130 13 21MB
English Pages 300 Year 1993
5
MITSUBISHI Cordia Tredia Precis Mirage •= Galant 1983 thru 1993 am four-cyllnder models
^Hayneji)
1669
Automotive Repair IManual
Digitized by the Internet Archive in
2011
http://www.archive.org/details/mitsubishifwdmodOOwarr
Z—
Mitsubishi F WD Models
Automotive Repair
Manual by Larry Warren and John H Haynes Member
of the Guild of
Motoring Writers
Models covered: Mitsubishi Galant, Cordia, Tredia, Precis
and Mirage
1983 through 1990 Does not cover V6 models or all-wheel drive
(8W5 -
1669)
A /Un'CMCTlVli /«:
1/
II
'>n«a
Toe wear
•
Overinflation
• Measure and
Lack
of rotation
• Rotate
or caster
• Repair or replace axle and suspen-
Malfunctioning
• Repair
Incorrect
adjust pressure.
camber
sion parts. tires.
suspension
or replace
suspension
Unbalanced wheel
• Balance
Out-of-round
• Turn
parts.
or
replace. or replace.
brake drum
Lack of
Center wear
rotation
Uneven wear
5.3 This chart will help you determine the condition of the tires, the probable cause(s) of abnormal wear and the corrective action necessary
• Rotate
tires.
Chapter
If a tire loses air on a steady check the valve core first to make sure it's snug (special inexpensive wrenches are commonly available at
5.4a
basis,
auto parts stores)
6.2 left
1
Tune-up and routine maintenance
5.8 To extend the life of the tires, check the air pressure at least once a week with an accurate gauge (don't
5.4b If the valve core is tight, raise the corner of the vehicle with the low tire and spray a soapy water solution onto the tread as the tire is turned slowly leaks will cause small bubbles to appear
The power steering fluid filler cap/dipstick is located on the side of the engine compartment - unscrew the cap to check the dipstick and/or add fluid
may have embedded itself in the tire or for a "plug" may have begun to leak (radial tire punctures are repaired with a plug
forget the spare!)
The power steering fluid level should be kept between the MIN and MAX lines on the dipstick
Don't forget to keep the spare
tread for an object that
9
that
(refer to
a puncture). If a puncture is suspected, it can be easily by spraying a solution of soapy water onto the suspected area (see illustration). The soapy solution will bubble if there's a leak. Unless the puncture is unusually large, a tire shop or service station can usually
-11
1
tire
your owner's manual or the
inflated to the specified
tire
pressure
sidewall).
that's installed in
verified
repair the
Carefully inspect the inner sidewall of
fluid.
Power steering
fluid level
check
tire.
each tire for evidence of brake you see any, inspect the brakes immediately. Correct air pressure adds miles to the lifespan of the tires, improves 6 mileage and enhances overall ride quality. Tire pressure cannot be accurately estimated by looking at a tire, especially if it's a radial. A tire pressure gauge is essential. Keep an accurate gauge in the vehicle. The pressure gauges attached to the nozzles of air hoses at gas stations are often inac5
6
If
Refer to illustrations 6.2 and 6.6 Warning The electric cooling fan can activate at any time, even when the :
ignition is in the Off position.
cable 1
when working
in
Unlike manual steering, the
which may, over a period 2
Disconnect the fan motor or negative battery
the vicinity of the fan.
The fluid
power steering system
relies
on
fluid
of time, require replenishing.
reservoir for the
power steering pump is located on the inner
fender panel near the front of the engine (see illustration).
curate.
Always check tire pressure when the tires are cold. Cold, in this case, not been driven over a mile in the three hours preceding a tire pressure check. A pressure rise of four to eight pounds is not uncommon once the tires are warm. Unscrew the valve cap protruding from the wheel or hubcap and push 8 the gauge firmly onto the valve stem (see illustration). Note the reading on the gauge and compare the figure to the recommended tire pressure shown on the label attached to the inside of the glove compartment door. Be sure to reinstall the valve cap to keep dirt and moisture out of the valve stem mechanism. Check all four tires and, necessary, add enough air to bring them up to the recommended pressure.
For the check, the front wheels should be pointed straight ahead and
7
3
means the vehicle has
the engine should be
if
4
Use a clean rag
cap. This
will
off.
to
wipe
off
the reservoir cap and the area around the
help prevent any foreign matter from entering the reservoir
during the check.
5 6
Remove
the cap and note the dipstick attached to
it.
Wipe off the fluid with a clean rag, reinsert the dipstick, then withdraw and read the fluid level. The level should be between the MIN and MAX marks (see illustration). Never allow the fluid level to drop below the MIN
it
mark. 7 If additional
fluid is required,
pour the specified type directly
into the
'IMKJHSiil.
1
-12
Chapter
The automatic transaxle
7.4
the battery (view
reservoir, using
8
If
a funnel
to
is
1
Tune-up and routine maintenance
fluid dipstick (arrow) Is
Check the fluid with the transaxle at normal operating temperature - the level should be kept in the HOT range (between the two lines)
located near
7.6
from underneath the vehicle)
prevent
spills.
the reservoir requires frequent
fluid additions, all
power steering
hoses, hose connections and the power steering pump should be carefully
checked
for leaks.
Automatic transaxle
7
fluid level
check
Refer to illustrations 7.4 and 7.6 Warning The electric cooling fan can activate at any time, even wtien the :
ignition is in the Off position.
Disconnect the fan motor or negative battery
when working in the vicinity of the fan. 1 The level of the automatic transaxle fluid should be carefully maintained. Low fluid level can lead to slipping or loss of drive, while overfilling can cause foaming, loss of fluid and transaxle damage. 2 The transaxle fluid level should only be checked when the engine is at normal operating temperature. Caution: If the vehicle has just been driven for a long time at high speed or in city traffic in hot weather, or if it has cable
been pulling a trailer, an accurate fluid level reading cannot be obtained. Allow the fluid to cool down for about 30 minutes. Park on level ground, apply the parking brake and start the engine. 3 While the engine is idling, depress the brake pedal and move the selector lever through all the gear ranges, beginning and ending in Park. 4 With the engine still idling, remove the dipstick (see Illustration). 5 Wipe the fluid off the dipstick with a clean rag and reinsert it until the cap seats. Pull the dipstick out again. The fluid level should be in the HOT range (see illustration). If the level is at the low side of the range, add the specified automatic transmission fluid through the dipstick tube with a funnel. 7 Add the fluid a little at a time and keep checking the level until it's cor-
6
8.3
rect.
The
8 If if
condition of the fluid should also be checked along with the level.
the fluid at the end of the dipstick it
smells burned, the
fluid
is black or a dark reddishbrown color, or should be changed (Section 33). If you're in
doubt about the condition of the fluid, purchase some new pare the two for color and odor.
fluid
1
and com-
2 3
8
Engine
oil
and
filter
4
change
5 Refer
to illustrations 8.3. 8.9, 8.
14
and
8.
18
1 Frequent oil changes are the most important preventive maintenance procedures that can be done by the home mechanic. As engine oil ages, it becomes diluted and contaminated, which leads to premature engine
6
These tools are required when changing the engine oil and filter
Drain pan - It should be prevent spills
fairly
shallow
in
depth, but wide to
Rubber gloves - When removing the drain plug and filter, you will get oil on your hands (the gloves will prevent burns) Breaker bar - Sometimes the oil drain plug is tight and a long breaker bar is needed to loosen it Socket - To be used with the breaker bar or a ratchet (must be the correct size to fit the drain plug - six-point preferred) Filter wrench - This is a metal band-type wrench, which requires clearance around the filter to be effective Filter wrench - This type fits on the bottom of the filter and can be turned with a ratchet or breaker bar (different size wrenches are available for different types of filters)
wear.
2 Although some sources recommend oil filter changes every other oil change, a new filter should be installed every time the oil is changed.
3 this
Gather together all necessary tools and materials before beginning procedure (see illustration).
4 3 5 6 7 8
Chapter
1
Use the proper size box-end wrench or six-point socket remove the oil drain plug to avoid rounding it off
8.9
1-13
Tune-up and routine maintenance
8.14
to
special
The oil filter is usually on very tight and will require a wrench for removal - DO NOT use the wrench to tighten the
new
filter
You should have plenty of clean rags and newspapers handy to mop spills. Access to the underside of the vehicle is greatly improved if the vehicle can be lifted on a hoist, driven onto ramps or supported by jackstands. Warning: Do not work under a vehicle which is supported only by 4
up any
a bumper, hydraulic or scissors-type jack. If this is your first oil change, get under the vehicle and familiarize yourself with the locations of the oil drain plug and the oil filter. The engine 5
and exhaust components will be warm during the actual work, so note how when working under the vehicle.
they are situated to avoid touching them
Warm the engine to normal operating temperature. If the new oil or any tools are needed, use this warm-up time to gather everything neces6
sary for the job. Refer to
Recommended lubricants and fluids at the begin-
ning of this Chapter for the type of
With the engine
7
built-up sludge will
oil
oil
required.
warm (warm engine
be removed with
It),
drain better and more and support the vehicle.
oil will
raise
Make sure It's safely supported! Move all necessary tools, rags and newspapers under the vehicle. Set the drain pan under the drain plug. Keep In mind that the oil will initially flow from the pan with some force; position the pan accordingly. 8
Being careful not to touch any of the hot exhaust components, use a wrench to remove the drain plug near the bottom of the oil pan (see illustration). Depending on how hot the oil is, you may want to wear gloves while unscrewing the plug the final few turns. 1 Allow the old oil to drain into the pan. It may be necessary to move the pan as the oil flow slows to a trickle. 11 After all the oil has drained, wipe off the drain plug with a clean rag. Small metal particles may cling to the plug and would immediately con-
8.18
Lubricate the
oil filter
gasket with clean engine on the engine
oil
before
installing the filter
9
taminate the
new
oil.
Clean the area around the drain plug opening and reinstall the plug. it securely with the wrench. If a torque wrench is available, use it to
12
tighten the plug.
Move
1
the drain pan into position under the
oil filter.
Use the filter wrench to loosen the oil filter (see illustration). Chain or metal band filter wrenches may distort the filter canister, but doesn't mat1
It
be discarded anyway. Completely unscrew the old filter. Be careful;
ter since the filter will 1
oil
inside the
1
filter
into the drain
it's full
of
oil.
Empty the
pan.
Compare the old filter with the new one to make sure they're the same
type. 1
the
22
Use a clean rag to remove all oil, mounts to the engine.
dirt
and sludge from the area where
new oil to circulate. Run the engine for only about a minute and then shut it off. Immediate-
gine and allow the
24
Tighten
Move
to the engine compartment and locate the oil filler cap. Pour the fresh oil through the filler opening into the engine. A funnel should be used to prevent spills. 23 Pour four quarts of fresh oil into the engine. Wait a few minutes to allow the oil to drain into the pan, then check the level on the oil dipstick (see Section 4 If necessary). If the oil level is above the MIN mark, start the en-
21
ly look under the vehicle and check for leaks at the oil pan drain plug and around the oil filter. If either is leaking, tighten with a bit more force. 25 With the new oil circulated and the filter now completely full, recheck the level on the dipstick and add more oil as necessary. 26 During the first few trips after an oil change, make it a point to check frequently for leaks and proper oil level. 27 The old oil drained from the engine cannot be reused in its present state and should be disposed of. Oil reclamation centers, auto repair shops and gas stations will normally accept the oil, which can be refined and used again. After the oil has cooled it can be drained into a container (capped plastic jugs, topped bottles, milk cartons, etc.) for transport to a
disposal
site.
oil filter
1 Apply a light coat of clean oil to the rubber gasket on the new oil filter (see illustration). 19 Attach the new filter to the engine, following the tightening directions
on the filter canister or packing box. Most filter manufacturers recommend against using a wrench due to the possibility of overtightening the filter and damaging the seal. 20 Remove all tools, rags, etc. from under the vehicle, being careful not
9
Windshield wiper blade inspection and replacement
printed
to spill the
oil in
the drain pan, then lower the vehicle.
1
The windshield wiper and blade assembly should be Inspected peridamage, loose components and cracked or worn blade ele-
odically for
ments.
2
Road film can
build
up on the wiper blades and
affect their efficiency.
-14
1
9.5
Lift
Chapter
up on the release
lever
and
1
slide the blade
Tune-up and routine maintenance
assembly pin
out of the arm
Use a small screwdriver
9.6
to pry the lock
up and over the end
of the blade insert, then slide the insert out of the wiper arm, away,;
from the lock
9.8
Press the retaining tab
down and
9.9b
in,
out of the hook
then slide the wiper assembly the end of the wiper arm
9.9a
in
pliers to pull the two support rods out of the blade element
To check the clutch pedal freeplay, measure the distance between the natural resting place of the pedal and the point at which you encounter resistance
With the rods out, it's an easy job to remove the element from the frame
so they should be washed regularly with a mild detergent solution. 3 The action of the wiping mechanism can loosen bolts, nuts and fasteners, so they should be checked and tightened, as necessary, at the
Use needle-nose
10.1
same
time the wiper blades are checked.
4
the wiper blade elements are cracked, worn or warped, or no longer
If
clean adequately, they should be replaced with
new
ones.
Chapter
1
Tune-up and routine maintenance
1
-15
Adjust the clutch pedal freeplay by turning the cable adjusting nut until the specified clearance (C) is achieved
10.2
Early Refer
models
to illustrations 9.5
and 9.6
arm assembly away from the glass for clearance, lift up on the release lever and detach the blade assembly from the arm (see illustra-
5
Lift
the
tion).
6
Pry the metal lock on the end of the wiper arm up with a small screwit clears the metal tab on the end of the insert, then slide the
driver until insert
7
away from the lock, out of the arm (see illustration). new insert into place until the hole in the end snaps over
11.1
Face shield/safety goggles - When removing corrosion with a brush, the acidic particles can easily fly up into
1
the tab.
your eyes
Later models Refer 8
and 9.9b wiper blade/arm away from
Pull the
2 Baking soda - A
9.9a
to illustrations 9.8,
the glass, depress the retaining in
the
With the rods removed, slide the element out of the wiper frame
Slide the
new element
will
cable clamps
Treated felt washers - Placing one of these on each post, under the cable clamps, will help prevent corrosion Puller - Sometimes the cable clamps are very difficult to pull off the posts, even after the nut/bolt has been completely loosened. This tool pulls the clamp straight up and off the post without damage. Battery post/cable cleaner - Here is another cleaning tool which is a slightly different version of number 4 above, but it
5
then insert the rods to
into place in the frame,
the battery posts
Battery post/cable cleaner - This wire brush cleaning tool will remove all traces of corrosion from the battery posts and
4
(see illustration). 1
soda and water can be
help prevent corrosion
ers to pull the two metal support rods out of the rubber element (see illustration).
solution of baking
used to neutralize corrosion Petroleum jelly - A layer of this on
3
arm (see illustration). Bend the end of the element out of the way and use needle-nose pli-
tab and slide the assembly out of the hook
9
Tools and materials required for battery maintenance
Slide the
directly
lock
10
it
place.
6
Clutch pedal freeplay check and adjustment (cable-operated clutch)
Refer 1
in
to illustrations 10.
1
and 10.2
Push down on the clutch pedal and use a small it
illustration). ter's
2
it
Working
in
does the same thing Rubber gloves - Another safety item
8 steel ruler to
moves freely before the clutch resistance The freeplay should be within the limits listed in isn't, must be adjusted. Specifications, if
the distance that
7
measure
is felt
this
servicing the battery;
to
consider
remember that's acid inside
when the battery!
(see
Chap-
it
the engine compartment, turn the outer cable adjusting nut
(located at the point where the cable enters the bulkhead) until the clearance between the nut and insulator projection listed in the Specifications is
achieved (see illustration). Recheck the freeplay. Repeat the adjustment as necessary. 3
tually dilute sulfuric acid, in
your eyes.
It
which
will also ruin
will cause injury if splashed on
clothes and painted surfaces.
the battery cables, always detach the negative cable
your skin or
When removing
first
and hook
it
up
last!
Check and maintenance Battery maintenance is an important procedure which will help ensure you aren't stranded because of a dead battery. Several tools are required for this procedure (see illustration). 2 When checking/servicing the battery, always turn the engine and all 1
that
11
Battery check, maintenance and charging
accessories
and 11.7c Warning: Certain precautions must be followed when checking and servRefer
to illustrations 11.1, 11.6, 11.7a, 11.7b
Hydrogen gas, which is highly flammable, is always prescells, so keep lighted tobacco and all other open flames and sparks away from the battery. The electrolyte inside the battery is acicing the battery.
ent in the battery
off.
A sealed (sometimes called maintenance-free), battery is standard 3 equipment on these vehicles. The cell caps cannot be removed, no electrolyte checks are required and water cannot be added to the cells. However, a standard aftermarket battery has been installed, the following maintenance procedure can be used. if
-16
1
Chapter
1
Tune-up and routine maintenance
^•3l^:i^
11 .6 Use a wrench to check the tightness of the battery cable bolts;
when removing corroded
bolts,
it
11 .7a
When cleaning the cable corrosion must be removed (the inside of the clamp is tapered to match the taper on the post, so don't remove too much material)
Battery terminal corrosion
11 .7b
clamps,
may
be necessary to use special battery pliers
f1 ,
"^
all
SMALL CRACKS
GREASE
K ALWAYS CHECK GLAZED
of the belt.
fe^
4
Remove the caps and check the electrolyte (water) level in each of the
battery cells (see Section 4). split-ring indicator in
low,
12.3a Here are some of the more common problems associated with drivebelts (check the belts very carefully to prevent an untimely breakdown)
Regardless of the type of tool used on the battery posts, a clean, shiny surface should be the result
11 .7c
the underside
add
distilled
each
It
must be above the plates. There's usually a
cell to indicate
the correct level.
wateronly, then reinstall the
cell
If
the level
is
caps. Caution: Overfill-
may cause electrolyte to spill over during periods of tieavy causing corrosion and damage to nearby components. 5 The external condition of the battery should be checked periodically. Look for damage such as a cracked case. Check the tightness of the battery cable bolts (see illustration) to en6 sure good electrical connections. Inspect the entire length of each cable, looking for cracked or abraded insulation and frayed conductors. ing the cells ctiarging,
7
If
corrosion (visible as white,
fluffy
deposits) (see illustration)
is
evi-
remove the cables from the terminals, clean them with a battery brush and reinstall them (see illustrations). Corrosion can be kept to a minimum by applying a layer of petroleum jelly or grease to the terminals. 8 Make sure the battery carrier is in good condition and the hold-down clamp is tight, if the battery is removed (see Chapter 5 for the removal and installation procedure), make sure that no parts remain in the bottom of the
dent,
carrier
when
it's
reinstalled.
1
2.3b
Check V-ribbed
belts for signs of
belt looks
wear
worn, replace
like
these -
if
the
it
When reinstalling the hold-down clamp, don't
overtighten the nuts.
Corrosion on the carrier, battery case and surrounding areas can be removed with a solution of water and baking soda. Apply the mixture with a
9
small brush,
let
it
work, then rinse
it
off
with plenty of clean water.
10 Any metal parts of the vehicle damaged by corrosion should be coated with a zinc-based primer, then painted.
Charging Remove all of the cell caps (if equipped) and cover the holes with a clean cloth to prevent spattering electrolyte. Disconnect the negative battery cable and hook the battery charger leads to the battery posts (positive 1 1
4 2 3
.
Chapter
Tune-up and routine maintenance
1
-17
Alternator
BELT DEFLECTION
RULER
1
Water pump
brace boll
pulley
Alternator pulley Alternator
support bolt
MAKE SURE RULER IS PERPENDICULAR TO STRAIGHT EDGE
Crankshaft pulley
Measuring drivebelt deflection with a straightedge and ruler
12.4
to positive,
negative to negative), then plug
in
the charger.
Make sure
1
it
1
2 volts
if
the alternator to adjust the drivebelt tension
is
has a selector switch. If you're using a charger with a rate higher than two amps, check the 1 battery regularly during charging to make sure it doesn't overheat. If you're using a trickle charger, you can safely let the battery charge overnight after you've checked it regularly for the first couple of hours. If the battery has removeable cell caps, measure the specific gravity 1 with a hydrometer every hour during the last few hours of the charging cycle. Hydrometers are available inexpensively from auto parts stores follow the instructions that come with the hydrometer. Consider the battery charged when there's no change in the specific gravity reading for two set at
Move
2.6
it
Belt tension adjuster
Adjust
hours and the electrolyte in the cells is gassing (bubbling) freely. The spegravity reading from each cell should be very close to the others. If not,
cific
the battery probably has a bad cell(s).
Some batteries with sealed tops have built-in
hydrometers on the top charge by the color displayed in the hydrometer window. Normally, a bright-colored hydrometer indicates a full charge and a dark hydrometer indicates the battery still needs charging. Check the battery manufacturer's instructions to be sure you know what the colors 1
that indicate the state of
Loosen the lock
12.7
bolt
and turn the adjusting
bolt to tighten
or loosen the drivebelt
mean. 15
If
the battery has a sealed top
hook up a charge.
A
digital
fully
and no
built-in
hydrometer, you can
voltmeter across the battery terminals to check the
charged battery should read
1
2.6 volts or higher.
means you will have to twist the belt to check the underside. Use your fingers to feel the belt where you can't see it. If any of the above conditions are evident, replace the belt (go to Step 8). 4 The tightness of each belt is checked by pushing on at a distance halfway between the pulleys (see illustration). Apply about 1 pounds of force with your thumb and see how much the belt moves down (deflects) Refer to the Specifications listed in this Chapter for the amount of deflection allowed in each belt. the belt should be inspected, which
it
Drivebelt check, adjustment
12
Refer to
and replacement
illustrations 12.3a, 12.3b, 12.4, 12.6, 12.7
and 12.10
5
Check 1
The
drivebelts are either V-belts or V-ribbed belts.
Sometimes reend of the en-
left
The good condition and proper adjustment of the belts is critical to Because of their composition and the high stresses to which they are subjected, drivebelts stretch and deteriorate as they get older. They must therefore be periodically inspected. The number of belts used on a particular vehicle depends on the ac2 cessories installed. One belt transmits power from the crankshaft to the alternator and water pump. The air conditioning compressor and power gine.
the operation of the engine.
pumps
are driven by other belts.
off, open the hood and locate the drivebelts at the left end of the engine. With a flashlight, check each belt: On V-belts, check for cracks and separation of the belt plies (see illustration). On V-ribbed belts, check for separation of the adhesive rubber on both sides of the core, core separation from the belt side and a severed core. Also on Vribbed belts, check for separation of the ribs from the adhesive rubber, cracking or separation of the ribs, and torn or worn ribs or cracks in the inner ridges of the ribs (see illustration). On both belt types, check for fraying and glazing, which gives the belt a shiny appearance. Both sides of
3
If
adjustment
is
necessary,
it
is
done by moving the belt-driven acces-
sory on the bracket.
ferred to as "fan" belts, the drivebelts are located at the
steering
Adjustment
With the engine
On some components, a belt must be adjusted, loosen the adjustment (brace) bolt that secures the component to the slotted bracket and pivot the component (away from the engine block to tighten the belt, toward the block to loosen the belt) (see illustration). It's helpful to lever the component or power steering pump with a large prybar when adjusting the belt because the prybar enables you to precisely position the component until the adjuster bolt is tightened. Be very careful not to damage the housing of the component, particularly the aluminum housing of the alternator. Recheck the belt tension using the above method. On some components, loosen the lock bolt. Turn the adjusting bolt to 7 6
if
tension the
belt,
then retighten the lock bolt (see illustration).
Replacement 8
To replace a
ment, but
some
slip
belt, follow
the belt
belts, you'll
off
have
the
above procedures
for drivebelt adjust-
the crankshaft pulley and remove
to
remove other
belts to get at the
it.
To replace
one you're
re-
because of the way the belts are arranged on the crankshaft pulley. Because of this and because belts tend to wear out more or less together, is a good idea to replace all belts at the same time. Mark each placing
it
2 3 6
1
1
1
-18
Chapter
Tune-up and routine maintenance
1
ALWAYS CHECK
hose
for
chafed or burned areas that may cause an untimely
and
WRONG
CORRECT When
12.10
WRONG
installing a V-ribbed belt, mal2
After adjusting the cable, be sure the throttle lever contacts the ISC
JO
notor.
Ilode/s with cruise control ^ordia
and Tredia
off
hrottle lever !4 55 >6 57
the cable adjusting nuts and detach the cable from the
and bracket (see
illustration).
Detach the cable from the pedal (see illustration 1 6.4). Detach the cable from the firewall (see illustration 16.5). From the engine compartment, pull the cable through the firewall. Installation is the reverse of removal. Be sure there are no sharp
>ends
in
the cable.
idling,
use the adjusting nuts
to
remove the freeplay
Tighten the adjusting nuts against each other.
Rev the engine
to
be sure a binding condition
is
not present.
Actuator cable 31 Detach the cable from the throttle lever. 32 Detach the cable from the actuator and remove the cable. is
Installation
the reverse of removal. After installation, adjust the cable freeplay as
described beginning with the next Step. 33 With the engine idling, use the adjusting nuts from the cable.
to
remove the freeplay
Tighten the adjusting nuts against each other.
Rev the engine
to
be sure a binding condition
is
not present.
Galant
iCcelerator pedal cable
Back
29 30
34 35
^efer to illustration 16.23
>3
4-19
Fuel and exhaust systems
Refer
to illustration
Removal and
16.37
installation
Note This procedure applies to both accelerator cables AandB in illustra:
tion 16.37.
36 Remove the cover from the speed control actuator. 37 Loosen the throttle cable adjusting nut (of the cable being replaced) and lift the cable housing off the bracket (see illustration).
Throttle cable details for Cordia and Tredia with cruise control. Adjustment nuts are shown by the arrows
16.23
oaJVH
1
6.37
Throttle cable details
for Galant with cruise control 1
A
Cruise control actuator
3
Accelerator pedal
4
Selector
5 6
Intermediate
7 8 9
«A3^H
Accelerator cable
2
Intermediate link link
B A
Throttle lever
Adjusting bolts
Stopper
10
Accelerator cable
11
Adjusting nut A
12
Lock nut
B
4-20
1
Chapter 4
—
Accelerator cable A
g^
\ Adjusting'
6.56
Fuel and exhaust systems
Throttle cable Intermediate link details for Mirage
1
6.66
MPI models.
Front hanger 17.1
38 39
If
you're not planning to service the exhaust system - inspect and, replace the rubber hangers (Precis shown)
throttle
cable from the intermediate
if
52
link.
replacing the cable to the accelerator pedal, detach the cable from
the pedal. Detach the throttle cable guide from the firewall (see illustration
1
6.4).
From outside the vehicle,
pull
the throttle cable through the fire-
40
If
replacing the cable to the throttle body,
near the
throttle
remove the
retaining bolts
body, detach the cable from the throttle lever and remove
the cable.
41
Installation
is
the reverse of removal. Don't leave any sharp bends
in
the cable.
Adjustment 42 Run the engine until reaches normal operating temperature. Verify necessary (see Chapter 1 ). Turn off the idle speed is correct and adjust it
it if
the engine.
Depress the accelerator pedal and check to be sure the throttle lever fully open to fully closed. 44 Remove any sharp bends from the accelerator cable. 45 Check the arrangement and placement of the cable. 46 With the cover of the speed control actuator removed, loosen the adjustment nuts and locknuts to free the intermediate links. 47 Turn the ignition key to the "ON" position for fifteen seconds (to actuate the ISC motor). 48 With intermediate link "A" (pedal cable) against the stopper (see illustration 16.37), use adjusting nut "A" to adjust the cable so intermediate link "A" just begins to move then, back off adjusting nut "A two turns. 49 Using adjusting nut "B", tighten the cable so the lever on intermediate link "B" just contacts the lever on intermediate link "A". 50 Loosen the two bolts retaining the cable near the throttle body. 51 Adjust the cable to remove the remainder of the slack from 43
moves smoothly from
"
it.
Tighten the intermediate
link
if
warranted,
locknuts and the two bolts retaining the
cable near the throttle body.
53
After adjusting the cable,
be sure the
throttle lever
contacts the ISO
motor.
54
wall.
.
Rear hanger
Middle hanger
Anytime you raise the vehicle - even
Detach the
Use the adjusting bolts to adjust the f reeplay for the throttle lever cable on Mirage MPI models
Install
the cover of the speed control actuator.
Mirage (MPI) Refer
to illustrations
16.56
and 16.66
Accelerator pedal cable removal and installation 55 Detach the cable housing from the engine. 56 Detach the cable from the intermediate link (see illustration). 57 Detach the cable from the firewall (see illustration 16.5). 58 Detach the cable from the accelerator pedal (see illustration 1 6.4) 59 Pull the cable through the firewall from the engine compartment. 60 Installation is the reverse of removal. After installation, be sure nc sharp bends are in the cable and that a binding condition is not presenti Throttle lever cable removal 61
62 63 64
and
installation
Detach the cable housing from the engine. Detach the cable from the intermediate link Detach the cable from the throttle lever and remove Installation
is
it.
the reverse of removal.
Adjustment 65 66
Remove
the air cleaner Using the adjusting bolts (see illustration), adjust the cable
67
to the
a slight amount of freeplay at the lever. After adjusting the cable to the throttle lever, be sure the lever touches
throttle lever
so there
is
the idle position switch.
68 1
With the intermediate
link
against the stopper (see illustratior
6.56), loosen the adjusting bolt for the cable to the accelerator pedal anc
4-21
Fuel and exhaust systems
Chapter 4
quiet.
Look for any damaged or bent
parts,
open seams,
holes, loose con-
nections, excessive corrosion or other defects which could allow exhaust
fumes
to enter the vehicle. Deteriorated exhaust system components should not be repaired; they should be replaced with new parts. If the exhaust system components are extremely corroded or rusted 3 together, welding equipment will probably be required to remove them. The convenient way to accomplish this is to have a muffler repair shop re-
move the corroded sections with a cutting torch. If, however, you want to save money by doing it yourself (and you don't have a welding outfit with a cutting torch), simply cut off the old components with a hacksaw. If you have compressed air, special pneumatic cutting chisels can also be used. If you do decide to tackle the job at home, be sure to wear safety goggles to protect your eyes from metal chips and work gloves to protect your hands. Here are some simple guidelines to follow when repairing the exhaust 4 system: a)
17.4 Exhaust system bolts and nuts, particularly those on the exhaust manifold and catalytic converters, can be very difficult to loosen - spraying them with a penetrant will free up the threads
b)
c)
remove all the freeplay from the cable. 69 Be sure to check that the throttle valve fully opens and closes with the use 70
17
d)
fasteners during reassembly.
of the accelerator pedal. Install
Be sure to allow sufficient clearance between newly installed parts and all points on the underbody to avoid overheating the floor pan and possibly damaging the interior carpet and insulation. Pay particularly close attention to the catalytic converter and heat shield. 5 To replace the front catalytic converter refer to Chapter 2A and remove the exhaust manifold and converter as an assembly. Then unbolt the
the air cleaner.
e)
Exhaust system servicing - general information
Refer to illustrations
1 7. 1
Work from the back to the front when removing exhaust system components. Apply penetrating oil to the exhaust system component fasteners (see illustration) to make them easier to remove. Use new gaskets, hangers and clamps when installing exhaust systems components. Apply anti-seize compound to the threads of all exhaust system
and
1
converter from the manifold. Installation
7.4
is
the reverse of removal.
Warn ing Inspection and repair of extiaust system components should be :
done only after enough time has elapsed after driving the vehicle to allow the system components to cool completely. A Iso, when working under the vehicle, make sure it is securely supported on jackstands.
The exhaust system consists of the exhaust manifold(s), the catalytic and all connecting pipes, brackets, hangers and clamps. The exhaust system is attached to the body with mounting brackets and rubber hangers (see illustration). any of the parts are improperly installed, excessive noise and vibration will be trans1
1
8
Refer
mitted to the body.
2
Conduct regular inspections of the exhaust system to keep
to illustration
18.2
A turbocharger system is used to increase power. As increased power
converter, the muffler, the tailpipe
If
Turbocharger - general information
is
is opened, more air/fuel mixture chambers by the turbocharger.
required and the throttle
the combustion
is
forced into
A turbine wheel in the turbocharger is driven by the exhaust stream and connected by a shaft to drive a compressor wheel (fan) to pressurize the intake air stream (see illustration). The amount of pressurized air alis
it
safe and
18.2
OSLlfrff
Details of the turbocharger
system
1 2
4-22 lowed
into the
Chapter 4 engine
is
Fuel and exhaust systems
controlled by an exhaust by-pass valve (waste-
gate).
6 Look for evidence of wheel-to-housing contact. Be sure the shaft rotates freely. Rotating stiffness could indicate the' 7 presence of sludged oil or coking (hardened oil deposits) from overheating.
1
8
Turbocharger - inspection
9
Push
in
on one of the shaft wheels while turning
it.
Be sure the wheels
turn freely without contacting the housings.
Caution Operation of the turbocharger without all the ducts and filters installed can result in personal injury and/or allow foreign objects to damage the wheel blades.
9
:
1 1 1
Note The turbocharger is not serviceable and must be replaced as a unit.
Be sure the exhaust manifold has no loose connections or cracks. Check the oil drain line for any restrictions. Visually inspect the actuator and wastegate linkage for damage. Check the hose to the wastegate.
:
Every turbocharger has
1
its
own
noise level
when
operating.
If
the
noise level changes, suspect a problem. If
sound of the turbocharger goes up and down in pitch: Check for heavy dirt build up in the compressor housing and on the compressor wheel. b) Check for an air inlet restriction.
the
20
Turbocharger - removal and installation
a)
1
a high pitch or whistling: c) Look for an inlet air or exhaust gas leak. 2 With the engine off and the turbocharger stopped, make a visual inspection of the turbocharger and components. Check for loose duct connections from the air cleaner to the turbo3
4
charger.
6
If
4 5
the noise level
is
Be sure the duct from the turbocharger-to-intake system is not loose. Visually check the wheels of the turbocharger for damage from for-
eign objects.
2 3 5
Remove
the heat protectors (see illustration 18.2). Disconnect the oil return pipe from the oil pan. Remove the oil pipe from the turbocharger and the oil filter bracket. Remove the air intake pipe connecting bolt. Disconnect the remaining hoses and electrical connectors from the
turbocharger.
Remove the turbocharger mounting
nuts and
remove the turbochar-
ger assembly from the exhaust manifold.
7
Pour clean engine
8
Installation
is
oil
into the turbocharger.
the reverse of removal.
Be sure
to
use a new gasket.
Chapter 5
Engine
electrical
systems
Contents Alternator
- removal and
16
installation
- check and replacement 4 Battery check and maintenance See Chapter 1 2 Battery - emergency jump starting Battery - removal and installation 3 Centrifugal advance mechanism - check and component replacement 12 Charging system - check 15 Charging system - general information and precautions 14 Distributor pickup air gap - check and adjustment 13 Distributor - removal and installation 8 Drivebelt check, adjustment and replacement See Chapter 1 Battery cables
General information Igniter - replacement
1
10
- check and replacement system - check Ignition system - general information and precautions Ignition timing check and adjustment Pickup coil check and replacement Spark plug replacement Spark plug wire, distributor cap and rotor check and replacement Starter motor - testing in vehicle Ignition
- removal and installation - removal and installation Starting system - general information and precautions Vacuum advance unit - check and replacement Voltage regulator/alternator brushes - replacement
Note: The
air
is
applicable only to the models listed below.
to 0.01 5 in
.8L
0.008
to 0.01 5 in
2.0L
0.031
in
1986 1987 and 1988 1
.8L
2.0L
0.008 to 0.01 5
in
Not available 0.008 to 0.015
in
Galant
1985 and 1986 1 987 on Mirage (1985 through 1988 1.5L) Precis (1987 through 1989)
1
See Chapter
1
19 21
0.008
1
See Chapter
20
Cordia and Tredia
1983 1984 and 1985
1
11
Starter solenoid
gap
gap check and adjustment procedure
See Chapter
Starter motor
Specifications
Distributor pickup air
7 6 5
Ignition coil
0.031
in
Not available 0.008 to 0.015 0.031
in
in
18 9 17
5-2
Chapter 5
Engine
electrical
systems
Ignition coil Primary resistance Cordia/Tredia
1983 1984 through 1986
1
.04 to
.27
ohms
ohms ohms
1.8L
1.15
2.0L
1
.2
1
1987
ohms ohms
1.8L
1.25
2.0L
1
.2
1988 1.8L
1.13 to 1.37
2.0L Galant
1
1985 and 1986 1987 1988 1989 on
1.2
.32
ohms
0.72 to 0.88 0.77 to 0.95
later
ohms ohms
ohms
Not available
Mirage 1985 through 1988
989 and
1
0.72 to 0.88
SOHC DOHC
1
.08 to
1
1.2
(all)
.6L engine
ohms ohms
ohms
0.77 to 0.95
ohms
1.5L engine
1989 1 990 and
ohms ohms
0.72 to 0.88 0.9 to
later
1
.2
Precis
1987 1988 1989 1990
Not available 1.1 to 1.3
ohms
Not available 0.72 to 0.88 ohms
Secondary resistance Cordia/Tredia
1983 1984 through 1986
7.10 to 9.60k
.8L
8.35k
2.0L
13.7k
1
ohms
ohms ohms
1987 1.8L
11.0k
2.0L
13.7k
ohms ohms
1988 9.4 to 12.6k
1.8L
2.0L Galant
ohms ohms
11.7 to 15.7k
1985 1986 1987 1988 1989 on
13.7k
ohms
26.0k ohms 10.8 to 13.2k
ohms
Not available
SOHC DOHC
10.3 to 13.9k 10.3 to 13.9k
ohms ohms
Mirage
1985 through 1988 1 989 and 1 990 1 .5L engine; 1 991 and later 1 .5L engine
13.7k 1
989 and
later
1
.6L engine
1
ohms 1 3.9K ohms 29k ohms
0.3 to
20
to
Precis
1987through 1989
11.6to 15.8k
1990and
11.3 to 13.9k
Pickup
later
ohms ohms
coil resistance
Note: The pickup
coil resistance
check
is
applicable only to the models listed below
Cordia and Tredia 1.8L Turbo (1984 through 1988) 2.0L (1986 through 1988) Mirage 1.6L (1985 through 1988)
920 130 920
to to to
1120 ohms 190 ohms 1120 ohms
1
.
Engine
Chapter 5
5-3
systems
electrical
General information
1
The engine electrical systems include all ignition, charging and starting components. Because of their engine-related functions, these components are discussed separately from chassis electrical devices such as the lights, the instruments, etc. (which are included in Chapter 12). Always observe the following precautions when working on the electrical
systems: Be extremely careful
a)
They are
nents.
easily
when servicing engine electrical compodamaged checked, connected or handled it
improperly.
on
b)
Never leave the
c)
d)
engine off. Don't disconnect the battery cables while the engine is running. Maintain correct polarity when connecting a battery cable from
e)
another vehicle during jump starting. Alwayc; jismnnt^ct the nega tive cahip fir.37rf
7.5
6
Ignition
Refer
system - check
to illustration 6.2
Warning Because of ttie very high voltage generated by the ignition system, extreme care should be taken when this check is performed. :
1
If
Terminal identification for the primary circuit of the 1990 DIS coil
the engine turns over but won't
from any spark plug and attach
it
to
start,
disconnect the spark plug wire
a calibrated
ignition tester (available at
On non-DIS models, there's still no spark, the coil-to-cap wire may be bad (check the resistance with an ohmmeter - should be 7000 ohms per foot or less). If a known good wire doesn't make any difference in the test results, the ignition module may be defective. 8
if
it
most auto parts stores). Connect the clip on the 2
tester to a bolt or metal bracket on the engine (see illustration). If you're unable to obtain a calibrated ignition tester, remove the wire from one of the spark plugs and, using an insulated tool, hold the end of the wire about 1/4-inch from a good ground. Crank the engine and watch the end of the tester or spark plug wire to 3 see if bright blue, well-defined sparks occur. If you're not using a calibrated tester, have an assistant crank the engine for you. Warning: Keep clear of drivebelts and other moving engine components that could injure you. If sparks occur, sufficient voltage is reaching the plug to fire it (repeat 4 the check at the remaining plug wires to verify the wires, distributor cap and rotor [if equipped] and other coils [DIS systems] are OK). However, the plugs themselves may be fouled, so remove them and check them as described in Chapter 1 On non-DIS models, if no sparks or intermittent sparks occur, remove 5 the distributor cap and check the cap and rotor as described in Chapter 1 If moisture is present, dry out the cap and rotor, then reinstall the cap. 6 On non-DIS models, if there's still no spark, detach the coil secondary wire from the distributor cap and hook it up to the tester (reattach the plug wire to the spark plug), then repeat the spark check. Again, if you don't have a tester, hold the end of the wire about 1 /4-inch from a good ground. If
sparks occur now, the distributor cap, rotor or plug wire(s)
may be defec-
Ignition coil
- check and replacement
Check Distributorless Ignition
System
Refer
and
to illustrations 7.2, 7.5
(DIS)
7.
Primary circuit (1989) Disconnect the primary wiring connector for the coils. Using an ohmmeter, measure the resistance between the coil connector terminals (see illustration) No. 4 and 2 (No. 1 and 4 cylinders). 1
2
Measure the resistance between terminals No. 4 and
no sparks occur, check the wire connections at the coil to make sure they're clean and tight. Check for voltage to the coil. Make any necessary repairs, then repeat the check again. If
1
(No. 2
and 3 cylin-
ders).
3
Compare
the readings to the Specifications at the beginning of this
Chapter. Replace any
coil
if
not to specification.
Primary circuit (1990) Disconnect the primary wiring connector for the coils. Using an ohmmeter, measure the resistance between the coil con5 nector terminals (see illustration) No. 3 and 2 (No. 1 and 4 cylinders).
4
Measure the resistance between terminals No. 3 and
tive.
7
7
1
(No. 2
and 3 cylin-
ders).
6
Compare
the readings to the Specifications at the beginning of this
Chapter. Replace any
coil
if
not to specification.
2 4 3 5 7
2 4
1
1
Chapter 5
For No. 1 and No. 4 cylinders
a
Engine
electrical
5-5
systems
® 1
^
; \
--
y ForNo. 2andNo. 3 cylinders 7.7 On the DIS coil, check between the two secondary terminals to check the resistance of the secondary circuit
{Secondary circuit Using an ohmmeter, measure the resistance between the high voltage (secondary) terminals for cylinders the No. 1 and 4 (see illustration). Measure the resistance between the high voltage terminals for cylinders No. 2 and 3. 8
Compare
coil resistance of the
primary circuit (typical
shown)
coil is
if
not to specification.
others
Refer
to illustration 7.
1
9
Detach the cable from the negative terminal
10
Locate the
11
Checking the
the readings to the Specifications at the beginning of this
Chapter. Replace any coil All
7.11
Using an ohmmeter, check the a)
of the battery.
coil.
coil:
Measure the resistance between the nals (see illustration).
resistance listed
in this
positive
and negative termi-
Compare your reading with the primary coil Chapter's Specifications.
Detach the high tension lead from the coil. Measure the resistance between the positive terminal and high tension terminal. Compare your reading with the secondary coil resistance listed in this Chap-
b)
ter's Specifications. 1
If
either of the
fied resistance,
above
tests yield resistance values outside the speci-
replace the
coil.
Replacement
16
Detach the cable from the negative terminal of the Detach the wiring to the coil assembly. Detach the coil assembly from it's mounting. Remove the coil assembly.
1
Installation
1
1 1
is
battery.
8.6 Before removing the distributor, paint or scribe an alignment mark on the edge of the distributor base directly beneath the rotor tip - DO NOT use a lead pencil
the reverse of removal. while the distributor is out of the engine, or the alignment marks
8
Distributor
- removal and
installation
8 Refer to
illustration
will
be use-
less.
8.6
Detach the primary wiring from the
distributor.
Installation
Removal
If the crankshaft has been moved while the distributor is out, the number one piston must be repositioned at TDC. This can be done by feeling for compression pressure at the number one plug hole as the crankshaft is turned. Once compression is felt, align the TDC marks on the drivebelt pulley and the timing cover.
Note:
Detach the cable from the negative battery terminal. 2 Unplug the coil high tension lead from the distributor cap. 3 Detach the vacuum hose(s) from the advance unit (if equipped). 4 Look for a raised "1 " on the distributor cap. This marks the location for the number one cylinder spark plug wire terminal. If the cap does not have a mark for the number one terminal, locate the number one spark plug and trace the wire back to the terminal on the cap. 5 Remove the distributor cap (see Chapter 1 and turn the engine over until the rotor is pointing toward the number one spark plug terminal (see locating TDC procedure in Chapter 2). 6 Make a mark on the edge of the distributor base directly below the rotor tip and in line with it (see illustration). Also, mark the distributor base and the engine block to ensure that the distributor is installed correctly. 7 Remove the distributor hold-down nut and washer, then pull the distributor straight out to remove it. Caution: DO NOT turn the crankshaft 1
)
9
Insert the distributor into the
the block that
it
was
in
engine
in
exactly the same relationship to
when removed.
1 To mesh the helical gears on the camshaft and the distributor, may be necessary to turn the rotor slightly. Recheck the alignment marks between the distributor base and the block to verify that the distributor is in the same position was in before removal. Also check the rotor to see it's aligned with the mark you made on the edge of the distributor base. it
it
if
1
Loosely
1
Reconnect the
13
Install
1
Reattach the vacuum
install
the nut. electrical leads.
the distributor cap. line(s) to
the advance unit
(if
equipped).
6 5 7
.
5-6
Engine
Chapter 5
electrical
To detach the vacuum unit from the distributor remove the two screws (arrows)
.
.
.
systems
down, detach it from the pin (arrow) on the breaker base and pull it out
then
tilt it
.
.
Replacement 6
I
Pull the rotor off the shaft
(see Chapter
1 ).
7 Remove the vacuum unit mounting screws (see illustration). Remove the vacuum unit link from the pin on the breaker base, 8 detach the vacuum unit (see illustration).
9
Installation
Igniter
1
1
is
the reverse of removal.
- replacement
Refer to the exploded views
12.7a, 12.7b, 12.7c
2 Pickup
coil
on 3
resistance
When
thei
and
procedure (see
for the
illustrationi
12.7d).
installing the igniter,
do not wipe away the conductive greas^
it.
Adjust the
air
gap (see Section
1
3) before reinstalling the distributoi
measuring terminals
11
Pickup
coil
On
Cordia/Tredia 1.8L Turbo (1984 and 1985) and Mirage 1.6L (1985), use the measuring terminals shown to check the resistance of the pickup coil 11.3
Refer
check and replacement
to illustration 11.3
Note: This procedure applies only
1
Reattach the spark plug wires
1
Connect the cable
1
Check
to the
plugs
(if
removed).
to the
models
Cordia/Tredia 1.8L Turbo (1984 1.6L (1985) Remove the distributor cap. Remove the rotor from the distributor. 2
and
listed below.
1985); Mirage
1
to the negative terminal of the battery.
the ignition timing (see Chapter
1
)
and tighten the
distributor
3
hold-down nut securely.
it's
Using an ohmmeter, check the resistance of the pickup coil by probin measuring terminals (see illustration). Compare the results to thi
Chapter's Specifications.
4 9
Vacuum advance
Refer
to illustrations 9.
Check
5
Remove the vacuum
line.
If
line
from the vacuum advance
unit
and plug the
there are two lines, disconnect and plug the outer (furthest from the
distributor) line.
2
Connect a timing
3 4
Attach a
light to
vacuum pump
the vehicle.
to the
coil
if
not within the specifications (see illustrs
Cordia/Tredia 1.8L Turbo (1986 ttirougti 1988); Mirage 1.6L (1986 ttirougii 1988)
7 and 9.8
1
Replace the pickup
tion12.7d).
- check and replacement
unit
advance
The
unit
holds vacuum, the advance plate
timing should gradually advance. in
coil
resistance, detach the distributor primar
ohmmeter to check the resistance between the two lead
(see illustration 12.7c). Compare the reading to the specifications at the front of 6 7 Replace the pickup coil if not within the specifications.
this
chapte
unit.
With the engine running, gradually apply vacuum to the advance while watching the timing marks with the timing light.
5
To check the pickup
wires and use an
If
it
unit
doesn't advance, but the
the distributor
is
binding.
doesn't advance, and the unit does not hold vacuum, replace the
Cordia/Tredia 2.0L (1986 ttirougti 1988)
If
unit.
it
Disconnect the pickup
coil leads (see illustration 12.7b). Using and ohmmeter, check the resistance between the terminals c the pickup coil. 10 Compare the reading to the specification at the beginning c
8 9
Chapter 5 this
Chapter.
11
Replace the pickup
12
Engine
electrical
butor. coil
Centrifugal advance
if
not within the specifications.
mechanism - check
1
line(s)
and 12.7d from vacuum advance
(g)®
12.7a
Connect a timing
3 4
Start the engine.
5 6
to illustrations 12.7a. 12.7b, 12.7c
Detach the vacuum
2
light
according to
it's
manufacturer's instructions.
While watching the timing marks with the use of the timing speed while watching the timing marks advance. The timing should advance smoothly. If
the timing
unit
on the
distri-
7
damage
or binding.
Replace parts as needed (see illustrations).
®
Rotor shaft Spring retainers
1
Breattier
13
2
Cap
14
3 4 5 6 7 8 9
Contact carbon Rotor Cable assembly
15 16 17
Distributor shaft
Ground wire
18
Oil seal
Igniter
19
Dowel pin
20
Packing Housing
Signal rotor
21
O-ring
Advance plate Vacuum advance Vacuum advance
unit (dual-diaphragm type)
22 23
Driven gear
unit (single-diaphragm type)
24
Pin
11
12
raise
does not advance smoothly, check the advance weights,
springs and plate for
Exploded view of the distributor for Cordia and Tredia 2.0L (1984 and 1985), Galant (1985 and 1986), Mirage 1.5L (1985 through 1988) and Precis (1987 through 1989)
10
light,
the engine
and component replacement Refer
5-7
systems
Centrifugal advance springs Centrifugal advance weights
Washer
5-8
Chapter 5
Engine
electrical
Pickup
systems
coil
Dust-proof cover for signal generator
Rotor
@r^« Advance Igniter
plate
(may be outside
distributor)
Dust-proof cover for igniter
Vacuum advance
unit
Centrifugal advance weights
Centrifugal advance springs
Signal rotor shaft assembly
12.7b
Exploded view of the distributor
Packing
for Cordia
and Tredia 2.0L (1986 through 1988)
(
I
Chapter 5
Engine
electrical
5-9
systems
G^
1
2.7c
Exploded view of the distributor for Cordis and Tredia 1 .8L Turbo through 1988) and Mirage 1.6L (1986 through 1988)
(1
986
Breather
10
Screw
18
Centrifugal advance spring
2
Cap
11
Signal rotor
19
Centrifugal advance weight
3
Contact carbon Rotor
12 13
Screw
20
Spring pin
Pick-up coil
21
Cover
14
Stator
Driven gear O-ring
Seal ring Snap-ring
8 9
Vacuum advance Screw
15 16 17
Rotor shaft
7
22 23 24 25
1
4
5 6
unit
Pin
Spring retainer
Shaft Oil seal
Housing
5-10
Chapter 5
12.7d
Engine
electrical
systems
Exploded view of the distributor for Cordia and Tredia 1.8L Turbo (1984 and 1985) and IMirage 1.6L (1985)
1
2 3
Breather
Cap
12 13
Breaker Plate
Contact carbon Rotor
14
Washer
15
Shaft
Centrifugal
advance springs advance plate Centrifugal advance weights Centrifugal advance base
16
Bearing
Centrifugal
17
Oil seal
18 19
Housing
Signal rotor
20
Spring pin
10
Pickup
21
11
Ignitor
Gear Vacuum
4
5 6 7 8 9
coil
22
O-ring
control
)
.
Chapter 5
Engine
5-11
systems
electrical
tumed to Start, then go oft immediately.
If it remains on. there is a malfunccharging system (see Section 14). Be very careful when making electrical circuit connections to a vehicle
tion in the
equipped with an alternator and note the following: a) When reconnecting wires to the alternator from the
battery,
be sure
to note the polarity.
b)
Before using arc welding equipment to repair any part of the vehicle, disconnect the wires from the alternator and the battery terminals.
c)
d)
Never start the engine with a battery charger connected. Always disconnect both battery leads before using a battery charger.
e)
The
alternator
serious injury
turned by an engine drivebelt which could cause your hands, hair or clothes become entangled in it
is
if
with the engine running. f)
Because the alternator is connected directly to the battery, could cause a fire overloaded or shorted out. Wrap a plastic bag over the alternator and secure with rubberbands before steam cleaning the engine. it
arc or g)
To adjust the air gap between the igniter and the signal rotor, loosen the igniter mounting screws, insert a feeler gauge of the specified thickness between the igniter and one of the signal 13.2
if
it
push the igniter against the gauge and tighten the mounting screws
rotor projections,
Charging system - check
15
1
If
a malfunction occurs
in
the charging
circuit,
assume that the alternator is causing the problem. Distributor pickup air
13
gap - check and adjustment
follow-
Check
the drivebelt tension and condition (Chapter 1 ). Replace worn or deteriorated. Make sure the alternator mounting and adjustment bolts are tight. Inspect the alternator wiring harness and the connectors at the alternator. They must be in good condition and tight.
Refer to illustration 13.2
b)
procedure applies to Cordis and Tredia 2.0L (1983 through Galant (all models), Mirage 1.5L (1985 through 1 988) and Precis
Ttiis
.(1987 through 1989)
c)
d)
it
it's
if
1988),
check the
ing items: a)
Note:
don't automatically
First
Check the fusible
link(s).
If
burned, determine the cause, repair the
2
and replace the link (the vehicle won't start and/or the accessories won't work if the fusible link blows). Sometimes a fusible link may look good, but still be bad. If in doubt, remove and check for
thickness listed
continuity.
Anytime you disturb the pickup
|1
air
gap
in
the distributor
it
circuit
must be
properly adjusted.
Loosen the pickup mounting screws. Place a feeler gauge of the in this Chapter's Specifications between one of the projections on the signal rotor and the pickup (see illustration). Gently push the pickup toward the signal rotor until it's a snug - not 3 tight - fit against the feeler gauge. Tighten the pickup mounting screws. J4 i5 Check the adjustment by noting the amount of drag on the feeler gauge when you pull out of the gap between the signal rotor and the pickup. You should feel a slight amount of drag. If you feel excessive drag on the gauge, the gap is probably too small. If you don't feel any drag on the gauge when you pull out, the air gap is too large.
it
e)
(a
shrieking or squealing f)
g)
it
'
and check the alternator for abnormal noises sound indicates a bad bearing).
Start the engine
Check the
specific gravity of the battery electrolyte.
If
it's
low,
charge the battery (doesn't apply to maintenance free batteries). Make sure the battery is fully charged (one bad cell in a battery can cause overcharging by the alternator). Disconnect the battery cables (negative
h)
first,
then positive).
In-
spect the battery posts and the cable clamps for corrosion. Clean
them thoroughly necessary (see Chapter 1 if
it
)
.
Reconnect the cable
to the positive terminal. i)
With the key
off,
connect a
test light
between the negative battery
post and the disconnected negative cable clamp. If
1
Charging system - general information and precautions
14
the test
ceed 2)
The charging system includes the regulator, the battery, the fusible link(s)
The charging system supplies electrical power for the ignition systhe lights, the radio, etc. The alternator is driven by a drivebelt at the
nents.
tem,
front of the
I
;
!
to
of the voltage regulator
is
to limit the alternator's voltage
a preset value. This prevents power surges,
circuit
overloads,
etc., dur-
peak voltage output. The fusible link can be either a short length of insulated wire integral with the engine compartment wiring harness or afuse-like device installed in the underhood electrical panel. See Chapter 1 2 for additional informaing
tion
regarding fusible
links.
The charging system doesn't ordinarily require periodic maintenance. However, the drivebelt, battery and wires and connections should be inspected
Chapter 1 should come on when the
light
the test
light
comes on, there is a short (drain) in the electrical The short must be repaired before the
Disconnect the alternator wiring harness. (a)
If
the
light
goes
(b)
If
the
light
stays on, pull each fuse
out, the alternator
key
is
bad.
is
until
the
light
goes out
you which component is shorted). Using a voltmeter, check the battery voltage with the engine off. If 2 should be approximately 12-volts. Start the engine and check the battery voltage again. It should now be 3 approximately 14-to- 15 volts. 4 Turn on the headlights. The voltage should drop, and then come back up, if the charging system is working properly. 5 If the voltage reading is more than the specified charging voltage, re(this will tell
place the voltage regulator (refer to Section 16). ,
ignition
pro-
of the vehicle.
alternator diode(s) stator or rectifier
at the intervals outlined in
The dashboard warning
does not come on, reattach the clamp and
charging system can be checked. 3)
engine.
The purpose
j
If
system
an integral voltage and wiring between all the compo-
alternator, with
light
to the next step.
may be
malfunctioning.
may be bad
If
the voltage
is
less, the
or the voltage regulator
5-12
Chapter 5
16.2
Engine
electrical
systems
Typical Cordia and Tredia
mounting
alternator
details
(others similar)
Power steering
1
oil
pump assembly 2 3
Alternator
4
Electrical connection
Bracket
1
6.25
Mirage
alternator 1
(1
989 on) details
Air conditioner drivebelt
Power steering
3
Drivebelt
4
Water pump pulley Water pump pulley Alternator brace
drivebelt
Electrical connection
Alternator
Alternator - removal and installation
Cordia, Precis Refer 1
.5L
2
5 6 7 8
16
1
mounting
and
2
3 4 5 6
Tredia
to illustration 16.2
Remove the drivebelts tor the power steering
nator (see Chapter
1).
oil
pump and
the alter-
Remove Remove Remove
the
oil
pump
(see illustration).
the lower mounting bolt for the alternator.
Detach the
Remove
power steering
the adjusting bracket for the alternator.
electrical
connectors from the alternator.
the alternator. the reverse of removal.
7
Installation
8
Adjust the belts tension (see Chapter
is
1 ).
1 3 4 6 5 8 9 7
Chapter 5
Engine
electrical
5-13
systems
Mirage 1.6L (1989 on)
16.32
alternator 1
2
Power steering drivebelt
3 4 5 6 7
Water pump pulley Water pump pulley Alternator brace assembly Electrical connector
8 9
Battery
10
Galant Remove the left fan motor. Remove the drivebelts for the power steering oil pump and the alter-
9 1
nator (see Chapter
27 28 29 30
Remove Remove
Label and detach the electrical connectors from the alternator.
31
the lower mounting bolt from the alternator.
(see Chapter
1
Remove Remove
the alternator.
1
Installation
1
Adjust the belts tension (see Chapter
32 33 34 35 36 37 38 39
the reverse of removal. 1 ).
Mirage (1985 through 1988) Remove the alternator drivebelt and any other belt interfering with
removal (see Chapter
Remove
1
Label and detach the alternator electrical connectors.
21
22 23
its
1).
1
20
the alternator mounting bolts.
Remove any component Remove the alternator. Installation
is
Radiator Alternator
the alternator. is
the reverse of removal.
Adjust the belts tension (see Chapter
12
1
11
12
1 ).
1.6L
the alternator brace.
is
Washer tank Battery tray
1).
Remove
1
Battery holder
the lower mounting bolt from the alternator.
Installation
1
mounting details
Drivebelt
Remove the drivebelts for the power steering pump and the alternator Remove Remove Remove
1).
the water
pump
pulleys (see illustration).
the alternator brace. the radiator (see Chapter
3).
Label and detach the electrical connectors from the alternator.
Remove Remove
the lower mounting bolt from the alternator.
the alternator.
Installation
is
the reverse of removal
Adjust the belts tension (see Chapter
1 ).
interfering with alternator removal.
17
Voltage regulator/alternator brushes - replacement
the reverse of removal.
Adjust the belt(s) tension (see Chapter
1 ).
1988 Precis (Bosch type) Refer
Mirage (1989 on) Refer to illustrations 16.25
and 16.32
1.5L 24 Remove the drivebelts for the power steering, air conditioning and the alternator (see Chapter 1). 25 Remove the alternator brace (see illustration). 26 Label and detach the electrical connectors from the alternator.
to illustrations 17.2, 17.3
and
17.4
you are replacing the brushes (but not the regulator itself), the following procedure requires that you unsolder the old brush leads from the regulator and solder the new ones into place. Unless you are skilled with a soldering gun, have this procedure performed by someone who is. If you overheat and damage the regulator, you could end up spending a lot more Note
:
If
money than necessary. Remove the alternator. 1
5-14
Chapter 5
1 7.2 To detach the voltage regulator/brush holder assembly, remove the two mounting screws (arrows) and pull the regulator/brush holder straight out
17.10a
1
7.3
ruler
Engine
electrical
systems
Measure the brushes with a small - if they're shorter than 3/16 of an inch, install new ones
Heating the rear bearing box of the alternator splitting the alternator easier
will
make 1
17.11 1
Alternator pulley
2
Seal Rotor assembly Rear bearing Bearing retainer Front bearing
3 4
5 6
To detach worn brushes from the voltage regulator/brush holder assembly, carefully unsolder the brush leads and extract each brush and lead from the holder
17.4
7.1
Ob
Use two screwdrivers
to split the alternator
Exploded view of the Meico type alternator
Terminal
14
Brush Brush spring Slinger (if equipped)
10
Plate
15
Rectifier
11
Regulator and
16
Rear bracket
7 8 9
Front bracket
12
Stator
13
brush holder
Chapter 5 If
L
ItfUf/^l
...III Try
B^
V
Limit line
17.12a
Wear
If
mm (.079-. 118
17.12b
line,
If
the brushes are being replaced, unsolder and solder the pigtails at the area shown
Wire
in.)'
ami 17.13
limit line
the brushes are worn past the wear limit they should be replaced
3
3
5-15
systems
electrical
Soldered
o
2
Engine
1^
When
Remove Remove
installing new brushes, they should extend out of the holder the proper amount
the voltage regulator mounting screw^s (see illustration). the regulator/brush holder assembly and
length of the brushes (see illustration).
If
Wire
measure the
they are less than 3/16-inch
them with new ones. Note: Ifyou're simply replacing the voltage regulator, skip the next step - the new regulator assembly includes a new set of brushes so the following step is unnecessary. :4 Unsolder the brush wiring connections (see illustration) and remove [the brushes and springs. long, replace
!5
Installation is the
reverse of removal.
When placing the two covers together, use a piece of wire through the rear case and into the brush holder to retain the brushes in the holder
17.14
Be sure to solder the new brush
(leads properly.
I
i
I
All others Refer
(Meico type)
to illustrations
1 7. 1
0a, 17.10b, 17.11, 17.12a, 17.12b, 17.13
and
\\l714 ;
(
j
f
j
,"
1 '
j
i
6 7 8
18
Remove the alternator (see Section 1 6). Remove the bolts retaining the two halves of the alternator together. Mount the front of the alternator face down in a vise. Using rags as a
cushion, clamp to the front case portion of the alternator.
9 10
Remove
all
nuts from the back of the alternator.
Using a 200-watt soldering
iron,
heat the rear bearing area (bearing
box) of the rear case (see illustration). Insert two standard screwdrivers
J
, '
I
'
[
The sole function of the starting system is to turn over the engine quickenough to allow it to start. The starting system consists of the battery, the starter motor, the starter solenoid and the wires connecting them. The solenoid is mounted dily
rectly
on the
starter motor.
The solenoid/starter motor assembly is
installed
on the transaxle
bell-
between the two halves of the alternator (not too deep or you will damage the stator) and pry the rear case off the alternator (see illustration). Caution: Pry gently or you'll break the delicate aluminum case.
housing.
Unsolder the regulator/brush holder (see illustration). Note: While applying heat to electrical components, it's a good idea to use a pair of needle-nose pliers as a heat sink. Don t apply heat for more than about five seconds. 12 Inspect the brushes for excessive wear (see illustration) and replace them if necessary by unsoldering (see illustration). 1 3 When installing new brushes, solder the pigtails so the brush limit line will be about 0.079 to 0.1 1 8 in. above the end of the brush holder (see il-
then connects the battery to the starter. The battery supplies the electrical energy to the starter motor, which does the actual work of cranking the en-
carefully
11
i
system - general information and precautions
Starting
When the noid
is
To reassemble, compress the brushes into their holder and retain them with a straight piece of wire that can be pulled from the back of the
when reassembled (see illustration). To reassemble, reverse disassembly procedure.
alternator
15
key
is
turned to the Start position, the starter solecircuit.
The
starter solenoid
gine.
Always observe the following precautions when working on the
start-
ing system: a)
Excessive cranking of the starter motor can overheat it and cause damage. Never operate the starter motor for more than 30 seconds at a time without pausing to allow it to cool for at least two serious
minutes.
lustration).
14
ignition
actuated through the starter control
b)
c)
The
starter is connected directly to the battery and could arc or cause a fire if mishandled, overloaded or shorted out. Always detach the cable from the negative terminal of the battery before working on the starting system.
1
.
5-16 19
Chapter 5
motor - testing
Starter
in
Engine
electrical
systems
vehicle
Note: Before diagnosing starter problems, charged.
make sure
the battery
is fully
1 the starter motor does not turn at all when the switch is operated, make sure that the shift lever is in Neutral or Park (automatic transmission) If
or that the clutch pedal
is
depressed (manual transmission).
t^ake sure that the battery is charged and that all cables, both at the battery and starter solenoid terminals, are clean and secure.
2 3
If
the starter motor spins but the engine
ning clutch
in
the starter motor
is
slipping
not cranking, the overrun-
is
and the
starter
motor must be
replaced.
4 all
If,
when the switch
is
actuated, the starter motor does not operate at
but the solenoid clicks, then the problem
lies
with either the battery, the
main solenoid contacts or the starter motor itself (or the engine is seized). 5 If the solenoid plunger cannot be heard when the switch is actuated, the battery is bad, the fusible link is burned (the circuit is open) or the solenoid
itself is
defective.
20.3
To check the solenoid, connect a jumper lead between the battery {+) and the ignition switch wire terminal (the small terminal) on the solenoid. If the starter motor now operates, the solenoid is OK and the problem is in
Typical mounting details for the starter motor
6
the ignition switch, neutral start switch or the wiring.
20
does not operate, remove the starter/solenoid assembly for disassembly, testing and repair. If the starter motor cranks the engine at an abnormally slow speed, 8 first make sure that the battery is charged and that all terminal connections are tight. If the engine is partially seized, or has the wrong viscosity oil in it, 7
If
the starter motor
it will crank slowly. 9 Run the engine until normal operating temperature is reached. On engines equipped with a DIS ignition system, relieve the fuel pressure and leave the fuel pump disconnected throughout testing (see Chapter 4). On all others, disconnect the coil wire from the distributor cap and ground it on
Refer 1
2
motor - removal and
installation
to illustration
20.3
Detach the cable from the negative terminal of the battery. Clearly label, then disconnect the wires from the terminals on the
starter solenoid.
3 4
21
the engine.
10
Starter
still
Remove the mounting bolts (see illustration) and remove the starter Installation is the reverse of removal.
Starter solenoid
- removal and
installation
On all models, connect a voltmeter positive lead to the positive battery Refer
post and connect the negative lead to the negative post.
Crankthe engine and take the voltmeter readings as soon as a steady figure is indicated. Do not allow the starter motor to turn for more than 30 seconds at a time. A reading of 9 volts or more, with the starter motor turn1
ing at normal cranking speed,
the cranking speed
is
is
normal.
slow, the motor
If
the reading
is faulty.
If
is
9 volts or more but
the reading
is
less than 9
and the cranking speed is slow, the solenoid contacts are probably burned, the starter motor is bad, the battery is discharged or there is a bad
volts
connection.
21 .3
To separate the solenoid from the starter motor, remove the nut and detach the lead (arrow) .
.
1
2 3
to illustration
21.3 and 21.4
^
,;,
Disconnect the cable from the negative terminal of the battery. Remove the starter motor (see Section 1 9). Disconnectthe large motor lead from the solenoid terminal (see illus-
tration).
Remove the screws which secure the solenoid (see illustration). Pull the solenoid from the starter body flange. 5 6 Installation is the reverse of removal. 4
21.4
...
and
to the starter
motor
then remove the solenoid mounting screws (arrows) pull the solenoid straight off the starter flange
11
Emissions control systems
Chapter 6 Contents
8 13
Catalytic converter
Computerized Engine Controls (CEC) Deceleration devices (carbureted models) Evaporative emission control system Evaporative emission control system check and canister replacement Exhaust Gas Recirculation (EGR) system General information Heated Air Intake (HAI) system (carbureted models) High altitude compensation system
9 3
Idle-up
system (carbureted models) (1 988 and earlier models)
Mixture Control Valves (carbureted models)
Oxygen sensor replacement Positive
See Chapter
Crankcase Crankcase
Ventilation
1
Positive
6
and replacement Secondary air supply system
1
4 12
General information
11
Jet air system
Ventilation
Thermostatically controlled
air
(PCV) system (PCV) valve check
^
See Chapter
1
7 cleaner check
control devices requires specialized tools,
Remember,
5 10 See Chapter 1 2
See Chapter
equipment and
1
training.
the most frequent cause of emissions control problems
is
vacuum hose or wire, so always check the hose and wiring connections a problem is suspected. Note: Because of a Federally mandated extended warranty which covers the emission control simply a loose or broken
To prevent pollution
of the
atmosphere from incompletely burned and
evaporating gases, and to maintain good driveabillty and fuel economy,
a number of emission control systems and devices are incorporated. They include the: Positive
Crankcase
Ventilation
(PCV) system
Evaporative emission control system
Heated Air Intake (HAI) system (carbureted models) and on models) Exhaust Gas Recirculation (EGR) system Secondary air supply system (except MPI models)
Jet air system (except 1989
Catalytic converter
Deceleration devices (carbureted models)
Before assuming that an emissions control system
check the
fuel
and
ignition
systems
carefully.
is
malfunctioning,
The diagnosis
of
emission
if
system components, check with your dealer about warranty coverage before working on any emissions-related systems. Pay close attention to any special precautions outlined in this Chapter. It should be noted that the illustrations of the various systems may not exactly match the system installed on your vehicle because of changes made by the manufacture during production or from year-to-year.
A Vehicle Emissions Control Information (VECI) label is located in the engine compartment. This label contains important emissions specifications and adjustment information, as well as a vacuum hose schematic with emissionscomponents identified. When servicing the engine or emissions systems, the VECI label in your particular vehicle should always be checked
for up-to-date information.
.
6-2
Emissions control systems
Chapter 6
valve closes, the bowl vent valve opens to connect the carburetor bowl to the canister, allowing fuel vapors to flow to the canister where they are
Positive Crankcase Ventilation (PCV) system
2
stored 1 The Positive Crankcase Ventilation (PCV) system reduces hydrocarbon emissions by scavenging crankcase vapors. It does this by circulating fresh air from the air cleaner through the crankcase, where mixes with blow-by gases and is then rerouted through a PCV valve to the intake it
until
the next time the key
is
turned on.
Purge control system The purge control system is closed during idle to prevent vaporized from entering the intake manifold. At higher engine speeds, the purge control valve opens. 5
fuel
manifold.
2
The main components of the PCV system are the PCV valve, a fresh and the vacuum hoses connecting these two components
air filtered inlet
with the engine.
3
To maintain
idle quality,
vacuum
PCV valve
the
restricts the flow
when
the
in-
and high load conditions, vacuum is low, so the PCV passage opens more to facilitate flow. 4 Checking and replacement of the PCV valve and filter is covered in take manifold
Chapter
is
high. During acceleration
1
Thermo valve The thermo valve, which monitors the engine coolant temperature at 6 the intake manifold, controls the purge control sytem when the engine coolant temperature
is
lower than the pre-set temperature. This reduces
CO
and HC emissions under engine warmup conditions. The thermo valve opens the purge control system when the engine coolant temperature is above the pre-set temperature. The thermo valve also controls the choke breaker, EGR valve and choke opener.
Fuel
cap
filler
The fuel filler cap is equipped with a vacuum escape of fuel vapor into the atmosphere. 7
Evaporative emission control system
3
relief
valve to prevent the
Overfill limiter Refer
to illustrations 3.2a, 3.2b,
3.2c
and 3. 2d
8
Warning: Gasoline is extremely flammable, so take extra precautions wtien you work on any part of the fuel system. Don smoke or allow open flames or bare light bulbs near the work area, and don work in a garage where a natural gas-type appliance (such as a water heater or clothes dryer) with a pilot light is present. If you spill any fuel on your skin, rinse it off immediately with soap and water When you perform any kind of work on the fuel system, wear safety glasses and have a Class B type fire extinguisher on hand.
The typical overfill limiter consists of two valves: The pressure valve, which opens when fuel tank internal pressure
a)
exceeds normal pressure.
't
't
1 The evaporative emission control system is designed to prevent the escape of fuel vapors from the fuel system into the atmosphere. 2 The typical evaporative emission control system consists of a canister, a bowl vent valve, a purge control system, an overfill limiter, a thermo valve, a fuel check valve and a specially designed fuel filler cap (see illus-
b)
The vacuum is
valve, which
opens when
fuel
tank internal pressure
lower than normal pressure.
Fuel check valve The fuel check valve, prevents fuel leaks in the event of a vehicle rolThe valve contains two balls. Under normal conditions, the fuel vapor passage in the valve is open, but, should the vehicle roll over, one of 9
lover.
the balls closes the fuel passage, preventing fuel leakage.
4
Heated Air Intake (HAI) system (carbureted models)
trations).
Refer
Canister When the engine is inoperative, fuel vapors generated inside the fuel
3
tank and the carburetor float chamber are absorbed and stored ister.
in
the can-
When the engine is running, the fuel vapors absorbed in the canister
are drawn into the intake manifold through the purge control.
to illustration 4.2
Carbureted models are equipped with a F4eated Air Intake (HAI) system to permit leaner carburetion, which reduces HC and CO emissions, improves warm-up characteristics and minimizes carburetor icing. 2 The air cleaner is equipped with an air control valve inside the snorkel to regulate the temperature of intake air, which is admitted to the carburetor through the fresh air duct, the heat cowl and air duct, or through both 1
routes (see illustration).
Bowl vent valve (carbureted models) 4 The bowl vent valve controls the carburetor bowl vapors. When the engine is running, intake vacuum acts on a diaphragm to close the bowl vent valve so that the bowl is connected to an air vent. During engine operation, the diaphragm is kept open by a solenoid valve - even when intake manifold vacuum falls to a value equal to atmospheric pressure - as long as the ignition key is turned on. When the key is turned off, the solenoid
Fueliniector
To thernno valve .j^.^^3^g^,Q3g
Purge control valve
Fuel check valve
Fuel
filler
(vacuum Air cleaner
Bowl vent valve
Overfill limiter
To ttiermo
valve Overfill limiter
Purge
(Leveling tube)
Air cleaner
(2-way valve) Carburetor' Carburetor float
chamber
control
Fuel
valve
(Vacuum
filler
cap relief) I
^
Engine
„
Canister
4-HlV
^
Intake manifold
—
Orifice
Canister
Fuel vapor
Purge
air
Fuel ctieck valve
Fuel tank
Overfill linniter
(2-way valve)
Filter
3.2a
Details of the evaporative emission control for carbureted
models
(typical)
system
3.2b
Details of tfie evaporative emission control for TBI
models
(typical)
system
cap relief)
Chapter 6
Throttle
6-3
Emissions control systems
body
Engine coolant temperature sensor
Details of the evaporative emission control
3.2c
for 1.5L
MPI models
system
(typical)
Canister
Engine coolant tennperature sensor
6
3.2d
Details of the evaporative emission control
system
for 1.6L
MPI models
(typical)
Vacuum motor Fresh
Air cleaner air
Temperature sensor
duct
Intake
manifold
vacuum
Exhaust manifold
4.2 The Heated Air Intake (HAI) system: when the engine is cold, the temperature sensor allows intake manifold vacuum to the vacuum motor, which opens the air control valve, allowing hot air to be drawn into the air cleaner through the heat cowl and air duct
1
1
6-4
Chapter 6
Emissions controi systems valve, which
terrupts the
senses engine temperature. The thermo valve invacuum signal to the EGR valve during warm-up when
less NOx is generated and less EGR promotes better driveability. The sub-EGR valve opens and closes with the throttle valve via a
c)
linkage to regulate
EGR flow through
the
EGR
valve
in
response,
to the throttle valve position.
3
um
On another type of EGR system no sub-EGR valve is used. A VacuRegulator Valve (VRV) is used to modulate the vacuum signal to the
EGR valve.
7
Intake stroke
Refer
The
valve (arrow) allows a super lean mixture to be admitted Into the combustion chamber during the intake stroke
3
The
sensor
in
jet
air control
the
air
valve
When
operated by a vacuum motor. A temperature when the vacuum motor receives intake intake air is below about 86-degrees F, the tem-
vacuum
vacuum
to to the
valve up and causes hot
motor.
be drawn through 1 1 3-degrees F, the temperature sensor does not allow vacuum to the vacuum motor and the air control valve remains down. This causes cold air to be drawn through the fresh air duct. When intake air temperature is between about 86 to 1 1 3-degrees F, the air control valve is partially open and intake air is a blend of air drawn through both routes. air control
the heat cowl and
duct.
air
Jet air system
Refer
(1
ber
8
Catalytic converter
air to
When intake air is above about
988 and earlier models)
Refer
to illustration
1 The catalytic converter is an emission control device added to the exhaust system to reduce pollutants from the exhaust gas stream. The converter(s) being used are a three-way catalyst type (see illus2 tration). It lowers the levels of oxides of nitrogen (NOx) as well as hydro-
to illustration 5.
In
9
Deceleration devices (carbureted models)
is
Deceleration spark advance system advanced during deceleration by a vacuum advance This unit normally has ported vacuum applied to but when the vehicle is decelerating, the Electronic Control Unit (ECU) sends a signal to a solenoid valve which opens to apply the higher vacuum from the intake manifold. This advances the ignition timing, reducing HC 1
unit
Ignition timing
on the
is
distributor.
it,
emissions.
Dashpot 2 ing
3
The carburetor
HC
throttle
is
equipped with a dashpot which slows the rate at its normal idling position, thereby reduc-
valve closes to
emissions.
For further information on the dashpot, refer to Chapter
4.
Exhaust Gas Recirculation (EGR) system
6
The Exhaust Gas
(EGR) system is designed to reduce The EGR system recirculates a of the exhaust gas from an exhaust port in the cylinder head into a
oxides of nitrogen portion
in
Recirculation
the vehicle exhaust.
port located in the intake manifold.
2
'
emissions-related components suet) as ttie catalytic converter, cfieck with a dealer service department before replacing ttie converter at your own expense.
which the
1
8.2
Note: Because of a Federally mandated extended warranty wfiict) covers
carbons (HC) and carbon monoxide (CO).
addition to the intake and exhaust valves, each combustion chamequipped with a smaller jet valve (see illustration) which allows a super lean mixture to be admitted into the combustion chamber during the intake stroke. This super lean mixture swirls as it enters the combustion chamber. The swirl continues throughout the compression stroke and improves flame propagation after ignition, assuring efficient combustion. 2 Air is admitted through intake openings located near the primary throttle valve of the carburetor, then routed to the jet valve via a passage through the intake manifold and cylinder head, where it is drawn through the jet valve opening into the combustion chamber. The jet valve is operated by a forked rocker arm which also activates 3 the intake valve (they share the same cam lobe). This design ensures that the intake and jet valve open simultaneously. 1
to illustration 7.
The secondary
is
perature sensor allows intake manifold
5
supply system
cleaner controls
manifold vacuum. This draws the
air
air supply system (see illustration), installed on all models except those equipped with MPI, delivers air to the front catalytict converter through a reed valve(s) to promote further oxidation of exhaust; emissions during engine warm-up, deceleration and heavy engine loads. The reed valve(s) is actuated by vacuum generated by exhaust pulsation. The system is controlled by the secondary air control valve, a sole2 noid valve and the vehicle's Electronic Control Unit (ECU). 1
5.1
Secondary
On one type of EGR system EGR flow is controlled by an EGR valve,
a sub-EGR valve
(if
equipped) and a thermo valve (see illustration
The
EGR valve
throttle
is
controlled by carburetor
valve opening;
wide open b)
Mixture Control Valves (carbureted models)
Cordia/Tredia (1984 through 1986), Mirage (1985) and Precis (1987) Deceleration Solenoid Valve (DSV)
13.1a). a)
10
EGR
flow
is
vacuum
suspended
at
response to idle and during in
to the
EGR valve
When the throttle is closed suddenly during deceleration, the remain-
prevent
throttle conditions.
The vacuum applied
1
ing fuel in the intake manifold
is
controlled by a thermo
2
this,
causes a temporarily overrich mixture. To
the solenoid shuts
The solenoid
also shuts
off
off
the fuel (see illustration 13.1a).
the fuel
when
the engine
is
switched
off.
Secondary
air
6-5
Emissions control systems
Chapter 6
control
solenoid valve
Engine speed Cootoant temp, sensor Idle position
switch
Air cleaner
Reed valve
Front catalytic
Intake nnanifold
converte
Details of the
7.1
secondary
air
supply system
Slow Cut Solenoid Valve (SCSV) This solenoid is used 6 (see illustration 13.1b).
to
reduce the
rich
mixture during deceleration
Mixture Control Valve (MCV) (1988 and 1989 Precis) 7
When the throttle is closed suddenly during deceleration, the remain-
causes a temporarily overrich mixture. To prevent this, the solenoid temporarily supplies air from another passage to correct the air to fuel ratio and reduce emissions. ing fuel in the intake manifold
cfUTTi
zif.
11
8.2
Some models use two
Idle-up
system (carbureted models)
catalytic converters,
others only use one 1
Front converter
2
Rear converter
(if
Electrical load or power steering load
equipped)
Refer 1
to illustration 11.1
This idle-up system consists of a dashpot assembly, a solenoid valve,
sensing circuitry and an oil pump pressure switch in the power steering system (see illustration). When there is an electrical load or power steering load at idle that re2 electrical load
Enrichment Solenoid Valve (ESV) 3 gine
This solenoid is
is
used
to supply extra fuel that
cold or heavy acceleration
is
is
needed when the en-
quires a greater engine speed, the solenoid valve
Jet Solenoid Valve (JSV) This solenoid is the main air to fuel ratio controller (see illustration 4 13.1 a). The amount of time it is energized will be increased as more fuel is needed.
throttle shaft.
Air conditioning load 3
and
and the ECU (see illustration). 4 When the air conditioning compressor is engaged at idle, a greater engine speed is required, the solenoid valve is opened, allowing vacuum
Feedback Solenoid Valve (FBSV) When
to illustration 11.3
This idle-up system consists of a throttle opener assembly, a solenoid
valve, an air conditioning switch
1989)
This solenoid works to maintain the proper air to fuel ratio. 5 energized the vehicle will run leaner (see illustration 13.1b).
opened, allowing vac-
the dashpot opens the throttle valve slightly via the idle-up lever on the
Refer
Cordia/Tredia (1987 and 1988), Mirage (1986 through 1988) and Precis (1988
is
uum from the intake manifold to act on the dashpot. This vacuum acting on
required (see illustration 13.1a).
it
is
to act on the throttle opener. This vacuum acting opener causes the engine speed to increase.
from the intake manifold
on the
throttle
6
1
6-6
Chapter 6
Emissions control systems
Solenoid valve (Closed)
To intake manifold
^^ ^ Solenoid valve (Opened) Electrical
'"^
T-!^^Wi
l
To intake
load switch iT J
ECU
nnanifold
Throttle opener setting screw
a Power \
V
steering
T
switch
Throttle valve
Battery
11.1
Details of the idle-up
Air conditioning
,
Throttle
r
linkages and the
speedome-
cable have been connected and that the transaxle has been
filled
with
proper level (see Chapter 1 ). 4 Install the battery and tray and connect the cables (negative cable ist). Road test the vehicle for proper operation and check for leaks. jbricant to the
if
Manual transaxle overhaul - general information ^efer to illustrations 4.4a
7A-5
Manual transaxle
and 4.4b
Overhauling a manual transaxle is a difficult job for the do-it-yourselfer. I involves the disassembly and reassembly of many small parts. Numer'
it
it
7A
4.4a
Back-up Gasket
Typical four-speed transaxle
components - exploded view
10
Spacers
19
Bolts
11
Breather
20
Steel ball
12
21
4
Bolt
13
5 6 7 8 9
Locking plate
14
Speedometer gear assembly
15
Bolt
16
Transaxle case
1
Outer bearing race
18
Gasket Poppet plugs Gasket Poppet springs Poppet balls Reverse idler gear shaft Reverse idler gear
Reverse Reverse
1
2 3
light
switch
17 7
shift lever
assembly
shift rail
22 23
Spring pins
24
First/second shift fork
25 26 27
3rd/4th shift
First/second shift
rail
3rd/4th shift fork Interlock plungers
rail
28 29 30
Output shaft assembly
31
Intermediate gear assembly
32 33 34 35 36
Bolts
Spacer Differential
assembly
Bearing retainer Input shaft
assembly
Bearing outer race Clutch housing
7A-6
Chapter 7 Part
A
Manual transaxle
- but actually noting how they are installed when you remove make much easier to get the transaxle back together. Before taking the transaxle apart for repair, will help you have some
the parts go the parts
will
it
it
idea what area of the transaxle
is
if
malfunctioning. Certain problems can
be closely tied to specific areas in the transaxle, which can make compo nent examination and replacement easier. Refer to the Troubleshooting section at the front of this
manual
for information
regarding possible
sources of trouble.
I
1—30 S 31
4.4b
Typical five-speed transaxle
5th gear actuator
12
Intermediate gear assembly
2
Collar
13
3 4
O-ring
14
Seat Locking plate
15
1
1
17 7
Speedometer gear assembly Reverse idler gear shaft Reverse idler gear Reverse shift gear Output shaft assembly
7
Seat
18
Outer bearing race
8 9
Input shaft assembly
19
Spacer
5 6
Select
rail
fork
16
assembly
assembly
Bearing retainer
20
Differential
10
Spacer
21
Reverse
11
Bearing outer race
22
First/second shift
shift rail rail
components - exploded view Interlock plunger
gear lug Selector spacer Poppet ball Poppet spring
33 34 35 36 37 38 39 40
31
Plug
41
Fifth
32
Interlock plunger
42
Clutch housing
23 24 25 26 27 28 29 30
First/second shift fork Third/fourth shift fork
Spring pin Third/fourth shift Fifth
rail
Transaxle bracket Clutch cable bracket
Backup Gasket
light
switch
Steel ball
Transaxle case Breather
gear actuator switch
3
'chapter? Part B
Automatic transaxle
Contents Automatic transaxle fluid and filter ctiange Automatic transaxle fluid level check Automatic transaxle - removal and installation Diagnosis - general General information Neutral start switch
See Chapter See Chapter
- check, replacement and adjustment
replacement
1
Oil seal
1
Selector linkage - removal, installation and adjustment
8
Throttle valve (TV) cable (three-speed models)
2
and adjustment Transaxle mount - check and replacement
1
- check
7
Specifications
7B
Clearances Selector lever assembly adjusting sleeve-to-lever end clearance (15.2 to 15.9
mm) mm) mm)
Throttle valve (TV) cable clearance
0.677 to 0.705 in (17.2 to 17.9 0.598 to 0.625 in (15.2 to 15.9 0.04 + 0.02 in (1 + 0.5 mm)
Torque specifications
Ft-ibs
Galant
0.598
to
0.625
1986 and 1987 on
earlier
Transaxle-to-engine bolts
mm mm X 20 mm X 60 mm X 40 mm X 55 mm X 65 mm
6 x
8 8 8 1 1 1
in
other models
All
X
1
2
7 to 9
1
2
22
to
36
1 1
to
1
filler
to
31 to
Torque converter-to-driveplate bolts Drain and
25 40 1 6 to 23 31 to 40 30 to 35 See Chapter 22
plugs
Throttle valve lower cable bracket bolt
10
Neutral start switch bolts
8
pan bolts Starter motor bolts
See Chapter
Fluid
20
to
25
1
1
2 3 4 5
:
7B-2
Chapter 7 Part B
behind the
Insert the tip of a large screwdriver (arrow)
seal
and very
carefully pry
oil
Automatic transaxie
Apply a
3.6
and
out
it
thin layer of
carefully tap
it
grease to the outer edge of the new seal bore with a large socket and hammer
into the
not proceed with the preliminary checks until
General information
it
has been repaired and
runs normally.
Check the throttle valve cable (if equipped) for freedom of movement. necessary (see Section 6). Note: The throttle valve cable may function properly when the engine is shut off and cold, but it may malfunction once the engine is hot. Check it cold and at normal engine operating
4 All
vehicles covered
manual come equipped with
in this
either a four
speed manual transaxie or a three-or four-speed automatic transaxle. All information on the automatic transaxie is included in this Part of Chapter 7. Information for the manual transaxie can be found in Part A of
or five
this
Due to the complexity of the automatic transaxie and the need for speequipment
to
perform most service operations,
removal and
this
Chapter conand
routine maintenance, adjustment
tains only general diagnosis,
the transaxie requires major repair work,
pense, even
if
Inspect the selector control cable (see Section
the repair work
is
(Vlost fluid
dure
may
may be caused by four general poor engine performance, improper adjustments, tiydraulic malfunctions or mechanical malfunctions. Diagnosis of these problems should always begin with a check of the easily repaired items: fluid level and condition (see Chapter 1), selector linkage adjustment and throttle linkage adjustment. Next, perform a road test to determine if the problem has been corrected or if more diagnosis is necessary. If the problem persists after the preliminary tests
and corrections are completed,
additional
diagnosis should be done by a dealer service department or transmission repair shop. Refer to the Troubleshooting section at the front of this
manu-
ture.
If
fluid level
the fluid level
as described
in
Chapter
1
unusually low, add enough
is
fluid to bring
within the designated area of the dipstick, then
check
If
is
abnormally high, drain
fluid tor
gine coolant
in
the level
the
fluid is
3
in
the excess, then check
contamination by coolant. The presence of en-
in
fail-
the internal radiator walls that separate the
coolant from the transmission If
off
the automatic transmission fluid indicates that a
ure has occurred
coolant
to find, the following proce-
Identify the fluid. IVIake sure fluid
it's
transmission
(automatic transmission
fluid is
fluid
and not engine oil or
a deep red
color).
Make a careful visual inspection of the suspected component and the 9 area immediately around it. Pay particular attention to gasket mating surfaces.
A
mirror
is
often helpful for finding leaks
in
areas that are hard
to
see. 1
If
the leak
still
cannot be found, clean the suspected area thoroughly
with a degreaser or solvent, then dry 11
it.
Drive the vehicle for several miles at normal operating temperature
and varying speeds. After driving the vehicle, visually inspect the suspected component again. 1 Once the leak has been located, the cause must be determined before can be properly repaired. a gasket is replaced but the sealing flange is bent, the new gasket will not stop the leak. The bent flange must be straightened. 1 Before attempting to repair a leak, check to make sure that the following conditions are corrected or they may cause another leak. Note: Some of the following conditions cannot be fixed without highly specialized tools and expertise. Such problems must be referred to a transmission shop or a If
dealer sen/ice department.
Gasket leaks
the fluid level
the drained
c)
is difficult
for external
leaks. b)
a leak
it
problem diagnosis.
Preliminary checks 1 Drive the vehicle to warm the transaxie to normal operating temperaCheck the
If
help.
Try to pinpoint the source of the leak. Dnve the vehicle several miles, 8 then park it over a large sheet of cardboard. After a minute or two, you should be able to locate the leak by determining the source of the fluid dripping onto the cardboard.
conditions:
a)
s
leaks are easy to locate visually. Repair usually consists of
replacing a seal or gasket.
7
done by a transmission shop.
Note: Automatic transaxie malfunctions
2
it
it
Diagnosis - general
al for transaxie
Make sure that
Fluid leak diagnosis 6
brake
2
5).
properly adjusted and that the linkage operates smoothly.
procedures.
installation
should be left to a dealer service department or an automotive or transmission repair shop. You can, however, remove and install the transaxie yourself and save the exIf
it if
temperature.
5
Chapter.
cialized
Adjust
foaming, drain
it
fluid
and
(see Chapter
refill
3).
the transaxie, then check for
the fluid or a high fluid level.
Check the engine idle speed. Note:
If the
engine is malfunctioning, do
1
Check the pan
may
indicate
periodically.
Make sure the bolts are tight, no bolts are
good condition and the pan is flat (dents in the pan damage to the valve body inside).
missing, the gasket
is in
is leaking, the fluid level or the fluid pressure may be may be plugged, the pan bolts may be too tight, the pan sealing flange may be warped, the sealing surface of the transaxie housing may be damaged, the gasket may be damaged or the transaxie casting may be cracked or porous. sealant instead of gasket material has been 1
If
the pan gasket
too high, the vent
If
1 3
8 9 7
Chapter 7 Part B
3.11
1
7B-3
Automatic transaxle
Driven gear assembly
component 1
details
O-ring
2 3
Spring pin
4
O-ring
5
Sleeve
3.12 When assembling the driven gear to the sleeve, make sure the spring pin is installed with the slit facing away from the shaft
Gear
used to form a seal between the pan and the transaxle housing, wrong sealant.
it
may be
Pfhe
,
16
';
If
check
a transaxle seal
is
leaking, the fluid level or pressure
may be
for
movement
too
may be plugged, the seal bore may be damaged, the seal may be damaged or improperly installed, the surface of the shaft protruding through the seal may be damaged or a loose bearing may be caushigh, the vent itself
ing excessive shaft 1
Make sure
good condition and the tube is speedometer transmission fluid is evident, check the O-
the dipstick tube seal
gear or sensor ring for
for
leakage.
If
is in
damage. Also inspect the side gear
shaft
oil
seals for leakage.
1
1
the case
to
Fluid comes out vent pipe or fill tube 20 If this condition occurs, the transaxle is overfilled, there is coolant in the fluid, the case is porous, the dipstick is incorrect, the vent is plugged or the drain back holes are plugged.
3
Oil seal
1
the
to illustrations 3.4, 3.6, 3.11
speedometer driven gear O-rings. Replacement of these seals is relasince the repairs can usually be performed without removing
lively easy,
The driveaxle oil seals are located at the sides of the transaxle, where
I
the driveaxles are attached.
If
leakage
at the seal is
suspected, raise the
and support securely on jackstands. If the seal cant will be found on the sides of the transaxle. Refer to Chapter 8 and remove the driveaxles. 3 vehicle
4
removed
with a screwdriver or pry bar, a spewill
be required.
Using a large section of pipe or a large deep socket as a drift, install the new oil seal (see illustration). Drive it into the bore squarely and make sure it's completely seated. 7
Install
the driveaxle(s).
Be
careful not to
damage
the
lip
of the
new
seal.
The speedometer cable and
driven gear housing
is
located on the
mine
if
the O-ring
is
leaking.
9
Disconnect the speedometer cable from the transaxle.
1
Unscrew the retaining bolt and remove the speedometer gear assem-
bly. 1 Drive out the spring pin and separate the driven gear from the sleeve (see illustration). 12 Install new O-rings on the driven gear and reassemble the housing using a new spring pin (see illustration). 1 Install the speedometer gear and cable assembly.
it
is
leaking, lubri-
Using a screwdriver or prybar, carefully pry the oil seal out of the trans-
axle bore (see illustration).
4
Transaxle mount - check and replacement
Refer
to illustration 4.
a large screwdriver or pry bar between the mount and transaxle it back and forth (see illustration). 2 The transaxle bracket should not move away from the mount. If it does, replace the mount. To replace a mount, support the transaxle with a jack, remove the nut 3 and through bolt and the bracket-to-transaxle bolts, then detach the mount. It may be necessary to lower the transaxle slightly to provide enough clearance to remove the mount. 4 Installation is the reverse of removal. 1
Insert
bracket and pry
the transaxle from the vehicle.
2
seal cannot be
replacement
and 3. 12 Oil leaks frequently occur due to wear of the driveaxle oil seals, and/or
Refer
oil
seal removal tool (available at auto parts stores)
transaxle housing. Look for lubricant around the cable housing to deter-
itself appears to be leaking, the casting is porous and will be repaired or replaced. Make sure the oil cooler hose fittings are tight and in good condition. If
the
If
cial oil
8
Case leaks have
5 6
movement.
properly seated. Periodically check the area around the
[
!
Pry on the transaxle mount with a large screwdriver to
4.1
Seal leaks
78
1
7B-4 5
Chapter 7 Part B
Automatic transaxle
Selector linkage - removal, installation and adjustment
Removal Refer 1
2 (if
to illustrations 5.2, 5.5a, 5.5b, 5.5c, 5.5d, 5.5e, 5.5f
and 5.5g
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orts '61 thm '73 models '66 thm '74 models '74 thm '90 all models '75 thm '82 a 760 Series all models '82 thm '88
120, 130 Series
140 240 260 740
Series Series Series
all
all
-
PEUGEOT 663
504
all
diesel
models
'74
thm
'83
Laser - see MITSUBISHI Eclipse (2097) Other PLYIHOUTH titles, see DOOOE
PONTIAC T1 000
J-2000
6000
- see CHEVROLET Chevette (449) - see GENERAL MOTORS (766) see GENERAL
SPECIAL MANUALS 1479 1654 1667 1480 1762 1736 1763 482 2060 1666 299 393 300
Automotive Body Refiair a Pakiting Manual Automotive Electrical Manual Automotive Emissions Control Manual Automotive Heating a Air Conditioning Manual Chevrolet Engine Overtiaul Manual GM a Ford Diesel Engine Repair Manual Ford Engine Overhaul Manual Fuel Injection Manual Holley Carburetor Manual Small Engine Repair Manual SU Carburetors thm '86 Weber Carburetors thm '79 Zenitti/Stromberg CD CartMiretors thm '76
MOTORS (829J
Over 100 Haynes motorcycle manuals
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Inc.,
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asterisl< (') indicate
Haynes North America,
Samurai/Sidakick/Geo Tracker
VW
Calais
'658
1 1 1 1
'91
OLDSMOBILE
Accord CVCC all models '76 thnj 83 Accord all models '84 thru '89 Accord all models '90 thru '93 Civic 1200 all models '73 thru '79 Civic 1300 & 1500 CVCC '80 thm '83 Civic 1500 CVCC all models '75 thm '79
too, 1300, 1400 a 1600 '71 thm '79 600 a 1 800 2WD a 4WD '80 thm '89
NISSAN Pick-ups/Pathfinder gas models '80 thm '93
CHEVROLET ASTRO (1477) - see CHEVROLET
1023 150 935
•1339
074 024
Ninety-eight
see
1
•1025
&
'93
MORRIS
%
-
1
1
Mirage '83 thru '93 Pick-up & Montero '83 thm Eclipse, Eagle Talon & Plymouth Laser '90 thm '94
2022 2097
Full-size
'2039
thm
300ZX all models incl. Tuitx) Maxima all models '85 thm
Buick Century, Chevrolet Celebrity, Olds Cutlass Ciera & Pontiac 6000 all models '82 thru '93 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza Pontiac J-2000 & Sunbird '82 thru '92 Buick Skylark & Somerset, Olds Calais & Pontiac Grand Am '65 thru '91 Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme & Pontiac Grand Prix front wheel drive '88 thru '90 Chevrolet Lumina APV, Oldsmobile Silhouette S Pontiac Trans Sport thm '92
237
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all
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SUZUKI See FORD
1137 1 341
GMC
'78
911 all Coupe & Targa models except Turbo a Canera 4 '65 thm '89 914 all 4 cyl models 69 thm '76 924 all models incl. Turbo '76 thm '82 944 all models incl. Turbo '83 thm '89
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Vans 4 Pick-ups
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'
thm
'84 thru '93 Cougar '83 thru '88
Thunderbird/Mercury Thunderbird/Mercury Cougar '89 and Vans all V8 Ecorioline models '69 thru
Safari
679 123
'74
MERCURY
Metro - see CHEVROLET Spiint (1727) Prizm - see CHEVROLET Nova (1642) Storm all models '90 thru '93 Tracker - see SUZUKI Samurai (1626)
DATSUN 402 647 228 525 206 563
41 9
GEO
CHRYSLER '2058
082 267 370
346 983 698 697
'79 thru '92;
GENERAL MOTORS
front
S-15 Pick-ups '82 thnj '92 Sprint & Geo Metro '85 thru '91 Vans - Chevrolet & GMC, V8 & in-line 6 cylinder models '68 thru '92
•1727 •345
Mustang,
'766
'68
Versailles ('75 thnj 86)
Mustang & Mercury Capri
incl. Turbo Capn, '79 thru '86 Mustang V8 all models '64-1/2 thru '73 Mustang II 4 cyl, V6 & V8 '74 thnj '78 Pinto & Mercury Bobcat '75 thru '80 Probe all models '89 thru '92 Ranger/Bronco II gas models '83 thnj '93 Taurus & Mercury Sable '86 thru '92
Astro
554 866
'75 thnj '80
& Mercury
('75 thnj '82);
XB-7 & Lincoln
CHEVROLET •1477
Granada & Mercury Monarch Ford & Mercury Mid-size, Cougar
MK Coupe all I
i 1600
626 Sedan & Coupe (rear wheel drive) all models '79 thm '82 626 a MX-6 (front wheel drive) '83 thm B Series Pick-ups '72 thm '93 GLC Hatchback (rear wheel drive) all models '77 thm '83 GLC (front wheel drive) 81 thm '85 MPV all models '89 thm '93 RX-7 all models '79 thm '85 RX-7 all models '86 thm '91
1643 Aerostar Mini-vans '86 thru '92 Bronco and Pick-ups '73 thru '79 Bronco and Pick-ups '80 thru '91 Courier Pick-up all models '72 thru '82 Ford Engine Overhaul Manual Escort/Mercury Lynx '81 thru '90 Escort/Mercury Tracer '91 thru '93 Explorer & Mazda Navajo '91 thru '92 Fairmont & Mercury Zephyr '78 thnj '83 Fiesta all models '77 thru '80 Ford & Mercury Full-size, Ford LTD & lulercury fvtarquis ('75 thnj '82); Ford Custom 500,Country Squire, Crown Victoria & Mercury Colony Park ('75 thru '87); Ford LTD Crown Victoria & Mercury Gran Marquis ('83 thru '87)
Ford Thunderbird
2000
296
239 397 1 027
980
FORD
CADILLAC '751
1
Prix - see GENERAL MOTORS (1671) - see BUICK Full-size (1551) Parisienne - see BUICK Full-size (1551) Phoenix/Oldsmobile Omega '80 thm '84 Sunbird see GENERAL MOTORS (766^ Trans Sport - see GENERAL MOTORS (2035)
RENAULT
648
'68 thru '78
'81
Firebird all models '82 thm '92 Full-size Rear Wheel Drive - see BUICK Oldsmobile. Pontiac Full-size RWD (1551) Full-size Front Wheel Drive - see BUICK Oldsmobile. Pontiac Full-size FWD (1627) Grand Am - see GENERAL MOTORS (1420)
MERCEDES-BENZ
MOTORS (1420) Somerset - see GENERAL
264
MAZDA
460 094 273
.
& Century
1200, 1300. 1500
757
Oldsmobile Custom Cruiser
Mid-size Regal
413
see Mitsubishi Eclipse (2097)
Catalina - see Buick Full-size (1551) Fiero all models '64 thm '88 Firebird V8 models except Turbo '70 thm
PORSCHE
LADA
2047
Buick Estate '70 thnj '90. Electra'70 thnj '84. LeSabre '70 thru '85, Limited '74 thnj '79
627
412
1777
EAGLE
Oldsmobile Delta 88 Royale. Ninety Eight and Regency; Pontiac Bonneville Buick Oldsmobile & Pontiac Full-size (Rear wheel drive)
see Buick Full-size
Brougham - see Buick
Grandville '85
JEEP
1
Buick, Oldsmobile & Pontlac Full-size (Front wheel drive) '85 thru '93 Buick Electra, LeSabre and Pari* Avenue;
gasoline models thnj '93; Trooper, '84 thm '91 all
'78 thai '83
- see DODGE Dart (234) Colt all models '71 thru '77 Colt/Plymouth Champ (front wheel drive)
-
Grand
all
BMW
1232 555 867
'86 thru '93
XJ6 all 6 cyl models '68 thm '86 XJ12 & XJS all 1 2 cyl models '72 thm
'478
Challenger '67-'76
Healey Sprite
models
all
Trooper & Pick-up,
242
all
AUSTIN
Bonneville
Full-size (1551)
Pick-up, '81
400 « 600 - see CHRYSLER Mid-size (1337) Aries & Plymouth Reliant '61 thru '89 Caravan & Plymouth Voyager Mint-Vans models '84 thru '93 Challenger/Plymouth Saporrxi
vehicle,
FWD (1627). RWD (1551)
CVCC all
HYUNDAI
'1641
'723 '1231
'64 thru '91 models '79 thnj '89
your
Bonneville
DODGE
AUDI
models
all
for
861 Lawrence Drive, Newbury Park,
also available
CA 91320
•
(805)
498-6703
CARBON DEPOSITS
NORMAL
Symptoms: Dry
Symptoms: Brown
sooty deposits indicate a rich mixture or weak Ignition. Causes misfiring, hard
and
starting
hesitation.
Recommendation: Check a clogged
for
tan color
and
to grayish-
slight electrode
wear. Correct heat range for engine and operating conditions.
cleaner, high float
Recommendation: When new
choke and worn igUse a spark plug with a longer core nose for
spark plugs are installed, replace with plugs of the same
air
level, sticky
nition points.
heat range.
greater anti-fouling protection.
ASH DEPOSITS Symptoms:
OIL DEPOSITS
Symptoms: caused by poor
coating
Oily oil
control. Oil
leaking past worn valve guides or piston rings into the is
combustion chamber. Causes hard starting, misfiring and Correct
the mechanical condition with necessary repairs and install new plugs.
TOO HOT Symptoms: absence
Blistered, white
of deposits. Results in life.
Recommendation: Check
for
the correct plug heat range,
over-advanced
ignition timing,
lean fuel mixture, intake manifold vacuum leaks and sticking valves. Check the coolant level and make sure the radiator is not clogged.
may
the spark, causing misfiring and hesitation during accel-
Recommendation:
new valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gasoline brands.
WORN Symptoms: Rounded
Recommendation: with new plugs of
Recommendation: Check
for
the correct plug heat range,
over-advanced
ignition timing, lean fuel mixture, clogged cooling system and lack of lubrication.
HIGH SPEED GLAZING Symptoms:
Insulator has yellowish, glazed appearance. Indicates that combustion
chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating. Causes misfiring at high
speeds.
Recommendation:
Install
new
plugs. Consider using a colder plug if driving habits warrant.
de-
posits lodge between the electrodes. Heavy deposits accumulate and bridge the elec-
trode gap.
same
Insulators may be cracked or chipped. Improper gap setting techniques can also result in a fractured insulator tip.
Can
lead to piston
damage. Recommendation:
IVIake sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine.
SPLASHED DEPOSITS Symptoms: of
After long periods misfiring, deposits can
loosen when normal combustion temperature is restored by
an overdue tune-up. At high speeds, deposits flake off the piston and are thrown against the hot insulator, causing misfiring.
Recommendation: Replace the plugs with new ones or clean and reinstall the originals.
MECHANICAL DAMAGE
GAP BRIDGING Symptoms: Combustion
Replace the
heat range.
DETONATION
engine
elec-
trodes with a small amount of deposits on the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy.
Symptoms:
to
exces-
stall
PREIGNITION
chamber. Can lead damage.
If
sive deposits accumulate over a short time or low mileage, in-
Symptoms: Melted
electrodes. Insulators are white, but may be dirty due to misfiring or flying debris in the combustion
t
Excessive amounts
mask
in-
eroded electrode and
shortened plug
»l
tives.
eration.
hesition.
Recommendation:
sulator,
Light brown deposits encrusted on the side or center electrodes or both. Derived from oil and/or fuel addi-
The plug ceases to in a dead cyl-
Symptoms: May be caused by a foreign object
in
the
combus-
tion chamber or the piston striking an incorrect reach (too
long) plug. Causes a dead cylinder and could result in piston
resulting inder.
damage.
Recommendation: Locate the
Recommendation:
faulty plug
and remove the deposits from between the elec-
the foreign object from the engine and/or install the correct
trodes.
reach plug.
fire,
Remove
jivery
manual based on a complete teardown and •"Twr
,V-.^>;r.^^^^!^i_'-^
rebuild!
V, ,
^^
Haynes mechanic, author and photographer with Mitsubishi Galant
m^rm
"'.!
."''
.N
Models covered by ":ffM
-:--.^
_
this
manual:
Cordia & Tredia (1983 thru 1988), Precis (1987 thru 1993) Mirage (1985 thru 1992), Galant (1985 thru 1987, 1989 thru 1993) Does not include V6 engine or all-wheel drive information
i
Haynes Manuals Explain • • • • •
Best:
step-by-step procedures linked to hundreds of easy-to-follow photos using common tools Written from "hands-on" experience Quick and easy troubleshooting sections Detailed wiring diagrams Color spark plug diagnosis .
.
.
ISBN
1
56392 091