ENGINE MECHANICAL 3-1 ASSEMBLY 3-64

ENGINE 3-1 ENGINEBLOCK 3-65

REMOVAL&INSTALLATION 3-l GENERALINFORMAITON3-65
ROCKERARM(VALVE)COVER 3-l DISASSEMBLY 3-65
REMOVAL&INSTALLATION 3-l INSPECTION 3-65
ROCKERARM/SHAFTS 3-4 REFINISHING 3-67
REMOVAL& INSTALLATION 3-4 ASSEMBLY 3-67
THERMOSTAT 3-7 ENGINESTART-UPAND BREAK-IN 3-.69
REMOVAL& INSTALLATION 3-7 STARTINGTHE ENGINE 3-69
INTAKEMANIFOLD 3-7 BREAKINGIT IN 3-69
REMOVAL& INSTALLATION 3-7 KEEPIT MAINTAINED 3-69
EXHAUSTMANIFOLD 3-14 SPECIFICATIONS CHARTS
REMOVAL&INSTALLATION 3-14 ENGINEMECHANICAL
TURBOCHARGER3-17 SPECIFICATIONS 3-70
REMOVAL& INSTALLATION 3-17 TORQUESPECIFICATIONS 3-81
RADIATOR 3-18
REMOVAL& INSTALLATION 3-18
ENGINEFAN 3-19
REMOVAL&INSTALLATION 3-19
WATERPUMP 3-20
REMOVAL& INSTALLATION 3-20
CYLINDERHEAD 3-23
REMOVAL&INSTALLATION 3-23
OIL PAN 3-30
REMOVAL& INSTALLATION 3-30
OIL PUMP 3-33
REMOVAL&INSTALLATION 3-33
CRANKSHAFTDAMPER 3-36
REMOVAL&INSTALLATION 3-36
TIMINGCOVERANDBELT 3-36
REMOVAL& INSTALLATION 3-36
INSPECTION 3-48
FRONTCRANKSHAFTSEAL 3-48
REMOVAL& INSTALLATION 3-48
CAMSHAFT,BEARlNGSAND
LIFTERS 3-48
REMOVAL& INSTALLATION 3-48
INSPECTION 3-53
BALANCESHAFT 3-54
REMOVAL&INSTALLATION 3-54
REARMAIN SEAL 3-54
REMOVAL&INSTALLATION 3-54
FLYWHEEL/DRIVEPLATE3-55
REMOVAL&INSTALLATION 3-55
EXHAUST SYSTEM 3-55
INSPECTION 3-55
REPLACEMENT 3-56
ENGINE RECONDITIONING 3-57
DETERMINIGENGINECONDITION 3-57
COMPRESSION TEST 3-57
OIL PRESSURETEST 3-57
BUYOR REBUILD? 3-57
ENGINEOVERHAULTIPS 3-58
TOOLS 3-58
OVERHAULTIPS 3-58
CLEANING 3-58
REPAIRINGDAMAGEDTHREADS 3-59
ENGINEPREPARATION3-59
CYLINDERHEAD 3-60
DISASSEMBLY 3-60
INSPECTION 3-
REFINISHING& REPAIRING 3-63
3-2 ENGINEANDENGINEOVERHAUL
REMOVAL&INSTALLATION
# See Figure 1
In the processof removingthe engine,you will
comeacrossa numberof stepswhich call for the re-
moval of a separatecomponentor system,suchas
“disconnectthe exhaustsystem”or “removethe radi-
ator.” In most instances,a detailedremovalproce-
durecan befound elsewherein this manual.
It is virtually impossibleto list eachindividual
wire and hosewhich must be disconnected,simply
becauseso manydifferentmodeland engrnecombi-
nationshavebeenmanufacturedCarefulobservation
and commonsensearethe bestpossibleapproaches
to any repairprocedure.
Removaland installationof the enginecan be
madeeasierif you follow thesebasicpoints:
l If you haveto drain any of the fluids, usea
suitablecontainer.
l Alwaystag any wires or hosesand, if possrble,
the componentstheycamefrom beforedisconnect-
ing them.
l Becausethereareso manybolts and fasteners
involved,storeand labelthe retainersfrom compo-
nentsseparatelyin muffin pans,jars or coffeecans.
This will preventconfusionduring installatron.
l Afterunboltingthe transmisstonor transaxle,
alwaysmakesure it is properlysupported.
l If it is necessaryto disconnectthe air condi-
tioning system,havethis serviceperformedby a
qualifiedtechnicianusinga recovery/recyclingsta-
tion If the systemdoesnot haveto be disconnected,
unboltthe compressorand set it aside.
l Whenunboltingthe enginemounts,always
makesurethe engineis properlysupported.When
removingthe engine,makesurethat any lifting de-
vices are properlyattachedto the engine.It is recom-
mendedthat if your engineISsuppliedwith lifting
hooks,your lifting apparatusbe attachedto them.
l Lift the enginefrom its compartmentslowly,
checkingthat no hoses,wires or othercomponents
are still connected.
l Afterthe engineis clearof the compartment,
placeit on an enginestandor workbench.
l After the enginehas beenremoved,you can
performa partialor full teardownof the engineusing
the proceduresoutlinedin this manual.
1. Relievefuel systempressure.
Observeall applicable safety precautions
when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vapors to comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnectthe negativebatterycable.
3. Removethe engineundercoverif equipped.
4. Matchmarkthe hoodand hingesand remove 16. Slowly lift the engineand removeit from the
the hood assembly. vehicle.
5. Removethe air cleanerassemblyand all ad- To install:
joining air intakeductwork. 17. Installthe engineand secureall control
6. Drainthe enginecoolant,removethe radiator bracketsand mounts.
hoses,and removethe radiatorassembly,coolant 18. Installthe transaxle,and transfercaseif
reservoir,and intercooler,as equipped. equipped.
19. The balanceof the installationis the reverse
of removalwith the addition of the following notes:
a. Use newclamps or O-rings to connectthe
cooling systemwhen hot; serious burnscan high pressurefuel lme and the fuel return line.
occurfrom the steamand hot coolant. Also, b. Use new gasketsto connectthe exhaust
when draining enginecoolant, keep in mind systemto the engine.
that cats and dogsare attractedto ethylene c. Fill the enginewith the properamountof
glycol antifreezeand could drink any that is engineoil and coolant.
left in an uncoveredcontaineror in puddles d. Startthe engine,allow it to reachnormal
on the ground.This will prove fatal in suffi- operatingtemperature.
cient quantities.Always drain coolant into a e. Checkfor leaks.
sealable container.Coolantshouldbe reused f. Checkthe ignition timing and adjust if nec-
unlessit is contaminatedor is several years essary.
old. g. Roadtest the vehicle and checkall fluid
levelsand functionsfor proper operation.
7. Removethe transaxleandtransfercaseas
equipped.
8. Tagand detachthe following electricalcon-
nections:
l Acceleratorcable
l Heaterhoses
l Brakeboostervacuumhose
l Vacuumhoses
l Fuel lines
l Enginegroundcables
l Any applicablesensors
l Coolanttemperatureand oil pressuresend-
ing units
l ExhaustGas Recirculation(EGR)tempera- Fig. 1 Alignmentof the engine mountstop-
ture sensor oer bracket-Diamante shown
l Connectionfor the idle speedcontrol mo-
tor
l Fuel injectors
l Powertransistor
l Ignition coil and any applicabledistributor REMOVAL&INSTALLATION
connections
l The connectionsfor the alternator
l Powersteeringpressureswitch Except3.OL(SOHCand DOHC)and 3.5L
l A/C compressor Engines
l Refrigeranttemperatureswitch # See Figures2 thru 11
l Condenser
9. Removethe air conditionerdrive beltand the 1. Disconnectthe negativebatterycable.
air conditioningcompressor.Leavethe hosesat- 2. If necessary,removethe air intakehose.
tached.Do not dischargethe system.Placethe com- 3. If necessary,removethe throttlecablefrom
pressorasideand secureit using a suitabledevice. the cableroutingclips.
10. Removethe powersteeringpumpand place
the pumpasrdeand secureit using a surtabledevice.
11. Removethe exhaustmanifold-to-exhaust
pipe nuts. Discardthe gasket.
12. Installthe enginehoist equipmentand make
certainthe attachingpoints on the engineare secure.
13. Raisethe hoist enoughto supportthe engine.
14. Removethe front and rearengineroll stop-
pers
15. Removethe left enginemountand support
Doublecheckthat all cables, hoses,harness
connectors,etc., are disconnectedfrom the
engine. Fig. 2 If necessary, removethe throttle ca-
ble from the cable routing clips

Fig. 3 Removethe breather hose from the
93153p17
Fig. 6 . . . then position the wires out of the
Fig. 9 Remove the valve cover retaini
4. If equipped,
removethebreather hosefrom
thevalvecover.
5. Remove thecrankcaseventilation
tubefrom
thevalvecover.
6. Onthe1.6Land2.gL(DOHC) engines,re-
movetheignitionwirecover.
7. Labelandremovetheignitionwiresandsep-
arators.
8. Remove theuppertimingbeltcover.
9. Remove thevalvecoverretainingbolts,start
ingfromtheoutsideandworkingin.
10. Remove thevalvecoverandgasketfromthe
cylinderhead.
To install:
11. Cleanthevalvecovergasketsealingsurfaces,
12, Installnewvalvecovergasketsandif
equipped, O-ringsontothevalvecovers.
ENGINEANDENGINEOVERHAUL
3-3
Fig. 4 Removethe PCWvalve and hosefrom
Fig. 7 The uppertiming cover is retained by
three bolts. Unfastenthe bolts . . .
then lift the valve cover
13. Placethevalvecoverintopositionandbegin-
ningin thecenterof thevalvecoverandworkingout-
ward,tightentheretainingboltsasfollows:
l 15L engine:12-18inchIbs.(l-2 Nm)
l 1.6L,1.8L,2.OLDOHC,and2.4Lengines:
24-36inchIbs.(2-3 Nm)
* 2.OLSOHCengine:WO inchIbs.(4-5
Nm)
14. Installthecrankcase ventilation
tube.
15. Installtheignitionwireseparators andtheig-
nitionwires.
16. Onthe1.6Land2.OL(DOHC) engines,
install
theignitionwirecover.
17. Installtheair intakehose.
18. Connect thenegative batterycable.
19. Runtheengineandcheckfor leaksand
properoperation.
Fig. 8 . . . then carefully remove the cover
from the engine
3.OLand 3.5L Engines
b See Figure 12
1. Disconnect thenegativebatterycable.
2. Remove theupperintakemanifoldasde-
scribedin thissection.
3. Onthe3.OLDOHCengine,remove theigni-
tionwirecover.
4. Remove theignitionwiresandsparkplugs.
5. Remove thecrankcase ventilationtubesfrom
bothvalvecovers.
6. Remove theretainingnutsandenginewiring
frombothvalvecoversandmoveaside.
7. Remove thevalvecoverretainingboltsand
studs.
8. Remove bothvalvecoversfromtheengine.
3-4 ENGINEANDENGINEOVERHAUL
To install:
Rear bank 7. Lubricatethe rockershaftwith cleanengine
oil and Installthe rockersand springs.
REMOVAL&INSTALLATION 8. Installthe rockerarm and shaftassemblies.
6 011 010 og Tightenthe rockerarm shaftretainerbolts to 23 ft.
1.5L and 1.8L Eflgin8S Ibs. (32 Nm).
9. Checkvalveadjustmentand installthe valve
,# See Figures13 and 14 cover.Tightenthe valvecover bolts to 16 inch Ibs.
(1.8 Nm) for the 1.5L engineor to 29 inch Ibs. (3.3
1. Disconnectthe negativebatterycable. Nm) for the 1.8L engine.
2. For 1.8L engines,labeland disconnectthe 10. If detached,connectthe sparkplug cables.
1.03 07 02] sparkplug cables. 11. Connectthe acceleratorcable,breatherhose
7923PG25
3. Disconnectthe acceleratorcable,breather and PCV hose.
hoseand PCV hoseconnections. 12. Connectthe negativebatterycable.
Fig. 12 Rocker cover bolt torque se- 4. Removethe rockercover.
quence-3.01 DOHCengine 5. Loosenboth rockerarm shaftassemblies 2.OLSOHCEngine
graduallyand evenlyand removethe rocketshafts
To install: from the vehicle. # See Figure 15
9. Cleanthe valve cover gasketsealingSW 6. If disassemblyis required,keepall parts in
Onthis engine,the hydrauliclifters are built into
faces. the exactorder of removal.
the rockerarms. If lifter serviceis required,simply
10 Installnewvalve cover gasketsontothe valve
covers.
11. Placethe valvecovers into position.
12. Reinstallthe valve cover retainingbolts and
studsand tightenin sequenceto:
l 3.OLSOHCengine:7 ft. Ibs. (9 Nm)
l 3.OLDOHCengine:42-54 inch Ibs. (4-5
NM
l 3.5L engine:30 inch Ibs. (3 Nm)
13. Installthe enginewiring andtightenthe re-
taining nuts.
14. Installthe crankcaseventilationtubesinto
both valve covers.
15. Installthe ignition wire separators,the igni-
tion wires, and the sparkplugs.
16. Onthe 3.OLDOHCengine,installthe ignition
wire cover.
17. Installthe upperintakemanifoldas described
in this section.
18. Connectthe negativebatterycable.
19. Runthe engineand checkfor leaksand
properoperation.

1. Breather hose 10. Rocker arm A

2. P.C.V. hose 11. Rocker arm 6
3. Rocker cover 12. Rocker arm shaft (Intake side)
4. Rocker cover gasket 13. Adjusting screw
Valve clearance pre-adjustment 14. Nut
5. Oil seal 15. Rocker arm C
6. Oil seal 16. Rocker arm shaft (Exhaust side)
7. Rocker arms and rocker arm shaft 17. Adjusting screw
6. Rocker arms and rocker arm shaft 18. Nut
9. Rocker shaft spring 19. Camshaft
Fig 13 Camshaft rocker arm and shafl as- 7923PG27

( ser;lblies-l.5L dngine g3’53goi :ig. 14 Camshaft,rocker arm and shaft assemblies-l .8L engine

Fig. 15 Camshaft,rocker arm and shaft as-
remblies-2.01 SOHCengine
removethe lifter from the bore in the rockerarm. It is
recommendedthat all of the rockerarms and lashad-
justersbe replacedat the sametime.
1. Disconnectthe negativebatterycable.
2. Removethe valve cover.
3. Matchmarkthe distributorto the cylinder
headand removethe distributor.
4. Removecamshafttiming belt.
5. Workingin a crisscrosspatternfrom the cen-
ter outward,loosenthe camshaftbearingcapsin
gradualsteps.
6. Removethe rockerarms,shaftsand bearing
capsas an assembly.
*It is essentialthat all parts be kept in the
sameorder andorientation for reinstallation.
Be sure to markand separateparts, so parts
will not be mixedduring reassembly.
7. Disassemblerockershaftassembly.Starting
at rearbearingcap,slide eachpieceoff shafts.
*Inspect the roller surfacesof the rockers.
Replaceif there are any signs of damageor
if the roller doesnot turn smoothly. Check
the inside bore of the rockersand lifter for
wear.
To install:
8. Apply a drop of sealantto the rearedgesof
the end caps.
9. Installthe assemblyinto the front bearing
cap, makingsurethe notchesin the rockershaftsare
facing up. Insertthe installationbolt, but do not
tightenat this point.
10. Installthe remainingcapbolts. Tightenall
bolts evenlyand graduallyto 15 ft. Ibs. (20 Nm). Re-
move the lash adjusterretainers.
11. Installthe timing belt as required.
12. Align the matchmarksand installthe distribu-
tor.
13. Removethe lashadjusterretainingtools.
ENGINEANDENGINEOVERHALJL
3-5
14. Installthe valve cover,with a newgasketand
semi-circularpackingin place.
15. Connectthe negativebatterycable.
16. Runthe engineand checkignition timing.
1.6L and 2.OLDOHC(Turbo and Non-turbo)
Engines
6 See Figure 16
1. Disconnectthe negativebatterycable.
2. Removethe valve coverand discardthe gas-
ket.
3. Install lashadjusterretainertools MD998443
or equivalent,to the rockerarm.
4. Removethe rockershaft hold-downbolts
graduallyand evenlyand removethe rockershaft/arm
assemblies.
5. If disassemblyis required,keepall partsin
the exactorderof removal.Inspectthe roller surfaces
of the rockers.Replaceif thereare anysigns of dam-
age or if the roller doesnot turn smoothly.Checkthe
inside boreof the rockersand the adjustertip for
wear.
To install:
6. Lubricatethe rockershaftwith cleanengine
oil and installthe rockersand springs in their proper
places.
7. Installthe rockershaftassemblieson the en-
gine. Tightenthe bolts graduallyand evenlyto 21-25
ft. Ibs. (29-35 Nm).
*When installing the rocker arm shaft,
makecertain the notchis properly located.
8. Removethe lashadiusterretaininatools
9. Installthe valve coverwith a newgasket.
10. Connectthe negativebatterycable.
*o Nm
IILlbs -
9315390 3
F:ig. 16 Camshaft,rocker arm and shaft as
siemblies-1.6L and 2.OLDOHCengines
2.4L Engine
# See Figures 17, 16, and 19
1. Disconnectthe negativebatterycable.
2. Removethe acceleratorcablefrom the retain-
ing clampsand positionthe acceleratorcableout of
the way.
3. Removethe air intakehose.
4. Disconnectthe breatherhoseandthe PCV
hose.
5. Disconnectthe sparkplug cablesfrom the
sparkplugs.
6. Removethe rockercoverand gasket.
7. Installlashadjusterretainertools MD998443
or equivalent,to the rockerarm.
8. Removethe rockershafthold-downbolts
graduallyand evenlyand removethe rockershaft/arm
assemblies.
9. Disassemblethe rockersand the rockershaft
springsfrom the rockershafts.If they areto be
reused,notethe locationand positionrngof all rocker
shaftcomponents.It is recommendedthat all lash
adjustersand rockersbe replacedas a completeset.
To install:
10. Immersethe lashadjustersin cleandiesel
fuel, and using a small wire, movethe plungerup
and downfour or five times.while pushingdown
lightly on the checkball in orderto bleedthe air from
the adjuster.
11. Installthe lashadjustersto the rockerarms
andattachthe specialholdingtool.
12. Lubricatethe rockershaftwith cleanengine
oil and installthe rockerarms.
13. Temporarilytightenthe rockershaftassembly
with the mountingbolts so that all rockerarms on the
inlet valve side do not pushon the valves,
14. Fit the rockershaftspringsfrom aboveand
positionthemso that they are at right anglesto the
plug side. Installthe rockerspringsbeforeinstalling
the exhaustside rockershaftand rockerarm assem-
bly.
15. Installthe exhaustside rockershaftassembly
in the engine.Tightenthe rockershaft mountingbolts
graduallyand evenlyto 23 ft. Ibs.(32 Nm).
16. Removethe lashadjusterretainingtools.
17. Installthe rockercoverand tightenthe
mountingbolts to 30 inch Ibs. (3 Nm).
18. Reinstallthe sparkplug wires to the spark
plugs.
19. Reconnectthe PCVand breatherhoses.
20. Installthe air intakehose.
21. Reattachthe acceleratorcablebracketsand
reconnectthe acceleratorcable.
22. Connectthe negativebatterycable.
3.OLSOHCEngine
6 See Figures 20 and 21
Onthis engine,the hydrauliclashadjustersare
built into the rockerarms,
1. Disconnectthe negativebatterycable.
2. Removethe valve cover. Install lashadjuster
retainertools MD998443 or equivalent,to preventthe
auto-lashadjusterfrom falling out of the rockerarm.
3. Loosenrockerarm and shaftassemblyevenly
in severalsteps.Removethe rockerarm and shaftas-
semblyas a completeunit.
4. Removethe rearcamshaftbearingcapand
slide the rockerarms,springsand washersfrom the
shaft.If they areto be reused,notethe locationand
positioningof all rockershaftcomponents.It is rec-
 .

3-6 ENGINEANDENGINEOVERHAUL
Arrow mark (bearing cap)

Arrow mark
fcyllnder head)
7923PG35

Fig. 21 Wheninstalling the rocker arm/shafi

assemblies, ensure that the arrow marks
point in the same direction as the arrow
stampedinto the cylinder head-3.01 SOHC
engine

7. Lubricatethe camshaftand rockershaftwith

cleanengineoil and position on the cylinderhead.
8. Apply a drop of sealantto the rearedgesof
the end caps.
9. Installthe assemblymakingsurethe notches
in the rockershaftsarefacing up.
79231632 10. Installthe cap bolts andtightenevenlyand
IFig. 17 Rocker arm shafts and components-2.41 engine graduallyto 14 ft. Ibs. (20 Nm). Removethe lashad-
juster retainers
11. Installthe valve cover.
12. Connectthe negativebatterycable.

3.OLOOHCEngine
) See Figure 22
1. Relievethe fuel systempressure.

Observeall applicable safety precautions

when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. 00 not allow fuel spray or
Fig. 18 Installing the rocker shaft springs- vaporsto comein contactwith a sparkor
openflame. Keepa dty chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
13. Bearing cap storage;also, always properly seal fuel con-
14.
15.
Rocker
spring
arm tainers to avoid the possibility of fire or ex-
16. Rocker arm
plosion.
17. Spring
16 Bearing cap no. 3 2. Disconnectbatterynegativecable.
IQ. Rocker arm 3. Removethe timino belt coverandtimina belt.
20. spring Referto the timing belt procedurein this section.
21. Rocker arm
22. Spring
23. Bearing cap no. 2
24. Rocker arm
25. spring
26. Rocker arm
27. Spring
28. Rocker arm shaft
29. Rocker arm shaft
30. Bearing cap no. 1
7923PG3

Fig. 20 Rocker arm assembly-3.01 SOHCengine

ommendedthat all lashadjustersand rockersbe re- downlightly on the checkball in orderto bleedout 7923PG3

placedas a completeset.
To install:
5. Immersethe lashadjustersin cleandiesel
fuel. Usinga small wire, movethe plungerof the lash
adjusterup and down4 or 5 times while pushing
the air. Installthe lashadjustersin the rockerarms.
6. Usinga light coat of engineoil, assemblethe
rockerarmsto the shaft.Installthe rearcamshaft
bearingcap.
Fig. 22 The rocker arms sit beneath the
camshaftand are supportedon one end bl
the valve stem and on the other end by the
hydraulic lash adjuster-Oiamante wit1
3.OLOOHCengine
 ENGINEANDENGINEOVERHAUL
3-7
4. Remove thecentercover,breather andPCV 3. installthelashadjusterclipsontherocker unless it is contaminatedor is several years
hoses,andsparkplugcables. arms,thenloosenthebearingcapbolts.Donotre- old.
5. Remove therockercover. movetheboltsfromthebearingcaps.
6. Remove thethrottlebodystay,bothcamshaft 4. Remove therockerarms,shaftsandbearing 3. Remove anynecessary components to access
sprockets,andoil seals. capsasanassembly. thethermostat.
7. Remove theCamshaft PositionfCMP)sensor lo hlstall: 4. Remove thethermostat housinqretaininq
nd adapter fromtherearof thecamshah. ’ 5. Installthebearingcaps/rockerarmassem- bolts.
8. Remove theintakeandexhaust camshafts. blies.Tightentheboltsto 23ft. Ibs.(31Nm). 5. Liftthehousingfromtheengine.
9. Remove rockerarmsandlashadjusters from 6. Remove thelashadjusterclips. 6. Remove thethermostat takingnoteof its
hehead.It is recommended thatall lashadjusters 7. Installtherockerarmcoverusinga newgas- originalpositioninthehousing.
mdrockersbereplaced asa complete set. ket. To Install:
To Install: 8. Connect thenegativebatterycable. *In order to preventleakage, makesure
10. Immerse thelashadjusters in cleandiesel both matingsurfaces are clean and free of
uel.Usinga smallwire,movetheplungerof thelash any old gasketmaterial.
tdjusterupanddownfourorfivetimeswhilepush-
ngdownlightlyonthecheckballin orderto bleed 7. Installthethermostat so itsflangeseats
juttheair.Lubricate andinstallthelashadjusters in REMOVAL&INSTALLATION tightlyinthemachined grooveintheintakemanifold
hecylinderhead. orthermostat case.Referto itslocationpriorto re-
11. Lubricate thecamshafts withcleanenqineoil b See Figures 24, 25, 26, and 27 moval.Aliqnthereliefvalvewiththealignment mark
nd positionthecamshafts onthecylinderhead. onthethermostat housing.
12. Installthebearingcaps.Tightenthecapsin 1. Disconnect
thenegativebatterycable. 8. Usea newgasketor D-ringandreinstallthe
sequence, in 2 or 3 steps.Caps2,3 and4 havea 2. Drainthecoolingsystem. thermostat housing. Torquethehousingmounting
rontmark.Installwiththemarkalignedwiththefront boltstothefollowingspecifications:
narkonthecylinderhead.IntakecapshaveI l 1.8Lengine:16ft. Ibs.(22Nm)
stamped onthecapandexhaustcapshaveE.Also, Never open, service or drain the radiator or l 1.5L,1.61,2.OLDOHC,and1990-922.OL
)esuretherockerarmiscorrectlymounted onthe cooling systemwhen hot; serious bumscan SOHCengines:12-14ft. Ibs.(17-20Nm)
ashadjusterandthevalvestemend.Torquethefront occurfrom the steamandhot coolant. Also, l 19932.01SOHCengine:7-10ft. Ibs.
mdrearretaining capboltsto 14ft. Ibs.(20Nm)and when draining enginecoolant, keepin mind (10-15Nm)
ightenthecenter3 retainingcapboltsto 8 ft. Ibs. that cats and dogsare attractedto ethylene l 2.4Lengine:IO ft. Ibs.(14Nm)
11Nm). glycol antifreezeand could drink any that is l 3.OLand3.5Lengines:12-14ft. Ibs.
13. Applya coatingof engineoil to theoil seals left in an uncoveredcontaineror in puddles (17-20Nm)
mdinstall. on the ground.Thiswill provefatal in suffi- 9. Fillthesystemwithcoolant.
14. Installthetimingbelt,valvecoverandall re- cient quantities.Always drain coolant into a 10. Installtheremoved air intakeplumbing.
atedparts.Refertothetimingbeltprocedure in this sealable container. Coolantshouldbe reused
;ection.
15. Connect thenegative batterycableandcheck
or leaks.
3.51Engine
I See Figure 23
1. Disconnect
thenegative
batterycable.
2. Removetherockerarmcover.

g. 26 Remove the thermostat from the

ousing, noting the location of usingthe thermostat,always re-
3-8' ENGINEANDENGINEOVERHAUL\
1. Engine hanger
2. Intake manifold
3. intake manifold
4. Intake manifold
:ig. 28 Explodedview of the intake and exhaust manifold mounting-l .5L (4615) engine
,.11. Connect
. . the negativebatterycable,
. run the
vemcieunnl me tnermostatopensano till the radiator
completely.
12. Oncethe vehicle hascooled,recheckthe
coolantlevel.
REMOVAL&INSTALLATION
1.51 Engine
# See Figure 28
1. Relievethe fuel systempressure.
Observeall applicablesafety precautions
when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vapors to comein contactwith a sparkor
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnectbatterynegativecableand drain
the cooling system.
Neveropen, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
5.
stay 6.
7.
gasket 8.
when draining enginecoolant, keepin mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.Thiswill prove fatal In suffi-
cient quantities.Always drain coolant into a
sealable container. Coolantshould be reused
unless it is contaminatedor is several years
old.
3. Disconnectthe upperradiatorhose,heater
hoseand waterbypasshose.
4. Removethe thermostathousingfrom intake
manifold.
5. Disconnectthe acceleratorcable,breather
hoseand air intakehose.
6. Removeall vacuumhosesand pipesas nec-
essary,includingthe brakeboostervacuumline.
7. Removethe throttlebodyassembly.
8. Disconnectthe high pressurefuel line and
the fuel returnhose.
9. Tagand detachthe electricalconnectorsfrom
the oxygensensor,coolanttemperaturesensor,in-
takeair temperature,idle speedcontrol assembly,
EGRtemperaturesensor,sparkplug wires and dis-
tributor.
10. Removethe fuel rail, fuel injectors,pressure
regulatorand insulators.
11. Removethe EGRvalvefrom the intakemani-
fold.
12. Removethe intakemanifoldsupportbracket
and removethe enginemountsupportbracket.
13. Removethe intakemanifoldmountingbolts
and removethe intakemanifoldassembly.
To Install:
14. Cleanall gasketmaterialfrom the cylinder
headintakemountingsurfaceand intakemanifoldas-
sembly.Checkboth surfacesfor cracksor otherdam-
Nm
ft.lbs.
Engine hanger
Exhaust manifold cover
Exhaust manifold
Exhaust manifold gasket
7923ffi38
age.Checkthe intakemanifoldwaterpassagesand
jet air passagesfor clogging.Cleanif necessary.
15. Usinga straightedge,measurethe distortion
of the intakemanifold-to-cylinderhead.Totaldistor-
tion or warpageshouldbe 0.006 inches(0.15mmor
less).
16. Installa newintakemanifoldgasketto the
headand installthe manifold.Torquethe manifoldin
a crisscrosspattern,startingfrom the insideand
working outwardsto 13 ft. Ibs. (18 Nm).
17. Installthe intakemanifoldsupportbracket
and torquethe mountingbolts to 16 ft. Ibs. (22 Nm).
18. Installthe enginemountsupportbracketand
torquethe mountingbolts to 26 ft. Ibs. (36 Nm).
19. Usinga newgasket,install the EGRvalveand
torquethe mountingbolts to 15 ft. Ibs. (21 Nm).
20. Using newinsulatorsand O-rings,install the
fuel deliverypipe, injectorsand pressureregulatorto
the engine.Torquethe retainingbolts to 7-9 ft. Ibs.
(10-14 Nm).
21. Attachthe electricalconnectorsto the oxygen
sensor,coolanttemperaturesensor,intakeair tem-
perature,idle speedcontrol assembly,EGRtempera-
ture sensor,sparkplugwires and distributor.
22. Usinga newO-ring for the feedpipe and a
newclampfor the returnpipe, installthe fuel hoses.
23. Installthe throttlebody assembly.
24. Installthe vacuumhosesand pipesas neces-
sary, includingthe brakeboostervacuumline.
25. Installand adjustthe acceleratorcable.Install
the breatherand air Intakehose.
26. Usinga newgasket,install the thermostat
housingto the intakemanifoldand tightenthe
mountingboltsto 13 ft. Ibs. (18 Nm).
27. Connectthe upperradiatorhose,heaterhose
and waterbypasshose.Besureto usenewhose
clamps.

28. Fill the systemwith coolant.
29. Connectthe negativebatterycable,run the
vehicleuntil the thermostatopens,fill the radiator
completely.
30. Checkandadjustthe idle speedand ignition
timing.
31. Oncethe vehiclehas cooled,recheckthe
coolantlevel.
1.8L Engine
) See Figures 29 and 30
I. Relievethe fuel systempressure.
Observeall applicable safety precautions
whenworking aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a sparkor
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnectbatterynegativecableand drain
the cooling system.
Never open, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
leff in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
Fig. 29 Explodedview of the intake mani.
old mounting-1993 1.8L engine
ENGINEANDENGINEOVERHAUL
3-9
3. Disconnectthe acceleratorcableand the air
intakehose.
4. Tagand detachthe electricalconnectorsfrom
the oxygensensor,coolanttemperaturesensor,idle
speedcontrol assembly,EGRtemperaturesensor,oil
pressureswitch,sparkplug wires and distributor.
5. Disconnectthe wiring from the throttleposi-
tion sensor,fuel Injectorsand disconnectthe ground
cables.
6. Removeall vacuumhosesand pipesas nec-
essary,includingthe brakeboosterand PCVvacuum
lines.
7. Disconnectthe upperradiatorhose,heater
hoseand waterbypasshose.
8. Disconnectthe high pressurefuel line and
the fuel returnhose.
9. Removethe fuel rail, fuel injectors,pressure
regulatorand insulators.
10. Removethe intakemanifoldsupportbracket.
11. If the thermostathousingis preventingre-
moval of the Intakemanifold,removeit.
12. Removethe intakemanifoldmounting
bolts/nutsand removethe intakemanifoldassembly.
To install:
13. Cleanall gasketmaterialfrom the cylinder
headintakemountingsurfaceand intakemanifoldas-
sembly Checkboth surfacesfor cracksor otherdam-
age.Checkthe intakemanifoldwater passagesand
jet air passagesfor clogging.Cleanif necessary.
14. Usinga straightedge,measurethe distortion
of the intakemanifold-to-cylinderhead.Total distor-
tion or warpageshould be0.006 inches(0.15mmor
less).
15. Installa new intakemanifoldgasketto the
headand installthe manifold.Torquethe manifoldin
a crrsscrosspattern,startingfrom the insideand
workingoutwardsto 14 ft. Ibs.(20 Nm).
16. If removed,install the thermostathousing.
17. Installthe Intakemanifoldbracebracket.
18. Installthe fuel deliverypipe, injectorsand
pressureregulatorto the engine.Torquethe retaining
bolts to 108 Inch Ibs. (12 Nm).
Fig. 30 Explodedview of the intake mani,
iold mounting-1994-00 1.8L engine
19. Usinga newO-ring for the feedpipe and a
newclampfor the returnpipe, install the fuel hoses,
20. Connectthe upperradiatorhose,heaterhose
andwaterbypasshoses.
21. Installthe vacuumhosesand pipesas neces-
sary.Be sureto connectthe brakeboosterand PCV
vacuumlines
22. Connectthe wiring to the throttleposition
sensor,fuel injectorsand connectthe groundcables,
23. Attachthe electricalwiring to the oxygensen-
sor, coolanttemperaturesensor,Idlespeedcontrol
assembly,EGRtemperaturesensor,oil pressure
switch,sparkplugwires and distributor.
24. Connectand adjustthe acceleratorcableand
installthe air intakehose.
25. Fill the systemwith coolant.
26. Connectthe negativebatterycable,run the
vehicleuntil the thermostatopens,fill the radiator
completely.
27. Checkand adjustthe idle speedand ignition
timing.
28. Oncethe vehiclehascooled,recheckthe
coolantlevel.
2.OLSOHCEngine
# See Figure 31
1. Relievethe fuel systempressure.
Observeall applicable safety precautions
when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
Fig. 31 Explodedview of the intake mani
fold mounting-2.01 SOHCermine
3-10 ENGINEANDENGINEOVERHAUL
2. Disconnectthe batterynegativecable.
3. Drainthe cooling system.
Never open, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
4 Disconnectthe acceleratorcableand air in-
takehose.
5. Disconnectthe upperradiatorhose,heater
hoseand waterbypasshose.
6. Unplugthe vacuumconnectionat the power
brakeboosterandthe PCVvalve if still connected.
Disconnectall remainingvacuumhosesand pipesas
necessary.
7. Disconnectthe high pressurefuel line, fuel
returnhoseand removethrottlecontrol cablebrack-
ets
8. Tagand detachthe electricalconnectorsfrom
the oxygensensor,coolanttemperaturesensor,
therm0switch, idle speedcontrol assembly,EGR
temperaturesensor,distributor,fuel injectorsand
sparkplug wires. Positionthe enginewiring harness
aside.
9. Matchmarkthe distributorhousingto the in-
takemanifold,and removethe distributor.
10. Removethe intakemanifoldbracketand the
enginehanger.
11. If the thermostathousingis preventingre-
movalof the intakemanifold,removeit.
12. Removethe intakemanifoldmountingbolts
and removethe intakemanifoldassembly.Drsassem-
ble manifoldfrom the Intakeplenumon a work bench
as required
To install:
13. Cleanall gasketmaterialfrom the cylinder
headintakemountingsurfaceand intakemanifoldas-
sembly.Checkboth surfacesfor cracksor otherdam-
age.Checkthe intakemanifoldwaterpassagesand
jet air passagesfor clogging.Cleanif necessary.
14 Assemblethe intakemanifoldassemblyusing
all newgaskets.Torqueair intakeplenumbolts to
11-14ff. Ibs. (15-19 Nm).
15. Installa newintakemanifoldgasketto the
headand installthe manifold.Torquethe manifoldin
a crrsscrosspattern,startingfrom the insideand
working outwardsto 11-14 ff. Ibs.(15-19 Nm).
16. Installthe fuel deliverypipe, injectorsand
pressureregulatorto the engine.Torquethe retaining
bolts to 4 ft. Ibs (6 Nm).
17. install the thermostathousing,intakemani-
fold bracebracket,and enginehangerbracket.
18 Connector installall hoses,cablesand elec-
trical connectorsthat were removedor disconnected
during the removalprocedure.
19. Align the distributormatchmarksand install
the distributor.
20. Fill the systemwith coolant,
21. Connectthe negativebatterycable,run the
vehicle until the thermostatopens,fill the radiator
completely.
22. Adjustthe acceleratorcable.Checkand ad-
just the idle speedand ignition timing.
23. Oncethe vehiclehascooled,recheckthe
coolantlevel.
1.6L and 2.OLDDHCEngines
# See Figure 32
1. Relievethe fuel systempressure.
Observeall applicablesafety precautions
when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
ulosion.
2. Disconnectbatterynegativecableand drain
the cooling system.
Never open,service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when drainingenginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
Fig. 32 Explodedview of the intake mani-
fold and related components-1.6L and
2.OLDDHCengine
3. Disconnectthe acceleratorcableand air in-
take hose.
4. Disconnectthe coolanthosefrom the throttle
housing.
5. Detachthe vacuumconnectionat the power
brakeboosterandthe PCVvalve If still connected.
Disconnectall remainingvacuumhosesand pipesas
necessary.
6. Drsconnectthe high pressurefuel line, fuel
returnhoseand removethrottlecontrol cablebrack-
ets
7. Tagand detachthe electricalconnectorsfrom
the oxygensensor,coolanttemperaturesensor,
therm0switch,throttleposition sensor,rdlespeed
controlassembly,EGRtemperaturesensor,distribu-
tor, fuel injectorsand sparkplugwires. Positionthe
enginewiring harnessaside.
8. Removethe intakemanifoldbracket.
9. Removethe intakemamfoldmountingbolts
and removethe intakemanifoldassembly.Disassem-
ble manifoldon a work benchas required.
To install:
10. Cleanall gasketmaterialfrom the cylinder
headintakemountingsurfaceand intakemanifoldas-
sembly.Checkboth surfacesfor cracksor otherdam-
age.Checkthe intakemanifoldwaterpassagesand
jet air passagesfor clogging.Cleanif necessary.
11. Assemblethe Intakemanifoldassemblyusing
all newgaskets.
12. Installa newintakemanifoldgasketto the
headand install the manifold.Torquethe manifoldin
a crisscrosspattern,startingfrom the insideand
working outwardsto 11-14 ft. Ibs.(15-20 Nm).
13. Installthe fuel deliverypipe, injectorsand
pressureregulatorto the engine.Torquethe retaining
bolts to 4 ft. Ibs. (6 Nm).
14. Installthe intakemanifoldbracebracketand
tightenbolts to 13-18 ft. Ibs. (18-25 Nm).
15. Connector installall hoses,cablesand elec-
trical connectorsthat wereremovedor disconnected
duringthe removalprocedure.
16. Fill the systemwith coolant.
17. Connectthe negativebatterycable,run the
vehicleuntil the thermostatopens,fill the radiator
completely.
18. ‘Adjust the acceleratorcable.
19. Checkand adjustthe idle speedand ignition
timing.
20. Oncethe vehiclehascooled,recheckthe
coolantlevel.
2.4L Engine
) See Figures33 thru 51
93153p37
Fig. 33 Detachthe A/Ctemp electrical con- 1
 .

ENGINEAND,ENGINEOVERHAUL
3-11

Fig. 34 Unplugthe connectorfrom the Throt- Fig. 35 Detach the connectorsfrom all of
tle Position (TP) sensor the fuel injectors

Fig. 38 Unplugthe connectorfrom the Man- Fig. 39 Detachthe connectorfor the Idle Air
ifold AbsolutePressure(MAP)sensor Control (IAC) motor

93wp3a

Fig. 40 Removethe engine harnessretain- 93153p5a 93153p5a

ing bracketbolts,then movethe harnessout Fig. 41 Removethe accelerator cable end Fig. 42 Remove the accelerator cable
of the way from the throttle lever bracket retaining bolts . . .

93i53p9a

93153p59 Fig. 44 Disconnectthe EGRhose and the 93153p53

Fig. 43 . . . then position the accelerator three vacuumhoses on the back of the in- Fig. 45 Removethe hose shown here from
cable outof the way takemanifold the throttle body
 .
3-12 ENGINEANDENGINEOVERHAUL

1
L Fig. 46 Removethe brake booster vacuum
hose from the back of the intake manifold
93153p54

rail’retaini”g
fitti”g
bo,ts
...
Fig 47 Remove the fuel feed line-to-fuel

Fig. 49 From underneaththe vehicle, re- 93153p39 93153p73

move the two intake manifold support Fig. 50 Removethe intake manifold retain- Fig. 51 . . . then remove the manifold from
ing bolts . . . the cylinder head

1. Relievethefuelsystempressure. 4. Disconnectthecoolanthosefromthethrottle etairpassages for clogging.Cleanif necessary.

housing. 12. Assemble theintakemanifoldassembly using
5. Detach thevacuumconnection atthepower IIInewgaskets.
Observeall applicablesafety precautions brakeboosterandthePCVvalveif stillconnected. 13. Positiona newintakemanifoldgasketonthe
when working aroundfuel. Wheneverservic- Clisconnect
all remaining
vacuumhosesandpipesas lead,theninstallthemanifold. Torquethemanifold
- __. necessary. n a crisscross pattern,startingfromtheinsideand
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or vorkingoutwards to 15ft. Ibs.(20Nm)for bolts,and
vapors._to comein contactwith a spark or o 26ft. Ibs.(35Nm)for nutson1994vehiclesor 15
openflame. Keepa dry chemicalfire extin- Fuel injection systemsremain underpres- ft. Ibs.(20Nr$ for nutson1995-00vehicles.
guishernear the work area. Always keepfuel sure after the engine has beenturnedOFF. 14. Installthefueldeliverypipe,injectorsand
in a containerspecifically designedfor fuel Properly relieve fuel pressurebefore discon- [xessureregulator to theengine.Torquetheretaining
storage; also, always properly seal fuel con- nectingany fuel lines. Failure to do so may )oltsto 4 ft. Ibs.(6Nm).
tainers to avoid the possibility of fire or ex- result in fire or personalinjury. 15. Installtheintakemanifoldbracebracketand
plosion. tightenboltsto 21ft. Ibs.(29Nm).
6. Disconnect thehighpressure fuelline,fuel 16. Connect or installall hoses,cablesandelec-
2. Disconnectbatterynegative
cableanddrain returnhoseandremove throttlecontrolcablebrack- tricalconnectors thatwereremoved or disconnected
thecoolingrtfctnm n+C.
cm. durinotheremovalorocedure.
7. Tagandunplugtheelectricalconnectors 17: Fillthesystemwithcoolant.
fromthecoolanttemperature sensor,coolanttemper- ,18
. : Connect
.., ,, .,thenegative
, , battery
,,,,cable,
,. run,. the
aturegauge,IACvalve,ignitioncoil,EGRtempera- vemcleunrnmemermosrar opens,mltneraalaror
Ruver open, service or drain the radiator or completely.
@Ming systemwhen hot; serious burnscan turesensor,knocksensor,oxygensensor,throttle
positionsensor,distributor,A/Ctemperature sensor, 19. Adjusttheaccelerator cable.Checkandad-
II&ur from the steamand hot coolant. Also, justtheidlespeedandignitiontiming.
draining enginecoolant, keep in mind ’ fuelinjectorsandignitionpowertransistor. Position
theenginewiringharness aside. 20. Oncethevehiclehascooled,recheck the
j “thiatcats and dogsare attractedto ethylene coolantlevel.
.....____“..” 11_,1-...... any that is 8. Labelanddisconnect thesparkplugwires
t uncoveredcontaineror in puddles fromthesparkplugs.
9. Remove theintakemanifoldstaybracket. 3.OLand 3SL Engines
FEol ihaground.This will prove fatal in suffi-
k ici?M quantities. Always drain coolant into a IO. Remove theintakemanifoldmounting bolts ti See Figures52 thru 57
$1pealable container. Coolantshould be reused andremovetheintakemanifoldassembly. Disassem-
h’ uniassit is contaminatedor is several years blemanifoldona workbenchasrequired. 1. Relievethefuelsystempressure.
Tanis”.+..ll.
j$O'd.
**w
W.>. Cleanall gasketmaterialfromthecylinder
!&S 3. Disconnect theaccelerator
cable,breather headintakemounting surfaceandintakemanifoldas- Observeall applicablesafety precautions
fir!:
El.;, andair intakehose. sembly.Checkbothsurfaces for cracksor otherdam-
+w..” when working aroundfuel. Wheneverservic-
age.Checktheintakemanifoldwaterpassages and
 ENGINEANDENGINEOVERHAUL
3-13
EGR pipe - Up to 1993 <Callfornla> model
EGR pipe - From 1994 <California> model
Intake manlfold plenum stay, rear
Intake manifold plenum stay. front
EGR valve
EGR valve gasket <For Caiifornta>
>
Throttle body
Throttle body gasket
Intake mantfold plenum
Intake manifold plenum gasket
:ig. 52 Explodedview of air intake plenum assembly-3.01 DOHCengine
ing the fuel system,always work in a well 3. Removethe air intakehose(s).
ventilated area. Do not allow fuel spray or 4. Disconnectthe acceleratorcontrol cables
vapors to comein contactwith a spark or from the throttlebody.
openflame. Keepa dry chemicalfire extin- 5. Tagand disconnectthe vacuumhosesin-
guishernear the work area. Always keepfuel cludingthe brakeboosterhose.
in a containerspecifically designedfor fuel 6. Tagand detachthe wire harnessconnectors,
storage;also, always properly seal fuel con- 7. Disconnectthe high pressureand returnfuel
tainers to avoid the possibility of fire or ex- hoses.
plosion. 8. DisconnectEGRpipe and removethe EGR
valve and EGRtemperaturesensorfrom the intake
2. Disconnectbatterynegativecableand drawn plenumassembly.
the cooling system. 9. If equipped,removethe manifoldpressure
sensor.
10. Removethe plenumretainingbracket.
11. Removethe plenumretainingnutsand bolts
Never open, service or drain the radiator or
cooling systemwhen hot; serious burnscan and removethe air intakeplenumfrom the intake
manifold.Discardthe gasket.
occurfrom the steamandhot coolant. Also,
when draining enginecoolant, keep in mind 12. Removethe uppertiming belt covers.
13. Removethe waterpumpstay bracket.
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is *It is not necessav to removethe fuel ln-
left in an uncoveredcontaineror in puddles jectors from the intake unlessthe manifold ,
on the ground.This will prove fatal in suffi- assemblyis beingreplaced.
cient quantities.Always drain coolant into a
sealable container. Coolantshouldbe reused 14. Removethe fuel rail with the injectorsat-
unlessit is contaminatedor is several years tached.
old.
15. Disconnectthe coolanthosesfrom the intake
manifold.Besureto notethe connections.
16. Removethe intakemanifoldmountingnuts
and removethe intakemanifold.
17. Cleanthe gasketmountingsurfaces.
To install:
18. Checkall itemsfor cracks,cloggingand
warpage.Maximumwarpageis 0.0059 inches
(0.15mm).Replaceany questionableparts.
19. Thoroughlycleanand dry the matingsurfaces
of the heads,intakemanifoldandair intakeplenum.
20. Install newintakemanifoldgasketsto the
cylinderheadswith the adhesiveside facingup.
21. Placethe manifoldon the cylinderheads.
22. Lubricatethe studs lightly with oil and install
the nuts.
23. Forvehiclesproducedup to and including
Novemberof 1993,tightenthe mountingnutsas fol-
lows:
a. Front bank nuts:27-43 inch Ibs. (3-5 Nm)
b. Rearbank nuts:9-11 ft. Ibs. (12-15 Nm)
c. Front bank nuts:9-11 ft. Ibs. (12-15 Nm)
24. For vehiclesproducedafterNovemberof
1993, tightenthe mountingnuts as follows:
a. Front bank nuts:48-72 inch Ibs. (5-8 Nm)
b. Rearbank nuts to: 14-17 ft. Ibs. (20-23
Nm)
c. Front bank nuts to: 14-17 ft. Ibs. (20-23
NM
25. Usingnewclamps,connectthe coolanthoses
to the intakemanifold.
26. UsingnewO-rings,install the fuel rail as-
sembly,if removed.Tightenthe mountingbolts to
7-9 ft. Ibs.(10-13 Nm).
27. Installa new intakeair plenumgasketand in-
stall the plenum.Tightenthe retainingnutsand bolts
evenlyand graduallyto 13 ft. Ibs. (18 Nm).
28. Installthe retainingbracketand tightenthe
retainingbolts to 13 ft. Ibs. (18 Nm).
29. If removed,installthe manifoldpressuresen-
sor.
30. Usinga newgasket,install the EGRvalve and
tightenthe bolts to 16 ft. Ibs. (22 Nm).
31. Installthe EGRtemperaturesensorand
tightenthe fitting to 7-9 ft. Ibs. (10-12 Nm).
32. Connectthe EGRpipe and tightenthe fittings
to 43 ft. Ibs. (60 Nm).
33. Replacethe O-ring and connectthe high
pressurefuel hose.Tightenthe retainingboltsto 48
inch Ibs. (5 Nm).
34. Usinga newhoseclamp,connectthe fuel re-
turn hose.
35. Installthe waterpumpstay bracket.
36. Installthe uppertiming belt covers.
37. Connectthe harnessconnectorand vacuum
hoses.
38. Connectand adjustthe acceleratorcables.
39. Installthe air intakehose(s).
40. Fill the systemwith coolant.
41. Connectthe negativebatterycable,run the
vehicleuntil the thermostatopens,fill the radiator
completely.
42. Checkand adjustthe idle speedand ignition
timing.
43. Oncethe vehiclehascooled,recheckthe
coolantlevel.
 .

3-14 ENGINEANDENGINEOVERHAUL

1. Connection for high-pressure fuel hose

2. O-ring
3. Connection for fuel return hose
4. Connection for vacuum hoses
5. Wrring harness connector
6. Oxy en sensor <For Calrfornia from
199 P models>
7. Fuel rail (with injectors)
8 Insulators
9. Timing belt upper cover
10. Water pump stay mountrng bolt
11. Intake manifold mounting nut
12. Intake manifold mounting nut
13 Cone disc spring
14. Intake manrfold
15. intake manifold gasket

:ig. 53 Intake manifold and related components-3.01 DDHCenaine

Fig. 55 Explodedview of the intake mani- :ig. 56 Explodedview of air intake plenum
fold mounting-3.01 SDHCengine Issembly-3.5L engine

REMOVAL&INSTALLATION
1.5L and 1.8L Engine
# See Figures58 and 59
1. Disconnectbatterynegativecable.
2. Raisethe vehicleand supportsafely
3. Removethe exhaustpipe to exhaustmanifold
nutsand separateexhaustpipe. Discardgasket,
4. Lowervehicle.
5. Removeelectriccooling fan assembly,if nec-
essary.
6. If the oxygensensoris locatedin the mani-
fold, removethe sensor.
7. DisconnectnecessaryEGRcomponents.
8. Removeouterexhaustmanifoldheatshield
and enginehanger.Detachthe electricalconnector
and removethe oxygensensor.
9. Removethe exhaustmanifoldmounting
bolts,the inner heatshieldand the exhaustmanifold.
To install:
10. Cleanall gasketmaterialfrom the matingsur-
facesand checkthe manifoldfor damage.
11. Usinga newgasket,installthe manifold.For
1.5L engines,tightenthe nuts in a crisscrosspattern
to 13 ft. Ibs. (18 Nm). For 1.8L engines,tightenthe
inner nuts in a crisscrosspatternto 13 ft. Ibs. (18
Nm) and tightenthe two outer(larger)nutsto 22 ft.
Ibs. (30 Nm).
12. Installthe heatshields,
13. ConnectEGRcomponents.
14. If removed,installthe oxygensensor.

Fig. 58 Explodedview of the exhaust man,
ifold -1.5L enoine
15. Installthe electriccooling fan assemblyas re-
quired.
16. Installa newflangegasketand connectthe
exhaustpipe.
17. Connectthe negativebatterycableand check
for exhaustleaks.
1.8L and 2.OLEngines
u See Figures 80, 81, and 62
1. Disconnectthe negativebatterycable.
2. Raisethe vehicleand supportsafely.
3. Removethe front exhaustpipeto exhaust
manifoldnuts and separateexhaustpipe. Discardthe
gasket.
4. Lowerthe vehicle.
5. If equippedwith air conditioning,remove
condensercooling fan assembly.
6. Usingspecialtool MD998703 or equivalent,
disconnectand removethe oxygensensor.
:z**
::EEWl
93153915
:ig. 60 Exhaustmanifold exploded view-
!.OLSOHCengine
ENGlNEANDENGlNEOVERHAbL
3-15
93153g1
Fig. 59 Exhaustmanifold exploded vlew-
1.8L engine
7. Removeouterexhaustmanifoldheatshield
andthe enginehanger.
8. Removethe exhaustmanifoldmountingnuts,
the inner heatshield andthe exhaustmanifoldfrom
the engine.
To install:
9. Cleanall gasketmaterialfrom the mating
surfacesand checkthe manifoldfor damageor crack-
ing.
10. Usinga newgasket,install the exhaustmani-
fold, to the engine.Tightenthe nutsto in a crrsscross
patternto 11-14 ft Ibs. (15-20 Nm) for 2.OLSOHC
engineor to 18-22 ft. Ibs. (25-30 Nm)for 1.6L and
2.OLDOHCengine.
11. Installthe outerheatshield andtightenthe
mountingbolts to 10 ft. Ibs. (14 Nm).
12. Installthe electriccooling fan assembly,if re-
moved.
13. Usinga newflangegasket,connectthe ex-
haustpipe and tightenthe mountingnutsto 29-36 ft.
Ibs. (40-50 Nm).
:ig. 81 Exhaustmanifold exploded view-
I .8L and 2.OL(non-turbo)DOHCengine
14. Connectthe negativebatterycableand check
for exhaustleaks.
2.4L Engine
g See Figures63 thru 71
1, Disconnectbatterynegativecable.
2. Raisethe vehicleand supportsafely.
3. Removethe exhaustpipe-to-exhaustmani-
fold nuts,the hangerretainingbolt, then separatethe
exhaustpipe. Discardthe gasket.
4. Removethe outerexhaustmanifoldheat
shield and enginehanger.
5. Removethe exhaustmanifoldmountingnuts
and the exhaustmanifoldfrom the engine.
To install:
6. Cleanall gasketmaterialfrom the mating
surfacesand checkthe manifoldfor damageor crack-
ing.
7. Installa newgasketand installthe manifold.
Tightenthe nutsto in a crisscrosspatternto 18-21
ft Ibs. (25-29 Nm).
8. Installthe heatshieldsandtightenthe
mountingbolts IO ft Ibs. (14 Nm).
9. Installa newflangegasketand connectthe
exhaustpipe.Tightenthe mountingnutsto 32 ft. Ibs.
(44 Nm).
10. Connectthe negativebatterycableand check
for exhaustleaks.
3.OLEngines
) See Figures72 and 73
Do not attemptthe work on the exhaustsys-
tem until it hascompletelycooled.
1. Disconnectbatterynegativecable.
2. Raisethe vehicleand supportsafely.
3. Removethe exhaustpipe to exhaustmanifold
nuts and removethe front exhaustpipe.
4. Lowerthe vehicle.
5. If removingthe front manifold,removecon-
denserelectriccooling fan assembly.
9315391;
-ig. 82 Exhaustmanifold exploded view-
!.OL (turbo) DOHCengine
 3-16 ,ENGlNEANDENGlNEOVERHAUL

Fig. 64 Remove the hanger retaining bolt

* . I(

Fig 66 Remove the heat shield retaining Fig, 67 . . . then remove the heat shield
bolts. . . g3’~‘51 from the exhaustmanifold

Fig. 71 Removethe exhaust manifold gas-

Fig. 69 Removethe engine lifting eye from Fig. 70 , . . then removethe manifold from ket, thoroughly clean the mountmg sur-
the manifold . . . the cylinder head / faces, and replace the gasket ’ 93’53p72

6. FortheDOHCengine,if removing thrafront 13. Remove theexhaustmanifoldmounting bolts 21. Installthedrivebelt(s)andadjustfor proper
manifold,removethealternator
andmountin! 3bracket themanifold. tension.
fromthevehicle. To install: 22.L-Connect
7. FortheDOHCengine,separate /r nnm
theI$,, I.vIII- -4” PI,*, -11rm.A.^L -,‘&^-:-If-e.-
17. lrlMll dll yWK1 Illdlell~l
IL- -_-I!-- - .-
110111LIle lKWi~ SIN-
I-
rorexnausr # thenegative
L,leaks. batterycableandcheck
pressorfromthemounting bracket.Leavingthe facesandcheckthemanifoldfor damage.
hoses~~~, positionthecompressor aside, 15. Installa newgasketandinstallthemanifold. 3.51 Engfne
8. ff removingthefrontmanifold,remove theoil Tightenthenuts--.._ina crisscross patternto 21ft. Ibs. A Sam Finnwn 74
dipstickandtubefromtheengine. (30Nm). .’ SOHCengineorto 14ft. Ibs.(19
to1the
9. FortheDOHCengine,if removing thefront Nm)for1heDOHCengine.
manifold,removetheheatprotector. 16. IIWalltheheatshields.
IO. If removing
therearmanifold, disconnect the 17. c“IIII”“IUI” L”ll L”“““ll” IIIlu#lb p,““l~,aa~
EGRtube. androllstopperbracket, if removed. Do not attemptthe work on the exhaustsys-
11. FortheSOHCengine,if removing therear 18. Installtheoxygensensor. tern until it hascompletelycooled.
manifold,removetheintakeplenumstayandtheroll 19. Installtheelectriccoolingfanassembly, A/C
stopperbracket. compressor, dipsticktubeandalternator, asrequired. 1. Disconnectbatterynegative
cable.
12. Unplugtheelectricalconnectorandremove 20. Installa newflangegasketandconnect the 2. Raisethevehicleandsupportsafely.
theoxygensensor. exhaustpipeor converter assembly. 3. Remove theexhaustpipeto exhaustmanifold
nutsandremovethefrontexhaustpipe.
 ENGlNEANDENGlNEOVERHAiJL
3-17
8. If removingthe rearmanifold,disconnectthe
EGRtube.
9. Removethe exhaustmanifoldmountingbolts
the manifold.
To install:
10. Cleanall gasketmaterialfrom the matingsur-
facesand checkthe manifoldfor damage.
11. Installa newgasketand install the manifold.
Tightenthe nuts in a crisscrosspatternto 21 ft. Ibs.
(30 Nm).
12. Installthe heatprotector(s).
13. If installrngthe rear manifold,replacethe
gasketand connectthe EGRtube.
14. If installingthe front manifold,installthe ra-
diatorand cooling fan assembly.
15. If installingthe front manifold,installthe al-
ternator.
16. Installthe drive belt(s)and adjustfor proper
tension.
17. Raiseand safelysupportthe vehiclesecurely
on lackstands.
18. Installa newflangegasketand connectthe
exhaustpipe or converterassembly.
19 Lowerthe vehicle
20. Connectthe negativebatterycableand check
for exhaustleaks. 93153q21

Fig. 75 Exploded view the turbocharget

mounting (1 of 2)

REMOVAL&INSTALLATION

2.OL DOHC Engine (1990-93 Galant Only)

# See Figures 75 and 76
Manyturbochargerfailuresare due to oil supply
problems.Heatsoakafterhot shutdowncancause
the engineoil in the turbochargerand oil linesto
“coke.” Oftenthe oil feedlines will becomepartially
or completelyblockedwith hardenedparticlesof car-
bon, blockingoil flow. Checkthe oil feedpipe and oil
returnline for cloggrng.Cleanthesetubeswell. Al-
ways usenewgasketsaboveand belowthe oil feed
eyeboltfitting. Do not allow particlesof dirt or old
gasketmaterialto enterthe oil passagehole and that
Fig. 73 Exploded view of the exhaust man
no portionof the newgasketblocksthe passage.
ifold -3.OL DOHC engine 1. Disconnectthe negativebatterycable.
2. Drainthe engineoil, cooling systemand re- 9315392:

movethe radiator Onvehiclesequippedwith A/C, :ig. 76 Exploded view of the turbocharger

removethe condenserfan assemblywith the radiator. nounting (2 of 2)

glycol antifreeze and could drink any that is

9315392c
Fig. 74 Exhaust manifold exploded view-
3.5L engine
4. Lowerthe vehicle.
5. If removingthe front manifold,removethe ra-
diator and cooling fan assembly.
6. If removingthe front manifold,removethe al-
ternator.
7. Removethe heatprotector(s).
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.
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
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 Detachthe oxygensensorconnectorand re-
movethe sensor.
4. Removethe oil dipstick andtube.
5. Removethe air intakebellowshose,the
wastegatevacuumhose,the connectionsfor the air
outlet hose,andthe upperand lowerheatshield.
6. Unboltthe powersteeringpumpand bracket
assemblyand leavingthe hosesconnected,wire it
aside.
7. Removethe self-lockingexhaustmanifold
nuts,the triangularengrnehangerbracket,the eye-
 l

3-18 ENGINEANDENGINEOVERHAUL
boltandgaskets thatconnecttheoil feedlinetothe 16. If removed,installthepowersteeringpump cient quantities.Always drain coolant into a
turbocentersectionandthewatercoolinglines.The andbracket. sealable container. Coolantshould be reused
waterlineundertheturbohasa threaded connection. 17. Installtheheatshields,airoutlethose,waste- unlessit is contaminatedor is several years
8. Remove theexhaustpipenutsandgasketand gatehoseandair intakebellows. old.
lift offtheexhaustmanifold.Discardthegasket, 18. Installtheoil dipsticktubeanddipstick.In-
9. Remove the2 throughboltsand2 nutsthat stalltheoxyqensensor. 3. Disconnect theoverflowtube.Somevehicles
holdtheexhaustmanifoldto theturbocharger, 19. In&h theradiatorassembly. mayalsorequireremovalof theoverflowtank.
10. Remove the2 capscrews fromtheoil return 20. Filltheenginewithoil,fill thecoolingsystem 4. Disconnect upperandlowerradiatorhoses.
line(undertheturbo).Discardthegasket.Separate andreconnect thenegative batterycable. 5. Detach theelectricalconnectors fromthe
theturbofromtheexhaustmanifold. The2 water coolingfanandairconditioning condenser fan,if
pipesandoil feedlinecanstill beattached. equipped.
11. Visuallychecktheturbinewheel(hotside) 6. ForMirageandDiamante models,remove
andcompressor wheel(coldside)for crackingor Operatingthe enginewithout the proper thefanassembly.
otherdamage. Checkwhether theturbinewheeland amountandtype of engineoil will result in 7. Disconnect thetherm0sensorwires,
thecompressor wheelcanbeeasilyturnedbyhand. severe enginedamage. 8. If equipped withanautomatic transaxle, dis-
Checkfor oil leakaae. Checkwhetheror notthe connect andplugtheautomatic transaxlecooler
wastegate valveremainsopen.If anyproblemis . #I , I lines.
found,replacethepart.Inspectoil passages for re- 9. Remove theupperradiatormountsandlift
strictionor deposits andcleanasrequired, outtheradiatorassembly or radiator/fanassembly,
12. Thewasteaate canbechecked witha ores- REMOVAL
& INSTALLATION asapplicable.
suretester.Applyapproximately 9 psitothe&h&or To install:
andmakesuretherodmoves.Donotapplymore $ See Figures77 thru 91 10. Installtheradiatoror radiatorandfan,if re-
than10.3psiorthediaphragm inthewastegate may movedasanassembly.
bedamaged. Vacuum appliedtothewastegate actua- I. Disconnect
thenegativebatterycable. 11. Connect theautomatic transaxlecoolerlines
torshouldbemaintained, replaceif leaksvacuum, 2. Drainthecoolingsystemwhensafe. if disconnected.
Donotattempt to adjustthewastegate valve. 12. Connect thetherm0sensorwires,
To install: 13. Installthefan,if removed separately.
13. Primetheoil returnlinewithcleanengineoil. Neveropen, service or drain the radiator or 14. Installtheradiatorhoses.
Replace all lockingnuts.Beforeinstallingthe cooling systemwhen hot: serious burnscan 15. Installtheaircleanersupportbracket, if re-
threaded connection forthewaterinletpipe,apply occurfrom the steamand hot coolant. Also, noved.
lightoil to theinnersurfaceof thepipeflange.As- when draining enginecoolant, keep in mind 16. Installtheoverflowtubeandreservoir,if re-
sembletheturbocharger andexhaustmanifold. that cats and dogsare attractedto ethylene noved.
14. Installtheexhaustmanifoldusinga newgas- glyeol antifreezeand could drink any that is 17. Fillthesystemwithcoolant.
ket. left in an uncoveredcontaineror in puddles 18. Connect thenegative batterycable,runthe
15. Connect thewatercoolinglines,oil feedline on the ground.This will prove fatal in suffi- vehicleuntilthethermostat opens,fill theradiator
andenginehanger.

93153003
Fig. 77 Use a pair of pliers to remove the Fig. 78 . . . then disconnectthe overflow Fig. 79 Use pliers to release the hoseclamp
hose clamp . . . hose from the radiator tension . . .

”
Fig. 80 . . . then removethe upper radiator Fig. 81 From underneaththe vehicle, re- Fig. 82 . . . then disconnectthe lower radi-
hose from the radiator move the hose clamp , . . ator hose
 ENGINEANDENGINEOVERHA~L
3-19

93153po3 93153P29

Fig. 87 Detachthe connectorsfor the elec-

radiator to prevent contamination

93153px

/..:
Fig 89 Remove the radiator mount g3’Bpz]
bolts lFig.PO,..thenremovethemo”n~;~~ Fig. 91 Carefully graspthe radiator and fan
the radiator and radiator support panel assemblyand lift Stout of the vehicle

completely andchecktheautomatic
transaxlefluid
level,if equipped.
79. Oncethevehiclehascooled.recheck
the
coolantIevel.

ExceptDiamante
6 See Figures77 thru 93
1. Disconnect
thenegativebatterycable. Fig. 92 The fans are retained to the radla- n153p23
2. Drainandrecycletheenginecoolant.
tor by four retaining bolts. Removethe re- Fig. 93 . . . then carefully lift the fan from
taining bolts . . . the radiator

3-20 ENGINEANDENGINEOVERHAUL
Never open, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeandcould drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities. Always drain coolant into a
sealable container. Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
3. Removethe overflowhoseand disconnect
the upperradiatorhose.
*It is recommendedthat each clampbe
matchmarkedto the hose. Observethe marks
and reinstall the clampsexactly when rein-
stalling the radiator.
4. If equippedwith an automatictransaxle,re-
moveand plugthe fluid cooler hoses.
5. Unplugthe electricalconnector(s)from the
coolantfan motor.
6. Removethe mountingbolts,then removethe
fan and shroudassemblyfrom the vehicle.
7. Removethe fan bladeretainernut from the
shafton the fan motor andseparatethe fan from the
motor.
8. Removethe motorto shroudattaching
screwsandthe motor from the shroud.
To tnstall:
9. Installthe motorto the shroudand secure
with the mountingbolts.
10. Installthe remainingcomponentsin the re-
verseorderof removal.
11. Fill the coohngsystem.Connectthe negative
batterycableand checkthe cooling fan for properop-
eration.
Diamante
# See Figure 94
1. Disconnectthe negativebatterycable
:ig. 94 Explodedview of the fan mountingand related components-
liamante
2. Drainthe cooling systemonly whenthe radi-
ator and the engineareat safetemperatures.
Neveropen, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamandhot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container. Coolantshouldbe reused
unless it is contaminatedor is several years
old.
3. Unplugthe cooling fan and radiatorsensor
connector(s).Most of theseconnectorsemploya wa-
terproofconnector.Whendisconnecting,makesure
all partsof the connectorremainintact.
4. Disconnectthe upperradiatorhosefrom the
radiatorand removeoverflowtank.
5. Removethe fan mountingscrews.The radia-
tor and condensercooling fans are separatelyremov-
able.
6. Removethe fan assemblyand disassemble
as required.
To install:
7. Posrtionthe fan and installthe mounting
screws
8 Installthe electricalconnectorsand the upper
radiatorhose.
9. Refill the cooling system.
IO. Connectthe negativebatterycableand check
the fan for orooer ooeration.
REMOVAL& INSTALLATION
1.5L and 1.8L Engine
) See Figures 95 and 98
Fig. 95 Water pump and related components-Mirage with 1.51
(4615) engine
.
1. Disconnectthe negativebatterycable
2. Drainthe cooling system.
Never open,service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
3. Removethe engineundercover.
4 Disconnectthe clampbolt from the power
steeringhose.
5. Removethe enginedrive belts.
6. Supportthe enginewith the appropriate
equipmentand removethe enginemount bracket.
7. Removethe timing belt Reierto the timing
belt procedurein this section
8 Removethe powersteeringpumpbracket.
9. Removethe alternatorbrace.
*The water pumpmountingbolts are differ-
ent in length, notetheir positioningfor re-
assembly.
10. Removethe waterpump,gasketand O-ring
wherethe waterinlet pipe(s)joins the pump.
To install:
11, Thoroughlyclean both gasketsurfacesof the
wateroumoand block.
12. For 1.5L engines,install a newO-ring into
the grooveon the front end of the waterinlet pipe. Do
not applyoils or greaseto the O-ring.Wetthe O-ring
with wateronly
13. For 1.8L engines,applya 0.09-0.12 in.
(2.5-3 Omm)continuousbeadof sealantto water
pumpand rnstallthe pumpassembly.Installthe wa-
ter pumpwithin 15 minutesof the applrcationof the
7923PGO

ealant.Wait 1 hour afterinstallationof the water
pumpto refill the cooling systemor startthe engine.
14. Installthe gasketand pumpassemblyand
tightenthe bolts to 17 ft. Ibs. (24 Nm). Usecarewhen
aligningthe waterpumpwith the waterinlet pipe.
15. Installthe remainingcomponentsin the re-
verseorder of removal.
16. Fill the systemwith coolant.
Fig
ENGINEANDENGINEOVERHAUL
3-21
1. Disconnectthe negativebatterycable.
2. Drainthe enginecoolant.
Neveropen, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container. Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
3. Removethe timing belt. Referto the timing
belt procedurein this section.
4. If necessary,removethe alternatorbracefrom
the waterpump.
5. If necessary,removethe timing belt rear
cover.
6. Removethe waterpumpmountingbolts.
7. Removethe waterpump,gasketand O-ring.
7923PG08
To Install:
8. Installa newO-ring on the waterinlet pipe.
Coatthe O-ringwith wateror coolant.Do not allow
oil or othergreaseto contactthe O-ring.
17. Connectthe negativebatterycable,run the 9. Usea newgasketand installthe waterpump
vehicle until the thermostatopensand fill the radiator to the engineblock Torquethe mountingbolts to
completely. 8.7-11 ft. Ibs. (12-15 Nm). Installthe alternator
18. Oncethe vehicle hascooled,recheckthe braceon the waterpump.Torquethe bracepivot bolt
coolantlevel. to 17 ft. Ibs. (24 Nm).
10. If removed,installthe timing belt rearcover.
1.6L and 2.OL(SOHCand OOHC)Engines 11. Installthe timing belt. Referto the timing belt
procedurein this section.
+ See Figure 97
12. Installthe remainingcomponents.
13. Refillthe enginewith coolant.
14. Connectthe negativebatterycable,startthe
engineand checkfor leaks.
2.4L Engine
) See Figures98 thru 108
1. Disconnectthe negativebatterycable
2. Drainthe cooling system.
Never open,service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container. Coolantshouldbe reused
unless it is contaminatedor is several years
old.
3. Removethe engineundercover.
4. Disconnectthe clamp bolt from the power
steeringhose.
5 Supportthe enginewith the appropriate
equipmentand removethe enginemountbracket.
6. Removethe enginedrive beltsand the A/C
tensionerbracket.
7. Removethe timing belt coversfrom the front
of the engine.
3-22 ENGINEANDENGINEOVERHAUL
\

93153p30

Fig. 98 Removethe wafer pumppulley re- Fig. 99 . . . then removethe pulley from the Fig. 100 Removethe A/C belt idler pulley
taining bolts ~ . . pump

931531183

Fig 101 Removethe A/C beit idler pulley Fig. 102 . . * then remove the idler pulley g. 103 Removethe alternator brace from
braEketretainingboit..., g3’a/ retaining bracket

Fig. 104 Removethe water pumpretaining Fig. lfJ5 . . . then remove the bolts on the
bolts on the top . . . bottom of the pumpassembly

Fig. 107 if the impeller fins on the water

able to replace the water pumprather than

reuseit Fig. 108 Water pump bolt identification-2.41 Engine

8. Removethe camshaftand silent shafttiming
belts.Referto the timing belt procedurein this sec-
tion
9. Removethe A/C belt idler pulleyand pulley
bracket.
10. Removethe alternatorbrace,
11. Removethe waterpump,gasketand O-ring
wherethe waterinlet pipe(s)joins the pump.
To install:
12. Thoroughlycleanboth gasketsurfacesof the
waterpumpand block.
13. Installa newO-ring into the grooveon the
front end of the waterinlet pipe and wet with clean
antifreezeonly. Do not applyoils or greaseto the O-
ring.
14. Usinga newgasket,install the waterpump
assembly.Tightenbolts with the headmark4 to 10
ft Ibs. (14 Nm) and bolts with the headmark7 to 18
ft. Ibs. (24 Nm).
15. Installthe A/C pulleyand pulleybracket,
16. Installthe timing belts.Referto the timing
belt procedurein this section.
17. Installthe enginedrive belts.
18. Installthe enginemount bracket.
19. Installthe engineundercover,
20. Fill the systemwith coolant.
21. Connectthe negativebatterycable,run the
vehicleuntil the thermostatopensand fill the radiator
completely.
22. Oncethe vehiclehascooled,recheckthe
coolantlevel.
3.OLand 3.5L Engines
# See Figure 109
1. Disconnectthe negativebatterycable,
2. Drainthe cooling system.
ENGlNEANDENGlNEOVERHAiL
3-23
Never open,service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshouldbe reused
unless it is contaminatedor is several years
old.
3. Removethe engineundercover.
4. Disconnectthe clampbolt from the power
steeringhose.
5. Supportthe enginewith the appropriate
equipmentand removethe enginemountbracket.
6. Removethe timing belt. Referto the timing
belt procedurein this section.
7. Disconnectthe coolanthosesfrom the pump,
if equipped.
8. Removethe alternatorbrace.
*The water pumpbolts are different in size.
Notetheir locationsfor installation.
9. Removethe waterpump,gasketand O-ring
wherethe waterinlet pipe joins the pump.
To install:
10. Thoroughlycleanboth gasketsurfacesof the
waterpumpand block.
11. Installa newO-ring into the groove on the
front end of the waterinlet pipe. Do not applyoils or
greaseto the O-ring.Wetwith wateronly.
12. Usinga newgasket,install the waterpump
assemblyto the engineblock.Torquethe mounting
boltsto 17 ft. Ibs.(24 Nm).
13. Connectthe hosesto the pump.
14. Installthe timing belt.Referto the timing belt
procedurein this section.
15. Installthe enginedrive belts.
16. Fill the systemwith coolant.
17. Connectthe negativebatterycable,run the
vehicle until the thermostatopensand fill the radiator
completely.
18. Oncethe vehicle hascooled,recheckthe
coolantlevel.
REMOVAL
& INSTALLATION
1.5L Engine
u See Figures 110 and 111
1. Relievethe fuel systempressure.
Observeall applicable safety precautions
whenworking aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a sparkor
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
2. Disconnectthe negativebatterycable.
3. Drainthe cooling system.

Neveropen, service or drain the radiator or

cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when drainingengine coolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container. Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
4. Removethe air intakehoseand the air
cleanerassembly.
5. Disconnectthe groundcableconnectionand
the acceleratorcable.
Atr Intake hose 6. Disconnectthe PCVand the breatherhose
Connactlon of’ radlator upper hose connection.
5 Water outlet fming
6. Gasket 7. Labeland disconnectthe vacuumhosesfrom
7 Connacmn of harness the intakeand throttlebody.
8 Connection of heater hose
9. Connection of water hose A 8. Disconnectthe vacuumline for the brake
10. ConnectIon of water hose booster.
11. Connection of radiator Iowar hose
1f Thn&ostat housing 9. Removethe upperradiatorhose,throttle
body hoses,bypasshoseand heaterhoseconnec-
14 Inlet water pye
15 O-ring tions
7923Fw 10. Disconnectthe fuel feedand returnlines.
:ig. 109 Water pumpand related components-3.01 DOHCshown 11. Removethe sparkplug wires.
3-24 ENGINEANDENGINEOVERHAUL
Front of engine
Intake side e not usesealeron the gasket.
Exhaust side
7923PG13
Fig. 110 Cylinder head bolt loosening se-
uuence-Mirage with 1.5L (4615) ermine
inwe side 0 Front of engine
((9
Exhaust side
7923PG14
Fig. 111 Cyllnder head bolt tightening se-
quence-Mirage with 1.5L (4615) engine
12. Disconnectthe electricalharnessplugsfrom
the following:
l CrankshaftPosition (CKP)and Camshaft
Position (CMP) sensors
l HeatedOxygen(HO*S)sensor
l EngineCoolantTemperature(ECT)sensor
and gaugesender
l Idle SpeedControl (ISC) motor
l ThrottlePosition (TP) sensor
l IntakeAir Temperature(IAT) sensor
l ExhaustGas Recirculation(EGR)tempera-
ture sensor
13. Disconnectelectricalharnessplugsfrom the
ignition distributor,fuel injectors,powertransistor
and groundcable.
14. Disconnectthe enginecontrolwiring har-
ness.
15. Removethe clampthat holdsthe powersteer-
ing pressurehoseto the enginemountingbracket.
16. Placea jack and wood block underthe oil
panand carefullylift just enoughto takethe weight
off the enginemountingbracketand removethe
bracket.
17. Removethe valve cover.
18. Removethe timing belt uppercover.
19. Rotatethe crankshaftclockwiseand align the
timing marks.
20. Attachthe timing belt to the camshaft
sprocketwith cord or a wire tie.
21. Securethe camshaftfrom turningand remove
the camshaftsprocketwith the timing belt attached.
22. Removethe timing belt rear uppercover.
23. Removethe exhaustpipe from the exhaust
manifold.
24. Loosenthe cylinderheadmountingbolts in
sequenceusingthreesteps.
25. Removethe cylinderhead.
To install:
26. Thoroughlycleanthe matingsurfacesof the
headand block.
27. Placea newheadgasketon the cylinder
block with the identificationmarksfacing upward.Do
28. Carefullyinstall the cylinderheadon the
block.Tightenthe cylinder headbolts as outlined in
the followlngsteps:
a. Tightenthe bolts to 36 ft. Ibs. (49 Nm) in
the correct sequence
b. Loosenthe bolts completelyin the reverse
of the tighteningorder,
c. Tightenthe bolts, in sequence,to 14 ft.
Ibs. (20 Nm)
d. Tighten eachbolt, in sequence,90 degrees
e. Tighteneachbolt, in sequence,an addi-
tional 90 degrees
29. Installa newexhaustpipe gasketand connect
the exhaustpipe to the manifold.
30. Installthe upperreartiming cover.
31. Align the timing marksand installthe cam
sprocket.Torquethe retainingbolt to 51 ft. Ibs. (76
Nm). Checkthe belttensionand adjust,if necessary.
Installthe outertiming cover.
32. Installthe valve cover and torquethe retain-
ing bolts to 16 inch Ibs.(1.8 Nm).
33. Installthe enginemount bracketand remove
the supportjack.
34. Installthe clampthat holdsthe powersteer-
ing pressurehoseto the enginemountingbracket.
35. Attachthe following electricalconnectors:
l CKPand CMP sensors
l HOPSsensor
l ECTsensorand gaugesender
l ISC motor
l TP sensor
l IAT sensor
l EGRtemperaturesensor
36. Connectwiring for the ignition distributor,
fuel injectors,powertransistorand groundcable.
37. Connectthe enginecontrolwiring harness.
38. Replacethe O-ringsand connectthe fuel
lines.
39. Installthe air cleanerassembly.Connectthe
breatherhose.
40. Fill the systemwith coolant.
41. Connectthe negativebatterycable.
1.8L Engine
# See Figures 112 and 113
1. Relievefuel systempressure.Disconnectthe
negativebatterycable.
2. Removethe air cleanerassembly.
3. Drainthe cooling system.
Neveropen, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
lefl in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshould be reused
unless it is contaminatedor is several years
old.
4. Disconnectthe brakeboostervacuumhose
and PVCvalve connection.
5. Notethe locations,then disconnectthe vac-
uum hosesfrom the intakeand throttlebody.
6. Removethe upperradiatorhose,overflow
tube andthe waterhosefrom the thermostatto the
throttle body.
7. Disconnectthe fuel feedand returnlines.
8. Unplugthe acceleratorcableconnectionfrom
the throttle body.
9. Detachthe wiring from the oil pressure
switch.
10, Disconnectthe wiring from the following
components:
l HeatedOxygen(HO*S)sensor
l EngineCoolantTemperature(ECT)sensor
and gaugesender
l Idle Air Control (IAC) motor
l ExhaustGas Recirculation(EGR)tempera-
ture sensor
l ThrottlePosition (TP) sensor
l Knocksensor
l Fuel injectors
11. Removethe sparkplug wires.
12. Unboltthe control harnessassemblyand po-
sition aside.
13. Removethe thermostathousing,thermostat
andthe thermostatcasewith O-ring from the engine.
14. Removethe rockercover.
15. Removethe timing belt uppercover.
16. Rotatethe crankshaftclockwiseand align the
timing marks.
17. Attachthe timing beltto the camshaft
sprocketwith cord or a wire tie.
18. Securethe camshaftfrom turningand remove
the camshaftsprocketwith the timing belt attached.
19. Removethe timing belt rear uppercover.
20. Loosenthe cylinderheadbolts in two or three
stepsin the propersequence.
21. Removethe cylinder headfrom the engine.
Intake side Front of engine c=>
I
Exhaust side Loosening&der
7923PG15
Fig. 112 Cylinder head bolt loosening se-
quence-l .8L engine
intake side Front of engine *
Exhaust side libhtenng order
Fig. 113 Cylinder head bolt torque se-
quence-l .8L engine

Whenremovinathe cvlinder head.take care
not to bendor iamag;! the plug guide.The
plug guidecan not be replaced.
To install:
22. Thoroughlycleanthe matingsurfacesof the
headand block.
23. Placea newheadgasketon the cylinder
blockwith the identificationmarksfacing upward.Do
not usesealeron the gasket.
24. Carefullyinstallthe cylinder headon the
block.
25. Measurethe cylinderheadbolts prior to in-
stallation Replaceanythat exceed3.795 in.
(96.4mm)
26. Apply a small amountof engineoil to the
threadsectionof the bolt and install so the chamfer
of the washerfacesupward.
27. Tightenthe cylinderheadbolts as follows:
a. In the propertighteningsequence,torque
bolts to 54 ft. Ibs. (75 Nm).
b. In the reverseorder of the tighteningse-
quence,fully loosenall bolts.
c In the propertrghteningsequence,torque
bolts to 14 ft. Ibs. (20 Nm).
d. In the propertighteningsequence,tighten
bolts 1/4turn (90 degrees).
e. In the propertighteningsequence,tighten
bolts an additional1/4turn (90 degrees).
28. Installthe camshaftsprocketandtightenthe
bolt to 65 ft. Ibs (90 Nm),while holdingthe sprocket
in placeusing the appropriatewrench.Confirm
propertiming markalignment.
29. Installthe uppertiming belt cover and rocker
cover.Torquethe rockercover bolts to 29 inch Ibs.
(3 Nm).
30. Loosenthe waterpipe mountingbolt for ease
of thermostathousinginstallation.
31. Apply a thin beadof sealantMD970389 or
equivalent,to the watertube connectionon the ther-
mostatcase.
32. Apply a small amountof waterto the O-ring
of the water inlet pipe and pressthe thermostatcase
assemblyonto the water inlet pipe. Installthe ther-
mostatcaseassemblymountingbolt tighteningto 16
ff. Ibs.(22 Nm).
33. Tightenthe waterpipe mountingbolt.
34. Installthe thermostatinto the housingso the
jiggle valve is locatedat the top. Tightenthe housing
bolts to 10 ft. Ibs (14 Nm).
35. Attachthe wiring to the following compo-
nents:
l HO& sensor
l ECTsensorand gaugesender
l IAC motor
l EGRtemperaturesensor
l TP sensor
l Knocksensor
l Fuel injectors
36. Connectthe upperradiatorhoseto the ther-
mostathousing.
37. Connectthe acceleratorcableconnectionto
the throttlebody.
38. Connectthe oil pressureswitch.
39. Installthe sparkplug wires,
40. Connectthe control harnessassembly.
41. Replacethe O-ring for the high pressurehose
and install a newclamp on the returnhoseand re-
connectthe fuel lines.
ENGINEANDENGINEOVERHAUL
3-25
42. Installthe air intakehose.Connectthe
breatherhoseand air cleanercasecover
43. Reconnectthe brakeboosterandthe PCV
vacuumhoses.
44. Fill the systemwith coolant.
45. Connectthe negativebatterycable
2.01 SOHCEngine
# See Figures 114 and 115 Front of engne I)
Intake side
1. Disconnectthe negativebatterycable.
2. Drainthe coolrngsystem.
~~
Never open, service or drain the radiator or
cooling systemwhen hot; serious burnscan
Exhaust side
occurfrom the steamand hot coolant. Also,
93153~24
when draining enginecoolant, keep in mind
that cats anddogsare attractedto ethylene Fig. 114 Cylinder head bolt loosening se-
quence-2.01 SOHCengine
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.Thiswill prove fatal in suffi-
cient quantities.Always drain coolantinto a
sealable container. Coolantshouldbe reused
unless it is contaminatedor is several years
old.
3. Removethe air intakehose.
4. Disconnectthe acceleratorcableand remove
the bracket.
5. Disconnectthe high pressurefuel line and
removethe O-ring.
Front of engme I)
Intake side
Observeall applicablesafety precautions
when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contactwith a sparkor
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
Exhaust side
in a containerspecifically designedfor fuel
93153g25
storage;also, always properlyseal fuel con-
tainers to avoid the possibility of fire or ex- Fig. 115 Cylinder head bolt tightening se-
plosion. quence-2.01 SDHCengine
6. Disconnectthe upperradiatorhose,the 14. Removethe through-boltfrom the left side
coolantby-passhoseand the heaterhosefrom the enginemount.It maybe necessaryto adjustthe jack
headand/or intakemanifold. slightly to allow the bolt to comefree Whenthe bolt
7. Disconnectthe brakeboostervacuumhose. has beenremoved,disconnectthe nutsand bolts
8. Removethe fuel returnhose. holdingthe mountingbracketto the engineand re-
9. Labeland detachthe vacuumhose(s)run- movethe bracket
ning to the manifold.Disconnectthe PCVhoseat the 15. Removethe valve cover and gasket.Remove
valve cover. the half-circleplug from the head.
10. Tagand disconnectthe sparkplug wires from 16. Removethe uppertiming belt cover.Turn the
the drstnbutorcap crankshaftclockwiseuntil all the timing marksalign,
11. Labeland detacheachelectricalconnector, settingthe engineto TDUcompressionfor No. 1
includingthe distributor leadand the injectorcon- cylinder.
nectors Notethat some of the wiring must be drs- 17. Removethe bolt holdingthe camshaft
connectedat the firewall.Whenall the connectorsare sprocketto the camshaft.Removethe camshaft
loose,removethe bracketbolts holdingthe control sprocket,with the beltattached,and placeit on the
wiring harnessrn placeand movethe harnessto an lowertiming belt cover. Do NOTallow the beltto
out-of-the-waylocation. comeoff the sprocket
12. Removethe clamp holdingthe powersteering
and air conditioninghosesto the top of the left en-
gine mount bracket.Move the hosesout of the way
but don’t drsconnecteitherhosefrom its system. Do not rotate the crankshaftoncethe
13. Positiona floor lack and a broadpieceof camshaftsorocketis removed.
lumberunderthe engine.Elevatethe jack lust enough
to supportthe enginewithout raisingit.
3-26 ENGINEANDENGINEOVERHAUL
18. Removethe self-lockingnutsandthe small
retainingbolt holdingthe exhaustpipe to the bottom
of the exhaustmanifold.Separatethe pipe from the
manifoldand removethe gasket.
19. Removethe bolts holdingthe supportbrace
to the bottomof the intakemanifold.
20. Usethe specialhex wrench(MB 998051-01)
and loosenthe headbolts in the ordershownin 2 or
3 passes.Whenall are finger loose,removethe bolts.
21. Rockthe headgentlyto breakit loose;if tap-
ping is necessary,do so with a rubberor wooden
malletat the cornersof the head.DONOTpry the
headup by wedgingtools betweenthe headandthe
block.
22. Lift the headfree of the engine.It is coming
off with both manifoldsandthe intakeplenumat-
tached;the help of an assistantis recommendedfor
lifting. Supportthe headassemblyon woodenblocks
on a suitableworkbench.Referto Cleaningand In-
spectionin this sectionfor work to be donebeforein-
stallingthe head.If the headhasbeenremovedfor
work otherthan gasketreplacement,the rockeras-
semblyand camshaftor othercomponentsmaybe
removed.
Beforereinstallation,the headshould be com-
pletelyassembledon the bench.This allows proper
locationand tighteningof all the externalitems.
To install:
23. Placea newgasketon the engineso that the
identifyingmarkfacesup (towardsthe head)and is at
the timing belt end of the block. Installa newgasket
on the exhaustpipe.
Do not apply sealant to the headgasketor
matingsurfaces.
24. Installthe headstraightdownonto the block.
Try to eliminatemost of the side-to-side adjust-
mentsas this may movethe gasketout of position.
Installthe bolts by handand just starteachbolt 1 or
2 turns on the threads.
25. The headbolt torquespecificationis 68 ft.
Ibs. (92 Nm) for a cold engine.The bolts must be
tightenedin the ordershown in 3 steps.Onthe first
pass,tightenall the bolts to about22 ft. Ibs. (30 Nm),
then proceedthroughthe ordertighteningeachbolt
to about45 ft. Ibs. (61 Nm).Thefinal torque is
achievedon the third pass.
26. Installthe intakemanifoldsupportbraceto
the manifoldand tightenthe bolts to 16 ft. Ibs.(22
Nm).
Intake side
Front of
I engine
Exhaust side
Fig. 116 Cylinder head bolt removal se-
quence-l .6L and 2.OLDDHCengines
27. Makingsurethe gasketis still in place,con-
nectthe exhaustpipe to the baseof the exhaustman-
ifold. Use newself-lockingnuts;tightenthe nutsand
the small bracketbolt to 26 ft. Ibs. (35 Nm).
28. Makesurethe camshafthas not changedpo-
sition during repalrs.Carefullyinstall the camshaft
sprocketand belt onto the camshaft.Tightenthe re-
taining bolt to 66 ft. Ibs. (91 Nm).
29. Installthe uppertiming belt cover,then
tightenthe bolts to 8 ft. Ibs. (11 Nm).
30. Apply sealantto the contactsurfacesof the
half-circleplug and installthe plug in the head In-
stall the valve cover and gasket.
31. Installthe enginemountbracketto the en-
gine.Tightenthe mountingnutsand boltsto 42 ft.
Ibs. (57 Nm).
32. Adjustthe jack (if necessary)so that the en-
gine mount bushingaligns with the bodywork
bracket.Installthe through-boltand tightenthe nuts
snug.
33. Slowly releasetensionon the floor jack so
thatthe weightof the enginebearsfully on the
mount.Tightenthe through-boltto 52 ft. Ibs. (71
Nm) and the small safetynut to 26 ft. tbs.(36 Nm).
34. Installthe bracketholdingthe powersteering
hoseand air conditioninghoseto the top of the en-
gine mount.
35. Positionthe controlwiring harnessand in-
stall the retainingbolts.Attacheachelectricalcon-
nectorto its properlocation,makingsurethe wires
are properlyroutedandfirmly connected.
36. Installthe sparkplug wires in the distributor
cap.
37. Connectthe PCV hoseand the vacuum
hose(s).
38. Connectthe fuel returnline. Connectthe
brakeboostervacuumhose.
39. Installthe heaterhose,the coolantby-pass
hoseand.theupperradiatorhose.Paycloseattention
to the position and routingof thesehosesand insure
that theyare not crimpedor constricted.Installthe
clamps in the samelocationas beforeremoval.
40. Installa newO-ring on the high pressurefuel
line and lubricateit with a coatingof gasoline.Care-
fully connectthe high pressurefuel line to the fuel
rail, taking carenot to damagethe O-ring.Tightenthe
bolts only to 4 ft. Ibs. (6 Nm).
41. Connectthe acceleratorcableand adjust it as
necessary.
42. Installthe air intakehose.
43. Fill the cooling systemwith coolant.
44. Changingthe oil andfilter is recommended
to eliminatepollutantsin the oil.
intake side
Front of
entine
Exhaustside
7923PG18
Fig. 117 Cylinder head bolt torque se-
quence-l .6L and 2.OLDDHCengines
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enginedamage.
45. Connectthe negativebatterycable.
46. Startthe engineand checkfor leaksof fuel,
vacuumor oil.
47. Checkthe operationof all engineelectrical
systemsas well as dashboardgaugesand lights.
48. Performnecessaryadjustmentsto the accel-
eratorcable,drive beltsand enginespecifications.
Adjust the coolantlevelafterthe enginehascooled
Off.
1.6L and 2.OLDDHCEngines
ti See Figures 116,117, and 116
1. Relievefuel systempressure.
2. Disconnectthe negativebatterycable.
3. Drainthe cooling system.
Never open,service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when drainingenginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container. Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
4. Disconnectthe acceleratorcable.Therewill
be 2 cablesif equippedwith cruise-control.
5. Removethe air cleanerwith the air intake
hose.
6. Detachthe electricalconnectorsfrom the the
oxygensensor,enginecoolanttemperaturesensor,
the enginecoolanttemperaturegaugeunit and the
enginecoolanttemperatureswitchon vehicleswith
air conditioning.
7. Disconnectthe wiring from the ISC motor,
throttle position sensor,crankshaftanglesensor,fuel
injectors,ignition coil, powertransistor,noisefilter,
knocksensoron turbochargedengines,EGRtemper-
aturesensor(Californiavehicles),groundcableand
enginecontrolwiring harness.
Painted mark Painted mark
Fig. 116 To ensure that the bolts are tight-
ened exactly 160 total degrees, mark the
head bolt and cylinder head as shown-
11.6L and 2.OLDDHCengines

8. Remove theupperradiatorhoseandthe
overflowtube.
9. Remove thesparkplugcablecentercover,
thenremovethesparkplugcables.
10. Disconnect andplugthehighpressure fuel
line.
11. Disconnect thesmallvacuumhoses.
12. Remove theheaterhoseandwaterbypass
hose.
13. Remove thePCVhose.
14. If turbocharged,removethevacuumhoses,
waterlineandeyeboltconnection fortheoil linefor
theturbo.
15. Disconnect andplugthefuelreturnhose.
16. Disconnect thebrakeboostervacuumhose.
17. Remove thetimingbelt.
18. Remove thevalvecoverandthehalf-round
seal.
19. Onnon-turbocharged engines,removethe
exhaustpipeself-locking nutsandseparate theex-
haustpipefromtheexhaustmanifold.Discardthe
gasket.
20. Onturbocharged engines,removethesheet
metalheatprotector andremove theboltsthatattach
theturbocharger to theexhaustmanifold.
21. Loosenthecylinderheadmounting boltsin 3
steps,startingfromtheoutsideandworkinginward,
Liftoffthecylinderheadassembly andremovethe
n headgasket.
To install:
22. Thoroughly cleananddrythematingsurfaces
of theheadandblock.Checkthecylinderheadfor
cracks,damage or enginecoolantleakage.Remove
scale,sealingcompound andcarbon.Cleanoil pas-
Fig. 119 Remove the upper radiator g3153p44
hose 1Fig. 129 . . . and also the lower rad:gzi
*. . hosesfrom the thermostathousing
Fig. 122Removethe three thermostathous-
ing retaining bolts . . .
ENGlNEANDENGlNEOVERHALiL
3-27
sagesthoroughly. Checktheheadfor flatness.Endto 31. Installtheaircleanerandintakehose.Con-
end,theheadshouldbewithin0.002in.(0.05mm) nectthebreather hose.
normally,with0.008in.(0.2mm) themaximum al- 32. Change theengineoil andoil filter,
lowedoutof true.Thetotalthickness allowedto be 33. Fillthesystemwithcoolant.
removed fromtheheadandblockis0.008in. 34. Connect thenegative
batterycable.
(0.2mm) maximum. 35. Runthevehicleuntilthethermostat opens,
23. Placea newheadgasketonthecylinder andfill theradiatorcompletely.
blockwiththeidentification marksatthefronttop 36. Checkandadjusttheidlespeedandignition
(upward)position.Makesurethegaskethasthe timing.
properidentification markfor theengine.Donotuse 37. Oncethevehiclehascooled,recheck the
sealeronthegasket.Replace theturbogasketand coolantlevel.
ring,if equipped.
24. Carefullyinstallthecylinderheadonthe 2.41 Engine
block.Using3 evensteps,torquetheheadbolts,in b See Figures119 thru 131
sequence, to 65-72ft. Ibs.(90-100Nm).Thistorque
appliesto a coldengine.If checking cylinderhead 1. Relievethefuelsystempressure.
bolttorqueonhotengine,thedesiredspecification is 2. Disconnect thenegativebatterycable.
7240 ft. Ibs.(100-110Nm). 3. Remove theaircleanerwithall air intake
25. Onturbocharged engine,installtheheat hoses.
shield.Onnon-turbocharged engines,installa new 4. Drainthecoolingsystem.
exhaustpipegasketandconnecttheexhaustpipeto
themanifold.
26. Applysealerto theperimeter of thehalf-
roundsealandtotheloweredgesof thehalf-round Neveropen, service or drain the radiator or
portionsof thebelt-sideof thenewgasket.Installthe cooling systemwhen hot; serious burnscan
valvecover. occurfrom the steamand hot coolant. Also,
27. Installthetimingbeltandall relateditems. when draining enginecoolant, keep in mind
28. Connect or installall previously disconnected that cats and dogsare attractedto ethylene
hoses,cablesandelectricalconnections. Adjustthe glycol antifreezeand could drink any that is
throttlecable(s). left in an uncoveredcontaineror in puddles
29. Installthesparkplugcablecentercover. on the ground.Thiswill provefatal in suffi-
30. Replace theO-ringsandconnect thefuel eient quantities.Always drain coolant into a
lines. sealable container.Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
/ cyl.der
Fig 121head g3153W
Removethe heater hose from the
93153p50
Fig. 124 Usinga suitable device, suchas a
breaker bar and the appropriate socket,
Fig. 123 . . . then remove the thermostat loosen the cylinder head bolts in the proper
housingfrom the cylinder head sequence
3-28 ENGINEANDENGINEOVERHAUL

lntsltaelde
Front of engine c3

Fig. 127 Graspthe cylinder head and lift it

off the engine block with the manifolds at-
Fig. 125 Cylinder head bolt removal se- ig. 126 A magnetcan be extremely help- tached. It is a good idea to use a helper for
quence-2.41(4664) engine I ful when removingthe cylinder head bolts 1 1this, as the assembly is very heavy

93153pOO 33153p4!3 Fig. 130 Also, make sure to thoroughly

Fig. 128 Removethe cylinder head gasket Fig, 129 Thoroughly clean the gasket sur- clean the engine block mating surfaces be-
from the block faces of the cylinder head fore reassemblingthe engine

l IntakeAir Temperature(IAT)sensor 23. Inspectthecylinderheadboltlengthpriorto

l ThrottlePosition(TP)sensor installation.
If thelengthexceeds 3.91in.(99.4mm),
: /I;%;,; rZ;Z;;(lAC) motor theboltmustbereplaced. Installthewasherontothe
boltsothechamfer onthewasherfacestowardsthe
l Ignitioncoil headof thebolt.
l Camshaft Position(CMP)sensor 24. Carefullyinstallthecylinderheadonthe
l Exhaust GasRecirculation(EGR)solenoid blockandtightenthecylinderheadboltsasfollows:
valve a. Followingthepropertightening sequence,
11. Remove thesparkplugwirecoverandwires. tightenthecylinderheadboltsto 58ft. Ibs.(78
12. Atthethermostat caseassembly, removethe Nm).
coolanthosesandunboltthethermostat casefrom b. Loosenall boltscompletely.
theengine. c. Torqueboltsto 15ft. Ibs.(20Nm). ’
Fig. 131 Cylinder head bolt installation se- 13. Remove theuppertimingbeltcover d. Tightenboltsanadditional1/4turn.
14. Alignall timingmarks. e. Tightenboltsanadditional1/4turn.
15. Securethetiminabeltto thecamshaft 25. Installthenewexhaustpipeaasketandcon-
5. Disconnect theaccelerator
cable.Removethe sprocket withcordor a wiretie. necttheexhaustpipetothemanifold. Tightenthe
cablemounting bracketsandpositionthecable 16. Remove thecamshaft sprocket. boltsto 33ft. Ibs.(44Nm).
aside. 17. Remove thevalvecoverandthehalf-round 26. Installthethermostat caseandtightenthe
6. Remove thebreather
hose. seal. mounting boltsto 18ft. Ibs.(24Nm).
‘7. Labelanddisconnectthevacuumlinesatthe 18. Disconnect theintakemanifoldstaybracket 27. Connect thecoolanthosestothethermostat
tree body. fromtheintakemanifold. case.
. 8. D&connect andplugthehighpressurefuel 19. Remove theexhaustpipeself-lockingnuts 28. Applysealerto theperimeter of thehalf-
lint3 andseparate theexhaustpipefromtheexhaustmani- roundsealandto theloweredgesofthehalf-round
fold.Discardthegasket, portionsofthebelt-sideof thenewgasket.Installthr
iliiL.-

9. Disconnect
andplugthefuelreturnhose.
10. Labelanddetachtheconnectors
fromthefol- 20. Loosenthecylinderheadmounting boltsin3 valvecover.
lowingcomponents: steps,startingfromtheoutsideandworkinginward. 29. Installthecamshaft sprocket withthetiming
* A$ compressor Liftoffthecylinderheadassembly andremove the beltattached. Remove thecordorwiretie.
* Powersteeringpressure
switch headgasket. 30. Installtheuppertimingbeltcover.
* HeatedOxygen(HO$)sensor To install: 31. Connect theintakemanifoldstayandtighten
* EngineCoolantTemperature(ECT)gauge 21. Thoroughly cleanthematingsurfacesofthe themounting boltsto 22ft. Ibs.(30Nm).
sender headandblock. 32. Attachtheconnectors to thefollowingcom-
l ECTsensor 22. Placea newheadgasketonthecylinder ponents:
l ManifoldAbsolutePressure
(MAP)sensor blockwiththeidentification marksatthefronttop l A/Ccompressor
(upward)position.Donotusesealeronthegasket. l Powersteeringpressure switch

l HOzSsensor
l ECTgaugesender
l ECTsensor
l MAP sensor
l IAT sensor
l TP sensor
l IAC motor
l injector harness
l ignition coil
l CMP sensor
l EGRsolenoidvalve
33. Installthe sparkplugwires and cover,
34. Replacethe O-ringsand connectthe fuel
lines.
35. Installthe air cleanerand intakehose.Con-
nectthe breatherhose.
36. Fill the cooling system.
37. Connectthe negativebatterycable
3.01 DDHCEngine
ti See Figures 132 and 133
1. Relievefuel systempressure.Disconnectthe
negativebatterycable.
2. Drainthe cooling system.
Neveropen,service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keepin mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.Thiswill prove fatal in suffi-
cient quantltles.Always drain coolant into a
sealable container. Coolantshouldbe reused
unless it is contaminatedor is several years
old.
3. Removethe air intakehoses.
4. Removeair intakeplenumand intakemani-
fold.
5. Removethe exhaustmanifold.
6. Removethe timing belt.Referto the timing
belt procedurein this section.
7. Removethe breatherhose.
8. Removethe sparkplug wire centercover and
removethe sparkplugwires.
9. Removethe rockercovers.
10. Removethe intakecamshaftsprockets.
11. Removethe reartiming belt cover.
12. Removethe ignition coil assembly.
13. Disconnectall waterhosesfrom the thermo-
stat housingand removethe housing.
14. Disconnectthe waterinlet from the front
head.
15. Loosenthe cylinderheadmountingbolts in
the reverseof the torquesequenceand loosenthe
bolts in threesteps.Lift off the cylinderheadassem-
bly and removethe headgasket.
To install:
16. Thoroughlycleanthe sealingsurfacesof the
headand block.
17. Placea newheadgasketon the cylinder
block with the identificationmarksin the front top
(upward)position. Do not usesealeron the gasket,
18. Carefullyinstallthe cylinderheadon the
block. Besurethe headbolt washersare installed
with the chamferededgeupward.Usingthreeeven
steps,torquethe headbolts in sequence,to 76-83 ft.
Ibs. (105-115 Nm).
ENGINEANDENGINEOVERHAUL
3-29
33. Fill the systemwrthcoolant.
34. Connectthe negabvebatterycable.
35. Adjustthe acceleratorcable.
36. Startthe engine.
37. Checkand adjustthe idle speedand ignition
timing.
38. Oncethe vehiclehascooled,recheckthe
coolantlevel.
3.OLSDHCEngine
# See Figure 132
1. Relievethe fuel systempressure.
2. Disconnectthe negativebatterycable.
3. Drainthe cooling system.
@ Timing belt side
Neveropen, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when drainingenginecoolant, keep in mind
that cats and dogsare attractedto ethylene
7923PG26 alvcol antifreezeand could drink any that is
:ig. 132 Tightenthe cylinder head bolts ac- Leftin an uncoveredcontaineror in puddles
:ording to the sequence shown-3.01 on the ground.This will Drovefatal in suffi-
SDHCand DDHC)engines cient quantities.Alwaysdrain coolant into a
sealable container.Coolantshouldbe reused
Unlessit is Contaminatedor is several years
Rear bank old.
4. Removethe air intakehose.
[::od 5. Removethe exhaustmanifold.
6. Removethe air intakeplenumand intake
04 ~8 01 manifold.
Front bank 7. Removethe timing belt. Referto the timing
'1 "8 belt procedurein this section.
8. Removethe camshaftsprocketsand the rear
509 010 011 6 timing belt cover.
1.03 07 02 9. Removethe powersteeringpump bracket.If
7923ffi25
removingthe rearhead,removethe alternatorbrace.
10. Disconnectthe waterinlet pipe.
Fig. 133 Rocker cover bolt torque se- 11. Removethe purgepipe assembly.
quence-Diamante 3.OLDDHCengine 12. Removethe valve cover,
13. Usingthe reversesequenceof the installation
19. InstallnewO-ring and connectthe waterinlet sequence,loosenthe cylinderheadmountingbolts in
to the head.Tightenthe mountingbolt to 9-11 ft. Ibs threesteps.Lift off the cylmderheadassemblyand
(12-15 Nm). removethe headgasket.
20. Replacethe gasketsand installthe thermostat To install:
housing.Tightenthe mountingbolts to 12-14 ft. Ibs. 14. Thoroughlycleanthe sealingsurfacesof the
(17-20 Nm). headand block.
21. Usingnewhoseclamps,connectthe hosesto 15. Placea newheadgasketon the cylinder
the thermostathousing. block makingsurethe identificationmark on the
22. Installthe Ignitioncoil and torquethe mount- cylrnderheadgasketis in the front top (upward)loca-
ing boltsto 7 ft. Ibs. (10 Nm). tion. Do not usesealeron the gasket,
23. Installthe reartiming beltcover and torque 16. Carefullyinstallthe cylinderheadon the
the mountingbolts to 17 ft. Ibs. (24 Nm). block. Besurethe headbolt washersare installed
24. Installthe intakecamshaftsprockets.Tighten with the chamferededgeupward.Usingthreeeven
the retainingbolt to 65 ft. Ibs.(90 Nm). steps,torquethe headbolts in sequence,to 7683 ft.
25. Apply sealerto the loweredgesof the valve Ibs. (105-115 Nm).
cover.Tightenthe bolts in the propersequenceto 17. Apply sealerto the loweredgesof the half-
44-51 inch Ibs. (5-6 Nm). roundportionsand installthe valve cover.Tighten
26. Connectthe sparkplug wires and installthe valve cover bolts to 7 ft. Ibs. (9 Nm).
centercover.Tightenthe bolts that securethe center 18. Installthe purgepipe assembly.
cover to 27 inch Ibs. (3 Nm) 19. Connectthe water inlet pipe.
27. Installthe breatherhose. 20. Installthe powersteeringpumpbracketand
28. Installthe timing belt. Referto the timing belt alternatorbrace.
procedurein this section, 21. Installthe reartiming belt coverand camshaft
29. Installthe exhaustmanifoldassembly. sprockets.Torquethe retainingbolt to 65 ft. Ibs. (90
30. Usingall newgaskets,installthe intakeman- Nm).
ifold and air intakeplenum. 22. Installthe timing belt.Referto the timing belt
31. Installthe air intakehoses. procedurein this section.
32. Changethe engineoil and oil filter.

3-30 ENGINEANDENGINEOVERHAUL
23. Usingall newgaskets,install the intakeman-
ifold, air intakeplenumand exhaustmanifold.
24. Installthe air intakehose.
25. Fill the systemwith coolant.
26. Connectthe negativebatterycable.
27. Startthe engine.
28. Checkand adjustthe idle speedand ignition
timing.
29. Oncethe vehiclehascooled,recheckthe
coolantlevel.
3.51 Engine
ti See Figure 134
1. Disconnectthe negativebatterycable.
2. Drainthe enginecoolant
Never open, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamandhot coolant. Also,
when draining enginecoolant, keep in mind
that cats and dogsare attractedto ethylene
glycol antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
3. Removethe timing belt.Referto the timing
belt procedurein this section.
4. Removethe intakeand exhaustmanifolds.
5. Removethe sparkplug wires.
6. Removethe cylrnderheadcovers.
7. Removethe timing belt rearcentercover.
8. Loosenthe cylinderheadbolts graduallyin
threestages,in the oppositeof the installationse-
quence.
9. Removethe cylinderhead.
To install:
10. Cleanthe cylinderheadand mountingsur-’
faceon the engineblock.
11. Installthe cylinderheadusing a newgasket.
12. Tightenthe bolts in sequenceusingthree
stagesto 76-83 ft. Ibs. (103-113 Nm).
13. Installthe timing belt rearcentercover.
14. Installthe cylinderheadcoversusing new
gaskets.Tightenthe boltsto 2-3 ft. Ibs.(334 Nm).
15. Installthe sparkplug wires,
16. Installthe intakeand exhaustmanifolds,
17. Installthe timing belt. Referto the timing belt
procedurein this section.
7923PGD2
Fig. 134 Cylinder head bolt tightening se-
quence-3.5L engine
18. Installany remainingcomponents.
19. Refillthe cooling system.
20. Connectthe negativebatterycable.
REMOVAL&INSTALLATION
1.5L Engine
p See Figure 135
1. Disconnectthe negativebatterycable.
2. Drainthe engineoil.
The EPAwarns that prolongedcontactwith
usedengineoil maycausea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soonas possibleafter exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
3. Removethe bell housinglowercover.
4. Removethe oil pan retainerbolts.Tapthe oil
panwith a rubbermalletto breakseal.
*Do not use a prytool when removingthe oil
pan. If available, oil pan removertool
MD998727or equivalentmaybe usedto
breakthe seal.
IFig. 135 Oil pan and related components-Mirage 1.5L (4615) engine
.
To install:
5. Cleanall gasketsurfacesof the cylinder
block and the oil pan.
6. Apply sealantto the gasketsurfacesof the oil
pan.
7. Installthe oil panonto the cylinderblock
within 15 minutesafterapplyingsealant.Installthe
fastenersandtightento 60 inch Ibs. (7 Nm).
8. Installthe bell housingcover.
9. Installthe oil drain plugwith a newsealand
tightento 29 ft. Ibs. (40 Nm).
10. Lowerthe vehicleand fill the crankcaseto the
properlevelwith cleanengineoil.
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enginedamage.
11. Connectthe negativebatterycable.Startthe
engineand checkfor leaks.
1.8L Engine
# See Figure 136
1. Disconnectthe negativebatterycable.
2. Raisethe vehicleand supportsafely.
3. Removethe oil pan drain plug and drainthe
engineoil.
The EPAwarns that prolongedcontactwith
usedengineoil may causea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should

Fig 136 Oil pan and related components-
I,.s; engine g3i53g26
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soon as possibleafter exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
4. Disconnectand lowerthe exhaustpipe from
the enginemanifold.
5. Removethe bell housinglowercover.
6. Removethe oil pan retainerboltsand remove
the oil pan.
*Do not use a prytool when removingthe oil
pan. If available, oil pan removertool
MD998727or equivalentmay be usedbreak
the seal.
To install:
7. Cleanall gasketsurfacesof the cylinder
block andthe oil pan.
8. Apply sealantaroundthe gasketsurfacesof
the oil pan.
9. Installthe oil pan ontothe cylinderblock
within 15 minutesafterapplyingsealant.Installthe
fastenersand tightento 60 inch Ibs. (5 Nm).
10. installthe bell housingcover.
11. Connectthe exhaustpipe to the enginemani-
fold with newgasketin place.Tightenthe exhaust
pipeto manifoldflangenutsto 33 ft. Ibs. (45 Nm).
Installand tightenthe supportbolt to 18 ft. Ibs. (25
Nm).
12. Installthe oil drain plug and tightento 29 ft.
Ibs. (40 Nm).
13. Fill the crankcaseto the properlevel.
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enginedamage.
14. Connectthe negativebatterycable.Startthe
engineand checkfor leaks.
1.6L and 2.OLEngines
FRONTWHEELDRIVE
ti See Figures137 and 138
1. Disconnectthe negativebatterycable.
2. Raisethe vehicleand supportsafely.
3. Removethe oil pan drain plug and drain the
engineoil.
ENGINEANDENGINEOVERHAUL
3-31
93153gza
Fig. 137 Oil pan and related components-
2.OLSOHCengine
93153g29
Fig. 138 Oil pan and removal for FWDand
AWDl.liL and 2.OLDDHCenoines
The EPAwarns that prolongedcontactwith
usedengineoil maycausea numberof skin
disorders,includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soon as possibleafter exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
4. Disconnectand lowerthe exhaustpipe from
the enginemanifold.
5. Usingthe appropriateequipment,supportthe
weightof the engine.
6. Removethe retainerbolts andthe center
crossmember,
7. Removethe oil pan bolts. Usingspecialtool
MD998727,tap in betweenthe engineblock and the
oil pan.
*Do not use a chisel, screwdriver or similar
tool when removingthe oil pan. Damageto
enginecomponentsmay occur.
8. Inspectthe oil pan for damageand cracks.
Replaceif faulty.While the pan is removed,inspect
the oil screenfor clogging,damageand cracks.Re-
placeif faulty.
To install:
9. Usinga wire brushor othertool, scrapeclean
all gasketsurfacesof the cylinderblock andthe oil
panso that all loose materialis removed.Cleanseal-
ing surfacesof all dirt and oil.
10. Apply sealantaroundthe gasketsurfacesof
the oil pan in such a mannerthat all bolt holesare
circled andthereis a continuousbeadof sealer
aroundthe entireperimeterof the oil pan.
*The continuousbeadof sealer shouldbe
applied in a beadapproximately0.16 in.
(4mm)in diameter.
11. Installthe oil pan onto the cylinderblock
within 15 minutesafterapplyingsealant.Installthe
fastenersandtightento 4-6 ft. Ibs. (G8 Nm).
12. Installthe crossmemberand tightenthe
mountingbolts to 72 ft. Ibs.(100 Nm).
13. Connectthe exhaustpipe to the enginemani-
fold with newgasketIn place.Tightenthe exhaust
pipe to manifoldflangenutsto 29 ft. Ibs. (40 Nm)
14. Installthe oil drain plug and tightento 33 ft.
Ibs.
15. Lowerthe vehicleand fill the crankcaseto the
properlevelwith cleanengineoil.
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enginedamage.
16. Connectthe negativebatterycable.
17. Startthe engineand checkfor leaks.
ALL WHEELDRIVE
ti See Figure 138
1. Disconnectthe negativebatterycable.
2. Raisethe vehicleand supportsafely.
3. Removethe oil pan drain plug and drain the
engineoil.
TheEPAwarns that prolongedcontactwith
usedengineoil maycausea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectiveglovesshould
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soon as possibleafter exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
4. Disconnectand lowerthe exhaustpipe from
the enginemanifold.
5. Removethe transferassemblyand right dri-
veshaft.
6. Usingthe appropriateequipment,supportthe
weightof the engineand removethe centercross-
member.
7. Disconnectthe returnpipe for the tur-
bochargerfrom the side of the oil pan.
8. Removethe oil pan bolts. Usingspecialtool
MD998727,tap In betweenthe engineblock andthe
oil pan.
*Do not use a chisel, screwdriver or similar
tool when removingthe oil pan. Damageto
enginecomponentsmay occur.

3-32 ENGINEANDENGINEOVERHAUL
9. Inspectthe oil panfor damageand cracks.
Replaceif faulty,While the pan is removed,inspect
the oil screenfor clogging,damageand cracks,Re-
place if faulty.
To install:
10. Usinga wire brushor othertool, scrapeclean
all gasketsurfacesof the cylinderblock andthe oil
panso that all loose materialis removed.Cleanseal-
ing surfacesof all dirt and oil.
11, Apply sealantaroundthe gasketsurfacesof
the oil pan in such a mannerthat all bolt holesare
circled and thereis a continuousbeadof sealer
aroundthe entireperimeterof the oil pan.
*The continuousbeadof sealer shouldbe
applied in a beadapproximately0.16 in.
(4mm)in diameter.
12. Installthe oil pan ontothe cylinderblock
within 15 minutesafterapplyingsealant.Installthe
fastenersand tightento 4-6 ft. Ibs. (68 Nm).
13. Installthe oil returnpipe using a newgasket,
if removed.Tightenretainersto 5-7 ft. Ibs. (7-10
Nm).
14. Installthe left memberand tightenthe forward
retainerbolts to 72 ft. Ibs. (100 Nm).Tightenthe
rearwardleft memberbolts to 58 ft. Ibs. (80 Nm).
15. Installthe transferassemblyand right drive-
shaft.
16. Connectthe exhaustpipe from the engine
manifoldwith newgasketin place.Tightenthe ex-
haustpipe to manifoldflangenutsto 29 ft. Ibs. (40
Nm).
17. Installthe oil drain plug and tightento 33 ft.
Ibs.
18. Lowerthe vehicleandfill the crankcaseto the
properlevelwith cleanengineoil.
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enaine damage.
19. Connectthe negativebatterycable.Startthe
engineand checkfor leaks.
2.4L Engine
) See Figure 139
1, Disconnectthe negativebatterycable.
-
,(L.. mM_ K%
2
-Ip
t 8*t.almcwr
:y&pn
::Elm
93153g30
Fig. 139 Oil pan and related components-
2.4L engine
2. Removethe oil pandrain plug and drainthe
engineoil.
The EPAwarns that prolongedcontactwith
usedengineoil maycausea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectiveglovesshould
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soonas possibleafter exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
3. Removethe oil dipstick andtubeassembly.
4. Detachthe HeatedOxygen(HOaS)sensor
connector.
5. Removethe front exhaustpipe from the vehi-
cle.
6. Removethe bell housingcover.
7. Removethe oil pan retainerbolts. Usingspe-
cial tool MD998727 or equivalent,tap in betweenthe
engineblock andthe oil pan.
*Do not use a prytool when removingthe oil
pan. Damageto enginecomponentsmay oc-
cur.
To install:
8. Apply sealantaroundthe gasketsurfacesof
the oil pan.
9. Installthe oil pan onto the cylinderblock
within 15 minutesafterapplyingsealant.Installthe
fastenersandtightento 6 ft. Ibs. (8 Nm).
10. Installthe oil drain plug and tightento 29 ft.
Ibs. (39 Nm).
11. Installthe bell housingcover,andtightenthe
mountingboltsto 7 ft. Ibs. (9 Nm).
12. Installthe front exhaustpipe andtightenthe
boltsat the catalyticconverterto 36 ft. Ibs. (49 Nm).
Tightenthe nutsat the exhaustmanifoldto 32 ft. Ibs.
(44Nm).
13. Reconnectthe HOPSsensorconnector.
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enginedamage.
15. Connectthe negativebatterycable.Startthe
engineand checkfor leaks.
3.OLEngines
u See Figure 140
1. Disconnectthe negativebatterycable.
2. Removethe oil pandrain plug and drain the
The EPAwarns that prolongedcontactwith
usedengineoil may causea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soon as possibleafter exposureto useden-
.
Groove Hole of bolt
7923PG67
Fig. 140 Oil pan bolt tightening sequence
andapplication of sealant to the pan-Dia-
mante3.OLengines
gine oil. Soapandwater, or waterless hand
cleanershouldbe used.
3. Removethe left side crossmember.If .
equippedwith 4WS,it will also be necessaryto re-
movethe right side crossmember.
4. Removethe startermotor.
5. Disconnectthe roll stopperstay bracket,from
the reartransaxlestaybracket.Removethe both
transaxlestaybrackets.
6. Removethe bell housinglowercover.
7. Removethe oil pan mountingbolts. Using
specialtool MD998727or equivalent,separateand
removethe engineoil pan.
To install:
8. Apply a 0.16 in. (4mm) continuousbeadof
sealeraroundthe surfaceof the oil pan.
*Assemble the oil panto the cylinder block
within 15 minutesafter applyingthe sealant.
9. Installthe oil panmountingbolts. Following
propersequence,tightenmountingbolts to 48 inch
Ibs. (6 Nm).
10. Install lowerbell housingcoverand the
startermotor.
11, Installthe transaxlestaybracketsand connect
the roll stopperbracket.
12. Installthe crossmember andtightenthe
mountingbolts to 43-51 ft. Ibs. (60-70 Nm).
13. Fill the enginewith the properamountof oil.
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enginedamage.
14. Connectthe negativebatterycableand check
for leaks.
3.5L Engine
p See Figures 141, 142, and 143
1, Disconnectthe negativebatterycable.
2. Drainthe engineoil.
The EPAwarns that prolongedcontactwith
usedengineoil may causea numberof skin
disorders,includinacancer!Youshould
makeeve’ryeffort to minimizeyour exposure
 ENGINEANDENGINEOVERHAUL
3-33
4. Placea block of wood againstthe side of the
panand tap the block with a hammerto breakthe
sealand removethe lowerpan.
5. Removethe starter.
6. Removethe dipstick tube.
7. Unboltthe upperoil pan.

Do not pry or use seal breakertool to remove

7923PG68
the oil pan. Damageto the aluminumsurface
Fig. 141 Install a bolt in the threaded hole can result.
to force the oil pan from the engine block- 8. Screwa bolt into the threadedhole to force
3.5L engine the oil panfrom the engineblock and removethe
pan.
9. Removethe bolt usedto removethe pan.
To install:
10. Cleanand degreasethe sealingsurfacesof
15 the upperoil panand engineblock.
11. Apply a beadof sillcone sealantalong the
mountingsurfaceof the upperoil pan.
12. Installthe upperoil pan.Tightenthe bolts in
16 sequenceto 4 ft Ibs.(6 Nm).
13. Installthe dipsticktube using a newO-ring.
14. Installthe starterassembly. 93153927
15. Cleanand degreasethe sealingsurfaceof the
lower oil pan.
Fig. 144 Exploded view of the oil pump
16. Placea beadof sealanton the mountingsur- mounting-l .5L engine
Groove Hole of bolt faceof the loweroil pan. Install the lowerpan.
7923PG69
Tightenthe bolts in sequenceto 7-9 ft. Ibs.(10-12
Fig.142 Apply sealant andtighten the bolts Nm).
Inthe order shown-3.51 engine, upperoil 17. Installthe drain plug usinga newwasher,
Ian shown Tightenthe drain plug to 29 ft. Ibs (39 Nm).
18. Lowerthe vehicleand fill the crankcaseto the
correctlevel.

View from above Operatingthe enginewithout the proper

amountandtype of engineoil will result in
severe enginedamage.
19 Connectthe negativebatterycable.
20. Startthe engrneand checkfor leaks,

Flange bolt tightening sequence

6 2 4
REMOVAL& INSTALLATION

1.5L and 1.8L Engines

p See Figures144 and 145 93153931

Fig. 145 Exploded view of the oil pump

7923PG70
:ig. 143Apply sealant andtighten the bolts
in the order shown-3.51 engine, lower oil
pan shown
to usedengine oil. Protectivegloves should
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soon as possibleafter exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
3. Removethe mountingboltsfrom the lower
oil pan.
*Whenever the oil pumpis disassembledor
the cover removed,the gear cavity mustbe
filled with petroleumjelly to seal the pump
and act as a prime. Do not use grease.
1. Drsconnectthe negativebatterycable.
2. Raiseand supportthe vehicle.
3. Drainthe engineoil.
The EPAwarns that prolongedcontactwith
usedengineoil may causea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should
be worn when changingthe oil. Washyour
mounting-l.81 engine
handsand any other exposedskin areas as
soon as possibleafter exposureto useden-
gine oil. Soap
. . .and
. water, or waterless hand
cleaner snoutdbe used.
4. Supportthe engineusing a suitabledevice
5. Removethe front engmemount bracketand
accessorydrive belts.
6. Removetiming belt upperand lowercovers.
7. Removethe timing belt and crankshaft
sprocket.Referto the timing belt procedurein this
section.
8. Removethe oil panand removethe oil
screen.
3-34 ENGINEANDENGINEOVERHAUL
9. Removethe front cover mountingbolts. Note
the lengthsof the mountingbolts as theyare re-
movedfor properinstallation.
10. Removethe front caseassemblyand oil
pumpassembly.
11. Removethe oil pumpcover.
12. Removethe innerand outergearsfrom the
front case.
To install
13. Removeall gasketmaterialfrom the mating
surfacesand cleanall parts.
14. Thoroughlycoat both oil pumpgearswith
cleanengineoil and installthem in the correctdirec-
tion of rotation.
15. Installthe pumpcover andtightenthe boltsto
84 inch Ibs.(10 Nm).
16. Coatthe reliefvalveand spring with cleanen-
gine oil. Installthemandtightenthe plug to 33 ft.
Ibs. (45 Nm).
17. Installa newfront crankshaftsealand coat
the lips of the sealwith cleanengineoil.
18. Installthe front caseand oil pumpassembly
to the engineblock using a newgasket.Tightenthe
bolts to loft. Ibs. (14 Nm)
19. Installthe oil screenwith newgasket.Torque
the screenbolts to 14 ft. Ibs. (19 Nm).
20. Installthe oil pan.
21. Installthe crankshaftsprocketandtiming
belt. Referto the timing belt procedurein this sec-
tion.
22. Fill the crankcaseto the properlevel.
Operatingthe enginewithout the proper
amountandtype of engineoil will result in
severe enoinedamaae.
23. Connectthe negativebatterycable.
1.6L, 2.OLand 2.4L Engines
p See Figures 146, 147, 148, and 149
*Whenever the oil pumpis disassembledor
the cover removed,the gear cavity mustbe
filled with petroleumjelly to seal the pump
and act as a prime. Do not use grease.
1. Disconnectthe negativebatterycable.
2. Rotatethe engineso No. 1 cylinder is on Top
DeadCenter(TDC) of its compressionstroke.
3. Drainthe engineoil.
The EPAwarns that prolongedcontactwith
usedengineoil may causea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should
be worn when changingthe oil. Washyour
handsand any other exposedskin areas as
soon as possibleafler exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
4 Usingthe properequipment,supportthe
weightof the engine Removethe front enginemount
bracketandaccessorydrive belts.
5 Removetiming belt upperand lowercovers.
6. Removethe timing beltand crankshaft
sprocket.Referto the timing belt procedurein this
section.
7. Detachthe electricalconnectorfrom the oil
pressuresendingunit and removethe oil pressure
sensor.Removethe oil filter and the oil filter bracket.
8. Removethe oil pan,oil screenand gasket.
9. Usingspecialtool MD998162, removethe
plug cap in the enginefront cover.
10. Removethe plugon the side of the engine
block. Inserta Phrllipsscrewdriverwith a shankdi-
ameterof 0.32 in. (8mm) into the plug hole.This will
hold the silent shaft.
11. Removethe drivengearbolt that securesthe
oil pumpdrivengearto the silent shaft.
12. Removethe front cover mountingbolts. Note
the lengthsof the mountingbolts as they are re-
movedfor properinstallation.
13. Removethe front casecover and oil pump
assembly.If necessary,the silent shaftcancomeout
with the cover assembly.
14. Removethe oil pumpcover, locatedon the
backof the enginefront cover. Removethe oil pump
drive and driven gears.
15. Afterdisassemblingthe oil pump,cleanall
componentsand removegasketmaterialfrom mating
surfaces.
16. Assemblethe oil pumpgearsinto the front
caseand rotateit to ensuresmoothrotationand no
looseness.Besurethereis no ridgewearon the con-
tact surfacebetweenthe front caseandthe gearsur-
faceof the oil pumpfront cover.
To install
17. Align the timing markon the oil pumpdrive
gearwith that on the drivengearand installthem into
the enginefront case.Apply engine011to the gears.
18. Installthe oil pumpcoverand tightenthe re-
tainer bolts to 13 ft. Ibs.(18 Nm).
19. Usingthe appropriatedriver, installa new
crankshaftseal into the front case.
Phrllips screwdrrver
7923PG71
Fig. 146 Holding the silent shaft for oil
pump gear removal-2.01 engine
7923PG73
Fig. 148 Aligning oil pumptiming marks-
2.OLermine
20. Position newfront casegasketin place.Set
seal guidetool MD998285 on the front end of the
crankshaftto protectthe sealfrom damage.Apply a
thin coatof oil to the outercircumferenceof the seal
pilot tool.
21. Installthe front caseassemblythrougha new
front casegasketandtemporarilytightenthe flange
bolts.
22. Mountthe oil filter on the bracketwith newoil
filter bracketgasketin place.Installthe bolts with
washersandtightento 14 ft. Ibs. (19 Nm).
23. Inserta Phillips screwdriverinto the hole in
the left side of the engineblockto lock the silent
shaftin place.
24. Installthe oil pumpdrive gearontothe left
silent shaft.Tightenthe drivengearbolt to 27 ft. Ibs.
(37Nm).
25. Installa newO-ringto the groove in the front
caseand installthe plug cap. Usingthe specialtool
MD998162,tightenthe capto 17 ft. Ibs. (24 Nm).
26. Installthe oil screenin positionwith new
gasketin place.
27. Cleanboth matingsurfacesof the oil panand
the cylinderblock.Apply sealantIn the groovein the
oil panflange.
*After applyingsealantto the oil pan, do
not exceed15 minutesbefore installing the
oil pan.
28. Installthe oil panto the engineand secure
with the retainers.Tightenbolts to 5 ft. Ibs. (7 Nm).
29. installthe oil pressuregaugeunit and the oil
pressureswitch.Connectthe electricalharnesscon-
nector.
30. Installthe oil cooler.Securewith oil cooler
bolt tightenedto 31 ft. Ibs (43 Nm).
31. Refillthe crankcase.
32. Install newoil filter.
7923PG72
Fig. 147 Use the special socket and holder
:o remove the balance shaft plug-2.0 en-
7ine
L= Bolt length below
head /mm (cn.)]
Fig. 149 Front case bolt identification-
?.OLand 2.4L engines

Operatingthe enginewithout the proper
amountand type of engineoil will result in
severe enginedamage.
33. Connectthe negativebatterycableand start
the engine.
34. Verify correctoil pressure
35. Inspectfor leaks.
3.OLEngines
b See Figure 150
*Whenever the oil pumpis disassembledor
the cover removed,the gear cavity mustbe
filled with petroleumjelly to seal the pump
and act as a prime. 00 not use grease.
1. Disconnectthe negativebatterycable.
2. Drainthe engineoil.
ENGINEANDENGINEOVERHAUL
3-35
To install: 3.5L Engine
10. Thoroughlycleanall gasketmaterialfrom all
mountingsurfaces. p See Figures 151 and 152
11. Apply engineoil to the entiresurfaceof the
1. Disconnectthe negativebatterycable.
gearsor rotors. 2. Removethe timing belt. Referto the timing
12. Assemblethe front casecover and oil pump
belt procedurein this section.
assemblyto the engineblock.
3. Drainthe engineoil.
13. Installthe oil screenwith newgasket.
14. Installthe oil pan
15. Installthe crankshaftsprocketandtiming
belt. Referto the timing belt procedurein this sec-
tion
16. Installthe timing belt covers.
17. Installthe drive belts andthe front engine
mount bracket.
18. Connectthe negativebatterycable,refill the
crankcaseand checkfor adequateoil pressure.
Fig. 151 Apply sealant to the rear of the oil
Operatingthe enginewithout the proper
pumpcase-3.5L ermine
amountandtype of engineoil will result in
severe enginedamage.

The EPAwarns that prolongedcontactwith

usedengineoil may causea numberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should
be worn when changingthe oil. Washyour
handsandany other exposedskin areas as
soon as possibleafter exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
3. Removethe front enginemountbracketand
accessorydrive belts.
4. Removetiming belt upperand lowercovers.
5. Removethe timing belt and crankshaft
sprocket.Referto the timing belt procedurein this
section.
6 Removethe oil pan.
7. Removethe oil screenand gasket.
8. Removethe front cover mountingbolts. Note
the lengthsof the mountingboltsas they are re-
movedfor properinstallation.
9. Removethe front and oil pump
assembly.

I
11 Nm
8 ft.lbs.

Removal steps
1. 011 pressure gauge unit 12. Oil screen gasket
2. 011 filter 13. Baffle plate
3. 011 filter bracket 14. Plug
4. 011 filter bracket gasket 15. Reltef spring
5. Drain plug 16. Relief plunger
6. Drawn plug gasket 17. Crankshaft oil seal
7 011 pan, lower 10. Oil pump case
8. Cover 19. 0-ring
9 011 pan, upper 20. 011 pump cover
10. Baffle date 21. 011 pump outer rotor
9315393i 11. 011 screen 22. 011 pump inner rotor
7g. 150 Exploded view of the oil pump
nounting-3.01 engines 7g. 152 Explodedview of the oil pump mounting-3.51 engine
 3-36 ENGINEANDENGINEOVERHAUL

The EPAwarns that urolonaedcontactwith

usedengineoil may cause”anumberof skin
disorders, includingcancer!Youshould
makeevery effort to minimizeyour exposure
to usedengineoil. Protectivegloves should
be worn when changingthe oil. Washyour
handsandany other exposedskin areas as
soonas possible after exposureto useden-
gine oil. Soapandwater, or waterless hand
cleaner shouldbe used.
4. Remove thesolashshieldfromthewheel 93153p65 93153p60

well. Fig. 153 Remove the fasteners, then re- Fig. 154 Unfastenthe crankshaftpulley re-
5. Remove theoil filteradapter. move the side inner fender splash shield talning bolts, then remove the pulley
6. Remove thelowerandupperoil pans.
7. Remove thelowerbaffle,oil pumppick-up 3. Raiseandsupportthevehicle. 1. Disconnect thenegative batterycable.
andupperbaffle.
8. Remove theoil pumpcasemounting bolts 4. Remove thepassenger sidefrontwheel. 2. Remove theengineundercover.
andtheoil pumpcase. 5. Remove thepassenger sideinnerfender 3. Raiseandsafelysupporttheweightoftheen-
9. Remove theoil pumpgearcover. splashshieldto gainaccessto thecrankshaft gineusingtheappropriate equipment. Remove the
10. Makematchmarks ontheoil pumprotorsbe- damper. frontenginemountbracketandaccessory drivebelts.
fore,,.removing them. 6. Onthe1.5L,1.6L,2.OLand2.4Lengines, re- 4. If necessary, remove thecoolantreservoir
r.--
nemove-IL- -.( -L.11---‘I
mecranksnarr searrrom--. me
IL- 011 -.I pump
_ -- movetheoullev-to-sorocket bolts. tank.
case. 7. Onthei .5L,i .8L,3.OLand3.5Lengines, re- 5. Usingtheproperequipment, slightlyraise
To instell: movethecrankshaft pulleycenterretainingbolt. theengineto taketheweightoffthesideengine
12. Installa newcrankshaft sealin theoil pump 8. Remove thedamper fromthecrankshaft us mount.Remove theenginemountbracket.
cover. inga suitablepuller. 6. Remove thedrivebelts,tensionpulleybrack-
13. Applyengineoil totherotors,thenalignthe -la install: ets,waterpumppulleyandcrankshaft pulley.
matchmarks andinstalltherotorsintheoil pump 9. Placethedamper ontothecrankshaft,ensur- 7. Remove all attraching screwsandremovethe
case. ingthekey-wayisaligned. upperandlowertimin{Jbeltcovers.
14. Installtherotorcover.Tightentheboltsto 7 10. Onthe1.5L,1.8L,3.OLand3.5Lengines,in- 8. Makea markon thebackof thetimingbelt
ft. Ibs.(10Nm). stallthlecrankshaft
pulleycenterretainingboltand indicating thedirectior I of rotationso it maybere-
15. Applya 0.113in.(3mm)beadof sealantto tightentheboltasfollows: assembled inthesame ! directionif it is to bereused.
4) 1.5Lengine:51-72ft. Ibs.(70-100Nm) Loosenthetimingbelttensioner andremove thetim-
thebackof theoil pumpcase.I[nsrall -‘-‘I me
IL ca-~--se on meIL-
engineandtightentheboltsto IOft,,,Ihc -. 11 , .4 Nm). l 1.8Land3.5Lengines:134ft. Ibs.(185 ingbelt.
16. Installtheupperbafflertlalteandoil pump NM *If coolant or engineoil comesin contact
pick-upusinga newgasket.Ticfhtti,, ,,lGhafflc,
an tha
va,,,tihnltc
““a,., l 3.OLengines:108-116ft. lbs.(150-160 with the timing bplt L,thaw
.,,s,,will
n,,, r(mcti~~llv
u,uu.,vu,,,
Wll

to 7 ft. Ibs.(10Nm)andthepitk-upboltsto 13ft. NW

11. Onthe1.5L,1.6L,2.OLand2.4Lengines, in- shortenits life. A,ISo, do not allow engineoil
Ibs.(18Nm). #.I nn..lr”* In rind In,
“I IruuI(IIILLuIrulll&t the timing belt sprock-
17. Installthelowerbaffleintheupperoil pan. stallthepulley-to-sprocket
boltsandtightenthebolts ets or tensionerassembly.
Tightentheboltsto 8 ft. Ibs.(11Nm). asfollows:
18. Installtheoil pans. l 1.5Lengine:10ft. Ibs.(14Nm) 9. Remove thetensioner spacer,tensioner
19. Installtheoil filteradapterusinga newgas- * 1.6Land2.OLengines:14-22ft. Ibs. springandtensioner assembly.
ket.Tightenthelargerboltto 30ft. Ibs.(41Nm)and (20-30Nm) 10. InspectthetimingbeltforIcracksonbacksur-
thesmallerboltto 1’ u ‘L- Inn‘I--’ l 2.4Lengine:18ft. Ibs.(25Nm) face,sides,bottomandcheckfor !;eoarated ( canvas.
20. InstallthetilllIllYuljllOlluIclllallllllY~ullIPV- 12. Onthe1.6Land2.OLengines,installthepul- Checkthetensioner pulleyfor smoothrotation.
: nents.Referto thetimingbeltprocedure in thissec- ley-to-sprocketboltsandtightenthemto 14-22ft. To install:
: tion. Ibs.(20-30Nm). 11. Positionthetensioner, tensioner springand
21. Filltheenginewiththecorrectamountof oil. 13. Installthesplashshield. tensioner spaceronengineblock.
14. Installthewheel,thencarefullylowertheve- 12. Alignthetimingmarksonthecamshaft
I. hicle.
I 15. Installtheaccessorydrivebelts.Referto Sec-
sprocket andcranksha ft sprocket.
No.1 pistononTDCotnthecomoression
Thiswill position
stroke.
Operatingthe enginewithout the proper tion1. 13. Positionthetimingbeltonthecrankshaft
amountandtype of engineoil will result in 16. Connect thenegative
batterycable. sprocket andkeeping thetensionsideof thebolt
severe enginedamage. tight,setit onthecam, shaftsprocket.
- 14. Applycounterc Yockwise forceto thecamshaft
22. Chrmxt
-s --, the ,.-JXL.._h;lttm
, I” nenntive I -..-., cnhle
--I.-. -r .__.._.tn
snrnckd ._nive
J..- tensin
._ - _Intothebeltandmakesureall
23. Starttheengineandcheckfor leaks. timingmarksarealigned.
REMOVAL
&INSTALLATION 15. Loosenthepivotsidetensioner boltandthe
clnt&In hnlt Allnurthn rnrinn tn tdm III-I thn slack,
r),“I 44”” ““IL. “ll”sl LllU .y”“yj L” L”I\U Low Ul” L
, d I, I’

.-Refer to Section1 for the propertiming ., 16. Tighten

, , , the ,, ,,slot
,, side, tensioner
, , , ,,bolt. ,,ark,~clthen
belt service interval. mep~vorsloeDOI~. ITmep~vorsloeOOII IS ogntened
REMOVAL
&INSTALLATION first,thetensioner couldturnwithbolt,causingover
1.5L Engine tension.
6 See Figures 153 and154 17. Turnthecrankshaft clockwise. Loosenthe
1999-94 MODELS pivotsidetensioner boltandthentheslotsideboltto
1. Disconnectthenegativebatterycable. allowthespringtotakeupanyremaining slack.
2. Remove theaccessory drivebeltsfrom b See Figures155 and 156
aroundthecrankshaft
pulley.Referto Section1.
 ENGINEANDENGINEOVERHAUL
3-37
6. Removetiming belt upperand lowercovers.
7. Makea markon the backof the timing belt
indicatingthe directionof rotationso it may be re-
assembledin the samedirectionif it is to be reused.
Loosenthe timing belttensionerand movethe ten-
sionerto provideslackto the timing belt.Tightenthe
tensionerin this position.
8. Removethe timing belt.

Coolantand engineoil will damagethe rub-

ber in the timing belt, drastically reducingits
life. Do not allow engineoil or coolantto
contactthe timing belt, the sprocketsor ten-
sioner assembly.
9. If defective,removethe tensionerspacer,ten-
sioner springandtensionerassembly.
To install:
10. Positionthe tensioner,tensionerspring and
tensionerspaceron engineblock.
11. Align the timing markson the camshaft
sprocketand crankshaftsprocket.This will position
No. 1 piston on TDC on the compressionstroke.
12. Positionthe timing belt on the crankshaft
sprocketand keepingthe tensionside of the belt
tight, set it on the camshaftsprocket,thenthe ten-
1. Ben 7. washer sioner.
8. Crankshaft pullet 14. Flsnge
2. Power4teerlna Dump
9. Damper pulls i 5. Tensbner spacer 13. Apply slight counterclockwiseforceto the
10. upper ccwer 16. Tef~kner WkW camshaftsprocketto give tensionto the belt and be
11. Lowercowr 1; Tgibnrr
12. llmingbeil sureall timing marksarealigned.
13. crsnkshat? E#ocket 19: camehan sprocket 14. Loosenthe pivot sidetensionerbolt andthe
91251ga
slot side bolt. Allow the spring to removethe slack.
Fig. 155 Explodedview of the timing belt covers, timing belt and related parts-1990-94 1.51 15. Tightenthe slot side tensionerbolt, thenthe
engine pivot side bolt. If the pivot side bolt is tightenedfirst,
the tensionercould turn with bolt, causingover ten-
sion.
16. Turn the crankshaftclockwise.Loosenthe
pivot side tensionerbolt, thenthe slot side bolt to al-
low the spring to takeup any remainingslack.
Tightenthe slot bolt, thenthe pivot side bolt to 17 ft.
Ibs. (24 Nm).
17. Installthe timing belt coversand tightenthe
cover boltsto 84-96 inch Ibs.(E-11 Nm). Installall
otherapplicablecomponents.

liming mark

ming mark

Fig. 156 Camshaftand crankshaft sprocket mark alignment for proper timing belt installa-
tion-1990-94 1.51 engine

Tightenthe slot bolt andthenthe pivot side bolt to 1995-00MOOFLS

14-20 ft. Ibs. (20-27 Nm). Timing mark
18. Checkthe belttensionby holding the ten- ) See Figure 157
sionerand timing belttogetherby handand give the Timing mark
1. Disconnectthe negativebatterycable.
belt a slight thumbpressureat a point levelwith ten- 2. Removethe engineundercover.
sioner center.Makesurethe belt cog crestcomesas 3. Rotatethe crankshaftclockwlseand position
deepas aboutl/4 of the width of the slot side ten- the engineat TDC of the compressionstroke. Crankshaft sprocket
sionerbolt head.Do not manuallyovertightenthe 4. Raiseand safelysupportthe weight of the en- 79235g5t
belt or it will makea howling noise. gine using the appropriateequipment.Removethe Fig. 157 Align the timing belt sprocketsas
19. Installthe timing belt coversand all related A/C clamp,front enginemount bracketand accessory indicatedbefore removingthe timing belt-
items. drive belts. 1995-00 1.51 engine
20. Connectthe negativebatterycable. 5. Removethe crankshaftpulley.
3-38 ENGINEANDENGINEOVERHAUL
1.61&?2.OL(Non-Turbo)DOHCEngines
g See Figure 158
*The 1.6L engine is not equippedwith
silent shafts. Disregardall instructionsper-
taining to silent shafts if working on that en-
gine.
1. Disconnectthe negativebatterycable.
2. Removethe engineundercover.
3. If necessary,removethe coolantreservoir.
4. Usingthe properequipment,slightly raise
the engineto takethe weightoff the side engine
mount.Removethe enginemountbracket.
5. Removethe drive belts,tensionpulleybrack-
ets,waterpumppulleyand crankshaftpulley.
6. Removeall attachingscrewsand removethe
upperand lowertiming belt covers.
7. Rotatethe crankshaftclockwiseand align the
timing marksso No. 1 piston will beat TDC of the
compressionstroke.At this time the timing markson
the camshaftsprocketandthe uppersurfaceof the
cylinderheadshouldcoincide,and the dowelpin of
the camshaftsprocketshould beat the upperside.
*Always rotate the crankshaftin a clockwise
direction. Make a mark on the backof the
timing belt indicatingthe direction of rotation
so it may be reassembledin the samedirec-
tion if it is to be reused.
8. Removethe autotensionerand removethe
outermosttiming belt.
9. Removethe timing belt tensionerpulley,ten-
sionerarm, idler pulley,oil pumpsprocket,special
washer,flangeand spacer.
10. Removethe silent shaft(inner) belttensioner
and removethe belt.
To install:
11. Align the timing markson the crankshaft
sprocketand the silent shaftsprocket.Fit the inner
timing belt over the crankshaftand silent shaft
sprocket.Ensurethat thereis no slack in the belt.
12. While holdingthe innertiming belttensioner
with your fingers,adjustthe timing belttensionby
applyinga force towardsthe centerof the belt, until
the tensionside of the belt is taut.Tightenthe ten-
sioner bolt.
*When tighteningthe bolt of the tensioner,
ensurethat the tensioner pulley shaft does
not rotate with the bolt. Allowing it to rotate
with the bolt can causeexcessivetension on
the belt.
13. Checkbelt for propertensionby depressing
the belt on it’s long side with your finger and noting
the belt deflection.Thedesiredreadingis 0.20-0.28
in. (5-7mm). If tensionis not correct,readjustand
checkbelt deflection.
14. Installthe flange,crankshaftand washerto
the crankshaft.Theflangeon the crankshaftsprocket
must be installedtowardsthe innertrming belt
sprocket.Tightenbolt to 80-94 ft. Ibs. (110-130
Nm).
15. To installthe oil pump sprocket,inserta
Phillips screwdriverwith a shaft0.31 in. (8mm) in di-
ameterinto the plug hole in the left side of the cylin-
der block to hold the left silent shaft.Tightenthe nut
to 36-43 ft. Ibs. (50-60 Nm).
16. Usinga wrench,hold the camshaftat it’s
hexagonbetweenjournal No. 2 and 3, thentighten
the bolt to 58-72 ft. Ibs. (80-100 Nm). If no hexagon
is presentbetweenjournal No. 2 and 3, hold the
sprocketstationarywith a spannerwrenchwhile
tighteningthe retainerbolt.
17. Carefullypushthe autotensionerrod in until
the set hole in the rod aligns with the hole in the
cylinder.Placea wire into the hole to retainthe rod.
18. Installthe tensionerpulleyonto the tensioner
arm. Locatethe pinholein the tensionerpulleyshaft
to the left of the centerbolt. Then,tightenthe center
bolt finger-tight.
19. Wheninstallingthe timing belt,turn the 2
camshaftsprocketsso their dowelpins are locatedon
top. Align the timing marksfacingeachotherwith the
top surfaceof the cylinderhead.Whenyou let go of
the exhaustcamshaftsprocket,it will rotate1 tooth in
the counterclockwisedirection.This should betaken
into accountwheninstallingthe timing beltson the
sprocket.
*Both camshaftsprocketsare usedfor the
intake and exhaustcamshaftsand are pro-
vided with 2 timing marks.Whenthe
sprocketis mountedon the exhaust
camshaft,use the timing mark on the right
with the dowel pin hole on top. For the intake
camshaflsprocket,usethe 1 on the left with
the dowel pin hole on top.
20. Align the crankshaftsprocketand oil pump
sprockettiming marks.
21. Afteralignmentof the oil pumpsprockettim-
ing marks,removethe plug on the cylinderblockand
inserta Phillips screwdriverwith a shaftdiameterof
0.31 in. (8mm) throughthe hole. If the shaftcanbe
inserted2.4 in. deep,the silent shaft is in the correct
position. If the shaftof the tool canonly be inserted
0.61 .Oin. (2C-25mm) deep,turn the oil pump
sprocket1 turn and realignthe marks.Reinsertthe
tool makingsure it is inserted2.4 in. deep.Keepthe
tool insertedin holefor the remainderof this proce-
dure.
*The above step assuresthat the oil pump
socketis in correct orientation to the silent
shafts. This step mustnot be skippedor a vi-
bration may developduringengineopera-
tion.
22. Installthe timing beltas follows:
a. Install the timing belt aroundthe intake
camshaftsprocketand retain it with 2 spring
clips or binder clips.
b. Install the timing belt aroundthe exhaust
sprocket,aligning the timing markswith the
cylinder headtop surfaceusing 2 wrenches.Re-
tain the belt with 2 spring clips.
c. Install the timing belt aroundthe idler pul-
ley, oil pump sprocket,crankshaftsprocketand
the tensionerpulley.Removethe 2 spring clips.
d. Lift upwardon the tensionerpulley in a
clockwisedirectionand tighten the centerbolt.
Make sureall timing marksare aligned.
e. Rotatethe crankshaft‘14 turn counterclock-
wise. Then,turn in clockwiseuntil the timing
marksare alrgnedagain.
23. To adjustthe timing (outer)belt,turn the
crankshaft‘14turn counterclockwise,then turn it
clockwiseto move No. 1 cylinderto TDC.
24. Loosenthe centerbolt. Usingtool
MD998738or equivalentand a torquewrench,apply
a torqueof 22-25 inch. Ibs. (2.6-2.8 Nm).Tighten
the centerbolt.
25. Screwthe specialtool into the engineleft
supportbracketuntil its end makescontactwith the
tensionerarm. At this point, screwthe specialtool in
somemore and removethe set wire attachedto the
autotensioner,if the wire was not previouslyre-
moved.Thenremovethe specraltool.
26. Rotatethe crankshaft2 completeturns clock-
wise and let it sit for approximately15 minutes.Then,
measurethe autotensionerprotrusion(the distance
betweenthe tensionerarm and autotensionerbody)
to ensurethat it is within 0.15-0.18 in. (3.8-4.5mm).
If out of specification,repeatStepl-4 until the spec-
ifiedvalue is obtained.
27. If the timing belt tensionadjustmentis being
performedwith the enginemountedin the vehicle,
and clearancebetweenthe tensionerarm andthe auto
tensionerbodycannotbemeasured,the following al-
ternativemethodcan be used:
a. Screw in specialtool MD998738 or equiv-
alent,until its end makescontactwith the ten-
sioner arm.
b. After the specialtool makescontactwith
the arm, screw it in some more to retractthe auto
tensionerpushrodwhile countingthe numberof
turns the tool makesuntil the tensionerarm is
broughtinto contactwith the auto tensioner
body. Make surethe numberof turns the special
tool makesconformswith the standardvalue of
21/a-3 turns.
c. Installthe rubber plug to the timing belt
rear cover.
28. Installthe timing belt coversand all related
items.
29. Connectthe negativebatterycable.
1.8L & 2.OLSOHCEngines
g See Figures 159, 160, and 161
1. Positionthe engineso the No. 1 piston is at
TDC of the compressionstroke.
2. Disconnectthe negativebatterycable.
3. Removethe engineundercover.
4. Usingthe properequipment,slightly raise
the engineto takethe weightoff the side engine
mount.Removethe enginemount bracket.
5. Removethe drive belts,tensionpulleybrack-
ets,waterpump pulleyand crankshaftpulley.
6. Removeall attachingscrewsand removethe
upperand lowertiming belt covers.
7. Removethe timing beltcovers.
8. Removethe outercrankshaftsprocketand
flange.
9. Removethe silent shaft(inner) belttensioner
and removethe belt.

To install:
IO. Align the timing marksof the silent shaft
sprocketsandthe crankshaftsprocketwith the timing
markson the front case.
11. Wrapthe timing beltaroundthe sprocketsso
thereis no slack in the upperspanof the beltand the
timing marksare still aligned.
12. Installthe tensionerpulleyand movethe pul-
ley by handso the long side of the belt deflectsabout
l/d in. (6mm).
13. Hold the pulleytightly so the pulleycannot
rotatewhenthe bolt is tightened.Tightenthe bolt to
15 ft. Ibs.(20 Nm) and recheckthe deflection
amount.
14. Installthe timing belttensionerfully toward
the waterpumpand tightenthe bolts. Placethe upper
end of the spring againstthe waterpumpbody.
15. Align the timing marksof the camshaft,
crankshaftand oil pumpsprocketswith their corre-
spondingmarkson the front caseor rearcover.
*There is a possibility to align all timing
marksand havethe oil pumpsprocketand
silent shaft out of time, causingan enginevi-
bration duringoperation. If the following step
is not followed exactly, there is a 50 percent
chancethat the silent shaft alignmentwill be
180 degreesoff.
16. Beforeinstallingthe timing belt,ensurethat
the left side (rear)silent shaft(oil pumpsprocket)is
in the correctpositionas follows:
a. Removethe plug from the rear side of the
block and inserta tool with shaft diameterof
0.31 in. (8mm) into the hole.
b. With the timing marksstill aligned,the
shaft of the tool must be able to go in at least
2’13 in. (59mm). If the tool can only go in about
1 in. (25mm), the shaft is not in the correctori-
entationand will causea vibration during engine
operation.Removethe tool from the hole and
turn the oil pump sprocket1 completerevolution.
Realignthe timing marksand insertthe tool. The
shaft of the tool must go in at least21/3 in.
(59mm).
c. Recheckand realign the timing marks.
d. Leavethe tool in placeto hold the silent
shaft while continuing
17. Installthe beltto the crankshaftsprocket,oil
pumpsprocket,then camshaftsprocket,in that order.
While doing so, makesurethereis no slackbetween
the sprocketexceptwherethe tensioneris installed.
18. Recheckthe timing marks’alignment.If all
are aligned,loosenthe tensionermountingbolt and
allow the tensionerto applytensionto the belt.
ENGlNEANDENGlliEOVERHAUL
3-39
E
91251gbl
Fig. 180 Silent shaft sprocket alignment
marksfor belt replacement-l.81 and 2.OL
SOHCengines
19. Removethe tool that is holdingthe silent
shaftand rotatethe crankshafta distanceequalto 2
teethon the camshaftsprocket.This will allow the
tensionerto automaticallyapplythe propertension
on the belt. Do not manuallyovertightenthe belt or it
will howl.
20. Tightenthe lower mountingbolt first, thenthe
upperspacerbolt.
21. To verify correctbelttension,checkthatthe
deflectionat the longestspanof the belt is about1/2
in. (13mm).
22. The installationof the timing belt coversand
all relateditems,is the reverseof the removalproce-
dure. Makesureall piecesof packingare positioned
in the inner groovesof the coverswhen installing.
23. Connectthe negativebatterycable.
2.OL(Turbo)OOHCEngine
ti See Figures162 and 163
1. Disconnectthe negativebatterycable.
2. Removethe engineundercover.
3. Removethe enginemount bracket.
4. Removethe drive belts.
5. Removethe belttensionerpulley.
6. Removethe waterpumppulleys.
7. Removethe crankshaftpulley.
8. Removethe stud bolt from the enginesup-
port bracketand removethe timing belt covers.
9. Rotatethe crankshaftclockwiseto line up the
camshafttiming marks.Alwaysturn the crankshaftin
the normaldirectionof rotationonly.
10. Loosenthe tensionpulleycenterbolt.
*If the timing belt is to be reused,markthe
direction of rotation on the flat side of the
belt with an arrow.
11. Move the tensionpulleytowardsthe water
pumpand removethe timing belt.
12. Removethe crankshaftsprocketcenterbolt
using specialtool MB9g67to hold the crankshaft
sprocketwhile removingthe centerbolt. Then,use
MB998778 or equivalentpullerto removethe
sprocket.
13. Mark the directionof rotationon the timing
belt B with a arrow.
14. Loosenthe centerbolt on the tensionerand
removethe belt.
00 not rotate the camshaftsor the crankshafl
while the timing belt is removed.
.
/---
PLUG
91251gb2
Fig. 161 Checkingthe rear silent shafl for
jroper positioning-1.8L and 2.OL SOHC
Pnoines
To Install:
15. Placethe crankshaftsprocketon the crank-
shaft.Usetool MB9g67or equivalentto hold the
crankshaftsprocketwhile tighteningthe centerbolt.
Tightenthe centerbolt to 80-94 ft. Ibs. (108-127
Nm).
16. Align the timing markson the crankshaft
sprocketB andthe balanceshaft.
17. Installtiming belt B on the sprockets.Posi-
tion the centerof the tensionerpulleyto the left and
abovethe centerof the mountingbolt.
18. Pushthe pulleyclockwisetowardthe crank-
shaftto applytensionto the belt andtightenthe
mountingbolt to 14ft. Ibs. (19 Nm) Do not let the
pulleyturn whentighteningthe bolt becauseit will
causeexcessivetensionon the belt.The belt should
deflect0.20-0.28 in. (5-7mm) whenfinger pressure
is appliedbetweenthe pulleys.
19. Installthe crankshaftsensingbladeand the
crankshaftsprocket.Apply engineoil to the mounting
bolt and tightenthe bolt to 80-94 ft. Ibs. (108-127
Nm).
20. Usea pressor vise to compressthe auto-ten-
sioner pushrod,Inserta set pin whenthe holesare
lined up.
Tming marks Cylinder had
I top surface
Ti
m
Crank&aft
sprocket
79235g60
:ig. 162 Camshaft and crankshaft timing
lelt sprocketTOCalignment mark position-
ng for timing belt removal and installa-
ion- 2.OLturbo engine
 l

3-40 ENGINEANDENGINEOVERHAUL
Counterbaiance 2.41 Engine 7. Remove thepowersteeringpump,alternator
# See Figures 164 thru 162 airconditioning compressor, tensionpulleyandac-
companying brackets,asrequired.
1. Besurethattheengine’sNo.1 pistonisat 8 Remove theupperfronttimingbeltcover.
TDCin thecompressionstroke. 9. Remove thewaterpumppulleyandthe
crankshaft pulley(s).
10. Remove thelowertimingbeltcovermountinf
screwsandremove thecover.
Wait at least 90 secondsafter the negative 11. If thebelt(s)areto bereused,markthedirec.
battery cable is disconnectedto preventpos- tionof rotationonthebelt.
sible deploymentof the air bag. 12. Remove thetiming(outer)belttensioner and
19235861 2. Disconnect removethebelt.Unboltthetensioner fromtheblock
thenegative
batterycable. andremove.
Fig. 163 Timing belt 5 installation mark 3. Removethesparkplugwiresfromthetreeon
alignment- 2.OLturbo 13. Remove theoutercrankshaft sprocket
and
theuppercover. flange.
4. Drainthecoolingsystem. 14. Remove thesilentshaft(inner)belttensioner
andremove theinnerbelt.Unboltthetensioner from
theblockandremoveit.
Do not compressthe pushrodtoo quickly, Neveropen, service or drain the radiator or 15. Toremove thecamshaft sprockets,useSST
damageto the pushrodcan occur. cooling systemwhen hot; serious bumscan Ml39g67-01 andMlT308239, ortheirequivalents.
occurfrom the steamand hot coolant. Also, To in!3tall:
21. Installtheauto-tensioner ontheengine. when draining enginecoolant, keep in mind 16. Installthecamshaft sprockets andtightenthr
22. Alignthetimingmarksonthecamshaft that cats and dogsare attractedto ethylene centerboltto 65ft. Ibs.(90Nm).
sprocket,crankshaft sprocket andtheoil pump glycol antifreezeand could drink any that is 17. Alignthetimingmarkofthesilentshaftbelt
sprocket. left in an uncoveredcontaineror in puddles sprockets onthecrankshaft andsilentshaftwiththe
23. Afteraligningthemarkontheoil pump on the ground.This will prove fatal in suffi- marksonthefrontcase.Wrapthesilentshaftbelt
: sprocket,remove thecylinderblockplugandinserta cient quantities.Always dramcoolant into a aroundthesprockets sothereis noslackin theuppe
prytoolin theholeto checkthepositionof thecoun- sealable container. Coolantshouldbe reused !spanofthebeltandthetimingmarksarestill in line.
terbalance shaft.Theorvtoolshouldao inat least unless it is contaminatedor is several years 18. Installthetensioner initiallysotheactual
2.36in.(60mm)or more,if not,rotai;!theoil pump old. I:enterof thepulleyisaboveandto theleftof thein-
sprocket onceandrealignthetimingmarksothepry- jtallationbolt.
toolgoesin.Donotremovetheon/ooluntilthetfrn- 5. Remove
theshroud,fanandaccessory
drive 19. Movethepulleyupbyhandsothecenter
ingbeltis installed. . I:lelts. jpanof thelonasideof thebeltdeflectsabout11~ in.
24. Installthetimingbeltontheintakecamshaft 6. Remove
theradiatorasrequired.
andsecureit witha clip.
25. Installthetiminabeltontheexhaust
camshaft.
26. Alignthetimingmarkswiththecylinderhead
topsurfaceusingtwowrenches. Securethebeltwith
anotherclip.
27. tnstatfthebeltaroundtheidlerpulley,oil
pumpsprocket, crankshaftsprocket andthetensioner
pulley.
28. Turnthetensioner pulleysothepinholesare
atthebottom.Pressthepulleylightlyagainstthetim-
ingbelt.
29. Screwthespecialtoolintotheleftengine
supportbracketuntilit contacts thetensionerarm,
thenscrewthetoolin a littlemoreandremovethe Pm3p70

pushrodpinfromtheauto-tensioner. Remove the Fig 164 Removethe upper engine mount- Fig. 165 Remove the upper engine mount
specialtoolandtightenthecenterboltto 35ft. Ibs. to-mountbracket nuts al%@] through-bolt . . .
(48Nm).
30. Turnthecrankshaft ‘Idturncounterclockwise,
thenclockwise untilthetimingmarksarealigned.
31. Loosenthecenterbolt.InstallMitsubishi
SpecialToolMD998767, orequivalent, ontheten-
sionerp&y. Turnthetensioner pulleycounterclock-
wisewitha torqueof 2.6ft. Ibs.(3.5Nm)andtighten
thecenterboftto35ft. tbs.(48Nm).Donotletthe
tensioner pUtFey turnwhentightening thebolt.
32. Turnthecrankshaft clockwise tworevolutions
andalignthetimingmarks.
33. After15minutes, measure theprotrusion of
thepushrodontheauto-tensioner. Thestandard
measurement is0.150-0.177 in (3.8-4.5mm). Ifthe
I protrusionis outof specification, loosentheten-
I sionerpulley,applythepropertorqueto thebeltand
: retightenthecenterbolt.
34. Installthetimingbeltcoversandall applica-
i blecomponents.
 ENGINEANDENGINEOVERHAUL
3-41

93153p34

Fig. 170 Loosen the bolt on the tensioner

pulley and slide the pulley to the left to re-
lieve the tension on the timing belt

93153p91

Fig. 173 Unfastenthe two timing belt ten-

sioner retaining bolts . . .

Fig. 176 After unfasteningthe retainer, re-

Fig. 174. . . then removethe tensionerfrom Fig. 175 Removethe bolt and remove the movethe CKPtrigger wheel from the crank-
the engine block crankshafttiming belt pulley shaft

Fig. 177 Removethe silent shaft tensioner Fig, 178 I . . then removethe tensionerfrom Fig. 179 Removethe silent shaft belt from
retafnfng bolt . . . the engine block the engine

3-42 ENGINEANDENGINEOVERHAUL
Fig. 180 Silent shaft alignment marks. No,
tice the tension side of the inner (silen
shaft) belt-2.41 enaine
Timing merk
(pun+ on sprocket)
liming m&k
(notch in sprocket)
79245g31
:ig. 181 Timing belt pulley alignmenl
narks-2.41 enoine
20. Hold the pulleytightly so it does not rotate
whenthe bolt is tlghtened.Tightenthe bolt to 15 ft.
Ibs. (20 Nm). If the pulleyhasmoved,the beltwill be
too tight
21. Installthe timing belt tensionerfully toward
the waterpumpandtemporarilytightenthe bolts.
Placethe upperend of the springagainstthe water
pumpbody.Align the timing marksof the cam,
crankshaftand oil pumpsprocketswith the corre-
spondingmarkson the front caseor head.
*If the following stepsare not followed ex-
actly, there is a chancethat the silent shaft
alignmentwill be 180 degreesoff. This will
causea noticeablevibration in the engine
andthe entire procedurewill haveto be re-
peated.
22. Beforeinstallingthe timing belt,ensurethat
the left side silent shaft is in the correctposition.
*It is possibleto align the timing markson
the camshaftsprocket,crankshaftsprocket
andthe oil pumpsprocketwith the lefl bal-
anceshaft out of alignment.
23. With the timing markon the oil pumppulley
alignedwith the markon the front case,checkthe
alignmentof the left balanceshaftto assurecorrect
shafttiming.
a. Removethe plug locatedon the left side of
the block in the areaof the starter.
b. Inserta tool havinga shaft diameterof 0.3
in. (8mm) into the hole.
c. With the timing marksstill aligned,the tool
must be able to go in at least2l/s in. (59mm). If
it can only go m about 1 in. (25mm), turn the oil
pump sprocketone completerevolution.
d. Recheckthe position of the balanceshaft
with the timing marksreahgned.Leavethe tool in
placeto hold the silent shaft while continuing.
24. Installthe belt to the crankshaftsprocket,oil
pumpsprocketandthe camshaftsprocket,in that or-
der. While doing so, be surethereis no slack be-
tweenthe sprocketsexceptwherethe tensionerwill
take it up whenreleased.
25. Recheckthe timing marks’alignment.
26. If all are aligned,loosenthe tensionermount-
ing bolt, and allow the tensionerto applytensionto
the belt.
27. Removethe tool that is holdingthe silent
shaft in placeandturn the crankshaftclockwisea dis-
tanceequalto two teethof the camshaftsprocket.
This will allow the tensionerto automaticallytension
the belt the properamount.
Do not manuallyapply pressureto the ten-
sioner. Thiswill overtightenthe belt andwill
causea howling noise.
28. Firsttightenthe lowermountingbolt and then
tightenthe upperspacerbolt.
If any bindingis felt when adiustinothe tim-
ing delt tension by turningth;! crankshaft,
STOPturningthe engine, becausethe pis-
tons may be hitting the valves.
29. To verify that belt tensionis correct,check
that the deflectionof the longestspan(betweenthe
camshaftand oil pumpsprockets)is I/* in. (13mm).
30. Installthe lowertiming belt cover. Be surethe
packingis properlypositionedin the inner groovesof
the coverswheninstalling.
31. Installthe waterpumppulleyand the crank-
shaftpulley(s).
32. Installthe upperfront timing belt cover.
33. Installthe powersteeringpump,alternator,
air conditioningcompressor,tensionpulleyand ac-
companyingbrackets,as required.
34. Installthe radiator,shroud,fan and accessory
drive belts.
35. Installthe sparkplug wires to the tree on the
uppercover.
36. Refillthe cooling system.
37. Connectthe negativebatterycable.Startthe
engmeand checkfor leaks.
3.OLSDHCEngine
1992-94 MODELS
# See Figures 182 and 183
1. Disconnectthe negativebatterycable.
2. Removethe engineundercover
3. Removethe cruisecontrol actuator
4. Removethe accessorydrive belts.
.
5. Removethe air conditionercompressorten-
sion pulleyassembly.
6. Removethe tensionpulleybracket.
7. Usingthe properequipment,slightly raise
the engineto takethe weightoff the side engine
mount.Removethe enginemountingbracket.
8. Detachthe powersteeringpump pressure
switch connector.Removethe powersteeringpump
and wire aside.
9. Removethe enginesupportbracket.
10. Removethe crankshaftpulley.
11. Removethe timing belt cover cap.
12. Removethe timing belt upperand lowercov-
ers.
13. If the sametiming beltwill be reused,mark
the directionof the timing belt’srotationfor installa-
tion in the samedirection.Makesurethe engineis
positionedso the No. 1 cylinder is at the TDC of its
compressionstrokeand the sprockets’timing marks
are alignedwith the engine’stiming mark indicators.
14. Loosenthe timing belt tensionerbolt and re-
movethe belt. If the tensioneris not beingremoved,
position it as far awayfrom the centerof the engine
as possibleand tightenthe bolt.
15. If the tensioneris beingremoved,paintthe
outsideof the spring to ensurethat it is not installed
backwards.Unboltthe tensionerand removeit along
with the spring.
To install:
16. Installthe tensioner,if removed,and hookthe
upperend of the springto the waterpumppin and
the lowerend to the tensionerin exactlythe samepo-
sition as originally installed.If not alreadydone,po-
sition both camshaftsso the marksalign with those
on the rear.Rotatethe crankshaftso the timing mark
aligns with the markon the oil pump.
17. Installthe timing belt on the crankshaft
sprocketand while keepingthe belttight on the ten-
sion side, installthe belt on the front camshaft
sprocket.
18. Installthe belt on the waterpumppulley,then
the rearcamshaftsprocketand the tensioner.
19. Rotatethe front camshaftcounterclockwiseto
tensionthe belt betweenthe front camshaftand the
crankshaft.If the tlmlng marksbecamemisaligned,
repeatthe procedure.
20. Installthe crankshaftsprocketflange.
21. Loosenthe tensionerbolt and allow the
spring to applytensionto the belt.
22. Turn the crankshaft2 full turns in the clock-
wise directionuntil the timing marksalign again.
Nowthat the belt is properlytensioned,torquethe
tensionerlock bolt to 21 ft. Ibs. (29 Nm). Measure
the belttension betweenthe rearcamshaftsprocket
and the crankshaftwith belt tensiongauge,The spec-
ification is 46-68 Ibs. (210-310 N).
23. Installthe timing covers.Makesureall pieces
of packingare positionedin the innergroovesof the
coverswhenInstalling.
24. installthe crankshaftpulley.Tightenthe bolt
to 108-116ft. Ibs. (150-160 Nm)
25. Installthe enginesupportbracket.
26. Installthe powersteeringpumpand recon-
nectwire harnessat the powersteeringpumppres-
sure switch.
27. Installthe enginemountingbracketand re-
movethe enginesupportfixture.
28. Installthe tensionpulleysand drive belts.
29. Installthe cruisecontrol actuator.
30 Installthe engineundercover.
 ENGINEANDENGINEOVERHAU'L
3-43

2. Bolt
3. Washer
4. Crankshaft pulley
5. Access cover
6. Right side upper
front cover
7. Cap
8. Left side upper front
OOVM 90 Nm
9. Front lower cover 65 ft.lbs.
10. Flange
I
16

r
11
I
26 Nm
19 ft.lbs.

11. Lookbolt
12. Tensioner
13. Tensbner spring
14. Timing bait
15. Crankshaft sprocket
16. Bott
I 17. Camshaft sprocket
155 Nm 18. Left slde rear cover
112 ft.lbs. 19. Right side rear cwer
91'251gb:

:ig. 182 Explodedview of the timing belt covers, timing belt and related parts-1992-94 Mitsubishi 3.OLSOHCengine

TIMING MARK
TIMING MARK ON ON BELT COVER
REAR COVER OR
ALTERNATOR BRACKET

CAMSHAFT SPROCKET

TIMINQ BELT TENSIONER

ON FRONT CASE

CRANKSHAFT SPROCKET

:ig. 183 Crankshaftand camshaftsprocket alignmentfor proper timing belt replacement-1992-94 Mitsubishi 3.OLSOHCengine

3-44 ENGINEANDENGINEOVERHALJL
31. Connectthe negativebatterycable.
32. Roadtest the vehicle.
EXCEPT 1992-94 MODELS
$ See Figure 184
1. Positionthe engineso the No. 1 cylinderis at
TDC of its compressionstroke.
2. Disconnectthe negativebatterycable.
Wait at least 90 secondsafter the negative
battery cable is disconnectedto preventpos-
sible deploymentof the air bag.
3. Removethe engineundercover.
4. Removethe front undercoverpanel.
5. Removethe cruisecontrol pumpandthe link
assembly.
6. Removethe alternator.
7. Raiseand suspendthe engineso that force is
not appliedto the engmemount,
8. Removethe timing coversfrom the engine.
9. If the sametiming beltwill be reused,mark
the directionof the timing belt’s rotationfor installa-
tion in the samedirection.Makesurethe engineis
positronedso the No. 1 cylinder is at the TDC of its
compressionstrokeand the timing marksare aligned
with the engine’stiming mark indicatorson the valve
coversor head.
Timing belt tensioner
:ig. 184 Align the sprocketsproperly before removing or installing the timing belt-1995-96 Diamantewith the 3.OL(6672) SDHCengine
10. Loosenthe centerbolt of tensionerpulleyand
unboltauto-tensionerassemblyTheauto-tensioner
assemblymust be resetto correctlyadjustbelt ten-
sion. Removethe timing belt.
11. Usinga wrench,hold the camshaftat its
hexagonand removethe camshaftsprocketbolt.
12. Removeand positionthe auto-tensionerinto
a vise with soft jaws.The plugat the rearof tensioner
protrudes,besureto usea washeras a spacerto
protectthe plugfrom contactingvise jaws.
13. Slowly pushthe rod Into the tensioneruntil
the set hole rn rod is alignedwith set hole in the
auto-tensioner.
14. Inserta 0.055 in. (1.4mm)wire into the
alignedset holes.Unclampthe tensionerfrom the
vise and install it on the engine.Trghtentensronerto
17 ft. Ibs. (24 Nm).
15. Cleanand inspectbothautotensioner
mountingbolts. Coatthe threadsof the old boltswith
threadsealer.If newbolts are installed,Inspectthe
headsof the newbolts. If thereis white paint on the
bolt head,no sealeris required.If thereis no parnton
the headof the bolt, applya coat of threadsealerto
the bolt. Installboth bolts andtightento 17 ft. Ibs.
(24 Nm).
To install:
16. Installthe tensioner,if removed,and hook the
upperend of the springto the waterpump pin and
the lower endto the tensionerin exactlythe samepo-
sition as originally installed.
Timing mark
(on belt cover)
Crankshaft
sprocket
.
17. Ensureboth camshaftsare still positionedso
the timing marksalign with thoseon the reartiming
covers.
18. Rotatethe crankshaftso the timing mark
aligns with the markon the front cover.
19. Installthe timing belt on the crankshaft
sprocketand while keepingthe belt tight on the ten-
sion side, mstallthe belt on the front (left) camshaft
sprocket.
20 Installthe belt on the waterpumppulley,then
the rear(right) camshaftsprocketandthe tensioner.
21. Loosenthe bolt that securesthe adjustment
of the tensionerand lightly pressthe tensioner
againstthe timing belt.
22. Checkthatthe timing marksare in alignment.
23 Rotatethe crankshaft2 full turns in the clock-
wise directiononly, then realignthe timing marks,
24. Tightenthe bolt that securesthe tensionerto
19 ft. Ibs.(26 Nm).
25. installthe lowerandthe uppertiming belt
covers,along with all otherapplicablecomponents.
3.OLDDHCEngine
1992-94 MODELS
# See Figure 185
1. Positionthe engineso the No. 1 cylinderis at
TDC of its compressionstroke.
2. Disconnectthe negativebatterycable.
3. Removethe engineundercover.
7923W

TIMINQ MARKS ON
RIQHT SIDE VALVE COVER
CRANKSHAFTSPROCKETS
:ig. 185 Crankshaftand camshaftsprocket alignmentfor proper timing belt replacement-1992-94 Mitsubishi 3.OLDOHCengine
4. Removethe cruisecontrol actuator.
5. Removethe alternator.Removethe air hose
and pipe.
6. Removethe belttensionerassemblyandthe
powersteeringbelt.
7. Removethe crankshaftpulley.
8. Disconnectthe brakefluid levelsensor.
9. Removethe timing belt uppercover.
10. Usingthe properequipment,slightly raisethe
engineto takethe weightoff the side enginemount.
Removethe enginemountbracket.
11. Removethe alternator/airconditioneridler
pulley.
12. Removethe enginesupportbracket.The
mountingbolts are differentlengths;markthemfor
properinstallation.
13. Removethe timing belt lowercover.Timing
bolt cover mountingbolts are differentin length,note
their position during removal.
14. If the sametiming beltwill be reused,mark
the directionof the timing belt’srotationfor installa-
tion in the samedlrection.Make surethe engineis
positionedso the No. 1 cylinderis at the TDC of its
compressionstrokeandthe sprockets’timingmarks
are alignedwith the engine’stiming mark indicators
on the valve coversor head.
15. Loosenthe timing belt tensionerbolt and re-
movethe belt.
16. Removethe tensionerassembly.
To install:
17. If the autotensionerrod is fully extended,re-
set it as follows:
a. Clampthe tensionerin a soft-jaw vice in
level position.
b. Slowly push the rod in with the vice until
the set hole in the rod is alignedwith the hole in
the cylinder.
ENGlNEANDENGlNEOVERHiUL
3-45
c. Inserta stiff wire into the set holes to retain
the position.
d. Removethe assemblyfrom the vice.
18. Leavethe retainingwire in the tensionand in-
stall to the engine.
19. If the timing marksof the camshaftsprockets
and crankshaftsprocketare not alignedat this point,
proceedas follows:
*Keep fingers out from betweenthe
camshaftsprockets.Thesprocketsmay move
unexpectedlybecauseof valve springpres-
sure and could pinchfingers.
a. Align the mark on the crankshaftsprocket
with the mark on the front case.Thenmove the
sprocket2 teethclockwiseto lower the piston so
the valve can’ttouch the piston whenthe
camshaftsare being moved.
b. Turn eachcamshaftsprocket1 at a time to
align the timing markswith the mark on the valve
cover or head.If the intakeand exhaustvalves of
the samecylinder are openedsimultaneously,
they could interferewith eachother. Therefore,if
any resistanceis felt, turn the other camshaftto
move the valve.
c. Align the timing mark of the crankshaft
sprocket,then continue1 tooth fartherin the
counterclockwisedirectionto facilitatebelt instal-
lation.
20. Using4 spring loadedpaperclips to hold the
belt on the camsprockets,install the beltto the
sprocketsin the following order:
l M-exhaust camshaftsprocketfor the
front head
l 2nd-intake camshaftsprocketfor the
front head
l trd-water pump pulley
TIMING MARKS ON
LEFT SIDE VALVE COVER
91251gb5
l Ah-intake camshaftsprocketfor the rear
head
l 5th-exhaust camshaftsprocketfor tile
rear head
l Gth-idler pulley
l 7th-crankshaft sprocket
l 8th-tensioner pulley
21. Turn the tensionerpulleyso its pin holesare
locatedabovethe centerbolt. Thenpressthe ten-
sionerpulleyagainstthe timing beltand simultane-
ouslytightenthe centerbolt.
22. Makecertainthat all timing marksare still
aligned.If so, removethe 4 clips.
23. Turn the crankshaftl/d turn counterclockwise,
thenturn it clockwiseuntil all timing marksare
aligned.
24. Loosenthe centerbolt on the tensionerpul-
ley. Usingtool MD998767 or equivalentanda torque
wrench,applya torqueof 7 ft. Ibs. (10 Nm).Tighten
the tensionerbolt; makesurethe tensionerdoesn’t
rotatewith the bolt.
25. Removethe set wire attachedto the autoten-
sioner,if the wire was not previouslyremoved.
26. Rotatethe crankshaft2 completeturns clock-
wise and let it sit for approximately5 minutes.Then,
makesurethe set pin caneasily be insertedand re-
movedfrom the hole in the tensioner.
27. Measurethe autotensionerprotrusion(the
distancebetweenthe tensionerarm and autoten-
sioner body)to ensurethat it is within 0.15-0.18 in.
(3.8-4 5mm). If out of specification,repeatSteps
l-4 until the specifiedvalueis obtained.
28. Makesureall piecesof packingare posi-
tioned in the inner groovesof the lowercover, posi-
tion cover on engineand install mountingbolts in
their original location.
3-46 ENGINEANDENGINEOVERHAUL
29. Installthe enginesupportbracketand secure
using mountingbolts in their original location.Lubri-
catethe reamingareaof the reamerbolt and tighten
slowly.
30. Installthe idler pulley.
31. Installthe enginemountbracket.Removethe
enginesupportfixture.
32. Make sureall piecesof packingare posi-
tioned in the innergroovesof the uppercoverand in-
stall.
33. Connectthe brakefluid levelsensor.
34. Installthe crankshaftpulley.Tightenthe bolt
to 130-137ft. Ibs. (180-190 Nm).
35. installthe belt tensionerassemblyandthe
powersteeringbelt.
36 installthe air hoseand pipe.
37 Installthe alternator.
38. Installthe cruisecontrol actuator.
39. Installthe engineundercover.
40. Connectthe negativebatterycable.
199546 MODELS
# See Figure 186
1, Positionthe engineso the No. 1 cylinder is at
TDC of its compressionstroke.
2. Disconnectthe negativebatterycable.
3. Removethe engineundercover.
4 Removethe cruisecontrol actuator.
Timing marks
(on right
rocker cover) Camshaft sprocket
Crankshaft sprocket
Fig. 186 Sprocketalignment for timing belt installation-1995116 Diamantewith the 3.N (6672) DDDDengine
5. Removethe alternator,Removethe air hose
andpipe.
6. Removethe belt tensionerassemblyand the
powersteeringbelt.
7. Removethe crankshaftpulley.
8. Disconnectthe brakefluid levelsensor.
9. Removethe timing belt uppercover.
10. Usingthe properequipment,slightly raisethe
engineto takethe weightoff the side enginemount.
Removethe enginemountbracket.
11, Removethe alternator/airconditioneridler
..,,ll^,.
pu,ey.
12. Removethe enginesupportbracket.The
mountingbolts are differentlengths;markthemfor
, . installation.
orooer
13. Removethe timing belt lowercover.Timing
bolt cover mountingbolts aredifferentin length,note
their position during removal.
Be sure to disconnectthe negativebattery
cable. Wait at least 90 secondsafter the neg-
ative batterycable is disconnectedto prevent
possibledeploymentof the air bag.
14. If the sametiming belt WIIIbe reused,mark
the directionof thetrming belts rotationfor installa-
tion In the samedirection,Besurethe engineis posi-
tionedso the No. 1 cylinder is at the TDC of its com-
pressionstrokeand the timing marksarealignedwith
the engine’stiming mark indicatorson the reartiming
covers.
Turningthe camshaftsprocketwhen the tim-
ing belt is removedcould causethe valves to
contactwith the pistons,resulting in severe
enginedamage.
15. Removethe bolts that securethe auto-ten-
sionerto the engineblock and removethe tensioner.
To install:
*The auto-tensionerassemblymustbe re-
set to correctlv
_ adiust
- belt tension.
16. Loosenthe centerbolt of tensionerpulleyto
providetiming beltslack.
17. Removethe timing belt assembly.
18. Posrtionthe auto-tensionerinto a vise with
soft iaws.Theolua at the rearof tensionerprotrudes,
be sureto usea v&her as a spacerto protectthe
plugfrom contactingvise jaws.
19. Slowlypushthe rod mtothe tensioneruntil
the set hole in rod is alignedwith set hole in the
auto-tensioner.
20. Inserta 0.055 in. (1.4mm)wire into the
alignedset holes,Removethe tensionerfrom the vise
and install it on the engine.
21. Tightentensionermountingbolts to 17 ft. Ibs.
(24 Nm).
Timing marks
mark (on oil pump case)

DONOTrotate or turn the camshaftswhen re-
movingthe sprocketsor severe enginedam-
age will result from internal componentin-
terference.
22. Align the markon the crankshaftsprocket
with the mark on the front case.Then,movethe
crankshaftsprocket1 tooth counterclockwise.
23. Align the timing marksof the camshaftswith
the markson the rearcovers.
24. Using largepaperclips to securethe timing
belt to the sprockets,installthe timing belt in the fol-
lowing order.Besurecamshafts-to-cylinderheads
and crankshaft-to-frontcovertiming marksare
aligned.Installthe timing belt aroundthe pulleysin
the following order:
a. Exhaustcamshaftsprocket(front bank).
b. Intakecamshaftsprocket(front bank).
c. Waterpump pulley.
d. Intakecamshaftsprocket(rear bank).
e. Exhaustcamshaftsprocket(rear bank).
f. Tensionerpulley.
g. Crankshaftpulley.
h. Idler pulley.
*Since the camshaftsprocketsturn easily,
securethem with box wrencheswhen in-
stalling the timing belt.
25. Align all timing markson the crankshaftand
raisethe tensionerpulleyagainstthe belt to remove
slack,snugtensionerbolt.
26. Checkthe alignmentof all the timing marks
and removethe clips that securethe timing beltto the
camshaftsprockets.
27. Rotatethe engine1/4turn counterclockwise,
then rotatethe engineclockwiseto align the timing
marks.Checkthat all the timing marksare in align-
ment.
28. Loosenthe centerbolt on the tensionerpul-
ley.
29. Usingtool MD998752 or equivalentand a
torquewrench,apply 84 inch Ibs.(10 Nm) to the tool
on the tensioner.Tightenthe tensionerbolt to 35 ft.
Ibs.(49 Nm) and besurethe tensionerdoesnot ro-
tatewith the bolt.
Timing marks
Fig. 187 Cleanthe timing marksto verify their position when aligning-3.51 engine
ENGINEANDENGINEOVERHAUL
3-47
30. Rotatethe crankshafttwo completeturns
clockwiseand let it sit for approximatelyfive minutes.
Then,checkthat the set pin caneasily be inserted
and removedfrom the hole in the auto-tensioner.
31. Removethe set wire attachedto the auto-ten-
sioner
32. Measurethe auto-tensionerprotrusion(the
distancebetweenthe tensionerarm and auto-ten-
sioner body)to ensurethat it is within 0.15-0.18 in.
(3.8-4.5mm). If out of specification,repeatadjust-
mentprocedureuntil the specifiedvalueis obtained.
33. Checkagainthatthe timing markson all
sprocketsare in properalignment.
34. Installthe timing belt coversand all otherap-
plicablecomponents.
3.51 Engine
p See Figure 187
1. Disconnectthe negativebatterycable.
2. Drainthe cooling system.
Neveropen, service or drain the radiator or
cooling systemwhen hot; serious burnscan
occurfrom the steamand hot coolant. Also,
when draining enginecoolant, keepin mind
that cats and dogsare attractedto ethylene
giycoi antifreezeand could drink any that is
left in an uncoveredcontaineror in puddles
on the ground.This will prove fatal in suffi-
cient quantities.Always drain coolant into a
sealable container.Coolantshouldbe reused
unlessit is contaminatedor is several years
old.
3. Removethe drive belts.
4. Removethe upperradiatorshroud.
5. Removethe fan and fan pulley.
6. Withoutdisconnectingthe lines, removethe
powersteeringpumpfrom its bracketand position it
to the side Removethe pumpbrackets.
7. Removethe belttensionerpulleybracket.
8. Withoutreleasingthe refrigerant,removethe
air conditioningcompressorfrom its bracketand po-
sition it to the side.
9. Removethe bracket.
liming marks
Tinning marks
79245934
10. Removethe cooling fan bracket.
11, On somevehiclesIt may be necessaryto re-
movethe pulleyfrom the crankshaftto accessthe
lowercover bolts.
12. Removethe timing belt cover bolts and the
upperand lowercoversfrom the engme.
13. Detachthe crankshaftpositionsensorcon-
nector
14. UsingSSTMB9g67-01 and MD998754,or
their equivalents,removethe crankshaftpulleyfrom
the crankshaft.
15. Usea shop ragto cleanthe timing marksto
assist in properlyaligningthe timing marks.
16. Loosenthe centerbolt on the tensionpulley
and removethe timing belt.
@if the sametiming belt will be reused,
markthe direction of timing belt’s rotation,
for installation in the samedirection. Be sure
engine is positionedso No. 1 cylinder is at
the TDCof it’s compressionstroke andthe
sprocketstiming marksare alignedwith the
engine’stiming mark indicators.
17. Removethe auto-tensioner,the tensionpul-
ley and the tensionarm assembly.
18. Removethe sprocketsby holdingthe hexago-
nal portion of the camshaftwith a wrenchwhile re-
movingthe sprocketbolt.
To install:
19. Installthe crankshaftpulleyand turn the
crankshaftsprockettiming markforward(clockwise)
threeteethto movethe piston slightly past No. 1
cylindertop deadcenter.
20. If removed,installthe camshaftsprocketsand
tightenthe bolts to 64 ft. Ibs. (88 Nm).
21, Align the timing markof the left bankside
camshaftsprocket.
22. Align the timing markof the right bankside
camshaftsprocket,and hold the sprocketwith a
wrenchso that it doesn’tturn.
23. Setthe timing belt ontothe waterpumppul-
ley.
24. Checkthat the camshaftsprockettiming mark
of the left bankside is alignedand clampthe timing
belt with doubleclips.
25. Setthe timing belt onto the idler pulley.
if any bindingis felt when adjustingthe tim-
ing belt tension by turningthe crankshaft,
STOPturningthe engine, becausethe pis-
tons may be hitting the valves.
26. Turn the crankshaftoneturn counterclock-
wise and setthe timing belt ontothe crankshaft
sprocket.
27. Setthe timing belt on the tensionpulley.
28. Placethe tensionpulleypin hole so that it is
towardsthe top. Pressthe tensionpulleyontothe
timing belt,andthen provisionallytightenthe fixing
bolt. Tightenthe bolt to 35 ft. Ibs. (48 Nm).
29. Slowlyturn the crankshafttwo full turns in the
clockwisedirectionuntil the timing marksalign. Re-
movethe four doubleclips.
30. Installthe crankshaftpositionsensorconnec-
tor.
31. Installthe upperand lowercoverson the en-
gine and securethemwith the retainingscrews.Be
surethe packingis properlypositionedin the inner
groovesof the coverswhen installing.
 .
3-48 ENGINEANDENGINEOVERHAUL
32. Installthecrankshaftpulleyif it wasremoved.
Tightentheboltto 110ft. Ibs.(150Nm).
33. Installtheairconditioningbracketandcom-
pressorontheengine.Installthebelttensioner.
34. Installthepowersteeringpumpintoposition.
Installthefanpulleyandfan.
35. Installthefanshroudontheradiator.
36. Refillthecoolingsystem. I
37. Connect thenegative batterycable.
38. Starttheenaineandcheckforfluidleaks.
INSPECTION

ti See Figures 188 thru 195

Fig. 188 CIneeK
’ ror
m prematurepanrngof the Fig. 189 Checkif the teeth are cracked or
Aninspection of thetimingbeltshouldbeper- , belt 1 1damaged
IIUIIII~U
^__^-Iat^I I---.--
IWSIarly I.-. II. .- I.ommg
me meupper
. Ioerr
I.cover I
isoff. Ifthetiminabeltshowsanvsiansof failure.it
shouldbereplaced. Recommended timingbeltre:
placement intervalscanbefoundin Section1 of this
manual.

; REMOVAL&INSTALLATION

u See Figure 198

Onall engines,thecamshaft oil sealrepuiresthe Fig. 191You may only have damageon one
removalof thetimingbelt(s).It is advisedto replace Fig. 190 look for noticeable cracks or wear side of the belt; if so, the guide-could be 1
thesealwhilereplacing thetimingbelts. on the belt face the culprit
*The seal is locatedbehindthe crankshaft
timino sorocket.
” .
I I
1. Toremove thesealusea suitablesealremoval
toolandpryit outofthecover.
2. Thoroughly cleanthesealingareaof thefront
i
fYi”f.V
““.“I.

3. Usinga suitableinstallation tool(a large

socketworkswellif noneis available), installtheseal
intothr?frontcover,

EnI
Make surf!to install the seal to the correct
depth,if the seal is installed too far, an oil
leak will occur.
Fig. 192 Foreign materials can get in be-
tween the teeth and cause damage fraying, gla&g or damageof any kind ’

REMOVAL&INSTALLATION

1.!I Engine
+ See Figures 197 and 198
1. Disconnectthenegativebatterycable.
2. Rotate
theengineandpositiontheNo.1 pis-
tonto TDCof itscompression stroke.
3. Disconnecttheaccelerator
cable,breather
hoseandPCVhoseconnections.
4. Matchmark thepositionino
of thedistributor

c
housingandthepositioning of thedistributor
rotorto0
theengineblockandremove thedistributor.
Fig 194 Damage on only one side of the Fig. 195 ALWAYSraplace the timing belt at
. 5. Remove thevalvecoveranddiscardthegas-
timing belt may indicate a faulty guide the interval soecified br the manufacturer
Itet.
6. Loosenbothrockerarmassemblies gradually
andevenly,andremove therocketshaftsfromtheve- *DO NOTallow the camshaftor the crank- 8. Remove thetimingbeltassembly.
hicle. shaft to rotate after the timing belt is re- 9. Holdingthecamshaft sprocket
fromturning,
7. Removethetimingbeltcovers. moved. loosenandremove theboltthatsecuresthesprocket.
 ENGINEANDENGINEOVERHAUL
3-49
10. Removethe camshaftsprocketfrom the
camshaft.Notethe positioningof the dowelpin at the
end of the camshaft.
11. Removethe camshaftoil sealfrom the front
of the cylinder head.
12. Removethe camshaftfrom the head.
13. Carefullycheckall partsfor damageand
wear
To install:
011 pump 14. Lubricatethe camshaftwith heavyengineoil
MS8
and slide it mto the head.Be sureto positionthe
dowelpin at the 12 o’clockposition.
15. Checkthe camshaftend-playbetweenthe
thrust caseand camshaft.The camshaftend-play
should be0.002-0.008 m (0.05-O 20mm). If the
end-playis not within specification,replacethe
camshaftthrust bearing.
16 Installa newcamshaftoil seal.Besureto Iu-
bricatethe lips of the sealwith cleanengine011.
17. Installthe camshaftsprocketand install the
mountrngbolt. Tightenthe bolt to 51 ft. Ibs.(70 Nm)
while holdingthe camshaftfrom turning.
7923PG51 18. Installthe timing belt assembly.
Fig. 196 Crankshaftseal installation-Dia 19. Installthe timing belt covers. Fig 199Camshaft rocker arm andshaft as-
manteshown, others similar 20. Installthe rockershaftassemblies.Torquethe (r.mblies-1.8L Agine g3i53033
bolts graduallyand evenlyto 23 ft. Ibs.(32 Nm).
21. Checkvalveadjustmentand installthe valve 15. Carefullycheckall partsfor damageand
coverwith a newgasket.Tightenthe valve cover bolt
wear.
to 16 inch Ibs (1.8 Nm). To install:
22 Align the distributormarksand installthe
16. Lubricatethe camshaftjournalsand camshaft
distributor. with cleanengineoil and install the camshaftin the
23. Connectthe acceleratorcable,breatherhose cylinderhead.Besureto positionthe dowelpin at
and PCV hose. the end of the camshaftas notedduringthe removal
24. Connectthe negativebatterycableand check
procedure.
the ignition timing
17. Checkthe camshaftend-playbetweenthe
1.8L Engine thrustcaseand camshaftThe camshaftend-play
shouldbe 0.002-0.008 in. (0.05-0.20mm). If the
# See Figure 199 end-playIS not within specification,replacethe
camshaftthrust bearing
1. Disconnectthe negativebatterycable 18. Installa newcamshaftoil seal.Be sureto Iu-
2. Rotatethe engineand positionthe No. 1 pis- bricatethe lips of the sealwith cleanengineoil.
ton to TDC of its compressionstroke. 19. Installcamshaftsprocketandtorquethe re-
3. Labeland disconnectthe sparkplug cables. tainerbolt to 65 ft. Ibs. (90 Nm). Besureto secure
4. Matchmarkthe positronrngof the distributor the sprocketwhile tighteningthe bolt.
housingandthe positioningof the distributorrotor to 20 Installthe timing belt assembly.
the engineblock and removethe distributor. 21. Installthe timing belt covers.
5. Detachthe air flow sensorconnectorand re- 22. Installthe rockerarm and shaftassemblies.
movethe air cleanercasecover. Tightenthe rockerarm shaftretainerbolts to 23 ft.
6. Drsconnectthe acceleratorcable,breather Ibs (32 Nm).
hoseand PCVhoseconnections. 23 Checkthe valve adjustmentand install the
7. Removethe rockercover and discardthe valve coverwith a newgasket.Tightenthe valve
:ig. 197 Camshaft,rocker arm andshaft as gasket. cover bolts to 29 inch Ibs.(3.3 Nm).
remblies-1.5L engine 8. Loosenboth rockerarm shaftassemblies 24. Align the distributor marksand install the
graduallyand evenlyand removethe rocketshafts distributor.
from the vehicle.Do not disassemblyrockerarms 25. Connectthe sparkplug cables.
and rockerarm shaftassemblies. 26. Connectthe acceleratorcable,breatherhose
9. Removethe timing belt covers. and PCVhose.
27. Attachthe air flow sensorconnectorand in-
stall the air cleanercasecover.
DONOTallow the camshaftor the crankshaft 28. Connectthe negativebatterycable.
to rotate after the timing belt is removed! 29. Runthe engineat idle until normaloperating
temperatureis reached.
10. Removethe timing beltassembly. 30. Checkidle speedand ignition timing and ad-
11. Holdingthe camshaftsprocketfrom turning, just as required.
loosenand removethe bolt that securesthe sprocket.
7923PG5
12. Removethe camshaftsprocketfrom the 2.OLSDHCEngine
Fig. 198 Positioning of the camshaftdowe camshaft.Notethe positioningof the dowelpin at the # See Figure 200
pin-Mirage 1.5L (4615) engine end of the camshaft.
13. Removethe camshaftoil sealfrom the front 1. Disconnectthe negativebatterycable.
of the cylinderhead. 2. Disconnectthe breatherand the PCVhoses
14. Removethe camshaftfrom the head.

3-50 ENGINEANDENGINEOVERHALJL
93153QO2
F:ig. 200 Camshaft,rocker arm andshaft as-
1 iemblies-2.01 SOHCermine
s terial on matingsurfaces,
3. Removethe acceleratorcablebracketand po-
sition the cableaside.
4. Install lashadjusterretainertools MD998443
or equivalent,to the rockerarm.
5. Removethe valve coverand semi-circular
packing.
6. Matchmarkthe distributorhousingto the
cylinderhead,and removethe distributor,
7. Removethe timing belt coversand the timing
belt.
8 Removethe camshaftsprocket.
9. Removethe carrier bolts and removethe
rockerarms,rockershaftsand bearingcapsfrom the
engineas an assembly.
10. Removethe camshaftfrom the cylinderhead.
11. Inspectthe bearingjournalson the camshaft
for excesswearor damage.
12. Measurethe cam lobe heightand compareto
the
desiredreadings.
13. Inspectthe bearingsurfacesin the cylinder
head.
14. Replaceany componentsthat are damagedor
show signs of excesswear,
To install:
15. Lubricatethe camshaftjournalsand camshaft
with cleanengineoil and installthe camshaftin the
cylinderhead.
16. Align the camshaftbearingcapswith the ar-
row marks(dependingon cylindernumbers)and in-
stall in numericalorder,
17. Installthe rockershaftassemblyto the cylin-
der head.Torquethe bearingcap bolts from the cen-
ter outward,in threesteps,unh a final torqueof 15
ft. Ibs. (20 Nm) is reached.
18. Apply a coatingof engineoil to the oil seal.
Usingthe propersize driver, press-frtthe seal into
the cylinderhead.
19. install the camshaftsprocketand torquere-
taining bolt to 65 ft. Ibs. (90 Nm).
20. Installthe timing belt.
21. Ahgn the matchmarksand installthe distrrbu-
tor.
22. Removethe lashadjusterretainingtools.
23. Installthe valvecover and all relatedparts
24. Connectthe negativebatterycableand run
engineto checkfor leaks,
25. Checkand adjust ignition timing, if neces-
sary.
l.‘6L and 2.lJL DOHCEngines
6 See Figures 201 and 202
1. Disconnectthe negativebatterycable.
2. Removethe acceleratorcablebracketand po-
sition the cableaside.
3. Removethe breatherhoseand disconnectthe
PCVhose.
4. Labeland disconnectthe sparkplug cables.
5. Matchmarkthe distributorhousingto the
cylinderhead,and removethe distributor.
6. Removethe rockercover.
7. Install lashadjusterretarnertools MD998443
or equivalent,to the rockerarm.
93153gO:
:ig. 201 Camshaftand rocker arms-i.61
rnd 2.OLDOHCengines
r ,
w Camshaft sprocket side
ei i i ij
.
8. Removethe timing belt coversand the timing
belt assembly.
9. Removethe camshaftsprocketretainerbolt
while holding shaftstationarywith an appropriate
wrench.Removethe sprocketfrom the shaft.
10. Removethe camshaftoil seal.
11. Removeboth rockerarm shaftassemblies
from the head.Do not drsassemblethe rockerarms
and rockerarm shaftassemblies.
12. Removethe camshaftfrom the cylinderhead.
13. inspectthe bearingjournalson the camshaft,
cylinderhead,and bearingcaps.
To install:
14. Lubricatethe camshaftjournalsand camshaft
with cleanengineoil and installthe camshaftin the
cylinderhead.
15. Installthe rockerarm and shaftassemblies.
Tightenthe rockerarm shaft retainerbolts to 21-25
ft. Ibs. (2935 Nm).
16 Apply a coatingof engineoil to the oil seal.
Usingthe propersize driver, press-fitthe seal into
the cylinderhead.
17. Instal!camshaftsprocketand retainerbolt.
Tightenthe bolts to 65 ft. Ibs. (90 Nm).
18. Installthe hming belt and belt covers.
19. Align the matchmarksand installthe distribu-
tor.
20. Removethe lashadjusterretainingtools,
21. Installthe rockercover using newgasketma-
22. Connectthe sparkplug cables.
23. Installthe breatherhoseand connectthe PCV
hose.
24. Connectthe negativebatterycable.
25. Runthe engmeat idle until normaloperating
temperatureis reached.Checkidle speedand igni-
tion timing; adjustas required.
2.4L Engine
) See Figures 203 and 204
1. Relievethe fuel systempressurefollowing
properprocedure.
2. Disconnectthe negativebatterycable.
3. Disconnectthe acceleratorcable,PCV hoses,
breatherhoses,sparkplug cablesand the removethe
valve cover.
*Always rotate the crankshaftin a clockwise
direction. Make a mark on the backof the
timing belt indicatingthe direction of rotation
so it may be reassembledin the samedirec-
tion if it is to be reused.
4. Rotatethe crankshaftclockwiseand align the
timing marksso that the No. 1 pistonwill be at TDC
of the compressionstroke.At this time the timing
markson the camshaftsprocketand the uppersur-
face of the cyhnderheadshouldcoincide,andthe
dowel pin of the camshaftsprocketshould beat the
upperside.
5 Removethe timing belt upperand lowercov-
ers.
6. Removethe camshafttiming belt.
7. Usea wrenchbetweenthe No 2 and No. 3
journalsto hold the camshaft;removethe camshaft
sprockets.
8 Loosenthe bearingcap bolts in 2-3 steps.
Labeland removeall camshaftbearingcaps,
*If the bearingcapsare difficult to remove,
use a plastic hammerto gently tap the rear
part of the camshaft.

:ig. 203 Camshaft,rocker arm and shaft assemblies-2.41 engine
Intake side Exhaust side
7923PG57
Fig. 204 Camshaftidentification-2.41 en-
gine
9. Removethe intakeand exhaustcamshafts.
10. Removethe rockerarmsand lashadjusters
*It is essentialthat all parts be kept in the
sameorder and orientationfor reinstallation.
In order to preventconfusionduring installa-
tion, be sure to markandseparateall parts.
To install:
11. Installthe lashadjustersand rockerarms into
the cylinderhead.Lubricatelightlywith cleanoil
prior to installation.
12. Lubricatethe camshaftswith heavyengineoil
and positionthe camshaftson the cylinderhead.
13 Checkthe camshaftjournalsand lobesfor
wearor damage.Also, checkthe cylinderheadoil
holesfor clogging.Visually inspectthe rockerarm
roller and replaceif dented,damagedor evidenceof
seizureis evident.Checkthe roller for smoothrota-
tion. ReplaceIf excessplay or bindingis present.
Also, inspectthe valve contactsurfacefor possible
damageor seizure.It is recommendedthat all rocker
armsand lashadjustersbe replacedtogether.
*Do not confusethe intake camshaftwith
the exhaustcamshaft.The intake camshaft
has a split on the rear face for driving the ,
crankangle sensor.
14. Makesurethe dowelpin on bothcamshaft
sprocketendsare locatedon the top.
15. Installthe bearingcaps.Tightenthe capsin
sequenceand rn 2 or 3 steps.No 2 and 5 capsare of
the sameshape.Checkthe markingson the capsto
identifythe cap numberand intake/exhaustsymbol.
ENGlNEANDENGlNEOVERHALiL
3-51
5. Removethe centercover,breather,PCV
hoses,and the sparkplug cables.
6. Removethe rockercover and the semi-circu-
lar packing.
7. Matchmarkthe position of the crankshaftpo-
sition sensorat the rearof the camshaft,then remove
the sensor.
8. If equippedwith a camshaftsensor,remove
the sensorfrom the front of the engine.
9 Beingsureto hold the flats of the camshaft,
loosenthe camshaftsprocketbolts.
10. Notingthe positionmgand locationof the
sprockets,removethe sprocketsfrom the camshafts.
*Be sure to note the positioningof the knock
pin at the end of the camshaftsfor reinstalla-
tion purposes.
*Be sure to keepthe valve train components
labeled and in properorder for reassembly.
11. Loosenthe bearingcap bolts in 2-3 steps.
9315393'
12. Labeland removeall camshaftbearingcaps.
*If the bearingcapsare difficult to remove,
use a plastic hammerto gently tap the com-
Only1 (intake)or I? (exhaust)is stampedon No. 1 ponents.
bearingcap Also, makesurethe rockerarm is cor- 13. Mark the componentsand removethe intake
rectly mountedon the lash adjusterand the valve and the exhaustcamshafts.
stemend.Torquethe retainingboltsto 15 ft. Ibs.(20 14. Removethe rockerarmsand the lashad-
Nm). justers.Be sureto notethe locationof the valve train
16. Apply a coatingof engineoil to the oil seal. componentsfor reinstallationpurposes.
Usingthe propersize driver, press-fitthe seal into
the cylinderhead.
17. Installthe camshaftsprockets.While holding
the camshaftat its hexagon,betweennumber2 and 3
journalstightensprocketbolts to 58-72 ft. Ibs.
(80-l 00 Nm).
18. Installthe timing belt,coversand related
components.
19. Installthe valve cover, using newgasket,and
reconnectall relatedcomponents
20. Reconnectthe negativebatterycable.
3.OLDOHCEngine
# See Figures 205 and 206
1. Relievethe fuel systempressure.
2. Disconnectnegativebatterycable.
3. Removethe intakemanifoldplenum.
4. Removethe timing belt cover andthe timing
belt.
DONOTrotate the crankshaftor camshafts
after the timing belt has beenremoved.If ro-
tated, severe internal enginedamagewill re-
sult from the pistonshitting the valves.
1semblies-3.01 DOHCengine I
Left bank
7923PG58
Fig. 206 Proper positioning of the camshaftknock pins-3.01 DOHCengine
 .
3-52 ENGINEANDENGINEOVERHAUL
15. Checkthe camshaftjournalsfor wearor dam-
age.Checkthe cam lobesfor damage.Also, check
the cylinderheadoil holesfor clogging.
To install:
*Lubricate the valve train components with
clean engine oil.
16. Bleedand installthe lashadjustersto the to
the original boresin the cylinderhead.
17. Installthe rockerarmsto the cylinderhead.
18. Lubricatethe camshaftswith cleanengineoil
and position the camshaftson the cylinderhead
Siit
7923'659

Fig. 208 Right bank camshafl identifica-

Be sure to properly position the knock pins of tion-3.01 SDHC engine
the camshaft to prevent valve to piston inter-
ference.
Right bank Left bank

*Do not confuse the intake camshaft with

the exhaust camshaft. The intake camshaft
on the Diamante has a B or J stamped on the
hexagon depending on the application. The
exhaust camshaft on the Diamante has a D or
K stamped on the hexagon depending on ap-
plication.
-Install the bearing caps according to the 7923PG60

identification mark and cap number. Bearing Fig. 207 Camshaft, rocker arm and shaft as- Fig. 209 Proper positioning of the
caps No. 2,3 and are marked as such. The iemblies-3.01 SDHC engine :amshafts-3.OL SDHC enoine
caps also are marked I for intake or E for ex-
haust.
19 Installthe bearingcaps.Tightenthe caps in
sequence,graduallyin 2 or 3 steps Caps2,3 and 4
havea front mark. Installwith the markalignedwith
the front markon the cylinderhead.Torquethe re-
taining bolts for capsNo. 2,3 and 4 to 8 ft. Ibs. (11
Nm) and torquethe retainingboltsfor the front and
rearcapsto 14 ft. Ibs.(20 Nm).
20. Apply a coatingof engineoil to the oil seals
and installthe oil sealsto the front and rearof the \
Tmngboltside Armwmark(cql~ndertmad)
camshafts.
21. Holdingthe flats of the camshaft,installand
tightenthe sprocketboltsto 65 ft. Ibs.(90 Nm).
22. If removed,installthe camshaftpositionsen-
sor andtightenthe mountingboltsto 78 inch Ibs. (9
Nm).
23. Aligning the matchmark,installthe crankshaft
position sensorat the rearof the camshaftand
tightenthe mountrngnut to 7 ft. Ibs. (12 Nm).
24. Align the markson the camshaftand crank-
7923PG61
shaftsprockets.Installthe timing belt assembly.
25. Installthe rockercover and the semi-circular :ig. 210 Alignment of the rocker shafts and application of sealant-3.01 SDHC engine
packing.
26. Installthe intakemanifoldplenum. ,. 5. ,.^.
Removethe distributorhousingadapterand 11. Removethe rockerarms, rockershaftsand
27. Installthe sparkplug cables,centercover, aiscara
^ tne
- u-rmg. bearmgcaps,as an assembly
breatherand PCV hoses. 6; Kemovethe valve coversand the tlmmg belt. 12. Removethe camshaftfrom the cylinderhead.
28. Connectthe negativebatterycableand check 7 Usingcamshaftsprocketholdingtool 13. Inspectthe bearingjournalson the camshaft,
for leaks. MB9g67 and MD998719 or equivalent,hold the cylinder head,and bearingcaps.
sprocketand loosenthe bolt. To install:
3.OL SDHC Engine 8. Removethe bolt and notethe positioningof
the of the knockpin at the end of the camshaftand *The right bank camshaft is identified by a
ti See Figures 207, 208, 209, and 210 4mm slit at the rear end of the camshaft.
removethe sprocket.
1. Disconnectthe negativebatterycable, 9. Installauto lashadjusterretainertools 14. Lubricatethe camshaftjournalsand camshaft
2. Rotateand positionthe engineto TDC of MD998443 or equivalent,on the rockerarms. with cleanengmeoil and installthe camshaftin the
compressionstroke. *Be sure to note the position of the rocker cylinderhead Be sureto properlypositionthe knock
3. If removingthe right side (front) camshaft, arms, rocker shafts and bearing caps for re- pin of the camshaftas notedduring removal.
matchmarkthe distributorrotor and distributorhous- installation purposes. 15. Apply sealerat the endsof the bearingcaps
ing to the engineblock and removethe distributor. and installthe rockerarms, rockershaftsand bearing
4. Removethe Intakemanifoldplenumstay 10 Removethe camshaftbearingcapsbut do not capsas an assembly Properlypositronthe arrowson
bracket. removethe boltsfrom the caps. the bearingcaps.

16. Torquethe bearingcap bolts in the following
sequence:No. 3, No. 2, No. 1 and No. 4 to 85 inch
Ibs. (10 Nm).
17. Repeatthe sequenceincreasingthe torqueto
14ft. Ibs. (20 Nm).
18. Removethe auto lashadjusterretainertools
from the rockerarms.
19. Installthe camshaftsprocketand bolt.
20. Usingcamshaftsprocketholdingtool
MB9g67and MD998719 or equivalent,hold the
sprocketand tightenthe bolt to 65 ft. Ibs. (90 Nm).
21. Installthe timing beltand valve covers.
22. Usinga newO-ring, install the distributorex-
tensionhousing.
23. Installthe intakemanifoldplenumstay
bracket.
24. Installthe distributorassembly Besureto
align the rotor and distributorhousingmatchmarks.
25. Connectthe negativebatterycableand check
for leaks.
3.5L Engine
+ See Figures211 and 212
1. Disconnectthe negativebatterycable.
2. Removethe timing belt. Referto the timing
belt procedurein this section.
3. Removethe rockerarm cover.
4. Installthe lashadjusterclips on the rocker
arms,then loosenthe bearingcap bolts. Do not re-
move the bolts from the bearingcaps.
5. Removethe rockerarms,shaftsand bearing
capsas an assembly.
6. Removethe camshafts.
To install:
7. Lubricatethe camshaftswith engineoil and
positionthemon the cylinderheads.
8. Positionthe dowelDinsas shownin the
drawing.
9. Installthe bearingcaps/rockerarm assem-
blies. Tightenthe bolts to 23 ft. Ibs. (31 Nm).
10. hstall the rockerarm cover using a newgas-
ket.
11. Installthe timing beltand remainingcompo-
nents Referto the timing belt procedurein this sec-
tion.
12. Connectthe negativebatterycable.
INSPECTION
CamshaftLobe Liff
Camshaftlobe lift is the amount(measuredin
inchesor millimeters)that the camshaftis capableof
LIFTINGthe valve train componentsin orderto open
the valves.The lobe lift is a measureof how much
taller the “egg shaped”portionof the camshaftlobe
is abovethe baseor circular portionof the shaft lobe.
Lift is directlyproportionalto howfar the valvescan
openand a worn camshaft(with poor lobe lift) cannot
fully openthe valves.The lobe lift thereforecan be
directly responsiblefor properor poor engineperfor-
mance.
Lobe lift can be measuredin 2 ways,depending
on whattools areavailableand whetheror not the
camshafthasbeenremovedfrom the engine.A dial
gaugecan be usedto measurethe lift with the
camshaftinstalled,while a micrometeris normally
only usedoncethe shafthas beenremovedfrom the
engine.
ENGINEANDENGINEOVERHAUL
3-53
10 Rocker arm shaft
11 Lash ad,uster
12 Rocker arm C
13 Rocker arm six,,
14 Lash adluster
15 Thrust case
16 orng
17 Camshan
1923PGD
:ig. 211 Explodedview of the camshaftmounting-3.51 engine
3. Turn the crankshaftover until the tappetis on
Rear bank Front bank
the basecircle of the camshaftlobe.
4. Zerothe dial indicator.Continueto rotatethe
crankshaftslowly until the pushrod(or camshaft
lobe) is in the fully raisedposition.
5. Comparethe total lift recordedon the dial indi-
catorwith the elevationspecificationshownin the
EngineSpecificationchart.
To checkthe accuracyof the original indicator
reading,continueto rotatethe crankshaftuntil the in-
7923PGD4
dicatorreadszero.If the lift on any lobe is below
Fig. 212 Camshaftdowel position duringin- specifiedwearlimits listed,the camshaftand the
stallation-3.51 engine valvetappetsmust be replaced.
6. Installthe valve cover(s).
DIALGAUGEMETHOD
MICROMETER
Lobe lift maybe checkedwith the camshaftin-
stalled.In all cases,a dial gaugeis positronedsome- ) See Figure 213
whereon the valvetrain (pushrod,lifter, or camshaft
itself) and the camshaftis thenturnedto measurethe A micrometermay usedto measurecamshaftlobe
lift, butthis is usuallyonly after it hasbeenremoved
lift.
Checkthe lift of eachlobe in consecutiveorder from the engine.Oncethe valve cover is removed
and makea noteof the reading.
1. Removethe valve coverfor accessto the
camshaft.
2. Installa dial indicatorso thatthe actuating
point of the indicatoris directlyplacedon the I
camshaft.
*A remotestarter can be usedto turn the
engineover duringthe next steps. If a re-
motestarter is not available, removethe
spark plugsin order to relieve enginecom- @
pression,andturn the engineover usinga
large wrench or socketon the crankshaft Fig. 213 Camshafflobe IIR Is measuredIn
damperbolt. BESUREto only turn the engine
in the normal direction of rotation.
3-54 ENGINEANDENGINEOVERHALJL
fromthe, accessmay be possible(thougha little 4. Removethe oil filter, oil pressureswitch,oil
awkward)to measurethe camshaftlobes usinga mi- gaugesendingunit, oil filter mountingbracketand
crometer gasket.
In any case,two measurementsare necessaryfor 5. Removeengineoil pan,oil screenand gas-
eachlobe. MeasurementY or the total LOBEHEIGHT ket.
and measurementX or the total LOBEWIDTH.To 6. Removethe relief plug,gasket,reliefspring
find the lobe lift, you simply subtractX from Y (sub- and relrefplunger.
tractthe width from the height). 7. Lowerthe vehicle.
Noteeachmeasurement,then makeyour calcula- 8. Usingthe properequipment,supportthe
tion to determinethe lift. Notethe final resultsand re- weightof the engine.
peatthe processon the remainingcamshaftlobes. 9. Removethe front enginemountbracketand
Finally,you shouldcompareyour resultsto the spec- accessorydrive belt,
ificationschartsand decideif a newcamshaftis in 10. Removethe timing beltsand sprockets.
your future. 11. Usingspecialtool MD998162, removethe
plug cap in the enginefront cover.
12. Removethe plug on the side of the engine
block. Inserta Phillips screwdriverwith a shankdi-
ameterof 0.32 in. (8mm) into the plug hole. This will
REMOVAL&INSTALLATION hold the silent shaft.
13. Removethe drivengearbolt that securesthe
2.OLand 2.4L Engines oil pumpdriven gearto the silent shaft.
14. Removeand tag the front cover mounting
p See Figure 214 bolts. Notethe lengthsof the mountingboltsas they
are removedfor properinstallation.
*A special oil seal guidetool, 18998285, 15. Removethe front casecoverand oil pump
and a plug cap sockettool, MD998182,or ex- assembly.If necessary,the silent shaftcan comeout
act equivalentsare neededto completethis with the coverassembly.
operation. 16. Removethe silent shaftoil seals,the crank-
shaft oil sealand front casegasket
1. Disconnectthe negativebatterycable. 17. Removethe silent shaftsand inspectas fol-
2. Raiseand safelysupportthe vehicle. lows:
3. Drainthe engineoil.
a. Checkthe oil holes in the shaft for clog-
ging.
b. Checkjournals of the shaft for seizure,
The EPAwarns that prolongedcontactwith damageand contactwith bearing.If there is any-
usedengineoil may causea numberof skin thing wrong with the journal, replacethe silent
disorders, includingcancer!Youshould shaft bearing,silent shaft or front case.
makeevery effort to minimizeyour exposure c. Checkthe silent shaft oil clearance.If the
to usedengineoil. Protectivegloves should clearanceis beyondthe specifications,replace
be worn when changingthe oil. Washyour the silent shaft bearing,silent shaft or front case.
handsand any other exposedskin areas as The specificationsfor oil clearancesare as fol-
soon as possibleafter exposureto useden- lows
gine oil. Soapand water, or waterless hand Rightshaft
cleanershouldbe used. l Front-0.0012-0.0024 in. (0.030.06mml
l Rear+0.0008-0.0021 in. (6.02-O 05mm)
Left shaft
l Front-0.002&0.0036 in. (0.05-0.09mm)
l Rear-O.0017-O.0033 in. (0.04-0.08mm)
To install:
18. Lubricatethe bearingsurfaceof the shaftand
the bearingjournalswith cleanengineoil. Carefully
installthe silent shaftsto the block.
19. Cleanthe gasketmaterialfrom the mating
surfaceof the cylinderblockand the enginefront
cover.Install newgasketin place.
20. Installthe oil pumpdrive gearand driven
gearto the front case,lining up the timing marks.
21. Lubricatethe gearswith cleanengineoil. In-
stall the oil pumpcover,with newgasketin placeand
tightenthe mountingboltsto 13 ft. Ibs.(18 Nm).
22. Usingpropersizedriver, install the crankshaft
oil seal into the front enginecase.
23. Usingthe propersizesocketwrench,pressin
the silent shaftoil seal into the front case.
24. Placepilot tool MD998285 or equivalent,
ontothe noseof the crankshaft.Apply cleanengine
oil to the outercircumferenceof the pilot tool.
93153g3 25. Installthe front caseonto the engineblock
:ig. 214 Explodedview of the balanceshaf and temporarilytightenthe flangebolts (otherthan
assemblies-2.01 and 2.4L enoines thosefor tighteningthe filter bracket).
26. Mountthe oil filter bracketwith newgasketin
place.Installthe 4 bolts with washersand tightento
16 ft Ibs. (22 Nm).
27. Insertthe Phillips screwdriverinto the hole
on the side of the engineblock.
28. Securethe oil pumpdriven gearonto the left
silent shaftby tighteningthe driven gearflangebolt
to 29 ft. Ibs. (40 Nm).
29. Installa newO-ring ontothe groove in the
front case.Usingspecialsockettool, installand
tightenthe plug capto 20 ft. Ibs (27 Nm).
30. Installthe oil pump relief plungerand spring
into the bore in the oil filter bracketandtightento 36
ft. Ibs. (50 Nm). Makesurea newgasketis in place.
31. Cleanboth matingsurfacesof the oil panand
the cylinderblock.
32. Apply sealantin the groove in the oil pan
flange,keepingtowardsthe inside of the bolt holes.
Thewidth of the sealantbeadappliedis to beabout
0.16 in. (4mm)wide.
*After applyingsealant to the oil pan, do
not exceed15 minutesbefore installing the
oil pan.
33. Installthe oil panto the engineand secure
with the retainers.Tightenbolts to 6 ft. Ibs. (8 Nm).
34. Installthe oil pressuregaugeunit andthe oil
pressureswitch.Attachthe electricalharnesscon-
nector
35. Installnewoil filter and fill enginewith clean
engineoil.
36. Installthe timing beltsand all relateditems,
*The timing of the oil pumpsprocketand
connectedsilent shaft can be incorrect, even
with the timing markaligned. Make certain
that all special timing belt installation proce-
duresare followed to ensureproper orienta-
tion of the silent shafts.
37. Installany remainingcomponentsremoved
duringdisassembly.
38. Connectthe negativebatterycableand start
the engine.
39. Checkfor propertiming and inspectfor leaks.
REMOVAL&INSTALLATION
p See Figure 215
1. Disconnectthe negativebatterycable.
2. Removethe transaxlefrom the vehicle,as
outlinedin Section7.
3. Removethe flywheel/driveplateassembly.
4. Removethe rearengineplateand the bell-
housingcover.
5. If the crankshaftrearoil sealcaseis leaking,
removeit. Otherwise,just removethe oil seal.Some
engineshavea separatorthat shouldalso be re-
moved.
To install:
6. Lubricatethe inner diameterof the newseal
with cleanengineoil.
7. Installthe oil sealin the crankshaftrearoil
sealcaseusing tool MD998376 or equivalent.Press
the sealall the way in without tilting it. Forcethe oil
separatorinto the oil sealcaseso the oil hole in the
separatoris downward.

al drive plate and rear
+ See Figures216 thru 222
*Safety glassesshouldbe worn at all times
whenworking on or near the exhaustsystem.
Olderexhaustsystemswill almost always be
coveredwith loose rust particles which will
showeryou when disturbed.Theseparticles
are morethan a nuisanceandcould injure
your eye.
DONOTperformexhaustrepairs or inspec-
tion wtth the engineor exhausthot. Allow thr
systemto cool completelybefore attempting
any work. Exhaustsystemsare notedfor
sharpedges,flaking metal and rustedbolts.
Glovesand eye protectionare required. A
m3p73
Fig. 216 Cracksin the muffler are a guar-
anteed leak
ENGINEANDENGINEOVERHAUL
3-55
8. Runa beadof sealeralonganyseamsbe- To lnstell:
tweenthesealcaseandblock.Installthesealcase 7. Coatthethreadsof thedriveplate/flywheelre-
witha newgasket. tainingboltswiththreadlockingcompound.
9. Installtheflywheel/driveplate
andtransaxle. 8. Positionthedriveplatelflywheelonthecrank-
10. Connect thenegative
batterycableandcheck shaftflange.
for leaks. 9. Onautomatic transaxle equippedmodels,in-
11. Adjustoil levelasnecessary. stallthedriveplateadapter.
10. Installandtightenthebolts,in aalternating
starpattern,tothefollowingspecifications:
l 1.5Lengine:98ft. Ibs.(135Nm)
l 1.6L,2.01and2.4Lengines:94-101ft.
REMOVAL&INSTALLATION Ibs.(130-140Nm)
l 1.81engine:72ft. Ibs.(100Nm)
b See Figure 215 l 3.OLand3.5Lengines:53-56ft. Ibs.
(72-76Nm)
1. Disconnect
thenegative
batterycable. 11. If equipped witha manualtransaxle, install
2. Removethetransaxle,
asoutlinedinSection theclutchandpressure plate.
7, 12. Installthetransaxle.Referto Section7.
3. If equippedwitha manualtransaxle, remove 13. Connect thenegative batterycable.
theclutchdiscandpressure plate.Referto Section7.
4. Markthepositionof theflywheel/driveplate
onthecrankshaft andremovetheretainingbolts.
5. Onautomatic transaxle
equipped models,re-
movethedriveplate adapter.
6. Remove theflywheel/driveplate
fromtheen-
gine.
healthysupply of penetratingoil and rags is tothebackof thevehicle.Ondualexhaustsystems,
highly recommended. rememberto insoectbothsidesof thevehicle.Check
thecompleteexhaustsystemfor openseams,holes
Yourvehiclemustberaisedandsupported safely looseconnections,
or otherdeterioration
whichcould
to inspecttheexhaust
systemproperly.Placing4
safetystandsunderthevehiclefor supportshould
provideenoughroomforyouto slideunderthevehi-
cleandinspectthesystemcompletely. Startthein-
spectionattheexhaustmanifoldor turbochargerpipe
wheretheheaderpipeisattached andworkyourway
fm3p77
Fig. 216 Makesure the exhaustcomponents
are not contactingthe body or suspension
lcca3P78
Fig 217 Checkthe muffler for rotted spot Fig. 219 Cheekfor overstretchedor torn ex-
welds and seams haust hangers
3-56 ENGINEANDENGINEOVERHAUL
220 Exampleof a badly deterioratedex- 1
Fig.
haust pipe
F)ermitexhaust fumesto seepintothepassenger
C:ompartment. Inspectall mounting bracketsand
bangers for deterioration,
somemodelsmayhave
ubberO-ringsthatcanbeoverstretched andnon-
supportive.Thesecomponents will needto bere-
Ilacedif found.It hasalwaysbeena practiceto usea
F)ointedtoolto pokeupintotheexhaistsystem
vherethedeterioration spotsareto seewhetheror
d theycrumble. Somemodelsmayhaveheatshield
:overingcertainpartsof theexhaustsystem, it will
ttenecessary to removetheseshieldsto havetheex-
laustvisiblefor inspectionalso.
3EPLACEMEMT
1 See Figure 223
Therearebasicallytwotypesof exhaustsystems.
)neis theflangetypewherethecomponent endsare
attachedwithboltsanda gasketin-between. The
)therexhaust systemis theslipjointtype.These
:omponents slipintooneanotherusingclampsto
ioldthemtogether.
liiow the exhaustsystemto cool sufficiently
Iefore sprayinga solvent exhaustfasteners.
Somesolventsare highly flammableand
:ould ignite whensprayedon hot exhauti
:omponents.
. fold,thestudwill haveto beremoved
ka3p70
Fig. 223 Nuts and bolts will be extremely
difflcuit to remove when deteriorated with
rust
,
Fig. 222 Some systems, like this one, use
Fig. 221 inspect flanges for gaskets that
have deteriorated and need replacement
Beforeremoving anycomponent of theexhaust tractor,whichoflenmeansremovalof themanifoldit
system,ALWAYS squirta Liquidrustdissolvingagent self.Next,disconnect thecomponent fromthe
ontothefasteners for easeof removal.A lotof mounting; slighttwistingandturningmaybere-
knuckleskinwill besavedbyfollowingthisrule.It quiredto remove thecomponent completely fromthr
mayevenbewiseto spraythefasteners andallow vehicle.Youmayneedto taponthecomponent with
themtosit overniqht. a rubbermalletto loosenit. If all elsefails,usea
hacksaw aratetheparts.Anoxy-acetylene
to sep; cut-
FlangeType tingtorchmayI3efasterbutthesparksareOANGER-
OUSnearthefueltank,ant1attheveryleast,acci-
b See Figure 224 dentscouldhappen, resultingin damage to the
under-car parts,notto meiitionyourself.
Do NOTperform exhaustrepairs or inspec- Slip Joint Type
tion with the engineor exhausthot. Allow the
systemto cool completelybefore attempting V See Figure 225
any work. Exhaustsystemsare notedfor Beforeremoving anycomponent ontheslipjoint
sharpedges,flaking metal and rustedbolts. typeexhaustsystem, ALWAYS squirta liquidrust
Glovesand eye protectionare required.A dissolvingagentontothefasteners for easeof re-
healthy supplyof penetratingoil and rags is moval.Startbyunbolting theexhaustpieceatboth
highly recommended.Neverspray liquid rust ends(if required).Whenunboltingtheheadpipe fron
dissolving agentonto a hot exhaustcompo- themanifold,makesurethattheboltsarefreebefore
nent. tryingto remove them.if yousnapa studin theex-
haustmanifold. thestudwill haveto beremoved wit1
Beforeremoving anycomponent onaflangetype a boltextractor,
whichoftenmeansremovalof the
system,ALWAYS squirta liquidrust._
dissolvingagent manifolditself.Next.removethemountina U-bolts
ontothefasteners foreaseof removal. Startbyun- fromaroundtheexhaustpipeyouareext&tingfrom
boltingtheexhaustpieceatbothends(if required). thevehicle.Don’tbesurprisedif theU-boltsbreak
Whenunbolting theheadpipe fromthemanifold, whileremoving thenuts.Loosentheexhaustpipe
makesurethattheboltsarefreebeforetryingto re- fromanymounting bracketsretainingit to thefloor
movethem.if yousnapa studintheexhaustmani- panandseparate thecomponents.
witha boltex-
Fig. 224 Exampleof a flange type exhaust Fig. 225 Example of a common slip joini
systemjoint type system

Anythingthat generatesheatand/or friction WIII
eventuallyburn or wearout (for example,a light bulb
generatesheat,thereforeits life span is limited).With
this in mind, a runningenginegeneratestremendous
amountsof both;friction is encounteredby the mov-
ing and rotatingpartsinsidethe engineand heatis
createdby friction and combustionof the fuel How-
ever,the enginehassystemsdesignedto help reduce
the effectsof heatand friction and provideadded
longevrty.Theoiling systemreducesthe amountof
friction encounteredby the moving parts insidethe
engine,while the cooling systemreducesheatcre-
atedby friction and combustion If eithersystemis
not maintained,a break-downwill be inevitable.
Therefore,you can seehow regularmaintenancecan
affectthe service life of your vehicle,If you do not
drain,flush and refill your cooling systemat the
properintervals,depositsWIIIbeginto accumulatein
the radiator,therebyreducingthe amountof heatit
canextractfrom the coolant Thesameappliesto
your oil and filter; If it is not changedoftenenoughit
becomesladenwith contaminatesand is unableto
properlylubricatethe engine.This increasesfriction
and wear.
Thereare a numberof methodsfor evaluatingthe
conditionof your engine.A compressiontest can re-
vealthe conditionof your pistons,piston rings,
cylinder bores,headgasket(s),valvesand valve
seats.An oil pressuretest canwarnyou of possible
enginebearing,or oil pumpfailures.Excessrveoil
consumption,evidenceof oil in the engineair intake
areaand/or bluish smokefrom the tailpipe may indi-
cateworn piston rings, worn valve guidesand/or
valve seals.As a generalrule,an enginethat usesno
morethan one quartof oil every1000 miles is in
goodcondition. Enginesthat useone quartof oil or
more in lessthan 1000 miles shouldfirst be checked
for oil leaks.If any oil leaksare present,havethem
fixed beforedetermininghow muchoil is consumed
by the engine,especrallyif bluesmoke is not visible
at the tailpipe
COMPRESSION
TEST
# See Figure 226
tccs3801
Fig. 226A screw-in type compressiongauge
is more accurate and easier to use without
an assistant
ENGINEANDENGINEOVERHAUL
3-57
A noticeablelackof enginepower,excessiveoil
consumptionand/or poor fuel mileagemeasured
over an extendedperiodare all indicatorsof internal
enginewear.Worn piston rings, scoredor worn
cylinderbores,blown headgaskets,stickingor burnt
valves,and worn valve seatsare all possibleculprits.
A checkof eachcylinders compressionWIIIhelp lo-
catethe problem.
*A screw-in type compressiongaugeis
more accuratethanthe type you simply hold
againstthe sparkplug hole. Althoughit takes
slightly longerto use, it’s worth the effort to
obtain a moreaccuratereading.
1 Makesurethat the properamountand vis-
cosity of engineoil is in the crankcase,thenensure
the batteryis fully charged.
2. Warm-upthe engineto normaloperating
temperature,then shutthe engineOFF.
3. Disablethe ignition system.
4. Labeland disconnectall of the sparkplug
wires from the plugs,
5. Thoroughlycleanthe cylinderheadarea
aroundthe sparkplug ports,then removethe spark
plugs.
6. Setthe throttleplateto the fully open(wide-
openthrottle)position You can block the accelerator
linkageopenfor this, or you canhavean assistant
fully depressthe acceleratorpedal.
7. Installa screw-intype compressiongauge
into the No. 1 sparkplug hole until the fitting is snug.
Be careful not to crossthreadthe spark plug
hole.
8. Accordingto the tool manufacturersinstruc-
tions, connecta remotestartingswitchto the starting
circuit.
9. With the ignition switch in the OFFposition,
usethe remotestartingswitchto crankthe engine
throughat leastfive compressionstrokes(approxi-
mately5 secondsof cranking)and recordthe highest
readingon the gauge
10. Repeatthe test on eachcylinder,crankingthe
engineapproximatelythe samenumberof compres-
sion strokesand/ortime as the first.
11. Comparethe hrghestreadingsfrom each
cylinderto that of the others.The indicatedcompres-
sion pressuresare consideredwithin specificationsif
the lowestreadingcylinder is within 75 percentof the
pressurerecordedfor the highestreadingcylinder
For example,if your highestreadingcylinderpres-
surewas 150 psi (1034 kPa),then75 percentof that
would be 113 psi (779 kPa).So the lowestreading
cylindershould be no lessthan 113 psi (779 kPa).
12. If a cylinderexhibitsan unusuallylow com-
pressionreading,pour a tablespoonof cleanengine
oil into the cylinderthroughthe sparkplug hole and
repeatthe compressiontest. If the compressionrises
afteraddingoil, it meansthat the cylinder’spiston
rings and/or cylinderboreare damagedor worn, If
the pressureremainslow,the valves maynot beseat-
ing properly(a valvejob is needed),or the headgas-
ket maybe blown nearthat cylinder. If compression
in anytwo adjacentcylindersis low, and if the addi-
tion of oil doesn’thelp raisecompression,thereis
leakagepastthe headgasket.Oil and coolantin the
combustionchamber,combinedwith blueor con-
stantwhite smokefrom the tailpipe,are symptomsof
this problem.However,don’t bealarmedby the nor-
malwhite smokeemittedfrom the tailpipe during en-
gine warm-upor from cold weatherdriving. There
maybe evidenceof waterdropletson the enginedip-
stick and/or oil dropletsin the cooling systemif a
headgasketis blown.
OIL PRESSURETEST
Checkfor properoil pressureat the sendingunit
passagewith an externallymountedmechanicaloil
pressuregauge(as opposedto relying on a factory
Installeddash-mountedgauge).A tachometermay
also be needed,as somespecificationsmay require
runningthe engineat a specific rpm.
1. With the enginecold, locateand removethe oil
pressuresendingunit.
2. Followrngthe manufacturersinstructions,
connecta mechanicaloil pressuregaugeand, if nec-
essary,a tachometerto the engine.
3 Startthe engineand allow it to idle.
4 Checkthe oil pressurereadingwhencold and
recordthe number.You may needto run the engine
at a specifiedrpm, so checkthe specifications,
5. Runthe engineuntil normaloperatingtemper-
atureis reached(upperradiatorhosewill feelwarm)
6. Checkthe oil pressurereadingagainwith the
enginehot and recordthe number.Turn the engine
OFF.
7. Compareyour hot oil pressurereadingto that
given in the chart If the readingis low,checkthe
cold pressurereadingagainstthe chart.If the cold
pressureISwell abovethe specification,andthe hot
readingwas lowerthanthe specification,you may
havethe wrongviscosity oil in the engine.Change
the oil, makingsureto usethe propergradeand
quantity,then repeatthe test.
Low oil pressurereadingscould beattributedto
internalcomponentwear,pump relatedproblems,a
low oil level,or oil viscosity that is too low. High oil
pressurereadingscould be causedby an overfilled
crankcase,too htghof an oil viscosity or a faulty
pressurereliefvalve.
Nowthat you havedeterminedthat your engineis
worn out, you must makesomedecisions.Theques-
tion of whetheror not an engineISworth rebuilding
is largelya subjectivematterand oneof personal
worth. Is the enginea popularone,or IS it an obso-
letemodel?Are partsavailable?Will it get acceptable
gas mileageonce It is rebuilt?Is the car its being put
into worth keeping?Would it be lessexpensiveto
buy a newengine,haveyour enginerebuiltby a pro,
rebuild it yourselfor buy a usedenginefrom a sal-
vageyard?Orwould It be simplerand lessexpensive
to buy anothercar? If you haveconsideredall these
mattersand more,and havestill decidedto rebuild
the engine,then it is time to decidehowyou will re-
build it.
3-58 ENGINEANDENGINEOVERHAUL '
*The editors at Chiltonfeel that most engine spectthecomponent, buythenecessary partsand OVERHAULTIPS
machiningshouldbe performedby a profes- delivertheseto a shopfor actualmachine work.
sional machineshop. Don’tthink of it as Muchoftheassembly work(crankshaft, bearings, Aluminum hasbecome extremely popularfor use
wasting money,rather, as an assurancethat pistonrods,andothercomponents) is wellwithinthe in engines,dueto itslowweight.Observe thefollow-
the job has beendoneright the first time. scopeof thedo-it-yourselfmechanic’s toolsandabil- ingprecautions whenhandlingaluminum parts:
Thereare manyexpensiveandspecialized ities.Youwill haveto decideforyourselfthedepthof l Neverhottankaluminum parts(thecaustichot
tools requiredto performsuchtasks as bor- involvementyoudesireinanenginerepairor rebuild. 6nksolutionwill eatthealuminum.
ing and honingan engineblock or havinga l Remove all aluminum parts(identification
tag,
valve job doneon a cylinder head. Evenin- TOOLS etc.)fromenginepartspriorto thetanking.
spectingthe parts requires expensivemi- l Alwayscoatthreadslightlywithengineoil or
crometersand gaugesto properly measure Thetoolsrequiredfor anengineoverhaulor parts anti-seizecompounds beforeinstallation,to prevent
wear and clearances.Also, a machineshop replacement will dependonthedepthof yourin- seizure.
can deliver to you clean, and readyto as- volvement. Witha fewexceptions,theywill bethe l Neverovertighten boltsorsparkplugsespe-
sembleparts, savingyou time and aggrava- toolsfoundina mechanic’s toolkit(seeSection1 of ciallyinaluminum threads.
tion. Your maximumsavingswill comefrom thismanual). Morein-depthworkwill requiresome Whenassembling theengine,anypartsthatwill
performingthe removal, disassembly,as- orall of thefollowing: beexposed to frictionalcontactmustbeprelubed to
semblyand installation of the engineand l A dialindicator(readinginthousandths) providelubrication at initialstart-up.Anyproduct
purchasingor renting only the tools required mounted ona universalbase specificallyformulated for thispurposecanbeused,
to performthe abovetasks. Dependingon l Micrometers andtelescopegauges butengineoil is notrecommended asa prelubein
the particular circumstances,you may save * Jawandscrew-type pullers mostcases.
40 to 60 percentof the cost doing theseyour- ‘ Scraper Whensemi-permanent (locked,butremovable) in-
self. l Valvespringcompressor stallationof boltsor nutsis desired,threadsshould
l Ringgroovecleaner becleanedandcoatedwithLoctite@ or anothersimi-
A complete rebuildoroverhaulof anenginein- Pistonringexpander andcompressor
volvesreplacing all ofthemovingparts(pistons,
l
, lar,commercial non-hardening sealant.
l Ridgereamer
rods,crankshaft, camshaft, etc.)withnewonesand l Cylinderhoneor glazebreaker CLEANING
machining thenon-moving wearingsurfaces of the l Plastigage@
blockandheads.Unfortunately, thismaynotbecost Enginestand
effective.Forinstance, yourcrankshaftmayhave
l
Theuseof mostof thesetoolsis illustratedin ) See Figures227, 228, 229, 230, and 231
beendamaged or worn,butit canbemachined un- thissection.Manycanberentedfor a one-timeuse Beforetheengineanditscomponents arein-
dersizefora minimalfee. froma localpartsjobberor tool supplyhousespe- spected,theymustbethoroughly cleaned.
Youwill
So,asyoucansee,youcanreplaceeverything in- cializingin automotive work. needto removeanvenainevarnish,oil sludoeand/or
sidetheengine,but,it iswiserto replaceonlythose Occasionally, theuseof specialtoolsis calledfor. carbondepositsfromail of thecomponentsio insure
partswhicharereallyneeded, and,if possible,repair Seetheinformation onSpecialToolsandtheSafety aInaccurateinspection. Acrackintheengineblockor
themoreexpensive ones.Laterinthissection,we Noticeinthefrontof thisbookbeforesubstituting c:ylinder
head caneasily becomeoverlookedif hidden
will breaktheenginedownintoitstwomaincompo- anothertool. trya layerof sludgeor carbon.
nents:thecylinderheadandtheengineblock.We
will discusseachcomponent, andtherecommended
partsto replaceduringa rebuildoneach.

Mostengineoverhaulprocedures arefairlystan-
dard.Inadditionto specificpartsreplacement proce-
duresandspecifications for yourindividualengine,
thissectionis alsoa guideto acceptable rebuilding
procedures.Examples of standard rebuilding practice
aregivenandshouldbeusedalongwithspecificde-
tailsconcerning yourparticular engine.
Competent andaccurate machine shopservices
will ensuremaximum performance, reliabilityanden-
ginelife.Inmostinstances it is moreprofitablefor Fig. 227 Thoroughly clean the gasket sur-
thedo-it-yourselfmechanic to remove, cleanandin- faces of the cylinder head as well as . . .

fccs3911

::“,z s,rpuse,a piece of fn old ring to 1

Fig. 229 Usea ring expandertool to remove 230 Clean the piston ring grooves us- clean the grooves Be careful the ring can
the piston rings ing a ring groove cleaner tool, or . . .

Most of the cleaningprocesscan becarriedout
with commonhandtools and readilyavailablesol-
ventsor solutions.Carbondepositscan bechipped
awayusinga hammerand a hardwoodenchisel. Old
gasketmaterialandvarnishor sludgecanusuallybe
removedusinga scraperand/or cleaningsolvent.Ex-
tremelystubborndepositsmay requirethe useof a
powerdrill wrth a wire brush.If usinga wire brush,
useextremecarearoundany critical machinedsur-
faces(suchas the gasketsurfaces,bearingsaddles,
cylinderbores,etc.). USEOFA WIREBRUSHIS NOT
RECOMMENDEDONANY ALUMINUM COMPO-
NENTSAlwaysfollow any safetyrecommendations
given by the manufacturerof the tool and/or solvent.
You shouldalwaysweareyeprotectionduringany
cleaningprocessinvolvrngscraping,chippingor
sprayingof solvents.
An alternativeto the messand hassleof cleaning
the partsyourselfis to drop themoff at a local garage
or machineshop.Theywill, morethan likely, have
the necessaryequrpmentto properlycleanall of the
partsfor a nominalfee.
Always wear eye protectionduringany clean-
ing processinvolving scraping,chippingor
sprayingof solvents.
Removeany oil galleyplugs,freezeplugsand/or
pressed-inbearingsand carefullywashand degrease
all of the enginecomponentsincludingthe fasteners
and bolts. Small partssuchas the valves,springs,
etc.,should be placedin a metalbasketand allowed
to soak.Usepipe cleanertype brushes,and cleanall
passagewaysin the components.Usea ring ex-
panderand removethe rings from the pistons.Clean
the piston ring grooveswith a specialtool or a piece
of brokenring Scrapethe carbonoff of the top of the
piston.You shouldneverusea wire brushon the
pistons.After preparingall of the pistonassemblies
in this manner,washand degreasethemagain.
Use extremecare when cleaningaroundthe
cylinder headvalve seats. A mistakeor slip
may cost you a new seat.
Whencleaningthe cylinderhead,removecarbon
from the combustronchamberwith the valves in-
stalled.This will avoid damagingthe valve seats.
:ig. 234 Drill out the damagedthreads with
he specified size bit. Be sure to drill corn.
rletely throughthe hole or to the bottomoi
I blind hole
ENGINEAND
ENGINEOVERHAUL
3-59
REPAIRINGDAMAGEDTHREADS
# See Figures232, 233, 234, 235 and 236
Severalmethodsof repairingdamagedthreadsare
available Heli-Coil@(shownhere),Keenserts@ and
Microdop areamongthe mostwidely used.All in-
volve basicallythe sameprinciple-drilling out
strippedthreads,tappingthe holeand installinga
prewoundinsert-making welding,pluggingand
oversizefastenersunnecessary.
Two typesof threadrepairinsertsare usuallysup-
plied: a standardtypefor most inch coarse,rnchfine,
metric courseand metrrcfine threadsizesand a
sparklug typeto fit most sparkplug port sizes.Con-
sult the individualtool manufacturerscatalogto de-
termineexactapplications.Typicalthreadrepairkits
will containa selectionof prewoundthreadedinserts,
a tap (correspondingto the outsidediameterthreads
of the insert)and an installationtool. Sparkplug in-
serts usuallydiffer becausethey requirea tap
equippedwrth pilot threadsanda combined
reamer/tapsection.Most manufacturersalso supply
blister-packedthreadrepair Insertsseparatelyin ad-
dition to a masterkit containinga varietyof taps and
insertsplus installationtools
Beforeattemptingto repaira threadedhole, re-
move anysnapped,brokenor damagedbolts or
studs.Penetratingoil can be usedto freefrozen
threads.The offendingitem can usuallybe removed
with lockingpliers or usinga screw/studextractor.
Afterthe hole is clear,the threadcan be reparred,as
shownin the seriesof accompanyingillustrations
and in the krt manufacturersinstructions.
THREADED
lCCS3039
replaced with thread repair inserts
:ig. 235 Usingthe kit, tap the hole in order
o receive the thread insert. Keep the tap
veil oiled and backit out frequentlyto avoid
:logging the threads
To properlyrebuildan engine,you mustfirst re-
move it from the vehicle,then disassembleand diag-
noseit. Ideallyyou should placeyour engineon an
enginestand.This affordsyou the bestaccessto the
enginecomponents.Followthe manufacturersdirec-
tions for usingthe standwith your particularengine.
Removethe flywheelor flexplatebeforeinstallingthe
engineto the stand.
Nowthat you havethe engineon a stand,and as-
sumingthat you havedrainedthe oil and coolant
from the engine,it’s time to strip it of all but the nec-
essarycomponents.Beforeyou startdisassembling
the engine,you maywantto takea momentto draw
somepictures,or fabricatesome labelsor containers
to markthe locationsof various componentsand the
bolts and/or studswhich fastenthem. Modernday
enginesusea lot of little bracketsand clips which
hold wiring harnessesand such,and theseholders
are oftenmountedon studs and/or bolts that can be
easily mixed up. The manufacturerspenta lot of time
and moneydesigningyour vehicle,andthey wouldn’t
havewastedany of it by haphazardlyplacingbrack-
ets, clips or fastenerson the vehicle.If it’s present
whenyou disassembleit, put it backwhenyou as-
semble,you will regretnot rememberingthat little
bracketwhich holds a wire harnessout of the pathof
a rotatingpart.
You shouldbeginby unboltinganyaccessories
still attachedto the engine,such as the waterpump,
powersteeringpump,alternator,etc.Then,unfasten
any manifolds(intakeor exhaust)which werenot re-
movedduringthe engineremovalprocedure.Finally,
Fig.233 Standardthread repair insert (left),
andspark plug thread insert
im3043
Fig. 236 Screw the insert onto the installer
1001 until the tang engagesthe slot. Thread
‘he insert into the hole until it is l/4-l/~ turn
lelow the top surface, then removethe tool
andbreak off the tano usina a uunch
 3-60 ENGINE/ -w
remove anycoversremaining ontheenginesuchas sameenvironment. Thesamegoesforanyother unchanged. Oneaspectto payattentionto is careful
therockerarm,frontor timingcoverandoil pan. component onthecylinderhead.Thinkof it asanin- labelingof thepartsonthedualcamshaft cylinder
Somefrontcoversmayrequirethevibrationdamper surancepolicyagainstfutureproblems relatedto that head.Therewill beanintakecamshaft andfollowers
and/orcrankpulleyto beremoved beforehand.The component. aswellasanexhaustcamshaft andfollowersand
ideais to reducetheengineto thebarenecessities Unfortunately,
theonlywayto findoutwhichcom- theymustbelabeledassuch.Insomecases,the
(cylinderhead(s),valvetrain,engineblock,crank- ponentsneedreplacing, is to disassemble andcare- components areidenticalandcouldeasilybein-
shaft,pistonsandconnecting rods),plusanyother fullycheckeachpiece.Afterthecylinderhead(s)are stalledincorrectly.
DONOTMIXTHEMUP!Deter-
‘in block’components suchasoil pumps,balance disassembled,thoroughly cleanall of thecompo- miningwhichiswhichis verysimple;theintake
shaftsandauxiliaryshafts. nents. camshaft andcomponents areonthesamesideof
Finally,removethecylinderhead(s)fromtheen- theheadaswastheintakemanifold.Conversely, the
gineblockandcarefullyplaceona bench.Disassem- DISASSEMBLY exhaustcamshaft andcomponents areonthesame
blyinstructionsforeachcomponent followlaterin sideof theheadaswastheexhaustmanifold.
thissection. ti See Figures 237 and 238
CupType CamshaftFollowers
Whether it is a singleor dualoverhead
camshaft
cylinderhead,thedisassembly procedure
is relatively 6 See Figures 239, 240, and 241
Therearetwobasictypesof cylinderheadsused t “” ““’ 1 Mostcylinderheadswithcuptypecamshaft fol-
ontoday’sautomobiles: theOverhead Valve(OHV) lowerswill havethevalvespring,retainerandlocks
andtheOverhead Camshaft (OHC).Thelattercan recessed withinthefollowersbore.Youwill needa
alsobebrokendownintotwosubgroups: theSingle C-clampstylevalvespringcompressor tool,anOHC
Overhead Camshaft (SOHC) andtheDualOverhead springremoval tool(orequivalent)
anda smallmag-
Camshaft (DOHC). Generally, if thereis onlya single netto disassemble thehead.
1
camshaft ona head.it is iustreferred to asanOHC 1. If notalreadyremoved, remove thecamshaft(s)
1 head.Also,anenginewithanOHVcylinderheadis j:, ’ : .;:-, and/orfollowers,Marktheirpositionsfor assembly.
I alsoknownasa pushrodengine. _I 2. Positionthecylinderheadto allowuseof a C-
Mostcylinderheadsthesedaysaremadeof an “’ clampstylevalvespringcompressor tool.
aluminum alloydueto itslightweight,durabilityand At is preferredto position the cylinder head
L--L I_---1^-_..^I:,:^^I I^...^..^_^^^I:_-_..^^,L-
IIRN il~llSlt?l ~Lldll~l~S. IlUWttVtJ, MS1 11011W8S lilt:
materialof choiceinthepast,andis still usedon lasket’surtace facing you with tee valve
springsfacing the oppositedirection andthe
manyvehiclestoday.Whether madefromaluminum leadlaying horizontal.
or iron,all cylinderheadshavevalvesandseats.
Someusefwovalvespercylinder,whilethemorehi- 3. WiththeOHCspringremovaladaptertoolpo-
techengineswill utilizea multi-valve configuration ,itionedinsideofthefollowerbore,compress the
using3‘4 andeven5 valvespercylinder.Whenthe alvespringusingtheC-clampstylevalvespring
valvecontacts theseat,it doessoonprecisionma- :ompressor.
chinedsurfaces, whichsealsthecombustion cham-
ber,All cylinderheadshaveavalveguideforeach
valve.Theauidecentersthevalvetotheseatandal-
lowsit to moveupanddownwithinit.Theclearance Fig, 237 Explodedview of a valve, seal,
between thevalveandguidecanbecritical.Too spring, retamer and locks from an OHC
muchclearance andtheenginemayconsume oil, 1cylinder head ----r-1
losevacuum and/ordamaae theseat.Toolittle.and
thevalvecanstickin theguidecausingtheengineto
runpoorlyif atall,andpossiblycausingseveredam-
age.Thelastcomponent all cylinderheadshaveare
valvesprings.Thespringholdsthevalveagainstits
seat.It alsoreturnsthevalveto thispositionwhen
thevalvehasbeenopenedbythevalvetrainor
camshaft. Thespringis fastened to thevalvebya re-
tainerandvalvelocks(sometimes calledkeepers). tcca3p51
Aluminum headswill alsohavea valvespringshim fig. 239 C-clamp type spring compressor
to keepthespringfromwearingawaythealuminum. and an OHCspring removal tool (center) for
Anidealmethodof rebuilding thecylinderhead cup type followers
wouldinvolvereplacing all of thevalves,guides,
seats,springs,etc.withnewones.However, depend-
ingonhowtheenginewasmaintained, oftenthisis
notnecessary. A majorcauseof valve,guideandseat
wearis animproperly tunedengine.Anenginethatis
~~f~t~~ rich,will oftenwashthelubricating oil
outoftheguidewithgasoline, causingit to wear
~~fdfy.lonely, anenginewhichis runningtoo
leanwifl pfacehighercombustion temperatures on
Mevalvesandseatsallowingthemto wearor even
bum.Springsfall victimto thedrivinghabitsofthe
f~~iduaf.A driverwhooftenrunstheenginerpmto
tfreredfinewill wearoutor breakthespringsfaster
thenonetfratstayswellbelowit. Unfortunately,
mileagetakesit tot1onall of theparts.Generally, the
valves,guides,springsandseatsin a cylinderhead oi a multi-valve cylinder
canbemachined andre-used, savingyoumoney. Fig. 240 Most cup type follower cylinder
.However, if avalveis burnt,it maybewiseto replace t has 2 intake and2 ex- heads retain the camshaft using bolt-on
all of thevalves,sincetheywereall operating inthe bearing caps /
 ENGINEAND
ENGINEOVERHAUL
3-61
6. Withdraw thevalvefromthecylinderhead. *Due to enginevarnish, the retainer may
7. If equipped,
remove thevalveseal. stick to the valve locks. A gentle tap with a
hammermay help to breakit loose.
*Special valve seal removal tools are avail-
able. Regularor needlenosetype pliers, if 4. Remove thevalvelocksfromthevalvetip
usedwith care, will work justaswell. If us- and/orretainer. Asmallmagnet mayhelpin remov-
ing ordinary pliers, be sure not to damage ingthesmalllocks.
the follower bore. Thefollower and its bore 5. Liftthevalvespring,toolandall,off of the
are machinedto close tolerancesand any valvestem.
damageto the bore will effect this relation- 6. If equipped, remove thevalveseal.If theseal
ship. is diflicultto removewi‘ththevalvein place,tryre-
movingthevalvefirst,thentheseal.Followthesteps
8. If equip(jed,
remove thevalvespringshim.A belowforvalveremoval I.
smallmagnetictoolor screwdriver
will aidin re- 7. Positiontheheadto allowaccess forwith-
moval. drawingthevalve.
9. Repeat Steps3 through8 untilall ofthevalves - --.---a- LL-. L-..- -.-.. .~. . .
havebeenremoved. -Cylinder
** nears InaI nave seena IOIor
mnesanuIul aUUJl.IllcrY
nllrr rh..sr . ..x..
*#....a
IIQVli.lltUJllrUVlllliU
... . ..lmr~...r~
RockerArm Type CamshaftFollowers the..valve
_ --lock gmve and/or
culty in Dmuval -__-I UT
-Z.L- ._-I__-I*.LI_ L-- diffi-
tip, causing
me vane. II ms nas nap-
L--
b See Figures 242 thru 250 nnnnd llse a metal file to carefully remove
r-..--, ”

Mostcylinderheadswithrockerarm-type the high spotsaround the lock._grooves

:. ---_--L -II____ --
n-s.. a:.-
and/ortip. UIIIY IIIU II enuugn IU alluw NP
camshaft followersareeasilydisassembled usinga
standard valvespringcompressor. However, certain moval.
modelsmaynothaveenoughopenspacearoundthe 8. Remove thevalvefromthecylinderhead.
to?&55 springforthestandard toolandmayrequireyouto 9. If equipped, removethevalvespringshim.A
Fig. 241 Position the DHCspring tool in the usea C-clampstylecompressor toolinstead. smallmagnetic toolor screwdriver will aidin re-
follower bore, then compress the spring 1. If notalreadyremoved, remove therocker moval.
with a C-clamptype tool armsand/orshaftsandthecamshaft. If applicable, 10. Repeat Steps3 though9 untilall of thevalves
- alsoremove thehydrauliclashadjusters.
Marktheir havebeenremoved.
positionsfor assembly.
4. Remove thevalvelocks.Asmallmagnetic
tool 2. Positionthecylinderheadto allowaccessto INSPECTION
or screwunver
WIIIalaIn removal. thevalvespring.
5. Release
thecompressor toolandremovethe 3. Usea valvespringcompressor toolto relieve
pringassembly. thespringtensionfromtheretainer. Nowthatall of thecylinderheadcomponents are
clean,it’stimeto inspectthemfor wearand/ordam-

Imp53 Fig. 243 Anotherexampleof the rocker arm

Fig. 242 Example of the shaft mounted type DHChead. This model uses a follower all of the followers mustfirst be re
meker arms on some DHCheads iider the camshaft

@Ja3Ps
Fig.245... then the camshaftcan be re-
movedby sliding it out (shown), or unbolt-
ing a bearfng cap (not shown)

3-62 ENGINEANDENGINEOVERHAUL
lge.Toaccurately inspectthem,youwill needsome
,pecializedtools:
l AO-l in.micrometer for thevalves
l A dialindicatoror insidediametergaugefor
hevalveguides
l A spring ressuretestgaue
If youdo noPhaveaccessto tYle propertools,
‘oumaywantto bringthecomponents to a shop
hatdoes.
lalves
1 See Figures 251 and 252
Thefirstthingto inspectarethevalveheads.Look
E:loselyatthehead,margin andfacefor anycracks,
Erxcessivewearor burning.Themarginisthebest
c)lace?olookfor burning.Itshouldhaveasquared
lCZS3144
Fig. 251Valve stemsmay be rolled on a flat I
suhace to checkfor bends
edgewithanevenwidthall aroundthediameter.
Whena valveburns,themarginwill lookmeltedand
theedgesrounded. Alsoinspectthevalveheadfor
anysignsof tulipping.Thiswill showasa liftingof
theedgesor dishinginthecenterof theheadandwill
usuallynotoccurtoall of thevalves.All of theheads
shouldlookthesame,anythatseemdishedmore
thanothersareprobablybad.Next,inspectthevalve
lockgroovesandvalvetips.Checkforanyburrs
aroundthelockgrooves, especially
if youhadto file
themto remove thevalve.Valvetipsshouldappear
flat,althoughslightrounding withhighmileageen-
ginesis normal.Slightlywornvalvetipswill needto
bemachined flat.last,measure thevalvestemdiam-
eterwiththemicrometer. Measure theareathatrides
withintheguide,especially towardsthetipwhere
mostof thewearoccurs.Takeseveralmeasurements
I Fio. 252 Use a micrometerr to check the
valve stem diameter
I
254 Checkthe valve spring fo
s on a flat surface; a carpenter
.
alongitslengthandcompare themto eachother.
Wearshouldbeevenalongthelengthwithlittleto no
taper.If nominimumdiameter is giveninthespecifi-
cations,thenthestemshouldnotreadmorethan
0.001in.(0.025mm) belowtheunwornareaofthe
valvestem.Anyvalvesthatfail theseinspections
shouldbereplaced.
Springs,Retainersand Valve Locks
$ See Figures253 and 254
Thefirstthingtocheckis themostobvious,bro-
kensprings.Nextcheckthefreelengthandsquare-
nessof eachspring.If applicable,
insureto distin-
guishbetween intakeandexhaust springs.Usea
rulerand/orcarpenter’ssquareto measure thelength.
Acarpenter’ssquareshouldbeusedto checkthe
hrnknn itc
Cylinder Head
Thereareseveralthingsto checkonthecylinder
head:valveguides,seats,cylinderheadsurfaceflat-
ness,cracksandphysicaldamage.
VA1YEGUIDES
N See Figure 255 \
Nowthatyouknowthevalvesaregood,youcan
usethemto checktheguides,althougha newvalve,
if available,
is preferred.
Beforeyoumeasure any-
thing,lookattheguidescarefullyandinspectthem
for anycracks,chipsor breakage. Alsoif theguideis
a removable style(asin mostaluminum heads),
checkthemforanylooseness orevidence of move-
ment.All oftheguidesshouldappearto beatthe
sameheightfromthespringseat.If anyseemlower
(or higher)fromanother, theguidehasmoved.
Mounta dialindicatorontothesorinasideof the
cylinderhead.Lightlyoil thevalvestemandinsertit
 ENGINEANDENGINEOVERHAUL
3-63
Placea straightedge
acrossthegasketsurface. Valves
Usingfeelergauges, determinetheclearance atthe
centerof thestraightedge
andacrossthecylinder Anyvalvesthatwerenotreplaced shouldbe
headatseveralpoints.Checkalongthecenterline refaced andthetipsgroundflat.Unlessyouhaveac-
anddiagonally ontheheadsurface.If thewarpage cessto a valvegrindingmachine, thisshouldbe
exceeds0.003in.(0.076mm) withina 6.0in. donebya machine shop.Ifthevalvesareinex-
(152cm)span,or0.006in.(0.152mm) overthetotal tremelygoodcondition,aswellasthevalveseats
lengthof thehead,thecylinderheadmustberesur- andguides, , theymaybelappedinwithoutpetform-
I faced.Afterresurfacing
theheadsof a V-typeengine mgmacnme worK.
theintakemanifoldflangesurfaceshouldbechecker, 4 It is_a- recnmmended
___ .- - - _ practiceto lapthevalves
andif necessary,milledproportionally
to allowfor evenaftermachine workhasbeenp&formed and/or
thechangein itsmounting position. newvalveshavebeenpurchased. Thisinsuresa pos-
itivesealbetween thevalveandseat.
CRACKSANDPHYSICALDAMAGE
LAPPINGTHEVALVES
Generally, cracksarelimitedtothecombustion
-guide..clearance; read the 1 chamber, hbwever, it is notuncommon for thehead *Before iaoaino the valves to the seats,
to crackina sparkplughole,port,outsideof the read the rest of the cylinder headsectionto
heador inthevalvespring/rocker armarea.Thefirst insurethat any related parts are in accept-
intothecylinderhead.Positionthedialindicator area.Ito inspect
* is alwaysthehottest:theexhaust able enoughconditionto continue.
againstthevalvestemnearthetieandzerothe seawpon area.
8I .,“““I llly”Lv”l~ .ml”“l”- plr”llll”“, ““I ,“a’ *Before anv valve seat machiningand/or
gauge.Graspthevalvestemand’wiggle towardsand lappingcan be performed,the guidesmust
awayfromthedialindicatorandobserve theread- because youdon’tseea crackdoesnotmeanit is not
there.Somemorereliablemethods for inspecting for be within factory recommendedspecifica-
ings.Mountthedialindicator90degrees fromthe tions.
initialpointandzerothegaugeandagaintakea read- cracksincludeMagnaflux?a magn$i,c processor
ing.Compare thetworeadings fora outof round Zyglo? a dye penetrant. Ma{ -’
InatluxW IS used only on 1. Invertthecylinderhead.
condition.Checkthereadings againstthespecifica- ferrousmetal(castiron)heatIs.Zyglo@ usesa spray 2. _Linhtlv
-. Iuhrir;rBthevalvestemsandinsert
~..... .--.._-._
tionsgiven.AnInsideDiameter (I.D.)gaugedesigned onfluorescent mixturealongwitha blacklightto re- themintothecylinderheadintheirnumbered order.
forvalveguideswill giveyouanaccurate valveguide vealthecracks.It is stronglyrecommended to have 3. Raisethevalvefromtheseatandapplya small
boremeasurement. IftheI.D.gaugeis used,compare yourcylinderheadchecked professionally for cracks, amountof finelanninncompound to theseat.
thereadings withthespecifications given.Any especially
I .* I,. if theenginewasknownto have ..^..over- 4. Moistenthesuctionheadof a hand-lapping
i guidesthatfailtheseinspections shouldbereplaced nearea analorieaKea orconsumea coolant.Contact a toolandattachit totheheadof thevalve.
i or machined. localshopforavailability andpricingof theseser- 5. Rotatethetoolbetween thepalmsof both
I vices. hands,changing thepositionof thevalveonthe
I Physicaldamage is usuallyveryevident.Forex-
VALVESEATS valveseatandliftingthetooloftento preventgroov-
amnb P hrnbn mntlntinn ear from dropping the
A visualinspection of thevalveseatsshouldshow ing.
I and/or bolt.All ofthese
.a,... . 6. Lapthevalveuntila smooth,polishedcircleis
a slightlywornandpittedsurfacewherethevalve uetecIsSIIOUIO oenxeaor,ITunrepairaole, meneaa
facecontacts theseat.Inspect theseatcarefullyfor evidlentonthevalveandseat.
shouldbereplaced. 7‘. Remove thetoolandthevalve.Wipeawayall
severepittingor cracks.Also,a seatthatis badly
wornwill berecessed intothecylinderhead.A se- tracesof thegrindingcornpoundandstorethevalve
Camshaftand Followers to maintain its lappedloca
verelywornor recessed seatmayneedto bere-
placed:All cracked seatsmustbereplaced. Aseat Inspect thecamshaft(s) andfollowersasdescribed
concentricity gauge,if available, shouldbeusedto earlierin thissection.
checktheseatrun-out.If run-outexceeds specifica- Do not get the valves out of order after they
tionstheseatmustbemachined (if nosoecification REFINISHING & REPAIRING have beenlapped.Theymustbe put back
is givenuse0.002in.or O.O51mt$. with the samevalve seat with which they \
Manyof theprocedures :..^^I...
gIveI --I:^:-L!-- --A
WI WIIIIISIIIIIIJ ~IIU were lapped.
CYLtNDEt? HEADSURFACEFLATNESS repairingthecylinderheadcomponents mustbeper-
) See Figures 256 and 257 formedbya machine shop.Certainsteps,if thein-
spected partis notworn,canbeperformed yourself Springs,Retainersand Valve locks
Afteryouhavecleaned thegasketsurfaceof the inexpensively. However, youspenta lotof timeand
cylinderheadof anyoldgasketmaterial, checkthe effortsofar,whyrisktryingto savea couplebucksif Thereis norepairor refinishing
possiblewiththe
headforflatness. youmighthaveto doit all overagain? springs,retainersandvalvelocks.If theyarefoundto
bewornor defective, theymustbereplaced withnew
I- lor
\- known
- nnod\r-narts
a---r .-.

Cylinder Head
procedures
Mostrefinishing dealingwiththe

VALVEGWDE
elf any machiningor replacementsare
e valve guides,the seats mustbe

Unlessthevalveguidesneedmachining or re-
Fig. 257 Checksshouldalso be madealong placing,theonlyserviceto performis to thoroughly‘
cleanthemof anydirtor oil residue.
 .
3-64 ENGINEANDENGINEOVERHAUL
Thereareonlytwotypesof valveguidesusedon machined. CupType CamshaflFollowers
automobile engines: thereplaceable-type (allalu- If theseatsarein goodcondition,thevalvescan
minumheads)andthecast-inintegral-type (most Toinstallthesprings,retainers andvalvelockson
belappedto theseats,andthecylinderheadassem- headswhichhavethesecomponents recessed into
castironheads). Therearefourrecommended meth- bled.Seethevalvessectionfor instructions
onlap-
odsfor repairing wornguides. thecamshaft followersbore,youwill needa small
ping. screwdriver-type tool,somecleanwhitegreaseanda
. Knurling If thevalveseatsareworn,crackedor damaged,
Inserts lotof patience. Youwill alsoneedtheC-clampstyle
l
theymustbeservicedbya machine shop.Thevalve springcompressor andtheOHCtoolusedto disas-
l Reaming oversize seatmustbeperfectlycenteredtothevalveguide,
Replacing semblethehead.
l
whichrequiresveryaccuratemachining. 1. Lightlylubricatethevalvestemsandinsertall
Knurlingis a processin whichmetalis displaced
andraised,therebyreducing clearance, givinga true of thevalvesintothecylinderhead.If possible,main-
CYLINDERHEADSURFACE taintheiroriginallocations.
center,andprovidingoil control.It is theleastex-
pensivewayof repairingthevalveguides.However, If thecylinderheadis warped,it mustbema- 2. If equipped, installanyvalvespringshims
chinedflat.If thewarpage is extremely
severe,the whichwereremoved.
it is notnecessarily thebest,andin somecases,a headmayneedto bereplaced. Insomeinstances,it 3. If equipped, installthenewvalveseals,keep-
knurledvalveguidewill notstandupfor morethan maybepossibleto straighten a warpedheadenough ingthefollowingin mind:
a shorttime.It requiresa specialknurlizerandpre- to allowmachining. Ineithercase,contacta profes- l If thevalvesealpressesovertheguide,
cisionreamingtoolsto obtainproperclearances. It sionalmachine sh& for service. lightlylubricatetheouterguidesurfaces.
wouldnotbecosteffectiveto purchase thesetools, l If thesealis an0-rinatvoe.it rc rn+#fld
unlessyouplanon rebuildingseveralof thesame *Any OHCcylinder headthat showsexces- ., ,,
I” .1.1.“1.“”

sive warpageshouldhave the camshaftbear- justaftercompressing thespringbutbeforethe

cylinderhead. ing journals align boredafter the cylinder valvelocks.
Installing
a guideinsertinvolvesmachining the headhas beenresurfaced. 4. Placethevalvespringandretaineroverthe
guidetoaccepta bronzeinsert.Onestyleisthecoil- stem.
typewhichis installedintoa threaded guide.Another 5. Positionthespringcompressor andtheOHC
isthethin-walledinsertwheretheguideis reamed tool,thencompress thespring.
: oversize to accepta split-sleeve insert.Afterthein- Failure to align bore the camshaftbearing 6. Usinga smallscrewdriver asa spatula, fill
sertis installed,a specialtoolis thenrunthroughthe journals could result in severe enginedam- thevalvestemsideof thelockwithwhitegrease.Use
guideto expandtheinsert,lockingit to theguide. age includingbut not limited to: valve and theexcessgreaseonthescrewdriver to fastenthe
Theinsertis thenreamed to thestandard sizefor oiston damage.connectinurod damaoe, locktothedriver.
propervalveclearance. iamshaft and/orcrankshaftbreakage, 7. Carefullyinstallthevalvelock,whichis stuck
Reamina for oversize
valvesrestoresnormalclear- to theendofthescrewdriver, tothevalvestemthen
antesandprovidesatruevalveseat.Mostcast-in pressonit withthescrewdriver untilthegrease
i tvpeguidescanbereamed to acceptanvalvewithan CRACKSANDPHYSICALDAMAGE squeezes out.Thevalvelockshouldnowbestuckto
oversizestem.Thecostfactorforthiscanbecome Certaincrackscanberepairedin bothcastiron thestem.
quitehighasyouwill needto purchase thereamer andaluminum heads.Forcastiron,a tapered 8. Repeat Steps6 and7 fortheremaining valve
andnew,oversize stemvalvesforall guideswhich threadedinsertis installedalongthelengthof the lock.
werereamed. Oversizesaregenerally 0.003to 0.030 crack.Aluminum canalsousethetaperedinserts, 9. Relievethespringpressure slowlyandinsure
in.(0.076to 0.762mm), with0.015in.(0.381mm) however weldingis thepreferred method.Some thatneithervalvelockbecomes dislodged bythere-
beingthemostcommon. physicaldamage canberepaired throughbrazingor tainer.
Toreplace cast-intypevalveguides,theymustbe welding.Contact a machine shopto getexpertadvict 10. Remove thespringcompressor tool. \
drilledout,thenreamed to acceptreplacement foryourparticulardilemma. 11. Repeat Steps2 through10untilall of the
guides,Thismustbedoneona fixturewhichwill al- springshavebeeninstalled.
lowcentering andlevelingoff of theoriginalvalve ASSEMBLY 12. Installthefollowers,camshaft(s) andany
seator quide,otherwise a seriousguide-to-seat mis- othercomponents thatwereremoved for disassem-
alignment mayoccurmakingit impossible to prop- + See Figure 258 bly.
erlymachine theseat.
Replaceable-type guidesarepressedintothe Thefirststepforanyassembly jobisto havea RockerArm Type CamshaftFollowers
cylinderhead.A hammer anda stepped driftor cleanareain whichto work.Next,thoroughly clean 1. Lightlylubricate thevalvestemsandinsertall
punchmaybeusedto installandremovetheguides. all of thepartsandcomponents thatareto beassem- of thevalvesintothecylinderhead.If possible,main-
Beforeremoving theguides,measure theprotrusion bled.Finally,placeall of thecomponents ontoa suit- taintheiroriginallocations.
onthespringsideof theheadandrecordit for instal- ableworkspaceand,if necessary, arrangetheparts 2. If equipped, installanyvalvespringshims
tation.Usethestepped driftto hammer outtheold totheirrespectivepositions. whichwereremoved.
guidefromthecombustion chamber sideof thehead. 3. If equipped, installthenewvalveseals,keep-
whenin~llfng, determine whetheror nottheguide ingthefollowingin mind:
alsosealsa waterjacketinthehead,andif it does, l If thevalvesealpressesovertheguide,
usethe~o~ended sealingagent.If thereis no lightlylubricatetheouterguidesurfaces.
waterjacketgreasethevalveguideanditsbore.Use l If thesealis anO-ringtype,it is installed
thestepped drift,andhammer thenewguideintothe justaftercompressing thespringbutbeforethe
cylinderheadfromthespringsideof thecylinder valvelocks.
head.A stackaf washers thesamethickness asthe 4. Placethevalvespringandretaineroverthe
measured Eaton mayhelptheinstallation stem.
process. 5. Positionthespringcompressor tooland
compress thespring.
VALVESEATS 6. Assemble thevalvelocksto thestem.
*Before any valve seat maChiningcan be 7. Relievethespringpressure slowlyandinsure
aerformed.the guidesmustbe within factory thatneithervalvelockbecomes dislodgedbythere-
recommendedspecifications. tainer.
- 1Fig. 258 Onceassembled,checkthe valve 8. Remove thespringcompressor tool.
; rlf any machtningor replacementswere 1clearance and correct as needed 9. Repeat Steps2 through8 untilall of the
I madeto the valve guides, the seats must be springshavebeeninstalled.
 I)

ENGINEANDENGINEOVERHAUL
3-65
10. Installthecamshaft(s),
rockers,shaftsand waysnumber1.However, dependingontheengine
anyothercomponents thatwereremoved for disas- placement, thefrontoftheenginecouldeitherbethe
sembly. flywheelor damper/pulley end.Generally
thefrontof
theenginefacesthefrontof thevehicle.Usea num-
berpunchor scribeandalsomarkthemainbearing
capsfromfrontto rearwiththefrontmostcapbeing
number 1 (if therearefivecaps,markthem1 through
GENERALINFORMATION 5, frontto rear).
A thoroughoverhaul or rebuildof anengineblock
wouldincludereplacing thepistons,rings,bearings,
timingbelt/chain assembly andoil pump.ForOHV Takespecial care when pushingthe connect-
enginesalsoincludea newcamshaft andlifters.The ing rod up from the crankshaftbecausethe
blockwouldthenhavethecylindersboredandhoned sharpthreadsof the rod bolts/studswill
oversize(or if usingremovable cylindersleeves,new scorethe crankshaftjournal. Insurethat spe-
sleevesinstalled) andthecrankshaft wouldbecut cial plastic capsare installed over them, or
undersizeto providenewwearingsurfaces andper- cut two piecesof rubberhoseto do the
feetclearances. However,yourparticular enginemay same.
Again,rotatetheengine,thistimeto positionthe
number onecylinderbore(headsurface)up.Turnthe
crankshaft untilthenumber onepistonisatthebot-
tomof itstravel,thisshouldallowthemaximum ac-
cessto itsconnecting rod.Remove thenumberone
connecting rodsfastenersandcapandplacetwo
lengthsof rubberhoseovertherodbolts/studs to
protectthecrankshaft fromdamage. Usinga sturdy
woodendowelanda hammer, pushtheconnecting
rodupabout1 in.(25mm)fromthecrankshaft and
remove theupperbearinginsert.Continue pushing
ortappingtheconnecting rodupuntilthepiston
ringsareoutof thecylinderbore.Remove thepiston
androdbyhand,puttheupperhalfof thebearingin-
sertbackintotherod,installthecapwithitsbearing
insertinstalled, andhand-tighten thecapfasteners. If
thepartsarekeptin orderinthismanner, theywill
notgetlostandyouwill beabletotellwhichbear-
ingscameformwhatcylinderif anyproblems are
discovered anddiagnosisis necessary. Remove all
theotherpistonassemblies inthesamemanner. On
V-styleengines,remove all ofthepistonsfromone
bank,thenreposition theenginewiththeothercylin-
derbankheadsurfaceup,andremove thatbanksnis-
tonassemblies.
Theonlyremaining component intheengine
blockshouldnowbethecrankshaft. Loosenthemain
bearingcapsevenlyuntilthefasteners canbeturned
preventthe assembliesfrom beingremoved, byhand,thenremove themandthecaps.Remove the
Fig. 260 Carefully tap the piston out of the crankshaft fromtheengineblock.Thoroughly clean
necessitatingits removal. bore using a wooden dowel all of thecomponents.
Thereareseveraldifferenttypesof ridgereamers
onthemarket,noneof whichareinexpensive, Unless housingor transmission mounting surface. Youmust INSPECTION
.3“me.+ ,-ins,rdnnn;nn mh~lil.-linn
a ylwx “Gal “I cllylllc Ir;““ll”llly
;I nn+:n:nnL.*
13 dllLILlpxC”,
l.^W
““I-
beableto accesstheconnecting rodfasteners and
rowor renta reamer. turnthecrankshaft duringdisassembly. Also,all en- Nowthattheengineblockandall of itscompo-
1. Turnthecrankshaft untilthepistonis atthe ginecovers(timing,front,side,oil pan,whatever) nentsareclean,it’stimeto inspectthemfor wear
bottomof itstravel. shouldhavealreadybeenremoved. Engines which and/ordamage. Toaccurately inspectthem,youwill
2. Covertheheadof thepistonwitha rag. aresei2,edor lockedupmaynotbeableto becom- needsomespecialized tools:
3. Followthetoolmanufacturers instructions and nletelv
r’-‘-‘, disassembled, anda core(salvage yard)en- l Twoorthreeseparate micrometers to measure
cutawaytheridge,exercising extreme careto avoid gineshouldbepurchased. theprstons andcrankshaft journals
~ ioo deepfy. If not doneduringthecylinderheadremoval,re- l A dialindicator
4. Remove theridgereamer, theragand1asmany movethetimingchain/belt and/orgear/sprocket as- l Telescoping gauges forthecylinderbores
armings aspossible.Continue untilaII of the sembly.Remove theoil pick-upandpumpassembly l A rodalignment fixtureto checkfor bentcon-
biter ridgeshavebeenremoved. and,if necessary, thepumpdrive.If equipped, re- nettingrods
moveanybalance or auxiliaryshafts.If necessary,re- If youdo nothaveaccessto thepropertools,
~1SA~E~BLY movethecylinderridgefromthetopof thebore.See youmaywantto bringthecomponents to a shop
thecylinderridgeremovalprocedure earlierinthis thatdoes.
b See Figures259 and 260 section. Generally, youshouldn’t expectcracksin theen-
Rotate theengineoversothatthecrankshaft is ex- gineblockor itscomponents unlessit wasknownto
Theenginedisassembly instructions
followingas- leak,consume or mixenginefluids,it wasseverely
sumethatyouhavetheenginemounted onanengine posed.Usea numberpunchor scribeandmarkeach
stand.If not,it is easiestto disassembletheengine connecting rodwithitsrespective cylindernumber. overheated, ortherewasevidence of badbearings
ona benchor thefloorwithit restingonthebell Thecylinderclosesttothefrontof theengineisal- and/orcrankshaft damage. Avisualinspection
3-66 ENGINEANDENGINEOVERHAUL
shouldbeperformed onall of thecomponents, but (0.0381mm-O.0635mm). Inspectandmeasure the crankshaft, butyoushouldhardlyfeelthemwithyour
justbecause youdon’tseea crackdoesnotmeanit cylinderbores.Theboreshouldbechecked for out- fingernail.Whenmeasuring thecrankshaftwitha mi-
is notthere.Somemorereliablemethods for inspect- of-roundness, taperandsize.Theresultsofthisin- crometer, youwill takereadings atthefrontandrear
ingfor cracksincludeMagnaflux?a magnetic spectionwill determine whether thecylindercanbe of eachjournal,thenturnthemicrometer 90degrees
processorZyglo@‘, a dyepenetrant. Magnaflux@ is usedin itsexistingsizeandcondition, or a reboreto andtaketwomorereadings, frontandrear.Thedif-
usedonlyonferrousmetal(castiron).Zyglo@ usesa thenextoversizeis required(or inthecaseof remov- ferencebetween thefront-to-rear readingsis thejour-
sprayonfluorescent mixturealongwitha blacklight ablesleeves,havereplacements installed). naltaperandthefirst-to-90degreereadingisthe
to revealthecracks.It is stronglyrecommended to Theamountof cylinderwallwearisalwaysgreater out-of-round measurement. Generally,thereshould
haveyourengineblockchecked professionally
for atthetopof thecylinderthanatthebottom.This benotaperor out-of-roundness found,however, up
cracks,especiallyif theenginewasknownto have wearis knownastaper.Anycylinderthathasataper to 0.0005in.(0.0127mm) for eithercanbeover-
overheated and/orleakedor consumed coolant.Con- of 0.0012in.(0.305mm) or more,mustberebored. looked.Also,thereadings shouldfall withinthefac-
tacta localshopforavailabilityandpricingof these Measurements aretakenata numberof positionsin toryspecifications for journaldiameters.
services. eachcylinder:atthetop,middleandbottomandat \ If thecrankshaft journalsfall withinspecifications,
twopointsateachposition;thatis,ata point90de- it is recommended thatit bepolishedbeforebeing
EngineBlock greesfromthecrankshaft centerline,aswellasa returned to service.Polishing thecrankshaft insures
pointparalleltothecrankshaft centerline.Themea- thatanyminorburrsor highspotsaresmoothed,
ENGINEBLOCKBEARINGALIGNMENT surements aremadewitheithera specialdialindica- therebyreducing thechanceof scoringthenewbear-
Remove themainbearingcapsand,if still in: toror atelescopic gaugeandmicrometer. Ifthenec- ings.
stalled,themainbearinginserts.Inspectall of the essaryprecisiontoolstochecktheborearenot
mainbearingsaddlesandcapsfor damage, burrsor available, taketheblockto a machine shopandhave Pistonsand ConnectingRods
highspots.If damage isfound,andit is causedfrom themmikeit.Alsoif youdon’thavethetoolsto check
a spunmainbearing,theblockwill needto bealign- thecylinderbores,chances areyouwill nothavethe PISTONS
boredor,if severeenough, replacement. Anyburrsor necessary devicesto checkthepistons,connecting N See Figure 262
highspotsshouldbecarefullyremoved witha metal rodsandcrankshaft. Takethesecomponents withyou
file. andsaveyourselfanextratrip. Thepistonshouldbevisuallyinspected for any
Placea straightedgeonthebearingsaddles, in the Forourprocedures, wewill useatelescopic signsof crackingor burning(causedbyhotspotsor
engineblock,alongthecenterline of thecrankshaft. If gaugeanda micrometer. Youwill needoneof each,’ detonation),andscuffingor excessive wearonthe
anyclearance existsbetween thestraightedgeandthe witha measuring rangewhichcoversyourcylinder skirts.Thewristpinattaches thepistontothecon-
saddles, theblockmustbealign-bored. boresize. nettingrod.Thepistonshouldmovefreelyonthe
Align-boringconsistsof machining themain 1, Positionthetelescopic gaugeinthecylinder wristpin,bothslidingandpivoting.Graspthecon-
bearingsaddlesandcapsbymeansof aflycutterthat bore,loosenthegaugeslockandallowit to expand. nettingrodsecurely, or mountit ina vise,andtryto
runsthroughthebearingsaddles. rockthepistonbackandforthalongthecenterline of
*Your first two readingswill be at the top of thewristpin.Thereshouldnotbeanyexcessive play
DECKFLATNESS the cylinder bore, then proceedto the middle evidentbetween thepistonandthepin.If thereareC-
and finally the bottom,makinga total of six clipsretainingthepininthepistonthenyouhave
Thetopof theengineblockwherethecylinder measurements.
headmountsis calledthedeck.Insurethatthedeck \ wristpinbushings intherods.Thereshouldnotbe
surfaceis cleanof dirt,carbondepositsandoldgas- 2. Holdthegaugesquareinthebore,90degrees anyexcessive playbetween thewristpinandtherod
ketmaterial.Placea straightedge acrossthesurface fromthecrankshaft centerline,andgentlytightenthe bushing.Normalclearance forthewristpinisap-
of thedeckalongitscenterline and,usingfeeler lock.Tiltthegaugebackto removeit fromthebore. prox.0.001-0.002 in.(0.025mm-0.051mm).
gauges, checktheclearance alongseveralpoints.Re- 3. Measure thegaugewiththemicrometer and Usea micrometer andmeasure thediameter of the
peatthechecking procedure withthestraightedge recordthereading. piston,perpendicular to thewristpin,ontheskirt.
placedalongbothdiagonals of thedecksurface.If 4. Again,holdthegaugesquareinthebore,this Compare thereadingto itsoriginalcylindermeasure-
thereadingexceeds 0.003in.(0.076mm) withina 6.0 timeparallelto thecrankshaft centerline,andgently mentobtained earlier.Thedifference between thetwo
in.(152cm)span,or 0.006in.(0.152mm) overthe tightenthelock.Again,youwill tilt thegaugebackto readingsis thepiston-to-wall clearance. If theclear-
totallengthof thedeck,it mustbemachined. removeit fromthebore. anteiswithinspecifications, thepistonmaybeused
5. Measure thegaugewiththemicrometer and asis.If thepistonis outof specification, butthebore
CYLINDERBORES recordthisreading. Thedifference between thesetwo is not,youwill needa newpiston.If bothareoutof
readings is theout-of-round measurement of the specification,
youwill needthecylinderreboredand
$ See Figure 261 cylinder. oversizepistonsinstalled. Generally if twoor more
6. Repeat steps1 through5, eachtimegoingto pistons/bores areoutof specification, it is bestto re-
Thecylinderboreshousethepistonsandare boretheentireblockandpurchase a complete setof
slightlylargerthanthepistonsthemselves.
Acom- thenextlowerposition,untilyoureachthebottomof
monpiston-to-bore clearance
is 0.0015-0.0025
in. thecylinder.Thengoto thenextcylinder,andcon- oversize pistons.
tinueuntilall of thecylindershavebeenmeasured.
Thedifference between thesemeasurements will
tellyouall aboutthewearin yourcylinders. The
measurements whichweretaken90degrees fromthe
crankshaft centerline will alwaysreflectthemost
wear.,That is because atthispositioniswheretheen-
ginepowerpresses thepistonagainstthecylinder
borethehardest. Thisis knownasthrustwear.Take
yourtop,90degreemeasurement andcompare it to
yourbottom,90degreemeasurement. Thedifference
between themis thetaper.Whenyoumeasure your
pistons,youwill compare thesereadings to yourpis-
tonsizesanddetermine piston-to-wall clearance.
Crankshaft
Inspect
thecrankshaft for visiblesignsof wearor
damage.
All of thejournalsshouldbeperfectlyround
andsmooth.Slightscoresarenormalfor a used
 ENGINEANDENGINEOVERHAUL
3-67
crankshaft.
Replace
anyfreezeoroil galleyplugs
CONNECTING ROD
Youshouldhavetheconnecting
StraiQhtness ata machine
rodchecked
shop.If theconnecting
for
rod
1 whichwereremoved
Crankshaft
duringdisassembly.

is bent,it will unevenly wearthebearingandpiston,

aswellasplacegreaterstressonthesecomponents. u See Figures265, 266, 267, and 266
Anybentor twistedconnecting rodsmustbere-
placed.If therodsarestraightandthewristpinclear- 1. Remove themainbearinginsertsfromthe
anceiswithinspecifications, thenonlythebearing blockandbearingcaps.
endoftherodneedbechecked. Placetheconnecting 2. If thecrankshaftmainbearingjournalshave
rodintoa vice,withthebearinginsertsin place,in- beenrefinished to a definiteundersize,
installthe
stallthecaptotherodandtorquethefasteners to correctundersize bearina.Besurethatthebearina
specifications. Usea telescoping gaugeandcarefully insertsandbearingboresareclean.Foreignmateiial
measure theinsidediameter of thebearings. Com- underinsertswill distortbearinqandcausefailure.
parethisreadingto therodsoriginalcrankshaft jour- 3. Placetheuppermainbearinginsertsin bores
naldiameter measurement. Thedifference is theoil
clearance. If theoil clearance is notwithinspecifica- *The oil holes in the bearinginserts must
tions,installnew . bearings in therodandtakeanother be
measurement. it theClearance is still outof :specifica- L . . aligned
. with the oil holes in the cylinder
block.
tions,andthecrankshaft is not,therodwill needto shopasthepistonsmustbeinstalledinthecon,ect
bereconditioned bya machine shop. relationshipto
therodor enginedamage canoccur,
*You can also use Plastigage’@tocheckthe
bearingclearances.Theassen-Mm....=sectinn - _______ Pistons and Connecting Rods I
has completeinstructionson its use. b See Fiaute 264
--- --*------

Camshaft \ Onlypistonswiththewristpinretained byC-clips

areserviceable bythehome-mechanic. Pressfit pis-
Inspectthecamshaft andlifters/followers
asde I” requirespecialpresses
tons and/orheatersto re-
scribedearlierin thissection. \ rrrove/install
theconnecting rodandshouldonlybe
PC srformed bya machine shop.
Bearings All pistonswill havea markindicating
thedirec-
All of theenainebearinos
~~~ I~ should
.- - be
-- visuallv
..-_-.., in- tir9nto thefrontof theengineandthemustbein-
spected forwe; and/ordamage. Thebearingshould stalledintotheengineinthatmanner. Usuallyit is a
lookevenlywornall aroundwithnodeepscoresor notchorarrowonthetopof thepiston,or it maybe
pits.If thebearingis severelyworn,scored,pittedor theletterFcastor stamped intothepiston.
heatblued,thenthebearing, andthecomponents ASEtiBlY
thatuseit, shouldbebroughtto a machine shopfor
inspection. Full-circlebearings(usedonmost
camshafts, auxiliaryshafts,balanceshafts,etc.)re- Beforeyoubeginassembling theengine,firstgive
quirespecialized toolsfor removalandinstallation,’ yourselfa clean,dirtfreeworkarea.Next,cleanevery
andshouldbebroughtto a machine shopfor service. enginecomponent again.Thekeytoa QOOd assem-
hhr Iaio ~rGiOllll,lc7.Ja.
“‘I
da~nlinmw

Oil Pump Mounttheengineblockintotheenginestandand II

wasnIt onelasttimeusmgwateranddetergent (dish-
*The oil pumpis responsiblefor providing 1ILl.M0,,y “GSGl
unrhinn ycxII~nrirc
rldarnant ““1n well), While washing it,
constantlubricationto the whole engineand scrubthecylinderbore:j\witha softbristlebrushand
so it is recommendedthat a new oil pumpbe thoroughly cleanall oftht: oil oassaoes.Comoletelv
installed when rebuildingthe engine. drytheengineandspray theentireassembly down’
Completely disassembletheoil pumpandthor- withananti-rustsolutioinsuchasWD-4Q@ or similar Fig. 265 Apply a strip of gauging material
oughlycleanall of thecomponents. Inspecttheoil proIduct.Takea cleanlint-freeragandwipeupany to the bearmg lournal, then mstall and
pumpQears andhousingfor wearand/ordamage. In- exelessanti-rustsolutionfromthebores,bearing !torguethe~~p * ,’ /
surethatthepressure reliefvalveoperates
properly sacIdles,etc.Repeat thefinalcleaningprocessonthe
andthereis nobindingor stickingdueto varnishor
debris.If all of thepartsarein properworkingcondi-
tion,lubricate
blethepump.
thegearsandreliefvalve,andassem- r
REFINISHING
# See Figure 263
Almostall engineblockrefinishing mustbeper- I
IUIIII~Uuya macnme snap.ir mecynnoers arenorro
berebored, thenthecylinderglazecanberemoved
witha ballhone.Whenremoving cylinderglazewith
a ballhone,usea lightor penetratingtypeoil to Iu-
bricatethehone.Donotallowthehoneto rundryas
thismaycauseexcessive scoringof thecylinder Fig. 266After the cap is removedagain, use
boresandwearonthehone.If newpistonsarere-
quired,theywill needto beinstalledto theconnect-
ingrods.Thisshouldbeoerformed bva machine

3-68 ENGINEANDENGINEOVERHAUL
crankshaftend-play
Fig. 266 Carefully pry the crankshafl Ez
and forth while reading the dial gauge for
end-play
4. Installthelowermainbearinginsertsin bear-
ingcaps.
5. Cleanthematingsurfaces of blockandrear
mainbearingcap.
6. Carefullylowerthecrankshaft intoplace.Be
carefulnotto damage bearingsurfaces.
7. Checktheclearance of eachmainbearingby
usingthefollowingprocedure:
a. Placea pieceof Plastigage@ or its equiva-
lent,on bearingsurfaceacrossfull widthof bear-
ingcapandaboutV4in. off center.
b. Installcapandtightenboltsto specifica-
tions.Donotturncrankshaft whilePlastigage@
in place.
c. Remove thecap.UsingthesuppliedPlasti-
gage@ scale,checkwidthof Plastigage@ at
widestpointto getmaximum clearance. Differ-
encebetween readingsis taperof journal.
d. If clearanceexceeds specifiedlimits,try a
0.001in.or 0.002in. undersize bearingin com-
binationwiththestandard bearing.Bearingclear-
antemustbewithinspecifiedlimits.If standard
and0.002in. undersize bearingdoesnotbring
clearance withindesiredlimits,refinishcrank-
shaftjournal,theninstallundersize bearings.
.
8. Installtherearmainseal. theinnerportionof thelowerland.If thelower
9. Afterthebearings havebeenfitted,applya landshavehighsteps,thepistonshouldbere-
lightcoatof engineoil to thejournalsandbearings. placed.
Installtherearmainbearingcap.Installall bearing 2. Unlessnewpistonsareinstalled, besureto
capsexceptthethiustbearingcap.Besurethatmain I installthepistonsinthecylindersfromwhichthey
bearingcapsareinstalledin originallocations. wereremoved. Thenumbers ontheconnecting rod
Tightenthebearingcapboltsto specifications. andbearingcapmustbeonthesamesidewhenin-
10. Installthethrustbearingcapwithboltsfin- stalledinthecylinderbore.If aconnecting rodis
ger-tight. evertransposed fromoneengineor cylinderto an-
11. Prythecrankshaft forwardagainstthethrust other,newbearings shouldbefittedandtheconnect-
surfaceof upperhalfof bearing. ingrodshouldbenumbered to correspond withthe *
12. Holdthecrankshaft forwardandprythethrust newcylindernumber. Thenotchonthepistonhead
bearingcapto therear.Thisalignsthethrustsur- goestowardthefrontof theengine.
facesof bothhalvesof thebearing. 3. Installall of therodbearinginsertsintothe
13. Retaintheforwardpressure onthecrankshaft. \ rodsandcaps.
Tightenthecapboltsto specifications. 4. Installtheringstothepistons.Installtheoil
14. Measure thecrankshaft end-playasfollows: controlringfirst,thenthesecondcompression ring
a. Mounta dialgaugeto theengineblock andfinallythetopcompression ring.Usea piston
andpositionthetip of thegaugeto readfromthe ringexpander tooltoaidin installation andto help
crankshaft end. reducethechanceof breakage.
b. Carefullyprythecrankshaft towardtherear 5. Makesuretheringgapsareproperlyspaced
of theengineandholdit therewhileyouzerothe aroundthecircumference of thepiston.Fita piston
gauge. ringcompressor aroundthepistonandslidethepis-
c. Carefullyprythecrankshaft towardthe tonandconnecting rodassembly downintothe
frontof theengineandreadthegauge. cylinderbore,pushingit inwiththewoodenhammer
d. Confirmthatthereadingis withinspecifi- handle.Pushthepistondownuntilit is onlyslightly
cations.If not,installa newthrustbearingand belowthetopofthecylinderbore.Guidethecon-
repeattheprocedure. If thereadingis still outof nettingrodontothecrankshaft bearingjournalcare-
specifications witha newbearing,havea ma- fully,to avoiddamaging thecrankshaft.
chineshopinspectthethrustsurfaces of the 6. Checkthebearingclearance of alltherod
crankshaft, andif possible,repairit. bearings, fittingthemto thecrankshaft bearingjour-
15. Rotatethecrankshaft soasto positionthe nals.Followtheprocedure inthecrankshaft installa-
firstrodjournaltothebottomof itsstroke. tionabove.
7. Afterthebearings havebeenfitted,applya
Pistonsand ConnectingRods lightcoatingof assembly oil to thejournalsandbear-
# See Figures 269, 270,271, and 272 ings.
8. Turnthecrankshaft untiltheappropriate
1. Beforeinstallingthepiston/connecting rod bearingjournalisatthebottomof itsstroke,then
assembly, oil thepistons,pistonringsandthecylin- pushthepistonassembly all thewaydownuntilthe
connecting rodbearingseatsonthecrankshaft jour-
derwallswithlightengineoil. Installconnectingrod
boltprotectors or rubberhoseontotheconnecting nal.Becarefulnotto allowthebearingcapscrewsto
strikethecrankshaft bearingjournalsanddamage
rodbolts/studs. Alsoperformthefollowing:
a. Selecttheproperringsetfor thesizecylin- them.
derbore. 9. Afterthepistonandconnecting rodassem-
blieshavebeeninstalled, checktheconnecting rod
b. Positiontheringin theborein whichit is
goingto beused. sideclearance oneachcrankshaft journal.
c. Pushtheringdownintotheborearea 10. Primeandinstalltheoil pumpandtheoil
pumpintaketube.
wherenormalringwearis notencountered.
d. Usetheheadof thepistonto positionthe 11. Installtheauxiliary/balance shaft(s)/assem-
ringin theboreso thattheringis squarewith bly(ies).
is thecylinderwall.Usecautionto avoiddamage to
theringor cylinderbore. Cylinder Head(S)
e. Measure thegapbetween theendsof the 1. Installthecylinderhead(s)usingnewgaskets.
ringwitha feelergauge.Ringgapin a worn 2, Installthetimingsprockets/gears
andthe
cylinderis normallygreaterthanspecification. If belt/chain
assemblies.
theringgapis greaterthanthespecifiedlimits,
try anoversizeringset. EngineCoversand Components
f. Checktheringsideclearance of thecom-
pressionringswitha feelergaugeinsertedbe- Installthetimingcover(s)andoil pan.Referto
tweentheringandits lowerlandaccording to yournotesanddrawings madepriorto disassembly
specification. Thegaugeshouldslidefreely andinstallall of thecomponents
thatwereremoved.
aroundtheentireringcircumference without Installtheengineintothevehicle.
binding.Anywearthatoccurswill forma stepat
 ENGINEANDENGINEOVERHAUL
3-69

hYs3222
Fig. 271 Most rings are marked to show
which side of the ring should face up when
installed to the piston
J

4. Allowtheengineto reachnormaloperating
tt?mperature
(theupperradiatorhosewill behotto
tlie touch).
STARTING
THEENGINE 5. Atthispointyoucanperformanynecessary
Checks oradjustments,
suchascheckingtheignition
clearance using the ring and a Nowthattheengineis installedandeverywireand timing.
hoseis properlyconnected,gobackanddouble 6. Installanyremaining
components
or body
checkthatall coolantandvacuumhosesarecon- anelswhichwereremoved.
, netted.Checkthatyouroil drainplugis installedand
IREAKING
IT IN
Makethefirstmilesonthenewengine,easyones.
arvthesoeedbutdonotaccelerate hard.Mostim-
oriantly,do notlugtheengine,andavoidsustained
ighspeedsuntilat least100miles.Checktheen-
ineoil andcoolantlevelsfrequently. Expect
theen-
ineto usea littleoil untiltheringsseat.Changethe
il andfilterat500miles,1500miles,thenevery
 1.5L ENGINE MECHANICAL SPECIFICATIONS 1.5L ENGINE MECHANICAL SPECIFICATIONS
English Metric English Metric
Description Specificationr Specifications Cescriptlon Specifications Specifications
General Information Valve guide
Enginetype 4 Cylinder In-LineOvethead Camshaft Length
Displacement 69 6 cubic I” 15L Intake 1 732 I” 44 Omm
sore 2 972 I” 75 5mm Exhaust 1 949 I” 49 5mm
Stroke 3 226 I” 82mm Selwe wes 0002,0010.002cIn 0 05,O 25,O 50mm
Compression rat10 921 Valve seat
Firingorder l-3-4-2 Seat contactwidth 0 035-o 051 I” 0 S-13mm
Cylinder Head Seat angle (all) 44.44 5”
Overall height 4 209.4 217 I” 1059-107 lmm Valve spring
Flatness (maximum) 0 002 I” 0 05mm Free length
Camshaft bearing-to-camshaftclearance 0 0016-O0031 I” 0 04-OOBmm Intake
Camshaft Standard 1 615 I” 461mm
Camshaft height Llmlt 1 776 I” 451mm
Intake Exhaust
Standard 1 5256 I”. 39 75mm Standard 1 643 I” 46 8mm
Limit 1.5059 In 38.25mm Llmlt 1 603 I” 45 6mm
Exhaust Load
Standard 1 5394 I” 391mm Intake
Llmlt 1 5197 In 38 6mm Exhaust 64 It Ibs. 290Nm
Journal outside diameter - 161101” 46mm Cylinder Block
Bearing 011clearance Bore
Standard 0 1X324.0a)39 I” 0 06-O10mm Dnmeter 2 9724-Z 9736 I” 75 50.75 53mm
Limit 0 0055 I” 0 14mm Out-of-round(ma) 0 006 I” 0 02mm
Rocker arms Taper (max.) 0 006 I” 0 02mm
lwde diameter 0 744 I”. 18 Smm Overall height
Arm-to-shaltclearance Standard 10075-10083In 255 9.256 1mm
Standard 0 OCQ4-00016 I”. 0 Old 04mm Llrnbt 10 073 I” 254 62mm
Llmlt 0 004 I” Olmm
Rocker arm shaft
OutsIdediameter 0 744 I” 16 9mm
Valves
Valve length
Intake 3 9665 I” 100 75mm
Exhaust 3 9763 I” 101.05mm
_ Stemoutslde diameter
Intake 0 2585.0 2591 I” 6.565-6 5tlOmm
Exhaust 0 2571-o 2579 I” 6 530-6 55Omm
Faceangle (ail) 45-45 5”
Head thickness (margm) No 1
Intake Standard 0 0012-o 0028 I”. 0 03-O07mm
Standard 0 039 I”. 1 Omm Llmlt 0 0047 I” 0 12mm
Llmlt 0 02u In. 05mm No 2
Exhaust Standard 0 OCOE-00024 I” 0 02-O06mm
0 059 I” 1.5mm Llmlt 0 0047 I” 0 l2mm
0 039 I”. 1.Omm End gap
No 1
Standard 0 0079-o 0157 I”. 0 20-O40mm
0 02-O05mm Limit 0 031 I” 0 8mm
0 1Omm No 2
Standard 0 0079.0.0136 I” 0 20-O35mm
0 05-OOSmm Ltmlt 0.031 I” 0.8mm
0 15mm 01
Standard 0 0079.0 0276 I” 0 20-O70mm
Limit 0 039 I” 1 Omm
0 15mm Connecting rod
0 25mm Bend (mex) 0 CO20I” 0 05mm
Twst (max) 0 0039 In 0 10mm
0 07mm
 1.5L ENGINE MECHANICAL SPECIFICATIONS 1.6L ENGINE MECHANICAL SPECIFICATIONS
English Metric
Description Specifications Specifications
Connecting rod (cont’d)
Pistonp,n press-mload 1,100.3,300 II Ibs 5,000.15,OWNm
Connectingrod bearing 011clearance
Standard 0 0006-OCO24I” 0 02-O06mm
Limit 0 0059 I”. 015mm
Crankshaft
Main bearing 011clearanc8
Standard 0 0006.0 0026 I” 0 02-O07mm
Ltmit 0 0059 I” 0 15mm
Pin outslde diameter 165111 42mm
Journal outside dlametei 1 89 I”. 46mm
Out-al-round imax I 0oLx%l” 0 015mm

SI& clearance
Standard 0 0016-O0039 I” 0 04-O1Omm
Llmtt 0 0079 I” 0 20mm
Bodyclearance
Standard 0 0039-o 0071 I”. 0 10-O16mm
Llmlt 0013am 0 35mm
AelM
spring
Free length . 1635 I” 46 6mm
Load (@1 579 tn (40 1mm) 13H Ibs 61Nm

1.6L ENGINE MECHANICAL SPECIFICATIONS

English Metric
Description Specifications Specifications
General Information

Camshaftheight
Intake
Standard 1 3556 I” 35 2Omm
Llmlt 1 3661 I” 34 70mm
Exhaust
Standard 1 3743 I” 34 W7mm
Llmlt 1 3546 I”. 34 407mm
Journal outslde diameter 1021n 26mm
Bearing011clearance 0 0020-0 w35 I” 0 05-0 09mm
End-play 0 004.0 oQ6In 0 i-02mm
 1.6L ENGINE MECHANICAL SPECIFICATIONS
English Metric
OWCriptkUl SpeciflCatiOllS Specifications
Piston Rings (cont’d)
End 9ap
No 1
standard 0 0096-00157,“. 0 25-O40mm
Limit 0 031 1” 0 6mm
No 2
Standard 0 0136-O0197 1” 0 350 mm
Ltmlt 0 039 I”. 1 Omm
04
standard 0 0079-O0276 I” 0 2Q.O70mm
Limit 0 039 I” 1 Omm
SeNlce SlZeS 0 010,O 020.0 030.0 039 m 0 25.0 50,O 75, 1 Omm
Connecting rod
Bend(max) 0 0020 I”. 0 05mm
Test (max.) 0 0039 I” 0 1Omm
Rod bigend side clearance
Standard 0 0039-o 0096 I” 0.10-O25mm Standard 146111 37 15mm
Limit 0 016 I” 0 4mm Llmlt 1441n 36 65mm
Pistonpm press-mload 1.6533,658 fl Ibs 7.500.17.500Nm
Connecbngred bearingal clealilnce
Standard 0 oowo 002u I” 0 02-O05mm
Llmlt oOO41n 0 lmm 110.15mm
Crankshaft Limit 109.65mm
Mm bearingMI clearance Exhaust
Standard 0 ooot-0 0020 I”. 0 02-O05mm 4 476 in 11370mm
Llmlt 0 004 I”. Oimm 4 457 I” 11325mm
Pmoutslde diameter 177m 45mm
Journalout&e diameter 224111 57mm 0 2340 I” 6 Omm
Out-of-round(max ) 00006lll 0 015mm 0 2340 1” 6 Omm
Crankshaftend.play 45-45 5”
SIatU&rd 0 002-O0071 1” 0 05-O16mm
Llmlt 0 0096 I” 0 25mm
1 Omm
Flywheel 0 5mm
Run-out(max ) 0 0051 I” 0 13mm
011Pump 13mm
lip clearance 0 6mm
Drive gear
Standard 0 0063.0 W63 m. 016.021mm Intake
Llmlt OCW6lfl 0 25mm Standard 0 @JOB-00020 m 0 02-O05mm
Driven gear Llmtt 0 0039 I” 0 1Omm
standard 0 0051-O0071 I”. 0 136 16mm
Llmlt 0 0096 I”. 0 25mm
Sideclearance
Dive gear
standard 0 0331.0 0055 I”. 0 060 14mm
Llmlt 00096lll 0 25mm
then gear
Standard 0 0024-O0047 I” 006.0 12mm
Limit 0.0096 I” 0 25mm Seatangle (all) 44-44 5”
R&l spring Valve spring
Free length 1635 I” 46 6mm Freelength
Load (01 579 I” (40 tmm) 13 11Ibs 61Nm Intake
standard 2 cmI” 50 9mm
93153m 1961n 49.9mm
Llmlt
EXhaUSt
standard 2 w I” 50 9mm
Llmlt 1961n 49.9mm
Load B 1 74 I” (44 2mm)
Intake 59 It Ibs. 216Nm
Exhaust 59 It lbs 216Nm
93153&!6
 l&L ENGINE MECHANICAL SPECIFICATIONS
English Metric
Description Speclficabons Specifications
Oil Pump (cont’d)
bdycleamnce
Standard 0 0039-o0071 I” 0 10-O18mm

2.OL SOHC ENGINE MECHANICAL SPECIFICATIONS

Gasket surfaceflatness (ma ) 0 004 I” Olmm English Metric
Piston De5Criptl0li Specifications Specifications
Outslde diameter 3191n 81 Omm General Information
Pistonpm autslde diameter 0751n 190mm Engine type 4 CyknderIn-LmeOvetiead Camshalt
Pistonp,” press-,” load 1,100.3.300fl Ibs 5,000.15,OOONm Dsplacement 121 9 cubic I” 2OL
Piston-to-cylmderclearance 0 0008-O0016 I” 0 02-O04mm Bore 3.35 I” 85mm
Piston Rings Stroke 3461n 88mm
851
Flnng order l-3-4-2
0 0012-0 0028 1” 0 03-O07mm Cylinder Head
0.0039 I”. O.lmm

0 0008-OCO24I” 0 02-O06mm
0 0039 1” Olmm

0 0098-O0157 m 0 25-O40mm
0 031 I” 0 8mm

0 0157-O0217 ,n 0 40-O55mm
0031 I” 08mm

0 1X378-00236 m 0 200 60mm

Llmlt 0 039 I” 1 Omm
Connecting rod
Rod big end side clearance
Standard 0 0039.0 0098 m 0 10-O25mm
Llmlt 0 016 I” 0.4mm
Crankshaftpl” o~~clearance
Standard 0 OG98-00020 I”. 0.02-O08mm Stem outs& diameter
Lllllll 0 004 I” Olmm Intake 0 315 I”. 8Omm
Crankshafl Exhaust 0311 I”. 7 9mm
Crank&It ]ournal outsidediameter 1 97 I". 50mm Faceangle (all) 45.45 5
Pin outsIdediameter 1771n 45mm Head thickness(margm)
Journal011clearance Intake
Standard 0 0008-O0016 I” 0 020 04mm 0 047 I” 12mm
Llmlt 0 004 In Olmm 0 020 I”. 0 5mm
Out.&round (ma ) 0 0006 1” 0 015mm
Crankshaftend-play 0 079 I” 20mm
Standard 0 002-O0098 I” 0 050 25mm 0 031 I” 08mm
Llmlt 00041n Olmm
Oil Pump
Tip clearance 0 0008-OOQ24I”.
Standard 0 0024-O0071 I” 0 06-O18mm 0 0039 I”
Llmlt 0 0138 I”. 0.35mm Exhaust
Sideclearance Standard 0 0020-0 w35 I”. 0 05-O09mm
Standard 0 0016-O0039 I” 0 04-O1Omm Llmlt 0 0059 I” 0 15mm
Valve guide
InsIdediameter 0 315 1” 8 Omm
Oulslde dlametet 0516ln 131mm
valve 5eat
 2.OL SOHC ENGINE MECHANICAL SPECIFICATIONS 2.OL DOHC (NON-TURBO) ENGINE MECHANICAL SPECIFICATIONS
Engbsh Metric English Metric
Description Specifications Specifications Description Specifications Speciticatlonr
Valve sorino General Information
Engine type 4 Cylmdet In-LoneDual Overixad Camshaft
S&dard 1 36 I” Dlsplacemenl 12’ 3 cubic m 2OL
Llmlt 1 96 I” Bore 3351n 85mm
Squareness Stroke 3 46 I” 68mm
Standard 2” Comprwon rat10 981
Llmll 4” Flung order l-54-2
Cylinder Block Cylinder Head
lnslde diameter 335m 65mm Overall height 5 193.5 201 Ill 131 9.1321mm
O&of-round (max) 0 008 I”. 0 02mm Flatness (maximum) 0 008 1” 0 2mm
Taper (max) 0 008 I” 0 02mm Camshaft m
Overall height 11 413.11 421 I” 263 Q-290lmm Camshaftheight
Gasket surface flatness (mex ) 0 002 I”. 0 05mm lndentlficaiw mark A, D
Piston Intake
Outsidedlameler 3 346 I”. 64 99mm Standard 14m 35 49mm
Piston-lo-cylinderclearance 0 004-o 04312I” 0 01-O03mm Llmlt 1 36 I”. 34 99mm
Piston Rings lndentll!cat!onmark B C, E, F
Intake
Standard 1 39 I”. 35 20mm
0.0012-0 0026 I”. 0 03-O07mm Llmlt 1 37 I”. 34 70mm
0 004 I” 01mm lndentlllcallon mark A
Exhaust 7
0 0008-O0024 I” 0 02-O06mm Standard 1 39 I”. 35 20mm m
0 004 I” Olmm Lrmt 1 37 I”. 34 70mm
lndenbllcabonmah C
Exhaust
0 0098-0 0157 I”. 0 25.0 40mm Standard 14m 35 49mm
0 031 I” 0 6mm Limit 1 38 I”. 34 QQmm

0.0079-O0136 I”. 0 20-O35mm

0 031 I” 08mm

0 0079-O0276 I”.

Stem outside diameter

Intake 0 260 I”. 6 6mm
Exhaust 0 256 I”. 6 5mm
Face angle (all) 45-45 50
Piston pm outside diameter 0631ll 21mm Head lhlckness (margm)
Piston p,” press-!” load 1,653.3,656ft Ibs 7,500.17,5WNm Intake
Crankshaft PI” 011clearance Standard 0 039 WI. 1 Omm
Standard Llmlt 0 020 I”. 0 5mm
0 oooa-o 0020 In. 0 02-O05mm
Limit 0 004 I” Olmm Exhaust
Crankshaft Standard 0 059 I”. 15mm
Man bearing 011clearance Limit 0 031 I”. 0 6mm
Standard 0 ciw0 0020 I”. 0 02-O05mm Stem-to-gude clearance
Llmlt 0 004 I”. Olmm Intake
Pm outside dwneler 1771n 45mm Standard 0 oooa-o 0020 I” 0 02-O05mm
Journal outslde diameter 2 24 I” 57mm Llmlt 0 0039 in 0 1Omm
Out-of-round(max) 0 0006 I” 0 015mm Exhaust
CrankshaHend-play Standard 0 0020-O0035 I” 0 05-O09mm
Standard 0 002-O0071 I” 0 05-O16mm Llmlt 0 W59 m 0 15mm
Limtt 0 0098 I” 0 25mm Valve guide
Flywheel lnstde diameter 026Om 66mm
Run-out(max) 0 0051 I” 0.13mm OutsIde diameter 0 476 I” 121mm
Oil Pump Valve seat
Seal contactwldlh 0 035-o 051 I”. 0 Q-13mm
Seat angle (all) 44-44.5
Valve spring
 2.OL DOHC (NON-TURBO) ENGINE MECHANICAL SPECIFICATIONS 2.OL DOHC (TURBO) ENGINE MECHANICAL SPECIFICATIONS
English Metric
Description Specifications Specifications
General Information

Cyltnder Block
lnslde dnnetet 335m 65mm
Out&round (ma) 0 006 I” 0 02mm
Taper (ma) oooh 0 OPmm
Overall haght 11 413-l 1 421 I”. 269 9-290 lmm
Gasket surfaceflatness (ma ) 0 002 I” 0 05mm
Piston Camshafl height
lndentlkcatlon mark A. D
Intake
Standard 1 4 In 35 49mm
Side clearance Llmlt 1 36 I” 34 99mm
No 1 lndentlflcatlon mark E C. E, F
Standard 0 0012-O0028 I”. 0 03-O07mm Intake
Llmlt 0 004 I” Olmm Standard 1 39 I”. 35 20mm
No 2 Llmlt 1 37 I”. 34 70mm
Standard 0 0012-OW26 I” 0 03-O07mm lndentlflcal!on mark A
Llmlt 0 004 I” Olmm Exhaust
Standard 1 39 I”. 35 20mm
Llmlt 1 37 I”. 34 70mm
Standard 00096-0 0157 I” 0 25-O40mm lndentlflcatlon mark C
Limit 0 031 I” 0 8mm Exhaust
No 2 Standard 1 4 I” 35 49mm
Standard 0 0177-O0236 I” 0 45-O6Omm Llmlt 1 36 I” 34 99mm
Llmlt 0 031 I”. 0 6mm lndentlflcatlon mark E, F
011 Exhaust
Standard 0 0079.0 0276 I” 0 20-O70mm Standard 1 37 I”. 34 91mm
Llmlt 1351n 34 41mm
Camshaftjournal outslde dlametar 1021n 25 96mm
Vhf&S

Piston pin outslde diameter Ot331n Zlmm

Piston ownoress-m load 1.653-3.856n Ibs 7 500-l 7 500Nm

Standard 0 039 I”. 1 Omm

LilTlIt 0 020 I”. 0 5mm
Mm bearing 011clearance Exhaust
Standard 0 OOOB-0 0020 1” 0 02-O05mm Standard 0 059 I”. 15mm
Llmlt 0 004 I” Olmm Llmlt 0 031 I”. 0 6mm
Pin outsIde diameter 1 77 I”. 45mm Stem-to-guideclearance
Journal outslde diameter 2 24 I”. 57mm Intake
Out-of-round(max ) 0 0006 I” 0 015mm Standard 0 0008-0 0020 I” 0 02-O05mm
Crankshall end&v Llmtt 0 0039 I” OlOmm
Standard’ ‘ 0 002-O0071 I” 0 05-O16mm Exhaust
Llmlt 0 0096 I”. 0 25mm Standatd 0 0020-0 0035 I”. 0 05.0 09mm
FlVWheel Limit 0 0059 I”. 015mm
Run-out(max) 0 BO51I” 0 13mm Valve guide
Oil Pump lnslde diameter 0260 In. 66mm
OutsIdedlametat 0 476 I” 12 lmm
Valve peat
Seat contact wdth 0 035-o 051 m 0 9.1 3mm
Seat angle (all) 44.44 5”
93153c12
 2.OL DOHC (TURBO) ENGINE MECHANICAL SPECIFICATIONS 2.4L SOHC ENGINE MECHANICAL SPECIFICATIONS
English Metric English MlxdC
Description Specifications Specifications Description Specifications Specifications
Valve spring General Information
Free length Enginetype 4 CylinderIn-LmeOverhead Camshaft
Standard 1 90 I”. 46 3mm Displacement 143 4 cLblc I” 24L
Llmlt 1 98 I” 49 9mm Bore 341 I” 86 5mm
Squareness Stroke 3941n 1OOmm
Standard 2’ Compressionrat10 651
Llmlt 4’ Frrlngorder l-3-4-2
Cylinder Head
Overall height 3 539-3 547 I” 89 9-90 1mm
Flatness (maxlmum) 0 008 1” 02mm
Camshaft
Camshaftheight
lndenbflcatlonmark D
Intake
Standard 167Ill 42 4mm
Llrnd 165vl 419mm
Exhaust
Standard 167m 42 4mm
Limit 165In 419mm
lndenbflcabonmark AR
Intake
Standard 1751n 44 53mm
Llmlt 1.73 I” 44 03mm
Exhaust
Standard 175m 44 53mm
Llmlt I 73 I” 44 03mm
Camshalt journal outside dnmeter 1 34 I” 33 95mm
Valves
Stem outsidediameter
Intake 0315m 8 Omm
Exhaust 0311 I” 7 9mm
Face angle (all) 45.45 5
Head thickness(margm)
intake
Standard 0047m 1 2mm
Llmlt 0.020 I” 0 5mm
Exhaust
Standard 0 079 I” 2 Omm
Llmlt 0 031 ,” 0 8mm
Stem-to-guideclearance
Intake
Standard 0 0008-O0024 I” 0 03-O&mm
Llmlt 0 0039 I” 0 1Omm
Exhaust
Standard 0 oQ20-00035 I” 0 05-O09mm
Llmlt 0 0059 In 0 15mm
Valve guide
lwde diameter 0 315 tn. 8 Omm
OutsIdediameter 0 516 I” 131mm
Valve seal
Seat contactwdlh 0 035.0 051 I” 0 9-l 3mm
Seat angle (all) 44-44 5”
Valve spring
Free length
Standard 1961n 49 6mm
Llmlt I 98 I” 49 9mm
Squareness
Standard 2”
Llmlt 4”
93153ci4
 2.4L SOHC ENGINE MECHANICAL SPECIFICATIONS 2.4L DOHC ENGINE MECHANICAL SPEClFlCATlONS
English Metric English Metric
Description Specifications Specifications Description Specifications Specifications
Cylinder Block General Information (cont’d)
lnstdednmeter 3 35 I”. 85mm
Out-o-round (max ) 0008ln 0 02mm
Taper(max) 0008ln 0 02mm
Overall hwght 11 413-11 421 I” 289 9-290 lmm
Gasket&ace flatness (max ) 0 002 I” 0 05mm
Piston
OutsIdedlameler 3 346 I” 04 99mm
Plslon-to-cylinderclearance 0 004-o 0012 I” 0 01-O03mm
Piston Rings

Fmngorder l-3-4-2
Standard 0 0012-O0928 I” 0 03-O07mm Cylinder Head
Lfmlt 0 004 I” Olmm Overall height 5 193.5 201 K1 131 9-132 lmm
No 2 Flatness (maxtmum) 0 008 I” 0.2mm
Standard 00008-O 0024 I” 0 02-Offimm Camshaft
Llmlt 0004," Olmm Camshaft height
Endgap lndentlhcabonmalk A, D
No 1 Intake
Standard 0 0098-O0157 In 0 25-O40mm Standard 1 4 I”. 35 49mm
Llmlt 0 031 I”. 0 Smm Limit 1331n 34 99mm
No 2 lndentlkcatlonmark 8, C, E. F
.Standard 0 0079-o 0138 I” 0 20-O35mm
Llmlt 0 031 I”. 0 8mm
011
Standard 00079-002761". 0 20-O70mm

Standard 0 0039-o 0098 I” 0 10.0 25mm

Llmlt 0 016 m 0 4mm
Pistonpin outside dlametar 0631n 21mm
Pistonpin press-mload 1,653-3,&a fl Ibs. 7,500~17,500Nm
Crankshaftom 011clearance
Standard 0 02-O05mm

Mambeanna 011clearance
Standard 0 OuoE-00020 I”. 0.024 05mm
Limit 0004 I”. 0 lmm
Pmoutslde diameter 1 77 I” 45mm
Journaloutside diameter 2P4m _
wmm
Out-al-round(max ) o-i& I”. 0015mm
Crankshaftend-play Head thickness(margtn)
Standard 0002-00071 I”. 0 050 18mm Intake
Ltmit 000981n 0 25mm 0 039 I”. 1 Omm
StaMkrd
Flywheel 0 020 I”. 05mm
hrnft
Exhaust
Standard 0 059 I” 15mm
Sideclearance
Llmlt 0 031 I” 0.8mm
Dnve gear OOm-00055," 0 08.0 14mm Stem-to-guldaclearance
Driven gear 0 0024-O0047 I” 006012mm Intake
Standard 0 cooa- NJ20 I”. 0 02-O05mm
2.4L DOHC ENGINE MECHANICAL SPECIFICATIONS Llmlt 0 0039 I”. O.lOmm
English Metric Exhaust
lMCriptlOfl Specifications Specifications Standard 0002+0M)35m 005.009mm
General Information Limit 0 0059 I”. 015mm
4 Cyi~nderIn-LmeDual Overhead Camshaft Valve guide
143 4 cubtc I”. 24L lnslde diameter 02mm 6 6mm
Outside diameter 0 476 I”. 121mm
 2.4L DOHC ENGINE MECHANICAL SPECIFICATIONS 2.4L DOHC ENGINE MECHANICAL SPECIFICATIONS
English Metric
Description Specifications Specdications
Valve seat
Seat contactwldlh 0.035-o 051 I” 0 9-l 3mm
Seat angle (all) 44-44 5”
Valve spring 0 06-O14mm
Freelength
Standard 1901n 46 3mm
Llmlt 1 96 I” 49 9mm 3.OL SOHC ENGINE MECHANICAL SPECIFICATIONS
squareness English Metric
Standard 2” Description Specifications Specifications
Llmlt 4” General Information
Cylinder Block Engmetype 6 CylmderGO”Single Overhead Camshatl
lwde diameter 3351n 65mm Displacement 161 4 cubic I” 3OL
Out-of-round(max) 0 006 in 0 02mm Bore 3 59 I”. 91 lmm
Taper (mu) 0 006 I” 0 02mm Stroke 2 99 In. 76mm
Overall height 11 413-11421 I” 269 9-290 lmm Compreswn rat0 1001
Gasket surfacellatnass (max ) 0 002 In 0 05mm Firingorder 1-2-3-4-5-6
Piston Cylinder Head
OutsIdediameter 3 346 In 64 99mm Overall helghl 3 31 I” 64mrn
Plslon-lo-cylinderclearance 0 006.0 0016 m 0 02.0 04mm Flatness (maxImum) 0 006 I” 0 2mm
PioFn Rings Camshaft
Side clearance CamshafthelgM
No 1 Standard 1 62 ,n 41 25mm
Standard 0 0012-O0026 I” 0 03-O07mm Llmlt 1601n 40 75mm m
Limit 0 004 I”. Olmm Camshaft~oumaloutslde diameter 1 34 I” 33 95mm
No 2 Valves
Standard 0 Cot 2-o 0028 I” 0 03-O07mm
Llmlt 0 004 I” Olmm
End 9ap
No 1
Standard O.W96-00157 I” 0.25-O40mm
Llmtt 0 031 I”. 0 6mm
.__
NO 9
Standard 0 0177-O0236 I” 0.45-O6Omm
Lrmt 0 031 I” 0 6mm
011
Standard 0 0979.0 0276 I” 0 PO-O70mm
Llmll 0 039 I” 1 Omm
Connecting rod
Rod big end side clearance
Standard 0 0039-o co96 I” 0 10-O25mm
Llmlt 0 016 m. 0 4mm
Plstonpin outsIde dlametar 0631n Zlmm
Pistonp,” press-,” load 1,653.3,656 H Ibs 7,5Wl7,500Nm
Crankshatl pin 011clearance
Standard 0 0006-0 0020 I” 0 02-O05mm
Llmlt 0004m 0 tmm
Crankshaft
Man bearing011clearance
Standard 0 0006-0 0020 1” Seat contactwidth 0 9-1 3mm
0 02-O05mm
Llmlt Seat angle [all)
0 004 I” Olmm
Valve spring
Pin outstdedlameler 177m 45mm
Journaloutside diameter 224111 57mm Free length
Out-of-round(max ) 0015mm Standard 1.96 I”. 49 0mm
ooGQ6m
Crankshaltand-play Llmlt 46 6mm
Standard 0 002-o 0071 I”. 0 05-O16mm Load (Installedheight) Ibs (Nm) at m (mm) 72.5 Ibs @l 591 I”. 329 Nm @!40.4mm
Llmll OW96Ul 0 25mm Squareness
Flwhd -.
Standard
I

Run-out(max) 0 0051 I” 0 13mm Lmxt 4’

Cylinder Block
93153ci7
 3.OL SOHC ENGINE MECHANICAL SPEClFlCATlONS 3.OL DOHC ENGINE MECHANICAL SPECIFICATIONS
English Metric English Metric
Description Specifications Specifications Dsscription Specifications
Cylinder Block (cont’d) General lnformstlon (cont’d)
Taper (max.) 0008ln 0 OZmm Compraswm ratio
Overall klght 8 28.8 29 I”. 2104-210 6mm Fmngorder l-2-3-45-6
Gasket sudace flatness (max ) 0 ofI39 In Olmm Cylinder Head
Piston Overall helghl 5 20 I”. 132mm
Oufslde diameter 358ln. 91 lmm Flatness (manmum) 0 008 I” 0 2mm
Piston-to-cylinderclearanca 0.008-o 0020 I” 0 020 04mm Camshall
.,
Piston Rinas
Side clearance
Camhalt height
Standard 1 37 m 3491mm
Llmll 1 37 I”. 3491mm
Standard 0 COIZ-0W28 I”. 0 03-O07mm Camshalt journal out&e diameter 1 02 m. 25 96mm
Llrw 0004 I” Olmm VdVRS
No 2 Stem outsrdediameter
Standard 0 0008-0 0024 I”. 0 020 06mm Intake 0 260 I”. 60mm
Ltmlt 00041” Olmm Exhaust 0 256 I”. 6 5mm
End gap Face angle (all) 45-45 5”
No 1 Head thickness(mamn)
Standard 00118-00177,” 0.30-O40mm Intake
Llmlt 0 031 I” 0 8mm Standard 0 039 I” 1 Omm
No 2 Llmlt 0019,” 0 5mm
Standard 0 0177-O0236 I”. 0 45-O60mm Exhaust
Llmlt 0.031 I” 0 8mm Standard 0 059 I”. 15mm
011 Llmlt 0 039 m. l.Omm
Standard 0 0079-o 02% I” 0 200 fiOmm Stem-to-gudeclearam
Llmlt 0 039 I” 1 Omm intake
C0nnactlng rod Standard 0 oo#l-0 002il I”. 0 02-O05mm
Rod big end side clearance Limit 0 0039 I”. 0 IOmm
Standard 0 00390 0098 I”. 0 10.0 25mm Exhaust
Llmlt 0 016 m , 04mm Standard 0 0020-0 0035 I”. 0 05-O09mm
Piston pin outslde diameter 087al 22mm Lllllll 0 0059 m. 0 15mm
Piston pin prawn load 1,652.3.867It Ibs. 7.350.17,ZOONm Valve guida
Crankshaftpm 011clearance lwde dtameter 0 280 In. 6 6mm
Standard 0 ow3-0 mm I”. 0 02-O05mm Outs& diameter 0.476 I” 12 lmm
Llmlt 0004m O.lmm Vahreseal
Crankshat Seat contactwtdlh 0 035-o 051 ,“. 0413mm
Mm bearing 011clearance Seat angle (all) 44.44 5’
Standard o.rYm-0 oao I”. 0 02.0 05mm Valve spring
Llmlt 0 Oil4 1” Olmm
Pmouts& dfameter 197n 50mm
Journalouts& diameter 236111
Out-al-round hnax 1 0 OW8 in

Llmlt 4”
Cvlindsf Block
FT~pclearance 0 0024.0 0071 I”. OC6016mm tnslde dlametar 3.66 I”. 93mm
St& clearance 0 0016-O0039 I”. 004-O 10mm Out-&round (max ) 0 008 I”. 0 02mm
Body clearance Taper (max) 0 006 I”. 0 OPmm
Overall hslght 8 97-8 98 in. 227 9.228 1mm
Standard o.cn340 0071 I”. 010-018mm
Gasket surfacellatnezs (max.) 0 CO39I” Olmm
Llmlt 0 0138 I” 0 35mm
Platen
Outs& diameter 3 66 I”. 93mm
3.OL DOHC ENGINE MECHANICAL SPECIFICATIONS Plslon-t@cylmn&rClearance o.oQB-00020 M. 0 020.04mm
English M&lC Piston Rings
Description Spscificalions SpecHicatiOllS
Gemal lrlformtlon
Eqne type 6 CylmderW Dual Overhead Camshaft
Displacement 1814cubicm. 3OL
Bore 359m 91 lmm
Slfoke 2 99 I”. 76mm
9315x19
 3.OL DOHC ENGINE MECHANICAL SPECIFICATIONS 3.5L SOHC ENGINE MECHANICAL SPECIFICATIONS
English Metric English hletrlc
oescliptiin SpeclfiCatiOllS Specifications Description Speciffcationr Specificationr
Piston Rings (cont’d) Valves
Endgap Stem outstdedmmetar
No 1 Intake 0 236 I”. 6 Omm
standard 0 0118-O0177 ,“. 0.300 40mm Exhaust 0 236 I”. 60mm
Llmlt 0 031 I” 08mm Face angle (all) 4545.5”
No 2 Head thickness(margm)
Standard 0.01770 0236 I” 0 450 6Omm Intake
Llmlt 0 031 I”. 08mm Standard 0 0039 I” OlOmm
011 Llmlt 0 019 I”. 05mlll
Standard 0.0039-0 0137 I” 0 10-O35mm Exhaust
Llmlt 0.039 1” 1 Omm Sl.SldZld 0 047 I” 12mm
Connecting rod Llmd 00281n 0 7mm
Rod big end side clearance stem-to-gude clearance
Slandard 0.0039-O0098 m. 0.100 25mm Intake
Llmlt 0016m 0 4mm 0 0008-O0020 I” 0 020 05mm
standard
Pistonpm outside dnmeter 087111 22mm Llmlt OW391n 0 lOmm
Pistonpi” press-,” load 1,652.3,887fl Ibs. 7,350.17,200Nm EXhaUsl
Crankshaftpm 011clearance 0 0016-O0028 I”. 0 040 07mm
standarc
Standard 00012-oOOx)m 0 030 05mm Llmlt 0 0059 I” 0 15mm
Llmlt 0 004 I” Olmm Valve guide
Crankshaft lnstde dram&t 0315m 6 Omm
Mm bearing011clearanca
OutsIdediameter 0 433 I” 11 Omm
Standard 0 ooO8-00020 I” 0 020 05mm Valve seat
Llmlt 0 004 9”. Dimm
Seat contactwidth 0 035-O051 I” 0 9-l 3mm
Pmoutslde diameter 2171n 55mm
Journalouts& dlametar Seal angle (all) 44-44 5’
2521n Mmm
Out-ol-round(max ) OoOffiRl 0 015mm Valve spring
Crankshaftend-play Free knoth
standard 0 002-O0098 I” 0 05-O25mm Standard 2 01 I” 51mm
Llmlt 0 012 I” 03mm Llmlt 1 97 I”. 5omm
Oil Pump Squareness
Tip clearance 0 CO24.00071 m 006018mm Standard 2”
Side clearance 0 0016-O0039 in. 0 040 1Omm Llmlt 4”
Bodyclearance Cylinder Block
lnslde diameter 3 65 I”. 93mm
Out-ol-round(max ) 0 008 in 0 02mm
Taper (max ) 0 008 I” 0 02mm
Overall height 8 28-8 29 I” 2104.2106mm
3.5L SOHC ENGINE MECHANICAL SPECIFICATIONS Gasket surfaceflatness (max) 0 002 I” 0 05mm
English Metric Piston
Description Specifications Specifications
General Information
Engmetype 6 Cylinder60” SingleOvedvzad Camshaft
Displacement 213 5 cubic I” 3SL
Bore 3 65 I”. 93mm Side clearance
Stroke 3 37 m. 85 8mm No 1
Comprasslonratio 901 standard 0 0012-OCO281”. 0 03-O07mm
Llmlt 0 004 In O.lmm
No. 2
Standard 0 CCQ8-00024 I” 0 02-O06mm
Llmlt 0 004 I” Otmm

Llmlt 1 44 I”. 36 45mm

Camshaft]oumal outs& dtameter 1771n 44 95mm 01
Standard 0 0079-O0236 I” 0 20-OMXnm
 3.5L SOHC ENGINE MECHANICAL SPECIFICATIONS TORQUE SPECIFICATIONS
English Metric Components English Metric
Description Specifications Specifications Camshall
Connecting rod Camshalt sprwket bolt
Rod big end side clearance 1 5L engjne 51 it Ibs 70 Nm
Standard 0 0039-o 0096 I” 0 10-O25mm 1 6L, 1 8L, and 2 OL(SOHC and DOHC)engines 6511 Ibs 90 Nm
Llrnll 0016ln 0 4mm 2 4L engine 56.72 R Ibs. 60-l 00 Nm
Piston pin outslde dnmeler 067rn 22mm 3 OL(SOHCand DOHC)engme 65 It Ibs WNm
P~slonpin press-~”load Flngerprewre Bearingcap retalnlng bolts
Crankshalt pm 011clearance 2 OLSOHC engine 1511 Ibs 2ONm
Standard 0 0006-0 0020 in 0 02-O05mm 1 6L and 2 OLDOHC engines 21.25ft Ibs 29-35 Nm
Llmtt 0 004 I” Olmm 2 4L eng,ne 15 fl lbs. 20 Nm
Crankshaft 3 OL(SOHCand DOHC)engme 0
Maln bearing 011clearance 3 5L engine 23 11Ibs 31 Nm
Standard 0 0006-0 0020 I” 0 02-O05mm Crankshalt dampedpullev
Llmlt 0 004 I” Olmm Pullev bolts
Pin outsidedram&r 197m 50mm 1 5L engine loft Ibs 14Nm
Journaloutslde diameter 2361n 60mm 1 6L and 2 OL(SOHC and DOHC)engines 14.22 It lbs 20-30 Nm
Out-+round (max ) - 0 0006 I”. 0015mm 2 4L enqme 16 fl Ibs. 25 Nm
Crankshaftend.play Center reta!ino bolt
Standard 0 002-0 0096 I”. 0 05-O25mm 51-72 It lbs 70.100 Nm
13411 Ibs 165Nm
3 OL(SOHCand DOHC) engine 106-11611lbs 150-160 Nm
TIPclearance 0 1X24-0 0071 1” 0 06-O16mm Cvllnder head
Side clearance 0 0016-O0039 I” 0 040 IOmm
Bodyclearance
Standard 0 0039-o 0071 I” 0 10.0.16mm

1 6L englne 22lt Ibs 3ONm

2 OLSOHC engine 11.14ll Ibs 15-19 Nm
2 4L engine 16-21it Ibs 25-29 Nm
3 OLSOHC engine 21 ll Ibs 29 Nm
3 OLDOHCenwe 14 It Ibs 19Nm
3 5L eqne - 21 It Ibs 29 Nm m
Flywheel/dnvaplale retainingb&s
98 It Ibs 135Nm
1 5L engine
1 6L 2 OL(SOHCand DOHC),and 2 4L engmes 94.101 II Ibs 130-140 Nm
F5
1 6L engine
3 OLSOHC,3 OLDOHC,and 3 5L engmes
72 It lbs
53-56 It Ibs
100 Nm /
Intake manlfoid retanmg bolts
72-76 Nm
m
1 5L engine 1311 lbs 16Nm
16Land20L DOHC engines
1 6L engine
Ii-141 Ibs
1411 Ibs
15-19 Nm
P
2 OLSOHC engme 0
Plenum bolts 11.14R Ibs.
11-1411 Ibs
15.19Nm
15.19Nm
m
Manifold bolts
2 4L eng,ne left Ibs 25 Nm
1994 models is
Bolts 15fl ibs 20 Nm
NUk 26 ‘I lbs. 35 Nm
7
1995.00 models m
SOItS 15fi Ibs 20 Nm
Nuts 15 ft Ibs. 20 Nm
3 OLSOHC 3 OLDOHC, and 3 5L engines 0
93153~24
 TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS
Components English Mstrlc Components English Metric
011pan retamg bolls Timingbelts
15L eng,ne 60 Inch Ibs. 7Nm 1 5L engine 16 fl Ibs. 25 Nm
1 6L and 2 OLLXJHC
engmes 4-6 tl Ibs 6-8 Nm PlVOlboll
1 EL eqne 60 Inch Ibs. 7Nm 1990-94models 14an Ibs 20.27 Nm
2 OLSOHC engme 4-6 ft. Ibs 6-8 Nm 199500 models 17 Il. Ibs. 24 Nm
2 4L
eng,ne 6 fl Ibs. 6Nm 2.OLDOHCturbo engine
3 OLSOHCengme 48 Inch Ibs. 6Nm Balance shaft tensloner pulley bolt 14 fl Ibs 19Nm
3 OLDOHCengme 48 mchIbs. 6Nm Tlmmg belt tensu~nerpulley boil 35 IL Ibs. 46 Nm
3 5L engme 2 4L engme
Upper 011pan 411 Ibs 6Nm BalanceshafltenSlonerpulley bolt 15 n Ibs 20 Nm
Lower 011pa” 7-9 Il. Ikls 10-12 Nm Trmmgbelt tensioner pulley bdt 35n Ibs. 46Nm
011Pump 3 OLSOHC engine
1 5L and 16L engmes Tensioner lock bolt 21 n ibs 29 Nm
Pump cover 64 Inch Ibs 10 Nm 3 OL DOHCengme
RM valve 33 n Ibs. 45 Nm 1992-94models
Pumpscreen 14 fl Ibs 19Nm Tensionerlock bolt 7 It Ibs. 10Nm
16L, 2 OL(SOHC and DOHC),and 2 4L engmes 1995% models
011filter bracket 14 n tbs. 19Nm Tensionerretalnmgbolts 17n Ibs 24 Nm
Pump wver 17 11Ibs. 24 Nm 3 5L engine 16 n Ibs. 25 Nm
Pump drive gear retammgbolt 27 II Ibs. 37 Nm Tenwner pulley flxed bolt 35 n Ibs 46 Nm
Plug cap 17n Ibs. 24 Nm Waterpump
3 OL(SOHCand DOHC) engme
Ballle plate retalnlng bolts 0n Ibs 11 Nm
Pump retanlng bolts
1 5L and 16L engines i7n Ibs 24 Nm
m
Pump case retammgbolts ion Ibs. 14Nm 16L and 2 OL(SOHCand COHC)engmes 9.11 n Ibs 12-15 Nm
Pump cover retamng bolts 7 n Ibs. 1ONm 2 4L eng,ne
3 5L engme Bolts markedwith ~4, ion Ibs 14Nm
Baffle plate retammgbolts 7 n Ibs. lONm Bolts mahed wth ~7, 1Elt Ibs 24 Nm
Pump case retalmng bolts 10 It Ibs 14Nm 3 OLSOHC,3 OLDOHC, and 3 5L engines 17 n Ibs 24 Nm
Pick-upretalnmg bolts 13 n Ibs. 16 Nm @ Referto the prccedure
Rotorcover 7 ft Ibs 1ONm 9x&26
Rockerarm (valve) cover retalnmgbolts
1 5L engine 12-16 mch Ibs. 1-2Nm
1 6L ,l EL,2 OLDOHC. and 2 4L engines 24.36 mchIbs. 2-3 Nm
2 OLSOHC engme 48.60 mchIbs. 4-5 Nm
3 OLSOHC engine 7n Ibs 9Nm
3 OLDOHC engme 42.54 Inch Ibs 4-5 Nm
3.5L eng,ne 30 Inch Ibs 3Nm
Rockerarms and pushrods
Rockerarm retalmngbolts
15L, 1 6L and 2 4L engines 23 fl Ibs 32 Nm
16L and 2 OLDOHC engines 21-25 fl Ibs. 29-35 Nm
3 5L engine 16 It Ibs 25 Nm
Thermostat
1 ELengine 16ft Ibs 22 Nm
1 5L, 1 6L. 2 OLWHC, and 1990.92 2 OLSOHC eng,nes 12.14 ft lbs. 17-20 Nm
19932 OLSOHC engine 7-10 It Ibs lo-15 Nm
2 4L Eqne loft lbs 13Nm
3 OLSOHC,3 OLDOHC, and 3 5L eqnes 12.14lt Ibs 17-20 Nm
93153~25