Is Your Porsche Cayenne Radio On The Fritz Here's What It Could Mean
Vnx.su montero-1989-service-manual
1.
2. x
Service Manual
MONTCRO
GROUP INDEX NrJDAA-A
Introduction and
Master Troubleshooting ......*....*...*..
Lubrication and Maintenance ......... m.
1989 : Volume 1
FOREWORD
This Service Manual has been prepared with the
latest service information available at the time of
publication. It is subdivided into various group
categories and each section contains diagnosis,
disassembly, repair, and installation procedures
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.
4liP
A
.
n
WESUPPORT
VOLUNTARY TECHNICIAN
CE,TT,flCA~ONMROUGH
MITSUBISHIMOlUR SALES OF AMERICR Inr
Mitsubishi Motors corporation reserves the right to make changes in
design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
Front Suspension ............................. y
Rear Axle *.......*.......*................a.....*.. m
Service
Srakes- Parking ............................. &
Clutch ................................................ Hi
Cooling ............................................. w
Engine ............................................... m
Intake and Exhaust ,.......*..........*...... ml
Fuel System ...................................... mE
Propeller Shaft and Universal
Joint ........ m;
Rear Suspension .............................. mt
Power Steering ......a*........................ m
Transmission - fity$tic ............. &!a
Wheels and Tires ............................. FP
Body .................................................. m
Heater and Air Conditioning ........... p!’
Emission Control Systems .............. &!!!!
NOTE
For Electrical refer to .._
Volume-2 “Electrical”
Q 198’8 Mitsubishi Motors Corporation Printed in Japan
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INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual E-m+
HOW TO USE THIS MANUAL
gg$I!
NWS&Wl g-
LIMIT
g&i-
s :CONTENTS
Shows the standard for judging the quality of a part
or assembly on inspection and means the maxi-
g ’
mum or minimum value within which the part or ar-=
assembly must be-kept functionally or in strength.
s
m.
It is a value established outside the range of E-
standard value. z
The preceding page contains the GROUP INDEX
which lists the group title and group number.
PAGE NUMBERS
All page numbers consist of two sets of digits
separated by a dash. The digits preceding the dash
identify the number of the group. The digits follow-
ing the dash represent the consecutive page
number within the group. The page numbers can
be found on the top left or right of each page.
TEXT
Unless otherwise specified, each service procedure
covers all models. Procedures covering specific
models are identified by the model codes, or similar
designation (engine type, transmission type, etc.).
A description of these designations is covered in
this unit under “VEHICLE IDENTIFICATION”.
TROUBLESHOOTING
Troubleshootings are classified into master trouble-
shooting and group troubleshooting and located as
follows:
The master troubleshooting is prepared when the
trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for
causes of problems related to that individual group
only; a troubleshooting guide is prepared for each
appropriate group.
SERVICE PROCEDURES
The sewice steps are arranged in numerical order
and attentions to be paid in performing vehicle ser-
vice are described in detail in SERVICE POINTS.
DEFINITION OF TERMS
STANDARD VALUE
indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
incidental operation
rformed before re-
Removal steps : The numbers before part names b
correspond to numbers in the il-
lustration and indicate the order of
removal.
Disassemblv steos : The numbers before oat-tI ---I--
names co&pond to num6&
in the illustration, and indicate
the order of’disassembly.
Installation steps : This is provided if installation
cannot be made in the reverse
order of “Removal steps”; omit-
ted if installation in the reverse
order of “Removal steps” is
possible.
Reassembly steps : This is provided if reassembly
cannot be made in the reverse
order of “Disassembly steps”:
omitted if reassembly in the
reverse order
The following abbreviations are used in this manual for classification of model types.
M/T : Indicates the manual transmission, or models equipped with the manual transmission.
A/T : Indicates the automatic transmission, or models equipped with the automatic transmission.
F.B.C. : Indicates the feed back carburetor, or engines equipped with the feed back carburetor.
M.P.I. : Indicates the multi-point injection, or engines equipped witkthe multi-point injection.
2.6 L Engine : Indicates the 2.6 liters (155.9 cuin.) engine, or a model equipped with such an engine.
3.0 L Engine : Indicates the 3.0 liters (181.4 cu.in.) engine, or a model equipped with such an engine.
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4. INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual 3
Page number Group title Section title
7-io
t
COOLING - Thedostat
vrra-r ITHERML .-.
REMOVAL AND INSTALLATlON I
Indicates tightening
torque
Repair kit or set parts are
shown. fOnlv verv freouentlv
-
1. Connection of enginecoolant temperature
syitch connector (Vehicles with an air condition-
3. Water outlet fitting
4. Water outlet fitting gasket
+ee 5 Thermostat
I
This number corresponds to
the number in “Removal
steps”, “Disassembly
steps”, “Installation steps”
or “Reassembly steps”.
LSERVICE POINTS OF INSTALLATION-
S. INSTALIATION OF THERMOSTAT
Install the thermostat to the intake manifold as illustrated.
caution
The thermostat Range tits over the manifold seat;
ensure that the thermostat is not installed at an angle.
An explanation of procedures, notes, etc.
regarding removal, installation. disassembly
and reassembly.
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4 INTRODUCTION AND MASTER TROUBLESHOOTING -Vehicle Identification
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER LOCATIONm..
The vehicle identification number (V.I.N.) is located on a plate
attached to the left top side of the instrument panel.
--
VEHICLE IDENTIFICATION CODE CHART PLATE
All vehicle identification numbers contain 17 digits. The ve!h%
number is a code which tells country, make, vehicle type, etc.
I---
-
-.
6th
digit
Price
class
4-
High
5-
Pre-
mium
T-
t
7th
digit
8th
digit
9th / 10th 11th 12th thru
digit digit digit 17th digit
3rd
digit
Vehicle
type
4
Multi-
purpose
vehicle
(MW
7-
Truck
Body 1 Engine 1 zi$c” / Efe’ Plant
Serial
number
J- 000001
I--Nagoya to
-3 999999
3- cu.in.1 3
3-door S-
metal- 3.0liters
topor (181.4
van cuin.)
9
Ibs.and
with
hydraulic
brakes
G-
5001-
6000
Ibs. and
with
hydraulic
brakes
1 X
!1 -
NOTE
““Check digit” means a single number or letter)( used to verify the accuracy of transcription of vehicle identification
number.
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6. INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification 5
VEHICLE DENTlFlCATlON NUMBER LIST
FEDERAL NWCG
L
VIN (except sequence number)
JA7FJ43E q KJ
Brand Engine displacement
2.555 liters (155.9 cu.in.)
Model code
L042GTNJLF
JA7FJ43S 0 KJ
JA7FJ43S 0 KJ
JA7FJ53S Cl KJ
JA4GJ41 S 17 KJ
JA4GJ41 S 0 KJ
JA4GJSlSCiKJ
MITSUBISHI
MONTERO
2.972 liters (181.4 cub.)
L141GTNJLF
L141 GTRJLF
L141 GTRULF
Ll46GVMNJLF
L146GVMRJLF
L146GWMRULF
CALIFORNIA (Can also be sold in Federal states.]
VIN (except sequence number)
JA7FJ43E 0 KJ
Brand Engine displacement
2.555 liters (155.9 cu.in.)
Model code
L042GTNJLH
I I I .~
JA7FJ43S q KJ
JA7FJ43S q KJ
JA7FJ53S 0 KJ
JA4GJ41 S 0 KJ
JA4GJ41 S q KJ
JA4GJ51 S Cl KJ
MITSUBISHI
MONTERO 2.972 liters (181.4 win.)
L141 GTNJLH
L141GTRJLH
L141 GTRULH
L146GVMNJLH
Ll46GVMRJLl-l
L146GWMRULH
A MllSUBlSHlw-B-_1
mc .---I ^ I
I -----xv2 I
VEHICLE INFORMATION CODE PLATE NN!CO.-
Vehicle information code plate is riveted on the cowl top outer
panel (2.6L Engine) or front end upper bar (3.OL Engine) in the
engine compartment.
The plate shows model code, engine model, transmission
model, and body color code.
1. MODEL L146G VMNJLF
2. ENGINE 6672
L Engine model
3. TRANS V5MTl
AXLE
-L Transmission model
4. COLOR, TRIM H84
OPT L Monotone exterior
HlXH84X85 color code
/-T___ Exterior code --:
Two-tone color code
Two-tone exterior isshownbytheexterior
mevision
code followed by the two color codes.
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7. 6 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
~3.0 L Engine>
CHASSIS NUMBER
STAMPING LOCATION NOOCE-
The chassis number is stamped on the side of the frame near ._
the right rear wheel.
CHASSIS NUMBER CODE CHART
L141 v KJOOOOOI
I I I I
VEHICLE SAFETY CERTIFICATION LABEL NWCF
The vehicle safety certification label is attached to face of left
door pillar.
This label indicates the month and year of manufacture, Gross
Vehicle Weight Rating (G.V.W.R.), front and rear Gross Axle
Weight Rating (G.A.W.R.), and Vehicle Identification Number
(V.I.N.).
ENGINE MODEL STAMPING Nwce-
The engine model is stamped on the right front side on the
top edge of the cylinder block (for M-liter engines). For 3.0-
liter engines, it is stamped at the right rear of the top of the
cylinder block.
These engine model numbers are as shown in the following.
Engine model Engine displacement 1
G54B 2.555 liters (155.9 cu.iiTI
6G72 2.972 liters (181.4 cu.in.)
The engine serial number is stamped near the engine model
number, and the serial number cycles, as shown below.
_ ~-
Engine serial number Number cycling
AA0201 to YY9999 AA0201 ----3 A.49989
/ Lo ABOOOl ---+ AY9999
I
1LmBAOOOl ---+ YY9999
__.
-..:-:-- I
1-
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8. INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification 7
BODY COLOR CODE
Exterior code
Wonotone
C46
H84
R82
s55
T86
wo9
R48
x15
rwo-tone
Cl XC46X85
H1XH84X85
R2XR82X85
Sl XS55X85
T6HT86H84
W6XWO9X85
X2HX15H84
A) : Metallic paint
Body color
Brown(M)
Silver(M)
Red
Beige(M)
Blue(M)
White
Red (M)
Black
Brown(M)/
Black
Silver(M)/
Black
Redl
Black
Beige (MM
Black
Blue(M)/
Silver(M)
White/
Black
Black/
Silver(M)
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8 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Service
PRECAUTIONS BEFORE SERVICE
PROTECTING THE VEHICLE WmoAAK
If there is a likelihood of damaging painted or interior parts
during service operations, protect them with suitable covers
(such as seat covers. fender covers, etc.).
REMOVAL AND DISASSEMBLY
When checking a malfunction. find the cause of the problem.
If it is determined that removal and/or disassembly is neces-
s&y, perform the work by following the procedures contained
in this Workshop Manual.
If punch marks or mating marks are made to avoid error in
assembly and facilitate the assembly work, be sure to make
them in locations which will have no detrimental effect on
performance and/or appearances.
If an area having many parts, similar parts, and/or parts which
are symmetrical right and left is disassembled, be sure to
arrange the parts so that they do not become mixed during the
assembly process.
I. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which are to
be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.
SPECIAL TOOLS
If other tools are substituted for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged, or the mechanic might be injured; therefore, be
sure to use the special tool whenever doing any work for
which the use of one is specified.
PARTS TO BE REPLACED
If any of the following parts are removed, they must be
replaced with new parts.
I. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts
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10. INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Service 9
nm (in.) smo59
PARTS
When replacing parts, use MITSUBISHI genuine parts
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (11.8 in.) from
any plastic parts and all opening parts (doors, luggage
compartment, etc.).
SERVICING ELECTRICAL SYSTEM
1. Note the following before proceeding with work on the
electrical system.
Note that the following must never be done:
Unauthorized modifications of any electrical device or
wiring, because such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result
in a fire in the vehicle.
2. When servicing the electrical system, disconnect the
negative cable terminal from the battery.
Caution
1. Before connecting or disconnecting the negative
cable, be sure to turn off the ignition switch and the
fighting switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
2. After completion of the work steps [when the
battery’s negative (-) terminal is connected], warm
up the engine and allow it to idle for approximately
five minutes under the conditions described below,
in order to stabilize engine control conditions, and
then check to be sure that the idling is satisfactory.
For 3.OL Engine models: If the engine rpm is high,
switch OFF the ignition switch, and then, after
switching it ON again, let the engine idle for 2 or 3
minutes.
This will cause the engine rpm to decrease about
100 rpm, so repeat this procedure until the pre-
scribed idling speed is reached.
Engine coolant temperature : 85”-95°C (‘l85403”F)
Lights, accessories : OFF
Transmission : neutral position
(Automatic transmission models: “IV or “P”J
Steering wheel : neutral (center) position
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11. 10 INTRODUCTION AND MASTER TROUBLESHOOTiNG - Precautions Before Service
F1617
WIRING HARNESSES
1. Secure the wiring harnesses by using clamps. However,
for any harness which passes to the engine or other
vibrating parts of the vehicle, allow some slack within a
range that does not allow the engine vibrations to cause
the harness to come into contact with any of the
surrounding parts.
Then secure the harness by using a clamp.
In addition, if a mounting indication mark (yellow tape) is
on a harness, secure the indication mark in the specified
location.
2. If any section of a wiring harness contacts the edge of a
part, or a corner, wrap the section of the harness with tape
or something similar in order to protect it from damage.
3. When disconnecting a connector, be sure to pull only the
connector, not the harness.
4. Disconnect connectors which have catches by pressing in
the direction indicatedby the arrows in the illustration.
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12. INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Servicre 11
5. Connect connectors which have catches by inserting the
connectors until they snap.
I
I cwE331
I
10A 15A
ELECTRICAL COMPONENTS
1. When installing any of the vehicle parts, be careful not to
pinch or damage any of the wiring harnesses.
2. Sensors, relays, etc., are sensitive to strong impacts.
Handle them with care so that they are not dropped or
mishandled.
3. The electronic parts used for relays, etc., are sensitive to
heat. If any service which causes a temperature of 80°C
(176°F) or more is performed, remove the part or parts in
question before carrying out the service.
FUSES AND FUSIBLE LINKS
1. If a blown-out fuse is to be replaced, be sure to use only a
fuse of the specified capacity. If a fuse of a capacity larger
than that specified is used, parts may be damaged and the
circuit may not be protected adequately.
Caution
1. If a fuse is blown-out, be sure to eliminate the cause
of the problem before installing a new fuse.
2. Check the condition of fuse holders. If rust or dirt is
found, clean metal parts with a fine-grained sandpa-
per until proper metal-to-metal contact is made.
Poor contact of any fuse holder will often lead to
voltage drop or heating in the circuit and could
result in improper circuit operation.1cnlY589
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13. 12 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Service
Nominal
size
0.3 mm2
0.5 mm2
0.85 mm*
1.25 mm2
2.0 mm*
3.0 mm2
5.0 mm2
Permissible current
SAE I
Other
areas
2. If additional optional equipment is to be installed in the
vehicle, follow the procedure listed in the appropriate
instruction manual; however, be sure to pay careful
attention to the following points:
(1) In order to avoid overloading the wiring, take the
electrical current load of the optional equipment into
consideration, and determine the appropriate wire size.
(2) Where possible, route the wiring through the existing
harnesses.
(3) If an ammeter or similar instrument is to be connected
to a live-wire circuit, use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
no contactwith any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS
Be careful to avoid spilling any gasoline, oil, etc., or rubber
parts, they might be adversely affected.
LUBRICANTS
In accordance with the instructions in this Service Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
BRAKE FLUID
Be careful to avoid spilling any brake fluid on painted
surfaces, because the paint coat might be discolored or
damaged.
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14. INTRODUCTION AND MASTER TROUBLESHOOTING - t+mwtionsBefore Service ‘I3
DOING SERVICE WORK IN GROUPS OF TWO OR
MORE TECHNICIANS
If the service work is to be done by two or more technicians
working together, extra caution must be taken.
NOTE ON INSTALLATION OF RADIO EQUlPM$ihl-
The computers of the electronic control system has been
designed so that external radio waves will not interfere with
their operation.
However, if antenna or cable of amateur transceiver etc. is
routed near the computers, it may affect the operation of the
computers. even if the output of the transceiver is no more
than 25W.
To protect each of the computers from interference by
transmitter (hum, transceiver, etc.). the following should be
observed.
1. Install the antenna on the roof or rear bumper.
2. Because radio waves are emitted from the coaxial cable of
the antenna, keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross
the wiring harness, route it so that it runs at right angles to
the wiring harness.
3. The antenna and the cable should be well matched, and
the standing-wave ratio” should be kept low.
4. A transmitter having a large output should not be installed
in the vehicle.
5. After installation of transmitter, run the engine at idle, emit
radio waves from the transmitter and make sure that the
engine is not affected.
*STANDING-WAVE RATIO
If an antenna and a cable having different impedances are
connected, the input impedance Zi will vary in accordance
with the length of the cable and the frequency of the
transmitter, and the voltage distribution will also vary in
accordance with the location.
The ratio between this maximum voltage and minimum
voltage is called the standing-wave ratio. It can also be
represented by the ratio between the impedances of the
antenna and the cable.
The amount of radio waves emitted from the cable increases
as the standing-wave ratio increases, and this increases the
possibility of the electronic components being adversely
affected.
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14
Treatment Before I
INTRODUCTION AND MASTER TROUBLESHOOTING - AftertheFotiingofastmsm
TREATMENT BEFORE/AFTER THE FORD-
ING OF A STREAM
INSPECTION AND SERVICE BEFORE FORDING
A STREAM NOW%-
Vehicles which are driven through water, or which may
possibly be driven through water, should be subjected to the
following inspections and maintenance procedures in ad-
vance.
e Seal the speedometer cable with a water-resistant grease ~_
or tape.
a Inspect the dust boots and breather hose for cracks or
damage, and replace them if cracks or damage are found.
,- . 1^.
dometer cable 1
Steering joint assembly / 1Drive shaft boot -l(. ‘/ Torsion bar dust cover 1Breath& hose==
OOW528
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16. Treatment Before /
INTRODUCTION AND MASTER TROUBLESHOOTING - AftertheFordingofaStream I5
l Apply grease to the lubricating points of the front suspen-
sion, steering linkage and propeller shaft.
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17. 16
Treatment Before I
INTRODUCTION AND MASTERTROUBLESHOOTING - AftertheFordingofaStream
INSPECTION AND SERVICE AFTER FORDING A
STREAM
After fording a stream, check the following points. If abnormal
condition is evident, clean, replace or lubricate.
=Check for water. mud. sand. etc. in the rear brake drum.
clutch housing, &tarte; mot&, brake pipe and fuel pipe:
Check for water in the fluid or oil inside the front
differential. rear differential, transmission and transfer
case.
Apply grease to the lubricating points of the front suspen-
sion, steering linkage and propeller shaft.
Check all boots and breather hoses for cracks and
damage.
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18. INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting 17
TOWING AND HOISTING
This vehicle can only be towed from the front with convention-
al sling-type equipment and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4” x 4” x 55” wood beam) should be placed
forward of under guard and under towing hook/shipping tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system must be used. This system must be
completely independent. of the primary lifting and towing
attachment. Care must be taken in the installation of safety
chains to insure they do not cause damage to bumper, painted
surfaces or lights.
LIFTING-GROUND CLEARANCE
Towed vehicle should be raised until wheels are a minimum of
10 cm (4 in.) from the ground. Be sure there is adequate
ground clearance at the opposite end of the vehicle, especially
when towing over rough terrain or when crossing sharp rises
such as curbs. If necessary, ground clearance can be in-
creased by removing the wheels from the lifted end of the
disabled vehicle and carrying the lifted end closer to the
ground. A 20 cm (8 in.) ground clearance must be maintained
between brake drums and ground.
FRONT TOWING PICKUP
The vehicle may be towed on its rear wheels for extended
distances, provided the parking brake is released.
Make cartain the transmission remains in “NEUTRAL”.
SAFETY PRECAUTIONS
The following precautions should be taken when towing the
vehicle.
1. Remove exhaust tips and any other optional equipment,
that interface with the towing sling. Padding (heavy shop
towel or carpeting) should be placed between the towing
sling cross bar and any painted surfaces, and bumper
surfaces.
2. A safety chain system completely independent of the
primary lifting and towing attachment must be used.
3. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior
to moving the vehicle.
4. Operator should refrain from going under a vehicle unless
the vehicle is adequately supported by safety stands.
5. Never allow passengers to ride in a towed vehicle.
6. State and local rules and regulations must be followed
when towing a vehicle.
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18 INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting
HOISTING
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with
the proper adapters in order to support the vehicle at the
proper locations. (Shown in the illustration)
Conventional hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the side ._
frame.
FLOOR JACK
A regular floor jack may be used under the front crossmember
or rear axle housing.
Caution
1. A floor jack must never be used on any part of the
underbody.
2. Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.
EMERGENCY JACKING
Jack receptacles are located at the No. 2 crossmember and .
rear axle housing to accept the jack supplied with the vehicle
for emergency road service. Always block the opposite wheels
and jack only on a level surface.
FRAME CONTACT SUPPORT LOCATIONS
1,175 mm (46.3 in.)
Wheel base
2.350 mm (92.5 in.)
Sectlon A-A
NOTE
The locations of the support point shown as Section A-A are
the same as those of the twin post hoist shown in the next
paw.
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20. INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting 19
LIFTIYG AND JACKING SUPPORT LOCATIONS
<2.6L Engine><2.6L Engine>
<3.OL Engine><3.OL Engine>
C Twin post hoistC Twin post hoist
m Floor jackm Floor jack
@@
Emergency jacking (jack supplied with the vehicle)Emergency jacking (jack supplied with the vehicle)
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22. INTRODUCTION AND MASTERTROUBLESHOOTING - GeneralDataandSpecmcations 21
L042G L141G
TNSL FM TNJL F/H TRJL F/H TRUL F/H
Engine
Model No. G54B 6672 6672 6672
Type In-line OHC V-type, OHC V-type, OHC V-type, OHC
Number of cylinders 4 6 6 6
Bore 91.1 mm(3.59in.j 91.1 mm(3.59in.j 91.1 mm(3.59in.) 91.1 mm(3.59in.
Stroke 98.0 mm (3.86 in.) 76.0 mm (2.99 in.) 76.0 mm (2.99 in.) 76.0 mm (2.99 in.
Piston displacement 2,555 cm3 2,972 cm3 2,972 cm3 2,972 cm3
(155.9 cuin.) (181.4cu.in.) (181.4cu.in.) (181.4 cuin.)
Compression ratio 8.7 8.9 8.9 8.9
Firing order 1-3-4-2 1-2-3-4-5-6 I -2-345-5 1-2-3-4.5-8
Basic ignition timing 7”BTDC 22” 5”BTDC 22” 5”BTDC i 2” 5”BTDC +-2”
Transmission &transfer case
Model No. KM145 V5MTl KM148 KM148
Type S-speed manual 5-speed manual &peed automatic &peed automatic
Gear ratio
Transmission 1st 3.967 3.918 2.826 2.826
2nd 2.136 2.261 1.493 1.493
3rd 1.360 1.395 1.ooo 1.000
4th 1.ooo 1.000 0.688 0.688
5th 0.856 0.829 -
Reverse 3.587 3.925 2.703 2.703
Transfer case High 1.ooo 1.ooo 1.ooo 1.ooo
Low 1.944 1.925 1.925 1.925
Final ring ratiogear 4.625 4.625 4.625 4.625
Clutch
Type Dry single disc & Dry single disc & -
diaphragm spring diaphragm spring
Chassis
Tire size
Front suspension
Type
Rear suspension
Type
Brakes
Type Front
Rear
P225ff 5Rl5 P235ff5Rl5
independent Independent double-wishbone
double-wishbone
Rigid axle Rigid axle
Disc Disc
Drum Drum (Leading and trailing)
(Leadingand trailing)
Power steering
Gear type
Gear ratio
Fuel tank capacity
Integral type Integral type (Recirculating ball nut)
(Recirculatingballnut)
16.4 16.4
liters (gals.) 60 (15.9) 75 (19.8)
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23. -_-
22 INTRODUCTION AND MASTER TROUBLESHOOTING - General Data and Specifications
<&door vehicles>
L-
chicle dimensions mm (in.)
Overall length
Withoutspare tire a
With spare tire @
Overall width 0
Overall height @
Wheelbase Q
Tread Front @
Rear 8
Overhang Front @
Rear @
Height at curb weight Wt.)
Front bumperto ground @
Rear bumper to ground 0
Minimum running ground @
clearance
Angle of approach 8
Angle of departure 8
Ramp breakover angle 63
,hicle weights kg (Ibs.)
Curb weight
Gross vehicle weight rating
Gross axle Front
weight rating Rear
Seating capacity
gine
Model No.
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Firing order
Basic ignition timing
VMNJL F/H VMRJL F/H
4,570 (179.9)
4,605 (181.3)
1,680 (66.1)
1,890 (74.4)
2,695 (106.1)
1,400 (55.1)
I,41 5 (55.7)
745 (29.3)
1,I 65 (45.9)
4,570 (179.9)
4,605(181.3)
1,680 (66.1)
1,890 (74.4)
2,695(106.1)
1.400(55.1)
1,415 (55.7)
745 (29.3)
1,165(45.9)
490 (19.3)
450(17.7)
215 (8.5)
490 (19.3)
450(17.7)
215 (8.5)
38”
28”
18”
38”
28
18”
-i
1,780 (3,924)
2,400 (5,291)
1,100(2,425)
1,600 (3,527)
5
1,795 (3,957)
2,400 (5,291)
1,100(2.425)
1,600 (3,527)
5
6672
V-type, OHC
6
91 .I mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3 (181.4 cu.in.)
8.9
l-2-3-4-5-6
5”BTDC i2”
6672
V-type, OHC
6
91.l mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3 (181.4 cuin.)
8.9
1-2-3-4-5-6
5”BTDC 22” :
L146G
L
_-. 1 TSB Revision I
.-
WMRUL F/H
4.570 (179.9)
4,605 (181.3)
1,680 (66.1)
1,890 (74.4)
2,695(106.1)
1,400(55.1)
1,415 (55.7)
745 (29.3)
1,165 (45.9)
490 (19.3)
450 (17.7)
215 (8.5)
38”
28”
18
1,805 (3,979)
2,400 (5,291)
1,100 (2,425)
1,600 (3,527)
5
3072
V-type, OHC
3
31.l mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3 (181.4 cu.in.)
3.9
l-2-3-4-5-6
5”BTDC 22”
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24. INTRODUCTION AND MASTER TROUBLESHOOTING - General Dataand Swxifications 23
Transmission &transfer case
Model No.
Type
Gear ratio
Transmission 1St
2nd
3rd
4th
5th
Reverse
Transfer case High
Low
Final ring gear ratio
Elutch
Type
Chassis
Tire size
Front suspension
Type
Rear suspension
Type
Brakes
Type Front
Rear
Power steering
Gear type
Gear ratio
Fuel tank capacity liter (gal.)
VMNJL F/H VMRJL F/H WMRUL F/H
EMT1 KM148 KM148
5-speed manual 4-speed automatic 4-speed automatic
3.918
2261
1.395
1.000
0.829
3.925
1.000
1.925
4.625
2.826 2.826
1.493 1.493
1.ooo 1.ooo
0.688 0.688
2.703
1.ooo
1.925
4.625
-
2.703
1.ooo
-1.925
4.625
Dry single disc &
diaphragm spring
P235ff 5 R15
L146G 7
Independent doublewishbone
Rigid axle
Disc
Drum (Leading and trailing)
Integral type (Recirculating ball nut)
16.4
92 (24.3)
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25. 24 INTRODUCTION AND MASTER TROUBLESHOOTING - WasterTroubleshooting
Tightening Torque I
TIGHTENING TORQUE
Description
Thread for general purposes
(size x pitch) mm
6x1.0
8x 1.25
10x1.25
12x 1.25
14x 1.5
16x 1.5
18x 1.5
20x1.5
22x 1.5
24x 1.5
Description
Taper thread for pipes (size)
PT1/8
PT l/4
PT3B
Taper thread for dry sealed pipes (size)
NF’TF l/16
NPTF l/8
NPTF l/4
Head mark f
Nm
3.0-3-s
7.9-12
16-23
29-43
46-70
67-l 00
100-150
150-190
ZOO-260
269-320
ft.lbs.
2.2-2.9 4.9-7.8 3.6-5.8
5.8-8.7 13-19 9.4-14
12-17 27-39 20-29
2’132 47-72 35-53
35-52 77-110 57-35
51-77 130-160 SO-120
74-110 180-230 130-170
110-140 160-320 1go-240
150-190 340-430 250-320
1go-240 420-550 310-410
Head mark [
Nm
I
ft.lbs.
Nm ftlbs. Remarks
7.9-I 2 5.9-9.7 Internal thread: Aluminum
76-19 12-14 Internal thread: Cast iron
19-30 14-22 Internal thread: Aluminum
34-45 25-33 Internal thread: Cast iron
39-54 29-40 Internal thread: Aluminum
58-73 43-54 Internal thread: Cast iron
4.9-7.8 3.6-5.8 Internal thread: Aluminum
7.9-12 5.8-8.7 Internal thread: Cast iron
7.9-12 5.8-8.7 Internal thread: Aluminum
16-1s 12-14 Internal thread: Cast iron
19-13 14-22 Internal thread: Aluminum
34-45 25-33 Internal thread: Cast iron
MASTER TROUBLESHOOTING NceKAAO
ENGINE OVERHEATS
Symptom Probable cause
-
Reference
page or remedy
Engine overheats Cooling system faulty
Incorrect ignition timing
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26. INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting 25
ENGINE WILL NOT CRANK OR CRANKS SLOWLY
Symptom
Engine will not crank or cranks
slowly
Probable cause
Starting system faulty
Reference
page or remedy
8-134.135
ENGINE WILL NOT START OR BE HARD TO START (CRANKS OK)
Symptom
Engine will not start or be hard to
start(Cranks OK)
ROUGH IDLE OR ENGINE STALL
Probable cause
No fuel supply to carburetor or injection system
Carburetor or injection system problems
Ignition system problems
Vacuum leaks
- Purge control valve hose
- Vacuum hoses
l intake manifold
- Air intake plenum
l Carburetor or throttle body
l EGRvalve
Compression too low
Reference
page or remedy
14-34,90
14-34,90
3-147 to 149
Repair as
necessary
3-11.65
Symptom Probable cause
Reference
page or remedy
Rough idle or
engine stalls
Vacuum leaks
l Purge control valve hose
l Vacuum hoses
l Intake manifold
l Air intake plenum
l Carburetor or throttle body
l EGRvalve
1 Ignition system problems
Repair as
necessary
8-147 to 149
Idle speed set too low 1O-10.14-62
1~~ .Idle mrxture too lean or too rich 14-11
Carburetor or fuel injection system problems
Exhaust gas recirculation (EGR) system problems
m-34.90
25-17.32
Engine overheats 7-4
Compression too low 9-11, 65
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27. ‘p
? f! .., .-, _-_ ,_- ____ ____ _L(
26 INTRODUCTION AND MASTER TROUBLESHOOTlNG - Master Troubleshooting
ENGINE HESITATES OR POOR ACCELERATION
Symptom Probable cause
Engine hesitates or
poor acceleration
-IIgnition system problem
Vacuum leaks
l Purge control valve hose
l Vacuum hoses
- intake manifold
l Air intake plenum
* Carburetor or throttle body
l EGRvalve
ENGINE DIESELING
Reference
page or remedy
8-147 to 149
Repair as
necessary
Air cleaner clogged
Fuel line clogged
113.10
1442.99
Carburetor or fuel injection system problem
Auxiliary acceleration pump faulty (cold engine)
Emission control system problem
l EGR system always on
- High-altitude compensation (HAC) system problem
Engine overheats
14-34.90
14-23
25-77.22.32
7-4
Compression too low g-II.65
ISymptom Probable cause
IReference
page or remedy
I I I
I -..
Engine dieseling (runs after
ignition switch is turned off)
Carburetor problems
Incorrect ignition timing
14-34
8-14710 149
EXCESSIVE OIL CONSUMPTION
Symptom Probable cause Reference
page or remedy
Excessive oil consumption Oil leak
Positive crankcaseventilation line clogged
Valve stem seal worn or damaged
Valve stem worn
Piston ring worn or damaged
Repair as
necessary
o-13
Replace
Replace
9-43
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28. INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting 27
POOR FUEL MILEAGE
Symptom Probable cause Reference
page or remedy
Poor fuel mileage Fuel leak Repair as
necessary I
1Air cleaner clogged
1 Ignition problems
1 11-3.10 1
1 8-147to 149 1
Carburetor or fuel injection system problems 1434.90 I
Compression too low 1g-II.65 1
Tires improperly inflated 1 22-2 I
Clutch slips 16-4 I
Brakes drag 1 5-13 I
NOISE
Probable cause
Reference
page or remedy
Noise Loose bolts and nuts Retighten as
necessary I
1 Enaine noise I9-11 I
HARD STEERING
Symptom
Hard steering
Probable cause
Loose power steering oil pump belt
Low fluid level
Air in power steering system
Low tire pressure
Excessive turning resistance of upper or lower ball joint
Excessivelytight linkage ball joint
Improperfrontwheel alignment
Excessive turning resistance of tie-rod ball joint
No lubricantion of tie-rod
Sticky flow control valve
No lubrication of idler arm
Reference
page or remedy
19-10
19-11
19-11
22-2
2-27
1937
2-13
19-38 ’
Lubricate
19-33
19-39
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29. INTRODUCTION MASTER TROUBLESHOOTING - Master Troubleshootha
POOR RETURN OF STEERING WHEEL TO CENTER
Symptom Probable cause Reference
page or remedy
Poor return of steering
wheel to center
improper front wheel alignment 2-13
Improper tire pressure 22-2
Damaged front wheel bearing 2-21
POOR RIDING
Probable cause
Reference
page or remedy
Poor riding Impropertire pressure
lmbalanced wheels
22-2
22-4
1 Improper front or rear wheel alignment 1 2-13.17-3.6
1 Malfunctioning shock absorber 1 2-27,174.a
1 Broken or worn stabilizer
1 Broken or worn torsion bar spring j 2-36 I
Loose suspension securing bolt(s) Retighten I
1 Worn lower arm bushing / 231 I
ABNORMAL TIRE WEAR
Symptom Probable cause
Reference
page or remedy
Abnormal tire wear Improper front or rear wheel alignment 2-l 3,17-3.6
Improper tire pressure 22-2
lmbalanced wheels 22-4
Loose wheel bearings 2-19
Malfunctioning shock absorber 2-27. 174.8
ROAD WANDER
Symptom Probable cause
Reference
page or remedy
Road wander zImproper front or rear wheel alignment 2-13. 17-3,6
Excessive play of steering wheel 19-6
Poor turning resistance of upper ball joint ~ 2-27
Improper tire pressure 22-2
/ Loose or worn lower arm or upper arm bushing 2-28.31
Loose or worn wheel bearinas
I
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30. INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshootina 29
VEHICLE PULLS TO ONE SIDE
Symptom
Vehicle pulls to one side
Probable cause
Improper front or rear wheel alignment
lmbalanced or worn tires
Uneven tire pressure
Excessive turning resistance of upper ball joint
Wheel bearing seizure
Broken or worn torsion bar spring
Bend front axle drive shaft
Deformed lowerarm
Reference
page or remedy
2-l 3.17-3.6
/ 224
22-2
2-27
2-21
2-36
2-40
230
STEERING WHEEL SHIMMY
Symptom Probable cause
Reference
page or remedy
Steering wheel shimmy Improper front or rear wheel alignment 1 2-13,17-3,6 1
Improper tire pressure 1 22-2 I
Imbalanced wheels Repair I
1 Poorturning resistance of upper ball joint
Excessive play of steering wheel
1 2-27 I
19% I
Broken or weak stabilizer 1 2-39 I
Worn lower arm or upper arm bushing I 2-28.31 1
Malfunctioning shock absorber I 2-27 I
/ Broken or weak torsion bar spring or, leaf spring or coil spring / 2-36,17-4,9
Wear, play, or seizure of wheel bearing 2-19
BOTTOMING
Symptom Probable cause
Reference
page or remedy
Bottoming Overloaded vehicle Correct
Broken or weak torsion bar spring, leaf spring or coil spring 236.1749
1 Malfunctionina shock absorber 1 2-27,174 8 1
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31. I”! 1: 1’ --- -~~
30 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting
WHEEL BEARING TROUBLESHOOTING
Trouble Symptom Probable cause
Pitting
Flaking
Cracking Chipping or cracking of cage or roller edges
Flat spotting When large load is applied, race and roller contact
surfaces compress, forming indentations
Nicks
?ust, corrosion
Near
Xscoioration
Pitting occurs because of uneven rotation of race
and bearing surfaces
The surface peels because of uneven rotation of
the race and bearing surfaces
Instead of rolling along race surface,
rollers slide, thus damaging surface
Damage or wear caused by minute particles
adhering to surfaces results in rough movement
and such high temperatures that parts of surface
melt
Appears on various areas of the bearing
Wear of surface areas caused by friction
Grease discoloration results from grease
deterioration which causes particles of pigment
contained in grease to adhere to surfaces
Heat discoloration will appear as a deep brown or
purple
Excessive bearing preload
Excessive load
End of bearing life
Improper bearing assembly
Impact when bearing was
installed (such as being hit
with a hammer)
Excessive bearing preload
Excessive load
Vibration when bearings are
not used, such as during
shipment on freight cars,
transport trucks, etc.
Improper grease
Excessive bearing preload
Excessive load
Faulty oil seal
Excessive variation of loads on
bearings
Use of grease other than that
specified
Improper grease
Use of grease otherthan
that specified
Faulty oil seal
Presence of water or moisture
Improper grease
Foreign matter
Rust or corrosion due to
moisture
Use of grease otherthan that
specified
Faulty oil eal
Use of grease other than
that specified
Faulty oil seal
Excessive bearing preload
Excessive load
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32. METERS AND GAUGES - Specifications
METERS AND GAUGES
SPECIFICATIONS
GENERAL SPECIFICATIONS
METERS AND GAUGES
Items
Speedometer
Tw
Tachometer
Twe
Detection source
Fuel gauge
Type
Fuel gauge unit
Tw
Engine coolant temperature gauge
Vw
Engine coolant temperature gauge unit
Type
Oil pressure gauge
Twe
Oil pressure gauge unit
Type
Inclinometer
Tw
Damping system
Voltage meter
Twe
Specifications
Electromagnetic type
Pulse type
Ignition coil
Bimetal type (voltage limiter incorporated for 7V)
Variable resistance type
Bimetal type (7V operation)
Thermistor type
Bimetal type
Bimetal type
Gravity type
Oil-filled system
Bimetal type
INDICATOR AND WARNING LIGHTS
Items Specifications
Turn signal indicator lights W 1.4 (74)
High beam indicator light W 1.4 (74)
Door-ajar warning light W 1.4 (741
Fasten seat belt indicator W 1.4 (74)
Brake warning light W 1.4 (74)
Charging warning light W 1.4 (74)
4WD indicator light W 1.4 (74)
Maintenance required warning light W 1.4 (74)
Check engine warning light W 3.4 (158)
PJF oil temperature warning light W 1.4 (74)
Overdrive indicator light W 1.4 (74)
Freewheeling hub light W 1.4 (74)
NOTE
The values parentheses denote SAE grade numbers.
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33. 8-164 METERS AND GAUGES - Specifications
BUZZER
Items
Range of voltage used V
While buzzing (Terminal voltage at 13V)
Sound pressure dB
Fundamental frequency Hz
Specifications
IO-16
5357
900+150
SERVICE SPECIFICATIONS
terns
Standard values
Speedometer indication error mph
20
40
60
80
100
Tachometer indication error rpm
1,000 rpm
3,000 rpm
5,000 rpm
Fuel gauge resistance value a
Between terminals 1 (power supply) and 2 (fuel gauge unit)
Between terminals 2 (fuel gauge unit) and 3 (ground)
Between terminals 1 (power supply) and 3 (ground)
Fuel gauge unit resistance value n
Float point “F”
Float point I E”
Fuel gauge unit float position mm (in.)
2.6L Engine
Float point “F”
Float point “E”
3.OL Engine (2door vehicles)
Float point “F”
Float point “E”
3.OL Engine &door vehicles)
Float point “F”
Float point “E”
Engine coolant temperature gauge resistance value R
Between terminals 1 (power supply)
and 2 (water temperature gauge unit)
Oil pressure gauge resistance value CI
Voltage meter resistance value fi
Voltage meter indication V
IOV
16V
TSB Revision
Specifications
2:
2;
23”
‘:
rp
+100
+150
k25Om
55
165
110
l-5
103-l 17
11-13 (.43-.51)
180-182 (7.09-7.17)
9-11 (.35-.43)
229-231 (9.02-9.09)
15-17 (.59-.67)
224-226 (8.82-8.90)
55
Approx. 50
380=460
+0.5-
-t-O.5
I
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34. METERS AND GAUGES - Troubleshooting 8-165
TROUBLESHOOTING
METER CIRCUIT
OPERATION
Fuel Gauge
When the ignition switch is turned to “ON”,
current flows through fuse No. 3 fuel gauge,
fuel gauge unit and ground, in turn operating
the fuel gauge.
When fuel level is high, the fuel gauge unit
internal resistance is small so that the current
passing through the circuit is relatively large.
This causes the gauge pointer to swing to-
wards “F”.
When fuel level becomes low, the unit internal
resistance is increased, so only a small current
flows the circuit and the gauge pointer swings
towards “E”.
Inside the fuel gauge, there is a voltage limiter
which functions to maintain a constant output
voltage (at 7V) to the gauge units (fuel gauge
unit and engine coolant temperature gauge
unit).
Engine Coolant Temperature Gauge
When the ignition switch is turned to “ON”,
current flows through fuse No. 3, engine
coolant temperature gauge, engine coolant
temperature gauge unit, and ground, in turn,
operating the engine coolant temperature
gauge.
When coolant temperature is high, the gauge
unit internal resistance is small so that the
current passing through the circuit is relatively
large. This causes the gauge pointer to swing
towards “H”.
When coolant temperature is low, the unit
internal resistance is increased so a small
current flows in the circuit, and the gauge
pointer swings towards “C”.
Oil-pressure gauge
With the ignition key at the “ON” position,
current flows to fuse No. 3, oil-pressure
gauge, the Oil-pressure gauge unit, and
ground, and the oil-pressure gauge is acti-
vated.
When the oil pressure is high, the contacts
(within the unit) close for a long time, with the
result that the amount of current flowing
through the circuit is great, and the gauge’s
indicator indicates at the high-pressure area.
With the oil pressure is low, the contacts
(within the unit) open for a short time, with
the result that the amount of current flowing
through the circuit is low, and the gauge’s
indicator indicates at the low-pressure area.
Brake Warning Light
l When the ignition switch is turned to “ON”
and before the engine starts, current flows
through fuse No. 3, brake warning light, alter-
nator and ground. The brake warning light
goes on and stays on until the engine starts.
The light goes off once the engine starts.
Burnt-out bulb check.
l If the brake fluid level falls below the preset
level or the parking brake is applied, the brake
fluid level sensor switch or the parking brake
switch contacts close. This causes current to
flow through the brake warning light and brake
fluid level sensor or parking brake switch to
ground, causing the warning light to go on.
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35. 8-166 METERS AND GAUGES - Troubleshooting
METER ClRCUlT
CIRCUIT DIAGRAM <2.6L Engine>
To seat belt wammg I
timer
[Refer to P.8-84.1
To seat belt warning
buzzer [Refer to P.8-84.1
Toaltemator [Referto P&51.1
To dimmer, passing
switch and light control
relay [Refer to P.8-64.1
To dome light
[Refer to P.8-78.
To door switch
[Refer to P.8-78.1
I
@jay@fMulti-purpose fuse
Combination meter
1 TSB Revision http://vnx.su/
36. METERS AND GAUGES - Troubleshooting 8-‘l67
Wiring color code
B: Black Br: Brown
LI: Light blue 0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
Lg: Light green
W: White
lE3l
Oil pressure
gauge unit
El
4WD
indicator switch
El
I
I
II-II 1
I 1 1 1 IC!
Parking brake
switch El
84 y I y D-29 y
BI IB
Y{
"
@- yB
U
0
WL/B
g: YL
a* y
YL?
I
Combination gauge
Engine
I^-^^.
coola
^I, ._
Remarks
(1) For information concerning the ground points
(2)
(example: q ), refer to PB-12.
The symbols @), Q, etc. indicate that the wiring
is connected (using the same numerical symbol1
to the facing page.
(In other words, @ on the right page is
connected to @I on the left page.)
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37. 8-168 METERS AND GAUGES -m~Troubleshooting
METER CIRCUIT
CIRCUIT DWGRAM <3.OL Engine>
B
y . m
- -_ Sub fusible link
EB
I--:&(-- -. .A_i
I-.
I mou
$kin fusible 3-R m3-R
u
z
I
cl? To light control relay e 3-R
( IIp1
[Refer to P.8-65.1
OFF
ACC
C-66
Dioc
@j Multi-purpose fuse
buzzer [Refer to P.8-84.1
To alternator
[Refer to P.8-51 .I
To dimmer, passing
witch and light control
clay [Refer to P.8-65.1
To dome light
[Refer to P.8-78.1
To door switch
Combination meter
---- . _
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38. METERS AND GAUGES - Troubleshooting 8-169
IEd
Oil pressure
gauge unit
Wiring color code
B: Black Br: Brown
LI: Light blue 0: Orange
g”R2;y
L: Blue
Y: Yellow
G: Green
P: Pink
Lg: Light green
W: White
indicator switch
Q 0.85-B
WI,
BY
04 In
! ! -+! To cigarette lighter
I I
! I I [Refer to P.8-94.1
I
$: 1".25-GB
I I
Parking brake
-9. switch al
Combination ga
Remarks
(1) For information concerning the ground points
(2) The symbo s 1 , Q, etc. Indicate that the witin
(example: ,)Ffer to P.814.
is connected usrng the same numerical symbo 19
.- AL- *__:_-
Dage.
we
iIs,-@ on the right page is
connected to @ on the left page.)
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39. 8-170
-__..- .._
METERS AND GAUGES - Service Adjustment Procedures
Tachodweil meter
Female pin
(Insert opposite
side of lock
$%%ck
retainer)
retainer side)
OlLozm
SERVICE ADJUSTMENT PROCEDURES
SPEEDOMETER INSPECTION NwilAFa
NOTE
if there is a special regulation for speedometer -indicator
difference in the area where the vehicle is operated, be sure
to meet the requirement of the regulation.
(1) Adjust tire inflation pressure to the standard value. (Refer
to GROUP 22 - General Specifications.)
(2) Use speedometer tester to check indicator difference.
Caution
When checking with speedometer tester, block
nonoperating wheels to prevent vehicle moving.
TACHOMETER INSPECTION <2.6L Engine> ~08nm~
Connect a tachdwell meter, and then compare the meter
readings at various engine speeds with the values indicated
on the tachometer.
Standard value:
1,000 rpm
3,000 rpm
5,000 rpm
Caution
flO0 rpm
+I50 rpm
+250 rpm
The tachometer is the negative-ground type, and there-
fore should not be connected in reverse polarity to the
battery. If the tachometer is connected in reverse polar-
ity, the transistors and diodes will be damaged.
TACHOMETER INSPECTION <3.OL Engine> N(YM~
(I) Insert paper clip on 1 pin connector (from harness side)
located between the ignition coil (primary side) and LC
filter.
Caution
Insert paper clip along terminal wall as illustrated.
(2) Connect a tachodwell meter to paper clip. Compare the
tachodwell meter reading with the tachometer reading at
each engine speed and check that the error is within the
standard value.
Standard value:
1,000 rpm +I00 rpm
3,000 rpm *I50 rpm
5,000 rpm 5250 rpm
Caution
The tachometer is the negative-ground type, and
therefore should not be connected in reverse to the
battery. If the tachometer is connected in reverse,
transistors and diodes will be damaged.
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40. METERS AND GAUGES - Service Adjustment Procedures 8-171
(2.6L Engine> Stopper (upper)
<3.OL Engine> ,Horizontal line
<2.6L Engine>
I
FUEL GAUGE SIMPLE TEST NO*HlCK
(I) Remove connector from fuel gauge unit in fuel tank.
(2) Connect test light between yellow and black wires on
connector.
(3) Turn ON ignition key.
(4) Assure test light flashes and gauge needle moves.
(5) If test light flashes but gauge needle does not move,
replace fuel gauge.
If test light does not flash (and gatige needle does not
move), check fuse for broken wire, o: resistance between
gauge terminals (see pages 8-174.). or break in harness.
FUEL GAUGE UNIT INSPECTION NomIIG
To check the fuel gauge unit, remove the unit from the fuel
tank. (Refer to GROUP 14 - Fuel Tank.)
FUEL GAUGE UNIT FLOAT POSITION CHECK
Move the float and measure the float position at points “F”
and “E” when the float arm contacts the stopper.
Standard value:
<2.6L Engine>
A 11-13 mm (43-51 in.)
B 180-182 mm (7.09-7.17 in.)
<3.OL Engine (Gdoor vehicles)>
A 9-11 mm (.35-.43 in.)
B 229-231 mm (9.02-9.09 in.)
<3.OL Engine @l-door vehicles)>
A 15-17 mm (.59-.67 in.)
B 224-226 mm (8.82-8.90 in.)
FUEL GAUGE UNIT RESISTANCE CHECK
(I) Check that the resistance between terminals is within the
standard value when the fuel gauge unit float is between
positions “F” and “E”.
Standard value:
Point F l-5 !&-l
Point E 103-117 fI
(21Also checkthat the resistancechangessmoothly when
the float is moved to “F” and “E”.
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41. METERS AND GAUGES - Service Adjustment Procedures
ENGINE COOLANT TEMPERATURE GAUGE
SIMPLE TEST NI8moO.
(1) Remove connector from engine coolant temperature
gauge unit in engine compartment.
(2) Ground harness side connector via test light.
(3) Turn ON ignition key.
(4) Check that test light flashes and gauge needle moves.
(5) If test light flashes hut the gauge needle does not move,
replace engine coolant temperature gauge.
If test light does not flash (and gauge needle does not
move), check fuse for broken wire, or resistance between
gauge terminals (see pages 8-174.). or break in harness.
ENGINE COOLANT TEMPERATURE GAUGE UNIT
INSPECTION WIKO
Refer to GROUP 7 - Engine Coolant Temperature Gauge
Unit.
FOILPRESSURE GAUGE SIMPLE TEST
(I) Disconnect the wiring connector from the oil preszi
gauge unit inside the engine compartment.
(2) Ground the connector at the harness through a test light.
(3) Turn the ignition key to the ON position.
(4) Check to be sure that the test light illuminates steadily
and the indicator of the oil pressure gauge moves.
(5) If both the test light and gauge operate, the circuit to the
gauge unit is normal and the gauge unit itself is faulty. If
the test light flashes but the gauge does not operate, the
gauge is faulty.
If neither the test light nor the gauge operates, the oil
pressure gauge circuit is faulty.
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42. METERS AND GAUGES - sewice Adjustment Procedures/Combination Meter 8-173
Oil pressure
gauge unit
’ lc Test light
- @ (12Vr3.4W)
COMBINATION METER
OIL PRESSURE GAUGE UNIT CURRENT CHECKHIm
(1) Disconnect the wiring connector from the oil pressure
gauge unit inside the engine compartment.
(2) Apply battery voltage (through the test light) to the gauge
unit side terminal.
(3) Check to be sure that the test light switches OFF when
the engine is stopped, and that it flashes while the
engine is running.
VOLTAGE METER SIMPLE TEST NoN5Gc
(I) Connect a voltmeter for testing.
(2) Turn the ignition key to the ON position.
(3) Compare the readings of the voltmeter for testing and of
the vehicle’s voltage meter.
Standard value:
1ov f0.5V
16V f0.5V
REMOVAL AND INSTALLATlON - NOSNJAFl
Removal steps
1. Meter cover
l 4 2. Connection of speedometer cable
3. Meter assembly
NOTE
(1) Reverse the removal procedures to reinstall.
(2) I)* : Refer to “Service Points of Installation”.
INSPECTION
REED SWITCH
Using an ohmmeter, check that continuity and discontinuity
alternate between terminals 1 and 2 four times at every
rotation of the shaft of the speedometer cable connection.
I 1II 181,522
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43. * __ -
8-174 METERS AND GAUGES - Combination Meter
BUZZER
Check to be sure that buzzer sounds when the battery’s
positive (t-1 terminal is connected to terminal 2 and the
battery’s negative (-1 terminal is connected to terminal 1.
-
FUEL GAUGE
Measure the resistance value between the terminals by
using an ohmmeter.
Standard value:
1-2 terminals: 55 a
2-3 terminals: 165 ti
1-3 terminals: 110 0
Caution
If there is a malfunction of the ground contact of the
voltage regulator even once during vehicle operation,
the excessive current flowing through the heat coil of
the engine coolant temperature gauge and the fuel
gauge will cause permanent distortion of the bimetal,
resulting in the indications being consistently lower
than the actual value.
For this reason, therefore, be sure to make the earth
contact securely.
ENGINE COOLANT TEMPERATURE GAUGE
Measure the resistance value between the terminals by
using an ohmmeter.
Standard value:
Bimetal type
1-2 terminals: 55 Q
SERVICE POINTS OF INSTALLATION
2. INSTALLATION OF SPEEDOMETER CABLE
Insert the cable until its stopper properly fits to the
speedometer groove.
Caution
Poor installation of the cable may cause a fluctuating
meter pointer, or noise and a damaged harness inside
the instrument panel.
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44. METERS AND GAUGES - Combination Meter/3-meter Unit
DISASSEMBLY AND REASSEMBLY
8-175
,6 Disassembly steps
1. Meter cover
2. Buzzer
3. Fuel and engine coolant temperature gauge
4. Tachometer
5. Speedometer
6.
7.
Indicator panel
8.
Meter glass
9.
Window plate
Meter case
10. Printed circuit board
NOTE
Reverse the disassembly procedures to reassemble,
3-METER UNIT
REMOVAL AND fNSTALLATlON
Removal steps
1. Meter pad
2. Gauge assembly
NOTE
Reverse the removal procedures to reinstall.
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45. 6-176 METERS AND GAUGES - 3-meter Unit
DISASSEMBLY AND REASSEMBLY
INSPECTION
OIL PRESSURE GAUGE
Measure the resistance value between the terminals with an
ohmmeter.
Standard value: Approx. 50 n
VOLTAGE METER
Measure the resistance value between the terminals with an
ohmmeter.
Standard value: 380450 fl
INCLINOMETER
(1) Check to be sure that operation is smooth when the
inclinometer is titled up/down and to the left and right.
(2) The inclinometer can be considered to be in good condi-
tion if the pointer indicates the spherical dial horizontal
center line when the meter case is placed on a level
surface.
Dissssembly steps
1. Meter glass
2. Window plate
3. Oil pressure gauge
4. Inclinometer
5. Voltage meter
6. Meter case
7. Meter harness
NOTE
Reverse the disassembly procedures to reassemble.
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46. METERS AND GAUGES - Indicators and Warning Lights 8-177
INDICATORS AND WARNING LIGHTS
Symbol Operation
Turn signal indicator
++
This indicator flashes, as do the same side of turn-signal
light flashes. If the turn-signal light is burnt out, the blinking
of indicator slows down.
This indicator is common with hazard light.
=0
High beam indicator This indicator illuminates when the headlights are on high
beam.
=
*
Door-ajar warning light This warning light comes on when the door is either open or
not completely closed.
4
Fasten seat belt indicator This indicator goes on for four to eight seconds when the
ignition key is in “ON” position, even if the driver has
fastened his seat belt.
BRAKE
Brake warning light This warning light comes on when the ignition key is in
“ON” position, and goes off after the engine has started.
This warning light comes on when the parking brake is
applied or brake fluid level falls less than the specific level.
I
Charging warning light This warning light comes on when the ignition key is in
- +
“ON” position, and goes off after the engine has started.
This warning light comes on when the drive belt breaks or
the trouble occurs in the charging system.
%?
Overdrive indicator This indicator will illuminates when the overdrive control
switch is switched to the “OFF” position.
am0133
T%
AR fluid temperature warning This A/T fluid temperature warning light comes on when
light automatic transmission fluid temperature becomes abnor-
mally high.
ma68
Free-wheeling hub indicator This indicator comes on when the automatic free-wheeling
WE-
hubs are locked.
z4
4WD indicator This indicator will light up when the transfer case shift lever
is shifted to the four wheel driving position (either the “4H”
or the “4L” position) and the ignition key is in the “ON”
position.
Maintenance required warning This light comes on when the ignition key is in “ON”
MAINT light position, and goes off after the engine has started.
REQD
(Lights up after every 50,000 miles, 80,000 miles, 100,000
miles and 120,000 miles travelled.)
CHECK
ENGINE
Engine warning light This light illuminates when the ignition key is turned to the
“ON” position, but should go out in a few seconds.
If the light illuminates while the vehicle is moving, there is a
malfunction of a component related to exhaust gases.
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47. METERS AND GAUGES - Indicators and Warning Lights
MAINTENANCE REQUIRED SYSTEM
RESET SWITCH
After checking is completed. use the reset switch (located at
the rear of the combination meter) to switch OFF the
warning light.
Note that the warning lights bulb should be removed after
the 120,000 mileage.
NOTE
If the speedometer is to be replaced, set the new odometer
to the same reading as the odometer being removed.
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48. o-1
LUBRICATION
AND
MAINTENANCE
INDEX NWOA-
GENERAL INFORMATION ................................. 2
MAINTENANCE SERVICE ................................. 9
Air Cleaner Element ........................................ 12
Automatic Transmission ................................. 22
Ball Joint and Steering Linkage Seals ............. 24
Ball Joints with Grease Fitting ........................ 25
Brake Hoses .................................................... 24
Canister ........................................................... 16
Carburetor Choke Mechanism
and Linkage ..................................................... 11
Crankcase Emission Control System (Positive
Crankcase Ventilation Valve) ........................... 13
Distributor Cap, Rotor and
Advanced angle System ................................. 17
Drive Belt ............................................... ..-....... 19
Drive Shaft Boots ............................................ 25
EGR Valve .............................................. .._...-- 16
Engine Coolant ................................................ 23
Engine Idling Speed ............................. .._...._.._ IO
Engine Oil ........................................................ 20
Engine Oil Filter ................................... ..-*__..*... 21
Engine Oil Inspection ...................................... 20
Evaporative Emission Control
System (except Canister) ................................ 15
Exhaust System (Connection
Portion of Muffler and Pipings,
and Keeping Warmth Covers) ................ .._...... 26
Front Axle and Rear Axle ................................. 25
Front Disc Brake Pads ..................................... 24
Front Wheel Bearing ....................................... 25
Fuel Filter ......................................................... 12
Fuel Hoses, and Vapor Hoses ......................... 12
Fuel System .................................................... 12
Ignition Cables ................................................ 16
Intake Temperature Control
System ............................................................ 18
Manual Transmission ...................................... 22
Oxygen Sensor ............................... ..- ............. 17
Propeller Shaft Joints ...................................... 26
Rear Axle Oil (Limited Slip
Differential) ...................................................... 26
Rear Drum Brake Linings and
Rear Wheel Cylinders ._._.................................. 24
Solenoid Valve Air Filter of
Vacuum Control System ................................. 18
Spark Plugs ..................................................... 16
Timing Belt ...................................................... 19
Transfer Case .................................................. 23
Vacuum Hoses, Secondary Air Hoses,
Crankcase Ventilation Hoses
and Water Hoses ............................................ 12
Valve Clearance ..................._......~.. .................. 9
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIES TABLE ..................... 6
SCHEDULED MAINTENANCE TABLE .............. 3
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49. LUBRlCATlON AND MAINTENANCE-General Information
GENERAL INFORMATION ?uloP&B
Maintenance and lubrication service recommenda-
tions have been compiled to provide maximum protec-
tion for the vehicle owner’s investment against all rea-
sonable types of driving conditions. Since these
conditions vary with the individual vehicle owner’s
driving habits, the area in which the vehicle is operated
and the type of driving to which the vehicle is sub
jetted, it is necessary to prescribe lubrication and
maintenance service on a time frequency as well as
mileage interval basis.
Oils, lubricants and greases are classified and graded
according to standards recommended by the Society
of Automotive Engineers (SAE), the American Petro-
leum institute (API) and the National Lubricating
Grease Institute (NLGI).
MAINTENANCE SCHEDULES
Information for service maintenance is provided under
“SCHEDULED MAINTENANCE TABLE”.
Three schedules are provided; one for “Required
Maintenance”, one for “General Maintenance” and
one for “Severe Usage Service”.
SEVERE SERVICE
Vehicles operating under severe service conditions will
require more frequent service.
Component service information is included in appropri-
ate units for vehicles operaing under one or more of
the following conditions:
1. Trailer towing or police. taxi, or commercial type
operation.
2. Operation of Vehicle
(1)
13)
(4)
(5)
(6)
(7)
Short-trip operation at freezing temperature
(engine not thoroughly warmed up)
More than 50%operation in heavy city traffic
during hot weather above 32°C (90°F)
Extensive idling
Driving in sandy areas
Driving in salty areas
Driving in dusty conditions
Driving on-off-road
ENGINE OIL
The SAE grade number indicates the viscosity of en-
gine oils, for example, SAE 30. which is a single grade
oil. Engine oils are also identified by a dual number, for
example, SAE lOW-30, which indicates a multigrade
oil.
The API classification system difines oil performance
in terms of engine usage. Only engine oil designed
“For Service SF” or “For Service SF/CC”, when avail-
able, should be used. These oils contain sufficient
chemical additives to provide maximum engine protec-
tion. Both the SAE grade and the API designation can
be found on the container.
used.
FUEL USAGE STATEMENT
Use gasolines having a minimum anti-knock index
(Octane Value) of 87, (R + M)/Z. This designation is
comparable to a Research Octane Number of 91.
Unleaded gasolines only must be used in vehicles
equipped with catalyst emission control systems.
All vehicles, so equipped, have labels located on
the instrument panel and on the back of fuel filler
lid that state, “UNLEADED GASOLINE ONLY”.
These vehicles also have fuel filler tubes especially
designed to accept the smaller diameter unleaded
gasoline dispensing nozzles only.
MATERIALS ADDED TO FUEL
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intend-
ed for gum and varnish removal may contain highly
active solvents or similar ingredients that can be
harmful to gasket and diaphragm matertals used in
fuel system component parts.
=
Caution
Test results submitted to EPA have shown that
laboratory animals develop skin cancer after
prolonged contact with used engine oil. Accord-
ingly, the potential exists for humans to develop
a number of skin disorders, including cancer,
from such exposure to used engine oil.
Care should be taken, therefore, when changing
engine oil, to minimize the amount and length of
exposure time to used engine oil on your skin.
Protective clothing and gloves, that cannot be
penetrated by oil, should be worn. The skin
should be thoroughly washed with soap and
water, or use waterless hand cleaner, to remove
any used engine oil. Do not use gasoline, thin-
ners, or solvents.
GEAR LUBRICANTS
The SAE grade number also indicates the viscosity
of Multi-Purpose Gear Lubricants.
The API classification system defines gear lubri- r
cants in terms of usage. Typical gear lubricants
conforming to API GL-4 or GL-5 with a viscosity of
SAE 8OW. SAE 96 are recommended for manual
transmission, front axle and rear axle (conventional
differential), and MITSUBISHI genuine gear oil Part
No. 8149630EX or equivalent, for rear axle (limited-
slip differential).
LUBRICANTS-GREASES
Semi-solid lubricants bear the NLGI designation
and are further classified as grades 0, 1, 2, 3 etc..
Whenever “Chassis Lubricant” is specified, Multi-
Purpose Grease; NLGI grade No. 2, should be
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50. LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table o-3
SCHEDULED MAINTENANCE TABLE ram&-
SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHI-
CLE PERFORMANCE
Inspection and service should be performed any time a malfunction is observed or suspected. Retain receipts
for all vehicle emission services to protect your emission warranty.
Emission Control System
Maintenance
Check Intake Temperature Control System*3 Every 5 Years or X X
Replace Solenoid Valve Air Cleaner Element of Vacuum X X
Control System*’ Every 5 Years
or
NOTE
(1) *’ : Shows recommended maintenance items for California vehicles only, but are required for vehicles except for
California. <2.6L Engine>
-(2) *’ : <2.6L Engine>
(3) *3 : Except for California
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51. _1 1. $
--
ES-’
o-4 LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table
GENERAL MAINTENANCE SERVICE FOR PROPERVEHICLE PERFORMANCE
E-I
-g:
i
General Maintenance
Timing Belt
~___
Drive,Belt (for Water Pump and
Alternator)
Service interval
Kilometers inihousands 12 24 36 48 60 72 84 9e
Mileage in Thousands 7.5 15 22.5 30 37.5 45 52.5 6C
Replace at X
Replace
at X X
, I , I 1 1 1 1 1
Engine Oil Change Oil Every 12 Months or X X X X X X X X
Engine Oil Filter Replace Every 12 Months or X X X X
Manual Transmission and Transfer Check Oil Level
Oil
at X X
Automatic Transmission Fluid Check Fluid Level Every 12 Months or X X X X
1
Automatic Transmission and
Transfer Fluid
Change Fluid
at X X
Engine Coolant Change Coolant Every 2 Years orI I I /xl I I lx
Front Disc Brake Pads Inspect for Wear Every 12 Months or X X X X
Rear Drum Brake Linings and Wheel Inspect for Wear and Leaks Every 2
Cylinders Years orI I I Ix/ I I lx
Brake Hoses Check for Deterioration or Leaksvery
12 Months
ori /X/ /XI ~I,( /X
Ball Joint and Steering Linkage Seals Inspect for Grease Leaks and Damage
Every 2 Years
or
1 x X
Drive Shaft Boots Inspect for Grease Leaks and Damage
I
Every 12 Months
or
xi x x x
Ball Joints with Grease Fitting Lubricate Grease Every 12 Months or xi x
I
;x X
Front Wheel Bearing Lubricate Grease Every 2 Years or xi x
Front Axle and Rear
With LSD* Change Oil at X X
Axle
Without LSD* Inspect Oil Level at X X
Propeller Shaft Joint Lubricate Grease Even! 2 Years or X X
Exhaust System
I
Check and Service as Required Every 2
Connection Portion of Muffler, Years or X X
Pipings and Converter Heat Shields
NOTE
* : LSD -Limited-slip differential
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52. LUBRICATION AND MAINTENANCE-Scheduled MaintenanceTable
SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDlTlONS
The maintenance items should be performed according to the following table:
mission and
Transfer Case
Severe usage conditions
A-Driving in dusty conditions
B-Trailer towing, or police, taxi, or commercial type operation
C-Extensive idling
D-Shot--trip operation at freezing temperatures (engine not thoroughly warmed up)
E-Driving in sandy areas
F-Driving in salty areas
G-More than 50% operation in heavy city traffic during hot weather above 32°C (90°F)
H-Driving on off-road
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53. O-6 LUBRICATION AND MAINTENANCE - Recommended Lubricants and Lubricant Capacities Table
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLgm., E;f
=I~-’
RECOMMENDED LUBRICANTS
aax.:sFzEXBT
1 -Parts
Engine oil
Specifications
API classification SF or SF/CC
Remarks
/ For further details, refer to SAE
1vrscosity number
Manual transmission API classification GL-4 or higher SAE grade number: SAE 8OW or
75Wl85W
~ _
Automatic transmission Automatic transmission fluid
DEXRON type
Transfer case API classification GL-4 or higher SAE grade number: SAE 8OW or
75wmiw
Front axle API classification GL-5 or higher For further details, refer to SAE
viscosity number
Conventional differential API classification GL-5 or higher For further details, refer to SAE
viscositv number
Rear axle
Limited-slip differential Mitsubishi Genuine Gear Oil Part No.
8148630EXor equivalent
Power steering Automatic Transmission Fluid
DEXRON type
Brakes and clutch Conforming to DOT3
Engine coolant D&QUEEN LONG-LIFE COOLANT
(Part No. 0103044) or HIGH QUALITY
ETHYLENE GLYCOL ANTIFREEZE
COOLANT
Door hinges, back door hinges Engine oil I--- - -
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54. LUBRICATION AND MAINTENANCE - Recommended Lubricantsand Lubricant Capacities Table o-7
LUBRICANT CAPACITIES TABLE
Description
Engine oil
Crankcase (except for oil filter)
Oil filter
Oil cooler
Cooling system (including front heater and coolant reserve tank)
Manual transmission
Automatic transmission
Transfer case
Front axle
Rear axle
Conventional differential
Limited-slip differential
Power steering
Fuel tank
T
*I: 2-doer models
*? 4-ooor models
SELECTION OF LUBRICANTS
qnticipated barometric
:emperature range SAE viscosity No.
38
zoco
100
27 80
16 60
0 32
-12
-23
-29
IO
-10
-20
“SAE 5W-20 Not recommended for sustained
high speed vehicle operation.
<2.6L Engine>
Metric U.S. Metric U.S.
measure measure measure measure
4.9 liters
0.4 liter
8.0 liters
2.2 liters
2.2 liters
1.1 liters
1.8 liters
1.8 liters
1.06 liters
60 liters
:
5.0 qts.
l/2 qt.
-
8-l/2 qts.
4.7 pints.
-
4.7 pints.
2.3 pints.
3.8 pints.
3.8 pints
2.2 pints.
15.9 gals.
T <3.OL Engine>
4.71 liters
0.4 liter
0.3 liter
9.1 liters
2.5 liters
7.2 liters
2.2 liters
1.1 liters
2.6 liters
2.6 liters
1.06 liters
75 liters”’
92 liters**
5.0 qts.
lr2qt.
1/2qt.
9-l/2 qts.
5.3 pints.
15.2 pints.
4.7 pints.
2.3 pints.
5.5 pints.
5.5 pints.
2.2 pints.
19.8 gals.*’
24.3 gals.“:
1
ENGINE OIL
Only those engine oils should be used which conform to the
requirements of the API. classification “For Service SF” or “For
Service SF/CC”, and have the proper SAE grade number for the
expected temperature range.
Caution
Nondetergent or straight mineral oil must never be used.
Energy Conserving Oil
In order to improve fuel economy and conserve energy new,
lower friction engine oils have been developed. These oils are
readily available and can be identified by such labels as “Energy
conserving”, “Energy saving”, “Improved fuel economy”, etc.
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55. O-8 LUBRICATION AND MAINTENANCE - Recommended LuMcantrandLubricantCapacltiesTable
72POO30
Oil Identification Symbol
A standard symbol appears on the top of oil containers and has
three distinct areas for identifying various aspects of the oil.
The top portion will indicate the quality of the oil. The center
portion will show the SAE viscosity grade, such as SAE
IOW-30. “Energy Conserving”shown in the lower portion, in-
dicates that the oil has fuel-saving capabilities.
FRONT AXLE/REAR AXLE (CONVENTIONAL DIFFERENTIAL)
Lubricant API classification
GL-5 or higher
Anticipated temperature
range
Viscbsity range
Above-23"C(-10°F)
-20"Ct034"C
(-10°F to -30°F)
Below -34°C (-30°F)
SAE90 -
SAE 85W-90
SAE 8OW-90
SAE 80W
SAE 8OW-90
SAE 75W
REAR AXLE (LIMITED-SLIP DIFFERENTIAL)
COOLANT
Refer to P.3-4.
Relation between Coolant Concentration and Specific Gravity
Coolanttemperature “C (“F) and specific gravity
lO(50) ZO(68) 30(86) M(lW 50(122)
Freezing Safe operating
temperature temperature
“C (“F) “C(“F)
1 1.054 1 1.050 1 1.046 / 1.042 1 1.036 1 -16(3.2)
1 1.063 1 1.058 1 1.054 / 1.049 1 1.044 1 -20(A)
1.071 1.067 1.062 1.057 1.052 -25(-13)
1.079 1.074 1.069 1.064 1.058 -3O(-22)
1.087 1.082 1.076 1.070 1.064 -36k32.8)
1.095 j 1.090 1.084 1.077 1.070 -42 (*I
1 1.103 ( 1.098 ( 1.092 j 1.084 1 1.076 1 -5O(-58)
-11(12.2)
-15(5)
-20(-4)
-25(-13)
-31 -(23.8)
-37(-35)
-45(-w
Coolant
concentration
(Specific
volume)
30%
35%
40%
45%
50%
-
55%
60%
The safe operating temperature is - 15°C (5°F) when the measured specific gravity is 1.058 at the coolanttemperature of
20°C (68°F).
Cautions
1. If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely af-
fected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling proper-
ties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concen-
tration level within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
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56. LUBRICATION AND MAINTENANCE - Maintenance Service o-9
MAINTENANCE SERVICE NaosAca
VALVE CLEARANCE (Jet valve) (Check and adjust
as required)
<2.6L Engine>
(1) Warm up the engine until the coolant temperature reaches
85”-95°C (185”-205°F).
(2) Remove the air cleaner assembly.
(3) Remove the all spark plugs.
(4) Remove the rocker cover.
(5) Align the notch in the crankshaft pulley with the “T” mark
on the timing chain cover.
Check to be sure that the camshaft sprocket and the
timing chain’s mating mark are in the position shown in
the figure.
Caution
Be sure not to rotate the crankshaft counterclockwise
direction.
Note
If the camshaft sorocket’s mating mark is at the 180”
opposite position, the No. 4 cylinder is at top dead center.
With the No. 1 cylinder at compression (6) Measure the jet valve clearance at the places shown by
top dead center. the arrows in the figure.
Standard value (when hot engine) : 0.25 mm (.0098 in.)
Note
The valve clearance when cold is 0.17 mm LOO67 in.)
No. 1 No. 2
5EN27.1
With the No. 4 cylinder at compression
top dead center.
Caution
Be careful not to press the jet valve in, because the jet
valve spring’s force is not strong.
Timin
chain
side
No. 3 No. 4
5ENZ22
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57. LUBRICATIGN AND MAINTENANCE - Maintenance Service
(7) Apply specified sealant to portions indicated in ilIustration.
Specified sealant : 3M ART Part NO. 8660
(8) Install the rocker cover.
(9) Install the spark plugs.
(10)lnstall the air cleaner assembly.
ENGINE IDLlNG SPEED <2.6L Engine> WSADG.
Caution
The improper setting (throttle valve opening) will increase
exhaust gas temperature at deceleration, reducing catalyst
life greatly and deteriorating exhaust gas cleaning perfor-
mance. If also has effect on fuel consumption and engine
braking.
Inspection Conditions
l Engine Coolant temperature: 85-90°C (185205°F)
l Lights and accessories (air-conditioner, etc.): OFF
0 Transmission: Neutral
l Steering wheel: Centered (for power steering equipped
vehicles)
(1) Prepare a timing light and tachometer.
(2) Start the engine and allow it to idle.
(3) Depress accelerator pedal once to release the fast idle.
(4) Inspect the ignition timing. Adjust the ignition timing if
necessan/.
Standard ignition timing : 7” BTDC &2”*
*: When inspecting the standard ignition timing at high
altitudes, disconnect the white striped vacuum hose
from the distributor auxiliary compression chamber
and temporarily close the end of the hose with a blind
plug. (Federal indicated high-altitude specification ve-
hicles, California).
NOTE
Inspect and adjust ignition timing as described in GROUP
&Ignition System.
(5) Run the engine for more than 5 seconds at an engine
speed of 2,000 to 3,OOOipm.
(6) Run the engine at idIe for 2 minutes.
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58. LUBRICATION AND MAINTENANCE - Maintenance Service
(7) Read the idling speed.
O-II
If outside specified limits, readjust the speed to the
specified value by adjusting the idle speed adjusting
screw No. 1 (SAS-1).
Curb idle speed (rpm)
For the First 500 km
(300 miles)
After 500 km
(300 miles)
800elOO
Caution
DO NOT TOUCH SAS-2. The idle speed adjusting screw
(SASS) is the preset screw that determines the relation-
ship between the throttle valve and free lever, and has
been accurately set at the factory. If this setting is
disturbed, throttle opener adjustment and dash pot adjust-
ment cannot be done accurately.
CARBURETOR CHOKE MECHANISM AND LINK-
AGE (Clean) <2.6L Engine> NW-
The choke mechanism is used to facilitate engine starting
during cold weather. Inject a solvent into the end of the auto-
choke and the throttle valves (where they pass through the air
horn) to prevent the choke from becoming stuck by gum
deposits on the shaft. At the same time, inject a solvent to
clean dirt from the fast idle cam and link.
Caution
1. All carburetors have a tamper-proof choke. The chok-
erelated parts are factory adjusted. The choke adjust-
ment is required during service, except when major
carburetor service or overhaul choke calibration related
parts adjustments are needed by state or local inspec-
tions.
2. All carburetors also have a tamper-resistant idle mix-
ture adjusting screw. The CO setting has been done as
a factory adjustment. Neither removal of the plug nor
adjustment of the mixture screw is required during
service unless a major carburetor overhaul, throttle
body replacement, or high idle-CO adjustments are
needed by state or local inspections.
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59. LUBRICATION AND MAINTENANCE - Maintenance Service
FUEL FILTER (Replace)
<2.6L Engine>
The fuel filter should be replaced regularly because its
performance is reduced by dirt and water collected over an
extended period of use. Replace as required.
FUEL SYSTEM (Check for leaks) -
TANK, LINES AND FUEL FILLER CAP CONNECTIONS
1.
2.
3.
Check for damage or leakage in the fuel lines and
connections.
Inspect the surface of fuel hoses for heat and mechanical
damage. Hard and brittle rubber, cracking, checking, tears,
cuts, abrasions and excessive swelling indicate deteriora-
tion of the rubber.
If the fabric casing of the rubber hose is exposed by
cracks and abrasions in the fuel system, the hoses should
be changed.
VACUUM HOSES, SECONDARY AIR HOSES,
CRANKCASE VENTILATION HOSES AND WATER
HOSES (Replace) -
Replace them and make sure that the hoses do not come in
contact with any heat source or moving component which
might cause heat damage or mechanical wear.
FUEL HOSES, AND VAPOR HOSES (Replace) -F
Service procedures to check the hoses for damage are the
same as those described in the section “Vacuum hoses,
secondary air hoses, crankcase ventilation hoses and water
hoses”.
For removal and installation procedures, refer to GROUP 14 -
Fuel Line and Vapor Line.
AIR CLEANER ELEMENT (Replace) r4wsAKG
The air cleaner element will become dirty and loaded with
dust during use, and the filtering effect will be substantially
reduced. Replace it with a new one.
REPLACEMENT OF AIR CLEANER ELEMENT
<2.6L Engine>
1. Remove the wing nut. Use pliers only if the wing nut is
difficult to remove.
2. Unsnap the finger clips.
3. Remove the element by hand, and replace it with a new
element.
4. Install the air cleaner element, and then install the cover
and housing, taking care that the arrows are aligned.
5. Tighten the wing nut by hand.
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60. LUBRICATION AND MAINTENANCE - Maintenance Service o-13
<3.OL Engine>
(1)
(2)
(3)
(4)
Loosen the clamp coupling the air intake hose and the air
cleaner cover, and separate the hose.
Disconnect the air flow sensor connectors.
Disconnect the air cleaner cover clip.
Lifting the air intake hose, remove the air cleaner cover.
Air cleaner
VI
hc
mtilation
lse
Breather
’ hose
Rocker
/cover
Intake
manifold
Caution
The air cleaner cover should be removed carefully,
because it includes the air-flow sensor.
Remove the air cleaner element.
Set a new air cleaner element and clamp the air cleaner
cover.
I
PCV valve
I
CRANKCASE EMISSION CONTROL SYSTEM (Pos-
itive crankcase ventilation valve) (Clean) NW
The crankcase ventilation system must be kept clean to
maintain good engine performance.
k-.-J SEMcsl
From rocker cover
7EMOOSO
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61. LUBRICATION AND MAINTENANCE - Maintenance Service
<2.6L Engine>
(I) Disconnect the ventilation hose from the positive crank-
case ventilation valve. Then, remove Positive Crankcase
Ventilation valve from the rocker cover and reconnect it to
the ventilation hose.
(2) idle the engine and put a finger to the open end of Positive
Crankcase Ventilation valve to make sure that intake
manifold vacuum is felt on the finger.
NOTE
At this time, the plunger inside the Positive Crankcase
Ventilation valve moves back and forth.
(3) If vacuum is not felt on finger, clean the Positive Crank-
case Ventilation valve and ventilation hose in cleaning
solvent or replace if necessary.
(4) After completion of the work, set the reset switch (at the
rear of the meter) to switch OFF the “maintenance-
required” warning light.
(Refer to GROUP 8 - Meters and Gauges.)
<3.OL Engine>
(1) Disconnect the ventilation hose from the air-intake ple-
num. and connect a hand vacuum pump to the ventilation
hose.
(2) At this time, make sure that there is leakage when vacuum ,.,
is applied, If there is no leakage when vacuum is applied,
either clean the positive crankcase ventilation valve or
replace it.
(3) After completion of the work, set the reset switch (at the
rear of the meter) to switch OFF the “maintenance-
required” warning light.
(Refer to GROUP 8 - Meters and Gauges.1
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62. LUBRICATION AND MAINTENANCE - Maintenance Service o-15
EVAPORATIVE EMISSION CONTROL SYSTEM (Check for leaks and clogging) - except
canister NWSAMB.
<2.6L Engine> Air cleaner Purge control valve
mannolu
- Fuel vapor
--- Purge air
I ’
II
Fuel check valve
(Required FMVSS 301)
i
Overfill limiter
(2-way valve)
Vapor-liquid
seoarator
Overfill Iimiter
Gel filler cap
(Level tul be)
vacuum relief) -
Fuel filler pipe/w y l”..-
Thermal
expansion
To carburetor -
++ ,J-
Filter Fuel tank
Fuel gauge unit
/Air cleaner<3.OL Engine> 03W527
Overfill limiter
--- Purge air
- Fuel vapor
Cani&er Fi,ti
1. If the fuel-vapor vent line is clogged or damaged, a fuel-
vapor mixture escapes into the atmosphere causing
excessive emissions. Disconnect the line at both ends,
and blow it clean with compressed air. Remove the filler
cap from the filler pipe and check to see if there is
evidence that the packing makes improper contact to the
filler pipe.
2. The overfill limiter (Two-way valve) installed on the vapor
line should be checked for correct operation.
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63. O-16 LUBRlCATlON AND MAINTENANCE - Maintenance Service
NGK
CANISTER (Replace) -a
If or when the canister filter becomes clogged, the purge air
volume will decrease and consequently, the canister capacity
will be reduced.
After completion of the work, set the reset switch (at the rear
of the meter) to switch OFF the “maintenance-required”
warning light.
(Refer to GROUP 8 - Meters and Gauges.)
SPARK PLUGS (Replace) NoLs.4~
1. Spark plugs must fire properly to assure proper engine
performance and emission-control.
Therefore, they should be replaced periodically with new
ones.
2. The new plugs should be checked for the proper gap.
Spark plug gap : U-1.1 mm (.039-.043 in.)
IGNITION CABLES (Replace)
The ignition cables should be replaced periodically with new
ones.
After replacing, make sure that the ignition cables and
terminals are properly connected and full seated.
NOTE
When disconnecting an ignition cable, be sure to hold cable
cap. If the cable is disconnected by pulling on the cable alone,
an open circuit might result.
EGR VALVE (Replace)
Replace EGR valve to a new one.
MO.SMG
REMOVAL OF EGR VALVE
<2.6L Engine>
1. Disconnect the vacuum hoses from the EGR valve.
2. Remove the EGR valve from the intake manifold.
3. Replace the EGR valve gasket with a new one.
4. Install the EGR valve on the intake manifold and tighten to
the specified torque.
After completion of the work, set the reset switch (at the
rear of the meter) to switch OFF the “maintenance-
required” warning light.
(Refer to GROUP 8 - Meters and Gauges.)
<3.OL Engine>
1. Disconnect the vacuum hoses from the EGR valve.
-2. Remove the EGR valve from the air intake plenum.
3. Replace the EGR valve gasket with a new one.
4. Install the EGR valve on the air intake plenum and tighten
to the specified torque.
After completion of the work, set the reset switch (at the
rear of the meter) to switch OFF the “maintenance-
required” warning light.
(Refer to GROUP 8 - Meters and Gauges.)
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64. LUBRICATION AND MAINTENANCE - Maintenance Service O-17
Ele
Hexagon nut Housing Spring
03Esso
OXYGEN SENSOR (Replace) NOOSAOF
The oxygen sensor is a device which controls the fuel mixture.
If the oxygen sensor is damaged, the exhaust-gas cleaning
effect as well as driveability deteriorates. Therefore, it should
be replaced periodically with a new one.
After completion of the work, set the reset switch (at the rear
of the meter) to switch OFF the “maintenance-required”
warning light.
(Refer to GROUP 8 - Meters and Gauges.)
REMOVAL OF OXYGEN SENSOR
<2.6L Engine>
1. Disconnect the connector of the oxygen sensor.
2. Remove the oxygen sensor from the exhaust manifold.
3. Replace the oxygen sensor on the exhaust manifold and
tighten to the specified torque.
<3.OL Engine>
1. Disconnect the connector of the oxygen sensor.
2. Remove the oxygen sensor from the front exhaust pipe.
3. Replace the oxygen sensor on the front exhaust pipe and
tighten to the specified torque.
DISTRIBUTOR CAP, ROTOR AND ADVANCED AN-
GLE SYSTEM (Check) <2.6L Engine> NoosA3B
Check the distributor cap, rotor and spark advance system to
maintain driveability and good exhaust gas.
INSPECTION OF DISTRIBUTOR CAP AND ROTOR
Inspect in accordance with the following procedure. Repair or
replace as necessary.
l Check the cap for cracks.
l Check the cap and rotor electrodes for damage.
l Wipe clean the cap and rotor.
INSPECTION OF CENTRIFUGAL SPARK ADVANCE DNICE
1. Start the engine and allow it to idle.
2. FD;nnect the vacuum hoses from the vacuum cham-
*: Disconnect the vacuum hoses from both the main and
sub vacuum chambers, (High-altitude areas nation-
wide, California)
3. Inspect the advance angle while slowly increasing engine
speed.
The advance angle should change smoothlyas engine
speed increases.
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65. O-18 LUBRICATION AND MAINTENANCE - Maintenance Service
Centrifugalproperties (Reference)
0 500 1000 1500 2000 2500 3000 3500
Distributor rpm SEW
Pressure kPa (psi) 5~031
NOTE
Symptom Probable Cause
4. When any of the above symptoms appear, disassemble and
inspect the distributor.
INSPECTION OF VACUUM ADVANCE DEVICE
1. Start the engine and allow it to idle.
2. Disconnect the vacuum-hoses from the vacuum cham-
her*.
Connect a vacuum pump to the nipple.
*: Disconnect the vacuum hoses from the main vacuum
chambers. (High-altitude areas nationwide, California)
3. Slowly apply vacuum with the vacuum pump and inspect
the advance angle.
The advance angle should change smoothly as the
vacuum increases.
NOTE
Symptom
Advance angle is too large
Probable Cause
Vacuum controller spring is weak
or missing
Advance angle changes
suddenly
Spring is broken
Angie too small or hysteresis Poor breaker base operation
is too large
Does not advance Diaphragm is damaged
4. When any of the above symptoms appear, disassemble
and inspect the distributor.
After removing the distributor, inspect each part as
described in GROUP 8 - Ignition System.
INTAKE TEMPERATURE CONTROL SYSTEM
(Check) t4oosATa
Check the vacuum motor of the intake temperature control
system to protect driveability and fuel consumption.
2.6 L Engine, refer to GROUP 25 - Exhaust Emission Control
System.
3.0 L Engine, refer to GROUP 14 - MPI-Service Adjustment
Procedure.
SOLENOID VALVE AIR FILTER OF VACUUM CON-
TROL SYSTEM (Replace) <2.6L Engine>
[Secondary air control solenoid valve, thro-
ttle opener control solenoid valve] NOOSAVA
Pull out the filter assembly in the direction of the arrow and
replace with a new filter assembly.
-
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66. LUBRICATION AND MAINTENANCE - Maintenance Service o-19
waterpump
Pulleyn
I pulley
Alternator
pUlk?y
o4soo2l
TIMING BELT (Replace) Iywsmc
Replace the belt with a new one periodically to assure proper
engine performance.
For removal and installation procedures, refer to GROUP 9 -
Timing belt.
DRIVE BELT (For water pump and alternator)
(Replace) NOOSBSK
<2.6L Engine>
Replace them with new ones, and make sure there is no
interference between the belt and other engine components.
Then check the tension of the belt for the water pump and
alternator.
The deflection of the belt must be specified, when depressed
at a point midway between the water pump pulley and the
alternator pulley with a force of 100 N (22 Ibs.).
REPLACEMENT OF DRIVE BELT
Vehicles without an air conditioner
1. Loosen the alternator brace bolt and alternator support
nut, and then remove the alternator drive belt.
2. install a new alternator drive belt.
3. Contact a bar or similar object to the stator part of the
alternator in order to provide the appropriate tension, and
then adjust the amount of belt deflection.
Standardvalue : 9-12 mm (.3!5-.47 in.)
4. Tighten the alternator brace bolt and alternator support
nut at the specified torque.
Vehicles with an air conditioner
1. Loosen the tension pulley nut.
2. Loosen the tension adjustment nut and then remove the
air conditioner compressor’s drive belt.
3. Loosen the alternator brace bolt and alternator support
nut.
4. Loosen the tension adjustment bolt, and remove the
alternator drive belt.
5. Install a new alternator drive belt.
6. Adjust the amount of deflection of the belt by using the
tension adjustment bolt.
Standard value : 9-12 mm (.35-.47 in.)
7. Tighten the alternator support nut, and the alternator
brace bolt at the specified torque.
8. Install the air conditioner compressor’s drive belt, and
adjust the amount of deflection of the drive belt.
Refer to GROUP 24 - Service Adjustment Procedures.
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L.... ” F
~-. _ _.
O-20 LUBRICATION AND MAINTENANCE - Maintenance Service
AAlternater pulley
<2.6L Engine> Good
t-l
e
4.OL Engine>
72JOO5
Good
l-l
c3.OL Engine>
Replace them with new ones, and make sure there is no
interference between the belt and other engine components.
(1) Remove the air conditioner compressor belt and power
steering belt.
(2) Back the nut off l/8 turn.
(3) Loosen the adjusting bolt and remove the drive belt.
(4) Attach a new drive belt.
(5) Apply 100 N (22 tbs.) to the belt back at the middle point
between the alternator pulley and the drive belt lower
tensioner.
Turn the adjusting bolt to adjust the drive belt sag to the
standard value.
Standard value: 6.6-6.0 mm (.2X-.315 in.)
Otherwise, use the tension gauge to adjust the sag to the
standard value.
Standard value : 500-700 N (110-155 Ibs.)
NOTE
When the tension gauge is used, select any part between
any pulleys.
(6) Tighten the nut.
ENGINE OIL INSPECTION NwaBS*
(1) Check to ensure that the engine oil level is within the level
range indicated on the oil dip stick.
(2) Check to ensure that the oil is not noticeably dirty or
mixed with coolant or gasoline, and that it has the proper
viscosity.
ENGINE OIL (Change) WSAPiBb
Always use lubricants which conform to the requirements of
the API classification “For Service SF” or “For Service SF/CC”
when available, and have the proper SAE grade number for
the expected temperature range.
Never use nondetergent or straight mineral oil.
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68. LUBRICATION AND MAINTENANCE - Maintenance Service o-21
(I) Afterwarming up the engine, remove the oil filler cap.
(2) Remove the drain plug to allow the engine oil to drain.
(3) Replace the drain plug gasket with a new one and tighten
the drain plug.
(4) Supply new engine oil through the oil filler.
Engine oil total capacity :
<2.6L Engine> 4.9 liters (5.0 qts.)
<3.OL Engine> 4.7 liters (5.0 qts.)
[including oil filter 0.4 liter (l/2 qt.)]
(5) Start and run the engine a few minutes.
(6) Stop the engine and check the engine oil level.
ENGINE OIL FILTER (Change) NWSABG
The quality of replacement filters varies considerably. Only
high quality filters should be used to assure most efficient
service.
Genuine oil filters require that the filter is capable of with-
standing a pressure of 256 psi are high quality filters and are
recommended as follows:
Oil Filter Part Number
Mitsubishi Genuine Parts : MD031805 or equivalent
NOTE
Factory installed Mitsubishi Engine Oil Filter Part No.
MD084693 or MD031805.
ENGINE OIL FILTER SELECTION
This vehicle is equipped with a full-flow, throw-away oil filter.
The same type of replacement filter is recommended as a
replacement filter for this vehicle. It is possible, particularily in
cold weather, that this vehicle may develop high oil pressure
for a short duration. You should be sure that any replacement
filter used on this vehicle is a high-quality filter and is capable
of withstanding a pressure of 256 psi (manufacturer’s specifi-
cations) to avoid filter and engine damage. The following is a
high-quality filter and is strongly recommended for use on this
vehicle : Mitsubishi Engine Oil Filter P/N MD031805 or
MD084693.
Any replacement oil filter should be installed in accordance
with the oil filter manufacturer’s installation instructions.
(1) Remove the engine oil filler cap.
(2) Remove the engine oil drain plug, and drain out the engine
oil.
(3) Remove the engine oil filter by using the oil filter wrench.
(4) Clean the oil filter mounting surface of the oil filter
bracket.
(5) Coat engine oil to the O-ring of new oil filter.
(6) Turn the oil filter by hand to install to the block.
NOTE
The oil filter tightening torque is 11-13 Nm (8-10 ftlbs.)
(7) Supply engine oil.
(8) Start and run engine and check for engine oil leaks.
(9) After stopping engine, check oil level and replenish as
necessary.
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69. LUBRICATION AND MAINTENANCE - Maintenance Service
HOT upper limit
HOT lower limit
COLD upper limit
COLD lower limit
COLD HOT
372029
i
MANUAL TRANSMISSION (Check oil level) NWSSCC
inspect each component for evidence of leakage, and check
the oil level by remaining the filler plug. If the oil is
contaminated, it is necessary to replace it with new oil.
INSPECTlON
l With the vehicle on a level surface, remove the filler plug
and check whether or not the oil is at the same level as the
bottom of the threads.
l Check whether or not the transmission oil is excessively
dirty, and if the viscosity is normal.
REPLACING TRANSMISSION OIL
1. Remove the drain plug and drain the transmission oil.
2. Replace the gasket with a new one and tighten the drain
plug.
3. Apply a coating of sealant to the threaded part when
installing the drain plug and the filler plug of the transmis-
sion of models with the 3.OL engine.
Specified sealant: Three Bond 1105D or equivalent
4. Fill with new oil through the filler plug until the-oil level _
reaches the plug hole.
Manual transmission oil capacity :
<2.6L Engine> 2;2 liters (4.7 pints)
<3.OL Engine> 2.5 liters (5.3 pints)
AUTOMATIC TRANSMISSION (Check fluid level)
Nwssoe
Check the fluid level by removing the fluid level gauge. If the
fluid is contaminated, it is necessary to replace it wjth new
fluid.
1. Place the vehicle on a level surface.
2. Wipe the area around the oil dipstick to remove accumu-
lated dirt and then pull out the oil dipstick.
3. Set the selector lever to the “P” (Park) position and apply
the parking brake. Next, start the engine..
4. Check if the engine idle speed and fluid operating ”
temeprature (50-80°C; 12%176°F) are normal.
5. Move the selector lever toeach position in turn to fill the
torque convertor and hydraulic system with fluid and then
return the selector lever to the “N” (Neutral) position.
6. Make sure the fluid level is in the “HOT” range of the oil
dipstick. If the fluid level is low, add fluid until it reaches
the “HOT” range.
REPLACEMENT OF AUTOMATIC TRANSMISSION FLUID
Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new fluid after the cause of any contamination -
has been corrected.
1. Place a large flat contain-er beneath the drain plug.
2. Remove the drain plug and drain the fluid.
3. Replace the gasket with a new one and tighten the drain
plug.
4. Pour 5 liters (10.6 pints) of specified ATF into casethrough
dipstick hole. [Total quantity of ATF required is approx. 7 ~-’
liters (14.8 pints). Actually however, approx. 5.5 liters (11.6
pints) of fluid can be replaced because rest of fluid
remains in torque converter.]
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