spark plugs 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

00-38GENERAL- Scheduled Maintenance Table
SCHEDULED MAINTENANCE
TABLEMOOOA-
SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER
VEHICLE PERFORMANCE
Inspection and Services should be performed any time a malfunction is ob\
served or suspected. Retain receipts
for all vehicle emission services to protect your emission warranty.
Kilometers in Thousands 24 48 72 80 96
No.Emwsron Control System MaintenanceService IntervalsMileage in Thousands 15 30 45 50 60
1Check Fuel System (Tank, Line and Connections and Fuel Tank Filler Tube\
Cap) orXfor Leaks Every 5 Years
2Check Fuel Hoses Every 2 Years for leaks or damage orXX
3Replace Air Cleaner ElementatXX
4Replace Spark PlugsatXX
GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE
L
1
1
1
1
1
i
IO.General Maintenance
Service Intervals
7Engine Oil
8
9
IO
III2
I3
14
15
I6
I71
8
L
I
I
I
I
I\
I
II
I
I
;(
Kilometers in Thousands 24 48 72 80 96
Mileage in Thousands 15 30 45 50 60 Timing
Belt (Including the Balancer
Belt)
ReplaceatX
Drive Belt (for Water Pump
Inspect for tensionatXXand Generator)
Non-TurboChange Every Year Every 12,000 kmOr (7,500 miles)
Turbo Change Every 6 Months Every 8,000 km
Or (5.000 miles
)
II
Non-Turbo
Change Every Year or X X XX
Every 16,000 kmOr (10,000 miles)
Engine Oil Filter
TurboChange Every Year
Manual Transaxle Oil 4utomatrc
Transaxle Fluid Inspect Oil Level
at
XX
Inspect Fluid Level Every Yearor X X XX
Change FluidatXX
Engine Coolant
Replace Every 2 YearsOrI 1x1 I IX
Disc Brake Pads1 inspect for Wear Every Yearor/XlXlXl I
X
3rum
Brake Linings
and Rear iNheel
Cylinders Inspect for Wear and Leaks Every 2 Years
or
XX
3rake HosesCheck for Deterioration or Leaks Every Year or X X XX
3all Joint and SteeringInspect for Grease Leaks and-inkage
Seals
Damage Every 2 Years
Or I/ XII x
Irive Shaft Boots Inspect for Grease Leaks and Damage Every Year or XXXX
3ear Axle <AWD>Change OilatXX
Exhaust System (Connectron>ortion of Muffler, Pipings and
Check and Service as Required Every 2 YearsConverter Heat Shields)
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00-40GENERAL- Maintenance Service
Caution
The air cleaner cover should be removed carefully,
because it includes the volume air flow sensor.
/
(5) Remove the air cleaner element.(6) Set a new air cleaner element and install the air cleaner cover.
I hose,I
Plug gapgauge
Measurementrection01
If
0110182 <Turbo>
(1) Disconnect the volume air flow sensor connector.
(2) Disconnect the breather hose, purge hose, by-pass air hose and boost hose connections.
(3)Remove the air intake hose on the air cleaner cover side
and then move the air intake hose to the front of the air
cleaner body.
(4) Unclamp the air cleaner cover.
Caution
Care must be taken when removing the air cleaner
cover, because the volume air flow sensor is at-
tached.
(5) Take out the air cleaner element.
(6) Check the air cleaner element for dirt or clogging; if necessary, clean by using compressed air.
(7) Replace the air cleaner element if the dirt or clogging
is
serious.
(8) Insert the element into the air cleaner body and install the air cleaner cover.
(9) Install the air intake hose.
(10)Connect the breather hose, purge hose, by-pass air
hose and boost hose.
(11
)Connect the volume air flow sensor connector.
4. SPARK PLUGS (Replace)
h%OSAOFa
1. Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission
level.
Therefore, they should be replaced periodically with
new ones.
2. The new plugs should be checked for the proper gap.
Spark plug gap:<Non-Turbo>
<Turbo> 1.0-1.1
mm (.039-.043

in.)
0.7-0.8 mm (.028-.031 in.)
3.Install the spark plug and tighten to 20-30 Nm (15-21
ftlbs.).
5. TIMING BELT (Replace)moossAsa
Replace the belt with a new one periodically to assure
proper engine performance.
For disassembly and reassembly procedures, refer to
GROUP 11 -Service Adjustment Procedures.
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II-8ENGINE <SOHC> - Service Adjustment Procedures
8 VALVE
W Tlmlng belt side
il6
16
727
(3) If any abnormal noise IS not eliminated by racing, check the
lash adjuster.
@ Stop the engine.
@ Set the engine so that cylinder No. 1 is positioned at
the top dead centre of the compression.
@ Press the rocker arm at the area indicated by the+ arrow mark to check whether the rocker arm is lowered
or not.
@ Slowly turn the crankshaft 360 degrees clockwise.
@ In the same procedure as Step 0, check the rocker
arm at the area indicated by the
0 arrow mark.
@ If the rocker arm lowers easily when the part directly
above the rocker arm lash adjuster is pressed, the lash
adjuster is defective and must be replaced. When re-
placing the lash adjuster, bleed the air from all adjus-
ters and then assemble them. Then inspect with proce-
dures
@ to 0, and confirm that there are no abnormal-
ities
NOTE
lThe lash adjuster can be accurately checked for de-
fects with the leak down test.
l Refer to the engine service manual for the leak down test and lash adjuster air bleeding procedure.
If the rocker arm is extremely hard when pressed
down, the lash adjuster is normal, so look for a different
cause of abnormal sound.
COMPRESSION PRESSURE CHECK
MllFFAL
(1) Before inspection, verify that the engine oil, starter motor and battery are normal. Then, perform the following.
l Engine coolant temperature:
80- 95°C
(176- 203°F)
l Lights, electric cooling fan and accessories: OFF
l Transaxle:
P range
0 Steering wheel: Neutral position
(2) Disconnect the spark plug cable.
(3) Remove all the spark plugs
(4) Disconnect the connector of the distributor.
NOTE
This will prevent the engine control module from controll- ing the ignition and fuel injection.
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II-IOENGINE <SOHC> - Service Adjustment Procedures
(3) Remove the PCV hose from the PCV valve and attach a
vacuum gauge.
(4) Check that the negative pressure at the intake manifold
during idle revolution is normal.
Standard value:
(8 VALVE>Approx. 500 mmHg (20 in.Hg)
<16VALVE>Approx. 510 mmHg (20 in.Hg)
(5) If outside the standard value, isolate the cause by referring
to the following table and repair the fault.
Symptom
CauseRemed
y
l The vacuum gauge reading is less than l Ignition timing is retarded.l Adjust the ignition timing.
standard value, but the pointer is
stable.
l The vacuum gauge pointer swings l The gas mixture is excessivelyl Check
Multiport Fuel Injection
slowly.rich.system.
l The vacuum gauge pointer drops irre-
l The gas mixture is excessively
l Check
Multiport Fuel Injectiongularly.lean.system.
l The vacuum gauge pointer drops inter-
0 Incomplete close contact of in-0 Check and repair the valve.mittently to 30 to 160
mmHg
(1.2 to take and exhaust valve seats.
6.3 in.Hg).
l The vacuum gauge pointer drops sud-l Broken cylinder head gasketl ,Replace cylinder head gasket. denly
from the normal reading to 250 mmHg
(9.8 in.Hg). then returns to
normal.
/ OlR0175
condition.
Timina mark
‘timing mark._*-
Camshaft sprocket TIMING BELT TENSION ADJUSTMENT
(8 VALVE>MllFGCEa
There are 2 access holes in the timing belt front lower cover.
These can be used to readjust the tension of the timing belt by
the following procedure without removing the timing belt front lower cover. However, timing belt “B”, which drives the right
silent shaft, cannot be adjusted unless the cover is removed. (1) Turn the steering wheel all the way to the left.
(2) Remove the left side undercover panel.
NOTE
This work is done so that the crankshaft can be turned.
(3) Place a piece of wood against the engine oil pan and jac
k
up.(4) Remove the engine mounting bracket.
(5) Remove the timging belt front upper cover.
(6) Remove the four spark plugs.
(7) Turn the crankshaft clockwise and check the timing belt
(8) Turn the crankshaft clockwise and align the timing marks.
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ENGINE <SOHC> - Servioe Adjustment ProceduresII-II
Access
cover
,-
(0 a0
<
0 0
0 0
0
101 II0221
Access cover
Screwdriver slot
3EN075
(9) Remove the air conditioning drive belt and the generator drive belt.
(10)Removle the access covers. There are easily removed by
inserting a screwdriver into the slots indicated by the raised
arrows in the timing belt cover and twisting. (1l)lnset-t
the special tool (MD998051-01)
from the pivot side
access hole and loosen the tension spacer (with a tensioner lock nut on it) 1 to 2 turn.
Next insert a 14 mm socket wrench from the slot side
access hole and loosen the tensioner lock bolt 1 to 2 turn.
(12)Turn the crankshaft clockwise by two teeth of the camshaft
sprocket.
(13)First ticjhten the timing belt tensioner installation bolt (on
the
lo&er side), and then tighten the tensioner spacer
(upper side).
Caution
Be sure to tighten the bolt (lower side) first. lf the
tensioner spacer of pivot side is tightened first, the
tensioner will rotate with it and belt tension may
becorn; loose.
(14)lnstall the access cover. The access cover may be easily
installeNd by passing the hooks between the guides and
sliding it in.
(15)lnstall the air conditioning drive belt and generator drive
belt and adjust the slack. (Refer to P.l
l-l 2.)
(16)lnstall the timing belt front upper cover.
(17)lnstall the engine mounting bracket.
(18)lnstall the spark plugs.
(19)lnstall the left side undercover panel.
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ENGINE <DOHC>- Service Adiustment Procedures11-59
7 Go;;ikv position
switch
(11)Check that there is continuity between the closed throttle
position switch terminal and body.
NOTE
When there is continuity, a clearance will be created between the throttle lever and dash pot rod when the dash
pot rod is pressed lightly.
(12) When there is no continuity, lower the engine speed when the dash pot begins operation to within the standard value
tolerance. Make sure to create continuity between the
closed throttle position switch terminal and body.
COMPRESSION PRESSURE CHECK Ml 1 FFAL
(1) Before inspection, verify that the engine oil, starter motor
and battery are normal. Then, perform the following.
lEngine coolant temperature: 80- 95°C
(1 76- 205’F)
l Lights, electnc
cooling fan and accessories: OFF
0 Transaxle: P range 0 Steering wheel: Neutral position
(2) Disconnect the spark plug cable.
(3) Remove all the spark plugs.
(4) Disconnect the connector of the crankshaft position sensor.
NOTE
This will prevent the engine control module from controll- ing the ignition and fuel injection.
(5) Cover the spark plug holes with a cloth, etc., and crank the engine. Then verify that no foreign material sticks to the
cloth, etc.
Caution
1.During cranking, be especially careful of the spark plug
installing hole.
2. Very hot water, oil, fuel, etc., which may have entered
the cylinder somehow, will violently spout through the
spark plug hole if the compression is measured in the
entrapped state. This is
vex/ dangerous.
(6) Set up the compression gauge in the spark plug mounting
hole.
(7) Fully open the throttle valve, and cranking the engine.
measure the compression pressure.
Standard value: <Non-Turbo> Up to 1991: 1,350
kPa (192 psi) [250- 400 rpml
From 1992: 1,550
kPa (220 psi) [250-400 rpm]
<Turbo> 1 ,150 kPa (164 psi) [250- 400 rpml
Limit:
<Non-Turbo>
up to 1991: 960
kPa (137 psi) [250- 400 rpml
From 1992: 1 ,120 kPa (159 psi) [250- 400 rpml
CTurbo>
800
kPa (114 psi) [250- 400 rpml
(8) Measure the compression pressure of each cylinder. and verify that the pressure difference among the cylinders
is
less than the limit value.
Limit: max. 100
kPa (14 psi) TSB Revision
I

FUEL SYSTEM <SOHC-8 VALVE> -On-Vehicule Inspection of MFI Components13-49
VOLUME AIR FLOW SENSOR
@ ;;vonent
connector
Intake air amount
(Wsec)162451
Multipoh fuel
injection relay
Volume air flow sensor
/\2/\N
Harness side
connector
IHjhcillo)
1.10
f-i5V
Engine
control
module
MlOYFAA
J 6FU1394
OPERATION
l The volume air flow sensor is incorporated
within the air cleaner; it functions to convert the
amount of engine air intake to pulse signals of a
frequency proportional to the amount of engine air intake, and to input those/signals to the en-
gine control module. The engine control module
then, based upon those signals, calculates the amount to fuel injection, etc.
TROUBLESHOOTING HINTS
Hint 1:
If the engine sometimes stalls, try starting the en-
gine and shaking the volume air flow sensor har-
ness.
If the engine then stalls, incorrect or improper con-
tact of the volume air flow sensor connector is the probable cause.
Hint 2:
If, when the ignition switch is switched ON (but the
engine is not started), the volume air flow sensor
output frequency is any value other than zero, a
malfunction of the volume air flow sensor or of the
engine control module is the probable cause. Hint 3:
If idling is possible even though the volume air flow
sensor output frequency is deviated from the stand-
ard value, the cause is usually a malfunction other
than of the volume air flow sensor. l The power for the volume air flow sensor is
supplied from the multiport fuel injection relay
to the volume air flow sensor, and is grounded at the engine control module. The volume air
flow sensor, by intermitting the flow of the
5V
voltage applied from the engine control module,
produces pulse signals.
Examples:
(1) The flow of air within the volume air flow sensor is disturbed. (Air duct disconnection or clogged
air cleaner element)
(2) Incomplete combustion within a cylinder. (Malfunction of spark plugs, ignition coil, injec-
tors, compression pressure, etc.)
(3) Air is taken into the intake manifold through a leaking gasket, etc.
(4) Incomplete close contact of the EGR valve seat.
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FUEL SYSTEM <SOHC-8 VALVE>- On-Vehicule Inspection of MFI Components13-65
(1) Improper adjustment of the basic idling speed.
(2) Deposits adhering to the ttirottle valve.
(3) Air being taken into the intake manifold due to a gasket leak, etc.
OPERATION
ISC motor position sensor is a variable resistor type,
and is integrated in the
ISC motor system. The slid-
ing pin of
ISC motor position sensor is in contact
with the end of the plunger. Therefore, as the plun- ger moves, the internal resistance of
ISC motor pos-
ition sensor varies. This leads to the variation of the (4) Improper seating of the EGR valve seat.
(5) lmcomplete combustion within a cylinder. (Mal-
function of spark plugs, ignition coil, injectors,
compression pressure, etc.)
the plunger position of the
ISC motor system, and
sends the signal to ECM. ECM processes the
ISC
motor position sensor signal, idle signal, coolant
temperature signal, load signal (A/T &
A/C) and ve-
hicle speed signal to control the opening angle of
the throttle valve and revolution speed during
en-
output voltage. ISC motor position sensor detects gine idling.
TROUBLESHOOTING HINTS
Since idling is not controlled when ISC motor posi-
tion sensor is troubled, idling may not be evenly
maintained.
INSPECTION
Using Scan tool
FunctionItem No. Data display Inspection conditions Load conditions
Standard value
Data reading 15 Sensor detec-
. Engine coolant tempera-
Air conditioning 500- 1,300 mV
tion voltage
ture: 85-95’C (185-203°F)
switch: OFF
. Lights, cooling fan, electrical accessories: OFF Air conditioning 800-
1,800 mV. Transaxle: neutral (A/T
mod-
switch: ON
els: “P”
range)
1 Closed throttle position Air conditioning900- 1,900 mVswitch: ON (The compressorswitch: ON
clutch must be operating Select lever:
when the air conditioning shift to “D”
switch is ON.)
range.* Engine: running at idle
NOTEThe idle speed control motor position sensor output voltage may be about\
500 mV higher than indicated above when
the vehicle is new [driven approximately 500 km (300 miles) or less].
CautionBefore shifting the select lever to the “D” range, apply the brake\
s to prevent the vehicle from moving forward.
HARNESS INSPECTION
Measure the power supply voltage of
the idle speed control motor position
ei;;;it;;sco$ected
__...._ -.-
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13-90 FUEL SYSTEM <SOHC-8 VALVE>- On-Vehicule Inspection of MFI Components
INJECTORS
Fuel
Connector
Solenoid coil
Plunger
Needle valve -----I
InjectionFilter6FUO514
M13rrAA
Multiport
fuel injection relay
No.1 &j No.2& No.3& No,4+
tI
lFUO642
Engine control module connector
CJ=JW=U-I
0 1 LO636
OPERATION
l The
injectorsare electromagnetic-valve-
equipped injection nozzles that function to inject
fuel based upon injection signals from the
engine control module.
lBecause the surface area of the injection ports is
fixed and because the pressure of the fuel
relative to the pressure within the manifold is
also regulated to a fixed pressure, the amount of
fuel injection by injectors is determined by the
TROUBLESHOOTING HINTS
Hint 1:
If there is a problem with starting while the engine is
warm, perform the combustion test and check for leakage of the injectors.
Hint
2,
If the engine can’t be started, and the injectors are
not activated during cranking, the cause is probably
a malfunction such as described below, not with the
injectors.
(I) Malfunction of the circuit for supply of power to the engine control module, or of the ground cir-
cuit.
(2) Malfunction of the multiport fuel injection relay.
(3) Malfunction of the crankshaft position sensor and/or the camshaft position sensor.
Hint
3.
If there is a cylinder for which the idling condition
does not change when, during idling, the fuel length of time that the needle valve is open, or,
in other words, by the length of time of current
~-
flow to the solenoid coil.
lBattery power supply is supplied, by way of the
multiport fuel injection relay, to the injectors.
When the engine control module switches ON
the power transistor within the unit and current
flows to the solenoid coil, the injectors open and
fuel is injected.
injection of the injectors is cut off in sequence,
check that cylinder as described below.
(1) Check the injector and harness.
(2) Check the spark plugs and the high-tension
cable.
(3) Check the compression pressure. Hint 4:
If the injector activation time deviates from the
standard value even though the results of the
checking of the injector’s harness and of the injector itself are normal, the cause may be pressumed to
be one of the following,
(1) Incomplete combustion within the cylinder. (Malfunction of the spark plugs, the ignition coil,
the compression pressure, etc.)
(2) Incomplete close contact of the EGR valve seat.
(3) Increased engine resistance.
1 TSB RevisionI