1900 MITSUBISHI DIAMANTE coolant reservoir

UNDERHDDD MAINTENANCE COMPONENT LOCATIONS-2AL ENGINE
II
1. Power steering belt 7. PCV valve
2. Washer solvent bottle 8. Distributor cap and rotor
3. Power steering reservoir 9. Fuel filter (under air inlet tube)
4. Oil fill cap 10. Air filter housing
5. Brake master cylinder reservoir 11. Engine compartment fuse box
6. Spark plug and plug wire 12. Battery 13. Automatic transaxle fluid dipstick
14. Coolant recovery tank
15. Radiator cap
16. Engine oil dipstick

UNDERHOOD MAINTENANCE COMPONENT LOCATIONS-l .8L ENGINE
1. Coolant recovery tank
2. Battery
3. Engine compartment fuse box
4. Air filter housing
5. Clutch fluid reservoir
6. Brake master cylinder reservoir 7. Spark plug and plug wire
8. PCV valve
9. Engine oil fill cap
10. Fuel filter
11. Engine compartment relay center
12. Washer solvent bottle 13. Power steering reservoir
14. Power steering belt
15. Engine oil dipstick
16. Radiator cap

.
GENERALINFORMATIONAND MAINTENANCE l-41
93151p18 Fig. 202 . , . to remove the cap from the
radiator
93151p17 Fig. 205 Be sure the rubber gasket on the
radiator cap has a tight seal e Fig. 203 Pour the proper *I~ coolant mix- 1 Fig. 204 . . . make sure to fill the coolant
recovery tank to the proper level also ture into the radiator . . .
.I
4. Allow the engine to cool completely and drain fluid. Any brake fluid that is removed from
ie system again.
5. Repeat this processuntil the drained water is
lear
and free of scale.
6. Flush the recovery tank with water and leave ’
mpty. the system should be discarded. Also, do not
allow any brake fluid to come in contact with
a painted surface; it will damage the paint.
When adding fluid to the system, ONLY use fresh
DOT 3 brake fluid from a sealed container. DOT 3
brake fluid will absorb moisture when it is exposed to
.a . . . , .*a. . . * .*. . .
- 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-
4. Place a drain pan of suff i ’ 1 . . . ..I .I. 1,~ cient quantities. Always tne atmospnere, wnrcn wnr rower 1r.s oourng pomr. A
container that has been opened once, closed and
placed on a shelf will allow enough moisture to enter
over time to contaminate the fluid within. If your brake
fluid is contaminated with water, you could boil the
brake fluid under hard braking conditions and lose all
or some braking ability. Don’t take the risk, buy fresh
brake fluid whenever you must add to the system.
crenr capacrry unaer me
drain) on the radiator.
rrrasuc perwcss easuy bind; Before open-
ing a plastic radiator petcock, spray it with
some penetrating lubricant. drain coolant into a
earner. sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
The brake master cylinder ~a~~~~r,~~ :A I~nnL.4 n-n 7. Fill and bleed the cooling system as described
Brake fluid contains polyglycol ethers and
polyglycols. Avoid contact with the eyes and ,LEVEL CHECK
wash your hands thoroughly after handling
brake fluid. If vou do oet brake fluid in vour
eyes, flush your eyeswith clean, runniug wa-
a-.. ‘Y-- ar -l-..n-- II -.._ I____ k See Figures 206 thru 211
.a-11-- - __-PA._ radiator and open the petcock (
- w&1--x3_ --mm.._..- . . ..-I...
5. Drain the cooling system completely.
6. Close the petcock.
7. Remove the drain pan.
If necessary, install the splash shield under the 8.
L.-l
venicie.
9. Lower the vehicle.
10. Determine the capacity of the cooling system,
then properly refill the system at the recovery tank
and radiator with a 50/50 mixture of fresh coolant and
fKm”“ll 15 IUMLC” “II- brake booster and fire- der the hood, attached to the
wall on the drivers side of the engine compartment.
FLUID RECOMMENDATIONS rer mr 13 mmures. IT eye irriIauon persim, or if you have taken brake fluid internally,
IMMEDIATELY seek medical assistance.
ala in oreerring me sysrem.
12. Start the engine and allow it to idle until the
thermostat opens (the upper radiator hose will be-
come hot). The coolant level should go down, this is
normal as the system bleeds the air pockets out of the
svstem.
IRVf!l ._._. 14. Turn the engine OFF and check for leaks. IMMEDIATELY seek medical assistance.” Brake fluid contains polyglycol ethers and
polyglycols. Avoid contact with the eyes and
wash your hands thoroughly after handling
brakefluid. If you do get brake fluid in your
eyes, flush your eyes with clean, running wa-
or if vou have taken brake fluid internallv.
Before removing the master cylinder reservoir cap,
make sure the vehicle is resting on level ground and Be careful to avoid spilling any brake fluid on
painted surfaces, because the paint coat will
become discolored or damaged.
Observe the fluid level indicators on the master
._ ._ __
‘eve1 should be between the MIN
ano
ivw unes. 13. Refill the system with coolant to the proper ter for 15 minutes; If eye irritation persists, cylinder; the tluld II
..J ..I” I....
FLUSHING & CLEANINGTHE SYSTEM
1. Drain the cooling system completely as de:
scribed earlier.
2. Close the petcock and fill the system with a
cooling system flush (clean water may also be used,
but is not as efficient).
3. Idle the engine until the upper radiator hose
gets hot. Clean, high quality brake fluid is essential to
the safe and proper operation of the brake
system. You should always buy the highest
quality brake fluid that is available. If the
brake fluid becomes contaminated, drain and
flush the system, then refill the master cylin-
der with new fluid. Never reuse any brake clean all dirt away from the top of the master cylinder.
Unscrew the cap and fill the master cylinder until the
level is between the MIN and MAX lines.
If the level of the brake fluid is less than half the
volume of the reservoir, it is advised that you check
the brake system for leaks. Leaks in a hydraulic brake
system most commonly occur at the wheel cylinder
and brake line junction points.

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

l
3-18 ENGINEANDENGINEOVERHAUL
bolt and gaskets that connect the oil feed line to the
turbo center section and the water cooling lines. The
water line under the turbo has a threaded connection.
8. Remove the exhaust pipe nuts and gasket and
lift off the exhaust manifold. Discard the gasket,
9. Remove the 2 through bolts and 2 nuts that 16. If removed, install the power steering pump
and bracket.
17. Install the heat shields, air outlet hose, waste-
gate hose and air intake bellows.
18. Install the oil dipstick tube and dipstick. In-
stall the oxyqen sensor. cient quantities. Always drain coolant into a
sealable container. Coolant should be reused
unless it is contaminated or is several years
old.
3. Disconnect the overflow tube. Some vehicles
hold the exhaust manifold to the turbocharger,
10. Remove the 2 capscrews from the oil return
line (under the turbo). Discard the gasket. Separate
the turbo from the exhaust manifold. The 2 water
pipes and oil feed line can still be attached. 19. In&h the radiator assembly.
20. Fill the engine with oil, fill the cooling system
and reconnect the negative battery cable.
11. Visually check the turbine wheel (hot side)
and compressor wheel (cold side) for cracking or
other damage. Check whether the turbine wheel and
the compressor wheel can be easily turned by hand.
Check for oil leakaae. Check whether or not the Operating the engine without the proper
amount and type of engine oil will result in
severe engine damage.
wastegate valve remains open. If any problem is .
found, replace the part. Inspect oil passages for re- #I , I
striction or deposits and clean as required,
12. The wasteaate can be checked with a ores-
REMOVAL & INSTALLATION sure tester. Apply approximately 9 psi to the&h&or
and make sure the rod moves. Do not apply more
than 10.3 psi or the diaphragm in the wastegate may
be damaged. Vacuum applied to the wastegate actua-
tor should be maintained, replace if leaks vacuum,
Do not attempt to adjust the wastegate valve. $ See Figures 77 thru 91
I. Disconnect the negative battery cable.
2. Drain the cooling system when safe.
To
install: 13. Prime the oil return line with clean engine oil.
Replace all locking nuts. Before installing the
threaded connection for the water inlet pipe, apply
light oil to the inner surface of the pipe flange. As-
semble the turbocharger and exhaust manifold.
14. Install the exhaust manifold using a new gas-
ket.
15. Connect the water cooling lines, oil feed line
and engine hanger. Never open, service or drain the radiator or
cooling system when hot: serious burns can
occur from the steam and hot coolant. Also,
when draining engine coolant, keep in mind
that cats and dogs are attracted to ethylene
glyeol antifreeze and could drink any that is
left in an uncovered container or in puddles
on the ground. This will prove fatal in suffi-
Fig. 77 Use a pair of pliers to remove the
Fig. 78 . . .
then disconnect the overflow
hose clamp . . .
hose from the radiator may also require removal of the overflow tank.
4. Disconnect upper and lower radiator hoses.
5. Detach the electrical connectors from the
cooling fan and air conditioning condenser fan, if
equipped.
6. For Mirage and Diamante models, remove
the fan assembly.
7. Disconnect the therm0 sensor wires,
8. If equipped with an automatic transaxle, dis-
connect and plug the automatic transaxle cooler
lines.
9. Remove the upper radiator mounts and lift
out the radiator assembly or radiator/fan assembly,
as applicable.
To install:
10. Install the radiator or radiator and fan, if re-
moved as an assembly.
11. Connect the automatic transaxle cooler lines
if disconnected.
12. Connect the therm0 sensor wires,
13. Install the fan, if removed separately.
14. Install the radiator hoses.
15. Install the air cleaner support bracket, if re-
noved.
16. Install the overflow tube and reservoir, if re-
noved.
17. Fill the system with coolant.
18. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
93153003 Fig. 79 Use pliers to release the hose clamp
tension . . .
Fig. 80 . . .
then remove the upper radiator
hose from the radiator Fig. 81 From underneath the vehicle, re-
move the hose clamp , . . ”
then disconnect the lower radi- Fig. 82 . . .
ator hose

3-36 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.

3-38 ENGINEANDENGINEOVERHAUL
1.61&? 2.OL (Non-Turbo) DOHC Engines
g See Figure 158
*The 1.6L engine is not equipped with
silent shafts. Disregard all instructions per-
taining to silent shafts if working on that en-
gine.
1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. If necessary, remove the coolant reservoir.
4. Using the proper equipment, slightly raise
the engine to take the weight off the side engine
mount. Remove the engine mount bracket.
5. Remove the drive belts, tension pulley brack-
ets, water pump pulley and crankshaft pulley.
6. Remove all attaching screws and remove the
upper and lower timing belt covers.
7. Rotate the crankshaft clockwise and align the
timing marks so No. 1 piston will be at TDC of the
compression stroke. At this time the timing marks on
the camshaft sprocket and the upper surface of the
cylinder head should coincide, and the dowel pin of
the camshaft sprocket should be at the upper side.
*Always rotate the crankshaft in a clockwise
direction. Make a mark on the back of the
timing belt indicating the direction of rotation
so it may be reassembled in the same direc-
tion if it is to be reused.
8. Remove the auto tensioner and remove the
outermost timing belt.
9. Remove the timing belt tensioner pulley, ten-
sioner arm, idler pulley, oil pump sprocket, special
washer, flange and spacer.
10. Remove the silent shaft (inner) belt tensioner
and remove the belt.
To install: 11. Align the timing marks on the crankshaft
sprocket and the silent shaft sprocket. Fit the inner
timing belt over the crankshaft and silent shaft
sprocket. Ensure that there is no slack in the belt.
12. While holding the inner timing belt tensioner
with your fingers, adjust the timing belt tension by
applying a force towards the center of the belt, until
the tension side of the belt is taut. Tighten the ten-
sioner bolt.
*When tightening the bolt of the tensioner,
ensure that the tensioner pulley shaft does
not rotate with the bolt. Allowing it to rotate
with the bolt can cause excessive tension on
the belt.
13. Check belt for proper tension by depressing
the belt on it’s long side with your finger and noting
the belt deflection. The desired reading is 0.20-0.28
in. (5-7mm). If tension is not correct, readjust and
check belt deflection.
14. Install the flange, crankshaft and washer to
the crankshaft. The flange on the crankshaft sprocket
must be installed towards the inner trming belt
sprocket. Tighten bolt to 80-94 ft. Ibs. (110-130
Nm).
15. To install the oil pump sprocket, insert a
Phillips screwdriver with a shaft 0.31 in. (8mm) in di-
ameter into the plug hole in the left side of the cylin-
der block to hold the left silent shaft. Tighten the nut
to 36-43 ft. Ibs. (50-60 Nm).
16. Using a wrench, hold the camshaft at it’s
hexagon between journal No. 2 and 3, then tighten
the bolt to 58-72 ft. Ibs. (80-100 Nm). If no hexagon
is present between journal No. 2 and 3, hold the
sprocket stationary with a spanner wrench while
tightening the retainer bolt.
17. Carefully push the auto tensioner rod in until
the set hole in the rod aligns with the hole in the
cylinder. Place a wire into the hole to retain the rod.
18. Install the tensioner pulley onto the tensioner
arm. Locate the pinhole in the tensioner pulley shaft
to the left of the center bolt. Then, tighten the center
bolt finger-tight.
19. When installing the timing belt, turn the 2
camshaft sprockets so their dowel pins are located on
top. Align the timing marks facing each other with the
top surface of the cylinder head. When you let go of
the exhaust camshaft sprocket, it will rotate 1 tooth in
the counterclockwise direction. This should be taken
into account when installing the timing belts on the
sprocket.
*Both camshaft sprockets are used for the
intake and exhaust camshafts and are pro-
vided with 2 timing marks. When the
sprocket is mounted on the exhaust
camshaft, use the timing mark on the right
with the dowel pin hole on top. For the intake
camshafl sprocket, use the 1 on the left with
the dowel pin hole on top.
20. Align the crankshaft sprocket and oil pump
sprocket timing marks.
21. After alignment of the oil pump sprocket tim-
ing marks, remove the plug on the cylinder block and
insert a Phillips screwdriver with a shaft diameter of
0.31 in. (8mm) through the hole. If the shaft can be
inserted 2.4 in. deep, the silent shaft is in the correct
position. If the shaft of the tool can only be inserted
0.61 .O in. (2C-25mm) deep, turn the oil pump
sprocket 1 turn and realign the marks. Reinsert the
tool making sure it is inserted 2.4 in. deep. Keep the
tool inserted in hole for the remainder of this proce-
dure.
*The above step assures that the oil pump
socket is in correct orientation to the silent
shafts. This step must not be skipped or a vi-
bration may develop during engine opera-
tion.
22. Install the timing belt as follows:
a. Install the timing belt around the intake
camshaft sprocket and retain it with 2 spring
clips or binder clips.
b. Install the timing belt around the exhaust
sprocket, aligning the timing marks with the
cylinder head top surface using 2 wrenches. Re-
tain the belt with 2 spring clips. c. Install the timing belt around the idler pul-
ley, oil pump sprocket, crankshaft sprocket and
the tensioner pulley. Remove the 2 spring clips.
d. Lift upward on the tensioner pulley in a
clockwise direction and tighten the center bolt.
Make sure all timing marks are aligned.
e. Rotate the crankshaft ‘14 turn counterclock-
wise. Then, turn in clockwise until the timing
marks are alrgned again.
23. To adjust the timing (outer) belt, turn the
crankshaft ‘14 turn counterclockwise, then turn it
clockwise to move No. 1 cylinder to TDC.
24. Loosen the center bolt. Using tool
MD998738 or equivalent and a torque wrench, apply
a torque of 22-25 inch. Ibs. (2.6-2.8 Nm). Tighten
the center bolt.
25. Screw the special tool into the engine left
support bracket until its end makes contact with the
tensioner arm. At this point, screw the special tool in
some more and remove the set wire attached to the
auto tensioner, if the wire was not previously re-
moved. Then remove the specral tool.
26. Rotate the crankshaft 2 complete turns clock-
wise and let it sit for approximately 15 minutes. Then,
measure the auto tensioner protrusion (the distance
between the tensioner arm and auto tensioner body)
to ensure that it is within 0.15-0.18 in. (3.8-4.5mm).
If out of specification, repeat Step l-4 until the spec-
ified value is obtained.
27. If the timing belt tension adjustment is being
performed with the engine mounted in the vehicle,
and clearance between the tensioner arm and the auto
tensioner body cannot be measured, the following al-
ternative method can be used:
a. Screw in special tool MD998738 or equiv-
alent, until its end makes contact with the ten-
sioner arm.
b. After the special tool makes contact with
the arm, screw it in some more to retract the auto
tensioner pushrod while counting the number of
turns the tool makes until the tensioner arm is
brought into contact with the auto tensioner
body. Make sure the number of turns the special
tool makes conforms with the standard value of
21/a-3 turns.
c. Install the rubber plug to the timing belt
rear cover.
28. Install the timing belt covers and all related
items.
29. Connect the negative battery cable.
1.8L & 2.OL SOHC Engines
g See Figures 159, 160, and 161
1. Position the engine so the No. 1 piston is at
TDC of the compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
4. Using the proper equipment, slightly raise
the engine to take the weight off the side engine
mount. Remove the engine mount bracket.
5. Remove the drive belts, tension pulley brack-
ets, water pump pulley and crankshaft pulley.
6. Remove all attaching screws and remove the
upper and lower timing belt covers.
7. Remove the timing belt covers.
8. Remove the outer crankshaft sprocket and
flange.
9. Remove the silent shaft (inner) belt tensioner
and remove the belt.

BRAKES 9-27
93159g17
Fig. 124 HCU mounting-Diamante
after removal. It will be necessary to hold the relay
box aside to allow wrench access.
7. Detach the wiring harness connections at the
hydraulic unit.
8. Disconnect the hydraulic unit ground strap
from the chassis.
9. Remove the 3 bolts holding the hydraulic unit
bracket. Remove the unit and the bracket.
*The hydraulic unit is heavy; use care when
removing it. The unit must remain in the up-
right position at all times and be protected
from impact and shock.
IO. Set the unit upright, supported by blocks on
the workbench. The hydraulic unit must not be tilted
or turned upside down. No component of the hy-
draulic unit should be loosened or disassembled.
11. Loosen the nut holding the bracket to the hy-
draulic unit and remove the bracket.
12. Disconnect the external ground wire from the
bracket.
To install: 13. Install the bracket if removed.
14. Connect the ground wire to the bracket.
15. Install the hydraulic unit into the vehicle,
keeping it upright at all times.
16. Install the retaining nuts and tighten.
17. Connect the hydraulic unit wiring harness.
18. Connect each brake line loosely to the correct
port and double check the placement. Tighten each
line to 11 ft. Ibs. (15 Nm).
19. Fill the reservoir to the MAX line with brake
fluid.
20. Bleed the master cylinder, then bleed the
brake lines.
21. Secure the relay box in position and install
the air duct.
22. Install the splash shield.
Galant and Mirage
ti See Figures 125 and 126
1. Use a syringe or similar device to remove as
much fluid as possible from the reservoir. Some fluid
will be spilled from lines during removal of the hy-
draulic unit; protect adjacent painted surfaces.
Brake fluid contains polyglycol ethers and
polyglycols. Avoid contact with the eyes and
wash your hands thoroughly after handling
brake fluid. If you do get brake fluid in your
eyes, flush your eyes with clean, running wa-
ter for 15 minutes. If eye irritation persists,
1. Bracket
2. Air conditioning relay box
3. Oil reservoir
4. Motor relay
5. Valve relay
6. Brake pipe
7. Hydraulic unit
8. Hydraulic unit bracket
Fig. 125 HCU mounting-Mirage
or if you have taken brake fluid internally,
17. Fill the reservoir to the MAX line with brake IMMEDIATELY seek medical assistance. fluid.
2. Remove the splash shield from the left front
wheel house or fender area.
3. Remove the coolant reserve tank.
4. Remove the coolant reservoir bracket.
5. Remove the dust shield from below the hy-
draulic unit.
6. Disconnect the
brake hoses and lines from
the hydraulic unit. Correct reassembly is critical. La-
bel or identify the lines before removal. Plug each
line and each port immediately after removal.
7. Remove the cover from the relay box. Dis-
connect the electrical harness to the hydraulic unit.
8. Remove the bolts holding the 3 mounting
brackets to the vehicle; remove the unit downward
and out of the vehicle. 18. Bleed the brake system.
19. Install the dust shield and the coolant reserve
tank with its bracket.
20. Install the fender splash shield.
21. Check ABS system function by turning the ig-
nition ON and observing the dashboard warning
lamp. Test drive the vehicle and confirm system op-
eration.
REMOVALANDINSTALLATION
) See Figures 127 and 128
*The hydraulic unit is heavy; use care when
removing it. The unit must remain in the up-
right position at all times and be protected
from impact and shock.
9. Set the unit upright, supported by blocks on
the workbench. The hydraulic unit must not be tilted
or turned upside down. No component of the hy-
draulic unit should be loosened or disassembled.
10. The brackets and relays may be removed if
desired.
To install: 11. Install the brackets and relays if they were re-
moved. Tighten the bracket bolts to 16 ft. Ibs. (22
Nm). 1. Ensure that the ignition switch is OFF through-
out the procedure.
2. For Galant and Diamante models, remove the
left side luggage compartment trim panel.
3. For Mirage models, remove the floor console
assembly.
4. Release the lock on the bottom of the connec-
tor. Detach the multi-pin connector from the control
unit.
12. Install the hydraulic unit into the vehicle,
keeping it upright at all times.
13. Install the retaining bolts holding the brackets
to the vehicle. Tighten the bolts to 16 ft. Ibs. (22 Nm).
14. Connect the hydraulic unit wiring harness.
15. Install the cover on the relay box.
16. Connect each brake line loosely to the correct
port and double check the placement. Tighten each
line to IO ft. Ibs. (13 Nm). 5. Remove the retaining nuts and remove the
control unit from its bracket. The bracket may be re-
moved if desired. To install: 6. Place the bracket in position if it was removed.
Install the controller and tighten the retaining nuts.
7. Connect the ground wire to the bracket, if re-
moved. Insure a proper, tight connection. The ground
must be connected before the multi-pin harness is
connected.
8. Attach the multi-pin connector and secure the
lock.
9. Install the luggage compartment trim or the
floor console.
Fig. 126 HCU mounting-Galant