trunk MITSUBISHI SPYDER 1990 Service Repair Manual

GENERAL Vehicle Identification
Theft protection label
Fororiginal parts
MITSUBISHI
0 0 2 0 0 1 4
Forreplacement parts
MITSUBISHI
0 0 2 0 0 1 5
0 0 0 0 4 7 4 3THEFT
PROTECTION
In order to protect against theft, a Vehicle Identification Number
is stamped in, or attached as a label to, the foll owing
major parts of the engine and transaxle,
as main
outer panels:
Engine cylinder block, Transaxle housing. Door, Quar-
ter panel, Hood, Liftgate, Trunk lid, Bumpers
In addition, a theft-protection label is attached t o replacement
parts for the body outer panel main and the
same data are stamped into replacement parts for th e engine
and the transaxle.
Cautions regarding panel repairs:‘
1.When repainting original so first mask-
ing the theft-protection label, and, after be
sure to peel off the masking tape.
2.The theft-protection label for parts cov-
ered bymasking tape, such part&an be
as is. The masking tape should removed
ing is finished.
3.The theft-protection label should not be from
original or replacement parts.
,
. .
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GENERAL Vehicle
Target area (A: for original equipment parts, B: for replacement parts)
Front bumperRear bumper
Trunk lid
A
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GENERAL Main and Adhesive Table
MAIN SEALANT AND ADHESIVE TABLE
SEALANTS FOR ENGINE ACCESSORIES
Application Recommended brand
Sealing between rocker cover and camshaft bearing c ap
DOHC ATD Part No. 8680 or equivalent
and
engines only)
1Sealing between semi-circular packing and rocker co ver and between
semi-circular packing and cylinder head
Oil pressure switch (except
and engines). . .
Engine coolant temperature switch, Engine coolant t emperature sensor, Nut Locking Part No. 4171 or
valve, switch, Joints, Engine coolant temperature lent
gauge unit (large size)
Engine coolant temperature gauge unit (small size, only) ATD Part No. 8660 or equivalent
Oil pan (except
engine)MITSUBISHI GENUINE ‘Part
0 or equivalent
SEALING BETWEEN GLASS AND WEATHERSTRIP
Application
Sealing between tempered glass and weatherstrip
Sealing between body flange and weatherstrip
Sealing between laminated glass and weatherstripRecommended brand
ATD Part No. 8513 or equivalent
ATD Part No. 8509 or equivalent
ADHESION WITH RIBBON SEALER
Application Recommended brand
Waterproof film for door, Fender panel, Splash shie ld, Mud guard, Rear
ATD Part No. 8625 or equivalent
combination light
ADHESIVES FOR INTERIOR TRIM
Application Recommended brandI
Adhesion of polyvinyl chloride sheetI Part No. 368 or equivalentI
Adhesion of door weatherstrip to body ATD No. 8001 or ATD Part No.
8011 or equivalent
Sealing between grommet or packing, and metal seal
Adhesion of headlining and other interior trim mate rials
Adhesion of fuel tank to pad
ATD Part No. 8513 or equivalent
Part No. or ATD Part No.
8080 or equivalent
BODY SEALANT
ApplicationRecommended brandI
Sealing of sheet metal, drip rail, floor, body side panel, trunk, front panel ATD No. 8531 or ATD Part No.
and the like joints8848or equivalent
Sealing of
hinges
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CONTENTS
DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Door Glass and Regulator . . . . . . . . . . . . . . . . . . .56
Door Handle and Latch. . . . . . . . . . . . . . . . . . . . .59
Door Opening Weatherstrip. . . . . . . . . . . . . . . . . .63
Door Trim and Waterproof Film . . . . . . . . . . . . . .54
On-vehicle Service. . . . . . . . . . . . . . . . . . . . . . . . . .48
Sealant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Service Specifications. . . . . . . . . . . . . . . . . . . . . . .33
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
ELECTRIC CONVERTIBLE TOP. . . . . . . . . . . .91
Balance Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Convertible Top Assembly. . . . . . . . . . . . . . . . . . .94
Convertible Top Bypass Switch . . . . . . . . . . . . . .104
Convertible Top Control Module. . . . . . . . . . . . .105
Convertible Top Switch. . . . . . . . . . . . . . . . . . . . .103
Front Roof Weatherstrip. . . . . . . . . . . . . . . . . . . .100
Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
On-vehicle Service. . . . . . . . . . . . . . . . . . . . . . . . . .94
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Drive Motor. . . . . . . . . . . . . . . . . . . . . . . .99
Driven Gear . . . . . . . . . . . . . . . . . . . . . . .96
Rail Weatherstrip and
Top Cover Retainer . . . . . . . . . . . . . . . . . . . . . . . .
101
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
FENDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Sealants
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FUEL FILLER DOOR . . . . . . . . . . . . . . . . . . . . . . .6
HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ENTRY SYSTEM . . . . . . . . . . . . . . . .72
Entry System
. . . . . . . . . . . . . . . . . . . . . . .77
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
SUNROOF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
On-vehicle Service. . . . . . . . . . . . . . . . . . . . . . . . . .82
Sealant and Adhesive . . . . . . . . . . . . . . . . . . . . . . .82
Sunroof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
UNDER COVER. . . . . . . . . . . . . . . . . . . . . . . . . . .81
WINDSHIELD AND WINDOW GLASS . . . . . . . .
7
Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
On-vehicle Service
. . . . . . . . . . . . . . . . . . . . . . . . . .10
Quarter Window Glass . . . . . . . . . . . . . . . . . . . . . .22
Quarter Window Glass and
Regulator Assembly. . . . . . . . . . . . . . . . . . . . . . . . .26
Sealant and Adhesive. . . . . . . . . . . . . . . . . . . . . . . .7
Service Specifications. . . . . . . . . . . . . . . . . . . . . . . .7
Special Tool
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Windshield and Window Glass . . . . . . . . . . . . . . .15
TRUNK LID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Trunk Lid
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
TRUNK LID LOCK RELEASE HANDLE AND
CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

TRUNK LID
B O D Y Trunk Lid
TROUBLESHOOTING SymptomProbable cause Remedy
Improper closure Striker and latch not properly aligned
Adjust the alignment
Difficult locking and unlocking.
Uneven body clearance Incorrectly installed trunk lid
Adjust the installation of trunk lid
Uneven height Incorrect trunk lid bumper height Adjust the trunk lid bumper height
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BODY Trunk Lid
TRUNK LID
REMOVAL AND INSTALLATION of trunk lid step
trunk lid striker linkageAdjustment of clearance
around trunk lid
1. Bumper
2. Trunk lid striker
3. Trunk lid opening weatherstrip
Trunk lid latch removal steps
l Rear end trim (Refer to GROUP
Trims.)4. Trunk lid latch
Caution1.Never try to disassemble the gas spring
or burn it.
2.Always bore a hole in the gas spring to release
the interior gas before the spring is discarded.
0 0 0 0 4 7 5 2
Trunk lid gas spring removal steps 6. Lock cover
7. Trunk lid gas spring
8. Ball joint
Trunk lid removal steps
5. Harness connector
6. Lock cover
7. Trunk lid gas spring
9. Trunk lid hinge
10. Trunk lid
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BODY Trunk Lid
Slit
I
I
Trunk lid opening weatherstrip
Trunk lid
in.)
Bumper
REMOVAL SERVICE POINT
LOCK COVER
a flat-tip screwdriver, etc., into the slit, and r emove
the lock cover.
INSTALLATION SERVICE POINTS
TRUNK LID OPENING WEATHERSTRIP
INSTALLATION
(1)Install the trunk lid opening weatherstrip so that the marked
part is at the position shown in the illustration.
(2) Install so that the notch on the trunk lid open ing
weatherstrip is approximately at the center of the panel
notch shown in the illustration.
BUMPER INSTALLATION
Install the bumper as shown in the figure.
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BODY Trunk Lid Lock Release Handle and Cable
REMOVAL AND INSTALLATION Trunk lid lock release handleremoval steps
1. Release handle cover2. Retainer3. Lock cylinder
l Scuff plate (Driver’s side)
(Refer to GROUP
Trims.)
l Front seat (Driver’s side)
(Refer to GROUP
Front seat.)
4. Trunk lid lock release handle
. .
Adjustment of trunk lid step
frunk lid striker linkage .
Trunk lid lock cableremoval steps
1. Release handle cover
l Scuff plate (Driver’s side)
(Refer to GROUP
Trims.)
l Front seat (Driver’s side)
(Refer to GROUP
Front seat.)
4. Trunk lid lock release handlel Quarter trim, lower (L.H.) and luggagecompartment side trim (Refer to GROUP 5. Trunk lid latch
6. Trunk lid lock release cable
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42-96BODY Electric Convertible
DRIVEN GEAR
REMOVAL AND INSTALLATION
Removal steps
l Quarter trim, lower (Refer to GROUP Trims.)
1. Balance link installation screw
2. Bushing
3. Main pivot bolt
4. Bushing 5. driven gear
B u s h i n g
REMOVAL SERVICE POINT
DRIVEN GEAR REMOVAL
Lift pivot and support with 102 mm
366 mm 279 mm
(4 in.
14 in. 11 in.) block of wood or equivalent.
INSTALLATION SERVICE POINTS
DRIVEN GEAR/BUSHING
INSTALLATION
(1) Position the driven gear and insert the main
pivot bolt, then tighten two driven gear installation
bolts.
(2) Remove the main pivot bolt.
(3) Install the driven gear to the main pivot complete
bracket.
NOTE
To align motor drive gear and driven gear, change
Bypass switch in left rear of trunk to manual posit ion.
Revision

ALPHABETICAL INDEX
TENSIONDrive Belt, Check and Adjustment . . . . . . . .11. . . . . . . .. . . . . . . . . . . .
TENSION PULLEY ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . . . . . . . . ENGINE (TURBO) AND ENGINE>.. . . . . . . . .TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .THEFT-ALARM SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . .T H E R M O S T A T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .THICKNESS
Front Brake Disc, Check. . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Brake Disc, Check. . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE BODY
ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . . . . .
ENGINE (TURBO) AND ENGINE>.. . . . . .THROTTLE BODY MINIMUM AIR FLOW, Check. . . . . . .THROTTLE BODY (THROTTLE VALVE AREA) ENGINE (TURBO) AND ENGINE>, Cleaning .
THROTTLE POSITION SENSORAdjustment
ENGINE (TURBO) AND ENGINE>. . . . . . . . . . . . . . . . . . . . . . . . . .On-vehicle ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . .
ENGINE (TURBO) AND . . .TIE ROD END BALL JOINT, Breakaway Torque Check. . . .TIMING BELT
. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TIMING BELT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TIMING BELT, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE INFLATION PRESSURE, Check. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOE CONTROL ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TORQUE CONVERTER STALLTesting
ENGINE (NON-TURBO)>. . . . . . . . . . . ENGINE (TURBO) AND ENGINE>TOTAL BACKLASH Rear Axle, Check. . . . . . . . . . . .TRAILING ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSAXLE ENGINE (NON-TURBO)>. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE (TURBO) AND . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE (TURBO) AND ENGINE> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning and . . . . . . . . . . . . . . . . . . . . . ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . .M/T ENGINE (TURBO) AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M/T ENGINE (TURBO) AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .TRANSAXLECASEDisassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSAXLE CONTROL
ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . . ENGINE (TURBO) AND ENGINE>. . . .A/T ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . ENGINE (TURBO) AND . . .
TRANSAXLE FLUID
Automatic, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement ENGINE (NON-TURBO)> . . . . . . . . . . . . .
ENGINE (TURBO) . . . TRANSAXLE FLUID LEVELCheck ENGINE (NON-TURBO)> . . . . . . . . . . . . . . . . ENGINE (TURBO) AND ENGINE>. . . . .
TRANSAXLE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . , . . TRANSAXLE OIL
Manual, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement ENGINE . . . . . . . . . . . . . .
. . . . . .
TRANSAXLE OIL COOLER
ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . . . . .
ENGINE (TURBO) AND ENGINE>.. . . . . .
TRANSAXLE OIL LEVEL
Check
ENGINE (NON-TURBO)>.. . . . . . . . . . . . .
ENGINE (TURBO) AND ENGINE>..
TRANSAXLE RANGE SENSOR, Continuity Check ENGINE (NON-TURBO)>. . . . . . . . . . . . . . . . . . . . . .TRANSFER
ENGINE (TURBO) AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER CASE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER CASE ADAPTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSFER DRIVEN GEAR . . . . . . . . . . . . . . . . .TRANSFER OIL, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . .TRANSFER OIL, Replacement ENGINE AND ENGINE>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSFER OIL LEVEL
ENGINE AND ENGINE>. . . . . . . . . . - -
. . . . . . . . . . .
TRANSFER OIL, Replacement ENGINE (TURBO) AND ENGINE>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSFER SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRIM, Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRIMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRUNK LID LOCK RELEASE CABLE. . . . . . . . . . . . . . . . . . . .
TRUNK LID LOOK RELEASE HANDLE. . . . . . . . . . . . . . . . . .TUBING AND FITTINGS, Handling. . . . . . . . . . . . . . . . . . . . . .TURBOCHARGER BYPASS VALVE, CHECK. . . . . . . . . .. . .
TURBOCHARGER WASTE GATE SOLENOID
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .On-vehicle Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . .UPPER ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension>. . . . . . . . . . . . . . . . . . . . ... . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
VACUUM
EGR Port, Check ENGINE ENGINE (TURBO) AND . . . . . . Manifold, Check . . . . . . . . . . . . . . . . . . . . 11 C-l
. . . . . . . . . . . . . . . . . . . . . .