Engine Mechanical:
Complete engine disassembly, assembly, rebuild procedures for all available engine variants (4G63, 6A12, 6A13).
Fuel System:
Fuel injection systems (MPI), fuel pumps, injectors, fuel filters, fuel pressure regulation, evaporative emission control (EVAP).
Ignition System:
Ignition coils, spark plugs, distributor (if applicable), ignition timing, ignition control module.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant types, fan operation, pressure testing.
Exhaust System:
Exhaust manifolds, catalytic converters, mufflers, oxygen sensors (O2 sensors), emissions control systems.
Transmission Manual:
Manual transmission disassembly, assembly, clutch replacement, synchronizers, gears, bearings, fluid specifications.
Transmission Automatic:
Automatic transmission disassembly, assembly, torque converter, valve body, planetary gear sets, fluid specifications, shift solenoid operation.
Drivetrain AWD:
All-Wheel Drive (AWD) system for VR-4 models: transfer case, viscous coupling, center differential, rear differential, axle shafts, maintenance.
Suspension Front:
MacPherson strut front suspension: control arms, ball joints, tie rods, sway bar, bushings, strut replacement, alignment specifications.
Suspension Rear:
Multi-link rear suspension: trailing arms, control arms, shock absorbers, springs, bushings, alignment specifications.
Steering System:
Power steering system: pump, rack and pinion, hoses, fluid types, steering angle sensor (if applicable).
Brake System:
Front and rear disc brakes, ABS (Anti-lock Braking System) operation and components, brake fluid specifications, bleeding procedures, caliper and rotor replacement.
Electrical System Charging:
Alternator, battery, starter motor, charging system testing and repair.
Electrical System Lighting:
Headlights, taillights, interior lights, fog lights, bulb types, wiring diagrams for lighting circuits.
Electrical System Instruments:
Instrument cluster, gauges (speedometer, tachometer, fuel, temperature), warning lights, diagnostic connectors (OBD-I).
Electrical System ECU:
Engine Control Unit (ECU) diagnostics, sensor inputs (MAP, TPS, ECT, CKP, CMP), actuator outputs, wiring diagrams.
HVAC System:
Heating, Ventilation, and Air Conditioning (HVAC) system: A/C compressor, refrigerant, evaporator, condenser, heater core, blower motor, control panels.
Body Interior:
Interior trim removal and installation, seat adjustments, dashboard components, door panels, headliner.
Body Exterior:
Body panel removal and installation (fenders, hood, trunk), door mechanisms, glass replacement, bumper assemblies.
Body Chassis:
Frame construction, rust prevention, underbody coatings, jacking points, towing information.
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common drivability issues, electrical faults, and mechanical problems. Diagnostic trouble codes (DTCs) for OBD-I systems.
Engine Repair:
Engine overhaul, piston and ring replacement, cylinder head removal and installation, valve adjustments, timing belt replacement (critical for 4G63).
Transmission Overhaul:
Complete teardown and rebuilding of both manual and automatic transmissions, including torque converter replacement and clutch pack inspection/replacement.
Brake Service:
Brake pad replacement, rotor resurfacing/replacement, caliper rebuilding, ABS system diagnostics and repair, brake bleeding procedures.
Suspension Replacement:
Replacement of struts, shocks, control arms, ball joints, tie rod ends, bushings, and springs.
Electrical Component Testing:
Testing and replacement of sensors, actuators, relays, fuses, motors, and ECUs using multimeter and oscilloscope procedures.
HVAC Repair:
Diagnosis and repair of A/C system leaks, refrigerant recharging, compressor replacement, blower motor repair, and heater control valve replacement.
Bodywork Repair:
Procedures for removing and installing body panels, door hinges, window regulators, and exterior trim pieces.
Wiring Diagrams:
Detailed wiring schematics for all major electrical systems, including engine control, lighting, power windows, and more.
Torque Specifications:
Comprehensive list of torque specifications for all critical fasteners throughout the vehicle.
Depth Level:
Factory Level - Covers everything from basic maintenance to full engine and transmission rebuilds.
Diagnostic Capabilities:
Advanced diagnostic procedures using OBD-I codes and sensor data analysis.
Rebuild Procedures:
Detailed, step-by-step instructions for complete engine, transmission, and differential rebuilds.
Customization Options:
Information relevant to modifications, particularly for the VR-4 model (e.g., turbocharger systems).
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (using quality synthetic or mineral oil).
Air Filter Replacement Interval:
Every 15,000 miles (24,000 km) or 12 months.
Fuel Filter Replacement Interval:
Every 30,000 miles (48,000 km) or 24 months.
Cabin Air Filter Replacement Interval:
Not standard on all trims, if equipped, every 15,000 miles (24,000 km) or 12 months.
Coolant Flush Interval:
Every 30,000 miles (48,000 km) or 24 months.
Engine Oil Spec:
API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for exact recommendation based on climate).
Engine Oil Capacity 4G63:
Approx. 4.5 quarts (4.3 liters) with filter change.
Engine Oil Capacity V6:
Approx. 5.0-5.3 quarts (4.7-5.0 liters) with filter change.
Brake Fluid Spec:
DOT 3 or DOT 4.
Power Steering Fluid Spec:
Genuine Mitsubishi Power Steering Fluid or Dexron II/III ATF.
Timing Belt Failure:
Critical failure point on 4G63 engines if not replaced at recommended intervals. Causes severe engine damage (bent valves, piston damage).
Oil Leaks:
Common valve cover gasket and oil pan gasket leaks due to age and material degradation.
Suspension Wear:
Worn control arm bushings, ball joints, and tie rod ends can lead to clunking noises and poor handling.
Automatic Transmission Issues:
Some models may experience rough shifting or slipping if fluid and filter are not regularly maintained.
A/C System Failures:
Leaks in the A/C system (hoses, seals) are common with age, leading to loss of refrigerant.
Oxygen Sensor Failure:
Can lead to poor fuel economy and increased emissions.
Interior Electronics:
Power window regulators, door lock actuators, and instrument cluster illumination can fail over time.
