transmission MITSUBISHI TRITON 1997 Workshop Manual

GENERAL ± How to Use This Manual00-2
HOW TO USE THIS MANUAL00100010210
SCOPE OF MAINTENANCE, REPAIR
AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components.
For detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
ªOn-vehicle Serviceº is procedures for performing
inspections and adjustments of particularly
important locations with regard to the construction
and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage,
etc.) must also be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection
or the value to which the part or assembly is
corrected and adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a
part or assembly on inspection and means the
maximum or minimum value within which the part
or assembly must be kept functionally or in strength.
It is a value established outside the range of
standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
CAUTION
Indicates the presentation of information particularly
vital to the worker during the performance of
maintenance 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.
INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a
basic value with a tolerance of +10% except the
following cases when the upper and lower limits
of tightening torque are given.
(1) The tolerance of the basic value is within +10%.
(2) Special bolts or the like are in use.
(3) Special tightening methods are used.

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

MPI ± Troubleshooting13A-57
DATA LIST REFERENCE TABLE13100890180
Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.
NOTE
*1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes
10% higher than the standard frequency.
*
2. The idle position switch normally turns off when the voltage of the throttle position sensor is 50 ±
100 mV higher than the voltage at the idle position. If the idle position switch turns back on after
the throttle position sensor voltage has been by 100 mV and the throttle valve has been opened,
the idle position switch and the throttle position sensor need to be adjusted.
*3. The injector drive time represents the time when the cranking speed is at 250 r/min or below when
the power supply voltage is 11 V.
*4. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10%
longer than the standard time.
*5. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes
30 steps greater than the standard value.
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
11Oxygen
sensorEngine:After having
warmed up
Air/fuel mixture is
made leaner when de-
When at 4,000 r/min,
engine is suddenly
decelerated200 mV or lessCode No.
1113A-11
made leaner when de-
celerating, and is made
richer when racing.
When engine is
suddenly raced600 ± 1,000 mV
Engine:After having
warmed up
The oxygen sensor
signal is used to check
the air/fuel mixture
ratio and control
Engine is idling400 mV or less
(Changes)
600 ± 1,000 mV
ratio, and control
condition by the en-
gine-ECU.2,500 r/min400 mV or less
(Changes)
600 ± 1,000 mV
12Air flow
sensor*1
Engine coolant
temperature:
80 ± 95C

Lamps and all
accessories: OFF
Engine is idling22 ± 48 Hz
<4G63>
19 ± 45 Hz
<4G64>±±
accessories: OFF

Transmission:
Neutral (A/T:
P range)2,500 r/min80 ± 120 Hz
<4G63>
67 ± 107 Hz
<4G64>
Engine is racedFrequency
increases in
response to
racing

MPI ± Troubleshooting13A-60
Item
No.Reference
page Inspection
procedure
No. Normal condition Inspection contents Inspection
item
28A/C switchEngine: Idling
(when A/C switch isA/C switch: OFFOFFProcedure
No. 2913A-43
(
ON, A/C compressor
should be operating.)A/C switch: ONON
29Inhibitor
switch
Ignition switch: ONP or NP or NProcedure
No 27
13A-42
switch
D, 2, L or RD, 2, L or R
No. 27
41Injectors *3Engine: CrankingWhen engine cool-
ant temperature is
0C51 ± 76 ms
<4G63>
60 ± 90 ms
<4G64>±±
When engine
coolant temperature
is 20C26 ± 38 ms
<4G63>
30 ± 45 ms
<4G64>
When engine
coolant temperature
is 80C5.7 ± 8.5 ms
<4G63>
6.7 ± 10.1 ms
<4G64>
Injectors*4
Engine coolant
temperature:
80 ± 95C

Lamps and all
accessories: OFF
Engine is idling1.9 ± 3.1 ms
<4G63>
2.2 ± 3.4 ms
<4G64>
accessories: OFF

Transmission:
Neutral (A/T :
P range)2,500 r/min1.8 ± 3.0 ms
<4G63>
1.9 ± 3.1 ms
<4G64>
When engine is
suddenly racedIncreases
44Ignition coils
and power
Engine: After
having warmed upEngine is idling2±18BTDC±±
transistors
g

Timing lamp is set.
(The timing lamp
is set in order to
check actual
ignition timing.)2,500 r/min23 ± 43 BTDC
<4G63>
27 ± 47 BTDC
<4G64>

MPI ± Troubleshooting13A-61
Item
No.Reference
page Inspection
procedure
No. Normal condition Inspection contents Inspection
item
45ISC
(stepper)
motor
p
osition*5

Engine coolant
temperature:
80 ± 95C

Lamps and all
A/C switch: OFF2 ± 25 STEP±±
osition 5
Lam s and all
accessories: OFF

Transmission:
Neutral (A/T :
P range)

Idleposition
A/C switch:
OFF
ONIncreases by
10 ± 70 steps

Idle osition
switch: ON

Engine: Idling

When A/C switch
is ON, A/C
compressor should
be operating
A/C switch: OFF

Select lever:
N range
D
rangeIncreases by
5 ± 50 steps
49A/C relayEngine: After having
warmed up/Engine is
idlingA/C switch: OFFOFF (Compressor
clutch is not
operating)Procedure
No. 2913A-43
A/C switch: ONON (Compressor
clutch is
operating)

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

ENGINE COOLING ± Radiator14-15
REMOVAL SERVICE POINT
A
TRANSMISSION FLUID COOLER HOSE REMOVAL
After removing the hose from the radiator, plug the hose
and the radiator nipple to prevent dust or foreign particles
from getting in.

MANUAL TRANSMISSION ± General Information22-2
GENERAL INFORMATION22100010113
ItemsVehicles with 4G63 engineVehicles with 4D56 engine
Transmission modelR5M21-5R5M21-5
Type5-speed, floor-shift5-speed, floor-shift
Gear ratio1st4.3304.330
2nd2.3552.355
3rd1.5091.509
4th1.0001.000
5th0.8270.827
Reverse4.1424.142
Speedometer gear ratio (driven/drive)29/826/8
ItemsVehicles with 4G64 engineVehicles with 4D56 engine
Transmission modelV5M21-9V5MT1-4
Type5-speed, floor-shift5-speed, floor-shift
Gear ratio1st3.9673.918
2nd2.1362.261
3rd1.3601.395
4th1.0001.000
5th0.8560.829
Reverse3.5783.925
Transfer type2-speed2-speed
Gear ratioHigh1.0001.000
Low1.9251.925
Speedometer gear ratio (driven/drive)27/825/8

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.