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2008 MITSUBISHI AIRTREK Service Repair Manual .pdf



Original filename: 2008 MITSUBISHI AIRTREK Service Repair Manual.pdf
Title: WorkManual.pdf
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00-1

GROUP 00

GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . .

00-2

SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) . . . . . . . . . . . . . . . . . .

00-27

SRS SERVICE PRECAUTIONS . . . . .

00-28

HOW TO USE
TROUBLESHOOTING/INSPECTION
SERVICE POINTS . . . . . . . . . . . . . . .

00-6

VEHICLE IDENTIFICATION . . . . . . .

00-16

SUPPORT LOCATIONS FOR LIFTING
AND JACKING . . . . . . . . . . . . . . . . . . 00-31

GENERAL DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . .

00-20

STANDARD PART/TIGHTENINGTORQUE TABLE . . . . . . . . . . . . . . . .

PRECAUTIONS BEFORE SERVICE.

00-22

00-33

00-2

GENERAL
HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL
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.

M1001000100660

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
HOW TO USE THIS MANUAL

NOTES

00-3

00-4

GENERAL
HOW TO USE THIS MANUAL

(s
.
<<A>>
>>A<<

Symbols are used to show the locations for lubrication
.
These symbols are included in the diagram of component parts or on the page following the component
parts page. The symbols do not always have accompanying text to support that symbol.

disassembly.
or reassembly.

Multi-purpose grease unless there is a

AC301960

00-5

GENERAL
HOW TO USE THIS MANUAL

For bolts and nuts which do
not have a tightening torque
listed, refer to the "Standard
Parts tightening-torque Table"

parts sets are

On removal,
reassembly are described

AC300860

00-6

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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
Gathering information
from the customer.
Check trouble symptom.
Reoccurs
Read the diagnosis code.

No diagnosis code
or communication
with MUT-II/III not
possible

Does not reoccur

Diagnosis code
displayed.

Diagnosis code
displayed.

After taking note of the
malfunction code, erase the
diagnosis code memory.

No diagnosis
code.

Recheck trouble symptom.
Read the diagnosis codes.
Diagnosis code
displayed.

Refer to the INSPECTION CHART
FOR TROUBLE SYMPTOMS
(Refer to applicable group.)

Read the diagnosis code.

Refer to the INSPECTION CHART
FOR DIAGNOSIS CODES
(Refer to applicable group.)

No diagnosis
code.

INTERMITTENT MALFUNCTIONS

AC300864AC

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 ).

00-7

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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).

<Using the MUT-III>
<Using the MUT-III>

16-PIN

8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgment values have
been provided in this chart as reference information.

MB991911
MB991824

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>
<Using the MUT-II>
Steering shaft

MUT-II

AC300830 AC

Connect the MUT-II to the diagnosis connector, and
read the diagnosis code.

MB991827

AC308915 AC

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).

00-8

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>

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>

Steering shaft

MUT-II

CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>

AC300830 AC

Steering shaft

<Using the MUT-III>

MUT-II
16-PIN
AC300830 AC

<Using the MUT-III>

MB991911
16-PIN
MB991824

MB991911
MB991827

AC308915 AC

MB991824

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 ".

MB991827

AC308915 AC

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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>

00-9

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

Steering shaft
MB991529

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

AC300831AB

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.

00-10

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Relevant circuit(s) of the component which
the Code No. indicates are described.

AC301964AB

00-11

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Explains about the basic
operation of the components.

Start of diagnosis
procedure

Describes
inspection
procedure.

Explains about
technical details.

Describes the
conditions for that
diagnosis code being
set.

Describes possible
causes(s) for that
diagnosis code.

AC301965AB

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>
MD998459

AC300881AB

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.

00-12

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

<Ordinary (non-waterproof) Connectors>

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>

Connector

CAUTION
AC300882AB

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>

AC300890

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.
MB991219

ACX00865AB

00-13

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR INSPECTION SERVICE
POINTS
VISUAL INSPECTION

• Low connection pressure due to rusted terminals
or foreign matter lodged in terminals
CONNECTOR PIN INSPECTION



Connector disconnected or
improperly connected

AC300898

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.

Stretched or broken wires

CONNECTOR ENGAGEMENT INSPECTION
Harness wire breakage
at terminal section

MB991219

Low contact
pressure
Good
Bad

AC300899AB
AC300896AB

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

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)

00-14

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A
BLOWN FUSE

Battery

Fuse

Load
switch

Short-circuit
occurrence
section

Load

AC300900AB

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.)

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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.

AC300901

00-15

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.

00-16

GENERAL
VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION CODE PLATE
1

No.

Item

Content

1

MODEL

CU2WXNMM CU2W:
L6
Vehicle model

3

2

5

M1001000400713

The plate shows model code, engine model,
transmission model and body colour code.

XNMML6:
Model series

4

6

7

AC301477AB

The vehicle information code plate is riveted to the
back of the hood.

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

For monotone colour vehicles, the body colour code
shall be indicated.

MODELS
Model code

Engine model

Price class

Transmission
model

Fuel supply
system

CU2W

4G63-DOHC (1,997
mL)

Comfort

F5M42
<2WD, 5M/T>

MPI

XNMML6
XNMMZL6
XNHMZL6

CU5W

XNMYZL6

Sport
4G69-SOHC MIVEC
(2,378 mL)

Comfort

XRMYZL6

XRHYZL6
XRHYZR6

W5M42
<4WD, 5M/T>
W4A42
<4WD, 4A/T with
sport mode>

XRMYZR6
XNHYZL6

W5M42
<4WD, 5M/T>

Sport

W5M42
<4WD,5M/T>
W4A42
<4WD, 4A/T with
sport mode>

00-17

GENERAL
VEHICLE IDENTIFICATION

MODEL CODE

CU 2 W X N M M Z L 6

1

2 3 4 5 6 7 8 9 10

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

AC301363 AB

00-18

GENERAL
VEHICLE IDENTIFICATION

CHASSIS NUMBER

The chassis number is stamped on the toeboard
inside the engine compartment.

AC300903AB

J

M B

X

N

CU

2

W

4

U

000001

1

2

4

5

6

7

8

9

10

11

3

AC309285AB

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





00-19

GENERAL
VEHICLE IDENTIFICATION

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.
This engine model numbers are shown as follows.

<4G63>

Engine model

Engine displacement

4G63

1,997 mL

4G69

2,378 mL

The engine serial number is stamped near the
engine model number.
Front of the
vehicle
AC300905AD

<4G69>

Front of the vehicle

AC309481AB

00-20

GENERAL
GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS
M1001000900558

8
7
9

1

3

4
6

2

5
AC300072AB

Items

CU2W
XNMML6

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
Seating capacity
Engine
Transmission
Fuel system

XNMMZL6

75
5

Model code

4G63

Total displacement mL

1,997

Model code

F5M42

Type

5-speed manual

Fuel supply system

MPI

NOTE: *: Vehicles with roof rails

W5M42

XNHMZL6

00-21

GENERAL
GENERAL DATA AND SPECIFICATIONS

Items

CU5W
XNMYZL6

Vehicle
dimensions
mm

Vehicle
weight kg

XRMYZL6/R XNHYZL6
6

XRHYZL6/R
6

LHD: 1,560,
RHD: 1,565

1,540

LHD: 1,560,
RHD: 1,565

W5M42

W4A42

W5M42

W4A42

Type

5-speed
manual

4-speed
automatic

5-speed
manual

4-speed
automatic

Fuel supply system

MPI

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

Kerb weight

1,540

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
Max. trailer-nose weight

570
75

Seating capacity

5

Engine

Model code

4G69

Total displacement mL

2,378

Transmission Model code

Fuel system

NOTE: *: Vehicles with roof rails

00-22

GENERAL
PRECAUTIONS BEFORE SERVICE

PRECAUTIONS BEFORE SERVICE
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.

M1001000500538

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
PRECAUTIONS BEFORE SERVICE

00-23

INITIALIZATION PROCEDURE FOR
LEARNING VALUE IN MPI ENGINE

LEARNING PROCEDURE FOR IDLING 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.

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.

Service

Item

At replacing engine
assembly *1,*2

All ranges

− *3

Misfire-related

At replacing injector and Learning value for
air/fuel ratio
at cleaning *2
At replacing throttle body Idle speed
control-related
and at cleaning *2
At replacing detonation
sensor

Learning value for
knocking

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
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.

00-24

GENERAL
PRECAUTIONS BEFORE SERVICE

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).

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

AC300693

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.

Approximately 40 cm

AC300832AB

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.

00-25

GENERAL
PRECAUTIONS BEFORE SERVICE

MUT-II/III

MUT-III sub assembly

MUT-II Sub-assembly
Vehicle communication interface (V.C.I.)

Rom pack
MB991824

MUT-III USB cable
AC300834AB

MB991827

MUT-III main harness A

Do not used

MB991910

MUT-III main harness B

MB991911

MUT-III measurement adapter

MB991825

MUT-III trigger harness

MB991826
AC305090AB

Refer to the "MUT-II REFERENCE MANUAL",
"MUT-II OPERATING INSTRUCTIONS" or "MUT-III
OPERATION MANUAL" for instructions on handling
the MUT-II/III.

00-26

GENERAL
PRECAUTIONS BEFORE SERVICE

ENGINE OILS

CAUTION
<Using the MUT-II>
Steering shaft

MUT-II

AC300830 AC

<Using the MUT-III>

16-PIN

MB991911
MB991824

MB991827

AC308915 AC

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".

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.

00-27

GENERAL
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
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

M1001009800020

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.

SRS warning lamp

Seat belt with pre-tensioner

Driver's air bag
module

Passenger's (front)
air bag module
Side air bag module
Side impact sensor

Clock spring

SRS-ECU

Side impact sensor
Side air bag module
Front impact sensor
AC301343 AB

00-28

GENERAL
SRS SERVICE PRECAUTIONS

SRS SERVICE PRECAUTIONS
M1001006000047

CAUTION

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.

SRS-ECU connector

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.
SRS-ECU terminal No. Destination of harness

AC300634 AB

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.

Remedy

1, 2

Instrument panel wiring harness →
Front wiring harness (RH) → Front
impact sensor (RH)

Correct or replace each wiring
harness.

3, 4

Instrument panel 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

Correct or replace the instrument
panel wiring harness.

9, 10

Instrument panel wiring harness →
Air bag module (Front passenger's
side)

Correct or replace the instrument
panel wiring harness.

11, 12

Instrument panel wiring harness →
Clock spring → Air bag module
(Driver's side)

Correct or replace instrument panel
wiring harness. Replace the clock
spring.

13

Instrument panel wiring harness →
Junction block (fuse No.3)

Correct or replace the instrument
panel wiring harness.

GENERAL
SRS SERVICE PRECAUTIONS

00-29

SRS-ECU terminal No.

Destination of harness

Remedy

16

Instrument panel wiring harness →
Junction block (fuse No.2)

Correct or replace the instrument
panel wiring harness.

20

Instrument panel wiring harness →
Diagnosis connector

Correct or replace the instrument
panel wiring harness.

21, 22

Floor wiring harness (RH) → Side air Correct or replace the floor wiring
bag module (LH)
harness.

23, 24

Floor wiring harness (RH) → Side air Correct or replace the floor wiring
bag module (RH)
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)

Connect or replace the floor wiring
harness.

34, 36

Floor wiring harness (LH) → Side
impact sensor (LH)

Connect or replace the floor wiring
harness.

40, 42

Floor wiring harness (RH) → Side
impact sensor (RH)

Connect or replace the floor wiring
harness.

DANGER
Insulating tape
Battery

Battery cable
AC300580AB

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.

00-30

GENERAL
SRS SERVICE PRECAUTIONS

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
SRS-Harness connector

SRS-ECU harness connector
(rear side)

AC300673AB

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.

GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-31

SUPPORT LOCATIONS FOR LIFTING AND JACKING
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.

<2WD>

Rear suspension crossmember

<4WD>

Rear differential

AC300835

00-32

GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING

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.
AXLE STANDS
Bolts

Bolts

Rubber
Rubber

SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Bolts

Bolts

AC300836AB

00-33

GENERAL
STANDARD PART/TIGHTENING-TORQUE TABLE

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
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.
Thread size
Torque N⋅m

M1001001100362

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

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

Flange bolt and nut tightening torque
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

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.

NOTES

11A-1

GROUP 11A

00
11

ENGINE
MECHANICAL

12
13
14
15
16

CONTENTS

17
GENERAL INFORMATION . . . . . . . .

11A

SERVICE SPECIFICATIONS. . . . . . .

11A

SEALANTS . . . . . . . . . . . . . . . . . . . .

11A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11A

ON-VEHICLE SERVICE. . . . . . . . . . .

CAMSHAFT AND VALVE STEM
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

21

11A

22

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A

25

REMOVAL AND INSTALLATION . . . . . . . .

REMOVAL AND INSTALLATION <2WD>. .

11A

REMOVAL AND INSTALLATION <4WD>. .

11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

27

CRANKSHAFT OIL SEAL . . . . . . . . . 11A

31

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

REMOVAL AND INSTALLATION . . . . . . . .

11A

CYLINDER HEAD GASKET . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . .

11A

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . .

11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

CRANKSHAFT PULLEY . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . .

11A

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . .

11A

26

32
33
34
35
36
37
42
51
52
54
55

ENGINE MECHANICAL

11A-2

GENERAL INFORMATION

GENERAL INFORMATION
M1111000100356

Item

4G63

Total displacement mL

1,997

Bore ™ Stroke mm

85 ™ 88

Compression ratio

10.0

Compression chamber

Pentroof

Camshaft arrangement

DOHC

Number of valve
Valve timing

Intake

8

Exhaust

8

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

SERVICE SPECIFICATIONS
M1112000300234

Item

Standard value

Limit

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

Drive belt tension

Balancer timing belt tension (When
adjusted)

Deflection mm

5-7

-

Balancer timing belt tension (When
replaced)

Deflection mm

5-7

-

ENGINE MECHANICAL

11A-3

SEALANTS

Item

Standard value

Limit

5 - 10

-

Timing belt tensioner adjuster rod protrusion amount mm

3.8 - 4.5

-

Timing belt tensioner adjuster rod movement mm

Within 1

-

Balancer timing belt tension (When
checked)

Deflection mm

SEALANTS
M1112000500238

Item

Specified Sealant

Remark

Cylinder head

MITSUBISHI GENUINE PART MD970389 or
equivalent

Semi-drying
sealant

Camshaft position sensor support
Rocker cover
Camshaft end seal

3M ATD Part No.8660 or equivalent

Rocker cover gasket

MITSUBISHI GENUINE PART MD970389 or
equivalent

Engine oil pan <2WD>
Engine upper oil pan <4WD>
Engine lower oil pan <4WD>

SPECIAL TOOLS
M1112000600279

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

ENGINE MECHANICAL

11A-4

SPECIAL TOOLS

Tool

Number

Name

Use

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

MD998375

Crankshaft front oil seal
installer

MB991654

Cylinder head bolt wrench
(12)

D998713

D998727

D998781

B990938

D998776

Crankshaft front oil seal
installation

D998285

B991654

Removal and installation of
cylinder head bolt

ENGINE MECHANICAL

11A-5

SPECIAL TOOLS

Tool

Number

Name

Use

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

D998738

B991367

B991385

D998767

Valve timing belt tension
adjustment

ENGINE MECHANICAL

11A-6

ON-VEHICLE SERVICE

Tool

Number

Name

Use

MB991454

Engine hanger balancer

MB991527

Hanger

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.

MB991895

Engine hanger

B991454

B991527

Z203830

MB991928
A: MB991929
B: MB991930
E C: MB991931
D: MB991932
E: MB991933
F: MB991934

Slide bracket (HI)

F
A

D
B

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

C
B991928

ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100399

CAUTION
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.

Indicator mark

A

AC107639AB

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 3 11A .)
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.

ENGINE MECHANICAL

11A-7

ON-VEHICLE SERVICE

AUTO-TENSIONER CHECK
M1111003000154

CAUTION

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 3 11A .)

16-pin

MUT-II

AC107640AB

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 3 11A .)
5. Install the drive belt.(Refer to 3 11A .)

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 3 11A .)
2. Measure the drive belt tension vibration frequency
by the following procedures:

MB991668
AC211862 AB

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.

ENGINE MECHANICAL

11A-8

ON-VEHICLE SERVICE

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.
Power steering
oil pump pulley

Power steering
oil pump pulley

Water pump
pulley

AC102807AB

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 autotensioner.(Refer to 3 11A .)

IGNITION TIMING CHECK

15˚

MB991668
Water pump
pulley

10 – 20 mm

Belt tension gauge

M1111001700425

15˚

AC102022
Y0195AU

MUT-II
Gentry tap with
your finger
AC102806 AB

(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 autotensioner. (Refer to 3 11A .)
When using a tension gauge
1. Check the drive belt tension. (Refer to 3 11A .)

AK000871 AC

1. Before inspection, set the vehicle to the preinspection 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 3 13A ,
GROUP 13A - Troubleshooting - Inspection chart
for diagnosis code).

ENGINE MECHANICAL

11A-9

ON-VEHICLE SERVICE

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.

Standard value: 750 – 100 r/min
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 3 13A ,
GROUP 13A - Troubleshooting - Inspection chart
for diagnosis code).

IDLE MIXTURE CHECK
M1111002100255

AC102022
Y0195AU

MUT-II

IDLE SPEED CHECK
M1111003500472

AC102022
Y0195AU
AK000871 AC

MUT-II

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition.
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.
4. Connect a timing light.

1. Before inspection, set the vehicle to the preinspection condition.
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.
4. Connect a timing light.

Engine speed
ditection connector

AK000899 AC

Engine speed
ditection connector

AK000899 AC

5. Start the engine and let it run at idle.
6. Check that ignition timing is at the standard value.
Standard value: approximately 10• BTDC
7. Check the idle speed.

5. Start the engine and let it run at idle.
6. Check that ignition timing is at the standard value.
Standard value: approximately 10• BTDC
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:

ENGINE MECHANICAL

11A-10
œ
œ
œ
œ
œ
œ
œ

ON-VEHICLE SERVICE

Diagnosis output
Fuel pressure
Injector
Ignition coil, spark plug cable, spark plug
EGR control system
Evaporative emission control system
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

Crank angle
sensor
connector

AK201364AC

1. Before inspection, set the vehicle to the preinspection condition.
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-ECU<M/
T> or engine-A/T-ECU<A/T> from carrying out
ignition and fuel injection.

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

AC102022
Y0195AU

MUT-II

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

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition.
2. Turn the ignition switch to "LOCK" (OFF) position.
3. Connect a tachometer or connect the MUT-II to
the diagnosis connector.
Vacuum
gauge

Fuel pressure
regulator

AK201369AB

ENGINE MECHANICAL

11A-11

ON-VEHICLE SERVICE

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.
Standard value: 750 – 100 r/min
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 3 11B ). If not improved,
go to step 5.
5. Bleed air from the lash adjusters (Refer to 3 11A
).
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 3 11B ).

<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.

Good
Max
Min.
AKX00328 AE

1. Check the engine oil and replenish or replace the
oil if necessary.

ENGINE MECHANICAL

11A-12

ON-VEHICLE SERVICE

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.

High-pressure chamber
AK100001AC

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.

Drive pattern for air breeding
Gradually open
Close the throttle valve
the throttle valve
Approximately
3,000 r/min
Idle speed

15 s

15 s

Once
AKX00330AE

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.

ENGINE MECHANICAL
CRANKSHAFT PULLEY

11A-13

CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600409

Pre-removal Operation
œ Under Cover Removal (Refer to GROUP 51, Under Cover
3 51 ).

Post-installation Operation
œ Drive Belt Tension Check (Refer to 3 11A ).
œ Under Cover Installation (Refer to GROUP 51, Under
Cover 3 51 ).

2
1

25 ± 4 N·m

AC300537AB

<<A>>

1.
2.

Removal steps
Drive belt
Crank shaft damper pulley


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