engine MITSUBISHI DIAMANTE 1900 Repair Manual

FUELSYSTEM 5-9
p See Figures 37, 38, 39, 49, and 41
REMOVAL& INSTALLATION
1. Properly relieve the fuel system pressure as
outlined earlier in this section.
2. Remove the vacuum hose from the fuel pres-
sure regulator.
3. Disconnect the fuel return hose from the
pressure regulator.
Fig. 33 Unplug the fuel injector connector
, Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not apow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
I ,“~“*I.“. ..-.. * . ..” ._“. .-... To install:
I
Fig. 36 If the correct “noid” light flashes
while the engine is running, the injector dri-
ver circuit inside the PCM is working 5. Replace the O-ring on fuel pressure regulator
with a new one and coat it lightly with clean, thin oil.
6. Insert the regulator straight into the rail, then
chl . . . . . * * . . , .
xk mat n can oe rorarea rreery. 4. Remove the fuel regulator retainer bolts or re-
move the retaining snapring, then remove the fuel rrwkdnr frnm the fl~el rail
91055pu2 Fig. 35 Plug the correct “noid” light directly
into the iniector harness connector
I I I , r,
If it does not rotate smoothly, remove it
and inspect the O-ring for deformation or
damage.
7. When properly installed, align the mounting
holes. If equipped, install and tighten the retaining
bolts to 8 ft. Ibs. (11 Nm). If equipped, install the reg-
ulator retaining snapring.
8. Connect the fuel return hose to the pressure
regulator.
9. Install the vacuum hose to the fuel pressure
regulator.
10. Connect the negative battery cable and pres-
surize the fuel system. Inspect for leaks.
1 ret;rnline ~ . . g315sp10 1 1 ~~~.~~~s~~~~~u~s,“p”“““’ the hose? 1 Fig 37 Remove the hose clamp on the fuel
Fig. 39 Remove the vacuum hose from the
pressure regulator Fig. 40 Remove the regulator-to-fuel rail re-
taining bolts, then remove the pressure reg-
ulator from the fuel rail

FUELSYSTEM 5-11
93155gZi Fig. 46 Fuel tank and related components exploded view-1997-98
Mirage
Vapor hose
Filler
hose
Fig. 48 Connection of the vapor and filler hoses-1990-93 FWD Galanl Qt. 49 Fuel tank and related components-1990-93 FWD Galant
1990-92 Mirage
p See Figure 44
REMOVAL &INSTALLATION
Fuel injection systems remain under pres-
sure after the engine has been turned OFF.
Properly relieve fuel pressure before discon-
necting any fuel lines. Failure to do so may
result in fire or personal iniury.
*Cover all fuel hose connections with a
shop towel, prior to disconnecting, to prevent
splash of fuel that could be caused by resid-
ual pressure remaining in the fuel line. Fig. 47 Fuel tank and related components exploded view-1999-00
1996 moclab>
1. Properly relieve the fuel system pressure us-
ing proper procedures. Disconnect the negative bat-
tery cable
2. Raise the vehicle and support safely.
3.
Dram the fuel from the fuel tank Into an ap-
proved container.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin- guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
4. Lower the tank slightly and detach any re-
maining electrical or hose connectors at the fuel tank.
5. Remove the fuel tank from the vehicle as de-
scribed In this section.
6 Remove the five nuts securing the fuel pump
to the fuel tank and remove the pump assembly.
To install:
7. Install fuel pump into fuel tank, with new
packing gasket, and tighten mounting nuts.
8. Install the fuel tank into the vehrcle. Refer to
the procedure in this section.

FUELSYSTiM 5-13
1. BODY HARNESS CONNECTION
2 HOSE CONNECTION
3 PURGE HOSE
4 VAPOR HOSE
5 VENT HOSE
6 FllLER HOSE
7 PIPE ASSEMBLY
8. BAND ASSEMBLY
9 FUEL TANK ASSEMBLY
10. DIFFERENTIAL PRESSURE
SENSOR
11 FUEL HARNESS
12 HIGH-PRESSURE FUEL HOSE 1; ;;JL RETURN HOSE
15 FUEL PUMP MODULE
16 FILLER NECK
17 FUEL CAP
IS REINFORCEMENT
19 PACKING
20 VAPOR HOSE
21 SEPARATOR ASSEMBLY
22 VAPOR HOSE
23 FUEL CHECK VALVE ASSEMBLY
24 FUEL FILLER NECK ASSEMBLY
Fig. 54 Fuel tank and related components-1999-00 Galant
:ia. 55 Fuel tank and related components-1992-96 Diamante
11. Align the 3 projections on packing with the
holes on the fuel pump and the nipples on the pump
facing the same direction as before removal.
12. Install the holdrng bolt through the bottom of
the tank. Make sure the gasket on the bolt is replaced
and is not pinched during installation. Torque to 10
ft. Ibs. (14 Nm).
1 PatkIng brake cable COnneCtlo” 11
2 Fuel tank “.qm hose
12 Fuel fllk, neck
3 “apot hose 13 Fuel filler assembly
4 Pressure hose 14
5 Vapor hose COnneCflOn Fuel p,pe
6 Fuel pump am gauge assembly
7 Vapor hose
8 Valve assembly
9 Fuel mer cap
10 FllkY hose
:ig. 56 Fuel tank and related components-1997-00 Diamante 93155g15
cal harness of the fuel gauge unit to allow for the fuel
pling. Lower the lateral rod and suspend from the
tank to be lowered slightly. If not, label and discon-
axle beam using wire.
nect the electrical harness at the fuel gauge unit.
6. Detach the high pressure fuel line connector 9. Remove the six retaining bolts and gasket
from the base of the tank.
at the pump.
10. Remove the fuel pump assembly.
7. Loosen self-lockinq nuts on tank suooort
To install: straps to the end of the stud bolts.
8 Remove the right side lateral rod attaching
bolt and drsconnect the arm from the right body cou- *If the packing material is damaged or de-
formed, replace it with new packing.
7923PG79 :ig. 57 Proper method of supporting real
rxhaust system-Diamante 3.01 engine

.
5-16 FUELSYSTEM
6. Disconnect the return hose and the high
pressure fuel hose.
7. Using special tool MB991480 or equivalent,
remove the fuel pump retaining cap and remove the
pump assembly.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
To install:
*If the packing material is damaged or de-
formed, replace it with new packing.
8. Install the packing to the fuel tank.
9. Install the fuel pump assembly to the tank
and align the mating marks on the pump and the
floorpan.
10. Tighten the fuel pump retaining cap using
tool MB991480 or equrvalent.
11. Connect the high pressure hose, return hose
and the fuel tank wirmg.
12. Connect the negative battery cable.
13. Check the fuel pump for proper pressure and
inspect the entire system for leaks.
14. Apply sealant to the access cover and install
the cover.
15. Install the rear seat cushion.
TESTING
1. Relieve fuel system pressure.
2. Disconnect the battery negative cable.
3. Disconnect the fuel hrgh pressure hose at the
delivery pipe side.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
alosion.
4. Connect a fuel pressure gauge to tools
MD998709 and MD998742 or exact equivalent, with
appropriate adapters, seals and/or gaskets to prevent
leaks during the test. Install the gauge and adapter
between the delivery pipe and high pressure hose. In-
stall carefully to prevent leaks.
5. Connect the negative battery cable.
6. Apply battery voltage to the terminal for fuel
pump activation (located in the engine compartment)
to run the fuel pump, and check for leaks.
7. Start the engine and run at curb idle speed.
8. Measure the fuel pressure and compare to
the specifications listed in the chart in Section 1.
9. Locate and disconnect the vacuum hose run-
ning to the fuel pressure regulator. Plug the end of
the hose and record the fuel pressure again. The fuel
pressure should have increased approximately IO
psi. 10. Reconnect the vacuum hose the fuel pressure
regulator. After the fuel pressure stabilizes, race the
engine 2-3 times and check that the fuel pressure
does not fall when the engine is running at idle.
il. Check to be sure there is fuel pressure in the
return hose by gently pressing the fuel return hose
with fingers while racing the engine. There will be no
fuel pressure in the return hose when the volume of
fuel flow is low.
12. If fuel pressure is too low, check for a
clogged fuel filter, a defective fuel pressure regulator
or a defective fuel pump, any of which will require re-
placement.
13. If fuel pressure is too high, the fuel pressure
regulator is defective and will have to be replaced or
the fuel return is bent or clogged. If the fuel pressure
readmg does not change when the vacuum hose is
disconnected, the hose is clogged or the valve is
stuck in the fuel pressure regulator and it will have to
be replaced.
14. Stop the engine and check for changes in the
fuel pressure gauge. It should not drop. If the gauge
reading does drop, watch the rate of drop. If fuel
pressure drops slowly, the likely cause is a leaking
injector which will require replacement. If the fuel
pressure drops immediately after the engine is
stopped, the check valve in the fuel pump isn’t clos-
ing and the fuel pump will have to be replaced.
15. Relieve fuel system pressure.
16. Disconnect the high pressure hose and re-
move the fuel pressure gauge from the delivery pipe.
17. Install a new O-ring in the groove of the high
pressure hose. Connect the hose to the delivery pipe
and tighten the screws. After Installation, apply bat-
tery voltage to the terminal for fuel pump activation to
run the fuel pump. Check for leaks.

6-2 CHASSIS ELECTRICAL
) See Figure 1
For any 12 volt, negative ground, electrical system
to operate, the electricity must travel in a complete
circurt. This simply means that current (power) from
the posibve (t) terminal of the battery must eventu-
ally return to the negative (-) terminal of the battery.
Along the way, this current will travel through wires,
fuses, switches and components. If, for any reason,
the flow of current through the circuit is interrupted,
the component fed by that circuit will cease to func-
tion properly.
Perhaps the easiest way to visualize a circuit is to
think of connecting a light bulb (with two wires at-
tached to it) to the battery-one wire attached to the
negative (-) terminal of the battery and the other wire
to the positive (t) terminal. With the two wires touch-
ing the battery terminals, the circuit would be com-
plete and the light bulb would illummate. Electricity
would follow a path from the battery to the bulb and
back to the battery. It’s easy to see that wrth longer
wires on our light bulb, it could be mounted any-
where. Further, one wire could be fitted with a switch
so that the light could be turned on and off.
The normal automotive circuit differs from this
simple example in two ways, Frrst, instead of having
a return wire from the bulb to the battery, the current
travels through the frame of the vehicle. Since the
negative (-) battery cable is attached to the frame
(made of electrically conductive metal), the frame of
the vehicle can serve as a ground wire to complete
the circuit. Secondly, most automotive circuits con-
tain multiple components which receive power from a
single circuit. This lessens the amount of wire
needed to power components on the vehicle.
HOW DOES ELECTRlClTYWORK:THE
WATER ANALOGY
Electricity is the flow of electrons-the subatomic
particles that constitute the outer shell of an atom.
Electrons spin in an orbit around the center core of
RETURN
RETURN
CONDUCTOR
CONDUCTOR
GROUND
GROUND
lccs2w
Fig. 1 This example illustrates a simple cir-
cuit. When the switch is closed, power from
the positive (t) battery terminal flows
through the fuse and the switch, and then
to the light bulb. The light illuminates and
the circuit is completed through the ground
wire back to the negative (-) battery termi-
nal. In reality, the two ground points shown
in the illustration are attached to the metal
frame of the vehicle, which completes the
circuit back to the battery
an atom The center core is comprised of protons
(positive charge) and neutrons (neutral charge). Elec-
trons have a negative charge and balance
out the
positive charge of the protons. When an outside force
causes the number of electrons to unbalance the
charge of the protons, the electrons will split off the
atom and look for another atom to balance out. If this
imbalance is kept up, electrons will continue to move
and an electrical flow will exist.
Many people have been taught electrical theory
using an analogy with water. In a comparison wrth
water flowing through a pipe, the electrons would be
the water and the wire is the pipe.
The flow of electricity can be measured much like
the flow of water through a pipe. The unit of measure-
ment used is amperes, frequently abbreviated as
amps (a). You can compare amperage to the volume
of water flowing through a pipe. When connected to a
circuit, an ammeter WIII measure the actual amount of
current flowing through the circuit. When relatively
few electrons flow through a circuit, the amperage is
low. When many electrons flow, the amperage is
high.
Water pressure is measured in units such as
pounds per square inch (psi); The electrical pressure
is measured in unrts called volts (v). When a volt-
meter is connected to a circuit, it is measuring the
electrical pressure.
The actual flow of electricity depends not only on
voltage and amperage, but also on the resistance of
the circuit The higher the resistance, the higher the
force necessary to push the current through the cir-
cuit. The standard unit for measuring resistance is an
ohm. Resistance in a crrcuit varies dependmg on the
amount and type of components used in the circuit.
The main factors which determine resistance are:
l Material-some materials have more resis-
tance than others Those with high resistance are said
to be insulators Rubber materials (or rubber-like
plashcs) are some of the most common insulators
used in vehicles as they have a very high resistance
to electricity Very low resistance materials are said to
be conductors. Copper wire is among the best con-
ductors. Silver is actually a superior conductor to
copper and is used in some relay contacts, but its
high cost prohibits its use as common wiring Most
automotive wiring is made of copper.
l Size-the larger the wire size being used, the
less resistance the wire will have. This IS why com-
ponents which use large amounts of electricity usu-
ally have large wires supplying current to them.
l Length-for a given thickness of wire, the
longer the wire, the greater the resistance. The
shorter the wire, the less the resistance. When deter-
mining the proper wire for a circuit, both size and
length must be considered to design a circuit that can
handle the current needs of the component.
l Temperature-with many materials, the higher
the temperature, the greater the resistance (positive
temperature coefficient). Some materials exhibit the
opposite trait of lower resistance with higher temper-
atures (negative temperature coefficient). These prin-
ciples are used in many of the sensors on the engine
OHM'S LAW
There is a direct relationship between current,
voltage and resistance. The relationship between cur- rent, voltage and resistance can be summed up by a
statement known as Ohm’s law.
Voltage (E) is equal to amperage (I) times resis-
tance (R): E=l x R
Other forms of the formula are R=E/I and I=E/R
In each of these formulas, E is the voltage in volts,
I is the current in amps and R IS the resistance in
ohms. The basic point to remember is that as the re-
sistance of a circuit goes up, the amount of current
that flows in the circuit will go down, if voltage re-
mains the same.
The amount of work that the electricity can perform
is expressed as power. The unit of power is the watt
(w). The relationship between power, voltage and
current
IS expressed as:
Power(w) is equal to amperage (I) times voltage
(E): W=l x E
This is only true for direct current (DC) circuits:
The alternating current formula is a tad different, but
since the electrical circuits in most vehicles are DC
type, we need not get into AC circuit theory.
POWERSOURCE
Power is supplied to the vehicle by two devices:
The battery and the alternator. The battery supplies
electrical power during starting or during periods
when the current demand of the vehicle’s electrical
system exceeds the output capacity of the alternator.
The alternator supplies electrical current when the
engine is running
Just not does the alternator supply
the current needs of the vehicle, but it recharges the
battery.
The Battery
In most modern vehicles, the battery is a lead/acid
electrochemical device consisting of six 2 volt sub-
sections (cells) connected in series, so that the unit
is capable of producing approximately 12 volts of
electrical pressure. Each subsection consists of a se-
ries of positive and negative plates held a short dis-
tance apart in a solutron of sulfuric acid and water.
The two types of plates are of dissimilar metals,
This sets up a chemrcal reaction, and it is this reac-
tion which produces current flow from the battery
when Its positive and negattve terminals are con-
nected to an electrical load. The power removed from
the battery is replaced by the alternator, restoring the
battery to its original chemical state.
The Alternator
On some vehicles there isn’t an alternator, but a
generator. The difference IS that an alternator sup-
plies alternating current which is then changed to di-
rect current for
use on the vehicle, while a generator
produces direct current. Alternators tend to be more
efficient and that is why they are used.
Alternators and generators are devices that consist
of coils of wires wound together making big electro-
magnets. One group of coils spins within another set
and the interaction of the magnetic fields causes a
current to flow. This current is then drawn off the
coils and fed into the vehicles electrical system.

6-8 CHASSIS ELECTRICAL
Fig. 16 Exploded view of the blower motor
and related components-1990-92 Mirage
11. Install the resistor and the glove box assem- W 12. Install the right side instrument panel under-
cover panel.
13. Connect the negative battery cable.
1990-93 Galant
# See Figure 19
1. Disconnect the negative battery cable.
2. Remove the glove box stopper.
3. Swing the glove box door open all the way
and remove the bottom retainina screws. Remove the
glovebox
1 Under cover 4993 models, 1
2 Glove box
3 corner pane,
4 Glove box frame
5 RBSlStOr
93156~23
Fig. 17 Exploded view of the blower motor
and related components-1993-96 Mirage
4. Remove the dash undercover. Note that some 9. Detach the electrical connector from the fan
ot the screws and retainers are concealed behind
small covers which must be removed.
5 Remove the heater duct for the passenger’s
feet.
6. Carefully detach the lo-pin connector run-
ning to the back of the glove box frame. Disconnect
the single wire (glove box switch) running to the back
of the glove box frame.
7. Remove the four bolts holding the glove box
frame and remove the frame.
8. Disconnect the small air hose running from
the fan motor to the fan housing. motor.
10. Remove the three small bolts holding the mo-
tor to the housing, then remove the motor and fan.
To install: 11. Check the inside of the case carefully: any de-
bris can snag the fan and cause noise or poor airflow.
12. Inspect the gasket (packing) under the motor
and replace it if cracked or damaged. Reinstall the fan
and motor to the case and Install the retaining bolts.
13. Attach the air hose and electrical connector.
14. Install the glove box frame and connect both
the lo-pin and sinqle pin connectors properly.
15. Install the heater duct
16. Install the undercover, taking care to insure it
is in place and all the fasteners are secure.
17. Install the glove box and its stopper.
18. Connect the negative battery cable.
:ig. 19 Exploded view of the blower motor and related components-1990-93 Galant
1. stopper
‘2 Glove box
3 Under cover
4 Foot shower duct
5 Connector for MFI control relay and ,
connector for glove box swtch
6 Glove box frame
7 Cowl side trim
8 Engine control module
9 Evaporator lnstallatlon bolts, nuts and
clips or
duct mounting clips Kvehlcles wthout air
condltionlng>
Fig. 18 Exploded view of the blower motor
and related components-1997-00 Mirage
--.
8
12’ Hose
Blower assemblv
Blower motor assembly
Packtng
;;c, tnstallatlon nut
Blower motor and fan assembly
Blower case
1994-00 Galant
) See Figures 20 and 21
1. Disconnect the negative battery cable.
2. Remove the three instrument panel under-
cover mounting screws and remove the cover.
3 If equipped with A/C, unplug and remove the
compressor module.
4. Detach the electrical connector from the fan
motor.
5. Remove the three small bolts holding the
motor to the housing and remove the motor and fan.
; y&M 5 m- M ,RC m .3RcuP
3 lulomafs corn-r ECU :2%brtr-Mbi&C>
.“eM *nn mi
1 slmhn.m”m,n 8 ~y~tipJ*-m-=%9 md
S sa*n”nlUSW
931561
Fig. 20 Exploded view of the blower mote
and related comoonents-1994-98 Galan

640 CHASSIS ELECTRICAL
careful not to allow anything to come in contact with
the air bag unit.
16. Remove the glove box lamp assembly.
17. Remove the remaining instrument panel
mounting screws and remove the instrument panel
from the vehicle.
18. Remove the left side foot shower ductwork,
lap cooler duct and center duct.
19. Remove the front and center reinforcements
and center stay assembly.
20. Remove the air distribution duct assembly.
21. Detach all connectors from heater-box-
mounted items.
22. Remove the heater box mounting screws and
nut, then remove the unit from the vehicle.
23. Disassemble on a workbench. Remove the
heater core from the heater case.
To install:
24. Thoroughly clean and dry the inside of the
case and install the heater core and all related parts.
25. Install the heater unit to the vehicle and install
the mounting screws and nut. Be sure the evaporator
case and heater case are fitted together properly. At-
tach all connectors to heater-box-mounted items.
26. Install the air distribution duct assembly. In-
stall the front and center reinforcements and center
stay assembly.
27. Install the center duct, lap cooler duct and left
side foot shower duct.
28. Install the instrument panel and mounting
screws.
29. Install the glove box lamp assembly.
30. Secure the steering column and attach all
steering column connectors.
31. Install the speedometer cable adapter to the
instrument panel.
32. Install the instrument cluster and the instru-
ment cluster bezel.
33. Install the speakers to the top of the instru-
ment panel.
34. Install the cup holder.
35. Install the climate control system control
head.
36. Install the stereo entertainment system and
bezel.
37. Install the screw below the glove box assem-
bly, and the entire glove box unit.
38. Install the steering column covers.
39. Install the knee protector support bracket, the
protector and the decorative plugs.
40. Install the console and the ashtray. 41. Install the right side foot shower duct.
42. Install the passenger side undercover.
43. Connect the heater hoses to the core tubes.
44. Fill the cooling system.
45. Connect the negative battery cable and check
the entire climate control system for proper operation
and leaks.
Galant
# See Figures 26, 27, and 28
1. Disconnect the negative battery cable.
2. Disarm the air bag. Refer to the procedure
earlier in this section.
3. With the engine cold, set the temperature
control lever to the FULL HOT position. Drain the en-
gine coolant.
4. Disconnect the coolant hoses running to the
heater pipes at the firewall.
5. Remove the center console.
6. Remove the heater cover.
7. Remove the steering wheel.
8. Remove the small steering column panel.
9. Remove the undercover.
10. Remove the upper and lower steering column
covers and detach the wiring connectors.
11. Remove the instrument cluster hood.
12. Remove the mounting screws for the instru-
ment cluster.
13. Pull the cluster out and disconnect the
speedometer adapter behind the cluster. Remove the
cluster.
14. Remove the floor console and the under-
frame.
15. Disconnect and remove the air duct, lap
heater duct, side defroster duct and the vertical de-
froster duct.
16. Remove the glove box.
17. Remove the ashtray and its mount. Discon-
nect the light wiring before removing.
18. Remove the heater control faceplate.
19. Remove the heater control panel and discon-
nect its harness.
20. Remove the right side undercover from the
instrument panel and remove the underframe.
21. On the left side of the instrument panel, re-
move the fuse box cover and unbolt the fusebox from
the instrument panel.
22. Remove the front pillar (windshield pillar
trim) from each pillar.
23. Remove the kick panel trim from each side.
Fig. 26 Exploded view of the heater core and
related components-1990-93 Galant
:IQ. 27 Exploded view of the heater core and
-elated components-1994-98 Galant 24. Loosen the defroster garnish, disconnect the
photo sensor wiring and remove the garnish and de-
froster grille.
25. Remove the grille for the center air outlet.
26. Remove the bolts holding the steering col-
umn bracket to the instrument panel.
27, Remove the center reinforcement bracket.
28. On the left side, remove the retaining nuts
holding the instrument panel underframe to the body.
29. On the right side, remove the underframe re-
taining bolts. Note that the bolts are different; the
flanged bolt must be correctly reinstalled.
30. Remove the remaining nuts and bolts holding
the instrument panel. As the instrument panel comes
loose, label and disconnect the wiring harnesses.
Carefully remove the instrument panel.
31. If equipped with automatic climate control,
remove the power control unit on the lower front of
the heater unit.
32. Remove the duct joint between the heater unit
and evaporator case (with air conditioning) or blower
assembly (heater only).
33. Carefully separate the vacuum hose harness
at the connector.
34. Remove the heater unit from the vehicle.
35. To remove the heater core, first remove the
cover from the water valve. Disconnect the links and
remove the vacuum actuator.
36. Remove the clamps and slide the heater core
out of the case. Remove the water valve after the core
is removed.
37. With the case removed, the heater core may
be changed after the water valve is removed. Remove
the plastic cover, remove the clamps and hose and
remove the water valve.
To install:
38. Thoroughly clean and dry the inside of the
case. Install the core and the water valve, using new
hose or clamps.
39. Install the vacuum actuator and the connect-
ing link. Put the cover on the water valve.
40. Install the heater unit and tighten the mount-
ing bolts.
41. Carefully attach the vacuum hose connector
to the vacuum harness. Make certain the hoses mate
firmly and securely.
42. Install the heater cover, then install the center
console.
43. Install the duct joint between heater and evap-
orator or blower.
44. Install the power control unit and carefully
connect the links and rods.
Fig. 28 Exploded view of the heater core and
related components-1999-00 Galant

CHASSIS ELECTRICAL 6-27
1. Remove the fuse box cover.
2. lnsoect the fuses to determine which is faulty.
REPLACEMENT 3. Grasp the fuse and remove it from the fuse
box. Never exceed the amperage rating of a blown
4. Inspect the box terminals and clean if cor- fuse. If the replacement fuse also blows,
It See Figures 120 thru 127 check for a problem in the circuit.
roded. If any terminals are damaged, replace the ter-
Fuses are located either in the engine Compartment minals. ’
5. Plug in a new fuse of the same amperage rat- 6. Check for proper operation of the affected
or passenger compartment fuse and relay panels. If a component or circuit.
fuse blows, at least one, but possibly several compo- ing.
ients/circuits will not function properly.
Fig, 120 The engine compartment fuse box
is typically located adjacent to the
battery
Fig. 122 The engine compartment fuse box
contains a combination of fuses, maxi-
fuses, relays, and diodes. Most can be re-
moved by simply pulling upward
I Do not replace blown fusible links with stan-
dard wire. Only fusible type wire with Hy
palon insulation can be
used, or damage to
the electrical system will occur!
A number of fusible links are used on these vehi-
cles to protect wiring and electrical components.
There is a collection of fusible links located near the
battery. These are referred to as the main fuse links. A
second group of links are located in the box with the
dedicated fuses. If replacement of a fuse link is re-
quired, use the exact same link as removed.
When a fusible link blows it is very important to
Fig. 121 Grasp the engine compartment find out why. They are placed in the electrical system
. ’ ‘“‘,+“” 1 ous wiring failures. fuse box cover and pull It straight up to re- for protection against dead shorts to ground, which
move it can be caused by electrical component failure or vari-
Fig. 123 The interior fuse box is located un-
der the driver’s side of the instrument panel
Fig. 125 Typically a fuse removal tool is lo-
cated in the fuse box to aid in removing the
fuses Fig. 126 Grasp the fuse with the removal
tool and pull it straight out to remove it Fig. 124 Grasp the interior fuse box cover,
depress the retaining
tabs and lift up to re-

.
6-28 CHASSIS ELECTRICAL
Do not just replace the fosible link to correct
a problem! RESETTlNGAND/OR REPLACEMENT REPLACEMENT
When replacing all fusible links, they are to be re-
placed with the same type of prefabricated link avail-
able from your vehicle manufacturer. Circuit breakers are located inside the fuse panel.
They are automatically reset when the problem cor-
rects itself, is repaired, or the circuit cools down to
allow operation again. The turn signal and hazard flasher unit is located
in the interior fuse panel located under the driver’s
left side knee protector. They are replaced by simply
pulling them straight out. Note that the prongs are
arranged in such a way that the flasher must be prop-
erly oriented before attempting to install it. Turn the
flasher until the orientation of the prongs is correct
and simply push it firmly in until the prongs are fully
engaged.
1990-92 Mirage fuse location chart
,-Lw 1993-96 Mirage fuse location chart
93156glO
1997-00 Mirage passenger compartment fuse
location chart
1997-00 Mirage engine compartment fuse location chart
Engine compartment
9ight side Engine compartment
I
I I 12 Power window
Control 30A
13
@I Radiator fan motor 30A
14 E-J
Headllghls 40A
15
;2” lgnttlon switch 30A NO Symbol Electrical system Capacrty
16 0 Fuse(+B) 60A
Some fuses may not be installed on your vehicle,
depending on the vehicle model or specihcations.
Identification of fuse
i0A Red

CHASSIS ELECTRlCiL 6-29
1990-93 Galant fuse location chart Fuse Load Capacities
l-15A Cigarette hghter
Z-10A Radm
3-10A Heater relay
4-10A (E P S.)
5-10A Belt
6-10A Turn signals
7-10A Meters
6-10A Horn
9-15A Wiper
lo-10A (4 A/T)
ll-15A (Door locks)
12-10A Dome hght, clock
13-10A Backup hghts
14-15A Stop hghts
15-30A Heater
16m20A (Sunroof)
17-20A (ECS)
1% spare fuse
ldentlfxation of fuse
10A Red
15A Light blue
20A Yellow
30A Green
93156g13
1994-98 Galant fuse location chart
Passenger compartment
1. 15A StoplIghts
2- 10A Turn signals
3- 1 OA Backup Itghts
4. 30A Heater
5. i5A Wiper
6- IOA Meters
7. 30A Rear wndow defogger
;: fo& fl$oof)
IO- 15A Cagaretle lighler
11. 10A Heater relay
12. IOA Horn
13. Spare fuse
( ): II so equipped
A!T Automallc transaxle Engine compartment
Fusible links
I- 30A Ignition swlch
2. 50A (ABS)
3. 30A Radiator fan
4. 40A Headkghts
5. 30A Power wndow
Fuse
6- 30A (ABS)
7. 30A Condenser fan
6. 10A Hazard
9. 20A Engine
10. 10A (Au conditioning)
11. 10AHigh beam
12. 10ATall lkghts
13. 10A (Theft)
14. i5A Fog lkghls
( ): If so equipped
93156g14
1999-00 Galant fuse location chart