Part 1
FUEL USAGE STATEMENTCAUTION: Using leaded gasoline in this car will damage the catalytic converters and heated oxygen sensors, and affect the warranty coverage validity. This vehicle must use unleaded gasoline only.
This vehicle has a fuel filler tube which is especially designed to accept only the smaller-diameter unleaded gasoline dispensing nozzle.
The 2.4L model is designed to operate on unleaded gasoline having a minimum octane rating of 87 [(MON + RON)/2], or 91 RON.
NOTE:
^ MON: Motor Octane Number
^ RON: Research Octane Number
GASOLINE CONTAINING ALCOHOL
Some gasoline sold at service stations contain alcohol although they may not be so identified. Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory.
Gasohol: A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your vehicle. If driveability problems are experienced as a result of using gasohol, it is recommended that the vehicle be operated on gasoline.
Methanol: Do not use gasoline containing methanol (wood alcohol). Using this type of alcohol can result in vehicle performance deterioration and damage critical parts in the fuel system components. Fuel system damage and performance problems resulting from the use of gasoline containing methanol may not be covered by the new vehicle warranty.
GASOLINE CONTAINING METHYL TERTIARY BUTYL ETHER (MTBE)
Unleaded gasoline containing 15% or less MTBE may be used in your vehicle. (Fuel containing MTBE over 15% in volume may cause reduced engine performance and produce vapor lock or hard starting.
MATERIALS ADDED TO FUEL
Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials intended for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts.
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
RECOMMENDED LUBRICANTS
LUBRICANT CAPACITY TABLE
LUBRICANT SELECTION
ENGINE OIL
CAUTION: Never use nondetergent or straight mineral oil. Oil Identification Symbol
Use only engine oils displaying the ILSAC certification mark (Starburst symbol) on the container.
If these oils are not available, an API classification SL or SL/CF can be used.
OIL VISCOSITY
The SAE grade number indicates the viscosity of the oil. A proper SAE grade number should be selected according to ambient temperature.
NOTE: SAE 5W-20, SAE 5W-30 and SAE 10W-30 engine oil can be used in outdoor temperatures ranging from -18 to 38°C (0 to 100°F). However, for optimum fuel economy and cold staffing, select the low SAE viscosity grade oil for the expected temperature range. SAE 5W-20 or SAE 5W-30 engine oil is recommended.
SELECTION OF COOLANT
COOLANT
Relationship between Coolant Concentration and Specific Gravity
CAUTION:
^ If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.
^ Do not use a mixture of different brands of anti-freeze.
Example
The safe operating temperature is -15°C (5°F) when the specific gravity is 1.058 at the coolant temperature of 20°C (68°F)
SCHEDULED MAINTENANCE TABLE
SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE
Inspection and service should be performed any time if a malfunction is observed or suspected.
GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE
SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS
Maintenance should be carried out according to the following table:
Severe usage conditions:
1. Driving on dusty, rough, muddy or salt-spread roads
2. Towing or police, taxi or commercial operation
3. Extensive idling and/or low speed operation
4. Repeated short-trip operation at freezing temperatures (engine not thoroughly warmed up)
5. Extended use of brakes while driving
6. Driving in sandy areas
7. More than 50% operation in heavy city traffic during hot weather above 90°C (32°F)
MAINTENANCE SERVICE
1. FUEL SYSTEM (TANK, PIPE LINE AND CONNECTION, AND FUEL TANK FILLER TUBE CAP) (CHECK FOR LEAKS)
Check for damage or leakage in the fuel lines and connections.
2. FUEL HOSES (CHECK CONDITION)
1. Inspect the surface of fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.
2. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be replaced.
3. AIR CLEANER ELEMENT (REPLACE)
The air cleaner element will become dirty during use, reducing its effectiveness. Replace it with a new one. REPLACEMENT OF AIR CLEANER ELEMENT
1. Unclamp the air cleaner housing.
2. Remove the air cleaner element and install a new one.
3. When clamping the air cleaner housing in place, be sure that the cover is completed closed.
4. EVAPORATIVE EMISSION SYSTEM (EXCEPT EVAPORATIVE EMISSION CANISTER) (CHECK FOR CLOGGING)
If the fuel-vapor vent line is clogged or damaged, fuel vapor will escape into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean with compressed air. Remove the fuel tank filler tube cap from the filler tube and check to see if there is evidence that the seal makes improper contact to the filler tube.
5. SPARK PLUGS (REPLACE)
CAUTION: Iridium plugs are used. Use care not to damage the iridium tips of the plugs. Do not adjust the spark plug gap.
1. Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission level.
Therefore, they should be replaced periodically with new ones.
Spark plug type
2. The new plugs should be checked for the proper gap.
Spark plug gap: 0.7 - 0.8 mm (0.028 - 0.031 inch)
3. Install the spark plugs and tighten to 25 ± 4 Nm (18 ± 3 ft. lbs.).
6. INTAKE AND EXHAUST VALVE CLEARANCE (INSPECT AND ADJUST)
1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition:
^ Engine coolant temperature: 80 - 95°C (176 - 203°F)
^ Lights, and all accessories: OFF
^ Transaxle: P range
2. Remove all of the ignition coils.
3. Remove the rocker cover.
4. Turn the crankshaft clockwise until the notch on the pulley is lined up with T mark on the timing indicator.
5. Move the rocker arms on the No.1 and No.4 cylinders up and down by hand to determine which cylinder has its piston at the top dead center on the compression stroke. If both intake and exhaust valve rocker arms have a valve lash, the piston in the cylinder corresponding to these rocker arms is at the top dead center on the compression stroke.
6. Valve clearance inspection and adjustment can be performed on rocker arms indicated by white arrow mark when the No.1 cylinder piston is at the top dead center on the compression stroke, and on rocker arms indicated by black arrow mark when the No.4 cylinder piston is at the top dead center on the compression stroke.
7. Measure the valve clearance. If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance using a thickness gauge while turning the adjusting screw.
Standard value (hot engine):
Intake valve: 0.20 mm (0.008 inch)
Exhaust valve: 0.30 mm (0.012 inch)
8. While holding the adjusting screw with a screwdriver to prevent it from turning, tighten the lock nut to the specified torque.
Tightening torque: 9.0 ± 1.0 Nm (80 ± 9 inch lbs.)
9. Turn the crankshaft through 360° to line up the notch on the crankshaft pulley with the T mark on the timing indicator.
10. Repeat steps 7 and 8 on other valves for clearance adjustment.
11. Install the rocker cover.
12. 1nstall the ignition coils.
7. TIMING BELT (REPLACE)
Replace the belt with a new one according to the maintenance schedule to assure proper engine performance.
8. DRIVE BELT (FOR GENERATOR, WATER PUMP, POWER STEERING OIL PUMP) (CHECK CONDITION)
CAUTION: Check the drive belt tension after turning the crankshaft clockwise one turn or more.
1. Make sure that the indicator mark is within the area marked with A in the illustration.
2. If the mark is out of the area, replace the drive belt.
NOTE: The drive belt tension check is not necessary as auto-tensioner is adopted.
9. EXHAUST SYSTEM (CONNECTIONS PORTION OF MUFFLER, MUFFLER PIPES AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE AS REQUIRED)
1. Check for holes and exhaust gas leaks due to damage, corrosion, etc.
2. Check the joints and connections for looseness and exhaust gas leaks.
3. Check the rubber hangers and brackets for damage.
10. ENGINE OIL (CHANGE)
1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80°C (176°F) to 90°C (194°F).
WARNING: Use care as oil could be hot.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque.
Tightening torque: 39 ± 5 Nm (29 ± 3 ft. lbs.)
5. Refill the specified quantity of oil.
Specified Engine Oil: Engine oils displaying ILSAC certification symbol or conforming to the API classification SL, SL/CF
Total quantity: 4.3 dm3 (4.5 quarts)
NOTE: SAE 5W-20, SAE 5W-30 and SAE 10W-30 engine oil can be used in outdoor temperatures ranging from -18 to 38°C (0 to 100°F). However, for optimum fuel economy and cold staffing, select the low SAE viscosity grade oil for the expected temperature range. SAE 5W-20 or SAE 5W-30 engine oil is recommended.
6. Install the engine oil filler cap.
7. Start the engine and run it at idle for a few minutes.
8. Stop the engine and check to ensure that the engine oil level is within the level range indicated on the dip stick.
11. ENGINE OIL FILTER (REPLACE)
The quality of replacement filters varies considerably. Only high quality filters should be used to assure most efficient service.
Genuine oil filters require that the filter is capable of withstanding a pressure of 1,765 kPa (256 psi) are high quality filters and are recommended as follows:
Mitsubishi Oil Filter Part Number: MD136466, MD322508, MD356000 or equivalent
Engine Oil Filter Selection
This vehicle is equipped with a full-flow, throw-away oil filter. The same type of filter is recommended as a replacement filter for this vehicle. It is possible, particularly in cold weather, that this vehicle may develop high oil pressure for a short duration. Make sure that any replacement filter used on this vehicle is a high-quality filter. The filter must withstand a pressure of 1,765 kPa (256 psi) [manufacturer's specifications] to avoid filter and ultimately engine damage. The following is a high-quality filter and is strongly recommended for use on this vehicle: Mitsubishi Engine Oil Filter Part number MD136466, MD322508 and MD356000.
Any replacement oil filter should be installed in accordance with the oil filter manufacturer's installation instructions.
Oil Filter Replacement
1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80°C (176°F) to 90°C (194°F).
WARNING: Use care as oil could be hot.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
4. Use an oil filter wrench to remove the engine oil filter.
5. Clean the filter bracket side mounting surface and ensure the old O-ring has been removed.
6. Apply a small amount of engine oil to the O-ring of the new oil filter.
7. Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with an oil filter wrench.
8. Install the drain plug and refill engine oil.
9. Rev the engine a few times, and check to be sure that no engine oil leaks from the installation section of the oil filter.
12. MANUAL TRANSAXLE OIL
Checking transaxle oil level
1. Remove the filler plug.
2. Check that the oil level is up to the lower edge of the filler plug hole.
3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque.
Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.)
Transaxle oil replacement
1. Remove the filler plug.
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.
Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.)
4. Fill with gear oil API classification GL-4 SAE 75W - 85W or 75W90 until the level comes to the lower portion of filler plug hole.
Quantity: 2.2 dm3 (2.32 quarts)
Quantity: 2.3 dm3 (2.43 quarts)
5. Tighten the filler plug to the specified torque.
Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.)
13. TRANSMISSION FLUID
Checking transmission fluid level
1. Drive the vehicle until the transmission fluid temperature rises to the normal operating temperature [70 - 80°C (158 - 176°F)]
NOTE: The transmission fluid temperature is measured with scan tool MB991958 (MUT-III sub assembly).
NOTE: If it takes some amount of time until the transmission fluid reaches its normal operating temperature [70 - 80°C (158 - 176°F)], check the transmission fluid level by referring to the left diagram.
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then move the selector lever to the N position.
4. After wiping off any dirt around the dipstick, remove the dipstick and check the condition of the transmission fluid.
NOTE: If the transmission fluid smells as if it is burnt, it means that the transmission fluid has been contaminated by fine particles from the bushings and friction materials. Transaxle overhaul and cooler line flushing may be necessary.
5. Check transmission fluid level is at the HOT mark on the dipstick. If the transmission fluid level is less than this, add DIAMOND ATF SP III transmission fluid until the level reaches the HOT mark.
NOTE: If the transmission fluid level is too low, the oil pump will draw in air along with the transmission fluid, which will cause to form bubbles. If the transmission fluid level is too high, rotating components inside the transaxle will churn the fluid and air into a foamy liquid. Both conditions (level too low or too high) will cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes.
NOTE: In either ease, air bubbles can interfere normal valve, clutch, and brake operation. Also, foaming can cause transmission fluid to escape from the transaxle vent where it may be mistaken for a leak.
6. Securely insert the dipstick.
NOTE: The transmission fluid should always be replaced under the following conditions:
^ When troubleshooting the transaxle.
^ When overhauling the transaxle.
^ When the transmission fluid is noticeably dirty or burnt (driving under severe conditions).
Change transmission fluid
If you have an transmission fluid changer, use this changer to replace the transmission fluid. If you do not have an transmission fluid changer, replace the transmission fluid by the following procedure.
1. Disconnect the hose shown in the illustration which connects the transaxle and the oil cooler (inside the radiator). Place a container under the hose to collect the discharge.
CAUTION: The engine should be stopped within one minute after it is started. If all the transmission fluid has drained out before then, the engine should be stopped at that point.
2. Start the engine and let the transmission fluid drain out. (Running conditions: N range with engine idling)
Approximately 3.5 dm3 (3.7 quarts) of transmission fluid should be removed.
3. Remove the drain plug from the bottom of the transaxle case to drain the transmission fluid.
Approximately 2.0 dm3 (2.1 quarts) of transmission fluid should be removed.
4. Install the drain plug with a new gasket, and tighten it to the specified torque.
Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.)
CAUTION: Stop pouring if the full volume of transmission fluid cannot be added.
5. Add new transmission fluid (DIAMOND ATF SP III) through the oil filter tube.
Approximately 5.5 dm3 (5.8 quarts) of transmission fluid should be added.
6. Repeat the procedure in Step 2 (to pump out the rest of the contaminated transmission fluid)
7. Add new transmission fluid (DIAMOND ATF SP III) through the oil filter tube.
Approximately 3.5 dm3 (3.7 quarts) of transmission fluid should be added.
NOTE: Check for contamination or a burnt odor. If the transmission fluid is still contaminated or burnt, repeat Steps 6 and 7 before proceeding to Step 8.
8. Reconnect the hose which was disconnected in step 1 above, and firmly replace the dipstick.
9. Start the engine and run it at idle for one to two minutes.
10. Move the selector lever through all positions, and then move it to the N position.
11. Check that the transmission fluid level is at the "COLD" mark on the dipstick. If the level is less than this, add transmission fluid.
12. Drive the vehicle until the transmission fluid temperature rises to the normal operating temperature [70 - 80°C (158 - 176°F)], and then check the transmission fluid level again. The transmission fluid level must be at the HOT mark.
NOTE: The transmission fluid temperature is measured with scan tool MB991958 (MUT-III sub assembly).
NOTE: The COLD level is for reference only; the HOT level should be regarded as the standard level.
NOTE: If it takes some amount of time until the transmission fluid reaches its normal operating temperature [70 - 80°C (158 - 176°F)], check the transmission fluid level by referring to the left diagram.
13. When the transmission fluid is less than the specified level, add transmission fluid. When the transmission fluid is greater than the specified level, drain the excess fluid through the drain plug to adjust the transmission fluid to the specified level.
14. Firmly insert the dipstick into the oil filler tube.