1900 MITSUBISHI DIAMANTE Repair Manual

.
3-20 ENGINEANDENGINEOVERHAUL
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the overflow hose and disconnect
the upper radiator hose.
*It is recommended that each clamp be
matchmarked to the hose. Observe the marks
and reinstall the clamps exactly when rein-
stalling the radiator.
4. If equipped with an automatic transaxle, re-
move and plug the fluid cooler hoses.
5. Unplug the electrical connector(s) from the
coolant fan motor.
6. Remove the mounting bolts, then remove the
fan and shroud assembly from the vehicle.
7. Remove the fan blade retainer nut from the
shaft on the fan motor and separate the fan from the
motor.
8. Remove the motor to shroud attaching
screws and the motor from the shroud.
To tnstall: 9. Install the motor to the shroud and secure
with the mounting bolts.
10. Install the remaining components in the re-
verse order of removal.
11. Fill the coohng system. Connect the negative
battery cable and check the cooling fan for proper op-
eration.
Diamante
# See Figure 94
1. Disconnect the negative battery cable 2. Drain the cooling system only when the radi-
ator and the engine are at safe temperatures. 1. Disconnect the negative battery cable
2. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Unplug the cooling fan and radiator sensor
connector(s). Most of these connectors employ a wa-
terproof connector. When disconnecting, make sure
all parts of the connector remain intact.
4. Disconnect the upper radiator hose from the
radiator and remove overflow tank.
5. Remove the fan mounting screws. The radia-
tor and condenser cooling fans are separately remov-
able.
6. Remove the fan assembly and disassemble
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the engine undercover.
4 Disconnect the clamp bolt from the power
steering hose.
5. Remove the engine drive belts.
6. Support the engine with the appropriate
equipment and remove the engine mount bracket.
7. Remove the timing belt Reier to the timing
belt procedure in this section
8 Remove the power steering pump bracket.
9. Remove the alternator brace.
as required.
To install: 7. Posrtion the fan and install the mounting
screws
*The water pump mounting bolts are differ-
ent in length, note their positioning for re-
assembly.
8 Install the electrical connectors and the upper
radiator hose.
9. Refill the cooling system.
IO. Connect the negative battery cable and check
the fan for orooer ooeration. 10. Remove the water pump, gasket and O-ring
where the water inlet pipe(s) joins the pump.
To install: 11, Thoroughly clean both gasket surfaces of the
water oumo and block.
12. For 1.5L engines, install a new O-ring into
the groove on the front end of the water inlet pipe. Do
not apply oils or grease to the O-ring. Wet the O-ring
with water only
13. For 1.8L engines, apply a 0.09-0.12 in.
(2.5-3 Omm) continuous bead of sealant to water
pump and rnstall the pump assembly. Install the wa-
ter pump within 15 minutes of the applrcation of the
REMOVAL & INSTALLATION
1.5L and 1.8L Engine
) See Figures 95 and 98
7923PGO :ig. 94 Exploded view of the fan mounting and related components- Fig. 95 Water pump and related components-Mirage with 1.51
liamante (4615) engine

ENGINEANDENGINEOVERHAUL 3-21
7923PG08
ealant. Wait 1 hour after installation of the water
pump to refill the cooling system or start the engine.
14. Install the gasket and pump assembly and
tighten the bolts to 17 ft. Ibs. (24 Nm). Use care when
aligning the water pump with the water inlet pipe.
15. Install the remaining components in the re-
verse order of removal.
16. Fill the system with coolant. 17. Connect the negative battery cable, run the
vehicle until the thermostat opens and fill the radiator
completely.
18. Once the vehicle has cooled, recheck the
coolant level.
1.6L and 2.OL (SOHC and OOHC) Engines
+ See Figure 97
Fig
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
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 timing belt. Refer to the timing
belt procedure in this section.
4. If necessary, remove the alternator brace from
the water pump.
5. If necessary, remove the timing belt rear
cover.
6. Remove the water pump mounting bolts.
7. Remove the water pump, gasket and O-ring.
To Install: 8. Install a new O-ring on the water inlet pipe.
Coat the O-ring with water or coolant. Do not allow
oil or other grease to contact the O-ring.
9. Use a new gasket and install the water pump
to the engine block Torque the mounting bolts to
8.7-11 ft. Ibs. (12-15 Nm). Install the alternator
brace on the water pump. Torque the brace pivot bolt
to 17 ft. Ibs. (24 Nm).
10. If removed, install the timing belt rear cover.
11. Install the timing belt. Refer to the timing belt
procedure in this section.
12. Install the remaining components.
13. Refill the engine with coolant.
14. Connect the negative battery cable, start the
engine and check for leaks.
2.4L Engine
) See Figures 98 thru 108
1. Disconnect the negative battery cable
2. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the engine undercover.
4. Disconnect the clamp bolt from the power
steering hose.
5 Support the engine with the appropriate
equipment and remove the engine mount bracket.
6. Remove the engine drive belts and the A/C
tensioner bracket.
7. Remove the timing belt covers from the front
of the engine.

3-22 ENGINEANDENGINEOVERHAUL

Fig. 98 Remove the wafer pump pulley re-
taining bolts ~ . .
Fig 101 Remove the A/C beit idler pulley
braEketretainingboit..., g3’a/ 93153p30 Fig. 99 . . . then remove the pulley from the
pump
931531183 Fig. 102 . . * then remove the idler pulley
retaining bracket
Fig. 104 Remove the water pump retaining
Fig. lfJ5 . . . then remove the bolts on the
bolts on the top . . .
bottom of the pump assembly
Fig. 107 if the impeller fins on the water
able to replace the water pump rather than
reuse it Fig. 100 Remove the A/C belt idler pulley
g. 103 Remove the alternator brace from
Fig. 108 Water pump bolt identification-2.41 Engine

ENGlNEANDENGlNEOVERHAiL 3-23
8. Remove the camshaft and silent shaft timing
belts. Refer to the timing belt procedure in this sec-
tion
9. Remove the A/C belt idler pulley and pulley
bracket.
10. Remove the alternator brace,
11. Remove the water pump, gasket and O-ring
where the water inlet pipe(s) joins the pump.
To install:
12. Thoroughly clean both gasket surfaces of the
water pump and block.
13. Install a new O-ring into the groove on the
front end of the water inlet pipe and wet with clean
antifreeze only. Do not apply oils or grease to the O-
ring.
14. Using a new gasket, install the water pump
assembly. Tighten bolts with the head mark 4 to 10
ft Ibs. (14 Nm) and bolts with the head mark 7 to 18
ft. Ibs. (24 Nm).
15. Install the A/C pulley and pulley bracket,
16. Install the timing belts. Refer to the timing
belt procedure in this section.
17. Install the engine drive belts.
18. Install the engine mount bracket.
19. Install the engine undercover,
20. Fill the system with coolant.
21. Connect the negative battery cable, run the
vehicle until the thermostat opens and fill the radiator
completely.
22. Once the vehicle has cooled, recheck the
coolant level.
3.OL and 3.5L Engines
# See Figure 109
1. Disconnect the negative battery cable,
2. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Remove the engine undercover.
4. Disconnect the clamp bolt from the power
steering hose.
5. Support the engine with the appropriate
equipment and remove the engine mount bracket.
6. Remove the timing belt. Refer to the timing
belt procedure in this section.
7. Disconnect the coolant hoses from the pump,
if equipped.
8. Remove the alternator brace.
*The water pump bolts are different in size.
Note their locations for installation.
9. Remove the water pump, gasket and O-ring
where the water inlet pipe joins the pump.
To install: 10. Thoroughly clean both gasket surfaces of the
water pump and block.
11. Install a new O-ring into the groove on the
front end of the water inlet pipe. Do not apply oils or
grease to the O-ring. Wet with water only.
Atr Intake hose
Connactlon of’ radlator upper hose
5 Water outlet fming
6. Gasket
7 Connacmn of harness
8 Connection of heater hose
9. Connection of water hose A
10. ConnectIon of water hose
11. Connection of radiator Iowar hose
1 f Thn&ostat housing
14 Inlet water pye
15 O-ring
7923Fw :ig. 109 Water pump and related components-3.01 DOHC shown
12. Using a new gasket, install the water pump
assembly to the engine block. Torque the mounting
bolts to 17 ft. Ibs. (24 Nm).
13. Connect the hoses to the pump.
14. Install the timing belt. Refer to the timing belt
procedure in this section.
15. Install the engine drive belts.
16. Fill the system with coolant.
17. Connect the negative battery cable, run the
vehicle until the thermostat opens and fill the radiator
completely.
18. Once the vehicle has cooled, recheck the
coolant level.
REMOVAL & INSTALLATION
1.5L Engine
u See Figures 110 and 111
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 the negative battery cable.
3. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
4. Remove the air intake hose and the air
cleaner assembly.
5. Disconnect the ground cable connection and
the accelerator cable.
6. Disconnect the PCV and the breather hose
connection.
7. Label and disconnect the vacuum hoses from
the intake and throttle body.
8. Disconnect the vacuum line for the brake
booster.
9. Remove the upper radiator hose, throttle
body hoses, bypass hose and heater hose connec-
tions
10. Disconnect the fuel feed and return lines.
11. Remove the spark plug wires.

3-24 ENGINEANDENGINEOVERHAUL
Intake side Front of engine
e
Exhaust side
7923PG13 Fig. 110 Cylinder head bolt loosening se-
uuence-Mirage with 1.5L (4615) ermine
inwe side 0 Front of engine
((9
Exhaust side
7923PG14 Fig. 111 Cyllnder head bolt tightening se-
quence-Mirage with 1.5L (4615) engine
12. Disconnect the electrical harness plugs from
the following:
l Crankshaft Position (CKP) and Camshaft
Position (CMP) sensors
l Heated Oxygen (HO*S) sensor l Engine Coolant Temperature (ECT) sensor
and gauge sender
l Idle Speed Control (ISC) motor l Throttle Position (TP) sensor l Intake Air Temperature (IAT) sensor l Exhaust Gas Recirculation (EGR) tempera-
ture sensor
13. Disconnect electrical harness plugs from the
ignition distributor, fuel injectors, power transistor
and ground cable.
14. Disconnect the engine control wiring har-
ness.
15. Remove the clamp that holds the power steer-
ing pressure hose to the engine mounting bracket.
16. Place a jack and wood block under the oil
pan and carefully lift just enough to take the weight
off the engine mounting bracket and remove the
bracket.
17. Remove the valve cover.
18. Remove the timing belt upper cover.
19. Rotate the crankshaft clockwise and align the
timing marks.
20. Attach the timing belt to the camshaft
sprocket with cord or a wire tie.
21. Secure the camshaft from turning and remove
the camshaft sprocket with the timing belt attached.
22. Remove the timing belt rear upper cover.
23. Remove the exhaust pipe from the exhaust
manifold.
24. Loosen the cylinder head mounting bolts in
sequence using three steps.
25. Remove the cylinder head.
To install:
26. Thoroughly clean the mating surfaces of the
head and block. 27. Place a new head gasket on the cylinder
block with the identification marks facing upward. Do
not use sealer on the gasket.
28. Carefully install the cylinder head on the
block. Tighten the cylinder head bolts as outlined in
the followlng steps:
a. Tighten the bolts to 36 ft. Ibs. (49 Nm) in
the correct sequence
b. Loosen the bolts completely in the reverse
of the tightening order,
c. Tighten the bolts, in sequence, to 14 ft.
Ibs. (20 Nm)
d. Tighten each bolt, in sequence, 90 degrees
e. Tighten each bolt, in sequence, an addi-
tional 90 degrees
29. Install a new exhaust pipe gasket and connect
the exhaust pipe to the manifold.
30. Install the upper rear timing cover.
31. Align the timing marks and install the cam
sprocket. Torque the retaining bolt to 51 ft. Ibs. (76
Nm). Check the belt tension and adjust, if necessary.
Install the outer timing cover.
32. Install the valve cover and torque the retain-
ing bolts to 16 inch Ibs. (1.8 Nm).
33. Install the engine mount bracket and remove
the support jack.
34. Install the clamp that holds the power steer-
ing pressure hose to the engine mounting bracket.
35. Attach the following electrical connectors:
l CKP and CMP sensors l HOPS sensor l ECT sensor and gauge sender l ISC motor l TP sensor l IAT sensor l EGR temperature sensor
36. Connect wiring for the ignition distributor,
fuel injectors, power transistor and ground cable.
37. Connect the engine control wiring harness.
38. Replace the O-rings and connect the fuel
lines.
39. Install the air cleaner assembly. Connect the
breather hose.
40. Fill the system with coolant.
41. Connect the negative battery cable.
1.8L Engine
# See Figures 112 and 113
1. Relieve fuel system pressure. Disconnect the
negative battery cable.
2. Remove the air cleaner assembly.
3. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glycol antifreeze and could drink any that is
lefl in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
4. Disconnect the brake booster vacuum hose
and PVC valve connection. 5. Note the locations, then disconnect the vac-
uum hoses from the intake and throttle body.
6. Remove the upper radiator hose, overflow
tube and the water hose from the thermostat to the
throttle body.
7. Disconnect the fuel feed and return lines.
8. Unplug the accelerator cable connection from
the throttle body.
9. Detach the wiring from the oil pressure
switch.
10, Disconnect the wiring from the following
components:
l Heated Oxygen (HO*S) sensor l Engine Coolant Temperature (ECT) sensor
and gauge sender
l Idle Air Control (IAC) motor l Exhaust Gas Recirculation (EGR) tempera-
ture sensor
l Throttle Position (TP) sensor l Knock sensor l Fuel injectors
11. Remove the spark plug wires.
12. Unbolt the control harness assembly and po-
sition aside.
13. Remove the thermostat housing, thermostat
and the thermostat case with O-ring from the engine.
14. Remove the rocker cover.
15. Remove the timing belt upper cover.
16. Rotate the crankshaft clockwise and align the
timing marks.
17. Attach the timing belt to the camshaft
sprocket with cord or a wire tie.
18. Secure the camshaft from turning and remove
the camshaft sprocket with the timing belt attached.
19. Remove the timing belt rear upper cover.
20. Loosen the cylinder head bolts in two or three
steps in the proper sequence.
21. Remove the cylinder head from the engine.
Intake side
Front of engine c=>
I
Exhaust side
Loosening &der 7923PG15 Fig. 112 Cylinder head bolt loosening se-
quence-l .8L engine
intake side Front of engine *
Exhaust side libhtenng order
Fig. 113 Cylinder head bolt torque se-
quence-l .8L engine

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

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

ENGlNEANDENGlNEOVERHALiL 3-27
8. Remove the upper radiator hose and the
sages thoroughly. Check the head for flatness. End to 31. Install the air cleaner and intake hose. Con-
overflow tube. end, the head should be within 0.002 in. (0.05mm) nect the breather hose.
9. Remove the spark plug cable center cover,
normally, with 0.008 in. (0.2mm) the maximum al- 32. Change the engine oil and oil filter,
then remove the spark plug cables.
lowed out of true. The total thickness allowed to be 33. Fill the system with coolant.
10. Disconnect and plug the high pressure fuel
removed from the head and block is 0.008 in.
line. 34. Connect the negative battery cable.
(0.2mm) maximum. 35. Run the vehicle until the thermostat opens,
11. Disconnect the small vacuum hoses.
23. Place a new head gasket on the cylinder and fill the radiator completely.
12. Remove the heater hose and water bypass
block with the identification marks at the front top 36. Check and adjust the idle speed and ignition
hose.
(upward) position. Make sure the gasket has the timing.
13. Remove the PCV hose.
proper identification mark for the engine. Do not use 37. Once the vehicle has cooled, recheck the
14. If turbocharged, remove the vacuum hoses,
sealer on the gasket. Replace the turbo gasket and coolant level.
water line and eyebolt connection for the oil line for
ring, if equipped.
the turbo.
24. Carefully install the cylinder head on the 2.41 Engine
15. Disconnect and plug the fuel return hose. block. Using 3 even steps, torque the head bolts, in
16. Disconnect the brake booster vacuum hose.
sequence, to 65-72 ft. Ibs. (90-100 Nm). This torque b See Figures 119 thru 131
17. Remove the timing belt. applies to a cold engine. If checking cylinder head
18. Remove the valve cover and the half-round
bolt torque on hot engine, the desired specification is 1. Relieve the fuel system pressure.
seal.
7240 ft. Ibs. (100-110 Nm). 2. Disconnect the negative battery cable.
19. On non-turbocharged engines, remove the 3. Remove the air cleaner with all air intake
25. On turbocharged engine, install the heat
hoses.
exhaust pipe self-locking nuts and separate the ex-
shield. On non-turbocharged engines, install a new
haust pipe from the exhaust manifold. Discard the
exhaust pipe gasket and connect the exhaust pipe to 4. Drain the cooling system.
gasket.
the manifold.
20. On turbocharged engines, remove the sheet
26. Apply sealer to the perimeter of the half-
metal heat protector and remove the bolts that attach
round seal and to the lower edges of the half-round Never open, service or drain the radiator or
the turbocharger to the exhaust manifold.
portions of the belt-side of the new gasket. Install the cooling system when hot; serious burns can
21. Loosen the cylinder head mounting bolts in 3
valve cover. occur from the steam and hot coolant. Also,
steps, starting from the outside and working inward,
27. Install the timing belt and all related items. when draining engine coolant, keep in mind
Lift off the cylinder head assembly and remove the
28. Connect or install all previously disconnected that cats and dogs are attracted to ethylene
n head gasket.
hoses, cables and electrical connections. Adjust the glycol antifreeze and could drink any that is
To install:
throttle cable(s). left in an uncovered container or in puddles
22. Thoroughly clean and dry the mating surfaces
29. Install the spark plug cable center cover. on the ground. This will prove fatal in suffi-
of the head and block. Check the cylinder head for
30. Replace the O-rings and connect the fuel eient quantities. Always drain coolant into a
cracks, damage or engine coolant leakage. Remove
lines. sealable container. Coolant should be reused
scale, sealing compound and carbon. Clean oil pas- unless it is contaminated or is several years
old.
g3153p44 Fig. 119 Remove the upper radiator hose
* . . 1 Fig. 129 . . . and also the lower rad:gzi / cyl.der head g3153W
Fig 121 Remove the heater hose from the
hoses from the thermostat housing
Fig. 122 Remove the three thermostat hous-
Fig. 123 . . . then remove the thermostat
ing retaining bolts . . .
housing from the cylinder head
93153p50 Fig. 124 Using a suitable device, such as a
breaker bar and the appropriate socket,
loosen the cylinder head bolts in the proper
sequence