Mitsubishi MOTORS CARISMA 1996 Reference manual

SERVICE BULLETIN
SERVICE GROUP, WARRANTY & SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV
SERVICE BULLETIN No.: ESB-96E11-502
Date:1997-03-31 <Model> <M/Y>
Subject: OMISSION OF TIGHTENING TORQUE OF A/C
COMPRESSOR TENSION PULLEY FIXING
BOLT
CARISMA 96-10
Group: ENGINE
Correction
O. Kai - E.V.P.
After Sales Service
1. Description:
This Service Bulletin informs you that omission has been rectified of the tightening torque of
A/C compressor tension pully fixing bolt under Service DRIVE BELT TENSION CHECK AND
ADJUSTMENT in Group 11A of the Workshop Manual.
2. Applicable Manual:
Manual Pub. No. Language Page(s)
’96 CARISMA Workshop Manual PWDE9502 (English) 11A-7
Chassis PWDS9503 (Spanish)
PWDF9504 (French)
PWDG9505 (German)
PWDD9506 (Dutch)
PWDW9507 (Swedish)
PWDI96E1 (Italian)
3. Details:
Please refer to the attached page(s).
ww W r s o M u s o.uk
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2
4. Tighten the lock bolt.
Tightening torque: 23 Nm
5. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
6. Tighten the adjusting bolt.
Tightening torque: 6 Nm
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT
1. Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration). In
addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the
standard value.
Standard value:
Items When
checked When a used belt is
installed
When a new
belt is
installed
Tension N 392 - 588 441 - 539 637 - 833
Deflection
mm 10.0 - 12.0 10.0 - 11.0 7.0 - 9.0
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tension pulley fixing bolt A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing bolt A.
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
• Check after turning the crankshaft once or more
clockwise (right turn).
4G9 ENGINE - On vehicle Service 11A-7
<Vehicles without A/C>
Oil pump pulley
Tensioner pulley
Crankshaft
pulley
A01U0016
<Vehicles with A/C>
Oil pump pulley
Crankshaft
pulley
Tensioner
pulley
A/C
compressor
pulley
A20R0002
Tightening torque: 25Nm
<Added>
11100130035
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SERVICE BULLETIN
SERVICE BULLETIN
SERVICE GROUP, WARRANTY & SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV
NO.: ESB-96E13-501
DATE: 1996-05-15 <MODEL> <M/Y>
(EC,EXP)CARISMA 96-00
SUBJECT: CORRECTION OF FUEL GAUGE UNIT INSTALLATION
PROCEDURE
GROUP: FUEL
INFORMATION:
1. Description
This Service Bulletin informs you that the installation procedure for the fuel gauge
Unit & pump assembly or the fuel gauge unit & pipe assembly has been corrected.
2. Effective Date:
3. Applicable Manual:
Manual Pub. No. Page(s)
’96 CARISMA Workshop PWDE9502 (English) 13F-3, 13F-5
Manual PWDS9503 (Spanish)
PWDF9504 (French)
PWDG9505 (German)
PWDD9506 (Dutch)
PWDW9507 (Swedish)
PWDI96E1 (Italian)
4. Details:
Please refer to the attached pages.
O. Kai -E.V.P.
After Sales Service
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FUEL TANK
REMOVAL AND INSTALLATION
FUEL SUPPLY - Fuel Tank 13F-3
Pre-removal Operation
(1) Draining the Fuel
(2) Reduce the Inner Pressure of Fuel Line and Hose
(Refer to GROUP 13A - On-vehicle Service.)
(3) Removal of the Centre Exhaust Pipe
(Refer to GROUP 15.)
Post-Installation Operation
(1) Installation of Exhaust Pipe (Refer to GROUP 15.)
(2) Refilling the Fuel
(3) Checking for Fuel Leaks
13500190046
Removal steps
1. Hoses Connection 8. Fuel pump module
2. Band 9. Fuel vapor hose
3. Protector 10. Fuel Filler cap
4. Fuel tank assembly 11. Fuel rubber drain
5. Fuel main hose 12. Filler neck assembly
6. Fuel return hose 13. Leveling hose
7. Cap 14. Filler hose
<Added>
4
A 3
INSTALLATION SERVICE POINT
4
4
A 3
3
CAP INSTALLATION
Using a special tool tighten the cap to the specified
torque so that the alignment mark of the fuel tank
and that of the fuel pump module are in alignment.
Caution
• When the cap is tightened, use care to prevent
the fuel pump module from turning with the cap.
If alignment marks are out of alignment, the float
will be positioned incorrectly, resulting in improp-
er operation of the fuel remainder warning lamp.
Front of car Alignment
marks
Alignment
ran
g
e
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(5) Check to be sure that the fuel tank packing is not damaged
or deformed, and then securely install the packing.
NOTE
If the packing is damaged or deformed, replace with new
packing.
(6) Apply soapy water to the inside of the packing, and then
install the fuel pump module.
Caution
• Do not tilt the fuel pump module when installing.
• The packing should not be folded over as shown
by (A) in the illustration
(7) Using a special tool, tighten the cap to the specified torque
so that the alignment mark of the fuel tank and that of the
fuel pump module are in alignment.
Caution
• When the cap is tightened, use care to prevent the fuel
pump module from turning with the cap. If alignment
marks are out of alignment, the float will be positioned
incorrectly, resulting in improper operation of the fuel
remainder warning lamp.
(8) Check for leaks from the installation section of the fuel pump
module by the following procedure.
1. Apply soapy water to the circumference of the cap.
2. Choke the vapor hose and main hose, apply an internal
pressure of 10 kPa or less from the return hose and
check to be sure that no bubbles form in the soapy water.
FUEL GAUGE CHECK
Refer to GROUP 54 - Combination Meter.
FUEL SUPPLY - Fuel Tank 13F-5
<Changed>
13500310039
Front of car
Ali
g
nment marks
Alignment
range
(Not good)
Packing
OK
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SERVICE BULLETIN
SERVICE GROUP, WARRANTY & SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV
SERVICE BULLETIN No.: ESB-96E13-506
Date:1997-02-28 <Model> <M/Y>
Subject: CORRECTION TO PROCEDURE FOR
EVACUATION OF WATER FROM THE FUEL
FILTER
CARISMA 97-10
Group: FUEL
Correction
O. Kai - E.V.P.
After Sales Service
1. Description:
This Service Bulletin informs you that the procedure has been corrected for evacuation of water
from the fuel filter.
2. Applicable Manual:
Manual Pub. No. Language Page(s)
’97 CARISMA Workshop PWDE9502-A (English) 13E-61
Manual chassis SUPPLEMENT PWDS9503-A (Spanish)
PWDF9504-A (French)
PWDG9505-A (German)
PWDD9506-A (Dutch)
PWDW9507-A (Swedish)
PWDI96E1-A (Italian)
3. Details:
Please refer to the attached page(s).
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2
EVACUATION OF WATER FROM FUEL FILTER
Evacuate water by the following procedures.
1. Remove the air cleaner assembly
2. Remove the fuel filter cap.
3. Use a manual pump to remove any water, and then attach the
fuel filter cap.
<Correct>
2. Place a drainage tray under the filter.
3. Connect a hose to the drain plug and let it hang down into the
tray.
4. Open the fuel pump air plug.
5. Loosen the drain plug a few turns and tighten the drain plug
when clean fuel comes through.
6. Bleed the air.
EVACUATION OF AIR FROM FUEL LINE
Bleed the air from the fuel line after refilling the fuel:
• When the fuel is drained for service.
• When fuel filter is replaced.
• When main fuel line is removed.
1. Connect a long piece of tubing to the bleedscrew of the fuel
injection pump with its open end in a drip tray.
2. Open the bleedscrew and operate the pump on the fuel filter
until clear fuel flows out of the bleedscrew.
3. Close the bleedscrew and remove the tubing.
4. Turn the ignition switch to the “ON” position.
5. Now pump a few more times until resistance is felt; then pump
five more strokes to pressurise the system.
6. Start the engine and check for leakage.
DIESEL FUEL - On-vehicle Service 13E-61
Fuel filter cap
Air plug
Drain plug
A03U0038
N07B015
03U0039
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SERVICE BULLETIN
SERVICE GROUP, WARRANTY & SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV
SERVICE BULLETIN No.: ESB-96E35-001
Date:1997-02-28 <Model> <M/Y>
Subject: FRONT BRAKE DISASSEMBLY AND
REASSEMBLY PROCEDURES CARISMA 96-10
Group: SERVICE BRAKE
Correction
O. Kai - E.V.P.
After Sales Service
1. Description:
Procedures for disassembling and reassembling the front disc brake caliper assemblies
Have been established as shown in this Service Bulletin.
2. Applicable Manual:
Manual Pub. No. Language Page(s)
’96 CARISMA Workshop Manual PWDE9502 (English) 35A-11, 35A-21
PWDS9503 (Spanish)
PWDF9504 (French)
PWDG9505 (German)
PWDD9506 (Dutch)
PWDW9507 (Swedish)
PWDI96E1 (Italian)
3. Details:
Please refer to the attached page(s).
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2
FRONT DISC BRAKE PAD CHECK AND
REPLACEMENT
NOTE
The brake pads have wear indicators that contact the brake
disc when the brake pad thickness becomes 2 mm and emit
a squealing sound to warn the driver.
1. Check brake pad thickness through caliper body check
port.
Standard value: 10 mm
Limit: 2.0 mm
Caution
1. When the limit is exceeded, replace the pads at both
sides, and also the brake pads for the wheels on the
opposite side at the same time.
2. If there is a significant difference in the thickness of
the pads on the left and right sides, check the sliding
condition of the piston, lock pin and guide pin
2. Remove lock pin. Lift caliper assembly and retain with
wires.
Caution
do not wipe off the special grease that is on the lock pin
or allow it to contaminate the lock pin.
3. Remove the following parts from caliper support
1. Pad & wear indicator assembly
2. Pad assembly
3. Outer shim
4. In order to measure the brake drag torque after pad
installation, measure the rotary-sliding resistance of the
hub (A) with the pads removed. (Refer to P.35A-20.)
5. Install the pads and the caliper assembly, and then check
the brake drag torque. (Refer to P.35A-20.)
BASIC BRAKE SYSTEMS - On vehicle Service 35A-11
35100150044
<Changed> guide pins
Remove the bolt
indicated by arrow.
<Changed> body <Changed>
A14U0041
<Deleted>
A14S0088
B14G0017
A14S0019
When new When worn
Pad
Brake disc
Wear indicator
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3
2. After installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
Caution
• Do not let any oil, grease or other contamination
get onto the friction surfaces of the pads and
brake disc.
3. Clean piston and insert into cylinder with special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the lock
pin.
5. Check brake drag torque as follows.
(1) Start the engine and then depress the brake pedal 2-
3 times
(2) Stop engine.
(3) Turn brake disc forward 10 times.
6. Check hub torque (B) with spring balance.
7. Calculate the drag torque of the disc brake [difference
between hub torque (B) and hub torque (A)].
Standard value: 40 N or less
8. If the difference between brake drag torque and hub
torque exceeds the standard value, replace the disc
brake assembly.
BASIC BRAKE SYSTEMS - Front Disc Brake 35A-21
14A0036
B14X0102
14A0014
<Changed>
guide pins
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4
DISASSEMBLY AND REASSEMBLY
Caliper assembly disassembly
steps Pad assembly disassembly steps
A
A
B
1. Bolt
2. Bolt
3. Caliper support
4. Guide pin
5. Boot
6. Piston
7. Piston boot
8. Piston seal
9. Caliper body
10. Caliper bleeder cap
11. Caliper bleeder
1. Bolt
12.Pad and wear indicator
assembly
13.Pad assembly
14.Outer shim
35A-21A BASIC BRAKE SYSTEM - Front Disc Brake
<Added>
Brake caliper kit Brake pad kit Brake caliper piston
seal kit
Grease
14U0108 14U0110 14U0111
14U0109
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5
LUBRICATION POINTS
DISASSEMBLY SERVICE POINTS
When disassembling the front disc brakes, disassemble
both sides (left and right) as a set.
APISTON /PISTON BOOT REMOVAL
Protect caliper body with cloth. Blow compressed air
through brake hose to remove piston and piston boot.
Caution
Blow compressed air gently
<Added>
BASIC BRAKE SYSTEMS - Front Disc Brake 35A-21B
14U0108
Grease : Repair kit grease
Grease: Repair kit grease
14U0102
14U0103
14N0139
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6
BPISTON SEAL REMOVAL
(1) Remove piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
(2) Clean piston surface and inner cylinder with
trichloroethylene, alcohol or specified brake fluid.
Specified brake fluid: DOT3 or DOT4
INSPECTION
• Check cylinder for wear, damage or rust.
• Check piston surface for wear, damage or rust.
• Check caliper body or sleeve for wear.
• Check pad for damage or adhesion of grease, check
backing metal for damage.
35A-21C BASIC BRAKE SYSTEM - Front Disc Brake
35100630081
<Added>
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SERVICE BULLETIN
SERVICE BULLETIN
SERVICE GROUP, WARRANTY & SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV
NO.: ESB-96E37-002
DATE: 1996-07-30 <MODEL> <M/Y>
CARISMA 96-10
SUBJECT: CHANGE OF POWER STEERING RETURN HOSE
AND BOLT TIGHTENING TORQUES
GROUP: STEERING
INFORMATION:
1. Description
The power steering return hose has been changed on left-hand drive models. In
Addition, the tightening torque specifications for pressure hose attaching bolts and
Eye bolts have been changed.
2. Effective Date:
Return hose: From September 21, 1995
Pressure hose attaching bolt and eye bolt torques: From July 12, 1995
3. Applicable Manual:
Manual Pub. No. Page(s)
’96 CARISMA Workshop PWDE9502 (English) 37A-20
Manual PWDS9503 (Spanish)
PWDF9504 (French)
PWDG9505 (German)
PWDD9506 (Dutch)
PWDW9507 (Swedish)
PWDI95E1 (Italian)
4. Details:
Please refer to the attached page.
O. Kai -E.V.P.
After Sales Service
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POWER STEERING HOSES
REMOVAL AND INSTALLATION
37A-20 STEERING - Power Steering Hoses
37200570069
Pre-removal Operation
• Power Steering Fluid Draining (Refer to P.37A-8.) Post-installation Operation
• Power Steering Fluid Supplying (Refer to P.37A-8.)
• Power Steering Fluid Line Bleeding
(Refer to P.37A-8.)
<Old>
<New>
<Old>
<New>
<Old>
<New>
<R.H. drive vehicles>
<L.H. drive vehicles>
6. Eye bolt
7. Washer
8. Pressure hose
9. O-ring
Removal steps
4
4
A 3
3
1. Suction hose
2. Oil reservoir
4
4
A 3
3
3. Return hose
4. O-ring
5. Pressure switch connector
INSTALLATION SERVICE POINT
4
4
A 3
3
RETURN HOSE/SUCTION HOSE INSTALLATION
Connect the hose so that the marking is facing upwards.
Return hose
Suction hose
Facing upward
Facin
g
upward
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SERVICE BULLETIN
SERVICE BULLETIN
SERVICE GROUP, WARRANTY & SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV
NO.: ESB-96E52-001
DATE: 1996-05-15 <MODEL> <M/Y>
(EC,EXP)CARISMA 96-00
SUBJECT: ESTABLISHMENT OF REAR SEATBACK COVER
REPLACEMENT PROCEDURE
GROUP: INTERIOR
INFORMATION:
1. Description
This Service Bulletin informs you that the rear seatback cover replacement procedure
Has been established.
2. Effective Date:
3. Applicable Manual:
Manual Pub. No. Page(s)
’96 CARISMA Workshop PWDE9502 (English) 52A-13
Manual PWDS9503 (Spanish)
PWDF9504 (French)
PWDG9505 (German)
PWDD9506 (Dutch)
PWDW9507 (Swedish)
PWDI96E1 (Italian)
4. Details:
Please refer to the attached pages.
O. Kai -E.V.P.
After Sales Service
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REAR SEAT
REMOVAL AND INSTALLATION
• REMOVAL SERVICE POINTS REAR
SEATBACK COVER REMOVAL
(1)Remove the trim clips from the back (7 places) and both
sides (4 places) of the rear seatback cover.
(2) Unfasten the fastener to remove the lock assembly
mounting screws.
(3)Remove the lock assembly from the rear seatback.
Caution
•
Never remove the knob from the lever.
(4)Remove the hog ring to remove the rear seatback cover.
• INSTALLATION SERVICE POINTS REAR
SEATBACK COVER INSTALLATION
(1)While laying the rear seatback cover over the rear seatback
frame pad assembly, install the hog ring on the front of the
rear seatback. Use hog ring pliers to install the hog ring.
(2)Install the lock assembly.
(3)Install the trim clips.
(4)Using hog ring pliers, install the hog ring on the back of the
rear seatback.
INTERIOR - Seat 52A-13
52200180036
Knob
Lock
assembly
Lever
Removal steps
1. Headrestraint 4. Rear seatback assembly
2. Seat cushion 5. Headrestraint guide
3. Side seatback assembly 6. Rear seat striker
Fastener
Lock
assembly
Screws
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