1900 MITSUBISHI DIAMANTE Repair Manual

.
l-10 GENERALINFORMATIONAND MAINTENANCE
which are available today will have two scales so the
The conversion factor chart is used by taking the
Standard or Metric measurements may easily be given specification and multiplying it by the neces-
taken. If any of the various measuring tools which are sary conversion factor. For instance, looking at the
available to you do not contain the same scale as first line, if you have a measurement in inches such
listed in the specifications, use the accompanying
as “free-play should be 2 in.” but your ruler reads
conversion factors to determine the proper value. only in millimeters, multiply 2 in. by the conversion factor of 25.4 to get the metric equivalent of 50.8mm.
Likewise, if the specification was given only in a Met-
ric measurement, for example in Newton Meters
(Nm), then look at the center column first. If the mea-
surement is 100 Nm, multiply it by the conversion
factor of 0.738 to get 73.8 ft. Ibs.
b See Figures 32,33, and 34
The Vehicle Identification Number (VIN) is located
on a plate which is attached to the left top side of the
instrument panel. These numbers are visible from the
outside of the vehicle. All Vehicle Identification Num-
bers contain 17 digits. The vehicle number is a code
which tells country, make, vehicle type, engine, body
and many other important characteristics of that spe-
cific vehicle.
There is also a vehicle information code plate
which is riveted to the bulkhead in the engine com-
partment. The plate shows the VIN, model code, en-
gine model, transaxle model and body color codes.
The engine code used on this plate differs from the
code letter used in the 8th position of the Vehicle
Identification Number (VIN). Either code can be used
to identify the particular engine in the vehicle. Since
the vehicle owners card is usually carried, it may be if the engine is equipped with a turbocharger. If the
8th VIN number is a U, there is no doubt that the en-
gine in question is a 2.OL DOHC engine equipped
with a turbocharger.
The engine codes found on the vehicle information
code plate are as follows:
l 4G15--1.5L SOHC engine l 4G61-1.6L DOHC engine l 4G93-1.8L SOHC engine l 4G63-2.OL (SOHC or DOHC) engine l 4G64-2.4L (SOHC or DOHC) engine l 6G72-3.OL (SOHC or DOHC) engine l 6G74-3.5L DOHC engine
A vehicle safety certification label is attached to
the face of the left door pillar post. This label indi-
cates the month and year of manufacture, Gross Ve-
hicle Weight Rating (GRVW) front and rear, and Ve-
hicle Identification Number (VIM). 4 character code as on the vehicle information code
plate is used. The engine serial number is also
stamped near the engine model number. As men-
tioned above, the engine can also be identified by the
8th digit in the VIN number.
The transaxle model code is located on the vehicle
information code plate. The transaxle identification
number is etched on a boss located on the front up-
per portion of the case.
The code for the drive axle is etched on a boss lo-
cated on the case of the differential carrier.
easier to use the code letter in the VIN for engine ref-
erence. A second reason for referring to the VIN for
engine identification is that code 4663, located on
the vehicle information code plate, does identify the
engine as a 2.OL DOHC engine, but does not tell you ) See Figure 35
The engine model number is stamped at the front
side on the top edge of the cylinder block. The same
Fig. 32 The Vehicle Identification Number
g3’51p’o of the instrument panel _I:^1 / Fig. 33 The vehicle model, engine model,
(VIN) plate is attached to the top left side
bansaxle model, and body color code are all
noted on the vehicle information code plate
ENGINE AND VEHiCLE IDENTlFlCATlON
EnglnCode
ModelYerr
todeal
LIten (cc)
Cu. In. W. Fuel+ Type m.hWg. Code@ Year ,G15JA 1.5 (1468) 92 4 MFI SOHC Mitsubishi
L 1990
IG61N 1.6(15QQ) 98 4 MFI DOHC
Mitsubishi M 1991
1G93lC 1.8 (1834) 112 4 MFI SOHC Mitsubishi N 1992
IG63N 2.0 (1997) 122 4 MFI SOHC “-Mitsubishi P
1993
!G63Fi 2.0 (1997) 122 4 MFI DOHC Mitsubishi
R 1994
,G63iU 2.0 (1997) 122 4 MFI-Tuibo DOHC Mitsubishi
S 1995
.GMffi 2.4 (2351) 143 4 MFI SOHC
Mitsubishi T 1996
iG64L 2.4 (2351) 143 4 MFI DOHC Mitsubishi V
lEzH 3.0 1997
(2972) 161 6 MFI SOHC Mitsubishi W 1998
;G7ZJ 3.0 (2Q72) 161 6 MFI GQHC Mitsubishi
~.. X 1999
iG7zL 3.0 (2972) 181
~ 6 MFI SOHC ___-___ Miisubishi
Y 2000
iG74lP 3.5 (3497) 213 6 MFI SOHC Miisubishi
The transfer case has no separate model code, the
code is located on the transaxle. The transfer case is
onlv eoUiODed on manual transaxle All Wheel Drive
(AWD)‘mbdels.
Fig. 34 Your car should have a vehicle
Fig. 35 Engine model number location-
4663 (2.OL) engine shown

UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL ENGINE
II
1. Power steering belt 7. PCV valve
2. Washer solvent bottle 8. Distributor cap and rotor
3. Power steering reservoir 9. Fuel filter (under air inlet tube)
4. Oil fill cap 10. Air filter housing
5. Brake master cylinder reservoir 11. Engine compartment fuse box
6. Spark plug and plug wire 12. Battery 13. Automatic transaxle fluid dipstick
14. Coolant recovery tank
15. Radiator cap
16. Engine oil dipstick

UNDERHOOD MAINTENANCE COMPONENT LOCATIONS-l .8L ENGINE
1. Coolant recovery tank
2. Battery
3. Engine compartment fuse box
4. Air filter housing
5. Clutch fluid reservoir
6. Brake master cylinder reservoir 7. Spark plug and plug wire
8. PCV valve
9. Engine oil fill cap
10. Fuel filter
11. Engine compartment relay center
12. Washer solvent bottle 13. Power steering reservoir
14. Power steering belt
15. Engine oil dipstick
16. Radiator cap

GENERALINFORMATIONAND MAlNTENANdE 1-13
Engine GENERAL ENGINE SPECIFICATIONS Fuel Net Net
Com-
Oil
Displacement Engine Engine No. of System Horsepower Torque @ rpm Bore x Stroke pression
Pressure
MFI Mult+wt fuel mfectw,
MFI-T - Multlporl fuel mfectlon-turbocharged
SOHC - Smgle overhead camshaft
DOHC - Double OvedEad camshaft

l
l-14 GENERALINFORMATIONAND MAINTENANCE
Proper maintenance and tune-up is the key to long
and trouble-free vehicle life, and the work can yield
its own rewards. Studies have shown that a properly
tuned and maintained vehicle can achieve better gas
mileage than an out-of-tune vehicle. As a conscien-
tious owner and driver, set aside a Saturday morning,
say once a month, to check or replace items which
could cause major problems later. Keep your own
personal log to jot down which services you per-
formed, how much the parts cost you, the date, and
the exact odometer reading at the time. Keep all re-
selfer, these receipts are the only proof you have that ceipts for such items as engine oil and filters, so that
they may be referred tp in case of related problems or
to determine operating expenses. As a do-it-your- the required maintenance was performed. In the event
of a warranty problem, these receipts will be invalu-
able.
The literature provided with your vehicle when it
was originally delivered includes the factory recom-
mended maintenance schedule. If you no longer have
this literature, replacement copies are usually avail-
able from the dealer. A maintenance schedule is pro-
vided later in this section, in case you do not have
the factory literature. *
REMOVAL &INSTALLATION
Except 2.gL Turbocharged Engine
b See Figures 36 thru 41 9. Place a new air cleaner element inside the
lower housing. Make sure the seal on the element is
fully seated in the groove.
10. Install the upper air cleaner housing and inlet
tube onto the lower housing.
11. Tighten the clamp on the inlet tube at the
throttle body.
12. Attach the breather hose onto the air inlet tube.
13. Plug the connector into the MAF sensor.
14. Attach the air cleaner housing retaining clips.
15. Connect the negative battery cable.
2.DL Turbocharged Engine
b See Figure 42
1. Disconnect the negative battery cable.
2. Detach the air flow sensor connector.
3. Unfasten the boost hose.
4. Disconnect the solenoid valve with hoses.
93151p50 Fig. 36 Release the retaining clips from the
air cleaner housing
r3151p47 Fig. 37 Unplug the MAF sensor connector
Fig. 49
. . . then remove the air outlet tube
and upper housing from the lower housing 1. Disconnect the negative battery cable. 5. Disconnect the air intake hose.
2. Release the retaining clips from the air 6. Unfasten tie air cleaner retainer bolts and the
cleaner housing. air cleaner assembly.
3. Loosen the clamp on the air outlet tube at the 7. Unclamp the cover and remove from the hous-
throttle body. ing.
4. Detach the breather hose from the air inlet
tube. *Care must be taken when removing the air
cleaner cover. The air flow sensor is at-
5. Unplug the MAF sensor connector.
6. Separate the upper and lower air cleaner tached and could be damaged during cover
removal.
housings and remove the air outlet tube and upper
housing from the lower housing.
7. Remove the air cleaner element from the
housing.
To install:
8. Clean the inside of the air cleaner housing of
any dirt and debris that has collected inside. 8. Remove the air cleaner element. Thoroughly
clean the air cleaner housing prior to replacing the air
filter.
To install:
9. Install the new air cleaner element into the
housing. Install and secure the cover in place.
Fig. 38 Detach the breather hose from the
air tniet tube
Fig. 41 Remove the air cleaner element
from the housing Fig. 39 Loosen the clamp on the air outlet
tube at the throttle body . . .
Fig. 42 Detach the air flow sensor connec-
tor, the boost hose and the solenoid valve
connector

GENERALINFORMATIONAND MAINTENANCE l-15
10. install the air cleaner assembly and the re- *Wrap shop towels around the fitting that is
tainer bolts. being dtsconnected to absorb residual fuel in
11. Connect the air intake hose. the lines. 9. While holding the fuel filter nut with aback-
up wrench, tighten the banjo bolt to 22 ft. Ibs. (30
Nm). Tighten the flare nut to 25 ft. Ibs. (35 Nm), with
12. Attach the solenoid valve.
4. Cover the hose connection with shop towels to a back-up wrench on the nut.
13. Connect the boost hose.
14. Attach the air flow sensor connector. prevent any splash of fuel that could be caused by 10. Tighten the filter mounting bolts to 10 ft. Ibs.
residual pressure in the fuel pipe line. Hold the fuel (14 Nm).
15. Connect the negative battery cable. 11.

filter nut securely with a backup wrench, then remove Connect the negative battery cable. Turn the
REMOVAL &INSTALLATION the banjo bolt on the engine feed line. Disconnect the
high-pressure fuel line from the filter. Remove and
discard the gaskets.
5. While holding the fuel filter nut securely with a
back-up wrench, loosen the filter feed pipe flare nut key to the ON position to pressurize the fuel system
and check for leaks.
12. If repairs of a leak are required, remember to
release the fuel pressure before opening the fuel sys-
tern.
u See Figures 43 thru 48
On most vehicles covered by this manual, the fuel
filter is located in the engine compartment, mounted
to the firewall.
Do not use conventional fuel filters, hoses or
clamps when servicing fuel injection sys
terns. They are not compatible with the injec-
tion
system and could fail, causing personal
injury or damage to the vehicle. Use only
hoses and clamps specifically designed for
fuel injection systems.
1. Properly relieve the fuel system pressure as
outlined in Section 5 of this manual. on the bottom of the filter. Separate the flare nut con-
nection from the filter. If equipped, remove and dis-
card the gaskets.
6. Remove the mounting bolts and remove
. ,,,. ,.
.a r I,.,< I the
ruer rrrter. II necessary, remove me ruer rrrrer oracket.
To install:
7. Install the filter to its bracket only finger-tight.
Movement of the filter will ease attachment of the fuel
lines.
Ensure that the filter is installed with the flow
arrow in the proper direction. The flow arrow
typically points toward the engine side of the
filter. improper installation of the fuel filter
will cause the vehicle to run poorly.
2. If not already done, disconnect the negative REMOVAL&INSTALLATION
u See Figures 49, 50, and 51
1, Disconnect the negative battery cable.
2. If necessary for access, remove the air intake
hose and air cleaner assembly.
3. If necessary, unfasten the retaining clamp, then
disconnect the ventilation hose from the PCV valve.
4. Remove the PCV valve from the camshaft
(rocker) cover.
To install:
5. Install the PCV valve into the rocker cover. If
the valve is threaded, tighten the valve until snug.
battery cable.
3. On most models. the iob is made easier if the
air inlet hose and upper air cleaner housing is re-
moved from the vehicle. *Make sure new O-rings are installed prior
to installation.
8. Insert the filter feed pipe to the lower connec-
tion of the filter and manually screw in the main
pipe’s flare nut. 6. Reconnect the ventilation hose to the valve.
7. If removed, install the air intake hose and the
a .ir cleaner assembly.
8. Connect the negative battery cable.
Fig. 43 Use a back-up wrench on the fuel
I I
93151@3
filter nut when loosening the banjo-bolt on Fig. 44 After the banjo-bolt is loose, remove
I
1 the engine feed line - from the fuel filter
93151p93 Fig. 48 Make sure to use a back-up wrench
1 when unfastening the main fuel pipe also 1 Fig. 47 Remove the two filter bracket re-
taining bolts . . . Fig. 45 Make sure to replace the copper
washers on the banjo-bolt fitting
Fig. 48 . . . then remove the filter from the
vehicle

*
l-16 GENERALINFORMATIONAND MAINTENANCE
Fig. 49 Grasp the valve and gently remove
Fig. 50 Twist and pull on the valve to re-
it from the valve cover
move it from the hose Fig. 51 Inspect the grommet and replace if
cracked or leaking oil
SERVICING
corrosive acid can also eat away at components un-
der the hood.
Always visually inspect the battery case for cracks,
leakage and corrosion. A white corrosive substance
u See Figure 52
The evaporative canister requires no periodic ser-
vicing. However, a careful inspection of the canister
and hoses should be made frequently, Replace dam- on the battery case or on nearby components would
indicate a leaking or cracked battery. If the battery is
cracked, it should be replaced immediately. GENERALMAINTENANCE '_
devices that increase parasitic load may discharge a
battery sooner. If the vehicle is to be stored for 6-B
weeks in a secure area and the alarm system, if pre-
sent, is not necessary, the negative battery cable
should be disconnected at the onset of storage to
protect the battery charge.
Remember that constantly discharging and
recharging will shorten battery life. Take rare not to
allow a battery to be needlessly discharged.
aged components as required.
The canister is typically located under one of the
front fenders, however on some later models it may
be under the rear of the vehicle, near the gas tank,
r on most models # See Figure 53
A battery that is not sealed must be checked peri-
odically for electrolyte level. You cannot add water to
a sealed maintenance-free battery (though not all
maintenance-free batteries are sealed); however, a
sealed battery must also be checked for proper elec-
trolyte level, as indicated by the color of the built-in
hydrometer “eye.”
Always keep the battery cables and terminals free
of corrosion. Check these components about once a
year. Refer to the removal, installation and cleaning
procedures outlined in this section,
Keep the top of the battery clean, as a film of dirt
can help completely discharge a battery that is not
used for long periods. A solution of baking soda and
water may be used for cleaning, but be careful to
flush this off with clear water. DO NOT let any of the
solution into the filler holes. Baking soda neutralizes
battery acid and will de-activate a battery cell.
Batteries in vehicles which are not operated on a
regular basis can fall victim to parasitic loads (small
BA-ITERY FLUID
Check the battery electrolyte level at least once a
month. or more often in hot weather or during peri-
ods of extended vehicle operation. On non-sealed
batteries, the level can be checked either through the
case on translucent batteries or by removing the cell
caps on opaque-cased types. The electrolyte level in
each cell should be kept filled to the split ring inside
each ceil, or the line marked on the outside of the
case.
If the level is low, add only distilled water through
the opening until the level is correct. Each cell is sep-
arate from the others, so each must be checked and
filled individuallv. Distilled water should be used, be-
cause the chemicals and minerals found in most
drinking water are harmful to the battery and could
significantly shorten its life.
If water is added in freezing weather, the vehicle
should be driven several miles to allow the water to
mix with the electrolyte. Otherwise, the battery could
freeze.
current drains which are constantly drawing current
from the battery). Normal parasitic loads may drain a Although some maintenance-free batteries have
removable cell caos for access to the electrolyte, the
cause a short circuit, leading to sparks and possible
personal injury.
Do not smoke, have an open flame or create
sparks near a battery; the gases contained in the bat-
tery are very explosive and, if ignited, could cause se-
vere injury or death.
All batteries, regardless of type, should be care-
fully secured by a battery hold-down device. If this is
not done, the battery terminals or casing may crack
from stress applied to the battery during vehicle oper-
ation. A battery which is not secured may allow acid
to leak out, making it discharge faster; such leaking m / built-in hydrometer. .

*Although the readings from built-in hy-
drometers found in sealed batteries may
vary, a green eye usually indicates a prop
erly charged battery with sufficient fluid
level. A dark eye is normally an indicator of a
battery wlth sufficient fluid, but one which
may be low in charge. And a light or yellow
eye is usually an indication that electrolyte
supply has dropped below the necessary
tcu1@32 Fig. 53 A typical location for the built-in hv- level for battery (and hydrometer) operation.
drometer on maintenan
ce-free batteries ’ I In this last case. sealed batteries with an in-
sufficient electrolyte level must usually be
’ discarded.

G,ENERALlNFORMATlONAND MAINTENANCE l-17
Fig. 54 On
non-maintenance-free
batteries,
the fluid level can be checked through the Fig. 55 If the fluid
level
is low, add only dis-
1 case on translucent models; the cell caps 1
must be removed on other models
1 1 tilled water through the opening until the
1 level is correct
Checking the Specific Gravity
A hydrometer is required to check the specific
# See Figures 54, 55, and 56
gravity on all batteries that are not maintenance-free.
On batteries that are maintenance-free, the soecific
gravity is checked by observing the built-in hydrome-
ter “eye” on the top of the battery case. Check with
your battery’s manufacturer for proper interpretation
of its built-in hvdrometer readinas. gravity of the battery. It should be between 1.20 and As stated earlier, the specific gravity of a battery’s
electrolyte level can be u
1.26 on the gravity scale. Most auto supply stores sed as an indication of bat-
tery charge. At least once
carry a variety of inexpensive battery testing hydrom- ? a year, check the specific
eters. These can be used on any non-sealed battery
, , , ,,
.,, . .
IO rest me specmc gravny in each cell.
The battery testing hydrometer has a squeeze bulb
at one end and a nozzle at the other. Battery electrolyte
the hydrometer until the float is lifted
-he specific gravity is then read by not-
n of the float. If gravity is low in one or mg tne posrtro
Battery electrolyte contains sulfuric acid. If
you should splash any on your skin or in your
eyes, flush the affected area with plenty of
clear water. If it lands in your eyes, get med-
ical help immediately.
The fluid (sulfuric acid solution) contained in the
battery cells will tell you many things about the con-
dition of the battery. Because the cell plates must be
kept submerged below the fluid level in order to op-
erate, maintaining the fluid level is extremely impor-
tant. And. because the soecific aravitv of the acid is
an indication of electrical charge, testing the fluid can
be an aid in determining if the battery must be re-
placed. A battery in a vehicle with a properly operat-
ing charging system should require little mainte-
nance, but careful, periodic inspection should reveal
problems before they leave you stranded. Fig. 57 Maintenance is performed with
Fig. 58 The underside of this special bat-
household items and with special tools like
tery tool has a wire brush to clean post ter-
I this post cleaner
I 1 minals Fig. 56 Check the specific gravity of the bat-
tery’s electrolyte with a hydrometer
more cells, the battery should be slowly charged and
Lhecked aqain to see if the aravitv has come
UP. Gen-
erally, if affer charging, the specific gravity between any
two cells varies more than 50 points (0.50) the battery
should be replaced, as it can no longer produce suffi-
cient voltage to guarantee proper operation.
CABLES
) See Figures 57, 56, 69, 60, and 61
Once a year (or as necessary), the battery termi-
nals and the cable clamps should be cleaned. Loosen