1900 MITSUBISHI DIAMANTE lug pattern

GENERALINFORMATIONAND MAlNTENANdE 1-29
i
*Bug screens which are mounted in front of
the condenser (unless they are original
equipment) are regarded as obstructtons.
l The condensation drain tube expels any water
which accumulates on the bottom of the evaporator
housing into the engine compartment. If this tube is
obstructed, the air conditioning performance can be
restricted and condensation buildup can spill over
onto the vehicle’s floor.
l Make sure the air passage selection lever is
operating correctly. Start the engine and warm it to
normal operating temperature, then make sure the
temperature selection lever is operating correctly.
-w
~1 ELEMENT(REFILL)CARE& REPLACEMENT
SYSTEM INSPECTION
b See Figure 125 b See Figures 126 thru 135
For maximum effectiveness and longest element
Although the A/C system should not be serviced
by the do-it-yourselfer, preventive maintenance can
be practiced and A/C system inspections can be per-
formed to help maintain the efficiency of the vehicle’s
A/C system. For A/C system inspection, perform the
following:
The easiest and often most important check for the
air conditioning system consists of a visual inspec-
tion of the system components. Visually inspect the
air conditioning system for refrigerant leaks, dam-
aged compressor clutch, abnormal compressor drive
belt tension and/or condition, plugged evaporator
drain tube, blocked condenser fins, disconnected or
broken wires, blown fuses, corroded connections and
poor insulation.
A refrigerant leak will usually appear as an oily
residue at the leakage point in the system. The oily
residue soon picks up dust or dirt particles from the
surrounding air and appears greasy. Through time,
this will build up and appear to be a heavy dirt im-
pregnated grease.
For a thorough visual and operational inspection,
check the following: * Check the surface of the radiator and con-
denser for dirt, leaves or other material which might
block air flow.
l Check for kinks in hoses and lines. Check the
system for leaks.
l Make sure the drive belt is properly tensioned.
When the air conditioning is operating, make sure the
drive belt is free of noise or slippage.
l Make sure the blower motor operates at all ap-
propriate positions, then check for distribution of the
air from all outlets with the blower on HIGH or MAX.
*Keep in mind that under conditions of high
humidity, air discharged from the A/C vents
may not feel as cold as expected, even if the
system is working properly. This is because
vaporized moisture in humid air retains heat
more effectively than dry air, thereby making
humid air more difficult to cool.
lifp thp winrkhi&i nnri winor hlarlP~ shmM hP kmt . ..“. .I.” . . * ““I.. “.” I..” ...r”* “.“““” “, ,““,” “” ,~“r~ clean. Dirt, tree sap, road tar and so on will cause
streaking, smearing and blade deterioration if left on
the glass. It is advisable to wash the windshield care-
fully with a commercial glass cleaner at least once a
month. Wipe off the rubber blades with the wet rag
afterwards. Do not attempt to move wipers across the
windshield by hand; damage to the motor and drive
mechanism will result.
To inspect and/or replace the wiper blade ele-
ments, place the wiper switch in the LOW speed po-
sition and the ignition switch in the ACC position.
When the wiper blades are approximately vertical on
the windshield, turn the ignition switch to OFF.
Examine the wiper blade elements. If they are
found to be cracked, broken or torn, they should be
replaced immediately. Replacement intervals will vary
with usage, although ozone deterioration usually lim-
its element life to about one year. If the wiper pattern
is smeared or streaked, or if the blade chatters across
the glass, the elements should be replaced. It is easi-
est and most sensible to replace the elements in
pairs.
If your vehicle is equipped with aftermarket blades,
there are several different types of refills and your vehi-
tcca-23 Fig. 126 Bosch@ wiper blade and fft kit
Fig. 129 T&o* wioer blade and fit kit tCS1224
lW1Z?5 Fig. 127 LexoP wiper blade and fit kit
Fig. 128 Pylon@ wiper blade and adapter
Fig. 131 To remove and install a LexoP
Fig, 130 Tripledge@ wiper blade and fit kit wiper blade refill, slip out the old insert and
slide in a new one

.
1-32 GENERALINFORMATIONAND MAINTENANCE
CONDITION
EFFECT
CAUSE
CORRECTION UNDER-INFLATION
EXCESSIVE SPEED’ WORN OR OUT-
OF-ALIGNMENT
ADJUST PRESSURE TO
SPECIFICATIONS WHEN
TIRES ARE COOL
ROTATE TIRES
/ BALANCE WHEELS INSPECT SUSPENSION
HAVE TIRE INSPECTED FOR FURTHER USE.
lCCSi267 ig. 144 Common tire wear patterns and causes
1~~~1265 Fig. 145 Tread wear indicators will appear
when the tire is worn
inflation, do not drive more than a mile before check-
ing. A cold tire is generally one that has not been dri-
ven for more than three hours.
A plate or sticker is normally provided somewhere
in the vehicle (door post, hood, tailgate or trunk lid)
which shows the proper pressure for the tires. Never
counteract excessive pressure build-up by bleeding
off air pressure (letting some air out). This will cause
the tire to run hotter and wear quicker.
Never exceed the maximum tire pressure
embossed on the tire! This is the pressure to
be used when the tire is at maximum load-
ing, but it is rarely the correct pressure for
everyday driving. Consult the owner’s man-
ual or the tire pressure sticker for the correct
tire pressure.
Once you’ve maintained the correct tire pressures
for several weeks, you’ll be familiar with the vehicle’s
braking and handling personality. Slight adjustments
in tire pressures can fine-tune these characteristics,
1~~~1264 Fig. 146 Accurate tread depth indicators are
inexuensive and handv
Fig. 147 A penny works well for a quick
check of tread death
but never change the cold pressure specification by
more than 2 psi. A slightly softer tire pressure will
give a softer ride but also yield lower fuel mileage. A
slightly harder tire will give crisper dry road handling
but can cause skidding on wet surfaces. Unless
you’re fully attuned to the vehicle, stick to the recom-
mended inflation pressures.
All tires made since 1968 have built-in tread wear
indicator bars that show up as j/2 in. (13mm) wide
smooth bands across the bre when V,~ in. (1.5mm) of
tread remains. The appearance of tread wear indica-
tors means that the tires should be replaced. In fact,
many states have laws prohibiting the use of tires
with less than this amount of tread.
You can check your own tread depth with an inex-
pensive gauge or by using a Lincoln head penny.
Shp the Lrncoln penny (with Lincoln’s head upside- down) into several tread grooves. If you can see the
top of Lincoln’s head in 2 adjacent grooves, the tire
has less than V,~ in. (1.5mm) tread left and should be
replaced. You can measure snow tires in the same
manner by using the “tails” side of the Lincoln
penny. If you can see the top of the Lincoln memor-
ial, its time to replace the snow tire(s).
CAREOFSPECIALWHEELS
If you have invested money in magnesium, alu-
minum alloy or sport wheels, special precautions
should be taken to make sure your investment is not
wasted and that your special wheels look good for the
life of the vehicle.
Special wheels are easily damaged and/or
scratched. Occasionally check the rims for cracking,
impact damage or air leaks. If any of these are found,
replace the wheel. But in order to prevent this type of
damage and the costly replacement of a special
wheel, observe the following precautions:
l Use extra care not to damage the wheels dur-
ing removal, installation, balancing, etc. After re-
moval of the wheels from the vehicle, place them on a
mat or other protective surface. If they are to be
stored for any length of time, support them on strips
of wood. Never store tires and wheels upright; the
tread may develop flat spots.
l When driving, watch for hazards; it doesn’t take
much to crack a wheel.
l When washing, use a mild soap or non-abra-
sive dish detergent (keeping in mind that detergent
tends to remove wax). Avoid cleansers with abrasives
or the use of hard brushes. There are many cleaners
and polishes for special wheels.
l If possrble, remove the wheels during the win-
ter. Salt and sand used for snow removal can se-
verely damage the finish of a wheel.
l Make certain the recommended lug nut torque
is never exceeded or the wheel may crack. Never use
snow chains on special wheels; severe scratching
will occur.

ENGINEANDENGINEOVERHALJL 3-5
Fig. 15 Camshaft, rocker arm and shaft as-
remblies-2.01 SOHC engine
remove the lifter from the bore in the rocker arm. It is
recommended that all of the rocker arms and lash ad-
justers be replaced at the same time.
1. Disconnect the negative battery cable.
2. Remove the valve cover.
3. Matchmark the distributor to the cylinder
head and remove the distributor.
4. Remove camshaft timing belt.
5. Working in a crisscross pattern from the cen-
ter outward, loosen the camshaft bearing caps in
gradual steps.
6. Remove the rocker arms, shafts and bearing
caps as an assembly.
*It is essential that all parts be kept in the
same order and orientation for reinstallation.
Be sure to mark and separate parts, so parts
will not be mixed during reassembly.
7. Disassemble rocker shaft assembly. Starting
at rear bearing cap, slide each piece off shafts.
*Inspect the roller surfaces of the rockers.
Replace if there are any signs of damage or
if the roller does not turn smoothly. Check
the inside bore of the rockers and lifter for
wear.
To install:
8. Apply a drop of sealant to the rear edges of
the end caps.
9. Install the assembly into the front bearing
cap, making sure the notches in the rocker shafts are
facing up. Insert the installation bolt, but do not
tighten at this point.
10. Install the remaining cap bolts. Tighten all
bolts evenly and gradually to 15 ft. Ibs. (20 Nm). Re-
move the lash adjuster retainers.
11. Install the timing belt as required.
12. Align the matchmarks and install the distribu-
tor.
13. Remove the lash adjuster retaining tools. 14. Install the valve cover, with a new gasket and
semi-circular packing in place.
15. Connect the negative battery cable.
16. Run the engine and check ignition timing.
1.6L and 2.OL DOHC (Turbo and Non-turbo)
Engines
6 See Figure 16
1. Disconnect the negative battery cable.
2. Remove the valve cover and discard the gas-
ket.
3. Install lash adjuster retainer tools MD998443
or equivalent, to the rocker arm.
4. Remove the rocker shaft hold-down bolts
gradually and evenly and remove the rocker shaft/arm
assemblies.
5. If disassembly is required, keep all parts in
the exact order of removal. Inspect the roller surfaces
of the rockers. Replace if there are any signs of dam-
age or if the roller does not turn smoothly. Check the
inside bore of the rockers and the adjuster tip for
wear.
To install: 6. Lubricate the rocker shaft with clean engine
oil and install the rockers and springs in their proper
places.
7. Install the rocker shaft assemblies on the en-
gine. Tighten the bolts gradually and evenly to 21-25
ft. Ibs. (29-35 Nm).
*When installing the rocker arm shaft,
make certain the notch is properly located.
8. Remove the lash adiuster retainina tools
9. Install the valve cover with a new gasket.
10. Connect the negative battery cable.
F :ig. 16 Camshaft, rocker arm and shaft as
s iemblies-1.6L and 2.OL DOHC engines
*o Nm
IILlbs -
9315390 3
2.4L Engine
# See Figures 17, 16, and 19
1. Disconnect the negative battery cable.
2. Remove the accelerator cable from the retain-
ing clamps and position the accelerator cable out of
the way.
3. Remove the air intake hose.
4. Disconnect the breather hose and the PCV
hose.
5. Disconnect the spark plug cables from the
spark plugs.
6. Remove the rocker cover and gasket.
7. Install lash adjuster retainer tools MD998443
or equivalent, to the rocker arm.
8. Remove the rocker shaft hold-down bolts
gradually and evenly and remove the rocker shaft/arm
assemblies.
9. Disassemble the rockers and the rocker shaft
springs from the rocker shafts. If they are to be
reused, note the location and positionrng of all rocker
shaft components. It is recommended that all lash
adjusters and rockers be replaced as a complete set.
To install: 10. Immerse the lash adjusters in clean diesel
fuel, and using a small wire, move the plunger up
and down four or five times. while pushing down
lightly on the check ball in order to bleed the air from
the adjuster.
11. Install the lash adjusters to the rocker arms
and attach the special holding tool.
12. Lubricate the rocker shaft with clean engine
oil and install the rocker arms.
13. Temporarily tighten the rocker shaft assembly
with the mounting bolts so that all rocker arms on the
inlet valve side do not push on the valves,
14. Fit the rocker shaft springs from above and
position them so that they are at right angles to the
plug side. Install the rocker springs before installing
the exhaust side rocker shaft and rocker arm assem-
bly.
15. Install the exhaust side rocker shaft assembly
in the engine. Tighten the rocker shaft mounting bolts
gradually and evenly to 23 ft. Ibs. (32 Nm).
16. Remove the lash adjuster retaining tools.
17. Install the rocker cover and tighten the
mounting bolts to 30 inch Ibs. (3 Nm).
18. Reinstall the spark plug wires to the spark
plugs.
19. Reconnect the PCV and breather hoses.
20. Install the air intake hose.
21. Reattach the accelerator cable brackets and
reconnect the accelerator cable.
22. Connect the negative battery cable.
3.OL SOHC Engine
6 See Figures 20 and 21
On this engine, the hydraulic lash adjusters are
built into the rocker arms,
1. Disconnect the negative battery cable.
2. Remove the valve cover. Install lash adjuster
retainer tools MD998443 or equivalent, to prevent the
auto-lash adjuster from falling out of the rocker arm.
3. Loosen rocker arm and shaft assembly evenly
in several steps. Remove the rocker arm and shaft as-
sembly as a complete unit.
4. Remove the rear camshaft bearing cap and
slide the rocker arms, springs and washers from the
shaft. If they are to be reused, note the location and
positioning of all rocker shaft components. It is rec-

3-8' ENGINEANDENGINEOVERHAUL
Nm ft.lbs.
1. Engine hanger 5. Engine hanger
2. Intake manifold stay 6. Exhaust manifold cover
3. intake manifold 7. Exhaust manifold
4. Intake manifold gasket 8. Exhaust manifold gasket
7923ffi38 :ig. 28 Exploded view of the intake and exhaust manifold mounting-l .5L (4615) engine
11. Connect the negative battery cable, run the ,. . . .
vemcie unnl me tnermostat opens ano till the radiator
completely. age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
12. Once the vehicle has cooled, recheck the
coolant level.
REMOVAL &INSTALLATION 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.
15. Using a straight edge, measure the distortion
of the intake manifold-to-cylinder head. Total distor-
tion or warpage should be 0.006 inches (0.15mm or
less).
16. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crisscross pattern, starting from the inside and
working outwards to 13 ft. Ibs. (18 Nm).
17. Install the intake manifold support bracket
and torque the mounting bolts to 16 ft. Ibs. (22 Nm).
18. Install the engine mount support bracket and
torque the mounting bolts to 26 ft. Ibs. (36 Nm).
19. Using a new gasket, install the EGR valve and
torque the mounting bolts to 15 ft. Ibs. (21 Nm).
20. Using new insulators and O-rings, install the
fuel delivery pipe, injectors and pressure regulator to
the engine. Torque the retaining bolts to 7-9 ft. Ibs.
(10-14 Nm).
1.51 Engine
# See Figure 28
1. Relieve the 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 battery negative cable and 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,
3. Disconnect the upper radiator hose, heater
hose and water bypass hose.
4. Remove the thermostat housing from intake
manifold.
5. Disconnect the accelerator cable, breather
hose and air intake hose.
6. Remove all vacuum hoses and pipes as nec-
essary, including the brake booster vacuum line.
7. Remove the throttle body assembly.
8. Disconnect the high pressure fuel line and
the fuel return hose.
9. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor, in-
take air temperature, idle speed control assembly,
EGR temperature sensor, spark plug wires and dis-
tributor.
10. Remove the fuel rail, fuel injectors, pressure
regulator and insulators.
11. Remove the EGR valve from the intake mani-
fold.
12. Remove the intake manifold support bracket
and remove the engine mount support bracket.
13. Remove the intake manifold mounting bolts
and remove the intake manifold assembly.
To Install: 14. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly. Check both surfaces for cracks or other dam- 21. Attach the electrical connectors to the oxygen
sensor, coolant temperature sensor, intake air tem-
perature, idle speed control assembly, EGR tempera-
ture sensor, spark plug wires and distributor.
22. Using a new O-ring for the feed pipe and a
new clamp for the return pipe, install the fuel hoses.
23. Install the throttle body assembly.
24. Install the vacuum hoses and pipes as neces-
sary, including the brake booster vacuum line.
25. Install and adjust the accelerator cable. Install
the breather and air Intake hose.
26. Using a new gasket, install the thermostat
housing to the intake manifold and tighten the
mounting bolts to 13 ft. Ibs. (18 Nm).
27. Connect the upper radiator hose, heater hose
and water bypass hose. Be sure to use new hose
clamps.

ENGINEANDENGINEOVERHAUL 3-9
28. Fill the system with coolant.
29. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
30. Check and adjust the idle speed and ignition
timing.
31. Once the vehicle has cooled, recheck the
coolant level.
1.8L Engine
) See Figures 29 and 30
I. Relieve the 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 battery negative cable and 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
leff 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.
Fig. 29 Exploded view of the intake mani.
old mounting-1993 1.8L engine
3. Disconnect the accelerator cable and the air
intake hose.
4. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor, idle
speed control assembly, EGR temperature sensor, oil
pressure switch, spark plug wires and distributor.
5. Disconnect the wiring from the throttle posi-
tion sensor, fuel Injectors and disconnect the ground
cables.
6. Remove all vacuum hoses and pipes as nec-
essary, including the brake booster and PCV vacuum
lines.
7. Disconnect the upper radiator hose, heater
hose and water bypass hose.
8. Disconnect the high pressure fuel line and
the fuel return hose.
9. Remove the fuel rail, fuel injectors, pressure
regulator and insulators.
10. Remove the intake manifold support bracket.
11. If the thermostat housing is preventing re-
moval of the Intake manifold, remove it.
12. Remove the intake manifold mounting
bolts/nuts and remove the intake manifold assembly.
To install: 13. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
14. Using a straight edge, measure the distortion
of the intake manifold-to-cylinder head. Total distor-
tion or warpage should be 0.006 inches (0.15mm or
less).
15. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crrsscross pattern, starting from the inside and
working outwards to 14 ft. Ibs. (20 Nm).
16. If removed, install the thermostat housing.
17. Install the Intake manifold brace bracket.
18. Install the fuel delivery pipe, injectors and
pressure regulator to the engine. Torque the retaining
bolts to 108 Inch Ibs. (12 Nm). 19. Using a new O-ring for the feed pipe and a
new clamp for the return pipe, install the fuel hoses,
20. Connect the upper radiator hose, heater hose
and water bypass hoses.
21. Install the vacuum hoses and pipes as neces-
sary. Be sure to connect the brake booster and PCV
vacuum lines
22. Connect the wiring to the throttle position
sensor, fuel injectors and connect the ground cables,
23. Attach the electrical wiring to the oxygen sen-
sor, coolant temperature sensor, Idle speed control
assembly, EGR temperature sensor, oil pressure
switch, spark plug wires and distributor.
24. Connect and adjust the accelerator cable and
install the air intake hose.
25. Fill the system with coolant.
26. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
27. Check and adjust the idle speed and ignition
timing.
28. Once the vehicle has cooled, recheck the
coolant level. 2.OL SOHC Engine
# See Figure 31
1. Relieve the 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.
Fig. 30 Exploded view of the intake mani,
iold mounting-1994-00 1.8L engine Fig. 31 Exploded view of the intake mani
fold mounting-2.01 SOHC ermine

3-10 ENGINEANDENGINEOVERHAUL
2. Disconnect the battery negative 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 and air in-
take hose.
5. Disconnect the upper radiator hose, heater
hose and water bypass hose.
6. Unplug the vacuum connection at the power
brake booster and the PCV valve if still connected.
Disconnect all remaining vacuum hoses and pipes as
necessary.
7. Disconnect the high pressure fuel line, fuel
return hose and remove throttle control cable brack-
ets
8. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor,
therm0 switch, idle speed control assembly, EGR
temperature sensor, distributor, fuel injectors and
spark plug wires. Position the engine wiring harness
aside.
9. Matchmark the distributor housing to the in-
take manifold, and remove the distributor.
10. Remove the intake manifold bracket and the
engine hanger.
11. If the thermostat housing is preventing re-
moval of the intake manifold, remove it.
12. Remove the intake manifold mounting bolts
and remove the intake manifold assembly. Drsassem-
ble manifold from the Intake plenum on a work bench
as required
To install: 13. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly. Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
14 Assemble the intake manifold assembly using
all new gaskets. Torque air intake plenum bolts to
11-14ff. Ibs. (15-19 Nm).
15. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crrsscross pattern, starting from the inside and
working outwards to 11-14 ff. Ibs. (15-19 Nm).
16. Install the fuel delivery pipe, injectors and
pressure regulator to the engine. Torque the retaining
bolts to 4 ft. Ibs (6 Nm).
17. install the thermostat housing, intake mani-
fold brace bracket, and engine hanger bracket.
18 Connect or install all hoses, cables and elec-
trical connectors that were removed or disconnected
during the removal procedure.
19. Align the distributor matchmarks and install
the distributor.
20. Fill the system with coolant,
21. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely. 22. Adjust the accelerator cable. Check and ad-
just the idle speed and ignition timing.
23. Once the vehicle has cooled, recheck the
coolant level.
1.6L and 2.OL DDHC Engines
# See Figure 32
1. Relieve the 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-
ulosion.
2. Disconnect battery negative cable and 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.
Fig. 32 Exploded view of the intake mani-
fold and related components-1.6L and
2.OL DDHC engine
3. Disconnect the accelerator cable and air in-
take hose.
4. Disconnect the coolant hose from the throttle
housing.
5. Detach the vacuum connection at the power
brake booster and the PCV valve If still connected.
Disconnect all remaining vacuum hoses and pipes as
necessary.
6. Drsconnect the high pressure fuel line, fuel
return hose and remove throttle control cable brack-
ets
7. Tag and detach the electrical connectors from
the oxygen sensor, coolant temperature sensor,
therm0 switch, throttle position sensor, rdle speed
control assembly, EGR temperature sensor, distribu-
tor, fuel injectors and spark plug wires. Position the
engine wiring harness aside.
8. Remove the intake manifold bracket.
9. Remove the intake mamfold mounting bolts
and remove the intake manifold assembly. Disassem-
ble manifold on a work bench as required.
To install:
10. Clean all gasket material from the cylinder
head intake mounting surface and intake manifold as-
sembly. Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and
jet air passages for clogging. Clean if necessary.
11. Assemble the Intake manifold assembly using
all new gaskets.
12. Install a new intake manifold gasket to the
head and install the manifold. Torque the manifold in
a crisscross pattern, starting from the inside and
working outwards to 11-14 ft. Ibs. (15-20 Nm).
13. Install the fuel delivery pipe, injectors and
pressure regulator to the engine. Torque the retaining
bolts to 4 ft. Ibs. (6 Nm).
14. Install the intake manifold brace bracket and
tighten bolts to 13-18 ft. Ibs. (18-25 Nm).
15. Connect or install all hoses, cables and elec-
trical connectors that were removed or disconnected
during the removal procedure.
16. Fill the system with coolant.
17. Connect the negative battery cable, run the
vehicle until the thermostat opens, fill the radiator
completely.
18. ‘Adjust the accelerator cable.
19. Check and adjust the idle speed and ignition
timing.
20. Once the vehicle has cooled, recheck the
coolant level.
2.4L Engine
) See Figures 33 thru 51
93153p37 Fig. 33 Detach the A/C temp electrical con- 1

.
3-12 ENGINEANDENGINEOVERHAUL
93153p54
1
L Fig. 46 Remove the brake booster vacuum
hose from the back of the intake manifold Fig 47 Remove the fuel feed line-to-fuel rail’retaini”g fitti”g bo,ts . . .
Fig. 49 From underneath the vehicle, re-
move the two intake manifold support
1. Relieve the fuel system pressure.
4. Disconnect the coolant hose from the throttle
Observe all applicable safety precautions
ing the fuel system, always work in a well when working around fuel. Whenever servic-
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 battery negative cable and drain
the cooling rtfctnm 93153p39 Fig. 50 Remove the intake manifold retain-
ing bolts . . .
h
n ousing.
5. Detach the vacuum connection at the power
b
rake booster and the PCV valve if still connected.
C lisconnect all remaining vacuum hoses and pipes as
ecessary. et air passages for clogging. Clean if necessary.
12. Assemble the intake manifold assembly using
III new gaskets.
13. Position a new intake manifold gasket on the
lead, then install the manifold. Torque the manifold
n a crisscross pattern, starting from the inside and
vorking outwards to 15 ft. Ibs. (20 Nm) for bolts, and
o 26 ft. Ibs. (35 Nm) for nuts on 1994 vehicles or 15
t. Ibs. (20 Nr$ for nuts on 1995-00 vehicles.
14. Install the fuel delivery pipe, injectors and
xessure regulator to the engine. Torque the retaining
)olts to 4 ft. Ibs. (6 Nm). Fuel injection systems remain under pres- f
sure after the engine has been turned OFF.
Properly relieve fuel pressure before discon-
necting any fuel lines. Failure to do so may [
result in fire or personal injury.
t 6. Disconnect the high pressure fuel line, fuel
return hose and remove throttle control cable brack- t
n+C.
cm. durino the removal orocedure. 15. Install the intake manifold brace bracket and
ighten bolts to 21 ft. Ibs. (29 Nm).
16. Connect or install all hoses, cables and elec-
rical connectors that were removed or disconnected
7. Tag and unplug the electrical connectors
from the coolant temperature sensor, coolant temper- 17: Fill the system with coolant.
18 Connect the negative battery cable, run the
, . : .., ,, ., , ,
,,,, ,. ,.
93153p73 Fig. 51 . . .
then remove the manifold from
the cylinder head
Ruver open, service or drain the radiator or
@Ming system when hot; serious burns can
II&ur from the steam and hot coolant. Also,
draining engine coolant, keep in mind ’
j “thiat cats and dogs are attracted to ethylene
. . . ..____ “..” 11_,1 -...... any that is
t uncovered container or in puddles
FE ol iha ground. This will prove fatal in suff i-
k ici?M quantities. Always drain coolant into a
$1 pealable container. Coolant should be reused
h’ uniass it is contaminated or is several years
j$O'd.
**w
ature gauge, IAC valve, ignition coil, EGR tempera-
ture sensor, knock sensor, oxygen sensor, throttle
position sensor, distributor, A/C temperature sensor,
fuel injectors and ignition power transistor. Position
the engine wiring harness aside.
8. Label and disconnect the spark plug wires
from the spark plugs.
9. Remove the intake manifold stay bracket.
IO. Remove the intake manifold mounting bolts
and remove the intake manifold assembly. Disassem-
ble manifold on a work bench as required.
Tan is”.+..ll. vemcle unrn me mermosrar opens, ml tne raalaror
completely.
19. Adjust the accelerator cable. Check and ad-
just the idle speed and ignition timing.
20. Once the vehicle has cooled, recheck the
coolant level.
3.OL and 3SL Engines
ti See Figures 52 thru 57
1. Relieve the fuel system pressure.
W.>. Clean all gasket material from the cylinder
!&S head intake mounting surface and intake manifold as-
fir!: 3. Disconnect the accelerator cable, breather
Observe all applicable safety precautions
El .;,
+w..” and air intake hose. sembly. Check both surfaces for cracks or other dam-
age. Check the intake manifold water passages and when working around fuel. Whenever servic-

3-16 ,ENGlNEANDENGlNEOVERHAUL
Fig 66 Remove the heat shield retaining
bolts. . . g3’~‘51 Fig. 64 Remove the hanger retaining bolt
* . I(
Fig, 67 . . .
then remove the heat shield
from the exhaust manifold
Fig. 69 Remove the engine lifting eye from
the manifold . . . Fig. 70 , . . then remove the manifold from
the cylinder head Fig. 71 Remove the exhaust manifold gas-
/ faces, and replace the gasket ’ 93’53p72 ket, thoroughly clean the mountmg sur-
6. For the DOHC engine, if removing thr
a front
manifold, remove the alternator and mountin!
from the vehicle. 3 bracket
7. For the DOHC engine, separate the I$,, I.vIII- /r nnm
pressor from the mounting bracket. Leaving the
hoses ~~~, position the compressor aside,
8. ff removing the front manifold, remove the oil
dipstick and tube from the engine.
9. For the DOHC engine, if removing the front
manifold, remove the heat protector. 13. Remove the exhaust manifold mounting bolts
the manifold.
To install:
-4” PI,*, -11 rm.A.^L -,‘&^-:-I f-e.- IL- -_-I!-- - .-
17. lrlMll dll yWK1 Illdlell~l 110111 LIle lKWi~ SIN- faces and check the manifold for damage.
15. Install a new gasket and install the manifold.
Tighten the nuts in a crisscross pattern to 21 ft. Ibs.
(30Nm). .’ --.._
Nm) for 1
16. II 21. Install the drive belt(s) and adjust for proper
tension.
to1 the SOHC engine or to 14 ft. Ibs. (19
he DOHC engine.
Wall the heat shields. 22. Connect the negative battery cable and check
I- L- L, #
ror exnausr leaks.
3.51 Engfne
A Sam Finnwn 74
17. c
“IIII”“IUI” L”ll L”“““ll” IIIlu#lb p,““l~,aa~
and roll stopper bracket, if removed.
18. Install the oxygen sensor.
19. Install the electric cooling fan assembly, A/C
compressor, dipstick tube and alternator, as required.
20. Install a new flange gasket and connect the
exhaust pipe or converter assembly. Do not attempt the work on the
exhaust sys-
tern until it has completely coo
led.
1. Disconnect battery negative cable.
2. Raise the vehicle and support safely.
3. Remove the exhaust pipe to exhaust manifold
nuts and remove the front exhaust pipe. IO. If removing the rear manifold, disconnect the
EGR tube.
11. For the SOHC engine, if removing the rear
manifold, remove the intake plenum stay and the roll
stopper bracket.
12. Unplug the electrical connector and remove
the oxygen sensor.