HOW TO USE THIS BOOK 1-2 OPERATION INFOREIGNCOUNTRIESl-33

WHERETOBEGIN l-2 ENGINE l-33

AVOIDINGTROUBLE1-2 OILLEVELCHECK 1-33
MAINTENANCEORREPAIR?1-2 OIL& FILTERCHANGE l-34
AVOIDINGTHEMOSTCOMMONMISTAKES l-2 MANUALTRANSAXLEl-35
TOOLSAND EQUIPMENT 1-2 FLUIDRECOMMENDATIONS l-35
SPECIALTOOLS l-4 LEVELCHECK l-35
YOUR VEHICLE SAFELY 1-4 DRAIN&REFILL l-36
AUTOMATICTRANSAXLEl-36
DON'TS l-6 FLUIDRECOMMENDATIONS l-36
FASTENERS,MEASUREMENTSAND LEVELCHECK 1-36
CONVERSIONS l-6 DRAIN&REFILL l-36
BOLTS,NUTSANDOTHERTHREADED PAN& FILTERSERVICE1-36
RETAINERS1-6 TRANSFERCASE(AWDGAlANT ONLY) l-38
TORQUE l-7 FLUIDRECOMMENDATIONS l-38
TORQUEWRENCHES l-7 LEVELCHECK l-38
TORQUEANGLEMETERS1-9 DRAIN&REFILL l-38
STANDARDANDMETRIC MEASUREMENTSl-9 REARDRlVEAXLE(AWDGALANTONLY)l-38
SERIAL NUMBER IDENTIFICATION l-10 FLUIDRECOMMENDATIONS l-38
VEHICLEIDENTIFICATIONNUMBER l-10 LEVELCHECK l-38
ENGINEIDENTIFICATIONNUMBER I-10 DRAIN&REFILL l-38
TRANSAXLEIDENTIFICATION I-10 COOLINGSYSTEMl-39
DRlVEAXLE(AWDGALANTONLY)l-10 FLUIDRECOMMENDATIONS l-39
TRANSFERCASE(AWDGALANTONLY) l-10
ROUTINEMAINTENANCEAND TUNE-UP l-14
AIRCLEANER(ELEMENT)1-14
REMOVAL&INSTALLATION1-14 iM-41
FUELFILTER 1-15
REMOVAL&INSTALLATION l-15
PCVVALVE l-15
REMOVAL&INSTALLATIONl-15
EVAPORATIVECANISTER l-16
SERVICING 1-16
BATTERY 1-16
PRECAUTIONSI-16
GENERALMAINTENANCE1-16
BATTERYFLUID 1-16
CABLES I-17
CHARGINGI-18
REPLACEMENT1-18
BELTS 1-18
INSPECTiON l-18
ADJUSTMENT 1-18
REMOVAL&INSTALLATION1-18
TIMINGBELTS l-20
INSPECTIONl-20
HOSES I-20
INSPECTIONl-20
REMOVAL&INSTALLATION1-21
CV-BOOTS 1-21
INSPECTIONl-21
SPARKPLUGS l-22
SPARKPLUGHEATRANGEl-22
REMOVAL&INSTALLATIONl-22
INSPECTION&GAPPING 1.-23
SPARKPLUG WIRES 1-24
TESTING 1-24
REMOVAL&INSTALLATION1-24
DISTRIBUTORCAPANDROTOR l-25
REMOVAL&INSTALLATIONl-25
INSPECTION 1-25
IGNITIONTIMING 1-25
. GENERALINFORAMTION l- .25
lNSPECTlON&ADJUSTMENl1-26
VALVELASH l-27
ADJUSTMENT l-27
IDLESPEED 1-28
AIR CONDITIONINGSYSTEM 1-28
SYSTEMSERVlCEiiREPAlRl-28
PREVENTIVEMAINTENANCE 1-28
SYSTEMINSPECTION l-29
WINDSHIELD WIPERS l-29
ELEMENT(REFILL)CARE&
REPLACEMENTl-29
TIRESANDWHEELSl-30
TIREROTATION I-30
TIREDESIGN 1-31
TIRESTORAGEl-31
INFLATION&INSPECTION l-31
CAREOFSPECIALWHEELSl-32
FLUIDS AND LUBRICANTS 1-33
FLUIDDISPOSAL 1-33
FlJELANDENGlNEOILRECOMMENDATlONS
ENGINEOIL l-33
FUEL l-33
 .

1-2 GENERALINFORMATIONAND
MAINTENANCE

Chitton’sTotal Car Caremanualfor the 199M10 name.As long as you rememberyour own code,the everythingbackin its properposition.Wewill supply
Mitsubishi Mirage, Galantand Diamanteis intended lines can be reconnectedby matchingsimilar letters explodedviews wheneverpossible.Whenmaking
to helpyou learnmoreaboutthe innerworkingsof or names.Do rememberthat tapewill dissolvein adjustments,performthem in the properorder.One
your vehiclewhile savingyou moneyon its upkeep gasolrneor otherfluids; if a componentis to be adjustmentpossiblywill affectanother.
and operation. washedor cleaned,useanothermethodof identifica- 2. Overtorquing(or undertorquing).While it is
The beginningof the book will likely be referredto tion. A permanentfelt-tippedmarkeror a metalscribe more commonfor overtorquingto causedamage,
the most,sincethat is whereyou will find information can bevery handyfor markingmetalparts.Remove undertorquingmayallow a fastenerto vibrate loose
for maintenanceand tune-up.The othersectionsdeal anytapeor paperlabelsafterassembly. causingseriousdamage.Especiallywhendealing
with the more complexsystemsof your vehicle.Oper- with aluminumparts,payattentionto torquespecifi-
ating systemsfrom enginethroughbrakesare cov- cationsand utilize a torquewrenchin assembly.If a
eredto the extentthat the averagedo-it-yourselferbe- torquefigure is not available,rememberthat if you
comesmechanicallyinvolved.This book will not It’s necessaryto mentionthe differencebetween are usingthe right tool to performthe job, you will
explainsuchthings as rebuildinga differentialfor the maintenanceand repair Maintenanceincludesrou- probablynot haveto strainyourselfto get a fastener
simple reasonthat the expertiserequiredandthe in- tine inspections,adjustments,and replacementof tight enough.The pitch of mostthreadsis so slight
vestmentin specialtools makethis task uneconomi- partswhich show signs of normalwear Maintenance that the tensionyou put on the wrenchwill be multi-
cal. It will, however,give you detailedinstructionsto compensatesfor wearor deterioration.Repairimplies plied manytimes in actualforce on whatyou are
helpyou changeyour own brakepadsand shoes,re- that somethinghasbrokenor is not working.A need tightening.A good exampleof how critical torqueis
placesparkplugs,and performmanymorejobs that for repair is oftencausedby lackof maintenance.Ex- can be seenin the caseof sparkplug installation,es-
cansaveyou money,give you personalsatisfaction ample,drainingand refilling the automatictransaxle peciallywhereyou are puttingthe plug into an alu-
and helpyou avoid expensiveproblems. fluid is maintenancerecommendedby the manufac- minum cylinderhead.Too little torquecan fail to
A secondarypurposeof this book is a referencefor turer at specificmileageintervals.Failureto do this crushthe gasket,causingleakageof combustion
ownerswho wantto understandtheir vehicleand/or canshortenthe life of the transmission/transaxle,re- gasesand consequentoverheatingof the plugand
their mechanicsbetter.In this case,no tools at all are quiring very expensiverepairs.While no maintenance engineparts.Too muchtorquecan damagethe
required. programcan preventitemsfrom breakingor wearing threadsor distort the plug, changingthe sparkgap.
out, a generalrule can be stated:MAINTENANCEIS Thereare manycommercialproductsavailablefor
CHEAPERTHAN REPAIR. ensuringthat fastenerswon’t come loose,evenif they
Two basicmechanrc’srulesshouldbe mentioned are not torquedjust right (a very commonbrandis
Beforeremovingany bolts, readthroughthe entire here.First, wheneverthe leftside of the vehicleor en- Loctite? If you’reworriedaboutgettingsomething
procedure.This will give you the overallview of what gine is referredto, it is meantto specifythe drivers togethertight enoughto hold, but looseenoughto
tools and supplieswill be required.Thereis nothing side. Conversely,the right side of the vehicle means avoid mechanicaldamageduring assembly,one of
morefrustratingthan havingto walkto the bus stop the passengersside.Second,screwsand bolts are theseproductsmight offersubstantialinsurance.Be-
on Mondaymorning becauseyou wereshort one bolt removedby turning counterclockwise,and tightened fore choosinga threadlockingcompound,readthe
on Sundayafternoon.So readaheadand planahead. by turning clockwrseunlessspecificallynoted. labelon the packageand makesurethe productis
Eachoperationshould beapproachedlogicallyand Safetyis alwaysthe most importantrule. Con- compatiblewith the materials,fluids, etc. involved.
all proceduresthoroughlyunderstoodbeforeattempt- stantlybe awareof the dangersinvolvedin working 3. Crossthreading.This occurswhena part such
ing any work. on an automobileandtakethe properprecautions. as a bolt is screwedinto a nut or castingat the wrong
All sectionscontainadjustments,maintenance,re- Seethe informatronin this sectionregardingSER- angleand forced.Crossthreadingis more likely to
movaland installationprocedures,and in somecases, VICINGYOURVEHICLESAFELYandthe SAFETY occur if accessis difficult. It helpsto cleanand lubri-
repairor overhaulprocedures.Whenrepairis not con- NOTICEon the acknowledgmentpage. catefasteners,thento startthreadingthe bolt, spark
sideredpractical,we tell you howto removethe part plug,etc.with your fingers If you encounterresis-
andthen howto installthe newor rebuiltreplacement. tance,unscrewthe partand startover againat a dif-
In this way,you at leastsavelaborcosts.“Backyard” ferentangleuntil it canbe insertedandturnedseveral
repairof somecomponentsis just not practical. times without mucheffort.Keepin mind that many
parts,especiallysparkplugs,havetaperedthreads,
Payattentionto the instructionsprovided.There
so that gentleturningwill automaticallybring the part
are3 commonmistakesin mechanicalwork:
you’rethreadingto the properangle.Don’tput a
1. Incorrectorderof assembly,disassemblyor
Many proceduresin this book requireyou to “label wrenchon the part until its beentighteneda couple
adjustment.Whentaking somethingapartor putting
and disconnect. . ” a group of lines, hosesor wires. of turns by hand.If you suddenlyencounterresis-
it together,performingsteps in the wrong order usu-
Don’t be lulled into thinkingyou can rememberwhere tance,andthe part hasnot seatedfully, don’tforce it.
ally just costsyou extratime; however,it CAN break
everythinggoes-you won’t. If you hook up vacuum Pull it backout to makesure it’s cleanandthreading
something.Readthe entireprocedurebeforebegin-
or fuel lines incorrectly,the vehicle mayrun poorly, if properly.
ning disassembly.Performeverythingin the order in
at all. If you hook up electricalwiring incorrectly,you Besureto takeyour time and be patient,and al-
which the instructionssay you should,even if you
may instantlylearna very expensivelesson. ways planahead.Allow yourselfampletime to per-
can’timmedratelyseea reasonfor it. Whenyou’re
You don’t needto knowthe official or engineering form repairsand maintenanceYou mayfind main-
takingapartsomethingthat is very intricate,you
namefor eachhose or line. A pieceof maskingtape taining your car a satisfyingand enjoyable
might wantto drawa pictureof how it lookswhenas-
on the hoseand a pieceon its fitting will allow you to experience.
sembledat one point in orderto makesureyou get
assignyour own labelsuch as the letterA or a short

b See Figures 1 thru 15 The bestapproachis to proceedslowly, gathering savingswill befar outweighedby frustrationand
a good qualityset of thosetools that are usedmost mangledknuckles.
Naturally,withoutthe propertools and equipment frequently Don’tbe misled by the low cost of bargain Beginaccumulatingthosetools that are usedmost
it is impossibleto properlyserviceyour vehicle.It tools. It is far betterto spenda little morefor better frequently:thoseassociatedwith routinemaintenance
would also bevirtually impossibleto catalogevery quality.Forgedwrenches,6 or 12-point socketsand andtune-up.In additionto the normalassortmentof
tool that you would needto performall of the opera- fine tooth ratchetsare by far preferableto their less screwdriversand pliers,you shouldhavethe follow-
tions in this book.Of course,It would be unwisefor expensivecounterparts.As anygood mechaniccan ing tools:
the amateurto rush out and buyan expensiveset of tell you, therearefew worseexperiencesthantrying l Wrenches/socketsand combinationopen
tools on the theorythat he/shemay needone or more to work on a vehiclewith badtools. Your monetary end/boxendwrenchesin sizesfrom %-% in. or
of themat sometime,
 GENERALINFORMATIONAND
MAINTENANCE
l-3
3-19mm,aswellasa % in.or~/ain.sparkplug careful when usingthem, as they can change l Grease gunfor chassislubrication (unless
socket(depending
onplugtype). the amountof torque appliedto the socket. yourvehicleis notequipped withanygreasefit-
Jackstands forsupport. tings-for details,pleasereferto information
onFlu-
-if possible, buyvarious lengthsocketdrive l
idsandLubricants, laterinthissection).
extensions.Universal-jointandwobble ex- l Oilfilterwrench.
l Hydrometer for checking thebattery(unless
tensionscan be extremelyuseful, but be l Spoutor funnelfor pouringfluids.
equiooed witha sealed,maintenance-free batten/).
O’A containerfor drainingoil andotherfluids.
l Ragsforwipinguptheinevitable mess.
Inadditiontotheaboveitemsthereareseveral
pi othersthatarenotabsolutely necessary,
buthandyto
1 havearound.TheseincludeOilDry@(oranequiva-
lentoil absorbent gravel-suchascatlitter)andthe
usualSUDDIV of lubricants.
antifreeze
andfluids.al-
thoughthe.&canbepurchased asneeded. Thisis a
basiclistfor routinemaintenance, butonlyyourper-
sonalneedsanddesirecanaccurately determine your
Fig. 1 Ail but the most basic procedures
Afterperforming
a fewprojectsonthevehicle,
you’llbeamazedattheothertoolsandnon-toolson

lWSl2U2

Fig, 3 A hydraulic floor jack and a set of tm1204

jackstandsare essential for lifting andsup Fig. 5 Various drivers, chisels and ptybars
porting the vehicle are great tools to have in your toolbox

Fig. 7 Althoughnot always necessary,us-

ing specialized brake tools will save time

Fig. 11 inductive type timing light \

I-4 GENERALINFORMATIONAND
MAINTENANCE
l Feeleraauoesfor valveadiustment
* Timing-light.
Thechoiceof a timingfightshouldbemade
carefully.A lightwhichworksontheDCcurrent
suppliedbythevehicle’sbatteryis thebestchoice;
it shouldhavea xenontubefor brightness. Onany
vehiclewithanelectronicignitionsystem,a timing
lightwithan inductivepickupthatclampsaround
theNo.1 sparkplugcableis preferred.
Inadditionto thesebasictools,thereareseveral
othertoolsandgaugesyoumayfinduseful.These
include:
l Compression gauge.Thescrew-intypeis
slowerto use,buteliminates thepossibilityof a
Fig. 13 A vacuum/pressuretester is neces- fauliyreadingdueto escaping pressure.
Fig. 12 A screw-in type compressiongauge- l Manifoldvacuumgauge.
is recommendedfor compressiontesting sary for manytesting procedures l 12Vtestlight.
l A combination volt/ohmmeter
l inductionAmmeter. Thisis usedfor determin-
ingwhetheror notthereis currentina wire.These
arehandyfor useif awireis brokensomewhere ina
wiringharness.
Asa finalnote,vouwill orobablvfinda torque
wrenchnecessary for all butthemostbasicwork.
Thebeamtypemodelsareperfectlyadequate, al-
thoughthenewerclicktypes(breakaway) areeasier
to use.Theclicktypetorquewrenches tendto be
moreexpensive. Alsokeepin mindthatall typesof
torquewrenches shouldbeperiodically checked
and/orrecalibrated. Youwill haveto decidefor your-
lmvl
selfwhichbetterfits yourpocketbook, andpurpose.
Fig. 15 Proper information is vital, so at
Fig. 14 Most modernautomotive multime- ways have a Chiiton Total Car Care manua
ters incorporate many helpful features handy Normally, theuseof specialfactorytoolsis
avoidedfor repairprocedures, sincethesearenot
yourworkbench. Someusefulhousehold itemsare:a ilightlymoresophisticated,
theyneednotbeoutra- readilyavailableforthedo-it-yourself mechanic.
largeturkeybasteror siphon,emptycoffeecansand feouslyexpensive.Thereareseveralinexpensive Whenit is possibleto performthejobwithmore
icetrays(tostoreparts),ballof twine,electricaltape achldwellmetersonthemarketthatareeverybitas commonly availabletools,it will bepointedout,but
for wiring,smallrollsof coloredtapefor tagginglines Toadfortheaverage mechanic asa professional occasionally, a specialtoolwasdesigned to perform
or hoses,markers andpens,a notepad,golftees(for nodel.Justbesurethatit goesto a least1200-1500 a specificfunctionandshouldbeused.Beforesub-
pluggingvacuumlines),metalcoathangers ora roll pmonthetachscaleandthatit workson4,6 and8- stitutinganothertool,youshouldbeconvinced that
of mechanic’swire(toholdthingsoutof theway), :ylinderengines.
Thekeytothesepurchases is to neitheryoursafetynortheperformance ofthevehicle
dentalpickor similarlong,pointedprobe,a strong nakethemwithaneyetowardsadaptability andwide will becompromised.
magnet, anda smallmirror(toseeintorecesses and ange.A basiclistoftune-uptoolscouldinclude: Specialtoolscanusuallybepurchased froman
undermanifolds). l Tach/dwell
meter. automotive partsstoreorfromyourdealer.Insome
A moreadvanced setoftools,suitablefortune-up l Sparkplugwrenchandgappingtool. casesspecialtoolsmaybeavailabledirectlyfromthe
work,canbedrawnupeasily.Whilethetoolsare toolmanufacturer.

p See Figures16, 17, 16, and 19 l Doshieldyoureyeswhenever youworkaround nitionsystemcontainsEXTREMELY HIGHVOLT-

thebattery.Batteriescontainsulfuricacid.Incaseof AGE.Insomecasesit canevenexceed50,000volts.
It is virtuallyimpossible
to anticipateall ofthehaz- contactwiththeeyesor skin,flushtheareawithwater l Dofollowmanufacturer’s directionswhenever
ardsinvolvedwithautomotive maintenance andser- or a mixtureof waterandbakingsoda,thenseekim- workingwithpotentiallyhazardous materials.Most
vice,butcareandcommon sensewill preventmost mediate medicalattention. chemicals andfluidsarepoisonousif takeninter-
accidents. l Dousesafetystands(jackstands) foranyun- nally.
Therulesof safetyfor mechanics rangefrom“don’t dervehicleservice.Jacksarefor raisingvehicles; l Doproperlymaintain yourtools.Looseham-
smokearoundgasoline,” to “usethepropertool(s)for jackstandsarefor makingsurethevehiclestays merheads, mushroomed punches andchisels,frayed
thejob.”Thetricktoavoidinginjuriesisto develop raiseduntilyouwantit to comedown.Whenever the or poorlygrounded electricalcords,excessively
safeworkhabitsandtotakeeverypossibleprecaution. vehicleis raised,blockthewheelsremaining onthe wornscrewdrivers, spreadwrenches (openend),
groundandsettheparkingbrake. crackedsockets,slippingratchets,or faultydroplight
l Douseadequate ventilationwhenworking socketscancauseaccidents.
withanychemicals or hazardous materials,Likecar- * Likewise,keepyourtoolsclean;a greasy
l Dokeepa fireextinguisherandfirstaidkit bonmonoxide, theasbestos dustresultingfrom wrenchcanslipoff a bolthead,ruiningtheboltand
handy. somebrakeliningwearcanbehazardous in suffi- oftenharmingyourknucklesin theprocess.
l Dowearsafetyglassesor goggleswhencut- cientquantities. l Dousethepropersizeandtypeof toolforthe
ting,drilling,grindingor prying,evenif youhave l Dodisconnect thenegativebatterycablewhen jobathand.Doselecta wrenchor socketthatfitsthe
20-20vision.If youwearglassesforthesakeof vi- workingontheelectricalsystem.Thesecondary ig- nutor bolt.Thewrenchor socketshouldsit straight,
sion,wearsafetygogglesoveryourregularglasses. notcocked.
1-6 GENERALINFORMATIONAND
MAINTENANCE
lwo.WIRE CouDuClOR TMREE-WIRE CONO”CTOI monoxideis poisonous;it takesa longtime to leave
MIRD WIRE GROUNDING GROUNDING TNRU
THE CASE A CmxlIT the humanbodyand you can build up a deadlysup-
ply of it in your systemby simply breathingin a !ittle
everyday.You may not realizeyou are slowly poi-
soning yourself.Alwaysusepowervents,windows,
fans and/or openthe garagedoor.
l Don’twork aroundmoving partswhile wearing
looseclothing.Shortsleevesare muchsaferthan
long, loosesleeves.Hard-toedshoeswith neoprene
soles protectyour toes and give a bettergrip on slip-
perysurfaces.Jewelrysuchas watches,fancybelt
buckles,beadsor bodyadornmentof any kind is not
. safeworkingarounda vehicle.Longhair shouldbe
tied backundera hat or cap.
l Don’tusepocketsfor toolboxes.A fall or bump
i$Y$$pQ candrive a screwdriverdeepinto your body. Evena
raghangingfrom your backpocketcan wraparound
p-+ a spinningshaftor fan.
l Don’tsmokewhenworkingaroundgasoline,
TNHREE-WIRE CONDUCTOR THREE-WIRE CONDUCTOR cleaningsolventor otherflammablematerial.
ONE WIRE TO 4 GROUND GROUNOlNG TMRU
AN ADAPTER PLUG l Don’tsmokewhenworkrngaroundthe battery.
Fig.16 Screwdriversshouldbe kept in good tccm21
Whenthe batteryis beingcharged,it gives off explo-
:onditionto preventinjury or damagewhich Fig. 17 Powertools should always be prop- sive hydrogengas.
:ould result it the blade slips from the screw erly grounded l Don’tusegasolineto washyour hands;there
are excellentsoapsavailable.Gasolinecontainsdan-
7 gerousadditiveswhichcanenterthe bodythrougha
cut or throughyour pores.Gasolinealso removesall
the naturaloils from the skin so that bonedry hands
0 0 will suck up oil and grease.
l Don’tservicethe air conditioningsystemun-

PP
lessyou are equippedwith the necessarytools and
trainmg.Whenliquid or compressedgas refrigerant
is releasedto atmosphericpressureit will absorb
heatfrom whateverit contacts.This will chill or freeze
anythingit touches.
l Don’tusescrewdriversfor anythingotherthan
tccs1022
driving screws!A screwdriverusedas an pryingtool
Fig. 16 Using the correct size wrench will Fig. 19 NEVERwork undera vehicle unlessit can snapwhenyou leastexpectit, causinginjuries.
help prevent the possibility of roundingoff is supportedusingsafety stands(jackstands) At the very least,you’ll ruin a goodscrewdriver.
a nut . Don’tusean emergencyjack (thatlittle ratchet,
scissors,or pantographjack suppliedwith the vehi-
l Do, whenpossible,pull on a wrenchhandle l Do setthe parkingbrakeand block the drive cle) for anythingotherthan changinga flat! These
ratherthan push on it, and adjustyour stanceto pre- wheelsif the work requiresa runningengine. jacksare only Intendedfor emergencyuse out on the
vent a fall. road;theyare NOTdesignedas a maintenancetool. If
l Do be surethat adjustablewrenchesare you are seriousaboutmamtainingyour vehicleyour-
tightly closedon the nut or bolt and pulledso that self, investin a hydraulicfloor jack of at leasta 1%
the force is on the side of the fixed jaw. ton capacity,and at leasttwo sturdyjackstands.
l Don’t runthe enginein a garageor anywhere
l Do strikesquarelywith a hammer;avoid glanc- elsewithout properventilation-EVER! Carbon
ing blows.

sion which can increasethe torque necessaryto properinstallationand safeoperationof the vehicle
achievethe desiredclamp loadfor which thatfastener afterwards.
was originally selected.Additionally,besurethat the Threadgaugesareavailableto help measurea bolt
driver surfaceof the fastenerhasnot beencompro- or stud’sthread.Most automotiveand hardware
p See Figures20, 21, 22, and 23 mised by roundingor otherdamage.In some casesa storeskeepgaugesavailableto helpyou selectthe
Althoughtherearea greatvarietyof fastenersfound driver surfacemay becomeonly partiallyrounded,al- propersize. In a pinch,you can useanothernut or
in the moderncar or truck,the mostcommonlyused lowingthe driver to catch in only one direction.In bolt for a threadgauge.If the bolt you are replacingis
retaineris the threadedfastener(nuts,bolts,screws, manyof theseoccurrences,a fastenermaybe in- not too badly damaged,you can selecta matchby
studs,etc.).Most threadedretainersmaybe reused, stalledand tightened,but the driver would not be able finding anotherbolt which will threadin its place.If
providedthatthey are not damagedin useor during to grip and loosenthe fasteneragain.(This could lead you find a nut whichthreadsproperlyontothe dam-
the repair.Someretainers(suchas stretchbolts or J to frustrationdownthe line shouldthat component agedbolt, then usethat nut to helpselectthe replace-
torqueprevailingnuts)are designedto deformwhen ever needto be disassembledagain). mentbolt If however,the bolt you are replacingis so
tightenedor in useand shouldnot be reinstalled. If you must replacea fastener,whetherdueto de- badlydamaged(brokenor drilled out) that its threads
Wheneverpossible,we will noteanyspecialre- sign or damage,you mustALWAYSbe sureto use cannotbe usedas a gauge,you might startby look-
tainerswhich shouldbe replacedduring a procedure. the properreplacementIn all cases,a retainerof the ing for anotherbolt (from the sameassemblyor a
Butyou shouldalwaysinspectthe conditionof a re- samedesign,materialand strengthshould be used. similar locationon your vehicle)which will thread
tainerwhenIt is removedand replaceanythat show Markingson the headsof most bolts will helpdeter- into the damagedbolt’s mounting.If so, the otherbolt
signs of damage.Checkall threadsfor rust or corro- minethe properstrengthof the fastener.Thesame can be usedto selecta nut;the nut canthen be used
material,threadand pitch must be selectedto assure to selectthe replacementbolt.
 GENERALINFORMATIONAND
MAlNTENAiCEI-7
of the bolt head,screwheador nut faceandthe base
materialor washer(the surfaceon which the fastener
is rotating).Approximately40 percentof the applied
torque is usedin overcomingthreadfriction. This
leavesonly about 10 percentof the appliedtorqueto
developa usefulclamp load (the forcewhich holdsa
PHILLIPS RECESS
joint together).This meansthat friction canaccount
POZIDRIVE TORX@ CLUTCH RECESS
for as muchas 90 percentof the appliedtorqueon a
fastener.

TORQUEWRENCHES

ti See Figures 24 and 25

In most applications,a torquewrenchcan beused
to assureproperinstallationof a fastener.Torque
INDENTED HEXAGON HEXAGON TRIMMED HEXAGON WASHER HEAD
wrenchescome in various designsand most auto-
tccs1037 motive supplystoreswill carrya varietyto suit your
Fig. 20 Here are a few of the most commonscrew/bolt driver styles needs.A torquewrenchshould be usedanytime we
supplya specifictorquevaluefor a fastener.A torque
wrenchcanalso be usedif you are followingthe gen-
eralguidelinesIn the accompanyingcharts.Keepin
mind that becausethereis no worldwidestandardiza-
tion of fasteners,the chartsare a generalguideline

GRADE 8 MADE 2 GRADE 5 QRADE 8 GRADE 7 WADE 0 ALLEN CARRIAGE

NUTS

e
Q
PUIN JAM CASTLE SELF-LOCKINQ SPEED
(CASTELLATED)

A - Length
B - Diameter (major diameter)
C- Threads per inch or mm
D- Thread length
E - Size of the wrench required
F- Root diameter (minor diameter)
FILLISTER
IccSlO3l
Fig. 22 Threadedretainer sizes are deter
mined using these measurements
LOCKWASHERS

4% 43 Q c3
INTERNAL EXTERNAL SPLIT PLAIN
Toonl TQonl

STUD

Fig. 21 There are many different types of threaded retainers found on vehicles

In all cases,beabsolutelysureyou haveselected

the properreplacement.Don’t beshy, you canalways
ask the storeclerk for helo. Torqueis definedas the measurementof resis- .
tanceto turning or rotating.It tendsto twist a body
aboutan axis of rotation.A commonexampleof this
would betighteninga threadedretainersuch as a nut,
Be aware that when you find a bolt with dam- bolt or screw.Measuringtorque is one of the most
agedthreads,you may also find the nut or
commonwaysto help assurethat a threadedretainer
drilled hole it was threadedinto hasalso has beenproperlyfastened.
beendamaged.If this is the case, you may Whentighteninga threadedfastener,torqueis ap- E - DCTERNAL
tm1016
haveto drill andtap the hole, replace the nut
plied in threedistinct areas,the head,the bearing Yg. 23 Special fasteners such as these
or otherwise repair the threads. NEVERtry to
surfaceand the clamp load. About50 percentof the font@’head bolts are used by manufactur-
force a replacementbolt to fit into the dam- measuredtorque is usedin overcomingbearingfric-
aaedthreads. ?rs to discourage people from working on
tion This is the friction betweenthe bearingsurface
rehicles without the proper tools
 .
l-8 GENERALINFORMATIONAND
MAINTENANCE
U.S. Bolts
UEonlr
Iy* lU2 5 tw7
I*cll*olwu c
tbqn2lamlu
am~mkr. Q @ 63
HaaIm Toqw mdmuo TORW m TolqW
(h&l!&, RA&. m 111 R./U. If410 lm R.Abs. I(n Hm

'I4 - 20 i 0.7 68 8 1.1 10.8 10 1.4 13.5

-28 08 8.1 10 1.4 13.6

tccsio15
%s-18 11 1.5 14.9 17 2.3 23.0 19 2.6 25.8
-24 13 1.8 17.6 19 2.6 25.7
Fig. 24 Various styles of torque wrenches
S-16 18 2.5 24.4 31 4.3 42.0 34 4.7 46.0
are usually available at your local automo- -24 20 2.75 27.1 35 4.8 47.5
tive supply store %s-14 28 3.8 37.0 49 8.8 66.4 55 7.6 74.5
-20 30 42 40.7 55 7.6 74.5

and should be usedwith caution.Again,the general 'h-13 39 5.4 52.8 75 10.4 101.7 85 11.75 115.2
rule of “if you are using the right tool for the job, you -20 41 5.7 55.6 85 117 115.2

should not haveto strainto tightena fastener”ap- 'h-12 51 7.0 69.2 110 15.2 149.1 120 16.6 162.7
plies here. -18 55 7.6 74.5 120 16.6 162.7
H-11 83 11.5 112.5 150 20.7 203.3 167 23.0 226.5
BeamType -18 95 13.1 128.8 170 23.5 230.5
s-10 105 14.5 142.3 270 37.3 366.0 280 36.7 379.6
# See Figure 26 -16 115 15.9 155.9 295 40.8 400.0

The beamtype torquewrenchis one of the most VD- 9 160 2.: 216.9 395 54.6 535.5 440 60.9 596.5
-14 175 237.2 435 80.1 589.7
populartypes.It consistsof a pointerattachedto the
headthat runsthe lengthof the flexible beam(shaft) l- 6 iti 32.5 318.6 lE 81.6 799.9 660 91.3 894.8
-14 34.6 338.9 91.3 849.8
to a scalelocatednearthe handle.As the wrenchis
pulled,the beambendsand the pointerindicatesthe
torque usingthe scale. Metric Bolts
Click (Breakaway)Type 4.6,4.8 8.8
$ See Figure 27
c @w
Anotherpopulardesignof torquewrenchISthe I*rdn*lrTwlr rullllllnl~
click type.To usethe click type wrenchyou pre-ad- mm04 iEn% (nnr) RJU. I(n llm RAk m mu
just it to a torquesetting.Oncethe torque is reached,
6x1.0 2-3 2-.4 3-4 3-6 4-.8 5-8
the wrenchhasa reflexsignalingfeaturethat causes
a momentarybreakawayof the torquewrenchbody, 8x 1.25 6-8 .6-l 8-12 9-14 12-1.9 13-19
sendingan impulseto the operator’shand. 10X1.25 12-17 1.5-2.3 16-23 20-29 2.7-4.0 27-39
12x125 21-32 2.9-4.4 29-43 35-53 4.8-7.3 47-72
Pivot HeadType
14x 1.5 35-52 4.8-7.1 48-70 57-65 7.8-11.7 77-110
# See Figure 27 and 28 16x 1.5 51-77 7.0-10.6 67-100 90-120 12.4-16.5 130-W

Sometorquewrenches(usuallyof the click type) 18x 1.5 74-110 10.2-15.1 100-150 130-170 17.9-23.4 MO-230
may beequippedwith a pivot headwhich canallow it 20x 1.5 llO-140 15.1-19.3 150-190 190-240 26.2-46.9 160-320
to be used in areasof limited access.BUT,it must be 22x 1.5 150-190 22.0-26.2 200-260 250-320 34.5-44.1 340-430
usedproperly.To hold a pivot headwrench,grasp
24x 1.5 190-240 26.2-48.9 260-320 310-410 42.7-56.5 420-550
the handlelightly,and as you pull on the handle,it lccs1098
should befloatedon the pivot point. If the handle
:ig. 25 Standardand metric bolt torque specifications based on bolt strengths-WARNING:
comesin contactwith the yokeextensionduringthe
processof pulling,thereis a very good chancethe Ise only as a guide
torque readingswill be inaccuratebecausethis could 1
alterthe wrenchloadingpoint. The designof the han-
dle is usuallysuch as to makeit inconvenientto de-
liberatelymisusethe wrench.
PIVOTEO HANDLE
*It shouldbe mentionedthat the use of any
U-joint, wobble or extensionwill have an ef-
fect on the torque readings,no matterwhat
type of wrenchyou are using. For the most
accuratereadings, install the socketdirectly
on the wrenchdriver. If necessary,straight
extensions(which hold a socketdirectly un-
der the wrenchdriver) will have the least ef-
fect on the torque reading. Avoid any exten-
sion that alters the lengthof the wrenchfrom
the handleto the head/drivingpoint (suchas BEAU OR MEASURING ELEMENT
. tccslo3~
a crow’s foot). U-joint or wobble extensions Yg. 26 Exampleof a beam type torque wrench
can greatly affect the readings;avoid their
use at all times.
 GENERALINFORMATIONAND
MAINTENANCE
l-9
dardtorquewrenchareusuallyusedfirstto remove
anycompliance fromthejoint.Thefasteneristhen
tightenedthespecified additionalportionof a turn
measured in degrees.A torqueanglegauge(mechan-
icalprotractor)is usedfor theseapplications.

Fig. 27 A click type or breakaway torque ) See Figure 31

wrench-note that this one has a pivoting
head Throughoutthismanual, specifications
aregivento
helpyoudetermine theconditionof variouscompo-

v
:ig. 30 Somespecifications require the use nentsonyourvehicle,orto assistyouintheirinstalla-
rf a torque angle meter (mechanical pro. tion.Someof themostcommon measurements in-
ractor) cludelength(in.or cm/mm), torque(ft.Ibs.,inchIbs.
or Nm)andpressure (psi,in.Hg,kPaor mmHg).In
mostcases,westriveto providethepropermeasure-
manyaluminum cylinderheads).Inthesecases,a mentasdetermined bythemanufacturers engineers.
torqueanglemethodof installation
wouldbespeci- Though,insomecases,thatvaluemaynotbecon-
fied.Wheninstallingfasteners
whicharetorqueangle venientlymeasured withwhatis availablein your
tightened,
a predetermined seatingtorqueandstan- toolbox.Luckily,manyof themeasuring devices

CONVERSION FACTORS
WRONG WRONG LENGTH-DISTANCE
Inches (I”.) x 25.4 = Millimeters (mm) x .0394 = Inches
PIVOTED HANDLE TOR(IUE WRENCH
tccS1041 Feet (ft.) x ,305 = Meters (m) x 3.281 = Feet
Miles x 1.609 = Kilometers (km) x .0621 = Miles
Fig. 28 Torque wrenches with pivoting
heads must be grasped and used properly VOLUME
to prevent an incorrect reading Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 = in3
IMP Pints (IMP pt.) x .568 = Liters (L) x 1.76 = IMP pt.
IMP Quarts (IMP qt.) x 1.137 = Liters (L) x .88 = IMP qt.
Rigid Case(Direct Reading) IMP Gallons (IMP gal.) x 4.546 = Liters (L) 7, .22 = IMP gal.

# See Figure 29 IMP Quarts (IMP qt ) x 1.201 = US Quarts (US qt.) x ,833 = IMP qt.
IMP Gallons (IMP gal.) x 1.201 = US Gallons (US gal.) x ,833 = IMP gal.
A rigidcaseor directreadingtorquewrenchis Fl. Ounces x 29.573 = Millihters x 034 = Ounces
equipped witha dialindicatorto showtorquevalues. us Pints (Us pt.) x ,473 = Liters (L) x 2.113 = Pints
Oneadvantage of thesewrenches is thattheycanbe US Quarts (US qt.) x .946 = Liters (L) x 1.057 = Quarts
heldatanypositiononthewrenchwithoutaffecting US Gallons (US gal.) x 3.785 = Liters (L) x ,264 = Gallons
accuracy. Thesewrenches areoftenpreferred be- MASS-WEIGHT
causetheytendto becompact, easyto readandhave Ounces (oz.) x 28.35 = Grams (g) x ,035 = Ounces
a greatdegreeof accuracy. Pounds (lb ) x ,454 = Kdograms (kg) x 2.205 = Pounds
PRESSURE ’
Pounds Per Sq. In. (psi) x 6.895 = Kilopascals (kPa) x ,145 = psi
Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
Inches of Water (H,O) x .07355 = Inches of Mercury x 13 783 = H,O
Inches of Water (H,O) x .03613 = psi x 27.684 = Hz0
Inches of Water (H,O) x ,248 = Kilopascals (kPa) x4026 = H,O
TORQUE
Pounds-Force Inches (in-lb) x ,113 = Newton Meters (N.m) x 8.85 = in-lb
Pounds-Force Feet (ft-lb) x 1.356 = Newton Meters (N*m) x ,738 = ft-lb
VELOCITY
lccs1042
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
Fig. 29 The rigid case (direct reading)
torque wrench usesa dial indicator to show POWER
torque Horsepower (Hp) x ,745 = Kdowatts x 1.34 = Horsepower
FUEL CONSUMPTION’
Mdes Per Gallon IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
TORQUEANGLEMETERS Kilometers Per Liter (Km/L) x 2.352 = IMP MPG
Miles Per Gallon US (MPG) x ,425 = Kilometers Per Liter (Km/L)
# See Figure 30 Kdometers Per Liter (Km/L) x 2.352 = US MPG
*It 1s common to covert from miles per gallon (mpg) to hters/lOO kilometers (l/100 km), where mpg (IMP) x l/ID0 km
Becausethefrictionalcharacteristics
of eachfas- = 282 and mpg (US) x l/lo0 km = 235.
tenerorthreaded holewill vary,clamploadswhich
arebasedstrictlyontorquewill varyaswell.Inmost TEMPERATURE
applications,
thisvarianceISnotsignificant enough Degree Fahrenheit CF) = (“C x 1.8) + 32
to causeworry.But,in certainapplications,a manu- Degree Celsms (‘C) = CF - 32) x 56 tccsio4d
facturersengineersmaydetermine thatmoreprecise Fig. 31 Standardand metric conversionfactors chart
clamploadsarenecessary (suchisthecasewith
 .
l-10 GENERALINFORMATIONAND
MAINTENANCE
whichareavailable todaywill havetwoscalessothe Theconversion factorchartis usedbytakingthe factorof 25.4to getthemetricequivalentof 50.8mm.
Standard or Metricmeasurements mayeasilybe givenspecification andmultiplying it bytheneces- Likewise, if thespecification
wasgivenonlyina Met-
taken.If anyofthevariousmeasuring toolswhichare saryconversion factor.Forinstance, lookingatthe ric measurement, for examplein NewtonMeters
available toyoudonotcontainthesamescaleas firstline,if youhavea measurement in inchessuch (Nm),thenlookatthecentercolumnfirst.If themea-
listedinthespecifications,usetheaccompanying as“free-playshouldbe2 in.”butyourrulerreads surement is 100Nm,multiplyit bytheconversion
conversion factorsto determinethepropervalue. onlyin millimeters, multiply2 in.bytheconversion factorof 0.738to get73.8ft. Ibs.

if theengineis equipped witha turbocharger.If the 4 charactercodeasonthevehicleinformation code

8thVINnumberis a U,thereis nodoubtthattheen- plateis used.Theengineserialnumberis also
b See Figures32,33, and 34 ginein questionis a 2.OLDOHCengineequipped stamped neartheenginemodelnumber. Asmen-
withaturbocharger. tionedabove,theenginecanalsobeidentifiedbythe
TheVehicleIdentificationNumber (VIN)is located Theenginecodesfoundonthevehicleinformation 8thdigitintheVINnumber.
ona platewhichis attached to thelefttopsideof the codeplateareasfollows:
instrument panel.Thesenumbers arevisiblefromthe l 4G15--1.5LSOHCengine
outsideof thevehicle.AllVehicleIdentification Num- l 4G61-1.6LDOHCengine
berscontain17digits.Thevehiclenumberisa code l 4G93-1.8LSOHCengine Thetransaxlemodelcodeis locatedonthevehicle
whichtellscountry,make,vehicletype,engine,body l 4G63-2.OL(SOHCor DOHC) engine information
codeplate.Thetransaxleidentification
andmanyotherimportant characteristics
of thatspe- l 4G64-2.4L(SOHCor DOHC)engine numberis etchedona bosslocatedonthefrontup-
cificvehicle. l 6G72-3.OL(SOHCor DOHC) engine perportionof thecase.
Thereis alsoa vehicleinformation codeplate l 6G74-3.5LDOHCengine
whichis rivetedto thebulkhead in theenginecom- A vehiclesafetycertification
labelis attached to
partment. TheplateshowstheVIN,modelcode,en- thefaceof theleftdoorpillarpost.Thislabelindi-
ginemodel,transaxlemodelandbodycolorcodes. catesthemonthandyearof manufacture, GrossVe- Thecodefor thedriveaxleis etchedona bosslo-
Theenginecodeusedonthisplatediffersfromthe hicleWeightRating(GRVW) frontandrear,andVe- catedonthecaseof thedifferential
carrier.
codeletterusedin the8thpositionof theVehicle hicleIdentificationNumber (VIM).
IdentificationNumber(VIN).Eithercodecanbeused
to identifytheparticularenginein thevehicle.Since
thevehicleownerscardis usuallycarried,it maybe
easierto usethecodeletterintheVINfor engineref- ) See Figure 35
erence.Asecondreasonfor referringtotheVINfor Thetransfercasehasnoseparate modelcode,the
engineidentificationisthatcode4663,locatedon codeis locatedonthetransaxle.
Thetransfercaseis
Theenginemodelnumberisstamped atthefront onlveoUiODed onmanualtransaxleAllWheelDrive
thevehicleinformation codeplate,doesidentifythe sideonthetopedgeof thecylinderblock.Thesame
engineasa 2.OLDOHCengine,butdoesnottellyou (AWD)‘mbdels.

Fig. 32 The Vehicle Identification Number Fig. 33 The vehicle model, engine model, Fig. 34 Your car should have a vehicle
(VIN) plate is attachedto the top left side bansaxle model,and bodycolor codeare all
of the instrumentpanel _I:^1 / notedon the vehicle informationcodeg3’51p’o
plate

ENGINEANDVEHiCLEIDENTlFlCATlON
EnglnCode ModelYerr
todeal LIten(cc) Cu. In. W. Fuel+ Type m.hWg. Code@ Year
,G15JA 1.5 (1468) 92 4 MFI SOHC Mitsubishi L 1990
IG61N 1.6(15QQ) 98 4 MFI DOHC Mitsubishi M 1991
1G93lC 1.8 (1834) 112 4 MFI SOHC Mitsubishi N 1992
IG63N 2.0 (1997) 122 4 MFI SOHC “-Mitsubishi P 1993
!G63Fi 2.0 (1997) 122 4 MFI DOHC Mitsubishi R 1994
,G63iU 2.0 (1997) 122 4 MFI-Tuibo DOHC Mitsubishi S 1995
.GMffi 2.4 (2351) 143 4 MFI SOHC Mitsubishi T 1996
iG64L 2.4 (2351) 143 4 MFI DOHC Mitsubishi V 1997
lEzH 3.0 (2972) 161 6 MFI SOHC Mitsubishi W \ 1998
;G7ZJ 3.0 (2972)
(2Q72) 161 Mitsubishi
~..
iG7zL 3.0 181 66 MFI
MFI GQHC
SOHC Miisubishi X ___-___ 1999
~ Y 2000
iG74lP 3.5 (3497) 213 6 MFI SOHC Miisubishi
Fig. 35 Engine model number location-
4663 (2.OL)engine shown
 UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL ENGINE
II
1. Powersteeringbelt 7. PCVvalve 13. Automatictransaxlefluid dipstick
2. Washersolventbottle 8. Distributorcapand rotor 14. Coolantrecoverytank
3. Powersteeringreservoir 9. Fuelfilter (underair inlettube) 15. Radiatorcap
4. Oil fill cap 10. Air filter housing 16. Engineoil dipstick
5. Brakemastercylinderreservoir 11. Enginecompartmentfuse box
6. Sparkplugand plugwire 12. Battery
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