Chapter 2 TECHNICAL DATA ‘VEHICLE DIMENSIONS: ROUTINE MAINTENANCE TUNE-UP ENGINE ENGINE ELECTRICAL COOLING SYSTEM FUEL SYSTEM go00000 VEHIGLE DIMENSIONS. Overall Length: All models exoxpt MWB Yan MWB Van... je Overall wid SWB Van, 4s 4:Van, MWB Van, 365 mm. 14705 mm GL and GLX Wagons... 169 mm SE Wagon, 4x4 Wagon 1.695 mm, Overall heigt SWB Van, GL, SE Wagons . 1840 mm 4x4 Van. 4x4 Wagon . 1975 mm MWB Van ... 1955 mm Wheelbase: SWB Van, GL, ms. erat 2235mm 434 Wagon *.2240 mm MWB Van .. -2.435 mm Front track 4x 2models .. seek mm 4x4 models . <1 480mm Rea 4x2 models . - 1 380mm 4xd models . 1415 mm Ground clearance: 4x2 models 190 mm dix 4 models 210mm 18 CLUTCH 1 MANUAL TRANSMISSION (1 AUTOMATIC TRANSMISSION O FRONT AXLE AND SUSPENSION o REAR AXLE AND SUSPENSION O STEERING 7 BRAKES ng circle (kerb to kerh): GL, GLX and SE Wagons 29.0 a. 98m 4xAmodels > mm ROUTINE MAINTENANCE Recommended lubricants and fluids W-a0) oF LOW-S0 SG TSW-85W GLA or ISW-RSW GLA or Dexron lI Engine (down to —20°C) Manual transmission ‘Transfer case Automatic ransmission Differential: Conventional type Hypoid 80W or 90 GLA or GLs Limited stip .. Castrol LS 90 oF LSX 90) GIS or GLa Power stecring Dexten IT ‘Cooling system Water Mitsubishi inh Brake fluid . ‘Wheel beatings, steering and ‘front suspension joints, propeller shafi and up iePNo 2 wreseTechnical Data Rofill capacities 2.4 litre, areas 1% Bee Ignition timing at idle’... .....,..... S142 BIDC Coa a0 fires Hightension lead resistance... Less than 22 kiohms Without filter. “dS lites Sparkpleer: Manual transmission ....... 06050055 2.0 litres: ‘Transfer cuse veccenveseeeded Ire ah oo Aulomutic transmission TL litres Tease as rae Gap UNIAN 0a am fe lites Dave bel deflection poe velar ha digs elle ‘Alternator and air conditioning belt. .7—10.mm 20 litre madels exept MWB Van .....1.2 litres: y, Ran Sea DR sas feegmm Pewee lve clearance...» Hydraulic-non adjustable ail 24 ite 4x 2models 5... .c.e 1-5 Titres 4x4 models Lice tBlitves Torque wrench settings as ne, . OO lives Spark plugs ..-.2-...22.... 2. 20=30.Nm lant: All2.0 litre models... TA Tires approx 24 litre Vans +B? litres approx 24 ive Wagon “Raine cee: ENGINE Fuel tank: 4x 2models . cossccs.2.5Slitres General specifications 4x4models . % #: . Gb litres Engine type ee ee vevsces 4eyl OHC Torque wrench settings See Ata se 4683 Engine sump drain plug ...0.-02.0.0. 35=45 Nm tegen heed 4G64 Manual transmission: Filles pligessx oe saag.catucn 2 Dieta. tll eter eats Flectionie fuel injection (EFI) 4x 2transmission Displacement: 4xAvansmission . 20itre 1997 ce Transfer case: 24 litre - 2350cc Filler and drvin plugs ..,..0+-+- aie Differential fromt and reau 2.0 lite - 85.0 mm Fillerplug <2 c...1.+0: 24 litre... 96.5 min Rede Stroke: 20 ire TUNE-UP Compression pressure Siandard --...--.0.-2 1.200 kPa inimum - 22. BU KPa Differential limit between eylinders. 1K) KPa Idle spec ne 0.2 mm 2.0 litre — _ Crossflow, allay Manual .c..ccc0cc¢erseeeee-75250spm Height... cecccsececsee es B99 = 9041 mm Automatic (in N range) ......----80U250 rpm Distortion limit fos ab oe OTOH 24 litre — Valve seat angle (inlet and exhaust) ....4++ 2+ 0-44" Manual and automatic (in N range) 800+ 50 rpm Valve seat contact width .... . 09-13 mm Idle Cott: Valve face angle (inlet and exhaust) .......-..-. 45", EOS 5 crys ¥ = 0.5% with Walve stem to gu clearance: secondary air disconnected Tilet occ ees c cee reese e+ 02 0.06 mn 19Technical Data ExhaUSE 6.5 seis e eee 0.05 0.09 mm ‘Wear limit — Inet. 10mm Exhaust ,..-.--+- 15mm Valve head margin limit: Inlet, 0.7mm Exhaust... 15mm Valve springs free length: Green springs — Standard 47.5 mm Limit 46,5 nm White — Standard 49.8 mm Limit , 48.8 mam Valve springs squureness limit . £ Valve gui ‘Type -.. a Replaceable Service sizes « 0.25, 0.5mm Press-in lemperature Room temperature Gylinder block 85.00 — BS.03 mm. Bore diameter wear limit ‘Taper and ovality limit Pision to cylinder bore clearance - Cylinder block face distortion limit... 0.1mm *Cylinder block face muchining limit... 02 em Piston and rings Piston diameter standard 20 litre » 84.97 85.00 2A litre 80.47 ~ 86: 0.25, 0. Piston aversizen I 0.75 and 1.0 mm Piston rings: Side clearanee — ‘Top ring... 0.03 ~ 0.07 mum Second ring. «0.02 = 0406 man ‘Wear 0.1 mim End gap — ‘Top ring (h25=0/40:mm Second ring... 0:45 ~ 0,60 mm Oil ring to. 1993. 0,20 —0,70 mm Oil sing 1993 on « = 0400.40 mm Wear limit — Top and second ring «2.50004 ...244/.0,8'mm Oil ring ...2+.+4++ 1.0mm, 20 Connecting rods and bearings 0,05 mm, 0.1 mm ing rod bend limit... ing rex twist limit ing rod side clear nit oe ++ 0,100.25 mm ees Site 0.4 mm ‘Connecting rad bearing oil clearance: Standard ie 0.02 — 0.05 mm Limit ; 0,1 mm Undersize bearings avai 25,0.50 and (1.75 mm Crankshaft and main bearings Main journal diameter .. . Main bearing oi! clearanc 56.98 ~ $7.00: mm, ‘Standard ~~ 0.02 - 0.05 mm Limit . . Om Crankshaft 1 float 005 0.18 mm 2 0.25 mm Cunkpin diameter 44.98 — 45.00 rama Main journal and crankpin taper and ovality Ii 0.01 mam Flywheel runout limi 20.13 mim Camshaft and rocker gear Number of bearings . 3 94 — 33.95 mm 0.05 —0.09 mm ‘Camshaft end float: Standard ., 0.1 =0.2 mm Limit a S 4mm Rocker arm diameter 18.910 — 18.928 mm Rocker arm to shaft clearance Standard - 1.01 =0.08 mm Limit eects 0.1 mm, Rockershaft diameter . 18.89 ~ 18.90 mm Counter balance shaft Journal diameter: Right front -- 41,96 =41.98 mm Right rear ar » 80,95 =40.97 mm Left front... ie 1847-1848 mm Left rear "i 40.95 — 40.97 mm Oil clearance: Right front. ©, 0.03 —01.06 mm Right tear 0,05 = 0.09 iment ‘Left front 02 = 0.05 mm Lett + 0.05 = 0.09 mmTechnical Data Lubrication Regulated oil pressure (approximate) .. 300-600 kPa Oil pump clearances: ‘Drive gear tip clearance limit... . Driven gear tip clearance limit. Drive gear side clearance limi 0.30 mm mm To April 1987... 0.23 mm From May 1987... <2 048 mm Driven gear side clearance limit — To April 1987... 20.20 mum From Muy 1987... geo OES an *Combined machining of cylinder block and cylinder head not to exceed 0,2 mm, ‘Torque wrench settings Cylinder head bolts... Refer to text 25mm length 65 mm length Main beating cap bolts . vevees 50-55 Nm Big cnd cap nuts... 6. 30-33.Nm Flywheel/drive plate bolts... - 130140 Nm Crankshaft pulley bolts... -20-30Nm Crankshaft sprocket bolt... 110-130 Nm Oil pump sprocket mut... +e-- 50—60Nmn Coonter balance shaft sprocket bolt... ...... 4@Nm Timing belt tensioner pivot mut ......-..... 49Nm 49Nm 19Nm Timing belt tensioner adjusting bolt... - Timing belt tensioner pivot bolt ......- ENGINE ELECTRICAL Starter motor: Make is vee eyeae Type Manual transmission .. Automatic transmission Minimum brush length » Mitsubishi 0,9 kW direct drive 1.2 kW reduction drive + To wear limit line Drive pinion stop clearance ....,...03—2.0.mm Alternator: Make .....5-.+ wevaee Mitsubishi ‘Type : 14.volt, internal regulator Rated output - Fickd winding resistance Minimum brush leayth Lonition coil: Primary coil resistance — Ao litre - ‘ 24 litre « J. 40, 60, 65.0F 7S amp 35 ohms "To wear limit line .--L08= 1.32 ohms ..-- 0,720.88 ohms 21 Seoundary coil resistance — 2.0 hire . . 2.4 Nitre . Ballast resistor resistance (2.0 litre) 12.75 = 17.25 kiohms 10.29 = 13.92 feos - 122-149 ohms Torque wrench settings Starter motor retaining bolts .......- 27-34 Nm ‘Alicrnator pivot bolt... 12-15 Nm ‘Aliernator clamp aut .- 20-25 Nm COOLING SYSTEM Mitsubishi Long Life coolant concentration: Temperatures down to-15°C «+. AM mY/litre (30% volume in water) ‘Temperatures below -15°C ..... (500 mUlitre (30% volume in water) ‘Thermostat Opening temperature — 20 litre... nat 87rc TANG cc evens 57144 i + .88°C Minimum valve lift..........- -8.0 mm Radiator cap relief pressure: Sc aceasta ac ieaee exe TON ORRP A SG,SH oe eee eee 75108 kPa FUEL AND ENGINE MANAGEMENT SYSTEM 2.0 litre carburettor models Carburetor: Make oo 0c60 00 oe Mikuni Type ...2.-se.see+y Twin throat downdraught Choke type... . Automatic, wax element Carburettor mode! 1987 to bate 1985 — Manual transmission ...... 32-35 DIDTA-376 Automatic transmission —35 DIDTA-377 Late 1988 to tate 192 — ‘Manual transmission 235 DIDTA-386 ‘Automatic transmission 2.35 DIDTA-387 From late 1992 — Manual transmission. - Automatic transmission: Main jet: Primary .. Secondary Pilot jet: Primaty o¢. +++.Technical Data condity see eeeediieeseree NOOO Enrichment jet .. : No 60) Float level oo. 000 000. 2ees eee Nom adjustable Foe! pump Type... -.-Meehanical, non repairable é -. 18-28 kd =. 48 — 60 ohms at 20°C Delivery pressure Fucl cut solenoid resistance Choke fast idle opeain Manual transmission ....-.-... 0.67—0.76 mm Automatic transmission 0-76 —0.85 mm ‘Throttle cable free play ........-.-.-.--.. 0mm 2.4 litre EF] models Fuel pressure: Atidle 2... 0++-+---- +.) 188 kPa ‘Atidle with pressume regulator vacuum hose disconnected Injector resistance Pressure regulator solenoid resistance oo +) 250-260 kPa 23 ohms at 20°C Se 36 —46.0hms at 20°C CLUTCH ‘Type of control: 2.0 Hite 5 i bat Cable 24 litre aA Hydraulic Clutch pedal height. tees 202 208 mm Clutch pedal free pla Cable. 2... +. 20-35mm Hydraulic - H78-15mm Clutch driven plate minimum rivet head depth Pressuire plate spring distortion limit Master cylinder inner diameter ....... Slave cylinder inner diameter Torque wrench settings Clutch pressure plate bolts -.- 18-21 Nm Master cylinder mounting bolts «9-14 Nm Slave cylinder mounting bolis.-. - 30 42 Nm MANUAL TRANSMISSION ‘Transmission type... cesses speed ‘Transmission model: SE4x2model ......... KMI35 SP4x4model ....-.- MIT SG, SH 4x2 models ......... -RSM21 SG, SH 4x4 models .......-.........WSM31 22 Torque wrench settings Propeller shaft retaining bolts . . 50-60.Nm Transmission mounting bolts (4x2) .-.. 70-95 Nm ‘Transmission mounting bolts (4x4) .....35-55 Nm AUTOMATIC TRANSMISSION ‘Transmission type wd speed ‘Transmission mod SP models... Awan SG, SH models... cevvey rrr RAW ‘Rickdown cable sct measurements: titre « z 2+ 52= 53 mm titre oie +071 mm tee 1800-2 100 rpm 050— 350 rpm Torque wrench settings “Torque converter retaining bolts ........35-42.Nm ansmission mounting bolts: 10mm Simm... Propeller shaft retaining bolts - Drain plug ..... FRONT AXLE AND SUSPENSION Front axle —4 x4 models: Type Final drive ratio Hub end float. ..--- «Semi floating hyp 5 IOS 10.05 mm or less Hub turaing effort (spring scale on whee! stud) - 5-18 Drive shaft end float seneeeyes 04-07 mm ‘Automatic free wheeling, hub — Return spring ength (minimum), sees 35 mm Shift spring length (minimum) ..mm Brake pinte thickness (minimum)... 9.6mm Free wheeling hub turning resistance (maximum, spring scale on wheel stud) . er a4 ‘Crownwheel backlash 6.240). Ql1 0.16 mm ‘Crownwhee! runout limit seee 05 mm, Drive pinion total backlash limit ..<. 6. +. 14mm Drive pinion turning torque — With oil seal... cece eceee OG 0.7Nm Without oil seal civeeee ss Oat 0.5.Nm Front axle— 4x 2 models:Technical Data Hub end Moat 22.2... eee Bere Hub beuring preload... 8.Nm (see tex!) “Upper ball joint turning torque... 0.8-3.5 Nm ‘Lower ball joint turing torque (4x 2) =4Nm Lawer ball joint end float (4 x 4) - -0.5 mm ‘Wheel alignment: Toe in — SPmodels .... ‘ 0-6mm SG, SH models... (eee cdots Fegan Camber. (0 deg 30 min = 43 min Coster... « Sdeg # Tdeg Kingpin inclination — AxImodels...........5 10 deg 30 min Ax4models ...............+-., 8deg 30 min ‘Toe out an turns (outside wheel at 20 deg) — 4x 2models ......... ~ 1 deg 30 min 4x ¢models «650... =, B deg 30 min Sere tec eee ee 4x2modch .......... ---- 5mm 4x4 models 21) teceeee 45 mm Torque wrench settings Freewheeling hub housing bolts... , $0—60 Nem Wheel hub to brake disc bolts (4.x 4) .... 50~60Nm Weel hubyio brake disc muts (4x2)... 47-2. Nm to steering knuckle ... 120-180 Nm to upperarm . _ 35-55 Nm it to steering knuckle ... 120-180 Nm ‘Tic rod ball joint to steering knuckle .... 35=45 Nm Radiusitod to lower suspensionanm nuts... -.--..,--,, 85—110.Nm ‘Crowawhec! bolts sas ete -+-+- 80-90 Nm cetpee ee eee 160 200 Nen ar. pain gshn REAR AXLE AND SUSPENSION Rei les Type Final drive ratio Axle shaftend float... (0.05 ~ 0.20 mm Crownwheel backlash... ..,.. 0.11 -0.16 mm Drive pinion total backlash limit 5.0mm, Drive pinion turing torque — With oil Seal 2.2.2.2... 06-0. Nm eon 04-05 Nm Tarque wrench settings Final drive assembly retaining nuts... 25~30 Nm 23 30-45 Nm 50—60 Nm 20-30 Nin 180-230 Nm 190-250 Nm 83-110 Nm 80 — 90 Nm 55—65 Nm 50-60 Nm Shackle retaining nuts. Propeller shaft nuts asece Shock absorber muts 1. Rear axle bearing lock nut Pinion flange nut . . . U bolts nuts . Crownwheel bolts» Side bearing cap bolts ..... Backing plate retaining nuts. STEERING Steering wheel free play limit: Manual steering eevee 40mm Power steering (with engine running)... 40 mm Tic sod end ball joint turning torque ....... 1-3Nm Bevel gear assembly: Bevel gear torque (output side) - . 0.05—0.10 Nm Bevel gear torque (input side)... 0,250.45 Nm ‘Total bevel gear torque ».0.30-0.55 Nm torque — Manual/stecring ........ .06—1.2.Nm Power stecring : 0.7-14Nm Power steering: Drive belt deflection ........,..<....6—9mm Pomp pressure — Pressure gauge valve closed . 7.3-8.2MPa Pressure gauge valve opened ..... 0.8— 1.0 MPa ‘Clearance between vane and rotor... . 006mm Pulley shaft side play ...........02.-.0.1 mm ‘Torque wrench settings Steering wheel nuts ssseccrereeseeec 34=50 Nm Steering column retaining bolts ........ 14—20'Nm. Steering shaftto bevel gear pinch bolt... 30=40 Nm Upper steering shaft to lower steering shaft pinch boll ............,30-38Nm Upper steering column to lowersteering column bolts .........., 1§—20Nm Tie rod end castellated mut ........... 35—45 Nm Stecring wear retaining bolts ........... 70-90 Nm Steering pear yoke pinch bolt... .. 30-40 Nm Intermediate shaft flexible joint nuts. Bevel gear assembly retaining boll BRAKES Front brake: Caliper bore diameter .........<.....57.15 mmDisc diameter — 4x2 models , 4xdmodels .....0...- Dise mininwm thickness... Dise maximum runout Dise pad wearlimlt 2. Rear drum brake: Whecl cylinder bore diameter - Brake drum inner diameter Technical Data Brake pedal Height 2: ...... 196 = 202 mm Free play... 3-8mim Handbrake lever stroke: 4x Zmodels sever 46 notehes 4x4 models . i 5-7 natehes ‘Torque wrench settings Brake pedal pivot bolt and nut .. 19-28 Nm Front caliper anchor plate bolts «+... 80—100 Nm 40-50 Nm 32-42 Nm