Mitsubishi Mirage 1990 Configuration guide

HOWTO USETHIS BOOK 1-2
WHERETOBEGIN l-2
AVOIDINGTROUBLE1-2
MAINTENANCEORREPAIR?1-2
AVOIDINGTHEMOSTCOMMONMISTAKESl-2
TOOLSAND EQUIPMENT 1-2
SPECIALTOOLSl-4
YOURVEHICLESAFELY 1-4
DON'TS l-6
FASTENERS,MEASUREMENTSAND
CONVERSIONS l-6
BOLTS,NUTSANDOTHERTHREADED
RETAINERS1-6
TORQUE l-7
TORQUEWRENCHESl-7
TORQUEANGLEMETERS1-9
STANDARDANDMETRICMEASUREMENTSl-9
SERIALNUMBERIDENTIFICATION l-10
VEHICLEIDENTIFICATIONNUMBER l-10
ENGINEIDENTIFICATIONNUMBER I-10
TRANSAXLEIDENTIFICATIONI-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
EVAPORATIVECANISTERl-16
SERVICING1-16
BATTERY 1-16
PRECAUTIONSI-16
GENERALMAINTENANCE1-16
BEL
BATTERYFLUID1-16
CABLES I-17
CHARGINGI-18
REPLACEMENT1-18
TS 1-18
INSPECTiONl-18
ADJUSTMENT1-18
REMOVAL&INSTALLATION1-18
TIMINGBELTS l-20
INSPECTIONl-20
HOSES I-20
INSPECTIONl-20
REMOVAL&INSTALLATION
CV-BOOTS 1-21
INSPECTIONl-21
SPARKPLUGSl-22
SPARKPLUGHEATRANGE
REMOVAL&INSTALLATION
INSPECTION&GAPPING 1.
SPARKPLUGWIRES 1-24
TESTING 1-24
REMOVAL&INSTALLATION
DISTRIBUTORCAPANDROTOR
REMOVAL&INSTALLATION
INSPECTION1-25
IGNITIONTIMING 1-25
. GENERALINFORAMTIONl-
lNSPECTlON&ADJUSTMENl
VALVELASH l-27
ADJUSTMENTl-27
IDLESPEED 1-28
1-21
l-22
l-22
-23
1-24
l-25
l-25
.25
1-26
AIRCONDITIONINGSYSTEM 1-28
SYSTEMSERVlCEiiREPAlRl-28
PREVENTIVEMAINTENANCE1-28
SYSTEMINSPECTIONl-29
WINDSHIELDWIPERS l-29
ELEMENT(REFILL)CARE&
REPLACEMENTl-29
TIRESANDWHEELSl-30
TIREROTATIONI-30
TIREDESIGN 1-31
TIRESTORAGEl-31
INFLATION&INSPECTION l-31
CAREOFSPECIALWHEELSl-32
OPERATIONINFOREIGNCOUNTRIES
l-33
ENGINE l-33
OILLEVELCHECK1-33
OIL& FILTERCHANGE l-34
MANUALTRANSAXLEl-35
FLUIDRECOMMENDATIONSl-35
LEVELCHECK l-35
DRAIN&REFILL l-36
AUTOMATICTRANSAXLEl-36
FLUIDRECOMMENDATIONSl-36
LEVELCHECK1-36
DRAIN&REFILL l-36
PAN& FILTERSERVICE1-36
TRANSFERCASE(AWDGAlANTONLY) l-38
FLUIDRECOMMENDATIONSl-38
LEVELCHECKl-38
DRAIN&REFILL l-38
REARDRlVEAXLE(AWDGALANTONLY)l-38
FLUIDRECOMMENDATIONSl-38
LEVELCHECKl-38
DRAIN&REFILL l-38
COOLINGSYSTEMl-39
FLUIDRECOMMENDATIONSl-39
iM-41
FLUIDSAND LUBRICANTS 1-33
FLUIDDISPOSAL 1-33
FlJELANDENGlNEOILRECOMMENDATlONS
ENGINEOIL l-33
FUEL l-33

.
1-2 GENERALINFORMATIONANDMAINTENANCE
Chitton’sTotalCarCaremanualforthe199M10
MitsubishiMirage,GalantandDiamanteis intended
to helpyoulearnmoreabouttheinnerworkingsof
yourvehiclewhilesavingyoumoneyonitsupkeep
andoperation.
Thebeginningofthebookwill likelybereferredto
themost,sincethatiswhereyouwill findinformation
for maintenanceandtune-up.Theothersectionsdeal
withthemorecomplexsystemsofyourvehicle.Oper-
atingsystemsfromenginethroughbrakesarecov-
eredtotheextentthattheaveragedo-it-yourselferbe-
comesmechanicallyinvolved.Thisbookwill not
explainsuchthingsasrebuildingadifferentialforthe
simplereasonthattheexpertiserequiredandthein-
vestmentinspecialtoolsmakethistaskuneconomi-
cal.Itwill, however,giveyoudetailedinstructionsto
helpyouchangeyourownbrakepadsandshoes,re-
placesparkplugs,andperformmanymorejobsthat
cansaveyoumoney,giveyoupersonalsatisfaction
andhelpyouavoidexpensiveproblems.
A secondarypurposeofthisbookis areferencefor
ownerswhowanttounderstandtheirvehicleand/or
theirmechanicsbetter.Inthiscase,notoolsatallare
required.
Beforeremovinganybolts,readthroughtheentire
procedure.Thiswill giveyoutheoverallviewofwhat
toolsandsupplieswill berequired.Thereis nothing
morefrustratingthanhavingtowalktothebusstop
onMondaymorningbecauseyouwereshortonebolt
onSundayafternoon.Soreadaheadandplanahead.
Eachoperationshouldbeapproachedlogicallyand
allproceduresthoroughlyunderstoodbeforeattempt-
inganywork.
Allsectionscontainadjustments,maintenance,re-
movalandinstallationprocedures,andinsomecases,
repairoroverhaulprocedures.Whenrepairisnotcon-
sideredpractical,wetellyouhowtoremovethepart
andthenhowto installthenewor rebuiltreplacement.
Inthisway,youatleastsavelaborcosts.“Backyard”
repairofsomecomponentsisjustnotpractical.
Manyproceduresinthisbookrequireyouto “label
anddisconnect.. ” agroupoflines,hosesorwires.
Don’tbelulledintothinkingyoucanrememberwhere
everythinggoes-you won’t.Ifyouhookupvacuum
orfuellinesincorrectly,thevehiclemayrunpoorly,if
atall.Ifyouhookupelectricalwiringincorrectly,you
mayinstantlylearnaveryexpensivelesson.
Youdon’tneedto knowtheofficialorengineering
nameforeachhoseorline.A pieceofmaskingtape
onthehoseandapieceonitsfittingwill allowyouto
assignyourownlabelsuchastheletterA orashort
name.As longasyourememberyourowncode,the
linescanbereconnectedbymatchingsimilarletters
ornames.Dorememberthattapewill dissolvein
gasolrneorotherfluids;if acomponentisto be
washedorcleaned,useanothermethodof identifica-
tion.A permanentfelt-tippedmarkerorametalscribe
canbeveryhandyfor markingmetalparts.Remove
anytapeor paperlabelsafterassembly.
It’snecessarytomentionthedifferencebetween
maintenanceandrepair Maintenanceincludesrou-
tineinspections,adjustments,andreplacementof
partswhichshowsignsof normalwear Maintenance
compensatesforwearordeterioration.Repairimplies
thatsomethinghasbrokenor is notworking.A need
forrepairis oftencausedbylackofmaintenance.Ex-
ample,drainingandrefillingtheautomatictransaxle
fluidis maintenancerecommendedbythemanufac-
tureratspecificmileageintervals.Failuretodothis
canshortenthelifeofthetransmission/transaxle,re-
quiringveryexpensiverepairs.Whilenomaintenance
programcanpreventitemsfrombreakingorwearing
out,ageneralrulecanbestated:MAINTENANCEIS
CHEAPERTHANREPAIR.
Twobasicmechanrc’srulesshouldbementioned
here.First,whenevertheleftsideofthevehicleoren-
gineis referredto,it ismeanttospecifythedrivers
side.Conversely,therightsideofthevehiclemeans
thepassengersside.Second,screwsandboltsare
removedbyturningcounterclockwise,andtightened
byturningclockwrseunlessspecificallynoted.
Safetyisalwaysthemostimportantrule.Con-
stantlybeawareofthedangersinvolvedinworking
onanautomobileandtaketheproperprecautions.
SeetheinformatroninthissectionregardingSER-
VICINGYOURVEHICLESAFELYandtheSAFETY
NOTICEontheacknowledgmentpage.
Payattentiontotheinstructionsprovided.There
are3 commonmistakesinmechanicalwork:
1. Incorrectorderofassembly,disassemblyor
adjustment.Whentakingsomethingapartorputting
ittogether,performingstepsinthewrongorderusu-
allyjustcostsyouextratime;however,it CANbreak
something.Readtheentireprocedurebeforebegin-
ningdisassembly.Performeverythingintheorderin
whichtheinstructionssayyoushould,evenifyou
can’timmedratelyseeareasonfor it.Whenyou’re
takingapartsomethingthatisveryintricate,you
mightwantto drawapictureof howit lookswhenas-
sembledatonepointinordertomakesureyouget
everythingbackin itsproperposition.Wewill supply
explodedviewswheneverpossible.Whenmaking
adjustments,performthemintheproperorder.One
adjustmentpossiblywill affectanother.
2. Overtorquing(orundertorquing).Whileit is
morecommonforovertorquingtocausedamage,
undertorquingmayallowafastenertovibrateloose
causingseriousdamage.Especiallywhendealing
withaluminumparts,payattentiontotorquespecifi-
cationsandutilizeatorquewrenchinassembly.Ifa
torquefigureis notavailable,rememberthatifyou
areusingtherighttooltoperformthejob,youwill
probablynothavetostrainyourselftogetafastener
tightenough.Thepitchofmostthreadsis soslight
thatthetensionyouputonthewrenchwill bemulti-
pliedmanytimesinactualforceonwhatyouare
tightening.A goodexampleofhowcriticaltorqueis
canbeseeninthecaseofsparkpluginstallation,es-
peciallywhereyouareputtingtheplugintoanalu-
minumcylinderhead.Toolittletorquecanfailto
crushthegasket,causingleakageofcombustion
gasesandconsequentoverheatingoftheplugand
engineparts.Toomuchtorquecandamagethe
threadsordistorttheplug,changingthesparkgap.
Therearemanycommercialproductsavailablefor
ensuringthatfastenerswon’tcomeloose,evenifthey
arenottorquedjustright(averycommonbrandis
Loctite? Ifyou’reworried about gettingsomething
togethertightenoughto hold,butlooseenoughto
avoidmechanicaldamageduringassembly,oneof
theseproductsmightoffersubstantialinsurance.Be-
forechoosingathreadlockingcompound,readthe
labelonthepackageandmakesuretheproductis
compatiblewiththematerials,fluids,etc.involved.
3. Crossthreading.Thisoccurswhenapartsuch
asaboltisscrewedintoanutorcastingatthewrong
angleandforced.Crossthreadingismorelikelyto
occurifaccessisdifficult.Ithelpstocleanandlubri-
catefasteners,thentostartthreadingthebolt,spark
plug,etc.withyourfingers Ifyouencounterresis-
tance,unscrewthepartandstartoveragainatadif-
ferentangleuntilit canbeinsertedandturnedseveral
timeswithoutmucheffort.Keepinmindthatmany
parts,especiallysparkplugs,havetaperedthreads,
sothatgentleturningwill automaticallybringthepart
you’rethreadingtotheproperangle.Don’tputa
wrenchonthepartuntilits beentightenedacouple
ofturnsbyhand.Ifyousuddenlyencounterresis-
tance,andtheparthasnotseatedfully,don’tforceit.
Pullit backoutto makesureit’scleanandthreading
properly.
Besuretotakeyourtimeandbepatient,andal-
waysplanahead.Allowyourselfampletimeto per-
formrepairsandmaintenanceYoumayfindmain-
tainingyourcarasatisfyingandenjoyable
experience.
b SeeFigures1 thru15
Naturally,withoutthepropertoolsandequipment
it is impossibleto properlyserviceyourvehicle.It
wouldalsobevirtuallyimpossible to catalogevery
toolthatyouwouldneedto performall oftheopera-
tions inthisbook.Ofcourse,Itwouldbeunwisefor
theamateurto rushoutandbuyanexpensivesetof
toolsonthetheorythathe/shemayneedoneor more
ofthematsometime,
Thebestapproachisto proceedslowly,gathering savingswill be faroutweighedbyfrustrationand
agoodqualitysetofthosetoolsthatareusedmost mangledknuckles.
frequentlyDon’tbemisledbythelowcostofbargain Beginaccumulatingthosetoolsthatareusedmost
tools.It isfarbetterto spenda littlemorefor better frequently:thoseassociatedwithroutinemaintenance
quality.Forgedwrenches,6 or12-pointsocketsand andtune-up.Inadditiontothenormalassortmentof
finetoothratchetsarebyfarpreferabletotheirless screwdriversandpliers,youshouldhavethefollow-
expensivecounterparts.Asanygoodmechaniccan ingtools:
tellyou,therearefewworseexperiencesthantrying l Wrenches/socketsandcombinationopen
toworkonavehiclewithbadtools.Yourmonetary end/boxendwrenchesinsizesfrom%-% in.or

GENERALINFORMATIONANDMAINTENANCEl-3
3-19mm,aswellasa% in.or~/ain.sparkplug carefulwhenusingthem,astheycanchange
socket(dependingonplugtype). the amountoftorqueappliedtothesocket.
-if possible,buyvariouslengthsocketdrive
l Jackstandsforsupport.
extensions.Universal-joint and wobbleex-
l Oilfilterwrench.
tensionscanbeextremelyuseful,butbe
l
Spoutorfunnelforpouringfluids.
l Greasegunforchassislubrication(unless
yourvehicleisnotequippedwithanygreasefit-
tings-for details,pleaserefertoinformationonFlu-
idsandLubricants,laterinthissection).
l Hydrometerforcheckingthebattery(unless
equiooedwithasealed,maintenance-freebatten/).
Inadditiontotheaboveitemsthereareseveral
O’Acontainerfordrainingoilandotherfluids.
l Ragsforwipinguptheinevitablemess.
pi
1 othersthatarenotabsolutelynecessary,buthandyto
havearound.TheseincludeOilDry@(oranequiva-
lentoilabsorbentgravel-suchascatlitter) and the
usualSUDDIVoflubricants.antifreezeandfluids.al-
thoughthe.&canbepurchasedasneeded.Thisisa
basiclistforroutinemaintenance,butonlyyourper-
sonalneedsanddesirecanaccuratelydetermineyour
Fig. 1 Ail but the most basic procedures Afterperformingafewprojectsonthevehicle,
you’llbeamazedattheothertoolsandnon-toolson
lWSl2U2
Fig, 3 A hydraulicfloor jack anda set of
jackstandsareessentialfor lifting andsup
portingthevehicle
tm1204
Fig.5Variousdrivers, chiselsandptybars
are greattools to havein your toolbox
Fig. 7 Althoughnotalways necessary,us-
ingspecializedbraketools will savetime
Fig.11 inductivetype timing light \

I-4 GENERALINFORMATIONANDMAINTENANCE
Fig.12Ascrew-intypecompressiongauge- Fig. 13Avacuum/pressuretester is neces-
is recommendedfor compressiontesting sary for manytestingprocedures
Fig.14Mostmodernautomotivemultime-
ters incorporatemanyhelpfulfeatures
yourworkbench.Someusefulhouseholditemsare:a
largeturkeybasterorsiphon,emptycoffeecansand
icetrays(tostoreparts),balloftwine,electricaltape
forwiring,smallrollsofcoloredtapefortagginglines
orhoses,markersandpens,anotepad,golftees(for
pluggingvacuumlines),metalcoathangersoraroll
ofmechanic’swire(toholdthingsoutoftheway),
dentalpickorsimilarlong,pointedprobe,astrong
magnet,andasmallmirror(toseeintorecessesand
undermanifolds).
Amoreadvancedsetoftools,suitablefortune-up
work,canbedrawnupeasily.Whilethetoolsare
lmvl
Fig. 15 Properinformation is vital, so at
wayshavea ChiitonTotalCarCaremanua
handy
l Feeleraauoesforvalveadiustment
* Timing-light.
Thechoiceofatimingfightshouldbemade
carefully.AlightwhichworksontheDCcurrent
suppliedbythevehicle’sbatteryisthebestchoice;
itshouldhaveaxenontubeforbrightness.Onany
vehiclewithanelectronicignitionsystem,atiming
lightwithaninductivepickupthatclampsaround
theNo.1sparkplugcableispreferred.
Inadditiontothesebasictools,thereareseveral
othertoolsandgaugesyoumayfinduseful.These
include:
l Compressiongauge.Thescrew-intypeis
slowertouse,buteliminatesthepossibilityofa
fauliyreadingduetoescapingpressure.
l Manifoldvacuumgauge.
l 12Vtestlight.
l Acombinationvolt/ohmmeter
l inductionAmmeter.Thisisusedfordetermin-
ingwhetherornotthereiscurrentinawire.These
arehandyforuseifawireisbrokensomewhereina
wiringharness.
Asafinalnote,vouwillorobablvfindatorque
wrenchnecessaryforallbutthemostbasicwork.
Thebeamtypemodelsareperfectlyadequate,al-
thoughthenewerclicktypes(breakaway)areeasier
touse.Theclicktypetorquewrenchestendtobe
moreexpensive.Alsokeepinmindthatalltypesof
torquewrenchesshouldbeperiodicallychecked
and/orrecalibrated.Youwill havetodecideforyour-
selfwhichbetterfitsyourpocketbook,andpurpose.
ilightlymoresophisticated,theyneednotbeoutra-
feouslyexpensive.Thereareseveralinexpensive
achldwellmetersonthemarketthatareeverybitas
Toadfortheaveragemechanicasaprofessional
nodel.Justbesurethatitgoestoaleast1200-1500
pmonthetachscaleandthatitworkson4,6and8-
:ylinderengines.Thekeytothesepurchasesisto
nakethemwithaneyetowardsadaptabilityandwide
ange.Abasiclistoftune-uptoolscouldinclude:
l Tach/dwellmeter.
l Sparkplugwrenchandgappingtool.
Normally,theuseofspecialfactorytoolsis
avoidedforrepairprocedures,sincethesearenot
readilyavailableforthedo-it-yourselfmechanic.
Whenitispossibletoperformthejobwithmore
commonlyavailabletools,itwillbepointedout,but
occasionally,aspecialtoolwasdesignedtoperform
aspecificfunctionandshouldbeused.Beforesub-
stitutinganothertool,youshouldbeconvincedthat
neitheryoursafetynortheperformanceofthevehicle
willbecompromised.
Specialtoolscanusuallybepurchasedfroman
automotivepartsstoreorfromyourdealer.Insome
casesspecialtoolsmaybeavailabledirectlyfromthe
toolmanufacturer.
p SeeFigures16, 17,16, and19
Itisvirtuallyimpossibletoanticipateallofthehaz-
ardsinvolvedwithautomotivemaintenanceandser-
vice,butcareandcommonsensewillpreventmost
accidents.
Therulesofsafetyformechanicsrangefrom“don’t
smokearoundgasoline,”to“usethepropertool(s)for
thejob.”Thetricktoavoidinginjuriesistodevelop
safeworkhabitsandtotakeeverypossibleprecaution.
Dokeepafireextinguisherandfirstaidkit l
handy.
Dowearsafetyglassesorgoggleswhencut- l
ting,drilling,grindingorprying,evenifyouhave
20-20vision.Ifyouwearglassesforthesakeofvi-
sion,wearsafetygogglesoveryourregularglasses.
l Doshieldyoureyeswheneveryouworkaround
thebattery.Batteriescontainsulfuricacid.Incaseof
contactwiththeeyesorskin,flushtheareawithwater
oramixtureofwaterandbakingsoda,thenseekim-
mediatemedicalattention.
l Dousesafetystands(jackstands)foranyun-
dervehicleservice.Jacksareforraisingvehicles;
jackstandsareformakingsurethevehiclestays
raiseduntilyouwantittocomedown.Wheneverthe
vehicleisraised,blockthewheelsremainingonthe
groundandsettheparkingbrake.
l Douseadequateventilationwhenworking
withanychemicalsorhazardousmaterials,Likecar-
bonmonoxide,theasbestosdustresultingfrom
somebrakeliningwearcanbehazardousinsuffi-
cientquantities.
l Dodisconnectthenegativebatterycablewhen
workingontheelectricalsystem.Thesecondaryig-
nitionsystemcontainsEXTREMELYHIGHVOLT-
AGE.Insomecasesitcanevenexceed50,000volts.
l Dofollowmanufacturer’sdirectionswhenever
workingwithpotentiallyhazardousmaterials.Most
chemicalsandfluidsarepoisonousiftakeninter-
nally.
l Doproperlymaintainyourtools.Looseham-
merheads,mushroomedpunchesandchisels,frayed
orpoorlygroundedelectricalcords,excessively
wornscrewdrivers,spreadwrenches(openend),
crackedsockets,slippingratchets,orfaultydroplight
socketscancauseaccidents.
* Likewise,keepyourtoolsclean;agreasy
wrenchcanslipoffabolthead,ruiningtheboltand
oftenharmingyourknucklesintheprocess.
l Dousethepropersizeandtypeoftoolforthe
jobathand.Doselectawrenchorsocketthatfitsthe
nutorbolt.Thewrenchorsocketshouldsitstraight,
notcocked.

1-6 GENERALINFORMATIONANDMAINTENANCE
Fig.16Screwdriversshouldbekeptingood
:onditionto preventinjuryordamagewhich
:ouldresultit thebladeslipsfromthescrew
0 0
PP
tccs1022
Fig. 16 Usingthe correct sizewrenchwill
help preventthe possibility of roundingoff
a nut
7
lwo.WIRE CouDuClOR TMREE-WIRE CONO”CTOI
MIRD WIRE GROUNDING GROUNDING TNRU
THE CASE A CmxlIT
.
i$Y$$pQ
p-+
TNHREE-WIRE CONDUCTOR THREE-WIRE CONDUCTOR
ONE WIRE TO 4 GROUND GROUNOlNG TMRU
AN ADAPTER PLUG tccm21
Fig.17Powertools shouldalways beprop-
erly grounded
Fig.19NEVERworkunderavehicleunlessit
issupportedusingsafetystands(jackstands)
l Do,whenpossible,pullonawrenchhandle l Dosettheparkingbrakeandblockthedrive
ratherthanpushonit,andadjustyourstanceto pre-
ventafall. wheelsiftheworkrequiresarunningengine.
l Dobesurethatadjustablewrenchesare
tightlyclosedonthenutor boltandpulledsothat
theforceisonthesideofthefixedjaw.
l Dostrikesquarelywithahammer;avoidglanc-
ingblows.
l Don’truntheengineinagarageoranywhere
elsewithoutproperventilation-EVER! Carbon
monoxideis poisonous;ittakesa longtimeto leave
thehumanbodyandyoucanbuildupadeadlysup-
plyofit inyoursystembysimplybreathingina !ittle
everyday.Youmaynotrealizeyouareslowlypoi-
soningyourself.Alwaysusepowervents,windows,
fansand/oropenthegaragedoor.
l Don’tworkaroundmovingpartswhilewearing
looseclothing.Shortsleevesaremuchsaferthan
long,loosesleeves.Hard-toedshoeswithneoprene
solesprotectyourtoesandgiveabettergriponslip-
perysurfaces.Jewelrysuchaswatches,fancybelt
buckles,beadsorbodyadornmentofanykindis not
safeworkingaroundavehicle.Longhairshouldbe
tiedbackunderahatorcap.
l Don’tusepocketsfortoolboxes.Afallor bump
candriveascrewdriverdeepintoyourbody.Evena
raghangingfromyourbackpocketcanwraparound
aspinningshaftorfan.
l Don’tsmokewhenworkingaroundgasoline,
cleaningsolventorotherflammablematerial.
l Don’tsmokewhenworkrngaroundthebattery.
Whenthebatteryis beingcharged,it givesoffexplo-
sivehydrogengas.
l Don’tusegasolinetowashyourhands;there
areexcellentsoapsavailable.Gasolinecontainsdan-
gerousadditiveswhichcanenterthebodythrougha
cutorthroughyourpores.Gasolinealsoremovesall
thenaturaloilsfromtheskinsothatbonedryhands
will suckupoil andgrease.
l Don’tservicetheairconditioningsystemun-
lessyouareequippedwiththenecessarytoolsand
trainmg.Whenliquidorcompressedgasrefrigerant
is releasedtoatmosphericpressureitwill absorb
heatfromwhateveritcontacts.Thiswill chillorfreeze
anythingittouches.
l Don’tusescrewdriversforanythingotherthan
drivingscrews!Ascrewdriverusedasanpryingtool
cansnapwhenyouleastexpectit,causinginjuries.
Attheveryleast,you’llruinagoodscrewdriver.
. Don’tuseanemergencyjack(thatlittleratchet,
scissors,orpantographjacksuppliedwiththevehi-
cle)foranythingotherthanchangingaflat!These
jacksareonlyIntendedforemergencyuseoutonthe
road;theyareNOTdesignedasamaintenancetool.If
youareseriousaboutmamtainingyourvehicleyour-
self,investinahydraulicfloorjackofatleasta1%
toncapacity,andatleasttwosturdyjackstands.
sionwhichcanincreasethetorquenecessaryto properinstallationandsafeoperationofthevehicle
achievethedesiredclamploadforwhichthatfastener afterwards.
wasoriginallyselected.Additionally,besurethatthe Threadgaugesareavailabletohelpmeasureabolt
p SeeFigures20, 21,22, and23
driversurfaceofthefastenerhasnotbeencompro- orstud’sthread.Mostautomotiveandhardware
misedbyroundingor otherdamage.Insomecasesa storeskeepgaugesavailableto helpyouselectthe
Althoughthereareagreatvarietyoffastenersfound driversurfacemaybecomeonlypartiallyrounded,al- propersize.Inapinch,youcanuseanothernutor
inthemoderncarortruck,themostcommonlyused lowingthedrivertocatchinonlyonedirection.In boltfor athreadgauge.Iftheboltyouarereplacingis
retaineristhethreadedfastener(nuts,bolts,screws, manyoftheseoccurrences,afastenermaybein- nottoobadlydamaged,youcanselectamatchby
studs,etc.).Mostthreadedretainersmaybereused, stalledandtightened,butthedriverwouldnotbeable findinganotherboltwhichwill threadinits place.If
providedthattheyarenotdamagedinuseor during togripandloosenthefasteneragain.(Thiscouldlead youfindanutwhichthreadsproperlyontothedam-
therepair.Someretainers(suchasstretchboltsor J tofrustrationdownthelineshouldthatcomponent agedbolt,thenusethatnutto helpselectthereplace-
torqueprevailingnuts)aredesignedtodeformwhen everneedtobedisassembledagain). mentbolt Ifhowever,theboltyouarereplacingisso
tightenedor inuseandshouldnotbereinstalled. Ifyoumustreplaceafastener,whetherdueto de- badlydamaged(brokenor drilledout)thatitsthreads
Wheneverpossible,wewill noteanyspecialre- signor damage,youmustALWAYSbesuretouse cannotbeusedasagauge,youmightstartbylook-
tainerswhichshouldbereplacedduringaprocedure. theproperreplacementInallcases,aretainerofthe ingforanotherbolt(fromthesameassemblyora
Butyoushouldalwaysinspecttheconditionofare- samedesign,materialandstrengthshouldbeused. similar locationonyourvehicle)whichwill thread
tainerwhenIt is removedandreplaceanythatshow Markingsontheheadsofmostboltswill helpdeter- intothedamagedbolt’smounting.Ifso,theotherbolt
signsofdamage.Checkallthreadsfor rustorcorro- minetheproperstrengthofthefastener.Thesame canbeusedtoselectanut;thenutcanthenbeused
material,threadandpitchmustbeselectedto assure toselectthereplacementbolt.

GENERALINFORMATIONANDMAlNTENAiCEI-7
POZIDRIVE PHILLIPS RECESS TORX@ CLUTCH RECESS
INDENTED HEXAGON HEXAGON TRIMMED HEXAGON WASHER HEAD
tccs1037
Fig.20Hereare a few of the mostcommonscrew/bolt driver styles
GRADE 8 MADE 2 GRADE 5 QRADE 8 GRADE 7 WADE 0 ALLEN CARRIAGE
NUTS
Qe
PUIN
JAM CASTLE
(CASTELLATED) SELF-LOCKINQ SPEED
FILLISTER
LOCKWASHERS
4% 43 Q c3
INTERNAL
EXTERNAL SPLIT PLAIN
Toonl TQonl
STUD
Fig.21Thereare manydifferent typesof threadedretainersfoundonvehicles
Inallcases,beabsolutelysureyouhaveselected
theproperreplacement.Don’tbeshy,youcanalways
askthestoreclerkforhelo.
Beawarethatwhenyoufind a boltwith dam-
agedthreads,youmayalsofind thenutor
drilled holeit wasthreadedintohasalso
beendamaged.If this is thecase,youmay
haveto drill andtapthehole, replacethenut
or otherwiserepairthethreads.NEVERtry to
forceareplacementbolttofit intothedam-
aaedthreads.
Torqueisdefinedasthemeasurementofresis- .
tancetoturningor rotating.Ittendstotwistabody
aboutanaxisofrotation.A commonexampleofthis
wouldbetighteningathreadedretainersuchasanut,
boltorscrew.Measuringtorqueisoneofthemost
commonwaystohelpassurethatathreadedretainer
hasbeenproperlyfastened.
Whentighteningathreadedfastener,torqueisap-
pliedinthreedistinctareas,thehead,thebearing
surfaceandtheclampload.About50 percentofthe
measuredtorqueisusedinovercomingbearingfric-
tion Thisisthefrictionbetweenthebearingsurface
ofthebolthead,screwheadornutface and thebase
materialorwasher(thesurfaceonwhichthefastener
is rotating).Approximately40 percentoftheapplied
torqueis usedinovercomingthreadfriction.This
leavesonlyabout10percentoftheappliedtorqueto
developausefulclampload(theforcewhichholdsa
jointtogether).Thismeansthatfrictioncanaccount
forasmuchas90percentoftheappliedtorqueona
fastener.
TORQUEWRENCHES
ti SeeFigures24and25
Inmostapplications,atorquewrenchcanbeused
toassureproperinstallationofafastener.Torque
wrenchescomeinvariousdesignsandmostauto-
motivesupplystoreswill carryavarietytosuityour
needs.Atorquewrenchshouldbeusedanytimewe
supplyaspecifictorquevalueforafastener.A torque
wrenchcanalsobeusedifyouarefollowingthegen-
eralguidelinesIntheaccompanyingcharts.Keepin
mindthatbecausethereis noworldwidestandardiza-
tion offasteners,thechartsareageneralguideline
A - Length
B - Diameter (major diameter)
C - Threads per inch or mm
D - Thread length
E - Size of the wrench required
F - Root diameter (minor diameter)
IccSlO3l
Fig. 22 Threadedretainer sizesare deter
minedusingthesemeasurements
E - DCTERNAL
tm1016
Yg. 23 Special fasteners such as these
font@’headbolts are usedby manufactur-
?rsto discouragepeoplefrom working on
rehicleswithoutthe propertools

.
l-8 GENERALINFORMATIONANDMAINTENANCE
tccsio15
Fig. 24 Variousstyles of torque wrenches
areusuallyavailable at your local automo-
tivesupplystore
andshouldbeusedwithcaution.Again,thegeneral
ruleof “if youareusingtherighttoolforthejob,you
shouldnothavetostraintotightenafastener”ap-
plieshere.
BeamType
# SeeFigure26
Thebeamtypetorquewrenchisoneofthemost
populartypes.Itconsistsofapointerattachedtothe
headthatrunsthelengthoftheflexiblebeam(shaft)
toascalelocatednearthehandle.Asthewrenchis
pulled,thebeambendsandthepointerindicatesthe
torqueusingthescale.
Click(Breakaway)Type
$ SeeFigure27
AnotherpopulardesignoftorquewrenchISthe
clicktype.Tousetheclicktypewrenchyoupre-ad-
justittoatorquesetting.Oncethetorqueisreached,
thewrenchhasareflexsignalingfeaturethatcauses
amomentarybreakawayofthetorquewrenchbody,
sendinganimpulsetotheoperator’shand.
PivotHeadType
# SeeFigure27and28
Sometorquewrenches(usuallyoftheclicktype)
maybeequippedwithapivotheadwhichcanallowit
to beusedinareasof limitedaccess.BUT,itmustbe
usedproperly.To holdapivotheadwrench,grasp
thehandlelightly,andasyoupullonthehandle,it
shouldbefloatedonthepivotpoint.Ifthehandle
comesincontactwiththeyokeextensionduringthe
processof pulling,thereisaverygoodchancethe
torquereadingswill beinaccuratebecausethiscould
alterthewrenchloadingpoint.Thedesignofthehan-
dleis usuallysuchasto makeit inconvenienttode-
liberatelymisusethewrench.
*It shouldbementionedthattheuseofany
U-joint,wobbleorextensionwill haveanef-
fect onthetorquereadings,nomatterwhat
typeofwrenchyouare using.Forthemost
accuratereadings,installthesocketdirectly
onthewrenchdriver. If necessary,straight
extensions(whichholdasocketdirectlyun-
derthewrenchdriver)will havetheleastef-
fectonthetorquereading.Avoidanyexten-
sionthataltersthe lengthofthewrenchfrom
thehandletothehead/drivingpoint(suchas
acrow’sfoot). U-jointorwobbleextensions
cangreatlyaffectthereadings;avoidtheir
useatall times.
U.S. Bolts
UEonlr
Iy* lU2 5 tw7
I*cll*olwu
Q
c
tbqn2lamlu
am~mkr. @ 63
HaaIm Toqw mdmuo TORW
(h&l!&, RA&. m 111 R./U. If410 lm
m TolqW
R.Abs. I(n Hm
'I4- 20 i 0.7 68 8 1.1 10.8 10 1.4 13.5
-28 08 8.1 10 1.4 13.6
%s-18 11 1.5 14.9 17 2.3 23.0 19 2.6 25.8
-24 13 1.8 17.6 19 2.6 25.7
S-16 18 2.5 24.4 31 4.3 42.0 34 4.7 46.0
-24 20 2.75 27.1 35 4.8 47.5
%s-14 28 3.8 37.0 49 8.8 66.4 55 7.6 74.5
-20 30 42 40.7 55 7.6 74.5
'h-13 39 5.4 52.8 75 10.4 101.7 85 11.75 115.2
-20 41 5.7 55.6 85 117 115.2
'h-12 51 7.0 69.2 110 15.2 149.1 120 16.6 162.7
-18 55 7.6 74.5 120 16.6 162.7
H-11 83 11.5 112.5 150 20.7 203.3 167 23.0 226.5
-18 95 13.1 128.8 170 23.5 230.5
s-10 105 14.5 142.3 270 37.3 366.0 280 36.7 379.6
-16 115 15.9 155.9 295 40.8 400.0
VD- 9 160 2.: 216.9 395 54.6 535.5 440 60.9 596.5
-14 175 237.2 435 80.1 589.7
l- 6 iti 32.5 318.6 lE 81.6 799.9 660 91.3 894.8
-14 34.6 338.9 91.3 849.8
Metric Bolts
4.6,4.8 8.8
c @
w
mm04 iEn% (nnr)
I*rdn*lrTwlr rullllllnl~
RJU. I(n llm RAk m mu
6x1.0 2-3 2-.4 3-4 3-6 4-.8 5-8
8x 1.25 6-8 .6-l 8-12 9-14 12-1.9 13-19
10X1.25 12-17 1.5-2.3 16-23 20-29 2.7-4.0 27-39
12x125 21-32 2.9-4.4 29-43 35-53 4.8-7.3 47-72
14x 1.5 35-52 4.8-7.1 48-70 57-65 7.8-11.7 77-110
16x 1.5 51-77 7.0-10.6 67-100 90-120 12.4-16.5 130-W
18x 1.5 74-110 10.2-15.1 100-150 130-170 17.9-23.4 MO-230
20x 1.5 llO-140 15.1-19.3 150-190 190-240 26.2-46.9 160-320
22x 1.5 150-190 22.0-26.2 200-260 250-320 34.5-44.1 340-430
24x 1.5 190-240 26.2-48.9 260-320 310-410 42.7-56.5 420-550
lccs1098
:ig. 25 Standardandmetric bolt torquespecificationsbasedon bolt strengths-WARNING:
Ise only as a guide 1
PIVOTEO HANDLE
BEAU OR MEASURING ELEMENT
Yg.26 Exampleof a beamtypetorquewrench
. tccslo3~

GENERALINFORMATIONANDMAINTENANCEl-9
Fig. 27 A click type or breakawaytorque
wrench-note that this one hasa pivoting
head
v
WRONG WRONG
PIVOTED HANDLE TOR(IUE WRENCH
tccS1041
Fig. 28 Torque wrenches with pivoting
headsmustbe graspedand usedproperly
to preventan incorrectreading
RigidCase(Direct Reading)
# SeeFigure29
Arigidcaseordirectreadingtorquewrenchis
equippedwithadialindicatortoshowtorquevalues.
Oneadvantageofthesewrenchesisthattheycanbe
heldatanypositiononthewrenchwithoutaffecting
accuracy.Thesewrenchesareoftenpreferredbe-
causetheytendtobecompact,easytoreadandhave
agreatdegreeofaccuracy.
lccs1042
Fig. 29 The rigid case (direct reading)
torquewrenchusesa dial indicatorto show
torque
TORQUEANGLEMETERS
# SeeFigure30
Becausethefrictionalcharacteristicsofeachfas-
tenerorthreadedholewillvary,clamploadswhich
arebasedstrictlyontorquewillvaryaswell.Inmost
applications,thisvarianceISnotsignificantenough
tocauseworry.But,incertainapplications,amanu-
facturersengineersmaydeterminethatmoreprecise
clamploadsarenecessary(suchisthecasewith
:ig. 30Somespecificationsrequiretheuse
rf a torque angle meter(mechanicalpro.
ractor)
manyaluminumcylinderheads).Inthesecases,a
torqueanglemethodofinstallationwouldbespeci-
fied.Wheninstallingfastenerswhicharetorqueangle
tightened,apredeterminedseatingtorqueandstan-
dardtorquewrenchareusuallyusedfirsttoremove
anycompliancefromthejoint.Thefasteneristhen
tightenedthespecifiedadditionalportionofaturn
measuredindegrees.Atorqueanglegauge(mechan-
icalprotractor)isusedfortheseapplications.
) SeeFigure31
Throughoutthismanual,specificationsaregivento
helpyoudeterminetheconditionofvariouscompo-
nentsonyourvehicle,ortoassistyouintheirinstalla-
tion.Someofthemostcommonmeasurementsin-
cludelength(in.orcm/mm),torque(ft.Ibs.,inchIbs.
orNm)andpressure(psi,in.Hg,kPaormmHg).In
mostcases,westrivetoprovidethepropermeasure-
mentasdeterminedbythemanufacturersengineers.
Though,insomecases,thatvaluemaynotbecon-
venientlymeasuredwithwhatisavailableinyour
toolbox.Luckily,manyofthemeasuringdevices
CONVERSION FACTORS
LENGTH-DISTANCE
Inches (I”.) x 25.4 = Millimeters (mm) x .0394 = Inches
Feet (ft.) x ,305 = Meters (m) x 3.281 = Feet
Miles x 1.609 = Kilometers (km) x .0621 = Miles
VOLUME
Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 = in3
IMP Pints (IMP pt.) x .568 = Liters (L) x 1.76 = IMP pt.
IMP Quarts (IMP qt.) x 1.137 = Liters (L) x .88 = IMP qt.
IMP Gallons (IMP gal.) x 4.546 = Liters (L) 7,.22 = IMP gal.
IMP Quarts (IMP qt ) x 1.201 = US Quarts (US qt.) x ,833 = IMP qt.
IMP Gallons (IMP gal.) x 1.201 = US Gallons (US gal.) x ,833 = IMP gal.
Fl. Ounces x 29.573 = Millihters x 034 = Ounces
us Pints (Us pt.) x ,473 = Liters (L) x 2.113 = Pints
US Quarts (US qt.) x .946 = Liters (L) x 1.057 = Quarts
US Gallons (US gal.) x 3.785 = Liters (L) x ,264 = Gallons
MASS-WEIGHT
Ounces (oz.)
x 28.35 = Grams (g) x ,035 = Ounces
Pounds (lb ) x ,454 = Kdograms (kg) x 2.205 = Pounds
PRESSURE ’
Pounds Per Sq. In. (psi) x 6.895 = Kilopascals (kPa) x ,145 = psi
Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
Inches of Water (H,O) x .07355 = Inches of Mercury x 13 783 = H,O
Inches of Water (H,O) x .03613 = psi x 27.684 = Hz0
Inches of Water (H,O) x ,248 = Kilopascals (kPa) x4026 = H,O
TORQUE
Pounds-Force Inches (in-lb) x ,113 = Newton Meters (N.m) x 8.85 = in-lb
Pounds-Force Feet (ft-lb) x 1.356 = Newton Meters (N*m) x ,738 = ft-lb
VELOCITY
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
POWER
Horsepower (Hp) x ,745 = Kdowatts x 1.34 = Horsepower
FUEL CONSUMPTION’
Mdes Per Gallon IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
Kilometers Per Liter (Km/L) x 2.352 = IMP MPG
Miles Per Gallon US (MPG) x ,425 = Kilometers Per Liter (Km/L)
Kdometers Per Liter (Km/L) x 2.352 = US MPG
*It 1scommon to covert from miles per gallon (mpg) to hters/lOO kilometers (l/100 km), where mpg (IMP) x l/ID0 km
= 282 and mpg (US) x l/lo0 km = 235.
TEMPERATURE
Degree Fahrenheit CF) = (“C x 1.8) + 32
Degree Celsms (‘C) = CF - 32) x 56 tccsio4d
Fig. 31Standardandmetricconversionfactors chart

.
l-10 GENERALINFORMATIONANDMAINTENANCE
whichareavailabletodaywillhavetwoscalessothe Theconversionfactorchartisusedbytakingthe
StandardorMetricmeasurementsmayeasilybe givenspecificationandmultiplyingitbytheneces-
taken.Ifanyofthevariousmeasuringtoolswhichare saryconversionfactor.Forinstance,lookingatthe
availabletoyoudonotcontainthesamescaleas firstline,ifyouhaveameasurementininchessuch
listedinthespecifications,usetheaccompanying as“free-playshouldbe2in.”butyourrulerreads
conversionfactorstodeterminethepropervalue. onlyinmillimeters,multiply2in.bytheconversion
factorof25.4togetthemetricequivalentof50.8mm.
Likewise,ifthespecificationwasgivenonlyinaMet-
ricmeasurement,forexampleinNewtonMeters
(Nm),thenlookatthecentercolumnfirst.Ifthemea-
surementis100Nm,multiplyitbytheconversion
factorof0.738toget73.8ft.Ibs.
b SeeFigures32,33, and34
TheVehicleIdentificationNumber(VIN)islocated
onaplatewhichisattachedtothelefttopsideofthe
instrumentpanel.Thesenumbersarevisiblefromthe
outsideofthevehicle.AllVehicleIdentificationNum-
berscontain17digits.Thevehiclenumberisacode
whichtellscountry,make,vehicletype,engine,body
andmanyotherimportantcharacteristicsofthatspe-
cificvehicle.
Thereisalsoavehicleinformationcodeplate
whichisrivetedtothebulkheadintheenginecom-
partment.TheplateshowstheVIN,modelcode,en-
ginemodel,transaxlemodelandbodycolorcodes.
Theenginecodeusedonthisplatediffersfromthe
codeletterusedinthe8thpositionoftheVehicle
IdentificationNumber(VIN).Eithercodecanbeused
toidentifytheparticularengineinthevehicle.Since
thevehicleownerscardisusuallycarried,itmaybe
iftheengineisequippedwithaturbocharger.Ifthe
8thVINnumberisaU,thereisnodoubtthattheen-
gineinquestionisa2.OLDOHCengineequipped
withaturbocharger.
Theenginecodesfoundonthevehicleinformation
codeplateareasfollows:
l 4G15--1.5LSOHCengine
l 4G61-1.6LDOHCengine
l 4G93-1.8LSOHCengine
l 4G63-2.OL(SOHCorDOHC)engine
l 4G64-2.4L(SOHCorDOHC)engine
l 6G72-3.OL(SOHCorDOHC)engine
l 6G74-3.5LDOHCengine
Avehiclesafetycertificationlabelisattachedto
thefaceoftheleftdoorpillarpost.Thislabelindi-
catesthemonthandyearofmanufacture,GrossVe-
hicleWeightRating(GRVW)frontandrear,andVe-
hicleIdentificationNumber(VIM).
4charactercodeasonthevehicleinformationcode
plateisused.Theengineserialnumberisalso
stampedneartheenginemodelnumber.Asmen-
tionedabove,theenginecanalsobeidentifiedbythe
8thdigitintheVINnumber.
Thetransaxlemodelcodeislocatedonthevehicle
informationcodeplate.Thetransaxleidentification
numberisetchedonabosslocatedonthefrontup-
perportionofthecase.
Thecodeforthedriveaxleisetchedonabosslo-
catedonthecaseofthedifferentialcarrier.
easiertousethecodeletterintheVINforengineref-
erence.AsecondreasonforreferringtotheVINfor
engineidentificationisthatcode4663,locatedon
thevehicleinformationcodeplate,doesidentifythe
engineasa2.OLDOHCengine,butdoesnottellyou
) SeeFigure35
Theenginemodelnumberisstampedatthefront
sideonthetopedgeofthecylinderblock.Thesame
Fig. 32 TheVehicle Identification Number
g3’51p’oof the instrumentpanel _I:^1 /
Fig. 33 Thevehicle model, enginemodel,
(VIN)plate is attachedto the top left side bansaxlemodel,andbodycolorcodeareall
notedonthevehicleinformationcodeplate
ENGINEANDVEHiCLEIDENTlFlCATlON
EnglnCode ModelYerr
todeal LIten(cc)
Cu. In.
W. Fuel+ Type m.hWg.
Code@
Year
,G15JA 1.5 (1468) 92 4 MFI SOHC Mitsubishi L 1990
IG61N 1.6(15QQ) 98 4 MFI DOHC Mitsubishi M 1991
1G93lC 1.8 (1834) 112 4 MFI SOHC Mitsubishi N 1992
IG63N 2.0 (1997) 122 4 MFI SOHC “-Mitsubishi P 1993
!G63Fi 2.0 (1997) 122 4 MFI DOHC Mitsubishi R 1994
,G63iU 2.0 (1997) 122 4 MFI-Tuibo DOHC Mitsubishi S 1995
.GMffi 2.4 (2351) 143 4 MFI SOHC Mitsubishi T 1996
iG64L 2.4 (2351) 143 4 MFI DOHC Mitsubishi V
lEzH 3.0 1997 (2972) 161 6 MFI SOHC Mitsubishi W \ 1998
;G7ZJ 3.0 (2Q72) 161 6 MFI GQHC Mitsubishi
~.. X 1999
iG7zL 3.0 (2972) 181 ~ 6 MFI SOHC ___-___Miisubishi Y 2000
iG74lP 3.5 (3497) 213 6 MFI SOHC Miisubishi
Thetransfercasehasnoseparatemodelcode,the
codeislocatedonthetransaxle.Thetransfercaseis
onlveoUiODedonmanualtransaxleAllWheelDrive
(AWD)‘mbdels.
Fig. 34 Your car should have a vehicle
Fig. 35 Enginemodel numberlocation-
4663(2.OL)engineshown

UNDERHDDD MAINTENANCE COMPONENTLOCATIONS-2AL ENGINE II
1. Powersteeringbelt 7. PCVvalve
2. Washersolventbottle 8. Distributorcapandrotor
3. Powersteeringreservoir 9. Fuelfilter (underair inlettube)
4. Oilfill cap 10. Airfilter housing
5. Brakemastercylinderreservoir 11. Enginecompartmentfusebox
6. Sparkplugandplugwire 12. Battery
13. Automatictransaxlefluiddipstick
14. Coolantrecoverytank
15. Radiatorcap
16. Engineoil dipstick

UNDERHOODMAINTENANCE COMPONENTLOCATIONS-l .8L ENGINE
1. Coolantrecoverytank
2. Battery
3. Enginecompartmentfusebox
4. Airfilter housing
5. Clutchfluid reservoir
6. Brakemastercylinderreservoir
7. Sparkplugandplugwire
8. PCVvalve
9. Engineoil fill cap
10. Fuelfilter
11. Enginecompartmentrelaycenter
12. Washersolventbottle
13. Powersteeringreservoir
14. Powersteeringbelt
15. Engineoil dipstick
16. Radiatorcap

GENERALINFORMATIONANDMAlNTENANdE1-13
Engine
GENERAL ENGINE SPECIFICATIONS
Fuel Net Net Com- Oil
Displacement Engine Engine No. of System Horsepower Torque @ rpm Bore x Stroke pression Pressure
MFI Mult+wt fuel mfectw,
MFI-T- Multlporl fuel mfectlon-turbocharged
SOHC - Smgleoverhead camshaft
DOHC - Double OvedEad camshaft

l
l-14 GENERALINFORMATIONANDMAINTENANCE
Propermaintenanceandtune-upisthekeytolong
andtrouble-freevehiclelife,andtheworkcanyield
itsownrewards.Studieshaveshownthataproperly
tunedandmaintainedvehiclecanachievebettergas
mileagethananout-of-tunevehicle.Asaconscien-
tiousowneranddriver,setasideaSaturdaymorning,
sayonceamonth,tocheckorreplaceitemswhich
couldcausemajorproblemslater.Keepyourown
personallogtojotdownwhichservicesyouper-
formed,howmuchthepartscostyou,thedate,and
theexactodometerreadingatthetime.Keepallre-
selfer,thesereceiptsaretheonlyproofyouhavethat
ceiptsforsuchitemsasengineoilandfilters,sothat
theymaybereferredtpincaseofrelatedproblemsor
todetermineoperatingexpenses.Asado-it-your-
therequiredmaintenancewasperformed.Intheevent
ofawarrantyproblem,thesereceiptswillbeinvalu-
able.
Theliteratureprovidedwithyourvehiclewhenit
wasoriginallydeliveredincludesthefactoryrecom-
mendedmaintenanceschedule.Ifyounolongerhave
thisliterature,replacementcopiesareusuallyavail-
ablefromthedealer.Amaintenancescheduleispro-
videdlaterinthissection,incaseyoudonothave
thefactoryliterature. *
REMOVAL&INSTALLATION
Except2.gLTurbochargedEngine
b SeeFigures36thru41
9. Placeanewaircleanerelementinsidethe
lowerhousing.Makesurethesealontheelementis
fullyseatedinthegroove.
10.Installtheupperaircleanerhousingandinlet
tubeontothelowerhousing.
11.Tightentheclampontheinlettubeatthe
throttlebody.
12.Attachthebreatherhoseontotheairinlettube.
13.PlugtheconnectorintotheMAFsensor.
14.Attachtheaircleanerhousingretainingclips.
15.Connectthenegativebatterycable.
2.DLTurbochargedEngine
b SeeFigure42
1. Disconnectthenegativebatterycable.
2. Detachtheairflowsensorconnector.
3. Unfastentheboosthose.
4. Disconnectthesolenoidvalvewithhoses.
93151p50
Fig.36Releasetheretainingclipsfromthe
air cleanerhousing
r3151p47
Fig.37 Unplugthe MAFsensorconnector
Fig.49. . . thenremovethe air outlettube
andupperhousingfrom the lower housing
1. Disconnectthenegativebatterycable. 5. Disconnecttheairintakehose.
2. Releasetheretainingclipsfromtheair 6. Unfastentie aircleanerretainerboltsandthe
cleanerhousing. aircleanerassembly.
3. Loosentheclampontheairoutlettubeatthe 7. Unclampthecoverandremovefromthehous-
throttlebody. ing.
4. Detachthebreatherhosefromtheairinlet
tube. *Care mustbetakenwhenremovingtheair
cleanercover.Theair flow sensoris at-
5. UnplugtheMAFsensorconnector.
6. Separatetheupperandloweraircleaner tachedandcouldbedamagedduringcover
removal.
housingsandremovetheairoutlettubeandupper
housingfromthelowerhousing.
7. Removetheaircleanerelementfromthe
housing.
Toinstall:
8. Cleantheinsideoftheaircleanerhousingof
anydirtanddebristhathascollectedinside.
8. Removetheaircleanerelement.Thoroughly
cleantheaircleanerhousingpriortoreplacingtheair
filter.
Toinstall:
9. Installthenewaircleanerelementintothe
housing.Installandsecurethecoverinplace.
Fig. 38 Detachthe breatherhosefrom the
air tniet tube
Fig. 41 Removethe air cleaner element
fromthe housing
Fig. 39Loosenthe clamponthe air outlet
tubeat thethrottle body. . .
Fig.42 Detachthe air flow sensorconnec-
tor, the boosthoseandthe solenoidvalve
connector

GENERALINFORMATIONANDMAINTENANCEl-15
10.installtheaircleanerassemblyandthere- *Wrap shoptowelsaroundthefittingthatis
tainerbolts. beingdtsconnectedto absorbresidualfuel in
11.Connecttheairintakehose. thelines.
9. Whileholdingthefuelfilternutwithaback-
upwrench,tightenthebanjoboltto22ft.Ibs.(30
Nm).Tightentheflarenutto25ft.Ibs.(35Nm),with
12.Attachthesolenoidvalve. 4. Coverthehoseconnectionwithshoptowelsto aback-upwrenchonthenut.
13.Connecttheboosthose.
14.Attachtheairflowsensorconnector. preventanysplashoffuelthatcouldbecausedby 10.Tightenthefiltermountingboltsto10ft.Ibs.
residualpressureinthefuelpipeline.Holdthefuel (14Nm).
15.Connectthenegativebatterycable. 11.
\ filternutsecurelywithabackupwrench,thenremove Connectthenegativebatterycable.Turnthe
REMOVAL&INSTALLATION
thebanjoboltontheenginefeedline.Disconnectthe
high-pressurefuellinefromthefilter.Removeand
discardthegaskets.
5. Whileholdingthefuelfilternutsecurelywitha
back-upwrench,loosenthefilterfeedpipeflarenut
keytotheONpositiontopressurizethefuelsystem
andcheckforleaks.
12.Ifrepairsofaleakarerequired,rememberto
releasethefuelpressurebeforeopeningthefuelsys-
tern.
u SeeFigures43thru48
Onmostvehiclescoveredbythismanual,thefuel
filterislocatedintheenginecompartment,mounted
tothefirewall.
Donotuseconventionalfuel filters, hosesor
clampswhenservicingfuel injectionsys
terns.Theyarenotcompatiblewith theinjec-
tion systemand couldfail, causingpersonal
injuryordamagetothevehicle. Useonly
hosesandclampsspecificallydesignedfor
fuel injectionsystems.
1. Properlyrelievethefuelsystempressureas
outlinedinSection5ofthismanual.
onthebottomofthefilter.Separatetheflarenutcon-
nectionfromthefilter.Ifequipped,removeanddis-
cardthegaskets.
6. Removethemountingboltsandremove
. ,,,. ,. .a r I,.,< I the
ruerrrrter.IInecessary,removemeruerrrrreroracket.
Toinstall:
7. Installthefiltertoitsbracketonlyfinger-tight.
Movementofthefilterwilleaseattachmentofthefuel
lines.
Ensurethatthefilter is installedwiththeflow
arrowin theproperdirection.Theflow arrow
typically pointstowardtheenginesideofthe
filter. improperinstallationofthefuel filter
will causethevehicleto runpoorly.
2. Ifnotalreadydone,disconnectthenegative
REMOVAL&INSTALLATION
u SeeFigures49, 50, and51
1, Disconnectthenegativebatterycable.
2. Ifnecessaryforaccess,removetheairintake
hoseandaircleanerassembly.
3. Ifnecessary,unfastentheretainingclamp,then
disconnecttheventilationhosefromthePCVvalve.
4. RemovethePCVvalvefromthecamshaft
(rocker)cover.
Toinstall:
5. InstallthePCVvalveintotherockercover.If
thevalveisthreaded,tightenthevalveuntilsnug.
batterycable.
3. Onmostmodels.theiobismadeeasierifthe
airinlethoseandupperaircleanerhousingisre-
movedfromthevehicle.
*Make surenewO-ringsareinstalledprior
to installation.
8. Insertthefilterfeedpipetothelowerconnec-
tionofthefilterandmanuallyscrewinthemain
pipe’sflarenut.
6. Reconnecttheventilationhosetothevalve.
7. Ifremoved,installtheairintakehoseandthe
a.ircleanerassembly.
8. Connectthenegativebatterycable.
Fig. 43 Usea back-upwrench on the fuel I I
93151@3
filter nutwhenlooseningthe banjo-bolton Fig.44Afterthebanjo-boltis loose,remove
I
1the enginefeed line - fromthe fuel filter
93151p93
Fig.48Makesureto use a back-upwrench
1whenunfasteningthe mainfuel pipealso 1 Fig. 47 Removethe two filter bracket re- taining bolts . . .
Fig. 45 Make sure to replace the copper
washersonthe banjo-boltfitting
Fig.48 . . . thenremovethefilter fromthe
vehicle

*
l-16 GENERALINFORMATIONANDMAINTENANCE
Fig. 49Graspthe valve andgently remove Fig. 50 Twist and pull on the valve to re-
it fromthevalve cover moveit fromthe hose Fig. 51Inspectthe grommetandreplaceif crackedor leakingoil
SERVICING
corrosiveacidcanalsoeatawayatcomponentsun-
derthehood.
Alwaysvisuallyinspectthebatterycaseforcracks,
leakageandcorrosion.A whitecorrosivesubstance
u SeeFigure52
Theevaporativecanisterrequiresnoperiodicser-
vicing.However,acarefulinspectionofthecanister
andhosesshouldbemadefrequently,Replacedam-
onthebatterycaseor onnearbycomponentswould
indicatea leakingorcrackedbattery.Ifthebatteryis
cracked,it shouldbereplacedimmediately.
GENERALMAINTENANCE'_
devicesthatincreaseparasiticloadmaydischargea
batterysooner.Ifthevehicleistobestoredfor6-B
weeksinasecureareaandthealarmsystem,if pre-
sent,is notnecessary,thenegativebatterycable
shouldbedisconnectedattheonsetofstorageto
protectthebatterycharge.
Rememberthatconstantlydischargingand
rechargingwill shortenbatterylife.Takerare notto
allowabatteryto beneedlesslydischarged.
agedcomponentsasrequired.
Thecanisteristypicallylocatedunderoneofthe
frontfenders,howeveronsomelatermodelsit may
beundertherearofthevehicle,nearthegastank,
r onmostmodels
# SeeFigure53
A batterythatis notsealedmustbecheckedperi-
odicallyforelectrolytelevel.Youcannotaddwaterto
asealedmaintenance-freebattery(thoughnotall
maintenance-freebatteriesaresealed);however,a
sealedbatterymustalsobecheckedfor properelec-
trolytelevel,asindicatedbythecolorofthebuilt-in
hydrometer“eye.”
Alwayskeepthebatterycablesandterminalsfree
ofcorrosion.Checkthesecomponentsaboutoncea
year.Refertotheremoval,installationandcleaning
proceduresoutlinedinthissection,
Keepthetopofthebatteryclean,asafilm ofdirt
canhelpcompletelydischargeabatterythatis not
usedfor longperiods.Asolutionof bakingsodaand
watermaybeusedforcleaning,butbecarefulto
flushthisoffwithclearwater.DONOTletanyofthe
solutionintothefiller holes.Bakingsodaneutralizes
batteryacidandwill de-activateabatterycell.
Batteriesinvehicleswhicharenotoperatedona
regularbasiscanfallvictimtoparasiticloads(small
BA-ITERYFLUID
Checkthebatteryelectrolytelevelatleastoncea
month.ormoreofteninhotweatherorduringperi-
odsofextendedvehicleoperation.Onnon-sealed
batteries,thelevelcanbecheckedeitherthroughthe
caseontranslucentbatteriesor byremovingthecell
capsonopaque-casedtypes.Theelectrolytelevelin
eachcellshouldbekeptfilledtothesplitringinside
eachceil,orthelinemarkedontheoutsideofthe
case.
Ifthelevelis low,addonlydistilledwaterthrough
theopeninguntiltheleveliscorrect.Eachcellissep-
aratefromtheothers,soeachmustbecheckedand
filledindividuallv.Distilledwatershouldbeused,be-
causethechemicalsandmineralsfoundinmost
drinkingwaterareharmfultothebatteryandcould
significantlyshortenitslife.
Ifwaterisaddedinfreezingweather,thevehicle
shouldbedrivenseveralmilestoallowthewaterto
mixwiththeelectrolyte.Otherwise,thebatterycould
freeze.
currentdrainswhichareconstantlydrawingcurrent
fromthebattery).Normalparasiticloadsmaydraina Althoughsomemaintenance-freebatterieshave
removablecellcaosforaccesstotheelectrolyte,
the
causeashortcircuit,leadingto sparksandpossible
personalinjury.
Donotsmoke,haveanopenflameorcreate
sparksnearabattery;thegasescontainedinthebat-
teryareveryexplosiveand,if ignited,couldcausese-
vereinjuryordeath.
All batteries,regardlessoftype,shouldbecare-
fullysecuredbyabatteryhold-downdevice.Ifthis is
notdone,thebatteryterminalsor casingmaycrack
fromstressappliedtothebatteryduringvehicleoper-
ation.A batterywhichis notsecuredmayallowacid
to leakout,makingitdischargefaster;suchleaking
m / built-inhydrometer. . \
*Although thereadingsfrombuilt-inhy-
drometersfoundinsealedbatteriesmay
vary,a green eyeusually indicatesaprop
erly chargedbatterywith sufficientfluid
level. Adarkeyeis normallyanindicatorof a
batterywlth sufficientfluid, butonewhich
maybelow incharge.Anda light oryellow
eyeis usuallyanindicationthatelectrolyte
supplyhasdroppedbelowthenecessary
tcu1@32
Fig.53Atypical locationfor thebuilt-in hv- level for battery(andhydrometer)operation.
drometeronmaintenan
ce-freebatteries ’ I Inthislastcase.sealedbatterieswith anin-
sufficientelectrolytelevel mustusuallybe
’ discarded.

G,ENERALlNFORMATlONANDMAINTENANCEl-17
Fig.54On
non-maintenance-free
batteries,
the fluid level canbe checkedthroughthe Fig.55Ifthefluid level is low, addonlydis-
1case on translucentmodels;the cell caps1
mustberemovedon othermodels 1 1tilled water throughthe openinguntil the
1level is correct
Checkingthe SpecificGravity
Ahydrometerisrequiredtocheckthespecific
\
# SeeFigures54,55, and56
gravityonallbatteriesthatarenotmaintenance-free.
Onbatteriesthataremaintenance-free,thesoecific
gravityischeckedbyobservingthebuilt-inhydrome-
ter“eye”onthetopofthebatterycase.Checkwith
yourbattery’smanufacturerforproperinterpretation
ofitsbuilt-inhvdrometerreadinas.
gravityofthebattery.Itshouldbebetween1.20and
Asstatedearlier,thespecificgravityofabattery’s
electrolytelevelcanbeu
1.26onthegravityscale.Mostautosupplystores
sedasanindicationofbat-
terycharge.Atleastonce
carryavarietyofinexpensivebatterytestinghydrom-
?ayear,checkthespecific
eters.Thesecanbeusedonanynon-sealedbattery
, , ,,, .,, ..
IOrestmespecmcgravnyineachcell.
Thebatterytestinghydrometerhasasqueezebulb
atoneendandanozzleattheother.Batteryelectrolyte
thehydrometeruntilthefloatislifted
-hespecificgravityisthenreadbynot-
nofthefloat.Ifgravityislowinoneormgtneposrtro
Batteryelectrolytecontainssulfuricacid.If
youshouldsplashanyonyourskinor inyour
eyes,flushtheaffectedareawith plentyof
clearwater. If it landsinyoureyes,getmed-
ical helpimmediately.
Thefluid(sulfuricacidsolution)containedinthe
batterycellswilltellyoumanythingsaboutthecon-
ditionofthebattery.Becausethecellplatesmustbe
keptsubmergedbelowthefluidlevelinordertoop-
erate,maintainingthefluidlevelisextremelyimpor-
tant.And.becausethesoecificaravitvoftheacidis
anindicationofelectricalcharge,testingthefluidcan
beanaidindeterminingifthebatterymustbere-
placed.Abatteryinavehiclewithaproperlyoperat-
ingchargingsystemshouldrequirelittlemainte-
nance,butcareful,periodicinspectionshouldreveal
problemsbeforetheyleaveyoustranded. Fig. 57 Maintenance is performed with Fig. 58 The undersideof this special bat-
householditemsandwith specialtools like tery tool hasa wire brushto clean postter-
Ithis postcleaner
I 1
minals
Fig.56Checkthespecificgravityof thebat-
tery’s electrolyte with a hydrometer
morecells,thebatteryshouldbeslowlychargedand
Lheckedaqaintoseeifthearavitvhascome UP. Gen-
erally,ifaffercharging,thespecificgravitybetweenany
twocellsvariesmorethan50points(0.50)thebattery
shouldbereplaced,asitcannolongerproducesuffi-
cientvoltagetoguaranteeproperoperation.
CABLES
) SeeFigures57,56, 69, 60, and61
Onceayear(orasnecessary),thebatterytermi-
nalsandthecableclampsshouldbecleaned.Loosen

l
1-18 GENERALINFORMATIONANDMAINTENANCE
theclampsandremovethecables,negativecable
first.Onbatterieswithpostsontop,theuseofa
pullerspeciallymadeforthispurposeisrecom-
mended.Theseareinexoensiveandavailableinmost
alternatororturntheadjustingbolttoadjustbeltten-
sion.Oncethedesiredvalueisreached,securethe
boltorlocknutandrechecktension.
d”t” lJdlL> X”lt;>. 31°C LtXlllllldl lJdllt2)’ MLJIC, dlt’ X-
curedwithasmallbolt.
ST& I
REMOVAL&INSTALLATION
Cleanthecableclampsandthebatteryterminal
I
withawirebrush,untilallcorrosion,grease,etc.,is
removedandthemetalisshinv.Itisesneciallvimnnr-
tanttoc
knifeisusefulnere),sinceasmart
materialoroxidationtherewillpre
Cleanthecableclampsandthebatteryterminal
withawirebrush,untilallcorrosion,grease,etc.,is
removedandthemetalisshiny.Itisespeciallyimpor-
tanttocleantheinsideoftheclampthoroughly(anold
knifeisusefulhere),sinceasmalldepositofforeign
materialoroxidationtherewillpreventasoundelectri-
calconnectionandinhibiteitherstartingorcharging.
Specialtoolsareavailableforcleaningtheseparts,
onetypeforconventionaltoppostbatteriesandan-
othertypeforsideterminalbatteries.Itisalsoagood
ideatoapplysomedielectricgreasetotheterminal,as
thiswillaidinthepreventionofcorrosion,
Aftertheclampsandterminalsareclean,reinstall
thecables,negativecablelast;DONOThammerthe
clampsontobatteryposts.Tightentheclampsse-
curely,butdonotdistortthem.Givetheclampsand
terminalsathinexternalcoatingofgreaseafterin-
stallation,toretardcorrosion.
Checkthecablesatthesametimethattheterminals
arecleaned.Ifthecableinsulationiscrackedorbro-
ken,oriftheendsarefrayed,thecableshouldbere-
placedwithanewcableofthesamelengthandgauge.
CHARGING
thecables,negativecablelast;DONOThammerthe
curely,butdonotdistortthem.Givetheclampsand
terminalsathinexternalcoatingofgreaseafterin-
stallation,toretardcorrosion.
Checkthecablesatthesametimethattheterminals
arecleaned.Ifthecableinsulationiscrackedorbro-
ken,oriftheendsarefrayed,thecableshouldbere-
placedwithanewcableofthesamelengthandaauae.
CHARGING
Fig. 62 mere are typically 3 types of ac-
cessorydrive beltsfoundonvehiclestoday 1. Loosenthealternatorsupportnut.
2. Loosentheadjusterlockbolt.
3. Rotatetheadjusterboltcounterclockwiseto
I .I , . .. * ..
I
Tni”et*ll*
Fig. 62 Thereare typically 3 types of ac-
Fig. 64 Deepcracksin this belt will cause
flex, building up heat that will eventually
11,1.8L,2.OLand2.4LEngines
calconnectionandinhibiteitherstartingorcharging.
Specialtoolsareavailableforcleaningtheseparts,
onetypeforconventionaltoppostbatteriesandan-
othertypeforsideterminalbatterin,I+if QI@*3nnnd
ideatoapplysomedielectricgrr
thiswillaidinthepreventionof,,vIIuaIUII.
Aftertheclampsandterminalsareclean,reinstall
1.5L,1.6
ALTERNATORBE1T
e SeeFigures67,68, and69
1. Loosenthealternatorsupportnut.
2. Loosentheadjusterlockbolt.
3. Rotatetheadjusterboltcounterclockwiseto
releasethetensiononthebelt.
4. Removethebelt.
Toinstall:
5. Installthebeltonthepulleys.
6. Rotatetheadjusterboltclockwiseuntilthe
propertensionisreached.
7. Tightentheadjusterlockboltandthealternator
supportnut.
POWERSTEERINGBELT
8 SeeFigures70and71
1. Removethealternatorbeltasdescribedabove.
2. Loosenthepowersteeringpumpadjusting
bolts.
3. Removethepowersteeringoumofixedbolton
R Rntatn the cxiillrtm hnit A&+,& until the
r -r- .-.-._..._.______
7. Tightentheadjusterlockboltandthealternator
supportnut.
POWERSTEERINGBELT
1 ..“‘.I ““..Y...Y up II”“. ..IU...m.*
1leadto beltfailure V.
I I
Thechemicalreactionwhichtakesplacein
-
1 therearofthebracket.
4. Rotatethepumptowardtheengineandremove
thebelt.
all batteriesgeneratesexplosivehydrogen
gas.Asparkcancausethebatteryto explode
andsplashacid.Toavoidseriouspersonal
injury, besurethereis properventilationand
takeappropriatefire safetyprecautionswhen
connecting,disconnecting,or chargingabat-
teryandwhenusingjumpercables.
Tofnstall:
5. Installthebeltonthepulleys.
Abatteryshouldbechargedataslowratetokeep
theplatesinsidefromgettingtoohot.However,if
somemaintenance-freebatteriesareallowedtodis-
chargeuntiltheyarealmost“dead,”theymayhaveto
bechargedatahighratetobringthembackto“life.”
Alwaysfollowthechargermanufacturersinstructions
onchargingthebattery.
85The cover of this belt ex-
Fig. is worn,
REPLACEMENT
WhenitbecomesnecessarytoreolacethnhaeoN
‘” yyL’“‘J’IororeMer
selectonewithanamperageratingequaltc. a ----
thanthebatteryoriginallyinstalled.Deteriorationand
justplainagingofthebatterycables,startermotor,
andassociatedwiresmakesthebattery’sjobharder
insuccessiveyears.Theslowincreaseinelectrical
resistanceovertimemakesitprudenttoinstallanew
batterywithagreatercapacitythantheold.
1Fig. 67 Loosenthe adjusterlock bolt . . .
I ‘-
I-. -_
tm1217
Fig.66Installingtoo wide a belt canresylt
in seriousbelt wear and/orbreakage
thebeltandrunoutward.Allwornordamageddrive
beltsshouldbereplacedimmediately.Itisbesttore-
placealldrivebeltsatonetime,asapreventive
uringthisserviceoperation.
maintenancemeasure,d
- ADJUSTMENT
: *
INSPECTION
Excessivebelttensionwillcausedamagetotheal-
e SeeFigures62, 83,64, 65, and88
Inspectthebeltsforsignsofglazingorcracking.A
glazedbeltwillbeperfectlysmoothfromslippage,
whileagoodbeltwillhaveaslighttextureoffabric
visible.Crackswillusuallystartattheinneredgeof
pulleybearings,while,on
Ittensionwill Droduce slin
ternatorandwaterpump
theotherhand,loosebe r ------ r
andprematurewearonthebelt.Therefore,besureto
adjustthebelttensiontotheproperlevel.
To adjust the tension ’ ’ ’ ” ’ ‘*
adjustingboltorfixingb
alternatorbracketortens
onaonveDen.loosenme IFig.68. . . then
fromthe engine removethealternator
boltlocknutonthealternator,
iionpulley.Thenmovethe

GENERALINFORMATIONANDMAlNTENANdEl-19
792UQ4
Fig. 69 Accessory V-belt routing-Mii
subishf1.6L,1.6L,-1.6L,2.OLand2.4Len
gines
33151PM
Fig.70 After the adjustingandfixed bolt!
areloosened,rotatethe pump. . .
/F$71t immtl$mm&a the power:::
6. Rotatethepumpuntilthepropertensionis
reached.
7. Tightentheadjustingboltsonthepump.
8. Tightenthefixedboltontherearofthebracket.
9. Installthealternatorbelt.
A/r: COMPRESSOIlBELf
1. Loosenthetensionoullevandremovethebelt.
2. Theinstallationisthereverseoftheremoval.
.3.gL DGHC,3.OLSOHC(Gaiantmodels
only) and3.5LEngines
4. Removethebelt.
Toinstall:
5. Installthebeltonthecrankshaftandalternator
pulleys.
6. Usingtheadjustingboltonthetensioner,
tightenthebelttothedesiredtension.
7. Tightenthefixingnuttoholdtheadjustment.
8. Installtheundercoverandlowerthevehicleto
_,
thetloor.
9. Connectthenegativebatterycable.
POWERSliEERlNGBELf
6 SeeFigures72and73 1. DisconnecttheneaativebatteNcah+P
-I Waitat least60secondsafterthenegative
batterycableisdisconnectedto preventpoS-
sibie deploymentof theair bag.
2. Raiseandsafelysupportthevehicleandre-
mob
retheundercover.
3. RemovethealternatorandNCcompressor
belt.
4. Lowerthevehicleandremovethecruisecon-
trol oumn link iW%mblV.
79244Q.37 -- I-- r
---- - _I
Fig.72Serpentinebeltrouting-Mitsubishi 5. Placethepowersteeringhoseundertheoil
reservoir.
3.OLengines(except1696-00Galantmod- 6. Loosenthetensionpulleyfixingboltsandre-
els)
Generator pulP
1 movethepowersteeringpumpdrivebelt.
Toinstall:
1 7. installtheDowersteerinaoumur+r+v~hp++
8. Insertanextensionbar&eoufvaik;;t”f;;id‘he
openingattheendofthetensionpulleybracketand
pivotthepulleytoapplytensiontothebelt.
9. Tightenthefixingbolts.
10.Raisethevehicleandinstallthealternatorand
compressorbelt.
Il. Installtheundercoverandlower+hfivph+r+p
.I,.,.VII.“.Y.
12.Connectthenegativebatterycable.
I
3.OLSGHC(DiamanteModelsOnivl Enotne
I
,r ”
1. Disconnectthenegativebatterycable.
2.’LoosenthelockboltonthefacenftheA/C
_ __.-
tensionerpulley.
3 TurntheadiustinaboltoftheA/C+fincrnner
pulleytoloosenthetensionoftheA/Cbelt.
4. RemovetheA/Ccompressorbelt.
5. Loosenthelocknutonthefaceofthepower
toloosenthetc
7. Remov
Fig.73AccessoryV-beltrouting-Mitsubishi
3.5L and 1996-00 3.OLSOHCGalanten-
gines
steering/alternatortenslonerpulley.
6. Turntheadjustingboltofthetensionerpulley
msionofthebelt.
‘ethepowersteering/alternatorbelt.
Toinstall:
8. Installthepowersteering/alternatorbeltfirst
.* .* . ,^ ssordrivebelt.anatnentneA/ticompre:
9. Adjustthebeltst+
ingtheadjustingboltsanu II~IIWII pueeytlxmg
Ithepropertensionbyturn-
A.:-LI-..-..I,^,.’
nut/bolt.
10.Tightenthemountingnutofthepowersteer-
ing/alternatortensionerpulleyto36ft.Ibs.(50Nm).
Waitatleast60secondsafterthenegative
batterycableisdisconnectedto preventpos-
sible deploymentoftheair bag.
-The manufacturerdoesnotprovidea
torquespecificationfor theboltthatsecures
A/Ctensionerpulley.
2. Raiseandsafelysupportthevehicleandre- 11.Connectthenegativebatterycable.
movethefrontundercover.
3. Loosenthetensionpulleyfixingnutandrelieve
thetensiononthebeltbyturningtheadjustingbolt.

.
l-20 GENERALINFORMATIONANDMAINTENANCE
INSPECTION
# SeeFigures74thru 81
Allenginescoveredbythismanualutilizetiming
beltstodrivethecamshaftfromthecrankshaftsturn-
ingmotionandtomaintainpropervalvetiming.
Somemanufacturersscheduleperiodictimingbelt
replacementtoassureoptimumengineperformance,
tomakesurethemotoristisneverstrandedshould
thebeltbreak(astheenginewillstopinstantly)and
forsome(manufacturerswithinterferencemotors)to
preventthepossibilityofsevereinternalenginedam-
age St10Ula the Delt break.
Althoughthe1.5Land1.8Lenginesarenotlisted
asaninterferencemotors(itisnotlistedbytheman-
ufacturerasamotorwhosevalvesmightcontactthe
pistonsifthecamshaftwasrotatedseparatelyfrom
thecrankshaft)thefirst2reasonsforperiodicre-
placementstillapplyandthetimingbeltshouldbe
replacedat60,000miles(96,000km).The1.6L,
2.01,2.4L,3.OL,and35Lenginesarelistedasinter-
ferencemotors,sothetimingbeltMUSTbereplaced
at60,000miles(96,000km)toavoidsevereengine
damageifthebeltshouldbreak.
Butwhetherornotyoudecidetoreplacethetim-
ingbeltinthemanufacturersschedule,youwouldbe
wisetocheckitperiodicallytomakesureithasnot
becomedamagedorworn.Generallyspeaking,ase-
verelvwornbeltmavcauseenaineoerformanceto
drop~dramatically,butadamagedbelt(whichcould
giveoutsuddenly)maynotgiveasmuchwarning.In
general,anytimetheenginetimingcover(s)is(are)
removedyoushouldinspectthebeltforpremature
parting,severecracksormissingteeth.Also,anac-
cessplugisprovidedintheupperportionofthetim-
ingcoversothatcamshafttimingcanbechecked
withoutcoverremoval.Iftimingisfoundtobeoff,
coverremovalandfurtherbeltinspectionorreplace-
mentisnecessary.
tml245
Fig. 76 look for noticeablecracksor wear
onthe belt face
_
Forthetimingbeltremovalandinstallationproce-
dure,pleaserefertoSection3ofthismanual.
Fig. 74 Checkfor prematurepartingof the
belt
INSPECTION
. 75 Checkif the teeth are crackedor
fig. 77Youmayonly havedamageonone
side of the belt; if so, the guidecould be
the culprit
b SeeFigures82,8S, 84, and85 .
Upperandlowerradiatorhoses,alongwiththe
heaterhoses,shouldbecheckedfordeterioration,
leaksandloosehoseclampsatleastevery30,000
miles(48,000km).Itisalsowisetocheckthehoses
periodicallyinearlyspringandatthebeginningof
thefallorwinterwhenyouareperformingother
maintenance.Aquickvisualinspectioncoulddis-
coveraweakenedhosewhichmighthaveleftyou
strandedifithadremainedunrepaired.
Wheneveryouarecheckingthehoses,makesure
theengineandcoolingsystemarecold.Visuallyin-
spectforcracking,rottingorcollapsedhoses,andw-
placeasnecessary.Runyourhandalongthelength
ofthehose.Ifaweakorswollenspotisnotedwhen
squeezingthehosewall,thehoseshouldbere-
Fig. 78 Foreign materials can get in be- Fig. 79 Inspectthe timing belt for c
tweenthe teeth andcausedamage fraying, glazingor damageof any kind
Fig.80Damageononly onesideof thetim- I IFig. 81ALWAYSreplacethe timing belt at
ing belt mayindicatea faulty guide the interval specified bythe manufacturer
, L
placed.

GENERALINFORMATIONANDMAINTENANCEl-21
IWSIZXJ
FM. 83 A hoseclamnthat is taa tiaht can
Fig. 82 The cracks developing along this
hoseare a resultof age-relatedhardening caise older hosestd separateand‘iear on
either sideof the clamp
lCCS1221
Fig. 84A soft spongyhose(identifiable by
1
the swollen section) will eventually burst
andshouldbe replaced
IEMOVAL&,INSTALLATION '
1. Removetheradiatorpressurecap. her ofthesorinatensiontvoe(whichreouireoliers
3squeezethe 6bs andloosenjorofthe’screwten-
iontype(whichrequirescreworhexdriversto
oosen).Pulltheclampsbackonthehoseawayfrom
heconnection.
Neverremovethepressurecapwhile theen-
gineis running,or personalinjuryfrom
scaldinghotcoolantorsteammayresult. If
possible,wait untiltheenginehascooledto
removethepressurecap.Ifthis is notpossi-
ble,wrapathickclotharoundthepressure
capandturnit slowlyto thestop.Stepback
while thepressureis releasedfromthecool-
ingsystem.Whenyouaresureall thepres-
surehasbeenreleased,usetheclothto turn
andremovethecao.
2. Positionacleancontainerundertheradiator
and/orenginedraincockorplug,thenopenthedrain
andallowthecoolingsystemtodraintoanappropri-
atelevel.Forsomeupperhoses,onlyalittlecoolant
mustbedrained.Toremovehosespositionedlower
ontheengine,suchasalowerradiatorhose,theen-
tirecoolingsystemmustbeemptied.
Whendrainingcoolant,keepin mindthat
catsanddogsareattractedbyethylenegly-
col antifreeze,andarequitelikely to drink
anythatis left in anuncoveredcontaineror
inpuddlesontheground.Thiswill provefa-
tal insufficientquantity.Alwaysdrain
coolantintoasealablecontainer.Coolant
maybereusedunlessit is contaminatedor
severalyearsold.
9. Closetheradiatororenginedrainsandprop-
erlyrefillthecoolingsystemwiththecleandrained
enginecoolantorasuitablemixtureofethylenegly-
cotcoolantandwater.
10.Ifavailable,installapressuretesterandcheck
forleaks.Ifapressuretesterisnotavailable,runthe
engineuntilnormaloperatingtemperatureisreached
(allowingthesystemtonaturallypressurize),then
checkforleaks.
Ifyouarecheckingfor leakswiththesystem
at normaloperatingtemperature,BEEX-
TREMELYCAREFULnottotouchanymoving
or hotengineparts.Oncetemperaturehas
beenreached.shuttheenaineOFF.and
Fig.85Hosesare likely to deterioratefrom
the insideif the coolingsystemis notperi-
odically flushed
checkfor leaksaroundthe-hosefittingsand
connectionswhichwere removedearlier.
INSPECTION
b SeeFigures88and87
TheCV(ConstantVelocity)bootsshouldbe
checkedfordamageeachtimetheoilischangedand
anyothertimethevehicleisraisedforservice.These
bootskeepwater,grime,dirtandotherdamaging
matterfromenteringtheCV-joints.Anyofthese
couldcauseearlyCV-jointfailurewhichcanbeex-
pensivetorepair.Heavygreasethrownaroundthein-
sideofthefrontwheel(s)andonthebrake
caliper/drumcanbeanindicationofatornboot.
Thorouahlvcheckthebootsformissinaclamosand
3. Loosenthehoseclampsateachendofthe
roserequiringreplacement.Clampsareusuallyei-
4. Twist,pullandslidethehoseoffthefitting,
skingcarenottodamagetheneckofthecomponent
romwhichthehoseisbeingremoved.
*If thehoseisstuckatthe connection,do
lottry to insertascrewdriveror othersharp
oolunderthehoseendinaneffarttofree it,
IStheconnectionand/orhosemaybecome
lamaged.Heaterconnectionsespecially
naybeeasilydamagedbysucha procedure.
fthehoseisto bereplaced,usea single-
!dgedrazorbladeto makeaslice alongthe
lortionofthehosewhichisstuckonthecon-
section,perpendicularto theendofthe
lose.00notcutdeepsoasto preventdam-
agingtheconnection.Thehosecanthenbe
keeledfromtheconnectionanddiscarded.
Fig.86CV-bootsmustbeinspectedperiod-
5..Cleanbothhosemountingconnections.In-
,pecttheconditionofthehoseclampsandreplace
hem,ifnecessary.
Toinstall:
6. Diptheendsofthenewhoseintocleanen-
finecoolanttoeaseinstallation.
7. Slidetheclampsoverthereplacementhose,
henslidethehoseendsovertheconnectionsinto
rosition.
8. Positionandsecuretheclampsatleastl/din.
6.35mm)fromtheendsofthehose.Makesurethey
Irelocatedbeyondtheraisedbeadoftheconnector.