engine MITSUBISHI GALANT 1989 Service Owner's Manual

GENERAL -Lubrication and Maintenance/Recommended Lubricants and Lubricant Capacities Table00-35
If premium unleaded gasoltne IS not available,
MATERIALS ADDED TO FUEL
unleaded gasoline having a octane rating of 87 or
91 RON (Research Octane Number) may be used. Indiscriminate use of fuel system cleaning agents
In this case, the performance and fuel consumption should be avoided. Many of these materials
in-
WIII suffer a little degradatron.tended for gum and varnish removal may contain
highly active
solvents or similar ingredients that can
be harmful to gasket and diaphragm materials used
in fuel system component parts.
Gasolines containing alcohol
Some gasolrnes sold at service stations contain
alcohol, although they may not be SC identified. Use
of fuels containing alcohol is not recommended
unless the nature of the blend can be
determrned
as being satisfactory.
Gasohol
- A mixture of 10% ethanol (grain alcohol)
and 90% unleaded gasoline may be used
In your
car. If
driveability problems are experienced as a
result of using gasohol, it IS recommended that the
car be operated on gasoline. Methanol
- Do not use gasolines containing
methanol (wood alcohol). Use of this type of
alcohol can result in vehicle performance deteriora-
tion and damage critical parts in the fuel system
components. Fuel system damage and performance
problems, resulting from the use of gasolines
containing methanol, may not be covered by the
new car warranty.
Gasolines containing MTBE (Methyl Tertiary Butyl
Ether)
Unleaded gasolrne containrng
15% or less MTBE
may be used in your car. (Fuel containing MTBE
over 15% vol. may cause reduced engine per-
formance and produce vapor lock or hard starting.) RECOMMENDED

LUBRICANTS AND
LUBRICANT CAPACITIES TAB,&-
RECOMMENDED LUBRICANTS
Items
Engine Oil
Recommended lubricants
API classification SG or SGKD (For further details, refer to SAEviscosity number)
Manual Transaxle, Transfer

Rear Axle
API classification GL-4 or higher, SAE 75W-85W
Refer to P.OO-37.
Automatic Transaxle
Power Steering
Brake and Clutch
Engine Coolant DIAMOND ATF SP or equivalent
Automatic transmission fluid “DEXRON II” Conforming to
DOT3 or DOT4
DIA-QUEEN LONG-LIFE COOLANT (Part No. 0103044) or High
qualitv ethvlene-qlvcol
antifreeze coolant
Door HingesEngine oil
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00-36
GENERAL -Recommended Lubricants and Lubricant Capacities Table
LUBRICANT CAPACITIES TABLE
Descrrptron
Engrne 011
Crankcase
Models built up to April 1992 >

Models built from May 1992
Oil filter
Oil cooler Cooling System
(rncludrng heater and coolant reserve system)
Manual Transaxle
F5M22
F5M3
1

Transfer
qear Axle
4utomatrc Transaxle


‘ower Steering %el
Tank

Metric measure
3.5 dm3
4.0 dm3
4.0 dm3
0.3 dm3
0.3 dm3
7.2 dm3
1.8 dm31.9 qts.
2.3
dm32.4 qts.
2.3 dm32.4 qts.
3.6 dm363 qt.
3.7
dm374 qt.
6.1 dm3
6.5 dms
3.9 dm3 60
dm3
62 dm3
U.S. measure
3.7qts.
4.2qts.
4.2qts.
1 I2qt.
1 I2qt.
7.6qts.
5.4 qts.
6.9 qts.
95 qt.
15.9 gals.
16.4 gals.
Temperature range anticipated before next oil chanae
SAE SW-30 SW-40IRecommendedviscosity (SAE) M03BOOl
SELECTION OF LUBRICANTS
ENGINE OIL
Engine oil should be used which conform to the requirements
of the API classification “For Service SG” or “For Service
SGKD”, and have the proper SAE grade number for the
expected temperature range.
Caution
Nondetergent or straight mineral oil must never be used.
Energy Conserving Oil
In order to improve fuel economy and conserve energy new,
lower friction engine oils have been developed. These oils are readily available and can be identified by such labels as “Energy
Conserving”, “Energy Saving”,
“Improved Fuel Economy”,
etc.
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GENERAL - Recommended LubricaMs and Lubricant Capacities Table 00-37
721004

4
Oil Identification Symbol
A standard
.symbol appears on the top of oil containers and has
three district areas for identifying various aspects of the oil.
The top
polqion will indicate the quality of the oil. The center
portion will show the SAE viscosity grade, such as SAE lOW-30.
“Energy Conserving” shown in the lower portion,
indicates that the oil has fuel-saving capabilities.
REAR AXLE
API classificationGL-5 or higher
Anticipated temperature range
Above -23°C
(- 10°F)
-23°C to --34°C (-10°F
to -30°F)
Viscosity range
SAE 90
SAE 85W-90SAE 8OW-90
SAE 8OW. SAE 8OW-90
Below
-34°C
(-30°F)SAE 75W
SELECTION OF COOLANT
COOLANT
Relation between Antifreeze Concentration and Specific Gravity
Safe operatingCoolant
temperatureconcentration
“C(“F)(Specific volume)
-11 (12.2) 30%
-20
t-4)(,.‘_ -+j{@, ‘, :;35%
-2O(-4)40%
-25(-13)45%
-31 (-23.8) 50%
-37(-35)55%
-45(-49)60%
Example:
The safe operating temperature is - 15°C (5°F) when the measured specific gravity is 1.058 at the Coolant
temperature of 20°C (68°F).
Cautions
1. If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely
affected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling
properties will decrease, affecting the engine adversely. For these reas\
ons, be sure to maintain the
concentration level within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
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00-38GENERAL- Scheduled Maintenance Table
SCHEDULED MAINTENANCE
TABLEMOOOA-
SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER
VEHICLE PERFORMANCE
Inspection and Services should be performed any time a malfunction is ob\
served or suspected. Retain receipts
for all vehicle emission services to protect your emission warranty.
Kilometers in Thousands 24 48 72 80 96
No.Emwsron Control System MaintenanceService IntervalsMileage in Thousands 15 30 45 50 60
1Check Fuel System (Tank, Line and Connections and Fuel Tank Filler Tube\
Cap) orXfor Leaks Every 5 Years
2Check Fuel Hoses Every 2 Years for leaks or damage orXX
3Replace Air Cleaner ElementatXX
4Replace Spark PlugsatXX
GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE
L
1
1
1
1
1
i
IO.General Maintenance
Service Intervals
7Engine Oil
8
9
IO
III2
I3
14
15
I6
I71
8
L
I
I
I
I
I\
I
II
I
I
;(
Kilometers in Thousands 24 48 72 80 96
Mileage in Thousands 15 30 45 50 60 Timing
Belt (Including the Balancer
Belt)
ReplaceatX
Drive Belt (for Water Pump
Inspect for tensionatXXand Generator)
Non-TurboChange Every Year Every 12,000 kmOr (7,500 miles)
Turbo Change Every 6 Months Every 8,000 km
Or (5.000 miles
)
II
Non-Turbo
Change Every Year or X X XX
Every 16,000 kmOr (10,000 miles)
Engine Oil Filter
TurboChange Every Year
Manual Transaxle Oil 4utomatrc
Transaxle Fluid Inspect Oil Level
at
XX
Inspect Fluid Level Every Yearor X X XX
Change FluidatXX
Engine Coolant
Replace Every 2 YearsOrI 1x1 I IX
Disc Brake Pads1 inspect for Wear Every Yearor/XlXlXl I
X
3rum
Brake Linings
and Rear iNheel
Cylinders Inspect for Wear and Leaks Every 2 Years
or
XX
3rake HosesCheck for Deterioration or Leaks Every Year or X X XX
3all Joint and SteeringInspect for Grease Leaks and-inkage
Seals
Damage Every 2 Years
Or I/ XII x
Irive Shaft Boots Inspect for Grease Leaks and Damage Every Year or XXXX
3ear Axle Change OilatXX
Exhaust System (Connectron>ortion of Muffler, Pipings and
Check and Service as Required Every 2 YearsConverter Heat Shields)
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GENERAL - Scheduled Maintenance Table/Maintenance Service00-39
SCHEDULED MAINTENANCE UNDER SEVEiRE USAGE CONDITIONS
The maintenance items should be performed according to the following tab\
le:
Maintenance Item Service to be
Performed
IEngine Oil Change Every or
3 Months
(:z:.:a::I
Rear Drum Brake
Linings and Rear
Wheel Cylinders Inspect for Wear
and Leaks
1
Mileage Intervals Kilometers in Thousands (Miles in Thousands) Severe Usage
Conditions
More Frequently
Every 4,800 km
(3,000 miles)/xlxlx/xI I I1 Every
9,600 km (6,000 miles)
IxIxlxIxI I I>(
More Frequently1x1 I I I 1x1I I I I I I I
More Frequently
Ix1 I I I lx/
Severe usage conditions A-Driving in dusty conditions
- -B- I railer
towing or police.
taxi,
or commercial
type
operation
C-Extensive idling
D-Short trip operation at freezing temperatures (engine not thoroughly warmed up) E-Driving in sandy areas- -..F-Dnvlng In salty areas
G-More than 50% operation in heavy city trafic during
hot weather above 32°C (90°F)
MAINTENANCE SERVICE
1. FUEL SYSTEM (Tank, Lines, Connections and
Fuel Tank Filler Tube Cap) (Check for leaks)/2.
FUEL HOSES (Check for leaks or
damagekOOSnOB.
1.Check for damage or leakage in the fuel lines and con-
nections and looseness of the fuel tank filler tube cap.
2. Inspect the surface of fuel hoses for heat and mecha-
nicall damage. Hard and brittle rubber, cracking, check-
ing, tears, cuts, abrasions and excessive swelling
indicate deterioration of the rubber.
3. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses
should be changed.
3. AIR CLEANER ELEMENT (Replace)
MMlSAKH
The air cleaner element will become dirty and loaded with dust during use, and the filtering effect will be substantiallyreduced. Replace it with a new one.

(1) Loosen the clamp coupling the air intake hose and the air cleaner cover, and separate the hose.
(2) Disconnect the volume air flow sensor connectors.
(3) Unclamp the air cleaner cover clip.
(4) Lifting the air intake hose, remove the air cleaner cover.
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00-40GENERAL- Maintenance Service
Caution
The air cleaner cover should be removed carefully,
because it includes the volume air flow sensor.
/
(5) Remove the air cleaner element.(6) Set a new air cleaner element and install the air cleaner cover.
I hose,I
Plug gapgauge
Measurementrection01
If
0110182
(1) Disconnect the volume air flow sensor connector.
(2) Disconnect the breather hose, purge hose, by-pass air hose and boost hose connections.
(3)Remove the air intake hose on the air cleaner cover side
and then move the air intake hose to the front of the air
cleaner body.
(4) Unclamp the air cleaner cover.
Caution
Care must be taken when removing the air cleaner
cover, because the volume air flow sensor is at-
tached.
(5) Take out the air cleaner element.
(6) Check the air cleaner element for dirt or clogging; if necessary, clean by using compressed air.
(7) Replace the air cleaner element if the dirt or clogging
is
serious.
(8) Insert the element into the air cleaner body and install the air cleaner cover.
(9) Install the air intake hose.
(10)Connect the breather hose, purge hose, by-pass air
hose and boost hose.
(11
)Connect the volume air flow sensor connector.
4. SPARK PLUGS (Replace)
h%OSAOFa
1. Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission
level.
Therefore, they should be replaced periodically with
new ones.
2. The new plugs should be checked for the proper gap.
Spark plug gap:
1.0-1.1
mm (.039-.043

in.)
0.7-0.8 mm (.028-.031 in.)
3.Install the spark plug and tighten to 20-30 Nm (15-21
ftlbs.).
5. TIMING BELT (Replace)moossAsa
Replace the belt with a new one periodically to assure
proper engine performance.
For disassembly and reassembly procedures, refer to
GROUP 11 -Service Adjustment Procedures.
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GENERAL - Maintenance Service00-41
-1
6COOO9
L!6COO39
OlR0344
6. DRIVE BELT (For Water Pump and
Generator) (Inspect for tension)
MOOSBBN
(1) Place straight edge as shown in the illustration.
(2) Measure the deflection with a force of
100 N (22 Ibs.)
applied to belt mid-point between water pump pulley
and generator pulley. If the standard value is not ob-
tained, make adjustment.
Standard value: 9.0-l 1.5 mm (.354-.453
in.)
(3) Use a tension gauge to check the belt tension. If the standard value is not obtained, make adjustment.
When tension gauge is used, the tension may be
measured between any two pulleys.
Standard value:
250-500 N (55-110
Ibs.)
7. ENGINE OIL (Change)MOOSAABc
Always use lubricants which conform to the requirements
of the API classification “For Service SG” or “For Service SG/CD”
when available, and have the proper SAE grade
number for the expected temperature range.
Never
Lose nondetergent or straight mineral oil.
(1) After warming up the engine, remove the oil filler cap.
(2) Remove the drain plug to drain the engine oil. (3) Replace the drain plug gasket with a new one and
tighten the drain plug.
(4) Supply new engine oil through the oil filler.
Engiine oil capacity:
Items Engine oil capacity
Oil pan
1
Models built up toSOHC3.5 dm3 (3.7 qts.)
April 1992DOHC4.0 dm3 (4.2 qts.)
Models built from May 19924.0 dm3 (4.2 qts.)
Oil filter 0.3 dm3 (l/2 qt.)
Oil cooler
(clnly models with turbo) 0.3 dm3 (I/2 qt.)
(5) Start and run the engine a few minutes.
(6) Stop the engine and check the engine oil level.
8. ENGINE OIL FILTER (Change)
MOOSABG
The quality of replacement filters varies considerably. Only high
quatlity filters should be used to assure most efficient
service. Genuine oil filters require that the filter is capable of
withstarlding a pressure of 256 psi are high quality filters
and are recommended as follows:
Oil Filter Part No.
Mitsubishi Genuine Parts: MD135737,
MD136466
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00-42GENERAL -Maintenance Service
ENGINE OIL FILTER SELECTION
This vehicle is equipped with a full-flow, throw-away oilfilter.
The same type of replacement filter is recommended as a replacement filter for this vehicle. It is possible, particularily
in cold weather, that this vehicle may develop high oil
pressure for a short duration. You should be sure that any replacement filter used on this vehicle is a high-quality filter
and is capable of withstanding a pressure of 256 psi (manufacturer’s specifications) to avoid filter and engine
damage. The following is a high-quality filter and is strongly
recommended for use on this vehicle
: Mitsubishi Engine
Oil Filter Part No. MD1 35737 or MD1 36466.
Any replacement oil filter should be installed in accordance
with the oil filter manufacturer’s installation instructions. (1) Remove the engine oil filler cap.
(2) Remove the engine oil drain plug, and drain out the
engine oil.
(3) Remove the engine oil filter by using the oil filter
(4)
GLr!he oil filter mounting surface of the oil filter
bracket.
OSPOO26 1 09A.0024(5) Coat engine oil to the O-ring of new oil filter.
(6) Screw in the oil filter with hand until it touches the sur-
face of the flange and then tighten it with the filter
wrench, etc.
l For MD135737:
One full turn or 14 Nm
(loft. Ibs.)0For MD136466:3/4 turn or 17 Nm (12 ft. Ibs.)
(7) Supply engine oil.
(8) Start and run engine and check for engine oil leaks.
(9) After stopping engine, check oil level and replenish as
necessary.
9. MANUAL TRANSAXLE (Inspect oil level)
MOO66CE
Inspect each component for evidence of leakage, and
check the oil level by remaining the filler plug. If the oil is
contaminated, it is necessary to replace it with new oil.
I. With the vehicle parked at a level place, remove the filler plug and check to be sure that the oil level is up to
the lower edge of the filler plug hole.
2. Check to be sure that the transmission oil is not noticeably dirty, and that it has a suitable viscosity.
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GENERAL -Maintenance Service
(1O)Star-t engine and allow to idle for at least two minutes.
Then, with parking brake on, move selector
fever
momentarily to each position, ending in “N” Neutral
position.
(11)Add sufficient ATF to bring fluid level to lower mark.
Recheck fluid level after transaxle is at normal Operating
temperature. Fluid level should be between upper and lower marks of
“HOT” range, Insert dipstick fully to prevent dirt from
entering transaxle.
OOA0051
11 .ENGINE
COOLANT (Change)MOOSEEAC
Check the cooling system parts, such as radiator, heater,
and oil cooler hoses, thermostat and connections for
leakage and damage.
CHANGE COOLANT
1. Remove the radiator cap.
2. Loosen the drain plug to drain the coolant.
3. Drain the coolant from the reserve tank.
4. After draining the coolant, tighten the drain plug securely.
5.Supply the coolant into the radiator until it is filled up to
its filler neck.
6. Supply the coolant into the reserve tank.
7. After warming the engine until the thermostat opens, remove the radiator cap and check the coolant level.
8.Supply the coolant into the radiator until it is filled up to
its filler neck, and install the radiator cap securely.
9.Fill the reserve tank with coolant up to the “FULL” line.
14K512
1 12.DISC BRAKE PADS (Inspect for wear) MWSBFA
Check for fluid contamination and wear. Replace complete
set of pads if defective.
Caution
The pads for the right and left wheels should be
reDlaced at the same time. Never “split” or intermix
brkke pad sets.
All four pads must be replace as a complete set.
Thickness of lining (A)
Limit: 2.0 mm (.08 in.)
13.REAR DRUM BRAKE LININGS AND REAR
WHEEL CYLINDERS (Inspect for wear and
leaks)MOOSBGB
1. Remove the brake drum and check the thickness of brake shoe lining for wear. Check the automatic brake
adjusting system by hand to see if it operates smoothly.
Also see if the gears are in proper mesh with each
other. To assure smooth functioning, apply a very thin
coat of multipurpose grease to the friction surface of
adjuster and link shaft.
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00-46GENERAL - Table of Main Sealants and Adhesives
TABLEOF MAINSEALANTS
AND
ADHESIVES
MONA--
Application Recommended brand
1. Sealing for engine accessory parts 3M
ATD Part No.8660
or equivalent
(1) Sealing
for semi-circular packing of rocker cover and
cylinder head
(2) l
Sealrng for semi-circular packing and rocker cover, 3M
ATD Part No.8660
or equivalent
cylinder head
l Oil pressure switch
(3) l Engine coolant temperature switch l Engine coolant temperature sensor
l Thermal vacuum valvel Therm0
switch
l Engine coolant temperature gauge unit
l Joint 3M
Nut Locking Part
No.4171 or equivalent
(4) Oil pan MITSUBISHI GENUINE Part No.MD997110
or
equivalent
2. Sealing for weatherstrip
(1) l Sealing of tempered glass and weatherstrip 3M
ATD Part No. 8513 or equivalent
l Sealing
of body flange and weatherstrip 3M
ATD Part No.8509
or equivalent
(2) Sealing of laminated glass and weatherstrip 3M
ATD Part No.8509
or equivalent
3. Gluing with ribbon sealer l Door waterproof film
l Fender panel
l Splash shield
l Mud guard 3M
ATD Part No.8625
or equivalent
l Rear combination light TSB Revision