Mitsubishi Laser Talon 1991 Service Manual
Mitsubishi Laser Talon 1991 Service Manual
Mitsubishi Laser Talon 1991 Service Manual
LASER
,
Lubrication and Maintenance . . . . . . . . ‘- ‘8
0
TALON
; “. i ,
.Front Suspension . . . . . . . . . . . . . . ..*............d...
I
Chrysler Corporation reserves the right to make changes in design 0’: to
make additions to or improvements in its products without lmqoslng NOTE: For Electrical, refer to
d ., . any obligations upon itself to install them on its products previously Volume-2 “Electrical”.
manufactured.
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2 INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual
CONTENTS LIMIT -9
The preceding page contains GROUP INDEX which Shows the standard for judging the quality of a part -
lists the group title and group number. or assembly on inspection and,means the maximum
or minimum value within which the part or assembly
PAGE NUMBERS
must be kept functionally or in strength. It is a value
All page numbers consist of two sets of digits
established outside the range of standard value.
separated by a dash. The digits preceding the dash
identify the number of the group. The digits follow-
ing the dash represent the consecutive page num-
ber within the group. The page numbers can be
found on the top left or right of each page.
TEXT
Unless otherwise specified, each service procedure
covers all models. Procedures covering specific
models are identified by the model codes, or similar
designation (engine type, transaxle type, etc.). A Removal steps : The numbers before part
description of these designations is covered in this name correspond to numbers
unit under “VEHICLE IDENTIFICATION”. in the illustration, and indicate
the order of removal.
TROUBLESHOOTING Disassembly steps : The numbers before part
name correspond to num-
Troubleshootings are classified into master trouble- bers in the illustration,
shooting and group troubleshooting and located as and indicate the order of
disassembly.
follows: Installation steps : This is provided if installa-
The master troubleshooting is prepared when the tion cannot’be made in the
trouble symptom relates to two or more groups and reverse order of “Removal
steps “; omitted if installa-
given in MASTER TROUBLESHOOTING. tion in the reverse order of
The group troubleshooting guide is prepared for “Removal steps” k possi- rL+
causes of problems related to that individual group ble. . .
only; a troubleshooting guide is prepared for each Reassembly steps : This is .provided if reas-
sembly cannot be made
appropriate group. in the reverse order of
“Disassembly steps” ;
SERVICE PROCEDURES omitted if reassembly in
The service steps are arranged in numerical order the reverse order of “Dis-
assembly steps” is possi-
and attentions to be paid in performing vehicle ble.
service are described in detail in SERVICE POINTS.
DEFINITION OF TERMS
STANDARD VALUE .IVL , -....-
ce : Removal
Indicates the value used as the standard for judging l 4 : Installation
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.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
M/T : Indicates the manual transaxle, or models equipped with the manual transaxle.
A/T: Indicates the automatic transaxle, or models equipped with the automatic transaxle.
MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection.
SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such an
engine.
DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an
engine.
Turbo: Indicates an engine with turbocharger, or a model equipped with such an engine.
Non-Turbo: Indicates an engine without turbocharger, or a model equipped with such an engine.
FWD: Indicates the front wheel drive vehicles.
AWD: Indicates the all wheel drive vehicles.
ABS: Indicates the anti-lock braking system or models equipped with the anti-lock braking system.
INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual 3
I
524 4
BRAKES-Roar Brake Wlmd Cylinder
4
REAR BRAKE WHEEL CYLINDER
3ENjOVAL AND lNSTAU.AllON
I I
-
Remwal stepa
1. Brake drum
2. Bleeder screw
3. Brake tube connection NOTE
l * 4. Wheel cylinder assembly I1 l Reverse the removal procedures to reinstall.
l e 5. Wheel cylinder boot 12) M : Refer to ‘Service Points of Aemcval”.
l + 6. Piston assembly (3) l * : Refer to ‘Service Points of Installation’.
- n** 7. Piston cue 14) q :Nc+-r-reusab(epatts
SERWE POINTS REMOVAL’
-7. REMOVAL OF PISTON CUP
Using a screwdriver, remove the piston cup from the piston.
INSPECTION -
Check the following points. and if there is any abnormality, replace
the entire wheel cylinder assembly.
(1) Check piston and wheel cylinder walls for rust or damage.
(2) Check clearance between the cylinder and the piston.
Measure in two perpendicular directions to figure the clear-
ance between the wheel cylinder inner diameter fmax.value)
and the piston outer diameter (minvalue).
NOTE
If the difference is more than the limit, replace the piston and
wheel cylinder as an assembly.
rIndicates
3. Checking the passenger compartment-temperature sensor, outside-air sensor, air-
thermostat sensor and refrigerant-temperature sensor circuits
the
circuit diagram
for checking
(including the
I I* interface of the
air conditioner
control unit).
in the opera-
tion descrip-
Provides the
I--
Operation description the numbers
cuit operation A negative-characterlstlc thermstor 1s employed for each sensor in order 10 convey the amblent
for basic under- temperature of the sensor pan ,o resistance used in har-
The sensor power-supply I2 5V) of the awcondltww ““I, IS applied to the
standing. lermlnals 116). (15). (17) (5) dlvlded res~~,ance ness and com-
reSlSta”ce R
ponent layout
Tmublrhooting 4 I diaarams.
Dlagnosls
1 judgement)
when trouble-
Indicates the
diagnosis out-
put code No.
and the system
conditions dur-
kng o u t p u t .
The connector
symbol indicates
the device side reht flow is indicat- :
connector (for an ed by the arrow.
intermediate con- In this instance, the
nector, the male current flow is in
side connector) both directions, up
as seen from the c
\
terminal front
(the connector’s
connection face).
I
Indicates Indicates the
device side con- that the con- branch point of a
nector is the harness of a differ-
direct-inser- ent line diameter
tion type. nr line colour. I
6 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identificetion
rr
\
12th to
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
17th
Digit Digit Digit Digit Digit Digit Digit Digit Digit Digit Digit Digits
4- E- 3- B- S- 3- 4- T- M- E- 000001
USA Eagle Passen- Manual Laser or Medium 3 door 1.8 liter 1991 DSM to
P- ger Car Seat Belt Talon 4- Hatch- (107 Year 999999
Plymouth c- FWD High back cu.in.)
Auto- T- 5- [SOHC-
matic Talon Premium MPI1
Seat Belt AWD 6- R-
Special 2.0 liters
(122
cu.in.)
[DOHC-
MPI]
u-
2.0 liters
(122
I
cuin.)
[DOHC-
MPI-
Turbo]
NOTE * “Check digit” means a single number or letter x used to verify the accuracy of transcription of vehicle identification number.
INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
2 y$y:/e ‘f$$l
2. ENGINE 4G63
IEngine model
3. TRANSAXLE F5M33
yTransaxle model
4. COLOR, B14
TRIM OPT I Monotone exterior
color code
following:
I 1 LAB0001 - - - - - - - +AY9999 : 1
I 1 t-BAOOOI - - - - - - - +YY9999 ’ 1
INTRODUCTlON AND MASTER TROUBLESHOOTING - Vehicle Identification 9
LOCATIONS
OOA0057 OOA0055
IO INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
Part
Fender
Door
- .
31AO250
INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification 11
31A0256
31AO260
12 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
Front bumper
The label is attached at the inner side of the parts shown in the figure. 31A0332
Rear bumper
The label is attached at the inner side of the parts shown in the figure. 31A0332
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions befdre Service ‘1 S
J
” , ‘. 5,
OOY192 FOOO 1. 7
SPECIAL TOOLS
If other tools are substituted for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged, or the technician might be injured; therefore, be sure
to use the special tool whenever doing any work for which the
use of one is specified.
FOOO18
PARTS TO BE REPLACED
If any of the following parts are removed, they must be
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
0
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts
OOD511
I4 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service
PARTS
When replacing parts, use MOPAR genuine parts.
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (12 in.) from any
plastic parts and all opening parts (doors, luggage compart-
ment, etc.).
mm (In.1 smo59
Caution
1. Before connecting or disconnecting the negative
cable, be sure to turn off the ignition switch and the
lighting switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
2. For MPI-equipped models, after completion of the
work steps [when the battery’s negative (-) termi-
nal is connected], warm up the engine and allow it
to idle for approximately five minutes under the
conditions described below, in order to stabilize
engine control conditions, and then check to be
sure that the idling is satisfactory.
Engine coolant temperature: 85-95°C (185-203°F)
Lights, electric fans, accessories: OFF
Transaxle: neutral position
(A/T models: “N” or “P”)
Steering wheel: neutral (center) position
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Set&e 15
WIRING HARNESSES
1. Secure the wiring harnesses by using cla’mps. However, for
any harness which passes to the engine or other vibrating
parts of the vehicle, allow some slack within a range that
does not allow the engine vibrations to cause the harness
to come into contact with any of the surrounding parts.
Then secure the harness by using a clamp.
In addition, if a mounting indication mark (yellow tape) is on
a harness, secure the indication mark in the specified
location.
F16171
Cl6385
Cl6367
Y16347
16 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service
ELECTRICAL COMPONENTS
1. When installing any of the vehicle parts, be careful not to
pinch or damage any of the wiring harnesses.
Cl6362
OOYSss
Caution
1. If a fuse is blown-out, be sure to eliminate the cause
of the problem before installing a new fuse. ;i
2. Check the condition of fuse holders. If rust or dirt is
found, clean metal parts with a fine-grained sand-
paper until proper metal-to-metal contact is made.
10A 15A Poor contact of any fuse holder will often lead to
voltage drop or heating in the circuit and colild
COY569 result in improper circuit operation.
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Sew&e ‘37
Permissible current
2. If additional optional equipment is to be installed, in ttie
Nominal SAE vehicle, follow the procedure listed in the ap@@priate
r ‘.
size In engine Other instruction manual; however, be sure to pay “careful
gi:e compart- areas
attention to the following points: “9:
ment
(1) In order to avoid overloading the wiring;’ take the
0.3 mm2 AWG 22 - 5A electrical current load of the optional ,equipment into
0.5 mm2 AWG 20 7A 13A consideration, and determine the appropriate .wire size:
0.85 mm’ AWG 18 9A 17A (2) Where possible, route the wiring through the existing
1.25 mm2 AWG 16 12A 22A harnesses.
2.0 mm2 AWG 14 16A 30A (3) If an ammeter or similar instrument is to be connected
3.0 mm’ AWG 12 21A 40A to a live-wire circuit, use tape to protect the wire, use a
5.0 mm2 AWG 10 31A 54A clamp to secure the wire, and make sure that there is
no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
oorsas
LUBRICANTS
In accordance with the instructions in this Service Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
!’
>,IIV/ :
BRAKE FLUID
Be careful to avoid spilling any brake fluid on painted surfaces,
because the paint coat might be discolored or damaged.
18 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions b&ire Service
c
llJ/RE;~R TOWING RECOMMENDATION
I
Mitsubishi Laser Talon 1991 Service Manual
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20 INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting
SAFETY PRECAUTIONS
The following precautions should be taken when towin the
vehicle.
1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO
OR WRAPPING AROUND THE BUMPER.
2. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior to
moving the vehicle.
3. Operator should refrain from going under a vehicle while it
is lifted by the towing equipment, unless the vehicle in
adequately supported by satefy stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed
when towing a vehicle.
<AWD>
Refer to the section “Special Handling Instructions for AWD
Models”.
HOISTING
Frame contact support location
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations.
Caution
OOAOI 71
When service procedures require removing rear sutpen-
sion, fuel tank, spare tire and lift gate, place addmonal
<FWD>: 928mm (36.5 in.) weight on rear end of vehicle or anchor vehicle to hoist to
<AWD>: 998mm (39.3 in.)
prevent tipping of center of gravity changes.
FLOOR JACK
The usual type of floor jack is used at the following locations.
Front:
<FWD> Under the mid point of centermember
<AWD> Under the mid point of crossmember
Rear:
<FWD> Under the jack up bracket of rear floor pan
<AWD> Under the rear differential
Cautions
1. Never use a jack at the lateral rod or rear suspension
assembly. <FWD>
2. In order to prevent scarring the centermember <MID>
I <FWD> Rear <AWD> I
or crossmember <AWD>, place a piece of cloth on the
jack’s contact surface (to prevent corrosion caused by
damage to the coating).
3. A floor jack must never be used on any part of the
underbody.
4. Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.
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