light MITSUBISHI DIAMANTE 1900 Repair Manual

.
1-2 GENERALINFORMATIONAND MAINTENANCE
Chitton’s Total Car Care manual for the 199M10
Mitsubishi Mirage, Galant and Diamante is intended
to help you learn more about the inner workings of
your vehicle while saving you money on its upkeep
and operation.
The beginning of the book will likely be referred to
the most, since that is where you will find information
for maintenance and tune-up. The other sections deal
with the more complex systems of your vehicle. Oper-
ating systems from engine through brakes are cov-
ered to the extent that the average do-it-yourselfer be-
comes mechanically involved. This book will not
explain such things as rebuilding a differential for the
simple reason that the expertise required and the in-
vestment in special tools make this task uneconomi-
cal. It will, however, give you detailed instructions to
help you change your own brake pads and shoes, re-
place spark plugs, and perform many more jobs that
can save you money, give you personal satisfaction
and help you avoid expensive problems.
A secondary purpose of this book is a reference for
owners who want to understand their vehicle and/or
their mechanics better. In this case, no tools at all are
required.
Before removing any bolts, read through the entire
procedure. This will give you the overall view of what
tools and supplies will be required. There is nothing
more frustrating than having to walk to the bus stop
on Monday morning because you were short one bolt
on Sunday afternoon. So read ahead and plan ahead.
Each operation should be approached logically and
all procedures thoroughly understood before attempt-
ing any work.
All sections contain adjustments, maintenance, re-
moval and installation procedures, and in some cases,
repair or overhaul procedures. When repair is not con-
sidered practical, we tell you how to remove the part
and then how to install the new or rebuilt replacement.
In this way, you at least save labor costs. “Backyard”
repair of some components is just not practical.
Many procedures in this book require you to “label
and disconnect. . ” a group of lines, hoses or wires.
Don’t be lulled into thinking you can remember where
everything goes-you won’t. If you hook up vacuum
or fuel lines incorrectly, the vehicle may run poorly, if
at all. If you hook up electrical wiring incorrectly, you
may instantly learn a very expensive lesson.
You don’t need to know the official or engineering
name for each hose or line. A piece of masking tape
on the hose and a piece on its fitting will allow you to
assign your own label such as the letter A or a short name. As long as you remember your own code, the
lines can be reconnected by matching similar letters
or names. Do remember that tape will dissolve in
gasolrne or other fluids; if a component is to be
washed or cleaned, use another method of identifica-
tion. A permanent felt-tipped marker or a metal scribe
can be very handy for marking metal parts. Remove
any tape or paper labels after assembly.
It’s necessary to mention the difference between
maintenance and repair Maintenance includes rou-
tine inspections, adjustments, and replacement of
parts which show signs of normal wear Maintenance
compensates for wear or deterioration. Repair implies
that something has broken or is not working. A need
for repair is often caused by lack of maintenance. Ex-
ample, draining and refilling the automatic transaxle
fluid is maintenance recommended by the manufac-
turer at specific mileage intervals. Failure to do this
can shorten the life of the transmission/transaxle, re-
quiring very expensive repairs. While no maintenance
program can prevent items from breaking or wearing
out, a general rule can be stated: MAINTENANCE IS
CHEAPER THAN REPAIR.
Two basic mechanrc’s rules should be mentioned
here. First, whenever the left side of the vehicle or en-
gine is referred to, it is meant to specify the drivers
side. Conversely, the right side of the vehicle means
the passengers side. Second, screws and bolts are
removed by turning counterclockwise, and tightened
by turning clockwrse unless specifically noted.
Safety is always the most important rule. Con-
stantly be aware of the dangers involved in working
on an automobile and take the proper precautions.
See the informatron in this section regarding SER-
VICING YOUR VEHICLE SAFELY and the SAFETY
NOTICE on the acknowledgment page.
Pay attention to the instructions provided. There
are 3 common mistakes in mechanical work:
1. Incorrect order of assembly, disassembly or
adjustment. When taking something apart or putting
it together, performing steps in the wrong order usu-
ally just costs you extra time; however, it CAN break
something. Read the entire procedure before begin-
ning disassembly. Perform everything in the order in
which the instructions say you should, even if you
can’t immedrately see a reason for it. When you’re
taking apart something that is very intricate, you
might want to draw a picture of how it looks when as-
sembled at one point in order to make sure you get everything back in its proper position. We will supply
exploded views whenever possible. When making
adjustments, perform them in the proper order. One
adjustment possibly will affect another.
2. Overtorquing (or undertorquing). While it is
more common for overtorquing to cause damage,
undertorquing may allow a fastener to vibrate loose
causing serious damage. Especially when dealing
with aluminum parts, pay attention to torque specifi-
cations and utilize a torque wrench in assembly. If a
torque figure is not available, remember that if you
are using the right tool to perform the job, you will
probably not have to strain yourself to get a fastener
tight enough. The pitch of most threads is so slight
that the tension you put on the wrench will be multi-
plied many times in actual force on what you are
tightening. A good example of how critical torque is
can be seen in the case of spark plug installation, es-
pecially where you are putting the plug into an alu-
minum cylinder head. Too little torque can fail to
crush the gasket, causing leakage of combustion
gases and consequent overheating of the plug and
engine parts. Too much torque can damage the
threads or distort the plug, changing the spark gap.
There are many commercial products available for
ensuring that fasteners won’t come loose, even if they
are not torqued just right (a very common brand is
Loctite? If you’re worried
about getting something
together tight enough to hold, but loose enough to
avoid mechanical damage during assembly, one of
these products might offer substantial insurance. Be-
fore choosing a threadlocking compound, read the
label on the package and make sure the product is
compatible with the materials, fluids, etc. involved.
3. Crossthreading. This occurs when a part such
as a bolt is screwed into a nut or casting at the wrong
angle and forced. Crossthreading is more likely to
occur if access is difficult. It helps to clean and lubri-
cate fasteners, then to start threading the bolt, spark
plug, etc. with your fingers If you encounter resis-
tance, unscrew the part and start over again at a dif-
ferent angle until it can be inserted and turned several
times without much effort. Keep in mind that many
parts, especially spark plugs, have tapered threads,
so that gentle turning will automatically bring the part
you’re threading to the proper angle. Don’t put a
wrench on the part until its been tightened a couple
of turns by hand. If you suddenly encounter resis-
tance, and the part has not seated fully, don’t force it.
Pull it back out to make sure it’s clean and threading
properly.
Be sure to take your time and be patient, and al-
ways plan ahead. Allow yourself ample time to per-
form repairs and maintenance You may find main-
taining your car a satisfying and enjoyable
experience.
b See Figures 1 thru 15
Naturally, without the proper tools and equipment
it is impossible to properly service your vehicle. It
would also be virtually impossible
to catalog every
tool that you would need to perform all of the opera-
tions in this book. Of course, It would be unwise for
the amateur to rush out and buy an expensive set of
tools on the theory that he/she may need one or more
of them at some time, The best approach is to proceed slowly, gathering savings will
be far outweighed by frustration and
a good quality set of those tools that are used most mangled knuckles.
frequently Don’t be misled by the low cost of bargain Begin accumulating those tools that are used most
tools. It is far better to spend a little more for better frequently: those associated with routine maintenance
quality. Forged wrenches, 6 or 12-point sockets and and tune-up. In addition to the normal assortment of
fine tooth ratchets are by far preferable to their less screwdrivers and pliers, you should have the follow-
expensive counterparts. As any good mechanic can ing tools:
tell you, there are few worse experiences than trying
l Wrenches/sockets and combination open
to work on a vehicle with bad tools. Your monetary end/box end wrenches in sizes from %-% in. or

GENERALINFORMATIONAND MAINTENANCE l-3
3-19mm, as well as a % in. or ~/a in. spark plug careful when using them, as they can change
socket (depending on plug type). the amount of torque applied to the socket.
-if possible, buy various length socket drive
l Jackstands for support.
extensions. Universal-joint and wobble ex- l Oil filter wrench.
tensions can be extremely useful, but be l Spout or funnel for pouring fluids.
l Grease gun for chassis lubrication (unless
your vehicle is not equipped with any grease fit-
tings-for details, please refer to information on Flu-
ids and Lubricants, later in this section).
l Hydrometer for checking the battery (unless
equiooed with a sealed, maintenance-free batten/).
In addition to the above items there are several O’ A container for draining oil and other fluids.
l Rags for wiping up the inevitable mess.
pi 1 others that are not absolutely necessary, but handy to
have around. These include Oil Dry@ (or an equiva-
lent oil absorbent gravel-such as cat litter) and the
usual SUDDIV of lubricants. antifreeze and fluids. al-
though the.& can be purchased as needed. This is a
basic list for routine maintenance, but only your per-
sonal needs and desire can accurately determine your
Fig. 1 Ail but the most basic procedures
After performing a few projects on the vehicle,
you’ll be amazed at the other tools and non-tools on
lWSl2U2 Fig, 3 A hydraulic floor jack and a set of
jackstands are essential for lifting and sup
porting the vehicle tm1204 Fig. 5 Various drivers, chisels and ptybars
are great tools to have in your toolbox
Fig. 7 Although not always necessary, us-
ing specialized brake tools will save time
Fig. 11 inductive type timing light

I-4 GENERALINFORMATIONAND MAINTENANCE
Fig. 12 A screw-in type compression gauge- Fig. 13 A vacuum/pressure tester is neces-
is recommended for compression testing sary for many testing procedures
Fig. 14 Most modern automotive multime-
ters incorporate many helpful features
your workbench. Some useful household items are: a
large turkey baster or siphon, empty coffee cans and
ice trays (to store parts), ball of twine, electrical tape
for wiring, small rolls of colored tape for tagging lines
or hoses, markers and pens, a note pad, golf tees (for
plugging vacuum lines), metal coat hangers or a roll
of mechanic’s wire (to hold things out of the way),
dental pick or similar long, pointed probe, a strong
magnet, and a small mirror (to see into recesses and
under manifolds).
A more advanced set of tools, suitable for tune-up
work, can be drawn up easily. While the tools are
lmvl Fig. 15 Proper information is vital, so at
ways have a Chiiton Total Car Care manua
handy
l Feeler aauoes for valve adiustment
* Timing-light.
The choice of a timing fight should be made
carefully. A light which works on the DC current
supplied by the vehicle’s battery is the best choice;
it should have a xenon tube for brightness. On any
vehicle with an electronic ignition system, a timing
light with an inductive pickup that clamps around
the No. 1 spark plug cable is preferred.
In addition to these basic tools, there are several
other tools and gauges you may find useful. These
include:
l Compression gauge. The screw-in type is
slower to use, but eliminates the possibility of a
fauliy reading due to escaping pressure.
l Manifold vacuum gauge. l 12V test light. l A combination volt/ohmmeter l induction Ammeter. This is used for determin-
ing whether or not there is current in a wire. These
are handy for use if a wire is broken somewhere in a
wiring harness.
As a final note, vou will orobablv find a torque
wrench necessary for all but the most basic work.
The beam type models are perfectly adequate, al-
though the newer click types (breakaway) are easier
to use. The click type torque wrenches tend to be
more expensive. Also keep in mind that all types of
torque wrenches should be periodically checked
and/or recalibrated. You will have to decide for your-
self which better fits your pocketbook, and purpose.
ilightly more sophisticated, they need not be outra-
feously expensive. There are several inexpensive
achldwell meters on the market that are every bit as
Toad for the average mechanic as a professional
nodel. Just be sure that it goes to a least 1200-1500
pm on the tach scale and that it works on 4,6 and 8-
:ylinder engines. The key to these purchases is to
nake them with an eye towards adaptability and wide
ange. A basic list of tune-up tools could include:
l Tach/dwell meter. l Spark plug wrench and gapping tool. Normally, the use of special factory tools is
avoided for repair procedures, since these are not
readily available for the do-it-yourself mechanic.
When it is possible to perform the job with more
commonly available tools, it will be pointed out, but
occasionally, a special tool was designed to perform
a specific function and should be used. Before sub-
stituting another tool, you should be convinced that
neither your safety nor the performance of the vehicle
will be compromised.
Special tools can usually be purchased from an
automotive parts store or from your dealer. In some
cases special tools may be available directly from the
tool manufacturer.
p See Figures 16, 17, 16, and 19
It is virtually impossible to anticipate all of the haz-
ards involved with automotive maintenance and ser-
vice, but care and common sense will prevent most
accidents.
The rules of safety for mechanics range from “don’t
smoke around gasoline,” to “use the proper tool(s) for
the job.” The trick to avoiding injuries is to develop
safe work habits and to take every possible precaution.
Do keep a fire extinguisher and first aid kit
l handy.
Do wear safety glasses or goggles when cut- l ting, drilling, grinding or prying, even if you have
20-20 vision. If you wear glasses for the sake of vi-
sion, wear safety goggles over your regular glasses.
l Do shield your eyes whenever you work around
the battery. Batteries contain sulfuric acid. In case of
contact with the eyes or skin, flush the area with water
or a mixture of water and baking soda, then seek im-
mediate medical attention.
l Do use safety stands (jackstands) for any un-
dervehicle service. Jacks are for raising vehicles;
jackstands are for making sure the vehicle stays
raised until you want it to come down. Whenever the
vehicle is raised, block the wheels remaining on the
ground and set the parking brake.
l Do use adequate ventilation when working
with any chemicals or hazardous materials, Like car-
bon monoxide, the asbestos dust resulting from
some brake lining wear can be hazardous in suffi-
cient quantities.
l Do disconnect the negative battery cable when
working on the electrical system. The secondary ig- nition system contains EXTREMELY HIGH VOLT-
AGE. In some cases it can even exceed 50,000 volts.
l Do follow manufacturer’s directions whenever
working with potentially hazardous materials. Most
chemicals and fluids are poisonous if taken inter-
nally.
l Do properly maintain your tools. Loose ham-
merheads, mushroomed punches and chisels, frayed
or poorly grounded electrical cords, excessively
worn screwdrivers, spread wrenches (open end),
cracked sockets, slipping ratchets, or faulty droplight
sockets can cause accidents.
* Likewise, keep your tools clean; a greasy
wrench can slip off a bolt head, ruining the bolt and
often harming your knuckles in the process.
l Do use the proper size and type of tool for the
job at hand. Do select a wrench or socket that fits the
nut or bolt. The wrench or socket should sit straight,
not cocked.

.
l-8 GENERALINFORMATIONAND MAINTENANCE
tccsio15 Fig. 24 Various styles of torque wrenches
are usually available at your local automo-
tive supply store
and should be used with caution. Again, the general
rule of “if you are using the right tool for the job, you
should not have to strain to tighten a fastener” ap-
plies here.
Beam Type
# See Figure 26
The beam type torque wrench is one of the most
popular types. It consists of a pointer attached to the
head that runs the length of the flexible beam (shaft)
to a scale located near the handle. As the wrench is
pulled, the beam bends and the pointer indicates the
torque using the scale.
Click (Breakaway) Type
$ See Figure 27
Another popular design of torque wrench IS the
click type. To use the click type wrench you pre-ad-
just it to a torque setting. Once the torque is reached,
the wrench has a reflex signaling feature that causes
a momentary breakaway of the torque wrench body,
sending an impulse to the operator’s hand.
Pivot Head Type
# See Figure 27 and 28
Some torque wrenches (usually of the click type)
may be equipped with a pivot head which can allow it
to be used in areas of limited access. BUT, it must be
used properly. To hold a pivot head wrench, grasp
the handle lightly, and as you pull on the handle, it
should be floated on the pivot point. If the handle
comes in contact with the yoke extension during the
process of pulling, there is a very good chance the
torque readings will be inaccurate because this could
alter the wrench loading point. The design of the han-
dle is usually such as to make it inconvenient to de-
liberately misuse the wrench.
*It should be mentioned that the use of any
U-joint, wobble or extension will have an ef-
fect on the torque readings, no matter what
type of wrench you are using. For the most
accurate readings, install the socket directly
on the wrench driver. If necessary, straight
extensions (which hold a socket directly un-
der the wrench driver) will have the least ef-
fect on the torque reading. Avoid any exten-
sion that alters the length of the wrench from
the handle to the head/driving point (such as
a crow’s foot). U-joint or wobble extensions
can greatly affect the readings; avoid their
use at all times.
U.S. Bolts
UEonlr
Iy*
lU2 5 tw7
I*cll*olwu
Q c
tbqn2lamlu
am~mkr. @ 63
HaaIm Toqw mdmuo TORW
(h&l!&, RA&. m 111 R./U. If410 lm m TolqW
R.Abs.
I(n Hm
'I4 - 20 i 0.7 68 8 1.1 10.8 10 1.4 13.5
-28 08 8.1 10 1.4 13.6
%s-18 11 1.5 14.9 17 2.3 23.0 19 2.6 25.8
-24 13 1.8 17.6 19 2.6 25.7
S-16 18 2.5 24.4 31 4.3 42.0 34 4.7 46.0
-24 20 2.75 27.1 35 4.8 47.5
%s-14 28 3.8 37.0 49 8.8 66.4 55 7.6 74.5
-20 30 42 40.7 55 7.6 74.5
'h-13 39 5.4 52.8 75 10.4 101.7 85 11.75 115.2
-20 41 5.7 55.6 85 117 115.2
'h-12 51 7.0 69.2 110 15.2 149.1 120 16.6 162.7
-18 55 7.6 74.5 120 16.6 162.7
H-11 83 11.5 112.5 150 20.7 203.3 167 23.0 226.5
-18 95 13.1 128.8 170 23.5 230.5
s-10 105 14.5 142.3 270 37.3 366.0 280 36.7 379.6
-16 115 15.9 155.9 295 40.8 400.0
VD- 9 160 2.: 216.9 395 54.6 535.5 440 60.9 596.5
-14 175 237.2 435 80.1 589.7
l- 6 iti 32.5 318.6 lE 81.6 799.9 660 91.3 894.8
-14 34.6 338.9 91.3 849.8
Metric Bolts
4.6,4.8 8.8
c
@ w
mm04 iEn% (nnr) I*rdn*lrTwlr rullllllnl~
RJU.
I(n llm RAk
m mu
6x1.0 2-3 2-.4 3-4 3-6 4-.8 5-8
8x 1.25 6-8 .6-l 8-12 9-14 12-1.9 13-19
10X1.25 12-17 1.5-2.3 16-23 20-29 2.7-4.0 27-39
12x125 21-32 2.9-4.4 29-43 35-53 4.8-7.3 47-72
14x 1.5 35-52 4.8-7.1 48-70 57-65 7.8-11.7 77-110
16x 1.5 51-77 7.0-10.6 67-100 90-120 12.4-16.5 130-W
18x 1.5 74-110 10.2-15.1 100-150 130-170 17.9-23.4 MO-230
20x 1.5 llO-140 15.1-19.3 150-190 190-240 26.2-46.9 160-320
22x 1.5 150-190 22.0-26.2 200-260 250-320 34.5-44.1 340-430
24x 1.5 190-240 26.2-48.9 260-320 310-410 42.7-56.5 420-550
lccs1098 :ig. 25 Standard and metric bolt torque specifications based on bolt strengths-WARNING:
Ise only as a guide
1
PIVOTEO HANDLE
BEAU OR MEASURING ELEMENT
Yg. 26 Example of a beam type torque wrench . tccslo3~

*
l-16 GENERALINFORMATIONAND MAINTENANCE
Fig. 49 Grasp the valve and gently remove
Fig. 50 Twist and pull on the valve to re-
it from the valve cover
move it from the hose Fig. 51 Inspect the grommet and replace if
cracked or leaking oil
SERVICING
corrosive acid can also eat away at components un-
der the hood.
Always visually inspect the battery case for cracks,
leakage and corrosion. A white corrosive substance
u See Figure 52
The evaporative canister requires no periodic ser-
vicing. However, a careful inspection of the canister
and hoses should be made frequently, Replace dam- on the battery case or on nearby components would
indicate a leaking or cracked battery. If the battery is
cracked, it should be replaced immediately. GENERALMAINTENANCE '_
devices that increase parasitic load may discharge a
battery sooner. If the vehicle is to be stored for 6-B
weeks in a secure area and the alarm system, if pre-
sent, is not necessary, the negative battery cable
should be disconnected at the onset of storage to
protect the battery charge.
Remember that constantly discharging and
recharging will shorten battery life. Take rare not to
allow a battery to be needlessly discharged.
aged components as required.
The canister is typically located under one of the
front fenders, however on some later models it may
be under the rear of the vehicle, near the gas tank,
r on most models # See Figure 53
A battery that is not sealed must be checked peri-
odically for electrolyte level. You cannot add water to
a sealed maintenance-free battery (though not all
maintenance-free batteries are sealed); however, a
sealed battery must also be checked for proper elec-
trolyte level, as indicated by the color of the built-in
hydrometer “eye.”
Always keep the battery cables and terminals free
of corrosion. Check these components about once a
year. Refer to the removal, installation and cleaning
procedures outlined in this section,
Keep the top of the battery clean, as a film of dirt
can help completely discharge a battery that is not
used for long periods. A solution of baking soda and
water may be used for cleaning, but be careful to
flush this off with clear water. DO NOT let any of the
solution into the filler holes. Baking soda neutralizes
battery acid and will de-activate a battery cell.
Batteries in vehicles which are not operated on a
regular basis can fall victim to parasitic loads (small
BA-ITERY FLUID
Check the battery electrolyte level at least once a
month. or more often in hot weather or during peri-
ods of extended vehicle operation. On non-sealed
batteries, the level can be checked either through the
case on translucent batteries or by removing the cell
caps on opaque-cased types. The electrolyte level in
each cell should be kept filled to the split ring inside
each ceil, or the line marked on the outside of the
case.
If the level is low, add only distilled water through
the opening until the level is correct. Each cell is sep-
arate from the others, so each must be checked and
filled individuallv. Distilled water should be used, be-
cause the chemicals and minerals found in most
drinking water are harmful to the battery and could
significantly shorten its life.
If water is added in freezing weather, the vehicle
should be driven several miles to allow the water to
mix with the electrolyte. Otherwise, the battery could
freeze.
current drains which are constantly drawing current
from the battery). Normal parasitic loads may drain a Although some maintenance-free batteries have
removable cell caos for access to the electrolyte, the
cause a short circuit, leading to sparks and possible
personal injury.
Do not smoke, have an open flame or create
sparks near a battery; the gases contained in the bat-
tery are very explosive and, if ignited, could cause se-
vere injury or death.
All batteries, regardless of type, should be care-
fully secured by a battery hold-down device. If this is
not done, the battery terminals or casing may crack
from stress applied to the battery during vehicle oper-
ation. A battery which is not secured may allow acid
to leak out, making it discharge faster; such leaking m / built-in hydrometer. .

*Although the readings from built-in hy-
drometers found in sealed batteries may
vary, a green eye usually indicates a prop
erly charged battery with sufficient fluid
level. A dark eye is normally an indicator of a
battery wlth sufficient fluid, but one which
may be low in charge. And a light or yellow
eye is usually an indication that electrolyte
supply has dropped below the necessary
tcu1@32 Fig. 53 A typical location for the built-in hv- level for battery (and hydrometer) operation.
drometer on maintenan
ce-free batteries ’ I In this last case. sealed batteries with an in-
sufficient electrolyte level must usually be
’ discarded.

l
1-18 GENERALINFORMATIONAND MAINTENANCE
the clamps and remove the cables, negative cable
first. On batteries with posts on top, the use of a
puller specially made for this purpose is recom-
mended. These are inexoensive and available in most alternator or turn the adjusting bolt to adjust belt ten-
sion. Once the desired value is reached, secure the
bolt or locknut and recheck tension.
d”t” lJdlL> X”lt;>. 31°C LtXlllllldl lJdllt2)’ MLJIC, dlt’ X- cured with a small bolt. ST& I REMOVAL &INSTALLATION
Clean the cable clamps and the battery terminal I
with a wire brush, until all corrosion, grease, etc., is
removed and the metal is shinv. It is esneciallv imnnr-
tant to c
knife is useful nere), since a smart
material or oxidation there will pre Clean the cable clamps and the battery terminal
with a wire brush, until all corrosion, grease, etc., is
removed and the metal is shiny. It is especially impor-
tant to clean the inside of the clamp thoroughly (an old
knife is useful here), since a small deposit of foreign
material or oxidation there will prevent a sound electri-
cal connection and inhibit either starting or charging.
Special tools are available for cleaning these parts,
one type for conventional top post batteries and an-
other type for side terminal batteries. It is also a good
idea to apply some dielectric grease to the terminal, as
this will aid in the prevention of corrosion,
After the clamps and terminals are clean, reinstall
the cables, negative cable last; DO NOT hammer the
clamps onto battery posts. Tighten the clamps se-
curely, but do not distort them. Give the clamps and
terminals a thin external coating of grease after in-
stallation, to retard corrosion.
Check the cables at the same time that the terminals
are cleaned. If the cable insulation is cracked or bro-
ken, or if the ends are frayed, the cable should be re-
placed with a new cable of the same length and gauge.
CHARGING
the cables, negative cable last; DO NOT hammer the
curely, but do not distort them. Give the clamps and
terminals a thin external coating of grease after in-
stallation, to retard corrosion.
Check the cables at the same time that the terminals
are cleaned. If the cable insulation is cracked or bro-
ken, or if the ends are frayed, the cable should be re-
placed with a new cable of the same length and aauae.
CHARGING
Fig. 62 mere are typically 3 types of ac-
cessory drive belts found on vehicles today 1. Loosen the alternator support nut.
2. Loosen the adjuster lock bolt.
3. Rotate the adjuster bolt counter clockwise to
I .I , . . . * . .
I Tn i”et*ll* Fig. 62 There are typically 3 types of ac-
Fig. 64 Deep cracks in this belt will cause
flex, building up heat that will eventually 11, 1.8L, 2.OL and 2.4L Engines
cal connection and inhibit either starting or charging.
Special tools are available for cleaning these parts,
one type for conventional top post batteries and an-
other type for side terminal batterin, I+ if QI@* 3 nnnd
idea to apply some dielectric grr
this will aid in the prevention of ,,vIIuaIUII.
After the clamps and terminals are clean, reinstall 1.5L, 1.6
AL TERNA TOR BE1 T
e See Figures 67,68, and 69
1. Loosen the alternator support nut.
2. Loosen the adjuster lock bolt.
3. Rotate the adjuster bolt counter clockwise to
release the tension on the belt.
4. Remove the belt.
To install:
5. Install the belt on the pulleys.
6. Rotate the adjuster bolt clockwise until the
proper tension is reached.
7. Tighten the adjuster lock bolt and the alternator
support nut.
POWER STEERING BELT
8 See Figures 70 and 71
1. Remove the alternator belt as described above.
2. Loosen the power steering pump adjusting
bolts.
3. Remove the power steering oumo fixed bolt on
R Rntatn the cxiillrtm hnit A&+,& until the r -r- .- .- ._.. ._ .______
7. Tighten the adjuster lock bolt and the alternator
support nut.
POWER STEERING BELT
1 ..“‘.I ““..Y...Y up II”“. ..IU. ..m.*
1 lead to belt failure V.
I
I
The chemical reaction which takes place in - 1 the rear of the bracket.
4. Rotate the pump toward the engine and remove
the belt.
all batteries generates explosive hydrogen
gas. A spark can cause the battery to explode
and splash acid. To avoid serious personal
injury, be sure there is proper ventilation and
take appropriate fire safety precautions when
connecting, disconnecting, or charging a bat-
tery and when using jumper cables. To fnstall:
5. Install the belt on the pulleys.
A battery should be charged at a slow rate to keep
the plates inside from getting too hot. However, if
some maintenance-free batteries are allowed to dis-
charge until they are almost “dead,” they may have to
be charged at a high rate to bring them back to “life.”
Always follow the charger manufacturers instructions
on charging the battery. 85 The cover of this belt ex-
Fig. is worn,
REPLACEMENT
When it becomes necessary to reolace thn haeoN
‘” yyL’“‘J’ I or oreMer
select one with an amperage rating equal tc .
a ----
than the battery originally installed. Deterioration and
just plain aging of the battery cables, starter motor,
and associated wires makes the battery’s job harder
in successive years. The slow increase in electrical
resistance over time makes it prudent to install a new
battery with a greater capacity than the old. 1 Fig. 67 Loosen the adjuster lock bolt . . .
I ‘-
I -. -_ tm1217 Fig. 66 Installing too wide a belt can resylt
in serious belt wear and/or breakage
the belt and run outward. All worn or damaged drive
belts should be replaced immediately. It is best to re-
place all drive belts at one time, as a preventive
uring this service operation. maintenance measure, d
- ADJUSTMENT : *
INSPECTION Excessive belt tension will cause damage to the al-
e See Figures 62, 83, 64, 65, and 88
Inspect the belts for signs of glazing or cracking. A
glazed belt will be perfectly smooth from slippage,
while a good belt will have a slight texture of fabric
visible. Cracks will usually start at the inner edge of pulley bearings, while, on
It tension will
Droduce slin ternator and water pump
the other hand, loose be
r ------ r
and premature wear on the belt. Therefore, be sure to
adjust the belt tension to the proper level.
To
adjust the tension ’ ’ ’ ” ’ ‘* adjusting bolt or fixing b
alternator bracket or tens on a onve Den. loosen me I Fig. 68 . . . then
from the engine remove the alternator
bolt locknut on the alternator,
iion pulley. Then move the

t
GENERALINFORMATIONAND MAINTENANCE l-23
gap increases, the plug’s voltage requirement also in-
creases. It requires a greater voltage to jump the the spark plug counterclockwise to loosen and re-
move the spark plug from the bore.
wider gap and about &o to three times as much volt-
age to fire the plug at high speeds than at idle. The
improved air/fuel ratio control of modern fuel injec-
tion combined with the higher voltage output of mod- Be sure not to use a flexible extension on the place. The click may be felt or heard, then gently pull
ern ignition systems will often allow an engine to run socket. Use of a flexible extension may allow back on the boot to assure proper contact.
.___. . _
significantly longer on a set of standard spark plugs, a shear force to be agptf’ ea to me plug.
A 12. On the 3.OL fSOHC and DOHC) and 3.5L en-
LL_ _I___ -u I_ IL-
but keep in mind that efficiency will drop as the gap shear force could break tne pug on III me
tion 3 for the installation procedure.
widens (along with fuel economy and power). cylinder head, leading to costly and frustrat-
13. If equipped, install the center cover.
When you’re removing spark plugs, work on one ing repairs.
at a time. Don’t start by removing the plug wires all at
once, because, unless you number them, they may To install:
INSPECTION & GAPPING
11. Apply a small amount of silicone dielectric
compound to the end of the spark plug lead or inside
the spark plug boot to prevent sticking, then install
the boot to the spark plug and push until it clicks into
gines, install the upper intake manifold. Refer to Sec-
,,Y” ..1111 uy”’ 1 the neaative bat&v cable and if become mixed up. Take a minute before you begin
and number the wrrpc with +sne
1. Disconnect. ~~.~
--..-., -..-.-, -..-
thevehicle has been run recently, allow the engine to
thoroughly cool.
2. If equipped, remove the center cover.
3. On the 3.OL (SOHC and DOHC) and 3.5L en-
gines, the upper intake manifold must be removed to
access the rear spark plugs. Refer to Section 3 for the
removal procedure.
4. Carefully twist the spark plug wire boot to
loosen it, then pull upward and remove the boot from
the plug. Be sure to pull on the boot and not on the
wire, otherwise the connector located inside the boot
may become separated.
5. Using compressed air, blow any water or de-
bris from the spark plug well to assure that no harm-
ful contaminants are allowed to enter the combustion
chamber when the spark plug is removed. If com-
pressed air is not available, use a raa or a brush to must be replaced.
Check the plugs for deposits and wear, If they are 7. Inspect the spark plug boot for tears or dam-
age. If.a damaged boot is found, the spark plug wire
8. Using a wire feelergauge, check and adjust
the spark plug gap. When using a gauge, the proper
size should pass between the electrodes with a slight
drag. The next larger size should not be able to pass
while the next smaller size should pass freely.
9. Carefully thread the plug into the bore by
hand. If resistance is felt before the plug is almost
completely threaded, back the plug out and begin
threading again. In small, hard to reach areas, an old
spark plug wire and boot could be used as a thread-
ing tool. The boot will hold the plug while you twist
the end of the wire and the wire is supple enough to
twist before it would allow the plug to crossthread.
Do not use the spark plug sock?
l -- K-rrA tha nhme Alwmm rarntdlv thw GL I” IlllGa”
the possibility of crossthreading and damag- lad the plug
. ..Y f..“YY. rn”Y,‘““mY*“.‘, .I**” by hand or using an old plug wire to prevent
ing the cylinder head bore.
10. Carefully tighten the spark plug. If the plug
you are installing is equipped with a crush washer,
seat the plug, then tighten about I/, turn to crush the
washer. If you are installing a tapered seat plug,
tighten the plug to specifications provided by the ve-
hicle or plug manufacturer. b See Figures 98, 97, 98, 99, and 100
not going to be replaced, clean the plugs thoroughly.
Remember that any kind of deposit will decrease the
efficiency of the plug. Plugs can be cleaned on a
spark plug cleaning machine, which can sometimes
be found in service stations, or you can do an accept-
able job of cleaning with a stiff brush. If the plugs are’
cleaned, the electrodes must be filed flat. Use an ig-
nition points file, not an emery board or the like,
which will leave deposits. The electrodes must be
filed perfectly flat with sharp edges; rounded edges
reduce the spark plug voltage by as much as 50%.
Check spark plug gap before installation. The
ground electrode (the L-shaped one connected to the
body of the plug) must be parallel to the center elec-
trode and the specified size wire gauge (please refer
to the Tune-Up Specifications chart for details) must
pass between the electrodes with a slight drag:
*,NEVER adjust the gap on a used platinum
. clean the area.
*Remove the spark plugs when the engine
is cold, if possible, to prevent damage to the
threads. If removal of the plugs is difficult,
apply a few drops of penetrating oil or sili-
cone spray to the area around the base of the
plug, and allow it a few minutes to work.
6. Using a spark plug socket that is equipped
with a rubber insert to properly hold the plug, turn type spark plug.
Always check the gap on new plugs as they are
not always set correctly at the factory. Do not use a
flat feeler gauge when measuring the gap on a used
plug, because the reading may be inaccurate. A
round-wire type gapping tool is the best way to check
the gap. The correct gauge should pass through the
electrode gap with a slight drag. If you’re in doubt, try
one size smaller and one laraer. The smaller aauqe

.
1-26 GENERALINFORMATIONAND MAINTENANCE
TDC of the compression stroke. If this happens, the
piston WIII be at the beginning of the power stroke
just as the compressed and ignited air/fuel mixture
forces the piston down and turns the crankshaft. Be-
cause it takes a fraction of a second for the spark
plug to ignite the mixture in the cylinder, the spark
plug must fire a little before the piston reaches TDC.
Otherwise, the mixture will not be completely ignited
as the piston passes TDC and the full power of the
explosion will not be used by the engine.
The timing measurement is given in degrees of
crankshaft rotation before the piston reaches TDC
(BTDC). If the setting for the ignition timing is 10”
BTDC, each spark plug must fire 10 degrees before
each piston reaches TDC. This only holds true, how-
ever, when the engine is at idle speed. The combus-
tion process must be complete by 23”ATDC to main-
tain proper engine performance, fuel mileage, and
low emissions.
As the engine speed increases, the pistons go
faster. The spark plugs have to ignite the fuel even
sooner if it IS to be completely ignited when the pis-
ton reaches TDC. If the ignition is set too far ad-
vanced (BTDC), the ignition and expansion of the fuel
in the cylinder wtll occur too soon and tend to force
the piston down while it is still traveling up. Thus
causes pre ignition or “knockmg and pinging”. If the
ignition spark is set too far retarded, or after TDC
(ATDC), the piston will have already started on its
way down when the fuel is ignited. The piston will be
forced down for only a portion of its travel, resulting
in poor engine performance and lack of power.
Timing marks or scales can be found on the rim of
the crankshaft pulley and the timing cover. The marks
on the pulley correspond to the posrtion of the piston
in the No. 1 cylinder. A stroboscopic (dynamic) tim-
ing light is hooked onto the No. 1 cylinder spark plug
wrre. Every time the spark plug fires, the timing light
flashes. By aiming the light at the timing marks while
the engine is running, the exact position of the piston
within the cylinder can be easily read (the flash of
light makes the mark on the pulley appear to be
standing still). Proper timing is indicated when the
mark and scale are in specified alignment.
When checking timing with the engine run-
ning, take care not to get the timing light
wires tangled in the tan blades and/or drive
belts.
INSPECTION &ADJUSTMENT
1990-96 Models
e See Figures 113 thru 119
1. Set the parking brake, start and run the engine
until normal operating temperature is obtained. Keep
all lights and accessories OFF and the front wheels
straight-ahead. Place the transaxle in
P for automatic
transaxle or Neutral for manual transaxle.
2. If not at specification, set the idle speed to the
correct level.
3. Turn the engine
OFF. Remove the water-
proof cover from the igmtion timing adjusting con-
nector, and connect a jumper wire from this terminal
Fig. 113 Ignition timing adjustment con-
nector-1990-92 Mirage with 1.5L engine
93151QM Fig. 115 Ignition timing adjustment con-
nectar-Galant with 2.OL engines
93151QO1 Fig. 117 Ignition timing adjustment con.
nectar-1994-96 Galant
to a good ground. Refer to the corresponding illustra-
tions for the correct location of the timing adjustment
connector.
4. Connect a conventional power timing light to
the No. 1 cylinder spark plug wire. Start the engine
and run at idle.
5. Aim the timing light at the timing scale lo-
cated near the crankshaft pulley.
6. Loosen the distributor or crank angle sensor
hold-down nut just enough so the housing can be ro-
tated.
7. Turn the housing in the proper direction until
the specified timing is reached. Tighten the hold-
down nut and recheck the timing. Turn the engine
OFF. 8. Remove the jumper wire from the ignition
timing adjusting terminal and install the water-proof
cover.
9. Start the engine and check the actual timing
(the timing without the terminal grounded). This
reading should be approximately 5 degrees more
than the basic timing. Actual timing may increase ac-
cording to altitude. Also, actual timing may fluctuate
because of slight variation accomplished by the ECU.
Fig. 114 Ignition timing adjustment con-
nectar-Miracle with 1.6L enaine
CHECK CONNECTOR 93151QO! Fig. 116 Ignition timing adjustment con.
nectar-1992-96 Oiamante
93151gOB Fig. 116 Ignition timing adjustment con-
nector-1993-96 Mirage with 1.5L engine
Fig. 119 Ignition timing adjustment con-
nector-1993-96 Mirage with 1.6L engine
As long as the basic timing is correct, the engine is
timed correctly.
10. Turn the engine
OFF. 11. Disconnect the timing apparatus and
tachometer.
1997-00 Models
The ignition timing is controlled by the Engine
Control Module (ECM) and is not adjustable. How-
ever it can be inspected using a scan tool.

.
l-30 GENERAL'INFORMATIONAND MAINTENANCE
n Pylon@ inserts, the clip
be removed prior to siidi then the insert can be re
After installing the replacement
strip and pull up while twisting counterclockwise.
The backing strip will snap out of the retaining tab.
Do this for the remaining tabs until the refill is free of
the blade. The length of these refills is molded into
the end and they should be replaced with identical
types. cate the front end is out of alignment or that the tires
are out of balance.
TIRE ROTATION
# See Figures 137 and 138
Tires must be rotated periodically to equalize wear
patterns that vary with a tire’s position on the vehicle.
Tires will also wear in an uneven way as the front
1 Fin 1% Tha Trinlarlna@
cle might have any kind. Aftermarket blades and arms
rarely use the exact same type blade or refill as the
original equipment. Here are some typiel aftermarket
blades; not all may be available for your vehicle:
The Anco@ type uses a release button that is
pushed down to allow the refill to slide out of the
yoke jaws. The new refill slides back into the frame
,
and locks in place.
Some Trico@ refills are removed by locating where
the metal backing strip or the refill is wider. Insert a
small screwdriver blade between the frame and metal
backing strip. Press down to release the refill from
the retaining tab.
Other types of Trico@’ refills have two metal tabs
which are unlocked by squeezing them together. The
rubber filler can then be withdrawn from the frame
iaws. A new refill is installed bv insertina the refill lowed to touch the olass steering/suspension system wears to the point where
the alianment should be reset.
# See Figure 138
Common sense and good driving habits will af-
ford maximum tire life. Fast starts, sudden stops
and hard cornering are hard on tires and will
shorten their useful life span. Make sure that you
don’t overload the vehicle or run with incorrect
pressure in the tires. Both of these practices will in-
crease tread wear.
*For optimum tire life, keep the fires prop
eriy inflated, rotate them often and have the
wheel alignment checked periodically.
Inspect your tires frequently. Be especially care-
ful to watch for bubbles in the tread or sidewall,
deep cuts or underinflation. Replace any tires with
bubbles in the sidewall. If cuts are so deep that they
penetrate to the cords, discard the tire. Any cut in
the sidewall of a radial tire renders it unsafe. Also
look for uneven tread wear patterns that may indi- Rotating the tires will ensure maximum life for the
tires as a set, so you will not have to discard a tire
early due to wear on only part of the tread. Regular
DIRECTIONAL TIRES DIRECTIONAL TIRES
jnto the front frame jaws and &ding it rearward to
engage the remaining frame jaws. There are usually
four jaws; be certain when installing that the refill is
engaged in all of them. At the end of its travel, the
tabs will lock into place on the front jaws of the wiper
blade frame.
Another type of refill is made from polycarbonate.
The refill has a simple locking device at one end
which flexes downward out of the groove into which
the jaws of the holder fit, allowing easy release. By
sliding the new refill through all the jaws and push-
ing through the slight resistance when it reaches the
end of its travel, the refill will lock into position.
To replace the Tridon@ refill, it is necessary to re-
move the wiper blade. This refill has a plastic backing
strip with a notch about 1 in. (25mm) from the end.
Hold the blade (frame) on a hard surface so that the
frame is tightly bowed. Grip the tip of the backing Fig. 138 A label with information concern-
ing the tires is typically located on one of
the door pillars
tion”

.
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.