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
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(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
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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
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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
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(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
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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)
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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.
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