Mitsubishi L400 Delica Space Gear Starwagon 1994-1999 Workshop Repair Service Manual PDF - MMTBSL400OPES.zip

A full factory-style repair guide featuring Electrical Wiring Diagrams for the Mitsubishi L400 covering model years 1994 through 1999, packed with every detail needed to service, troubleshoot, fix, and rebuild the vehicle to professional workshop standards.

The Mitsubishi L400 1994-1999 workshop service repair manual contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

MAKE: Mitsubish

YEAR: 1994, 1995, 1996, 1997, 1998, 1999 (2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 applicable)

MODEL: Delica L400 (Space Gear, Starwagon)

PRODUCT DETAILS:

Total Pages: 2,211 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

Chassis & Engine....1

'95....1

PWEE9410_L400_95_CHASSIS_00....1

GENERAL....1

HOW TO USE THIS MANUAL....2

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS....2

DEFINITION OF TERMS....2

INDICATION OF TIGHTENING TORQUE....2

MODEL INDICATIONS....3

EXPLANATION OF MANUAL CONTENTS....4

HOW TO USE TROUBLESHOOTING / INSPECTION SERVICE POINTS....6

TROUBLESHOOTING CONTENTS....6

HOW TO USE THE INSPECTION PROCEDURES....7

CONNECTOR MEASUREMENT SERVICE POINTS....8

CONNECTOR INSPECTION....9

INSPECTION SERVICE POINTS FOR A BLOWN FUSE....10

POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS....10

VEHICLE IDENTIFICATION....11

VEHICLE INFORMATION CODE PLATE....11

MODELS....12

MODEL CODE....13

CHASSIS NUMBER....14

ENGINE MODEL NUMBER....15

MAJOR SPECIFICATIONS....16

PRECAUTIONS BEFORE SERVICE....19

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)-AIR BAG....22

SUPPORT LOCATIONS FOR LIFTING AND JACKING....26

SUPPORT POSITIONS (OR A GARAGE JACK AND AXLE STANDS....26

SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT AND H-BAR LIFT....27

STANDARD PARTS-TIGHTENING-TORQUE TABLE....28

MAIN SEALANT AND ADHESIVE TABLE....29

PWEE9410_L400_95_CHASSIS_11....31

ENGINE....31

4G6....33

GENERAL INFORMATION....34

SERVICE SPECIFICATIONS....36

SEALANT....36

SPECIAL TOOLS....37

SERVICE ADJUSTMENT PROCEDURES ....39

DRIVE BELT TENSION INSPECTION AND ADJUSTMENT....39

IGNITION TIMING INSPECTION AND ADJUSTMENT....40

IDLE SPEED INSPECTION AND ADJUSTMENT....41

IDLE FEEDBACK CHECK....42

IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT FOR ABS....44

COMPRESSION PRESSURE INSPECTION....45

INTAKE MANIFOLD VACUUM INSPECTION....46

LASH ADJUSTER CHECK....47

SERVICE ADJUSTMENT PROCEDURES ....49

DRIVE BELT TENSION INSPECTION AND ADJUSTMENT....49

IGNITION TIMING INSPECTION AND ADJUSTMENT....49

IDLE SPEED INSPECTION....50

IDLE MIXTURE INSPECTION....51

COMPRESSION PRESSURE INSPECTION....51

INTAKE MANIFOLD VACUUM INSPECTION....53

LASH ADJUSTER CHECK....53

CAMSHAFT....54

CAMSHAFT OIL SEAL....56

OIL PAN, OIL SCREEN....59

CYLINDER HEAD GASKET....61

TIMING BELT, TIMING BELT B....68

CRANKSHAFT FRONT OIL SEAL....74

CRANKSHAFT REAR OIL SEAL....76

ENGINE ASSEMBLY....78

4D5....84

GENERAL INFORMATION....85

SERVICE SPECIFICATIONS....87

SEALANTS....87

SPECIAL TOOLS....88

SERVICE ADJUSTMENT PROCEDURES....89

DRIVE BELT TENSION INSPECTION AND ADJUSTMENT....89

VALVE CLEARANCE INSPECTION AND ADJUSTMENT....91

INJECTION TIMING INSPECTION AND ADJUSTMENT....92

IDLE SPEED INSPECTION AND ADJUSTMENT....95

IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT-FOR A/C....95

IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT - FOR ABS....96

COMPRESSION PRESSURE INSPECTION....96

TIMING BELT TENSION ADJUSTMENT....98

TIMING BELT "B" TENSION ADJUSTMENT....99

CRANKSHAFT PULLEY....100

CAMSHAFT, CAMSHAFT OIL SEAL....101

OIL PAN, OIL SCREEN....104

CYLINDER HEAD GASKET....106

TIMING BELT/TIMING BELT B....109

CRANKSHAFT FRONT OIL SEAL....113

CRANKSHAFT REAR OIL SEAL....114

ENGINE ASSEMBLY....116

PWEE9410_L400_95_CHASSIS_12....120

LUBRICATION....120

GENERAL INFORMATION....121

LUBRICANTS....122

SERVICE ADJUSTMENT PROCEDURES....122

ENGINE OIL INSPECTION....122

ENGINE OIL REPLACEMENT....122

OIL FILTER REPLACEMENT....124

OIL LEVEL WARNING SYSTEM INSPECTION....124

ENGINE OIL COOLER <4D56>....126

PWEE9410_L400_95_CHASSIS_13....127

FUEL....127

MULTIPOINT FUEL INJECTION (MPI)....129

GENERAL INFORMATION....130

SERVICE SPECIFICATIONS....133

SEALANT....133

SPECIAL TOOLS....133

TROUBLESHOOTING....135

SERVICE ADJUSTMENT PROCEDURES....207

THROTTLE BODY (THROTTLE VALVE AREA) CLEANING....207

IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT....207

FIXED SAS ADJUSTMENT....209

BASIC IDLE SPEED ADJUSTMENT....209

FUEL PRESSURE TEST....211

FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE)....214

FUEL PUMP OPERATION CHECK....214

ON-VEHICLE INSPECTION OF MPI COMPONENTS....215

COMPONENT LOCATION....215

CONTROL RELAY INSPECTION....218

INTAKE AIR TEMPERATURE SENSOR INSPECTION....219

ENGINE COOLANT TEMPERATURE SENSOR INSPECTION....219

THROTTLE POSITION SENSOR INSPECTION....220

IDLE POSITION SWITCH INSPECTION....220

OXYGEN SENSOR INSPECTION....221

INJECTOR INSPECTION....222

IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) INSPECTION....223

PURGE CONTROL SOLENOID VALVE INSPECTION....223

EGR CONTROL SOLENOID VALVE INSPECTION....223

INJECTOR....224

THROTTLE BODY....226

ELECTRONIC CONTROLLED CARBURETTOR....227

GENERAL INFORMATION....228

SERVICE SPECIFICATIONS....229

SEALANT....230

SPECIAL TOOLS....230

SERVICE ADJUSTMENT PROCEDURES....231

CARBURETTOR APPEARANCE....231

THROTTLE POSITION SENSOR (TPS) ADJUSTMENT....232

CARBURETTOR SECONDARY VALVE OPERATION INSPECTION....232

CARBURETTOR ACCELERATION PUMP INSPECTION....233

CHOKE VALVE INSPECTION....233

ELECTRIC AUTO CHOKE INSPECTION....234

ELECTRIC CHOKE HEATER INSPECTION....235

ELECTRIC CHOKE RELAY INSPECTION....235

CHOKE BREAKER SYSTEM INSPECTION....236

CHOKE BREAKER OPENING INSPECTION AND ADJUSTMENT....236

FAST IDLE INSPECTION AND ADJUSTMENT....237

AUXILIARY ACCELERATOR PUMP (AAP) INSPECTION....239

VACUUM SWITCH CONTROL VACUUM INSPECTION....239

FUEL PUMP CONTROL SYSTEM INSPECTION....240

INSPECTION PROCEDURES USING THE ECI CHECKER....241

COMPONENT LOCATION....243

ENGINE COOLANT TEMPERATURE SENSOR INSPECTION....245

THROTTLE POSITION SENSOR (TPS) INSPECTION....245

ENGINE SPEED SENSOR (IGNITION COIL (-) TERMINAL) INSPECTION....246

VACUUM SWITCH INSPECTION....246

OXYGEN SENSOR INSPECTION....247

FEEDBACK SOLENOID VALVE (FBSV) INSPECTION....247

STOW CUT SOLENOID VALVE (SCSV) INSPECTION....248

CARBURETTOR....249

DIESEL FUEL....250

GENERAL INFORMATION....251

SERVICE SPECIFICATIONS....251

SPECIAL TOOL....251

SERVICE ADJUSTMENT PROCEDURES....251

FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT....251

ENGINE IDLING SPEED INSPECTION AND ADJUSTMENT....251

FUEL DISCHARGE PREVENTION....251

EVACUATION OF WATER FROM FUEL FILTER....252

EVACUATION OF AIR FROM FUEL LINE....252

FUEL FILTER CARTRIDGE REPLACEMENT....252

FUEL INJECTION PUMP INSPECTION....253

BOOST COMPENSATOR INSPECTION....253

INJECTION NOZZLE INSPECTION AND ADJUSTMENT....253

INJECTION NOZZLE....255

INJECTION PUMP....257

FUEL SUPPLY AND ENGINE CONTROL....259

GENERAL INFORMATION....260

SERVICE ADJUSTMENT PROCEDURES....260

ACCELERATOR CABLE INSPECTION AND ADJUSTMENT....260

FUEL FILTER CARTRIDGE REPLACEMENT ....261

POWER RELAY CHECK ....261

FUEL TANK....262

ACCELERATOR CABLE AND PEDAL....265

FUEL FILTER ....267

FUEL FILTER ....268

PWEE9410_L400_95_CHASSIS_14....270

COOLING....270

GENERAL INFORMATION....271

SERVICE SPECIFICATIONS....271

LUBRICANT....271

SEALANTS....272

SERVICE ADJUSTMENT PROCEDURES....272

RADIATOR CAP VALVE OPENING PRESSURE....272

ENGINE COOLANT REPLACEMENT....272

CONCENTRATION MEASUREMENT....274

COOLING FAN....275

THERMOSTAT....277

WATER PUMP....280

WATER HOSE AND WATER PIPE....282

RADIATOR....285

PWEE9410_L400_95_CHASSIS_15....287

INTAKE AND EXHAUST....287

SERVICE SPECIFICATIONS....288

SPECIAL TOOL....288

SEALANT....288

SERVICE ADJUSTMENT PROCEDURES....289

INTAKE MANIFOLD VACUUM INSPECTION....289

TURBOCHARGER SUPERCHARGING INSPECTION....289

WASTE GATE ACTUATOR INSPECTION....289

AIR TEMPERATURE SWITCH INSPECTION....290

POWER RELAY CHECK....290

AIR CLEANER....291

INTERCOOLER AND INTERCOOLER FAN-ECU....294

INTAKE MANIFOLD....295

<4G63 (CARBURETTOR)>....295

<4G63 (MPI), 4G64>....297

INTAKE AND EXHAUST MANIFOLD, TURBOCHARGER <4D56>....299

EXHAUST MANIFOLD <4G63, 4G64>....301

EXHAUST PIPE AND MAIN MUFFLER....302

PWEE9410_L400_95_CHASSIS_16....305

ENGINE ELECTRICAL....305

CHARGING SYSTEM....306

GENERAL INFORMATION....306

SERVICE SPECIFICATIONS....307

SPECIAL TOOL....308

SERVICE ADJUSTMENT PROCEDURES....308

ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST....308

OUTPUT CURRENT TEST....309

REGULATED VOLTAGE TEST....311

CHECKING WITH AN ANALYZER....313

ALTERNATOR....315

STARTING SYSTEM....316

GENERAL INFORMATION....316

IGNITION SYSTEM....317

GENERAL INFORMATION....317

SERVICE SPECIFICATIONS....319

LUBRICANT....320

SPECIAL TOOLS....320

SERVICE ADJUSTMENT PROCEDURES....320

CENTRIFUGAL ADVANCE CONTROL DEVICE INSPECTION ....320

VACUUM ADVANCE CONTROL DEVICE INSPECTION ....321

IGNITION COIL INSPECTION....321

POWER TRANSISTOR INSPECTION ....322

RESISTIVE CODE INSPECTION....323

SPARK PLUG CHECK AND CLEANING....323

WAVE-FORM INSPECTION USING AN ANALYZER (Ignition Primary and Secondary Voltage wawe-forms)....324

DISTRIBUTOR....331

GLOW SYSTEM....333

GENERAL INFORMATION....333

SERVICE SPECIFICATIONS....334

SEALANT....334

SERVICE ADJUSTMENT PROCEDURES....335

SELF-REGULATING GLOW SYSTEM INSPECTION....335

GLOW CONTROL UNIT INSPECTION....336

GLOW PLUG RELAY INSPECTION....338

GLOW PLUG INSPECTION....338

ENGINE COOLANT TEMPERATURE SENSOR INSPECTION....339

GLOW PLUG....340

PWEE9410_L400_95_CHASSIS_17....341

EMISSION CONTROL....341

EMISSION CONTROL ....343

GENERAL INFORMATION....343

EMISSION CONTROL DEVICE REFERENCE TABLE....343

SERVICE SPECIFICATIONS....344

SEALANT....344

VACUUM HOSE....344

VACUUM HOSE PIPING DIAGRAM....344

VACUUM CIRCUIT DIAGRAM....345

VACUUM HOSE INSPECTION....345

VACUUM HOSE INSTALLATION....345

CRANKCASE EMISSION CONTROL SYSTEM....346

GENERAL INFORMATION....346

SYSTEM DIAGRAM....346

COMPONENT LOCATION....346

POSITIVE CRANKCASE VENTILATION SYSTEM INSPECTION....347

PCV VALVE INSPECTION....347

EVAPORATIVE EMISSION CONTROL SYSTEM....348

GENERAL INFORMATION....348

SYSTEM DIAGRAM....348

COMPONENT LOCATION....348

PURGE CONTROL SYSTEM INSPECTION....349

PURGE PORT VACUUM INSPECTION....349

PURGE CONTROL SOLENOID VALVE INSPECTION....350

EXHAUST GAS RECIRCULATION (EGR) SYSTEM....351

GENERAL INFORMATION....351