1900 MITSUBISHI DIAMANTE Power steering

l
3-40 ENGINEANDENGINEOVERHAUL
Counterbaiance
19235861
Fig. 163 Timing belt 5 installation mark
alignment- 2.OL turbo
Do not compress the pushrod too quickly,
damage to the pushrod can occur.
21. Install the auto-tensioner on the engine.
22. Align the timing marks on the camshaft
sprocket, crankshaft sprocket and the oil pump
sprocket.
23. After aligning the mark on the oil pump
: sprocket, remove the cylinder block plug and insert a
prytool in the hole to check the position of the coun-
terbalance shaft. The orvtool should ao in at least 7. Remove the power steering pump, alternator
air conditioning compressor, tension pulley and ac-
companying brackets, as required.
8 Remove the upper front timing belt cover.
9. Remove the water pump pulley and the
crankshaft pulley(s).
10. Remove the lower timing belt cover mountinf
screws and remove the cover.
11. If the belt(s) are to be reused, mark the direc.
tion of rotation on the belt.
12. Remove the timing (outer) belt tensioner and
remove the belt. Unbolt the tensioner from the block
and remove.
13. Remove the outer crankshaft sprocket and
flange.
14. Remove the silent shaft (inner) belt tensioner
and remove the inner belt. Unbolt the tensioner from
the block and remove it.
15. To remove the camshaft sprockets, use SST
Ml39g67-01 and MlT308239, or their equivalents.
To in!3tall:
16. Install the camshaft sprockets and tighten thr
center bolt to 65 ft. Ibs. (90 Nm).
17. Align the timing mark of the silent shaft belt
sprockets on the crankshaft and silent shaft with the
marks on the front case. Wrap the silent shaft belt
around the sprockets so there is no slack in the uppe
!
I span of the belt and the timing marks are still in line.
18. Install the tensioner initially so the actual
:enter of the pulley is above and to the left of the in-
jtallation bolt. 2.36 in. (60mm) or more, if not, rotai;! the oil pump
sprocket once and realign the timing mark so the pry-
24. Install the timing belt on the intake camshaft
and secure it with a clip. .
25. Install the timina belt on the exhaust old. 2.41 Engine
I: # See Figures 164 thru 162
1. Be sure that the engine’s No. 1 piston is at
TDC in the compression stroke.
Wait at least 90 seconds after the negative
battery cable is disconnected to prevent pos-
sible deployment of the air bag.
2. Disconnect the negative battery cable.
3. Remove the spark plug wires from the tree on
the upper cover.
4. 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 dram coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
tool goes in. Do not remove the on/ool until the tfrn- 5. Remove the shroud, fan and accessory drive
ing belt is installed. lelts.
6. Remove the radiator as required. 19. Move the pulley up by hand so the center
jpan of the lona side of the belt deflects about 11~ in.
camshaft.
26. Align the timing marks with the cylinder head
top surface using two wrenches. Secure the belt with
another clip.
27. tnstatf the belt around the idler pulley, oil
pump sprocket, crankshaft sprocket and the tensioner
pulley.
28. Turn the tensioner pulley so the pinholes are
at the bottom. Press the pulley lightly against the tim-
ing belt.
29. Screw the special tool into the left engine
support bracket until it contacts the tensioner arm,
then screw the tool in a little more and remove the
pushrod pin from the auto-tensioner. Remove the
special tool and tighten the center bolt to 35 ft. Ibs.
(48 Nm). Fig 164 Remove the upper engine mount-
to-mount bracket nuts al%@]
Pm3p70 Fig. 165 Remove the upper engine mount
through-bolt . . .
30. Turn the crankshaft ‘Id turn counterclockwise,
then clockwise until the timing marks are aligned.
31. Loosen the center bolt. Install Mitsubishi
Special Tool MD998767, or equivalent, on the ten-
sioner p&y. Turn the tensioner pulley counterclock-
wise with a torque of 2.6 ft. Ibs. (3.5 Nm) and tighten
the center boftto 35 ft. tbs. (48 Nm). Do not let the
tensioner pUtFey turn when tightening the bolt.
32. Turn the crankshaft clockwise two revolutions
and align the timing marks.
33. After 15 minutes, measure the protrusion of
the pushrod on the auto-tensioner. The standard
measurement is 0.150-0.177 in (3.8-4.5mm). If the
I protrusion is out of specification, loosen the ten-
I sioner pulley, apply the proper torque to the belt and
: retighten the center bolt.
34. Install the timing belt covers and all applica-
i ble components.

.
3-42 ENGINEANDENGINEOVERHAUL
Fig. 180 Silent shaft alignment marks. No,
tice the tension side of the inner (silen
shaft) belt-2.41 enaine
Timing merk
(pun+ on sprocket)
liming m&k
(notch in sprocket)
79245g31 :ig. 181 Timing belt pulley alignmenl
narks-2.41 enoine
20. Hold the pulley tightly so it does not rotate
when the bolt is tlghtened. Tighten the bolt to 15 ft.
Ibs. (20 Nm). If the pulley has moved, the belt will be
too tight
21. Install the timing belt tensioner fully toward
the water pump and temporarily tighten the bolts.
Place the upper end of the spring against the water
pump body. Align the timing marks of the cam,
crankshaft and oil pump sprockets with the corre-
sponding marks on the front case or head.
*If the following steps are not followed ex-
actly, there is a chance that the silent shaft
alignment will be 180 degrees off. This will
cause a noticeable vibration in the engine
and the entire procedure will have to be re-
peated.
22. Before installing the timing belt, ensure that
the left side silent shaft is in the correct position.
*It is possible to align the timing marks on
the camshaft sprocket, crankshaft sprocket
and the oil pump sprocket with the lefl bal-
ance shaft out of alignment.
23. With the timing mark on the oil pump pulley
aligned with the mark on the front case, check the
alignment of the left balance shaft to assure correct
shaft timing. a. Remove the plug located on the left side of
the block in the area of the starter.
b. Insert a tool having a shaft diameter of 0.3
in. (8mm) into the hole.
c. With the timing marks still aligned, the tool
must be able to go in at least 2l/s in. (59mm). If
it can only go m about 1 in. (25mm), turn the oil
pump sprocket one complete revolution.
d. Recheck the position of the balance shaft
with the timing marks reahgned. Leave the tool in
place to hold the silent shaft while continuing.
24. Install the belt to the crankshaft sprocket, oil
pump sprocket and the camshaft sprocket, in that or-
der. While doing so, be sure there is no slack be-
tween the sprockets except where the tensioner will
take it up when released.
25. Recheck the timing marks’ alignment.
26. If all are aligned, loosen the tensioner mount-
ing bolt, and allow the tensioner to apply tension to
the belt.
27. Remove the tool that is holding the silent
shaft in place and turn the crankshaft clockwise a dis-
tance equal to two teeth of the camshaft sprocket.
This will allow the tensioner to automatically tension
the belt the proper amount.
Do not manually apply pressure to the ten-
sioner. This will overtighten the belt and will
cause a howling noise.
28. First tighten the lower mounting bolt and then
tighten the upper spacer bolt.
If any binding is felt when adiustino the tim-
ing delt tension by turning th;! crankshaft,
STOP turning the engine, because the pis-
tons may be hitting the valves.
29. To verify that belt tension is correct, check
that the deflection of the longest span (between the
camshaft and oil pump sprockets) is I/* in. (13mm).
30. Install the lower timing belt cover. Be sure the
packing is properly positioned in the inner grooves of
the covers when installing.
31. Install the water pump pulley and the crank-
shaft pulley(s).
32. Install the upper front timing belt cover.
33. Install the power steering pump, alternator,
air conditioning compressor, tension pulley and ac-
companying brackets, as required.
34. Install the radiator, shroud, fan and accessory
drive belts.
35. Install the spark plug wires to the tree on the
upper cover.
36. Refill the cooling system.
37. Connect the negative battery cable. Start the
engme and check for leaks.
3.OL SDHC Engine
1992-94 MODELS
# See Figures 182 and 183
1. Disconnect the negative battery cable.
2. Remove the engine undercover
3. Remove the cruise control
actuator 4. Remove the accessory drive belts. 5. Remove the air conditioner compressor ten-
sion pulley assembly.
6. Remove the tension pulley bracket.
7. Using the proper equipment, slightly raise
the engine to take the weight off the side engine
mount. Remove the engine mounting bracket.
8. Detach the power steering pump pressure
switch connector. Remove the power steering pump
and wire aside.
9. Remove the engine support bracket.
10. Remove the crankshaft pulley.
11. Remove the timing belt cover cap.
12. Remove the timing belt upper and lower cov-
ers.
13. If the same timing belt will be reused, mark
the direction of the timing belt’s rotation for installa-
tion in the same direction. Make sure the engine is
positioned so the No. 1 cylinder is at the TDC of its
compression stroke and the sprockets’ timing marks
are aligned with the engine’s timing mark indicators.
14. Loosen the timing belt tensioner bolt and re-
move the belt. If the tensioner is not being removed,
position it as far away from the center of the engine
as possible and tighten the bolt.
15. If the tensioner is being removed, paint the
outside of the spring to ensure that it is not installed
backwards. Unbolt the tensioner and remove it along
with the spring.
To install:
16. Install the tensioner, if removed, and hook the
upper end of the spring to the water pump pin and
the lower end to the tensioner in exactly the same po-
sition as originally installed. If not already done, po-
sition both camshafts so the marks align with those
on the rear. Rotate the crankshaft so the timing mark
aligns with the mark on the oil pump.
17. Install the timing belt on the crankshaft
sprocket and while keeping the belt tight on the ten-
sion side, install the belt on the front camshaft
sprocket.
18. Install the belt on the water pump pulley, then
the rear camshaft sprocket and the tensioner.
19. Rotate the front camshaft counterclockwise to
tension the belt between the front camshaft and the
crankshaft. If the tlmlng marks became misaligned,
repeat the procedure.
20. Install the crankshaft sprocket flange.
21. Loosen the tensioner bolt and allow the
spring to apply tension to the belt.
22. Turn the crankshaft 2 full turns in the clock-
wise direction until the timing marks align again.
Now that the belt is properly tensioned, torque the
tensioner lock bolt to 21 ft. Ibs. (29 Nm). Measure
the belt tension between the rear camshaft sprocket
and the crankshaft with belt tension gauge, The spec-
ification is 46-68 Ibs. (210-310 N).
23. Install the timing covers. Make sure all pieces
of packing are positioned in the inner grooves of the
covers when Installing.
24. install the crankshaft pulley. Tighten the bolt
to 108-116ft. Ibs. (150-160 Nm)
25. Install the engine support bracket.
26. Install the power steering pump and recon-
nect wire harness at the power steering pump pres-
sure switch.
27. Install the engine mounting bracket and re-
move the engine support fixture.
28. Install the tension pulleys and drive belts.
29. Install the cruise control actuator.
30 Install the engine undercover.

ENGlNEANDENGlNEOVERHiUL 3-45
TIMINQ MARKS ON RIQHT SIDE VALVE COVER TIMING MARKS ON LEFT SIDE VALVE COVER
CRANKSHAFT SPROCKETS
91251gb5 :ig. 185 Crankshaft and camshaft sprocket alignment for proper timing belt replacement-1992-94 Mitsubishi 3.OL DOHC engine
4. Remove the cruise control actuator.
5. Remove the alternator. Remove the air hose
and pipe.
6. Remove the belt tensioner assembly and the
power steering belt.
7. Remove the crankshaft pulley.
8. Disconnect the brake fluid level sensor.
9. Remove the timing belt upper cover.
10. Using the proper equipment, slightly raise the
engine to take the weight off the side engine mount.
Remove the engine mount bracket.
11. Remove the alternator/air conditioner idler
pulley.
12. Remove the engine support bracket. The
mounting bolts are different lengths; mark them for
proper installation.
13. Remove the timing belt lower cover. Timing
bolt cover mounting bolts are different in length, note
their position during removal.
14. If the same timing belt will be reused, mark
the direction of the timing belt’s rotation for installa-
tion in the same dlrection. Make sure the engine is
positioned so the No. 1 cylinder is at the TDC of its
compression stroke and the sprockets’timing marks
are aligned with the engine’s timing mark indicators
on the valve covers or head.
15. Loosen the timing belt tensioner bolt and re-
move the belt.
16. Remove the tensioner assembly.
To install:
17. If the auto tensioner rod is fully extended, re-
set it as follows:
a. Clamp the tensioner in a soft-jaw vice in
level position.
b. Slowly push the rod in with the vice until
the set hole in the rod is aligned with the hole in
the cylinder. c. Insert a stiff wire into the set holes to retain
the position.
d. Remove the assembly from the vice.
18. Leave the retaining wire in the tension and in-
stall to the engine.
19. If the timing marks of the camshaft sprockets
and crankshaft sprocket are not aligned at this point,
proceed as follows:
*Keep fingers out from between the
camshaft sprockets. The sprockets may move
unexpectedly because of valve spring pres-
sure and could pinch fingers.
a. Align the mark on the crankshaft sprocket
with the mark on the front case. Then move the
sprocket 2 teeth clockwise to lower the piston so
the valve can’t touch the piston when the
camshafts are being moved.
b. Turn each camshaft sprocket 1 at a time to
align the timing marks with the mark on the valve
cover or head. If the intake and exhaust valves of
the same cylinder are opened simultaneously,
they could interfere with each other. Therefore, if
any resistance is felt, turn the other camshaft to
move the valve.
c. Align the timing mark of the crankshaft
sprocket, then continue 1 tooth farther in the
counterclockwise direction to facilitate belt instal-
lation.
20. Using 4 spring loaded paper clips to hold the
belt on the cam sprockets, install the belt to the
sprockets in the following order:
l M-exhaust camshaft sprocket for the
front head
l 2nd-intake camshaft sprocket for the
front head
l trd-water pump pulley
l 5th-exhaust camshaft sprocket for tile
rear head
l Ah-intake camshaft sprocket for the rear
l Gth-idler pulley head l 7th-crankshaft sprocket l 8th-tensioner pulley
21. Turn the tensioner pulley so its pin holes are
located above the center bolt. Then press the ten-
sioner pulley against the timing belt and simultane-
ously tighten the center bolt.
22. Make certain that all timing marks are still
aligned. If so, remove the 4 clips.
23. Turn the crankshaft l/d turn counterclockwise,
then turn it clockwise until all timing marks are
aligned.
24. Loosen the center bolt on the tensioner pul-
ley. Using tool MD998767 or equivalent and a torque
wrench, apply a torque of 7 ft. Ibs. (10 Nm). Tighten
the tensioner bolt; make sure the tensioner doesn’t
rotate with the bolt.
25. Remove the set wire attached to the auto ten-
sioner, if the wire was not previously removed.
26. Rotate the crankshaft 2 complete turns clock-
wise and let it sit for approximately 5 minutes. Then,
make sure the set pin can easily be inserted and re-
moved from the hole in the tensioner.
27. Measure the auto tensioner protrusion (the
distance between the tensioner arm and auto ten-
sioner body) to ensure that it is within 0.15-0.18 in.
(3.8-4 5mm). If out of specification, repeat Steps
l-4 until the specified value is obtained.
28. Make sure all pieces of packing are posi-
tioned in the inner grooves of the lower cover, posi-
tion cover on engine and install mounting bolts in
their original location.

3-46 ENGINEANDENGINEOVERHAUL
29. Install the engine support bracket and secure
using mounting bolts in their original location. Lubri-
cate the reaming area of the reamer bolt and tighten
slowly.
30. Install the idler pulley.
31. Install the engine mount bracket. Remove the
engine support fixture.
32. Make sure all pieces of packing are posi-
tioned in the inner grooves of the upper cover and in-
stall.
33. Connect the brake fluid level sensor.
34. Install the crankshaft pulley. Tighten the bolt
to 130-137ft. Ibs. (180-190 Nm).
35. install the belt tensioner assembly and the
power steering belt.
36 install the air hose and pipe.
37 Install the alternator.
38. Install the cruise control actuator.
39. Install the engine undercover.
40. Connect the negative battery cable.
199546 MODELS
# See Figure 186
1, Position the engine so the No. 1 cylinder is at
TDC of its compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
4 Remove the cruise control actuator. 5. Remove the alternator, Remove the air hose the engine’s timing mark indicators on the rear timing
and pipe.
6. Remove the belt tensioner assembly and the
power steering belt.
7. Remove the crankshaft pulley.
8. Disconnect the brake fluid level sensor.
9. Remove the timing belt upper cover.
10. Using the proper equipment, slightly raise the
engine to take the weight off the side engine mount.
Remove the engine mount bracket.
11, Remove the alternator/air conditioner idler
..,,ll^,. covers.
Turning the camshaft sprocket when the tim-
ing belt is removed could cause the valves to
contact with the pistons, resulting in severe
engine damage.
15. Remove the bolts that secure the auto-ten-
sioner to the engine block and remove the tensioner.
pu,ey. 12. Remove the engine support bracket. The To install:
mounting bolts are different lengths; mark them for
orooer installation. *The auto-tensioner assembly must be re-
set to correctlv adiust belt tension. , . 13. Remove the timing belt lower cover. Timing
bolt cover mounting bolts are different in length, note
their position during removal.
Be sure to disconnect the negative battery
cable. Wait at least 90 seconds after the neg-
ative battery cable is disconnected to prevent
possible deployment of the air bag.
14. If the same timing belt WIII be reused, mark
the direction of the trming belts rotation for installa-
tion In the same direction, Be sure the engine is posi-
tioned so the No. 1 cylinder is at the TDC of its com-
pression stroke and the timing marks are aligned with _ -
16. Loosen the center bolt of tensioner pulley to
provide timing belt slack.
17. Remove the timing belt assembly.
18. Posrtion the auto-tensioner into a vise with
soft iaws. The olua at the rear of tensioner protrudes,
be sure to usea v&her as a spacer to protect the
plug from contacting vise jaws.
19. Slowly push the rod mto the tensioner until
the set hole in rod is aligned with set hole in the
auto-tensioner.
20. Insert a 0.055 in. (1.4mm) wire into the
aligned set holes, Remove the tensioner from the vise
and install it on the engine.
21. Tighten tensioner mounting bolts to 17 ft. Ibs.
(24 Nm).
Timing marks
(on right
rocker cover)
Camshaft sprocket
Timing marks
mark (on oil pump case)
Crankshaft sprocket
Fig. 186 Sprocket alignment for timing belt installation-1995116 Diamante with the 3.N (6672) DDDD engine

ENGINEANDENGINEOVERHAUL 3-47
DO NOT rotate or turn the camshafts when re-
moving the sprockets or severe engine dam-
age will result from internal component in-
terference.
22. Align the mark on the crankshaft sprocket
with the mark on the front case. Then, move the
crankshaft sprocket 1 tooth counterclockwise.
23. Align the timing marks of the camshafts with
the marks on the rear covers.
24. Using large paper clips to secure the timing
belt to the sprockets, install the timing belt in the fol-
lowing order. Be sure camshafts-to-cylinder heads
and crankshaft-to-front cover timing marks are
aligned. Install the timing belt around the pulleys in
the following order:
a. Exhaust camshaft sprocket (front bank).
b. Intake camshaft sprocket (front bank).
c. Water pump pulley.
d. Intake camshaft sprocket (rear bank).
e. Exhaust camshaft sprocket (rear bank).
f. Tensioner pulley.
g. Crankshaft pulley.
h. Idler pulley.
*Since the camshaft sprockets turn easily,
secure them with box wrenches when in-
stalling the timing belt.
25. Align all timing marks on the crankshaft and
raise the tensioner pulley against the belt to remove
slack, snug tensioner bolt.
26. Check the alignment of all the timing marks
and remove the clips that secure the timing belt to the
camshaft sprockets.
27. Rotate the engine 1/4 turn counterclockwise,
then rotate the engine clockwise to align the timing
marks. Check that all the timing marks are in align-
ment.
28. Loosen the center bolt on the tensioner pul-
ley.
29. Using tool MD998752 or equivalent and a
torque wrench, apply 84 inch Ibs. (10 Nm) to the tool
on the tensioner. Tighten the tensioner bolt to 35 ft.
Ibs. (49 Nm) and be sure the tensioner does not ro-
tate with the bolt. 30. Rotate the crankshaft two complete turns
clockwise and let it sit for approximately five minutes.
Then, check that the set pin can easily be inserted
and removed from the hole in the auto-tensioner.
31. Remove the set wire attached to the auto-ten-
sioner
32. Measure the auto-tensioner protrusion (the
distance between the tensioner arm and auto-ten-
sioner body) to ensure that it is within 0.15-0.18 in.
(3.8-4.5mm). If out of specification, repeat adjust-
ment procedure until the specified value is obtained.
33. Check again that the timing marks on all
sprockets are in proper alignment.
34. Install the timing belt covers and all other ap-
plicable components.
3.51 Engine
p See Figure 187
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
giycoi 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 drive belts.
4. Remove the upper radiator shroud.
5. Remove the fan and fan pulley.
6. Without disconnecting the lines, remove the
power steering pump from its bracket and position it
to the side Remove the pump brackets.
7. Remove the belt tensioner pulley bracket.
8. Without releasing the refrigerant, remove the
air conditioning compressor from its bracket and po-
sition it to the side.
9. Remove the bracket.
Timing marks
liming marks
Tinning marks
79245934 Fig. 187 Clean the timing marks to verify their position when aligning-3.51 engine
10. Remove the cooling fan bracket.
11, On some vehicles It may be necessary to re-
move the pulley from the crankshaft to access the
lower cover bolts.
12. Remove the timing belt cover bolts and the
upper and lower covers from the engme.
13. Detach the crankshaft position sensor con-
nector
14. Using SST MB9g67-01 and MD998754, or
their equivalents, remove the crankshaft pulley from
the crankshaft.
15. Use a shop rag to clean the timing marks to
assist in properly aligning the timing marks.
16. Loosen the center bolt on the tension pulley
and remove the timing belt.
@if the same timing belt will be reused,
mark the direction of timing belt’s rotation,
for installation in the same direction. Be sure
engine is positioned so No. 1 cylinder is at
the TDC of it’s compression stroke and the
sprockets timing marks are aligned with the
engine’s timing mark indicators.
17. Remove the auto-tensioner, the tension pul-
ley and the tension arm assembly.
18. Remove the sprockets by holding the hexago-
nal portion of the camshaft with a wrench while re-
moving the sprocket bolt.
To install: 19. Install the crankshaft pulley and turn the
crankshaft sprocket timing mark forward (clockwise)
three teeth to move the piston slightly past No. 1
cylinder top dead center.
20. If removed, install the camshaft sprockets and
tighten the bolts to 64 ft. Ibs. (88 Nm).
21, Align the timing mark of the left bank side
camshaft sprocket.
22. Align the timing mark of the right bank side
camshaft sprocket, and hold the sprocket with a
wrench so that it doesn’t turn.
23. Set the timing belt onto the water pump pul-
ley.
24. Check that the camshaft sprocket timing mark
of the left bank side is aligned and clamp the timing
belt with double clips.
25. Set the timing belt onto the idler pulley.
if any binding is felt when adjusting the tim-
ing belt tension by turning the crankshaft,
STOP turning the engine, because the pis-
tons may be hitting the valves.
26. Turn the crankshaft one turn counterclock-
wise and set the timing belt onto the crankshaft
sprocket.
27. Set the timing belt on the tension pulley.
28. Place the tension pulley pin hole so that it is
towards the top. Press the tension pulley onto the
timing belt, and then provisionally tighten the fixing
bolt. Tighten the bolt to 35 ft. Ibs. (48 Nm).
29. Slowly turn the crankshaft two full turns in the
clockwise direction until the timing marks align. Re-
move the four double clips.
30. Install the crankshaft position sensor connec-
tor.
31. Install the upper and lower covers on the en-
gine and secure them with the retaining screws. Be
sure the packing is properly positioned in the inner
grooves of the covers when installing.

.
3-48 ENGINEANDENGINEOVERHAUL
32. Install the crankshaft pulley if it was removed.
Tighten the bolt to 110 ft. Ibs. (150 Nm).
33. Install the air conditioning bracket and com-
pressor on the engine. Install the belt tensioner.
34. Install the power steering pump into position.
Install the fan pulley and fan.
35. Install the fan shroud on the radiator.
36. Refill the cooling system.
I
37. Connect the negative battery cable.
38. Start the enaine and check for fluid leaks.
Fig. 188 CI ’ m
belt neeK ror premature panrng of the
Fig. 189 Check if the teeth are cracked or
IUIIII~U at IWSI
arly me me upper ommg oerr cover 1 1 damaged ,
I
is off. If the timina belt shows anv sians of failure. it INSPECTION
ti See Figures 188 thru 195
An inspection of the timing belt should be per-
I ^__^ -I ^I I---.-- I.-. II. .- I. . I I.
should be replaced. Recommended timing belt re:
placement intervals can be found in Section 1 of this
manual.
; REMOVAL&INSTALLATION
u See Figure 198
On all engines, the camshaft oil seal repuires the
Fig. 190 look for noticeable cracks or wear
removal of the timing belt(s). It is advised to replace
the seal while replacing the timing belts. on the belt face
*The seal is located behind the crankshaft
timino sorocket. I I Fig. 191 You may only have damage on one
side of the belt; if so, the guide-could be 1
the culprit
” .
1. To remove the seal use a suitable seal removal
tool and pry it out of the cover.
2. Thoroughly clean the sealing area of the front
fYi”f.V
i ““.“I. 3. Using a suitable installation tool (a large
socket works well if none is available), install the seal
into thr ? front cover,
EnI
Make surf! to install the seal to the correct
depth, if the seal is installed too far, an oil
leak will occur.
Fig. 192 Foreign materials can get in be-
REMOVAL &INSTALLATION
1 .!I Engine
+ See Figures 197 and 198
1. Disconnect the negative battery cable.
2. Rotate the engine and position the No. 1 pis-
ton to TDC of its compression stroke.
3. Disconnect the accelerator cable, breather
hose and PCV hose connections.
4. Matchmark the positionino of the distributor
housing and the positioning of thedistributor rotor to0
the engine block and remove the distributor.
5.
. Remove the valve cover and discard the gas- tween the teeth and cause damage
fraying, gla&g or damage of any kind
’
Itet.
6. Loosen both rocker arm assemblies gradually
and evenly, and remove the rocket shafts from the ve-
hicle.
7. Remove the timing belt covers.
c
Fig 194 Damage on only one side of the
timing belt may indicate a faulty guide Fig. 195 ALWAYS raplace the timing belt at
the interval soecified br the manufacturer
*DO NOT allow the camshaft or the crank-
shaft to rotate after the timing belt is re-
moved. 8. Remove the timing belt assembly.
9. Holding the camshaft sprocket from turning,
loosen and remove the bolt that secures the sprocket.

ENGINEAND ENGINEOVERHAUL 3-59
Most of the cleaning process can be carried out
with common hand tools and readily available sol-
vents or solutions. Carbon deposits can be chipped
away using a hammer and a hard wooden chisel. Old
gasket material and varnish or sludge can usually be
removed using a scraper and/or cleaning solvent. Ex-
tremely stubborn deposits may require the use of a
power drill wrth a wire brush. If using a wire brush,
use extreme care around any critical machined sur-
faces (such as the gasket surfaces, bearing saddles,
cylinder bores, etc.). USE OF A WIRE BRUSH IS NOT
RECOMMENDED ON ANY ALUMINUM COMPO-
NENTS Always follow any safety recommendations
given by the manufacturer of the tool and/or solvent.
You should always wear eye protection during any
cleaning process involvrng scraping, chipping or
spraying of solvents.
An alternative to the mess and hassle of cleaning
the parts yourself is to drop them off at a local garage
or machine shop. They will, more than likely, have
the necessary equrpment to properly clean all of the
parts for a nominal fee.
Always wear eye protection during any clean-
ing process involving scraping, chipping or
spraying of solvents.
Remove any oil galley plugs, freeze plugs and/or
pressed-in bearings and carefully wash and degrease
all of the engine components including the fasteners
and bolts. Small parts such as the valves, springs,
etc., should be placed in a metal basket and allowed
to soak. Use pipe cleaner type brushes, and clean all
passageways in the components. Use a ring ex-
pander and remove the rings from the pistons. Clean
the piston ring grooves with a special tool or a piece
of broken ring Scrape the carbon off of the top of the
piston. You should never use a wire brush on the
pistons. After preparing all of the piston assemblies
in this manner, wash and degrease them again.
Use extreme care when cleaning around the
cylinder head valve seats. A mistake or slip
may cost you a new seat.
When cleaning the cylinder head, remove carbon
from the combustron chamber with the valves in-
stalled. This will avoid damaging the valve seats.
:ig. 234 Drill out the damaged threads with
he specified size bit. Be sure to drill corn.
rletely through the hole or to the bottom oi
I blind hole REPAIRING DAMAGEDTHREADS
# See Figures 232, 233, 234, 235 and 236
Several methods of repairing damaged threads are
available Heli-Coil@ (shown here), Keenserts@ and
Microdop are among the most widely used. All in-
volve basically the same principle-drilling out
stripped threads, tapping the hole and installing a
prewound insert-making welding, plugging and
oversize fasteners unnecessary.
Two types of thread repair inserts are usually sup-
plied: a standard type for most inch coarse, rnch fine,
metric course and metrrc fine thread sizes and a
spark lug type to fit most spark plug port sizes. Con-
sult the individual tool manufacturers catalog to de-
termine exact applications. Typical thread repair kits
will contain a selection of prewound threaded inserts,
a tap (corresponding to the outside diameter threads
of the insert) and an installation tool. Spark plug in-
serts usually differ because they require a tap
equipped wrth pilot threads and a combined
reamer/tap section. Most manufacturers also supply
blister-packed thread repair Inserts separately in ad-
dition to a master kit containing a variety of taps and
inserts plus installation tools
Before attempting to repair a threaded hole, re-
move any snapped, broken or damaged bolts or
studs. Penetrating oil can be used to free frozen
threads. The offending item can usually be removed
with locking pliers or using a screw/stud extractor.
After the hole is clear, the thread can be reparred, as
shown in the series of accompanying illustrations
and in the krt manufacturers instructions.
THREADED
lCCS3039
replaced with thread repair inserts
:ig. 235 Using the kit, tap the hole in order
o receive the thread insert. Keep the tap
veil oiled and back it out frequently to avoid
:logging the threads
To properly rebuild an engine, you must first re-
move it from the vehicle, then disassemble and diag-
nose it. Ideally you should place your engine on an
engine stand. This affords you the best access to the
engine components. Follow the manufacturers direc-
tions for using the stand with your particular engine.
Remove the flywheel or flexplate before installing the
engine to the stand.
Now that you have the engine on a stand, and as-
suming that you have drained the oil and coolant
from the engine, it’s time to strip it of all but the nec-
essary components. Before you start disassembling
the engine, you may want to take a moment to draw
some pictures, or fabricate some labels or containers
to mark the locations of various components and the
bolts and/or studs which fasten them. Modern day
engines use a lot of little brackets and clips which
hold wiring harnesses and such, and these holders
are often mounted on studs and/or bolts that can be
easily mixed up. The manufacturer spent a lot of time
and money designing your vehicle, and they wouldn’t
have wasted any of it by haphazardly placing brack-
ets, clips or fasteners on the vehicle. If it’s present
when you disassemble it, put it back when you as-
semble, you will regret not remembering that little
bracket which holds a wire harness out of the path of
a rotating part.
You should begin by unbolting any accessories
still attached to the engine, such as the water pump,
power steering pump, alternator, etc. Then, unfasten
any manifolds (intake or exhaust) which were not re-
moved during the engine removal procedure. Finally,
Fig. 233 Standard thread repair insert (left),
and spark plug thread insert
im3043 Fig. 236 Screw the insert onto the installer
1001 until the tang engages the slot. Thread
‘he insert into the hole until it is l/4-l/~ turn
lelow the top surface, then remove the tool
and break off the tano usina a uunch

.
4-18 DRIVEABILITYAND EMISSIONS CONTROLS
Name ; Symbol Name j Symbol
I
Arr conditioning compressor clutch relay ; N Heated oxygen sensor (Rear)
j ”
Air condrtioning swatch , s 1 Idle air control motor
/ F
/
Check engrne/Malfunction Indicator lamp
/ Q lgnrtion trmrng adjustment connector
j D
Crankshaft position sensor / M Injector
! O
Data link connector
j p Intake air temperature sensor / K
Distributor (wrth bulk-in camshaft position sensor, , B Manifold absolute pressure sensor
ignition coil and rgnrtron power transistor) I 1 H
Multrport fuel in]ectron (MFI) relay
i T
EGR solenord
i J PaWNeutral positron switch j A
Engine control module
I u I Power steering pressure switch
Engine coolant temperature sensor c / Throttle position sensor
Evaporative emission purge solenoid
I I I (with burl&In closed throttle position switch) / L _
/ G
I
I
- Fuel pump check terminal /
I j E i Vehicle speed sensor (reed switch)
/ R
Heated oxygen sensor (Front)
I w I
i -
Ilectronic engine control component locations-l 51 engine 93154go1