Ch 6 Chassis Electrical

UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS 6-2 BASICELECTRICALTHEORY6-2 HOWDOESELECTRICITY WORK: THEWATERANALOGY 6-2 OHM'S LAW 6-2 ELECTRICALCOMPONENTS6-2 POWERSOURCE 6-2 GROUND 6-3 PROTECTIVE DEVICES 6-3 SWITCHES&RELAYS 6-3 LOAD 6-3 WIRING& HARNESSES 6-3 CONNECTORS 6-4 TESTEQUIPMENT 6-4 JUMPERWIRES 6-4 TESTLIGHTS 6-4 MULTIMETERS 6-5 TROUBLESHOOTING ELECTRICAL SYSTEMS 6-5 TESTING 6-5 OPENCIRCUITS 6-5 SHORTCIRCUITS 6-6 VOLTAGE 6-6 VOLTAGEDROP 6-6 RESISTANCE 6-8 WIREAND CONNECTORREPAIR6-6 BATTERY CABLES 6-7 DISCONNECTING THE CABLES 6-7 AIR BAG (SUPPLEMENTAL RESTRAINT SYSTEM) 6-7 GENERALINFORMATION6-7 SERVICEPRECAUTIONS 6-7 DISARMING 6-7 REARMING 6-7 HEATING AND AIR CONDITIONING 6-7 BLOWERMOTOR 6-7 REMOVAL&INSTALLATION 6-7 HEATERCORE 6-9 REMOVAL& INSTALLATION 6-9 AIR CONDITIONINGCOMPONENTS 6-11 REMOVAL& INSTALLATION 6-11 CONTROLCABLES 6-12 ADJUSTMENT 6-12 CONTROLPANEL 6-12 REMOVAL& INSTALLATION 6-12 CRUISE CONTROL 6-13 ENTERTAINMENT SYSTEMS 6-14 RADIORECEIVER/AMPLIFIER/TAPE PLAYER/CDPLAYER 6-14 SPEAKERS 6-14 REMOVAL& INSTALLATION 6-14 WINDSHIELD WIPERS AND WASHERS 6-15 WINDSHIELDWIPERBLADEAND ARM 6-15 REMOVAL& INSTALLATION 6-15 WINDSHIELDWIPERMOTOR 6-16 _ REMOVAL&INSTALLATION 6-16 WINDSHIELDWASHERPUMP 6-17 REMOVAL&INSTALLATION 6-17

INSTRUMENTS AND SWITCHES 6-17 INSTRUMENTCLUSTER 6-17 REMOVAL&INSTALLATION 6-17 GAUGES 6-18 REMOVAL&INSTALLATION 6-18 WINDSHIELDWIPERSWITCH 6-19 REMOVAL&INSTALLATION 6-19 REARWINDOWWIPERSWITCH6-19 REMOVAL&INSTALLATION 6-19 DIMMERSWITCH 6-19 REMOVAL& INSTALLATION 6-19 . HEADLIGHTSWITCH 6-19 REMOVAL& INSTALLATION 6-19 LIGHTING 6-19 HEADLIGHTS 6-19 REMOVAL&INSTALLATION 6-19 AIMINGTHEHEADLIGHTS 6-20 SIGNALAND MARKERLIGHTS 6-21 REMOVAL&INSTALLATION 6-21 CIRCUIT PROTECTION 6-27 FUSES 6-27 REPLACEMENT 6-27 FUSIBLELINKS 6-27 CIRCUITBREAKERS 6-28 RESETTING AND/OR REPLACEMENT 6-28 FLASHERS 6-28 REPLACEMENT 6-28 WIRING DIAGRAMS 6-31

6-2 CHASSISELECTRICAL

) See Figure 1 For any 12 volt, negativeground,electricalsystem to operate,the electricitymusttravel in a complete circurt.This simply meansthat current(power)from the posibve(t) terminalof the batterymust eventually returnto the negative(-) terminalof the battery. Along the way,this currentwill travelthroughwires, fuses,switchesand components.If, for any reason, the flow of currentthroughthe circuit is interrupted, the componentfed by that circuit will ceaseto function properly. Perhapsthe easiestway to visualizea circuit is to think of connectinga light bulb (with two wires attachedto it) to the battery-one wire attachedto the negative(-) terminalof the batteryandthe otherwire to the positive (t) terminal.With the two wires touching the batteryterminals,the circuit would be completeand the light bulb would illummate.Electricity would follow a pathfrom the batteryto the bulband backto the battery.It’s easyto seethatwrth longer wires on our light bulb, it could be mountedanywhere.Further,onewire could befitted with a switch so thatthe light could beturnedon and off. The normalautomotivecircuit differsfrom this simpleexamplein two ways, Frrst,insteadof having a returnwire from the bulbto the battery,the current travelsthroughthe frameof the vehicle.Sincethe negative(-) batterycableis attachedto the frame (madeof electricallyconductivemetal),the frameof the vehiclecan serveas a groundwire to complete the circuit. Secondly,most automotivecircuits contain multiplecomponentswhich receivepowerfrom a singlecircuit. This lessensthe amountof wire neededto powercomponentson the vehicle.

HOWDOESELECTRlClTYWORK:THE WATERANALOGY Electricityis the flow of electrons-the subatomic particlesthat constitutethe outershell of an atom. Electronsspin in an orbit aroundthe centercore of

RETURN CONDUCTOR GROUND

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Fig. 1 This exampleillustrates a simple circuit. Whenthe switch is closed, power from the positive (t) battery terminal flows through the fuse and the switch, and then to the light bulb. The light illuminates and the circuit is completedthroughthe ground wire back to the negative (-) battery terminal. In reality, the two groundpointsshown in the illustration are attachedto the metal frame of the vehicle, which completesthe circuit backto the battery

an atom Thecentercore is comprisedof protons (positive charge)and neutrons(neutralcharge).Electrons havea negativechargeand balanceoutthe positive chargeof the protons.Whenan outsideforce causesthe numberof electronsto unbalancethe chargeof the protons,the electronswill split off the atomand look for anotheratomto balanceout. If this imbalanceis kept up, electronswill continueto move andan electricalflow will exist. Many peoplehavebeentaughtelectricaltheory usingan analogywith water.In a comparisonwrth waterflowing througha pipe,the electronswould be the waterand the wire is the pipe. Theflow of electricitycan be measuredmuch like the flow of waterthrougha pipe. Theunit of measurementusedis amperes,frequentlyabbreviatedas amps(a). You cancompareamperageto the volume of waterflowing througha pipe. Whenconnectedto a circuit, an ammeterWIIImeasurethe actualamountof currentflowing throughthe circuit. Whenrelatively few electronsflow througha circuit, the amperageis low. Whenmanyelectronsflow, the amperageis high. Waterpressureis measuredin units such as poundspersquareinch (psi); Theelectricalpressure is measuredin unrtscalledvolts (v). Whena voltmeteris connectedto a circuit, it is measuringthe electricalpressure. Theactualflow of electricitydependsnot only on voltageand amperage,but also on the resistanceof the circuit Thehigherthe resistance,the higherthe force necessaryto pushthe currentthroughthe circuit. The standardunit for measuringresistanceis an ohm. Resistancein a crrcuitvaries dependmgon the amountand type of componentsusedin the circuit. The main factorswhich determineresistanceare: l Material-some materialshavemore resistancethanothers Thosewith high resistanceare said to be insulators Rubbermaterials(or rubber-like plashcs)are someof the most commoninsulators used in vehiclesas they havea very high resistance to electricity Very low resistancematerialsare saidto beconductors.Copperwire is amongthe bestconductors.Silver is actuallya superiorconductorto copperand is usedin some relaycontacts,but its high cost prohibits its useas commonwiring Most automotivewiring is madeof copper. l Size-the largerthe wire size beingused,the lessresistancethe wire will have.This IS why componentswhich use largeamountsof electricityusually havelargewires supplyingcurrentto them. l Length-for a giventhicknessof wire, the longerthe wire, the greaterthe resistance.The shorterthe wire, the lessthe resistance.Whendetermining the properwire for a circuit, both sizeand lengthmust be consideredto designa circuit that can handlethe currentneedsof the component. l Temperature-with manymaterials,the higher the temperature,the greaterthe resistance(positive temperaturecoefficient).Somematerialsexhibit the oppositetrait of lower resistancewith highertemperatures(negativetemperaturecoefficient).Theseprinciples are usedin manyof the sensorson the engine

OHM'S LAW Thereis a direct relationshipbetweencurrent, voltageand resistance.The relationshipbetweencur-

rent,voltageand resistancecan besummedup by a statementknownas Ohm’slaw. Voltage(E) is equalto amperage(I) times resistance(R): E=lx R Otherforms of the formulaare R=E/Iand I=E/R In eachof theseformulas,E is the voltagein volts, I is the currentin ampsand R ISthe resistancein ohms.The basicpoint to rememberis that as the resistanceof a circuit goesup, the amountof current that flows in the circuit will go down, if voltageremainsthe same. The amountof work that the electricitycanperform is expressedas power.The unit of poweris the watt (w). The relationshipbetweenpower,voltageand currentIS expressedas: Power(w) is equalto amperage(I) times voltage (E):W=l x E This is only true for directcurrent(DC) circuits: The alternatingcurrentformula is a tad different,but sincethe electricalcircuits in mostvehiclesare DC type,we neednot get into AC circuit theory.

POWERSOURCE Poweris suppliedto the vehicle by two devices: The batteryandthe alternator.Thebatterysupplies electricalpowerduringstartingor during periods whenthe currentdemandof the vehicle’selectrical systemexceedsthe outputcapacityof the alternator. Thealternatorsupplieselectricalcurrentwhenthe engineis running Justnot doesthe alternatorsupply the currentneedsof the vehicle,but it rechargesthe battery.

The Battery In most modernvehicles,the batteryis a lead/acid electrochemicaldeviceconsistingof six 2 volt subsections(cells) connectedin series,so that the unit is capableof producingapproximately12 volts of electricalpressure.Eachsubsectionconsistsof a series of positiveand negativeplateshelda short distanceapartin a solutronof sulfuric acid and water. Thetwo typesof platesare of dissimilar metals, This setsup a chemrcalreaction,and it is this reaction which producescurrentflow from the battery whenIts positiveand negattveterminalsare connectedto an electricalload.Thepowerremovedfrom the batteryis replacedby the alternator,restoringthe batteryto its original chemicalstate.

The Alternator Onsomevehiclesthereisn’t an alternator,but a generator.ThedifferenceISthat an alternatorsupplies alternatingcurrentwhich is then changedto directcurrentfor useon the vehicle,while a generator producesdirectcurrent.Alternatorstendto be more efficientandthat is why they are used. Alternatorsand generatorsare devicesthat consist of coils of wires woundtogethermakingbig electromagnets.Onegroup of coils spins within anotherset andthe interactionof the magneticfields causesa currentto flow. This currentis then drawnoff the coils and fed into the vehicleselectricalsystem.

CHASSISELECTRliAL6-3

Theaveragevehiclecontainsmetersand metersof wiring, with hundredsof individualconnections.To protectthe manywires from damageand to keep M themfrom becominga confusingtangle,they are orI RELAY ganizedinto bundles,enclosedin plastic or tapedto-M-L SWITCH getherand calledwiring harnesses.Differenthar86 87 i nessesservedifferentpartsof the vehicle.Individual wires are color codedto helptracethemthrougha -~~ ------w-J harnesswheresectionsare hiddenfrom view. tcca6go2 Automotivewiring or circuit conductorscan be eiFig. 4 Relays are composedof a coil and a ther single strandwire, multi-strandwire or printed circuitry.Singlestrandwire hasa solid metalcore switch. These two componentsare linked and is usuallyused insidesuch componentsas altertogether so that when one operates, the nators,motors,relaysand otherdevices.Multiother operates at the same time. The large strandwire hasa core madeof manysmall strandsof wires in the circuit are connectedfrom the wire twistedtogetherinto a single conductor.Most of battery to one side of the relay switch (B+) the wiring in an automotiveelectricalsystemis made and from the opposite side of the relay up of multi-strandwire, eitheras a single conductor switch to the load (component). Smaller or groupedtogetherin a harness.All wiring is color wires are connectedfrom the relay coil to codedon the insulator,,eitheras a solid color or as a the control switch for the circuit and from coloredwire with an identificationstripe.A printed circuit is a thin film of copperor otherconductorthat the oppositeside of the relay coil to ground is printedon an insulatorbacking.Occasionally,a SWITCH

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6-4 CHASSISELECTRICAL I printedcircuitis sandwiched between twosheetsof plasticfor moreprotection andflexibility.Acomplete printedcircuit,consisting of conductors, insulating materialandconnectors for lampsor othercomponentsis calleda printedcircuitboard.Printedcircuitryis usedin placeof individualwiresor harnessesin placeswherespaceis limited,suchas behindinstrument panels. Sinceautomotive electricalsystems areverysensitiveto changes in resistance, theselectionof properlysizedwiresis criticalwhensystems arerepaired, A looseor corrodedconnection or a replacement wire thatis toosmallfor thecircuitwill addextraresistanceandanadditional voltagedropto thecircuit. Thewiregaugenumberis anexpression of the cross-section areaof theconductor. Vehicles from countries thatusethemetricsystemwill typicallydescribethewiresizeasitscross-sectional areain squaremillimeters. Inthismethod, thelargerthe wire,thegreaterthenumber. Anothercommon systernfor expressing wiresizeistheAmerican Wire Gauge(AWG)system.Asgaugenumberincreases, areadecreases andthewirebecomes smaller.An18 gaugewireis smallerthana 4 gaugewire.A wire witha highergaugenumberwill carrylesscurrent thana wirewitha lowergaugenumber. Gauge wire sizerefersto thesizeof thestrandsof theconductor, notthesizeof thecomplete wirewithinsulator.It is possible,therefore, to havetwowiresof thesame gaugewithdifferentdiameters because onemayhave thickerinsulation thantheother. It is essential to understand howa circuitworks beforetryingto figureoutwhyit doesn’t. Anelectrical schematic showstheelectricalcurrentpathswhena circuitis operating properly.Schematics breakthe entireelectricalsystemdownintoindividualcircuits. Ina schematic, usuallynoattemptis madeto representwiringandcomponents astheyphysicallyappearonthevehicle;switchesandothercomponents areshownassimplyaspossible.Faceviewsof harnessconnectors showthecavityor terminallocations in all multi-pinconnectors to helplocatetestpoints.

l Weatherproof-these connectors aremost commonly usedwheretheconnector isexposed to theelements. Terminals areprotected againstmoistureanddirtbysealingringswhichprovideaweathet-tight seal.All repairsrequiretheuseof a special terminalandthetoolrequired to serviceit. Unlike standard bladetypeterminals, theseweatherproof terminals cannotbestraightened oncetheyarebent. ‘Makecertainthattheconnectors areproperlyseated andall of thesealingringsarein placewhenconnettingleads. l Molded-theseconnectors requirecomplete replacement of theconnector if foundto bedefective. Thismeanssplicinga newconnector assembly into theharness. All splicesshouldbesoldered to insure propercontact.Usecarewhenprobingtheconnectionsor replacing terminals inthem,asit is possible to createa shortcircuitbetween oppositeterminals. If thishappens to thewrongterminalpair,it is possible todamage certaincomponents. Alwaysusejumper wiresbetween connectors for circuitchecking and NEVER probethroughweatherproof seals. l HardShell-unlikemoldedconnectors, the terminalcontactsin hard-shell connectors canbereplaced.Replacement usuallyinvolvestheuseof a specialterminalremoval toolthatdepresses thelockingtangs(barbs)ontheconnector terminalandallowstheconnector to beremoved fromtherearof the shell.Theconnector shellshouldbereplaced if it showsanyevidence of burning,melting,cracks,or breaks.Replace individualterminals thatareburnt, corroded, distortedor loose.

CONNECTORS

Pinpointing theexactcauseof troublein anelectricalcircuitis mosttimesaccomplished bytheuse of specialtestequipment. Thefollowingdescribes differenttypesof commonly usedtestequipment and brieflyexplainshowto usethemin diagnosis. Inadditionto theinformation coveredbelow,thetool manufacturer’s instructions booklet(provided with thetester)shouldbereadandclearlyunder.$ood beforeattempting anytestprocedures.

# See Figures 5 and 6

JUMPER WIRES

Threetypesof connectors arecommonly usedin automotive applications-weatherproof, moldedand hardshell.

Never usejumperwires madefrom a thinner gaugewire thanthe circuit beingtested. If

the jumperwire is of too small a gauge,it may overheatand possibly melt. Neveruse jumpersto bypasshigh resistanceloads in a circuit. Bypassingresistances,in effect, creates a short circuit. This may, in turn, cause damageand fire. Jumperwires shouldonly be usedto bypasslengthsof wire or to simulate switches. Jumperwiresaresimple,yetextremely valuable, piecesof testequipment. Theyarebasicallytestwires whichareusedto bypasssectionsof a circuit.Althoughjumperwirescanbepurchased, theyareusuallyfabricated fromlengthsof standard automotive wireandwhatever typeof connector (alligatorclip, spadeconnector or pinconnector) thatis requiredfor theparticular application beingtested.Incramped, hard-to-reach areas,it is advisable to haveinsulated bootsoverthejumperwireterminalsin orderto preventaccidental grounding. It is alsoadvisable to ineludea standard automotive fuseinanyjumperwire. Thisis commonly referred to asa “fusedjumper”.By insertinganin-linefuseholderbetween a setof test leads,a fusedjumperwirecanbeusedfor bypassing opencircuits.Usea 5 ampfuseto provideprotection againstvoltagespikes. Jumperwiresareusedprimarilyto locateopen electricalcircuits,oneithertheground(-) sideof the circuitor onthepower(+)side.If anelectricalcornponentfailsto operate, connectthejumperwirebetweenthecomponent anda goodground.If thecornponentoperates onlywiththejumperinstalled, the groundcircuitis open.If thegroundcircuitis good, butthecomponent doesnotoperate, thecircuitbetweenthepowerfeedandcomponent maybeopen. Bymovingthejumperwiresuccessively backfrom thecomponent towardthepowersource,youcan isolatetheareaof thecircuitwheretheopenis located.Whenthecomponent stopsfunctioning, orthe poweris cutoff,theopenis in thesegment of wire between thejumperandthepointpreviously tested. Youcansometimes connectthejumperwiredirectlyfromthebatteryto the“hot”terminalof the component, butfirstmakesurethecomponent uses 12voltsin operation. Someelectricalcomponents, suchasfuelinjectorsor sensors, aredesigned to operateonabout4 to5 volts,andrunning12voltsdirectlyto thesecomponents will causedamage.

TESTLIGHTS

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# See Figure 7 Thetestlightis usedto checkcircuitsandcomponentswhileelectricalcurrentisflowingthrough

Fig. 5 Hard shell (left) and weatherproof (right) connectors have replaceable terminals

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Fig. 7 A 12 volt test light is used to di% 1the presenceof voltage in a circuit

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CHASSISELECTRiCAL 6-5 voltmeterhasa positiveanda negative lead.Toavoid them.It is usedfor voltageandgroundtests.Touse damage to themeter,alwaysconnectthenegative a 12volttestlight,connectthegroundclipto a good leadto thenegative (-) sideof thecircuit(toground groundandprobewherever necessary withthepick. thegroundsideofthecircuit)andconnect Thetestlightwill illuminate whenvoltageisdetected. or nearest the positive lead to the positive(t)sideof thecircuit Thisdoesnotnecessarily meanthat12volts(orany (tothepowersourceorthenearest powersource). particular amountof voltage)is present;it only Notethatthenegative voltmeterleadwill alwaysbe meansthatsomevoltageis present. It is advisable blackandthatthepositivevoltmeter will alwaysbe beforeusingthetestlighttotouchitsgroundclip somecolorotherthanblack(usuallyred). andprobeacrossthebatterypostsor terminals to l Ohmmeter-the ohmmeter is designed to read makesurethelightis operating properly. resistance (measured in ohms)in a circuitorcomponent.Mostohmmeters will havea selectorswitch whichpermitsthemeasurement of differentrangesof Do not use a test light to probeelectronic igresistance (usuallytheselectorswitchallowsthe nition, sparkplug or coil wires. Neveruse a multiplication of themeterreadingby10,100,1,000 pick-typetest light to probewiring on comand10,000). Someohmmeters are“auto-ranging” puter controlled systemsunlessspecifically whichmeansthemeteritselfwill determine which instructedto do so. Anywire insulationthat scaleto use.Sincethemetersarepowered byaninis piercedby the test light probeshouldbe ternalbattery,theohmmeter canbeusedlikeaselftaped andsealed with silicone after testing. powered testlight.Whentheohmmeter is connected, currentfromtheohmmeter flowsthroughthecircuit Likethejumperwire,the12volttestlightis used or component beingtested.Sincetheohmmeter’s into isolateopensin circuits.But,whereas thejumper ternalresistance andvoltageareknownvalues,the wireis usedto bypasstheopento operate theload, amountof currentflowthroughthemeterdepends on the12volttestlightis usedto locatethepresence of theresistance of thecircuitor component being voltageina circuit.If thetestlightilluminates, there tested.Theohmmeter canalsobeusedto performa is poweruptothatpointinthecircuit;if thetestlight continuitytestfor suspected opencircuits.Inusing doesnotilluminate, thereis anopencircuit(no themeterfor makingcontinuitychecks,donotbe power).Movethetestlightinsuccessive stepsback concerned withtheactual resistance readings. Zero towardthepowersourceuntilthelightinthehandle resistance, or anyohmreading,indicates continuity illuminates. Theopenis between theprobeanda in thecircuit,Infiniteresistance indicates anopening pointwhichwaspreviouslyprobed. in thecircuit.A highresistance readingwherethere Theself-powered testlightis similarin designto shouldbenoneindicates a probleminthecircuit. the12volttestlight,butcontainsa 1.5voltpenlight Checksfor shortcircuitsaremadeinthesamemanbatteryinthehandle.It is mostoftenusedin placeof neraschecksfor opencircuits,exceptthatthecircuit a multimeter to checkfor openor shortcircuitswhen mustbeisolatedfrombothpowerandnormal poweris isolatedfromthecircuit(continuity test). ground.Infiniteresistance indicates nocontinuity, Thebatteryina self-powered testlightdoesnot whilezeroresistance indicates a deadshort. providemuchcurrent.A weakbatterymaynotproI’ videenoughpowerto illuminate thetestlighteven whena complete circuitis made(especially if thereis Never usean ohmmeterto checkthe resishighresistance inthecircuit).Alwaysmakesurethat tance of a componentor wire while there is thetestbatteryis strong.Tocheckthebattery,briefly touchthegroundclipto theprobe;if thelightglows voltage applied to the circuit. brightly,thebatteryisstrongenoughfor testing. l Ammeter-anammeter measures theamount *A self-poweredtest light shouldnot be of currentflowingthrougha circuitin unitscalled usedon any computercontrolledsystemor amperes oramps.Atnormaloperating voltage,most component.The small amountof electricity circuitshavea characteristic amountof amperes, transmittedby the test light is enoughto called“currentdraw”whichcanbemeasured using damagemanyelectronic automotivecompoanammeter. Byreferringto a specified currentdraw nents. rating,thenmeasuring theamperes andcomparing thetwovalues,onecandetermine whatis happening MULTIMETERS withinthecircuittoaidin diagnosis. Anopencircuit, for example, will notallowanycurrentto flow,sothe Multimeters areanextremely usefultoolfortrouammeter readingwill bezero.A damaged component bleshooting electricalproblems. Theycanbepuror circuitwill haveanincreased currentdraw,sothe chasedineitheranalogor digitalformandhavea readingwill behigh.Theammeter isalwaysconpricerangeto suitanybudget. A multimeter is avoltnettedin serieswiththecircuitbeingtested.All of meter,ammeter andohmmeter (alongwithotherfeathecurrentthatnormallyflowsthroughthecircuit tures)combined intooneinstrument. It is oftenused mustalsoflowthroughtheammeter; if thereis any whentestingsolidstatecircuitsbecause of itshigh otherpathforthecurrentto follow,theammeter readinputimpedance (usually10megaohms or more).A ingwill notbeaccurate. Theammeter itselfhasvery briefdescription of themultiietermaintestfunctions littleresistance to currentflowand,therefore, will not follows: affectthecircuit,butit will measure currentdrawonly l Voltmeter--the voltmeter is usedto measure whenthecircuitis closedandelectricityisflowing. voltageatanypointina circuit,orto measure the Excessive currentdrawcanblowfusesanddrainthe voltagedropacrossanypartof a circuit.Voltmeters battery,whilea reduced currentdrawcancausemousuallyhavevariousscalesanda selectorswitchto torsto runslowly,lightsto dimandothercompoallowthereadingof differentvoltageranges. The nentsto notoperateproperly.

Whendiagnosing a specificproblem, organized troubleshooting is a must.Thecomplexity of a modernautomotive vehicledemands thatyouapproach anyproblemina logical,organized manner. There arecertaintroubleshooting techniques, however, whicharestandard: l Establish whentheproblemoccurs. Does the problemappearonlyundercertainconditions? Were thereanynoises,odorsor otherunusualsymptoms? Isolatetheproblemarea.Todothis,makesomesimpletestsandobservations, theneliminate thesysternsthatareworkingproperly.Checkfor obvious problems, suchasbrokenwiresandlooseor dirty connections. Alwayschecktheobviousbeforeassumingsomething complicated isthecause. l Testfor problems systematically to determine thecauseoncetheproblemareais isolated.Areall thecomponents functioning properly? Istherepower goingto electricalswitchesandmotors.Performing careful,systematic checkswill oftenturnupmost causesonthefirstinspection, withoutwastingtime checking components thathavelittleor norelationshipto theproblem. l Testall repairsaftertheworkis doneto make surethattheproblemisfixed.Somecausescanbe tracedto morethanonecomponent, soa carefulverificationof repairworkis important in orderto pickup additional malfunctions thatmaycausea problem to reappear or a differentproblem to arise.A blown fuse,for example, isa simpleproblemthatmayrequiremorethananotherfuseto repair.If youdon’t lookfor a problem thatcauseda fuseto blow,a shortedwire(forexample) maygoundetected. Experience hasshownthatmostproblems tend to betheresultof a fairlysimpleandobvious cause,suchas looseor corrodedconnectors, bad groundsor damaged wireinsulationwhichcausesa short.Thismakescarefulvisualinspection of componentsduringtestingessential to quickandaccuratetroubleshooting. -

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OPENCIRCUITS # See Figure 8

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6-6 CHASSISELECTRICAL Thistestalreadyassumes theexistence of anopen inthecircuitandit is usedto helplocatetheopen portion 1. Isolatethecircuitfrompowerandground. 2. Connect theself-powered testlightor ohmmetergroundclipto thegroundsideofthecircuitand probesectionsof thecircuitsequentially. 3. If thelightis outorthereis infiniteresistance, theopenis between theprobeandthecircuitground. 4. If thelightis onor themetershowscontinuity, theopenis between theprobeandtheendof thecircuittowardthepowersource.

SHORTCIRCUITS *Never use a self-poweredtest tight to perform checksfor opensor shortswhen power is appliedto the circuit undertest. Thetest linht m.3.m.

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1. Isolatethecircuitfrompower.,.*. andground. , 2. Connect theself-powered ’ ugntoronmmeted tergroundclipto a goodgroundandprobeanyeasyto-reachpointinthecircuit. 3. If thelightcomesonor thereis continuity, thereis a shortsomewhere in thecircuit. 4. Toisolatetheshort,probea testpointateither endof theisolatedcircuit(thelightshouldbeonor themetershouldindicatecontinuity). 5. Leavethetestlightprobeengaged andsequentially openconnectors or switches, remove parts,etc.untilthelightgoesoutor continuityis broken 6. Whenthelightgoesout,theshortis between thelasttwocircuitcomponents whichwereopened, \rnl -r*l?IVuLlHbt Thistestdetermines voltageavailable fromthe batteryandshouldbethefirststepinanyelectrical troubleshooting procedure aftervisualinspection, Manyelectricalproblems, esoeciallv oncomouter controlled systems, canbecausedbya lowstateof chargeinthebattery.Excessive corrosionatthebatterycableterminals cancausepoorcontactthatwill preventpropercharging andfull batterycurrentflow, 1. Setthevoltmeter selectorswitchto the20V position. 2. Connect themultimeter negative leadtothe h*+tnn,‘n nnn,,,;~,,. , \ ..^,a^-L.--:^^l allU --_I‘I---!I?... MW~ 3 IlG~dllYt: t-1 pUSI UI Lellllllldl lilt, pUSlIlVe leadto thebattery’s positive(t) postor terminal. 3. TurntheignitionswitchONto providea load, 4. Awellchargedbatteryshouldregisterover12 volts.If themeterreadsbelow115_vnlts _.-,tha . hq*anr powermaybeinsufficient to operate theeler systemproperly.

VOLTAGEDROP # See Figure 9 Whencurrentflowsthrougha load,thevoltagebeyondtheloaddrops.Thisvoltagedropis duetothe resistance createdbytheloadandalsobysmallresistances createdbycorrosionattheconnectors and damaged insulationonthewires.Themaximum allowablevoltagedropunderloadis critical,especially

Fig. 10 Checkingthe resistanceof a coolant temperature sensor with an ohmmeter. Readingis 1.04 kilohms if thereis morethanoneloadin thecircuit,sinceall voltagedropsarecumulative. 1. Setthevoltmeter selectorswitchtothe20volt ^,.^X^.. pJbl1IUII. 2. Connect themultimeter negative leadto a goodground. 3. .Operate thecircuitandcheckthevoltageprior tothehrstcomponent (load). 4. Thereshouldbelittleor novoltagedropinthe circuitpriorto thefirstcomponent. If a voltagedrop exists,thewireor connectors inthecircuitaresusWY.+ thefirstcomponent inthecir.5. Whileoperating

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positivemeterleadandobservethevoltagereadings. Asmallvoltagedropshouldbenoticed.Thisvoltage dropis causedbytheresistance of thecomponent. 6. Repeat thetestfor eachcomponent (load) de .-IL.‘.. .I uuwnmecrrcun. 7. If a largevoltagedropis noticed,thepreceding component, wireor connector is suspect.

# See Figures 10 and 11 Fig. 11 Sparkplug wires can be checke; Neveruse an ohmmeterwith power applied to the circuit. Theohmmeteris designedto operateon its 0wn power supply. Thenormal 1^ . . . systemvoltage could damii! volt.. electrical age the meter! 1. Isolatethecircuitfromthevehicle’spower CnlOrAn 2. Ensure thattheignitionkeyis OFFwhendisconnecting anycomponents orthebattery. 3. Wherenecessary, alsoisolateat leastoneside of thecircuitto bechecked, in orderto avoidreading parallelresistances. Parallelcircuitresistances will alwaysgivea lowerreadingthantheactualresistance of eifhy n<+hnhmnnh-r GI “I II It: “I a lb1 It?>. 4. Connect themeterleadsto bothsidesof the circuit(wireor component) andreadtheactualmeasuredohmsonthemeterscale.Makesuretheselectorswitchis setto theproperohmscalefor thecircuitbeingtested,to avoidmisreading theohmmeter testvalue. I)““IW.

Almostanyonecanreplacedamaged wires,as longasthepropertoolsandpartsareavailable. Wire andterminals areavailable to fit almostanyneed. Eventhespecialized weatherproof, moldedandhard shellconnectors arenowavailable fromaftermarket cl mdicm ““yp,8w’“. Besuretheendsof all thewiresarefittedwiththe properterminalhardware andconnectors. Wrapping a wirearounda studis nevera permanent solution andwill onlycausetroublelater.Replace wiresoneat atimeto avoidconfusion. Alwaysroutewiresexactly thesameasthefactory. *If connectorrepair is necessary,only attempt it if you havethe propertools. Weatherproof and hard shell connectorsrequire spectal tools to release the pins inside the connector.Attemptingto repair these connectorswith conventionalhandtools will damagethem.

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CHASSISELECTRICAL 6-7

Whenworkingonanyelectricalcomponent onthe vehicle,it is alwaysa goodideato disconnect the negative (-) batterycable.Thiswill preventpotential damage to manysensitiveelectricalcomponents suchasthePowertrain ControlModule(PCM),radio, alternator, etc. *Any time you disengagethe battery cables, it is recommendedthat you disconnectthe

negative(-) battery cable first. This will prevent your accidentallygroundingthe positive (+) terminal to the bodyof the vehicle when disconnectingit, therebypreventingdamage to the abovementionedcomponents. Beforeyoudisconnect thecable(s), firstturnthe ignitiontotheOFFposition.Thiswill preventa draw onthebatterywhichcouldcausearcing(electricity tryingto grounditselfto thebodyof a vehicle,just likea sparkplugjumpingthegap)and,of course,

damaging somecomponents suchasthealternator diodes. Whenthebatterycable(s)arereconnected (negativecablelast),besureto checkthatyourlights, windshield wipersandotherelectrically operated safetycomponents areall workingcorrectly.If your vehiclecontainsanElectronically TunedRadio(ETR), don’tforgetto alsoresetyourradiostations.Dittofor theclock.

SERVICE PRECAUTIONS

l Withtheinflatormoduleonthebench,never placeanythingonor closetothemodulewhichmay bethrownintheeventof anaccidental deployment.

b See Figures 12,13, and 14

DISARMING # See Figure 15

Fig, 14 Be sure to observe any precaution labels on the vehicle regarding the air bag system

Fig. 12 To preventpersonalinjury, ALWAYS carry a-live -ah bag fac!ng away from you in 1 1case of accidental deployment

place a live airbag with the cover facing up in case of accidental deployment

REMOVAL &INSTALLATION Mirage b See Figures 16, 17, and 18

* Somevehicles are equippedwtth an air bag -I-- ‘-------- sLe inaiscl Knownas I11 Supplemental fiatable Restraint(SIR)or SuouiementaiFiea

1. Beforeservicingthevehicle,refertotheprecautionsinthebeginning of thissection. 2. Positionthefrontwheelsin thestraight-ahead positionandplacethekeyintheLOCKposition.Removethekeyfromtheignitionlockcylinder. 3. Disconnect thenegative batterycableandinsulatethecableendwithhigh-quality electrical tape or similarnon-conductive wrapping. 4. Waitatleastoneminutebeforeworkingonthe vehicle.Theairbaasvstemis desianed to retain enoughvoltagetodeploytheair bagfora shortperiodof timeafterthebatteryhasbeendisconnected.

-.-‘-syr1em,

3,holdsee bagand

trimcoverarepointedaway. l Placetheinflatormoduleona benchor other surfacewiththebagandtrimcoverfacingup.

1. Disconnect thenegative batterycable. 2. Remove therightsideinstrument panelundercover panel. 3. Remove thegloveboxpanelandframe. 4. Detach theblowermotorelectricalconnection. 5. Disconnect andremove theresistor. 6. Disconnect theblowermotorventilation tube.

1. Connect theneoative batterscable.turntheia-

7!r!3PG93

Fig. 15 insulate the negative battery cable .I to prevent accidental deploymentof the air bag

7. Remove theblowermotormounting bolts,removetheblowermotor. To install: 8. Positiontheblowermotorandinstallthe mounting bolts. 9. Attachtheblowermotorelectricalconnection. 10. Connect theblowermotorventilation tube.

6-8 CHASSISELECTRICAL

1 2 3 4 5

Under cover 4993 Glove box corner pane, Glove box frame RBSlStOr

1

models,

93156~23

Fig. 16 Explodedview of the blower motor andrelated components-1990-92 Mirage

Fig. 17 Explodedview of the blower motor andrelated components-1993-96 Mirage

Fig. 18 Explodedview of the blower motor and related components-1997-00 Mirage

11. Installthe resistorand the glove box assem-

4. Removethe dashundercover.Notethat some ot the screwsand retainersare concealedbehind small coverswhich must be removed. 5 Removethe heaterduct for the passenger’s feet. 6. Carefullydetachthe lo-pin connectorrunning to the backof the glove box frame.Disconnect the single wire (glove box switch)runningto the back of the glove box frame. 7. Removethe four bolts holdingthe glove box frameand removethe frame. 8. Disconnectthe small air hoserunningfrom the fan motorto the fan housing.

9. Detachthe electricalconnectorfrom the fan motor. 10. Removethe threesmall bolts holdingthe motor to the housing,thenremovethe motor and fan.

W

12. Installthe right side instrumentpanelundercover panel. 13. Connectthe negativebatterycable.

1990-93 Galant # See Figure 19 1. Disconnectthe negativebatterycable. 2. Removethe glove box stopper. 3. Swingthe glove box door openall the way and removethe bottomretaininascrews.Removethe glovebox

--.

8

To install: 11. Checkthe insideof the casecarefully:any debris cansnagthe fan and causenoiseor poor airflow. 12. Inspectthe gasket(packing)underthe motor and replaceit if crackedor damaged.Reinstallthe fan and motorto the caseand Installthe retainingbolts. 13. Attachthe air hoseand electricalconnector. 14. Installthe glove box frameand connectboth the lo-pin and sinqle pin connectorsproperly. 15. Installthe heaterduct 16. Installthe undercover,taking careto insureit is in placeand all the fastenersare secure. 17. Installthe glove box and its stopper. 18. Connectthe negativebatterycable.

1994-00 Galant ) See Figures20 and 21 1. Disconnectthe negativebatterycable. 2. Removethe threeinstrumentpanelundercover mountingscrewsand removethe cover. 3 If equippedwith A/C, unplugand removethe compressormodule. 4. Detachthe electricalconnectorfrom the fan motor. 5. Removethe threesmall bolts holdingthe motorto the housingand removethe motor and fan.

12’


1990 models>

1. ‘2 3 4 5 6 7 8 9

stopper Glove box Under cover Foot shower duct Connector for MFI control relay and connector for glove box swtch Glove box frame Cowl side trim Engine control module Evaporator lnstallatlon bolts, nuts and clips duct mounting clips Kvehlcles wthout condltionlng>

,

Hose Blower assemblv Blower motor assembly Packtng ;;c, tnstallatlon nut Blower Blower

motor and fan assembly case

or air

:ig. 19 Explodedview of the blower motor and related components-1990-93 Galant

; y&M 3 lulomafs corn-r .“eM *nn mi 1 slmhn.m”m,n

ECU

5 mM ,RC m .3RcuP :2%brtr-Mbi&C> 8 ~y~tipJ*-m-=%9 md S sa*n”nlUSW 931561

Fig. 20 Explodedview of the blower mote andrelated comoonents-1994-98 Galan

CHASSISELECtRldAL6-9 15. Installthe instrumentpanelpassengersside lowerbracket. 16. Installthe PCM, mountingbracketand MFI control relay. 17. Installthe inside/outsideair changeover dampermotor assembly. 18. Installthe screwbelowthe glove box assembly, and the entireglove box unit. 19. Installthe lower instrumentpaneland shower duct. 20. Connectthe negativebatterycableand check the entireclimatecontrol systemfor properoperation. 93156g27

Fig. 21 Explodedview of the blower motor andrelated components-1999-00 Galant

REMOVAL& INSTALLATION

To install: 6. Checkthe insideof the casecarefully;any debriscan snagthe fan and causenoiseor poor airflow. 7. Installthe blowermotor, in the blowercase and securewith the threemountingbolts, 8. Attachthe blowermotor electrlcalconnector, 9. Installthe compressormodule,if removed. 10. Installthe undercover,takmgcareto insureit is in placeand all the fastenersare secure. 11. Connectthe negativebatterycable.

Diamante u See Figures 24 and25 1. Disarmthe air bag Referto the procedure earlier in this section. 2. Dramthe cooling systemand disconnectthe heaterhosesfrom the core tubes.Plugthe hoses. 3. Removethe passengerside undercover. 4. Removethe right side foot showerduct.

5. To removethe console,removethe ashtray and removethe revealedscrew.Thenremovethe 4 screwsfrom the sidesof the assemblyand remove. 6. Removethe decorativeplugsfrom the drlver’s kneeprotector.Removethe revealedscrews,the kneeprotectorassemblyand the protectorsupport bracket. 7. Removethe steeringcolumncovers. 8. Removethe glove box striker,glove box, glove box outercasingand the screwbelowthe assembly. 9. Removethe radio bezeland the stereoentertainmentsystem. 10. Removethe climatecontrolsystemcontrol head. 11. Removethe cup holder. 12. Removethe speakersfrom the top of the instrumentpanel. 13. Removethe instrumentclusterbezelandthe instrumentcluster. 14. To removethe speedometercableadapter from the instrumentpanel,first disconnectthe speedometercablefrom the transaxle.Thenunlock the adapterfrom the instrumentpanel,pull the speedometercableslightly inwards,and removethe adapter 15. Detachall steeringcolumn connectors,removethe column mountingbolts,and allowthe steeringcolumnto reston the front seat.Bevery

Diamante u See Figures22 and 23 1. Disarmthe air bag,as outlinedearlierin this section.

Wait at least 1 minutebefore working on the vehicle. Theair bagsystemis designedto retain enoughvoltage to deploythe air bag for a short period of time even after the battery has beendisconnected. 2. Removethe passengerside lower instrument paneland showerduct, 3. Removethe glove box striker,glove box, glove box outercasingand the screwbelowthe assembly. 4. Removethe evaporatorcasemountingbolt and nut. 5. Removethe inside/outsideair changeover dampermotor assembly. 6 Removethe PCM, mountingbracketand MFI control relay. 7. Removethe instrumentpanelpassengers side lower bracket. 8. Removethe moldedhosefrom the blowerassembly. 9. Removethe blowermotor assembly. 10. Removethe fan retainingnut andfan in order to replacethe motor,

Fig. 23 Explodedview of the blower motor and related components-1997-00 Dia-

To install: 11. Checkthat the blowermotor shaftis not bent and that the packingis in good condition, Cleanall partsof dust,etc. 12. Assemblethe motor and fan. Installthe blowermotor thenattachthe connector. 13. Installthe moldedhose.Installthe duct or undercover. 14. Installthe evaporatorcasemountingbolt and nut.

Fig.25 Heatercore andrelated components explodedview-1997-00 Diamante

640

CHASSISELECTRICAL

carefulnotto allowanything to comein contactwith theair bagunit. 16. Remove thegloveboxlampassembly. 17. Remove theremaining instrument panel mounting screwsandremove theinstrument panel fromthevehicle. 18. Remove theleftsidefootshowerductwork, lapcoolerductandcenterduct. 19. Remove thefrontandcenterreinforcements andcenterstayassembly. 20. Remove theairdistribution ductassembly. 21. Detachall connectors fromheater-boxmounted items. 22. Remove theheaterboxmounting screwsand nut,thenremove theunitfromthevehicle. 23. Disassemble onaworkbench. Remove the heatercorefromtheheatercase. To install: 24. Thoroughly cleananddrytheinsideof the caseandinstalltheheatercoreandall relatedparts. 25. Installtheheaterunitto thevehicleandinstall themounting screwsandnut.Besuretheevaporator caseandheatercasearefittedtogetherproperly.Attachall connectors to heater-box-mounted items. 26. Installtheairdistribution ductassembly. Installthefrontandcenterreinforcements andcenter stayassembly. 27. Installthecenterduct,lapcoolerductandleft sidefootshowerduct. 28. Installtheinstrument panelandmounting screws. 29. Installthegloveboxlampassembly. 30. Securethesteeringcolumnandattachall steeringcolumnconnectors. 31. Installthespeedometer cableadaptertothe instrument panel. 32. Installtheinstrument clusterandtheinstrumentclusterbezel. 33. Installthespeakers to thetopof theinstrumentpanel. 34. Installthecupholder. 35. Installtheclimatecontrolsystemcontrol head. 36. Installthestereoentertainment systemand bezel. 37. Installthescrewbelowthegloveboxassembly,andtheentiregloveboxunit. 38. Installthesteeringcolumncovers. 39. Installthekneeprotector supportbracket, the protector andthedecorative plugs. 40. Installtheconsoleandtheashtray.

41. Installtherightsidefootshowerduct. 42. Installthepassenger sideundercover. 43. Connect theheaterhosesto thecoretubes. 44. Fillthecoolingsystem. 45. Connect thenegative batterycableandcheck theentireclimatecontrolsystemfor properoperation andleaks.

Fig. 26 Explodedview of the heatercore and related components-1990-93 Galant

:IQ. 27 Explodedview of the heater core and -elatedcomponents-1994-98 Galant

Galant # See Figures 26, 27, and 28 1. Disconnect thenegative batterycable. 2. Disarmtheair bag.Referto theprocedure earlierinthissection. 3. Withtheenginecold,setthetemperature controlleverto theFULLHOTposition.Draintheenginecoolant. 4. Disconnect thecoolanthosesrunningtothe heaterpipesatthefirewall. 5. Remove thecenterconsole. 6. Remove theheatercover. 7. Remove thesteering wheel. 8. Remove thesmallsteeringcolumnpanel. 9. Remove theundercover. 10. Remove theupperandlowersteeringcolumn coversanddetachthewiringconnectors. 11. Remove theinstrument clusterhood. 12. Remove themounting screwsfortheinstrumentcluster. 13. Pulltheclusteroutanddisconnect the speedometer adapterbehindthecluster.Remove the cluster. 14. Remove thefloorconsoleandtheunderframe. 15. Disconnect andremovetheairduct,lap heaterduct,sidedefroster ductandtheverticaldefrosterduct. 16. Remove theglovebox. 17. Remove theashtrayandits mount.Disconnectthelightwiringbeforeremoving. 18. Remove theheatercontrolfaceplate. 19. Remove theheatercontrolpanelanddisconnectitsharness. 20. Remove therightsideundercover fromthe instrument panelandremovetheunderframe. 21. Ontheleftsideof theinstrument panel,removethefuseboxcoverandunboltthefuseboxfrom theinstrument panel. 22. Remove thefrontpillar(windshield pillar trim)fromeachpillar. 23. Remove thekickpaneltrimfromeachside.

24. Loosenthedefroster garnish,disconnect the photosensorwiringandremove thegarnishanddefrostergrille. 25. Remove thegrilleforthecenterair outlet. 26. Remove theboltsholdingthesteeringcolumnbracketto theinstrument panel. 27, Remove thecenterreinforcement bracket. 28. Ontheleftside,removetheretainingnuts holdingtheinstrument panelunderframe to thebody. 29. Ontherightside,removetheunderframe retainingbolts.Notethattheboltsaredifferent; the flangedboltmustbecorrectlyreinstalled. 30. Remove theremaining nutsandboltsholding theinstrument panel.Astheinstrument panelcomes loose,labelanddisconnect thewiringharnesses. Carefullyremove theinstrument panel. 31. If equipped withautomatic climatecontrol, remove thepowercontrolunitonthelowerfrontof theheaterunit. 32. Remove theductjointbetween theheaterunit andevaporator case(withairconditioning) or blower assembly (heateronly). 33. Carefullyseparate thevacuumhoseharness attheconnector. 34. Remove theheaterunitfromthevehicle. 35. Toremovetheheatercore,firstremovethe coverfromthewatervalve.Disconnect thelinksand removethevacuum actuator. 36. Remove theclampsandslidetheheatercore outof thecase.Remove thewatervalveafterthecore is removed. 37. Withthecaseremoved, theheatercoremay bechanged afterthewatervalveis removed. Remove theplasticcover,remove theclampsandhoseand remove thewatervalve. To install: 38. Thoroughly cleananddrytheinsideofthe case.Installthecoreandthewatervalve,usingnew hoseorclamps. 39. Installthevacuum actuatorandtheconnectinglink.Putthecoveronthewatervalve. 40. Installtheheaterunitandtightenthemountingbolts. 41. Carefully attachthevacuumhoseconnector to thevacuumharness. Makecertainthehosesmate firmlyandsecurely. 42. Installtheheatercover,theninstallthecenter console. 43. Installtheductjointbetween heaterandevaporatoror blower. 44. Installthepowercontrolunitandcarefully connectthelinksandrods.

Fig. 28 Explodedview of the heater core and related components-1999-00 Galant

CHASSISELECTRICAL 6-11 45. Installthe heaterhosesunderthe hood. 46. Installthe mstrumentpanelby reversingits removalprocedure. 47. Installthe centerconsole. 48. install the upperand lowersteeringcolumn covers. 49. Installthe centerpanelundercover. 50. Installthe small column panel. 51. Installthe steeringwheel. 52. Fill the cooling system. 53. Connectthe negativebatterycableand check the entireclimatecontrol systemfor properoperation and leaks.

Mirage # See Figures 29, 30, and 31 1. Disconnectthe negativebatterycable. 2. Drainthe cooling systemand disconnectthe heaterhoses. 3. Removethe front seatsby removingthe covers over the anchorbolts,the underseattray,the seat belt guide ring, the seatmountingnutsand bolts and disconnectthe seatbelt switchwiring harnessfrom underthe seat.Thenlift out the seats 4. Removethe floor consoleby first taking out the coin holderand the consolebox tray. Removethe remotecontrol mirror switch or cover.All of these itemsrequireonly a plastictrim tool to carefullypry themout. 5. Removethe rearhalf of the console. 6. Removethe shift leverknob on manualtransmission vehicles. 7. Removethe front consolebox assembly. 8. A numberof the instrumentpanelpiecesmay be retamedby pin typefasteners.Theymay be removedusing the following procedure: a. Pressdown on the centerpin with a suitable blunt pointedtool. Pressdown a little more than l/re in. (2mm) to releasethe clip. Pull the clip outwardto remove it. b. Do not oush the oin inwardmore than necessarybecauseit may damagethe grommet or the pin may fall in if pushedin too far. Once the clips are removed,use a plastic trim stick to pry the piece loose. 9. Removeboth lowercowl trim panels(kick panels). 10. Removethe ashtray. 11. Removethe centerpanelaroundthe radio. 12. Removethe sunglasspocketat the upperleft side of paneland the side panelinto which it mounts, 13. Removethe drivers side kneeprotectorand the hood releasehandle. 14. Removethe steeringcolumntop and bottom covers. 15. Removethe radio. 16. Removethe glove box strikerand box assembly. 17. Removethe instrumentpanellowercover,2 small piecesin the center,by pullingforward. 18. Removethe heatercontrol assemblyscrew. 19. Removethe instrumentclusterbezeland pull out the Qaugeassembly. 20. Removethe speedometeradapterby disconnectingthe speedometercableat the transaxle pullingthe cableSightlytowardsthe vehicleinterior and giving a Slighttwist on the adapterto releaseit. 21. Inserta small flat-tippedtool to openthe tab on the QauQeclusterconnector.Removethe harness connectors.

Fig. 29 Explodedview of the heater core and related components-1990-92 Mirage

93l%Q%

Fig. 30 Heater core and related components-1993-96 Mirage

Fig.31 Explodedview of the heatercore and related components-1997-00 Mirage

22. Remove,by pryingwith a plastictrim tool, the right side speakercover andthe speaker,the upper side defrostergrilles and the clock or plugto gain accessto someof the instrumentpanelmountingbolts. 23. Lowerthe steeringcolumn by removingthe bolt and nut. 24. Removethe instrumentpanelbolts andthe instrumentpanel. 25 Drsconnectthe air selection,temperatureand modeselectioncontrol cablesfrom the heaterbox and removethe heatercontrol assembly. 26. Removethe connectorfor the MFI control relay. 27. Removebothstampedsteelinstrumentpanel supports. 28. Removethe heaterductwork. 29. Removethe heaterbox mountingnuts. 30 Removethe automatictransmissionELCcontrol box. 31. Removethe evaporatormountingnutsand clips. 32. With the evaporatorpulledtowardthe vehicle interior,removethe heaterunit. Becarefulnot to damagethe heatertubesor to spill coolant. 33. Removethe cover platearoundthe heater tubesand the core fastenerclips. Pull the heatercore

from the heaterbox, beingcarefulnot to damagethe fins or tankends. I

To install:

34. Thoroughlycleanand dry the insideof the case.Installthe heatercoreto the heaterbox. Install the clips and cover, 35. Installthe evaporatorandthe automatictransmission ELCbox. 36. Installthe heaterbox and connectthe duct work. 37. Connectall wires and control cables, 38. Installthe instrumentpanelassemblyand the consoleby reversmgtheir removalprocedures. 39 Installthe seats. 40. Refillthe cooling system. 41. Connectthe negativebatterycableand check the entireclimatecontrol systemfor properoperation Checkthe systemfor leaks.

REMOVAL&INSTALLATION Repairor serviceof air Conditioningcomponents is not coveredby this manual,becauseof the risk of

6-12 CHASSISELECTRICAL personalinjuryor death,andbecause of thelegal ramifications of servicingthesecomponents without theproperEPAcertification andexperience. Cost, personalinjuryor death,environmental damage, and legalconsiderations (suchasthefactthatit isa federalcrimeto ventrefrigerant intotheatmosphere), dictatethattheA/Ccomoonents onyourvehicle shouldbeservicedonly’bya MotorVehicleAirConditioning(MVAC)trained,andEPAcertifiedautomotivetechnician. *If your vehicle’s A/CsystemusesR-12refrlgerant and is in needof recharging,the AK systemcan be convertedover to R-Ma refrigerant (less environmentallyharmful and expensive).Referto Section1 for additional informationon R-12to R-134aeonversions, and for additional considerations dealing with your vehicle’s A/Csystem.

ADJUSTMENT

\

1. Disconnect thenegative batterycable.Remove theglovebox,if necessary, 2. Movethemodeselectionleverto theDEFROST position.Movethemodeselectiondamper leverFULLYINWARD andconnectthecableto the lever.Adiustasrequired. 3. M&e tht3temperature controlleverto its HOlli 5STposition.Movetheblendairdamperlever FULL’t ’ DOWNWARD andconnectthecableto the lever.i4djustasrequired.

Fig. 32 Usinga suitable prytool, release the

4. Movetheairselectioncontroileverto theRECIRCposition.Movetheair selectiondamper FULLY INWARD andconnectthecableto thelever.Adjustas required.

REMOVAL&INSTALLATION ti See Figures32 thru 45 1. Disconnect thenegative batterycable. 2, Unfasten theretainingclipsandremove the centertrimpanel. 3. Remove theradioltape and/orCDplayerassembly, 4. Remove thecontrolassembly asfollows: a. Remove theretainingscrew(s). b. Presstheleverpinto disconnect theair outletchangeover dampercable. *The bossand clampare neededfor the assembly line dluringfactory installation, however they are not necessaryfor service prodedures. n dIIal, Cnanithebossandclampwitha pairof b,. nippers,to removetheheatercontrolassembly fromthevehicle. To install: 5. Installthecontrolpanel,asfollows: a. Setthetemperature controlknobonthe panelto MAXHOT.. b. Settheair mixdamperleverattheupper partof theheaterunitto theMAXHOTposition, thenattachthecableto theleverpin.

then remove the shi automatic transaxles

C. Pushtheoutercablein thedirectionof the arrowsothatthereis no looseness, thensecure withtheclip. d. Settheknobfor theair outletchangeover onthecontrolto theDEFposition. e. Settheair outletchangeover damperlever of theheaterunitto theDEFposition,thenattach thecableto theleverpin. f. Pushtheoutercablein thedirectionof the arrowso thereis no loosen&s,thensecureit withtheclip. g. Settheleverfor theinside/outside air changeover on theheatercontrolassemblv to the air recirculation position. h. Settheinside/outside air changeover damperleverof theblowerunitto theair recirculationposition(withtheinside/outside air changeover damperlevertouchedto thestopper of theblowercase),thenattachthecableto the leverpin. i. Pushtheoutercablein thedirectionof the arrowso thatthereis no looseness, thensecure it withtheclip. j. Properlypositionthecontrolassembly and securewiththeretainingscrew(s). 6. Installthestopper. 7. Connect thenegative batterycableandcheck theclimatecontrolsystemfor properoperationbeforeinstallingtheremaining components. 8. Installtheradio/tape and/orCDplayerassembly. 9. Installthecentertrimoanel,makinasurethe clipsareengaged properly. 10. Connect thenegative batterycable.

Fig. 34 Removethe two center trim panel retaining screws . . .

93156p27

Fig. 35 . . . then remove the center trim panel from the vehicle

Fig 36 Removethe radio retaining screws /(twiperside)... y

Fig. 37, . . then slide the radio chassisand bracket out of the instrumentDane1

CHASSISELECTRICiL6-13 .

9315fip14

Fig. 38 Pull the radia far enoughout to access the electrical connectors. . .

Fig. 39. . . then detachthe connectorsfrom I the rear of the radio

Fig. 41 Removethe heater control panel re-

Fig. 42 Removethe control cable from the

Cruisecontrolisa speedcontrolsystemthat maintains a desiredvehiclespeedundernormaldrivingconditions. However, steepgradesupor down maycausevariationsintheselected speeds. The ! electronic cruisecontrolsystemhasthecapabilityto cruise,coast,resume speed,accelerate, “tap-up”and “tap-down”. Themainpartsof thecruisecontrolsystemarethe functional controlswitches, speedcontrolassembly,

actuator, intermediate link,auto-cruise controlmoduleassembly, speedsensor,andtherelease switches. Depending upontheyearand/ormodelof your vehicle,thecruisecontrolsystemis eithervacuumor electronically controlled. Thecruisecontrolmodule assembly containsa lowspeedlimitwhichwill preventsystemengagement below25mph(40km/h). Themoduleis controlledbythefunctional switches

I Fig. 40 Finally, detach the antenna cable and remove the radio from the vehicle

Fig 43 Removethe control cable from the bleid door g3156p1g /

locatedona leveronthesteeringcolumnor steering wheelandontheinstrument panel. Thereleaseswitches aremounted onthe brake/clutch/accelerator pedalbracket. Whenthe brakeor clutchpedalis depressed, thecruisecontrol systemis electrically disengaged andthethrottleis returned to theidleposition.

6-14 CHASSISELECTRICAL CRUISE CONTROL TROUBLESHOOTING Problem WIII not hold proper speed

Posable Cause 1Incorrect cable adjustment F.~. _I.~_- 1L .-AL‘- I. I -

trrnarng Inrome nnKage

\

Cruise intermittently

cuts out

Leaking vacuum servo diaphragm Leaking vacuum tank Faulty vacuum or vent valve Faulty stepper motor Faulty transducer Faulty speed sensor Faulty cruise control module Clutch or brake switch adjustment too tight -chnrt VI I”, . *r vt nna* “y”‘, in the cruise control circuit Faulty transdu cer I-

\

‘

Leaking vacuum circuit Faulty cruise control switch Faulty stepper motor

Note. Use this chart as a guide. Not all systems will use the components

listed.

t-, ,--

I

4. Slidetheradiochassisoutof theinstrument *panelanddisconnect theradiowiringharness and

REMOVAL&INSTALLATION # See Figures 32 thru 40, 46 and 47 1. Disconnect batterynegative cable. *If equippedwith an air bag, be sure to disarm it before enteringthe vehicle. 2. Remove thepanelfromaroundtheradio,On somemodelsthepanelis retained withscrews,On others,usea plastictrimtoolto prythelowerpadof theradiopanelloose. 3. Remove theradio/tape/CD playermounting bracketretaining screws,

*Depending on the speakerinstallation, it maysave time at installation to identify and tag all wires before they are disconnected. 5. Remove themounting brackets fromtheradio. To install: 6. Theinstallation is thereverseof theremoval procedure. Makeall electricalandantenna connectionsbeforefastening theradioassembly in place. 7. Testall functionsof theentertainment system priorto finalinstallation. If all aresatisfactory, install theunitandcenterpanel. 8. Connect thenegative batterycableandrecheck theentiresystemfor properoperation.

,

CDChanger 1. Disconnect thenegative batterycable. 2. Openthetrunklid. 3. Remove anynecessary trimto accesstheCD changer. 4. Remove theCD-changer-to-bracket retaining screws. 5. Liftthechanger fromthebracketanddetach theelectricalconnectors. 6. Remove thechanger fromthevehicle. To install: 7. Theinstallation isthereverseof removal.

REMOVAL&INSTALLATION

l

Front (InstrumentPanel Mounted)Speaker u See Figure 48 1. Disconnect thenegative batterycable. 2. Remove thefrontspeaker garnish. 3. Remove theretainers, detachtheharness connectorandremovethefrontspeaker,

Handlethe speakercarefully to avoid damagingthe coneduringremoval and installation. 4. Installation isthereverseof theremovalprocedure

CHASSISELECTRlCiL6-15 Door Speakers ) See Figures50, 51, and 52 -tI. n:n?.nnnnr, IL,^llaydwa ..^rr‘:....battery&je, lJ13lr”IIIIObI IlIt: 2. Remove thedoortrimpanel.Referto theprocedurein Section10. themounting screws,detachthehar3. Remove nessconnector andremove thefrontspeaker.

Handlethe speakercarefully to avoid damaging the cone duringremoval and installa93156g19 tion. Fig. 48 Typical front (instrument panel mounted)speaker mounting

4. Installation isthereverseof theremovalprocedure Rear DeckSpeakers # See Figure 53 1. Disconnect thenegative batterycable. 2. Remove thespeaker cover. 3. Remove thespeaker retaining screws. 4. Liftthespeaker outof thecavity. 5. Detachtheelectricalandremovethespeaker, 6. Theinstallation is thereverseof removal.

Door MountedTweeters # See Figure 49 1. Disconnect thenegative batterycable. 2, Remove thedeltacover(triangular shaped coverbehindthesidemirrorandabovethedoor panel. 3. Remove thespeaker retainingscrews 4. Liftthespeaker outof thecavity. 5. Detach theelectricalandremove thespeaker, 6. Theinstallation isthereverseof removal. Fig. 50 Removethe four speaker retaining screws

Fig. 51 Lifl the speaker from the door cavity . . .

rate tweeter

REMOVAL&lNSTAL~TlON

I

n See Figures 54 and 55 *This procedurealso applies to rear wiper1 arms on the DiamanteWagonand Mirage Hatchbacks. 1. Disconnect thenegative batterycable. 2. Remove thewindshield wiperarmsbyremovingthecap,unscrewing thecapnutsthenliftingthe armsfromthelinkageposts.

Fig. 54 Removethe wiper arm retaining nut cap, then loosen the windshield wiper arm ...._S~.. . 1rerauungnut I

9315W38

Fig. 55 Removethe wiper arm by lifting it #--- at.- ,:-n-1-- ---‘1 mfifl me ffffnfffg pusfs

646

CHASSISELECTRICAL

To install: 3. Installthewiperbladeandarmassemblies, Tightentheretainingnutsto 7-12ft. Ibs.(10-16 Nm). 4. Notethatthedriverssidewiperarmshouldbe markedD or Dr andthepassenger’s sidewiperarm shouldbemarked A or As.Theidentification marks shouldbelocatedatthebaseof thearm,nearthe pivot.Installthearmssothebladesare1 inchfrom thegarnishmoldingwhenparked. 5. Connect thenegative batterycableandcheck thewipersystemfor properoperation.

REMOVAL&INSTALLATION 1999-92 Mirage FRONT

‘~

2. Remove therearwiperarmbyremoving the capnutcover,unscrewing thecapnutandliftingthe armfromthelinkagepost. 3. Remove thelargeinteriortrimpanel.Usea plastictrimstickto unhookthetrimclipsof theliftgatetrim.Therewill bea rowof metalliftgateclips acrossthetop.Therewill be2 rowsof trimclipsthat retaintherestof thepanel. 4. Disconnect theelectricalharness atthewiper \ motor.Remove therearwiperassembly. Donot loosenthegrommet for thewiperpost. To install: 5. Installthemotorandgrommet. Mountthe grommet sothearrowonthegrommet is pointing downward. 6. Installthewiperarm. 7. Connect thenegative batterycableandcheck rearwipersystemfor properoperation. 8. If operationis satisfactory, fit thetabsonthe upperpartoftheliftgatetrimintotheliftgateclips andsecuretheliftgatetrim.

1993-00 Mirage 1. Disconnect thenegative batterycable. 2. Remove thewindshield wiperarmsbyun1. Disconnect thenegative batterycable. screwingthecapnutsandliftingthearmsfromthe 2. Remove thewindshield wiperarmsbyunlinkageposts. screwingthecapnutsandliftingthearmsfromthe . 3. Remove thefrontdeckgarnishpanel. linkageposts, 4. Remove bothwindshield holders. 3. Remove thefrontdeckgarnishpanel. 5: Remove theclipsthatholdthedeckcover.If 4. Remove bothwindshield holders. theyarethepintype,theymayberemoved usingthe 5. Remove theclipsthatholdthedeckcover.If followingprocedure: theyarethepintype,theymayberemoved usingthe a. Remove theclipbypressingdownon the , followingprocedure. centerpinwitha suitablebluntpointedtool. a. Remove theclipby pressingdownonthe Pressdowna littlemorethanl/r6 in. (2mm). centerpinwitha suitablebluntpointedtool. Thisreleases theclip.Pulltheclipoutwardto rePressdowna littlemorethanl/r6 in. (2mm). moveit. Thisreleases theclip.Pulltheclipoutwardto reb. Donotpushthepininwardmorethan moveit. necessary because it maydamage thegrommet, b. Donotpushthepininwardmorethan or if pushedtoofar,thepinmayfall in.Oncethe necessary because it maydamage thegrommet clipsareremoved, usea plastictrimstickto pry or if pushedtoofar,thepinmayfall in. Oncethe thedeckcoverloose. clipsareremoved, usea plastictrimstickto pry 6. OnMirage,remove theair intakescreen. thedeckcoverloose. 7, Loosenthewipermotorassembly mounting 6. Remove theair intakescreen. boltsandremovethewindshield wipermotor.Dis7. Loosenthewipermotorassembly mounting connectthelinkagefromthemotorassembly. If necboltsandremovethewindshield wipermotor.Disessary,removethelinkagefromthevehicle. connectthelinkaaefromthemotorassemblv. If necessary,removethelinkagefromthevehicle.*The installation angle of the crankarm and motor has beenfactory set, do not remove *The installation angle of the crankarm and them unlessit is necessaryto do so. If arm motor has beenfactory set. Do not remove mustbe removed,removethem only after unlessnecessary.If arm mustbe removed, markingtheir mountingpositions. removeonly after markingmountingpositions. To Install: 8. Installthewindshield wipermotorandconTo install: nectthelinkage.Connect theelectricalharness tothe 8. Installthewindshield wipermotorandconmotor. nectthelinkage.Connect theelectricalharness to the 9. Wheninstallingthetrimandgarnishpieces motor. andreusingpintypeclips,usethefollowingproce9. Wheninstallingthetrimandgarnishpieces dure: andreusingpintypeclips,usethefollowingprocea. Withthepinpulledout,insertthetrimclip dure: intotheholein thetrim. a. Withthepinpulledout,insertthetrimclip b. Pushthepininwarduntilthepin’sheadis intotheholein thetrim. flushwiththegrommet. b. Pushthepininwarduntilthepin’sheadis c. Checkthatthetrimis secure. flushwiththegrommet. IO. Installthewiperarmsandtightennutsto 17 c. Checkthatthetrimis secure. ft. Ibs.(24Nm). 10. Installthewiperarmsandtightenthenuts. 11. Connect thenegative batterycableandcheck 11. Connect thenegative batterycableandcheck thewiper I-- -_-^-_-----,:-II 101 plupel uperatlull. thewipersystemfor properoperation.

2. Remove thewindshield wiperarmsbyunscrewing thecapnutsandliftingthearmsfromthe linkageposts. 3. Remove thefrontgarnishpanel. 4. Remove theair inlettrimpieces. 5. Remove theholecover. 6. Remove thewipermotorbyloosening the mounting bolts,removing themotorassembly, then disconnecting thelinkage. *The installation angle of the crankarm and motorhas beenfactory set; do not remove them unlessit is necessaryto do so. If they mustbe removed,removethem only after markingtheir mountingpositions. To install: 7. Installthewindshield wipermotorandconnectthelinkage. 8. Reinstallalltrimpieces. 9. Reinstall thewiperblades.Notethatthedriver’ssidewiperarmshouldbemarkedD or Dr and thepassengers sidewiperarmshouldbemarked A or As.Theidentification marksshouldbelocatedat thebaseof thearm,nearthepivot.Installthearmsso thebladesare1 inchfromthegarnishmoldingwhen parked. 10. Connect thenegative batterycableandcheck thewipersystemfor properoperation. Diamanteand 199440 Galant FRONT b See Figures 56, 57, 58, and 59 1. Disconnect thenegative batterycable.

Fig. 56 Removethe retaining clips from the front garnish panel

systerr

REAR 1. Disconnect thenegative batterycable.

1990-93 Galant 1. Disconnect thenegative batterycable.

Fig. 57 lift the panel up and remove it from 1 the vehicle I

CHASSISELECTRICAL 647 3. Remove thewindshield wiperarmsbyunscrewing thecapnutsandliftingthearmsfromthe linkageposts. 4. Remove thefrontdeckgarnishassembly. 5. Remove theair inletc(Iver. 6. Disconnect theelectric xl harness plugfrom thewipermotor. ,I6 #-n\,LIr 7. Remove theaccessho,,LIVIGil. 8. Remove thewipermotormounting bolts. 9. Detachthemotorcrankarmfromthewiper linkane and remnve .._ _ _ the . _ mntnr _ _ a- ‘-

I I Fig 59 Pull the motor from the firewaii and / de&h the linkage “‘%‘y 1 2. Matchmarkthe wirier armstn the shaftand

markthearmsto thepropersidefor reinstallation

REMOVAL&INSTALLATION Mirage 1. Disconnect thenegative batterycable.Remove thecentertrimpanel. 2. Remove thekneeprotector. If pintypeclipsare used,theymayberemoved usingthefollowingprocedure: a. Pressdownonthecenterpinwitha suitablebluntpointedtool.Pressdowna littlemore than‘IIS in. (2mm).Thisreleases theclip.Pull theclip outwardto removeit. b. Donotpushthepininwardmorethan necessary because it maydamage thegrommet or thepinmayfall in, if pushedin toofar.Once theclipsareremoved, usea plastictrimstickif necessary to prythekneeprotectorloose. 3. Remove theinstrument clusterbezel. 4. Remove theinstrument cluster.Disassemble andremovegauges or thespeedometer asrequired. *if the speedometercable adapterrequires setvice, disconnectthe cable at the transaxie end. Pull the cable slightly toward the vehi-

*The installation angle of the crankarm and motor has beenfactory set. Do not remove them unlessnecessary.if they mustbe removed,removethem only after markingtheir mountingpositions. To install: 10. Installthewindshield wipermotorandconnectthelinkage. 11. Attachtheelectricalharness plug. ’ 12. Installtheaccessholecover. 13. Installtheair inletcover. 14. Installthefrontdeckgarnishassembly. 15. Reinstall thewiperarmandtightenthe mounting nutsto 14ft. Ibs.(19Nm).Installthearms sothebladesareparallelto thegarnishmolding whenparked. 16. Connect theneaative battervcableandcheck thewipersystemfor properoperation.

1 1 Disconn& thethP rwnativo hatton/ rahlm ““I”“,,,,,, liftgatelowertrim. IICUVBI, --. .-- I~IIIUV~ -^- ^..^tilt: .L^lfAdllllll~ -_,_:..:--IIUL -.A 3: Liftthesmatr andremove thewiperarm. 4. Remove themountina boltsandremove the .I,”

~‘“p.L’,”

YULL”‘,

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tie interior, release the lock by turningthe adapterto the right or left and removethe adapter. 5. Theinstallation is thereverseof theremoval procedure. Usecarenotto damage theprintedcircuit boardor anygaugecomponents. 6. Connect thenegative batterycableandcheck all cluster-related itemsfor properoperation. Gaiant @See FiguresBg thru 66 1. Disconnect negative batterycable. 2. Remove the2 retainerscrewsfromthelower surfaceof themeterhood. 3. Remove theretainerscrewsfromtheunderside topportionof themeterhood. 4. Carefullyremove themeterhoodfromtheface of thecombination meter. 5. Remove the4 retainerscrewsandthecombinationmeterassembly withthebezelattached. Removethefrontbezelandremovegaugesor the speedometer asrequired. *if the speedometercable adapterrequires service, disconnectthe cable at the transaxie end. Pull the cable slightly toward the vehi-

To install: 5. Installthemotorandinstalltheretaining bolts. 6. Installthewiperarmsothatthearmis 3.35 inches(85mm)between themeasurement points, whenparked. Securethewiperarmwiththeretaining nut. *Before proceeding,connectthe battery and checkthe operationof the motor. if satisfaetory, disconnectthe cable andcompletethe installation. 7. Installtheinteriortrimpiece n WIIIIW II^_^^^IAL-^I-I:..- vatreryoable L-AL-o. LIEIl~&WVt: andrecheck thesystemfor properoperation.

REMOVAL&INSTALLATION

-

Front and Rear the I. nivnnnprt YIV”“I1IIYVL VI”nonatiua “UyuL’.”haltorv “UL’“‘,rahlo UUUIU.

1

2. Removethe windshieldwasherfluid resarvnir

3. Drainanywasherfluidinthereservoirintoan appropriate container. 4. Remove thepumpfromthereservoirbyeither removing theretaining hardware ortwistinggently tlntil

it is frpp frnm thP rosorvnir

lo Install: 5. Inspect thepumpsealonthereservoir,replace if necessary. 6. Installthepumpintoplaceuntilseatedonthe seal. 7. Installthewindshield washerfluidreservoir. A “. Refill .,“...Sthp .V.”wxhpr ....“III.fllk-l ,*..*”rpqprvnir IYUY..“m,. 9. Connect thenegative batterycable.

tie interior, release the lock by turningthe adapterto the rigM or left and removethe adapter. 6. Theinstallation is thereverseof theremoval procedure. Usecarenotto damage theprintedcircuit boardor anygaugecomponents. 7. Connect thenegative batterycableandcheck iIIIcluster-related itemsfor properoperation.

.

6-18 CHASSISELECTRICAL

Fig. 64 Grasp the instrument cluster and carefully pull it out of the instrumentpanel

tached;the cluster has sockets on the back

Fig. 66 . , . these sockets engageconnectors solidly mountedbehindthe cluster

Diamante 1. Disconnect thenegative batterycable. *If equippedwith an air bag, be sure to disarm it before enteringthe vehicle. 2. Remove thehoodlockreleasehandleand switches fromthekneeprotectorbelowthesteering column.Thenremovetheexposed retaining screws andremove thekneeprotector. 3. Remove theupperandthelowersteeringcolumncovers. 4. Remove theinstrument clusterbezel. 5. Remove theinstrument cluster.Disassemble andremove gaugesorthespeedometer asrequired. *If the speedometercable adaptermustbe serviced. disconnectthe cable at the transaxle end. Pull the cable slightly toward the vehicle interior, release the lock by turning the adapterto the right or left andremove the adapter. 6. Theinstallation isthereverseof theremoval procedure. Usecarenotto damage theprintedcircuit boardor anygaugecomponents, 7. Connect thenegative batterycableandcheck all cluster-related itemsfor properoperation.

REMOVAL &INSTALLATION

I

83156pD6

Fig. 69 Removethe gaugeretaining screws b See Figures 67, 66, 69, and 70

Fig. 70 . . . then carefully lift the gauges from the instrumentcluster to removethem

CHASSISELECTRICAL 6-19 1. Disconnect thenegative batterycable. 2. Remove theinstrument cluster,asoutlined earlierinthissection. 3. Remove theretaining screwsfor theinstrument clusterlensandcoverassembly. Remove thecover andlens. 4. Remove theretainingscrewsfor thegaugeor warninglampto bereplaced, thenremovethegauge orwarninglamp. To install: 5. Placethegaugeorwarninglampintoplace andtightentheretaining screws. 6. Installtheinstrument clusterlensandcover assembly. 7. Installtheinstrument cluster. \ 8. Connect thenegative batterycable.

are all built into 1 multi-functioncombination switch that is mountedon the steeringcolumn. Refer to Section8 for proceduresregardingthe combinationswitch. ,

REMOVAL&INSTALLATION

:

1. Disconnect thenegative batterycable. theswitch 2. Usinga suitableprytool,disengage retaining tabs. 3. Gentlypulltheswitchfromtheinstrument panel. theelectricalconnector andremove the 4. Detach switch. 5. Theinstallation is thereverseof removal.

REMOVAL &INSTALLATION *The headlights,turn signals, dimmer switch, horn switch, windshield wiper/washer, intermittentwiper switch and on somemodels,the cruise control function

# See Figures 71, 72, and 73

the retaining clips from either side of the switch trim plate . . .

Fig. 72 . . . then carefully pull the switch and trim plate out of the instrumentpanel

1. Disconnect thenegative batterycable. 2. Usinga smallscrewdriver or othersuitable tool,carefullyprytheretainingclipsfromeitherside of theswitchtrimplate. 3. Carefullypulltheswitchandtrimplateoutof theinstrument panel. 4. Detach theelectricalconnectors andremove theswitch. 5. Theinstallation isthereverseof removal.

REMOVAL &INSTALLATION *On all modelsthe headlights,turn signals, and on somemodels,the cruise control function are all built into 1 multi-functioncombination switch that is mountedon the steerinq column.Refer to Section8 for procedures6 gardingthe combinationswitch.

REMOVAL &INSTALLATION *

Fig. 73 Detachthe electrical connectorsand remove the switch

9. Connect thenegative batterycable.

REMOVAL &INSTALLATION

CompositeHeadlights 6 See Figures74, 75, 76, 77, anU78

Sealed BeamHeadlights 1. Raisetheheadlights usingthepop-upswitch. 2. Disconnect thenegative batterycable. 3. Unfasten theretainingscrews,thenremove the upperandthelowerheadlight bezels. 4. Remove theheadlight retainingringscrews, andtheheadlight retainingring. 5. Pulltheheadlight partiallyout,detachtheconnectar,thenremoveheadlight assembly fromthevehicle. To install: 6. Attachtheheadlight electricalconnector. 7. Properlypositiontheheadlight andtheretainingring,theninstalltheretaining screws. 8. Installtheheadlight bezelsandsecurewiththe retaining screws.

Halogenbulbscontaingas underpressure. Handlingthe bulbincorrectlycould causeit to shatter into flying glass fragments.Do NOTleave the light switch ON.Always allow the bulb to cool before removal. Handlethe bulb only by the base;avoid touchingthe glass itself. Wheneverhandlinga halogen bulb, ALWAYSfollow these precautions: l Turntheheadlight switchOFFandallowthe bulbtocoolbeforechanging it. LeavetheswitchOFF untilthechangeis complete. l ALWAYS weareyeprotection whenchanging a halogenbulb.

Handlethebulbonlybyits base.Avoidtouchingtheglass. l DONOTdropor scratchthebulb. l Keepdirtandmoisture awayfromthebulb. * Placetheusedbulbinthenewbulb’scarton anddisposeof it properly. 1. Openthevehicle’shoodandsecureit inanuprightposition. 2. Disconnect thenegative batterycable. 3. Remove thesocketcoverbypullingit straight off,orturningit clockwise thenpullingit off. 4. Carefullytwistthebulbandsocketcounterclockwise, thenpulltheassembly fromtheheadlight housing. 5. Holdingthebaseof thebulb,detachit fromthe connector harness. To install: 6. Holdingthebaseofthebulb,installit securely in theconnector. 7. Installtheconnector andbulbassembly inthe housingandtwistto lockintoposition. 8. Installthesealingcoverbypushingit on l

.

6-20 CHASSISELECTRICAL

Fig. 74 Twist and pull on the cover to unlock it in order to accessthe headlight bulb and socket assembly

93Mm

.

NO

0000

6957Q39

L

Fig. 77 Unplugthe bulb from the socket, being careful not to touch the glass portion of the bulb

I

and/orturningit counterclockwise. Makesurethe coveris installedsecurelyorthelenswill beoutof focus,orwatermaygetintothelightunit. 9. Disconnect thenegative batterycableand checktheheadlight operation.

AIMINGTHEHEADLIGHTS $ See Figures79, 88, 81, 82, and 83 ’’ Theheadlights mustbeproper’ ’ ’ IO ’ provrae ly armea thebest,safestroadillumination. Thelightsshould :.__1__1 __ -___-_-. bechecked for properaimandadfusreu asIlweSYdly. Certainstateandlocalauthorities haverequirements for headlight aiming;theseshouldbechecked before adjustment is made.

then carefully pull’ it from the

Fig, 75 Turn the inner head light bulb and

Fig. 78 NEVERhold the halogenbulb by the glass, ALWAYShold it with the base ,

Aboutoncea year, when the headllgfttsare replacedor any time front endwork is performed on your vehicle, the headlightshould be accuratelyaimed by a reputablerepair shopuslngthe properequipment.Headlights not properly aimed can makeit virtually impossibleto see arId may blind other drivers on the road, POSSIibly causingan accident. Notethat the’following procedureis a temporary fix, until you cantake your vehicle to a repair shopfor a properadjustment. Headlight adjustment maybetemporarily made usinga wall,asdescribed below,or ontherearof anothervehicle.Whenadjusted, thelightsshouldnot

glarein oncoming caror truckwindshields, nor shouldtheyilluminate thepassenger compartment of vehiclesdrivinginfrontof you.Theseadjustments areroughandshouldalwaysbefine-tuned bya repairshopwhichis equipped withheadlight aiming tools.Improper adjustments maybebothdangerous andillegal. Formostof thevehiclescoveredbythismanual, horizontal andverticalaimingof eachsealed beam unitis providedbytwoadjusting screwswhichmove theretainingringandadjustingplateagainstthetensionof a coilspring.Thereis noadjustment forfocus;thisis doneduringheadlight manufacturing. *Because the compositeheadlightassembly is bolted into position, no adjustment shouldbe necessaryor possible. Someapplications, however, maybe boltedto an adjuster plate or may be retained by adjusting screws. If so, follow this procedurewhen ad@stingthe lights, BUTalways have the adjustmentcheckedby a reputableshop. Beforeremoving theheadlight bulbor disturbing theheadlamp inanyway,notethecurrentsettingsin orderto easeheadlight adjustment uponreassembly. If thehighor lowbeamsettingof theoldlampstill works,thiscanbedoneusingthewallof a garageor a building: 1. Parkthevehicleona levelsurface, withthe fueltankaboutr/afull andwiththevehicleemptyof all extracargo(unlessnormallycarried).Thevehicle shouldbefacingawallwhichis nolessthan6 feet (1.8m)highand12feet(3.7m)wide.Thefrontof the vehicleshouldbeabout25feetfromthewall. 2. If aimingisto beperformed outdoors,it isadvisabletowaituntilduskin orderto properlyseethe %

2. SCFEWRH

TCCAE@

ScFlEwLn TCcAssa

Fig. 79 Location of the aiming screws on most vehicles with sealed beamheadlights

Fig. 88 Dual headlightadjustmentscrew locations--one side shown here (other side should be mirror image)

TCC&z3

Fig. 81 Example of headlight adjustment screw location for compositeheadlamps

CHASSISELECTRICAL 6-21

Fig. 82 low-beam headlight pattern alignment

93156pE.3

Fig. 85 Removethe washer fluid reservoir retaining screws . . .

Fig. 83 High-beamheadlight pattern alignment headlight beamsonthewall.If donein a garage, darkentheareaaroundthewallasmuchaspossible byclosingshadesor hanging clothoverthewindows. 3. Turntheheadlights ONandmarkthewallat thecenterof eachlight’slowbrram,thenswitchon thebrightsandmarkthecenterof eachlightshigh beam.Ashortlengthof maskin g tapewhichis visible fromthefrontof the. whir+ ._..._._ ma ..._y beused.Although marking all fourpo:sitionsis advisable, markingone positionfromeachlightshouldbesufficient. 4. If neithar he;Irn ononesideis working, ~. __ andif anotherlike-sizedvehicleisavailable, parkthesecnnri nm in the wart .

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the whirlo Lll”

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jhtsONandadjustthebeams to marcnme headli! marksonthewall. adjustment checked as 6. Havetheheadlight soonaspossiblebya reputable repairshop.

then move the reservoir out of !ss the parking and side markerlamp bult,1~_.. nn loo4-98 ._“~- Galantmod-

5. Theinstallation is thereverseof removal. REMOVAL&INSTALLATION ParkingAnd Side Marker Lights p See Figures 84, 85, 88, 87, 88, and 89

md

U,,”

markthebeamsusingthesame-side light.Then switchthevehiclessotheoneto beaimedis backin theoriginalspot.It mustbeparkednocloserto or fartherawayfromthewallthanthesecondvehicle. 5. Performanynecessary repairs,butmakesure thevehicleis notmoved,or is returned totheexact spotfromwhichthelightsweremarked. Turnthe

5315@61

1Fio. 8

Frontturn Signal I

p See Figures910, 91, 92, and 93 n,-.nn+:.m b.Hnn,nnL.L 1. Disconnect tlI(? z Ill7yau”e “allcly ul”IC. 2. Remove thet 10retaininoscrewsfromthe lens. 3. Remove thelensfromthefrontfascia. 4. Graspthebulbsocketandrotateit counterclockwise to removeit fromthelamp. 5. Pullthebulboutto removeit fromthesocket. 6. Installation is thereverseof removal. 1

I. Disconnect thenegative batterycable. anynecessary components to access 2. Remove thebulbs. 3. Rotate thebulbsocketsandrotatethemcounterclockwise to removethem. 4. Graspthebulbandremoveit fromthesocket bypullingit straightout.

I-

6-22 CHASSISELECTRICAL

Fig. 87 After the washe: fluid reservoir removed,the parkinglamp bulb (B) and the side marker lamp (A) are accessible on 1994-98 Galant models

b

Fig. 88 Twist the bulb socket to release it from the lens

Fig. 89 Pull the bulb assembly out of the socket to remove

. then removethe lens from the

Fig. 92 Twist the bulb socket to release it from the lens I

93156p69

Fig 90 Removethe turn signal lens retaining’screw . . . g3156p71 /

Pull the bulb assembly out of the

Fig. 94 The back-uplamp socket assembly located on the undersideof the trunk lid.

. . . then unfastenthe trim panel re-

Rear Turn Signal, Brake and Tail lights p See Figures 94, 95, 96, and 97. 1. Disconnect thenegative batterycable. 2, Openthetrunklid,hatch,ortailgateandremovetheretainers, thenremovetheinnertrimpanel in orderto getto therearlampassembly. 3. Turnthenecessary bulbandsocketassembly to unlockit fromthehousing,thenpullit fromthe housing. 4. Depress andtwistthebulbl/a turncounterclockwise. Pullthebulbfromthesocketandreplace witha newoneof thesametype. 5. Installation isthereverseof theremovalprocerl.._^ UUIt?.

Fig. 96 Twid : the bulb socket to release it from the lens

Fig. 97 Depressand turn the bulb assembly, then pull it out of the socket to remove

CHASSISELECTRlCiL6-23

93156P57

Fig. 98 The back-uplamp socket assembly is located on the undersideof the trunk lid Back-uplight u See Figures 98, 99, and 100 1I Disconnect thenegative batterycable. 2. Openthetrunklid. 3. If equipped, removethetrimontheunderside of thetrunklid. 4. Turnthesocketcounterclockwise ‘14of a turn to releaseit fromthelens. 5. Pullthebulboutto removeit fromthesocket, 6. Theinstallation isthereverseof removal. 7. Connect thenegative batterycable. 8. Verifytheoperation of thelamp. Side Marker light # See Figures101, lOi, 103, and 104

thetworetainingscrewsfromthe I. Remove lens. 2. Remove thelensfromtherearfascia. 3. Graspthebulbsocketandrotateit counterclockwise to removeit fromthelamp. 4. Pullthebulboutto removeit fromthe’socket. 5. Installation isthereverseof removal.

2. Openthetrunklidanddetachtheelectrical connector fromthelampassembly. 3. Remove theretainingscrewholdingthelamp assembly. 4. Lowerthelampassembly fromthelamplens. 5. Rotate thebulbclockwise whilepushingit gentlyinwardto removeit fromthesocket. 6. Theinstallation isthereverseof removal..

High-mountBrake light 199fH6 MIllAGE, 1990-93GALANT,AND 7992-96DlAMANTE

799446 GALANT

1, Disconnect thenegative batterycable. 2. OntheMirageandGalant,remove thesquare retainerclipsor boltsfromthehigh-mount brake lightcoverandremove thecover. 3. OntheDiamante, pressgentlyinwardonthe sidesoftheliahtcoverandremoveit fromthelamp.

p See Figures 105, 106, 107, 108, and 109 1. Disconnect thenegative batterycable. *The lamp assemblyis accessiblefrom the trunk underneaththe packageshelf.

Fig 101screw Remove re- 1 / ;;x,;;:,sdhen 1taining . ~ .the side marker light 93156p75

Fig. 104 Pull the bulb assemblystraight out of the socket to remove

Fig 100 Pull the bulb assemblystraight out of the socket to remove it *1W5y]

Fig. 99 Twist the bulb socketto release the locking tabs from the lens

puii the lens awaG;::

Fig. 105 Detachthe high-mountbrake light electrical connector

1

Fig 103 it 1 1fror;l the Twist iens the bulb socket to release 93156p73

Fig. 106 Removethe lamp retaining screws . a*

’

.

6-24 CHASSISELECTRICAL

Fig. 107 . . . then lower the lamp assembly for accessto the bulbs 4. thebulbclockwise whilepushingit ., Rotate gentlyinwardto removeit fromthesocket. 5. Theinstallation isthereverseof removal. 1997-00 MIRAGE, 1994-00 GALANT, AND f 997-90 DIAMANTE

1. Disconnect thenegative batterycable. *The bulb socketis accessiblefrom the trunk underneaththe packageshelf. 2. Ooenthetrunklidand detachtheelwtrical connector fromthebulbsocket, 3. Rotatethesocketcounterclockwise andremoveit fromthelampassembly. 4. Rotate thebulbclockwise whilepushingit gentlyinwardto removeit fromthesocket. 5. Theinstallation isthereverseof removal.

Fig. 110 Removethe two lamp lens retaining screws . . .

Fig. 108 Rotate the bulb assembly. . . LicensePlate lights

Dome/PassengerArea lamps

p See Figures 110,111, and 112

p See Figures113, 114, and 115

1. Disconnect thenegative batterycable. thetworetainingscrewsfor thelamp 2. Remove lens. 3. Lowerthelensfromthetrunklid. 4. Graspthebulbandremoveit fromtheterminalsonthelens. To install: 5. Placethebulbintoplaceonthelensand lightlypressintotheterminals onthelens. 6. Placethelensintopositiononthetrunklid andtightenthetworetainingscrews. 7. Connect thenegative batterycable. 8. Verifytheoperation of thelamp.

1, Usinga smallprytool,carefullyremovethe coverlensfromthelampassembly. 2. Remove thebulbfromits retaining clipcontacts.Ifthebulbhastaperedends,gentlydepress the springclip/metal contactanddisengage thelight bulb,thenpullit freeof thetwometalcontacts. To install: 3. Beforeinstallingthelightbulbintothemetal contacts, ensurethatall electricalconducting surfacesarefreeof corrosionor dirt. 4. Positionthebulbbetween thetwometalcontacts.If thecontacts havesmallholes,besurethat thetapered endsof thebulbaresituatedin them.

Fig. ill . . . then lower the lens to access the bulb

Fig. 112 Removethe bulb by pulling it from the terminals on the lens

CHASSISELECTRICAL 6-25

ig. 118 Pull the bulb straight out to remove

ove the socket from 6. Installthecoverlensuntilitsretaining tabsare properlyengaged.

’ Lightbulbapplication chart-1990-92Mirage Bulb Chart - Outaide

InstrumentCluster light bulbs b See Figures116,llf,ll8,

Fig. 119 Onsome of the bulbs, it is neces!aOUIDcover IOme

1;;tbqrlrnsferthe colore ’’ ”

and 119

1. Disconnect thenegative batterycable. 2: Remove theinstrument clusterasoutlinedin thissection. 3. Turnthedesiredbulbsocketcounterclockwise to removeit fromthecluster. , 4. Graspthebulbandpullit straightoutto removeit fromthesocket. I To install: 5. If necessary, transferthecoloredbulbcoverto thenewbulb. 6. Placea newbulbintothesocketandlightly

. .’ ’ press i+in+n n,app II

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Placethesocketintotheclusterandturnthe ,“.

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pithpr it ic faldtv nr

9. Connect thenegative batterycable.

Outside

I

Inside

1Lmelatel~hls 1 EL&

, JvR,,Is~,,o~ Bulb Chart-In

*__.. __.

6-26 CHASSISELECTRICAL Light bulb applicationchart-199&93

Galant

Light bulb applicationchart-1994-98 Galant

Light bulb applicationchart-1999-00 Galant Light Bulbs -Outside Descrrptron

Outside

SAE TradeNo --55W 90a 9005 65W 271B\1\1 1157NA 199 ZCP 168 3CP 3212~~ 2057 1156 32cp 32~x1 1156 168 3CP

Wattage

HeadlIght loutsldel Headlight (Inside1 Front turn-srgnal lkghts Fronr srde-marker lrghts Parkrng hghts Stop and tarllrghts Rear turn-srgnal lrghts Backup lkghts Rear srde-marker lkghts

LI168

Descrrptron

7t License 6

Wattage

- ...-- -plate Ilght

Stop and tall Irghl

/

3cp

1 32/2cp

--_.--8W 8W 8W low 5W 5W

168 1

2057

I

Inside Description

1 Wattage

1

14w 14W t4w t4w Ashtray light Shtft tndrcaror Ilght fautomatlc Iransaxlel Overdrwe rndvzator light lautomatlc transaxle)

rrunk lrght

Light bulb applicationchart-1992-96 Diamante

Light bulb applicationchart-1997-00 Diamante

Outside

Description

wattage

SAE trade NO

l----if 1 - Headlrght Irnslde)

65W

2 - HeadlIght loutsldel 3 - Parktng and front s!de markrr l,ght 4 - Front turn-srgnal light 5 - Hugh-mounted stop lbght 1 6- Eackuplrght

55w

I

3cP

9005 9006 168

24cp 21cp

1156NA 921

21cp

1921

8 - Rear side marker lkght 9 - License plate light IO - Rear turn-slgnal lkght

3cP 32cp

168 1156

Description

Wattage

7 - Stop/tall light

Dome light Door light Luggage compartment lrght Rear personal lrght Glove compartment lbght Vanity mrrror lkght Arr condltfoner control panel lkght Cigarette lighter rllumrnallcm l1gbt

Exterior 1 - He;;;fghts 2-

(inner) - 12V 65W

keadlights (outer) 12V 55W fHB41 Parking and front - 12V 3cp side marker lrght 4 - Fronl turn-slgnal lights 12V 32cp 5 - Front fog llghl 12V 55W (H3) 3-

6769lo1112-

Rear tdm-stgnal lights 12V 45cp Reversrng light - 12V 32cp Lrcense plate light 12V 3cp Stop I tall lights 12V 43/3cp Stop I tall Ibghts 12V 3212~~ Hugh mounted stop - 12V 21W light RearsIde-marker light - 12V 3cp

interior RoomlIghts 12V 6W Spot lights 12V RW Rear personal lrglils - 1% 8W Door IIghts (clear) 12V 3 4W Trunk hght - 12V 5W

CHASSISELECTRICAL 6-27 1. Remove thefuseboxcover. 2. lnsoectthefusesto determine whichisfaulty. 3. Graspthefuseandremoveit fromthefuse REPLACEMENT box. theboxterminals andcleanif cor4. Inspect roded.Ifanyterminals aredamaged, replace theterIt See Figures120 thru 127 minals.’ FusesarelocatedeitherintheengineCompartment 5. Plugina newfuseof thesameamperage ratorpassenger compartment fuseandrelaypanels.If a ing. fuseblows,at leastone,butpossiblyseveralcompoients/circuits will notfunctionproperly.

Never exceedthe amperagerating of a blown fuse. If the replacementfuse also blows, checkfor a problemin the circuit. 6. Checkfor properoperation of theaffected component or circuit.

Do not replace blown fusible links with standardwire. Onlyfusible type wire with Hy palon insulationcan be used,or damageto the electrical systemwill occur!

Fig, 120 The engine compartmentfuse box is typically located adjacent to the battery

Fig. 121 Grasp the engine compartment fuse box cover and pull It straight up to remove it . ’ ‘“‘,+“” 1

Fig. 122 The engine compartmentfuse box contains a combination of fuses, maxifuses, relays, and diodes. Most can be removed by simply pulling upward I

Fig. 123 The interior fuse box is located under the driver’s side of the instrumentpanel

Fig. 125 Typically a fuse removal tool is located in the fuse box to aid in removingthe fuses

Fig. 126 Grasp the fuse with the removal tool and pull it straight out to remove it

A number of fusiblelinksareusedonthesevehiclesto protectwiringandelectricalcomponents. Thereis a collectionof fusiblelinkslocatednearthe battery.Thesearereferred toasthemainfuselinks.A secondgroupof linksarelocatedin theboxwiththe dedicated fuses.If replacement of a fuselinkis required,usetheexactsamelinkasremoved. Whena fusiblelinkblowsit is veryimportant to findoutwhy.Theyareplacedin theelectricalsystem for protection againstdeadshortsto ground,which canbecausedbyelectricalcomponent failureorvariouswiringfailures.

Fig. 124 Graspthe interior fuse box cover, depressthe retaining tabsand lift up to re-

.

6-28 CHASSISELECTRICAL Do not just replace the fosible link to correct a problem!

RESETTlNGAND/OR REPLACEMENT

REPLACEMENT

Whenreplacingall fusible links, they areto be replacedwith the sametype of prefabricatedlink availablefrom your vehiclemanufacturer.

Circuit breakersare locatedinsidethe fuse panel. Theyare automaticallyresetwhenthe problemcorrectsitself, is repaired,or the circuit cools downto allow operationagain.

Theturn signaland hazardflasherunit is located in the interiorfuse panellocatedunderthe driver’s left side kneeprotector.Theyare replacedby simply pullingthemstraightout. Notethatthe prongsare arrangedin such a waythat the flashermust be properly orientedbeforeattemptingto install it. Turn the flasheruntil the orientationof the prongsis correct and simply pushit firmly in until the prongsarefully engaged.

1990-92 Mirage fuse locationchart

1993-96 Mirage fuse locationchart

1997-00 Mirage passengercompartmentfuse locationchart

,-Lw

93156glO

Engine compartment 9ight side

1997-00 Mirage enginecompartmentfuse locationchart Engine compartment

NO

Symbol

16

0

Electrical

system

Fuse(+B)

Capacrty 60A

Some fuses may not be installed on your vehicle, depending on the vehicle model or specihcations.

Identification i0A

I

I

I

12

Power window Control

30A

13

@I

Radiator

30A

14

E-J

Headllghls

40A

15

;2”

lgnttlon

30A

fan motor

switch

of fuse Red

CHASSISELECTRlCiL6-29 1990-93 Galantfuse locationchart Fuse Load Capacities l-15A Cigarette hghter Z-10A Radm 3-10A Heater relay 4-10A (E P S.) 5-10A Belt 6-10A Turn signals 7-10A Meters 6-10A Horn 9-15A Wiper lo-10A (4 A/T) ll-15A (Door locks) 12-10A Dome hght, clock 13-10A Backup hghts 14-15A Stop hghts 15-30A Heater 16m20A (Sunroof) 17-20A (ECS) spare fuse 1% ldentlfxation of fuse Red 10A Light blue 15A Yellow 20A Green 30A 93156g13

1994-98 Galantfuse locationchart

Passenger compartment 1. 234. 5. 67. ;: IO11. 12. 13.

15A StoplIghts 10A Turn signals 1OA Backup Itghts 30A Heater i5A Wiper IOA Meters 30A Rear wndow defogger fo& fl$oof) 15A Cagaretle lighler 10A Heater relay IOA Horn Spare fuse

( ): II so equipped A!T Automallc transaxle

Engine compartment Fusible links I2. 3. 4. 5.

30A 50A 30A 40A 30A

Ignition swlch (ABS) Radiator fan Headkghts Power wndow

Fuse 67. 6. 9. 10. 11. 12. 13. 14. (

30A (ABS) 30A Condenser fan 10A Hazard 20A Engine 10A (Au conditioning) 10AHigh beam 10ATall lkghts 10A (Theft) i5A Fog lkghls ): If so equipped 93156g14

1999-00 Galantfuse locationchart

6-30 CHASSISELECTRICAL 1992-96 Diamantefuse locationchart I

Fuse load caaacities 1 - 15A Cigarette lighter 2 - 10A Radio 3 - 10A Heater relay, (Power window relay) 4 - 10A (E.P.S) 5 - 10A Turn signals, SRS 6 - 10A Meters, SRS 7 - 15A Wiper 8-10A (4AIT) 9- 15A Steering handle lock, (Door locks) lo- 10A Dome light, Clock 11 - 10A Backup lights 12 -2OA StoplIghts 13 -3OA Heater 14 - 20A (Sunroof)

15 -2OA 16 - 20A 17 -

Horn (E.C.S.) spare fuse

( ) indicates optlonal equipment E P.S.: Electronic Control Power Steering E.C.S.: Electronic Control Suspension SRS~ Supplement Restratnt System A/T: Automatic Transaxle

93156fllE

1997-00 Diamantepassengercompartmentfuse location chart No

Symbol Electrical System I

capactty I

Spare fuses are contained in the fuse housing use a fuse of the same capacity for replacement.

199740 Diamanteenclinecompartmentfuse location chart

CHASSISELECTRICAL 6-31

INDEX OF WIRING DIAGRAMS DIAGRAM

1

Sample Diagram: How To Read & Interpret Wiring Diagrams

DIAGRAM

2

Sample Diagram: Wiring Diagram Symbols

DIAGRAM

3

1990-92 Galant 2.OL SOHC Engine Schematic

DIAGRAM

4

1993 Galant 2.OL SOHC Engine Schematic

DIAGRAM

5

1990 Galant 2.OL DOHC Engine Schematic

DIAGRAM

6

1991-93 Galant 2.OL DOHC Engine Schematic

DIAGRAM

7

1994 Galant 2.4L SOHC Engine Schematic

DIAGRAM

8

1994 Galant 2.4L DOHC Engine Schematic

DIAGRAM

9

199500

DIAGRAM

10

1993-96 Mirage 1.5L Engine Schematic

DIAGRAM

11

1993-96 Mirage 1.8L Engine Schematic

DIAGRAM

12

1997-00 Mirage 1.5L Engine Schematic

DIAGRAM

13

1997-00 Mirage 1.8L Engine Schematic

DIAGRAM

14

1992-93 Diamante 3.OL SOHC Engine Schematic

DIAGRAM

15

1994-95 Diamante 3.OL SOHC Engine Schematic

DIAGRAM

16

1992-93 Diamante 3.OL DOHC Engine Schematic

DIAGRAM

17

1994-95 Diamante 3.OL DOHC Engine Schematic

DIAGRAM

18

1996-00 Diamante 35L Engine Schematic

DIAGRAM

19

1990-95 Galant/Mirage

DIAGRAM

20

1990-93 Galant Charging Chassis Schematics

DIAGRAM

21

1990-93 Galnt Cooling Fans Chassis Schematics

DIAGRAM

22

1990-93 Galant Headlights Chassis Schematics

DIAGRAM

23

1990-93 Galant Taillights/Parking

DIAGRAM

24

1990-93 Galant Backup Lights/Brake Lights/Horn Chassis Schematics

DIAGRAM

25

1990-93 Galant Turn Signal Chassis Schematics

DIAGRAM

26

1990-93 Galant Power Windows Chassis Schematics

DIAGRAM

27

1990-93 Galant Power Windows wl ETACS Control Unit Chassis Schematics

Galant 2.4L Engine Schematic

Starting Chassis Schematics

Lights Chassis Schematics

6-32 CHASSISELECTRICAL

INDEX OF WIRING DIAGRAMS DIAGRAM

28

1990-93 Galant Wipers Chassis Schematics

DIAGRAM

29

1990-93 Galant Wipers w/ ETACS Control Unit Chassis Schematics

DIAGRAM

30

1990-93 Galant Power Door Locks Chassis Schematics

DIAGRAM

31

1990-93 Galant Power Door Locks wl ETACS Control Unit Chassis Schematics

DIAGRAM

32

1996-00 Galant Starting System Chassis Schematics

DIAGRAM

33

1994-00 Galant Charging System Chassis Schematics

DIAGRAM

34

1994-00 Galant Charging System Chassis Schematics

DIAGRAM

35

1994-00 Galant Headlights Chassis Schematics

DIAGRAM

36

1994-00 Galant Taillights Chassis Schematics

DIAGRAM

37

1994-00 Galant Brake Lights/Backup

DIAGRAM

38

1994-00 Galant Turn Signal Chassis Schematics

DIAGRAM

39

1994-00 Galant Power Windows Chassis Schematics

DIAGRAM

40

1994-00 Galant Wipers Chassis Schematics

DIAGRAM

41

1994 Galant Power Door Locks w/ ETACS Control Unit Chassis Schematics

DIAGRAM

42

1994-00 Galant Power Door Locks Chassis Schematics

DIAGRAM

43

1992-00 Diamante Starting System Chassis Schematics

DIAGRAM

44

1992-00 Diamante Charging System Chassis Schematic

DIAGRAM

45

1992-93 Diamante Cabling System Chassis Schematic

DIAGRAM

46

1994-95 Diamante Cooling System Chassis Schematics

DIAGRAM

47

1996-00 Diamante Headlights Chassis Schematics

DIAGRAM

48

1992-95 Diamante Taillights/Backup

DIAGRAM

49

1992-95 Diamante Turn Signal Chassis Schematics

DIAGRAM

50

1992-00 Diamante Brake Lights, Horn Chassis Schematic

DIAGRAM

51

1992-95 Diamante Power Windows Chassis Schematics

DIAGRAM

52

1992-95 Diamante Wipers Chassis Schematics

DIAGRAM

53

1992-93 Diamante Power Door Locks Chassis Schematics

Lights/Horn Chassis Schematics

m

b

Lights Chassis Schematics

CHASSISELECTRlCiL6-33

INDEX OF WIRING DIAGRAMS DIAGRAM

54

1994-95 Diamante Power Door Locks Chassis Schematics

DIAGRAM

55

1996-00 Diamante Cooling System Chassis Schematics

DIAGRAM

56

1996-00 Diamante Taillights Chassis Schematics

DIAGRAM

57

1996-00 Diamante Turn Signal Chassis Schematics

DIAGRAM

58

1996-00 Diamante Power Windows Chassis Schematics

DIAGRAM

59

1996-00 Diamante Power Door Locks Chassis Schematics

DIAGRAM

60

1992-95 Diamante Headlights Chassis Schematics

DIAGRAM

61

1996-00 Diamante Wipers Chassis Schematics

DIAGRAM

62

1993-96 Mirage Charging System Chassis Schematics

DIAGRAM

63

1993 Mirage 1.5L Cooling System Chassis Schematics

DIAGRAM

64

1994-96 Mirage 1.5L Cooling System Chassis Schematics

DIAGRAM

65

1993 Mirage 1.8L Cooling System Chassis Schematics

DIAGRAM

66

1994-96 Mirage 1.8L Cooling System Chassis Schematics

DIAGRAM

67

1993-96 Mirage Headlights Chassis Schematics

DIAGRAM

68

1993-96 Mirage Taillights Chassis Schematics

DIAGRAM

69

1993-96 Mirage Turn Signal Chassis Schematics

DIAGRAM

70

1993-96 Mirage Brake/ Backup Lights/ Horn Chassis Schematics

DIAGRAM

71

1993-98 Mirage-Power

DIAGRAM

72

1993-96 Mirage Wipers Chassis Schematics

DIAGRAM

73

1993-96 Mirage Power Door Locks Chassis Schematics

DIAGRAM

74

1997-00 Mirage Starting Chassis Schematics

DIAGRAM

75

1997-00 Mirage Charging Chassis Schematics

DIAGRAM

76

1997-00 Mirage Cooling Chassis Schematics

DIAGRAM

77

1997-00 Mirage Headight Chassis Schematics

Windows Chassis Schematics

6-34 CHASSISELECTRICAL

INDEX OF WIRING DIAGRAMS DIAGRAM

78

1997-00 Mirage Taillight/Parking

Lights Chassis Schematics

DIAGRAM

79

1997-00 Mirage Turn Signal Chassis Schematics

DIAGRAM

80

1997-00 Mirage Brake Lights/ Backup Lights/Horns

DIAGRAM

81

1997-00 Mirage Power Windows Chassis Schematics

DIAGRAM

82

1997-00 Mirage Wipers Chassis Schematics

DIAGRAM

83

1997-00 Mirage Power Door Locks Chassis Schematics

Chassis Schematics

.

SAMPLE HOT IN RIM

DIAGRAM:

HOW TO READ & INTERPRET

WIRING

HOT AT

WIRING

DIAGRAMS

WIRE COLOR ABBREVIATIONS

DIAGRAM

SYMBOLS

HO

TI’ r ALL TIM ES FUSEE ISA CIRCUIT BREAKER

SOLENOID

1

WIWIZRTIWN

i

SOLENOID

KNOCK SENSOR

‘=iT

NORHbUY OPEN SWITCH

NORMALLY CLOSED SWITCH

El

lzl

NORNALLY

NORMALLY 3 POSITION SWITCH

RELAY

REIAY

SATTERY

l

CONTROL HODUsE

RESISTOR

RESISTOR

VARIABLE RESISTOR

VARIABLE RESISTOR

WEED SENSOR

AICAND HEATING SYSTEMS

m

MOTOR

CHOKE RRACKh /

A

\

El

I

c-l 1

OTHER SYSTEM REFERENCE

GROUND

D m m

HEATED

m

IdI1 GYlR OXYGEN SENSOR

HEATING ELEHENT

HEATING ELEMENT

‘m c3 DIAGRAM DIAGRAM

1

2 TccaGW02

TccaGWOl

1990-92 GALANT

2.OL SOHC ENGINE

SCHEMATIC

HOT IN RIB aR START

1993 GALANT

HOTINRWORSTART FROH 16NlTlON SWITCH

STEki CIRCUT

HOT IN RUR OR STlRT

2.OL SOHC ENGINE SCHEMATIC

HOT AT ALL TIMES

HOT IN RU4 DR START FRDtl IGNITION SWITCH

t

E 4’

Tm CHECK >EN6lNE LIGHT

IGNITION PDWER TRANSISTOR

IEEE LIGHT

4 &Rl,DR

s

D

ICNlTlOK FUWER TRARSlSTOR

m

TO OATA LINK CONRECTM ( ! s

--

TO UC

SPEED&TEfl/ REED !iWlTCH

i%

a ;

WI CWJTROL UNIT

AIT

EGR TEnFERA~ SENSOR mLIFoRRlA WLn

VOLUME AIR FLOW SENSOR I

.

An

B 11 STARTING CIRCUT

L

MT

m

DIAGRAM3

n/T.

I

11

STEK ClRCUT

5E % ! FUSE I7 IOA

EGR TEMFERATLRE SERSDR , (~~IFORR~A ONLV)

*

HOT AT ALL TIMES

NOlE MFI CCMECTOR Cl0 = ‘AWI CONNECTOR Cl, = %’ WI CDNNECTOR Cl2 = C

!

0

IDLE SFEED > CONTROL MOTOR

NOTE I’IFI CORRECTOR Cl0 = -AWI coRNEcmR CII - 3’ “FI CONNECTOR Cl2 I 77

DIAGRAM l

4 93156E02

93156EOl

1990 GALANT

2.OL DOHC ENGINE

1991-93 GALANT

SCHEMATIC NOTE: I’IFI CONNfCTOR Cl0 - ‘A’ IlFI CONNECTOR CII = -G’ NFI CORNECTOR Cl?! - y:

NOT IN RUN OR STMT FROM IGNITION SWlTCH

2.OL DOHC ENGINE

FUSIBLE FRON

LINK 0

P-

SCHEMATIC

STARTING ClRCUlT

d a 61

TO MTA LINK CGWECTGR

TO UC CGNTROLI e! ” l-L

DIAGRAM

DIAGRAM

5 93156EO3

c P

I t

6 9135f5EO4

1994 GALANT

2.4L SOHC ENGINE

SCHEMATIC

NOTE ECM CONNECTOR CS9 = ‘A’ ECH CONNECTOR C60 = B ECH CONNECTOR Cti, = -I’

IGI SI

1994 GALANT NOTE ECH CONNECTOR C59 = ‘AECH CONNECTOR C60 = ‘B ECH CONNECTOR CM = -17

* ON :li

2.4 DOHC ENGINE

SCHEMATIC

HOT AT ALL Tl?lES FUSE s 20A

HQt IN RUN OR START FRQ+l IGNITION SWITCH

s

FVSE 0 IOA

CHECK ENGINE > LIGHT

-T-T

CHECU / ENOM LIGHT

I CRANKSHAFT/ CAMSHAFT POSITION SENSOR

FUEL

Pup

PQW2R TRANSISTOR

TO DATA LINU CONNECTOR

m

(D

A

a= TO AK CONTROLS

ENGINE CONTROL WCCU.2

TO CDDLING SYSTEM VEHICLE SPEED SENSOR

FROM START1116 CIRCWT

f

m FRONT H2AT2D OXYGEN SENSOR

EGR TEllPERATuRE SENSOR

REAR HUTED OXYGEN SENSOA

REAR HEATED OXYGEN SENSOR

!NSlNE 3OLANT rEMPERATu3E ENSOR

vJ* HOT AT

HOT AT ALL TlblES

DIAGRAM

7

DIAGRAM 93156E05

.

8

TIM!3

1996-00 GALANT

2.4L ENGINE

1993-96 MIRAGE

SCHEMATIC

HOT AT AU. TIMES

HOT IN RW OR STMT FROU

HOTAT*LLTlMES

1SL ENGINE SCHEMATIC HOT IN WN M STM

FWE I IOA TO OATA LINC -CTOS

)l$fE

! I

i

To .- szl 1_/5 %-5

f

-.I

i

AtT,

N/T . P 5 i 1 sTAmlNG CIRCUIT

HOT*1

DIAGRAM

9

RCE I2 ImA .lllm

STEGG CWCUT HOT Al

PI3

~WIKEKI SISSVH3 _____ --.. --.._ "b -.-_ "--I " OP-9 --IT^l^----" ^._. --L^ .---~..-"--^L--*l---.--."..". -.---__i___i_ ~-,-=L".-".. I.I_ ^^.. I."I___ -1^~--. "x-_-.xI.-" ~,..lll^".._"l ._^. __I ^_ _..-_ __-_.*.x^ _Ix-^ ^._I"--x^.~ I._II.x_xI__-_" ----.I~_x^^~~.."--^.^~._."".~-~.,"~.-1.~

A-37

A-92

D-26

1997-00 MIRAGE HOT AT UL

1.8L ENGINE

SCHEMATIC

TIMES FUSIRLE LINK

1992-93 DIAMANTE

HOT IN RiN GR START FRW IGNITION SWITCH

:04

NOTE ECM CGNNECTOR CZI = ‘4. ECM COmECTOR CL2 = w Et24 COtWECTOR CZ3 = ‘IT

HOT AT ML

3.OL SOHC ENGINE TIHGS FUSS I zG4

HOT IN R&S4 OR STbRT FROn IGNITIW SWITCH

HOT IM RUN OR START FROM IGNlnON SWITCH 4

51 IGHlnON

FAiLUlE

SCHEMATIC

SENSOR

FUSE b IO4

CHECK ENGINE LIGHT

TO VEHICLG

ENGINE CONTROL MO4M.E IECH) II

ENGINE CONTROL MWUE

,1 TO COOLING SYSTlw4

NTA NIT . 5 \ (I) I 4

cI> 72

D

F!u3swE .-cn c&n

POWER 1 STEERIMG

FROM STARTING CIRCUT

SWITCH

CD

POSITION 6 SWITCH FL&G 2 IOA HOT AT MFI MFI Hfl WI

CONNECTOR CONNECTOR CONNECTOR CONNECTOR

8.37 811 6.59 Sk0

EGR TEHFRR4TLtGE SENSOR

TIMES

= ‘4. - 3’ = ‘C’ g ‘D-

DIAGRAM

13

DIAGRAM 93156E15

14

KNOCK SENM FLsC I9 104

hl c3 -i zu

noTIE

Ecn ComEcTm Ktl-cEE~‘c scn-us=r

1994-95 DIAMANTE

3.OL SOHC ENGINE

IIOTATILLTHS

SCHEMATIC

1992-93 DIAMANTE

HOTINMORSTMT

NOTE: EcncoaEcTmcEl-*AEcncoloeCTmczz.F ten-TmcEs*r

CEI . -A* lGz&l NlTCl4

d

I

I -I

HOTATNLTIIES

3.OL DOHC ENGINE mTlNalNmsTART Fmn lsmlon SmTal

SCHEMATIC HOTIN~ORSTART motl lsnlTloN SmTal

t

.I

TO CooLlm SysTEll

’ \\\

DIAGIWM

15 93156EOQ

DIAGRAM

16

1994-95 DIAMANTE NOTE: ECH CONNECTOR CZI . *A’ ECN CONNECTOR C22 * 8’ ECN CONNECTOR CZ3 = Kc” ECH CONNECTOR Cl05 * .O-

HOT AT ML

3.OL DOHC ENGINE TIMES FUSG

SCHEMATIC

1996-00 DIAMANTE

3SL ENGINE SCHEMATIC

HOT IN RUN OR START FROn IGNITION SWITCH

:9A

HOT AT ALL TIMES FLBG 39

CH

HOTINRUNORSTART FRan IGNITICU

t

-

TO DATA LINK CONNECTOR TO DATh LIM CCNNECTOR

TO VEHICLE SPEED SENSOR

TR&LE

TO AIC CONTROLS

TO

TO COOLING SYSTEM

SYZ&

z :m

$5” 1

$g$F m 0 1

TO COOLING SYSTEM

FROM STARTING SYm3

HOTP:

FUEL TANK PRESSURE SENSOR $.

FUSE I9 IQA

*

DIAGRAM

NANIFOLO DIFFERENTIAL PRESSURE SENSOR

TIMES

17

I NOTE: BFI CONPECTOR RI05 = ‘A’ HFI CONNECTOR BID9 = ‘8’

HOT AT

DIAGRAM 93156Ell

=

18 93156E16

1990-95 GALANTMIRAGE

CHASSIS SCHEMATIC

1990-93 GALANT CHASSIS SCHEMATIC

HOTATALLliM55 Fu5m5 Fu5lnE UM Llwl 5 5 as

L P

LINK LA

4-

I

zI

DIAGRAM

19

3

DIAGRAM 93156801

.lm55 UNK I w

ALTERNAlun

20 93156802

. HOT AT ML

1990-93 GALANT

CHASSIS

SCHEMATIC

1990-93 GALANT

TIMES FlBlSLG LINK 5 3OA

CHASSIS

TIMES -FlJSlBLE LINK 7 4oA

IGNITION SWITCH

SCHEMATIC HOT AT ALL TMES

I m-----------------v-

---

coNoENsEn

FAN MOTOR RELAY Ml)

LIGHTING SWlTC4l

5 * PREsslJm SWITCH

DIAGRAM

HEADLIGHT RELAY

21

DIAGRAM 93156803

22

1990-93 GALANT

CHASSIS

SCHEMATIC

1990-93 GALANT

CHASSIS

SCHEMATIC

HOT AT ALL TIMES FUSIBLE LINK 5 JOA

HOT AT ALL TINES FUSIBLE LINK I LOA

HOT AT ALL TIMES FUSIBLE LINK LA

P B

IGNITION SWITCH

ACCY d FUS2 5 lo* FUSE 2 IOA

LIGHTING SWITCH 5

PARK/ NEUTRAL PQSITION SWITCH

-

t

m ; RIGHT FRONT coMBINATla4 LIGHT

e ”

L

n

-

5

l (D

RIGHT REAR COnSlNATloN LIGHT

+

RIGHT REAR COHSINATION TAlLLIGHT

+

LEFT REAR LID LIGHT (EXCEPT 19901

ID

RIGHT REAR LID LIGHT EXCEPT 1999)

HIGH WOWED BRAKE LIGHT

DIAGRAM

23

DIAGRAM 93156B05

24 93156806

1990-93 GALANT CHASSIS SCHEMATIC

1990-93 GALANT CHASSIS SCHEMATIC W/O ETACS

HOT AT ALL TIRES

HOT AT ALL TINGG

HOT AT

L TIMEG FUSE

HOT IN RW

TA!!HT ELAY

IGNITION SWITCN

y

2

6z

2 e

% SlGtEL HAzmo FLAGHER lmll

c is L .

” 4

R .

TLWN-SIGNAL GWWW

DIAGRAM

DJAGRAM

25 93156607

26 93156610

1990-93 GALANT

CHASSIS SCHEMATIC

1990-93 GALANT CHASSIS SCHEMATIC w/o ETACS

w/ ETACS

HOT IN RLIN OR START

STAUT FUSS IO IOA

I

.r

I

ETACS CiWTROL (ECU)

kNiT

-

-

I

COUNN SWITCH

I *

lNTERWlTTENT WIPER REIN

I WASHER CONTROL SWlTCH

DATA LIM COmECToA

RAIN SWITCH

DIAGRAM

27

DIAGRAM 93156Bl

28 93156812

1990-93 GALANT CHASSIS SCHEMATIC w/ ETACS

HOTINRUNORSTART

2

1990-93 GALANT CHASSIS SCHEMATIC w/o ETACS

HOT IN R(N aR START

,

1

2 I,

d

DOOR LOCK

1

\

0 1991-9s

v

I999 OKLY 2

id I

COLLWN SWITCH

WASHER MOTOR

B

r/

DIAGRAM

29

LEFT Et!l LOCK ACTUATW

DIAGRAM 93156813

30 93156B14

1996-00 GALANT CHASSIS SCHEMA.TIC

1990-93 GALANT CHASSIS SCHEMATIC MANUAL TRANSMISSION

WI ETACS NOT AT AU TIMES FUSE 5 I5A

NOT AT AU

TIMES

16NITIoW SWITCH .

i 0

ETACS CMfWOL

:

WIT

MTTENY = z zz

> ii - STBRTER NOTOR i

T

3

-cLuTcN FEMA’ Foslnow ~clwcll

AUTOMATIC TRANSMISSION HOT AT ALL TlHES

0

r I

mGNT Et LOCK

(1

AcllJAToll I

I w/o Tumo

TlBBO

4

FE !3vzE

DIAGRAM

31

DIAGIUM 93156815

32 93156616

1994-00 GALANT CHASSIS SCHEMATIC

1994-00 GALANT CHASSIS SCHEMATIC HOT AT UL

e 34 _ TIMES , FUSIBLE LINK ‘6 4GA

HOT AT UL

TIMES FUSISLE LINK 1 101

HOT AT

TIMES Fusl8i.E LINK

HOT AT UL

TIMES

HOT AT ALL TIMES FUSE J SGA

LA 34 IGNITION SWITCH

. TIMES Fl!SlELE LINK 2 IGGA

I

IGNITION SWITCH . ACCY LOCK w a

4 1

FUSE G ID* &i 2

> P

a CONDENSER FAN IlOTOR IQEUY (LO)

’ ---. .

E GENERATOK RELAY

--

‘I

d

d

COHBINAl nETER

J! B

CONDENSER FAN MOTOR

8 I

&

ALTERNATOR

r-

IC RECUATOR

4 s I ENGINE CONTROC FIODLLE I

1

DIAGRAM

33

DIAGRAM

34

CONDENSER FAN HOTOll RELAY Gil)

1994-00 GALANT CHASSIS SCHEMATIC

1994-00 GALANT CHASSIS SCHEMATIC

HOTAT ALL TIHES HOT AT UL

MDT IN RUN FUGE

TlMES FuslGLE LINK 6 LOA

FUSIBLE LINK b t&A

Y

t *

m!

B

LL

0:

TAGUGNT RELAY

---------m-w l

L P

is FU5E b lo*

HEADLMIT RELAY

0 OFF.

LIGHTING SWlTcH

AHEAD TbJL

WFT WE POGlTlONl IlAltG LIGHT

RlGHT REAR LID TAILLICM

LEFT REAR LID TAJLLIGHT LIGH-llNG SWITCH

DIAGRAM

DIAGRAM

35 93156B19

36 93166620

1994-00 GALANT CHASSIS SCHEMATIC

1994-00 GALANT CHASSIS SCHEMATIC

PARK! NEUTRAL POGITION SWITCH

a@

RIGHT REAB

CLoCKGPRlNG

cctmiN*noI( LIGHT

HIGH HOlMTl?D BRWE LIGHT GEAR SPOILER)

DIAGRAM

37

DIAGRAM 93156621

38 93156822

1994-00 GALANT

CHASSIS

SCHEMATIC

1994-00 GALANT

CHASSIS

SCHEMATIC

HOTINRUNORSTART

COLUPlN SWITCH INTERMl-l’ENT WIFER RELAY

iii WIPER PlOTOR

RIGHT REAR POWER WINDOW SW SWITCH

LEFTREAR FQWER

RIGHT FRONT POWER WINDOW SUG SWITCH

RIGHT FRONT FOWER WINDOW MOTOR

WINDOW ilOlOR

DIAGRAM

39

DIAGRAM 93156825

40 93156826

1994 GALANT

CHA!BIS

DIAGRAM

SCHEMATIC

199440

41

GALANT

CHASSIS

DIAGRAM 93156827

SCHEMATIC

42 93156828

1992-00 DIAMANTE CHASSIS SCHEMATIC HOT AT ML

1992-95 DIAMANTE CHASSIS SCHEMATIC 1992-1995

TlMES FUSIBLE LINK

HOT AT ALL TIMES FUSIBLE LINK

HOT IN RUN OR START

:0 A

LA

P IONITIMI SWITCH

ii: 2

.

KEY REMINDER SWITCH

IC EGLKATOR

HOT IN RI J

1996-2000

HOT AT ALL TlMES FUSE IS 15A

NOT AT ALL Tll’+i?S FUSIBL2 LINK 1. WA

START FUSE I2 IOA

ALL TlflES

HOT IN RUN OR START FUSE I3 IOA

1996-2000

$ GENERATOR RELAY IGNITION SWITCN

CHARGING LIGHT

1 ASSIST ECN

.

PARKI NEUTRAL FoslTloN SWITCN

DIAGRAM43

DIAGRAM44 93156829

93156830

1994-95 DIAMANTE CHASSIS SCHEMATIC

1992-93DIAMANTE CHASSIS SCHEMATIC HOT AT ALL TIMES FUSIBLE LINK s JOA

HOT AT

TINES FIBUJLE LINK

HOT AT ALL TIHES

toA t L

IL

IGNITION SWITCN

IPNITION

i

L-

RUN

CONDENSER FAN 1 MOTOR

CONDENSER FAN ) MOTOR

RADIATOR ) i=&R

% 3

I

a

I

CONDENSER FAN I’IOTQR RELAY (HI)

_---

RAJJIATOR FAN MOTOR D RELAY

1

1

RADIATOR FAN HOTOR RELAY (HI)

b

CONDENSER FAN MOTOR REIAY

TO ENGINE CONTROL noDuE

d - THERM0 SENSOR

--RESISTOR

I RADIATOR ASSEMBLY

ENi:NE CONTROL MODULE

ii CONDENSER FAN RESISTOR m

DIAGRAM

45

DIAGRAM

46 93156B32

1992-95 DIAMANTE

CHASSIS SCHEMATIC

1992-95 DIAMANT E CHASSIS SCHEMATIC HOT AT I

I

HEBUCHT NEIAY (LO1

RIGHT FRONT l’UI(INGl SIOE MAmEN LISHT

al6liT REAR comRINATlw TMLLlCltT

RIGHT REM LID LIQHT

DIAGRAM

47

DIAGRAM 93156633

48

1992-95 DIAMANTE

F 0

CHASSIS

SCHEMATIC

1992-00 DIAMANTE

CHASSIS

SCHEMATIC

0 7

TURN SIGNAL *ND HAZARO FLASHER UNIT LEFT REAR COMBINATIQI LIGHT

1992-95

LEFT REM LID LIGHT

” E&l *1

RIGHT REAR cotlBINATta LIGHT

CI

m

RIGHT REM LID LIGHT

?

1996-00

HOT AT ALL TIMES FUSE I6 >

2

”

HIGN MOUMED STOP LIGHT

HOT AT ALL TIMES FUSE 19 ISA

3 ------t e (L

ZEY ”

HORN 1 RELAY

TO ETACS L!NlT HORN SWITCH

DIAGRAM

49

DIAGRAM 93156635

50 93156B36

1992-95 DIAMANTE CHASSIS SCHEMATIC 1START

HOT AT ALL TIMES

1992-95 DIAMANT E CHASSIS SCHEMATIC

ROT AT ALL TIMES HOTlNAmORSTART

FuEe II IDA

HOTINRUNORSTART

HOT IN RUI FUSE

I9 IOA E f

-

.L I

I START

ED:’ (9s-951

-I

CDLWR SWITCH

F-l

LEFT REAR DDOR coNTRDL UylT I

DIAGRAM

51

DIAGRAM 93156837

52 93156B38

1994-95 DIAMANTE CHASSIS SCHEMATIC

1992-93 DIAMAJNTE CHASSIS SCHEMATIC HOT IN NUN ON START FUSE II IOA

I START FUSS 4, WA

HOT AT ALL TIMES

d a

s

ETACS WIT

I

I

4

VEtllCLi2 SPEED SENSOR

MVLESS ENTRY CONTROL UST

LEFT WOR CONTROL WIT I $

0

-

IJFT FRONT Es ACTUATOR

LEFT iz

RIGHT REAR OOOR LOCK ACTUATON

iiz OOOR LOCK ACTUATQR

LOCK ACTUATON

DIAGRAM

DIAGRAM

53 93156839

54 93156840

1996-00 DIAMANTE CHASSIS SCHEMATIC .L TIMES FUSIBLE LINK I 6 Lo1

HOT AT ALL TIMES

HOT b

1996-00 DIAMANTE CHASSIS SCHEMATIC

TIMES ‘FUSE

HOT IN RlM OR START FUSE I IDA

LA

TAILLIGHT RELAY

5 PARK

I,

*I R’f

PARK/NEUTRAL POSlTlON SWITCH

.Dmz

d a

ASSIST ELECTRONIC CONTROL cm-7 (ECU)

e d

1

RADIATOR

RADlATOR FAN RELAY WI)

2AY

I (

CONDENSER FAN HOTQR

lNSTRlMENT

PANEL 3’*“’

CONTROL UNIT

1

* HEADLIGHT SWITCH

I LEFT REAR SlDE MARKER LIGHT

LEFT REAR LID LIGHT

DIAGRAM

55

DIAGRAM

56 93156866

199640 DIiUW.ANTE CHASSIS SCHEMATIC

199640 DIAMANTE CHASSIS SCHEMATIC H6TINRlN6RSTM

MT FIB6 A WA

TlmNslcNuAm -UNIT

AT ML TIMES FUSE II WA

T AK&T RELAY

RllmsTAl 1

-..-

L

ii f

ii:

r

I

1 FHERWlW6W MAIN SWITCH CMIVER SIDE)

I

;

I

Rl6H-r RUR WORCDWTROL WlT

RIGHT fMNT wcwc6NTna WT

I

I

P

DIAGRAM

DIAGRAM

57 93156B67

58 93156868

1996-00 DIAMANTE CHASSIS SCHEMATIC HOT AT ALL TlHES FUSS II ISA

HOT AT ALL TIMES FUSS 12 I6A

1992-95 DIAMANTE CHASSIS SCHEiWATIC

HOT AT ALL TIMES HOT AT FUSIGLS LINK I s KEY REtllN5ER SWITCH I

ETACS ELECTKGMC

CONTROL UGT (ECUI

LIGHT AUTOtlATIC

s INSTRUMENT PAML ELECTRONIC CONTROL MT (ECU1

LEFT FGGNT GOGR M0GU.G

FRONT OOOR SWlTCH LEFT SloEI

LEFT

1

HEAGLlGHT SWITCH

i

-r? R’z

LOCK ACTUATOi3

UNIT

5 J

4

.-------------

VEHICLE SPEW SENSOR

RIGHT FKONT DooR LGUt ACTUATO

SHUf-OFF

OOOR LOCK ACTUATOR

LNLOCK

DIAGRAM

59

DIAGRAM 93156669

60 93156870

1996-00 DIAMANT E CHASSIS SCHEMATIC

1993-96 MIRAGE CHASSIS SCHEMATIC

HOT AT

TlnEs FUSlBLE LINK [ :oA

HOT Al

HOT AT ALL TIMES FUSISLE LINU 5 MA

TIMES FUSISLE LINK I,

P

ASSIST ELECTRONIC CONTROL WIT omJl

IGNITION SWlTCH

, WINDEHIELO WIRER MOTolr

FUSE 3 ID1 :

l s --

INsTRunENT FANEL ELECTRONIC CONlROL UNIT (ECU)

I

I

GENERATOR RELAY

I

--

CWSlNATtffl METER

TO ENOINE CONTROL

t

h MO, CFF

&LO -H1

DIAGRAM

AmOb

*LO %I

OfF

mPER SWITCH

VARIASLE INTERtllTTENT

- WIPER/ WASHER COLUMN 3WlTCH

DIAGRAM

61 93156B71

62 93156841

MANUAL TRANSMISSION

1993 MIRAGE 1.5L CHASSIS SCHEMATIC HOT ATALL TIHES HOT AT ALL TIMES FWSLE LINK s LPI

1994-96 MIRAGE

ML

CHASSIS

SCHEMATIC

FUSISLE LINK L SW

IF IGNlTi#l SWITCH

I

L STARR&

I

RADIATOR FAN MOTOR CONTROL RELAY

HOT Al ALL rims FUSISLE LINM 5 LOA

HOT1

1LFAN CONDENSER MOTOR RELAY

AUTOMATIC TRANSMISSION

. TIHES FUSlSLE LINK

ISOA

4 r1 ( I

NAOIATOR ZLLY )

m

1 RABATOR !ZEHIlLY

i

DIAGRAM

63 DIAGRAM 93156B42

64 93WB43

1994-96 MIRAGE 1.8L CHASSIS SCHEMATIC

1993 MIRAGE 1.8L CHASSIS SCHEMATIC HOT AT ALL TIMES FUSISLE LINK 5 UA z

HOT AT ALL TIMES

HOT AT ALL TIMES FUSISLE LINK la 3GA

NOT AT ALL TltlES

5 d

IGNITIOW SWiTCH AUTOt4ATlC COHFRESSOR CONTROL OFF ,

G/B ”

c d I,

E Fii

?: 0

f

------? 5

RADIATOR FAN PlOTOR CONTROL RELAY

RAGIATOR FAN MOTOR CONTROL RELAY

[ e c

EE 1 -, c &

d a RESISTOR

d CONDENSER FAN MOTOR

RADIATOR FM MOTOR

r

< ENGINE CONTROL MOOLU

VEHICLE WEE0 SENSOR

DIAGRAM

DIAGRAM

65 93156B44

66

‘28

93156845

1993-96 MIRAGE CHASSIS SCHEMATIC

1993-96 MIRAGE CHASSIS SCHEMATIC

HOT AT ALL nm3 FUSIBLE i-7 LINK

HOT &T

ALL’ :3 E3 IIMES lmsLE INK OA

ILi

F c

TAILUGHT RELAY

, -. C4

---------~------------

FUSE 2 loA

5

5 RIGNT PMKWCI m

SiIER LIGHT

7

I

RIGHT

1

P

DIAGlU’dM

67

Eiz NARKER uGHT

MARKER UGHT

DIAGRAM

68 93156847

1993-96 MIRAGE CHASSIS SCHEMATIC

1993-96 MIRAGE CHASSIS SCHEMATIC

c OFF.

TURN SIGNAL AND HAZARD FIASHER WIT

0

-

RIGHT REAR COtlBIKATlQN UGHT

LEFT REAR CDMSINA LIGHT

HIGH NOWTED BRAKE LIGHT RBAR SHELF) COLIJNN TWN SIGNAL SWITCH

HOT AT Ml.

HOT IN Ruw OR START FUSE e IQ*

TIMES

RIGHT Zh~T10t4 LIGHT

>

MGWT FRONT 2LL

PARK/ NEUTRAL POSITION SWITCH

CI) 72

D cn m

LEFT REAR COtlBINATlDN LIGHT

cn

SIGNAL

RIGHT REAR COHSINATION LIGHT

DIAGRAM

69

DIAGRAM

70 93156850

1993-96 MIRAGE

CHASSIS

SCHEMATIC

1993-96 MIRAGE w/ INTERMITTENT WIPER

CHASSIS

SCHEMATIC

HOT IN RUN OR START

I-

COLUMN SWlTCH

I

I

INTERMITTENT WIPER RELAY

II

I

I I

I

VdRlABLE INTERMITTENT WIPER CONTRDL SWITCH

WINDSHIELD

r WINDSHIELD WIPER MOTOR

1 WINDSHIELD WASHER nOTOR

w/o INTERMITTENT WIPER

HOT IN RUN OR START

COLUWN SWITCH

I 1 --

LEFT FRONT POWER WINDOW NOTOR

DIAGRAM71 93156852

DIAGRAM

72 93156853

1993-96 MIRAGE CHASSIS SCHEMATIC HOT AT ALL TIHEE

1997-00 MIRAGE CHASSIS SCHEMATIC

HOT AT ALL TIMES

HOT AT ALL TlIlES FUSIBLE LINK

HOT AT N.L TIMES FusmlE LIRK s SOA

LA

1

z

ICNITIOW SWITCH

‘ISNITIQII SWITCH

,

LEFT-

FRONT DOOR LOCK ACTUATOR

1994-96

RIGHT

HOT AT ALL TIMES FUSE 1) ZOA

1 r! d --

LEFT FRW OOUR kt%ATlm

1 LEFT

’

Ez LOCK ACTUATOR

DIAGRAM

I c ii RIGHT zr LOCK KTWTOR

I RIWT iii% LOCK ACTUATOR

73

DIAGRAM 93156954

74 93156855

1997-00 MIRAGE CHASSIS SCHEMATIC

1997-00 MIRAGE CHASSIS SCHEMATIC

c;T ALl . TIMES

Ml’

AT ALL TIMES

HOT AT ALL TIMES

0 HOT Ar

L TIMES

NOT AT ALL TIMES

HOT A-r

L TIMES FUSISLE LINK 2 IQOA

ALTEl?t&ATOR

IC REGuLAToR

ENGINE CONTROL MOOLU (EUl)

DIAGRAM

DIAGRAM

75 93156856

76 93156B57

,1997-00MIRAGE CHASSIS SCHEMATIC HOT AT AU

1997-00 MIRAGE CHASSIS SCHEMATIC HOT AT ALL Tll’iES

TIMES

PI OR.

HEAG

TAlL

5

RIGHT FRONT COllSINATlO)I LIGHT

uz IJFr

REAR WOE MAKKER LIGHT

m

0f

HEAOLIGHT SWITCH

DIAGRAM

77

DIAGRAM

78

RIGHT REAR SIDE MARKER LIGHT

1997-00 MIRAGE CHASSIS SCHEMATIC

1997-00 MIRAGE CHASSIS SCIfEWTIC

RIGHT ZiilNAT,ON LIGHT

HOT AT AU

TMES FUSE

34

$

RIGHT FRONT

RIGHT IE&4ATllm UGHT

EL

)ET TmN SIGNAL RIGHT REAR CONEINATIQII LIGHT

DIAGRAM

79

DIAGRAM

80

1997-00 MIRAGE CHASSIS SCHEMATIC HOT IN RR4 OR STMT

1997-00 MIRAGE CHASSIS SCHEMATIC

w/o

HOT AT ALL TIMES FUSIBLE LINK 6 SOA

INTERMITTENT CONTROL

LEFT REAR 4 DOOR or&Y)

HOT IN RUN OR START t FUSE

COLUllN SWITCH

1

POWER WINDOW tiAlN SWITCH

RIGHT REAR (4WWOM.I)

I d

dF

.

a?E 0 WASHER MOTOR

WIPER MOTOR

. W/ INTERMITTENT CONTROL

r

HOT IN RUN GR START FUSE

5

d COLUtlN SWITCH I

INTERMITTENT WIPER RELAY I

WASHER CONTROL SWITCH

.HI

HI

OFF

*LO

MT=

I

WIPER SWITCH

LO

T

RIGHT FRONT POWER WINDOW MOTOR

WIPER MOTOR

LEFT REAR POWER WINDOW MOTOR (4 GOOR ONLY)

1 DIAGRAM

81

DIAGRAM 93156862

82

.

1997-00 MIRAGE

CHASSIS

SCHEMATIC HOT AT

START FUSE I IOA

_ TIMES FUSE J LOA

ETACS ELECTRONIC CCMROL (ECU1

DIAGRAM

83

93156B64