Mitsubishi MOTORS Space Runner 1999 Instruction manual

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General ........................
Engine .........................
Fuel ...........................
Engine Cooling .................
Intake and Exhaust ............
Engine Electrical ...............
Engine and Emission Control ....
Clutch .........................
Automatic Transmission ........
Front Axle ......................
Wheel and Tyre .................
Front Suspension ...............
Service Brakes .................
Steering ........................
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This manual outlines changes in servicing
procedures related to the chassis including vehicle
inspections, adjustments, and improvements in the
newly equipped models. Use the following manuals
in combination with this manual required.
TECHNICAL INFORMATION MANUAL
PYDE9802
WORKSHOP MANUAL
CHASSIS GROUP PWDE9803
ENGINE GROUP PWEEjjjj
(Looseleaf edition)
ELECTRICAL WIRING PHDE9802
PHDE9802-A
BODY REPAIR MANUAL PBDE9802
PARTS CATALOGUE
SPACE RUNNER B608V500Aj
SPACE WAGON B608W500Aj
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
“GDI” is the trade mark which Mitsubishi Motors
Corporation holds.
EMitsubishi Motors Corporation May 1999

General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tyre . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.
TECHNICAL INFORMATION MANUAL IMXE99E1
WORKSHOP MANUAL
ENGINE GROUP PWEEjjjj
(Looseleaf edition)
ELECTRICAL WIRING EMXE99E1
BODY REPAIR MANUAL BMXE99E1
PARTS N606H509Dj
Allinformation,illustrationsandproductdescriptions
contained in this manual are current as at the time
of publication. We, however, reserve the right to
make changes at any time without prior notice or
obligation.
EMitsubishi Motors Corporation September 1998
“GDI is the trade mark which Mitsubishi Motors
Corporation holds.
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51
52
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55
Interior and Supplemental
Restrain System (SRS) . . . . . . . . .
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . .

WARNING!
(1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner,
or any SRS-related component, can lead to personal injury or death to service personnel (from
inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger
(from rendering the SRS inoperative).
(2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove
the SRS-ECU, air bag module, clock spring and seat belt with pre-tensioner before drying or
baking the vehicle after painting.
SRS-ECU, air bag module, clock spring and side impact sensor: 93C or more
Seat belt with pre-tensioner: 90C or more
(3) Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related
component must be performed only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B – Supplemental Restraint System (SRS), before beginning any service or maintenance of
any component of the SRS and seat belt with pre-tensioner or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

00-1
GENERAL
CONTENTS
HOW TO USE THIS MANUAL 2..............
Model Indications 2............................
VEHICLE IDENTIFICATION 3.................
Models 3......................................
Model Code 3.................................
Chassis Number 4.............................
Engine Model Number 5........................
New Vehicles 5................................
MAJOR SPECIFICATIONS 6..................

GENERAL - How to Use This Manual
00-2
HOW TO USE THIS MANUAL
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
2000: Indicates models equipped with the 2,000 mL <4G63> petrol engine.
2400: Indicates models equipped with the 2,400 mL <4G64> petrol engine.
MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection.
GDI: Indicates the gasoline direct injection, or engine equipped with the gasoline direct injection.
SOHC: Indicates an engine with the single overhead camshaft, or models equipped with such an
engine.
DOHC: Indicates an engine with the double overhead camshaft, or models equipped with such an
engine.
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.
A/C: Indicates the air conditioner.

GENERAL - Vehicle Identification 00-3
VEHICLE IDENTIFICATION
MODELS
Model code Engine model Transmission model Fuel supply system
N63W SNUEL6/R6 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) MPI
SNFEL6
SNUJL6
SRUEL6/R6 F4A42 (2WD-4A/T)
SRFEL6
SRUJL6
N64W SNHCL6 4G64-DOHC-GDI F5M42 (2WD-5M/T) GDI
SNGCL6
(2,351 mL)
SNHGL6
SRHCL6 F4A42 (2WD-4A/T)
SRGCL6
SRHGL6
MODEL CODE
No. Items Contents
1Development N6: SPACE RUNNER
(2WD)
2Engine type 3: 2,000 mL petrol engine
4: 2,400 mL petrol engine
3Body type W: Wagon
4Body style S: 3-door station wagon
5Transmission type N: 5-speed manual
transmission
R: 4-speed automatic
transmission
6Trim level U,F,H,G: GLX
7Specification engine
feature
E,J: MPI-SOHC
C,G: GDI-DOHC
8Steering wheel location L: Left hand
R: Right hand
9Destination 6: For Europe
1234
56789

GENERAL - Vehicle Identification
00-4
CHASSIS NUMBER
123 456789 11
10
No. Items Contents
1Fixed figure JAsia
2Distribution channel MJapan channel
3Destination AFor Europe, right hand drive
BFor Europe, left hand drive
4Body style S3-door station wagon
5Transmission type N5-speed manual transmission
R4-speed automatic transmission
6Development order N6 SPACE RUNNER (2WD)
7Engine 34G63: 1,997 mL petrol engine
44G64: 2,351 mL petrol engine
8 Sort W Station wagon
9Model year Y2000
10 Plant ZOkazaki Motor Vehicle Works
11 Serial number - -

GENERAL - Vehicle Identification 00-5
ENGINE MODEL NUMBER
1. The engine model number is stamped at the cylinder
block as shown in the following.
Engine model Engine displacement mL
4G63
4G64
1,997
2,351
2. The engine serial number is stamped near the engine
model number.
Engine serial number AA0201 to YY9999
NEW VEHICLES
New vehicles has been added as shown below.
New vehicle has been developed from the respective basic vehicle. Specification show only a particular
part of the new vehicle. For the remaining par, refer to specifications for basic vehicle.
New vehicle Basic vehicle
N63W SNUEL6 N61W SNUCL6
N63W SNUER6 N61W SNUCR6
N63W SNFEL6 N61W SNFCL6
N63W SNUJL6 N61W SNUGL6
N63W SRUEL6 N61W SRUCL6
N63W SRUER6 N61W SRUCR6
N63W SRFEL6 N61W SRFCL6
N63W SRUJL6 N61W SRUGL6
N64W SNHCL6 N61W SNUCL6
N64W SNGCL6 N61W SNFCL6
N64W SNHGL6 N61W SNUGL6
N64W SRHCL6 N61W SRUCL6
N64W SRGCL6 N61W SRFCL6
N64W SRHGL6 N61W SRUGL6

GENERAL - Major Specifications
00-6
MAJOR SPECIFICATIONS
2
5
1
48
76
3*
9
3
Items N63W
SNUEL6,
SNUER6,
SNFEL6,
SNUJL6
N63W
SRUEL6,
SRUER6,
SRFEL6,
SRUJL6
N64W
SNHCL6,
SNGCL6,
SNHGL6
N64W
SRHCL6,
SRGCL6,
SRHGL6
Vehicle Overall length 14,290
dimensions Overall width 21,695
mm
Overall height
(unladen)
31,650
1,680*
Wheelbase 42,550
Track-front 51,460
Track-rear 61,465
Overhang-front 7890
Overhang-rear 8850
Ground clear-
ance (unladen)
9155
Vehicle Kerb weight 1,360 1,380 1,400 1,420
weight kg Max. gross vehicle
weight
1,880 1,920
Max. axle weight
rating-front
1,000 1,050
Max. axle weight
rating-rear
900
Seating capacity 5
Engine Model No. 4G63 4G64
Total displacement
mL
1,997 2,351
Transmis- Model No. F5M42 F4A42 F5M42 F4A42
sion Type 5-speed manual 4-speed
automatic
5-speed manual 4-speed
automatic
Fuel system Fuel supply system Electronically controlled multipoint
injection
Gasoline Direct Injection
*: Vehicles with roof rails

11C-1
ENGINE
<4G6-MPI>
CONTENTS
GENERAL 3.................................
Outline of Changes 3..........................
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 3.................
SEALANTS 4................................
SPECIAL TOOLS 5..........................
ON-VEHICLE SERVICE 6.....................
Drive Belt Tension Check and Adjustment 6......
Ignition Timing Check 9........................
Idle Speed Check 10...........................
Idle Mixture Check 10..........................
Compression Pressure Check 11................
Manifold Vacuum Check 12.....................
Lash Adjuster Check 12........................
CRANKSHAFT PULLEY 15..................
CAMSHAFT AND CAMSHAFT OIL SEAL 16..
OIL PAN 19.................................
CRANKSHAFT OIL SEAL 21.................
CYLINDER HEAD GASKET 24...............
TIMING BELT 27............................
TIMING BELT B 31..........................
ENGINE ASSEMBLY 34.....................

11C-2
NOTES

ENGINE <4G6-MPI> - General/General Information/
Service Specifications 11C-3
GENERAL
OUTLINE OF CHANGES
The following service procedures have been established in line with the addition of vehicles with 4G63-MPI
engine.
GENERAL INFORMATION
Items 4G63
Total displacement mL 1,997
Bore ´Stroke mm 85.0 ´88.0
Compression ratio 10.0
Combustion chamber Pentroof type
Camshaft arrangement SOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake Opening BTDC 11_
Closing ABDC 53_
Exhaust Opening BBDC 63_
Closing ATDC 21_
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS
Items Standard value Limit
Alternator drive belt checked Vibration frequency Hz 177 - 232 -
Tension N 343 - 588 -
Deflection (Reference value) mm 6.7 - 9.8 -
When adjusting the alternator Vibration frequency Hz 201 - 222 -
drive belt Tension N 441 - 539 -
Deflection (Reference value) mm 7.2 - 8.4 -
When replacing the alternator Vibration frequency Hz 241 - 276 -
drive belt Tension N 637 - 833 -
Deflection (Reference value) mm 5.0 - 6.4 -
Power steering oil pump and A/C Vibration frequency Hz 108 - 132 -
compressor drive belt tension
(When checked) Tension N 392 - 588 -
Deflection (Reference value) mm 11.7 - 15.3 -

ENGINE <4G6-MPI> - Service Specifications/Sealants
11C-4
Items LimitStandard value
Power steering oil pump and A/C Vibration frequency Hz 114 - 126 -
compressor drive belt tension
(When adjusted) Tension N 441 - 539 -
Deflection (Reference value) mm 12.5 - 14.3 -
Power steering oil pump and A/C Vibration frequency Hz 137 - 157 -
compressor drive belt tension
(When replaced) Tension N 637 - 834 -
Deflection (Reference value) mm 8.8 - 11.0 -
Basic ignition timing 5_BTDC ±3_-
Ignition timing Approx.10_BTDC -
Idle speed r/min 750 ±100 -
CO contents % 0.5 or less -
HC contents ppm 100 or less -
Compression pressure kPa-r/min 1,400 Min. 1,060
Compression pressure difference of all cylinder kPa - Max. 100
Intake manifold vacuum kPa -Min. 69
Cylinder head bolt shank length mm -99.4
Auto-tensioner push rod movement mm Within 1 -
Timing belt tension torque Nm (Reference value) 3.5 -
Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -
Timing belt B tension mm 5-7 -
SEALANTS
Items Specified sealants Remarks
Rocker cover and cylinder head
Semi-circular packing
3M ATD Part No.8660 or equivalent -
Oil pan
Thermostat case
MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
Flywheel or drive plate bolt 3M Stud Locking 4170 or equivalent -

ENGINE <4G6-MPI> - Special Tools 11C-5
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub assem-
bly
DChecking the ignition timing
DChecking the idle speed
DErasing diagnosis code
DMeasuring the drive belt tension
MB991668 Belt tension meter
set
Measuring the drive belt tension
(used together with the MUT-II)
MD998299 MAS screwdriver Adjustment of the mixture adjusting screw
<Vehicles without catalytic converter>
MB990767 End yoke holder DHolding the camshaft sprocket
DHolding the crankshaft sprocket
MD998719 or
MD998754
Crankshaft pulley
holder pin
DHolding the camshaft sprocket
DHolding the crankshaft sprocket
MD998713 Camshaft oil seal
installer
Press-in of the camshaft oil seal
MD998443 Auto-lash adjuster
holder
Supporting of auto-lash adjuster
MD998727 Oil pan remover Removal of oil pan
MD998781 Flywheel stopper Securing the flywheel or drive plate

ENGINE <4G6-MPI> - Special Tools/On-vehicle Service
11C-6
Tool UseNameNumber
MD998776 Crankshaft rear oil
seal installer
Press-in of the crankshaft rear oil seal
MB990938 Handle Press-in of the crankshaft rear oil seal
MD998767 Tension pulley
socket wrench
Timing belt tension adjustment
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter Supporting the engine assembly during
removal and installation of the transmission
MB991453 Engine hanger
assembly
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Check the drive belt tension in the following procedure.
Standard value:
Vibration frequency Hz 177 - 232
Tension N 343 - 588
Deflection (Reference value) mm 6.7 - 9.8

ENGINE <4G6-MPI> - On-vehicle Service 11C-7
<When using the MUT-II>
1. Connect the special tool (belt tension meter set) to the
MUT-II.
2. Connect the MUT-II to the diagnosis connector.
3. Turn the ignition switch to ON and select “Belt Tension
Measurement” from the menu screen.
4. Hold the microphone to the middle of the drive belt
between the pulleys (at the place indicated by the arrow),
about 10 - 20 mm away from the rear surface of the
belt and so that it is perpendicular to the belt (within
an angle of ±15_).
5. Gently tap the middle of the belt between the pulleys
(the place indicated by the arrow) with your finger as
shown in the illustration, and check that the vibration
frequency of the belt is within the standard value.
Caution
(1) The temperature of the surface of the belt should
be as close as possible to normal temperature.
(2) Do not let any contaminants such as water or
oil get onto the microphone.
(3) If strong gusts of wind blow against the
microphone or if there are any loud sources of
noise nearby, the values measured by the
microphone may not correspond to actual values.
(4) If the microphone is touching the belt while the
measurement is being made, the values measured
by the microphone may not correspond to actual
values.
(5) Do not take the measurement while the vehicle’s
engine is running.
<When using a tension gauge>
Use a belt tension gauge to check that the belt tension is
within the standard value.
<Belt deflection check>
Apply 98 N of force to the middle of the drive belt between
the pulleys (at the place indicated by the arrow) and check
that the amount of deflection is within the standard value.
MB991668
(Micro-
phone)
Alternator
pulley
Crankshaft
pulley
15_15_10 - 20 mm
Water pump
pulley
Belt tension gauge
Crankshaft
pulley
Alternator
pulley
Water pump
pulley
Crankshaft
pulley
Alternator
pulley
98 N
Water pump
pulley

ENGINE <4G6-MPI> - On-vehicle Service
11C-8
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Standard value:
Items When adjusting When replacing
Vibration frequency Hz 201 - 222 241 - 276
Tension N 441 - 539 637 - 833
Deflection
(Reference value) mm
7.2 - 8.4 5.0 - 6.4
4. Tighten the nut of the alternator pivot bolt.
Tightening torque: 49 Nm
5. Tighten the lock bolt.
Tightening torque: 22 Nm
6. Tighten the adjusting bolt.
Tightening torque: 5 Nm
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT
1. Check if the belt tension is within the standard value
using one of the methods below.
Standard value:
Items When
checked
When a
used belt is
installed
When a new
belt is
installed
Vibration
frequency
Hz
108 - 132 114 - 126 137 - 157
Tension N 392 - 588 441 - 539 637 - 834
Deflection
(Reference
value) mm
11.7 - 15.3 12.5 - 14.3 8.8 - 11.0
<When measuring the vibration frequency>
With your finger tip lightly tap the centre of the belt between
the pulleys in the location shown by the arrow in the
illustration and then measure the belt vibration frequency.
NOTE
Refer to P.11C-7 for information regarding the vibration
frequency measurement method using MUT-II.
<When measuring the tension>
Use a belt tension gauge to measure the belt tension.
Adjusting bolt
Lock bolt
<Vehicles without A/C>
Oil pump pulley
98 N
Crankshaft
pulley
Tensioner pulley
AB
98 N
Crankshaft
pulley
Tensioner
pulley
AB
A/C
compressor
pulley
Oil pump pulley
<Vehicles with A/C>

ENGINE <4G6-MPI> - On-vehicle Service 11C-9
<When measuring the deflection>
Apply 98 N of pressure against the location between
the pulleys shown by the arrow in the illustration and
then measure the deflection.
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
Tightening torque: 25 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
IGNITION TIMING CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Check that engine idle speed is within the standard value.
Standard value: 750 ±100 r/min
6. Select No.17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the standard
value.
Standard value: 5_BTDC±3_
8. If the basic ignition timing is outside the standard value,
inspect the MPI system while referring to GROUP 13A
- Troubleshooting.
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this condition
may damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 10_BTDC
NOTE
1. Ignition timing is variable within about ±7_, even
under normal operating.
2. And it is automatically further advanced by about
5_from standard value at higher altitudes.

ENGINE <4G6-MPI> - On-vehicle Service
11C-10
IDLE SPEED CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to “LOCK” (OFF) position and
connect the MUT-II to the diagnosis connector.
3. Check the basic ignition timing.
Standard value: 5_BTDC±3_
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a
reading of the idle speed.
Standard value: 750 ±100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
6. If the idle speed is outside the standard value, inspect
the MPI components by referring to GROUP 13A -
Troubleshooting.
IDLE MIXTURE CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to “LOCK” (OFF) position and
connect the MUT-II to the diagnosis connector.
3. Check that the basic ignition timing is within the standard
value.
Standard value: 5_BTDC±3_
4. Run the engine at 2,500 r/min for 2 minutes.
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value
CO contents: 0.5% or less
HC contents: 100 ppm or less
7. If there is a deviation from the standard value, check
the following items:
DDiagnosis output
DClosed-loop control (When the closed-loop control
is normal, the output signal of the oxygen sensor
changes between 0 - 400 mV and 600 - 1,000 mV
at idle.)
DFuel pressure
DInjector
DIgnition coil, spark plug cable, spark plug
DLeak in the EGR system and in the EGR valve
DEvaporative emission control system
DCompression pressure

ENGINE <4G6-MPI> - On-vehicle Service 11C-11
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
COMPRESSION PRESSURE CHECK
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE
Doing this will prevent the engine-ECU <M/T> or
engine-A/T-ECU <A/T> from carrying out ignition and fuel
injection.
5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the spark plug hole when
cranking.
2. If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 250 - 400 r/min):
1,400 kPa
Limit (at engine speed of 250 - 400 r/min):
Min. 1,060 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 100 kPa
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
Compression gauge