Ch 6 Chassis Electrical

8/14/2019 Ch 6 Chassis Electrical

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TROUBLESHOOTINGELECTRICAL SYSTEMS 6-2ELECTRICALTHEORY6-2HOWDOESELECTRICITY ORK:THEWATERANALOGY 6-2OHM'S LAW 6-2POWERSOURCE 6-2GROUND 6-3PROTECTIVE EVICES 6-3SWITCHES&RELAYS 6-3LOAD 6-3WIRING& HARNESSES 6-3CONNECTORS 6-4EQUIPMENT 6-4JUMPERWIRES 6-4TESTLIGHTS 6-4MULTIMETERS 6-5LECTRICALSYSTEMS 6-5OPENCIRCUITS 6-5SHORTCIRCUITS 6-6VOLTAGE 6-6VOLTAGE ROP 6-6RESISTANCE 6-8AND CONNECTORREPAIR6-6CABLES 6-7HE CABLES 6-7RESTRAINT SYSTEM) 6-7

6-7SERVICE RECAUTIONS 6-7DISARMING 6-7REARMING 6-7CONDITIONING 6-7MOTOR 6-7REMOVAL&INSTALLATION 6-7

INSTRUMENTS AND SWITCHES 6-17INSTRUMENTCLUSTER 6-17REMOVAL&INSTALLATION 6-17GAUGES 6-18REMOVAL&INSTALLATION 6-18WINDSHIELDWIPERSWITCH 6-19REMOVAL&INSTALLATION 6-19REARWINDOWWIPERSWITCH 6-19REMOVAL INSTALLATION 6-19DIMMERSWITCH 6-19REMOVAL& INSTALLATION 6-19 .HEADLIGHT WITCH 6-19REMOVAL INSTALLATION 6-19LIGHTING 6-19HEADLIGHTS 6-19REMOVAL&INSTALLATION 6-19AIMINGTHEHEADLIGHTS 6-20SIGNALAND MARKER IGHTS 6-21REMOVAL&INSTALLATION 6-21CIRCUIT PROTECTION 6-27

FUSES 6-27REPLACEMENT 6-27FUSIBLE INKS 6-27CIRCUITBREAKERS 6-28RESETTING ND/ORREPLACEMENT 6-28FLASHERS 6-28REPLACEMENT 6-28WIRING DIAGRAMS 6-31

REMOVAL& INSTALLATION 6-9TIONING OMPONENTS 6-11REMOVAL& INSTALLATION 6-11ADJUSTMENT 6-12ANEL 6-12REMOVAL& INSTALLATION 6-12CONTROL 6-13T SYSTEMS 6-14RECEIVER/AMPLIFIER/TAPEPLAYER/CD LAYER 6-14REMOVAL& INSTALLATION 6-14WASHERS 6-15


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6-2 CHASSIS LECTRICAL

) See Figure 1For any 12 volt, negativeground,electricalsystemto operate, he electricitymust ravel n a complete

circurt.This simply means hat current power) romthe posibve t) terminalof the batterymust eventu-ally return o the negative -) terminalof the battery.Along he way, his currentwill travel hroughwires,fuses,switchesand components. f, or any reason,the low of current hrough he circuit s interrupted,the component ed by that circuit will cease o func-tion properly.Perhaps he easiestway o visualizea circuit is tothink of connecting light bulb (with wo wires at-tached o it) to the battery-one wire attached o thenegative -) terminal of the batteryand he otherwireto the positive (t) terminal.With he wo wires touch-ing he battery erminals, he circuit would be com-pleteand he light bulb would llummate.Electricitywould ollow a path rom the battery o the bulbandback o the battery. ts easy o see hatwrth ongerwires on our light bulb, t could be mountedany-where.Further,one wire could be itted with a switchso that he ight could be urnedon and off.The normalautomotivecircuit differs rom thissimple example n two ways, Frrst, nsteadof havinga returnwire from the bulb o the battery, he currenttravels hrough he rameof the vehicle.Since henegative -) batterycable s attached o the rame(madeof electricallyconductivemetal), he rame ofthe vehiclecan serveas a groundwire to completethe circuit. Secondly,most automotivecircuits con-tain multiplecomponentswhich receivepower rom asinglecircuit. This lessens he amountof wireneeded o powercomponents n the vehicle.HOWDOESELECTRlClTYWORK:THEWATER NALOGY

Electricity s the low of electrons-the subatomicparticles hat constitute he outer shell of an atom.Electrons pin in an orbit around he centercore of

RETURN RETURNCONDUCTOR CONDUCTORGROUND GROUNDlccs2wFig. 1 This example llustrates a simple cir-cuit. When he switch is closed, power fromthe positive (t) battery terminal flowsthrough the fuse and the switch, and thento the light bulb. The light illuminates andthe circuit is completed hrough he ground

an atom The centercore s comprisedof protons(positive charge)and neutrons neutralcharge).Elec-trons havea negative hargeand balanceouthepositive chargeof the protons.Whenan outside orcecauses he numberof electrons o unbalancehechargeof the protons, he electronswill split off heatom and ook or anotheratom o balanceout. f thisimbalance s kept up , electronswill continue o moveandan electrical low will exist.Many peoplehavebeen aughtelectrical heoryusingan analogywith water. n a comparisonwrthwater lowing hrougha pipe, he electronswould bethe waterand he wire is the pipe.The low of electricitycan be measuredmuch ikethe low of water hrougha pipe. The unit of measure-mentused s amperes, requently bbreviated samps (a). You can compareamperageo the volumeof water lowing hrougha pipe. Whenconnectedo acircuit, an ammeterWIIImeasure he actualamountofcurrent lowing hrough he circuit. When elativelyfew electrons low througha circuit, he amperageslow. Whenmanyelectrons low, he amperageshigh.Waterpressure s measured n units such aspoundsper square nch (psi); The electricalpressureis measuredn unrtscalledvolts (v). Whena volt-meter s connectedo a circuit, it is measuring heelectricalpressure.The actual low of electricitydepends ot only onvoltageand amperage, ut also on the resistance fthe circuit The higher he resistance,he higher heforce necessaryo push he current hrough he cir-cuit. The standard nit or measuring esistances anohm. Resistancen a crrcuitvaries dependmg n theamountand ype of components sed n the circuit.The main actorswhich determine esistance re:

l Material-some materialshavemore resis-tance hanothers Thosewith high resistance re saidto be nsulators Rubbermaterials or rubber-likeplashcs)are some of the most common nsulatorsused n vehiclesas hey havea very high resistanceto electricity Very ow resistancematerialsare said obe conductors.Copperwire is among he bestcon-ductors.Silver is actual lya superiorconductor ocopperand s used n some relaycontacts,but tshigh cost prohibits ts use as commonwiring Mostautomotivewiring is madeof copper.l Size-the larger he wire size beingused, heless resistance he wire will have.This IS why com-ponentswhich use argeamountsof electricityusu-

ally have argewires supplyingcurrent o them.l Length-for a given hicknessof wire, helonger he wire, he greater he resistance. heshorter he wire, he less he resistance.Whendeter-mining he properwire for a circuit , both size andlengthmust be considered o designa circuit that canhandle he currentneedsof the component.l Temperature-with manymaterials, he higherthe emperature,he greater he resistance positivetemperature oefficient).Some materialsexhibit heopposite rait of lower resistancewith higher emper-atures negative emperature oefficient).Theseprin-ciples are used n manyof the sensorson the engine

rent,voltageand resistance an be summstatement nownas Ohms aw.Voltage E) s equal o amperage I) titance R): E=lx ROther orms of the ormulaare R=E/IaIn eachof these ormulas,E s the volI is the current n ampsand R IS he resiohms.The basic point o remember s thsistanceof a circuit goesup, he amounthat lows in the circuit will go down, f vmains he same.The amountof work that he electricitis expressed s power.The unit of powe(w). The relationshipbetween ower,volcurrent S expressed s:Power(w) is equal o amperage I) tim(E): W=l x EThis is only rue or direct current DCThe alternating urren t ormula s a tad dsince he electricalcircuits in most vehictype,we neednot get nto AC circuit the

POWERSOURCEPower s supplied o the vehicle by wThe batteryand he alternator. he batteelectricalpowerduringstartingor dur ingwhen he currentdemandof the vehiclesystemexceeds he outputcapacityof thThe alternator upplieselectricalcurrenengine s running Justot does he altethe currentneedsof the vehicle,but t rebattery.

The BatteryIn most modernvehicles, he battery electrochemical eviceconsistingof six sections cells) connected n series,so this capableof producingapproximately 2electricalpressure.Eachsubsection onries of positive and negativeplatesheldatanceapart n a solutronof sulfuric acid aThe wo typesof platesare of dissimilThis sets up a chemrcal eaction,and t istion which produces urrent low from thwhen ts positive and negattve erminals

nected o an electrical oad.The power rethe battery s replaced y he alternator,battery o its original chemicalstate.The Alternator

Onsome vehicles here snt an alterngenerator. he difference S hat an alternplies alternating urrentwhich s then chrect current or use n the vehicle,while producesdirect current.Alternators endefficientand hat s why hey are used.Alternators nd generators re deviceof coils of wires wound ogethermaking


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CHASSIS LECTRliA

SWITCH&--;r-- ----

-~~

85 M I-M-L RELAYSWITCH86 87 i--- ----w-J

tcca6go2Fig. 4 Relays are composedof a coil and aswitch. These two componentsare linkedtogether so that when one operates, theother operates at the same ime. The largewires in the circuit are connected rom thebattery to one side of the relay switch (B+)

The average ehicle containsmeterwiring, with hundreds f individualconprotect he manywires from damage nthem rom becominga confusing angganized nto bundles,enclosed n plasgetherand calledwiring harnesses.Dinesses erve differentpartsof the vehiwires are color coded o help race hemharnesswheresectionsare hidden romAutomotivewiring or circuit conducther single strandwire, multi-strandwicircuitry. Singlestrandwire hasa solidand s usuallyused nside such compnators,motors, relaysand other devicestrandwire hasa core madeof manyswire twisted ogether nto a single cond


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ICHASSIS LECTRICALetweenwosheets for more rotectionnd lexibility. complete l Weatherproof-theseonnectorsremost the umperwire is of too small af conductors,nsulating commonlysed hereheconnectors exposedo may overheatand possibly melt.nd onnectorsor amps r other ompo- theelements.erminalsreprotectedgainstmois-s called printed ircuit oard. rintedir- tureanddirtbysealingingswhich rovide weath-

jumpers o bypasshigh resistancet-tighteal.All repairsequireheuseof a special circuit. Bypassing esistances, nn place f ndividual iresor har- ates a short circuit. This may, in n places here paces imited, uch s terminal nd he ool requiredo servicet. Unlikenstrumentanels. standardladeype erminals,hese eatherproof

damageand fire. Jumperwires sbe used o bypass engthsof wireSince utomotivelectricalystemsrevery en- terminalsannot estraightenednce hey rebent. late switches.

n resistance,heselectionf prop-Make ertainhat heconnectorsreproperly eated

sizedwires s criticalwhen ystemsre epaired, andall of thesealingings re n place hen on-nettingeads. Jumper ires resimple, etextremoose r corrodedonnectionr a replacementire pieces f testequipment.hey rebassmall or the ircuitwill addextra esis- l Molded-these onnectorsequire omplete which reusedo bypassectionsf areplacementf theconnectorf foundo bedefective.anadditionaloltage rop o thecircuit. thoughumper ires anbepurchasThewiregauge umbers anexpressionf the Thismeansplicing new onnectorssemblynto ally abricatedrom engths f standarea f the onductor.ehiclesrom theharness.ll splices hould esolderedo insureproper ontact. se arewhen robingheconnec- wireandwhateverypeof connectorahatuse hemetric ystem ill typically e- spade onnectorr pinconnector)hahewiresize s tscross-sectionalrea n tionsor replacingerminalsn hem, s t is possiblen hismethod,he argerhe to create short ircuit etweenppositeerminals.ftheparticularpplicationeingestedhard-to-reachreas,t is advisableo h

greaterhenumber.notherommonys- thishappenso thewrongerminal air, t is possibleto damageertain omponents.lways se umper boots ver he umper ire erminalsniresize s heAmerican ire ventaccidentalrounding.t s alsoadAWG)ystem. sgauge umberncreases, wiresbetweenonnectorsor circuit heckingndNEVERrobehrough eatherproofeals. elude standardutomotiveuse n annd hewirebecomesmaller. n18ire s smallerhan 4 gauge ire.A wire

l HardShell-unlikemoldedonnectors,he This s commonlyeferredo asa fusinsertingn n-line useholder etweterminalontactsn hard-shellonnectorsanbe e-a higher auge umber ill carry ess urrent placed. eplacementsuallynvolvesheuseof a leads, fusedumper irecanbeusedwitha ower auge umber. auge ire open ircuits. se 5 ampuse o proo thesize f thestrandsf theconductor, specialerminalemovalool hatdepresseshe ock- againstoltage pikes.sizeof thecompleteirewith nsulator.t s ing angsbarbs) n heconnectorerminal ndal-lows heconnectoro be emovedrom he earof the Jumper ires reused rimarilyo oherefore,o havewowiresof thesame shell. he onnectorhell hould e eplacedf it electricalircuits, neitherhegrounddifferent iametersecausenemay avensulationhan heother. shows nyevidencef burning, elting,racks, r

circuit r on hepower+)side. f anelbreaks. eplacendividualerminalshat reburnt, ponentails o operate,onnecthe umIt s essentialo understandowa circuitworks corroded,istortedr oose. tweenhecomponentnda good rourying o figure utwhy t doesnt. nelectrical ponent peratesnlywith he umpernhowsheelectricalurrent aths hen ground ircuit s open.f theground irroperly. chematicsreakhe but hecomponentoes otoperate,hystem ownnto ndividualircuits. tweenhepowereed nd omponena schematic,sually oattempts madeo repre- Pinpointingheexact ause f troublen anelec- Bymovinghe umper iresuccessivtricalcircuit s mostimes ccomplishedy heuse thecomponentowardhepower ourcwiringand omponentss heyphysicallyp-ehicle; witchesndother omponents of specialestequipment.he ollowing escribes isolatehearea f thecircuitwhereheoshown ssimply spossible. ace iews f har- differentypes f commonlysedestequipmentnd cated.Whenhecomponenttopsunchow he avity r terminalocations briefly xplains ow o use hemn diagnosis.nad- powers cutoff, heopens n thesego help ocateestpoints. dition o the nformationovered elow,he ool betweenhe umper nd hepointprevmanufacturersnstructionsookletprovided ith You an ometimesonnecthe umthe ester) hould e ead nd learly nder.$oode- rectly rom hebatteryo the hot ermforeattemptingny estprocedures. component,ut irstmake ure hecom

See Figures 5 and 6 JUMPER IRES 12volts n operation.ome lectricalosuch s uel njectors r sensors,redeThreeypes f connectorsrecommonlysedn erate nabout to 5 volts,and unninpplications-weatherproof,olded nd rectlyo these omponentsill cause

Never use umperwires made rom a thinner TEST IGHTSgaugewire than he circuit being ested. If# See Figure 7The est ight s usedo check ircuinents hileelectricalurrents lowing


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CHASSIS LECTRiCt s usedor voltage ndgroundests. ouse voltmeteras positive nda negativeead. oavoid12volt est ight, onnectheground lip o a good damageo hemeter, lways onnecthenegativeprobe hereverecessaryith hepick. lead o henegative-) sideof hecircuit togroundwill illuminate hen oltages detected. or nearestheground ideof hecircuit) nd onnectdoesotnecessarily eanhat12volts orany thepositiveead o hepositive(t) ideof thecircuit When iagnosingspecific robletroubleshootings a must. he omplemount f voltage)s present;t only (to hepower ource r henearestower ource).hat ome oltages present.t s advisable Note hat henegativeoltmetereadwill always e ernautomotiveehicle emandshat ohe est ight o ouchtsground lip black nd hat hepositive oltmeter ill always e anyproblemn a ogical, rganized aprobe crosshebattery osts r erminalso some olorotherhan lack usuallyed). arecertainroubleshootingechniquewhich restandard:

s operatingroperly. l Ohmmeter-thehmmeters designedo read l Establishhenheproblemccresistancemeasuredn ohms)n a circuit r compo-nent.Mostohmmetersill have selectorwitch problemppear nlyunder ertain onthere nynoises, dors r other nusua test light to probe electronic g- which ermitshemeasurementf differentangesf Isolateheproblemrea. odo his,mspark plug or coil wires. Never use a resistanceusuallyheselector witch llows hemultiplicationf hemetereading y10,100,1,000 ple ests ndobservations,hen liminwiring on com- ternshatareworking roperly. heckunlessspecifically and10,000). ome hmmetersre auto-rangingwhichmeanshemetertselfwill determinehich problems,uch sbroken iresand onstructed o do so. Any wire insulation hat scaleo use.Sincehemetersrepoweredyan n- connections.lways heckheobvious pierced by the test light probeshould be ternal attery,heohmmeteranbeusedikea self- sumingomethingomplicateds hecth silicone after testing. l Testor problemsystematicapoweredest ight.Whenheohmmeters connected, thecause nceheproblemreas so

Like he umper ire, he12volt est ight s used currentrom heohmmeterlows hroughhecircuit thecomponentsunctioningroperlyn circuits. ut,whereashe umper or componenteingested. inceheohmmetersn-ternal esistancend oltage reknown alues,he goingo electricalwitchesndmotoro bypassheopeno operatehe oad, amountf currentlow hroughhemeter ependsncareful, ystematichecks ill oftenur

12volt est ight s usedo ocatehepresencef the esistancef hecircuit r componenteing causesn he irst nspection,ithoutoltagen a circuit.f he est ight lluminates,here tested. heohmmeteranalsobeusedo perform checkingomponentshathaveittleoris power p o hatpoint n hecircuit;f the est ight ship o heproblem.does ot lluminate,heres anopen ircuit no continuityest or suspectedpen ircuits.nusingthemeteror makingontinuityhecks, onotbe l Test ll repairs fter hework s dpower).Move he est ight n successiveteps ack concernedith heactualesistanceeadings.ero sure hat heproblems ixed.Some aowardhepower ource ntil he ight n hehandle tracedo morehan ne omponentoilluminates.he pens betweenheprobe nda resistance,r anyohm eading,ndicatesontinuity fication f repair ork s mportantn opointwhichwaspreviously robed. in hecircuit,nfiniteesistancendicatesnopeningin hecircuit. high esistanceeading herehere additional alfunctionshatmay ausThe elf-poweredest ight s similarn designo should enonendicatesproblemn hecircuit. reappearr a different roblemo arisehe12volt est ight,but ontains 1.5 olt penlight Checksor short ircuits remaden hesameman- fuse,or example,s a simple roblembatteryn hehandle.t s most ften sedn place f neraschecksor open ircuits, xcepthat hecircuit quiremorehan notheruse o repaira multimetero checkor open r short ircuits hen look or a problemhat aused fuse opowers solatedrom hecircuit continuityest). must e solatedrombothpower ndnormalground.nfiniteesistancendicatesocontinuity, shorted ire forexample) ay o undThebatteryn a self-poweredest ightdoes ot Experienceasshownhatmost rprovidemuch urrent. weak attery ay otpro- while ero esistancendicatesdead hort. to be he esult f a fairly simple ndovideenough owero lluminatehe est ighteven I cause, uch s ooseor corrodedonwhen completeircuit s madeespeciallyf theres grounds r damagedire nsulationhigh esistancen hecircuit). lwaysmake ure hat Never use an ohmmeter o check he resis- short. hismakesareful isual nspethe estbatterys strong. ocheckhebattery, riefly tance of a component r wire while there is ponents uringesting ssentialo qutouchheground lip o heprobe;f the ightglows voltage applied o the circuit. rate roubleshooting.brightly,hebatterys strong noughor esting.*A self-powered est light should not be l Ammeter-an mmeter easuresheamount - Iused on any computercontrolled systemor of currentlowing hrough circuitn units alledcomponent. he small amountof electricity amperesr amps. tnormal peratingoltage,mostcircuits ave characteristicmountf amperes, OPENCIRCUITStransmittedby the test light is enough odamagemanyelectronic automotivecompo- called current rawwhich anbemeasuredsinganammeter.y eferringo a specifiedurrent raw # See Figure 8nents. rating,henmeasuringheamperesnd omparingMULTIMETERS the wovalues, ne andeterminehats happeningwithin hecircuit o aid n diagnosis.nopen ircuit,for example,ill notallowanycurrento low,so heMultimetersreanextremelysefulool or rou-bleshootinglectrical roblems.hey anbepur- ammetereading ill bezero. damagedomponentor circuitwill have n ncreasedurrent raw, o hechasedn either nalog r digital ormandhave reading ill behigh. he mmeters always on-price angeo suitanybudget. multimeters a volt- nettedn series ith hecircuitbeingested. ll ofmeter, mmeterndohmmeteralongwithotherea- thecurrenthatnormallylows hroughhecircuittures) ombinedntoone nstrument.t s often sed must lso low hroughheammeter;f theres anywhenesting olidstate ircuits ecausef ts high other athor hecurrento ollow, heammeteread-inputmpedanceusually 0megaohmsr more). ingwill notbeaccurate.he mmetertselfhas erybriefdescriptionf hemultiietermainest unctionsfollows: little esistanceo currentlowand, herefore, ill notaffecthe ircuit, ut t will measureurrent raw nly

l Voltmeter--theoltmeters usedo measure whenhecircuits closed ndelectricitys lowing.


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.CHASSIS LECTRICALThis est lready ssumesheexistencef anopencircuit nd t is usedo help ocateheopen1. Isolatehecircuit rompower ndground.2. Connectheself-poweredest ightor ohmme-ground lip o heground ideof hecircuit ndf hecircuit equentially.3. If he ight s outor heres nfinite esistance,opens betweenheprobe nd hecircuit round.4. If the ight s onor hemeter hows ontinuity,opens betweenheprobe nd heendof hecir-hepower ource.

use a self-powered est tight to per-or opensor shorts when powerFig. 10 Checking he resistanceotemperature sensor with an Reading s 1 .04 kilohmsunder est. The est

he dmn~nsrl hu nutnitls nnuva~ if theres morehan ne oad n hecircuit, ince llY.. 1 ullly u, ..7IYG pz .1. Isolatehecircuit rompower ndground.2. Connectheself-powered .,.*. ,ted ugnt r onmme-ground lip o a good round ndprobe nyeasy-oint n hecircuit.3. If he ight omes nor heres continuity,s a short omewheren hecircuit.4. To solateheshort, robe estpoint teitherof he solatedircuit the ightshould eonormeter houldndicateontinuity).5. Leavehe est ightprobe ngagednd e-

voltage rops recumulative.1. Set hevoltmeterelectorwitcho he20volt^,.^X^..pJbl1IUII.2. Connecthemultimeteregativeead o agood round.3. Operatehecircuit nd heckhevoltage rior.to hehrst omponentload).4. There hould e ittleor novoltage rop n hecircuit rior o he irstcomponent.f a voltage ropexists,hewireor connectorsn hecircuit resus-WY.+)JGW 5. While peratinghe irstcomponentn hecir-.positivemeteread ndobservehevoltageeadings.A small oltage rop hould enoticed. his oltagedrop s causedy he esistancef hecomponent.6. Repeathe est or each omponentload)de -IL- ... .Iuuwnme rrcun.

pen onnectorsr switches,emoveuntil he ightgoes utor continuitys bro-6. Whenhe ightgoes ut, heshort s betweencircuit omponentshichwere pened,

This estdeterminesoltage vailablerom hend hould e he irststep nanyelectricalrocedurefter isual nspection,lectrical roblems,soeciallvncomouterystems,anbecaused ya owstate f

7. If a large oltage rop s noticed,heprecedingcomponent,ireor connectors suspect.

# See Figures 10 and 11n hebattery. xcessiveorrosion t hebat-cableerminalsan ause oor ontacthatwillroper hargingnd ull batteryurrentlow,1. Set hevoltmeterelectorwitcho he20V2. Connecthemultimeteregativeead o henn,,,;~,,.\ ..^,a -L.--:^^l --_I I- ---!I?...

Neveruse an ohmmeterwith power appliedto the circuit. The ohmmeter s designed ooperate on its 0wn power supply. The normal1^ . . . .

Fig. 11 Sparkplug wires can be c

3 IlG~dllYt: t-1 pUSI UI Lellllllldl allU lilt, pUSlIlVeo hebatterysositivet) postor erminal.3. Turn he gnition witchON o provide oad,4. Awellchargedatteryhould egister ver12f hemetereads elow 15 vnlts hahq*anr_ -,may e nsufficiento operateheeler

ii! volt electrical systemvoltage could dam-age he meter!1. Isolatehecircuit rom hevehicles owerCnlOrAn)IW.2. Ensurehat he gnition ey s OFFwhen is-

Almost nyone an eplace amagelongas heproperoolsandparts reavand erminalsreavailableo fit almostEvenhespecializedeatherproof,oldshell onnectorsrenowcl mdicm

availableromconnectingnycomponentsr hebattery. yp,8w.3. Where ecessary,lso solate t east ne ide Be ure heends f all thewiresare iof hecircuit o bechecked,n ordero avoid eading propererminal ardwarend onnectparallelesistances.arallel ircuit esistancesill a wirearound stud s never permanSee Figure 9 always ivea ower eadinghan heactualesistance andwill onlycauseroubleater.Repla

When urrentlows hrough load,hevoltage e- of eifhy n< hn mnnh-rGI I II It: I a lb1 t?>. a ime o avoid onfusion.lwaysoutew4. Connecthemetereadso both ides f he thesame s he actory.drops. his oltage rop s due o hereatedy he oadand lsobysmall e- circuit wireor component)nd eadheactualmea-sured hms n hemeter cale.Make ure heselec- *If connector epair is necessaryreated ycorrosion t heconnectorsnd tor switchs set o heproper hm caleor hecir- tempt t if you have he proper oolerproof and hard shell connectors


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I I CHASSIS LECTRIC

When orking nanyelectricalomponentn hevehicle,t is always good dea o disconnecthenegative-) battery able. hiswill prevent otentialdamageo many ensitivelectricalomponentssuch s hePowertrainontrolModulePCM),adio,alternator,tc.*Any time you disengage he battery cables,it is recommendedhat you disconnect he

negative (-) battery cable irst. This will pre-vent your accidentally grounding he positive(+) terminal to the body of the vehicle whendisconnectingt, thereby preventingdamageto the above mentionedcomponents.Before oudisconnecthecable(s),irst urn heignitiono heOFFposition. hiswill prevent drawon hebattery hich ould ause rcing electricitytrying o groundtself o hebody f a vehicle,ustlikea spark lug umpinghegap) nd, f course,

damagingome omponentsuch s hdiodes.Whenhebatteryable(s) re econtivecableast), esure o checkhat owindshield ipers ndother lectricalsafety omponentsreall working orrevehicle ontainsnElectronicallyunedontorgeto also eset our adio tattheclock.

SERVICERECAUTIONSb See Figures 12,13, and 14

Fig, 14 Be sure to observe any precautionlabels on the vehicle regarding he air bagsystem

Fig. 12 To prevent personal njury, ALWAYS*carry a-live -ah bag ac!ng away from you in 11 ase of accidental deployment Somevehicles are equippedwtth an air bag-.---syr1em, aisclKnownas I11I-- ------- - sLe upplementaln-fiatable Restraint SIR) o Suouiementa iFiea

l With he nflatormodule n hebplace nythingnor close o hemodube hrownn heevent f anaccidentaDISARMING# See Figure 151. Before ervicinghevehicle,efecautionsn hebeginningf hissectio2. Positionhe rontwheelsn hesposition ndplacehekey n heLOCKmovehekey rom he gnitionockcyli3. Disconnecthenegativeatterysulatehecable ndwithhigh-qualityor similar on-conductiverapping.4. Wait t east neminute efore vehicle. he ir baa vstems desianeenougholtageodeployheair bag orriodof ime fter hebattery asbeen

1. Connectheneoativeattersab

3,hold e-e bag ndtrimcover repointed way.l Placehe nflatormodule na bench r othersurface ith hebag nd rimcover acing p.

Fig. 15 nsulate the negative bato prevent accidental deploymebagplace a live airbag with the cover facing upin case of accidental deployment

1. Disconnecthenegativeattery able.2. Removehe ight ide nstrumentanel n- 7. Removeheblowermotormoumoveheblowermotor.


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Fig. 16 Explodedview of the blower motorand related components-1990-92 Mirage11. Install he resistorand he glove box assem-W12. Install he right side instrumentpanelunder-cover panel .13. Connect he negativebatterycable.

1990-93 Galant# See Figure 19

1. Disconnect he negativebattery able.2. Remove he glove box stopper.3. Swing he glove box door openall the wayand remove he bottom retaininascrews.Remove heglovebox

1 Under cover 4993 models, 12 Glove box3 corner pane,4 Glove bo x frame5 RBSlStOr93156~23Fig. 17 Explodedview of the blower motorand related components-1993-96 Mirage

4. Remove he dashundercover.Note hat some 9. Detach he electricalconnector root the screwsand retainers re concealed eh indsmall covers which must be removed.5 Remove he heaterduct or the passengersfeet.6. Carefullydetach he o-pin connector un-ning o the backof the glove box rame.Disconnectthe single wire (glove box switch) running o the backof the glove box frame.7. Remove he our bolts holding he glove boxframeand remove he rame.8. Disconnect he small air hose running romthe an motor o the an housing.

motor.10. Remove he hreesmall bolts holdtor to the housing, hen emove he motoTo install:11. Check he nside of the casecarebris can snag he an and causenoise or 12. Inspect he gasket packing)undeand replace t if crackedor damaged.Reiand motor o the caseand Install he reta13. Attach he air hoseand electrical14. Install he glove box rameand cothe o-pin and sinqle pin connectorspro15. Install he heaterduct16. Install he undercover,aking caris in placeand all the asteners re secur17. Install he glove box and ts stopp18. Connect he negativebattery abl

1. stopper2 Glove box3 Under cover4 Foot shower duct5 Connector for MFI control relay and ,connector for glove box swtch6 Glove box frame7 Cowl side trim8 Engine control module

Fig. 18 Explodedview of the blowand related components-1997-0

--. 8

12 HoseBlower assemblvBlower motor assemblyPacktng;;c, tnstallatlon nutBlower motor and fan assemblyBlower case

1994-00 Galant) See Figures 20 and 21

1. Disconnect he negativebatteryc2. Remove he hree nstrumentpancover mountingscrewsand remove he c3 If equippedwith A/C, unplugandcompressormodule.4. Detach he electricalconnector romotor.5. Remove he hreesmall bolts holmotor o the housingand remove he mo

; y&M 5 m- M ,


9/76

CHASSIS LECtRldA

93156g27Fig. 21 Explodedview of the blower motorand related components-1999-00 GalantTo install:6. Check he nside of the casecarefully;anyebriscan snag he an and causenoise or poor air-low.7. Install he blowermotor, n the blowercasend securewith the hree mountingbolts,8. Attach he blowermotor electrlcal onnector,9. Install he compressormodule, f removed.10. Install he undercover,akmgcare o insure tis in placeand all the asteners re secure.11. Connect he negativebattery able.

Diamante See Figures 22 and 23

1. Disarm he air bag,as outlinedearlier n thisection.

ait at least 1 minutebefore working on theair bag system s designed oetain enough oltage to deploy he air bagort period of time even after the bat-s been disconnected.2. Remove he passenger ide lower ns trumentaneland shower duct,3. Remove he glove box striker, glove box,and he screw below he as-4. Remove he evaporator ase mountingbolt5. Remove he nside/outside ir changeovermotor assembly.6 Remove he PCM, mountingbracketand MFI7. Remove he nstrument anelpassengers8. Remove he moldedhose rom the bloweras-9. Remove he blowermotor assembly.10. Remove he an retainingnut and an n orderreplace he motor,To install:11. Check hat he blowermotor shaft s not benthat he packing s in good condition, Cleanall

15. Install he nstrumentpanelpassengers idelowerbracket.16. Install he PCM, mountingbracketand MFIcontrol relay.17. Install he nside/outsideair changeoverdampermotor assembly.18. Install he screwbelow he glove box assem-bly, and he entireglove box unit.19. Install he ower nstrument aneland showerduct.20. Connect he negativebatterycableand checkthe entireclimate control system or properopera-tion.

REMOVAL& INSTALLATIONDiamanteu See Figures 24 and25

1. Disarm he air bag Refer o the procedureearlier n this section.2. Dram he cooling systemand disconnect heheaterhoses rom the core ubes.Plug he hoses.3. Remove he passenger ide undercover.4. Remove he right side oot showerduct.

5. To remove he console, emoveand remove he revealed crew.Then emscrews rom the sides of the assemblya6. Remove he decorativeplugs rovers kneeprotector.Remove he revealekneeprotectorassembly nd he protectbracket.7. Remove he steeringcolumncov8. Remove he glove box striker, glglove box outer casingand he screwbesembly.9. Remove he radio bezeland he stainmentsystem.10. Remove he climate controlsystehead.11. Remove he cup holder.12. Remove he speakers rom the ostrumentpanel.13. Remove he instrument lusterbinstrument luster.14. To remove he speedometer abfrom the instrument anel, irst disconnespeedometer able rom the ransaxle.Tthe adapter rom the instrument anel,pspeedometer ableslightly nwards,andadapter15. Detach ll steeringcolumn connmove he column mountingbolts,and asteeringcolumn o rest on the ront seat

Fig. 23 Explodedview of the bloand related components-1997


10/76

CHASSIS LECTRICALt o allowanythingo comen contact ithair bagunit.16. Removeheglovebox amp ssembly.17. Removehe emainingnstrumentanelcrews nd emovehe nstrumentanelvehicle.18. Removehe eftside ootshower uctwork,cooler uct nd enter uct.19. Removehe rontand entereinforcements

enter tayassembly.20. Removeheair distributionuct ssembly.21. Detachll connectorsromheater-box-tems.22. Removeheheater oxmountingcrews ndheunit rom hevehicle.23. Disassemblena workbench.emovehee rom heheaterase.To install:24. Thoroughlylean nddry he nside f heheheater ore ndall related arts.25. Installheheater nit o hevehicle nd nstallmountingcrews ndnut.Be ure heevaporatorheaterase re itted ogetherroperly. t-ll connectorso heater-box-mountedtems.26. Installheair distributionuct ssembly.n-and entereinforcementsnd enter27. Installhecenter uct,apcooler uct nd eftshower uct.28. Installhe nstrumentanel ndmounting29. Installheglovebox amp ssembly.30. Securehesteeringolumn ndattach llolumn onnectors.31. Installhespeedometerable daptero heanel.32. Installhe nstrumentluster nd he nstru-33. Installhespeakerso he opof he nstru-34. Installhecupholder.35. Installheclimate ontrol ystemontrol36. Installhestereo ntertainmentystem nd37. Installhescrew elowheglove oxassem-and heentire love oxunit.38. Installhesteeringolumn overs.39. Installheknee rotectorupport racket,hend hedecorativelugs.40. Installheconsole nd heashtray.

41. Installhe ight ide ootshower uct.42. Installhepassengerideundercover.43. Connectheheater oseso hecore ubes.44. Fill hecooling ystem.45. Connecthenegativeatteryable nd hecktheentire limateontrol ystemor proper perationand eaks.Galant# See Figures 26, 27, and 28

1. Disconnecthenegativeatteryable.2. Disarmheair bag.Refero heprocedureearliern hissection.3. With heengine old, et he emperaturecontrolever o heFULL OT osition. rainheen-gine oolant.4. Disconnecthecoolant osesunningo heheater ipes t he irewall.5. Removehecenter onsole.6. Removeheheaterover.7. Removehesteering heel.8. Removehesmall teeringolumn anel.9. Removeheundercover.10. Removeheupper nd ower teeringolumncovers nddetachhewiring onnectors.11. Removehe nstrumentluster ood.12. Removehemountingcrewsor he nstru-ment luster.13. Pull he luster utanddisconnecthespeedometerdapterehindhecluster. emovehecluster.14. Removehe loorconsole nd heunder-frame.15. Disconnectnd emoveheair duct,apheater uct, idedefrosteruct nd hevertical e-froster uct.16. Removeheglovebox.17. Removeheashtray nd ts mount. iscon-necthe ightwiringbeforeemoving.18. Removeheheater ontrolaceplate.19. Removeheheaterontrol anel nddiscon-nect tsharness.20. Removehe ight ideundercoverrom heinstrumentanel nd emoveheunderframe.21. On he eftsideof he nstrumentanel,e-movehe useboxcover ndunbolthe useboxromthe nstrumentanel.22. Removehe rontpillar windshieldillartrim) romeach illar.23. Removehekickpanelrim romeach ide.

24. Loosenhedefrosterarnish, iscphoto ensor iringand emovehegarnfroster rille.25. Removehegrille or hecenter ir26. Removeheboltsholdinghesteeumn racketo he nstrumentanel.27, Removehecentereinforcemen28. On he eftside, emovehe etainholdinghe nstrumentanel nderframo29. On he ight ide, emoveheundetaining olts.Note hat heboltsaredifferflanged oltmust ecorrectlyeinstalled30. Removehe emaininguts ndbothe nstrumentanel. s he nstrumentaloose,abel nddisconnecthewiringharCarefullyemovehe nstrumentanel.31. If equippedithautomaticlimateremovehepower ontrol niton he owetheheater nit.32. Removeheductointbetweenheandevaporatorasewithair conditioninassemblyheater nly).33. Carefullyeparatehevacuumosat heconnector.34. Removeheheater nit rom he e35. To emoveheheater ore,irst emcoverrom hewater alve.Disconnectheremovehevacuumctuator.36. Removeheclamps nd lide hehoutof hecase. emovehewater alve ftis removed.37. W ith hecase emoved,heheatebechangedfter hewater alve s removtheplastic over, emoveheclamps ndhremovehewater alve.To install:38. Thoroughlylean nddry he nsidcase.nstallhecoreand hewater alve,

hose r clamps.39. Installhe acuumctuatornd heing ink.Put hecover n hewater alve.40. Installheheater nitand ightenhingbolts.41. Carefullyttachhe acuum oseto he acuum arness. ake ertainhehfirmlyand ecurely.42. Installheheaterover,hennstaconsole.43. Installheductointbetweeneatorator r blower.44. Installhepower ontrol n itand connecthe inksand ods.


11/76

CHASSIS LECTRIC45. Install he heaterhosesunder he hood.46. Install he mstrument anelby reversing tsremovalprocedure.47. Install he centerconsole.48. install he upperand ower steeringcolumncovers.49. Install he centerpanelundercover.50. Install he small column panel.51. Install he steeringwheel.52. Fill the cooling system.53. Connect he negativebatterycableand checkthe entireclimate control system or properoperationand eaks.

Mirage# See Figures 29, 30, and 31

1. Disconnect he negativebattery able.2. Drain he cooling systemand disconnect heheaterhoses.3. Remove he ront seatsby removing he cov-ers over he anchorbolts, he underseatray, he seatbelt guide ring, he seat mountingnutsand bolts anddisconnect he seatbelt switch wiring harness romunder he seat.Then ift out the seats4. Remove he loor consoleby first taking outthe coin holderand he consolebox tray. Remove heremotecontrol mirror switch or cover.All of theseitems requireonly a plastic rim tool to carefullyprythem out.5. Remove he rear half of the console.6. Remove he shift leverknob on manual rans-mission vehicles.7. Remove he ront consolebox assembly.8. A numberof the nstrument anelpiecesmaybe retamed y pin type asteners. heymay be re-movedusing he ollowing procedure:

a. Press down on the centerpin with a suit-able blunt pointed ool. Pressdown a little morethan /re in. (2mm) to release he clip. Pu ll heclip outward o remove t.b. Do not oush he oin inward more hannecessarybecause t may damage he grommetor the pin may all in if pushed n too far. Oncethe clips are removed,use a plastic rim stick topry the piece oose.9. Removeboth ower cowl trim panels kickpanels).10. Remove he ashtray.11. Remove he centerpanelaround he radio.12. Remove he sunglasspocketat the upper eftside of paneland he side panel nto which t mounts,13. Remove he drivers side kneeprotectorandthe hood releasehandle.14. Remove he steeringcolumn op and bottomcovers.15. Remove he radio.16. Remove he glove box striker and box assem-bly.17. Remove he nstrument anel owercover, 2small pieces n the center,by pulling orward.18. Remove he heater ontrol assembly crew.19. Remove he nstrument lusterbezeland pullout he Qauge ssembly.20. Remove he speedometer dapterby discon-

Fig. 29 Explodedview of the heater core and related components-1990-92 Mi

93%Q%Fig. 30 Heater core and related compo-nents-1993-96 Mirage22. Remove,by pryingwith a plastic rim too l, theright side speaker over and he speaker, he upperside defrostergrilles and he clock or p lug o gain ac-cess o some of the instrument anelmountingbolts.23. Lower he steeringcolumn by removing hebolt and nut.24. Remove he ns trumentpanelbolts and heinstrumentpanel.25 Drsconnecthe air selection, emperature ndmodeselectioncontrol cables rom the heaterboxand remove he heater ontrol assembly.26. Remove he connector or the MFI control re-lay.27. Removebothstamped teel nstrumentpanelsupports.28. Remove he heaterductwork.29. Remove he heaterbox mountingnuts.30 Remove he automatic ransmissionELCcon-trol box.31. Remove he evaporatormountingnutsand

34. Thoroughly leanand dry hecase. nstall he heatercore o the hethe clips and cover,35. Install he evaporatorand hemission ELC box.36. Install he heaterbox and con

Fig. 31 Exploded iew of the herelated components-1997-00from the heaterbox, beingcarefulnofins or tankends.To install:

work.37. Connectall wires and contro38. Install he instrument anelaconsoleby reversmg heir removalpr39 Install he seats.40. Refill he cooling system.41. Connect he negativebatterythe entireclimatecontrol system or ption Check he system or leaks.


12/76

CHASSIS LECTRICALnjury r death, ndbecausef the egalf servicinghese omponentsithoutproper PA ertificationndexperience.ost,njury r death, nvironmentalamage,ndsuch s he act hat t is a fed-crimeo vent efrigerantnto heatmosphere),hat heA/C omoonentsnyourvehicle

4. Move heairselectionontroiever o theRE-CIRC osition.Moveheair selectionamper ULLYINWARDnd onnecthecableo the ever.Adjust srequired.C. Pushheouter able n thedarrow o hat heres no oosene

serviced nlyby MotorVehicle irCon-MVAC)rained, ndEPA ertified utomo- REMOVAL&INSTALLATION

with heclip.d. Set heknobor theair outleon hecontrolo theDEF ositione. Set heair outlet hangeovof theheater nit o theDEF ositthecableo the everpin.f. Pushheouter ablen thedarrow o theres no oosen&s,hewith heclip.your vehicles A/Csystemuses R-12 e-and s in needof recharging, hecan be convertedover to R-Ma(less environmentallyharmfulRefer o Section1 for addi-on R-12 o R-134aeonver-additional considerationssystem.

ti See Figures32 thru 451. Disconnecthenegativeattery able.2, Unfastenhe etaininglipsand emovehecenterrimpanel.3. Removehe adioltapend/orCDplayer s-sembly,4. Removehecontrol ssemblys ollows:a. Removehe etainingcrew(s).b. Presshe everpin o disconnectheairoutlet hangeoveramperable.

*The bossand clampare needed or the as-

1. Disconnecthenegativeattery able. emovesembly ine dever they arededures.n Cnan

luring actory installation, how-not necessary or service pro-

glovebox, f necessary,2. Move hemode electionever o theDE-osition.Move hemode election amperFULLYNWARDnd onnecthecableo the3. M&e tht emperatureontrolever o ts5ST osition. ove heblend ir dampereverDOWNWARDnd onnecthecableo the4djust s required.

b,.dIIal, heboss ndclamp itha pairofnippers,o removeheheater ontrol ssemblyfrom hevehicle.To install:5. Installhecontrol anel, s ollows:a. Set he emperatureontrol nobon hepanelo MAXHOT..b. Set heair mixdampereverat heupperpartof theheater nit o theMAXHOT osition,thenattachhecableo the everpin.

then remove the shia suitable prytool, release the automatic transaxles

g. Set he ever or the nside/ochangeovern theheater ontrol air recirculationosition.h. Set he nside/outsideir chadampereverof theblower n it o tlationpositionwith he nside/ouchangeoveramperever ouchedof theblower ase),henattachheleverpin.i. Pushheouter able n thedarrow o that heres no ooseneit with heclip.j. Properly ositionhecontrosecure ith he etainingcrew(s)6. Installhestopper.7. Connecthenegativeatteryatheclimate ontrol ystemor proper fore nstall inghe emainingompon8. Installhe adio/tapend/orCDsembly.9. Installhecenterrimoanel,mclipsareengagedroperly. 10. Connecthenegativeattery a

Fig. 34 Remove he two centerretaining screws . . .


13/76

CHASSIS LECTRIC

Fig. 38 Pull the radia far enoughout to ac-cess the electrical connectors . .9315fip14Fig. 39. . . then detach he connectors rom I I Fig. 40 Finally, detach the antthe rear of the radio and remove he radio from the v

Fig. 41 Remove he heater controlpanel re- Fig. 42 Remove he control cable from the Fig 43 Remove he control cabbleid door

Cruise ontrols a speed ontrol ystemhatmaintainsdesiredehicle peed nder ormal ri-vingconditions. owever,teep rades por downmay ause ariationsn heselectedpeeds. he !electronicruise ontrol ystem as hecapabilityocruise, oast, esumepeed, ccelerate,tap-up nd

actuator,ntermediateink,auto-cruiseontrolmod-uleassembly,peed ensor, nd he eleaseswitches.Dependingponheyear nd/ormodel f yourvehicle,hecruise ontrol ystems either acuumrelectronicallyontrolled.he ruise ontrolmodule

located na ever n hesteeringolumwheel ndon he nstrumentanel.The eleasewitchesremountednbrake/clutch/acceleratoredal rackebrake r clutch edals depressed,hecsystems electricallyisengagednd h


14/76

CHASSIS LECTRICALCRUISE CONTROL TROUBLESHOOTING

Problem Posable CauseWIII not hold proper speed 1 ncorrect cable adjustmentF.~. _I.~_ 1L .-AL- I. I - \

\

Cruise intermittently cuts out

trrnarng Inrome nnKageLeaking vacuum servo diaphragmLeaking vacuum tankFaulty vacuum or vent valveFaulty stepper motorFaulty transducerFaulty speed sensorFaulty cruise control module lutch or brake switch adjustment too tight-chnrt *r nna* in the cruise control circuitcerVI I, . vt y,I- Faulty transdu

Leaking vacuum circuitFaulty cruise control switchFaulty stepper motor

Note. Use this chart as a guide. Not all systems will use the components listed.

See Figures 32 thru 40, 46 and 471. Disconnectattery egativeable.

with an air bag, be sure to dis-before entering he vehicle.2. Removehepanelromaroundhe adio,Onmodelshepanels retained ithscrews, nse plasticrim ool o pry he ower adofoose.3. Removehe adio/tape/CDlayermountingetainingcrews,

4. Slide he adio hassis utof he nstrument*panelnddisconnecthe adiowiringharnessnd*Depending on he speaker nstallation, itmay save time at installation to identify andtag all wires before hey are disconnected.

5. Removehemountingracketsrom he adio.To install:6. The nstallations he eversef he emovalprocedure.ake ll electricalndantennaonnec-tionsbeforeasteninghe adio ssemblyn place.7. Test ll unctionsf heentertainmentystemprior o inal nstallation.f all aresatisfactory,nstalltheunitand enter anel.8. Connecthenegativeattery able nd echecktheentire ystemor proper peration.

CD Changer1. Disconnecthenegativeattery2. Openhe runkid.3. Removenynecessaryrim o acchanger.4. RemoveheCD-changer-to-bscrews.5. Lift hechangerrom hebracketheelectricalonnectors.6. Removehechangerrom he ehTo install:7. The nstallations he eversef r

REMOVAL&INSTALLATIONFront (InstrumentPanel Mountedu See Figure 48

1. Disconnecthenegativeattery2. Removehe ront peakerarnis3. Removehe etainers,etachhenector nd emovehe rontspeaker,


15/76

CHASSIS LECTRlCiDoor Speakers 4. Installations he eversef he e) See Figures 50, 51, and 52 dure

-tI. lJ13lrIIIIObIlIt:laydwa:n?.nnnnr,L,^.^rr:.... attery je, Rear Deck Speakers2. Removehedoor rimpa el.Refero hepro-ceduren Section 0. # See Figure 533. Removehemountingcrews, etachhehar- 1. Disconnecthenegativeattery aness onnectornd emovehe rontspeaker. 2. Removehespeakerover.3. Removehespeakeretainingcr4. Lift hespeakerutof hecavity.

Handle he speakercarefully to avoid dam- 5. Detachheelectrical nd emoveaging he cone during removal and nstalla-tion.6. The nstallations he everse f re

93156g19Fig. 48 Typical front (instrument panelmounted)speaker mount ingDoor MountedTweeters# See Figure 49

1. Disconnecthenegativeatteryable.2, Removehedelta over triangularhapedcover ehindhesidemirror ndabovehedoorpanel.3. Removehespeakeretainingcrews4. Lift hespeakerutof hecavity.5. Detachheelectricalnd emovehespeaker,6. The nstallations he eversef removal.

rate tweeter

Fig. 50 Remove he four speaker retaining Fig. 51 Lifl the speaker rom thescrews ity . . .

REMOVAL&lNSTAL~TlON In See Figures 54 and 55*This procedurealso applies o rear wiper1arms on he DiamanteWagonand MirageHatchbacks.


16/76

646 CHASSIS LECTRICALTo install: 2. Removehe earwiper rmby emovinghe 2. Removehewindshield iper rm3. Installhewiperblade ndarmassemblies, capnutcover, nscrewinghecapnutand ifting he screwinghecapnuts nd ifting hearmTightenhe etaining utso 7-12 t. Ibs. 10-16 arm rom he inkage ost. linkage osts.Nm). 3. Removehe argenteriorrimpanel. se 3. Removehe rontgarnish anel4. Notehat hedrivers idewiper rm hould e plasticrimstick o unhookhe rimclipsof he ift- 4. Removeheair nlet rimpiecesmarked or Dr and hepassengersidewiper rm gaterim.There ill bea rowof metaliftgate lips 5. Removehehole over.should emarked or As.The dentificationarks acrosshe op.There ill be2 rowsof rimclips hat 6. Removehewipermotor y oosshould e ocated t hebase f hearm, earhe retainhe estof hepanel. mountingolts, emovinghemotor sspivot. nstallhearms o heblades re1 inch rom 4. Disconnectheelectrical arnesst hewiper disconnectinghe inkage.

thegarnish olding hen arked. motor. emovehe earwiper ssembly.onot \5. Connecthenegativeatteryable nd heck loosenhegrommetor hewiperpost. *The installation angle of the crathewiper ystemor proper peration. To install: motor has been actory set; do not5. Installhemotor ndgrommet. ounthe them unless t is necessary o do sgrommeto hearrow n hegrommets pointing mustbe removed, emove hem ondownward. marking heir mountingpositions.REMOVAL&INSTALLATION 6. Installhewiperarm. To install:7. Connecthenegativeatteryable nd heck 7. Installhewindshield ipermotrearwiper ystemor proper peration. nect he inkage.1999-92 Mirage 8. If operations satisfactory,it the abs n he 8. Reinstallll rimpieces.upper artof he iftgaterim nto he iftgate lips 9. Reinstallhewiperblades. oteFRONT ~ and ecurehe iftgaterim. vers idewiper rm hould emarkedthepassengersidewiper rm hould

1. Disconnecthenegativeatteryable. 1993-00 Mirage or As.The dentificationarks hould 2. Removehewindshield iper rms y un- 1. Disconnecthenegativeatteryable.

thebase f hearm, ear hepivot. nstascrewinghecapnuts nd ifting hearmsrom helinkage osts. 2. Removehewindshield iper rms yun- theblades re1 nch rom hegarnish screwinghecapnuts nd ifting hearmsrom he . parked.3. Removehe rontdeck arnish anel. linkage osts, 10. Connecthenegativeattery ab4. Removeothwindshieldolders. 3. Removehe rontdeck arnish anel. thewiper ystemor proper peration.5: Removeheclips hathold hedeck over. fthey re hepin ype, heymay e emovedsinghe 4. Removeothwindshieldolders.5. Removeheclips hathold hedeck over.f Diamanteand 199440 Galantfollowing rocedure:a. Removeheclip by pressing own n he they re hepin ype,heymay e emovedsinghe, following rocedure. FRONTcenter inwitha suitable luntpointedool.Press own littlemorehan /r6 in. (2mm). a. Removeheclip by pressingownon he b See Figures 56, 57, 58, and 59This eleasesheclip.Pull heclip outwardo re- center inwitha suitable luntpointedool.movet. Press own littlemore han /r6 in. (2mm). 1. Disconnecthenegativeatteryb. Donotpush hepin nwardmore han This eleasesheclip.Pull heclip outwardo re-necessaryecauset maydamagehegrommet, movet.

or if pushedoo ar, hepin may all in. Onceheb. Donotpush hepin nwardmore han

clipsare emoved,sea plasticrimstick o pry necessaryecauset maydamagehegrommetthedeck over oose. or if pushedoo ar, hepin may all n. Oncehe6. OnMirage,emoveheair ntake creen. clipsare emoved,sea plasticrimstick o pry7, Loosenhewipermotor ssembly ounting thedeck over oose.boltsandemovehewindshield ipermotor. is- 6. Removeheair ntake creen.connecthe inkagerom hemotor ssembly.f nec- 7. Loosenhewipermotor ssembly ountingessary,emovehe inkagerom he ehicle. bolts nd emovehewindshield ipermotor. is-connecthe inkaaerom hemotor ssemblv.f nec-*The installation angle of the crank arm andmotor has been actory set, do not removethem unless t is necessary o do so. If armmustbe removed, emove hem only aftermarking heir mountingpositions.To Install:8. Installhewindshield ipermotor nd on-necthe inkage. onnectheelectrical arnesso hemotor.9. Whennstallinghe rimandgarnish iecesand eusing in ype lips,use he ollowing roce-dure:a. With hepin pulled ut, nsert he r imclipinto hehole n the rim.b. Pushhepin nward ntil hepinsheadsflushwith hegrommet.c. Checkhat he rim s secure.IO. Installhewiper rms nd ighten uts o 17ft. bs. 24Nm).

essary,emovehe inkagerom hevehicle.-*The installation angle of the crank arm andmotor has been actory set. Do not removeunlessnecessary. f arm mustbe removed,removeonly after markingmountingposi-tions.

To install:8. Installhewindshield ipermotor nd on-necthe inkage. onnectheelectrical arnesso hemotor.9. Whennstallinghe rimandgarnish iecesand eusing in ype lips,use he ollowing roce-dure:a. With hepin pulled ut, nsert he rimclipinto hehole n the rim.b. Pushhepin nward ntil hepinsheadsflushwith hegrommet.c. Checkhat he rim s secure.

Fig. 56 Remove he retaining clipfront garnish panel


17/76

CHASSIS LECTRICA3. Removehewindshield iper rms yun-screwinghecapnuts nd ifting hearmsrom helinkage osts.4. Removehe rontdeck arnish ssembly.Iver.xl harnesslug rom

,I6 -n\,LIr5. Removeheair nletc(6. Disconnectheelectricthewipermotor.7. Removeheaccess o,, LIVIGil.

To install:5. Installhemotor nd nstallhe e6. Installhewiper rm o hat heainches85mm)etweenhemeasurewhen arked. ecurehewiper rmwithnut.*Before proceeding,connect he

8. Removehewipermotormountingolts.9. Detachhemotor rank rm rom hewiperlinkaneand remnve he mntnr

motor has been actory set. Do not removethem unlessnecessary. f they mustbe re-moved, emove hem only after marking heirmountingpositions.

check he operationof the motor.tory, disconnect he cable and cominstallation.o. WIIIIWLIEl~&WVt: vatreryoathesystemor proper peration.

..- a- - - _ _ _ . _ _ _

*The installation angle of the crank arm and 7. Installhe nteriorrimpiecen II^_^^ AL- I-I:..- L-AL--

To install:10. Installhewindshield ipermotor nd on- REMOVAL&INSTALLATIONnect he inkage.

I 14. Installhe rontdeck arnish ssembly.I. YIVI1IIYVLI UyuL.UL,U2. Remove he windshieldwasher lu

1. Attachheelectrical arnesslug.12. Installheaccess ole over.13. Installheair nlet over.15. Reinstallhewiper rmand ightenhemountinguts o 14 t. Ibs. 19Nm).nstallhearmsso heblades reparallelo hegarnish olding

-Front and Rear

1 nivnnnprt the nonatiua haltorv ra

3. Drain nywasherluid n he esappropriateontainer.4.I when arked.

Removehepumprom he ese16. Connectheneaativeatterv able nd heck removinghe etainingardwarer wistlntil it is frpp frnm thP rosorvnirthewiper ystemor proper peration. lo Install:5. Inspecthepump eal n he es

/ de&h the linkageFig 59 Pull the motor rom the firewaii and%y 1 I,,,,,, theif necessary.

1 1 Disconn& thP rwnativo hatton/ rahlm 6. Installhepumpntoplace ntils. I , ~p.L, YULL, -YI .liftgateower rim. seal.3: Lift hesmatrUVBI, I~IIIUV~ tilt: lfAdllllll~ IIULII --. .-- -^- ..^ L^ _,_:..:-- .A 7. Installhewindshield asherluid2. Matchmark he wirier arms n the shaftand A Refill thp wxhpr fllk-l rpqprvni rmarkthe rmso heproper ide or reinstallation and emovehewiperarm.4. Removehemountinaolts nd emovehe. .,...SV. ...III. *..* YUY..m9. Connecthenegativeatteryab

REMOVAL&INSTALLATIONtie interior, release he lock by turning he tie interior, release he lock by tuadapter o the right or left and remove he adapter o the rigM or left and remadapter. adapter.

5. The nstallations he everse f he emoval 6. The nstallations he eversef hMirage

1. Disconnecthenegativeattery able. emovethecenterrimpanel.

procedure.se are ot o damageheprinted ircuit procedure.se are ot o damagehepboard r anygauge omponents. board r anygaugeomponents.6. Connecthenegativeattery able nd heck 7. Connecthenegativeattery aball cluster-relatedtemsor proper peration. i IIcluster-relatedtemsor proper per2. Removeheknee rotector.f pin ype lipsareused,heymay e emovedsinghe ollowing ro-cedure:a. Press own n hecenter inwitha suit-ablebluntpointedool. Press own littlemorethan IIS n. (2mm). his eleasesheclip. Pulltheclip outwardo removet.b. Donotpush hepin nwardmore hannecessaryecauset maydamagehegrommetor thepin may all in, f pushedn too ar. Oncetheclipsare emoved,sea plasticrimstick fnecessaryo pry heknee rotectoroose.3. Removehe nstrumentluster ezel.

Gaiant@See Figures Bg hru 66

1. Disconnectegativeattery able.2. Removehe2 retainercrewsrom he owersurface f hemeter ood.3. Removehe etainercrewsrom heundersidetopportion f hemeter ood.4. Carefullyemovehemeter oodrom he aceof hecombinationeter.5. Removehe4 retainercrews nd hecombi-nationmeter ssemblyith hebezel ttached.e-


18/76

CHASSIS LECTRICAL

Fig. 64 Grasp the instrument cluster andcarefully pull it out of the instrumentpanel tached; he cluster has sockets on the back Fig. 66 . , . these sockets engtors solidly mountedbehind he

1. Disconnecthenegativeatteryable.with an air bag, be sure to dis-t before entering he vehicle.

2. Removehehood ock elease andle ndrom heknee rotectorelowhesteeringemoveheexposedetainingcrewsheknee rotector.3. Removeheupper nd he ower teeringol-4. Removehe nstrumentluster ezel.5. Removehe nstrumentluster. isassembleauges r hespeedometers equired.

the speedometer able adapter mustbedisconnect he cable at thele end. Pull the cable slightly towardrelease the lock by turn-the right or left and remove6. The nstallations he everse f the emovalse are ot o damageheprinted ircuitr anygauge omponents,7. Connecthenegativeattery able nd hecktemsor proper peration.


19/76

CHASSIS LECTRIC1. Disconnecthenegativeattery able. are all built into 1 multi-functioncombination2. Removehe nstrumentluster, soutlined 1. Disconnecthenegativeatteryearliern hissection. switch hat is mounted n the steering col- 2. Using small crewdriverr othumn. Refer o Section8 for procedures e-3. Removehe etainingcrewsor he nstrument tool,carefully ry he etaininglips rogarding he combination witch.clusterens nd over ssembly.emovehecover of heswitchrimplate.3.and ens. Carefully ull heswitch nd rim,4. Removehe etainingcrewsor hegauge r the nstrumentanel.4. Detachheelectricalonnectowarningampo be eplaced,hen emovehegauge theswitch.or warningamp.

REMOVAL&INSTALLATION : 5. The nstallations he eversef To install:5. Placehegauge r warningampntoplaceand ightenhe etainingcrews. 1. Disconnecthenegativeatteryable.6. Installhe nstrumentlusterens nd over 2. Using suitable rytool, isengageheswitchassembly. retainingabs. REMOVALINSTALLATION7. Installhe nstrumentluster. 3. Gently ull he witchrom he nstrument8. Connecthenegativeattery able. panel.\ 4. Detachheelectricalonnectornd emovehe *On all models he headlights, switch. and on somemodels, he cruise c5. The nstallations he everse f removal. tion are all built into 1 multi-funcnation switch hat is mountedon REMOVALINSTALLATION column.Refer o Section8 for progarding he combination witch.*The headlights, urn signals, dimmerswitch, horn switch, windshield

REMOVALINSTALLATIONwiper/washer, ntermittentwiper switch and *on somemodels, he cruise control function # See Figures 71, 72, and 73

the retaining clips from either side of theswitch trim plate . . . Fig. 72 . . . then carefully pull the switchand trim plate out of the instrumentpanel Fig. 73 Detach he electrical conremove he switch

REMOVALINSTALLATIONSealed Beam Headlights

1. Raiseheheadlightssinghepop-up witch.2. Disconnecthenegativeatteryable.3. Unfastenhe etainingcrews,hen emoveheupper nd he ower eadlightezels.4. Removeheheadlightetainingingscrews,and heheadlightetaininging.5. Pull heheadlightartially ut,detachhecon-nectar,hen emove eadlightssemblyrom heve-hicle.

9. Connecthenegativeattery able.CompositeHeadlights6 See Figures 74, 75, 76, 77, anU78

Halogenbulbs containgas underpressure.Handling he bulbncorrectly couldcausetto shatter nto flying glass fragments.DoNOT eave the light switch ON.Always allowthe bulb o cool before removal. Handle hebulb only by the base;avoid touching heglass tself. Wheneverhandlinga halogenbulb, ALWAYSollow these precautions:

l Handlehebulbonlyby ts baseing heglass.l DONOT ropor scratchhebulbl Keep irtandmoisturewayrom* Placeheused ulb n henewbuanddispose f t properly.1. Openhevehicles ood nd ecrightposition.2. Disconnecthenegativeattery3. Removehesocket over ypulloff,or urningt clockwisehen ulling4. Carefullywist hebulb nd ockclockwise,henpull heassemblyromhousing.5. Holdinghebase f hebulb, etconnectorarness.


20/76

.CHASSIS LECTRICAL

Fig. 74 Twist and pull on the cover to un-lock it in order to access he headlight bulband socket assembly93MmFig, 75 Turn the inner head light bulb and then carefully pull

NO 0000

. glare n oncomingaror ruckwindshshouldhey lluminatehepassengevehicles rivingn rontof you.Theseare ough nd hould lways e ine-tupairshopwhichs equipped ithheadtools. mproperdjustmentsay eboand llegal.

Fig. 77 Unplug he bulb rom the socket, be-ng careful not to touch he glass portion ofthe bulb I

6957Q39

Fig. 78 NEVER old the halogen bulb by theglass, ALWAYS old it with the base ,

Aboutonce a year, when he headllgfttsarereplaced or any ime front end work is per-formed on your vehicle, the headlightshouldbe accuratelyaimed by a reputable epairshop uslng he proper equipment.Headlightsnot properly aimed can make t virtually im-possible o see ar d may blind other driversibly causingan accident.Note hat thefollowing procedure s a tempo-rary fix, until you can ake your vehicle to arepair shop or a proper adjustment.Headlightdjustmentay e emporarily adeusing wall,asdescribedelow, r on he earofanotherehicle.When djusted,he ights hould ot

Formost f hevehiclesovered yhorizontalnd ertical iming f eachsunit s provided y woadjustingcrewthe etainingingandadjustinglate sionof a coil spring. heres noadjuscus; his s done uring eadlight an*Because the compositeheadligbly is bolted nto position, no adjshould be necessaryor possible.plications, however, may be boltejuster plate or may be retained byscrews. If so, follow this procedu@sting he lights, BUTalways hajustmentcheckedby a reputable

Beforeemovingheheadlightulbotheheadlampn anyway,note hecurrorder o ease eadlightdjustmentpoIf hehighor owbeam etting f heolworks,hiscanbedone singhewalla building:1. Parkhe ehicle na level urfafuel ank bout/a ull andwith hevehall extra argo unless ormallyarrieshould e acing wallwhich s no es(1.8m) igh nd12 eet 3.7m) ide. vehicle hould eabout 5 eet rom h2. If aimings o beperformedutdvisableo waituntilduskn ordero pro

urningt counterclockwise.ake ure hes installedecurelyr he enswill beoutofr watermay et nto he ightunit.9. Disconnecthenegativeattery able ndheheadlightperation.

See Figures 79, 88, 81, 82, and 83Theheadlights ust eproper best, afestoad llumination. y armeaOprovraeThe ights hould:.__1__1_ -___-_-.

on the road, POSSIcheckedor proper imandadfusreus lweSYdly.tate nd ocalauthoritiesave equirementsheadlightiming;hese hould echeckedefores made.


21/76

CHASSIS LECTRICA

Fig. 82 low-beam headlight pattern alignment

Fig. 85 Remove he washer fluidretaining screws . . .

Fig. 83 High-beamheadlight pattern alignmentheadlighteams n hewall. f donen a garage,darkenhearea roundhewallasmuch spossibleby closing hades r hanginglothover hewin-dows.3. Turn heheadlightsNandmarkthe allatthecenter f eachightsow br am,hen witch nthebrights ndmarkhecenter f eachightshighbeam. short ength f maskin apewhichs visiblefrom he rontof hewhir+ ma._..._._._ beused. lthoughmarkingll ourpo: itionss advisable, arkingnepositionromeachight hould esufficient.

4. If neithar he;. __rn on one ide s working, nd fanotherike-sizedehicles available,arkhesec-nnri nm in the wart cnnt whrw the whirlo um md

headli!htsONandadjusthebeamso marcn e

I. Disconnecthenegativeattery able.

marks n hewall.

2. Removenynecessaryomponentso access

6. Haveheheadlightdjustmentheckedssoon spossible ya reputableepair hop.

REMOVAL&INSTALLATIONParkingAnd Side Marker Lightsp See Figures 84, 85, 88 , 87, 88, and 89

!ss the parking1~ n oo4-98 G

I

1 I-lens.

1Fio. 8 then move he reser

3. Removehe ens rom he ront as

marker amp bult, _.. ._~-5. The nstallations he eversef re

Front urn Signalp See Figures 91

1. Disconnectl2. Removehe0, 91, 92, and 93I(? ,-.nn+:.m.Hnn, nz Ill7yaue allcly ulI10 etaininocrews

. . . I_ WIIY I .8 %,I VUVLfdYI T.I I IU Ll Vll lUlY , .UU U,,markhebeams singhe ame-sideight.Thenswitchhevehicleso heone o beaimeds backn


22/76


Fig. 87 After the washe: fluid reservoirremoved, he parking amp bulb (B) and heside marker lamp (A) are accessible on Fig. 88 Twist the bulb socket to release it1994-98 Galant models from the lens Fig. 89 Pull the bulb assemblysocket to remove

g3156p71Fig 90 Remove he turn signal lens retain-ingscrew . . . . then remove he lens from the

Rear Turn Signal, Brake and Tail lightsp See Figures 94, 95, 96, and 97.

1. Disconnecthenegativeattery able.2, Openhe runk id, hatch, r ailgate nd e-ovehe etainers,hen emovehe nnerrimpanelin ordero get o he ear amp ssembly.3. Turn henecessaryulband ocket ssemblyo unlockt rom hehousing,hen ull t from hehousing.

Fig. 92 Twist the bulb socket tofrom the lens

Fig. 94 The back-up amp socket assemblyPull the bulb assembly out of the located on the undersideof the trunk lid. . . . then unfasten he trim


23/76

CHASSIS LECTRlC

93156P57Fig. 98 The back-up amp socket assembly Fig. 99 Twist the bulb socket o release theis located on the undersideof the trunk lid locking tabs from the lens Fig 100 Pull the bulb assemblyof the socket to remove itBack-up ightu See Figures 98, 99, and 100

1 Disconnecthenegativeattery able.2. Openhe runkid.3. If equipped,emovehe rimon heundersideof he runk id.4. Turn hesocket ounterclockwise14 f a urnto releaset from he ens.5. Pull hebulbout o removet from hesocket,6. Thenstallations he everse f removal.7. Connecthenegativeatteryable.8. Verify heoperationf he amp.Side Marker light# See Figures 101, lOi, 103, and 104

I. Removehe wo etainingcrewsrom he 2. Openhe runkid anddetachhelens. connectorrom he amp ssembly.2. Removehe ens rom he ear ascia. 3. Removehe etainingcrew old3. Grasphebulb ocket nd otatet counter- assembly.clockwiseo removet from he amp. 4. Lowerhe amp ssemblyrom h4. Pull hebulbout o removet from hesocket. 5. Rotatehebulb lockwise hilep5. Installations he everse f removal. gentlynwardo removet from hesoc6. The nstallations he everse f rHigh-mountBrake ight 199fH6 MIllAGE, 1990-93GAL799446 GALANT 7992-96DlAMANTE

p See Figures 105, 106, 107, 108, and 109 1, Disconnecthenegativeattery2. On heMirage ndGalant,emo1. Disconnecthenegativeattery able.*The lamp assembly s accessible rom thetrunk underneath he packageshelf.

retainerlipsor bolts rom hehigh-mlight over nd emovehecover.3. On heDiamante,ress entlynsides f he iahtcover nd emovet r

1 aining screw . ~ . ig 101 Remove he side marker light re-3156p75/ ;;x,;;:,sdhen puii the lens awaG;:: 1 1 ror;l the iensig 103 Twist the bulb socket to


24/76

.6-24 CHASSIS LECTRICAL

Fig. 107 . . . then lower the lamp assemblyfor access o the bulbs4. Rotatehebulb lockwise hilepushingt.,gentlynwardo removet from hesocket.5. The nstallations he everse f removal.

1997-00 MIRAGE, 1994-00 GALANT, ANDf 997-90 DIAMANTE1. Disconnecthenegativeattery able.

*The bulb socket s accessible rom thetrunk underneath he packageshelf.2. Ooenhe runkidand detach he elwtricalconnectorrom hebulb ocket,3. Rotatehesocket ounterclockwisend e-movet rom he amp ssembly.4. Rotatehebulb lockwise hilepushingtgentlynwardo removet from hesocket.

Fig. 108 Rotate he bulb assembly. . .License Plate lightsp See Figures 110,111, and 112

1. Disconnecthenegativeattery able.2. Removehe wo etainingcrewsor he amplens.3. Lowerhe ens rom he runkid.4. Grasphebulb nd emovet from he ermi-nalson he ens.To install:5. Placehebulb ntoplace n he ens ndlightly ressnto he erminalsn he ens.6. Placehe ens ntoposition n he runk idand ightenhe wo etainingcrews.7. Connecthenegativeattery able.8. Verify heoperationf he amp.

Dome/ PassengerArea lampsp See Figures 113, 114, and 115

1, Using small rytool, arefullyecoverens rom he amp ssembly.2. Removehebulb rom ts retainitacts.f hebulbhas aperednds, entspring lip/metalontact nddisengagbulb, hen ull t freeof he wometal oTo install:3. Beforenstallinghe ightbulb ntcontacts,nsurehatall electricalondufaces re reeof corrosion r dirt.4. Positionhebulbbetweenhe wotacts.f hecontactsave mall oles, ethe aperednds f hebulbare ituate5. The nstallations he everse f removal.

Fig. 110 Remove he two lamp lens retain-ing screws . . . Fig. ill . . . then lower the lens to accessthe bulb Fig. 112 Remove he bulb by pullithe terminals on the lens


25/76

CHASSIS LECTRIC

ove the socket from ig. 118 Pull the bulb straight ou

6. Installhecoverensuntil ts retainingabs reproperly ngaged. Lightbulbapplicationhart-1990Bulb Chart - OutaideInstrumentCluster ight bulbsb See Figures 116,llf,ll8, and 119

1. Disconnecthenegativeatteryable.2: Removehe nstrumentluster soutlinednthissection.3. Turn hedesired ulb ocket ounterclockwiseto removet from hecluster., 4. Grasphebulb ndpull t straight ut o re-movet from hesocket. I 1Lmelatel~hlsFig. 119 On some of the bulbs, it is neces-;tbqrlrnsfertheolore . . 1 EL&!aOUIDover Ome Bulb Chart-In

*__.__., , JvR,,Is~,,oress+n+n,app

I I l ~UVV.

To install:5. If necessary,ransferhecolored ulb overothenewbulb.6. Place newbulb nto hesocket nd ightlyPlacehesocketnto hecluster nd urn he

,. IIpithpr it ic faldtv nr 9. Connecthenegativeattery able. I

Outside Inside


26/76

6-26 CHASSIS LECTRICALLight bulb applicationchart-199&93 Galant Light bulb applicationchart-1994-98 Galant

Description 1 Wattage 1

rrunk lrght Overdrwe rndvzator lightlautomatlc transaxle)

Light bulb applicationchart-1992-96 Diamante Light bulb applicationchart-1997-00 DiamanteOutside

Description wattage SAEtradeNO1 - Headlrght Irnslde) 65W 9005l----if- HeadlIght loutsldel 55w 90063 - Parktng and front 3cP 168s!de markrr l,ght4 - Front turn-srgnal light 24cp 1156NA5 - Hugh-mounted stoplbght 21cp 9211 6- Eackuplrght I 19211cp7 - Stop/tall light8 - Rear side markerlkght9 - License plate light 3cP 168

IO - Rear turn-slgnal lkght 32cp 1156

Description Wattage

Dome lightDoor lightLuggage compartment lrghtRear personal lrghtGlove compar tment lbghtVanity mrrror lkghtArr condltfoner control

Outside

7 License plate Ilght / 3cp 1686 Stop and tall Irghl 1 32/2cp 1 2057 I

Inside

Light bulb applicationchart-1999-0Light Bulbs -Outside

Descrrptron WattageHeadlIght loutsldel 55WHeadlight (Inside1 65WFront turn-srgna l lkghts 271B\1\1Fronr srde-marker lrghts ZCPParkrng hghts 3CPStop and tarllrghts 3212~~Rear turn-srgnal lrghts 32cpBackup lkghts 32~x1Rear srde-marker lkghts 3CP

--

LDescrrptron Wattage- . .-- -- --_ ---8W

8W8Wlow5W5W

14w14Wt4wt4w

Ashtray lightShtft tndrcaror Ilghtfautomatlc Iransaxlel

Exterior interior1 - He;;;fghts (inner) - 12V 65W2- keadlights (outer) 12V 55WfHB41

6 - Rear tdm-stgnal lights 12V 45cp7 - Reversrng light - 12V 32cp6 - Lrcense plate light 12V 3cp9 - Stop I tall lights 12V 43/3cplo- Stop I tall Ibghts 12V 3212~~11- Hugh mounted stop - 12V 21Wlight

RoomlIghts 12V 6Spot lights 12V RRear personal lrglilsDoor IIghts (clear) Trunk hght - 12V 5W- Parking and front - 12V 3cpside marker lrght4 - Fronl turn-slgnal lights 12V 32cp5 - Front fog llghl 12V 55W (H3) 12- RearsIde-marker light - 12V 3cp


27/76

CHASSIS LECTRICA1. Removehe useboxcover.2. lnsoecthe useso determinehich s aulty.

REPLACEMENT 3. Grasphe use nd emovet from he usebox. Never exceed he amperage ating4. Inspecthebox erminalsnd leanf cor- fuse. If the replacement use also bIt See Figures 120 thru 127 check or a problem n the circuit.roded.f any erminalsredamaged,eplacehe er-Fuses re ocated ithern heengine ompartment

minals.5. Plugn a new useof hesame mperageat- 6. Checkor proper perationf heaor passengerompartmentuse nd elay anels.f a componentr circuit.fuseblows, t east ne, utpossibly everal ompo- ing.ients/circuitsill not unction roperly.

Fig, 120 The engine compartment use boxis typically located adjacent o the battery

Fig. 122 The engine compartment use boxcontains a combination of fuses, maxi-fuses, relays, and diodes. Most can be re-moved by simply pulling upward I

Do not replace blown usible links wdard wire. Only usible type wire wpalon nsulation can beused, r dathe electrical systemwill occur!A numberf usibleinksareused ncles o protect iring ndelectricalom

Theres a collection f usibleinks ocabattery. hese re eferredo as hemainsecond roup f linksare ocatedn hebdedicateduses.f replacementf a fusequired, se heexact ameinkas emoWhen usibleinkblows t is very mFig. 121 Grasp the engine compartment findoutwhy.They replacedn heelec

. ,+ 1 ouswiring ailures.fuse box cover and pull It straight up to re- for protectiongainst ead hortso gromove it canbecaused yelectricalomponena

Fig. 123 The nterior fuse box is located un-der the drivers side of the instrumentpanelFig. 124 Grasp he interior fuse bdepress he retaining tabsand lift


28/76

.6-28 CHASSIS LECTRICALDo not just replace the fosible link to correcta problem! RESETTlNGAND/OR EPLACEMENT REPLACEMENT

When eplacingall fusible inks, hey are o be re-placedwith the same ype of prefabricatedink avail-able rom your vehicle manufacturer.Circuit breakers re ocated nside he use panel.Theyare automatically esetwhen he problemcor-rects tself, s repaired,or the circuit cools down oallow operationagain.

The urn signaland hazard lasherunin the nterior use panel ocatedunder hleft side kneeprotector.Theyare replacpulling hem straightout. Note hat he parranged n such a way hat he lashermerly orientedbeforeattempting o installflasheruntil he orientationof the prongand simply push t firmly in until he proengaged.

1990-92 Mirage fuse ocation chart,-Lw

1993-96 Mirage use location chart

93156glO

1997-00 Mirage passenger omparlocation chart

1997-00 Mirage enginecompartment use ocation chartEngine compartment9ight side

Engine compartment

I I I

12 Power windowControl 30A13 @I Radiator fan motor 30A14 E-J Headllghls 40A

15 ;2 lgnttlon switch 30A

NO Symbol Electrical system C16 0 Fuse(+B)

Some fuses may not be installed on your depending on the vehicle model or specihcatioIdentification of fuse

i0A Red


29/76

CHASSIS LECTRlC1990-93 Galant use ocation chart

Fuse Load Capacitiesl-15A Cigarette hghterZ-10A Radm3-10A Heater relay4-10A (E P S.)5-10A Belt6-10A Turn signals7-10A Meters6-10A Horn9-15A Wiperlo-10A (4 A/T)ll-15A (Door locks)12-10A Dome hght, clock13-10A Backup hghts14-15A Stop hghts15-30A Heater16m20A (Sunroof)17-20A (ECS)1% spare fuseldentlfxation of fuse10A Red15A Light blue20A Yellow30A Green 93156g13

1994-98 Galant use location chart

Passenger compartment1. 15A StoplIghts2- 10A Turn signals3- 1OA Backup Itghts4. 30A Heater5. i5A Wiper6- IOA Meters7. 30A Rear wndow defogger;: fo& fl$oof)

IO- 15A Cagaretle lighler11. 10A Heater relay12. IOA Horn13. Spare fuse( ): II so equippedA!T Automallc transaxle

Engine compartmentFusible linksI- 30A Ignition swlch2. 50A (ABS)3. 30A Radiator fan4. 40A Headkghts5. 30A Power wndow

Fuse6- 30A (ABS)7. 30A Condenser fan6. 10A Hazard9. 20A Engine10. 10A (Au conditioning)11. 10AHigh beam12. 10ATall lkghts13. 10A (Theft)14. i5A Fog lkghls

( ): If so equipped 93156g14

1999-00 Galant use ocation chart


30/76

CHASSIS LECTRICAL1992-96 Diamante use location chart

I

Fuse load caaacities 15 -2OA Horn16 - 20A (E.C.S.)1 - 15A Cigarette lighter 17 - spare fuse2 - 10A Radio3 - 10A Heater relay, (Power window ( ) indicates optlonal equipmentrelay) E P.S.: Electronic Control Power Steer-4 - 10A (E.P.S) ing5 - 10A Turn signals, SRS E.C.S.: Electronic Control Suspension6 - 10A Meters, SRS SRS~ Supplement Restratnt System7 - 15A Wiper A/T: Automatic Transaxle8-10A (4AIT)9- 15A Steering handle lock, (Doorlocks)lo- 10A Dome light, Clock11 - 10A Backup lights12 -2OA StoplIghts13 -3OA Heater14 - 20A (Sunroof) 93156fllE

1997-00 Diamantepassenger ompartment use location chartNo Symbol Electrical System

Icapactty

I

Spare fuses are contained in the fuse housinguse a fuse of the same capacity for replacement.

199740 Diamanteenclinecompartment use location chart


31/76

CHASSIS LECTRIC

INDEX OF WIRING DIAGRAMSDIAGRAM 1 Sample Diagram: How To Read & Interpret Wiring DiagramsDIAGRAM 2 Sample Diagram: Wiring Diagram Symbols

DIAGRAM 3 1990-92 Galant 2.OL SOHC Engine SchematicDIAGRAM 4 1993 Galant 2.OL SOHC Engine SchematicDIAGRAM 5 1990 Galant 2.OL DOHC Engine SchematicDIAGRAM 6 1991-93 Galant 2.OL DOHC Engine SchematicDIAGRAM 7 1994 Galant 2.4L SOHC Engine SchematicDIAGRAM 8 1994 Galant 2.4L DOHC Engine SchematicDIAGRAM 9 199500 Galant 2.4L Engine Schematic

DIAGRAM 10 1993-96 Mirage 1.5L Engine SchematicDIAGRAM 11 1993-96 Mirage 1.8L Engine SchematicDIAGRAM 12 1997-00 Mirage 1.5L Engine SchematicDIAGRAM 13 1997-00 Mirage 1.8L Engine SchematicDIAGRAM 14 1992-93 Diamante 3.OL SOHC Engine SchematicDIAGRAM 15 1994-95 Diamante 3.OL SOHC Engine SchematicDIAGRAM 16 1992-93 Diamante 3.OL DOHC Engine SchematicDIAGRAM 17 1994-95 Diamante 3.OL DOHC Engine SchematicDIAGRAM 18 1996-00 Diamante 35L Engine SchematicDIAGRAM 19 1990-95 Galant/Mirage Starting Chassis SchematicsDIAGRAM 20 1990-93 Galant Charging Chassis SchematicsDIAGRAM 21 1990-93 Galnt Cooling Fans Chassis SchematicsDIAGRAM 22 1990-93 Galant Headlights Chassis SchematicsDIAGRAM 23 1990-93 Galant Taillights/Parking Lights Chassis Schematics


32/76

CHASSIS LECTRICALINDEX OF WIRING DIAGRAMS

DIAGRAM 28 1990-93 Galant Wipers Chassis SchematicsDIAGRAM 29 1990-93 Galant Wipers w/ ETACS Control Unit Chassis SchematicsDIAGRAM 30 1990-93 Galant Power Door Locks Chassis SchematicsDIAGRAM 31 1990-93 Galant Power Door Locks wl ETACS Control Unit Chassis SchematicsDIAGRAM 32 1996-00 Galant Starting System Chassis SchematicsDIAGRAM 33 1994-00 Galant Charging System Chassis SchematicsDIAGRAM 34 1994-00 Galant Charging System Chassis SchematicsDIAGRAM 35 1994-00 Galant Headlights Chassis SchematicsDIAGRAM 36 1994-00 Galant Taillights Chassis SchematicsDIAGRAM 37 1994-00 Galant Brake Lights/Backup Lights/Horn Chassis SchematicsDIAGRAM 38 1994-00 Galant Turn Signal Chassis SchematicsDIAGRAM 39 1994-00 Galant Power Windows Chassis Schematics mDIAGRAM 40 1994-00 Galant Wipers Chassis Schematics

bDIAGRAM 41 1994 Galant Power Door Locks w/ ETACS Control Unit Chassis SchematicsDIAGRAM 42 1994-00 Galant Power Door Locks Chassis SchematicsDIAGRAM 43 1992-00 Diamante Starting System Chassis SchematicsDIAGRAM 44 1992-00 Diamante Charging System Chassis SchematicDIAGRAM 45 1992-93 Diamante Cabling System Chassis Schematic

DIAGRAM 46 1994-95 Diamante Cooling System Chassis SchematicsDIAGRAM 47 1996-00 Diamante Headlights Chassis SchematicsDIAGRAM 48 1992-95 Diamante Taillights/Backup Lights Chassis SchematicsDIAGRAM 49 1992-95 Diamante Turn Signal Chassis Schematics

DIAGRAM 50 1992-00 Diamante Brake Lights, Horn Chassis SchematicDIAGRAM 51 1992-95 Diamante Power Windows Chassis Schematics


33/76

CHASSIS LECTRlINDEX OF WIRING DIAGRAMS

DIAGRAM 54DIAGRAM 55DIAGRAM 56DIAGRAM 57DIAGRAM 58DIAGRAM 59DIAGRAM 60DIAGRAM 61DIAGRAM 62DIAGRAM 63DIAGRAM 64DIAGRAM 65DIAGRAM 66DIAGRAM 67DIAGRAM 68DIAGRAM 69DIAGRAM 70DIAGRAM 71DIAGRAM 72DIAGRAM 73DIAGRAM 74

1994-95 Diamante Power Door Locks Chassis Schematics1996-00 Diamante Cooling System Chassis Schematics1996-00 Diamante Taillights Chassis Schematics1996-00 Diamante Turn Signal Chassis Schematics1996-00 Diamante Power Windows Chassis Schematics1996-00 Diamante Power Door Locks Chassis Schematics1992-95 Diamante Headlights Chassis Schematics1996-00 Diamante Wipers Chassis Schematics1993-96 Mirage Charging System Chassis Schematics1993 Mirage 1.5L Cooling System Chassis Schematics1994-96 Mirage 1.5L Cooling System Chassis Schematics1993 Mirage 1.8L Cooling System Chassis Schematics1994-96 Mirage 1.8L Cooling System Chassis Schematics1993-96 Mirage Headlights Chassis Schematics1993-96 Mirage Taillights Chassis Schematics1993-96 Mirage Turn Signal Chassis Schematics1993-96 Mirage Brake/ Backup Lights/ Horn Chassis Schematics1993-98 Mirage-Power Windows Chassis Schematics1993-96 Mirage Wipers Chassis Schematics1993-96 Mirage Power Door Locks Chassis Schematics1997-00 Mirage Starting Chassis Schematics


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CHASSIS LECTRICALINDEX OF WIRING DIAGRAMS

DIAGRAM 78 1997-00 Mirage Taillight/Parking Lights Chassis Schematics

DIAGRAM 79 1997-00 Mirage Turn Signal Chassis SchematicsDIAGRAM 80 1997-00 Mirage Brake Lights/ Backup Lights/Horns Chassis SchematicsDIAGRAM 81 1997-00 Mirage Power Windows Chassis SchematicsDIAGRAM 82 1997-00 Mirage Wipers Chassis SchematicsDIAGRAM 83 1997-00 Mirage Power Door Locks Chassis Schematics


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WIRING DIAGRAM SYMBOLSHOW TO READ & INTERPRET WIRING DIAGRAMSWIRE COLORABBREVIATIONS HOALL TTM

FUSEEISA

T IN RM H OT A T rES

CIRCUITBREAKER

1 i = T

KNOCKSOLENOD SOLENOD SENSOR

3 P OS T O N S W TC HNORNALLY NORMALLYNORHbUYOPEN

SWTCH

E

RESSTOR

m

NORMALLYCLOSEDSWTCH

lz l

RESSTOR

E

SATTERY REIAY

WIWIZRTIWN CONTROL HODUsE

AICANDHEATNGSYSTEMS

IOTHERSYSTEMREFERENCE

CHOKE RRACKhARABLE VARABLERESSTOR RESSTOR WEEDSENSOR A/ \

GROUNDHEATED

IdI1GYlROXYGEN SENSOR HEATNG ELEHENT HE

DIAGRAM 2DIAGRAM 1 TccaGWOl


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1990-92 GALANT 2.OL SOHC ENGINE SCHEMATIC 1993 GALANT 2.OL SOHC ENGINE SCHEMATICHOT IN RIB aR START

STEkCIRCUT

HOTNRWORSTARTFROH16NTONSWTCH

t

HOT IN RUR OR STRT H OT A T A L L T M ES HOT IN RU4 DR STARTFRDtlIGNITIONSWTCH

IEEELGHT

! as ;--

Tm>CHECN6lNIGHT

%

EGNITIONPDWER4 RANSSTORD 4smTO OATALINK SPEED&TECONRECTM REED( ! WlTCH TOUCWI CWJTROL UNIT

IDLE> SFEEDCONTROLMOTOR

AT ! nT

I 10

1STEKCRCUT

EGRTEnFERA~SENSORmLIFoRRlAWLn

VOLUMEAIR FLOWSENSORI 5!%FUSE *I7IOAH OT A T A LL T M ES

EGRTEMFERATLRESERSDR, (~~FORR~AONLV)

An L MT.

B m

11STARTNGCIRCUT NOTEI IFI CORRECTOR C0 =-A-WI coRNEcmR CII - 3F I CONNECTOR C2 I 77

DIAGRAM 4O R C 0 = A-R Cl, = %T OR C 2 = C

DIAGRAM3 l93156EOl


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NOTEIIFI CONNfCTOR C0 - AIlFI CONNECTOR CII =-GNFI CORNECTOR Cl?! - y:

1991-93 GALANT 2.OL DOHC ENGINE SCHEMATIC990 GALANT 2.OL DOHC ENGINE SCHEMATIC FUSIBLERONINKP-

STARTNG0 C RCU T

d1

a6

NOT IN RUN OR STMTFROMIGNITIONSWTCH

TO MTALINKCGWECTGR T O U CCGNTROL

l-Le! c I P t

DIAGRAM 593156EO3

DIAGRAM 6


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1994 GALANT 2.4L SOHC ENGINE SCHEMATIC 1994 GALANT 2.4 DOHC E NGINE SCHEMATICNECTOR CS9= ANECTOR C60 = BECTOR Cti, = -I

NOTEECH CONNECTOR C59 = A-ECH CONNECTOR C60 = BECH CONNECTOR CM = -17H OT A T A L L T ? E S

FUSEs20A

s

HQt IN RUN OR STARTFRQ+IGNITIONSWTCH

*ON:liIGISI

FVSE0IOA

>CHECKENGNELGHT

FUELPup

TO DATALINUCONNECTOR

ICRANKSHAFTCAMSHAFTPOSTONSENSOR

PQW2RTRANSSTOR

m (DA a=

TOAKCONTROLS

ENGNE CONTROL WCCU.2

mFRONTH2AT2DOXYGENSENSOR

TOCDDLINGSYSTEMVEHCLESPEEDSENSORf FROMSTART1116CIRCWT

EGRTEPERATuRESENSOR

93156E05

HOT AT

!NSlNE3OLANTrEMPERATu3EENSOR

REARHEATEDOXYGENSENSOR

REARHUTEDOXYGENSENSOA

TM 3vJ*

H OT A T A L L T b ES

DIAGRAM 7.

DIAGRAM 8


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1993-96 MIRAGE 1SL ENGINE SCHEMATICHOT AT AU. TMES H OT I N W N M S TM

1996-00 GALANT 2.4L ENGINE SCHEMATICHOTAT*LLTMES HOT IN RW OR STMT

FROU

FWEIIOA

)$fE

!I

To.-1_/szl5

RCEI2ImA.lllm

i

i

AtT, N/T.5 Pi 1sTAmlNGCIRCUIT

HOT*1STEGGCWCUT

DIAGRAM 9


40/76


41/76

1997-00 MIRAGE 1.8L ENGINE SCHEMATIC 1992-93 DIAMANTE 3.OL SOHC ENGINE SCHEMATICNOTE HOT AT ML T HGS HOT IN R&S4OR STbRT HOT IMRUN OR STARTECMCGNNECTOR CZI =4. FUSS FROnE CM C Om EC TO R C L2 = w I IGNITIWE 2 4 C O WE CT OR C Z3 = T zG4 SW TCH

FROMIGNnONSWTCH4

HOT AT UL T MES HOT IN RiN GR STARTFUSIRLE FRWLINK IGNITION:04 SWTCH5

I GH n ON F A LU E S EN SO R

FUSEbIO4

CHECKENGNELGHT

TOVEHCLG

ENGNE CONTROL MO4MEIECH)

ENGNE CONTROL MWUE

, 1TOCOOLNGSYSTw4

EGRTEHFRR4TLGESENSOR

1POST

NTA NIT5 (I)I 4\FROMSTARTNGCIRCUT

HOT AT

FWKNOCKSENM

P OS T O N 6SWTCHFL&G2IOATMESNE CT OR 8 3 7 = 4.E CT OR 8 11 - 3CTOR 659 =C NECTOR Sk0 g D-

93156E15DIAGRAM 13 DIAGRAM 14


42/76

1994-95 DIAMANTE 3.OL SOHC ENGINE SCHEMATICI OTAT LLTHS HOT NMORSTMTm Ec Tm C EI . -A *

lGz&NTC4

d

I I -I .I

\\\ DIAGIWM 15 93156EOQ

1992-93 DIAMANTE 3.OL DOHC ENGINE SCHEMATICNOTE HOTATNLT ES mT NaNmsTART HOT N~ORSTARTEcncoaEcTmcE-*A-EcncooeCTmczzF Fmn motlten-TmcEs*r lsmlon lsn T oNSmTa SmTa

t

TOCooLmSysTEl

DIAGRAM 16


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1994-95 DIAMANTE 3.OL DOHC ENGINE SCHEMATIC 1996-00 DIAMANTE 3SL ENGINE SCHEMATICHOT AT ALL T MES HOT NRUNORSTART

39 FLBG FRanIGNITICUHOT AT ML T MES HOT IN RUN OR STARTNECTOR CZI . *ACTOR C22 * 8 FUSG FROnNECTOR CZ3 =Kc :9A IGNITIONECTOR C05 * .O- SWTCHt

CHTO DAThLMCCNNECTOR

TO DATALINKCONNECTOR -TR&LE

T O A I CCONTROLS

H

TOSYZ&

NAN FOLO FUELDIFFERENT AL TANKPRESSURE PRESSURESENSOR SENSOR$. =

TOCOOLNGSYSTEM$5 z: $g$Fm m 0

1 1TO FROMCOOL NG START NGSYSTEM SYm3

*HOTP

FUSEI9IQATMES

INOTEBFI CONPECTOR RI05 =AHFI CONNECTOR BID9 =8

DIAGRAM 18DIAGRAM 1793156El


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GALANTMIRAGE CHASSIS SCHEMATIC 1990-93 GALANT CHASSIS SCHEMATICHOTATALLM55

Fu5m5 Fu5nEUM Lw5 5as P L

LINK4- LA I

z I 3

DIAGRAM 1993156801

DIAGRAM 20

.m55-UNKIw

ALTERNAun


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. 1990-93 GALANT CHASSIS SCHEMATIC 1990-93 GALANT CHASSIS SCHEMATICA T M L T MES

FBSLGLINK53OAIGNITIONSWTCH

DIAGRAM 21

-- coNoENsEnFANMOTORRELAY-- M)

5*PREsslJmSWTCH

TMES-FJSBLELINK74oA

H OT A T A L L T ME S

I HEADLGHTRELAYm-----------------v-

DIAGRAM 2293156803

LGHTNGSWTC4


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1990-93 GALANT CHASSIS SCHEMATIC 1990-93 GALANT CHASSIS SCHEMATICH OT A T A L L T N ES

FUSBLELINKILOA

FUSE LGHTNG2 SWTCHIOA

LEFT REARLID LGHT(EXCEPT 19901

RGHTFRONTcoMBNATa4LGHT

n -

H OT AT A LL T ME S

P

FUSBLELINK5JOA

PARK NEUTRALP QS T O N S W T CH

RGHTREARCOnSNAToNLGHT

5+

R G HT R EA RCOHSNATONTALLGHTID

R G HT R EA RLID LGHTEXCEPT 1999)

H OT AT A LL T ME SFUSBLELINKLA

BIGNITIONSWTCH

ACCYd

FUS25lo*

5

- t

m;

e

lL(D

+

DIAGRAM 23 DIAGRAM 2493156B05


47/76

1990-93 GALANT CHASSIS SCHEMATICH OT A T A LL T N GG H OT A T

IGNITIONSWTCN

LT MEGFUSE

2 6z%

SlGtELHAzmoFLAGHERlml

cisTLWN-SGNAL

L R GWWW. 4 .

y

2e

T A H TELAY

DIAGRAM 2593156607

1990-93 GALANT CHASSIS SCHEMATICW/O ETACS HOT AT ALL T RES HOT IN RW

DJAGRAM 26


48/76

1990-93 GALANT CHASSIS SCHEMATICSTAUT

FUSSIOIOA

II E TA CS C WT RO L k N T(ECU) I*I

DATALMCOmECToA

RAINSWTCH

w/o ETACS1990-93 GALANT CHASSIS SCHEMATIC

HOT IN RLIN OR START

.r - I - SlNTERWTTENTWIPER REIN

WASHERCONTROLSWTCH

DIAGRAM 2793156Bl

DIAGRAM 28


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1990-93 GALANT CHASSIS SCHEMATICHOTNRUNORSTART HOT IN R(N aR START

2 ,2I,

d 1\ 01991-9s v I999 OKLY

2id

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Ch 6 Chassis Electrical