1996 Talon Volume 1 of 2 - Mirage Performance Online
Contents
1. Tread Rear mm in D 1 505 59 2 1 505 59 2 1 510 59 4 1 510 59 4 Overhang Front mm in 7 930 36 6 930 36 6 930 36 6 930 36 6 Overhang Rear 8 935 36 8 935 36 8 935 36 8 mm in Minimum running ground 9 155 6 1 155 6 1 155 6 1 155 6 1 clearance mm in Angle of approach 10 11 5 degrees Angle of departure 11 degrees Vehicle Curb weights 1 265 2 789 1 300 2 866 1 310 2 888 1 345 2 965 weight Gross vehicle weight rating 1 750 3 858 1 750 3 858 1 750 3 858 1 750 3 858 kg Ibs 1 025 2 260 Gross axle weight rating 1 010 2 227 1 010 2 227 1 025 2 260 Front Gross axle weight rating 800 1 764 800 1 764 775 1 709 775 1 709 Rear Seating capacity 4 4 4 4G63 DOHC 1 997 121 9 4G63 DOHC 1 997 121 9 F4AC1 F5M33 F4A33 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic Fuel Fuel supply system Electronically Electronically Electronically Electronically system controlled multi controlled multi controlled multi controlled multi port fuel injec port fuel injection port fuel injec port fuel injection i oon Model No 420A DOHC Piston displacement 1 996 121 8 cm cu in Model No 420A DOHC 1 996 121 8 Engine2. BODY Rear Bumper REAR BUMPER REMOVAL AND INSTALLATION Pre removal and Post installation Operation Rear End Trim and Rear Side Trim RE Removal and Installation Refer to GROUP 23A 90 A18X0676 Removal steps 1 Rear panel garnish 5 Connector harness 2 Rear combination light 6 Rear bumper assembly 3 Rear bumper upper plate A 7 Rear bumper side plate 4 Rear bumper upper plate B 28A 74 BODY Rear Bumper DISASSEMBLY AND REASSEMBLY A18X1009 Disassembly steps 1 Rear bumper lower plate 4 Rear bumper stay assembly 2 Rear bumper reinforcement 5 Rear bumper face 3 Rear bumper core BODY Garnishes 23A T5 GARNISHES REMOVAL AND INSTALLATION 3 18X0675 00003748 Front deck garnish removal steps Rear panel garnish removal steps 1 Wiper arm assembly e Rear end trim 2 Front deck garnish Refer to P 23A 90 3 Rear panel garnish 23A 76 BODY Moldings MOLDINGS SEALANT AND ADHESIVE Specified sealant and adhesive Side protector molding 3M ATD Part No 6382 or equivalent and 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent MOLDINGS REMOVAL AND INSTALLATION 4B 18 0672 00003749 de 2 18X0666 Adhesive tape 3M ATD Part No 6382 or equivalent 15 mm 59 in wide and 1 2 mm 047 in thick Adhesive 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent 1 Windshield molding
3. PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM SRS 1 Items to follow when servicing SRS 1 Be sure to read GROUP 23B Supplemental Restraint System SRS For safe operations please follow the directions and heed all warnings 2 Always Se the designated special tools and test equipment 3 Wait at least 60 seconds after disconnecting the battery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected 4 Never attempt to disassemble or repair the SRS components SRS ECU air bag module and clock spring If faulty replace it 5 Warning labels must be heeded when servicing or handling SRS components Warning labels are located in the following locations Sun visor Glove box SRS ECU Steering wheel Air bag module Clock spring Steering gear and linkage clamp 6 Store components removed from the SRS in a clean and dry place The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward Do not place anything on top of it 7 Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag Refer to GROUP 23B Air Bag Module Disposal Procedures 8
4. 12 00 0 NN i d mM Fuel pump Ignition timing check terminal adjustment connector Ki 4 DON Idle air control motor C N 7 Throttle position sen Sor with builtin closed Na 17 throttle position switch oe ED Gr rercesecerert EI CEET TJ GF Y Evaporative emission purge solenoid Ignition coil Ignition e power transistor N BL ISS AS NS AUR oo a e Spore OE Be A o Fuel pressure solenoid Ze sy Crankshaft position sensor gt Crankshaft sprocket IN A6FU2053 Xo NS Wu Y Turbocharger waste lt gate solenoid JH a 5 EE Camshaft position sensor A 57222 Power seng EG pressure switch E O NS T AS X SN ZE ae TURBO On vehicle Inspecti n of MFI Components 14 241 UN Check engine Malfunction indicator lamp te Data link connector Q 16 0740 go B16xo910 Heated oxygen sensor Rear MFI relay and fuel pump relay 16 1174 14F 10 FUEL SUPPLY AND ENGINE CONTROL Accelerator Cable And Pedal ACCELERATOR CABLE AND PEDAL GENERAL INFORMATION A cable type accelerator mechanism and a suspended type pedal have been adopted SERVICE SPECIFICATION
5. 8 el Volume lt O CQ o I lt Q Partial BACKUP Service Manual Cooling P ee Engine FOREWORD This Service Manual has been prepared with the latest service information available at the time of publication It is subdivided into various group categories and ach section contains diagnostic disassembly repair and installation procedures along with complete specifications and tightening Joints ZU A sl SS references Use of this manual will aid properly ian i pr performing any servicing necessary to maintain or Rear Suspension 1 7 restore the high levels of performance and reliability p pa designed into these outstanding vehicles Steering Safe EEE MES This BACKUP DSM manual is to be used ONLY as a BACKUP Please DO NOT REDISTRIBUTE WHOLE SECTIONS This BACKUP was sold to you under the fact that you do indeed OWN a GENUINE DSM MANUAL It CANNOT BE considered a REPLACEMENT Unless your original manual was lost or destroyed Es Please See README TXT or README HTML for additional information Thank you Gimmiemymanual hotmail com Body and Supplemental Restraint System SRS Heaters and Air Conditioning 1 Emission Control Systems amp 4 CHRYSLER l a COR TION For Electrical refer to Volume 2 Electrica Chrysler Motors Corporation reserves the right to make ch
6. Item Standard value Accelerator cable play mm in 1 2 04 08 LUBRICANT Specified lubricant Quantity Accelerator pedal pin spring MOPAR Multi mileage Lubricant Part As required accelerator cable end No 2525035 or equivalent TROUBLESHOOTING Throttle valve will not Misadjusted accelerator cable Agjust fully open or close Misadjusted auto cruise control cable Adjust Broken return spring Replace Throttle lever malfunction Accelerator pedal op Accelerator pedal wrongly tightened Repair eration not smooth over acceleration Misinstalled accelerator cable Repair Accelerator cable requires lubrication Lubricate or replace FUEL SUPPLY AND ENGINE CONTROL A celecator C ble And 14 11 ON VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT For models equipped with the auto cruise control system refer to GROUP 14G On vehicle Service 1 Turn A C and lights OFF inspect and adjust at no load Warm engine until stabilized at idle Confirm idle speed is at prescribed rpm Stop engine ignition switch OFF Confirm there are no sharp bends in accelerator cable Check inner cable for correct slack If there is too much slack or no slack adjust play by the following procedures 1 Turn the ignition switch to the ON position without starting the engine and leave in that condition for approximately 15 seconds in order to initialize the AC mot
7. VEHICLES FOR CALIFORNIA INTRODUCTION Vehicle Identification VIN except sequence number Brand EE AESAKA4Y TE Eagle Talon lt FWD gt 2 0 dm 122 0 D31AMNHML9E DOHC MFI 420A D31 AMRHML9E AESAKS4F TE Eagle Talon lt FWD gt 2 0 dm 122 0 cu in D32AMNGFL9E DOHC MFIi Turbo 4963 D32AMRGFL9E 4ESALS4F TE Eagle Talon lt AWD gt Ehe D33AMRGFL9E VEHICLES FOR CANADA V I N except sequence number 4E3AK44Y TE Eagle Talon lt FWD gt 54 Eagle Talon lt FWD gt 4E3AL54F TE Eagle Talon lt AWD gt Engine Displacement Model cod 2 0 dm 122 0 cu in DOHC MFI 420A 2 0 dm 122 0 cu in DOHC MFI Turbo 4G63 D31 AMRHMLSE D32AMNGFL5E D32AMRGFL5E D33AMNGFLSE MODEL ENGINE TRANS SES COLOR TRIN S OPT D33AMRGFL5E VEHICLE INFORMATION CODE PLATE Vehicle information code plate is riveted onto the bulkhead in the engine compartment The place shows model code engine model transaxle model and body color code 1 MODEL D32AM D32AM Vehicle model RGFL4E Model series Engine model 1 4G643 H CA6A F4A33 R25 87V 03V ENGINE EXT TRANS COLOR TRIM OPT Exterior code Transaxle code R25 Body color code 87V Interior code 03V Equipment code VEHICLE SAFETY CERTIFICATION LABEL 1 The vehicle safety certification label is attache
8. 1 Bolts nuts and washers are all made of steel 2 If plastic parts are fastened and plated with zinc 3 If bolts are tightened to plastic or die cast in 2 The threads and bearing surface of bolts and serted nuts nuts are all in dry condition 4 If self tapping screws or self locking nuts are used Standard bolt and nut tightening torque Bolt nominal diameter Pitch mm Torque Nm ft lbs mm Head mark 4 Head mark 7 Head mark e M5 0 8 2 5 1 8 4 9 3 6 5 9 4 3 4 9 3 6 8 8 6 5 9 8 7 2 12 8 7 22 16 25 18 24 17 44 33 52 38 41 30 81 60 96 71 wes ee Flange bolt and nut tightening torque Bolt nominal diameter Pitch mm Torque Nm ft Ibs mm Head mark 4 Head mark 7 Head mark 8 M6 1 0 4 9 3 6 9 8 7 2 12 8 7 M8 1 25 13 9 4 24 17 M10 1 25 26 19 49 36 M10 1 5 24 247 44 83 EE M12 1 75 42 31 81 60 96 71 PE CONTENTS CAMSHAFT AND CAMSHAFT OIL PISTON AND CONNECTING ROD 87 SEAL AE 29 SEALANTS Bon 5 CAMSHAFT AND ROCKER ARMS ag ON VEHICLE SERVICE 10 CRANKSHAFT FLYWHEEL DRIVE Basic Idle Speed Adjustment PLATE AND CYLINDER BLOCK ue eod Man oa Refer to GROUP 14A CRANKSHAFT FRONT OIL SEAL 34 Compression Pressure Check 14 CRANKSHAFT PULLEY 28 Curb Idle Speed Check 13 Sp ERE Drive Belt Ten
9. Malfunction indicator lamp Manifold differential pressure MDP sensor Crankshaft position sensor Data link connector Multiport fuel injection MFI relay EGR solenoid Engine control module ECM Engine coolant temperature sensor Park Neutral position switch Power steering pressure switch Resistor N U 0 V J X Evaporative emission purge solenoid Fuel pressure solenoid Fuel pump check terminal Fuel pump relay D J Throttle position sensor with built in closed M throttle position switch E Turbocharger waste gate solenoid Vehicle speed sensor OQ VAa lt ID Heated oxygen sensor Front Heated oxygen sensor Rear Idle air control motor temperature sensor and barometric pressure sensor Y Q 2 Volume air flow sensor with built in intake air F K Ignition coil Ignitigh powentransistor NOTE The Name column is in alphabetical order 2 gt zs mul hm 7m Ved VNA sch UU JE 6FU2077 E 6FU2078 6FU2480 i i In rds ii MFI TURBO On vehicle Inspection of MFI Components 14A 239 D IATA LECT Volume air flow sensor with 7 4 built in intake air temperature E sensor and barometric pressure HII 7 Air conditioning compressor clutch relay d Lon Vehicle speed sensor A ELY
10. Whenever you finish servicing the SRS check the SRS warning light operation to make sure that the system functions properly 2 Observe the following when carrying out operations on places where SRS components are installed including operations not directly related to the SRS air bag 1 When removing or installing parts do not allow any impact or shock to the SRS components 2 SRS components should not be subjected to heat over 93 C 200 F so remove the SRS compo nents before drying or baking the vehicle after painting After re installing them check the SRS warning light operation to make sure that the system functions properly 26 INTRODUCTION General Data and Specifications GENERAL DATA AND SPECIFICATIONS 00 0073 GENERAL SPECIFICATIONS lt FWD gt 2 D31AMNHML4E D31AMRHML4E D32AMNGFL4E DS2AMRGFL4E D31AMNHML9E D31AMRHML9E D32AMNGFL9E D32AMRGFL9E D31AMNHML5E D31AMRHML5E D32AMNGFLSE D32AMRGFLSE Vehicle Overall length mm in 11 4 375 172 2 4 375 172 2 4 375 172 2 4 375 172 2 dimen Overall width mm in 2 1 735 68 3 1 735 68 3 1 745 68 7 1 745 68 7 sions Overall height unladen 3 1 305 51 4 1 305 51 4 1 305 51 4 2 510 98 8 mm in Tread Front mm in 5 1 510 59 4 1 510 59 4 1 515 59 6 1 515 59 6 T Items Wheelbase mm in Al 2 510 98 8 2 510 98 8 2 510 98 8
11. vacuum hose 7 Engine coolant temperature sensor connection connector 21 High pressure fuel hose connection 8 Ignition power transistor connector 22 Fuel return hose connection 9 Throttle position sensor connector 23 By pass valve hose connection 10 Capacitor connector 24 Wer hose connection 11 Manifold differential pressure 25 Vacuum hoses connection Sensor connector Injector connectors Agnition coil connector 26 Breather hose connection 27 PCV hose connection lt Cold engine gt 12 15 Nm 78 Nm gt 0lm gt 20 N 87 11 ftlbs lt 490 90 58 ft Ibs gt 0 ft lbs 15 ft Ibs 90 4907 SSC 17 ft lbs 27 34 Nm 20 25 16 01x0200 00003920 10 mm 39 in Cylinder head ifled sealant 5 Sealant MOPAR Part No 4318034 or equivalent Geh GE ec e Timing belt Dq 36 Thermostat case assembly Refer to P 9A 42 Cq 27 0 ring 28 Power steering pump 38 Flange bolts and flange nut 29 Rocker cover Refer to GROUP 11 Exhaust 30 Semicircular packing Manifold and Turbocharger 31 Heat protector gt B lt 4 39 Cylinder head bolt 32 Water hose connection 40 Cylinder head assembly 33 Water hose A connection 41 Ring Ap PEd 34 Radiator upper hose connection 42 Gasket A pE 35 Radiator lower hose connection 43 Cylinder head gasket Crankshaft sprocket Crankshaft sensing blade
12. AMSHAFT SPROCKET INTAKE CAMSHAFT SPROCKET REMOVAL 1 Use a wrench at the hexagonal part of the camshaft to prevent the crankshaft from turning to loosen the camshaft sprocket bolt 2 Remove the camshaft sprockets Bp FRONT CAMSHAFT BEARING CAP CAMSHAFT BEARING CAP REAR CAMSHAFT BEARING R H REAR CAMSHAFT FEARING L H REMOVAL 1 Loosen the bearing cap installation bolts in two or three steps 2 Remove the bearing cap NOTE If the bearing cap is difficult to remove use a plastic hammer to gently tap the rear part of the camshaft and then remove Intake side 7 Exhaust side INSTALLATION SERVICE POINTS 1 pA INTAKE CAMSHAFT EXHAUST CAMSHAFT 1 INSTALLATION ME 1 Install the camshafts on the cylinder head Caution E Do not confuse the intake side and the exhaust side NOTE Install new camshafts using the following procedure 1 Remove the rocker arms 2 Lay the camshafts on the cylinder head and install the bearing caps 3 Check that the camshaft can be easily turned by hand 4 After checking remove the bearing caps and the camshafts and install the rocker arms 0140033 2 The camshaft s dowel pins should be at the positions Dowel pins shown in the figure Exhaust side intake side 2 01 ENGINE TURBO Camshaft and Camshaft Oil Seal 9A 31 PB lt REAR CAMSHAFT BEARING CAP R H VREAR CAMSHAFT BEARING CAP CAMS
13. Crankshaft sprocket 222 01 ENGINE TURBO Timing BeltB gt Crankshaft Crankshaft sprocket B 01 0201 0990767 A11A0119 pC CRANKSHAFT SENSING BLADE INSTALLATION When installing make sure the direction is correct See figure pD lt q CRANKSHAFT SPROCKET INSTALLATION Use the special tool to install the crankshaft sprocket and bolt NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt 9A 49 ARA 9A 50 2 0L ENGINE TURBO Camshaft and Rocker Arms CAMSHAFT AND ROCKER ARMS q REMOVAL AND INSTALLATION Lubricate all Le internal parts with engine oil during reassembly 45 6EN1079 Removal steps 1 Plate C 3 Bearing cap 3 pE 2 Camshaft oil seal 9 Bearing cap No 4 PD 3 Circular packing B Rocker arm Lash adjuster Oil delivery body lt 4 Bearing cap front PC 5 Bearing cap rear kA PC 6 Bearing cap No 2 PC4 7 Bearing cap No 5 8 9 de Camshaft 2 3 2 0L ENGINE TURBO gt Camsh tt and Rocker Arms 9A 5 6ENO421 dam Camshaft sprocket side intake side camshaft 6EN0289 pin Capnumber Symbol identifying intake or exhaust 6EN0464 Camshaft sprocket_side E i INSTALLATION SERVICE POINTS pA lt q LASH ADJUSTER INSTALLATION 1 Immerse the lash adjuster in clean diesel fuel 2 Using t
14. D998373 MB991 603 MD998371 MD998372 eventing foreign substances after transfer or installation of crank fitting counterbalance Bearing _ d with MB991603 Jg uide stopper for use in removal d installation of counterbal Crankshaft front oil seal installa Yon ECounterbalance shaft front bear ing removal Counterbalance shaft rear bear ing removal Used with MB991 603 Leak down test of lash adjuster MD998772 Valve spring compressor MD998737 Valve stem seal installer H placed by Miller Front case cap plug f installation oe Valve and related parts rel and installation 9A 28 2 0L ENGINE lt TURBO gt Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation e Under Cover Removal e Drive Belt Tension Adjustment Refer to P 9A 10 Refer to GROUP 23A Under Cover anay Refer to GROUP 23 nder Cover 1 25 Nm 18 ft lbs 01 0179 Removal steps 1 Drive belt Generator 2 Drive belt K steering 3 Drive belt A C 4 Crankshaft pulley 2 01 ENGINE TURBO Camshaft and Camebatt sed 9A 29 CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pm removal Operation Post installation Operation e Timing Belt Front Upper Cover Removal e Timing Belt Front Upper Cover inst
15. HAFT BEARING CAP FROM CAMSHAFT BEARING CAP INSTALLATION Tighten the bearing cap installation bolts to the specified torque in two or three steps Caution Tighten uniformly otherwise the rocker arms will not be straight CAMSHAFT OIL SEAL INSTALLATION Use the special tool to drive the camshaft oil seal into position carefully 2 0L ENGINE lt TURBO gt Cylinder H ad Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pm removal Operation e Fuel Line inner Pressure Release Refer to GROUP 14A On vehicle Service e Engine Coolant Drainin Refer to GROUP O Maintenance Service e Engine Oil Draining Refer to GROUP O Maintenance Service 9A 87 Post installation Operation e Engine Oil Refilling Refer to GROUP O Maintenance Service e Engine Coolant Refillin Refer to GROUP 0 intenance Service Removal steps 01 0198 Za Ya 4 36ftibs aN aN 2 NAA 3 Engine oil 4 9 Nm o 01X0197 00003919 1 Accelerator cable connection 14 Camshaft position sensor connector Refer to GROUP 14F On vehicle 15 Crankshaft position sensor Service connector 2 Air hoseC 16 Air conditioning compressor 3 Idle air control motor connector connector 4 Knock sensor connector 17 Control wiring harness 5 Heated oxygen sensor connector 18 Center cover 6 Engine coolant temperature gauge 19 Spark plug cable unit connector 20 Brake booster
16. INTRODUCTION General Data and Specifications 27 lt AWD gt D33AMNGFL4E D33AMRGFL4E D33AMNGFL9E D33AMRGFL9E D33AMNGFL5E D33AMRGFL5E Vehicle dimensions Overall length mm in 1 4 375 4 375 Overall width mm in 2 Overall height unladen mm in 3 Wheelbase mm in 4 2 510 98 8 2 510 8 Tread Front mm in 45 Tread Rear mm in 1 510 4 1 510 4 Overhang Front mm in 71 930 36 6 is Overhang Rear mm in 8 935 36 8 935 36 8 Minimum running ground clearance 9 145 5 7 145 5 7 mm in Angle of approach degrees 10 12 2 12 2 Angle of departure degrees 11116 2 16 2 Vehicle weight kg Curb weights 1 420 3 130 1 455 3 208 ee Gross vehicle weight rating 1 850 4 079 1 850 4 079 Gross axle weight rating Front 1 050 2 315 1 050 2 315 Gross axle weight rating Rear 850 1 874 850 1 874 Seating capacity Engine Model No 4G63 DOHC 4G63 DOHC Piston displacement em cu in 1997 121 9 1997 121 9 Transaxle Model No W5M33 W4A33 Type 5 speed manual 4 speed automatic Fuel system Fuel supply system Electronically controlled Electronically controlled multiport fuel injection multiport fuel injection 28 INTRODUCTION Tightening Torque TIGHTENING TORQUE Each torque value in the table is a standard value The values in the table are not applicable for tightening under the following conditions 1 If toothed washers are inserted
17. RVICE SPECIFICATIONS Drive bel Tension Nges When chee 26 49551 102 For generator 490 686 110 2 154 3 When a used belt is installed 392 88 2 Deflection When checked 9 0 11 5 35 45 O vaue gt Wiena used bets nstaled 10008 Drive bet Tension N bs When cheked 25 05 RER For power 4906881021543 343 441 772 992 7 Deflection 55 80 92529 mm in When a new belt is installed 4 5 5 5 18 22 oes i Whenausedbetisinale 60 70 24 28 Drive belt Tension Ibs 255 333 573 750 For AG p 382 441 860 992 PER 255 339 673 180 Deflection 5 75 26 30 mm n 55 80 22 24 When used belt is installed 6 5 7 5 26 20 O LAwaliqnion mnaatide o Curb idle speed r min CO contents 100 or less Compression pressure at 250 400 r min kPa psi 1250 178 min 935 133 Compression pressure difference of all cylinder kPa psi max 109014 Intake manifold vacuum kPa in Hg min 60 18 Installation dimension of front roll stopper bracket assemblv mm in 43 3 1 69 12 PEN Auto tensioner push rod movement mm in Within 1 04 Timing belt tension torque Nm ft lbs 3 5 2 6 Auto tensioner protlusion mm um Timing belt B tension mm in Camshaft Cam height Intake mm in Cam hei
18. TS n Items Specified sealants Fender to body panel MOPAR Silicone Rubber Sealer Part No 4026070 or equivalent S Splash shield to fender MOPAR Silicone Rubber Sealer Part No 4026070 or Auto Glass Adhesive and Sealer Part 2298825 or equivalent FENDER REMOVAL AND INSTALLATION Pre removal and post installation Operation Front Bumper Removal and installation Refer toP 23A 71 18X0734 Sealant MOPAR Silicon Rubber Sealer Part No 4026070 or Auto Glass Adhesive and Sealer Part No 2298825 or equivalent e 18 0729 Sealant MOPAR Silicon Rubber Sealer Part No 4026070 or equivalent 00000131 Removal steps 1 Splash shield e Side air dam Refer to P 23A 79 2 Front fender panel BODY Front Bumper 23A 71 FRONT BUMPER REMOVAL AND INSTALLATION Pre removal and Post installation Operation PB Splasn shield Removal and Installation E Refer to GROUP 23A 61 1 18 0666 Removal steps 1 Fog light 5 Front bumper corner plate 2 Front side marker light 6 Pad 3 Front bumper center plate 7 Front fascia bracket 4 Front bumper assembly 23A 72 BODY Front Bumper DISASSEMBLY AND REASSEMBLY A18X 0678 C Disassembly steps 1 Fog light hole cover 5 Front bumper reinforcement 2 Front license plate bracket 6 Front bumper core 3 Bolt plate 7 Front bumper stay assembly 4 Front bumper side plate 8 Front bumper face
19. allation Refer to P 9A 42 Refer to P 9A 42 e Engine Adjustment 19 21 Nm 14 15 ft Ibs H i H i 01 0185 00003915 10 mm 39 in 10 mm 10 mm 39in 39 in Er 01A0046 0140047 Specified sealant MOPAR Part No 4318034 or equivalent Removal steps Installation steps 1 Accelerator cable connection 15 Intake camshaft 2 Center cover 14 Exhaust camshaft 3 Spark plug cable pB lt q 13 Rear camshaft bearing R H 4 Breather hose gt 12 Rear camshaft bearing cap L H 5 PCV hose gt 11 Camshaft beating cap 6 Rocker cover B lt 4 10 Front camshaft bearing 7 Timing belt Refer to P 9A 42 gt 16 Camshaft oil seal A 8 Exhaust camshaft sprocket 9 Intake camshaft sprocket A 9 Intake camshaft sprocket 8 Exhaust camshaft sprocket B 10 Front camshaft bearing cap 7 Timing belt Refer to P 9A 42 B 11 Camshaft bearing cap 17 Semi circular packing B 12 Rear camshaft bearing cap R H 6 Rocker cover B 13 Rear camshaft bearing cap L H 5 PCV hose f 14 Exhaust camshaft 4 Breather hose 15 intake camshaft 3 Spark plug cable 16 Camshaft oil seal 2 Center cover 17 Semicircular packing 1 Accelerator cable connection Refer to GROUP 14F On ve Service 9A 30 2 0L ENGINE TURBO Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS Ap EXHAUST C
20. anges in DEAE P design to make additions to or improvements in its products without 4 ds ON imposing any obligations upon itself to install them on its products T previously manufactured 1995 Mitsubishi Motors Corporation Printed In U S A INTRODUCTION 2 Vehiel ld ntifi tion 13 VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number V I N is located on a plate attached to the left top side of the instrument panel A00X0051 VEHICLE IDENTIFICATION CODE CHART PLATE All vehicle identification numbers contain 17 digits The vehicle m number is a code which tells country make vehicle type AIRBAG A i HC U Engine Y 2 0dm 122 0cu iri JADOHC MFIJ 2 0dm 122 0cuiiri DOHC MFI Turbo Check digits 123456789X Model year 71960 12 Serial unmber 000001 to 999999 NOTE Check digit means a single number or letter X used to verify the accuracy of transcription of Vehicle identification number VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR FEDERAL VIN except sequence number 4E3AK44Y TE Eagle Talon lt FWD gt 4E3AK54F TE Eagle Talon lt FWD gt 4E3AL54F TE Eagle Talon lt AWD gt Engine displacement 2 0 dm 122 0 cu in DOHC MFI 420A D32AMRGFLA4E D33AMNGFLA4E D33AMRGFL4E 2 0 dm 122 0 cu in DOHC MFI Turbo 4G63 14
21. asher accelerator cable removal installation procedures are 7 Accelerator pedal pin referred to GROUP 14G Auto cruise control system FUEL SUPPLY AND ENGINE CONTROL Accelerator Cable And Pedal 14 13 INSTALLATION SERVICE POINT pA ACCELERATOR CABLE INSTALLATION Turbo Clamp the accelerator cable so that its marking is as shown 23A 4 BODY Hood Bungei INSTALLATION SERVICE POINT av E mal FE gt A lt q BUMPER INSTALLATION 55 in Install the bumper as shown in the diagram 1 18X0722 16 02 1 INSPECTION HOOD SWITCH CONTINUITY CHECK Terminal No Switch position Hood switch unpressed OFF 16 0816 18X0831 Hood switch depressed ON 00000129 D BODY Fend 2345 FENDER a SEALANTS Fender to body panel MOPAR Silicone Rubber Sealer Part No 4026070 or equivalent pum DOCE UTE NR FENDER REMOVAL AND INSTALLATION Pre removal and post installation Operation Front Bumper Removal and Installation Refer toP 23A 71 18X0734 Sealant MOPAR Silicon Rubber Sealer Part No 4026070 or Auto Glass Adhesive and Sealer Part No 2298825 or equivalent 1850736 18 0729 Sealant MOPAR Silicon Rubber Sealer Part No 4026070 or equivalent 00000131 Removal steps 1 Splash shield Side air dam Refer to P 23A 79 2 Front fender panel 23 5 BODY Fender FENDER 5 SEALAN
22. d to face of left door pillar 2 This label indicates Gross Vehicle Weight Rating G V W R Gross Axle Weight Rating G A W R front rear and Vehicle Identification Number V I N Theft protection Jabel For original parts JT 0040212 For replacement parts 00A0213 00000222 15 ENGINE MODEL STAMPING 1 The engine model number is stamped at the front side on the top edge of the cylinder block as shown in the following Engine model Engine displacement 420A 2 0 dm 122 0 cu in 4G63 2 0 dm 122 0 cu in 2 The 4G63 or 420A engine serial number is stamped near the engine model number and the serial number cycles as shown below Engine serial number AA0201 to YY9999 THEFT PROTECTION In order to protect against theft a Vehicle Identification Number VIN is stamped in or attached as a label to the following major parts of the engine and transaxle as well as main outer panels Engine cylinder block Transaxle housing Fender Door Quar ter panel Hood Liftgate Bumpers In addition a theft protection label is attached to replacement parts for the body outer panel main components and the same data are stamped into replacement parts for the engine and the transaxle Cautions regarding panel repairs 1 When repainting original parts do so after first mask ing the theft protection label and after painting be sure to peel off the masking tape 2 The theft protectio
23. djuster _ AGEN1031 4 After air bleeding set lash adjuster on the special tool Leak down tester MD998440 5 After plunger has gone down 0 2 to 0 5 mm 008 to 020 in measure time taken for it to go down 1 mm 039 in Replace if measured time is out of specification Standard value 4 20 seconds I mm 04 in Diesel fuel at 15 20 59 68 F 9A 54 2 01 ENGINE TURBO Cylinder Head and Valve CYLINDER HEAD AND VALVE REMOVAL AND INSTALLATION ubricate all internal parts with engine oil during reassembly Removal steps 1 Cylinder head bolt See 2 Cylinder head assembly 3 Gasket p B 4 4 Retainer lock 5 Valve spring retainer 6 Valve spring B 7 Intake valve 8 Retainer lock 9 Valve spring retainer 10 Valve spring T 6EN0948 B 11 Exhaust valve pA 12 Valve stem seal 13 Valve spring seat C pA 14 Valve stem seal 15 Valve spring seat 16 Intake valve guide 17 Exhaust valve guide 18 Intake valve seat 19 Exhaust valve seat 20 Cylinder head de ON VEHICLE INSPECTION COMPONENT LOCATION Air conditioning compressor clutch relay Air conditioning switch Camshaft position sensor 14A 238 MFI TURBO On vehicle Inspection of MEI Components OF MFI COMPONENTS p 3 d E Symbol Name A Ignition timing adjustment connector W Injector Knock sensor m Check engine
24. e Drip line weatherstrip Refer to P 23A 10 Refer to 55221 2 Belt line molding e Door older _ Refer to P 23A 50 Refer to P 23A 50 pA 3 Side protector molding 5 Drip molding 4 Liftgate molding Refer to P 23A 18 BODY Moldings _ 3A 77 REMOVAL SERVICE POINT EE Ap SIDE PROTECTOR MOLDING REMOVAL 1 Apply masking tape to the outside circumference of the side protector molding A18A0777 2 Insert fishing line 20 8 mm 03 in in between the body and the side protector molding pull both ends alternately to cut the adhesive section and remove the side protector molding 1 When reusing the side protector molding pull the fishing line along the edge of the body so as not to damage the edge of the side protector Molding 2 If the adhesive is difficult to remove heat it to 40 C 104 F a A 3 Scrape off the double sided tape with a resin spatula 4 Tear off the masking tape 5 Scrape off a small amount of the adhesive with a cutter Knife A Resin spatula H A18A0993 H 6 Use a shop towel moistened with degreaser MOPAR SUPER KLEEN or equivalent to wipe the body surface 18A0784 INSTALLATION SERVICE POINT pA SIDE PROTECTOR MOLDING INSTALLATION Double sided tape affixing to the side protector Molding when reusing 1 Scrape off the double sided tape with a resin spatula or gasket scraper Primer 22212222 Bis
25. embly I Rear oil seal case Flywheel bolt or drive plate bolt replaced by Miller tool number MB991 502 Scan tool MUT II dd m oll seal instalan MD998713 spamshaft oil d b stall Camshaft oil seal installer Zeg Zeit ech MD998727 General service tool Use scraper and Oil pan gasket cutter 8xcercise care mom Tool number and nami Replaced Miller tool number MD998781 Flywheel stopper MD998776 Crankshaft rear oil seal installa ton Crankshaft rear oil EE e 1 Use with MB990938 seal installer 4r qui MB990938 Handle Br AVR GENERAL SERVICE 852 lt engine assembly TOOL Y when removing and installing 2203827 d transaxle Engine litter MB991 453 Engine hanger assembly MD998767 MD998767 Tensioner pulley wrench MD998778 MD998778 Crankshaft sprocket puller MD998782 Valve litter set 5 2 3 de EEN 1 jd FL MB990767 700 Crankshaft sprocke End yoke holder General service tool Use shop towel Crankshaft oil seal rs MD998705 Silent shaft bearing installer for front and rear gt bearings MB991 603 Silent shaft bearing MD998375 Crankshaft front oil seal installer MD998371 Silent shaft bearing puller MD998372 Silent shaft bearing puller MD998440 Leak down tester MD998162 MD998285 M
26. ght Exhaust mm in Journal diameter mm in Cylinder head Flatness of gasket surface mm in Grinding limit of gasket surface A with cylinder block grinding mm in Overall height mm in 131 9 132 1 5 91 5 20 Oversize valve guide hole both intake and exhaust 12 05 12 97 0 05 O S mm in 4744 4752 Oversize valve guide hole both intake and exhaust 12 25 12 27 0 25 O S mm in 4823 Oversize valve guide hole both intake and exhaust 12 50 12 52 0 50 O S mm in 4921 4929 Cylinder head bolt Valve Valve spring 78 11 4 or more 84 48 8 334 0 04 0 08 0016 0031 e Press 00 1 653 lt Connecting Big end jar nce mim in 0 10 0 25 0Q 098 0 4 016 Crankshaft End pl Poet 0 05 0 18 0020 0 25 0098 s 1 74 AA 0 1 004 0 Cylinder atness of gasket surface mm in Includes combined with cylinder bloc grinding mm in Overall height mm in Inner diameter mm in mm in Crankshaft bear Shank lengthimm in ing cap bolt EE Bearing cap front rear and cylinder head Oil pressure gauge unit d Oil pressure switch Oil pan cylipder block and thermostat case MITSUBISHI GENUINE PART MD970389 or equivalent ass
27. he cam height Standard value 34 91 mm 1 37 in Limit 34 51 mm 1 35 in ROCKER ARM 1 Check the roller surface If any dents damage or seizure is evident replace the rocker arm 2 Check rotation of the roller If it does not rotate smoothly or if looseness is evident replace the rocker arm 3 Check the inside diameter If damage or seizure is evident replace the rocker arm LASH ADJUSTER LEAK DOWN TEST Caution 1 The lash adjuster is a precision part Keep it free from dust and other foreign matter 2 Do not disassemble lash adjuster 3 pii cleaning lash adjuster use clean diesel fuel only 2 0L ENGINE lt TURBO gt Canish ftiand Rocker Arms 6 0421 1 Immerse the lash adjuster in clean diesel fuel 2 While lightly pushing down inner steel ball using the special tool MD998442 move the plunger up and down four or five times to bleed air Use of the retainer helps the air bleeding of the rocker arm mounted type lash adjuster Remove the small wire and press the plunger If the plunger is hard to be pushed in the lash adjuster is normal If the plunger can be pushed in all the way readily bleed the lash adjuster again and test again If the plunger is still loose replace the lash adjuster Caution Immediately after air bleeding hold lash adjuster up right to prevent fuel from spilling l Division 1 mm 039in adjuster Lash a
28. he special tool MD998442 move the plunger up and down 4 or times while pushing down lightly on the check ball to bleed out the air pB CAMSHAFT INSTALLATION 1 Apply engine oil to journals and cams of the camshafts 2 Install the camshafts on the cylinder head Do not confuse the intake camshaft with the exhaust one The intake camshaft has a slit on its rear end for driving the crankshaft position sensor 3 Install the crankshaft sprocket B or spacer and flange to an end of the crankshaft Then turn the crankshaft until the timing marks are lined up to set No cylinder to the TDC 4 Set the camshafts so that their dowel pins are positioned at top gt BEARING CAPS INSTALLATION 1 According to the identification mark stamped on top of each bearing cap install the caps to the cylinder head Only 71 or R is stamped on No 1 bearing cap No is stamped on No 2 to No 5 bearing caps No 6 bearing cap has no stamping I For intake camshaft side E For exhaust camshaft side 2 Tighten the bearing caps in the order shown two to three times Tighten to specification in the final sequence 3 Check that the rocker arm is held in position on the lash adjuster and valve stem end 9 0058 0185 9A 52 2 0L ENGINE TURBO Camsh fti and Rocker Arms gt 04 CIRCULAR PACKING INSTALLATION CAMSHAFT OIL SEAL INSTALLATION INSPECTION CAMSHAFT 1 Measure t
29. hesive Door garnish Side air dam 3M ATD Part No 6382 or equivalent and 3MATD Part No 8608 Super Fast Urethane Primer or equivalent AERO PARTS REMOVAL AND INSTALLATION 18 0673 00003750 Adhesive tape 3M ATD Part No 6382 or equivalent 4 mm 15 in wide and 1 5 mm 059 in thick Adhesive 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent Door garnish removal Side air dam removal steps 3 Rear side air dam pA 1 Door garnish pA pad 2 Front side air dam A A 23A 80 BODY Aero Parts 18 0679 00003751 18X0833 Rear spoiler removal steps e Liftgate lower trim Refer to P 23A 90 3 High mounted stop light 1 Connector harness 4 Dual lock fastener small 2 Rear spoiler assembly 5 Du lllock fastener large REMOVAL SERVICE POINT AP DOOR GARNISH FRONT SIDE AIR DAM REAR SIDE AIR DAM REMOVAL Carry out th same procedure as for the side protector mold ings Refer to P 23A 76 INSTALLATION SERVICE POINT pA DOOR GARNISH FRONT SIDE AIR DAM REAR SIDE AIR DAM INSTALLATION Carry out the same procedure as for the side protector mold ings Refer to P 23A 76
30. n label for replacement parts is cov ered by masking tape so such parts can be painted as is The masking tape should be removed after paint ing is finished 3 The theft protection label should not be removed from original parts or replacement parts 16 INTRODUCTION Vehicle Identification LOCATIONS Target area A for original equipment parts B for replacement parts Engine lt Non turbo gt lt Turbo gt or FO ET weer o A CON gt FU AA NETA 00 0095 00003677 Manual transaxle lt N A turbo gt lt Turbo gt j B xoo92 00x0048 00003678 00 Automatic transaxle lt Non turbo gt lt Turbo gt 00003679 0900x0033 nes Target area A for original equipment parts B for replacement parts Fender 31X0354 31x0321 The illustration indicates left hand side outer Right hand side is symmetrically opposite 00003680 Quarter panel The label is attached at the inner side of the parts shown in the figure As31x0325 The illustration indicates right hand side outer Left hand side is symmetrically opposite AN AN AN A T5 M 31x0356 31 0473 00003681 18 INTRODUCTION Vehicle Identification Precautions before Service Target area A for original equipment parts B for replacement parts Front bumper Rear bumper 00003682 00X0078
31. or N 0 2 Loosen the adjusting bolt to release the cable 3 After moving the plate to the position immediately before the throttle lever starts to move move the Intake manifold Adjusting bolts plate back towards the throttle body by the standard value amount only to bring the accelerator cable play to the standard value s Standard value 1 2 mm 04 08 in 4 Tighten the adjusting bolts to the specified torque 8 Adjust accelerator cable play and confirm throttle lever stopper touches the fixed SAS A03N0008 14F 12 FUEL SUPPLY AND ENGINE CONTROL Accelerator Cable P dal ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post Installation Operation Accelerator Cable Adjustment Refer to P 14F 10 for models equipped with auto cruise control system refer to GROUP14G On vehicle Service 4 9 Nm 3 6ft Ibs lt Turbo gt 4 9 Nm 3 6 ft Ibs 4 9 Nm 3 6ft Ibs 03X0121 A lt Non turbo gt 4 9 Nm 3 6ft Ibs 07 0009 Grease MOPAR Multi Mileage Lubricant Part No 2525035 or equivalent 3 6ft lbs 00003894 Accelerator cable removal steps 8 Bushing 1 Cli 9 pring 2 Adiustin bolts 10 Accelerator pedal arm 6 3 Accelerator cable 11 Accelerator pedal bracket Accelerator pedal removal steps 12 Accelerator pedal stopper 4 Accelerator cable connection NOTE 5 Cotter pin For models equipped with auto cruise control system the 6 W
32. sion Check and CRANKSHAFT REAR OIL SEAL 35 IT ANA 10 CYLINDER HEAD AND VALVE 54 22 ja 5 CYLINDER HEAD GASKET 37 Eer ENGINE ASSEMBLY 23 Manifold Vacuum Check 16 ENGINE MOUNTING 19 SERVICE SPECIFICATIONS 3 ENGINE ROLL STOPPER 22 SPECIAL TOOLS 5 ENGINE OIL COOLER 79 TIMING BELT 42 GENERAL INFORMATION 2 TIMING BELT 47 OIL PAN AND OIL SCREEN 32 TRANSAXLE MOUNTING 20 OIL PAN OIL PUMP AND TROUBLESHOOTING 9 COUNTERBALANCE SHAFT 59 GENERAL INFORMATION Items Specifications Number of cylinders 4 Bore mm in 85 0 3 35 Stroke mm in 88 0 3 46 Piston displacement cm cu in 1 997 121 9 Compression ratio 8 5 Fring order Counterbalance shaft Equipped 21 BTDC Closes 51 ABDC Exhaust valve Opens 57 BBDC Closes 15 ATDC Lubrication system Pressure feed full flow filtration Oil pump type Involute gear type LUBRICATION SYSTEM Valve timing Intake valve Camshaft Counterbalance shaft From water Oil filter outlet fitting Crankshaft Oil pump Counterbalance shaft 2 0L ENGINE lt TURBO gt Service Specifications 9A 3 SE
33. xoese Adhesive tape Backing paper A18X0697 BODY Moldings 2 Use a shop towel moistened with degreaser MOPAR SUPER KLEEN or equivalent to wipe the molding surface 3 Remove a small portion of the residual adhesive Caution Do not remove all of the residual adhesive 4 Soak a sponge in the primer and apply evenly to the Side protector molding in the places shown in the illustra tion Specified primer 3M ATD Part No 8608 Super Urethane Primer Caution 1 Always apply it on the entire dirid because a lot or little will reduce its strength 2 Do not touch the coated surface 5 After applying the primer let it dry for 3 to 30 minutes 6 Affix the specified double sided tape to the side protector molding Specified adhesive tape Part No 6382 or equivalent 15 mm 59 in wide and 1 2 m An thick Side protector molding installation 1 Tear off the double sided tape backing paper NOTE If you attach the adhesive tape to the edge of the backing paper it will be easy to tear off 2 Install the side protector molding NOTE If the double sided tape is difficult to affix during winter etc warm the bonding surfaces of the body and the side protector molding to about 40 60 C 104 140 F before affixing the tape 3 Firmly press in the side protector molding BODY Aero Parts 23A 79 SEALANT AND ADHESIVE Items Specified sealant and ad
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