MITSUBISHI DIAMANTE 1900 Owner's Guide

.
1-32 GENERALINFORMATIONAND MAINTENANCE
CONDITION
EFFECT
CAUSE
CORRECTION UNDER-INFLATION
EXCESSIVE SPEED’ WORN OR OUT-
OF-ALIGNMENT
ADJUST PRESSURE TO
SPECIFICATIONS WHEN
TIRES ARE COOL
ROTATE TIRES
/ BALANCE WHEELS INSPECT SUSPENSION
HAVE TIRE INSPECTED FOR FURTHER USE.
lCCSi267 ig. 144 Common tire wear patterns and causes
1~~~1265 Fig. 145 Tread wear indicators will appear
when the tire is worn
inflation, do not drive more than a mile before check-
ing. A cold tire is generally one that has not been dri-
ven for more than three hours.
A plate or sticker is normally provided somewhere
in the vehicle (door post, hood, tailgate or trunk lid)
which shows the proper pressure for the tires. Never
counteract excessive pressure build-up by bleeding
off air pressure (letting some air out). This will cause
the tire to run hotter and wear quicker.
Never exceed the maximum tire pressure
embossed on the tire! This is the pressure to
be used when the tire is at maximum load-
ing, but it is rarely the correct pressure for
everyday driving. Consult the owner’s man-
ual or the tire pressure sticker for the correct
tire pressure.
Once you’ve maintained the correct tire pressures
for several weeks, you’ll be familiar with the vehicle’s
braking and handling personality. Slight adjustments
in tire pressures can fine-tune these characteristics,
1~~~1264 Fig. 146 Accurate tread depth indicators are
inexuensive and handv
Fig. 147 A penny works well for a quick
check of tread death
but never change the cold pressure specification by
more than 2 psi. A slightly softer tire pressure will
give a softer ride but also yield lower fuel mileage. A
slightly harder tire will give crisper dry road handling
but can cause skidding on wet surfaces. Unless
you’re fully attuned to the vehicle, stick to the recom-
mended inflation pressures.
All tires made since 1968 have built-in tread wear
indicator bars that show up as j/2 in. (13mm) wide
smooth bands across the bre when V,~ in. (1.5mm) of
tread remains. The appearance of tread wear indica-
tors means that the tires should be replaced. In fact,
many states have laws prohibiting the use of tires
with less than this amount of tread.
You can check your own tread depth with an inex-
pensive gauge or by using a Lincoln head penny.
Shp the Lrncoln penny (with Lincoln’s head upside- down) into several tread grooves. If you can see the
top of Lincoln’s head in 2 adjacent grooves, the tire
has less than V,~ in. (1.5mm) tread left and should be
replaced. You can measure snow tires in the same
manner by using the “tails” side of the Lincoln
penny. If you can see the top of the Lincoln memor-
ial, its time to replace the snow tire(s).
CAREOFSPECIALWHEELS
If you have invested money in magnesium, alu-
minum alloy or sport wheels, special precautions
should be taken to make sure your investment is not
wasted and that your special wheels look good for the
life of the vehicle.
Special wheels are easily damaged and/or
scratched. Occasionally check the rims for cracking,
impact damage or air leaks. If any of these are found,
replace the wheel. But in order to prevent this type of
damage and the costly replacement of a special
wheel, observe the following precautions:
l Use extra care not to damage the wheels dur-
ing removal, installation, balancing, etc. After re-
moval of the wheels from the vehicle, place them on a
mat or other protective surface. If they are to be
stored for any length of time, support them on strips
of wood. Never store tires and wheels upright; the
tread may develop flat spots.
l When driving, watch for hazards; it doesn’t take
much to crack a wheel.
l When washing, use a mild soap or non-abra-
sive dish detergent (keeping in mind that detergent
tends to remove wax). Avoid cleansers with abrasives
or the use of hard brushes. There are many cleaners
and polishes for special wheels.
l If possrble, remove the wheels during the win-
ter. Salt and sand used for snow removal can se-
verely damage the finish of a wheel.
l Make certain the recommended lug nut torque
is never exceeded or the wheel may crack. Never use
snow chains on special wheels; severe scratching
will occur.

GENERALINFORMATIONAND MAINTENANC-E 1133
Used fluids such as engine oil, transaxle fluid, an-
tifreeze and brake fluid are hazardous wastes and
must be disposed of properly. Before draining any
fluids, consult with your local authorities; in many ar-
eas, waste oil, antifreeze, etc. is being accepted as a
part of recycling programs. A number of service sta-
tions and auto parts stores are also accepting waste
fluids for recycling.
Be sure of the recycling center’s policies before
draining any fluids, as many will not accept different
fluids that have been mixed together.
ENGINE OIL
6 See Figure 148
WMitsubishi recommends that SAE 5W-30
viscosity engine oil should be used for all clia
mate conditions, however, SAE low-30 is ac
ceptable for vehicles operated in moderate-
to-hot climates. the SAE number, the lighter the oil; the lower the vis-
cosity, the easier it is to crank the engine in cold
weather but the less the oil will lubricate and protect
the engine in high temperatures. This number is
marked on every oil container.
Oil viscosity’s should be chosen from those oils
recommended for the lowest anticipated temperatures
during the oil change interval. Due to the need for an
oil that embodies both good lubrication at high tem-
peratures and easy cranking in cold weather, multi-
grade oils have been developed. Basically, a multi-
grade oil is thinner at low temperatures and thicker at
high temperatures. For example, a low-40 oil (the W
stands for winter) exhibits the characteristics of a 10
weight (SAE 10) oil when the car is first started and
the oil is cold. Its lighter weight allows it to travel to
the lubricating surfaces quicker and offer less resis-
tance to starter motor cranking than, say, a straight
30 weight (SAE 30) oil. But atier the ensine reaches
operating temperature, the low-40 oil begins acting
like straight 40 weight (SAE 40) oil, its heavier weight
providing greater lubrication with less chance of
foaming than a straight 30 weight oil. Synthetic oil is not for every car and every type of
driving, so you should consider your engine’s condi-
tion and your type of driving. Also, check your car’s
warranty conditions regarding the use of synthetic oils.
FUEL
All models equipped with a SOHC (Single Over-
head Camshaft) engine are designed to operate using
regular unleaded fuel with a minimum of 87 octane.
All models equipped with a DOHC (Dual Overhead
Camshaft) engine are designed to operate using reg-
ular unleaded fuel with a minimum of 91 octane. Mit-
subishi warns that using gasoline with a lower octane
rating can cause persistent and heavy knocking, and
may cause internal engine damage.
If your vehicle is having problems with rough idle
or hesitation when the enoine is cold, it mav be
caused by low volatility fuel. If this occurs, iry a dif-
ferent grade or brand of fuel.
'OPERATION 1~ FOREIGN COUNTRIES
lccS1235 Fig. 148 look for the API oil identification
Non-detergent motor oils or straight mineral
label when choosing your enaine oil oils should not be used in your engine.
When adding oil to the crankcase or changing the
0 Nil or filter, it is important that oil of an equal quality
I original equipment be used in your car. The use of
. tc mtenor 011s may void the warranty, damage your en-
gine, or both. __
The SAE (Society of Automotive Engineers) grade
number of oil indicates the viscosity of the oil (its
ability to lubricate at a given temperature). The lower
Fig. 149 Grasp the oil level dipstick and pull
upward to remove it from the dipstick
tube
The API (American Petroleum Institute) designa-
tions, also found on the oil container, indicates the
classification of engine oil used under certain given
operating conditions. Only oils designated for use
Service SJ heavy duty detergent should be used in
your car. Oils of the SJ type perform may functions If you plan to drive your car outside the United
States or Canada, there is a possibility that fuels will
be too low in anti-knock quality and could produce
engine damage. It is wise to consult with local au-
thorities upon arrival in a foreign country to deter-
mine the best fuels available.
inside the engine besides their basic lubrication.
Through a balanced system of metallic detergents
and polymeric dispersants, the oil prevents high and
low temperature deposits and also keeps sludge and
dirt particles in suspension. Acids, particularly sulfu-
OILLEVELCHECK ric acid, as well as other by-products of engine com-
bustion are neutralized by the oil. If these acids are
# See Figures 149, 150, and 151
allowed to concentrate, thev can cause corrosion and
rapid wear of the internal engine parts.
Synthetic Oil
There are many excellent synthetic and fuel-effi-
cient oils currently available that can provide better
gas mileage, longer service life and, in some cases,
better engine protection. These benefits do not come
without a few hitches, however; the main one being
the price of synthetic oil, which is significantly more
expensive than conventional oil.
.
The EPA warns that urolonoed contact with used engine oil ma; cause-a number of skin
disorders, including cancer! You should
make every effort to minimize your exposure
to
used engine oil. Protective gloves should
be worn when changing the oil. Wash your
hands and any other exposed skin areas as
soon as possible after exposure to used en-
gine oil. Soap and water, or waterless hand
cleaner should be used.
Fig. 150 Wipe the dipstick clean and rein-
sert it into the dipstick
tube to get the cor-
rect oil level The engine oil dipstick is typically located in the
Fig. 151 The oil level should be between the
marks/notches on the dipstick

.
l-34 GENERALINFORMATIONAND MAINTENANCE
Engine oil level should be checked every time you
put fuel in the vehicle or are under the hood perform- miles of highway driving. Fluid which is warmed to
normal operating temperature will flow faster, drain
ing other maintenance.
1. Park the vehicle on a level surface.
2. The enaine mav be either hot or cold when
, if it is hot, wait a few min- checking oil level. The EPA warns that prolonged contact with
used engine oil may cause a num’ * * *
dianrAnrr inrldinn ranrnrl V#lll more completely and remove more contaminants
frnm tho clnnine
utes after the engine has been turned OFF to allow the
oil to drain back into the crankcase. If the engine is
cold, do not start it before checking the oil level. point on the oil pan. If not, you may have to raise the
vehicle slightly higher on one jackstand (side) than
3. Open the hood and locate the engine oil dip-
stick. Pull the dipstick from its tube, wipe it clean,
and reinsert it. Make sure the diDstick is fullv in-
serted.
4. Pull the dipstick from its tube again. Holding it to used engin
be worn whet
handsandan
so*m ..#a . . . . .
IDer 01 SKlll u,yu,u=,+, ,,,u,uu,,,u uu,,u=, i , vu should
uff art to minimize your exposure
le oil. Protective gloves should
1 changing the oil. Wash your
y other exposed skin areas as
111 aJ vv4ble after exposure to used en-
m nil St-mn mwl w&or nr umtarlncr hand gin Y “II. ““up “ll” .,U.“I, “rn W.Y.“. .““I .I....” cleaner should be used.
horizontally, read the oil level. The oilshould be be-
tween the MIN and MAX marks or the notches on the
dipstick. If the oil is below the MIN mark or lower
notch, add oil of the proper viscosity through the
capped opening of the valve cover. *The engine oil and oil filter should be
changed at the recommended intervals on
the Maintenance Chart. Though some manu-
facturers have at times recommended chang-
ing the filter only at every other oil change, ’
Chilton recommends that you always change
ll”,,, Cl>” ““y”‘“. 1. Raise and support the vehicle safely on jack-
stands. Make sure the oil drain olua is at the lowest
the other.
2. Before you crawl under the vehicle, take a look
at where you will be working and gather all the nec-
essary tools, such as a few wrenches or a ratchet and
strip of sockets, the drain pan, some clean rags and,
if the oil filter is more accessible from underneath the
vehicle, you will also want to grab a bottle of oil, the
new filter and a filter wrench at this time.
5. Reolace the diostick. and check the level aaain
. The benefit of fresh oil
p See Figures 152 thru 153
The oil and filter should be changed every 7,500
miles (12,000 km) under normal service and every
3,000 miles (5,000 km) under severe service.
93151p-55 Fig. 152 loosen the drain plug on the en-
a wrench. The drain plug’s 3. Position the drain pan beneath the oil pan
drain plug. Keep in mind that the fast flowing oil,
which will spill out as you pull the plug from the pan,
will flow with enough force that it could miss the pan.
Position the drain pan accordingly and be ready to
move the pan more directly beneath the plug as the
oil flow lessens to a trickle.
4. Loosen the drain ~lua with a wrench (or socket
and driver), then carefuliy unscrew the plug with your
fingers. Use a rag to shield your fingers from the
heat. Push in on the plug as you unscrew it so you
draining the oil, make sure that the engine is at oper- can feel when all of the screw threads are out of the
ating temperature. Hot oil will hold more impurities hole (and so you will keep the oil from seeping past
in suspension and will flow better, allowing the re- the threads until you are ready to remove the plug).
moval of more oil and dirt. You can then remove the plug quickly to avoid hav-
It is a good idea to warm the engine oil first so it ing hot oil run down your arm. This will also help as-
will flow better. This can be accomolished bv 15-20 sure that have the plug in your hand, not in the bot-
tom of a pan of hot oil.
Fig. 153 When loosened sufficiently, slowly
turn the drain plug by hand, keeping con- Fig. 154 When you are ready, carefully pull
Fig. 156 Also inspect the drain plug th
before installing it back into the oil
Fig. 155 Clean and inspect the threads on
the oil pan Make sure the gasket on the drain plug is
in place and does not require replacement Fig. 157 A plier-type filter wrench Is used
here to loosen the filter

GENERALINFORMATIONAND MAINTENANCE l-35
Fig. 158 When the filter is sufficiently loos-
Fig. 181 Before installing a new oil filter,
clean the gasket mounting surface of the oil
filter housing and inspect the threads Fig. 182 Loosen and remove the oil filler
cap . . .
surface. When you tighten the filter, rotate it about a
quarter-turn after it contacts the mounting boss (or Fig. 183 . , , then insert a funnel, and pour
oil directly into the engine
follow any instructions
which are provided on the fil-
ter or parts box).
Operating the engine without the proper
amount and type of engine oil will result In
severe engtne damage. FLUID RECOMMENDATIONS
For all vehicles with manual transaxles, use Hy-
poid gear oil SAE 75W-85W, or 75W-9OW conform-
ing to API specifications GL-4 or higher.
LEVELCHECK Be careful of the oil; when at operating tem-
perature, it is hot enough to cause a severe
bum.
5. Allow the oil to drain until nothing but a few
drops come out of the drain hole. Check the drain
plug to make sure the threads and sealing surface are
not damaged. Carefully thread the plug into position
and tighten it snug, and give a slight additional turn.
You don’t want the plug to fall out (as you would
quickly become stranded), but the pan threads are
EASILY stripped from overtightening (and this can be
time consuming and/or costly to fix).
6. To remove the filter, you may need an oil filter
wrench since the filter may have been fitted too
tightly and/or the heat from the engine may have
made it even tighter. A filter wrench can be obtained
at any auto parts store and is well-worth the invest-
ment. Loosen the filter with the filter wrench. With a
rag wrapped around the filter, unscrew the filter from
the boss on the side of the engine. Be careful of hot
oil that will run down the side of the filter. Make sure
that your drain pan is under the filter before you start
to remove it from the engine; should some of the hot
oil happen to get on you, there will be a place to
dump the filter in a hurry and the filter will usually
spill a good bit of dirty oil as it is removed.
7. Wipe the base of the mounting boss with a
clean, dry cloth. When you install the new filter,
smear a small amount of fresh oil on the gasket with
your finger, just enough to coat the entire contact 8. Remove the jackstands and carefully lower the
vehicle, then IMMEDIATELY refill the engine
crankcase with the proper amount of oil. DO NOT
WAIT TO DO THIS because if you forget and some-
one tries to start the vehicle, severe engine damage
will occur.
9. Refill the engine crankcase slowly, checking
the level oflen, you may r..‘:-- U.-1 :L ..-..” II.. .-L-e
lVL,VY II,UL II UUUU,,J ,“,\U.J
less than the amount of oil listed in the capacity chart
to refill the crankcase. But, that is only until the en-
gine is run and the oil filter is filled with oil. To make
sure the proper level is obtained, run the engine to
normal operating temperature, shut the engine OFF,
allow the oil to drain back into the oil pan, and
recheck the level. Top off the oil at this time to the fill
mark.
*If the vehicle Is not resting on level
ground, the oil level reading on the dipstick
may be slightly off. Be sure to check the level
only when the vehicle is sitting level.
10. Drain your used oil in a suitable container for
recycling. b See Flgures 184 and 185
Inspect each component for leaking. Check the oil
level by removing the filler plug. If the oil is contami-
nated, it is necessary to replace it with new oil. Check
the oil level as follows:
89571gM Fig. 164 Typtcal manual transaxle drain and
filler plug location

.
l-36 GENERALINFORMATIONAND MAINTENANCE
Install the drain plug and tighten to 22 ft. Ibs.
(304Nm)
5. Refill the transaxle to the proper level, as
shown in the Capacities chart, with the appropriate
fluid. The oil level should be at the bottom of the oil
filler hole. I
6. When the oil reaches the orooer level, install
the filler plug and tighten to 22 ft. Ibs. (30 Nm).
FLUID RECOMMENDATIONS
8957i565 Fig, 165 Oil, when at the proper level, will
reach the lower edge of tC=+ frfr*r u*rn -non-
ing Mitsubishi recommends the use of Mercon@auto-
matic transmission fluid.
LEVELCHECK
Fig. 170 The fluid level is OK if it is within
the between the HOT and ADD areas on the
&&i& Do not overfill the transaxle or
-.*".."... -- .*"- problems could o ccur
1. Makesure the vehicle is oarked on a level sur-
face.
2. Remove the filler plug and make sure the oil
level is up to the lower edge of the filler plug hole.
3. Check to be sure that the transaxle oil is not
noticeably dirty and that it has a suitable viscosity. u See Figures 168,169, and 170
fluid is at normal operating temperature, drive the ve- The transaxle dipstick is located behind the air in-
hicle at least 10 miles. let hose, towards the firewall.
1. Park the vehicle on a level surface.
2. The transaxle should be at normal operating
temperature when checking fluid level. To ensure the 5. Pull the dipstick from its tube again. Holding it
horizontally, road the fluid level. The fkrid should be
between the MIN and MAX mark. If the fluid is below
the MIN mark, add fluid through the dipstick tube.
DRAIN & REFILL
6. Insert the dipstick, and check the level again
after adding any fluid. Be careful not to overfill the
transaxle.
3. With the selector lever in P and the parking
DRAIN & REFILL u See Figures 166 and 167
1. Make sure the vehicle is parked on a level sur-
face.
2. Raise and safely support the vehicle. Place a brake applied, start the engine.
4. Open the hood and locate the transaxle fluid
dipstick. Pull the dipstick from its tube, wipe it clean,
and reinsert it. Make sure the dipstick is fully in-
serted.
suitable drain pan under the manual transaxle.
3. Remove the filler plug and the drain plug and
allow the oil to drain completely.
Fig. 166 The automatic transaxle dipstick is
typically located under the air cleaner inlet
Fig. 166 Use a box-end wrench to loosen
the manual transaxle drain plug . . . tube. Pull the dipstick up to remove it from
the transaxle
Fig. 169 Wipe the dipstick clean and Insert
/fluid level reading ., it mto the transaxle agam to get the correct
j The fluid should be changed according to the
schedule in the Maintenance Intervals chart. If the car
is normally used in severe service, such as stop and
start driving, trailer towing, or the like, the interval
should be halved. If the car is driven under especially
nasty conditions, such as in heavy city traffic where
the temperature normally reaches 90°F (32%), or in
very hilly or mountainous areas, or in police, taxi, or b See Figures 171 thru 177
1. Raise and support the vehicle safely.
2. Place a suitable drain pan under the transaxle
drain plug.
3. Remove the transaxle pan drain plug. Let the
fluid completely drain out of the transaxle.
4. Install the drain plug and tighten it to 22-25 ft.
lbs. (30-35 Nm).
5. If equipped, remove the drain plug on the dif-
ferential of the transaxle.
6. Install the differential drain plug and tighten ft
to 22-25 ft. Ibs. (30-35 Nm).
7. Remove the drain pan.
8. Lower the vehicle.
9. Fill the transaxle through the dipstick to the
proper level.
10. Place the gear selector lever in P and start the
engine. Run the engine at idle, engage the emergency
brake and hold the brake pedal down. Move the gear
selector lever through all transaxle ranges for approx-
imately 5 minutes.
11. Return the selector lever to P and leave the
engine running at idle.
12. Check the transaxle fluid level. The fluid level
at normal operating temperature should read within
the crosshatched area of the fluid level dipstick.
13. If the fluid level reads below the crosshatched
area, adjust the level by adding fluid in small incre-
ments until the correct fluid level is obtained.
PAN &FILTER SERVICE
b See Figures 178 thru 184

_. .I ..-.
-._.
GENERALINFORMATIONAND MAINTENANCE l-37
Fig. 172 Carefully pull the transaxie drain
plug out and to the side, out of the way oi
flowing transaxie oil Fig. 173 The differential drain plug is lo-
cated at the bottom of the transaxie, to the
left of the fluid pan. Typically the drain plug
reauires a 17mm wrench
periodically checking the fluid level to
make sure you do not overfill the transaxle pan mounting
bolts, a 1Omm wrench is re-
Fig. 179 . . , then carefully lower the fluid
quired. Remove the pan retaining bolts . . . pan from the transaxle
Fig, 181 . , . then remove the transaxie film
ter from the valve body Fig. 182 Remove the transaxie pan
gasket from the pan

t
1-38 GENERALINFORMATIONAND MAINTENANCE
11 I Add the recommended automatic transaxle
fluid to the transaxle through the dipstick tube. You
will need a long necked funnel, or a funnel and tube
to do this. A quick check of the capacities chart later
in this Section will reveal the capacity of the transaxle
in your vehicle. On a first fill after removing the pan
and filter, this number should be cut into a ‘hand
checked on the dipstick before refilling.
12. With the transaxle in P, put on the parking
brake, block the front wheels, start the engine and let
it idle. DO NOT RACE THE ENGINE. DO NOT MOVE
THE LEVER THROUGH ITS RANGES.
13. With the lever in Park, check the fluid level. If
it’s OK, take the car out for a short drive, park on a
level surface, and check the level again, as outlined
earlier in this section. Add more fluid if necessary. Be
careful not to overfill, which will cause foaming and
w fluid loss. n of the transfer case filler
3. Remove the filler and the drain plug and allow
the oil to drain into the drain pan.
4. After the fluid has drained completely, install
the drain plug and tighten to 24 ft. Ibs. (32 Nm).
5. Refill the transfer case to the proper level with
Fig. 184 . . .
the transaxle case before in-
stalling the gasket
and pan onto the case FLUID RECOMMENDATIONS Hypoid gear oil SAE 75W-85W/75W-9OW conform-
ing to API specifications GL-4 or higher. The oil level
-‘-,*I’ -nnnh +‘* “%om edge of the oil filler hole.
nxfer raw filler nlm and tinhtm When adding fluid or refilling the transfer case,
use Hypoid gear oil SAE 75W-85W or 75W-9OW
conforming to API specifications 61-4 or higher.
LEVELCHECK 6. Install the tra .._._. ____ .._. T.-J _.._ .lJ . .._..
to 24 ft. lbs. (32 Nm).
7. Carefully lower the vehicle.
u See Figure 185
, 1 FLUID RECOMMENDATIONS
delivery service, the fluid should be changed accord-
ing to the severe service schedule.
The fluid must be hot before it is drained; a 20 u See Figure 187
Since fluid viscosity range may
vary depending on
specific temperature range of operation, please refer
~~
tne transaxle case.
You’ll be very sorry later if you do. bottom edge of the transfer case filler 1 1 Fig. 187 Rear axle lubricant application I
*If the drained fluld is discolored (brown or
1 plug hole chart black), thick, or pmmll~ hmmt nnrinmm I transaxle trouble .llln3llU ““III., url,““P s, probably due to overheat-
,r..rr,rA “#.a.- rrdr
trig, should be susp~~lr;u. lvUl vLlr J
transaxle should be inspected by a reliable
transaxle specialist to determine the prob-
lem.
5. Remove the pan and gasket.
6. Clean the pan with solvent and allow it to air
dry. If you use a rag to wipe out the pan, you risk
leaving bits of lint behind, which will clog the dinky
hydraulic passages in the bansaxle.
7. Remove the filter retaining bolts and remove
the filter from the valve bodv. lnsoect each component for leaking. Check the oil
he filler plug. If the oil is contami-
ry to replace it with new oil.
if% nn IPVPI z11rf2r~
level by removing t
nated, it is necessa
1. Park the vehi,., -.. ,-.“, __. ,“-_.
2. Remove the filler plug and make sure the oil
level reaches the lower edge of the filler plug hole.
3. Check to be sure that the oil is not noticeably
dirty and that it has the proper viscosity.
4. If necessary, add oil through the filler hole until
is runs out of the hole. to the accompanying chart for the proper fluid for
your vehicle.
LEVEL CHECK
1. Make sure the vehicle is parked on level
ground.
2. Remove the oil fill plug to check the oil level.
3. The oil level is sufficient if it reaches the lower
portion of the filler plug hole. If the fluid is low, add
as required through the filler plug.
To install: .
8. Install a new filter, then install the retaining
bolts and tighten them to 5 ft. Ibs. (7 Nm).
9. Position the gasket on the pan, then install
the pan. Tighten the bolts evenly and in rotation to
8-9ft. Ibs. (10-12 Nm.). Do not overtighten.
IO. Lower the vehicle. DRAIN & REFILL
I8 DRAIN & REFILL
u See Figure 188 ) See Figure- 14
1. Raise and safely support the vehicle, for access
to the transfer case.
2. Place a suitable drain pan under the transfer
case fluid drain plug. 1. Position the vehicle on a flat surface or raise
and safely support the vehicle in a level position.
2. Place a suitable drain pan under the rear axle.

GENERALINFORMATIONAND MAINTENANCE 1-39
leak. In most cases, you will be able to trace the leak
to a loose fitting or damaged hose.
Evaporating ethylene glycol antifreeze will have a
sweet smell and leave small, white (salt-like) de-
oosits, which can be heloful in tracino a leak. glove box and passenger side floorboard area, and
check the carpet for any signs of moisture. The
smartest way to go about finding a leak visually is to
first inspect any and all joints in the system such as
where the radiator hoses connect to the radiator and
the engine. Another thing to look for is white crusty
stains that are signs of a leak where the coolant has
6. Install the filler plug and tighten to’24 ft. Ibs.
(32 Nm).
7. If raised, carefully lower the vehicle. amount of fluid. The level should ieach thk bottom of me rating on It, lap3 1s a danciara 10 use out some
the oil filler hole. A Qss
tin,t.as ran +tw,, 4liE cars are higher. Overpressurizing the system can
lose, or worse, in the radiator or
your cooling system is con- IIC~KI LUG MU PuaJbly cause an injury or a burn if
s of a leak are probable. There the coolant is hot. Overpressurizing is normally con-
WI” U”.VlUl ,.“,,I I” 9” about finding the source of trolled by the radiator cap which has a vent valve in it
your leak. which is opened when the system reaches it’s maxi-
The first wav should be a visual insnection. Durina mum pressure rating. To pressure test the system: 7 “1sl I ly”lsJa IJ” Wll” IJU
If a the fluid level of
stantly low, the chance cause a rupture in a I:
h.n+n. nrrrn nnA . . . . ..I.
FLUID RECOMMENDATIONS the visual inspection, look around the &tire engine -
area including the radiator and the heater hoses. The *The pressure test should be performed with
the enaine OFF.
A good quality ethylene glycol based or other alu-
minum compatible antifreeze is recommended for
use in the vehicles covered by this manual. It is best
to add a 50150 mix of antifreeze and distilled water to
avoid diluting the coolant in the system. interior of the car should be inspected behind the
LEVELCHECK
recovery tank and its marking as a guideline.
*Never overfill the recovery tank.
A coolant level that consistently drops is usually a
sign of a small, hard to detect leak, although in the
worst case it could be a sign of an internal engine “_y “,~--
1 Fia. 190 A visual insaection for leaks will 1
sometimes find a leak. This photo shows Fig. 191 Remove the recovery tank cap to
/ * ,, / evfdence of a leak at the upper radfator
* / /the system allow the pressure tester
to be connected to hose-to-thermostat housing junction
Fig. 189 The coolant level should be be-
1 coo,ant recovery tank tween the FULL and LOW levels on the
“‘~‘_I j Fig. 192 This cooling system requires a Fig. 193 Thread the adapter onto the re-
e’ffi1pg7 / g’051p96 / 1 covety tank threaded adapter for the recovery tank to al-
low the pressure tester to
be connected

l-40 GENERALINFORMATIONAND MAINTENANCE
aiffiip98 Fig. 194 Pump the cooling system with pres-
sure, making sure not to overpressurize the
1 system or damage can occur
1. Remove the radiator or recovery tank cap.
2. Using the proper adapter, insert it onto the
opening and connect the pressure tester,
3. Begin pressurizing the system by pumping the
pressure tester and watching the gauge, when the
maximum pressure is reached, stop.
4. Watch the gauge carefully and see if the pres-
sure on the gauge drops, if it does, a leak is definitely
present.
5. If the pressure stayed somewhat stable, visu-
ally inspect the system for leaks, If the pressure
dropped, repressurize the system and then visually
inspect the system.
,
/ observe the pressure reading “@‘p~ 1 Fig 195 Watch the gauge on the system and
dropped more than 20%, a leak definitely exists, if
the oressure droo is less than 20%. the svstem is
most likely okay:
, cooling system when hot; serious burns can
Another way coolant is lost is by a internal engine occur from the steam and hot coolant. Also,
leak, causing the oil to be contaminated or the when draining engine coolant, keep in mind
coolant to be burned in the process of combustion that cats and dogs are attracted to ethylene
and sent out the exhaust. To check for oil contamina- glyeol antifreeze and could drink any that is
tion, remove the dipstick and check the condition of left in an uncovered container or in puddles
the oil in the oil pan. If the oil is murky and has a on the ground. This will prove fatal in suffi-
white or beige “milkshake” look to it, the coolant is cient quantities. Always drain coolant into a
contaminating the oil through an internal leak and the sealable container. Coolant should be reuser
enqine must be torn down to find the leak. If the oil mless it is contaminated or is several years
6. If no signs of a leak are noticed visually, pres-
surize the system to the maximum pressure rating of
the system and leave the uressure tester connected
fl sr about 30 minutes. Return after 30 minutes and
V erify the pressure on the gauge, if the pressure does not verify the situation, removing the spark
plugs one at a time and checking the electrodes for a
green or white tint can verify an internal coolant leak
and identify which cylinder(s) is the culprit and aiding
your search for the cause of the leak. If the spark
plugs appear okay, another method is to use a gas
analyzer or emissions tester, or one of several hand-
held tools that most professional shops possess. This
tools are used to check the cooling system for the
presence of Hydrocarbons (HC’s) in the coolant.
DRAIN & REFILL
p See figures 196 thru 205
Ensure that the engine is completely cool prior to
starting this service.
Never open, service or drain the radiator or
Ippears okay, the coolant can be burned and going
jut the tailpipe. A quick test for this is a cloud of
Nhite smoke appearing from the tailpipe, especially
In start-up. On cold days, the white smoke will ap-
Iear, this is due to condensation and the outside
emperature, not a coolant leak. If the “smoke test”
Fig. 196 The draincock is usually located at
Fig. 197 Gently rotate the draincock coun-
the bottom of the radiator
terclockwise to open the draincock . . .
Fig. 199 Allow the fluid to drain until it stops
and tighten the draineock hand tight
93151p27
1. Remove the recovery tank or radiator cap.
2, Raise and support the vehicle.
3. If necessary, remove the splash shield from un
ler the front of the vehicle.
93im76 Fig, 198 . _ . then allow the coolant to drain
out of the radiator and cooling system
Fig. 200 Make sure to heed the caution on
the radiator cap and NEVER open the cap
1 when the engine is hot ,, Fig. 201 Grasp the radiator cap and rotate
it counterclockwise . . .

.
GENERALINFORMATIONAND MAINTENANCE l-41
93151p18 Fig. 202 . , . to remove the cap from the
radiator
93151p17 Fig. 205 Be sure the rubber gasket on the
radiator cap has a tight seal e Fig. 203 Pour the proper *I~ coolant mix- 1 Fig. 204 . . . make sure to fill the coolant
recovery tank to the proper level also ture into the radiator . . .
.I
4. Allow the engine to cool completely and drain fluid. Any brake fluid that is removed from
ie system again.
5. Repeat this processuntil the drained water is
lear
and free of scale.
6. Flush the recovery tank with water and leave ’
mpty. 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.
When adding fluid to the system, ONLY use fresh
DOT 3 brake fluid from a sealed container. DOT 3
brake fluid will absorb moisture when it is exposed to
.a . . . , .*a. . . * .*. . .
- Never open, service or drain the radiator or
cooling system when hot; serious bums can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep In mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
4. Place a drain pan of suff i ’ 1 . . . ..I .I. 1,~ cient quantities. Always tne atmospnere, wnrcn wnr rower 1r.s oourng pomr. A
container that has been opened once, closed and
placed on a shelf will allow enough moisture to enter
over time to contaminate the fluid within. If your brake
fluid is contaminated with water, you could boil the
brake fluid under hard braking conditions and lose all
or some braking ability. Don’t take the risk, buy fresh
brake fluid whenever you must add to the system.
crenr capacrry unaer me
drain) on the radiator.
rrrasuc perwcss easuy bind; Before open-
ing a plastic radiator petcock, spray it with
some penetrating lubricant. drain coolant into a
earner. sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
The brake master cylinder ~a~~~~r,~~ :A I~nnL.4 n-n 7. Fill and bleed the cooling system as described
Brake fluid contains polyglycol ethers and
polyglycols. Avoid contact with the eyes and ,LEVEL CHECK
wash your hands thoroughly after handling
brake fluid. If vou do oet brake fluid in vour
eyes, flush your eyeswith clean, runniug wa-
a-.. ‘Y-- ar -l-..n-- II -.._ I____ k See Figures 206 thru 211
.a-11-- - __-PA._ radiator and open the petcock (
- w&1--x3_ --mm.._..- . . ..-I...
5. Drain the cooling system completely.
6. Close the petcock.
7. Remove the drain pan.
If necessary, install the splash shield under the 8.
L.-l
venicie.
9. Lower the vehicle.
10. Determine the capacity of the cooling system,
then properly refill the system at the recovery tank
and radiator with a 50/50 mixture of fresh coolant and
fKm”“ll 15 IUMLC” “II- brake booster and fire- der the hood, attached to the
wall on the drivers side of the engine compartment.
FLUID RECOMMENDATIONS rer mr 13 mmures. IT eye irriIauon persim, or if you have taken brake fluid internally,
IMMEDIATELY seek medical assistance.
ala in oreerring me sysrem.
12. Start the engine and allow it to idle until the
thermostat opens (the upper radiator hose will be-
come hot). The coolant level should go down, this is
normal as the system bleeds the air pockets out of the
svstem.
IRVf!l ._._. 14. Turn the engine OFF and check for leaks. IMMEDIATELY seek medical assistance.” Brake fluid contains polyglycol ethers and
polyglycols. Avoid contact with the eyes and
wash your hands thoroughly after handling
brakefluid. If you do get brake fluid in your
eyes, flush your eyes with clean, running wa-
or if vou have taken brake fluid internallv.
Before removing the master cylinder reservoir cap,
make sure the vehicle is resting on level ground and Be careful to avoid spilling any brake fluid on
painted surfaces, because the paint coat will
become discolored or damaged.
Observe the fluid level indicators on the master
._ ._ __
‘eve1 should be between the MIN
ano
ivw unes. 13. Refill the system with coolant to the proper ter for 15 minutes; If eye irritation persists, cylinder; the tluld II
..J ..I” I....
FLUSHING & CLEANINGTHE SYSTEM
1. Drain the cooling system completely as de:
scribed earlier.
2. Close the petcock and fill the system with a
cooling system flush (clean water may also be used,
but is not as efficient).
3. Idle the engine until the upper radiator hose
gets hot. 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 clean all dirt away from the top of the master cylinder.
Unscrew the cap and fill the master cylinder until the
level is between the MIN and MAX lines.
If the level of the brake fluid is less than half the
volume of the reservoir, it is advised that you check
the brake system for leaks. Leaks in a hydraulic brake
system most commonly occur at the wheel cylinder
and brake line junction points.