tire type MITSUBISHI DIAMANTE 1900 Repair Manual

GENERALINFORMATIONAND MAINTENANCE l-21
IWSIZXJ FM. 83 A hose clamn that is taa tiaht can
Fig. 82 The cracks developing along this
hose are a result of age-related hardening caise older hoses td separate and ‘iear on
either side of the clamp
lCCS1221 Fig. 84 A soft spongy hose (identifiable by
1 the swollen section) will eventually burst
and should be replaced
IEMOVAL &,INSTALLATION '
1. Remove the radiator pressure cap. her of the sorina tension tvoe (which reouire oliers
3 squeeze the 6bs and loosenj or of the’screw ten-
ion type (which require screw or hex drivers to
oosen). Pull the clamps back on the hose away from
he connection. Never remove the pressure cap while the en-
gine is running, or personal injury from
scalding hot coolant or steam may result. If
possible, wait until the engine has cooled to
remove the pressure cap. If this is not possi-
ble, wrap a thick cloth around the pressure
cap and turn it slowly to the stop. Step back
while the pressure is released from the cool-
ing system. When you are sure all the pres-
sure has been released, use the cloth to turn
and remove the cao.
2. Position a clean container under the radiator
and/or engine draincock or plug, then open the drain
and allow the cooling system to drain to an appropri-
ate level. For some upper hoses, only a little coolant
must be drained. To remove hoses positioned lower
on the engine, such as a lower radiator hose, the en-
tire cooling system must be emptied.
When draining coolant, keep in mind that
cats and dogs are attracted by ethylene gly-
col antifreeze, and are quite likely to drink
any that is left in an uncovered container or
in puddles on the ground. This will prove fa-
tal in sufficient quantity. Always drain
coolant into a sealable container. Coolant
may be reused unless it is contaminated or
several years old. 9. Close the radiator or engine drains and prop-
erly refill the cooling system with the clean drained
engine coolant or a suitable mixture of ethylene gly-
cot coolant and water.
10. If available, install a pressure tester and check
for leaks. If a pressure tester is not available, run the
engine until normal operating temperature is reached
(allowing the system to naturally pressurize), then
check for leaks.
If you are checking for leaks with the system
at normal operating temperature, BE EX-
TREMELY CAREFUL not to touch any moving
or hot engine parts. Once temperature has
been reached. shut the enaine OFF. and
Fig. 85 Hoses are likely to deteriorate from
the inside if the cooling system is not peri-
odically flushed check for leaks around the-hose fittings and
connections which were removed earlier.
INSPECTION
b See Figures 88 and 87
The CV (Constant Velocity) boots should be
checked for damage each time the oil is changed and
any other time the vehicle is raised for service. These
boots keep water, grime, dirt and other damaging
matter from entering the CV-joints. Any of these
could cause early CV-joint failure which can be ex-
pensive to repair. Heavy grease thrown around the in-
side of the front wheel(s) and on the brake
caliper/drum can be an indication of a torn boot.
Thorouahlv check the boots for missina clamos and 3. Loosen the hose clamps at each end of the
rose requiring replacement. Clamps are usually ei-
4. Twist, pull and slide the hose off the fitting,
sking care not to damage the neck of the component
rom which the hose is being removed.
*If the hose is stuck at the connection, do
lot try to insert a screwdriver or other sharp
ool under the hose end in an eff art to free it,
IS the connection and/or hose may become
lamaged. Heater connections especially
nay be easily damaged by such a procedure.
f the hose is to be replaced, use a single-
!dged razor blade to make a slice along the
lortion of the hose which is stuck on the con-
section, perpendicular to the end of the
lose. 00 not cut deep so as to prevent dam-
aging the connection. The hose can then be
keeled from the connection and discarded. Fig. 86 CV-boots must be inspected period-
5.. Clean both hose mounting connections. In-
,pect the condition of the hose clamps and replace
hem, if necessary.
To install:
6. Dip the ends of the new hose into clean en-
fine coolant to ease installation.
7. Slide the clamps over the replacement hose,
hen slide the hose ends over the connections into
rosition.
8. Position and secure the clamps at least l/d in.
6.35mm) from the ends of the hose. Make sure they
Ire located beyond the raised bead of the connector.

.
l-30 GENERAL'INFORMATIONAND MAINTENANCE
n Pylon@ inserts, the clip
be removed prior to siidi then the insert can be re
After installing the replacement
strip and pull up while twisting counterclockwise.
The backing strip will snap out of the retaining tab.
Do this for the remaining tabs until the refill is free of
the blade. The length of these refills is molded into
the end and they should be replaced with identical
types. cate the front end is out of alignment or that the tires
are out of balance.
TIRE ROTATION
# See Figures 137 and 138
Tires must be rotated periodically to equalize wear
patterns that vary with a tire’s position on the vehicle.
Tires will also wear in an uneven way as the front
1 Fin 1% Tha Trinlarlna@
cle might have any kind. Aftermarket blades and arms
rarely use the exact same type blade or refill as the
original equipment. Here are some typiel aftermarket
blades; not all may be available for your vehicle:
The Anco@ type uses a release button that is
pushed down to allow the refill to slide out of the
yoke jaws. The new refill slides back into the frame
,
and locks in place.
Some Trico@ refills are removed by locating where
the metal backing strip or the refill is wider. Insert a
small screwdriver blade between the frame and metal
backing strip. Press down to release the refill from
the retaining tab.
Other types of Trico@’ refills have two metal tabs
which are unlocked by squeezing them together. The
rubber filler can then be withdrawn from the frame
iaws. A new refill is installed bv insertina the refill lowed to touch the olass steering/suspension system wears to the point where
the alianment should be reset.
# See Figure 138
Common sense and good driving habits will af-
ford maximum tire life. Fast starts, sudden stops
and hard cornering are hard on tires and will
shorten their useful life span. Make sure that you
don’t overload the vehicle or run with incorrect
pressure in the tires. Both of these practices will in-
crease tread wear.
*For optimum tire life, keep the fires prop
eriy inflated, rotate them often and have the
wheel alignment checked periodically.
Inspect your tires frequently. Be especially care-
ful to watch for bubbles in the tread or sidewall,
deep cuts or underinflation. Replace any tires with
bubbles in the sidewall. If cuts are so deep that they
penetrate to the cords, discard the tire. Any cut in
the sidewall of a radial tire renders it unsafe. Also
look for uneven tread wear patterns that may indi- Rotating the tires will ensure maximum life for the
tires as a set, so you will not have to discard a tire
early due to wear on only part of the tread. Regular
DIRECTIONAL TIRES DIRECTIONAL TIRES
jnto the front frame jaws and &ding it rearward to
engage the remaining frame jaws. There are usually
four jaws; be certain when installing that the refill is
engaged in all of them. At the end of its travel, the
tabs will lock into place on the front jaws of the wiper
blade frame.
Another type of refill is made from polycarbonate.
The refill has a simple locking device at one end
which flexes downward out of the groove into which
the jaws of the holder fit, allowing easy release. By
sliding the new refill through all the jaws and push-
ing through the slight resistance when it reaches the
end of its travel, the refill will lock into position.
To replace the Tridon@ refill, it is necessary to re-
move the wiper blade. This refill has a plastic backing
strip with a notch about 1 in. (25mm) from the end.
Hold the blade (frame) on a hard surface so that the
frame is tightly bowed. Grip the tip of the backing Fig. 138 A label with information concern-
ing the tires is typically located on one of
the door pillars
tion”

GENERALINFORMATIONAND MAlNTENANdE 1-31
When rotating “unidirectional tires,” make sure
that they always roll in the same direction. This
means that a tire used on the left side of the vehicle
must not be switched to the right side and vice-versa.
Such tires should only be rotated front-to-rear or
rear-to-front, while always remaining on the same
side of the vehicle. These tires are marked on the
sidewall as to the direction of rotation; observe the
marks when reinstalling the tire(s).
Some styled or “mag” wheels may have different
offsets front to rear. In these cases, the rear wheels
must not be used up front and vice-versa. Further-
more, if these wheels are equipped with unidirectional
tires, they cannot be rotated unless the tire is re-
mounted for the proper direction of rotation.
*The compact or space-saver spare is
strictly for emergency use. it must never be
included in the tire rotation or placed on the
vehicle for everyday use. check the installed tire for any sign of interference
with the body or suspension while the vehicle is stop-
ping, turning sharply or heavily loaded.
Snow Tires
Good radial tires can produce a big advantage in
slippery weather, but in snow, a street radial tire does
not have sufficient tread to provide traction and con-
trol. The small grooves of a street tire quickly pack
with snow and the tire behaves like a billiard ball on a
marble floor, The more open, chunky tread of a snow
tire will self-clean as the tire turns, providing much
better grip on snowy surfaces.
To satisfy municipalities requiring snow tires dur-
ing weather emergencies, most snow tires carry either
an M + S designation after the tire size stamped on
the sidewall, or the designation “all-season.” In gen-
eral, no change in tire size is necessary when buying
snow tires.
Most manufacturers stronqlv recommend the use styled wheels, see if inexpensive steel
wheels are available, Although the look of
the vehicle will change, the expensive
wheels will be protected from salt, curb hits
and pothole damage.
TIRESTORAGE
If they are mounted on wheels, store the tires at
proper inflation pressure. All tires should be kept in a
cool, dry place. If they are stored in the garage or
basement, do not let them stand on a concrete floor;
set them on strips of wood, a mat or a large stack of
newspaper. Keeping them away from direct moisture
is of paramount importance. Tires should not be
stored upright, but in a flat position.
INFLATION & INSPECTION
b See Figures 140 thru 147
TIRE DESIGN
p See Figure 139
for maximum satisfaction, tires should be used in
sets of four. Mixing of different types (radial, bias-
belted, fiberglass belted) must be avoided. In most
cases, the vehicle manufacturer has designated a
type of tire on which the vehicle will perform best.
Your first choice when replacing tires should be to
use the same type of tire that the manufacturer rec-
ommends.
When radial tires are used, tire sizes and wheel di-
ameters should be selected to maintain ground clear-
ante and tire load caoacitv eauivalent to the oriainal
specified tire. Radial tiresshould always be used in
sets of four. of 4 snow tires on their
lehicies for reasons of stabil-
ity. If snow tires are fitter
1 only to the drive wheels, the
opposite end of the vehil cle may become very unsta-
ble when braking or turn
ring on slippery surfaces.
This instability can lead to unpleasant endings if the
A*:,,“- r-..l, ^_.. ..& ^_^^, &I.
UIIVU MII I LUUII~~MLL iue slide in time.
Note that snow tires, whether 2 or 4, will affect ve-
hicle handling in all non-snow situations. The stiffer,
heavier snow tires will noticeably change the turning
and braking characteristics of the vehicle. Once the
snow tires are installed, you must re-learn the behav-
ior of the vehicle and drive accordingly.
*Consider buying extra wheels on which to
mount the snow tires. Once done, the “snow
iheeis” can be installed and removed as
needed. This eliminates the potential
dam- age to tires or wheels from seasonal removal
and installation. Even if your vehicle has
lb The importance of proper tire inflation cannot be
overemphasized. A tire employs air as part of its
structure. It is designed around the supporting
strength of the air at a specified pressure. For this
reason, improper inflation drastically reduces the
tire’s ability to perform as intended. A tire will lose
some air in day-to-day use; having to add a few
pounds of air periodically is not necessarily a sign of
a leaking tire.
Two items should be a permanent fixture in every
glove compartment: an accurate tire pressure gauge
and a tread depth gauge. Check the tire pressure (in-
eluding the spare) regularly with a pocket type gauge.
Too often, the gauge on the end of the air hose at
vnr rr corner narane is not accurate because it suffers
~rs check tire oressure when the
Radial tires should never be used on only the
XI I._.
‘-’ --“‘“’ J s too much abuse. Alwa!
tires are cold, as pressure increases with tempera-
ture. If you must move the vehicle to check the tire
front axle.
When selecting tires, pay attention to the original
size as marked on the tire. Most tires are described
using an industry size code sometimes referred to as
P-Metric. This allows the exact identification of the
tire specifications, regardless of the manufacturer. If
selecting a different tire size or brand, remember to
METRIC TIRE SIZES
(MILLIMETERS)
145 CDNStRUCtlDN l-6-E
R - RADIAL
D
WA9
Fig. 139 P-Metric tire coding Fig. 140 Tires should be checked frequently
I I Fig. 141 Tires with deep cuts, or cuts which
for any sion of auncture or damaoe
buioe, should be replaced immediately
l DRIVE WHEEL HEAW
ACCELERATION
l OVERINFLATION
*LACK OF ROTATION
Fig. 142 Examples of inflation-related tire
RADIAL TIRE
fig. 143 Radial tires have a characteristic
sidewall bulge; don’t try to measure pres-
sure by looking at the tire. Use a quality air
pressure gauge

.
1-32 GENERALINFORMATIONAND MAINTENANCE
CONDITION
EFFECT
CAUSE
CORRECTION UNDER-INFLATION
EXCESSIVE SPEED’ WORN OR OUT-
OF-ALIGNMENT
ADJUST PRESSURE TO
SPECIFICATIONS WHEN
TIRES ARE COOL
ROTATE TIRES
/ BALANCE WHEELS INSPECT SUSPENSION
HAVE TIRE INSPECTED FOR FURTHER USE.
lCCSi267 ig. 144 Common tire wear patterns and causes
1~~~1265 Fig. 145 Tread wear indicators will appear
when the tire is worn
inflation, do not drive more than a mile before check-
ing. A cold tire is generally one that has not been dri-
ven for more than three hours.
A plate or sticker is normally provided somewhere
in the vehicle (door post, hood, tailgate or trunk lid)
which shows the proper pressure for the tires. Never
counteract excessive pressure build-up by bleeding
off air pressure (letting some air out). This will cause
the tire to run hotter and wear quicker.
Never exceed the maximum tire pressure
embossed on the tire! This is the pressure to
be used when the tire is at maximum load-
ing, but it is rarely the correct pressure for
everyday driving. Consult the owner’s man-
ual or the tire pressure sticker for the correct
tire pressure.
Once you’ve maintained the correct tire pressures
for several weeks, you’ll be familiar with the vehicle’s
braking and handling personality. Slight adjustments
in tire pressures can fine-tune these characteristics,
1~~~1264 Fig. 146 Accurate tread depth indicators are
inexuensive and handv
Fig. 147 A penny works well for a quick
check of tread death
but never change the cold pressure specification by
more than 2 psi. A slightly softer tire pressure will
give a softer ride but also yield lower fuel mileage. A
slightly harder tire will give crisper dry road handling
but can cause skidding on wet surfaces. Unless
you’re fully attuned to the vehicle, stick to the recom-
mended inflation pressures.
All tires made since 1968 have built-in tread wear
indicator bars that show up as j/2 in. (13mm) wide
smooth bands across the bre when V,~ in. (1.5mm) of
tread remains. The appearance of tread wear indica-
tors means that the tires should be replaced. In fact,
many states have laws prohibiting the use of tires
with less than this amount of tread.
You can check your own tread depth with an inex-
pensive gauge or by using a Lincoln head penny.
Shp the Lrncoln penny (with Lincoln’s head upside- down) into several tread grooves. If you can see the
top of Lincoln’s head in 2 adjacent grooves, the tire
has less than V,~ in. (1.5mm) tread left and should be
replaced. You can measure snow tires in the same
manner by using the “tails” side of the Lincoln
penny. If you can see the top of the Lincoln memor-
ial, its time to replace the snow tire(s).
CAREOFSPECIALWHEELS
If you have invested money in magnesium, alu-
minum alloy or sport wheels, special precautions
should be taken to make sure your investment is not
wasted and that your special wheels look good for the
life of the vehicle.
Special wheels are easily damaged and/or
scratched. Occasionally check the rims for cracking,
impact damage or air leaks. If any of these are found,
replace the wheel. But in order to prevent this type of
damage and the costly replacement of a special
wheel, observe the following precautions:
l Use extra care not to damage the wheels dur-
ing removal, installation, balancing, etc. After re-
moval of the wheels from the vehicle, place them on a
mat or other protective surface. If they are to be
stored for any length of time, support them on strips
of wood. Never store tires and wheels upright; the
tread may develop flat spots.
l When driving, watch for hazards; it doesn’t take
much to crack a wheel.
l When washing, use a mild soap or non-abra-
sive dish detergent (keeping in mind that detergent
tends to remove wax). Avoid cleansers with abrasives
or the use of hard brushes. There are many cleaners
and polishes for special wheels.
l If possrble, remove the wheels during the win-
ter. Salt and sand used for snow removal can se-
verely damage the finish of a wheel.
l Make certain the recommended lug nut torque
is never exceeded or the wheel may crack. Never use
snow chains on special wheels; severe scratching
will occur.

GENERALINFORMATIONAND MAINTENANCE l-35
Fig. 158 When the filter is sufficiently loos-
Fig. 181 Before installing a new oil filter,
clean the gasket mounting surface of the oil
filter housing and inspect the threads Fig. 182 Loosen and remove the oil filler
cap . . .
surface. When you tighten the filter, rotate it about a
quarter-turn after it contacts the mounting boss (or Fig. 183 . , , then insert a funnel, and pour
oil directly into the engine
follow any instructions
which are provided on the fil-
ter or parts box).
Operating the engine without the proper
amount and type of engine oil will result In
severe engtne damage. FLUID RECOMMENDATIONS
For all vehicles with manual transaxles, use Hy-
poid gear oil SAE 75W-85W, or 75W-9OW conform-
ing to API specifications GL-4 or higher.
LEVELCHECK Be careful of the oil; when at operating tem-
perature, it is hot enough to cause a severe
bum.
5. Allow the oil to drain until nothing but a few
drops come out of the drain hole. Check the drain
plug to make sure the threads and sealing surface are
not damaged. Carefully thread the plug into position
and tighten it snug, and give a slight additional turn.
You don’t want the plug to fall out (as you would
quickly become stranded), but the pan threads are
EASILY stripped from overtightening (and this can be
time consuming and/or costly to fix).
6. To remove the filter, you may need an oil filter
wrench since the filter may have been fitted too
tightly and/or the heat from the engine may have
made it even tighter. A filter wrench can be obtained
at any auto parts store and is well-worth the invest-
ment. Loosen the filter with the filter wrench. With a
rag wrapped around the filter, unscrew the filter from
the boss on the side of the engine. Be careful of hot
oil that will run down the side of the filter. Make sure
that your drain pan is under the filter before you start
to remove it from the engine; should some of the hot
oil happen to get on you, there will be a place to
dump the filter in a hurry and the filter will usually
spill a good bit of dirty oil as it is removed.
7. Wipe the base of the mounting boss with a
clean, dry cloth. When you install the new filter,
smear a small amount of fresh oil on the gasket with
your finger, just enough to coat the entire contact 8. Remove the jackstands and carefully lower the
vehicle, then IMMEDIATELY refill the engine
crankcase with the proper amount of oil. DO NOT
WAIT TO DO THIS because if you forget and some-
one tries to start the vehicle, severe engine damage
will occur.
9. Refill the engine crankcase slowly, checking
the level oflen, you may r..‘:-- U.-1 :L ..-..” II.. .-L-e
lVL,VY II,UL II UUUU,,J ,“,\U.J
less than the amount of oil listed in the capacity chart
to refill the crankcase. But, that is only until the en-
gine is run and the oil filter is filled with oil. To make
sure the proper level is obtained, run the engine to
normal operating temperature, shut the engine OFF,
allow the oil to drain back into the oil pan, and
recheck the level. Top off the oil at this time to the fill
mark.
*If the vehicle Is not resting on level
ground, the oil level reading on the dipstick
may be slightly off. Be sure to check the level
only when the vehicle is sitting level.
10. Drain your used oil in a suitable container for
recycling. b See Flgures 184 and 185
Inspect each component for leaking. Check the oil
level by removing the filler plug. If the oil is contami-
nated, it is necessary to replace it with new oil. Check
the oil level as follows:
89571gM Fig. 164 Typtcal manual transaxle drain and
filler plug location

GENERALINFORMATIONAND MAINTENANCE 1-45
SLING TYPE
WHEEL LIFT TYPE
cles
SUNG TYPE
WHEEL LIFT TYPE
FLAT BED TYPE
Fig. 220 Rear towing position-FWD vehi
cles
personal injury. Remember that batteries contain a
small amount of explosive hydrogen gas which is a
by-product of battery charging. Sparks should always
be avoided when working around batteries, especially
when attaching jumper cables. To minimize the pos-
sibility of accidental sparks, follow the procedure
carefully.
NEVER hook the batteries up in a series cir-
cuit or the entire electrical system will go up
in smoke. includino the starter!
Vehicles equipped with a diesel engine may utilize
two 12 volt batteries. If so, the batteries are con-
nected in a parallel circuit (positive terminal to posi-
tive terminal, negative terminal to negative terminal).
owrng methods
a tow truck IS used
Lrftrng method for 4 wheels-Good
Front wheels lifted-No good
Front wheels lifted-No good
Rear wheels lifted-No good
Towing by rope or cable-Good
e9571g92 qemarks
. For4WD models, the basic principle is that
all four wheels are to be rarsed before
towing.
. The shift lever should be set to 1 st gear and
the parking brake should be applied.
l The vehicle must not be towed by tofacing
only its front wheels or only the rear wheels
on a rollino dollv, because to do so will
result in d&e&ration of the visfx~s
coupling and result in the viscous coupling
causing the vehicle to jump forward
suddenly.
l If only the front wheels or only the rear
wheels are lifted for towing, the bumper
wrll bedamyd.
In addrtron. II trng of the rear wheels causes
the or1 to flow forward. and may result in
heat damage to the rear bushing of the
transfer, and so should never be done.
l The front and rear wheels must rotate
normally.
l The various mechanisms must function
normally.
l The shift lever must be set to the neutral
~Asi&n and the ignition key must be set to
Fig. 221 Towing instructions-AWD models
Hooking the batteries up in parallel circuit increases
battery cranking power without increasing total bat-
tery voltage output. Output remains at 12 volts. On
the other hand, hooking two 12 volt batteries up in a
series circuit (positive terminal to negative terminal,
positive terminal to negative terminal) increases total
battery output to 24 volts (12 volts plus 12 volts).
l Be sure that both batteries are of the same volt-
age. Vehicles covered by this manual and most vehi-
cles on the road today utilize a 12 volt charging sys-
tem.
l Be sure that both batteries are of the same po-
larity (have the same terminal, in most cases NEGA-
TIVE grounded).
l Be sure that the vehicles are not touching or a
short could occur.
l On serviceable batteries, be sure the vent cap
holes are not obstructed.
l Do not smoke or allow sparks anywhere near
the batteries.
l In cold weather, make sure the battery elec-
trolyte is not frozen, This can occur more readily in a
battery that has been in a state of discharge.
l Do not allow electrolyte to contact your skin or
clothing.
1. Make sure that the voltages of the 2 batteries
are the same. Most batteries and charging systems
are of the 12 volt variety.
MAKE CONNECTIONS IN NUMERICAL ORDER
A FIRST JUMPER CABLE
WITH CHARGED BATTERY
-
lccslQ?,Q
Fig. 222 Connect the jumper cables to the
batteries and engine in the order shown

ENGINEANDENGINEOVERHAUL 3-31
I,.s; engine g3i53g26
Fig 136 Oil pan and related components-
be worn when changing the oil. Wash your
hands and any other exposed skin areas as
soon as possible after exposure to used en-
gine oil. Soap and water, or waterless hand
cleaner should be used.
4. Disconnect and lower the exhaust pipe from
the engine manifold.
5. Remove the bell housing lower cover.
6. Remove the oil pan retainer bolts and remove
the oil pan.
*Do not use a prytool when removing the oil
pan. If available, oil pan remover tool
MD998727 or equivalent may be used break
the seal.
To install:
7. Clean all gasket surfaces of the cylinder
block and the oil pan.
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 60 inch Ibs. (5 Nm).
10. install the bell housing cover.
11. Connect the exhaust pipe to the engine mani-
fold with new gasket in place. Tighten the exhaust
pipe to manifold flange nuts to 33 ft. Ibs. (45 Nm).
Install and tighten the support bolt to 18 ft. Ibs. (25
Nm).
12. Install the oil drain plug and tighten to 29 ft.
Ibs. (40 Nm).
13. Fill the crankcase to the proper level.
Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
14. Connect the negative battery cable. Start the
engine and check for leaks.
1.6L and 2.OL Engines
FRONT WHEEL DRIVE
ti See Figures 137 and 138
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Remove the oil pan drain plug and drain the
engine oil.
93153gza Fig. 137 Oil pan and related components-
2.OL SOHC engine
93153g29 Fig. 138 Oil pan and removal for FWD and
AWD l.liL and 2.OL DDHC enoines
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.
4. Disconnect and lower the exhaust pipe from
the engine manifold.
5. Using the appropriate equipment, support the
weight of the engine.
6. Remove the retainer bolts and the center
crossmember,
7. Remove the oil pan bolts. Using special tool
MD998727, tap in between the engine block and the
oil pan.
*Do not use a chisel, screwdriver or similar
tool when removing the oil pan. Damage to
engine components may occur.
8. 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: 9. 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.
10. 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.
11. Install the oil pan onto the cylinder block
within 15 minutes after applying sealant. Install the
fasteners and tighten to 4-6 ft. Ibs. (G8 Nm).
12. Install the crossmember and tighten the
mounting bolts to 72 ft. Ibs. (100 Nm).
13. Connect the exhaust pipe to the engine mani-
fold with new gasket In place. Tighten the exhaust
pipe to manifold flange nuts to 29 ft. Ibs. (40 Nm)
14. Install the oil drain plug and tighten to 33 ft.
Ibs.
15. 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 engine damage.
16. Connect the negative battery cable.
17. Start the engine and check for leaks.
ALL WHEEL DRIVE
ti See Figure 138
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. 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.
4. Disconnect and lower the exhaust pipe from
the engine manifold.
5. Remove the transfer assembly and right dri-
veshaft.
6. Using the appropriate equipment, support the
weight of the engine and remove the center cross-
member.
7. Disconnect the return pipe for the tur-
bocharger from the side of the oil pan.
8. Remove the oil pan bolts. Using special tool
MD998727, tap In between the engine block and the
oil pan.
*Do not use a chisel, screwdriver or similar
tool when removing the oil pan. Damage to
engine components may occur.

.
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

ENGINEANDENGINEOVERHAUL 3-35
Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
33. Connect the negative battery cable and start
the engine.
34. Verify correct oil pressure
35. Inspect for leaks.
3.OL Engines
b See Figure 150
*Whenever the oil pump is disassembled or
the cover removed, the gear cavity must be
filled with petroleum jelly to seal the pump
and act as a prime. 00 not use grease.
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, 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 front engine mount bracket and
accessory drive belts.
4. Remove timing belt upper and lower covers.
5. Remove the timing belt and crankshaft
sprocket. Refer to the timing belt procedure in this
section.
6 Remove the oil pan.
7. Remove the oil screen and gasket.
8. Remove the front cover mounting bolts. Note
the lengths of the mounting bolts as they are re-
moved for proper installation.
9. Remove the front
assembly. and oil pump
9315393i 7g. 150 Exploded view of the oil pump
nounting-3.01 engines
To install:
10. Thoroughly clean all gasket material from all
mounting surfaces.
11. Apply engine oil to the entire surface of the
gears or rotors.
12. Assemble the front case cover and oil pump
assembly to the engine block.
13. Install the oil screen with new gasket.
14. Install the oil pan
15. Install the crankshaft sprocket and timing
belt. Refer to the timing belt procedure in this sec-
tion 3.5L Engine
p See Figures 151 and 152
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to the timing
belt procedure in this section.
3. Drain the engine oil.
16. Install the timing belt covers.
17. Install the drive belts and the front engine
mount bracket.
18. Connect the negative battery cable, refill the
crankcase and check for adequate oil pressure.
Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage. Fig. 151 Apply sealant to the rear of the oil
pump case-3.5L ermine
I 11 Nm
8 ft.lbs.
Removal steps
7g. 152 Exploded view of the oil pump mounting-3.51 engine
1. 011 pressure gauge unit
2. 011 filter
3. 011 filter bracket
4. 011 filter bracket gasket
5. Drain plug
6. Drawn plug gasket
7 011 lower pan,
8. Cover
9 011 pan, upper
10. Baffle date 11. 011 screen
12.
13.
14.
15.
16.
17.
10.
19.
20.
21.
22. Oil screen gasket
Baffle plate
Plug
Reltef spring
Relief plunger
Crankshaft oil seal
Oil pump case
0-ring
011 pump cover
011 pump outer rotor
011 pump inner rotor

ENGINEANDENGINEOVERHAUL 3-67
CONNECTING ROD
You should have the connecting rod checked for
StraiQhtness at a machine shop. If the connecting rod
is bent, it will unevenly wear the bearing and piston,
as well as place greater stress on these components.
Any bent or twisted connecting rods must be re-
placed. If the rods are straight and the wrist pin clear-
ance is within specifications, then only the bearing
end of the rod need be checked. Place the connecting
rod into a vice, with the bearing inserts in place, in-
stall the cap to the rod and torque the fasteners to
specifications. Use a telescoping gauge and carefully
measure the inside diameter of the bearings. Com-
pare this reading to the rods original crankshaft jour-
nal diameter measurement. The difference is the oil
clearance. If the oil clearance is not within specifica-
tions, install new bearings in the rod and take another
.
specifica- L
need to
shop as the pistons must be installed in the con measurement. it the Clearance is still out of :
tions, and the crankshaft is not, the rod will
be reconditioned by a machine shop.
*You can also use Plastigage’
@to check the
bearing clearances. The assen- . ...= - _______
Mm sectinn has complete instructions on its use.
Camshaft
Inspect the camshaft and lifters/followers as de
scribed earlier in this section.
Bearings
All of the enaine bearinos should be visuallv in-
~~~ I~ .- - -- ..-_-..,
spected for we; and/or damage. The bearing should
look evenly worn all around with no deep scores or
pits. If the bearing is severely worn, scored, pitted or
heat blued, then the bearing, and the components
that use it, should be brought to a machine shop for
block. ,ect
relationshipto the rod or engine damage can occur,
Pistons and Connecting Rods
I
b See Fiaute 264 --- --*------
Only pistons with the wrist pin retained by C-clips
are serviceable by the home-mechanic. Press fit pis-
tons require special presses and/or heaters to re- I”
rr
rove/install the connecting rod and should only be
PC srformed by a machine shop.
All pistons will have a mark indicating the direc-
tir 9n to the front of the engine and the must be in-
stalled into the engine in that manner. Usually it is a
notch or arrow on the top of the piston, or it may be
the letter F cast or stamped into the piston.
ASEtiBlY
1
crankshaft. Replace any freeze or oil galley plugs
which were removed during disassembly.
Crankshaft
u See Figures 265, 266, 267, and 266
1. Remove the main bearing inserts from the
block and bearing caps.
2. If the crankshaft main bearing journals have
been refinished to a definite undersize, install the
correct undersize bearina. Be sure that the bearina
inserts and bearing bores are clean. Foreign mateiial
under inserts will distort bearinq and cause failure.
3. Place the upper main bearing inserts in bores
*The oil holes in the bearing inserts must
be aligned with the oil holes in the cylinder
. . .
inspection. Full-circle bearings (used on most
camshafts, auxiliary shafts, balance shafts, etc.) re-
quire specialized tools for removal and installation, ’
and should be brought to a machine shop for service.
Oil Pump Before you begin assembling the engine, first give
yourself a clean, dirt free work area. Next, clean every
engine component again. The key to a QOOd assem-
hhr io da~nlinmw “‘I Ia ~rGiOllll,lc7.Ja. Mount the engine block into the engine stand and
II
*The oil pump is responsible fo
r providing wasn It one last time usmg water and detergent (dish-
unrhinn rldarnant ~nrirc well), While washing it, with a soft bristle brush and
: oil oassaoes. Comoletelv constant lubrication to the whole engine and 1ILl.M 0, ,y “GSGl ycx II ““1 n
so it is recommended that a new oil pump be scrub the cylinder bore:
installed when rebuilding the engine. thoroughly clean all oft
dry the engine and spra
Completely disassemble the oil pump and thor- with an anti-rust solutio
oughly clean all of the components. Inspect the oil
pro
pump Qears and housing for wear and/or damage. In- exe
sure that the pressure relief valve operates properly sac
and there is no binding or sticking due to varnish or
debris. If all of the parts are in proper working condi-
tion, lubricate the gears and relief valve, and assem-
r
j ht
y the entire assembly down’
in such as WD-4Q@ or similar Fig. 265 Apply a strip of gauging material
Iduct. Take a clean lint-free rag and wipe up any
less anti-rust solution from the bores, bearing
Idles, etc. Repeat the final cleaning process on the !torguethe~~p * ,’ / to the bearmg lournal, then mstall and
ble the pump.
REFINISHING
# See Figure 263
Almost all engine block refinishing must be per-
I
IUIIII~U uy a macnme snap. ir me cynnoers are nor ro
be rebored, then the cylinder glaze can be removed
with a ball hone. When removing cylinder glaze with
a ball hone, use a light or penetrating type oil to Iu-
bricate the hone. Do not allow the hone to run dry as
this may cause excessive scoring of the cylinder
bores and wear on the hone. If new pistons are re-
quired, they will need to be installed to the connect-
ing rods. This should be oerformed bv a machine Fig. 266 After the cap is removed again, use