bolt pattern MITSUBISHI DIAMANTE 1900 Repair Manual

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-

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

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

3-10 ENGINEANDENGINEOVERHAUL
2. Disconnect the battery negative 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 and air in-
take hose.
5. Disconnect the upper radiator hose, heater
hose and water bypass hose.
6. Unplug the vacuum connection at the power
brake booster and the PCV valve if still connected.
Disconnect all remaining vacuum hoses and pipes as
necessary.
7. Disconnect the high pressure fuel line, fuel
return hose and remove throttle control cable brack-
ets
8. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor,
therm0 switch, idle speed control assembly, EGR
temperature sensor, distributor, fuel injectors and
spark plug wires. Position the engine wiring harness
aside.
9. Matchmark the distributor housing to the in-
take manifold, and remove the distributor.
10. Remove the intake manifold bracket and the
engine hanger.
11. If the thermostat housing is preventing re-
moval of the intake manifold, remove it.
12. Remove the intake manifold mounting bolts
and remove the intake manifold assembly. Drsassem-
ble manifold from the Intake plenum on a work bench
as required
To install: 13. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly. Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
14 Assemble the intake manifold assembly using
all new gaskets. Torque air intake plenum bolts to
11-14ff. Ibs. (15-19 Nm).
15. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crrsscross pattern, starting from the inside and
working outwards to 11-14 ff. Ibs. (15-19 Nm).
16. Install the fuel delivery pipe, injectors and
pressure regulator to the engine. Torque the retaining
bolts to 4 ft. Ibs (6 Nm).
17. install the thermostat housing, intake mani-
fold brace bracket, and engine hanger bracket.
18 Connect or install all hoses, cables and elec-
trical connectors that were removed or disconnected
during the removal procedure.
19. Align the distributor matchmarks and install
the distributor.
20. Fill the system with coolant,
21. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely. 22. Adjust the accelerator cable. Check and ad-
just the idle speed and ignition timing.
23. Once the vehicle has cooled, recheck the
coolant level.
1.6L and 2.OL DDHC Engines
# See Figure 32
1. Relieve the fuel system pressure.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
ulosion.
2. Disconnect battery negative cable and drain
the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
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.
Fig. 32 Exploded view of the intake mani-
fold and related components-1.6L and
2.OL DDHC engine
3. Disconnect the accelerator cable and air in-
take hose.
4. Disconnect the coolant hose from the throttle
housing.
5. Detach the vacuum connection at the power
brake booster and the PCV valve If still connected.
Disconnect all remaining vacuum hoses and pipes as
necessary.
6. Drsconnect the high pressure fuel line, fuel
return hose and remove throttle control cable brack-
ets
7. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor,
therm0 switch, throttle position sensor, rdle speed
control assembly, EGR temperature sensor, distribu-
tor, fuel injectors and spark plug wires. Position the
engine wiring harness aside.
8. Remove the intake manifold bracket.
9. Remove the intake mamfold mounting bolts
and remove the intake manifold assembly. Disassem-
ble manifold on a work bench as required.
To install:
10. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly. Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
11. Assemble the Intake manifold assembly using
all new gaskets.
12. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crisscross pattern, starting from the inside and
working outwards to 11-14 ft. Ibs. (15-20 Nm).
13. Install the fuel delivery pipe, injectors and
pressure regulator to the engine. Torque the retaining
bolts to 4 ft. Ibs. (6 Nm).
14. Install the intake manifold brace bracket and
tighten bolts to 13-18 ft. Ibs. (18-25 Nm).
15. Connect or install all hoses, cables and elec-
trical connectors that were removed or disconnected
during the removal procedure.
16. Fill the system with coolant.
17. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
18. ‘Adjust the accelerator cable.
19. Check and adjust the idle speed and ignition
timing.
20. Once the vehicle has cooled, recheck the
coolant level.
2.4L Engine
) See Figures 33 thru 51
93153p37 Fig. 33 Detach the A/C temp electrical con- 1

.
3-12 ENGINEANDENGINEOVERHAUL
93153p54
1
L Fig. 46 Remove the brake booster vacuum
hose from the back of the intake manifold Fig 47 Remove the fuel feed line-to-fuel rail’retaini”g fitti”g bo,ts . . .
Fig. 49 From underneath the vehicle, re-
move the two intake manifold support
1. Relieve the fuel system pressure.
4. Disconnect the coolant hose from the throttle
Observe all applicable safety precautions
ing the fuel system, always work in a well when working around fuel. Whenever servic-
ventilated area. Do not allow fuel spray or - __.
vapors to come in contact with a spark or
._
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnect battery negative cable and drain
the cooling rtfctnm 93153p39 Fig. 50 Remove the intake manifold retain-
ing bolts . . .
h
n ousing.
5. Detach the vacuum connection at the power
b
rake booster and the PCV valve if still connected.
C lisconnect all remaining vacuum hoses and pipes as
ecessary. et air passages for clogging. Clean if necessary.
12. Assemble the intake manifold assembly using
III new gaskets.
13. Position a new intake manifold gasket on the
lead, then install the manifold. Torque the manifold
n a crisscross pattern, starting from the inside and
vorking outwards to 15 ft. Ibs. (20 Nm) for bolts, and
o 26 ft. Ibs. (35 Nm) for nuts on 1994 vehicles or 15
t. Ibs. (20 Nr$ for nuts on 1995-00 vehicles.
14. Install the fuel delivery pipe, injectors and
xessure regulator to the engine. Torque the retaining
)olts to 4 ft. Ibs. (6 Nm). Fuel injection systems remain under pres- f
sure after the engine has been turned OFF.
Properly relieve fuel pressure before discon-
necting any fuel lines. Failure to do so may [
result in fire or personal injury.
t 6. Disconnect the high pressure fuel line, fuel
return hose and remove throttle control cable brack- t
n+C.
cm. durino the removal orocedure. 15. Install the intake manifold brace bracket and
ighten bolts to 21 ft. Ibs. (29 Nm).
16. Connect or install all hoses, cables and elec-
rical connectors that were removed or disconnected
7. Tag and unplug the electrical connectors
from the coolant temperature sensor, coolant temper- 17: Fill the system with coolant.
18 Connect the negative battery cable, run the
, . : .., ,, ., , ,
,,,, ,. ,.
93153p73 Fig. 51 . . .
then remove the manifold from
the cylinder head
Ruver open, service or drain the radiator or
@Ming system when hot; serious burns can
II&ur from the steam and hot coolant. Also,
draining engine coolant, keep in mind ’
j “thiat cats and dogs are attracted to ethylene
. . . ..____ “..” 11_,1 -...... any that is
t uncovered container or in puddles
FE ol iha ground. This will prove fatal in suff i-
k ici?M quantities. Always drain coolant into a
$1 pealable container. Coolant should be reused
h’ uniass it is contaminated or is several years
j$O'd.
**w
ature gauge, IAC valve, ignition coil, EGR tempera-
ture sensor, knock sensor, oxygen sensor, throttle
position sensor, distributor, A/C temperature sensor,
fuel injectors and ignition power transistor. Position
the engine wiring harness aside.
8. Label and disconnect the spark plug wires
from the spark plugs.
9. Remove the intake manifold stay bracket.
IO. Remove the intake manifold mounting bolts
and remove the intake manifold assembly. Disassem-
ble manifold on a work bench as required.
Tan is”.+..ll. vemcle unrn me mermosrar opens, ml tne raalaror
completely.
19. Adjust the accelerator cable. Check and ad-
just the idle speed and ignition timing.
20. Once the vehicle has cooled, recheck the
coolant level.
3.OL and 3SL Engines
ti See Figures 52 thru 57
1. Relieve the fuel system pressure.
W.>. Clean all gasket material from the cylinder
!&S head intake mounting surface and intake manifold as-
fir!: 3. Disconnect the accelerator cable, breather
Observe all applicable safety precautions
El .;,
+w..” and air intake hose. sembly. Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and when working around fuel. Whenever servic-

.
3-14 ENGINEANDENGINEOVERHAUL
1. Connection for high-pressure fuel hose
2. O-ring
3. Connection for fuel return hose
4. Connection for vacuum hoses
5. Wrring harness connector
6. Oxy
P en sensor 199 models>
7. Fuel rail (with injectors)
8 Insulators
9. Timing belt upper cover
10. Water pump stay mountrng bolt
11. Intake manifold mounting nut
12. Intake manifold mounting nut
13 Cone disc spring
14. Intake manrfold
15. intake manifold gasket
:ig. 53 Intake manifold and related components-3.01 DDHC enaine
Fig. 55 Exploded view of the intake mani- :ig. 56 Exploded view of
fold mounting-3.01 SDHC engine
Issembly-3.5L engine air intake plenum
5. Remove electric cooling fan assembly, if nec- 4. Lower vehicle. To install: 10. Clean all gasket material from the mating sur-
REMOVAL &INSTALLATION
1.5L and 1.8L Engine
# See Figures 58 and 59 essary. faces and check the manifold for damage.
6. If the oxygen sensor is located in the mani- 11. Using a new gasket, install the manifold. For
fold, remove the sensor. 1.5L engines, tighten the nuts in a crisscross pattern
7. Disconnect necessary EGR components. to 13 ft. Ibs. (18 Nm). For 1.8L engines, tighten the
8. Remove outer exhaust manifold heat shield inner nuts in a crisscross pattern to 13 ft. Ibs. (18
and engine hanger. Detach the electrical connector Nm) and tighten the two outer (larger) nuts to 22 ft.
1. Disconnect battery negative cable.
2. Raise the vehicle and support safely
3. Remove the exhaust pipe to exhaust manifold
nuts and separate exhaust pipe. Discard gasket, and remove the oxygen sensor.
9. Remove the exhaust manifold mounting
bolts, the inner heat shield and the exhaust manifold. Ibs. (30 Nm).
12. Install the heat shields,
13. Connect EGR components.
14. If removed, install the oxygen sensor.

ENGlNEANDENGlNEOVERHAbL 3-15
Fig. 58 Exploded view of the exhaust man,
ifold -1.5L enoine
15. Install the electric cooling fan assembly as re-
quired.
16. Install a new flange gasket and connect the
exhaust pipe.
17. Connect the negative battery cable and check
for exhaust leaks.
1.8L and 2.OL Engines
u See Figures 80, 81, and 62
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Remove the front exhaust pipe to exhaust
manifold nuts and separate exhaust pipe. Discard the
gasket.
4. Lower the vehicle.
5. If equipped with air conditioning, remove
condenser cooling fan assembly.
6. Using special tool MD998703 or equivalent,
disconnect and remove the oxygen sensor.
:z**
::EEWl
93153915
:ig. 60 Exhaust manifold exploded view-
!.OL SOHC engine
93153g1 Fig. 59 Exhaust manifold exploded vlew-
1.8L engine
7. Remove outer exhaust manifold heat shield
and the engine hanger.
8. Remove the exhaust manifold mounting nuts,
the inner heat shield and the exhaust manifold from
the engine.
To install: 9. Clean all gasket material from the mating
surfaces and check the manifold for damage or crack-
ing.
10. Using a new gasket, install the exhaust mani-
fold, to the engine. Tighten the nuts to in a crrsscross
pattern to 11-14 ft Ibs. (15-20 Nm) for 2.OL SOHC
engine or to 18-22 ft. Ibs. (25-30 Nm) for 1.6L and
2.OL DOHC engine.
11. Install the outer heat shield and tighten the
mounting bolts to 10 ft. Ibs. (14 Nm).
12. Install the electric cooling fan assembly, if re-
moved.
13. Using a new flange gasket, connect the ex-
haust pipe and tighten the mounting nuts to 29-36 ft.
Ibs. (40-50 Nm).
:ig. 81 Exhaust manifold exploded view-
I .8L and 2.OL (non-turbo) DOHC engine
14. Connect the negative battery cable and check
for exhaust leaks.
2.4L Engine
g See Figures 63 thru 71
1, Disconnect battery negative cable.
2. Raise the vehicle and support safely.
3. Remove the exhaust pipe-to-exhaust mani-
fold nuts, the hanger retaining bolt, then separate the
exhaust pipe. Discard the gasket.
4. Remove the outer exhaust manifold heat
shield and engine hanger.
5. Remove the exhaust manifold mounting nuts
and the exhaust manifold from the engine.
To install: 6. Clean all gasket material from the mating
surfaces and check the manifold for damage or crack-
ing.
7. Install a new gasket and install the manifold.
Tighten the nuts to in a crisscross pattern to 18-21
ft Ibs. (25-29 Nm).
8. Install the heat shields and tighten the
mounting bolts IO ft Ibs. (14 Nm).
9. Install a new flange gasket and connect the
exhaust pipe. Tighten the mounting nuts to 32 ft. Ibs.
(44 Nm).
10. Connect the negative battery cable and check
for exhaust leaks.
3.OL Engines
) See Figures 72 and 73
Do not attempt the work on the exhaust sys-
tem until it has completely cooled.
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.
4. Lower the vehicle.
5. If removing the front manifold, remove con-
denser electric cooling fan assembly.
9315391; -ig. 82 Exhaust manifold exploded view-
!.OL (turbo) DOHC engine

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-

ENGINEANDENGINEOVERHAUL 3-55
8. Run a bead of sealer along any seams be-
tween the seal case and block. Install the seal case
with a new gasket.
9. Install the flywheel/driveplate and transaxle.
10. Connect the negative battery cable and check
for leaks.
11. Adjust oil level as necessary.
REMOVAL &INSTALLATION To lnstell:
7. Coat the threads of the driveplate/flywheel re-
taining bolts with thread locking compound.
8. Position the driveplatelflywheel on the crank-
shaft flange.
9. On automatic transaxle equipped models, in-
stall the driveplate adapter.
10. Install and tighten the bolts, in a alternating
star pattern, to the following specifications:
l 1.5L engine: 98 ft. Ibs. (135 Nm) l 1.6L, 2.01 and 2.4L engines: 94-101 ft.
Ibs. (130-140 Nm)
al drive plate and rear b See Figure 215
1. Disconnect the negative battery cable.
2. Remove the transaxle, as outlined in Section
7,
3. If equipped with a manual transaxle, remove
the clutch disc and pressure plate. Refer to Section 7.
4. Mark the position of the flywheel/driveplate
on the crankshaft and remove the retaining bolts.
5. On automatic transaxle equipped models, re-
move the driveplate adapter.
6. Remove the flywheel/driveplate from the en-
gine.
l 1.81 engine: 72 ft. Ibs. (100 Nm) l 3.OL and 3.5L engines: 53-56 ft. Ibs.
(72-76 Nm)
11. If equipped with a manual transaxle, install
the clutch and pressure plate.
12. Install the transaxle. Refer to Section 7.
13. Connect the negative battery cable.
healthy supply of penetrating oil and rags is
highly recommended.
Your vehicle must be raised and supported safely to the back of the vehicle. On dual exhaust systems,
remember to insoect both sides of the vehicle. Check
the complete exhaust system for open seams, holes
loose connections, or other deterioration which could + See Figures 216 thru 222
*Safety glasses should be worn at all times
when working on or near the exhaust system.
Older exhaust systems will almost always be
covered with loose rust particles which will
shower you when disturbed. These particles
are more than a nuisance and could injure
your eye. to inspect the exhaust system properly. Placing 4
safety stands under the vehicle for support should
provide enough room for you to slide under the vehi-
cle and inspect the system completely. Start the in-
spection at the exhaust manifold or turbocharger pipe
where the header pipe is attached and work your way
DO NOT perform exhaust repairs or inspec-
tion wtth the engine or exhaust hot. Allow thr
system to cool completely before attempting
any work. Exhaust systems are noted for
sharp edges, flaking metal and rusted bolts.
Gloves and eye protection are required. A
m3p73 Fig. 216 Cracks in the muffler are a guar-
anteed leak Fig 217 Check the muffler for rotted spot
Fig. 219 Cheek for overstretched or torn ex-
welds and seams
haust hangers
fm3p77 Fig. 216 Make sure the exhaust components
are not contacting the body or suspension
lcca3P78