum hose (White stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple.

2. Plug the vacuum hose (White stripe).

Vacuum

Engine speed (r/min)

AK100011

3. Start the engine.

4. Check that a fairly constant negative is generated regardless of the engine speed.

5. If no negative pressure is generated, the port is probably blocked and should be cleaned.

EGR CONTROL SOLENOID VALVE CHECK <4G1>

M1173003100238

NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position.

Engine speed (r/min)

AK201224AB

3. Start the engine and check that, after raising the engine speed by racing the engine, purge vacuum raises according to engine speed.

NOTE: If there is a problem with change in vacuum, the throttle body purge port may be clogged and require cleaning.

EGR PORT VACUUM CHECK <4G6>

M1173002900156

White stripe

AK300786

Battery

AKX00351

1. Disconnect the vacuum hose from the solenoid valve.

2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left).

4. Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.

Battery voltage Normal condition

Applied Vacuum leaks

Not applied Vacuum maintained

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

AKX00352

5. Measure the resistance between the terminals of the solenoid valve.

Standard value: 29 − 35 Ω (at 20°C)

EGR CONTROL SOLENOID VALVE CHECK <4G6>

M1173003100249

NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position.

17-17

1. Disconnect the vacuum hose from the solenoid valve.

2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left).

4. Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.

Battery voltage

Not applied Open Vacuum

Applied Open Vacuum leaks

B nipple

Normal condition

condition

maintained

Closed Vacuum

maintained

Battery

AK201251AB

5. Measure the resistance between the terminals of the solenoid valve.

AK100016

Standard value: 29 − 35 Ω (at 20°C)

17-18

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND INSTALLATION

M1173010500175

Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3).

<4G1>

<4G6>

21 ± 4 N·m

AC208130

19 ± 3 N·m

Removal steps

1. Emission vacuum hose connection

CATALYTIC CONVERTER

REMOVAL AND INSTALLATION

M1173003900386

Refer to GROUP 15 - Exhaust Pipe and Main Muffler P.15-11.

Removal steps (Continued)

2. EGR valve

3. EGR valve gasket

AC301219

GROUP 13

FUEL

CONTENTS

MULTIPORT FUEL INJECTION (MPI) <4G1> . . . . . . . . . . . . . . 13A

MULTIPORT FUEL INJECTION (MPI) <4G6> . . . . . . . . . . . . . . 13B

13-1

FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C

NOTES

GROUP 32

POWER PLANT

MOUNT

CONTENTS

32-1

GENERAL INFORMATION . . . . . . . . 32-2

SERVICE SPECIFICATION . . . . . . . . 32-3

SPECIAL TOOL . . . . . . . . . . . . . . . . . 32-3

ENGINE MOUNTING . . . . . . . . . . . . . 32-4

REMOVAL AND INSTALLATION . . . . . . . . 32-4

TRANSMISSION MOUNTING . . . . . . 32-5

REMOVAL AND INSTALLATION . . . . . . . . 32-5

ENGINE ROLL STOPPER,

CENTERMEMBER . . . . . . . . . . . . . . . 32-7

REMOVAL AND INSTALLATION . . . . . . . . 32-7

CROSSMEMBER . . . . . . . . . . . . . . . . 32-8

REMOVAL AND INSTALLATION . . . . . . . . 32-8

32-2

POWER PLANT MOUNT

GENERAL INFORMATION

The engine mounting system employs the inertial axis four-point suspension method, which is field proven.

• The optimised locations of the front and rear roll mounts well distribute their loads thereby reducing engine idling vibrations.

CONSTRUCTION DIAGRAM

Engine front mounting bracket

• The fore-and-aft, liquid-filled engine mount of

M1321000100340

cylinder type is adopted to reduce engine shake for improved riding comfort.

Transmission mounting body side bracket

Engine front roll stopper bracket

Engine rear roll stopper bracket

Y0290AU

AC107318

AC303563

POWER PLANT MOUNT

SERVICE SPECIFICATION

Item Standard value

Protruding length of stabilizer link thread part mm 22 ± 1.5

SPECIAL TOOL

Tool Numb er Name Use

MB991897 Ball joint remover Knuckle and tie rod end ball joint

disconnection

NOTE: Steering linkage puller (MB990635 or MB991113) is also

AC106827

available to disconnect knuckle and tie rod end ball joint.

32-3

M1321000300333

M1321000600378

32-4

POWER PLANT MOUNT

ENGINE MOUNTING

REMOVAL AND INSTALLATION

M1321001100440

CAUTION

*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal Operation

Raise the engine and transmission assembly until its weight is not applied to the insulator, and support it securely.

<4G1> <4G6>

44 ± 10 N·m*

67 ± 7 N·m*

44 ± 10 N·m*

12 ± 2 N·m

67 ± 7 N·m*

AC303999 AC303968

Removal steps

1. Pressure hose clamp <4G6>

AC304304

Removal steps (Continued)

2. Self-locking nuts

3. Engine front mounting bracket

POWER PLANT MOUNT

TRANSMISSION MOUNTING

32-5

REMOVAL AND INSTALLATION

M1321001400430

CAUTION

*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal Operation

• Raise the engine and transmission assembly until its weight is not applied to the insulator, and support it securely.

• Battery and Battery tray Removal

• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner

P.15-3).

• Engine Rear Roll Stopper Bracket Removal (Refer to

P.32-7).

80 ± 7 N·m*

Post-installation Operation

• Engine Rear Roll Stopper Bracket Installation (Refer to

P.32-7).

• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner

P.15-3).

• Battery and Battery tray Installation

80 ± 7 N·m*

>>A<<

Removal steps

1. Transmission mounting body side bracket

2. Transmission mounting stopper

47 ± 7 N·m*

AC303988

47 ± 7 N·m*

AC303989

AC304258

32-6

POWER PLANT MOUNT

TRANSMISSION MOUNTING

INSTALLATION SERVICE POINT >>A<< TRANSMISSION MOUNTING

STOPPER INSTALLATION

Engine side

Transmission mounting body side bracket

Transmission mounting stopper

AC200645

Install the transmission mounting stopper so that its arrow points upward.

POWER PLANT MOUNT

ENGINE ROLL STOPPER, CENTERMEMBER

32-7

REMOVAL AND INSTALLATION

M1321002300287

CAUTION

*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal and Post-installation Operation

Under Cover Removal and Installation

45 ± 5 N·m*

<4G1> <4G6>

45 ± 5 N·m*

52 ± 7 N·m*

11 ± 1 N·m

69 ± 10 N·m

52 ± 7 N·m*

>>B<<

>>A<<

52 ± 7 N·m*

69 ± 10 N·m

Engine front roll stopper bracket and centermember removal steps

1. Engine front roll stopper bracket connecting bolt Centermember and engine front roll

•

stopper bracket assembly

2. Engine mounting cushion stopper <4G6>

3. Engine front roll stopper bracket

4. Centermember

69 ± 10 N·m

5. Engine rear roll stopper bracket

6. Transmission case rear roll stopper

7. Engine rear roll stopper bracket

AC303978

AC304309

Engine rear roll stopper bracket removal steps

connecting bolt

bracket

32-8

POWER PLANT MOUNT

CROSSMEMBER

INSTALLATION SERVICE POINTS >>A<< ENGINE FRONT ROLL STOPPER

BRACKET INSTALLATION

Hole

>>B<< ENGINE MOUNTING CUSHION STOPPER INSTALLATION <4G6>

Engine mounting cushion stopper

Hole

Front of vehicle

AC005918

Install the engine front roll stopper bracket so that its hole points towards the front side of the vehicle.

Install the engine mounting cushion stopper as shown.

Front of vehicle

AC304315

CROSSMEMBER

REMOVAL AND INSTALLATION

CAUTION

• Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B Service Precautions P.52B-5, Air bag Module and Clock Spring P.52B-210. Also, set the front wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this, the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious injury.

: Indicates parts which should be initially tightened, and then fully tightened after placing the

• * vehicle horizontally and loading the full weight of the engine on the vehicle body.

: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle

• * on the earth in the unladen condition.

Pre-removal Operation

• Centermember Removal (Refer to P.32-7).

• Front Exhaust Pipe Removal (Refer to GROUP 15,

Exhaust Pipe and Main Muffler P.15-11).

• Stee ring Wheel Air Bag Module Assembly Removal (Refer to GROUP 37, Steering Wheel P.37-17).

• Power Steering Fluid Draining (Refer to GROUP 37, On-vehicle Service P.37-13).

M1321003200368

Post-installation Operation

• Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-11).

• Centermember Installation (Refer to P.32-7).

• Clock Spring Centring (Refer to GROUP 52B, Air Bag

Modules and Clock Spring P.52B-210).

• Steering Wheel Air Bag Module Assembly Installation (Refer to GROUP 37, Steering Wheel P.37-17).

• Power Steering Fluid Supplying (Refer to GROUP 37, On-vehicle Service P.37-13).

• Power Steering Fluid Line Bleeding (Refer to GROUP 37, On-vehicle Service P.37-13).

• Press the dust cover with a finger to check whether the dust cover cracked or damaged.

• Checking Steering Wheel Position with Wheels Straight Ahead.

• Front Wheel Alignment Check and Adjustment (Refer to GROUP 33, On-vehicle Service P.33-5).

<L.H. drive vehicles>

POWER PLANT MOUNT

CROSSMEMBER

32-9

52 ± 7 N·m*

45 ± 5 N·m*

12 ± 2 N·m

70 ± 10 N·m

21 ± 4 N·m

70 ± 10 N·m

57 ± 7 N·m

18 ± 2 N·m

25 ± 4 N·m

21 ± 4 N·m

108 ± 10 N·m

>>B<<

186 ± 10 N·m*

Removal steps

1. Lower arm and knuckle connection

2. Self-locking nut

3. Lower arm assembly

4. Shaft cover

5. Steering shaft assembly and gear box connecting bolt

6. Engine rear roll stopper bracket connection bolt

7. Engine rear roll stopper bracket

8. Return hose connection

167 ± 9 N·m

49 ± 10 N·m

<<A>> <<B>>

>>A<<

AC304000

Removal steps (Continued)

9. Eye bolt

10. Pressure hose connection

11. Gasket

12. Clamp

13. Self-locking nut

14. Tie rod end and knuckle connection Crossmember assembly

•

15. Stabilizer bar

16. Steering gear and linkage

17. Crossmember

32-10

<R.H. drive vehicles>

POWER PLANT MOUNT

CROSSMEMBER

52 ± 7 N·m*¹

45 ± 5 N·m*¹

57 ± 7 N·m

18 ± 2 N·m

5.0 ± 1.0 N·m

70 ± 10 N·m

25 ± 4 N·m

21 ± 4 N·m

108 ± 10 N·m

>>B<<

186 ± 10 N·m*²

167 ± 9 N·m

Removal steps

1. Lower arm and knuckle connection

2. Self-locking nut

3. Lower arm assembly

4. Eye bolt

5. Pressure hose connection

6. Gasket

7. Return hose connection

8. Shaft cover

9. Steering shaft assembly and gear box connecting bolt

49 ± 10 N·m

<<A>>

<<B>>

>>A<<

AC101614

Removal steps (Continued)

10. Self-locking nut

11. Ti e r od end a nd knu c k le conn e c tion

12. Engine rear roll stopper bracket connection bolt Crossmember assembly

•

13. Engine rear roll stopper bracket

14. Stabilizer bar

15. Steering gear and linkage

16. Crossmember

POWER PLANT MOUNT

CROSSMEMBER

32-11

REMOVAL SERVICE POINTS <<A>> TIE ROD END AND KNUCKLE

DISCONNECTION

CAUTION

• Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to ball joint threads.

• Hang special tool with a cord to prevent it from falling.

Cord

Nut

Ball joint

1. Install the special tool ball joint remover (MB991897) as shown in the figure.

MB991897

Bolt

AC208247

<<B>> CROSSMEMBER ASSEMBLY REMOVAL

Piece of wood

Transmission jack

AC102600

1. Use a transmission jack to hold the crossmember, and then remove the crossmember mounting nuts and bolts.

2. Lower the crossmember with the engine rear roll stopper bracket, the stabilizer bar, the return tube, and the steering gear.

INSTALLATION SERVICE POINTS >>A<< STABILIZER

BAR/BUSHING/FIXTURE INSTALLATION

Bolt

Parallel

Knob

Good

Bad

AC106821

2. Turn the bolt and knob as necessary to make the jaws of the special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.

3. Tighten the bolt with a wrench to disconnect the tie rod end.

Outside of vehicle

Bushing (LH)

Approximately 10 mm

Identification mark

Fixture (LH)

AC006141

Align the stabilizer bar identification mark with the right end of the bushing (LH).

>>B<< SELF-LOCKING NUT INSTALLATION

AC101741

Tighten the self-locking nut until the stabilizer link thread part protruding length meets the standard value.

Standard value (A): 22 ± 1.5 mm

NOTES

GROUP 15

INTAKE AND

EXHAUST

CONTENTS

15-1

GENERAL INFORMATION . . . . . . . . 15-2

SERVICE SPECIFICATION . . . . . . . . 15-2

SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2

AIR CLEANER . . . . . . . . . . . . . . . . . . 15-3

REMOVAL AND INSTALLATION . . . . . . . . 15-3

INLET MANIFOLD . . . . . . . . . . . . . . . 15-5

REMOVAL AND INSTALLATION <4G1> . . 15-5

REMOVAL AND INSTALLATION <4G6> . . 15-6

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-7

EXHAUST MANIFOLD . . . . . . . . . . . . 15-7

REMOVAL AND INSTALLATION <4G1> . . 15-7

REMOVAL AND INSTALLATION <4G6> . . 15-9

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-10

EXHAUST PIPE AND MAIN

MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-11

REMOVAL AND INSTALLATION . . . . . . . . 15-11

15-2

INTAKE AND EXHAUST

GENERAL INFORMATION

The exhaust pipe is divided into three parts.

SERVICE SPECIFICATION

Item Standard value Limit

Manifold distortion of the installation surface mm 0.15 or less 0.20

SPECIAL TOOL

Tool Numb e r Name Use

MD998770 Oxygen sensor wrench Removal and installation of

engine control oxygen sensor

M1151000100402

M1151000300428

M1151000600399

INTAKE AND EXHAUST

AIR CLEANER

15-3

REMOVAL AND INSTALLATION

M1151002100486

CAUTION

Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions.

• Avoid any shock or load to these parts when removing and installing them.

• When installing, securely set the air cleaner cover clamp to the air cleaner body.

NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state and local laws.

<4G1>

9.0 ± 1.0 N·m

10*

4.0 ± 1.0 N·m

12 ± 1 N·m

9.0 ± 1.0 N·m

12 ± 1 N·m

Clamp

AC303618

15-4

INTAKE AND EXHAUST

AIR CLEANER

<4G6>

10*

9.0 ± 1.0 N·m

12 ± 1 N·m

Removal steps

1. Air cleaner intake duct

2. Air cleaner air flow sensor connector <4G6>

3. Air cleaner assembly <4G1> or Air cleaner and air cleaner air flow sensor assembly <4G6>

4. Rocker cover breather hose connection

5. Air cleaner to throttle body duct

4.0 ± 1.0 N·m

12 ± 1 N·m

6. Air cleaner air flow sensor <4G6>

7. Air cleaner air flow sensor gasket

8. Air cleaner cover

9. Air cleaner element

10. Air cleaner body assembly

11. Ai r clea n e r brack e t

4.0 ± 1.0 N·m

8.8 ± 1.0 N·m

Clamp

9.0 ± 1.0 N·m

AC303619

Removal steps (Continued)

<4G6>

INTAKE AND EXHAUST

INLET MANIFOLD

15-5

REMOVAL AND INSTALLATION <4G1>

M1151003000749

Pre-removal Operation

• Fuel Line Pressure Reduction (Refer to GROUP 13A On-vehicle Service P.13A-389).

• Engine Coolant Draining (Refer to GROUP 14 On-vehicle Service P.14-22).

• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).

• Throttle Body Assembly Removal (Refer to GROUP 13A

P.13A-400).

• Fuel Delivery Pipe and Fuel Injector Assembly Removal (Refer to GROUP 13A P.13A-398).

9.0 ± 1.0 N·m

21 ± 4 N·m

18 ± 2 N·m

9.0 ± 1.0 N·m

Post-installation Operation

• Fuel Delivery Pipe and Fuel Injector Assembly Installation (Refer to GROUP 13A P.13A-398).

• Throttle Body Assembly Installation (Refer to GROUP 13A P.13A-400).

• Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).

• Engine Coolant Supplying (Refer to GROUP 14 -

On-vehicle Service P.14-22).

• Accelerator Cable Adjustment (Refer to GROUP 17 On-vehicle Service P.17-2).

• Fuel Leak Check

18 ± 2 N·m

5.0 ± 1.0 N·m

18 ± 2 N·m

31 ± 3 N·m

49 ± 9 N·m

Removal steps

1. Inlet manifold absolute pressure sensor

2. Engine control pressure sensor O-ring

3. Engine control detonation sensor connector

4. T/M housing front lower cover stay (L.H.)

5. Battery wiring harness clamp connection

6. Inlet manifold stay

7. Brake booster vacuum hose connection

AC303642

Removal steps (Continued)

8. Emission control equip hose connection

9. Fuel vapour control hose connection

10. Inlet manifold stay

11. Inlet m a n ifol d

12. Inlet manifold gasket

13. EGR valve

14. EGR valve gasket

15. Emission vacuum hose & pipe and emission solenoid valve assembly

15-6

INTAKE AND EXHAUST

INLET MANIFOLD

REMOVAL AND INSTALLATION <4G6>

M1151003001236

Pre-removal Operation

• Fuel Line Pressure Reduction (Refer to GROUP 13A On-vehicle Service P.13A-389).

• Engine Coolant Draining (Refer to GROUP 14 On-vehicle Service P.14-22).

• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).

• Throttle Body Assembly Removal (Refer to GROUP 13B

P.13B-336).

• Fuel Delivery Pipe and Fuel Injector Assembly Removal (Refer to GROUP 13B P.13B-334).

5.0 ± 1.0 N·m

20 ± 2 N·m

Post-installation Operation

• Fuel Delivery Pipe and Fuel Injector Assembly Installation (Refer to GROUP 13B P.13B-334).

• Throttle Body Assembly Installation (Refer to GROUP 13B P.13B-336).

• Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).

• Engine Coolant Supplying (Refer to GROUP 14 -

On-vehicle Service P.14-22).

• Accelerator Cable Adjustment (Refer to GROUP 17 On-vehicle Service P.17-2).

• Fuel Leak Check

11 ± 1 N·m

9.0 ± 1.0 N·m

36 ± 6 N·m

13 ± 1 N·m

(Engine oil)

36 ± 6 N·m

11 ± 1 N·m

20 ± 2 N·m

36 ± 6 N·m

31 ± 3 N·m

Removal steps

1. Emission control equip hose connector

2. Brake booster vacuum hose connection

3. Earth cable connection

AC303657

Removal steps (Continued)

4. Engine control detonation sensor connector

5. Engine oil level gauge and guide assembly

6. Engine oil filler O-ring

7. Emission vacuum hose connection

INTAKE AND EXHAUST

EXHAUST MANIFOLD

Removal steps (Continued)

8. Battery wiring harness clamp

9. Inlet manifold stay

10. Inlet manifold

11. Inlet m a n ifol d g asket

12. Emission vacuum hose & pipe and emission solenoid valve assembly

13. EGR valve

14. EGR valve gasket

15-7

INSPECTION

M1151003100616

Check the following points; replace the part if a problem is found.

Inlet Manifold Check

1. Check for damage or cracking of any part.

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION <4G1>

M1151003300568

29 ± 3 N·m

2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation passages.

3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm or less Limit: 0.20 mm

29 ± 3 N·m

44 ± 5 N·m

(Engine oil)

29 ± 3 N·m

24 ± 4 N·m

35 ± 6 N·m

50 ± 10 N·m

17 ± 2 N·m

29 ± 3 N·m

AC303662

15-8

INTAKE AND EXHAUST

EXHAUST MANIFOLD

Removal steps

1. Front exhaust pipe connection

2. Exhaust pipe gasket

<<A>> >>A<<

3. Engine control oxygen sensor (front)

4. Engine oil level gauge and guide assembly

5. Engine oil filler O-ring

REMOVAL SERVICE POINT <<A>> ENGINE CONTROL OXYGEN

SENSOR (FRONT) REMOVAL

MD998770

Engine control oxygen sensor (front)

AC212566

Use special tool oxygen sensor wrench (MD998770) to remove the engine control oxygen sensor (front).

Removal steps (Continued)

6. Exhaust manifold cover

7. Exhaust manifold bracket

8. Exhaust manifold

9. Exhaust manifold gasket

INSTALLATION SERVICE POINT >>A<< ENGINE CONTROL OXYGEN

SENSOR (FRONT) INSTALLATION

MD998770

Engine control oxygen sensor (front)

AC212566

Use special tool oxygen sensor wrench (MD998770) to install the engine control oxygen sensor (front).

INTAKE AND EXHAUST

EXHAUST MANIFOLD

15-9

REMOVAL AND INSTALLATION <4G6>

Pre-removal and Post-installation Operation

Under cover Removal and Installation

29 ± 3 N·m

49 ± 9 N·m

M1151003300579

49 ± 5 N·m

29 ± 3 N·m

14 ± 1 N·m

44 ± 5 N·m

<<A>> >>A<<

9.0 ± 2.0 N·m

Removal steps

1. Front exhaust pipe connection

2. Exhaust pipe gasket

3. Engine control oxygen sensor (front)

4. Exhaust manifold cover

5. Exhaust manifold bracket

49 ± 5 N·m

44 ± 5 N·m

50 ± 10 N·m

35 ± 6 N·m

14 ± 1 N·m

AC303680

Removal steps (Continued)

6. Starter cover

7. Starter cover bracket

8. Engine hanger

9. Exhaust manifold

10. Exhaust manifold gasket

15-10

INTAKE AND EXHAUST

EXHAUST MANIFOLD

REMOVAL SERVICE POINT <<A>> ENGINE CONTROL OXYGEN

SENSOR (FRONT) REMOVAL

MD998770

Engine control oxygen sensor (front)

AC212566

Use special tool oxygen sensor wrench (MD998770) to remove the engine control oxygen sensor (front).

INSPECTION

M1151003400543

Check the following points; replace the part if a problem is found.

Exhaust Manifold Check

1. Check for damage or cracking of any part.

INSTALLATION SERVICE POINT >>A<< ENGINE CONTROL OXYGEN

SENSOR (FRONT) INSTALLATION

MD998770

Engine control oxygen sensor (front)

AC212566

Use special tool oxygen sensor wrench (MD998770) to install the engine control oxygen sensor (front).

2. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm or less Limit: 0.20 mm

INTAKE AND EXHAUST

EXHAUST PIPE AND MAIN MUFFLER

15-11

REMOVAL AND INSTALLATION

<4G1>

45 ± 5 N·m

50 ± 10 N·m

<4G6>

M1151008700301

13 ± 2 N·m

59 ± 10 N·m

13 ± 2 N·m

45 ± 5 N·m

AC303694

13 ± 2 N·m

45 ± 5 N·m

50 ± 10 N·m

Exhaust main muffler removal steps

1. Exhaust main muffler

3. Exhaust pipe gasket

4. Exhaust muffler hanger

Centre exhaust pipe removal steps

2. Centre exhaust pipe

3. Exhaust pipe gasket

7. Exhaust pipe gasket

59 ± 10 N·m

<<A>> >>A<<

AC30 3695

Front exhaust pipe removal steps

5. Engine control oxygen sensor (rear)

6. Front exhaust pipe

7. Exhaust pipe gasket

8. Exhaust pipe gasket

9. Exhaust muffler hanger

15-12

INTAKE AND EXHAUST

EXHAUST PIPE AND MAIN MUFFLER

REMOVAL SERVICE POINT <<A>> ENGINE CONTROL OXYGEN

SENSOR (REAR) REMOVAL

MD998770

Engine control oxygen sensor (rear)

AC212566

Use special tool oxygen sensor wrench (MD998770) to remove the engine control oxygen sensor (rear).

INSTALLATION SERVICE POINT >>A<< ENGINE CONTROL OXYGEN

SENSOR (REAR) INSTALLATION

MD998770

Engine control oxygen sensor (rear)

AC212566

Use special tool oxygen sensor wrench (MD998770) to install the engine control oxygen sensor (rear).

GROUP 14

ENGINE COOLING

CONTENTS

14-1

GENERAL INFORMATION . . . . . . . . 14-2

SERVICE SPECIFICATIONS. . . . . . . 14-2

LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2

SEALANTS . . . . . . . . . . . . . . . . . . . . 14-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-3

TROUBLESHOOTING . . . . . . . . . . . . 14-5

INSPECTION CHART FOR TROUBLE

SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 14-5

INSPECTION PROCEDURE FOR

TROUBLE SYMPTOMS . . . . . . . . . . . . . . . 14-6

ON-VEHICLE SERVICE. . . . . . . . . . . 14-22

ENGINE COOLANT LEAK CHECK . . . . . . 14-22

RADIATOR CAP VALVE OPENING

PRESSURE CHECK. . . . . . . . . . . . . . . . . . 14-22

ENGINE COOLANT REPLACEMENT . . . . 14-22

CONCENTRATION MEASUREMENT . . . . 14-23

COOLING FAN MOTOR DRIVE CONTROL

UNIT CHECK. . . . . . . . . . . . . . . . . . . . . . . . 14-23

FAN CONTROL RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24

COOLING FAN MOTOR CHECK . . . . . . . . 14-25

THERMOSTAT . . . . . . . . . . . . . . . . . . 14-26

REMOVAL AND INSTALLATION . . . . . . . . 14-26

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-27

WATER PUMP . . . . . . . . . . . . . . . . . . 14-29

REMOVAL AND INSTALLATION <4G1> . . 14-29

REMOVAL AND INSTALLATION <4G6> . . 14-30

WATER HOSE AND WATER PIPE . . 14-31

REMOVAL AND INSTALLATION <4G1> . . 14-31

REMOVAL AND INSTALLATION <4G6> . . 14-33

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-34

RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-35

REMOVAL AND INSTALLATION . . . . . . . . 14-35

14-2

ENGINE COOLING

GENERAL INFORMATION

The cooling system is designed to keep every part of the engine at appropriate temperature in whatever condition the engine may be operated. The cooling method is of the water-cooled, pressure forced circulation type in which the water pump pressurizes coolant and circulates it throughout the engine. If the coolant temperature exceeds the prescribed

Item Specification

Radiator Performance kJ/h 4G13 Standard vehicles 137,720

temperature, the thermostat opens to circulate the coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into the air. The water pump is of the centrifugal type and is driven by the alternator drive belt from the crankshaft. The radiator is the corrugated fin, down flow type.

M1141000100371

Vehicles with capacity up radiator (option)

4G18 Standard vehicles 161,288

Vehicles with capacity up radiator (option)

4G63 181,800

A/T oil cooler Performance kJ/h 5,651

161,288

181,800

SERVICE SPECIFICATIONS

M1141000300416

Item Standard value Limit

High-pressure valve opening pressure of radiator cap kPa 93 − 123 Minimum 83

Range of coolant antifreeze concentration of radiator % 30 − 60 -

Thermostat Valve opening temperature of

thermostat °C

Full-opening temperature of thermostat °C

Valve lift mm 8.5 or m or e -

4G1 88 ± 1.5 -

4G6 82 ± 1.5 -

4G1 100 -

4G6 95 -

LUBRICANT

Item Specified coolant Quantity L

Engine coolant (including condense tank)

DIAQUEEN SUPER LONG LIFE COOLANT or an equivalent

4G1 5.0

4G6 7.0

M1141000400338

ENGINE COOLING

SEALANTS

Item Specified sealant

Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent

14-3

M1141000500324

Water pump <4G1>, Thermostat case <4G6>, Cooling water outlet hose fitting <4G6>

MITSUBISHI GENUINE Part No.MD970389 or equivalent

SPECIAL TOOLS

Tool Numb e r Name Use

MB991502 MUT-II sub assembly Reading diagnosis code

B991502

M1141000600246

14-4

ENGINE COOLING

SPECIAL TOOLS

Tool Numb e r Name Use

DO NOT USE

MB991824

MB991827

MB991910

MB991911

MB991955

A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826

MUT-III sub assembly

A: Vehicle

communication

interface (V.C.I.) B: MUT-III USB cable C: MUT-III main

harness A (Vehicles

with CAN

communication

system) D: MUT-III main

harness B (Vehicles

without CAN

communication

system) E: MUT-III

measurement

adapter F: MUT-III trigger

harness

Checking the A/T (Diagnosis display using the MUT-III)

MB991825

MB991826

MB991955

ENGINE COOLING

TROUBLESHOOTING

Tool Numb e r Name Use

14-5

MB991223

A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set

A: Test harness B: LED harness C: LED harness

adapter D: Probe

Making voltage and resistance measurement during troubleshooting

A: Connector pin contact

pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester

connection

MB991223

MB991871 LLC changer Coolant refilling

MB991871

TROUBLESHOOTING

INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Inspection

Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan <4G6> do not operate

Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan <4G6> do not change speed or stop

Cooling fan (L.H.) does not operate {When cooling fan (R.H.) <4G1> or A/C condenser fan <4G6> operate} <Vehicles with A/C>

Cooling fan (R.H.) <4G1> or A/C condenser fan <4G6> does not operate {When cooling fan (L.H.) operate} <Vehicles with A/C>

M1141005600360

procedure No.

Reference page

P.14-6

P.14-16

P.14-20

P.14-21

14-6

ENGINE COOLING

TROUBLESHOOTING

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or A/C Condenser Fan <4G6> do not Operate

Cooling Fan (L.H.) and Cooling Fan (R.H.) or A/C Condenser Fan Drive Circut

ENGINE-ECU <M/T> OR ENGINE-A/T-ECU <A/T>

C-123

(MU801824)

C-122

(MU803784)

A-13

(MU802611)

C-111

2 3 4

21 C-123 <M/T> 18 C-122 <A/T>

1 A-13 <LHD> 12 C-111 <RHD>

1179810

FAN CONTROL RELAY A-09X

FUSIBLE LINK No.2

B-W

R-Y

J/C (6)

C-12 <LHD> C-134 <RHD>

R-Y

8 A-13 <LHD> 11 C-111 <RHD>

R-Y

ENGINE CONTROL RELAY B-16X

A-13

(MU802611)

C-111

2 3 4

1179810

(MU802322)

COOLING FAN MOTOR DRIVE CONTROL UNIT

COOLING FAN MOTOR (R.H.) <4G1 (VEHICLES WITH A/C> OR A/C CONDENSER FAN MOTOR <4G6>

A-18-1

A-18

2211

A-18-2

COOLING FAN MOTOR (L.H.)

Wire colour code B : Black LG : Light green

G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

AC303577

ENGINE COOLING

TROUBLESHOOTING

14-7

CIRCUIT OPERATION

• The cooling fan motor drive control unit is powered from fusible link (2).

• The engine-ECU <M/T> or engine-A/T-ECU <A/T> uses input signals from the A/C switch, the water temperature sensor unit and the vehicle speed sensor <M/T> or the output shaft speed sensor <A/T> to control the speed of the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6>.

• The engine-ECU <M/T> or engine-A/T-ECU <A/T> controls the cooling fan motor drive control unit to activate the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6>.

TECHNICAL DESCRIPTION

• The cause could be a malfunction of the cooling fan motor drive control unit power supply or earth circuit.

• If the communication line wiring harness between the cooling fan motor drive control unit and the engine-ECU <M/T> or engine-A/T-ECU <A/T> is short-circuited to earth, the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)> or the A/C condenser fan motor <4G6> will not rotate.

• The cause could also be a malfunction of the cooling fan motor (L.H.). <Vehicles without A/C>

• The cause could also be a malfunction of imput signal from the A/C switch, the water temperature sensor unit and the vehicle speed sensor <M/T> or the output shaft speed sensor <A/T> to the engine-ECU <M/T> or engine-A/T-ECU <A/T>.

• The cause could also be a malfunction of the cooling fan motor drive control unit or the engine-ECU <M/T> or engine-A/T-ECU <A/T>.

TROUBLESHOOTING HINTS

• Malfunction of fusible link (2)

• Malfunction of fan control relay

• Malfunction of cooling fan motor (L.H.) <Vehicles

without A/C>

• Malfunction of cooling fan motor drive control unit

• Malfunction of engine-ECU <M/T> or

engine-A/T-ECU <A/T>

• Damaged wiring harness or connector

DIAGNOSIS

STEP 1. Check the cooling fan motor (L.H.). <Vehicles without A/C>

Refer to P.14-25.

Q: Is the cooling fan motor (L.H.) in good condition?

Go to Step 2 .

YES : NO : Replace the cooling fan motor (L.H.) (Refer

to P.14-35). Then go to Step 24 .

STEP 2. Measure the power supply voltage at cooling fan motor drive control unit connector A-18.

Connector: A-18

A-18

3 2 1

AC100293

(1) Disconnect cooling fan motor drive control unit

connector A-18 and measure wiring harness side connector.

(2) Turn the ignition switch to the "ON" position.

A-18 Connector (Component side)

AC000246

(3) Measure the voltage between cooling fan motor

drive control unit connector A-18 terminal 3 and body earth.

• The voltage should measure system voltage.

(4) Turn the ignition switch to the "LOCK" (OFF)

position.

(5) Connect cooling fan motor drive control unit

connector A-18.

Q: Is the measured voltage system voltage?

Go to Step 17 .

YES : NO : Go to Step 3 .

14-8

ENGINE COOLING

TROUBLESHOOTING

STEP 3. Check the cooling fan motor drive control unit connector A-18.

Connector: A-18

A-18

3 2 1

AC100293

Q: Is the connector in good condition?

YES : .

Go to Step 4 .

NO : . Repair or replace the connector. Then go to

Step 24 .

STEP 4. Check the fusible link No.2.

Relay box

(1) Disconnect fan control relay connector A-09X

(remove the fan control relay) and measure relay box side connector.

(2) Turn the ignition switch to the "ON" position.

A-09X Connector (Relay box side)

AC303511

(3) Measure the voltage between fan control relay

connector A-09X terminal 4 and body earth.

• The voltage should measure system voltage.

(4) Turn the ignition switch to the "LOCK" (OFF)

position.

(5) Connect fan control relay connector A-09X

(install the fan control relay).

Q: Is the measured voltage system voltage?

Go to Step 8 .

YES : NO : Go to Step 6 .

Fusible link No.2

AC303509

Q: Is the fusible link No.2 in good condition?

YES : .

Go to Step 5 .

NO : . Replace the fusible link No.2. Then go to

Step 24 .

STEP 5. Measure the power supply voltage at fan control relay connector A-09X.

Connector: A-09X

A-09X

Relay box

Fan control relay

AC303510

STEP 6. Check the fan control relay connector A-09X.

Connector: A-09X

A-09X

Q: Is the connector in good condition?

YES :

Go to Step 7 .

NO : Repair the connector or replace the relay

Relay box

Fan control relay

AC303510

box. Then go to Step 24 .

ENGINE COOLING

TROUBLESHOOTING

14-9

STEP 7. Check the harness wire between fusible link No.2 and fan control relay connector A-09X terminal 4.

Relay box

Fusible link No.2

Connector: A-09X

AC303509

Relay box

Fan control relay

A-09X

Q: Is the connector in good condition?

Go to Step 10 .

YES : NO : Repair the connector or replace the relay

box. Then go to Step 24 .

STEP 10. Check the harness wire between fan control relay connector A-09X terminal 2 and cooling fan motor drive control unit connector A-18 terminal 3.

Connector: A-09X

A-09X

Connector: A-18

Relay box

Fan control relay

AC303510

Q: Is the harness wire in good condition?

YES : .

An intermittent malfunction is suspected (Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : . Repair the damaged harness wire. Then go

to Step 24 .

STEP 8. Check the fan control relay.

Refer to P.14-24.

Q: Is the fan control relay in good condition?

Go to Step 9 .

YES : NO : Replace the fan control relay. Then go to

Step 24 .

STEP 9. Check the fan control relay connector A-09X.

Connector: A-09X

Relay box

Fan control relay

A-18

3 2 1

AC100293

Q: Is the harness wire in good condition?

Go to Step 11 .

YES : NO : Repair the damaged harness wire. Then go

to Step 24 .

STEP 11. Measure the terminal voltage at fan control relay connector A-09X.

Connector: A-09X

A-09X

Relay box

Fan control relay

A-09X

AC303510

(1) Disconnect fan control relay connector A-09X

(remove the fan control relay) and measure relay box side connector.

(2) Turn the ignition switch to the "ON" position.

14-10

A-09X Connector (Relay box side)

ENGINE COOLING

TROUBLESHOOTING

STEP 12. Check the J/C No.6 C-12 <L.H. drive vehicles> or C-134 <R.H. drive vehicles>, intermediate connector A-13 <L.H. drive vehicles> C-111 <R.H. drive vehicles> and fan control relay connector A-09X.

Connector: C-12 <L.H. drive vehicles>

AC303517

(3) Measure the voltage between fan control relay

connector A-09X terminal 1 and body earth.

• The voltage should measure system voltage.

(4) Turn the ignition switch to the "LOCK" (OFF)

position.

(5) Connect fan control relay connector A-09X

(install the fan control relay).

Q: Is the measured voltage system voltage?

YES : . NO : . Go to Step 12 .

Go to Step 14 .

C-12

AC303524

Connector: C-134 <R.H. drive vehicles>

C-134

AC303525

Connector: A-13 <L.H. drive vehicles>

A-13

AC303526

Connector: C-111 <R.H. drive vehicles>

C-111

2 3 4

1179810

AC303527

ENGINE COOLING

TROUBLESHOOTING

14-11

Connector: A-09X

A-09X

Relay box

Fan control relay

AC303510

Q: Are there connectors in good condition?

YES : .

Go to Step 13 .

NO : . Repair or replace the connector. Then go to

Step 24 .

STEP 13. Check the harness wire between J/C No.6 C-12 terminal 33 <L.H. drive vehicles> or C-134 terminal 33 <R.H. drive vehicles> and fan control relay connector A-09X terminal 1.

Connector: C-12 <L.H. drive vehicles>

Q: Are these harness wires in good condition?

An intermittent malfunction is suspected

YES :

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Repair the damaged harness wire. Then go

to Step 24 .

STEP 14. Check the continuity between fan control relay connector A-09X and body earth.

Connector: A-09X

A-09X

Relay box

Fan control relay

AC303510

(1) Disconnect fan control relay connector A-09X

(remove the fan control relay) and measure relay box side connector.

C-12

AC303524

Connector: C-134 <R.H. drive vehicles>

C-134

AC303525

Connector: A-09X

Relay box

Fan control relay

A-09X Connector (Relay box side)

AC303533

(2) Measure the resistance between fan control relay

connector A-09X terminal 3 and body earth.

• Continuity exists.

(3) Connect fan control relay connector A-09X

(install the fan control relay).

Q: Does the continuity exists?

YES : An intermittent malfunction is suspected

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Go to Step 15 .

A-09X

AC303510

14-12

ENGINE COOLING

TROUBLESHOOTING

STEP 15. Check the fan control relay connector A-09X.

Connector: A-09X

A-09X

Q: Is the connector in good condition?

Go to Step 16 .

YES : NO : Repair the connector or replace the relay

Relay box

Fan control relay

AC303510

box. Then go to Step 24 .

STEP 16. Check the harness wire between fan control relay connector A-09X terminal 3 and body earth.

Connector: A-09X

Relay box

STEP 17. Check the continuity between cooling fan motor drive control unit connector A-18 and body earth.

Connector: A-18

A-18

3 2 1

AC100293

(1) Disconnect cooling fan motor drive control unit

connector A-18 and measure wiring harness side connector.

A-18 Connector (Wiring harness side)

Fan control relay

A-09X

AC303510

Q: Is the harness wire in good condition?

An intermittent malfunction is suspected

YES :

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Repair the damaged harness wire. Then go

to Step 24 .

AC303534

(2) Measure the resistance between cooling fan

motor drive control unit connector A-18 terminal 1 and body earth.

• Continuity exists.

(3) Connect cooling fan motor drive control unit

connector A-18.

Q: Dose the continuity exists?

YES : Go to Step 20 . NO : Go to Step 18 .

ENGINE COOLING

TROUBLESHOOTING

14-13

STEP 18. Check the cooling fan motor drive control unit connector A-18.

Connector: A-18

A-18

3 2 1

AC100293

Q: Is the connector in good condition?

Go to Step 19 .

YES : NO : Repair or replace the connector. Then go to

Step 24 .

STEP 19. Check the harness wire between cooling fan motor drive control unit connector A-18 terminal 1 and body earth.

Connector: A-18

STEP 20. Check the cooling fan motor drive control unit connector A-18, intermediate connector A-13 <L.H. drive vehicles> or C-111 <R.H. drive vehicles> and engine-ECU connector C-123 <M/T> or engine-A/T-ECU connector C-122 <A/T>.

Connector: A-18

A-18

3 2 1

AC100293

Connector: A-13 <L.H. drive vehicles>

A-13

A-18

3 2 1

AC100293

Q: Is the harness wire in good condition?

An intermittent malfunction is suspected

YES :

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Repair the damaged harness wire. Then go

to Step 24 .

A-13

AC303526

Connector: C-111 <R.H. drive vehicles>

C-111

2 3 4

1179810

AC303527

14-14

ENGINE COOLING

TROUBLESHOOTING

Connector: C-123 <M/T>, C-122 <A/T>

Engine-ECU <M/T> or engine-A/T-ECU <A/T>

C-123 <M/T> or C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these connectors in good condition?

Go to Step 21 .

YES : NO : Repair or replace the connector. Then go to

Step 24 .

STEP 21. Check the harness wire between cooling fan motor drive control unit connector A-18 terminal 2 and engine-ECU connector C-123 terminal 21 <M/T> or engine-A/T-ECU connector C-122 terminal 18 <A/T>.

Connector: A-18

A-18

3 2 1

AC100293

Connector: C-123 <M/T>, C-122 <A/T>

Engine-ECU <M/T> or engine-A/T-ECU <A/T>

C-123 <M/T> or C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these harness wires in good condition?

YES : Go to Step 22 . NO : Repair the damaged harness wire. Then go

to Step 24 .

ENGINE COOLING

TROUBLESHOOTING

14-15

STEP 22. Check the cooling fan motor drive control unit.

Connector: C-123 <M/T>, C-122 <A/T>

Engine-ECU <M/T> or engine-A/T-ECU <A/T>

C-123 <M/T> or C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555

(1) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>.

(5) Check for the cooling fan operation.

• The cooling fan rotates. (with connector terminal pin 21 <M/T> or 18 <A/T> disconnected)

• The cooling fan stops. (When connector terminal pin 21 <M/T> or 18 <A/T> is connected to the body earth.)

(6) Turn the ignition switch to the "OFF" position. (7) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>, and push in connector terminal pin 21 <M/T> or 18 <A/T> to disconnect connector.

(8) Reconnect the connector with connector terminal

pin still installed.

Q: Does the cooling fan rotate? And when the

connector terminal pin is connected to the body earth, does the cooling fan stop?

YES :

Go to Step 23 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 24 .

STEP 23. MUT-II/III self-diag code

Check if an MPI system self-diag code is set. (Refer to GROUP 13A - Trouble shooting P.13A-9) <4G1> or (Refer to GROUP 13B - Trouble shooting

P.13B-9) <4G6>.

C-123 connector <M/T> (Harness side connector: ECU side view)

C-122 connector <A/T> (Harness side connector: ECU side view)

AC303559

(2) Pull out connector terminal pin 21 <M/T> or 18

<A/T> to disconnect connector.

(3) Reconnect the connector with connector terminal

pin still removed.

(4) Turn the ignition switch to the "ON" position.

Q: Diagnosis code set?

Inspection chart for diagnosis code (Refer

YES :

to GROUP 13A - Trouble shooting

P.13A-15) <4G1> or Inspection chart for

diagnosis code (Refer to GROUP 13B Trouble shooting P.13B-15) <4G6>.

NO : Replace the engine-ECU <M/T> or

engine-A/T-ECU <A/T> (Refer to GROUP 13A P.13A-401). Then go to Step 24 .

STEP 24. Check the symptoms.

Q: Does the cooling fan motor (L.H.) and the cooling

fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6> operate correctly?

YES :

This symptoms is complete.

NO : Return to Step 1 .

14-16

ENGINE COOLING

TROUBLESHOOTING

INSPECTION PROCEDURE 2: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or A/C Condenser Fan <4G6> do not Change Speed or Stop

COOLING FAN (L.H.) AND COOLING FAN (R.H.) OR A/C CONDENSER FAN DRIVE CIRCUIT

Refer to P.14-6.

CIRCUIT OPERATION

Refer to P.14-6.

TECHNICAL DESCRIPTION

• If the communication line wiring harness between the cooling fan motor drive control unit and the engine-ECU <M/T> or the engine-A/T-ECU <A/T> is open, the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)>, or the A/C condenser fan motor <4G6> rotate to prevent the engine from overheating.

• If the system voltage is continuously supplied to the cooling fan motor drive control unit by a fan motor relay malfunction and a short circuit on the cooling fan motor drive control unit power supply wiring harness, the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)>, or the A/C condenser fan motor <4G6> rotate.

• The cause could also be a malfunction of the cooling fan motor (L.H.). <Vehicles without A/C>

• The cause could also be a malfunction of input signal from the A/C switch, the water temperature sensor unit and the vehicle speed sensor <M/T> or the output shaft speed sensor <A/T> to the engine-ECU <M/T or engine-A/T-ECU <A/T>.

• The cause could also be a malfunction of the cooling fan motor drive control unit or the engine-ECU <M/T> or engine-A/T-ECU <A/T>.

TROUBLESHOOTING HINTS

• Malfunction of fan control relay

• Malfunction of cooling fan motor (L.H.) <Vehicles

without A/C>

• Malfunction of cooling fan motor drive control unit

• Malfunction of engine-ECU <M/T> or

engine-A/T-ECU <A/T>

• Damaged wiring harness or connector

DIAGNOSIS

STEP 1. Check the fan control relay.

Refer to P.14-24.

Q: Is the fan control relay in good condition?

Go to Step 2 .

YES : NO : Replace the fan control relay. Then go to

Step 8 .

STEP 2. Check the fan control relay connector A-09X.

Connector: A-09X

A-09X

Q: Is the connector in good condition?

YES : Go to Step 3 . NO : Repair the connector or replace the relay

box. Then go to Step 8 .

Relay box

Fan control relay

AC303510

ENGINE COOLING

TROUBLESHOOTING

14-17

STEP 3. Check the harness wire between fan control relay connector A-09X terminal 2 and cooling fan motor drive control unit connector A-18 terminal 3.

Connector: A-09X

A-09X

Connector: A-18

A-18

3 2 1

Relay box

Fan control relay

AC303510

STEP 4. Check the cooling fan motor drive control unit connector A-18, intermediate connector A-13 <L.H. drive vehicles> or C-111 <R.H. drive vehicles> and engine-ECU connector C-123 <M/T> or engine-A/T-ECU connector C-122 <A/T>.

Connector: A-18

A-18

3 2 1

AC100293

Connector: A-13 <L.H. drive vehicles>

A-13

AC100293

Q: Is the harness wire in good condition?

Go to Step 4 .

YES : NO : Repair the damaged harness wire. Then go

to Step 8 .

A-13

AC303526

Connector: C-111 <R.H. drive vehicles>

C-111

2 3 4

1179810

AC303527

14-18

ENGINE COOLING

TROUBLESHOOTING

Connector: C-123 <M/T>, C-122 <A/T>

Engine-ECU <M/T> or engine-A/T-ECU <A/T>

C-123 <M/T> or C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these connectors in good condition?

Go to Step 5 .

YES : NO : Repair or replace the connector. Then go to

Step 8 .

STEP 5. Check the harness wire between cooling fan motor drive control unit connector A-18 terminal 2 and engine-ECU connector C-123 terminal 21 <M/T> or engine-A/T-ECU connector C-122 terminal 18 <A/T>.

Connector: A-18

A-18

3 2 1

AC100293

Connector: C-123 <M/T>, C-122 <A/T>

Engine-ECU <M/T> or engine-A/T-ECU <A/T>

C-123 <M/T> or C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these harness wires in good condition?

YES : Go to Step 6 . NO : Repair the damaged harness wire. Then go

to Step 8 .

ENGINE COOLING

TROUBLESHOOTING

14-19

STEP 6. Check the cooling fan motor drive control unit.

Connector: C-123 <M/T>, C-122 <A/T>

Engine-ECU <M/T> or engine-A/T-ECU <A/T>

C-123 <M/T> or C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555

(1) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>.

(5) Check for the cooling fan operation.

• The cooling fan rotates. (with connector terminal pin 21 <M/T> or 18 <A/T> disconnected)

• The cooling fan stops. (When connector terminal pin 21 <M/T> or 18 <A/T> is connected to the body earth.)

(6) Turn the ignition switch to the "OFF" position. (7) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>, and push in connector terminal pin 21 <M/T> or 18 <A/T> to disconnect connector.

(8) Reconnect the connector with connector terminal

pin still installed.

Q: Does the cooling fan rotate? And when the

connector terminal pin is connected to the body earth, does the cooling fan stop?

YES :

Go to Step 7 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 8 .

STEP 7. MUT-II/III self-diag code

Check if an MPI system self-diag code is set. (Refer to GROUP 13A - Trouble shooting P.13A-9) <4G1> or (Refer to GROUP 13B - Trouble shooting

P.13B-9) <4G6>.

C-123 connector <M/T> (Harness side connector: ECU side view)

C-122 connector <A/T> (Harness side connector: ECU side view)

AC303559

(2) Pull out connector terminal pin 21 <M/T> or 18

<A/T> to disconnect connector.

(3) Reconnect the connector with connector terminal

pin still removed.

(4) Turn the ignition switch to the "ON" position.

Q: Diagnosis code set?

Inspection chart for diagnosis code (Refer

YES :

to GROUP 13A - Trouble shooting

P.13A-15) <4G1> or Inspection chart for

diagnosis code (Refer to GROUP 13B Trouble shooting P.13B-15) <4G6>.

NO : Replace the engine-ECU <M/T> or

engine-A/T-ECU <A/T> (Refer to GROUP 13A P.13A-401). Then go to Step 8 .

STEP 8. Check the symptoms.

Q: Does the cooling fan motor (L.H.) and the cooling

fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6> operate correctly?

YES :

This symptoms is complete.

NO : Return to Step 1 .

14-20

INSPECTION PROCEDURE 3: Cooling Fan (L.H.) does not Operate {When Cooling Fan (R.H.) <4G1> or A/C Condenser Fan <4G6> Operate} <Vehicles with A/C>

ENGINE COOLING

TROUBLESHOOTING

COOLING FAN (L.H.) AND COOLING FAN (R.H.) OR A/C CONDENSER FAN DRIVE CIRCUIT

Refer to P.14-6.

CIRCUIT OPERATION

Refer to P.14-6.

TECHNICAL DESCRIPTION

The cause could be a malfunction of the cooling fan motor (L.H.) or cooling fan motor drive control unit.

TROUBLESHOOTING HINTS

• Malfunction of cooling fan motor (L.H.)

• Malfunction of cooling fan motor drive control unit

DIAGNOSIS

STEP 1. Check the cooling fan motor (L.H.).

Refer to P.14-25.

Q: Is the cooling fan motor (L.H.) in good condition?

Go to Step 2 .

YES : NO : Replace the cooling fan motor (L.H.) (Refer

to P.14-35). Then go to Step 3 .

STEP 2. Check the cooling fan motor drive control unit.

Refer to P.14-23.

Q: Is the cooling fan motor drive control unit in good

condition? YES :

Go to Step 3 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 3 .

STEP 3. Check the symptoms.

Q: Do the cooling fan (L.H.) operate (when the cooling

fan (R.H.) <4G1> or A/C condenser fan <4G6> operate)?

YES :

This symptoms is complete.

NO : Return to Step 1 .

ENGINE COOLING

TROUBLESHOOTING

INSPECTION PROCEDURE 4: Cooling Fan (R.H.) <4G1> or A/C Condenser Fan <4G6> does not Operate {When Cooling Fan (L.H.) Operate} <Vehicles with A/C>

14-21

COOLING FAN (L.H.) AND COOLING FAN (R.H.) OR A/C CONDENSER FAN DRIVE CIRCUIT

Refer to P.14-6.

CIRCUIT OPERATION

Refer to P.14-6.

TECHNICAL DESCRIPTION

The cause could be a malfunction of the cooling fan motor (R.H.) <4G1> or A/C condenser fan motor <4G6> or cooling fan motor drive control unit.

TROUBLESHOOTING HINTS

• Malfunction of cooling fan motor (R.H.) <4G1> or A/C condenser fan motor <4G6>

• Malfunction of cooling fan motor drive control unit

DIAGNOSIS

STEP 1. Check the cooling fan motor (R.H.) <4G1> or A/C condenser fan motor <4G6>.

Cooling fan motor (R.H.) check. (Refer to P.14-25) <4G1>. A/C condenser fan motor check. (Refer to GROUP 55 P.55-97) <4G6>.

Q: Is the cooling fan motor (R.H.) <4G1> or A/C

condenser fan motor <4G6> in good condition? YES : Go to Step 2 .

NO : Replace the cooling fan motor (R.H.) (Refer

to P.14-35) <4G1> or A/C condenser fan motor (Refer to GROUP 55 P.55-96) <4G6>. Then go to Step 3 .

STEP 2. Check the cooling fan motor drive control unit.

Refer to P.14-23.

Q: Is the cooling fan motor drive control unit in good

condition? YES :

Go to Step 3 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 3 .

STEP 3. Check the symptoms.

Q: Do the cooling fan (R.H.) <4G1> or A/C condenser

fan <4G6> operate (when the cooling fan (L.H.) operate)?

YES :

This symptoms is complete.

NO : Return to Step 1 .

14-22

ENGINE COOLING

ON-VEHICLE SERVICE

ENGINE COOLANT LEAK CHECK

M1141001000300

WARNING

When pressure testing the cooling system, slowly release cooling system pressure to avoid getting burned by hot coolant.

CAUTION

• Be sure to completely clean away any moisture from the places checked.

• When the tester is taken out, be careful not to spill any coolant.

• Be careful when installing and removing the tester and when testing not to deform the filler neck of the radiator.

Cap adapter

Adapter

2. Increase the pressure until the indicator of the gauge stops moving.

Minimum limit: 83 kPa Standard value: 93 − 123 kPa

3. Replace the radiator cap if the reading does not remain at or above the limit.

ENGINE COOLANT REPLACEMENT

M1141001200434

WARNING

When removing the radiator cap, use care to avoid contact with hot coolant or steam. Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise.

1. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.

ACX01844

1. Check that the coolant level is up to the filler neck. Install a radiator tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections.

2. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP VALVE OPENING PRESSURE CHECK

M1141001300389

NOTE: Be sure that the cap is clean before testing. Rust or other foreign material on the cap seal will cause an improper reading.

Cap adapter

AC211643 AB

1. Use a cap adapter to attach the cap to the tester.

<4G1> Inlet side

Cylinder block drain plug

AC208283

<4G6> Inlet side

Cylinder block drain plug

AC303355

2. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.

3. Remove the radiator condenser tank and drain the coolant.

4. Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area.

Cylinder block drain plug

ENGINE COOLING

ON-VEHICLE SERVICE

9. Reinstall the radiator cap.

10.Start the engine and let it warm up until the thermostat opens.

11.Afte r r epea te d ly r evv ing th e e n gin e u p t o 3 ,00 0 r/min several times, then stop the engine.

12.Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap.

14-23

AC200625

5. Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten to the standard torque.

Specified sealant: 3M Nut Locking Part

No.4171 or equivalent

Tightening torque:

40 ± 5 N⋅m <4G1> 44 ± 5 N⋅m <4G6>

6. Securely tighten the drain plug of the radiator.

7. Reinstall the radiator condenser tank.

CAUTION

Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminium components.

MB991871

CAUTION

Do not overfill the radiator condenser tank.

13.Add coolant to the radiator condenser tank between the "F" and "L" mark if necessary.

CONCENTRATION MEASUREMENT

M1141001100352

Measure the temperature and specific gravity of the engine coolant to check the antifreeze concentration.

Standard value: 30 − 60% (allowable

concentration range)

Recommended antifreeze: DIAQUEEN SUPER

LONG LIFE COOLANT or equivalent

CAUTION

If the concentration of the anti-freeze is below 30%, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60%, both the anti-freezing and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.

AIR HOSE

AC303612

8. By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60%. Use special tool LLC changer (MB991871) to refill the coolant. A convenient mixture is a 50% water and 50% antifreeze solution (freezing point: −31°C).

Recommended antifreeze: DIAQUEEN SUPER

LONG LIFE COOLANT or equivalent

Quantity:

5.0 L <4G1>

7.0 L <4G6>

NOTE: For how to use special tool MB991871, refer to its manufacturerís instructions.

COOLING FAN MOTOR DRIVE CONTROL UNIT CHECK

M1141006100216

1. Remove the cooling fan motor drive control unit connector.

Cooling fan motor

Y1716AU

drive control unit

123

AC103195

2. Turn the ignition switch to the "ON" position, and measure the voltage between terminal 1 and 3 at the harness side connector.

Standard value: system voltage

14-24

ENGINE COOLING

ON-VEHICLE SERVICE

3. Connect the cooling fan motor drive control unit connector, and disconnect the cooling fan motor (L.H.) connector.

4. Ensure that the A/C switch is off, and start the engine and run it at idle.

Cooling fan motor drive control unit

AC303496

5. Measure the voltage between the cooling fan motor drive control unit side connector terminal 1 and 2.

Standard value: 1V or less

WARNING

Stay clear of the fan when the fan starts running.

6. Turn the A/C switch to the "ON" position.

7. Measure the voltage between the cooling fan motor drive control unit side connector terminal 1 and 2 while the fan is running. The voltage should repeat the values below.

Standard value:

1. 1 V or less

2. 8.2 ± 0.7 V

3. System voltage ± 2.6 V

8. If the voltage does not repeatedly change as indicated, replace the cooling fan motor drive control unit. (Refer to P.14-35).

FAN CONTROL RELAY CONTINUITY CHECK

M1141006200280

Fan control relay

AC211776

Battery voltage

Termi n al No. to be connected to tester

Not applied 4 − 2 Open circuit

Connect

4 − 2 Less than 2 ohms terminal No.1 and battery (−) terminal. Connect terminal No.3 and battery (+) terminal.

AC301712

Continuity test results

ENGINE COOLING

ON-VEHICLE SERVICE

14-25

COOLING FAN MOTOR CHECK

Cooling fan motor drive control unit

Cooling fan motor (L.H.) connector

AC303501

Cooling fan motor Cooling fan motor drive control unit

(R.H.) connector

<4G1 with A/C>

AC303502

M1141007100060

1. Remove the cooling fan motor connector.

2. Check to see that the cooling fan motor of the radiator turns when applying battery power between the connector terminal 1 and 2 of the cooling fan motor. Also check to see that there is no abnormal sound coming from the cooling fan motor at this time.

3. If the cooling fan motor is defective, replace it. (Refer to P.14-35).

14-26

ENGINE COOLING

THERMOSTAT

REMOVAL AND INSTALLATION

M1141002400442

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).

• Air Cleaner Assembly Removal and Installation (Refer to

GROUP 15 P.15-3).

• Battery Removal and Installation

<4G1>

22 ± 4 N·m

<4G6>

AC203409

13 ± 2 N·m

AC301429

ENGINE COOLING

THERMOSTAT

14-27

Removal steps

1. Water temperature gauge unit connector <4G6>

2. Water temperature sensor unit connector <4G6>

<<A>> >B<<

3. Radiator lower hose connection

REMOVAL SERVICE POINT <<A>> RADIATOR LOWER HOSE

DISCONNECTION

Mating marks

Removal steps (Continued)

4. Engine control oxygen sensor connector and connector bracket <4G1>

5. Control wiring harness clip <4G6>

6. Cooling water inlet hose fitting

>>A<<

7. Thermostat

>>B<< RADIATOR LOWER HOSE CONNECTION

Projection

Cooling water inlet hse fitting

Mating marks

AC200642

AC200641

Make mating marks on the radiator lower hose and the hose clamp. Disconnect the radiator lower hose.

INSTALLATION SERVICE POINTS >>A<< THERMOSTAT INSTALLATION

CAUTION

Make absolutely sure that no oil adheres to the rubber ring of the thermostat. Also do not fold or scratch the rubber ring during installation.

Jiggle valve

Rubber ring

AC000279

Install the thermostat so that the jiggle valve is facing straight up. Be careful not to fold or scratch the rubber ring.

1. Insert radiator lower hose as far as the projection of the Cooling water inlet hose fitting.

2. Align the mating marks on the radiator lower hose and hose clamp, and then connect the radiator lower hose.

INSPECTION

M1141002500427

THERMOSTAT CHECK

ACX00400

1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature.

Standard value: 88 ± 1.5°C <4G1> 82 ± 1.5°C <4G6>

14-28

Valve lift

ACX00401

ENGINE COOLING

THERMOSTAT

2. Check that the amount of valve lift is at the

standard value when the water is at the full-opening temperature.

NOTE: Measure the valve height when the thermostat is fully closed, and use this measurement to compare the valve height when the thermostat is fully open.

Standard value: 100°C <4G1> 95°C <4G6> Amount of valve lift: 8.5 mm or more

ENGINE COOLING

WATER PUMP

14-29

REMOVAL AND INSTALLATION <4G1>

M1141002700421

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).

• Val v e Ti ming Bel t Remova l and In stallatio n ( Refer to

GROUP 11A P.11A-33).

23 ± 2 N·m

Bolt specifications

8 × 50

8 × 30

Screw diameter × length mm

8 × 25

24 ± 3 N·m

14 ± 1 N·m

Removal steps

1. Alternator adjusting brace

>>A<<

2. Water pump assembly

INSTALLATION SERVICE POINT >>A<< WATER PUMP ASSEMBLY

INSTALLATION

1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.

Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent

AC303372

2. Apply a bead of the specified sealant.

Specified Sealant: MITSUBISHI GENUINE PART No. MD 9 70 389 or eq uiv a le n t

3. With the sealant still wet (within 15 minutes after the sealant is applied), install the water pump assembly. Do not apply the sealant in an area more than the required.

14-30

ENGINE COOLING

WATER P UMP

REMOVAL AND INSTALLATION <4G6>

M1141002700432

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).

• Val v e Ti ming Be lt a n d Bala n c er Timing Bel t Remov al and

Installation (Refer to GROUP 11C P.11C-35).

22 ± 4 N·m

Bolt specifications

8 × 70

8 × 22

23 ± 3 N·m

14 ± 1 N·m

Removal steps

1. Alternator adjusting brace

2. Water pump assembly

INSTALLATION SERVICE POINT >>A<< COOLING WATER LINE O-RING

INSTALLATION

Water pump assembly

Cooling water line O-ring

8 × 14

8 × 25

8 × 22

Screw diameter × length mm

AC301467

Removal steps (Continued)

3. Water pump gasket

>>A<<

4. Cooling water line O-ring

Fit the cooling water line O-ring to the groove in the water pump inlet pipe. Then lubricate the cooling water line O-ring and the inside of the water pump assembly with water, and then insert the water pump inlet pipe to the water pump assembly.

Water pump inlet pipe

AC103005

ENGINE COOLING

WATER HOSE AND WATER PIPE

14-31

REMOVAL AND INSTALLATION <4G1>

M1141003300415

Pre-removal and Post-installation Operation

• Under Cover Removal and Installation

• Engine Coolant Draining and Supplying (Refer to

P.14-22).

• Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3).

• Thermostat Removal and Installation (Refer to P.14-26).

23 ± 4 N·m

13 ± 2 N·m

<<A>> >>B<<

Removal steps

1. Water temperature sensor unit connector

2. Water temperature gauge unit connector

3. Control wiring harness and harness bracket

4. Radiator upper hose connection

5. Throttle body water feed hose

6. Thermostat case assembly

>>A<<

13 ± 2 N·m

AC203411

Removal steps (Continued)

7. Thermostat case gasket

8. Cooling water line O-ring

9. Control wiring harness clamp

10. Throttle body water return hose

11. Heater w ater h o s e conn e ction

12. Water pump inlet pipe

13. Cooling water line O-ring

14-32

ENGINE COOLING

WATER HOSE AND WATER PIPE

REMOVAL SERVICE POINT <<A>> RADIATOR UPPER HOSE

DISCONNECTION

Mating marks

AC200641

After making mating marks on the radiator upper hose and hose clamp, disconnect the radiator upper hose.

INSTALLATION SERVICE POINTS >>A<< COOLING WATER LINE O-RING

INSTALLATION

>>B<< RADIATOR UPPER HOSE CONNECTION

Projection

Thermostat case assembly

1. Insert radiator upper hose as far as the projection of the thermostat case assembly.

2. Align the mating marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.

Radiator upper hose

Mating marks

AC200642

CAUTION

Water pump or thermostat case

Cooling water line O-ring

Water pump inlet pipe

AC200644

Do not allow engine oil or other grease to adhere to the O-ring

Insert the cooling water line O-ring to the water pump inlet pipe, and coat the outer portion of the cooling water line O-ring with water or engine coolant.

ENGINE COOLING

WATER HOSE AND WATER PIPE

14-33

REMOVAL AND INSTALLATION <4G6>

M1141003300426

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Supplying (Refer to

P.14-22).

• Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3).

• Thermostat Removal and Installation (Refer to P.14-26).

13 ± 2 N·m

<<A>> >>C<<

>>B<<

13 ± 2 N·m

Ø3 mm

Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent

Removal steps

1. Radiator upper hose connection

2. Cooling water outlet hose fitting

3. Throttle body water return hose

4. Throttle body water feed hose

5. Thermostat case assembly

6. Heater water hose connection

Ø3 mm

>>A<<

23 ± 4 N·m

AC303471

Removal steps (Continued)

7. Control wiring harness clamp

8. Water pump inlet pipe

9. Cooling water line O-ring

14-34

ENGINE COOLING

WATER HOSE AND WATER PIPE

REMOVAL SERVICE POINT <<A>> RADIATOR UPPER HOSE

DISCONNECTION

Mating marks

AC200641

After making mating marks on the radiator upper hose and hose clamp, disconnect the radiator upper hose.

INSTALLATION SERVICE POINTS >>A<< COOLING WATER LINE O-RING

INSTALLATION

>>B<< THERMOSTAT CASE ASSEMBLY/COOLING WATER OUTLET HOSE FITTING INSTALLATION

1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.

2. Apply a bead of the specified sealant.

Specified Sealant: MITSUBISHI GENUINE PART No. MD 9 70 389 or eq uiv a le n t

3. With the sealant still wet (within 15 minutes after the sealant is applied), install the thermostat case assembly or cooling water outlet hose fitting. Do not apply the sealant in an area more than the required.

>>C<< RADIATOR UPPER HOSE CONNECTION

Projection

Radiator upper hose

CAUTION

Water pump or thermostat case

O-ring

Water inlet pipe

AC200644

Do not allow engine oil or other grease to adhere to the cooling water line O-ring

Insert the cooling water line O-ring to the water pump water inlet pipe, and coat the outer portion of the cooling water line O-ring with water or engine coolant.

Mating marks

Cooling water outlet hose fitting

AC200642

1. Insert radiator upper hose as far as the projection of the cooling water outlet hose fitting.

2. Align the mating marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.

INSPECTION

M1141003400296

WATER PUMP INLET PIPE AND THROTTLE BODY WATER HOSES CHECK

Check the water pipe and hoses for cracks, damage and clogs. Replace them if necessary.

ENGINE COOLING

RADIATOR

14-35

REMOVAL AND INSTALLATION

M1141001500468

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Supplying (Refer to

P.14-22).

• Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3).

<4G1 (Vehicles without A/C)>

12 ± 2 N·m

AC303472

14-36

ENGINE COOLING

RADIATOR

<4G1 (Vehicles with A/C)>

12 ± 2 N·m

AC303473

<4G6>

12 ± 2 N·m

<<A>> >>A<< <<A>> >>A<<

12 ± 2 N·m

Radiator removal steps

1. Drain plug

2. Radiator cap

3. Radiator condenser tank hose

4. Radiator condenser tank assembly

5. Radiator upper hose

6. Radiator lower hose

7. Cooling fan motor drive control unit connector

AC303474

Radiator removal steps

8. T/M oil cooler line hose connection <A/T>

9. Radiator support upper insulator Radiator and cooling fan motor &

•

shroud assembly

10. Radiator support lower insulator

11. T/M oi l coo l e r line ho s e <A/T>

ENGINE COOLING

RADIATOR

14-37

Radiator removal steps

12. Cooling fan motor & shroud assembly

13. A/C condenser fan motor & shroud assembly <4G6>

14. Radiator assembly

Cooling fan motor removal steps

3. Radiator condenser tank hose

<<A>> >>A<<

5. Radiator upper hose

7. Cooling fan motor drive control unit connector

REMOVAL SERVICE POINT <<A>> RADIATOR UPPER

HOSE/RADIATOR LOWER HOSE DISCONNECTION

Cooling fan motor removal steps (Continued)

12. Cooling fan motor & shroud assembly

15. Cooling fan (L.H.)

16. Cooling fan (R.H.) <4G1 (Vehicles with A/C)>

17. Cooling fan motor drive control unit

18. Cooling fan motor (L.H.)

19. Cooling fan (R.H.) motor <4G1 (Vehicles with A/C)>

20. Cooling fan shroud

INSTALLATION SERVICE POINT >>A<< RADIATOR LOWER

HOSE/RADIATOR UPPER HOSE CONNECTION

Projection

Radiator hose

Mating marks

AC200641

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hoses.

Mating marks

Cooling water hose fitting or thermostat case assembly

AC200642

1. Insert radiator lower hose as far as the projection of the cooling water inlet hose fitting.

2. Insert radiator upper hose as far as the projection of the thermostat case assembly <4G1> or the cooling water outlet hose fitting <4G6>.

3. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

NOTES

GROUP 37

POWER STEERING

CONTENTS

37-1

GENERAL INFORMATION . . . . . . . . 37-3

SERVICE SPECIFICATIONS. . . . . . . 37-6

LUBRICANTS . . . . . . . . . . . . . . . . . . 37-7

SEALANTS . . . . . . . . . . . . . . . . . . . . 37-7

SPECIAL TOOLS. . . . . . . . . . . . . . . . 37-8

ON-VEHICLE SERVICE. . . . . . . . . . . 37-11

STEERING WHEEL FREE PLAY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-11

STEERING ANGLE CHECK. . . . . . . . . . . . 37-11

TIE ROD END BALL JOINT TURNING

TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 37-12

STATIONARY STEERING EFFORT

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-12

STEERING WHEEL RETURN TO

CENTRE CHECK . . . . . . . . . . . . . . . . . . . . 37-13

DRIVE BELT TENSION CHECK . . . . . . . . . 37-13

FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-13

FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-13

POWER STEERING SYSTEM AIR

BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-13

OIL PUMP PRESSURE TEST . . . . . . . . . . 37-14

POWER STEERING PRESSURE

SWITCH CHECK. . . . . . . . . . . . . . . . . . . . . 37-15

TIE ROD END BALL JOINT DUST COVER

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-15

STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING

MECHANISM CHECK. . . . . . . . . . . . . . . . . 37-15

STEERING WHEEL*. . . . . . . . . . . . . . 37-17

REMOVAL AND INSTALLATION

<COMFORT> . . . . . . . . . . . . . . . . . . . . . . . 37-17

REMOVAL AND INSTALLATION

<SPORT> . . . . . . . . . . . . . . . . . . . . . . . . . . 37-19

Continued on next page

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING

•

Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and paassenger (from rendering the SRS inoperative).

•

Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer.

•

MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.

NOTE The SRS includes the following components: SRS air bag control unit, SRS warning light, front impact sensors, air bag module, clock spring, and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

37-2

STEERING SHAFT* . . . . . . . . . . . . . . 37-21

REMOVAL AND INSTALLATION . . . . . . . . 37-21

DISASSEMBLY AND REASSEMBLY. . . . . 37-22

POWER STEERING GEAR BOX AND

LINKAGE* . . . . . . . . . . . . . . . . . . . . . 37-24

REMOVAL AND INSTALLATION . . . . . . . . 37-24

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 37-26

DISASSEMBLY AND REASSEMBLY. . . . . 37-27

TIE ROD END BALL JOINT DUST COVER

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 37-36

POWER STEERING OIL PUMP

ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 37-37

REMOVAL AND INSTALLATION . . . . . . . . 37-37

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37-38

DISASSEMBLY AND REASSEMBLY . . . . . 37-39

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37-41

POWER STEERING HOSES*. . . . . . . 37-42

REMOVAL AND INSTALLATION . . . . . . . . 37-42

POWER STEERING

GENERAL INFORMATION

Power steering has been adopted in all vehicles to make the steering system easier to handle.

FEATURES

• A 4-spoke steering wheel is used. <Comfort>

• MOMO leather-wrapped 3-spoke steering wheel

is used. <Sport>

• A steering column has a shock absorbing mechanism and a tilt steering mechanism.

SPECIFICATIONS

Item Comfort Sport

• Integral-type rack and pinion gear with high rigidity and excellent response is used.

• A vane type pump with a fluid flow rate control system which change steering effort according to the engine speed is used.

• The separate plastic resin oil reservoir is used to reduce weight and to make the fluid level checking easier.

37-3

M1372000100337

Steering wheel

Steering column

Power steering type Integral type

Oil pump Type Vane pump

Steering gear

Type 4-spoke type MOMO leather-wrapped

Outside diameter mm 380 365

Maximum number of turns 3.19 2.86 <L.H. drive vehicles>

Column mechanism Shock absorbing mechanism and Tilt steering mechanism

Basic discharge amount cm

Relief pressure MPa 8.8 8.8

Reservoir type Separate type (plastic)

Pressure switch Equipped

Type Rack and pinion

Stroke ratio (Rack stroke/Steering wheel maximum turning radius)

Rack stroke mm 146 131 <L.H. drive vehicles>

/rev.

7.2 <1300, 1600>

8.1 <2000>

45.74 45.74

3-spoke type

3.08 <R.H. drive vehicles>

7.2 <1300, 1600>

8.1 <2000>

141 <R.H. drive vehicles>

37-4

CONSTRUCTION DIAGRAM 1300, 1600 - L.H. drive vehicles

POWER STEERING

GENERAL INFORMATION

Steering wheel

Oil reservoir

Suction hose

Oil pump assembly

1300, 1600 - R.H. drive vehicles

Pressure hose assembly

Return hose

Steering gear

Steering column shaft assembly

Steering wheel

AC304488

Suction hose

Oil reservoir

Oil pump assembly

Pressure hose assembly

Return hose

Steering gear

Steering column shaft assembly

AC304489

2000 - L.H. drive vehicles

POWER STEERING

GENERAL INFORMATION

37-5

Steering wheel

Oil reservoir

Suction hose

Oil pump assembly

2000 - R.H. drive vehicles

Pressure hose assembly

Return hose

Steering gear

Steering column shaft assembly

Steering wheel

AC304486

Oil reservoir

Suction hose

Oil pump assembly

Pressure hose assembly

Return hose

Steering gear

Steering column shaft assembly

AC304487

37-6

POWER STEERING

SERVICE SPECIFICATIONS

M1372000300386

Item Standard value Limit

Steering wheel free play mm

Steering angle Inner wheel Comfort 39°30' ± 1°30'

Toe -i n A t th e cen tr e of t yr e tr ea d mm 1 ± 2

Tie rod end ball joint turning torque N⋅ m0.5 − 2.5

Tie rod swing resistance N [Tie rod swing torque N⋅m] 8 − 27 [1.5 − 4.9]

Stationary steering effort N [Fluctuation allowance N] 29 or less [5.9 or less]

Oil pump pressure MPa (750 ± 100 r/min.)

With engine running

With engine stopped 10 or less

Sport (L.H. drive vehicles) 33°40' +1°00'/-2°00'

Sport (R.H. drive vehicles) 37°00' +1°00'/-2°00'

Outer wheel (reference)

Toe -a ng le ( pe r wh ee l) 0 °03' ± 06'

Oil pump relief pressure 8.8 − 9.5

Pressure under no-load conditions 0.2 − 0.7

Steering gear retention hydraulic pressure 8.8 − 9.5

Comfort 32°30'

Sport (L.H. drive vehicles) 28°46'

Sport (R.H. drive vehicles) 30°00'

−

Oil pressure switch operating pressure MPa

Steering gear total pinion torque N⋅m [Change in torque N⋅m]

Opening dimension of special tool boot band crimping tool (MB991561) mm2.9

Band crimped width mm 2.4 − 2.8

OFF → ON 1.5 − 2.0

ON → OFF 0.7 − 2.0

1300, 1600 (Comfort) 0.8 − 2.1 [0.6 or less]

1600 (Sport), 2000 0.7 − 2.1 [0.6 or less]

−

POWER STEERING

LUBRICANTS

M1372000400350

Item Specified lubricant Quantity

Power steering fluid ATF DEXRON III or DEXRON II Approximately 1.0 L

Steering gear Bearing ATF DEXRON III or DEXRON II As required

O-ring and seal ring

Oil seal

Special tool (MB991212, MB991213)

Pinion and valve assembly seal ring part

Bellows Silicon grease As required

Tie rod end ball joint Multipurpose grease SAE J310,

Oil pump Friction surface of rotor vane,

cam ring and pump cover

O-ring

NLGI No.2 or equivalent

ATF D EX R ON II I or DE XR ON II As r e qu ired

As required

37-7

SEALANTS

M1372000500357

Item Specified sealant

Steering shaft cover assembly bolt hole on the toeboard 3M ATD Part No.8513 or equivalent

Steering gear End plug 3M ATD Part No.8661, 8663 or

Rack support cover

equivalent

37-8

POWER STEERING

SPECIAL TOOLS

Tool Numb er Name Use

MB991897 Ball joint remover Knuckle and tie rod end ball joint

disconnection

NOTE: Steering linkage puller (MB990635 or MB991113) is also

AC106827

MB990326 Preload socket Tie rod end ball joint turning torque

MB990326

available to disconnect knuckle and tie rod end ball joint.

check

M1372000600354

MB991548

MB991549

MB990662

MB991548 Power steering oil

Oil pump pressure test pressure gauge adapter (Pump side)

MB991549 Power steering oil

pressure gauge adapter (Hose side)

MB990662 Power steering oil

pressure gauge

MB990784 Ornament remover Cover removal

MB990784

MB991006

MB990228 or MB991006

Preload socket Steering gear total pinion torque

check and adjustment

POWER STEERING

SPECIAL TOOLS

Tool Numb er Name Use

37-9

MB991621

MB990925

MB990607 Torque wrench

socket

• Rack support cover removal <Comfort>

• Rack support adjustment <Comfort>

MB991621 Piston driver • Rack support cover removal

<Sport>

• Rack support adjustment <Sport>

MB990925 Bearing and oil

seal installer set

• Lower bearing removal

• Oil seal and bearing installation

• MB990927, MB990938, MB990939

(For details, refer to GROUP 26, Special Tools P.26-4).

MB991120 Needle bearing

Needle bearing removal

puller

MB991120

MB991202

MB991199

MB991197

MB991202 Oil seal and

bearing installer

• Oil seal installation <Comfort>

• Needle bearing installation

• Lower bearing installation

MB991199 Oil seal and

Oil seal installation <Sport>

bearing installer

MB991197 Bar (long type) Oil seal installation

MB991212

Oil seal protector Rack installation

MB991213

MB991212

37-10

POWER STEERING

SPECIAL TOOLS

Tool Numb er Name Use

MB991203

MB991317

MB990941

MB991203 Oil seal and

Oil seal and bearing installation

bearing installer

MB991317 Seal ring installer Seal rings installation

MB990941 Torque tube

Lower oil seal installation

bearing installer

MB991561 Boot band crimping

Bellows band installation

tool

MB991561

MB990776

MB990776 Front axle base Tie rod end ball joint dust cover

installation

POWER STEERING

ON-VEHICLE SERVICE

37-11

STEERING WHEEL FREE PLAY CHECK

M1372001000311

1. With the engine running (hydraulic operation), set the front wheels straight ahead.

ACX01122

2. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions.

Limit: 30 mm

3. When the play exceeds the limit, check for the play on the steering shaft and steering linkage connection. Correct or replace.

4. If the free play still exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Load 5 N towards the steering wheel circumference and check the play.

Standard value (steering wheel play with the engine stopped): 10 mm or less

1. Place the front wheel on a turning radius gauge and measure the steering angle.

Standard value:

Inner wheels

Comfort 39°30' ± 1°30'

Sport (L.H.

33°40' +1°00'/-2°00'

drive vehicles)

Sport (R.H.

37°00' +1°00'/-2°00'

drive vehicles)

Outer wheels (reference)

Comfort 32°30'

Sport (L.H.

28°46'

drive vehicles)

Sport (R.H.

30°00'

drive vehicles)

2. If the steering angle is not within the standard value, adjust the toe-in as follows.

Standard value: at the centre of tyre tread: 1 ± 2 mm Toe an gle (p er w he e l): 0°03' ± 06'

Lock nut

Clip

5. If the play exceeds the standard value, remove the steering gear (Refer to P.37-24) and check the total pinion torque (Refer to P.37-27).

STEERING ANGLE CHECK

M1372001100374

AC000756

AC006074

3. Loosen the lock nut, and unclip the bellows.

4. Adjust the toe-in by turning the left and right tie rod turnbuckles by the same amount (in opposite directions).

NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle.

5. Tighten the lock nut to the specified torque, and tighten the bellows by the clip.

Tightening torque: 40 ± 5 N⋅m

6. Recheck the steering angle.

37-12

POWER STEERING

ON-VEHICLE SERVICE

TIE ROD END BALL JOINT TURNING TORQUE CHECK

M1372001500297

CAUTION

• Do not remove the tie rod end nut from the ball joint. Loosen it and use special tool to avoid possible damage to the ball joint threads.

• Hang special tool with cord to prevent it from falling.

Cord

Nut

Ball joint

1. Install special tool ball joint remover (MB991897) as shown in the figure.

Parallel

MB991897

Bolt

AC208247

Bolt

4. Move the ball joint stud several times and install the nut on the stud. Using special tool preload socket (MB990326), measure the ball joint turning torque.

Standard value: 0.5 − 2.5 N⋅m

5. If the turning torque exceeds the standard value, replace the tie rod end.

6. If the turning torque is under the standard value, check the ball joint for axial play or ratcheting. If no axial play or ratcheting, the ball joint can be re-used.

CAUTION

Always use a new ball joint nut as it is a self-locking nut.

7. Install the tie rod end to the knuckle, then tighten a new self-locking nut to the specified torque.

Tightening torque: 25 ± 5 N⋅m

STATIONARY STEERING EFFORT CHECK

M1372001700332

1. With the vehicle stopped on a flat and paved surface, turn the steering wheel to the straight ahead position.

2. Start the engine and set the engine idle speed.

Standard value: 1000 ± 100 r/min

Knob

Good

Bad

AC106821

2. Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.

3. Tighten the bolt with a wrench to disconnect the tie rod end.

MB990326

ACX01122

3. Attach a spring balance to the outer circumference of the steering wheel and measure the steering force required to turn the steering wheel from the straight ahead position to the left and right (within a range of 1.5 turns). Also check to be sure that there is no significant change in the required steering effort.

Standard value: Steering effort: 29 N or less Fluctuation allowance: 5.9 N or less

4. If the measured value exceeds the standard value, check and adjust the related parts.

ACX01129

POWER STEERING

ON-VEHICLE SERVICE

37-13

STEERING WHEEL RETURN TO CENTRE CHECK

M1372001800317

Conduct a road test:

1. Make both gradual and sudden turns and check the steering wheel return.

70˚

ACX01130

2. At a vehicle speed of approximately 35 km/h, turn the steering wheel 90°, hold a few seconds, then release. If the steering wheel then returns 70° or more, the return can be judged satisfactory.

NOTE: There will be a momentary feeling or "heaviness" when the wheel is turned quickly, but this is not abnormal (Oil pump discharge amount is especially apt to be insufficient during idling).

DRIVE BELT TENSION CHECK

M1372001900392

For vehicles with 1300 and 1600 engine, refer to GROUP 11A, On-vehicle Service − Drive Belt Ten si on C he ck P.11A-7. For vehicles with 2000 engine, refer to GROUP 11C, On-vehicle Service − Drive Belt Tension Check

P.11C-7.

FLUID LEVEL CHECK

M1372002000284

1. Park the vehicle on a flat, level surface.

2. Start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 − 60°C.

3. With the engine running, turn the wheel all the way to the left and right several times.

Fluid level change: Within 5 mm

4. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm or more, air bleeding should be done.

FLUID REPLACEMENT

M1372002100333

1. Raise and support the front wheels.

Return hose

Vinyl hose

AC100369

2. Disconnect the return hose connection, and then connect a vinyl hose to the return hose, and drain the fluid into a container.

3. Disconnect the ignition coil connectors (Refer to GROUP 16, Ignition Coil P.16-38or P.16-39).

4. While operating the starter motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid.

5. Connect the return hose securely, and then secure with the clip.

6. Fill the oil reservoir with specified fluid up to between "MAX" and "MIN" marks, and then bleed the air.

Specified fluid: ATF DEXRON III or DEXRON II

POWER STEERING SYSTEM AIR BLEEDING

M1372002200330

Perform air bleeding procedure as necessary after replacing the steering gear or the steering fluid lines.

1. Raise and support the front wheels.

2. Disconnect the ignition coil connectors (Refer to GROUP 16, Ignition Coil P.16-38 or P.16-39).

While engine running While engine stopped

ACX01131

37-14

POWER STEERING

ON-VEHICLE SERVICE

CAUTION

Perform air bleeding only while cranking the engine. If air bleeding is performed while the engine is running, air could enter the fluid. During air bleeding, refill the steering fluid supply so that the level never falls below the "MIN" mark on the oil reservoir.

3. Turn the steering wheel all the way to the left and right five or six times while using the starter motor to crank the engine intermittently several times (for 15 to 20 seconds).

4. Connect the ignition coil connectors (Refer to GROUP 16, Ignition Coil P.16-38 or P.16-39).

5. Start the engine (idling).

6. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir.

7. Confirm that the fluid is not milky, and that the level is between "MAX" and "MIN" marks.

8. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right.

CAUTION

If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control valve, and this condition could cause reduce the life of the power steering components.

Fluid level change: Within 5 mm

OIL PUMP PRESSURE TEST

M1372002300315

Pressure

Temperature gauge

gauge (MB990662)

Oil reservoir

Adapter (MB991548)

Oil pump

1. Disconnect the pressure hose from the oil pump, and then connect the following special tools.

• MB990662: Power Steering Oil Pressure Gauge

• MB991548: Power Steering Oil Pressure Gauge

Adapter (pump side)

• MB991549: Power Steering Oil Pressure Gauge Adapter (hose side)

2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50

− 60°C.

3. Start the engine and idle it at 1000 ± 100 r/min.

Shut-off valve (fully closed)

Adapter (MB991549)

ACX01133

While engine running While engine stopped

ACX01131

9. Confirm that the change in the fluid level is no more than 5 mm when the engine is stopped and when it is running.

10.If the change of the fluid level is 5 mm or more, the air has not been completely bled from the system. The air bleeding procedure must be repeated.

CAUTION

The pressure gauge shut-off valve must not remain closed for more than 10 seconds.

4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Open it again immediately after checking the pressure.

Standard value: 8.8 − 9.5 MPa

5. If it is not within the standard value, replace the oil pump.

6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge.

Standard value: 0.2 − 0.7 MPa

POWER STEERING

ON-VEHICLE SERVICE

37-15

7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear, so check these parts and repair as necessary.

8. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value.

Standard value: 8.8 − 9.5 MPa

9. If not the standard value, overhaul the steering gear. Remeasure fluid pressure.

10. Remove the special tools, and then tighten the pressure hose to the specified torque.

Tightening torque: 57 ± 7 N⋅m

11. B l eed th e s yst e m (Re f er to P.37-13).

POWER STEERING PRESSURE SWITCH CHECK

M1372007200324

Adapter (MB991548)

Temperature gauge

Pressure gauge (MB990662)

Oil pump

Shut-off valve

2. Bleed air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50

− 60°C.

3. The engine should be idling.

4. Disconnect the connector for the oil pressure switch, and place an ohmmeter at the switch.

5. Gradually close the shut-off valve of the pressure gauge and increase the hydraulic pressure, then check whether or not the hydraulic pressure that activates the switch is the standard value.

Standard value: 1.5 − 2.0 MPa

6. Gradually open the shut-off valve and reduce the hydraulic pressure; then check whether or not the hydraulic pressure that deactivates the switch is the standard value.

Standard value: 0.7 − 2.0 MPa

7. Remove the special tools, and then tighten the pressure hose to the specified torque.

Tightening torque: 57 ± 7 N⋅m

8. Bleed the system (Refer to P.37-13).

TIE ROD END BALL JOINT DUST COVER CHECK

M1372008600262

1. Press the dust cover with your finger to check whether the dust cover is cracked or damaged.

2. If the dust cover is cracked or damaged, replace the tie rod end.

NOTE: If the dust cover is cracked or damaged, the ball joint could be damaged.

Oil reservoir

Adapter (MB991549)

ACX01134

1. Disconnect the pressure hose from the oil pump, and then connect the following special tools.

• MB990662: Power Steering Oil Pressure Gauge

• MB991548: Power Steering Oil Pressure Gauge

Adapter (pump side)

• MB991549: Power Steering Oil Pressure Gauge Adapter (hose side)

STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK

M1372013500090

If a collision accident occurs or severe impact is applied on the steering wheel, the collision energy absorbing mechanism may have operated. Once the mechanism has operated, it will be inoperative even it has suffered no apparent damage. Determine if the steering column shaft can be reused by the following procedure. If the collision energy absorbing mechanism has already operated, replace the steering column shaft assembly. If any excessive radial free play on the steering wheel is found with the tilt lever in the lock position, always check the steering shaft assembly.

37-16

POWER STEERING

ON-VEHICLE SERVICE

WARNING

• If the vehicle continues to be driven after

the collision absorbing mechanism has operated, the steering column shaft may be damaged while it is in use.

• If there is a slack in the one-way capsule,

do not attempt to repair it but replace the steering column shaft assembly.

Inspection Procedure

1. Remove the lower and upper column covers.

CAUTION

Do not release the tilt lever until the steering column has been installed to complete this inspection procedure.

2. Ensure that the tilt lever is in the lock position.

NOTE: If not, place the tilt lever in the lock position.

One way capsule

AC304673AC304673

AC304672

AC304923

Steering column assembly

Steering column mounting bolt

AC304673AC304673

3. Loosen the two steering column mounting bolts (upper) by two turns.

4. Hold the one-way capsules as shown, and then try to lock them. If there is a slack in either of the capsules, replace the steering column shaft assembly.

NOTE: When installing a new steering column shaft assembly, place the tilt lever in the lock position, if it is not in place.

CAUTION

• Be careful that nothing is pinched between the one-way capsules and the body.

• Do not release the tilt lever until the steering column has been installed to complete this inspection procedure.

5. If no problem is found during the inspection, tighten the steering column mounting bolts to the specified torque.

Tightening torque: 12 ± 2 N⋅m

Mitsubishi Lancer 2005 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual