ESP MITSUBISHI GALANT 1989 Service Repair Manual

GENERAL - How to Use This Manual
QfitIIICQ CTEEQINC CFAR RnY..^-TV..&” Y.LLI.II.Y Y_.. w-1.
REMOVAL AND INSTALLATION
1, Jpn assemble and gear box connecting
2 Connectlo” for return tube
3 Connectm
for pressure hose4 cotter P!”6 T!e-rod end and knuckle connecting
I
J rl”.#l ~“,. dLlrr_. ..__
10. Center member rear mouniing
bou11, Front exhaust p’pe4. H 12. Gear box assembly
. . 13. Mounting rubber Denotes non-re-
p usable part
.
Y.T-*c As..
-

6
Repair kit or set parts are shown.
(Only very frequently used parts
Operating procedures, cautions,
II-’ iY,W11 ’etc. on removal, installation, dis-
se&an: 3rM&rr&paNo.~3W[scribed, ,~ 1assembly and reassembly are
de-
37A-24STEERING- NINA Steering Gear Box
-SERVICE POINTS OF
REMOVALJll37?kM6. DlSCONNECllON OF TIEROD END
Using the special tool, disconnect
the tie rod from theknuckle.ceurion1. BesretotiethewrdofthespeciaitodtomenP-.2. Loosenthenutbutdonotremoveit.
12. REMOVAL OF GEAR BOX ASSEMBLY
Thus number corresponds to the
number ?pyi:,“~&‘R~;;?Isteps”,“Installation steps” or “Reas-semblv steps”.
/LUBRlCATlON AND SEALING POINTS-
The title of the page (fOilOWingthe page on which the diagram of
component parts is presented)
indicating the locations of lubnca-
tion and sealingprocedures.

00-6GENERAL - How to Use This Manual
EXPLANATION OF THE TROUBLESHOOTING GUIDEIndicates con-
nector’s termi-
nal number. 3. Checking
the pasmngw compartment-twnpwatu* UnSO!. ~ F, ah-thermo8tat sensor and refdgwant-tempnaturs sensor ufalitsIndicates
the
circuit diagram
(including the interface of the
air conditioning
control unit).
number. Num-
bers are used temperawe
of
the Sensor pm
to resistanceeach sensor t? order to convest lb+ amben
The sense, power-supply l2.W of The atrcOnd,f,oner control unit s aD&d~to each SmSOt snd lhevoltages of te,mmaIs 116). (151. (17) and (51 are
dwded by the reslstme va!ueS.of each ““Freelstance R..
TmuMnhooting
hints *Dtagnoss
in the opera
-
tion descrip-
tions only as necessary, and
these numbers
correspond to
the numbers
used in har-
ness and com-
ponent layout diagrams.Provides
the
necessary de-
scription of
cir-
curt operation
for basic under-
(standing.
NO
1, The passenger cPrrlpmme”l-lemperatu4
-r tnput sigrml is
hid toZ’C (77-F).,, “”NO 1’2 The ou~sde.ar sensor
inpu
srgnal IS held to WC (5IpF).._N
O 13 The air#t,?,mpSf~ SenSO, VlPut SlgMl 6 t+ 10 4% G33-F):I-Airwndtlimluconhdunittwmirutwtmge
~~
I16I lYle *“MIPassenger com,wnme”t-tawa.1 sensor Parr lem,mat”r~ 25-c OFFI 7 to WV1,‘W. _: ,. L. .LI17A~r.,hermos,at seworsensor
Pm
remoeraure 2% 177% WM”
m cQndlt*Ow IS OFF 1 Lo, o-‘l,W
,
terminals to be 4
_
.: ._. 4
-hiIndicates
the
conditions un-
der which the
check should
be made. Provides hints
(including
standards for
I-- judgement)
when trouble-
shooting
pro-
cedures are fol-
lowed.
Indicates the on-
board diagnostic
L:
output code No.
and the system
conditions
dur-
ina output.
Indicates the specification to
be used for judgement of
the check results.
If there is no particular men-
tion of conditions in th
e
‘Conditions” column, the column
shows the
specifica-:ionunder normal condi-
:ions.

00-34GENERAL- Lubrication and Maintenance
LUBRICATION AND
MAINTE-
NANCEMOOPA-
Maintenance and lubrication service recommenda-
tions have been compiled to provide maximum protection for the vehicle owner’s investment
against all reasonable types of driving conditions. Since these conditions vary with the individual
vehicle owner’s driving habits, the area in which the
vehicle is operated and the type of driving to which
the vehicle is subjected, it is necessary to prescribe lubrication and maintenance service on a time
frequency as well as mileage interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by the Society of Automotive Engineers (SAE), the Amer-
ican Petroleum Institute (API) and the National
Lubricating Grease Institute (NLGI).
MAINTENANCE SCHEDULES Information for service maintenance is provided
under “SCHEDULED MAINTENANCE TABLE”.
Three schedules are provided; one for “Required Maintenance”, one for “General Maintenance” and
one for “Severe Usage Service”.
The item numbers used in the “SCHEDULED MAINTENANCE TABLE” correspond to th
e
“MAINTENANCE SERVICE” section numbers.
SEVERE SERVICE
Vehicles operating under severe service conditions
will require more frequent service. Component service information
isIncluded i
n
appropriate units for vehicles operating under one or
more of the following conditrons:
1.Trailer towing or police, taxi, or
commerciai
type
operation
2. Operation of Vehicle (1) Short-trip operation at freezing temperature(engine not thoroughly warmed up)
(2) More than 50% operation in heavy city traffic during hot weather above
32°C (90°F)
(3) Extensive idling
(4) Driving in sandy areas
(5) Driving in salty areas
(6) Driving in dusty conditions
ENGINE OIL
The SAE grade number indicates the viscosity of engine oils, for example, SAE 30, which is a single
grade oil. Engine oils are also identified by a dual number, for example, SAE 1
OW-30, which Indicates
a multigrade oil.
The API classification system defines oil perform- ance in terms of engine usage. Only engine oil
designed “For Service SG” or “For Service
SGKD”,
when available, should be used. These oils contain
sufficient chemical additives to provide maximum
engine protection. Both the SAE grade and the API
designation can be found on the container.
Caution
Test results submitted to EPA have shown that
laboratory animals develop skin cancer after
prolonged contact with used engine oil. Accor-
dingly, the potential exists for humans to de-
velop a number of skin disorders, including
cancer, from such exposure to used engine oil.
Care should be taken, therefore, when changing engine oil, to minimize the amount and length of
exposure time to used engine oil on your skin.
Protective clothing and gloves, that cannot be
penetrated by oil, should be worn. The skin
should be thoroughly washed with soap and
water, or use waterless hand cleaner, to remove
any used engine oil. Do not use gasoline,
thinners, or solvents.
GEAR LUBRICANTS
The SAE grade number also indicates the viscosity of Multi-Purpose Gear Lubricants.
The API classfication
system defines gear lubricants
in terms of usage. Typically gear lubricants conform-
ing to API
GL-4 or GL-5 with a viscosity of SAE 75W-85W
are recommended for manual transaxle.
LUBRICANTS
- GREASES
Semi-solid lubricants, bear the
NLGI designation and
are further classified as grades 0, 1, 2, 3 etc.
Whenever “Chassis Lubricant” is specified,
Multi-
Purpose Grease, NLGI grade 2 should be used.
FUEL USAGE STATEMENT
Your vehicle must use unleaded gasoline only.
This vehicle has a fuel filler tube especially designed
to accept only the smaller-diameter unleaded gaso- line
dispensrng nozzle.
Caution
Using leaded gasoline in your vehicle will damage
the catalytic converter, and affect the warranty
coverage validity.
All vehicles except those with DOHC engines
Your vehicle is designed to operate on unleaded
gasoline having a minimum octane rating of 87 or
91 RON (Research Octane Number).
Vehicles equipped with DOHC engines
Your vehicle is designed to operate on premiumunleaded gasoline having a minimum
octane rating
of 91 or 95 RON (Research Octane Number).
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ENGINE - Service Adjustment Procedures 11-9
(5) Cover the spark plug holes with a cloth, etc., and crank the engine. Then verify that no foreign material sticks to the
cloth, etc.
Caution
1. During cranking, be especially careful of the spark plug
installing hole.
2.Very hot water, oil, fuel, etc., which may have entered
the cylinder somehow, will violently spout through the spark plug hole if the compression is measured in the
entrapped state. This is very dangerous.
MANIFOILD VACUUM INSPECTIONMllFNAC
(6)
(7)
(8)
Set up the compression gauge in the spark plug mounting
hole.
Fully open the throttle valve, and cranking the engine,
measure the compression pressure.
Standard value:
<8VALVE>1,250 kPa (178 psi) [250-400 rpm]
< 1 Ei VALVE>
1,300 kPa (185 psi) [250-400 rpm]
Limit:
(8 VALVE>880 kPa (125 psi) [250-400 rpm]
980 kPa (139 psi)
[250-400 rpm]
Measure the compression pressure of each cylinder, and
verify that the pressure difference among the cylinders is
less than the limit value.
Limit: max. 100
kPa (14 psi)
(9) If a cylinder’s compression pressure or pressure difference IS outside
the limit, fill a small amount of engine oil through
the spark plug hole and repeat Items (7) and (8) above.
@ If the compression is increased when the oil is filled, the piston and/or cylinder wall may be worn or
damaged.
@ If the compression is not increased even though the oil is filled, the valve may be thermally seized, the valve
contact may be improper or pressure may leak at the
gasket.
(10) Connect the connector of the distributor.
(11) Install the spark plug and spark plug cable.
(12)Erase the diagnostic trouble code with the Scan tool or re-
connect the battery (-)
cable
10 seconds or more after it
was disconnected.
NOTE
This will erase the memory of the diagnostic trouble code
which
resu,lted from disconnection of the distributor con-
nector.
(1) Before inspection and adjustment, put the vehicle into the
followin~g state.
l Engine coolant temperature:
85-95°C (185-203°F)
l
Ligt-Its, electric, cooling fan, and accessories: OFF
l Transaxle: Neutral
(N or P for vehicles with an automa-
tic transaxle)
l Steering wheel: Neutral position
(2) Check that the idling revolution speed is normal.
TSB Revision

11-32ENGINE >
- Winder Head Gasket
sprocket
’lG90001
Intake side Front of engine e
I
Exhaust side\olCOll!iLoosening order
SERVICE POINTS OF REMOVALMllJEAZ
27. REMOVAL OF CAMSHAFT SPROCKET
(1) Rotate the crankshaft in the forward (right) direction
and align the timing mark.
Caution
The crankshaft must always be rotated in the for-
ward direction only.
(3) Use the special tool to remove the camshaft sprocketwith the timing belt attached.
Caution
After removing the camshaft sprocket, be sure not
to rotate the crankshaft.
32. REMOVAL OF CYLINDER HEAD ASSEMBLY
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head as-
sembly.
SERVICE POINTS OF INSTALLATIONMllJDCV
33. INSTALLATION OF CYLINDER HEAD GASKET
(1) Use a scraper or gasket remover to remove the gasket adhering of the cylinder block.
Caution
When doing this, be careful not to let any foreign
substances such as gasket scraps enter the cylin-
der or the engine coolant and oil passages.
(2) Tie the camshaft sprocket and timing belt with a cord
so that the position of the camshaft sprocket will notmove with respect to the timing belt.
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ENGINE - Timinn Belt
11-45
sprocket
vlGVO001 MD998754
vlB990767-01
-
&
00B00°
(2) Tie the camshaft sprocket and timing belt with a cord
so that the position of the camshaft sprocket will not
move with respect to the timing belt.
(3) Use the special tool to remove the camshaft sprocket with the timing belt attached.
Caution
After removing the camshaft sprocket, be sure not
to rotate the crankshaft.
17. REMOVAL OF OIL PUMP SPROCKET
(1) Remove the plug on the side of the cylinder block.
(2) Insert a Phillips screwdriver [shank diameter 8 mm
(31
in.)] to block the left silent shaft.
(3) Remove the oil pump sprocket nut.
(4) Remove the oil pump sprocket.
23. REMOVAL OF TIMING BELT “B”
Make a mark on the back of the timing belt indicating the
direction of rotation so it may be reassembled in the same
direction if it is to be reused.
Caution
Water or oil on the belt shorten its life drastically, so
the removed timing belt, sprocket, and tensioner
must be free from oil and water. These parts should
not be washed. Replace parts if seriously contami-
nated.
If there is oil or water on each part check the front
case oil seals, camshaft oil seal and water pump for
leaks.
INSPECTIONMl 1 KCAD
TIMING BELTS
The timing belts must be checked closely. Should the following
defects be evident, replace the belt with a new one.
(1) Hardened back surface rubber Glossy, non-elastic, and so hard that no mark is produced
even when scratched by a fingernail.
\ TSB RevisionI

ENGINE - Service Adiustment Procedures11-59
7 Go;;ikv position
switch
(11)Check that there is continuity between the closed throttle
position switch terminal and body.
NOTE
When there is continuity, a clearance will be created between the throttle lever and dash pot rod when the dash
pot rod is pressed lightly.
(12) When there is no continuity, lower the engine speed when the dash pot begins operation to within the standard value
tolerance. Make sure to create continuity between the
closed throttle position switch terminal and body.
COMPRESSION PRESSURE CHECK Ml 1 FFAL
(1) Before inspection, verify that the engine oil, starter motor
and battery are normal. Then, perform the following.
lEngine coolant temperature: 80- 95°C
(1 76- 205’F)
l Lights, electnc
cooling fan and accessories: OFF
0 Transaxle: P range 0 Steering wheel: Neutral position
(2) Disconnect the spark plug cable.
(3) Remove all the spark plugs.
(4) Disconnect the connector of the crankshaft position sensor.
NOTE
This will prevent the engine control module from controll- ing the ignition and fuel injection.
(5) Cover the spark plug holes with a cloth, etc., and crank the engine. Then verify that no foreign material sticks to the
cloth, etc.
Caution
1.During cranking, be especially careful of the spark plug
installing hole.
2. Very hot water, oil, fuel, etc., which may have entered
the cylinder somehow, will violently spout through the
spark plug hole if the compression is measured in the
entrapped state. This is
vex/ dangerous.
(6) Set up the compression gauge in the spark plug mounting
hole.
(7) Fully open the throttle valve, and cranking the engine.
measure the compression pressure.
Standard value: Up to 1991: 1,350
kPa (192 psi) [250- 400 rpml
From 1992: 1,550
kPa (220 psi) [250-400 rpm]
1 ,150 kPa (164 psi) [250- 400 rpml
Limit:

up to 1991: 960
kPa (137 psi) [250- 400 rpml
From 1992: 1 ,120 kPa (159 psi) [250- 400 rpml
CTurbo>
800
kPa (114 psi) [250- 400 rpml
(8) Measure the compression pressure of each cylinder. and verify that the pressure difference among the cylinders
is
less than the limit value.
Limit: max. 100
kPa (14 psi) TSB Revision
I

FUEL SYSTEM VALVE> - TroubleShooting13-19
PROBLEM SYMPTOMS TABLE (FOR YOURINFORMATION)
:tShock
Surge
Knocking
0,GRun ona (“dieselrng”)
6
Items Symptom
-- -... __----. -~-
The starter IS used to crank the engine, but there IS no
combustron
wrthrn
the cylinders.
(no rnrtral combustron)
and the engine won’t start~-.-__Startrng
problem There IS combustron
wrthrn
the cylrnders.
but then the engrne
soon stalls.
(Initial combustion, then stall)
(Startrng takes a long t1me.l
I
Idling
rnstabrlrty
/ Engrne won’t start qurckly~--_~ -...
Engine speed doesn’t remain constant; changes during idling.
Usually, aludgement can be based upon the movement of the tachometer pointer, and
the
vibration transmitted to the steering wheel, shift lever, body, etc. This is call\
ed rougt
Idling.
The
engtnedoesn’t idle at the usual correct speed.
Thus non-contrnuity of rdlrng Includes the followrng elements(1) Die out
. . . . ..The
engine stalls when the foot IS taken from the accelator pedal,
regardless of whether the vehicle IS moving or not.(2)Pass out . . . ..The
engine stalls when the accelerator pedal IS depressed or while it IS berng
used.
“Hestatton” IS the delay In response of
the vehicle (engine rpm) that occurs
when the accelerator is depressed
Inorder to accelerate from the speed atwhich the vehicle is now traveling, or a
temporary drop in vehicle speed (enginerpm) during such acceleration. Hesltatron
Serious
hesstatlon IS called “sag”.
Poor
acceleration
E Stumbl
e
2
5
Time lFUO223
Poor
acceleration IS rnabilrty
to obtain an acceleration corresponding to the degree of
throttle opening, even though acceleration IS smooth, or the rnabrlrty to reach maxmum
speed.
Engrne rpm response IS delayed when .
the accelerator pedal is initrally
depressed
for acceleratron
from the stopped
condition ldllng
Stumble
Trme lFUO224
The
feeling of a comparatlvley large Impact or vrbration
when the engine IS accelerated
or decelerated.
This IS repeated surging
ahead dunng constant speed travel or dunng
vanable
speed
travel.
A sharp sound
IIke a hammer strtklng the cylinder walls during
dnvtng
and whrch
adversely affects driving.
The
condrtion In which the engrne
continues to run after the lgnltion switch 1s turned to
OFF. Also called
“dreselrng”.
TSB Revision

FUEL SYSTEM VALVE> -On-Vehicule Inspection of MFI Components13-105
fine probe7FU1264 1
(15) Reduce the internal pressure of the fuel pipes and hoses.
(Refer to
P.13-102.)
(16) Disconnect the fuel pressure gauge and the special toolsfrom the fuel rail.
Caution
Because there will be some residual pressure in the fuel
pipe line, use a shop towel to cover so that fuel doesn’t
splatter.
(17)Replace the O-ring at the end of the fuel high-pressure
hose with a new one. (18)After
connecting the fuel high-pressure hose to the fuel
rail, tighten the installation bolt.
(19)Check to be sure that there is no fuel leakage.
@ Apply battery voltage to the terminal for activation of the fuel pump so as to activate the fuel pump.
@ With fuel pressure applied, check for leakage of the fuel
line.
INSPECTION OF ENGINE CONTROL MODULE
TERMINAL VOLTAGEMl 3ZALBa
(1) Connect the extremely fine probe (paper clip, etc.) to the probe of the voltmeter.
(2) At each terminal of the engine control module connector,
insert the extremely fine probe from the wire side, and
measure the voltage referring to the check chart.
NOTE
1. In the state in which the connector of the engine
control module is connected, measure the voltage.
2. Measure the voltage across each terminal to the
terminal No. 106.
(ground terminal).
3. You may find it convenient to pull out the engine control module to make it easier to reach the connector
terminals.
4.Inspection need not be executed in the chart’s sequence.
Caution
Short-circuiting the positive
(+) probe between a con-
nector terminal and ground could damage the vehicle
wiring, the sensor, the engine control module, or all
there. Use care to prevent this!
(3) If voltmeter shows any deviation from standard value, check the corresponding sensor, actuator and related
electrical wiring, then repair or replace.
(4) After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem.

FUEL SYSTEM VALVE> -Fuel Line and Vapor Line/Fuel Filter 13-115
Higt
fuel
&ring Oi’
FUEL FILTER
REMOVAL AND INSTALLATION
~zgz&i&r” 1@Release of Residual Pressure from High
2. INSTALLATION OF HIGH PRESSURE FUEL HOSE
Apply engine oil to the hose union.Insert the hose, being careful not to damage the O-ring, and
tighten securely.
Caution Because there is high pressure applied between the
fuel pump and the injection mixer, be especially sure
that there is no fuel leakage in this area.
25-35 N
m
18-25
ft.lbs.
Post-installation Operation@Measurement of Fuel Pressure
Fuel filter removal steps
1. Eye bolt (Refer to P.13-114.)2. O-ring3. Connection for high pressure fuel hose
4. O-ring
5. Connection for fuel main pipe
6. Mounting bolt
7. Fuel filter (Refer to P.13-114.)
TSB Revision 03AO231