1900 MITSUBISHI DIAMANTE check engine light

1997-00 MIRAGE 1.8L ENGINE SCHEMATIC
1992-93 DIAMANTE 3.OL SOHC ENGINE SCHEMATIC NOTE
HOT AT ML TIHGS
HOT IN R&S4 OR STbRT
HOT IM RUN OR START
ECM CGNNECTOR CZI = ‘4.
FUSS FROn
ECM COmECTOR CL2 = w
I IGNITIW
Et24 COtWECTOR CZ3 = ‘IT
zG4 SWITCH FROM
IGNlnON
SWITCH
4 HOT AT UL TIMES
HOT IN RiN GR START
FUSIRLE
FRW
LINK
IGNITION
:04 SWITCH
5
1
IGHlnON FAiLUlE SENSOR
FUSE
b
IO4
CHECK
ENGINE
LIGHT
TO
VEHICLG
ENGINE CONTROL MO4M.E
IECH)
II
ENGINE CONTROL MWUE
, 1 TO
COOLING
SYSTlw4
EGR
TEHFRR4TLtGE
SENSOR 1 POWER
STEERIMG
cI>
72
D
cn
c&n
.-
CD NT A NIT
.
5 (I)
I 4 FROM
STARTING
CIRCUT
HOT AT F!u3swE SWITCH
KNOCK
SENM
FLsC
I9
104 POSITION 6
SWITCH
FL&G
2
IOA
TIMES
hl
c3
-i
zu MFI CONNECTOR 8.37 = ‘4.
MFI CONNECTOR 811 - 3’
Hfl CONNECTOR 6.59 = ‘C’
WI CONNECTOR Sk0 g ‘D-
93156E15 DIAGRAM 13
DIAGRAM 14

7-2 'DRIVETRAIN
Because of the way an internal combustron engine
breathes, it can produce torque, or twisting force,
only within a narrow speed range. Most modern,
overhead valve pushrod engines must turn at about
2500 rpm to produce their peak torque By 4500 rpm
they are producrng so lrttle torque that contrnued in-
creases in engine speed produce no power increases.
The torque peak on overhead camshaft engines IS
generally much higher, but much narrower.
The manual transaxle and clutch are employed to
vary the relationship between engine speed and the
speed of the wheels so that adequate engine power can
be produced under all crrcumstances. The clutch al-
lows engine torque to be applied to the transaxle input
shaft gradually, due to mechanical slippage. Conse-
quently, the vehicle may be started smoothly from a
full stop The transaxle changes the ratio between the
rotating speeds of the engine and the wheels by the
use of gears. The gear ratios allow full engine power to
be applied to the wheels during acceleration at low
speeds and at highway/passing speeds.
In a front wheel drive transaxle, power is usually
transmitted from the input shaft to a mainshaft or out-
put shaft located slightly beneath and to the side of
the input shaft. The gears of the mainshaft mesh with
gears on the input shaft, allowing power to be carried
from one to the other. All forward gears are in con-
stant mesh and are free from rotating with the shaft
unless the synchronizer and clutch IS engaged. Shaft-
ing from one gear to the next causes one of the gears
to be freed from rotating with the shaft and locks an-
other to it. Gears are locked and unlocked by internal
dog clutches which slide between the center of the
gear and the shaft. The forward gears employ syn-
chronizers; friction members which smoothly bring
gear and shaft to the same speed before the toothed
dog clutches are engaged.
SHIFT LINKAGE
1. Disconnect the shift linkage from the transaxle.
2. On the transaxle, put select lever in N and
move the shift lever in
4th gear. Depress the clutch,
if necessary, to shift.
3. Move the shift lever in the vehicle to the
4th gear position until it contacts the stop.
4. Turn the adjuster turnbuckle so the shift cable
eye aligns with the eye in the gear shift lever. When
installing the cable eye, make sure the flange side of
the plastic bushing at the shift cable end is on the
cotter pin side.
5 The cables should be adjusted so the clear-
ance between the shift lever and the 2 stoppers are
equal when the shift lever IS moved to 3rd and 4th
gear. Move the shift lever to each positron and check i
that the shifting is smooth
REMOVAL &INSTALLATION
1, Disconnect the negative battery cable 2. Remove any components necessary to access
the back-up light switch.
3. Unplug the back-up light switch connector.
4. Remove the switch from the case using the ap-
propriate size socket and drive tool.
To install: 5. Install the switch and tighten it to 22-25 ft. Ibs.
(30-35 Nm).
6. Attach the back-up light switch connector
7. Install any components removed to access the
back-up light switch
8. Connect the negative battery cable.
REMOVAL & INSTALLATION
Mirage
*If the vehicle is going to be roiled while the
halfshafts are out of the vehicle, obtain 2 outer
CV-joints or proper equivalent tools and install
to the hubs. If the vehicle is rolled without the
proper torque applied to the front wheel bear-
ings, the bearings will no longer be usable.
*The suspension components should not be
tightened until the vehicles weight is resting
on the ground.
1. Remove the battery and battery tray.
2. Remove the air cleaner assembly and vacuum
hoses.
3. Note the locations and disconnect the shifter
cables.
4. If equipped with 1.61 engine, remove the ten-
sion rod.
5. Detach the backup lamp switch connector,
speedometer cable connection and remove the starter
motor.
6. Raise the vehicle and support safely.
7. Remove the front wheels and the inner wheel
panels.
8. Remove the undercover and splash pan.
9. Drain the transaxle oil into a suitable con-
tainer
10. Support the engine and remove the cross-
member.
11. Remove the upper transaxle mounting bolt
and bracket.
12 Disconnect the stabilizer bar, tie rod ends and
the lower ball joint connections.
13 Remove the clutch release cylinder and clutch
oil line bracket. Do not disconnect the fluid lines and
secure the slave cylinder with wire.
14 Disconnect the clutch cable, if equipped with
cable controlled clutch system.
15. Remove the halfshafts by inserting a prybar
between the transaxle case and the driveshaft and
prying the shaft from the transaxle. Do not pull on the
driveshaft Doing so damages the inboard joint. Do
not insert the prybar so far the oil seal in the case is
damaged.
*It is not necessary to disconnect the half-
shafts from the steering knuckle. Remove the
shaft with the hub and knuckle as an assem-
bly. Tie the shafts aside. Note the circle clip
on the end of the inboard shafts should not
be reused.
16. Remove the bellhousing lower cover.
17 Remove the transaxle to engine bolts and
lower the transaxle from the vehrcle.
To install:
*When installing the transaxle, be sure to
align the splines of the transaxle with the
clutch disc.
18 Install the transaxle to the engine and install
the mounting bolts. Tighten the bolts to 31-40 ft. Ibs.
(43-55 Nm) on 1990-92 models and 35 ft. Ibs. (48
Nm) on 1993-00 models.
19 Install the bellhousing cover.
*When installing the halfshafts, use new
circlips on the axle ends. Care must be taken
to ensure that the oil seal lip of the transaxle
is not damaged by the serrated part of the
driveshaft.
20. Install and fully seat the halfshafts into the
transaxle.
21. Install the slave cylinder.
22. Connect the ball joints, tie rod ends and the
stabilizer bar connections.
23. Install the upper transaxle mounting bracket
and bolt.
24. Install the crossmember.
25. Install the undercover.
26. Install the upper transaxle-to-engine mount-
ing bolts, Tighten the bolts to 31-40 ft. Ibs. (43-55
Nm) on 199C-92 models and 35 ff. Ibs. (48 Nm) on
1993-00 models.
27. Install the starter motor.
28 Connect the backup light switch connector
and speedometer cable.
29 Connect and adjust the shifter cables.
30 Install the air cleaner assembly.
31. Install the front wheels.
32 Make sure the vehicle is level when refilling
the transaxle Use Hypoid gear oil or equivalent, GL-
4 or higher.
33. Connect the negative battery cable and check
the transaxle for proper operation. Make sure the re-
verse lights operate when in reverse.
Galant
1999-93 MODELS
rlf the vehicle is going to be rolled on its
wheels while the halfshafts are out of the ve-
hicle, obtain two outer CV-joints or proper
equivalent tools and install to the hubs. If the
vehicle is rolled without the proper torque
applied to the front wheel bearings, the bear-
ings will no longer be usable.
1. Remove the battery and the air intake hoses.
2. If equipped with Active-ECS, unplug the
compressor wiring.
3. Remove the auto-cruise actuator and under-
hood bracket, located on the passenger side inner
fender well.
4. Drain the transaxle and transfer case fluid, if
equipped, into a suitable waste container.
5. Remove the retainer bolt and pull the
speedometer cable from the transaxle assembly.
6. Remove the cotter pin securing the select and
shift cables and remove the cable ends from the
transaxle.

DRIVETRAIN 7-3
7. Remove the connection for the clutch release
38. Install the battery.
bolt to 54 ft. Ibs. (73 Nm). Install the front engine roll
cylinder and without disconnecting the hydraulic line,
39. If equipped with Active-ECS, connect the air
stopper through-bolt and hand-tighten. Once the full
and secure it aside.
compressor.
weight of the engine is on the mounts, tighten the
8. Disconnect the backup light switch harness
40. Make sure the vehicle is level when refilling
bolt to 42 ft. Ibs. (57 Nm).
and position aside.
the transaxle. Use Hypoid gear oil or equivalent, GL-
30.
Install the triangular stay bracket and tighten
9. Detach the starter electrical connections, if
4 or higher.
the mounting bolts to 65 ft. Ibs. (88 Nm).
necessary, remove the starter motor and position
41. Check the transaxle and transfer case for
31. Connect the clutch release cylinder.
aside.
proper operation. Make sure the reverse lights come
32. Install the halfshafts, using new circlips on
10. Remove the transaxle mount bracket.
on when in reverse.
the axle ends.
11. Remove the upper transaxle mounting bolts.
12.
Raise the vehicle and support safely on jack-
1!I94-Ol? MODELS
stands.
13. Remove the undercover and the front wheels. 1. Disconnect the negative battery cable and When histalling the axleshaft, keep the in-
14.
Remove the cotter pin and disconnect the tie wait at least 90 seconds before performing any work. board joint straight in relation to the axle, so
rod end from the steering knuckle. 2. Remove the air cleaner and intake hoses. not to damage the oil seal lip of the
15. Remove the self-locking nut from the half- 3. Drain the transaxle into a suitable waste con- transaxle, with the serrated part of the half-
ShaftS. tainer. shaft.
16.
Disconnect the lower arm ball joint from the 4. Remove the cotter pins and clips securing the
steering knuckle. select and shift cables and remove the cable ends 33. Connect the tie rod and ball joints to the steer-
17. Remove the halfshafts from the transaxle. from the transaxle. ing knuckle. Tighten the ball joint self-locking nuts to
18. On AWD models, disconnect the front ex- 5. If equipped with Active-ECS, disconnect the 48 ft. Ibs. (65 Nm). Tighten the tie rod end nut to 21 ft.
haust pipe. air compressor. Ibs. (28 Nm) and secure with a new cotter pin.
19.
On AWD ‘models, remove the transfer case by 6. Disconnect the backup light switch harness 34.
Connect the damper fork to the lower control
removing the attaching bolts, moving the transfer and position aside. arm and tighten the through-bolt to 65 ft. Ibs. (88 Nm).
case to the left and lowering the front side. Remove it 7. Disconnect the speedometer electrical con- 35.
Connect the stabilizer link to the damper fork,
from the rear driveshaft. Be careful of the oil seal. Do nectar, from the transaxle assembly. and tighten the self-locking nut to 29 ft. Ibs. (39 Nm).
not allow the driveshaft to hang; once the front is re- 8. Remove the starter motor and position aside. 36. Install the underpan.
moved from the transfer, tie it up. Cover the transfer 9. Using special tool M2203827 or equivalent, 37. Install wheels and lower vehicle.
case openings to keep out dirt. support the engine assembly. 38. Install the transaxle mount bracket to the
20.
Remove the cover from the transaxle bell- 10. Remove the rear roll stopper mounting transaxle, and tighten the mounting nuts to 32 ft. Ibs.
housing. bracket. (43 Nm).
21. On AWD models, remove the crossmember 11. Remove the transaxle mount bracket. 39. install the rear roll stopper mounting bracket.
and the triangular gusset. 12. Remove the upper transaxle mounting bolts. 40.
Remove the engine support. Tighten the
22. Remove the transaxle lower coupling bolt. It 13. Raise and safely support the vehicle. transaxle mount through-bolt to 51 ft. Ibs. (69 Nm)
is just above the halfshaft opening on FWD or trans- 14. Remove the front wheel assemblies. and tighten the front engine roll stopper through-bolt.
fer case opening on AWD. 15. Remove the right hand undercover. 41. Install the upper transaxle mounting bolts
23.
Support the weight of the engine from above 16. Remove the cotter pin and disconnect the tie and tighten to 35 ft. Ibs. (48 Nm).
(chain hoist). Support the transaxle using a transmis- rod end, from the steering knuckle. 42. Install the starter motor.
sion jack and remove the remaining lower mounting 17. Disconnect the stabilizer bar link, from the 43. Attach the backup light switch and the
bolts. damper fork. speedometer connector.
24. On turbocharged vehicle, be careful not to 18. Disconnect the damper fork, from the lateral 44.
Connect the select and shift cables and install
damage the lower radiator hose with the transaxle lower control arm. new cotter pins.
housing during removal. Wrap tape on both the lower 19. Disconnect the later lower arm, and the com- 45.
Install the air cleaner and the air intake hose.
hose and the transaxle housing to prevent damage. pression arm, lower ball joints, from the steering 46. Connect the negative battery cable.
Move the transaxle assembly to the right and care- knuckle. 47. Make sure the vehicle is level, and refill the
fully lower it from the vehicle. 20. Pry the halfshafts from the transaxle, and se- transaxle.
To install: cure aside. 48.
Check the transaxle for proper operation. Make
25.
Install the transaxle to the engine and install 21. Remove the connection for the clutch release sure the reverse lights come on when in reverse.
the mounting bolts, Tighten the bolts to 35 ft. Ibs. (48 cylinder and without disconnecting the hydraulic line,
Nm). Install the transaxle lower coupling bolt. secure aside.
26.
Install the underpan, crossmember and the 22. Remove the cover from the transaxle bell-
triangular gusset. housing.
27.
Install the transfer case on AWD models and 23. Remove the engine front roll stopper REMOVAL&INSTALLATION
connect the exhaust pipe. through-bolt.
28.
Install the halfshafts, using new circlips on 24. Remove the crossmember and the triangular ) See Figures 1 thru 13
the axle ends. Try to keep the inboard joint straight in right hand stay.
relation to the axle. Be careful not to damage the oil 25. Support the transaxle, using a transmission
seal lip of the transaxle with the serrated part of the jack, and remove the transaxle lower coupling bolt.
halfshaft.
29. Connect the tie rod and ball joint to the steer- *The coupling bolt threads from the englne
side, into the transaxle, and is located just
ing knuckle.
30. Install the transaxle mount bracket. above the halfshaft opening.
31. Install wheels and lower vehicle. Retorque 26. Slide the transaxle rearward and carefully
axle shaft nuts to 145-188 ft. Ibs. (200-260 Nm). lower it from the vehicle.
32. Install the starter motor. To install:
33. Connect the backup light switch and the 27. Install the transaxle to the engine. Install the
speedometer cable. mounting bolts and tighten to 35 ft. Ibs. (48 Nm). In-
34. Install the clutch release cylinder. stall the transaxle lower coupling bolt and tighten to
35.
Connect the select and shift cables and install 22-25 ft. Ibs. (30-34 Nm).
new cotter pins. 28. Install the cover to the transaxle bellhousing
36. Install the air intake hose. and tighten the mounting bolts to 7 ft. Ibs. (9 Nm).
37. Install the auto-cruise actuator and bracket. 29. Install the crossmember and tighten the front
mounting bolts to 65 ft. Ibs. (88 Nm) and the rear

7-10 DRIVETRAIN
The automatic transaxle allows engine torque and
power to be transmitted to the front wheels within a
narrow range of engine operating speeds. It will allow
the engine to turn fast enough to produce plenty of
power and torque at very low speeds, while keeping it
at a sensible rpm at high vehicle speeds (and it does
this job without driver assistance). The transaxle uses
a light fluid as the medium for the transmission of
power. This fluid also works in ths operation of vari-
ous hydraulic control circuits and as a lubricant. Be-
cause the transaxle fluid performs all of these func-
tions, trouble within the unit can easily travel from one
part to another For this reason, and because of the
complexity and unusual operating principles of the
transaxle, a very sound understanding of the basic
principles of operation will simplify troubleshooting
REMOVAL &INSTALLATION
Pan removal, fluid and filter
in Section 1 of this manual changes are covered
REMOVAL &INSTALLATION
1990-97 Mirage and 1990-93 Galant
# See Figure 44
1. Disconnect the negative battery cable.
2. Disconnect the selector cable from the lever
3. Remove the two retaining screws and lift off
the switch.
To install: 4. Mount and position new switch. Do not tighten
the bolts until the switch is adjusted.
5. Connect selector cable and adjust switch.
6. After installation and adjustment make sure the
engine only starts in the
P and N selections. Also check
that the reverse lights operate only in the R selectlon.
1994-00 Galant and 1998-00 Mirage
e See Figure 44
93157pm Fig. 44 Typically, the park/neutral position
switch is located on the top of the transaxle
1. Disconnect the negative battery cable.
2. Remove the nut attaching the shift control ca-
ble from the transaxle manual shaft lever. Position
the control cable out of the way.
3. Place the manual shaft lever in the Neutral
position, remove the nut and the manual shaft lever.
4. Detach the park/neutral switch electrical con-
nector.
5. Remove the park/neutral switch mounting
bolts and remove the switch from the transaxle man-
ual shaft.
To install: 6. Install the park/neutral switch to the transaxle
manual shaft and install the switch mounting bolts
Do not tighten the mounting bolts unh the switch is
adjusted.
7. Install the manual shaft lever to the park/neu-
tral switch with the nut. Make sure that the shaft lever
is in the Neutral position.
8. Adjust the switch in the following manner:
turn the switch body until the hole in the body of the
switch aligns with the hole in the manual shaft lever.
Insert a drill bit or equivalent into the holes. Tighten
the switch mounting bolts to 8 ft. Ibs. (11 Nm).
9. Attach the electrical connector.
10. Install the control cable to the manual shaft
lever with the nut. Adjust the cable so that there is no
slack in the cable and that the selector lever moves
smoothly
11. Reconnect the negative battery cable Check
for proper starting and proper reverse light operatron.
Diamante
ti See Figure 44
1. Disconnect the negative battery cable.
Wait at least 90 seconds after the negative
battery cable is disconnected to prevent pos-
sible deployment of the air bag.
2. Disconnect the selector cable from the lever.
3. Remove the two retaining screws and lift off
the switch.
To install: 4. Install the lever, tighten the bolts only hand
tight.
5. Rotate switch body so the manual control lever
0.20 inch (5mm) hole and the switch body 0.20 inch
(5mm) holes are aligned.
6. Tighten the mounting bolts to 7-8 ft. Ibs.
(10-12 Nm).
7. Connect the selector cable to the lever.
8. Connect the negative battery cable.
9. After installahon and adjustment make sure the
engine only starts in the
P and N selections. Also
check that the reverse lights operate only in the R se- lection.
ADJUSTMENT
1990-97 Mirage and 1990-93 Galant
1. Disconnect the negative battery cable and lo-
cate the neutral safety switch on the top of the
transaxle.
*Apply parking brake and chock wheels be-
fore placing transaxle into the N position
2. At the transmission, loosen the shift cable ad-
justment nut. Inside the vehicle place the gearshift
selector lever in N
3. Place the manual shift control lever in N.
4. Loosen neutral safety switch mounhng screws
and rotate switch body so the manual control lever
0.20 in. (5mm) hole and the switch body 0.20 in.
(5mm) holes are aligned.
5. Tighten switch body mounting bolts to 7-8 ft.
Ibs. (lo-12 Nm).
6. At the shift cable adjusting nut, gently pull ca-
ble to remove any slack. Tighten locknut to 8 ft. Ibs.
(12 Nm)
7. Verify that the switch lever moves to positions
corresponding to each position of the selector lever.
Connect the negative battery terminal.
8. Make sure the engine only starts in the
P and
N positions. Also make sure the reverse lights oper-
ate only in
R selection.
REMOVAL&INSTALLATION
Diamante
) See Figures 45, 46, 47, and 48
1. Properly disarm the SRS system (air bag).
Refer to Section 6.
2. Raise and safely support the vehicle.
3. Remove the front wheels.
4. Remove the engine side cover and undercov-
ers.
5. Drain the transaxle assembly into a suitable
container.
6. If equipped, remove the front catalytic con-
verter.
7. Remove the exhaust pipe, main muffler and
catalytic converter.
8. Disconnect the tie rod end and ball joint from
the steering knuckle.
9. Unbolt the support bearing for the left side
halfshaft.
10. Remove the halfshafts by inserting a prybar
between the transaxle case and the driveshaft and
prying the shaft from the transaxle.
11. Remove the air cleaner assembly and adjoin-
ing duct work.
12. Detach the engine harness connection.
13. If the vehicle is equipped with Active Elec-
tronlc Controlled Suspension (Active-ECS), remove
the compressor assembly from the transaxle and sus-
pend with wire. Do not allow the compressor to hang
from the air hose.
14. If equipped, remove the roll stopper stay
bracket.
15. Disconnect the speedometer cable from the
transaxle.
16. Remove the clip that secures the shifter and
disconnect the shifter control cable from the
transaxle.
17. Disconnect and plug the oil cooler hoses
from the transaxle.
18. Detach the following:

DRIVETRAIN 7-13
27. Shde the transaxle rearward and carefully
lower it from the vehicle.
To install: 28. After the torque converter has been mounted
on the transaxle, install the transaxle assembly to the
engine. Install the mounting bolts and tighten to 35
ft. Ibs. (48 Nm).
29. Install the transaxle lower coupling bolt and
tighten to 21-25 ft Ibs. (29-34 Nm).
30. Connect the torque converter to the flexplate
and tighten the bolts to 33-38 ft. Ibs. (45-52 Nm).
31. Install the cover to the transaxle bellhous-
ing and tighten the mounting bolts to 7 ft. Ibs. (9
Nm).
32 Install the crossmember and tighten the front
mounting bolts to 65 ft. Ibs (88 Nm) and the rear
bolt to 54 ft. Ibs. (73 Nm) Install the front engine roll
stopper through-bolt and lightly tighten. Once the full
weight of the engine is on the mounts, tighten the ’
bolt to 42 ft. Ibs. (57 Nm),
33. Install the triangular stay bracket and tighten
the mounting bolts to 65 ft. Ibs. (88 Nm).
34. Install the halfshafts, using new circlips on
the axle ends.
When installing the axleshaft, keep the in-
board joint straight in relation to the axle, so
as not to damage the oil seal lip of the
transaxle with the serrated part of the half-
shaft.
35. Connect the tie rod and ball joints to the
steering knuckle. Tighten the ball joint self-locking
nuts to 48 ft. Ibs. (65 Nm). Tighten the tie rod end nut
to 21 ft. Ibs. (28 Nm) and secure with a new cotter
pin.
36. Connect the damper fork to the lower control
arm and tighten the through-bolt to 65 ft Ibs. (88
Nm).
37. Connect the stabilizer link to the damper fork,
and tighten the self-locking nut to 29 ft. Ibs. (39 Nm).
38. Install the undercover.
39. Install the wheels and carefully lower the ve-
hicle
40. Install the transaxle mount bracket to the
transaxle, and tighten the mounting nuts to 32 ft. Ibs.
(43 Nm).
41. Install the rear roll stopper mounting bracket.
42. Remove the engine support. Tighten the
transaxle mount through-bolt to 51 ft. Ibs. (69 Nm)
and tighten the front engine roll stopper through-bolt.
43. Install the upper transaxle mounting bolts
and tighten to 35 fl. Ibs. (48 Nm).
44. Install the starter motor.
45. Install the dipstick tube and the dipstick
46. Install the shifter cable mounting bracket.
47. Connect the shifter lever and tighten the re-
taining nut to 14 ft. Ibs. (19 Nm).
48. Connect the oil cooler lines and secure with
clamps.
49. Attach the electrical connectors for the
speedometer, solenoid, neutral safety switch (in-,
hibitor switch), the pulse generator, kickdown servo
switch and oil temperature sensor.
50. Install the air cleaner and the air intake hose.
51. Connect the negative battery cable.
52. Make sure the vehicle is level, and refill the
transaxle. Start the engine and allow to idle for 2 minutes. Apply parking brake and move selector
through each gear position, ending in N. Recheck
fluid level and add if necessary. Fluid level should be
between the marks in the HOT range.
53. Check the transaxle for proper operation.
Make sure the reverse lights come on when in re-
verse and the engine starts only in
P or N.
Mirage
*If the vehicle is going to be rolled on its
wheels while the halfshafts are out of the ve-
hicle, obtain two outer CV-joints or proper
equivalent tools and install to the hubs. If the
vehicle is rolled without the proper torque
applied to the front wheel bearings, the bear-
ings will no longer be usable.
1. Disconnect the negative battery cable then
the positive battery cable.
2. Remove the battery and battery tray.
3. Remove the air hose and air cleaner assem-
bly.
4. Raise the vehicle and support safely.
5. Remove the under guard pan.
6. Drain the transaxle oil into a suitable con-
tainer.
7. If equipped with 1.6L engine, remove the ten-
sion rod.
8. Disconnect the control cable and cooler
lines.
9. On 3-speed transaxles, disconnect the throt-
tle control cable.
10. On 4-speed transaxles, perform the following:
a. Detach the shift control solenoid valve
connector.
b. Disconnect the inhibitor switch and kick-
down servo switch.
c. Disconnect the pulse generator and oil
temperature sensor.
11. Disconnect the speedometer cable and re-
move the starter.
12. Remove the transaxle mounting bolts and
bracket.
13. Disconnect the stabilizer bar from the lower
control arm.
14. Disconnect the steering tie rod end and the
ball joint from the steering arm.
15. Remove the halfshafts at the inboard side
from the transaxle. Tie the joint assembly aside.
*It is not necessary to disconnect the half-
shafts from the wheel hubs.
16. Support the engine and remove the center
member.
17. Remove the bellhousing cover and remove
the driveplate bolts.
18 Remove the transaxle assembly lower con-
necting bolt, located just over the halfshaft opening.
19. Properly support the transaxle assembly, then
lower it, moving it to the right for clearance.
To install: 20. After the torque converter has been mounted
on the transaxle, install the transaxle assembly on the
engine. Install the mounting bolts and tighten to
31-40 ft. Ibs. (43-55 Nm) on 1990-92 models and
35 ft. Ibs. (48 Nm) on 1993-00 models.
21. Tighten the driveplate bolts to 33-38 ft. Ibs.
(46-53 Nm). Install the bellhousing cover.
22. Install the center member. 23. Replace the circlips and install the halfshafts
to the transaxle.
24. Install the tie rods, ball joints and stabilizer
links to the steering arm
25. Install the transaxle mounting bracket and
bolts.
26. Install the starter.
27. Connect the speedometer cable.
28. Connect the inhibitor switch, kickdown servo
switch, the pulse generator and oil temperature sen-
sor, if disconnected.
29. Connect the shift control solenoid valve con-
nector.
30. Connect the control cables and oil cooler
lines.
31. Install the tension rod, if removed.
32. Install the air cleaner assembly.
33. Install the battery tray and battery.
34. Connect the positive then the negative termi-
nal.
35. Refill with Dexron@ II, Mopar ATF Plus type
7176 or equivalent, automatic transaxle fluid.
36. Start the engine and allow to idle for two min-
utes. Apply parking brake and move selector through
each gear position, ending in N. Recheck fluid level
and add if necessary. Fluid level should be between
the marks in the HOT range.
ADJUSTMENTS
Shifter Control Cable Adjustment
1. The shifter cable adjustment is done at the
neutral safety switch (inhibitor switch). Locate the
switch on the transaxle and note the alignment holes
in the arm and the body of the switch. Place the se-
lector lever in N. Place the manual lever of the
transaxle in the neutral position.
2. Check alignment of the hole in the manual
control lever to the hole in the inhibitor switch body.
If the holes do not align, adjustment is required.
3. To adjust, loosen the nut on the cable end and
pull the cable end by hand until the alignment holes
match. Tighten the nut. Check that the transaxle
shifts and conforms to the positions of the selector
lever.
Throttle Valve Cable
The throttle valve adjustment applies only to the
1990-96 Mirage.
1. Place selector lever and manual control lever
in N position.
2. Loosen adjusting nut. While lightly pulling on
control cable tighten mounting nut to 7-10 ft. Ibs.
(X-14 Nm).
3. When adjustment is complete, be sure selector
lever is still in the N position. Verify all functions
correspond to the position indicated on the selector
lever.
The halfshaft removal and installation and over-
haul are the same as a manual transaxle Please refer
to Manual Transaxle in this Section

SUSPENSION AND STEERING 8-33
*Matchmark the pinion input shaft of the
rack to the lower steering column joint for in-
stallation purposes.
6. Remove the pinch bolt holding the lower
steering column joint to the rack and pinion input
shaft.
7. Remove the cotter pins and disconnect the tie
rod ends from the steering knuckle.
8. Remove the rack and pinion steering assem-
bly and its rubber mounts from the right side of the
vehicle.
To install: 9. Align the matchmarks of the input shaft and
install the rack to the vehicle.
10. Secure the rack using the retainer clamps and
bolts. Tighten the bolts to 51 ft. Ibs. (70 Nm).
11. Tighten the steering column pinch bolt to 13
ft. Ibs. (18 Nm).
12. Install the center member.
13. Install the front exhaust pipe.
14. Connect the HO$ sensor.
15. Connect the tie rod ends to the steering
knuckles and tighten the castle nuts to 25 ft. Ibs. (34
Nm). Install new cotter pins.
16. Install the wheels and connect the negative
battery cable.
17. Have a front end alignment performed.
REMOVAL &INSTALLATION
Diamante
FRONT
*Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clock spring and render SRS system in-
operative.
1. Disconnect the negative battery cable.
2. Disconnect the front exhaust pipe.
3. If equipped with AWD, remove the transfer
case assembly.
4. Remove the bolt holding the lower steering
column joint to the rack and pinion input shaft.
5. Remove the cotter pins and disconnect the tie
rod ends.
6. Remove the left and right frame members.
7. Remove the stabilizer bar bracket.
8. If equipped with four-wheel steering, discon-
nect the lines going to the rear pump.
9. Remove the rack and pinion steering assem-
bly and its rubber mounts. Move the rack to the right
to remove it from the crossmember.
To install: IO. Install the rack and mounting bolts. Tighten
the bolts to 51 ft. Ibs. (70 Nm). When installing the
rubber rack mounts, align the projection of the
mounting rubber with the indentation in the cross:
member. Install the pinch bolt.
11. Connect the pressure and return lines to the
rack and to the rear pump, if equipped.
12. Install the frame members and tighten the
bolts to 43-51 ft. Ibs. (60-70 Nm).
13. Connect the tie rods and install new cotter
pins. 14. Install the transfer case and front exhaust
pipe.
15. Refill the reservoir and bleed the system.
16. Have a front end alignment performed.
REAR
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Drain the power steering fluid.
4. Remove the main muffler assembly.
5. Remove the rear shock absorber lower
mounting bolts.
6. Using the proper equipment, support the
weight of the rear differential. Remove the 2 small
crossmember brackets.
7. Remove the large self-locking crossmember
mounting nuts on the differential side.
8. Remove the oil line clamp bolts.
9. Remove the pressure tubes.
IO. Hold the tie rod ends stationary and remove
the tie rod end nuts. Remove the tie rod ends from
the trailing arms.
11. Remove the mounting bolts and remove the
rear steering gear.
To install: 12. Secure the unit to the crossmember. Move
the power cylinder piston rod over its full stroke to
determine its neutral position.
13. Align the tie rod ends with the holes in the
trailing arms and install the nuts. Adjust the length of
the tie rods with the nuts if necessary. The difference
in length between the 2 tie rod ends should not ex-
ceed 0.04 in. (1 mm). The nuts’ torque specification is
42 ft. Ibs. (58 Nm).
14. Replace the O-rings and install the pressure
tubes. Clamp in place.
15. Install the large self-locking crossmember
mounting nuts on the differential side. Tighten to
80-94 ft. Ibs. (110-130 Nm).
16. Remove the support equipment.
17. Install the 2 small crossmember brackets.
18. Install the shock mounting bolts.
19. Install the muffler assembly.
20. Refill the reservoir and bleed the system.
21. Have a front end alignment performed. _
Galant
1990-93 MODELS
1. Disconnect the negative battery cable.
2. Drain the power steering fluid.
3. Raise the vehicle and support safely.
4. Remove the bolt holding lower steering col-
umn joint to the rack and pinion input shaft.
5. Remove the transfer case, if equipped.
6. Remove the cotter pins and using the proper
tools, separate the tie rod ends from the steering
knuckle.
7. Locate the triangular brace near the stabilizer
bar brackets on the crossmember and remove both
the brace and the stabilizer bar bracket.
8. Support the center crossmember.
9. Remove the through-bolt from the round roll
stopper and remove the rear bolts from the center
crossmember.
10. Disconnect the front exhaust pipe, if
equipped with FWD.
11. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings. Plug the
fittings to prevent excess fluid leakage. 12. Lower the crossmember slightly.
13. Remove the rack and pinion steering assem-
bly and its rubber mounts. Move the rack to the right
to remove from the crossmember. Tilt the assembly
downward and remove from the left side of the vehi-
cle. Use caution to avoid damaging the boots.
To install: 14. Install the rack and install the mounting bolts. Tighten the mounting bolts to 43-58 ft. Ibs. (60-80
Nm). When installing the rubber rack mounts, align
the projection of the mounting rubber with the inden-
tation in the crossmember.
15. Connect the power steering fluid lines to the
rack.
16. Connect the exhaust pipe, if removed.
17. Raise the crossmember into position. Install
the center member mounting bolts and tighten to 72
ft. Ibs. (100 Nm). Install the roll stopper bolt and new
nut. Tighten nut to 47 ft. Ibs. (65 Nm).
18. Install the stabilizer bar brackets and brace.
19. Connect the tie rod ends and tighten nuts to
25 ft. Ibs. (34 Nm).
20. Install the transfer case, if removed. Check
and fill fluid.
21. Refill the reservoir with power steering fluid
and bleed the system.
22. Have a front end alignment performed.
1994-M MODELS
+ See Figure 96
Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clock spring and render SRS system in-
operative.
1. Disconnect the negative battery cable.
2. Raise and properly support the vehicle.
3. Remove both front wheel assemblies.
4. Remove the bolt holding lower steering col-
umn joint to the rack and pinion input shaft.
5. Remove the stabilizer bar.
6. Remove the cotter pins, and using joint sepa-
rator MB991 113 or equivalent, disconnect the tie rod
ends from the steering knuckle.
7. On vehicles equipped with Electronic Control
Power steering (EPS), detach the wiring harness from
the solenoid connector.
8. Locate the two triangular braces near the
crossmember and remove both.
9. Support the center crossmember. Remove the
through-bolt from the front round roll stopper and re-
move the bolts securing the center crossmember.
10. Remove the center crossmember. ,
Il. Properly support the engine and remove the
rear roll stopper through-bolt.
12. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings. Plug the
fittings to prevent excessive fluid leakage.
13. Remove the clamp bolts and the two bolts se-
curing the rack assembly to the chassis.
14. Remove the rack and pinion steering assem-
bly and its rubber mounts.
*When removing the rack and pinion as-
sembly, tilt the assembly to the vehicle side
of the compression lower arm and remove
from the left side of the vehicle.

9-2 BRAKES
Hydraulic systems are used to actuate the brakes
of all modern automobiles. The system transports the
power required to force the frictional surfaces of the
braking system together from the pedal to the indi-
vidual brake units at each wheel. A hydraulic system
is used for two reasons.
First, fluid under pressure can be carried to all
parts of an automobile by small pipes and flexible
hoses without taking up a significant amount of room
or posing routing problems.
Second, a great mechanical advantage can be
given to the brake pedal end of the system, and the
foot pressure required to actuate the brakes can be
reduced by making the surface area of the master
cylinder pistons smaller than that of any of the pis-
tons in the wheel cylinders or calipers.
The master cylinder consists of a fluid reservoir
along with a double cylinder and piston assembly.
Double type master cylinders are designed to sepa-
rate the front and rear braking systems hydraulically
in case of a leak. The master cylinder converts me-
chanical motion from the pedal into hydraulic pres-
sure within the lines. This pressure is translated back
into mechanical motion at the wheels by either the
wheel cylinder (drum brakes) or the caliper (disc
brakes).
Steel lines carry the brake fluid to a point on the
vehicle’s frame near each of the vehicle’s wheels. The
fluid is then carried to the calipers and wheel cylin-
ders by flexible tubes in order to allow for suspen-
sion and steering movements.
In drum brake systems, each wheel cylinder con-
tains two pistons, one at either end, which push out-
ward in opposite directions and force the brake shoe
into contact with the drum.
In disc brake systems, the cylinders are part of the
calipers. At least one cylinder in each caliper is used
to force the brake pads against the disc.
All pistons employ some type of seal, usually
made of rubber, to minimize fluid leakage. A rubber
dust boot seals the outer end of the cylinder against
dust and dirt. The boot fits around the outer end of
the piston on disc brake calipers, and around the
brake actuating rod on wheel cylinders.
The hydraulic system operates as follows: When at
rest, the entire system, from the piston(s) in the mas-
ter cylinder to those in the wheel cylinders or
calipers, is full of brake fluid. Upon application of the
brake pedal, fluid trapped in front of the master cylin-
der piston(s) is forced through the lines to the wheel
cylinders. Here, it forces the pistons outward, in the
case of drum brakes, and inward toward the disc, in
the case of disc brakes. The motion of the pistons is
opposed by return springs mounted outside the
cylinders in drum brakes, and by spring seals, in disc
brakes.
Upon release of the brake pedal, a spring located
inside the master cylinder immediately returns the
master cylinder pistons to the normal position. The
pistons contain check valves and the master cylinder
I
has compensating ports drilled in it. These are un-
covered as the pistons reach their normal position.
The piston check valves allow fluid to flow toward the
wheel cylinders or calipers as the pistons withdraw.
Then, as the return springs force the brake pads or
shoes into the released position, the excess fluid
reservoir through the compensating ports. It is during the time the pedal is in the released position that any
fluid that has leaked out of the system will be re-
placed through the compensating ports.
Dual circuit master cylinders employ two pistons,
located one behind the other, in the same cylinder.
The primary piston is actuated directly by mechanical
linkage from the brake pedal through the power
booster. The secondary piston is actuated by fluid
trapped between the two pistons. If a leak develops in
front of the secondary piston, it moves forward until it
bottoms against the front of the master cylinder, and
the fluid trapped between the pistons will operate the
rear brakes. If the rear brakes develop a leak, the pri-
mary piston will move forward until direct contact
with the secondary piston takes place, and it will
force the secondary piston to actuate the front brakes.
In either case, the brake pedal moves farther when the
brakes are applied, and less braking power is avail-
able.
All dual circuit systems use a switch to warn the
driver when only half of the brake system is opera-
tional. This switch is usually located in a valve body
which is mounted on the firewall or the frame below
the master cylinder. A hydraulic piston receives pres-
sure from both circuits, each circuits pressure being
applied to one end of the piston. When the pressures
are in balance, the piston remains stationary. When
one circuit has a leak, however, the greater pressure
in that circuit during application of the brakes will
push the piston to one side, closing the switch and
activating the brake warning light.
In disc brake systems, this valve body also con-
tains a metering valve and, in some cases, a propor-
tioning valve. The metering valve keeps pressure
from traveling to the disc brakes on the front wheels
until the brake shoes on the rear wheels have con-
tacted the drums, ensuring that the front brakes will
never be used alone. The proportioning valve con-
trols the pressure to the rear brakes to lessen the
chance of rear wheel lock-up during very hard brak-
ing.
Warning lights may be tested by depressing the
brake pedal and holding it while opening one of the
wheel cylinder bleeder screws. If this does not cause
the light to go on, substitute a new lamp, make conti-
nuity checks, and, finally, replace the switch as nec-
essary.
The hydraulic system may
be checked for leaks by applying pressure to the pedal gradually and steadily.
If the pedal sinks very slowly to the floor, the system
has a leak. This is not to be confused with a springy
or spongy feel due to the compression of air within
the lines. If the system leaks, there will be a gradual
change in the position of the pedal with a constant
pressure.
Check for leaks along all lines and at wheel cylin-
ders. If no external leaks are apparent, the problem is
inside the master cylinder,
DISC BRAKES
Instead of the traditional expanding brakes that
press outward against a circular drum, disc brake
systems utilize a disc (rotor) with brake pads posi-
tioned on either side of it. An easily-seen analogy is
the hand brake arrangement on a bicycle. The pads
squeeze onto the rim of the bike wheel, slowing its
motion. Automobile disc brakes use the identical principle but apply the braking effort to a separate
disc instead of the wheel.
The disc (rotor) is a casting, usually equipped with
cooling fins between the two braking surfaces. This
enables air to circulate between the braking surfaces
making them less sensitive to heat buildup and more
resistant to fade. Dirt and water do not drastically af-
fect braking action since contaminants are thrown off
by the centrifugal action of the rotor or scraped off
the by the pads. Also, the equal clamping action of
the two brake pads tends to ensure uniform, straight
line stops. Disc brakes are inherently self-adjusting.
There are three general types of disc brake:
1. A fixed caliper.
2. A floating caliper.
3. A sliding caliper.
The fixed caliper design uses two pistons
mounted on either side of the rotor (in each side of
the caliper). The caliper is mounted rigidly and does
not move.
The sliding and floating designs are quite similar.
In fact, these two types are often lumped together. In
both designs, the pad on the inside of the rotor is
moved into contact with the rotor by hydraulic force.
The caliper, which is not held in a fixed position,
moves slightly, bringing the outside pad into contact
with the rotor. There are various methods of attaching
floating calipers. Some pivot at the bottom or top,
and some slide on mounting bolts. In any event, the
end result is the same.
DRUM BRAKES
Drum brakes employ two brake shoes mounted on
a stationary backing plate. These shoes are posi-
tioned inside a circular drum which rotates with the
wheel assembly. The shoes are held in place by
springs. This allows them to slide toward the drums
(when they are applied) while keeping the linings and
drums in alignment. The shoes are actuated by a
wheel cylinder which is mounted at the top of the
backing plate. When the brakes are applied, hydraulic
pressure forces the wheel cylinder’s actuating links
outward. Since these links bear directly against the
top of the brake shoes, the tops of the shoes are then
forced against the inner side of the drum. This action
forces the bottoms of the two shoes to contact the
brake drum by rotating the entire assembly slightly
(known as servo action). When pressure within the
wheel cylinder is relaxed, return springs pull the
shoes back away from the drum.
Most modern drum brakes are designed to self-
adjust themselves during application when the vehi-
cle is moving in reverse. This motion causes both
shoes to rotate very slightly with the drum, rocking
an adjusting lever, thereby causing rotation of the ad-
justing screw. Some drum brake systems are de-
signed to self-adjust during application whenever the
brakes are applied. This on-board adjustment system
reduces the need for maintenance adjustments and
keeps both the brake function and pedal feel satisfac-
tory.
POWER BOOSTERS
Virtually all modern vehicles use a vacuum as-
sisted power brake system to multiply the braking
force and reduce pedal effort. Since vacuum is always
available when the engine is operating, the system is

BRAKiS 9-3
simple and efficient. A vacuum diaphragm is located gine. Have an assistant observe the brake lights at the
on the front of the master cylinder and assists the dri- rear of the vehicle while you push on the brake pedal.
ver in applying the brakes, reducing both the effort The lights should come on just as the brake pedal
and travel he must put into moving the brake pedal. passes the point of free play.
The vacuum diaphragm housing is normally con- 9.
Adjust the brake light switch as necessary. The
netted to the intake manifold by a vacuum hose. A small amount of free play in the
pedal should not
check valve is placed at the point where the hose en-
ters the diaphragm housing, so that during periods
Of low manifold vacuum brakes assist will not be lost.
Depressing the brake pedal closes off the vacuum
source and allows atmospheric pressure to enter on
one side of the diaphragm. This causes the master
cylinder pistons to move and apply the brakes. When
the brake pedal is released, vacuum is applied to
REMOVAL &INSTALLATION
both sides of the diaphragm and springs return the
diaphragm and master cylinder pistons to the re- ) See Figures 2 thru 10
leased position.
If the vacuum supply fails, the brake pedal rod will
contact the end of the master cylinder actuator rod
and the system will apply the brakes without any
power assistance. The driver will notice that much
higher pedal effort is needed to stop the car and that
the pedal feels harder than usual.
Vacuum leak Test
1. Operate the engine at idle without touching the
brake pedal for at least one minute.
2. Turn off the engine and wait one minute.
3. Test for the presence of assist vacuum by de-
pressing the brake pedal and releasing it several
3 MASTER N- 188A11Ly
times. If vacuum is present in the system, light appli- . KLNsIMEm 0s CLWRANCE
BETWEEN BRAKE WOSTER
cation will produce less and less pedal travel. If there PUSHROO AN0 PRIMARY PISTCU
is no vacuum, air is leaking into the system.
System Operation Test
1. With the engine OFF, pump the brake pedal
until the supply vacuum is entirely gone.
2. Put light, steady pressure on the brake pedal.
3. Start the engine and let it idle. If the system is
operating correctly, the brake pedal should fall to-
ward the floor if the constant pressure is maintained.
Power brake systems may be tested for hydraulic
leaks just as ordinary systems are tested.
REMOVAL&INSTALLATION
$ See Figure 1
1. Disconnect the negative battery cable.
2. Detach the stop lamp switch electrical harness
connector.
3. Loosenthe locknut holding the switch to the
bracket. Remove the locknut and the switch.
To install:
4.
Install the new switch and install the locknut,
tightening it just snug.
5. Reposition the brake light switch so that the
distance between the outer case of the switch and the
pedal is 0.02-0.04 in. (0.5-l .Omm). Note that the
switch plunger must press against the pedal to keep
the brake lights off. As the pedal moves away from
the switch, the plunger extends and closes the
switch, which turns on the stop lights.
6.
Hold the switch in the correct position and
tighten the locknut.
7. Connect the wiring to the switch.
8. Check the operation of the switch. Turn the ig-
nition key to the ON position but do not start the en-