light MITSUBISHI DIAMANTE 1900 Owner's Manual

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

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-

ENGINEANDENGINEOVERHAUL 3-13
EGR pipe - Up to 1993 model
EGR pipe - From 1994 model
Intake manlfold plenum stay, rear
Intake manifold plenum stay. front
EGR valve
EGR valve gasket
Throttle body >
Throttle body gasket
Intake mantfold plenum
Intake manifold plenum gasket
:ig. 52 Exploded view of air intake plenum assembly-3.01 DOHC engine
ing the fuel system, always work in a well
3. Remove the air intake hose(s). ventilated area. Do not allow fuel spray or 4. Disconnect the accelerator control cables vapors to come in contact with a spark or from the throttle body. 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 drawn
the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
5. Tag and disconnect the vacuum hoses in-
cluding the brake booster hose.
6. Tag and detach the wire harness connectors,
7. Disconnect the high pressure and return fuel
hoses.
8. Disconnect EGR pipe and remove the EGR
valve and EGR temperature sensor from the intake
plenum assembly.
9. If equipped, remove the manifold pressure
sensor.
10. Remove the plenum retaining bracket.
11. Remove the plenum retaining nuts and bolts
and remove the air intake plenum from the intake
manifold. Discard the gasket.
12. Remove the upper timing belt covers.
13. Remove the water pump stay bracket.
*It is not necessav to remove the fuel ln-
jectors from the intake unless the manifold ,
assembly is being replaced.
14. Remove the fuel rail with the injectors at-
tached. 15. Disconnect the coolant hoses from the intake
manifold. Be sure to note the connections.
16. Remove the intake manifold mounting nuts
and remove the intake manifold.
17. Clean the gasket mounting surfaces.
To install: 18. Check all items for cracks, clogging and
warpage. Maximum warpage is 0.0059 inches
(0.15mm). Replace any questionable parts.
19. Thoroughly clean and dry the mating surfaces
of the heads, intake manifold and air intake plenum.
20. Install new intake manifold gaskets to the
cylinder heads with the adhesive side facing up.
21. Place the manifold on the cylinder heads.
22. Lubricate the studs lightly with oil and install
the nuts.
23. For vehicles produced up to and including
November of 1993, tighten the mounting nuts as fol-
lows:
a. Front bank nuts: 27-43 inch Ibs. (3-5 Nm)
b. Rear bank nuts: 9-11 ft. Ibs. (12-15 Nm)
c. Front bank nuts: 9-11 ft. Ibs. (12-15 Nm)
24. For vehicles produced after November of
1993, tighten the mounting nuts as follows:
a. Front bank nuts: 48-72 inch Ibs. (5-8 Nm)
b. Rear bank nuts to: 14-17 ft. Ibs. (20-23
Nm)
c. Front bank nuts to: 14-17 ft. Ibs. (20-23
NM
25. Using new clamps, connect the coolant hoses
to the intake manifold.
26. Using new O-rings, install the fuel rail as-
sembly, if removed. Tighten the mounting bolts to
7-9 ft. Ibs. (10-13 Nm).
27. Install a new intake air plenum gasket and in-
stall the plenum. Tighten the retaining nuts and bolts
evenly and gradually to 13 ft. Ibs. (18 Nm).
28. Install the retaining bracket and tighten the
retaining bolts to 13 ft. Ibs. (18 Nm).
29. If removed, install the manifold pressure sen-
sor.
30. Using a new gasket, install the EGR valve and
tighten the bolts to 16 ft. Ibs. (22 Nm).
31. Install the EGR temperature sensor and
tighten the fitting to 7-9 ft. Ibs. (10-12 Nm).
32. Connect the EGR pipe and tighten the fittings
to 43 ft. Ibs. (60 Nm).
33. Replace the O-ring and connect the high
pressure fuel hose. Tighten the retaining bolts to 48
inch Ibs. (5 Nm).
34. Using a new hose clamp, connect the fuel re-
turn hose.
35. Install the water pump stay bracket.
36. Install the upper timing belt covers.
37. Connect the harness connector and vacuum
hoses.
38. Connect and adjust the accelerator cables.
39. Install the air intake hose(s).
40. Fill the system with coolant.
41. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
42. Check and adjust the idle speed and ignition
timing.
43. Once the vehicle has cooled, recheck the
coolant level.

l
3-18 ENGINEANDENGINEOVERHAUL
bolt and gaskets that connect the oil feed line to the
turbo center section and the water cooling lines. The
water line under the turbo has a threaded connection.
8. Remove the exhaust pipe nuts and gasket and
lift off the exhaust manifold. Discard the gasket,
9. Remove the 2 through bolts and 2 nuts that 16. If removed, install the power steering pump
and bracket.
17. Install the heat shields, air outlet hose, waste-
gate hose and air intake bellows.
18. Install the oil dipstick tube and dipstick. In-
stall the oxyqen sensor. cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Disconnect the overflow tube. Some vehicles
hold the exhaust manifold to the turbocharger,
10. Remove the 2 capscrews from the oil return
line (under the turbo). Discard the gasket. Separate
the turbo from the exhaust manifold. The 2 water
pipes and oil feed line can still be attached. 19. In&h the radiator assembly.
20. Fill the engine with oil, fill the cooling system
and reconnect the negative battery cable.
11. Visually check the turbine wheel (hot side)
and compressor wheel (cold side) for cracking or
other damage. Check whether the turbine wheel and
the compressor wheel can be easily turned by hand.
Check for oil leakaae. Check whether or not the Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
wastegate valve remains open. If any problem is .
found, replace the part. Inspect oil passages for re- #I , I
striction or deposits and clean as required,
12. The wasteaate can be checked with a ores-
REMOVAL & INSTALLATION sure tester. Apply approximately 9 psi to the&h&or
and make sure the rod moves. Do not apply more
than 10.3 psi or the diaphragm in the wastegate may
be damaged. Vacuum applied to the wastegate actua-
tor should be maintained, replace if leaks vacuum,
Do not attempt to adjust the wastegate valve. $ See Figures 77 thru 91
I. Disconnect the negative battery cable.
2. Drain the cooling system when safe.
To
install: 13. Prime the oil return line with clean engine oil.
Replace all locking nuts. Before installing the
threaded connection for the water inlet pipe, apply
light oil to the inner surface of the pipe flange. As-
semble the turbocharger and exhaust manifold.
14. Install the exhaust manifold using a new gas-
ket.
15. Connect the water cooling lines, oil feed line
and engine hanger. 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
glyeol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
Fig. 77 Use a pair of pliers to remove the
Fig. 78 . . .
then disconnect the overflow
hose clamp . . .
hose from the radiator may also require removal of the overflow tank.
4. Disconnect upper and lower radiator hoses.
5. Detach the electrical connectors from the
cooling fan and air conditioning condenser fan, if
equipped.
6. For Mirage and Diamante models, remove
the fan assembly.
7. Disconnect the therm0 sensor wires,
8. If equipped with an automatic transaxle, dis-
connect and plug the automatic transaxle cooler
lines.
9. Remove the upper radiator mounts and lift
out the radiator assembly or radiator/fan assembly,
as applicable.
To install:
10. Install the radiator or radiator and fan, if re-
moved as an assembly.
11. Connect the automatic transaxle cooler lines
if disconnected.
12. Connect the therm0 sensor wires,
13. Install the fan, if removed separately.
14. Install the radiator hoses.
15. Install the air cleaner support bracket, if re-
noved.
16. Install the overflow tube and reservoir, if re-
noved.
17. Fill the system with coolant.
18. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
93153003 Fig. 79 Use pliers to release the hose clamp
tension . . .
Fig. 80 . . .
then remove the upper radiator
hose from the radiator Fig. 81 From underneath the vehicle, re-
move the hose clamp , . . ”
then disconnect the lower radi- Fig. 82 . . .
ator hose

ENGINEANDENGINEOVERHAUL 3-25
When removina the cvlinder head. take care
not to bend or iamag;! the plug guide. The
plug guide can not be replaced.
To install:
22. Thoroughly clean the mating surfaces of the
head and block.
23. Place a new head gasket on the cylinder
block with the identification marks facing upward. Do
not use sealer on the gasket.
24. Carefully install the cylinder head on the
block.
25. Measure the cylinder head bolts prior to in-
stallation Replace any that exceed 3.795 in.
(96.4mm)
26. Apply a small amount of engine oil to the
thread section of the bolt and install so the chamfer
of the washer faces upward.
27. Tighten the cylinder head bolts as follows:
a. In the proper tightening sequence, torque
bolts to 54 ft. Ibs. (75 Nm).
b. In the reverse order of the tightening se-
quence, fully loosen all bolts.
c In the proper trghtening sequence, torque
bolts to 14 ft. Ibs. (20 Nm).
d. In the proper tightening sequence, tighten
bolts 1/4 turn (90 degrees).
e. In the proper tightening sequence, tighten
bolts an additional 1/4 turn (90 degrees).
28. Install the camshaft sprocket and tighten the
bolt to 65 ft. Ibs (90 Nm), while holding the sprocket
in place using the appropriate wrench. Confirm
proper timing mark alignment.
29. Install the upper timing belt cover and rocker
cover. Torque the rocker cover bolts to 29 inch Ibs.
(3 Nm).
30. Loosen the water pipe mounting bolt for ease
of thermostat housing installation.
31. Apply a thin bead of sealant MD970389 or
equivalent, to the water tube connection on the ther-
mostat case.
32. Apply a small amount of water to the O-ring
of the water inlet pipe and press the thermostat case
assembly onto the water inlet pipe. Install the ther-
mostat case assembly mounting bolt tightening to 16
ff. Ibs. (22 Nm).
l ECT sensor and gauge sender l IAC motor 33. Tighten the water pipe mounting bolt.
34. Install the thermostat into the housing so the
jiggle valve is located at the top. Tighten the housing
bolts to 10 ft. Ibs (14 Nm).
35. Attach the wiring to the following compo-
nents:
l HO& sensor
l EGR temperature sensor l TP sensor l Knock sensor l Fuel injectors
36. Connect the upper radiator hose to the ther-
mostat housing.
37. Connect the accelerator cable connection to
the throttle body.
38. Connect the oil pressure switch.
39. Install the spark plug wires,
40. Connect the control harness assembly.
41. Replace the O-ring for the high pressure hose
and install a new clamp on the return hose and re-
connect the fuel lines. 42. Install the air intake hose. Connect the
breather hose and air cleaner case cover
43. Reconnect the brake booster and the PCV
vacuum hoses.
44. Fill the system with coolant.
45. Connect the negative battery cable
2.01 SOHC Engine
# See Figures 114 and 115
1. Disconnect the negative battery cable.
2. Drain the coolrng system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the air intake hose.
4. Disconnect the accelerator cable and remove
the bracket.
5. Disconnect the high pressure fuel line and
remove the O-ring.
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.
6. Disconnect the upper radiator hose, the
coolant by-pass hose and the heater hose from the
head and/or intake manifold.
7. Disconnect the brake booster vacuum hose.
8. Remove the fuel return hose.
9. Label and detach the vacuum hose(s) run-
ning to the manifold. Disconnect the PCV hose at the
valve cover.
10. Tag and disconnect the spark plug wires from
the drstnbutor cap
11. Label and detach each electrical connector,
including the distributor lead and the injector con-
nectors Note that some of the wiring must be drs-
connected at the firewall. When all the connectors are
loose, remove the bracket bolts holding the control
wiring harness rn place and move the harness to an
out-of-the-way location.
12. Remove the clamp holding the power steering
and air conditioning hoses to the top of the left en-
gine mount bracket. Move the hoses out of the way
but don’t drsconnect either hose from its system.
13. Position a floor lack and a broad piece of
lumber under the engine. Elevate the jack lust enough
to support the engine without raising it.
Front of engne I)
Intake side
~~
Exhaust side
93153~24 Fig. 114 Cylinder head bolt loosening se-
quence-2.01 SOHC engine
Front of engme I)
Intake side
Exhaust side
93153g25 Fig. 115 Cylinder head bolt tightening se-
quence-2.01 SDHC engine
14. Remove the through-bolt from the left side
engine mount. It may be necessary to adjust the jack
slightly to allow the bolt to come free When the bolt
has been removed, disconnect the nuts and bolts
holding the mounting bracket to the engine and re-
move the bracket
15. Remove the valve cover and gasket. Remove
the half-circle plug from the head.
16. Remove the upper timing belt cover. Turn the
crankshaft clockwise until all the timing marks align,
setting the engine to TDUcompression for No. 1
cylinder.
17. Remove the bolt holding the camshaft
sprocket to the camshaft. Remove the camshaft
sprocket, with the belt attached, and place it on the
lower timing belt cover. Do NOT allow the belt to
come off the sprocket
Do not rotate the crankshaft once the
camshaft sorocket is removed.

3-26 ENGINEANDENGINEOVERHAUL
18. Remove the self-locking nuts and the small
retaining bolt holding the exhaust pipe to the bottom
of the exhaust manifold. Separate the pipe from the
manifold and remove the gasket.
19. Remove the bolts holding the support brace
to the bottom of the intake manifold.
20. Use the special hex wrench (MB 998051-01)
and loosen the head bolts in the order shown in 2 or
3 passes. When all are finger loose, remove the bolts.
21. Rock the head gently to break it loose; if tap-
ping is necessary, do so with a rubber or wooden
mallet at the corners of the head. DO NOT pry the
head up by wedging tools between the head and the
block.
22. Lift the head free of the engine. It is coming
off with both manifolds and the intake plenum at-
tached; the help of an assistant is recommended for
lifting. Support the head assembly on wooden blocks
on a suitable workbench. Refer to Cleaning and In-
spection in this section for work to be done before in-
stalling the head. If the head has been removed for
work other than gasket replacement, the rocker as-
sembly and camshaft or other components may be
removed.
Before reinstallation, the head should be com-
pletely assembled on the bench. This allows proper
location and tightening of all the external items.
To install: 23. Place a new gasket on the engine so that the
identifying mark faces up (towards the head) and is at
the timing belt end of the block. Install a new gasket
on the exhaust pipe.
Do not apply sealant to the head gasket or
mating surfaces.
24. Install the head straight down onto the block.
Try to eliminate most of the side-to-side adjust-
ments as this may move the gasket out of position.
Install the bolts by hand and just start each bolt 1 or
2 turns on the threads.
25. The head bolt torque specification is 68 ft.
Ibs. (92 Nm) for a cold engine. The bolts must be
tightened in the order shown in 3 steps. On the first
pass, tighten all the bolts to about 22 ft. Ibs. (30 Nm),
then proceed through the order tightening each bolt
to about 45 ft. Ibs. (61 Nm). The final torque is
achieved on the third pass.
26. Install the intake manifold support brace to
the manifold and tighten the bolts to 16 ft. Ibs. (22
Nm). 27. Making sure the gasket is still in place, con-
nect the exhaust pipe to the base of the exhaust man-
ifold. Use new self-locking nuts; tighten the nuts and
the small bracket bolt to 26 ft. Ibs. (35 Nm).
28. Make sure the camshaft has not changed po-
sition during repalrs. Carefully install the camshaft
sprocket and belt onto the camshaft. Tighten the re-
taining bolt to 66 ft. Ibs. (91 Nm).
29. Install the upper timing belt cover, then
tighten the bolts to 8 ft. Ibs. (11 Nm).
30. Apply sealant to the contact surfaces of the
half-circle plug and install the plug in the head In-
stall the valve cover and gasket.
31. Install the engine mount bracket to the en-
gine. Tighten the mounting nuts and bolts to 42 ft.
Ibs. (57 Nm).
32. Adjust the jack (if necessary) so that the en-
gine mount bushing aligns with the bodywork
bracket. Install the through-bolt and tighten the nuts
snug.
33. Slowly release tension on the floor jack so
that the weight of the engine bears fully on the
mount. Tighten the through-bolt to 52 ft. Ibs. (71
Nm) and the small safety nut to 26 ft. tbs. (36 Nm).
34. Install the bracket holding the power steering
hose and air conditioning hose to the top of the en-
gine mount.
35. Position the control wiring harness and in-
stall the retaining bolts. Attach each electrical con-
nector to its proper location, making sure the wires
are properly routed and firmly connected.
36. Install the spark plug wires in the distributor
cap.
37. Connect the PCV hose and the vacuum
hose(s).
38. Connect the fuel return line. Connect the
brake booster vacuum hose.
39. Install the heater hose, the coolant by-pass
hose and.the upper radiator hose. Pay close attention
to the position and routing of these hoses and insure
that they are not crimped or constricted. Install the
clamps in the same location as before removal.
40. Install a new O-ring on the high pressure fuel
line and lubricate it with a coating of gasoline. Care-
fully connect the high pressure fuel line to the fuel
rail, taking care not to damage the O-ring. Tighten the
bolts only to 4 ft. Ibs. (6 Nm).
41. Connect the accelerator cable and adjust it as
necessary.
42. Install the air intake hose.
43. Fill the cooling system with coolant.
44. Changing the oil and filter is recommended
to eliminate pollutants in the oil.
Intake side
I Front of
engine
Exhaust side
Fig. 116 Cylinder head bolt removal se-
quence-l .6L and 2.OL DDHC engines intake
side
Front of
entine
Exhaust side 7923PG18
Fig. 117 Cylinder head bolt torque se-
quence-l .6L and 2.OL DDHC engines Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
45. Connect the negative battery cable.
46. Start the engine and check for leaks of fuel,
vacuum or oil.
47. Check the operation of all engine electrical
systems as well as dashboard gauges and lights.
48. Perform necessary adjustments to the accel-
erator cable, drive belts and engine specifications.
Adjust the coolant level after the engine has cooled
Off.
1.6L and 2.OL DDHC Engines
ti See Figures 116,117, and 116
1. Relieve fuel system pressure.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
4. Disconnect the accelerator cable. There will
be 2 cables if equipped with cruise-control.
5. Remove the air cleaner with the air intake
hose.
6. Detach the electrical connectors from the the
oxygen sensor, engine coolant temperature sensor,
the engine coolant temperature gauge unit and the
engine coolant temperature switch on vehicles with
air conditioning.
7. Disconnect the wiring from the ISC motor,
throttle position sensor, crankshaft angle sensor, fuel
injectors, ignition coil, power transistor, noise filter,
knock sensor on turbocharged engines, EGR temper-
ature sensor (California vehicles), ground cable and
engine control wiring harness.
Painted mark Painted mark
Fig. 116 To ensure that the bolts are tight-
ened exactly 160 total degrees, mark the
11.6L and 2.OL DDHC engines head bolt and cylinder head as shown-

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