1900 MITSUBISHI DIAMANTE oil temperature

DISTRIBUTOR IGNITION SYSTEM
GENERALINFORMATION 2-2
DIAGNOSISANDTESTING 2-2
SECONDARYSPARKTEST 2-2
CYLINDERDROPTEST 2-2
ADJUSTMENTS 2-3
IGNITION COIL 2-3
TESTING 2-3
REMOVAL&INSTALLATION 2-3
POWERTRANSISTOR
(Ignition Module) 2-4
REMOVAL&INSTALLATION 2-4
DISTRIBUTOR 2-4
REMOVAL&INSTALLATION 2-4 2-2
INSTALLATION 2-4
CRANKSHAFTANDCAMSHAFTPOSITION
SENSORS 2-5
DISTRIBUTORLESS IGNITION
SYSTEM 2-5
GENERALINFORMATION 2-5
DIAGNOSISANDTESTING 2-5
ADJUSTMENTS 2-5
IGNITION COIL(s) 2-5
TESTING 2-5
REMOVAL&INSTALLATION 2-6
POWERTRANSISTOR
(IGNITION MODULE) 2-7
REMOVAL&INSTALLATION 2-7
CRANKSHAFTANDCAMSHAFTPOSITION
SENSORS 2-7
FIRING ORDERS 2-7
CHARGING SYSTEM 2-8
GENERALINFORMATION 2-8
ALTERNATORPRECAUTIONS 2-8
ALTERNATOR 2-8
TESTING 2-8 I
REMOVAL&INSTALLATION 2-9
REGULATOR 2-10
REMOVAL&INSTALLATION 2-10
STARTING SYSTEM 2-10
GENERALINFORMATION 2-10
STARTER 2-10
TESTING 2-10
REMOVAL&INSTALLATION 2-11
SENDING UNITS 2-11
ENGINECOOLANTTEMPERATURE
SENDING UNIT 2-11
TESTING 2-11
REMOVAL&INSTALLATION 2-11
OIL PRESSURESENDING UNIT 2-12
TESTING 2-12
REMOVAL&INSTALLATION 2-12

3-2 ENGINEANDENGINEOVERHAUL
REMOVAL &INSTALLATION
# See Figure 1
In the process of removing the engine, you will
come across a number of steps which call for the re-
moval of a separate component or system, such as
“disconnect the exhaust system” or “remove the radi-
ator.” In most instances, a detailed removal proce-
dure can be found elsewhere in this manual.
It is virtually impossible to list each individual
wire and hose which must be disconnected, simply
because so many different model and engrne combi-
nations have been manufactured Careful observation
and common sense are the best possible approaches
to any repair procedure.
Removal and installation of the engine can be
made easier if you follow these basic points:
l If you have to drain any of the fluids, use a
suitable container.
l Always tag any wires or hoses and, if possrble,
the components they came from before disconnect-
ing them.
l Because there are so many bolts and fasteners
involved, store and label the retainers from compo-
nents separately in muffin pans, jars or coffee cans.
This will prevent confusion during installatron.
l After unbolting the transmisston or transaxle,
always make sure it is properly supported.
l If it is necessary to disconnect the air condi-
tioning system, have this service performed by a
qualified technician using a recovery/recycling sta-
tion If the system does not have to be disconnected,
unbolt the compressor and set it aside.
l When unbolting the engine mounts, always
make sure the engine is properly supported. When
removing the engine, make sure that any lifting de-
vices are properly attached to the engine. It is recom-
mended that if your engine IS supplied with lifting
hooks, your lifting apparatus be attached to them.
l Lift the engine from its compartment slowly,
checking that no hoses, wires or other components
are still connected.
l After the engine is clear of the compartment,
place it on an engine stand or workbench.
l After the engine has been removed, you can
perform a partial or full teardown of the engine using
the procedures outlined in this manual.
1. Relieve 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. Remove the engine undercover if equipped. 4. Matchmark the hood and hinges and remove
the hood assembly.
5. Remove the air cleaner assembly and all ad-
joining air intake duct work.
6. Drain the engine coolant, remove the radiator
hoses, and remove the radiator assembly, coolant
reservoir, and intercooler, as equipped.
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.
7. Remove the transaxle and transfer case as
equipped.
8. Tag and detach the following electrical con-
nections:
l Accelerator cable l Heater hoses l Brake booster vacuum hose l Vacuum hoses l Fuel lines l Engine ground cables l Any applicable sensors l Coolant temperature and oil pressure send-
ing units
l Exhaust Gas Recirculation (EGR) tempera-
ture sensor
l Connection for the idle speed control mo-
tor
l Fuel injectors l Power transistor l Ignition coil and any applicable distributor
connections
l The connections for the alternator l Power steering pressure switch l A/C compressor l Refrigerant temperature switch l Condenser
9. Remove the air conditioner drive belt and the
air conditioning compressor. Leave the hoses at-
tached. Do not discharge the system. Place the com-
pressor aside and secure it using a suitable device.
10. Remove the power steering pump and place
the pump asrde and secure it using a surtable device.
11. Remove the exhaust manifold-to-exhaust
pipe nuts. Discard the gasket.
12. Install the engine hoist equipment and make
certain the attaching points on the engine are secure.
13. Raise the hoist enough to support the engine.
14. Remove the front and rear engine roll stop-
pers
15. Remove the left engine mount and support
Double check that all cables, hoses, harness
connectors, etc., are disconnected from the
engine.
16. Slowly lift the engine and remove it from the
vehicle.
To install:
17. Install the engine and secure all control
brackets and mounts.
18. Install the transaxle, and transfer case if
equipped.
19. The balance of the installation is the reverse
of removal with the addition of the following notes:
a. Use new clamps or O-rings to connect the
high pressure fuel lme and the fuel return line.
b. Use new gaskets to connect the exhaust
system to the engine.
c. Fill the engine with the proper amount of
engine oil and coolant.
d. Start the engine, allow it to reach normal
operating temperature.
e. Check for leaks.
f. Check the ignition timing and adjust if nec-
essary.
g. Road test the vehicle and check all fluid
levels and functions for proper operation.
Fig. 1 Alignment of the engine mount stop-
oer bracket-Diamante shown
REMOVAL &INSTALLATION
Except 3.OL (SOHC and DOHC) and 3.5L
Engines
# See Figures 2 thru 11
1. Disconnect the negative battery cable.
2. If necessary, remove the air intake hose.
3. If necessary, remove the throttle cable from
the cable routing clips.
Fig. 2 If necessary, remove the throttle ca-
ble from the cable routing clips

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

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

ENGINEANDENGINEOVERHAUL 3-13
EGR pipe - Up to 1993 model
EGR pipe - From 1994 model
Intake manlfold plenum stay, rear
Intake manifold plenum stay. front
EGR valve
EGR valve gasket
Throttle body >
Throttle body gasket
Intake mantfold plenum
Intake manifold plenum gasket
:ig. 52 Exploded view of air intake plenum assembly-3.01 DOHC engine
ing the fuel system, always work in a well
3. Remove the air intake hose(s). ventilated area. Do not allow fuel spray or 4. Disconnect the accelerator control cables vapors to come in contact with a spark or from the throttle body. open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnect battery negative cable and drawn
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.
5. Tag and disconnect the vacuum hoses in-
cluding the brake booster hose.
6. Tag and detach the wire harness connectors,
7. Disconnect the high pressure and return fuel
hoses.
8. Disconnect EGR pipe and remove the EGR
valve and EGR temperature sensor from the intake
plenum assembly.
9. If equipped, remove the manifold pressure
sensor.
10. Remove the plenum retaining bracket.
11. Remove the plenum retaining nuts and bolts
and remove the air intake plenum from the intake
manifold. Discard the gasket.
12. Remove the upper timing belt covers.
13. Remove the water pump stay bracket.
*It is not necessav to remove the fuel ln-
jectors from the intake unless the manifold ,
assembly is being replaced.
14. Remove the fuel rail with the injectors at-
tached. 15. Disconnect the coolant hoses from the intake
manifold. Be sure to note the connections.
16. Remove the intake manifold mounting nuts
and remove the intake manifold.
17. Clean the gasket mounting surfaces.
To install: 18. Check all items for cracks, clogging and
warpage. Maximum warpage is 0.0059 inches
(0.15mm). Replace any questionable parts.
19. Thoroughly clean and dry the mating surfaces
of the heads, intake manifold and air intake plenum.
20. Install new intake manifold gaskets to the
cylinder heads with the adhesive side facing up.
21. Place the manifold on the cylinder heads.
22. Lubricate the studs lightly with oil and install
the nuts.
23. For vehicles produced up to and including
November of 1993, tighten the mounting nuts as fol-
lows:
a. Front bank nuts: 27-43 inch Ibs. (3-5 Nm)
b. Rear bank nuts: 9-11 ft. Ibs. (12-15 Nm)
c. Front bank nuts: 9-11 ft. Ibs. (12-15 Nm)
24. For vehicles produced after November of
1993, tighten the mounting nuts as follows:
a. Front bank nuts: 48-72 inch Ibs. (5-8 Nm)
b. Rear bank nuts to: 14-17 ft. Ibs. (20-23
Nm)
c. Front bank nuts to: 14-17 ft. Ibs. (20-23
NM
25. Using new clamps, connect the coolant hoses
to the intake manifold.
26. Using new O-rings, install the fuel rail as-
sembly, if removed. Tighten the mounting bolts to
7-9 ft. Ibs. (10-13 Nm).
27. Install a new intake air plenum gasket and in-
stall the plenum. Tighten the retaining nuts and bolts
evenly and gradually to 13 ft. Ibs. (18 Nm).
28. Install the retaining bracket and tighten the
retaining bolts to 13 ft. Ibs. (18 Nm).
29. If removed, install the manifold pressure sen-
sor.
30. Using a new gasket, install the EGR valve and
tighten the bolts to 16 ft. Ibs. (22 Nm).
31. Install the EGR temperature sensor and
tighten the fitting to 7-9 ft. Ibs. (10-12 Nm).
32. Connect the EGR pipe and tighten the fittings
to 43 ft. Ibs. (60 Nm).
33. Replace the O-ring and connect the high
pressure fuel hose. Tighten the retaining bolts to 48
inch Ibs. (5 Nm).
34. Using a new hose clamp, connect the fuel re-
turn hose.
35. Install the water pump stay bracket.
36. Install the upper timing belt covers.
37. Connect the harness connector and vacuum
hoses.
38. Connect and adjust the accelerator cables.
39. Install the air intake hose(s).
40. Fill the system with coolant.
41. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
42. Check and adjust the idle speed and ignition
timing.
43. Once the vehicle has cooled, recheck the
coolant level.

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

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

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