1991-1996 Mitsubishi Magna Verada TR TS KR KS Service & Repair Manual

MlTSUBlSHl MOTORS Workshop Manual

7 --- 1 QUICK REFERENCE INDEX: To use, bend nlar~ual hack to expose black ' i nlarhen on pages of the various groups. Then, hy means of, the index.marks I on this page, locate the corresponding black marker on the bage of the group 1 1 VOII desire to find. 1 I . i 1 GROUP INDEX m~eneral Information 1 11 Engine -- -- 1 12 Lubrication / 13 Fuel - > 1 14 Cooling --- - p5 Intake and Exhaust k6 Engine Electrical R and S SERIES WORKSHOP MANUAL 7---- -- I 22 Manual Transmission L_ INCLUDING 1995 MODEL SEDAN AND WAGON Part No. AW342051 [ 26 Front Axle 3 @7 Rear A - MITSUBISHI MOTORS ACTIVE-Electronic Control Suspension [ F a r s~s~ension - - 35 service . -- Brakes . -- - 11111 COPYRIGHT 1995 1 36 Parking Brakes SERVICE DIVISION TONSLEY PARK SOUTH AUSTRALIA 1 42A Body -- I 1 428 Body Repa 1 51 Exterior x Body Repair Manual - 528 supplemental . . Restraint System -- (SRS) MITSUBISHI MOTORS AUSTRALIA LTD. AUST CO. No. W7 870 395 -- Heater, Air conditioner p5 and Ventilation O Mitsubishi Motors Australia Ltd. March 1995 REVISED -- .

List of effective pages Filling instructions File these pages in your TRJKR-TSJKS Loose Leaf Workshop Manual part number AW34205 1. All revised pages carry a revision date, part number and REVISED or ADDED to signify that the page has been modified. Alterations to the text and/or illustrations are indicated by a single vertical marker adjacent to the revision. Major revisions or new page layouts carry the revision date, part number and REVISED or ADDED only, no vertical line. Fit the new pages to your manual as soon as possible, removing the current pages they replace. Destroy the old pages to avoid confusion at a later date. Group 00 pages 00-2-5 to 00-2-7 00-2- 10 to 00-2- 11 Group 13 page 13-3-1 Group 16 pages 16-3A-3 & 16-3B-2 16-3C-7 & 16-5-1 16-6- 1 Group 23 pages 23-2- 14 to 23-2- 15 23-4A- 1 to 23-4A-3 Group 33A page 33A-2- 1 to 33A-2-2 Group 33B page 33B-5-3 to 33B-5-4 33B-5-8 Group 34 page 34-2- 1 Group 37 pages 37-4- 1 37-2B- 1 Group 42B page 42B- 1-5 Group 5 1 pages 5 1-3-8 to 5 1-3-9 Group 52 pages 52-2-8 to 52-2-9 52-2- 1 1 Group 52B pages 52B-0- 1 52B-3-3 52B-3-5 52B-3-7 52B-3- 10 to 53B-3- 1 1 52B-3- 13 52B-3- 15 to 52B-3- 16 53B-3- 18 to 52B-3- 19 52B-5- 1 52B-6-5 Group 53 pages 54-3C-4 to 54-3C-5 54-3D- 1 to 54-3D-3 Group 54 pages 54-3D- 12 to 54-3D- 18 54-3D-20 to 54-3D-2 1 54-3D-24 to 54-3D-28 54-3D-36 to 54-3D-40 54-3D-60 to 54-3D-64 54-3D-70 to 54-3D-7 1 54-3D-74 to 54-3D-78 ~ 54-3D-80 54-3D-82 to 54-3D-86 54-3D- 104 to 54-3D- 105 54-3D- 108 to 54-3D- 1 10 54-3D- 1 12. to 54-3D- 1 13 54-3D- 118 to 54-3D- 12 1 54-3D- 124 to 54-3D- 125 54-3D- 134 to 54-3D- 139 54-3D- 146 to 54-3D- 150 54-3D- 152 to 54-3D- 154 54-3D- 156 to 54-3D- 159 54-3D- 162 54-3D- 168 to 54-3D- 176 54-3D- 178 to 54-3D- 183 1 54-3D- 190 to 54-3D- 195 54-3D- 196 to 54-3D-203 54-3D-208 to 54-3D-2 14 , 54-3D-2 16 54-9-6 to 54-9-8 54-12-8 & 54-12-11 Group 55 page 55-2-4 0 Mitsubishi Motors Australia Ltd. Sept. 1994 AW342051-A REVISED

SECTION 1 - INTRODUCTION USING THE MANUAL The pages of this service manual are numbered using a three segment numbering system, these number groups located in the centre of each page, are divided by a dash, and serve the following functions. The first figure indicates the service manual group; The second figure indicates the section number within a group; The last figure is the page sequence number within the section. Each section commences with page 1. EXAMPLE Section 4 - ~h~ine Overhaul - 1 illustrations are numbered in sequence within each section. When reference is made to a side of the vehicle, or a handed component, the side is defined as viewed from the driver's seat unless otherwise specified. Where possible the component parts described in this manual have been identified by a part number or serial number. Where this is the case, the component part or serial number should be established and then reconciled with the service specifications/descriptions in this manual. Group 11 - Engine METRIC CONVERSION In this manual all measurements and capacities are quoted in Metric Units. To carry out conversions from Metric to imperial or vice versa, multiply the unit to be converted by the appropriate factor, or in the case of Temperature, Fuel and Oil consumption apply the required formula. These may be found in the Conversion Values column of the Conversion Chart. Page number within section Examples: Converting millimetres to inches 1.2 mm x 0.03937 (from table) = 0.050" !'? Converting OF to OC 860F: 5 OC =-(OF-32) (from table) 9 5 . - -(86-32) - 9

CONVERSION CHART - METRIC AND IMPERIAL MEASURES I I LENGTH Quantity MASS AREA I Metric units VOLUME Conversion Values VOLUME- FLUIDS FORCE TORQUE PRESSURE VACUUM VELOCITY TEMPERATURE Name Symbol millimetre metre kilometre gram kilogram tonne square millirnetre square centimetre square metre cubic centimetre cubic metre newton newton metre kilopascal kilopascal kilometre per hour degree Celsius metric to imperial 1 mm = 0.03937 inches 1 m = 1.09 yard 1 km = 0.621 miles 1 g = 0.0353 02s. 1 kg = 2.2 lbs. 1 t = 0.984 ton 1 mm" 0.00155 in.' 1 cm2 = 0.155 in.2 1 m2 = 1.20 yd' 1 cm3 = 0.0610 in.' 1 m3 = 35.3 ft.3 1 litre = 1.76 pts. 1 litre = 0.2199 gallon 1 N = 0.225 lb. force 1 Nrn = 0.74 lb. ft. 1 Nrn = 8.94 1b. ins. 1 kPa = 0.145 p.s.i. 1 kPa = 0.295 in. Hg. 1 km/h = 0.621 m.p.h. OF =- Oc + 32 5 imperial to metric 1 inch = 25.4 mm 1 yard = 0.914 m 1 mile = 1.61 km 1 oz. = 28.3 g 1 lb. = 0.454 kg 1 ton = 1.02 t 1 in.2 = 645.16 mm2 1 in.' = 6.45 crn' 1 yd2 = 0.836 m2 1 in.' = 16.4 cm3 1 ft.3 = 0.0283 m' 1 pt. = 0.568 litre 1 gallon = 4.546 litre 1 lb. force = 4.45 N 1 Ib. ft. = 1.36 Nm 1 Ib. in. = 0.113 Nrn 1 p.s.i. = 6.89 kPa 1 in. Hg. = 3.386 kPa 1 m.p.h. = 1.61 km/h 5 OC = -(OF-32) 9 1 POWER I kilowatt I kW 1 k kW = 1.34 h.p. 1 1 h.p. = 0.746 kW I litre per 100 krn litre per 1000 km

00-2-1 SECTION 2 - VEHICLE SPECIFICATIONS < R Series > - Magna Sedan Magna Wagon Verada Sedan

00-2-2 SECTION 2 - VEHICLE SPECIFICATIONS < S Series> Verada Wagon

00-2-3 MODEL IDENTIFICATION < R Series > Australia Model Name Magna GLX Magna GLX Magna Executive Magna Executive Magna SE Magna SE Magna Elite Magna Executive Magna Executive Verada V6Ei Verada V6Xi Magna GLX Magna GLX Magna Executive Magna Executive Magna SE Magna SE Magna Executive Magna Executive Verada V6Ei Model Code TR1-H-41 TR2-H-41 TR3-D-41 TR4-D-41 TR3-P-41 TR4-P-41 TR4-X-41 TR5-D-41 TR6-D-41 KR8-P-41 KR8-X-41 TR1-H-45 TR2-H-45 TR3-D-45 TR4-D-45 TR3-P-45 TR4-P-45 TR5-D-45 TR6-D-45 KR8-P-45 New Zealand Model Model Name Code Magna GLX TR7-D-41 Magna GLX TR8-D-41 Magna Super Saloon TR7-P-41 Magna Super Saloon TR8-P-41 V3000 Executive KR5-D-41 V3000 Executive KR6-D-41 V3000 Super Saloon KR6-P-41 V3000 SEi KR6-X-41 Magna GLX TR7-H-45 Magna GLX TR8-H-45 V3000 Executive KR5-D-45 V3000 Executive KR6-D-45 V3000 Elite KR6-P-45 Body TY pe Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Wagon Wagon Wagon Wagon Wagon Wagon Wagon Wagon Wagon Body Type Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Wagon Wagon Wagon Wagon Wagon Papua New Guinea, Brunei & Fiji Model Model Body Name Code Type Magna Executive TR7-D-41 Sedan Magna Executive TR8-D-41 Sedan Magna SE TR7-P-41 Sedan Magna SE TR8-P-41 Sedan Magna Elite TR8-X-41 Sedan Verada Ei KR6-P-41 Sedan Verada Xi KR6-X-41 Sedan Magna Executive TR7-D-45 Wagon Magna Executive TR8-D-45 Wagon Magna SE TR7-P-45 Wagon Magna SE TR8-P-45 Wagon Verada Ei KR6-P-45 Wagon Engine TY pe 2.6L Carby 2.6L Carby 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI Multi 3.OL ECI-Multi 3.OL ECI-Multi 2.6L Carby 2.6L Carby 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi Engine Type 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi Engine TY pe 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 2.6L ECI-Multi 2.6L ECI Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi Transaxle 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic Transaxle 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic Price Line GLX GLX Executive Executive S E SE Elite Executive Executive V6Ei V6Xi GLX GLX Executive Executive SE SE Executive Executive V6 Ei Price Line GLX GLX Super Saloon Super Saloon Executive Executive Super Saloon SEi GLX GLX Executive Executive Elite Price Line Executive Executive SE SE Elite Ei Xi Executive Executive SE S E V6 Ei

MODEL IDENTIFICATION cS Series> Australia klodel Model Body Name Code Type Magno GLX TS I -H-4 1 Sedan Magn;~ GLX TS2-H-4 1 Sedan Magna Executive TS3-D-4 1 Sedan Magna Executi\.e TS4-D-4 I Sedan M;L~I~;L SE TS3-P-4 1 Sedan Magna SE TS4-P-4 1 Sedan Magna SE TS6-P-4 1 Scdan Magno Executite TS5-D-41 Sedan Mt~g~ia Executi\ c TS6-D-41 Sedan Vcr;~cl;~ V6Ei KSX-P-4 I Scdan Vcr;~di~ V6Xi KSX-X-41 Sedan Magna CiLX TS I -H-45 Wagon Mag~i;~ GLX TS2-H-45 Wagon Magn;~ Exccurivc TS3-D-45 Wagon hl;~g~i;~ Executive TS4-D-45 Wagon Magnu SE TS3-P-45 Wagon hlugna SE TS4-P-45 Wagon Mi~grli~ SE TS6-P-45 Wagon Magna Executi\.e TS5-D-45 Wagon hlugnu Exccuti\,e TS6-D-45 Wag011 Vel-ada V6t:1 KSX-P-45 Wagon New Zealand Model Name MiLgll;' G LX Magna (ILX Magni~ Super Saloon Magnu Super St~loon V3000 Executive V.7')OO E x c c ~ ~ t i v e V.ir/Oo Super Si~loon V3000 SEi Mag~ia GLX M ;Lg"iL G LX V3000 Executi\,e V3OOO Exccutivc V3OOO Elite Model Code TS7-D-41 TSX-D-4 1 TS7-P-4 1 TSX-P-4 1 KSS-D-4 I KS6-D-4 I KS6-P-4 I KS6-X-4 1 TS7-H-45 TSX-H-45 KS5-D-45 KS6-D-45 KS6-P-45 Papua New Guinea, Brunei & Fiji Model Model Name Code Mi~g~ia Executi\ c TS7-D-4 I Magna Executi\ e TSX-D-4 I Magna SE TS7-P-4 1 Magn;~ SE TSX-P-4 I Magna Elite TSX-X-4 I Veracla Ei KS6-P-4 I Vcl-ads Xi KS6-X-4 I Magnil Exccuti\~e TS7-D-45 Magna Executive TS8-D-45 Magna SE TS7-P-45 Mngna SF: TS8-P-45 Verada Ei KS6-P-45 Hody 'Iy pe Sedan Sedan Sedan SetIan Scdan Sedan Sedan Sedan Wag 0 n Wagon Wag 0 n Wagon Wagon Hody TY pe Sedan Sedan Sedan Scdan Sedan Scdan Scclan Wagon Wagon Wagon Wagon Wagon - South East Asia Model Model Hody Name Code TY pe Sigma KS2-X-4 1 Sedan Sigma KS2-X-45 Wagon Engine 5pe 2.6L Carby 2.6L Carby 2.6L ECT-Multi 2.6L ECT-Multi 2.6L ECI-Multi 2.6L ECT-Mu!ti 3.0L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.0L ECI-Multi 3.OL ECI-Multi 2.6L Carby 2.6L Carby 2.6L ECI-Mul ti 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.0L ECI-Multi 3.0L ECI-Mult~ Engine 'rype 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.0L ECI-Multi 3.0L ECI-Multi 3.0L ECI-Multi Engine TY pe 2.6L ECI-Multi 2.6L ECI-Mulli 2.6L ECI-Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi 3.OL ECI-Multi 2.6L ECT-Multi 2.6L ECI Multi 2.6L ECI-Multi 2.6L ECI-Multi 3.OL ECI-Multi Engine Type 3.OL ECI-Mulli 3.OL ECI-Multi Transaxle 5 speed manual 4 specd automatic 5 spccd manual 4 speed automatic 5 speed manual 4 spced automatic 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 4 speed automatic 5 spccd manual 4 speed automatic 5 speed manual 4 spced automatic 5 speed manual 4 speed automatic 4 speed automatic 5 speed manual 4 spced automatic 4 speed automatic Transaxle 5 speed manual 4 speed automatic 5 speed manual 4 specd automatic 5 \peed manual 4 specd automatic 4 spccd automatic 4 speed automatic 5 speed manual 4 speed automatic 5 spced manual 4 speed automatic 4 speed automatic Transaxle 5 speed manual 4 speed automatic 5 speed manual 4 spced automatic 4 speed automatic 4 spced automatic 4 speed auto~natic 5 speed manual 4 specd automatic 5 speed manual 4 speed automatic 4 spced automatic Transaxle 4 speed automatic 4 \peed automatic Price Line GLX GLX Executivc Executivc SE SE SE Executive Executive V6Ei V6Xi GLX GLX Executive Executive S E SE S E Excculi\ e Exccutitc V6Ei Price 1,iiie GLX GLX Super Saloon Super S;~loon Executi\ c Executi\ e Super Saloon SEi GLX GLX Executive Executive Elite Price Line Executive Executive SF: S E Elite Ei Xi Exccuti\c Executive SE SE E i Price Line O Mitsubishi Motors Australia Ltd. March 1995 AW342051 -B REVISED

1991-1996 Mitsubishi Magna Verada TR TS KR KS Service & Repair Manual

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