1995-2003 Mitsubishi Mirage Service & Repair Manual

00-1 GENERAL CONTENTS 001 09000904 GENERAL <BODY AND CHASSIS> . . .. . . ... . . . ... ...... .. .. . . .. 00 GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . ... . .. . . . .. . . . . . . . .. . . OOE

00-2 GENERAL <BODY AND CHASSIS> CONTENTS M)109001172 GENERAL DATA AND SPECIFICATIONS .. 24 Engine Coolant ............................. 44 HOW TO USE THIS MANUAL ............ 3 Definition of Terms .......................... 3 Explanation of Manual Contents .............. 4 Model Indications ........................... 3 Maintenance. Repair and Servicing Explanations ....................... 3 Tightening Torque Indication .................. 3 HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS ........... 6 Connector Inspection Service Points .......... 10 Connector Measurement Service Points ........ 9 Special Tool Note ........................... 3 Engine Oil .................................. 39 Engine Oil Filter ............................ 40 Evaporative Emission Control System ......... 33 Exhaust System ............................ 51 Fuel Hoses ................................. 32 Fuel System ................................ 32 Ignition Cables .............................. 33 Manual Transaxle ........................... 41 Rear Drum Brake Linings and Rear Wheel Cylinders ....................... 45 SRS Air Bag System ........................ 47 Timing Belt ................................. 34 Spark Plugs ................................ 33 How to Cope with Intermittent Malfunctions ... 11 How to Use the Inspection Procedures ....... 8 PRECAUTIONS BEFORE SERVICE ....... 19 Inspection Service Points for a Blown Fuse ... 12 RECOMMENDED LUBRICANT AND Troubleshooting Contents .................... 6 LUBRICANT CAPACITY TABLE ........... 28 LUBRICATION AND MAINTENANCE ...... 27 SCHEDULED MAINTENANCE TABLE ..... 31 MAINTENANCE SERVICE ................. 32 TOWING AND HOISTING ................. 21 MAIN SEALANT AND ADHESIVE TABLE .. 52 TIGHTENING TORQUE ................... 26 Air Cleaner Element ......................... 32 Automatic Transaxle ......................... 41 Ball Joint and Steering Linkage Seals ........ 46 Brake Hoses ............................... 46 Disc Brake Pads ............................ 45 Distributor Cap and Rotor .................... 34 Drive Belt .................................. 35 Drive Shaft Boots ........................... 46 VEHICLE IDENTIFICATION ............... 13 Engine Model Stamping ..................... 16 Theft Protection ............................. 16 Vehicle Identification Code Chart Plate ........ 13 Vehicle Identification Number List ............. 14 Vehicle Identification Number Location ........ 13 Vehicle Information Code Plate ............... 15 Vehicle Safety Certification Label ............. 15

GENERAL - How to Use This Manual 00-3 MAINTENANCE, REPAIR AND SERVlC I NG EXPLAN AT1 0 N S This manual providesexplanations,etc. concerning procedures for the inspection, maintenance,repair and servicing of the subject model. Unless other- wise specified, each service procedure covers all models. Procedures covering specific models are identified by the modelcodes, or similar designation (engine type, transaxle type, etc.). A description of these designations is covered in this manual under “VE H I C LE I DENT I F I CAT I 0 N ” . ON-VEHICLE SERVICE “On-vehicle Service” are proceduresfor performing inspections and adjustments of particularly impor- tant locations with regard to the construction and for maintenance and servicing, but other inspections (for looseness, play, cracking, damage, etc. ) must also be performed. SERVICE PROCEDURES The service steps are arranged in numericalorder. Attention must to be paid in performing vehicle serviceare describedin detail in SERVICE POINTS. DEFINITION OF TERMS STANDARD VALUE Indicatesthe value usedas the standardfor 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 assemblyon inspectionand meansthe maxi- mum or minimum value within which the part or HOW TO USE THIS MANUAL 001 0001 0234 assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presentedin order to facilitate assembly and adjustment procedures, and so they can be com- pleted in a shorter time). CAUTION Indicates the presentation of information particularly vital to the worker duringthe performance of maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or damage to component parts, or a reduction of component or vehicle function or performance, etc. TIGHTENING TORQUE INDICATION The tightening torque shown in this manual is a basic value with a tolerance of -c 10% except the following cases when the upper and lower limits of tightening torque are given. (1) The tolerance of the basic value is within f 10%. (2) Special bolts or the like are in use. (3) Special tightening methods are used. SPECIAL TOOL NOTE Only MMC special tool part numbers are called out in the repair sections of this manual. Please refer to the special tool cross referencechart, which is located in the service manual at the beginning of each group, for a cross referencefrom the MMC special tool number to the special tool number that is available in your market. M 0 D EL INDlCATlONS The following abbreviations are used in this manual for classification of model types. M/T : Indicates the manual transaxle, or models equipped with the manual transaxle. Indicates the automatic transaxle, or models equipped with the automatic transaxle. -_____

00-4 GENERAL - How to Use This Manual EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. 0 Removal steps . The part designation number corresponds to the number in the illustration to indicate removal 0 steps The part designation number corresponds to the number in the illustration to indicate disassembly steps. 0 0 Disassembly steps : the work in that section is started, and proce- section is finished. A diagram of the component parts is pro- to give the reader a better understanding of the installed condition of component parts. necessary. I Installation steps : Specified in case installation is impossible in reverse order of removal steps Omitted if installation is possible in reverse order of removal steps Specified in case reassembly is impossible in reverse order of disassembly steps Omitted if reassembly is possible in reverse order of disassembly steps Reassembly steps Classifications of Major Maintenance / Service points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc ), these are arranged together as major maintenance and service points and explained in detail 4Ab ' Indicates that there are essential points for removal or disassembly. FA4 : Indicates that there are essential points for installation or reassembly. - Symbols for Lubrication, Sealants and Adhesives Information concerningthe locations for lubrication and 6 : Grease for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained. (multipurpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid or automatic transmission fluid pressor oil :a : Engine oil, gear oil or air conditioning com- a : Adhesive tape or butyl rubber tape

GENERAL - How to Use This Manual Terminal 1 3 4 5 Battery voltage Power is not supplied *4 Power is supplied 0 - 0 -+ __ 00-5 0-0 indicates that there is continuity between the terminals. 0-0 indicates terminals to which battery voltage is applied FI the group the section the group STEERING - Power Steering Gear Box 37A-23 POWER STEERING GEAR BOX REMOVAL AND INSTALLATION 15h 18Nm . D Removal sleps 1 Joint assembly and gear box connecting bolt 2 Solenoid valve wnnector <Vehicles with EPS> 3 Cotter p ~ n 4 Connection tor tie-rod end and knuckle 5 Stay (LH) 6 Slay (R H ) 7 Center member assemblv Repair kit or set parts are shown. (Only very frequently used parts I are shown.)

00-6 GENERAL - How to Use Troubleshooting/lnspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTlON SERVICE POINTS 00100020121 Troubleshootingof electronic control systems for which the scan tool can be used follows the basic outline described below. Furthermore, even in systems for which the scan tool cannot be used, part of these systems still follow this outline. TROUBLESHOOTING CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING The main procedures for diagnostic troubleshooting are shown. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. DIAGNOSTIC FUNCTION The following diagnostic functions are shown. 0 0 0 Input inspection service points INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to the next page on how to read the inspection procedures.) INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms, even though the results of inspection using the scan tool show that all diagnostic trouble codes are normal, inspection proceduresfor each trouble symptom will be found by means of this chart. INSPECTION PROCEDURE FOR DIAGNOSTIC SYMPTOM Indicatesthe inspection procedurescorresponding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms. (Refer to the next page on how to read the inspection procedures.) SERVICE DATA REFERENCE TABLE Inspectionitems and normaljudgementvalues have been providedin this chart as referenceinformation. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items and standard values have been provided in this chart as reference information. Terminal Voltage Checks Method of reading diagnostic trouble codes Method of erasing diagnostic trouble codes Connect a needle-nosed wire probe or paper clip to a voltmeter probe. Insert the needle-nosed wire probe into each of the ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE 1. Measure voltage with the ECU connectors connected. 2. You may find it convenient to pull out the ECU to make it easier to reach the connector terminals. 3. Checks don’t have to be carried out in the order given in the chart. Caution Short-circuiting the positive (+) probe betweena connectorterminal and ground could damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this ! If voltage readings differ from Normal Condition values, check related sensors, actuators, and wiring, then replace or repair.

GENERAL - How to Use Troubleshooting/lnspection Service Points 00-7 4. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem. Terminal Resistance and Continuity Checks 1. 2. 3. 4. 5. Turn the ignition switch to “OFF. Disconnect the ECU connector. Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart. NOTE Checks don’t have to be carried out in the order given in the chart. Caution If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this! If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem. ’ 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here.

00-8 GENERAL - How to Use Troubleshooting/lnspection Service Points 1 E~U switch component (Refer to p3-44 ) / Measure at switch connector A-44 Disconnect the connector, and at the harness side 0 Voltage between terminal 6 - earth and terminal 8 - ground 0K:Approx 5V 4 OK HOW TO USE THE INSPECTION PROCEDURES 3. Indicates voltage and resistance to be measured at a particular connector. (Refer to “Connector Measurement Service Points”.) The connector position can be located in the wiring diagram in Volume -2 manual by means of this symbol Indicates operation and inspection procedures, inspection terminals ~ ~ ~ ~ ~ ~ ~ $ ~ ~ ~ ~ conditions The causes of many problems occurring in electronic circuitry are generally the connectors, components, the ECU and the 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. CHECKING PROCEDURE 4 i°K \ 4 OK Check the following connector. A-44 -.., ~ I Check trouble symptom I I 4 Inspect the contact condition at each connector terminal. (Refer to “Connector Inspection Service Points”.) The connector position can be located in the wiring diagram in Vol- ume-2 manual by means of this symbol Caution After carrying out connector inspection, always be sure to recon- nect the connector as it was before. witch is pressed. hich should not be illuminated is tes the operation and inspection proce- it is defective 1 Replace the ECS-ECU. \ \ I I 5. Confirm that there are trouble symptoms. If trouble symptoms have dis. pappeared, the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection. If it seems that trouble symptoms still remain, proceed to the next stage of instructions. I 6. If trouble symptoms still remain up to this stage, there is a possibility that there is ar open or short circuit in the harness between the connectors, so check the harness. Alternatively, the cause may be a defective ECU, so try replacingthe ECU and check if the trouble symptom disappears. HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to the connector measurements. Carry out this inspection while referring to Volume 2 Electrical manual. Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses. For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown Fuse I’ . MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeatthe inspection procedure from the beginning.

GENERAL - How to Use Troubleshooting/lnspection Service Points 00-9 ooooo2 \ Inspection harness for connector pin contact pressure CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting and discon- necting the connectors. Turn the ignition switch to ON when measuring if there are no instructions to the contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED (WITH CIRCUIT IN A CONDITION OF CONTINUITY) Waterproof Connectors Be sure to use the special tool (harness connector). Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion. Ordinary (non-waterproof) Connectors Check by inserting the 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 a special tool (the extra-thin probe in the harness set for checking) for this purpose. IF INSPECTING WITH THE CONNECTOR DISCONNECTED <When Inspecting a Female Pin> Use the special tool (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 probe should never be forcibly inserted, as it may cause a defective contact. <When Inspecting a Male Pin> Touch the pin directly with the test bar. Caution At this time, be careful not to short the connector pins with the test probes. To do so may damage the circuits inside the ECU.

00-1 0 GENERAL - How to Use Troubleshooting/lnspection Service Points Connector disconnected or improperly connected 16S0256 Defective connector contact Harness wire breakage at terminal section Low contact pressure 1630254 000002 19 l6R1317 A 16U1318 CONNECTOR INSPECTION SERVICE POINTS VISUAL INSPECTION 0 0 0 0 Connector is disconnected or improperly connected Connector pins are pulled out Due to harness tension at terminal section Low contact pressure betweenmale and female terminals Low connectionpressuredue to rustedterminalsor foreign matter lodged in terminals CONNECTOR PIN INSPECTION If the connector pin stopper is damaged, the terminal connec- tions (male and female pins) will not be perfect even when the connector body is connected, because the pins may pull out of the back side of the connector. Therefore, gently pull the wires one by one to make sure that no pins pull out of the connector. CONNECTOR ENGAGEMENT INSPECTION Use the special tool (connector pin connection pressure inspection harness of the inspection harness set) to inspect the engagement of the male pins andfemale pins. [Pin drawing force : 1 N (.2 Ibs.) or more]

1995-2003 Mitsubishi Mirage Service & Repair Manual

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