Mitsubishi Sigma Repair Service Manual 1991-1997
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi Sigma 1991-1997, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi Sigma 1991-1997 Models workshop service repair manual includes:
* 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: Mitsubishi
MODEL: Sigma (a.k.a. Mitsubishi Diamante)
YEAR: 1991 1992 1993 1994 1995 1996 1997
PRODUCT DETAILS:
Total Pages: 4,121 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
EWD...1
91-95MY_F10_f20...1
...
WM...1908
91-95_f10-f20...1908
PWGE9004_SIGMA_ABCDEFG_CHASSIS_00...1908
GENERAL...1908
HOW TO USE THIS MANUAL...1910
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS...1910
DEFINITION OF TERMS...1910
MODEL INDICATIONS...1910
EXPLANATION OF MANUAL CONTENTS...1911
EXPLANATION OF CIRCUIT DIAGRAMS...1913
VEHICLE IDENTIFICATION...1914
VEHICLE INFORMATION CODE PLATE...1914
MODELS...1914
MODEL CODE...1915
CHASSIS NUMBER...1915
MAJOR SPECIFICATIONS...1918
PRECAUTIONS BEFORE SERVICE...1919
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)-AIR BAG...1923
SUPPORT LOCATIONS FOR LIFTING AND JACKING...1928
STANDARD PARTS-TIGHTENING-TORQUE TABLE...1932
MAIN SEALANT AND ADHESIVE TABLE...1933
PWGE9004_SIGMA_ABCDEFG_CHASSIS_11...1935
ENGINE...1935
SPECIFICATIONS...1936
GENERAL SPECIFICATIONS...1936
SERVICE SPECIFICATIONS...1936
SEALANTS...1937
SPECIAL TOOLS...1938
SERVICE ADJUSTMENT PROCEDURES <SOHC>...1940
DRIVE BELT TENSION INSPECTION AND ADJUSTMENT...1940
IGNITION TIMING INSPECTION AND ADJUSTMENT...1941
IDLE SPEED INSPECTION...1942
IDLE MIXTURE INSPECTION...1943
COMPRESSION PRESSURE INSPECTION...1945
MANIFOLD VACUUM INSPECTION...1946
SERVICE ADJUSTMENT PROCEDURES <DOHC>...1949
DRIVE BELT TENSION INSPECTION AND ADJUSTMENT...1949
IGNITION TIMING INSPECTION AND ADJUSTMENT <Vehicles built up to November, 1992>...1950
IGNITION TIMING INSPECTION <Vehicles built from December, 1992>...1952
IDLE SPEED INSPECTION...1954
IDLE MIXTURE INSPECTION...1954
COMPRESSION PRESSURE INSPECTION...1955
MANIFOLD VACUUM INSPECTION...1956
OIL PAN...1959
TIMING BELT <SOHC>...1965
TIMING BELT <DOHC>...1969
CAMSHAFT OIL SEALS <SOHC>...1975
CAMSHAFT OIL SEALS <DOHC>...1976
CRANKSHAFT FRONT OIL SEAL...1978
CRANKSHAFT REAR OIL SEAL...1979
CYLINDER HEAD GASKET <SOHC>...1981
CYLINDER HEAD GASKET <DOHC>...1984
ENGINE ASSEMBLY <SOHC>...1987
ENGINE ASSEMBLY <DOHC>...1990
PWGE9004_SIGMA_ABCDEFG_CHASSIS_12...1993
LUBRICATION...1993
GENERAL INFORMATION...1994
SPECIFICATIONS...1995
GENERAL SPECIFICATIONS...1995
LUBRICANTS...1995
SERVICE ADJUSTMENT PROCEDURES...1995
ENGINE OIL INSPECTION...1995
ENGINE OIL REPLACEMENT...1996
OIL FILTER REPLACEMENT...1996
ENGINE OIL COOLER <DOHC>...1997
PWGE9004_SIGMA_ABCDEFG_CHASSIS_13...1999
FUEL...1999
GENERAL INFORMATION...2002
MULTI POINT INJECTION SYSTEM DIAGRAM...2002
SPECIFICATIONS...2009
GENERAL SPECIFICATIONS...2009
SERVICE SPECIFICATIONS...2010
SEALANTS...2011
SPECIAL TOOLS...2011
TROUBLESHOOTING...2013
EXPLANATION OF TROUBLESHOOTING PROCEDURES...2013
EXPLANATION AND PRECAUTION RELATED TO HARNESS CHECING...2014
ENGINE WARNING LAMP (CHECK ENGINE LAMP)...2016
ITEMS INDICATED BY THE ENGINE WARNING LAMP...2016
ENGINE WARNING LAMP INSPECTION...2017
SELF-DIAGNOSIS...2017
READ OUT OF MALFUNCTION CODE...2020
TRACTION CONTROL (TCL) SYSTEM...2023
AUTO-CRUISE CONTROL SYSTEM...2073
SERVICE ADJUSTMENT PROCEDURES <ENGINE>...2097
THROTTLE BODY (THROTTLE VALVE AREA) CLEANING...2097
IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT <Except for Vehicles with TCL>...2097
THROTTLE POSITION SENSOR ADJUSTMENT <Vehicles with TCL>...2099
IDLE POSITION SWITCH AND ACCELERATOR POSITION SENSOR (APS) ADJUSTMENT <Vehicles with TCL>...2099
FIXED SAS ADJUSTMENT...2101
BASIC IDLE SPEED ADJUSTMENT...2101
ACCELERATOR CABLE INSPECTION AND ADJUSTMENT...2103
FUEL FILTER REPLACEMENT...2104
FUEL GAUGE UNIT REPLACEMENT...2104
TWO-WAY VALVE REPLACEMENT...2105
FUEL PUMP OPERATION CHECK...2105
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE)...2105
INSPECTING OPERATION OF THE TCL (TRACTION CONTROL) SYSTEM...2106
AUTO-CRUISE CONTROL CABLES INSPECTION AND ADJUSTMENT...2112
ACCELERATOR PEDAL SWITCH INSPECTION AND ADJUSTMENT...2116
AUTO-CRUISE CONTROL MAIN SWITCH CHECK...2116
AUTO-CRUISE CONTROL SETTING CHECK...2116
SPEED-INCREASE SETIING CHECK...2117
SPEED REDUCTION SETTING CHECK...2117
CHECK OF RETURN TO THE SET SPEED BEFORE CANCELLATION AND AUTO-CRUISE CONTROL CANCELLATION...2118
ON-VEHICLE INSPECTION OF MPI COMPONENTS...2120
COMPONENT LOCATION...2120
POWER SUPPLY AND IGNITION SWITCH-IG <Vehicles built up to November, 1992>...2130
POWER SUPPLY AND IGNITION SWITCH-IG <Vehicles built from December, 1992>...2133
ENGINE CONTROL UNIT POWER EARTH...2137
FUEL PUMP <Vehicles built up to November, 1992>...2138
FUEL PUMP <Vehicles built from December, 1992>...2141
AIR FLOW SENSOR...2145
INTAKE AIR TEMPERATURE SENSOR...2150
BAROMETRIC PRESSURE SENSOR...2153
ENGINE COOLANT TEMPERATURE SENSOR...2155
THROTTLE POSITION SENSOR...2158
IDLE POSITION SWITCH...2161
ACCELERATOR POSITION SENSOR (APS) <Vehicles with TCL>...2164
TOP DEAD CENTRE SENSOR <SOHC, DOHC-Vehicles built up to November, 1992>...2166
CRANK ANGLE SENSOR <SOHC, DOHC-Vehicles built up to November, 1992>...2170
CAMSHAFT POSITION SENSOR <DOHC-Vehicles built from December, 1992>...2173
CRANK ANGLE SENSOR <DOHC-Vehicles built from December, 1992>...2176
IGNITION SWITCH-ST <M/T>...2179
IGNITION SWITCH-ST AND INHIBITOR SWITCH <A/T> <Vehicles built up to November, 1992>...2180
IGNITION SWITCH-ST AND INHIBITOR SWITCH <A/T> <Vehicles built from December, 1992>...2182
VEHICLE SPEED SENSOR...2184
POWER STEERING FLUID PRESSURE SWITCH...2186
AIR CINDITIONER SWITCH AND POWER RELAY...2188
DETONATOR SENSOR...2190
ELECTRIC LOAD SWITCH ...2192
FAN MOTOR RELAY (RADIATOR FAN, CONDENSOR FAN)...2194
INDUCTION CONTROL VALVE POSITION SENSOR...2196
OXYGEN SENSOR...2198
INJECTORS...2201
IDLE SPEED CONTROL SERVO (STEPPER MOTOR)...2208
IGNITION COIL AND POWER TRANSISTOR ...2214
PURGE CONTROL SOLENOID VALVE...2223
EGR CONTROL SOLENOID VALVE <Vehicles built from December, 1992>...2225
VACUUM SOLENOID VALVE <Vehicles with TCL>...2227
VENTILATION SOLENOID VALVE <Vehicles with TCL>...2230
VARIABLE INDUCTION CONTROL SERVO...2233
ENGINE/TRANSMISSION OVERALL CONTROL SIGNAL <DONC-A/T>...2235
ENGINE/TRANSMISSION OVERALL CONTROL SIGNAL <SOHC-A/T-Vehicles built from December, 1991>...2237
TRACTION CONTROL SIGNAL <Vehicles with TCL>...2239
FUEL PRESSURE TEST...2241
DETONATION SENSOR...2244
FUEL TANK...2245
FUEL LINE AND VAPOR LINE...2248
TCL CONTROL UNIT...2250
TCL SWITCH...2251
HYRAULITIC UNIT <VEHICLES WITH TCL>...2251
ACCELERATOR CABLE AND PEDAL...2252
AUTO-CRUISE CONTROL...2254
PWGE9004_SIGMA_ABCDEFG_CHASSIS_14...2265
COOLING...2265
SPECIFICATIONS...2266
GENERAL SPECIFICATIONS...2266
SERVICE SPECIFICATIONS...2266
LUBRICANTS...2267
SEALANT...2267
SERVICE ADJUSTMENT PROCEDURES...2267
COOLANT LEAK CHECKING...2267
RADIATOR CAP VALVE OPENING PRESSURE CHECKING...2268
COOLANT REPLACEMENT...2268
CONCENTRATION MEASUREMENT...2269
COOLANT INSPECTION...2270
THERMOSTAT CHECKING...2270
WATER PUMP...2271
RADIATOR...2272
PWGE9004_SIGMA_ABCDEFG_CHASSIS_15...2275
INTAKE AND EXHAUST...2275
SPECIFICATIONS...2276
GENERAL SPECIFICATIONS...2276
SERVICE SPECIFICATIONS...2276
SERVICE ADJUSTMENT PROCEDURES...2276
VARIABLE INDUCTION CONTROL SYSTEM INSPECTION <Vehicles built up to November, 1991>...2276
INTAKE MANIFOLD VACUUM INSPECTION...2278
INTAKE MANIFOLD...2279
EXHAUST MANIFOLD...2284
EXHAUST PIPE AND MAIN MUFFLER...2288
PWGE9004_SIGMA_ABCDEFG_CHASSIS_16...2289
ENGINE ELECTRICAL...2289
CHARGING SYSTEM...2292
SPECIFICATIONS...2292
GENERAL SPECIFICATIONS...2292
SERVICE SPECIFICATIONS...2292
SPECIAL TOOLS...2292
SERVICE ADJUSTMENT PROCEDURES...2293
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT LINE...2293
OUTPUT CURRENT TEST...2294
REGULATED VOLTAGE TEST...2296
INSPECTION USING AN ANALYZER...2299
ALTERNATOR <SOHC>...2301
ALTERNATOR <DOHC>...2302
STARTING SYSTEM...2303
SPECIFICATIONS...2303
GENERAL SPECIFICATIONS...2303
SERVICE ADJUSTMENT PROCEDURES...2303
STARTER RELAY INSPECTION <VEHICLES WITH THEFT-ALARM SYSTEM>...2303
IGNITION SYSTEM...2305
SPECIFICATIONS...2305
GENERAL SPECIFICATIONS...2305
SERVICE SPECIFICATIONS...2306
SPECIAL TOOLS...2306
SERVICE ADJUSTMENT PROCEDURES <SOHC> ...2306
IGNITION COIL INSPECTION...2306
POWER TRANSISTOR INSPECTION...2307
RESISTIVE CODE INSPECTION...2307
CHECKING THE DETONATION SENSOR...2307
SPARK PLUG CHECK AND CLEANING...2308
INSPECTION USING AN ANALYZER (SECONDARY AND PRIMARY IGNITION VOLTAGE WAVEFORMS)...2309
SERVICE ADJUSTMENT PROCEDURES <DOHC>...2317
IGNITION COIL INSPECTION...2317
POWER TRANSISTOR INSPECTION...2317
RESISTIVE CODE INSPECTION...2318
CHECKING THE DETONATION SENSOR...2319
SPARK PLUG CHECK...2319
INSPECTION USING AN ANALYZER (SECONDARY AND PRIMARY IGNITION VOLTAGE WAVEFORMS)...2320
CRANK ANGLE SENSOR AND CAMSHAFT POSITION SENSOR ...2325
PWGE9004_SIGMA_ABCDEFG_CHASSIS_17...2326
EMISSION CONTROL...2326
SPECIFICATIONS...2327
GENERAL SPECIFICATIONS...2327
SERVICE SPECIFICATIONS...2327
SEALANTS AND ADHESIVE...2327
SERVICE ADJUSTMENT PROCEDURES...2328
EMISSION CONTROL DEVICE REFERENCE TABLE...2328
COMPONENT LAYOUT <SOHC>...2329
VACUUM HOSE PIPING DIAGRAM <SOHC - Vehicles built up to November, 1992>...2333
VACUUM HOSE LAYOUT <SOHC, DOHC - except vehicles with TCL - Vehicles built up to November, 1992> ...2340
CAUTIONS ON INSPECTION...2343
CRANKCASE EMISSION CONTROL SYSTEM...2343
EVAPORATIVE EMISSION CONTROL SYSTEM...2345
EXHAUST EMISSION CONTROL SYSTEM <Vehicles built from December, 1992>...2349
CATALYTIC CONVERTER...2352
PWGE9004_SIGMA_ABCDEFG_CHASSIS_21...2353
CLUTCH...2353
SPECIFICATIONS...2354
GENERAL SPECIFICATIONS...2354
SERVICE SPECIFICATIONS...2354
LUBRICANTS...2354
SERVICE ADJUSTMENT PROCEDURES...2355
CLUTCH PEDAL INSPECTION AND ADJUSTMENT...2355
BLEEDING...2356
CLUTCH PEDAL...2357
CLUTCH MASTER CYLINDER...2362
PWGE9004_SIGMA_ABCDEFG_CHASSIS_22...2363
MANUAL TRANSMISSION...2363
SPECIFICATIONS...2364
GENERAL SPECIFICATIONS...2364
SERVICE SPECIFICATIONS...2364
LUBRICANTS...2364
SPECIAL TOOLS...2364
SERVICE ADJUSTMENT PROCEDURES...2365
OIL LEVEL CHECK...2365
CHANGING OIL...2365
SPEEDOMETER CABLE REPLACEMENT...2365
TRANSMISSION CONTROL...2367
SHIFT LEVEL ASSEMBLY...2369
TRANSMISSION ASSEMBLY...2370
PWGE9004_SIGMA_ABCDEFG_CHASSIS_23...2375
AUTOMATIC TRANSMISSION...2375
GENERAL INFORMATION...2377
SPECIFICATIONS...2387
GENERAL SPECIFICATIONS...2387
SERVICE SPECIFICATIONS...2387
LUBRICANTS...2387
SPECIAL TOOLS...2388
TROUBLESHOOTING...2389
SERVICE ADJUSTMENT PROCEDURES...2405
TRANSMISSION FLUID LEVEL INSPECTION...2405
TRANSMISSION FLUID REPLACEMENT...2406
READ OUT OF MALFUNCTION CODE...2407
SHIFT PATTERNS...2417
CONVERTER STALL TEST...2423
OIL PRESSURE TEST...2424
ACTUATOR TEST...2428
KICKDOWN SERVO ADJUSTMENT...2428
LINE PRESSURE ADJUSTMENT...2429
REDUCING PRESSURE ADJUSTMENT...2431
THROTTLE-POSITION SENSOR ADJUSTMENT...2434
ACCELERATOR PEDAL SWITCH INSPECTION AND ADJUSTMENT...2434
SELECTOR LEVEL OPERATION CHECK...2434
INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT...2435
SPEEDOMETER CABLE REPLACEMENT...2436
TRANSMISSION CONTROL...2437
SELECTOR LEVER ASSEMBLY...2439
TRANSMISSION OIL COOLER HOSES...2441
TRANSMISSION ASSEMBLY...2443
PWGE9004_SIGMA_ABCDEFG_CHASSIS_26...2447
FRONT AXLE...2447
SPECIFICATIONS...2448
GENERAL SPECIFICATIONS...2448
SERVICE SPECIFICATIONS...2448
LUBRICANTS...2448
SPECIAL TOOLS...2449
SERVICE ADJUSTMENT PROCEDURES...2451
HUB END PLAY INSPECTION...2451
AXLE HUB...2452
DRIVE SHAFT...2458
PWGE9004_SIGMA_ABCDEFG_CHASSIS_27...2469
REAR AXLE...2469
SPECIFICATIONS...2470
GENERAL SPECIFICATIONS...2470
SERVICE SPECIFICATIONS...2470
SERVICE ADJUSTMENT PROCEDURES...2470
WHEEL BEARING END PLAY INSPECTION...2470
REAR HUB ROTARY-SLIDING RESISTANCE (TORQUE) ADJUSTMENT...2471
REAR AXLE HUB...2471
PWGE9004_SIGMA_ABCDEFG_CHASSIS_31...2473
WHEEL AND TYRE...2473
SPECIFICATIONS...2474
GENERAL SPECIFICATIONS...2474
SERVICE SPECIFICATIONS...2474
TROUBLESHOOTING...2475
SERVICE ADJUSTMENT PROCEDURES...2476
TYRE INFLATION PRESSURE CHECK...2476
TYRE WEAR CHECK...2476
WHEEL RUNOUT CHECK...2476
PWGE9004_SIGMA_ABCDEFG_CHASSIS_32...2477
POWER PLANT MOUNT...2477
SPECIFICATIONS...2478
SERVICE SPECIFICATIONS...2478
SPECIAL TOOLS...2478
ENGINE MOUNTING...2479
TRANSMISSION MOUNTING...2480
ENGINE ROLL STOPPER AND ENGINE DAMPER...2481
RIGHTMEMBER, LEFTMEMBER AND CROSSMEMBER...2482
PWGE9004_SIGMA_ABCDEFG_CHASSIS_33A...2485
FRONT SUSPENSION...2485
SPECIFICATIONS...2486
GENERAL SPECIFICATIONS...2486
SERVICE SPECIFICATIONS...2486
SPECIAL TOOLS...2487
SERVICE ADJUSTMENT PROCEDURES...2488
FRONT WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT...2488
STRUT ASSEMBLY...2489
LOWER ARM...2492
STABILIZER BAR...2494
PWGE9004_SIGMA_ABCDEFG_CHASSIS_33B...2496
ACTIVE-ELECTRONIC CONTROL SUSPENSION...2496
SPECIFICATIONS...2499
GENERAL SPECIFICATIONS...2499
SERVICE SPECIFICATIONS...2500
SPECIAL TOOLS...2501
TROUBLESHOOTING...2503
SERVICE ADJUSTMENT PROCEDURES...2590
ALARM LAMP CHECK...2590
SYSTEM CHECKING BY USING ALARM LAMP...2590
CHECKING BY SELF-DIAGNOSIS...2590
ROLLING DIAPHRAGM CHECKING...2592
SYSTEM OPERATION CHECK...2592
LOW-PRESSURE SWITCH (LOW-PRESSURE TANK SIDE) ACTUATION PRESSURE CHECK...2594
HIGH-PRESSURE SWITCH (HIGH-PRESSURE TANK SIDE) ACTUATION PRESSURE CHECK...2597
G-SENSOR OUTPUT VOLTAGE CHECK...2598
STRUT ASSEMBLY...2599
LOWER ARM...2604
SHOCK ABSORBER ASSEMBLY...2606
RESERVE TANK ASSEMBLY (FRONT)...2610
RESERVE TANK ASSEMBLY (REAR)...2612
AIR COMPRESSOR ASSEMBLY...2613
SOLENOID VALVE AND DRYER...2615
AIR TUBE...2621
HEIGHT SENSOR...2623
ACTIVE-ECS SENSOR AND SWITCH...2626
CONTROL UNIT...2627
ACTIVE-ECS RELAY...2628
PWGE9004_SIGMA_ABCDEFG_CHASSIS_34...2630
REAR SUSPENSION...2630
SPECIFICATIONS...2631
GENERAL SPECIFICATIONS...2631
SERVICE SPECIFICATIONS...2631
SPECIAL TOOLS...2632
SERVICE ADJUSTMENT PROCEDURES...2633
WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT...2633
REAR SUSPENSION ASSEMBLY <Vehicles not equipped with 4WS>...2634
REAR SUSPENSION ASSEMBLY <Vehicles equipped with 4WS>...2636
UPPER ARM, LOWER ARM AND ASSIST LINK...2637
TRAILING ARM...2639
SHOCK ABSORBER ASSEMBLY...2641
STABILIZER BAR...2643
PWGE9004_SIGMA_ABCDEFG_CHASSIS_35...2645
SERVICE BRAKES...2645
SPECIFICATIONS...2646
GENERAL SPECIFICATIONS...2646
SERVICE SPECIFICATIONS...2647
LUBRICANTS...2648
SEALANTS AND ADHESIVES...2648
SPECIAL TOOLS...2648
ANTI-LOCK BRAKE SYSTEM TROUBLESHOOTING...2649
SERVICE ADJUSTMENT PROCEDURES...2729
BRAKE PEDAL INSPECTION AND ADJUSTMENT...2729
BRAKE BOOSTER OPERATING TEST...2729
CHECK VALVE OPERATION CHECK...2730
PROPORTIONING VALVE FUNCTION TEST...2730
BRAKE FLUID LEVEL SENSOR CHECK...2731
BLEEDING...2731
FRONT DISC BRAKE PAD CHECK AND REPLACEMENT...2732
FRONT DISC BRAKE ROTOR INSPECTION...2734
THICKNESS CHECK...2736
REAR DISC BRAKE PAD CHECK AND REPLACEMENT...2736
REAR BRAKE DISC THICKNESS CHECK...2738
REAR BRAKE DISC RUN-OUT CHECK...2738
REAR BRAKE DISC RUN-OUT CORRECTION...2738
BRAKE LINING THICKNESS CHECK...2739
BRAKE DRUM INSIDE DIAMETER CHECK...2739
BRAKE LINING AND BRAKE DRUM CONNECTION CHECK...2739
CHECKING OPERATION OF THE ABS (ANTI-LOCK BRAKING SYSTEM)...2740
BRAKE PEDAL...2752
MASTER CYLINDER AND BRAKE BOOSTER...2754
BRAKE LINE...2757
FRONT DISC BRAKE...2764
REAR DISC BRAKE...2770
HYDRAULITIC UNIT <VEHICLES WITH A.B.S.>...2774
WHEEL SPEED SENSOR <VEHICLES WITH A.B.S.>...2779
ELECTRONIC CONTROL UNIT <VEHICLES WITH A.B.S.>...2782
PWGE9004_SIGMA_ABCDEFG_CHASSIS_36...2784
PARKING BRAKES...2784
SPECIFICATIONS...2785
GENERAL SPECIFICATIONS...2785
SERVICE SPECIFICATIONS...2785
LUBRICANTS...2785
SEALANTS...2785
SERVICE ADJUSTMENT PROCEDURES...2785
PARKING BRAKE LEVER STROKE CHECK...2785
PARKING BRAKE SWITCH CHECK...2786
LINING RUNNING-IN...2787
PARKING BRAKE LEVER AND PARKING BRAKE CABLE...2789
PARKING BRAKE DRUM...2792
PWGE9004_SIGMA_ABCDEFG_CHASSIS_37A...2795
STEERING...2795
SPECIFICATIONS...2798
GENERAL SPECIFICATIONS...2798
SERVICE SPECIFICATIONS...2798
LUBRICANTS...2801
SEALANT AND ADHESIVES...2801
SPECIAL TOOLS...2803
TROUBLESHOOTING <E.P.S.>...2807
SERVICE ADJUSTMENT PROCEDURES...2822
STEERING ADJUSTMENT PROCEDURES...2822
STEERING ANGLE CHECK...2822
TIE ROD END BALL JOINT VARIATION CHECK (SHAFT DIRECTION)...2822
TIE ROD BALL JOINT STARTING TORQUE CHECK...2823
STATIONARY STEERING EFFORT CHECK...2823
CHECKING STEERING WHEEL RETURN TO CENTRE...2827
E.P.S. SOLENOID CHECK...2827
V-BELT TENSION CHECK...2831
FLUID LEVEL CHECK...2832
FLUID REPLACEMENT...2833
BLEEDING...2833
OIL PUMP PRESSURE TEST...2834
POWER STEERING OIL PRESSURE SWITCH CHECK...2835
STEERING WHEEL AND SHAFT...2836
POWER STEERING GEAR BOX...2842
POWER STEERING OIL PUMP...2856
POWER STEERING HOSES...2861
E.P.S. CONTROL UNIT...2864
PWGE9004_SIGMA_ABCDEFG_CHASSIS_37B...2865
4-WHEEL STEERING SYSTEM (4WS)...2865
SPECIFICATIONS...2866
GENERAL SPECIFICATIONS...2866
SERVICE SPECIFICATIONS...2866
SPECIAL TOOLS...2867
TROUBLESHOOTING...2868
SERVICE ADJUSTMENT PROCEDURES...2869
BLEEDING...2869
FUNCTION CHECK...2870
REAR OIL PUMP DISCHARGE FLOW VOLUME CHECK...2870
BALL JOINT ROTATION STARTING TORQUE CHECK...2870
POWER CYLINDER...2871
CONTROL VALVE...2874
REAR OIL LINE...2875
REAR OIL PUMP...2876
PWGE9004_SIGMA_ABCDEFG_CHASSIS_42...2877
BODY...2877
SPECIFICATIONS...2879
GENERAL SPECIFICATIONS...2879
SERVICE SPECIFICATIONS...2880
SEALANT AND ADHESIVE...2880
SPECIAL TOOLS...2881
TROUBLESHOOTING <SUNROOF>...2882
SERVICE ADJUSTMENT PROCEDURES...2887
HOOD ALIGNMENT ADJUSTMENT...2887
TRUNK LID ADJUSTMENT...2887
FUEL FILLER DOOR ADJUSTMENT...2888
DOOR GLASS ADJUSTMENT...2888
WATER TEST...2889
SUNROOF FIT ADJUSTMENT...2889
HOOD...2891
TRUNK LID...2894
FUEL TANK FILLER DOOR...2897
FENDER...2898
WINDSHIELD GLASS...2900
QUARTER WINDOW GLASS...2911
REAR WINDOW GLASS...2912
DOOR ASSEMBLY...2918
DOOR TRIM AND WATERPROOF FILM...2921
DOOR GLASS AND REGULATOR...2922
DOOR HANDLE AND LATCH...2927
DOOR RUNCHANNEL...2940
DOOR MOULDING AND DRIP LINE WEATHERSTRIP...2941
SUNROOF...2942
PWGE9004_SIGMA_ABCDEFG_CHASSIS_51...2949
EXTERIOR...2949
SPECIFICATIONS...2950
GENERAL SPECIFICATIONS...2950
SERVICE SPECIFICATIONS...2951
SPECIAL TOOLS...2951
FRONT BUMPER...2952
REAR BUMPER...2956
GRILLES...2958
GARNISHES AND MOULDINGS...2961
AERO PARTS...2965
MUD GUARD...2968
WINDSHIELD WIPER AND WASHER...2969
REAR WIPER AND WASHER...2985
HEADLAMP WASHER...2988
DOOR MIRROR...2991
PWGE9004_SIGMA_ABCDEFG_CHASSIS_52...2992
INTERIOR...2992
SPECIFICATIONS...2993
GENERAL SPECIFICATIONS...2993
SERVICE SPECIFICATIONS...2993
ADHESIVE...2993
SPECIAL TOOLS...2994
INSTRUMENT PANEL...2994
FLOOR CONSOLE...3001
TRIMS...3001
HEADLINING...3003
INSIDE REAR VIEW MIRROR...3004
FRONT SEAT...3005
REAR SEAT...3015
FRONT SEAT BELT...3017
REAR SEAT BELT...3018
PWGE9004_SIGMA_ABCDEFG_CHASSIS_52B...3020
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...3020
GENERAL INFORMATION <Vehicles without front passenger's air bag>...3021
CONSTRUCTION DIAGRAM...3021
GENERAL INFORMATION <Vehicles with front passenger's air bag>...3022
CONSTRUCTION DIAGRAM...3022
SRS SERVICE PRECAUTIONS...3023
SPECIFICATIONS...3028
SERVICE SPECIFICATIONS...3028
SPECIAL TOOLS AND TEST EQUIPMENT...3028
TROUBLESHOOTING...3031
SRS DOAGNOSTIC PROCEDURES - INITIAL STOPS...3031
DIAGNOSTIC SEQUENCE...3032
SRS MAINTENANCE...3090
POST-COLLISION DIAGNOSIS...3095
INDIVIDUAL COMPONENT SERVICE...3099
WARNING/CAUTION LABELS...3099
FRONT IMPACT SENSOR...3101
SRS DIAGNOSIS UNIT (SDU)...3103
AIR BAG MODULE AND CLOCK SPRING...3111
AIR BAG MODULE DISPOSAL PROCEDURES...3127
UNDEPLOYED AIR BAG MODULE DISPOSAL...3127
DEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES...3134
PWGE9004_SIGMA_ABCDEFG_CHASSIS_54...3135
CHASSIS ELECTRICAL...3135
BATTERY...3137
SPECIFICATION...3137
SERVICE ADJUSTMENT PROCEDURES...3137
IGNITION SWITCH...3139
SPECIAL TOOLS...3139
TROUBLESHOOTING ...3140
IGNITION SWITCH...3147
METERS AND GAUGES...3151
SPECIFICATIONS...3151
SERVICE ADJUSTMENT PROCEDURES...3152
COMBINATION METER...3156
INDICATORS AND WARNING LAMPS...3158
LIGHTING SYSTEM...3159
SPECIFICATIONS...3159
SPECIAL TOOLS...3159
TROUBLESHOOTING ...3160
SERVICE ADJUSTMENT PROCEDURES...3167
HEADLAMP AND FRONT TURN SIGNAL LAMP...3174
FRONT FOG LAMP...3177
REAR COMBINATION LAMP...3178
REAR LID LAMP...3180
ROOM LAMP...3180
HIGH MOUNTED STOP LAMP...3181
RELAY...3182
RESISTOR <R.H. Drive Vehicle>...3183
SWITCH...3184
RHEOSTAT...3185
LIGHTING MONITOR BUZZER...3186
COLUMN SWITCH...3187
SPECIAL TOOLS...3187
COLUMN SWITCH ...3187
HORN...3191
HORN SWITCH...3191
HORN RELAY...3191
AUDIO SYSTEM...3193
TROUBLESHOOTING...3193
RADIO AND TAPE PLAYER...3215
DOOR SPEAKER...3215
MOTOR ANTENNA AND ANTENNA FEEDER CABLE...3216
REAR WINDOW DEFOGGER...3219
SPECIAL TOOLS...3219
TROUBLESHOOTING...3220
SERVICE ADJUSTMENT PROCEDURES...3226
REAR WINDOW DEFOGGER SWITCH...3226
REAR WINDOW DEFOGGER RELAY...3226
SWS (Simplified Wiring System)...3228
TROUBLESHOOTING...3228
THEFT-ALARM SYSTEM...3235
SPECIAL TOOLS...3235
TROUBLESHOOTING...3236
PWGE9004_SIGMA_ABCDEFG_CHASSIS_55...3249
HEATER, AIR CONDITIONER AND VENTILATION...3249
SPECIFICATIONS...3252
GENERAL SPECIFICATIONS...3252
SERVICE SPECIFICATIONS...3252
LUBRICANTS...3253
SEALANT...3253
SPECIAL TOOLS...3253
TROUBLESHOOTING...3254
SAFETY PRECAUTIONS...3277
SERVICE ADJUSTMENT PROCEDURES...3280
TEST PROCEDURES...3280
COMPRESSOR DRIVE BELT ADJUSTMENT...3282
CHARGING PROCEDURES <Vehicles using R-12 refrigerant>...3283
CHARGING THE REFRIGERANT <Vehicles using R-12 refrigerant>...3285
CHARGING <Vehicle using R-134a refrigerant>...3290
PERFORMANCE TEST...3294
REFRIGERANT LEAK REPAIR PROCEDURE...3296
HANDLING TUBING AND FITTINGS...3297
COMPRESSOR NOISE...3297
INSPECTION OF ENGINE COOLANT TEMPERATURE SWITCHES FOR CONDENSER FAN <VEHICLES WITH AIR CONDITIONER> AND FOR RADIATOR FAN...3298
POWER RELAY CHECK...3299
IDLE-UP OPERATION CHECK...3300
AIR CONDITIONER CONTROL PANEL ASSEMBLY...3301
A/C CONTROL UNIT...3305
POWER TRANSISTOR, BELT LOCK CONTROLLER...3305
HEATER UNIT...3306
DAMPER CONTROL MOTOR ASSEMBLY...3307
SENSOR...3310
BLOWER ASSEMBLY...3314
EVAPORATOR...3315
COMPRESSOR...3318
CONDENSER AND CONDENSER FAN MOTOR...3328
REFRIGERANT LINE...3330
VENTILATORS (INSTRUMENT PANEL FLOOR)...3334
VENTILATORS (AIR INLET AND AIR OUTLET)...3337
PWGE9004_SIGMA_ABCDEFG_CHASSIS_COVER...3338
97_F30...3349
PWGE9610_SIGMA_97_CHASSIS_00...3349
GENERAL...3349
HOW TO USE THIS MANUAL...3351
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS...3351
ON-VEHICLE SERVICE...3351
INSPECTION...3351
INDICATION OF DESTINATION...3351
DEFINITION OF TERMS...3351
INDICATION OF TIGHTENING TORQUE...3351
MODEL INDICATIONS...3351
EXPLANATION OF MANUAL CONTENTS...3352
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINT...3354
TROUBLESHOOTING CONTENTS...3354
DIAGNOSIS FUNCTION...3355
HOW TO USE THE INSPECTION PROCEDURES...3357
CONNECTOR MEASUREMENT SERVICE POINT...3358
CONNECTOR INSPECTION...3359
INSPECTION SERVICE POINTS FOR A BLOWN FUSE...3360
POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS...3360
VEHICLE IDENTIFICATION...3361
VEHICLE INFORMATION CODE PLATE LOCATION...3361
CODE PLATE DESCRIPTION...3361
MODELS...3361
CHASSIS NUMBER...3362
MODEL CODE...3364
ENGINE MODEL NUMBER...3364
MAJOR SPECIFICATIONS...3365
PRECAUTIONS BEFORE SERVICE...3368
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...3368
SERVICING THE ELECTRICAL SYSTEM...3369
APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS...3369
PRE-INSPECTION CONDITION...3369
VEHICLE WASHING...3370
MUT-II...3370
PWGE9610_SIGMA_97_CHASSIS_11...3378
ENGINE <6G7>...3378
GENERAL INFORMATION...3379
SERVICE SPECIFICATIONS...3379
SEALANT...3380
SPECIAL TOOLS...3380
ON-VEHICLE SERVICE...3382
DRIVE BELT TENSION CHECK AND ADJUSTMENT...3382
IGNITION TIMING CHECK...3383
IDLE SPEED CHECK...3384
IDLE MIXTURE CHECK...3385
COMPESSION PRESSURE CHECK...3386
MANIFOLD VACUUM CHECK...3387
LASH ADJUSTER CHECK...3388
CRANKSHAFT PULLEY...3392
CAMSHAFT...3393
CAMSHAFT OIL SEAL...3395
OIL PAN, LOWER...3397
OIL PAN, UPPER...3399
CYLINDER HEAD GASKET...3401
TIMING BELT...3403
CRANKSHAFT FRONT OIL SEAL...3407
CRANKSHAFT REAR OIL SEAL...3408
ENGINE ASSEMBLY...3410
PWGE9610_SIGMA_97_CHASSIS_12...3412
ENGINE LUBRICATION...3412
GENERAL INFORMATION...3413
LUBRICANTS...3414
SPECIAL TOOLS...3414
ON-VEHICLE SERVICE...3414
ENGINE OIL INSPECTION...3414
ENGINE OIL REPLACEMENT...3414
OIL FILTER REPLACEMENT...3415
PWGE9610_SIGMA_97_CHASSIS_13...3416
FUEL...3416
MULTIPOINT FUEL INJECTION (MPI)...3417
GENERAL INFORMATION...3418
SERVICE SPECIFICATIONS...3422
SEALANT...3422
SPECIAL TOOLS...3423
TROUBLESHOOTING...3425
ON-VEHICLE SERVICE...3494
THROTTLE BODY (THROTTLE VALVE AREA) CLEANING...3494
IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT...3494
FIXED SAS ADJUSTMENT...3496
BASIC IDLE SPEED ADJUSTMENT...3496
FUEL PRESSURE TEST...3497
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURISED FUEL LINES)...3499
FUEL PUMP OPERATION CHECK...3500
ON-VEHICLE INSPECTION OF MPI COMPONENTS...3501
COMPONENT LOCATION...3501
MPI CONTROL RELAY AND FUEL PUMP RELAY CONTINUITY CHECK...3502
INTAKE AIR TEMPERATURE SENSOR CHECK...3502
ENGINE COOLANT TEMPERATURE SENSOR CHECK...3502
THROTTLE POSITION SENSOR CHECK...3503
IDLE POSITION SWITCH CHECK...3503
OXYGEN SENSOR CHECK...3504
INJECTOR CHECK...3505
IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) CHECK...3507
PURGE CONTROL SOLENOID VALVE CHECK...3507
EGR CONTROL SOLENOID VALVE CHECK...3507
INJECTOR...3508
THROTTLE BODY...3511
PWGE9610_SIGMA_97_CHASSIS_14...3520
ENGINE COOLING...3520
GENERAL INFORMATION...3521
SERVICE SPECIFICATIONS...3521
LUBRICANT...3521
SEALANT...3521
ON-VEHICLE SERVICE...3522
ENGINE COOLANT LEAK CHECK...3522
RADIATOR CAP VALVE OPENING PRESSURE CHECK...3522
ENGINE COOLANT REPLACEMENT...3522
CONCENTRATION MEASUREMENT...3523
THERMOSTAT...3524
WATER PUMP...3527
WATER HOSE AND WATER PIPE...3528
RADIATOR...3530
PWGE9610_SIGMA_97_CHASSIS_15...3533
INTAKE AND EXHAUST...3533
GENERAL INFORMATION...3534
SERVICE SPECIFICATIONS...3534
SPECIAL TOOL...3534
AIR CLEANER...3535
INTAKE MANIFOLD PLENUM...3536
INTAKE MANIFOLD...3538
EXHAUST MANIFOLD...3540
EXHAUST PIPE AND MAIN MUFFLER...3541
PWGE9610_SIGMA_97_CHASSIS_16...3542
ENGINE ELECTRICAL...3542
CHARGING SYSTEM...3543
GENERAL INFORMATION...3543
SERVICE SPECIFICATIONS...3544
SPECIAL TOOLS...3544
ON-VEHICLE SERVICE...3545
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST...3545
OUTPUT CURRENT TEST...3546
REGULATED VOLTAGE TEST...3548
WAVE PATTERN CHECK USING AN ANALYSER...3550
ALTERNATOR RELAY CONTINUITY CHECK...3552
ALTERNATOR...3553
STARTING SYSTEM...3557
GENERAL INFORMATION...3557
SERVICE SPECIFICATION...3558
STARTER MOTOR...3559
IGNITION SYSTEM...3567
GENERAL INFORMATION...3567
SERVICE SPECIFICATIONS...3568
SPECIAL TOOL...3568
ON-VEHICLE SERVICE...3569
SPARK PLUG CABLE TEST...3569
SPARK PLUG TEST...3569
IGNITION COIL CHECK...3569
POWER TRANSISTOR CHECK...3570
SPARK PLUG CABLE RESISTANCE CHECK...3570
SPARK PLUG CHECK AND CLEANING...3571
CAMSHAFT POSITION SENSOR CHECK...3571
IGNITION SECONDARY VOLTAGE WAVE PATTERN CHECK...3572
IGNITION PRIMARY VOLTAGE WAVE PATTERN CHECK...3575
IGNITION SYSTEM...3579
DISTRIBUTOR...3581
CRANKSHAFT POSITION SENSOR...3582
PWGE9610_SIGMA_97_CHASSIS_17...3583
ENGINE AND EMISSION CONTROL...3583
ENGINE CONTROL SYSTEM...3585
GENERAL INFORMATION...3585
SERVICE SPECIFICATIONS...3585
ON-VEHICLE SERVICE...3585
ACCELERATOR CABLE CHECK AND ADJUSTMENT...3585
ACCELERATOR CABLE AND PEDAL...3586
AUTO-CRUISE CONTROL SYSTEM...3588
GENERAL INFORMATION...3588
SERVICE SPECIFICATIONS...3589
SPECIAL TOOLS...3589
TROUBLESHOOTING...3590
ON-VEHICLE SERVICE...3608
AUTO-CRUISE CONTROL SYSTEM OPERATION CHECK...3608
AUTO-CRUISE CONTROL COMPONENT CHECK...3609
AUTO-CRUISE CONTROL...3612
EMISSION CONTROL SYSTEM...3616
GENERAL INFORMATION...3616
EMISSION CONTROL DEVICE REFERENCE TABLE...3616
SERVICE SPECIFICATIONS...3616
SPECIAL TOOLS...3617
VACUUM HOSE...3617
VACUUM HOSE PIPING DIAGRAM...3617
VACUUM CIRCUIT DIAGRAM...3618
CRANKCASE EMISSION CONTROL SYSTEM...3620
GENERAL INFORMATION...3620
SYSTEM DIAGRAM...3620
COMPONENT LOCATION...3620
POSITIVE CRANKCASE VENTILATION SYSTEM CHECK...3621
POSITIVE CRANKCASE VENTILATION (PCV) VALVE CHECK...3621
EVAPORATIVE EMISSION CONTROL SYSTEM...3622
GENERAL INFORMATION...3622
PURGE PORT VACUUM CHECK...3622
CANISTER...3623
EXHAUST GAS REGULATION (EGR) SYSTEM...3624
GENERAL INFORMATION...3624
COMPONENT LOCATION...3625
EGR SYSTEM...3625
EGR VALVE CHECK...3626
EGR PORT VACUUM CHECK...3627
EGR SOLENOID CHECK...3627
CATALYTIC CONVERT <IF EQUIPPED>...3628
GENERAL INFORMATION...3628
PWGE9610_SIGMA_97_CHASSIS_21...3630
CLUTCH...3630
GENERAL INFORMATION...3631
SERVICE SPECIFICATIONS...3631
LUBRICANTS...3631
ON-VEHICLE SERVICE...3632
CLUTCH PEDAL CHECK AND ADJUSTMENT...3632
BLEEDING...3633
CLUTCH PEDAL...3634
CLUTCH CONTROL...3635
CLUTCH MASTER CYLINDER...3637
CLUTCH RELEASE CYLINDER...3638
PWGE9610_SIGMA_97_CHASSIS_22...3640
MANUAL TRANSMISSION...3640
LUBRICANT...3641
SPECIAL TOOLS...3641
ON-VEHICLE SERVICE...3642
TRANSMISSION OIL LEVEL CHECK...3642
TRANSMISSION OIL REPLACEMENT...3642
TRANSMISSION CONTROL...3643
SHIFT LEVEL ASSEMBLY...3645
TRANSMISSION ASSEMBLY...3646
PWGE9610_SIGMA_97_CHASSIS_23...3650
AUTOMATIC TRANSMISSION...3650
SERVICE SPECIFICATIONS...3651
LUBRICANT...3651
SPECIAL TOOLS...3651
TROUBLESHOOTING...3653
ON-VEHICLE SERVICE...3693
AUTOMATIC TRANSMISSION FLUID CHECK...3693
OIL FILTER REPLACEMENT...3693
AUTOMATIC TRANSMISSION FLUID REPLACEMENT...3694
THROTTLE POSITION SENSOR ADJUSTMENT...3695
INHIBITOR SWITCH CONTINUITY CHECK...3695
INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT...3695
A/T CONTROL COMPONENT LOCATION...3697
A/T CONTROL COMPONENT CHECK...3698
TORQUE CONVERTER STALL TEST...3700
HYDRAULIC PRESSURE TEST...3701
HYDRAULIC CIRCUIT...3706
LINE PRESSURE ADJUSTMENT...3707
SELECTOR LEVER OPERATION CHECK...3707
TRANSMISSION CONTROL...3708
TRANSMISSION ASSEMBLY...3711
PWGE9610_SIGMA_97_CHASSIS_26...3715
FRONT AXLE...3715
GENERAL INFORMATION...3716
SERVICE SPECIFICATIONS...3716
LUBRICANTS...3716
SPECIAL TOOLS...3717
ON-VEHICLE SERVICE...3719
HUB AXIAL PLAY CHECK...3719
HUB BOLT REPLACEMENT...3719
FRONT HUB AND KNUCKLE ASSEMBLY...3720
DRIVE SHAFT...3725
PWGE9610_SIGMA_97_CHASSIS_27...3737
REAR AXLE...3737
GENERAL INFORMATION...3738
SERVICE SPECIFICATIONS...3738
SPECIAL TOOLS...3738
ON-VEHICLE SERVICE...3739
HUB AXIAL PLAY CHECK...3739
REAR HUB ROTARY-SLIDING RESISTANCE CHECK...3739
HUB BOLT REPLACEMENT...3740
REAR HUB ASSEMBLY...3741
KNUCKLE...3743
PWGE9610_SIGMA_97_CHASSIS_31...3745
WHEEL AND TYRE...3745
GENERAL INFORMATION...3746
SERVICE SPECIFICATIONS...3746
TROUBLESHOOTING...3747
ON-VEHICLE SERVICE...3748
TYRE INFLATION PRESSURE CHECK...3748
TYRE WEAR CHECK...3748
WHEEL RUNOUT CHECK...3748
WHEEL AND TYRE...3748
PWGE9610_SIGMA_97_CHASSIS_32...3749
POWER PLANT MOUNT...3749
SPECIAL TOOLS...3750
ENGINE MOUTING...3751
TRANSMISSION MOUTING...3753
ENGINE ROLL STOPPER, CENTRE MEMBER...3754
CROSSMEMBER...3755
PWGE9610_SIGMA_97_CHASSIS_33...3758
FRONT SUSPENSION...3758
GENERAL INFORMATION...3759
SERVICE SPECIFICATIONS...3760
SPECIAL TOOLS...3760
ON-VEHICLE SERVICE...3761
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT...3761
STRUT ASSEMBLY...3762
LOWER ARM...3765
STABILISER BAR...3767
PWGE9610_SIGMA_97_CHASSIS_34...3770
REAR SUSPENSION...3770
GENERAL INFORMATION...3771
SERVICE SPECIFICATIONS...3772
SPECIAL TOOLS...3772
ON-VEHICLE SERVICE...3773
REAR SUSPENSION ASSEMBLY...3774
UPPER ARM ASSEMBLY...3776
TRAILING ARM ASSEMBLY...3778
LOWER ARM AND TOE CONTROL ARM ASSEMBLIES...3779
SHOCK ABSORBER ASSEMBLY...3781
PWGE9610_SIGMA_97_CHASSIS_35...3784
SERVICE BRAKES...3784
BASIC BRAKE SYSTEM...3785
GENERAL INFORMATION...3786
SERVICE SPECIFICATIONS...3787
LUBRICANTS...3787
SEALANT...3788
SPECIAL TOOLS...3788
ON-VEHICLE SERVICE...3789
BRAKE PEDAL CHECK AND ADJUSTMENT...3789
STOP-LAMP SWITCH CHECK...3790
BRAKE BOOSTER OPERATING TEST...3790
CHECK VALVE OPERATION CHECK...3791
PROPORTIONING VALVE FUNCTION TEST...3791
BRAKE FLUID LEVEL SENSOR CHECK...3792
BLEEDING...3792
FRONT DISC BRAKE PAD CHECK AND REPLACEMENT...3793
FRONT DISC BRAKE ROTOR CHECK...3795
FRONT BRAKE DISC RUN-OUT CHECK...3795
FRONT BRAKE DISC RUN-OUT CORRECTION...3796
FRONT BRAKE DISC THICKNESS CHECK...3796
REAR DISC BRAKE PAD AND REPLACEMENT...3797
REAR BRAKE DISC THICKNESS CHECK...3798
REAR BRAKE DISC RUN-OUT CHECK...3798
REAR BRAKE DISC RUN-OUT CORRECTION...3799
BRAKE PEDAL...3800
MASTER CYLINDER AND BRAKE BOOSTER...3801
FRONT DISC BRAKE...3806
REAR DISC BRAKE...3811
PROPORTIONING VALVE...3815
ANTI-SKID BRAKING SYSTEM (ABS)...3816
GENERAL INFORMATION...3817
SERVICE SPECIFICATIONS...3818
SEALANT...3818
SPECIAL TOOLS...3818
TROUBLESHOOTING...3819
ON-VEHICLE SERVICE...3838
BLEEDING...3838
ABS OPERATION CHECK...3838
HYDRAULIC UNIT INSPECTION...3839
SOLENOID VALVE CHECK...3841
MOTOR OPERATION CHECK...3842
MOTOR RELAY CHECK...3842
VALVE RELAY CHECK...3842
REMEDY FOR A FLAT BATTARY...3842
PROPORTIONING VALVE...3843
HYDRAULIC UNIT...3844
WHEEL SPEED SENSOR...3846
ELECTRONIC CONTROL UNIT...3848
PWGE9610_SIGMA_97_CHASSIS_36...3849
PARKING BRAKES...3849
GENERAL INFORMATION...3850
SERVICE SPECIFICATIONS...3850
LUBRICANTS...3850
ON-VEHICLE SERVICE...3851
PARKING BRAKE LEVER STROKE CHECK...3851
LINING RUNNING-IN...3852
REPLACING DUST BOOT...3853
PARKING BRAKE LEVEL...3854
PARKING BRAKE CABLE...3855
PARKING BRAKE...3857
PWGE9610_SIGMA_97_CHASSIS_37...3860
STEERING...3860
GENERAL INFORMATION...3861
SERVICE SPECIFICATIONS...3862
LUBRICANTS...3862
SEALANT...3863
SPECIAL TOOLS...3863
ON-VEHICLE SERVICE...3866
STEERING WHEEL FREE PLAY CHECK...3866
STEERING ANGLE CHECK...3866
TIE ROD END BALL JOINT STARTING TORQUE CHECK...3866
STATIONARY STEERING EFFORT CHECK...3867
CHECKING STEERING WHEEL RETURN TO CENTRE...3867
FLUID LEVEL CHECK...3867
FLUID REPLACEMENT...3868
BLEEDING...3868
OIL PUMP PRESSURE TEST...3869
POWER STEERING PRESSURE SWITCH CHECK...3871
STEERING WHEEL AND SHAFT...3872
POWER STEERING GEAR BOX...3875
POWER STEERING OIL PUMP...3887
POWER STEERING HOSES...3891
PWGE9610_SIGMA_97_CHASSIS_42...3893
BODY...3893
HOOD...3894
TRUNK LID...3896
SPECIAL TOOLS...3896
REMOVAL AND INSTALLATION...3897
FENDER...3900
SEALANT...3900
FENDER...3900
FUEL FILLER DOOR...3901
WINDSHIELD AND WINDOW GLASS...3903
SEALANT AND ADHESIVE...3903
SPECIAL TOOLS...3903
WINDOW GLASS...3904
WINDSHIELD...3906
REAR WINDOW GLASS...3909
DOOR...3911
SERVICE SPECIFICATIONS...3911
SEALANT...3911
SPECIAL TOOLS...3911
TROUBLESHOOTING...3911
ON-VEHICLE SERVICE...3930
DOOR ASSEMBLY...3935
DOOR TRIM AND WATERPROOF FILM...3938
DOOR GLASS AND REGULATOR...3939
DOOR HANDLE AND LATCH...3941
DOOR BELT LINE MOULDING AND DOOR OPENING WEATHERSTRIP...3944
KEYLESS ENTRY SYSTEM...3945
SPECIAL TOOLS...3945
TROUBLESHOOTING...3945
REMOVAL AND INSTALLATION...3954
SUNROOF...3956
SERVICE SPECIFICATIONS...3956
SEALANT...3956
SPECIAL TOOLS...3956
TROUBLESHOOTING...3957
ON-VEHICLE SERVICE...3960
SUNROOF...3962
PWGE9610_SIGMA_97_CHASSIS_51...3967
EXTERIOR...3967
SERVICE SPECIFICATION...3968
SEALANT AND ADHESIVE...3968
SPECIAL TOOLS...3968
FRONT BUMPER...3969
REAR BUMPER...3971
GRILLES AND GARNISHES...3972
MOULDINGS...3974
AERO PARTS...3978
WINDSHIELD WIPER AND WASHER...3980
DOOR MIRROR...3992
PWGE9610_SIGMA_97_CHASSIS_52...3998
INTERIOR...3999
SPECIAL TOOLS...4000
INSTRUNENT PANEL...4001
FLOOR CONSOLE...4005
TRIMS...4006
HEADLINING AND INSIDE REAR VIEW MIRROR...4008
FRONT SEAT...4010
REAR SEAT...4016
FRONT SEAT BELT...4017
REAR SEAT BELT...4018
SUPPLEMENTAL RESTRAINT SYSTEM...4019
GENERAL INFORMATION...4020
WARNING/CAUTION LABELS...4022
SRS SERVICE PRECAUTIONS...4024
SPECIAL TOOLS...4025
TST EQUIPMENT...4025
TROUBLESHOOTING...4026
SRS MAINTENANCE...4034
POST-COLLISION DIAGNOSIS...4037
INDIVIDUAL COMPONENT SERVICE...4040
SRS AIR BAG CONTROL UNIT (SRS-ECU)...4041
AIR BAG MODULES AND CLOCK SPRING...4042
AIR BAG MODULE DISPOSAL PROCEDURES...4049
UNDEPLOYED AIR BAG MODULE DISPOSAL...4049
DEPLOYED AIR BAG MODULE DISPOSAL...4054
PWGE9610_SIGMA_97_CHASSIS_54...4055
CHASSIS ELECTRICAL...4055
BATTERY...4057
ON-VEHICLE SERVICE...4057
FLUID LEVEL AND SPECIFIC GRAVITY CHECK...4057
BATTERY INSPECTION ...4057
BATTERY CHARGING...4058
BATTERY TESTING PROCEDURE...4059
IGNITION SWITCH...4060
SPECIAL TOOLS...4060
TROUBLESHOOTING...4061
IGNITION SWITCH...4065
IGNITION SWITCH CONTINUITY CHECK...4066
KEY REMINDER SWITCH, KEY HOLE ILLUMINATION LIGHT CONTINUITY CHECK...4066
COMBINATION METERS...4067
SERVICE SPECIFICATIONS...4067
SEALANT...4067
SPECIAL TOOLS...4067
TROUBLESHOOTING...4068
ON-VEHICLE SERVICE...4081
SPEEDOMETER CHECK...4081
TACHOMETER CHECK...4081
FUEL GAUGE SIMPLE CHECK...4082
FUEL GAUGE UNIT CHECK...4082
FUEL GAUGE UNIT FLOAT HEIGHT...4082
FUEL GAUGE UNIT RESISTANCE...4082
TERMISTOR...4083
ENGINE COOLANT TEMPERATURE GAUGE SIMPLE CHECK...4083
ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK...4083
COMBINATION METERS...4085
VEHICLE SPEED SENSOE CHECK...4086
FUEL GAUGE CHECK...4086
ENGINE COOLANT TEMPERATURE GAUGE CHECK...4086
CENTRE WARNING DISPLAY...4088
SPECIAL TOOLS...4088
TROUBLESHOOTING...4088
CENTRE WARNING DISPLAY...4094
CLOCK SWITCH CONTINUITY CHECK...4094
HEADLAMP, POSITION LAMP ASSEMBLY AND FRONT TURN SIGNAL LAMP ASSEMBLY...4095
SERVICE SPECIFICATIONS...4095
SPECIAL TOOLS...4095
TROUBLESHOOTING...4095
ON-VEHICLE SERVICE...4102
HEADLAMP AIMING...4102
LUMINOUS INTENSITY MEASUREMENT...4104
HEADLAMP, POSITION LAMP ASSEMBLY AND FRONT TURN SIGNAL LAMP ASSEMBLY...4105
COLUMN SWITCH CONTINUITY CHECK...4106
COLUMN SWITCH CONTINUITY CHECK...4106
HAZARD LIGHT SWITCH CONTINUITY CHECK...4106
HEADLAMP RELAY CONTINUITY CHECK...4107
HEADLAMP BULB REPLACEMENT...4107
POSITION LAMP BULB REPLACEMENT...4107
SIDE TURN SIGNAL LAMP...4108
FOG LAMP...4109
SERVICE SPECIFICATIONS...4109
SPECIAL TOOLS...4109
TROUBLESHOOTING...4109
ON-VEHICLE SERVICE...4112
FOG LAMP AIMING...4112
FOG LAMP...4113
FOG LAMP SWITCH CONTINUITY CHECK...4114
FOG LAMP RELAY CONTINUITY CHECK...4114
REAR COMBINATION LAMP AND REAR LID LAMP...4115
TAILLAMP RELAY CONTINUITY CHECK...4116
HIGH MOUNTED STOP LAMP...4117
INTERIOR LAMP...4118
SPECIAL TOOLS...4118
TROUBLESHOOTING...4118
INTERIOR LAMP...4123
ROOM LAMP SWITCH CONTINUITY CHECK...4124
RHEOSTAT...4125
HAZARD WARNING LAMP SWITCH...4126
HORN...4127
CIGARETTE LIGHTER...4128
ACCESSORY SOCKET...4129
RADIO, TAPE PLAYER AND CD PLAYER ...4130
TROUBLESHOOTING...4130
RADIO, TAPE PLAYER AND CD PLAYER ...4152
DOOR SPEAKER AND REAR SPEAKER...4153
ANTENNA...4154
REAR WINDOW DEFOGGER...4156
ON-VEHICLE SERVICE...4156
PRINTED-HEATER LINE CHECK...4156
PRINTED-HEATER LINE REPAIR...4156
REQUIRED MATERIALS...4156
REAR WINDOW DEFOGGER SWITCH...4156
SIMPLIFIED WIRING SYSTEM (SWS)...4158
SPECIAL TOOLS...4158
TROUBLESHOOTING...4158
SIMPLIFIED WIRING SYSTEM (SWS)...4182
PWGE9610_SIGMA_97_CHASSIS_55...4183
HEATER, AIR CONDITIONING AND VENTILATION...4183
GENERAL INFORMATION...4185
SAFETY PRECAUTION...4185
SERVICE SPECIFICATIONS...4186
LUBRICANTS...4186
SPECIAL TOOLS...4187
TROUBLESHOOTING...4187
ON-VEHICLE SERVICE...4209
SIGHT GLASS REFRIGERANT LEVEL TEST...4209
MAGNETIC CLUTCH TEST...4210
RECEIVER DRIER TEST...4210
DUAL PRESSURE SWITCH CHECK...4210
COMPRESSOR DRIVE BELT ADJUSTMENT...4210
CHARGING...4211
PERFORMANCE TEST...4215
REFRIGERANT LEAK REPAIR...4216
POWER RELAY CHECK...4217
IDLE-UP OPERATION CHECK...4218
AIR CONDITIONING CONTROL UNIT ASSEMBLY...4219
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR...4220
BLOWER MOTOR ASSEMBLY AND BLOWER MOTOR HI RELAY...4221
DAMPER CONTROL MOTOR ASSEMBLY AND POWER TRANSISTOR...4223
COMPRESSOR AND TENSION PULLEY...4226
REFRIGERANT LINE...4231
CONDENSER AND CONDENSER FAN MOTOR...4232
SENSOR...4234
PHOTO SENSORS...4234
OUTSIDE AIR TEMPERATURE SENSOR...4234
HEATER WATER TEMPERATURE SENSOR...4235
VENTILATORS...4236
VENTILATORS (AIR OUTLET)...4237
PWGE9610_SIGMA_97_CHASSIS_COVER...4238
Mitsubishi Sigma Repair Service Manual 1991-1997
