sensor MITSUBISHI GALANT 1989 Service Repair Manual

MANUAL TRANSAXLE - Transaxle
60-72 Nm
43-52 ftfbs.
i“1
30-35
Nm
22-25
ft.lbs. /(
7-4 filhs
60-72 Nm
43-52 ftlbs.
/-
.,- 17-25 ft.lbs.17-26 Nm12-19 ft.lbs.
09A0019
+I)Il. Under cover
12. Cotter pin
*I)13. Connection for tie rod end
14. Self-locking nut
l 4 15. Front height sensor rod 18. Circiip
19. Bell housing cover
20.
/?a;saxle assembly lower part coupling
21. Transaxle assembly
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MANUAL TRANSAXLE
- Transaxl
e
22-13
part ofirive shaftITransaxle
09LOO58
12R0124
Normal
12R036:s
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(2) Keep the removed drive shaft as far away from the
transaxle case as possible, and secure (by using rope,
etc.) the joints to the body so that it does not fall.
21. REMOVAL OF TRANSAXLE ASSEMBLY
Support the transaxle assembly by using a transaxle jack;
then, after moving the transaxle assembly to the right, lower it.
NOTE
When supporting the transaxle’assembly by the transaxle
jack, take care to be sure that the jack’s force is applied to a
wide area, not to only a small localized area.
SERVICE POINTS OF INSTALLATION MZ?MDAK
17. INSTALLATION OF DRIVE SHAFT
(1) Provisionally install the drive shaft so that the inboard
joint part of the drive shaft is straight, and not bentrelative to the transaxle.
Caution
Care must be taken to ensure that the oil seal lip
part of the transaxle is not damaged by the serrated
part of the drive shaft.
(2) Align the serrations and securely insert the drive shaft into the transaxle.
15. INSTALLATION OF FRONT HEIGHT SENSOR ROD
Install the rod so that dimension A in the figure is within the
following range.
Dimension A:
254.5* 0.5 mm (lo& .02 in.)
NOTE
(1) Adjust the rod length so that dimension B is equal.
(2) The ball joint on the end of the rod should be installed with the ball centered.
Defective
I

MANUAL TRANSAXLE - SDecifications2245
SPECIFICATIONSM?zcA-B
GENERAL SPECIFICATIONSItems
Specifications
Model W5M31
Applicable engine 4G63
Tvw
5-speed
Gear ratio
1 St2.846
2nd1.684
3rd1.115 4th
0.833
5th
0.690
Reverse 3.166
Reduction ratio Primary
1.680
Secondary 3.100
Transfer
1.090
Speedometer gearratio(driven/drive)30136
NOTE: The AWD vehicles have been discontinued from 1993 models. W5M33
4G63-TIC
5-speed
2.846
1.684
1.115
0.833 0.666
3.166
1.275
3.866
1.090
30136
TORQUE SPECIFICATIONS
TRANSAXLE
Items
Bell housing cover mounting bolt
10-127-
9
Starter motor mounting bolt 27-34
20-25
Transaxle mount bracket mounting bolt60-8043-5
8
Shift cable and select cable bracket mounting bolt
15-2211-16
Rear cover mounting bolt 35-42
26-30
Transaxle case mounting bolt 35-4226-30
Clutch release cylinder mounting bolt 15-2211-16
Clutch tube to transaxle assembly 15-2211-16
Front height sensor rod to lower arm 17-2612-19
Transaxle mounting bolt
[I2 mm diameter bolt] 43-5
5
32-39
Transaxle mounting bolt [IO mm diameter bolt]
30-3522-25
Transaxle mounting bolt
18 mm diameter bolt]IO-127-
9
Tie rod end to knuckle 24-35
17-25
Lower arm ball joint to knuckle60-7243-52
Center bearing bracket installation bolts 36-4626-33
Front exhaust pipe to exhaust fitting
30-4022-29
Front exhaust pipe clamp
30-4022-29
Right member installation bolt (front)30- 10058-72
qight member installation bolt (rear)70-80jl-58 rransfer
assembly mounting bolt
55-60IO-43
Nm M22CGBft.lbs.
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MANUAL TRANSAXLE
- Transaxle22-21
2430
30-35 Nm 22-25\
ftlbs.
-.
60-72 Nm\‘I..-\)43-52 ti.lhe~
lo-12 Nm
7-9 ft.lbs. 1
40-43 ftlbs..-3d-2FNm
--A 17-25 ft.lbs.
36-46 -_ --Nm _ _.-7.--.--l ‘-“’ 26-33
ftlbs.,f ’
80-106
NmEQ-73 fi Ihr77
30-40’ Nm
22-28 ft.lbs.
30-40 Nm
22-29 ftlbs.
70-80 Nm51-58 ft.lbs.
40-60 Nm
29-43 ft.lbs.
l *
10. Under cover
11. Speed sensor
12. Cotter pin
13. Connection for tie rod end (Refer to
P.22-12.)14. Self-locking nut 15. Connection for lower arm ball joint (Refer to
P.22-12.)16. Connection for drive shaft (Refer to P.22-12.)
17. Circlip
18. Front exhaust pipe
19. Transfer assembly (Refer to
P.22-23.120. Bell housing cover
21. Right member
22. Gusset
23.
;f;saxle assembly lower part coupling
24. Transaxle assembly (Refer to
P.22-13.1
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23-1
AUTOMATIC
TRANSAXLE
CONTENTShl23AA-
GENERALINFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICEADJUSTMENTPROCEDURES.....
Drive Shaft OilSealsReplacement...........
KeyInterlockMechanismCheck............... Kickdown
ServoAdjustment ......................
Line Pressure Adjustment .........................
Park/Neutral Position Switch
Adjustment
............................................................
ReducingPressure Adjustment .................
Selector LeverOperation
Check...............
Shift
LockMechanismCheck....................
Speedometer
CableReplacement .............
Throttle-position Sensor Adjustment ..........
TransaxleFluidLevelInspection ...........i...
TransaxleFluidReplacement .....................
Transfer
Oil LevelInspection .....................
Transfer
OilReplacement ..........................
SPECIAL
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . .21
SPECIFICATIONS ...........................................19
General Specifications
................................19
Lubricants....................................................20
Torque Specifications .................................20
2TRANSAXLEASSEMBLY . . . . . . . . . . . . .105
82
92
83
86
88
84
91
83
84
93
92
82
82
82
82
TRANSAXLEASSEMBLY . . . . . . . . . . . . .101
TRANSAXLE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
TRANSAXLE OIL
COOLERHOSES . . . . . . . . . . . . .100
TRANSFER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . .108
TROUBLESHOOTING
....................................
CircuitDiagram...........................................
Converter Stall Test ...................................
Datalink
andTest................................................
E.L.C. 4-speed Automatic Transaxle
ControlComponents
Layout
......................
Element in Use at Each Position
of Selector Lever .......................................
Fail-safe Item ..............................................
Fault Code Description ...............................
OilPressure Tests
.....................................
Shift Patterns ..............................................
Transaxle
Control........................................
22
60
59
26
80
37
32
28
52
37 59

23-22 AUTOMATIC
TRANSAXLE
- Troubleshooting
Based upon use of the troubleshooting
guide, the probable location of the prob-
lem should be estimated.
Checks should be made of fluid levels
and the condition of the ATF, as well as
1 found to be necessary
.
the condition of the manual control ca-
bles; adjustments should then be made if
If a presumption has been made that
there is an abnormal condition some-
where in the electronic-control system,
check the fault code, in order to determine
the probable location of the problem, by using a scan tool or voltmeter.
When the abnormal system is discovered,
check each element (sensors, etc.) one by
one, and make repairs as necessary.
When the abnormal condition is pre- sumed to be in the oil-pressure-control
When the result of the oil-pressure test does not satisfy the specified pressure,
1 passages for leakage, etc
.
check each system at places related to
the valve body, check the oil-pressure
If the problem is unusually dirty ATF,
abnormal noises, oil leakage, or slippage
L##t he traniaxle.1
of the clutch or brakes or an abnormal
condition of the transaxle Itself,
disassem-
TROUBLESHOOTING
Functional malfunctions of the ELGWT can lead to other
problems,
such
as those described
below:
(1) Improper
maintenance
and/or
adjustments
(2) Malfunctions of the electronic control functions
(3) Malfunctions of mechanical functions
(4) Malfunctions of hydraulic control functions
(5) Malfunctions of engine performance
etc.
In order

to properly
determine (“Troubleshoot”)
the
source
of
these
malfunctions,
it is first essential
to methodically ques-
tion
the
user
concerning

the details
of the problem,
such as
the

condition of
the
problem,
the
situation at
the
time the
problem
occurred,

and any other relevant
information, all in as much detail

as possible.
The user
should
also be asked
whether or not the problem has occurred more than once,
and under
what conditions. Subsequently,
certain

tests should
be conducted in a certain
order,
as described
at
the
left.
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23-24AUTOMATIC TRANSAXLE - Troubleshooting
TROUBLESHOOTING GUIDE
T-----lO"ni31-
z.Ip.c
8Ea
=
s"oz6
E.
;In.ci!
a
-
F
X
-
-
X
77
c-
X
F-
i-
1g I”,PC-
ms?A
E
EEF.E053%
2
xsib-or z-
Pp
s E
a=g
n6
BE0.cY.20 (befl
-St.3-
zbaz
ti?BEa,fs
off)-
dI?f
s50>z6-0vi@zEiECE$,aZ5%-
-
7-
-
Ibr
I
Problem
Presumed causeTi3::-0 e
2Ts
y.=:,02 EF
g'5 +
v-60
F $2
s?
$=
2
$5
X
@63
X
X
I’
-
57-
-X-
-
G-- X
-
-X
X
e:,
Damaged or worn gear or other rotating part.
or rnproperadjustment of the preload
n
8 Malfunction of
parklng
mechamsm
9 Cracked drive plate. or loose bolt
10 Worn InsIde
diameter of front clutch retainer
11Low flutd
level
X
-
1z12 Line
pressure too low (seal damaged, leakage, looseness, etc.)E:o 13Malfunctton of valve body (sticking valve. worktng cavity,
j$adjustment, etc )XX
I
:?I14‘cMalfunction of front clutch or poston
)_O15Malfunction of rear clutch or pistoni;;E16 Malfunction of klckdown band or piston
le17 Improper adjustment of kickdown servoj318Malfunction of low-reverse brake or piston-6s 19 O-ring of low-reverse brake circuit between valve
body and case not Installed
20 Malfunction of end clutch or
piston (check ball hole, other)
2,Malfunction of Park/Neutral positjon switch, damaged
or disconnected wiring, or improper adjustment
22
Malfunction of TPS. or improper adjustment
23 Pulse generator
(A) damaged or disconnectedwlnng. or short&cut^
NOTE: Qo indicates items of high priority during inspection.
Abbreviations: TPS = Throttle position sensor SCSV = Shift control solenoid valve

23-28AUTOMATIC TRANSAXLE - Troubleshooting ’
Fault Code Description for 1989 and 1990 model
FaultcodeFault code (for voltmeter)CauseRemedy
21Abnormal increase of TPS output
l Check the throttle position sen-
sor connector.
l Check the throttle position sen-
sor itself.
22
23
- l Adjust the throttle position sen-
Abnormal decrease of TPS outputsor.l Check the accelerator switch (No. 28: output or not).
l Check the throttle position sen- sor output circuit harness.
Incorrect adjustment of the
throttle-position sensor system
24Damaged or disconnected wiring
of the oil temperature sensor sys-
tern
l Check the oil temperature sen-
sor circuit harness.
l Check the oil temperature sen-
sor connector.
l Check the oil temperature sen-
sor itself.
25
26
Damaged or disconnected wiring l Check the kickdown
servo
of the kickdown
servo switch sys-
switch output circuit harness. tern.
or improper contact l Check the kickdown
servo
switch connector.
l Check the kickdown
servo
Short circuit of the kickdown
servo switch itself.
switch system
27Damaged or disconnected wiring
of the ignition pulse pick-up cable
system l Check the ignition pulse signal
line.
28Short circuit of the accelerator
switch system or improper adjust-
ment l Check the accelerator switch
output circuit harness.
l Check the accelerator switch
connector.
l Check the accelerator switch it-
self.
31
l Adjust the accelerator switch.
Malfunction of the microprocessor l Replace the control unit.
32First gear command during hrgh-speed drivingl Replace the control unit.
Damaged or disconnected wiring
of the pulse generator
B system l Check the pulse generator Boutput circuit harness.
l Check pulse generator B itself.
l Check the vehicle speed reed
switch (for chattering).
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23-30AUTOMATIC TRANSAXLE - Troubleshooting
l Check the pulse generator Aoutput circuit harness.
0Check the pulse venerator
con- nectar.
-l Check pulse generator A andpulse generator B themselves.
Fault Code Description for 1990.5, 1991, 1992
and 1993 model
rP
Fault
code
IFault code (for voltmeter) CauseIRemedy
53Third gear non-synchronous
* Front clutch
slippage.
l Rear clutch slippage.
54
Fourth gear non-synchronouslCheck the pulse generator A
output circuit harness.
l Check the pulse generator A
connector.
l Check pulse generator A itself.
l Kickdown brake slippage.
ipproprlate transa-
4Wl-
0
0
0
0
0
-
0
-
0
0
FWI
0
0
0
0
-
-
0
0
xle1CodeNo, output pattern Description
Remedy
‘I n
Abnormal increase of TPS out-
Put
Abnormal decrease of TPS out-
Put
l Adjust the throttle position
sensor.
l Check the accelerator switch
(Code No. 24 output or not).
Malfunction of the throttle-position sensor or incorrect
adjustment
Damaged or disconnected wir-
ing of low oil temperature sen- l Check the oil temperature
sensor connector.
sor (1992 model) or oil temper- l Check the oil temperature
ature sensor (1993 model) sensor itself.
16Short circuit of hiah oil temDer-
ature sensor (1992 model) ’
17Damaged or disconnected wir-
ing of high oil temperature
sensor or short-circuit of low
oiz;eyIperature sensor (1992
Damaged or disconnected wir-
ing of the kickdown
servo
switch
Short circuit of the kickdown
servo switch l Check the throttle position
sensor connector.
l Check the throttle position sensor itself.
D Check the kickdown
servo
switch connector.
B Check the kickdown
servo
switch itself.
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