fuel cap MITSUBISHI DIAMANTE 1900 Repair Manual

HOW TO USE THIS BOOK 1-2
WHERE TOBEGIN l-2
AVOIDINGTROUBLE 1-2
MAINTENANCEORREPAIR? 1-2
AVOIDINGTHEMOSTCOMMONMISTAKES l-2
TOOLS AND EQUIPMENT 1-2
SPECIALTOOLS l-4
YOUR VEHICLE SAFELY 1-4
DON'TS l-6
FASTENERS, MEASUREMENTS AND
CONVERSIONS l-6
BOLTS,NUTSANDOTHERTHREADED
RETAINERS 1-6
TORQUE l-7
TORQUEWRENCHES l-7
TORQUEANGLEMETERS 1-9
STANDARDANDMETRIC MEASUREMENTS l-9
SERIAL NUMBER IDENTIFICATION l-10
VEHICLE IDENTIFICATION NUMBER l-10
ENGINE IDENTIFICATION NUMBER I-10
TRANSAXLEIDENTIFICATION I-10
DRlVEAXLE(AWDGALANTONLY) l-10
TRANSFERCASE(AWDGALANTONLY) l-10
ROUTINE MAINTENANCE AND TUNE-UP l-14
AIRCLEANER(ELEMENT) 1-14
REMOVAL&INSTALLATION 1-14
FUELFILTER 1-15
REMOVAL &INSTALLATION l-15
PCVVALVE l-15
REMOVAL&INSTALLATION l-15
EVAPORATIVECANISTER l-16
SERVICING 1-16
BATTERY 1-16
PRECAUTIONS I-16
GENERALMAINTENANCE 1-16
BEL BATTERYFLUID 1-16
CABLES I-17
CHARGING I-18
REPLACEMENT 1-18
TS 1-18
INSPECTiON l-18
ADJUSTMENT 1-18
REMOVAL&INSTALLATION 1-18
TIMINGBELTS l-20
INSPECTION l-20
HOSES I-20
INSPECTION l-20
REMOVAL&INSTALLATION
CV-BOOTS 1-21
INSPECTION l-21
SPARKPLUGS l-22
SPARKPLUGHEATRANGE
REMOVAL&INSTALLATION
INSPECTION &GAPPING 1.
SPARKPLUG WIRES 1-24
TESTING 1-24
REMOVAL&INSTALLATION
DISTRIBUTORCAPANDROTOR
REMOVAL&INSTALLATION
INSPECTION 1-25
IGNITIONTIMING 1-25
. GENERALINFORAMTION l-
lNSPECTlON&ADJUSTMENl
VALVE LASH l-27
ADJUSTMENT l-27
IDLESPEED 1-28 1-21
l-22
l-22
-23
1-24
l-25
l-25
.25
1-26
AIR CONDITIONING SYSTEM 1-28
SYSTEMSERVlCEiiREPAlR l-28
PREVENTIVEMAINTENANCE 1-28
SYSTEM INSPECTION l-29
WINDSHIELD WIPERS l-29
ELEMENT(REFILL)CARE&
REPLACEMENT l-29
TIRESANDWHEELS l-30
TIRE ROTATION I-30
TIRE DESIGN 1-31
TIRESTORAGE l-31
INFLATION &INSPECTION l-31
CARE OFSPECIALWHEELS l-32 OPERATION INFOREIGNCOUNTRIES l-33
ENGINE l-33
OILLEVELCHECK 1-33
OIL& FILTER CHANGE l-34
MANUALTRANSAXLE l-35
FLUIDRECOMMENDATIONS l-35
LEVELCHECK l-35
DRAIN&REFILL l-36
AUTOMATICTRANSAXLE l-36
FLUIDRECOMMENDATIONS l-36
LEVELCHECK 1-36
DRAIN&REFILL l-36
PAN & FILTERSERVICE 1-36
TRANSFERCASE(AWDGAlANT ONLY) l-38
FLUIDRECOMMENDATIONS l-38
LEVELCHECK l-38
DRAIN&REFILL l-38
REARDRlVEAXLE(AWDGALANTONLY) l-38
FLUIDRECOMMENDATIONS l-38
LEVELCHECK l-38
DRAIN&REFILL l-38
COOLINGSYSTEM l-39
FLUIDRECOMMENDATIONS l-39
iM-41
FLUIDS AND LUBRICANTS 1-33
FLUID DISPOSAL 1-33
FlJELANDENGlNEOILRECOMMENDATlONS
ENGINE OIL l-33
FUEL l-33

UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL ENGINE
II
1. Power steering belt 7. PCV valve
2. Washer solvent bottle 8. Distributor cap and rotor
3. Power steering reservoir 9. Fuel filter (under air inlet tube)
4. Oil fill cap 10. Air filter housing
5. Brake master cylinder reservoir 11. Engine compartment fuse box
6. Spark plug and plug wire 12. Battery 13. Automatic transaxle fluid dipstick
14. Coolant recovery tank
15. Radiator cap
16. Engine oil dipstick

UNDERHOOD MAINTENANCE COMPONENT LOCATIONS-l .8L ENGINE
1. Coolant recovery tank
2. Battery
3. Engine compartment fuse box
4. Air filter housing
5. Clutch fluid reservoir
6. Brake master cylinder reservoir 7. Spark plug and plug wire
8. PCV valve
9. Engine oil fill cap
10. Fuel filter
11. Engine compartment relay center
12. Washer solvent bottle 13. Power steering reservoir
14. Power steering belt
15. Engine oil dipstick
16. Radiator cap

GENERALINFORMATIONAND MAlNTENANdE 1-25
osen the distributor cap retain-
Fig. 106. . . then remove the cap from the
distributor
Fig. 107 Grasp the rotor and pull it straight
off of the distributor shaft
REMOVAL &INSTALLATION
1. Disconnect the negative battery cable.
*Depending on the reason for removing the
distributor cap, it may make more sense to Fig. 108 The rotor must be aligned correctly
to the distributor shaft before installation
other physical damage. Make sure the distributor
cap’s center button is free of damage. Check the cap
terminals for dirt or corrosion. Always check the rotor
blade and spring closely for damage. Replace any
comoonents where damaae is found.
smmE
ALGNME
LOCATOR
b See Figures 105,106,107, and 108 GENERAL INFORMATION
b See Figures 111 and 112
Ignition timing is the measurement, in degrees of
crankshaft rotation, of the point at which the spark
plugs fire in each of the cylinders. It is measured in
degrees before or after Top Dead Center (TDC) of the
compression stroke.
Ideally, the air/fuel mixture in the cylinder will be
ignited by the spark plug just as the piston passes
I 1 COMBUSTION
ENDS 23’ ATDC
SPEED INCREASES
9ir&1$?6
Fig. 111 Advancing the ignition timing
’
CCURS
COMBUSTION
DC
ENDS 23 ATDC
3. Remove the distributor cap retaining screws or
clips and remove the cap from the distributor.
4. Note its installed position, then remove the ro-
tor from the distributor shaft. leave the spark plug wires attached. This is
handy if you are testing spark plug wires, or
if removal is necessary to access other com-
ponents, and wire length allows you to repo-
sition the cap out of the way.
2. Label and disconnect the spark plug wires
from the distributor cao.
5. The installation is the reverse of the removal.
INSPECTION
u See Figures 109 and 110
9mg27
After removing the distributor cap and rotor, clean
the components (both inside and outside of the cap)
using soap and water. If compressed air is available,
carefully dry the components (wearing safety gog-
gles) or allow the parts to air dry. You can dry them
with a clean, soft cloth, but don’t leave any lint or
moisture behind.
Once the cap and rotor have been thoroughly Inspection points for the dis Fig. 112 Retarding the tgnttion timing
cleaned, check for cracks, carbon tracks, burns or

l-28 GENERALINFORMATIONAND MAINTENANCE
may result in skin or eye irritation or frostbite. Al- formed to help maintain the efficiency of the vehicle’s
though low in toxicity (due to chemical stability), in- A/C system. For preventive maintenance, perform the
The idle speed is factory set and usually no ad- halation of concentrated refrigerant fumes is danger- following:
justments are ever necessary. If an adjustment be- ous and can result in death; cases of fatal cardiac
l The easiest and most important preventive
comes necessary, first check that the spark plugs, in- arrhythmia have been reported in people accidentally maintenance for your A/C system is to be sure that it
jectors, idle air control servo and compression subjected to high levels of refrigerant. Some early is used on a regular basis. Running the system for
pressure are all normal. symptoms include loss of concentration and drowsi- five minutes each month (no matter what the season)
Data from various sensors and switches are used ness. + will help ensure that the seals and all internal compo-
by the ECU to determine the proper fuel/air mixture
for optimal engine performance. cGeneraiiy, the limit for exposure is lower nents remain lubricated.
for R-134a than it is for R-12. Exceptional *Some newer vehicles automatically oper-
care must be practiced when handling R- ate the A/C system compressor whenever the
134a. windshield defroster is activated. When run-
Also, refrigerants can decompose at high tempera- ning, the compressor lubricates the A/C sys
tures (near gas heaters or open flame), which may re- tern components; therefore, the A/C system
SYSTEM SERVICE& REPAIR suit in hydrofluoric acid, hydrochloric acid and phos- would not need to be operated each month.
gene (a fatal nerve gas). * In order to prevent heater core freeze-up during
R-12 refrigerant can damage the environment be- A/C operation, it is necessary to maintain proper an-
cause it is a Chlorofluorocarbon (CFC), which has tifreeze protection. Use a hand-held coolant tester
been proven to add to ozone layer depletion, leading (hydrometer) to periodically check the condition of
to increasing levels of UV radiation. UV radiation has the antifreeze in your engine’s cooling system.
been linked with an increase in skin cancer, suppres-
sion of the human immune system, an increase in *Antifreeze should not be used longer than
cataracts, damage to crops, damage to aquatic organ- the manufacturer specifies.
isms, an increase in ground-level ozone, and in- . For efficient operation of an air conditioned ve-
creased global warming. hicle’s cooling system, the radiator cap should have a
R-134a refrigerant is a greenhouse gas which, if holding pressure which meets manufacturers specifi-
allowed to vent into the atmosphere, will contribute to cations. A cap which fails to hold these pressures
global warming (the Greenhouse Effect). should be replaced.
It is usually more economically feasible to have a
l Any obstruction of or damage to the condenser
certified MVAC automotive technician perform A/C configuration will restrict air flow which is essential
system service on your vehicle. Some possible rea- to its efficient operation. It is, therefore, a good rule
sons for this are as follows: to keep this unit clean and in proper physical shape.
l While it is illegal to service an A/C system
without the proper equipment, the home mechanic ti See Figure 122
*it is recommended that the A/C svstem be
serviced by an EPA Section 609 cehified au-
tomotivetechnicfan utilizing a refrigerant re-
covery/recycling machfne.
The do-it-yourselfer should not service his/her
own vehicle’s A/C system for many reasons, includ-
ing legal concerns, personal injury, environmental
damage and cost. The following are some of the rea-
sons why you may decide not to service your own ve-
hicle’s A/C system.
According to the U.S. Clean Air Act, it is a federal
crime to service or repair (involving the refrigerant) a
Motor Vehicle Air Conditioning (MVAC) system for
money without being EPA certified. It is also illegal to
vent R-12 and R-134a refrigerants into the atmos-
phere. Selling or distributing A/C system refrigerant
(in a container which contains less than 20 pounds oi
refrigerant) to any person who is not EPA 609 certi-
fied is also not allowed by law.
State and/or local laws may be more strict than the
federal regulations, so be sure to check with your
state and/or local authorities for further information.
For further federal information on the legality of ser-
vicing your AK system, call the EPA Stratospheric
Ozone Hotline.
*Federal law dictates that a fine of up to
$25,000 may be levied on people convicted
of venting refrigerant into the atmosphere.
Additionally, the EPA may pay up to $10,000
for information or services leading to a crimf
nai conviction of the violation of these laws.
When servicing an A/C system you run the risk of
handling or coming in contact with refrigerant, which
Fig. 122 A label with information concern-
ing the A/C system is typically located in the
engine compartment
f would haveto purchase an expensive refrigerant re-
covery/recycling machine to service his/her own ve-
hicle.
l Since only a certified person may purchase re-
frigerant-according to the Clean Air Act, there are
specific restrictions on selling or distributing A/C
system refrigerant-it is legally impossible (unless
certified) for the home mechanic to service his/her
own vehicle. Procuring refrigerant in an illegal fash-
ion exposes one to the risk of paying a $25,000 fine
to the EPA.
R-12 Refrigerant Conversion
If your vehicle still uses R-12 refrigerant, one
way to save A/C system costs down the road is to invesh-
gate the possibility of having your system converted
to R-134a. The older R-12 systems can be easily
converted to R-134a refrigerant by a certified auto-
motive technician by installing a few new compo-
nents and changing the system oil.
The cost of R-12 is steadily rising and will con-
tinue to increase, because it is no longer imported or
manufactured in the United States. Therefore, it is of-
ten possible to have an R-12 system converted to R-
134a and recharged for less than it would cost to just
charge the system with R-12.
If you are interested in having your system con-
verted, contact local automotive service stations for
more details and information.
u See Figures 123 and 124
Although the A/C system should not be serviced
by the do-it-yourselfer, preventive maintenance can
be practiced and A/C system inspections can be per- Fig. 123 A coolant tester can be used to de-
1 termine the freezing and boiling levels of
the coolant in your vehicle
Fig. 124 To ensure efficient cooling system
operation, inspect the radiator cap gasket
and seal

.
l-34 GENERALINFORMATIONAND MAINTENANCE
Engine oil level should be checked every time you
put fuel in the vehicle or are under the hood perform- miles of highway driving. Fluid which is warmed to
normal operating temperature will flow faster, drain
ing other maintenance.
1. Park the vehicle on a level surface.
2. The enaine mav be either hot or cold when
, if it is hot, wait a few min- checking oil level. The EPA warns that prolonged contact with
used engine oil may cause a num’ * * *
dianrAnrr inrldinn ranrnrl V#lll more completely and remove more contaminants
frnm tho clnnine
utes after the engine has been turned OFF to allow the
oil to drain back into the crankcase. If the engine is
cold, do not start it before checking the oil level. point on the oil pan. If not, you may have to raise the
vehicle slightly higher on one jackstand (side) than
3. Open the hood and locate the engine oil dip-
stick. Pull the dipstick from its tube, wipe it clean,
and reinsert it. Make sure the diDstick is fullv in-
serted.
4. Pull the dipstick from its tube again. Holding it to used engin
be worn whet
handsandan
so*m ..#a . . . . .
IDer 01 SKlll u,yu,u=,+, ,,,u,uu,,,u uu,,u=, i , vu should
uff art to minimize your exposure
le oil. Protective gloves should
1 changing the oil. Wash your
y other exposed skin areas as
111 aJ vv4ble after exposure to used en-
m nil St-mn mwl w&or nr umtarlncr hand gin Y “II. ““up “ll” .,U.“I, “rn W.Y.“. .““I .I....” cleaner should be used.
horizontally, read the oil level. The oilshould be be-
tween the MIN and MAX marks or the notches on the
dipstick. If the oil is below the MIN mark or lower
notch, add oil of the proper viscosity through the
capped opening of the valve cover. *The engine oil and oil filter should be
changed at the recommended intervals on
the Maintenance Chart. Though some manu-
facturers have at times recommended chang-
ing the filter only at every other oil change, ’
Chilton recommends that you always change
ll”,,, Cl>” ““y”‘“. 1. Raise and support the vehicle safely on jack-
stands. Make sure the oil drain olua is at the lowest
the other.
2. Before you crawl under the vehicle, take a look
at where you will be working and gather all the nec-
essary tools, such as a few wrenches or a ratchet and
strip of sockets, the drain pan, some clean rags and,
if the oil filter is more accessible from underneath the
vehicle, you will also want to grab a bottle of oil, the
new filter and a filter wrench at this time.
5. Reolace the diostick. and check the level aaain
. The benefit of fresh oil
p See Figures 152 thru 153
The oil and filter should be changed every 7,500
miles (12,000 km) under normal service and every
3,000 miles (5,000 km) under severe service.
93151p-55 Fig. 152 loosen the drain plug on the en-
a wrench. The drain plug’s 3. Position the drain pan beneath the oil pan
drain plug. Keep in mind that the fast flowing oil,
which will spill out as you pull the plug from the pan,
will flow with enough force that it could miss the pan.
Position the drain pan accordingly and be ready to
move the pan more directly beneath the plug as the
oil flow lessens to a trickle.
4. Loosen the drain ~lua with a wrench (or socket
and driver), then carefuliy unscrew the plug with your
fingers. Use a rag to shield your fingers from the
heat. Push in on the plug as you unscrew it so you
draining the oil, make sure that the engine is at oper- can feel when all of the screw threads are out of the
ating temperature. Hot oil will hold more impurities hole (and so you will keep the oil from seeping past
in suspension and will flow better, allowing the re- the threads until you are ready to remove the plug).
moval of more oil and dirt. You can then remove the plug quickly to avoid hav-
It is a good idea to warm the engine oil first so it ing hot oil run down your arm. This will also help as-
will flow better. This can be accomolished bv 15-20 sure that have the plug in your hand, not in the bot-
tom of a pan of hot oil.
Fig. 153 When loosened sufficiently, slowly
turn the drain plug by hand, keeping con- Fig. 154 When you are ready, carefully pull
Fig. 156 Also inspect the drain plug th
before installing it back into the oil
Fig. 155 Clean and inspect the threads on
the oil pan Make sure the gasket on the drain plug is
in place and does not require replacement Fig. 157 A plier-type filter wrench Is used
here to loosen the filter

ENGlNEELECTRliAL 2-5
Fig. 19 Adjusting the distributor-1.5L en-
gine shown, others similar
4. Install the hold-down nut.
5. Attach the distributor harness connectors.
6. Install the distributor cap.
7. Connect the negative battery cable.
8. Adjust the ignition timing and tighten the hold-
down nut to 8 ft. Ibs. (11 Nm).
For procedures on the position sensors, please re-
fer to Section 4 in this manual.
The ignition system found on the 1.6L, 1997-60
1.8L, 2.OL DOHC, 1999-00 2.4L SOHC, 2.4L DOHC,
and 3.OL DOHC engines is a distributorless type.
The advance of this system, like the distributor type
ignition, is controlled by the Engine Control Unit
(ECU) or Powertrain Control Module (PCM). The
distributorless ignition system contains a crank an-
gle/position sensor which detects the crank angle or
position to each cylinder and converts this data into
pulse signals. These signals are sent to the
ECLVPCM, which calculates the engine rpm and
regulates the fuel injection and ignition timing ac-
cordingly. The system also contains a top dead cen-
ter sensor which detects the top dead center position
of each cylinder and converts this data into pulse
signals. These signals are then sent to the
ECU/PCM, which calculates the sequence of fuel in-
jection and engine rpm.
When the ignition switch is turned ON, battery
voltage is applied to the ignition coil primary wind-
ing. As the crank angle sensor shaft rotates, ignition
signals are transmitted from the multi port injection
control unit to the power transistor. These signals
activate the power transistor to cause ignition coil
primary winding current to flow from the ignition
coil negative terminal through the power transistor
to ground or be interrupted, repeatedly. This action
induces high voltage in the secondary winding of
the ignition coil. From the ignitron coil, the sec-
ondary winding current produced flows through the
spark plug to ground, thus causing ignition in each
cylinder.
Refer to Diagnosis and Testing under Distributor
Ignition in this section,
There are no adjustments to the distributorless ig-
nition system other than the ignition timing adjust-
ment. Refer to section 1 for ignition timing adjust-
ment.
TESTING
1.6L and 1990 2.OL DOHC Engines
6 See Figures 21 and 22
1. Disconnect the negative battery cable and igni-
tion coil harness connector.
2. Measure the primary coil resistance as follows:
a. Measure the resistance between terminals
of the coil pack,
NOT THE WIRE HARNESS, between 4 and 2 (coils at the No. 1 and No. 4
cylinder srdes) of the ignition coil, and between
terminals 4 and
1 (coils at the No. 2 and No. 3
cylinder sides).
93152go9 Fig. 21 Measuring ignition coil primary re-
sistance-1.6L and 1990 2.OL DDHC en-
gines
.
For No 1 and No. 4
cvlmders
Fig. 22 Measuring ignition coil secondary
resistance-l .6L and 1990 2.OL DOHC en-
gines
b. Compare reading to the desrred primary
coil resistance of 0.77-0.95 ohms.
3. Measure the coil secondary resistance as fol-
lows:
c. Detach the connector from the ignition coil.
d. Measure the resistance between the high-
voltage terminals for the No. 1 and No. 4 cylin-
ders, and between the high-voltage terminals for
the No. 2 and No. 3 cylinders.
e. Compare the measured resistance to the
desired secondary coil resistance of 10.3-13.9
kilo-ohms.
4. If the readings are not within the specified
value, replace the ignition coil.
1991-!I3 2.OL DDHC Engines
# See Figures 23 and 24
n 0
Fig. 23 Measuring the primary ignition coil
resistance-1991-93 2.OL DOHC enoines
I I
FOR NO 1 AND NO. 4 CYLINDERS
Id
FOR NO. 2 AND NO. 3 CYUNDERS
89572611
Fig. 24 Measuring ignition coil secondary
resistance-1991-93 2.OL DOHC engines

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 3-25
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.