oil MITSUBISHI GALANT 1989 Service Repair Manual

00-l
GENERAL
CONTENTS
GENERAL DATA AND SPECIFICATIONS.....23
HOWTOUSETHISMANUAL......................
3
Definition of Terms ......................................3
ExplanationofCircuitDiagrams..................7
Explanation of
ManualContents .................4
Explanation of the Troubleshooting
Guide .............................................................
6
Model
Indications .........................................3
Scope of Maintenance, Repair and
Servicing Explanations
..................................
3
Troubleshooting .............................................3
LUBRICATIONANDMAINTENANCE............
34
MAINTENANCE SERVICE............................... 39
AirCleanerElement
.....................................39
Automatic
Transaxle
.....................................43
Ball Joint and Steering Linkage Seals ........45
Brake Hoses................................................. 45
Disc Brake Pads ........................................... 44
Drive Belt (For Water Pump and
Generator) .......................................................
41
Drive
Shaft Boots .........................................45
Engine Coolant
............................................. 44
Engine Oil .....................................................
41
Engine Oil Filter ...........................................41
Exhaust System
............................................ 45
FuelHoses
...................................................39
Fuel System
.................................................39
Manual Transaxle ..........................................42
RearAxle......................................................45
Rear Drum Brake Linings and
RearWheel Cylinders
..................................44
Spark
Plugs...................................................40
Timing Belt...................................................40
MASTER
TROUBLESHOOTING.....................28
PRECAUTIONS
BEFORESERVICE................15
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIESTABLE..................35
SCHEDULED
MAINTENANCETABLE ...........38
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS
.......................................20
TABLE OF MAIN SEALANTS
AND
ADHESIVES ............................................46
TIGHTENING TORQUE
................................... 27
TOWING
ANDHOISTING ..............................17
VEHICLE
IDENTIFICATION .............................8
Chassis Number ...........................................
11
EngineModel
Stamping
...............................12
Theft Protection ............................................12
Vehicle Identification Code Chart Plate.......
8
Vehicle Identification Number List
..............8
Vehicle Identification Number Location .......
8
Vehicle Information
CodePlate...................1 1
Vehicle SafetyCertificationLabel................12

00-4GENERAL - How to Use This Manual
EXPLANATION OF MANUAL CONTENTSIndicates procedures to
be performed before the
work in that section is
started, and procedures
to be performed after
the work in that section
is finished.
Maintenance and Servicing Procedures
(1) A diagram of the component parts is provided near the front of each section in
order to give the reader a better under-
standing of the installed condition of
component parts.
(2) The numbers provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol
mindicates a non-reusable part; the tighten-
ing torque is provided where applicable. l Removal steps:
The part designation number corres-
ponds to the number in the illustration
to indicate removal steps.
l Disassembly steps: The part designation number corres-
ponds to the number in the illustration
to indicate disassembly steps.
l Installation steps: Specified in case installation is impossi-
ble in reverse order of removal steps.
Omitted if installation is possible in
reverse order of removal steps.
8 Reassembly steps: Specified in case reassembly is im-
possible in reverse order of disassem-
bly steps.
Omitted if reassembly is possible in reverse order of disassembly steps.
Classificationsof Major Maintenance/
Service Points
When there are major points relative to mainte-
nance and servicing procedures (such as essential
maintenance and service points, maintenance and
service standard values, information regarding the
use of special tools, etc.), these are arranged
together as major maintenance and service points
and explained in detail.
*+ : Indicates that there are essential points for
removal or disassembly.
I)+ : Indicates that there are essential points forinstallation or reassembly. necessary. In this exam-
ple, sealant is applied
(where indicated) to the
I---
Symbols for Lubrication, Sealants and
Adhesives
4 . . . . .Grease
(multipurpose grease unless there is Information
concerning the locations for lubrica-
tion and for application of sealants and adhesives
is provided, by using symbols, in the diagram of
component parts or on the page following the
component parts page, and explarned.
a brand or type specified)
4 . . . . Sealant or adhesive
a. . . . .Brake fluid. automatic transmission
fluid or air conditioner compressor oil
a. . . . . Engine oil or gear oil
. . .Adhesive tape or butyl
rubber tape

GENERAL - How to Use This Manual
QfitIIICQ CTEEQINC CFAR RnY..^-TV..&” Y.LLI.II.Y Y_.. w-1.
REMOVAL AND INSTALLATION
1, Jpn assemble and gear box connecting
2 Connectlo” for return tube
3 Connectm
for pressure hose4 cotter P!”6 T!e-rod end and knuckle connecting
I
J rl”.#l ~“,. dLlrr_. ..__
10. Center member rear mouniing
bou11, Front exhaust p’pe4. H 12. Gear box assembly
. . 13. Mounting rubber Denotes non-re-
p usable part
.
Y.T-*c As..
-

6
Repair kit or set parts are shown.
(Only very frequently used parts
Operating procedures, cautions,
II-’ iY,W11 ’etc. on removal, installation, dis-
se&an: 3rM&rr&paNo.~3W[scribed, ,~ 1assembly and reassembly are
de-
37A-24STEERING- NINA Steering Gear Box
-SERVICE POINTS OF
REMOVALJll37?kM6. DlSCONNECllON OF TIEROD END
Using the special tool, disconnect
the tie rod from theknuckle.ceurion1. BesretotiethewrdofthespeciaitodtomenP-.2. Loosenthenutbutdonotremoveit.
12. REMOVAL OF GEAR BOX ASSEMBLY
Thus number corresponds to the
number ?pyi:,“~&‘R~;;?Isteps”,“Installation steps” or “Reas-semblv steps”.
/LUBRlCATlON AND SEALING POINTS-
The title of the page (fOilOWingthe page on which the diagram of
component parts is presented)
indicating the locations of lubnca-
tion and sealingprocedures.

00-20GENERAL - Special Handling Instructions for AWD Models
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS
TOWIN
G
MomMA
Towing methods
If a tow truck is used Lifting method for 4 wheels-Good Remarks
l For AWD models, the basic principle is that
all four wheels are to be raised before
towing.
l The shift lever should be set to 1
st gear and
the parking brake should be applied. <M/T
>
l The selector lever should be set to “P” position and the parking brake should be
applied.
<AK>
OOA0032
Front wheels lifted-No good l The vehicle must not be towed by placing
only its front wheels or only the rear wheels
on a rolling dolly, because to do so willresult in deterioration of the viscous
coupling and result in the viscous coupling
causing the vehicle to jump forward
suddenly.
OOA0034
Front wheels lifted-No good l
If only the front wheels or only the rear
wheels are lifted for towing, the bumper
will be damaged. In addition, lifting of the rear wheels causes
the oil to flow forward, and may result in
heat damage to the rear bushing of the
transfer, and so should never be done.
Rear wheels lifted-No good
OOA0033
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00-30GENERAL - Master Troubleshooting
EXCESSIVE OIL CONSUMPTION Symptom Probable cause Reference page or remedy
1
r-Excessive 011 consumption
Oil leak Repair as necessary.I Valve
stem seal worn or damaged. Repair as necessary.
Valve stem worn. Repair as necessary.
Piston ring worn or damaged. Repair as necessary.
POOR FUEL MILEAGE Symptom
Poor fuel mtleage
Probable cause
Fuel leak
Air cleaner clogged. Ignition system problems.
Fuel injection system problems.
Compression too low.
Tires improperly inflated.
Clutch slips.Brakes drag. Reference page or remedy
Repair as necessary.
-
16-32
13-8, 119, 205
1 l-6
31-3 21-4
35-l 3
NOISE
SymptomNoise Probable cause
Loose bolts and nuts.
Engine noise Reference page or remedy
Retighten as necessary.
Repair as necessary.
HARD STEERING
Symptom
Hard steering Probable cause
Reference page or remedy
Loose power steering oil pump belt
37A-21
Low fluid level Replenish
Air in power steering system
37A-22
Low tire pressure31-3
Excessive turning resistance of lower arm ball33A-11
joint Excessively tightened of steering gear box 37A-33
rack support cover
Improper front wheel alignment
Excessive turning resistance of tie-rod ball
joint
Malfunctioning electronic controlled power
steering system
Sticky flow control valve
Bent rack in steering gear box
J
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33A-5
37A-15, 33 37A-9
37A-50,
51 37A-42

GENERAL - Master Troubleshooting
00-31
POOR RETURN OF STEERING WHEEL TO CENTER
Symptom
Probable cause Reference page
’Poor return of steering wheel to
Improper front wheel alignment33A-5center
Improper tire pressure31-3
Excessive tightened rack support cover 37A-35, 36, 37
Damaged front wheel bearing
26-9
POOR RIDING
Symptom
Poor riding Probable cause
Reference page or remedy
Improper tire pressure
31-3
lmbalanced wheelsRepair
Improper front or rear wheel alignment33A-5
34-5, 11, 23, 35
Malfunctioning shock absorber Malfunctioning
electronic control suspension
33B-90system
Broken or worn stabilizer
33A-6. 13, 1734-l 1, 35, 37
Broken or worn coil spri#ng
Loose suspension secuiring bolt(s)
Retighten
Worn lower arm bushing
33A-10
Worn suspension arm bushing 33A-IO
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ABNORMAL TIRE WEAR
Symptom
Abnormal tire wear Probable cause
Improper front or rear wheel alignment Reference page
33A-534-5, 23
131-3
lmbalanced wheelsII
Loose wheel bearings
27-3, 15
Malfunctioning shock absorber
33A-634-l 1, 35

00-32
GENERAL - Master Troubleshooting
ROAD WANDER Symptom
Road wander Probable cause
Improper front or rear wheel alignment Reference page
33A-534-5, 23
Excessive play of steering wheel
37A-15
Poor turning resistance of lower arm ball joint33A-11
Improper tire pressure 31-3
Loose or worn lower arm bushing
33A-10
26-9
Loose or worn wheel bearings
Loose rack support cover in steering gear box 37A-35. 36, 37
VEHICLE PULLS TO ONE SIDE Symptom Probable cause Reference page
Vehrcle pulls to one side
Improper front or rear wheel alignment33A-5
34-5. 2
3
lmbalanced or worn tires 31-3
Uneven tire pressure Excessive turning resistance of lower arm ball
33A-17joint
Wheel bearing seizure
Replace
Broken or weak coil spring33A-7
Bent front axle drive shaft 26-13
Deformed lower arm
33A-10
STEERING WHEEL SHIMMY
Symptom
Steerlng wheel shlmmy
Probable cause
Improper front or rear wheel alignment Reference page or remedy
33A-534-5, 23
Improper tire pressure I 31-3
lmbalanced wheels
Replace
1 Poor turning resistance of lower arm ball joint) 33A-11
] Excessive play of steering wheel) 37A-15
Broken or weak front stabilizer
Worn lower arm bushing33A-13. 17
33A-10
Malfunctioning shock absorber
Broken or weak coil spring
Wear, play, or seizure of wheel bearing33A-6
34-11, 3
5
Replace
Wear, play, or seizure of drive shaft ball joint
26-12
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GENERAL - Master Troubleshootinn
00-33
BOTTOMING Symptom Probable cause
1 Reference page or remedy
Bottoming
Malfunctioning shock absorber
WHEEL BEARING TROUBLESHOOTING TroublePitting
Flaking
Cracking
Sympton Probable cause
Pitting occurs because of uneven rotation of race Excessive bearing preload
and bearing surfaces Excessrve
load
The surface peels because of uneven rotation of
End of bearing life ,
the race and bearing surfaces Improper bearing assembly
Chipping or cracking of cage or roller edges Impact when
beanng was installed
(such as being hit with a hammer)
Flat spotting When large load is applied, race and roller
contact surfaces compress, formingindentations Excessive bearing preload
Excessive load
Vibration when bearings are not used, such as during shipment on
freight cars, transport trucks, etc.
NicksInstead of roiling along race surface, rollers slide, insufficient grease
thus damaging surface Excessive bearing preload
Excessive load
Faulty oil seal
Smearing Damage or wear caused by minute particles Excessive variation of loads on
adhering to surfaces results in
rolugh movement bearings
and such high temperatures that parts of surface Use of grease other than that
melt specified
Insufficient grease
Rust, corrosion Appears on various areas of the bearing Use of grease other than that
specified Faulty oil seal
Presence of water or moisture
WearWear of surface areas caused by friction Insufficient grease
Foreign matter
Rust or corrosion due to moisture
Use of grease other than that
specified
Faulty oil seal Irscoloration
Grease discoloration results from grease
deterioration which causes partic:les
of
pigment contained in grease to adhere
to surfaces Heat discoloration will appear
as a deep brown on purple Use of grease other than that
specified
Faulty oil seal Excessive bearing preload
Excessive load
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00-34GENERAL- Lubrication and Maintenance
LUBRICATION AND
MAINTE-
NANCEMOOPA-
Maintenance and lubrication service recommenda-
tions have been compiled to provide maximum protection for the vehicle owner’s investment
against all reasonable types of driving conditions. Since these conditions vary with the individual
vehicle owner’s driving habits, the area in which the
vehicle is operated and the type of driving to which
the vehicle is subjected, it is necessary to prescribe lubrication and maintenance service on a time
frequency as well as mileage interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by the Society of Automotive Engineers (SAE), the Amer-
ican Petroleum Institute (API) and the National
Lubricating Grease Institute (NLGI).
MAINTENANCE SCHEDULES Information for service maintenance is provided
under “SCHEDULED MAINTENANCE TABLE”.
Three schedules are provided; one for “Required Maintenance”, one for “General Maintenance” and
one for “Severe Usage Service”.
The item numbers used in the “SCHEDULED MAINTENANCE TABLE” correspond to th
e
“MAINTENANCE SERVICE” section numbers.
SEVERE SERVICE
Vehicles operating under severe service conditions
will require more frequent service. Component service information
isIncluded i
n
appropriate units for vehicles operating under one or
more of the following conditrons:
1.Trailer towing or police, taxi, or
commerciai
type
operation
2. Operation of Vehicle (1) Short-trip operation at freezing temperature(engine not thoroughly warmed up)
(2) More than 50% operation in heavy city traffic during hot weather above
32°C (90°F)
(3) Extensive idling
(4) Driving in sandy areas
(5) Driving in salty areas
(6) Driving in dusty conditions
ENGINE OIL
The SAE grade number indicates the viscosity of engine oils, for example, SAE 30, which is a single
grade oil. Engine oils are also identified by a dual number, for example, SAE 1
OW-30, which Indicates
a multigrade oil.
The API classification system defines oil perform- ance in terms of engine usage. Only engine oil
designed “For Service SG” or “For Service
SGKD”,
when available, should be used. These oils contain
sufficient chemical additives to provide maximum
engine protection. Both the SAE grade and the API
designation can be found on the container.
Caution
Test results submitted to EPA have shown that
laboratory animals develop skin cancer after
prolonged contact with used engine oil. Accor-
dingly, the potential exists for humans to de-
velop a number of skin disorders, including
cancer, from such exposure to used engine oil.
Care should be taken, therefore, when changing engine oil, to minimize the amount and length of
exposure time to used engine oil on your skin.
Protective clothing and gloves, that cannot be
penetrated by oil, should be worn. The skin
should be thoroughly washed with soap and
water, or use waterless hand cleaner, to remove
any used engine oil. Do not use gasoline,
thinners, or solvents.
GEAR LUBRICANTS
The SAE grade number also indicates the viscosity of Multi-Purpose Gear Lubricants.
The API classfication
system defines gear lubricants
in terms of usage. Typically gear lubricants conform-
ing to API
GL-4 or GL-5 with a viscosity of SAE 75W-85W
are recommended for manual transaxle.
LUBRICANTS
- GREASES
Semi-solid lubricants, bear the
NLGI designation and
are further classified as grades 0, 1, 2, 3 etc.
Whenever “Chassis Lubricant” is specified,
Multi-
Purpose Grease, NLGI grade 2 should be used.
FUEL USAGE STATEMENT
Your vehicle must use unleaded gasoline only.
This vehicle has a fuel filler tube especially designed
to accept only the smaller-diameter unleaded gaso- line
dispensrng nozzle.
Caution
Using leaded gasoline in your vehicle will damage
the catalytic converter, and affect the warranty
coverage validity.
All vehicles except those with DOHC engines
Your vehicle is designed to operate on unleaded
gasoline having a minimum octane rating of 87 or
91 RON (Research Octane Number).
Vehicles equipped with DOHC engines
Your vehicle is designed to operate on premiumunleaded gasoline having a minimum
octane rating
of 91 or 95 RON (Research Octane Number).
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GENERAL -Lubrication and Maintenance/Recommended Lubricants and Lubricant Capacities Table00-35
If premium unleaded gasoltne IS not available,
MATERIALS ADDED TO FUEL
unleaded gasoline having a octane rating of 87 or
91 RON (Research Octane Number) may be used. Indiscriminate use of fuel system cleaning agents
In this case, the performance and fuel consumption should be avoided. Many of these materials
in-
WIII suffer a little degradatron.tended for gum and varnish removal may contain
highly active
solvents or similar ingredients that can
be harmful to gasket and diaphragm materials used
in fuel system component parts.
Gasolines containing alcohol
Some gasolrnes sold at service stations contain
alcohol, although they may not be SC identified. Use
of fuels containing alcohol is not recommended
unless the nature of the blend can be
determrned
as being satisfactory.
Gasohol
- A mixture of 10% ethanol (grain alcohol)
and 90% unleaded gasoline may be used
In your
car. If
driveability problems are experienced as a
result of using gasohol, it IS recommended that the
car be operated on gasoline. Methanol
- Do not use gasolines containing
methanol (wood alcohol). Use of this type of
alcohol can result in vehicle performance deteriora-
tion and damage critical parts in the fuel system
components. Fuel system damage and performance
problems, resulting from the use of gasolines
containing methanol, may not be covered by the
new car warranty.
Gasolines containing MTBE (Methyl Tertiary Butyl
Ether)
Unleaded gasolrne containrng
15% or less MTBE
may be used in your car. (Fuel containing MTBE
over 15% vol. may cause reduced engine per-
formance and produce vapor lock or hard starting.) RECOMMENDED

LUBRICANTS AND
LUBRICANT CAPACITIES TAB,&-
RECOMMENDED LUBRICANTS
Items
Engine Oil
Recommended lubricants
API classification SG or SGKD (For further details, refer to SAEviscosity number)
Manual Transaxle, Transfer
<AWD>
Rear Axle <AWD>
API classification GL-4 or higher, SAE 75W-85W
Refer to P.OO-37.
Automatic Transaxle
Power Steering
Brake and Clutch
Engine Coolant DIAMOND ATF SP or equivalent
Automatic transmission fluid “DEXRON II” Conforming to
DOT3 or DOT4
DIA-QUEEN LONG-LIFE COOLANT (Part No. 0103044) or High
qualitv ethvlene-qlvcol
antifreeze coolant
Door HingesEngine oil
1 TSB Revision