Ch 1 General Info & Maint.

HOW TO USE THIS BOOK 1-2 WHERETOBEGIN l-2 AVOIDINGTROUBLE1-2 MAINTENANCEORREPAIR? 1-2 AVOIDINGTHEMOSTCOMMONMISTAKES l-2 TOOLSAND EQUIPMENT 1-2 SPECIALTOOLS l-4 YOUR VEHICLE SAFELY 1-4 DON'TS l-6 FASTENERS,MEASUREMENTSAND CONVERSIONS l-6 BOLTS,NUTSANDOTHERTHREADED RETAINERS1-6 TORQUE l-7 TORQUEWRENCHES l-7 TORQUEANGLEMETERS1-9 STANDARDANDMETRIC MEASUREMENTSl-9 SERIAL NUMBER IDENTIFICATION l-10 VEHICLEIDENTIFICATION NUMBER l-10 ENGINEIDENTIFICATION NUMBER I-10 TRANSAXLEIDENTIFICATION I-10 DRlVEAXLE(AWDGALANTONLY)l-10 TRANSFERCASE(AWDGALANTONLY) l-10 ROUTINEMAINTENANCEAND TUNE-UP l-14 AIRCLEANER(ELEMENT)1-14 REMOVAL&INSTALLATION1-14 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 l-25 DISTRIBUTORCAPANDROTOR 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 CONDITIONING SYSTEM 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

OPERATION INFOREIGNCOUNTRIESl-33 ENGINE l-33 OILLEVELCHECK 1-33 OIL& FILTERCHANGE l-34 MANUALTRANSAXLEl-35 FLUIDRECOMMENDATIONS l-35 LEVELCHECK l-35 DRAIN&REFILL l-36 AUTOMATICTRANSAXLEl-36 FLUIDRECOMMENDATIONS l-36 LEVELCHECK 1-36 DRAIN&REFILL l-36 PAN& FILTERSERVICE1-36 TRANSFERCASE(AWDGAlANT ONLY) l-38 FLUIDRECOMMENDATIONS l-38 LEVELCHECK l-38 DRAIN&REFILL l-38 REARDRlVEAXLE(AWDGALANTONLY)l-38 FLUIDRECOMMENDATIONS l-38 LEVELCHECK l-38 DRAIN&REFILL l-38 COOLINGSYSTEMl-39 FLUIDRECOMMENDATIONS l-39

iM-41

.

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.Operating systemsfrom enginethroughbrakesare coveredto the extentthat the averagedo-it-yourselferbecomesmechanicallyinvolved.This book will not explainsuchthings as rebuildinga differentialfor the simple reasonthat the expertiserequiredandthe investmentin specialtools makethis task uneconomical. It will, however,give you detailedinstructionsto helpyou changeyour own brakepadsand shoes,replacesparkplugs,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 proceduresthoroughlyunderstoodbeforeattempting any work. All sectionscontainadjustments,maintenance,removaland installationprocedures,and in somecases, repairor overhaulprocedures.Whenrepairis not consideredpractical,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 operations 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 identification. A permanentfelt-tippedmarkeror a metalscribe can bevery handyfor markingmetalparts.Remove anytapeor paperlabelsafterassembly.

It’s necessaryto mentionthe differencebetween maintenanceand repair Maintenanceincludesroutine 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.Example,drainingand refilling the automatictransaxle fluid is maintenancerecommendedby the manufacturer at specificmileageintervals.Failureto do this canshortenthe life of the transmission/transaxle,requiring 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 engine 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. Constantlybe awareof the dangersinvolvedin working on an automobileandtakethe properprecautions. Seethe informatronin this sectionregardingSERVICINGYOURVEHICLESAFELYandthe 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 usually just costsyou extratime; however,it CAN break something.Readthe entireprocedurebeforebeginning 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 lookswhenassembledat 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 torquespecificationsand 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 multiplied manytimes in actualforce on whatyou are tightening.A good exampleof how critical torqueis can be seenin the caseof sparkplug installation,especiallywhereyou are puttingthe plug into an aluminum 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.Before 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 lubricatefasteners,thento startthreadingthe bolt, spark plug,etc.with your fingers If you encounterresistance,unscrewthe partand startover againat a differentangleuntil 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 suddenlyencounterresistance,andthe part hasnot seatedfully, don’tforce it. Pull it backout to makesure it’s cleanandthreading properly. Besureto takeyour time and be patient,and always planahead.Allow yourselfampletime to perform repairsand maintenanceYou mayfind maintaining 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 following tools: l Wrenches/socketsand combinationopen end/boxendwrenchesin sizesfrom %-% in. or

GENERALINFORMATIONAND MAINTENANCE l-3 3-19mm,aswellasa % in.or~/ain.sparkplug socket(depending onplugtype). -if possible, buyvarious lengthsocketdrive extensions.Universal-jointandwobble extensionscan be extremelyuseful, but be

careful when usingthem, as they can change the amountof torque appliedto the socket. l Jackstands forsupport. l Oilfilterwrench. Spoutor funnelfor pouringfluids. l

pi 1

Fig. 1 Ail but the most basic procedures

l Grease gunfor chassislubrication (unless yourvehicleis notequipped withanygreasefittings-for details,pleasereferto information onFluidsandLubricants, laterinthissection). l Hydrometer for checking thebattery(unless equiooed witha sealed,maintenance-free batten/). O’A container for drainingoil andotherfluids. l Ragsforwipinguptheinevitable mess.

Inadditiontotheaboveitemsthereareseveral othersthatarenotabsolutely necessary, buthandyto havearound.TheseincludeOilDry@(oranequivalentoil absorbent gravel-suchascatlitter)andthe usualSUDDIV of lubricants. antifreeze andfluids.althoughthe.&canbepurchased asneeded. Thisis a basiclistfor routinemaintenance, butonlyyourpersonalneedsanddesirecanaccurately determine your Afterperforming a fewprojectsonthevehicle, you’llbeamazed attheothertoolsandnon-toolson

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Fig, 3 A hydraulic floor jack and a set of jackstandsare essential for lifting andsup porting the vehicle

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Fig. 5 Various drivers, chisels and ptybars are great tools to have in your toolbox

Fig. 7 Althoughnot always necessary,using specialized brake tools will save time

Fig. 11 inductive type timing light \

I-4

GENERALINFORMATIONAND MAINTENANCE 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 determiningwhetheror notthereis currentina wire.These arehandyfor useif awireis brokensomewhere ina wiringharness. Asa finalnote,vouwill orobablvfinda torque wrenchnecessary for all butthemostbasicwork. Thebeamtypemodelsareperfectlyadequate, althoughthenewerclicktypes(breakaway) areeasier to use.Theclicktypetorquewrenches tendto be moreexpensive. Alsokeepin mindthatall typesof torquewrenches shouldbeperiodically checked and/orrecalibrated. Youwill haveto decidefor yourselfwhichbetterfits yourpocketbook, andpurpose. l

Fig. 12 A screw-in type compressiongaugeis recommendedfor compressiontesting

Fig. 13 A vacuum/pressuretester is necessary for manytesting procedures

Fig. 14 Most modernautomotive multimeters incorporate many helpful features

Fig. 15 Proper information is vital, so at ways have a Chiiton Total Car Care manua handy

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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’s wire(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 ofthehazardsinvolvedwithautomotive maintenance andservice,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 goggleswhencutting,drilling,grindingor prying,evenif youhave 20-20vision.If youwearglassesforthesakeof vision,wearsafetygogglesoveryourregularglasses.

ilightlymoresophisticated, theyneednotbeoutrafeouslyexpensive. 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,thenseekimmediate medicalattention. l Dousesafetystands(jackstands) foranyundervehicle service.Jacksarefor raisingvehicles; jackstands arefor makingsurethevehiclestays raiseduntilyouwantit to comedown.Whenever the vehicleis raised,blockthewheelsremaining onthe groundandsettheparkingbrake. l Douseadequate ventilationwhenworking withanychemicals or hazardous materials, Likecarbonmonoxide, theasbestos dustresultingfrom somebrakeliningwearcanbehazardous in sufficientquantities. l Dodisconnect thenegativebatterycablewhen workingontheelectricalsystem.Thesecondary ig-

Normally, theuseof specialfactorytoolsis avoidedfor repairprocedures, sincethesearenot readilyavailableforthedo-it-yourself mechanic. Whenit is possibleto performthejobwithmore commonly available tools,it will bepointedout,but occasionally, a specialtoolwasdesigned to perform a specificfunctionandshouldbeused.Beforesubstitutinganothertool,youshouldbeconvinced that neitheryoursafetynortheperformance ofthevehicle will becompromised. Specialtoolscanusuallybepurchased froman automotive partsstoreorfromyourdealer.Insome casesspecialtoolsmaybeavailabledirectlyfromthe toolmanufacturer.

nitionsystemcontainsEXTREMELY HIGHVOLTAGE.Insomecasesit canevenexceed50,000volts. l Dofollowmanufacturer’s directionswhenever workingwithpotentiallyhazardous materials. Most chemicals andfluidsarepoisonousif takeninternally. l Doproperlymaintain yourtools.Loosehammerheads, 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 lwo.WIRE CouDuClOR MIRD WIRE GROUNDING THE CASE

TMREE-WIRE GROUNDING A CmxlIT

CONO”CTOI TNRU

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TNHREE-WIRE CONDUCTOR ONE WIRE TO 4 GROUND

Fig.16 Screwdriversshouldbe kept in good :onditionto preventinjury or damagewhich :ould result it the blade slips from the screw

THREE-WIRE GROUNOlNG AN ADAPTER

CONDUCTOR TMRU PLUG tccm21

Fig. 17 Powertools should always be properly grounded

7

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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 prevent 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 glancing blows.

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 beencomprop See Figures20, 21, 22, and 23 mised by roundingor otherdamage.In some casesa driver surfacemay becomeonly partiallyrounded,alAlthoughtherearea greatvarietyof fastenersfound lowingthe driver to catch in only one direction.In in the moderncar or truck,the mostcommonlyused manyof theseoccurrences,a fastenermaybe inretaineris the threadedfastener(nuts,bolts,screws, stalledand tightened,but the driver would not be able studs,etc.).Most threadedretainersmaybe reused, to grip and loosenthe fasteneragain.(This could lead providedthatthey are not damagedin useor during J to frustrationdownthe line shouldthat component the repair.Someretainers(suchas stretchbolts or ever needto be disassembledagain). torqueprevailingnuts)are designedto deformwhen If you must replacea fastener,whetherdueto detightenedor in useand shouldnot be reinstalled. sign or damage,you mustALWAYSbe sureto use Wheneverpossible,we will noteanyspecialrethe properreplacementIn all cases,a retainerof the tainerswhich shouldbe replacedduring a procedure. samedesign,materialand strengthshould be used. Butyou shouldalwaysinspectthe conditionof a reMarkingson the headsof most bolts will helpdetertainerwhenIt is removedand replaceanythat show minethe properstrengthof the fastener.Thesame signs of damage.Checkall threadsfor rust or corromaterial,threadand pitch must be selectedto assure

monoxideis poisonous;it takesa longtime to leave the humanbodyand you can build up a deadlysupply of it in your systemby simply breathingin a !ittle everyday.You may not realizeyou are slowly poisoning 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 slipperysurfaces.Jewelrysuchas watches,fancybelt buckles,beadsor bodyadornmentof any kind is not safeworkingarounda vehicle.Longhair shouldbe 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 explosive hydrogengas. l Don’tusegasolineto washyour hands;there are excellentsoapsavailable.Gasolinecontainsdangerousadditiveswhichcanenterthe bodythrougha 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 conditioningsystemunlessyou 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 vehicle) for anythingotherthan changinga flat! These jacksare only Intendedfor emergencyuse out on the road;theyare NOTdesignedas a maintenancetool. If you are seriousaboutmamtainingyour vehicleyourself, 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 damagedbolt, then usethat nut to helpselectthe replacementbolt If however,the bolt you are replacingis so badlydamaged(brokenor drilled out) that its threads cannotbe usedas a gauge,you might startby looking 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

PHILLIPS

POZIDRIVE

RECESS

TORX@

CLUTCH

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 joint together).This meansthat friction canaccount for as muchas 90 percentof the appliedtorqueon a fastener.

RECESS

TORQUEWRENCHES ti See Figures 24 and 25

INDENTED

HEXAGON

HEXAGON

TRIMMED

HEXAGON

WASHER

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Fig. 20 Here are a few of the most commonscrew/bolt driver styles

GRADE

8

MADE

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GRADE

5

QRADE

8

GRADE

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WADE

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In most applications,a torquewrenchcan beused to assureproperinstallationof a fastener.Torque wrenchescome in various designsand most automotive supplystoreswill carrya varietyto suit your needs.A torquewrenchshould be usedanytime we supplya specifictorquevaluefor a fastener.A torque wrenchcanalso be usedif you are followingthe generalguidelinesIn the accompanyingcharts.Keepin mind that becausethereis no worldwidestandardization of fasteners,the chartsare a generalguideline

CARRIAGE

NUTS e Q PUIN

JAM

CASTLE (CASTELLATED)

SELF-LOCKINQ

SPEED

A B CDE FFILLISTER

Length Diameter (major diameter) Threads per inch or mm Thread length Size of the wrench required Root diameter (minor diameter) IccSlO3l

Fig. 22 Threadedretainer sizes are deter mined using these measurements

LOCKWASHERS

4% INTERNAL Toonl

43 EXTERNAL TQonl

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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 damagedthreads,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 damaaedthreads.

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 applied in threedistinct areas,the head,the bearing surfaceand the clamp load. About50 percentof the measuredtorque is usedin overcomingbearingfriction This is the friction betweenthe bearingsurface

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Yg. 23 Special fasteners such as these font@’head bolts are used by manufactur?rs to discourage people from working on rehicles without the proper tools

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GENERALINFORMATIONAND MAINTENANCE U.S. UEonlr Iy*

Bolts

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Fig. 24 Various styles of torque wrenches are usually available at your local automotive supply store and should be usedwith caution.Again,the general rule of “if you are using the right tool for the job, you should not haveto strainto tightena fastener”applies here.

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14.9 17.6

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18 20

2.5 2.75

24.4 27.1

31 35

4.3 4.8

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28 30

3.8 42

37.0 40.7

49 55

8.8 7.6

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5.4 5.7

52.8 55.6

75 85

10.4 117

101.7 115.2

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7.0 7.6

69.2 74.5

110 120

15.2 16.6

149.1 162.7

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83 95

11.5 13.1

112.5 128.8

150 170

20.7 23.5

203.3 230.5

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BeamType # See Figure 26

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105 115

14.5 15.9

142.3 155.9

270 295

37.3 40.8

366.0 400.0

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36.7

379.6

The beamtype torquewrenchis one of the most populartypes.It consistsof a pointerattachedto the headthat runsthe lengthof the flexible beam(shaft) to a scalelocatednearthe handle.As the wrenchis pulled,the beambendsand the pointerindicatesthe torque usingthe scale.

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160 175

216.9 237.2

395 435

54.6 80.1

535.5 589.7

440

60.9

596.5

318.6 338.9

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799.9 849.8

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32.5 34.6

Metric Bolts

Click (Breakaway)Type $ See Figure 27

4.6,4.8

8.8 @w rullllllnl~

c

Anotherpopulardesignof torquewrenchISthe click type.To usethe click type wrenchyou pre-adjust it to a torquesetting.Oncethe torque is reached, the wrenchhasa reflexsignalingfeaturethat causes a momentarybreakawayof the torquewrenchbody, sendingan impulseto the operator’shand.

Pivot HeadType # See Figure 27 and 28 Sometorquewrenches(usuallyof the click type) may beequippedwith a pivot headwhich canallow it to be used in areasof limited access.BUT,it must be usedproperly.To hold a pivot headwrench,grasp the handlelightly,and as you pull on the handle,it should befloatedon the pivot point. If the handle comesin contactwith the yokeextensionduringthe processof pulling,thereis a very good chancethe torque readingswill be inaccuratebecausethis could alterthe wrenchloadingpoint. The designof the handle is usuallysuch as to makeit inconvenientto deliberatelymisusethe wrench.

*It shouldbe mentionedthat the use of any U-joint, wobble or extensionwill have an effect 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 under the wrenchdriver) will have the least effect on the torque reading. Avoid any extension that alters the lengthof the wrenchfrom the handleto the head/drivingpoint (suchas a crow’s foot). U-joint or wobble extensions can greatly affect the readings;avoid their use at all times.

I*rdn*lrTwlr mm04 iEn% 6x1.0 8x 1.25 10X1.25

(nnr)

RJU.

I(n

2-3

2-.4

llm 3-4

RAk

mu

m

3-6

4-.8

5-8

6-8

.6-l

8-12

9-14

12-1.9

13-19

12-17

1.5-2.3

16-23

20-29

2.7-4.0

27-39 47-72

12x125

21-32

2.9-4.4

29-43

35-53

4.8-7.3

14x

1.5

35-52

4.8-7.1

48-70

57-65

7.8-11.7

16x

1.5

51-77

7.0-10.6

67-100

90-120

12.4-16.5

77-110 130-W

18x

1.5

74-110

10.2-15.1

100-150

130-170

17.9-23.4

MO-230

20x

1.5

llO-140

15.1-19.3

150-190

190-240

26.2-46.9

160-320

22x

1.5

150-190

22.0-26.2

200-260

250-320

34.5-44.1

340-430

24x

1.5

190-240

26.2-48.9

260-320

310-410

42.7-56.5

420-550 lccs1098

:ig. 25 Standardand metric bolt torque specifications based on bolt strengths-WARNING: Ise only as a guide 1

PIVOTEO

BEAU

OR MEASURING

Yg. 26 Exampleof a beam type torque wrench

ELEMENT

.

HANDLE

tccslo3~

GENERALINFORMATIONAND MAINTENANCE l-9 dardtorquewrenchareusuallyusedfirstto remove anycompliance fromthejoint.Thefasteneristhen tightened thespecified additionalportionof a turn measured in degrees. A torqueanglegauge(mechanicalprotractor) is usedfor theseapplications.

Fig. 27 A click type or breakaway torque wrench-note that this one has a pivoting head

v

Throughout thismanual, specifications aregivento helpyoudetermine theconditionof variouscomponentsonyourvehicle,orto assistyouintheirinstallation.Someof themostcommon measurements includelength(in.or cm/mm), torque(ft.Ibs.,inchIbs. or Nm)andpressure (psi,in.Hg,kPaor mmHg).In mostcases,westriveto providethepropermeasurementasdetermined bythemanufacturers engineers. Though,insomecases,thatvaluemaynotbeconvenientlymeasured withwhatis availablein your toolbox.Luckily,manyof themeasuring devices

:ig. 30 Somespecifications require the use rf a torque angle meter (mechanical pro. ractor) manyaluminum cylinderheads).Inthesecases,a torqueanglemethodof installation wouldbespecified.Wheninstallingfasteners whicharetorqueangle tightened, a predetermined seatingtorqueandstan-

HANDLE

TOR(IUE

CONVERSION

FACTORS

x 25.4

(mm)

LENGTH-DISTANCE

WRONG

WRONG

PIVOTED

) See Figure 31

WRENCH tccS1041

Fig. 28 Torque wrenches with pivoting heads must be grasped and used properly to prevent an incorrect reading

Inches (I”.) Feet (ft.)

x ,305

Miles

x 1.609

x 16.387

Cubic Inches (in3) IMP Quarts (IMP qt.)

A rigidcaseor directreadingtorquewrenchis equipped witha dialindicatorto showtorquevalues. Oneadvantage of thesewrenches is thattheycanbe heldatanypositiononthewrenchwithoutaffecting accuracy. Thesewrenches areoftenpreferred becausetheytendto becompact, easyto readandhave a greatdegreeof accuracy.

= Kilometers

(km)

= Inches = Feet

x .0621

= Miles

= Cubic Centimeters

x .061

= in3

x .568

= Liters (L)

x 1.76

= IMP pt.

x 1.137

= Liters (L)

x .88

= IMP qt. = IMP gal. = IMP qt.

x 4.546

= Liters (L)

7, .22

IMP Quarts (IMP qt )

x 1.201

= US Quarts (US qt.)

x ,833

IMP Gallons

x 1.201

= US Gallons

x ,833

= IMP gal.

x 034

= Ounces

IMP Gallons

# See Figure 29

x .0394 x 3.281

= Meters (m)

VOLUME IMP Pints (IMP pt.)

Rigid Case(Direct Reading)

= Millimeters

(IMP gal.) (IMP gal.)

Fl. Ounces

x 29.573

(US gal.)

= Millihters

us Pints (Us pt.)

x ,473

= Liters (L)

x 2.113

= Pints

US Quarts (US qt.)

x .946

= Liters (L)

x 1.057

= Quarts

x 3.785

= Liters (L)

x ,264

= Gallons

x ,035

= Ounces

x 2.205

= Pounds

US Gallons

(US gal.)

MASS-WEIGHT Ounces (oz.)

x 28.35

Pounds (lb )

PRESSURE

= Grams (g)

x ,454

= Kdograms

(kg)

x 6.895

= Kilopascals

’

Pounds Per Sq. In. (psi)

x .4912

Inches of Mercury (Hg) Inches of Mercury

(Hg)

x 3.377

(kPa)

= psi = Kilopascals

x ,145

= psi

x 2.036

= Hg

x .2961

(kPa)

= Hg

Inches of Water (H,O)

x .07355

= Inches of Mercury

x 13 783

= H,O

Inches of Water (H,O)

x .03613

= psi

Inches of Water (H,O)

x ,248

= Kilopascals

x 27.684

= Hz0

(kPa)

x4026

= H,O

x 8.85

TORQUE

lccs1042

Fig. 29 The rigid case (direct reading) torque wrench usesa dial indicator to show torque

Pounds-Force

Inches (in-lb)

Pounds-Force

Feet (ft-lb)

# See Figure 30 Because thefrictionalcharacteristics of eachfastenerorthreaded holewill vary,clamploadswhich arebasedstrictlyontorquewill varyaswell.Inmost applications, thisvarianceISnotsignificant enough to causeworry.But,in certainapplications, a manufacturersengineers maydetermine thatmoreprecise clamploadsarenecessary (suchisthecasewith

= Newton

Meters (N.m)

= Newton

Meters (N*m)

x 1.609

= Kilometers

x ,745

= Kdowatts

x .354

= Kilometers

= in-lb

x ,738

= ft-lb

x .621

= MPH

VELOCITY Miles Per Hour (MPH)

Per Hour (KPH)

POWER Horsepower

FUEL

TORQUEANGLEMETERS

x ,113 x 1.356

(Hp)

x 1.34

= Horsepower

CONSUMPTION’

Mdes Per Gallon Kilometers

Miles Per Gallon Kdometers

IMP (MPG)

Per Liter (Km/L)

x 2.352

US (MPG)

x ,425

Per Liter (Km/L)

x 2.352

Per Liter (Km/L)

= IMP MPG = Kilometers

Per Liter (Km/L)

= US MPG

*It 1s common to covert from miles per gallon (mpg) to hters/lOO = 282 and mpg (US) x l/lo0 km = 235.

kilometers

(l/100

km), where mpg (IMP)

x l/ID0

km

TEMPERATURE Degree Fahrenheit CF) Degree Celsms (‘C)

= (“C x 1.8) + 32 = CF - 32) x 56

Fig. 31 Standardand metric conversionfactors chart

tccsio4d

.

l-10

GENERALINFORMATIONAND MAINTENANCE

whichareavailable todaywill havetwoscalessothe Standard or Metricmeasurements mayeasilybe taken.If anyofthevariousmeasuring toolswhichare available toyoudonotcontainthesamescaleas listedinthespecifications, usetheaccompanying conversion factorsto determine thepropervalue.

b See Figures32,33, and 34 TheVehicleIdentification Number (VIN)is located ona platewhichis attached to thelefttopsideof the instrument panel.Thesenumbers arevisiblefromthe outsideof thevehicle.AllVehicleIdentification Numberscontain17digits.Thevehiclenumberisa code whichtellscountry,make,vehicletype,engine,body andmanyotherimportant characteristics of thatspecificvehicle. Thereis alsoa vehicleinformation codeplate whichis rivetedto thebulkhead in theenginecompartment. TheplateshowstheVIN,modelcode,enginemodel,transaxlemodelandbodycolorcodes. Theenginecodeusedonthisplatediffersfromthe codeletterusedin the8thpositionof theVehicle Identification Number(VIN).Eithercodecanbeused to identifytheparticularenginein thevehicle.Since thevehicleownerscardis usuallycarried,it maybe easierto usethecodeletterintheVINfor enginereference.Asecondreasonfor referringtotheVINfor engineidentification isthatcode4663,locatedon thevehicleinformation codeplate,doesidentifythe engineasa 2.OLDOHCengine,butdoesnottellyou

Fig. 32 The Vehicle Identification Number (VIN) plate is attachedto the top left side of the instrumentpanel _I:^1

todeal LIten(cc) ,G15JA IG61N 1G93lC IG63N !G63Fi ,G63iU .GMffi iG64L lEzH ;G7ZJ ~.. iG7zL

1.5 (1468) 1.6(15QQ) 1.8 (1834) 2.0 (1997) 2.0 (1997) 2.0 (1997) 2.4 (2351) 2.4 (2351) 3.0 (2972) 3.0 (2972) (2Q72) 3.0

Cu. In. 92 98 112 122 122 122 143 143 161 161 181

iG74lP

3.5 (3497)

213

Theconversion factorchartis usedbytakingthe givenspecification andmultiplying it bythenecessaryconversion factor.Forinstance, lookingatthe firstline,if youhavea measurement in inchessuch as“free-playshouldbe2 in.”butyourrulerreads onlyin millimeters, multiply2 in.bytheconversion

factorof 25.4to getthemetricequivalent of 50.8mm. Likewise, if thespecification wasgivenonlyina Metric measurement, for example in NewtonMeters (Nm),thenlookatthecentercolumnfirst.If themeasurement is 100Nm,multiplyit bytheconversion factorof 0.738to get73.8ft. Ibs.

if theengineis equipped witha turbocharger. If the 8thVINnumberis a U,thereis nodoubtthattheenginein questionis a 2.OLDOHCengineequipped withaturbocharger. Theenginecodesfoundonthevehicleinformation codeplateareasfollows: l 4G15--1.5LSOHCengine l 4G61-1.6LDOHCengine l 4G93-1.8LSOHCengine l 4G63-2.OL(SOHCor DOHC) engine l 4G64-2.4L(SOHCor DOHC)engine l 6G72-3.OL(SOHCor DOHC) engine l 6G74-3.5LDOHCengine A vehiclesafetycertification labelis attached to thefaceof theleftdoorpillarpost.Thislabelindicatesthemonthandyearof manufacture, GrossVehicleWeightRating(GRVW) frontandrear,andVehicleIdentification Number (VIM).

4 character codeasonthevehicleinformation code plateis used.Theengineserialnumberis also stamped neartheenginemodelnumber. Asmentionedabove,theenginecanalsobeidentifiedbythe 8thdigitintheVINnumber.

) See Figure 35

Thetransfercasehasnoseparate modelcode,the codeis locatedonthetransaxle. Thetransfercaseis onlveoUiODed onmanualtransaxle AllWheelDrive (AWD)‘mbdels.

Theenginemodelnumberisstamped atthefront sideonthetopedgeof thecylinderblock.Thesame

Fig. 33 The vehicle model, engine model, bansaxle model,and bodycolor codeare all / notedon the vehicle informationcodeg3’51p’o plate

ENGINE ANDVEHiCLEIDENTlFlCATlON EnglnCode Fuel+ Type m.hWg. W. 4 4 4 4 4 4 4 4 6 66

MFI MFI MFI MFI MFI MFI-Tuibo MFI MFI MFI MFI MFI

SOHC DOHC SOHC SOHC DOHC DOHC SOHC DOHC SOHC GQHC SOHC

Mitsubishi Mitsubishi Mitsubishi “-Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Miisubishi

6

MFI

SOHC

Miisubishi

Code@ L M N P R S T V W X ~ Y

Thetransaxle modelcodeis locatedonthevehicle information codeplate.Thetransaxle identification numberis etchedona bosslocatedonthefrontupperportionof thecase.

Thecodefor thedriveaxleis etchedona bosslocatedonthecaseof thedifferential carrier.

Fig. 34 Your car should have a vehicle

ModelYerr Year 1990 1991 1992 1993 1994 1995 1996 1997 \ 1998 ___-___ 1999 2000

Fig. 35 Engine model number location4663 (2.OL)engine shown

UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL

1. 2. 3. 4. 5. 6.

Powersteeringbelt Washersolventbottle Powersteeringreservoir Oil fill cap Brakemastercylinderreservoir Sparkplugand plugwire

7. 8. 9. 10. 11. 12.

PCVvalve Distributorcapand rotor Fuelfilter (underair inlettube) Air filter housing Enginecompartmentfuse box Battery

13. 14. 15. 16.

ENGINE

Automatictransaxlefluid dipstick Coolantrecoverytank Radiatorcap Engineoil dipstick

II

UNDERHOODMAINTENANCE COMPONENT LOCATIONS-l .8L ENGINE

1. 2. 3. 4. 5. 6.

Coolantrecoverytank Battery Enginecompartmentfuse box Air filter housing Clutchfluid reservoir Brakemastercylinderreservoir

7. 8. 9. 10. 11. 12.

Sparkplugandplugwire PCVvalve Engineoil fill cap Fuelfilter Enginecompartmentrelaycenter Washersolventbottle

13. 14. 15. 16.

Powersteeringreservoir Powersteeringbelt Engineoil dipstick Radiatorcap

GENERALINFORMATIONAND MAlNTENANdE1-13 GENERAL ENGINE SPECIFICATIONS Engine Displacement

MFI Mult+wt fuel mfectw, MFI-T - Multlporl fuel mfectlon-turbocharged SOHC - Smgle overhead camshaft DOHC - Double OvedEad camshaft

Engine

Engine

No. of

Fuel System

Net Horsepower

Net Torque @ rpm

Bore x Stroke

Compression

Oil Pressure

l

l-14

GENERALINFORMATIONAND MAINTENANCE

Propermaintenance andtune-upisthekeyto long andtrouble-free vehiclelife,andtheworkcanyield itsownrewards. Studieshaveshownthata properly tunedandmaintained vehiclecanachievebettergas mileage thananout-of-tune vehicle.Asa conscientiousowneranddriver,setasidea Saturday morning, sayoncea month,to checkor replaceitemswhich couldcausemajorproblems later.Keepyourown personallogtojot downwhichservicesyouperformed,howmuchthepartscostyou,thedate,and theexactodometer readingatthetime.Keepall receiptsforsuchitemsasengineoil andfilters,sothat theymaybereferred tp incaseof relatedproblems or to determine operating expenses. Asa do-it-yourselfer,thesereceiptsaretheonlyproofyouhavethat

therequiredmaintenance wasperformed. Intheevent of a warrantyproblem, thesereceiptswill beinvaluable. Theliteratureprovidedwithyourvehiclewhenit wasoriginallydelivered includes thefactoryrecommended maintenance schedule. If younolongerhave thisliterature, replacement copiesareusuallyavailablefromthedealer.A maintenance schedule is providedlaterinthissection,in caseyoudonothave * thefactoryliterature.

REMOVAL&INSTALLATION Except2.gL TurbochargedEngine b See Figures 36 thru 41

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

1. Disconnect thenegative batterycable. 2. Release theretaining clipsfromtheair cleanerhousing. 3. Loosentheclampontheairoutlettubeatthe throttlebody. 4. Detach thebreather hosefromtheair inlet tube. 5. UnplugtheMAFsensorconnector. theupperandloweraircleaner 6. Separate housings andremove theair outlettubeandupper housingfromthelowerhousing. theaircleanerelement fromthe 7. Remove 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

9. Placea newaircleanerelementinsidethe lowerhousing.Makesurethesealontheelement is fullyseatedin thegroove. 10. Installtheupperaircleanerhousingandinlet tubeontothelowerhousing. 11. Tightentheclampontheinlettubeatthe throttlebody. 12. Attachthebreather hoseontotheair inlettube. 13. Plugtheconnector intotheMAFsensor. 14. Attachtheaircleanerhousingretaining clips. 15. Connect thenegative batterycable. 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 fromthehousing. *Care mustbe takenwhen removingthe air cleaner cover. Theair flow sensoris attachedand 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 connector, the boost hose and the solenoid valve connector

GENERALINFORMATIONAND MAINTENANCE l-15 10. installtheaircleanerassembly andtheretainerbolts. 11. Connect theair intakehose. 12. Attachthesolenoidvalve. 13. Connect theboosthose. 14. Attachtheairflowsensorconnector. 15. Connect thenegative batterycable. \

REMOVAL&INSTALLATION u See Figures 43 thru 48 Onmostvehiclescoveredbythismanual, thefuel filteris locatedintheenginecompartment, mounted to thefirewall.

Do not use conventionalfuel filters, hosesor clampswhen servicing fuel injection sys terns. Theyare not compatiblewith the injection systemandcouldfail, causingpersonal injury or damageto the vehicle. Useonly hosesand clampsspecifically designedfor fuel injection systems. 1. Properlyrelievethefuelsystempressure as outlinedinSection5 of thismanual. 2. If notalreadydone,disconnect thenegative batterycable. 3. Onmostmodels. theiobis madeeasierif the air inlethoseandupperaircleanerhousingis removedfromthevehicle.

Fig. 43 Use a back-upwrench on the fuel filter nut when looseningthe banjo-bolt on I 1the engine feed line -

*Wrap shoptowels aroundthe fitting that is being dtsconnectedto absorbresidual fuel in the lines. 4. Coverthehoseconnection withshoptowelsto preventanysplashof fuelthatcouldbecausedby residualpressure inthefuelpipeline.Holdthefuel filternutsecurely witha backupwrench,thenremove thebanjoboltontheenginefeedline.Disconnect the high-pressure fuellinefromthefilter.Remove and discardthegaskets. 5. Whileholdingthefuelfilternutsecurely witha back-upwrench,loosenthefilterfeedpipeflarenut onthebottomof thefilter.Separate theflarenutconnectionfromthefilter.If equipped, removeanddiscardthegaskets. bolts remove . 6.,,,.Remove ,. themounting .a and r I,.,< I the ruerrrrter.II necessary, remove me ruer rrrreroracket. To install: 7. Installthefilterto itsbracketonlyfinger-tight. Movement of thefilterwill easeattachment of thefuel lines.

Ensurethat the filter is installed with the flow arrow in the proper direction. Theflow arrow typically pointstoward the engineside of the filter. improperinstallation of the fuel filter will causethe vehicle to run poorly. *Make sure new O-ringsare installed prior to installation. 8. Insertthefilterfeedpipeto thelowerconnectionof thefilterandmanually screwin themain pipe’sflarenut.

9. Whileholdingthefuelfilternutwithabackupwrench,tightenthebanjoboltto 22ft. Ibs.(30 Nm).Tightentheflarenutto25ft. Ibs.(35Nm),with a back-upwrenchonthenut. 10. Tightenthefiltermounting boltsto 10ft. Ibs. (14Nm). 11. Connect thenegative batterycable.Turnthe keyto theONpositionto pressurize thefuelsystem andcheckfor leaks. 12. If repairsof a leakarerequired, remember to release thefuelpressure beforeopeningthefuelsystern.

REMOVAL&INSTALLATION u See Figures49, 50, and 51 1, Disconnect thenegative batterycable. 2. If necessary for access,removetheair intake hoseandaircleanerassembly. 3. If necessary, unfasten theretainingclamp,then disconnect theventilationhosefromthePCVvalve. 4. Remove thePCVvalvefromthecamshaft (rocker)cover. To install: 5. InstallthePCVvalveintotherockercover.If thevalveis threaded, tightenthevalveuntilsnug. 6. Reconnect theventilationhoseto thevalve. 7. If removed, installtheair intakehoseandthe a.ircleanerassembly. 8. Connect thenegative batterycable.

93151@3

I Fig. 44 After the banjo-boltis loose, removeI from the fuel filter

Fig. 45 Make sure to replace the copper washers on the banjo-bolt fitting

Fig. 47 Remove the two filter bracket retaining bolts . . .

Fig. 48 . . . then remove the filter from the vehicle

93151p93

Fig. 48 Make sure to usea back-upwrench 1when unfasteningthe main fuel pipe also 1

*

l-16

GENERALINFORMATIONAND MAINTENANCE

Fig. 49 Graspthe valve and gently remove it from the valve cover

SERVICING u See Figure 52 Theevaporativecanisterrequiresno periodicservicing. However,a carefulinspectionof the canister and hosesshouldbe madefrequently,Replacedamagedcomponentsas required. The canisteris typically locatedunderone of the front fenders,howeveron some latermodelsit may be underthe rearof the vehicle,nearthe gastank,

r on most models

Fig. 50 Twist and pull on the valve to remove it from the hose corrosiveacid canalso eatawayat componentsunder 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 '_

devicesthat increaseparasiticload maydischargea batterysooner.If the vehicle is to be storedfor 6-B weeksin a secureareaand the alarmsystem,if present, is not necessary,the negativebatterycable should bedisconnectedat the onsetof storageto protectthe batterycharge. Rememberthat constantlydischargingand rechargingwill shortenbatterylife. Takerare not to allow a batteryto be needlesslydischarged.

# See Figure 53

BA-ITERY FLUID

A batterythat is not sealedmust be checkedperiodicallyfor electrolytelevel.You cannotadd waterto a sealedmaintenance-freebattery(thoughnot all maintenance-freebatteriesare sealed);however,a sealedbatterymust also becheckedfor properelectrolyte 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

Checkthe batteryelectrolytelevelat leastoncea month.or more often in hot weatheror during periods 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 separatefrom the others,so eachmust be checkedand filled individuallv.Distilled watershouldbe used,becausethe 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

m causea short circuit, leadingto sparksand possible personalinjury. Do not smoke,havean openflameor create sparksneara battery;the gasescontainedin the battery are very explosiveand, if ignited,could causesevere injury or death. All batteries,regardlessof type,should becarefully securedby a batteryhold-downdevice.If this is not done,the batteryterminalsor casingmay crack from stressappliedto the batteryduringvehicleoperation.A batterywhich is not securedmayallow acid to leakout, makingit dischargefaster;such leaking

Fig. 51 Inspectthe grommetand replace if cracked or leaking oil

/

tcu1@32

Fig. 53 A typical location for the built-in hvdrometer on maintenance-free batteries ’ I ’

built-in hydrometer.

.

\

*Although the readingsfrom built-in hydrometersfound 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 insufficient electrolyte level mustusually be discarded.

G,ENERALlNFORMATlONAND MAINTENANCE l-17

Fig. 54 Onnon-maintenance-freebatteries, the fluid level can be checkedthrough the 1case on translucent models; the cell caps1 must be removedon other models 1 Checkingthe Specific Gravity

Fig. 55 If the fluid level is low, add only dis1tilled water through the opening until the 1level is correct

Asstatedearlier,thespecificgravityof a battery’s electrolyte levelcanbeusedasanindicationof batterycharge.Atleastonce ?a year,checkthespecific gravityof thebattery.It shouldbebetween 1.20and A hydrometer is requiredto checkthespecific gravityonall batteries thatarenotmaintenance-free. 1.26onthegravityscale.Mostautosupplystores carry a variety of inexpensive battery testing hydromOnbatteries thataremaintenance-free, thesoecific battery gravityischecked byobserving thebuilt-inhydrome- eters. , , ,These ,, can .,,beused .. onanynon-sealed IOrestmespecmc gravnyineachcell. ter“eye”onthetopof thebatterycase.Checkwith Thebatterytestinghydrometer hasasqueeze bulb yourbattery’s manufacturer for properinterpretation atoneendanda nozzle attheother.Battery electrolyte of itsbuilt-inhvdrometer readinas. thehydrometer untilthefloatis lifted -hespecificgravityisthenreadbynotmgtneposrtro n of thefloat.If gravityis lowinoneor 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 medical help immediately. \

# See Figures 54, 55, and 56

Thefluid(sulfuricacidsolution)contained inthe batterycellswill tellyoumanythingsabouttheconditionof thebattery.Because thecellplatesmustbe keptsubmerged belowthefluidlevelin orderto operate,maintaining thefluidlevelis extremely important.And.because thesoecificaravitvof theacidis anindicationof electricalcharge,testingthefluidcan beanaidindetermining if thebatterymustbereplaced.A batteryin avehiclewitha properlyoperatingchargingsystemshouldrequirelittlemaintenance,butcareful,periodicinspection shouldreveal problems beforetheyleaveyoustranded.

Fig. 57 Maintenance is performed with householditems and with special tools like I this post cleaner I

Fig. 56 Checkthe specific gravity of the battery’s electrolyte with a hydrometer morecells,thebatteryshouldbeslowlycharged and Lhecked aqaintoseeif thearavitvhascomeUP. Generally,if affercharging, thespecificgravitybetween any twocellsvariesmorethan50points(0.50)thebattery shouldbereplaced, asit cannolongerproduce sufficientvoltageto guarantee properoperation.

CABLES ) See Figures 57, 56, 69, 60, and 61 Oncea year(orasnecessary), thebatteryterminalsandthecableclampsshouldbecleaned. Loosen

Fig. 58 The underside of this special battery tool has a wire brushto clean post ter1minals

l

1-18 GENERALINFORMATIONAND MAINTENANCE alternator orturntheadjustingboltto adjustbelttension.Oncethedesiredvalueis reached, securethe boltor locknutandrecheck tension.

theclampsandremovethecables,negative cable first.Onbatteries withpostsontop,theuseof a pullerspeciallymadeforthispurposeis recommended. Theseareinexoensive andavailablein most d”t”

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CHARGING I

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curedwitha smallbolt. Cleanthecableclampsandthebatteryterminal witha wirebrush,untilall corrosion, grease, etc.,is removed andthemetalisshiny. shinv.It isespecially esneciallv imporimnnrtantto clean c theinsideof theclampthoroughly (anold knifeis usefulhere), nere),sincea small smartdepositof foreign material or oxidation therewill prevent pre a soundelectricalconnection andinhibiteitherstartingor charging. Specialtoolsareavailable forcleaning theseparts, onetypeforconventional toppostbatteries andanbatteries. It ifisalso good othertypeforsideterminalbatterin, I+ QI@* 3annnd ideatoapplysomedielectric grr grease totheterminal, as corrosion, thiswill aidintheprevention of ,,vIIuaIUII. Aftertheclampsandterminals areclean,reinstall thecables,negative cablelast;DONOThammer the clampsontobatteryposts.Tightentheclampssecurely,butdonotdistortthem.Givetheclampsand terminals athinexternalcoatingof greaseafterinstallation, to retardcorrosion. Checkthecablesatthesametimethattheterminals arecleaned. If thecableinsulation is cracked orbroken,or if theendsarefrayed,thecableshouldbereaauae. placedwitha newcableofthesamelengthandgauge.

I

I

1.5L, 1.611,1.8L, 2.OLand 2.4L Engines ALTERNA TORBE1T e See Figures67,68, and 69 Fig. 62 There mere are typically 3 types of accessory drive belts found on vehicles today

I

POWERSTEERING BELT

Fig. 64 Deep cracks in this belt will cause flex, building up II”“. heat that ..IU. will ..m.*eventually V. ..“‘.I ““..Y...Y 1 1lead to belt failure

-

:*

INSPECTION e See Figures 62, 83, 64, 65, and 88 Inspect thebeltsfor signsof glazingor cracking. A glazedbeltwill beperfectlysmoothfromslippage, whilea goodbeltwill havea slighttextureof fabric visible.Crackswill usuallystartattheinneredgeof

1. Remove thealternator beltasdescribed above. 2. Loosenthepowersteeringpumpadjusting bolts. 3. Remove thepowersteeringoumofixedbolton therearof thebracket. 4. Rotate thepumptowardtheengineandremove thebelt. To fnstall: 5. Installthebeltonthepulleys.

Fig. 85 The cover of this belt is worn, ex-

REPLACEMENT Whenit becomes necessary to reolacethnhaeoN oreMer selectonewithanamperage ratingequaltcI‘”or . yyL’“‘J’ a ---thanthebatteryoriginallyinstalled.Deterioration and justplainagingofthebatterycables,startermotor, andassociated wiresmakesthebattery’s jobharder insuccessive years.Theslowincrease in electrical resistance overtimemakesit prudentto installa new batterywitha greatercapacitythantheold.

1. Loosenthealternator supportnut. 2. Loosentheadjusterlockbolt. to .. bolt * ..counterclockwise I 3. Rotate .I tension , the . adjuster release the onthebelt. 4. Remove thebelt. Tn install: i”et*ll* To 5. Installthebeltonthepulleys. R the until 6. Rntatn Rotate thecxiillrtm adjusterhnit boltA&+,& clockwise untilthe the is .______ reached. rproper -r- tension .- .-._..._ 7. Tightentheadjusterlockboltandthealternator supportnut. 8 See Figures 70 and 71

The chemicalreactionwhich takes place in all batteriesgeneratesexplosive hydrogen gas. A spark can causethe batteryto explode andsplash acid. To avoid serious personal injury, be sure there is properventilation and take appropriatefire safety precautionswhen connecting,disconnecting,or charginga battery andwhen usingjumpercables. A batteryshouldbecharged ata slowrateto keep theplatesinsidefromgettingtoohot.However, if somemaintenance-free batteries areallowedto dischargeuntiltheyarealmost“dead,”theymayhaveto becharged ata highrateto bringthembackto “life.” Alwaysfollowthechargermanufacturers instructions oncharging thebattery.

REMOVAL &INSTALLATION

I

I

1Fig. 67 Loosenthe adjuster lock bolt . . . ‘-

tm1217 I -. -_ Fig. 66 Installing too wide a belt can resylt in serious belt wear and/or breakage

thebeltandrunoutward. Allwornor damaged drive beltsshouldbereplaced immediately. It is bestto replaceall drivebeltsatonetime,asa preventive maintenance measure, duringthisserviceoperation.

ADJUSTMENT Excessive belttensionwill causedamage tothealternatorandwaterpumppulleybearings, while,on theotherhand,loosebeIttensionwill Droduce r ------ slinr andpremature wearonthebelt.Therefore, besureto adjustthebelttensionto theproperlevel. ‘* ’ ’ ’Den. ” ’loosen Toadjust the tension ona onve me adjustingboltorfixingbboltlocknutonthealternator, alternator bracketor tens iionpulley.Thenmovethe

Fig. 68 . . . then remove the alternator I from the engine

GENERAL INFORMATION ANDMAlNTENANdEl-19 6. Rotatethepumpuntilthepropertensionis reached. 7. Tightentheadjusting boltsonthepump. 8. Tightenthefixedboltontherearof thebracket. 9. Installthealternator belt. A/r: COMPRESSOIl BELf 1. Loosenthetensionoullevandremove thebelt. 2. Theinstallation isthereverseof theremoval. .3.gL DGHC,3.OLSOHC(Gaiant models only) and 3.5L Engines

4. Remove thebelt. To install: 5. Installthebeltonthecrankshaft andalternator pulleys. 6. Usingtheadjusting boltonthetensioner, tightenthebeltto thedesiredtension. 7. Tightenthefixingnutto holdtheadjustment. 8. andlowerthevehicleto _, Installtheundercover thetloor. 9. Connect thenegative batterycable. POWERSliEERlNGBELf 1. Disconnect theneaative batteNcah+P

6 See Figures72 and 73 -I

Wait at least 60 secondsafter the negative battery cable is disconnectedto preventpoSsibie deploymentof the air bag. 2. Raiseandsafelysupportthevehicleandreretheundercover. mob 3. Remove thealternator andNC compressor belt. 4. Lowerthevehicleandremovethecruisecontrol oumn link iW%mblV. 79244Q.37

--

Fig. 72 Serpentinebelt routing-Mitsubishi 3.OLengines (except 1696-00 Galant models) 1 792UQ4

Fig. 69 Accessory V-belt routing-Mii subishf 1.6L, 1.6L,-1.6L, 2.OLand 2.4L en gines

Generator

pulP

1

I I

33151PM

Fig. 70 After the adjusting and fixed bolt! are loosened, rotate the pump . . . Fig. 73 AccessoryV-beltrouting-Mitsubishi 3.5L and 1996-00 3.OL SOHCGalant engines

Wait at least 60 secondsafter the negative battery cable is disconnectedto preventpossible deploymentof the air bag.

/ F$71t immtl$mm&a

the power :::

2. Raiseandsafelysupportthevehicleandremovethefrontundercover. 3. Loosenthetensionpulleyfixingnutandrelieve thetensiononthebeltbyturningtheadjusting bolt.

----

-

_I

I-r 5. Place thepowersteeringhoseundertheoil reservoir. 6. Loosenthetensionpulleyfixingboltsandremovethepowersteeringpumpdrivebelt. To install: 7. installtheDowersteerinaoumur+r+v~ hp++ 8. Insertanextension bar&eoufvaik;;t”f;;id‘he openingattheendof thetensionpulleybracketand pivotthepulleyto applytensionto thebelt. 9. Tightenthefixingbolts. 10. Raisethevehicleandinstallthealternator and compressor belt. Il. Installtheundercover andlower+hfi .I,.,vph+r+p .VII.“.Y. 12. Connect thenegative batterycable.

3.OLSGHC(DiamanteModels Onivl Enotne 1. Disconnect thenegative batterycable. 2.’ Loosenthelockboltonthefacenf A/C _the__.tensioner pulley. 3 Turntheadiustinaboltof theA/C+fincrnner pulleyto loosenthetensionof theA/Cbelt. 4. Remove theA/Ccompressor belt. 5. Loosenthelocknutonthefaceof thepower steering/alternator tensloner pulley. 6. Turntheadjusting boltof thetensioner pulley to loosenthetcmsionof thebelt. 7. Remov ‘ethepowersteering/alternator belt. To install: 8. Install beltfirst .* .* . the ,^ powersteering/alternator anatnentneA/ti compre: ssordrivebelt. 9. Adjustthebeltst+I thepropertensionbyturnA.:-L I-..-.. I,^, .’ ingtheadjusting boltsanu II~IIWII pueeytlxmg nut/bolt. 10. Tightenthemounting nutof thepowersteering/alternator tensioner pulleyto 36ft. Ibs.(50Nm). -The manufacturerdoes not provide a torque specificationfor the bolt that secures A/Ctensionerpulley. 11. Connect thenegative batterycable. ,r

”

.

l-20

GENERALINFORMATIONAND MAINTENANCE

INSPECTION # See Figures 74 thru 81 Allenginescoveredbythismanualutilizetiming beltsto drivethecamshaft fromthecrankshafts turningmotionandto 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 preventthepossibilityof severeinternalenginedambelt ageSt10Ula the Delt break. Although the1.5Land1.8Lenginesarenotlisted asaninterference motors(it is notlistedbythemanufacturer asa motorwhosevalvesmightcontactthe pistonsif thecamshaft wasrotatedseparately from thecrankshaft) thefirst2 reasons for periodicreplacement stillapplyandthetimingbeltshouldbe replaced at60,000miles(96,000km).The1.6L, 2.01,2.4L, 3.OL,and35L enginesarelistedasinterferencemotors,sothetimingbeltMUSTbereplaced at60,000miles(96,000km)to avoidsevereengine damage if thebeltshouldbreak. Butwhether or notyoudecideto replacethetimtml245 ingbeltin themanufacturers schedule, youwouldbe Fig. 76 look for noticeable cracks or wear wisetocheckit periodically to makesureit hasnot become damaged orworn.Generally speaking, a se_on the belt face verelvwornbeltmavcauseenaineoerformance to drop~dramatically, buta damaged belt(whichcould giveoutsuddenly) maynotgiveasmuchwarning.In general, anytimetheenginetimingcover(s)is (are) removed youshouldinspectthebeltfor premature parting,severecracksor missingteeth.Also,anaccessplugis providedintheupperportionof thetimingcoversothatcamshaft timingcanbechecked withoutcoverremoval.If timingis foundto beoff, coverremovalandfurtherbeltinspection or replacementis necessary. Forthetimingbeltremovalandinstallation procedure,pleasereferto Section3 of thismanual.

INSPECTION

. 75 Check if the teeth are cracked or

fig. 77 You may only have damageon one side of the belt; if so, the guide could be the culprit

Fig. 78 Foreign materials can get in between the teeth and cause damage

Fig. 79 Inspect the timing belt for c fraying, glazing or damageof any kind

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 quickvisualinspection coulddiscoveraweakened hosewhichmighthaveleftyou stranded if it hadremained unrepaired. Whenever youarechecking thehoses,makesure theengineandcoolingsystemarecold.Visuallyinspectforcracking,rottingor collapsed hoses,andwplaceasnecessary. Runyourhandalongthelength of thehose.If a weakor swollenspotis notedwhen squeezing thehosewall,thehoseshouldbereplaced.

Fig. 80 Damageon only one side of the timing belt may indicate a faulty guide I ,

Fig. 81 ALWAYSreplace the timing belt at I the interval specified by the manufacturer L

GENERALINFORMATIONAND MAINTENANCE l-21 9. Closetheradiatororenginedrainsandproperlyrefillthecoolingsystemwiththecleandrained enginecoolantor a suitablemixtureof ethylene glycotcoolantandwater. 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,BEEXTREMELYCAREFULnot to touchany moving or hot engineparts. Oncetemperaturehas beenreached.shutthe enaine OFF.and checkfor leaks aroundthe-hosefittings and connectionswhich were removedearlier.

INSPECTION b See Figures 88 and 87

lCCS1221

Fig. 84 A soft spongy hose (identifiable by the swollen section) will eventually burst and should be replaced 1

Fig. 85 Hosesare likely to deteriorate from the inside if the cooling system is not periodically flushed

IEMOVAL&,INSTALLATION

3. Loosenthehoseclampsateachendofthe roserequiringreplacement. Clampsareusuallyeiherofthesorinatensiontvoe(whichreouireoliers 3squeeze the6bsandloosenjor of the’screw teniontype(whichrequirescreworhexdriversto oosen).Pulltheclampsbackonthehoseawayfrom heconnection. 4. Twist,pullandslidethehoseoffthefitting, skingcarenotto damage theneckof thecomponent romwhichthehoseis beingremoved.

'

1. Remove theradiatorpressure cap.

Never removethe pressurecap while the engine is running,or personalinjury from scaldinghot coolant or steammayresult. If possible, wait until the enginehascooled to removethe pressurecap. If this is not possible, wrap a thick cloth aroundthe pressure cap andturn it slowly to the stop. Stepback while the pressureis releasedfrom the cooling system.Whenyou are sure all the pressure has beenreleased, use the cloth to turn and removethe cao. 2. Positiona cleancontainer undertheradiator and/orenginedraincock or plug,thenopenthedrain andallowthecoolingsystemto drainto anappropriatelevel.Forsomeupperhoses,onlya littlecoolant mustbedrained. Toremovehosespositioned lower ontheengine,suchasa lowerradiatorhose,theentirecoolingsystemmustbeemptied.

Whendraining coolant, keep in mindthat cats and dogsare attractedby ethyleneglycol antifreeze,and are quite likely to drink any that is left in an uncoveredcontaineror in puddleson the ground.This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reusedunless it is contaminatedor several years old.

*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!dgedrazor blade to makea slice alongthe lortion of the hosewhich is stuckon the consection,perpendicularto the end of the lose. 00 not cut deepso as to preventdamagingthe connection.The hosecanthen be keeledfrom the connectionand discarded. 5.. Cleanbothhosemounting connections. In,pecttheconditionof thehoseclampsandreplace hem,if necessary. To install: 6. Diptheendsof thenewhoseintocleanenfinecoolanttoeaseinstallation. 7. Slidetheclampsoverthereplacement hose, henslidethehoseendsovertheconnections into rosition. 8. Positionandsecuretheclampsatleastl/d in. 6.35mm) fromtheendsof thehose.Makesurethey Irelocatedbeyondtheraisedbeadof theconnector.

TheCV(Constant Velocity)bootsshouldbe checked for damage eachtimetheoil is changed and anyothertimethevehicleis raisedfor service.These bootskeepwater,grime,dirtandotherdamaging matterfromenteringtheCV-joints. Anyof these couldcauseearlyCV-jointfailurewhichcanbeexpensiveto repair.Heavygreasethrownaroundtheinsideof thefrontwheel(s)andonthebrake caliper/drum canbeanindicationof a tornboot. Thorouahlv checkthebootsfor missinaclamosand

Fig. 86 CV-bootsmust be inspectedperiod-

l-22

GENERALINFORMATIONAND MAINTENANCE

tears.If thebootis damaged, it shouldbereplaced trodeis totheblock’scoolingpassages) thecoolerit immediately. Pleasereferto Section7 for procedures. will operate. A plugthatabsorbslittleheatandremainstoocoolwill quicklyaccumulate depositsof oil andcarbonsinceit is nothotenoughto burn themoff.Thisleadsto plugfoulingandconsequently to misfiring.A plugthatabsorbstoomuchheatwill havenodepositsbut,duetotheexcessive heat,the ti See Figure 88 ,electrodes will burnawayquicklyandmightpossibly leadto preignition or otherignitionproblems. PreigAtypicalsparkplugconsistsof a metalshellsurnitiontakesplacewhenplugtipsgetsohotthatthey roundinga ceramicinsulator. A metalelectrode exglowsufficiently to ignitetheair/fuelmixturebefore tendsdownward throughthecenterof theinsulator theactualsparkoccurs.Thisearlyignitionwill usuandprotrudes a smalldistance. Located attheendof allycausea pingingduringlowspeedsandheavy theplugandattached to thesideof theoutermetal loads. shellis thesideelectrode. Thesideelectrode bends Thegeneralruleof thumbfor choosingthecorrect inata 90”anglesothatitstip is justpastandparalheatrangewhenpickinga sparkplugis:if mostof lelto thetio ofthecenterelectrode. Thedistance betweenthesetwoelectrodes (measured inthousandths of aninchor hundredths of a millimeter) is calledthe sparkpiuggap.

yourdrivingis longdistance, highspeedtravel,usea colderplug;if mostof yourdrivingis stopandgo, usea hotterplug.Originalequipment plugsaregenerallya goodcompromise between the2 stylesand mostpeopleneverhavetheneedto changetheir plugsfromthefactory-recommended heatrange.

REMOVAL &INSTALLATION ti See Figures 90 thru 95 A setof sparkplugsusuallyrequiresreplacement afterabout20,000-30,000 miles(32,000-48,000 km),depending onyourstyleof driving.Innormal operation pluggapincreases about0.001in. (0.025mrn) forevery2,500miles(4,000km).Asthe

INSULATOR CRACKS OFTEN OCCUR HERE

SIDE ELECTRODE (SEND TO ADJUST

GAP)

ENTER ELECTRODE: FILE FLAT WHEN ADJUSTING GAP; DO NOT BEND

Fig. 88 Cross-sectionof a spark plug

I

Fig. 90 Carefully twist the boot end of the spark plug wire andwithdraw the sparkplug wire boot from the cylinder head

Fig. 91 A special spark plug socket with a rubber insert is required to remove the spark plugs. Typically the spark plugs require a Yaspark plug socket

Thesparkplugdoesnotproduce a spark,butinsteedprovidesa gapacrosswhichthecurrentcan arc.Thecoilproduces anywhere from20,000to 50,000volts(depending onthetypeandapplication) whichtravelsthroughthewirestothesparkplugs. Thecurrentpassesalongthecenterelectrode and jumpsthegaptothesideelectrode, andin doingso, ignitestheair/fuelmixtureinthecombustion charnber.

SPARKPLUG HEATRANGE ti See Figure 89 Sparkplugheatrangeistheabilityof theplugto dissipate heat.Thelongertheinsulator(orthefarther it extendsintotheengine),thehottertheplugwill operate; theshortertheinsulator(theclosertheelec-

Fig. 92 A locking extension such as this is extremely helpful when removing spark plugsthat are centrally located in the cyhn-

Fig, 93 Using the appropriate sized spark plugsocket, necessaryextensionsanddrive tools, loosen the spark plug . . .

93151ptxl

Fig. 94 . . . then carefully withdraw the spark plug from the engine

Fig. 95 After removingthe plug from the engine, inspect it using the spark plug condition chart in this section to determine the runningcondition of your engine

t

GENERALINFORMATIONAND MAINTENANCE l-23 gapincreases, theplug’svoltagerequirement alsoincreases. It requiresa greatervoltageto jumpthe widergapandabout&o to threetimesasmuchvoltageto firetheplugathighspeedsthanatidle.The improved air/fuelratiocontrolof modernfuelinjectioncombined withthehighervoltageoutputof modernignitionsystems will oftenallowanengineto run significantly longerona setof standard sparkplugs, butkeepin mindthatefficiency will dropasthegap widens(alongwithfueleconomy andpower). Whenyou’reremoving sparkplugs,workonone ata time.Don’tstartbyremoving theplugwiresall at once,because, unlessyounumber them,theymay become mixedup.Takea minutebeforeyoubegin andnumber thewrrpcwith+sne 1. Disconnect. 1theneaative ~~.~ --..-., bat&vcable -..-.-, and -..- if thevehiclehasbeenrunrecently, allowtheengineto thoroughly cool. 2. If equipped, remove thecentercover. 3. Onthe3.OL(SOHCandDOHC) and3.5Lengines,theupperintakemanifoldmustberemoved to accesstherearsparkplugs.Referto Section3 forthe removalprocedure. 4. Carefullytwistthesparkplugwirebootto loosenit,thenpullupwardandremove thebootfrom theplug.Besureto pullonthebootandnotonthe wire,otherwise theconnector locatedinsidetheboot maybecome separated. 5. Usingcompressed air,blowanywateror debrisfromthesparkplugwelltoassurethatnoharmful contaminants areallowedtoenterthecombustion chamber whenthesparkplugis removed. If compressed air is notavailable, usea raaor a brushto cleanthearea. *Remove the sparkplugswhenthe engine is cold, if possible,to preventdamageto the threads. If removal of the plugs is difficult, apply a few dropsof penetratingoil or silicone spray to the area aroundthe base of the plug, and allow it a few minutesto work. 6. Usinga sparkplugsocketthatis equipped witha rubberinsertto properlyholdtheplug,turn ,,Y”

..1111

uy”’

thesparkplugcounterclockwise to loosenandremovethesparkplugfromthebore.

Be sure not to usea flexible extensionon the socket. Useof a flexible.___. extensionmay . _allow ea to me plug. A a shearforce to be agptf’LL_ _I___ shearforce could breaktne pug -u on I_ III ILme cylinder head, leadingto costly andfrustrating repairs. To install: 7. Inspect thesparkplugbootfor tearsor damage.If.adamaged bootis found,thesparkplugwire mustbereplaced. 8. Usinga wirefeelergauge, checkandadjust thesparkpluggap.Whenusinga gauge,theproper sizeshouldpassbetween theelectrodes witha slight drag.Thenextlargersizeshouldnotbeableto pass whilethenextsmallersizeshouldpassfreely. 9. Carefully threadtheplugintotheboreby hand.If resistance is feltbeforetheplugisalmost completely threaded, backtheplugoutandbegin threading again.Insmall,hardto reachareas,anold sparkplugwireandbootcouldbeusedasathreadingtool.Thebootwill holdtheplugwhileyoutwist theendofthewireandthewireis suppleenoughto twistbeforeit wouldallowtheplugto crossthread.

Do not usethe spark plug sock? l -- K-rrA Alwmm rarntdlv thw lad the plug by handor usingan old plug wire to prevent the possibility of crossthreadingand damaging the cylinder headbore. GL

tha nhme . ..Y f..“YY.

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10. Carefullytightenthesparkplug.If theplug youareinstallingisequipped withacrushwasher, seattheplug,thentightenaboutI/,turnto crushthe washer.If youareinstallinga taperedseatplug, tightentheplugto specifications providedbythevehicleor plugmanufacturer.

11. Applya smallamountof siliconedielectric compound totheendof thesparkplugleador inside thesparkplugbootto preventsticking,theninstall thebootto thesparkplugandpushuntilit clicksinto place.Theclickmaybefeltor heard,thengentlypull backonthebootto assurepropercontact. 12. Onthe3.OLfSOHCandDOHC) and3.5Lengines,installtheupperintakemanifold. Referto Section3 fortheinstallation procedure. 13. Ifequipped, installthecentercover.

INSPECTION & GAPPING b See Figures 98, 97, 98, 99, and 100 Checktheplugsfor depositsandwear,Iftheyare notgoingto bereplaced, cleantheplugsthoroughly. Remember thatanykindof depositwill decrease the efficiencyof theplug.Plugscanbecleaned ona sparkplugcleaningmachine, whichcansometimes befoundin servicestations,or youcandoanacceptablejobof cleaningwitha stiffbrush.If theplugsare’ cleaned, theelectrodes mustbefiledflat.Useanignitionpointsfile,notanemeryboardorthelike, whichwill leavedeposits. Theelectrodes mustbe filedperfectlyflatwithsharpedges;rounded edges reducethesparkplugvoltagebyasmuchas50%. Checksparkpluggapbeforeinstallation. The groundelectrode (theL-shaped oneconnected to the bodyoftheplug)mustbeparallelto thecenterelectrodeandthespecifiedsizewiregauge(pleaserefer to theTune-Up Specifications chartfor details)must passbetween theelectrodes witha slightdrag: *,NEVER.adjustthe gap on a usedplatinum type spark plug. Alwayscheckthegaponnewplugsastheyare notalwayssetcorrectlyatthefactory.Donotusea flatfeelergaugewhenmeasuring thegapona used plug,because thereadingmaybeinaccurate. A round-wire typegappingtoolisthebestwaytocheck thegap.Thecorrectgaugeshouldpassthroughthe electrode gapwitha slightdrag.If you’reindoubt,try onesizesmallerandonelaraer.Thesmalleraauqe

l-24

GENERALINFORMATIONAND MAINTENANCE

tm2903

b%slZl2

Fig. 97 A variety of tools and gauges are neededfor spark plug service

Fig. 98 Checkingthe spark plug @auwith a feeler gauge. thetwoends.Takethelengthandmultiplyit by6,000 to achievethemaximum resistance allowableineach wire,resistance shouldnotexceedthisvalue.If resistancedoesexceed 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 ig. 100 If the standardplug Is in good conftlon, the electrode may be filed flatWARNING:do not file platinum plugs shouldgothrougheasily,whilethelargerone I’ shouldn’t gothroughatall.Wiregapping toolsusuallyhavea bending toolattached. Usethatto adjust thesideelectrode untiltheproperdistanceisob- \ tained.Absolutely neverattempt to bendthecenter electrode. Also,becarefulnotto bendthesideelectrodetoofaror toooftenasit mayweaken andbreak offwithintheengine,requiringremovalof thecylinderheadto retrieveit.

1. Remove theair cleanerinlettube. 2. If eouiooed, remove thecentercoverfromthe valvecovei. 3. Labeleachsparkplugwireandmakea noteof itsrouting.

tccs2904

Fig. 99 Adjustingthe spark plug gap *Don’t rely on wiring diagramsor sketches 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 replacing thesparkplugwires,matchtheolc wirewithanappropriately sizedwireinthenewset. 6. Lubricate thebootsandterminals withdielectricgreaseandinstallthewireonthecoilpack.Make surethewiresnapsintoplace. 7. Routethewirein theexactpathastheoriginal thewireto thesparkplug. andconnect 8. Repeat theprocessfor eachremaining wire, iorkingfromthelongestwireto theshortest. 9. Installtheair cleanerinlettube.

TESTING tcG1009

Fig. 102 Checkingindividual plug wire resistance with a digital ohmmeter

# See Figures191 and 102 Ateverytune-up/inspection, visuallycheckthe sparkplugcablesfor burnscuts,or breaksin theinsulation.Checkthebootsandthenipplesonthedistributorcapand/orcoil.Replace anydamaged wiring. Every50,000miles(80,000km)or 60months, the resistance of thewiresshouldbechecked withan ohmmeter. Wireswithexcessive resistance will cause misfiring,andmaymaketheenginedifficultto startin dampweather. Tocheckresistance, anohmmeter shouldbeused ’ oneachwireto testresistance between theendconnectors.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 Ignitiontimingisthemeasurement, in degrees of crankshaft rotation,of thepointatwhichthespark plugsfire ineachof thecylinders.It is measured in degrees beforeor afterTopDeadCenter(TDC)of the compression stroke. Ideally,theair/fuelmixtureinthecylinderwill be ignitedbythesparkplugjustasthepistonpasses osen the distributor cap retain-

Fig. 106. . . then remove the cap from the distributor

I

1

COMBUSTION ENDS 23’ ATDC

SPEED INCREASES

Fig. 107 Graspthe rotor and pull it straight off of the distributor shaft

REMOVAL&INSTALLATION b See Figures 105,106,107, and 108 1. Disconnect thenegative batterycable. *Depending on the reasonfor removingthe distributorcap, it may makemoresenseto leave the sparkplug wires attached.This is handyif you are testingspark plug wires, or if removal is necessaryto accessother components,and wire lengthallows you to reposition the cap out of the way. 2. Labelanddisconnect thesparkplugwires fromthedistributor cao. 3. Remove thedistributor capretaining screwsor clipsandremove thecapfromthedistributor. 4. Noteits installedposition,thenremove therotorfromthedistributor shaft. 5. Theinstallation is thereverseof theremoval.

Fig. 108The rotor mustbe aligned correctly to the distributor shaft before installation otherphysicaldamage. Makesurethedistributor cap’scenterbuttonis freeof damage. Checkthecap terminals for dirtor corrosion.Alwayschecktherotor bladeandspringcloselyfor damage. Replace any comoonents wheredamaae isfound.

9ir&1$?6

Fig. 111 Advancingthe ignition timing ’ CCURS DC

COMBUSTION ENDS 23 ATDC

smmE

ALGNME LOCATOR

INSPECTION u See Figures109 and 110 Afterremoving thedistributor capandrotor,clean thecomponents (bothinsideandoutsideof thecap) usingsoapandwater.If compressed air is available, carefullydrythecomponents (wearingsafetygoggles)or allowthepartsto airdry.Youcandrythem witha clean,softcloth,butdon’tleaveanylintor moisturebehind. Oncethecapandrotorhavebeenthoroughly cleaned, checkforcracks,carbontracks,burnsor

9mg27

Fig. 112 Retardingthe tgnttion timing

Inspectionpoints for the dis

.

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.Becauseit 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 crankshaftrotationbeforethe piston reachesTDC (BTDC).If the settingfor the ignition timing is 10” BTDC,eachsparkplug mustfire 10 degreesbefore eachpiston reachesTDC.This only holdstrue, however,whenthe engineis at idle speed.The combustion processmust be completeby 23”ATDC to maintain properengineperformance,fuel mileage,and low emissions. As the enginespeedincreases,the pistonsgo faster.Thesparkplugs haveto ignite the fuel even sooner if it ISto be completelyignitedwhenthe piston reachesTDC. If the ignition is set too far advanced(BTDC),the ignition and expansionof the fuel in the cylinderwtll occurtoo soon andtendto force the piston downwhile it is still travelingup. Thus causespre ignition or “knockmgand pinging”. If the 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)timing 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 within the cylindercanbe easily read(theflash of light makesthe markon the pulleyappearto be standingstill). Propertiming is indicatedwhenthe markand scaleare in specifiedalignment.

Whencheckingtiming with the enginerunning, 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 waterproof coverfrom the igmtiontiming adjustingconnector,and connecta jumperwire from this terminal

Fig. 113 Ignition timing adjustment connector-1990-92 Mirage with 1.5L engine

Fig. 114 Ignition timing adjustment connectar-Miracle with 1.6L enaine

CHECK CONNECTOR 93151QM

Fig. 115 Ignition timing adjustment connectar-Galant with 2.OLengines

93151QO!

Fig. 116 Ignition timing adjustment con. nectar-1992-96 Oiamante

93151QO1

93151gOB

Fig. 117 Ignition timing adjustment con. nectar-1994-96 Galant

Fig. 116 Ignition timing adjustment connector-1993-96 Mirage with 1.5L engine

to a good ground.Referto the correspondingillustrations 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 scalelocatednearthe crankshaftpulley. 6. Loosenthe distributoror crankanglesensor hold-downnut just enoughso the housingcanbe rotated. 7. Turn the housingin the properdirectionuntil the specifiedtiming is reached.Tightenthe holddown nut and recheckthe timing. Turn the engine

OFF. 8. Removethe jumperwire from the ignition timing adjustingterminaland installthe water-proof cover. 9. Startthe engineand checkthe actualtiming (thetiming without the terminalgrounded).This readingshould be approximately5 degreesmore thanthe basictiming. Actualtiming may increaseaccording to altitude.Also, actualtiming mayfluctuate becauseof slight variationaccomplishedby the ECU.

Fig. 119 Ignition timing adjustment connector-1993-96 Mirage with 1.6L engine As long as the basictiming is correct,the engineis timed correctly. 10. Turn the engineOFF. 11. Disconnectthe timing apparatusand tachometer.

1997-00 Models The ignition timing is controlledby the Engine ControlModule(ECM)and is not adjustable.However it can be inspectedusinga scantool.

GENERALINFORMATIONAND MAlNTENANdEI-27 ADJUSTMENT u See Figures 120 and 121 The only enginesthat requireperiodicadjustment of the valvesarethe 1.5L enginein the 1990-95 Mirageand the 1.8L in the 1993-95 Mirage.

Incorrectvalve clearancewill causenoisy and/or unsteadyengineoperation, reduced engineoutput,and possibleenginedamage. Checkthe valve clearancesand adjustas required while the engine is hot. 1. Warmthe engineto operatingtemperature. Turn the engineOFF.Disconnectthe negativebattery cable. 2. Removeall sparkplugsso enginecanbe easily 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 cylinder pistonsto Top DeadCenter(TDC). 5. Wigglethe rockerarms on No. 1 and4 cylindersup 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 compressionstroke,checkNo. 1 intakeand exhaust; No. 2 intakeand exhaust.Thenturn the crankshaftclockwise 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

AA

No.2

AA

No.3

BB

No.4

BB 93151g10

Fig. 121 Adjustingthe valve clearance

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 clearante usinga feelergaugewhile turningthe adjusting

screw.Whenat specification,tightenthe locknut.Be sureto hold the screwsecurelyin placewhentighteningthe locknutto preventit from turningwhen tighteningthe locknut.Tighteningtorqueof the locknut 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 negativebattery cable.

ENGINETUNE-UP SPECIFICATIONS Engine Displacement

Engine

Spark Plugs

Ignition liming

Gap

(as.)

Idle Fuel Pump

Speed (rpm)

Valve Clearance

l-28

GENERALINFORMATIONAND MAINTENANCE

Theidlespeedis factorysetandusuallynoadjustments areevernecessary. If anadjustment becomesnecessary, firstcheckthatthesparkplugs,injectors,idleair controlservoandcompression pressure areall normal. Datafromvarioussensorsandswitchesareused bytheECUto determine theproperfuel/airmixture for optimalengineperformance.

SYSTEMSERVICE&REPAIR ti See Figure 122 *it is recommendedthat the A/Csvstembe servicedby an EPASection609 cehified automotivetechnicfanutilizing a refrigerant recovery/recyclingmachfne. Thedo-it-yourselfer shouldnotservicehis/her ownvehicle’sA/Csystemfor manyreasons,includinglegalconcerns, personalinjury,environmental damage andcost.Thefollowingaresomeof thereasonswhyyoumaydecidenotto serviceyourownvehicle’sA/Csystem. According to theU.S.CleanAirAct,it is afederal crimeto serviceor repair(involvingtherefrigerant) a MotorVehicleAirConditioning (MVAC)systemfor moneywithoutbeingEPAcertified.It isalsoillegalto ventR-12andR-134arefrigerants intotheatmosphere.Sellingor distributing A/Csystemrefrigerant (ina container whichcontainslessthan20poundsoif refrigerant) to anypersonwhois notEPA609certifiedis alsonotallowedby law. Stateand/orlocallawsmaybemorestrictthanthe federalregulations, sobesuretocheckwithyour stateand/orlocalauthorities for furtherinformation. Forfurtherfederalinformation onthelegalityof servicingyourAK system,calltheEPAStratospheric Ozone Hotline. *Federal law dictatesthat a fine of up to $25,000may be levied on peopleconvicted of venting refrigerant into the atmosphere. Additionally, the EPAmay pay up to $10,000 for informationor services leadingto a crimf nai convictionof the violation of these laws. WhenservicinganA/Csystemyouruntheriskof handlingor comingincontactwithrefrigerant, which

mayresultin skinor eyeirritationor frostbite.Althoughlowintoxicity(dueto chemical stability),inhalationof concentrated refrigerant fumesis dangerousandcanresultindeath;casesoffatalcardiac arrhythmia havebeenreportedin peopleaccidentally subjected to highlevelsof refrigerant. Someearly symptoms includelossof concentration anddrowsi+ ness. cGeneraiiy, the limit for exposureis lower for R-134athan it is for R-12. Exceptional care mustbe practicedwhen handlingR134a. Also,refrigerants candecompose athightemperatures(neargasheaters or openflame),whichmayresuitin hydrofluoric acid,hydrochloric acidandphosgene(afatalnervegas). R-12refrigerant candamage theenvironment becauseit isa Chlorofluorocarbon (CFC),whichhas beenprovento addto ozonelayerdepletion, leading to increasing levelsof UVradiation.UVradiationhas beenlinkedwithanincrease in skincancer,suppressionof thehumanimmune system, anincrease in cataracts, damage to crops,damage to aquaticorganisms,anincrease in ground-level ozone,andincreased globalwarming. R-134arefrigerant is a greenhouse gaswhich,if allowedto ventintotheatmosphere, will contribute to globalwarming(theGreenhouse Effect). It is usuallymoreeconomically feasibleto havea certifiedMVACautomotive technician performA/C systemserviceonyourvehicle.Somepossiblereasonsforthisareasfollows: l Whileit is illegalto serviceanA/Csystem withouttheproperequipment, thehomemechanic wouldhavetopurchase anexpensive refrigerant recovery/recycling machine to servicehis/herownvehicle. l Sinceonlya certifiedpersonmaypurchase refrigerant-according to theCleanAirAct,thereare specificrestrictions onsellingor distributing A/C systemrefrigerant-itis legallyimpossible (unless certified)forthehomemechanic to servicehis/her ownvehicle.Procuring refrigerant inanillegalfashionexposes oneto theriskof payinga $25,000 fine to theEPA. R-12 Refrigerant Conversion If yourvehiclestill usesR-12refrigerant, oneway to saveA/Csystemcostsdowntheroadis to inveshgatethepossibilityof havingyoursystemconverted toR-134a.TheolderR-12systems canbeeasily converted to R-134arefrigerant bya certifiedautomotivetechnician byinstallinga fewnewcomponentsandchanging thesystemoil. Thecostof R-12is steadilyrisingandwill continueto increase, because it is nolongerimported or manufactured intheUnitedStates.Therefore, it is oftenpossibleto haveanR-12systemconverted to R134aandrecharged for lessthanit wouldcostto just chargethesystemwithR-12. If youareinterested in havingyoursystemconverted,contactlocalautomotive servicestationsfor moredetailsandinformation.

u See Figures 123 and 124 Fig. 122 A label with information concerning the A/Csystemis typically located in the engine compartment

Although theA/Csystemshouldnotbeserviced bythedo-it-yourselfer, preventive maintenance can bepracticed andA/Csysteminspections canbeper-

formedto helpmaintain theefficiency of thevehicle’s A/Csystem.Forpreventive maintenance, performthe following: l Theeasiestandmostimportant preventive maintenance for yourA/Csystemisto besurethatit is usedona regularbasis.Running thesystemfor fiveminutes eachmonth(nomatterwhattheseason) will helpensurethatthesealsandall internalcomponentsremainlubricated. *Some newer vehicles automaticallyoperate the A/Csystemcompressorwheneverthe windshield defroster is activated.Whenrunning, the compressorlubricatesthe A/Csys tern components;therefore, the A/Csystem would not needto be operatedeach month. * Inorderto preventheatercorefreeze-up during A/Coperation, it is necessary to maintain properantifreezeprotection. Usea hand-held coolanttester (hydrometer) to periodically checktheconditionof theantifreeze inyourengine’s coolingsystem. *Antifreeze shouldnot be usedlonger than the manufacturerspecifies. . Forefficientoperation of anairconditioned vehicle’scoolingsystem, theradiatorcapshouldhavea holdingpressure whichmeetsmanufacturers specifications.Acapwhichfailsto holdthesepressures shouldbereplaced. l Anyobstruction of or damage tothecondenser configuration will restrictair flowwhichis essential to itsefficientoperation. It is,therefore, a goodrule to keepthisunitcleanandin properphysicalshape.

Fig. 123 A coolant tester can be usedto determine the freezing and boiling levels of the coolant in your vehicle 1

Fig. 124 To ensureefficient cooling system operation, inspect the radiator cap gasket and seal

GENERALINFORMATIONAND MAlNTENANdE1-29 i *Bug screenswhich are mountedin front of the condenser(unlessthey are original equipment)are regardedas obstructtons. l Thecondensation draintubeexpelsanywater whichaccumulates onthebottomoftheevaporator housingintotheenginecompartment. If thistubeis obstructed, theairconditioning performance canbe restricted andcondensation buildupcanspillover ontothevehicle’sfloor.

l Makesuretheair passage selectionleveris operating correctly.Starttheengineandwarmit to normaloperating temperature, thenmakesurethe temperature selectionleveris operating correctly.

-w ~1

ELEMENT(REFILL)CARE&REPLACEMENT b See Figures 126 thru 135

SYSTEMINSPECTION

Formaximum effectiveness andlongestelement

b See Figure 125

lifp thp winrkhi&i .

Although theA/Csystemshouldnotbeserviced bythedo-it-yourselfer, preventive maintenance can bepracticed andA/Csysteminspections canbeperformedto helpmaintain theefficiency of thevehicle’s A/Csystem.ForA/Csysteminspection, performthe following: Theeasiestandoftenmostimportant checkfor the airconditioning systemconsistsof a visualinspectionof thesystemcomponents. Visuallyinspectthe airconditioning systemfor refrigerant leaks,damagedcompressor clutch,abnormal compressor drive belttensionand/orcondition, pluggedevaporator draintube,blockedcondenser fins,disconnected or brokenwires,blownfuses,corrodedconnections and poorinsulation. A refrigerant leakwill usuallyappearasanoily residueattheleakage pointin thesystem. Theoily residuesoonpicksupdustor dirtparticlesfromthe surrounding airandappears greasy.Throughtime, thiswill buildupandappearto bea heavydirtimpregnated grease. Fora thoroughvisualandoperational inspection, checkthefollowing:

tcca-23

* Checkthesurfaceof theradiatorandcondenserfor dirt,leavesor othermaterialwhichmight blockairflow. l Checkfor kinksin hosesandlines.Checkthe systemfor leaks. l Makesurethedrivebeltis properlytensioned. Whentheair conditioning is operating, makesurethe drivebeltisfreeof noiseor slippage. l Makesuretheblowermotoroperates atall appropriatepositions,thencheckfor distribution of the airfromall outletswiththebloweronHIGHor MAX. *Keep in mindthat underconditionsof high humidity,air dischargedfrom the A/Cvents may not feel as cold as expected,even if the systemis working properly. This is because vaporizedmoisturein humidair retains heat more effectively than dry air, thereby making humidair more difficult to cool.

tCS1224

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nnri winor hlarlP~ shmM hP kmt

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clean.Dirt,treesap,roadtarandsoonwill cause streaking, smearing andbladedeterioration if lefton theglass.It isadvisable to washthewindshield carefullywitha commercial glasscleanerat leastoncea month.Wipeofftherubberbladeswiththewetrag afterwards. Donotattempt to movewipersacrossthe windshield byhand;damage to themotoranddrive mechanism will result. Toinspectand/orreplacethewiperbladeelements,placethewiperswitchintheLOWspeedpositionandtheignitionswitchintheACCposition. Whenthewiperbladesareapproximately verticalon thewindshield, turntheignitionswitchto OFF. Examine thewiperbladeelements. Iftheyare foundto becracked, brokenor torn,theyshouldbe replaced immediately. Replacement intervalswill vary withusage,althoughozonedeterioration usuallylimitselement lifetoaboutoneyear.If thewiperpattern is smeared or streaked, or if thebladechatters across theglass,theelements shouldbereplaced. It iseasiestandmostsensibleto replacetheelements in pairs. Ifyourvehicleis equipped withaftermarket blades, thereareseveraldifferent typesof refillsandyourvehi-

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. 129 T&o* wioer blade and fit kit

Fig, 130 Tripledge@wiper blade and fit kit

Fig. 131 To remove and install a LexoP wiper blade refill, slip out the old insert and slide in a new one

.

l-30

GENERAL'INFORMATIONAND MAINTENANCE

thenthe insert can be re After installing the replacement

n Pylon@inserts, the clip be removedprior to siidi stripandpullupwhiletwistingcounterclockwise. Thebackingstripwill snapoutof theretaining tab. Dothisfor theremaining tabsuntiltherefillis freeof theblade.Thelengthoftheserefillsis moldedinto theendandtheyshouldbereplaced withidentical types.

lowedto touchtheolass

1 Fin

1% Tha Trinlarlna@

catethefrontendis outof alignment or thatthetires areoutof balance.

TIREROTATION # See Figures 137 and 138 Tiresmustberotatedperiodically to equalize wear patterns thatvarywithatire’spositiononthevehicle. Tireswill alsowearinanunevenwayasthefront steering/suspension systemwearstothepointwhere thealianment shouldbereset. Rotating thetireswill ensuremaximum lifeforthe tiresasa set,soyouwill nothaveto discarda tire earlydueto wearononlypartof thetread.Regular

# See Figure 138 clemighthaveanykind.Aftermarket bladesandarms rarelyusetheexactsametypebladeorrefillasthe originalequipment. Herearesometypiel aftermarket blades;notallmaybeavailable foryourvehicle: TheAnco@ typeusesa releasebuttonthatis pusheddownto allowtherefillto slideoutof the yokejaws.Thenewrefillslidesbackintotheframe , andlocksin place. SomeTrico@refillsareremoved bylocatingwhere themetalbackingstriportherefilliswider.Inserta smallscrewdriver bladebetween theframeandmetal backingstrip.Pressdownto releasetherefillfrom theretaining tab. Othertypesof Trico@’ refillshavetwometaltabs whichareunlocked bysqueezing themtogether. The rubberfillercanthenbewithdrawn fromtheframe 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 thejawsandpushingthroughtheslightresistance whenit reaches the endof itstravel,therefillwill lockintoposition. ToreplacetheTridon@ refill,it is necessary to removethewiperblade.Thisrefillhasa plasticbacking stripwitha notchabout1 in.(25mm) fromtheend. Holdtheblade(frame)ona hardsurfacesothatthe frameistightlybowed.Gripthetipof thebacking

Common senseandgooddrivinghabitswill affordmaximum tire life.Faststarts,suddenstops andhardcorneringarehardontiresandwill shortentheirusefullife span.Makesurethatyou don’toverloadthevehicleor runwithincorrect pressurein thetires.Bothof thesepracticeswill increasetreadwear. *For optimumtire life, keepthe fires prop eriy inflated, rotate them often and have the wheel alignmentcheckedperiodically. Inspectyourtiresfrequently. Beespeciallycareful to watchfor bubblesin thetreador sidewall, deepcutsor underinflation. Replace anytireswith bubblesin thesidewall.If cutsaresodeepthatthey penetrate to thecords,discardthetire.Anycutin thesidewallof a radialtirerendersit unsafe.Also lookfor uneventreadwearpatternsthatmayindi-

Fig. 138 A label with information concerning the tires is typically located on one of the door pillars

DIRECTIONAL

tion”

TIRES

DIRECTIONAL

TIRES

GENERALINFORMATIONAND MAlNTENANdE1-31 Whenrotating“unidirectional tires,”makesure thattheyalwaysroll inthesamedirection.This meansthata tireusedontheleftsideof thevehicle mustnotbeswitched to therightsideandvice-versa. Suchtiresshouldonlyberotatedfront-to-rear or rear-to-front, whilealwaysremaining onthesame sideof thevehicle.Thesetiresaremarked onthe sidewallasto thedirectionof rotation;observe the markswhenreinstalling thetire(s). Somestyledor “mag”wheelsmayhavedifferent offsetsfrontto rear.Inthesecases,therearwheels mustnotbeusedupfrontandvice-versa. Furthermore,if thesewheelsareequipped withunidirectional tires,theycannotberotatedunlessthetireis remounted fortheproperdirectionof rotation. *The compactor space-saverspare is strictly for emergencyuse. it mustnever be includedin the tire rotation or placedon the vehicle for everydayuse.

TIREDESIGN p See Figure 139 for maximum satisfaction, tiresshouldbeusedin setsof four.Mixingof differenttypes(radial,biasbelted,fiberglassbelted)mustbeavoided.Inmost cases,thevehiclemanufacturer hasdesignated a typeof tireonwhichthevehiclewill performbest. Yourfirstchoicewhenreplacing tiresshouldbeto usethesametypeof tirethatthemanufacturer recommends. Whenradialtiresareused,tiresizesandwheeldiameters shouldbeselected to maintain groundclearanteandtireloadcaoacitveauivalent to theoriainal specified tire.Radialtiresshouldalwaysbeusedin setsof four. Radial tires shouldnever be usedon only the front axle.

checktheinstalledtirefor anysignof interference withthebodyorsuspension whilethevehicleis stopping,turningsharplyor heavilyloaded. Snow Tires Goodradialtirescanproducea bigadvantage in slipperyweather, butin snow,a streetradialtiredoes nothavesufficienttreadto providetractionandcontrol.Thesmallgroovesof a streettirequicklypack withsnowandthetirebehaves likea billiardballona marblefloor,Themoreopen,chunkytreadof a snow tirewill self-clean asthetireturns,providingmuch bettergriponsnowysurfaces. Tosatisfymunicipalities requiringsnowtiresduringweather emergencies, mostsnowtirescarryeither anM+ Sdesignation afterthetiresizestamped on thesidewall,or thedesignation “all-season.” Ingeneral,nochangeintiresizeis necessary whenbuying snowtires. Mostmanufacturers stronqlvrecommend theuse of 4 snowtiresontheir\lehiciesfor reasons of stability.If snowtiresarefitter1onlyto thedrivewheels,the oppositeendof thevehilclemaybecome veryunstablewhenbrakingor turnringonslipperysurfaces. Thisinstabilitycanleadto unpleasant endingsif the A*:,,“-r-..l, ^_....&^_^^,&I. UIIVU MII I LUUII~~MLL iueslidein time. Notethatsnowtires,whether2 or 4,will affectvehiclehandlinginall non-snowsituations. Thestiffer, heaviersnowtireswill noticeably change theturning andbrakingcharacteristics of thevehicle.Oncethe snowtiresareinstalled, youmustre-learnthebehavior of thevehicleanddriveaccordingly. *Consider buyingextra wheels on which to mountthe snow tires. Oncedone,the “snow iheeis” can be installed and removedas needed.This eliminatesthe potential damage to tires or wheels from seasonalremoval and installation. Evenif your vehicle has

styled wheels, see if inexpensivesteel wheels are available, Althoughthe look of the vehicle will change,the expensive wheels will be protectedfrom salt, curb hits and potholedamage.

TIRESTORAGE Iftheyaremounted onwheels,storethetiresat properinflationpressure. Alltiresshouldbekeptin a cool,dryplace.If theyarestoredinthegarageor basement, donotletthemstandona concrete floor; setthemonstripsof wood,a mator a largestackof newspaper. Keeping themawayfromdirectmoisture is of paramount importance. Tiresshouldnotbe storedupright,butina flatposition.

INFLATION & INSPECTION b See Figures 140 thru 147 Theimportance of propertireinflationcannotbe overemphasized. Atireemploys air aspartof its structure. It is designed aroundthesupporting strengthof theairata specifiedpressure. Forthis reason,improper inflationdrasticallyreduces the tire’sabilityto performasintended. Atirewill lose someair in day-to-day use;havingto adda few poundsof airperiodically is notnecessarily a signof a leakingtire. Twoitemsshouldbea permanent fixturein every glovecompartment: anaccurate tirepressure gauge anda treaddepthgauge.Checkthetirepressure (ineludingthespare)regularlywitha pockettypegauge. Toooften,thegaugeontheendof theairhoseat vnrrrcornernarane is notaccurate because it suffers XI I._. ‘-’ much --“‘“’abuse. J sAlwa!~rschecktireoressure whenthe too tiresarecold,aspressure increases withtemperature.If youmustmovethevehicleto checkthetire

lb

Whenselecting tires,payattention totheoriginal sizeasmarkedonthetire.Mosttiresaredescribed usinganindustrysizecodesometimes referred to 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 for any sion of aunctureor damaoe I (MILLIMETERS) 145

CDNStRUCtlDN R - RADIAL

Fig. 141 Tires with deep cuts, or cutswhich I buioe, should be replaced immediately

l-6-E D WA9

RADIAL l

l

Fig. 139 P-Metric tire coding

DRIVE WHEEL HEAW ACCELERATION OVERINFLATION

*LACK

OF ROTATION

Fig. 142 Examplesof inflation-related tire

TIRE

fig. 143 Radial tires have a characteristic sidewall bulge; don’t try to measure pressure by looking at the tire. Use a quality air pressuregauge

.

1-32 GENERALINFORMATIONAND MAINTENANCE CONDITION

EFFECT

UNDER-INFLATION CAUSE EXCESSIVE

CORRECTION

HAVE TIRE INSPECTED

WORN OR OUTOF-ALIGNMENT

SPEED’

ADJUST PRESSURE TO SPECIFICATIONS WHEN TIRES ARE COOL ROTATE TIRES

/ BALANCE

WHEELS

INSPECT SUSPENSION

FOR FURTHER USE. lCCSi267

ig. 144 Commontire wear patterns and causes 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 memorial, its time to replacethe snowtire(s). 1~~~1264

Fig. 146 Accuratetread depthindicatorsare inexuensiveand handv

1~~~1265

Fig. 145 Tread wear indicators will appear when the tire is worn inflation,do not drive morethan a mile beforechecking. A cold tire is generallyonethat has not beendriven 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 maximumloading, but it is rarely the correct pressurefor everydaydriving. Consultthe owner’s manual 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,

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 recommendedinflationpressures. 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 indicators meansthat the tires shouldbe replaced.In fact, manystateshavelawsprohibitingthe useof tires with lessthanthis amountof tread. You cancheckyour own treaddepthwith an inexpensivegaugeor by using a Lincoln headpenny. Shp the Lrncolnpenny(with Lincoln’sheadupside-

CAREOFSPECIALWHEELS If you haveinvestedmoneyin magnesium,aluminum 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 wheelsduring removal,installation,balancing,etc.After removal 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-abrasive 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 winter. Salt and sand usedfor snow removalcanseverelydamagethe finish of a wheel. l Makecertainthe recommendedlug nut torque is neverexceededor the wheelmay crack.Neveruse snowchainson specialwheels;severescratching will occur.

GENERALINFORMATIONAND MAINTENANC-E 1133

Usedfluidssuchasengineoil,transaxle fluid,antifreezeandbrakefluidarehazardous wastesand mustbedisposed of properly.Beforedrainingany fluids,consultwithyourlocalauthorities; in manyareas,wasteoil,antifreeze, etc.is beingaccepted asa partof recyclingprograms. A number of servicestationsandautopartsstoresarealsoaccepting waste fluidsfor recycling. Besureof therecyclingcenter’s policiesbefore draininganyfluids,asmanywill notacceptdifferent fluidsthathavebeenmixedtogether.

ENGINE OIL 6 See Figure 148 WMitsubishirecommendsthat SAE5W-30 viscosity engineoil shouldbe usedfor all clia mateconditions,however, SAElow-30 is ac ceptablefor vehicles operatedin moderateto-hot climates.

theSAEnumber, thelightertheoil;thelowertheviscosity,theeasierit is tocranktheenginein cold weatherbutthelesstheoil will lubricate andprotect theenginein hightemperatures. Thisnumberis markedoneveryoil container. Oilviscosity’s shouldbechosenfromthoseoils recommended forthelowestanticipated temperatures duringtheoil changeinterval.Dueto theneedfor an oil thatembodies bothgoodlubrication athightemperatures andeasycrankingincoldweather, multigradeoilshavebeendeveloped. Basically, a multigradeoil is thinnerat lowtemperatures andthickerat hightemperatures. Forexample, a low-40 oil (theW standsforwinter)exhibitsthecharacteristics of a 10 weight(SAE10)oil whenthecaris firststartedand theoil is cold.Itslighterweightallowsit to travelto thelubricating surfaces quickerandofferlessresistanceto startermotorcranking than,say,a straight 30weight(SAE30)oil. Butatiertheensinereaches operating temperature, thelow-40 oil beginsacting likestraight40weight(SAE40)oil, itsheavierweight providinggreaterlubrication withlesschanceof foamingthana straight30weightoil. TheAPI(American Petroleum Institute) designations,alsofoundontheoil container, indicates the classification of engineoil usedundercertaingiven operating conditions. Onlyoilsdesignated for use ServiceSJheavydutydetergent shouldbeusedin yourcar.Oilsof theSJtypeperformmayfunctions insidetheenginebesides theirbasiclubrication. Througha balanced systemof metallicdetergents andpolymeric dispersants, theoil prevents highand lowtemperature depositsandalsokeepssludgeand dirtparticlesin suspension. Acids,particularly sulfuricacid,aswellasotherby-products of enginecombustionareneutralized bytheoil. If theseacidsare allowedto concentrate, thevcancausecorrosionand rapidwearof theinternalengineparts.

lccS1235

Fig. 148 look for the API oil identification label when choosingyour enaine oil

Non-detergentmotor oils or straight mineral oils shouldnot be usedin your engine.

Whenaddingoil to thecrankcase or changing the 0Nil orfilter,it is important thatoil of anequalquality tcI.originalequipment beusedinyourcar.Theuseof mtenor011s mayvoidthewarranty, damage __yourengine,or both. TheSAE(Societyof Automotive Engineers) grade number of oil indicates theviscosityof theoil (its abilityto lubricate ata giventemperature). Thelower

SyntheticOil Therearemanyexcellent synthetic andfuel-efficientoilscurrentlyavailable thatcanprovidebetter gasmileage,longerservicelifeand,insomecases, betterengineprotection. Thesebenefitsdonotcome withouta fewhitches,however; themainonebeing thepriceof synthetic oil,whichissignificantly more expensive thanconventional oil.

Fig. 149Graspthe oil level dipstickand pull upwardto remove it from the dipstick tube

Fig. 150 Wipe the dipstick clean and reinsert it into the dipstick tubeto getthe correct oil level

.

Synthetic oil is notforeverycarandeverytypeof driving,soyoushouldconsider yourengine’s conditionandyourtypeof driving.Also,checkyourcar’s warranty conditions regarding theuseof synthetic oils.

FUEL All modelsequipped witha SOHC(SingleOverheadCamshaft) enginearedesigned to operate using regularunleaded fuelwitha minimum of 87octane. All modelsequipped witha DOHC(DualOverhead Camshaft) enginearedesigned to operateusingregularunleaded fuelwitha minimum of 91octane.Mitsubishiwarnsthatusinggasolinewitha loweroctane ratingcancausepersistent andheavyknocking, and maycauseinternalenginedamage. If yourvehicleis havingproblems withroughidle or hesitation whentheenoineis cold,it mavbe causedbylowvolatilityfuel.Ifthisoccurs,iry a differentgradeor brandof fuel.

'OPERATION 1~FOREIGN COUNTRIES Ifyouplanto driveyourcaroutsidetheUnited Statesor Canada, thereis a possibilitythatfuelswill betoolowinanti-knock qualityandcouldproduce enginedamage. It is wiseto consultwithlocalauthoritiesuponarrivalina foreigncountryto determinethebestfuelsavailable.

OILLEVELCHECK # See Figures149, 150, and 151

\

The EPAwarns that urolonoedcontactwith usedengineoil ma; cause-anumberof skin disorders, includingcancer!Youshould makeevery effort to minimizeyour exposure to usedengineoil. Protectivegloves should be worn when changingthe oil. Washyour handsand any other exposedskin areas as soon as possibleafter exposureto usedengine oil. Soapandwater, or waterless hand cleaner shouldbe used. Theengineoil dipstickis typicallylocatedinthe

Fig. 151The oil level shouldbe betweenthe marks/notcheson the dipstick

.

l-34

GENERALINFORMATIONAND MAINTENANCE

Engineoil levelshouldbechecked everytimeyou putfuelinthevehicleor areunderthehoodperformingothermaintenance. 1. Parkthevehicleona levelsurface. 2. Theenainemavbeeitherhotorcoldwhen checking oil level. , if it is hot,waita fewminutesaftertheenginehasbeenturnedOFFtoallowthe oil todrainbackintothecrankcase. Iftheengineis cold,donotstartit beforechecking theoil level. 3. Openthehoodandlocatetheengineoil dipstick.Pullthedipstickfromitstube,wipeit clean, andreinsertit. MakesurethediDstickis fullv inserted. 4. Pullthedipstickfromitstubeagain.Holdingit horizontally, readtheoil level.TheoilshouldbebetweentheMINandMAXmarksor 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 ena 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 inrldinn uu,,u=, ranrnrli V#lll u,yu,u=,+, , vu should uffart to minimizeyour exposure to usedenginle oil. Protectivegloves should be worn whet1changingthe oil. Washyour handsandany other exposedskin areas as so*m ..#avv4ble . . . . . after exposureto useden111 aJ

m “II. nil ““up St-mn “ll” mwl w&or nr umtarlncr hand .,U.“I, “rn W.Y.“. .““I.I....” ginY

cleaner shouldbe used.

*The engineoil and oil filter shouldbe changedat the recommendedintervals on the MaintenanceChart.Thoughsomemanufacturers have at times recommendedchanging the filter only at every other oil change, ’ Chiltonrecommendsthat you always change . The benefit of fresh oil

drainingtheoil, makesurethattheengineis atoperatingtemperature. Hotoil will holdmoreimpurities in suspension andwill flowbetter,allowingtheremovalof moreoil anddirt. It is a goodideato warmtheengineoil firstsoit will flowbetter.Thiscanbeaccomolished bv15-20

milesof highwaydriving.Fluidwhichiswarmed to normaloperating temperature will flowfaster,drain morecompletely andremovemorecontaminants frnm ll”,,, tho Cl>”clnnine ““y”‘“.

1. Raiseandsupportthevehiclesafelyonjackstands.Makesuretheoil drainoluais atthelowest pointontheoil pan.If not,youmayhaveto raisethe vehicleslightlyhigherononejackstand (side)than theother. 2. Beforeyoucrawlunderthevehicle,takea look atwhereyouwill beworkingandgatherall thenecessarytools,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 avoidhavinghotoil rundownyourarm.Thiswill alsohelpassurethathavethepluginyourhand,notinthebottomof a panof hotoil.

Fig. 153Whenloosenedsufficiently, slowly turn the drain plug by hand, keeping con-

Fig. 154 Whenyou are ready, carefully pull

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

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 filter housingand inspect the threads

Be careful of the oil; when at operatingtemperature, it is hot enoughto causea severe bum. 5. Allowtheoil to drainuntilnothingbuta few dropscomeoutofthedrainhole.Checkthedrain plugtomakesurethethreadsandsealingsurfaceare notdamaged. Carefully threadtheplugintoposition andtightenit snug,andgivea slightadditional turn. Youdon’twanttheplugtofall out(asyouwould quicklybecome stranded), butthepanthreadsare EASILY strippedfromovertightening (andthiscanbe timeconsuming and/orcostlyto fix). 6. Toremove thefilter,youmayneedanoil filter wrenchsincethefiltermayhavebeenfittedtoo tightlyand/ortheheatfromtheenginemayhave madeit eventighter.Afilterwrenchcanbeobtained atanyautopartsstoreandiswell-worththeinvestment.Loosenthefilterwiththefilterwrench.Witha ragwrapped aroundthefilter,unscrew thefilterfrom thebossonthesideof theengine.Becarefulof hot oil thatwill rundownthesideof thefilter.Makesure thatyourdrainpanis underthefilterbeforeyoustart to removeit fromtheengine;shouldsomeofthehot oil happen to getonyou,therewill bea placeto dumpthefilterina hurryandthefilterwill usually spilla goodbitof dirtyoil asit is removed. 7. Wipethebaseof themounting bosswitha clean,drycloth.Whenyouinstallthenewfilter, smeara smallamountoffreshoil onthegasketwith yourfinger,justenoughto coattheentirecontact

Fig. 182 Loosen and remove the oil filler cap . . . surface.Whenyoutightenthefilter,rotateit abouta quarter-turn afterit contacts themounting boss(or followanyinstructions whichareprovidedonthefilteror partsbox).

Operatingthe enginewithout the proper amountandtype of engineoil will result In severe engtnedamage. 8. Remove thejackstands andcarefullylowerthe vehicle,thenIMMEDIATELY refilltheengine crankcase withtheproperamountof oil. DONOT WAITTODOTHISbecause if youforgetandsomeonetriesto startthevehicle,severeenginedamage will occur. 9. Refilltheenginecrankcase slowly,checking theleveloflen,youmayr..‘:-U.-1 :L II...-L-e ,“,\U.J lVL,VY II,UL II ..-..” UUUU,,J lessthantheamountof oil listedinthecapacitychart to refillthecrankcase. But,thatis onlyuntiltheengineis runandtheoil filteris filledwithoil.Tomake suretheproperlevelis obtained, runtheengineto normaloperating temperature, shuttheengineOFF, allowtheoil to drainbackintotheoil pan,and recheck thelevel.Topofftheoil atthistimeto thefill mark. *If the vehicle Is not resting on level ground,the oil level readingon the dipstick may be slightly off. Be sure to checkthe level only when the vehicle is sitting level. 10. Drainyourusedoil ina suitablecontainer for recycling.

Fig. 183 . , , then insert a funnel, and pour oil directly into the engine

FLUIDRECOMMENDATIONS Forall vehicleswithmanual transaxles, useHypoidgearoil SAE75W-85W, or 75W-9OW conformingto APIspecifications GL-4or higher. LEVELCHECK b See Flgures 184 and 185 Inspecteachcomponent for leaking.Checktheoil levelbyremoving thefillerplug.Iftheoil is contaminated,it is necessary to replaceit withnewoil. Check theoil levelasfollows:

89571gM

Fig. 164Typtcal manualtransaxle drain and filler plug location

.

l-36

GENERALINFORMATIONAND MAINTENANCE 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).

I

FLUIDRECOMMENDATIONS 8957i565

Fig, 165 Oil, when at the proper level, will reachthe lower edgeof tC=+ frfr*r u*rn -noning 1. Makesurethevehicleis oarkedona levelsurface. 2. Remove thefiller plugandmakesuretheoil levelis uptotheloweredgeof thefiller plughole. 3. Checkto besurethatthetransaxle oil is not noticeably dirtyandthatit hasa suitableviscosity.

DRAIN& REFILL u See Figures 166 and 167 1. Makesurethevehicleisparkedona levelsurface. 2. Raiseandsafelysupportthevehicle.Placea suitabledrainpanunderthemanual transaxle. 3. Remove thefillerplugandthedrainplugand allowtheoil to draincompletely.

Fig. 166 Use a box-end wrench to loosen the manualtransaxle drain plug . . .

Mitsubishirecommends theuseof Mercon@automatictransmission fluid.

LEVELCHECK u See Figures 168,169, and 170 Thetransaxle dipstickis locatedbehindtheair inlethose,towardsthefirewall. 1. Parkthevehicleona levelsurface. 2. Thetransaxle shouldbeatnormaloperating temperature whenchecking fluidlevel.Toensurethe fluidis atnormaloperating temperature, drivethevehicleat least10miles. 3. Withtheselectorleverin P andtheparking brakeapplied,starttheengine. 4. Openthehoodandlocatethetransaxle fluid dipstick.Pullthedipstickfromitstube,wipeit clean, andreinsertit. Makesurethedipstickis fully inserted.

Fig. 166 The automatictransaxle dipstick is typically located underthe air cleaner inlet tube. Pull the dipstick up to remove it from the transaxle

Fig. 170 The fluid level is OKif it is within the betweenthe HOTand ADDareas on the &&i& -.*".."... Do -- 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, removethedrainplugonthedifferentialof thetransaxle. 6. Installthedifferential drainplugandtightenft 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 approximately5 minutes. 11. Returntheselectorleverto P andleavethe enginerunningat idle. 12. Checkthetransaxle fluidlevel.Thefluidlevel at normaloperating temperature shouldreadwithin thecrosshatched areaof thefluidleveldipstick. 13. If thefluidlevelreadsbelowthecrosshatched area,adjustthelevelbyaddingfluidin smallincrementsuntilthecorrectfluidlevelis obtained.

PAN&FILTERSERVICE b See Figures178 thru 184

Fig. 169 Wipe the dipstick clean and Insert it mto the transaxle agamto get the correct /fluid level reading ., j

Thefluidshouldbechanged according to the schedule in theMaintenance Intervals chart.If thecar is normallyusedin severeservice,suchasstopand startdriving,trailertowing,or thelike,theinterval shouldbehalved.If thecaris drivenunderespecially nastyconditions, suchasin heavycitytrafficwhere thetemperature normallyreaches 90°F(32%),or in veryhillyor mountainous areas,or in police,taxi,or

_.

.I

..-. -._.

GENERALINFORMATIONAND MAINTENANCE l-37

periodically checkingthe fluid level to make sure you do not overfill the transaxle

Fig. 172 Carefully pull the transaxie drain plug out and to the side, out of the way oi flowing transaxie oil

Fig. 173 The differential drain plug is located at the bottom of the transaxie, to the left of the fluid pan. Typically the drain plug reauires a 17mmwrench

pan mountingbolts,a 1Ommwrench is required. Removethe pan retaining bolts . . .

Fig. 179 . . , then carefully lower the fluid pan from the transaxle

Fig, 181 . , . then remove the transaxie film ter from the valve body

Fig. 182 Removethe transaxie pan gasket from the pan

t

1-38 GENERALINFORMATIONAND MAINTENANCE

w

11I Addtherecommended automatic transaxle fluidto thetransaxle throughthedipsticktube.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 earlierinthissection.Addmorefluidif necessary. Be carefulnotto overfill,whichwill causefoamingand fluidloss.

FLUIDRECOMMENDATIONS Whenaddingfluidor refillingthetransfercase, useHypoidgearoil SAE75W-85W or 75W-9OW conforming to APIspecifications 61-4or higher.

n of the transfer case filler 3. Remove thefillerandthedrainplugandallow theoil to drainintothedrainpan. 4. Afterthefluidhasdrainedcompletely, install thedrainplugandtightento 24ft. Ibs.(32Nm). 5. Refillthetransfercasetotheproperlevelwith Hypoidgearoil SAE75W-85W/75W-9OW conformingto APIspecifications GL-4or higher.Theoil level -‘-,*I’ -nnnh+‘* “%omedgeof theoil fillerhole. 6. Installthetranxfer .._._.raw ____filler .._.nlm T.-Jand _.._tinhtm .lJ..._.. to 24ft. lbs.(32Nm). 7. Carefullylowerthevehicle.

LEVELCHECK Fig. 184 . . . the transaxle case before installing the gasket andpan onto the case 1

u See Figure 185

, FLUIDRECOMMENDATIONS

deliveryservice,thefluidshouldbechanged accordingto thesevereserviceschedule. Thefluidmustbehotbeforeit is drained; a 20

u See Figure 187 Sincefluidviscosityrangemayvarydepending on specifictemperature rangeof operation, pleaserefer

~~

tnetransaxle case.You’ll beverysorrylaterif youdo. *If the drainedfluld is discolored (brown or black),

thick,

or pmmll~ .llln3llU

hmmt ““III.,

nnrinmm url,““P

transaxle troubles, probablydueto overheat,r..rr,rA “#.a.trig, shouldbe susp~~lr;u. lvUl rrdr vLlrJ transaxle shouldbe inspectedby a reliable transaxle specialist to determinethe problem. 5. Remove thepanandgasket. 6. Cleanthepanwithsolventandallowit to air dry.If youusea ragto wipeoutthepan,yourisk leavingbitsof lintbehind,whichwill clogthedinky hydraulicpassages inthebansaxle. 7. Remove thefilterretainingboltsandremove thefilterfromthevalvebodv. To install: . 8. Installa newfilter,theninstalltheretaining boltsandtightenthemto 5 ft. Ibs.(7 Nm). 9. Positionthegasketonthepan,theninstall thepan.Tightentheboltsevenlyandin rotationto 8-9ft. Ibs.(10-12Nm.).Donotovertighten. IO. Lowerthevehicle.

bottomedge of the transfer case filler 1 1plug hole lnsoecteachcomponent for leaking.Checktheoil levelbyremoving thefillerplug.If theoil is contaminated,it is necessa ryto replaceit withnewoil. if% nn 1. Parkthevehi,., -.. IPVPI ,-.“, z11rf2r~ __.,“-_. Remove the filler plugandmakesuretheoil 2. levelreaches theloweredgeof thefillerplughole. 3. Checkto besurethattheoil is notnoticeably dirtyandthatit hastheproperviscosity. addoil throughthefillerholeuntil 4. If necessary, is runsoutof thehole. DRAIN& REFILL ) See Figure-14I8 1. Raiseandsafelysupportthevehicle,foraccess tothetransfercase. 2. Placea suitabledrainpanunderthetransfer casefluiddrainplug.

1Fig. 187 Rear axle lubricant application I chart I totheaccompanying chartfor theproperfluidfor yourvehicle. LEVELCHECK 1. Makesurethevehicleis parkedonlevel ground. 2. Remove theoil fill plugto checktheoil level. 3. Theoil levelis sufficientif it reaches thelower portionof thefillerplughole.If thefluidis low,add asrequiredthroughthefillerplug. DRAIN& REFILL u See Figure 188 1. Positionthevehicleona flatsurfaceor raise andsafelysupportthevehicleina levelposition. 2. Placeasuitabledrainpanundertherearaxle.

GENERALINFORMATIONAND MAINTENANCE 1-39 leak.Inmostcases,youwill beableto tracetheleak to a loosefittingor damaged hose. Evaporating ethylene glycolantifreeze will havea sweetsmellandleavesmall,white(salt-like)deoosits,whichcanbehelofulintracinoa leak.

amountof fluid.Thelevelshouldieachthkbottomof theoil fillerhole. 6. Installthefillerplugandtightento’24ft. Ibs. (32Nm). 7. If raised,carefullylowerthevehicle.

FLUIDRECOMMENDATIONS A goodqualityethylene glycolbasedor otheraluminumcompatible antifreeze is recommended for useinthevehiclescoveredbythismanual.It is best to adda 50150mixof antifreeze anddistilledwaterto avoiddilutingthecoolantinthesystem.

A Qss Itin,t.as 7 “1sl ly”lsJa ran IJ” +tw,, Wll” 4liE IJU \ If a thefluidlevelof yourcoolingsystemis cons of a leakareprobable. There stantlylow,thechance WI”U”.VlUl,.“,,I I” 9” aboutfindingthesourceof yourleak. Thefirstwavshouldbeavisualinsnection. Durina thevisualinspection, lookaroundthe&tire engineareaincluding theradiatorandtheheaterhoses.The interiorof thecarshouldbeinspected behindthe

gloveboxandpassenger sidefloorboard area,and checkthecarpetfor anysignsof moisture. The smartest wayto goaboutfindinga leakvisuallyis to firstinspectanyandall jointsin thesystemsuchas wheretheradiatorhosesconnect to theradiatorand theengine.Anotherthingto lookfor iswhitecrusty stainsthataresignsof a leakwherethecoolanthas

meratingonIt,lap3 1sadanciara10useoutsome carsarehigher.Overpressurizing thesystemcan causea ruptureina I:lose,or worse,intheradiatoror . . . . ..I. h.n+n. nrrrn nnA IIC~KILUGMUPuaJblycauseaninjuryor a burnif thecoolantis hot.Overpressurizing is normallycontrolledbytheradiatorcapwhichhasa ventvalvein it whichis openedwhenthesystemreaches it’smaximumpressure rating.Topressure testthesystem: *The pressuretest should be performedwith the enaine OFF.

LEVELCHECK

recovery tankanditsmarkingasa guideline. *Never overfill the recovery tank. A coolantlevelthatconsistently dropsis usuallya signof a small,hardto detectleak,althoughinthe worstcaseit couldbea signof aninternalengine

Fig. 189 The coolant level should be beFULLtank and LOW levels on“‘~‘_I the 1tween coo,antthe recovery

“_y “,~-1Fia. 190 A visual insaection for leaks will 1 sometimes find a leak. This photo shows evfdence of a leak at the upper radfator / hose-to-thermostat * housingjunction * /

Fig. 191 Removethe recovery tank cap to allow the pressuretester to beconnected to /the system ,, /

Fig. 192 This cooling system requires a Fig. 193 Thread the adapter onto the reto al- / 1covety tank j threadedadapterfor the recoverytank g’051p96 e’ffi1pg7 / low the pressuretester to be connected

l-40

GENERALINFORMATIONAND MAINTENANCE doesnotverifythesituation,removing thespark plugsoneata timeandchecking theelectrodes fora greenor whitetintcanverifyaninternalcoolantleak andidentifywhichcylinder(s)istheculpritandaiding yoursearchforthecauseof theleak.Ifthespark plugsappearokay,anothermethodisto usea gas analyzer or emissions tester,or oneof severalhandheldtoolsthatmostprofessional shopspossess. This toolsareusedto checkthecoolingsystemfor the presence of Hydrocarbons (HC’s)inthecoolant.

DRAIN& REFILL aiffiip98

p See figures 196 thru 205

Fig. 194Pumpthe cooling systemwith pressure, makingsure not to overpressurizethe 1system or damagecan occur

Fig 195 Watchthe gaugeon the systemand / observe the pressurereading “@‘p~1

1. Remove theradiatoror recovery tankcap. 2. Usingtheproperadapter, insertit ontothe openingandconnectthepressure tester, 3. Beginpressurizing thesystembypumping the pressure testerandwatching thegauge,whenthe maximum pressure is reached, stop. 4. Watchthegaugecarefullyandseeif thepres, sureonthegaugedrops,if it does,a leakis definitely present. 5. If thepressure stayedsomewhat stable,visually inspectthesystemfor leaks,If thepressure dropped, repressurize thesystemandthenvisually inspectthesystem. 6. If nosignsof a leakarenoticedvisually,pressurizethesystemto themaximum pressure ratingof thesystemandleavetheuressure testerconnected flsrabout30minutes. Returnafter30 minutes and Verifythepressure onthegauge,if thepressure

droppedmorethan20%,a leakdefinitelyexists,if theoressure droois lessthan20%.thesvstem , is mostlikelyokay: Anotherwaycoolantis lostis bya internalengine leak,causingtheoil to becontaminated orthe coolantto beburnedintheprocessof combustion andsentouttheexhaust. Tocheckfor oil contamination,remove thedipstickandchecktheconditionof theoil intheoil pan.If theoil is murkyandhasa whiteor beige“milkshake” lookto it,thecoolantis contaminating theoil throughaninternalleakandthe enqinemustbetorndownto findtheleak.Iftheoil Ippearsokay,thecoolantcanbeburnedandgoing jutthetailpipe.A quicktestforthisis a cloudof Nhitesmokeappearing fromthetailpipe,especially In start-up.Oncolddays,thewhitesmokewill apIear,thisis dueto condensation andtheoutside emperature, nota coolantleak.Ifthe“smoketest”

Ensure thattheengineis completely coolpriorto startingthisservice.

Neveropen, service or drain the radiator or cooling systemwhen hot; serious burnscan occurfrom the steamandhot coolant. Also, when draining enginecoolant, keep in mind that cats and dogsare attractedto ethylene glyeol antifreezeandcould drink any that is left in an uncoveredcontaineror in puddles on the ground.This will provefatal in sufficient quantities.Always drain coolant into a sealable container. Coolantshouldbe reuser mlessit is contaminatedor is several years 1. Remove therecovery tankor radiatorcap. 2, Raiseandsupportthevehicle. 3. If necessary, remove thesplashshieldfromun lerthefrontof thevehicle.

93im76

Fig. 196 The draincockis usually located at the bottom of the radiator

Fig. 197 Gently rotate the draincock counterclockwise to open the draincock . . .

Fig. 199Allow the fluid to drain until it stops and tighten the draineockhandtight

Fig. 200 Make sure to heed the caution on the radiator cap and NEVERopen the cap when the engine is hot ,, 1

Fig, 198 . _ . then allow the coolant to drain out of the radiator and cooling system

93151p27

Fig. 201 Graspthe radiator cap and rotate it counterclockwise. . .

.

GENERALINFORMATIONAND MAINTENANCE l-41

93151p18

Fig. 202 . , . to remove the cap from the radiator

Fig. 203 Pour the proper *I~ coolant mix- 1 ture into the radiator . . . 4. Allowtheengineto coolcompletely anddrain ie systemagain. 5. Repeat thisprocessuntil thedrainedwateris learandfreeof scale. 6. Flushtherecovery tankwithwaterandleave’ empty.

93151p17

Fig. 205 Be sure the rubber gasket on the radiator cap has a tight seal . . . ..I .I. 1,~ 4. Placea drainpanof sufficrenr ’ 1capacrry unaerme radiatorandopenthepetcock (drain)ontheradiator. - w&1--x3_ --mm.._... . ..-I...bind; Beforeopenrrrasuc perwcss easuy ing a plastic radiator petcock,spray it with somepenetratinglubricant. 5. Drainthecoolingsystemcompletely. 6. Closethepetcock. 7. Remove thedrainpan. 8. If necessary, installthesplashshieldunderthe L.-l venicie. 9. Lowerthevehicle. 10. Determine thecapacityof thecoolingsystem, thenproperlyrefillthesystemattherecovery tank andradiatorwitha 50/50mixtureof freshcoolantand alain oreerring mesysrem. 12. Starttheengineandallowit to idleuntilthe thermostat opens(theupperradiatorhosewill becomehot).Thecoolantlevelshouldgodown,thisis normalasthesystembleedstheair pocketsoutof the

svstem.

13. Refillthesystemwithcoolantto theproper IRVf!l ._._. 14. TurntheengineOFFandcheckfor leaks.

Neveropen, service or drain the radiator or cooling systemwhen hot; serious bumscan occurfrom the steamand hot coolant. Also, when drainingenginecoolant, keep In mind that cats and dogsare attractedto ethylene glycol antifreezeandcould drink any that is left in an uncoveredcontaineror in puddles on the ground.This will prove fatal in sufficient quantities.Always drain coolant into a sealable container.Coolantshouldbe reused unlessit is contaminatedor is several years old. 7. Fillandbleedthecoolingsystemasdescribed earner.

ThebrakemastercylinderfKm”“ll ~a~~~~r,~~ :AI~nnL.4 n-n 15 IUMLC” “IIderthehood,attached to thebrakeboosterandfirewallonthedriverssideof theenginecompartment. FLUIDRECOMMENDATIONS

Brakefluid containspolyglycol ethersand polyglycols. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. If you do get brakefluid in your eyes, flush your eyes with clean, runningwater for 15 minutes;If eye irritation persists, or if vou havetaken brakefluid internallv. IMMEDIATELY seek medical assistance.”

FLUSHING& CLEANINGTHESYSTEM 1. Drainthecoolingsystemcompletely asde: scribedearlier. 2. Closethepetcock andfill thesystemwitha coolingsystemflush(cleanwatermayalsobeused, butis notasefficient). 3. Idletheengineuntiltheupperradiatorhose getshot.

Clean, high quality brakefluid is essentialto the safe and proper operationof the brake system.Youshouldalways buy the highest quality brakefluid that is available. If the brakefluid becomescontaminated,drain and flush the system,then refill the mastercylinder with new fluid. Never reuseany brake

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 brake .a fluid.will absorb . . , moisture .*a. when .. * it.*.is exposed . .to tneatmospnere, wnrcnwnrrower1r.s oourngpomr.A container thathasbeenopenedonce,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, your eyeswith clean, runniugwaa-.. ‘Y--flush ar -l-..n-II -.._ I____ .a-11--persim, - __-PA._ rer mr 13 mmures.IT eye irriIauon or if you havetaken brakefluid internally, IMMEDIATELY seek medical assistance.

Be careful to avoid spilling any brakefluid on paintedsurfaces,becausethe paint coat will becomediscolored or damaged. Observe onthemaster ._ ._the __fluidlevelindicators cylinder; the tluldII‘eve1 shouldbebetween theMIN ..J ..I” I.... anoivw unes. Beforeremoving themastercylinderreservoircap, makesurethevehicleis restingonlevelgroundand cleanall dirtawayfromthetopof themastercylinder. Unscrew thecapandfill themastercylinderuntilthe levelis between theMIN andMAXlines. If thelevelof thebrakefluidis lessthanhalfthe volumeof thereservoir,it isadvisedthatyoucheck thebrakesystemfor leaks.Leaksina hydraulicbrake systemmostcommonly occuratthewheelcylinder andbrakelinejunctionpoints.

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

Fig. 208 Unscrew the master cylinder cap and remove it from the reservoir

Fig. 210 . . . makesure to pushthe gasket back to the normal position

Fig. 211 Carefully pour approvedbrakefluid from a fresh, sealed container directly into the reservoir

93151p29 I

93151p31

Fig. 209 If the master cylinder capgasket is swelled like such, it can be a sign of contamination. If the gasket is swelled . . .

FLUID RECOMMENDATIONS Whenaddingor changing thefluidinthesystems, usea qualitybrakefluidconforming to DOT3 specificationsfromansealedcontainer. Neverreuseold brakefluid. LEVELCHECK b See Figures 212, 213, and 214 1. Wipetheclutchmastercylinderreservoircap andthesurrounding areacleanwitha shoptowel.

Fig. 212 The clutch master cylinder has MAX(A) and MIN (B) fill lines on the reser volr

2. Inspectthefluidin thereservoir, makingsure fluidis between theMAXandtheMINmarks. 3. If required, removetheclutchmastercylinder reservoirlid.thenaddfreshfluidItofill tothetopfull markonthe’reservoir.

FLUIDRECOMMENDATIONS Whenaddingor changing thepowersteering fll$,“” Dexron@il ATF(Automatic Transmission

Be careful to avoid sfBillingany brakefluid on paintedsurfaces,bet:ausethe paint coat will becomediscoloredor damaged.

. b See Figures 215, 216, 217, and 218

4. Reinstall thelid ontotheclutchmastercylinder. 5. If removed, installtheair cleanerassembly.

Likeall othergeneralmaintenance items,check every3,OOfl miles(4,800km)or oncea month.Inspecttheoil levelinthereservoirbychecking thepo-

LEVELCHECK

GENERALINFORMATIONAND MAINTENANCE l-43 l Specialcarwashingdetergent is thebestto use.Liquiddishwashing detergent canremove wax andleavethecar’spaintunprotected andin addition someliquiddetergents contains abrasives whichcan scratchthepaint. l Birddroppings shouldberemoved fromthe paintwork assoonaspossible,otherwise thefinish maybepermanently stained.

93151p14

Fig. 215 Twist the reservoir cap, then lift up on the integral cap/dipstickassembly I I

93151p12

Fig. 216 Wipe the dipstick off, reinsert it into the reservoir and checkthe level I

Whenthe car is driven immediatelyafter being washed,apply the brakesseveral times in order to removeany moisturefrom the brakingsurfaces.

Enginecleaningagentsshouldnot be used when the engine is warm, a fire risk is present as most enginecleaningagentsare highly flammable.

sitionofthefluidagainstthemarkonthedipstick, Addfluidtothereservoirif thefluiddoesnotreach theappropriate full line.

Onmostmodels,themanufacturer doesn’tinstall lubrication fittingson lubepointsonthesteering linkageor suspension. However, if thelubrication pointdoeshavea greasefitting,lubricate withmultipurposeNLGINo.2 (Lithiumbase)grease.

CARWASHING Thecarshouldbewashed atregularintervalsto removedirt,dust,insects,andtarandotherpossibly damaging stainsthatcanadheretothepaintandmay causedamage. Properexteriormaintenance also helpsintheresalevalueof thevehiclebymaintaining its like-newappearance. Mt is particularlyimportantta frequentiy washthe car in the wintertimeto preventcorrosion, whensalt has beenusedon the roads. Therearemanyprecautions andtipsonwashing, includingthefollowing: l Whenwashingthecar,donotexposeit dodirectsunlight. . Uselukewarm waterto softenthedirtbefore youwashwitha sponge, andplentyof water,to avoid scratching. l A detergent canbeusedtofacilitatethesofteningof dirtandoil.

* Awater-soluble greasesolventmaybeusedin casesof stickydirt.However, usea washplace witha drainage separator. Drythecarwitha cleanchamoisandrememl berto cleanthedrainholesinthedoorsandrocker panels. l If equipped witha powerradioantenna, it must bedriedafterwashing.

Neverclean the bumperswith gasoline or paint thinner, always usethe sameagentas usedon the paintedsurfacesof the vehicle. Tarspotscanberemoved withtarremover or l kerosene afterthecarhasbeenwashed. l Astiff-bristlebrushandlukewarm soapywater canbeusedto cleanthewiperblades.Frequent cleaningimproves visibilitywhenusingthewipers considerably. Washoffthedidfromtheunderside (wheel l housings, fenders,etc.). l Inareasof highindustrialfallout,morefrequentwashingis recommended.

Duringhighpressurewashingthe spraynonle mustneverbe closerto the vehicle than13 inches(30cm).Do not sprayinto the locks. Whenwashingorsteamcleaningtheengine, l avoidsprayingwateror steamdirectlyontheelectricalcomponents or nearthedistributoror ignition components. Aftercleaningtheengine,thespark plugwellsshouldbeinspected forwaterandblown dryif necessary.

Automatic carwashingis a simpleandquickway to cleanyourcar,butit is worthremembering thatit is notasthorough aswhenyouyourselfcleanthe car.Keeping theunderbody cleanis vitallyimportant, andsomeautomatic washersdonotcontainequipmentfor washingtheunderside of thecar. Whendrivingintoanautomatic was,makesure thefollowingprecautions havebeentaken: l Makesureall windowsareup,andnoobjects thatyoudonotwantto getwetareexposed. l Insomecases,rotatingthesideviewmirrors incanhelpto avoidpossibledamage. l If yourcaris equipped witha powerantenna, lowerit. If yourvehiclehasa solidmounted, nonpowerantenna, it is bestto removeit, butthisis not alwayspractical.Inspect thesurroundings to reduce theriskof possibledamage, andcheckto seeif the antenna canbemanually lowered.

Most manufacturersdo not recommendautomaticcar washingin the first six monthsdue to the possibility of insufficient paint curing; a safe bet is to wait until after six monthsof ownership(when purchasednew) to use an automaticcar wash.

WAXING eBefore applyingwax, the vehicle mustbe washedandthoroughlydried. Waxingavehiclecanhelpto preserve theappearanteof yourvehicle.Awiderangeof polymer-based carwaxesareavailable today.Thesewaxesareeasy to useandproducea long-lasting, highglossfinish thatprotectsthebodyandpaintagainstoxidation, roaddirt,andfading. Sometimes, waxinga neglected vehicle,or one thathassustained chemical or naturalelement damage(suchasacidrain)requiremorethanwaxing, anda light-dutycompound canbeapplied.Forseverelydamaged surfaces, it is bestto consulta professionalto seewhatwouldberequired to repairthe damage. Waxingprocedures differaccording to manufacturer,type,andingredients, so it is bestto consult thedirections onthewaxand/orpolishpurchased.

1-44

GENERALINFORMATIONAND MAINTENANCE

INTERIORCLEANING

cleaningyou must do to maintainthe appearanceof your vehicle.Personaldiscretionis advisedhere.

Upholstery Fabriccanusuallybecleanedwith soapywateror a properdetergent.For more difficult spots causedby oil, ice cream,soda,etc., usea fabric cleaneravailable 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 fading, discoloring,etc.,as somecleanerswill only causetheseproblemsafterthey havedried Leatherupholsteryrequrresspecialcare,it canbe cleanedwith a mild soapand a soft cloth. It is recommendedthata specialleathercleanerbe usedto cleanbut alsotreatthe leathersurfacesin your vehicle. 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 special 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 dashboardattractssunlightacceleratingthe aging,fadingand possiblyevencracking the surfaces.Theseprotectantsalso attractmoredust to stick to the surfacestheytreat, Increasingthe

# See Figures219 and 220 To preventthe bumperfrom deforming,thesevehicles 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.

On most modelscoveredby this manual,the wheelbearmgsusedare sealedunits and do not require routinemaintenance.Howeveron someGalant and Mirage models,the rearwheelbearingdo require periodicrepacking.For removaland installationinstructions,pleasereferto Section7 (for rear bearings) 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 replacing. Beforehandlingthe bearings,thereare a few thingsthat you shouldrememberto do and not to do.

DOthe following: Removeall outsidedirt from the housingbefore 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 housingbeforereplacing the bearin l

Do NOTdo El, he followino:

Do not work in dirty sirroundings. Do not usedirty, chippedor damagedtools. l Do not work on woodenwork benchesor use woodenmallets. l Do not handlebearingswith dirty or moist hands. l l

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.

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 Mirage modelsrequireperiodic maintenance.A premium 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 coupling may result if the vehicleis towedwith only 2 wheelson the ground.

p See Figure 222 # See Figure 221

Whenevera vehicle is jump started,precautions must be followedIn orderto preventthe possibility of

GENERALINFORMATIONAND MAINTENANCE 1-45 SLINGTYPE

qemarks

owrng methods

. 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.

a tow truck IS used Lrftrng method for 4 wheels-Good

WHEELLIFTTYPE

Front wheels

lifted-No

good

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.

Front wheels

lifted-No

good

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.

SUNGTYPE

Rear wheels

lifted-No

good

WHEELLIFTTYPE

Towing by rope or cable-Good

cles

l l l

The front and rear wheels must rotate normally. The various mechanisms must function normally. The shift lever must be set to the neutral ~Asi&n and the ignition key must be set to

e9571g92

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 possibility of accidentalsparks,follow the procedure carefully.

NEVERhookthe batteriesup in a series circuit or the entire electrical systemwill go up in smoke. includinothe starter! Vehiclesequippedwith a dieselenginemay utilize two 12 volt batteries.If so, the batteriesare connectedin a parallelcircuit (positive terminalto positive terminal,negativeterminalto negativeterminal).

Fig.221 Towing instructions-AWD models Hookingthe batteriesup in parallelcircuit increases batterycrankingpowerwithout increasingtotal battery 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 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

Be surethat both batteriesare of the samevoltage.Vehiclescoveredby this manualand most vehicles on the roadtodayutilize a 12 volt chargingsystem. l Besurethat both batteriesare of the samepolarity (havethe sameterminal,in most casesNEGATIVE 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 batteryelectrolyte is not frozen,This can occur morereadilyin a batterythat hasbeenin a stateof discharge. l

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(withthegoodbattery)intoa positionsothejumpercablescanreach thedeadbatteryandthatvehicle’sengine.Makesure thatthevehiclesdo NOTtouch. 3. Placethetransmissions/transaxles of bothvehiclesin Neutral (MT)or P (AT),asapplicable, then firmlysettheirparkingbrakes. *ff necessaryfor safety reasons,the hazard lights on bothvehicles may be operated throughoutthe entire procedurewithout significantiy increasingthe diff icuity of jumping the dead battery. 4. Turnall lightsandaccessories OFFonboth vehicles.Makesuretheignitionswitchesonbothvehiclesareturnedto theOFFposition. 5. Coverthebatterycellcapswitha rag,butdo notcovertheterminals. 6. Makesuretheterminals onbothbatteries are cleanandfreeof corrosionor properelectricalconnectionwill beimpeded. If necessary, cleanthebatteryterminalsbeforeproceeding. 7. Identifythepositive(+)andnegative (-) terminalsonbothbatteries. 8. Connect thefirstjumpercableto thepositive (t) terminalof thedeadbattery,thenconnectthe otherendof thatcabletothepositive(t) terminalof thebooster(good)battery. 9. Connect oneendof theotherjumpercableto thenegative (−) terminalontheboosterbatteryandthefinalcableclampto anenginebolthead, alternator bracketor othersolid,metallicpointonthe enginewiththedeadbattery. Tryto picka groundon theenginethatis positioned awayfromthebatteryin orderto minimize thepossibilityof the2 clamps touchingshouldoneloosenduringtheprocedure. DONOTconnectthisclampto thenegative (-) terminalof thebadbattery.

cableonthedonorbattery.Disconnect thepositive cablefromthedonorbatteryandfinally,disconnect thepositivecablefromtheformerlydeadbattery.Be carefulwhendisconnecting thecablesfromthepositiveterminalsnottoallowthealligatorclipstotouch anymetaloneithervehicleor a shortandsparkswill occur. I $ See Figures223,224, 225,226, and 227 Yourvehiclewassuppliedwitha jackforemergencyroadrepairs.Thisjackisfinefor changing a flattireor othershorttermprocedures notrequiring youto gobeneath thevehicle.If it is usedinan

emergency situation,carefullyfollowtheinstructions providedeitherwiththejackor inyourownersmanual.Donotattempt to usethejackonanyportionsof thevehicleotherthanspecifiedbythevehiclemanufacturer.Alwaysblockthediagonally oppositewheel whenusinga jack. A moreconvenient wayof jackingistheuseof a garageor floorjack.Youmayusethefloorjackto raisethefrontof thevehiclebyplacingit underthe frontsubframe. Therearofthevehicleismosteasily raisedbyusingthelift pointsonthedriprail.All modelsareequipped withlift pointslocatedonthe mid-crossmember inthefrontanda bracketlocated onthefloorpanunderneath thetrunk. Neverplacethejackundertheradiator,engineor transaxle components. Severeandexpensive damage will resultwhenthejackis raised.Additionally, never themetalwill jackunderthefloorpanor bodywork; Whenever youplanto workunderthevehicle,you mustsupportit onjackstands or ramps.Neveruse cinderblocksor stacksof woodto supportthevehicle,evenif you’reonlygoingto beunderit fora few minutes. Nevercrawlunderthevehiclewhenit is onlybythetire-changing jackor other supported *Always position a block of wood or small rubberpad on top of the jack or jackstandto protectthe lifting point’s finish when lifting or supportingthe vehicle. Smallhydraulic, screw,or scissorsjacksaresatisfactoryfor raisingthevehicle.Drive-ontrestlesor

Be very careful to keepthe jumpercables away from movingparts (cooling fan, belts, etc.) on bothengines. 10. Checkto makesurethatthecablesarerouted awayfromanymovingparts,thenstartthedonorvehicle’sengine.Runtheengineatmoderate speedfor severalminutes to allowthedeadbatterya chance to receivesomeinitialcharge. 11. Withthedonorvehicle’s enginestill running 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 operatingproperly. 13. TurnONtheheadlights, heaterblowerand,if equipped, thereardefroster of bothvehiclesin order to reducetheseverityof voltagespikesandsubsequentriskof damage to thevehicles’electricalsystemswhenthecablesaredisconnected. Thisstepis especially important to anyvehicleequipped with computer controlmodules. 14. Carefullydisconnect thecablesinthe’reverse orderof connection. Startwiththenegative cablethat is attached to theengineground,thenthenegative

&stands also on the

Fig. 226 Place the jackstandsalso subframeto supportthe front of the

Fig. 225 The most practical place to place front of the vehicle is

Fig. 227 All modelscovered by this are equipped with lift points on t crossmemberin the front and on a

GENERAL INFORMATION ANDMAINTENANCE 1-47 rampsare also a handyand safeway to both raise and supportthe vehicle.Becarefulthough,some rampsmay betoo steepto drive your vehicleonto without scrapingthe front bottompanels.Neversupport the vehicleon anysuspensionmember(unless specificallyinstructedto do so by a repairmanual)or by an underbodypanel.

The following safetypoints cannotbe overemphasized: l Alwaysblockthe oppositewheelor wheelsto keepthe vehiclefrom rolling off the jack. l Whenraisingthe front of the vehicle,firmly apply the parkingbrake.

SCHEDULED (MITSUBISHI

MAINTENANCE DIAMANTE,

LmI,..“w.

cvctom

“,YL”,‘.

MILEAGE

INTERVAL

(x1000)

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

J

J

J

J

4

S/I

J

J

J

S/I

4

4

J

$/I

J

J

J

Fuel hoses

+ Manual transaxle oil (Galant)

connectlon & fuel tank filler

R. Replace

& MIRAGE)

7.5

4

Fvha,,rt

INTERVALS

GALANT, VEHICLE

TO BE

Ball loints &steering linkage seals Dnve belt(s)

l Whenthe drive wheelsareto remainon the ground,leavethe vehicle in gearto help preventit from rolling. l Alwaysusejackstandsto supportthe vehicle whenyou areworking underneath.Placethe stands beneaththe vehrcle’sjacking brackets Beforeclimbing underneath,rock the vehiclea bit to makesure it is firmly supported.

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