boot MITSUBISHI SPYDER 1990 Service Repair Manual

CONTENTS
GENERAL DATA AND SPECIFICATIONS. .
HOW TO USE THIS MANUAL. . . . . . . . . . . . .3
Explanation of Manual Contents. . . . . . . . . . . . . .4
Model Indications
. . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance, Repair and
Servicing Explanations. . . . . . . . . . . . . . . . . . . . . . .
3
Special Tool Note. . . . . . . . . . . . . . . . . . . . . . . . . . .3
Terms Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tightening Torque Indication. . . . . . . . . . . . . . . . .3
HOW TO USE TROUBLESHOOTING/
INSPECTION SERVICE POINTS. . . . . . . . . . . .6
Connector Inspection Service Points
. . . . . . . . . .10
Connector Measurement Service Points . . . . . . . .9
How to Cope with Intermittent Malfunctions . . .11
How to Use the Inspection Procedures
. . . . . . .
8
Inspection Service Points for a Blown Fuse . . .
12
Troubleshooting Contents. . . . . . . . . . . . . . . . . . . .6
LUBRICATION AND MAINTENANCE . . . . . . .33
MAIN SEALANT AND ADHESIVE TABLE
. .
MAINTENANCE SERVICE. . . . . . . . . . . . . . . . . .38
Air Cleaner Element. . . . . . . . . . . . . . . . . . . . . . . .39
Automatic Transaxle Fluid
. . . . . . . . . . . . . . . . . . .45
Ball Joint and Steering Linkage Seals
. . . . . . . .50
Brake Hoses.... . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Disc Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Drive Belt (For Generator, Water Pump, Power
Steering Pump). . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Drive Shaft Boots
. . . . . . . . . . . . . . . . . . . . . . . . . . .50
Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Evaporative Emission Control System . . . . . . . . .
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Fuel Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Ignition Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
Manual Transaxle Oil . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
Rear Drum Brake Linings and
Rear Wheel Cylinders . . . . . . . . . . . . . . . . . . . . . . .
Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
SRS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Timing Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Transfer Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
PRECAUTIONS BEFORE SERVICE. . . . . . . .20
RECOMMENDED LUBRICANTS
LUBRICANT CAPACITIES TABLE. . . . . . . . . .34
SCHEDULED MAINTENANCE TABLE. . . . .
SPECIAL HANDLING INSTRUCTIONS FOR
AWD MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
TIGHTENING TORQUE. . . . . . . . . . . . . . . . . . . .32
TOWING AND HOISTING . . . . . . . . . . . . . . . . . .22
VEHICLE IDENTIFICATION. . . . . . . . . . . . . . . . .13
Engine Model Stamping. . . . . . . . . . . . . . . . . . . . .15
Theft Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
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 Maintenance
Incorrect Correct
5. SPARK PLUGS
1.Spark plugs must spark properly to assure proper engine
performance and reduce exhaust emission
Therefore, they should be periodically with new
ones.
2. The new plugs should be checked gap.
Spark plug gap:, . .
Engine (Turbo)>’
mm
Engine (Non-turbo)> ,
1.22-1.35 mm
in.)
Engine> .
in.)
3. Install the spark plug and tighten to the
Tightening torque:
Engine (Turbo) and Engine>
25 Nm (18
E n g i n e ( N o n - t u r b o ) >
28 Nm (20
6. IGNITION CABLES (Replace)
The ignition cables should. be replaced periodicall y with new
ones. After replacing, make sure that the ignition cables are
routed properly and fully seated.
NOTE
When disconnecting an ignition cable; be sure to ho ld the
cable boot. If the cable is disconnected by pulling on the
cable alone, an open circuit might result.
7. TIMING BELT (Replace)
00100220027
Replace the belt with a new one periodically to ass ure proper
engine performance.
For disassembly and assembly procedures; Refer to GROUP
Timing Belt.
Refer to GROUP
Timing Belt.
Refer to GROUP 11
Timing Belt.
8. DRIVE BELT (For Generator, Water Pump, Power Steering Pump) (Check condition)
Check the tension of the drive belt. Check the driv e belt
for evidence of cuts and cracks, and replace it if defective.
TSB Revision

GENERAL Maintenance Service
2.Check the wheel cylinder boots for evidence, a’ brake
fluid leak. Visually check the
boots for tears or
cracks. (A slight amount of fluid on the boot may not
be a leak, but may be preservative assembly.)
Caution
The shoes for the right and left be,
replaced at the same time.
Never split or intermix brake
sets.
All four shoes must be replaced as a set.
Thickness of lining
Limit: 1.0 mm in.)
17. BRAKE HOSES (Check for
leaks)
Check of brake hoses and tubing should be
brake service operations.
The hoses should be checked for:
1.Correct length, severe surface cracking, pulling, scuffing
or worn spots. (If the fabric casing of the hoses i s exposed
by cracks of abrasion in the rubber hose cover, the hoses
should be replaced. Eventual deterioration of may
occur with possible bursting failure.)
2. Faulty installation, casing twisting or interfer ence
wheel,’ tire or chassis.
18. BALL JOINT AND STEERING SEALS
(Check for grease leaks damage)
1. These components, which are permanently lubricat ed
at the factory, do not require periodic lubrication. Damaged
seals and boots should be replaced to prevent leakage
or contamination of the grease.
2.Check the dust cover and boots for proper sealing, leakage
and damage. Replace them if defective.
19. DRIVE SHAFT BOOTS (Check for leaks
and damage)
1. These components, which are permanently lubricat ed
at the factory, do not require periodic Damaged
boots should be replaced to prevent leakage or contamina-
tion of the grease.
2.Check the boots for proper sealing, leakage and damage.
Replace it if defective.
AXLE OIL (Check oil level)-AWD
Remove the filler plug and check the oil level at bottom of
filler hole. If the oil level is slightly below the filler hole, it
is in satisfactory condition.

CLUTCH Service Specifications/Lubricants
SERVICE SPECIFICATIONS
Clutch pedal height mm (in.)
Clutch pedal
pin play mm (in.)
Clutch pedal free play mm (in.) Distance between the clutch pedal and
the
when the clutch is disengaged mm (in.)
LUBRICANTS
Standard value
6-13
70 (2.76) or more
Items
Clutch fluid
Push rod assembly
Boot
Specified lubricants
Brake Fluid DOT 3 or DOT 4
Rubber grease
Q u a n t i t y
A s r e q u i r e d
As required
Release cylinder push rod MITSUBISHI genuine grease
Part No. 0101011 or equivalentAs required
Clutch pedal shaft, bushings and end of the Brake grease SAE
No. 1As required
pedal
Clutch master cylinder push rod, pin
and washer
Clutch release cylinder
pin
Revision

21CLUTCH OVERHAUL Clutch
CLUTCH
REMOVAL AND INSTALLATION Engine
Removal steps
1. Oil tube
2. Clutch release cylinder 5. Clutch release lever
3. Clutch flywheel
6. Clutch control equip stud
7. Boot
4. Clutch release bearing
NOTE
The modular clutch assembly flywheel assembly) used in this vehicle consists o f a single,
dry-type clutch disc and a diaphragm style clutch c over. The clutch unit is serviced as an assembly.
No disassembly is possible.
Revision

(Turbo)
CLUTCH RELEASE CYLINDER Engine (Turbo) and
Engine>
DISASSEMBLY AND REASSEMBLY
21200150057
Brake fluid or
8.0
TSB Revision
Disassembly steps
1. Push rod
2. Boot
3. Piston cup
4. Piston
4
q31
2
5Piston
IBrake fluid or
5. Conical spring6. Cap
7. Bleeder plug
8. Release cylinder

MANUAL TRANSAXLE OVERHAUL
Housing
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
19 Nm14
24 Nm
16
Lubricate all internalparts with engine oil
during reassembly.
22100019
Disassembly steps
1.Bolt2. Select lever assembly3.Select lever shoe4. Interlock plate bolt5.Gasket 6. Lock pin
7. Spring pin 8. Neutral return spring
9.Stopper body10.Controlfinger
1
Interlock plate
12. Neutral return spring assembly
13. Control shaft
14. Control shaft boot
15. Oil seal 16. Needle 17. Needle,
Return spring
21. plate
22. Spring pin
TSB Revision

SHAFT Propeller
M a t i n g m a r k s
joint boot
Center propeller
shaft Lbbro’ joint
assembly
REMOVAL SERVICE
PROPELLER SHAFT ASSEMBLY REMOVAL
(1) Make on the flange
and ‘flange yoke and remove the
shaft.
. .
C a u t i o n ’
the propeller shaft in a straight and level
manner so as to ensure that the boot is not
through pinching. ,
NOTE
Damage to the boot can be and the Work will
be easier, if a piece of cloth or material is inserted
in the boot.
(2) Use special tool a to let objects
SPACER REMOVAL
The number of spacers depends on models. Check the num-
ber of spacers used and write it down for reference during
reassembly.
Oil seal lipINSTALLATION SERVICE POINT
PROPELLER SHAFT ASSEMBLY INSTALLATION
Caution
Do not damage the transfer case oil seal
TSB Revision. .

PROPELLER SHAFT Propeller Shaft
DISASSEMBLY AND REASSEMBLY
186 Nm
3
n u- - -
2 0
21
joint kit joint boot kitUniversal joint kit
Disassembly steps
1. Snap ring
2. Journal bearing3.Journal
4.Flange yoke5. Sleeve yoke assembly
6. Front propeller shaft
7. Self-locking nut 8. Center yoke. a s s e m b l y
Snap ring
12. Boot band 13. Lobro joint assembly
14. Rubber packing 15. Lobro joint boot
16. Washer
17. Center propeller shaft
18. Self-locking nut 19. Companion flange 20. Center ‘bearing assembly
21. Rear propeller shaft
TSB Revision

PROPELLER SHAFT Shaft
Mat i n g m ar k s
Inner race
Cag e
Cag e
Lbbro ioint
Plastic
JOINT ASSEMBLY REMOVAL
(1) Lobro joint boot from the joint assembly.
(2) Put mating marks on the outer race, cage and in ner race
with a scriber.
(3) Remove the outer race and balls.
NOTE
Note the positions of balls so that they can be
in their original positions.
(4)Remove the inner race with cage from the center propeller
shaft by using a puller (commercially available).
NOTE
When changing the grease on the Lobro joint assembl y,
wipe off the grease and clean the outer and inner
cage and balls.
(5)If the outer race cannot be removed, remove the complete
joint assembly from the center
using a puller (commercially available).
JOINT BOOT REMOVAL
When reusing the Lobro joint boot, apply plastic ta pe to the
spline section of the center propeller before removing.
TSBRevision