Engine Mechanical:
Disassembly, inspection, assembly, torque specifications, timing, lubrication, cooling system, turbocharger system
Engine Management And Emissions:
ECM, sensors (O2, MAP, MAF, etc.), actuators, fuel injection, ignition system, evaporative emission control (EVAP), EGR, OBD-II diagnostics
Transmission Manual:
Gears, clutch, synchronizers, shift forks, lubrication, overhaul, troubleshooting (e.g., Getrag 6-speed)
Transmission Automatic Or Dct:
SST (Super-Sport Transmission) details, mechatronics, torque converter, hydraulic control, programming, fluid specifications
Drivetrain And Axles:
Front and rear differentials, ACD (Active Center Differential), AYC (Active Yaw Control) system, driveshafts, CV joints, propeller shaft
Suspension And Steering:
Front struts, rear shocks, springs, control arms, bushings, steering rack, power steering system, wheel alignment specifications
Brakes And Wheel Hub:
Brake system components (calipers, rotors, pads, ABS, EBD, brake booster, master cylinder), parking brake, wheel bearings, hub assemblies, bolt pattern
Body And Exterior:
Body panel removal and installation, doors, hood, trunk, bumpers, fenders, spoilers, glass, seals, weatherstripping, paint codes
Interior And Trim:
Dashboard, seats, door panels, headliner, carpeting, HVAC controls, airbags, seatbelts
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn
Climate Control HVAC:
A/C system components, refrigerant, compressor, condenser, evaporator, heater core, blower motor, controls
Safety Systems:
Airbag system (SRS), seatbelt pre-tensioners, impact sensors, ABS, traction control, stability control (ASC)
Infotainment And Audio:
Radio, speakers, navigation system (if equipped), amplifier, antenna
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, spark plug replacement
Diagnostic Procedures:
Troubleshooting charts, fault code interpretation (DTCs), symptom-based diagnostics, wiring harness testing
Major Component Overhaul:
Engine rebuild, transmission rebuild, differential overhaul, turbocharger replacement
Component Replacement:
Step-by-step instructions for replacing parts like alternators, starters, fuel pumps, radiators, brake calipers, suspension arms, etc.
Calibration And Programming:
ECU re-flashing, transmission control module (TCM) programming, steering angle sensor calibration, throttle body relearn procedures
Structural Repairs:
Frame straightening, body panel replacement, welding procedures (if applicable to the manual's scope)
Electrical Troubleshooting:
Using multimeters, oscilloscopes, interpreting wiring diagrams, diagnosing circuit faults
Depth Level:
Comprehensive Factory Level - Covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Tools References:
Information on necessary diagnostic tools, scan tools, and specialized equipment
Torque Specifications:
Detailed torque values for all fasteners across various systems
Clearances And Tolerances:
Specific measurements for component clearances during assembly and rebuilds
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled
Displacement:
2.0 Liters (1998 cc)
Bore X Stroke:
86.0 mm x 86.0 mm
Horsepower Hp:
291 hp @ 6,500 rpm (US Market GSR/MR)
Torque Lb-Ft:
300 lb-ft @ 3,500 rpm (US Market GSR/MR)
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger Type:
MHI TD05H-15G or similar Mitsubishi Heavy Industries turbocharger
Engine Oil Type:
SAE 5W-30 API SN, ILSAC GF-5 (or equivalent ester-based synthetic)
Engine Oil Capacity Liters:
4.5 Liters (4.8 US Quarts) with filter change
Coolant Type:
Long-life coolant, ethylene glycol based (e.g., Mitsubishi DiaQueen Super Long Life Coolant)
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions recommended for performance vehicles)
Engine Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for iridium-tipped plugs
Transmission Fluid Change Manual:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) - highly recommended to check frequently
Transmission Fluid Change Dct:
Every 24,000 miles (39,000 km) or 24 months for TC-SST fluid change (critical)
Transfer Case Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km)
Rear Differential Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km)
Clutch Wear Manual:
High-performance clutches can wear faster under aggressive driving. Dual-mass flywheel can also be a wear item.
Turbocharger Failure:
Can occur due to oil starvation, improper cooling, or debris ingestion. Regular oil changes are crucial.
Engine Internal Wear:
While robust, sustained high-boost operation without proper maintenance can lead to premature wear of rings and bearings.
Dct Tc Sst Issues:
Mechatronic unit failures, clutch pack wear, and solenoid issues can occur, especially if fluid maintenance is neglected. Requires specialized knowledge for repair.
Acd Ayc System Faults:
Can experience electrical issues or solenoid failures, leading to error codes and loss of functionality. Requires specialized diagnostic tools.
Exhaust Manifold Cracking:
Some early 4B11T engines experienced exhaust manifold cracking due to heat cycling. Aftermarket solutions are available.
Bilstein Strut Leaks:
Performance dampers (e.g., Bilstein on MR models) can develop leaks over time, especially with aggressive use.