Mitsubishi Galant

1990-2001 of release

Repair and car operation



Mitsubishi Galant
+ Identification numbers of the car
+ Controls
+ Options and routine maintenance
+ The engine
+ Cooling and heating systems
+ The power supply system and release
+ Engine electric equipment
+ Control systems of the engine
- Manual transmission
   + 5-step manual box of a gear change (РКПП)
   - Automatic transmissions (АТ)
      The general information and functioning principle
      Problem diagnostics АТ - the general information
      The adjustments made without removal АТ from the car
      Removal and pallet installation картера АТ
      Removal, installation and adjustment of the gauge-switch of the permission of start
      Removal and installation АТ
      Major repairs АТ
   + Distributing box
+ Coupling and трансмиссионная a line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Problem diagnostics АТ - the general information

Refusals АТ occur on one of following five reasons more often:

a) Decrease in efficiency of return of the engine;
b) Infringement of adjustments;
c) Malfunction of hydraulics;
d) Mechanical damages;
e) Refusals of the onboard processor / its alarm chain.

The problem diagnostics always should begin with the most simple checks: estimate level and condition ATF (see the Head of Adjustment and routine maintenance), check up adjustment of drives of a gear change and throttle заслонки. Further, spend trial runs of the car for the purpose of definition of efficiency of the brought corrections. If to eliminate a problem it was not possible, it is necessary to drive away the car on a car repair shop for more detailed diagnostics with application of the special equipment. The description of infringements of functioning АТ some of symptoms is resulted in the Section devoted to a problem diagnostics of knots and systems of the car in the beginning of the present Management.

The list of the most typical refusals АТ

The corresponding subsection in the Section devoted to a problem diagnostics of knots and systems of the car in Introduction to the present Management see also.


Transmission provides car movement forward or back

adjustment of draughts of switching Is broken;
level Has fallen hydraulic pressure as a result of infringement of passableness of the oil filter, wrong installation клапанной assemblages, or damages редукционного the valve / the operating valve of the converter of rotation ATF/is underestimated.

Movement is absent in positions “D” and “2”

It is faulty a lobby муфта couplings

Forward transfers do not function

It is faulty back муфта couplings;
accumulator "N-D" valve Is faulty.

The engine глохнет at switching of transmission from position “N” in position “D” or “R”

the Engine does not develop demanded capacity;
assemblage АТ is incorrectly established клапанная;
the control ball клапанной assemblages Is jammed;
the valve of coupling of the converter of rotation, or accumulator "N-D" valve Is faulty.

The box revolves at advance


level ATF / hydraulic pressure Has fallen;
It is faulty one-pass муфта couplings;
assemblage Is faulty клапанная;
it is worn excessively out back муфта couplings.

The box revolves at backspacing inclusion


level ATF / hydraulic pressure Has fallen;
the brake contour of the lowered transfers/backspacing Is faulty;
it is worn excessively out a lobby муфта couplings;
assemblage Is faulty клапанная.

Too weak reception of the car takes place at movement on 2nd and 3rd transfers


level ATF / hydraulic pressure Has fallen;
the rotation converter Is faulty;
It is faulty back муфта couplings;
It is faulty/is wrong assemblage is established клапанная;
brake assemblage of inclusion of a mode kickdown Is faulty;
adjustment of the servo-driver of a mode kickdown Is broken.

Efficiency of braking by the engine in a mode “L” is lowered


assemblage Is faulty клапанная;
brake assemblage of modes of the lowered transfers/backspacing Is faulty.

Turns останова the rotation converter are excessively underestimated


capacity developed by the engine Is insufficient;
the rotation converter Is faulty.

Turns останова the rotation converter are excessively overestimated


level ATF / hydraulic pressure Has fallen;
It is faulty one-pass муфта couplings;
It is faulty a lobby муфта couplings;
It is faulty back муфта couplings;
assemblage Is faulty клапанная.

The car moves at translated in position “N” transmissions


It is faulty forward or back муфта couplings.

Transmission is not translated in парковочное position


adjustment of a drive of switching Is broken;
the mechanism of inclusion of position “Р” Is faulty.

Discrepancy between chosen and actually joining modes takes place


level ATF / hydraulic pressure Has fallen;
assemblage Is faulty клапанная;
It is faulty a lobby муфта couplings;
the brake tape of inclusion of a mode kickdown Is faulty;
adjustment of the servo-driver of a mode kickdown Is broken;
the operating regulator Is faulty.

There is no transmission switching on a hill-climbing gear in any of positions


serviceability of functioning throttle заслонки Is broken;
the valve of switching of 1/2 transfers Is faulty;
the valve of switching of 2/3 transfers Is faulty;
the operating regulator Is faulty.

Serviceability of switching of transmission from 1st transfer on 2nd is broken


level ATF / hydraulic pressure Has fallen;
passableness of the oil filter Is broken;
the brake tape of a mode kickdown Is faulty;
adjustment of the servo-driver of a mode kickdown Is broken;
It is faulty a lobby муфта couplings;
the operating regulator Is faulty;
assemblage Is faulty клапанная.

Serviceability of switching of transmission from 2nd transfer on 3rd is broken

level ATF / hydraulic pressure Has fallen;
passableness of the oil filter Is broken;
the brake tape of a mode kickdown Is faulty;
adjustment of the servo-driver of a mode kickdown Is broken;
It is faulty a lobby муфта couplings;
the operating regulator Is faulty;
assemblage Is faulty клапанная.

Switching of 1st transfer on 2nd and with 2nd on 3rd occurs too sharply

adjustment of a cable of a drive throttle заслонки Is broken;
assemblage Is faulty клапанная;
the operating regulator Is faulty;
It is faulty a lobby муфта couplings;
the brake tape of a mode kickdown Is faulty;
adjustment of the servo-driver of a mode kickdown Is broken.

Switching of 3rd transfer on 2nd and with 2nd on 1st occurs too sharply

the brake tape of a mode kickdown Is faulty;
adjustment of the servo-driver of a mode kickdown Is broken;
the operating regulator Is faulty;
assemblage Is faulty клапанная.

The rotation converter at work publishes a howling sound

the oil pump Is faulty.

The rotation converter jingles at work

Has burst приводной a disk;
Ослаб a bolt of fastening of the converter of rotation to приводному to a disk.

Primary checks

 PERFORMANCE ORDER

1. During a short trip warm up transmission to normal working temperature.
2. Check up level ATF (see the Head of Adjustment and routine maintenance):

a) If to a liquid has not enough, make corresponding updating, having added necessary quantity fresh ATF. Be convinced of correctness of the spent updating under indications measuring щупа, then check up transmission on presence of signs of external leaks;
b) If level is excessively high, merge surplus ATF, then check up it on presence of traces of presence of the cooling liquid, testifying to infringement of tightness of internal partitions of the radiator separating its heat exchanger from lateral tanks with ATF;
c) If ATF it is made foam, empty transmission and fill with its fresh liquid, - merged ATF check up on presence of traces of presence of a cooling liquid.
3. Check up installation of turns of idling of the engine (see the Head of the Power supply system and release). In case of need drive away the car on a car repair shop for performance of corresponding adjustments.

If the engine is not perfectly in order, it is not necessary to start performance of primary checks of transmission until corresponding corrections will be made.

4. Make sure of correctness of adjustment and smoothness of a course of draught/cable of a drive of switching of draught.


Diagnostics of leaks ATF

The general information

The majority of leaks easily come to light at visual check. Repair usually consists in replacement of a corresponding defective epiploon or a lining. If to reveal a source of leak during external survey it is not possible, operate, as it is described more low.

First of all it is necessary to exclude probability of an error in definition of the nature of leak. It is not necessary to confuse ATF to impellent oil or a brake liquid (трансмиссионная the liquid usually has dark red colour).

For revealing of a source of leak make short (some kilometres) a trip, then park the car over the spread blank leaf of a cardboard. After pair minutes the leak source can be revealed on traces of a liquid dripping on a cardboard.

Attentively examine a suspected site and a surface surrounding it, special attention giving to joints interfaced прокладочных surfaces. For the purpose of expansion of a corner of the review take advantage of a pocket pocket mirror.

If to reveal a leak source still it is not possible, carefully wipe a surface of a suspected site the rags moistened with solvent, then dry it.

Make one more short trip, this time often changing speed of movement, then again examine the cleaned suspected site.

After revealing of a source of leak, it is necessary to define and eliminate the reason of its development, and only then to pass to performance of necessary regenerative works. Replacement of the damaged lining will not lead to desirable result if to leave not eliminated the defect of the interfaced surface which have led to an exit of a sealant out of operation. So, the deformed flange it is necessary отрихтовать.

In below-mentioned subsections the most typical reasons of development of leaks ATF and conditions which should be executed that there were no relapses are listed.

Part from the listed requirements cannot be executed without application of the special equipment. In this case the car should be driven away on a car repair shop.


Leaks through прокладочные surfaces

 PERFORMANCE ORDER

1. Periodically examine the pallet картера transmissions. Check presence on the places and reliability of a tightening of fixing bolts, watch, that on a cover there were no traces of mechanical damages (pallet deformation can lead to failure located in transmission клапанной assemblages).
2. Excessively hard tightening of fixing bolts, infringement of passableness of a ventilating line, mechanical damage of a sealing surface concern number of the possible reasons of development of leaks through the pallet картера transmissions, lining destruction, and also occurrence of cracks or порозности walls картера. If the lining of the pallet or картера transmissions is formed by a hermetic pillow, the probability of a wrong choice of type of the last is not excluded. Overflow can result in leaks чрез картера трансмиссионной a liquid, or increase of pressure ATF a pallet lining also.


Leaks through epiploons and cuffs

 PERFORMANCE ORDER

1. Excessively high level/pressure ATF, infringement of passableness of a ventilating branch pipe, mechanical damage of walls of a landing nest, damage out of operation concern number of the most typical reasons of an exit of epiploons of transmission actually an epiploon, or wrong installation of the last. The probability of damage of a pin of the shaft passed in an epiploon, or excessive люфт the last as a result of deterioration of bearings is not excluded also.
2. Check up a condition and correctness of planting of a sealing cuff of a directing tube measuring щупа. Periodically examine on presence of signs of leaks a surface around an arrangement приводной gear wheels of a speedometer/gauge of speed (VSS). In case of need make replacement of a sealing ring.


Leaks through defects in walls картера transmissions

 PERFORMANCE ORDER

1. The reason of development of leaks ATF formation of cracks or a time in a body картера transmissions can be, - consult at experts of car-care centre.
2. Check up tightness штуцерных knots of connection of hoses of cooler ATF.


Leaks through сапун and a jellied mouth

 PERFORMANCE ORDER

Leaks through сапун ventilation or a jellied mouth can occur owing to overflow of transmission, hit in ATF a cooling liquid, passableness infringement sapuna / a ventilating branch pipe or returnable drainage apertures.


Check of serviceability of functioning of mechanical subsystems АТ

Check on completely braked car (stall test)

 PERFORMANCE ORDER

1. Working capacity of transmission and the engine is made by measurement of frequency of rotation of a cranked shaft in positions “R” and “D” АТ at completely braked car.

ATF should be прогрета to normal working temperature (50 80С). Duration of each check should not exceed five seconds. Check should be made forces of two persons: one should observe of wheels of the car, the second makes necessary manipulations in car salon.

2. Brake forward and back wheels of the car.
3. Connect to the engine a tachometre.
4. Completely cock a lay brake.
5. The left foot squeeze out against the stop a pedal of a foot brake.
6. Translate a control lever a distributing box in position Н2.
7. Start the engine. Translate selector AT lever in position “D”, squeeze out against the stop a pedal of gas and quickly consider tachometre indications.

If during check performance back wheels of the car start to rotate before frequency of rotation of the engine will reach demanded value (2300 2600 rpm), release a pedal of gas and stop check.

8. Make similar check with transmission transfer in position “R”.
9. If frequency of rotation of the engine in both cases appears identical and below demanded, hence, the engine does not develop full capacity, or is faulty муфта a free course of hydrotransformer AT.

If frequency below demanded on 600 rpm, the hydrotransformer is probably faulty actually.

10. If frequency of rotation of the engine above transmission demanded in position “D”, it can testify to excessive pressure decrease in the basic highway, proslipping in муфте a free course № 2, infringement of serviceability of functioning муфты a free course of a raising planetary number, or proslipping in муфте direct transfer of a distributing box.
11. Excess of frequency of rotation of the engine in position “R” transmissions testifies to pressure drop in the basic highway, proslipping in муфте direct transfer, proslipping in a brake of the first and back transfers, infringement of serviceability of functioning муфты a free course of a raising planetary number, or proslipping in муфте direct transfer of a distributing box.
12. If engine turns are overestimated in both positions of transmission, means, or pressure in the basic highway has excessively fallen, or level ATF mismatches demanded value, or serviceability of functioning муфты a free course of a raising planetary number is broken, or proslipping in муфте direct transfer of a distributing box takes place.


Check of time of delay of switching

 PERFORMANCE ORDER

1. If at the engine working on single turns to translate the selector lever in one of advance ranges, till the moment of the beginning of movement there should pass some time. On duration of the given delay it is possible to judge serviceability of functioning blocking муфт a raising planetary number, a forward course, direct transfer and a brake of the first and back transfers.

Check should be made on прогретом to normal working temperature the engine. The end result should be received a method of averaging of results of three checks, between each of which should pass not less than one minute. It is more low resulted detailed descriptions of a course of performance of the given check.

2. Completely cock a lay brake. Translate a control lever of a distributing box in position Н2.
3. Start the engine and check up turns of its idling, - in case of need make corresponding adjustment.
4. Translate the lever of the selector from position “N” in position “D” and by means of a stop watch measure delay time, - average value of three consecutive measurements should not exceed 1.2 seconds.
5. Operating in a similar manner, define time of a delay of inclusion of a reverse gear which should not exceed 1.5 seconds.
6. The reason of excessive size of a delay of inclusion too low pressure in the basic highway, infringement of serviceability of functioning муфты a forward course, муфты a free course of a raising number of planetary assemblage, or a brake of the first and back transfers can be.


Hydraulic checks

The general information

 PERFORMANCE ORDER

For performance described below checks the help of the assistant is required.

1. Check up level and condition ATF (see the Head of Adjustment and routine maintenance).
2. During a short trip warm up transmission to normal working temperature.
3. Поддомкратьте the car also establish it on props, - driving wheels should appear completely torn off from the earth.
4. Operating according to instructions of manufacturers of the device, connect a tachometre. Arrange a tachometre so that its indicator was well looked through from a driver's place.
5. Find unions of connection of a manometre on lateral walls картера transmissions, near to a line of its joint with the pallet. Turn out a stopper and connect a transitive nozzle of a measuring instrument to corresponding union.

For some measurements the manometre with a scale to 28 кГс/см2 (Specifications see) is required.


6. Make measurements of hydraulic pressure АТ at various turns of the engine and in various positions of the lever of the selector. Compare results of measurements to requirements of Specifications. In case of need make corresponding регулриовки, replace defective components.
7. Having finished measurements tighten stoppers of unions with demanded effort.


The analysis of results of check of pressure in lines

Transmission F3А21

 PERFORMANCE ORDER

1. Excessively low pressure in positions “D”, “L” and “2” at normal indications in position “R” testifies to presence of leaks in a contour back муфты couplings, or through a sealing ring of the accumulator 1-2.
2. The underestimated pressure in positions “D” and “R” at norm in position “L” speaks about leaks in a lobby contour муфты couplings.
3. The underestimated pressure in positions “D” and “L” at normal in position “2” is the certificate of leaks in a contour of the lowered transfers/backspacing.
4. The lowered pressure in all modes can specify in malfunction of the oil pump, easing of bolts of fastening клапанной assemblages, infringement of passableness of the filter or jamming of the valve of a regulator of pressure.


Transmissions of series F4А20 (F4А22 and F4А23/33/51)

 PERFORMANCE ORDER

1. The reasons of understating/overestimate of pressure in all lines can be: infringement of passableness of the oil filter, infringement of adjusting parametres of an operating regulator, jamming of the valve of a regulator of pressure, wrong pressure of dump of the oil pump, leak ATF in клапанной to assemblage.
2. Wrong редукционное pressure can testify to passableness infringement редукционного the filter, jamming редукционного the valve, or development of leaks in клапанной to assemblage.
3. Wrong pressure in a line of a brake contour of a mode kickdown speaks about infringement of serviceability of functioning of the servo-driver of a mode, or functioning refusal клапанной assemblages.
4. The reasons of the wrong indication at measurement of pressure of a lobby муфты couplings can be: leaks ATF in the mode servo-driver kickdown, or клапанной to assemblage, refusal клапанной assemblages, leaks on the piston or the holder муфты.
5. Wrong pressure face муфты specifies in leaks ATF on mufte/klapannoj to assemblage, or infringement of serviceability of functioning by last.
6. Wrong pressure in a brake line of the lowered transfers/backspacing specifies in leaks ATF on a site between клапанной assemblage and картером transmissions (a sealing ring), functioning refusal клапанной assemblages or leaks through the piston or the holder of corresponding brake assemblage.
7. The reasons of the wrong indication at measurement of pressure of the converter of rotation can be: leaks ATF in маслоохладителе, or lines of a connecting path, infringement of serviceability of functioning of the converter, leak through an epiploon of a primary shaft, jamming of the electromagnetic valve of coupling of the converter (valve TCCSV), or refusal of the valve of management of the converter.


Check of pressure of an operating regulator (transmission F3А21)

 PERFORMANCE ORDER

1. Necessity for performance of the given check arises only in case of infringement of correctness of the moments of switching of transmission. Adjustment of a cable of a drive throttle заслонки thus should not be broken.
2. Connect a manometre to corresponding union on картере transmissions.
3. Consider measuring instrument indications in position “D” transmissions. Compare results of measurement to requirements of Specifications.
4. The reason of deviations of pressure at the set speed of movement of the car jamming of the valve of an operating regulator, or infringement of passableness of the filter of a regulator can be.
5. The operating regulator should in due time and react smoothly to measurement of speed and come back to base pressure (0 20 кПа) at a vehicle stop.


Trial runs

Tests should be made at прогретой to normal working temperature (50 80 С) ATF.


The moments of switching of modes of a distributing box (Н2, Н4 and L 4) are various, besides, in mode L4 inclusion of 4th transfer and hydrotransformer blocking are forbidden.


Check in a range “D” in normal and sports operating modes АТ

 PERFORMANCE ORDER

1. Translate selector AT lever in position “D”, squeeze out against the stop a pedal of gas and keep it in this position. Check up the moments of a gear change 1-2, 2-3 and 3-4, - compare results of check to requirements of Specifications.
2. Check is made for normal and sports modes of functioning АТ.
3. Absence of switching 1-2 testifies to an input out of operation the electromagnetic valve № 2, or залипания the valve 1-2.
4. For absence of switching 2-3 the electromagnetic valve № 1 answers, the probability залипания the valve of switching 2-3 is not excluded also.
5. In the absence of switching 3-4 check up a condition of the valve 3-4.
6. Infringement of serviceability of functioning throttle заслонки and valves of switching 1-2/2-3/3-4 can appear the reason of failure of the moments of a gear change.
7. Absence of blocking of the hydrotransformer speaks refusal of the electromagnetic valve № 3, or залипанием the valve of inclusion of blocking.
8. Estimate smoothness of a gear change. Excessively high pressure in the basic highway, infringement of serviceability of functioning of the hydroaccumulator, or the control ball valve can appear the reason of occurrence of pushes.
9. Moving with the blocked hydrotransformer, or on 4th transfer, estimate intensity of vibrations and a noise background.

The reason of occurrence of vibrations and noise balancing infringement карданного a shaft can be also.

10. Disperse the car before inclusion of 4th transfer and, braking, define the moments of switching 4-3, 3-2 and 2-1. Compare results of check to requirements of Specifications.
11. Estimate smoothness lowering switchings.
12. Check up quality of blocking of the hydrotransformer, - at uniform movement on 4th transfer blocking should occur for the speed approximately 75 km/h. Slightly press a gas pedal, - engine turns should not change considerably, otherwise hydrotransformer blocking is broken.


Check in a range “2”

 PERFORMANCE ORDER

1. Translate selector AT lever in position “2”, squeeze out against the stop a pedal of gas and keep it in this position.
2. Define the moment of switching 1-2, compare result of check to requirements of Specifications.

In the given mode of switching 2-3, 3-4 and hydrotransformer blocking are forbidden; at movement with a speed of 100 km/h and above braking by the engine it is forbidden.

3. Moving on 2nd transfer, release a pedal of gas and estimate efficiency of braking of the car the engine. If braking is absent, hence, the brake of maintenance of the given mode is faulty.


Check in a range “L”

 PERFORMANCE ORDER

1. At mode inclusion “L” any raising switchings are forbidden, - the car should move all time for the first transfer.
2. Release a pedal of gas and estimate intensity of braking by the engine. If braking is absent, hence, the brake of inclusion of the first and back transfers is faulty.
3. Estimate noise level and vibrations in the course of braking of the car by the engine.


Check in a range “R”

 PERFORMANCE ORDER

Translate selector AT lever in position “R” and begin movement in squeezed out against the stop a gas pedal,-proslipping of frictional elements of management should be absent.


Check in a range “Р”

 PERFORMANCE ORDER

Park the car on a bias not less than 5 and translate the selector lever in position “Р”, a lay brake do not cock, - the car should remain motionless.