light MITSUBISHI SPYDER 1990 Service Manual Online

Evaporative
emission
canister side
Rubber hose
F U E L T A N K ,
I N S T A L L A T I O N
Install the fuel relief
on the left.,
,
I..- ,
I N S P E C T I O N
FUEL TANK PRESSURE RELIEF VALVE SIMPLE .,
WARNING
To avoid bodily injury, do not breathe fuel
Attach a clean hose and tank
Inspection procedure,
Lightly blow from inlet A i r p a s s e s
(fuel tank side).slight feeling of
Lightly blow from outlet side.Air
resistance, , .
EVAPORATIVE EMISSION VENTILATION SOLENOID
CHECK
(1) Connect a hand vacuum pump to nipple (A) of the
solenoid.
Check airtightness by applying a vacuum with voltag e
applied directly from the ‘battery to
evaporative
emission ventilation solenoid. and
(3) Measure the resistance between the terminals of the
solenoid.
Standard value: 17-21 (at
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(Turbo) and Engine>
EXHAUST GAS RECIRCULATION
GENERAL INFORMATION
The exhaust gas recirculation (EG system lowers
the nitrogen oxide
emission level. When the
air/fuel mixture combustion temperature is high,
a large quantity of nitrogen oxides is gener-
ated in the combustion Therefore, this
system recirculates part of emission gas from the
exhaust port of the cylinder head to the combustion
OPERATION
When the engine coolant is low, when
the engine is at idle or when a wide open throttle
operation is performed, the EGR valve is kept
closed, achieving no EGR.
The manifold differential pressure sensor is locate d
in the intake manifold plenum. This sensor detects
variations in the manifold pressure when
the EGR solenoid is momentarily operated. If the
manifold negative pressure the EGR sys-
tem is normal.
SYSTEM DIAGRAM
Engine (Turbo)>
(EGR) SYSTEM17300520205
chamber through the intake manifold to decrease
the mixture combustion temperature, result-
ing in reduction of
The EGR flow rate is controlled by the EGR valve
so as not to decrease the
In normal vehicle operation performed after warm-
ing up of the engine, the EGR valve is opened
to carry out EGR.
The ECM uses this to check the operation of the, EGR system. If a problem is found, the check en-’
indicator light illuminates to warn
the driver that a problem has occurred.
EGR valve
relay
EGRsolenoid
Engine control
module
Isensor
Engine coolant
temperature sensor
sensor
Manifold differential
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pressure sensor,

CONTENTS
MANUAL TRANSAXLE ENGINEMANUAL TRANSAXLE ENGINE
(NON-TURBO)>(TURBO) AND ENGINE>
GENERAL INFORMATION . . . . . . . . . . . . . . 22GENERAL INFORMATION . . . . . . . . . . . . . . . .
2
LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . 24LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . .6
ON-VEHICLE SERVICE. . . . . . . . . . . . . . . . .
2 4
Transaxle Oil Level Check . . . . . . . . . . . . . . . .
24
Transaxle Oil Replacement . . . . . . . . . . . . . . .
24
SERVICE SPECIFICATIONS. . . . . . . . . . . . .24
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . .24
TRANSAXLE ASSEMBLY. . . . . . . . . . . . . . .28
TRANSAXLE CONTROL*. . . . . . . . . . . . . . . .25ON-VEHICLE SERVICE
. . . . . . . . . . . . . . . . 8
Shift Lever Assembly
. . . . . . . . . . . . . . . . . . . . .
27
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . .24
Transaxle Oil Level Check . . . . . . . . . . . . . . . . .8
Transaxle Oil Replacement
. . . . . . . . . . .. . .
Transfer Oil Level Check ...... . . . . . . . . . . .
Transfer Oil Replacement. . . . . . . . . . . . . . . . . .8
SERVICE SPECIFICATIONS. . . . . . . . . . ...
SPECIAL TOOLS 7. . . . . . . . . . . . . . . . . .
TRANSAXLE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . ... . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 1 2
TRANSAXLE CONTROL*... . . . . . . . .
Shift Lever Assembly. . . . . . . . . . . . . . . . . . . . . .1 1
TRANSFER ASSEMBLY . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . .
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRA
INT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1)Improper service or maintenance of any component of the or any component, can lead to personalinjury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from
rendering the inoperative).Service or maintenance of any or component must be performed only at an authorized MITSUBISHI dealer.(3)MITSUBISHI dealer personnel must thoroughly review this manual,and especially its GROUP
Restraint System and GROUP 00 Maintenance Service, before beginning any or maintenance of
any component of the or any component.
NOTEThe SRS includes the following components: warning light, air bag module,clock spring, and interconnecting
wiring. Other
components (that may have to be removed/installed in connection with service or maintenance)
are indicated in the table of contents by an asterisk

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
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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
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MANUAL TRANSAXLE
ENGINE (TURBO) AND ENGINE> Transaxle Assembly
11
DRIVE SHAFT REMOVAL
(1) a pry bar between the transaxle case and the drive
shaft, and then pry the drive shaft from the transa xle.
Caution
1.Use a pry bar to remove drive shaft from the
assembly, or the T.J. assembly may be
damaged.
2.Do not insert the bar too far, or the oil’
be damaged.
(2) Use the special tool to cover the transaxle cas e not to’
let foreign materials get into the transaxle case.
DRIVE SHAFT WITH INNER SHAFT
DISCONNECTION
Lightly tap the center -bearing bracket plastic
hammer or similar tool “to remove the inner shaft f rom
the transaxle.
,
(2) Suspend the removed drive shaft with inner shaf t with
wire so that there are no sharp bends in any of the joints.
(3) Use the special tool to cover the transaxle case not to
let foreign materials get into the transaxle case.
R E L E A S E
Remove the clutch release cylinder without disconne cting
the line, and suspend to a nearby parts with a wire,
etc.
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MANUAL TRANSAXLE
ENGINE (NON-TURBO)> Transaxle Control
TRANSAXLE ASSEMBLY
REMOVAL AND INSTALLATION
l Transaxle Oil Draining (Refer to GROUP 00
(Refer to GROUP 42 Under Cover.)
Post-installation Operationl
Supplying Transaxle Oil (Refer to GROUP 00 Maintenance Service.)l Shift Lever Check
l Speedometer ‘Operation Check
l Under Cover Installation
(Refer to GROUP 42
Under Cover.) I n s t a l l a t i o n
8
54Nm
Removal steps
1. Air cleaner cover and air intakehose assembly2. Air cleaner element
3. Battery tray
4. Battery tray stay
5. Shift cable and select cable
connection6. Backup light connectorl b
7. Vehicle speed sensor connector
8. Starter motor
9.
roll stopper bracket mounting
10. Transaxle mounting bracket
mounting nuts
l Supporting engine assembly
Revision

MANUAL TRANSAXLE OVERHAUL
Items
Transaxle
Backup light switch
Bearing retainer bolt
Bell housing cover mounting bolt
Center differential lock actuator mou
Center differential lock indicator
Center differential shift lever
Differential drive gear bolt
Input shaft lock nut
Interlock plate bolt
Intermediate gear lock nut
3324
33
24
Output gear mounting bolt
Poppet plug
Rear cover bolt
Rear cover bolt
Restrict ball
Reverse brake cone machine screw
Reverse idler gear shaft bolt
Reverse shift lever assembly
Select lever mounting bolt
Shift cable bracket mounting bolt
Speedometer sleeve bolt
Starter motor mounting bolt
Stopper bracket bolt
Transaxle case tightening bolt
Transaxle mount bracket mounting
Transaxle mounting bolt mm
Transaxle mounting bolt mm diamet
Transaxle mounting bolt
mm diamet
Transaxle switch
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MANUALTRANSAXLE OVERHAUL Transaxle
TRANSAXLE
DISASSEMBLY AND REASSEMBLY
33N m24
19 Nm14I
36
27Nm
Disassembly steps
1. Bolt 2. Rear cover
3. Reverse brake cone
41 Wave spring 5. Machine screw
6. Backup light switch
7.Gasket8.Poppetplug
9.Poppet spring10.Poppetball
11.Bolt
Lubricate all internaloil
12. Speedometer. driven gear assembly 13. Air breather 14. Spring
15. Lock nut 16. Lock nut17. speed synchronizer assembly
18.
speed shift fork .
19.Synchronizer ring
20. speed gear21.Needle bearing22. speed intermediate gear
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MANUAL TRANSAXLE OVERHAUL,
Center
Side
DISASSEMBLY SERVICE
ROLLER REMOVAL
Remove-the taper roller bearings ‘using the special
NOTE
(1) Do not reuse the bearing removed from shaft.
(2) Replace the inner and
races the taperroller
bearing as a set.
REASSEMBLY SERVICE POINTS
I N S T A L L A T I O N
(1) Install the spacer, side gear, pinion gear,
and
pinion shaft to the center differential
(2) Holding down the pinion shaft, select the of maxi-
mum thickness that allows the pinion gear to
and install it to the shaft.
(3) Install the side gear, spacer and output gear
the bolt to the specified torque.
(4) Select the spacer of maximum thickness that all ows the
side gear to turn lightly and install it.
Check that both side gears turn lightly.
Standard,
Center differential side gear end play:
mm in.) .
TAPER ROLLER BEARINGS INSTALLATION
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