1900 MITSUBISHI DIAMANTE engine coolant

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.

3-26 ENGINEANDENGINEOVERHAUL
18. Remove the self-locking nuts and the small
retaining bolt holding the exhaust pipe to the bottom
of the exhaust manifold. Separate the pipe from the
manifold and remove the gasket.
19. Remove the bolts holding the support brace
to the bottom of the intake manifold.
20. Use the special hex wrench (MB 998051-01)
and loosen the head bolts in the order shown in 2 or
3 passes. When all are finger loose, remove the bolts.
21. Rock the head gently to break it loose; if tap-
ping is necessary, do so with a rubber or wooden
mallet at the corners of the head. DO NOT pry the
head up by wedging tools between the head and the
block.
22. Lift the head free of the engine. It is coming
off with both manifolds and the intake plenum at-
tached; the help of an assistant is recommended for
lifting. Support the head assembly on wooden blocks
on a suitable workbench. Refer to Cleaning and In-
spection in this section for work to be done before in-
stalling the head. If the head has been removed for
work other than gasket replacement, the rocker as-
sembly and camshaft or other components may be
removed.
Before reinstallation, the head should be com-
pletely assembled on the bench. This allows proper
location and tightening of all the external items.
To install: 23. Place a new gasket on the engine so that the
identifying mark faces up (towards the head) and is at
the timing belt end of the block. Install a new gasket
on the exhaust pipe.
Do not apply sealant to the head gasket or
mating surfaces.
24. Install the head straight down onto the block.
Try to eliminate most of the side-to-side adjust-
ments as this may move the gasket out of position.
Install the bolts by hand and just start each bolt 1 or
2 turns on the threads.
25. The head bolt torque specification is 68 ft.
Ibs. (92 Nm) for a cold engine. The bolts must be
tightened in the order shown in 3 steps. On the first
pass, tighten all the bolts to about 22 ft. Ibs. (30 Nm),
then proceed through the order tightening each bolt
to about 45 ft. Ibs. (61 Nm). The final torque is
achieved on the third pass.
26. Install the intake manifold support brace to
the manifold and tighten the bolts to 16 ft. Ibs. (22
Nm). 27. Making sure the gasket is still in place, con-
nect the exhaust pipe to the base of the exhaust man-
ifold. Use new self-locking nuts; tighten the nuts and
the small bracket bolt to 26 ft. Ibs. (35 Nm).
28. Make sure the camshaft has not changed po-
sition during repalrs. Carefully install the camshaft
sprocket and belt onto the camshaft. Tighten the re-
taining bolt to 66 ft. Ibs. (91 Nm).
29. Install the upper timing belt cover, then
tighten the bolts to 8 ft. Ibs. (11 Nm).
30. Apply sealant to the contact surfaces of the
half-circle plug and install the plug in the head In-
stall the valve cover and gasket.
31. Install the engine mount bracket to the en-
gine. Tighten the mounting nuts and bolts to 42 ft.
Ibs. (57 Nm).
32. Adjust the jack (if necessary) so that the en-
gine mount bushing aligns with the bodywork
bracket. Install the through-bolt and tighten the nuts
snug.
33. Slowly release tension on the floor jack so
that the weight of the engine bears fully on the
mount. Tighten the through-bolt to 52 ft. Ibs. (71
Nm) and the small safety nut to 26 ft. tbs. (36 Nm).
34. Install the bracket holding the power steering
hose and air conditioning hose to the top of the en-
gine mount.
35. Position the control wiring harness and in-
stall the retaining bolts. Attach each electrical con-
nector to its proper location, making sure the wires
are properly routed and firmly connected.
36. Install the spark plug wires in the distributor
cap.
37. Connect the PCV hose and the vacuum
hose(s).
38. Connect the fuel return line. Connect the
brake booster vacuum hose.
39. Install the heater hose, the coolant by-pass
hose and.the upper radiator hose. Pay close attention
to the position and routing of these hoses and insure
that they are not crimped or constricted. Install the
clamps in the same location as before removal.
40. Install a new O-ring on the high pressure fuel
line and lubricate it with a coating of gasoline. Care-
fully connect the high pressure fuel line to the fuel
rail, taking care not to damage the O-ring. Tighten the
bolts only to 4 ft. Ibs. (6 Nm).
41. Connect the accelerator cable and adjust it as
necessary.
42. Install the air intake hose.
43. Fill the cooling system with coolant.
44. Changing the oil and filter is recommended
to eliminate pollutants in the oil.
Intake side
I Front of
engine
Exhaust side
Fig. 116 Cylinder head bolt removal se-
quence-l .6L and 2.OL DDHC engines intake
side
Front of
entine
Exhaust side 7923PG18
Fig. 117 Cylinder head bolt torque se-
quence-l .6L and 2.OL DDHC engines Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
45. Connect the negative battery cable.
46. Start the engine and check for leaks of fuel,
vacuum or oil.
47. Check the operation of all engine electrical
systems as well as dashboard gauges and lights.
48. Perform necessary adjustments to the accel-
erator cable, drive belts and engine specifications.
Adjust the coolant level after the engine has cooled
Off.
1.6L and 2.OL DDHC Engines
ti See Figures 116,117, and 116
1. Relieve fuel system pressure.
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. Disconnect the accelerator cable. There will
be 2 cables if equipped with cruise-control.
5. Remove the air cleaner with the air intake
hose.
6. Detach the electrical connectors from the the
oxygen sensor, engine coolant temperature sensor,
the engine coolant temperature gauge unit and the
engine coolant temperature switch on vehicles with
air conditioning.
7. Disconnect the wiring from the ISC motor,
throttle position sensor, crankshaft angle sensor, fuel
injectors, ignition coil, power transistor, noise filter,
knock sensor on turbocharged engines, EGR temper-
ature sensor (California vehicles), ground cable and
engine control wiring harness.
Painted mark Painted mark
Fig. 116 To ensure that the bolts are tight-
ened exactly 160 total degrees, mark the
11.6L and 2.OL DDHC engines head bolt and cylinder head as shown-

ENGlNEANDENGlNEOVERHALiL 3-27
8. Remove the upper radiator hose and the
sages thoroughly. Check the head for flatness. End to 31. Install the air cleaner and intake hose. Con-
overflow tube. end, the head should be within 0.002 in. (0.05mm) nect the breather hose.
9. Remove the spark plug cable center cover,
normally, with 0.008 in. (0.2mm) the maximum al- 32. Change the engine oil and oil filter,
then remove the spark plug cables.
lowed out of true. The total thickness allowed to be 33. Fill the system with coolant.
10. Disconnect and plug the high pressure fuel
removed from the head and block is 0.008 in.
line. 34. Connect the negative battery cable.
(0.2mm) maximum. 35. Run the vehicle until the thermostat opens,
11. Disconnect the small vacuum hoses.
23. Place a new head gasket on the cylinder and fill the radiator completely.
12. Remove the heater hose and water bypass
block with the identification marks at the front top 36. Check and adjust the idle speed and ignition
hose.
(upward) position. Make sure the gasket has the timing.
13. Remove the PCV hose.
proper identification mark for the engine. Do not use 37. Once the vehicle has cooled, recheck the
14. If turbocharged, remove the vacuum hoses,
sealer on the gasket. Replace the turbo gasket and coolant level.
water line and eyebolt connection for the oil line for
ring, if equipped.
the turbo.
24. Carefully install the cylinder head on the 2.41 Engine
15. Disconnect and plug the fuel return hose. block. Using 3 even steps, torque the head bolts, in
16. Disconnect the brake booster vacuum hose.
sequence, to 65-72 ft. Ibs. (90-100 Nm). This torque b See Figures 119 thru 131
17. Remove the timing belt. applies to a cold engine. If checking cylinder head
18. Remove the valve cover and the half-round
bolt torque on hot engine, the desired specification is 1. Relieve the fuel system pressure.
seal.
7240 ft. Ibs. (100-110 Nm). 2. Disconnect the negative battery cable.
19. On non-turbocharged engines, remove the 3. Remove the air cleaner with all air intake
25. On turbocharged engine, install the heat
hoses.
exhaust pipe self-locking nuts and separate the ex-
shield. On non-turbocharged engines, install a new
haust pipe from the exhaust manifold. Discard the
exhaust pipe gasket and connect the exhaust pipe to 4. Drain the cooling system.
gasket.
the manifold.
20. On turbocharged engines, remove the sheet
26. Apply sealer to the perimeter of the half-
metal heat protector and remove the bolts that attach
round seal and to the lower edges of the half-round Never open, service or drain the radiator or
the turbocharger to the exhaust manifold.
portions of the belt-side of the new gasket. Install the cooling system when hot; serious burns can
21. Loosen the cylinder head mounting bolts in 3
valve cover. occur from the steam and hot coolant. Also,
steps, starting from the outside and working inward,
27. Install the timing belt and all related items. when draining engine coolant, keep in mind
Lift off the cylinder head assembly and remove the
28. Connect or install all previously disconnected that cats and dogs are attracted to ethylene
n head gasket.
hoses, cables and electrical connections. Adjust the glycol antifreeze and could drink any that is
To install:
throttle cable(s). left in an uncovered container or in puddles
22. Thoroughly clean and dry the mating surfaces
29. Install the spark plug cable center cover. on the ground. This will prove fatal in suffi-
of the head and block. Check the cylinder head for
30. Replace the O-rings and connect the fuel eient quantities. Always drain coolant into a
cracks, damage or engine coolant leakage. Remove
lines. sealable container. Coolant should be reused
scale, sealing compound and carbon. Clean oil pas- unless it is contaminated or is several years
old.
g3153p44 Fig. 119 Remove the upper radiator hose
* . . 1 Fig. 129 . . . and also the lower rad:gzi / cyl.der head g3153W
Fig 121 Remove the heater hose from the
hoses from the thermostat housing
Fig. 122 Remove the three thermostat hous-
Fig. 123 . . . then remove the thermostat
ing retaining bolts . . .
housing from the cylinder head
93153p50 Fig. 124 Using a suitable device, such as a
breaker bar and the appropriate socket,
loosen the cylinder head bolts in the proper
sequence

3-28 ENGINEANDENGINEOVERHAUL
lntsltaelde Front of engine c3
Fig. 125 Cylinder head bolt removal se- Fig. 127 Grasp the cylinder head and lift it
off the engine block with the manifolds at-
ig. 126 A magnet can be extremely help- tached. It is a good idea to use a helper for
quence-2.41(4664) engine I ful when removing the cylinder head bolts 1 1 this, as the assembly is very heavy
93153pOO Fig. 128 Remove the cylinder head gasket 33153p4!3 Fig, 129 Thoroughly clean the gasket sur- Fig. 130 Also, make sure to thoroughly
clean the engine block mating surfaces be-
from the block
faces of the cylinder head fore reassembling the engine
l Intake Air Temperature (IAT) sensor l Throttle Position (TP) sensor
: /I;%;,; rZ;Z;;(lAC) motor 23. Inspect the cylinder head bolt length prior to
installation. If the length exceeds 3.91 in. (99.4mm),
the bolt must be replaced. Install the washer onto the
bolt so the chamfer on the washer faces towards the
l Ignition coil head of the bolt. l Camshaft Position (CMP) sensor 24. Carefully install the cylinder head on the l Exhaust Gas Recirculation (EGR) solenoid block and tighten the cylinder head bolts as follows:
valve a. Following the proper tightening sequence,
11. Remove the spark plug wire cover and wires. tighten the cylinder head bolts to 58 ft. Ibs. (78
12. At the thermostat case assembly, remove the Nm).
coolant hoses and unbolt the thermostat case from b. Loosen all bolts completely.
the engine. c. Torque bolts to 15 ft. Ibs. (20 Nm). ’
Fig. 131 Cylinder head bolt installation se-
13. Remove the upper timing belt cover d. Tighten bolts an additional 1/4 turn.
14. Align all timing marks. e. Tighten bolts an additional 1/4 turn.
15. Secure the timina belt to the camshaft 25. Install the new exhaust pipe aasket and con-
iliiL.-
5.
9. Disconnect and plug the fuel return hose. Disconnect the accelerator cable. Remove the
cable mounting brackets and position the cable
10. Label and detach the connectors from the fol- aside.
lowing components: 6. Remove the breather hose.
* A$ compressor
* Power steering pressure switch ‘7. Label and disconnect the vacuum lines at the
* Heated Oxygen (HO$) sensor tree body.
* Engine Coolant Temperature (ECT) gauge . 8. D&connect and plug the high pressure fuel
sender
lint3
l
ECT sensor l Manifold Absolute Pressure (MAP) sensor sprocket with cord or a wire tie.
fold. Discard the gasket, 16. Remove the camshaft sprocket.
20. Loosen the cylinder head mounting bolts in 3 17.
steps, starting from the outside and working inward. Remove the valve cover and the half-round
seal.
Lift off the cylinder head assembly and remove the 18. Disconnect the intake manifold stay bracket
head gasket.
To install: from the intake manifold.
21. Thoroughly clean the mating surfaces of the 19. Remove the exhaust pipe self-locking nuts
head and block. and separate the exhaust pipe from the exhaust mani-
22. Place a new head gasket on the cylinder
block with the identification marks at the front top
(upward) position. Do not use sealer on the gasket. nect the exhaust pipe to the manifold. Tighten the
portions of the belt-side of the new gasket. Install thr bolts to 33 ft. Ibs. (44 Nm).
valve cover. 26.
29. Install the thermostat case and tighten the
Install the camshaft sprocket with the timing mounting bolts to 18 ft. Ibs. (24 Nm).
belt attached. Remove the cord or wire tie.
30. Install the upper timing belt cover. 27. Connect the coolant hoses to the thermostat
31. Connect the intake manifold stay and tighten case.
the mounting bolts to 22 ft. Ibs. (30 Nm). 28.
32. Attach the connectors to the following com- Apply sealer to the perimeter of the half-
round seal and to the lower edges of the half-round
ponents: l A/C compressor l Power steering pressure switch

ENGINEANDENGINEOVERHAUL 3-29
l HOzS sensor l ECT gauge sender l ECT sensor l MAP sensor l IAT sensor l TP sensor l IAC motor l injector harness l ignition coil l CMP sensor l EGR solenoid valve
33. Install the spark plug wires and cover,
34. Replace the O-rings and connect the fuel
lines.
35. Install the air cleaner and intake hose. Con-
nect the breather hose.
36. Fill the cooling system.
37. Connect the negative battery cable
3.01 DDHC Engine
ti See Figures 132 and 133
1. Relieve fuel system pressure. 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 quantltles. 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 hoses.
4. Remove air intake plenum and intake mani-
fold.
5. Remove the exhaust manifold.
6. Remove the timing belt. Refer to the timing
belt procedure in this section.
7. Remove the breather hose.
8. Remove the spark plug wire center cover and
remove the spark plug wires.
9. Remove the rocker covers.
10. Remove the intake camshaft sprockets.
11. Remove the rear timing belt cover.
12. Remove the ignition coil assembly.
13. Disconnect all water hoses from the thermo-
stat housing and remove the housing.
14. Disconnect the water inlet from the front
head.
15. Loosen the cylinder head mounting bolts in
the reverse of the torque sequence and loosen the
bolts in three steps. Lift off the cylinder head assem-
bly and remove the head gasket.
To install: 16. Thoroughly clean the sealing surfaces of the
head and block.
17. Place a new head gasket on the cylinder
block with the identification marks in the front top
(upward) position. Do not use sealer on the gasket,
18. Carefully install the cylinder head on the
block. Be sure the head bolt washers are installed
with the chamfered edge upward. Using three even
steps, torque the head bolts in sequence, to 76-83 ft.
Ibs. (105-115 Nm).
@ Timing belt side
7923PG26 :ig. 132 Tighten the cylinder head bolts ac-
:ording to the sequence shown-3.01
SDHC and DDHC) engines
Rear bank
[::od
04
~8 01
Front bank
'1 "8
509 010 011 6
1.03 07 02 7923ffi25 Fig. 133 Rocker cover bolt torque se-
quence-Diamante 3.OL DDHC engine
19. Install new O-ring and connect the water inlet
to the head. Tighten the mounting bolt to 9-11 ft. Ibs
(12-15 Nm).
20. Replace the gaskets and install the thermostat
housing. Tighten the mounting bolts to 12-14 ft. Ibs.
(17-20 Nm).
21. Using new hose clamps, connect the hoses to
the thermostat housing.
22. Install the Ignition coil and torque the mount-
ing bolts to 7 ft. Ibs. (10 Nm).
23. Install the rear timing belt cover and torque
the mounting bolts to 17 ft. Ibs. (24 Nm).
24. Install the intake camshaft sprockets. Tighten
the retaining bolt to 65 ft. Ibs. (90 Nm).
25. Apply sealer to the lower edges of the valve
cover. Tighten the bolts in the proper sequence to
44-51 inch Ibs. (5-6 Nm).
26. Connect the spark plug wires and install the
center cover. Tighten the bolts that secure the center
cover to 27 inch Ibs. (3 Nm)
27. Install the breather hose.
28. Install the timing belt. Refer to the timing belt
procedure in this section,
29. Install the exhaust manifold assembly.
30. Using all new gaskets, install the intake man-
ifold and air intake plenum.
31. Install the air intake hoses.
32. Change the engine oil and oil filter. 33. Fill the system wrth coolant.
34. Connect the negabve battery cable.
35. Adjust the accelerator cable.
36. Start the engine.
37. Check and adjust the idle speed and ignition
timing.
38. Once the vehicle has cooled, recheck the
coolant level.
3.OL SDHC Engine
# See Figure 132
1. Relieve the fuel system pressure.
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
alvcol antifreeze and could drink any that is
Left in an uncovered container or in puddles
on the ground. This will Drove fatal in suff i-
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.
5. Remove the exhaust manifold.
6. Remove the air intake plenum and intake
manifold.
7. Remove the timing belt. Refer to the timing
belt procedure in this section.
8. Remove the camshaft sprockets and the rear
timing belt cover.
9. Remove the power steering pump bracket. If
removing the rear head, remove the alternator brace.
10. Disconnect the water inlet pipe.
11. Remove the purge pipe assembly.
12. Remove the valve cover,
13. Using the reverse sequence of the installation
sequence, loosen the cylinder head mounting bolts in
three steps. Lift off the cylmder head assembly and
remove the head gasket.
To install: 14. Thoroughly clean the sealing surfaces of the
head and block.
15. Place a new head gasket on the cylinder
block making sure the identification mark on the
cylrnder head gasket is in the front top (upward) loca-
tion. Do not use sealer on the gasket,
16. Carefully install the cylinder head on the
block. Be sure the head bolt washers are installed
with the chamfered edge upward. Using three even
steps, torque the head bolts in sequence, to 7683 ft.
Ibs. (105-115 Nm).
17. Apply sealer to the lower edges of the half-
round portions and install the valve cover. Tighten
valve cover bolts to 7 ft. Ibs. (9 Nm).
18. Install the purge pipe assembly.
19. Connect the water inlet pipe.
20. Install the power steering pump bracket and
alternator brace.
21. Install the rear timing belt cover and camshaft
sprockets. Torque the retaining bolt to 65 ft. Ibs. (90
Nm).
22. Install the timing belt. Refer to the timing belt
procedure in this section.

.
3-30 ENGINEANDENGINEOVERHAUL
23. Using all new gaskets, install the intake man-
ifold, air intake plenum and exhaust manifold.
24. Install the air intake hose.
25. Fill the system with coolant.
26. Connect the negative battery cable.
27. Start the engine.
28. Check and adjust the idle speed and ignition
timing.
29. Once the vehicle has cooled, recheck the
coolant level.
3.51 Engine
ti See Figure 134
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. Remove the intake and exhaust manifolds.
5. Remove the spark plug wires.
6. Remove the cylrnder head covers.
7. Remove the timing belt rear center cover.
8. Loosen the cylinder head bolts gradually in
three stages, in the opposite of the installation se-
quence.
9. Remove the cylinder head.
To install: 10. Clean the cylinder head and mounting sur-’
face on the engine block.
11. Install the cylinder head using a new gasket.
12. Tighten the bolts in sequence using three
stages to 76-83 ft. Ibs. (103-113 Nm).
13. Install the timing belt rear center cover.
14. Install the cylinder head covers using new
gaskets. Tighten the bolts to 2-3 ft. Ibs. (334 Nm).
15. Install the spark plug wires,
16. Install the intake and exhaust manifolds,
17. Install the timing belt. Refer to the timing belt
procedure in this section.
7923PGD2 Fig. 134 Cylinder head bolt tightening se-
quence-3.5L engine
18. Install any remaining components.
19. Refill the cooling system.
20. Connect the negative battery cable.
REMOVAL &INSTALLATION
1.5L Engine
p See Figure 135
1. Disconnect the negative battery cable.
2. Drain the engine oil.
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.
3. Remove the bell housing lower cover.
4. Remove the oil pan retainer bolts. Tap the oil
pan with a rubber mallet to break seal.
*Do not use a prytool when removing the oil
pan. If available, oil pan remover tool
MD998727 or equivalent may be used to
break the seal. To install:
5. Clean all gasket surfaces of the cylinder
block and the oil pan.
6. Apply sealant to the gasket surfaces of the oil
pan.
7. Install the oil pan onto the cylinder block
within 15 minutes after applying sealant. Install the
fasteners and tighten to 60 inch Ibs. (7 Nm).
8. Install the bell housing cover.
9. Install the oil drain plug with a new seal and
tighten to 29 ft. Ibs. (40 Nm).
10. Lower the vehicle and fill the crankcase to the
proper level with clean engine oil.
Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
11. Connect the negative battery cable. Start the
engine and check for leaks.
1.8L Engine
# See Figure 136
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Remove the oil pan drain plug and drain the
engine oil.
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
I Fig. 135 Oil pan and related components-Mirage 1.5L (4615) engine

3-36 ENGINEANDENGINEOVERHAUL
The EPA warns that urolonaed 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.
4. Remove the solash shield from the wheel
93153p65 93153p60 well.
5. Remove the oil filter adapter.
6. Remove the lower and upper oil pans.
7. Remove the lower baffle, oil pump pick-up
and upper baffle.
8. Remove the oil pump case mounting bolts
and the oil pump case.
9. Remove the oil pump gear cover.
10. Make matchmarks on the oil pump rotors be-
fore removing them.
,,. r.-- -IL- -.( -L.11---‘I --. IL- -.I _ --
nemove me cranksnarr sear rrom me 011 pump
case.
To instell:
12. Install a new crankshaft seal in the oil pump
cover.
13. Apply engine oil to the rotors, then align the
matchmarks and install the rotors in the oil pump Fig. 153 Remove the fasteners, then re-
move the side inner fender splash shield
3. Raise and support the vehicle.
4. Remove the passenger side front wheel.
5. Remove the passenger side inner fender
splash shield to gain access to the crankshaft
damper.
6. On the 1.5L, 1.6L, 2.OL and 2.4L engines, re-
move the oullev-to-sorocket bolts.
7. On thei .5L, i .8L, 3.OL and 3.5L engines, re-
move the crankshaft pulley center retaining bolt.
8. Remove the damper from the crankshaft us
ing a suitable puller.
-la install:
9. Place the damper onto the crankshaft, ensur-
ing the key-way is aligned.
10. On the 1.5L, 1.8L, 3.OL and 3.5L engines, in-
e crankshaft pulley center retaining bolt and
the bolt as follows: Fig. 154 Unfasten the crankshaft pulley re-
talning bolts, then remove the pulley
case.
14. Install the rotor cover. Tighten the bolts to 7
ft. Ibs. (10 Nm).
15. Apply a 0.113 in. (3mm) bead of sealant to
the back of the oil pump case. I[ -‘-‘I IL -~-- IL-
nsrall me ca
se on me engine and tighten the bolts to IOft Ihc 11 ,,, -. , .4 Nm).
16. Install the upper baffle r tlal te and oil pump
pick-up using a new gasket. Tic fhtti,, ,,lG va,,,ti ““a,., an tha hafflc, hnltc to 7 ft. Ibs. (10 Nm) and the pit k-up bolts to 13 ft.
Ibs. (18 Nm).
17. Install the lower baffle in the upper oil pan.
Tighten the bolts to 8 ft. Ibs. (11 Nm).
18. Install the oil pans.
19. Install the oil filter adapter using a new gas-
ket. Tighten the larger bolt to 30 ft. Ibs. (41 Nm) and
the smaller bolt to 1’ u ‘L- Inn ‘I--’ stall thl
tighten
4
) 1.5L engine: 51-72 ft. Ibs. (70-100 Nm)
l 1.8L and 3.5L engines: 134 ft. Ibs. (185
NM
l 3.OL engines: 108-116 ft. lbs. (150-160 NW 11. On the 1.5L, 1.6L, 2.OL and 2.4L engines, in-
stall the pulley-to-sprocket bolts and tighten the bolts
as follows:
l 1.5L engine: 10 ft. Ibs. (14 Nm)
* 1.6L and 2.OL engines: 14-22 ft. Ibs. 1. Disconnect the negative battery cable.
2. Remove the engine under cover.
3. Raise and safely support the weight of the en-
gine using the appropriate equipment. Remove the
front engine mount bracket and accessory drive belts.
4. If necessary, remove the coolant reservoir
tank.
5. Using the proper equipment, slightly raise
ets, water pump pulley
7. Remove all attr
upper and lower timin{
8. Make a mark o
indicating the directior
assembled in the same the engine to take the weight off the side engine
mount. Remove the engine mount bracket.
6. Remove the drive belts, tension pulley brack-
and crankshaft pulley.
aching screws and remove the
J belt covers.
n the back of the timing belt
I of rotation so it may be re-
! direction if it is to be reused.
tensioner and remove the tim-
Loosen the timing belt
ing belt.
*If coolant or engine oil comes in contact
with the timing bplt thaw will r(mcti~~llv Wll L, .,,s,, n,,, u,uu.,vu,,,
shorten its life. A ,IS o, do not allow engine oil
#.I nn..lr”* In rind In,
“I IruuI(IIIL Lu Irulll&t the timing belt sprock-
ets or tensioner assembly.
9. Remove the tensioner spacer, tensioner
spring and tensioner assembly.
cracks on back sur-
;eoarated canvas.
20. Install the tilllIllY uljllOllu IclllallllllY ~ullIPV-
:
nents. Refer to the timing belt procedure in this sec-
: tion.
21. Fill the engine with the correct amount of oil.
I . (20-30 Nm)
l 2.4L engine: 18 ft. Ibs. (25 Nm)
12. On the 1.6L and 2.OL engines, install the pul-
ley-to-sprocket bolts and tighten them to 14-22 ft.
Ibs. (20-30 Nm).
13. Install the splash shield.
14. Install the wheel, then carefully lower the ve- 10. Inspect the timing belt for I
face, sides, bottom and check for ! (
Check the tensioner pulley for smooth rotation.
To install:
11. Position the tensioner, tensioner spring and
tensioner spacer on engine block.
12. Align the timing marks on the camshaft
ft sprocket. This will position
tn the comoression stroke.
I hicle.
sprocket and cranksha
15. Install the accessory drive belts. Refer to Sec-
No. 1 piston on TDC o
Operating the engine without the proper tion 1.
13. Position the timing belt on the crankshaft
amount and type of engine oil will result in 16. Connect the negative battery cable.
sprocket and keeping the tension side of the bolt
severe engine damage.
-
22. -s
Chrmxt the nenntive h;lttm cnhle --, , I” ,.-J XL.._ I -..-., --I.-.
23. Start the engine and check for leaks.
REMOVAL &INSTALLATION
tight, set it on the cam, shaft sprocket.
14. Apply counterc Yockwise force to the camshaft
snrnckd tn nive tensin In -r .__.._. ._ J..- ._ - _ to the belt and make sure all
timing marks are aligned.
15. Loosen the pivot side tensioner bolt and the
clnt
&In hnlt Allnur thn rnrinn tn tdm III-I thn slack, cl then , d I, I’ r),“I 44”” ““IL. “ll”sl LllU .y”“yj L” L”I\U Low Ul” L .-Refer to Section 1 for the proper timing 16. Tighten the slot side tensioner bolt ark
., , , , ,, ,, ,, , , , , ,, . ,, ,~
REMOVAL &INSTALLATION
6 See Figures 153 and 154
1. Disconnect the negative battery cable.
2. Remove the accessory drive belts from
around the crankshaft pulley. Refer to Section 1. belt service interval.
1.5L Engine
1999-94 MODELS
b See Figures 155 and 156 me p~vor sloe DOI~. IT me p~vor sloe OOII
IS ogntened
first, the tensioner could turn with bolt, causing over
tension.
17. Turn the crankshaft clockwise. Loosen the
pivot side tensioner bolt and then the slot side bolt to
allow the spring to take up any remaining slack.

ENGINEANDENGINEOVERHAUL 3-37
1. Ben
2. Power4teerlna Dump 7. washer
8. Crankshaft pullet
9. Damper pulls
10. upper ccwer
11. Lowercowr
12. llmingbeil
13. crsnkshat? E#ocket 14. Flsnge
i 5. Tensbner spacer
16. Tef~kner WkW
1; Tgibnrr
19: camehan sprocket
91251ga
Fig. 155 Exploded view of the timing belt covers, timing belt and related parts-1990-94 1.51
engine
Fig. 156 Camshaft and crankshaft sprocket mark alignment for proper timing belt installa-
tion-1990-94 1.51 engine
Tighten the slot bolt and then the pivot side bolt to
14-20 ft. Ibs. (20-27 Nm).
18. Check the belt tension by holding the ten-
sioner and timing belt together by hand and give the
belt a slight thumb pressure at a point level with ten-
sioner center. Make sure the belt cog crest comes as
deep as about l/4 of the width of the slot side ten-
sioner bolt head. Do not manually overtighten the
belt or it will make a howling noise.
19. Install the timing belt covers and all related
items. 1995-00 MOOFLS
) See Figure 157
1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. Rotate the crankshaft clockwlse and position
the engine at TDC of the compression stroke.
4. Raise and safely support the weight of the en-
gine using the appropriate equipment. Remove the
A/C clamp, front engine mount bracket and accessory
drive belts.
20. Connect the negative battery cable.
5. Remove the crankshaft pulley. 6. Remove timing belt upper and lower covers.
7. Make a mark on the back of the timing belt
indicating the direction of rotation so it may be re-
assembled in the same direction if it is to be reused.
Loosen the timing belt tensioner and move the ten-
sioner to provide slack to the timing belt. Tighten the
tensioner in this position.
8. Remove the timing belt.
Coolant and engine oil will damage the rub-
ber in the timing belt, drastically reducing its
life. Do not allow engine oil or coolant to
contact the timing belt, the sprockets or ten-
sioner assembly.
9. If defective, remove the tensioner spacer, ten-
sioner spring and tensioner assembly.
To install: 10. Position the tensioner, tensioner spring and
tensioner spacer on engine block.
11. Align the timing marks on the camshaft
sprocket and crankshaft sprocket. This will position
No. 1 piston on TDC on the compression stroke.
12. Position the timing belt on the crankshaft
sprocket and keeping the tension side of the belt
tight, set it on the camshaft sprocket, then the ten-
sioner.
13. Apply slight counterclockwise force to the
camshaft sprocket to give tension to the belt and be
sure all timing marks are aligned.
14. Loosen the pivot side tensioner bolt and the
slot side bolt. Allow the spring to remove the slack.
15. Tighten the slot side tensioner bolt, then the
pivot side bolt. If the pivot side bolt is tightened first,
the tensioner could turn with bolt, causing over ten-
sion.
16. Turn the crankshaft clockwise. Loosen the
pivot side tensioner bolt, then the slot side bolt to al-
low the spring to take up any remaining slack.
Tighten the slot bolt, then the pivot side bolt to 17 ft.
Ibs. (24 Nm).
17. Install the timing belt covers and tighten the
cover bolts to 84-96 inch Ibs. (E-11 Nm). Install all
other applicable components.
liming mark
ming mark
Timing mark
Timing mark
Crankshaft sprocket
79235g5t Fig. 157 Align the timing belt sprockets as
indicated before removing the timing belt-
1995-00 1.51 engine