maintenance MITSUBISHI SPYDER 1990 Service Repair Manual

REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) Improper service or maintenance of any componen t of the SRS, or any component,
can lead to personal injury or death to service per sonnel
firing. of the bag)
or to the driver and passenger (from rendering the SRS inoperative).
(2) If it is possible that the SRS components are
heat over baklng or
in drying after painting, remove the SRS components (air bag module,
beforehand.
(3) Service or maintenance of any SRS component or SRS-related component
be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly rev iew this manual, and
Its GROUP
Supplemental Restraint System (SRS), before beginning any service or maintenance of any compo-
nent of the SRS or any SRS-related component.
NOTE
Section titles with the asterisks in the table of contents in each group indicate operations requiring

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 How to Use This
HOW TO USE THIS MANUAL
MAINTENANCE, REPAIR AND
SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair
and servicing of the subject model. Unless other-
wise specified, each service procedure covers all
models. Procedures covering specific models are
identified by the model codes, or similar designati on
(engine type, transaxle type, etc.). A description
of these designations is covered in this manual
under “VEHICLE IDENTIFICATION”.
ON-VEHICLE SERVICE
“On-vehicle Service” are procedures for performing
inspections and adjustments of particularly impor-
tant locations with regard to the construction and
for maintenance and servicing, but other inspec-
tions (for looseness, play, cracking, damage, etc.
must also be performed.
SERVICE PROCEDURES
The service steps are arranged in numerical order
and attention must to be paid in performing vehicle
service are described in detail in SERVICE POINTS.
TERMS DEFINITION
STANDARD VALUE
Indicates the value used as the standard for judgin g
the quality of a part or assembly on inspection
or the value to which the part or assembly is cor-
rected and adjusted. It is given by tolerance.
LIMIT
Indicates a maximum or minimum value, the part
or assembly should be kept within, in order to be functional. This value is established outside the
standard value range.
REFERENCE VALUE
Indicates the adjustment value prior to starting th e
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be com-
pleted in a shorter time).
CAUTION
Indicates the presentation of information particula rly
vital to the worker during the performance of maint e-
nance and servicing procedures in order to avoid
the possibility of injury to the worker, or damage
to component parts, or a reduction of component
or vehicle function or performance, etc..
TIGHTENING TORQUE INDICATION
The tightening torque shown in this manual is a
basic value with a tolerance of
10% except the
following cases when the upper. and
of tightening torque are given. (1) The tolerance of the ‘basic value
10%.
(2) Special bolts or, the ‘like are
(3) Special tightening methods are used.
SPECIAL TOOL NOTE
When the MMC special tool is described, please
refer to the special tool
is located at the beginning of each group, for a
cross reference from the tool, number
to the special tool number that available in your
market..
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
M/T
Indicates the manual transaxle, or models equipped with the manual transaxle.
A/T
Indicates the automatic transaxle, or models equip ped with the automatic transaxle.
MFI: Indicates the
fuel injection, or engines equipped with the fuel injection.
Turbo: Indicates the engine with turbocharger, or m odels equipped
such an
Non-turbo: Indicates the engine without turbocharger, or models equipped with, such anengine.
FWD: Indicates the front wheel drive vehicles.
AWD: Indicates the all wheel drive vehicles.
ABS: Indicates the anti-lock braking system or mode ls equipped with the
braking

GENERAL How to Use This Manual
EXPLANATION OF MANUAL CONTENTS
Maintenance and Servicing Procedures
l
l
Classifications of Major Maintenance Service points
Symbols for Lubrication, Sealants and Adhesives
a

GENERAL Lubrication arid Maintenance,
00100120067
Maintenance and lubrication service recommenda-
tions have been compiled to provide maximum
protection for the vehicle owner’s investment
against all reasonable types of driving conditions.
Since these conditions vary with the individual ve-
hicle owner’s driving habits, the area in which the
vehicle is operated and the type of to which
the vehicle is subjected, it is necessary to prescr ibe
lubrication and maintenance service on a time fre-
quency as well as mileage interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by
the Society of Automotive Engineers (SAE), the
American Petroleum Institute (API) and the National
Lubricating Grease Institute (NLGI).
MAINTENANCE SCHEDULES
Information for service maintenance is provided
under “SCHEDULED MAINTENANCE TABLE”.
Three schedules are provided; one for “Required
Maintenance”, one for “General Maintenance” and
one for “Severe Usage Service”. Item numbers in the “SCHEDULED MAINTE-
NANCE TABLE” correspond to the item
in the “MAINTENANCE SERVICE” section.
SEVERE SERVICE
Vehicles operating under severe service conditions
will require more frequent service. Component service information is included in ap-
propriate units for vehicles operating under one
or more of the following conditions:
1. Police, taxi, or commercial type operation
2. Operation of Vehicle
(1) Short-trip operation at freezing temperature
(engine not thoroughly warmed up)
(2) More than 50% operation in heavy city traf-
fic during hot weather above
(3) Extensive idling
(4) Driving in sandy areas
(5) Driving in salty areas
(6) Driving in dusty conditions
ENGINE OIL
Either of the following engine oils should be used:
(1) Engine oil displaying EOLCS certification mark
(2) Engine oil conforming to the API classification SH
or ECII.
For further details, refer to “LUBRICANTS SELEC-
TION” section.
Caution
Test to EPA have shown
laboratory animals develop skin after
prolonged contact with used engine oil. Accord-
ingly, the potential exists for
to
a number:, of skin disorders, including
from such exposure to used
Care should be taken, when changing
engine oil, to minimize the
of exposure time to used your
skin. Protective clothing and that
be penetrated by worn.
should be thoroughly with soap
use waterless hand remove,
any used engine oil. Do not use gasoline, thin- ners, or solvents.
GEAR LUBRICANTS
The SAE grade number indicates
of Multi-purpose Gear Lubricants.
The API classification system
cants in terms of gear lubricants
conforming to API
or ‘with a
of SAE are recommended for
transaxle.
LUBRICANTS GREASES
Semi-solid lubricants bear the
designation
and are further classified as grades 0, 1, 2; 3 etc .
Whenever “Chassis Lubricant” is specified, Multi-
purpose Grease,
grade 2, should be used.
FUEL USAGE
Your car must use unleaded
This car has a fuel filler tube especially
to accept only the smaller-diameter unleaded gaso- line dispensing nozzle.
Caution
Using leaded gasoline in your car will damage
the catalytic converter and oxygen sensor, and
affect the warranty coverage validity.
Your car is designed to operate on premium
leaded gasoline having a minimum octane rating
of 91 or 95 RON (Research Octane
If premium unleaded gasoline is not
leaded gasoline having a octane rating of 87,
91 RON (Research Octane Number) may be used. In this case, the performance and fuel consumption
will suffer a little degradation.
Gasolines Containing Alcohol
Some gasolines sold at service stations contain
alcohol, although they may not be so identified.
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G E N E R A L Scheduled Maintenance Table
SCHEDULED MAINTENANCE TABLE00100140124
M A INTE N A NCE
VEHICLE PERFORMANCE
Inspection and services be performed any time a is observed or suspected. Retain
receipts for all vehicle emission services to prote ct your emission warranty.
GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE,
I
9
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GENERAL Scheduled Maintenance Table/Maintenance Service
SCHEDULED MAINTENANCE UNDER SEVERE USAGE
The maintenance items should be performed according to the following table:
Severe usage conditions
A
Driving in dusty conditions
Trailer towing or police, taxi, or commercial type
operation
Extensive idling, driving in stop and go traffic
Short-trip operation at freezing temperatures
gine not throughly warmed up)
,
Driving in sandy areas
Driving in salty areas
More than 50% operation in traffic or at
sustained high speeds during hot weather above
Driving on off-road
MAINTENANCE SERVICE
1.FUEL SYSTEM (Tank, Pipe
and Fuel Tank Filler Tube (Check
HOSES (Check condition)
1. Check for damage or leakage in” the
lines.’ and
connections and looseness of the fuel tank filler t ube
2. the surface of fuel hoses for heat and
damage. Hard and brittle rubber, cracking,
cuts,abrasions and excessive swelling’
deterioration of the rubber.
3. If the fabric casing of the rubber
is exposed’ b y
cracks and abrasions in the fuel the
be changed.
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GENERAL Maintenance Service
Engine (Non-turbo)>
Engine (Turbo)>
AIR CLEANER ELEMENT (Replace)00100180058
The air cleaner element become dirty and loaded with
dust during use, and the filtering effect will be
reduced.
Replace it with a new one.
(1) Unclamp the air cleaner cover.
(2) Take out the air cleaner element, install a new one.
(3) Be sure when clamping the air cleaner cover in place
that the cover is completed closed.
4.EVAPORATIVE EMISSION CONTROL SYSTEM
(Check for leaks and clogging)
except evapo-
rative emission canister
1.If the fuel-vapor vent line is clogged or damaged, a fuel
vapor mixture escapes into the atmosphere causing
excessive emissions. Disconnect the line at both en ds,
and blow it clean with compressed air. Remove the f uel
tank filler tube cap from the fuel tank filler tube and check
to see if there is evidence that the packing makes improper
contact to the fuel tank filler tube.
2.The fuel tank pressure control valve installed on the vapor
line should be checked for correct operation.
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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.
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GENERAL Maintenance
Generator pulley
Crankshaft
Water pump
pump
GENERATOR AND WATER PUMP DRIVE
CHECK
Engine (Turbo) and Engine>
Check the belt tension with the tension gauge, or c heck the
belt deflection by pressing. the middle point of
belt by
force of 98 (22 Ibs.).
Standard value:
Tension (Ibs.)
Deflection mm (in.)
245 490 (55.1
9.0 11.5
,
Engine (Non-turbo)>
Check the belt tension with the tension gauge at th e middle
point of the belt, or check the belt deflection by pressing,
the belt point by a force of 98
(22 Ibs.). .
Standard value:
Tension (Ibs.)
Deflection mm (in.)

4 0 0 490 (90 --
9.0 12.0
POWER STEERING PUMP DRIVE BELT TENSION CHECK
Engine (Turbo) and Engine>
1. Pull or push at the mid point of the belt with a force
of 98
(22 Ibs.) to measure dirve belt deflection.
Standard value:
mm in.)
2. Use a tension gauge to measure belt tension. S t a n d a r d v a l u e :
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