1900 MITSUBISHI DIAMANTE power steering fluid

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

1-42 GENERAL~INFORMATION AND MAINTENANCE
Fig. 206 The fluid level should be between
llow,be*“retoch~ckiebrake~ . the MAX and MIN hnes if the fhud level IS
93151p31 Fig. 209 If the master cylinder capgasket
is swelled like such, it can be a sign of con-
tamination. If the gasket is swelled . . . Fig. 207 Wipe the master cylinder reservoir
clean before opening the cap to ensure that
no contamination enters the brake fluid
Fig. 210 . . .
make sure to push the gasket
back to the normal position
93151p29 I Fig. 208 Unscrew the master cylinder cap
and remove it from the reservoir
Fig. 211 Carefully pour approved brake fluid
from a fresh, sealed container directly into
the reservoir
2. Inspect the fluid in the reservoir, making sure
fluid is between the MAX and the MIN marks.
FLUID RECOMMENDATIONS
When adding or changing the fluid in the systems,
use a quality brake fluid conforming to DOT 3 speci-
fications from an sealed container. Never reuse old
brake fluid.
LEVEL CHECK
b See Figures 212, 213, and 214
1. Wipe the clutch master cylinder reservoir cap
and the surrounding area clean with a shop towel. 3. If required, remove the clut ch master cylinder
reservoir lid. then add fresh fluid I FLUID RECOMMENDATIONS
mark on the’reservoir. to fill to the top full
When adding or changing the power steering
fll$,“” Dexron@il ATF (Automatic Transmission
-
- .
Be careful to avoid sf Billing any brake fluid on LEVELCHECK
painted surfaces, bet
:ause the paint coat will
become discolored or damaged.
b See Figures 215, 216, 217, and 218
4. Reinstall the lid onto the clutch master cylin- Like all other general maintenance items, check
der. every 3,OOfl miles (4,800 km) or once a month. In-
5. If removed, install the air cleaner assembly. spect the oil level in the reservoir by checking the po-
Fig. 212 The clutch master cylinder has
MAX (A) and MIN (B) fill lines on the reser
volr

GENERALINFORMATIONAND MAINTENANCE l-43
l Special car washing detergent is the best to
use. Liquid dishwashing detergent can remove wax
and leave the car’s paint unprotected and in addition
some liquid detergents contains abrasives which can
scratch the paint.
l Bird droppings should be removed from the
paintwork as soon as possible, otherwise the finish
may be permanently stained.
When the car is driven immediately after be-
ing washed, apply the brakes several times
93151p14 93151p12 Fig. 215 Twist the reservoir cap, then lift up
I I
in order to remove any moisture from the
Fig. 216 Wipe the dipstick off, reinsert it braking surfaces.
on the integral cap/dipstick assembly
into the reservoir and check the level
I
Engine cleaning agents should not be used
when the engine is warm, a fire risk is pre-
sent as most engine cleaning agents are
highly flammable.
sition of the fluid against the mark on the dipstick,
Add fluid to the reservoir if the fluid does not reach
the appropriate full line.
On most models, the manufacturer doesn’t install
lubrication fittings on lube points on the steering
linkage or suspension. However, if the lubrication
point does have a grease fitting, lubricate with multi-
purpose NLGI No. 2 (Lithium base) grease.
CAR WASHING
The car should be washed at regular intervals to
remove dirt, dust, insects, and tar and other possibly
damaging stains that can adhere to the paint and may
cause damage. Proper exterior maintenance also
helps in the resale value of the vehicle by maintaining
its like-new appearance.
Mt is particularly important ta frequentiy
wash the car in the wintertime to prevent cor-
rosion, when salt has been used on the roads.
There are many precautions and tips on washing,
including the following:
l When washing the car, do not expose it do di-
rect sunlight.
. Use lukewarm water to soften the dirt before
you wash with a sponge, and plenty of water, to avoid
scratching.
l A detergent can be used to facilitate the soften-
ing of dirt and oil. * A water-soluble grease solvent may be used in
cases of sticky dirt. However, use a washplace with a
drainage separator.
l Dry the car with a clean chamois and remem-
ber to clean the drain holes in the doors and rocker
panels.
l If equipped with a power radio antenna, it must
be dried after washing.
Never clean the bumpers with gasoline or
paint thinner, always use the same agent as
used on the painted surfaces of the vehicle.
l Tar spots can be removed with tar remover or
kerosene after the car has been washed.
l A stiff-bristle brush and lukewarm soapy water
can be used to clean the wiper blades. Frequent
cleaning improves visibility when using the wipers
considerably.
l Wash off the did from the underside (wheel
housings, fenders, etc.).
l In areas of high industrial fallout, more fre-
quent washing is recommended.
During high pressure washing the spray nonle
must never be closer to the vehicle than 13
inches (30cm). Do not spray into the locks.
l When washing or steam cleaning the engine,
avoid spraying water or steam directly on the electri-
cal components or near the distributor or ignition
components. After cleaning the engine, the spark
plug wells should be inspected for water and blown
dry if necessary. Automatic car washing is a simple and quick way
to clean your car, but it is worth remembering that it
is not as thorough as when you yourself clean the
car. Keeping the underbody clean is vitally important,
and some automatic washers do not contain equip-
ment for washing the underside of the car.
When driving into an automatic was, make sure
the following precautions have been taken:
l Make sure all windows are up, and no objects
that you do not want to get wet are exposed.
l In some cases, rotating the side view mirrors
in can help to avoid possible damage.
l If your car is equipped with a power antenna,
lower it. If your vehicle has a solid mounted, non-
power antenna, it is best to remove it, but this is not
always practical. Inspect the surroundings to reduce
the risk of possible damage, and check to see if the
antenna can be manually lowered.
Most manufacturers do not recommend auto-
matic car washing in the first six months due
to the possibility of insufficient paint curing;
a safe bet is to wait until after six months of
ownership (when purchased new) to use an
automatic car wash.
WAXING
eBefore applying wax, the vehicle must be
washed and thoroughly dried.
Waxing a vehicle can help to preserve the appear-
ante of your vehicle. A wide range of polymer-based
car waxes are available today. These waxes are easy
to use and produce a long-lasting, high gloss finish
that protects the body and paint against oxidation,
road dirt, and fading.
Sometimes, waxing a neglected vehicle, or one
that has sustained chemical or natural element dam-
age (such as acid rain) require more than waxing,
and a light-duty compound can be applied. For se-
verely damaged surfaces, it is best to consult a pro-
fessional to see what would be required to repair the
damage.
Waxing procedures differ according to manufac-
turer, type, and ingredients, so it is best to consult
the directions on the wax and/or polish purchased.

3-2 ENGINEANDENGINEOVERHAUL
REMOVAL &INSTALLATION
# See Figure 1
In the process of removing the engine, you will
come across a number of steps which call for the re-
moval of a separate component or system, such as
“disconnect the exhaust system” or “remove the radi-
ator.” In most instances, a detailed removal proce-
dure can be found elsewhere in this manual.
It is virtually impossible to list each individual
wire and hose which must be disconnected, simply
because so many different model and engrne combi-
nations have been manufactured Careful observation
and common sense are the best possible approaches
to any repair procedure.
Removal and installation of the engine can be
made easier if you follow these basic points:
l If you have to drain any of the fluids, use a
suitable container.
l Always tag any wires or hoses and, if possrble,
the components they came from before disconnect-
ing them.
l Because there are so many bolts and fasteners
involved, store and label the retainers from compo-
nents separately in muffin pans, jars or coffee cans.
This will prevent confusion during installatron.
l After unbolting the transmisston or transaxle,
always make sure it is properly supported.
l If it is necessary to disconnect the air condi-
tioning system, have this service performed by a
qualified technician using a recovery/recycling sta-
tion If the system does not have to be disconnected,
unbolt the compressor and set it aside.
l When unbolting the engine mounts, always
make sure the engine is properly supported. When
removing the engine, make sure that any lifting de-
vices are properly attached to the engine. It is recom-
mended that if your engine IS supplied with lifting
hooks, your lifting apparatus be attached to them.
l Lift the engine from its compartment slowly,
checking that no hoses, wires or other components
are still connected.
l After the engine is clear of the compartment,
place it on an engine stand or workbench.
l After the engine has been removed, you can
perform a partial or full teardown of the engine using
the procedures outlined in this manual.
1. Relieve fuel system pressure.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnect the negative battery cable.
3. Remove the engine undercover if equipped. 4. Matchmark the hood and hinges and remove
the hood assembly.
5. Remove the air cleaner assembly and all ad-
joining air intake duct work.
6. Drain the engine coolant, remove the radiator
hoses, and remove the radiator assembly, coolant
reservoir, and intercooler, as equipped.
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
7. Remove the transaxle and transfer case as
equipped.
8. Tag and detach the following electrical con-
nections:
l Accelerator cable l Heater hoses l Brake booster vacuum hose l Vacuum hoses l Fuel lines l Engine ground cables l Any applicable sensors l Coolant temperature and oil pressure send-
ing units
l Exhaust Gas Recirculation (EGR) tempera-
ture sensor
l Connection for the idle speed control mo-
tor
l Fuel injectors l Power transistor l Ignition coil and any applicable distributor
connections
l The connections for the alternator l Power steering pressure switch l A/C compressor l Refrigerant temperature switch l Condenser
9. Remove the air conditioner drive belt and the
air conditioning compressor. Leave the hoses at-
tached. Do not discharge the system. Place the com-
pressor aside and secure it using a suitable device.
10. Remove the power steering pump and place
the pump asrde and secure it using a surtable device.
11. Remove the exhaust manifold-to-exhaust
pipe nuts. Discard the gasket.
12. Install the engine hoist equipment and make
certain the attaching points on the engine are secure.
13. Raise the hoist enough to support the engine.
14. Remove the front and rear engine roll stop-
pers
15. Remove the left engine mount and support
Double check that all cables, hoses, harness
connectors, etc., are disconnected from the
engine.
16. Slowly lift the engine and remove it from the
vehicle.
To install:
17. Install the engine and secure all control
brackets and mounts.
18. Install the transaxle, and transfer case if
equipped.
19. The balance of the installation is the reverse
of removal with the addition of the following notes:
a. Use new clamps or O-rings to connect the
high pressure fuel lme and the fuel return line.
b. Use new gaskets to connect the exhaust
system to the engine.
c. Fill the engine with the proper amount of
engine oil and coolant.
d. Start the engine, allow it to reach normal
operating temperature.
e. Check for leaks.
f. Check the ignition timing and adjust if nec-
essary.
g. Road test the vehicle and check all fluid
levels and functions for proper operation.
Fig. 1 Alignment of the engine mount stop-
oer bracket-Diamante shown
REMOVAL &INSTALLATION
Except 3.OL (SOHC and DOHC) and 3.5L
Engines
# See Figures 2 thru 11
1. Disconnect the negative battery cable.
2. If necessary, remove the air intake hose.
3. If necessary, remove the throttle cable from
the cable routing clips.
Fig. 2 If necessary, remove the throttle ca-
ble from the cable routing clips

.
3-20 ENGINEANDENGINEOVERHAUL
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the overflow hose and disconnect
the upper radiator hose.
*It is recommended that each clamp be
matchmarked to the hose. Observe the marks
and reinstall the clamps exactly when rein-
stalling the radiator.
4. If equipped with an automatic transaxle, re-
move and plug the fluid cooler hoses.
5. Unplug the electrical connector(s) from the
coolant fan motor.
6. Remove the mounting bolts, then remove the
fan and shroud assembly from the vehicle.
7. Remove the fan blade retainer nut from the
shaft on the fan motor and separate the fan from the
motor.
8. Remove the motor to shroud attaching
screws and the motor from the shroud.
To tnstall: 9. Install the motor to the shroud and secure
with the mounting bolts.
10. Install the remaining components in the re-
verse order of removal.
11. Fill the coohng system. Connect the negative
battery cable and check the cooling fan for proper op-
eration.
Diamante
# See Figure 94
1. Disconnect the negative battery cable 2. Drain the cooling system only when the radi-
ator and the engine are at safe temperatures. 1. Disconnect the negative battery cable
2. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Unplug the cooling fan and radiator sensor
connector(s). Most of these connectors employ a wa-
terproof connector. When disconnecting, make sure
all parts of the connector remain intact.
4. Disconnect the upper radiator hose from the
radiator and remove overflow tank.
5. Remove the fan mounting screws. The radia-
tor and condenser cooling fans are separately remov-
able.
6. Remove the fan assembly and disassemble
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the engine undercover.
4 Disconnect the clamp bolt from the power
steering hose.
5. Remove the engine drive belts.
6. Support the engine with the appropriate
equipment and remove the engine mount bracket.
7. Remove the timing belt Reier to the timing
belt procedure in this section
8 Remove the power steering pump bracket.
9. Remove the alternator brace.
as required.
To install: 7. Posrtion the fan and install the mounting
screws
*The water pump mounting bolts are differ-
ent in length, note their positioning for re-
assembly.
8 Install the electrical connectors and the upper
radiator hose.
9. Refill the cooling system.
IO. Connect the negative battery cable and check
the fan for orooer ooeration. 10. Remove the water pump, gasket and O-ring
where the water inlet pipe(s) joins the pump.
To install: 11, Thoroughly clean both gasket surfaces of the
water oumo and block.
12. For 1.5L engines, install a new O-ring into
the groove on the front end of the water inlet pipe. Do
not apply oils or grease to the O-ring. Wet the O-ring
with water only
13. For 1.8L engines, apply a 0.09-0.12 in.
(2.5-3 Omm) continuous bead of sealant to water
pump and rnstall the pump assembly. Install the wa-
ter pump within 15 minutes of the applrcation of the
REMOVAL & INSTALLATION
1.5L and 1.8L Engine
) See Figures 95 and 98
7923PGO :ig. 94 Exploded view of the fan mounting and related components- Fig. 95 Water pump and related components-Mirage with 1.51
liamante (4615) engine

ENGlNEANDENGlNEOVERHiUL 3-45
TIMINQ MARKS ON RIQHT SIDE VALVE COVER TIMING MARKS ON LEFT SIDE VALVE COVER
CRANKSHAFT SPROCKETS
91251gb5 :ig. 185 Crankshaft and camshaft sprocket alignment for proper timing belt replacement-1992-94 Mitsubishi 3.OL DOHC engine
4. Remove the cruise control actuator.
5. Remove the alternator. Remove the air hose
and pipe.
6. Remove the belt tensioner assembly and the
power steering belt.
7. Remove the crankshaft pulley.
8. Disconnect the brake fluid level sensor.
9. Remove the timing belt upper cover.
10. Using the proper equipment, slightly raise the
engine to take the weight off the side engine mount.
Remove the engine mount bracket.
11. Remove the alternator/air conditioner idler
pulley.
12. Remove the engine support bracket. The
mounting bolts are different lengths; mark them for
proper installation.
13. Remove the timing belt lower cover. Timing
bolt cover mounting bolts are different in length, note
their position during removal.
14. If the same timing belt will be reused, mark
the direction of the timing belt’s rotation for installa-
tion in the same dlrection. Make sure the engine is
positioned so the No. 1 cylinder is at the TDC of its
compression stroke and the sprockets’timing marks
are aligned with the engine’s timing mark indicators
on the valve covers or head.
15. Loosen the timing belt tensioner bolt and re-
move the belt.
16. Remove the tensioner assembly.
To install:
17. If the auto tensioner rod is fully extended, re-
set it as follows:
a. Clamp the tensioner in a soft-jaw vice in
level position.
b. Slowly push the rod in with the vice until
the set hole in the rod is aligned with the hole in
the cylinder. c. Insert a stiff wire into the set holes to retain
the position.
d. Remove the assembly from the vice.
18. Leave the retaining wire in the tension and in-
stall to the engine.
19. If the timing marks of the camshaft sprockets
and crankshaft sprocket are not aligned at this point,
proceed as follows:
*Keep fingers out from between the
camshaft sprockets. The sprockets may move
unexpectedly because of valve spring pres-
sure and could pinch fingers.
a. Align the mark on the crankshaft sprocket
with the mark on the front case. Then move the
sprocket 2 teeth clockwise to lower the piston so
the valve can’t touch the piston when the
camshafts are being moved.
b. Turn each camshaft sprocket 1 at a time to
align the timing marks with the mark on the valve
cover or head. If the intake and exhaust valves of
the same cylinder are opened simultaneously,
they could interfere with each other. Therefore, if
any resistance is felt, turn the other camshaft to
move the valve.
c. Align the timing mark of the crankshaft
sprocket, then continue 1 tooth farther in the
counterclockwise direction to facilitate belt instal-
lation.
20. Using 4 spring loaded paper clips to hold the
belt on the cam sprockets, install the belt to the
sprockets in the following order:
l M-exhaust camshaft sprocket for the
front head
l 2nd-intake camshaft sprocket for the
front head
l trd-water pump pulley
l 5th-exhaust camshaft sprocket for tile
rear head
l Ah-intake camshaft sprocket for the rear
l Gth-idler pulley head l 7th-crankshaft sprocket l 8th-tensioner pulley
21. Turn the tensioner pulley so its pin holes are
located above the center bolt. Then press the ten-
sioner pulley against the timing belt and simultane-
ously tighten the center bolt.
22. Make certain that all timing marks are still
aligned. If so, remove the 4 clips.
23. Turn the crankshaft l/d turn counterclockwise,
then turn it clockwise until all timing marks are
aligned.
24. Loosen the center bolt on the tensioner pul-
ley. Using tool MD998767 or equivalent and a torque
wrench, apply a torque of 7 ft. Ibs. (10 Nm). Tighten
the tensioner bolt; make sure the tensioner doesn’t
rotate with the bolt.
25. Remove the set wire attached to the auto ten-
sioner, if the wire was not previously removed.
26. Rotate the crankshaft 2 complete turns clock-
wise and let it sit for approximately 5 minutes. Then,
make sure the set pin can easily be inserted and re-
moved from the hole in the tensioner.
27. Measure the auto tensioner protrusion (the
distance between the tensioner arm and auto ten-
sioner body) to ensure that it is within 0.15-0.18 in.
(3.8-4 5mm). If out of specification, repeat Steps
l-4 until the specified value is obtained.
28. Make sure all pieces of packing are posi-
tioned in the inner grooves of the lower cover, posi-
tion cover on engine and install mounting bolts in
their original location.

3-46 ENGINEANDENGINEOVERHAUL
29. Install the engine support bracket and secure
using mounting bolts in their original location. Lubri-
cate the reaming area of the reamer bolt and tighten
slowly.
30. Install the idler pulley.
31. Install the engine mount bracket. Remove the
engine support fixture.
32. Make sure all pieces of packing are posi-
tioned in the inner grooves of the upper cover and in-
stall.
33. Connect the brake fluid level sensor.
34. Install the crankshaft pulley. Tighten the bolt
to 130-137ft. Ibs. (180-190 Nm).
35. install the belt tensioner assembly and the
power steering belt.
36 install the air hose and pipe.
37 Install the alternator.
38. Install the cruise control actuator.
39. Install the engine undercover.
40. Connect the negative battery cable.
199546 MODELS
# See Figure 186
1, Position the engine so the No. 1 cylinder is at
TDC of its compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
4 Remove the cruise control actuator. 5. Remove the alternator, Remove the air hose the engine’s timing mark indicators on the rear timing
and pipe.
6. Remove the belt tensioner assembly and the
power steering belt.
7. Remove the crankshaft pulley.
8. Disconnect the brake fluid level sensor.
9. Remove the timing belt upper cover.
10. Using the proper equipment, slightly raise the
engine to take the weight off the side engine mount.
Remove the engine mount bracket.
11, Remove the alternator/air conditioner idler
..,,ll^,. covers.
Turning the camshaft sprocket when the tim-
ing belt is removed could cause the valves to
contact with the pistons, resulting in severe
engine damage.
15. Remove the bolts that secure the auto-ten-
sioner to the engine block and remove the tensioner.
pu,ey. 12. Remove the engine support bracket. The To install:
mounting bolts are different lengths; mark them for
orooer installation. *The auto-tensioner assembly must be re-
set to correctlv adiust belt tension. , . 13. Remove the timing belt lower cover. Timing
bolt cover mounting bolts are different in length, note
their position during removal.
Be sure to disconnect the negative battery
cable. Wait at least 90 seconds after the neg-
ative battery cable is disconnected to prevent
possible deployment of the air bag.
14. If the same timing belt WIII be reused, mark
the direction of the trming belts rotation for installa-
tion In the same direction, Be sure the engine is posi-
tioned so the No. 1 cylinder is at the TDC of its com-
pression stroke and the timing marks are aligned with _ -
16. Loosen the center bolt of tensioner pulley to
provide timing belt slack.
17. Remove the timing belt assembly.
18. Posrtion the auto-tensioner into a vise with
soft iaws. The olua at the rear of tensioner protrudes,
be sure to usea v&her as a spacer to protect the
plug from contacting vise jaws.
19. Slowly push the rod mto the tensioner until
the set hole in rod is aligned with set hole in the
auto-tensioner.
20. Insert a 0.055 in. (1.4mm) wire into the
aligned set holes, Remove the tensioner from the vise
and install it on the engine.
21. Tighten tensioner mounting bolts to 17 ft. Ibs.
(24 Nm).
Timing marks
(on right
rocker cover)
Camshaft sprocket
Timing marks
mark (on oil pump case)
Crankshaft sprocket
Fig. 186 Sprocket alignment for timing belt installation-1995116 Diamante with the 3.N (6672) DDDD engine