2005 MITSUBISHI AIRTREK Service Repair Manual

00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 00-2
HOW TO USE
TROUBLESHOOTING/INSPECTION
SERVICE POINTS . . . . . . . . . . . . . . . 00-6
VEHICLE IDENTIFICATION . . . . . . . 00-16
GENERAL DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . . 00-20
PRECAUTIONS BEFORE SERVICE. 00-22
SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). . . . . . . . . . . . . . . . . . 00-27
SRS SERVICE PRECAUTIONS . . . . . 00-28
SUPPORT LOCATIONS FOR LIFTING
AND JACKING . . . . . . . . . . . . . . . . . . 00-31
STANDARD PART/TIGHTENING-
TORQUE TABLE . . . . . . . . . . . . . . . . 00-33

HOW TO USE THIS MANUAL
GENERAL00-2
M1001000100660
SCOPE OF MAINTENANCE, REPAIR AND
SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components. For
detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
"On-vehicle Service" is procedures for performing
inspections and adjustments of particularly important
locations with regard to the construction and for
maintenance and servicing, but other inspection (for
looseness, play, cracking, damage, etc.) must also
be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
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.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
• If a DANGER is not followed, the result is severe
bodily harm or even death.
• If a WARNING is not followed, the result could be
bodily injury.
• If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.
INDICATION OF TIGHTENING TORQUE
Tightening torques (units: N⋅m) are set to take into
account the central value and the allowable
tolerance. The central value is the target value, and
the allowable tolerance provides the checking range
for tightening torques. If bolts and nuts are not
provided with tightening torques, refer to P.00-33.
MODEL INDICATIONS
The following abbreviations are used in this manual
for identification of model types.
MPI::Indicates the multipoint injection.
SOHC::Indicates an engine with the single overhead
camshaft.
DOHC::Indicates an engine with the double
overhead camshaft.
2000:: Indicates models equipped with the 2,000 mL
<4G63> petrol engine.
2400::Indicates models equipped with the 2,400 mL
<4G69> petrol engine.
M/T:: Indicates the manual transmission.
A/T:: Indicates the automatic transmission.
A/C:: Indicates the air conditioner.

GENERAL 00-3
NOTES

GENERAL00-4
<<A>>
>>A<<
(s
.
disassembly.
or reassembly.
Symbols are used to show the locations for lubrication
.
These symbols are included in the diagram of compo-
nent parts or on the page following the component
parts page. The symbols do not always have accomp-
anying text to support that symbol.
Multi-purpose grease unless there is a
AC301960

GENERAL 00-5
parts sets are
On removal,
For bolts and nuts which do
not have a tightening torque
listed, refer to the "Standard
Parts tightening-torque Table"
reassembly are described
AC300860

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
GENERAL00-6
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
M1001000200582
CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the MUT-II/III can be used follows the basic outline
described below. Even in systems for which the MUT-II/III cannot be used, some of these systems still follow
this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is required, the details of such differences or additions will also
be listed.
Diagnosis method
2. SYSTEM OPERATION AND SYMPTOM
VERIFICATION TESTS
If verification of the symptom(s) is difficult,
procedures for checking operation and verifying
symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the
"Diagnosis function " section are described.
4. DIAGNOSIS CODE CHART
Diagnostic trouble codes and diagnostic items are
shown.
5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to
each diagnosis code (Refer to How to read
inspection procedure ).
AC300864AC
Gathering information
from the customer.
Check trouble symptom.
Read the diagnosis code. Read the diagnosis code.
Refer to the INSPECTION CHART
FOR TROUBLE SYMPTOMS
(Refer to applicable group.)
Refer to the INSPECTION CHART
FOR DIAGNOSIS CODES
(Refer to applicable group.)
INTERMITTENT MALFUNCTIONS
After taking note of the
malfunction code, erase the
diagnosis code memory.
Recheck trouble symptom.
Read the diagnosis codes.
Reoccurs Does not reoccur
Diagnosis code
displayed.
Diagnosis code
displayed.
Diagnosis code
displayed.
No diagnosis code
or communication
with MUT-II/III not
possible
No diagnosis
code.
No diagnosis
code.

GENERAL 00-7
6. TROUBLE SYMPTOM CHART
If there are trouble symptoms even though the
MUT-II/III does not find any diagnosis codes,
Inspection procedures for each trouble symptom will
be found by means of this chart.
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptoms classified in the Symptom Chart
(Refer to How to read inspection procedure P.00-9).
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgment values have
been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors,
inspection items, and judgment values have been
provided in this chart as reference information.
10. INSPECTION PROCEDURE BY USING AN
OSCILLOSCOPE
When there are inspection procedures using an
oscilloscope, these are described here.
DIAGNOSIS FUNCTION
HOW TO READ DIAGNOSIS CODE
CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>
Connect the MUT-II to the diagnosis connector, and
read the diagnosis code.
<Using the MUT-III>
Connect the MUT-III to the 16-pin diagnosis
connector, and read the diagnosis code.
NOTE: For details on how to use the MUT-III, refer to
the "MUT-III operation manual."
1. Ensure that the ignition switch is at the
"LOCK" (OFF).
2. Start up the personal computer.
3. Connect MUT-III USB cable MB991827 to
special tool Vehicle Communication Interface
(V.C.I.) MB991824 and the personal
computer.
4. Connect MUT-III main harness B MB991911
to the V.C.I.
5. Connect MUT-III main harness B to the
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON"
position.
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green
colour.
7. Start the MUT-III system on the PC and turn
the ignition switch to the "ON" position.
8. Read the diagnosis code.
9. Disconnecting the MUT-III is the reverse of
the connecting sequence, making sure that
the ignition switch is at the "LOCK" (OFF).
AC300830
Steering shaft
MUT-II
AC
<Using the MUT-II>
AC308915AC
MB991911
16-PIN
MB991827
MB991824
<Using the MUT-III>

GENERAL00-8
NOTE: The ABS warning lamp may flash when the
ignition switch is turned ON with the MUT-II/III
connected. This is because the diagnosis display
function of the ABS warning lamp is activated by
grounding the diagnosis connector terminal No.1,
and is not detrimental in any way.
ERASING DIAGNOSIS CODE (BY USING THE
MUT-II/III)
CAUTION
(OFF) position.
Connect the MUT-II/III to the diagnosis connector,
and erase the diagnosis code. The procedure is the
same as "HOW TO READ DIAGNOSIS CODE ".
ERASING DIAGNOSIS CODE (BY USING NO
MUT-II/III)
CAUTION
Some diagnosis codes can not be erased
according to the procedure below. If you attempt
to erase a diagnosis code, refer to an applicable
GROUP.
1. Turn the ignition switch to the "LOCK" (OFF)
position.
2. Disconnect the negative battery cable, wait for at
least 10 minutes, and then reconnect it.
3. Start the engine and let it run at idle for 10
minutes.
INPUT SIGNAL CHECK (WHEN USING THE
MUT-II/III) <SWS>
CAUTION
(OFF) position.
AC300830
Steering shaft
MUT-II
AC
<Using the MUT-II>
AC308915AC
MB991911
16-PIN
MB991827
MB991824
<Using the MUT-III>
AC300830
Steering shaft
MUT-II
AC
<Using the MUT-II>
AC308915AC
MB991911
16-PIN
MB991827
MB991824
<Using the MUT-III>

GENERAL 00-9
1. Connect the MUT-II/III to the diagnosis connector,
and erase the diagnosis code.
2. If the MUT-II/III buzzer sounds once when each
switch is operated (ON/OFF), the input signal for
that switch circuit system is normal.
INPUT SIGNAL CHECK (WHEN USING A
VOLTMETER) <SWS>
1. Use the special tool diagnosis code check
harness (MB991529) to connect the ETACS
terminal (terminal 9) and the earth terminals
(terminals 4 and 5) of the diagnosis connector to
the voltmeter.
2. If the needle of the voltmeter flickers once when
each switch is operated (ON/OFF), the input
signal for that switch circuit system is normal.
HOW TO USE THE INSPECTION
PROCEDURES
The causes of many of the problems occurring in
electric circuitry are generally the connectors,
components, the ECU, the wiring harnesses
between connectors, in that order. These inspection
procedures follow this order. They first try to discover
a problem with a connector or a defective
component.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC300831AB
Steering shaft
MB991529

GENERAL00-10
AC301964AB
Relevant circuit(s) of the component which
the Code No. indicates are described.

GENERAL 00-11
HARNESS CHECK
Check for an open or short circuit in the harness
between the terminals which were faulty according to
the connector measurements. Carry out this
inspection while referring to the Electrical Wiring
Manual. Here, "Check the wiring harness between
the power supply and terminal xx" also includes
checking for blown fuse. For inspection service
points when there is a blown fuse, refer to
"Inspection Service Points for a Blown Fuse ."
MEASURES TO TAKE AFTER REPLACING THE
ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection
procedure from the beginning.
CONNECTOR MEASUREMENT SERVICE
POINTS
Turn the ignition switch to the "LOCK" (OFF) position
when connecting and disconnecting the connectors.
Turn the ignition switch to "ON" when measuring,
unless there are instructions to the contrary.
IF INSPECTING WITH THE CONNECTOR
CONNECTED
<Waterproof Connectors>
Be sure to use special tool harness connector
(MD998459). Never insert a test probe from the
harness side, as this will reduce the waterproof
performance and result in corrosion.
AC301965AB
Explains about the basic
operation of the components.
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Start of diagnosis
procedure
Describes possible
causes(s) for that
diagnosis code.
Describes
inspection
procedure.
AC300881AB
MD998459

GENERAL00-12
<Ordinary (non-waterproof) Connectors>
Check by inserting the multi-meter test probe from
the harness side. Note that if the connector (control
unit, etc.) is too small to permit insertion of the test
probe, it should not be forced; use the backprobing
tool for this purpose.
IF INSPECTING WITH THE CONNECTOR
DISCONNECTED
<When Inspecting a Female Pin>
Use the special tool inspection harness (MB991219)
(inspection harness for connector pin contact
pressure in the harness set for inspection). The
inspection harness for connector pin contact
pressure should be used. the test bar should never
be forcibly inserted, as it may cause a defective
contact.
<When Inspecting a Male Pin>
CAUTION
At this time, be careful not to short the connector
pins with the test bars. To do so may damage the
circuits inside the ECU.Touch the pin directly
with the test bar.
AC300882AB
Connector
ACX00865AB
MB991219
AC300890

GENERAL 00-13
CONNECTOR INSPECTION SERVICE
POINTS
VISUAL INSPECTION
•
Connector is disconnected or improperly connected
• Connector pins are pulled out
• Due to harness tension at terminal section
• Low contact pressure between male and female
terminals
• Low connection pressure due to rusted terminals
or foreign matter lodged in terminals
CONNECTOR PIN INSPECTION
If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be
perfect even if the connector body is connected, and
the pins may pull out of the reverse side of the
connector. Therefore, gently pull the harnesses one
by one to make sure that no pins pull out of the
connector.
CONNECTOR ENGAGEMENT INSPECTION
Use the special tool inspection harness (MB991219)
(connector pin connection pressure inspection
harness of the inspection harness set) to inspect the
engagement of the male pins and females pins. (Pin
drawing force: 1 N or more)
AC300896AB
Connector disconnected or
improperly connected
Stretched or broken wires
Low contact
pressure
Harness wire breakage
at terminal section
Good
Bad
AC300898
AC300899AB
MB991219

GENERAL00-14
INSPECTION SERVICE POINTS FOR A
BLOWN FUSE
Remove the blown fuse and measure the resistance
between the load side of the blown fuse and the
earth. Close the switches of all circuits which are
connected to this fuse. If the resistance is almost 0 Ω
at this time, there is a short somewhere between
these switches and the load. If the resistance is not 0
Ω, there is no short at the present time, but a
momentary short has probably caused the fuse to
blow.
The main causes of a short circuit are the following.
• Harness being clamped by the vehicle body
• Damage to the outer casing of the harness due to
wear or heat
• Water getting into the connector or circuitry
• Human error (mistakenly shorting a circuit, etc.)
AC300900AB
Battery
Fuse
Load
switch
Load
Short-circuit
occurrence
section

GENERAL 00-15
HOW TO COPE WITH INTERMITTENT
MALFUNCTIONS
NOTE: If determining the cause is difficult, the flight
recorder function of the MUT-II/III can also be used.
Intermittent malfunctions often occur under certain
conditions, and if these conditions can be
ascertained, determining the cause becomes simple.
In order to ascertain the conditions under which an
intermittent malfunction occurs, first ask the
customer for details about the driving conditions,
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the
trouble symptoms. Next, ascertain whether the
reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or
some other factor. If vibration is thought to be the
cause, carry out the following checks with the
connectors and components to confirm whether the
trouble symptom occurs. The objects to be checked
are connectors and components which are indicated
by inspection procedures or given as probable
causes (which generates diagnosis codes or trouble
symptoms).
• Gently shake the connector up, down and to the
left and right.
• Gently shake the wiring harness up, down and to
the left and right.
• Gently rock each sensor and relay, etc. by hand.
• Gently shake the wiring harness at suspensions
and other moving parts.
AC300901

VEHICLE IDENTIFICATION
GENERAL00-16
M1001000400713
VEHICLE IDENTIFICATION CODE PLATE
The vehicle information code plate is riveted to the
back of the hood.
The plate shows model code, engine model,
transmission model and body colour code.
For monotone colour vehicles, the body colour code
shall be indicated.
MODELS
AC301477AB
1
2
3
45 6 7
No. Item Content
1 MODEL CU2WXNMM
L6
CU2W:
Vehicle model
XNMML6:
Model series
2 ENGINE 4G63 Engine model
3 EXT W83A Exterior code
4 TRANS AXLE F5M42 F5M42:Trans
mission
model
5 COLOUR W83 W83: Body
colour code
6 INT 62A 62A: Interior
code
7 OPT ZP3 ZP3:
Equipment
code
Model code Engine model Price class Transmission
model
Fuel supply
system
CU2W XNMML6 4G63-DOHC (1,997
mL)
Comfort F5M42
<2WD, 5M/T>
MPI
XNMMZL6 W5M42
<4WD, 5M/T>XNHMZL6 Sport
CU5W XNMYZL6 4G69-SOHC MIVEC
(2,378 mL)
Comfort W5M42
<4WD, 5M/T>
XRMYZL6 W4A42
<4WD, 4A/T with
sport mode>
XRMYZR6
XNHYZL6 Sport W5M42
<4WD,5M/T>
XRHYZL6 W4A42
<4WD, 4A/T with
sport mode>
XRHYZR6

GENERAL 00-17
MODEL CODE
CU 2 W LZX N M M 6
AC301363
1 2 3 4 5 6 7 8 9 10
AB
No. Item Content
1 Development CU: MITSUBISHI
OUTLANDER
2 Engine type 2: 1,997 mL petrol engine
5: 2,378 mL petrol engine
3 Sort W: Wagon
4 Body style X: 5-door hatchback
5 Transmission
type
N: 5-speed manual
transmission
R: 4-speed automatic
transmission
6 Trim level M: COMFORT
H: SPORT
7 Specification
engine feature
M: MPI-DOHC
Y: MPI-SOHC MIVEC
8 Special feature None: 2WD
Z: 4WD
9 Steering wheel
location
L: Left hand
R: Right hand
10 Destination 6: For Europe

GENERAL00-18
CHASSIS NUMBER The chassis number is stamped on the toeboard
inside the engine compartment.
AC300903AB
J M B X CU 2 W 4 U 000001N
AC309285AB
1 2 3 4 5 6 7 8 9 10 11
No. Item Content
1 Fixed figure J Asia
2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
B For Europe, left hand drive
4 Body style X 5-door hatchback
5 Transmission type N 5-speed manual transmission
R 4-speed automatic transmission
6 Development order CU OUTLANDER
7 Engine 2 1,997 mL petrol engine
5 2,378 mL petrol engine
8 Soft W Station wagon
9 Model year 4 2004
10 Plant U Mizushima
11 Serial number − −

GENERAL 00-19
ENGINE MODEL STAMPING The engine model is stamped on the cylinder block.
This engine model numbers are shown as follows.
The engine serial number is stamped near the
engine model number.
AC300905
<4G63>
AD
Front of the
vehicle
AC309481AB
<4G69>
Front of the vehicle
Engine model Engine displacement
4G63 1,997 mL
4G69 2,378 mL

GENERAL DATA AND SPECIFICATIONS
GENERAL00-20
M1001000900558
NOTE: *: Vehicles with roof rails
AC300072AB
1
2
7
3 4
6
5
8
9
Items CU2W
XNMML6 XNMMZL6 XNHMZL6
Vehicle
dimensions mm
Front track 1 1,495
Overall width 2 1,750
Front overhang 3 945
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,545
Ground clearance (unladen) 7 195
Overall height (unladen) 8 1,620/1,670*
Rear track 9 1,505
Vehicle weight kg Kerb weight 1,435 1,540
Max. gross vehicle weight 1,970 2,070
Max. axle weight rating-front 1,050
Max. axle weight rating-rear 1,065
Max. trailer weight With brake 1,500
Without brake 570
Max. trailer-nose weight 75
Seating capacity 5
Engine Model code 4G63
Total displacement mL 1,997
Transmission Model code F5M42 W5M42
Type 5-speed manual
Fuel system Fuel supply system MPI

GENERAL 00-21
NOTE: *: Vehicles with roof rails
Items CU5W
XNMYZL6 XRMYZL6/R
6
XNHYZL6 XRHYZL6/R
6
Vehicle
dimensions
mm
Front track 1 1,495
Overall width 2 1,750
Front overhang 3 945
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,545
Ground clearance (unladen) 7 195
Overall height (unladen) 8 1,620/1,670*
Rear track 9 1,505
Vehicle
weight kg
Kerb weight 1,540 LHD: 1,560,
RHD: 1,565
1,540 LHD: 1,560,
RHD: 1,565
Max. gross vehicle weight 2,070
Max. axle weight rating-front 1,050
Max. axle weight rating-rear 1,065
Max. trailer weight With brake 1,500
Without
brake
570
Max. trailer-nose weight 75
Seating capacity 5
Engine Model code 4G69
Transmission Model code W5M42 W4A42 W5M42 W4A42
Type 5-speed
manual
4-speed
automatic
5-speed
manual
4-speed
automatic
Fuel system Fuel supply system MPI

PRECAUTIONS BEFORE SERVICE
GENERAL00-22
M1001000500538
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)
CAUTION
Items to review when servicing SRS:
1. Be sure to read GROUP 52B − Supplemental
Restraint System (SRS). For safe operation,
please follow the directions and heed all
warnings.
2. Wait at least 60 seconds after disconnecting
the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.
3. Warning labels must be heeded when
servicing or handling SRS components.
Warning labels can be found in the following
locations.
• Front impact sensor
• Hood
• Sun visor
• Glove box
• SRS-ECU
• Steering wheel
• Clock spring
• Steering joint cover
• Air bag module (Driver's or front
passenger's)
• Side air bag module (Driver's side or front
passenger's side)
• Side impact sensor
• Seat belt pre-tensioner
• Instrument panel
4. Always use the designated special tools and
test equipment.
5. Store components removed from the SRS in a
clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward. Do
not place anything on top of it.
6. Never attempt to disassemble or repair the
SRS components (SRS-ECU, air bag module
and clock spring).
7. Whenever you finish servicing the SRS, check
the SRS warning lamp operation to make sure
that the system functions properly.
8. Be sure to deploy the air bag before
disposing of the air bag module or disposing
of a vehicle equipped with an air bag (Refer to
GROUP 52B − Air Bag Module Disposal
Procedures).
Observe the following when carrying out
operations on places where SRS components are
installed, including operations not directly
related to the SRS air bag.
1. When removing or installing parts, do not
allow any impact or shock to the SRS
components.
2. If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt
pre-tensioner.
• SRS-ECU, air bag module, clock spring,
front impact sensor, the side impact
sensor: 93 °C or more
• Seat belt pre-tensioner: 90 °C or more

GENERAL 00-23
INITIALIZATION PROCEDURE FOR
LEARNING VALUE IN MPI ENGINE
Initialization Procedure
1. After the ignition switch is in "LOCK" (OFF)
position, connect MUT-II/III with the diagnosis
connector.
2. Select the item on the screen of the initialization
for learning, and perform the initialization.
NOTE: *1
: Initialize A/T-related learning value.
NOTE: *2
: After initializing the learning value, the
idling learning in MPI engine is required (Refer to
LEARNING PROCEDURE FOR IDLING IN MPI
ENGINE).
NOTE: *3: The datum items on MUT-II/III display are
shown, but do not use them.
LEARNING PROCEDURE FOR IDLING IN
MPI ENGINE
Purpose
When the engine-ECU <M/T> or the
engine-A/T-ECU <A/T> is replaced, or when the
learning value is initialized, the idling is not stabilized
because the learning value in MPI engine is not
completed. In this case, carry out the learning
method for the idling through the following
procedures.
Learning Procedure
1. Start the engine and carry out the warm-up for the
engine coolant temperature to reach 80°C or
more.
2. When the engine coolant temperature is 80°C or
more, the warm-up is not needed if the ignition
switch is in "ON" position once.
3. Place the ignition switch in "LOCK" (OFF) position
and stop the engine.
4. After 10 seconds or more, start the engine again.
5. For 10 minutes, carry out the idling under the
condition shown below and then confirm the
engine has the normal idling.
• Transmission: Neutral (A/T: "P" range)
• Operation in ignition-related, fan and
attachments: Not to be operated
• Engine coolant temperature: 80°C or more
NOTE: When the engine stalls during the idling,
check the dirtiness (on the throttle valve) of the
throttle body and then perform the service from
Procedure 1 again.
Service Item
At replacing engine
assembly *1,
*2
All ranges
− *3 Misfire-related
At replacing injector and
at cleaning *2
Learning value for
air/fuel ratio
At replacing throttle body
and at cleaning *2
Idle speed
control-related
At replacing detonation
sensor
Learning value for
knocking

GENERAL00-24
SERVICING ELECTRICAL SYSTEM
CAUTION
Before connecting or disconnecting the negative
(−) cable, be sure to turn off the ignition switch
and the lighting switch (If this is not done, there
is the possibility of semiconductor parts being
damaged).
Before replacing a component related to the
electrical system and before undertaking any repair
procedures involving the electrical system, be sure to
first disconnect the negative (−) cable from the
battery in order to avoid damage caused by
short-circuiting.
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine
inspection can be carried out. If you see the words
"Set the vehicle to the pre-inspection condition". In
this manual, it means to set the vehicle to the
following condition.
• Engine coolant temperature 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
• A/T: P range
VEHICLE WASHING
If high-pressure car-washing equipment or steam
car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
avoid damage to plastic components, etc.
• Spray nozzle distance: Approx. 40 cm or more
• Spray pressure: 3,900 kPa or less
• Spray temperature: 82°C or less
• Time of concentrated spray to one point: within
30 sec.
AC300693
AC300832AB
Approximately 40 cm

GENERAL 00-25
MUT-II/III
Refer to the "MUT-II REFERENCE MANUAL",
"MUT-II OPERATING INSTRUCTIONS" or "MUT-III
OPERATION MANUAL" for instructions on handling
the MUT-II/III.
AC300834AB
MUT-II Sub-assembly
Rom pack
AC305090
MB991910
MB991826
MB991911
MB991825
MB991824
MB991827
AB
Vehicle communication interface (V.C.I.)
MUT-III main harness A
MUT-III USB cable
MUT-III main harness B
MUT-III measurement adapter
MUT-III trigger harness
Do not used
MUT-III sub assembly

GENERAL00-26
CAUTION
Turn the ignition switch to the "LOCK" (OFF)
position before connecting or disconnecting the
MUT-II/III.
Connect the MUT-II/III to the diagnosis connector as
shown in the illustration.
IN ORDER TO PREVENT VEHICLES
FROM FIRE
"Improper installation of electrical or fuel related parts
could cause a fire. In order to retain the high quality
and safety of the vehicle, it is important that any
accessories that may be fitted or
modifications/repairs that may be carried out which
involve the electrical or fuel systems, MUST be
carried out in accordance with MMC's
information/Instructions".
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
• Wear protective clothing, including impervious
gloves where practicable.
• Avoid contaminating clothes, particularly
underpants, with oil.
• Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
• Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from
personal clothing.
• Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
• Obtain First Aid treatment immediately for open
cuts and wounds.
• Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
• Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
• Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
• If skin disorders develop, obtain medical advice
without delay.
AC300830
Steering shaft
MUT-II
AC
<Using the MUT-II>
AC308915AC
MB991911
16-PIN
MB991827
MB991824
<Using the MUT-III>

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
GENERAL 00-27
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
M1001009800020
The Supplemental Restraint System (SRS) and seat
belt with pre-tensioner is designed to supplement the
driver's and front passenger's seat belts to help
reduce the risk or severity of injury to the driver and
front passenger by activating and deploying both
front air bags in certain frontal collisions.
The SRS consist of four air bag modules, SRS air
bag control unit (SRS-ECU), two front impact
sensors, two side impact sensors, SRS warning
lamp, clock spring and seat belt pre-tensioner. Front
air bags are located in the centre of the steering
wheel and above the glove box. Side air bag are
located inside the front seatback assemblies. Each
air bag is made up of a folded air bag and an inflator
unit. The SRS-ECU under the front floor console
monitors the system and has a front air bag safing
G-sensor, front air bag analog G-sensor and a side
air bag safing G-sensor. The front impact sensor is
assembled outside the headlamp support panel to
monitor impact in case of front impact. The side
impact sensors inside the centre pillars monitor the
shock incurred by the sides of the vehicle. The
warning lamp on the instrument panel indicates the
operational status of the SRS. The clock spring is
installed in the steering column. The seat belt
pre-tensioner is built into the driver's and
passenger's front seat belt retractor.
Only authorized service personnel should do work on
or around the SRS components. Those service
personnel should read this manual carefully before
starting any such work.
AC301343
SRS warning lamp
Driver's air bag
module
Clock spring
Passenger's (front)
air bag module
Side air bag module
Side impact sensor
Side air bag module
Side impact sensor
Front impact sensor
SRS-ECU
Seat belt with pre-tensioner
AB

SRS SERVICE PRECAUTIONS
GENERAL00-28
M1001006000047
DANGER
In order to avoid injury to yourself or others
from accidental deployment of the air bag
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-9.
CAUTION
Never Attempt to Repair the Following
Components:
1. SRS air bag control unit (SRS-ECU)
2. Front impact sensor
3. Clock spring
4. Driver's and front passenger's air bag
modules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE
procedures in this manual, starting at page
P.52B-174.
CAUTION
Do not attempt to repair the wiring harness
connectors of the SRS. If a defective wiring
harness is found, repair or replace it by referring
to the table below.
AC300634
SRS-ECU connector
AB
SRS-ECU terminal No. Destination of harness Remedy
1, 2 Instrument panel wiring harness →
Front wiring harness (RH) → Front
impact sensor (RH)
Correct or replace each wiring
harness.
Front wiring harness (LH) → Front
impact sensor (LH)
Correct or replace each wiring
harness.
7 Instrument panel wiring harness→
Earth
Correct or replace the instrument
panel wiring harness.
8 Instrument panel wiring harness →
SRS warning lamp
Air bag module (Front passenger's
side)
Clock spring → Air bag module
(Driver's side)
Correct or replace instrument panel
wiring harness. Replace the clock
spring.
Junction block (fuse No.3)

GENERAL 00-29
DANGER
After disconnecting the battery cable, wait 60
seconds or more before proceeding with the
following work. In addition, insulate the
negative battery terminal with a tape. The
condenser inside the SRS-ECU is designed
to retain enough voltage to deploy the air
bag for a short time even after the battery
has been disconnected, so serious injury
may result from unintended air bag
deployment if work is done on the SRS
system immediately after the battery cables
are disconnected.
Junction block (fuse No.2)
Diagnosis connector
21, 22 Floor wiring harness (RH) → Side air
bag module (LH)
Correct or replace the floor wiring
harness.
23, 24 Floor wiring harness (RH) → Side air
bag module (RH)
Correct or replace the floor wiring
harness.
27, 28 Floor wiring harness (RH) → Seat
belt pre-tensioner (Front
passenger's side)
Connect or replace the floor wiring
harness.
29, 30 Floor wiring harness (LH) → Seat
belt pre-tensioner (driver's side)
harness.
34, 36 Floor wiring harness (LH) → Side
impact sensor (LH)
harness.
40, 42 Floor wiring harness (RH) → Side
impact sensor (RH)
harness.
SRS-ECU terminal No. Destination of harness Remedy
AC300580AB
Insulating tape
Battery
Battery cable

GENERAL00-30
CAUTION
The SRS components and seat belt with
pre-tensioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and front
passenger’s air bag modules, clock spring, side
air bag modules, and seat belt pre-tensioner
before drying or baking the vehicle after painting.
• SRS-ECU, air bag modules, clock spring,
impact sensors: 93°C or more
• Seat belt with pre-tensioner 90°C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
CAUTION
If checks are carried out by using the SRS-ECU
harness connector, observe the following
procedures: Insert the special tool (probe in the
harness set) MB991222 into connector from
harness side (rear side), and connect the tester
to this probe. If any tool than special tool is used,
damage to the harness and other components
will result. Never insert the probe directly to the
terminals from the front of the connector. The
terminals are plated to increase their
conductivity, so that if they are touched directly
by the probe, the plating may break, which will
cause drops in reliability.
AC300673AB
SRS-Harness connector
SRS-ECU harness connector
(rear side)

SUPPORT LOCATIONS FOR LIFTING AND JACKING
GENERAL 00-31
M1001000700093
SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR
DOUBLE-POST LIFT AND PLATE TYPE LIFT
CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
GARAGE JACK
CAUTION
Never support any point other than the specified one, or that point will be deformed.
AC300835
<2WD> <4WD>Rear suspension crossmember Rear differential

GENERAL00-32
AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT
CAUTION
• If rubber attachments with grooves that are too thick are used at the front support positions, the
front fender may become bent, so be sure to use rubber attachments with groove thicknesses of
18 mm or less.
• If attachments which are not high enough are used, they may damage areas such as the side step.
Be sure to use attachments which are high enough, or remove the side step if not using
attachments.
AC300836AB
AXLE STANDS
SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Bolts Bolts
Bolts Bolts
Rubber
Rubber

STANDARD PART/TIGHTENING-TORQUE TABLE
GENERAL 00-33
PLATE TYPE LIFT
CAUTION
To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
Support the side sill flange with a lift.
STANDARD PART/TIGHTENING-TORQUE TABLE
M1001001100362
Each torque value in the table is a standard value for
tightening under the following conditions.
1. Bolts, nuts and washers are all made of steel and
plated with zinc.
2. The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
1. If toothed washers are inserted.
2. If plastic parts are fastened.
3. If bolts are tightened to plastic or die-cast
inserted nuts.
4. If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Flange bolt and nut tightening torque
NOTE: .
• Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
• Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the
bolt strength.
Thread size Torque N⋅m
Bolt nominal
diameter (mm)
Pitch
(mm)
Head mark "4" Head mark "7" Head mark "8"
M5 0.8 2.5 ± 0.5 5.0 ± 1.0 6.0 ± 1.0
M6 1.0 5.0 ± 1.0 9.0 ± 2.0 10 ± 2
M8 1.25 12 ± 2 22 ± 4 25 ± 4
M10 1.25 24 ± 4 44 ± 10 53 ± 7
M12 1.25 41 ± 8 83 ± 12 98 ± 12
M14 1.5 73 ± 12 140 ± 20 155 ± 25
M16 1.5 110 ± 20 210 ± 30 235 ± 35
M18 1.5 165 ± 25 300 ± 40 340 ± 50
M20 1.5 225 ± 35 410 ± 60 480 ± 70
M22 1.5 300 ± 40 555 ± 85 645 ± 95
M24 1.5 395 ± 55 735 ± 105 855 ± 125
Thread size Torque N⋅m
Bolt nominal
diameter (mm)
Pitch
(mm)
Head mark "4" Head mark "7" Head mark "8"
M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2
M8 1.25 13 ± 2 24 ± 4 27 ± 5
M10 1.25 26 ± 4 49 ± 9 58 ± 7
M10 1.5 24 ± 4 45 ± 8 55 ± 10
M12 1.25 46 ± 8 95 ± 15 105 ± 15
M12 1.75 43 ± 8 83 ± 12 98 ± 12

11A-1
GROUP 11A
ENGINE
MECHANICAL
CONTENTS
GENERAL INFORMATION . . . . . . . . 11A
SERVICE SPECIFICATIONS. . . . . . . 11A
SEALANTS . . . . . . . . . . . . . . . . . . . . 11A
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A
ON-VEHICLE SERVICE. . . . . . . . . . . 11A
DRIVE BELT TENSION CHECK. . . . . . . . . 11A
AUTO-TENSIONER CHECK . . . . . . . . . . . 11A
IGNITION TIMING CHECK. . . . . . . . . . . . . 11A
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A
COMPRESSION PRESSURE CHECK. . . . 11A
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A
CRANKSHAFT PULLEY . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . . 11A
CAMSHAFT AND VALVE STEM
SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . 11A
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION 2WD. . 11A
REMOVAL AND INSTALLATION 4WD. . 11A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A
CRANKSHAFT OIL SEAL . . . . . . . . . 11A
CYLINDER HEAD GASKET. . . . . . . . 11A
TIMING BELT . . . . . . . . . . . . . . . . . . . 11A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A
00
11
12
13
14
15
16
17
21
22
25
26
27
31
32
33
34
35
36
37
51
52
42
54
55

GENERAL INFORMATION
ENGINE MECHANICAL
11A-2
GENERAL INFORMATION
M1111000100356
SERVICE SPECIFICATIONS
M1112000300234
Item 4G63
Bore ™ Stroke mm 85 ™ 88
Compression ratio 10.0
Compression chamber Pentroof
Camshaft arrangement DOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake opening BTDC 17•
Intake closing ABDC 51•
Exhaust opening BBDC 57•
Exhaust closing ATDC 13•
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
Auto-lash adjuster Equipped
Item Standard value Limit
Drive belt tension Vibration frequency Hz
(Reference)
110 - 144 -
Tension N (Reference) 245 - 412 -
Basic ignition timing 5• BTDC – 2• -
Ignition timing Approximately
10• BTDC
-
Idle speed r/min 750 – 100 -
CO contents % 0.5 or less -
HC contents ppm 100 or less -
Compression pressure kPa-r/min 1,370 - 250 930 - 250
Compression pressure difference of all cylinders kPa - Maximum 98
Intake manifold vacuum kPa - Minimum 60
Cylinder head bolt nominal length mm - 99.4
Balancer timing belt tension (When
adjusted)
Deflection mm 5 - 7 -
replaced)

SEALANTS
ENGINE MECHANICAL
11A-3
SEALANTS
M1112000500238
SPECIAL TOOLS
M1112000600279
checked)
Timing belt tensioner adjuster rod protrusion amount mm 3.8 - 4.5 -
Timing belt tensioner adjuster rod movement mm Within 1 -
Item Standard value Limit
Item Specified Sealant Remark
Cylinder head MITSUBISHI GENUINE PART MD970389 or
equivalent
Semi-drying
sealantCamshaft position sensor support
Rocker cover
Camshaft end seal 3M ATD Part No.8660 or equivalent
Rocker cover gasket MITSUBISHI GENUINE PART MD970389 or
equivalentEngine oil pan 2WD
Engine upper oil pan 4WD
Engine lower oil pan 4WD
Tool Number Name Use
MB991502 MUT-II sub assembly œ Drive belt tension check
œ Checking the ignition timing
œ Checking the idle speed
MB991668 Belt tension meter set Drive belt tension check (used
together with MUT-II)
MD998772 Valve spring compressor Compressing valve spring
MD998737 Valve stem seal installer Valve stem seal installation
B991502
B991668
MD998772

SPECIAL TOOLS
ENGINE MECHANICAL
11A-4
MD998713 Camshaft oil seal installer Camshaft oil seal installation
MD998727 Oil pan remover Oil pan removal 2WD
MD998781 Flywheel stopper Supporting the flywheel
MB990938 Installer bar Crankshaft rear oil seal
installation
MD998776 Crankshaft rear oil seal
installer
MD998285 Crankshaft front oil seal
guide
Crankshaft front oil seal
installation
MD998375 Crankshaft front oil seal
installer
MB991654 Cylinder head bolt wrench
(12)
Removal and installation of
cylinder head bolt
D998713
D998727
D998781
B990938
D998776
D998285
B991654

SPECIAL TOOLS
ENGINE MECHANICAL
11A-5
MD998738 Adjusting bolt Supporting the timing belt
tensioner arm and timing belt
tensioner adjuster
MB991367 Special spanner Holding the crankshaft camshaft
drive sprocket
MB991385 Pin
MD998767 Tensioner wrench Valve timing belt tension
adjustment
D998738
B991367
B991385
D998767

ON-VEHICLE SERVICE
ENGINE MECHANICAL
11A-6
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100399
CAUTION
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.
1. Make sure that the indicator mark is within the
area marked with A in the illustration.
2. If the mark is out of the area, replace the drive
belt. (Refer to 311A.)
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.
MB991454 Engine hanger balancer When the engine hanger is used:
Supporting the engine assembly
during removal and installation of
the transmission assembly
NOTE: Special tool MB991454 is
a part of engine hanger
attachment set MB991453.MB991527 Hanger
MB991895 Engine hanger
MB991928
A: MB991929
B: MB991930
C: MB991931
D: MB991932
E: MB991933
F: MB991934
Engine hanger
A: Joint (50) ™ 2
B: Joint (90) ™ 2
C: Joint (140) ™ 2
D: Foot (standard) ™ 4
E: Foot (short) ™ 2
F: Chain and hook
assembly
B991454
B991527
Z203830
B991928
A
B
C
D
E
F
Slide bracket (HI)
AC107639AB
Indicator mark
A

ON-VEHICLE SERVICE
ENGINE MECHANICAL
11A-7
AUTO-TENSIONER CHECK
M1111003000154
OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to 311A.)
3. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
4. If there are any problems in the procedure 1 or 3,
replace the auto-tensioner.(Refer to 311A.)
5. Install the drive belt.(Refer to 311A.)
FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
When using MUT-II
1. Check the drive belt tension. (Refer to 311A.)
2. Measure the drive belt tension vibration frequency
by the following procedures:
CAUTION
To prevent damage to MUT-II, always turn the
ignition switch to the LOCK (OFF) position
before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
connector.
(3) Turn the ignition switch to ON position, and
select BELT TENSION on the menu screen.
AC107640AB
AC211862
16-pin
AB
MUT-II
MB991668

ON-VEHICLE SERVICE
ENGINE MECHANICAL
11A-8
CAUTION
œ The temperature of the surface of the belt
should be as close to normal temperature as
possible.
œ Do not allow any contaminants such as water
or oil to get onto the microphone.
œ If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
œ If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.
œ Do not take the measurement while the
vehicle’s engine is running.
(4) Hold special tool belt tension meter set
(MB991668) to the middle of the drive belt
between the pulleys (at the place indicated by
arrow), approximately 10 - 20 mm away from
the rear surface of the belt so that it is
perpendicular to the belt (within an angle of –
15 degree).
(5) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and
measure that the vibration frequency of the
belt is within the standard value.
Standard value: 110 - 144 Hz
3. If not within the standard value, replace the auto-
tensioner. (Refer to 311A.)
When using a tension gauge
1. Check the drive belt tension. (Refer to 311A.)
2. Use a belt tension gauge in the middle of the belt
between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
the standard value.
Standard value: 245 - 412 N
3. If not within the standard value, replace the auto-
tensioner.(Refer to 311A.)
IGNITION TIMING CHECK
M1111001700425
1. Before inspection, set the vehicle to the pre-
inspection condition.
2. Turn the ignition switch to the LOCK (OFF)
position and then connect the MUT-II to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Use the MUT-II to measure engine idle speed and
check that it is within the standard value.
Standard value: 750 – 100 r/min
6. Select No. 17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5• BTDC – 2•
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to 313A,
GROUP 13A - Troubleshooting - Inspection chart
for diagnosis code).
AC102806AB
MB991668
15˚
15˚
Gentry tap with
your finger
Water pump
pulley
Power steering
oil pump pulley
10 – 20 mm
AC102807AB
Belt tension gauge
Water pump
pulley
Power steering
oil pump pulley
AC102022
Y0195AU
AK000871
MUT-II
AC

ON-VEHICLE SERVICE
ENGINE MECHANICAL
11A-9
CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
condition may damage the engine.
9. Press the MUT-II clear key (Select a forced driving
cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
Standard value: approximately 10• BTDC
NOTE: .
œ The ignition timing may fluctuate within – 7•
BTDC. This is normal.
œ In higher altitude, the ignition timing is more
advanced than the standard value by
approximately 5•.
11.Remove the timing light.
12.Turn off the ignition switch and then remove the
MUT-II.
IDLE SPEED CHECK
M1111003500472
2. Turn the ignition switch to LOCK (OFF) position.
3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.
6. Check that ignition timing is at the standard value.
7. Check the idle speed.
NOTE: .
œ The idle speed is controlled automatically by
the idle speed control system.
œ When using the MUT-II, select item No. 22 and
take a reading of the idle speed.
8. If the idle speed is outside the standard value,
inspect the MPI system (Refer to 313A,
GROUP 13A - Troubleshooting - Inspection chart
for diagnosis code).
IDLE MIXTURE CHECK
M1111002100255
3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.
6. Check that ignition timing is at the standard value.
7. Run the engine at 2,500 r/min for 2 minutes.
8. Set the CO, HC tester.
9. Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
10.If there is a deviation from the standard value,
check the following items:
AC102022
Y0195AU
AK000871
MUT-II
AC
AK000899
Engine speed
ditection connector
AC
AC102022
Y0195AU
AK000871
MUT-II
AC
AK000899
Engine speed
ditection connector
AC

ON-VEHICLE SERVICE
ENGINE MECHANICAL
11A-10
œ Diagnosis output
œ Fuel pressure
œ Injector
œ Ignition coil, spark plug cable, spark plug
œ EGR control system
œ Evaporative emission control system
œ Compression pressure
NOTE: Replace the three way catalyst when the
CO and HC contents are not within the standard
value, even though the result of the inspection is
normal on all items.
COMPRESSION PRESSURE CHECK
M1111002600465
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE: Doing this will prevent the engine-ECUM/
T or engine-A/T-ECUA/T from carrying out
ignition and fuel injection.
CAUTION
œ Keep away from the spark plug hole when
cranking.
œ If compression is measured with water, oil,
fuel, etc., that has come from cracks inside
the cylinder, these materials will become
heated and will gush out from the spark plug
hole, which is dangerous.
5. Cover the spark plug hole with a shop towel etc.,
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
6. Set compression gauge to one of the spark plug
holes.
7. Crank the engine with the throttle valve fully open
and measure the compression pressure.
Standard value (at engine speed of 250 r/
min):
1,370 kPa
Limit (at engine speed of 250 r/min):
Minimum 930 kPa
8. Measure the compression pressure for all the
cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
9. If there is a cylinder with compression or a
compression difference that is outside the limit,
pour a small amount of engine oil through the
spark plug hole, and repeat the operations in
steps from (6) to (8).
(1) If the compression increases after oil is added,
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
surface.
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
10.Connect the crank angle sensor connector.
11.Install the spark plugs and spark plug cables.
12.Use the MUT-II to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.
MANIFOLD VACUUM CHECK
M1111002700417
3. Connect a tachometer or connect the MUT-II to
the diagnosis connector.
AK201364AC
Crank angle
sensor
connector
AC102022
Y0195AU
AK000871
MUT-II
AC
AK201369AB
Fuel pressure
regulator
Vacuum
gauge

ON-VEHICLE SERVICE
ENGINE MECHANICAL
11A-11
4. Attach a three-way joint to the vacuum hose
between the fuel pressure regurator and the air
intake plenum, and connect a vacuum gauge.
5. Start the engine and check that idle speed is
within the standard valve.
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
7. Turn off the ignition switch.
8. Remove the vacuum gauge and the three-way
joint, and then connect the vacuum hose.
9. Remove the engine tachometer or the MUT-II.
LASH ADJUSTER CHECK
M1111002900336
If an abnormal noise (knocking) that seems to be
coming from the lash adjuster is heard after starting
the engine and dose not stop, carry out the following
check.
NOTE: .
œ The abnormal noise which is caused by a
problem with the lash adjusters is generated after
the engine is started, and will vary according to
the engine speed. However, this noise is not
related to the actual engine load.
Because of this, if the noise dose not occur
immediately after the engine is started, if it dose
not change in accordance with the engine speed,
or if it changes in accordance with the engine
load, the source of the noise is not the lash
adjusters.
œ If there is a problem with the lash adjusters, the
noise will almost never disappear, even if the
engine has been run at idle to let it warm up.
The only case where the noise might disappear is if
the oil in the engine has not been looked after
properly and oil sludge has caused the lash
adjusters to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the
engine is started, and that the noise changes in
accordance with changes in the engine speed.
If the noise dose not occur immediately after the
engine is started, or if it dose not change in
accordance with the engine speed, the problem is
not being caused by the lash adjusters, so check
for some other cause of the problem. Moreover, if
the noise dose not change in accordance with the
engine speed, the cause of the problem is
probably not with the engine (In these cases, the
lash adjusters are normal).
3. While the engine is idling, check that the noise
level does not change when the engine load is
varied (for example, by shifting from N to D).
If the noise level changes, the cause of the noise
is probably parts striking because of worn
crankshaft bearings or connecting rod bearings
(In such cases, the lash adjusters are normal).
4. After the engine has warmed up, run it at idle and
check if any noise can be heard.
If the noise has become smaller or disappeared,
oil sludge could make the lash adjusters stick.
Clean the lash adjusters (Refer to GROUP 11D -
Rocker Arms and Camshaft - Rocker Arms and
Camshaft Inspection 311B). If not improved,
go to step 5.
5. Bleed air from the lash adjusters (Refer to 311A
).
6. If the noise has not disappeared even after the air
bleeding, clean the lash adjusters (Refer to
GROUP 11D - Rocker Arms and Camshaft -
Rocker Arms and Camshaft Inspection 311B).
LASH ADJUSTER AIR BLEEDING
NOTE: .
œ If the vehicle is parked on a slope fir a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high
pressure chamber when starting the engine.
œ After parking the vehicle for long periods, the oil
drains out of the oil passage, and it takes time for
the oil to be supplied to the lash adjuster, so air
can get into the high-pressure chamber.
œ If either of the above situations occur, the
abnormal noise can be eliminated by bleeding
the air from inside the lash adjusters.
1. Check the engine oil and replenish or replace the
oil if necessary.
AKX00328
Good
Min.
Max
AE

ON-VEHICLE SERVICE
ENGINE MECHANICAL
11A-12
NOTE: .
œ If there is an only small amount of oil, air will
be drawn in through the oil screen and will get
into the oil passage.
œ If the amount of oil is greater than normal, then
the oil will being mixed by the crankshaft and a
large amount of air may get mixed into the oil.
œ If the oil is degenerated, air and oil will not
separate easily in oil, and the amount of air
mixed into the oil will increase.
œ If the air which has been mixed in with the oil
due to any of the above reasons gets into the
high pressure chamber of the lash adjuster,
the air inside the high pressure chamber will
be compressed when the valve is open and
the lash adjuster will over-compress, resulting
in abnormal noise when the valve close. This
is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air
inside the lash adjusters is then released, the
operation of the lash adjusters will return to
normal.
2. Run the engine at idle for 1 - 3 minutes to let it
warm up.
3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
if the abnormal noise disappears (The noise
should normally disappear after 10 - 30
repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is
probably not due to air inside the lash adjusters).
4. After the noise has disappeared, repeat the drive
pattern shown in the illustration above a further 5
times.
5. Run the engine at idle for 1 - 3 minutes and check
that the noise has disappeared.
AK100001
High-pressure chamber
AC
AKX00330
Gradually open
the throttle valve Close the throttle valve
Approximately
3,000 r/min
Idle speed
Once
15 s 15 s
Drive pattern for air breeding
AE

CRANKSHAFT PULLEY
ENGINE MECHANICAL
11A-13
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600409
Pre-removal Operation
œ Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Post-installation Operation
œ Drive Belt Tension Check (Refer to 311A).
œ Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
AC300537AB
25 ± 4 N·m
1
2
Removal steps
A 1. Drive belt
2. Crank shaft damper pulley

CRANKSHAFT PULLEY
ENGINE MECHANICAL
11A-14
REMOVAL SERVICE POINT
A DRIVE BELT REMOVAL
The following operations will be needed due to the
serpentine drive system with the drive belt auto-
tensioner.
1. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner, and turn the auto-
tensioner anti-clockwise until it hits the stopper.
CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk.
2. Align hole A with hole B, insert an L-shaped
hexagon wrench, etc. to fix and then remove the
drive belt.
AC107640ACHole A
Auto-tensioner
Hole B
AC107641AB
L-shaped
hexagon
wrench
Auto-tensioner

CAMSHAFT AND VALVE STEM SEAL
ENGINE MECHANICAL
11A-15
M1112006600211
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
œ Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
œ Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
œ Battery and Battery Tray Removal
œ Valve Timing Belt Removal (Refer to 311A).
œ Valve Timing Belt Installation (Refer to 311A).
œ Battery and Battery Tray Installation
œ Air Cleaner and Air Cleaner Bracket installation (Refer to
œ Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
AC300538
1
12
9
8
7
6
5
11
4
3
2
AB
N
3.0 ± 0.5 N·m
11 ± 1 N·m
11 ± 1 N·m
3.5 ± 0.5 N·m
9.0 ± 2.0 N·m
11 ± 1 N·m
11 ± 1 N·m
10N
8.8 ± 1.0 N·m
Removal steps
1. Accelerator cable connection
2. Rocker cover centre cover
3. Crank angle sensor connector
4. Control wiring harness connection
œ Spark plug cables and ignition coils
(Refer to GROUP 16, Ignition Coil
316).
5. Rocker cover PCV hose
6. Rocker cover breather hose
N 8. Rocker cover
M 9. Camshaft end seal
10. Spark plug hole gaskets
Removal steps RQWLQXHG

ENGINE MECHANICAL
11A-16
L 11. Rocker cover gasket
A K 12. Radiator upper hose connection

AC300539
19
18
17
16
15
14
13
29
28
27
26
25
24
23
22
20
21
34*
33*
32*
30
31*
AB
N
N
N
35*
33*
32*
31*
N
Apply engine oil to all
moving parts before
installation.
11 ± 1 N·m
20 ± 1 N·m
89 ± 9 N·m
14 ± 1 N·m
22 ± 4 N·m
10 ± 2 N·m
25 ± 4 N·m
Removal steps
13. Camshaft position sensor support
cover
14. Camshaft position sensor support
cover gasket
J 15. Camshaft position sensing cylinder
I 16. Camshaft position sensor support
B H 17. Camshaft sprockets
G 18. Camshaft oil seals
F 19. Camshaft bearing caps, front
F 20. Camshaft bearing caps, rear
F 21. Camshaft bearing caps, No.2
E 25. Inlet camshaft
E 26. Exhaust camshaft
27. Rocker arms
D 28. Rocker arm lash adjusters
29. Oil delivery body
30. Spark plugs
C C 31. Valve spring retainer locks
32. Valve spring retainers
B 33. Valve springs
A 34. Inlet valve stem seals
A 35. Exhaust valve stem seals

ENGINE MECHANICAL
11A-17
LUBRICATION AND SEALING POINTS
The bottom view of the rocker cover
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
Engine oil
(Lip section)
10 mm
10 mm10 mm
View A
Sealant: 3M ATD Part No.8660
or equivalent
10 mm10 mm
Rocker
cover
Cylinder
head
φ 3 mm
AC300541
A
A
A
Sealant:
MITSUBISHI GENUINE
PART MD970389 or
equivalent
Sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
Top view of cylinder head

ENGINE MECHANICAL
11A-18
REMOVAL SERVICE POINTS
A RADIATOR UPPER HOSE
DISCONNECTION
Make mating marks on the radiator hose and the
hose clamp. Disconnect the radiator hose.
B CAMSHAFT SPROCKETS REMOVAL
1. Hold the hexagon part of the camshaft with a
wrench.
2. Loosen the camshaft sprocket mounting bolts and
remove the camshaft sprocket.
C VALVE SPRING RETAINER LOCKS
REMOVAL
CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.
Use special tool valve spring compressor
(MD998772) to compress the valve spring, remove
the valve spring retainer locks.
INSTALLATION SERVICE POINTS
A EXHAUST VALVE STEM SEALS/INLET
VALVE STEM SEALS INSTALLATION
1. Check the valve stem seal colour to identify the
inlet side or exhaust side.
2. Apply a small amount of engine oil to the valve
stem seals.
AC200641AC
Mating marks
AC201457AB
AC201799
MD998772
AB
AC201542AB
Exhaust sideInlet side
Gray Gray green

ENGINE MECHANICAL
11A-19
CAUTION
œ Valve stem seals cannot be reused.
œ The special tool valve stem seal installer
(MD998737) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
3. Use special tool to fill a new valve stem seal in the
valve guide using the valve stem area as a guide.
B VALVE SPRINGS INSTALLATION
Install the valve springs with its identification colour
painted end facing the locker arm.
C VALVE SPRING RETAINER LOCKS
INSTALLATION
Use special tool valve spring compressor
(MD998772) to compress the valve spring in the
same manner as removal.
D ROCKER ARM LASH ADJUSTERS
INSTALLATION
CAUTION
If the rocker arm lash adjuster is reused, always
clean and check it before installation. (Refer to
GROUP 11B, Rocker Arms and Camshaft -
Inspection).
E EXHAUST CAMSHAFT/INLET CAMSHAFT
INSTALLATION
1. Remove sealant remained on the cylinder head.
2. Apply engine oil to the cam and the journal of the
camshaft.
CAUTION
Do not install wrong camshaft at the side of inlet
or exhaust. The exhaust camshaft has a slit at the
rear surface.
3. Install the camshaft to the cylinder head.
F CAMSHAFT BEARING CAPS, NO. 4/
CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT
BEARING CAPS, NO. 5/CAMSHAFT BEARING
CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/
CAMSHAFT BEARING CAPS, FRONT
INSTALLATION
1. Set the dowel pin of the camshaft to the position
as shown in the illustration.
AC107414 AC
MD998737
Valve
Valve stem
seal
Valve guide
AC201453AB
Rocker arm side
Identification
colour
AC201799
MD998772
AB
AC201458AB
Engine front
Slit
Exhaust camshaft
AC201459AB
Dowel pin
Exhaust sideInlet side
Approximately 3˚

ENGINE MECHANICAL
11A-20
2. Since the shape of camshaft bearing caps No.2 -
5 is identical, check the identification marks so
that the bearing cap No., inlet side, or exhaust
side cannot be mistaken to install to the direction
as shown in the illustration.
Identification mark (engraved on the front
and bearing caps No.2 - 5)
I: Inlet side
E: Exhaust side
3. Apply sealant to the positions (6 areas) of the
upper side of the cylinder head as shown in the
illustration.
Specified sealant: MITSUBISHI GENUINE
NOTE: Install the camshaft bearing caps, rear
and camshaft bearing caps, front within 15
minutes after applying liquid gasket.
4. Position the camshaft bearing caps, rear in the
direction as shown in the illustration for
installation.
5. Check the identification marks on the camshaft
bearing caps, front so that inlet side and exhaust
side cannot be mistaken in the same way as that
of bearing caps No.2 - 5.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
the pressure in 2 to 3 times and finally tighten to
the specified torque.
Tightening torque: 20 – 1 N¼m
7. Ensure that the rocker arms are installed properly.
NOTE: Remove an excess of sealant completely.
G CAMSHAFT OIL SEALS INSTALLATION
1. Apply engine oil to the entire inner diameter of the
oil seal lip.
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seals.
H CAMSHAFT SPROCKETS INSTALLATION
1. Hold the hexagon part of the camshaft with a
wrench in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolts to
the specified torque.
AC201460
E4
AB
Bearing
cap No.
Identification of
inlet side and
exhaust side
Engine front
AC201461AB
Engine front
AC201462AB
Front
markingEngine front
AC102323ABMD998713
AC201457AB

ENGINE MECHANICAL
11A-21
I CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.
2. Apply the sealant to the camshaft position sensor
support flange in a continuous bead as shown in
the illustration.
NOTE: Install the camshaft position sensor
support within 15 minutes after applying liquid
gasket.
3. Install the camshaft position sensor support to the
cylinder head.
CAUTION
4. Tighten the camshaft position sensor support
mounting bolts to the specified torque.
J CAMSHAFT POSITION SENSING
CYLINDER INSTALLATION
1. Set the dowel pin of the exhaust camshaft to the
position (No.1 cylinder at compression TDC) as
shown in the illustration.
NOTE: Use the force of the exhaust valve spring
to rotate anti-clockwise.
2. Install the vane (small) of the camshaft position
sensing cylinder at an angle of approximately 45
degrees to the position of the dowel pin of the
exhaust camshaft.
3. Tighten the camshaft position sensing cylinder
mounting bolts to the specified torque.
K RADIATOR UPPER HOSE CONNECTION
1. Insert each hose as far as the projection of the
water outlet fitting.
2. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
L ROCKER COVER GASKET INSTALLATION
1. Remove sealant remained on the rocker cover.
2. Apply sealant to the positions (4 areas) of the
lower side of the rocker cover as shown in the
illustration.
NOTE: Install the rocker cover gasket within 15
3. Install the rocker cover gasket to the rocker cover.
AC201463
φ 3 mm AB
AC201464AB
Dowel pin
Vane (large)
Vane (small)
Approximately 45˚
AC200642
Mating marks
Projection
Water outlet fitting
AE
AC201465AB

ENGINE MECHANICAL
11A-22
M CAMSHAFT END SEAL INSTALLATION
Apply sealant to the positions of the camshaft end
seal as shown in the illustration and install to the
cylinder head.
Specified sealant: 3M ATD Part No.8660 or
equivalent
NOTE: Install the camshaft end seal within 15
N ROCKER COVER INSTALLATION
1. Apply sealant to the positions of the rocker cover
gasket (6 areas) as shown in the illustration.
NOTE: Install the rocker cover within 15 minutes
after applying liquid gasket.
2. Install the rocker cover to the cylinder head.
CAUTION
3. Tighten the rocker cover mounting bolts to the
specified torque.
Tightening torque: 3.5 – 0.5 N¼m
AC201468
Cylinder head
10 mm
10 mm
AB
AC201469
Engine front
AB

OIL PAN
ENGINE MECHANICAL
11A-23
OIL PAN
REMOVAL AND INSTALLATION 2WD
M1112002800592
351).
œ Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
œ Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
œ Front Exhaust Pipe Installation (Refer to GROUP 15,
œ Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Cover 351).
AC300542
N
9.0 ± 3.0 N·m
26 ± 5 N·m
9.0 ± 1.0 N·m
39 ± 5 N·m 3
4
5
2
AB
1
35 ± 6 N·m
9.0 ± 3.0 N·m
Removal steps
1. Exhaust manifold bracket
2. Flywheel housing front lower cover
3. Engine oil pan drain plug
B 4. Engine oil pan drain plug gasket
A A 5. Engine oil pan

OIL PAN
ENGINE MECHANICAL
11A-24
A ENGINE OIL PAN REMOVAL
1. Remove the engine oil pan mounting bolts.
CAUTION
Perform this slowly to avoid deformation of the
engine oil pan flange.
2. Remove the engine oil pan using special tool oil
pan remover (MD998727).
A ENGINE OIL PAN INSTALLATION
1. Remove sealant from the engine oil pan and
cylinder block surfaces.
2. Apply a bead of the sealant to the cylinder block
mating surface of the engine oil pan as shown.
NOTE: Install the engine oil pan within 15 minutes
after applying sealant.
3. Assemble the engine oil pan to the cylinder block.
CAUTION
sealant surface during that time.
4. Tighten the engine oil pan mounting bolts to the
specified torque. Be careful when installing, as the
oil pan mounting bolts (indicated in the illustration)
have different lengths from the other bolts.
B ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION
Replace the gasket with a new gasket. Install the
new gasket in the direction shown in the illustration.
AC102324 AB
MD998727 MD998727
AC102133AB
Groove portion
φ 4 mm
Bolt hole portion
AC102698
M6 × 8 mm
AB
AC102325 AE
Engine
oil pan
side

OIL PAN
ENGINE MECHANICAL
11A-25
REMOVAL AND INSTALLATION 4WD
M1112002800600
351).
œ Front Exhaust Pipe Removal (Refer to GROUP 15,
œ Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).
œ Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).
œ Front Exhaust Pipe Installation (Refer to GROUP 15,
Cover 351).
AC300543
N
3
4
6
5
1
2
AB
9.0 ± 3.0 N·m
9.0 ± 1.0 N·m
44 ± 10 N·m
22 ± 4 N·m
9.0 ± 3.0 N·m
9.0 ± 3.0 N·m
9.0 ± 3.0 N·m
39 ± 5 N·m
Removal steps
D 1. Transmission housing front lower
cover stay
2. Flywheel housing front lower cover
3. Engine oil pan drain plug
C 4. Engine oil pan drain plug gasket
A B 5. Engine lower oil pan
B A 6. Engine upper oil pan

OIL PAN
ENGINE MECHANICAL
11A-26
A ENGINE LOWER OIL PAN REMOVAL
1. Remove the engine lower oil pan mounting bolts.
CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
2. Apply a piece of wood to the lower oil pan and
strike it with a hammer to remove the engine lower
oil pan.
B ENGINE UPPER OIL PAN REMOVAL
1. Remove the engine upper oil pan mounting bolts.
CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
2. Screw in the bolt into bolt hole A in the location
shown. Then lift the upper oil pan and remove it.
A ENGINE UPPER OIL PAN INSTALLATION
1. Remove sealant from the engine upper oil pan
and cylinder block surfaces.
2. Apply a bead of the sealant to the mating surface
of the engine upper oil pan as shown.
NOTE: Install the engine upper oil pan within 15
minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
block.
CAUTION
4. Insert the bolts to the engine upper oil pan as
shown, and tighten them to the specified torque.
AC102931AB
Engine lower oil pan
AC102946AB
A
A
AC102242AB
Groove
φ 4 mm
portion
Bolt hole
portion
AC102929AB
B
B
B
B
B
B
B
BB
B
B
B
B
B
B
B
A
A

OIL PAN
ENGINE MECHANICAL
11A-27
NOTE: D: Nominal diameter, L: Nominal length
B ENGINE LOWER OIL PAN INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.
2. Apply a bead of the sealant to the mating surface
of the engine lower oil pan as shown.
NOTE: Install the engine lower oil pan within 15
minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine
upper oil pan.
CAUTION
4. Insert the bolts to the engine lower oil pan as
shown, and tighten them to the specified torque in
the order shown.
NOTE: D: Nominal diameter, L: Nominal length
C ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION
Replace the gasket with a new one. Install the new
gasket in the direction shown in the illustration.
D TRANSMISSION HOUSING FRONT
LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
stay in the following order.
1. Tighten the engine side four mounting bolts to the
specified torque.
2. Tighten the transmission side two mounting bolts
to the specified torque.
INSPECTION
M1112002900210
œ Check the oil pan for cracks.
œ Check the oil pan sealant-coated surface for
damage and deformation.
Name Symbol Quantity Size mm
(D ™ L)
Flange bolt A 2 M6 ™ 16
B 16 M6 ™ 18
AC102243AB
Groove
φ 4 mm
portion
Bolt hole
portion
AC102930AB
A-3
B-6
B-7
B-10
B-11B-1
B-4
B-5
B-12 B-2
B-8
B-9
Name Symbol Quantity Size mm
(D ™ L)
Flange bolt A 1 M6 ™ 75
B 11 M6 ™ 10
AC102325 AF
Engine lower
oil pan side

CRANKSHAFT OIL SEAL
ENGINE MECHANICAL
11A-28
CRANKSHAFT OIL SEAL
M1112003100273
AC300544AB
1
2
3
Lip section
Engine oil
3 9
9
6
4
N
N
Lip section
5
8
7
132 ± 5 N·m
Crankshaft front oil seal removal
steps
œ Valve timing belt, balancer timing
belt (Refer to 311A).
D 1. Crankshaft balancer shaft drive
sprocket
2. Crankshaft key
C 3. Crankshaft front oil seal
Crankshaft rear oil seal removal
steps
A œ Transmission assembly
B B 4. Flywheel bolts
5. Flywheel adapter plate
6. Flywheel assembly
7. Flywheel adapter plate
8. Crankshaft bush
A 9. Crankshaft rear oil seal

CRANKSHAFT OIL SEAL
ENGINE MECHANICAL
11A-29
A TRANSMISSION ASSEMBLY REMOVAL
CAUTION
Do not remove the flywheel bolt shown by the
arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly
322A.
B FLYWHEEL BOLTS REMOVAL
1. Use special tool flywheel stopper (MD998781) to
secure the flywheel.
2. Remove the flywheel bolts.
A CRANKSHAFT REAR OIL SEAL
INSTALLATION
1. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
2. Use the following special tools to press-fit the oil
seal.
œ Installer bar (MB990938)
œ Crankshaft rear oil seal installer (MD998776)
B FLYWHEEL BOLTS INSTALLATION
1. Use special tool flywheel stopper (MD998781) to
secure the flywheel in the same manner as
removal.
2. Tighten the flywheel bolts to the specified torque.
C CRANKSHAFT FRONT OIL SEAL
INSTALLATION
1. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
2. Apply a small amount of engine oil to the outer
diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.
AC300897
Flywheel bolt
Engine front
AB
Flywheel
assembly
AC211914AC
MD998781
AC102328 AB
Oil seal
MB990938
MD998776 Crankshaft
(Engine oil)
AC211914AC
MD998781
AC102329AC
MD998285
(Engine oil)
(Oil applied to the
circumference)
Oil seal
Crankshaft MD998375

CYLINDER HEAD GASKET
ENGINE MECHANICAL
11A-30
D CRANKSHAFT BALANCER SHAFT DRIVE
SPROCKET INSTALLATION
1. Clean or degrease the front case, the crankshaft
and the crankshaft balancer shaft drive sprocket
as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
in the direction shown in the illustration.
M1112004000655
AC211222
Crankshaft
balancershaft
drive sprocket
Engine front
Front case
Crankshaft
AB
: Clean
: Clean and degrease
œ Fuel Line Pressure Reduction [Refer to GROUP 13A, On-
vehicle Service - Fuel Pump Connector Disconnection
(How to Reduce Pressurized Fuel Lines) 313A.]
351).
œ Engine Coolant Draining (Refer to GROUP 14, On-vehicle
œ Air Cleaner and Air Cleaner Bracket Removal (Refer to
œ Battery Removal
œ Rocker Cover Centre Cover Removal (Refer to 311A
).
œ Valve Timing Belt Removal (Refer to 311A).
œ Valve Timing Belt Installation (Refer to 311A).
œ Rocker Cover Centre Cover Installation (Refer to 311A
).
œ Battery Installation
œ Air Cleaner and Air Cleaner Bracket installation (Refer to
œ Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
œ Accelerator Cable Adjustment (Refer to GROUP 17, On-
vehicle Service - Accelerator Cable Check and
Adjustment 317).
Cover 351).
œ Fuel Leak Check

ENGINE MECHANICAL
11A-31
AC300545
1
17
14
13
12
11
9
8
7
65
10
4
3
2
18
19N
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m
13 ± 1 N·m
AB
(Engine oil)
20
15
5.0 ± 1.0 N·m
16
Removal steps
1. A/C compressor connector
2. Power steering fluid pressure
switch connector
3. Crank angle sensor connector
4. Ignition coil connectors
5. Detonation sensor connector
6. Purge control solenoid valve
connector
7. EGR control solenoid valve
connector
8. Injector connectors
9. Throttle position sensor connector
10. Idle speed control servo connector
11. Camshaft position sensor
connector
12. Oxygen sensor connector
13. Engine coolant temperature sensor
connector
14. Engine coolant temperature gauge
unit connector
15. Capacitor connector
16. Accelerator cable connection
17. Brake booster vacuum hose
connection
18. Engine oil level gauge and guide
assembly
19. O-ring
20. Canister vacuum hose connection

ENGINE MECHANICAL
11A-32
AC300546
5.0 ± 1.0 N·m
(Engine oil)
26
25
24
23
22
21
30
29
27
28
N (Engine oil)
31 ± 3 N·m
11 ± 1 N·m
N
AB
Cold engine
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
Removal steps
21. Detonation sensor connection
22. Battery wiring harness connection
23. Inlet manifold stay
œ Exhaust manifold (Refer to GROUP
15, Exhaust Manifold 315).
œ Water outlet fitting and thermostat
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
314).
œ Rocker cover (Refer to 311A).
24. Heater water hose connection
25. Fuel return line hose connection
C 26. Fuel high-pressure hose
connection
C 27. O-ring
A B 28. Cylinder head bolts
29. Cylinder head assembly
A 30. Cylinder head gasket

ENGINE MECHANICAL
11A-33
A CYLINDER HEAD BOLTS REMOVAL
Using special tool cylinder head bolt wrench
(MB991654), loosen the cylinder head bolts in two or
three steps in the order of the numbers shown in the
illustration.
NOTE: If the cylinder head bolts cannot be pulled out
due to the washer being trapped in the valve spring,
raise the bolt slightly, then remove it while holding it
by using a magnet.
A CYLINDER HEAD GASKET INSTALLATION
CAUTION
Do not allow any foreign materials to get into the
coolant passages, oil passages and cylinder.
1. Remove the gasket from the cylinder head and
cylinder block.
2. Assemble to the cylinder block so the cylinder
head gasket identification mark 63 is at the top
surface and on the exhaust side.
B CYLINDER HEAD BOLTS INSTALLATION
1. Check that the nominal length of each cylinder
head bolt meets the limit. If it exceeds the limit,
replace the bolt with a new one.
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
AC201623
MB991654
Engine front
1
2
4697
3 5 10 8
AB
AC107217AC
Identification
mark 63
Exhaust side
AC102537
A
AB
(Engine oil)

ENGINE MECHANICAL
11A-34
3. Use special tool cylinder head bolt wrench
(MB991654) to tighten the cylinder head bolts as
follows:
(1) Tighten the cylinder head bolts to 78 – 2 N¼m
in the order shown.
(2) Loosen the bolts fully in the reverse order of
that shown.
(3) Tighten the cylinder head bolts to 20 – 2 N¼m
in the order shown.
(4) Apply a paint mark to the heads of the cylinder
head bolts and cylinder head, then tighten 90
degree angle as shown.
CAUTION
The bolt is not tightened sufficiently if the bolt is
tightened less than 90 degree angle.
(5) Tighten the bolt an additional 90 degree angle
as shown. Then check to see that the paint
mark on the head of the cylinder head bolts
and the paint mark on the cylinder head are
aligned.
(6) If tightening the bolt 90 degree angle results in
moving the paint mark on the bolt past the
paint mark on the cylinder head, remove the
bolt and start over from step 1.
C O-RING/FUEL HIGH-PRESSURE HOSE
INSTALLATION
CAUTION
Do not let any engine oil get into the delivery
pipe.
1. Apply a small amount of new engine oil to the O-
ring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel high-
pressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
AC201625
MB991654
10
9
7524
8 6 1 3
Engine front
AB
AC102331AB
Paint marking
90˚ 90˚
Step (4) Step (5)
Paint marking

TIMING BELT
ENGINE MECHANICAL
11A-35
TIMING BELT
M1112004300656
351).
œ Crankshaft Shaft Damper Pulley Removal (Refer to
311A).
œ Crankshaft Shaft Damper Pulley Installation (Refer to
311A).
Cover 351).
AC300547
10
9
8
7
6
5
3
2
11 ± 1 N·m
8.8 ± 1.0 N·m
11 ± 1 N·m
23 ± 3 N·m
48 ± 5 N·m
79 ± 5 N·m
21 ± 4 N·m
9.0 ± 1.0 N·m
22 ± 4 N·m
44 ± 10 N·m
N
4
11
AB
1
Removal steps
2. Timing belt upper cover
3. Water pump pulley
4. Idler pulley
H 5. End cap
6. Auto-tensioner
7. Timing belt lower cover
œ Engine front mounting bracket
(Refer to GROUP 32, Engine
Mount 332).
G œ Valve timing belt tension
adjustment
A F 8. Valve timing belt
E 9. Timing belt tensioner pulley
10. Timing belt tensioner arm
D 11. Timing belt tensioner adjuster

TIMING BELT
ENGINE MECHANICAL
11A-36
A VALVE TIMING BELT REMOVAL
CAUTION
Never turn the crankshaft anti-clockwise.
1. Turn the crankshaft clockwise, align each timing
mark to set No.1 cylinder to TDC of its
compression stroke.
2. Remove the timing belt under cover rubber plug
and then set the special tool adjusting bolt
(MD998738).
AC300548
21
20
19
18
17
16
15
13
14
35 ± 6 N·m
49 ± 9 N·m
22 ± 4 N·m
8.8 ± 1.0 N·m
167 N·m
19 ± 3 N·m
49 ± 9 N·m
22 ± 4 N·m
AB
(Engine oil)
12
Removal steps
12. Power steering fluid pressure
switch connector
B 13. Power steering oil pump assembly
14. A/C compressor connector
15. Power steering oil pump bracket
16. Timing belt idler pulley
17. Crank angle sensor
C C 18. Crankshaft camshaft drive sprocket
C 19. Crankshaft angle sensing blade
B œ Balancer timing belt tension
adjustment
A 20. Balancer timing belt tensioner
D A 21. Balancer timing belt

AC102487
Timing mark
AC102492AB
Timing belt
under cover
MD998738

TIMING BELT
ENGINE MECHANICAL
11A-37
CAUTION
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.
3. Screw in the special tool until it comes in contact
with the timing belt tensioner arm.
4. Gradually screw in the special tool. Then align the
timing belt tensioner adjuster rod set hole A with
the timing belt tensioner adjustor cylinder set hole
B.
5. Insert a wire, etc.in the set hole.
CAUTION
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.
6. After removal of adjusting bolt special tool, loosen
the timing belt tensioner pulley mounting bolt and
remove the valve timing belt.
B POWER STEERING OIL PUMP ASSEMBLY
REMOVAL
With the hose installed, remove the power steering
oil pump assembly from the bracket.
NOTE: Secure the removed power steering oil pump
assembly with cord or rope at a position where they
will not interfere with the removal of the balancer
timing belt.
C CRANKSHAFT CAMSHAFT DRIVE
SPROCKET REMOVAL
1. Use the following special tools to support the
crankshaft camshaft drive sprocket.
œ Special spanner (MB991367)
œ Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft camshaft drive sprocket.
D BALANCER TIMING BELT REMOVAL
CAUTION
To reuse the balancer timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.
A BALANCER TIMING BELT/BALANCER
TIMING BELT TENSIONER INSTALLATION
1. Ensure that the crankshaft balancershaft drive
sprocket timing marks and balancershaft sprocket
timing marks are aligned.
AC107289
MD998738
Timing belt
tensioner arm
AB
AC102775AB
A
B
AC107185AB
Wire
Timing belt
tensioner pulley
mounting bolt
AC102332AB
MB991385
MB991367
Crankshaft
camshaft
drive
sprocket
AC102689AB
Balancershaft sprocket
Belt tension side
Timing mark
Timing mark
Crankshaft
balancershaft
drive sprocket

TIMING BELT
ENGINE MECHANICAL
11A-38
2. Install the balancer timing belt on the crankshaft
balancershaft drive sprocket and balancershaft
sprocket. There should be no slack on the tension
side.
3. Assemble and temporarily fix the centre of the
pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the mounting
bolt, and the pulley flange is at the front-side of
the engine.
4. Adjust the balancer timing belt tension.
B BALANCER TIMING BELT TENSION
ADJUSTMENT
CAUTION
When tightening the mounting bolt, ensure that
the tensioner does not rotate with the bolt.
Allowing it to rotate with the bolt can cause
excessive tension of the belt.
1. With your fingers, lift the balancer timing belt
tensioner in the direction of the arrow. Apply
pressure of 3.0 – 0.4 N¼m to the balancer timing
belt. Tighten the assembling bolt to the specified
torque. Then, fix the balancer timing belt
tensioner.
2. Turn the crankshaft clockwise two turns to set
No.1 cylinder to TDC of its compression stroke
and check that the sprocket timing marks are
aligned.
AC102690 AB
Centre of
the pulley
Centre of the
mounting bolt
AC102691
AC102689AC
Balancershaft sprocket
Timing mark
Timing mark
Crankshaft
balancershaft
drive sprocket

TIMING BELT
ENGINE MECHANICAL
11A-39
3. Apply a pressure of approximately 100N at the
centre (arrow area) between the sprocket as
shown, then inspect whether the belt deflection is
within the standard value.
Standard value:
At adjustment: 5 - 7 mm
At replacement: 5 - 7 mm
4. If not within the standard value, adjust the belt
tension again.
C CRANKSHAFT ANGLE SENSING BLADE/
CRANKSHAFT CAMSHAFT DRIVE SPROCKET
INSTALLATION
1. Clean or degrease the crankshaft, the crankshaft
angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as
shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the direction
shown.
3. Place the larger chamfer side of the crank shaft
pulley washer in the direction shown and then
assemble on the crankshaft pulley centre bolt.
4. Apply some engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
5. Use the following special tool as during removal to
support the crankshaft camshaft drive sprocket.
œ Special spanner (MB991367)
œ Pin (MB991385)
6. Tighten the crankshaft pulley centre bolts to the
specified torque.
Tightening torque: 167 N¼m
D TIMING BELT TENSIONER ADJUSTER
INSTALLATION
1. Install according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
CAUTION
If the compression is too fast, the procedure may
damage the rod.
(1) Slowly compress the timing belt tensioner
adjuster rod using a press or vice, then align
the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
AC102693AB
Deflection
Approximately 100 N
AC211535AB
: Clean
: Clean and degrease
: Apply engine oil
Crankshaft camshaft
drive sprocket
Crankshaft pulley
center bolt
Crankshaft
Crankshaft angle
sensing blade
Crankshaft
pulley washer
Engine front
AC102332AB
MB991385
MB991367
Crankshaft
camshaft
drive
sprocket
AC102334AB
A
B

TIMING BELT
ENGINE MECHANICAL
11A-40
(2) Insert a wire or pin into the aligned set hole.
NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Assemble the timing belt tensioner adjuster to the
engine, then tighten the assembling bolt to the
specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.
E TIMING BELT TENSIONER PULLEY
INSTALLATION
Temporarily tighten the timing belt tensioner pulley as
shown.
F VALVE TIMING BELT INSTALLATION
1. Align the timing marks on the camshaft sprocket,
crankshaft camshaft drive sprocket and engine oil
pump sprocket.
2. Adjust the timing mark of the engine oil pump
sprocket. Unplug the cylinder block plug. Insert a
bolt (M6 sectional width 10 mm, minor diameter
45 mm) from the plug hole and then check. If the
bolt comes in contact with the balancer shaft turn
the sprocket one rotation. Re-adjust the timing
mark and then check to see that the bolt fits. Do
not remove the bolt until the valve timing belt is
assembled.
AC102335AB
Wire
AC102336AB
Timing belt tensioner
pulley hole
AC102486
Crankshaft
camshaft
drive sprocket Engine oil
pump sprocket
AC
Timing mark
Camshaft sprocket
Timing mark
Timing mark
AC102337AE
Plug
Balancershaft
Bolt
Cylinder
block

2005 MITSUBISHI AIRTREK Service Repair Manual

2005 MITSUBISHI AIRTREK Service Repair Manual

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