1900 MITSUBISHI DIAMANTE torque

GENERALINFORMATIONAND MAlNTENANdE 1-13
Engine GENERAL ENGINE SPECIFICATIONS Fuel Net Net
Com-
Oil
Displacement Engine Engine No. of System Horsepower Torque @ rpm Bore x Stroke pression
Pressure
MFI Mult+wt fuel mfectw,
MFI-T - Multlporl fuel mfectlon-turbocharged
SOHC - Smgle overhead camshaft
DOHC - Double OvedEad camshaft

GENERAL INFORMATION AND MAlNTENANdE l-19
792UQ4 Fig. 69 Accessory V-belt routing-Mii
subishf 1.6L, 1.6L,-1.6L, 2.OL and 2.4L en
gines
33151PM Fig. 70 After the adjusting and fixed bolt!
are loosened, rotate the pump . . .
/ F$71t immtl$mm&a the power ::: 6. Rotate the pump until the proper tension is
reached.
7. Tighten the adjusting bolts on the pump.
8. Tighten the fixed bolt on the rear of the bracket.
9. Install the alternator belt.
A/r: COMPRESSOIl BEL f
1. Loosen the tension oullev and remove the belt.
2. The installation is the reverse of the removal.
.3.gL DGHC, 3.OL SOHC (Gaiant models
only) and 3.5L Engines 4. Remove the belt.
To install:
5. Install the belt on the crankshaft and alternator
pulleys.
6. Using the adjusting bolt on the tensioner,
tighten the belt to the desired tension.
7. Tighten the fixing nut to hold the adjustment.
8. Install the undercover and lower the vehicle to
_,
the tloor.
9. Connect the negative battery cable.
POWER SliEERlNG BEL f
6 See Figures 72 and 73 1. Disconnect the neaative batteN cah+P
-I
Wait at least 60 seconds after the negative
battery cable is disconnected to prevent poS-
sibie deployment of the air bag.
2. Raise and safely support the vehicle and re-
mob re the undercover.
3. Remove the alternator and NC compressor
belt.
4. Lower the vehicle and remove the cruise con-
trol oumn link iW%mblV. 79244Q.37
-- I-- r ---- - _I
Fig. 72 Serpentine belt routing-Mitsubishi 5. Place the power steering hose under the oil
reservoir.
3.OL engines (except 1696-00 Galant mod-
6.
Loosen the tension pulley fixing bolts and re-
els)
Generator pulP
1 move the power steering pump drive belt.
To install:
1 7. install the Dower steerina oumu r+r+v~ hp++
8. Insert an extension bar &eoufvaik;;t”f;;id‘he
opening at the end of the tension pulley bracket and
pivot the pulley to apply tension to the belt.
9. Tighten the fixing bolts.
10. Raise the vehicle and install the alternator and
compressor belt.
Il. Install the undercover and lower +hfi vph+r+p
.I,., .VII.“.Y.
12. Connect the negative battery cable.
I 3.OL SGHC (Diamante Models Onivl Enotne
I ,r ” 1. Disconnect the negative battery cable.
2.’ Loosen the lockbolt on the face nf the A/C _ __.- tensioner pulley.
3
Turn the adiustina bolt of the A/C +fincrnner
pulley to loosen the tension of the A/C belt.
4. Remove the A/C compressor belt.
5.
Loosen the locknut on the face of the power
to loosen the tc
7. Remov
Fig. 73 Accessory V-belt routing-Mitsubishi
3.5L and 1996-00 3.OL SOHC Galant en-
gines steering/alternator tensloner pulley.
6. Turn the adjusting bolt of the tensioner pulley
msion of the belt.
‘e the power steering/alternator belt.
To install:
8. Install the power steering/alternator belt first
.* .* . ,^
ssor drive belt. ana tnen tne A/ti compre:
9. Adjust the belts t+
ing the adjusting bolts anu
II~IIWII pueey tlxmg I the proper tension by turn-
A.:-L I-..-.. I,^, .’
nut/bolt.
10. Tighten the mounting nut of the power steer-
ing/alternator tensioner pulley to 36 ft. Ibs. (50 Nm).
Wait at least 60 seconds after the negative
battery cable is disconnected to prevent pos-
sible deployment of the air bag. -The manufacturer does not provide a
torque specification for the bolt that secures
A/C tensioner pulley.
2. Raise and safely support the vehicle and re- 11. Connect the negative battery cable.
move the front undercover.
3. Loosen the tension pulley fixing nut and relieve
the tension on the belt by turning the adjusting bolt.

GENERALINFORMATIONAND MAlNTENANdE I-27
ADJUSTMENT
u See Figures 120 and 121
The only engines that require periodic adjustment
of the valves are the 1.5L engine in the 1990-95 Mi-
rage and the 1.8L in the 1993-95 Mirage.
Incorrect valve clearance will cause noisy
and/or unsteady engine operation, reduced
engine output, and possible engine damage.
Check the valve clearances and adjust as re-
quired while the engine is hot.
1. Warm the engine to operating temperature.
Turn the engine OFF. Disconnect the negative battery
cable.
2. Remove all spark plugs so engine can be eas-
ily turned by hand
3. Remove the valve cover.
4. Turn the crankshaft clockwise until the notch
on the pulley is aligned with the
T mark on the timing
belt lower cover. This brings both No. 1 and 4 cylin-
der pistons to Top Dead Center (TDC).
5. Wiggle the rocker arms on No. 1 and 4 cylin-
ders up and down to determine which cylinder is at
TDC on the compression stroke. Both rocker arms
should move if the piston in that cylinder is at TDC
on the compression stroke.
6. Measure the valve clearance with a feeler
gauge. When the No. 1 piston is at TDC on the com-
pression stroke, check No. 1 intake and
exhaust; No.
2 intake and exhaust. Then turn the crankshaft clock-
wise 1 turn to bring No. 4 to TDC on its compression
stroke. With No. 4 on TDC, compression stroke,
check No. 2 exhaust and intake; and No. 4 intake and
exhaust. Clearance is as follows:
1990-92 1.5L engine:
No.1 No.2
No.3 No.4
when engine is on TDC of cylinder 1 and (B) when engine is on TDC of cylinder 4
No.1 No.2
No.3 No.4
AA AA BB BB
93151g10 Fig. 121 Adjusting the valve clearance
l Exhaust valve: 0.0098 in. (0.25mm) screw. When at specification, tighten the locknut. Be l Intake valve: 0.0059 in. (0.15mm)
1993-95 1.5L engine: sure to hold the screw securely in place when tight-
l Exhaust valve: 0.0098 in. (0.25mm) ening the locknut to prevent it from turning when
* Intake valve: 0.008 in. (0.20mm) tightening the locknut. Tightening torque of the lock-
nut is as follows:
1993-95 1.8L engine:
l Exhaust valve: 0.012 in. (0.30mm) l 1.5L engine: 9-11 ft. Ibs. (12-15 Nm)
l Intake valve: 0.008 in. (0.20mm) l 1.8L engine: 7 ft. Ibs. (9 Nm)
8. Recheck the clearance and readjust.
7. If the valve clearance is out of specification,
9. After adjusting the valves, install the valve
loosen the rocker arm locknut and adjust the clear-
ante using a feeler gauge while turning the adjusting cover and spark plugs, and connect the negative bat-
tery cable.
Engine
ENGINE TUNE-UP SPECIFICATIONS Ignition
Spark Plugs liming
Fuel Idle
Speed Valve
Displacement
Engine
Gap (as.) Pump (rpm)
Clearance

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

ENGINE MECHANICAL 3-1
ENGINE 3-1
REMOVAL &INSTALLATION 3-l
ROCKERARM(VALVE)COVER 3-l
REMOVAL &INSTALLATION 3-l
ROCKER ARM/SHAFTS 3-4
REMOVAL & INSTALLATION 3-4
THERMOSTAT 3-7
REMOVAL & INSTALLATION 3-7
INTAKE MANIFOLD 3-7
REMOVAL & INSTALLATION 3-7
EXHAUSTMANIFOLD 3-14
REMOVAL &INSTALLATION 3-14
TURBOCHARGER 3-17
REMOVAL & INSTALLATION 3-17
RADIATOR 3-18
REMOVAL & INSTALLATION 3-18
ENGINE FAN 3-19
REMOVAL &INSTALLATION 3-19
WATER PUMP 3-20
REMOVAL & INSTALLATION 3-20
CYLINDER HEAD 3-23
REMOVAL &INSTALLATION 3-23
OIL PAN 3-30
REMOVAL & INSTALLATION 3-30
OIL PUMP 3-33
REMOVAL &INSTALLATION 3-33
CRANKSHAFT DAMPER 3-36
REMOVAL &INSTALLATION 3-36
TIMING COVERAND BELT 3-36
REMOVAL & INSTALLATION 3-36
INSPECTION 3-48
FRONT CRANKSHAFTSEAL 3-48
REMOVAL & INSTALLATION 3-48
CAMSHAFT,BEARlNGSAND
LIFTERS 3-48
REMOVAL & INSTALLATION 3-48
INSPECTION 3-53
BALANCE SHAFT 3-54
REMOVAL &INSTALLATION 3-54
REAR MAIN SEAL 3-54
REMOVAL&INSTALLATION 3-54
FLYWHEEL/DRIVEPLATE 3-55
REMOVAL &INSTALLATION 3-55
EXHAUST SYSTEM 3-55
INSPECTION 3-55
REPLACEMENT 3-56
ENGINE RECONDITIONING 3-57
DETERMINIG ENGINE CONDITION 3-57
COMPRESSION TEST 3-57
OIL PRESSURETEST 3-57
BUYOR REBUILD? 3-57
ENGINE OVERHAULTIPS 3-58
TOOLS 3-58
OVERHAULTIPS 3-58
CLEANING 3-58
REPAIRING DAMAGEDTHREADS 3-59
ENGINE PREPARATION 3-59
CYLINDER HEAD 3-60
DISASSEMBLY 3-60
INSPECTION 3-
REFINISHING & REPAIRING 3-63 ASSEMBLY 3-64
ENGINE BLOCK 3-65
GENERALINFORMAITON 3-65
DISASSEMBLY 3-65
INSPECTION 3-65
REFINISHING 3-67
ASSEMBLY 3-67
ENGINE START-UP AND BREAK-IN 3-
STARTING THE ENGINE 3-69
BREAKING IT IN 3-69
KEEP IT MAINTAINED 3-69
SPECIFICATIONS CHARTS
ENGINE MECHANICAL
SPECIFICATIONS 3-70
TORQUE SPECIFICATIONS 3-81 .69

3-4 ENGINEANDENGINEOVERHAUL
Rear bank
6 011 010 og
1.03 07 02]
7923PG25 Fig. 12 Rocker cover bolt torque se-
quence-3.01 DOHC engine
To install:
9. Clean the valve cover gasket sealing SW
faces.
10 Install new valve cover gaskets onto the valve
covers.
11. Place the valve covers into position.
12. Reinstall the valve cover retaining bolts and
studs and tighten in sequence to:
l 3.OL SOHC engine: 7 ft. Ibs. (9 Nm) l 3.OL DOHC engine: 42-54 inch Ibs. (4-5
NM
l 3.5L engine: 30 inch Ibs. (3 Nm)
13. Install the engine wiring and tighten the re-
taining nuts.
14. Install the crankcase ventilation tubes into
both valve covers.
15. Install the ignition wire separators, the igni-
tion wires, and the spark plugs.
16. On the 3.OL DOHC engine, install the ignition
wire cover.
17. Install the upper intake manifold as described
in this section.
18. Connect the negative battery cable.
19. Run the engine and check for leaks and
proper operation.
( ser;lblies-l.5L dngine g3’53goi Fig 13 Camshaft rocker arm and shafl as- REMOVAL &INSTALLATION
1.5L and 1.8L Eflgin8S
,# See Figures 13 and 14
1. Disconnect the negative battery cable.
2. For 1.8L engines, label and disconnect the
spark plug cables.
3. Disconnect the accelerator cable, breather
hose and PCV hose connections.
4. Remove the rocker cover.
5. Loosen both rocker arm shaft assemblies
gradually and evenly and remove the rocket shafts
from the vehicle.
To install: 7. Lubricate the rocker shaft with clean engine
oil and Install the rockers and springs.
8. Install the rocker arm and shaft assemblies.
Tighten the rocker arm shaft retainer bolts to 23 ft.
Ibs. (32 Nm).
9. Check valve adjustment and install the valve
cover. Tighten the valve cover bolts to 16 inch Ibs.
(1.8 Nm) for the 1.5L engine or to 29 inch Ibs. (3.3
Nm) for the 1.8L engine.
10. If detached, connect the spark plug cables.
11. Connect the accelerator cable, breather hose
and PCV hose.
12. Connect the negative battery cable.
2.OL SOHC Engine
# See Figure 15
6. If disassembly is required, keep all parts in
the exact order of removal. On this engine, the hydraulic lifters are built into
the rocker arms. If lifter service is required, simply
1. Breather hose
2. P.C.V. hose
3. Rocker cover
4. Rocker cover gasket
Valve clearance pre-adjustment
5. Oil seal
6. Oil seal
7. Rocker arms and rocker arm shaft
6. Rocker arms and rocker arm shaft
9. Rocker shaft spring 10. Rocker arm A
11. Rocker arm 6
12. Rocker arm shaft (Intake side)
13. Adjusting screw
14. Nut
15. Rocker arm C
16. Rocker arm shaft (Exhaust side)
17. Adjusting screw
18. Nut
19. Camshaft
7923PG27 :ig. 14 Camshaft, rocker arm and shaft assemblies-l .8L engine

ENGINEANDENGINEOVERHAUL 3-7
4. Remove the center cover, breather and PCV
hoses, and spark plug cables.
5. Remove the rocker cover.
6. Remove the throttle body stay, both camshaft
sprockets, and oil seals.
7. Remove the Camshaft Position fCMP) sensor 3. install the lash adjuster clips on the rocker
arms, then loosen the bearing cap bolts. Do not re-
move the bolts from the bearing caps.
4. Remove the rocker arms, shafts and bearing
caps as an assembly.
lo hlstall: unless it is contaminated or is several years old.
3. Remove any necessary components to access
the thermostat.
4. Remove the thermostat housinq retaininq
nd adapter from the rear of the camshah. ’
8. Remove the intake and exhaust camshafts.
9. Remove rocker arms and lash adjusters from
he head. It is recommended that all lash adjusters
md rockers be replaced as a complete set.
To Install:
10. Immerse the lash adjusters in clean diesel
uel. Using a small wire, move the plunger of the lash
tdjuster up and down four or five times while push-
ng down lightly on the check ball in order to bleed
jut the air. Lubricate and install the lash adjusters in
he cylinder head.
11. Lubricate the camshafts with clean enqine oil
nd position the camshafts on the cylinder head.
12. Install the bearing caps. Tighten the caps in
sequence, in 2 or 3 steps. Caps 2,3 and 4 have a
ront mark. Install with the mark aligned with the front
nark on the cylinder head. Intake caps have I
stamped on the cap and exhaust caps have E. Also,
)e sure the rocker arm is correctly mounted on the
ash adjuster and the valve stem end. Torque the front
md rear retaining cap bolts to 14 ft. Ibs. (20 Nm) and
ighten the center 3 retaining cap bolts to 8 ft. Ibs.
11 Nm).
13. Apply a coating of engine oil to the oil seals
md install.
14. Install the timing belt, valve cover and all re-
ated parts. Refer to the timing belt procedure in this
;ection. 5. Install the bearing caps/rocker arm assem-
blies. Tighten the bolts to 23 ft. Ibs. (31 Nm).
6. Remove the lash adjuster clips.
7. Install the rocker arm cover using a new gas-
ket.
8. Connect the negative battery cable.
REMOVAL &INSTALLATION
b See Figures 24, 25, 26, and 27
1. Disconnect the negative battery cable.
2. Drain the cooling system.
Never open, service or drain the radiator or
cooling system when hot; serious bums 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 bolts.
5. Lift the housing from the engine.
6. Remove the thermostat taking note of its
original position in the housing.
To Install:
*In order to prevent leakage, make sure
both mating
surfaces are clean and free of
any old gasket material.
7. Install the thermostat so its flange seats
tightly in the machined groove in the intake manifold
or thermostat case. Refer to its location prior to re-
moval. Aliqn the relief valve with the alignment mark
on the thermostat housing.
8. Use a new gasket or D-ring and reinstall the
thermostat housing. Torque the housing mounting
bolts to the following specifications:
l 1.8L engine: 16 ft. Ibs. (22 Nm) l 1.5L, 1.61, 2.OL DOHC, and 1990-92 2.OL
SOHC engines: 12-14 ft. Ibs. (17-20 Nm)
l 1993 2.01 SOHC engine: 7-10 ft. Ibs.
(10-15 Nm)
l 2.4L engine: IO ft. Ibs. (14 Nm) l 3.OL and 3.5L engines: 12-14 ft. Ibs.
(17-20 Nm)
9. Fill the system with coolant.
10. Install the removed air intake plumbing.
15. Connect the negative battery cable and check
or leaks.
3.51 Engine
I See Figure 23
1. Disconnect the negative battery cable.
2. Remove the rocker arm cover.
g. 26 Remove the thermostat from the
ousing, noting the location of using the thermostat, always re-

3-8' ENGINEANDENGINEOVERHAUL
Nm ft.lbs.
1. Engine hanger 5. Engine hanger
2. Intake manifold stay 6. Exhaust manifold cover
3. intake manifold 7. Exhaust manifold
4. Intake manifold gasket 8. Exhaust manifold gasket
7923ffi38 :ig. 28 Exploded view of the intake and exhaust manifold mounting-l .5L (4615) engine
11. Connect the negative battery cable, run the ,. . . .
vemcie unnl me tnermostat opens ano till the radiator
completely. age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
12. Once the vehicle has cooled, recheck the
coolant level.
REMOVAL &INSTALLATION 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.
15. 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).
16. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crisscross pattern, starting from the inside and
working outwards to 13 ft. Ibs. (18 Nm).
17. Install the intake manifold support bracket
and torque the mounting bolts to 16 ft. Ibs. (22 Nm).
18. Install the engine mount support bracket and
torque the mounting bolts to 26 ft. Ibs. (36 Nm).
19. Using a new gasket, install the EGR valve and
torque the mounting bolts to 15 ft. Ibs. (21 Nm).
20. Using new insulators and O-rings, install the
fuel delivery pipe, injectors and pressure regulator to
the engine. Torque the retaining bolts to 7-9 ft. Ibs.
(10-14 Nm).
1.51 Engine
# See Figure 28
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 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,
3. Disconnect the upper radiator hose, heater
hose and water bypass hose.
4. Remove the thermostat housing from intake
manifold.
5. Disconnect the accelerator cable, breather
hose and air intake hose.
6. Remove all vacuum hoses and pipes as nec-
essary, including the brake booster vacuum line.
7. Remove the throttle body assembly.
8. Disconnect the high pressure fuel line and
the fuel return hose.
9. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor, in-
take air temperature, idle speed control assembly,
EGR temperature sensor, spark plug wires and dis-
tributor.
10. Remove the fuel rail, fuel injectors, pressure
regulator and insulators.
11. Remove the EGR valve from the intake mani-
fold.
12. Remove the intake manifold support bracket
and remove the engine mount support bracket.
13. Remove the intake manifold mounting bolts
and remove the intake manifold assembly.
To Install: 14. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly. Check both surfaces for cracks or other dam- 21. Attach the electrical connectors to the oxygen
sensor, coolant temperature sensor, intake air tem-
perature, idle speed control assembly, EGR tempera-
ture sensor, spark plug wires and distributor.
22. Using a new O-ring for the feed pipe and a
new clamp for the return pipe, install the fuel hoses.
23. Install the throttle body assembly.
24. Install the vacuum hoses and pipes as neces-
sary, including the brake booster vacuum line.
25. Install and adjust the accelerator cable. Install
the breather and air Intake hose.
26. Using a new gasket, install the thermostat
housing to the intake manifold and tighten the
mounting bolts to 13 ft. Ibs. (18 Nm).
27. Connect the upper radiator hose, heater hose
and water bypass hose. Be sure to use new hose
clamps.