4WD MITSUBISHI TRITON 1997 Workshop Manual

GENERAL ± How to Use This Manual00-3
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
M/T: Indicates the manual transmission, or models equipped with the manual transmission.
A/T: Indicates the automatic transmission, or models equipped with the automatic transmission.
SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such
an engine.
MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection.
DIESEL: Indicates a diesel engine, or models equipped with such an engine.
2WD: Indicates the rear wheel-drive vehicles.
4WD: Indicates the 4 wheel-drive vehicles.

GENERAL ± Vehicle Identification00-17
MODELS00100550064
Model CodeEngine modelTransmission modelFuel supply system
K62TJERDEL64G63-SOHC (1,997 m
)R4AW2 (2WD-4A/T)MPI
ENDEL6R5M21 (2WD-5M/T)
K64TYNDL64D56 (2,477m
)R5M21 (2WD-5M/T)Fuel injection
ZNDL6
ENDL6
ENDR6
CENDL6
JENDL6
K75TCENDEL64G64-SOHC (2,351 m
)V5M21 (4WD-5M/T)MPI
K74TYNDFL64D56-Turbocharger with
intercooler (2 477 m
)
V5MT1 (4WD-5M/T)Fuel injection
ZNDFL6
intercooler (2,477 m
)
ENDFR6
JERDFL6V4AW2 (4WD-4A/T)
GJENXFL6V5MT1(4WD-5M/T)
CENDFL6
JENDFL6
JENHFL6

ENGINE COOLING ±
General Information/
Service Specifications/Lubricant/Sealants14-2
GENERAL INFORMATION14100010125
The cooling system is designed to keep every part
of the engine at appropriate temperature in
whatever condition the engine may be operated.
The cooling method is of the water-cooled, pressure
forced circulation type in which the water pump
pressurizes coolant and circulates it throughout the
engine. If the coolant temperature exceeds the
prescribed temperature, the thermostat opens to
circulate the coolant through the radiator as well
so that the heat absorbed by the coolant may be
radiated into the air.The water pump is of the centrifugal type and is
driven by the drive belt from the crankshaft.
The radiator is the corrugated fin, down flow type.
ItemsSpecifications
RadiatorPerformance kJ/h4G63 114,700
4G63 126,800
4G64, 4D56 <2WD>170,000
4D56 <4WD>227,300
Automatic transmission oil coolerPerformance kJ/h4G63 6,400
4D56 6,300
SERVICE SPECIFICATIONS14100030121
ItemsStandard valueLimit
High pressure valve opening pressure of radiator cap kPa75 ± 10565
Range of coolant antifreeze concentration of radiator %30 ± 60±
ThermostatValve opening temperature of thermostat
C82 + 1.5±
Full-opening temperature of thermostat
C95±
Valve lift (at 95
C) mm4G6, 4D56 <4WD>8.5 or more±
4D56 <2WD>8 or more±
LUBRICANT14100040100
ItemsQuantity

HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT4G637.4
4G64, 4D56 <2WD>7.7
4D56 <4WD>7.8
SEALANTS14100050110
ItemsSpecified sealantRemarks
Cylinder block drain plug3M Nut Locking Part No. 4171 or equivalentDrying sealant
Water by-pass fitting <4G6>Mitsubishi Genuine Parts No. MD970389 or
equivalentSemi-drying sealant

INTAKE AND EXHAUST ±
Turbocharger and Exhaust
Manifold <4D56-4WD>15-14
OIL PIPE AND OIL RETURN PIPE CHECK15100650010
Check the oil pipe and oil return pipe for clogging, bending,
or other damage. If there is clogging, clean it.
EXHAUST MANIFOLD CHECK
15100340108
Damage or cracking of any part.

MANUAL TRANSMISSION ± 4WD Indicator-ECU22-16
Terminal No.Inspection itemInspection condition
1: Ignition switchInspection condition
2: Transfer lever positionTerminal voltage
1Free wheel engage
switch
ON2HSystem voltage
switch
4H*10 V
24WD detection
switch
ON2HSystem voltage
switch
4H, 4L0 V
3Ignition switch (IG1)OFF±0 V
ON±System voltage
5Free wheel differen-
tial indicator lamp
ON2HSystem voltage
tial indicator lam
4H*10 V
6HI/LOW detection
switchONShifting from 4H to 4L
or vice versaSystem voltage
2H, 4H, 4L0 V
7Free wheel clutch
changeover solenoid
ON4H, 4L0 V
changeover solenoid
valve2H*2System voltage
104WD Indicator lampON2H0 V
4H, 4LSystem voltage
NOTE
*1: When vehicle has been moved once.
*2: Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.

FRONT AXLE ± General Information26-2
GENERAL INFORMATION26100010111
2WD
The front hub assembly which uses a double taper
roller bearing is mounted on the knuckle spindle.For vehicles with ABS, a rotor for detecting the
wheel speed is press-fitted into the front hub.
4WD
The front axle consists of the hub assembly, drive
shaft, inner shaft, front differential, freewheel clutch
assembly and actuator. The features are:

The wheel bearing uses a double taper roller
bearing. For vehicles with ABS, a rotor for
detecting the wheel speed is bolted to the brake
disc.

Drive shafts of almost identical length reduce
torque steer. In addition, a D.O.J.-B.J.-type
constant velocity ball joint has high power
transmission efficiency and reduces vibration
and noise.
A vacuum-type freewheel clutch has been
adopted in the freewheel mechanism. Its
solenoid valve and actuator switch powertrain
between 2WD and 4WD.

There are two types of differential gear. The
difference between them is gear ratio.
2WD
ItemSpecifications
Wheel bearingTypeDouble taper roller bearing
Inner bearing (O.D. x I.D.) mm65.1 x 34.9
Outer bearing (O.D. x I.D.) mm50.0 x 21.4
4WD

ItemSpecifications
Wheel bearingTypeDouble taper roller bearing
Inner bearing (O.D. x I.D.) mm73 x 45
Outer bearing (O.D. x I.D.) mm73 x 45
Drive shaftJoint typeOuter: B.J.
Inner: D.O.J.
Shaft length (joint to joint) mmRight: 318
Left: 291
Inner shaftO.D. x length mm31.5 x 304.2
Bearing (O.D. x I.D.) mm62 x 35

REAR AXLE ± Service Specifications27-4
SERVICE SPECIFICATIONS27100030121
ItemStandard valueLimit
Rear axle total backlash mm±5
Axle shaft axial play mmVehicles without ABS or rear differential lock0.05 ± 0.20±
Vehicles with ABS or rear differential lock0 ± 0.25±
Limited slip differential
p
reload Nm
Using special tool13 or more±
reload Nm
Without using special tool25 or more±
Axle shaft retainer
press-fitting force NVehicles without ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
78,000±
Vehicles with ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
98,000 ± 108,000±
Clearance between axle shaft retainer and snap ring mm0 ± 0.166±
Rear differential lock air pump pressure kPa25 ± 40±
Drive gear backlash mm2WD0.08 ± 0.13±
4WD0.13 ± 0.18±
Drive gear runout mm±0.05
Differential gear backlash mm2WD0 ± 0.250.2
4WD0 ± 0.0760.2
Limited slip differential
starting torque Nm
When a new clutch plate is used39 ± 74±
starting torque Nm
When re-installing current clutch plate25 ± 74±
Drive pinion
turning torque NmWithout oil sealWhen replacing
(with anti-rust agent)0.6 ± 0.9±
When replacing or reusing
(with gear oil applied)0.4 ± 0.5±
With oil sealWhen replacing
(with anti-rust agent)0.8 ± 1.1±
When replacing or
reusing (with gear oil applied)0.6 ± 0.7±

REAR AXLE ± Service Specifications/Lubricants/Sealants27-5
ItemStandard valueLimit
Horizontal difference between friction plate and friction disc thickness mm0 ± 0.05±
Clearance between friction plate and friction disc mm0.06 ± 0.20±
Clearance in side gear axial direction mm0.05 ± 0.20±
Difference between left and right dimensions from back thrust face of pressure
ring to end of thrust washer mm0 ± 0.05±
Friction plate and friction disc warping (flatness) mm±0.08
Friction plate and friction disc wear
(difference in the thickness of the friction surface and the projections) mm±0.1
LUBRICANTS27100040049
ItemSpecified lubricantsQuantity
Rear differential gear oil
Conventional differential:
Hypoid gear oil
API classification GL-5 or higher SAE viscosity No. 90,
80 W

Limited slipdifferential:
2WD1.6


Limited sli differential:
Hypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 8149630 EX
CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD
(GL-5, SAE 80W-90) or equivalent4WD2.6

SEALANTS27100050042
ItemsSpecified sealantsRemarks
Bearing case3M ATD Part No. 8661 or equivalentSemi-drying sealant
Dust cover
Axle housing (differential carrier mounting part)
Drive gear and differential case mounting part3M Stud Locking 4170 or equivalentAnaerobic sealant

WHEEL AND TYRE ± General Information/Service Specifications31-2
GENERAL INFORMATION31100010146
Both steel type and aluminium type wheels have
been adopted. The type of wheel used depends
on the vehicle model.
Items2WD4WD
WheelTypeSteel typeSteel typeAluminium type
Size14 x 6JJ16 x 6JJ15 x 7JJ
Amount of wheel offset333310 +1
Pitch circle diameter
(P.C.D.) mm139.7139.7139.7
TyreSize185R 14C 8PR205/80 R16 RF31 x 10.50 R15 LT
SERVICE SPECIFICATIONS31100030036
ItemsLimit
Tread depth of tyre mm1.6
Wheel runout (Radial runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less
Wheel runout (Lateral runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less

FRONT SUSPENSION ± Service Specifications/Sealant33A-3
SERVICE SPECIFICATIONS33200030088
ItemsStandard valueLimit
Toe-inAt the centre of tyre thread mm0 ± 7±
Toe-angle
(per wheel)
2WD0
± 0
19'±
(er wheel)
4WD
205/80 R16 tyre>0
± 0
16'±
4WD
x 10.50 R15 tyre>0
± 0
15'±
Camber0
10' ± 1
10' (Difference between
right and left within 30')±
Caster2WD1
45' ± 3
45' (Difference between
right and left within 30')±
4WD1
15' ± 3
15' (Difference between
right and left within 30')±
Kingpin inclination2WD15
00'±
4WD14
50'±
Shock absorber attaching dimension mm1 ± 2±
Upper arm ball joint starting torque Nm2WD0.8 ± 3.4±
Strut bar attaching dimension mm79±
Lower arm ball joint end play mm±0.5
Lower arm bush press-fitting force kN9.8±
Clearance between bump stopper and
bump stopper bracket mm4WD21 ± 23±
Stabilizer link assembly attaching
dimension mm4WD16 ± 18±
SEALANT33200050015
ItemSpecified sealant
Upper arm ball joint dust cover <2WD>3M ATD Part No. 8661 or equivalent