MITSUBISHI DIAMANTE 1900 Service Manual

1-42 GENERAL~INFORMATION AND MAINTENANCE
Fig. 206 The fluid level should be between
llow,be*“retoch~ckiebrake~ . the MAX and MIN hnes if the fhud level IS
93151p31 Fig. 209 If the master cylinder capgasket
is swelled like such, it can be a sign of con-
tamination. If the gasket is swelled . . . Fig. 207 Wipe the master cylinder reservoir
clean before opening the cap to ensure that
no contamination enters the brake fluid
Fig. 210 . . .
make sure to push the gasket
back to the normal position
93151p29 I Fig. 208 Unscrew the master cylinder cap
and remove it from the reservoir
Fig. 211 Carefully pour approved brake fluid
from a fresh, sealed container directly into
the reservoir
2. Inspect the fluid in the reservoir, making sure
fluid is between the MAX and the MIN marks.
FLUID RECOMMENDATIONS
When adding or changing the fluid in the systems,
use a quality brake fluid conforming to DOT 3 speci-
fications from an sealed container. Never reuse old
brake fluid.
LEVEL CHECK
b See Figures 212, 213, and 214
1. Wipe the clutch master cylinder reservoir cap
and the surrounding area clean with a shop towel. 3. If required, remove the clut ch master cylinder
reservoir lid. then add fresh fluid I FLUID RECOMMENDATIONS
mark on the’reservoir. to fill to the top full
When adding or changing the power steering
fll$,“” Dexron@il ATF (Automatic Transmission
-
- .
Be careful to avoid sf Billing any brake fluid on LEVELCHECK
painted surfaces, bet
:ause the paint coat will
become discolored or damaged.
b See Figures 215, 216, 217, and 218
4. Reinstall the lid onto the clutch master cylin- Like all other general maintenance items, check
der. every 3,OOfl miles (4,800 km) or once a month. In-
5. If removed, install the air cleaner assembly. spect the oil level in the reservoir by checking the po-
Fig. 212 The clutch master cylinder has
MAX (A) and MIN (B) fill lines on the reser
volr

GENERALINFORMATIONAND MAINTENANCE l-43
l Special car washing detergent is the best to
use. Liquid dishwashing detergent can remove wax
and leave the car’s paint unprotected and in addition
some liquid detergents contains abrasives which can
scratch the paint.
l Bird droppings should be removed from the
paintwork as soon as possible, otherwise the finish
may be permanently stained.
When the car is driven immediately after be-
ing washed, apply the brakes several times
93151p14 93151p12 Fig. 215 Twist the reservoir cap, then lift up
I I
in order to remove any moisture from the
Fig. 216 Wipe the dipstick off, reinsert it braking surfaces.
on the integral cap/dipstick assembly
into the reservoir and check the level
I
Engine cleaning agents should not be used
when the engine is warm, a fire risk is pre-
sent as most engine cleaning agents are
highly flammable.
sition of the fluid against the mark on the dipstick,
Add fluid to the reservoir if the fluid does not reach
the appropriate full line.
On most models, the manufacturer doesn’t install
lubrication fittings on lube points on the steering
linkage or suspension. However, if the lubrication
point does have a grease fitting, lubricate with multi-
purpose NLGI No. 2 (Lithium base) grease.
CAR WASHING
The car should be washed at regular intervals to
remove dirt, dust, insects, and tar and other possibly
damaging stains that can adhere to the paint and may
cause damage. Proper exterior maintenance also
helps in the resale value of the vehicle by maintaining
its like-new appearance.
Mt is particularly important ta frequentiy
wash the car in the wintertime to prevent cor-
rosion, when salt has been used on the roads.
There are many precautions and tips on washing,
including the following:
l When washing the car, do not expose it do di-
rect sunlight.
. Use lukewarm water to soften the dirt before
you wash with a sponge, and plenty of water, to avoid
scratching.
l A detergent can be used to facilitate the soften-
ing of dirt and oil. * A water-soluble grease solvent may be used in
cases of sticky dirt. However, use a washplace with a
drainage separator.
l Dry the car with a clean chamois and remem-
ber to clean the drain holes in the doors and rocker
panels.
l If equipped with a power radio antenna, it must
be dried after washing.
Never clean the bumpers with gasoline or
paint thinner, always use the same agent as
used on the painted surfaces of the vehicle.
l Tar spots can be removed with tar remover or
kerosene after the car has been washed.
l A stiff-bristle brush and lukewarm soapy water
can be used to clean the wiper blades. Frequent
cleaning improves visibility when using the wipers
considerably.
l Wash off the did from the underside (wheel
housings, fenders, etc.).
l In areas of high industrial fallout, more fre-
quent washing is recommended.
During high pressure washing the spray nonle
must never be closer to the vehicle than 13
inches (30cm). Do not spray into the locks.
l When washing or steam cleaning the engine,
avoid spraying water or steam directly on the electri-
cal components or near the distributor or ignition
components. After cleaning the engine, the spark
plug wells should be inspected for water and blown
dry if necessary. Automatic car washing is a simple and quick way
to clean your car, but it is worth remembering that it
is not as thorough as when you yourself clean the
car. Keeping the underbody clean is vitally important,
and some automatic washers do not contain equip-
ment for washing the underside of the car.
When driving into an automatic was, make sure
the following precautions have been taken:
l Make sure all windows are up, and no objects
that you do not want to get wet are exposed.
l In some cases, rotating the side view mirrors
in can help to avoid possible damage.
l If your car is equipped with a power antenna,
lower it. If your vehicle has a solid mounted, non-
power antenna, it is best to remove it, but this is not
always practical. Inspect the surroundings to reduce
the risk of possible damage, and check to see if the
antenna can be manually lowered.
Most manufacturers do not recommend auto-
matic car washing in the first six months due
to the possibility of insufficient paint curing;
a safe bet is to wait until after six months of
ownership (when purchased new) to use an
automatic car wash.
WAXING
eBefore applying wax, the vehicle must be
washed and thoroughly dried.
Waxing a vehicle can help to preserve the appear-
ante of your vehicle. A wide range of polymer-based
car waxes are available today. These waxes are easy
to use and produce a long-lasting, high gloss finish
that protects the body and paint against oxidation,
road dirt, and fading.
Sometimes, waxing a neglected vehicle, or one
that has sustained chemical or natural element dam-
age (such as acid rain) require more than waxing,
and a light-duty compound can be applied. For se-
verely damaged surfaces, it is best to consult a pro-
fessional to see what would be required to repair the
damage.
Waxing procedures differ according to manufac-
turer, type, and ingredients, so it is best to consult
the directions on the wax and/or polish purchased.

1-44 GENERALINFORMATIONAND MAINTENANCE
INTERIOR CLEANING
Upholstery
Fabric can usually be cleaned with soapy water or
a proper detergent. For more difficult spots caused by
oil, ice cream, soda, etc., use a fabric cleaner avail-
able at most parts stores. Be sure when purchasing
the cleaner to read the label to ensure it is safe to use
on your type of fabric. A safe method of testing the
cleaner is to apply a small amount to an area usually
unseen, such as under a seat, or other areas. Wart a
while, perhaps even a day to check the spot for fad-
ing, discoloring, etc., as some cleaners will only
cause these problems after they have dried
Leather upholstery requrres special care, it can be
cleaned with a mild soap and a soft cloth. It is recom-
mended that a special leather cleaner be used to
clean but also treat the leather surfaces in your vehi-
cle. Leather surfaces can age quickly and can crack if
not properly taken care of, so it is vital that the leather
surfaces be maintained.
Floor Mats and Carpet
The floor mats and carpet should be vacuumed or
brushed regularly. They can be cleaned with a mild
soap and water. Special cleaners are available to
clean the carpeted surfaces of your vehicle, but take
care in choosing them, and again it is best to test
them in a usually unseen spot.
Dashboard, Console, Door Panels, Etc.
The dashboard, console, door panels, and other
plastic, vinyl, or wood surfaces can be cleaned using
a mild soap and water. Caution must be taken to keep
water out of electronic accessories and controls to
avoid shorts or ruining the components Again spe-
cial cleaners are available to clean these surfaces, as
with other cleaners care must taken in purchasmg
and using such cleaners.
There are protectants available which can treat the
various surfaces in your car giving them a “shiny new
look”, however some of these protectants can cause
more harm than good in the long run. The shine that
is placed on your dashboard attracts sunlight accel-
erating the aging, fading and possibly even cracking
the surfaces. These protectants also attract more dust
to stick to the surfaces they treat, Increasing the cleaning you must do to maintain the appearance of
your vehicle. Personal discretion is advised here.
On most models covered by this manual, the
wheel bearmgs used are sealed units and do not re-
quire routine maintenance. However on some Galant
and Mirage models, the rear wheel bearing do require
periodic repacking. For removal and installation in-
structions, please refer to Section 7 (for rear bear-
ings) or Section 8 (for front bearings).
REPACKING
*Sodium based grease is not compatible
with lithium based grease. Read the package
labels and be careful not to mix the two
types. If there is any doubt as to the type of
grease used, completely clean the old
grease from the bearing and hub before re-
placing.
Before handling the bearings, there are a few
things that you should remember to do and not to do.
DO the following: l Remove all outside dirt from the housing be-
fore exposing the bearing.
l Treat a used bearing as gently as you would a
new one.
l Work with clean tools in clean surroundings. l Use clean, dry gloves, or at least clean, dry
hands.
l Clean solvents and flushing fluids are a must. l Use clean paper when laying out the bearings
to dry.
l Protect drsassembled bearings from rust and
dirt. Cover them up.
l Use clean, lint-free rags to wipe the bearings. l Keep the bearings in oil-proof paper when they
are to be stored or are not in use.
l Clean the inside of the housing before replac-
ing the bearin
Do NOT do he followino: El, l Do not work in dirty sirroundings. l Do not use dirty, chipped or damaged tools. l Do not work on wooden work benches or use
wooden mallets.
l Do not handle bearings with dirty or moist
hands.
l Do not use gasoline for cleaning. Use a safe
solvent.
l Do not spin dry bearings with compressed air.
They will be damaged.
l Do not use cotton waste or dirty cloths to wipe
bearings.
l Do not scratch or nick bearing surfaces. l Do not allow the bearina to come in contact
” with dirt or rust at any time.
The rear wheel bearinas on some Galant and Mi-
rage models require periodic maintenance. A pre-
mium high melting point grease meeting Grade
Multipurpose Grease NLGI Grade #2 or equivalent
must be used. Long fiber type greases must not be
used. This service is recommended every 30,000
miles (48,000 km).
*For information on Wheel Bearing removal
and installation, refer to Section 7 of this
manual.
1. Remove the wheel bearing.
2. Clean all parts in a non-flammable solvent and
let them air dry.
*Only use lint-free rags to dry the bearings.
Never spin-dry a bearing with compressed
air, as this will damage the rollers.
3. Check for excessive wear and damage. Replace
the bearing as necessary.
*Packina wheel bearinos with arease is
best accomplished by u&g a wheel bearing
packer (available at most automotive parts
stores).
4. If a wheel bearing packer is not available, the
bearings may be packed by hand.
a. Place a “healthy’ glob of grease in the
palm of one hand.
b. Force the edge of the bearing into the
grease so that the grease fills the space between
the rollers and the bearing cage.
c. Keep rotating the bearing while continuing
to push the grease through.
d. Continue until the grease is forced out the
other side of the bearing.
5. Place the packed bearing on a clean surface
and cover it until it is time for installation.
6. Install the wheel bearing.
# See Figures 219 and 220
To prevent the bumper from deforming, these vehi-
cles cannot be towed by a wrecker using sling-type
equipment. If these vehicles require towing, use a
wheel lift or flat bed equipment. It is recommended
that the vehicle be towed from the front If a flat bed is
not available.
Manual transaxle vehicles may be towed from the
rear provided that the transaxle is in Neutral and the
driveline has not been damaged. The steering wheel
must be clamped in the straight-ahead positron with a
steering wheel clamping device designed for towing
service use.
Do not use the steering column lock to secure
the front wheel uosition for towina.
Automatic transaxle vehicles may be towed on the
front wheels at speeds not to exceed 30 mph (50
km/h) for a distance not to exceed 18 miles (30 km).
If these limits can not be met, then the front wheels
must be placed on a tow dolly.
# See Figure 221
All Wheel Drive (AWD) vehicles should only be
towed with all 4 wheels on the ground or lifted from
the road surface. This means that the vehicle is to be
towed either with flatbed equipment, with all wheels
on dollies or flat towed. Damage to the viscous cou-
pling may result if the vehicle is towed with only 2
wheels on the ground.
p See Figure 222
Whenever a vehicle is jump started, precautions
must be followed In order to prevent the possibility of

GENERALINFORMATIONAND MAINTENANCE 1-45
SLING TYPE
WHEEL LIFT TYPE
cles
SUNG TYPE
WHEEL LIFT TYPE
FLAT BED TYPE
Fig. 220 Rear towing position-FWD vehi
cles
personal injury. Remember that batteries contain a
small amount of explosive hydrogen gas which is a
by-product of battery charging. Sparks should always
be avoided when working around batteries, especially
when attaching jumper cables. To minimize the pos-
sibility of accidental sparks, follow the procedure
carefully.
NEVER hook the batteries up in a series cir-
cuit or the entire electrical system will go up
in smoke. includino the starter!
Vehicles equipped with a diesel engine may utilize
two 12 volt batteries. If so, the batteries are con-
nected in a parallel circuit (positive terminal to posi-
tive terminal, negative terminal to negative terminal).
owrng methods
a tow truck IS used
Lrftrng method for 4 wheels-Good
Front wheels lifted-No good
Front wheels lifted-No good
Rear wheels lifted-No good
Towing by rope or cable-Good
e9571g92 qemarks
. For4WD models, the basic principle is that
all four wheels are to be rarsed before
towing.
. The shift lever should be set to 1 st gear and
the parking brake should be applied.
l The vehicle must not be towed by tofacing
only its front wheels or only the rear wheels
on a rollino dollv, because to do so will
result in d&e&ration of the visfx~s
coupling and result in the viscous coupling
causing the vehicle to jump forward
suddenly.
l If only the front wheels or only the rear
wheels are lifted for towing, the bumper
wrll bedamyd.
In addrtron. II trng of the rear wheels causes
the or1 to flow forward. and may result in
heat damage to the rear bushing of the
transfer, and so should never be done.
l The front and rear wheels must rotate
normally.
l The various mechanisms must function
normally.
l The shift lever must be set to the neutral
~Asi&n and the ignition key must be set to
Fig. 221 Towing instructions-AWD models
Hooking the batteries up in parallel circuit increases
battery cranking power without increasing total bat-
tery voltage output. Output remains at 12 volts. On
the other hand, hooking two 12 volt batteries up in a
series circuit (positive terminal to negative terminal,
positive terminal to negative terminal) increases total
battery output to 24 volts (12 volts plus 12 volts).
l Be sure that both batteries are of the same volt-
age. Vehicles covered by this manual and most vehi-
cles on the road today utilize a 12 volt charging sys-
tem.
l Be sure that both batteries are of the same po-
larity (have the same terminal, in most cases NEGA-
TIVE grounded).
l Be sure that the vehicles are not touching or a
short could occur.
l On serviceable batteries, be sure the vent cap
holes are not obstructed.
l Do not smoke or allow sparks anywhere near
the batteries.
l In cold weather, make sure the battery elec-
trolyte is not frozen, This can occur more readily in a
battery that has been in a state of discharge.
l Do not allow electrolyte to contact your skin or
clothing.
1. Make sure that the voltages of the 2 batteries
are the same. Most batteries and charging systems
are of the 12 volt variety.
MAKE CONNECTIONS IN NUMERICAL ORDER
A FIRST JUMPER CABLE
WITH CHARGED BATTERY
-
lccslQ?,Q
Fig. 222 Connect the jumper cables to the
batteries and engine in the order shown

.
I-46 GENERALINFORMATIONAND MAINTENANCE
2. Pull the jumping vehicle (with the good bat-
tery) into a position so the jumper cables can reach
the dead battery and that vehicle’s engine. Make sure
that the vehicles do NOT touch.
3. Place the transmissions/transaxles of both ve-
hicles in Neutral (MT) or P (AT), as applicable, then
firmly set their parking brakes.
*ff necessary for safety reasons, the hazard
lights on both vehicles may be operated
throughout the entire procedure without sig-
nificantiy increasing the diff icuity of jumping
the dead battery.
4. Turn all lights and accessories OFF on both
vehicles. Make sure the ignition switches on both ve-
hicles are turned to the OFF position.
5. Cover the battery cell caps with a rag, but do
not cover the terminals.
6. Make sure the terminals on both batteries are
clean and free of corrosion or proper electrical con-
nection will be impeded. If necessary, clean the bat-
tery terminals before proceeding.
7. Identify the positive (+) and negative (-) termi-
nals on both batteries.
8. Connect the first jumper cable to the positive
(t) terminal of the dead battery, then connect the
other end of that cable to the positive (t) terminal of
the booster (good) battery.
9. Connect one end of the other jumper cable to
the negative (−) terminal on the booster bat-
tery and the final cable clamp to an engine bolt head,
alternator bracket or other solid, metallic point on the
engine with the dead battery. Try to pick a ground on
the engine that is positioned away from the battery in
order to minimize the possibility of the 2 clamps
touching should one loosen during the procedure.
DO NOT connect this clamp to the negative (-) termi-
nal of the bad battery. cable on the donor battery. Disconnect the positive
cable from the donor battery and finally, disconnect
the positive cable from the formerly dead battery. Be
careful when disconnecting the cables from the posi-
tive terminals not to allow the alligator clips to touch
any metal on either vehicle or a short and sparks will
occur.
I
$ See Figures 223,224, 225,226, and 227
Your vehicle was supplied with a jack for emer-
gency road repairs. This jack is fine for changing a
flat tire or other short term procedures not requiring
you to go beneath the vehicle. If it is used in an emergency situation, carefully follow the instructions
provided either with the jack or in your owners man-
ual. Do not attempt to use the jack on any portions of
the vehicle other than specified by the vehicle manu-
facturer. Always block the diagonally opposite wheel
when using a jack.
A more convenient way of jacking is the use of a
garage or floor jack. You may use the floor jack to
raise the front of the vehicle by placing it under the
front subframe. The rear of the vehicle is most easily
raised by using the lift points on the drip rail. All
models are equipped with lift points located on the
mid- crossmember in the front and a bracket located
on the floorpan underneath the trunk.
Never place the jack under the radiator, engine or
transaxle components. Severe and expensive damage
will result when the jack is raised. Additionally, never
jack under the floorpan or
bodywork; the
metal will
Whenever you plan to work under the vehicle, you
must support it on jackstands or ramps. Never use
cinder blocks or stacks of wood to support the vehi-
cle, even if you’re only going to be under it for a few
minutes. Never crawl under the vehicle when it is
supported only by the tire-changing jack or other
*Always position a block of wood or small
rubber pad on top of the jack or jackstand to
protect the lifting point’s finish when lifting
or supporting the vehicle.
Small hydraulic, screw, or scissors jacks are satis-
factory for raising the vehicle. Drive-on trestles or
Be very careful to keep the jumper cables
away from moving parts (cooling fan, belts,
etc.) on both engines.
10. Check to make sure that the cables are routed
away from any moving parts, then start the donor ve-
hicle’s engine. Run the engine at moderate speed for
several minutes to allow the dead battery a chance to
receive some initial charge.
11. With the donor vehicle’s engine still running
slightly above idle, try to start the vehicle with the
dead battery. Crank the engine for no more than 10 &stands also on the
Fig. 225 The most practical place to place
front of the vehicle is
seconds at a time and let the starter cool for at least
20 seconds between tries. If the vehicle does not start
in 3 tries, it is likely thatsomething else is also
wrong or that the battery needs additional time to
charge.
12. Once the vehicle is started, allow it to run at
idle for a few seconds to make sure that it is operat-
ing properly.
13. Turn ON the headlights, heater blower and, if
equipped, the rear defroster of both vehicles in order
to reduce the severity of voltage spikes and subse-
quent risk of damage to the vehicles’ electrical sys-
tems when the cables are disconnected. This step is
especially important to any vehicle equipped with
computer control modules.
14. Carefully disconnect the cables in the’reverse
order of connection. Start with the negative cable that
is attached to the engine ground, then the negative Fig. 226 Place the jackstands also
subframe to support the front of the Fig. 227 All models covered by this
are equipped with lift points on t
crossmember in the front and on a

GENERAL INFORMATION AND MAINTENANCE 1-47
ramps are also a handy and safe way to both raise l When the drive wheels are to remain on the
and support the vehicle. Be careful though, some ground, leave the vehicle in gear to help prevent it
ramps may be too steep to drive your vehicle onto
The following safety points cannot be overempha- from rolling.
without scraping the front bottom panels. Never sup-
sized:
l Always use jackstands to support the vehicle
port the vehicle on any suspension member (unless l Always block the opposite wheel or wheels to when you are working underneath. Place the stands
specifically instructed to do so by a repair manual) or
keep the vehicle from rolling off the jack. beneath the vehrcle’s jacking brackets Before climb-
by an underbody panel.
l When raising the front of the vehicle, firmly ap- ing underneath, rock the vehicle a bit to make sure it
ply the parking brake. is firmly supported.
SCHEDULED MAINTENANCE INTERVALS (MITSUBISHI DIAMANTE, GALANT, & MIRAGE)
VEHICLE MILEAGE INTERVAL (x1000)
7.5 15
22.5 30 37.5 45 52.5 60 67.5 75 62.5 90 97.5
J J
J 4 J J 4 4 4 J J
J 4
4
J J J J 4 TO BE
Ball loints &steering linkage
S/I J J J
seals
Dnve belt(s) S/I 4 4 J
Fvha,,rt cvctom $/I
J J J LmI,..“w. “,YL”,‘. Fuel hoses
+
Manual transaxle oil (Galant)
connectlon & fuel tank filler
R. Replace S/I - Sefwce or Inspect FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) II a vehicle is operated under any of the following conditions it is considered severe service:
- Extremely dusty areas.
- 50% or more of the vehicle operation is in 32% (WF) or higher temperatures, or constant opsralion in
temperatures below 0% (32°F).
- Prolonged idling (vehicle operation in stop and go traffic).
_ Frequent short running periods (engine does not warm to normal operating temfwatures).
- Police, taxi, delivery usage or trailer towing usage.
0118 011 filter change-change every 3CQO 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.

1-48 GENERALINFORMATIONAND MAINTENANCE
CAPACITIES Engine
Drive

DISTRIBUTOR IGNITION SYSTEM
GENERALINFORMATION 2-2
DIAGNOSISANDTESTING 2-2
SECONDARYSPARKTEST 2-2
CYLINDERDROPTEST 2-2
ADJUSTMENTS 2-3
IGNITION COIL 2-3
TESTING 2-3
REMOVAL&INSTALLATION 2-3
POWERTRANSISTOR
(Ignition Module) 2-4
REMOVAL&INSTALLATION 2-4
DISTRIBUTOR 2-4
REMOVAL&INSTALLATION 2-4 2-2
INSTALLATION 2-4
CRANKSHAFTANDCAMSHAFTPOSITION
SENSORS 2-5
DISTRIBUTORLESS IGNITION
SYSTEM 2-5
GENERALINFORMATION 2-5
DIAGNOSISANDTESTING 2-5
ADJUSTMENTS 2-5
IGNITION COIL(s) 2-5
TESTING 2-5
REMOVAL&INSTALLATION 2-6
POWERTRANSISTOR
(IGNITION MODULE) 2-7
REMOVAL&INSTALLATION 2-7
CRANKSHAFTANDCAMSHAFTPOSITION
SENSORS 2-7
FIRING ORDERS 2-7
CHARGING SYSTEM 2-8
GENERALINFORMATION 2-8
ALTERNATORPRECAUTIONS 2-8
ALTERNATOR 2-8
TESTING 2-8 I
REMOVAL&INSTALLATION 2-9
REGULATOR 2-10
REMOVAL&INSTALLATION 2-10
STARTING SYSTEM 2-10
GENERALINFORMATION 2-10
STARTER 2-10
TESTING 2-10
REMOVAL&INSTALLATION 2-11
SENDING UNITS 2-11
ENGINECOOLANTTEMPERATURE
SENDING UNIT 2-11
TESTING 2-11
REMOVAL&INSTALLATION 2-11
OIL PRESSURESENDING UNIT 2-12
TESTING 2-12
REMOVAL&INSTALLATION 2-12

.~ P.X I_ - “, .- I .-., IS ” .~.I .r
2-2 ENGINE ELECTRICAL
nn
ity and trouble: shooting electrical circuits,
please refer to Section 6 of this manual.
I
The ignition system on the 1.5L, 1993-96 1.8L,
2.OL SOHC, 1994-98 2.4L SOHC, 3.OL SOHC, and
3.5L engines uses a pointless type distributor, whose
advance mechanism is controlled by the Engine Con-
trol Unit (ECU). On the 1.5L, 1.8L, 2.4L and 3.5L en-
gines, the distributor houses a built in ignition coil
and ignition power transistor. The 2.8L SOHC and
3.OL SOHC engines utilize a separate coil and tran-
sister assemblv.
When the ignition switch is turned ON, battery
voltage is applied to the ignition coil primary winding.
As the shaft of the distributor rotates, signals are
transmitted from the oowertrain control module to the
9105zp11 Fig. 1 This spark tester looks iust like a
Fiu. 2 This spark tester has an adjustable
spark plug, attach the clip to ground and air-gap for measuring spark strength and
crank the engine to check for spark testing different voltage ignition systems
.
ignition power trar rsistor. These signals activate the
power transistor to cause ignition coil primary wind-
ing current flow from the ignition coil negative termi-
nal through the power transistor to ground repeatedly.
This interruption induces high voltage in the ignition
coil secondarv windinas, which is diverted throuah
the distributor, spark plug cable and spark plug 6
ground, thus causing ignition in each cylinder.
I
SECONDARYSPARKTEST l;h.4-
! ,L ".~
'$ >,%
If See Figures 1 thru 6
91rJszp12 Fig. 4 This spark tester is the easiest to use
iust alace it on a plug wire and the spark
The best way to perform this procedure is to use a Fig. 3 Attach the clip to ground and crank
spark tester (available at most automotive parts stores). the engine to check for spark
I I voltage is detected and the bulb on the tof
-. will flash with each pulse
I nree types ot spark testers are commonly available.
The Neon Bulb type is connected to the spark plug
wire and flashes with each ignition pulse. The Air Gap
type must be adjusted to the individual spark plug gap
specified for the engine. The last type of spark plug
tester looks like a spark plug with a grounding clip on
the side, but there is no side electrode for the spark to
jump to. The last two types of testers allows the user to
not only detect the presence of spark, but also the in-
tensity (orange/yellow is weak, blue is strong).
1. Disconnect a spark plug wire at the spark plug
end.
2. Connect the plug wire to the spark tester and
ground the tester to an appropriate location on the
engine.
3. Crank the engine and check for spark at the
tester.
4. If spark exists at the tester, the ignition system
is functioning properly.
5. If spark does not exist at the spark plug wire,
perform diagnosis of the ignition system using indi-
vidual component diagnosis procedures,
CYLINDER DROPTEST
p See Figures 7, 8, and 9
The cylinder drop test is performed when an en-
gine misfire is evident. This test helps determine
which cylinder is not contributing the proper power.
The easiest way to perform this test is to remove the
plug wires one at a time from the cylinders with the
engine running. 1. Place the transaxle in P, engage the emer-
gency brake, and start the engine and let it idle.
2. Using a spark plug wire removing tool, prefer-
ably the plier type, carefully remove the boot from
one of the cylinders.
i ’
Make sure your body is free from touching
any part of the car which is metal. The sec-
ondary voltage in the ignition system is high and although it cannot kill you, it will shock
you and it does hurt.
3. The engine will sputter, run worse, and possi-
bly nearly stall. If this happens reinstall the plug wire
and move to the next cylinder. If the engine runs no
differently, or the difference is minimal, shut the en-
gine off and inspect the spark plug wire, spark plug,
and if necessary, perform component diagnostics as
covered in this section. Perform the test on all cylin-
ders to verify the which cylinders are suspect.

ENGINEELECTRICAL 2-3
91c6zp16 Fig. 9. . . note the idle speed and idle char-
acteristics of the engine. The cylinder(s)
with the least drag is the non-contributing
cyltnder(s) -
1
There are no adjustments to the distributor ignition
system other than the ignition timing adjustment. Re-
fer to section 1 for ignition timing adjustment.
TESTING
1.5L, 1.8L, 2.41, and 3.51 Englnes
u See Figures 10, 11, and 12
*The ignition cog is an integral part of the
distributor.
1. Measure the resistance of the primary ignition
coil as follows:
a. Unplug the electrical connector at the dis-
tributor. Using an ohmmeter, measure the resis-
tance between the two terminals of the distributor,
NOT THE WIRE HARNESS, except for the 3.5L
engine, in which you test across terminals 1 and
2 of the distributor.
b. Measure the resistance and compare to the
desired specifications of:
l 0.9-1.2 ohms on the 1.5L, 1.8L, and 2.4L
engines
l 0.5-0.7 ohms on the 35L engine
c. If the actual reading differs from the desired
specification, replace the ignition coil.
d. If the measured value is within standard al-
lowance, there are no broken wires or short cir-
cuits. 2. Measure the resistance of the secondary igni-
desired specifications of: tion coil as follows:
l 21329 kilo-ohms on the 1.5L, 1.8L, and
2.4L engines a. Insert one of the test leads into the sec-
ondary ignition coil terminal on top of the dis-
l 9-13 kilo-ohms on the 3.5L engine tributor cap.
d. If the measured value is within standard al- b. Touch the second test lead to terminal 1 or
terminal 2 of the distributor connector.
lowance, there are no broken wires or short cir-
cuits. c. Measure the resistance and comnare to the
e. If the actual reading differs from the de
sired specification, replace the ignition coi!l.
2.OL SOHC and 3.OL SOHC Engines
# See Figure 13

1. Measure the resistance of the primary ignition
coil as follows:
a. Unplug the electrical connector at the coil.
Using an ohmmeter, measure the resistance be-
tween the two terminals of the coil, NOT THE
WIRE HARNESS.
b. Measure the resistance and compare to the
desired specifications of:
l 0.9-1.2 ohms on the 2.OL SOHC engine l 0.72-0.88 ohms on the 3.OL SOHC engine
c. If the actual reading differs from the de-
sired specification, replace the ignition coil.
d. If the measured value is within standard al-
lowance, there are no broken wires or short cir-
cuits. 2.
desired specifications of: Measure the resistance of the secondary igni-
tion coil as follows:
l 20-29 kilo-ohms on the 2.OL SOHC en-
gine a. Insert one of the test leads into the sec-
ondary ignition coil terminal on top of the dis-
l 10.29-13.92 kilo-ohms on the 3.01 SOHC tributor cap.
engine b. Touch the second test lead to terminal 1 or
terminal 2 of the distributor connector.
d. If the measured value is within standard
allowance, there are no broken wires or short c. Measure the resistance and comoare to the
circuits.
e. If the actual reading differs from the
desired specification, replace the ignition
coi!l.
REMOVAL&INSTALLATION
1.5L, 1.8L, 2.4L, and 3.5L Engines
*The ignition coil is an tntegral part of the
distributor.
2.OL SOHC and 3.OL SDHC Engines
u See Figure 14
1. Disconnect the negative battery cable.
2. Remove the coil wire from the ignition coil by
gripping the boot and not the cable.
3. Detach the electrical connectors for the coil.
High voltage terminal -r
I Q3 ‘I u,
/ - Blm/ I L tflgn
tension
terminal
,
3=%@ @l&M Fig. IO Distributor connector pins and loca-
Fig. 11 Distributor connector pins and loca- Fig. 12 Dlstrfbufor connector plus and loca-
tiou-l.LL and 1.8L engines
lion-2.4L SOHC engtne tio&.5L engine