1900 MITSUBISHI DIAMANTE check engine

.~ P.X I_ - “, .- I .-., IS ” .~.I .r
2-2 ENGINE ELECTRICAL
nn
ity and trouble: shooting electrical circuits,
please refer to Section 6 of this manual.
I
The ignition system on the 1.5L, 1993-96 1.8L,
2.OL SOHC, 1994-98 2.4L SOHC, 3.OL SOHC, and
3.5L engines uses a pointless type distributor, whose
advance mechanism is controlled by the Engine Con-
trol Unit (ECU). On the 1.5L, 1.8L, 2.4L and 3.5L en-
gines, the distributor houses a built in ignition coil
and ignition power transistor. The 2.8L SOHC and
3.OL SOHC engines utilize a separate coil and tran-
sister assemblv.
When the ignition switch is turned ON, battery
voltage is applied to the ignition coil primary winding.
As the shaft of the distributor rotates, signals are
transmitted from the oowertrain control module to the
9105zp11 Fig. 1 This spark tester looks iust like a
Fiu. 2 This spark tester has an adjustable
spark plug, attach the clip to ground and air-gap for measuring spark strength and
crank the engine to check for spark testing different voltage ignition systems
.
ignition power trar rsistor. These signals activate the
power transistor to cause ignition coil primary wind-
ing current flow from the ignition coil negative termi-
nal through the power transistor to ground repeatedly.
This interruption induces high voltage in the ignition
coil secondarv windinas, which is diverted throuah
the distributor, spark plug cable and spark plug 6
ground, thus causing ignition in each cylinder.
I
SECONDARYSPARKTEST l;h.4-
! ,L ".~
'$ >,%
If See Figures 1 thru 6
91rJszp12 Fig. 4 This spark tester is the easiest to use
iust alace it on a plug wire and the spark
The best way to perform this procedure is to use a Fig. 3 Attach the clip to ground and crank
spark tester (available at most automotive parts stores). the engine to check for spark
I I voltage is detected and the bulb on the tof
-. will flash with each pulse
I nree types ot spark testers are commonly available.
The Neon Bulb type is connected to the spark plug
wire and flashes with each ignition pulse. The Air Gap
type must be adjusted to the individual spark plug gap
specified for the engine. The last type of spark plug
tester looks like a spark plug with a grounding clip on
the side, but there is no side electrode for the spark to
jump to. The last two types of testers allows the user to
not only detect the presence of spark, but also the in-
tensity (orange/yellow is weak, blue is strong).
1. Disconnect a spark plug wire at the spark plug
end.
2. Connect the plug wire to the spark tester and
ground the tester to an appropriate location on the
engine.
3. Crank the engine and check for spark at the
tester.
4. If spark exists at the tester, the ignition system
is functioning properly.
5. If spark does not exist at the spark plug wire,
perform diagnosis of the ignition system using indi-
vidual component diagnosis procedures,
CYLINDER DROPTEST
p See Figures 7, 8, and 9
The cylinder drop test is performed when an en-
gine misfire is evident. This test helps determine
which cylinder is not contributing the proper power.
The easiest way to perform this test is to remove the
plug wires one at a time from the cylinders with the
engine running. 1. Place the transaxle in P, engage the emer-
gency brake, and start the engine and let it idle.
2. Using a spark plug wire removing tool, prefer-
ably the plier type, carefully remove the boot from
one of the cylinders.
i ’
Make sure your body is free from touching
any part of the car which is metal. The sec-
ondary voltage in the ignition system is high and although it cannot kill you, it will shock
you and it does hurt.
3. The engine will sputter, run worse, and possi-
bly nearly stall. If this happens reinstall the plug wire
and move to the next cylinder. If the engine runs no
differently, or the difference is minimal, shut the en-
gine off and inspect the spark plug wire, spark plug,
and if necessary, perform component diagnostics as
covered in this section. Perform the test on all cylin-
ders to verify the which cylinders are suspect.

2-6 ENGINEELECTRICAL
Fig. 26 Measuring ignition coil secondary
resistance-1997-00 1.8L and 1994-00
2.4L SOHC engines
1. Disconnect the negative battery cable and igni-
tion coil harness connector. 89572914
89572g13
Fig. 28 Measure the primary coil resistance Fig. 27 Measure the secondary resistance
between the connector terminals-2.4L between the towers of the coil-2.4L DOHC
DOHC enaine engine
3. To check the secondary coil resistance, per-
. .
term the tollowmg:
a. Tag and disconnect the spark plug wires
from the ignition coil.
b. Measure the secondary resistance of the
coil between the towers of each individual coil.
c. If the resistance is not between 20.1-27.3
kilo-ohms, replace the ignition coil. 2. Measure the primary coil resistance as follows:
a. Measure the resistance between terminals
3 and 2 (coils at the No. 1 and No. 4 cylinder
sides) of the ignition coil, and between terminals
3 and 1 (coils at the No. 2 and No. 3 cylinder
sides).
b. Compare reading to the desired primary
coil resistance of 0.70-0.86 ohms.
3. Measure the coil secondary resistance as fol-
lows: 3.OL DOHC Engine
c. Detach the connector from the ignition coil.
d. Measure the resistance between the high-
voltage terminals for the No. 1 and No. 4 cylin-
ders, and between the high-voltage terminals for
the No. 2 and No. 3 cylinders.
e. The desired secondary coil resistance is
11.3-15.3 kilo-ohms.
4. If the readings are not within the specified
value, replace the ignition coil.
1997-00 1.8L and 1999-00 2.4L SOHC
Engines
+ See Figure 25 6 See Figures 28 and 29
1. Measure the resistance of the primary ignition
coil as follows:
a. Unplug the electrical connector at the coil
pack. Using an ohmmeter, measure the resis-
tance between the terminals of the coil pack,
NOT THE WIRE HARNESS. Measure the re-
sistance between terminals:
l 2-3 for Coil A l l-3 for Coil B l 4-3 for Coil C
b. Measure the resistance and compare to the
desired specifications of 0.67-0.81 ohms.
1. Measure the resistance of the secondarv iani-
tion coil as follows: , -
a. Insert one of the test leads into the sec-
ondary ignition coil terminal of the coil.
b. Touch the second test lead to terminal 1 or
terminal 2 of the coil connector.
c. Measure the resistance and compare to
the desired specifications of 9.4-12.8 kilo-
ohms.
d. If the measured value is within standard al-
lowance, there are no broken wires or short cir-
cuits.
e. If the actual reading differs from the de-
sired specification, replace the ignition coil.
2.4L DDHC Engines
# See Figures 26 and 27
1. Disconnect the negative battery cable.
2. To check the primary coil resistance, perform
the following:
a. Detach the electrical connector from the
coil pack.
b. Using an ohmmeter, measure the resis-
tance between the two terminals of the coil, NOT
THE WIRE HARNESS.
c. If the resistance is not between 0.74-0.90
ohms, replace the ignition coil. c. If the actual reading differs from the de-
sired specification, replace the ignition coil.
Fig. 28 Measuring ignition coil primary re-
sistance-3.01 DOHC engine
Fig. 29 Measuring ignition coil secondary
resistance-3.01 DOHC enaine d. If the measured value is within standard al-
lowance, there are no broken wires or short cir-
cuits.
2. Measure the resistance of the secondary igni-
tion coil as follows:
3. Insert the lead of the ohmmeter between coil
pack cylinder terminals:
l Between coil terminals l-4 for Co11 A l Between coil terminals 2-5 for Coil B l Between coil terminals 3-6 for Coil C
e. Measure the resistance and compare to the
desired specifications of 11.3-l 5.3 kilo-ohms.
f. If the measured value is within standard al-
lowance, there are no broken wires or short cir-
cuits.
g. If the actual reading differs from the de-
sired specification, replace the ignition coil pack.
REMOVAL&INSTALLATION
1.6L, 2.OL DOHC, and 2.4L DOHC Engines
# See Figure 30
1. Disconnect the negative battery cable.
2. Tag and remove the spark plug wires from the
ignition coil by gripping the boot and not the cable.
I
~::::L “1
I cemer Cwer
2 Scabpiwcabk
3 SPaark piug
I lgnlllancoll
5 Powertran3lrtor
6 ThrotflsDcnv*w
I Crankangle lmsm
93152g11
Fig. 30 Ignition system component loca-
lions-l .6L and 2.OL DOHC engines

.
2-10 ENGINEELECTRICAL 1
2. Disconnect and remove the air intake hose.
3. Loosen the tensioner pulley and remove the
alternator drive belt.
4. On California models, remove the rear bank
converter assembly.
5. Remove the engine roll stopper stay bracket
assembly.
6. On the 3.OL SDHC engine, disconneCt the
EGR temperature sensor wire and remove the EGR
pipe assembly.
7. On the 3.OL SOHC engine, remove the intake
plenum stay bracket assembly.
8. Detach the alternator wiring harness connec-
tors.
Fig, 47 Remove the alternator adjusting bolt
. a a 9. Remove the alternator upper and lower
mounting bolts.
10. From beneath the vehicle, remove the alterna-‘
I^”
._. To install:
11. Position the alternator on the lower mountino
fixture. Install and tighten the mounting bolt and nu<
to M-18 ft. Ibs. (20-25 Nm).
12. Connect the alternator wiring harness.
13. On the 3.OL SOHC engine, install the intake
plenum stay bracket and tighten the mounting bolt to
13 ft. Ibs. (18 Nm).
14. On the 3.OL SOHC engine, install the EGR
pipe and tighten the fitting connections to 43 ft. Ibs.
(60 Nm).
93152015
12. Position the alternator on the mour
sting hmrkd lnrtnll rmr( tinhtnn thn mm dim L VIUVI,VL. lllcllUll Ully llylllvll LltU ,,tvuln,,ly volt and nut
to 17 ft. Ibs. (24 Nm).
13. Reinstall the drive belt and adjust the ten-
pinnor fmtil the nmnor hdt toncinn ic art-:--~
15. On the 3.OL SOHC enoine. connect the EGR
- temperature sensor wire.
16. Connect the engine roll stopper stay and
tighten the mountina bolt to 35 ft. Ibs. (45 Nm) and
the nut to 36-43 ft. Tbs. (50-60 Nm).
’
17. Install the rear converter assembly, if re- Fia. 49 Alternator mountinu-3.0L DOHC enoine
14. Install the alternator upper bracket/brace and
connect the alternator electrical harness.
15. Install the water pump pulleys.
16.
Install the drive belts and adjust to the proper moved.
18. Reinstall the drive belt and adjust the ten-
sioner until the proper belt tension is achieved.
19. Connect the air intake hose.
20. Connect the neoativa hatterv rzahle and check -_. -_. __. _. _=-__
_ _-.._. , ___ _ _. _ _ _ _
the charoina system for orooer ooeration. - - _ -rr- -- - I Ull” Yvll air intake hose.
denser fan.
18.
Install the left side cover panel unde
r the ve-
15. Install the headlamp washer reservoir tank.
hid@ zx ran~kwl 1IIVI” YY ‘“~“““Y.
16. Connect the negative battery cable and check
19. Connect the negative battery cable and check
the charging svstem for proper operation.
-,-.- for proper operation. REMOVAL &INSTALLATION
3.OL SOHC n C, n---I_--
3.OL DOHC Engine
i fhs Itin** tension.
17. On turbocharged Galant models, install the
b See Figure 49
1. Disconnect the negative battery cable.
2. Remove the headlamp washer reservoir tank.
3.
Remove the condenser fan and upper radiator
insulator.
4.
Loosen the tensioner pulley and remove the
alternator drive belt. and J.DL engines
, - , lyures 50 and 51
1. Disconnect the negative battery cable. The voltage regulator on models covered by this
manual is an integral part of the alternator. If the reg-
ulator is defective, replace the alternator assembly.
5. Remove the alternator upper and lower
mounting bolts.
6. Remove the alternator support bracket
mn~lntinn h&c
_ _ _ _ -. ._ ,_._
--TT-.. -.--..-. ..-...
the vehicle.
8. Disconnect the alternator wiring harness.
Q Romnm thn slternatnr frnm thn mhirln V. llYlll”“Y LI1”“I~Y1IIU,“I II”,,, Lll” ,“,,,“,“. To install:
10.
Install the alternator to the vehicle and con-
nect the wiring harness. :z
E$llaf 3EG RtEWtiW~-~ 11
Install the alternatnr wnnnrt hrxket tn thp .._. -.. .._ - .._..._._.
--rT-.. -.--..-. .- I.._ .P _ vehicle and tighten the bracket mounting bolts to
specifications.

ENGINE ELECTRICAL 2-11
l.unVeMlil(GSflWtWJ
2.Gwwator harness con- connectk,,,
3. Engme OS, level d,pst,&
4 Generator
Fig. 51 Alternator mounting -3.51 engine
The starting system includes the battery, starter
motor, solenoid, ignition switch, circuit protection
and wiring connecting the components. An inhibitor
switch located in the park/neutral safety switch or
Transmission Range (TR) sensor is included in the
starting system to prevent the vehicle from being
started with the vehicle in gear.
When the ignition key is turned to the START po-
sition, current flows and energizes the starters sole-
noid coil. The solenoid plunger and clutch shift lever
are activated and the clutch pinion engages the ring
gear on the flywheel. The switch contacts close and
the starter cranks the engine until it starts.
To prevent damage caused by excessive starter ar-
mature rotation when the engine starts, the starter in-
corporates an over-running clutch in the pinion gear. 2. Connect a voltmeter between the positive ter-
minal of the battery and the starter B+ circuit.
3. Turn the ignition key to the START position
and note the voltage on the meter.
4. If voltage reads 0.5 volts or more, there is high
resistance in the starter cables or the cable ground,
repair as necessary. If the voltage reading is ok pro-
teed to the next step.
5. Connect a voltmeter between the positive ter-
minal of the battery and the starter M circuit,
6. Turn the ignition key to the START position
and note the voltage on the meter.
7. If voltage reads 0.5 volts or more, there is high
resistance in the starter. Repair or replace the starter
as necessary.
*Many automotive parts stores have starter
bench testers available for use by customers.
A starter bench test is the most definitive
way to determine the condition of your
starter. 3. Remove the resonator retaining nuts and re-
move the air intake hose and resonator assembly as
required.
rllse care when removing the air cleaner
cover because the air-flow sensor is attached
and is a sensitive component.
4. If equipped with Active-ECS suspension, re-
move the air compressor as follows:
a. Detach the two electrical connectors, from
the compressor.
b. Disconnect the air line at the compressor.
c. Remove the three mounting bolts, securing
the compressor to the chassis.
5. Raise the vehicle and support safely.
6. Remove the engine undercover.
7. Remove the heat shield from beneath the in-
take manifold on the 1.5L engine.
8. If necessary, detach the speedometer cable
connector at the transaxle end.
9. Detach the starter motor electrical connac-
TESTING
Voltage Drop Test
*The battery must be in good condition and
fully charged prior to performing this test. REMOVAL&INSTALLATION
# See Figures 52 and 53
1. Disconnect the negative battery cable.
2. Detach the air-flow sensor assembly connec-
tor and remove the breather hose.
1. Disable the ignition system by unplugging the
coil pack. Verify that the vehicle will not start. tions.
10. Remove the starter motor mounting bolts and
remove the starter.
11. The installation is the reverse of the removal
procedure. Tighten the starter mounting bolts to 22 ft.
Ibs. (31 Nm).
12. Connect the negative battery cable and check
the starter for proper operation.
9315zp19 Fig. 53 Location of the two starter retaining bolts

.
2-12 ENGINEELECTRICAL
*This section describes the operating prina
ciples of sending units, warning lights and
gauges. Sensors which provide information
to the Enafne Control Unit (ECU) or Electronic
or Power&in Control Module (FCM/PCM) are
covered in Section 4 of this manual.
Instrument panels contain a number of indicating
devices (gauges and warning lights). These devices
are composed of two separate components. One is
the sending unit, mounted on the engine or other re-
mote part of the vehicle, and the other is the actual
gauge or light in the instrument panel.
Several types of sending units exist, however most
can be characterized as being either a pressure type
or a resistance type. Pressure type sending units
convert liquid pressure into an electrical signal which
is sent to the gauge. Resistance type sending units
are most often used to measure temperature and use
variable resistance to control the current flow back to
the indicatinq device. Both types of sendinq units are
connected inseries by a wimto the batteryithiough
the ignition switch). When the ignition is turned ON,
current flows from the battery through the indicating
device and on to the sending unit.
89572$43 Fig. 54 Place the sending unit in water and
measure the resistance
2. Disconnect the sending unit wiring harness
and remove the coolant temperature sending unit.
3. Place the sending unit tip in a pan of warm wa-
ter. Use a thermometer to measure the water tempera-
tl KP
L”,“.
4. Measure the resistance across the sending uni
terminals while the sending unit is in the water.
5. Note the ohm reading and compare to the fol-
lowing specifications: i, 56, 57, and 56
1. Disconnect the negative battery cable.
2. Position a suitable drain pan under the radia-
tor.
3. Drain the engine coolant a level below the
coolant temperature sending unit.
4. Disconnect the sending unit wiring harness,
then remove the coolant temperature sending unit
from the engine.
To install:
5. Coat the sending unit threads with a suitable
thread sealant.
6. Install the engine coolant temperature gauge
sending unit into the bore in the engine and tighten
to 7-8 ft. Ibs. (10-12 Nm).
7. Attach the electrical harness connector to the
sendina unit.
8. fill the cooling system to the proper level.
:onnect the negative battery cable.
l Water temperature of 68°F (2O”C)-
2.21-2.69 kilo-ohms resistance
l Water temperature of 158°F (7O’Ck
90.5-117.5 ohms resistance
TESTING l Water temperature of 176°F (8O”C)-
264-328 ohms resistance.
The coolant temperature sendina unit is used to
operate the temperature gauge. Donot confuse this
sending unit with the other switches or sensors used
to signal the engine control unit or air conditioning
regarding temperature of the coolant. Usually, these
other units are mounted near the coolant temoerature
sensor used for engine control. If the resistance is not approximately accurate for
the temperature, the sending unit must be replaced.
Gauge Check
1. Detach the engine coolant gauge sending unit
electrical connector.
2. Connect a suitable test liaht (12V-3.4W) be-
tween the harness side connector and the around.
I
3. Turn the ignition switch to the ON position.
4. Check the condition of the test light and gauge
as follows:
a. If all components are operating properly,
the test light should illuminate and the gauge
needle should move.
b. If the test light is illuminated and the
gauge needle does not move, replace the coolant
temperature gauge.
c. If the test light is illuminated and the
gauge needle does not move, check the fuse for
a broken wire, or resistance between the gauge
terminals
d. If the test light is not illuminated and the
gauge is not moving, check, then replace the
wiring harness, if necessar!y.
Sender Check
p See Figure 64
1. Drain the engine coolant to a level below the
coolant temperature sending unit Fig. 55 Detach the connector from the
coolant temperature sending unit
'ESTING
tauga Check
See Ftgure 69

ENGINE ELECTRlCiL 2-13
ing the oil pressure sending unit
1. Detach the oil pressure gauge unit electrical
connector.
2. Use a suitable test lioht (12V-3.4W) to around
the harnesssideconnecto~ ’ ’ -
3. Turn the ignition to the ON position.
4. Check the condition of the test light and gauge
as follows:
a. If all components are operating properly,
the test light will flash or light steadily and the
oil pressure gauge needle will move. b. If the test light flashes or lights steadily but
the gauge does not move, the gauge must be re-
placed.
c. If neither the test light or the gauge oper-
ate, check the oil pressure gauge circuit and re-
place, if necessary.
Sending Unit Check
1. Remove the electrical harness connector from
the sending unit and remove the sending unit from
the oil filter head.
2. Connect an ohmmeter between the terminal
and the sending unit body cavity and check for con-
ductivity. If there is no conductivity, replace the send-
ing unit.
3. Next, insert a very thin wedge through the oil
hole in the end of the sending unit. Push the wedge
in slightly and measure resistance. There should be
- - -- d . . . .
no conoucovey.
4. If there is conductivity, even when wedge is
pushed, replace the sending unit.
5. If there is no conductivity when a 71 psi pres-
sure is placed through the oil hole, the sending unit
is operating properly. 6. Check to see that there is no air pressure leak-
age through the sending unit. If there is air pressure
leakage, the diaphragm is broken and the sending
unit will require replacement.
REMOVAL &INSTALLATION
b See Figures 60 thru 65
1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. Detach the electrical harness connector from
the sending unit, then remove the unit from the oil fil-
ter head.
To install:
4. Aoolv a thin bead of sealant to the threaded
portion of the oil pressure sending unit. Do not allow
sealer to contact the end of the threaded portion of
the sending unit.
5. Install the sending unit and tighten to 8 ft. tbs.
(12 Nm). Do not over-tighten the sending unit.
6. Attach the electrical harness connector to the
/pressure sending unit g3’9wi / m&e shape . . . Fig 60 Detach the connector from the oil
g3152w Fig 61 The body of the sending unit has a sending unit.
7. Carefully lower the vehicle, then connect the
negative battery cable.
93152PM Fig. 62 . , .
and the use of an oil pressure
sending unit socket greatly aids the removal
and installation
Fig. 65 Before installing the sending unit,
it is a good idea to place Teflon@ tape on
the threads

Troubleshooting Basic Starting System Problems Troubleshooting Basic Charging System Problems
Pmblem
Starter motor rotates engrne slowly cause
* Battery charge low or battery
defecttve Sobnlon
. Charge or replace battery
- Defective crrcurt between battery
and starter motor
* Low load current
* Hugh load current + Clean and ttghten, or replace
cables
* Bench-test starter motor Inspect
for wom brushes and weak
brush springs.
. Bench-test starter motor Check
engtne for fncbon, drag or coolant
rn cylinders. Check nng gear-to-
prnton gear clearance.
Starter motor wrll not rotate engrne
Starter motor dnve wrll not engage
(solenotd known to be good)
Starter motor dnve wtli not
dtsengage * Battery charge low or battery * Charge or replaoe battery
defecttve
* Faulty solenord . Check solenoid ground Reparr or
replace as necessary.
* Damaged drive pnron gear or * Replace damaged gear(s)
ring gear
* Starter motor engagement weak . Bench-test starter motor
. Starter motor rotates slowly wtth . Inspect dnve yoke pull-down and
high load current pornt gap, check for worn end
bushtngs. check m-g gear clear-
ance
. Engine setzed * Repatr engk7e
. Defecbve contact pant assembly * Reparr or replace contact pornt
assembly
. Inadequate contact pornt assembly + Repatr connectron at ground screw
ground
- Defeckve hold-In co11
* Replace field w~ndrng assembly
- Starter motor loose on flywheel . Ttghten mounttng bolts
houstng
. Worn drive end bustng . Replace bushtrg
* Damaged nng gear teeth . Replace ring gear or dnveplate
* Drive yoke return spnng broken or . Replace spnng
mtsstng
Starter motor dnve d&engages
prematurely
Low load current * Weak drive assembly thrust spnng * Replace dnve mechamsm
* Hold-tn co11 defeckve
. Replace field wtndtng assembly *
- Worn brushes . Replace brushes
* Weak brush springs * Replace spnngs Problem
Noisy alternator cause
* Loose mounbngs
. Loose drive pulley SoluIion
. Ttghten mountrng bolts
. Tighten pulley
. Worn beanngs
* Brush notse
* Internal circuits shorted (Hugh
pitched whrne) * Replace alternator
. Replace alternator
. Replace alternator
Squeal when starting engtne or . Glazed or loose belt * Replace or adfust belt
acceleratmg
Indicator light rematns on or . Broken belt . Install heft
ammeter rndrcates drscharge . Broken or dksconnected wares - Repatr or connect Waring
(ejrgrne runmng) * Internal aitemator problems * Replace alternator
. Defectrve voltage regulator . Replace vottage regulator/alternator
Car Irght bulbs contmually bum out- * Alternator/regulator overchargtng . Replace voltage
batter-v needs water conbnually regulatoriatternator
Car kghts flare on acceleratton . Battery low
. Internal alternator/regulator
problems * Charge or replace battery
. Replace alternator/regulator
Low voltage output (alternator lght
fltckers conbnually or ammeter
needle wanders) * Loose or worn belt
* Dkly or corroded connecttons
* Internal alternator/regulator
oroblems . Replace or adjust beit
. Clean or replace connecttons
* Replace alternator/regulator

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