engine MITSUBISHI SPYDER 1990 Service Repair Manual

MANUAL TRANSAXLETroubleshooting!
ENGINE (TURBO) AND ENGINE> On-vehicle Service
TROUBLESHOOTING
Symptom
Vibration, noise
Oil leakage
Hard shift
Jumps out of gear ProbableRemedy
Loose or damaged transaxle and engine mounts
Tighten or replace mounts
Inadequate shaft end play Correct the end play
Worn or damaged gears
Replace gears
Use of inadequate grade of oil Replace with specified oil
Low oil level
Refill
Inadequate engine idle speed Adjust the idle speed
Broken or damaged, oil seal or O-ring Replace the oil seal or O-ring
Faulty control cable Replace the control cable
Poor contact or wear of synchronizer ring and Correc t or replace
gear cone
Weakenecl synchronizer spring Replace synchronizer spring
Use of
grade of oil Replace with the specified oil
Worn gear shift fork or broken poppet spring Replace the shift fork or poppet
spring
Synchronizer hub to sleeve
clearance too
large
Replace the synchronizer hub and
sleeve
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ON-VEHICLE SERVICE
22100090053
TRANSAXLE OIL LEVEL CHECK
Refer to GROUP 00
Maintenance Service.
TRANSAXLE OIL REPLACEMENT
Refer to GROUP 00 Maintenance Service.
TRANSFER OIL LEVEL CHECK Refer to GROUP 00
Maintenance Service.
TRANSFER OIL REPLACEMENT
Refer to GROUP 00 Maintenance Service.
22100100055
22100110035
22100120035

MANUAL TRANSAXLE
ENGINE (TURBO) AND ENGINE>
TRANSAXLE CONTROL
REMOVAL AND INSTALLATION
Caution: SRSBe careful not to subject the SRS-ECU to anyshocks during removal and installation of thetransaxle control cable and shift lever assembly.
Engine>
3.9 Nm
2.9
Engine (Turbo)>
9
9
9 bs.
.
NOTE Resin clip positionTransaxle control cable assemblyremoval steps
1. Air cleaner and air intake hose
assembly2. lever knob3. Center panel
4. Cupholder assembly
5. Floor console assembly
6. Shift lever cover
7. Console side cover
8. Nut 9. Clip (passenger compartment side)
10. Clip (transaxle side
11. Shift cable and select cable con- nection (passenger compartment
12. and select cable con-
nection (transaxle side)
13. Shift cable and select cable as-
sembly Shift lever
assembly removal steps
2 . S h i f t 3. Center. 4. assembly
5. Floor console assembly
6. Shift lever panel
7. Console side cover
9. Clip(passenger compartment side)
11. Shift cable and select cable con-nection (passenger compartmentside)14. Shift lever 15. Distance piece 16. Bushing
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M A N U A L T R A N S A X L E
(TURBO) AND ENGINE> Transaxle
Neutral position
Neutral position
Shift lever
Shift lever
Shift lever
Bushing Bushing A
Slit
Down
INSTALLATION SERVICE
CABLE AND SELECT
CONNECTION (TRANSAXLE SIDE)
SELECT CABLE
(1)Connect the select cable to the transaxle side sele ct lever.
(2) Set the shift lever of the transaxle side at the neutral
position.
NOTE
When the shift lever of the transaxle side is set a t the
neutral position, the select lever of the transaxle side
is also set at the neutral position.
SHIFT CABLE
(1) Connect the shift cable to the transaxle shift lever.
(2) While leaving the select lever at the transaxle side in
the neutral position, move the shift lever at the transaxle
side in the direction of the arrow in the illustration to
set it to
gear.
NOTE
If the shift lever does not move easily, depress an d hold
the clutch pedal.
CABLE AND SELECT CABLE
CONNECTION (PASSENGER COMPARTMENT
SIDE)
SELECT CABLE
(1) While leaving the shift lever inside the passen ger
compartment in the neutral position, install the select cable
to the passenger compartment side of the shift leve r.
(2) Install the select cable so that the flange sid e of resin
bushing is positioned at the edge of lever
side.
SHIFT CABLE
(1) Pull the shift lever at the passenger compartme nt side
fully in the direction shown in the illustration
gear
position), and install the shift cable to the shift lever at
the passenger compartment side. Install so that the slit section of the bushing
is facing
either up or down.
(2) Put the shift lever to all the positions and ma ke sure
that the operation is smooth.
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MANUAL TRANSAXLE
ENGINE (TURBO) AND ENGINE>
SHIFT LEVER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
15
14
Disassembly steps
1.Nut2.Spring washer3.Plain washer4.Shift lever
Spring washer8.Plain washer9.Return spring10.Bushing11.Pipe
0 0 0 0 0 0 9 9
12.Bolt1 3 . L e v e r A
14.Bushing15.Collar16.Bushing17.Snap ring18.Washer19.20.Bustiing21.Bracket assembly
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MANUAL TRANSAXLE
ENGINE AND ENGINE> Transaxle
TRANSAXLE
REMOVAL AND INSTALLATION
Pre-removal Operationl Transaxle Oil Draining (Refer to GROUP 00 Maintenance Service.)l Removal
l Under Cover Removal
(Refer to GROUP 42
Under Cover.)
Engine>
Post-installation Operationl Supplying Transaxle Oil (Refer to GROUP 00 Maintenance Service.)l Shift Lever Operation Check
l Speedometer Operation Check
l Under Cover Installation
(Refer to GROUP 42
Under Cover.)
l Battery installation
56
6942
Engine (Turbo)>51
32
6
Removal steps
1. Air cleaner cover and air intake
hose assembly2. Air cleaner element
3. Air hose (Turbo)>
4. Air hose A Eingine (Turbo)>
5. Battery tray
6. Evaporative emission canister
Engine (Turbo)>
7. Evaporative emission canister holder
(Turbo)>
8. Battery tray stay 9. Shift cable
cableconnection10. Backup light switch connector11. Vehicle speed sensor connector
12. Starter motor
13. Transaxle assembly mounting 14. roll stopper bracket
15. Transaxle mounting bracket ing nuts
l Supporting engine assembly
Revision

MANUAL TRANSAXLE
-ENGINE (TURBO) AND ENGINE> Transaxle
Engine>
13
27
Engine>2 2 - 2 52 61813
I
78
85
20
Nm51-58
Lifiting up of the vehicle
16. Tie rod end ball joint and kunckleconnection17. Stabilizer link connection18. Damper fork19. Lateral lower arm ball joint andkunckle connection20. Compression lower ball jointand kunckle connection 21. Drive shaft connection
22. Clutch release cylinder connection
23. Bell housing cover
24.Stay
27. Transaxle mounting
28. Transaxle assembly
25. Center member assembly
26. mounting
Caution
Indicates parts which should be temporarily
tightened, and then fully
with the
vehicle on the ground in the unladen condition.
For tightening locations indicated by the symbol,
first tighten temporarily, and then make the final
tightening with the entire of the engine
applied to the vehicle body.
Revision

MANUAL TRANSAXLE
ENGINE AND ENGINE> Transaxle Assembly
I
Nut
ITransaxle
REMOVAL SERVICE POINTS
TRANSAXLE MOUNTING BRACKET MOUNTINGNUTS REMOVAL
Jack up the transaxle assembly gently with a garage jack,
and then remove the transaxle mounting bracket nuts .
Caution
Be sure not to tilt the transaxle assembly.
SUPPORTING ENGINE ASSEMBLY,
Set the special tool to the vehicle to support the engine
assembly.
ROD END BALL JOINT AND
LATERAL LOWER ARM BALL JOINT AND
KNUCKLE/COMPRESSION LOWER ARM BALL
JOINT AND DISCONNECTION
Caution
1.Using the special tool, loosen the tie rod end moun tlng
nut. Only loosen the nut; do not remove it from the
ball joint.
2.Support the special tool with a cold, etc. to prevent
it from coming off.
DRIVE DISCONNECTION
(1) Insert a pry bar between the transaxle case and the drive
shaft to remove the drive shaft.
NOTE
Do not remove the hub and knuckle from the drive sh aft.
Caution
1.Use a pry bar to remove the drive shaft from the
B.J. assembly, or the
assembly may be
damaged.
2.Do not insert the bar too far, or the oil seal may
be damaged.
(2) Suspend the removed drive shaft with wire so that there
are no sharp bends in any of the joints.
(3) Use the special tool as a cover not to let fore ign objects
get into the transaxle case.
Revision

MANUAL TRANSAXLE
ENGINE (TURBO) AND ENGINE> Transaxle Assembly
TransaxlemountTransaxle side
stopper
Front roll
member
CLUTCH.
Remove the clutch release cylinder without disconne cting
the oil line, and suspend
a nearby “a
etc.
INSTALLATION SERVICE POINT
TRANSAXLE MOUNTING
Align the notches on the stopper with the transaxle mount
bracket with the arrow mark facing toward the shown direction.
Then install the stopper.
CENTER MEMBER
If the dimension shown in the outside the standard
value when the weight of the engine is on the body;, replace
the front roll stopper bracket assembly. ,
Standard value (A): 43
3 mm (1.69 in.)
DRIVE SHAFT
Temporarily install the drive shaft so that the T.J . case of
the drive shaft is perpendicular to the transaxle.
Caution
Do not damage the oil seal lip by the serrated part of
the drive shaft.
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MANUAL ,
ENGINE AND Transaxle Assembly .
TRANSAXLE ASSEMBLY
REMOVAL INSTALLATION
22100270092
Pre-removal Operation
Transaxle Oil Draining to GROUP 00 Maintenance Service.)l Battery Removal
l Under Cover Removal
(Refer to GROUP 42
Under Cover.)
l Transfer Assembly Removal (Refer to
3.9 Nm
4
2.9
Post-installation Operation
l Supplying Transaxle Oil (Refer to GROUP 00
Maintenance Service.)l Shift Lever Operation Check
l Speedometer Operation Check
Transfer Assembly Installation (Refer to l Under Cover Installation
(Refer to GROUP 42 Under Cover.)
l Installation
69 Nm
51
56 Nm
42
15
51
Removal steps
Air cleaner cover and air intake
hose assembly
2. Air cleaner
3. Air hose 4. Air hose A
5. Battery tray
6. Evaporative emission canister
7. Evaporative emission canister
holder8. Battery tray stay 9. Shift cable and select cable
connection10. Backup light switch connector11. Vehicle speed sensor connector12. Starter motor13. Transaxle assembly mounting bolts14. Rear roll stopper bracket mountingbolts
15. Transaxle mounting bracket
mounting nuts
l Supporting engine assembly
Revision

MANUAL TRANSAXLE
ENGINE (TURBO) AND ENGINE> Transaxle Assembly
34 Nm
2 4 ’ . .
59-71 Nm
44-528.8 Nm8.5
26
7 8
85
Lifting up of the vehicle
16. Tie rod end ball joint and knuckle
connection17. Stabilizer link connection18. Damper fork19. Lateral lower arm ball joint and
27. Center member assembly 28. Transaxle assembly mounting bolt
29. Transaxle mounting 30. Transaxle assembly
knuckle connection
20. Compression lower arm ball jointand knuckle connection 21. Drive shaft nut 22. Drive shaft
23. Drive shaft with inner shaftconnection24. Clutch release cylinder connection
25. Bell housing cover
26. Stay
‘Caution
indicates parts which should, be temporarily
tightened, and, then.
tightened with the
vehicle on the ground in condition.
For tightening locations indicated by the symbol,
first tighten temporarily, and
the final
tightening with the entire the engine
applied to the vehicle body.
Revision