MITSUBISHI DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

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1-20 MITSUBISHI DIAMANTE " ECLIPSE " GALANT " LANCER " MIRAGE 67170-GALA-C16 MITSUBISHI DIAMANTE " ECLIPSE " GALANT " LANCER " MIRAGE 1-21 PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: " Never open, service or drain the radia- tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. " Observe all applicable safety precau- tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area.

Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

Refer to the additional fuel system precautions in this section. " Fuel injection systems often remain pressurized, even after the engine has been turned OFF . The fuel system pressure must be relieved before ... more. less.

disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. " Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. " The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo- sure to used engine oil. Soap and water, or waterless hand cleaner should be used. " All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering col- umn, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in acci- dental air bag deployment, possible per- sonal injury, and unnecessary system repairs. " Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non- deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. " Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con- tact with a painted surface; it will damage the paint. " Never operate the engine without the proper amount and type of engine oil; doing so will result in severe engine damage. " Timing belt maintenance is extremely important. Many models utilize an interfer- ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten- tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace- ment interval for the timing belt, and to the timing belt procedure for belt replacement and inspection. " Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys- tem(s) and may require the computer to undergo a relearning process once the neg- ative battery cable is reconnected. " When servicing drum brakes, only dis- assemble and assemble one side at a time, leaving the remaining side intact for refer- ence. ENGINE REPAIR Ê Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board com- puter systems and may require the computer to undergo a relearning pro- cess, once the negative battery cable is reconnected. Distributor REMOVAL Before removing the distributor, position No. 1 cylinder at TDC on the compression stroke and align the timing marks. 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: " Negative battery cable " Ignition wire cover, if equipped " Distributor harness connector " Distributor cap with all ignition wires still connected " Coil wire, if necessary 3. Matchmark the rotor to the distributor housing, and the distributor housing to the engine. 4. Remove or disconnect the following: " Hold-down nut Adjusting the distributor 41.5L Mirage shown 7923PG01 " Distributor from the engine INSTALLATION Timing Not Disturbed 1. Install or connect the following: " New distributor housing O-ring and lubricate with clean oil " Distributor in the engine, match- marks aligned " Hold-down nut " Distributor harness connectors " Distributor cap " Coil wire, if removed " Negative battery cable 2. Adjust the ignition timing and tighten the hold-down nut to 96 inch lbs. (11 Nm). Timing Disturbed 1. Install a new distributor housing O- ring and lubricate with clean oil. 2. Position the engine so the No. 1 pis- ton is at TDC of its compression stroke and the mark on the vibration damper is aligned with 0 on the timing indicator. 3. Align the distributor housing and gear mating marks. Install the distributor in the engine so the slot or groove of the distribu- tor 9s installation flange aligns with the dis- tributor installation stud in the engine block. Be sure the distributor is fully seated. Inspect alignment of the distributor rotor making sure the rotor is aligned with the position of the No. 1 ignition wire in the distributor cap. 4. Install or connect the following: " Hold-down nut " Distributor harness connectors " Distributor cap " Negative battery cable 5. Adjust the ignition timing and tighten the hold-down nut to 96 inch lbs. (11 Nm). Alternator REMOVAL 1.5L, 1.8L, and 2.4L Engines 1. Before servicing the vehicle, refer to the precautions at the beginning of this sec- tion. 2. Remove or disconnect the following: " Negative battery cable " Left side cover panel under the vehicle " Air intake hose, on turbocharged Galant models " Drive belts " Water pump pulleys " Alternator upper bracket/brace " Alternator wiring connectors " Alternator mounting bolts and remove the alternator 2.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this sec- tion. 2. Remove or disconnect the following: " Negative battery cable " Drive belts " Power steering hose clamp " Alternator brace " Alternator electrical connector " Engine mount, on vehicles with Anti-lock Brake Systems (ABS) " Alternator, tilting the engine as nec- essary 2.0L DOHC Turbo Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 1-22 MITSUBISHI DIAMANTE " ECLIPSE " GALANT " LANCER " MIRAGE Checking the ignition timing 41.5L Mirage shown 7923PG02 Exploded view of the alternator and related components 4Lancer with 2.0L engine 9357QG01 2. Disconnect the negative battery cable. 3. Remove the oil dipstick and tube assembly. 4. Disconnect the fuel pressure sole- noid connector. 5. Disconnect the knock sensor con- nector. 6. Disconnect the evaporative emis- sions purge solenoid connector. 7. Disconnect the ground cable con- nection. 8. Remove the fuel injectors. 9. Remove the accessory drive belt. 10. Disconnect the alternator wiring har- ness. 11. Remove engine mounting bolt. 12. Raise the engine slightly with a floor jack and remove the alternator from the vehicle. 3.0L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions at the beginning of this sec- tion. 2. Remove or disconnect the following: " Negative battery cable " Air intake hose " Alternator drive belt 3. On California models, remove the rear bank converter assembly. 4. Remove the engine roll stopper stay bracket assembly. 5. On the 3.0L engine, disconnect the Exhaust Gas Recirculation (EGR) tempera- ture sensor wire and remove the EGR pipe assembly. 6. On the 3.0L engine, remove the intake plenum stay bracket assembly. 7. Remove or disconnect the following: " Alternator wiring harness connec- tors " Alternator upper and lower mount- ing bolts 8. From beneath the vehicle, remove the alternator. 3.8L Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this sec- tion. 2. Disconnect the negative battery cable. 3. Remove the accessory drive belt. 4. Disconnect the alternator wiring har- ness. 5. Disconnect the A/C compressor assembly connector. 6. Remove the A/C compressor assem- bly from its mounting bracket with the A/C hose still connected and move off to one side. 7. Remove the alternator from under the vehicle. INSTALLATION 1.5L, 1.8L, and 2.4L Engines 1. Position the alternator on the lower mounting fixture and install the lower mounting bolt and nut. Tighten nut just enough to allow for movement of the alter- nator. 2. Install or connect the following: " Alternator upper bracket/brace and connect the alternator electrical harness " Water pump pulleys " Drive belts and adjust to the proper tension 3. On turbocharged Galant models, install the air intake hose. 4. Install or connect the following: " Left side cover panel under the vehicle as required " Negative battery cable and check for proper operation 2.0L SOHC Engine 1. Install or connect the following: " Alternator " Engine mount, if removed " Alternator connector " Alternator brace " Power steering hose clamp " Drive belts " Negative battery cable 2. Adjust drive belts. MITSUBISHI DIAMANTE " ECLIPSE " GALANT " LANCER " MIRAGE 1-23 Exploded view of the alternator and related components 43.8L engine 67170-GALA-G10

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