sensor MITSUBISHI DIAMANTE 1900 Owner's Manual

3-16 ,ENGlNEANDENGlNEOVERHAUL
Fig 66 Remove the heat shield retaining
bolts. . . g3’~‘51 Fig. 64 Remove the hanger retaining bolt
* . I(
Fig, 67 . . .
then remove the heat shield
from the exhaust manifold
Fig. 69 Remove the engine lifting eye from
the manifold . . . Fig. 70 , . . then remove the manifold from
the cylinder head Fig. 71 Remove the exhaust manifold gas-
/ faces, and replace the gasket ’ 93’53p72 ket, thoroughly clean the mountmg sur-
6. For the DOHC engine, if removing thr
a front
manifold, remove the alternator and mountin!
from the vehicle. 3 bracket
7. For the DOHC engine, separate the I$,, I.vIII- /r nnm
pressor from the mounting bracket. Leaving the
hoses ~~~, position the compressor aside,
8. ff removing the front manifold, remove the oil
dipstick and tube from the engine.
9. For the DOHC engine, if removing the front
manifold, remove the heat protector. 13. Remove the exhaust manifold mounting bolts
the manifold.
To install:
-4” PI,*, -11 rm.A.^L -,‘&^-:-I f-e.- IL- -_-I!-- - .-
17. lrlMll dll yWK1 Illdlell~l 110111 LIle lKWi~ SIN- faces and check the manifold for damage.
15. Install a new gasket and install the manifold.
Tighten the nuts in a crisscross pattern to 21 ft. Ibs.
(30Nm). .’ --.._
Nm) for 1
16. II 21. Install the drive belt(s) and adjust for proper
tension.
to1 the SOHC engine or to 14 ft. Ibs. (19
he DOHC engine.
Wall the heat shields. 22. Connect the negative battery cable and check
I- L- L, #
ror exnausr leaks.
3.51 Engfne
A Sam Finnwn 74
17. c
“IIII”“IUI” L”ll L”“““ll” IIIlu#lb p,““l~,aa~
and roll stopper bracket, if removed.
18. Install the oxygen sensor.
19. Install the electric cooling fan assembly, A/C
compressor, dipstick tube and alternator, as required.
20. Install a new flange gasket and connect the
exhaust pipe or converter assembly. Do not attempt the work on the
exhaust sys-
tern until it has completely coo
led.
1. Disconnect battery negative cable.
2. Raise the vehicle and support safely.
3. Remove the exhaust pipe to exhaust manifold
nuts and remove the front exhaust pipe. IO. If removing the rear manifold, disconnect the
EGR tube.
11. For the SOHC engine, if removing the rear
manifold, remove the intake plenum stay and the roll
stopper bracket.
12. Unplug the electrical connector and remove
the oxygen sensor.

ENGlNEANDENGlNEOVERHAiJL 3-17
Fig. 73 Exploded view of the exhaust man
ifold -3.OL DOHC engine
9315392c Fig. 74 Exhaust manifold exploded view-
3.5L engine
4. Lower the vehicle.
5. If removing the front manifold, remove the ra-
diator and cooling fan assembly.
6. If removing the front manifold, remove the al-
ternator.
7. Remove the heat protector(s). 8. If removing the rear manifold, disconnect the
EGR tube.
9. Remove the exhaust manifold mounting bolts
the manifold.
To install:
10. Clean all gasket material from the mating sur-
faces and check the manifold for damage.
11. Install a new gasket and install the manifold.
Tighten the nuts in a crisscross pattern to 21 ft. Ibs.
(30 Nm).
12. Install the heat protector(s).
13. If installrng the rear manifold, replace the
gasket and connect the EGR tube.
14. If installing the front manifold, install the ra-
diator and cooling fan assembly.
15. If installing the front manifold, install the al-
ternator.
16. Install the drive belt(s) and adjust for proper
tension.
17. Raise and safely support the vehicle securely
on lackstands.
18. Install a new flange gasket and connect the
exhaust pipe or converter assembly.
19 Lower the vehicle
20. Connect the negative battery cable and check
for exhaust leaks.
REMOVAL&INSTALLATION
2.OL DOHC Engine (1990-93 Galant Only)
# See Figures 75 and 76
Many turbocharger failures are due to oil supply
problems. Heat soak after hot shutdown can cause
the engine oil in the turbocharger and oil lines to
“coke.” Often the oil feed lines will become partially
or completely blocked with hardened particles of car-
bon, blocking oil flow. Check the oil feed pipe and oil
return line for cloggrng. Clean these tubes well. Al-
ways use new gaskets above and below the oil feed
eyebolt fitting. Do not allow particles of dirt or old
gasket material to enter the oil passage hole and that
no portion of the new gasket blocks the passage.
1. Disconnect the negative battery cable.
2. Drain the engine oil, cooling system and re-
move the radiator On vehicles equipped with A/C,
remove the condenser fan assembly with the radiator.
The EPA warns that prolonged contact with
used engine oil may cause a number of skin
disorders, including cancer! You should
make every effort to minimize your exposure
to used engine oil. Protective gloves should
be worn when changing 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.
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 Fig. 75 Exploded view
mounting (1 of 2)
93153q21 the turbocharget
9315392: :ig. 76 Exploded view of the turbocharger
nounting (2 of 2)
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 Detach the oxygen sensor connector and re-
move the sensor.
4. Remove the oil dipstick and tube.
5. Remove the air intake bellows hose, the
wastegate vacuum hose, the connections for the air
outlet hose, and the upper and lower heat shield.
6. Unbolt the power steering pump and bracket
assembly and leaving the hoses connected, wire it
aside.
7. Remove the self-locking exhaust manifold
nuts, the triangular engrne hanger bracket, the eye-

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

.
3-20 ENGINEANDENGINEOVERHAUL
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 overflow hose and disconnect
the upper radiator hose.
*It is recommended that each clamp be
matchmarked to the hose. Observe the marks
and reinstall the clamps exactly when rein-
stalling the radiator.
4. If equipped with an automatic transaxle, re-
move and plug the fluid cooler hoses.
5. Unplug the electrical connector(s) from the
coolant fan motor.
6. Remove the mounting bolts, then remove the
fan and shroud assembly from the vehicle.
7. Remove the fan blade retainer nut from the
shaft on the fan motor and separate the fan from the
motor.
8. Remove the motor to shroud attaching
screws and the motor from the shroud.
To tnstall: 9. Install the motor to the shroud and secure
with the mounting bolts.
10. Install the remaining components in the re-
verse order of removal.
11. Fill the coohng system. Connect the negative
battery cable and check the cooling fan for proper op-
eration.
Diamante
# See Figure 94
1. Disconnect the negative battery cable 2. Drain the cooling system only when the radi-
ator and the engine are at safe temperatures. 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
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. Unplug the cooling fan and radiator sensor
connector(s). Most of these connectors employ a wa-
terproof connector. When disconnecting, make sure
all parts of the connector remain intact.
4. Disconnect the upper radiator hose from the
radiator and remove overflow tank.
5. Remove the fan mounting screws. The radia-
tor and condenser cooling fans are separately remov-
able.
6. Remove the fan assembly and disassemble
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 engine undercover.
4 Disconnect the clamp bolt from the power
steering hose.
5. Remove the engine drive belts.
6. Support the engine with the appropriate
equipment and remove the engine mount bracket.
7. Remove the timing belt Reier to the timing
belt procedure in this section
8 Remove the power steering pump bracket.
9. Remove the alternator brace.
as required.
To install: 7. Posrtion the fan and install the mounting
screws
*The water pump mounting bolts are differ-
ent in length, note their positioning for re-
assembly.
8 Install the electrical connectors and the upper
radiator hose.
9. Refill the cooling system.
IO. Connect the negative battery cable and check
the fan for orooer ooeration. 10. Remove the water pump, gasket and O-ring
where the water inlet pipe(s) joins the pump.
To install: 11, Thoroughly clean both gasket surfaces of the
water oumo and block.
12. For 1.5L engines, install a new O-ring into
the groove on the front end of the water inlet pipe. Do
not apply oils or grease to the O-ring. Wet the O-ring
with water only
13. For 1.8L engines, apply a 0.09-0.12 in.
(2.5-3 Omm) continuous bead of sealant to water
pump and rnstall the pump assembly. Install the wa-
ter pump within 15 minutes of the applrcation of the
REMOVAL & INSTALLATION
1.5L and 1.8L Engine
) See Figures 95 and 98
7923PGO :ig. 94 Exploded view of the fan mounting and related components- Fig. 95 Water pump and related components-Mirage with 1.51
liamante (4615) engine

3-24 ENGINEANDENGINEOVERHAUL
Intake side Front of engine
e
Exhaust side
7923PG13 Fig. 110 Cylinder head bolt loosening se-
uuence-Mirage with 1.5L (4615) ermine
inwe side 0 Front of engine
((9
Exhaust side
7923PG14 Fig. 111 Cyllnder head bolt tightening se-
quence-Mirage with 1.5L (4615) engine
12. Disconnect the electrical harness plugs from
the following:
l Crankshaft Position (CKP) and Camshaft
Position (CMP) sensors
l Heated Oxygen (HO*S) sensor l Engine Coolant Temperature (ECT) sensor
and gauge sender
l Idle Speed Control (ISC) motor l Throttle Position (TP) sensor l Intake Air Temperature (IAT) sensor l Exhaust Gas Recirculation (EGR) tempera-
ture sensor
13. Disconnect electrical harness plugs from the
ignition distributor, fuel injectors, power transistor
and ground cable.
14. Disconnect the engine control wiring har-
ness.
15. Remove the clamp that holds the power steer-
ing pressure hose to the engine mounting bracket.
16. Place a jack and wood block under the oil
pan and carefully lift just enough to take the weight
off the engine mounting bracket and remove the
bracket.
17. Remove the valve cover.
18. Remove the timing belt upper cover.
19. Rotate the crankshaft clockwise and align the
timing marks.
20. Attach the timing belt to the camshaft
sprocket with cord or a wire tie.
21. Secure the camshaft from turning and remove
the camshaft sprocket with the timing belt attached.
22. Remove the timing belt rear upper cover.
23. Remove the exhaust pipe from the exhaust
manifold.
24. Loosen the cylinder head mounting bolts in
sequence using three steps.
25. Remove the cylinder head.
To install:
26. Thoroughly clean the mating surfaces of the
head and block. 27. Place a new head gasket on the cylinder
block with the identification marks facing upward. Do
not use sealer on the gasket.
28. Carefully install the cylinder head on the
block. Tighten the cylinder head bolts as outlined in
the followlng steps:
a. Tighten the bolts to 36 ft. Ibs. (49 Nm) in
the correct sequence
b. Loosen the bolts completely in the reverse
of the tightening order,
c. Tighten the bolts, in sequence, to 14 ft.
Ibs. (20 Nm)
d. Tighten each bolt, in sequence, 90 degrees
e. Tighten each bolt, in sequence, an addi-
tional 90 degrees
29. Install a new exhaust pipe gasket and connect
the exhaust pipe to the manifold.
30. Install the upper rear timing cover.
31. Align the timing marks and install the cam
sprocket. Torque the retaining bolt to 51 ft. Ibs. (76
Nm). Check the belt tension and adjust, if necessary.
Install the outer timing cover.
32. Install the valve cover and torque the retain-
ing bolts to 16 inch Ibs. (1.8 Nm).
33. Install the engine mount bracket and remove
the support jack.
34. Install the clamp that holds the power steer-
ing pressure hose to the engine mounting bracket.
35. Attach the following electrical connectors:
l CKP and CMP sensors l HOPS sensor l ECT sensor and gauge sender l ISC motor l TP sensor l IAT sensor l EGR temperature sensor
36. Connect wiring for the ignition distributor,
fuel injectors, power transistor and ground cable.
37. Connect the engine control wiring harness.
38. Replace the O-rings and connect the fuel
lines.
39. Install the air cleaner assembly. Connect the
breather hose.
40. Fill the system with coolant.
41. Connect the negative battery cable.
1.8L Engine
# See Figures 112 and 113
1. Relieve fuel system pressure. Disconnect the
negative battery cable.
2. Remove the air cleaner assembly.
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
lefl 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 brake booster vacuum hose
and PVC valve connection. 5. Note the locations, then disconnect the vac-
uum hoses from the intake and throttle body.
6. Remove the upper radiator hose, overflow
tube and the water hose from the thermostat to the
throttle body.
7. Disconnect the fuel feed and return lines.
8. Unplug the accelerator cable connection from
the throttle body.
9. Detach the wiring from the oil pressure
switch.
10, Disconnect the wiring from the following
components:
l Heated Oxygen (HO*S) sensor l Engine Coolant Temperature (ECT) sensor
and gauge sender
l Idle Air Control (IAC) motor l Exhaust Gas Recirculation (EGR) tempera-
ture sensor
l Throttle Position (TP) sensor l Knock sensor l Fuel injectors
11. Remove the spark plug wires.
12. Unbolt the control harness assembly and po-
sition aside.
13. Remove the thermostat housing, thermostat
and the thermostat case with O-ring from the engine.
14. Remove the rocker cover.
15. Remove the timing belt upper cover.
16. Rotate the crankshaft clockwise and align the
timing marks.
17. Attach the timing belt to the camshaft
sprocket with cord or a wire tie.
18. Secure the camshaft from turning and remove
the camshaft sprocket with the timing belt attached.
19. Remove the timing belt rear upper cover.
20. Loosen the cylinder head bolts in two or three
steps in the proper sequence.
21. Remove the cylinder head from the engine.
Intake side
Front of engine c=>
I
Exhaust side
Loosening &der 7923PG15 Fig. 112 Cylinder head bolt loosening se-
quence-l .8L engine
intake side Front of engine *
Exhaust side libhtenng order
Fig. 113 Cylinder head bolt torque se-
quence-l .8L engine

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-

3-28 ENGINEANDENGINEOVERHAUL
lntsltaelde Front of engine c3
Fig. 125 Cylinder head bolt removal se- Fig. 127 Grasp the cylinder head and lift it
off the engine block with the manifolds at-
ig. 126 A magnet can be extremely help- tached. It is a good idea to use a helper for
quence-2.41(4664) engine I ful when removing the cylinder head bolts 1 1 this, as the assembly is very heavy
93153pOO Fig. 128 Remove the cylinder head gasket 33153p4!3 Fig, 129 Thoroughly clean the gasket sur- Fig. 130 Also, make sure to thoroughly
clean the engine block mating surfaces be-
from the block
faces of the cylinder head fore reassembling the engine
l Intake Air Temperature (IAT) sensor l Throttle Position (TP) sensor
: /I;%;,; rZ;Z;;(lAC) motor 23. Inspect the cylinder head bolt length prior to
installation. If the length exceeds 3.91 in. (99.4mm),
the bolt must be replaced. Install the washer onto the
bolt so the chamfer on the washer faces towards the
l Ignition coil head of the bolt. l Camshaft Position (CMP) sensor 24. Carefully install the cylinder head on the l Exhaust Gas Recirculation (EGR) solenoid block and tighten the cylinder head bolts as follows:
valve a. Following the proper tightening sequence,
11. Remove the spark plug wire cover and wires. tighten the cylinder head bolts to 58 ft. Ibs. (78
12. At the thermostat case assembly, remove the Nm).
coolant hoses and unbolt the thermostat case from b. Loosen all bolts completely.
the engine. c. Torque bolts to 15 ft. Ibs. (20 Nm). ’
Fig. 131 Cylinder head bolt installation se-
13. Remove the upper timing belt cover d. Tighten bolts an additional 1/4 turn.
14. Align all timing marks. e. Tighten bolts an additional 1/4 turn.
15. Secure the timina belt to the camshaft 25. Install the new exhaust pipe aasket and con-
iliiL.-
5.
9. Disconnect and plug the fuel return hose. Disconnect the accelerator cable. Remove the
cable mounting brackets and position the cable
10. Label and detach the connectors from the fol- aside.
lowing components: 6. Remove the breather hose.
* A$ compressor
* Power steering pressure switch ‘7. Label and disconnect the vacuum lines at the
* Heated Oxygen (HO$) sensor tree body.
* Engine Coolant Temperature (ECT) gauge . 8. D&connect and plug the high pressure fuel
sender
lint3
l
ECT sensor l Manifold Absolute Pressure (MAP) sensor sprocket with cord or a wire tie.
fold. Discard the gasket, 16. Remove the camshaft sprocket.
20. Loosen the cylinder head mounting bolts in 3 17.
steps, starting from the outside and working inward. Remove the valve cover and the half-round
seal.
Lift off the cylinder head assembly and remove the 18. Disconnect the intake manifold stay bracket
head gasket.
To install: from the intake manifold.
21. Thoroughly clean the mating surfaces of the 19. Remove the exhaust pipe self-locking nuts
head and block. and separate the exhaust pipe from the exhaust mani-
22. Place a new head gasket on the cylinder
block with the identification marks at the front top
(upward) position. Do not use sealer on the gasket. nect the exhaust pipe to the manifold. Tighten the
portions of the belt-side of the new gasket. Install thr bolts to 33 ft. Ibs. (44 Nm).
valve cover. 26.
29. Install the thermostat case and tighten the
Install the camshaft sprocket with the timing mounting bolts to 18 ft. Ibs. (24 Nm).
belt attached. Remove the cord or wire tie.
30. Install the upper timing belt cover. 27. Connect the coolant hoses to the thermostat
31. Connect the intake manifold stay and tighten case.
the mounting bolts to 22 ft. Ibs. (30 Nm). 28.
32. Attach the connectors to the following com- Apply sealer to the perimeter of the half-
round seal and to the lower edges of the half-round
ponents: l A/C compressor l Power steering pressure switch

ENGINEANDENGINEOVERHAUL 3-29
l HOzS sensor l ECT gauge sender l ECT sensor l MAP sensor l IAT sensor l TP sensor l IAC motor l injector harness l ignition coil l CMP sensor l EGR solenoid valve
33. Install the spark plug wires and cover,
34. Replace the O-rings and connect the fuel
lines.
35. Install the air cleaner and intake hose. Con-
nect the breather hose.
36. Fill the cooling system.
37. Connect the negative battery cable
3.01 DDHC Engine
ti See Figures 132 and 133
1. Relieve fuel system pressure. 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
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 quantltles. 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 hoses.
4. Remove air intake plenum and intake mani-
fold.
5. Remove the exhaust manifold.
6. Remove the timing belt. Refer to the timing
belt procedure in this section.
7. Remove the breather hose.
8. Remove the spark plug wire center cover and
remove the spark plug wires.
9. Remove the rocker covers.
10. Remove the intake camshaft sprockets.
11. Remove the rear timing belt cover.
12. Remove the ignition coil assembly.
13. Disconnect all water hoses from the thermo-
stat housing and remove the housing.
14. Disconnect the water inlet from the front
head.
15. Loosen the cylinder head mounting bolts in
the reverse of the torque sequence and loosen the
bolts in three steps. Lift off the cylinder head assem-
bly and remove the head gasket.
To install: 16. Thoroughly clean the sealing surfaces of the
head and block.
17. Place a new head gasket on the cylinder
block with the identification marks in the front top
(upward) position. Do not use sealer on the gasket,
18. Carefully install the cylinder head on the
block. Be sure the head bolt washers are installed
with the chamfered edge upward. Using three even
steps, torque the head bolts in sequence, to 76-83 ft.
Ibs. (105-115 Nm).
@ Timing belt side
7923PG26 :ig. 132 Tighten the cylinder head bolts ac-
:ording to the sequence shown-3.01
SDHC and DDHC) engines
Rear bank
[::od
04
~8 01
Front bank
'1 "8
509 010 011 6
1.03 07 02 7923ffi25 Fig. 133 Rocker cover bolt torque se-
quence-Diamante 3.OL DDHC engine
19. Install new O-ring and connect the water inlet
to the head. Tighten the mounting bolt to 9-11 ft. Ibs
(12-15 Nm).
20. Replace the gaskets and install the thermostat
housing. Tighten the mounting bolts to 12-14 ft. Ibs.
(17-20 Nm).
21. Using new hose clamps, connect the hoses to
the thermostat housing.
22. Install the Ignition coil and torque the mount-
ing bolts to 7 ft. Ibs. (10 Nm).
23. Install the rear timing belt cover and torque
the mounting bolts to 17 ft. Ibs. (24 Nm).
24. Install the intake camshaft sprockets. Tighten
the retaining bolt to 65 ft. Ibs. (90 Nm).
25. Apply sealer to the lower edges of the valve
cover. Tighten the bolts in the proper sequence to
44-51 inch Ibs. (5-6 Nm).
26. Connect the spark plug wires and install the
center cover. Tighten the bolts that secure the center
cover to 27 inch Ibs. (3 Nm)
27. Install the breather hose.
28. Install the timing belt. Refer to the timing belt
procedure in this section,
29. Install the exhaust manifold assembly.
30. Using all new gaskets, install the intake man-
ifold and air intake plenum.
31. Install the air intake hoses.
32. Change the engine oil and oil filter. 33. Fill the system wrth coolant.
34. Connect the negabve battery cable.
35. Adjust the accelerator cable.
36. Start the engine.
37. Check and adjust the idle speed and ignition
timing.
38. Once the vehicle has cooled, recheck the
coolant level.
3.OL SDHC Engine
# See Figure 132
1. Relieve the 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
alvcol antifreeze and could drink any that is
Left in an uncovered container or in puddles
on the ground. This will Drove fatal in suff i-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
Unless it is Contaminated or is several years
old.
4. Remove the air intake hose.
5. Remove the exhaust manifold.
6. Remove the air intake plenum and intake
manifold.
7. Remove the timing belt. Refer to the timing
belt procedure in this section.
8. Remove the camshaft sprockets and the rear
timing belt cover.
9. Remove the power steering pump bracket. If
removing the rear head, remove the alternator brace.
10. Disconnect the water inlet pipe.
11. Remove the purge pipe assembly.
12. Remove the valve cover,
13. Using the reverse sequence of the installation
sequence, loosen the cylinder head mounting bolts in
three steps. Lift off the cylmder head assembly and
remove the head gasket.
To install: 14. Thoroughly clean the sealing surfaces of the
head and block.
15. Place a new head gasket on the cylinder
block making sure the identification mark on the
cylrnder head gasket is in the front top (upward) loca-
tion. Do not use sealer on the gasket,
16. Carefully install the cylinder head on the
block. Be sure the head bolt washers are installed
with the chamfered edge upward. Using three even
steps, torque the head bolts in sequence, to 7683 ft.
Ibs. (105-115 Nm).
17. Apply sealer to the lower edges of the half-
round portions and install the valve cover. Tighten
valve cover bolts to 7 ft. Ibs. (9 Nm).
18. Install the purge pipe assembly.
19. Connect the water inlet pipe.
20. Install the power steering pump bracket and
alternator brace.
21. Install the rear timing belt cover and camshaft
sprockets. Torque the retaining bolt to 65 ft. Ibs. (90
Nm).
22. Install the timing belt. Refer to the timing belt
procedure in this section.

.
3-32 ENGINEANDENGINEOVERHAUL
9. Inspect the oil pan for damage and cracks.
Replace if faulty, While the pan is removed, inspect
the oil screen for clogging, damage and cracks, Re-
place if faulty.
To install: 10. Using a wire brush or other tool, scrape clean
all gasket surfaces of the cylinder block and the oil
pan so that all loose material is removed. Clean seal-
ing surfaces of all dirt and oil.
11, Apply sealant around the gasket surfaces of
the oil pan in such a manner that all bolt holes are
circled and there is a continuous bead of sealer
around the entire perimeter of the oil pan.
*The continuous bead of sealer should be
applied in a bead approximately 0.16 in.
(4mm) in diameter.
12. Install the oil pan onto the cylinder block
within 15 minutes after applying sealant. Install the
fasteners and tighten to 4-6 ft. Ibs. (68 Nm).
13. Install the oil return pipe using a new gasket,
if removed. Tighten retainers to 5-7 ft. Ibs. (7-10
Nm).
14. Install the left member and tighten the forward
retainer bolts to 72 ft. Ibs. (100 Nm). Tighten the
rearward left member bolts to 58 ft. Ibs. (80 Nm).
15. Install the transfer assembly and right drive-
shaft.
16. Connect the exhaust pipe from the engine
manifold with new gasket in place. Tighten the ex-
haust pipe to manifold flange nuts to 29 ft. Ibs. (40
Nm).
17. Install the oil drain plug and tighten to 33 ft.
Ibs.
18. Lower the vehicle and fill the crankcase to the
proper level with clean engine oil.
Operating the engine without the proper
amount and type of engine oil will result in
severe enaine damage.
19. Connect the negative battery cable. Start the
engine and check for leaks.
2.4L Engine
) See Figure 139
1, Disconnect the negative battery cable. -
,(L.. K%
2 mM_
-Ip
t 8*t.almcwr
:y&pn
::Elm
93153g30 Fig. 139 Oil pan and related components-
2.4L engine
2. Remove the oil pan drain plug and drain the
engine oil.
The EPA warns that prolonged contact with
used engine oil may cause a number of skin
disorders, including cancer! You should
make every effort to minimize your exposure
to used engine oil. Protective gloves should
be worn when changing 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.
3. Remove the oil dipstick and tube assembly.
4. Detach the Heated Oxygen (HOaS) sensor
connector.
5. Remove the front exhaust pipe from the vehi-
cle.
6. Remove the bell housing cover.
7. Remove the oil pan retainer bolts. Using spe-
cial tool MD998727 or equivalent, tap in between the
engine block and the oil pan.
*Do not use a prytool when removing the oil
pan. Damage to engine components may oc-
cur.
To install:
8. Apply sealant around the gasket surfaces of
the oil pan.
9. Install the oil pan onto the cylinder block
within 15 minutes after applying sealant. Install the
fasteners and tighten to 6 ft. Ibs. (8 Nm).
10. Install the oil drain plug and tighten to 29 ft.
Ibs. (39 Nm).
11. Install the bell housing cover, and tighten the
mounting bolts to 7 ft. Ibs. (9 Nm).
12. Install the front exhaust pipe and tighten the
bolts at the catalytic converter to 36 ft. Ibs. (49 Nm).
Tighten the nuts at the exhaust manifold to 32 ft. Ibs.
(44 Nm).
13. Reconnect the HOPS sensor connector.
Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
15. Connect the negative battery cable. Start the
engine and check for leaks.
3.OL Engines
u See Figure 140
1. Disconnect the negative battery cable.
2. Remove the oil pan drain plug and drain the
The EPA warns that prolonged contact with
used engine oil may cause a number of skin
disorders, including cancer! You should
make every effort to minimize your exposure
to used engine oil. Protective gloves should
be worn when changing the oil. Wash your
hands and any other exposed skin areas as
soon as possible after exposure to used en-
Groove
Hole of bolt 7923PG67 Fig. 140 Oil pan bolt tightening sequence
and application of sealant to the pan-Dia-
mante 3.OL engines
gine oil. Soap and water, or waterless hand
cleaner should be used.
3. Remove the left side crossmember. If
equipped with 4WS, it will also be necessary to re-
move the right side crossmember.
4. Remove the starter motor.
5. Disconnect the roll stopper stay bracket, from
the rear transaxle stay bracket. Remove the both
transaxle stay brackets.
6. Remove the bell housing lower cover.
7. Remove the oil pan mounting bolts. Using
special tool MD998727 or equivalent, separate and
remove the engine oil pan.
To install: 8. Apply a 0.16 in. (4mm) continuous bead of
sealer around the surface of the oil pan.
*Assemble the oil pan to the cylinder block
within 15 minutes after applying the sealant.
9. Install the oil pan mounting bolts. Following
proper sequence, tighten mounting bolts to 48 inch
Ibs. (6 Nm).
10. Install lower bell housing cover and the
starter motor.
11, Install the transaxle stay brackets and connect
the roll stopper bracket.
12. Install the crossmember and tighten the
mounting bolts to 43-51 ft. Ibs. (60-70 Nm).
13. Fill the engine with the proper amount of oil.
.
Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
14. Connect the negative battery cable and check
for leaks.
3.5L Engine
p See Figures 141, 142, and 143
1, Disconnect the negative battery cable.
2. Drain the engine oil.
The EPA warns that prolonged contact with
used engine oil may cause a number of skin
disorders, includina cancer! You should
make eve’ry effort to minimize your exposure