1900 MITSUBISHI DIAMANTE fuel cap release

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-

FUELSYSTEM 513
l Always replace worn fuel fitting O-rings with
new. Do not substitute fuel hose or equivalent, where
I
The Multi-Point Injection (MPI) system is electroni-
rally controlled by the Engine Control Module (ECM),
based on data from various sensors. The ECM controls
the fuel flow, idle speed and ignition timing. fuel pipe is installed.
Fuel is supplied to the injectors by an electric in-
tank fuel pump and is distributed to the respective in-
jectors via the main fuel pipe. The fuel pressure ap-
plied to the injector is constant and higher than the
pressure in the intake manifold. The pressure is con-
trolled by the fuel pressure regulator. The excess fuel
is returned to the fuel tank through the fuel return pipe.
When an electric current flows in the injector, the
injector valve is fully opened to supply fuel. Since the
fuel pressure is constant, the amount of the fuel in-
jetted from the injector into the manifold is increased
or decreased in proportion to the time the electric
current flows. Based on ECU signals, the injectors in-
ject fuel to the cylinder manifold ports in firing order. Fuel injection systems remain under pres-
sure after the engine has been turned OFF.
Properly relieve fuel pressure before discon-
neeting any fuel lines. Failure to do so may
result in fire or personal injury.
1. Turn the ignition to the OFF position.
2. Loosen the fuel filler cap to release fuel tank
pressure.
I
The flow rate of the air drawn through the air
cleaner is measured by the air flow sensor. The air
enters the air intake plenum or manifold through the
throttle body. In the intake manifold, the air is mixed
with the fuel from the injectors and is drawn into the
cylinder, The air flow rate is controlled according to
the degree of the throttle valve and the servo motor
openings. The system is monitored through a num-
ber of sensors which feed information on engine con-
ditions and requirements to the ECM. The ECM cal-
culates the injection time and rate according to the
signals from the sensors,
Safety is the most important factor when perform-
ing not only fuel system maintenance but any type of
maintenance. Failure to conduct maintenance and re-
pairs in a safe manner may result in serious personal
injury or death. Maintenance and testing of the vehi-
cle’s fuel system components can be accomplished
safely and effectively by adhering to the following
rules and guidelines.
l To avoid the possibility of fire and personal in-
jury, always disconnect the negative battery cable un-
less the repair or test procedure requires that battery
voltage be applied.
l Always relieve the fuel system pressure prior to
disconnecting any fuel system component (injector,
fuel rail, pressure regulator, etc.), fitting or fuel line
connection. Exercise extreme caution whenever re- 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 va-
pors to come in contact with a spark or open
flame. Keep a dry chemical fire extinguisher
near the work area. Always keep fuel in a con-
tainer specifically designed for fuel storage;
also, always properly seal fuel containers to
avoid the possibility of fire or explosion.
3. For the Mirage, Diamante, and 1994-00
Galant, remove the rear seat cushion, then remove
the service cover and detach the fuel pump harness
connector.
4. For the 1990-93 FWD Galant, detach the fuel
pump harness connector located in the area of the
fuel tank. It may be necessary to raise the vehicle to
access the connector.
5. For the 1990-93 AWD Galant, remove the car-
pet from the trunk, locate the fuel tank wiring at the
pump access cover, then detach the wiring.
6. Start the vehicle and allow it to run until it
stalls from lack of fuel. Turn the key to the OFF posi-
tion.
7. Disconnect the negative battery cable, then at-
tach the fuel pump connector. Install the access .
cover, cushion or carpet as necessary.
8. Wrap shop towels around the fitting that is be-
ing disconnected to absorb residual fuel in the lines.
9. Place shop towels into proper safety container. Fig, 8 Detach the connector for the throttle
position (TP) sensor
93153ps5 Fig, 9 Remove the accelerator cable end
from the throttle lever
Fig. IO Remove the hose shown here from
lieving fuel system pressure to avoid exposing skin,
face and eyes to fuel spray. Please be advised that
fuel under pressure may penetrate the skin or any
part of the body that it contacts.
l Always place a shop towel or cloth around the
fitting or connection prior to loosening to absorb any
excess fuel due to spillage. Ensure that all fuel
spillage (should it occur) is quickly removed from
enginesurfaces. Ensure that all fuel soaked cloths or
towels are deposited into a suitable waste container.
l Always keep a dry chemical (Class B) fire ex-
tinguisher near the work area.
l Do not allow fuel spray or fuel vapors to come
into contact with a spark or open flame.
l Always use a backup wrench when loosening’
and tightening fuel line connection fittings. This will
prevent unnecessary stress and torsion to fuel line
piping. Always follow the proper torque specifica-
tions. REMOVAL &INSTALLATION
p See Figures 8 thru 18
1. Properly relieve the fuel system pressure as
outlined earlier in this section.
2. Drain the engine cooling system into a suit-
able container.
3. Matchmark the jocation of the adjuster bolt
on the accelerator cable mounting flange. This will
assure that the cable is installed in its original loca-
tion. Remove the throttle cable adjusting bolt and
disconnect the cable from the lever on the throttle
body. Position cable aside.