engine MITSUBISHI DIAMANTE 1900 Repair Manual

DRIVETRAIN 7-13
27. Shde the transaxle rearward and carefully
lower it from the vehicle.
To install: 28. After the torque converter has been mounted
on the transaxle, install the transaxle assembly to the
engine. Install the mounting bolts and tighten to 35
ft. Ibs. (48 Nm).
29. Install the transaxle lower coupling bolt and
tighten to 21-25 ft Ibs. (29-34 Nm).
30. Connect the torque converter to the flexplate
and tighten the bolts to 33-38 ft. Ibs. (45-52 Nm).
31. Install the cover to the transaxle bellhous-
ing and tighten the mounting bolts to 7 ft. Ibs. (9
Nm).
32 Install the crossmember and tighten the front
mounting bolts to 65 ft. Ibs (88 Nm) and the rear
bolt to 54 ft. Ibs. (73 Nm) Install the front engine roll
stopper through-bolt and lightly tighten. Once the full
weight of the engine is on the mounts, tighten the ’
bolt to 42 ft. Ibs. (57 Nm),
33. Install the triangular stay bracket and tighten
the mounting bolts to 65 ft. Ibs. (88 Nm).
34. Install the halfshafts, using new circlips on
the axle ends.
When installing the axleshaft, keep the in-
board joint straight in relation to the axle, so
as not to damage the oil seal lip of the
transaxle with the serrated part of the half-
shaft.
35. Connect the tie rod and ball joints to the
steering knuckle. Tighten the ball joint self-locking
nuts to 48 ft. Ibs. (65 Nm). Tighten the tie rod end nut
to 21 ft. Ibs. (28 Nm) and secure with a new cotter
pin.
36. Connect the damper fork to the lower control
arm and tighten the through-bolt to 65 ft Ibs. (88
Nm).
37. Connect the stabilizer link to the damper fork,
and tighten the self-locking nut to 29 ft. Ibs. (39 Nm).
38. Install the undercover.
39. Install the wheels and carefully lower the ve-
hicle
40. Install the transaxle mount bracket to the
transaxle, and tighten the mounting nuts to 32 ft. Ibs.
(43 Nm).
41. Install the rear roll stopper mounting bracket.
42. Remove the engine support. Tighten the
transaxle mount through-bolt to 51 ft. Ibs. (69 Nm)
and tighten the front engine roll stopper through-bolt.
43. Install the upper transaxle mounting bolts
and tighten to 35 fl. Ibs. (48 Nm).
44. Install the starter motor.
45. Install the dipstick tube and the dipstick
46. Install the shifter cable mounting bracket.
47. Connect the shifter lever and tighten the re-
taining nut to 14 ft. Ibs. (19 Nm).
48. Connect the oil cooler lines and secure with
clamps.
49. Attach the electrical connectors for the
speedometer, solenoid, neutral safety switch (in-,
hibitor switch), the pulse generator, kickdown servo
switch and oil temperature sensor.
50. Install the air cleaner and the air intake hose.
51. Connect the negative battery cable.
52. Make sure the vehicle is level, and refill the
transaxle. Start the engine and allow to idle for 2 minutes. Apply parking brake and move selector
through each gear position, ending in N. Recheck
fluid level and add if necessary. Fluid level should be
between the marks in the HOT range.
53. Check the transaxle for proper operation.
Make sure the reverse lights come on when in re-
verse and the engine starts only in
P or N.
Mirage
*If the vehicle is going to be rolled on its
wheels while the halfshafts are out of the ve-
hicle, obtain two outer CV-joints or proper
equivalent tools and install to the hubs. If the
vehicle is rolled without the proper torque
applied to the front wheel bearings, the bear-
ings will no longer be usable.
1. Disconnect the negative battery cable then
the positive battery cable.
2. Remove the battery and battery tray.
3. Remove the air hose and air cleaner assem-
bly.
4. Raise the vehicle and support safely.
5. Remove the under guard pan.
6. Drain the transaxle oil into a suitable con-
tainer.
7. If equipped with 1.6L engine, remove the ten-
sion rod.
8. Disconnect the control cable and cooler
lines.
9. On 3-speed transaxles, disconnect the throt-
tle control cable.
10. On 4-speed transaxles, perform the following:
a. Detach the shift control solenoid valve
connector.
b. Disconnect the inhibitor switch and kick-
down servo switch.
c. Disconnect the pulse generator and oil
temperature sensor.
11. Disconnect the speedometer cable and re-
move the starter.
12. Remove the transaxle mounting bolts and
bracket.
13. Disconnect the stabilizer bar from the lower
control arm.
14. Disconnect the steering tie rod end and the
ball joint from the steering arm.
15. Remove the halfshafts at the inboard side
from the transaxle. Tie the joint assembly aside.
*It is not necessary to disconnect the half-
shafts from the wheel hubs.
16. Support the engine and remove the center
member.
17. Remove the bellhousing cover and remove
the driveplate bolts.
18 Remove the transaxle assembly lower con-
necting bolt, located just over the halfshaft opening.
19. Properly support the transaxle assembly, then
lower it, moving it to the right for clearance.
To install: 20. After the torque converter has been mounted
on the transaxle, install the transaxle assembly on the
engine. Install the mounting bolts and tighten to
31-40 ft. Ibs. (43-55 Nm) on 1990-92 models and
35 ft. Ibs. (48 Nm) on 1993-00 models.
21. Tighten the driveplate bolts to 33-38 ft. Ibs.
(46-53 Nm). Install the bellhousing cover.
22. Install the center member. 23. Replace the circlips and install the halfshafts
to the transaxle.
24. Install the tie rods, ball joints and stabilizer
links to the steering arm
25. Install the transaxle mounting bracket and
bolts.
26. Install the starter.
27. Connect the speedometer cable.
28. Connect the inhibitor switch, kickdown servo
switch, the pulse generator and oil temperature sen-
sor, if disconnected.
29. Connect the shift control solenoid valve con-
nector.
30. Connect the control cables and oil cooler
lines.
31. Install the tension rod, if removed.
32. Install the air cleaner assembly.
33. Install the battery tray and battery.
34. Connect the positive then the negative termi-
nal.
35. Refill with Dexron@ II, Mopar ATF Plus type
7176 or equivalent, automatic transaxle fluid.
36. Start the engine and allow to idle for two min-
utes. Apply parking brake and move selector through
each gear position, ending in N. Recheck fluid level
and add if necessary. Fluid level should be between
the marks in the HOT range.
ADJUSTMENTS
Shifter Control Cable Adjustment
1. The shifter cable adjustment is done at the
neutral safety switch (inhibitor switch). Locate the
switch on the transaxle and note the alignment holes
in the arm and the body of the switch. Place the se-
lector lever in N. Place the manual lever of the
transaxle in the neutral position.
2. Check alignment of the hole in the manual
control lever to the hole in the inhibitor switch body.
If the holes do not align, adjustment is required.
3. To adjust, loosen the nut on the cable end and
pull the cable end by hand until the alignment holes
match. Tighten the nut. Check that the transaxle
shifts and conforms to the positions of the selector
lever.
Throttle Valve Cable
The throttle valve adjustment applies only to the
1990-96 Mirage.
1. Place selector lever and manual control lever
in N position.
2. Loosen adjusting nut. While lightly pulling on
control cable tighten mounting nut to 7-10 ft. Ibs.
(X-14 Nm).
3. When adjustment is complete, be sure selector
lever is still in the N position. Verify all functions
correspond to the position indicated on the selector
lever.
The halfshaft removal and installation and over-
haul are the same as a manual transaxle Please refer
to Manual Transaxle in this Section

8-12 SUSPENSION AND STEERING
Compression lower an assembly
removal steps Lateral lower arm assembly removal
Hcps
1. Connection for compression lower
arm ball joint and knuckle
2. Compressron lower arm mounting
bolt
3. Compression lower arm assembly 4. stay
5. ~mdtsoorber lower mounting
6. Connection for lateral lower arm
ball joint and knuckle
7. Metal lower arm mounting bolt
end nut
6. Lateral low% arm assemblv
CSUtlOll
l : Indicates parts wfdch should k temporarily tightened,
and then fully tightened with fhe vehicle on the ground
in the unladen wndluon.
93158p62 :ig. 39 Remove the lower control arm-to-body mounting bolts, then remove the arm from the
rehicle
8. Assemole me control arms and bushmgs. 7. Remove the compression arm,
^. To install:
Y. Install the lateral control arm to the vehicle
and install the inner mounting bolts. Install a new nut
and snug temporarily. -. .*.. a.
10. Install the compression arm to the vehicle.
* 11. Connect the ball joint studs to the knuckle.
Install new nuts and tighten to 43-51 ft. Ibs (59-71
Nm).
12. Lower the vehicle to the floor for the final
tightening. 3. Remove sway bar links or mounting nuts and
bolts from lower control arm. Remove the joint cups 1.
and bushings.
4. Raise the vehicle and support safely.
Disconnect the ball joint stud from the steer-
ing knuckle. 2. Remove the wheel and tire assembly
13. Once the full weight of the vehicle is on the
suspension, tighten the lateral arm rear bolt to 71-85
ft. Ibs. (98-118 Nm) and the front bolt to the damper
fork to 64 ft. Ibs. (88 Nm).
14. Tighten the bolts for the compresslon arm to
60 ft. Ibs. (83 Nm).
15. Reinstall the crossmember brackets with their
mounting bolts. Tighten the mounting bolts to 51-58
ft. Ibs. (69-78 Nm).
16. Have a front end alignment performed.
Mirage
ti See Figure 41
*The suspension components should not be
tightened until the vehicle’s weight is resting
on its wheels. 5. Remove the inner lower arm mounting bolt
and nut.
6. Remove the rear mount bolts from the retain-
ing clamp. Remove the rear retainer clamp if
equipped.
7. Remove the arm from the vehicle.
To install:
8. Install the control arm to the vehicle and in-
stall the inner mounting bolt. Install new nut and
tighten to 78 ft. Ibs. (108 Nm).
9. Install the rear mount clamp and bolts.
Tighten the clamp mounting bolts to 65 ft. Ibs. (90
Nm).
10. Connect the ball joint stud to the knuckle. In-
stall a new nut and tighten to 43-52 ft. Ibs. (60-72
Nm).
11. Install the sway bar and links.
12. Lower the vehicle to the floor for the final
tightening of the inner frame mount bolt.
13. Install the wheel and tire assembly.
REMOVAL&INSTALLATION
Mirage
1. Disconnect the negative battery cable.
2. Raise and safely support vehicle.
3. Disassemble the links, remove the locknut,
joint cup, bushing, and collar. Remove the sway bar
link bolts.
4. It will be necessary to remove the center cross-
member in order to remove the sway bar. The follow-
ing steps are required to remove the crossmember:
a. Remove the front exhaust pipe
b. Properly support the engine, remove the
engine roll stopper bolts. Remove the four center
member mounting bolts and remove the center
member assembly.
c. Remove both steering rack mounts.
d. Disconnect the lower control arm from the
crossmember,
e. Support the crossmember, remove the
mounting bolts and lower the crossmember for
access.
5. Remove the sway bar mounts and remove the
bar from the vehicle.
To install:
*Note that the bar brackets are marked left
and right.
6. Position the sway bar in the vehicle, then in-
stall the crossmember in the reverse order it was re-
moved.
7. Install the sway bar mount brackets, and
tighten the mounting bolts to 16 ft. Ibs. (22 Nm).
8. Connect the sway bar links and tighten the
bolts with rubber bushings, until the amount of bolt
protrusion at the end of link mounting bolt is 0.87
inches (22mm).
9. Lower the vehicle and connect the negative
battery cable.
1990-93 Galant
FWD VEHICLE
1. Disconnect the negative battery cable.
2. Raise and safely support vehicle.
3. Remove the front exhaust pipe and gasket
from the manifold and using wire, tie it down and out
of the way.
WWhen relocating the front exhaust pipe,
make sure the flexible joint is not bent more
than a few degrees or damage to the pipe
joint may occur.
4. Remove the center crossmember rear instal-
lation bolts.
5. Remove the sway bar link bolts. On the pil-
low-ball type, hold ball stud with a hex wrench and
remove the self-locking nut with a box wrench.
6. Remove the sway bar bolts and mounts.
7. Remove the bar from the vehicle, as follows:
a. Pull both ends of the sway bar toward the
rear of the vehicle.
b. Move the right sway bar end until the end
clears the lower arm.
c. Remove the sway bar out the right side of
the vehicle.

SUSPENSION AND STEERING 8-13
W-118 Nm*
71-W ft.lbs: 83Nm

69-78 Nm
Compression lower arm assembly
removal steps
1. Connection for compression lower
arm ball joint and knuckle
2. Comoression lower arm mouniina Lateral lower tmn assembly removal
steps
4. stay
bon ’ 3. Compression lower arm assembly 6. CMlnection for lateral lower arm
ball joint and knuckle
7. lateral lower arm mounting boll
andnllt
0. hleral lower am7 assembly
CWtlOtl
l : Indicates parts which should be temporarily tightened,
and then fully tightened with the vehicle on the ground
in the unladen condition
7923PGB8 Fig. 40 Exploded view of the lower control arms-Galant
tion and replace as required. 8.
9. Inspect all bushings for wear and deteriora-
Check the sway bar for damage, and replace
as required.
To install: 10. Install the sway bar into the vehicle.
11. Install the sway bar brackets on the vehicle,
following any side locating markings on the brackets.
Temporarily tighten the sway bar bracket. Align the
bushing end with the marked part of the sway bar and
then fully tighten the sway bar bracket.
12. If equipped with the pillow-ball type mount-
ing, install the sway bar links and link mounting nuts.
Using a wrench, secure the ball studs at both ends of
the sway bar link while tightening the mounting nuts.
Tighten the nuts on the sway bar bolt so that the dis-
tance of bolt protrusion above the top of the nut is
0.63-0.70 in. (1&18mm).
13. Install the front exhaust pipe with new gasket
in place. Tighten new self-locking nuts to 29 ft. Ibs.
(40 Nm). and the sway bar bracket and bushing.
6. 5. Remove the sway bar bracket installation bolt
Disconnect the sway bar coupling at the right
lower control arm. Pull out the left side sway bar
edge, pulling it out between the driveshaft and the
lower arm. Pull out the right side bar below the lower
arm.
To install:
14. Connect the negative battery cable.
A WD VEHICLE
I
1. Disconnect the negative battery cable.
2. Remove the front exhaust pipe.
3. Remove the center gusset and transfer as-
sembly.
4. Using a wrench to secure the ball studs at
both ends of the sway bar link, remove the sway bar
link mounting nuts. Remove the sway bar link. 11. Connect the negative battery cable.
REMOVAL & INSTALLATION
7. Install the bar into the vehicle in the same Diamante, Mirage, 1996-93 Galant, and manner as removal. 1999-00 Galant 8. Temporarily tighten the sway bar bracket.
Align the bushing end with the marked part of the
sway bar and then fully tighten the stabilizer bar
bracket.
9. Install and tighten the sway bar bracket bolt.
10. Install the sway bar links and link mounting
nuts Using a wrench, secure the ball studs at both
ends of the sway bar link while tightening the mount-
ing nuts. Tighten the nuts on the sway bar bolt so
that the distance of bolt protrusion above the top of
the nut is 0.63 to 0.70 in. (16 to 18mm).
11. Install the transfer assembly and gusset.
12. Install the left crossmember. Tighten the rear
mounting bolts to 58 ft Ibs. (80 Nm) and the front
mounting bolts to 72 ft. Ibs. (100 Nm). ) See Figures 45, 46, and 47
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely. Remove
the halfshaft nut.
3. If equipped with ABS, remove the front wheel
speed sensor
1994-90 Galant
4. If equipped with Active Electronic Control
Suspension (Active-ECS), disconnect the height sen-.
sor from the lower control arm.
5. Remove the caliper assembly and brake pads.
Suspend the caliper with a wire
6. Using a suitable ball joint separator tool, dis-
connect the ball joint and tie rod end from the steer-
ing knuckle.
7. Remove the halfshaft from the hub.
8. Unbolt the lower end of the strut and remove
the hub and steering knuckle assembly from the vehi-
cle.
9 Remove the hub, bearings and races as fol-
lows.
# See Figures 42, 43, and 44
1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle 3. Disconnect the sway bar links by removing
the self-locking nuts.
4. Remove the sway bar mounting brackets and
bushings.
5. Remove the bar from the vehicle.
6. Inspect all components for wear or damage,
and replace parts as needed.
To install: 7. Install the sway bar into the vehicle.
8. Loosely install the sway bar brackets on the
vehicle.
9. Align the side locating markings on the sway
bar, so that the marking on ihe bar, extends approxi-
mately 0.40 inches (1Omm) from the Inner edge of
the mounting bracket, on both sides.
10. With the sway bar properly aligned, tighten
the mounting bracket bolts to 28 ft. Ibs. (39 Nm).
11. Connect the sway links to the damper fork
and the sway bar. Tighten the locking nuts to 28 ft.
Ibs (39 Nm).
12. Lower the vehicle and connect the negative
battery cable.
Diamante
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Remove the front exhaust pipe and engine
undercover.
4. Remove the left and right frame members.
5. Remove the sway bar link.
6. Remove the sway bar brackets and remove
the sway bar from the vehicle.
To install: 7. Note that the bar brackets are marked left and
right. Lubricate all rubber parts and install the bush-
ings, the sway bar and brackets.
8. Install the sway bar link.
9. Install the frame members.
10. Install the engine undercover and exhaust
pipe.

.
SUSPENSION AND STEERING 8-21
1 nents Q3158!@3 1990-92 Mirage rear suspension compo-
1992-96 Diamante w/out 4 wheel steering
rear suspension components
1 ponents %” 1997-00 Diamante rear suspension corn
REMOVAL & INSTALLATION
Diamante
1. Disconnect the negative battery cable.
2. Raise and properly support vehicle.
3. Remove both rear wheels. !
4. Support the lower control arm with a jack.
5. Matchmark the positioning of the upper
spring plate to the vehicle for reinstallation purposes.
6. If equipped with Active Electronic Control
Suspension (Active-ECS), perform the following:
a. Loosen the nut that secures the air line to
I
93158QM 1990-93 Galant rear suspension compo-
nents
1992-96 Diamante with 4 wheel steering
rear suspension components
the to the top of the strut and discard the O-ring.
b. Remove the bolts that secure the actuator
to the top of the strut and remove the compo-
nent Disconnect the wiring harness.
7. Remove the shock absorber lower mounting
bolt and remove the two nuts that secure the shock
upper plate to the vehicle.
8. Lower the support jack and remove the shock
from the vehicle.
To install:
9. Position the uooer sprina elate and install the
strut. Use the support’jack to as% with installation.
10. Tighten the upper strut mounting nuts to 33
ft. Ibs. (45 Nm).
11. Tighten the lower strut mounting bolt to 71 ft.
Ibs. (98 Nm).
12. If equipped with Active-ECS perform the fol-
lowing:
a. Using a new O-ring, tighten the nut that
secures the air line to the to the top of the strut
to 84 inch Ibs. (9 Nm).
b. Install the actuator to the top of the shock
absorber and secure with mounting bolts. Con-
nect the wiring harness.
13. Remove the support jack, install wheels and
lower vehicle.
14. Connect the negative battery cable.
1990-93 Galant
FWD MODELS
*The strut assembly Is a load bearing com-
ponent, therefore the vehicle chassis and axle weight must be supported separately,
requiring the use of two separate lifting de-
vices.
1. Disconnect the negative battery cable.
2. Raise and support vehicle chassis.
3. Raise and support torsion axle and arm as-
sembly slightly. Make sure the jack does not contact
the lateral rod.
*Always use a wooden block between the
jack receptacle and the axle beam. Place the
jack at the center of the axle beam.
4. Remove the trunk interior trim to gain access
to the top mounting nuts.
5. If equipped with Active-ECS, perform the fol-
lowing steps:
a. Label and disconnect the air tubes from the
shock absorber.
*Immediately plug or cap the lines with
tape or similar product to prevent the entry of
dirt into the system. Do NOT bend or crimp
the air tubes. Plug or cover the air ports on
the joint and actuator.
b. Remove the O-ring and bushing.
c. Remove the actuator assembly.
6. Remove the top cap and upper shock mount-
ing nuts.
7. Remove the strut lower mounting bolt and re-
move the assembly from the vehicle.
To install:
8. Position the strut assembly so that the lower
mounting bolt can be installed and lightly tightened.
9. Use the jack to raise or lower the axle assem-
bly so that the top strut plate studs aligns through the
body. Raise the jack to hold the strut assembly in po-
sition
10. Install the top plate nuts on the studs. Tighten
the upper shock mounting nuts to 29 It. Ibs. (40 Nm).
11. With the car on the ground, tighten the lower
mounting bolt to 72 ft. Ibs. (100 Nm).
12. If equipped with Active-ECS, assemble the
actuator components in the following order:
a. Install the adapter to the mounting bracket.
b. Using new O-rings, connect the air line to
the actuator, Tighten the locknuts to 6 ft Ibs. (9
Nm).
c. Swab the air connectors with a solution of
soapy water. Start the engine, cycle the suspen-
sion controls and observe the joints for any sign
of air leaks.
13. Install top cap and interior trim.
AWD MODELS
1. Disconnect the negative battery cable.
2. Raise and support vehicle chassis.
3. Raise and support trailing arm assembly
slightly.
4. Remove the trunk interior trim to gain access
to the top mounting nuts.
5. Remove the top cap and upper shock mount-
ing nuts.
6. Remove the brake tube bracket bolt.
7. Remove the shock lower mounting bolt and
remove the assembly from the vehicle.
To install:
8. Position the strut assembly so that the lower
mounting bolt can be installed and lightly tightened.
9. Use a jack to raise or lower the trailing arm,
so that the top strut plate studs aligns through the

.
8132 SUSPENSION AND STEERING
(42 Nm) on Mirage and 36-39 ft. tbs. (49-53 Nm)
on Galant and Diamante models.
19. Have the front end alignment checked, and
adjusted if necessary.
Inner Tie Rods
11. Loosen the inner tie rod end nut from the
steering gear and remove the inner tie rod end.
To install: 12. Using a new lock plate, install the tie rod end
and tighten the tie rod to 65 ft. Ibs. (90 Nm). REMOVAL &INSTALLATION 13. Bend the tabs of the new lock plate to secure
1. Raise the front of the vehicle and support it
on jackstands.
2. Remove the wheel.
3. Remove the cotter pin and the outer tie rod
ball joint stud nut. Note the position of the steering
linkage.
4. Wire brush the threads on the tie rod shaft
and lubricate with penetrating oil.
5. Using a suitable ball joint separator tool, re-
move the tie rod ball joint from the steering knuckle.
6. Loosen the locknut and remove the tie rod
end from the tie rod. Count the number of complete
turns it takes to completely remove it.
7. Remove the tie rod-to-steering gear locknut.
8. Remove the clamps that secure the flexible
boot to the steering gear.
9. Slide the boot from the inner tie rod and re-
move the boot.
IO. Bend the lock plate tabs from the inner tie rod
end nut. the inner tie rod end.
14. Slide the boot onto the steering gear and se-
cure it with new clamps.
15. Install the outer tie rod end to the steering
gear locknut.
16. Install the outer tie rod end, turning it in ex-
actly as many turns as it was to remove the old one.
Make sure it is correctly positioned in relationship to
the steering linkage.
22. Have a front end alignment performed. 17. Connect the outer tie rod end to the steering
knuckle and install the castle nut. Tighten the nut to
25 ft. Ibs. (34 Nm,) on the Mirage and 21 ft. Ibs. (29
Nm) on the Galant and Diamante models.
18. Install a new cotter pin to the castle nut.
19. Tighten the tie rod end locking nut to 30 ft.
Ibs. (42 Nm) on the Mirage and 36-39 ft. Ibs. (49-53
Nm) on the Galant and Diamante models.
20. Install the wheel and tire assembly.
21. Lower the vehicle.
Mirage
) See Figure 95
*Prior to removal of the steering rack, cen-
ter the front wheels and remove the ignition
key. Failure to do so may damage the SRS
clockspring and render SRS system inopera-
tive. Be sure to properly disarm the air bag
system.
1. Disconnect the battery negative cable.
2. Raise the vehicle and support safely and re-
move the wheels.
5. Remove the center member. 3. Disconnect the Heated Oxygen (HOzS) sen-
sor and remove the front exhaust pipe.
4. Properly support the engine. Remove both
roll stopper mounting bolts and the four center mem-
ber installation bolts.
18
Nm 13 ft.lbs.
15 - 33 Nm /
11 - 25 ft.lbs. 7
03
L
69 Nm
51 ftlbs.
4.9 Nm 3.6 ft.lbs.
11 - 25 ft.lbs.
1. Steering shaft assembly and
gear box connecting bolt
2. Band
3. Cotter pin I
4. Tie-rod end and knuckle connection 5. Cylinder clamp
6. Gear housing clamp
7. Gear box assembly
8. Steering cover assembly
Fig. 95 Exploded view of the manual steering gear mounting-Mlrage

SUSPENSION AND STEERING 8-33
*Matchmark the pinion input shaft of the
rack to the lower steering column joint for in-
stallation purposes.
6. Remove the pinch bolt holding the lower
steering column joint to the rack and pinion input
shaft.
7. Remove the cotter pins and disconnect the tie
rod ends from the steering knuckle.
8. Remove the rack and pinion steering assem-
bly and its rubber mounts from the right side of the
vehicle.
To install: 9. Align the matchmarks of the input shaft and
install the rack to the vehicle.
10. Secure the rack using the retainer clamps and
bolts. Tighten the bolts to 51 ft. Ibs. (70 Nm).
11. Tighten the steering column pinch bolt to 13
ft. Ibs. (18 Nm).
12. Install the center member.
13. Install the front exhaust pipe.
14. Connect the HO$ sensor.
15. Connect the tie rod ends to the steering
knuckles and tighten the castle nuts to 25 ft. Ibs. (34
Nm). Install new cotter pins.
16. Install the wheels and connect the negative
battery cable.
17. Have a front end alignment performed.
REMOVAL &INSTALLATION
Diamante
FRONT
*Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clock spring and render SRS system in-
operative.
1. Disconnect the negative battery cable.
2. Disconnect the front exhaust pipe.
3. If equipped with AWD, remove the transfer
case assembly.
4. Remove the bolt holding the lower steering
column joint to the rack and pinion input shaft.
5. Remove the cotter pins and disconnect the tie
rod ends.
6. Remove the left and right frame members.
7. Remove the stabilizer bar bracket.
8. If equipped with four-wheel steering, discon-
nect the lines going to the rear pump.
9. Remove the rack and pinion steering assem-
bly and its rubber mounts. Move the rack to the right
to remove it from the crossmember.
To install: IO. Install the rack and mounting bolts. Tighten
the bolts to 51 ft. Ibs. (70 Nm). When installing the
rubber rack mounts, align the projection of the
mounting rubber with the indentation in the cross:
member. Install the pinch bolt.
11. Connect the pressure and return lines to the
rack and to the rear pump, if equipped.
12. Install the frame members and tighten the
bolts to 43-51 ft. Ibs. (60-70 Nm).
13. Connect the tie rods and install new cotter
pins. 14. Install the transfer case and front exhaust
pipe.
15. Refill the reservoir and bleed the system.
16. Have a front end alignment performed.
REAR
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Drain the power steering fluid.
4. Remove the main muffler assembly.
5. Remove the rear shock absorber lower
mounting bolts.
6. Using the proper equipment, support the
weight of the rear differential. Remove the 2 small
crossmember brackets.
7. Remove the large self-locking crossmember
mounting nuts on the differential side.
8. Remove the oil line clamp bolts.
9. Remove the pressure tubes.
IO. Hold the tie rod ends stationary and remove
the tie rod end nuts. Remove the tie rod ends from
the trailing arms.
11. Remove the mounting bolts and remove the
rear steering gear.
To install: 12. Secure the unit to the crossmember. Move
the power cylinder piston rod over its full stroke to
determine its neutral position.
13. Align the tie rod ends with the holes in the
trailing arms and install the nuts. Adjust the length of
the tie rods with the nuts if necessary. The difference
in length between the 2 tie rod ends should not ex-
ceed 0.04 in. (1 mm). The nuts’ torque specification is
42 ft. Ibs. (58 Nm).
14. Replace the O-rings and install the pressure
tubes. Clamp in place.
15. Install the large self-locking crossmember
mounting nuts on the differential side. Tighten to
80-94 ft. Ibs. (110-130 Nm).
16. Remove the support equipment.
17. Install the 2 small crossmember brackets.
18. Install the shock mounting bolts.
19. Install the muffler assembly.
20. Refill the reservoir and bleed the system.
21. Have a front end alignment performed. _
Galant
1990-93 MODELS
1. Disconnect the negative battery cable.
2. Drain the power steering fluid.
3. Raise the vehicle and support safely.
4. Remove the bolt holding lower steering col-
umn joint to the rack and pinion input shaft.
5. Remove the transfer case, if equipped.
6. Remove the cotter pins and using the proper
tools, separate the tie rod ends from the steering
knuckle.
7. Locate the triangular brace near the stabilizer
bar brackets on the crossmember and remove both
the brace and the stabilizer bar bracket.
8. Support the center crossmember.
9. Remove the through-bolt from the round roll
stopper and remove the rear bolts from the center
crossmember.
10. Disconnect the front exhaust pipe, if
equipped with FWD.
11. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings. Plug the
fittings to prevent excess fluid leakage. 12. Lower the crossmember slightly.
13. Remove the rack and pinion steering assem-
bly and its rubber mounts. Move the rack to the right
to remove from the crossmember. Tilt the assembly
downward and remove from the left side of the vehi-
cle. Use caution to avoid damaging the boots.
To install: 14. Install the rack and install the mounting bolts. Tighten the mounting bolts to 43-58 ft. Ibs. (60-80
Nm). When installing the rubber rack mounts, align
the projection of the mounting rubber with the inden-
tation in the crossmember.
15. Connect the power steering fluid lines to the
rack.
16. Connect the exhaust pipe, if removed.
17. Raise the crossmember into position. Install
the center member mounting bolts and tighten to 72
ft. Ibs. (100 Nm). Install the roll stopper bolt and new
nut. Tighten nut to 47 ft. Ibs. (65 Nm).
18. Install the stabilizer bar brackets and brace.
19. Connect the tie rod ends and tighten nuts to
25 ft. Ibs. (34 Nm).
20. Install the transfer case, if removed. Check
and fill fluid.
21. Refill the reservoir with power steering fluid
and bleed the system.
22. Have a front end alignment performed.
1994-M MODELS
+ See Figure 96
Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clock spring and render SRS system in-
operative.
1. Disconnect the negative battery cable.
2. Raise and properly support the vehicle.
3. Remove both front wheel assemblies.
4. Remove the bolt holding lower steering col-
umn joint to the rack and pinion input shaft.
5. Remove the stabilizer bar.
6. Remove the cotter pins, and using joint sepa-
rator MB991 113 or equivalent, disconnect the tie rod
ends from the steering knuckle.
7. On vehicles equipped with Electronic Control
Power steering (EPS), detach the wiring harness from
the solenoid connector.
8. Locate the two triangular braces near the
crossmember and remove both.
9. Support the center crossmember. Remove the
through-bolt from the front round roll stopper and re-
move the bolts securing the center crossmember.
10. Remove the center crossmember. ,
Il. Properly support the engine and remove the
rear roll stopper through-bolt.
12. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings. Plug the
fittings to prevent excessive fluid leakage.
13. Remove the clamp bolts and the two bolts se-
curing the rack assembly to the chassis.
14. Remove the rack and pinion steering assem-
bly and its rubber mounts.
*When removing the rack and pinion as-
sembly, tilt the assembly to the vehicle side
of the compression lower arm and remove
from the left side of the vehicle.

8-34 SUSPENSION AND STEERING'
Fig. 96 Exploded view of the power steering gear removal procedure- -Galant 43 Nm*
7 18 Nm
24-33 Nm
18-24 ttlbs.
15 Nm . 11 ftlbs. 6
57 Nm
42 ft.lbs.
\1- 69 Nm
51 ft.lbs. 24-33 Nm
18-24
ft.1 bs.
’ 78-86 Nm
58-65 ft.lbs.
69-78
Nm 51-58 ftlbs.
1. Joint assembly and gear box con-
necting bolt
2. Cotter pin
3. Connection for tie rod end and
knuckle
4. Stay
5. Center member assembly
6. Clamp
7. Bott
I 8. Gear box assembly
Caution
The fasteners marked * should be temporarily
tightened before they are finally tightened once
the total weight of the engine has been placed
on the vehicle
body.
7923PGAl
To install:
15. Center the rack assembly and insert the pin-
ion into the steering column shaft.
16. Install the rack and mounting bolts. Tighten
the mounting bolts to 51 ft. Ibs. (69 Nm).
17. Install the pinch bolt and tighten the bolt to
13 ft. Ibs. (18 Nm).
18. Connect the power steering fluid lines to the
rack and tighten the pressure hose fitting to 11 ft. Ibs.
(15 Nm). Secure the return hose with the clamp.
19. Raise the engine into position.
20. Install the rear roll stopper through-bolt and I
tighten to 32 ft. Ibs. (43 Nm).
21. Raise the crossmember into position. Install
_ the center member mounting bolts; tighten the front
bolts to 58-65 ft. Ibs. (78-88 Nm) and the rear bolt
to 51-58 ft. Ibs. (69-78 Nm).
22. Install the front roll stopper bolt and tighten
the nut to 32 ft. Ibs. (43 Nm).
23. Install the two triangular braces and tighten
the mounting bolts to 50-56 ft. Ibs. (69-78 Nm). 24. Install the stabilizer bar.
25. Connect the tie rod ends and tighten the nuts
to 20 ft. Ibs. (27 Nm).
26. On vehicles equipped with EPS, connect the
wiring harness to the solenoid connector.
27. Install the wheel assemblies and lower the
vehicle.
28. Refill the reservoir with power steering fluid
and bleed the system.
29. Have a front end alignment performed.
Mirage
1990-92 MODELS
I. Disconnect the battery negative cable.
2. Raise the vehicle and support safely.
3. Remove the pinch bolt holding the lower
steering column joint to the rack and pinion input
shaft. 4. Remove the cotter pins and disconnect the tie
rod ends from the steering’knuckle.
5. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings.
6. Remove the rack and pinion steering assem-
bly and its rubber mounts.
To install:
7. Install the steering gear into the vehicle and
secure using the retainer clamps and bolts.
8. Connect the power steering fluid lines to the
rack fittings.
9. Install the stabilizer bar and rear transaxle
bracket.
10. Connect the tie rod ends to the steering
knuckles.
ll= Connect the negative battery cable.
12. Refill the reservoir and bleed the system.
13. Have a front end alignment performed.

SUSPENSION AND STEERING 8-35
1. Steering shaft assembly and gear
box connecting bolt
2. Band
3. Cotter pin
4. Tie-rod end and knuckle connection
5. Return tube connection 6. Pressure tube connection
7. Cylinder clamp
8. Gear housing clamp
9. Gear box assembly 10. Steering cover assembly
7923PGAl FiD= 97 Exploded view of the power steering gear assembly-Mirage
1993-90 MODELS To install:
) See Figure 97
*Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clockspring and render SRS system in-
operative.
,mr;iin thepower steering system.
2. Disconnect the battery negative cable. Raise
the vehicle and support safely.
3. Disconnect the Heated Oxygen (HOPS) sen-
sor and remove the front exhaust pipe.
4. Properly support the engine.
5. Remove both roll stopper mounting bolts and
the four center member installation bolts. Remove the
center member.
6. Remove the center member. 11. Align the matchmarks of the input shaft and
install the rack to the vehicle.
12. Secure the rack using the retainer clamps and
bolts. Tighten the bolts to 51 ft. Ibs. (70 Nm).
13. Tighten the steering column pinch bolt to 13
ft. Ibs. (18 Nm).
14. Using new O-rings, connect the power steer-
ing fluid lines to the rack fittings.
15. Install the center member.
16. Install the front exhaust pipe.
17. Connect the H02S sensor.
18. Connect the tie rod ends to the steering
knuckles and tighten the castle nuts to 25 ft. Ibs. (34
Nm). Install new cotter pins.
19. Install the wheels and connect the negative
battery cable.
20. Refill ‘the reservoir and bleed the system.
21. Have a front end alignment performed.
stallation purposes. -
7. Remove the pinch bolt holding the lower REMOVALANDINSTALLATION
steering column joint to the rack and pinion input
shaft.
8. Remove the cotter pins and disconnect the tie
rod ends from the steering knuckle.
9. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings.
IO. Remove the rack and pinion steering assem-
bly and its rubber mounts from the right side of the
vehicle. Mirage
1, Drain the power steering system as follows:
a. Disconnect the return hose at the reservoir
and place into a suitable container.
b. Disable the ignition system. While crank-
ing the engine, turn the wheels several times, un-
til system has been drained. 2. Disconnect the battery negative cable.
3. Remove the pressure switch connector from
the side of the pump.
4. If the alternator is located under the oil pump,
cover it with a shop towel to protect it from oil.
5. Disconnect the pressure line.
6. Remove the steering pump drive belt and the
water pump pulley drive belt.
7. Remove the water pump pulley.
8. Remove the bolts that secure the oil pump,
then remove the pump from its bracket.
To install: 9. Install the power steering pump and tighten
the mounting bolts to specifications.
IO. Install the water pump pulley and tighten the
mounting bolts 14 ft. Ibs. (19 Nm).
11. Install and adjust the drive belts.
12. Replace the O-rings and connect the pressure
line. Connect the pressure line so the notch in the fit-
ting aligns and contacts the pump’s guide bracket.
Tighten the nut that secures the pressure line to 13 ft.
Ibs. (18 Nm).
13. Connect the return line.
14. Attach the pressure switch connector.
15. Refill the reservoir and bleed the system.
1990-93 Galant
FRONT
1. Disconnect the battery negative cable.
2. Remove the pressure switch connector from
the side of the pump.

8-36 SUSPENSION AND STEERING
4 SL Engine>
<1.8L Engine>
Removal steps
1. Drive belt
7. BoIt
2. Pressure switch connector
8. Bolt
3. Suction hose
9. Oil pump
4. Pressure hose
10. Oil pump brace
2 Elrg
11. Oil pumo bracket stay
12. Oil pump bracket
93158gal
Exploded view of the power steering pump-Mirage
3. If the alternator is located under the oil pump,
cover it with a shop towel to protect it from oil.
4. Disconnect the return fluid line.
5. Remove the reservoir cap and allow the re-
turn line to drain the fluid from the reservoir. If the
fluid is contaminated, disconnect the ignition high
tension cable and crank the engine several times to
drain the fluid from the gearbox.
6. Disconnect the pressure line.
7. Remove the pump drive belt.
8. Remove the pump mounting bolts and re-
move the pump from the engine.
To install: 9. Install the pump, wrap the belt around the
pulley and loosely tighten the mounting bolts.
10. Replace the O-rings and connect the pressure
line. Connect the pressure line so the notch in the fit-
ting aligns and contacts the pump’s guide bracket.
1 I. Connect the return line. Attach the pressure
switch connector.
12. Adjust the belt tension and tighten the adjust-
ing bolts to 25-33 ft. Ibs. (35-45 Nm).
13. Refill the reservoir and bleed the system.
REAR
1. Raise the vehicle and support safely.
2. Drain the differential gear oil.
3. Matchmark and remove the rear driveshaft.
4. Remove the rear halfshafts.
5. Remove the center exhaust pipe and muffler
assembly, as required.
35-45 Nm 9-14 Nm
14-Z Nm 25-33 ft.lbs.
9 7-10 klbs.
6/
2 g-lb Nm
7-10 ft.lbs.
Exploded view of the front power steering pump-1990-93 Galant

SUSPENSION AND STEERING 8-37
19-28 Nm
14-20 klbs.
/
12-18 Nm
9- 13 ft.lbs.
2rd
,
1. Feed tube
2. O-ring
3. Rear oil pump
4. O-ring
93158ga:
Exploded view of the rear power steering pump-1990-93 Galant
6. Disconnect the pressure and suction hoses
from the fittings on the pump.
7. The large mounting bolts that hold the differ-
ential carrier support plate to the underbody may use
self-locking nuts. Before removing them, support the
rear axle assembly in the middle with a transaxle
jack. Remove the nuts, then remove the support
plate(s) and the square dynamic damper from the rear
of the carrier.
8. Lower the differential carrier
and remove from
the vehicle.
9. Remove the pump retaining bolt and remove
the pump from the rear differential assembly.
To install: IO. Install the pump and tighten the mounting
bolt to 14-20 ft. Ibs. (19-28 Nm).
11. Raise the rear differential carrier into position
and install support member bolts. Replace all self-
locking nuts. Tighten all mounting nuts and bolts as
follows:
l Upper support plate to carrier bolts: 72-87
ft. Ibs. (100-120 Nm)
l Support member/dynamic damper to car-
rier bolts: 58-72 ft. Ibs. (80-100 Nm)
l Differential support member mounting bolt
nuts: 80-94 ft. Ibs. (110-130 Nm)
12. Connect the pressure and suction lines to the
pump.
13. Install new circlips on both rear driveshafts
and install. I
14.
Install the propeller shaft and tighten the
mounting hardware to 22-25 ft. Ibs. (30-35 Nm).
15. Install the center exhaust pipe and muffler.
1
16. Lower the vehicle. With the vehicle level, fill
the rear differential.
17. Fill the power steering system and properly
bleed.
1994-00 Galant
2.4L ENGINE
1. Disconnect the battery negative cable.
2. Loosen and remove the power steering pump
drive belt.
3. Remove the pressure switch connector from
the side of the pump.
*If the alternator is located under the oil
pump, cover it with a shop towel to protect it
frqm oil.
4. Disconnect the return fluid line. Remove the
reservoir cap and allow the return line to drain the
fluid from the reservoir. If the fluid is contaminated,
disconnect the ignition high tension cable and crank
the engine several times to drain the fluid from the
gearbox.
5. Disconnect the pressure line.
6. Unbolt and remove the pump from the
mounting bracket.
To install: 7. Install the pump, wrap the belt around the
pulley and lightly tighten the mounting bolts.
8. Replace the O-rings and connect the pressure
line. Connect the pressure line so the notch in the fit-
ting aligns and contacts the pump’s guide bracket.
Tighten the fitting to 13 ft. Ibs. (18 Nm).
9. Connect the return line and secure with the
clamp.
IO. Attach the pressure switch connector.
<2.4L ENGINE> 12 N-m 12 N-m
<3.OL ENGINE>
32 ft-lb
1. DRIVE BELT
2. PRESSURE SWITCH CONNECTOR
3. SUCTION HOSE
; i’;;‘;;RE HOSE 7. BOLT
8. ~O~~~E;TEER’NG PUMP
9. OIL PUMP
10. OIL PUMP BRACKET
6. BOLT
93158gal
Exploded view of the power steering pump-1994-00 Galant with 2.4L engine