MITSUBISHI SPYDER 1990 Service Repair Manual

WaterHose and Water Pipe Engine
ENGINE COOLING (Non-turbo)>
REMOVAL POINTS.
HEATER HOSE
Caution
For cover the a
before a heater hose, the-
below the hoses.
Cylinder block
O-ring
Water inlet pipe assembly
RADIATOR LOWER HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.
I N S T A L L A T I O N
P O I N T S
Insert the O-ring to the water inlet pipe, and coat
circumference of the water or engine
Do not allow or other grease to adhere the
O-ring.
RADIATOR LOWER HOSE CONNECTION
Align the mating marks on the radiator and hose clamp,
and then connect the radiator hose.
INSPECTION
WATER PIPE AND CHECK’
Check the water pipe and hose’ for cracks, damage,’
and replace them if necessary.
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Water Hose and
ENGINE COOLING and Engine>
WATER HOSE AND WATER PIPE
ENGINE (TURBO) AND ENGINE>1 4 1 0 0 3 3 0 2 4 5
REMOVAL AND INSTALLATION
Engine (Turbo)>
Pre-removal and Post-installation Operationl
Engine Coolant Draining and Supplying (Refer to
GROUP 00 Maintenance Service.)
l Air Hose (C) Removal and Installation (Refer to
GROUP 15
Charge Air Cooler.)
l Turbocharger Removal and Installation (Refer toGROUP 15 Exhaust Manifold.)
11
2417
24 Nm17
48Nm35
3
Specified Sealant:
or equivalent
58
Removal steps
1. Radiator upper hose connection
2. Radiator lower hose connection
3. Water hose4. Heater hose connection
5. Water hose
6. Thermostat case assembly
8. Water pipe assembly
9. Water hose
10. Water hose
11. Heater hose connection
12. inlet pipe assembly
hose
Water hose16. Water pipe assembly (A)17. Water pipe assembly (B)
18. Water
19. Water pipe (C)20. Joint
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Water Hose and Water Pipe
ENGINE COOLING and Engine>
Engine>
Pre-removal and Post-installation Operation“(1) Engine Coolant Draining and Supplying (Refer toGROUP 00 Maintenance Service.)(2) Air Cleaner Removal and Installation
(3) Exhaust Manifold Removal and
(Refer to GROUP 15 Exhaust Manifold.)
Specified Sealant:Mitsubishi Genuine Part No. or equivalent
Removal steps
1. Radiator upper hose connection 2. Radiator lower hose 3. Thermostat case assembly 4. O-ring
5. Water hose 6. Water hose
7. Heater hose connection
8. Water inlet pipe assembly 9. o-ring
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Water Hose and Water Engine (Turbo)
ENGINE and Engine>
Thermostat case assembly or water pump
O-ring
Water inlet pipe assembly
Engine (Turbo)> Engine>
in.)
Projection
Water fitting orwater inlet fitting
REMOVAL SERVICE POINT
RADIATOR
HOSE DISCONNECTION,After making mating marks on the radiator the hose
clamp, disconnect the radiator
INSTALLATION SERVICE POINTS
O-RING INSTALLATION
Insert the O-ring to the water inlet pipe, and coat the outer
circumference of the O-ring with water or engine co olant.
Caution
Do not allow engine oil or other grease to adhere t o the
O-ring.
THERMOSTAT CASE ASSEMBLY INSTALLATION
Squeeze out the sealant from the tube evenly and ap ply
it so that there is not too much places without
sealant.
Specified Sealant:
Mitsubishi Genuine Parts No. or equivalent
RADIATOR LOWER HOSE/RADIATOR UPPER
HOSE CONNECTION
(1) Insert each hose as far as the projection of th e water
outlet fitting or water inlet fitting.
(2) Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
INSPECTION
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, damage, c logs
and replace them if necessary.
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INTAKE
EXHAUST,
CHARGE AIR COOLER . . . . . . . . . . . . . . . . . . . .6
EXHAUST MANIFOLD
ENGINE (NON-TURBO)> . . . . . . . . . .17
ENGINE (TURBO)> . . . . . . . . . . . . . . .16
ENGINE> . . . . . . . . . . . . . . . . . . . . . . . .21
EXHAUST PIPE AND MAIN MUFFLER . . . . .22
GENERAL INFORMATION. . . . . . . . . . . . . . . . . .2
INTAKE MANIFOLD
ENGINE (NON-TURBO)> . . . . . . . . . . . 7
ENGINE (TURBO)>. . . . . . . . . . . . . . .11
ENGINE>. . . . . . . . . . . . . . . . . . . . . . . .14
ON-VEHICLE SERVICE. . . . . . . . . . . . . . . . . . . . .3
C O N T E N T S1 5 1 6 6 6 6 6 6 7 6
Intake Charge Pressure Control System
Check . . . . . . . . . . , . . . . . . . . . . . . .4
Intake Manifold Vacuum Check. . . . . . . . . . . . . . .
Turbocharger Bypass Valve Check . . . . .
. . . . . . . . . . . . . . . . . . 5
Turbocharger Waste Gate Solenoid Check
< T u r b o > . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . + . 4
Turbocharger Supercharging Pressure Check
< T u r b o > . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
.
SPECIAL TOOLS . . . . . . ‘ . . . . . . . . . . . . . . . . . . . .2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 2
.

General Information/Service Specifications/
INTAKE AND EXHAUST Special Tools/Troubleshooting
GENERAL
The intake manifold is made of an alloy,
and the shape provides an increased intake inertiaThe exhaust pipe is divided into three parts: the
effect and has a good volumetric efficiency. front pipe, the center pipe, and the main muffler.
‘I
Items .
Turbocharger gas turbine type
Identification
.
Supercharging pressure control Turbocharger waste ga te actuator and solenoid valve
Charge air cooler
Air cooled type
SERVICE SPECIFICATIONS ,
ItemsStandard valueLimit
Intake manifold andDistortion of the installation surface mm (in.)0.15 or less
air intake plenum
TurbochargerTurbocharger waste gate solenoid terminal 36-44
resistance [at .
Supercharging pressure (psi) ( 6 . 4 - 1 4 . 7 )
SPECIAL TOOLS
TROUBLESHOOTING
Symptom Exhaust gas leakage Probable cause
Loose joints
Broken pipe or muffler Remedy
Retighten
Repair or replace
Abnormal noise
Broken baffle in muffler
Broken rubber hangers
Interference of pipe or muffler with vehicle body
Broken pipe or mufflerReplace
Replace
Correct
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INTAKE AND EXHAUST Service
ON-VEHICLE SERVICE
INTAKE MANIFOLD VACUUM . Engine (Turbo)>
Refer to GROUP 11 A On-vehicle
Engine (Non-turbo)>
Refer to GROUP 11 On-vehicle Service.
Engine>’
Refer to GROUP 11 On-vehicle Service.
TURBOCHARGER SUPERCHARGINGPRESSURE CHECK
Caution
Do a test drive with two passengers in the and
where full throttle acceleration can be safely made .
A driver should not read the pressure gauge, but a front
passenger should.
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(1) Disconnect the hose (black) from the
gate solenoid, and connect the pressure gauge. to t he
hose. Plug the nipple of the solenoid valve
which
the hose (black) has been
(2)Drive the vehicle with and
to a speed of more than at gear.
the supercharging pressure when the pointer is stab ilized.
Standard value:
(3) If the supercharging pressure deviates from the standard
value, check the following items for possible cause s.
When pressure is high:
l Malfunction of turbocharger waste gate actuator
lMalfunction of turbocharger waste gate valve
l Disconnected or cracked turbocharger waste gate
actuator hose
When pressure is low:
lMalfunction of turbocharger waste gate actuator
l Supercharging pressure leaks
l Faulty turbocharger

INTAKE CHARGE PRESSURE CONTROL
CHECK
(1) After the diagnostic trouble code of system is com-
pletely read, turn off the ignition switch.
(2) Disconnect the hose (black) from the turbocharg er waste
gate solenoid and plug this hose.
(3) Connect a hand vacuum pump to the turbocharger waste
gate solenoid nipple to which the hose (black) was con-
n e c t e d .
(4) Use the vacuum pump to apply negative pressure, and
the negative pressure condition while the engine
is
and while it is idling.
Engine state
Normal state
(Ignition switch: ON) Negative pressure is
I maintainedI
(after warmup) Negative pressure leaks
NOTE
If this check indicates an abnormal condition, the turbocharger
waste solenoid is broken.
CHECK,
OPERATION CHECK .
(1) Connect a-hand
(2) Use a jumper connect
terminal and battery terminal.
(3) Connect and disconnect the jumper
battery
negative terminal to, negative
tightness. .
Jumper wire (B) nipple
I
Normal state
condition
I
Open
CloseNegative pressure leaks
Negative pressure is held.
Disconnected Open Negative pressure is held.
COIL RESISTANCE CHECK
Measure resistance between solenoid valve terminals .
Standard value: 36-44
[at
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INTAKE AND EXHAUST On-vehicle
TURBOCHARGER

(2) Connect the to,, the
turbocharger
(3) Apply a negative pressure
and check of the valve. Also check that air
tightness is maintained.
Negative pressure Valve operationI
Approx. 53 (16 It starts opening
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INTAKE AND EXHAUST
CHARGE AIR COOLER
. .
REMOVAL AND INSTALLATION
and Post-installation Operationl Front Bumper Removal and Installation
(Refer to GROUP Bumper.)
Hose
7 A
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7.2-9.4
Removal steps
1. Air cleaner assembly
2. Air duct assembly (B)
3. Relay box
4. Air bypass hose
5. Air intake hose
6. Air hose (C)
7. Turbocharger bypass valve
8. Air hose (B) 9. Charge air cooler duct
10. Charge air cooler
11. Air hose (A)
NOTEAlign the mating marks on the hoses and pipes, and
move them.
INSPECTION
l Check the charge air cooler fins for bending, damage,
or foreign matter.
l Check the charge air cooler hoses for cracking, dam age,
or wear.