HOW TO USE THIS BOOK 1-2 OPERATION INFOREIGNCOUNTRIESl-33

WHERETOBEGIN l-2 ENGINE l-33

AVOIDINGTROUBLE1-2 OILLEVELCHECK 1-33
MAINTENANCEORREPAIR?1-2 OIL& FILTERCHANGE l-34
AVOIDINGTHEMOSTCOMMONMISTAKES l-2 MANUALTRANSAXLEl-35
TOOLSAND EQUIPMENT 1-2 FLUIDRECOMMENDATIONS l-35
SPECIALTOOLS l-4 LEVELCHECK l-35
YOUR VEHICLE SAFELY 1-4 DRAIN&REFILL l-36
AUTOMATICTRANSAXLEl-36
DON'TS l-6 FLUIDRECOMMENDATIONS l-36
FASTENERS,MEASUREMENTSAND LEVELCHECK 1-36
CONVERSIONS l-6 DRAIN&REFILL l-36
BOLTS,NUTSANDOTHERTHREADED PAN& FILTERSERVICE1-36
RETAINERS1-6 TRANSFERCASE(AWDGAlANT ONLY) l-38
TORQUE l-7 FLUIDRECOMMENDATIONS l-38
TORQUEWRENCHES l-7 LEVELCHECK l-38
TORQUEANGLEMETERS1-9 DRAIN&REFILL l-38
STANDARDANDMETRIC MEASUREMENTSl-9 REARDRlVEAXLE(AWDGALANTONLY)l-38
SERIAL NUMBER IDENTIFICATION l-10 FLUIDRECOMMENDATIONS l-38
VEHICLEIDENTIFICATIONNUMBER l-10 LEVELCHECK l-38
ENGINEIDENTIFICATIONNUMBER I-10 DRAIN&REFILL l-38
TRANSAXLEIDENTIFICATION I-10 COOLINGSYSTEMl-39
DRlVEAXLE(AWDGALANTONLY)l-10 FLUIDRECOMMENDATIONS l-39
TRANSFERCASE(AWDGALANTONLY) l-10
ROUTINEMAINTENANCEAND TUNE-UP l-14
AIRCLEANER(ELEMENT)1-14
REMOVAL&INSTALLATION1-14 iM-41
FUELFILTER 1-15
REMOVAL&INSTALLATION l-15
PCVVALVE l-15
REMOVAL&INSTALLATIONl-15
EVAPORATIVECANISTER l-16
SERVICING 1-16
BATTERY 1-16
PRECAUTIONSI-16
GENERALMAINTENANCE1-16
BATTERYFLUID 1-16
CABLES I-17
CHARGINGI-18
REPLACEMENT1-18
BELTS 1-18
INSPECTiON l-18
ADJUSTMENT 1-18
REMOVAL&INSTALLATION1-18
TIMINGBELTS l-20
INSPECTIONl-20
HOSES I-20
INSPECTIONl-20
REMOVAL&INSTALLATION1-21
CV-BOOTS 1-21
INSPECTIONl-21
SPARKPLUGS l-22
SPARKPLUGHEATRANGEl-22
REMOVAL&INSTALLATIONl-22
INSPECTION&GAPPING 1.-23
SPARKPLUG WIRES 1-24
TESTING 1-24
REMOVAL&INSTALLATION1-24
DISTRIBUTORCAPANDROTOR l-25
REMOVAL&INSTALLATIONl-25
INSPECTION 1-25
IGNITIONTIMING 1-25
. GENERALINFORAMTION l- .25
lNSPECTlON&ADJUSTMENl1-26
VALVELASH l-27
ADJUSTMENT l-27
IDLESPEED 1-28
AIR CONDITIONINGSYSTEM 1-28
SYSTEMSERVlCEiiREPAlRl-28
PREVENTIVEMAINTENANCE 1-28
SYSTEMINSPECTION l-29
WINDSHIELD WIPERS l-29
ELEMENT(REFILL)CARE&
REPLACEMENTl-29
TIRESANDWHEELSl-30
TIREROTATION I-30
TIREDESIGN 1-31
TIRESTORAGEl-31
INFLATION&INSPECTION l-31
CAREOFSPECIALWHEELSl-32
FLUIDS AND LUBRICANTS 1-33
FLUIDDISPOSAL 1-33
FlJELANDENGlNEOILRECOMMENDATlONS
ENGINEOIL l-33
FUEL l-33

1-2 GENERALINFORMATIONAND
MAINTENANCE
Chitton’sTotal Car Caremanualfor the 199M10
Mitsubishi Mirage, Galantand Diamanteis intended
to helpyou learnmoreaboutthe innerworkingsof
your vehiclewhile savingyou moneyon its upkeep
and operation.
The beginningof the book will likely be referredto
the most,sincethat is whereyou will find information
for maintenanceand tune-up.The othersectionsdeal
with the more complexsystemsof your vehicle.Oper-
ating systemsfrom enginethroughbrakesare cov-
eredto the extentthat the averagedo-it-yourselferbe-
comesmechanicallyinvolved.This book will not
explainsuchthings as rebuildinga differentialfor the
simple reasonthat the expertiserequiredandthe in-
vestmentin specialtools makethis task uneconomi-
cal. It will, however,give you detailedinstructionsto
helpyou changeyour own brakepadsand shoes,re-
placesparkplugs,and performmanymorejobs that
cansaveyou money,give you personalsatisfaction
and helpyou avoid expensiveproblems.
A secondarypurposeof this book is a referencefor
ownerswho wantto understandtheir vehicleand/or
their mechanicsbetter.In this case,no tools at all are
required.
Beforeremovingany bolts, readthroughthe entire
procedure.This will give you the overallview of what
tools and supplieswill be required.Thereis nothing
morefrustratingthan havingto walkto the bus stop
on Mondaymorning becauseyou wereshort one bolt
on Sundayafternoon.So readaheadand planahead.
Eachoperationshould beapproachedlogicallyand
all proceduresthoroughlyunderstoodbeforeattempt-
ing any work.
All sectionscontainadjustments,maintenance,re-
movaland installationprocedures,and in somecases,
repairor overhaulprocedures.Whenrepairis not con-
sideredpractical,we tell you howto removethe part
andthen howto installthe newor rebuiltreplacement.
In this way,you at leastsavelaborcosts.“Backyard”
repairof somecomponentsis just not practical.
Many proceduresin this book requireyou to “label
and disconnect. . ” a group of lines, hosesor wires.
Don’t be lulled into thinkingyou can rememberwhere
everythinggoes-you won’t. If you hook up vacuum
or fuel lines incorrectly,the vehicle mayrun poorly, if
at all. If you hook up electricalwiring incorrectly,you
may instantlylearna very expensivelesson.
You don’t needto knowthe official or engineering
namefor eachhose or line. A pieceof maskingtape
on the hoseand a pieceon its fitting will allow you to
assignyour own labelsuch as the letterA or a short
b See Figures 1 thru 15
Naturally,withoutthe propertools and equipment
it is impossibleto properlyserviceyour vehicle.It
would also bevirtually impossibleto catalogevery
tool that you would needto performall of the opera-
tions in this book.Of course,It would be unwisefor
the amateurto rush out and buyan expensiveset of
tools on the theorythat he/shemay needone or more
of themat sometime,
name.As long as you rememberyour own code,the
lines can be reconnectedby matchingsimilar letters
or names.Do rememberthat tapewill dissolvein
gasolrneor otherfluids; if a componentis to be
washedor cleaned,useanothermethodof identifica-
tion. A permanentfelt-tippedmarkeror a metalscribe
can bevery handyfor markingmetalparts.Remove
anytapeor paperlabelsafterassembly.
It’s necessaryto mentionthe differencebetween
maintenanceand repair Maintenanceincludesrou-
tine inspections,adjustments,and replacementof
partswhich show signs of normalwear Maintenance
compensatesfor wearor deterioration.Repairimplies
that somethinghasbrokenor is not working.A need
for repair is oftencausedby lackof maintenance.Ex-
ample,drainingand refilling the automatictransaxle
fluid is maintenancerecommendedby the manufac-
turer at specificmileageintervals.Failureto do this
canshortenthe life of the transmission/transaxle,re-
quiring very expensiverepairs.While no maintenance
programcan preventitemsfrom breakingor wearing
out, a generalrule can be stated:MAINTENANCEIS
CHEAPERTHAN REPAIR.
Two basicmechanrc’srulesshouldbe mentioned
here.First, wheneverthe leftside of the vehicleor en-
gine is referredto, it is meantto specifythe drivers
side. Conversely,the right side of the vehicle means
the passengersside.Second,screwsand bolts are
removedby turning counterclockwise,and tightened
by turning clockwrseunlessspecificallynoted.
Safetyis alwaysthe most importantrule. Con-
stantlybe awareof the dangersinvolvedin working
on an automobileandtakethe properprecautions.
Seethe informatronin this sectionregardingSER-
VICINGYOURVEHICLESAFELYandthe SAFETY
NOTICEon the acknowledgmentpage.
Payattentionto the instructionsprovided.There
are3 commonmistakesin mechanicalwork:
1. Incorrectorderof assembly,disassemblyor
adjustment.Whentaking somethingapartor putting
it together,performingsteps in the wrong order usu-
ally just costsyou extratime; however,it CAN break
something.Readthe entireprocedurebeforebegin-
ning disassembly.Performeverythingin the order in
which the instructionssay you should,even if you
can’timmedratelyseea reasonfor it. Whenyou’re
takingapartsomethingthat is very intricate,you
might wantto drawa pictureof how it lookswhenas-
sembledat one point in orderto makesureyou get
The bestapproachis to proceedslowly, gathering
a good qualityset of thosetools that are usedmost
frequently Don’tbe misled by the low cost of bargain
tools. It is far betterto spenda little morefor better
quality.Forgedwrenches,6 or 12-point socketsand
fine tooth ratchetsare by far preferableto their less
expensivecounterparts.As anygood mechaniccan
tell you, therearefew worseexperiencesthantrying
to work on a vehiclewith badtools. Your monetary
.
everythingbackin its properposition.Wewill supply
explodedviews wheneverpossible.Whenmaking
adjustments,performthem in the properorder.One
adjustmentpossiblywill affectanother.
2. Overtorquing(or undertorquing).While it is
more commonfor overtorquingto causedamage,
undertorquingmayallow a fastenerto vibrate loose
causingseriousdamage.Especiallywhendealing
with aluminumparts,payattentionto torquespecifi-
cationsand utilize a torquewrenchin assembly.If a
torquefigure is not available,rememberthat if you
are usingthe right tool to performthe job, you will
probablynot haveto strainyourselfto get a fastener
tight enough.The pitch of mostthreadsis so slight
that the tensionyou put on the wrenchwill be multi-
plied manytimes in actualforce on whatyou are
tightening.A good exampleof how critical torqueis
can be seenin the caseof sparkplug installation,es-
peciallywhereyou are puttingthe plug into an alu-
minum cylinderhead.Too little torquecan fail to
crushthe gasket,causingleakageof combustion
gasesand consequentoverheatingof the plugand
engineparts.Too muchtorquecan damagethe
threadsor distort the plug, changingthe sparkgap.
Thereare manycommercialproductsavailablefor
ensuringthat fastenerswon’t come loose,evenif they
are not torquedjust right (a very commonbrandis
Loctite? If you’reworriedaboutgettingsomething
togethertight enoughto hold, but looseenoughto
avoid mechanicaldamageduring assembly,one of
theseproductsmight offersubstantialinsurance.Be-
fore choosinga threadlockingcompound,readthe
labelon the packageand makesurethe productis
compatiblewith the materials,fluids, etc. involved.
3. Crossthreading.This occurswhena part such
as a bolt is screwedinto a nut or castingat the wrong
angleand forced.Crossthreadingis more likely to
occur if accessis difficult. It helpsto cleanand lubri-
catefasteners,thento startthreadingthe bolt, spark
plug,etc.with your fingers If you encounterresis-
tance,unscrewthe partand startover againat a dif-
ferentangleuntil it canbe insertedandturnedseveral
times without mucheffort.Keepin mind that many
parts,especiallysparkplugs,havetaperedthreads,
so that gentleturningwill automaticallybring the part
you’rethreadingto the properangle.Don’tput a
wrenchon the part until its beentighteneda couple
of turns by hand.If you suddenlyencounterresis-
tance,andthe part hasnot seatedfully, don’tforce it.
Pull it backout to makesure it’s cleanandthreading
properly.
Besureto takeyour time and be patient,and al-
ways planahead.Allow yourselfampletime to per-
form repairsand maintenanceYou mayfind main-
taining your car a satisfyingand enjoyable
experience.
savingswill befar outweighedby frustrationand
mangledknuckles.
Beginaccumulatingthosetools that are usedmost
frequently:thoseassociatedwith routinemaintenance
andtune-up.In additionto the normalassortmentof
screwdriversand pliers,you shouldhavethe follow-
ing tools:
l Wrenches/socketsand combinationopen
end/boxendwrenchesin sizesfrom %-% in. or

3-19mm,aswellasa % in.or~/ain.sparkplug
socket(depending
onplugtype).
-if possible, buyvarious lengthsocketdrive
extensions.Universal-jointandwobble ex-
tensionscan be extremelyuseful, but be
Fig. 1 Ail but the most basic procedures
lWSl2U2
Fig, 3 A hydraulic floor jack and a set of
jackstandsare essential for lifting andsup
porting the vehicle
GENERALINFORMATIONAND
MAINTENANCE
l-3
careful when usingthem, as they can change l Grease gunfor chassislubrication (unless
the amountof torque appliedto the socket. yourvehicleis notequipped withanygreasefit-
Jackstands forsupport. tings-for details,pleasereferto information
onFlu-
l
idsandLubricants, laterinthissection).
l Oilfilterwrench.
l Hydrometer for checking thebattery(unless
l Spoutor funnelfor pouringfluids.
equiooed witha sealed,maintenance-free batten/).
O’A containerfor drainingoil andotherfluids.
l Ragsforwipinguptheinevitable mess.
Inadditiontotheaboveitemsthereareseveral
pi othersthatarenotabsolutely necessary,
buthandyto
1 havearound.TheseincludeOilDry@(oranequiva-
lentoil absorbent gravel-suchascatlitter)andthe
usualSUDDIV of lubricants.
antifreeze
andfluids.al-
thoughthe.&canbepurchased asneeded. Thisis a
basiclistfor routinemaintenance, butonlyyourper-
sonalneedsanddesirecanaccurately determine your
Afterperforming
a fewprojectsonthevehicle,
you’llbeamazedattheothertoolsandnon-toolson
tm1204
Fig. 5 Various drivers, chisels and ptybars
are great tools to have in your toolbox
Fig. 7 Althoughnot always necessary,us-
ing specialized brake tools will save time
Fig. 11 inductive type timing light \
I-4 GENERALINFORMATIONAND
MAINTENANCE
Fig. 12 A screw-in type compressiongauge-
is recommendedfor compressiontesting
Fig. 14 Most modernautomotive multime-
ters incorporate many helpful features
yourworkbench. Someusefulhousehold itemsare:a
largeturkeybasteror siphon,emptycoffeecansand
icetrays(tostoreparts),ballof twine,electricaltape
for wiring,smallrollsof coloredtapefor tagginglines
or hoses,markers andpens,a notepad,golftees(for
pluggingvacuumlines),metalcoathangers ora roll
of mechanic’swire(toholdthingsoutof theway),
dentalpickor similarlong,pointedprobe,a strong
magnet, anda smallmirror(toseeintorecesses and
undermanifolds).
A moreadvanced setoftools,suitablefortune-up
work,canbedrawnupeasily.Whilethetoolsare
p See Figures16, 17, 16, and 19
It is virtuallyimpossible
to anticipate
all ofthehaz-
ardsinvolvedwithautomotive maintenance andser-
vice,butcareandcommon sensewill preventmost
accidents.
Therulesof safetyfor mechanics rangefrom“don’t
smokearoundgasoline,” to “usethepropertool(s)for
thejob.”Thetricktoavoidinginjuriesisto develop
safeworkhabitsandtotakeeverypossibleprecaution.
l Dokeepa fireextinguisher andfirstaidkit
handy.
l Dowearsafetyglassesor goggleswhencut-
ting,drilling,grindingor prying,evenif youhave
20-20vision.If youwearglassesforthesakeof vi-
sion,wearsafetygogglesoveryourregularglasses.
Fig. 13 A vacuum/pressuretester is neces-
sary for manytesting procedures
lmvl
Fig. 15 Proper information is vital, so at
ways have a Chiiton Total Car Care manua
handy
ilightlymoresophisticated,
theyneednotbeoutra-
feouslyexpensive.Thereareseveralinexpensive
achldwellmetersonthemarketthatareeverybitas
Toadfortheaverage mechanic asa professional
nodel.Justbesurethatit goesto a least1200-1500
pmonthetachscaleandthatit workson4,6 and8-
:ylinderengines.
Thekeytothesepurchases is to
nakethemwithaneyetowardsadaptability andwide
ange.A basiclistoftune-uptoolscouldinclude:
l Tach/dwell
meter.
l Sparkplugwrenchandgappingtool.
l Doshieldyoureyeswhenever youworkaround
thebattery.Batteries containsulfuricacid.Incaseof
contactwiththeeyesor skin,flushtheareawithwater
or a mixtureof waterandbakingsoda,thenseekim-
mediate medicalattention.
l Dousesafetystands(jackstands) foranyun-
dervehicle service.Jacksarefor raisingvehicles;
jackstands arefor makingsurethevehiclestays
raiseduntilyouwantit to comedown.Whenever the
vehicleis raised,blockthewheelsremaining onthe
groundandsettheparkingbrake.
l Douseadequate ventilationwhenworking
withanychemicals or hazardous materials,Likecar-
bonmonoxide, theasbestos dustresultingfrom
somebrakeliningwearcanbehazardous in suffi-
cientquantities.
l Dodisconnect thenegativebatterycablewhen
workingontheelectricalsystem.Thesecondary ig-
l Feeleraauoesfor valveadiustment
* Timing-light.
Thechoiceof a timingfightshouldbemade
carefully.A lightwhichworksontheDCcurrent
suppliedbythevehicle’sbatteryis thebestchoice;
it shouldhavea xenontubefor brightness. Onany
vehiclewithanelectronicignitionsystem,a timing
lightwithan inductivepickupthatclampsaround
theNo.1 sparkplugcableis preferred.
Inadditionto thesebasictools,thereareseveral
othertoolsandgaugesyoumayfinduseful.These
include:
l Compression gauge.Thescrew-intypeis
slowerto use,buteliminates thepossibilityof a
fauliyreadingdueto escaping pressure.
l Manifoldvacuumgauge.
l 12Vtestlight.
l A combination volt/ohmmeter
l inductionAmmeter. Thisis usedfor determin-
ingwhetheror notthereis currentina wire.These
arehandyfor useif awireis brokensomewhere ina
wiringharness.
Asa finalnote,vouwill orobablvfinda torque
wrenchnecessary for all butthemostbasicwork.
Thebeamtypemodelsareperfectlyadequate, al-
thoughthenewerclicktypes(breakaway) areeasier
to use.Theclicktypetorquewrenches tendto be
moreexpensive. Alsokeepin mindthatall typesof
torquewrenches shouldbeperiodically checked
and/orrecalibrated. Youwill haveto decidefor your-
selfwhichbetterfits yourpocketbook, andpurpose.
Normally, theuseof specialfactorytoolsis
avoidedfor repairprocedures, sincethesearenot
readilyavailableforthedo-it-yourself mechanic.
Whenit is possibleto performthejobwithmore
commonly availabletools,it will bepointedout,but
occasionally, a specialtoolwasdesigned to perform
a specificfunctionandshouldbeused.Beforesub-
stitutinganothertool,youshouldbeconvinced that
neitheryoursafetynortheperformance ofthevehicle
will becompromised.
Specialtoolscanusuallybepurchased froman
automotive partsstoreorfromyourdealer.Insome
casesspecialtoolsmaybeavailabledirectlyfromthe
toolmanufacturer.
nitionsystemcontainsEXTREMELY HIGHVOLT-
AGE.Insomecasesit canevenexceed50,000volts.
l Dofollowmanufacturer’s directionswhenever
workingwithpotentiallyhazardous materials.Most
chemicals andfluidsarepoisonousif takeninter-
nally.
l Doproperlymaintain yourtools.Looseham-
merheads, mushroomed punches andchisels,frayed
or poorlygrounded electricalcords,excessively
wornscrewdrivers, spreadwrenches (openend),
crackedsockets,slippingratchets,or faultydroplight
socketscancauseaccidents.
* Likewise,keepyourtoolsclean;a greasy
wrenchcanslipoff a bolthead,ruiningtheboltand
oftenharmingyourknucklesin theprocess.
l Dousethepropersizeandtypeof toolforthe
jobathand.Doselecta wrenchor socketthatfitsthe
nutor bolt.Thewrenchor socketshouldsit straight,
notcocked.
1-6 GENERALINFORMATIONAND
MAINTENANCE
Fig.16 Screwdriversshouldbe kept in good
:onditionto preventinjury or damagewhich
:ould result it the blade slips from the screw
0 0
PP
tccs1022
Fig. 16 Using the correct size wrench will
help prevent the possibility of roundingoff
a nut
l Do, whenpossible,pull on a wrenchhandle
ratherthan push on it, and adjustyour stanceto pre-
vent a fall.
l Do be surethat adjustablewrenchesare
tightly closedon the nut or bolt and pulledso that
the force is on the side of the fixed jaw.
l Do strikesquarelywith a hammer;avoid glanc-
ing blows.
p See Figures20, 21, 22, and 23
Althoughtherearea greatvarietyof fastenersfound
in the moderncar or truck,the mostcommonlyused
retaineris the threadedfastener(nuts,bolts,screws,
studs,etc.).Most threadedretainersmaybe reused,
providedthatthey are not damagedin useor during
the repair.Someretainers(suchas stretchbolts or
torqueprevailingnuts)are designedto deformwhen
tightenedor in useand shouldnot be reinstalled.
Wheneverpossible,we will noteanyspecialre-
tainerswhich shouldbe replacedduring a procedure.
Butyou shouldalwaysinspectthe conditionof a re-
tainerwhenIt is removedand replaceanythat show
signs of damage.Checkall threadsfor rust or corro-
lwo.WIRE CouDuClOR TMREE-WIRE CONO”CTOI
MIRD WIRE GROUNDING GROUNDING TNRU
THE CASE A CmxlIT
. safeworkingarounda vehicle.Longhair shouldbe
i$Y$$pQ
p-+
TNHREE-WIRE CONDUCTOR THREE-WIRE CONDUCTOR
ONE WIRE TO 4 GROUND GROUNOlNG TMRU
AN ADAPTER PLUG
tccm21
Fig. 17 Powertools should always be prop-
erly grounded
7 gerousadditiveswhichcanenterthe bodythrougha
Fig. 19 NEVERwork undera vehicle unlessit
is supportedusingsafety stands(jackstands)
l Do setthe parkingbrakeand block the drive
wheelsif the work requiresa runningengine.
l Don’t runthe enginein a garageor anywhere
elsewithout properventilation-EVER! Carbon
sion which can increasethe torque necessaryto
achievethe desiredclamp loadfor which thatfastener
was originally selected.Additionally,besurethat the
driver surfaceof the fastenerhasnot beencompro-
mised by roundingor otherdamage.In some casesa
driver surfacemay becomeonly partiallyrounded,al-
lowingthe driver to catch in only one direction.In
manyof theseoccurrences,a fastenermaybe in-
stalledand tightened,but the driver would not be able
to grip and loosenthe fasteneragain.(This could lead
J to frustrationdownthe line shouldthat component
ever needto be disassembledagain).
If you must replacea fastener,whetherdueto de-
sign or damage,you mustALWAYSbe sureto use
the properreplacementIn all cases,a retainerof the
samedesign,materialand strengthshould be used.
Markingson the headsof most bolts will helpdeter-
minethe properstrengthof the fastener.Thesame
material,threadand pitch must be selectedto assure
monoxideis poisonous;it takesa longtime to leave
the humanbodyand you can build up a deadlysup-
ply of it in your systemby simply breathingin a !ittle
everyday.You may not realizeyou are slowly poi-
soning yourself.Alwaysusepowervents,windows,
fans and/or openthe garagedoor.
l Don’twork aroundmoving partswhile wearing
looseclothing.Shortsleevesare muchsaferthan
long, loosesleeves.Hard-toedshoeswith neoprene
soles protectyour toes and give a bettergrip on slip-
perysurfaces.Jewelrysuchas watches,fancybelt
buckles,beadsor bodyadornmentof any kind is not
tied backundera hat or cap.
l Don’tusepocketsfor toolboxes.A fall or bump
candrive a screwdriverdeepinto your body. Evena
raghangingfrom your backpocketcan wraparound
a spinningshaftor fan.
l Don’tsmokewhenworkingaroundgasoline,
cleaningsolventor otherflammablematerial.
l Don’tsmokewhenworkrngaroundthe battery.
Whenthe batteryis beingcharged,it gives off explo-
sive hydrogengas.
l Don’tusegasolineto washyour hands;there
are excellentsoapsavailable.Gasolinecontainsdan-
cut or throughyour pores.Gasolinealso removesall
the naturaloils from the skin so that bonedry hands
will suck up oil and grease.
l Don’tservicethe air conditioningsystemun-
lessyou are equippedwith the necessarytools and
trainmg.Whenliquid or compressedgas refrigerant
is releasedto atmosphericpressureit will absorb
heatfrom whateverit contacts.This will chill or freeze
anythingit touches.
l Don’tusescrewdriversfor anythingotherthan
driving screws!A screwdriverusedas an pryingtool
can snapwhenyou leastexpectit, causinginjuries.
At the very least,you’ll ruin a goodscrewdriver.
. Don’tusean emergencyjack (thatlittle ratchet,
scissors,or pantographjack suppliedwith the vehi-
cle) for anythingotherthan changinga flat! These
jacksare only Intendedfor emergencyuse out on the
road;theyare NOTdesignedas a maintenancetool. If
you are seriousaboutmamtainingyour vehicleyour-
self, investin a hydraulicfloor jack of at leasta 1%
ton capacity,and at leasttwo sturdyjackstands.
properinstallationand safeoperationof the vehicle
afterwards.
Threadgaugesareavailableto help measurea bolt
or stud’sthread.Most automotiveand hardware
storeskeepgaugesavailableto helpyou selectthe
propersize. In a pinch,you can useanothernut or
bolt for a threadgauge.If the bolt you are replacingis
not too badly damaged,you can selecta matchby
finding anotherbolt which will threadin its place.If
you find a nut whichthreadsproperlyontothe dam-
agedbolt, then usethat nut to helpselectthe replace-
mentbolt If however,the bolt you are replacingis so
badlydamaged(brokenor drilled out) that its threads
cannotbe usedas a gauge,you might startby look-
ing for anotherbolt (from the sameassemblyor a
similar locationon your vehicle)which will thread
into the damagedbolt’s mounting.If so, the otherbolt
can be usedto selecta nut;the nut canthen be used
to selectthe replacementbolt.
 GENERALINFORMATIONAND
MAlNTENAiCEI-7
of the bolt head,screwheador nut faceandthe base
materialor washer(the surfaceon which the fastener
is rotating).Approximately40 percentof the applied
torque is usedin overcomingthreadfriction. This
leavesonly about 10 percentof the appliedtorqueto
developa usefulclamp load (the forcewhich holdsa
PHILLIPS RECESS
joint together).This meansthat friction canaccount
POZIDRIVE TORX@ CLUTCH RECESS
for as muchas 90 percentof the appliedtorqueon a
fastener.

TORQUEWRENCHES

ti See Figures 24 and 25

In most applications,a torquewrenchcan beused
to assureproperinstallationof a fastener.Torque
INDENTED HEXAGON HEXAGON TRIMMED HEXAGON WASHER HEAD
wrenchescome in various designsand most auto-
tccs1037 motive supplystoreswill carrya varietyto suit your
Fig. 20 Here are a few of the most commonscrew/bolt driver styles needs.A torquewrenchshould be usedanytime we
supplya specifictorquevaluefor a fastener.A torque
wrenchcanalso be usedif you are followingthe gen-
eralguidelinesIn the accompanyingcharts.Keepin
mind that becausethereis no worldwidestandardiza-
tion of fasteners,the chartsare a generalguideline

GRADE 8 MADE 2 GRADE 5 QRADE 8 GRADE 7 WADE 0 ALLEN CARRIAGE

NUTS

e
Q
PUIN JAM CASTLE SELF-LOCKINQ SPEED
(CASTELLATED)

A - Length
B - Diameter (major diameter)
C- Threads per inch or mm
D- Thread length
E - Size of the wrench required
F- Root diameter (minor diameter)
FILLISTER
IccSlO3l
Fig. 22 Threadedretainer sizes are deter
mined using these measurements
LOCKWASHERS

4% 43 Q c3
INTERNAL EXTERNAL SPLIT PLAIN
Toonl TQonl

STUD

Fig. 21 There are many different types of threaded retainers found on vehicles

In all cases,beabsolutelysureyou haveselected

the properreplacement.Don’t beshy, you canalways
ask the storeclerk for helo.
Be aware that when you find a bolt with dam-
agedthreads,you may also find the nut or
drilled hole it was threadedinto hasalso
beendamaged.If this is the case, you may
haveto drill andtap the hole, replace the nut
or otherwise repair the threads. NEVERtry to
force a replacementbolt to fit into the dam-
aaedthreads.
Torqueis definedas the measurementof resis- .
tanceto turning or rotating.It tendsto twist a body
aboutan axis of rotation.A commonexampleof this
would betighteninga threadedretainersuch as a nut,
bolt or screw.Measuringtorque is one of the most
commonwaysto help assurethat a threadedretainer
has beenproperlyfastened.
Whentighteninga threadedfastener,torqueis ap- E - DCTERNAL
tm1016
plied in threedistinct areas,the head,the bearing Yg. 23 Special fasteners such as these
surfaceand the clamp load. About50 percentof the font@’head bolts are used by manufactur-
measuredtorque is usedin overcomingbearingfric-
?rs to discourage people from working on
tion This is the friction betweenthe bearingsurface
rehicles without the proper tools
 .
l-8 GENERALINFORMATIONAND
MAINTENANCE
U.S. Bolts
UEonlr
Iy* lU2 5 tw7
I*cll*olwu c
tbqn2lamlu
am~mkr. Q @ 63
HaaIm Toqw mdmuo TORW m TolqW
(h&l!&, RA&. m 111 R./U. If410 lm R.Abs. I(n Hm

'I4 - 20 i 0.7 68 8 1.1 10.8 10 1.4 13.5

-28 08 8.1 10 1.4 13.6

tccsio15
%s-18 11 1.5 14.9 17 2.3 23.0 19 2.6 25.8
-24 13 1.8 17.6 19 2.6 25.7
Fig. 24 Various styles of torque wrenches
S-16 18 2.5 24.4 31 4.3 42.0 34 4.7 46.0
are usually available at your local automo- -24 20 2.75 27.1 35 4.8 47.5
tive supply store %s-14 28 3.8 37.0 49 8.8 66.4 55 7.6 74.5
-20 30 42 40.7 55 7.6 74.5

and should be usedwith caution.Again,the general 'h-13 39 5.4 52.8 75 10.4 101.7 85 11.75 115.2
rule of “if you are using the right tool for the job, you -20 41 5.7 55.6 85 117 115.2

should not haveto strainto tightena fastener”ap- 'h-12 51 7.0 69.2 110 15.2 149.1 120 16.6 162.7
plies here. -18 55 7.6 74.5 120 16.6 162.7
H-11 83 11.5 112.5 150 20.7 203.3 167 23.0 226.5
BeamType -18 95 13.1 128.8 170 23.5 230.5
s-10 105 14.5 142.3 270 37.3 366.0 280 36.7 379.6
# See Figure 26 -16 115 15.9 155.9 295 40.8 400.0

The beamtype torquewrenchis one of the most VD- 9 160 2.: 216.9 395 54.6 535.5 440 60.9 596.5
-14 175 237.2 435 80.1 589.7
populartypes.It consistsof a pointerattachedto the
headthat runsthe lengthof the flexible beam(shaft) l- 6 iti 32.5 318.6 lE 81.6 799.9 660 91.3 894.8
-14 34.6 338.9 91.3 849.8
to a scalelocatednearthe handle.As the wrenchis
pulled,the beambendsand the pointerindicatesthe
torque usingthe scale. Metric Bolts
Click (Breakaway)Type 4.6,4.8 8.8
$ See Figure 27
c @w
Anotherpopulardesignof torquewrenchISthe I*rdn*lrTwlr rullllllnl~
click type.To usethe click type wrenchyou pre-ad- mm04 iEn% (nnr) RJU. I(n llm RAk m mu
just it to a torquesetting.Oncethe torque is reached,
6x1.0 2-3 2-.4 3-4 3-6 4-.8 5-8
the wrenchhasa reflexsignalingfeaturethat causes
a momentarybreakawayof the torquewrenchbody, 8x 1.25 6-8 .6-l 8-12 9-14 12-1.9 13-19
sendingan impulseto the operator’shand. 10X1.25 12-17 1.5-2.3 16-23 20-29 2.7-4.0 27-39
12x125 21-32 2.9-4.4 29-43 35-53 4.8-7.3 47-72
Pivot HeadType
14x 1.5 35-52 4.8-7.1 48-70 57-65 7.8-11.7 77-110
# See Figure 27 and 28 16x 1.5 51-77 7.0-10.6 67-100 90-120 12.4-16.5 130-W

Sometorquewrenches(usuallyof the click type) 18x 1.5 74-110 10.2-15.1 100-150 130-170 17.9-23.4 MO-230
may beequippedwith a pivot headwhich canallow it 20x 1.5 llO-140 15.1-19.3 150-190 190-240 26.2-46.9 160-320
to be used in areasof limited access.BUT,it must be 22x 1.5 150-190 22.0-26.2 200-260 250-320 34.5-44.1 340-430
usedproperly.To hold a pivot headwrench,grasp
24x 1.5 190-240 26.2-48.9 260-320 310-410 42.7-56.5 420-550
the handlelightly,and as you pull on the handle,it lccs1098
should befloatedon the pivot point. If the handle
:ig. 25 Standardand metric bolt torque specifications based on bolt strengths-WARNING:
comesin contactwith the yokeextensionduringthe
processof pulling,thereis a very good chancethe Ise only as a guide
torque readingswill be inaccuratebecausethis could 1
alterthe wrenchloadingpoint. The designof the han-
dle is usuallysuch as to makeit inconvenientto de-
liberatelymisusethe wrench.
PIVOTEO HANDLE
*It shouldbe mentionedthat the use of any
U-joint, wobble or extensionwill have an ef-
fect on the torque readings,no matterwhat
type of wrenchyou are using. For the most
accuratereadings, install the socketdirectly
on the wrenchdriver. If necessary,straight
extensions(which hold a socketdirectly un-
der the wrenchdriver) will have the least ef-
fect on the torque reading. Avoid any exten-
sion that alters the lengthof the wrenchfrom
the handleto the head/drivingpoint (suchas BEAU OR MEASURING ELEMENT
. tccslo3~
a crow’s foot). U-joint or wobble extensions Yg. 26 Exampleof a beam type torque wrench
can greatly affect the readings;avoid their
use at all times.
 GENERALINFORMATIONAND
MAINTENANCE
l-9
dardtorquewrenchareusuallyusedfirstto remove
anycompliance fromthejoint.Thefasteneristhen
tightenedthespecified additionalportionof a turn
measured in degrees.A torqueanglegauge(mechan-
icalprotractor)is usedfor theseapplications.

Fig. 27 A click type or breakaway torque ) See Figure 31

wrench-note that this one has a pivoting
head Throughoutthismanual, specifications
aregivento
helpyoudetermine theconditionof variouscompo-

v
:ig. 30 Somespecifications require the use nentsonyourvehicle,orto assistyouintheirinstalla-
rf a torque angle meter (mechanical pro. tion.Someof themostcommon measurements in-
ractor) cludelength(in.or cm/mm), torque(ft.Ibs.,inchIbs.
or Nm)andpressure (psi,in.Hg,kPaor mmHg).In
mostcases,westriveto providethepropermeasure-
manyaluminum cylinderheads).Inthesecases,a mentasdetermined bythemanufacturers engineers.
torqueanglemethodof installation
wouldbespeci- Though,insomecases,thatvaluemaynotbecon-
fied.Wheninstallingfasteners
whicharetorqueangle venientlymeasured withwhatis availablein your
tightened,
a predetermined seatingtorqueandstan- toolbox.Luckily,manyof themeasuring devices

CONVERSION FACTORS
WRONG WRONG LENGTH-DISTANCE
Inches (I”.) x 25.4 = Millimeters (mm) x .0394 = Inches
PIVOTED HANDLE TOR(IUE WRENCH
tccS1041 Feet (ft.) x ,305 = Meters (m) x 3.281 = Feet
Miles x 1.609 = Kilometers (km) x .0621 = Miles
Fig. 28 Torque wrenches with pivoting
heads must be grasped and used properly VOLUME
to prevent an incorrect reading Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 = in3
IMP Pints (IMP pt.) x .568 = Liters (L) x 1.76 = IMP pt.
IMP Quarts (IMP qt.) x 1.137 = Liters (L) x .88 = IMP qt.
Rigid Case(Direct Reading) IMP Gallons (IMP gal.) x 4.546 = Liters (L) 7, .22 = IMP gal.

# See Figure 29 IMP Quarts (IMP qt ) x 1.201 = US Quarts (US qt.) x ,833 = IMP qt.
IMP Gallons (IMP gal.) x 1.201 = US Gallons (US gal.) x ,833 = IMP gal.
A rigidcaseor directreadingtorquewrenchis Fl. Ounces x 29.573 = Millihters x 034 = Ounces
equipped witha dialindicatorto showtorquevalues. us Pints (Us pt.) x ,473 = Liters (L) x 2.113 = Pints
Oneadvantage of thesewrenches is thattheycanbe US Quarts (US qt.) x .946 = Liters (L) x 1.057 = Quarts
heldatanypositiononthewrenchwithoutaffecting US Gallons (US gal.) x 3.785 = Liters (L) x ,264 = Gallons
accuracy. Thesewrenches areoftenpreferred be- MASS-WEIGHT
causetheytendto becompact, easyto readandhave Ounces (oz.) x 28.35 = Grams (g) x ,035 = Ounces
a greatdegreeof accuracy. Pounds (lb ) x ,454 = Kdograms (kg) x 2.205 = Pounds
PRESSURE ’
Pounds Per Sq. In. (psi) x 6.895 = Kilopascals (kPa) x ,145 = psi
Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
Inches of Water (H,O) x .07355 = Inches of Mercury x 13 783 = H,O
Inches of Water (H,O) x .03613 = psi x 27.684 = Hz0
Inches of Water (H,O) x ,248 = Kilopascals (kPa) x4026 = H,O
TORQUE
Pounds-Force Inches (in-lb) x ,113 = Newton Meters (N.m) x 8.85 = in-lb
Pounds-Force Feet (ft-lb) x 1.356 = Newton Meters (N*m) x ,738 = ft-lb
VELOCITY
lccs1042
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
Fig. 29 The rigid case (direct reading)
torque wrench usesa dial indicator to show POWER
torque Horsepower (Hp) x ,745 = Kdowatts x 1.34 = Horsepower
FUEL CONSUMPTION’
Mdes Per Gallon IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
TORQUEANGLEMETERS Kilometers Per Liter (Km/L) x 2.352 = IMP MPG
Miles Per Gallon US (MPG) x ,425 = Kilometers Per Liter (Km/L)
# See Figure 30 Kdometers Per Liter (Km/L) x 2.352 = US MPG
*It 1s common to covert from miles per gallon (mpg) to hters/lOO kilometers (l/100 km), where mpg (IMP) x l/ID0 km
Becausethefrictionalcharacteristics
of eachfas- = 282 and mpg (US) x l/lo0 km = 235.
tenerorthreaded holewill vary,clamploadswhich
arebasedstrictlyontorquewill varyaswell.Inmost TEMPERATURE
applications,
thisvarianceISnotsignificant enough Degree Fahrenheit CF) = (“C x 1.8) + 32
to causeworry.But,in certainapplications,a manu- Degree Celsms (‘C) = CF - 32) x 56 tccsio4d
facturersengineersmaydetermine thatmoreprecise Fig. 31 Standardand metric conversionfactors chart
clamploadsarenecessary (suchisthecasewith
 .
l-10 GENERALINFORMATIONAND
MAINTENANCE
whichareavailable todaywill havetwoscalessothe Theconversion factorchartis usedbytakingthe factorof 25.4to getthemetricequivalentof 50.8mm.
Standard or Metricmeasurements mayeasilybe givenspecification andmultiplying it bytheneces- Likewise, if thespecification
wasgivenonlyina Met-
taken.If anyofthevariousmeasuring toolswhichare saryconversion factor.Forinstance, lookingatthe ric measurement, for examplein NewtonMeters
available toyoudonotcontainthesamescaleas firstline,if youhavea measurement in inchessuch (Nm),thenlookatthecentercolumnfirst.If themea-
listedinthespecifications,usetheaccompanying as“free-playshouldbe2 in.”butyourrulerreads surement is 100Nm,multiplyit bytheconversion
conversion factorsto determinethepropervalue. onlyin millimeters, multiply2 in.bytheconversion factorof 0.738to get73.8ft. Ibs.

if theengineis equipped witha turbocharger.If the 4 charactercodeasonthevehicleinformation code

8thVINnumberis a U,thereis nodoubtthattheen- plateis used.Theengineserialnumberis also
b See Figures32,33, and 34 ginein questionis a 2.OLDOHCengineequipped stamped neartheenginemodelnumber. Asmen-
withaturbocharger. tionedabove,theenginecanalsobeidentifiedbythe
TheVehicleIdentificationNumber (VIN)is located Theenginecodesfoundonthevehicleinformation 8thdigitintheVINnumber.
ona platewhichis attached to thelefttopsideof the codeplateareasfollows:
instrument panel.Thesenumbers arevisiblefromthe l 4G15--1.5LSOHCengine
outsideof thevehicle.AllVehicleIdentification Num- l 4G61-1.6LDOHCengine
berscontain17digits.Thevehiclenumberisa code l 4G93-1.8LSOHCengine Thetransaxlemodelcodeis locatedonthevehicle
whichtellscountry,make,vehicletype,engine,body l 4G63-2.OL(SOHCor DOHC) engine information
codeplate.Thetransaxleidentification
andmanyotherimportant characteristics
of thatspe- l 4G64-2.4L(SOHCor DOHC)engine numberis etchedona bosslocatedonthefrontup-
cificvehicle. l 6G72-3.OL(SOHCor DOHC) engine perportionof thecase.
Thereis alsoa vehicleinformation codeplate l 6G74-3.5LDOHCengine
whichis rivetedto thebulkhead in theenginecom- A vehiclesafetycertification
labelis attached to
partment. TheplateshowstheVIN,modelcode,en- thefaceof theleftdoorpillarpost.Thislabelindi-
ginemodel,transaxlemodelandbodycolorcodes. catesthemonthandyearof manufacture, GrossVe- Thecodefor thedriveaxleis etchedona bosslo-
Theenginecodeusedonthisplatediffersfromthe hicleWeightRating(GRVW) frontandrear,andVe- catedonthecaseof thedifferential
carrier.
codeletterusedin the8thpositionof theVehicle hicleIdentificationNumber (VIM).
IdentificationNumber(VIN).Eithercodecanbeused
to identifytheparticularenginein thevehicle.Since
thevehicleownerscardis usuallycarried,it maybe
easierto usethecodeletterintheVINfor engineref- ) See Figure 35
erence.Asecondreasonfor referringtotheVINfor Thetransfercasehasnoseparate modelcode,the
engineidentificationisthatcode4663,locatedon codeis locatedonthetransaxle.
Thetransfercaseis
Theenginemodelnumberisstamped atthefront onlveoUiODed onmanualtransaxleAllWheelDrive
thevehicleinformation codeplate,doesidentifythe sideonthetopedgeof thecylinderblock.Thesame
engineasa 2.OLDOHCengine,butdoesnottellyou (AWD)‘mbdels.

Fig. 32 The Vehicle Identification Number Fig. 33 The vehicle model, engine model, Fig. 34 Your car should have a vehicle
(VIN) plate is attachedto the top left side bansaxle model,and bodycolor codeare all
of the instrumentpanel _I:^1 / notedon the vehicle informationcodeg3’51p’o
plate

ENGINEANDVEHiCLEIDENTlFlCATlON
EnglnCode ModelYerr
todeal LIten(cc) Cu. In. W. Fuel+ Type m.hWg. Code@ Year
,G15JA 1.5 (1468) 92 4 MFI SOHC Mitsubishi L 1990
IG61N 1.6(15QQ) 98 4 MFI DOHC Mitsubishi M 1991
1G93lC 1.8 (1834) 112 4 MFI SOHC Mitsubishi N 1992
IG63N 2.0 (1997) 122 4 MFI SOHC “-Mitsubishi P 1993
!G63Fi 2.0 (1997) 122 4 MFI DOHC Mitsubishi R 1994
,G63iU 2.0 (1997) 122 4 MFI-Tuibo DOHC Mitsubishi S 1995
.GMffi 2.4 (2351) 143 4 MFI SOHC Mitsubishi T 1996
iG64L 2.4 (2351) 143 4 MFI DOHC Mitsubishi V 1997
lEzH 3.0 (2972) 161 6 MFI SOHC Mitsubishi W \ 1998
;G7ZJ
~..
iG7zL 3.0 (2972)
3.0 (2Q72) 161
181 66 MFI
MFI GQHC
SOHC Mitsubishi
Miisubishi X ___-___ 1999
~ Y 2000
iG74lP 3.5 (3497) 213 6 MFI SOHC Miisubishi
Fig. 35 Engine model number location-
4663 (2.OL)engine shown
 UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL ENGINE
II
1. Powersteeringbelt 7. PCVvalve 13. Automatictransaxlefluid dipstick
2. Washersolventbottle 8. Distributorcapand rotor 14. Coolantrecoverytank
3. Powersteeringreservoir 9. Fuelfilter (underair inlettube) 15. Radiatorcap
4. Oil fill cap 10. Air filter housing 16. Engineoil dipstick
5. Brakemastercylinderreservoir 11. Enginecompartmentfuse box
6. Sparkplugand plugwire 12. Battery
 UNDERHOODMAINTENANCE COMPONENT LOCATIONS-l .8L ENGINE
1. Coolantrecoverytank 7. Sparkplugandplugwire 13. Powersteeringreservoir
2. Battery 8. PCVvalve 14. Powersteeringbelt
3. Enginecompartmentfuse box 9. Engineoil fill cap 15. Engineoil dipstick
4. Air filter housing 10. Fuelfilter 16. Radiatorcap
5. Clutchfluid reservoir 11. Enginecompartmentrelaycenter
6. Brakemastercylinderreservoir 12. Washersolventbottle
 GENERALINFORMATIONAND
MAlNTENANdE1-13
GENERAL ENGINE SPECIFICATIONS
Engine Fuel Net Net Com- Oil
Displacement Engine Engine No. of System Horsepower Torque @ rpm Bore x Stroke pression Pressure

MFI Mult+wt fuel mfectw,

MFI-T - Multlporl fuel mfectlon-turbocharged
SOHC - Smgle overhead camshaft
DOHC - Double OvedEad camshaft

l-14 GENERALINFORMATIONAND
MAINTENANCE
Propermaintenance andtune-upisthekeyto long
andtrouble-freevehiclelife,andtheworkcanyield
itsownrewards. Studieshaveshownthata properly
tunedandmaintained vehiclecanachievebettergas
mileage thananout-of-tune vehicle.Asa conscien-
tiousowneranddriver,setasidea Saturday morning,
sayoncea month,to checkor replaceitemswhich
couldcausemajorproblems later.Keepyourown
personallogtojot downwhichservicesyouper-
formed,howmuchthepartscostyou,thedate,and
theexactodometer readingatthetime.Keepall re-
ceiptsforsuchitemsasengineoil andfilters,sothat
theymaybereferred tp incaseof relatedproblems or
to determine operatingexpenses. Asa do-it-your-
selfer,thesereceiptsaretheonlyproofyouhavethat
93151p50
Fig. 36 Releasethe retaining clips from the
air cleaner housing
r3151p47
Fig. 37 Unplugthe MAFsensor connector
Fig. 49 . . . then removethe air outlet tube
and upper housingfrom the lower housing
therequiredmaintenance wasperformed. Intheevent
of a warrantyproblem,thesereceiptswill beinvalu-
able.
Theliteratureprovidedwithyourvehiclewhenit
wasoriginallydeliveredincludes thefactoryrecom-
mended maintenanceschedule. If younolongerhave
thisliterature,
replacementcopiesareusuallyavail-
ablefromthedealer.A maintenance scheduleis pro-
videdlaterinthissection,in caseyoudonothave
thefactoryliterature. * 14. Attachtheaircleanerhousingretainingclips.
REMOVAL&INSTALLATION
Except2.gL TurbochargedEngine
b See Figures 36 thru 41
1. Disconnect thenegative batterycable.
2. Release theretainingclipsfromtheair
cleanerhousing.
3. Loosentheclampontheairoutlettubeatthe
throttlebody.
4. Detach thebreatherhosefromtheair inlet
tube.
5. UnplugtheMAFsensorconnector.
6. Separate theupperandloweraircleaner
housings andremove theair outlettubeandupper
housingfromthelowerhousing.
7. Remove theaircleanerelement fromthe
housing.
To install:
8. Cleantheinsideof theaircleanerhousingof
anydirtanddebristhathascollectedinside.
Fig. 38 Detachthe breather hose from the
air tniet tube
Fig. 41 Remove the air cleaner element
from the housing
l
9. Placea newaircleanerelementinsidethe
lowerhousing.Makesurethesealontheelement is
fullyseatedin thegroove.
10. Installtheupperaircleanerhousingandinlet
tubeontothelowerhousing.
11. Tightentheclampontheinlettubeatthe
throttlebody.
12. Attachthebreather
hoseontotheair inlettube.
13. Plugtheconnector intotheMAFsensor.
15. Connect thenegativebatterycable.
2.DLTurbochargedEngine
b See Figure 42
1. Disconnect thenegative batterycable.
2. Detach theairflowsensorconnector.
3. Unfasten theboosthose.
4. Disconnect thesolenoidvalvewithhoses.
5. Disconnect theair intakehose.
6. Unfasten tie aircleanerretainerboltsandthe
air cleanerassembly.
7. Unclamp thecoverandremove fromthehous-
ing.
*Care mustbe takenwhen removingthe air
cleaner cover. Theair flow sensoris at-
tachedand could be damagedduringcover
removal.
8. Remove theaircleanerelement. Thoroughly
cleantheaircleanerhousingpriorto replacing theair
filter.
To install:
9. Installthenewair cleanerelementintothe
housing.Installandsecurethecoverin place.
Fig. 39 Loosenthe clamp on the air outlet
tube at the throttle body . . .
Fig. 42 Detachthe air flow sensor connec-
tor, the boost hose and the solenoid valve
connector
 GENERALINFORMATIONAND
MAINTENANCE
l-15
10. installtheaircleanerassembly andthere- *Wrap shoptowels aroundthe fitting that is 9. Whileholdingthefuelfilternutwithaback-
tainerbolts. being dtsconnectedto absorbresidual fuel in upwrench,tightenthebanjoboltto 22ft. Ibs.(30
11. Connect theair intakehose. the lines. Nm).Tightentheflarenutto25ft. Ibs.(35Nm),with
12. Attachthesolenoidvalve. 4. Coverthehoseconnection withshoptowelsto a back-upwrenchonthenut.
13. Connect theboosthose. preventanysplashof fuelthatcouldbecausedby 10. Tightenthefiltermounting boltsto 10ft. Ibs.
14. Attachtheairflowsensorconnector. residualpressure inthefuelpipeline.Holdthefuel (14Nm).
15. Connect thenegative batterycable. \ filternutsecurely witha backupwrench,thenremove 11. Connect thenegative batterycable.Turnthe
thebanjoboltontheenginefeedline.Disconnect the keyto theONpositionto pressurize thefuelsystem
high-pressure fuellinefromthefilter.Remove and andcheckfor leaks.
discardthegaskets. 12. If repairsof a leakarerequired,remember to
5. Whileholdingthefuelfilternutsecurely witha releasethefuelpressure beforeopeningthefuelsys-
REMOVAL&INSTALLATION tern.
back-upwrench,loosenthefilterfeedpipeflarenut
onthebottomof thefilter.Separate theflarenutcon-
u See Figures 43 thru 48 nectionfromthefilter.If equipped, removeanddis-
Onmostvehiclescoveredbythismanual,
thefuel cardthegaskets.
filteris locatedintheenginecompartment,
mounted . 6.,,,.Remove
,. themounting bolts
.a and remove
r I,.,< I the REMOVAL&INSTALLATION
to thefirewall. ruerrrrter.II necessary,remove me ruerrrrreroracket.
To install:
7. Installthefilterto itsbracketonlyfinger-tight. u See Figures49, 50, and 51
Movement of thefilterwill easeattachment of thefuel 1, Disconnect thenegative batterycable.
Do not use conventionalfuel filters, hosesor lines. 2. If necessary for access,removetheair intake
clampswhen servicing fuel injection sys hoseandaircleanerassembly.
terns. Theyare not compatiblewith the injec- 3. If necessary, unfastentheretainingclamp,then
tion systemandcouldfail, causingpersonal disconnect theventilationhosefromthePCVvalve.
injury or damageto the vehicle. Useonly 4. Remove thePCVvalvefromthecamshaft
hosesand clampsspecifically designedfor Ensurethat the filter is installed with the flow
arrow in the proper direction. Theflow arrow (rocker)cover.
fuel injection systems. To install:
typically pointstoward the engineside of the
filter. improperinstallation of the fuel filter 5. InstallthePCVvalveintotherockercover.If
1. Properlyrelievethefuelsystempressureas thevalveis threaded, tightenthevalveuntilsnug.
outlinedinSection5 of thismanual. will causethe vehicle to run poorly.
6. Reconnect theventilationhoseto thevalve.
2. If notalreadydone,disconnect
thenegative 7. If removed, installtheair intakehoseandthe
batterycable. *Make sure new O-ringsare installed prior a.ircleanerassembly.
3. Onmostmodels. theiobis madeeasierif the to installation. 8. Connect thenegative batterycable.
air inlethoseandupperaircleanerhousingis re- 8. Insertthefilterfeedpipeto thelowerconnec-
movedfromthevehicle. tionof thefilterandmanually screwin themain
pipe’sflarenut.

Fig. 43 Use a back-upwrench on the fuel 93151@3

filter nut when looseningthe banjo-bolt on I I Fig. 44 After the banjo-boltis loose, removeI Fig. 45 Make sure to replace the copper
1the engine feed line - from the fuel filter washers on the banjo-bolt fitting

93151p93

Fig. 48 Make sure to usea back-upwrench Fig. 47 Remove the two filter bracket re- Fig. 48 . . . then remove the filter from the
1when unfasteningthe main fuel pipe also 1 taining bolts . . . vehicle

l-16 GENERALINFORMATIONAND
MAINTENANCE
Fig. 49 Graspthe valve and gently remove
it from the valve cover
SERVICING
u See Figure 52
Theevaporativecanisterrequiresno periodicser-
vicing. However,a carefulinspectionof the canister
and hosesshouldbe madefrequently,Replacedam-
agedcomponentsas required.
The canisteris typically locatedunderone of the
front fenders,howeveron some latermodelsit may
be underthe rearof the vehicle,nearthe gastank,
r on most models
causea short circuit, leadingto sparksand possible
personalinjury.
Do not smoke,havean openflameor create
sparksneara battery;the gasescontainedin the bat-
tery are very explosiveand, if ignited,could causese-
vere injury or death.
All batteries,regardlessof type,should becare-
fully securedby a batteryhold-downdevice.If this is
not done,the batteryterminalsor casingmay crack
from stressappliedto the batteryduringvehicleoper-
ation.A batterywhich is not securedmayallow acid
to leakout, makingit dischargefaster;such leaking
Fig. 50 Twist and pull on the valve to re-
move it from the hose
corrosiveacid canalso eatawayat componentsun-
der the hood.
Alwaysvisually inspectthe batterycasefor cracks,
leakageand corrosion.A whitecorrosive substance
on the batterycaseor on nearbycomponentswould
indicatea leakingor crackedbattery.If the batteryis
cracked,it shouldbe replacedimmediately.
GENERALMAINTENANCE
'_
# See Figure 53
A batterythat is not sealedmust be checkedperi-
odicallyfor electrolytelevel.You cannotadd waterto
a sealedmaintenance-freebattery(thoughnot all
maintenance-freebatteriesare sealed);however,a
sealedbatterymust also becheckedfor properelec-
trolyte level,as indicatedby the color of the built-in
hydrometer“eye.”
Alwayskeepthe batterycablesand terminalsfree
of corrosion.Checkthesecomponentsaboutoncea
year.Referto the removal,installationand cleaning
proceduresoutlinedin this section,
Keepthe top of the batteryclean,as a film of dirt
canhelp completelydischargea batterythat is not
usedfor long periods.A solution of bakingsodaand
watermay be usedfor cleaning,but be carefulto
flush this off with clearwater.DONOTlet anyof the
solution into the filler holes.Bakingsodaneutralizes
batteryacid and will de-activatea batterycell.
Batteriesin vehicleswhichare not operatedon a
regularbasiscanfall victim to parasiticloads (small
currentdrainswhich are constantlydrawingcurrent
from the battery).Normalparasiticloads maydrain a
m /
tcu1@32
Fig. 53 A typical location for the built-in hv-
drometer on maintenance-free batteries ’ I
’ discarded.
*
Fig. 51 Inspectthe grommetand replace if
cracked or leaking oil
devicesthat increaseparasiticload maydischargea
batterysooner.If the vehicle is to be storedfor 6-B
weeksin a secureareaand the alarmsystem,if pre-
sent, is not necessary,the negativebatterycable
should bedisconnectedat the onsetof storageto
protectthe batterycharge.
Rememberthat constantlydischargingand
rechargingwill shortenbatterylife. Takerare not to
allow a batteryto be needlesslydischarged.
BA-ITERY
FLUID
Checkthe batteryelectrolytelevelat leastoncea
month.or more often in hot weatheror during peri-
ods ofextendedvehicleoperation.On non-sealed
batteries,the levelcan becheckedeitherthroughthe
caseon translucentbatteriesor by removingthe cell
capson opaque-casedtypes.Theelectrolytelevel in
eachcell shouldbe keptfilled to the split ring inside
eachceil, or the line markedon the outsideof the
case.
If the level is low, add only distilled waterthrough
the openinguntil the level is correct.Eachcell is sep-
aratefrom the others,so eachmust be checkedand
filled individuallv.Distilled watershouldbe used,be-
causethe chemicalsand mineralsfound in most
drinking waterare harmfulto the batteryand could
significantlyshortenits life.
If wateris addedin freezingweather,the vehicle
shouldbe drivenseveralmiles to allow the waterto
mix with the electrolyte.Otherwise,the batterycould
freeze.
Althoughsomemaintenance-freebatterieshave
removablecell caosfor accessto the electrolyte,the
built-in hydrometer. . \
*Although the readingsfrom built-in hy-
drometersfound in sealed batteriesmay
vary,a greeneyeusuallyindicatesa prop
erly chargedbatterywith sufficient fluid
level. A dark eye is normally an indicator of a
batterywlth sufficient fluid, but one which
may be low in charge.And a light or yellow
eye is usually an indication that electrolyte
supply has droppedbelow the necessary
level for battery (and hydrometer)operation.
In this last case. sealed batterieswith an in-
sufficient electrolyte level mustusually be
 G,ENERALlNFORMATlONAND
MAINTENANCE
l-17

Fig. 54 Onnon-maintenance-freebatteries,
the fluid level can be checkedthrough the Fig. 55 If the fluid level is low, add only dis-
1case on translucent models; the cell caps1 1tilled water through the opening until the Fig. 56 Checkthe specific gravity of the bat-
must be removedon other models 1 1level is correct tery’s electrolyte with a hydrometer

Checkingthe Specific Gravity \ Asstatedearlier,thespecificgravityof a battery’s morecells,thebatteryshouldbeslowlycharged and

electrolytelevelcanbeusedasanindicationof bat- Lhecked aqaintoseeif thearavitvhascomeUP. Gen-
# See Figures 54, 55, and 56 terycharge.Atleastonce ?a year,checkthespecific erally,if affercharging,
thespecificgravitybetween
any
A hydrometer is requiredto checkthespecific gravityof thebattery.It shouldbebetween 1.20and twocellsvariesmorethan50points(0.50)thebattery
gravityonall batteriesthatarenotmaintenance-free. 1.26onthegravityscale.Mostautosupplystores shouldbereplaced, asit cannolongerproduce suffi-
Onbatteries thataremaintenance-free, thesoecific carrya variety of inexpensive battery testinghydrom- cientvoltageto guarantee properoperation.
gravityischecked byobserving thebuilt-inhydrome- eters.
, , ,These
,, can .,,beused.. onanynon-sealed battery
ter“eye”onthetopof thebatterycase.Checkwith IOrestmespecmc gravnyineachcell. CABLES
yourbattery’s manufacturer for properinterpretation Thebatterytestinghydrometer hasasqueeze bulb
of itsbuilt-inhvdrometer readinas. atoneendanda nozzle attheother.Battery electrolyte ) See Figures 57, 56, 69, 60, and 61
thehydrometer untilthefloatis lifted
-hespecificgravityisthenreadbynot- Oncea year(orasnecessary),
thebatterytermi-
mgtneposrtro n of thefloat.If gravityis lowinoneor nalsandthecableclampsshouldbecleaned. Loosen
Batteryelectrolyte containssulfuric acid. If
you shouldsplashany on your skin or in your
eyes, flush the affected area with plenty of
clear water. If it lands in your eyes, get med-
ical help immediately.
Thefluid(sulfuricacidsolution)contained inthe
batterycellswill tellyoumanythingsaboutthecon-
ditionof thebattery.Because thecellplatesmustbe
keptsubmerged belowthefluidlevelin orderto op-
erate,maintaining thefluidlevelis extremely impor-
tant.And.because thesoecificaravitvof theacidis
anindicationof electricalcharge,testingthefluidcan
beanaidindetermining if thebatterymustbere-
placed.A batteryin avehiclewitha properlyoperat-
ingchargingsystemshouldrequirelittlemainte-
nance,butcareful,periodicinspection shouldreveal Fig. 57 Maintenance is performed with Fig. 58 The underside of this special bat-
problems beforetheyleaveyoustranded. householditems and with special tools like tery tool has a wire brushto clean post ter-
I this post cleaner I 1minals
 l

1-18 GENERALINFORMATIONAND
MAINTENANCE
theclampsandremovethecables,negative cable alternator
orturntheadjustingboltto adjustbeltten-
first.Onbatteries
withpostsontop,theuseof a sion.Oncethedesiredvalueis reached, securethe
pullerspeciallymadeforthispurposeis recom- boltor locknutandrecheck
tension.
mended. Theseareinexoensiveandavailablein most
d”t” lJdlL> X”lt;>. 31°C LtXlllllldl lJdllt2)’ MLJIC, dlt’ X- ST& I REMOVAL
&INSTALLATION
curedwitha smallbolt. I
Cleanthecableclampsandthebatteryterminal
witha wirebrush,untilall corrosion, grease, etc.,is 1.5L, 1.611,1.8L, 2.OLand 2.4L Engines
removed andthemetalisshiny.
shinv.It isespecially
esneciallv impor-
imnnr-
tantto clean
c theinsideof theclampthoroughly (anold ALTERNA
TORBE1T
knifeis usefulhere),
nere),sincea small
smartdepositof foreign e See Figures67,68, and 69
material or oxidation therewill prevent
pre a soundelectri-
calconnection andinhibiteitherstartingor charging. Fig. 62 There
mere are typically 3 types of ac- 1. Loosenthealternator supportnut.
Specialtoolsareavailable forcleaning theseparts, cessory drive belts found on vehicles today 2. Loosentheadjusterlockbolt.
onetypeforconventional toppostbatteries andan-
batteries.
othertypeforsideterminalbatterin, It ifisalso
I+ QI@*3annnd
good I 3. Rotate
release the , the
.I tension. adjuster
.. bolt
* ..counterclockwise
onthebelt.
to
ideatoapplysomedielectric grr
grease totheterminal, as 4. Remove thebelt.
thiswill aidintheprevention corrosion,
of ,,vIIuaIUII. Tn install:
To i”et*ll*
Aftertheclampsandterminals areclean,reinstall 5. Installthebeltonthepulleys.
thecables,negative cablelast;DONOThammer the I 6. Rntatn
R Rotate thecxiillrtm
the adjusterhnit
boltA&+,&
clockwiseuntilthe
until the
clampsontobatteryposts.Tightentheclampsse- rproper
-r- tension is .______
.- .-._..._ reached.
curely,butdonotdistortthem.Givetheclampsand 7. Tightentheadjusterlockboltandthealternator
terminals athinexternalcoatingof greaseafterin- supportnut.
stallation,to retardcorrosion.
Checkthecablesatthesametimethattheterminals POWERSTEERING
BELT
arecleaned. If thecableinsulation is cracked orbro-
ken,or if theendsarefrayed,thecableshouldbere- 8 See Figures 70 and 71
placedwitha newcableofthesamelengthandgauge. aauae. 1. Remove thealternator
beltasdescribed
above.
CHARGING 2. Loosenthepowersteeringpumpadjusting
Fig. 64 Deep cracks in this belt will cause bolts.
flex, building up II”“.
..“‘.I ““..Y...Y heat that
..IU. will
..m.*eventually
V. 3. Remove thepowersteeringoumofixedbolton
1 I I 1lead to belt failure 1 therearof thebracket. -
4. Rotatethepumptowardtheengineandremove
The chemicalreactionwhich takes place in thebelt.
all batteriesgeneratesexplosive hydrogen To fnstall:
gas. A spark can causethe batteryto explode 5. Installthebeltonthepulleys.
andsplash acid. To avoid serious personal
injury, be sure there is properventilation and
take appropriatefire safety precautionswhen
connecting,disconnecting,or charginga bat-
tery andwhen usingjumpercables.
A batteryshouldbecharged ata slowrateto keep Fig. 85 The cover of this belt is worn, ex-
theplatesinsidefromgettingtoohot.However, if
somemaintenance-free batteries
areallowedto dis-
chargeuntiltheyarealmost“dead,”theymayhaveto
becharged ata highrateto bringthembackto “life.”
Alwaysfollowthechargermanufacturers instructions
oncharging thebattery.
REPLACEMENT
1Fig. 67 Loosenthe adjuster lock bolt . . .
Whenit becomes necessary to reolacethnhaeoN I ‘-
tm1217
selectonewithanamperage ratingequaltcI‘”or
. yyL’“‘J’
oreMer
a ---- I -. -_
thanthebatteryoriginallyinstalled.Deteriorationand Fig. 66 Installing too wide a belt can resylt
justplainagingofthebatterycables,startermotor, in serious belt wear and/or breakage
andassociated wiresmakesthebattery’s jobharder
insuccessive years.Theslowincrease in electrical thebeltandrunoutward. Allwornor damaged drive
resistanceovertimemakesit prudentto installa new beltsshouldbereplaced immediately.
It is bestto re-
batterywitha greatercapacitythantheold. placeall drivebeltsatonetime,asa preventive
maintenance measure,duringthisserviceoperation.
:*
- ADJUSTMENT
INSPECTION Excessive belttensionwill causedamage totheal-
ternatorandwaterpumppulleybearings, while,on
e See Figures 62, 83, 64, 65, and 88 theotherhand,loosebeIttensionwill Droduce
r ------ slinr
Inspectthebeltsfor signsof glazingor cracking.A andpremature wearonthebelt.Therefore, besureto Fig. 68 . . . then remove the alternator
adjustthebelttensionto theproperlevel.
glazedbeltwill beperfectlysmoothfromslippage,
Toadjust the tension ona onve
’ ’ ’Den.
” ’loosen me
‘* I from the engine
whilea goodbeltwill havea slighttextureof fabric
visible.Crackswill usuallystartattheinneredgeof adjustingboltorfixingbboltlocknutonthealternator,
alternator
bracketor tens iionpulley.Thenmovethe
 GENERAL
INFORMATION
ANDMAlNTENANdEl-19
6. Rotatethepumpuntilthepropertensionis 4. Remove thebelt.
reached. To install:
7. Tightentheadjustingboltsonthepump. 5. Installthebeltonthecrankshaft andalternator
8. Tightenthefixedboltontherearof thebracket. pulleys.
9. Installthealternator
belt. 6. Usingtheadjusting boltonthetensioner,
tightenthebeltto thedesiredtension.
A/r: COMPRESSOIl BELf 7. Tightenthefixingnutto holdtheadjustment.
1. Loosenthetensionoullevandremove thebelt. 8.
_, Installtheundercoverandlowerthevehicleto
2. Theinstallation
isthereverseof theremoval. thetloor.
9. Connect thenegative
batterycable.
.3.gL DGHC,3.OLSOHC(Gaiant models
only) and 3.5L Engines POWERSliEERlNGBELf
6 See Figures72 and 73 1. Disconnect
theneaative
batteNcah+P

-I
Wait at least 60 secondsafter the negative
battery cable is disconnectedto preventpoS-
sibie deploymentof the air bag.
2. Raiseandsafelysupportthevehicleandre-
mobretheundercover.
3. Remove thealternator
andNC compressor
belt.
4. Lowerthevehicleandremovethecruisecon-
trol oumn link iW%mblV.
---- - _I
79244Q.37 -- I-- r
5. Place thepowersteeringhoseundertheoil
Fig. 72 Serpentinebelt routing-Mitsubishi reservoir.
3.OLengines (except 1696-00 Galant mod- 6. Loosenthetensionpulleyfixingboltsandre-
els) 1 movethepowersteeringpumpdrivebelt.
To install:
792UQ4
Generator pulP 1 7. installtheDowersteerinaoumur+r+v~ hp++
Fig. 69 Accessory V-belt routing-Mii 8. Insertanextensionbar&eoufvaik;;t”f;;id‘he
subishf 1.6L, 1.6L,-1.6L, 2.OLand 2.4L en openingattheendof thetensionpulleybracketand
gines pivotthepulleyto applytensionto thebelt.
9. Tightenthefixingbolts.
10. Raisethevehicleandinstallthealternator and
compressor belt.
Il. Installtheundercover andlower+hfi
.I,.,vph+r+p
.VII.“.Y.
12. Connect thenegative
batterycable.
I 3.OLSGHC(DiamanteModels Onivl Enotne
1. Disconnect thenegative
,r

batterycable.
”

I 2.’ Loosenthelockboltonthefacenf _the__.-

A/C
tensioner pulley.
3 Turntheadiustinaboltof theA/C+fincrnner
pulleyto loosenthetensionof theA/Cbelt.
4. Remove theA/Ccompressor belt.
5. Loosenthelocknutonthefaceof thepower
33151PM steering/alternator tensloner pulley.
Fig. 70 After the adjusting and fixed bolt! 6. Turntheadjusting boltof thetensioner pulley
are loosened, rotate the pump . . . to loosenthetcmsionof thebelt.
7. Remov ‘ethepowersteering/alternator belt.
To install:
Fig. 73 AccessoryV-beltrouting-Mitsubishi 8. Install
.* .* . the
,^ powersteering/alternator beltfirst
3.5L and 1996-00 3.OL SOHCGalant en- anatnentneA/ti compre: ssordrivebelt.
gines 9. Adjustthebeltst+I thepropertensionbyturn-
ingtheadjusting A.:-L
boltsanu I-..-.. I,^, .’
II~IIWII pueeytlxmg
nut/bolt.
10. Tightenthemounting nutof thepowersteer-
ing/alternator tensioner pulleyto 36ft. Ibs.(50Nm).
Wait at least 60 secondsafter the negative -The manufacturerdoes not provide a
battery cable is disconnectedto preventpos- torque specificationfor the bolt that secures
sible deploymentof the air bag. A/Ctensionerpulley.
2. Raiseandsafelysupportthevehicleandre- 11. Connect thenegative batterycable.
movethefrontundercover.
/ F$71t immtl$mm&a the power ::: 3. Loosenthetensionpulleyfixingnutandrelieve
thetensiononthebeltbyturningtheadjustingbolt.
 .
l-20 GENERALINFORMATIONAND
MAINTENANCE

INSPECTION
# See Figures 74 thru 81
Allenginescoveredbythismanualutilizetiming
beltsto drivethecamshaft fromthecrankshafts turn-
ingmotionandto maintain propervalvetiming.
Somemanufacturers schedule periodictimingbelt
replacement to assureoptimum engineperformance,
to makesurethemotoristis neverstranded should
thebeltbreak(astheenginewill stopinstantly) and
for some(manufacturers withinterference motors)to Fig. 74 Checkfor premature parting of the . 75 Check if the teeth are cracked or
preventthepossibilityof severeinternalenginedam- belt
ageSt10Ula the Delt break.
Although the1.5Land1.8Lenginesarenotlisted
asaninterference motors(it is notlistedbytheman-
ufacturerasa motorwhosevalvesmightcontactthe
pistonsif thecamshaft wasrotatedseparately from
thecrankshaft) thefirst2 reasons for periodicre-
placement stillapplyandthetimingbeltshouldbe
replaced at60,000miles(96,000km).The1.6L,
2.01,2.4L, 3.OL,and35L enginesarelistedasinter-
ferencemotors,sothetimingbeltMUSTbereplaced
at60,000miles(96,000km)to avoidsevereengine
damage if thebeltshouldbreak.
Butwhether or notyoudecideto replacethetim- tml245 fig. 77 You may only have damageon one
ingbeltin themanufacturers schedule, youwouldbe Fig. 76 look for noticeable cracks or wear side of the belt; if so, the guide could be
wisetocheckit periodically to makesureit hasnot
become damaged orworn.Generally speaking, a se- _on the belt face the culprit
verelvwornbeltmavcauseenaineoerformance to
drop~dramatically, buta damaged belt(whichcould
giveoutsuddenly) maynotgiveasmuchwarning.In
general,anytimetheenginetimingcover(s)is (are)
removed youshouldinspectthebeltfor premature
parting,severecracksor missingteeth.Also,anac-
cessplugis providedintheupperportionof thetim-
ingcoversothatcamshaft timingcanbechecked
withoutcoverremoval.If timingis foundto beoff,
coverremovalandfurtherbeltinspection or replace-
mentis necessary.
Forthetimingbeltremovalandinstallation proce-
dure,pleasereferto Section3 of thismanual.

Fig. 78 Foreign materials can get in be- Fig. 79 Inspect the timing belt for c
tween the teeth and cause damage fraying, glazing or damageof any kind
INSPECTION
b See Figures 82,8S, 84, and 85 .
Upperandlowerradiatorhoses,alongwiththe
heaterhoses,shouldbechecked for deterioration,
leaksandloosehoseclampsat leastevery30,000
miles(48,000km).It is alsowiseto checkthehoses
periodically inearlyspringandatthebeginning of
thefall or winterwhenyouareperforming other
maintenance. A quickvisualinspectioncoulddis-
coveraweakened hosewhichmighthaveleftyou
stranded if it hadremained unrepaired.
Whenever youarechecking thehoses,makesure
theengineandcoolingsystemarecold.Visuallyin-
spectforcracking,rottingor collapsed hoses,andw-
placeasnecessary. Runyourhandalongthelength Fig. 80 Damageon only one side of the tim- Fig. 81 ALWAYSreplace the timing belt at
of thehose.If a weakor swollenspotis notedwhen
squeezing thehosewall,thehoseshouldbere- ing belt may indicate a faulty guide I ,
I the interval specified by the manufacturer
L

placed.
 GENERALINFORMATIONAND
MAINTENANCE
l-21
9. Closetheradiatororenginedrainsandprop-
erlyrefillthecoolingsystemwiththecleandrained
enginecoolantor a suitablemixtureof ethylene gly-
cotcoolantandwater.
10. If available,installa pressure
testerandcheck
for leaks.If a pressure
testeris notavailable,
runthe
engineuntilnormaloperating temperature
is reached
(allowingthesystemto naturallypressurize), then
checkfor leaks.

IWSIZXJ

Fig. 82 The cracks developing along this
hose are a result of age-related hardening
FM. 83 A hose clamn that is taa tiaht can
caise older hoses td separate and‘iear on
either side of the clamp
If you are checkingfor leaks with the system
at normaloperatingtemperature,BEEX-
TREMELYCAREFULnot to touchany moving
or hot engineparts. Oncetemperaturehas
beenreached.shutthe enaine OFF.and
checkfor leaks aroundthe-hosefittings and
connectionswhich were removedearlier.

lCCS1221
Fig. 84 A soft spongy hose (identifiable by
the swollen section) will eventually burst
and should be replaced 1 odically flushed
IEMOVAL&,INSTALLATION ' 3. Loosenthehoseclampsateachendofthe
1. Remove
theradiatorpressure
cap.
Never removethe pressurecap while the en-
gine is running,or personalinjury from
scaldinghot coolant or steammayresult. If
possible, wait until the enginehascooled to
removethe pressurecap. If this is not possi-
ble, wrap a thick cloth aroundthe pressure
cap andturn it slowly to the stop. Stepback
while the pressureis releasedfrom the cool-
ing system.Whenyou are sure all the pres-
sure has beenreleased, use the cloth to turn
and removethe cao.
2. Positiona cleancontainer
undertheradiator
and/orenginedraincock or plug,thenopenthedrain
andallowthecoolingsystemto drainto anappropri-
atelevel.Forsomeupperhoses,onlya littlecoolant
mustbedrained. Toremovehosespositioned lower
ontheengine,suchasa lowerradiatorhose,theen-
tirecoolingsystemmustbeemptied.
Whendraining coolant, keep in mindthat
cats and dogsare attractedby ethylenegly-
col antifreeze,and are quite likely to drink
any that is left in an uncoveredcontaineror
in puddleson the ground.This will prove fa-
tal in sufficient quantity. Always drain
coolant into a sealable container. Coolant
may be reusedunless it is contaminatedor
several years old.
INSPECTION
b See Figures 88 and 87
TheCV(Constant Velocity)bootsshouldbe
checked for damage eachtimetheoil is changedand
anyothertimethevehicleis raisedfor service.These
Fig. 85 Hosesare likely to deteriorate from bootskeepwater,grime,dirtandotherdamaging
the inside if the cooling system is not peri- matterfromenteringtheCV-joints.Anyof these
couldcauseearlyCV-jointfailurewhichcanbeex-
pensiveto repair.Heavygreasethrownaroundthein-
sideof thefrontwheel(s)andonthebrake
caliper/drum canbeanindicationof a tornboot.
roserequiringreplacement.
Clampsareusuallyei- Thorouahlv checkthebootsfor missinaclamosand
herofthesorinatensiontvoe(whichreouireoliers
3squeeze the6bsandloosenjor of the’screw ten-
iontype(whichrequirescreworhexdriversto
oosen).Pulltheclampsbackonthehoseawayfrom
heconnection.
4. Twist,pullandslidethehoseoffthefitting,
skingcarenotto damage theneckof thecomponent
romwhichthehoseis beingremoved.
*If the hose is stuckat the connection,do
lot try to insert a screwdriver or other sharp
ool underthe hose end in an effart to free it,
ISthe connectionand/orhosemay become
lamaged.Heaterconnectionsespecially
nay be easily damagedby sucha procedure.
f the hose is to be replaced, use a single- Fig. 86 CV-bootsmust be inspectedperiod-
!dgedrazor blade to makea slice alongthe
lortion of the hosewhich is stuckon the con-
section,perpendicularto the end of the
lose. 00 not cut deepso as to preventdam-
agingthe connection.The hosecanthen be
keeledfrom the connectionand discarded.
5.. Cleanbothhosemounting connections. In-
,pecttheconditionof thehoseclampsandreplace
hem,if necessary.
To install:
6. Diptheendsof thenewhoseintocleanen-
finecoolanttoeaseinstallation.
7. Slidetheclampsoverthereplacement hose,
henslidethehoseendsovertheconnections into
rosition.
8. Positionandsecuretheclampsatleastl/d in.
6.35mm) fromtheendsof thehose.Makesurethey
Irelocatedbeyondtheraisedbeadof theconnector.
l-22 GENERALINFORMATIONAND
MAINTENANCE
tears.If thebootis damaged, it shouldbereplaced trodeis totheblock’scoolingpassages) thecoolerit yourdrivingis longdistance,highspeedtravel,usea
immediately. Pleasereferto Section7 for procedures. will operate.A plugthatabsorbslittleheatandre- colderplug;if mostof yourdrivingis stopandgo,
mainstoocoolwill quicklyaccumulate depositsof usea hotterplug.Originalequipment plugsaregen-
oil andcarbonsinceit is nothotenoughto burn erallya goodcompromise between the2 stylesand
themoff.Thisleadsto plugfoulingandconsequently mostpeopleneverhavetheneedto changetheir
to misfiring.A plugthatabsorbstoomuchheatwill plugsfromthefactory-recommended heatrange.
havenodepositsbut,duetotheexcessive heat,the
ti See Figure 88 ,electrodes
will burnawayquicklyandmightpossibly REMOVAL
&INSTALLATION
Atypicalsparkplugconsistsof a metalshellsur- leadto preignitionor otherignitionproblems. Preig-
roundinga ceramicinsulator. A metalelectrode ex- nitiontakesplacewhenplugtipsgetsohotthatthey ti See Figures 90 thru 95
tendsdownward throughthecenterof theinsulator glowsufficientlyto ignitetheair/fuelmixturebefore
andprotrudes a smalldistance. Locatedattheendof theactualsparkoccurs.Thisearlyignitionwill usu- A setof sparkplugsusuallyrequiresreplacement
theplugandattached to thesideof theoutermetal allycausea pingingduringlowspeedsandheavy afterabout20,000-30,000 miles(32,000-48,000
shellis thesideelectrode. Thesideelectrode bends loads. km),depending onyourstyleof driving.Innormal
inata 90”anglesothatitstip is justpastandparal- Thegeneralruleof thumbfor choosingthecorrect operationpluggapincreases about0.001in.
lelto thetio ofthecenterelectrode. Thedistance be- heatrangewhenpickinga sparkplugis:if mostof (0.025mrn) forevery2,500miles(4,000km).Asthe
tweenthesetwoelectrodes (measured inthousandths
of aninchor hundredths of a millimeter)is calledthe
sparkpiuggap.

INSULATOR CRACKS
OFTEN OCCUR HERE

Fig. 91 A special spark plug socket with a

I
Fig. 90 Carefully twist the boot end of the rubber insert is required to remove the
ENTER ELECTRODE:
SIDE ELECTRODE
(SEND TO ADJUST GAP) FILE FLAT WHEN spark plug wire andwithdraw the sparkplug spark plugs. Typically the spark plugs re-
ADJUSTING
DO NOT BEND
GAP;
wire boot from the cylinder head quire a Yaspark plug socket

Fig. 88 Cross-sectionof a spark plug

Thesparkplugdoesnotproduce a spark,butin-
steedprovidesa gapacrosswhichthecurrentcan
arc.Thecoilproduces anywhere from20,000to
50,000volts(depending onthetypeandapplication)
whichtravelsthroughthewirestothesparkplugs.
Thecurrentpassesalongthecenterelectrode and
jumpsthegaptothesideelectrode, andin doingso,
ignitestheair/fuelmixtureinthecombustion charn-
ber.
SPARKPLUG
HEATRANGE
Fig. 92 A locking extension such as this is
ti See Figure 89 extremely helpful when removing spark Fig, 93 Using the appropriate sized spark
plugsthat are centrally located in the cyhn- plugsocket, necessaryextensionsanddrive
Sparkplugheatrangeistheabilityof theplugto tools, loosen the spark plug . . .
dissipateheat.Thelongertheinsulator(orthefarther
it extendsintotheengine),thehottertheplugwill
operate;theshortertheinsulator(theclosertheelec-

93151ptxl

Fig. 95 After removingthe plug from the en-

gine, inspect it using the spark plug condi-
Fig. 94 . . . then carefully withdraw the tion chart in this section to determine the
spark plug from the engine runningcondition of your engine
 t

GENERALINFORMATIONAND
MAINTENANCE
l-23
gapincreases, theplug’svoltagerequirement alsoin- thesparkplugcounterclockwise
to loosenandre- 11. Applya smallamountof siliconedielectric
creases. It requiresa greatervoltageto jumpthe movethesparkplugfromthebore. compound totheendof thesparkplugleador inside
widergapandabout&o to threetimesasmuchvolt- thesparkplugbootto preventsticking,theninstall
ageto firetheplugathighspeedsthanatidle.The thebootto thesparkplugandpushuntilit clicksinto
improved air/fuelratiocontrolof modernfuelinjec- place.Theclickmaybefeltor heard,thengentlypull
tioncombined withthehighervoltageoutputof mod- Be sure not to usea flexible extensionon the backonthebootto assurepropercontact.
ernignitionsystems will oftenallowanengineto run socket. Useof a flexible.___.
extensionmay
. _allow 12. Onthe3.OLfSOHCandDOHC) and3.5Len-
significantly longerona setof standard sparkplugs, ea to me plug. A
a shearforce to be agptf’LL_ gines,installtheupperintakemanifold.Referto Sec-
shearforce could breaktne _I___
pug -u
on I_
III IL-
me
butkeepin mindthatefficiency will dropasthegap tion3 fortheinstallation
procedure.
widens(alongwithfueleconomy andpower). cylinder head, leadingto costly andfrustrat- 13. Ifequipped,installthecentercover.
Whenyou’reremoving sparkplugs,workonone ing repairs.
ata time.Don’tstartbyremoving theplugwiresall at INSPECTION
& GAPPING
once,because, unlessyounumber them,theymay To install:
become mixedup.Takea minutebeforeyoubegin 7. Inspect thesparkplugbootfor tearsor dam- b See Figures 98, 97, 98, 99, and 100
andnumber thewrrpcwith+sne
,,Y” ..1111 uy”’
age.If.adamaged bootis found,thesparkplugwire
1. Disconnect. 1theneaative
~~.~ --..-.,
bat&vcable
-..-.-, and
-..- if mustbereplaced. Checktheplugsfor depositsandwear,Iftheyare
thevehiclehasbeenrunrecently, allowtheengineto 8. Usinga wirefeelergauge, checkandadjust notgoingto bereplaced, cleantheplugsthoroughly.
thoroughly cool. thesparkpluggap.Whenusinga gauge,theproper Remember thatanykindof depositwill decrease the
2. If equipped, remove thecentercover. sizeshouldpassbetween theelectrodes
witha slight efficiencyof theplug.Plugscanbecleaned ona
3. Onthe3.OL(SOHCandDOHC) and3.5Len- drag.Thenextlargersizeshouldnotbeableto pass sparkplugcleaningmachine, whichcansometimes
gines,theupperintakemanifoldmustberemoved to whilethenextsmallersizeshouldpassfreely. befoundin servicestations,or youcandoanaccept-
accesstherearsparkplugs.Referto Section3 forthe 9. Carefully threadtheplugintotheboreby ablejobof cleaningwitha stiffbrush.If theplugsare’
removalprocedure. hand.If resistanceis feltbeforetheplugisalmost cleaned, theelectrodes mustbefiledflat.Useanig-
4. Carefullytwistthesparkplugwirebootto completely threaded, backtheplugoutandbegin nitionpointsfile,notanemeryboardorthelike,
loosenit,thenpullupwardandremove thebootfrom threading again.Insmall,hardto reachareas,anold whichwill leavedeposits. Theelectrodes mustbe
theplug.Besureto pullonthebootandnotonthe sparkplugwireandbootcouldbeusedasathread- filedperfectlyflatwithsharpedges;rounded edges
wire,otherwise theconnector locatedinsidetheboot ingtool.Thebootwill holdtheplugwhileyoutwist reducethesparkplugvoltagebyasmuchas50%.
maybecome separated. theendofthewireandthewireis suppleenoughto Checksparkpluggapbeforeinstallation. The
5. Usingcompressed air,blowanywateror de- twistbeforeit wouldallowtheplugto crossthread. groundelectrode (theL-shaped oneconnected to the
brisfromthesparkplugwelltoassurethatnoharm- bodyoftheplug)mustbeparallelto thecenterelec-
ful contaminants areallowedtoenterthecombustion trodeandthespecifiedsizewiregauge(pleaserefer
chamber whenthesparkplugis removed. If com- Do not usethe spark plug sock? l -- K-rrA GL I” IlllGa”
to theTune-Up Specifications
chartfor details)must
pressed air is notavailable, usea raaor a brushto tha
. ..Y nhme Alwmm
f..“YY. rarntdlv thw lad the plug
rn”Y,‘““mY*“.‘, .I**”
passbetween theelectrodes witha slightdrag:
cleanthearea. by handor usingan old plug wire to prevent *,NEVER.adjustthe gap on a usedplatinum
*Remove the sparkplugswhenthe engine the possibility of crossthreadingand damag- type spark plug.
is cold, if possible,to preventdamageto the ing the cylinder headbore. Alwayscheckthegaponnewplugsastheyare
threads. If removal of the plugs is difficult, notalwayssetcorrectlyatthefactory.Donotusea
apply a few dropsof penetratingoil or sili- 10. Carefullytightenthesparkplug.If theplug flatfeelergaugewhenmeasuring thegapona used
cone spray to the area aroundthe base of the youareinstallingisequipped withacrushwasher, plug,because thereadingmaybeinaccurate. A
plug, and allow it a few minutesto work. seattheplug,thentightenaboutI/,turnto crushthe round-wire typegappingtoolisthebestwaytocheck
washer.If youareinstallinga taperedseatplug, thegap.Thecorrectgaugeshouldpassthroughthe
6. Usinga sparkplugsocketthatis equipped tightentheplugto specificationsprovidedbytheve-
witha rubberinsertto properlyholdtheplug,turn electrode gapwitha slightdrag.If you’reindoubt,try
hicleor plugmanufacturer. onesizesmallerandonelaraer.Thesmalleraauqe
 l-24 GENERALINFORMATIONAND
MAINTENANCE

b%slZl2 tm2903

Fig. 97 A variety of tools and gauges are Fig. 98 Checkingthe spark plug @auwith a tccs2904

neededfor spark plug service feeler gauge. - Fig. 99 Adjustingthe spark plug gap

thetwoends.Takethelengthandmultiplyit by6,000 *Don’t rely on wiring diagramsor sketches

ig. 100 If the standardplug Is in good con-
ftlon, the electrode may be filed flat-
WARNING:do not file platinum plugs
shouldgothrougheasily,whilethelargerone
I’ shouldn’tgothroughatall.Wiregapping toolsusu-
allyhavea bending toolattached.Usethatto adjust
thesideelectrodeuntiltheproperdistanceisob- \
tained.Absolutelyneverattemptto bendthecenter
electrode.Also,becarefulnotto bendthesideelec-
trodetoofaror toooftenasit mayweaken andbreak
offwithintheengine,requiringremovalof thecylin-
derheadto retrieveit.
to achievethemaximum resistanceallowableineach
wire,resistance
shouldnotexceedthisvalue.If resis-
tancedoesexceed thisvalue,replacethewire.
*Whenever the high tensionwires are re- ’
movedfrom the plugs, coil, or distributor,
silicone greasemustbe applied to the boot
before reconnection.Coatthe entire Interior
surfacewith a suitable silicone grease.
REMOVAL
&INSTALLATION
# See Figures90,103 and 104
1. Remove theair cleanerinlettube.
2. If eouiooed,
remove thecentercoverfromthe
valvecovei.
3. Labeleachsparkplugwireandmakea noteof
itsrouting.
for spark plugwire routing. Improper
arrangementof spark plugwires will induce
voltage betweenwires, causingmisfiring
and surging.Be careful to arrangespark plug
wires properly.
4. Startingwiththelongestwire,disconnect the
sparkplugwirefromthesparkplugandthenfrom
thecoilpackor distributor cap.
To install:
5. If replacingthesparkplugwires,matchtheolc
wirewithanappropriately sizedwireinthenewset.
6. Lubricate thebootsandterminals withdielec-
tricgreaseandinstallthewireonthecoilpack.Make
surethewiresnapsintoplace.
7. Routethewirein theexactpathastheoriginal
andconnect thewireto thesparkplug.
8. Repeat theprocessfor eachremaining wire,
iorkingfromthelongestwireto theshortest.
9. Installtheair cleanerinlettube.

TESTING
tcG1009

# See Figures191 and 102 Fig. 102 Checkingindividual plug wire re-
sistance with a digital ohmmeter
Ateverytune-up/inspection,visuallycheckthe
sparkplugcablesfor burnscuts,or breaksin thein-
sulation.Checkthebootsandthenipplesonthedis-
tributorcapand/orcoil.Replace anydamaged wiring.
Every50,000miles(80,000km)or 60months, the
resistanceof thewiresshouldbechecked withan
ohmmeter. Wireswithexcessive resistancewill cause
misfiring,andmaymaketheenginedifficultto startin
dampweather.
Tocheckresistance, anohmmeter shouldbeused ’
oneachwireto testresistance between theendcon-
nectors.Remove andinstall/replace
thewiresin or- ’
der,one-by-one.
Resistance onthesewiresshouldbe4,000-6,000
ohmsperfoot.Toproperlymeasure this,remove the
wiresfromtheplugsandthecoilpack.Donotpierce
anyignitionwirefor anyreason.Measure onlyfrom Fig. 103 Removethe spark plug wires from Fig. 104 Remove the plug wires from the
wire dividers
 GENERALINFORMATIONAND
MAlNTENANdE1-25

GENERALINFORMATION

b See Figures 111 and 112

osen the distributor cap retain-
Fig. 106. . . then remove the cap from the
distributor
Ignitiontimingisthemeasurement, in degrees
of
crankshaft rotation,of thepointatwhichthespark
plugsfire ineachof thecylinders.It is measuredin
degrees beforeor afterTopDeadCenter(TDC)of the
compression stroke.
Ideally,theair/fuelmixtureinthecylinderwill be
ignitedbythesparkplugjustasthepistonpasses
I 1
COMBUSTION
ENDS 23’ ATDC

SPEED INCREASES

Fig. 107 Graspthe rotor and pull it straight Fig. 108The rotor mustbe aligned correctly
off of the distributor shaft to the distributor shaft before installation

otherphysicaldamage. Makesurethedistributor 9ir&1$?6

cap’scenterbuttonis freeof damage.Checkthecap Fig. 111 Advancingthe ignition timing
terminals
for dirtor corrosion.Alwayschecktherotor ’
REMOVAL&INSTALLATION bladeandspringcloselyfor damage. Replaceany
comoonents wheredamaae isfound.
b See Figures 105,106,107, and 108 CCURS COMBUSTION
DC ENDS 23 ATDC
1. Disconnect thenegative batterycable.
*Depending on the reasonfor removingthe smmE
ALGNME
distributorcap, it may makemoresenseto LOCATOR
leave the sparkplug wires attached.This is
handyif you are testingspark plug wires, or
if removal is necessaryto accessother com-
ponents,and wire lengthallows you to repo-
sition the cap out of the way.
2. Labelanddisconnect thesparkplugwires
fromthedistributor cao.
3. Remove thedistributorcapretaining screwsor
clipsandremove thecapfromthedistributor.
4. Noteits installedposition,thenremove thero-
torfromthedistributor shaft.
5. Theinstallationis thereverseof theremoval.
INSPECTION

u See Figures109 and 110 9mg27

Afterremoving thedistributor
capandrotor,clean Fig. 112 Retardingthe tgnttion timing
thecomponents (bothinsideandoutsideof thecap)
usingsoapandwater.If compressed air is available,
carefullydrythecomponents (wearingsafetygog-
gles)or allowthepartsto airdry.Youcandrythem
witha clean,softcloth,butdon’tleaveanylintor
moisturebehind. Inspectionpoints for the dis
Oncethecapandrotorhavebeenthoroughly
cleaned,checkforcracks,carbontracks,burnsor
 .

1-26 GENERALINFORMATIONAND
MAINTENANCE
TDC of the compressionstroke.If this happens,the
pistonWIIIbe at the beginningof the powerstroke
just as the compressedand ignitedair/fuel mixture
forcesthe piston downandturns the crankshaft.Be-
causeit takesa fractionof a secondfor the spark
plug to ignitethe mixture in the cylinder,the spark
plug must fire a little beforethe piston reachesTDC.
Otherwise,the mixturewill not be completelyignited
as the piston passesTDC andthe full powerof the
explosionwill not be used by the engine.
Thetiming measurementis given in degreesof Fig. 114 Ignition timing adjustment con-
Fig. 113 Ignition timing adjustment con-
crankshaftrotationbeforethe piston reachesTDC
(BTDC).If the settingfor the ignition timing is 10” nector-1990-92 Mirage with 1.5L engine nectar-Miracle with 1.6L enaine
BTDC,eachsparkplug mustfire 10 degreesbefore
eachpiston reachesTDC.This only holdstrue, how-
ever,whenthe engineis at idle speed.The combus-
tion processmust be completeby 23”ATDC to main-
tain properengineperformance,fuel mileage,and
low emissions.
As the enginespeedincreases,the pistonsgo
faster.Thesparkplugs haveto ignite the fuel even
sooner if it ISto be completelyignitedwhenthe pis-
ton reachesTDC. If the ignition is set too far ad-
vanced(BTDC),the ignition and expansionof the fuel CHECK CONNECTOR
in the cylinderwtll occurtoo soon andtendto force 93151QM 93151QO!

the piston downwhile it is still travelingup. Thus Fig. 115 Ignition timing adjustment con- Fig. 116 Ignition timing adjustment con.
causespre ignition or “knockmgand pinging”. If the nectar-Galant with 2.OLengines nectar-1992-96 Oiamante
ignition sparkis set too far retarded,or afterTDC
(ATDC),the piston will havealreadystartedon its
waydownwhenthe fuel is ignited.The pistonwill be
forceddownfor only a portion of its travel,resulting
in poor engineperformanceand lackof power.
Timing marksor scalescan befound on the rim of
the crankshaftpulleyandthe timing cover.The marks
on the pulleycorrespondto the posrtionof the piston
in the No. 1 cylinder.A stroboscopic(dynamic)tim-
ing light is hookedonto the No. 1 cylindersparkplug
wrre.Everytime the sparkplug fires, the timing light
flashes.By aimingthe light at the timing markswhile
the engineis running,the exactposition of the piston 93151QO1 93151gOB

within the cylindercanbe easily read(theflash of
light makesthe markon the pulleyappearto be
standingstill). Propertiming is indicatedwhenthe
markand scaleare in specifiedalignment.
Whencheckingtiming with the enginerun-
ning, take care not to get the timing light
wires tangled in the tan bladesand/ordrive
belts.
INSPECTION&ADJUSTMENT
1990-96 Models
e See Figures113 thru 119
1. Setthe parkingbrake,startand run the engine
until normaloperatingtemperatureis obtained.Keep
all lights and accessoriesOFFand the front wheels
straight-ahead.Placethe transaxlein P for automatic
transaxleor Neutralfor manualtransaxle.
2. If not at specification,set the idle speedto the
correctlevel.
3. Turn the engineOFF.Removethe water-
proof coverfrom the igmtiontiming adjustingcon-
nector,and connecta jumperwire from this terminal
Fig. 117 Ignition timing adjustment con. Fig. 116 Ignition timing adjustment con-
nectar-1994-96 Galant nector-1993-96 Mirage with 1.5L engine
to a good ground.Referto the correspondingillustra-
tions for the correctlocationof the timing adjustment
connector.
4. Connecta conventionalpowertiming light to
the No. 1 cylindersparkplug wire. Startthe engine
and run at idle.
5. Aim the timing light at the timing scalelo-
catednearthe crankshaftpulley.
6. Loosenthe distributoror crankanglesensor
hold-downnut just enoughso the housingcanbe ro-
tated.
7. Turn the housingin the properdirectionuntil Fig. 119 Ignition timing adjustment con-
the specifiedtiming is reached.Tightenthe hold- nector-1993-96 Mirage with 1.6L engine
down nut and recheckthe timing. Turn the engine
OFF. As long as the basictiming is correct,the engineis
8. Removethe jumperwire from the ignition timed correctly.
timing adjustingterminaland installthe water-proof 10. Turn the engineOFF.
cover. 11. Disconnectthe timing apparatusand
9. Startthe engineand checkthe actualtiming tachometer.
(thetiming without the terminalgrounded).This
readingshould be approximately5 degreesmore 1997-00 Models
thanthe basictiming. Actualtiming may increaseac-
The ignition timing is controlledby the Engine
cording to altitude.Also, actualtiming mayfluctuate ControlModule(ECM)and is not adjustable.How-
becauseof slight variationaccomplishedby the ECU.
ever it can be inspectedusinga scantool.

ADJUSTMENT
u See Figures 120 and 121
The only enginesthat requireperiodicadjustment
of the valvesarethe 1.5L enginein the 1990-95 Mi-
rageand the 1.8L in the 1993-95 Mirage.
GENERALINFORMATIONAND
MAlNTENANdEI-27
l Exhaustvalve:0.0098 in. (0.25mm)
l Intakevalve:0.0059 in. (0.15mm)
1993-95 1.5L engine:
l Exhaustvalve:0.0098 in. (0.25mm)
* Intakevalve:0.008 in. (0.20mm)
1993-95 1.8L engine:
l Exhaustvalve:0.012 in. (0.30mm)
l Intakevalve:0.008 in. (0.20mm)
7. If the valve clearanceis out of specification,
loosenthe rockerarm locknutand adjustthe clear-
ante usinga feelergaugewhile turningthe adjusting
screw.Whenat specification,tightenthe locknut.Be
sureto hold the screwsecurelyin placewhentight-
eningthe locknutto preventit from turningwhen
tighteningthe locknut.Tighteningtorqueof the lock-
nut is as follows:
l 1.5L engine:9-11 ft. Ibs. (12-15 Nm)
l 1.8L engine:7 ft. Ibs. (9 Nm)
8. Recheckthe clearanceand readjust.
9. Afteradjustingthe valves,installthe valve
cover and sparkplugs,and connectthe negativebat-
tery cable.

ENGINETUNE-UP SPECIFICATIONS
Incorrectvalve clearancewill causenoisy Ignition Idle
and/or unsteadyengineoperation, reduced Engine Spark Plugs liming Fuel Speed Valve
engineoutput,and possibleenginedamage. Displacement Engine Gap (as.) Pump (rpm) Clearance
Checkthe valve clearancesand adjustas re-
quired while the engine is hot.
1. Warmthe engineto operatingtemperature.
Turn the engineOFF.Disconnectthe negativebattery
cable.
2. Removeall sparkplugsso enginecanbe eas-
ily turnedby hand
3. Removethe valvecover.
4. Turn the crankshaftclockwiseuntil the notch
on the pulley is alignedwith the T markon the timing
belt lowercover.This brings both No. 1 and 4 cylin-
der pistonsto Top DeadCenter(TDC).
5. Wigglethe rockerarms on No. 1 and4 cylin-
dersup and downto determinewhich cylinder is at
TDC on the compressionstroke.Both rockerarms
shouldmove if the piston in that cylinder is at TDC
on the compressionstroke.
6. Measurethe valveclearancewith a feeler
gauge.Whenthe No. 1 piston is at TDC on the com-
pressionstroke,checkNo. 1 intakeand exhaust; No.
2 intakeand exhaust.Thenturn the crankshaftclock-
wise 1 turn to bring No. 4 to TDC on its compression
stroke.With No. 4 on TDC,compressionstroke,
checkNo. 2 exhaustand intake;and No. 4 intakeand
exhaust.Clearanceis as follows:
1990-92 1.5L engine:

No.1 No.2 No.3 No.4

when engine is on TDCof cylinder 1 and (B)

when engine is on TDCof cylinder 4

No.1 No.2 No.3 No.4

AA AA BB BB
93151g10

Fig. 121 Adjustingthe valve clearance

l-28 GENERALINFORMATIONAND
MAINTENANCE
mayresultin skinor eyeirritationor frostbite.Al- formedto helpmaintain theefficiency of thevehicle’s
thoughlowintoxicity(dueto chemical stability),in- A/Csystem.Forpreventive maintenance, performthe
Theidlespeedis factorysetandusuallynoad- halationof concentrated refrigerant fumesis danger- following:
justments areevernecessary. If anadjustment
be- ousandcanresultindeath;casesoffatalcardiac l Theeasiestandmostimportant preventive
comesnecessary, firstcheckthatthesparkplugs,in- arrhythmia havebeenreportedin peopleaccidentally maintenance for yourA/Csystemisto besurethatit
jectors,idleair controlservoandcompression subjected to highlevelsof refrigerant. Someearly is usedona regularbasis.Running thesystemfor
pressure areall normal. symptoms includelossof concentration anddrowsi- fiveminutes eachmonth(nomatterwhattheseason)
Datafromvarioussensorsandswitchesareused ness. + will helpensurethatthesealsandall internalcompo-
bytheECUto determine theproperfuel/airmixture cGeneraiiy, the limit for exposureis lower nentsremainlubricated.
for optimalengineperformance. for R-134athan it is for R-12. Exceptional *Some newer vehicles automaticallyoper-
care mustbe practicedwhen handlingR- ate the A/Csystemcompressorwheneverthe
134a. windshield defroster is activated.Whenrun-
Also,refrigerants candecompose athightempera- ning, the compressorlubricatesthe A/Csys
tures(neargasheaters or openflame),whichmayre- tern components;therefore, the A/Csystem
suitin hydrofluoric acid,hydrochloric acidandphos- would not needto be operatedeach month.
SYSTEMSERVICE&REPAIR
gene(afatalnervegas). * Inorderto preventheatercorefreeze-up during
R-12refrigerant candamage theenvironment be- A/Coperation, it is necessary to maintain properan-
ti See Figure 122 causeit isa Chlorofluorocarbon (CFC),whichhas tifreezeprotection. Usea hand-held coolanttester
*it is recommendedthat the A/Csvstembe beenprovento addto ozonelayerdepletion, leading (hydrometer) to periodically checktheconditionof
servicedby an EPASection609 cehified au- to increasing levelsof UVradiation.UVradiationhas theantifreeze inyourengine’s coolingsystem.
tomotivetechnicfanutilizing a refrigerant re- beenlinkedwithanincrease in skincancer,suppres- *Antifreeze shouldnot be usedlonger than
covery/recyclingmachfne. sionof thehumanimmune system, anincrease in the manufacturerspecifies.
cataracts, damage to crops,damage to aquaticorgan-
Thedo-it-yourselfer shouldnotservicehis/her isms,anincrease in ground-level ozone,andin- . Forefficientoperation of anairconditioned ve-
ownvehicle’sA/Csystemfor manyreasons,includ- creased globalwarming. hicle’scoolingsystem, theradiatorcapshouldhavea
inglegalconcerns, personalinjury,environmental R-134arefrigerant is a greenhouse gaswhich,if holdingpressure whichmeetsmanufacturers specifi-
damage andcost.Thefollowingaresomeof therea- allowedto ventintotheatmosphere, will contributeto cations.Acapwhichfailsto holdthesepressures
sonswhyyoumaydecidenotto serviceyourownve- globalwarming(theGreenhouse Effect). shouldbereplaced.
hicle’sA/Csystem. It is usuallymoreeconomically feasibleto havea l Anyobstruction of or damage tothecondenser
According to theU.S.CleanAirAct,it is afederal certifiedMVACautomotive technician performA/C configuration will restrictair flowwhichis essential
crimeto serviceor repair(involvingtherefrigerant)a systemserviceonyourvehicle.Somepossiblerea- to itsefficientoperation. It is,therefore, a goodrule
MotorVehicleAirConditioning (MVAC)systemfor sonsforthisareasfollows: to keepthisunitcleanandin properphysicalshape.
moneywithoutbeingEPAcertified.It isalsoillegalto l Whileit is illegalto serviceanA/Csystem
ventR-12andR-134arefrigerants intotheatmos- withouttheproperequipment, thehomemechanic
phere.Sellingor distributing
A/Csystemrefrigerant wouldhavetopurchase anexpensive refrigerantre-
(ina container whichcontainslessthan20poundsoif covery/recycling machine to servicehis/herownve-
refrigerant)
to anypersonwhois notEPA609certi- hicle.
fiedis alsonotallowedby law. l Sinceonlya certifiedpersonmaypurchase re-
Stateand/orlocallawsmaybemorestrictthanthe frigerant-according to theCleanAirAct,thereare
federalregulations, sobesuretocheckwithyour specificrestrictions onsellingor distributing A/C
stateand/orlocalauthoritiesfor furtherinformation. systemrefrigerant-itis legallyimpossible (unless
Forfurtherfederalinformation onthelegalityof ser- certified)forthehomemechanic to servicehis/her
vicingyourAK system,calltheEPAStratospheric ownvehicle.Procuring refrigerant inanillegalfash-
Ozone Hotline. ionexposes oneto theriskof payinga $25,000 fine
*Federal law dictatesthat a fine of up to to theEPA.
$25,000may be levied on peopleconvicted
of venting refrigerant into the atmosphere. R-12 Refrigerant Conversion
Additionally, the EPAmay pay up to $10,000 If yourvehiclestill usesR-12refrigerant, oneway
for informationor services leadingto a crimf to saveA/Csystemcostsdowntheroadis to invesh-
nai convictionof the violation of these laws. Fig. 123 A coolant tester can be usedto de-
gatethepossibilityof havingyoursystemconverted termine the freezing and boiling levels of
WhenservicinganA/Csystemyouruntheriskof toR-134a.TheolderR-12systems canbeeasily
converted to R-134arefrigerant bya certifiedauto- the coolant in your vehicle 1
handlingor comingincontactwithrefrigerant, which
motivetechnician byinstallinga fewnewcompo-
nentsandchanging thesystemoil.
Thecostof R-12is steadilyrisingandwill con-
tinueto increase,because it is nolongerimported or
manufactured intheUnitedStates.Therefore, it is of-
tenpossibleto haveanR-12systemconverted to R-
134aandrecharged for lessthanit wouldcostto just
chargethesystemwithR-12.
If youareinterested in havingyoursystemcon-
verted,contactlocalautomotive servicestationsfor
moredetailsandinformation.

u See Figures 123 and 124 Fig. 124 To ensureefficient cooling system
Fig. 122 A label with information concern- AlthoughtheA/Csystemshouldnotbeserviced operation, inspect the radiator cap gasket
ing the A/Csystemis typically located in the bythedo-it-yourselfer,
preventive
maintenance
can and seal
engine compartment bepracticedandA/Csysteminspections
canbeper-
 GENERALINFORMATIONAND
MAlNTENANdE1-29
i
*Bug screenswhich are mountedin front of l Makesuretheair passage selectionleveris
the condenser(unlessthey are original operating
correctly.Starttheengineandwarmit to
equipment)are regardedas obstructtons. normaloperating
temperature, thenmakesurethe
l Thecondensation draintubeexpelsanywater temperature
selectionleveris operating
correctly.
whichaccumulates onthebottomoftheevaporator
housingintotheenginecompartment. If thistubeis
obstructed,
theairconditioning performance canbe
restricted
andcondensation buildupcanspillover -w
ontothevehicle’sfloor. ~1 ELEMENT(REFILL)CARE&REPLACEMENT

SYSTEMINSPECTION b See Figures 126 thru 135

Formaximum
effectiveness
andlongestelement
b See Figure 125 lifp thp winrkhi&i
. ..“. .I.” . . * ““I.. “.”
nnri winor hlarlP~ shmM hP kmt
I..” ...r”* “.“““” “, ,““,” “” ,~“r~

Although theA/Csystemshouldnotbeserviced clean.Dirt,treesap,roadtarandsoonwill cause

bythedo-it-yourselfer, preventive maintenance can streaking,smearing andbladedeterioration if lefton
bepracticed andA/Csysteminspections canbeper- theglass.It isadvisable to washthewindshield care-
formedto helpmaintain theefficiencyof thevehicle’s fullywitha commercial glasscleanerat leastoncea
A/Csystem.ForA/Csysteminspection, performthe month.Wipeofftherubberbladeswiththewetrag
following: * Checkthesurfaceof theradiatorandcon- afterwards.Donotattempt to movewipersacrossthe
Theeasiestandoftenmostimportant checkfor the denserfor dirt,leavesor othermaterialwhichmight windshield byhand;damage to themotoranddrive
airconditioning systemconsistsof a visualinspec- blockairflow. mechanism will result.
tionof thesystemcomponents. Visuallyinspectthe l Checkfor kinksin hosesandlines.Checkthe Toinspectand/orreplacethewiperbladeele-
airconditioning systemfor refrigerant
leaks,dam- systemfor leaks. ments,placethewiperswitchintheLOWspeedpo-
agedcompressor clutch,abnormal compressor drive l Makesurethedrivebeltis properlytensioned. sitionandtheignitionswitchintheACCposition.
belttensionand/orcondition, pluggedevaporator Whentheair conditioning is operating,
makesurethe Whenthewiperbladesareapproximately verticalon
draintube,blockedcondenser fins,disconnected or drivebeltisfreeof noiseor slippage. thewindshield, turntheignitionswitchto OFF.
brokenwires,blownfuses,corrodedconnections and l Makesuretheblowermotoroperates atall ap- Examine thewiperbladeelements. Iftheyare
poorinsulation. propriatepositions,thencheckfor distribution
of the foundto becracked, brokenor torn,theyshouldbe
A refrigerantleakwill usuallyappearasanoily airfromall outletswiththebloweronHIGHor MAX. replaced immediately. Replacement intervalswill vary
residueattheleakage pointin thesystem. Theoily *Keep in mindthat underconditionsof high withusage,althoughozonedeterioration usuallylim-
residuesoonpicksupdustor dirtparticlesfromthe humidity,air dischargedfrom the A/Cvents itselement lifetoaboutoneyear.If thewiperpattern
surrounding airandappears greasy.Throughtime, may not feel as cold as expected,even if the is smeared or streaked,or if thebladechatters across
thiswill buildupandappearto bea heavydirtim- systemis working properly. This is because theglass,theelements shouldbereplaced. It iseasi-
pregnated grease. vaporizedmoisturein humidair retains heat estandmostsensibleto replacetheelements in
Fora thoroughvisualandoperational inspection, more effectively than dry air, thereby making pairs.
checkthefollowing: humidair more difficult to cool. Ifyourvehicleis equipped withaftermarket blades,
thereareseveraldifferent typesof refillsandyourvehi-

tcca-23 tCS1224 lW1Z?5

Fig. 126 Bosch@wiper blade and fft kit Fig. 127 LexoP wiper blade and fit kit Fig. 128 Pylon@wiper blade and adapter

Fig. 131 To remove and install a LexoP

wiper blade refill, slip out the old insert and
Fig. 129 T&o* wioer blade and fit kit Fig, 130 Tripledge@wiper blade and fit kit slide in a new one
 .

l-30 GENERAL'INFORMATIONAND
MAINTENANCE

n Pylon@inserts, the clip thenthe insert can be re

be removedprior to siidi After installing the replacement

stripandpullupwhiletwistingcounterclockwise. catethefrontendis outof alignment

or thatthetires
Thebackingstripwill snapoutof theretaining tab. areoutof balance.
Dothisfor theremainingtabsuntiltherefillis freeof
theblade.Thelengthoftheserefillsis moldedinto TIREROTATION
theendandtheyshouldbereplaced withidentical
types. # See Figures 137 and 138
Tiresmustberotatedperiodicallyto equalizewear
patternsthatvarywithatire’spositiononthevehicle.
Tireswill alsowearinanunevenwayasthefront
lowedto touchtheolass steering/suspension systemwearstothepointwhere
thealianment shouldbereset.
Rotating thetireswill ensuremaximumlifeforthe
tiresasa set,soyouwill nothaveto discarda tire
1 Fin 1% Tha Trinlarlna@ earlydueto wearononlypartof thetread.Regular
# See Figure 138
Common senseandgooddrivinghabitswill af-
clemighthaveanykind.Aftermarket bladesandarms fordmaximum tire life.Faststarts,suddenstops
rarelyusetheexactsametypebladeorrefillasthe andhardcorneringarehardontiresandwill
originalequipment. Herearesometypiel aftermarket shortentheirusefullife span.Makesurethatyou
don’toverloadthevehicleor runwithincorrect
blades;notallmaybeavailable foryourvehicle: pressurein thetires.Bothof thesepracticeswill in-
TheAnco@ typeusesa releasebuttonthatis creasetreadwear.
pusheddownto allowtherefillto slideoutof the
yokejaws.Thenewrefillslidesbackintotheframe , *For optimumtire life, keepthe fires prop
andlocksin place. eriy inflated, rotate them often and have the
SomeTrico@refillsareremoved bylocatingwhere wheel alignmentcheckedperiodically.
DIRECTIONAL TIRES DIRECTIONAL TIRES
themetalbackingstriportherefilliswider.Inserta Inspectyourtiresfrequently. Beespeciallycare-
smallscrewdriver bladebetween theframeandmetal ful to watchfor bubblesin thetreador sidewall,
backingstrip.Pressdownto releasetherefillfrom deepcutsor underinflation. Replace anytireswith
theretaining tab. bubblesin thesidewall.If cutsaresodeepthatthey
Othertypesof Trico@’ refillshavetwometaltabs penetrate to thecords,discardthetire.Anycutin
whichareunlocked bysqueezing themtogether. The thesidewallof a radialtirerendersit unsafe.Also
rubberfillercanthenbewithdrawn fromtheframe lookfor uneventreadwearpatternsthatmayindi-
iaws.A newrefillis installedbvinsertinatherefill
jntothefrontframejawsand&ding it rearward to
engage theremaining framejaws.Thereareusually
fourjaws;becertainwheninstallingthattherefillis
engaged in all of them.Attheendof itstravel,the
tabswill lockintoplaceonthefrontjawsof thewiper
bladeframe.
Anothertypeof refillis madefrompolycarbonate.
Therefillhasa simplelockingdeviceatoneend
whichflexesdownward outof thegrooveintowhich
thejawsof theholderfit, allowingeasyrelease. By
slidingthenewrefillthroughall thejawsandpush-
ingthroughtheslightresistance whenit reaches the
endof itstravel,therefillwill lockintoposition.
ToreplacetheTridon@ refill,it is necessary
movethewiperblade.Thisrefillhasa plasticbacking
to re-
Fig. 138 A label with information concern-
tion”
stripwitha notchabout1 in.(25mm) fromtheend. ing the tires is typically located on one of
Holdtheblade(frame)ona hardsurfacesothatthe the door pillars
frameistightlybowed.Gripthetipof thebacking
 GENERALINFORMATIONAND
MAlNTENANdE1-31
Whenrotating“unidirectional tires,”makesure checktheinstalledtirefor anysignof interference styled wheels, see if inexpensivesteel
thattheyalwaysroll inthesamedirection.This withthebodyorsuspension whilethevehicleis stop- wheels are available, Althoughthe look of
meansthata tireusedontheleftsideof thevehicle ping,turningsharplyor heavilyloaded. the vehicle will change,the expensive
mustnotbeswitched to therightsideandvice-versa. wheels will be protectedfrom salt, curb hits
Suchtiresshouldonlyberotatedfront-to-rear or Snow Tires and potholedamage.
rear-to-front,whilealwaysremaining onthesame Goodradialtirescanproducea bigadvantage in
sideof thevehicle.Thesetiresaremarked onthe slipperyweather, butin snow,a streetradialtiredoes TIRESTORAGE
sidewallasto thedirectionof rotation;observe the nothavesufficienttreadto providetractionandcon-
markswhenreinstalling thetire(s). trol.Thesmallgroovesof a streettirequicklypack Iftheyaremounted onwheels,storethetiresat
Somestyledor “mag”wheelsmayhavedifferent withsnowandthetirebehaves likea billiardballona properinflationpressure.Alltiresshouldbekeptin a
offsetsfrontto rear.Inthesecases,therearwheels marblefloor,Themoreopen,chunkytreadof a snow cool,dryplace.If theyarestoredinthegarageor
mustnotbeusedupfrontandvice-versa. Further- tirewill self-clean asthetireturns,providingmuch basement, donotletthemstandona concrete floor;
more,if thesewheelsareequipped withunidirectional bettergriponsnowysurfaces. setthemonstripsof wood,a mator a largestackof
tires,theycannotberotatedunlessthetireis re- Tosatisfymunicipalities requiringsnowtiresdur- newspaper. Keeping themawayfromdirectmoisture
mounted fortheproperdirectionof rotation. ingweather emergencies, mostsnowtirescarryeither is of paramountimportance. Tiresshouldnotbe
*The compactor space-saverspare is anM+ Sdesignation afterthetiresizestamped on storedupright,butina flatposition.
strictly for emergencyuse. it mustnever be thesidewall,or thedesignation “all-season.” Ingen-
includedin the tire rotation or placedon the eral,nochangeintiresizeis necessary whenbuying INFLATION
& INSPECTION
vehicle for everydayuse. snowtires.
Mostmanufacturers stronqlvrecommend theuse b See Figures 140 thru 147
of 4 snowtiresontheir\lehiciesfor reasons of stabil-
TIREDESIGN ity.If snowtiresarefitter1onlyto thedrivewheels,the Theimportance of propertireinflationcannotbe
oppositeendof thevehilclemaybecome veryunsta- overemphasized. Atireemploys air aspartof its
p See Figure 139 blewhenbrakingor turnringonslipperysurfaces. structure. It is designedaroundthesupporting
Thisinstabilitycanleadto unpleasant endingsif the strengthof theairata specifiedpressure. Forthis
for maximum satisfaction,tiresshouldbeusedin A*:,,“-r-..l, ^_....&^_^^,&I. reason,improper inflationdrasticallyreduces the
UIIVU MII I LUUII~~MLL iueslidein time.
setsof four.Mixingof differenttypes(radial,bias- tire’sabilityto performasintended. Atirewill lose
belted,fiberglassbelted)mustbeavoided.Inmost Notethatsnowtires,whether2 or 4,will affectve-
hiclehandlinginall non-snowsituations. Thestiffer, someair in day-to-day use;havingto adda few
cases,thevehiclemanufacturer hasdesignated a poundsof airperiodically is notnecessarily a signof
typeof tireonwhichthevehiclewill performbest. heaviersnowtireswill noticeably change theturning
andbrakingcharacteristics of thevehicle.Oncethe a leakingtire.
Yourfirstchoicewhenreplacing tiresshouldbeto Twoitemsshouldbea permanent fixturein every
usethesametypeof tirethatthemanufacturer rec- snowtiresareinstalled, youmustre-learnthebehav-
ior of thevehicleanddriveaccordingly. glovecompartment: anaccurate tirepressure gauge
ommends. anda treaddepthgauge.Checkthetirepressure (in-
Whenradialtiresareused,tiresizesandwheeldi- *Consider buyingextra wheels on which to eludingthespare)regularlywitha pockettypegauge.
ameters shouldbeselected to maintain groundclear- mountthe snow tires. Oncedone,the “snow Toooften,thegaugeontheendof theairhoseat
anteandtireloadcaoacitveauivalent to theoriainal iheeis” can be installed and removedas XI I._.
vnrrrcornernarane is notaccurate because it suffers
specified tire.Radialtiresshouldalwaysbeusedin needed.This eliminatesthe potential dam- ‘-’ much
too --“‘“’abuse.
J sAlwa!~rschecktireoressure whenthe
setsof four. age to tires or wheels from seasonalremoval tiresarecold,aspressure increases withtempera-
and installation. Evenif your vehicle has ture.If youmustmovethevehicleto checkthetire

Radial tires shouldnever be usedon only the lb

front axle.
Whenselecting tires,payattentiontotheoriginal
sizeasmarkedonthetire.Mosttiresaredescribed
usinganindustrysizecodesometimes referredto as
P-Metric.Thisallowstheexactidentification of the
tirespecifications,
regardless of themanufacturer. If
selecting
a differenttiresizeor brand,remember to

METRIC TIRE SIZES

Fig. 140Tires should be checkedfrequently Fig. 141 Tires with deep cuts, or cutswhich
for any sion of aunctureor damaoe I I buioe, should be replaced immediately
(MILLIMETERS)
CDNStRUCtlDN l-6-E
145
R - RADIAL
D
WA9

RADIAL TIRE
l DRIVE WHEEL HEAW
ACCELERATION
l OVERINFLATION *LACK OF ROTATION fig. 143 Radial tires have a characteristic
sidewall bulge; don’t try to measure pres-
Fig. 142 Examplesof inflation-related tire sure by looking at the tire. Use a quality air
Fig. 139 P-Metric tire coding pressuregauge

1-32 GENERALINFORMATIONAND
MAINTENANCE
CONDITION
EFFECT
CAUSE
ADJUST PRESSURE TO
CORRECTION SPECIFICATIONS WHEN
TIRES ARE COOL
ROTATE TIRES
HAVE TIRE INSPECTED FOR FURTHER USE.
ig. 144 Commontire wear patterns and causes
1~~~1265
Fig. 145 Tread wear indicators will appear
when the tire is worn
inflation,do not drive morethan a mile beforecheck-
ing. A cold tire is generallyonethat has not beendri-
ven for morethan threehours.
A plateor sticker is normallyprovidedsomewhere
in the vehicle(door post, hood,tailgateor trunk lid)
which showsthe properpressurefor the tires. Never
counteractexcessivepressurebuild-up by bleeding
off air pressure(lettingsomeair out). Thiswill cause
the tire to run hotterandwearquicker.
Never exceedthe maximumtire pressure
embossedon the tire! This is the pressureto
be usedwhenthe tire is at maximumload-
ing, but it is rarely the correct pressurefor
everydaydriving. Consultthe owner’s man-
ual or the tire pressuresticker for the correct
tire pressure.
Onceyou’vemaintainedthe correcttire pressures
for severalweeks,you’ll befamiliar with the vehicle’s
brakingand handlingpersonality.Slight adjustments
in tire pressurescanfine-tunethesecharacteristics,
UNDER-INFLATION
EXCESSIVE SPEED’
1~~~1264
Fig. 146 Accuratetread depthindicatorsare
inexuensiveand handv
Fig. 147 A penny works well for a quick
check of tread death
but neverchangethe cold pressurespecificationby
morethan 2 psi. A slightly softertire pressurewill
give a softer ride but also yield lowerfuel mileage.A
slightly hardertire will give crisperdry roadhandling
but can causeskiddingon wet surfaces.Unless
you’refully attunedto the vehicle,stick to the recom-
mendedinflationpressures.
All tires madesince 1968 havebuilt-in treadwear
indicatorbarsthat show up as j/2in. (13mm)wide
smooth bandsacrossthe bre whenV,~in. (1.5mm)of
treadremains.Theappearanceof treadwear indica-
tors meansthat the tires shouldbe replaced.In fact,
manystateshavelawsprohibitingthe useof tires
with lessthanthis amountof tread.
You cancheckyour own treaddepthwith an inex-
pensivegaugeor by using a Lincoln headpenny.
Shp the Lrncolnpenny(with Lincoln’sheadupside-
.
WORN OR OUT-
OF-ALIGNMENT
BALANCE WHEELS
/ INSPECT SUSPENSION
lCCSi267
down) into severaltreadgrooves.If you canseethe
top of Lincoln’sheadin 2 adjacentgrooves,the tire
has lessthan V,~in. (1.5mm)treadleft and should be
replaced.You canmeasuresnowtires in the same
mannerby using the “tails” side of the Lincoln
penny.If you canseethe top of the Lincoln memor-
ial, its time to replacethe snowtire(s).
CAREOFSPECIALWHEELS
If you haveinvestedmoneyin magnesium,alu-
minum alloy or sport wheels,specialprecautions
should betakento makesureyour investmentis not
wastedandthat your specialwheelslook goodfor the
life of the vehicle.
Specialwheelsareeasily damagedand/or
scratched.Occasionallycheckthe rims for cracking,
impactdamageor air leaks.If any of thesearefound,
replacethe wheel.But in orderto preventthis type of
damageand the costly replacementof a special
wheel,observethe following precautions:
l Useextracarenot to damagethe wheelsdur-
ing removal,installation,balancing,etc.After re-
moval of the wheelsfrom the vehicle,placethemon a
mat or other protectivesurface.If they are to be
storedfor any lengthof time, supportthemon strips
of wood. Neverstoretires andwheelsupright;the
treadmaydevelopflat spots.
l Whendriving, watchfor hazards;it doesn’ttake
muchto cracka wheel.
l Whenwashing,usea mild soapor non-abra-
sive dish detergent(keepingin mind that detergent
tendsto removewax).Avoid cleanserswith abrasives
or the useof hardbrushes.Thereare manycleaners
and polishesfor specialwheels.
l If possrble,removethe wheelsduringthe win-
ter. Salt and sand usedfor snow removalcanse-
verelydamagethe finish of a wheel.
l Makecertainthe recommendedlug nut torque
is neverexceededor the wheelmay crack.Neveruse
snowchainson specialwheels;severescratching
will occur.
 GENERALINFORMATIONAND
MAINTENANC-E
1133

theSAEnumber, thelightertheoil;thelowerthevis- Synthetic

oil is notforeverycarandeverytypeof
cosity,theeasierit is tocranktheenginein cold driving,soyoushouldconsider yourengine’s
condi-
Usedfluidssuchasengineoil,transaxle fluid,an- weatherbutthelesstheoil will lubricate andprotect tionandyourtypeof driving.Also,checkyourcar’s
tifreezeandbrakefluidarehazardous wastesand theenginein hightemperatures. Thisnumberis warranty conditionsregarding
theuseof synthetic
oils.
mustbedisposed of properly.Beforedrainingany markedoneveryoil container.
fluids,consultwithyourlocalauthorities;in manyar- Oilviscosity’s shouldbechosenfromthoseoils FUEL
eas,wasteoil,antifreeze,
etc.is beingaccepted asa recommended forthelowestanticipated temperatures
partof recyclingprograms.A number of servicesta- duringtheoil changeinterval.Dueto theneedfor an All modelsequipped witha SOHC(SingleOver-
tionsandautopartsstoresarealsoaccepting waste oil thatembodies bothgoodlubrication athightem- headCamshaft) enginearedesigned to operateusing
fluidsfor recycling. peratures andeasycrankingincoldweather, multi- regularunleaded fuelwitha minimum of 87octane.
Besureof therecyclingcenter’s
policiesbefore gradeoilshavebeendeveloped. Basically,a multi- All modelsequipped witha DOHC(DualOverhead
draininganyfluids,asmanywill notacceptdifferent gradeoil is thinnerat lowtemperatures andthickerat Camshaft) enginearedesigned to operateusingreg-
fluidsthathavebeenmixedtogether. hightemperatures. Forexample, a low-40 oil (theW ularunleaded fuelwitha minimum of 91octane.Mit-
standsforwinter)exhibitsthecharacteristics of a 10 subishiwarnsthatusinggasolinewitha loweroctane
weight(SAE10)oil whenthecaris firststartedand ratingcancausepersistent andheavyknocking, and
theoil is cold.Itslighterweightallowsit to travelto maycauseinternalenginedamage.
thelubricating surfaces quickerandofferlessresis- If yourvehicleis havingproblems withroughidle
tanceto startermotorcranking than,say,a straight or hesitation
whentheenoineis cold,it mavbe
ENGINE
OIL 30weight(SAE30)oil. Butatiertheensinereaches causedbylowvolatilityfuel.Ifthisoccurs,iry a dif-
operating temperature, thelow-40 oil beginsacting ferentgradeor brandof fuel.
6 See Figure 148 likestraight40weight(SAE40)oil, itsheavierweight
providinggreaterlubrication withlesschanceof 'OPERATION
1~FOREIGN
COUNTRIES
WMitsubishirecommendsthat SAE5W-30 foamingthana straight30weightoil.
viscosity engineoil shouldbe usedfor all clia TheAPI(American Petroleum Institute)designa- Ifyouplanto driveyourcaroutsidetheUnited
mateconditions,however, SAElow-30 is ac tions,alsofoundontheoil container, indicates the Statesor Canada, thereis a possibilitythatfuelswill
ceptablefor vehicles operatedin moderate- classificationof engineoil usedundercertaingiven betoolowinanti-knock qualityandcouldproduce
to-hot climates. operating conditions. Onlyoilsdesignated for use enginedamage. It is wiseto consultwithlocalau-
ServiceSJheavydutydetergent shouldbeusedin thoritiesuponarrivalina foreigncountryto deter-
yourcar.Oilsof theSJtypeperformmayfunctions minethebestfuelsavailable.
insidetheenginebesides theirbasiclubrication.
Througha balanced systemof metallicdetergents
andpolymeric dispersants, theoil prevents highand
lowtemperature depositsandalsokeepssludgeand
dirtparticlesin suspension. Acids,particularlysulfu- OILLEVELCHECK
ricacid,aswellasotherby-products of enginecom-
bustionareneutralized bytheoil. If theseacidsare # See Figures149, 150, and 151 \
allowedto concentrate, thevcancausecorrosionand
rapidwearof theinternalengineparts.

lccS1235 The EPAwarns that urolonoedcontactwith

Fig. 148 look for the API oil identification Non-detergentmotor oils or straight mineral usedengineoil ma; cause-anumberof skin
label when choosingyour enaine oil oils shouldnot be usedin your engine. disorders, includingcancer!Youshould
. makeevery effort to minimizeyour exposure
SyntheticOil to usedengineoil. Protectivegloves should
Whenaddingoil to thecrankcase or changing the be worn when changingthe oil. Washyour
0Nilorfilter,it is importantthatoil of anequalquality Therearemanyexcellent synthetic
andfuel-effi- handsand any other exposedskin areas as
tcI.originalequipment beusedinyourcar.Theuseof cientoilscurrentlyavailable
thatcanprovidebetter soon as possibleafter exposureto useden-
mtenor011s mayvoidthewarranty, damage__youren- gasmileage,longerservicelifeand,insomecases, gine oil. Soapandwater, or waterless hand
gine,or both. betterengineprotection.Thesebenefitsdonotcome cleaner shouldbe used.
TheSAE(Societyof Automotive Engineers) grade withouta fewhitches,however; themainonebeing
number of oil indicatestheviscosityof theoil (its thepriceof synthetic
oil,whichissignificantly
more Theengineoil dipstickis typicallylocatedinthe
abilityto lubricate ata giventemperature). Thelower expensivethanconventional oil.

Fig. 150 Wipe the dipstick clean and rein-

Fig. 149Graspthe oil level dipstickand pull sert it into the dipstick tubeto getthe cor- Fig. 151The oil level shouldbe betweenthe
upwardto remove it from the dipstick tube rect oil level marks/notcheson the dipstick

l-34 GENERALINFORMATIONAND
MAINTENANCE
Engineoil levelshouldbechecked everytimeyou
putfuelinthevehicleor areunderthehoodperform-
ingothermaintenance.
1. Parkthevehicleona levelsurface.
2. Theenainemavbeeitherhotorcoldwhen
checking oil level. , if it is hot,waita fewmin-
utesaftertheenginehasbeenturnedOFFtoallowthe
oil todrainbackintothecrankcase. Iftheengineis
cold,donotstartit beforechecking theoil level.
3. Openthehoodandlocatetheengineoil dip-
stick.Pullthedipstickfromitstube,wipeit clean,
andreinsertit. MakesurethediDstickis fullv in-
serted.
4. Pullthedipstickfromitstubeagain.Holdingit
horizontally, readtheoil level.Theoilshouldbebe-
tweentheMINandMAXmarksor thenotches onthe
dipstick.If theoil is belowtheMINmarkor lower
notch,addoil oftheproperviscositythroughthe
cappedopeningof thevalvecover.
5. Reolace thediostick.andcheckthelevelaaain
p See Figures 152 thru 153
Theoil andfiltershouldbechanged
every7,500
miles(12,000km)undernormalserviceandevery
3,000miles(5,000km)undersevereservice.
93151p-55
Fig. 152 loosen the drain plug on the en-
a wrench. The drain plug’s
Fig. 155 Clean and inspect the threads on
the oil pan
The EPAwarns that prolongedcontactwith
usedengineoil may causea num’ IDer 01* SKlll
**
dianrAnrr ,,,u,uu,,,u
u,yu,u=,+, inrldinn uu,,u=,
ranrnrli V#lll
, vu should
uffart to minimizeyour exposure
to usedenginle oil. Protectivegloves should
be worn whet1changingthe oil. Washyour
handsandany other exposedskin areas as
so*m ..#avv4ble
111
aJ . . . . . after exposureto useden-
ginY
m “II.
nil ““up
St-mn “ll” .,U.“I,
mwl w&or “rnW.Y.“. .““I.I....”
nr umtarlncr hand
cleaner shouldbe used.
*The engineoil and oil filter shouldbe
changedat the recommendedintervals on
the MaintenanceChart.Thoughsomemanu-
facturers have at times recommendedchang-
ing the filter only at every other oil change, ’
Chiltonrecommendsthat you always change
. The benefit of fresh oil
drainingtheoil, makesurethattheengineis atoper-
atingtemperature. Hotoil will holdmoreimpurities
in suspension andwill flowbetter,allowingthere-
movalof moreoil anddirt.
It is a goodideato warmtheengineoil firstsoit
will flowbetter.Thiscanbeaccomolished bv15-20
Fig. 153Whenloosenedsufficiently, slowly
turn the drain plug by hand, keeping con-
Fig. 156 Also inspectthe drain plug th
before installing it back into the oil
Make sure the gasket on the drain plug is
in place and does not require replacement
.
milesof highwaydriving.Fluidwhichiswarmed to
normaloperatingtemperaturewill flowfaster,drain
morecompletelyandremovemorecontaminants
frnm
ll”,,, tho
Cl>”clnnine
““y”‘“.
1. Raiseandsupportthevehiclesafelyonjack-
stands.Makesuretheoil drainoluais atthelowest
pointontheoil pan.If not,youmayhaveto raisethe
vehicleslightlyhigherononejackstand (side)than
theother.
2. Beforeyoucrawlunderthevehicle,takea look
atwhereyouwill beworkingandgatherall thenec-
essarytools,suchasa fewwrenches or a ratchetand
stripof sockets, thedrainpan,somecleanragsand,
if theoil filteris moreaccessible
fromunderneath the
vehicle,youwill alsowantto graba bottleof oil,the
newfilterandafilterwrenchatthistime.
3. Positionthedrainpanbeneath theoil pan
drainplug.Keepin mindthatthefastflowingoil,
whichwill spilloutasyoupulltheplugfromthepan,
will flowwithenoughforcethatit couldmissthepan.
Positionthedrainpanaccordingly andbereadyto
movethepanmoredirectlybeneath theplugasthe
oil flowlessens to a trickle.
4. Loosenthedrain~luawitha wrench(orsocket
anddriver),thencarefuliyunscrew theplugwithyour
fingers.Usea ragto shieldyourfingersfromthe
heat.Pushin ontheplugasyouunscrewit soyou
canfeelwhenall of thescrewthreadsareoutofthe
hole(andsoyouwill keeptheoil fromseepingpast
thethreadsuntilyouarereadyto remove theplug).
Youcanthenremovetheplugquicklyto avoidhav-
inghotoil rundownyourarm.Thiswill alsohelpas-
surethathavethepluginyourhand,notinthebot-
tomof a panof hotoil.
Fig. 154 Whenyou are ready, carefully pull
Fig. 157 A plier-type filter wrench Is used
here to loosen the filter
 GENERALINFORMATIONAND
MAINTENANCE
l-35

Fig. 158 Whenthe filter is sufficiently loos-

Fig. 181 Before installing a new oil filter,

clean the gasketmountingsurfaceof the oil Fig. 182 Loosen and remove the oil filler Fig. 183 . , , then insert a funnel, and pour
filter housingand inspect the threads cap . . . oil directly into the engine

surface.Whenyoutightenthefilter,rotateit abouta
quarter-turnafterit contacts
themounting boss(or
Be careful of the oil; when at operatingtem- followanyinstructions whichareprovidedonthefil-
perature, it is hot enoughto causea severe teror partsbox). FLUIDRECOMMENDATIONS
bum. Forall vehicleswithmanual
transaxles,useHy-
poidgearoil SAE75W-85W, or 75W-9OW conform-
5. Allowtheoil to drainuntilnothingbuta few Operatingthe enginewithout the proper ingto APIspecifications
GL-4or higher.
dropscomeoutofthedrainhole.Checkthedrain amountandtype of engineoil will result In
plugtomakesurethethreadsandsealingsurfaceare severe engtnedamage. LEVELCHECK
notdamaged. Carefully threadtheplugintoposition
andtightenit snug,andgivea slightadditional turn. 8. Remove thejackstands andcarefullylowerthe b See Flgures 184 and 185
Youdon’twanttheplugtofall out(asyouwould vehicle,thenIMMEDIATELY refilltheengine
quicklybecome stranded), butthepanthreadsare crankcase withtheproperamountof oil. DONOT Inspecteachcomponent for leaking.Checktheoil
EASILY strippedfromovertightening (andthiscanbe WAITTODOTHISbecause if youforgetandsome- levelbyremoving thefillerplug.Iftheoil is contami-
timeconsuming and/orcostlyto fix). onetriesto startthevehicle,severeenginedamage nated,it is necessaryto replaceit withnewoil. Check
6. Toremove thefilter,youmayneedanoil filter will occur. theoil levelasfollows:
wrenchsincethefiltermayhavebeenfittedtoo 9. Refilltheenginecrankcase slowly,checking
tightlyand/ortheheatfromtheenginemayhave theleveloflen,youmayr..‘:--
lVL,VYU.-1
II,UL :L
II ..-..”II...-L-e
UUUU,,J ,“,\U.J
madeit eventighter.Afilterwrenchcanbeobtained lessthantheamountof oil listedinthecapacitychart
atanyautopartsstoreandiswell-worththeinvest- to refillthecrankcase.But,thatis onlyuntiltheen-
ment.Loosenthefilterwiththefilterwrench.Witha gineis runandtheoil filteris filledwithoil.Tomake
ragwrapped aroundthefilter,unscrew thefilterfrom suretheproperlevelis obtained, runtheengineto
thebossonthesideof theengine.Becarefulof hot normaloperating temperature, shuttheengineOFF,
oil thatwill rundownthesideof thefilter.Makesure allowtheoil to drainbackintotheoil pan,and
thatyourdrainpanis underthefilterbeforeyoustart recheck thelevel.Topofftheoil atthistimeto thefill
to removeit fromtheengine;shouldsomeofthehot mark.
oil happen to getonyou,therewill bea placeto
dumpthefilterina hurryandthefilterwill usually *If the vehicle Is not resting on level
spilla goodbitof dirtyoil asit is removed. ground,the oil level readingon the dipstick 89571gM
7. Wipethebaseof themounting bosswitha may be slightly off. Be sure to checkthe level Fig. 164Typtcal manualtransaxle drain and
clean,drycloth.Whenyouinstallthenewfilter, only when the vehicle is sitting level.
filler plug location
smeara smallamountoffreshoil onthegasketwith 10. Drainyourusedoil ina suitablecontainer for
yourfinger,justenoughto coattheentirecontact recycling.

l-36 GENERALINFORMATIONAND
MAINTENANCE
8957i565
Fig, 165 Oil, when at the proper level, will
reachthe lower edgeof tC=+ frfr*r u*rn -non-
ing
1. Makesurethevehicleis oarkedona levelsur-
face.
2. Remove thefiller plugandmakesuretheoil
levelis uptotheloweredgeof thefiller plughole.
3. Checkto besurethatthetransaxle oil is not
noticeablydirtyandthatit hasa suitableviscosity.
DRAIN& REFILL
u See Figures 166 and 167
1. Makesurethevehicleisparkedona levelsur-
face.
2. Raiseandsafelysupportthevehicle.Placea
suitabledrainpanunderthemanual transaxle.
3. Remove thefillerplugandthedrainplugand
allowtheoil to draincompletely.
Fig. 166 Use a box-end wrench to loosen
the manualtransaxle drain plug . . .
Installthedrainplugandtightento 22ft. Ibs.
(304Nm)
5. Refillthetransaxle
to theproperlevel,as
shownin theCapacities chart,withtheappropriate
fluid.Theoil levelshouldbeatthebottomof theoil
fillerhole.
6. Whentheoil reaches theorooerlevel,install
thefillerplugandtightento 22ft. Ibs.(30Nm).
FLUIDRECOMMENDATIONS
Mitsubishirecommends theuseof Mercon@auto-
matictransmission
fluid.
LEVELCHECK
u See Figures 168,169, and 170
Thetransaxle dipstickis locatedbehindtheair in-
lethose,towardsthefirewall.
1. Parkthevehicleona levelsurface.
2. Thetransaxle shouldbeatnormaloperating
temperature whenchecking fluidlevel.Toensurethe
fluidis atnormaloperating temperature, drivetheve-
hicleat least10miles.
3. Withtheselectorleverin P andtheparking
brakeapplied,starttheengine.
4. Openthehoodandlocatethetransaxle fluid
dipstick.Pullthedipstickfromitstube,wipeit clean,
andreinsertit. Makesurethedipstickis fully in-
serted.
Fig. 166 The automatictransaxle dipstick is
typically located underthe air cleaner inlet
tube. Pull the dipstick up to remove it from
the transaxle
Fig. 169 Wipe the dipstick clean and Insert
it mto the transaxle agamto get the correct
/fluid level reading ., j thetemperature normallyreaches 90°F(32%),or in
.
I
Fig. 170 The fluid level is OKif it is within
the betweenthe HOTand ADDareas on the
-.*".."... Do
&&i& -- not
.*"- overfill the transaxle or
problemscould occur
5. Pullthedipstickfromitstubeagain.Holdingit
horizontally,roadthefluidlevel.Thefkridshouldbe
between theMINandMAXmark.If thefluidis below
theMINmark,addfluidthroughthedipsticktube.
6. Insertthedipstick,andcheckthelevelagain
afteraddinganyfluid.Becarefulnotto overfillthe
transaxle.
DRAIN& REFILL
b See Figures171 thru 177
1. Raiseandsupportthevehiclesafely.
2. Placea suitabledrainpanunderthetransaxle
drainplug.
3. Remove thetransaxle pandrainplug.Letthe
fluidcompletely drainoutof thetransaxle.
4. Installthedrainplugandtightenit to 22-25ft.
lbs.(30-35Nm).
5. If equipped, removethedrainplugonthedif-
ferentialof thetransaxle.
6. Installthedifferentialdrainplugandtightenft
to 22-25ft. Ibs.(30-35Nm).
7. Remove thedrainpan.
8. Lowerthevehicle.
9. Fillthetransaxle throughthedipsticktothe
properlevel.
10. Placethegearselectorleverin P andstartthe
engine.Runtheengineat idle,engage theemergency
brakeandholdthebrakepedaldown.Movethegear
selectorleverthroughall transaxle rangesfor approx-
imately5 minutes.
11. Returntheselectorleverto P andleavethe
enginerunningat idle.
12. Checkthetransaxle fluidlevel.Thefluidlevel
at normaloperating temperature shouldreadwithin
thecrosshatched areaof thefluidleveldipstick.
13. If thefluidlevelreadsbelowthecrosshatched
area,adjustthelevelbyaddingfluidin smallincre-
mentsuntilthecorrectfluidlevelis obtained.
PAN&FILTERSERVICE
b See Figures178 thru 184
Thefluidshouldbechanged accordingto the
schedule in theMaintenance Intervalschart.If thecar
is normallyusedin severeservice,suchasstopand
startdriving,trailertowing,or thelike,theinterval
shouldbehalved.If thecaris drivenunderespecially
nastyconditions, suchasin heavycitytrafficwhere
veryhillyor mountainous areas,or in police,taxi,or
 _. .I ..-.
-._.

GENERALINFORMATIONAND
MAINTENANCE
l-37

Fig. 173 The differential drain plug is lo-

Fig. 172 Carefully pull the transaxie drain cated at the bottom of the transaxie, to the
plug out and to the side, out of the way oi left of the fluid pan. Typically the drain plug
flowing transaxie oil reauires a 17mmwrench

periodically checkingthe fluid level to pan mountingbolts,a 1Ommwrench is re- Fig. 179 . . , then carefully lower the fluid
make sure you do not overfill the transaxle quired. Removethe pan retaining bolts . . . pan from the transaxle

Fig, 181 . , . then remove the transaxie film Fig. 182 Removethe transaxie pan gasket
ter from the valve body from the pan
 t

1-38 GENERALINFORMATIONAND
MAINTENANCE
11I Addtherecommended automatic transaxle
fluidto thetransaxlethroughthedipsticktube.You
will needa longneckedfunnel,or a funnelandtube
to dothis.A quickcheckof thecapacities chartlater
inthisSectionwill revealthecapacityof thetransaxle
inyourvehicle.Onafirstfill afterremoving thepan
andfilter,thisnumber shouldbecutintoa ‘hand
checked onthedipstickbeforerefilling.
12. Withthetransaxle in P,putontheparking
brake,blockthefrontwheels,starttheengineandlet
it idle.DONOTRACETHEENGINE. DONOTMOVE
THELEVER THROUGH ITSRANGES.
13. Withtheleverin Park,checkthefluidlevel.If
it’sOK,takethecaroutfor a shortdrive,parkona
levelsurface,andcheckthelevelagain,asoutlined n of the transfer case filler
earlierinthissection.Addmorefluidif necessary. Be
carefulnotto overfill,whichwill causefoamingand
w fluidloss. 3. Remove thefillerandthedrainplugandallow
theoil to drainintothedrainpan.
4. Afterthefluidhasdrainedcompletely, install
thedrainplugandtightento 24ft. Ibs.(32Nm).
5. Refillthetransfercasetotheproperlevelwith
Hypoidgearoil SAE75W-85W/75W-9OW conform-
FLUIDRECOMMENDATIONS ingto APIspecifications GL-4or higher.Theoil level
-‘-,*I’ -nnnh+‘* “%omedgeof theoil fillerhole.
Whenaddingfluidor refillingthetransfercase, 6. Installthetranxfer
.._._.raw
____filler
.._.nlm
T.-Jand
_.._tinhtm
.lJ..._..
useHypoidgearoil SAE75W-85W or 75W-9OW to 24ft. lbs.(32Nm).
conforming
to APIspecifications 61-4or higher. 7. Carefullylowerthevehicle.
LEVELCHECK

Fig. 184 . . . the transaxle case before in- u See Figure 185
stalling the gasket andpan onto the case 1
,
FLUIDRECOMMENDATIONS
deliveryservice,thefluidshouldbechanged
accord-
ingto thesevereserviceschedule. u See Figure 187
Thefluidmustbehotbeforeit is drained;
a 20
Sincefluidviscosityrangemayvarydepending on
specifictemperature
rangeof operation,
pleaserefer

~~

case.You’ll beverysorrylaterif youdo.

tnetransaxle bottomedge of the transfer case filler 1 1Fig. 187 Rear axle lubricant application I
*If the drainedfluld is discolored (brown or 1plug hole chart I
black), thick, or pmmll~
.llln3llU
hmmt
““III.,
nnrinmm
url,““P

transaxle troubles, probablydueto overheat- totheaccompanying

chartfor theproperfluidfor
,r..rr,rA “#.a.-
trig, shouldbe susp~~lr;u. lvUl rrdr
vLlrJ lnsoecteachcomponent for leaking.Checktheoil
levelbyremoving thefillerplug.If theoil is contami- yourvehicle.
transaxle shouldbe inspectedby a reliable
transaxle specialist to determinethe prob- nated,it is necessaryto replaceit withnewoil.
1. Parkthevehi,., -.. IPVPI
if% nn ,-.“, z11rf2r~
__.,“-_. LEVELCHECK
lem.
2. Remove thefiller plugandmakesuretheoil
5. Remove thepanandgasket. levelreaches theloweredgeof thefillerplughole. 1. Makesurethevehicleis parkedonlevel
6. Cleanthepanwithsolventandallowit to air 3. Checkto besurethattheoil is notnoticeably ground.
dry.If youusea ragto wipeoutthepan,yourisk dirtyandthatit hastheproperviscosity. 2. Remove theoil fill plugto checktheoil level.
leavingbitsof lintbehind,whichwill clogthedinky 4. If necessary,addoil throughthefillerholeuntil 3. Theoil levelis sufficientif it reachesthelower
hydraulicpassages inthebansaxle. is runsoutof thehole. portionof thefillerplughole.If thefluidis low,add
7. Remove thefilterretainingboltsandremove asrequiredthroughthefillerplug.
thefilterfromthevalvebodv. DRAIN& REFILL
To install: . DRAIN& REFILL
8. Installa newfilter,theninstalltheretaining ) See Figure-14I8
boltsandtightenthemto 5 ft. Ibs.(7 Nm). u See Figure 188
9. Positionthegasketonthepan,theninstall 1. Raiseandsafelysupportthevehicle,foraccess
thepan.Tightentheboltsevenlyandin rotationto tothetransfercase. 1. Positionthevehicleona flatsurfaceor raise
8-9ft. Ibs.(10-12Nm.).Donotovertighten. 2. Placea suitabledrainpanunderthetransfer andsafelysupportthevehicleina levelposition.
IO. Lowerthevehicle. casefluiddrainplug. 2. Placeasuitabledrainpanundertherearaxle.
 GENERALINFORMATIONAND
MAINTENANCE
1-39
leak.Inmostcases,youwill beableto tracetheleak gloveboxandpassenger sidefloorboard area,and
to a loosefittingor damagedhose. checkthecarpetfor anysignsof moisture. The
Evaporating ethylene
glycolantifreeze
will havea smartestwayto goaboutfindinga leakvisuallyis to
sweetsmellandleavesmall,white(salt-like)de- firstinspectanyandall jointsin thesystemsuchas
oosits,whichcanbehelofulintracinoa leak. wheretheradiatorhosesconnect to theradiatorand
theengine.Anotherthingto lookfor iswhitecrusty
stainsthataresignsof a leakwherethecoolanthas

amountof fluid.Thelevelshouldieachthkbottomof meratingonIt,lap3 1sadanciara10useoutsome

A Qss Itin,t.as carsarehigher.Overpressurizing thesystemcan
theoil fillerhole. 7 “1sl ly”lsJa ran
IJ” +tw,,
Wll” 4liE
IJU causea ruptureina I:lose,or worse,intheradiatoror
6. Installthefillerplugandtightento’24ft. Ibs. h.n+n. nrrrn
nnA . . . . ..I.
(32Nm). \ If a thefluidlevelof yourcoolingsystemis con- IIC~KILUGMUPuaJblycauseaninjuryor a burnif
7. If raised,carefullylowerthevehicle. stantlylow,thechance s of a leakareprobable.
There thecoolantis hot.Overpressurizing is normallycon-
WI”U”.VlUl,.“,,I I” 9” aboutfindingthesourceof trolledbytheradiatorcapwhichhasa ventvalvein it
yourleak. whichis openedwhenthesystemreaches it’smaxi-
Thefirstwavshouldbeavisualinsnection. Durina mumpressure rating.Topressure testthesystem:
thevisualinspection, lookaroundthe&tire engine- *The pressuretest should be performedwith
FLUIDRECOMMENDATIONS areaincluding theradiatorandtheheaterhoses.The the enaine OFF.
interiorof thecarshouldbeinspected behindthe
A goodqualityethyleneglycolbasedor otheralu-
minumcompatible antifreeze
is recommended for
useinthevehiclescoveredbythismanual.It is best
to adda 50150mixof antifreezeanddistilledwaterto
avoiddilutingthecoolantinthesystem.
LEVELCHECK

“_y
“,~--
recoverytankanditsmarkingasa guideline. 1Fia. 190 A visual insaection for leaks will 1
*Never overfill the recovery tank. sometimes find a leak. This photo shows Fig. 191 Removethe recovery tank cap to
A coolantlevelthatconsistentlydropsis usuallya evfdence of a leak at the upper radfator allow the pressuretester to beconnected
to
signof a small,hardto detectleak,althoughinthe / hose-to-thermostat
* housingjunction * / /the system ,, /
worstcaseit couldbea signof aninternalengine

Fig. 189 The coolant level should be be- Fig. 192 This cooling system requires a Fig. 193 Thread the adapter onto the re-
1tween
coo,antthe FULLtank
recovery and LOW levels on“‘~‘_I
the j threadedadapterfor the recoverytank g’051p96
to al- / 1covety tank e’ffi1pg7
/
low the pressuretester to be connected
l-40 GENERALINFORMATIONAND
MAINTENANCE
doesnotverifythesituation,removing thespark
plugsoneata timeandchecking theelectrodesfora
greenor whitetintcanverifyaninternalcoolantleak
andidentifywhichcylinder(s)istheculpritandaiding
yoursearchforthecauseof theleak.Ifthespark
plugsappearokay,anothermethodisto usea gas
analyzeror emissionstester,or oneof severalhand-
heldtoolsthatmostprofessional shopspossess. This
toolsareusedto checkthecoolingsystemfor the
presence of Hydrocarbons(HC’s)inthecoolant.
DRAIN& REFILL
aiffiip98
p See figures 196 thru 205
Fig. 194Pumpthe cooling systemwith pres-
sure, makingsure not to overpressurizethe Fig 195 Watchthe gaugeon the systemand Ensure thattheengineis completely
coolpriorto
1system or damagecan occur / observe the pressurereading “@‘p~1 startingthisservice.

1. Remove theradiatoror recoverytankcap. droppedmorethan20%,a leakdefinitelyexists,if

2. Usingtheproperadapter, insertit ontothe theoressure droois lessthan20%.thesvstem
, is Neveropen, service or drain the radiator or
openingandconnectthepressure tester, mostlikelyokay: cooling systemwhen hot; serious burnscan
3. Beginpressurizing thesystembypumping the Anotherwaycoolantis lostis bya internalengine occurfrom the steamandhot coolant. Also,
pressure testerandwatching thegauge,whenthe leak,causingtheoil to becontaminated orthe when draining enginecoolant, keep in mind
maximum pressure
is reached,stop. coolantto beburnedintheprocessof combustion that cats and dogsare attractedto ethylene
4. Watchthegaugecarefullyandseeif thepres- andsentouttheexhaust. Tocheckfor oil contamina- glyeol antifreezeandcould drink any that is
sureonthegaugedrops,if it does,a leakis definitely , tion,remove thedipstickandchecktheconditionof left in an uncoveredcontaineror in puddles
present. theoil intheoil pan.If theoil is murkyandhasa on the ground.This will provefatal in suffi-
5. If thepressurestayedsomewhat stable,visu- whiteor beige“milkshake” lookto it,thecoolantis cient quantities.Always drain coolant into a
ally inspectthesystemfor leaks,If thepressure contaminating theoil throughaninternalleakandthe sealable container. Coolantshouldbe reuser
dropped, repressurize
thesystemandthenvisually enqinemustbetorndownto findtheleak.Iftheoil mlessit is contaminatedor is several years
inspectthesystem. Ippearsokay,thecoolantcanbeburnedandgoing
6. If nosignsof a leakarenoticedvisually,pres- jutthetailpipe.A quicktestforthisis a cloudof
surizethesystemto themaximum pressure ratingof Nhitesmokeappearing fromthetailpipe,especially 1. Remove therecovery tankor radiatorcap.
thesystemandleavetheuressure testerconnected In start-up.Oncolddays,thewhitesmokewill ap- 2, Raiseandsupportthevehicle.
flsrabout30minutes. Returnafter30 minutes and Iear,thisis dueto condensation andtheoutside 3. If necessary,
remove thesplashshieldfromun
Verifythepressure onthegauge,if thepressure emperature, nota coolantleak.Ifthe“smoketest” lerthefrontof thevehicle.

93im76

Fig. 196 The draincockis usually located at Fig. 197 Gently rotate the draincock coun- Fig, 198 . _ . then allow the coolant to drain
the bottom of the radiator terclockwise to open the draincock . . . out of the radiator and cooling system

93151p27

Fig. 200 Make sure to heed the caution on

Fig. 199Allow the fluid to drain until it stops the radiator cap and NEVERopen the cap Fig. 201 Graspthe radiator cap and rotate
and tighten the draineockhandtight when the engine is hot ,, 1 it counterclockwise. . .
 .

GENERALINFORMATIONAND
MAINTENANCE
l-41

93151p18

Fig. 202 . , . to remove the cap from the Fig. 203 Pour the proper *I~ coolant mix- 1
radiator ture into the radiator . . .
4. Allowtheengineto coolcompletely
anddrain
ie systemagain.
5. Repeatthisprocessuntil
thedrainedwateris
learandfreeof scale.
6. Flushtherecoverytankwithwaterandleave’
empty.
Neveropen, service or drain the radiator or
cooling systemwhen hot; serious bumscan
occurfrom the steamand hot coolant. Also,
when drainingenginecoolant, keep In mind
93151p17 that cats and dogsare attractedto ethylene
Fig. 205 Be sure the rubber gasket on the glycol antifreezeandcould drink any that is
radiator cap has a tight seal left in an uncoveredcontaineror in puddles
- on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
’ 1capacrry
4. Placea drainpanof sufficrenr . . . ..I .I. 1,~
unaerme sealable container.Coolantshouldbe reused
radiatorandopenthepetcock (drain)ontheradiator. unlessit is contaminatedor is several years
- w&1--x3_ --mm.._..-
. . ..-I...bind; Beforeopen-
rrrasuc perwcss easuy old.
ing a plastic radiator petcock,spray it with
somepenetratinglubricant. 7. Fillandbleedthecoolingsystemasdescribed
earner.
5. Drainthecoolingsystemcompletely.
6. Closethepetcock.
7. Remove thedrainpan.
8. If necessary,
L.-l installthesplashshieldunderthe ThebrakemastercylinderfKm”“ll
~a~~~~r,~~
:AI~nnL.4
15 IUMLC”
n-n
“II-
venicie.
9. Lowerthevehicle. derthehood,attachedto thebrakeboosterandfire-
10. Determine thecapacityof thecoolingsystem, wallonthedriverssideof theenginecompartment.
thenproperlyrefillthesystemattherecovery tank FLUIDRECOMMENDATIONS
andradiatorwitha 50/50mixtureof freshcoolantand
Fig. 204 . . . make sure to fill the coolant
recovery tank to the proper level also .I
fluid. Any brakefluid that is removedfrom
the systemshouldbe discarded.Also, do not
allow any brakefluid to come in contactwith
a paintedsurface;it will damagethe paint.
Whenaddingfluidto thesystem,ONLYusefresh
DOT3 brakefluidfroma sealedcontainer. DOT3
.a fluid.will absorb
brake . . , moisture
.*a. when.. * it.*.is exposed
. .to
tneatmospnere, wnrcnwnrrower1r.s oourngpomr.A
containerthathasbeenopenedonce,closedand
placedona shelfwill allowenoughmoisture to enter
overtimeto contaminate thefluidwithin.If yourbrake
fluidiscontaminated withwater,youcouldboilthe
brakefluidunderhardbrakingconditions andloseall
or somebrakingability.Don’ttaketherisk,buyfresh
brakefluidwhenever youmustaddto thesystem.
,LEVELCHECK
k See Figures206 thru 211
Brakefluid containspolyglycol ethersand
polyglycols. Avoid contactwith the eyes and
wash your handsthoroughlyafter handling
brakefluid. If vou do oet brakefluid in vour
eyes,
a-..‘Y--flush
rer mr ar your eyeswith
-l-..n-- clean, runniugwa-
II -.._ I____
.a-11--persim,
13 mmures.IT eye irriIauon - __-PA._
or if you havetaken brakefluid internally,
IMMEDIATELY seek medical assistance.

alain oreerring
mesysrem.
12. Starttheengineandallowit to idleuntilthe Brakefluid containspolyglycol ethersand Be careful to avoid spilling any brakefluid on
thermostatopens(theupperradiatorhosewill be- polyglycols. Avoid contactwith the eyes and paintedsurfaces,becausethe paint coat will
comehot).Thecoolantlevelshouldgodown,thisis wash your handsthoroughlyafter handling becomediscolored or damaged.
normalasthesystembleedstheair pocketsoutof the brakefluid. If you do get brakefluid in your
svstem. eyes, flush your eyes with clean, runningwa- Observe
._ ._the
__fluidlevelindicators onthemaster
13. Refillthesystemwithcoolantto theproper ter for 15 minutes;If eye irritation persists, cylinder;
..J ..I” the tluldII‘eve1
I.... shouldbebetween theMIN
._._.
IRVf!l or if vou havetaken brakefluid internallv. anoivw unes.
14. TurntheengineOFFandcheckfor leaks. IMMEDIATELY seek medical assistance.” Beforeremoving themastercylinderreservoircap,
makesurethevehicleis restingonlevelgroundand
FLUSHING& CLEANINGTHESYSTEM cleanall dirtawayfromthetopof themastercylinder.
Unscrew thecapandfill themastercylinderuntilthe
1. Drainthecoolingsystemcompletely asde: levelis between theMIN andMAXlines.
Clean, high quality brakefluid is essentialto If thelevelof thebrakefluidis lessthanhalfthe
scribedearlier. the safe and proper operationof the brake
2. Closethepetcock andfill thesystemwitha volumeof thereservoir,it isadvisedthatyoucheck
system.Youshouldalways buy the highest thebrakesystemfor leaks.Leaksina hydraulicbrake
coolingsystemflush(cleanwatermayalsobeused, quality brakefluid that is available. If the
butis notasefficient). systemmostcommonly occuratthewheelcylinder
brakefluid becomescontaminated,drain and andbrakelinejunctionpoints.
3. Idletheengineuntiltheupperradiatorhose flush the system,then refill the mastercylin-
getshot. der with new fluid. Never reuseany brake
1-42 GENERAL~INFORMATION
ANDMAINTENANCE

llow,be*“retoch~ckiebrake~
.
Fig. 206 The fluid level should be between
the MAXand MIN hnes if the fhud level IS
Fig. 207 Wipethe mastercylinder reservoir
clean before openingthe cap to ensurethat
no contaminationenters the brake fluid
93151p29 I

Fig. 208 Unscrew the master cylinder cap

and remove it from the reservoir

93151p31

Fig. 209 If the master cylinder capgasket Fig. 211 Carefully pour approvedbrakefluid
is swelled like such, it can be a sign of con- Fig. 210 . . . makesure to pushthe gasket from a fresh, sealed container directly into
tamination. If the gasket is swelled . . . back to the normal position the reservoir

2. Inspectthefluidin thereservoir, makingsure

fluidis betweentheMAXandtheMINmarks.
3. If required,
removetheclutchmastercylinder
FLUID RECOMMENDATIONS reservoirlid.thenaddfreshfluidItofill tothetopfull FLUIDRECOMMENDATIONS
markonthe’reservoir.
Whenaddingor changing thefluidinthesystems, Whenaddingor changing
thepowersteering
usea qualitybrakefluidconformingto DOT3 speci- fll$,“” Dexron@il ATF(Automatic
Transmission
ficationsfromansealedcontainer.
Neverreuseold - - .
brakefluid.
Be careful to avoid sfBillingany brakefluid on LEVELCHECK
LEVELCHECK paintedsurfaces,bet:ausethe paint coat will
becomediscoloredor damaged. b See Figures 215, 216, 217, and 218
b See Figures 212, 213, and 214
4. Reinstall
thelid ontotheclutchmastercylin- Likeall othergeneralmaintenance items,check
1. Wipetheclutchmastercylinderreservoircap der. every3,OOflmiles(4,800km)or oncea month.In-
andthesurrounding
areacleanwitha shoptowel. 5. If removed,
installtheair cleanerassembly. specttheoil levelinthereservoirbycheckingthepo-

Fig. 212 The clutch master cylinder has

MAX(A) and MIN (B) fill lines on the reser
volr

93151p14
Fig. 215 Twist the reservoir cap, then lift up
I
on the integral cap/dipstickassembly
sitionofthefluidagainstthemarkonthedipstick,
Addfluidtothereservoirif thefluiddoesnotreach
theappropriatefull line.
Onmostmodels,themanufacturer doesn’tinstall
lubricationfittingson lubepointsonthesteering
linkageor suspension. However,if thelubrication
pointdoeshavea greasefitting,lubricate withmulti-
purposeNLGINo.2 (Lithiumbase)grease.
CARWASHING
Thecarshouldbewashed atregularintervalsto
removedirt,dust,insects,andtarandotherpossibly
damaging stainsthatcanadheretothepaintandmay
causedamage. Properexteriormaintenancealso
helpsintheresalevalueof thevehiclebymaintaining
its like-newappearance.
Mt is particularlyimportantta frequentiy
washthe car in the wintertimeto preventcor-
rosion, whensalt has beenusedon the roads.
Therearemanyprecautions andtipsonwashing,
includingthefollowing:
l Whenwashingthecar,donotexposeit dodi-
rectsunlight.
. Uselukewarm waterto softenthedirtbefore
youwashwitha sponge, andplentyof water,to avoid
scratching.
l A detergent
canbeusedtofacilitatethesoften-
ingof dirtandoil.
GENERALINFORMATIONAND
MAINTENANCE
l-43
l Specialcarwashingdetergent
is thebestto
use.Liquiddishwashingdetergent
canremove wax
andleavethecar’spaintunprotected
andin addition
someliquiddetergents
containsabrasiveswhichcan
scratchthepaint.
l Birddroppingsshouldberemoved fromthe
paintworkassoonaspossible,otherwisethefinish
maybepermanently stained.
Whenthe car is driven immediatelyafter be-
ing washed,apply the brakesseveral times
93151p12 in order to removeany moisturefrom the
Fig. 216 Wipe the dipstick off, reinsert it brakingsurfaces.
I I
into the reservoir and checkthe level
Enginecleaningagentsshouldnot be used
when the engine is warm, a fire risk is pre-
sent as most enginecleaningagentsare
highly flammable.
Automatic carwashingis a simpleandquickway
to cleanyourcar,butit is worthremembering thatit
is notasthorough aswhenyouyourselfcleanthe
car.Keeping theunderbody cleanis vitallyimportant,
andsomeautomatic washersdonotcontainequip-
mentfor washingtheunderside of thecar.
Whendrivingintoanautomatic was,makesure
thefollowingprecautions havebeentaken:
l Makesureall windowsareup,andnoobjects
thatyoudonotwantto getwetareexposed.
l Insomecases,rotatingthesideviewmirrors
incanhelpto avoidpossibledamage.
* Awater-soluble greasesolventmaybeusedin l If yourcaris equipped witha powerantenna,
casesof stickydirt.However,usea washplace
witha lowerit. If yourvehiclehasa solidmounted, non-
drainage separator. powerantenna, it is bestto removeit, butthisis not
l Drythecarwitha cleanchamoisandremem- alwayspractical.Inspect thesurroundings to reduce
berto cleanthedrainholesinthedoorsandrocker theriskof possibledamage, andcheckto seeif the
panels. antenna canbemanually lowered.
l If equippedwitha powerradioantenna,
it must
bedriedafterwashing.
Most manufacturersdo not recommendauto-
maticcar washingin the first six monthsdue
to the possibility of insufficient paint curing;
Neverclean the bumperswith gasoline or
paint thinner, always usethe sameagentas a safe bet is to wait until after six monthsof
usedon the paintedsurfacesof the vehicle. ownership(when purchasednew) to use an
automaticcar wash.
l Tarspotscanberemoved withtarremoveror
kerosene afterthecarhasbeenwashed.
l Astiff-bristlebrushandlukewarm soapywater WAXING
canbeusedto cleanthewiperblades.Frequent
cleaningimproves visibilitywhenusingthewipers eBefore applyingwax, the vehicle mustbe
considerably. washedandthoroughlydried.
l Washoffthedidfromtheunderside (wheel
Waxingavehiclecanhelpto preserve theappear-
housings, fenders,etc.). anteof yourvehicle.Awiderangeof polymer-based
l Inareasof highindustrialfallout,morefre-
carwaxesareavailable today.Thesewaxesareeasy
quentwashingis recommended. to useandproducea long-lasting, highglossfinish
thatprotectsthebodyandpaintagainstoxidation,
roaddirt,andfading.
Sometimes, waxinga neglected vehicle,or one
Duringhighpressurewashingthe spraynonle
mustneverbe closerto the vehicle than13 thathassustained chemical or naturalelement dam-
inches(30cm).Do not sprayinto the locks. age(suchasacidrain)requiremorethanwaxing,
anda light-dutycompound canbeapplied.Forse-
l Whenwashingorsteamcleaningtheengine, verelydamaged surfaces,
it is bestto consulta pro-
avoidsprayingwateror steamdirectlyontheelectri- fessionalto seewhatwouldberequired to repairthe
calcomponents or nearthedistributoror ignition damage.
components.Aftercleaningtheengine,thespark Waxingprocedures differaccording to manufac-
plugwellsshouldbeinspected forwaterandblown turer,type,andingredients,so it is bestto consult
dryif necessary. thedirectionsonthewaxand/orpolishpurchased.
1-44 GENERALINFORMATIONAND
MAINTENANCE
INTERIORCLEANING
Upholstery
Fabriccanusuallybecleanedwith soapywateror
a properdetergent.For more difficult spots causedby
oil, ice cream,soda,etc., usea fabric cleaneravail-
able at most partsstores.Besurewhenpurchasing
the cleanerto readthe labelto ensureit is safeto use
on your type of fabric. A safemethodof testingthe
cleaneris to applya small amountto an areausually
unseen,such as undera seat,or otherareas.Warta
while, perhapsevena dayto checkthe spot for fad-
ing, discoloring,etc.,as somecleanerswill only
causetheseproblemsafterthey havedried
Leatherupholsteryrequrresspecialcare,it canbe
cleanedwith a mild soapand a soft cloth. It is recom-
mendedthata specialleathercleanerbe usedto
cleanbut alsotreatthe leathersurfacesin your vehi-
cle. Leathersurfacescanagequickly and cancrack if
not properlytakencareof, so it is vital thatthe leather
surfacesbe maintained.
Floor Mats and Carpet
Thefloor matsand carpetshould bevacuumedor
brushedregularly.Theycan be cleanedwith a mild
soapand water.Specialcleanersareavailableto
cleanthe carpetedsurfacesof your vehicle,but take
carein choosingthem,and againit is bestto test
them in a usuallyunseenspot.
Dashboard,Console,Door Panels, Etc.
Thedashboard,console,door panels,and other
plastic,vinyl, or wood surfacescan be cleanedusing
a mild soapandwater.Cautionmust be takento keep
waterout of electronicaccessoriesand controlsto
avoid shorts or ruining the componentsAgain spe-
cial cleanersareavailableto cleanthesesurfaces,as
with othercleanerscaremust takenin purchasmg
and using such cleaners.
Thereare protectantsavailablewhich cantreatthe
various surfacesin your car giving thema “shiny new
look”, howeversome of theseprotectantscan cause
more harmthan good in the long run. Theshinethat
is placedon your dashboardattractssunlightaccel-
eratingthe aging,fadingand possiblyevencracking
the surfaces.Theseprotectantsalso attractmoredust
to stick to the surfacestheytreat, Increasingthe
# See Figures219 and 220
To preventthe bumperfrom deforming,thesevehi-
cles cannotbetowedby a wreckerusing sling-type
equipment.If thesevehiclesrequiretowing, usea
wheellift or flat bedequipment.It is recommended
that the vehiclebe towedfrom the front If a flat bed is
not available.
Manualtransaxlevehiclesmay betowedfrom the
rearprovidedthatthe transaxleis in Neutralandthe
drivelinehasnot beendamaged.Thesteeringwheel
must be clampedin the straight-aheadpositronwith a
steeringwheelclampingdevicedesignedfor towing
serviceuse.
cleaningyou must do to maintainthe appearanceof
your vehicle.Personaldiscretionis advisedhere.
On most modelscoveredby this manual,the
wheelbearmgsusedare sealedunits and do not re-
quire routinemaintenance.Howeveron someGalant
and Mirage models,the rearwheelbearingdo require
periodicrepacking.For removaland installationin-
structions,pleasereferto Section7 (for rear bear-
ings) or Section8 (for front bearings).
REPACKING
*Sodium basedgrease is not compatible
with lithium basedgrease. Readthe package
labels and be careful not to mix the two
types. If there is any doubtas to the type of
greaseused, completelyclean the old
greasefrom the bearingand hub before re-
placing.
Beforehandlingthe bearings,thereare a few
thingsthat you shouldrememberto do and not to do.
DOthe following:
l Removeall outsidedirt from the housingbe-
fore exposingthe bearing.
l Treata usedbearingas gentlyas you would a
newone.
l Workwith cleantools in cleansurroundings.
l Useclean,dry gloves,or at leastclean,dry
hands.
l Cleansolventsand flushingfluids are a must.
l Usecleanpaperwhenlaying out the bearings
to dry.
l Protectdrsassembledbearingsfrom rust and
dirt. Coverthemup.
l Useclean,lint-free ragsto wipe the bearings.
l Keepthe bearingsin oil-proof paperwhenthey
are to be storedor are not in use.
l Cleanthe inside of the housingbeforereplac-
ing the bearin
Do NOTdo El,
he followino:
l Do not work in dirty sirroundings.
l Do not usedirty, chippedor damagedtools.
l Do not work on woodenwork benchesor use
woodenmallets.
l Do not handlebearingswith dirty or moist
hands.
Do not usethe steeringcolumnlock to secure
the front wheel uosition for towina.
Automatictransaxlevehiclesmay betowedon the
front wheelsat speedsnot to exceed30 mph (50
km/h) for a distancenot to exceed18 miles (30 km).
If theselimits can not be met,thenthe front wheels
must be placedon a tow dolly.
# See Figure 221
l Do not usegasolinefor cleaning.Usea safe
solvent.
l Do not spin dry bearingswith compressedair.
Theywill be damaged.
l Do not usecottonwasteor dirty clothsto wipe
bearings.
l Do not scratchor nick bearingsurfaces.
l Do not allow the bearinato come in contact
with dirt or rust at anytime. ”
The rear wheelbearinason some Galantand Mi-
rage modelsrequireperiodic maintenance.A pre-
mium high melting point greasemeetingGrade
MultipurposeGreaseNLGI Grade#2 or equivalent
must be used. Long fiber type greasesmust not be
used.This service is recommendedevery30,000
miles (48,000 km).
*For informationon WheelBearingremoval
and installation, refer to Section7 of this
manual.
1. Removethe wheelbearing.
2. Cleanall parts in a non-flammablesolventand
let themair dry.
*Only use lint-free ragsto dry the bearings.
Neverspin-drya bearingwith compressed
air, as this will damagethe rollers.
3. Checkfor excessivewearand damage.Replace
the bearingas necessary.
*Packina wheel bearinoswith arease is
bestaccomplishedby u&g a wheel bearing
packer(available at most automotiveparts
stores).
4. If a wheelbearingpackeris not available,the
bearingsmay be packedby hand.
a. Placea “healthy’ glob of greasein the
palm of one hand.
b. Forcethe edgeof the bearinginto the
greaseso that the greasefills the spacebetween
the rollers and the bearingcage.
c. Keeprotatingthe bearingwhile continuing
to push the greasethrough.
d. Continueuntil the greaseis forced out the
otherside of the bearing.
5. Placethe packedbearingon a cleansurface
and cover it until it is time for installation.
6. Installthe wheelbearing.
All WheelDrive (AWD)vehiclesshouldonly be
towedwith all 4 wheelson the groundor lifted from
the roadsurface.This meansthat the vehicle is to be
towedeitherwith flatbedequipment,with all wheels
on dollies or flat towed.Damageto the viscous cou-
pling may result if the vehicleis towedwith only 2
wheelson the ground.
p See Figure 222
Whenevera vehicle is jump started,precautions
must be followedIn orderto preventthe possibility of

SLINGTYPE
WHEELLIFTTYPE
cles
SUNGTYPE
WHEELLIFTTYPE
FLATBEDTYPE
Fig. 220 Rear towing position-FWD vehi
cles
personalinjury. Rememberthat batteriescontaina
small amountof explosivehydrogengaswhich is a
by-productof batterycharging.Sparksshouldalways
be avoidedwhenworkingaroundbatteries,especially
whenattachingjumpercables.To minimizethe pos-
sibility of accidentalsparks,follow the procedure
carefully.
NEVERhookthe batteriesup in a series cir-
cuit or the entire electrical systemwill go up
in smoke. includinothe starter!
Vehiclesequippedwith a dieselenginemay utilize
two 12 volt batteries.If so, the batteriesare con-
nectedin a parallelcircuit (positive terminalto posi-
tive terminal,negativeterminalto negativeterminal).
GENERALINFORMATIONAND
MAINTENANCE
1-45
owrng methods
a tow truck IS used
Lrftrng method for 4 wheels-Good
Front wheels lifted-No good
Front wheels lifted-No good
Rear wheels lifted-No good
Towing by rope or cable-Good
e9571g92
Fig.221 Towing instructions-AWD models
Hookingthe batteriesup in parallelcircuit increases
batterycrankingpowerwithout increasingtotal bat-
tery voltageoutput.Outputremainsat 12 volts. On
the otherhand,hookingtwo 12 volt batteriesup in a
seriescircuit (positiveterminalto negativeterminal,
positiveterminalto negativeterminal)increasestotal
batteryoutputto 24 volts (12 volts plus 12 volts).
l Be surethat both batteriesare of the samevolt-
age.Vehiclescoveredby this manualand most vehi-
cles on the roadtodayutilize a 12 volt chargingsys-
tem.
l Besurethat both batteriesare of the samepo-
larity (havethe sameterminal,in most casesNEGA-
TIVE grounded).
l Be surethat the vehiclesare not touchingor a
short could occur.
l On serviceablebatteries,be surethe vent cap
holesare not obstructed.
l Do not smokeor allow sparksanywherenear
the batteries.
l In cold weather,makesurethe batteryelec-
trolyte is not frozen,This can occur morereadilyin a
batterythat hasbeenin a stateof discharge.
qemarks
. For4WD models, the basic principle is that
all four wheels are to be rarsed before
towing.
. The shift lever should be set to 1st gear and
the parking brake should be applied.
l The vehicle must not be towed by tofacing
only its front wheels or only the rear wheels
on a rollino dollv, because to do so will
result in d&e&ration of the visfx~s
coupling and result in the viscous coupling
causing the vehicle to jump forward
suddenly.
l If only the front wheels or only the rear
wheels are lifted for towing, the bumper
wrll bedamyd.
In addrtron. II trng of the rear wheels causes
the or1to flow forward. and may result in
heat damage to the rear bushing of the
transfer, and so should never be done.
l The front and rear wheels must rotate
normally.
l The various mechanisms must function
normally.
l The shift lever must be set to the neutral
~Asi&n and the ignition key must be set to
l Do not allow electrolyteto contactyour skin or
clothing.
1. Make surethat the voltagesof the 2 batteries
are the same.Most batteriesand chargingsystems
are of the 12 volt variety.
MAKE CONNECTIONS IN NUMERICAL ORDER
A FIRST JUMPER CABLE
WITH CHARGED BATTERY
-
lccslQ?,Q
Fig. 222 Connectthe jumper cables to the
batteries and engine in the order shown
 .
I-46 GENERALINFORMATIONAND
MAINTENANCE
2. Pullthejumpingvehicle(withthegoodbat- cableonthedonorbattery.Disconnect thepositive emergency situation,carefullyfollowtheinstructions
tery)intoa positionsothejumpercablescanreach cablefromthedonorbatteryandfinally,disconnect providedeitherwiththejackor inyourownersman-
thedeadbatteryandthatvehicle’sengine.Makesure thepositivecablefromtheformerlydeadbattery.Be ual.Donotattempt to usethejackonanyportionsof
thatthevehiclesdo NOTtouch. carefulwhendisconnecting thecablesfromtheposi- thevehicleotherthanspecifiedbythevehiclemanu-
3. Placethetransmissions/transaxles
of bothve- tiveterminalsnottoallowthealligatorclipstotouch facturer.Alwaysblockthediagonally oppositewheel
hiclesin Neutral (MT)or P (AT),asapplicable,
then anymetaloneithervehicleor a shortandsparkswill whenusinga jack.
firmlysettheirparkingbrakes. occur. A moreconvenient wayof jackingistheuseof a
garageor floorjack.Youmayusethefloorjackto
*ff necessaryfor safety reasons,the hazard I raisethefrontof thevehiclebyplacingit underthe
lights on bothvehicles may be operated frontsubframe. Therearofthevehicleismosteasily
throughoutthe entire procedurewithout sig- $ See Figures223,224, 225,226, and 227 raisedbyusingthelift pointsonthedriprail.All
nificantiy increasingthe diff icuity of jumping modelsareequipped withlift pointslocatedonthe
the dead battery. Yourvehiclewassuppliedwitha jackforemer- mid-crossmember inthefrontanda bracketlocated
gencyroadrepairs.Thisjackisfinefor changing a onthefloorpanunderneath thetrunk.
4. Turnall lightsandaccessories OFFonboth flattireor othershorttermprocedures notrequiring Neverplacethejackundertheradiator,engineor
vehicles.Makesuretheignitionswitchesonbothve- youto gobeneath thevehicle.If it is usedinan transaxlecomponents. Severeandexpensive damage
hiclesareturnedto theOFFposition. will resultwhenthejackis raised.Additionally, never
5. Coverthebatterycellcapswitha rag,butdo jackunderthefloorpanor bodywork; themetalwill
notcovertheterminals.
6. Makesuretheterminals onbothbatteries are Whenever youplanto workunderthevehicle,you
cleanandfreeof corrosionor properelectricalcon- mustsupportit onjackstands or ramps.Neveruse
nectionwill beimpeded. If necessary,
cleanthebat- cinderblocksor stacksof woodto supportthevehi-
teryterminalsbeforeproceeding. cle,evenif you’reonlygoingto beunderit fora few
7. Identifythepositive(+)andnegative (-) termi- minutes.Nevercrawlunderthevehiclewhenit is
nalsonbothbatteries. supported onlybythetire-changingjackor other
8. Connect thefirstjumpercableto thepositive
(t) terminalof thedeadbattery,thenconnectthe
otherendof thatcabletothepositive(t) terminalof *Always position a block of wood or small
thebooster(good)battery. rubberpad on top of the jack or jackstandto
9. Connect oneendof theotherjumpercableto protectthe lifting point’s finish when lifting
thenegative (&minus;) terminalontheboosterbat- or supportingthe vehicle.
teryandthefinalcableclampto anenginebolthead, Smallhydraulic, screw,or scissorsjacksaresatis-
alternator bracketor othersolid,metallicpointonthe factoryfor raisingthevehicle.Drive-ontrestlesor
enginewiththedeadbattery. Tryto picka groundon
theenginethatis positioned awayfromthebatteryin
orderto minimize thepossibilityof the2 clamps
touchingshouldoneloosenduringtheprocedure.
DONOTconnectthisclampto thenegative (-) termi-
nalof thebadbattery.

Be very careful to keepthe jumpercables

away from movingparts (cooling fan, belts,
etc.) on bothengines.
10. Checkto makesurethatthecablesarerouted
awayfromanymovingparts,thenstartthedonorve-
hicle’sengine.Runtheengineatmoderate speedfor
severalminutes to allowthedeadbatterya chance to
receivesomeinitialcharge. &stands also on the Fig. 225 The most practical place to place
11. Withthedonorvehicle’s enginestill running front of the vehicle is
slightlyaboveidle,tryto startthevehiclewiththe
deadbattery.Cranktheenginefor nomorethan10
seconds ata timeandletthestartercoolforat least
20secondsbetween tries.If thevehicledoesnotstart
in3 tries,it is likelythatsomething elseisalso
wrongor thatthebatteryneedsadditional timeto
charge.
12. Oncethevehicleis started,allowit to runat
idlefora fewseconds to makesurethatit is operat-
ingproperly.
13. TurnONtheheadlights, heaterblowerand,if
equipped, thereardefroster of bothvehiclesin order
to reducetheseverityof voltagespikesandsubse-
quentriskof damage to thevehicles’electricalsys-
temswhenthecablesaredisconnected. Thisstepis
especially important to anyvehicleequipped with
computer controlmodules. Fig. 227 All modelscovered by this
14. Carefullydisconnect thecablesinthe’reverse Fig. 226 Place the jackstandsalso are equipped with lift points on t
orderof connection. Startwiththenegative cablethat subframeto supportthe front of the crossmemberin the front and on a
is attached to theengineground,thenthenegative
 GENERAL
rampsare also a handyand safeway to both raise
and supportthe vehicle.Becarefulthough,some
rampsmay betoo steepto drive your vehicleonto
without scrapingthe front bottompanels.Neversup-
port the vehicleon anysuspensionmember(unless
specificallyinstructedto do so by a repairmanual)or
by an underbodypanel.
INFORMATION
ANDMAINTENANCE
1-47
l Whenthe drive wheelsareto remainon the
ground,leavethe vehicle in gearto help preventit
The following safetypoints cannotbe overempha- from rolling.
sized: l Alwaysusejackstandsto supportthe vehicle
l Alwaysblockthe oppositewheelor wheelsto whenyou areworking underneath.Placethe stands
keepthe vehiclefrom rolling off the jack. beneaththe vehrcle’sjacking brackets Beforeclimb-
l Whenraisingthe front of the vehicle,firmly ap- ing underneath,rock the vehiclea bit to makesure it
ply the parkingbrake. is firmly supported.

SCHEDULED MAINTENANCE INTERVALS

(MITSUBISHI DIAMANTE, GALANT, & MIRAGE)

VEHICLE MILEAGE INTERVAL (x1000)

TO BE
7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 62.5 90 97.5
J J J 4 J J 4 4 4 J J J 4

4 J J J J 4

Ball loints &steering linkage

S/I J J J
seals
Dnve belt(s) S/I 4 4 J
Fvha,,rt
LmI,..“w.
cvctom
“,YL”,‘.
$/I J J J

Fuel hoses

Manual transaxle oil (Galant)

connectlon & fuel tank filler

R. Replace S/I - Sefwce or Inspect

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE)
II a vehicle is operated under any of the following conditions it is considered severe service:
- Extremely dusty areas.
- 50% or more of the vehicle operation is in 32% (WF) or higher temperatures, or constant opsralion in
temperatures below 0% (32°F).
- Prolonged idling (vehicle operation in stop and go traffic).
_ Frequent short running periods (engine does not warm to normal operating temfwatures).
- Police, taxi, delivery usage or trailer towing usage.
0118 011filter change-change every 3CQOmiles.
Disc brake pads - sewce or Inspect ever 6COOmiles
AN hlter element _ setwe or inspect every 15,000 miles.
Automatic transaxle lluld 8 filter . replace every 15,COOm&s.
Rear drum brake Ikmngs& rear wheel cylinders (Galant & Mirage)
Spark plugs (except Dlamante wlplabnum tip) - replace every 15,COOmiles.
Manual transaxle 011(mcludlng transfer (Galant & Mirage). replace every 30,000 miles.
1-48 GENERALINFORMATIONAND
MAINTENANCE
CAPACITIES
Engine Drive