
GENERAL  How  to  Use  This 
HOW  TO  USE  THIS  MANUAL
MAINTENANCE,  REPAIR  AND
SERVICING  EXPLANATIONS
This  manual  provides  explanations,  etc.  concerning procedures  for  the  inspection,  maintenance,  repair
and servicing of the subject model. Unless other-
wise specified, each service procedure covers all
models. Procedures covering specific models are
identified  by  the  model  codes,  or  similar  designati on
(engine  type,  transaxle  type,  etc.).  A  description
of  these  designations  is  covered  in  this  manual
under  “VEHICLE  IDENTIFICATION”.
ON-VEHICLE  SERVICE
“On-vehicle  Service”  are  procedures  for  performing
inspections  and  adjustments  of  particularly  impor-
tant  locations  with  regard  to  the  construction  and
for  maintenance  and  servicing,  but  other  inspec-
tions (for looseness, play, cracking, damage, etc.
  must  also  be  performed.
SERVICE  PROCEDURES
The  service  steps  are  arranged  in  numerical  order
and  attention  must  to  be  paid  in  performing  vehicle
service  are  described  in  detail  in  SERVICE  POINTS.
TERMS  DEFINITION
STANDARD  VALUE
Indicates  the  value  used  as  the  standard  for  judgin g
the  quality  of  a  part  or  assembly  on  inspection 
or the value to which the part or assembly is cor-
rected  and  adjusted.  It  is  given  by  tolerance.
LIMIT
Indicates  a  maximum  or  minimum  value,  the  part
or  assembly  should  be  kept  within,  in  order  to  be functional.  This  value  is  established  outside  the
standard value range.
REFERENCE  VALUE
Indicates  the  adjustment  value  prior  to  starting  th e
work  (presented  in  order  to  facilitate  assembly  and
adjustment procedures, and so they can be com- 
pleted  in  a  shorter  time).
CAUTION
Indicates  the  presentation  of  information  particula rly
vital  to  the  worker  during  the  performance  of  maint e-
nance and servicing procedures in order to avoid
the  possibility  of  injury  to  the  worker,  or  damage 
to component parts, or a reduction of component
or  vehicle  function  or  performance,  etc..
TIGHTENING  TORQUE  INDICATION
The  tightening  torque  shown  in  this  manual  is  a
basic value with a tolerance of 
 10% except the
following  cases  when  the  upper.  and 
of  tightening  torque  are  given. (1)  The  tolerance  of  the  ‘basic  value 
10%.
(2)  Special  bolts  or,  the  ‘like  are 
(3)  Special  tightening  methods  are  used. 
SPECIAL  TOOL  NOTE 
When  the  MMC  special  tool  is  described,  please
refer  to  the  special  tool 
is  located  at  the  beginning  of  each  group,  for  a
cross  reference  from  the   tool,  number
to the special tool number that  available in your
market..
MODEL  INDICATIONS
The  following  abbreviations  are  used  in  this  manual   for  classification  of  model  types.
M/T
  Indicates  the  manual  transaxle,  or  models  equipped   with  the  manual  transaxle.
A/T
  Indicates  the  automatic  transaxle,  or  models  equip ped  with  the  automatic  transaxle.
MFI:  Indicates  the 
  fuel  injection,  or  engines  equipped  with  the   fuel  injection.
Turbo:  Indicates  the  engine  with  turbocharger,  or  m odels  equipped 
 such an 
Non-turbo:  Indicates  the  engine  without  turbocharger,  or  models  equipped  with,  such  anengine.
FWD:  Indicates  the  front  wheel  drive  vehicles.
AWD:  Indicates  the  all  wheel  drive  vehicles.
ABS:  Indicates  the  anti-lock  braking  system  or  mode ls  equipped  with  the 
  braking  

11ENGINE  Crankshaft  pear  Oil 
  , 
 BOLT   PLATE  BOLT
R E M O V A L
Use  the  special  tool  to  secure.  the
 or drive plate,
and  remove  the  bolt.
INSTALLATION  SERVICE 
  CRANKSHAFT REAR  OIL  SEAL  INSTALLATION
(1)  Apply  a  small  amount  of  engine  oil  to  the  entir e  inside
diameter  of  the  oil  seal  lip.
(2)  Tap  in  the  oil  seal  as  shown  in  the  illustratio n.
  PLATE  BOLT  BOLT
(1) Clean off all sealant, oil and other substances which are
adhering  to  the  threaded  bolts,  crankshaft  thread  h oles
and  the  flywheel 
  or  drive  plate 
(2)  Apply  oil  to  the  bearing  surface  of  the  flywhee l 
or  drive  plate   bolt.
(3)  Apply  oil  to  the  crankshaft  thread  holes.
(4)  Apply  sealant  to  the  threaded  mounting  bolts.
Specified sealant:
  Stud  locking  4170  or  equivalent
  TSB Revision
(5)  Use  the  special  tool  to  secure  the  flywheel   or
drive  plate   and  then  tighten  the   the  speci-
fied torque.
Specified torque:
  Nm          

ENGINEService
SERVICE  SPECIFICATIONS
Drive  belt Tension (Ibs.) When  checked
(For
When  a  new  belt  is  installedtor)When  a  used  belt  is  installed
DeflectionWhenchecked
mm  (in.)When  a  new  belt  is  installed
value> When  a  used  belt  is  installed
Drive  belt Tension
 (Ibs.) When  checked
(For  power When  a  new  belt  is  installed
steeringWhen  a  used  belt  is  installed
DeflectionWhenchecked
mm  (in.)When  a  new  belt  is  installed
When  a  used  belt  is  installed
Drive  beltTension (Ibs.) When checked
  A/C When  a  new  belt  is  installed
When  a  used  belt  is  installed
DeflectionWhenchecked
mm  (in.)When  a  new  belt  is  installed 
When  a  used  belt  is  installed
  ignition  timing  at  idle
  ignition  timing  at  idle
 idle speed 
 contents 
  contents  ppm
  pressure  (at  250   400   (psi)
  pressure  difference  of  all  cylinder   (psi)
ntake  manifold  vacuum 
 (in. Hg)
  head  bolt  length  mm  (in.)
  tensioner  push  rod  movement  mm  (in.)
  belt  tension  torque  Nm 
  tensioner  rod  protrusion  mm  (in.)
 belt   tension  mm  (in.) Standard
Limit
  ,
490
 686 (110.2  154.3) 
7.5 9.0 
10.0
245 490 (55.1   110.2)
  1 5 4 . 3 )
343 441 (77.2   99.2)
5.5 8.0 
4.5
6.0
255  333  (57.3   75.0)
382  441  (86.0   99.2)
255
  333  (57.3   75.0)
6.5 7.5 
5.5 6.0 
6.5 7.5 
 3”
Approx. BTDC
0.5  or  less
100  or  less
1,350  (192)  ,020  (145)
  100  (14)
min.  60  (18)
99.4  (3.91)
Within  1 
3.5  (2.6)
3 . 8 - 4 . 5
5 7 
S E A L A N T S
ItemsS p e c i f i e d   s e a l a n t
Oil  pan,  cylinder  block  and  thermostat  case  assembl yMITSUBISHI  GENUINE  PART   or  equivalent
Flywheel  bolt  or  drive  plate  bolt
  Stud  locking  4170  or 
TSB  Revision   

INSTALLATION  SERVICE  POINTS
 CRANKSHAFT REAR OIL SEAL INSTALLATION
(1)  Apply  a  small  amount  of  engine  oil  to  the  entir e  inside
diameter  of  the  oil  seal  lip.
(2)  Tap  in  the  oil  seal  as  shown  in  the  illustratio n.
 DRIVE PLATE BOLT  BOLT
(1) Clean off all sealant, oil and other substances which are
adhering  to  the  threaded  bolts,  crankshaft  thread  h oles
and  the  flywheel 
  or  drive  plate 
(2)  Apply  oil  to  the  bearing  surface  of  the  flywhee l 
or  drive  plate   bolt.
(3)  Apply  oil  to  the  crankshaft  thread  holes.
(4)  Apply  sealant  to  the  threaded  mounting  bolts.
Specified sealant:
  Stud  locking  4170  or  equivalent
(5)  Use  the  special  tool  to  secure  the 
  or
drive  plate   and  then  tighten  the  bolts  to  the  speci-
fied torque. .
Specified torque: 127-137  Nm 
TSB  Revision      

ENGINE  OVERHAUL   Crankshaft,  Flywheel  and,   .  . 
INSPECTION11300880103
CRANKSHAFT  OIL  CLEARANCE 
(1)  Remove  oil  from  the  crankshaft 
bearing.
(2)  Install  the  crankshaft.
(3)  Cut  the 
  to  the  same  length  as  the   of
bearing  and  place  it  on 
  -with   axis;
(4)  Install  the  crankshaft  bearing  cap  carefully  an d  tighten
the  bolts 
  the  specified  torque.
(5)  Carefully  remove  the  crankshaft  bearing  cap.
(6)  Measure  the  width  of  the  Plastigage  at  its  wide st  part
by  using  a  scale  printed  on  the  Plastigage  package.
Standard  value: 
  mm   in.)
Limit:  0.1  mm 
  in.)
  BLOCK
(1)  Visually  check  for  scratches,  rust,  and  corrosi on.
Use  also  a  flaw  detecting  agent  for  the  check.  If  d efects
are  evident,  correct,  or  replace.
(2)  Using  a  straightedge  and  feeler  gauge,  check  th e  block
  top   for Make  sure  that  the  surface
is  free  from  gasket  chips  and  other  foreign  matter.
Standard  value:  0.05  mm 
  in.)
Limit:  0.1  mm 
  in.)
(3)  If  the  distortion  is  excessive,  correct  within  the  allowable
limit  or  replace.
Grinding  limit:  0.2  mm 
  in.)
Includes/combined  with  cylinder  head  grinding
Cylinder  block  height  (when  new):
  mm  (11.413-11.421  in.)
(4)Check  cylinder  walls  for  scratches  and  seizure.  If  defects
are  evident,  correct  (bored  to  oversize)  or  replace.
Center
Bottom
TSB  Revision
(5)  Using  cylinder  gauge,  measure  the  cylinder  bore   and
cylindricity. If worn badly, correct cylinder to an  oversize
and  replace  piston  and  piston  rings.  Measure  at  the 
points shown in illustration. 
Standard value: Cylinder  I.D.  86.50  mm  (3.4055  in.) 
Cylindricity  0.01  mm 
  in.)  or  less         

21CLUTCH  OVERHAUL   Specifications
SPECIFICATIONS21200030047
SERVICE SPECIFICATION  Engine (Turbo) and  Engine>
0.3
Diaphragm  spring  end  height  difference
TORQUE  SPECIFICATIONS
  Engine  (Turbo)  and   Engine>
Clutch  cover  bolt
Release  cylinder  mounting  bolt
Release  cylinder  union  bolt
Release  cylinder  bleeder  plug
Release  fork  fulcrum
Clutch  chamber  bracket  mountingbolt
Clutch  line  tube  flare  nut
N mft.
19 14
19
14
23
17
118.0
36 24
1914
1511
  Engine  (Non-turbo)>
Drive  plate  to  clutch   flywheel  bolt
  Revision    

GENERAL  INFORMATION
FRONT  AXLE   General   Specification/Lubricants
The  front  axle consists  of  a  knuckle,  front  hub,
unit  bearing  and  drive  shaft,  The  unit  bearing  is has a tripod joint (T.J.) on the transaxle side and
press-fitted  to  the  front  hub  and  bolted  to  the a
  joint 
(B.J.)  on  the  wheel  side.  A  center
kunckle.  Also,  the  unit 
  utilizes  a  double bearing  and  an  inner   been  adopted
in some models.
row  angular  contact  ball  bearing.  The  drive  shaft
CONSTRUCTION  DIAGRAM
Knuckle
inner
Drive  shaft
hub
Standard  valueLimit
Setting  of  boot  length  mm  (in.)
Opening  dimension  of  the  When  the   band  (small)  is  2.9 
special  tool   mm  crimped
(in.)When  the   band  (big)  is
crimped3.2
Crimped  width  of  the   band  mm  (in.)2.4  2.8 
Clearance  between  the   (larger  diameter  side) 0.1 1.55 
and  the  stepped  phase  of  the  B.J.  housing  mm  (in.).
Wheel  bearing  end  play  mm  (in.)0.05
Wheel  bearing  breakaway  torque  Nm 1  (9)  or  less
SERVICE  SPECIFICATIONS
LUBRICANTS
 Quantity  (oz.)  Specified  lubricant 
Inner
Outer  dust  sealFWD
  Engine  (Non-turbo)>105  (3.70)Repair  kit  grease
FWD
  Engine  (Turbo)  and   Engine>120  (4.23)
AWD
. grease
FWD  Engine  (Non-turbo)>110  (3.88) Repair  kit  grease
FWD  Engine  (Turbo)  130   . 
AWD95  (3.35)
TSB  Revision      

FRONT AXLE Front  Hub  Assembly
196-255  Nm
145-188
I(2)  Use  the  special  tool  to  tighten  the  drive  shaft   nut.
Caution
Before  securely  tightening  the  drive  shaft  nuts,  ma ke
sure  there isno  load  on  the  wheel  bearings.
(3)  If  the  position  of  the  cotter  pin  holes  does  no t  match,
tighten  the  nut  up  to  255  Nm  (188 
  in  maximum.
(4)  Install  the  cotter  pin  in  the  first  matching  ho les  and  bend
it  securely.
INSPECTION
WHEEL BEARING BREAKAWAY TORQUE CHECK
(1)  Install  the  special  tool  to  the  front  hub  assem bly  and
tighten  the  nut  to  the  specified  torque  196-255  Nm
 86 
(2)  Use  the  special  tool  to  measure  the  hub  rotatio n  break-
away  torque.
Limit:  1.0  Nm  (9   or  less
(3) The hub rotation breakaway torque should be wit hin the
limit  value  range,  and  there  should  be  no  engagemen t
or  feeling  of  roughness.  Nm
0 0 0 0 0 3 2 0
 FRONT HUB ASSEMBLY REMOVAL
Shift  the  knuckle  to  the  outside  in  order  to  mainta in  the  clear-
ance  between  the  front  hub  assembly  mounting  bolts  and
the drive shaft.
Caution
1.  Do  not  damage  the  ball  joint  boot.
2.For vehicles with ABS, be careful not to damage the
rotor.
INSTALLATION  SERVICE  POINT
  DRIVE  SHAFT  NUT  INSTALLATION
(1)  Install  the  drive  shaft  washer  in  the  specified   direction.
WHEEL  BEARING  END  PLAY  CHECK
(1)  Install  the  special  tool  to  the  front  hub  assem bly  and
tighten  the  nut  to  the  specified  torque  196-255  Nm
(2)  Measure  the  play  in  the  hub  axial  direction.
Limit:  0.05  mm 
  in.)
(3)  If  the  limit  value  of  wheel  bearing  end  play  ca nnot  be
obtained,  replace  the  front  hub  assembly.
 TSB Revision