clock MITSUBISHI DIAMANTE 1900 User Guide

3-36 ENGINEANDENGINEOVERHAUL
The EPA warns that urolonaed contact with
used engine oil may cause”a number of skin
disorders, including cancer! You should
make every effort to minimize your exposure
to
used engine oil. Protective gloves should
be worn when changing the oil. Wash your
hands and any other exposed skin areas as
soon as possible after exposure to
used en-
gine oil. Soap and water, or waterless hand
cleaner should be used.
4. Remove the solash shield from the wheel
93153p65 93153p60 well.
5. Remove the oil filter adapter.
6. Remove the lower and upper oil pans.
7. Remove the lower baffle, oil pump pick-up
and upper baffle.
8. Remove the oil pump case mounting bolts
and the oil pump case.
9. Remove the oil pump gear cover.
10. Make matchmarks on the oil pump rotors be-
fore removing them.
,,. r.-- -IL- -.( -L.11---‘I --. IL- -.I _ --
nemove me cranksnarr sear rrom me 011 pump
case.
To instell:
12. Install a new crankshaft seal in the oil pump
cover.
13. Apply engine oil to the rotors, then align the
matchmarks and install the rotors in the oil pump Fig. 153 Remove the fasteners, then re-
move the side inner fender splash shield
3. Raise and support the vehicle.
4. Remove the passenger side front wheel.
5. Remove the passenger side inner fender
splash shield to gain access to the crankshaft
damper.
6. On the 1.5L, 1.6L, 2.OL and 2.4L engines, re-
move the oullev-to-sorocket bolts.
7. On thei .5L, i .8L, 3.OL and 3.5L engines, re-
move the crankshaft pulley center retaining bolt.
8. Remove the damper from the crankshaft us
ing a suitable puller.
-la install:
9. Place the damper onto the crankshaft, ensur-
ing the key-way is aligned.
10. On the 1.5L, 1.8L, 3.OL and 3.5L engines, in-
e crankshaft pulley center retaining bolt and
the bolt as follows: Fig. 154 Unfasten the crankshaft pulley re-
talning bolts, then remove the pulley
case.
14. Install the rotor cover. Tighten the bolts to 7
ft. Ibs. (10 Nm).
15. Apply a 0.113 in. (3mm) bead of sealant to
the back of the oil pump case. I[ -‘-‘I IL -~-- IL-
nsrall me ca
se on me engine and tighten the bolts to IOft Ihc 11 ,,, -. , .4 Nm).
16. Install the upper baffle r tlal te and oil pump
pick-up using a new gasket. Tic fhtti,, ,,lG va,,,ti ““a,., an tha hafflc, hnltc to 7 ft. Ibs. (10 Nm) and the pit k-up bolts to 13 ft.
Ibs. (18 Nm).
17. Install the lower baffle in the upper oil pan.
Tighten the bolts to 8 ft. Ibs. (11 Nm).
18. Install the oil pans.
19. Install the oil filter adapter using a new gas-
ket. Tighten the larger bolt to 30 ft. Ibs. (41 Nm) and
the smaller bolt to 1’ u ‘L- Inn ‘I--’ stall thl
tighten
4
) 1.5L engine: 51-72 ft. Ibs. (70-100 Nm)
l 1.8L and 3.5L engines: 134 ft. Ibs. (185
NM
l 3.OL engines: 108-116 ft. lbs. (150-160 NW 11. On the 1.5L, 1.6L, 2.OL and 2.4L engines, in-
stall the pulley-to-sprocket bolts and tighten the bolts
as follows:
l 1.5L engine: 10 ft. Ibs. (14 Nm)
* 1.6L and 2.OL engines: 14-22 ft. Ibs. 1. Disconnect the negative battery cable.
2. Remove the engine under cover.
3. Raise and safely support the weight of the en-
gine using the appropriate equipment. Remove the
front engine mount bracket and accessory drive belts.
4. If necessary, remove the coolant reservoir
tank.
5. Using the proper equipment, slightly raise
ets, water pump pulley
7. Remove all attr
upper and lower timin{
8. Make a mark o
indicating the directior
assembled in the same the engine to take the weight off the side engine
mount. Remove the engine mount bracket.
6. Remove the drive belts, tension pulley brack-
and crankshaft pulley.
aching screws and remove the
J belt covers.
n the back of the timing belt
I of rotation so it may be re-
! direction if it is to be reused.
tensioner and remove the tim-
Loosen the timing belt
ing belt.
*If coolant or engine oil comes in contact
with the timing bplt thaw will r(mcti~~llv Wll L, .,,s,, n,,, u,uu.,vu,,,
shorten its life. A ,IS o, do not allow engine oil
#.I nn..lr”* In rind In,
“I IruuI(IIIL Lu Irulll&t the timing belt sprock-
ets or tensioner assembly.
9. Remove the tensioner spacer, tensioner
spring and tensioner assembly.
cracks on back sur-
;eoarated canvas.
20. Install the tilllIllY uljllOllu IclllallllllY ~ullIPV-
:
nents. Refer to the timing belt procedure in this sec-
: tion.
21. Fill the engine with the correct amount of oil.
I . (20-30 Nm)
l 2.4L engine: 18 ft. Ibs. (25 Nm)
12. On the 1.6L and 2.OL engines, install the pul-
ley-to-sprocket bolts and tighten them to 14-22 ft.
Ibs. (20-30 Nm).
13. Install the splash shield.
14. Install the wheel, then carefully lower the ve- 10. Inspect the timing belt for I
face, sides, bottom and check for ! (
Check the tensioner pulley for smooth rotation.
To install:
11. Position the tensioner, tensioner spring and
tensioner spacer on engine block.
12. Align the timing marks on the camshaft
ft sprocket. This will position
tn the comoression stroke.
I hicle.
sprocket and cranksha
15. Install the accessory drive belts. Refer to Sec-
No. 1 piston on TDC o
Operating the engine without the proper tion 1.
13. Position the timing belt on the crankshaft
amount and type of engine oil will result in 16. Connect the negative battery cable.
sprocket and keeping the tension side of the bolt
severe engine damage.
-
22. -s
Chrmxt the nenntive h;lttm cnhle --, , I” ,.-J XL.._ I -..-., --I.-.
23. Start the engine and check for leaks.
REMOVAL &INSTALLATION
tight, set it on the cam, shaft sprocket.
14. Apply counterc Yockwise force to the camshaft
snrnckd tn nive tensin In -r .__.._. ._ J..- ._ - _ to the belt and make sure all
timing marks are aligned.
15. Loosen the pivot side tensioner bolt and the
clnt
&In hnlt Allnur thn rnrinn tn tdm III-I thn slack, cl then , d I, I’ r),“I 44”” ““IL. “ll”sl LllU .y”“yj L” L”I\U Low Ul” L .-Refer to Section 1 for the proper timing 16. Tighten the slot side tensioner bolt ark
., , , , ,, ,, ,, , , , , ,, . ,, ,~
REMOVAL &INSTALLATION
6 See Figures 153 and 154
1. Disconnect the negative battery cable.
2. Remove the accessory drive belts from
around the crankshaft pulley. Refer to Section 1. belt service interval.
1.5L Engine
1999-94 MODELS
b See Figures 155 and 156 me p~vor sloe DOI~. IT me p~vor sloe OOII
IS ogntened
first, the tensioner could turn with bolt, causing over
tension.
17. Turn the crankshaft clockwise. Loosen the
pivot side tensioner bolt and then the slot side bolt to
allow the spring to take up any remaining slack.

ENGINEANDENGINEOVERHAUL 3-37
1. Ben
2. Power4teerlna Dump 7. washer
8. Crankshaft pullet
9. Damper pulls
10. upper ccwer
11. Lowercowr
12. llmingbeil
13. crsnkshat? E#ocket 14. Flsnge
i 5. Tensbner spacer
16. Tef~kner WkW
1; Tgibnrr
19: camehan sprocket
91251ga
Fig. 155 Exploded view of the timing belt covers, timing belt and related parts-1990-94 1.51
engine
Fig. 156 Camshaft and crankshaft sprocket mark alignment for proper timing belt installa-
tion-1990-94 1.51 engine
Tighten the slot bolt and then the pivot side bolt to
14-20 ft. Ibs. (20-27 Nm).
18. Check the belt tension by holding the ten-
sioner and timing belt together by hand and give the
belt a slight thumb pressure at a point level with ten-
sioner center. Make sure the belt cog crest comes as
deep as about l/4 of the width of the slot side ten-
sioner bolt head. Do not manually overtighten the
belt or it will make a howling noise.
19. Install the timing belt covers and all related
items. 1995-00 MOOFLS
) See Figure 157
1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. Rotate the crankshaft clockwlse and position
the engine at TDC of the compression stroke.
4. Raise and safely support the weight of the en-
gine using the appropriate equipment. Remove the
A/C clamp, front engine mount bracket and accessory
drive belts.
20. Connect the negative battery cable.
5. Remove the crankshaft pulley. 6. Remove timing belt upper and lower covers.
7. Make a mark on the back of the timing belt
indicating the direction of rotation so it may be re-
assembled in the same direction if it is to be reused.
Loosen the timing belt tensioner and move the ten-
sioner to provide slack to the timing belt. Tighten the
tensioner in this position.
8. Remove the timing belt.
Coolant and engine oil will damage the rub-
ber in the timing belt, drastically reducing its
life. Do not allow engine oil or coolant to
contact the timing belt, the sprockets or ten-
sioner assembly.
9. If defective, remove the tensioner spacer, ten-
sioner spring and tensioner assembly.
To install: 10. Position the tensioner, tensioner spring and
tensioner spacer on engine block.
11. Align the timing marks on the camshaft
sprocket and crankshaft sprocket. This will position
No. 1 piston on TDC on the compression stroke.
12. Position the timing belt on the crankshaft
sprocket and keeping the tension side of the belt
tight, set it on the camshaft sprocket, then the ten-
sioner.
13. Apply slight counterclockwise force to the
camshaft sprocket to give tension to the belt and be
sure all timing marks are aligned.
14. Loosen the pivot side tensioner bolt and the
slot side bolt. Allow the spring to remove the slack.
15. Tighten the slot side tensioner bolt, then the
pivot side bolt. If the pivot side bolt is tightened first,
the tensioner could turn with bolt, causing over ten-
sion.
16. Turn the crankshaft clockwise. Loosen the
pivot side tensioner bolt, then the slot side bolt to al-
low the spring to take up any remaining slack.
Tighten the slot bolt, then the pivot side bolt to 17 ft.
Ibs. (24 Nm).
17. Install the timing belt covers and tighten the
cover bolts to 84-96 inch Ibs. (E-11 Nm). Install all
other applicable components.
liming mark
ming mark
Timing mark
Timing mark
Crankshaft sprocket
79235g5t Fig. 157 Align the timing belt sprockets as
indicated before removing the timing belt-
1995-00 1.51 engine

3-38 ENGINEANDENGINEOVERHAUL
1.61&? 2.OL (Non-Turbo) DOHC Engines
g See Figure 158
*The 1.6L engine is not equipped with
silent shafts. Disregard all instructions per-
taining to silent shafts if working on that en-
gine.
1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. If necessary, remove the coolant reservoir.
4. Using the proper equipment, slightly raise
the engine to take the weight off the side engine
mount. Remove the engine mount bracket.
5. Remove the drive belts, tension pulley brack-
ets, water pump pulley and crankshaft pulley.
6. Remove all attaching screws and remove the
upper and lower timing belt covers.
7. Rotate the crankshaft clockwise and align the
timing marks so No. 1 piston will be at TDC of the
compression stroke. At this time the timing marks on
the camshaft sprocket and the upper surface of the
cylinder head should coincide, and the dowel pin of
the camshaft sprocket should be at the upper side.
*Always rotate the crankshaft in a clockwise
direction. Make a mark on the back of the
timing belt indicating the direction of rotation
so it may be reassembled in the same direc-
tion if it is to be reused.
8. Remove the auto tensioner and remove the
outermost timing belt.
9. Remove the timing belt tensioner pulley, ten-
sioner arm, idler pulley, oil pump sprocket, special
washer, flange and spacer.
10. Remove the silent shaft (inner) belt tensioner
and remove the belt.
To install: 11. Align the timing marks on the crankshaft
sprocket and the silent shaft sprocket. Fit the inner
timing belt over the crankshaft and silent shaft
sprocket. Ensure that there is no slack in the belt.
12. While holding the inner timing belt tensioner
with your fingers, adjust the timing belt tension by
applying a force towards the center of the belt, until
the tension side of the belt is taut. Tighten the ten-
sioner bolt.
*When tightening the bolt of the tensioner,
ensure that the tensioner pulley shaft does
not rotate with the bolt. Allowing it to rotate
with the bolt can cause excessive tension on
the belt.
13. Check belt for proper tension by depressing
the belt on it’s long side with your finger and noting
the belt deflection. The desired reading is 0.20-0.28
in. (5-7mm). If tension is not correct, readjust and
check belt deflection.
14. Install the flange, crankshaft and washer to
the crankshaft. The flange on the crankshaft sprocket
must be installed towards the inner trming belt
sprocket. Tighten bolt to 80-94 ft. Ibs. (110-130
Nm).
15. To install the oil pump sprocket, insert a
Phillips screwdriver with a shaft 0.31 in. (8mm) in di-
ameter into the plug hole in the left side of the cylin-
der block to hold the left silent shaft. Tighten the nut
to 36-43 ft. Ibs. (50-60 Nm).
16. Using a wrench, hold the camshaft at it’s
hexagon between journal No. 2 and 3, then tighten
the bolt to 58-72 ft. Ibs. (80-100 Nm). If no hexagon
is present between journal No. 2 and 3, hold the
sprocket stationary with a spanner wrench while
tightening the retainer bolt.
17. Carefully push the auto tensioner rod in until
the set hole in the rod aligns with the hole in the
cylinder. Place a wire into the hole to retain the rod.
18. Install the tensioner pulley onto the tensioner
arm. Locate the pinhole in the tensioner pulley shaft
to the left of the center bolt. Then, tighten the center
bolt finger-tight.
19. When installing the timing belt, turn the 2
camshaft sprockets so their dowel pins are located on
top. Align the timing marks facing each other with the
top surface of the cylinder head. When you let go of
the exhaust camshaft sprocket, it will rotate 1 tooth in
the counterclockwise direction. This should be taken
into account when installing the timing belts on the
sprocket.
*Both camshaft sprockets are used for the
intake and exhaust camshafts and are pro-
vided with 2 timing marks. When the
sprocket is mounted on the exhaust
camshaft, use the timing mark on the right
with the dowel pin hole on top. For the intake
camshafl sprocket, use the 1 on the left with
the dowel pin hole on top.
20. Align the crankshaft sprocket and oil pump
sprocket timing marks.
21. After alignment of the oil pump sprocket tim-
ing marks, remove the plug on the cylinder block and
insert a Phillips screwdriver with a shaft diameter of
0.31 in. (8mm) through the hole. If the shaft can be
inserted 2.4 in. deep, the silent shaft is in the correct
position. If the shaft of the tool can only be inserted
0.61 .O in. (2C-25mm) deep, turn the oil pump
sprocket 1 turn and realign the marks. Reinsert the
tool making sure it is inserted 2.4 in. deep. Keep the
tool inserted in hole for the remainder of this proce-
dure.
*The above step assures that the oil pump
socket is in correct orientation to the silent
shafts. This step must not be skipped or a vi-
bration may develop during engine opera-
tion.
22. Install the timing belt as follows:
a. Install the timing belt around the intake
camshaft sprocket and retain it with 2 spring
clips or binder clips.
b. Install the timing belt around the exhaust
sprocket, aligning the timing marks with the
cylinder head top surface using 2 wrenches. Re-
tain the belt with 2 spring clips. c. Install the timing belt around the idler pul-
ley, oil pump sprocket, crankshaft sprocket and
the tensioner pulley. Remove the 2 spring clips.
d. Lift upward on the tensioner pulley in a
clockwise direction and tighten the center bolt.
Make sure all timing marks are aligned.
e. Rotate the crankshaft ‘14 turn counterclock-
wise. Then, turn in clockwise until the timing
marks are alrgned again.
23. To adjust the timing (outer) belt, turn the
crankshaft ‘14 turn counterclockwise, then turn it
clockwise to move No. 1 cylinder to TDC.
24. Loosen the center bolt. Using tool
MD998738 or equivalent and a torque wrench, apply
a torque of 22-25 inch. Ibs. (2.6-2.8 Nm). Tighten
the center bolt.
25. Screw the special tool into the engine left
support bracket until its end makes contact with the
tensioner arm. At this point, screw the special tool in
some more and remove the set wire attached to the
auto tensioner, if the wire was not previously re-
moved. Then remove the specral tool.
26. Rotate the crankshaft 2 complete turns clock-
wise and let it sit for approximately 15 minutes. Then,
measure the auto tensioner protrusion (the distance
between the tensioner arm and auto tensioner body)
to ensure that it is within 0.15-0.18 in. (3.8-4.5mm).
If out of specification, repeat Step l-4 until the spec-
ified value is obtained.
27. If the timing belt tension adjustment is being
performed with the engine mounted in the vehicle,
and clearance between the tensioner arm and the auto
tensioner body cannot be measured, the following al-
ternative method can be used:
a. Screw in special tool MD998738 or equiv-
alent, until its end makes contact with the ten-
sioner arm.
b. After the special tool makes contact with
the arm, screw it in some more to retract the auto
tensioner pushrod while counting the number of
turns the tool makes until the tensioner arm is
brought into contact with the auto tensioner
body. Make sure the number of turns the special
tool makes conforms with the standard value of
21/a-3 turns.
c. Install the rubber plug to the timing belt
rear cover.
28. Install the timing belt covers and all related
items.
29. Connect the negative battery cable.
1.8L & 2.OL SOHC Engines
g See Figures 159, 160, and 161
1. Position the engine so the No. 1 piston is at
TDC of the compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
4. Using the proper equipment, slightly raise
the engine to take the weight off the side engine
mount. Remove the engine mount bracket.
5. Remove the drive belts, tension pulley brack-
ets, water pump pulley and crankshaft pulley.
6. Remove all attaching screws and remove the
upper and lower timing belt covers.
7. Remove the timing belt covers.
8. Remove the outer crankshaft sprocket and
flange.
9. Remove the silent shaft (inner) belt tensioner
and remove the belt.

.
ENGlNEANDENGlliEOVERHAUL 3-39
To install: IO. Align the timing marks of the silent shaft
sprockets and the crankshaft sprocket with the timing
marks on the front case.
11. Wrap the timing belt around the sprockets so
there is no slack in the upper span of the belt and the
timing marks are still aligned.
12. Install the tensioner pulley and move the pul-
ley by hand so the long side of the belt deflects about
l/d in. (6mm).
13. Hold the pulley tightly so the pulley cannot
rotate when the bolt is tightened. Tighten the bolt to
15 ft. Ibs. (20 Nm) and recheck the deflection
amount.
14. Install the timing belt tensioner fully toward
the water pump and tighten the bolts. Place the upper
end of the spring against the water pump body.
15. Align the timing marks of the camshaft,
crankshaft and oil pump sprockets with their corre-
sponding marks on the front case or rear cover.
*There is a possibility to align all timing
marks and have the oil pump sprocket and
silent shaft out of time, causing an engine vi-
bration during operation. If the following step
is not followed exactly, there is a 50 percent
chance that the silent shaft alignment will be
180 degrees off.
16. Before installing the timing belt, ensure that
the left side (rear) silent shaft (oil pump sprocket) is
in the correct position as follows:
a. Remove the plug from the rear side of the
block and insert a tool with shaft diameter of
0.31 in. (8mm) into the hole.
b. With the timing marks still aligned, the
shaft of the tool must be able to go in at least
2’13 in. (59mm). If the tool can only go in about
1 in. (25mm), the shaft is not in the correct ori-
entation and will cause a vibration during engine
operation. Remove the tool from the hole and
turn the oil pump sprocket 1 complete revolution.
Realign the timing marks and insert the tool. The
shaft of the tool must go in at least 21/3 in.
(59mm).
c. Recheck and realign the timing marks.
d. Leave the tool in place to hold the silent
shaft while continuing
17. Install the belt to the crankshaft sprocket, oil
pump sprocket, then camshaft sprocket, in that order.
While doing so, make sure there is no slack between
the sprocket except where the tensioner is installed.
18. Recheck the timing marks’alignment. If all
are aligned, loosen the tensioner mounting bolt and
allow the tensioner to apply tension to the belt.
E
91251gbl
Fig. 180 Silent shaft sprocket alignment
marks for belt replacement-l.81 and 2.OL
SOHC engines
19. Remove the tool that is holding the silent
shaft and rotate the crankshaft a distance equal to 2
teeth on the camshaft sprocket. This will allow the
tensioner to automatically apply the proper tension
on the belt. Do not manually overtighten the belt or it
will howl.
20. Tighten the lower mounting bolt first, then the
upper spacer bolt.
21. To verify correct belt tension, check that the
deflection at the longest span of the belt is about 1/2
in. (13mm).
22. The installation of the timing belt covers and
all related items, is the reverse of the removal proce-
dure. Make sure all pieces of packing are positioned
in the inner grooves of the covers when installing.
23. Connect the negative battery cable.
2.OL (Turbo) OOHC Engine
ti See Figures 162 and 163
1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. Remove the engine mount bracket.
4. Remove the drive belts.
5. Remove the belt tensioner pulley.
6. Remove the water pump pulleys.
7. Remove the crankshaft pulley.
8. Remove the stud bolt from the engine sup-
port bracket and remove the timing belt covers.
9. Rotate the crankshaft clockwise to line up the
camshaft timing marks. Always turn the crankshaft in
the normal direction of rotation only.
10. Loosen the tension pulley center bolt.
*If the timing belt is to be reused, mark the
direction of rotation on the flat side of the
belt with an arrow.
11. Move the tension pulley towards the water
pump and remove the timing belt.
12. Remove the crankshaft sprocket center bolt
using special tool MB9g67 to hold the crankshaft
sprocket while removing the center bolt. Then, use
MB998778 or equivalent puller to remove the
sprocket.
13. Mark the direction of rotation on the timing
belt B with a arrow.
14. Loosen the center bolt on the tensioner and
remove the belt.
00 not rotate the camshafts or the crankshafl
while the timing belt is removed.
/--- PLUG
91251gb2 Fig. 161 Checking the rear silent shafl for
jroper positioning-1.8L and 2.OL SOHC
Pnoines
To Install:
15. Place the crankshaft sprocket on the crank-
shaft. Use tool MB9g67 or equivalent to hold the
crankshaft sprocket while tightening the center bolt.
Tighten the center bolt to 80-94 ft. Ibs. (108-127
Nm).
16. Align the timing marks on the crankshaft
sprocket B and the balance shaft.
17. Install timing belt B on the sprockets. Posi-
tion the center of the tensioner pulley to the left and
above the center of the mounting bolt.
18. Push the pulley clockwise toward the crank-
shaft to apply tension to the belt and tighten the
mounting bolt to 14ft. Ibs. (19 Nm) Do not let the
pulley turn when tightening the bolt because it will
cause excessive tension on the belt. The belt should
deflect 0.20-0.28 in. (5-7mm) when finger pressure
is applied between the pulleys.
19. Install the crankshaft sensing blade and the
crankshaft sprocket. Apply engine oil to the mounting
bolt and tighten the bolt to 80-94 ft. Ibs. (108-127
Nm).
20. Use a press or vise to compress the auto-ten-
sioner pushrod, Insert a set pin when the holes are
lined up.
Tming marks Cylinder had
I top surface
Ti
m
Crank&aft
sprocket
79235g60 :ig. 162 Camshaft and crankshaft timing
lelt sprocket TOC alignment mark position-
ng for timing belt removal and installa-
ion- 2.OL turbo engine

l
3-40 ENGINEANDENGINEOVERHAUL
Counterbaiance
19235861
Fig. 163 Timing belt 5 installation mark
alignment- 2.OL turbo
Do not compress the pushrod too quickly,
damage to the pushrod can occur.
21. Install the auto-tensioner on the engine.
22. Align the timing marks on the camshaft
sprocket, crankshaft sprocket and the oil pump
sprocket.
23. After aligning the mark on the oil pump
: sprocket, remove the cylinder block plug and insert a
prytool in the hole to check the position of the coun-
terbalance shaft. The orvtool should ao in at least 7. Remove the power steering pump, alternator
air conditioning compressor, tension pulley and ac-
companying brackets, as required.
8 Remove the upper front timing belt cover.
9. Remove the water pump pulley and the
crankshaft pulley(s).
10. Remove the lower timing belt cover mountinf
screws and remove the cover.
11. If the belt(s) are to be reused, mark the direc.
tion of rotation on the belt.
12. Remove the timing (outer) belt tensioner and
remove the belt. Unbolt the tensioner from the block
and remove.
13. Remove the outer crankshaft sprocket and
flange.
14. Remove the silent shaft (inner) belt tensioner
and remove the inner belt. Unbolt the tensioner from
the block and remove it.
15. To remove the camshaft sprockets, use SST
Ml39g67-01 and MlT308239, or their equivalents.
To in!3tall:
16. Install the camshaft sprockets and tighten thr
center bolt to 65 ft. Ibs. (90 Nm).
17. Align the timing mark of the silent shaft belt
sprockets on the crankshaft and silent shaft with the
marks on the front case. Wrap the silent shaft belt
around the sprockets so there is no slack in the uppe
!
I span of the belt and the timing marks are still in line.
18. Install the tensioner initially so the actual
:enter of the pulley is above and to the left of the in-
jtallation bolt. 2.36 in. (60mm) or more, if not, rotai;! the oil pump
sprocket once and realign the timing mark so the pry-
24. Install the timing belt on the intake camshaft
and secure it with a clip. .
25. Install the timina belt on the exhaust old. 2.41 Engine
I: # See Figures 164 thru 162
1. Be sure that the engine’s No. 1 piston is at
TDC in the compression stroke.
Wait at least 90 seconds after the negative
battery cable is disconnected to prevent pos-
sible deployment of the air bag.
2. Disconnect the negative battery cable.
3. Remove the spark plug wires from the tree on
the upper cover.
4. 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 dram coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
tool goes in. Do not remove the on/ool until the tfrn- 5. Remove the shroud, fan and accessory drive
ing belt is installed. lelts.
6. Remove the radiator as required. 19. Move the pulley up by hand so the center
jpan of the lona side of the belt deflects about 11~ in.
camshaft.
26. Align the timing marks with the cylinder head
top surface using two wrenches. Secure the belt with
another clip.
27. tnstatf the belt around the idler pulley, oil
pump sprocket, crankshaft sprocket and the tensioner
pulley.
28. Turn the tensioner pulley so the pinholes are
at the bottom. Press the pulley lightly against the tim-
ing belt.
29. Screw the special tool into the left engine
support bracket until it contacts the tensioner arm,
then screw the tool in a little more and remove the
pushrod pin from the auto-tensioner. Remove the
special tool and tighten the center bolt to 35 ft. Ibs.
(48 Nm). Fig 164 Remove the upper engine mount-
to-mount bracket nuts al%@]
Pm3p70 Fig. 165 Remove the upper engine mount
through-bolt . . .
30. Turn the crankshaft ‘Id turn counterclockwise,
then clockwise until the timing marks are aligned.
31. Loosen the center bolt. Install Mitsubishi
Special Tool MD998767, or equivalent, on the ten-
sioner p&y. Turn the tensioner pulley counterclock-
wise with a torque of 2.6 ft. Ibs. (3.5 Nm) and tighten
the center boftto 35 ft. tbs. (48 Nm). Do not let the
tensioner pUtFey turn when tightening the bolt.
32. Turn the crankshaft clockwise two revolutions
and align the timing marks.
33. After 15 minutes, measure the protrusion of
the pushrod on the auto-tensioner. The standard
measurement is 0.150-0.177 in (3.8-4.5mm). If the
I protrusion is out of specification, loosen the ten-
I sioner pulley, apply the proper torque to the belt and
: retighten the center bolt.
34. Install the timing belt covers and all applica-
i ble components.

.
3-42 ENGINEANDENGINEOVERHAUL
Fig. 180 Silent shaft alignment marks. No,
tice the tension side of the inner (silen
shaft) belt-2.41 enaine
Timing merk
(pun+ on sprocket)
liming m&k
(notch in sprocket)
79245g31 :ig. 181 Timing belt pulley alignmenl
narks-2.41 enoine
20. Hold the pulley tightly so it does not rotate
when the bolt is tlghtened. Tighten the bolt to 15 ft.
Ibs. (20 Nm). If the pulley has moved, the belt will be
too tight
21. Install the timing belt tensioner fully toward
the water pump and temporarily tighten the bolts.
Place the upper end of the spring against the water
pump body. Align the timing marks of the cam,
crankshaft and oil pump sprockets with the corre-
sponding marks on the front case or head.
*If the following steps are not followed ex-
actly, there is a chance that the silent shaft
alignment will be 180 degrees off. This will
cause a noticeable vibration in the engine
and the entire procedure will have to be re-
peated.
22. Before installing the timing belt, ensure that
the left side silent shaft is in the correct position.
*It is possible to align the timing marks on
the camshaft sprocket, crankshaft sprocket
and the oil pump sprocket with the lefl bal-
ance shaft out of alignment.
23. With the timing mark on the oil pump pulley
aligned with the mark on the front case, check the
alignment of the left balance shaft to assure correct
shaft timing. a. Remove the plug located on the left side of
the block in the area of the starter.
b. Insert a tool having a shaft diameter of 0.3
in. (8mm) into the hole.
c. With the timing marks still aligned, the tool
must be able to go in at least 2l/s in. (59mm). If
it can only go m about 1 in. (25mm), turn the oil
pump sprocket one complete revolution.
d. Recheck the position of the balance shaft
with the timing marks reahgned. Leave the tool in
place to hold the silent shaft while continuing.
24. Install the belt to the crankshaft sprocket, oil
pump sprocket and the camshaft sprocket, in that or-
der. While doing so, be sure there is no slack be-
tween the sprockets except where the tensioner will
take it up when released.
25. Recheck the timing marks’ alignment.
26. If all are aligned, loosen the tensioner mount-
ing bolt, and allow the tensioner to apply tension to
the belt.
27. Remove the tool that is holding the silent
shaft in place and turn the crankshaft clockwise a dis-
tance equal to two teeth of the camshaft sprocket.
This will allow the tensioner to automatically tension
the belt the proper amount.
Do not manually apply pressure to the ten-
sioner. This will overtighten the belt and will
cause a howling noise.
28. First tighten the lower mounting bolt and then
tighten the upper spacer bolt.
If any binding is felt when adiustino the tim-
ing delt tension by turning th;! crankshaft,
STOP turning the engine, because the pis-
tons may be hitting the valves.
29. To verify that belt tension is correct, check
that the deflection of the longest span (between the
camshaft and oil pump sprockets) is I/* in. (13mm).
30. Install the lower timing belt cover. Be sure the
packing is properly positioned in the inner grooves of
the covers when installing.
31. Install the water pump pulley and the crank-
shaft pulley(s).
32. Install the upper front timing belt cover.
33. Install the power steering pump, alternator,
air conditioning compressor, tension pulley and ac-
companying brackets, as required.
34. Install the radiator, shroud, fan and accessory
drive belts.
35. Install the spark plug wires to the tree on the
upper cover.
36. Refill the cooling system.
37. Connect the negative battery cable. Start the
engme and check for leaks.
3.OL SDHC Engine
1992-94 MODELS
# See Figures 182 and 183
1. Disconnect the negative battery cable.
2. Remove the engine undercover
3. Remove the cruise control
actuator 4. Remove the accessory drive belts. 5. Remove the air conditioner compressor ten-
sion pulley assembly.
6. Remove the tension pulley bracket.
7. Using the proper equipment, slightly raise
the engine to take the weight off the side engine
mount. Remove the engine mounting bracket.
8. Detach the power steering pump pressure
switch connector. Remove the power steering pump
and wire aside.
9. Remove the engine support bracket.
10. Remove the crankshaft pulley.
11. Remove the timing belt cover cap.
12. Remove the timing belt upper and lower cov-
ers.
13. If the same timing belt will be reused, mark
the direction of the timing belt’s rotation for installa-
tion in the same direction. Make sure the engine is
positioned so the No. 1 cylinder is at the TDC of its
compression stroke and the sprockets’ timing marks
are aligned with the engine’s timing mark indicators.
14. Loosen the timing belt tensioner bolt and re-
move the belt. If the tensioner is not being removed,
position it as far away from the center of the engine
as possible and tighten the bolt.
15. If the tensioner is being removed, paint the
outside of the spring to ensure that it is not installed
backwards. Unbolt the tensioner and remove it along
with the spring.
To install:
16. Install the tensioner, if removed, and hook the
upper end of the spring to the water pump pin and
the lower end to the tensioner in exactly the same po-
sition as originally installed. If not already done, po-
sition both camshafts so the marks align with those
on the rear. Rotate the crankshaft so the timing mark
aligns with the mark on the oil pump.
17. Install the timing belt on the crankshaft
sprocket and while keeping the belt tight on the ten-
sion side, install the belt on the front camshaft
sprocket.
18. Install the belt on the water pump pulley, then
the rear camshaft sprocket and the tensioner.
19. Rotate the front camshaft counterclockwise to
tension the belt between the front camshaft and the
crankshaft. If the tlmlng marks became misaligned,
repeat the procedure.
20. Install the crankshaft sprocket flange.
21. Loosen the tensioner bolt and allow the
spring to apply tension to the belt.
22. Turn the crankshaft 2 full turns in the clock-
wise direction until the timing marks align again.
Now that the belt is properly tensioned, torque the
tensioner lock bolt to 21 ft. Ibs. (29 Nm). Measure
the belt tension between the rear camshaft sprocket
and the crankshaft with belt tension gauge, The spec-
ification is 46-68 Ibs. (210-310 N).
23. Install the timing covers. Make sure all pieces
of packing are positioned in the inner grooves of the
covers when Installing.
24. install the crankshaft pulley. Tighten the bolt
to 108-116ft. Ibs. (150-160 Nm)
25. Install the engine support bracket.
26. Install the power steering pump and recon-
nect wire harness at the power steering pump pres-
sure switch.
27. Install the engine mounting bracket and re-
move the engine support fixture.
28. Install the tension pulleys and drive belts.
29. Install the cruise control actuator.
30 Install the engine undercover.

.
3-44 ENGINEANDENGINEOVERHALJL
31. Connect the negative battery cable.
32. Road test the vehicle.
EXCEPT 1992-94 MODELS
$ See Figure 184
1. Position the engine so the No. 1 cylinder is at
TDC of its compression stroke.
2. Disconnect the negative battery cable.
Wait at least 90 seconds after the negative
battery cable is disconnected to prevent pos-
sible deployment of the air bag.
3. Remove the engine undercover.
4. Remove the front undercover panel.
5. Remove the cruise control pump and the link
assembly.
6. Remove the alternator.
7. Raise and suspend the engine so that force is
not applied to the engme mount,
8. Remove the timing covers from the engine.
9. If the same timing belt will be reused, mark
the direction of the timing belt’s rotation for installa-
tion in the same direction. Make sure the engine is
positroned so the No. 1 cylinder is at the TDC of its
compression stroke and the timing marks are aligned
with the engine’s timing mark indicators on the valve
covers or head. 10. Loosen the center bolt of tensioner pulley and
unbolt auto-tensioner assembly The auto-tensioner
assembly must be reset to correctly adjust belt ten-
sion. Remove the timing belt.
11. Using a wrench, hold the camshaft at its
hexagon and remove the camshaft sprocket bolt.
12. Remove and position the auto-tensioner into
a vise with soft jaws. The plug at the rear of tensioner
protrudes, be sure to use a washer as a spacer to
protect the plug from contacting vise jaws.
13. Slowly push the rod Into the tensioner until
the set hole rn rod is aligned with set hole in the
auto-tensioner.
14. Insert a 0.055 in. (1.4mm) wire into the
aligned set holes. Unclamp the tensioner from the
vise and install it on the engine. Trghten tensroner to
17 ft. Ibs. (24 Nm).
15. Clean and inspect both auto tensioner
mounting bolts. Coat the threads of the old bolts with
thread sealer. If new bolts are installed, Inspect the
heads of the new bolts. If there is white paint on the
bolt head, no sealer is required. If there is no parnt on
the head of the bolt, apply a coat of thread sealer to
the bolt. Install both bolts and tighten to 17 ft. Ibs.
(24 Nm).
To install: 16. Install the tensioner, if removed, and hook the
upper end of the spring to the water pump pin and
the lower end to the tensioner in exactly the same po-
sition as originally installed. 17. Ensure both camshafts are still positioned so
the timing marks align with those on the rear timing
covers.
18. Rotate the crankshaft so the timing mark
aligns with the mark on the front cover.
19. Install the timing belt on the crankshaft
sprocket and while keeping the belt tight on the ten-
sion side, mstall the belt on the front (left) camshaft
sprocket.
20 Install the belt on the water pump pulley, then
the rear (right) camshaft sprocket and the tensioner.
21. Loosen the bolt that secures the adjustment
of the tensioner and lightly press the tensioner
against the timing belt.
22. Check that the timing marks are in alignment.
23 Rotate the crankshaft 2 full turns in the clock-
wise direction only, then realign the timing marks,
24. Tighten the bolt that secures the tensioner to
19 ft. Ibs. (26 Nm).
25. install the lower and the upper timing belt
covers, along with all other applicable components.
3.OL DDHC Engine
1992-94 MODELS
# See Figure 185
1. Position the engine so the No. 1 cylinder is at
TDC of its compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
Timing mark
(on belt cover)
Timing belt tensioner
Crankshaft
sprocket
7923W :ig. 184 Align the sprockets properly before removing or installing the timing belt-1995-96 Diamante with the 3.OL (6672) SDHC engine

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

ENGINEANDENGINEOVERHAUL 3-47
DO NOT rotate or turn the camshafts when re-
moving the sprockets or severe engine dam-
age will result from internal component in-
terference.
22. Align the mark on the crankshaft sprocket
with the mark on the front case. Then, move the
crankshaft sprocket 1 tooth counterclockwise.
23. Align the timing marks of the camshafts with
the marks on the rear covers.
24. Using large paper clips to secure the timing
belt to the sprockets, install the timing belt in the fol-
lowing order. Be sure camshafts-to-cylinder heads
and crankshaft-to-front cover timing marks are
aligned. Install the timing belt around the pulleys in
the following order:
a. Exhaust camshaft sprocket (front bank).
b. Intake camshaft sprocket (front bank).
c. Water pump pulley.
d. Intake camshaft sprocket (rear bank).
e. Exhaust camshaft sprocket (rear bank).
f. Tensioner pulley.
g. Crankshaft pulley.
h. Idler pulley.
*Since the camshaft sprockets turn easily,
secure them with box wrenches when in-
stalling the timing belt.
25. Align all timing marks on the crankshaft and
raise the tensioner pulley against the belt to remove
slack, snug tensioner bolt.
26. Check the alignment of all the timing marks
and remove the clips that secure the timing belt to the
camshaft sprockets.
27. Rotate the engine 1/4 turn counterclockwise,
then rotate the engine clockwise to align the timing
marks. Check that all the timing marks are in align-
ment.
28. Loosen the center bolt on the tensioner pul-
ley.
29. Using tool MD998752 or equivalent and a
torque wrench, apply 84 inch Ibs. (10 Nm) to the tool
on the tensioner. Tighten the tensioner bolt to 35 ft.
Ibs. (49 Nm) and be sure the tensioner does not ro-
tate with the bolt. 30. Rotate the crankshaft two complete turns
clockwise and let it sit for approximately five minutes.
Then, check that the set pin can easily be inserted
and removed from the hole in the auto-tensioner.
31. Remove the set wire attached to the auto-ten-
sioner
32. Measure the auto-tensioner protrusion (the
distance between the tensioner arm and auto-ten-
sioner body) to ensure that it is within 0.15-0.18 in.
(3.8-4.5mm). If out of specification, repeat adjust-
ment procedure until the specified value is obtained.
33. Check again that the timing marks on all
sprockets are in proper alignment.
34. Install the timing belt covers and all other ap-
plicable components.
3.51 Engine
p See Figure 187
1. Disconnect the negative battery cable.
2. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
giycoi antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the drive belts.
4. Remove the upper radiator shroud.
5. Remove the fan and fan pulley.
6. Without disconnecting the lines, remove the
power steering pump from its bracket and position it
to the side Remove the pump brackets.
7. Remove the belt tensioner pulley bracket.
8. Without releasing the refrigerant, remove the
air conditioning compressor from its bracket and po-
sition it to the side.
9. Remove the bracket.
Timing marks
liming marks
Tinning marks
79245934 Fig. 187 Clean the timing marks to verify their position when aligning-3.51 engine
10. Remove the cooling fan bracket.
11, On some vehicles It may be necessary to re-
move the pulley from the crankshaft to access the
lower cover bolts.
12. Remove the timing belt cover bolts and the
upper and lower covers from the engme.
13. Detach the crankshaft position sensor con-
nector
14. Using SST MB9g67-01 and MD998754, or
their equivalents, remove the crankshaft pulley from
the crankshaft.
15. Use a shop rag to clean the timing marks to
assist in properly aligning the timing marks.
16. Loosen the center bolt on the tension pulley
and remove the timing belt.
@if the same timing belt will be reused,
mark the direction of timing belt’s rotation,
for installation in the same direction. Be sure
engine is positioned so No. 1 cylinder is at
the TDC of it’s compression stroke and the
sprockets timing marks are aligned with the
engine’s timing mark indicators.
17. Remove the auto-tensioner, the tension pul-
ley and the tension arm assembly.
18. Remove the sprockets by holding the hexago-
nal portion of the camshaft with a wrench while re-
moving the sprocket bolt.
To install: 19. Install the crankshaft pulley and turn the
crankshaft sprocket timing mark forward (clockwise)
three teeth to move the piston slightly past No. 1
cylinder top dead center.
20. If removed, install the camshaft sprockets and
tighten the bolts to 64 ft. Ibs. (88 Nm).
21, Align the timing mark of the left bank side
camshaft sprocket.
22. Align the timing mark of the right bank side
camshaft sprocket, and hold the sprocket with a
wrench so that it doesn’t turn.
23. Set the timing belt onto the water pump pul-
ley.
24. Check that the camshaft sprocket timing mark
of the left bank side is aligned and clamp the timing
belt with double clips.
25. Set the timing belt onto the idler pulley.
if any binding is felt when adjusting the tim-
ing belt tension by turning the crankshaft,
STOP turning the engine, because the pis-
tons may be hitting the valves.
26. Turn the crankshaft one turn counterclock-
wise and set the timing belt onto the crankshaft
sprocket.
27. Set the timing belt on the tension pulley.
28. Place the tension pulley pin hole so that it is
towards the top. Press the tension pulley onto the
timing belt, and then provisionally tighten the fixing
bolt. Tighten the bolt to 35 ft. Ibs. (48 Nm).
29. Slowly turn the crankshaft two full turns in the
clockwise direction until the timing marks align. Re-
move the four double clips.
30. Install the crankshaft position sensor connec-
tor.
31. Install the upper and lower covers on the en-
gine and secure them with the retaining screws. Be
sure the packing is properly positioned in the inner
grooves of the covers when installing.

ENGINEANDENGINEOVERHAUL 3-49
011 pump
MS8
7923PG51 Fig. 196 Crankshaft seal installation-Dia
mante shown, others similar
:ig. 197 Camshaft, rocker arm and shaft as
remblies-1.5L engine
7923PG5 Fig. 198 Positioning of the camshaft dowe
pin-Mirage 1.5L (4615) engine
10. Remove the camshaft sprocket from the
camshaft. Note the positioning of the dowel pin at the
end of the camshaft.
11. Remove the camshaft oil seal from the front
of the cylinder head.
12. Remove the camshaft from the head.
13. Carefully check all parts for damage and
wear
To install:
14. Lubricate the camshaft with heavy engine oil
and slide it mto the head. Be sure to position the
dowel pin at the 12 o’clock position.
15. Check the camshaft end-play between the
thrust case and camshaft. The camshaft end-play
should be 0.002-0.008 m (0.05-O 20mm). If the
end-play is not within specification, replace the
camshaft thrust bearing.
16 Install a new camshaft oil seal. Be sure to Iu-
bricate the lips of the seal with clean engine 011.
17. Install the camshaft sprocket and install the
mountrng bolt. Tighten the bolt to 51 ft. Ibs. (70 Nm)
while holding the camshaft from turning.
18. Install the timing belt assembly.
19. Install the timing belt covers.
20. Install the rocker shaft assemblies. Torque the
bolts gradually and evenly to 23 ft. Ibs. (32 Nm).
21. Check valve adjustment and install the valve
cover with a new gasket. Tighten the valve cover bolt
to 16 inch Ibs (1.8 Nm).
22 Align the distributor marks and install the
distributor.
23. Connect the accelerator cable, breather hose
and PCV hose.
24. Connect the negative battery cable and check
the ignition timing
1.8L Engine
# See Figure 199
1. Disconnect the negative battery cable
2. Rotate the engine and position the No. 1 pis-
ton to TDC of its compression stroke.
3. Label and disconnect the spark plug cables.
4. Matchmark the positronrng of the distributor
housing and the positioning of the distributor rotor to
the engine block and remove the distributor.
5. Detach the air flow sensor connector and re-
move the air cleaner case cover.
6. Drsconnect the accelerator cable, breather
hose and PCV hose connections.
7. Remove the rocker cover and discard the
gasket.
8. Loosen both rocker arm shaft assemblies
gradually and evenly and remove the rocket shafts
from the vehicle. Do not disassembly rocker arms
and rocker arm shaft assemblies.
9. Remove the timing belt covers.
DO NOT allow the camshaft or the crankshaft
to rotate after the timing belt is removed!
10. Remove the timing belt assembly.
11. Holding the camshaft sprocket from turning,
loosen and remove the bolt that secures the sprocket.
12. Remove the camshaft sprocket from the
camshaft. Note the positioning of the dowel pin at the
end of the camshaft.
13. Remove the camshaft oil seal from the front
of the cylinder head.
14. Remove the camshaft from the head.
(r.mblies-1.8L Agine g3i53033 Fig 199 Camshaft rocker arm and shaft as-
15. Carefully check all parts for damage and
wear.
To install:
16. Lubricate the camshaft journals and camshaft
with clean engine oil and install the camshaft in the
cylinder head. Be sure to position the dowel pin at
the end of the camshaft as noted during the removal
procedure.
17. Check the camshaft end-play between the
thrust case and camshaft The camshaft end-play
should be 0.002-0.008 in. (0.05-0.20mm). If the
end-play
IS not within specification, replace the
camshaft thrust bearing
18. Install a new camshaft oil seal. Be sure to Iu-
bricate the lips of the seal with clean engine oil.
19. Install camshaft sprocket and torque the re-
tainer bolt to 65 ft. Ibs. (90 Nm). Be sure to secure
the sprocket while tightening the bolt.
20 Install the timing belt assembly.
21. Install the timing belt covers.
22. Install the rocker arm and shaft assemblies.
Tighten the rocker arm shaft retainer bolts to 23 ft.
Ibs (32 Nm).
23 Check the valve adjustment and install the
valve cover with a new gasket. Tighten the valve
cover bolts to 29 inch Ibs. (3.3 Nm).
24. Align the distributor marks and install the
distributor.
25. Connect the spark plug cables.
26. Connect the accelerator cable, breather hose
and PCV hose.
27. Attach the air flow sensor connector and in-
stall the air cleaner case cover.
28. Connect the negative battery cable.
29. Run the engine at idle until normal operating
temperature is reached.
30. Check idle speed and ignition timing and ad-
just as required.
2.OL SDHC Engine
# See Figure 200
1. Disconnect the negative battery cable.
2. Disconnect the breather and the PCV hoses