Mitsubishi Pajero Sport – Manual Transmission Workshop Manual

Page 1
0$18$/
75$160,66,21
5504
&217(176
*(1(5$/ ,1)250$7,21 5111111111111111111
/8%5,&$176 5111111111111111111111111111111
6($/$176 511111111111111111111111111111111
2109(+,&/( 6(59,&( 6111111111111111111111
7UDQVPLVVLRQ 2LO &KHFN 611111111111111111111111
2LO 5HSODFHPHQW 611111111111111111111111111111
5543<3336;;
7:' 'HWHFWLRQ 6ZLWFK &RQWLQXLW\ &KHFN 71111111
+LJK2/RZ 'HWHFWLRQ 6ZLWFK &RQWLQXLW\ &KHFN 7111
75$160,66,21 &21752/ 811111111111111111
75$160,66,21 $66(0%/< :1111111111111111
7:' ,1',&$7250(&8 44111111111111111111111
Page 2
5505
*HQHUDO ,QIRUPDWLRQ2/XEULFDQWV26HDODQWV
*(1(5$/ ,1)250$7,21
,WHPV 6SHFLILFDWLRQV
7UDQVPLVVLRQ PRGHO 98074070%)* 98074070$(*
(QJLQH PRGHO 7'8 9*:
7\SH 80VSHHG/ IORRU0VKLIW
*HDU UDWLR 4VW 61<4;
5QG 51594
6UG 416<8
7WK 41333
8WK 31;5<
5HYHUVH 61<58
7UDQVIHU W\SH 50VSHHG
*HDU UDWLR +LJK 41333
/RZ 41<58
55433343569
6SHHGRPHWHU JHDU UDWLR +GULYHQ2GULYH, 592; 582;
/8%5,&$176
,WHPV 6SHFLILHG OXEULFDQWV 4XDQWLW\ /
7UDQVPLVVLRQ RLO +\SRLG JHDU RLO 6$( :8:0<3 RU :8:0;8: FRQIRUPLQJ WR
$3, */07
7UDQVIHU RLO +\SRLG JHDU RLO 6$( :8:0<3 RU :8:0;8: FRQIRUPLQJ WR
$3, */07
518
516
6($/$176
,WHPV 6SHFLILHG VHDODQW 5HPDUNV
2LO ILOOHU SOXJ 60 $7' 3DUW 1R1 ;993 RU HTXLYDOHQW 6HPL0GU\LQJ VHDODQW
2LO GUDLQ SOXJ 60 $7' 3DUW 1R1 ;993 RU HTXLYDOHQW 6HPL0GU\LQJ VHDODQW
&RQWURO OHYHU JDVNHW 60 $7' 3DUW 1R1 ;994 RU HTXLYDOHQW 6HPL0GU\LQJ VHDODQW
&RQWURO OHYHU DVVHPEO\ PRXQWLQJ EROW 60 6WXG /RFNLQJ 1R1 74:3 RU HTXLYDOHQW $QDHURELF VHDODQW
55433373636
5543338343;
Page 3
2Q0YHKLFOH 6HUYLFH
5506
7UDQVPLVVLRQ RLO
7UDQVPLVVLRQ
7UDQVIHU
)LOOHU SOXJ KROH
2LO ILOOHU SOXJ
2LO GUDLQ SOXJ
2109(+,&/( 6(59,&(
554333<35<5
75$160,66,21 2,/ &+(&.
41 5HPRYH WKH RLO ILOOHU SOXJ1 51 2LO OHYHO VKRXOG EH DW WKH ORZHU SRUWLRQ RI WKH ILOOHU SOXJ
KROH1
61 &KHFN WKDW WKH WUDQVPLVVLRQ RLO LV QRW QRWLFHDEO\ GLUW\/
DQG WKDW LW KDV D VXLWDEOH YLVFRVLW\1
71 7LJKWHQ WKH ILOOHU SOXJ WR WKH VSHFLILHG WRUTXH1
7LJKWHQLQJ WRUTXH=:31P
2,/ 5(3/$&(0(17
41 5HPRYH RLO ILOOHU SOXJ DQG RLO GUDLQ SOXJ1 51 'UDLQ RLO1 61 7LJKWHQ WKH RLO GUDLQ SOXJ WR WKH VSHFLILHG WRUTXH1
7LJKWHQLQJ WRUTXH=:31P
127( $SSO\ VHDODQW WR WKH RLO GUDLQ SOXJ WKUHDGV1
6SHFLILHG VHDODQW=
60$7'3DUW1R1 ;993 RU HTXLYDOHQW
71 )LOO ZLWK VSHFLILHG RLO WLOO WKH OHYHO FRPHV WR WKH ORZHU SRUWLRQ
RI RLO ILOOHU SOXJ KROH1
5543343363;
2LO GUDLQ SOXJ
2LO ILOOHU SOXJ
6SHFLILHG WUDQVPLVVLRQ RLO=
+\SRLG JHDU RLO 6$( :8:0<3 RU :8:0;8: FRQIRUPLQJ WR $3, */07
4XDQWLW\=
7UDQVPLVVLRQ 518 /
7UDQVIHU 516 /
81 7LJKWHQ WKH RLO ILOOHU SOXJ WR WKH VSHFLILHG WRUTXH1
7LJKWHQLQJ WRUTXH=:31P
127( $SSO\ VHDODQW WR WKH RLO ILOOHU SOXJ WKUHDGV1
6SHFLILHG VHDODQW=
60$7'3DUW1R1 ;993 RU HTXLYDOHQW
Page 4
5507
7:' '(7(&7,21 6:,7&+ &217,18,7< &+(&.
&KHFN WKH FRQWLQXLW\ EHWZHHQ WHUPLQDOV RI WKH EODFN FRQQHFWRU LQGLFDWHG LQ WKH LOOXVWUDWLRQ1
7UDQVIHU OHYHU SRVLWLRQ 7HUPLQDO 1R1
5+
7+
2Q0YHKLFOH 6HUYLFH
554334:3373
4 5
+,*+2/2: '(7(&7,21 6:,7&+ &217,18,7< &+(&.
&KHFN WKH FRQWLQXLW\ EHWZHHQ WHUPLQDOV RI WKH JUD\ FRQQHFWRU LQGLFDWHG LQ WKH LOOXVWUDWLRQ1
7UDQVIHU OHYHU SRVLWLRQ 7HUPLQDO 1R1
4 5
7+
7/
7+07/
55433543396
Page 5
7UDQVPLVVLRQ &RQWURO
5508
75$160,66,21 &21752/
5(029$/ $1' ,167$//$7,21
3UH0UHPRYDO 2SHUDWLRQ
- 6KLIW WKH 7UDQVPLVVLRQ &RQWURO /HYHU WR WKH 1 3RVLWLRQ1
- 6KLIW WKH 7UDQVIHU &RQWURO /HYHU WR WKH 7+ 3RVLWLRQ1
- )ORRU &RQVRO 5HPRYDO +5HIHU WR *5283 85
)ORRU &RQVRO1,
43 ï46 1P
47
43
46 45
44
6
:; 1P
< :
9 8
;
554336;3639
3RVW0LQVWDOODWLRQ 2SHUDWLRQ
- )ORRU &RQVRO ,QVWDOODWLRQ +5HIHU WR *5283 85 )ORRU &RQVRO1,
- &KHFN WKH 2SHUDWLRQ RI WKH 7UDQVPLVVLRQ DQG 7UDQVIHU &RQWURO /HYHUV DQG WKH 0RYHPHQW LQ (DFK /HYHU 3RVLWLRQ1
8 1P
7
4
<
;
ò'*
*$òò&*
ò%*
ò$*
$SSO\ WKH VHDODQWWR ERWK VLGHV RI WKH JDVNHW
6HDODQW= 60 $ 7' 3DUW 1R1 ;994 RU HTXLYDOHQW
7UDQVPLVVLRQ FRQWURO OHYHU DVVHPEO\ UHPRYDO VWHSV
41 5HWDLQHU SODWH 51 'XVW FRYHU 61 6KLIW OHYHU VKDIW 71 7UDQVPLVVLRQ FRQWURO OHYHU
DVVHPEO\
81 *DVNHW 91 6WRSSHU SODWH :1 *DVNHW ;1 &RQWURO OHYHU EXVKLQJ <1 7UDQVPLVVLRQ FRQWURO OHYHU
44/ 46
$SSO\ WKH VHDODQWWR ERWK VLGHV RI WKH JDVNHW
ò'* ò%*
ò$*
5
&RQWURO OHYHU DVVHPEO\ PRXQWLQJ EROW
8/ :
$GKHVLYH= 60 6WXG /RFNLQJ 1R1 74:3 RU HTXLYDOHQW
7UDQVIHU FRQWURO OHYHU DVVHPEO\ UHPRYDO VWHSV
41 5HWDLQHU SODWH 51 'XVW FRYHU
431 7UDQVIHU FRQWURO OHYHU DVVHPEO\
441 *DVNHW 451 6WRSSHU SODWH 461 *DVNHW 471 7UDQVIHU FRQWURO OHYHU
Page 6
5509
5(029$/ 6(59,&( 32,17
*$ò
&DXWLRQ +ROG WKH WUDQVPLVVLRQ FRQWURO OHYHU ZLWK WKH VSDQQHU DQG ORRVHQ WKH VKLIW OHYHU VKDIW1
6+,)7 /(9(5 6+$)7 5(029$/
7UDQVPLVVLRQ &RQWURO
7UDQVIHU 7UDQVPLVVLRQ
)URQW
?/1+1 GULYH YHKLFOHV!
)URQW
)URQW
?51+1 GULYH YHKLFOHV!
&
)URQW
%
&
$
&%
,167$//$7,21 6(59,&( 32,176
ò$*
,QVWDOO WKH VWRSSHU SODWHV VR WKDW WKH\ IDFH DV VKRZQ LQ WKH LOOXVWUDWLRQ1
ò%*
&
41 5HPRYH WKH DGKHVLYH VWLFNLQJ WR WKH FRQWURO OHYHU
51 8VHDWDS+0; [ 4158, WR UHPRYH WKH DGKHVLYH VWLFNLQJ
61 $SSO\ VSHFLILHG DGKHVLYH WR WKH WKUHDGV RI WKH FRQWURO
71 7KH GLPHQVLRQV RI WKH PRXQWLQJ EROWV YDU\ DFFRUGLQJ
67233(5 3/$7( ,167$//$7,21
75$16)(5 &21752/ /(9(5 $66(0%/<2 75$160,66,21 &21752/ /(9(5 $66(0%/<
DVVHPEO\ PRXQWLQJ EROWV1
WR WKH EROW KROHV LQ WKH FRQWURO KRXVLQJ/ DQG FOHDQ LW E\ EORZLQJ LQ DLU1
OHYHU DVVHPEO\ PRXQWLQJ EROWV1
6SHFLILHG DGKHVLYH=
60 6WXG /RFNLQJ 1R1 74:3 RU HTXLYDOHQW
WR WKHLU PRXQWLQJ ORFDWLRQV/ VR GR QRW FRQIXVH WKHP ZKHQ LQVWDOOLQJ1
)URQW
%ROW 'LDPHWHU [ /HQJWK PP
$ ; [ 4;
% ; [ 55
& ; [ 56
ò&*
6+,)7 /(9(5 6+$)7 ,167$//$7,21
&DXWLRQ +ROG WKH WUDQVPLVVLRQ FRQWURO OHYHU ZLWK WKH VSDQQHU DQG WLJKWHQ WKH VKLIW OHYHU VKDIW1
ò'*
'867 &29(5 ,167$//$7,21
,QVWDOO WKH GXVW FRYHU VR WKDW WKH\ IDFH DV VKRZQ LQ WKH LOOXVWUDWLRQ1
Page 7
7UDQVPLVVLRQ $VVHPEO\
550:
75$160,66,21 $66(0%/<
554336833;9
5(029$/ $1' ,167$//$7,21
&DXWLRQ
-= ,QGLFDWHV SDUWV ZKLFK VKRXOG EH LQLWLDOO\ WLJKWHQHG/ DQG WKHQ IXOO\ WLJKWHQHG DIWHU SODFLQJ WKH YHKLFOH KRUL]RQWDOO\ DQG ORDGLQJ WKH IXOO ZHLJKW RI WKH HQJLQH RQ WKH YHKLFOH ERG\1
3UH0UHPRYDO 2SHUDWLRQ
- 7UDQVPLVVLRQ DQG 7UDQVIHU &RQWURO /HYHU 5HPRYDO
+5HIHU WR 3155081,
- 7UDQVIHU &DVH 3URWHFWRU 5HPRYDO
- 7UDQVPLVVLRQ DQG 7UDQVIHU 2LO 'UDLQLQJ +5HIHU WR
3155061,
- )URQW DQG 5HDU 3URSHOOHU 6KDIW 5HPRYDO +5HIHU WR *5283 58 ï 3URSHOOHU 6KDIW1,
- )URQW DQG &HQWHU ([KDXVW 3LSH 5HPRYDO ?7'8! +5HIHU WR *5283 48 ï ([KDXVW 3LSH DQG 0DLQ 0XIIOHU,
?9*:!
64 1P
64 1P
46
<3 1P
45
43
:7 1P
6
3RVW0LQVWDOODWLRQ 2SHUDWLRQ
- )URQW DQG &HQWHU ([KDXVW 3LSH ,QVWDOODWLRQ ?7'8! +5HIHU WR *5283 48 ï ([KDXVW 3LSH DQG 0DLQ 0XIIOHU,
- )URQW DQG 5HDU 3URSHOOHU 6KDIW ,QVWDOODWLRQ +5HIHU WR *5283 58 ï 3URSHOOHU 6KDIW1,
- 7UDQVPLVVLRQ DQG 7UDQVIHU 2LO )LOOLQJ +5HIHU WR 3155061,
- 7UDQVIHU &DVH 3URWHFWRU ,QVWDOODWLRQ
- 7UDQVPLVVLRQ DQG 7UDQVIHU &RQWURO /HYHU
,QVWDOODWLRQ +5HIHU WR 3155081,
- 7UDQVPLVVLRQ DQG 7UDQVIHU &RQWURO /HYHU2SHUDWLRQ &KHFN
4
5
7
47
68 1P
8
68 1P
:7 1P
;
4<
49
55 1P
55 1P
77 1P-
48
*$ò
44
69 1P
<3 1P
69 1P
<
58 1P
9
97 1P
5HPRYDO VWHSV
41 +LJK2ORZ GHWHFWLRQ VZLWFK FRQQHFWRU 51 7:' GHWHFWLRQ VZLWFK FRQQHFWRU 61 %DFN0XS ODPS VZLWFK FRQQHFWRU 71 (DUWK FDEOH 81 6SHHG VHQVRU FRQQHFWRU 91 +HDW SURWHFWRU :1 &OXWFK UHOHDVH F\OLQGHU ;1 &OXWFK GDPSHU DVVHPEO\
?51+1 GULYH YHKLFOHV!
<1 ([KDXVW SLSH FODPS PRXQWLQJ EROW
431 7UDQVPLVVLRQ VWD\
4:
:
58 1P
6< 1P
55 1P
4;
97 1P
*%ò
ò%*
*&òò$*
441 ([KDXVW FODPS EUDFNHW 451 6WDUWHU PRWRU 461 6WDUWHU PRWRU FRYHU 471 '\QDPLF GDPSHU DVVHPEO\
-
6XSSRUW WKH WUDQVPLVVLRQ ZLWK D WUDQVPLVVLRQ MDFN
481 7UDQVIHU UROO VWRSSHU 491 7UDQVIHU PRXQW EUDFNHW 4:1 7UDQVIHU VXSSRUW EUDFNHW 4;1 1R15FURVVPHPEHU 4<1 7UDQVPLVVLRQ DVVHPEO\
Page 8
550;
7UDQVPLVVLRQ $VVHPEO\
?7'8!
68 1P
;
68 1P
<
7; 1P
43
7
44
5
56 1P
64 1P
:
7; 1P
6
4
68 1P
8
55 1P
77 1P-
49
45
46
47
55 1P
68 1P
55 1P
9
58 1P
97 1P
< 1P
5HPRYDO VWHSV
41 +LJK2ORZ GHWHFWLRQ VZLWFK FRQQHFWRU 51 7:' GHWHFWLRQ VZLWFK FRQQHFWRU 61 %DFN0XS ODPS VZLWFK FRQQHFWRU 71 (DUWK FDEOH 81 6SHHG VHQVRU FRQQHFWRU
*$ò 91 &OXWFK UHOHDVH F\OLQGHU
:1 ([KDXVW SLSH VXSSRUW EUDFNHW ;1 6SDFH UXEEHU <1 %HOO KRXVLQJ FRYHU
48
*%ò 431 6WDUWHU PRWRU
441 '\QDPLF GDPSHU DVVHPEO\
- 6XSSRUW WKH WUDQVPLVVLRQ ZLWK D WUDQVPLVVLRQ MDFN
ò%* 451 7UDQVIHU UROO VWRSSHU
461 7UDQVIHU PRXQW EUDFNHW 471 7UDQVIHU VXSSRUW EUDFNHW 481 1R15FURVVPHPEHU
*&òò$* 491 7UDQVPLVVLRQ DVVHPEO\
Page 9
5(029$/ 6(59,&( 32,176
*$ò
5HPRYH WKH FOXWFK UHOHDVH F\OLQGHU ZLWKRXW GLVFRQQHFWLQJ IOXLG OLQH1 7KHQ VXVSHQG WKHP ZLWK D FRUG1
&/87&+ 5(/($6( &</,1'(5 5(029$/
7UDQVPLVVLRQ $VVHPEO\
550<
?9*:!
%
&
*%ò
67$57(5 02725 5(029$/
5HPRYH WKH VWDUWHU PRWRU ZLWK WKH VWDUWHU PRWRU KDUQHVVHV VWLOO FRQQHFWHG/ DQG VHFXUH LW LQVLGH WKH HQJLQH FRPSDUWPHQW1
*&ò
75$160,66,21 $66(0%/< 5(029$/
&DXWLRQ :KHQ UHPRYLQJ WKH WUDQVPLVVLRQ DVVHPEO\ IURP WKH HQJLQH/ FDUH PXVW EH WDNHQ QRW WR VKDNH RU URFN ZLWK IRUFH/ EHFDXVH WR GR VR PLJKW FDXVH GDPDJH WR WKH HQG RI WKH PDLQ GULYH JHDU/ WKH SLORW EHDULQJ/ RU WKH FOXWFK GLVF/ HWF1
$
$
,167$//$7,21 6(59,&( 32,176
ò$*
75$160,66,21 $66(0%/< ,167$//$7,21
7KH VL]HV RI WKH PRXQWLQJ EROWV DUH GLIIHUHQW1 6R EH VXUH
&
QRW WR FRQIXVH WKHP1
?9*:!
?7'8!
&
$%
&
'
'
%ROW 'LDPHWHU [ /HQJWK PP
$ 45 [ 73
% /1+1 GULYH
YHKLFOHV
51+1 GULYH YHKLFOHV
& 45 [ 88
45 [ 73
45 [ 78
?7'8!
%ROW 'LDPHWHU [ /HQJWK PP
$ 43 [ 78
% ; [ 63
& 43 [ ;3
' 43 [ 58
Page 10
55043
7UDQVPLVVLRQ $VVHPEO\
= $SSUR[1
D
43 PP
7UDQVIHU UROO VWRSSHU LQQHU
7UDQVIHU UROOVWRSSHU
E E
ò%*
75$16)(5 52// 67233(5 ,167$//$7,21
41 7LJKWHQ WKH WUDQVIHU UROO VWRSSHU SURYLVLRQDOO\1 51 0DNH WKH HQJLQH DQG WUDQVPLVVLRQ DVVHPEO\ UHVW RQ WKH
7UDQVIHU UROO VWRSSHU RXWHU
HQJLQH PRXQW1
61 7LJKWHQ WKH WUDQVIHU UROO VWRSSHUV LQQHU DQG RXWHU ILQDOO\
VR WKDW WKH FOHDUDQFH +D, EHWZHHQ WKH WZR DUH DW WKH VKRZQ GLPHQVLRQ1
71 &KHFN WKDW WKH ULJKW DQG OHIW FOHDUDQFHV +E , EHWZHHQ WKH
VWRSSHUV DUH HTXDO1
7UDQVIHU PRXQWLQJ EUDFNHW
81 &KHFN WKDW WKH FOHDUDQFHV +F, EHWZHHQ WKH WUDQVIHU UROO
VWRSSHU DQG WUDQVIHU PRXQWLQJ EUDFNHW DUH HTXDO1
127( :KHQ QHZ/ D WUDQVIHU UROO VWRSSHU FRQVLVWV RI RQH SDUW/ EXW ZLOO VHSDUDWH LQWR RXWHU DQG LQQHU SDUW GXULQJ XVH1 7KLV LV QRUPDO1
FF
Page 11
7:' ,QGLFDWRU0(&8
55044
7:' ,1',&$7250(&8
5(029$/ $1' ,167$//$7,21
6
5
55433953373
4
5HPRYDO VWHSV
41 )URQW VFXII SODWH DWWDFKLQJ VFUHZ 51 &RZO VLGH WULP 61 7:' LQGLFDWRU0(&8
,163(&7,21
7:' ,1',&$7250(&8
41 0HDVXUH WKH YROWDJH ZLWK WKH FRQWURO XQLW DQG KDUQHVV
9LHZ $
$
VWLOO FRQQHFWHG1
51 (DUWK WHUPLQDO +;, DQG WKHQ PHDVXUH WHUPLQDO YROWDJH1
5543397336<
Page 12
55045
7:' ,QGLFDWRU0(&8
7HUPLQDO 1R1 ,QVSHFWLRQ LWHP ,QVSHFWLRQ FRQGLWLRQ
4= ,JQLWLRQ VZLWFK
4 )UHH ZKHHO HQJDJH 21 5+ 6\VWHP YROWDJH
VZLWFK
5 7:' GHWHFWLRQ 21 5+ 6\VWHP YROWDJH
VZLWFK
6 ,JQLWLRQ VZLWFK +,*4, 2)) ï 3 9
21 ï 6\VWHP YROWDJH
9 +,2/2: GHWHFWLRQ
VZLWFK
: )UHH ZKHHO FOXWFK 21 7+/7/ 3 9
FKDQJHRYHU VROHQRLG YDOYH
43 7:' ,QGLFDWRU ODPS 21 5+ 3 9
21 6KLIWLQJ IURP 7+WR7/
,QVSHFWLRQ FRQGLWLRQ
5= 7UDQVIHU OHYHU SRVLWLRQ
4
7+-
7+/7/ 3 9
RU YLFH YHUVD
5+/7+/7/ 3 9
5
5+-
7+/7/ 6\VWHP YROWDJH
7HUPLQDO YROWDJH
3 9
6\VWHP YROWDJH
6\VWHP YROWDJH
127(
4
-
= :KHQ YHKLFOH KDV EHHQ PRYHG RQFH1
5
-
= 6KLIW WKH OHYHU IURP 7+WR5+/ DQG WKHQ WXUQ WKH LJQLWLRQ VZLWFK WR 2)) DQG WKHQ EDFN WR 211
Loading...