CH 1 General Info & Maint.

HOW TO USE THIS BOOK 1-2 WHERE TOBEGIN l-2 AVOIDINGTROUBLE 1-2 MAINTENANCEORREPAIR?
1-2 AVOIDINGTHEMOSTCOMMONMISTAKES l-2 TOOLSAND EQUIPMENT 1-2 SPECIALTOOLS l-4 YOUR VEHICLE SAFELY 1-4 DON'TS l-6 FASTENERS,MEASUREMENTSAND CONVERSIONS l-6 BOLTS,NUTSANDOTHERTHREADED RETAINERS1-6 TORQUE l-7 TORQUEWRENCHES l-7 TORQUEANGLEMETERS 1-9 STANDARDANDMETRIC MEASUREMENTSl-9 SERIAL NUMBER IDENTIFICATION l-10 VEHICLE IDENTIFICATION NUMBER l-10 ENGINE IDENTIFICATION NUMBER I-10 TRANSAXLEIDENTIFICATION I-10 DRlVEAXLE(AWDGALANTONLY)l-10 TRANSFERCASE(AWDGALANTONLY) l-10 ROUTINEMAINTENANCEAND TUNE-UP l-14 AIRCLEANER(ELEMENT) 1-14 REMOVAL&INSTALLATION1-14 FUELFILTER 1-15 REMOVAL &INSTALLATION l-15 PCVVALVE l-15 REMOVAL&INSTALLATIONl-15 EVAPORATIVECANISTER l-16 SERVICING 1-16 BATTERY 1-16 PRECAUTIONSI-16 GENERALMAINTENANCE 1-16 BATTERYFLUID 1-16 CABLES I-17 CHARGING I-18 REPLACEMENT1-18 TS BEL 1-18 INSPECTiON l-18 ADJUSTMENT 1-18 REMOVAL&INSTALLATION1-18 TIMINGBELTS l-20 INSPECTIONl-20 HOSES I-20 INSPECTIONl-20 REMOVAL&INSTALLATION1-21 CV-BOOTS 1-21 INSPECTIONl-21 SPARKPLUGS l-22 l-22 SPARKPLUGHEATRANGE REMOVAL&INSTALLATIONl-22 -23 INSPECTION &GAPPING 1. SPARKPLUG WIRES 1-24 TESTING 1-24 REMOVAL&INSTALLATION1-24 l-25 DISTRIBUTORCAPANDROTOR REMOVAL&INSTALLATIONl-25 INSPECTION 1-25 IGNITIONTIMING 1-25 . GENERALINFORAMTION.25 llNSPECTlON&ADJUSTMENl1-26 VALVELASH l-27 ADJUSTMENT l-27 IDLESPEED 1-28 AIR CONDITIONING SYSTEM 1-28 SYSTEMSERVlCEiiREPAlRl-28 PREVENTIVEMAINTENANCE 1-28 SYSTEM INSPECTION l-29 WINDSHIELD WIPERS l-29 ELEMENT(REFILL)CARE& REPLACEMENTl-29 TIRESANDWHEELSl-30 TIREROTATION I-30 TIREDESIGN 1-31 TIRESTORAGEl-31 INFLATION &INSPECTION l-31 CARE OFSPECIALWHEELSl-32 FLUIDS AND LUBRICANTS 1-33 FLUIDDISPOSAL 1-33 FlJELANDENGlNEOILRECOMMENDATlONS ENGINE OIL l-33 FUEL l-33
l-33 OPERATION INFOREIGNCOUNTRIES ENGINE l-33 OILLEVELCHECK 1-33 OIL& FILTER CHANGE l-34 MANUALTRANSAXLEl-35 FLUIDRECOMMENDATIONS l-35 LEVELCHECK l-35 DRAIN&REFILL l-36 AUTOMATICTRANSAXLE l-36 FLUIDRECOMMENDATIONS l-36 LEVELCHECK 1-36 DRAIN&REFILL l-36 PAN& FILTERSERVICE1-36 TRANSFERCASE(AWDGAlANT ONLY) l-38 FLUIDRECOMMENDATIONS l-38 LEVELCHECK l-38 DRAIN&REFILL l-38 REARDRlVEAXLE(AWDGALANTONLY) l-38 FLUIDRECOMMENDATIONS l-38 LEVELCHECK l-38 DRAIN&REFILL l-38 COOLINGSYSTEMl-39 FLUIDRECOMMENDATIONS l-39
iM-41
1-2 GENERALINFORMATIONAND MAINTENANCE

ChittonsTotal Car Caremanualfor the 199M10 Mitsubishi Mirage, Galantand Diamanteis intended to helpyou learnmoreaboutthe innerworkingsof your vehiclewhile savingyou moneyon its upkeep and operation. The beginningof the book will likely be referredto the most,sincethat is whereyou will find information for maintenance tune-up.The othersectionsdeal and with the more complexsystemsof your vehicle.Operating systemsfrom enginethroughbrakesare coveredto the extentthat the averagedo-it-yourselferbecomesmechanicallyinvolved.This book will not explainsuchthings as rebuildinga differentialfor the simple reasonthat the expertiserequiredandthe investmentin specialtools makethis task uneconomical. It will, however,give you detailedinstructionsto helpyou changeyour own brakepadsand shoes,replacesparkplugs,and performmanymorejobs that cansaveyou money,give you personalsatisfaction and helpyou avoid expensiveproblems. A secondarypurposeof this book is a reference for ownerswho wantto understand vehicleand/or their their mechanicsbetter.In this case,no tools at all are required. name.As long as you remember your own code,the lines can be reconnected matchingsimilar letters by or names.Do remember tapewill dissolvein that gasolrneor otherfluids; if a componentis to be washedor cleaned,useanothermethodof identification. A permanent felt-tippedmarkeror a metalscribe can bevery handyfor markingmetalparts.Remove anytapeor paperlabelsafterassembly. everythingbackin its properposition.Wewill supply explodedviews wheneverpossible.Whenmaking adjustments, performthem in the properorder.One adjustment possiblywill affectanother. 2. Overtorquing undertorquing). (or While it is more commonfor overtorquingto causedamage, undertorquing allow a fastenerto vibrate loose may causingseriousdamage. Especially whendealing with aluminumparts,payattentionto torquespecificationsand utilize a torquewrenchin assembly.If a torquefigure is not available,remember if you that are usingthe right tool to performthe job, you will probablynot haveto strainyourselfto get a fastener tight enough.The pitch of mostthreadsis so slight that the tensionyou put on the wrenchwill be multiplied manytimes in actualforce on whatyou are tightening.A good exampleof how critical torqueis can be seenin the caseof sparkplug installation,especiallywhereyou are puttingthe plug into an aluminum cylinderhead.Too little torquecan fail to crushthe gasket,causingleakage combustion of gasesand consequent overheating the plugand of engineparts.Too muchtorquecan damage the threadsor distort the plug, changingthe sparkgap. Thereare manycommercialproductsavailablefor ensuringthat fasteners wont come loose,evenif they are not torquedjust right (a very commonbrandis gettingsomething Loctite? If youreworriedabout togethertight enoughto hold, but looseenoughto avoid mechanical damageduring assembly,one of theseproductsmight offersubstantialinsurance.Before choosinga threadlocking compound,readthe labelon the package makesurethe productis and compatiblewith the materials,fluids, etc. involved. 3. Crossthreading. occurswhena part such This as a bolt is screwedinto a nut or castingat the wrong angleand forced.Crossthreading more likely to is occur if accessis difficult. It helpsto cleanand lubricatefasteners, to startthreadingthe bolt, spark then plug,etc.with your fingers If you encounterresistance,unscrewthe partand startover againat a differentangleuntil it canbe insertedandturnedseveral times without mucheffort.Keepin mind that many parts,especiallysparkplugs,havetaperedthreads, so that gentleturningwill automaticallybring the part yourethreadingto the properangle.Dontput a wrenchon the part until its beentighteneda couple of turns by hand.If you suddenlyencounterresistance,andthe part hasnot seatedfully, dontforce it. Pull it backout to makesure its cleanandthreading properly. Besureto takeyour time and be patient,and always planahead.Allow yourselfampletime to perform repairsand maintenanceYou mayfind maintaining your car a satisfyingand enjoyable experience.
Beforeremovingany bolts, readthroughthe entire procedure. will give you the overallview of what This tools and supplieswill be required.Thereis nothing morefrustratingthan havingto walkto the bus stop on Mondaymorning because wereshort one bolt you on Sundayafternoon.So readaheadand planahead. Eachoperationshould beapproached logicallyand all procedures thoroughlyunderstood beforeattempting any work. All sectionscontainadjustments, maintenance, removaland installationprocedures, in somecases, and repairor overhaulprocedures. Whenrepairis not consideredpractical, tell you howto removethe part we andthen howto installthe newor rebuiltreplacement. In this way,you at leastsavelaborcosts.Backyard repairof somecomponents just not practical. is
Its necessary mentionthe differencebetween to maintenance repair Maintenance and includesroutine inspections, adjustments, replacement and of partswhich show signs of normalwear Maintenance compensates wearor deterioration.Repairimplies for that somethinghasbrokenor is not working.A need for repair is oftencausedby lackof maintenance. Example,drainingand refilling the automatictransaxle fluid is maintenance recommended the manufacby turer at specificmileageintervals.Failureto do this canshortenthe life of the transmission/transaxle, requiring very expensiverepairs.While no maintenance programcan preventitemsfrom breakingor wearing out, a generalrule can be stated:MAINTENANCE IS CHEAPER THAN REPAIR. Two basicmechanrcs rulesshouldbe mentioned here.First, whenever leftside of the vehicleor enthe gine is referredto, it is meantto specifythe drivers side. Conversely, right side of the vehicle means the the passengersside.Second,screwsand bolts are removedby turning counterclockwise, tightened and by turning clockwrseunlessspecificallynoted. Safetyis alwaysthe most importantrule. Constantlybe awareof the dangersinvolvedin working on an automobileandtakethe properprecautions. Seethe informatronin this sectionregardingSERVICINGYOURVEHICLESAFELYandthe SAFETY NOTICE the acknowledgment on page.
Many proceduresin this book requireyou to label and disconnect. . a group of lines, hosesor wires. Dont be lulled into thinkingyou can remember where everythinggoes-you wont. If you hook up vacuum or fuel lines incorrectly,the vehicle mayrun poorly, if at all. If you hook up electricalwiring incorrectly,you may instantlylearna very expensivelesson. You dont needto knowthe official or engineering namefor eachhose or line. A pieceof maskingtape on the hoseand a pieceon its fitting will allow you to assignyour own labelsuch as the letterA or a short
Payattentionto the instructionsprovided.There are3 commonmistakesin mechanical work: 1. Incorrectorderof assembly,disassemblyor adjustment. Whentaking somethingapartor putting it together,performingsteps in the wrong order usually just costsyou extratime; however,it CAN break something.Readthe entireprocedurebeforebeginning disassembly. Performeverythingin the order in which the instructionssay you should,even if you cantimmedrately a reasonfor it. Whenyoure see takingapartsomethingthat is very intricate,you might wantto drawa pictureof how it lookswhenassembledat one point in orderto makesureyou get
b See Figures 1 thru 15

Naturally,withoutthe propertools and equipment it is impossibleto properlyserviceyour vehicle.It would also bevirtually impossibleto catalogevery tool that you would needto performall of the operations in this book.Of course,It would be unwisefor the amateurto rush out and buyan expensiveset of tools on the theorythat he/shemay needone or more of themat sometime,
The bestapproachis to proceedslowly, gathering a good qualityset of thosetools that are usedmost frequently Dontbe misled by the low cost of bargain tools. It is far betterto spenda little morefor better quality.Forgedwrenches, or 12-point socketsand 6 fine tooth ratchetsare by far preferable their less to expensivecounterparts. anygood mechaniccan As tell you, therearefew worseexperiences trying than to work on a vehiclewith badtools. Your monetary
savingswill befar outweighed frustrationand by mangledknuckles. Beginaccumulating thosetools that are usedmost frequently: thoseassociatedwith routinemaintenance andtune-up.In additionto the normalassortmentof screwdriversand pliers,you shouldhavethe following tools: l Wrenches/sockets combinationopen and end/boxendwrenchesin sizesfrom %-% in. or
GENERALINFORMATIONAND MAINTENANCE l-3

3-19mm, wellasa % in.or~/a spark as in. plug socket (depending plugtype). on -if possible, buyvarious lengthsocketdrive extensions.Universal-jointandwobble extensionscan be extremelyuseful, but be careful when usingthem, as they can change the amountof torque appliedto the socket. l Jackstands support. for l Oilfilterwrench. Spout funnel pouring or for fluids. l
l Grease for chassis gun lubrication (unless yourvehicle notequipped anygrease is with fittings-for details, please to information Flurefer on idsandLubricants, inthissection). later l Hydrometer checking battery for the (unless equiooed a sealed, with maintenance-free batten/). OA container draining andother for oil fluids. l Rags wiping theinevitable for up mess.
pi
1
Inaddition theabove there several to items are others arenotabsolutely that necessary, handy but to have around. These include Dry@ anequivaOil (or the lentoil absorbent gravel-suchascatlitter)and usual SUDDIV of lubricants. antifreeze fluids. and although canbepurchased needed. is a the.& as This basic for routine list maintenance, onlyyourperbut sonalneeds desire accurately and can determine your Afterperformingfewprojects thevehicle, a on youllbeamazed theother andnon-tools at tools on
Fig. 1 Ail but the most basic procedures
lWSl2U2
Fig, 3 A hydraulic floor jack and a set of jackstandsare essential for lifting andsup porting the vehicle
tm1204
Fig. 5 Various drivers, chisels and ptybars are great tools to have in your toolbox
Fig. 7 Althoughnot always necessary,using specialized brake tools will save time
Fig. 11 inductive type timing light \
I-4
GENERALINFORMATIONAND MAINTENANCE
Feeler aauoes valve for adiustment * Timing-light. Thechoice a timingfightshould made of be carefully. lightwhichworksontheDCcurrent A supplied thevehicles by battery thebestchoice; is it should a xenon for brightness. any have tube On vehicle anelectronic with ignition system, timing a lightwithan inductive pickup clamps that around theNo.1 spark cableis preferred. plug Inaddition these tools,there several to basic are other andgauges may useful. tools you find These include: l Compression Thescrew-in is gauge. type slower use,buteliminates possibility a to the of fauliyreading to escaping due pressure. l Manifold vacuum gauge. l 12V light. test l A combination volt/ohmmeter l induction Ammeter. is used determinThis for ingwhether notthere current a wire.These or is in arehandy useif awireis broken for somewherea in wiringharness. Asa finalnote, will orobablv a torque vou find wrench necessary all butthemostbasic for work. Thebeam models perfectly type are adequate, although newer types the click (breakaway) easier are to use. clicktypetorque The wrenches to be tend more expensive. keep mind all types Also in that of torque wrenches should periodically be checked and/or recalibrated. will have decide yourYou to for selfwhichbetter yourpocketbook, purpose. fits and
l
Fig. 12 A screw-in type compressiongaugeis recommended compressiontesting for
Fig. 13 A vacuum/pressure tester is necessary for manytesting procedures
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Fig. 14 Most modernautomotive multimeters incorporate many helpful features yourworkbench. useful Some household are:a items large turkey baster siphon, or empty coffee and cans icetrays(tostore parts), of twine, ball electrical tape for wiring, smallrollsof colored for tagging tape lines or hoses, markers pens, notepad, tees(for and a golf plugging vacuum lines), metal hangers a roll coat or of mechanics (toholdthings of theway), wire out dental or similar pointed pick long, probe, strong a magnet, a smallmirror seeintorecesses and (to and under manifolds). A more advanced oftools,suitable tune-up set for work, bedrawn easily. can up While toolsare the
Fig. 15 Proper information is vital, so at ways have a Chiiton Total Car Care manua handy ilightly sophisticated, need beoutramore they not feously expensive. areseveral There inexpensive achldwell meters themarket areevery as on that bit Toad theaverage for mechanic a professional as nodel. besurethatit goes a least Just to 1200-1500 pmonthetach andthatit works 4,6 and8scale on :ylinder engines. keytothese The purchasesto is nake withaneyetowards them adaptability wide and ange. basic oftune-up couldinclude: A list tools l Tach/dwell meter. l Spark wrench gapping plug and tool.
Normally, useof special the factory is tools avoided repair for procedures, these not since are readily available thedo-it-yourself for mechanic. When is possible perform jobwithmore it to the commonly available it will bepointed but tools, out, occasionally, a special wasdesigned perform tool to a specific function should used. and be Before substituting another youshould convinced tool, be that neither safety theperformancethevehicle your nor of will becompromised. Special canusually purchased an tools be from automotive store fromyourdealer. some parts or In cases special maybeavailable tools directly the from toolmanufacturer.
p See Figures16, 17, 16, and 19 It is virtually impossible anticipate ofthehazto all ardsinvolved automotive with maintenance serand vice,butcare common will prevent and sense most accidents. Therules safety mechanics fromdont of for range smoke around gasoline, use proper to the tool(s) for thejob.Thetricktoavoiding injuries to develop is safe habits totake possible work and every precaution.
l Dokeep fireextinguisher firstaidkit a and handy. l Dowear safety glasses goggles cutor when ting,drilling, grinding prying, if youhave or even 20-20vision.If youwear glasses thesake vifor of sion,wear safety goggles yourregular over glasses.
l Doshield eyes your whenever workaround you thebattery. Batteries contain sulfuric Incase acid. of contact theeyes skin,flushthearea water with or with or a mixture water baking then imof and soda, seek mediate medical attention. l Dousesafety stands (jackstands) anyunfor dervehicle service. arefor raising Jacks vehicles; jackstands for making thevehicle are sure stays raised youwantit to come until down. Whenever the vehicle raised, thewheels is block remaining the on ground settheparking and brake. l Douseadequate ventilation working when withanychemicals hazardous or materials, carLike bonmonoxide, asbestos resulting the dust from some brake liningwearcanbehazardoussuffiin cientquantities. l Dodisconnect negative the battery when cable working theelectrical on system. secondary The ig-
nitionsystem contains EXTREMELY VOLTHIGH AGE. some In cases caneven it exceed 50,000 volts. l Dofollowmanufacturers directions whenever working potentially with hazardous materials. Most chemicals fluidsarepoisonous taken and if internally. l Doproperly maintain tools.Loose your hammerheads, mushroomed punches chisels, and frayed or poorly grounded electrical cords, excessively wornscrewdrivers, wrenches end), spread (open cracked sockets, slipping ratchets, faultydroplight or sockets cause can accidents. * Likewise, yourtoolsclean; greasy keep a wrench slipoff a bolthead, can ruining boltand the oftenharming knuckles theprocess. your in l Dousetheproper andtypeof toolforthe size jobathand. select wrench socket fitsthe Do a or that nutor bolt.Thewrench socket or should straight, sit notcocked.

lwo.WIRE CouDuClOR MIRD WIRE GROUNDING THE CASE TMREE-WIRE GROUNDING A CmxlIT CONOCTOI TNRU
i$Y$$pQ
p-+
TNHREE-WIRE CONDUCTOR ONE WIRE TO 4 GROUND
Fig.16 Screwdriversshouldbe kept in good :onditionto preventinjury or damagewhich :ould result it the blade slips from the screw
7
THREE-WIRE GROUNOlNG AN ADAPTER
CONDUCTOR TMRU PLUG tccm21
Fig. 17 Powertools should always be properly grounded
Fig. 16 Using the correct size wrench will help prevent the possibility of roundingoff a nut
l Do, whenpossible,pull on a wrenchhandle ratherthan push on it, and adjustyour stanceto prevent a fall. l Do be surethat adjustable wrenchesare tightly closedon the nut or bolt and pulledso that the force is on the side of the fixed jaw. l Do strikesquarelywith a hammer;avoid glancing blows.
PP
tccs1022
Fig. 19 NEVER undera vehicle unlessit work is supportedusingsafety stands(jackstands)
l Do setthe parkingbrakeand block the drive wheelsif the work requiresa runningengine.
l Dont runthe enginein a garageor anywhere elsewithout properventilation-EVER! Carbon
monoxideis poisonous;it takesa longtime to leave the humanbodyand you can build up a deadlysupply of it in your systemby simply breathingin a !ittle everyday.You may not realizeyou are slowly poisoning yourself.Alwaysusepowervents,windows, fans and/or openthe garagedoor. l Dontwork aroundmoving partswhile wearing looseclothing.Shortsleevesare muchsaferthan long, loosesleeves.Hard-toedshoeswith neoprene soles protectyour toes and give a bettergrip on slipperysurfaces. Jewelrysuchas watches,fancybelt buckles,beadsor bodyadornmentof any kind is not safeworkingarounda vehicle.Longhair shouldbe tied backundera hat or cap. l Dontusepocketsfor toolboxes.A fall or bump candrive a screwdriverdeepinto your body. Evena raghangingfrom your backpocketcan wraparound a spinningshaftor fan. l Dontsmokewhenworkingaroundgasoline, cleaningsolventor otherflammablematerial. l Dontsmokewhenworkrngaroundthe battery. Whenthe batteryis beingcharged,it gives off explosive hydrogengas. l Dontusegasolineto washyour hands;there are excellentsoapsavailable.Gasolinecontainsdangerousadditiveswhichcanenterthe bodythrougha cut or throughyour pores.Gasolinealso removesall the naturaloils from the skin so that bonedry hands will suck up oil and grease. l Dontservicethe air conditioningsystemunlessyou are equippedwith the necessary tools and trainmg.Whenliquid or compressed refrigerant gas is released atmosphericpressureit will absorb to heatfrom whateverit contacts.This will chill or freeze anythingit touches. l Dontusescrewdriversfor anythingotherthan driving screws!A screwdriverusedas an pryingtool can snapwhenyou leastexpectit, causinginjuries. At the very least,youll ruin a goodscrewdriver. . Dontusean emergency (thatlittle ratchet, jack scissors,or pantograph suppliedwith the vehijack cle) for anythingotherthan changinga flat! These jacksare only Intended emergency out on the for use road;theyare NOTdesignedas a maintenance If tool. you are seriousaboutmamtainingyour vehicleyourself, investin a hydraulicfloor jack of at leasta 1% ton capacity,and at leasttwo sturdyjackstands.
sion which can increasethe torque necessary to achievethe desiredclamp loadfor which thatfastener was originally selected. Additionally,besurethat the driver surfaceof the fastenerhasnot beencomprop See Figures20, 21, 22, and 23 mised by roundingor otherdamage.In some casesa driver surfacemay becomeonly partiallyrounded,alAlthoughtherearea greatvarietyof fasteners found lowingthe driver to catch in only one direction.In in the moderncar or truck,the mostcommonlyused manyof theseoccurrences, fastenermaybe ina retaineris the threaded fastener(nuts,bolts,screws, stalledand tightened,but the driver would not be able studs,etc.).Most threaded retainersmaybe reused, to grip and loosenthe fasteneragain.(This could lead providedthatthey are not damaged useor during in J to frustrationdownthe line shouldthat component the repair.Someretainers(suchas stretchbolts or ever needto be disassembled again). torqueprevailingnuts)are designed deformwhen to If you must replacea fastener,whetherdueto detightened in useand shouldnot be reinstalled. or sign or damage, mustALWAYSbe sureto use you Whenever possible,we will noteanyspecialrethe properreplacementIn all cases,a retainerof the tainerswhich shouldbe replaced during a procedure. samedesign,materialand strengthshould be used. Butyou shouldalwaysinspectthe conditionof a reMarkingson the headsof most bolts will helpdetertainerwhenIt is removedand replaceanythat show minethe properstrengthof the fastener.Thesame signs of damage.Checkall threadsfor rust or corromaterial,threadand pitch must be selected assure to
properinstallationand safeoperationof the vehicle afterwards. Threadgaugesareavailableto help measurea bolt or studsthread.Most automotiveand hardware storeskeepgaugesavailableto helpyou selectthe propersize. In a pinch,you can useanothernut or bolt for a threadgauge.If the bolt you are replacingis not too badly damaged, can selecta matchby you finding anotherbolt which will threadin its place.If you find a nut whichthreadsproperlyontothe damagedbolt, then usethat nut to helpselectthe replacementbolt If however,the bolt you are replacingis so badlydamaged (brokenor drilled out) that its threads cannotbe usedas a gauge,you might startby looking for anotherbolt (from the sameassemblyor a similar locationon your vehicle)which will thread into the damagedbolts mounting.If so, the otherbolt can be usedto selecta nut;the nut canthen be used to selectthe replacement bolt.
GENERALINFORMATIONAND MAlNTENAiCEI-7
of the bolt head,screwheador nut faceand base the materialor washer(the surfaceon which the fastener is rotating).Approximately40 percentof the applied torque is usedin overcomingthreadfriction. This leavesonly about 10 percentof the appliedtorqueto developa usefulclamp load (the forcewhich holdsa joint together).This meansthat friction canaccount for as muchas 90 percentof the appliedtorqueon a fastener.
POZIDRIVE
PHILLIPS
RECESS
TORX@
CLUTCH
RECESS
TORQUE WRENCHES ti See Figures 24 and 25

In most applications,a torquewrenchcan beused to assureproperinstallationof a fastener. Torque wrenchescome in various designsand most automotive supplystoreswill carrya varietyto suit your needs.A torquewrenchshould be usedanytime we supplya specifictorquevaluefor a fastener. torque A wrenchcanalso be usedif you are followingthe generalguidelinesIn the accompanying charts.Keepin mind that because thereis no worldwidestandardization of fasteners, chartsare a generalguideline the
INDENTED
HEXAGON
HEXAGON
TRIMMED
HEXAGON
WASHER
HEAD tccs1037
Fig. 20 Here are a few of the most commonscrew/bolt driver styles
GRADE
MADE
GRADE
QRADE
GRADE
WADE
ALLEN
CARRIAGE
NUTS e Q
PUIN
JAM CASTLE (CASTELLATED) SELF-LOCKINQ SPEED
A B CDE FFILLISTER
Length Diameter (major diameter) Threads per inch or mm Thread length Size of the wrench required Root diameter (minor diameter) IccSlO3l
Fig. 22 Threadedretainer sizes are deter mined using these measurements
LOCKWASHERS
4%
INTERNAL
Toonl
43
EXTERNAL TQonl
Q
SPLIT
c3
PLAIN
STUD
Fig. 21 There are many different types of threaded retainers found on vehicles
In all cases,beabsolutelysureyou haveselected the properreplacement. Dont beshy, you canalways ask the storeclerk for helo.
Be aware that when you find a bolt with damagedthreads,you may also find the nut or drilled hole it was threadedinto hasalso beendamaged.If this is the case, you may haveto drill andtap the hole, replace the nut or otherwise repair the threads. NEVER to try force a replacementbolt to fit into the damaaedthreads.
Torqueis definedas the measurement resis- . of tanceto turning or rotating.It tendsto twist a body aboutan axis of rotation.A commonexampleof this would betighteninga threadedretainersuch as a nut, bolt or screw.Measuringtorque is one of the most commonwaysto help assurethat a threaded retainer has beenproperlyfastened. Whentighteninga threadedfastener,torqueis applied in threedistinct areas,the head,the bearing surfaceand the clamp load. About50 percentof the measured torque is usedin overcomingbearingfriction This is the friction between bearingsurface the
E - DCTERNAL
tm1016
Yg. 23 Special fasteners such as these font@ head bolts are used by manufactur?rs to discourage people from working on rehicles without the proper tools
l-8
U.S. UEonlr Iy*
I*cll*olwu tbqn2lamlu am~mkr. Q HaaIm (h&l!&, 'I4 - 20 -28
tccsio15
Bolts
5 c @ 63 TORW lm 10.8 13.6 23.0 25.7 42.0 47.5 66.4 74.5 101.7 115.2 149.1 162.7 203.3 230.5 366.0 400.0 535.5 589.7 799.9 849.8 R.Abs. 10 19 34 55 85 120 167 280 440 660 m I(n 1.4 2.6 4.7 7.6 11.75 16.6 23.0 36.7 60.9 91.3 TolqW Hm 13.5 25.8 46.0 74.5 115.2 162.7 226.5 379.6 596.5 894.8 tw7
lU2
Toqw m 0.7 08 1.5 1.8 2.5 2.75 3.8 42 5.4 5.7 7.0 7.6 111 68 8.1 14.9 17.6 24.4 27.1 37.0 40.7 52.8 55.6 69.2 74.5 112.5 128.8 142.3 155.9 216.9 237.2 318.6 338.9 R./U. 8 10 17 19 31 35 49 55 75 85 110 120 150 170 270 295 395 435 lE
mdmuo
RA&. i 11 13 18 20 28 30 39 41 51 55 83 95 105 115 160 175 iti
If410 1.1 1.4 2.3 2.6 4.3 4.8 8.8 7.6 10.4 117 15.2 16.6 20.7 23.5 37.3 40.8 54.6 80.1 81.6 91.3
Fig. 24 Various styles of torque wrenches are usually available at your local automotive supply store
and should be usedwith caution.Again,the general rule of if you are using the right tool for the job, you should not haveto strainto tightena fastenerapplies here.
%s-18 -24 S-16 -24 %s-14 -20 'h-13 -20 'h-12 -18 H-11 -18 s-10 -16 VD9 -14 l6 -14
BeamType # See Figure 26

The beamtype torquewrenchis one of the most populartypes.It consistsof a pointerattached the to headthat runsthe lengthof the flexible beam(shaft) to a scalelocatednearthe handle.As the wrenchis pulled,the beambendsand the pointerindicatesthe torque usingthe scale.
11.5 13.1 14.5 15.9
2.:
32.5 34.6
Metric Bolts
4.6,4.8 c 8.8 w @ rullllllnl~ llm 3-4 8-12 16-23 29-43 48-70 67-100 100-150 150-190 200-260 260-320 RAk 3-6 9-14 20-29 35-53 57-65 90-120 130-170 190-240 250-320 310-410 m 4-.8 12-1.9 2.7-4.0 4.8-7.3 7.8-11.7 12.4-16.5 17.9-23.4 26.2-46.9 34.5-44.1 42.7-56.5 mu 5-8 13-19 27-39 47-72 77-110 130-W MO-230 160-320 340-430 420-550
lccs1098
Click (Breakaway)Type $ See Figure 27

Anotherpopulardesignof torquewrenchISthe click type.To usethe click type wrenchyou pre-adjust it to a torquesetting.Oncethe torque is reached, the wrenchhasa reflexsignalingfeaturethat causes a momentarybreakaway the torquewrenchbody, of sendingan impulseto the operatorshand.
mm04 iEn% 6x1.0 8x 1.25 10X1.25 12x125 14x 16x 18x 20x 22x 24x 1.5 1.5 1.5 1.5 1.5 1.5 (nnr) RJU. 2-3 6-8 12-17 21-32 35-52 51-77 74-110 llO-140 150-190 190-240
I*rdn*lrTwlr I(n 2-.4 .6-l 1.5-2.3 2.9-4.4 4.8-7.1 7.0-10.6 10.2-15.1 15.1-19.3 22.0-26.2 26.2-48.9
Pivot HeadType # See Figure 27 and 28

Sometorquewrenches(usuallyof the click type) may beequippedwith a pivot headwhich canallow it to be used in areasof limited access.BUT,it must be usedproperly.To hold a pivot headwrench,grasp the handlelightly,and as you pull on the handle,it should befloatedon the pivot point. If the handle comesin contactwith the yokeextensionduringthe processof pulling,thereis a very good chancethe torque readingswill be inaccurate because could this alterthe wrenchloadingpoint. The designof the handle is usuallysuch as to makeit inconvenient deto liberatelymisusethe wrench.
:ig. 25 Standardand metric bolt torque specifications based on bolt strengths-WARNING: Ise only as a guide 1
PIVOTEO
HANDLE
*It shouldbe mentionedthat the use of any U-joint, wobble or extensionwill have an effect on the torque readings,no matterwhat type of wrenchyou are using. For the most accuratereadings, install the socketdirectly on the wrenchdriver. If necessary,straight extensions(which hold a socketdirectly under the wrenchdriver) will have the least effect on the torque reading. Avoid any extension that alters the lengthof the wrenchfrom the handleto the head/drivingpoint (suchas a crows foot). U-joint or wobble extensions can greatly affect the readings;avoid their use at all times.
BEAU
OR MEASURING
ELEMENT
tccslo3~
Yg. 26 Exampleof a beam type torque wrench

dard torque wrench usually firstto remove are used anycompliance thejoint.Thefastener then from is tightened specified the additional portion a turn of measureddegrees.torque gauge in A angle (mechanicalprotractor) used these is for applications.
Fig. 27 A click type or breakaway torque wrench-note that this one has a pivoting head
) See Figure 31 Throughout manual, this specifications given are to helpyoudetermine condition various the of components yourvehicle, to assist intheirinstallaon or you tion.Some themost of common measurements include length or cm/mm), (ft.Ibs., Ibs. (in. torque inch or Nm) pressure in.Hg,kPa mmHg).In and (psi, or most cases, strive provide proper we to the measurement determinedthemanufacturers as by engineers. Though, some in cases, value notbeconthat may veniently measured whatis available your with in toolbox. Luckily, of themeasuring many devices
v
WRONG WRONG
:ig. 30 Somespecifications require the use rf a torque angle meter (mechanical pro. ractor) many aluminum cylinder heads). these In cases, a torque method installation bespeciangle of would fied.When installing fasteners aretorque which angle tightened,predetermined torque stana seating and
CONVERSION
LENGTH-DISTANCE
WRENCH
tccS1041
FACTORS
(mm) (km) x .0394 x 3.281 x .0621 = Inches = Feet = Miles
PIVOTED
HANDLE
TOR(IUE
Inches (I.) Feet (ft.) Miles
x 25.4 x ,305 x 1.609
= Millimeters = Meters (m) = Kilometers
Fig. 28 Torque wrenches with pivoting heads must be grasped and used properly to prevent an incorrect reading Rigid Case(Direct Reading) # See Figure 29 A rigidcase direct or reading torque wrench is equipped a dialindicator show with to torque values. One advantagethese of wrenches thattheycanbe is heldatanyposition thewrench on without affecting accuracy. wrenches oftenpreferred These are because tend becompact, to read have they to easy and a great degree accuracy. of
VOLUME
Cubic Inches (in3) IMP Pints (IMP pt.) IMP Quarts (IMP qt.) IMP Gallons IMP Gallons Fl. Ounces us Pints (Us pt.) US Quarts (US qt.) US Gallons (US gal.) (IMP gal.) (IMP gal.) IMP Quarts (IMP qt ) x 16.387 x .568 x 1.137 x 4.546 x 1.201 x 1.201 x 29.573 x ,473 x .946 x 3.785 = Cubic Centimeters = Liters (L) = Liters (L) = Liters (L) = US Quarts (US qt.) = US Gallons = Millihters = Liters (L) = Liters (L) = Liters (L) (US gal.) x .061 x 1.76 x .88 7, .22 x ,833 x ,833 x 034 x 2.113 x 1.057 x ,264 = in3 = IMP pt. = IMP qt. = IMP gal. = IMP qt. = IMP gal. = Ounces = Pints = Quarts = Gallons
MASS-WEIGHT Ounces (oz.)

Pounds (lb ) x 28.35 x ,454 = Grams (g) = Kdograms (kg) x ,035 x 2.205 = Ounces = Pounds
PRESSURE
Pounds Per Sq. In. (psi) Inches of Mercury (Hg) Inches of Mercury (Hg) Inches of Water (H,O) Inches of Water (H,O) Inches of Water (H,O)
x 6.895 x .4912 x 3.377 x .07355 x .03613 x ,248 = Kilopascals = psi = Kilopascals = psi = Kilopascals (kPa) (kPa) = Inches of Mercury (kPa) x ,145 x 2.036 x .2961 x 13 783 x 27.684 x4026 = psi = Hg = Hg = H,O = Hz0 = H,O
TORQUE
Pounds-Force Pounds-Force
lccs1042
Inches (in-lb) Feet (ft-lb)
x ,113 x 1.356
= Newton = Newton
Meters (N.m) Meters (N*m)
x 8.85 x ,738
= in-lb = ft-lb
VELOCITY
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
Fig. 29 The rigid case (direct reading) torque wrench usesa dial indicator to show torque TORQUEANGLEMETERS # See Figure 30 Because frictional the characteristics fasof each tener threaded will vary, or hole clamp which loads arebased strictly torque varyaswell.Inmost on will applications, variance notsignificant this IS enough to cause worry.But,in certain applications, a manufacturers engineers determine more may that precise clamp arenecessary isthecase loads (such with
POWER
Horsepower (Hp) x ,745 = Kdowatts x 1.34 = Horsepower
FUEL
CONSUMPTION
IMP (MPG) US (MPG) x .354 x 2.352 x ,425 x 2.352 = Kilometers = IMP MPG = Kilometers = US MPG kilometers (l/100 km), where mpg (IMP) x l/ID0 km Per Liter (Km/L) Per Liter (Km/L) Per Liter (Km/L) Per Liter (Km/L)
Mdes Per Gallon Kilometers Kdometers Miles Per Gallon
*It 1s common to covert from miles per gallon (mpg) to hters/lOO = 282 and mpg (US) x l/lo0 km = 235.
TEMPERATURE
Degree Fahrenheit CF) Degree Celsms (C) = (C x 1.8) + 32 = CF - 32) x 56 tccsio4d
Fig. 31 Standardand metric conversionfactors chart
l-10
Theconversion chart used taking factor is by the given specification multiplyingbythenecesand it saryconversion Forinstance, factor. looking the at firstline,if youhave measurement a in inches such asfree-play should 2 in.butyourrulerreads be onlyin millimeters, multiply in.bytheconversion 2 factor 25.4 getthemetric of to equivalent 50.8mm. of Likewise,thespecification given ina Metif was only ric measurement,example Newton for in Meters (Nm), lookatthecenter then column If themeafirst. surement 100Nm,multiply bytheconversion is it factor 0.738 get73.8 Ibs. of to ft.
which available will have scales the are today two so Standard Metric or measurements easily may be taken. anyofthevarious If measuring which tools are available youdonotcontain same as to the scale listedinthespecifications, theaccompanying use conversion factors determine proper to the value.
b See Figures32,33, and 34 TheVehicle Identification Number is located (VIN) ona plate whichis attached thelefttopsideof the to instrument These panel. numbers visible the are from outside thevehicle. Vehicle of All Identification Numberscontain digits. vehicle 17 The number a code is which country, tells make, vehicle engine, type, body andmany important other characteristicsthatspeof cificvehicle. There alsoa vehicle is information plate code whichis riveted thebulkhead theengine to in compartment. plateshows VIN,model The the code, enginemodel, transaxle model bodycolorcodes. and Theengine used thisplate code on differsfromthe codeletter in the8thposition theVehicle used of Identification Number Either canbeused (VIN). code to identify particular the engine thevehicle. in Since thevehicle owners is usually card carried, maybe it easier usethecodeletterintheVINfor engine to reference. second A reason referring theVINfor for to engine identification thatcode is 4663,located on thevehicle information plate, identify code does the engine a 2.OL as DOHC engine, doesnottellyou but
if theengine equipped a turbocharger. is with If the 8thVINnumber a U,thereis nodoubt theenis that ginein question a 2.OL is DOHC engine equipped withaturbocharger. Theengine codes found thevehicle on information code areasfollows: plate l 4G15--1.5L SOHC engine l 4G61-1.6LDOHC engine l 4G93-1.8LSOHC engine l 4G63-2.OL (SOHC DOHC) or engine l 4G64-2.4L(SOHC DOHC) or engine l 6G72-3.OL (SOHC DOHC) or engine l 6G74-3.5LDOHC engine A vehicle safety certification is attached label to thefaceof theleftdoorpillarpost.Thislabelindicates month yearof manufacture, Vethe and Gross hicleWeight Rating (GRVW) andrear,andVefront hicleIdentification Number (VIM).
4 character asonthevehicle code information code plate used. engine number also is The serial is stamped theengine near model number. menAs tioned above, engine alsobeidentified the the can by 8thdigitintheVINnumber.
Thetransaxle codeis located thevehicle model on information plate. transaxle code The identification number etched a boss is on located thefrontupon perportion thecase. of
Thecode thedriveaxleis etched a bosslofor on cated thecase thedifferential on of carrier.
) See Figure 35 Theengine model number stamped thefront is at sideonthetopedge thecylinder of block. same The
Thetransfer hasnoseparate code, case model the codeis located thetransaxle. transfer is on The case onlveoUiODedmanual on transaxle Wheel All Drive (AWD)mbdels.
Fig. 32 The Vehicle Identification Number (VIN) plate is attachedto the top left side of the instrumentpanel _I:^1
Fig. 33 The vehicle model, engine model, bansaxle model,and bodycolor codeare all / notedon the vehicle informationcodeg351po plate ModelYerr Year
1990 1991 1992 1993 1994 1995 1996 1997 \ 1998 ___-___ 1999 2000
Fig. 34 Your car should have a vehicle
todeal LIten (cc)

,G15JA IG61N 1G93lC IG63N !G63Fi ,G63iU .GMffi iG64L lEzH ;G7ZJ ~.. iG7zL iG74lP 1.5 (1468) 1.6(15QQ) 1.8 (1834) 2.0 (1997) 2.0 (1997) 2.0 (1997) 2.4 (2351) 2.4 (2351) 3.0 (2972) 3.0 (2Q72) 3.0 (2972) 3.5 (3497)
Cu. In. 92 98 112 122 122 122 143 143 161 161 181 213
ENGINE VEHiCLE AND IDENTlFlCATlON EnglnCode Fuel+ Type m.hWg. W.

4 4 4 4 4 4 4 4 6 6 6 6 MFI MFI MFI MFI MFI MFI-Tuibo MFI MFI MFI MFI MFI MFI SOHC DOHC SOHC SOHC DOHC DOHC SOHC DOHC SOHC GQHC SOHC SOHC Mitsubishi Mitsubishi Mitsubishi -Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Miisubishi Miisubishi
Code@ L M N P R S T V W X ~ Y
Fig. 35 Engine model number location4663 (2.OL)engine shown
UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL
ENGINE
1. 2. 3. 4. 5. 6.
Powersteeringbelt Washersolventbottle Powersteeringreservoir Oil fill cap Brakemastercylinderreservoir Sparkplugand plugwire
7. 8. 9. 10. 11. 12.
PCVvalve Distributorcapand rotor Fuelfilter (underair inlettube) Air filter housing Engine compartment box fuse Battery
13. 14. 15. 16.
Automatic transaxlefluid dipstick Coolantrecoverytank Radiatorcap Engine dipstick oil
II
UNDERHOODMAINTENANCE COMPONENT LOCATIONS-l .8L ENGINE
1. 2. 3. 4. 5. 6.
Coolantrecoverytank Battery Engine compartment box fuse Air filter housing Clutchfluid reservoir Brakemastercylinderreservoir
7. 8. 9. 10. 11. 12.
Sparkplugandplugwire PCVvalve Engine fill cap oil Fuelfilter Engine compartment center relay Washersolventbottle
13. 14. 15. 16.
Powersteeringreservoir Powersteeringbelt Engineoil dipstick Radiatorcap
GENERALINFORMATIONAND MAlNTENANdE 1-13

GENERAL ENGINE SPECIFICATIONS
Engine Displacement Engine Engine No. of Fuel System Net Horsepower Net Torque @ rpm Bore x Stroke Compression Oil Pressure
MFI Mult+wt fuel mfectw, MFI-T - Multlporl fuel mfectlon-turbocharged SOHC - Smgle overhead camshaft DOHC - Double OvedEad camshaft
l-14
therequired maintenance performed.theevent was In of a warranty problem, receipts beinvaluthese will able. Theliterature provided yourvehicle it with when wasoriginally delivered includes factory the recommended maintenance schedule.younolonger If have thisliterature, replacement areusually copies availablefromthedealer. maintenance A schedule prois videdlaterinthissection, case donothave in you * thefactory literature. 9. Place new cleaner a air element the inside lowerhousing. sure sealontheelement Make the is fullyseated thegroove. in 10. Install upper cleaner the air housing inlet and tube thelower onto housing. 11. Tighten clamp theinlettube the the on at throttle body. 12. Attach breather ontotheair inlet the hose tube. 13. Plug connector theMAF the into sensor. 14. Attach aircleaner the housing retaining clips. 15. Connect negative the battery cable. 2.DLTurbocharged Engine b See Figure 42 1. Disconnect negative the battery cable. 2. Detach airflowsensor the connector. 3. Unfasten boost the hose. 4. Disconnect solenoid withhoses. the valve 5. Disconnect air intake the hose. 6. Unfasten aircleaner tie retainer andthe bolts air cleaner assembly. 7. Unclamp cover remove thehousthe and from ing. *Care mustbe takenwhen removingthe air cleaner cover. Theair flow sensoris attachedand could be damagedduringcover removal. 8. Remove aircleaner the element. Thoroughly clean aircleaner the housing to replacing air prior the filter. To install: 9. Install new cleaner the air element the into housing. andsecure cover place. Install the in
Proper maintenance tune-up thekeyto long and is andtrouble-free vehicle andtheworkcanyield life, itsownrewards. Studies shown a properly have that tuned maintained canachieve gas and vehicle better mileage anout-of-tune than vehicle. a conscienAs tiousowner driver, aside Saturday and set a morning, sayonce month, check replace which a to or items could cause major problems Keep own later. your personal tojot down log which services peryou formed, much parts you,thedate, how the cost and theexact odometer reading thetime.Keep reat all ceipts suchitems engine andfilters, that for as oil so theymaybereferred incase related tp of problems or to determine operating expenses. a do-it-yourAs selfer, receipts theonlyproof have these are you that
REMOVAL &INSTALLATION Except2.gL Turbocharged Engine b See Figures 36 thru 41 1. Disconnect negative the battery cable. 2. Release retaining fromtheair the clips cleaner housing. the on tube 3. Loosen clamp theairoutlet atthe throttle body. 4. Detach breather fromtheair inlet the hose tube. the sensor connector. 5. Unplug MAF the and air 6. Separate upper lower cleaner housings remove air outlet andupper and the tube housing thelower from housing. the element the from 7. Remove aircleaner housing. To install: 8. Clean inside theaircleaner the of housing of anydirtanddebris hascollected that inside.
93151p50
Fig. 36 Releasethe retaining clips from the air cleaner housing
r3151p47
Fig. 37 Unplugthe MAFsensor connector
Fig. 38 Detachthe breather hose from the air tniet tube
Fig. 39 Loosenthe clamp on the air outlet tube at the throttle body . . .
Fig. 49 . . . then removethe air outlet tube and upper housingfrom the lower housing
Fig. 41 Remove the air cleaner element from the housing
Fig. 42 Detachthe air flow sensor connector, the boost hose and the solenoid valve connector

10. install aircleaner the assembly thereand tainer bolts. 11. Connect air intake the hose. 12. Attach solenoid the valve. 13. Connect boost the hose. 14. Attach airflowsensor the connector. 15. Connect negative the battery cable. \ *Wrap shoptowels aroundthe fitting that is being dtsconnected absorbresidual fuel in to the lines. 4. Cover hose the connection shop with towels to prevent splash fuelthatcouldbecaused any of by residual pressure thefuelpipeline.Holdthefuel in filternutsecurely a backup with wrench, remove then thebanjo ontheengine line.Disconnect bolt feed the high-pressure linefromthefilter.Remove fuel and discard gaskets. the 5. While holding fuelfilternutsecurely a the with back-up wrench, loosen filterfeedpipeflarenut the onthebottom thefilter.Separate flarenutconof the nection thefilter.If equipped, from remove disand cardthegaskets. boltsr I,.,< I the . 6. Remove mounting .a andremove ,,,. ,. the ruer rrrter. necessary, II remove ruer oracket. me rrrrer To install: 7. Install filterto itsbracket finger-tight. the only Movement thefilterwill ease of attachmentthefuel of lines. 9. While holding fuelfilternutwithabackthe upwrench, tighten banjo to 22ft. Ibs.(30 the bolt Nm). Tighten flarenutto25ft. Ibs.(35Nm), the with a back-up wrench thenut. on 10. Tighten filtermounting to 10ft. Ibs. the bolts (14Nm). 11. Connect negative the battery cable. the Turn keyto theONposition pressurize fuelsystem to the andcheck leaks. for 12. If repairs a leak required, of are remember to release fuelpressure opening fuelsysthe before the tern.
REMOVAL &INSTALLATION u See Figures 43 thru 48 Onmost vehicles covered thismanual, fuel by the filteris located theengine in compartment, mounted to thefirewall.
REMOVAL&INSTALLATION u See Figures49, 50, and 51 1, Disconnect negative the battery cable. 2. If necessary access, for remove air intake the hose aircleaner and assembly. 3. If necessary, unfasten retaining the clamp, then disconnect ventilation fromthePCV the hose valve. 4. Remove PCV fromthecamshaft the valve (rocker) cover. To install: 5. Install PCV intotherocker the valve cover. If thevalveis threaded, tighten valve snug. the until 6. Reconnect ventilation to thevalve. the hose 7. If removed, theair intake andthe install hose a.ircleaner assembly. 8. Connect negative the battery cable.
Do not use conventionalfuel filters, hosesor clampswhen servicing fuel injection sys terns. Theyare not compatiblewith the injecand tion system couldfail, causingpersonal injury or damageto the vehicle. Useonly hosesand clampsspecifically designedfor fuel injection systems. 1. Properly relieve fuelsystem the pressure as outlined Section of thismanual. in 5 2. If notalready disconnect negative done, the battery cable. 3. Onmost models. iobis made the easier the if air inlethose upper cleaner and air housing reis moved thevehicle. from
Ensurethat the filter is installed with the flow arrow in the proper direction. Theflow arrow typically pointstoward the engineside of the filter. improperinstallation of the fuel filter will causethe vehicle to run poorly. *Make sure new O-ringsare installed prior to installation. 8. Insert filterfeedpipeto thelower the connectionof thefilterandmanually in themain screw pipes nut. flare
Fig. 43 Use a back-upwrench on the fuel filter nut when looseningthe banjo-bolt on I 1the engine feed line -
93151@3
I Fig. 44 After the banjo-boltis loose, removeI from the fuel filter
Fig. 45 Make sure to replace the copper washers on the banjo-bolt fitting
93151p93
Fig. 48 Make sure to usea back-upwrench 1when unfasteningthe main fuel pipe also 1
Fig. 47 Remove the two filter bracket retaining bolts . . .
Fig. 48 . . . then remove the filter from the vehicle
l-16
Fig. 49 Graspthe valve and gently remove it from the valve cover
Fig. 50 Twist and pull on the valve to remove it from the hose
corrosiveacid canalso eatawayat componentsunder the hood. Alwaysvisually inspectthe batterycasefor cracks, leakage corrosion.A whitecorrosive substance and on the batterycaseor on nearbycomponents would indicatea leakingor crackedbattery.If the batteryis cracked,it shouldbe replacedimmediately.
Fig. 51 Inspectthe grommetand replace if cracked or leaking oil

devicesthat increaseparasiticload maydischargea batterysooner.If the vehicle is to be storedfor 6-B weeksin a secureareaand the alarmsystem,if present, is not necessary, negativebatterycable the should bedisconnected the onsetof storageto at protectthe batterycharge. Remember constantlydischargingand that recharging shortenbatterylife. Takerare not to will allow a batteryto be needlessly discharged.
SERVICING
u See Figure 52
Theevaporativecanisterrequiresno periodicservicing. However,a carefulinspectionof the canister and hosesshouldbe madefrequently, Replace damagedcomponents required. as The canisteris typically locatedunderone of the front fenders,howeveron some latermodelsit may be underthe rearof the vehicle,nearthe gastank,
GENERALMAINTENANCE '_
# See Figure 53
A batterythat is not sealedmust be checkedperiodicallyfor electrolytelevel.You cannotadd waterto a sealedmaintenance-free battery(thoughnot all maintenance-free batteries sealed);however,a are sealedbatterymust also becheckedfor properelectrolyte level,as indicatedby the color of the built-in hydrometereye. Alwayskeepthe batterycablesand terminalsfree of corrosion.Checkthesecomponents aboutoncea year.Referto the removal,installationand cleaning procedures outlinedin this section, Keepthe top of the batteryclean,as a film of dirt canhelp completelydischargea batterythat is not usedfor long periods.A solution of bakingsodaand watermay be usedfor cleaning,but be carefulto flush this off with clearwater.DONOTlet anyof the solution into the filler holes.Bakingsodaneutralizes batteryacid and will de-activatea batterycell. Batteriesin vehicleswhichare not operatedon a regularbasiscanfall victim to parasiticloads (small currentdrainswhich are constantlydrawingcurrent from the battery).Normalparasiticloads maydrain a
BA-ITERY FLUID
Checkthe batteryelectrolytelevelat leastoncea month.or more often in hot weatheror during periods ofextendedvehicleoperation.On non-sealed batteries, levelcan becheckedeitherthroughthe the caseon translucent batteriesor by removingthe cell capson opaque-cased types.Theelectrolytelevel in eachcell shouldbe keptfilled to the split ring inside eachceil, or the line markedon the outsideof the case. If the level is low, add only distilled waterthrough the openinguntil the level is correct.Eachcell is separatefrom the others,so eachmust be checkedand filled individuallv.Distilled watershouldbe used,becausethe chemicalsand mineralsfound in most drinking waterare harmfulto the batteryand could significantlyshortenits life. If wateris addedin freezingweather,the vehicle shouldbe drivenseveralmiles to allow the waterto mix with the electrolyte.Otherwise, batterycould the freeze. Althoughsomemaintenance-free batterieshave the removablecell caosfor accessto the electrolyte,
r on most models
m causea short circuit, leadingto sparksand possible personalinjury. Do not smoke,havean openflameor create sparksneara battery;the gasescontainedin the battery are very explosiveand, if ignited,could causesevere injury or death. All batteries,regardless type,should becareof fully securedby a batteryhold-downdevice.If this is not done,the batteryterminalsor casingmay crack from stressappliedto the batteryduringvehicleoperation.A batterywhich is not securedmayallow acid to leakout, makingit dischargefaster;such leaking
built-in hydrometer.
tcu1@32
Fig. 53 A typical location for the built-in hvdrometer on maintenan ce-free batteries I
*Although the readingsfrom built-in hydrometersfound in sealed batteriesmay vary,a greeneyeusually indicatesa prop erly chargedbatterywith sufficient fluid level. A dark eye is normally an indicator of a batterywlth sufficient fluid, but one which may be low in charge.And a light or yellow eye is usually an indication that electrolyte supply has droppedbelow the necessary level for battery (and hydrometer)operation. In this last case. sealed batterieswith an insufficient electrolyte level mustusually be discarded.
G,ENERALlNFORMATlONAND MAINTENANCE l-17
Fig. 54 Onnon-maintenance-free batteries, the fluid level can be checkedthrough the 1case on translucent models; the cell caps1 must be removedon other models 1 Checkingthe Specific Gravity \
Fig. 55 If the fluid level is low, add only dis1tilled water through the opening until the 1level is correct
Fig. 56 Checkthe specific gravity of the batterys electrolyte with a hydrometer more thebattery cells, should slowly be charged and Lhecked toseeif thearavitv come Genaqain has UP. erally, affer if charging, specific the gravity between any two varies than points cells more 50 (0.50)thebattery should replaced, it cannolonger be as produce sufficient voltage guarantee operation. to proper
Asstated earlier, specific the gravity a batterys of electrolyte canbeusedasanindication batlevel of terycharge. least ?a year, At once check specific the gravity thebattery. should between and of It be 1.20 A hydrometerrequired check specific is to the on scale. autosupply Most stores gravity all batteries arenotmaintenance-free. 1.26 thegravity on that carryavariety inexpensive testing of battery hydromOnbatteries aremaintenance-free, that thesoecific eters.,, canbeused anynon-sealed These .,, on battery gravity checked observing built-inhydrome- , , , is by the .. IOrestmespecmc gravny each in cell. tereyeonthetopof thebattery Check case. with Thebattery testing hydrometer asqueeze has bulb yourbatterys manufacturerproper for interpretation atoneend a nozzle theother. and at Battery electrolyte of itsbuilt-inhvdrometer readinas. thehydrometer thefloatis lifted until -he specific gravity thenread notis by mgtneposrtroof thefloat.If gravity lowinoneor n is Batteryelectrolyte containssulfuric acid. If you shouldsplashany on your skin or in your eyes, flush the affected area with plenty of clear water. If it lands in your eyes, get medical help immediately. # See Figures 54, 55, and 56 Thefluid(sulfuric solution) acid contained the in battery will tellyoumany cells things about conthe ditionof thebattery. Because cellplates be the must kept submerged thefluidlevelin order opbelow to erate, maintaining fluidlevelis extremely the important. because soecific And. the aravitv theacidis of anindication electrical of charge, testing fluidcan the beanaidindetermining battery bereif the must placed. battery avehicle a properly A in with operatingcharging system should require maintelittle nance, careful, but periodic inspection should reveal problems theyleave stranded. before you
CABLES
) See Figures 57, 56, 69, 60, and 61 Once year(orasnecessary), battery a the terminalsandthecable clamps should cleaned. be Loosen
Fig. 57 Maintenance is performed with householditems and with special tools like I this post cleaner I
Fig. 58 The underside of this special battery tool has a wire brushto clean post ter1minals

theclamps remove cables, and the negative cable first.Onbatteries posts top,theuseof a with on pullerspecially forthispurpose recommade is mended. areinexoensive available most These and in
dt lJdlL> Xlt;>. 31C LtXlllllldl lJdllt2) MLJIC, dlt XI
alternator turntheadjusting to adjust tenor bolt belt sion.Once desired is reached, the the value secure boltor locknut recheck and tension.
cured a smallbolt. with Clean cable the clamps thebattery and terminal witha wirebrush, all corrosion, until grease, is etc., removed themetal shiny. isespecially and isshinv. esneciallv It imporimnnrtant clean inside theclamp to c the of thoroughly old (an knifeis useful since small here), a smart nere), deposit foreign of material oxidation will preventsound or there pre a electricalconnection inhibit and either starting charging. or Special areavailable cleaning parts, tools for these onetypeforconventional postbatteries antop and batteries.is QI@* It agood other forsideterminal type batterin, if also3nnnd I+ idea apply to some dielectric grr totheterminal, grease as thiswill aidintheprevention,,vIIuaIUII. of corrosion, After clamps terminals clean, the and are reinstall thecables, negative last;DONOT cable hammer the clamps battery onto posts. Tighten clamps the securely, donotdistort but them. theclamps Give and terminalsthinexternal a coating grease inof after stallation, retard to corrosion. Check cables thesame thattheterminals the at time arecleaned.thecable If insulation cracked brois or ken, if theends frayed, cable or are the should rebe placed a new ofthesame with cable length gauge. andaauae.
ST&
REMOVAL &INSTALLATION
1.5L, 1.611,1.8L, 2.OLand 2.4L Engines ALTERNA BE1 TOR T e See Figures67,68, and 69
Fig. 62 There are typically 3 types of acmere cessory drive belts found on vehicles today
1. Loosen alternator the support nut. 2. Loosen adjuster bolt. the lock clockwise to * I 3. Rotate . adjuster ..counter .I the on.. bolt release tension thebelt. the, 4. Remove belt. the Tn iet*ll* To install: 5. Install beltonthepulleys. the R Rntatn the cxiillrtm hnit A&+,& until the 6. Rotate adjuster clockwise the the bolt until proper .-._..._reached. is r -r- tension .______ .7. Tighten adjuster boltandthealternator the lock support nut. POWER STEERING BELT 8 See Figures 70 and 71 1. Remove alternator asdescribed the belt above. 2. Loosen power the steering adjusting pump bolts. 3. Remove power the steering fixedbolton oumo therearof thebracket. 4. Rotate pump the toward engine remove the and thebelt. To fnstall: 5. Install beltonthepulleys. the
CHARGING
1 I I
Fig. 64 Deep cracks in this belt will cause flex, ..Y...Y up II. that will eventually ...I building heat ..IU. ..m.*V. 1 1lead to belt failure
The chemicalreactionwhich takes place in all batteriesgeneratesexplosive hydrogen gas. A spark can causethe batteryto explode andsplash acid. To avoid serious personal injury, be sure there is properventilation and take appropriatefire safety precautionswhen connecting,disconnecting,or charginga battery andwhen usingjumpercables. A battery should charged a slowrate keep be at to theplates inside getting hot.However, from too if some maintenance-free areallowed disbatteries to charge theyarealmost until dead, may to they have becharged a highrate bring back life. at to them to Always followthecharger manufacturers instructions oncharging battery. the Fig. 85 The cover of this belt is worn, ex-
REPLACEMENT
When becomes it necessary reolace haeoN to thn select withanamperage equal I yyLJ one rating tc or oreMer . a ---than battery the originally installed. Deterioration and justplainaging thebattery of cables, starter motor, andassociated makes batterys harder wires the job insuccessive Theslowincrease electrical years. in resistance timemakes prudent install new over it to a battery a greater with capacity theold. than I
tm1217 I -. -_ Fig. 66 Installing too wide a belt can resylt in serious belt wear and/or breakage
1Fig. 67 Loosenthe adjuster lock bolt . . . -
thebeltandrunoutward. wornor damaged All drive belts should replaced be immediately. best reIt is to place drivebelts onetime, a preventive all at as maintenance measure, thisservice during operation.
:*
ADJUSTMENT
Excessive tension cause belt will damage thealto ternator water and pump pulley bearings, on while, theother hand, be tension Droduce slinr loose It will r -----andpremature onthebelt. wear Therefore, sureto be adjust belttension theproper the to level. * loosen Toadjust the tension ona onveDen. me adjusting orfixingb locknut thealternator, bolt bolt on alternator bracket tens pulley. move or iion Then the
INSPECTION
e See Figures 62, 83, 64, 65, and 88 Inspect belts signsof glazing cracking. the for or A glazed will beperfectly belt smooth slippage, from whilea goodbeltwill have slighttexture fabric a of visible. Cracks usually attheinner of will start edge
Fig. 68 . . . then remove the alternator I from the engine
GENERAL INFORMATION MAlNTENANdE AND l-19

6. Rotate pump theproper the until tension is reached. 7. Tighten adjusting onthepump. the bolts 8. Tighten fixedboltontherearof thebracket. the 9. Install alternator the belt. A/r: COMPRESSOIl f BEL 1. Loosen tension the oullev remove belt. and the 2. Theinstallation thereverse theremoval. is of .3.gL DGHC,3.OLSOHC(Gaiant models only) and 3.5L Engines 6 See Figures72 and 73 -I Wait at least 60 secondsafter the negative battery cable is disconnected preventpoSto sibie deploymentof the air bag. 2. Raise safely and support vehicle rethe and re mob theundercover. 3. Remove alternator NC compressor the and belt. 4. Lower vehicle remove cruise the and the control oumn link iW%mblV.
79244Q.37 --
4. Remove belt. the To install: 5. Install beltonthecrankshaft alternator the and pulleys. 6. Using adjusting onthetensioner, the bolt tighten beltto thedesired the tension. 7. Tighten fixingnutto holdtheadjustment. the 8. Install undercover lower vehicle the and the to _, thetloor. 9. Connect negative the battery cable. POWER SliEERlNG f BEL 1. Disconnect neaative the batteN cah+P
Fig. 72 Serpentinebelt routing-Mitsubishi 3.OLengines (except 1696-00 Galant models) 1

792UQ4
Fig. 69 Accessory V-belt routing-Mii subishf 1.6L, 1.6L,-1.6L, 2.OLand 2.4L en gines
Generator
pulP
I
I
I-r 5. Place power the steering under oil hose the reservoir. 6. Loosen tension the pulley fixingbolts reand move power the steering drivebelt. pump To install: 7. install Dower the steerina r+r+v~ oumu hp++ 8. Insert extension &eoufvaik;;tf;;idhe an bar opening theendof thetension at pulley bracket and pivotthepulley apply to tension thebelt. to 9. Tighten fixingbolts. the 10. Raise vehicle install alternator the and the and compressor belt. Il. Install undercover lower.I,.,vph+r+p the and +hfi .VII..Y. 12. Connect negative the battery cable.
----
_I
33151PM
Fig. 70 After the adjusting and fixed bolt! are loosened, rotate the pump . . . Fig. 73 Accessory V-beltrouting-Mitsubishi 3.5L and 1996-00 3.OL SOHCGalant engines
Wait at least 60 secondsafter the negative battery cable is disconnected preventposto sible deploymentof the air bag. 2. Raise safely and support vehicle rethe and move frontundercover. the 3. Loosen tension the pulley fixingnutandrelieve thetension thebeltbyturning adjusting on the bolt.
3.OLSGHC (DiamanteModels Onivl Enotne 1. Disconnect negative the battery cable. 2. Loosen lockbolt thefacenftheA/C the on _ __.tensioner pulley. 3 Turn adiustina of theA/C+fincrnner the bolt pulley loosen tension theA/Cbelt. to the of 4. Remove A/Ccompressor the belt. 5. Loosen locknut theface thepower the on of steering/alternator tensloner pulley. 6. Turn adjusting of thetensioner the bolt pulley to loosen tc the msion thebelt. of 7. Removthepower e steering/alternator belt. To install: 8. .* . the steering/alternatorfirst belt .* Install power ,^ anatnen A/ti compre: drivebelt. tne ssor 9. Adjust belts I theproper the t+ tension turnby . ingtheadjusting anuII~IIWII pueey bolts A.:-LI-..-.. I,^, tlxmg nut/bolt. 10. Tighten mounting of thepower the nut steering/alternator tensioner to 36ft. Ibs.(50Nm). pulley -The manufacturerdoes not provide a torque specificationfor the bolt that secures A/Ctensionerpulley. 11. Connect negative the battery cable.
,r
/ F$71t immtl$mm&a
the power :::
l-20
INSPECTION
# See Figures 74 thru 81 Allengines covered thismanual timing by utilize belts drivethecamshaft thecrankshafts to from turningmotion to maintain and proper timing. valve Some manufacturers schedule periodic timing belt replacementassure to optimum engine performance, to make themotorist never sure is stranded should thebeltbreak theengine stopinstantly) (as will and for some (manufacturers interference with motors) to Fig. 74 Checkfor premature parting of the prevent possibility severe the of internal engine dambelt ageSt10Ula the Delt break. Although 1.5L 1.8L the and engines notlisted are asaninterference (it is notlisted themanmotors by ufacturer a motor as whose valves might contact the pistons thecamshaft rotated if was separately from thecrankshaft) first2 reasons periodic the for replacement apply thetiming should still and belt be replaced 60,000 (96,000 The1.6L, at miles km). 2.01,2.4L, and35L engines listed inter3.OL, are as ference motors, thetiming MUST replaced so belt be at60,000 (96,000 to avoid miles km) severe engine damagethebeltshould if break. Butwhether notyoudecide replace timor to the tml245 ingbeltin themanufacturers schedule, wouldbe you Fig. 76 look for noticeable cracks or wear wisetocheck periodically make it hasnot it to sure become damaged worn.Generally or speaking,sea _on the belt face verelv beltmav worn cause enaine oerformance to drop~dramatically, damaged (which buta belt could giveoutsuddenly) notgiveasmuch may warning. In general, timetheengine any timing cover(s) (are) is removed should you inspect beltfor premature the parting, severe cracks missing Also, acor teeth. an cess is provided theupper plug in portion thetimof ingcover thatcamshaft canbechecked so timing without removal. timing found beoff, cover If is to cover removal further inspection replaceand belt or ment necessary. is Forthetiming removal installation belt and procedure, please to Section of thismanual. refer 3 Fig. 78 Foreign materials can get in between the teeth and cause damage
. 75 Check if the teeth are cracked or
fig. 77 You may only have damageon one side of the belt; if so, the guide could be the culprit
INSPECTION
b See Figures 82,8S, 84, and 85 . Upper lower and radiator hoses, withthe along heater hoses, should checked deterioration, be for leaks loose clamps least 30,000 and hose at every miles (48,000 It is alsowiseto check hoses km). the periodically earlyspring atthebeginning in and of thefall or winter youareperforming when other maintenance. visualinspection disA quick could cover weakened which a hose might leftyou have strandedit hadremained if unrepaired. Whenever arechecking hoses, sure you the make theengine cooling and system cold.Visually are inspect cracking, for rotting collapsed or hoses, wand place necessary. yourhand as Run along length the of thehose. a weak swollen is noted If or spot when squeezing hose thehose the wall, should rebe placed.
Fig. 79 Inspect the timing belt for c fraying, glazing or damageof any kind
Fig. 80 Damageon only one side of the timing belt may indicate a faulty guide I
,
Fig. 81 ALWAYS replace the timing belt at I the interval specified by the manufacturer
L

9. Close radiator engine the or drains propand erlyrefillthecooling system theclean with drained engine coolant a suitable or mixture ethylene of glycotcoolant water. and 10. If available, a pressure andcheck install tester for leaks. a pressure is notavailable, the If tester run engine normal until operating temperaturereached is (allowing system naturally the to pressurize), then check leaks. for
IWSIZXJ
Fig. 82 The cracks developing along this hose are a result of age-related hardening
FM. 83 A hose clamn that is taa tiaht can caise older hoses td separate andiear on either side of the clamp
If you are checkingfor leaks with the system at normaloperatingtemperature,BEEXTREMELY CAREFUL to touchany moving not or hot engineparts. Oncetemperaturehas beenreached.shutthe enaine OFF.and checkfor leaks aroundthe-hosefittings and connectionswhich were removedearlier.
INSPECTION
b See Figures 88 and 87 TheCV(Constant Velocity) should boots be checked damage timetheoil is changed for each and anyother thevehicle raised service. time is for These boots water, keep grime, andother dirt damaging matter entering CV-joints. of these from the Any couldcause CV-joint early failure whichcanbeexpensive repair. to Heavy grease thrown around inthe sideof thefrontwheel(s) onthebrake and caliper/drum beanindication a tornboot. can of Thorouahlv theboots missina check for clamos and
lCCS1221
Fig. 84 A soft spongy hose (identifiable by the swollen section) will eventually burst and should be replaced 1
Fig. 85 Hosesare likely to deteriorate from the inside if the cooling system is not periodically flushed 3. Loosen hose the clamps each ofthe at end rose requiring replacement. areusually Clamps eiher thesorina of tension (which tvoe reouire oliers 3squeeze 6bsandloosenj of thescrew the or teniontype(which require screw hexdrivers or to oosen). theclamps onthehose from Pull back away heconnection. 4. Twist, andslidethehose thefitting, pull off sking notto damage neck thecomponent care the of rom which hose being the is removed. *If the hose is stuckat the connection,do lot try to insert a screwdriver or other sharp ool underthe hose end in an effart to free it, ISthe connectionand/orhosemay become lamaged.Heaterconnectionsespecially nay be easily damagedby sucha procedure. f the hose is to be replaced, use a single!dgedrazor blade to makea slice alongthe lortion of the hosewhich is stuckon the consection,perpendicularto the end of the lose. 00 not cut deepso as to preventdamaging connection.The hosecanthen be the keeledfrom the connectionand discarded. 5.. Clean hose both mounting connections. In,pect condition thehose the of clamps replace and hem, necessary. if To install: 6. Diptheends thenewhose clean of into enfinecoolant ease to installation. 7. Slide clamps thereplacement the over hose, hen thehose over connections slide ends the into rosition. 8. Position secure clamps least in. and the at l/d 6.35mm) theends thehose. surethey from of Make Irelocated beyond raised of theconnector. the bead
IEMOVAL &,INSTALLATION
1. Remove radiator the pressure cap.
'
Never removethe pressurecap while the engine is running,or personalinjury from scaldinghot coolant or steammayresult. If possible, wait until the enginehascooled to removethe pressurecap. If this is not possible, wrap a thick cloth aroundthe pressure cap andturn it slowly to the stop. Stepback while the pressureis releasedfrom the cooling system.Whenyou are sure all the pressure has beenreleased, use the cloth to turn and removethe cao. 2. Position clean a container theradiator under and/or engine draincock plug, open drain or then the andallowthecooling system drain anapproprito to atelevel. some For upper hoses, a littlecoolant only must drained. remove positioned be To hoses lower ontheengine, asa lower such radiator theenhose, tirecooling system beemptied. must
Fig. 86 CV-bootsmust be inspectedperiod-
Whendraining coolant, keep in mindthat cats and dogsare attractedby ethyleneglycol antifreeze,and are quite likely to drink any that is left in an uncoveredcontaineror in puddleson the ground.This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reusedunless it is contaminatedor several years old.
l-22
yourdriving longdistance, speed is high travel, a use colder if most yourdriving stopandgo, plug; of is usea hotter Original plug. equipment aregenplugs erallya goodcompromise between 2 styles the and most people have need change never the to their plugs thefactory-recommendedrange. from heat
tears. thebootis damaged, If it should replaced be trodeis totheblocks cooling passages) cooler the it immediately. refer Section for procedures. will operate. plugthatabsorbs heat rePlease to 7 A little and mains coolwill quickly too accumulate deposits of oil andcarbon it is nothotenough burn since to them Thisleads plugfouling consequently off. to and to misfiring. plugthatabsorbs much will A too heat have deposits duetotheexcessive the no but, heat, ti See Figure 88 ,electrodes burn quickly might will away and possibly lead preignition otherignition to or problems. PreigAtypical spark consists a metal surplug of shell nition takes when tipsgetsohotthatthey place plug roundingceramic a insulator. metal A electrode exglowsufficiently ignite air/fuel to the mixture before tends downward through center theinsulator the of theactual spark occurs. earlyignition usuThis will andprotrudessmalldistance. a Located theendof at allycause pinging a during speeds heavy low and theplugandattached thesideof theouter to metal loads. shellis thesideelectrode. sideelectrode The bends Thegeneral of thumb choosing correct rule for the inata 90angle thatitstip is justpast paralso and heat range picking spark is:if most when a plug of lelto thetio ofthecenter electrode. distance The between twoelectrodes these (measuredthousandths in of aninchor hundredthsa millimeter) called of is the spark gap. piug
ti See Figures 90 thru 95 A setof spark plugsusually requires replacement after about 20,000-30,000 (32,000-48,000 miles km),depending yourstyleof driving. normal on In operation gapincreases 0.001 plug about in. (0.025mrn) every for 2,500 miles(4,000 Asthe km).
INSULATOR CRACKS OFTEN OCCUR HERE
SIDE ELECTRODE (SEND TO ADJUST
GAP)
ENTER ELECTRODE: FILE FLAT WHEN ADJUSTING GAP; DO NOT BEND
Fig. 88 Cross-sectionof a spark plug Thespark does producespark, inplug not a but steed provides gapacross a which current the can arc.Thecoilproduces anywhere 20,000 from to 50,000 (depending thetypeandapplication) volts on which travels through wires thespark the to plugs. Thecurrent passes thecenter along electrode and jumps gaptothesideelectrode, in doing the and so, ignites air/fuel the mixture thecombustion in charnber.
Fig. 90 Carefully twist the boot end of the spark plug wire andwithdraw the sparkplug wire boot from the cylinder head
Fig. 91 A special spark plug socket with a rubber insert is required to remove the spark plugs. Typically the spark plugs require a Yaspark plug socket
SPARKPLUG HEATRANGE
ti See Figure 89 Spark heat plug range theabilityof theplugto is dissipate Thelonger insulator thefarther heat. the (or it extends theengine), hotter plugwill into the the operate; shorter insulator closer electhe the (the the
Fig. 92 A locking extension such as this is extremely helpful when removing spark plugsthat are centrally located in the cyhn-
Fig, 93 Using the appropriate sized spark plugsocket, necessaryextensionsanddrive tools, loosen the spark plug . . .
93151ptxl
Fig. 94 . . . then carefully withdraw the spark plug from the engine
Fig. 95 After removingthe plug from the engine, inspect it using the spark plug condition chart in this section to determine the runningcondition of your engine

gapincreases, plugs the voltage requirement inalso creases.requires greater It a voltage jump to the widergapandabout to three asmuch &o times voltageto firetheplugathighspeeds atidle.The than improved air/fuel control modern injecratio of fuel tioncombined thehigher with voltage output modof ernignition systems often anengine run will allow to significantly ona setof standard plugs, longer spark butkeep mind efficiency dropasthegap in that will widens (along fueleconomy power). with and When youre removing plugs, onone spark work ata time. Dont byremoving plugwiresall at start the once, because, younumber theymay unless them, become up.Take minute mixed a before begin you andnumber wrrpc +sne the with 1. Disconnect. neaative 1the ~~.~ --..-., cableandif bat&v-..-.-, -..thevehicle been recently, theengine has run allow to thoroughly cool. 2. If equipped, remove center the cover. 3. Onthe3.OL (SOHC DOHC) 3.5Lenand and gines, upper the intake manifold beremoved must to access rearspark the plugs. to Section forthe Refer 3 removal procedure. 4. Carefully thespark wirebootto twist plug loosen thenpullupward remove bootfrom it, and the theplug.Besure pullonthebootandnotonthe to wire,otherwise connector the located inside boot the may become separated. 5. Using compressed blowanywater deair, or brisfromthespark welltoassure noharmplug that ful contaminants allowed enter combustion are to the chamber thespark is removed.comwhen plug If pressed is notavailable, a raaor a brush air use to clean area. the *Remove the sparkplugswhenthe engine is cold, if possible,to preventdamageto the threads. If removal of the plugs is difficult, apply a few dropsof penetratingoil or silicone spray to the area aroundthe base of the plug, and allow it a few minutesto work. 6. Using spark socket is equipped a plug that witha rubber to properly theplug, insert hold turn
,,Y ..1111 uy
thespark counterclockwise plug to loosen reand move spark fromthebore. the plug
Be sure not to usea flexible extensionon the socket. Useof a flexible.___. extensionmay_ . allow ea plug. a shearforce to be agptf to me-u A LL_ on III me shearforce could breaktne _I___ I_ ILpug cylinder head, leadingto costly andfrustrating repairs. To install: 7. Inspect spark bootfor tears damthe plug or age.If.adamaged is found, spark wire boot the plug must replaced. be 8. Using wirefeelergauge, andadjust a check thespark gap. plug When a gauge, proper using the sizeshould between electrodes a slight pass the with drag. nextlarger should beableto pass The size not whilethenextsmaller should freely. size pass 9. Carefully thread plugintotheboreby the hand. resistancefeltbefore plugisalmost If is the completely threaded, theplugoutandbegin back threading Insmall, to reach again. hard areas, old an spark wireandbootcouldbeused athreadplug as ingtool.Thebootwill holdtheplugwhileyoutwist theendofthewireandthewireis supple enough to twistbefore wouldallowtheplugto crossthread. it
11. Apply small a amount silicone of dielectric compoundtheendof thespark lead inside to plug or thespark bootto prevent plug sticking, install then thebootto thespark andpush it clicksinto plug until place. clickmay feltor heard, gently The be then pull back thebootto assure on proper contact. 12. Onthe3.OL fSOHC DOHC) 3.5Lenand and gines, install upper the intake manifold. to SecRefer tion3 fortheinstallation procedure. 13. Ifequipped, thecenter install cover.
INSPECTIONGAPPING &
b See Figures 98, 97, 98, 99, and 100 Check plugs deposits wear, theyare the for and If notgoing bereplaced, theplugs to clean thoroughly. Remember anykindof deposit decrease that will the efficiency theplug.Plugs becleaned a of can on spark cleaning plug machine, cansometimes which befound service in stations, youcandoanacceptor ablejobof cleaning a stiffbrush. theplugs with If are cleaned, electrodes befiledflat.Use igthe must an nitionpoints notanemery file, board thelike, or which leave will deposits. electrodes be The must filedperfectly withsharp flat edges; rounded edges reduce spark voltage asmuch 50%. the plug by as Check pluggapbefore spark installation. The ground electrode L-shaped connectedthe (the one to bodyoftheplug)must parallel thecenter be to electrodeandthespecified wiregauge size (please refer to theTune-Up Specifications for details) chart must pass between electrodes a slightdrag: the with *,NEVERadjustthe gap on a usedplatinum . type spark plug. Always thegaponnewplugs theyare check as notalways correctly thefactory. notusea set at Do flatfeeler gauge measuring gapona used when the plug,because reading beinaccurate. the may A round-wire gapping isthebest tocheck type tool way thegap. correct The gauge should through pass the electrode witha slightdrag. youre doubt, gap If in try onesizesmaller onelaraer. smaller and The aauqe
Do not usethe spark plug sock? l -- K-rrA Alwmm rarntdlv thw lad the plug by handor usingan old plug wire to prevent the possibility of crossthreading damagand ing the cylinder headbore.
GL I IlllGa
tha f..YY. nhme . ..Y
rnY,mY*.,
.I**
10. Carefully tighten spark If theplug the plug. youareinstalling equipped acrush is with washer, seat plug, tighten I/,turnto crush the then about the washer. youareinstalling tapered plug, If a seat tighten plugto specifications the provided theveby hicleor plugmanufacturer.
l-24
b%slZl2
tm2903
Fig. 97 A variety of tools and gauges are neededfor spark plug service
Fig. 98 Checkingthe spark plug @au a with feeler gauge. thetwoends. thelength multiply by6,000 Take and it to achieve maximum the resistance allowable each in wire,resistance should exceed value. resisnot this If tance exceed value, does this replace wire. the *Whenever the high tensionwires are removedfrom the plugs, coil, or distributor, silicone greasemustbe applied to the boot before reconnection.Coatthe entire Interior surfacewith a suitable silicone grease.
tccs2904
Fig. 99 Adjustingthe spark plug gap *Dont rely on wiring diagramsor sketches for spark plugwire routing. Improper arrangementof spark plugwires will induce voltage betweenwires, causingmisfiring and surging.Be careful to arrangespark plug wires properly. 4. Starting thelongest disconnect with wire, the spark wirefromthespark andthen plug plug from thecoilpack distributor or cap. To install: 5. If replacing spark wires, the plug match olc the wirewithanappropriately wireinthenew sized set. 6. Lubricate boots terminals dielecthe and with tricgrease install wireonthecoilpack. and the Make surethewiresnaps place. into 7. Route wirein theexact astheoriginal the path the plug. andconnect wireto thespark 8. Repeat process each the for remaining wire, iorking thelongest to theshortest. from wire 9. Install air cleaner tube. the inlet
# See Figures90,103 and 104 ig. 100 If the standardplug Is in good conftlon, the electrode may be filed flatWARNING: not file platinum plugs do should through go easily, thelarger while one I shouldnt through all.Wiregapping usugo at tools allyhave bending attached. thatto adjust a tool Use thesideelectrode theproper until distance ob- \ is tained. Absolutely attempt bend center never to the electrode. becareful to bend sideelecAlso, not the trode faror toooften it may too as weaken break and offwithintheengine, requiring removal thecylinof derhead retrieve to it. 1. Remove air cleaner tube. the inlet 2. If eouiooed, remove center fromthe the cover valve covei. 3. Label spark wireandmake noteof each plug a itsrouting.
TESTING
tcG1009
# See Figures191 and 102 Atevery tune-up/inspection, check visually the spark cables burns or breaks theinplug for cuts, in sulation. Check boots thenipples thedisthe and on tributor and/or Replace damaged cap coil. any wiring. Every 50,000 (80,000 or 60months, miles km) the resistancethewiresshould checked an of be with ohmmeter. withexcessive Wires resistance cause will misfiring, maymake engine and the difficult startin to damp weather. Tocheck resistance, ohmmeter an should used be oneach to testresistance wire between endconthe nectors. Remove install/replace wiresin or- and the der,one-by-one. Resistance these should 4,000-6,000 on wires be ohms foot.Toproperly per measure remove this, the wires theplugs thecoilpack. notpierce from and Do anyignition for anyreason. wire Measure from only
Fig. 102 Checkingindividual plug wire resistance with a digital ohmmeter
Fig. 103 Removethe spark plug wires from
Fig. 104 Remove the plug wires from the wire dividers

GENERAL INFORMATION b See Figures 111 and 112 Ignition timing themeasurement, is in degrees of crankshaft rotation, thepoint which spark of at the plugs ineach thecylinders. is measured fire of It in degrees or after Dead before Top Center (TDC) the of compression stroke. Ideally, air/fuel the mixture thecylinder be in will ignited thespark justasthepiston by plug passes osen the distributor cap retainFig. 106. . . then remove the cap from the distributor
I 1
COMBUSTION ENDS 23 ATDC
SPEED INCREASES
Fig. 107 Graspthe rotor and pull it straight off of the distributor shaft
Fig. 108The rotor mustbe aligned correctly to the distributor shaft before installation other physical damage. surethedistributor Make caps center button freeof damage. thecap is Check terminals dirtor corrosion. for Always therotor check blade spring and closely damage. for Replace any comoonents damaae found. where is
9ir&1$?6
Fig. 111 Advancingthe ignition timing CCURS

DC COMBUSTION ENDS 23 ATDC
REMOVAL &INSTALLATION b See Figures 105,106,107, and 108 1. Disconnect negative the battery cable. *Depending on the reasonfor removingthe distributorcap, it may makemoresenseto leave the sparkplug wires attached.This is handyif you are testingspark plug wires, or if removal is necessaryto accessother components,and wire lengthallows you to reposition the cap out of the way. 2. Label disconnect spark wires and the plug fromthedistributor cao. 3. Remove distributor retaining the cap screws or clipsandremove capfromthedistributor. the 4. Note installed its position, remove rothen the torfromthedistributor shaft. 5. Theinstallation thereverse theremoval. is of INSPECTION u See Figures109 and 110 Afterremoving distributor androtor,clean the cap thecomponents inside outside thecap) (both and of using andwater. compressed is available, soap If air carefully thecomponents dry (wearing gogsafety gles)or allowtheparts airdry.Youcandrythem to witha clean, cloth, dont anylintor soft but leave moisture behind. Once capandrotorhave thoroughly the been cleaned, forcracks, check carbon tracks, burns or
ALGNME LOCATOR
smmE
9mg27
Fig. 112 Retardingthe tgnttion timing
Inspectionpoints for the dis

TDC of the compressionstroke.If this happens, the pistonWIIIbe at the beginningof the powerstroke just as the compressed ignitedair/fuel mixture and forcesthe piston downandturns the crankshaft. Becauseit takesa fractionof a secondfor the spark plug to ignitethe mixture in the cylinder,the spark plug must fire a little beforethe piston reaches TDC. Otherwise, mixturewill not be completelyignited the as the piston passesTDC andthe full powerof the explosionwill not be used by the engine. Thetiming measurement given in degreesof is crankshaft rotationbeforethe piston reachesTDC (BTDC).If the settingfor the ignition timing is 10 BTDC,eachsparkplug mustfire 10 degreesbefore eachpiston reaches TDC.This only holdstrue, however,whenthe engineis at idle speed.The combustion processmust be completeby 23ATDC to maintain properengineperformance, mileage,and fuel low emissions. As the enginespeedincreases, pistonsgo the faster.Thesparkplugs haveto ignite the fuel even sooner if it ISto be completelyignitedwhenthe piston reaches TDC. If the ignition is set too far advanced(BTDC),the ignition and expansionof the fuel in the cylinderwtll occurtoo soon andtendto force the piston downwhile it is still travelingup. Thus causespre ignition or knockmgand pinging. If the ignition sparkis set too far retarded, afterTDC or (ATDC),the piston will havealreadystartedon its waydownwhenthe fuel is ignited.The pistonwill be forceddownfor only a portion of its travel,resulting in poor engineperformance lackof power. and Timing marksor scalescan befound on the rim of the crankshaft pulleyandthe timing cover.The marks on the pulleycorrespondto the posrtionof the piston in the No. 1 cylinder.A stroboscopic(dynamic)timing light is hookedonto the No. 1 cylindersparkplug wrre.Everytime the sparkplug fires, the timing light flashes.By aimingthe light at the timing markswhile the engineis running,the exactposition of the piston within the cylindercanbe easily read(theflash of light makesthe markon the pulleyappearto be standingstill). Propertiming is indicatedwhenthe markand scaleare in specifiedalignment.
Fig. 113 Ignition timing adjustment connector-1990-92 Mirage with 1.5L engine
Fig. 114 Ignition timing adjustment connectar-Miracle with 1.6L enaine
CHECK CONNECTOR
93151QM 93151QO!
Fig. 115 Ignition timing adjustment connectar-Galant with 2.OLengines
Fig. 116 Ignition timing adjustment con. nectar-1992-96 Oiamante
93151QO1
93151gOB
Fig. 117 Ignition timing adjustment con. nectar-1994-96 Galant

to a good ground.Referto the correspondingillustrations for the correctlocationof the timing adjustment connector. 4. Connecta conventional powertiming light to the No. 1 cylindersparkplug wire. Startthe engine and run at idle. 5. Aim the timing light at the timing scalelocatednearthe crankshaft pulley. 6. Loosenthe distributoror crankanglesensor hold-downnut just enoughso the housingcanbe rotated. 7. Turn the housingin the properdirectionuntil the specifiedtiming is reached. Tightenthe holddown nut and recheckthe timing. Turn the engine
Whencheckingtiming with the enginerunning, take care not to get the timing light wires tangled in the tan bladesand/ordrive belts. INSPECTION &ADJUSTMENT 1990-96 Models e See Figures113 thru 119
1. Setthe parkingbrake,startand run the engine until normaloperatingtemperature obtained.Keep is all lights and accessoriesOFFand the front wheels straight-ahead. Placethe transaxlein P for automatic transaxleor Neutralfor manualtransaxle. 2. If not at specification,set the idle speedto the correctlevel. 3. Turn the engineOFF. Removethe waterproof coverfrom the igmtiontiming adjustingconnector,and connecta jumperwire from this terminal
As long as the basictiming is correct,the engineis timed correctly. 10. Turn the engineOFF. 11. Disconnect timing apparatus the and tachometer.
OFF.
8. Removethe jumperwire from the ignition timing adjustingterminaland installthe water-proof cover. 9. Startthe engineand checkthe actualtiming (thetiming without the terminalgrounded). This readingshould be approximately degreesmore 5 thanthe basictiming. Actualtiming may increaseaccording to altitude.Also, actualtiming mayfluctuate because slight variationaccomplished the ECU. of by
1997-00 Models
The ignition timing is controlledby the Engine ControlModule(ECM)and is not adjustable.However it can be inspectedusinga scantool.
GENERALINFORMATIONAND MAlNTENANdE I-27

ADJUSTMENT u See Figures 120 and 121
The only enginesthat requireperiodicadjustment of the valvesarethe 1.5L enginein the 1990-95 Mirageand the 1.8L in the 1993-95 Mirage.
l Exhaustvalve:0.0098 in. (0.25mm) l Intakevalve:0.0059 in. (0.15mm) 1993-95 1.5L engine: l Exhaust valve:0.0098 in. (0.25mm) * Intakevalve:0.008 in. (0.20mm) 1993-95 1.8L engine: l Exhaustvalve:0.012 in. (0.30mm) l Intakevalve:0.008 in. (0.20mm) 7. If the valve clearance out of specification, is loosenthe rockerarm locknutand adjustthe clearante usinga feelergaugewhile turningthe adjusting
screw.Whenat specification,tightenthe locknut.Be sureto hold the screwsecurelyin placewhentighteningthe locknutto preventit from turningwhen tighteningthe locknut.Tighteningtorqueof the locknut is as follows: l 1.5L engine:9-11 ft. Ibs. (12-15 Nm) l 1.8L engine:7 ft. Ibs. (9 Nm) 8. Recheck clearance readjust. the and 9. Afteradjustingthe valves,installthe valve cover and sparkplugs,and connectthe negativebattery cable.
Idle Fuel Pump Speed (rpm) Valve Clearance
Incorrectvalve clearancewill causenoisy and/or unsteadyengineoperation, reduced engineoutput,and possibleenginedamage. Checkthe valve clearancesand adjustas required while the engine is hot.
1. Warmthe engineto operatingtemperature. Turn the engineOFF. Disconnectthe negativebattery cable. 2. Removeall sparkplugsso enginecanbe easily turnedby hand 3. Removethe valvecover. 4. Turn the crankshaft clockwiseuntil the notch on the pulley is alignedwith the T markon the timing belt lowercover.This brings both No. 1 and 4 cylinder pistonsto Top DeadCenter(TDC). 5. Wigglethe rockerarms on No. 1 and4 cylindersup and downto determinewhich cylinder is at TDC on the compressionstroke.Both rockerarms shouldmove if the piston in that cylinder is at TDC on the compressionstroke. 6. Measurethe valveclearance a feeler with gauge.Whenthe No. 1 piston is at TDC on the compressionstroke,checkNo. 1 intakeand exhaust; No. 2 intakeand exhaust.Thenturn the crankshaft clockwise 1 turn to bring No. 4 to TDC on its compression stroke.With No. 4 on TDC,compressionstroke, checkNo. 2 exhaustand intake;and No. 4 intakeand exhaust.Clearance as follows: is 1990-92 1.5L engine:
No.1 No.2 No.3 No.4
ENGINETUNE-UP SPECIFICATIONS
Engine Displacement Spark Plugs Engine Gap Ignition liming (as.)
when engine is on TDCof cylinder 1 and (B) when engine is on TDCof cylinder 4
No.1 No.2 No.3 No.4
AA
AA
BB
BB
93151g10
Fig. 121 Adjustingthe valve clearance
l-28
mayresult skinor eyeirritation frostbite. in or Although intoxicity(due chemical low to stability), inhalation concentrated of refrigerant is dangerfumes ousandcanresult death; offatalcardiac in cases arrhythmia been have reported people in accidentally subjected highlevels refrigerant. early to of Some symptoms include of concentration drowsiloss and + ness. cGeneraiiy, the limit for exposureis lower for R-134athan it is for R-12. Exceptional care mustbe practicedwhen handlingR134a. Also,refrigerants decomposehightemperacan at tures gasheaters open (near or flame), which remay suitin hydrofluoric hydrochloric andphosacid, acid gene fatalnerve (a gas). R-12refrigerant damage environment can the because isa Chlorofluorocarbon which it (CFC), has been proven addto ozone depletion, to layer leading to increasing of UVradiation. radiation levels UV has been linked anincrease skincancer, with in suppressionof thehuman immune system, increase an in cataracts, damage crops, to damage aquatic to organisms, increase ground-level andinan in ozone, creased warming. global R-134a refrigerant a greenhouse which, is gas if allowed ventintotheatmosphere, contribute to will to global warming Greenhouse (the Effect). It is usually economically more feasible have to a certified MVAC automotive technician perform A/C system service yourvehicle. on Some possible reasons thisareasfollows: for l While is illegalto service A/Csystem it an without proper the equipment, home the mechanic wouldhaveto purchase expensive an refrigerant recovery/recycling machine service to his/her veown hicle. l Since a certified only person purchase may refrigerant-according theClean Act,there to Air are specific restrictions selling distributing on or A/C system refrigerant-itis legally impossible (unless certified) thehome for mechanic service to his/her ownvehicle. Procuring refrigerant anillegal in fashionexposes to theriskof paying $25,000 one a fine to theEPA. R-12 Refrigerant Conversion If yourvehicle uses refrigerant, way still R-12 one to save system down roadis to inveshA/C costs the gate possibility having system the of your converted toR-134a. olderR-12 The systems beeasily can converted R-134a to refrigerant a certified by automotive technician installing fewnew by a components changing system and the oil. Thecostof R-12 steadily andwill conis rising tinue increase, to becauseis nolonger it imported or manufactured United inthe States. Therefore,is ofit tenpossible have R-12 to an system converted Rto 134a recharged lessthanit wouldcostto just and for charge system R-12. the with If youareinterested having system in your converted, contact automotive local service stations for more details information. and formed helpmaintain efficiency thevehicles to the of A/Csystem. preventive For maintenance, the perform following: l Theeasiest most and important preventive maintenanceyourA/Csystem to besurethatit for is is used a regular on basis. Running system the for fiveminutes month matter theseason) each (no what will helpensure theseals all internal that and components remain lubricated. *Some newer vehicles automaticallyoperate the A/Csystemcompressorwheneverthe windshield defroster is activated.Whenrunning, the compressorlubricatesthe A/Csys tern components; therefore, the A/Csystem would not needto be operatedeach month. * Inorder prevent to heater freeze-up core during A/Coperation,is necessarymaintain it to proper antifreeze protection. a hand-held Use coolant tester (hydrometer)periodically thecondition to check of theantifreeze yourengines in cooling system. *Antifreeze shouldnot be usedlonger than the manufacturer specifies. . Forefficient operation anairconditioned of vehicles cooling system, radiator should a the cap have holding pressure meets which manufacturers specifications. capwhich to holdthese A fails pressures should replaced. be l Anyobstruction or damage thecondenser of to configuration restrict flowwhichis essential will air to itsefficient operation.is,therefore,goodrule It a to keep unitclean in proper this and physical shape.
Theidlespeed factory andusually adis set no justments evernecessary. adjustment are If an becomes necessary, check thespark first that plugs, injectors, air control andcompression idle servo pressure all normal. are Data various from sensors switches used and are bytheECU determine proper to the fuel/air mixture for optimal engine performance.
SYSTEMSERVICE&REPAIR ti See Figure 122 *it is recommended the A/Csvstembe that servicedby an EPASection609 cehified automotivetechnicfanutilizing a refrigerant recovery/recyclingmachfne. Thedo-it-yourselfer notservice should his/her ownvehicles system many A/C for reasons, includinglegal concerns, personal injury, environmental damage cost. following some thereaand The are of sons youmay why decide to service ownvenot your hicles system. A/C According theU.S. to Clean Act,it is afederal Air crime service repair to or (involving refrigerant) the a Motor Vehicle Conditioning Air (MVAC) system for money without being certified. isalsoillegal EPA It to ventR-12 R-134a and refrigerants theatmosinto phere. Selling distributing system or A/C refrigerant (ina container contains than20poundsf which less oi refrigerant) anyperson is notEPA certito who 609 fiedis alsonotallowed law. by State and/or lawsmaybemore than local strict the federal regulations, besuretocheck your so with state and/or authorities further local for information. Forfurther federal information thelegality seron of vicingyourAK system, theEPA call Stratospheric Ozone Hotline. *Federal law dictatesthat a fine of up to $25,000may be levied on peopleconvicted of venting refrigerant into the atmosphere. Additionally, the EPAmay pay up to $10,000 for informationor services leadingto a crimf nai convictionof the violation of these laws. When servicing A/Csystem runtheriskof an you handling coming contact refrigerant, or in with which
Fig. 123 A coolant tester can be usedto determine the freezing and boiling levels of the coolant in your vehicle 1
u See Figures 123 and 124 Fig. 122 A label with information concerning the A/Csystemis typically located in the engine compartment Although A/Csystem the should beserviced not bythedo-it-yourselfer, preventive maintenance can bepracticed A/Csystem and inspections bepercan
Fig. 124 To ensureefficient cooling system operation, inspect the radiator cap gasket and seal
GENERALINFORMATIONAND MAlNTENANdE 1-29 i

*Bug screenswhich are mountedin front of the condenser(unlessthey are original equipment)are regardedas obstructtons. l Thecondensation tube drain expels water any whichaccumulatesthebottom theevaporator on of housing theengine into compartment. tubeis If this obstructed, airconditioning the performance be can restricted condensation and buildup spillover can ontothevehicles floor. SYSTEMINSPECTION b See Figure 125 Although A/Csystem the should beserviced not bythedo-it-yourselfer, preventive maintenance can bepracticed A/Csystem and inspections bepercan formed helpmaintain efficiency thevehicles to the of A/Csystem. A/Csystem For inspection, perform the following: Theeasiest often important for the and most check airconditioning system consists a visualinspecof tionof thesystem components. Visually inspect the airconditioning system refrigerant damfor leaks, aged compressor abnormal clutch, compressor drive belttension and/or condition, plugged evaporator drain blocked tube, condenser disconnected fins, or broken wires, blown fuses, corroded connections and poorinsulation. A refrigerant will usually leak appear anoily as residue theleakage in thesystem. oily at point The residue picks dustor dirtparticles the soon up from surrounding andappears air greasy. Through time, thiswill buildupandappear bea heavy imto dirt pregnated grease. Fora thorough andoperational visual inspection, check following: the
l Make theair passage sure selection is lever operating correctly. theengine warm to Start and it normal operating temperature, make the then sure temperature selection is operating lever correctly.
-w ~1
ELEMENT(REFILL)CARE& REPLACEMENT b See Figures 126 thru 135 Formaximum effectiveness longest and element
lifp thp winrkhi&i
. ... .I. . . * I.. . I..
nnri winor hlarlP~ shmM hP kmt

...r* . , ,, ,~r~
* Check surface theradiator conthe of and denser dirt,leaves other for or material might which blockairflow. l Check kinksin hoses lines. for and Check the system leaks. for l Make thedrivebeltis properly sure tensioned. When air conditioningoperating, surethe the is make drivebeltisfreeof noise slippage. or l Make theblower sure motor operates all apat propriate positions, check distribution the then for of airfromall outlets theblower HIGHor MAX. with on *Keep in mindthat underconditionsof high humidity,air dischargedfrom the A/Cvents may not feel as cold as expected,even if the systemis working properly. This is because vaporizedmoisturein humidair retains heat more effectively than dry air, thereby making humidair more difficult to cool.
clean. treesap,roadtarandsoonwill cause Dirt, streaking, smearing blade and deteriorationlefton if theglass. isadvisable wash windshield It to the carefullywitha commercial cleaner least a glass at once month. offtherubber Wipe blades thewetrag with afterwards. notattempt move Do to wipers across the windshield hand; by damage themotor drive to and mechanism result. will Toinspect and/or replace wiperblade the elements, thewiper place switch theLOWspeed in positionandtheignition switch theACCposition. in When wiper the blades approximately on are vertical thewindshield, theignition turn switch OFF. to Examine wiper the blade elements.theyare If found becracked, to broken torn,theyshould or be replaced immediately. Replacement intervals vary will withusage, although deterioration ozone usually limitselement toabout year. thewiperpattern life one If is smeared streaked, if theblade or or chatters across theglass, elements the should replaced.iseasibe It estandmost sensible replace elements to the in pairs. Ifyourvehicle equipped aftermarket is with blades, there several are different of refillsand vehitypes your
tcca-23
tCS1224
lW1Z?5
Fig. 126 Bosch@ wiper blade and fft kit
Fig. 127 LexoP wiper blade and fit kit
Fig. 128 Pylon@ wiper blade and adapter
Fig. 129 T&o* wioer blade and fit kit
Fig, 130 Tripledge@ wiper blade and fit kit
Fig. 131 To remove and install a LexoP wiper blade refill, slip out the old insert and slide in a new one
l-30
GENERAL'INFORMATIONAND MAINTENANCE
n Pylon@inserts, the clip be removedprior to siidi stripandpullupwhiletwisting counterclockwise. Thebacking will snap of theretaining strip out tab. Dothisfor theremaining untiltherefillis freeof tabs theblade. length these The of refillsis molded into theendandtheyshould replaced identical be with types.
thenthe insert can be re After installing the replacement catethefrontendis outof alignment thatthetires or areoutof balance.
TIRE ROTATION
# See Figures 137 and 138 Tiresmust rotated be periodically equalize to wear patterns varywithatiresposition thevehicle. that on Tires alsowearinanuneven asthefront will way steering/suspension wears thepoint system to where thealianment should reset. be Rotating tireswill ensure the maximum forthe life tiresasa set,soyouwill nothave discard tire to a earlydueto wear onlypartof thetread. on Regular
lowed touch olass to the
1 Fin
1% Tha Trinlarlna@
# See Figure 138 clemight anykind. have Aftermarket andarms blades rarely theexact typeblade refillasthe use same or original equipment. aresome Here typiel aftermarket blades; allmay available yourvehicle: not be for TheAnco@ uses release type a button is that pushed to allowtherefillto slideoutof the down yoke Thenewrefillslides intotheframe , jaws. back andlocksin place. Some Trico@ areremoved locating refills by where themetal backing ortherefilliswider.Insert strip a smallscrewdriver between frame metal blade the and backing Press to release refillfrom strip. down the theretaining tab. Other of Trico@ have metal types refills two tabs which unlocked squeezing together. are by them The rubber canthenbewithdrawn theframe filler from iaws. newrefillis installed insertina refill A bv the jntothefrontframe and&ding it rearward jaws to engage remaining jaws.There usually the frame are fourjaws;becertain installing therefillis when that engaged all of them. theendof itstravel, in At the tabswill lockintoplace thefrontjawsof thewiper on blade frame. Another of refillis made polycarbonate. type from Therefillhasa simple locking device oneend at which flexes downward of thegroove which out into thejawsof theholder allowing release. fit, easy By sliding newrefillthrough thejawsandpushthe all ingthrough slightresistance it reaches the when the endof itstravel, refillwill lockintoposition. the Toreplace Tridon@ it is necessary rethe refill, to move wiperblade. refillhasa plastic the This backing stripwitha notch about in.(25mm) theend. 1 from Holdtheblade (frame) a hard on surface thatthe so frame tightlybowed. thetipof thebacking is Grip Common andgooddrivinghabits afsense will fordmaximum life.Faststarts, tire sudden stops andhardcornering hardontiresandwill are shorten useful span. their life Make thatyou sure dontoverload vehicle runwithincorrect the or pressure thetires.Bothof these in practices inwill crease wear. tread *For optimumtire life, keepthe fires prop eriy inflated, rotate them often and have the wheel alignmentcheckedperiodically. Inspect tiresfrequently. especially your Be careful to watch bubbles thetreador sidewall, for in deep or underinflation. cuts Replace tireswith any bubbles thesidewall. cutsaresodeep they in If that penetrate thecords, to discard tire.Anycutin the thesidewall a radialtirerenders unsafe. of it Also lookfor uneven wearpatterns mayinditread that
DIRECTIONAL
TIRES
DIRECTIONAL
TIRES
Fig. 138 A label with information concerning the tires is typically located on one of the door pillars
tion

When rotating unidirectional make tires, sure thattheyalways inthesame roll direction. This means a tireused theleftsideof thevehicle that on must beswitched therightsideandvice-versa. not to Such should berotated tires only front-to-rear or rear-to-front, always while remaining thesame on sideof thevehicle. These aremarked the tires on sidewall to thedirection rotation; as of observe the marks reinstalling tire(s). when the Some styled mag or wheels have may different offsets to rear. these front In cases, rear the wheels must beused frontandvice-versa. not up Furthermore, these if wheels equipped unidirectional are with tires,theycannot rotated be unless tireis rethe mounted theproper for direction rotation. of *The compactor space-saverspare is strictly for emergencyuse. it mustnever be includedin the tire rotation or placedon the vehicle for everydayuse. check installed for anysignof interference the tire withthebodyorsuspension thevehicle stopwhile is ping,turning sharply heavily or loaded. Snow Tires Good radial canproduce bigadvantage tires a in slippery weather, in snow, street tiredoes but a radial nothave sufficient to provide tread traction conand trol.Thesmall grooves a street quickly of tire pack withsnow thetirebehaves a billiardballona and like marble Themore floor, open, chunky of a snow tread tirewill self-clean thetireturns, as providing much better onsnowy grip surfaces. Tosatisfy municipalities requiring tiresdursnow ingweather emergencies, snow carry most tires either anM+ Sdesignation thetiresizestamped after on thesidewall, thedesignation or all-season. genIn eral,nochange tiresizeis necessary buying in when snow tires. Mostmanufacturers stronqlv recommend use the of 4 snow ontheir\lehicies reasons stabiltires for of ity.If snow arefitter onlyto thedrivewheels, tires 1 the opposite of thevehil may end cle become unstavery blewhen braking turn onslippery or ring surfaces. Thisinstability lead unpleasant can to endings the if A*:,,- I LUUII~~MLL &I.slideintime. r-..l, ^_.. ^_^^, ..& iue UIIVU MII Note snow whether or 4,will affect that tires, 2 vehiclehandling all non-snow in situations. stiffer, The heavier tireswill noticeably snow change turning the andbraking characteristics vehicle. the of the Once snow areinstalled, must tires you re-learn behavthe ior of thevehicle driveaccordingly. and *Consider buyingextra wheels on which to mountthe snow tires. Oncedone,the snow iheeis can be installed and removedas needed.This eliminatesthe potential damage to tires or wheels from seasonalremoval and installation. Evenif your vehicle has lb styled wheels, see if inexpensivesteel wheels are available, Althoughthe look of the vehicle will change,the expensive wheels will be protectedfrom salt, curb hits and potholedamage.
TIRESTORAGE
Iftheyaremounted wheels, thetiresat on store proper inflation pressure. tiresshould kept a All be in cool,dryplace. theyarestored thegarage If in or basement, notletthem do stand a concrete on floor; setthem strips wood, mat a large of on of a or stack newspaper. Keeping away direct them from moisture is of paramount importance. should be Tires not stored upright, ina flatposition. but
INFLATIONINSPECTION &
b See Figures 140 thru 147 Theimportanceproper inflation of tire cannot be overemphasized. employs aspartof its Atire air structure.is designed It around supporting the strength theairata specified of pressure. this For reason, improper inflation drastically reduces the tiresabilityto perform intended.tirewill lose as A some in day-to-day having adda few air use; to pounds airperiodically notnecessarilysignof of is a a leaking tire. Twoitems should a permanent in every be fixture glove compartment:accurate pressure an tire gauge anda tread depth gauge. Check tirepressure the (ineluding spare) the regularly a pocket gauge. with type Toooften, gauge theendof theairhose the on at vnrrrcorner XI I._.notaccurate narane is becausesuffers it - -- when toomuch J s ~rs tireoressure the abuse. Alwa! check tiresarecold,aspressure increases temperawith ture.If youmust move vehicle check tire the to the
TIRE DESIGN
p See Figure 139 for maximum satisfaction, should used tires be in setsof four.Mixingof different (radial, types biasbelted, fiberglass belted) beavoided. most must In cases, vehicle the manufacturer designated has a typeof tireonwhich vehicle perform the will best. Yourfirstchoice when replacing should to tires be usethesame of tirethatthemanufacturer type recommends. When tiresareused, sizes wheel radial tire and diameters should selected maintain be to ground clearanteandtireloadcaoacitv eauivalent theoriainal to specified Radial tire. tiresshould always used be in setsof four. Radial tires shouldnever be usedon only the front axle. When selecting payattention theoriginal tires, to sizeasmarked thetire.Mosttiresaredescribed on using industry code an size sometimes referred as to P-Metric. allows exact This the identificationthe of tirespecifications, regardless themanufacturer. of If selectingdifferent sizeor brand, a tire remember to
METRIC TIRE SIZES
Fig. 140Tires should be checkedfrequently for any sion of aunctureor damaoe I

(MILLIMETERS) 145 CDNStRUCtlDN R - RADIAL l-6-E D WA9
Fig. 141 Tires with deep cuts, or cutswhich I buioe, should be replaced immediately
RADIAL
l
TIRE
DRIVE WHEEL HEAW ACCELERATION OVERINFLATION
*LACK
OF ROTATION
Fig. 139 P-Metric tire coding
Fig. 142 Examplesof inflation-related tire
fig. 143 Radial tires have a characteristic sidewall bulge; dont try to measure pressure by looking at the tire. Use a quality air pressuregauge

CONDITION
EFFECT
UNDER-INFLATION CAUSE EXCESSIVE SPEED WORN OR OUTOF-ALIGNMENT
CORRECTION
ADJUST PRESSURE TO SPECIFICATIONS WHEN TIRES ARE COOL ROTATE TIRES FOR FURTHER USE.
/
BALANCE WHEELS INSPECT SUSPENSION
lCCSi267
HAVE TIRE INSPECTED
ig. 144 Commontire wear patterns and causes

down) into severaltreadgrooves.If you canseethe top of Lincolnsheadin 2 adjacentgrooves,the tire has lessthan V,~in. (1.5mm)treadleft and should be replaced. canmeasuresnowtires in the same You mannerby using the tails side of the Lincoln penny.If you canseethe top of the Lincoln memorial, its time to replacethe snowtire(s).
1~~~1264
Fig. 146 Accuratetread depthindicatorsare inexuensiveand handv
CAREOFSPECIALWHEELS
If you haveinvestedmoneyin magnesium, aluminum alloy or sport wheels,specialprecautions should betakento makesureyour investmentis not wastedandthat your specialwheelslook goodfor the life of the vehicle. Specialwheelsareeasily damaged and/or scratched. Occasionally checkthe rims for cracking, impactdamageor air leaks.If any of thesearefound, replacethe wheel.But in orderto preventthis type of damageand the costly replacement a special of wheel,observethe following precautions: l Useextracarenot to damagethe wheelsduring removal,installation,balancing,etc.After removal of the wheelsfrom the vehicle,placethemon a mat or other protectivesurface.If they are to be storedfor any lengthof time, supportthemon strips of wood. Neverstoretires andwheelsupright;the treadmaydevelopflat spots. l Whendriving, watchfor hazards; doesnttake it muchto cracka wheel. l Whenwashing,usea mild soapor non-abrasive dish detergent (keepingin mind that detergent tendsto removewax).Avoid cleansers abrasives with or the useof hardbrushes.Thereare manycleaners and polishesfor specialwheels. l If possrble,removethe wheelsduringthe winter. Salt and sand usedfor snow removalcanseverelydamagethe finish of a wheel. l Makecertainthe recommended nut torque lug is neverexceeded the wheelmay crack.Neveruse or snowchainson specialwheels;severescratching will occur.
1~~~1265
Fig. 145 Tread wear indicators will appear when the tire is worn
inflation,do not drive morethan a mile beforechecking. A cold tire is generallyonethat has not beendriven for morethan threehours. A plateor sticker is normallyprovidedsomewhere in the vehicle(door post, hood,tailgateor trunk lid) which showsthe properpressurefor the tires. Never counteract excessivepressurebuild-up by bleeding off air pressure(lettingsomeair out). Thiswill cause the tire to run hotterandwearquicker.
Fig. 147 A penny works well for a quick check of tread death
but neverchangethe cold pressurespecificationby morethan 2 psi. A slightly softertire pressurewill give a softer ride but also yield lowerfuel mileage.A slightly hardertire will give crisperdry roadhandling but can causeskiddingon wet surfaces.Unless yourefully attunedto the vehicle,stick to the recommendedinflationpressures. All tires madesince 1968 havebuilt-in treadwear indicatorbarsthat show up as j/2in. (13mm)wide smooth bandsacrossthe bre whenV,~ (1.5mm)of in. treadremains.Theappearance treadwear indicaof tors meansthat the tires shouldbe replaced.In fact, manystateshavelawsprohibitingthe useof tires with lessthanthis amountof tread. You cancheckyour own treaddepthwith an inexpensivegaugeor by using a Lincoln headpenny. Shp the Lrncolnpenny(with Lincolnsheadupside-
Never exceedthe maximumtire pressure embossedon the tire! This is the pressureto be usedwhenthe tire is at maximumloading, but it is rarely the correct pressurefor everydaydriving. Consultthe owners manual or the tire pressuresticker for the correct tire pressure.
Onceyouvemaintained correcttire pressures the for severalweeks,youll befamiliar with the vehicles brakingand handlingpersonality. Slight adjustments in tire pressurescanfine-tunethesecharacteristics,
GENERALINFORMATIONAND MAINTENANC-E 1133

theSAE number, lighter oil;thelower visthe the the cosity, easier is tocrank engine cold the it the in weather thelesstheoil will lubricate protect but and theengine hightemperatures. number in This is marked every container. on oil Oilviscositys should chosen those be from oils recommendedthelowest for anticipated temperatures during oil change the interval. to theneed an Due for oil thatembodies goodlubrication hightemboth at peratures easy and cranking coldweather, in multigrade have developed. oils been Basically,multia grade is thinner lowtemperatures thicker oil at and at hightemperatures. example,low-40 oil (theW For a stands winter) for exhibits characteristics 10 the of a weight 10)oil when caris firststarted (SAE the and theoil is cold.Itslighter weight allows to travel it to thelubricating surfaces quicker offerlessresisand tance starter to motor cranking say,a straight than, 30weight 30)oil. Butatiertheensine (SAE reaches operating temperature, low-40 oil begins the acting likestraight weight 40)oil, itsheavier 40 (SAE weight providing greater lubrication lesschance with of foaming a straight weight than 30 oil. TheAPI(American Petroleum Institute) designations,alsofound theoil container, on indicates the classification engine used of oil under certain given operating conditions. oilsdesignated use Only for Service heavy detergent SJ duty should used be in yourcar.Oilsof theSJtypeperform functions may inside engine the besides basic their lubrication. Through balanced a system metallic of detergents andpolymeric dispersants, oil prevents and the high lowtemperature deposits alsokeeps and sludge and dirtparticles suspension. particularly in Acids, sulfuricacid,aswellasother by-products engine of combustion neutralized theoil. If these are are by acids allowed concentrate, cancause to thev corrosion and rapid of theinternal wear engine parts. Synthetic is notforevery andevery of oil car type driving, youshould so consider engines your conditionandyour of driving. check cars type Also, your warranty conditions regarding useof synthetic the oils.
Used fluidssuch engine transaxle anas oil, fluid, tifreeze brake arehazardous and and fluid wastes must disposed properly. be of Before draining any fluids,consult yourlocalauthorities; many with in areas, waste antifreeze, is being oil, etc. accepted a as partof recycling programs.number service A of stationsandautoparts stores alsoaccepting are waste fluidsfor recycling. Besureof therecycling centers policies before draining fluids, many notaccept any as will different fluidsthathave mixed been together.
FUEL
All models equipped a SOHC with (Single Overhead Camshaft) aredesigned operate engine to using regular unleaded witha minimum 87octane. fuel of All models equipped a DOHC Overhead with (Dual Camshaft) aredesigned operate regengine to using ularunleaded witha minimum 91octane. fuel of Mitsubishi warns using that gasoline a lower with octane rating cause can persistent heavy and knocking, and may cause internal engine damage. If yourvehicle having is problems rough with idle or hesitation theenoine cold,it mavbe when is caused lowvolatility Ifthisoccurs, a difby fuel. iry ferent grade brand fuel. or of
ENGINE OIL
6 See Figure 148 WMitsubishirecommends SAE5W-30 that viscosity engineoil shouldbe usedfor all clia mateconditions,however, SAElow-30 is ac ceptablefor vehicles operatedin moderateto-hot climates.
'OPERATIONFOREIGN 1~ COUNTRIES
Ifyouplanto driveyourcaroutside United the States Canada, is a possibility fuelswill or there that betoolowinanti-knock quality couldproduce and engine damage.is wiseto consult localauIt with thorities arrivalina foreign upon country deterto mine best available. the fuels
OILLEVELCHECK
# See Figures149, 150, and 151 \
lccS1235
Fig. 148 look for the API oil identification label when choosingyour enaine oil When adding to thecrankcase changing oil or the 0Nil filter,it is important oil of anequal or that quality tc.original I equipment used yourcar.Theuseof be in mtenor may thewarranty, __ en011s void damage your gine,or both. TheSAE (Society Automotive of Engineers) grade number oil indicates viscosity theoil (its of the of abilityto lubricate a given at temperature). lower The
Non-detergent motor oils or straight mineral oils shouldnot be used your engine. in
SyntheticOil There many are excellent synthetic fuel-effiand cientoilscurrently available canprovide that better gasmileage, longer service and,insome life cases, better engine protection. benefits notcome These do without fewhitches, a however; main being the one thepriceof synthetic whichissignificantly oil, more expensive conventional than oil.
The EPAwarns that urolonoedcontactwith used engineoil ma; cause-anumberof skin disorders, includingcancer!Youshould makeevery effort to minimizeyour exposure to used engineoil. Protectivegloves should be worn when changingthe oil. Washyour handsand any other exposedskin areas as soon as possibleafter exposureto usedengine oil. Soapandwater, or waterless hand cleaner shouldbe used. Theengine dipstick typically oil is located the in
Fig. 149Graspthe oil level dipstickand pull upwardto remove it from the dipstick tube
Fig. 150 Wipe the dipstick clean and reinsert it into the dipstick tubeto getthe correct oil level
Fig. 151The oil level shouldbe betweenthe marks/notches the dipstick on
l-34
The EPAwarns that prolongedcontactwith usedengineoil may causea num 01 SKlll IDer * * * dianrAnrr inrldinn uu,,u=, V#lllshould ranrnrli , vu u,yu,u=,+,,,,u,uu,,,u uffart to minimizeyour exposure to usedengin oil. Protectivegloves should le be worn whet1changingthe oil. Washyour handsandany other exposedskin areas as so*maJ vv4ble after exposureto useden..#a 111 . . . . . cleaner shouldbe used. miles highway of driving. whichiswarmed Fluid to normal operating temperature flowfaster, will drain more completely remove contaminants and more
frnm tho clnnine ll,,, Cl>y.
Engine levelshould checked timeyou oil be every putfuelinthevehicle areunder hoodperformor the ingother maintenance. 1. Park vehicle a levelsurface. the on 2. Theenaine beeither orcoldwhen mav hot checking level. oil , if it is hot,waita fewminutes theengine been after has turned toallowthe OFF oil todrain intothecrankcase. engine back Ifthe is cold,donotstart before it checking oil level. the 3. Open hoodandlocate engine dipthe the oil stick.Pullthedipstick itstube, it clean, from wipe andreinsert Make thediDstick fullv init. sure is serted. 4. Pullthedipstick itstubeagain. from Holding it horizontally, theoil level. oilshouldbeberead The tween MINandMAX the marks thenotches the or on dipstick. theoil is below MINmark lower If the or notch, oil oftheproper add viscosity through the capped opening thevalve of cover. 5. Reolace diostick. check levelaaain the and the
m nr W.Y.. Ynil St-mn mwl .,U.I, umtarlncr hand ginII.upllw&or rn .I.I....
*The engineoil and oil filter shouldbe changedat the recommended intervals on the MaintenanceChart.Thoughsomemanufacturers have at times recommended changing the filter only at every other oil change, Chiltonrecommends you always change that . The benefit of fresh oil
p See Figures 152 thru 153 Theoil andfiltershould changed 7,500 be every miles(12,000 under km) normal service every and 3,000 miles (5,000 under km) severe service.
draining oil, make thattheengine atoperthe sure is ating temperature. oil will holdmore Hot impurities in suspension will flowbetter, and allowing rethe moval more anddirt. of oil It is a goodidea warm engine firstsoit to the oil will flowbetter. canbeaccomolished15-20 This bv
1. Raise support vehicle and the safely jackon stands. sure oil drainoluais atthelowest Make the pointontheoil pan.If not,youmayhave raise to the vehicle slightly higher onejackstand than on (side) theother. 2. Before crawlunder vehicle, a look you the take atwhere will beworking gather thenecyou and all essary such a fewwrenches a ratchet tools, as or and stripof sockets, drainpan, the some rags clean and, if theoil filteris more accessible underneath from the vehicle, will alsowant graba bottle oil,the you to of new andafilterwrench thistime. filter at 3. Position drainpanbeneath oil pan the the drainplug.Keep mind thefastflowing in that oil, which spilloutasyoupulltheplugfromthepan, will will flowwithenough thatit couldmiss pan. force the Position drainpanaccordingly beready the and to move panmore the directly beneath plugasthe the oil flowlessens a trickle. to 4. Loosen drain~luawitha wrench socket the (or anddriver), carefuliy then unscrew plugwithyour the fingers. a ragto shield fingers the Use your from heat. in ontheplugasyouunscrew soyou Push it canfeelwhen of thescrew all threads outofthe are hole(and youwill keep oil fromseeping so the past thethreads youareready remove plug). until to the Youcanthenremove plugquickly avoid the to havinghotoil rundown arm. will alsohelpasyour This surethathave pluginyourhand, inthebotthe not tomof a panof hotoil.
93151p-55
Fig. 152 loosen the drain plug on the ena wrench. The drain plugs
Fig. 153Whenloosenedsufficiently, slowly turn the drain plug by hand, keeping con-
Fig. 154 Whenyou are ready, carefully pull
Fig. 155 Clean and inspect the threads on the oil pan
Fig. 156 Also inspectthe drain plug th before installing it back into the oil Make sure the gasket on the drain plug is in place and does not require replacement
Fig. 157 A plier-type filter wrench Is used here to loosen the filter
Fig. 158 Whenthe filter is sufficiently loos-
Fig. 181 Before installing a new oil filter, clean the gasketmountingsurfaceof the oil filter housingand inspect the threads
Fig. 182 Loosen and remove the oil filler cap . . . surface. youtighten filter,rotate about When the it a quarter-turn it contacts mounting (or after the boss followanyinstructions areprovided thefilwhich on teror parts box).
Fig. 183 . , , then insert a funnel, and pour oil directly into the engine
Be careful of the oil; when at operatingtemperature, it is hot enoughto causea severe bum. 5. Allowtheoil to drainuntilnothing a few but drops come ofthedrainhole.Check drain out the plugtomake thethreads sealing sure and surface are notdamaged. Carefully thread plugintoposition the andtighten snug, givea slightadditional it and turn. Youdont theplugtofall out(asyouwould want quickly become stranded), thepanthreads but are EASILY stripped overtightening thiscanbe from (and timeconsuming costly fix). and/or to 6. Toremove filter,youmayneed oil filter the an wrench thefiltermayhave fittedtoo since been tightlyand/or heat theengine have the from may made even it tighter. filterwrench beobtained A can atanyautoparts andiswell-worth investstore the ment. Loosen filterwiththefilterwrench. a the With ragwrapped around filter,unscrew filterfrom the the theboss thesideof theengine. careful hot on Be of oil thatwill rundown sideof thefilter.Make the sure thatyourdrainpanis under filterbefore start the you to remove fromtheengine; it should some thehot of oil happen getonyou,there bea place to will to dump filterina hurryandthefilterwill usually the spilla goodbitof dirtyoil asit is removed. 7. Wipe base themounting witha the of boss clean, cloth.When install new dry you the filter, smear small a amount freshoil onthegasket of with yourfinger, enough coattheentire just to contact
FLUIDRECOMMENDATIONS Forall vehicles manual with transaxles, Hyuse poidgear SAE oil 75W-85W, 75W-9OW or conformingto APIspecifications or higher. GL-4 LEVELCHECK b See Flgures 184 and 185 Inspect component leaking. each for Check oil the levelbyremoving fillerplug.Iftheoil is contamithe nated, is necessary replace withnew Check it to it oil. theoil levelasfollows:
Operatingthe enginewithout the proper amountandtype of engineoil will result In severe engtnedamage. 8. Remove jackstands carefully the the and lower vehicle, IMMEDIATELY theengine then refill crankcase theproper with amount oil. DONOT of WAIT DOTHIS TO becauseyouforget someif and onetriesto start vehicle, the severe engine damage will occur. 9. Refilltheengine crankcase slowly, checking theleveloflen, mayr..:-- U.-1 ..-..II...-L-e you ,,\U.J lVL,VY :LUUUU,,J II,UL II lessthan amount oil listedinthecapacity the of chart to refillthecrankcase. thatis onlyuntiltheenBut, gineis runandtheoil filteris filledwithoil.Tomake suretheproper is obtained, theengine level run to normal operating temperature, theengine shut OFF, allowtheoil to drainback theoil pan, into and recheck level. offtheoil atthistimeto thefill the Top mark. *If the vehicle Is not resting on level ground,the oil level readingon the dipstick may be slightly off. Be sure to checkthe level only when the vehicle is sitting level. 10. Drain used ina suitable your oil container for recycling.
89571gM
Fig. 164Typtcal manualtransaxle drain and filler plug location
l-36
Install drain andtighten 22ft. Ibs. the plug to (304Nm) 5. Refillthetransaxle theproper as to level, shown theCapacities withtheappropriate in chart, fluid.Theoil levelshould atthebottom theoil be of fillerhole. 6. When oil reaches orooer the the level, install thefillerplugandtighten 22ft. Ibs.(30Nm). to
FLUID RECOMMENDATIONS
8957i565
Fig, 165 Oil, when at the proper level, will reachthe lower edgeof tC=+ u*rn -nonfrfr*r ing 1. Makesure vehicle oarked a levelsurthe is on face. 2. Remove filler plug make theoil the and sure levelis uptotheloweredge thefiller plughole. of 3. Check besure thetransaxle is not to that oil noticeably andthatit hasa suitable dirty viscosity.
Mitsubishi recommends useof Mercon@autothe matic transmission fluid.
LEVELCHECK
u See Figures 168,169, and 170 Thetransaxle dipstick located is behind air inthe lethose, towards firewall. the 1. Park vehicle a levelsurface. the on 2. Thetransaxle should atnormal be operating temperature checking level. ensure when fluid To the fluidis atnormal operating temperature, thevedrive hicleat least miles. 10 3. With selector in P andtheparking the lever brake applied, theengine. start 4. Open hood locate transaxle the and the fluid dipstick. thedipstick itstube, it clean, Pull from wipe andreinsert Make thedipstick fully init. sure is serted.
Fig. 170 The fluid level is OKif it is within the betweenthe HOTand ADDareas on the &&i& -.*".."... Do not overfill the transaxle or -- .*"problemscould occur 5. Pullthedipstick itstube from again. Holding it horizontally, thefluidlevel. fkridshould road The be between MINandMAX the mark. thefluidis below If theMINmark, fluidthrough dipstick add the tube. 6. Insert dipstick, check level the and the again after adding fluid.Becareful to overfill any not the transaxle.
DRAIN REFILL &

u See Figures 166 and 167 1. Make thevehicle parked a levelsursure is on face. 2. Raise safely and support vehicle. a the Place suitable panunder manual drain the transaxle. 3. Remove fillerplugandthedrainplugand the allowtheoil to drain completely.
DRAIN REFILL &

b See Figures171 thru 177 1. Raise support vehicle and the safely. 2. Place suitable panunder transaxle a drain the drainplug. 3. Remove transaxle drainplug.Letthe the pan fluidcompletely outof thetransaxle. drain 4. Install drainplugandtighten to 22-25ft. the it lbs.(30-35Nm). 5. If equipped, remove drainplugonthedifthe ferential thetransaxle. of 6. Install differential plugandtighten the drain ft to 22-25ft. Ibs.(30-35Nm). 7. Remove drainpan. the 8. Lower vehicle. the 9. Fillthetransaxle through dipstick the the to proper level. 10. Place gear the selector in P andstart lever the engine. theengine idle,engage emergency Run at the brake holdthebrake down. and pedal Move gear the selector through transaxle lever all ranges approxfor imately minutes. 5 11. Return selector to P andleave the lever the engine running idle. at 12. Check transaxle level. fluidlevel the fluid The at normal operating temperature read should within thecrosshatched of thefluidleveldipstick. area 13. If thefluidlevelreads below crosshatched the area, adjust levelbyadding in smallincrethe fluid ments thecorrect levelis obtained. until fluid
Fig. 166 Use a box-end wrench to loosen the manualtransaxle drain plug . . .
Fig. 166 The automatictransaxle dipstick is typically located underthe air cleaner inlet tube. Pull the dipstick up to remove it from the transaxle
PAN&FILTER SERVICE
b See Figures178 thru 184 Thefluidshould changed be according the to schedule theMaintenance in Intervals If thecar chart. is normally in severe used service, asstopand such startdriving, trailertowing, thelike,theinterval or should halved. thecaris driven be If under especially nasty conditions, asin heavy trafficwhere such city thetemperature normally reaches (32%),or in 90F veryhillyor mountainous or in police, or areas, taxi,
Fig. 169 Wipe the dipstick clean and Insert it mto the transaxle agamto get the correct /fluid level reading ., j
_.
.I
..-. -._.
Fig. 172 Carefully pull the transaxie drain plug out and to the side, out of the way oi flowing transaxie oil
Fig. 173 The differential drain plug is located at the bottom of the transaxie, to the left of the fluid pan. Typically the drain plug reauires a 17mmwrench
periodically checkingthe fluid level to make sure you do not overfill the transaxle
pan mountingbolts,a 1Omm wrench is required. Removethe pan retaining bolts . . .
Fig. 179 . . , then carefully lower the fluid pan from the transaxle
Fig, 181 . , . then remove the transaxie film ter from the valve body
Fig. 182 Removethe transaxie pan gasket from the pan

11I Addtherecommended automatic transaxle fluidto thetransaxle through dipstick You the tube. will need longnecked a funnel, a funnel tube or and to dothis.A quick check thecapacities later of chart inthisSection reveal capacity thetransaxle will the of inyourvehicle. afirstfill afterremoving pan On the andfilter,thisnumber should cutintoa hand be checked thedipstick on before refilling. 12. With transaxle P,putontheparking the in brake, thefrontwheels, theengine let block start and it idle.DONOT RACE ENGINE. NOT THE DO MOVE THE LEVER THROUGH RANGES. ITS 13. Withtheleverin Park, check fluidlevel. the If itsOK, thecaroutfor a short take drive,parkona levelsurface, check level and the again, outlined as earlier thissection. more if necessary. in Add fluid Be careful to overfill, not which cause will foaming and fluidloss.
n of the transfer case filler 3. Remove fillerandthedrainplugandallow the theoil to drainintothedrainpan. 4. Afterthefluidhasdrained completely, install thedrainplugandtighten 24ft. Ibs.(32Nm). to 5. Refillthetransfer totheproper with case level Hypoid oil SAE gear 75W-85W/75W-9OW conformingto APIspecifications or higher. oil level GL-4 The --,*I -nnnh %omedge theoil fillerhole. +* of 6. Install tranxfer raw filler nlm and tinhtm the .._._. ____.._.T.-J_.._.lJ..._.. to 24ft. lbs.(32Nm). 7. Carefully thevehicle. lower
FLUIDRECOMMENDATIONS When adding or refilling transfer fluid the case, useHypoid oil SAE gear 75W-85W 75W-9OW or conforming APIspecifications or higher. to 61-4 LEVELCHECK Fig. 184 . . . the transaxle case before installing the gasket andpan onto the case 1 delivery service, fluidshould changed the be accordingto thesevere service schedule. Thefluidmust hotbefore is drained;20 be it a u See Figure 185
, FLUIDRECOMMENDATIONS
u See Figure 187 Since viscosity may depending fluid range vary on specific temperature of operation, range please refer
~~
tnetransaxle Youll beverysorrylaterif youdo. case. *If the drainedfluld is discolored (brown or
black), thick, or pmmll~ .llln3llU hmmt III., nnrinmm url,P
bottomedge of the transfer case filler 1

1plug hole lnsoect component leaking. each for Check oil the levelbyremoving fillerplug.If theoil is contamithe nated, is necessato replace withnewoil. it ry it 1. Park vehi,.,nn IPVPIz11rf2r~ the if% -.. ,-., __. ,-_. Remove filler plugandmake theoil the sure 2. levelreaches lower of thefillerplughole. the edge to that 3. Check besure theoil is notnoticeably dirtyandthatit hastheproper viscosity. add the 4. If necessary, oil through fillerholeuntil is runsoutof thehole. DRAIN& REFILL ) See Figure-14 I8 1. Raise safely and support vehicle, access the for tothetransfer case. 2. Place suitable panunder transfer a drain the case drainplug. fluid
1Fig. 187 Rear axle lubricant application I chart I totheaccompanying for theproper for chart fluid yourvehicle. LEVELCHECK 1. Make thevehicle parked level sure is on ground. 2. Remove oil fill plugto check oil level. the the 3. Theoil levelis sufficient it reaches lower if the portion thefillerplughole.If thefluidis low,add of asrequired through fillerplug. the DRAIN& REFILL u See Figure 188 1. Position vehicle a flatsurface raise the on or andsafely support vehicle a levelposition. the in 2. Place suitable panunder rear a drain the axle.
transaxle troubles, probablydueto overheat,r..rr,rA #.a.-vLlr trig, shouldbe susp~~lr;u.lvUl rrdrJ transaxle shouldbe inspectedby a reliable transaxle specialist to determinethe problem. 5. Remove pan gasket. the and 6. Clean panwithsolvent allowit to air the and dry.If youusea ragto wipeoutthepan, risk you leaving of lintbehind, will clogthedinky bits which hydraulic passagesthebansaxle. in 7. Remove filterretaining andremove the bolts thefilterfromthevalvebodv. To install: . 8. Install new theninstall retaining a filter, the boltsandtighten to 5 ft. Ibs.(7 Nm). them 9. Position gasket thepan, install the on then thepan. Tighten boltsevenly in rotation the and to 8-9ft. Ibs.(10-12Nm.). notovertighten. Do IO. Lower vehicle. the
GENERALINFORMATIONAND MAINTENANCE 1-39

leak. most In cases, will beableto trace leak you the to a loose fittingor damaged hose. Evaporating ethylene antifreeze have glycol will a sweet andleave smell small, (salt-like) white deoosits, which beheloful tracino leak. can in a glove andpassenger floorboard and box side area, check carpet anysigns moisture. the for of The smartest to goabout way finding leak a visually to is firstinspect andall jointsin thesystem as any such where radiator the hoses connect theradiator to and theengine. Another to lookfor iswhitecrusty thing stains aresigns a leak that of where coolant the has
ieach of amount fluid.Thelevel of should thkbottom theoil fillerhole. 6. Install fillerplugandtighten ft. Ibs. the to24 (32 Nm). 7. If raised, carefully thevehicle. lower
A 1sl I lylsJa ran +tw,,4liE 7 Qss tin,t.asIJ Wll IJU \ If a thefluidlevelof yourcooling system conis s are There stantly thechanceof a leak probable. low, WI U.VlUl I 9 about ,.,,I finding source the of yourleak. Thefirstwavshould avisualinsnection. be Durina thevisualinspection, around &tire enginelook the area including radiator theheater the and hoses. The interior thecarshould inspected of be behind the
FLUID RECOMMENDATIONS
A good quality ethylene based other glycol or aluminum compatible antifreezerecommended is for useinthevehicles covered thismanual. is best by It to adda 50150 of antifreeze distilled to mix and water avoid diluting coolant thesystem. the in
merating It,lap3 1s danciara useoutsome on a 10 carsarehigher. Overpressurizingsystem the can in or cause rupture a I: or worse, theradiator a in lose, h.n+n. MU. . . . ..I. cause injuryor a burnif nrrrn PuaJbly nnA IIC~KI LUG an thecoolant hot.Overpressurizing is is normally controlledbytheradiator whichhasa ventvalvein it cap whichis opened thesystem when reaches maxiits mum pressure Topressure thesystem: rating. test *The pressuretest should be performedwith the enaine OFF.
LEVELCHECK
recovery anditsmarking a guideline. tank as *Never overfill the recovery tank. A coolant thatconsistently is usually level drops a signof a small, to detect although the hard leak, in worstcase couldbea signof aninternal it engine
_y ,~-1Fia. 190 A visual insaection for leaks will 1 sometimes find a leak. This photo shows evfdence of a leak at the upper radfator / hose-to-thermostathousingjunction * / *
Fig. 191 Removethe recovery tank cap to allow the pressuretester to beconnected to /the system ,, /
Fig. 189 The coolant level should be be1tween the FULLtank LOW levels on the coo,ant recovery and ~_I
Fig. 192 This cooling system requires a Fig. 193 Thread the adapter onto the reto al- / j threadedadapterfor the recoverytank g051p96 1covety tank effi1pg7 / low the pressuretester to be connected
l-40
doesnotverifythesituation, removing spark the plugs ata timeandchecking electrodes a one the for green white canverifyaninternal or tint coolant leak andidentify which cylinder(s) theculprit aiding is and yoursearch thecause theleak. thespark for of If plugs appear another okay, method to usea gas is analyzer emissions or oneof several or tester, handheldtoolsthatmost professional possess. shops This toolsareused check cooling to the system the for presence Hydrocarbons inthecoolant. of (HCs)
DRAIN REFILL &

aiffiip98
Fig. 194Pumpthe cooling systemwith pressure, makingsure not to overpressurizethe 1system or damagecan occur 1. Remove radiator recovery cap. the or tank 2. Using proper the adapter, it ontothe insert opening connect pressure and the tester, 3. Begin pressurizing system pumping the by the pressure andwatching gauge, the tester the when maximum pressure reached, is stop. 4. Watch gauge the carefully seeif thepresand , sureonthegauge drops, it does, leakis definitely if a present. 5. If thepressure somewhat visustayed stable, ally inspect system leaks, thepressure the for If dropped, repressurize system then the and visually inspect system. the 6. If nosignsof a leak noticed are visually, pressurize system themaximum the to pressure of rating thesystem leave uressure connected and the tester flsrabout minutes. 30 Return 30 minutes after and Verifythepressure thegauge, thepressure on if
p See figures 196 thru 205 Fig 195 Watchthe gaugeon the systemand / observe the pressurereading @p~ 1 dropped than more 20%,a leak definitely exists, if theoressure is lessthan droo 20%.thesvstem , is most likelyokay: Another coolant lostis bya internal way is engine leak, causing oil to becontaminated the orthe coolant beburned theprocess combustion to in of andsentouttheexhaust. check oil contaminaTo for tion,remove dipstick check condition the and the of theoil intheoil pan. theoil is murky hasa If and whiteor beige milkshake to it,thecoolant look is contaminating oil through internal andthe the an leak enqine betorndown findtheleak.Iftheoil must to Ippears thecoolant beburned going okay, can and jutthetailpipe. quick forthisis a cloudof A test Nhite smoke appearing thetailpipe, from especially In start-up. colddays, whitesmoke apOn the will Iear, is dueto condensation theoutside this and emperature, a coolant Ifthesmoke not leak. test Ensure theengine completely priorto that is cool starting service. this
Neveropen, service or drain the radiator or cooling systemwhen hot; serious burnscan occur the steamandhot coolant. Also, from when draining enginecoolant, keep in mind that cats and dogsare attractedto ethylene glyeol antifreezeandcould drink any that is left in an uncoveredcontaineror in puddles on the ground.This will provefatal in sufficient quantities.Always drain coolant into a sealable container. Coolantshouldbe reuser mlessit is contaminatedor is several years 1. Remove recovery or radiator the tank cap. 2, Raise support vehicle. and the 3. If necessary, remove splash the shield un from lerthefrontof thevehicle.
93im76
Fig. 196 The draincockis usually located at the bottom of the radiator
Fig. 197 Gently rotate the draincock counterclockwise to open the draincock . . .
Fig, 198 . _ . then allow the coolant to drain out of the radiator and cooling system
93151p27
Fig. 199Allow the fluid to drain until it stops and tighten the draineockhandtight
Fig. 200 Make sure to heed the caution on the radiator cap and NEVER open the cap when the engine is hot ,, 1
Fig. 201 Graspthe radiator cap and rotate it counterclockwise. . .
93151p18
Fig. 202 . , . to remove the cap from the radiator
Fig. 203 Pour the proper *I~ coolant mix- 1 ture into the radiator . . . 4. Allowtheengine coolcompletely drain to and ie system again. 5. Repeat processuntil drained is this the water learand of scale. free 6. Flush recovery withwater leave the tank and empty. Neveropen, service or drain the radiator or cooling systemwhen hot; serious bumscan occurfrom the steamand hot coolant. Also, when drainingenginecoolant, keep In mind that cats and dogsare attractedto ethylene glycol antifreezeandcould drink any that is left in an uncoveredcontaineror in puddles on the ground.This will prove fatal in sufficient quantities.Always drain coolant into a sealable container.Coolantshouldbe reused unlessit is contaminatedor is several years old. 7. Fillandbleed cooling the system described as earner.
Fig. 204 . . . make sure to fill the coolant recovery tank to the proper level also fluid. Any brakefluid that is removedfrom the systemshouldbe discarded.Also, do not allow any brakefluid to come in contactwith a paintedsurface;it will damagethe paint.
.I
93151p17
Fig. 205 Be sure the rubber gasket on the radiator cap has a tight seal 1,~ 4. Place drain of suffcrenr . . . ..I unaer a pan i 1capacrry .I. me radiator open petcock and the (drain) theradiator. on - w&1--x3_ --mm.._..-. ..-I... . rrrasuc perwcss easuy bind; Beforeopening a plastic radiator petcock,spray it with somepenetratinglubricant. 5. Drain cooling the system completely. 6. Close petcock. the 7. Remove drainpan. the 8. install shield under the L.-l If necessary, thesplash venicie. 9. Lower vehicle. the 10. Determine capacity thecooling the of system, thenproperly thesystem therecovery refill at tank andradiator a 50/50 with mixture fresh of coolant and alain oreerring sysrem. me 12. Start engine allowit to idleuntilthe the and thermostat (theupper opens radiator will behose come Thecoolant should down, is hot). level go this normal thesystem as bleeds air pockets of the the out
When adding to thesystem, usefresh fluid ONLY DOT brake froma sealed 3 fluid container. 3 DOT brake . absorb .*a. whenit is exposed fluidwill . . , moisture.. * .*. .a . .to tneatmospnere, wnrrower oourng A wnrcn 1r.s pomr. container hasbeen that opened closed once, and placed a shelfwill allowenough on moisture enter to overtimeto contaminate fluidwithin. yourbrake the If fluidiscontaminated water, couldboilthe with you brake under braking fluid hard conditions loseall and or some braking ability.Dont therisk,buyfresh take brake whenever must to thesystem. fluid you add ,LEVELCHECK k See Figures206 thru 211
Thebrake master cylinder ~a~~~~r,~~ II:AI~nnL.4 n-n fKmll 15 IUMLC derthehood, attached thebrake to booster fireand wallonthedriverssideof theengine compartment. FLUIDRECOMMENDATIONS
Brakefluid containspolyglycol ethersand polyglycols. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. If vou do oet brakefluid in vour eyes, ar -l-..n-- II -.._ I____ clean, a-..mrflush your eyeswithirriIauon runniugwa- __-PA._ rer Y--13 mmures.IT eye .a-11--persim, or if you havetaken brakefluid internally, IMMEDIATELY medical assistance. seek
svstem.
13. Refillthesystem coolant theproper with to IRVf!l ._._. 14. Turn engine andcheck leaks. the OFF for FLUSHING& CLEANINGTHE SYSTEM 1. Drain cooling the system completely de: as scribed earlier. 2. Close petcock fill thesystem a the and with cooling system (clean may beused, flush water also butis notasefficient). 3. Idletheengine theupper until radiator hose getshot.
Brakefluid containspolyglycol ethersand polyglycols. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. If you do get brakefluid in your eyes, flush your eyes with clean, runningwater for 15 minutes;If eye irritation persists, or if vou havetaken brakefluid internallv. IMMEDIATELY medical assistance. seek
Be careful to avoid spilling any brakefluid on paintedsurfaces,becausethe paint coat will becomediscolored or damaged. Observe on ._ ._thefluidlevelindicators themaster __ cylinder;I.... II should between MIN be the ..J ..I thetluldeve1 anoivw unes. Before removing master the cylinder reservoir cap, make thevehicle resting levelground sure is on and clean dirtaway thetopof themaster all from cylinder. Unscrew capandfill themaster the cylinder the until levelis between MIN andMAXlines. the If thelevelof thebrake is lessthanhalfthe fluid volume thereservoir, isadvised youcheck of it that thebrake system leaks. for Leaks a hydraulic in brake system commonly atthewheel most occur cylinder andbrake junction line points.
Clean, high quality brakefluid is essentialto the safe and proper operationof the brake system.Youshouldalways buy the highest quality brakefluid that is available. If the brakefluid becomescontaminated,drain and flush the system,then refill the mastercylinder with new fluid. Never reuseany brake
1-42 GENERAL~INFORMATION ANDMAINTENANCE
llow,be*retoch~ckiebrake~ .
Fig. 206 The fluid level should be between the MAXand MIN hnes if the fhud level IS Fig. 207 Wipethe mastercylinder reservoir clean before openingthe cap to ensurethat no contaminationenters the brake fluid
93151p29 I
Fig. 208 Unscrew the master cylinder cap and remove it from the reservoir
93151p31
Fig. 209 If the master cylinder capgasket is swelled like such, it can be a sign of contamination. If the gasket is swelled . . .
Fig. 210 . . . makesure to pushthe gasket back to the normal position 2. Inspect fluidin thereservoir, the making sure fluidis between MAX theMINmarks. the and 3. If required, remove clut master the ch cylinder reservoir then fresh Itofill tothetopfull lid. add fluid mark thereservoir. on
Fig. 211 Carefully pour approvedbrakefluid from a fresh, sealed container directly into the reservoir
FLUID RECOMMENDATIONS When adding changing fluidinthesystems, or the usea quality fluidconforming DOT specibrake to 3 fications ansealed from container. reuse Never old brake fluid. LEVELCHECK b See Figures 212, 213, and 214 1. Wipe clutch the master cylinder reservoir cap andthesurrounding clean a shop area with towel.
FLUIDRECOMMENDATIONS When adding changing power or the steering fll$, Dexron@il (Automatic ATF Transmission
Be careful to avoid sfBillingany brakefluid on paintedsurfaces,bet:ausethe paint coat will becomediscoloredor damaged.
4. Reinstall lid ontotheclutch the master cylinder. 5. If removed, theair cleaner install assembly.
.
LEVELCHECK b See Figures 215, 216, 217, and 218 Likeall other general maintenance check items, every 3,OOfl (4,800 or once month. miles km) a Inspect oil levelinthereservoir checking pothe by the
Fig. 212 The clutch master cylinder has MAX(A) and MIN (B) fill lines on the reser volr

l Special washing car detergentthebest is to use.Liquid dishwashing detergent remove can wax andleave cars unprotected in addition the paint and some liquiddetergents contains abrasives can which scratch paint. the l Birddroppings should removed the be from paintwork soonaspossible, as otherwise finish the maybepermanently stained.
93151p14
93151p12
Fig. 215 Twist the reservoir cap, then lift up on the integral cap/dipstickassembly I I
Fig. 216 Wipe the dipstick off, reinsert it into the reservoir and checkthe level I
Whenthe car is driven immediatelyafter being washed,apply the brakesseveral times in order to removeany moisturefrom the brakingsurfaces.
Enginecleaningagentsshouldnot be used when the engine is warm, a fire risk is present as most enginecleaningagentsare highly flammable. Automatic washing a simple quick car is and way to clean car,butit is worthremembering it your that is notasthorough when yourself the as you clean car.Keeping underbody is vitallyimportant, the clean andsome automatic washers notcontain do equipment washing underside thecar. for the of When driving anautomatic make into was, sure thefollowing precautions been have taken: l Make all windows up,andnoobjects sure are thatyoudonotwant getwetareexposed. to l Insome cases, rotating sideviewmirrors the incanhelp avoid to possible damage. l If yourcaris equipped a power with antenna, lowerit. If yourvehicle a solidmounted, has nonpower antenna,is best remove butthisis not it to it, always practical. Inspect surroundingsreduce the to theriskof possible damage, check seeif the and to antenna bemanually can lowered.
sitionofthefluidagainst mark thedipstick, the on Addfluidtothereservoir thefluiddoesnotreach if theappropriate line. full
Onmost models, manufacturer install the doesnt lubrication fittings lubepoints thesteering on on linkage suspension. or However,thelubrication if pointdoes a grease have fitting,lubricate multiwith purpose No.2 (Lithium grease. NLGI base)
* Awater-soluble solvent beused grease may in cases stickydirt.However, a washplace a of use with drainage separator. Drythecarwitha clean chamois rememand l berto clean drainholes thedoors rocker the in and panels. l If equipped a power antenna,must with radio it bedriedafter washing.
Neverclean the bumperswith gasoline or paint thinner, always usethe sameagentas usedon the paintedsurfacesof the vehicle. Tarspots beremoved tarremover can with or l kerosene thecarhasbeen after washed. l Astiff-bristle andlukewarm water brush soapy canbeused clean wiperblades. to the Frequent cleaning improves visibilitywhen using wipers the considerably. Wash thedidfromtheunderside off (wheel l housings, fenders, etc.). l Inareas highindustrial of fallout, fremore quent washing recommended. is
Most manufacturers not recommend do automaticcar washingin the first six monthsdue to the possibility of insufficient paint curing; a safe bet is to wait until after six monthsof ownership(when purchasednew) to use an automaticcar wash.
CAR WASHING
Thecarshould washed regular be at intervals to remove dust, dirt, insects, tarandother and possibly damaging thatcanadhere thepaint may stains to and cause damage. Proper exterior maintenance also helps theresale of thevehicle maintaining in value by its like-new appearance. Mt is particularlyimportantta frequentiy washthe car in the wintertimeto preventcorrosion, whensalt has beenusedon the roads. There many are precautions tipsonwashing, and including following: the l When washing car,donotexpose dodithe it rectsunlight. . Uselukewarm to soften dirtbefore water the youwash a sponge, plenty water, avoid with and of to scratching. l A detergent beused facilitate softencan to the ingof dirtandoil.
WAXING
eBefore applyingwax, the vehicle mustbe washedandthoroughlydried. Waxing vehicle help preserve appeara can to the anteof yourvehicle. widerange polymer-based A of carwaxes available These are today. waxes easy are to useandproduce long-lasting, glossfinish a high thatprotects body paint the and against oxidation, roaddirt,andfading. Sometimes, a neglected waxing vehicle, one or thathassustained chemical natural or element damage(such acidrain)require than as more waxing, anda light-duty compound beapplied. secan For verely damaged surfaces,is best consult proit to a fessional see wouldberequired repair to what to the damage. Waxing procedures according manufacdiffer to turer, andingredients, it is best consult type, so to thedirections thewaxand/or on polishpurchased.
Duringhighpressurewashingthe spraynonle mustneverbe closerto the vehicle than13 inches(30cm).Do not sprayinto the locks. When washing steam or cleaning engine, the l avoid spraying or steam water directly theelectrion calcomponentsnear distributor ignition or the or components. cleaning engine, spark After the the plugwellsshould inspected water blown be for and dryif necessary.
1-44
Upholstery
cleaningyou must do to maintainthe appearance of your vehicle.Personaldiscretionis advisedhere.
l Do not usegasolinefor cleaning.Usea safe solvent. l Do not spin dry bearingswith compressed air. Theywill be damaged. l Do not usecottonwasteor dirty clothsto wipe bearings. l Do not scratchor nick bearingsurfaces. l Do not allow the bearinato come in contact with dirt or rust at anytime. The rear wheelbearinason some Galantand Mirage modelsrequireperiodic maintenance. preA mium high melting point greasemeetingGrade MultipurposeGreaseNLGI Grade#2 or equivalent must be used. Long fiber type greasesmust not be used.This service is recommended every30,000 miles (48,000 km).
INTERIOR CLEANING
Fabriccanusuallybecleanedwith soapywateror a properdetergent. more difficult spots causedby For oil, ice cream,soda,etc., usea fabric cleaneravailable at most partsstores.Besurewhenpurchasing the cleanerto readthe labelto ensureit is safeto use on your type of fabric. A safemethodof testingthe cleaneris to applya small amountto an areausually unseen, such as undera seat,or otherareas.Warta while, perhapsevena dayto checkthe spot for fading, discoloring,etc.,as somecleanerswill only causetheseproblemsafterthey havedried Leatherupholsteryrequrresspecialcare,it canbe cleanedwith a mild soapand a soft cloth. It is recommendedthata specialleathercleanerbe usedto cleanbut alsotreatthe leathersurfacesin your vehicle. Leathersurfacescanagequickly and cancrack if not properlytakencareof, so it is vital thatthe leather surfacesbe maintained.
On most modelscoveredby this manual,the wheelbearmgsusedare sealedunits and do not require routinemaintenance. Howeveron someGalant and Mirage models,the rearwheelbearingdo require periodicrepacking.For removaland installationinstructions,pleasereferto Section7 (for rear bearings) or Section8 (for front bearings).
REPACKING *Sodium basedgrease is not compatible with lithium basedgrease. Readthe package labels and be careful not to mix the two types. If there is any doubtas to the type of greaseused, completelyclean the old greasefrom the bearingand hub before replacing.
Beforehandlingthe bearings, thereare a few thingsthat you shouldremember do and not to do. to
*For informationon WheelBearingremoval and installation, refer to Section7 of this manual.

1. Removethe wheelbearing. 2. Cleanall parts in a non-flammable solventand let themair dry.
Floor Mats and Carpet

Thefloor matsand carpetshould bevacuumedor brushedregularly.Theycan be cleanedwith a mild soapand water.Specialcleanersareavailableto cleanthe carpetedsurfacesof your vehicle,but take carein choosingthem,and againit is bestto test them in a usuallyunseenspot.
DOthe following:
Removeall outsidedirt from the housingbefore exposingthe bearing. l Treata usedbearingas gentlyas you would a newone. l Workwith cleantools in cleansurroundings. l Useclean,dry gloves,or at leastclean,dry hands. l Cleansolventsand flushingfluids are a must. l Usecleanpaperwhenlaying out the bearings to dry. l Protectdrsassembled bearingsfrom rust and dirt. Coverthemup. l Useclean,lint-free ragsto wipe the bearings. l Keepthe bearingsin oil-proof paperwhenthey are to be storedor are not in use. l Cleanthe inside of the housingbeforereplacing the bearin
l
*Only use lint-free ragsto dry the bearings. Neverspin-drya bearingwith compressed air, as this will damagethe rollers.
3. Checkfor excessivewearand damage.Replace the bearingas necessary.
Dashboard,Console,Door Panels, Etc.

Thedashboard, console,door panels,and other plastic,vinyl, or wood surfacescan be cleanedusing a mild soapandwater.Cautionmust be takento keep waterout of electronicaccessories controlsto and avoid shorts or ruining the componentsAgain special cleanersareavailableto cleanthesesurfaces, as with othercleanerscaremust takenin purchasmg and using such cleaners. Thereare protectants availablewhich cantreatthe various surfacesin your car giving thema shiny new look, howeversome of theseprotectants cause can more harmthan good in the long run. Theshinethat is placedon your dashboard attractssunlightacceleratingthe aging,fadingand possiblyevencracking the surfaces. Theseprotectants attractmoredust also to stick to the surfacestheytreat, Increasing the
*Packina wheel bearinoswith arease is bestaccomplishedby u&g a wheel bearing packer(available at most automotiveparts stores).
4. If a wheelbearingpackeris not available,the bearingsmay be packedby hand. a. Placea healthy glob of greasein the palm of one hand. b. Forcethe edgeof the bearinginto the greaseso that the greasefills the spacebetween the rollers and the bearingcage. c. Keeprotatingthe bearingwhile continuing to push the greasethrough. d. Continueuntil the greaseis forced out the otherside of the bearing. 5. Placethe packedbearingon a cleansurface and cover it until it is time for installation. 6. Installthe wheelbearing.
Do NOTdo El, followino: he

l l
Do not work in dirty sirroundings. Do not usedirty, chippedor damaged tools. l Do not work on woodenwork benchesor use woodenmallets. l Do not handlebearingswith dirty or moist hands.
# See Figures219 and 220

To preventthe bumperfrom deforming,thesevehicles cannotbetowedby a wreckerusing sling-type equipment. thesevehiclesrequiretowing, usea If wheellift or flat bedequipment.It is recommended that the vehiclebe towedfrom the front If a flat bed is not available. Manualtransaxlevehiclesmay betowedfrom the rearprovidedthatthe transaxleis in Neutralandthe drivelinehasnot beendamaged. steeringwheel The must be clampedin the straight-ahead positronwith a steeringwheelclampingdevicedesignedfor towing serviceuse.
Do not usethe steeringcolumnlock to secure the front wheel uosition for towina.
Automatictransaxlevehiclesmay betowedon the front wheelsat speedsnot to exceed30 mph (50 km/h) for a distancenot to exceed18 miles (30 km). If theselimits can not be met,thenthe front wheels must be placedon a tow dolly.
All WheelDrive (AWD)vehiclesshouldonly be towedwith all 4 wheelson the groundor lifted from the roadsurface.This meansthat the vehicle is to be towedeitherwith flatbedequipment, all wheels with on dollies or flat towed.Damage the viscous couto pling may result if the vehicleis towedwith only 2 wheelson the ground.
p See Figure 222 # See Figure 221

Whenever vehicle is jump started,precautions a must be followedIn orderto preventthe possibility of
GENERALINFORMATIONAND MAINTENANCE 1-45

SLINGTYPE
owrng methods a tow truck IS used Lrftrng method for 4 wheels-Good qemarks . For4WD models, the basic principle is that all four wheels are to be rarsed before towing. . The shift lever should be set to 1st gear and the parking brake should be applied.
WHEELLIFTTYPE
Front wheels
lifted-No
good
The vehicle must not be towed by tofacing only its front wheels or only the rear wheels on a rollino dollv, because to do so will result in d&e&ration of the visfx~s coupling and result in the viscous coupling causing the vehicle to jump forward suddenly.
Front wheels
lifted-No
good
If only the front wheels or only the rear wheels are lifted for towing, the bumper wrll bedamyd. In addrtron. II trng of the rear wheels causes the or1to flow forward. and may result in heat damage to the rear bushing of the transfer, and so should never be done.
cles SUNGTYPE
Rear wheels lifted-No good
WHEELLIFTTYPE
Towing by rope or cable-Good
l l l
The front and rear wheels must rotate normally. The various mechanisms must function normally. The shift lever must be set to the neutral ~Asi&n and the ignition key must be set to
e9571g92
FLATBEDTYPE
Fig.221 Towing instructions-AWD models

Hookingthe batteriesup in parallelcircuit increases batterycrankingpowerwithout increasingtotal battery voltageoutput.Outputremainsat 12 volts. On the otherhand,hookingtwo 12 volt batteriesup in a seriescircuit (positiveterminalto negativeterminal, positiveterminalto negativeterminal)increases total batteryoutputto 24 volts (12 volts plus 12 volts).
l Do not allow electrolyteto contactyour skin or clothing.
Fig. 220 Rear towing position-FWD vehi cles

personalinjury. Remember batteriescontaina that small amountof explosivehydrogengaswhich is a by-productof batterycharging.Sparksshouldalways be avoidedwhenworkingaroundbatteries,especially whenattachingjumpercables.To minimizethe possibility of accidentalsparks,follow the procedure carefully.
1. Make surethat the voltagesof the 2 batteries are the same.Most batteriesand chargingsystems are of the 12 volt variety.
MAKE CONNECTIONS IN NUMERICAL ORDER A FIRST JUMPER CABLE
NEVER the batteriesup in a series cirhook cuit or the entire electrical systemwill go up in smoke. includinothe starter!
Vehiclesequipped a dieselenginemay utilize with two 12 volt batteries.If so, the batteriesare connectedin a parallelcircuit (positive terminalto positive terminal,negativeterminalto negativeterminal).
Be surethat both batteriesare of the samevoltage.Vehiclescoveredby this manualand most vehicles on the roadtodayutilize a 12 volt chargingsystem. l Besurethat both batteriesare of the samepolarity (havethe sameterminal,in most casesNEGATIVE grounded). l Be surethat the vehiclesare not touchingor a short could occur. l On serviceablebatteries, surethe vent cap be holesare not obstructed. l Do not smokeor allow sparksanywhere near the batteries. l In cold weather,makesurethe batteryelectrolyte is not frozen,This can occur morereadilyin a batterythat hasbeenin a stateof discharge.
l
WITH CHARGED BATTERY
lccslQ?,Q
Fig. 222 Connectthe jumper cables to the batteries and engine in the order shown
I-46
cable thedonor on battery. Disconnect positive the cable thedonor from battery finally,disconnect and thepositive fromtheformerly battery. cable dead Be careful disconnecting cables theposiwhen the from tiveterminals toallowthealligator totouch not clips anymetal either on vehicle a short sparks or and will occur. I $ See Figures223,224, 225,226, and 227 Your vehicle supplied a jackforemerwas with gency repairs. jackisfinefor changing road This a flattireor other term short procedures requiring not youto gobeneath vehicle. it is used an the If in emergency situation, carefully followtheinstructions provided withthejackor inyourowners either manual.Donotattempt usethejackonanyportions to of thevehicle thanspecified thevehicle other by manufacturer. Always thediagonally block opposite wheel when using jack. a A more convenient of jacking theuseof a way is garage floorjack. may thefloorjackto or You use raise frontof thevehicle placing under the by it the frontsubframe. rearofthevehicle most The is easily raised using lift points thedriprail.All by the on models equipped lift points are with located the on mid-crossmember frontanda bracket inthe located onthefloorpan underneath trunk. the Never thejackunder radiator, place the engine or transaxle components. andexpensive Severe damage will result thejackis raised. when Additionally, never or the jackunder floorpan bodywork; metal the will Whenever planto workunder vehicle, you the you must support onjackstands ramps. use it or Never cinder blocks stacks wood support vehior of to the cle,even youre going beunder fora few if only to it minutes. crawlunder vehicle it is Never the when only jack supported bythetire-changing or other *Always position a block of wood or small rubberpad on top of the jack or jackstandto protectthe lifting points finish when lifting or supportingthe vehicle. Small hydraulic, screw, scissors aresatisor jacks factory raising vehicle. for the Drive-on trestles or
2. Pullthejumping vehicle thegoodbat(with tery)intoa position thejumper so cables reach can thedead battery thatvehicles and engine. sure Make thatthevehicles NOT do touch. 3. Place transmissions/transaxles vethe of both hicles Neutral (MT)or P (AT), applicable, in as then firmlysettheirparking brakes. *ff necessaryfor safety reasons,the hazard lights on bothvehicles may be operated throughoutthe entire procedurewithout significantiy increasingthe diff icuity of jumping the dead battery. 4. Turn lightsandaccessories onboth all OFF vehicles. suretheignition Make switches both on vehicles turned theOFFposition. are to 5. Cover battery caps a rag,butdo the cell with notcover terminals. the 6. Make theterminals bothbatteries sure on are clean freeof corrosion proper and or electrical connection beimpeded.necessary, thebatwill If clean teryterminals before proceeding. 7. Identify positive andnegative termithe (+) (-) nalsonbothbatteries. 8. Connect firstjumper to thepositive the cable (t) terminal thedead of battery, connect then the other of thatcable thepositive terminal end to (t) of thebooster (good) battery. 9. Connect endof theother one jumper to cable thenegative (−) terminal thebooster on batteryandthefinalcable clamp anengine head, to bolt alternator bracket other or solid,metallic onthe point engine thedead with battery. to picka ground Try on theengine is positioned fromthebattery that away in order minimize possibility the2 clamps to the of touching should loosen one during procedure. the DONOT connect clamp thenegative termithis to (-) nalof thebadbattery.
Be very careful to keepthe jumpercables away from movingparts (cooling fan, belts, etc.) on bothengines. 10. Check make thatthecables routed to sure are away anymoving then thedonor from parts, start vehicles engine. theengine moderate for Run at speed several minutes allowthedead to battery chance a to receive initialcharge. some 11. With donor the vehicles engine running still slightly above tryto start vehicle the idle, the with dead battery. theengine nomore 10 Crank for than seconds a timeandletthestarter forat least at cool 20seconds between If thevehicle notstart tries. does in3 tries,it is likelythatsomething isalso else wrong thatthebattery or needs additional to time charge. 12. Once vehicle started, it to runat the is allow idlefora fewseconds make thatit is operatto sure ingproperly. 13. TurnONtheheadlights, blower if heater and, equipped, rear the defroster both of vehicles order in to reduce severity voltage the of spikes subseand quent of damage thevehicles risk to electrical systems thecables disconnected. stepis when are This especially important anyvehicle to equipped with computer control modules. 14. Carefully disconnect cables thereverse the in orderof connection. withthenegative that Start cable is attached theengine to ground, thenegative then
&stands also on the
Fig. 225 The most practical place to place front of the vehicle is
Fig. 226 Place the jackstandsalso subframeto supportthe front of the
Fig. 227 All modelscovered by this are equipped with lift points on t crossmemberin the front and on a
GENERAL INFORMATION MAINTENANCE AND 1-47

rampsare also a handyand safeway to both raise and supportthe vehicle.Becarefulthough,some rampsmay betoo steepto drive your vehicleonto without scrapingthe front bottompanels.Neversupport the vehicleon anysuspensionmember(unless specificallyinstructed do so by a repairmanual)or to by an underbody panel. The following safetypoints cannotbe overemphasized: l Alwaysblockthe oppositewheelor wheelsto keepthe vehiclefrom rolling off the jack. l Whenraisingthe front of the vehicle,firmly apply the parkingbrake.
l Whenthe drive wheelsareto remainon the ground,leavethe vehicle in gearto help preventit from rolling. l Alwaysusejackstands supportthe vehicle to whenyou areworking underneath. Placethe stands beneath vehrclesjacking brackets Beforeclimbthe ing underneath, the vehiclea bit to makesure it rock is firmly supported.
SCHEDULED
(MITSUBISHI
MAINTENANCE
DIAMANTE, GALANT,
VEHICLE
INTERVALS
& MIRAGE)
INTERVAL
60
MILEAGE 45 J J
(x1000)
67.5 75 62.5
TO BE
7.5
15
22.5
30
37.5
52.5
90 J 4
97.5 4
J 4
4 J
4 J
J J
Ball loints &steering linkage seals Dnve belt(s)

Fvha,,rt
LmI,..w. ,YL,.
S/I S/I
$/I
J 4
J
J 4
J
J J
J
cvctom
Fuel hoses
+
Manual transaxle oil (Galant)
connectlon & fuel tank filler
R. Replace
S/I - Sefwce or Inspect
FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE)

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

CAPACITIES
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HOW TO USE THIS BOOK 1-2 WHERE TOBEGIN l-2 AVOIDINGTROUBLE 1-2 MAINTENANCEORREPAIR?

1-2 GENERALINFORMATIONAND MAINTENANCE

b See Figures 1 thru 15

GENERALINFORMATIONAND MAINTENANCE l-3

Fig. 1 Ail but the most basic procedures

Fig. 11 inductive type timing light \

Fig. 12 A screw-in type compressiongaugeis recommended compressiontesting for

Fig. 13 A vacuum/pressure tester is necessary for manytesting procedures

1-6 GENERALINFORMATIONAND MAINTENANCE

TNHREE-WIRE CONDUCTOR ONE WIRE TO 4 GROUND

THREE-WIRE GROUNOlNG AN ADAPTER

CONDUCTOR TMRU PLUG tccm21

Fig. 17 Powertools should always be properly grounded

Fig. 19 NEVER undera vehicle unlessit work is supportedusingsafety stands(jackstands)

l Dont runthe enginein a garageor anywhere elsewithout properventilation-EVER! Carbon

TORQUE WRENCHES ti See Figures 24 and 25

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

Fig. 22 Threadedretainer sizes are deter mined using these measurements

RA&. i 11 13 18 20 28 30 39 41 51 55 83 95 105 115 160 175 iti

BeamType # See Figure 26

11.5 13.1 14.5 15.9

Click (Breakaway)Type $ See Figure 27

Pivot HeadType # See Figure 27 and 28

Yg. 26 Exampleof a beam type torque wrench

GENERALINFORMATIONAND MAINTENANCE l-9

Inches (I.) Feet (ft.) Miles

x 25.4 x ,305 x 1.609

= Millimeters = Meters (m) = Kilometers

MASS-WEIGHT Ounces (oz.)

Inches (in-lb) Feet (ft-lb)

Meters (N.m) Meters (N*m)

Mdes Per Gallon Kilometers Kdometers Miles Per Gallon

Fig. 31 Standardand metric conversionfactors chart

Thecode thedriveaxleis etched a bosslofor on cated thecase thedifferential on of carrier.

Fig. 34 Your car should have a vehicle

todeal LIten (cc)

ENGINE VEHiCLE AND IDENTlFlCATlON EnglnCode Fuel+ Type m.hWg. W.

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

UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL

Powersteeringbelt Washersolventbottle Powersteeringreservoir Oil fill cap Brakemastercylinderreservoir Sparkplugand plugwire

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

13. 14. 15. 16.

Automatic transaxlefluid dipstick Coolantrecoverytank Radiatorcap Engine dipstick oil

UNDERHOODMAINTENANCE COMPONENT LOCATIONS-l .8L ENGINE

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

13. 14. 15. 16.

Powersteeringreservoir Powersteeringbelt Engineoil dipstick Radiatorcap

GENERALINFORMATIONAND MAlNTENANdE 1-13

Fig. 36 Releasethe retaining clips from the air cleaner housing

Fig. 37 Unplugthe MAFsensor connector

Fig. 38 Detachthe breather hose from the air tniet tube

Fig. 41 Remove the air cleaner element from the housing

GENERALINFORMATIONAND MAINTENANCE l-15

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

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

Fig. 51 Inspectthe grommetand replace if cracked or leaking oil

G,ENERALlNFORMATlONAND MAINTENANCE l-17

1-18 GENERALINFORMATIONAND MAINTENANCE

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

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

GENERAL INFORMATION MAlNTENANdE AND l-19

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

the power :::