17887210-9596ECB

Part ia 1’ 13A~CeKUPServicq ~Manual

::L .’

This Service Manual ‘has been prepared with thelatest service informatlon available at the timeof publication. It t is subdivided into various groupcategories andeach section contains diagnostic,disassembly, repair,” and instatjation proceduresalong with complete specificatiohs and tighteningreferences. Use of thismanual will aid-,in properly!?performing any servicing necessary to,maintain orrestore the high levels of performance and reliabilitydesigned into these outstanding vehicles.

This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTEWHOLE SECTIONS. This BACKUP was solq to you under the fact that you do indeed OWNa GENUINE DSM MANUAL. It CANNOT,,~$onsidered a REPLACEMENT (Unless your originalmanual was lost or destroyed.) ‘-.$‘,

Please See README.N or README.HTML for additional Information.

Thank you. [email protected]

IONChrysler Motors Co ration reserves the right to make changes indesign or to make a27.ions to or improvemqnts in its products withoutimposing any obligations upon itself to install them on its productspreviously manufactured.

@ lW!5 Mitsubishi Motors

Engine . . . .:I

IRear Suspen@n- ” -. . . . . . . .:‘i . . . :

ISteering “,,, ,I IN’........ ....... .. . . . . . . .w..

Emission Cont@Systems . . . . . . .-

l//i 1 / \\\\\I* *OOLOOOQ

1 2 3 4 5 6 7 8 9 1 0 1 1

VEHICLE IDENTIF ICATIONVEHICLE IDENTIFICATION NUMBER--LOCATIONThe vehicle identification number (V.1.N) is located on a plateattached to the left top side of the instrument panel.

V E H I C L E IDENTIFICATION C0b~ .&HART PLATEAll vehicle identification numbers contain 17 di$iti. Thti vehiclenumber is a code which tells country, make, vehicle type,!tc.No.

12345

78

9101112

I

Items Contents

Country 4: USAMake E: EAGLEVehicle type 3: Passenger carOthers A: Drive and passenger air hags ILine K: TALON <FWD>

L: TALON <AWD,

NOTE* “Check digit” means a single number or letter X used toverify the accuracy of transcription of Vehicle identificationnumber.

VEHICLE IDENTIFICATION NUMBER LISTVEHICLES FOR FEDERAL

V.I.N. (except sequence number) Brand4E3AK44Y*TE Eagle Talon <FWD>

4E3AK54F*TE Eagle Talon cFWD>

4E3AL54F*TE Eagle Talon <AWD>

Engine displ&ement . Modelcode

2.0 dm3 (122.0 cu.in.) D31AMNHML4E[DOHC-MFI (42OA)l D31 AMRHML4E

I

2.0 dms (122.0 cuin.) D32AMNGFL4E[DOHC-MFI-Turbo (4683)] D32AMHGFL4E

14 -~ - " INTRODUCTION -. Vehicle, jdentifictitjcjti

VEHICLES FOR CALIFORNIA

V.I.N. (except sequence number) Brand Engine Displacement Model code

4E3AK44Y’TE Eagle Talon <MID> 2.0 dm3 (122.0 cu.in.) D31AMNHMLSE[DOHC-MFI (420A)] D31 AMRHMLSE

4E3AK54F*TE Eagle Talon <FWD> 2.0 dm3 (122.0 cuin.) D32AMNGFLSE[DOHC-MFI-Turbo (4G63)] D32AMRGFLSE

4E3AL54F*TE Eagle Talon d\Wb D33AMNGFLSED33AMRGFLSE

VEHICLES FOR CANADA

V.I.N. (except sequence number) Brand4E3AK44YTE Eagle Talon -SVD>

4E3AK54F*TE Eagle Talon +WD>

4E3AL54F’TE Eagle Talon <AWD>

Engine Displacement

2.0 dms (122.0 cu.in.)[DOHC-MFI (420A)]

2.0 dm3 (122.0 cu.in.)[DOHC-MFI-Turbo (4663)]

Model code

D3l AMNHM.4!&D31 AMRHMtiE ::. /_D32AMNGFLS’D32AMRGFLSED33AMNGFLSE ’ -D33AMRGFLSE

-

VEHICLE INFORMATION CODE PLATEVehicle information code plate is riveted onto the bulkheadin the engine compartment.The place shows model code, engine model, transaxle model,and body color code.

VEHICLE SAFETY CERTIFICATION LABEL1. The vehicle safety certification label is attached 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 pro&ion .label

For original parts

mF!!!w! .iii2uiw !se!!!EE

rrbnnmrrbnnOOAO212

For replacement parts

[-i!zszElOOAO213

(10000222

ENGIN~E MODEL STAMPING1. The engine model number is stamped at the front side

on the top edge of the cylinder block as shown in thefollowing.

Engine model

420A

4G63

Engine displacement

2.0 dm3 (122.0 cu.@.)

2.0 dm3 (122.0 cu.in.1

2. The 4G63 or 420A engine serial number is stamped nearthe engine model number, and the serial number cycles,as shown below.

1 Engine serial number 1 AA0201 to W9999 1

THEFT PROTECTIONIn 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 mainouter panels:Engine cylinder block, Transaxle housing. Fender, Door, Quar-ter panel, Hood, Liftgate, BumpersIn addition, a theft-protection label is attached to replacementparts for the body outer panel main components, and thesame data are stamped into replacement parts for the engineand the transaxle.

Cautions regarding panel repairs:1. When repainting original parts, do so after first mask-

ing the theft-protection label, and, after painting, besure to peel off the masking tape.

2. The theft-protection label for replacement parts is cov-ered by masking tape, so.such parts can be paintedas is. The masking tape should be removed after palnt-lng is finished.

3. The theft-protection label should not be removed fromoriginal parts or replacement parts.

16 INTfiQDt~JJCTION’ r ,Vbhicie 4dentification

LOCATIONS

Target area (A: for original equipment parts, B: for replacement parts)

Engine

<Non-turbo>

Manual transaxle

eNdi%turbot

00x0092

Automatic transaxle

<Non-turbo>6

<Turbo>

<Turbo>A

oO”oo1. 00003678

<Turbo>100 mm

WOO3679ooA0.t~

Target area (A: for original equipment parts, B: for replacement parts)

Fender Door

31x0521 00003660

The illustraticn~indic&s !qfl- hand side, outer.Right hand side is symmetrically opposite. ‘. 3 ,’,. /., ,5

Quarter panel The label is attached at the inner ” ‘-,. I’side of the parts shown in the figure.

,i’., :;, i i I“. .. i

\’ t

The illustration indicates right hand side, outer.Left hand side is symmetrically opposite.

Hood Liftgate

6 ,: A

31xo4ra

00003661

INTRODUCTION.+y Vehicle I&#tification/Ptie,@autipw before Service ~~ t:’

Target area (A: for original equipment parts, B: for replacement parts)

Front bumper Rear bumper

PRECAUTIONS BEFORE SERVICESUPPLEMENTAL RESTRAINT SYSTEM (SRS)1. Items to follow when servicing SRS

(1) Be sure to read GROUP 238 - Supplemental Restraint System (SRS).For safe operations, please follow the directions and heed all warnings.

(2) Always r&e the <designated special tools and test equipment.

00003662

00X0016

(3) Wait at least 80 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 batteryhas been disconnected. Serious injury may result from unintended air bag deployment if workis 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 andclock spring). If faulty, replace it.

(5) Warning labels must be heeded when servicing or handling SRS components. Warning labelsare located in the following locations.0 Sun visorl Glove boxl SRS - ECUl Steering wheell Air bag modulel Clock springl 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 isfacing 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 vehicleequipped with an air bag. (Refer to GROUP 238 - Air Bag Module Disposal Procedures.)

(8) Whenever you finish servicing the SRS, check the SRS warning light operation to make surethat 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 systemfunctions properly.

26 INTRODUCTION - General Data and Specifications ”

GENERAL DATA AND SPECIFICATIONS

00x01073

GENERAL SPECIFICATIONS _

<FWD> -,

I

Fuel Fuel supply system Electronically Electronically Electronically Electronicallysystem controlled multi- controlled multi- controlled multi- controlled multi-

port fuel injec- port fuel injection port fuel injec- port fuel injectiontion t i o n

INTRODUCTION - General Data atl;d”Spe&fkations 27

<AWD>

Items D33AMNGFL4E D33AMRGFL4ED33AMNGFLSE D33AMRGFLSED33AMNGFL5E D33AMRGFLSE

Vehicle dimensions Overall length mm (in.) 1 4,375 (172.2) 4,375 (172.2)

Overall width mm (in.) 2 1,745 (68.7) 1,745 (68.7)

Overall height (unladen) mm (in.) 3 1,310 (51.6) 1,31 O-(51.6)

Wheelbase mm (in.) 4 2,510 (98.8) 2,510 (98.8)

Tread - Front mm (in.) 7 5 1,5 15 (59.6) 1,515 (59.6)

Tread - Rear mm (in.) 6 1,510 (59.4) i ,a 0 (59.4)

Overhang - Front mm (in.) -~-~-~T ~~ 930 (36.6) 930 (36.6) .I-.;

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 12.2i.”

’ Angle of departure degrees 11 16.2 16.2

Vehicle weight kg Curb weights 1,420 (3,130) 1,455 (3,208)(Ibs.)

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 4 4

Engine Model No. 4663 (DOHC) 4G63 (DOHC)

Piston displacement ems (cuin.) 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 controlledmultiport fuel injection multiport fuel injection

28 INTRODUCTION - Tightening Torque

TIGHTENING TORQUEEach torque value in the table is a standard valuefor tightening under the following conditions.(1) Bolts, nuts and washers are all made of steel

and plated with zinc.(2) The threads and bearing surface of bolts and

nuts are all in dry condition.

The values, in the table are not applicable:(1) If toothed washers are inserted.(2) If plastic parts are fastened.(3) If bolts are tightened to plastic or diecast in-

serted nuts.(4) If self-tapping screws or self-locking nuts are

used.

Standard bolt and nut tightening torque

Bolt nominal diameter(mm)

M5

Pitch (mm)

0.8

Torque Nm (ft.lbs.)

Head mark “4” Head mark ‘7” Head mark “8”

2.5 (1.8) 4.9 (3.6) 5.9 (4.3)I I I I

M6 1.0 4.9 (3.6) 1 8.8(6.5) 9.8 (7.2)

1 12(8.7) 1 22 (16) 1 25 (18)Ml0 1.25 24 (17) 44 (33) 52 (38)

Ml2 1.25 4 1 ( 3 0 ) 8i' (60) 96(71)Ml4 1.5 72 (53) 137(101) 157(116)

I I I

Ml6 q 1 1.5 111 (82) 206 (152) 235 (174)

Ml8 '1.5 167(123) 304 (224) 343 (253)M20 1.5 226 (166) 412 (304) 481 (354)M22 1.5 304 (.224) 647: 559(412) (477)M24 1.5 392 (289) '. .' 735(542) 853 (629)

Flange bolt and nut tightening torque

Bolt nominal diameter(mm)

Pitch (mm) Torque Nm (ft.lbs.)

Head mark “4 1 Head mark “7” Head mark ‘8’I I I L

M6 1.0 4.9 (3.6) 9.8 (7.2) 12 (8.7)I

M8 1.25 13 (9.4) 24(17) 28 (20)Ml0 1.25 26 (19) 49 (36) 57 (42)

-tMl0 1.5 24 (17) 44 (33) 54 (40)Ml2 1.25 46 (34) 93 (69) 103 (76)

Ml2 1 1.75 1 42(31) ) 81 (60) I96(71)

2.OL ENGINE<TURBO>

CONTENiS

CAMSHAFT AND CAMSHAFT OILSEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CAMSHAFT AND ROCKER ARMS . . . . . . 50CRANKSHAFT, FLYWHEEL, DRIVEPLATE AND CYLINDER BLOCK . . . . . . . . 73

CRANKSHAFT FRONT OIL SEAL . . . . . . 34

CRANKYAFT PULLEY . . . . . . . . . . . . . . . . 28

CRANKSHAFT: REAR OIL SEAL . . . . . . . 35

CYLINDER HEAD AND VALVE . . . . . . . . . 54CYLINDER HEAD GASKET . . . . . . . . . . . . 37ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . 23ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . 19

ENGINE ROLL STOPPER . . . . . . . . . . . . . . 22

ENGINE OIL COOLER . . . . . . . . . . . . . . . . . 79

GENERAL INFORMATION . . . . . . . . . . . . . . . .2

OIL PAN AND OIL SCREEN . . . . . . . . . . . 32

OIL PAN, OIL PUMP ANDCOUNTERBALANCE SHAFT . . . . . . . . . . . 59

PISTON AND CONNECTING ROD . . . . . . 87S~AtiNkS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 10

Basic Idle Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 14ACompression Pressure Check . . . . . . . . . . . . . 14Curb Idle Speed Check . . . . . . . . . . . . . . . . . . . 13Drive Belt Tension Check andAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . 14Ignition ‘Timing Check . . . . . . . . . . . . . . . . . . . . . 12

.: lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . 16Manifold Vacuum Check . . . . . . . . . . . . . . . . . . 16

SERVICE SPECIFICATIONS . . . . . . . . . . . . . .3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . .5TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . 42

TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . 47

TRANSAXLE MOUNTING . . . . . . . . . . . . . . 20

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .9

9Am2 2.OL ENGINE <TURBO> - General Information

GENERAL INFORMAtION

Items

TypeNumber of cylinders

Bore mm (in.)

Stroke mm (in.)

Piston displacement cm3 (cu.in.)

Compression ratio

Firing order

Counterbalance shaft

Valve timing Intake valve

Exhaust valve

Lubrication system

Oil pump typei’ c

Opens

Closes

Opens

Closes

Specifications

In-line OHV, DOHC

4

85.0 (3.35)

88.0 (3.46)

1,997 (121.9)

8.5

l-3-4-2

Equipped

21 “BTDC ” .51 “ABDC57”BBDC y I;,.

15”ATDC - ,, ;

Pressure feed-full floGr filtration

Involute gear type

LUBRICATION SYSTEM

Camshaft

Counte~alance shaft

Oil jet w

2.OL ENGINE <TURBO, L .Setiice Specifications

SERVICE SPECIFICATIONS

ItemsDrive belt(For generator)

Drive belt(For powersteering pump)

Drive belt(For A/Ccompressor)

1 Standard value 1 Limit IStandard value LimitTension N (Ibs.)Tension N (tbs.) When checkedWhen checked 245 - 490 (55.1 - 110.2)245 - 490 (55.1 - 110.2) --

When a new belt is installedWhen a new belt is installed 490-686 (110.2 -154.3) -490-686 (110.2 -154.3) -When a used belt is installedWhen a used belt is installed 392 (88.2)392 (88.2)

Deflection 1 When checked I 9.0-11.5(.35-&j) ( -mm (in.)<Referencevalue>

When a new belt is installedWhen a used belt is installed

When a used belt is installed 1 6.5-7.5 (.26-.30) -1 -1asic ignition timing at idle :ctual ianition timina at idle 1 Approx. 8: E

(750flfCIU liui llGll13 -70

HC contents ppm

1 5”BTDC f 3”’3TQc -

IO . ..” ::!*;, -1 0.5 or less+: I- .- 31’i. , ‘:f -

.-- .lw orless :: .I -,.: : -1 kPa (psi) 1250 (178) min. 935 (133)

max. 1OP 1141Compression pressure (at 250 - 400 r/min:Compression pressure difference of all cylinder kPa (psi) I \r.,

Installation dimension of front roll . ,Auto tensioner oush rod movement mm (in.)

Intake manifold vacuum kPa (in.Hg) min. 60 (18)stoboer bracket assemblv mm (in.) 43f3(1.69&.12) -

I\rMthin 1 1.041____ ._.._ - - ,~. ’Timing belt tension torque Nm (ft.lbs)

Auto tensionerr rod mmprotrusion (in.)Timingbell ~~ . .6 tension mm (in.)

Camshaft Cam height (Intake) mm (in.)Cam height (Exhaust) mm (in.)

-------- \-- #1 3.5(2.6) -

1 3.8 - 4.5 (.l.50--177) -1 5 - 7 (.20-A !8).

34.91 (1.3744) 34.41 (1.3547)34.91 p79f. 34.41 (1.3547)-5.96 (1 .oiioiI Journal diameter mm (in.)I

Cylinder head 1 Flatness of gasket surface mm (in.)12 - ,~-- .i~ , ,1 0.05 (,902a;>T\ . . 1 0.2 (.008) I- _ .-_

Grinding limit of gasket surfacel Includes/combined with cylinder block grinding mm

3) I

(in.)Overall height mm (in.) 131.9-132.1

(5.91 - 5.20)Oversize valve guide hole (both intake and exhaust) 12.05 - 12.970.05 O.S. mm (in.) (.4744-.4752) -Oversize valve guide hole (both intake and exhaust)0.25 O.S. mm (in.)Oversize valve guide hole (both intake and exhaust)0.50 O.S. mm (in.)

12.25 - 12.27(.4823- 4831) -12.50 - 12.52

-(.4921 - &?9)

I temsCylinder head

.Cytjnder head boltVal\ie ” :I

Valve sprini!

.+

Valve seatValve guide. . ,

.,:Oij +I@.

PistonPiston ring

Connecting rod ‘.Crankshaft

35JO i 35.33 (1.3898 - 1.3909) -; .’ .I, I.“’ .:’1

35.60 -~35.63 (MI1 6 -- 1.4028) - .‘,. ‘:! :,

Oversize exiiaust valve &at &g holeI

fl3r-r n ,S -mm-h \ ,L ..,. . ..I... ” 33.30-.33,33 (1.3110- 1.3122) -. I,

(It%:)/ iini. (in.) 245 (54)/4-0.0 (1.57) I ” “*

Prbje&@r+drs-.~i-.~.-ti.~ii

Side clearance 9.96N39.!4 (90310.06 - 0.12 LO02478 (11.4).or more

0.4 (.016)?l) . 0 . 2 5 LOO98)

Cyljnder bl& ,F’-‘i ,,1,1 , T o.oq (.qQ12 - .0020) -Flatness of gasket surface mm~(iri?)~~!i:~!~AI~ ;I ;O.OS (.0020) i J 0.1 (.004)l Includes/combined with cylinder block: I’/, ‘d

/Iarindina mm (in.) Il 0.2 (408)

.I ‘.,,’

Cverallheight mm (in.)Inner diameter mm (in.)

- Cylindricity mm,(in.)

j 283.9-284.1 (11.177-11.185)‘ i, , ;_85.0 (3.348) A’

SerIiici6%ifai packing and rocker cover MCPAfj~Par$oX31803+or equivalent

Bearing cap (front, rear) and cylinder head : ‘l ‘.., ;:?., A:Oil pressure gauge unit . j . . ~;s(.. r;$sp-,‘&y .’ :.:.> ,,., i$.; ; ;- y$: ,, .: : , It ,.Oil pressure switch i’ f $

Oil pan, cyliper bloc$ and thermostat case .MITSUBISHI GENUINE PART MD970389 or equivalentassembly

._ ..-_.. _t&w oil.Seal case : :

_ ,.,._ 4 _--.,__; . . . -‘I I .._

Flywheel bolt or dV&e~pt,ate.bo;a !.. i 431803!,~~~~~~~~~r,equiv~l~~t_~, .,,, ;?;‘&&.r”~ ”-'I i$ .!, ;""l'$y:“i f " 1 ; ii;

I' ‘ f

iPEClAL TOOLS TV., ..__

TooI _. :- Tool number and nan@

MB991 502

Scan tool(MUT-II) ;;;- ::I L

MD998713 ... .’‘;t

Camshaft oil seal-int:.:$qi

ajler-- .._ _ .._. .--.-.:w$;a

MD998727 1

Oil pan gasket cutter. _ . ._c- -._.: .‘. _

$%@a&d by Mi l ler *jtoothumber

DRB-III Scan tool I

@iT?e 1 i ,$ :.*-,,r’l-‘i- 1., / ,?

.I. . ,,

,.. I/

,General service tool ““’ “’(Use scraper andexcerci$e care)*i* ^... -&-...i -.... I. . . .._.__._. . .._$$&.:IJ ,i ,. ,; ;: 3. :?I

Application

idle speed inspection’

: A’-I I

. ^ ..-,. I__.-__:.. .- _... .._--__., .I.,^ , ,_ _ ..,. .-._” ____,,, *... _ .-,. _. - --..-y--“, .I_ .I

Tool number and nami

MD998781

Flywheel stopper

MD998778

Crankshaft rear oilseal installer

MB990938

~-----Handle

GENERAL SERVICETOOLMZ203827

Engine litter

MB991 453

‘En$&th;angerassembly

.

-.

MD998767 I : -:~&~~~~~~ ,+to ;tensioner installationMD998767

Tensioner pulleywrench

MD998778

Crankshaft sprocketpuller

MD998782,I.

_ ..- _ . . b._ ,... . . . _. “.Valve litter setI+:.? :< Ii ,,

: :,

MB990767

End yoke holder

Tool’number and name_di.L_ /-I

Ml$9:j193

P l u g

‘MD9981 62

PI& wrench

,_

lM~9$8;05,:.., i,._Silent shaft bearinginstaller(for front and rearbearihgs) !

MB991 603‘,.’&l&it shaft bearing,stopper

MD998375

Crankshaft front oilseal installer

MD998371

;;X$ shaft bearing

MD998372

Silent shaft bearingpuller

MD998440

Leak-down tester

(,.,,. .,

Replaced by Millertool number

General service tool(Use shop towel)

MD9981 62

,‘i

MD998285 i-”:3-.

MD998373 ,/‘. :

MB991 603I / *. . :.

C-3095-A

MD998371

-)

MD998372

$@vehting for&in substancesfro’m; riteri$transfer~$vJl ,j ,;,6

‘1,..,. * .d

--.-x~toppetifo~ use iti iemoval

Crankshaft front oil seal installa-tion : y. 4, ,:, * ,

“. ._

:.

‘Zotiirterbalanceshaft front bear-,itig removal

,.

I-

‘Counterbalance shaft rear bear-ing removal,’ (U&d with MB991 603)

.. Leakdown ted of lash adjuster

Application ioifi

Air bleeding of auto lasl’~ adj@W/ .I .>:,2, ,I!

‘I ,-. ., :

! , ’i

. .-..

,i. r _‘,.,.,! t

.

_

/II

.

. ..- ,,,...

SW-28 2.OL ENGINE <TURBO> - CrankdibfttPirlf@

CRANKSHAFT PULLEYREMOVAL AND INSTALLATION

Pre-removal Operations l Under Cover Removal

(Refer to GROUP 23A - Under Cover.)

Removal steps1. Drive belt (Generator)2. Drive belt (Power steering)3. Drive belt (A/C)4. Crankshaft pulley

AOlX0179

CAMSHAFT AND CAMSHAFT OIL SEALREMOVAL AND INSTALLATION

Pm-removal Operationl Timing Belt Front Upper Cover Removal

(Refer to P.QA-42.)

2.9 Nm 32.2 Fibs.

hTiming Belt Front Upper Cover Installation

bs.

4.9 Nm3.6 ft.lbs.

16

OlNOO42

Engine oil

6

OJAOO46 Cylinder head

Specified sealant: MOPAR Part No. 4318034 or equivalent

Removal steps1. Accelerator cable connection2. Center cover3. Spark plug cable4. Breather hose5. PCV hose6. Rocker cover7. Timing belt (Refer to P.9A-42.)8. Exhaust camshaft sprocket9. Intake camshaft sprocket

10. Front camshaft bearing cap11. Camshaft bearing cap12. Rear camshaft bearing cap (R.H.)13. Rear camshaft bearing cap (L.H.)14. Exhaust camshaft15. Intake camshaft16. Camshaft oil seal17. Semicircular packing

Installation steps.A+ 15. Intake camshaft,A+ 14. Exhaust camshaftFBI 13. Rear camshaft bearing cap (R.H.).B+ 12. Rear camshaft bearing cap (L.H.)FBI 11. Camshaft beating capbB+ 10. Front camshaft bearing capbC+ 16. Camshaft oil seal

9. Intake camshaft sprocket8. Exhaust camshaft sprocket7. Timing belt (Refer to P.9A-42.)

17. Semi-circular packing6. Rocker cover5. PCV hose4. Breather hose3. Spark plug cable2. Center cover1. Accelerator cat?@ cqn ection

(Refer to GROUP 14P‘II On-ve-tiicle Service.), ,_, -I

9A-30r

2.0L ENGINE GURBO~ + Camshaft and Uimshaft ‘Oil S&l:

REMOVAL SERVICE POINTSdA, EXHAUST CAMSHAFT SPROCKET/INTAKE

CAMSHAFT SPROCKET REMOVAL(1) Use a wrench at the hexagonal part of the camshaft

(to prevent the crankshaft from turning) to loosen thecamshaft sprocket bolt.

Plastic hammer

Intake s ide if Exhaust side I

Slits 01 A0048 I

Dowel tins

Exhaust side intake side*ol*oow

(2) Remove the camshaft sprockets.

46, FRONT CAMSHAFT BEARING CAP/CAMSHAFTBEARING CAP/REAR CAMSHAFT BEARING(R.H.)/REAR CAMSHAFT FEARING (L.H.) REMOVAL

(1) Loosen the bearing cap installati& bolts in two or threesteps.

--(2) Remove the bearing cap. ..

NOTEIf the bearing cap is difficult to remove, use a plastichammer to gently tap the rear part of the camshaft, andthen remove.

INSTALLATION SERVICE POINTS.A+ INTAKE CAMSHAFT/EXHAUST CAMSHAFT

INSTALLATION(1) Install the camshafts on the cylinder head.

CautionDo not confuse the Intake side and the exhaust side.

NOTEInstall 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.

(2) The camshaft’s dowel pins should be at the positionsshown in the figure.

2.OL ENGINE <TURBO* - i=amsf&Wand Camtihtift Oil &al

,Bq REAR CAMSHAFT BEARING CAP (R.H$REARCAMSHAFT BEARING CAP (L&.)/CAMSHAFTBEARING CAP/FROM CAMSHAFT BEARING CAPINSTALLATION

Tighten the bearing cap installation bolts to the specified torquein two or three steps.

CautionTighten uniformly, otherwise the rocker arms will not bestraight.

,C+ CAMSHAFT OIL SEAL INSTALLATIONUse the special tool to drive the camshaft oil seal into positioncarefully.

2.OL ENGINE .4tIJRBO~ i -CjjlffiZfer !Hi%d Gasket

CYLINDER HEAD GASKETREMOVAL AND INSTALLATION

1 I I

Pm-removal Operationl Fuel Line inner Pressure Release

(Refer to GROUP 14A-On-vehicle Service.)l Engine Coolant Draining

(Refer to GROUP O-Maintenance Service.)l Engine Oil Draining

(Refer to GROUP O-Maintenance Service.)

2.9 Nm

Post-installation Operationl Engine Oil Refilling

(Refer to GROUP O-Maintenancel Engine Coolant Refillin

Service.)

(Refer to GROUP 0-9aintenance Service.)I I 1

J4.9 Nm- - -. . .

?w

18, 12

ii!%- 25

01x0199

8-r65/ -2

R e m o v a l s t e p s ”1. Accelerator cable connection

$Iyfi;ot; GROUP 14F-On-vehicle

2. Air hose C3. Idle air control motor connector4. Knock sensor connector5. Heated oxygen sensor connector6. Engine coolant temperature gauge

unit connector7. Engine coolant temperature sensor

connector8. Ignition power transistor connector9. Throttle. position sensor connector

10. Capacitor connector11. Manifold’ differential pressure

sensor connector12. Injector;,connectors13. tgnition icoil connector

2 1 ' &ing OJAOO70

Engine oil

14. Camshaft position sensor connector15. Crankshaft position sensor

connector16. Air conditioning compressor

connector17. Control wiring harness18. Center cover19. Spark plug cable20. Brake booster vacuum hose

connectionFE+ 21. High-pressure fuel hose connection

22. Fuel return hose connection23. B -pass valve hose connection24. ater hose connectionVY25. Vacuum “hoses connection26. Breather;hose connection

27:. RX h o s e .connection,., .,!, a’:., < :; /, ‘,,.,

2.OL- ENGINE <TURBO> - Cylinder Head Gasket

<Cold en76 Nm-,, Nm+20 N m 8-7-11ftA8

ine> 12-15 Nm q

++90” -++90” 11 AI(58 ft.lbs.+O Ribs.+15 ft.lbs.++90” ++90”) \

a“- -I/

38.(

/34 3 6

-34 Nm-25 ft.lbs.

Cylinder head

Sealant: MOPAR Part No. 4318034 or equivalent

0 Timing belt(Refer to P.9A-42.)

28. Power steering pump29. Rocker cover30. Semicircular packing31. Heat protector (A)32. Water hose connection33. Water hose A connection

4A, ,Ed 34. Radiator upper hose ‘connectionqA, ,Ed 35. Radiator lower hose connection

LM ;I. ;h,enx$ostat case assembly

38: Flange bolts and flange nut(Refer to GROUP ll-ExhaustManifold and Turbocharger.)

.B+ 39. Cylinder head boltt. $$der head assembly

42: Gasket (A) .- 1:. :.A4 43. Cylinder head,Qask;et

01x0174

&eclfled sealant:MITSUBISHI GENUINE PARTMD970389 or equivalent

Crankshaft

sensing blade AOlXO201

AllAOllO

.C( CRANKSHAFT SENSING BLADE INSTALLATIONWhen installing, make sure the direction is correct. See figure.

.D+ CRANKSHAFT SPROCKET INSTALLATIONUse the special tool to install the crankshaft sprocket andbolt.

NOTEApply the minimum amount of-engine oil to the bearing surfaceand thread of the crankshaft bolt.

9A950 2.0L ENGINE ;clTlJRBO,~ 3Mishaft and Rock& Arms

CAMSHAFT AND ROCKER ARMSREMOVAL AND INSTALLATION

& Lubricate all

I

internal partswith engine oilduring reassembly.

t ’

11 I12

Removal steps1. Plate

FE+ 2. Camshaft oil seal.D+ 3. Circular packingbC+ 4. Bearing cap frontW+ 5. Bearing cap rearWq 6. Bearing cap No. 2bCi4 7. Bearing cap No. 5

6ENl079

,C+ 8. Bearing cap No. 3.C+ 9. Bearing cap No. 4,B+ 10. Camshaft

11. Rocker arm..A+ 12. Lash adjuster

13. Oil delivery body

atNO

C Camshaft sprocket side

W’ S’itintake side

t’ Dowel pin

04LF

C a p n u m b e rLu Symbol identifying

intake or exhaust

6EN0464

W Camshaft sprocket side11 9 7 8 10 12

53 12 486EN0192

INSTALLATION SERVICE POINTS,A4 LASH ADJUSTER INSTALLATION(1) Immerse the lash adjuster in clean diesel fuel.(2) Using the special tool (MD998442), move the plunger

up and down 4 or 5 times while pushing down lightlyon the check ball to bleed out the air.

.Bq CAMSHAFT INSTALLATION(1) Apply engine oil to journals and cams of the camshafts.(2) Install the camshafts on the cylfnder.head.

Do not confuse the intake’ camshaft’:with the exhaustone. The intake camshaft has a slit on its rear end fordriving the crankshaft position sensor.

(3) Install the crankshaft sprocket B or spacer and flangeto an end of the crankshaft. Then turn the crankshaftuntil the timing marks are lined up to set No.? cylinderto the TDC.

(4) Set the camshafts so that their dowel. pins are positionedat top.

:

.Cq BEARING CAPS INSTALLATION(1) According to the identification mark stamped on top of

each bearing cap, install the caps to the cylinder head.Only “L” or “R” is stamped on No. 1 bearing cap. CapNo. is stamped on No. 2 to No. 5 bearing caps, No.6 bearing cap has no stamping.I: For intake camshaft sideE: For exhaust camshaft side

(2) Tighten the bearing caps in the order shown two to threetimes. Tighten to specification in the final sequence.

(3) Check that the rocker arm is held in position on the lashadjuster and valve stem end.

2.OL ENGINE <TURBO>-- CamshMtiatid Robket Arms’

r

MD99871 3 I

9ENOO58

6ENOl85

,D+ CIRCULAR PACKING INSTALLATION

.E+ CAMSHAFT OIL SEAL INSTALLATION

INSPECTIONCAMSHAFT(1) Measure the 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

(3)or if looseness is evident, replace the rocker arm.Check the inside diameter. If damage or seizure ,is evident,replace the rocker arm.

LASH ADJUSTER LEAK DOWN TEST

Caution1. The lash adjuster is a precision part. Keep ‘it free

from dust and other foreign matter.2. Do not disassemble lash adjuster.3. When cleaning lash adjuster, use clean dies+ fuel

only.

2.OL, ENGINE <TURBGs - CatidhMt?iih&RBcker Mms S&!ifs

6ENO421

(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 fouror five times to bleed air.Use of the retainer helps the air bleeding of the rockerarm mounted type lash adjuster.

(3) Remove the small wire and press the plunger. If theplunger is hard to be pushed in, the lash adjuster is normal.If the plunger can be pushed in all the way readily, bleedthe lash adjuster again and test again. If the plungeris still loose, replace the lash adjuster.

CautionImmediately after air bleeding, hold lash adjuster upright to prevent fuel from spilling.

1’ Division = 1 mm LO39 in.1

MD99

7ENO438

Soale = 1 mm (.039 in.)MD9W40 1,l-l

Lashadjuster

(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 (908 to.020 in.), measure time taken for it to go down 1 mm

L (.039 in.). Replace if measured time is out of specification.

Standard value: 4-20 seconds/l mm (.04 in.)[Diesel fuel at M-20’% (59~68”F)j

2.OL -ENGINE <TURBO> - CylintW He& ti&$Val\ie -

CYLINDER HEAD AND VALVEREMOVAL AND INSTALLATION

I

I’ Lubricate all internal:m parts with engine oil1 during reassembly.

Removal stepsa, .C+ 1. Cyljnder head bolt

;. C&knkrn head assembly

.B+ 4: Retainer lock5. Valve spring retainer6. Valve spring

4W 7. Intake valve.B+ 8. Retainer lock

9. Valve spring retainerIO. Valve spring

6EN0948

11. Exhaust valve1:: ,A+ 12. Valve stem seal

13. Valve spring seat+C, .A+ 14. Valve stem seal

15. Valve sprin,g seat16. Intake valve guide17. Exhaust valve guide18. Intake valve seat19. Exhaust valve seat20. Cylinder headr _‘, . . .

ON-VEHICLE INSPECTION OF MFI COMPONENTSCOMPONENT LOCATION

NameAir conditioning compressor clutch relayAir conditioning switchCamshaft position sensorCheck engine/Malfunction indicator lampCrankshaft position sensorData link connectorEGR solenoidEngine control module (ECM)Engine coolant temperature sensorEvaporative emission purge solenoidFuel pressure solenoidFuel pump check terminalFuel pump relayHeated oxygen sensor (Front)Heated oxygen sensor (Rear)Idle air control motorIgnition coil (IgnitiQh powentransistor)

\>ylll”“l ,“a I Ici “J”‘LN’A Ignition timing adjustment connector EW Injector RN Knock sensor LU Manifold differential pressure (MDP) sensor

H0V Multiport fuel injection (MFI) relay YJ Park/Neutral position switch TX Power steering pressure switch PD Resistor IJ Throttle position sensor (with built-in closed

throttle position switch) GME Turbocharger waste gate sol8noid SY Vehicle speed sensor CQ2 Volume air flow sensor (with built-in intake airF temperature sensor and barometric pressure BK

sensor)

NOTEThe “Name” column is in alphabetical order.

6FU2077

6FU2078

6FU248o

MFI, <TURBO>.“L On-vehicle Inspectbn of MFI C&ii~ier;i@i ’ ‘f’#sesg

//LIdle air control motor-

, (stepper motor)

. *

-I

14A-240 MFI <TURBO>. 9’. On-vehici~~;In’specti~n of MFI ;CiirQYdneri& ”

Intake sidecamshaftsprocket

MFI <TURBO> - On-vehicle: ins@dtik;~6f .-MFi Componentsl&j#3&l

14F-10 FUEL SUPPLY AND ENGINE CONTROL - Accelerator Cable And P&M

ACCELERATOR CABLE AND ~-PEDALGENERAL INFORMATIONA cable-type accelerator mechanism and asuspended-type pedal have been adopted.

SERVICE SPECIFICATION

Item

Accelerator cable play mm (in.)

Standard value

l-2 (.04-.08)

LUBRICANT

Item

Accelerator pedal pin, springaccelerator cable end

Specified lubricant Quantity

MOPAR Multi-mileage Lubricant Part As requiredNo. 2525035 or equivalent

TROUBLESHOOTING213

Symptom Probable cause Remedy

Throttle valve will not Misadjusted accelerator cable Adjustfully open or close

Misadjusted auto-cruise control cable Adjust

Broken return spring Replace

Throttle lever malfunction Replace

Accelerator pedal op- Accelerator pedal wrongly tightened Repaireration not smooth(over acceleration) Misinstalled accelerator cable Repair

Accelerator cable requires lubrication Lubricate or replace

;

ON4EHICLE SERVICEACCELERiTOR CABLE CHECK ANDADJUSTMENTFor models equjpped with the auto-cruise control system,refer to GROUP 14G - On-vehicle Service.1. Turn AIC and lights OFF.

inspect and adjust at no load.2. Warm engine until stabilized at idle.3. Confirm idle speed is at prescribed rpm.4. Stop engine (ignition switch OFF).5. Confirm there are no sharp bends in accelerator cable.6. Check inner cable for correct slack.7. If there is too much slack or no slack, adjust play by

the following procedures.(13: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 theIAC motor.

4.9 Nm3.6 Ribs. dlate AOlA0021

(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 theplate back towards the throttle body by the standardvalue amount only to bring the accelerator cable playto’ the standard value. :

Standard value: l-2 mm (.04-.08 in.)(4) Tighten the adjusting bolts to the specified torque.

8. Adjust accelerator cable play and confirm throttle leverstopper touches the fixed SAS.

i: (,/.

14F-12 FUEL SUPPLY AND ENGINE CONTROL ‘- iGcelerator &6i’iiCA8d,@&@

ACCELERATOR CABLE AND PEDALREMOVAL AND INSTALLATION

Post-Installation Operation;I$ator*CaMe Adjustment, (Refer to P.l4F-10; for

to GROU 14G - On-vehicle Service.)“supped with auto-cruise control system, refer

1

I -

Grease:MOPAR Multi-Mileage LubricantPart No. 2525035 or equivalent

<Turbo>

4.9 Nm3.6ft.lbs.

k-2

I

4.93.6

4.9 Nm3.6hlbs.l

<Non-turbo>

4.9 Nm3.6ftlbs.

Accelerator cable removal steps1. Clip2. Adjusting bolts

,A+ 3. Accelerator cableAccelerator pedal removal steps4. Accelerator cable connection5. Cotter pin6. Washer7. Accelerator pedal pin

11

/13 Nm9.4 ft.lbs.

4.; Nm3.6ft.lbs.

8. Bushing9. Spring

10. Accelerator pedal arm11. Accelerator pedal bracket12. Accelerator pedal stopper

NOTEFor models equipped with auto-cruise control system, theaccelerator cabfe removaVinstallation procedures arereferred to GROUP 14G - Auto-cruise control system.

FUEL SUPPLY AND ENGINE CONTROL - Accelerator Cable And Pedal 14b!'f3

Clamp the accelerator cable so that its marking is as shown.

INSTALLATION SERVICE POINT,A(ACCELERATOR CABLE INSTALLATION <Turbo>

BODY - Hood

Bumper(small) Bumper

(large) 17 m m

10x072218X0721

00000130

mm (in.)18X0831

00000129

“I

r

:

INSTALLATION SERVICE POINT,A4 BUMPER INSTALLATION

Install the bumper as shown in the diagram.

,’t**.

INSPECTIONHOOD SWITCH CONTINUITY CHECK _, _ ,;x.,

FENDERSEALANTS

Items Specified sealants

Fender to body panel MOPAR Silicone Rubber Sealer Part No. 4026070 or equivalent

I Splash shield to fender MOPAR Silicone Rubber Sealer Part No. 4026070 or Auto GlassAdhesive and Sealer Part No. 2298825 or equivalent I

FENDERREMOVAL AND INSTALLATION

Prwemoval and post-installation OperationFront Bum

ger Removal and Installation

(Refer to .23A-71.)

18X0736

Removal steps1. Splash shield :l S@e air cjam (Refer to P.23A-79)i. Front fend& panel

Sealant:

10x0734

MOPAR Silicon Rubber Sealer Part No.4026070 or Auto Glass Adhesive and SealerPart No.2298825 or equivalent

18X0729

Sealant:MOPAR Silicon Rubber Sealer Part No.4026070 or equivalent

00000131

,,,-

FENDER

eODY - Fend&

SEALANTSI t e m s Specified sealants

I Fender to body panel I MOPAR Silicone Rubber Sealer Part No. 4026070 or equivalent I

I Splash shield to fender MOPAR Silicone Rubber Sealer Part No. 4026070 or Auto GlassAdhesive and Sealer Part No. 2298825 or equivalent

FENDERREMOVAL AND INSTALLATION

Preremoval and post-installation OperationFront Bum r Renioval and installation(Refer to .23A-71.)B”

18X0736

Removal steps1. Splash shieldl Side air dam (Refer to P.23A-79)2. Front fender panel

18X0734

Sealant:MOPAR Silicon Rubber Sealer Part No.4026070 or Auto Glass Adhesive and SealerPart No.2298825 or equivalent

18X0729

Sealant:MOPAR Silicon Rubber Sealer Part No.4026070 or equivalent

00000131

BODY i Front Bumper g?&p:*’

FRONT BUMPER ‘!$

REMOVAL AND INSTALLATION

Prs-removal and Post-installation OperationS lash shield Removal and Installation&efer to GROUP 23A-61.)

Removal steps1. Fog light2. Front side-marker light3. Front bumper center plate4. Front bumper assembly

;. Fc$t bumper corner plate

7: Front fascia bracket

23A-72 BODY - Pro’nt Biimper-

DISASSEMBLY AND REASSEMBLY

Disassembly steps1. Fog light hole cover2. Front license plate bracket3. Bolt plate4. Front bumper side plate

5. Front bumper reinforcement6. Front bumper core7. Front bumper stay assembly8. Front bumper face

REAR BUMPERREMOVAL AND INSTALLATION

6

Removal steps1. Rear panel garnish2. Rear combination light3. Rear bumper upper plate (A)4. Rear bumper upper plate (B)

~16x0676

5. Connector harness6. Rear bumper assembly7. Rear bumper side plate

BODY<- Rear Burnber

DISASSEMBLY AND REASSEMBLY

Alox1oos

Disassembly steps1. Rear bumper lower plate2. Rear bumper reinforcement3. Rear bumper core

4. Rear bumper stay assembly5. Rear bumper face

GARNISHES

BODY -; ~GarnisheS

REMOVAL AND INSTALLATION

13Nm

18X067500003740

Front deck garnish removal steps1. Wiper arm assembly2. Front deck garnish

Rear panel garnish removal stepsl Rear end trim

(Refq to P.$JA-90)3. Rea? ,-panel garnish

23A-76

MOLDINGS

BODY, ‘- Moldings

SEALANT AND ADHESIVEItems

Side protector molding

MOLDINGS

Specified sealant and adhesive

3M ATD Part No. 6382 or equivalent and3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent

REMOVAL AND INSTALLATION

Adhesive tape:3M ATD Part No. 6382 or equivalent15 mm (59 in.) wide and 1.2 mm (.047 in.) thick

Adhesive:3M ATD Part No. 8606 Super Fast Urethane Primer or equivalent

1. Windshield molding(Refer to P.23A-10)

2. Belt line molding(Refer to P.23A-50)

+A, .A+ 3. Side protector molding4. Liftgate molding

(Refer to P.23A-18)

l Drip line weatherstrip(Refer to P.23A-50)

s Door weatherstri holder(Refer to P.23AJO)

5. Drip molding

BODY - Moldings

Masking tape

Fishing line\ I

Double-sided tape

\I

. Adhesive

Aesin spatula

REMOVAL SERV’ICE POINT+A, SIDE PROTECTOR MOLDING REMOVAL(1) Apply masking tape to the outside circumference of the

side protector molding.

(2) Insert fishing line [0O.8 mm (.03 in.)] in between the bodyand the side protector molding, pull both ends alternatelyto cut the adhesive section and remove the side protectormolding.

Caution1. When reusing the side protector Molding, pull the

fishing line along the edge of the body so as notto damage the edge of the side protector Molding.

2. If the adhesive Is difficult to remove, heat it to40°C (104°F).

(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.

(6) Use a shop towel moistened with degreaser (MOPARSUPER KLEEN or equivalent) to wipe the body surface.

INSTALLATION SERVICE POINT,A+ SIDE PROTECTOR MOLDING INSTALLATIONDouble-sided tap6 affixing to the side protector Molding(when reusing)(1) Scrape off the double-sided tape with a resin spatula

or gasket scraper.

BfJDV - MotdtnQs-

Primer

(2) Use a shop towel moistened with degreaser (MOPARSUPER KLEEN or equivalent) to wipe the moldingsurface.

(3) Remove a small portion of the residual adhesive.

CautionDo not remove all of the residual adhesive.

(4) Soak a sponge in the primer, and apply evenly to theside protector molding in the places shown in the illustra-tion.

Specified primer: 3M ATD Part No. 8608 Super FastUrethane Prim* di’&@G!l~nt?j ‘!.: 6.

Caution ,‘j ,.:: ‘,.r.i. Always apply it on the entiie’ I&x%+-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 3g. minutes.

(6) Affix the specified double-sided tape to the side protectormolding.

Specified adhesive tape:3M ATD Part No. 6382 or equivalenf15 mm (59 in.) wide and %+~mrn.?#J47&L)~ thick.* ‘., * ?.& :i.&$ ”II .“‘<p+“:,+>

’ ( ,_ :.

Side protector molding installation(1) Tear off the double-sided tape backing paper.

NOTEIf you attach the adhesive tape to the edge of the backingpaper, it will be easy to tear off. -

Al8XO607

(2) Install the side protector molding.

NOTEIf the double-sided tape is difficult to affix during winter,etc., warm the bonding surfaces of the body and theside protector molding to about 40-6O”C (104-140°F)before affixing the tape.

(3) Firmly press in the side protector -molding.

AERO PARTS

BODY - Aero Patts

SEALANT AND ADHESIVEI

Items

Door garnish, Side air dam

Specified sealant and adhesive

3M ATD Part No. 6382 or equivalent and3MATD Part No. 8608 Super Fast Urethane Primer or equivalent

AERO PARTSREMOVAL AND INSTALLATION

Adhesive tape:3M ATD Part No. 6382 or equivalent4 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+A, ,A1 1. Door garnish

Side air dam removal steps

BODY * : Awe Paits

nm (in.) - 10x0133

Rear spoiler removal stepsl Liftgate lower trim (Refer to P.23A-90)1. Connector harness2. Rear spoiler assembly

18X0673

0 0 0 0 3 7 5 1

3. High mounted stop light4. Dua!-!oc\ fastener (small)5. Dual-lock fastener (large)

REMOVAL SERVICE POINT+A, DOOR GARNISH/FRONT SIDE-AIR DAM/REAR

SIDE-AIR DAM REMOVALCarry out..@b same procedure as for the side protector mold-ings. (Refer to P.23A-76.)

INSTALLATION SERVICE POINT.A+ DOOR GARNISH/FRONT SIDE-AIR DAM/REAR

SIDELAIR DAM INSTALLATIONCarry out the same procedure as for the side protector mold-ings. (Refer to P.23A-76.)