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00109000812

General . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

00 11 12 13 14 15 16 17 21 22 23 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

WORKSHOP MANUALFOREWORDThis Workshop Manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required. TECHNICAL INFORMATION MANUAL PYDE9802 WORKSHOP MANUAL ENGINE GROUP PWEEjjjj (Looseleaf edition) ELECTRICAL WIRING PHDE9802 BODY REPAIR MANUAL PBDE9802 PARTS CATALOGUE SPACE RUNNER B608V509Aj SPACE WAGON B608W509Aj

Engine Cooling . . . . . . . . . . . . . . . . . Intake and Exhaust ............

Engine Electrical . . . . . . . . . . . . . . . Engine and Emission Control . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission . . . . . . . . . . . Automatic Transmission . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . Front Axle . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . Wheel and Tyre . . . . . . . . . . . . . . . . . Power Plant Mount . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . .

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

Rear Suspension . . . . . . . . . . . . . . . Service Brakes . . . . . . . . . . . . . . . . . Parking Brakes . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . Body . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior . . . . . . . . . . . . . . . . . . . . . . . . Interior and Supplemental Restraint System (SRS) . . . . . . . . . Chassis Electrical . . . . . . . . . . . . . .

GDI is the trade mark which Mitsubishi Motors Corporation holds.E Mitsubishi Motors CorporationAug. 1998

Heater, Air Conditioner and Ventilation . . . . . . . . . . . . . . . . . . . . . .

WARNING! (1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative). (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensor, front seat assembly (side air bag module) and seat belt with pre-tensioner before drying or baking the vehicle after painting. SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more Seat belt with pre-tensioner: 90_C or more (3) Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and seat belt with pre-tensioner or any SRS-related component. NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

21-1

CLUTCHCONTENTSGENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2Clutch Pedal Inspection and Adjustment . . . . . . . 2 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321109000190

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 7

21-2

CLUTCH -

General Information/Service Specifications/Lubricants/On-vehicle Service

GENERAL INFORMATIONThe clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control.

21100010093

SERVICE SPECIFICATIONSItems Clutch pedal height mm Clutch pedal clevis pin play mm Clutch pedal free play mm Distance between the clutch pedal and the toeboard when the clutch is disengaged mm Standard value 224 - 227 211 - 214 1- 3 6 - 13 125 or more

21100030150

LUBRICANTSItems Clutch fluid Push rod assembly Boot Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011 Specified lubricants Brake fluid DOT3 or DOT4 Rubber grease Quantity As required

21100040078

Clutch pedal height

Clutch pedal clevis pin play

ON-VEHICLE SERVICECLUTCH PEDAL INSPECTION AND ADJUSTMENT

21100090158

A

B

1. Turn up the carpet, etc. under the clutch pedal. 2. Measure the clutch pedal height and the clutch pedal clevis pin play. Standard value (A): 224 - 227 211 - 214 Standard value (B): 1 - 3 mm

CLUTCH - On-vehicle ServiceSetting nut

21-3

3. If the clutch pedal height and the clutch pedal clevis pin play are outside the standard value, turn the setting nut to adjust them to the standard value. Caution Do not push in the master cylinder push rod at this time, otherwise the clutch will not operate properly.Clutch pedal

12 Nm

Clutch pedal free play

4. After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the toeboard when the clutch is disengaged are within the standard value ranges.C

Standard value (C): 6 - 13 mm Standard value (D): 125 mm or more 5. If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder or clutch. 6. Turn back the carpet, etc.

Distance between the clutch pedal and the toeboard when the clutch is disengaged

D

BLEEDINGSpecified fluid: Brake fluid DOT 3 or DOT 4

21100140143

Caution Use the specified brake fluid. Avoid using a mixture of the specified fluid and other fluid.

21-4 CLUTCH PEDAL

CLUTCH - Clutch Pedal21100160224

REMOVAL AND INSTALLATIONPost-installation Operation Clutch Pedal Adjustment (Refer to P.21-2)

5

712 Nm

4 612 Nm

2

1 10

3

8

9

Removal steps 1. Clutch switch 2. Clip 3. Snap pin 4. Bushing 5. Pin assembly

6. 7. 8. 9. 10.

Clutch master cylinder mounting nut Master cylinder member mounting bolt Clutch pedal Stopper Pedal pad

CLUTCH - Clutch Control

21-521100190216

CLUTCH CONTROLREMOVAL AND INSTALLATIONPre-removal Operation Clutch Fluid Draining Post-installation Operation D Clutch Fluid Supplying D Clutch Line Bleeding (Refer to P.21-3) D Clutch Pedal Adjustment (Refer to P.21-2)

3 1

4

5

7

912 Nm

6 8 812 Nm 19 Nm

2

29 Nm

Release cylinder push rod 15 Nm

Release fork

7, 8

Specified grease: MITSUBISHI genuine grease Part No. 0101011

Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Reservoir hose 4. Clutch master cylinder

Clutch release cylinder removal steps 5. Clutch pipe connection 6. Clutch release cylinder Clutch line removal steps 7. Clutch pipe 8. Clutch hose 9. Bracket 10. Clutch hose

21-6

CLUTCH - Clutch Control

3 1

4

5

7

2 9

12 Nm

7

6

812 Nm 19 Nm

Release cylinder push rod 15 Nm

Release fork

8

Specified grease: MITSUBISHI genuine grease Part No. 0101011

Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Reservoir hose 4. Clutch master cylinder

Clutch release cylinder removal steps 5. Clutch pipe connection 6. Clutch release cylinder Clutch line removal steps 7. Clutch pipe 8. Bracket 9. Clutch hose

CLUTCH - Clutch Control DISASSEMBLY AND REASSEMBLYCLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly.

21-721100210172

612 Nm

5

2

9 3 1 4

612 Nm

5

2

9 3 1 4

844 Nm

7

2

1

4

2 2

3Piston repair kit Disassembly steps 1. Piston stopper ring 2. Piston assembly "AA 3. Push rod assembly 4. Boot 5. Spring pin Clutch fluid: Brake fluid DOT3 or DOT4 Grease: Rubber grease

6. 7. 8. 9.

Nipple Gasket Damper assembly Master cylinder body

21-8

CLUTCH - Clutch Control INSTALLATION SERVICE POINT"AA PUSH ROD ASSEMBLY INSTALLATION Set the length of the push rod assembly to the shown dimension to make the adjustment of clutch pedal easier. 103 mm 121 mm

22-1

MANUAL TRANSMISSIONCONTENTSLUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3Transmission Oil Check . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission Oil Change . . . . . . . . . . . . . . . . . . . . . 3 Transfer Oil Check .