MITSUBISHI DIAMANTE 1900 Manual PDF

Troubleshooting Basic Starting System Problems Troubleshooting Basic Charging System Problems
Pmblem
Starter motor rotates engrne slowly cause
* Battery charge low or battery
defecttve Sobnlon
. Charge or replace battery
- Defective crrcurt between battery
and starter motor
* Low load current
* Hugh load current + Clean and ttghten, or replace
cables
* Bench-test starter motor Inspect
for wom brushes and weak
brush springs.
. Bench-test starter motor Check
engtne for fncbon, drag or coolant
rn cylinders. Check nng gear-to-
prnton gear clearance.
Starter motor wrll not rotate engrne
Starter motor dnve wrll not engage
(solenotd known to be good)
Starter motor dnve wtli not
dtsengage * Battery charge low or battery * Charge or replaoe battery
defecttve
* Faulty solenord . Check solenoid ground Reparr or
replace as necessary.
* Damaged drive pnron gear or * Replace damaged gear(s)
ring gear
* Starter motor engagement weak . Bench-test starter motor
. Starter motor rotates slowly wtth . Inspect dnve yoke pull-down and
high load current pornt gap, check for worn end
bushtngs. check m-g gear clear-
ance
. Engine setzed * Repatr engk7e
. Defecbve contact pant assembly * Reparr or replace contact pornt
assembly
. Inadequate contact pornt assembly + Repatr connectron at ground screw
ground
- Defeckve hold-In co11
* Replace field w~ndrng assembly
- Starter motor loose on flywheel . Ttghten mounttng bolts
houstng
. Worn drive end bustng . Replace bushtrg
* Damaged nng gear teeth . Replace ring gear or dnveplate
* Drive yoke return spnng broken or . Replace spnng
mtsstng
Starter motor dnve d&engages
prematurely
Low load current * Weak drive assembly thrust spnng * Replace dnve mechamsm
* Hold-tn co11 defeckve
. Replace field wtndtng assembly *
- Worn brushes . Replace brushes
* Weak brush springs * Replace spnngs Problem
Noisy alternator cause
* Loose mounbngs
. Loose drive pulley SoluIion
. Ttghten mountrng bolts
. Tighten pulley
. Worn beanngs
* Brush notse
* Internal circuits shorted (Hugh
pitched whrne) * Replace alternator
. Replace alternator
. Replace alternator
Squeal when starting engtne or . Glazed or loose belt * Replace or adfust belt
acceleratmg
Indicator light rematns on or . Broken belt . Install heft
ammeter rndrcates drscharge . Broken or dksconnected wares - Repatr or connect Waring
(ejrgrne runmng) * Internal aitemator problems * Replace alternator
. Defectrve voltage regulator . Replace vottage regulator/alternator
Car Irght bulbs contmually bum out- * Alternator/regulator overchargtng . Replace voltage
batter-v needs water conbnually regulatoriatternator
Car kghts flare on acceleratton . Battery low
. Internal alternator/regulator
problems * Charge or replace battery
. Replace alternator/regulator
Low voltage output (alternator lght
fltckers conbnually or ammeter
needle wanders) * Loose or worn belt
* Dkly or corroded connecttons
* Internal alternator/regulator
oroblems . Replace or adjust beit
. Clean or replace connecttons
* Replace alternator/regulator

ENGINE MECHANICAL 3-1
ENGINE 3-1
REMOVAL &INSTALLATION 3-l
ROCKERARM(VALVE)COVER 3-l
REMOVAL &INSTALLATION 3-l
ROCKER ARM/SHAFTS 3-4
REMOVAL & INSTALLATION 3-4
THERMOSTAT 3-7
REMOVAL & INSTALLATION 3-7
INTAKE MANIFOLD 3-7
REMOVAL & INSTALLATION 3-7
EXHAUSTMANIFOLD 3-14
REMOVAL &INSTALLATION 3-14
TURBOCHARGER 3-17
REMOVAL & INSTALLATION 3-17
RADIATOR 3-18
REMOVAL & INSTALLATION 3-18
ENGINE FAN 3-19
REMOVAL &INSTALLATION 3-19
WATER PUMP 3-20
REMOVAL & INSTALLATION 3-20
CYLINDER HEAD 3-23
REMOVAL &INSTALLATION 3-23
OIL PAN 3-30
REMOVAL & INSTALLATION 3-30
OIL PUMP 3-33
REMOVAL &INSTALLATION 3-33
CRANKSHAFT DAMPER 3-36
REMOVAL &INSTALLATION 3-36
TIMING COVERAND BELT 3-36
REMOVAL & INSTALLATION 3-36
INSPECTION 3-48
FRONT CRANKSHAFTSEAL 3-48
REMOVAL & INSTALLATION 3-48
CAMSHAFT,BEARlNGSAND
LIFTERS 3-48
REMOVAL & INSTALLATION 3-48
INSPECTION 3-53
BALANCE SHAFT 3-54
REMOVAL &INSTALLATION 3-54
REAR MAIN SEAL 3-54
REMOVAL&INSTALLATION 3-54
FLYWHEEL/DRIVEPLATE 3-55
REMOVAL &INSTALLATION 3-55
EXHAUST SYSTEM 3-55
INSPECTION 3-55
REPLACEMENT 3-56
ENGINE RECONDITIONING 3-57
DETERMINIG ENGINE CONDITION 3-57
COMPRESSION TEST 3-57
OIL PRESSURETEST 3-57
BUYOR REBUILD? 3-57
ENGINE OVERHAULTIPS 3-58
TOOLS 3-58
OVERHAULTIPS 3-58
CLEANING 3-58
REPAIRING DAMAGEDTHREADS 3-59
ENGINE PREPARATION 3-59
CYLINDER HEAD 3-60
DISASSEMBLY 3-60
INSPECTION 3-
REFINISHING & REPAIRING 3-63 ASSEMBLY 3-64
ENGINE BLOCK 3-65
GENERALINFORMAITON 3-65
DISASSEMBLY 3-65
INSPECTION 3-65
REFINISHING 3-67
ASSEMBLY 3-67
ENGINE START-UP AND BREAK-IN 3-
STARTING THE ENGINE 3-69
BREAKING IT IN 3-69
KEEP IT MAINTAINED 3-69
SPECIFICATIONS CHARTS
ENGINE MECHANICAL
SPECIFICATIONS 3-70
TORQUE SPECIFICATIONS 3-81 .69

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

ENGINEANDENGINEOVERHAUL 3-3
Fig. 3 Remove the
breather hose from the Fig. 4 Remove the PCW valve
and hose from
93153p17 Fig. 6 . . . then position the wires out of the
Fig. 7 The upper timing cover is retained by
three bolts. Unfasten the bolts . . . Fig. 8 . . . then carefully remove the cover
from the engine
Fig. 9 Remove the valve cover retaini
then lift the valve cover
4. If equipped, remove the breather hose from
13.
the valve cover. Place the valve cover into position and begin-
5. Remove the crankcase ventilation tube from ning in the center of the valve cover and working out-
the valve cover. ward, tighten the retaining bolts as follows:
6. On the 1.6L and 2.gL (DOHC) engines, re-
l 15L engine: 12-18 inch Ibs. (l-2 Nm)
move the ignition wire cover. l 1.6L, 1.8L, 2.OL DOHC, and 2.4L engines:
7. Label and remove the ignition wires and sep- 24-36 inch Ibs. (2-3 Nm)
arators. * 2.OL SOHC engine: WO inch Ibs. (4-5
8. Remove the upper timing belt cover. Nm)
14. Install the crankcase ventilation tube.
9. Remove the valve cover retaining bolts, start
15.
ing from the outside and working in. Install the ignition wire separators and the ig-
nition wires.
10. Remove the valve cover and gasket from the
16.
cylinder head. On the 1.6L and 2.OL (DOHC) engines, install
the ignition wire cover.
To install:
17. Install the air intake hose.
11. Clean the valve cover gasket sealing surfaces,
12, Install new valve cover gaskets and if 18. Connect the negative battery cable.
equipped, O-rings onto the valve covers. 19. Run the engine and check for leaks and
proper operation. 3.OL and 3.5L Engines
b See Figure 12
1. Disconnect the negative battery cable.
2. Remove the upper intake manifold as de-
scribed in this section.
3. On the 3.OL DOHC engine, remove the igni-
tion wire cover.
4. Remove the ignition wires and spark plugs.
5. Remove the crankcase ventilation tubes from
both valve covers.
6. Remove the retaining nuts and engine wiring
from both valve covers and move aside.
7. Remove the valve cover retaining bolts and
studs.
8. Remove both valve covers from the engine.

3-4 ENGINEANDENGINEOVERHAUL
Rear bank
6 011 010 og
1.03 07 02]
7923PG25 Fig. 12 Rocker cover bolt torque se-
quence-3.01 DOHC engine
To install:
9. Clean the valve cover gasket sealing SW
faces.
10 Install new valve cover gaskets onto the valve
covers.
11. Place the valve covers into position.
12. Reinstall the valve cover retaining bolts and
studs and tighten in sequence to:
l 3.OL SOHC engine: 7 ft. Ibs. (9 Nm) l 3.OL DOHC engine: 42-54 inch Ibs. (4-5
NM
l 3.5L engine: 30 inch Ibs. (3 Nm)
13. Install the engine wiring and tighten the re-
taining nuts.
14. Install the crankcase ventilation tubes into
both valve covers.
15. Install the ignition wire separators, the igni-
tion wires, and the spark plugs.
16. On the 3.OL DOHC engine, install the ignition
wire cover.
17. Install the upper intake manifold as described
in this section.
18. Connect the negative battery cable.
19. Run the engine and check for leaks and
proper operation.
( ser;lblies-l.5L dngine g3’53goi Fig 13 Camshaft rocker arm and shafl as- REMOVAL &INSTALLATION
1.5L and 1.8L Eflgin8S
,# See Figures 13 and 14
1. Disconnect the negative battery cable.
2. For 1.8L engines, label and disconnect the
spark plug cables.
3. Disconnect the accelerator cable, breather
hose and PCV hose connections.
4. Remove the rocker cover.
5. Loosen both rocker arm shaft assemblies
gradually and evenly and remove the rocket shafts
from the vehicle.
To install: 7. Lubricate the rocker shaft with clean engine
oil and Install the rockers and springs.
8. Install the rocker arm and shaft assemblies.
Tighten the rocker arm shaft retainer bolts to 23 ft.
Ibs. (32 Nm).
9. Check valve adjustment and install the valve
cover. Tighten the valve cover bolts to 16 inch Ibs.
(1.8 Nm) for the 1.5L engine or to 29 inch Ibs. (3.3
Nm) for the 1.8L engine.
10. If detached, connect the spark plug cables.
11. Connect the accelerator cable, breather hose
and PCV hose.
12. Connect the negative battery cable.
2.OL SOHC Engine
# See Figure 15
6. If disassembly is required, keep all parts in
the exact order of removal. On this engine, the hydraulic lifters are built into
the rocker arms. If lifter service is required, simply
1. Breather hose
2. P.C.V. hose
3. Rocker cover
4. Rocker cover gasket
Valve clearance pre-adjustment
5. Oil seal
6. Oil seal
7. Rocker arms and rocker arm shaft
6. Rocker arms and rocker arm shaft
9. Rocker shaft spring 10. Rocker arm A
11. Rocker arm 6
12. Rocker arm shaft (Intake side)
13. Adjusting screw
14. Nut
15. Rocker arm C
16. Rocker arm shaft (Exhaust side)
17. Adjusting screw
18. Nut
19. Camshaft
7923PG27 :ig. 14 Camshaft, rocker arm and shaft assemblies-l .8L engine

ENGINEANDENGINEOVERHALJL 3-5
Fig. 15 Camshaft, rocker arm and shaft as-
remblies-2.01 SOHC engine
remove the lifter from the bore in the rocker arm. It is
recommended that all of the rocker arms and lash ad-
justers be replaced at the same time.
1. Disconnect the negative battery cable.
2. Remove the valve cover.
3. Matchmark the distributor to the cylinder
head and remove the distributor.
4. Remove camshaft timing belt.
5. Working in a crisscross pattern from the cen-
ter outward, loosen the camshaft bearing caps in
gradual steps.
6. Remove the rocker arms, shafts and bearing
caps as an assembly.
*It is essential that all parts be kept in the
same order and orientation for reinstallation.
Be sure to mark and separate parts, so parts
will not be mixed during reassembly.
7. Disassemble rocker shaft assembly. Starting
at rear bearing cap, slide each piece off shafts.
*Inspect the roller surfaces of the rockers.
Replace if there are any signs of damage or
if the roller does not turn smoothly. Check
the inside bore of the rockers and lifter for
wear.
To install:
8. Apply a drop of sealant to the rear edges of
the end caps.
9. Install the assembly into the front bearing
cap, making sure the notches in the rocker shafts are
facing up. Insert the installation bolt, but do not
tighten at this point.
10. Install the remaining cap bolts. Tighten all
bolts evenly and gradually to 15 ft. Ibs. (20 Nm). Re-
move the lash adjuster retainers.
11. Install the timing belt as required.
12. Align the matchmarks and install the distribu-
tor.
13. Remove the lash adjuster retaining tools. 14. Install the valve cover, with a new gasket and
semi-circular packing in place.
15. Connect the negative battery cable.
16. Run the engine and check ignition timing.
1.6L and 2.OL DOHC (Turbo and Non-turbo)
Engines
6 See Figure 16
1. Disconnect the negative battery cable.
2. Remove the valve cover and discard the gas-
ket.
3. Install lash adjuster retainer tools MD998443
or equivalent, to the rocker arm.
4. Remove the rocker shaft hold-down bolts
gradually and evenly and remove the rocker shaft/arm
assemblies.
5. If disassembly is required, keep all parts in
the exact order of removal. Inspect the roller surfaces
of the rockers. Replace if there are any signs of dam-
age or if the roller does not turn smoothly. Check the
inside bore of the rockers and the adjuster tip for
wear.
To install: 6. Lubricate the rocker shaft with clean engine
oil and install the rockers and springs in their proper
places.
7. Install the rocker shaft assemblies on the en-
gine. Tighten the bolts gradually and evenly to 21-25
ft. Ibs. (29-35 Nm).
*When installing the rocker arm shaft,
make certain the notch is properly located.
8. Remove the lash adiuster retainina tools
9. Install the valve cover with a new gasket.
10. Connect the negative battery cable.
F :ig. 16 Camshaft, rocker arm and shaft as
s iemblies-1.6L and 2.OL DOHC engines
*o Nm
IILlbs -
9315390 3
2.4L Engine
# See Figures 17, 16, and 19
1. Disconnect the negative battery cable.
2. Remove the accelerator cable from the retain-
ing clamps and position the accelerator cable out of
the way.
3. Remove the air intake hose.
4. Disconnect the breather hose and the PCV
hose.
5. Disconnect the spark plug cables from the
spark plugs.
6. Remove the rocker cover and gasket.
7. Install lash adjuster retainer tools MD998443
or equivalent, to the rocker arm.
8. Remove the rocker shaft hold-down bolts
gradually and evenly and remove the rocker shaft/arm
assemblies.
9. Disassemble the rockers and the rocker shaft
springs from the rocker shafts. If they are to be
reused, note the location and positionrng of all rocker
shaft components. It is recommended that all lash
adjusters and rockers be replaced as a complete set.
To install: 10. Immerse the lash adjusters in clean diesel
fuel, and using a small wire, move the plunger up
and down four or five times. while pushing down
lightly on the check ball in order to bleed the air from
the adjuster.
11. Install the lash adjusters to the rocker arms
and attach the special holding tool.
12. Lubricate the rocker shaft with clean engine
oil and install the rocker arms.
13. Temporarily tighten the rocker shaft assembly
with the mounting bolts so that all rocker arms on the
inlet valve side do not push on the valves,
14. Fit the rocker shaft springs from above and
position them so that they are at right angles to the
plug side. Install the rocker springs before installing
the exhaust side rocker shaft and rocker arm assem-
bly.
15. Install the exhaust side rocker shaft assembly
in the engine. Tighten the rocker shaft mounting bolts
gradually and evenly to 23 ft. Ibs. (32 Nm).
16. Remove the lash adjuster retaining tools.
17. Install the rocker cover and tighten the
mounting bolts to 30 inch Ibs. (3 Nm).
18. Reinstall the spark plug wires to the spark
plugs.
19. Reconnect the PCV and breather hoses.
20. Install the air intake hose.
21. Reattach the accelerator cable brackets and
reconnect the accelerator cable.
22. Connect the negative battery cable.
3.OL SOHC Engine
6 See Figures 20 and 21
On this engine, the hydraulic lash adjusters are
built into the rocker arms,
1. Disconnect the negative battery cable.
2. Remove the valve cover. Install lash adjuster
retainer tools MD998443 or equivalent, to prevent the
auto-lash adjuster from falling out of the rocker arm.
3. Loosen rocker arm and shaft assembly evenly
in several steps. Remove the rocker arm and shaft as-
sembly as a complete unit.
4. Remove the rear camshaft bearing cap and
slide the rocker arms, springs and washers from the
shaft. If they are to be reused, note the location and
positioning of all rocker shaft components. It is rec-

.
3-6 ENGINEANDENGINEOVERHAUL
I Fig. 17 Rocker arm shafts and components-2.41 engine
Fig. 18 Installing the rocker shaft springs- 79231632
13. Bearing cap
14. Rocker arm
15. spring
16. Rocker arm
17. Spring
16 Bearing no. cap 3
IQ. Rocker arm
20. spring
21. Rocker arm
22. Spring
23. Bearing no. cap 2
24. Rocker arm
25. spring
26. Rocker arm
27. Spring
28. Rocker arm shaft
29. Rocker arm shaft
30. Bearing no. cap 1
Fig. 20 Rocker arm assembly-3.01 SOHC engine 7923PG3
ommended that all lash adjusters and rockers be re-
placed as a complete set.
To install:
5. Immerse the lash adjusters in clean diesel
fuel. Using a small wire, move the plunger of the lash
adjuster up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out
the air. Install the lash adjusters in the rocker arms.
6. Using a light coat of engine oil, assemble the
rocker arms to the shaft. Install the rear camshaft
bearing cap.
Arrow mark (bearing cap)
Arrow mark
fcyllnder head)
7923PG35 Fig. 21 When installing the rocker arm/shafi
assemblies, ensure that the arrow marks
point in the same direction as the arrow
stamped into the cylinder head-3.01 SOHC
engine
7. Lubricate the camshaft and rocker shaft with
clean engine oil and position on the cylinder head.
8. Apply a drop of sealant to the rear edges of
the end caps.
9. Install the assembly making sure the notches
in the rocker shafts are facing up.
10. Install the cap bolts and tighten evenly and
gradually to 14 ft. Ibs. (20 Nm). Remove the lash ad-
juster retainers
11. Install the valve cover.
12. Connect the negative battery cable.
3.OL OOHC Engine
) See Figure 22
1. Relieve the fuel system pressure.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. 00 not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dty chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnect battery negative cable.
3. Remove the timino belt cover and timina belt.
Refer to the timing belt procedure in this section.
7923PG3 Fig. 22 The rocker arms sit beneath the
camshaft and are supported on one end bl
the valve stem and on the other end by the
hydraulic lash adjuster-Oiamante wit1
3.OL OOHC engine

ENGINEANDENGINEOVERHAUL 3-7
4. Remove the center cover, breather and PCV
hoses, and spark plug cables.
5. Remove the rocker cover.
6. Remove the throttle body stay, both camshaft
sprockets, and oil seals.
7. Remove the Camshaft Position fCMP) sensor 3. install the lash adjuster clips on the rocker
arms, then loosen the bearing cap bolts. Do not re-
move the bolts from the bearing caps.
4. Remove the rocker arms, shafts and bearing
caps as an assembly.
lo hlstall: unless it is contaminated or is several years old.
3. Remove any necessary components to access
the thermostat.
4. Remove the thermostat housinq retaininq
nd adapter from the rear of the camshah. ’
8. Remove the intake and exhaust camshafts.
9. Remove rocker arms and lash adjusters from
he head. It is recommended that all lash adjusters
md rockers be replaced as a complete set.
To Install:
10. Immerse the lash adjusters in clean diesel
uel. Using a small wire, move the plunger of the lash
tdjuster up and down four or five times while push-
ng down lightly on the check ball in order to bleed
jut the air. Lubricate and install the lash adjusters in
he cylinder head.
11. Lubricate the camshafts with clean enqine oil
nd position the camshafts on the cylinder head.
12. Install the bearing caps. Tighten the caps in
sequence, in 2 or 3 steps. Caps 2,3 and 4 have a
ront mark. Install with the mark aligned with the front
nark on the cylinder head. Intake caps have I
stamped on the cap and exhaust caps have E. Also,
)e sure the rocker arm is correctly mounted on the
ash adjuster and the valve stem end. Torque the front
md rear retaining cap bolts to 14 ft. Ibs. (20 Nm) and
ighten the center 3 retaining cap bolts to 8 ft. Ibs.
11 Nm).
13. Apply a coating of engine oil to the oil seals
md install.
14. Install the timing belt, valve cover and all re-
ated parts. Refer to the timing belt procedure in this
;ection. 5. Install the bearing caps/rocker arm assem-
blies. Tighten the bolts to 23 ft. Ibs. (31 Nm).
6. Remove the lash adjuster clips.
7. Install the rocker arm cover using a new gas-
ket.
8. Connect the negative battery cable.
REMOVAL &INSTALLATION
b See Figures 24, 25, 26, and 27
1. Disconnect the negative battery cable.
2. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious bums can
occur from the
steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused bolts.
5. Lift the housing from the engine.
6. Remove the thermostat taking note of its
original position in the housing.
To Install:
*In order to prevent leakage, make sure
both mating
surfaces are clean and free of
any old gasket material.
7. Install the thermostat so its flange seats
tightly in the machined groove in the intake manifold
or thermostat case. Refer to its location prior to re-
moval. Aliqn the relief valve with the alignment mark
on the thermostat housing.
8. Use a new gasket or D-ring and reinstall the
thermostat housing. Torque the housing mounting
bolts to the following specifications:
l 1.8L engine: 16 ft. Ibs. (22 Nm) l 1.5L, 1.61, 2.OL DOHC, and 1990-92 2.OL
SOHC engines: 12-14 ft. Ibs. (17-20 Nm)
l 1993 2.01 SOHC engine: 7-10 ft. Ibs.
(10-15 Nm)
l 2.4L engine: IO ft. Ibs. (14 Nm) l 3.OL and 3.5L engines: 12-14 ft. Ibs.
(17-20 Nm)
9. Fill the system with coolant.
10. Install the removed air intake plumbing.
15. Connect the negative battery cable and check
or leaks.
3.51 Engine
I See Figure 23
1. Disconnect the negative battery cable.
2. Remove the rocker arm cover.
g. 26 Remove the thermostat from the
ousing, noting the location of using the thermostat, always re-

3-8' ENGINEANDENGINEOVERHAUL
Nm ft.lbs.
1. Engine hanger 5. Engine hanger
2. Intake manifold stay 6. Exhaust manifold cover
3. intake manifold 7. Exhaust manifold
4. Intake manifold gasket 8. Exhaust manifold gasket
7923ffi38 :ig. 28 Exploded view of the intake and exhaust manifold mounting-l .5L (4615) engine
11. Connect the negative battery cable, run the ,. . . .
vemcie unnl me tnermostat opens ano till the radiator
completely. age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
12. Once the vehicle has cooled, recheck the
coolant level.
REMOVAL &INSTALLATION when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal In suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
15. Using a straight edge, measure the distortion
of the intake manifold-to-cylinder head. Total distor-
tion or warpage should be 0.006 inches (0.15mm or
less).
16. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crisscross pattern, starting from the inside and
working outwards to 13 ft. Ibs. (18 Nm).
17. Install the intake manifold support bracket
and torque the mounting bolts to 16 ft. Ibs. (22 Nm).
18. Install the engine mount support bracket and
torque the mounting bolts to 26 ft. Ibs. (36 Nm).
19. Using a new gasket, install the EGR valve and
torque the mounting bolts to 15 ft. Ibs. (21 Nm).
20. Using new insulators and O-rings, install the
fuel delivery pipe, injectors and pressure regulator to
the engine. Torque the retaining bolts to 7-9 ft. Ibs.
(10-14 Nm).
1.51 Engine
# See Figure 28
1. Relieve the fuel system pressure.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnect battery negative cable and drain
the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
3. Disconnect the upper radiator hose, heater
hose and water bypass hose.
4. Remove the thermostat housing from intake
manifold.
5. Disconnect the accelerator cable, breather
hose and air intake hose.
6. Remove all vacuum hoses and pipes as nec-
essary, including the brake booster vacuum line.
7. Remove the throttle body assembly.
8. Disconnect the high pressure fuel line and
the fuel return hose.
9. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor, in-
take air temperature, idle speed control assembly,
EGR temperature sensor, spark plug wires and dis-
tributor.
10. Remove the fuel rail, fuel injectors, pressure
regulator and insulators.
11. Remove the EGR valve from the intake mani-
fold.
12. Remove the intake manifold support bracket
and remove the engine mount support bracket.
13. Remove the intake manifold mounting bolts
and remove the intake manifold assembly.
To Install: 14. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly. Check both surfaces for cracks or other dam- 21. Attach the electrical connectors to the oxygen
sensor, coolant temperature sensor, intake air tem-
perature, idle speed control assembly, EGR tempera-
ture sensor, spark plug wires and distributor.
22. Using a new O-ring for the feed pipe and a
new clamp for the return pipe, install the fuel hoses.
23. Install the throttle body assembly.
24. Install the vacuum hoses and pipes as neces-
sary, including the brake booster vacuum line.
25. Install and adjust the accelerator cable. Install
the breather and air Intake hose.
26. Using a new gasket, install the thermostat
housing to the intake manifold and tighten the
mounting bolts to 13 ft. Ibs. (18 Nm).
27. Connect the upper radiator hose, heater hose
and water bypass hose. Be sure to use new hose
clamps.

ENGINEANDENGINEOVERHAUL 3-9
28. Fill the system with coolant.
29. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
30. Check and adjust the idle speed and ignition
timing.
31. Once the vehicle has cooled, recheck the
coolant level.
1.8L Engine
) See Figures 29 and 30
I. Relieve the fuel system pressure.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnect battery negative cable and drain
the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
leff in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
Fig. 29 Exploded view of the intake mani.
old mounting-1993 1.8L engine
3. Disconnect the accelerator cable and the air
intake hose.
4. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor, idle
speed control assembly, EGR temperature sensor, oil
pressure switch, spark plug wires and distributor.
5. Disconnect the wiring from the throttle posi-
tion sensor, fuel Injectors and disconnect the ground
cables.
6. Remove all vacuum hoses and pipes as nec-
essary, including the brake booster and PCV vacuum
lines.
7. Disconnect the upper radiator hose, heater
hose and water bypass hose.
8. Disconnect the high pressure fuel line and
the fuel return hose.
9. Remove the fuel rail, fuel injectors, pressure
regulator and insulators.
10. Remove the intake manifold support bracket.
11. If the thermostat housing is preventing re-
moval of the Intake manifold, remove it.
12. Remove the intake manifold mounting
bolts/nuts and remove the intake manifold assembly.
To install: 13. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
14. Using a straight edge, measure the distortion
of the intake manifold-to-cylinder head. Total distor-
tion or warpage should be 0.006 inches (0.15mm or
less).
15. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crrsscross pattern, starting from the inside and
working outwards to 14 ft. Ibs. (20 Nm).
16. If removed, install the thermostat housing.
17. Install the Intake manifold brace bracket.
18. Install the fuel delivery pipe, injectors and
pressure regulator to the engine. Torque the retaining
bolts to 108 Inch Ibs. (12 Nm). 19. Using a new O-ring for the feed pipe and a
new clamp for the return pipe, install the fuel hoses,
20. Connect the upper radiator hose, heater hose
and water bypass hoses.
21. Install the vacuum hoses and pipes as neces-
sary. Be sure to connect the brake booster and PCV
vacuum lines
22. Connect the wiring to the throttle position
sensor, fuel injectors and connect the ground cables,
23. Attach the electrical wiring to the oxygen sen-
sor, coolant temperature sensor, Idle speed control
assembly, EGR temperature sensor, oil pressure
switch, spark plug wires and distributor.
24. Connect and adjust the accelerator cable and
install the air intake hose.
25. Fill the system with coolant.
26. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
27. Check and adjust the idle speed and ignition
timing.
28. Once the vehicle has cooled, recheck the
coolant level. 2.OL SOHC Engine
# See Figure 31
1. Relieve the fuel system pressure.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
Fig. 30 Exploded view of the intake mani,
iold mounting-1994-00 1.8L engine Fig. 31 Exploded view of the intake mani
fold mounting-2.01 SOHC ermine