1997 MITSUBISHI TRITON ABS

ENGINE <4D5> ± Service Specifications/Sealants11B-3
SERVICE SPECIFICATIONS11100030359
ItemsStandard valueLimit
Alternator drive belt
tension (for each
Tension NWhen checked245 ± 441±
tension (for each
belt)When a used belt is installed294 ± 392±)
When a new belt is installed392 ± 588±
Deflection
(Reference
When checked12.0 ± 17.0±
(Reference
value) mmWhen a used belt is installed13.0 ± 16.0±)
When a new belt is installed10.0 ± 13.0±
Power steering oil
pump drive belt ten
Tension NWhen checked294 ± 490±
pump drive belt ten-
sionWhen a used belt is installed343 ± 441±
When a new belt is installed490 ± 686±
Deflection
(Reference
When checked8.0 ± 12.0±
(Reference
value) mmWhen a used belt is installed9.0 ± 11.5±)
When a new belt is installed6.0 ± 8.0±
A/C compressor
drive
Tension NWhen checked320 ± 400±
drive
belt tensionWhen a used belt is installed320 ± 400±
When a new belt is installed480 ± 560±
Deflection
(Reference
When checked6.0 ± 7.0±
(Reference
value) mmWhen a used belt is installed6.0 ± 7.0±)
When a new belt is installed4.5 ± 5.5±
Valve clearance (at hot) mm0.25±
Injection timing (Value indicated on dial gauge mm)9
ATDC (1 + 0.03)±
Idle speed r/min750 + 100±
Idle up engine speed for ABS r/min1,900 + 100±
Compression pressure kPa3,040Min. 2,200
Compression pressure difference of all cylinder (at engine speed of 280
r/min) kPa±Max. 300
Timing belt tension mm4 ± 5±
Timing belt B tension mm4 ± 5±
SEALANTS11100050270
ItemsSpecified sealantRemarks
Oil panMITSUBISHI GENUINE PART
MD970389 or equivalentSemi-drying sealant
Semi-circular packing and rocker
cover seal, and cylinder head seal3M ATD Part No. 8660 or equivalent

MPI ± Troubleshooting13A-43
INSPECTION PROCEDURE 28
Power steering fluid pressure switch system
Probable cause
The presence or absence of power steering load is input to the engine-ECU.
The engine-ECU controls the idle speed control (ISC) servo based on this input.
Malfunction of power steering fluid pressure switch

Improper connector contact, open circuit or
short-circuited harness wire

Malfunction of the engine-ECU
Check the power steering fluid pressure switch.
(Refer to GROUP 37A ± On-vehicle Service.)NG
Replace
OK
Measure at the power steering fluid pressure switch connector
A-74.

Disconnect the connector, and measure at the harness side.

Voltage between 1 and earth (Ignition switch: ON)
OK:System voltageNGCheck the following
connector. C-50NG
Repair
OK
Check trouble symptom.
NG
Check harness wire be-
tween engine-ECU and
power steering fluid pres-
sure switch connector.NG
Repair
OK
Replace the engine-ECU.
OK
Check the following
connector. A-74NG
Repair
OK
Check trouble symptom.
NG
Replace the engine-ECU.
INSPECTION PROCEDURE 29
A/C switch and A/C relay system
Probable cause
When an A/C ON signal is input to the engine-ECU, the engine-ECU carries out
control of the idle speed control (ISC) servo, and also operates the A/C compressor
magnetic clutch.
Malfunction of A/C control system

Malfunction of A/C switch

Improper connector contact, open circuit or
short-circuited harness wire

Malfunction of the engine-ECU
Check the A/C compressor relay.
(Refer to GROUP 55 ± On-vehicle Service.)NG
Replace
OK
Measure at the engine-ECU connectors C-49, C-50.

Disconnect the connector, and measure at the harness side.


Voltage between 22 and earth, and 45 and earth
(Ignition switch: ON, A/C switch: ON)
OK:System voltage

Short circuit between 22 and earth
(Ignition switch: ON, A/C switch: ON)
OK:A/C compressor clutch turns on.


Voltage between 8 and earth, and 45 and earth
(Ignition switch: ON, A/C switch: ON)
OK:System voltage

Short circuit between 8 and earth
(Ignition switch: ON, A/C switch: ON)
OK:A/C compressor clutch turns on.NGCheck the A/C system. (Refer to GROUP 55 ± On-vehicle Service.)
OKCheck the following
connectors. C-49, C-50NG
Replace
OK
Check trouble symptom.
NG
Replace the engine-ECU.

ENGINE COOLING ±
General Information/
Service Specifications/Lubricant/Sealants14-2
GENERAL INFORMATION14100010125
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 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 drive belt from the crankshaft.
The radiator is the corrugated fin, down flow type.
ItemsSpecifications
RadiatorPerformance kJ/h4G63 114,700
4G63 126,800
4G64, 4D56 <2WD>170,000
4D56 <4WD>227,300
Automatic transmission oil coolerPerformance kJ/h4G63 6,400
4D56 6,300
SERVICE SPECIFICATIONS14100030121
ItemsStandard valueLimit
High pressure valve opening pressure of radiator cap kPa75 ± 10565
Range of coolant antifreeze concentration of radiator %30 ± 60±
ThermostatValve opening temperature of thermostat
C82 + 1.5±
Full-opening temperature of thermostat
C95±
Valve lift (at 95
C) mm4G6, 4D56 <4WD>8.5 or more±
4D56 <2WD>8 or more±
LUBRICANT14100040100
ItemsQuantity

HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT4G637.4
4G64, 4D56 <2WD>7.7
4D56 <4WD>7.8
SEALANTS14100050110
ItemsSpecified sealantRemarks
Cylinder block drain plug3M Nut Locking Part No. 4171 or equivalentDrying sealant
Water by-pass fitting <4G6>Mitsubishi Genuine Parts No. MD970389 or
equivalentSemi-drying sealant

FRONT AXLE ± General Information26-2
GENERAL INFORMATION26100010111
2WD
The front hub assembly which uses a double taper
roller bearing is mounted on the knuckle spindle.For vehicles with ABS, a rotor for detecting the
wheel speed is press-fitted into the front hub.
4WD
The front axle consists of the hub assembly, drive
shaft, inner shaft, front differential, freewheel clutch
assembly and actuator. The features are:

The wheel bearing uses a double taper roller
bearing. For vehicles with ABS, a rotor for
detecting the wheel speed is bolted to the brake
disc.

Drive shafts of almost identical length reduce
torque steer. In addition, a D.O.J.-B.J.-type
constant velocity ball joint has high power
transmission efficiency and reduces vibration
and noise.
A vacuum-type freewheel clutch has been
adopted in the freewheel mechanism. Its
solenoid valve and actuator switch powertrain
between 2WD and 4WD.

There are two types of differential gear. The
difference between them is gear ratio.
2WD
ItemSpecifications
Wheel bearingTypeDouble taper roller bearing
Inner bearing (O.D. x I.D.) mm65.1 x 34.9
Outer bearing (O.D. x I.D.) mm50.0 x 21.4
4WD

ItemSpecifications
Wheel bearingTypeDouble taper roller bearing
Inner bearing (O.D. x I.D.) mm73 x 45
Outer bearing (O.D. x I.D.) mm73 x 45
Drive shaftJoint typeOuter: B.J.
Inner: D.O.J.
Shaft length (joint to joint) mmRight: 318
Left: 291
Inner shaftO.D. x length mm31.5 x 304.2
Bearing (O.D. x I.D.) mm62 x 35

REAR AXLE ± General Information27-2
GENERAL INFORMATION27100010118

The rear axle is a banjo-type semi-floating type.
The axle shaft bearings are: *Single taper
bearings for vehicles without ABS or rear
differential lock. *Double-taper bearings for
vehicles with ABS or rear differential lock. ABS
rotor is press-fitted to the axle shaft retainer
ring.
Differential gear has 4 different types. A
torque-responsive mechanical-type limited slip
differential has a high performance against
driving on unstable surfaces such as muddy
roads.

Driveability on sand or muddy road has been
improved, and rear differential lock, which is
useful for emergency , has been used.
REAR AXLE
ItemVehicles without rear differential lockVehicles with rear differential lock
Axle housing typeBanjo typeBanjo type
Axle
shaft
Support methodSemi-floating typeSemi-floating type
shaft
Shaft O.D. (Bearing part x
Centre x Length) mm40.0 x 34.5 x 744.540.0 x 34.5 x 723.5 (LH)
40.0 x 34.5 x 761.0 (RH)
Bearing typeSingle taper (double taper)*Double taper
Bearing (O.D. x I.D.) mm80.0 x 40.080.0 x 40.0
NOTE
*: Vehicles with ABS.
DIFFERENTIAL
<2WD>
Item4G634D56
Drive gear typeHypoid gearHypoid gear
Reduction ratio4.6364.222
Limited slip differential typeTorque sensitivity type mechanicalTorque sensitivity type mechanical
Differential gear type
(type x quantity)
Side gearStraight bevel gear x 2Straight bevel gear x 2
(ty e x quantity)
Pinion gearStraight bevel gear x 2 [Straight bevel
gear x 4]Straight bevel gear x 2 [Straight bevel
gear x 4]
Number of teethSide gear5138
Drive pinion119
Side gear1414
Pinion gear1010
Bearing (O.D. x I.D.)
mm
Side80.0 x 45.280.0 x 45.2
mm
Front68.3 x 30.268.3 x 30.2
Rear76.2 x 36.576.2 x 36.5
NOTE
[ ]: Vehicles with limited slip differential

REAR AXLE ± Service Specifications27-4
SERVICE SPECIFICATIONS27100030121
ItemStandard valueLimit
Rear axle total backlash mm±5
Axle shaft axial play mmVehicles without ABS or rear differential lock0.05 ± 0.20±
Vehicles with ABS or rear differential lock0 ± 0.25±
Limited slip differential
p
reload Nm
Using special tool13 or more±
reload Nm
Without using special tool25 or more±
Axle shaft retainer
press-fitting force NVehicles without ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
78,000±
Vehicles with ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
98,000 ± 108,000±
Clearance between axle shaft retainer and snap ring mm0 ± 0.166±
Rear differential lock air pump pressure kPa25 ± 40±
Drive gear backlash mm2WD0.08 ± 0.13±
4WD0.13 ± 0.18±
Drive gear runout mm±0.05
Differential gear backlash mm2WD0 ± 0.250.2
4WD0 ± 0.0760.2
Limited slip differential
starting torque Nm
When a new clutch plate is used39 ± 74±
starting torque Nm
When re-installing current clutch plate25 ± 74±
Drive pinion
turning torque NmWithout oil sealWhen replacing
(with anti-rust agent)0.6 ± 0.9±
When replacing or reusing
(with gear oil applied)0.4 ± 0.5±
With oil sealWhen replacing
(with anti-rust agent)0.8 ± 1.1±
When replacing or
reusing (with gear oil applied)0.6 ± 0.7±

FRONT SUSPENSION ± Service Specifications/Sealant33A-3
SERVICE SPECIFICATIONS33200030088
ItemsStandard valueLimit
Toe-inAt the centre of tyre thread mm0 ± 7±
Toe-angle
(per wheel)
2WD0
± 0
19'±
(er wheel)
4WD
205/80 R16 tyre>0
± 0
16'±
4WD
x 10.50 R15 tyre>0
± 0
15'±
Camber0
10' ± 1
10' (Difference between
right and left within 30')±
Caster2WD1
45' ± 3
45' (Difference between
right and left within 30')±
4WD1
15' ± 3
15' (Difference between
right and left within 30')±
Kingpin inclination2WD15
00'±
4WD14
50'±
Shock absorber attaching dimension mm1 ± 2±
Upper arm ball joint starting torque Nm2WD0.8 ± 3.4±
Strut bar attaching dimension mm79±
Lower arm ball joint end play mm±0.5
Lower arm bush press-fitting force kN9.8±
Clearance between bump stopper and
bump stopper bracket mm4WD21 ± 23±
Stabilizer link assembly attaching
dimension mm4WD16 ± 18±
SEALANT33200050015
ItemSpecified sealant
Upper arm ball joint dust cover <2WD>3M ATD Part No. 8661 or equivalent

BASIC BRAKE SYSTEM ± General Information35A-3
GENERAL INFORMATION35100010120
The brake system has high reliability and durability
which maintains excellent braking performance and
braking feeling. The main features are as follows.

A dual type master cylinder is equipped in all
models.

Both a single type and a tandem type brake
booster have been adopted.
The following type of brake have been adopted.
Front: Floating caliper, 2-piston, ventilated disc
brakes (V4-W43, V5-W43) or floating caliper,
1-piston, ventilated disc brakes (V4-S60,
V5-S60)
Rear: Leading-trailing type drum brake.
Items2WD
vehicles>2WD
vehicles>4WD
vehicles>4WD
vehicles>
Master cylinder I.D. mm23.823.823.823.8
Brake booster effective dia.
of power cylinder mm230
205 + 230*230
180 + 205*205 + 230180 + 205
Brake booster boosting ratio5.05.07.07.0
Load sensing proportioning
valve decompression ratio0.150.150.150.15
Front brake disc effective
dia. mm200200222
228*222
228*
Front brake wheel cylinder
I.D. mm60.3
42.9*60.3
42.9*60.3
42.9*60.3
42.9*
Rear drum brake drum I.D.
mm254254270270
Rear drum brake wheel
cylinder I.D. mm23.823.823.823.8
Rear drum brake lining
thickness mm4.74.74.74.7
NOTE
*: Vehicles with ABS.