MITSUBISHI GALANT 1989 Service Service Manual

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
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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 Service00-43
1
O.AUTOMATIC
TRANSAXLE
Inspect fluid levelMOOSSDA
1. Drive until the fluid temperature reaches the usual ternperature
[70-80°C (160- 18O”F)I.
2. Plaice vehicle on level floor.
3.Move selector lever sequentially to every position to fill
torque converter and hydraulic circuit with fluid, then place lever in “N” Neutral position. This operation is
necessary to be sure that fluid level check is accurate.
4. Before removing dipstick, wipe all dirt from area around
dipstick. Then take out the dipstick and check the
condition of the fluid.
The transaxle should be overhauled under the following
conditions.l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
l If there is a noticeably great amount of metal particles in the fluid.
5.Chleck to see if fluid level is in “HOT” range on dipstick.
If fluid level is low, add ATF until level reaches “HOT”
range.
LO\N fluid level can cause a variety of conditions
because it allows pump to take in air along with fluid. Air
trapped in hydraulic circuit forms bubbles which make
fluid spongy. Therefore, pressures will be erratic. Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam and cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of ATF.In either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch,
and servo operation. Foaming can also result in fluid escaping from transaxle vent where it may be mistaken
for a leak.
6. Be sure to examine fluid on dipstick closely. Chaqge
fluid
Drain
tlhe fluid and check whether there is any evidence of
contamination. Replenish with new fluid after the cause of any contamina-
tion
has been corrected.
(1) Rernove drain plugs to let fluid drain.
(2) Rernove the oil pan.
(3) Check the oil filter for clogging and damage and replace
if necessary.
(4) Clean the inside of oil pan and 5 magnets.
(5) Attach the five magnets to the concave part of the oil
pan.
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(6) Clean both gasket surfaces of transaxle case and oil
pan.
(7) Install oil pan with new gasket and tighten oil pan bolts
to
IO-I 2 Nm (7.5-8.5 ftlbs.)
(8) Tighten drain plug with gasket to 30-35 Nm (22-25 ft.lbs.).
(9) Supply 4
dm3 (4.23 qts.) of specified ATF into case
through dipstick hole. [Total quantity of ATF required is 6.1
dm3 (6.45 qts.).
Actually however, approx. 4.5 dm3 (4.76 qts.) of fluid
car1 be replaced because rest of fluid remains in torque converter.]
1

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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14KO24
OOA0186
GENERAL - Maintenance Service00-45
2.Inspect the wheel cylinder boots for evidence of a brake
fluid leak. Visually check the boots for cuts, tears or heat cracks. (A slight amount of fluid on the boot may
not be a leak, but may be preservative fluid used at
assembly.)
Checking the Brake Shoes for Wear. Thiclkness
of lining (B)
Limit: 1.0 mm
(.04 in.)
14.BRAKEI HOSES (Check for deterioration or
leaks)MOOSBHA
Inspection of brake hoses and tubing should be included in
all brake service operations.
The hoses should be checked for: 1. Correct length, severe surface cracking, pulling, scuf- fing or worn spots. (If the fabric casing of the hoses is
exposed by cracks of abrasion in the rubber hose cover,
the hoses should be replaced. Eventual deterioration of hose may occur with possible bursting failure.)
2. Faulty installation, casing twisting or interference with wheel, tire of chassis.
15.BALL ,IOINT AND STEERING LINKAGE SEALS
(Inspect for grease leaks and damage)
MOOSBJAa
I, These components, which are permanently lubricated at the factory, do not require periodic lubrication.Damaged seals and boots should be replaced to
prevent leakage or contamination of the grease.
2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective. 16.DRIVE SHAFT BOOTS (Inspect for grease leaks
and damage) MOOSWAb
1. The.se components, which are permanently lubricated
at the factory, do not require periodic lubrication.
Damaged boots should be replaced to prevent leakage
or contamination of the grease.
2. Inspect the boots for proper sealing, leakage and damage. Replace it if defective.
17.REAR AXLE (Inspect oil level)-AWD MOOSBPQ
Remove the filler plug and inspect the oil level at bottom of
filler hole. If the oil level is slightly below the filler hole, it is
in satisfactory condition. 18.EXHAIJST
SYSTEM (CONNECTION PORTION
OF MUFFLER, PIPING AND CONVERTER HEAT
SHIELDS) (Check and service as
require$LsBU
1. Check for holes and gas leaks due to damage, corro- sion, etc.
2.Check the joints and connections for looseness and gas
leaks.
3. Check the hanger rubber and brackets for damage.
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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

GENERAL - Table of Main Sealants and Adhesives00-47
Application
4. Interior adhesive
(1) Gluing of vinyl chloride
leather cloth Recommended brand 3M
Part No. EC-l 368 or equivalent
(2) Gluing of door weatherstrip and body 3M
ATD Part No.8001 or 3M
ATD Part No. 8011 oequivalent
(3) Sealing of grommets, packing and metal 3M
ATD Part No.8513
or equivalent
(4) l Gluing of headlining, interior materials l Gluing of fuel tank and pad 3M
Part No.
EC-1368 or 3M
ATD Part No.8080
01equivalent
j. Body sealant 3M
ATD Part No.8531 or 3M
ATD Part No.8646
or
l Sealing of sheet metal joints such as sheet metal, drip equivalent
rail, floor, body side panel, trunk, front panel, etc.
l Sealing of tailgate hinge
Chassis sealant (1) l Sealing of flanges and screws l Fuel gauge unit packing 3M
ATD Part No.8659
or equivalent
(2) Sealing of flange surfaces, screws, packing and dust 3M
ATD Part No.8663
or equivalent
cover l Differential carrier packing
l Dust cover for ball joint and linkage
l Packing for steering gear box, shims
l Rack support cover and top cover for steering gear
housing
l Joints, etc. of knuckle arm flanges
(3) Sealing of accelerator arm bracket and
firewallDrying sealant
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00-48GENERAL - Table of Main Sealants and Adhesives
Application
Recommended brand
(4) Sealant for drum brake shoe hold-down pin, wheel 3M
ATD Part No.8513
or equivalent
cylinder
7. Instant super-strong adhesive l Gluing of all kinds of material 3M
ATD Part No.8155
or equivalent
plyethylene, polypropylene,
fluororesin and other surface absorbent materials>
3. Anaerobic super-strong adhesive
(I) Fixing of screws, bolts, etc. 3M
Stud locking Part No.4170
or equivalent
l Tightening parts for drive gear and differential case
l Tilt steering upper, lower column joint bolt
(2) Fixing of joints of bearings, fan, pulley, gear, etc.
(3) Sealing of small gaps and flange surface
(4) Steering angle 3M
Nut locking Part
No.4171 or equivalent
stopper bolt (Jeep)
3. Undercoating 3M
ATD Part No.8864
or equivalent
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