wheel MITSUBISHI DIAMANTE 1900 Repair Manual

HOW TO USE THIS BOOK 1-2
WHERE TOBEGIN l-2
AVOIDINGTROUBLE 1-2
MAINTENANCEORREPAIR? 1-2
AVOIDINGTHEMOSTCOMMONMISTAKES l-2
TOOLS AND EQUIPMENT 1-2
SPECIALTOOLS l-4
YOUR VEHICLE SAFELY 1-4
DON'TS l-6
FASTENERS, MEASUREMENTS AND
CONVERSIONS l-6
BOLTS,NUTSANDOTHERTHREADED
RETAINERS 1-6
TORQUE l-7
TORQUEWRENCHES l-7
TORQUEANGLEMETERS 1-9
STANDARDANDMETRIC MEASUREMENTS l-9
SERIAL NUMBER IDENTIFICATION l-10
VEHICLE IDENTIFICATION NUMBER l-10
ENGINE IDENTIFICATION NUMBER I-10
TRANSAXLEIDENTIFICATION I-10
DRlVEAXLE(AWDGALANTONLY) l-10
TRANSFERCASE(AWDGALANTONLY) l-10
ROUTINE MAINTENANCE AND TUNE-UP l-14
AIRCLEANER(ELEMENT) 1-14
REMOVAL&INSTALLATION 1-14
FUELFILTER 1-15
REMOVAL &INSTALLATION l-15
PCVVALVE l-15
REMOVAL&INSTALLATION l-15
EVAPORATIVECANISTER l-16
SERVICING 1-16
BATTERY 1-16
PRECAUTIONS I-16
GENERALMAINTENANCE 1-16
BEL BATTERYFLUID 1-16
CABLES I-17
CHARGING I-18
REPLACEMENT 1-18
TS 1-18
INSPECTiON l-18
ADJUSTMENT 1-18
REMOVAL&INSTALLATION 1-18
TIMINGBELTS l-20
INSPECTION l-20
HOSES I-20
INSPECTION l-20
REMOVAL&INSTALLATION
CV-BOOTS 1-21
INSPECTION l-21
SPARKPLUGS l-22
SPARKPLUGHEATRANGE
REMOVAL&INSTALLATION
INSPECTION &GAPPING 1.
SPARKPLUG WIRES 1-24
TESTING 1-24
REMOVAL&INSTALLATION
DISTRIBUTORCAPANDROTOR
REMOVAL&INSTALLATION
INSPECTION 1-25
IGNITIONTIMING 1-25
. GENERALINFORAMTION l-
lNSPECTlON&ADJUSTMENl
VALVE LASH l-27
ADJUSTMENT l-27
IDLESPEED 1-28 1-21
l-22
l-22
-23
1-24
l-25
l-25
.25
1-26
AIR CONDITIONING SYSTEM 1-28
SYSTEMSERVlCEiiREPAlR l-28
PREVENTIVEMAINTENANCE 1-28
SYSTEM INSPECTION l-29
WINDSHIELD WIPERS l-29
ELEMENT(REFILL)CARE&
REPLACEMENT l-29
TIRESANDWHEELS l-30
TIRE ROTATION I-30
TIRE DESIGN 1-31
TIRESTORAGE l-31
INFLATION &INSPECTION l-31
CARE OFSPECIALWHEELS l-32 OPERATION INFOREIGNCOUNTRIES l-33
ENGINE l-33
OILLEVELCHECK 1-33
OIL& FILTER CHANGE l-34
MANUALTRANSAXLE l-35
FLUIDRECOMMENDATIONS l-35
LEVELCHECK l-35
DRAIN&REFILL l-36
AUTOMATICTRANSAXLE l-36
FLUIDRECOMMENDATIONS l-36
LEVELCHECK 1-36
DRAIN&REFILL l-36
PAN & FILTERSERVICE 1-36
TRANSFERCASE(AWDGAlANT ONLY) l-38
FLUIDRECOMMENDATIONS l-38
LEVELCHECK l-38
DRAIN&REFILL l-38
REARDRlVEAXLE(AWDGALANTONLY) l-38
FLUIDRECOMMENDATIONS l-38
LEVELCHECK l-38
DRAIN&REFILL l-38
COOLINGSYSTEM l-39
FLUIDRECOMMENDATIONS l-39
iM-41
FLUIDS AND LUBRICANTS 1-33
FLUID DISPOSAL 1-33
FlJELANDENGlNEOILRECOMMENDATlONS
ENGINE OIL l-33
FUEL l-33

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.

1-6 GENERALINFORMATIONAND MAINTENANCE
Fig. 16 Screwdrivers should be kept in good
:ondition to prevent injury or damage which
:ould result it the blade slips from the screw
0
0
PP tccs1022 Fig. 16 Using the correct size wrench will
help prevent the possibility of rounding off
a nut
7
lwo.WIRE CouDuClOR TMREE-WIRE CONO”CTOI
MIRD WIRE GROUNDING GROUNDING TNRU
THE CASE A CmxlIT
.
i$Y$$pQ
p-+
TNHREE-WIRE CONDUCTOR THREE-WIRE CONDUCTOR
ONE WIRE TO 4 GROUND GROUNOlNG TMRU
AN ADAPTER PLUG
tccm21
Fig. 17 Power tools should always be prop-
erly grounded
Fig. 19 NEVER work under a vehicle unless it
is supported using safety stands (jackstands)
l Do, when possible, pull on a wrench handle l Do set the parking brake and block the drive
rather than push on it, and adjust your stance to pre-
vent a fall. wheels if the work requires a running engine.
l Do be sure that adjustable wrenches are
tightly closed on the nut or bolt and pulled so that
the force is on the side of the fixed jaw.
l Do strike squarely with a hammer; avoid glanc-
ing blows. l Don’t run the engine in a garage or anywhere
else without proper ventilation-EVER! Carbon monoxide is poisonous; it takes a long time to leave
the human body and you can build up a deadly sup-
ply of it in your system by simply breathing in a !ittle
every day. You may not realize you are slowly poi-
soning yourself. Always use power vents, windows,
fans and/or open the garage door.
l Don’t work around moving parts while wearing
loose clothing. Short sleeves are much safer than
long, loose sleeves. Hard-toed shoes with neoprene
soles protect your toes and give a better grip on slip-
pery surfaces. Jewelry such as watches, fancy belt
buckles, beads or body adornment of any kind is not
safe working around a vehicle. Long hair should be
tied back under a hat or cap.
l Don’t use pockets for toolboxes. A fall or bump
can drive a screwdriver deep into your body. Even a
rag hanging from your back pocket can wrap around
a spinning shaft or fan.
l Don’t smoke when working around gasoline,
cleaning solvent or other flammable material.
l Don’t smoke when workrng around the battery.
When the battery is being charged, it gives off explo-
sive hydrogen gas.
l Don’t use gasoline to wash your hands; there
are excellent soaps available. Gasoline contains dan-
gerous additives which can enter the body through a
cut or through your pores. Gasoline also removes all
the natural oils from the skin so that bone dry hands
will suck up oil and grease.
l Don’t service the air conditioning system un-
less you are equipped with the necessary tools and
trainmg. When liquid or compressed gas refrigerant
is released to atmospheric pressure it will absorb
heat from whatever it contacts. This will chill or freeze
anything it touches.
l Don’t use screwdrivers for anything other than
driving screws! A screwdriver used as an prying tool
can snap when you least expect it, causing injuries.
At the very least, you’ll ruin a good screwdriver.
. Don’t use an emergency jack (that little ratchet,
scissors, or pantograph jack supplied with the vehi-
cle) for anything other than changing a flat! These
jacks are only Intended for emergency use out on the
road; they are NOT designed as a maintenance tool. If
you are serious about mamtaining your vehicle your-
self, invest in a hydraulic floor jack of at least a 1%
ton capacity, and at least two sturdy jackstands.
sion which can increase the torque necessary to proper installation and safe operation of the vehicle
achieve the desired clamp load for which that fastener afterwards.
was originally selected. Additionally, be sure that the Thread gauges are available to help measure a bolt
p See Figures 20, 21, 22, and 23 driver surface of the fastener has not been compro- or stud’s thread. Most automotive and hardware
mised by rounding or other damage. In some cases a stores keep gauges available to help you select the
Although there are a great variety of fasteners found driver surface may become only partially rounded, al- proper size. In a pinch, you can use another nut or
in the modern car or truck, the most commonly used lowing the driver to catch in only one direction. In bolt for a thread gauge. If the bolt you are replacing is
retainer is the threaded fastener (nuts, bolts, screws, many of these occurrences, a fastener may be in- not too badly damaged, you can select a match by
studs, etc.). Most threaded retainers may be reused, stalled and tightened, but the driver would not be able finding another bolt which will thread in its place. If
provided that they are not damaged in use or during to grip and loosen the fastener again. (This could lead you find a nut which threads properly onto the dam-
the repair. Some retainers (such as stretch bolts or J to frustration down the line should that component aged bolt, then use that nut to help select the replace-
torque prevailing nuts) are designed to deform when ever need to be disassembled again). ment bolt If however, the bolt you are replacing is so
tightened or in use and should not be reinstalled. If you must replace a fastener, whether due to de- badly damaged (broken or drilled out) that its threads
Whenever possible, we will note any special re- sign or damage, you must ALWAYS be sure to use cannot be used as a gauge, you might start by look-
tainers which should be replaced during a procedure. the proper replacement In all cases, a retainer of the ing for another bolt (from the same assembly or a
But you should always inspect the condition of a re- same design, material and strength should be used. similar location on your vehicle) which will thread
tainer when It is removed and replace any that show Markings on the heads of most bolts will help deter- into the damaged bolt’s mounting. If so, the other bolt
signs of damage. Check all threads for rust or corro- mine the proper strength of the fastener. The same
can be used to select a nut; the nut can then be used
material, thread and pitch must be selected to assure
to select the replacement bolt.

.
l-10 GENERALINFORMATIONAND MAINTENANCE
which are available today will have two scales so the
The conversion factor chart is used by taking the
Standard or Metric measurements may easily be given specification and multiplying it by the neces-
taken. If any of the various measuring tools which are sary conversion factor. For instance, looking at the
available to you do not contain the same scale as first line, if you have a measurement in inches such
listed in the specifications, use the accompanying
as “free-play should be 2 in.” but your ruler reads
conversion factors to determine the proper value. only in millimeters, multiply 2 in. by the conversion factor of 25.4 to get the metric equivalent of 50.8mm.
Likewise, if the specification was given only in a Met-
ric measurement, for example in Newton Meters
(Nm), then look at the center column first. If the mea-
surement is 100 Nm, multiply it by the conversion
factor of 0.738 to get 73.8 ft. Ibs.
b See Figures 32,33, and 34
The Vehicle Identification Number (VIN) is located
on a plate which is attached to the left top side of the
instrument panel. These numbers are visible from the
outside of the vehicle. All Vehicle Identification Num-
bers contain 17 digits. The vehicle number is a code
which tells country, make, vehicle type, engine, body
and many other important characteristics of that spe-
cific vehicle.
There is also a vehicle information code plate
which is riveted to the bulkhead in the engine com-
partment. The plate shows the VIN, model code, en-
gine model, transaxle model and body color codes.
The engine code used on this plate differs from the
code letter used in the 8th position of the Vehicle
Identification Number (VIN). Either code can be used
to identify the particular engine in the vehicle. Since
the vehicle owners card is usually carried, it may be if the engine is equipped with a turbocharger. If the
8th VIN number is a U, there is no doubt that the en-
gine in question is a 2.OL DOHC engine equipped
with a turbocharger.
The engine codes found on the vehicle information
code plate are as follows:
l 4G15--1.5L SOHC engine l 4G61-1.6L DOHC engine l 4G93-1.8L SOHC engine l 4G63-2.OL (SOHC or DOHC) engine l 4G64-2.4L (SOHC or DOHC) engine l 6G72-3.OL (SOHC or DOHC) engine l 6G74-3.5L DOHC engine
A vehicle safety certification label is attached to
the face of the left door pillar post. This label indi-
cates the month and year of manufacture, Gross Ve-
hicle Weight Rating (GRVW) front and rear, and Ve-
hicle Identification Number (VIM). 4 character code as on the vehicle information code
plate is used. The engine serial number is also
stamped near the engine model number. As men-
tioned above, the engine can also be identified by the
8th digit in the VIN number.
The transaxle model code is located on the vehicle
information code plate. The transaxle identification
number is etched on a boss located on the front up-
per portion of the case.
The code for the drive axle is etched on a boss lo-
cated on the case of the differential carrier.
easier to use the code letter in the VIN for engine ref-
erence. A second reason for referring to the VIN for
engine identification is that code 4663, located on
the vehicle information code plate, does identify the
engine as a 2.OL DOHC engine, but does not tell you ) See Figure 35
The engine model number is stamped at the front
side on the top edge of the cylinder block. The same
Fig. 32 The Vehicle Identification Number
g3’51p’o of the instrument panel _I:^1 / Fig. 33 The vehicle model, engine model,
(VIN) plate is attached to the top left side
bansaxle model, and body color code are all
noted on the vehicle information code plate
ENGINE AND VEHiCLE IDENTlFlCATlON
EnglnCode
ModelYerr
todeal
LIten (cc)
Cu. In. W. Fuel+ Type m.hWg. Code@ Year ,G15JA 1.5 (1468) 92 4 MFI SOHC Mitsubishi
L 1990
IG61N 1.6(15QQ) 98 4 MFI DOHC
Mitsubishi M 1991
1G93lC 1.8 (1834) 112 4 MFI SOHC Mitsubishi N 1992
IG63N 2.0 (1997) 122 4 MFI SOHC “-Mitsubishi P
1993
!G63Fi 2.0 (1997) 122 4 MFI DOHC Mitsubishi
R 1994
,G63iU 2.0 (1997) 122 4 MFI-Tuibo DOHC Mitsubishi
S 1995
.GMffi 2.4 (2351) 143 4 MFI SOHC
Mitsubishi T 1996
iG64L 2.4 (2351) 143 4 MFI DOHC Mitsubishi V
lEzH 3.0 1997
(2972) 161 6 MFI SOHC Mitsubishi W 1998
;G7ZJ 3.0 (2Q72) 161 6 MFI GQHC Mitsubishi
~.. X 1999
iG7zL 3.0 (2972) 181
~ 6 MFI SOHC ___-___ Miisubishi
Y 2000
iG74lP 3.5 (3497) 213 6 MFI SOHC Miisubishi
The transfer case has no separate model code, the
code is located on the transaxle. The transfer case is
onlv eoUiODed on manual transaxle All Wheel Drive
(AWD)‘mbdels.
Fig. 34 Your car should have a vehicle
Fig. 35 Engine model number location-
4663 (2.OL) engine shown

GENERALINFORMATIONAND MAINTENANCE l-21
IWSIZXJ FM. 83 A hose clamn that is taa tiaht can
Fig. 82 The cracks developing along this
hose are a result of age-related hardening caise older hoses td separate and ‘iear on
either side of the clamp
lCCS1221 Fig. 84 A soft spongy hose (identifiable by
1 the swollen section) will eventually burst
and should be replaced
IEMOVAL &,INSTALLATION '
1. Remove the radiator pressure cap. her of the sorina tension tvoe (which reouire oliers
3 squeeze the 6bs and loosenj or of the’screw ten-
ion type (which require screw or hex drivers to
oosen). Pull the clamps back on the hose away from
he connection. Never remove the pressure cap while the en-
gine is running, or personal injury from
scalding hot coolant or steam may result. If
possible, wait until the engine has cooled to
remove the pressure cap. If this is not possi-
ble, wrap a thick cloth around the pressure
cap and turn it slowly to the stop. Step back
while the pressure is released from the cool-
ing system. When you are sure all the pres-
sure has been released, use the cloth to turn
and remove the cao.
2. Position a clean container under the radiator
and/or engine draincock or plug, then open the drain
and allow the cooling system to drain to an appropri-
ate level. For some upper hoses, only a little coolant
must be drained. To remove hoses positioned lower
on the engine, such as a lower radiator hose, the en-
tire cooling system must be emptied.
When draining coolant, keep in mind that
cats and dogs are attracted by ethylene gly-
col antifreeze, and are quite likely to drink
any that is left in an uncovered container or
in puddles on the ground. This will prove fa-
tal in sufficient quantity. Always drain
coolant into a sealable container. Coolant
may be reused unless it is contaminated or
several years old. 9. Close the radiator or engine drains and prop-
erly refill the cooling system with the clean drained
engine coolant or a suitable mixture of ethylene gly-
cot coolant and water.
10. If available, install a pressure tester and check
for leaks. If a pressure tester is not available, run the
engine until normal operating temperature is reached
(allowing the system to naturally pressurize), then
check for leaks.
If you are checking for leaks with the system
at normal operating temperature, BE EX-
TREMELY CAREFUL not to touch any moving
or hot engine parts. Once temperature has
been reached. shut the enaine OFF. and
Fig. 85 Hoses are likely to deteriorate from
the inside if the cooling system is not peri-
odically flushed check for leaks around the-hose fittings and
connections which were removed earlier.
INSPECTION
b See Figures 88 and 87
The CV (Constant Velocity) boots should be
checked for damage each time the oil is changed and
any other time the vehicle is raised for service. These
boots keep water, grime, dirt and other damaging
matter from entering the CV-joints. Any of these
could cause early CV-joint failure which can be ex-
pensive to repair. Heavy grease thrown around the in-
side of the front wheel(s) and on the brake
caliper/drum can be an indication of a torn boot.
Thorouahlv check the boots for missina clamos and 3. Loosen the hose clamps at each end of the
rose requiring replacement. Clamps are usually ei-
4. Twist, pull and slide the hose off the fitting,
sking care not to damage the neck of the component
rom which the hose is being removed.
*If the hose is stuck at the connection, do
lot try to insert a screwdriver or other sharp
ool under the hose end in an eff art to free it,
IS the connection and/or hose may become
lamaged. Heater connections especially
nay be easily damaged by such a procedure.
f the hose is to be replaced, use a single-
!dged razor blade to make a slice along the
lortion of the hose which is stuck on the con-
section, perpendicular to the end of the
lose. 00 not cut deep so as to prevent dam-
aging the connection. The hose can then be
keeled from the connection and discarded. Fig. 86 CV-boots must be inspected period-
5.. Clean both hose mounting connections. In-
,pect the condition of the hose clamps and replace
hem, if necessary.
To install:
6. Dip the ends of the new hose into clean en-
fine coolant to ease installation.
7. Slide the clamps over the replacement hose,
hen slide the hose ends over the connections into
rosition.
8. Position and secure the clamps at least l/d in.
6.35mm) from the ends of the hose. Make sure they
Ire located beyond the raised bead of the connector.

.
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”

GENERALINFORMATIONAND MAlNTENANdE 1-31
When rotating “unidirectional tires,” make sure
that they always roll in the same direction. This
means that a tire used on the left side of the vehicle
must not be switched to the right side and vice-versa.
Such tires should only be rotated front-to-rear or
rear-to-front, while always remaining on the same
side of the vehicle. These tires are marked on the
sidewall as to the direction of rotation; observe the
marks when reinstalling the tire(s).
Some styled or “mag” wheels may have different
offsets front to rear. In these cases, the rear wheels
must not be used up front and vice-versa. Further-
more, if these wheels are equipped with unidirectional
tires, they cannot be rotated unless the tire is re-
mounted for the proper direction of rotation.
*The compact or space-saver spare is
strictly for emergency use. it must never be
included in the tire rotation or placed on the
vehicle for everyday use. check the installed tire for any sign of interference
with the body or suspension while the vehicle is stop-
ping, turning sharply or heavily loaded.
Snow Tires
Good radial tires can produce a big advantage in
slippery weather, but in snow, a street radial tire does
not have sufficient tread to provide traction and con-
trol. The small grooves of a street tire quickly pack
with snow and the tire behaves like a billiard ball on a
marble floor, The more open, chunky tread of a snow
tire will self-clean as the tire turns, providing much
better grip on snowy surfaces.
To satisfy municipalities requiring snow tires dur-
ing weather emergencies, most snow tires carry either
an M + S designation after the tire size stamped on
the sidewall, or the designation “all-season.” In gen-
eral, no change in tire size is necessary when buying
snow tires.
Most manufacturers stronqlv recommend the use styled wheels, see if inexpensive steel
wheels are available, Although the look of
the vehicle will change, the expensive
wheels will be protected from salt, curb hits
and pothole damage.
TIRESTORAGE
If they are mounted on wheels, store the tires at
proper inflation pressure. All tires should be kept in a
cool, dry place. If they are stored in the garage or
basement, do not let them stand on a concrete floor;
set them on strips of wood, a mat or a large stack of
newspaper. Keeping them away from direct moisture
is of paramount importance. Tires should not be
stored upright, but in a flat position.
INFLATION & INSPECTION
b See Figures 140 thru 147
TIRE DESIGN
p See Figure 139
for maximum satisfaction, tires should be used in
sets of four. Mixing of different types (radial, bias-
belted, fiberglass belted) must be avoided. In most
cases, the vehicle manufacturer has designated a
type of tire on which the vehicle will perform best.
Your first choice when replacing tires should be to
use the same type of tire that the manufacturer rec-
ommends.
When radial tires are used, tire sizes and wheel di-
ameters should be selected to maintain ground clear-
ante and tire load caoacitv eauivalent to the oriainal
specified tire. Radial tiresshould always be used in
sets of four. of 4 snow tires on their
lehicies for reasons of stabil-
ity. If snow tires are fitter
1 only to the drive wheels, the
opposite end of the vehil cle may become very unsta-
ble when braking or turn
ring on slippery surfaces.
This instability can lead to unpleasant endings if the
A*:,,“- r-..l, ^_.. ..& ^_^^, &I.
UIIVU MII I LUUII~~MLL iue slide in time.
Note that snow tires, whether 2 or 4, will affect ve-
hicle handling in all non-snow situations. The stiffer,
heavier snow tires will noticeably change the turning
and braking characteristics of the vehicle. Once the
snow tires are installed, you must re-learn the behav-
ior of the vehicle and drive accordingly.
*Consider buying extra wheels on which to
mount the snow tires. Once done, the “snow
iheeis” can be installed and removed as
needed. This eliminates the potential
dam- age to tires or wheels from seasonal removal
and installation. Even if your vehicle has
lb The importance of proper tire inflation cannot be
overemphasized. A tire employs air as part of its
structure. It is designed around the supporting
strength of the air at a specified pressure. For this
reason, improper inflation drastically reduces the
tire’s ability to perform as intended. A tire will lose
some air in day-to-day use; having to add a few
pounds of air periodically is not necessarily a sign of
a leaking tire.
Two items should be a permanent fixture in every
glove compartment: an accurate tire pressure gauge
and a tread depth gauge. Check the tire pressure (in-
eluding the spare) regularly with a pocket type gauge.
Too often, the gauge on the end of the air hose at
vnr rr corner narane is not accurate because it suffers
~rs check tire oressure when the
Radial tires should never be used on only the
XI I._.
‘-’ --“‘“’ J s too much abuse. Alwa!
tires are cold, as pressure increases with tempera-
ture. If you must move the vehicle to check the tire
front axle.
When selecting tires, pay attention to the original
size as marked on the tire. Most tires are described
using an industry size code sometimes referred to as
P-Metric. This allows the exact identification of the
tire specifications, regardless of the manufacturer. If
selecting a different tire size or brand, remember to
METRIC TIRE SIZES
(MILLIMETERS)
145 CDNStRUCtlDN l-6-E
R - RADIAL
D
WA9
Fig. 139 P-Metric tire coding Fig. 140 Tires should be checked frequently
I I Fig. 141 Tires with deep cuts, or cuts which
for any sion of auncture or damaoe
buioe, should be replaced immediately
l DRIVE WHEEL HEAW
ACCELERATION
l OVERINFLATION
*LACK OF ROTATION
Fig. 142 Examples of inflation-related tire
RADIAL TIRE
fig. 143 Radial tires have a characteristic
sidewall bulge; don’t try to measure pres-
sure by looking at the tire. Use a quality air
pressure gauge

.
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.

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.