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Mitsubishi Space Star Chassis Supplement Service Manual – PDF
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Description
Mitsubishi Space Star Chassis Supplement Service Manual – PDF DOWNLOAD
FILE DETAILS:
Mitsubishi Space Star Chassis Supplement Service Manual – PDF DOWNLOAD
Language : English
Pages : 879
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mitsubishi Space Star Chassis Supplement Service Manual – PDF DOWNLOAD
FOREWORD.............................................................................. 2 WARNING!.............................................................................. 3 GENERAL............................................................................... 4 HOW TO USE THIS MANUAL............................................................ 5 HOW TO USE TROUBLESHOOTING / INSPECTION SERVICE POINTS............................ 9 VEHICLE IDENTIFICATION............................................................ 16 MAJOR SPECIFICATIONS.............................................................. 20 PRECAUTIONS BEFORE SERVICE........................................................ 21 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELTS WITH PRE-TENSIONER............. 25 SUPPORT LOCATIONS FOR LIFTING AND JACKING......................................... 30 STANDARD PARTS-TIGHTENING-TORQUE TABLE............................................ 34 ENGINE................................................................................ 36 ENGINE <4G9>...................................................................... 37 GENERAL INFORMATION........................................................... 38 SERVICE SPECIFICATIONS........................................................ 38 SEALANTS...................................................................... 39 SPECIAL TOOLS................................................................. 40 ON-VEHICLE SERVICE............................................................ 42 CRANKSHAFT PULLEY............................................................. 52 CAMSHAFT AND CAMSHAFT OIL SEAL................................................ 53 OIL PAN....................................................................... 57 CRANKSHAFT OIL SEAL........................................................... 59 CYLINDER HEAD GASKET.......................................................... 61 TIMING BELT................................................................... 64 ENGINE ASSEMBLY............................................................... 69 ENGINE <4G1>...................................................................... 74 GENERAL INFORMATION........................................................... 75 SERVICE SPECIFICATIONS........................................................ 75 SEALANT....................................................................... 76 SPECIAL TOOLS................................................................. 77 ON-VEHICLE SERVICE............................................................ 78 CRANKSHAFT PULLEY............................................................. 87 CAMSHAFT AND CAMSHAFT OIL SEAL................................................ 88 OIL PAN....................................................................... 90 CRANKSHAFT OIL SEALS.......................................................... 92 CYLINDER HEAD GASKET.......................................................... 94 TIMING BELT................................................................... 98 ENGINE ASSEMBLY...............................................................101 ENGINE LUBRICATION....................................................................106 GENERAL INFORMATION...............................................................107 LUBRICANTS........................................................................108 SPECIAL TOOLS.....................................................................108 ON-VEHICLE SERVICE................................................................108 FUEL..................................................................................112 GASOLINE DIRECT INJECTION (GDI)...................................................113 GENERAL INFORMATION...........................................................114 SERVICE SPECIFICATIONS........................................................118 SEALANT.......................................................................118 SPECIAL TOOLS.................................................................119 TROUBLESHOOTING...............................................................120 ON-VEHICLE SERVICE............................................................207 FUEL PUMP (HIGH PRESSURE).....................................................221 INJECTOR......................................................................226 THROTTLE BODY.................................................................229 INJECTOR DRIVER...............................................................231 THROTTLE VALVE CONTROLLER.....................................................232 MULTIPOINT FUEL INJECTION (MPI)...................................................234 GENERAL INFORMATION...........................................................235 SERVICE SPECIFICATIONS........................................................238 SEALANT.......................................................................238 SPECIAL TOOLS.................................................................239 TROUBLESHOOTING...............................................................240 ON-VEHICLE SERVICE............................................................298 INJECTOR......................................................................310 THROTTLE BODY.................................................................312 FUEL SUPPLY.......................................................................316 GENERAL INFORMATION...........................................................317 SPECIAL TOOL..................................................................317 FUEL TANK.....................................................................318 ENGINE COOLING........................................................................322 GENERAL INFORMATION...............................................................323 SERVICE SPECIFICATIONS............................................................323 LUBRICANT.........................................................................323 SEALANTS..........................................................................323 SPECIAL TOOL......................................................................324 TROUBLESHOOTING...................................................................324 ON-VEHICLE SERVICE................................................................329 THERMOSTAT........................................................................333 WATER PUMP........................................................................335 WATER HOSE AND WATER PIPE.........................................................337 RADIATOR..........................................................................340 INTAKE AND EXHAUST....................................................................342 GENERAL INFORMATION...............................................................343 SERVICE SPECIFICATIONS............................................................343 SPECIAL TOOL......................................................................343 ON-VEHICLE SERVICE................................................................343 INTAKE MANIFOLD...................................................................344 EXHAUST MANIFOLD..................................................................348 EXHAUST PIPE AND MAIN MUFFLER.....................................................351 ENGINE ELECTRICAL.....................................................................352 CHARGING SYSTEM...................................................................354 GENERAL INFORMATION...........................................................354 SERVICE SPECIFICATIONS........................................................356 SPECIAL TOOLS.................................................................356 ON-VEHICLE SERVICE............................................................357 ALTERNATOR....................................................................365 STARTING SYSTEM...................................................................374 GENERAL INFORMATION...........................................................374 SERVICE SPECIFICATIONS........................................................375 STARTER MOTOR.................................................................375 IGNITION SYSTEM...................................................................385 GENERAL INFORMATION...........................................................385 SERVICE SPECIFICATIONS........................................................387 SPECIAL TOOLS.................................................................388 ON-VEHICLE SERVICE............................................................388 IGNITION COIL <GDI>...........................................................399 CAMSHAFT POSITION SENSOR <GDI>................................................399 CRANK ANGLE SENSOR <GDI>......................................................400 DISTRIBUTOR <MPI>.............................................................401 DETONATION SENSOR.............................................................403 ENGINE AND EMISSION CONTROL...........................................................404 ENGINE CONTROL SYSTEM.............................................................406 GENERAL INFORMATION...........................................................406 SERVICE SPECIFICATIONS........................................................406 ON-VEHICLE SERVICE............................................................406 ACCELERATOR CABLE AND PEDAL...................................................407 ACCELERATOR PEDAL POSITION SENSOR <GDI>.......................................408 EMISSION CONTROL SYSTEM...........................................................409 GENERAL INFORMATION...........................................................409 SERVICE SPECIFICATIONS........................................................410 SPECIAL TOOL..................................................................410 VACUUM HOSE...................................................................411 CRANKCASE EMISSION CONTROL SYSTEM.............................................413 EVAPORATIVE EMISSION CONTROL SYSTEM...........................................416 EXHAUST GAS RECIRCULATION (EGR) SYSTEM........................................421 EGR VALVE.....................................................................425 CATALYTIC CONVERTER...........................................................426 CANISTER......................................................................427 CLUTCH................................................................................428 GENERAL INFORMATION...............................................................429 SERVICE SPECIFICATIONS............................................................429 LUBRICANTS........................................................................429 ON-VEHICLE SERVICE................................................................429 CLUTCH PEDAL......................................................................431 CLUTCH CONTROL....................................................................432 MANUAL TRANSMISSION...................................................................434 GENERAL INFORMATION...............................................................435 SERVICE SPECIFICATION.............................................................435 LUBRICANTS........................................................................435 SEALANT...........................................................................436 SPECIAL TOOLS.....................................................................436 ON-VEHICLE SERVICE................................................................437 TRANSMISSION CONTROL <F5MR1>*.....................................................440 TRANSMISSION CONTROL <F5M42>*.....................................................442 TRANSMISSION ASSEMBLY <F5MR1>.....................................................445 TRANSMISSION ASSEMBLY <F5M42>.....................................................449 FRONT AXLE............................................................................454 GENERAL INFORMATION...............................................................455 SERVICE SPECIFICATIONS............................................................455 SEALANT...........................................................................455 SPECIAL TOOLS.....................................................................456 ON-VEHICLE SERVICE................................................................458 AXLE HUB..........................................................................459 DRIVE SHAFT.......................................................................464 REAR AXLE.............................................................................468 GENERAL INFORMATION...............................................................469 SERVICE SPECIFICATIONS............................................................469 SPECIAL TOOLS.....................................................................469 ON-VEHICLE SERVICE................................................................470 REAR AXLE HUB.....................................................................471 WHEEL AND TYRE........................................................................474 GENERAL INFORMATION...............................................................475 SERVICE SPECIFICATIONS............................................................475 TROUBLESHOOTING...................................................................476 ON-VEHICLE SERVICE................................................................477 WHEEL AND TYRE....................................................................477 POWER PLANT MOUNT.....................................................................478 GENERAL INFORMATION...............................................................479 SERVICE SPECIFICATION.............................................................479 SPECIAL TOOLS.....................................................................479 ENGINE MOUNTING...................................................................480 TRANSMISSION MOUNTING.............................................................481 ENGINE ROLL STOPPER, CENTERMEMBER.................................................482 CROSSMEMBER.......................................................................483 FRONT SUSPENSION......................................................................486 GENERAL INFORMATION...............................................................487 SERVICE SPECIFICATIONS............................................................488 SPECIAL TOOLS.....................................................................489 ON-VEHICLE SERVICE................................................................490 STRUT ASSEMBLY....................................................................492 LOWER ARM.........................................................................495 STABILIZER BAR....................................................................497 REAR SUSPENSION.......................................................................500 GENERAL INFORMATION...............................................................501 SERVICE SPECIFICATION.............................................................502 SPECIAL TOOLS.....................................................................502 ON-VEHICLE SERVICE................................................................503 CONTROL LINK, UPPER LINK AND LOWER ARM............................................505 TRAILING ARM......................................................................508 STRUT ASSEMBLY....................................................................511 STABILIZER BAR....................................................................514 SERVICE BRAKES........................................................................516 BASIC BRAKE SYSTEM................................................................517 GENERAL INFORMATION...........................................................518 SERVICE SPECIFICATIONS........................................................519 LUBRICANTS....................................................................520 SEALANTS......................................................................520 SPECIAL TOOLS.................................................................520 ON-VEHICLE SERVICE............................................................521 BRAKE PEDAL...................................................................530 MASTER CYLINDER AND BRAKE BOOSTER.............................................532 FRONT DISC BRAKE..............................................................535 REAR DRUM BRAKE...............................................................537 WHEEL CYLINDER................................................................539 PROPORTIONING VALVE...........................................................540 ANTI-SKID BRAKING SYSTEM (ABS) <2WD>..............................................542 GENERAL INFORMATION...........................................................544 SERVICE SPECIFICATIONS........................................................545 LUBRICANTS....................................................................545 SEALANT.......................................................................545 SPECIAL TOOLS.................................................................545 TROUBLESHOOTING...............................................................546 ON-VEHICLE SERVICE............................................................557 BRAKE PEDAL...................................................................530 MASTER CYLINDER AND BRAKE BOOSTER.............................................532 FRONT DISC BRAKE..............................................................535 REAR DRUM BRAKE...............................................................561 PROPORTIONING VALVE...........................................................517 HYDRAULIC UNIT*...............................................................563 WHEEL SPEED SENSOR............................................................565 PARKING BRAKES........................................................................568 GENERAL INFORMATION...............................................................569 SERVICE SPECIFICATIONS............................................................569 LUBRICANTS........................................................................569 ON-VEHICLE SERVICE................................................................569 PARKING BRAKE LEVER*..............................................................571 PARKING BRAKE CABLE*..............................................................572 STEERING..............................................................................574 GENERAL INFORMATION...............................................................575 SERVICE SPECIFICATIONS............................................................576 LUBRICANTS........................................................................576 SPECIAL TOOLS.....................................................................576 ON-VEHICLE SERVICE................................................................578 STEERING WHEEL AND SHAFT*.........................................................585 POWER STEERING GEAR BOX*..........................................................588 POWER STEERING OIL PUMP...........................................................592 POWER STEERING HOSES..............................................................593 BODY..................................................................................596 HOOD..............................................................................598 FENDER............................................................................599 FUEL FILLER DOOR..................................................................600 WINDOW GLASS......................................................................601 ADHESIVES.....................................................................601 SPECIAL TOOLS.................................................................601 WINDOW REPAIR.................................................................601 WINDSHIELD....................................................................604 QUARTER WINDOW GLASS..........................................................608 TAILGATE WINDOW GLASS.........................................................610 DOOR..............................................................................612 SERVICE SPECIFICATIONS........................................................612 SEALANT.......................................................................612 SPECIAL TOOLS.................................................................612 TROUBLESHOOTING...............................................................613 ON-VEHICLE SERVICE............................................................625 DOOR ASSEMBLY.................................................................627 DOOR TRIM AND WATERPROOF FILM.................................................629 DOOR GLASS AND REGULATOR......................................................632 DOOR HANDLE AND LATCH.........................................................637 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP.........................640 TAILGATE..........................................................................641 SERVICE SPECIFICATION.........................................................641 SPECIAL TOOLS.................................................................641 TROUBLESHOOTING...............................................................642 ON-VEHICLE SERVICE............................................................642 TAILGATE ASSEMBLY.............................................................643 TAILGATE TRIM.................................................................645 TAILGATE HANDLE AND LATCH.....................................................646 KEYLESS ENTRY SYSTEM..............................................................647 SPECIAL TOOLS.................................................................647 TROUBLESHOOTING...............................................................647 ON-VEHICLE SERVICE............................................................650 KEYLESS ENTRY RECEIVER-ECU....................................................652 SUNROOF...........................................................................653 SPECIAL TOOLS.................................................................653 TROUBLESHOOTING...............................................................653 ON-VEHICLE SERVICE............................................................657 SUNROOF.......................................................................658 EXTERIOR..............................................................................662 SERVICE SPECIFICATIONS............................................................663 SEALANT AND ADHESIVE..............................................................663 SPECIAL TOOLS.....................................................................663 FRONT BUMPER......................................................................664 REAR BUMPER.......................................................................665 ROOF RAIL.........................................................................666 MOULDING AND GARNISH..............................................................667 WINDSHIELD WIPER AND WASHER*......................................................671 REAR WIPER AND WASHER*............................................................675 HEADLAMP WASHER*..................................................................678 MARKS.............................................................................680 DOOR MIRROR.......................................................................682 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS)......................................684 INTERIOR..........................................................................685 SERVICE SPECIFICATIONS........................................................686 SPECIAL TOOL..................................................................686 INSTRUMENT PANEL*.............................................................686 FLOOR CONSOLE*................................................................691 TRIMS.........................................................................692 INSIDE REAR VIEW MIRROR.......................................................693 SEAT*.........................................................................694 SEAT BELT.....................................................................699 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...............................................702 GENERAL INFORMATION...........................................................703 SRS SERVICE PRECAUTIONS.......................................................704 SPECIAL TOOLS.................................................................707 TEST EQUIPMENT................................................................708 TROUBLESHOOTING...............................................................708 SRS MAINTENANCE...............................................................720 POST-COLLISION DIAGNOSIS......................................................724 INDIVIDUAL COMPONENT SERVICE..................................................727 WARNING/CAUTION LABELS........................................................728 SRS AIR BAG CONTROL UNIT (SRS-ECU)............................................729 AIR BAG MODULES AND CLOCK SPRING..............................................731 SIDE IMPACT SENSOR............................................................735 SEAT BELT WITH PRE-TENSIONER..................................................738 AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES................740 CHASSIS ELECTRICAL....................................................................748 BATTERY...........................................................................751 SERVICE SPECIFICATION.........................................................751 ON-VEHICLE SERVICE............................................................751 IGNITION SWITCH AND IMMOBILIZER SYSTEM............................................754 SPECIAL TOOL..................................................................754 TROUBLESHOOTING...............................................................754 IGNITION SWITCH AND IMMOBILIZER SYSTEM........................................759 COMBINATION METERS................................................................762 SERVICE SPECIFICATIONS........................................................762 SEALANT.......................................................................762 SPECIAL TOOLS.................................................................763 TROUBLESHOOTING...............................................................764 ON-VEHICLE SERVICE............................................................768 COMBINATION METERS............................................................771 HEADLAMP AND FRONT TURN-SIGNAL LAMP*..............................................773 SERVICE SPECIFICATIONS........................................................773 SPECIAL TOOLS.................................................................773 TROUBLESHOOTING...............................................................773 ON-VEHICLE SERVICE............................................................777 HEADLAMP AND FRONT TURN-SIGNAL LAMP...........................................780 SIDE TURN-SIGNAL LAMP.............................................................783 SPECIAL TOOL..................................................................783 FRONT FOG LAMP....................................................................784 SERVICE SPECIFICATIONS........................................................784 SPECIAL TOOL..................................................................784 ON-VEHICLE SERVICE............................................................784 FRONT FOG LAMP................................................................786 REAR COMBINATION LAMP*............................................................787 SPECIAL TOOL..................................................................787 REAR COMBINATION LAMP.........................................................787 RHEOSTAT..........................................................................789 SPECIAL TOOL..................................................................789 RHEOSTAT......................................................................789 HAZARD WARNING LAMP SWITCH........................................................790 CIGARETTE LIGHTER.................................................................790 RADIO AND TAPE PLAYER.............................................................792 TROUBLESHOOTING...............................................................792 RADIO AND TAPE PLAYER.........................................................807 SPEAKER...........................................................................808 ANTENNA...........................................................................809 REAR WINDOW DEFOGGER..............................................................810 ON-VEHICLE SERVICE............................................................810 REAR WINDOW DEFOGGER SWITCH...................................................811 MULTI CENTER DISPLAY..............................................................812 TROUBLESHOOTING...............................................................812 MULTI CENTER DISPLAY..........................................................840 RADIATOR FAN MOTOR................................................................ 0 SERVICE BRAKES (ABS).............................................................. 26 DOOR GLASS AND REGULATOR (POWER WINDOWS).......................................... 0 DOOR HANDLE AND LATCH (DOOR LOCKING).............................................. 0 SUNROOF........................................................................... 0 WINDSHIELD WIPER AND WASHER....................................................... 0 REAR WIPER AND WASHER............................................................. 0 DOOR MIRROR (ELECTRONIC CONTROLLED DOOR MIRROR)................................... 0 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)............................................... 18 HEATER............................................................................ 0 AIR CONDITIONER................................................................... 0 HEATER, AIR CONDITIONER AND VENTILATION...............................................842 GENERAL INFORMATION...............................................................844 SERVICE SPECIFICATIONS............................................................845 LUBRICANTS........................................................................845 SPECIAL TOOLS.....................................................................845 TROUBLESHOOTING...................................................................846 ON-VEHICLE SERVICE................................................................848 HEATER CONTROL ASSEMBLY AND A/C SWITCH............................................859 HEATER UNIT*, HEATER CODE*, AND BLOWER UNIT.......................................862 RESISTOR, BLOWER FAN AND MOTOR, AND INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR....863 EVAPORATOR........................................................................865 AIR PURIFIER ASSEMBLY.............................................................867 COMPRESSOR AND TENSION PULLEY.....................................................868 REFRIGERANT LINE..................................................................872 CONDENSER AND CONDENSER FAN MOTOR.................................................875 VENTILATORS*......................................................................877
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