1900 MITSUBISHI DIAMANTE steering

GENERAL INFORMATION AND MAINTENANCE 1-47
ramps are also a handy and safe way to both raise l When the drive wheels are to remain on the
and support the vehicle. Be careful though, some ground, leave the vehicle in gear to help prevent it
ramps may be too steep to drive your vehicle onto
The following safety points cannot be overempha- from rolling.
without scraping the front bottom panels. Never sup-
sized:
l Always use jackstands to support the vehicle
port the vehicle on any suspension member (unless l Always block the opposite wheel or wheels to when you are working underneath. Place the stands
specifically instructed to do so by a repair manual) or
keep the vehicle from rolling off the jack. beneath the vehrcle’s jacking brackets Before climb-
by an underbody panel.
l When raising the front of the vehicle, firmly ap- ing underneath, rock the vehicle a bit to make sure it
ply the parking brake. is firmly supported.
SCHEDULED MAINTENANCE INTERVALS (MITSUBISHI DIAMANTE, GALANT, & MIRAGE)
VEHICLE MILEAGE INTERVAL (x1000)
7.5 15
22.5 30 37.5 45 52.5 60 67.5 75 62.5 90 97.5
J J
J 4 J J 4 4 4 J J
J 4
4
J J J J 4 TO BE
Ball loints &steering linkage
S/I J J J
seals
Dnve belt(s) S/I 4 4 J
Fvha,,rt cvctom $/I
J J J LmI,..“w. “,YL”,‘. Fuel hoses
+
Manual transaxle oil (Galant)
connectlon & fuel tank filler
R. Replace S/I - Sefwce or Inspect FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) II a vehicle is operated under any of the following conditions it is considered severe service:
- Extremely dusty areas.
- 50% or more of the vehicle operation is in 32% (WF) or higher temperatures, or constant opsralion in
temperatures below 0% (32°F).
- Prolonged idling (vehicle operation in stop and go traffic).
_ Frequent short running periods (engine does not warm to normal operating temfwatures).
- Police, taxi, delivery usage or trailer towing usage.
0118 011 filter change-change every 3CQO miles.
Disc brake pads - sewce or Inspect ever 6COO miles
AN hlter element _ setwe or inspect every 15,000 miles.
Automatic transaxle lluld 8 filter . replace every 15,COO m&s.
Rear drum brake Ikmngs & rear wheel cylinders (Galant & Mirage)
Spark plugs (except Dlamante wlplabnum tip) - replace every 15,COO miles.
Manual transaxle 011 (mcludlng transfer (Galant & Mirage). replace every 30,000 miles.

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

ENGlNEANDENGlNEOVERHAiJL 3-17
Fig. 73 Exploded view of the exhaust man
ifold -3.OL DOHC engine
9315392c Fig. 74 Exhaust manifold exploded view-
3.5L engine
4. Lower the vehicle.
5. If removing the front manifold, remove the ra-
diator and cooling fan assembly.
6. If removing the front manifold, remove the al-
ternator.
7. Remove the heat protector(s). 8. If removing the rear manifold, disconnect the
EGR tube.
9. Remove the exhaust manifold mounting bolts
the manifold.
To install:
10. Clean all gasket material from the mating sur-
faces and check the manifold for damage.
11. Install a new gasket and install the manifold.
Tighten the nuts in a crisscross pattern to 21 ft. Ibs.
(30 Nm).
12. Install the heat protector(s).
13. If installrng the rear manifold, replace the
gasket and connect the EGR tube.
14. If installing the front manifold, install the ra-
diator and cooling fan assembly.
15. If installing the front manifold, install the al-
ternator.
16. Install the drive belt(s) and adjust for proper
tension.
17. Raise and safely support the vehicle securely
on lackstands.
18. Install a new flange gasket and connect the
exhaust pipe or converter assembly.
19 Lower the vehicle
20. Connect the negative battery cable and check
for exhaust leaks.
REMOVAL&INSTALLATION
2.OL DOHC Engine (1990-93 Galant Only)
# See Figures 75 and 76
Many turbocharger failures are due to oil supply
problems. Heat soak after hot shutdown can cause
the engine oil in the turbocharger and oil lines to
“coke.” Often the oil feed lines will become partially
or completely blocked with hardened particles of car-
bon, blocking oil flow. Check the oil feed pipe and oil
return line for cloggrng. Clean these tubes well. Al-
ways use new gaskets above and below the oil feed
eyebolt fitting. Do not allow particles of dirt or old
gasket material to enter the oil passage hole and that
no portion of the new gasket blocks the passage.
1. Disconnect the negative battery cable.
2. Drain the engine oil, cooling system and re-
move the radiator On vehicles equipped with A/C,
remove the condenser fan assembly with the radiator.
The EPA warns that prolonged contact with
used engine oil may cause a number of skin
disorders, including cancer! You should
make every effort to minimize your exposure
to used engine oil. Protective gloves should
be worn when changing the oil. Wash your
hands and any other exposed skin areas as
soon as possible after exposure to used en-
gine oil. Soap and water, or waterless hand
cleaner should be used.
Never open, service or drain the radiator or
cooling system when hot; serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene Fig. 75 Exploded view
mounting (1 of 2)
93153q21 the turbocharget
9315392: :ig. 76 Exploded view of the turbocharger
nounting (2 of 2)
glycol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3 Detach the oxygen sensor connector and re-
move the sensor.
4. Remove the oil dipstick and tube.
5. Remove the air intake bellows hose, the
wastegate vacuum hose, the connections for the air
outlet hose, and the upper and lower heat shield.
6. Unbolt the power steering pump and bracket
assembly and leaving the hoses connected, wire it
aside.
7. Remove the self-locking exhaust manifold
nuts, the triangular engrne hanger bracket, the eye-

l
3-18 ENGINEANDENGINEOVERHAUL
bolt and gaskets that connect the oil feed line to the
turbo center section and the water cooling lines. The
water line under the turbo has a threaded connection.
8. Remove the exhaust pipe nuts and gasket and
lift off the exhaust manifold. Discard the gasket,
9. Remove the 2 through bolts and 2 nuts that 16. If removed, install the power steering pump
and bracket.
17. Install the heat shields, air outlet hose, waste-
gate hose and air intake bellows.
18. Install the oil dipstick tube and dipstick. In-
stall the oxyqen sensor. cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Disconnect the overflow tube. Some vehicles
hold the exhaust manifold to the turbocharger,
10. Remove the 2 capscrews from the oil return
line (under the turbo). Discard the gasket. Separate
the turbo from the exhaust manifold. The 2 water
pipes and oil feed line can still be attached. 19. In&h the radiator assembly.
20. Fill the engine with oil, fill the cooling system
and reconnect the negative battery cable.
11. Visually check the turbine wheel (hot side)
and compressor wheel (cold side) for cracking or
other damage. Check whether the turbine wheel and
the compressor wheel can be easily turned by hand.
Check for oil leakaae. Check whether or not the Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
wastegate valve remains open. If any problem is .
found, replace the part. Inspect oil passages for re- #I , I
striction or deposits and clean as required,
12. The wasteaate can be checked with a ores-
REMOVAL & INSTALLATION sure tester. Apply approximately 9 psi to the&h&or
and make sure the rod moves. Do not apply more
than 10.3 psi or the diaphragm in the wastegate may
be damaged. Vacuum applied to the wastegate actua-
tor should be maintained, replace if leaks vacuum,
Do not attempt to adjust the wastegate valve. $ See Figures 77 thru 91
I. Disconnect the negative battery cable.
2. Drain the cooling system when safe.
To
install: 13. Prime the oil return line with clean engine oil.
Replace all locking nuts. Before installing the
threaded connection for the water inlet pipe, apply
light oil to the inner surface of the pipe flange. As-
semble the turbocharger and exhaust manifold.
14. Install the exhaust manifold using a new gas-
ket.
15. Connect the water cooling lines, oil feed line
and engine hanger. 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
glyeol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
Fig. 77 Use a pair of pliers to remove the
Fig. 78 . . .
then disconnect the overflow
hose clamp . . .
hose from the radiator may also require removal of the overflow tank.
4. Disconnect upper and lower radiator hoses.
5. Detach the electrical connectors from the
cooling fan and air conditioning condenser fan, if
equipped.
6. For Mirage and Diamante models, remove
the fan assembly.
7. Disconnect the therm0 sensor wires,
8. If equipped with an automatic transaxle, dis-
connect and plug the automatic transaxle cooler
lines.
9. Remove the upper radiator mounts and lift
out the radiator assembly or radiator/fan assembly,
as applicable.
To install:
10. Install the radiator or radiator and fan, if re-
moved as an assembly.
11. Connect the automatic transaxle cooler lines
if disconnected.
12. Connect the therm0 sensor wires,
13. Install the fan, if removed separately.
14. Install the radiator hoses.
15. Install the air cleaner support bracket, if re-
noved.
16. Install the overflow tube and reservoir, if re-
noved.
17. Fill the system with coolant.
18. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
93153003 Fig. 79 Use pliers to release the hose clamp
tension . . .
Fig. 80 . . .
then remove the upper radiator
hose from the radiator Fig. 81 From underneath the vehicle, re-
move the hose clamp , . . ”
then disconnect the lower radi- Fig. 82 . . .
ator hose

.
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.

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.

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.