wheel bolt torque 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.

3.5L SOHC ENGINE MECHANICAL SPECIFICATIONS
Description
Connecting rod English
Specifications Metric
Specifications
Rod big end side clearance
Standard
Llrnll
Piston pin outslde dnmeler
P~slon pin press-~” load
Crankshalt pm 011 clearance
Standard 0 0039-o 0096 I” 0 10-O 25mm
0016ln
0 4mm
067rn 22mm
Flngerprewre
0 0006-0 0020 in
0 02-O 05mm
Llmtt
0 004 I” Olmm
Crankshaft
Maln bearing 011 clearance
Standard
0 0006-0 0020 I”
0 02-O 05mm
Llmlt
0 004 I”
Olmm
Pin outside dram&r
197m 50mm
Journal outslde diameter
2361n 60mm
Out-+round (max
) -
0 0006 I”.
0015mm
Crankshaft end.play
Standard
0 002-0 0096 I”.
0 05-O 25mm
TIP clearance
Side clearance
Body clearance
Standard 0
1X24-0 0071 1”
0
0016-O 0039 I” 0 06-O 16mm
0 040 IOmm
0 0039-o 0071 I” 0 10.0.16mm Components
Camshall
TORQUE SPECIFICATIONS English Metric
Camshalt sprwket bolt
1 5L engjne
1 6L, 1 8L, and 2 OL (SOHC and DOHC) engines
2 4L engine
3 OL (SOHC and DOHC) engme
Bearing cap retalnlng bolts
2 OL SOHC engine
1 6L and 2 OL DOHC engines
2 4L eng,ne
3 OL (SOHC and DOHC) engme
3 5L engine
Crankshalt dampedpullev 51 it Ibs
6511 Ibs
56.72 R Ibs.
65 It Ibs
1511 Ibs
21.25ft Ibs
15 fl lbs. 70 Nm
90 Nm
60-l 00 Nm
WNm
2ONm
29-35 Nm
20 Nm
0
23 11 Ibs 31 Nm
Pullev bolts
1 5L engine loft Ibs 14Nm
1 6L and 2 OL (SOHC and DOHC)engines
14.22 It lbs
20-30 Nm
2 4L enqme
16 fl Ibs. 25 Nm
Center reta!ino bolt
51-72 It lbs
13411 Ibs 70.100 Nm
165Nm
3 OL (SOHC and DOHC) engine
Cvllnder head 106-11611 lbs 150-160 Nm
1 6L englne
2 OL SOHC engine
2 4L
engine
3 OL SOHC engine
3 OL DOHC enwe
- 3 5L eqne
Flywheel/dnvaplale retaining b&s 22lt Ibs
11.14ll Ibs
16-21 it Ibs
21 ll Ibs
14 It Ibs
21 It Ibs 3ONm
15-19 Nm
25-29 Nm
29 Nm
19Nm
29 Nm
1 5L engine
1 6L 2 OL (SOHC and DOHC), and 2 4L engmes 98 It Ibs
94.101 II Ibs 135Nm
130-140 Nm
1 6L
engine 72 It lbs
100 Nm
3 OL SOHC, 3 OL DOHC, and 3 5L engmes
53-56 It Ibs
72-76 Nm
Intake manlfoid retanmg bolts
1 5L engine
16Land20L DOHC engines 1311 lbs
Ii-141 Ibs 16Nm
15-19 Nm
1 6L engine
2 OL SOHC engme
Plenum bolts
Manifold bolts
2 4L
eng,ne
1994 models 1411 Ibs
11.14R Ibs.
11-1411 Ibs
left Ibs 15.19Nm
15.19Nm
25 Nm
Bolts
NUk
1995.00 models 15fl ibs 20 Nm
26 ‘I lbs.
35 Nm
SOItS 15fi Ibs 20 Nm
Nuts
15 ft Ibs.
20 Nm
3 OL SOHC 3 OL DOHC, and 3 5L engines
0
93153~24
m
F5
/ m
P
0
m
is
7
m

.
5-14 FUEL SYSTEM
93155(10: ‘ig. 59 loosen self-locking nuts on tank
mpporf straps to the end of the stud bolts
-1990-93 FWD Galant
93i55Qo$ :ig. 60 Remove the six retaining bolts and
lasket from the base of the tank-1990-93
:WD Galant
Q m
0 a
cl@=
u a-
a al2
0
0
Q
a a
Posmdmng projectton 93155910 Fig. 61 Align the 3 projections on packing
with the holes on the fuel pump and the nip-
ples on the pump facing the same direction
as before removal-1990-93 FWD Galant
13. Install the right side lateral rod and attaching
bolt into the right body coupling. Tighten loosely
only, at this time.
14. Tighten the self-locking nuts on the tank sup-
port straps until the tank is fully seated. Torque the
nuts to 22 ft. Ibs. (31 Nm).
15. Install the high pressure fuel hose connector
and tighten to 29 ft. Ibs. (40 Nm).
16. Install the electrical connectors onto the fuel
pump and gauge unit assemblies.
17. Lower the vehicle so the suspension supports
the weight of the vehicle. Tighten the lateral rod at-
taching bolt to 58-72 ft Ibs. (So-100 Nm).
18. Refill the fuel tank with fuel drained during
this procedure.
19. Connect the negative battery cable and check
the entire system for proper operation and leaks. ALL WHEEL DRIVE (A WO)
# See Figures 62, 63, and 64
1. Relieve the fuel system pressure using proper
procedure.
2. Disconnect negative battery cable.
3. The fuel pump is located in the fuel tank. Re-
move the access cover located in the rear floor pan
4 Parbally drain the fuel tank into an approved
gasoline container.
Observe all applicable safety precautions
when workina around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
-ig. 62 The fuel pump is located in the fuel
r
ank. Remove the access cover located m
he rear floor pan -1990-93 AWD Galant
93155go7 Fig. 63 Remove the six pump retaining bolts
and remove the fuel pump and gauge as-
sembly from the tank-1990-93 AWD
1 Galant
93155goa Fig. 64 Install 3M ATD Part No. 8625 or
equivalent, to the rear floor pan and install
ihe access cover into place -1990-93 AWD
Ealant storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
5 Remove the electrical connector from the fuel
pump.
6. Remove the overfill limiter (two-way valve),
as required.
7. Remove the high pressure fuel hose connec-
tor.
8. Remove the six pump retaming bolts and re-
move the fuel pump and gauge assembly from the
tank. Note positioning of pump prior to removal from
tank.
To install:
*If the packing material is damaged or de-
formed, replace it with new packing.
9. Align the 3 projections on the packing with
the holes on the fuel pump and the nipples on the
pump facmg the same direction as before removal.
Install the retainers and tlghten to 2 ft. Ibs. (3 Nm).
10. Install the high pressure hose connection and
tighten to 29 ft. Ibs. (40 Nm).
11. Install the overfill limiter (two-way valve) and
the electrical connector to the fuel pump.
12. Fill the fuel tank with the gasoline removed
during this procedure.
13. Reconnect the negative battery cable and
check the entire system for leaks.
14. Install 3M ATD Part No. 8625 or equivalent,
to the rear floor pan and install the access cover into
place.
Diamante, 1993-00 Mirage, and 1994-98
Galant
# See Figures 65 thru 72
1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove the rear seat cushion, by pulling the
seat stopper outward and lifting the lower cushion
upward.
4. Remove the access cover.
5. Disconnect the fuel pump wiring.
6. Disconnect the return hose and the high
pressure fuel hose.
7. Remove the pump mounting nuts and remove
the pump assembly.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
To install:
rlf the packing material is damaged or de-
formed, replace it with new packing.
8. Install the packing to the fuel tank.
9. Install the fuel pump assembly to the tank and
tighten the retaining nuts to 22 inch Ibs. (2 5 Nm).

7-2 'DRIVETRAIN
Because of the way an internal combustron engine
breathes, it can produce torque, or twisting force,
only within a narrow speed range. Most modern,
overhead valve pushrod engines must turn at about
2500 rpm to produce their peak torque By 4500 rpm
they are producrng so lrttle torque that contrnued in-
creases in engine speed produce no power increases.
The torque peak on overhead camshaft engines IS
generally much higher, but much narrower.
The manual transaxle and clutch are employed to
vary the relationship between engine speed and the
speed of the wheels so that adequate engine power can
be produced under all crrcumstances. The clutch al-
lows engine torque to be applied to the transaxle input
shaft gradually, due to mechanical slippage. Conse-
quently, the vehicle may be started smoothly from a
full stop The transaxle changes the ratio between the
rotating speeds of the engine and the wheels by the
use of gears. The gear ratios allow full engine power to
be applied to the wheels during acceleration at low
speeds and at highway/passing speeds.
In a front wheel drive transaxle, power is usually
transmitted from the input shaft to a mainshaft or out-
put shaft located slightly beneath and to the side of
the input shaft. The gears of the mainshaft mesh with
gears on the input shaft, allowing power to be carried
from one to the other. All forward gears are in con-
stant mesh and are free from rotating with the shaft
unless the synchronizer and clutch IS engaged. Shaft-
ing from one gear to the next causes one of the gears
to be freed from rotating with the shaft and locks an-
other to it. Gears are locked and unlocked by internal
dog clutches which slide between the center of the
gear and the shaft. The forward gears employ syn-
chronizers; friction members which smoothly bring
gear and shaft to the same speed before the toothed
dog clutches are engaged.
SHIFT LINKAGE
1. Disconnect the shift linkage from the transaxle.
2. On the transaxle, put select lever in N and
move the shift lever in
4th gear. Depress the clutch,
if necessary, to shift.
3. Move the shift lever in the vehicle to the
4th gear position until it contacts the stop.
4. Turn the adjuster turnbuckle so the shift cable
eye aligns with the eye in the gear shift lever. When
installing the cable eye, make sure the flange side of
the plastic bushing at the shift cable end is on the
cotter pin side.
5 The cables should be adjusted so the clear-
ance between the shift lever and the 2 stoppers are
equal when the shift lever IS moved to 3rd and 4th
gear. Move the shift lever to each positron and check i
that the shifting is smooth
REMOVAL &INSTALLATION
1, Disconnect the negative battery cable 2. Remove any components necessary to access
the back-up light switch.
3. Unplug the back-up light switch connector.
4. Remove the switch from the case using the ap-
propriate size socket and drive tool.
To install: 5. Install the switch and tighten it to 22-25 ft. Ibs.
(30-35 Nm).
6. Attach the back-up light switch connector
7. Install any components removed to access the
back-up light switch
8. Connect the negative battery cable.
REMOVAL & INSTALLATION
Mirage
*If the vehicle is going to be roiled while the
halfshafts are out of the vehicle, obtain 2 outer
CV-joints or proper equivalent tools and install
to the hubs. If the vehicle is rolled without the
proper torque applied to the front wheel bear-
ings, the bearings will no longer be usable.
*The suspension components should not be
tightened until the vehicles weight is resting
on the ground.
1. Remove the battery and battery tray.
2. Remove the air cleaner assembly and vacuum
hoses.
3. Note the locations and disconnect the shifter
cables.
4. If equipped with 1.61 engine, remove the ten-
sion rod.
5. Detach the backup lamp switch connector,
speedometer cable connection and remove the starter
motor.
6. Raise the vehicle and support safely.
7. Remove the front wheels and the inner wheel
panels.
8. Remove the undercover and splash pan.
9. Drain the transaxle oil into a suitable con-
tainer
10. Support the engine and remove the cross-
member.
11. Remove the upper transaxle mounting bolt
and bracket.
12 Disconnect the stabilizer bar, tie rod ends and
the lower ball joint connections.
13 Remove the clutch release cylinder and clutch
oil line bracket. Do not disconnect the fluid lines and
secure the slave cylinder with wire.
14 Disconnect the clutch cable, if equipped with
cable controlled clutch system.
15. Remove the halfshafts by inserting a prybar
between the transaxle case and the driveshaft and
prying the shaft from the transaxle. Do not pull on the
driveshaft Doing so damages the inboard joint. Do
not insert the prybar so far the oil seal in the case is
damaged.
*It is not necessary to disconnect the half-
shafts from the steering knuckle. Remove the
shaft with the hub and knuckle as an assem-
bly. Tie the shafts aside. Note the circle clip
on the end of the inboard shafts should not
be reused.
16. Remove the bellhousing lower cover.
17 Remove the transaxle to engine bolts and
lower the transaxle from the vehrcle.
To install:
*When installing the transaxle, be sure to
align the splines of the transaxle with the
clutch disc.
18 Install the transaxle to the engine and install
the mounting bolts. Tighten the bolts to 31-40 ft. Ibs.
(43-55 Nm) on 1990-92 models and 35 ft. Ibs. (48
Nm) on 1993-00 models.
19 Install the bellhousing cover.
*When installing the halfshafts, use new
circlips on the axle ends. Care must be taken
to ensure that the oil seal lip of the transaxle
is not damaged by the serrated part of the
driveshaft.
20. Install and fully seat the halfshafts into the
transaxle.
21. Install the slave cylinder.
22. Connect the ball joints, tie rod ends and the
stabilizer bar connections.
23. Install the upper transaxle mounting bracket
and bolt.
24. Install the crossmember.
25. Install the undercover.
26. Install the upper transaxle-to-engine mount-
ing bolts, Tighten the bolts to 31-40 ft. Ibs. (43-55
Nm) on 199C-92 models and 35 ff. Ibs. (48 Nm) on
1993-00 models.
27. Install the starter motor.
28 Connect the backup light switch connector
and speedometer cable.
29 Connect and adjust the shifter cables.
30 Install the air cleaner assembly.
31. Install the front wheels.
32 Make sure the vehicle is level when refilling
the transaxle Use Hypoid gear oil or equivalent, GL-
4 or higher.
33. Connect the negative battery cable and check
the transaxle for proper operation. Make sure the re-
verse lights operate when in reverse.
Galant
1999-93 MODELS
rlf the vehicle is going to be rolled on its
wheels while the halfshafts are out of the ve-
hicle, obtain two outer CV-joints or proper
equivalent tools and install to the hubs. If the
vehicle is rolled without the proper torque
applied to the front wheel bearings, the bear-
ings will no longer be usable.
1. Remove the battery and the air intake hoses.
2. If equipped with Active-ECS, unplug the
compressor wiring.
3. Remove the auto-cruise actuator and under-
hood bracket, located on the passenger side inner
fender well.
4. Drain the transaxle and transfer case fluid, if
equipped, into a suitable waste container.
5. Remove the retainer bolt and pull the
speedometer cable from the transaxle assembly.
6. Remove the cotter pin securing the select and
shift cables and remove the cable ends from the
transaxle.

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

DRIVETRAIN 7-5
1, While the vehicle is still on the ground, re- IO. Insert the halfshaft into the tram&e. Be sure cle is being serviced could make a difference in joint
move the cotter pin, and loosen the axle nut. it is fully seated. type. Be sure to properly identify the joint before at-
2. Raise the vehicle and support it safely. 1 I. Pull the strut assembly out and install the tempting joint or boot replacement. Look for identifi-
3. If equipped with ABS, remove the front wheel other end to the hub. cation numbers at the large end of the boots and/or
speed sensor. 12. Install the center bearing bracket bolts and on the end of the metal retainer bands.
4. If equipped with Active Electronic Control tighten to 33 ft. Ibs. (45 Nm). The 3 types of joints used are the Birfield Joint,
Suspension (Active-ECS), perform the following: 13. Install the washer on the axle shaft so the (B.J.), the Tripod Joint (T.J.) and the Double Offset
a. Loosen the nut that secures the air line to chamfered edge faces outward. Install the axle nut, Joint (D.O.J.).
the to the top of the strut and discard the O-ring.
b. Remove the bolts that secure the actuator but do not tighten it fully at this time.
14. Connect the ball joint to the steering knuckle. *Do not disassemble a Birfield joint. Ser-
to.the top of the strut and remove the compo-
Torque the new retaining nut to 43-52 ft. Ibs. (68-72 vice with a new joint or clean and repack us-
nent. Disconnect the wiring harness.
Nm) and secure with a new cotter pin. ing a new boot kit.
5. Disconnect the lower ball joint and the tie rod
15. Connect the tie rod end to the steering
The distance between the large and small boot
end from the steering knuckle.
knuckle. Torque the retaining nut to 21 ft. Ibs. (29
bands is important and should be checked prior to
6. Remove the axle nut and the washer.
Nm) and secure with a new cotter pin.
and after boot service. This is so the boot will not be
7. If removing the left side axle with an inner 16. If equipped with ABS, install the front wheel
installed either too loose or too tight, which could
shaft, remove the center support bearing bracket speed sensor.
cause early wear and cracking, allowing the grease to
bolts and washers. Then, remove the halfshaft by set-
17. If equipped with Active-KS, perform the fol- get out and water and dirt in, leading to early joint
ting up a puller on the outside wheel hub and push-
lowing:
failure.
ing the halfshaft from the front hub. Tap the shaft a. Install the air line with a new O-ring.
union at the joint case with a plastic hammer to re- b. Install the actuator to the top of the strut. *The drfveshaft joints use special grease;
move the halfshaft and inner shaft from the transaxle. Connect the wiring harness. do not add any grease other than that sup-
8. If removing right side axle shafts without an 18. Install the wheel and lower the vehicle to the plied with the kit.
inner shaft, remove the halfshaft by setting up a floor.
puller on the outside wheel hub and pushing the half- 19. Tighten the axle nut to 145-188 ft. Ibs.
Double Offset Joint
shaft from the front hub. After pressing the outer (200-260 Nm) and secure with a new cotter pin.
shaft, insert a prybar between the transaxle case and The Double Offset Joint (D.O.J.) is bigger than
the halfshaft and pry the shaft from the transaxle.
CV-JOINTS OVERHAUL other joints and, in these applications, is normally
*Do not pull on the shaft; doing so damages used as an inboard joint.
the inboard joint. b See Figures 14 thru 27 1. Remove the halfshaft from the vehicle.
2. Side cutter pliers can be used to cut the metal
To install: These vehicles use several different types of joints. retaining bands. Remove the boot from the joint outer
9. Replace the circlips on the ends of the half- Engine size, transaxle type, whether the joint is an in- race.
shafts. board or outboard joint, even which side of the vehi-
TCCS7030 TCCS7031
I I TCCS7032 Fig. 15 Removing the outer band from the
Fig. 16 Removing the inner band from the
Fig. 14 Check the CV-boot for wear
W-boot
lho~sing IFi7~ / Fig 17 Removing the CV-boot from the joint 1 1 CV-boot
TCCS7035 Fig 18 Clean the CV-joint housing prior to
removing boot Tccs7W 1 1 sembiy Fig 19 Removing the CV-joint housing as-

DRlVETRilN 7-7
bansaxle. When the pedal is pushed inward, the disc
and plate separate (the clutch is disenqaqed) discon-
necti
M no the enoine from the transaxie.- .
The clutch driven disc mav comam asoestos.
Galant and Mirage
b See Figures 28 thru 41 ost clutches utilize a single plate, dry friction REMOVAL &INSTALLATION
.* * _ disc with a diaphragm-style spring pressure plate.
which has been determined to be a cancer ’ The clutch disc has a splined hub which attaches the
causing agent. Never clean clutch surfaces disc to the input shaft. The disc has friction material
with compressed air! Avoid inhaling any dust where it contacts the flywheel and pressure plate.
from any clutch surface! When cleaning Torsion springs on the disc help absorb engine
clutch surfaces, use a commercially avail- torque pulses. The pressure plate applies pressure to
able brake cleaning fluid. the clutch disc, holding it tight againstthe surface of
the flywheel. The clutch operating mechanism con-
sists of a release bearing, fork and cylinder assembly. The clutch driven disc may contain asbestos,
The purpose of the clutch is to disconnect and
The release fork and actuating linkage transfer which has been determined to be a cancer
connect engine power at the tram&e. A vehicle at
pedal motion to the release bearing. In the engaged causing agent. Never clean clutch surfaces
rest requires a lot of engine torque to get all that
weight moving. An internal combustion engine does position (pedal released) the diaphragm spring holds with compressed air! Avoid inhaling any dust
the pressure plate against the clutch disc, so engine from any clutch surface! When cleaning
not develop a high starting torque (unlike steam en-
torque is transmitted to the input shaft. When the clutch surfaces, use a commercially avail-
gines) so it must be allowed to operate without any
clutch pedal is depressed, the release bearing pushes able brake cleaning fluid.
load until it builds up enough torque to move the ve-
hicle. Torque increases with engine rpm. The clutch the diaphragm spring center toward the flywheel. The
diaphragm spring pivots the fulcrum, relieving the 1. Disconnect the negative battery cable.
allows the engine to build up torque by physically
disconnecting the engine from the transaxle, relieving load on the pressure plate. Steel spring straps riveted 2. Raise and safely support the vehicle.
the engine of any load or resistance. to the clutch cover lift the pn--“-- -I-‘^ I--- ‘!-- 3. Remove the transaxle assemblv from the ve-
The transfer of engine power to the transaxle (the clutch disc, disengaging the Gllyl,lo UllVc IIVIII II1c
4. Remove the oressure elate attachina bolts.
load) must be smooth and gradual; if it weren’t, drive transaxle and enabling the gc”-- +,, h,n -‘----’
line components would wear out or break quickly. The clutch is operating pryV’uV,J ,,.
l to be reused, loosen the bolts in a diagonal pattern 1
This gradual power transfer is made possible by It will stall the engine when released with the
vehicle held stationary. or 2 turns at a time. This will prevent warping the
gradually releasing the clutch pedal. The clutch disc
l The shift lever can be moved freely between 1st clutch cover assembly.
and pressure plate are the connecting link between
and reverse gears when the vehicle is stationary and 5. Remove the return clip and the pressure plate
the engine and transaxle. When the clutch pedal is
the clutch disengaged. release bearing. Do not use solvent to clean the bear-
released, the disc and plate contact each other (the ing.
clutch is engaged) ohvsicallv ioinina the enaine and 6. lnsoect the clutch release fork and fulcrum for hicle. Refer to the procedure earlier in this section.
pressure plate and clutch disc. If the pressure plate is
TCCS7118 Fig. 28 Loosen and remove the clutch and
. . . then carefully remove the clutch
essure plate bolts evenly, a little at a time
1~~~~~ -1 [it&ouldbeflat and pressure plate assembly from the fly
- ‘(
1 .
Fig. 33 Upon installation, it is usually a 7 1 / F@%!,d . then remove the flywhee;;:! 1 1 pound’to the flywheel bolts . Tccs7’z3~
Ftg. 31 If necessary, lock the flywheel III
the crankshaft m order replace d or have d
place and remove the retaining bolts . . . good Idea to apply a threadlockmg com-

7-8 DRIVETRAIN
/ sive Wear TCCS7124 1 Fig 34 Check the pressure plate for exces- TCCS7126 j / . Fig 38 Be sure that the flywheel surface is
clean, before installing the clutch
Fig. 38 Use the clutch alignment tool to
align the
clutch disc during assembly
Fig. 40 You may want to use a threadlock- Fig, 41 Be sure to use a torque wrench to
ing compound on the clutch assembly bolts
tighten all bolts
damage or wear. If necessary, remove the release fork the end of the release cylinder pushrod and the
and unthread the fulcrum from the transaxle. pushrod hole in the release fork.
7. Carefully inspect the condition of the clutch 13. Apply multi-purpose grease to the clutch re-
components and replace any worn or damaged parts.
lease bearing. Pack the bearing inner surface and the r Fig. 36 Typical clutch alignment tool, note
shaft ,,, 1 how the splines match the transaxle’s input
TCCS7130 Fig. 39 Pressure plate-to-flywheel bolt
holes should align
nodels and 16 ft. Ibs. (22 Nm) on all other models.
3emove the aligning tool.
. 18. Install the transaxle assembly.
19. Check for proper clutch operation.
4DJUSTMENTS
Pedal Free Play
1. Measure the clutch pedal height from the face
of the pedal pad to the firewall. The desired distances
are as follows:
a. Mirage--&6148 in. (168-171mm)
b. Galant -6.93-7.17 in. (176182mm)
2. Measure the clutch pedal clevis pin play at the
ace of the pedal pad. The standard values are as fol-
DWS: a. Mirage--0.04--0.12 in. (l-3mm)
b. Galant4.04-0.12 in. (l-3mm)
3. If the clutch pedal height or clevis pin play are
rot within the standard values, adjust as follows: