ECO mode MITSUBISHI DIAMANTE 1900 Owner's Manual

ENGINEAND ENGINEOVERHAUL 3-59
Most of the cleaning process can be carried out
with common hand tools and readily available sol-
vents or solutions. Carbon deposits can be chipped
away using a hammer and a hard wooden chisel. Old
gasket material and varnish or sludge can usually be
removed using a scraper and/or cleaning solvent. Ex-
tremely stubborn deposits may require the use of a
power drill wrth a wire brush. If using a wire brush,
use extreme care around any critical machined sur-
faces (such as the gasket surfaces, bearing saddles,
cylinder bores, etc.). USE OF A WIRE BRUSH IS NOT
RECOMMENDED ON ANY ALUMINUM COMPO-
NENTS Always follow any safety recommendations
given by the manufacturer of the tool and/or solvent.
You should always wear eye protection during any
cleaning process involvrng scraping, chipping or
spraying of solvents.
An alternative to the mess and hassle of cleaning
the parts yourself is to drop them off at a local garage
or machine shop. They will, more than likely, have
the necessary equrpment to properly clean all of the
parts for a nominal fee.
Always wear eye protection during any clean-
ing process involving scraping, chipping or
spraying of solvents.
Remove any oil galley plugs, freeze plugs and/or
pressed-in bearings and carefully wash and degrease
all of the engine components including the fasteners
and bolts. Small parts such as the valves, springs,
etc., should be placed in a metal basket and allowed
to soak. Use pipe cleaner type brushes, and clean all
passageways in the components. Use a ring ex-
pander and remove the rings from the pistons. Clean
the piston ring grooves with a special tool or a piece
of broken ring Scrape the carbon off of the top of the
piston. You should never use a wire brush on the
pistons. After preparing all of the piston assemblies
in this manner, wash and degrease them again.
Use extreme care when cleaning around the
cylinder head valve seats. A mistake or slip
may cost you a new seat.
When cleaning the cylinder head, remove carbon
from the combustron chamber with the valves in-
stalled. This will avoid damaging the valve seats.
:ig. 234 Drill out the damaged threads with
he specified size bit. Be sure to drill corn.
rletely through the hole or to the bottom oi
I blind hole REPAIRING DAMAGEDTHREADS
# See Figures 232, 233, 234, 235 and 236
Several methods of repairing damaged threads are
available Heli-Coil@ (shown here), Keenserts@ and
Microdop are among the most widely used. All in-
volve basically the same principle-drilling out
stripped threads, tapping the hole and installing a
prewound insert-making welding, plugging and
oversize fasteners unnecessary.
Two types of thread repair inserts are usually sup-
plied: a standard type for most inch coarse, rnch fine,
metric course and metrrc fine thread sizes and a
spark lug type to fit most spark plug port sizes. Con-
sult the individual tool manufacturers catalog to de-
termine exact applications. Typical thread repair kits
will contain a selection of prewound threaded inserts,
a tap (corresponding to the outside diameter threads
of the insert) and an installation tool. Spark plug in-
serts usually differ because they require a tap
equipped wrth pilot threads and a combined
reamer/tap section. Most manufacturers also supply
blister-packed thread repair Inserts separately in ad-
dition to a master kit containing a variety of taps and
inserts plus installation tools
Before attempting to repair a threaded hole, re-
move any snapped, broken or damaged bolts or
studs. Penetrating oil can be used to free frozen
threads. The offending item can usually be removed
with locking pliers or using a screw/stud extractor.
After the hole is clear, the thread can be reparred, as
shown in the series of accompanying illustrations
and in the krt manufacturers instructions.
THREADED
lCCS3039
replaced with thread repair inserts
:ig. 235 Using the kit, tap the hole in order
o receive the thread insert. Keep the tap
veil oiled and back it out frequently to avoid
:logging the threads
To properly rebuild an engine, you must first re-
move it from the vehicle, then disassemble and diag-
nose it. Ideally you should place your engine on an
engine stand. This affords you the best access to the
engine components. Follow the manufacturers direc-
tions for using the stand with your particular engine.
Remove the flywheel or flexplate before installing the
engine to the stand.
Now that you have the engine on a stand, and as-
suming that you have drained the oil and coolant
from the engine, it’s time to strip it of all but the nec-
essary components. Before you start disassembling
the engine, you may want to take a moment to draw
some pictures, or fabricate some labels or containers
to mark the locations of various components and the
bolts and/or studs which fasten them. Modern day
engines use a lot of little brackets and clips which
hold wiring harnesses and such, and these holders
are often mounted on studs and/or bolts that can be
easily mixed up. The manufacturer spent a lot of time
and money designing your vehicle, and they wouldn’t
have wasted any of it by haphazardly placing brack-
ets, clips or fasteners on the vehicle. If it’s present
when you disassemble it, put it back when you as-
semble, you will regret not remembering that little
bracket which holds a wire harness out of the path of
a rotating part.
You should begin by unbolting any accessories
still attached to the engine, such as the water pump,
power steering pump, alternator, etc. Then, unfasten
any manifolds (intake or exhaust) which were not re-
moved during the engine removal procedure. Finally,
Fig. 233 Standard thread repair insert (left),
and spark plug thread insert
im3043 Fig. 236 Screw the insert onto the installer
1001 until the tang engages the slot. Thread
‘he insert into the hole until it is l/4-l/~ turn
lelow the top surface, then remove the tool
and break off the tano usina a uunch

4-2 DRIVEABILITYAND EMISSIONS CONTROLS
OPERATION
p See Figures 1, 2, and 3
All engines are equipped with the Positive
Crankcase Venhlation (PCV) system. The PCV sys-
tem vents crankcase gases into the engine air intake
where they are burned with the fuel and air mrxture.
The PCV system keeps pollutants from being re-
leased into the atmosphere It also helps to keep the
engine 011 clean, by ridding the crankcase of moisture
and corrosive fumes. The PCV system consists of the
PCV valve, the nipple in the air intake and the con-
necting hoses.
Incorrect operation of the PCV system can cause
multiple driveability symptoms.
A plugged valve or hose may cause’
l Rough Idle l Stalling or slow idle speed l Oil leaks
tT9574goi Fig. 1 Typical PCV system airflow
89574g0r5 Fig. 3 . . .
or mounted in a grommet on the
valve cover
l Sludge in en ine
A leakrng valve or ose would cause: i?
l Rough idle l Stalling l High idle speed
p See Figures 4 and 5
1. Disconnect the ventilation hose from the PCV
valve. Remove the PCV valve from the engine Once
removed, reconnect the ventilation hose to the valve.
2. Start the engine and allow to idle. Place a fin-
ger over open end of the PCV valve. Make sure intake
manifold vacuum is felt on finger.
3. If vacuum is not felt, the PCV valve may be re-
stricted.
4. Turn the engine
OFF and remove the PCV
valve from the hose.
5. Insert a thin stick into the threaded end of the
PCV valve. Push on the inner plunger and inspect for
movement.
6. If plunger inside the PCV valve is not free to
move back and forth, the valve is clogged and WIII re-
quire replacement.
*It is possible to clean the valve using the
appropriate solvent, but replacement is rec-
ommended.
REMOVAL&INSTALLATION
For PCV valve removal and installation, please re-
fer to Section 1 of this manual.
89574QO’ Fig. 4 With the engine idling, check the end
of the PCV valve to see if vacuum is present
Positive crankcase
ventilation
89574go6 Fig. 5 Inspect the PCV valve for inner
plunger movement. If the plunger is bound
or sticking, replace the valve OPERATION
p See Figures 6 and 7
Changes in atmospheric temperature cause fuel
tanks to breathe, that is, the air within the tank ex-
pands and contracts with outside temperature
changes. If an unsealed system was used, when the
temperature rises, air would escape through the tank
vent tube or the vent in the tank cap. The air which
escapes contains gasoline vapors.
The Evaporative Emission Control System pro-
vides a sealed fuel system with the capability to store
and condense fuel vapors. When the fuel evaporates
in the fuel tank, the vapor passes through the EVAP
emission valve, through vent hoses or tubes to a car-
bon filled evaporative canister. When the engine is
operahng the vapors are drawn into the intake mani-
fold and burned during combustion.
A sealed, maintenance free evaporative canister is
used The canister is filled wrth granules of an acti-
vated carbon mixture. Fuel vapors entering the canis-
ter are absorbed by the charcoal granules. A vent cap
is located on the top of the canister to provide fresh
air to the canister when it is being purged. The vent
cap opens to provide fresh air into the canister, which
circulates through the charcoal, releasing trapped va-
pors and carrying them to the engine to be burned.
Fuel tank pressure vents fuel vapors into the can-
ister. They are held in the canister until they can be
drawn into the intake manifold. The canister purge
valve allows the canister to be purged at a pre-deter-
mined time and engine operating conditions.
Vacuum to the canister is controlled by the canis-
ter purge valve. The valve IS operated by the PCM.
The PCM regulates the valve by switching the ground
circuit on and off based on engine operating condi-
tions When energized, the valve prevents vacuum
from reaching the canister. When not energized the
valve allows vacuum to purge the vapors from the
canister.
During warm up and for a specified time after hot
starts, the PCM energizes (grounds) the valve pre-
venting vacuum from reaching the canrster. When the
engine temperature reaches the operating level of
about 120°F (49°C) the PCM removes the ground
from the valve allowing vacuum to flow through the
canister and purges vapors through the throttle body.
During certain Idle conditions, the purge valve may
be grounded to control fuel mixture calibrations.
The fuel tank is sealed with a pressure-vacuum re-
lief filler cap. The relief valve in the cap is a safety
feature, preventing excessive pressure or vacuum in
the fuel tank. If the cap is malfunctioning, and needs
to be replaced, ensure that the replacement is the
identical cap to ensure correct system operation,
OBD-II EVAP System Monitor
Some models have added system components
due to the EVAP system monitor incorporated in the
OBD-II engrne control system. A pressure sensor is
mounted on the fuel tank which measures pressure
inside the tank, and a purge flow sensor measures
the flow of the gases from the canister into the en-
gine.
The PCM can store trouble codes for EVAP sys-
tem performance, a list of the codes is provided later

.
4-8 DRIVEABILITYAND EMISSIONS CONTROLS
93154g17 Fig. 33 PCM mounting location-Mirage
Mirage and 1999-00 Galant
) See Figure 33
*The Powertrain Control Module (PCM) is
located above the passenger side kickpanel.
1. Disconnect the negative battery cable.
2. Remove the @love box, right side kickpanel
and lower panel assemblies.
3. Unplug the connectors and remove fasteners.
Remove the PCM.
4. Installation is the reverse of the removal proce-
dure.
1994-98 Galant
+ See Figure 34
1, Disconnect negative battery cable.
2. Remove both center console side panels.
3. Unplug the wiring connector and remove the
mounting hardware. Slide the PCM out the side.
4. installation is the reverse of the removal proce-
dure.
Diamante and 1990-93 Galant
) See Figures 35 and 38
*The Powertrain Control Module (PCM) is
located behind the glove box assembly.
1, If equipped, disarm the air bag system
2. Remove the passenger side lower instrument
panel and shower duct.
3. Remove the glove box striker, glove box, glove
box outer casing and the screw below the assembly.
4. Unplug wiring connector and remove mount-
ing hardware. Slide out the PCM.
To install: 5. Install the PCM with the mounting hardware.
6. Attach the wire connector.
7. Install the glove box striker, the glove box, the
glove box casing and the screw below the assembly.
Q3154g15 Fig. 35 PCM mounting location-1990-93
Galant
93154g16 Fig. 38 PCM mounting location-Diamante
8. Install the passenger side lower instrument
panel and the shower duct.
9. Reconnect the negative battery cable
OPERATION
The Oxygen (02) sensor is a device which pro-
duces an electrical voltage when exposed to the oxy-
gen present in the exhaust gases. The sensor is
mounted in the exhaust system, usually in the mani-
fold or a boss located on the down pipe before the
catalyst. The oxygen sensors used on some models
are electrically heated internally for faster switching
when the engine is started cold. The oxygen sensor
produces a voltage within 0 and 1 volt. When there is
a large amount of oxygen present (lean mixture), the
sensor produces a low voltage (less than 0.4~). When
there is a lesser amount present (rich mixture) it pro-
duces a higher voltage (0.6-I .Ov). The stoichiometric
or correct fuel to air ratio will read between 0.4 and
0.6~. By monitoring the oxygen content and convert-
ing it to electrical voltage, the sensor acts as a rich-
lean switch. The voltage is transmitted to the PCM.
Some models have two sensors, one before the
catalyst and one after. This is done for a catalyst eff i-
ciency monitor that is a part of the OBD-II engine
controls. The one before the catalyst measures the
exhaust emissions right out of the engine, and sends
the signal to the PCM about the state of the mixture
as previously talked about. The second sensor re-
ports the difference in the emissions after the exhaust
gases have gone through the catalyst. This sensor re-
ports to the PCM the amount of emissions reduction
the catalyst is performing.
The oxygen sensor will not work until a predeter-
mined temperature is reached, until this time the
PCM is running in what as known as OPEN LOOP
operation. OPEN LOOP means that the PCM has not
yet begun to correct the air-to-fuel ratio by reading the oxygen sensor. After the engine comes to operat-
ing temperature, the PCM will monitor the oxygen
sensor and correct the air/fuel ratio from the sensor’s
readings. This is what is known as CLOSED LOOP
operation.
A Heated Oxygen Sensor (H02S) has a heating el-
ement that keeps the sensor at proper operatmg tem-
perature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into CLOSED LOOP operation
sooner.
In CLOSED LOOP operation, the PCM monitors
the sensor input (along with other inputs) and adjusts
the injector pulse width accordingly. During OPEN
LOOP operation, the PCM ignores the sensor input
and adjusts the injector pulse to a preprogrammed
value based on other inputs.
TESTING
# See Figure 37
93154p36 Fig. 37 The HD2S can be monitored with an
appropriate and Data-stream capable scan
tool
Do not pierce the wires when testing this
sensor; this can lead to wiring harness dam-
age. Backprobe the connector to properly
read the voltage of the HD2S.
1. Disconnect the H02S.
2. Measure the resistance between PWR and
GND terminals of the sensor. Resistance should be
approximately 6 ohms at 68°F (20°C) If resistance is
not within specification, the sensor’s heater element
is faulty.
3. With the H02S connected and engine running,
measure the voltage with a Digital Volt-Ohmmeter
(DVOM) between terminals
HD2S and SIG RTN (GND) of the oxygen sensor connector. Voltage
should fluctuate between 0.01-l .O volts. If voltage
fluctuation is slow or voltage is not within specifica-
tion, the sensor may be faulty.
REMOVAL &INSTALLATION
) See Figures 38, 39, 40, 41, and 42
1. Disconnect the negative battery cable
2. Raise and support the vehicle safely.

4-28 DRIVEABILITYAND EMISSIONS CONTROLS
Fig. 88 Plug the scan tool into the DLC un-
Fig. 89 Follow the directions on the scan
der the driver’s side of the instrument panel
tool screen to retrieve the DTC’s 3. Locate the Diagnostic Link Connector (DLC),
which is usually under the left-hand side of the in-
strument panel.
4. Start the engine and drive the vehicle until the
transaxle goes into the failsafe mode.
5. Park the vehicle, but do not turn the ignition
OFF. Allow it to idle.
6. Attach a voltmeter (analog or digital) to the test
terminals on the Diagnostic Link Connector (DLC).
The negative lead should be attached to terminal 4
and the positive lead to terminal 1.
7. Observe the voltmeter and count the flashes
(or arm sweeps if using an analog voltmeter); note
the applicable codes.
- 8. After all of the DTC(s) have been retrieved, fix
the applicable problems, clear the codes, drive the
vehicle, and perform the retrieval procedure again to
ensure that all of the codes are gone.
WITHASCANTOOL
Control module reset procedures are a very im-
portant part of OBD II System diaqnostics.
This step should be done at the end of any fault
code repair and at the end of any driveability repair.
Clearing codes can be performed by any of the
Fig. 90 in this case, we would choor- A ’ ma*-. . . * .
Trouble Codes to retrieve the DTC’s
-.- -
A mere mar
. . methods below: l Clear the control module memory with the
se l-
I I ng. vi me rtim In mts venicie contains no Generic Scan Tool (GST) l DTC’S Clear the control module memory with the ve-
L’-‘m iufacturer’s specific tester
The Federal government decided that it was time
to create a standard for vehicle diagnostic systems
codes for ease of servicing and to insure that certain
of the vehicle’s systems were being monitored for
emissions purposes. Since OBD II codes are stan-
dardized (they all contain one letter and four num-
bers), they are easy to decipher.
The OBD II system in the Mitsubishi models is de-
signed so that it will flash the DTC’s out on a volt-
meter (even though a scan tool is better). However,
the first two characters of the code are not used. This
is because the transaxle is a part of the powertrain, so
all transaxle related codes will begin with a P. Also, *The MIL will may also be de-activated for
some codes if the vehicle completes three
consecutive trips without a fault detected
with vehicle conditions similar to those pre-
sent during the fault.
WITHOUTASCAN TOOL
If there are still codes p
resent, either the codes
were not properly cleared f
:Are the codes identical to
those flashed out previous
I$‘), or the underlying
problem is still there (Are I
only some of the codes the
same as oreviouslv?).
since there are no overlapping numbers between SAE
and Mitsubishi codes, the second digit is also not
necessary.
The system flashes the codes o
ut ma series of
flashes in
three nmm mh nrnlll -- J.-lr-, ---.. ~.--
p corresponding to
one of the
three last diaits of the OBD II code. There-
fore, Code WJJ wuuw UC:
IIKWAJ WI III XVWI flashes, followed by five flashes, then by three
flashes. Each group of flashes is se
pause. All of the flashes are of the (
witi the or$, nvrontinn hoinn mm sented by z
long flash,
(shorted Tt SWIWI LIIW. rparated by a brief
;ame duration,
88, “rw”I.‘L’“‘I uv,,,y LUI”.
Zero is repre-
1 long flash. Therefore, seven flashes, one
two flashes would indicate a PO702 code
3 nnmn^r ,.:*....:I I r
SCANTOOLCODES
. YYY” I ‘I” I cuI”I”.J PO100 Mass or Volume Air Flow Circuit Malfunc-
Lb
non
PO101 Mass orVolume Air Flow Circuit
Range/Performance Problem
PO102 Mass or Volume Air Flow Circuit Low In-
Put
.
To retrieve the codes, perform the following: PO103 Mass or Volume Air Flow Circuit High In-
i Put
1. Perform the preliminary inspection, located PO104 Mass or Volume Air Flow Circuit Intermit-
-;
Vehicle speed es446e35 Fig. 92 For OBO ii code retrieval without us-
ing a scan tool on Mitsubishi models, con-
nect the DVOM and jumper wire as shown
In 1996, all Mitsubishi switched from an arbitrary
code listing and format, to the federally regulated On
Board Diagnostics 2nd Generation (OBD II) code sys-
tern. Normally, OBD II equipped vehicles do not have
the option of allowing the person servicing the vehi-
cle to flash the codes out with a voltmeter; usually a
scan tool is necessary to retrieve OBD II codes. Mit-
subishi, however, does provide this option, earlier in this section. This is very important, since a
loose or disconnected wire, or corroded connector
terminals can cause a whole slew of unrelated DTC’s
to be stored by the computer; you will waste a lot of
time performing a diagnostic “goose chase.”
2. Grab some paper and a pencil or pen to write
down the DTC’s when they are flashed out. tent
PO105 Manifold Absolute Pressure/Barometric
Pressure Circuit Malfunction
PO106 Manifold Absolute Pressure/Barometric
Pressure Circuit Range/Performance Problem
PO107 Manifold Absolute Pressure/Barometric
Pressure Circuit Low Input

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.

DRIVETRAIN 7-3
7. Remove the connection for the clutch release
38. Install the battery.
bolt to 54 ft. Ibs. (73 Nm). Install the front engine roll
cylinder and without disconnecting the hydraulic line,
39. If equipped with Active-ECS, connect the air
stopper through-bolt and hand-tighten. Once the full
and secure it aside.
compressor.
weight of the engine is on the mounts, tighten the
8. Disconnect the backup light switch harness
40. Make sure the vehicle is level when refilling
bolt to 42 ft. Ibs. (57 Nm).
and position aside.
the transaxle. Use Hypoid gear oil or equivalent, GL-
30.
Install the triangular stay bracket and tighten
9. Detach the starter electrical connections, if
4 or higher.
the mounting bolts to 65 ft. Ibs. (88 Nm).
necessary, remove the starter motor and position
41. Check the transaxle and transfer case for
31. Connect the clutch release cylinder.
aside.
proper operation. Make sure the reverse lights come
32. Install the halfshafts, using new circlips on
10. Remove the transaxle mount bracket.
on when in reverse.
the axle ends.
11. Remove the upper transaxle mounting bolts.
12.
Raise the vehicle and support safely on jack-
1!I94-Ol? MODELS
stands.
13. Remove the undercover and the front wheels. 1. Disconnect the negative battery cable and When histalling the axleshaft, keep the in-
14.
Remove the cotter pin and disconnect the tie wait at least 90 seconds before performing any work. board joint straight in relation to the axle, so
rod end from the steering knuckle. 2. Remove the air cleaner and intake hoses. not to damage the oil seal lip of the
15. Remove the self-locking nut from the half- 3. Drain the transaxle into a suitable waste con- transaxle, with the serrated part of the half-
ShaftS. tainer. shaft.
16.
Disconnect the lower arm ball joint from the 4. Remove the cotter pins and clips securing the
steering knuckle. select and shift cables and remove the cable ends 33. Connect the tie rod and ball joints to the steer-
17. Remove the halfshafts from the transaxle. from the transaxle. ing knuckle. Tighten the ball joint self-locking nuts to
18. On AWD models, disconnect the front ex- 5. If equipped with Active-ECS, disconnect the 48 ft. Ibs. (65 Nm). Tighten the tie rod end nut to 21 ft.
haust pipe. air compressor. Ibs. (28 Nm) and secure with a new cotter pin.
19.
On AWD ‘models, remove the transfer case by 6. Disconnect the backup light switch harness 34.
Connect the damper fork to the lower control
removing the attaching bolts, moving the transfer and position aside. arm and tighten the through-bolt to 65 ft. Ibs. (88 Nm).
case to the left and lowering the front side. Remove it 7. Disconnect the speedometer electrical con- 35.
Connect the stabilizer link to the damper fork,
from the rear driveshaft. Be careful of the oil seal. Do nectar, from the transaxle assembly. and tighten the self-locking nut to 29 ft. Ibs. (39 Nm).
not allow the driveshaft to hang; once the front is re- 8. Remove the starter motor and position aside. 36. Install the underpan.
moved from the transfer, tie it up. Cover the transfer 9. Using special tool M2203827 or equivalent, 37. Install wheels and lower vehicle.
case openings to keep out dirt. support the engine assembly. 38. Install the transaxle mount bracket to the
20.
Remove the cover from the transaxle bell- 10. Remove the rear roll stopper mounting transaxle, and tighten the mounting nuts to 32 ft. Ibs.
housing. bracket. (43 Nm).
21. On AWD models, remove the crossmember 11. Remove the transaxle mount bracket. 39. install the rear roll stopper mounting bracket.
and the triangular gusset. 12. Remove the upper transaxle mounting bolts. 40.
Remove the engine support. Tighten the
22. Remove the transaxle lower coupling bolt. It 13. Raise and safely support the vehicle. transaxle mount through-bolt to 51 ft. Ibs. (69 Nm)
is just above the halfshaft opening on FWD or trans- 14. Remove the front wheel assemblies. and tighten the front engine roll stopper through-bolt.
fer case opening on AWD. 15. Remove the right hand undercover. 41. Install the upper transaxle mounting bolts
23.
Support the weight of the engine from above 16. Remove the cotter pin and disconnect the tie and tighten to 35 ft. Ibs. (48 Nm).
(chain hoist). Support the transaxle using a transmis- rod end, from the steering knuckle. 42. Install the starter motor.
sion jack and remove the remaining lower mounting 17. Disconnect the stabilizer bar link, from the 43. Attach the backup light switch and the
bolts. damper fork. speedometer connector.
24. On turbocharged vehicle, be careful not to 18. Disconnect the damper fork, from the lateral 44.
Connect the select and shift cables and install
damage the lower radiator hose with the transaxle lower control arm. new cotter pins.
housing during removal. Wrap tape on both the lower 19. Disconnect the later lower arm, and the com- 45.
Install the air cleaner and the air intake hose.
hose and the transaxle housing to prevent damage. pression arm, lower ball joints, from the steering 46. Connect the negative battery cable.
Move the transaxle assembly to the right and care- knuckle. 47. Make sure the vehicle is level, and refill the
fully lower it from the vehicle. 20. Pry the halfshafts from the transaxle, and se- transaxle.
To install: cure aside. 48.
Check the transaxle for proper operation. Make
25.
Install the transaxle to the engine and install 21. Remove the connection for the clutch release sure the reverse lights come on when in reverse.
the mounting bolts, Tighten the bolts to 35 ft. Ibs. (48 cylinder and without disconnecting the hydraulic line,
Nm). Install the transaxle lower coupling bolt. secure aside.
26.
Install the underpan, crossmember and the 22. Remove the cover from the transaxle bell-
triangular gusset. housing.
27.
Install the transfer case on AWD models and 23. Remove the engine front roll stopper REMOVAL&INSTALLATION
connect the exhaust pipe. through-bolt.
28.
Install the halfshafts, using new circlips on 24. Remove the crossmember and the triangular ) See Figures 1 thru 13
the axle ends. Try to keep the inboard joint straight in right hand stay.
relation to the axle. Be careful not to damage the oil 25. Support the transaxle, using a transmission
seal lip of the transaxle with the serrated part of the jack, and remove the transaxle lower coupling bolt.
halfshaft.
29. Connect the tie rod and ball joint to the steer- *The coupling bolt threads from the englne
side, into the transaxle, and is located just
ing knuckle.
30. Install the transaxle mount bracket. above the halfshaft opening.
31. Install wheels and lower vehicle. Retorque 26. Slide the transaxle rearward and carefully
axle shaft nuts to 145-188 ft. Ibs. (200-260 Nm). lower it from the vehicle.
32. Install the starter motor. To install:
33. Connect the backup light switch and the 27. Install the transaxle to the engine. Install the
speedometer cable. mounting bolts and tighten to 35 ft. Ibs. (48 Nm). In-
34. Install the clutch release cylinder. stall the transaxle lower coupling bolt and tighten to
35.
Connect the select and shift cables and install 22-25 ft. Ibs. (30-34 Nm).
new cotter pins. 28. Install the cover to the transaxle bellhousing
36. Install the air intake hose. and tighten the mounting bolts to 7 ft. Ibs. (9 Nm).
37. Install the auto-cruise actuator and bracket. 29. Install the crossmember and tighten the front
mounting bolts to 65 ft. Ibs. (88 Nm) and the rear

DRIVETRAIN 7-9
*When adjusting the clutch pedal height or
the clutch pedal clevis pin play, be careful
not to push the pushrod toward the master
cylinder.
d. Check that when the clutch pedal is de-
pressed all the way, the interlock switch switches
over from ON to OFF.
ADJUSTMENT
# See Figure 42
*The following adjustment is for the cable
actuated clutch system on the Mirage. The
Hydraulic systems on all other models are
self-adjusting.
1. Measure the clutch pedal height (measurement
A). The specificatron is 6.38-6.50 in.
(162-165mm).
*The clutch pedal height is not adjustable.
If not within specifications, part replacement
is required.
2. Depress clutch pedal several times and check
the pedal free-play (measurement B).
3. If measurement is not 0.67-0.87 in.
(17-22mm), adjustment is required.
4. To adjust, turn the outer cable adjusting nut,
located at the firewall, until free-play is within range.
5. Depress the clutch pedal several times and
recheck the measurement.
REMOVALANDINSTALLATION
1. Rotate the adjusting wheel counterclockwise to
loosen the cable.
2. Remove the cable retaining clamps.
3. Remove the cotter pin from the clutch actuat-
ing arm at the transaxle and disconnect the cable.
4. Disconnect the cable at the pedal and remove
the cable from the vehicle.
rln order to prevent cable binding or abra-
sion, be sure to take note of the cable rout-
ing, so that it can be reinstalled in the same
position.
To install:
5. Route the cable and make the connection at the
clutch pedal.
6. Make the connection at the transaxle and se-
cure the cable with the retaining clamp. Install a new
cotter pin.
7. Lubricate all pivot points.
8 Adjust the cable to achieve proper free-play.
REMOVAL &INSTALLATION
I
1. Disconnect the negative battery cable.
2. Remove necessary underhood components in
order to gain access to the clutch master cylinder.
Clutch pedal height
Fig. 42 Clutch pedal height (A) measure-
ment-Mirage
7923PGDl
3. Place a suitable drain pan under the vehicle to
catch the fluid once the line IS drsconnected, or place
a rag or shop towel under the fluid line of the master
cylinder.
4. Loosen the line at the cylinder and allow the
fluid to drain.
Clean, high quality brake fluid is essential to
the safe and proper operation of the brake
system. You should always buy the highest
quality brake fluid that is available. If the
brake fluid becomes contaminated, drain and
flush the system, then refill the master cylin-
der with new fluid. Never reuse any brake
fluid. Any brake fluid that is removed from
the system should be discarded. Also, do not
allow any brake fluid to come in contact with
a oainted surface; it will damage the paint.
5. Remove the clevis pin retainer at the clutch
pedal and remove the washer and clevis pm.
6. Remove the 2 nuts and pull the cylinder from
the firewall. A seal should be between the mounting
flange and firewall. This seal should be replaced.
7. The installation is the reverse of the removal
procedure.
8. Lubricate all pivot points with grease.
9. Bleed the system at the slave cylinder using
DOT 3 brake fluid and check the adjustment of the
clutch pedal.
REMOVAL &INSTALLATION
1. Disconnect the negative battery cable
2. Remove necessary underhood components in
order to gain access to the clutch release cylinder.
3. Place a suitable drain pan under the vehicle,
then remove the hydraulic line and allow the system
to drain.
Clean, high quality brake fluid is essential to
the safe and proper operation of the brake
system. You should always buy the highest quality brake fluid that is available. If the
brake fluid becomes contaminated, drain and
flush the system, then refill the master cylin-
der with new fluid. Never reuse any brake
fluid. Any brake fluid that is removed from
the system should be discarded. Also, do not
allow any brake fluid to come in contact with
a uainted surface; it will damage the paint.
4. Remove the bolts and pull the cylinder from
the transaxle housing. On some 1.5L engines, in-
stead of a pushrod bearing against the clutch arm, a
clevis pin and yoke is used. Simply remove the cir-
clip, pull out the clevis pin and remove the cylinder.
5. The installation IS the reverse of the removal
procedure.
6. Lubricate all pivot points with grease.
7. Bleed the system using DOT 3 brake fluid.
HYDRAULIC SYSTEM BLEEDING
) See Figure 43
With Hydraulic Clutch
1, Fill the reservoir with clean brake fluid meeting
DOT 3 specificatrons.
Clean, high quality brake fluid is essential to
the safe and proper operation of the brake
system. You should always buy the highest
quality brake fluid that is available. If the
brake fluid becomes contaminated, drain and
flush the system, then refill the master cylin-
der with new fluid. Never reuse any brake
fluid. Any brake fluid that is removed from
the system should be discarded. Also, do not
allow any brake fluid to come in contact with
a painted surface; it will damage the paint.
2. Press the clutch pedal to the floor, then open
the bleeder screw on the slave cvlinder.
3. Tighten the bleed screw and release the clutch
pedal.
4. Repeat the procedure until the fluid is free of
air bubbles.
7923PG91 Fig. 43 Bleeding a typical clutch hydraulic
system

. . . ,.x ..-~ .-....,, _s_s”., .._ ” *
8-28 SUSPENSION AND STEERING
REMOVAL&INSTALLATION
199%93 Mirage 1994-00 Mirage and Galant
b See Figures 76 thru 85 the NEUTRAL mark on the clockspring with the mat-
f ing mark on the casing. Then, install the steering
wheel and tighten the new retaining nut to 29 ft. Ibs.
(40 Nm).
8. Install the air bag module.
1. Disconnect the negative battery cable.
2. Remove the horn pad from the steering wheel,
by pulling the lower end of the pad upward. Detach I
If aqui
arm it --.-.- ---.-...= .-r-.‘- -.. _..- ._.. - -
Failure to do so could result in severe per-
sonal injury and damage to vehicle. pped with an air bag, be sure to dls- hnfnra sfarfinn rmairs on the vehicle.
9. Connect the negative battery cable, turn the key
to the ON position; the SRS warning light should illu-
minate for seven seconds and go out.
1990-93 Galant
hbin butin connector.
3. Remove steering wheel retaining nut:
. . . .‘ .
a. .a I <.
4. Matcnmarlc me steering wneel to me snan.
5. Use a steering wheel puller to remove the
steering wheel.
Do not hammer on steering wheel to remove
it. The collapsible column mechanism may
ha rlsmwmd.
To install:
6. Line up the matchmarks and install the steer-
ing wheel to the shaft.
7. Ti flhten the steering wheel attaching nut to 29
ft. Ibs. (40 Nm).
8. Reconnect the horn connector and install the
horn pad.
9. Connect the neaative battetv cable. 1. Disarm the SRS system as outlined in Section 6.
^ m *I
sand the air bag module
.,A +L. m++-,g w,,eel,
*. I z. Remove me cover
mounting nut from behill” ~IK ~(G~G!I
3. To detach the connector of the clocKsprmfl
from the air bag module, press the air bag’s lock to-
ward the module to spread the lock open. While
holding lock in this position, use a small tipped pry-
ing tool to gently pry the connector from the module.
4. Remove the air bag module and store in a
clean, dry place with the pad cover facing up.
5. Matchmark the steering wheel to the shaft.
6. Remove the steering wheel retaining nut and
use a steering wheel puller to remove the wheel. Do
not use a hammer, or the collapsible mechanism in
the column could be damaged.
To install:
7. Confirm that the front wheels are in a straight-
ahead position. Center the clocksprinfl by aligning 1. Disconnect the negative battery cable.
2. Remove the horn oad from the steerino wheel
as follows:- - - - r d
a. For 1990-91 models only, the horn pad is
removed by pushing the pad upward, to release
the pad from the retaining clips. Detach horn but-
ton connector and remove the pad.
b.
For 1992-93 models only, remove the
screw from the bottom of the pad and push the
pad upward, to release the pad from the retaining
clips. Detach horn button connector and remove
the pad.
3. Remove steering wheel retaining nut.
4. Matchmark the steering wheel to the shaft.
5. Use a steering wheel puller to remove the
steering wheel.
Fig. 76 The air bag is retained by two 8
located in access holes on the back
wheel. Remove the covers to access the
screws Fig. 78 After the air baa
retainino screws
Fig. 77 The retaining screws usually require are removed, grasp the airbag andiarefully
a Torx@ drive tool to remove them pull it from the steering wheel . . .
then detach the connector and Fig. 80 To prevent personal injury, ALWAYS fig. 81 To prevent personal Injury, ALWAYS
ove the air bag module from the vehi- carry a live air bag facing away from you in place a live airbag with the cover facing up

SUSPENSION AND STEERING 8-29
i ’
Do not hamme i4 l-ha nnlhnr !r on steering wheel to remove
,,. , II= ,,,,,,Jfble column mechanism may REMOVALANDINSTALLATION
I
be damaged.
To install:
ing

7.
6. Line up the matchmarks and install the steer-
/heel to the shaft.
Tighten the steering wheel attaching nut to
25-33 ft. Ibs. (35-45 Mm).
8. Attach the horn connector and install the horn
pad.
9. Connect the negative battery cable.
Diamante The air bag system (SRS or SIR) must be dis-
armed before removing the steering wheel.
Failure to do so may cause accidental de-
ployment, property damage or personal in-
MY.
1 Rscnnnnd the nnmtivn hattm rJhle . I._“” . ..I_. . ..I *.-~ _...” ““.‘“‘, _““._. 2. If equipped, disable the air bag system.
3. Remove the steering wheel as outlined earlier
in this section.
Be sure to disarm the SRS (air bag
before starting repairs OI
to do so could result in p
death. DO NOT perform ;
cle until after 90 seconds has passed. The ai
bag system is designed to retain enough
short term voltage to make air bag deploy-
ment possible; I) system,
n the vehicle. Failure
lersonal injury or
any work on the vehi-
ir 4. For Diamante models, remove the hood lock
release handle.
5. Remove the knee protector panel under the
steering column, then the upper and lower column
covers.
6. For Diamante models, remove the lap cooler
and foot blower duct work as necessary. Carefully de-
non
b. 1. Disarm the SRS system as outlined in Sec-
. . ^ I assembly. tach the combination switch connecto&.
8. -
7. For Mirage models, detach all connectors,
For Galant models, if equipped, remove the remove the wiring clip and remove the column switch
2. Remove the air bag module mounting nut
from behind the steering wheel.
3. Matchmark the steering wheel.
4. Detach the connector of the clockspring from
the air baq module, press the air baa’s lock towards four screws retaining the cruise control slip ring to
the switch.
9. For Galant models, remove the two retaining
screws from the combination switch and remove the
switch from the column.
Tn install: the modub to spread the lock open:While holding
lock in this position, use a small tipped prying tool to
gently pry the connector from the module.
5. Store the air bag module in a clean, dry place
..# ,I I I .
ut.
Iaft. wlrn me paa cover racmg up.
6. Remove the steering wheel retaining nl
7. Matchmark the steering wheel to the sl
8. Use a steering wheel puller to remove the
wheel. - . . - _-. . _
10. Install the switch assembly and secure all
harness connectors with clips if needed. Make sure
the wires are not pinched orout of place.
11. Install the column covers and knee protector
and all connectors.
12. If removed, install the foot blower duct work
anfl tan cnnler -..- .-
r --- ”
13. Confirm that the front wheels are in a
straight-ahead position.
14. Install the steering wheel, as outlined earlier
in thir
Do not use a hammer or the ~r”---‘~‘- 15. Connect the negative battery cable, turn the
key to the ON position, the SRS warning light should
NW down
rinntlv
wImpl* the puller
iem Fig. 84 . . . then tighte
until the wheel is suffL,,,,, lVvoV
To install:
0 Pnnfirm that thn frnnt whnalc ,?A in , .I. ““llllllll u,a, ,110 ll”lll I.ll~rJlJ CnIj 111 a
straight-ahead position. Center the clockspring by
aligning the NEUTRAL mark on the clockspring with
the mating mark on the casing.
10. Line up and install the steering wheel. illuminate for seven seconds and go out. If the warn-
ing light is not functioning properly, refer to SRS
s’ .’ ystem cllagnosls.
16. Check all functions of the combination switch
for proper operation.
wheel lows:
a. Position the front wheels in the straight
ahead position and place the key in the LOCK
93158p12 Fig. 85 Lift the steering wheel straight off
of the steering column and remove the 11. Tighten the retaining nut as follows:
REMOVAL &INSTALLATION

l On 1992-93 Diamante models, tighten the
nut to 29 ft. Ibs. (40 Nm) retammg I
l On
retaining I
12. lnstal
taining nuts 1
13. Conn
“... . ..” .‘“J...*.” ‘&.“WSJ Y..“.” . ..rn” VII”“..
the SRS warning light operation. 1994-00 Diamante models, tighten the
iut to 33 ft. Ibs. (45 Nm)
II the air bag module and tighten the r&
:o 48 inch Ibs. (5 Nm).
wt the rwnative hatim rahle ami rhwk
*On vehicles not covered here, the wind-
shield wiper switch is incorporated into the
combination switch and is not separately serl
viceable. Refer to the procedure
above.
Diamante
1. Disconnect the negative battery cable.
2. If equipped with an air bag, disarm as fol-
I” .L

8-30 SUSPENSION AND STEERING
position. Remove the key from the ignition lock
cylinder.
b. Disconnect the negative battery cable and
insulate the cable end with high-quality electrical
tape or similar non-conductive wrapping.
c. Wait at least 1 minute before working on
the vehicle. The air bag system is designed to re-
tain enough voltage to deploy the air bag for a
short period of time even after the battery has
been disconnected.
3. Remove the steering wheel. as outlined ear-
lier in this section.
4. Remove the hood lock release handle.
5. Remove the switches from the knee protector
below the steering column, and remove the exposed
retaining screws. Then remove the knee protector.
6. Remove the column covers.
7. Remove necessary duct work and detach the
windshield wiper switch connectors. +
8. Remove the retaining screws and remove the
windshield wiper switch assembly from the steering
column.
To install: 9. Install the wiper switch to the steering col-
umn and connect the connectors.
IO. Install any removed duct work.
11. Install the column covers.
12. Install the knee protector and switches.
13. Install the hood release handle.
14. Confirm that the front wheels are in a straight
ahead position. Install the steering wheel, as outlined
earlier in this section.
15. Connect the negative battery cable and check
the windshield wiper and washer for proper opera-
tion
REMOVAL &INSTALLATION
The air bag system (SRS or SIR) must be dis-
armed before removing the steering wheel.
Failure to do so may cause accidental de-
ployment, property damage or personal in-
jury.
1. If equipped, properly disarm the air bag sys-
tern:
2. Disconnect the negative battery cable.
3. Remove the hood lock release lever from the
lower panel.
4. Remove the lower instrument panel knee pro-
tector.
5. Remove the ductwork with the lower knee
panel and remove the steering wheel assembly.
Use proper steering wheel puller equipment
when removing the steering wheel. The use
of a hammer for removal could damage the
collapsible mechanism within the column.
6. Remove the lower and upper steering column
covers.
7. For Diamante models, remove the lap cooler
and foot shower duct work.
8. If necessary, remove the clip that holds the
wiring harness against the steering column. 9. Detach all necessary connectors.
10. For Galant and Diamante models, remove the
retaining screws, then remove the entire column
switch/clockspring assembly from the left side of the
steering column.
11. For Diarnante models, remove the mounting
screws from the ignition switch and pull the switch
from the interlock cylinder.
12. Insert the key into the steering lock cylinder
and turn to the
ACC position.
13. With a small, pointed tool, push the lock pin
of the steering lock cylinder inward and pull the lock
cylinder out.
14. Remove the key reminder switch, if equipped.
To install: 15. For Mirage, install the lock cylinder in the
lock cylinder bracket. Make sure the cylinder oper-
ates properly before breaking off the heads of the
special bolts, if the bracket was replaced.
16. For Galant and Diarnante models, install the
lock cylinder into the interlock housing. Be sure the
lock pin snaps into place. Install the ignition switch
into the interlock housing. Align the keyway of the ig-
nition switch with the lock cylinder and secure with
the mounting screws.
17. For Galant and Diamante models, install the
column switch/clockspring assembly to the and con-
nect the harness.
18. install the key reminder switch, if equipped.
19. Attach the harness connections and install
the wiring clip.
20. If removed, install the lap cooler and foot
shower duct work.
21. Install the steering column upper and lower
covers.
22. If necessary, install the knee protector and the
steering wheel.
23. Install the hood lock release lever.
24. Connect the negative battery cable, enable the
air bag system, and check the ignition switch and
lock for proper operation.
REMOVALANDINSTALLATION
Mirage and Galant
I. Disconnect the negative battery cable. If
equipped, disarm the air bag system.
2. Remove the hood lock release lever from the
lower panel.
3. Remove the lower instrument panel knee pro-
tector.
4. Remove the ductwork with the lower knee
panel and remove the steering wheel assembly.
*Use proper steering wheel puller equip-
ment when removing the steering wheel. The
use of a hammer for removal could damage
the collapsible mechanism within the col-
umn.
5. Remove the lower steering column cover.
6. Remove the upper steering column cover.
7. Remove the clip that holds the wiring harness
against the steering column.
8. For Galant models, insert the key into the
steering lock cylinder and turn to the ACC position.
9. For Galant models, using a small pointed
tool, push the lock pin of the steering lock cylinder
inward and pull the lock cylinder out. IO. For Galant models, remove the key reminder
switch, if equipped.
11. Unplug the ignition switch harness connec-
tor. Remove the ignition switch mounting screws and
pull the switch from the steering lock cylinder.
*Vehicles equipped with automatic
transaxle have safety-lock systems and will
have a key interlock cable installed in a slide
lever on the side of the key cyfinder. Care-
fully unhook the interlock cable from the lock
cylinder while withdrawing the cylinder from
the lock housing.
To install:
*To remove the steerlng lock, use a hack-
saw or equivalent to cut the special bolts
through the bracket. The bracket and bolts
must be replaced with new ones.
12. With the ignition key removed, install the
slide lever and the interlock cable to the steering lock
cylinder. Apply grease to the interlock cable and in-
stall the cylinder into the lock housing. Check for
normal operation of the interlock system.
13. Install the ignition switch into the rear of the
lock cylinder housing. Be sure to align the keyway of
the ignition switch with interlock cylinder.
14. Attach the harness connections and install
the wiring clip.
15. Install the steering column upper and lower
covers.
16. Install the knee protector.
17. Connect the negative battery cable, enable the
air
bag system (if equipped) and check the ignition
switch and lock for proper operation.
Diamante
Work MUST NOT be started until at least 90
seconds after the ignition switch is turned to
the LOCK position and the negative battery
cable is disconnected from the battery. This
will allow time for the air bag system backup
power supply to deplete its stored energy
preventing accidental air bag deployment
which could result in unnecessary air bag
system repairs and/or personal injury.
I. Disconnect the negative battery cable.
2. Disarm the air bag system, as outlined in
Section 6.
3. Remove the steering wheel, as outlined ear-
lier in this section.
4. Remove the hood lock release handle.
5. Remove the switches from the knee protector
below the steering column and remove the exposed
retaining screws. Then remove the knee protector.
6. Remove the steering column upper and lower
covers. Use care removing the covers to prevent
breakage of alignment tabs.
7. Remove lap cooler and foot shower
duct work. Detach the ignition switch harness connectors.
8. Remove mounting screws from the ignition
switch and pull switch from interlock cylinder.
To install: 9. Install ignition switch into interlock housing.
Align keyway of ignition switch with lock cylinder and
secure with mounting screws.
IO. Connect the ignition switch electrical harness
Plug.