Automatic Transaxle This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnostic, disassembly, repair, and installation procedures along with complete specifications and tightening references. Use of this manual will aid in properly performing any servicing necessary to maintain or restore the high levels of performance and reliability designed into these outstanding vehicles.
Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.
@ 1996 Mitsubishi Motors Corporation
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Wheel and Tire . . . . . . . . . . . . . . . . .
This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed OWN a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original manual was lost or destroyed.)
T h a n k y o u . G~mm~emymanual@hotma~l.com
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Printed in U.S.A.
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Interior and Supplemental Restraint System (SRS) . . . . . . . . Heater, Air Conditioning and Ventilation . . . . . . . . . . . . . . . . . . . . Alphabetical Index . . . . . . . . . . . . . . NOTE: Electrical system information is contained in Volume 2 “Electrical” of this paired Service Manual.
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WAR,NINGS REGARDING SERVICING OF SUPPLEMENTAL _, ” RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel .(from inadviertent firing. of the alr bag) or to the driver and passenger (from rendering the SRS inoperative). (2) If it is possible that the SRS components are subjected’to heat over 93°C 4290 In baklng or in drying after painting, remove the SRS components (air bag module, SRS-EClJ) beforehand. (3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially Its GROUP 526 - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS or any SRS-related component. & / NOTE Section titles with the asterisks (‘) in the table of contents in each group indicate operations requiring warnings.
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MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. M/T : Indicates the manual transaxle, or models equipped with the manual transaxle. A/T : Indicates the automatic transaxle, or models equipped with the automatic transaxle. MFI: Indicates the multiport fuel injection, or engines equipped with the multiport fuel injection. Turbo: Indicates the engine with turbocharger, or models equipped ,with such an engi.ne. Non-turbo: Indicates the engine without turbocharger, or models equipped with, such an engine. FWD: Indicates the front wheel drive vehicles. AWD: Indicates the all wheel drive vehicles. ABS: Indicates the anti-lock braking system or models equipped with the anti4ock braking &em.
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GENERAL - How to Use This Manual
EXPLANATION OF MANUAL CONTENTS
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Maintenance and Servicing Procedures 0 Installation steps : Specified in case installation is impossible in re verse order of removal steps. Omitted if installation is possible in reverse order of removal steps. l Reassembly steps : Specified in case reassembly is impossible in‘reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of dir&sembly steps.
The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. 0 Removal steps : The part designation number corresponds to the number in the illustration to indicate removal steps. l Disassembly steps : The part designation number corresponds to the, number in the illustration to indicate disassembly steps.
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Classifications of Major Maintenance / Service points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail. I +A, : Indicates that there are essential points for removal or disassembly.
)A4 : Indicates that there are essential ooints for installation or reassembly.
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Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained.
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* &I : Grease (multipurpose grease unless there is a brand or type specified) ; ; Sealant or adhesive . Brake fluid or automatic transmission fluid m : Engine oil, gear oil or air conditioning compressor oil : Adhesive tape or butvl rubber taoe
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GENERAL - How to Use This Manual
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37A-23
STEERING - Power Steering Gear B O X
POWER STEERING GEAR BOX REMOVAL AND INSTALLATION
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c lmnovel steps 1. Joint assemMy and gear box mnnediw box 2. Sdsnoa vaive con&or
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. Operating procedures, cautions, ’ etc. on removal, instalMtibn:“disassembly ‘and rwssembly, qfw described.
REMOVAL SERVICE POINTS 4 4n, TIE-ROD END DISCONNECTKM 1.
Be sun 10 tie the cord of the special tool lo the nearby
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Loosen the nut but do not remove il.
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FOG LIGHT RELAY CONTlNUfTY CHECK saltwy vob
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-. -*.. STEERING - Power Steering Gear Box
LUBRICATION AND SEALING POINTS 4anventlonal power stmlng gear box>
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0-0 indicates that there is continuity’ between the terminals. H indicates terminals‘ to which battery voltagqis applied.
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GENERAL - How to Use Troubleshooting/Inspection Service Points
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s10w To USE TR~~BLE~H~~TING~~N~PE~T~~~ SERVICE Pomm ‘_ .. oolooo2oo60 Troubleshooting of electronic control systems for which the scan tool can’be u%dfollows the basic outline described below. Furthermore, even in systems for which the scan tool cannot be used, part of these systems still follow this outline.
TROUBLESHOOTING CONTENTS
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1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING The main procedures for diagnostic troubleshooting are shown. 2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. 3. DIAGNOSTIC FUNCTION The following diagnostic functions are shown. l , Method of reading diagnostic trouble codes 0 Method of erasing diagnostic trouble codes l Input inspection service points
: 4. INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES 5. INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to the ,I next page on how to use the inspection procedures.) 6. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms, even though the scan tool displays no diagnostic trouble”code, inspection procedures for each trouble symptom will be found by means of this chart. 7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Indicates the inspection procedures corresponding to each trouble symptoms classifiedin the Inspection Chart for Trouble Symptoms. (Refer to the next page on how to use the inspection procedures.) 8. DATA LIST REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference infdmation. 9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items and standard values have been provided in this chart as reference information. Terminal Voltage Checks 1. Connect a needle-nosed wire probe or paper clip to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the ECU connector termi~nals from the wire side, and measure the voltage while referring to the check chart. NOTE 1. Measure voltage with the ECU connectors connected. 2. You may find it convenient to pull out the ECU to make it easier to reach the connector terminals. I 3. Checks don’t have to be carried out in the order given in the chart. r Caution Short-circuiting the positive (+) probe between a connector terminaland”ground &ould damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this ! 3. If voltage readings differ from Normal Condition values, ,check related sensor&, actuators, and wiring, then replace or repair.
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GENERAL - How to Use Troubleshooting/Inspection Service Points 4.
After repair or replacement, recheck -with the voltmeter to confirm @J the repair ,has correbted’ the problem.
Terminal Resistance and Continuity Checks 1. Turn the ignition switch to off. 2. Disconnect the ECU connector. 3. Measure the resistance and check for continuity between the terminals of the ECU harnqss-side;, connector while referring to the check chart. 1 : ? NOTE Checks don’t have to be carried out in the order given in the chart. ., Cautlon If resistance and continuity checks are performed dn the wrong terminals, damage* t&i46 vehicle wiring, sensors, ECU, and/or ohmmeter may occur. :. ‘^ Use care to prevent this! /i 4. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair 4es;qq@ed the problem. 1 ‘5. c 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here. :i, ‘; i,
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j GENERAL - How to Use Troubleshoo;ting/lnspection Service ~Po;‘k~s’ . . %\ .j I I , : HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally ;l$ &nec$ors, components, the ECU and the harnesses between connect&s, in that ot-der. These in@ecti&prb&dures follow this order, and they first try to discover a problem with a connector or a defeotive.componfBt. *:.) .,.I* ~,,“i,’ 1,
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Indicates insoectiori carried but usink the scan Indicates the opeqtion and.-‘.‘~, inspection procedu’res. ’ Indicates the OK judgement cuhtfitibn!L
2. Thick box lines: Detailed inspection ’ prOCe&r8S ðods) such ‘as component inspection and circuit inspection are listedon a seplfatb pa@,&nd are given here for reference.., :
17 Control mode selection switch
1 1 Measure bt switch connect ‘Of A-44 - a I 0 Djs :onn,ect --.MB oonnector- and measure at rhe harness side.
3. Indicates voltage and resistance to,” ~~~~~red at a pWic@ar c$utnectar. (Refer to “Connector Measurement Service Points”.) The connector position can be located in the wiring diagram in Volume -2 manual bv means of this svmbol. Indicates opiration and insp&ion prOCedUr8S, inspection terminals and inspection conditions. Indicates the OK judgement conditions. I
Inspect the contact condition at each connector terminal. (Refer to “Connector Inspection”.) The connector position can be located in the wiring diagram in Volume-2 manual by means of this symbol.
. Check trouble SymptOm. A
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Caution After carrying out connector inspection, always be sure to reconnect the connector as it was before. I , j ,I: ;, : ,i;J ,, ..;:; ,,.: I:; G&$7, ,‘^& ‘:I,@$ u;q
e EOS:ECU.
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Confirm that there are troublesymptoms. If trOUbl8SymptOmS havedisappeared, the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection. If it seems that trouble symptoms still remain, proceed to the next stage of instructions.
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If trouble symptoms still remain up to this stage, there is a possibility that there is an open or short circuit in the harness between the conn8ctors, so check the harness. Alternatively, the cause may be a defective ECU, so try replacing the ECU and check if the trouble symptom disappears.
HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to the connector measurements. Carry out this inspection while referring to Volume 2 Electrical manual. Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses. For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown Fuse”. MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning. TSB Revision
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GENERAL - How to Use Troubleshooting/Inspection Service ‘Points
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CONNECTOR MEA$UREM@lT ,SERlJCE PQilNTS I Turn the ignition switch to CFF when connecting and disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to the contrary.
ness connector
IF INSPECTING WITH THE CONNECTOR ._ CONNECTED (WITH CIRCUIT IN A CONDITION OF CONTINUlm Waterproof Connectors Be sure to use the special tool (harness connector). Never insert a test probe from the. harness side, because to do so will reduce the waterproof performance and result in corrosion.
’ Ordinary (non-waterproof) Connectors Check by inserting the test probe from’. the harness side. Note that if the connector (control unit, etc.) is too small to permit insertion of the test probe, it should not be forced; use a special tool (the extra-thin probe in the harness set for checking) for this purpose. “b’ 4:
IF INSPECTING WITH THE CONNECTOR DISCONNECTED,
Use the special tool (inspection harness for conne& pin contact pressure in the harness set, for ‘inspection). ” The inspection harness for connector pin contact pressure’ should be used. The test probe shoufd”never be forcibly inserted, as it may cause a defective contact. .I
/ Inspection harness for connector pin contact pressure AOlR0579
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Touch the pin directly with the test bar. .. ‘” IICaution At this time, be careful not to short the connector pins with the test probes. To do so may damage the circuits inside the ECU.
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GENERAL - How to Use TroubleshootindlnsPection Service: l?oinW
Connector disconnected or improperly connected
CONNECTOR INSPECTION SERVICE POINTS VISUAL INSPECTION l Connector is disconnected or improperly connected l Connector pins are pulled out l Harness wire breakage due to harness tension at terminal section l Low contact pressure between male and female terminals l Low connection pressure due to rusted terminals or foreign matter lodged in terminals
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Defective connector contact
breakage at terminal section
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,. CONNECTOR PIN INSPECTION’ If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect ‘even when the connector body is connected, because the pina: may pull, out of the back side of the connector. Therefore, gently pull the wires one by one to make sure-that no pins pull out’ ,,/ .Y of the connector. . ,. : _, /,,
CONNECTOR ENGAGEMENT INSPECTION ” Use the special tool (connector pin connection pressure inspection harness of the inspection harness set) to inspect’ the engagement of the male pins and female pins. [Pin drawing ) force : 1 N (.2 Ibs.) or more] .
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G E N E R A L - How to Use Troubleshooting/inspection Servid b%irrtiC’ I,
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HOW TO COPE WITH INTERMITTENT MALFUNCTldNS Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the I cause will be easier to find. TO COPE WITH INTERMITTENT MALFUNCTION; 1. Ask the customer about the malfunction Ask what it feels like,*what it sounds like, etc. Then ask about dnvrng conditions; weather, frequency of occurrence, and so on. 2.
Determine the conditiqw from the customer’s responses Typically, almost all intermittent malfunctions occur from conditions like vibration, temperature and/or moisture change, poor connections. From the customer’s replies, it should be reasoned which condition is influenced.
3. Use simulation test In the cases of vibration or poor connections, use the simulation tests below to attempt to
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duplicate the customer’s complaint. Determine the most likely circuit(s) and perform thesimulation tests on the connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for d,iagnostic trouble codes ’ and trouble symptoms. r_’ For temperature and/or moisture conditions related intermittent malfunctions, using common sense, try to change the .condkions of the suspetted circuit components, then use thesimulation tests below, 4. Verify the intermittent malfunction is eliminated Repair the malfunctioning part and try to duplicate the condition(s) again to verify the intermittent malfunction has been eliminated.
SIMULATION TESTS For these simulation tests, shake, then gently bend, pull, and twist the wiring of each of these examples to duplicate the intermittent malfunction. l Shake the connector up-and-down, and right-and-left. l Shake the wiring harness up-and-down, and right-and-left. l Vibrate the part or sensor. NOTE In case of difficulty in finding the cause of the intermittent malfunction, the data recorder function in the scan tool is effective.
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GENERAL - How to Use Troubleshooting/Inspection Service Pdintg
;NS$XTION SERVICE POINTS FOR A BLOWN ~,I‘ :
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Battery
I fuse
Remove the fuse and measure the resistance betkeen the load side of the fuse and ground. Set the switches” of all, circuits which are connected ib this fusb to’“a ‘konditlonzof continuity. If the resistance is almost W&&t this time, there is a short somewhere between.these switches a?d tht?_;l?ad. If the resistance is not 0 Q, there is ‘no short af,,Jhe, present time, but a momentary short has brobably caused ,the fuse to blow. . The main causes of a short circult’are the followin’g 0 Harness being clamped by the vehicle-body 0 Damage to the outercasing ‘of the harness due to wear or heat Water getting into the connector or circuitry , l 0 Human error (mistakenly shorting a circuit, etc.) , 2.’
Load switch Load
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GENERAL - Vehicle Identification
VEHICLE IDENTIFICATI~ -+ ’ .I\
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VEHICLE lDENTlFlCATl,W’i NUMBER i-&Tltih The vehicle identification nymb&,(kkN.) is 'locafed &6 d”pl
E: Mitsubishi Motor Manufacturing of America, Inc.
serial number 000001 to 999999 NOTE * “Check digit” means a single number or letter X used to verify the accuracy of transcription of vehicle identitication number.
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GENERAL - Vehicle Identificatibn
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VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR FEDERAL V.I.N. (except sequence number)
VEHICLE INFORMATION COC)E” PLATE 1 ,_ ;_ I I a’: Vehicle information code plate is riveted onto the ;bulkhead I ,I! in the engine compartment. The place shows model code, en@h& r&d& transaxle model, and body color code. No. 1 Item 1
VEHICLE SAFETY CERTIFICATION LABEL 1. The vehicle safety certification label is attached to face of left door pillar. 2. This label indicates Gross Vehicle Weight Rating (G.V.W.R.), Gross Axle Weight Rating (G.A.W.R.$ front, rear and Vehicle Identification Number (V.I.N.).
00X0066
ENGINE MODEL STAMPING 1. The engine model number is stamped at the front side on the top edge of the cylinder block as shown in the following. Engine model
1 Engine di.sDlacement
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1 2.0 dm3 (122.0 cu.in.) I
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1 2.0 dm3 (122.0 cu.in.) 4664
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Heat Drotector
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1 2.4 dm3 (146.5 cuin.)
2. The 4G6 and 420A engine serial number is stamped near the engine model number, and the serial number cycles, as shown below. Engine serial number
In order to protect against theft, a Vehicle Identification Number (VIN) is stamped in, or attached as a label to, the following major parts of the engine and transaxle, as well as main q.1 .I outer panels: Engine cylinder block, Transaxle housing. Fe‘hder, Door, Quarter panel, Hood, Liftgate, Trunk lid, Bumpers In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data are stamped into replacement parts for the engine and the transaxle.
Cautions regarding panel repairs:‘ .~, I -’ 1. When repainting original parts, 90 so after first masking the theft-protection label, and, after painting, be sure to peel off the masking tape. 2. The theft-protection label for replacem,ent parts iS covered by masking tape, sd such part&an be pa@ed as is. The masking tape should be removed aft& p&i@ing is finished. 3. The theft-protection label should not be ietioved from original parts or replacement parts.
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GENERAL - Vehicle Identificatio6
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LOCATIONS Target area (A: for original equipment parts, B: for replacement parts) Engine
Manual transaxle
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00003676 00x0092
Automatic transaxle .
IOOmm 6
00003679 00x0093
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GENERAL - Vehicle Identification
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For lifting, put rubber or similar between the side sill and rigid rack, or the side sill area will; be damaged. I POST TYPE Special care should be taken when raising the vehicle on a frame contact type ho/s!. The hoist:@& be equipped with the proper adapters in order to support the vehicle at the prop&, Id&ions. : Caution When service procedures require removing rear suspension, fuel tank and spare tire, place additionall weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravity‘ changes. ., . _
Notch OONOOJO
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00-26
GENERAL - Special Handling lnstructidng for AWD Models
SPECIAL HANDLING FOR AWD MODELS
INSTR~Ctldki& 00100740010
Speedometer tests, brake tests and wheel balance measurement for full-time AWD vehicles should be carried out according to the following procedures.
SPEEDOMETER TEST Refer to GROUP 54 - Combination Meter.
BRAKE TEST In order to stabilize the viscous coupling‘s dragging force, the brake test should always be conducted after the speedometer test.
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FRONT WHEEL MEASUREMENTS 1. Place the front wheels on’ the brake tester. 2. Perform the brake test. Caution The rear wheels should remain on the ground. 3. If the brake dragging force exceeds the specified value, jack up the vehicle and manualfy .rotate each wheel -to check the rotation condition of each wheel. .,,’ :’ ; ‘* c;;, NOTE If the brake dragging force exceeds the specified &lue; the cause may be the effect of the viscous ooupli@s dragging force, so jack up the front viheels and check the rotation condition of the wheels in this state for no effect by the viscous coupling‘s dragging force. j ” _I .* .,.A, :,” REAR WHEEL MEASUREMENTS After placing the rear wheels on the brake tester, follow the same procedures as for the front wheel measurements. Brake force of AWD models with ‘VCU If both front wheels are locked and rear wheel measurement is difficult, the measurement in this condition can be considered to comprise the total. Brake force Items Total for left and At 90 kg (198 Ibs.) ped- 20 % or more of rear axle weight right rear wheels al depression force Differenceforleft 8% or less of rear 8% or less of r e a r axle weight and right front axle weight wheels/difference for left and right rear wheels Total for front At90 kg(198Ibs.)ped- 50% or more of the vehicle’s weight and rear wheels al depression force or... Braking-stop distance
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At primary velocity of 50 km/h (31 mph): Within 15.0 m (49.2 ft.)
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GENERAL - Special Handling Instructions for AWL? Models
WHEEL BALANCE
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(11 )If oil pressure is 10% and pump is within specifici@ns,
inspect for worn engine bearings, or other ,reasons for .>“ 8’ ,I’’ oil pressure loss. b 2 ~~ & I ,_ ?, .:c ” . - . .; ‘1 “‘_: , ~, > ‘.; .J , &.. ;i.: 1 ’ __ J&L . , : , ru’l,” ;” I ’ ‘ C S? , * *,.: 1: c / 1. ..:- ,_., ,i ._, ’ /. _: ,’ I ., I
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Piston, C\onnecting Rod
ENGINE OVERblAUL - and Cylinder Block ‘*
PISTON, CONNECTING ROD ;AN”D CYLINDER BLOCK ., 1130211aoa
Rear 1 Engine block crankshaft seal Engine metal case crankshaft seal
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REMOVAL
Scr&driver
(1) insert a 3/16 flat bladed ‘screwdriver between the dust lip and the metal case of the .crankshaft seal. Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. ,, ,*
Rear crankshaft seal dust lip CENOl31
Caution Do not permit the sCrewdriver blade tb contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted. (2) Remove top ridge of cylinder bores with a reliable ridge
reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number.
(3) Ensure connecting rods and connecting rod caps match and proper set for the cylinder number. Identify them if necessary.
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(4) Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
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(5) Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore. Be careful not to nick crankshaft journals. (6) After removal, install bearing cap in the connecting orientation on the mating connecting rod.
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Piston, Connecting Rod
ENGINE OVERHAUL - and Cylindei Blbck ) DISASSEMBLY
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11202120012 ’ .#,S
(1) Separate piston from connectin’g rod by removing piston pin. (2) Using a suitable ring expander,, remove ubper and intermediate piston rings. ‘. I”,..
(3) Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. (4) Clean ring grooves of any carbon deposits.
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Pistoq, Connading Rod
ENGINE OVERkAUL - and Cylinder ‘Blo$k,.” REASSEMBLY
11202140018
(1) Install rings with manufacturer’s I.D. mark facing up, toward the top of the piston. Caution Install piston rings in the following order:
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(a) Oil ring expander. (b) Upper oil ring side rail. (c) Lower oil ring side rail. (d) No. 2 intermediate piston ring. (e) No. 1 upper piston ring. (2) Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander.
(3) Install upper side rail first and then the lower side rail.
(4) Install No. 2 piston ring and then No. 1 piston ring.
(5) Position piston ring end gaps as shown in the figure.
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Front of engine
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11D-48
Piston, Connqting. FJo?
ENGINE OVERHAUL - and Cylinder Blocks
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(6) Position oil ring expander gap at least 45 degrees irom the side ,rail gaps but not+ ‘on the “pistdn pin canter OJ on the thrust direction. Staggering ri,ng ,gap,is important for bil control. 1 a .4.; _ ’
(1) Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap.
(2) Before installing the ring compressor, make sure the oif ring expander ends are butted and the rail .gaps located; as shown in the figure. i , \‘p”
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Front of engine
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(3) Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure that position of rings does not change during this operation.
(4) The arrow should face toward the front of the engine. Install the pistons.
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(5) Rotate crankshaft so that the connecting .rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal.
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llD-50
Piston, Connecting f&d
ENGINE OVERHAUL - and Cylitider Blodk
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(6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
(7) Install connecting rod bearings selected based on !he obtained connecting rod bearing clearanck ‘: (Refer to CONNECTING ROD BEARING CLEARANCE.)
CENOO89
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ENGINE OVERHAUL
piqton, ConnectiTg Rod - a n d Byh,nder Bltsck::
(8) Install each bolt finger tight then alternately torque each nut to. assemble the cap properly. (9) Tighten the bolts to 27.0 Nm PLUS l/4 turn (20 ft.lbs. PLUS l/4 turn). Do not use a torque wrench for last step.
(lO)Using a feeler gauge, check connecting rod’ side clear-’ ante. Standard value: 0.13-0.38 mm (.005-.015 in.) Limit 0.37 mm (.015 in.)
Caution If burr’or scratch is present on the c&k&& edge (chamfer), cleanup with 400 grit sar@ paper to prevent seal damage during’ inritaUqtion .of I new’ ~s&tl? 1: *-
_ NOTE When installing seal, no lube on seal is needed. ~ .L ,‘, (11) Place Special Tool MB995059 on crankshaft. This is a i pilot tool with a magnetic base. (12)Position seal over pilot tool. Make sure you can read the words THIS SIDE OUT on seal. Pilot tool should remain on crankshaft during installation of seal. (13)Drive the seal into the block using Special Tool MB995080 and handle C-4171 until the tool bottoms out against the block.
Oil seal
95059 seal
Caution If the seal is driven into the bl,&k past flush, this ._ ‘, may cause an oil leak.
M 8995060 CEN0133
CEN0134
I
Piston, Connecting Rod
11 D-52
ENGINE OVERHAUL - and Cylinder a&k INSPECTION
11302130015
CYLINPER BLOCK
(1) Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. (2) Examine block and cylinder bores for cracks or fractures.
CYLINDER BORE
Front
(1) The cylinder walls should be checked for out-of-round and taper with Tool C-119 or equivalent ,,The cylinder bore out-of-round is 0.051 mm (.002, in.) maximum, and cylinder bore taper is 0.051 mm (.OQ2 in.) .maximum. If the cylinder walls are badly scuffed or’scored, the cylinder block should be rebored and honedStand new: pistons and rings fitted. Whatever type ~of bortng %quipment is used, boring and honing should be closely coordinated with the fitting of pistons and rings so that specified clearances may be maintained. (2) Measure the cylinder bore at three levels in directions A and B. Top measurement should be 10 mm (.39 in.) down and bottom measurement should -be 10 mm (.39 in.) up from bottom of bore.
B A
~
Standard value: 87.5 mm (3.445 in.)
“._ 1
CENW74
’ I PISTONS
(1) Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown in the figure. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center Ilne. Correct piston to bore clearance must be established in order to assure quiet and economical operation. Standard value: 0.012-0.044 mm (.0005-.OOi 7 in.) CENOO75
(2) Pistons and cylinder bores should be measured at normal ’ room temperature, 21 “C. (70°F). ._
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Piston, ConnqScting, Rocj
E N G I N E OVERhAUL - hd Cyiirider .BtbckPISTON RING
(1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (.47 in.) from bottom of cylinder bore. Check gap with feeler gauge. Standard value: Upper ring 0.23-0.52 mm (.OOQ-.020 In.) Intermediate ring 0.49-0.78 mm (.OlQ-.031 in.) Oil control ring 0.23-0.86 mm (.OOQ-.026 In.) Limit: Upper ring 0.8 mm (.031 in.) Intermediate ring 1.0 mm (.03Q in.) Oil control ring 1.0 mm (.03Q in.)
(2) Check piston ring to groove side clearance.
.
Standard value: 0.0~5-?$~ ,;mm (.OOlO-.oq?s in.) Limit: 0.10 mm (.004”in.) , I ‘,,a.’, I ‘. .
,!
_
; _-
“..
CRANKSHAFT MAIN BEARINGS
The crankshaft is supported in five main bearings. All upper bearing shells in the crankcase have oil grooves. All lower bearing shells installed in the (bedplate) main bearing caps are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal.
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IIQ-54
piston, Connwtipg RgQ Cylinder Block ;
ENGINE OVERHAUL - ahd
CONNECTING ROD BEARING CLEAR#CE
r., ,. -I _
_
.”
(1) Place a piece of Plastigage across the, entl’re width of .the bearing shell in the beating cap approximately 6.35 mm off center and away -from the .oil hole. ‘In, ,addition, suspect areas can be checked, by placing lPlastigage in the suspect area. (2) Before assembling the rod ‘caps with Plastlgage in place; ‘the crankshaft must be rotated until the connecting rod being checked starts moving toward the top of the engine., Only then should the cap be .assembled~ and torqued I ._ to the specification. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. (3) Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Standard value: 0.026-0.059 mm (.OOl-.0023 in.) Limit: 0.075 mm (.003 in.)
CONNECTING ROD BEARING ‘CAP BqLT%‘-, ,
StrtZched bolt
Threads are not straight on line Threads are straight qn line ,
Un&etched bolt CENOO51
~ I’ ’
(1) Since the connecting rod bearing cap bolts are torqued using a new procedure, they should ,be’ examined BEFORE reuse. If the threads are necked’ downiAreplace .+ the bolts. ,:.>- ’ 3 (2) Necking can be checked by holding a scale or’straight edge against the threads. If all the threads donot contact, the scale, the bolt should be replaced. ’ ,.I.,’ i * ., . , ,’
1 TSB Revision
I
ENGINE OVERHAUL ‘-“Cr~~kah&f :/
CRANKSHAFT REMOVAL Procedures after removing crankshaft sprocket, oil pan, pistons and connecting rods. (1) Using Tool MB995022, remove front crankshaft oil seal. Be careful not to damage the seal surface of cover. (2) Pry out rear seal with screwdriver. Be careful not to nick or damage crankshaft flange seal surface or retainer bore.
(3) Install knock sensor. Tighten knock sensor to 10 Nm (7 ftlbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark cont r o l .
(4) Select proper thickness main bearing shells by referring to CRANKSHAFT BEARING CLEARANCE.
CENO080
NOTE Upper and lower No. 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine. Bearing shells are available in standard and the following undersized: 0.016 mm, 0.032 mm, 0.250 mm. Never install an undersize bearing that will reduce clearance below specifications. CENO078
(5) Install the main bearing shells with the lubrication groove in the cylinder block.
Oil holes
CENO081
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ENGINE OVERHAUL - .Crankshdfi NOTE All upper bearing shells in the crankcase have oil grooves. All lower bearing shells installed in the (bedplate) main bearing caps are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal.
(6) Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the bkxk tab slots. (7) Oil the bearings and, journals and install,i crankshaft. ; 2 Caution Do no? get oil on bedplate m&ting rr&face: If may effect the sealer ability toi geai @edplate, ,::,. the I,, to cylinder block. ” 0.
(8) Apply 1.5 to 2.0 mm (.059 to .078 in.) bead of Loctite 19614 to cylinder block as shown in’ the figure. (9) Install main bearing cap bedplate together with lower’ bearing shells. Caution Use only the specified anaefroblc sealer “on r* &e’ bedplate or damage ma9 occur to the’;&ng[n&. ’ i, ’ ,’ / s / CEN0129
.,. .
; ’ i . ;
‘, ;
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.:
‘9,
11 D-58
ENGINE OVERHAUL - Crankih@ft I
.
L
(1O)Before installing the bolts, the threads should be oiled with engine oil.
(1l)lnstall main bearing bedplate to engine block bolts (1 thru 10) finger tight, then torque main bearing bolts to 75 Nm (55 ftlbs.) in sequence shown in the figure. (12)!nstall main bearing bedplate to engine block bolts (A thru K) finger tight, then torque each bolt to 28 Nm (20 ft.lbs.) in sequence shown in the figure.
(13)lnstall crankcase baffle into the opening in the b&k:’ Attach baffle to main bearing cap fasteners. /, ,I
Crankcase baffle
QN0127
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ENGINE OVERHAUL - Cratik~haft (14)Place new front seal into opening with seal spring towards the inside of engine. Install seal by using Tool MB995022 until flush with oil pump cover.
2
Caution if burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during instailatlon of new seal.
Oil seal
CEN0132
95059
NOTE When installing seal, no lube on seal is needed. (15)Place Special Tool MB995059 on crankshaft. This is a pilot tool with a magnetic base. (16)Position seal over pilot tool. Make sure you can read the words THIS SIDE OUT on seal. Pilot tool should remain on crankshaft during installation of seal. (17)Drive the seal into the block using Special Tool MB995060 and handle C-4171 until the tool bottoms out against the block.
seal
I I
Caution If the seal is driven into the block past flush, this may cause an oil leak.
CEN0133
CEN0134
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11 D-60
E N G I N E OVERHAUL - Cran\’
, -:i -^’
IlE-7
ENGINE c2.4Ls - On-vehicle Service
ON-VEHICLE SERVICE
11laoom34
DRIVE BELT TENSION CHECK AND A D J U S T M E N T
6ENO596
98 N (22 Ibs.)
Water pump pulley
GENERATOR DRIVE BELT TENSION CHECK ‘, Use the belt tension gauge to check belt tension at the shown point or check deflection by applying 68 N (22 Ibs.) to the .,’ , shown point. ,:f Standard value: Tension: 245 - 490 N (55.1 - 110.2 Ibs.) Deflection : 9.0 - 11.5 mm (.35 - .45 In.)
a,. I
i’ ‘,
_.(
,
‘,..T
Generator pulley Cranksha3Jlg!J 01A0184 Dullev
..
GENERATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the generator pivot bolt. 2. Loosen the lock bolt. 3. Turn the adjusting bolt to adjust the belt tension or deflection to the standard value. Standard value: Adjus bolt
1 Items Ta;new belt is
I
( yv’Iv’:used belt is 1
Tension N (Ibs.)
490-686 (110.2-154.3)
392 (88.2)
Deflection mm (in)
7.5-9.0 (.30-.35)
10.0 (-39)
4
Tighten the nut of the generator pivot bolt. Tightening torque: 23 Nm (17 ft.lbs.) 5. Tighten the lock bolt. Tightening torque: 23 Nm (17 ft.lbs.) 6. Tighten the adjusting bolt. Tightening torque: 10 Nm (7 ft.lbs.)
1 TSB Revision
IIE-8
ENGINE - O n - v e h i c l e S e r v i c e
I
POWER STEERING PUMP DRIVE BELT TENSION S’ CHECK 111001101aa
Use the belt tension gauge to check belt tension at the shown point or check deflection by applying 98 N (22 Ibs.) to the shown point. Standard value: Tension: 245 - 490 N (55.1 - 110.2 Ibs.) Deflection: 5.5 - 8.0 mm (.22 - .32 in.)”
pump pulley AOlC0028
POWER STEERING PUMP DRIVE BELT TENSION / / ADJUSTMENT 1. Loosen power steering pump fixing bolt (A, 8, C, D).
2. Move power steering pump, tension belt moderately and adjust tension. Standard value:
4. Tighten the remaining fixing bolts (6, C and D).. Tightening torque: Bolt B and D 28 Nm (21 ft.lbs.) Bolt C 22 Nm (16 ft.lbs.)
5. Check the belt deflection amount and readjust if necessary. Caution This check should be carried out after turning the crankshaft one full rotation or more in the forward direction (to the right).
A/C COMPRESSOR DRIVE BELT TENSION CHECK 111001ooooa
Use the belt tension gauge to check belt tension at the shown point (a) or (b), or check deflection by applying 98 N (22 Ibs.) to the shown point. Cranksh pulley
Standard value: Tension: 255 - 333 N (57.3 - 75.0 Ibs.) Deflection: 6.5 - 7.5 mm (-26 - -30 In.)
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i $1
ENGI’NE - On-vehicle Service
l-e&g
A/C COMPRESSOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen tension pulley fixing nut A. 2. Adjust belt tension with adjusting bolt B. Standard value: When a new belt is Items installed
4. Check the belt deflection amount and readjust if necessary. Caution This check should be carried out after turning the crankshaft one full rotation or more In the forward direction (to the right).
IGNITION TIMING CHECK
11100170108
1. Before inspection and adjustment set vehicle in the following condition. l Engine coolant temperature: 80-95°C (178-203°F) l Lights, electric cooling fan and all accessories: OFF o Transaxle: Neutral (P range on vehicles with A/T) 2. Turn the ignition switch to OFF and connect the scan
tool to the data link connector. 3. Set up a timing light.
4. Start the engine and run at idle. 5. Select No. 22 of the SCAN TOOL DATA LIST. 6. Check that engine idle speed is within the standard value. Standard value: 750 + 100 r/min
7. Select No. 17 of the SCAN TOOL ACTUATOR TEST.
Check that basic ignition timing is within the standard
value. Standard value: 5” BTDC f 3”
If the basic ignition timing is outside the standard value, inspect the MFI components by referring to GROUP 13A - Troubleshooting.
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llE-IO
ENGINE - On-vehicle Seryice, ,
.m
,.
10. Press the scan tool clear key (select a forced driving cancel mode) to release the ACTUATOR TEST NOTE If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 11. Check that the actual ignition timing is at the standard value. Standard value: Approx. 10” BTDC
NOTE 1. Ignition timing is variable within about &7”, even under normal operating. 2. And it is automatically further advanced by about 5” from IO” BTDC at higher altitudes.
CURB IDLE SPEED CHECK
11199199992
1. Before inspection and adjustment, set vehicles in the following condition. l Engine coolant temperature: 80-95°C (176-203°F) l Lights, electric cooling fan and all accessories: OFF l Transaxle: Neutral (P range on vehicles with A/T) 2. Turn the ignition switch to OFF and connect the scan tool to the data link connector. 3. Select No. 17 of the SCAN TOOL ACTUATOR TEST 4. Check the basic ignition timing. Standard value: 5” BTDC f 3”
5. Run the engine at idle for 2 minutes. 6. Select No. 22 of the SCAN TOOL DATA LIST. 7. Check the curb idle speed. Standard value: 750 f 100 r/min NOTE The idle speed is controlled automatically by the idle air control system. 8. If the idle speed is outside the standard value, check the MFI components by referring to GROUP 13A - Troubleshooting.
IDLE MIXTURE CHECK 1.
11199210292
Before inspection, set vehicles in the following condition: Engine coolant temperature: 80-95°C (176-203°F) l Lights, electric cooling fan and all accessories: OFF l Transaxle: Neutral (P range on vehicles with m 2. Turn the ignition switch to OFF and connect the scan tool to the data link connector. 3. Select No. 17 of the SCAN TOOL ACTUATOR TEST. 4. Check that the basic ignition timing is within the standard, : value. . l
Standard value: 5”BTDC f 3”
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ENGI’NE - On-vehicle Servide
,..,.
,..
31Ew
5.. Run the engine. 8. Set the CO, HC tester. 7. Check the CO contents and the HC contents at idle. jl
Standard value: CO contents: 0.5% or less HC contents: 100 ppm or less
8. tf the standard value is exceeded, check the following items: l Diagnostic output l Closed-loop control (When the closed-loop control is carried out normally, the output signal of the heated oxygen sensor repeats between O-400 .mV and 600-l ,000 mV at idle.) l
Fuel pressure
”
I’
T-1
.I,
“‘
, “. ” ;, :
0 Injector .? l Ignition coil, spark plug cable, spark p@i!” l EGR system ,and the EGR,valve’ leak,, l Evaporative emission coritro! syStem ., :- ‘ 0 Compression pressijre , ; ” ‘. ‘) b . ’ , .A ( NOTE Replace the three-way data&s1 tihene;er the CO and HC contents do not rem&in i&i& the stahdard value. (even though the result of the” in@&on is normal on all items.)
COMPsRESSION PRESSURE CHECK
11100260147
1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle to the following condition: l Engine coolant temperature: 80-95°C (176-203°F) l Lights, electric cooling fan and all accessories: OFF l Transaxle: Neutral (P range on vehicles with A/T) 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crankshaft position sensor Connector. NOTE Doing this will prevent the engine control unit from carrying out ignition and fuel injection.
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llE-12
ENGINE - On-vehicle Set&e
,*,
*..
,.,
_
5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution 1. Keep away from the spark plug hole when cranking. 2. If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.
6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250-400 r/min): 1,350 kPa (192 psi) Limit (at engine speed of 250-400 r/min): Min. 1,020 kPa (145 psi)
8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa (14 psi)
9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 7 and 8. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crankshaft position sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the scan tool to erase the diagnostic trouble codes, or disconnect the negative battery cable for;,more than ,-*. 10 seconds and reconnect it. NOTE This will erase the diagnostic trouble code resulting from the crankshaft position sensor connector ‘being dis:connetted. ’ .+
MANIFOLD VACUUM CHECK
1110027oa17
1. Before inspection, set vehicles in the following condition: l En ine coolant temperature: 80-95°C (176-203°F) l Lig1ts, electric cooling fan, and accessories: OFF l Transaxle: Neutral (P range on vehicles with A/T) 2. Set up the tachometer or connect the scan tool to the data link connector.
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ENGINE - On-vehicle Service’
WEA 3
3. Attach a three-way joint to the vacuum hose connected between the intake manifold plenum and the fuel pressure solenoid valve and connect a vacuum gauge. 4. Start the engine, and check that the curb idle speed is within the standard value range. Standard value: 750 It 100 r/min
5, Check the manifold vacuum. Limit: Min. 60 kPa (16 in.Hg)
LASH ADJUSTER CHECK
MIN OlRO340
111&s2
NOTE If an abnormal noise (rattling noise) probably caused by the 1 lash adjusters is heard and the noise does not stop, check L.,’ as follows. I .’ 1. Check the engine oil, and if required, refuel ar“replace it. NOTE l If the amount of the engine oil is insufficient, air will be sucked in from the oil strainer and mix in the oil passage. l If the amount of the engine oil is more than- the specified amount, it will be stirred by the crankshaft to make a lot of air mix in the oil. l If the oil is deteriorated, it will not easily separaJe from air and the amount of air mixed in the oil will increase. * ”
If the air which has mixed in the oil due to the above causes enters the high-pressure chamber in the lash adjusters, the air in the high-pressure chamber will be pressurized during opening of the valve, which causes the lash adjusters to shrink excessively, and an abnormal noise will be generated when the valve is closed. This is the same phenomenon as the one when the valve clearance has been excessively adjusted by mistake. In this case, if the air which has entered the lash adjusters is bled, things will be normalized.
High pressure chamber
7ENO392
2. Start the engine and perform gentle racing? several times (less than 10 times.) If the abnormal noise stops by racing, the air is bled from the high pressure chamber of the lash adjusters and the function of the lash adjusters is normalized. l : After raising the engine speed from idling to 3,000 r/min gradually (in 30 seconds), drop the speed gradually (in 30 seconds) to idling.
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I
IIE-14
ENGINE - On-vehicle Sewice, NOTE If the vehicle is parked on a slope for long, tne oil in the lash adjusters will ‘be’decreased and ‘air may enter the high-pressure’ chamber when the vehicle is started. l After the vehicle is parked for long, air may enter the high-pressure ,chamber because, the oil in the oil passage will be gone .and it bill take a time before : the oil is supplied to the lash’adjusters. : l
3.
6EN0727
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If an abnormal noise does not stop by racing, check the lash adjusters according to the following procedures. (1) Stop the enaine. (2) Set’the,No. Icylinder of the engine to the compression ’ top dead center. (3) Push the rocker arm indicated by the white arrow mark as shown in the illustration at left and check whether or not the arm lock goes down. (4) Turn slowly the crankshaft 360” clockwise. (5) Check the rocker arm indicated by the black arrow mark as shown in the illustration at left same as above (3). (6) If the rocker arm can be lowered easily when the part of the rocker arm which is directly above the top of the lash adjuster is pressed, the lash adjuster is defective and should be replaced with a new part. Furthermore, when replacing the lash adjuster, bleed all of the air from the lash adjuster and then install. After this, check that there is no problem by checking in steps (1) to (5). NOTE l A leak-down test can be carried out to accurately determine whether the lash adjuster is defective or not. l For the procedures for the leak-down test and air bleeding of the lash adjuster, refer to P. 11 F-32. Furthermore, if the rqcker arm feels extremely stiff and cannot be lowered when it is ,pressed, the lash adjuster is normal, so investigatefor some other cause of the abnormality.
11 Ed5
ENGINE - Engine Assembly
ENGINE ASSEMBLY
11200100411
REMOVAL AND INSTALLATION Pm-removal Operation l l l l
l l
1Post-installation Operation
Fuel Line Pressure Releasing (Refer to GROUP 13A - On-vehicle Service.) Hood Removal Engine Coolant Draining (Refer to GROUP 00 - Maintenance Service.) Transaxle Assembly Removal (M/Tz Refer to GROUP 22A-Transaxle Assembly.) (A/Tz Refer to GROUP 23A - Transaxle Assembly.) Radiator Removal (Refer to GROUP 14 -Radiator.) Under Cover Removal (Refer to GROUP 42 - Under Cover.)
l l
l l l l l
Radiator Installation (Refer to GROUP 14 - Radiator.) Transaxle Assembly Installation (M/T: Refer to GROUP 22A - Transaxle Assembly.) (A/TI Refer to GROUP 23A -Transaxle Assembly.) Engine Coolant Supplying (Refer to GROUP 00 - Maintenance Service.) Hood Installation Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.) Under Cover Installation (Refer to GROUP 42 - Under Cover.) Drive Belt Tension Adjustment
(Refer td GROUP 16 - Generator.) 6. Power steering pump Connection 7. A/C compressor connection
IIE-16
ENGINE a4L>
- Ey$n,e’ As+tj!y
., . _1 I/ .I _.., “. , “,, / .r. h.s .n./,
d 4.9 Nm \ / X L - 3.6 ft.lbs.
. i t
8. Accelerator cable connection 9. idle air control motor connector 10. Heated oxygen sensor connector 11. Engine coolant temperature gauge unit connector 12. Engine coolant temperature sensor connector 13. Ignition power transistor connector 14. Throttle position sensor connector 15. Capacitor connector 16. Manifold differential pressure sensor connector 17. Injector connectors 18. Ignition coil connector 19. Camshaft position sensor connector
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.
00005323
20. Crankshaft position sensor connector 21. Air conditioning compressor connector 22. Evaporative emission purge solenoid valve conneotdii’ “: 23. Control wiring harness 24. Brake booster vacuum hose connection ,C+ .25. High-pressure fuel !hosa connection 26. hose connection -- Fuel ._. . return . .. 27. water nose A connectron 28. Water hose 6 connection
29. Vacuum hoses connection
31iE47
ENG’INE - Engine Assembl,y
67 Nm 49 R.lbs.
\ 98-118 Nm 72-87 tl .Ibr. -‘,
*01x0367 _, ,
34Nm 28 ft.lbs.
30. Front exhaust pipe connection 31. Gasket eb .Bq 32. Engine mount bracket assembly dD, .A4 33. Engine assembly
REMOVAL SERVICE POINTS +A, POWER STEERING PUMP REMOVAL
Remotie‘the power steering pump from the bracket with the hose attached. NOTE Place the removed power steering pump in a place where it, will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. 46; A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still a t t a c h e d . NOTE: Place the removed A/C compressor in a place where it will not be ,a hindrance when removing and installing the engine assembly, and tie it with a cord. Cauti,on, *k p .‘! Do not bend the joint between the “tic hose and the A/C pipe by. force.
qc,
E N G I N E MOUNT +ACKET REMOVAL
A SS
EM B LY , F, (Lb;.,
.%
(1) Support the engine’.&th a garage jack; ‘:’ (2) Remove the special tool which was attached when the transaxle assembly tias removed. (3) Hold the engine &ssembly with a chain block or similar tool. (4) Place a garage jack against the engine oil pan with a piece of wood in, between, jack up the engine so that the weight of theiengine is no longer being applied to the engine mount bracket assembly, and then remove the engine mount bracket assembly. +D, ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine _’ )f 3 .“. t< : ‘,* i compartment. .:i’ “ /i’ +t, :r_ ::a -’ ‘7 ,“. ,*‘; 8. ,dJ$; j.t,‘. I.‘,, i ,q;$-+‘-; 6.. j , ,i; $‘p&
Install the engine asserhbly while checking that. ti;;;” &les, hoses, and harness connectors are not clamped. .B+ENGlNE MOUNT BRACKET ASSEMBLY / ; INSTALLATION ‘:
(1) Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket assembly while adjusting the position of the engine. (2) Support the engine with the garage jack. (3) Remove the chain block and support the engine assembly with the special tool.
C Engine side
Engine
(4) Align the notches on the stopper with the engine mount bracket with the arrow ‘mark, facing toward the shown direction. Then install the stopper.
Arro Engine mount bracket assembly
B01X0080
.Cd HIGH-PRESSURE FUEL HOSE CONNECTION
When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of clean engine oil to the hose union and then insert, being careful not to damage the O-ring. “: r ,, c Caution Do not let engine oil get Into the fuel rail. . I
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11 E-20
ENGINE k2.4L> -
Crankshaft
Pylley, _
CRANKSHAFT PULLEY
11200160150
REMOVAL AND INSTALLATION Pre-removal’ Operation l Under Cover Removal (Refer to GROUP 42 - Under Cover.)
Removal steps 1. Drive belt (Generator) 2. Drive belt (Power steering) 3. Drive belt (NC) 4. Crankshaft pulley
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(Refer to GROUP 42 - Under Cover.)
llE$H
EN,GINE - Camshaft and Camshaft Oil’ Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
11mo190326
REMOVAL AND INSTALLATION Pm-removal Operation l Battery Removal
journ& s&ion Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
‘ .,
01 x0031
,
lG9000
Engine oil
Removal steps 1. - . Accelerator . . . . . cable connection 2. Air Intake nose 3. Connection for breather hose 4. Connection for PCV hose 5. Spark plug cable --. 6. Rocker cover 7. Camshaft position sensor support 8. Camshaft position sensing cylinder TSB Revision
9. Timing belt upper cover ._ 4Ab bC+ 10. Camshaft gprocket .‘,. bB4 11. Camshaft oil seal +B, .A( 12. Rocker ?~!TI. and shaft assembly, flntakeside) ‘.’ 4B, .A4 13. Rocker ‘-arm and shaft assembly (Exhaust ‘side) I _ 14. Camshaft
11 E-22
ENGINE - Camshaft and Camshaft Oil ‘Seat REMOVAL SERVICE POINTS .:
‘c
’
dAbCAMSHAFT SPROCKET l$EMOVAL ,
(.
I
(1) Rotate the crankshaft in’the for&ard (right) direction and align the timing marks. (No.1 cylinder is the compression stroke top dead center position.) Caution The crankshaft must always be rotated in the direction only.
Camsha< sprocket
forward
(2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket will not move with respect to the timing belt.
(3) Use the special tool to remove the camshaft sprocket with the timing belt attached. ’ Caution After removing the camshaft sprocket, be sure not to rotate the crankshaft. ‘.
MB990767
> Camshaft R sprocket ei-y+$p*
,
AOlC0107
+B,ROCKER ARM AND SHAFT ASSEMBLY . REMOVAL
Before removing the rocker arm and”shaft assembly, install the special tools as shown in the illustratton. s,o that the lash adjusters will not fall out. I, i 1) .I .: ).
.:L ,
,(
INSTALLATION SERVICE i60iNTS FAdROCKER ARM AND SHAFT ASSEMBLY INSTALLATION
(1) Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve ‘bide do not push the valves. (2) Fit the rocker shaft spring from the above, and position it so that it is right angles to the pluc guide. .,_ TSB Revision
ENGINE -, Camshaft and Camshqft Oik Se@ I
yjig23
Install the rocker shaft spring g?fore installing, the ro&$l arm and rocker arm shaft dn @&‘&b&jst &i&-c i‘ 5” Z _. (3) Remove the special fool ior _ fixing> the iash ,$j&&. -“, !, r:,.1.- 1 I.> ” ! ‘il. ‘. . .; ‘l.i y\;; :;. .I : P, .: ./f f ?,.: *.- ,
(4) Confirm that the rocker shaft notch is in the direction shown in the diagram.
.Bd CAMSHAm OIL SEAL INSTALLATION
(1) Apply engine oil to the camshaft oil seal lip. (2) Use the special tool to presslfit the camshaft oil seal.
.Cd CAMSHAFT SPRO,CKET INSTALLATION
190767
MD996 MD998
[ TSB
Revision
11 E-24
ENGINE - Oil Pan and Oil Screen
OIL PAN AND OIL SCREEN
112oo2!io130
REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Engine Oil Draining and Supplying (Refer to GROUP 00 - Maintenance service.) l Oil Level Gauge Removal and Installation l Front Exhaust Pipe Removal and Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.)
04
m
Specified sealant: ‘, MITSUBISHI GENUINE PART No. MD970389 or equivalent
‘
7Nm 5 ft.lbs.
39 Nm WI3/p 29 ft.lbs. 2
Removal steps 1. Bell housing cover 2. Drain plug bB+ 3. G a s k e t +A, .A4 4. Oil p a n 5. Oil screen
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9Nin 7 ft.lbs. 01x0155 00000245
*_’
:_
ENGINE ‘ - Oil Pan and Oil Sctk REMOVAL
,SER\iiCE ,pOiMT
:
dA, OIL PAN REMOVAL _j:
;
Iv
.i /“
:,“:l
i’
:‘:(T,
‘4 !i.,,. y.,
After removing the oil pan mount&g bo&,’ remove the oil pan with the special tool and a brass bar.: :‘tf ,,; I 6 b I 1; Caution ” Do it slowly to avoid deformation of t&e oil pan flange.
INSTALLATION SERVICE POINTS .A4 OIL PAN INSTALLATION Caution After cleaning the oil pan’mountlng bolt holes In the oil seal case, the oil’ pan should be Installed.
.B+ GASKET INSTALLATION 1’ ~
Oil pan side
.’ I’ Replace the gasket and install, it in the dirtictioh ‘si?qnm in ; ,9. the illustration. ‘/ 4
Drain pl gasket
TSB Revision
11 E-26
ENGINE - Crankshaft Front Oil Seal
CRANKSHAFT FRONT OIL SEAL
112oo34oi89
REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt B Removal and Installation (Refer to F!lIE-41.)
l
..
‘.
01xol29 3
.‘;
Engine oil
01x0193
_I
00003917
Removal steps
1. Crankshaft sprocket B .A4 $ %nkshaft front oil seal
INSTALLATION SERVICE POINT .A4 CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Apply engine oil to the entire inside diameter of the oil seal lip. (2) Press-fit the oil seal until it is flush with the oil pump case.
TSB
Revision
11 I327
ENGINE - Crankshaft Rear Oil Seal
CRANKSHAFT REAR OIL SEAL
”
REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Transaxle Assembly Removal and Installation l
(M/T Refer to GROUP 22A-Transaxle Assembly.) (AIT: Refer to GROUP 23A-Transaxle Assembly.) Clutch Cover and Clutch Disc Removal and Installation
127-137 Nm 94-101 ft.lbs.
-101 ft.lbs.
‘01X0094
00004206
194 Crankshaft
9EN0102
Specified sealant: 3M Stud locking 4170 or equivalent
INSTALLATION SERVICE POINTS .A( CRANKSHAFT REAR OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the entire inside diameter of the oil seal lip. (2) Tap in the oil seal as shown in the illustration.
9EN0102
.Bd DRIVE PLATE BOLT /FLYWHEEL BOLT INSTALLATION (1) Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate . (2) Apply oil to the bearing surface of the flywheel CM/T> or drive plate CA/T> bolt. (3) Apply oil to the crankshaft thread holes. (4) Apply sealant to the threaded mounting bolts. Specified sealant: 3M Stud locking 4170 or equivalent
(5) Use the special tool to secure the fl$vheel ,&l/T> or drive plate , and then tighten the bolts I, . to the speci.’ fied torque. Specified torque: 127-137 Nm (94-101 ft.lbs.)
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I
‘. b
VI E-29
ENGINE - Cvlinder Head aask&
CYLINDER HEAD GASKET
112oo4ao512
REMOVAL AND INSTALLATION Pre-removal Operation Fuel Line inner Pressure Release (Refer to GROUP 13A - On-vehicle Service.) l Engine Coolant Draining (Refer to GROUP 00 - Maintenance Service.) l Engine Oil Draining (Refer to GROUP 00 - Maintenance Service.) l
Post-installation Operation Engine Oil Refilling (Refer to GROUP 00 - Maintenance Service.) l Engine Coolant Refilling (Refer to GROUP 00 - Maintenance Service.) l
Air intake hose Idle air control motor connector Heated oxygen sensor connector Engine coolant temperature gauge unit connector Engine coolant temperature sensor connector Ignition power transistor connector Throttle position sensor connector Capacitor connector Manifold differential pressure sensor connector Injector connectors Ignition coil connector
ENGINE - Cylinder Head Gasket REMOVAL SERVICE POINTS +A, CAMSHAFT SPROCKET REMOVAL (1) Rotate the crankshaft in the forward (right) direction ‘and, align the timing marks. (No.1 cylihder is the cdriipression’ stroke top dead center: position.) -: . ,^/ Caution The crankshaft must always be rota?$d in the iorward I ;. !, direction only.
Camshai;
sprocket
(2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket wilt not ?ndve with respect to the timing belt.
(3). Use the special tool to remove the camshaft sprocket with the timing belt attached. Caution After removing the camshaft sprocket, be sure not to rotate the crankshaft. -. I, ’ ; ,i’ Camshaft sprocket n01C0107
dB, RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION Place mating marks on the radiator hose and th”e’hose clamp, and then disconnect the radiator hose.
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11 E-32
ENGINE - Cylinder Head Gasket +C, CYLINDER HEAD BOLT REMOVAL Using the special tool, I’oosen the bolts in the order shown in the illustration (in 2 or 3 stages), and then remove the cylinder head assembly. Caution Because the plug guides cannot, be replaced by themselves, be careful not to damage or deform the plug guides when removing the cylinder head bolts.
Intake side
Front of engine o
Exhaust side
INSTALLATION SERVICE POINTS .A+ CYLINDER HEAD GASKET INSTALLATION (1) Wipe off all oil and grease from the gasket mounting I surface. (2) Install the gasket to the cylinder block with the identification mark facing upwards. .I _’ “ AOiAOO38
.B+CYLlNDER HEAD BOLT INSTALLATION (1) When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. Limit (A): 99.4 mm (3.91 in.) (2) Apply engine oil to the bolt thread and the washer.
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ENGINE - Cylinder Head Gasket Intake side
(3) Tighten the bolts by the following procedure.
Front of engine c3
1
FT]
Exhaust side
I
I
1 Tighten to 26Nm (15 ft.lbs.).
) In the ordershowh in the illustration.
BOlCOllS
4
Tighten 90” of a turn.
In the order shown in the illustration. Mark the head of the cylinder head bolt and cylinder head by paint.
5
Tighten 90” of a turn.
In the order shown in the illustration. Check that the painted m,ark,sf the head bolt is lined up with that of the. cylinder head. ,
Step 5
Step 4
Painted marks
Painted marks 01x0270
Thermostat case assembly or water pump
Caution 1. Alway”s make a tightening angle just 90”. If it is less, than 90°, the head bolt will be loosened. 2. If it is more than 90°, remove the head bolt and repeat the ‘procedure from step 1. v .u
.C+ O-RING INSTALLATION Insert the O-ring to the water inlet pipe, and coat the outer inside diameter of the O-ring with water or engine coolant.
Caution Do not let engine oil or other greases contact with the O-ring.
-ring
Water inlet pipe assembly A04XOOOl
FDA THERMOSTAT CASE ASSEMBLY INSTALLATION (1) Loosen the water inlet pipe bolt shown in the illustration.
11 E-34
ENGINE - Cvlinder Head ‘Gasket (2) Apply specified sealant to the thermostat case assembly in the places shown in the illustratfon. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivak lent (3) Apply a small amount of water,to the O-ring of the water inlet pipe, and then press the thermostat case assembly into the water inlet pipe. (4) Tighten the thermostat case assembly mounting, bolts. (5) Tighten the water inlet pipe bolts. ’ .E( RADIATOR LOWER HOSE/RADIATOR UPPER .,) HOSE CONNECTION (1) Insert each hose as far,as the projection of‘the water outlet fitting or water inlet fitting.
Projytion
Water outlet fitting or water inlet fitting
I
I
(2) Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
A04A0082
,F+-HIGH-PRESSURE FUEL HQSE ,C~Nl’@CTION When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of clean engine oil to the hose union’ and then insert, being careful not to damage the O-ring. Caution Do not let engine oil get into the fuel rail. S! )
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WE+35
ENGINE - Timing Belt
TIMING BELT
11200430220
REMOVAL AND INSTALLATION 1
I
Pre-removal Operation o Under Cover Removal (Refer to GROUP 42 - Under Cover.) l Engine Mount Bracket Removal (Refer to GROUP 32 - Engine Mounting.)
l l
1
1
Post-installation l
Opefatidn Under Cover Installation (Refer to GROUP 42 - Under Cover.) ,!’ ) Engine Adjustment Engine Mount Bracket installation (Refer to GROUP 32 - Engine Mounting.)
8.8 Nm
17-20 ft.lbs.
25 ilm 18ft.lbs.
Removal steps l Drive Belt Tension Adjustment
1. 2. 3. 4. 5. 6.
AOlX0350
IO:12 Nm 7.2-8.7 ft.lbs.
Driv& belt (Generator) Drive belt (Power steering) Tensioner pulley bracket Drive belt (A/C) Water pump pulley Water pump pulley (Power steering)
TSB Revision
7. Crankshaft pulley bD( 8. Timing belt front upper cover bD+ 9. T i m i n g b e l t f r o n t l o w e r cover bC+ l l i m i n g belt tension adjustment +A, .B+ 10. Timing belt
11. Tension pulley
.A( 12. Auto tensiorier
11 E-36
ENGINE - iiming lht marks
.,
.,
REMOVAL SERVICE POINT
,., :’
“..,_,
.,,,
-‘- .: :::I;
+A, TIMING BELT, REMOVAL ,*./,. (1) Turn the crankshaft in the forward direction (to the ight) to align the camshaft sprocket timing marks. m _ :: Caution Always turn the crankshaft in the forward~directlpn only. AOlXO134
(2) Loosen the tension pulley center bolt. (3) Move the tension pulley to the water pump side, and then remove the timing belt. Caution If the timing belt is to be reused, use chalk to mark (on its flat side) an arrow indicating the clock-wise direction.
INSTALLATION SERVICE POINTS
98N-196N (22-44 tbs.)
Auto tensioner
III
AOlZ0002
.A+ AUTO TENSIONER INSTALLATION (1) Apply 98-196 N (22-44 Ibs.) force to the push rod of the auto tensioner by pressingLit against a metal (cylinder block,..etc.), and measure the movement of the push rod. Standard value: Within 1 mm (.04 in.) A: Length when it is free (not pressed) B: Length when it is .pressed A-B: Movement (2) If it is out of the standard value, replace the auto tensioner. (3) Use a press or vise to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned. Caution If the compression speed is too fast, the rod may become damaged, so be sure to carry out this operation slowly.
(4) Once the holes are aligned, insert the set pin. NOTE When replacing the auto tensioner with !a,new part, the pin will be in the auto tensioner. (5) Install the auto tensioner to the engjne.
’
!
I
AblSOl3S
TSB Revision
ENGINE - Timing Belt .B+TlMlNG BELT INSTALLATION ^/ r- : 1 (1) Align the timing marks on the camshaft sprocket; crankshaft sprocket and oil pump sprocket. ’ ‘,. ,.: , ‘. 1 ’ ,:. ’ $5 r ,i II ^;.‘ . .r ,“’ ,-*.I) $4 ,“’ ’ ”, .,
1 TSB Revision
E N G I N E c?.4L> - Timing BeIt B i Crankshaft sprocket
$ i:g?#i
.Cq CRANKSHAFT SENSING BLADE INSTALLAtidk When installing, make sure the direction is correct. See figure.
Crankshaft
Crankshaft sprocket “B” Crankshaft sensina blade
AOlX0201
I
I
.Dd CRANKSHAFT SPROCKET INSTALLATION Use the special tool to install the crankshaft sprocket and bolt. NOTE Apply the minimum amount of engine oil to the bearing and thread of the rrankchnft hnlt ..I_
Items Standard value Timing belt Autotensioner rod projection length mm (in.) 12 (.47) Autotensioner rod pushed-in amount [when pushed with a force 1 .O (.039) or less of 98 - 196 N (22 - 44 Ibs.)] mm (in.) Rocker arms and camshaft Camshaft cam height mm (in.) Intake 37.39 (1.4720) (Identification mark: 1) -Exhaust 37.47 (1.4752) Camshaft journal O.D. mm (in.) .45 (1.77) Cvlinder head and valves -a Cylinder head flatness of gasket surface mm (in.) Less than 0.05 (.0020) -’ Cylinder head grinding limit of gasket surface mm (in.)
mm (in.)
\ \ \ \ F C ( J F F F
L
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Limit ,^
‘*
-
‘r .
)’ _>
i,,l
36.89 (1.4524) 36.97 (1.4555)
( 0.2 (mi) ’ ‘0.2 (.008)
ENGINE OVERHAUL - Specificdions Items
1 Standard value
Crankshaft, flywheel and drive plate Crankshaft end play mm (in.)
0.05-0.18 (.0020-.0071)
Crankshaft journal O.D. mm (in.)
57 (2.24)
Crankshaft pin O.D. mm (in.)
, .’ 0.25 (.0098)'s', _ :;
( 45(1.77)
I
( 0.02 -0.04 (.OOOS-.OOlS)
Cylinder block
_*
s:
j
Bearing cap bolt shank length mm (in.)
.Max.71.1 (2.80)
" Piston to cylinder clearance mm (in.)
0.02 - 0.04 (.0008 -.0016)
-
Cylinder block flatness of gasket surface mm (in.)
0.05
0.1 (.004j
(.0020)
:
Cylinder block grinding limit of gasket surface mm (in.) *Total resurfacing depth of both cylinder head and cylinder block Cylinder block overall height mm (in.) Cylinder block I.D. mm (in.)
'0.2 289.9 j 11.421)
290.1
(11.413
: .,
(.OO8) t
i I
1 86.50 (3.4055)
Cylindricity mm (in.)
, I
I1 0.1 (.904)
I
Crankshaft journal oil clearance mm (in.)
...1
1 &f”, ^?‘l
:
-I
I-
0.01 (.0004) or less
I I
REWORK DIMENSIONS Items
Standard val,ue
s,,
Cylinder head and valve 1 Oversize rework dimensions of valve guide hole mm (in.) (both intake and exhaust)
I
I
0.25 O.S. 1 11.25 - 11.27 (.4429- 4437) 0.50 O.S.
Intake oversize rework dimensions of valve seat hole mm (in.) Exhaust oversize rework dimensions of valve seat hole mm (in.)
1
1 0.05 O.S. 1 11.05 - 11.07 (.4350-.4358)
0.300.2.
11.50-11.52
I
(.4528-.4535)
34.3~A4.33(1.3504-
"
l.3516)
0.60 O.S.
34.60- 34.83 Il.3622 -1.3634)
0.30 O.S.
31.80-31.83
(1.2520-1.2531)
1 0.6OO.S. 1 32.10-32.13(1.2&&1.2650)~'~ 1 Crankshaft, flywheel and drive plate
r 0.01 (.ClOQ$) y less
Crankshaft out-of-roundness and taper of journal pin mm (in.)
-IManifold differential pressure sensor -i Intake manifold stay 7Intake manifold -IExhaust manifold and water pump 73il dipstick guide -Iieat protector -IExhaust manifold M8 -IExhaust manifold Ml 0
__ .
1
ENGINE OVERHAUL - Specifi,&d&s Items
Nm
ft. Ibs. . ~.
20+90”+90”
14.5 + 9d6 + %I”
Cylinder head and valves Cylinder head bolt [Tighten to 78 Nm (58 ft. Ibs.) and then completely loosen before finally tightening with above procedure.]
’
:
““’
,’
Front case, counterbalance shaft and oil pan Drain plug
40
29
Oil pan Oil screen
7 19
5, 14
Oil pressure switch
10
7
Relief plug
45
33.
Oil filter bracket
19
/
Plug
24
14 17.
Flange bolt
37
27
.,:
Oil pump cover screw
10
Oil pump cover bolt Front case Piston and connecting rod
17 24
7 12 17
.., f’-
Connecting rod cap
I20+90”-100”
Flywheel bolt
135
. 98
Drive plate bolt
135
98
Rear plate Bell housing cover Oil seal case
11 9 11
8
Bearing cap bolt
25 + 90” - 100”
.
.
: j _f>
I
,
:,
) :,. .-.: ,/, L
. -.’
c..
.
.
:, : ,.
7, ,, 8 14.!+ 900 - 1 og” .:I.
Revision
I
1 14.5 +#I” 7 199”
Crankshaft, flywheel and drive plate
TSB
_.
,;,
ENGINE OVERHAUL - Se+@
SEALANTS Items
Specified sealant
Camshaft position sensor support
Mitsubishi Genuine Part No. MD970369 or equivalent
Engine support bracket
3M ATD Part No. 8660 or equivalent
Thermostat housing
Mitsubishi Genuine Part No. MD970389 or equivalent
Water outlet fitting
Mitsubishi Genuine Part No. MD970389 or eauivalent
,’
Engine coolant temperature sensor
) 3M NUT Locking Part No. 4171 or equivalent
Engine coolant temperature gauge unit
1 3M ATD Part No. 8660 or equivalent
Oil pressure switch
3M ATD Part No. 8660 or equivalent
Oil pan
Mitsubishi Genuine Part No. MD970389 or eauivalent
Oil seal case
‘I
I
Mitsubishi Genuine Part No. MD970389 or equivalent
TSB Revision
1, ’ ,,’ i ‘I
ENGINE OVERHAUL - Special Tools, ,.
SPECIAL TOOLS
Crankshaft rear oil seal installer
MD9981 62
MD9981 62-01
Removal and installation of front case cap plug
MD99828501
Installation of crankshaft front oil seal
MD99837501
Installation of crankshaft front oil seal
Removal of counterbalance shaft rear bearing
Plug wrench Use with MD998763 MD998285 Crankshaft front oil seal guide 0 0 MD998375 Crankshaft front oil seal installer 0 MD998371
MD998371 -01
Silent shaft bearing puller
Use with MIT304204
MD998372
MD998372-01
Silent shaft bearing puller
Use with MIT304204
TSB Revision
Removal of counterbalance shaft rear bearing
ENGINE OVERHAUL - SDecial ToolB .
Air bleed wire
MD998705
Installation of counterbalance shaft bearing :
MD998373-01 Use with MB990938-01
.:
MD99871 3
Q
P CD
lnstaktion of camshaft: oil seal :’ ‘:,..
MD99871 3-01
Camshaft oil seal installer
MD998727
‘,
MD998727-01
Removal of oil pan
MD998752-01
Installation of auto tensioner
Oil pan remover T MD998767 Tension pulley wrench
MD998772 Valve spring compressor
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/’
General service tool
Compression of valve spring
llF-10
ENGINE OVERHAUL - SDecial Tools ( Tool number and name ) Supersession MD998774
MD998774-01
‘t
) Application
;i.
:
fnstallation of valve steam seal
Valve steam seal installer
_’ ,
MD998778 Crankshaft sprocket puller
Removal of crankshaft sprocket
.’
MD998785
Supporting counterbalance shaf sprocket ”
Sprocket stopper
t’
.I
Q 08 00
MD998780 Piston pin setting tool
8
MIT216941
Removal and piston pin
installation
o
f :
P MD998781
h
-
MD998783
Removal and installation of froni case cap plug ;’
Plug wrench retainer e
Use MD9981 62
:
,
with
MB991 603 Bearing installer stopper
MB991 654 Cylinder head bolt wrench (12) 6991654
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Removal and instaltation of rear bearing I*, .. .
Removal and installation cylinder head bolt
of
IlFal
ENGINE OVERHAUL - Generator and Ignition System
_
11300100148
GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION *,Ir
10Nm 7ft;!bs.
7
25 Nm 18 ft.lbs.
9’
il ...
’ i
\ 0,ll
q
23 Nm 17 ft.lbs. 5 4 10 14 ft.lbs. Nm
\
14 Nm 10 ft.lbs.
\ 22 Nm 18 ft.lbs.
o‘-- 5 Nm
3.8 ft.lbs.
24 Nm 17 ft.lbs. 11 Nm 8 ft.lbs.
6
6ENl244
Removal steps
1. 2. 3. 4. 5. 6. 7.
Drive belt Water pump pulley Power steering pump pulley Generator brace Generator Crankshaft pulley Spark plug cable
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8. 9. 10. 11. ,A( 12. 13.
Spark plug Ignition coil assembly Ignition power transistor assembly Camshaft position sensor Camshaft position sensor support Camshaft position sensing cylinder
I
11 F-12
ENGINE OVERHAUL - Generator and lgnitich Systev -, ,,L ,d, ,1, ,,I _,, , I
(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. 6ENl245
‘, ,, I . ‘.,
.“.
TSB
Revision
I. ,.
IIF
ENGINE OVERHAUL - Timing Belt
TIMING BELT
1130010011~
REMOVAL AND INSTALLATION a.
IO
45 Nm 33 ft.lbs.
I
45 Nm 33 ft.lbs. 15 I
6
9 Nm 7 ft.lbs.
14 Nm 10 ft.lbs. I
1
t 24’ Nm 17 ft.lbs.
8
35 ‘Nm 25 ft.lbs. 120 Nm 87 ft.lbs.
Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Crankshaft position sensor +A, bJ+ 4. Timing belt .I4 5. Tensioner pulley 6. Tensioner arm FHd 7. Auto tensioner 8. Idler pulley 46, .Gd 9. Oil pump sprocket +C, ,F+ 10. Crankshaft bolt 11. Crankshaft sprocket 4w TSB Revision
55 Nm 40 ft.lbs.
12. Flange , 13. Tensioner “B” ’ .-.. +E, FE4 14. Timing belt “E” “’ +F, .Dd ,I 5. Counterbalance; shaft sprocket * *.‘9 .Cq 16. Spacer 17. Crankshaft sprocket “B 4Gb FBI 18. Engine support bracket +H, .A+ 19. Camshaft sprocket bo!t ,_ 20. Camshaft sprocket 2 1 . T i m i n g b e l t r e a r , covq -
llF-14
ENGINE OVERHAUL 7 Timing Belt REMOVAL SERVICE POINTS
_
,
,
“ ’ ‘lrr “* ’
+A, TIMING BELT REMOVAL Mark belt running direction for reinstallation. NOTE (1) Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks. +B, OIL PUMP SPROCKET REMOVAL
dC, CRANKSHAFT BOLT LOOSENING
+D, CRANKSHAFT SPROCKET REMOVAL
+E,TlMlNG BELT “B” REMoVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and wtiter. These”parts should not be washed. Replace parts if seriously contaminated. TSB
Revision
31F45
ENGINE OVERHAUL - Timing Belt
(2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.’
+F, COUNTERBALANCE SHAFT SPROCKET REMOVAL
+G,CRANKSHAFT SPROCKET “B” REMOVAL
+H, CAMSHAFT SPROCKET BOLT LOOSENING
INSTALLATION SERVICE POINTS .A+ CAMSHAFT SPROCKET ThHTENING
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ENGINE OVERHAUL 1‘ Timing, Belt,
,,
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.B( ENGINE SUPPORT BRACKET INSTALLATION Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M ATD Part No. 8660 or equivalent
,..
Spacer
’% ,C+ SPACER INSTALLATION Install the spacer with the chamfered end towa$the oil seal. ‘,,’ ,
.D+COUNTERBALANCE SkiAFT S P R O C K E T ~ . INSTALLATION , t
:
,. ‘. ,-
:’
FEdTIMING BELT “B” INSTALLATION ‘(1) Align timing marks on the crankshaft sprocket “B” and counterbalance shaft sprocket with the ma&s bn$he front , case respectively. (2) Install the timing belt “B” on the crankshaft Sprocket “B” and counterbalance shaft sprocket. Thgre should be no slack on the tension side. ,’
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(3) Make sure that the relationship between the tensioner pulley center and the bolt center is as show*n in the illustration. ,’
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ENGINE OVERHAUL c2.4L> - Timing Belt (4) Move the tensioner “B” in the %Jirection of arrow while lifting with a finger to give a sufficient tension to the tension side of. timing belt. In this condition, tighten bolt to secure tensioner “B”. When the bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be over-tensioned. .
(5) Check to ensure that timing marks on sprockets and front case are in alignment. (6) Press with index finger the center of span on tension side of timing belt “B”. The bolt must deflect 6-7 mm (.20-.28 in.).
.F+ CRANKSHAFT BOLT TIGHTENING
.G+OIL PUMP SPROCKET INSTALLATION ~ (1) Insert a Phillips screwdriver [shank diameter-8 mm (.31 in.) shaft] through. the plug .hole on the left side of the cylinder block to block the left counterbalance shaft. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces ‘). ,I of the nuts. (4) Tighten the nuts to the specified torque. 1, ! ’ ,
Y6ENo664
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.Hd AUTO TENSIONER INsTALLATlON . (1) If the auto tensioner rod is ‘in its fully extended positton; .’ reset it as follows. :, (2) Clamp the auto-tensioner in ,the vise with, soft jaws:/“‘, , i 5
BEN022!
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11 F-18
ENGINE OVERHAUL b Timincl Belt .,. (3) Push in the rod little by little with the vise until the set hole A in the rod is aligned:with the hole q in the cylinder. (4) Insert a wire [1.4 mm’ (055 in.) in diameter] Into- the set _ holes. (5) Unclamp the auto tensioner fromthe vise. ,’ , I,, I ,’
.e’,
Z6EN0164
(6) Install the auto tensioner to front case and,, tighten to the specified torque. , *, Caution Leave the wire inqtalled in- the auto ,ten&?ner. ; ... %> ,’ ~
.I+ TENSIONER PULLEY INSTALLATION _ Install the tensioner pulley in such dire&ion that its M/o small holes are arranged vertically.
.,
,J+ TIMING BELT INSTALLATION (1) Check that the timing belt tensioner and have been, installed in position. (See ,Id) (2) Align timing mark on camshaft sprocket with timing mark on cylinder head.
(3) Align timing mark on crankshaft sprocket with timing mark on front case.
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ENGINE OVERHAUL c2.4L> - Timing Belt
WF-19
(4) Align the timing mark on oil pump sprocket with its mating mark.
6EN1026
(5) Remove the plug on cylinder block and insert a Phillips, screwdriver [shank diameter 8 mm. (.31 in.)] through the’ hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm (2.4 in.) or more, the timing marks are correctly aligned. Jf the inserted depth is only 20-25 mm (.8-l .O in.), turn the’oil pump sprocket one turn and realign timkig marks. Then check to ensure that the screwdriver can be inserted 60: mm’ (2.4 in.) or more. Keep the screwdriver inserted’ until installation of timin,g. belt is finished. (6) Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.
(7) Lift up the tensioner pulley in the direction of arrow and tighten the center bolt. (8) Check that all timing marks are lined up. (9) Remove the screwdriver inserted in step (5) and fit the plug. (1O)Give the crankshaft a quarter counterclockwise turn. Then, turn it clockwise until the timing marks are lined up again.
(1l)lnstall the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt. NOTE If the special tool is not available, use a commercially available torque wrench that is capable of measuring O-5 Nm (O-3.6 ftlbs.). (1Z)Torque to 3.5 Nm (2.5 ft.lbs.) with the torque wrench.
(13)Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification. TSB Revision
llF-20
ENGINE OVERHAUL - Timing ‘pelt .,
_
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L
(14)After giving two clockwise turns to’ the crankshaft, ‘let it alone for approx. 15 minutes: The,n; make sure that the auto tensioner setting wire moves freely. NOTE If the wire does not move freely, retieat step (10) above until it moves freely. ‘I + ‘. , (15)Remove the auto tensioner setting wire.
(16)Measure the distance “A” (between the tensioner arm and auto tensioner body). Standard value: 3.8-4.5 mm (.15-.18 in.)
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ENGINE OVERHAUL - Timing B@t INSPECTION
“1.1 F&23
:‘,
,3
_’
113002001y
TIMING BELT Replace belt if any of the following conditions exist.
x \
(1) Hardening of back rubber: Back side is glossy without resilience, and leaves no indent when pressed tiith fingernail.:’ I
OOB 000 &
Z8EN0066
(2) (3) (4) (5)
Cracks
Cracks Cracks Cracks Cracks
on rubber back. or peeling of canvas. on rib root. on belt sides.
Zl EN0249
(6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Rounded edge
Abnormal wear (Fluffy strand) Z8EN0067
I
(7) Abnormal wear on teeth. (8) Missing tooth.
12mm (.47 in.)
AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as necessary. (2) Check the rod end for wear or damage and replace as necessary. (3) Measure the rod protrusion. If it is out of specification, replace the auto tensioner. Standard value: 12 mm 1.47 in.)
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11 F-22
ENGINE OVERHAUL - ‘hing B&It’
I I
MN1033
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ENGINE OVERHAUL - Fuel and Emission Contry! PartsI < .(
Removal steps 1. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail 6. Insulator 7. Fuel pressure regulator
11 F;jp
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11 F-24
, i . . ; ,, ,‘ ENGINE OVERHAUL - Fuel and Emi$sibn’ Chrd kbts: INSTALLA+ldM
siRvi& &id& F‘:, * ;a *“t
.. ; :Y,‘! p,,
.A( INJECTORS / IN;IECTOR CklP INSTALkATlON‘ ,::” (1) Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector top end into fuel rail. Be careful not to damage O-ring during installation. :
lEN0388
,I? “.
)sB+ FUEL ‘PRESSURE REGULATOR INSTALLATION Before installing the pressure regulator, the O-ring must be lubricated with a drop of clean engine. ,O-ring to aid in installation.
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ENGINE OVERHAUL c2.4L> - Intake Manifold
INTAKE MANIFOLD REMOVAL AND INSTALLATION 13 .INm 9 ft.lbs. i3fl 30 Nm 24 Nm 22 ft.lbs- IA ftlhr.
, ‘, i.:.I “.C .!
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18 Nm - 13 ftlbs 18Nm ’ ’ 13 R.lbs. ir
10 I’
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31 Nm 22 ft.lbs. 6ENlb91
Removal steps 1. Water hose 2. Water hose .Dd 3. ,En#ine coolant temperature gauge bC+ 4. Engine coolant temperature sensor 5. Water inlet fitting 6. Thermostat
ENGINE OVERHAUL : - intake Manifold INSTALLATION SERVICE POIhiT$
‘li ‘t,. , ‘““^“+’
.A( SEALANT APPLICATJON TO THERC(IOSTAT HOUSING Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent NOTE (1) Be sure to install the housing quickly while th’e sealant > is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. one hour. I,
sealant
.B( SEALANT APPLICATION TO WATER -OUTLET FITTING Specified sealant: ’ Mitsubishi Genuine Part No.’ MD970389 or equivalent
8 / Y-A
NOTE (1) Be sure to install the housing quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. one hour.
@
3 mm 1.12 in.) diameier bead sealant
6 6EN0682
.Cd SEALANT APPLICATION To’ ENGii’lE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut Locking Part No. +171 or equivalent >’
PEN0091
.Dq SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8680 or equivalent
I
9EN0092
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ENGINE OVERHAUL - Exhaust Manifold ahd Water Pump
11300490054
EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION
7. Exhaust manifold gasket .A+ 8. Water inlet pipe .A+ 9. O-ring 10. Water pump 11. Water pump gasket
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11 F-28 ENGINE OVERHAUL
- Exhaust Manifold and. W&ter,‘Ptimp
INSTALLATION
SERVICE
POINT,‘,
.A4 WATER PIPE/Q-RING INST!LCATIQN
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, _ (1) Wet the O-ring (with vvater’j ‘k*facili& &s&biy.“” ‘.” Caution Keep the O-ring free of oil or grease.
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l~~b~~ , _, ,_,
ENGINE OVERHAUL - Rocker Arms and ,Ciihsh~ft I,
ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION & Lubricate all internal parts
3.3 Nm 2.4 ft.lbs.
2
u
6
9 I
f--- 53 EL. 4P
ZSEN~
70 Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil filler cap 4. Rocker cover 5. Rocker cover gasket 6. Oil seal ,Cd 7 . Oil seal 4A, bB+ 8. Rocker arms and rocker arm shaft 4A, ,S+ 9. Rocker arms and rocker arm shaft
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e .B+ 10. Rocker shaft spring ’ ~ 11. Rocker ,arm A ” 12. Rocker arm B 13. Rocker arm shaft (Intake side) ’ .A+ 14. Lash adjuster 15. Rocker arm C 16. Rocker arm A&t (Exhaust side) ,A4 17. Lash adjuster ’ 18. Camshaft
llF-30
ENGINE OVERHAUL - Rocker Arms and Camshaft REMOVAL SERVICE PQINT ‘, : (A,ROCKER ARMS AND RQCSER ARM
REMOVAL
.I
.- ,_ k ., ; SHAflS I -’
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Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. ‘*
INSTALLATION SERVICE POINTS ,A( LASH ADJUSTER INSTALLATION (1) Immerse the’ lash adjuster in clean diesel fuel. (2) Using a special tool, move the plunger up and down 4 or 5 times while pushing down lightly on the check bail in order to bleed out the air.
(3) Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Then use the special tool to prevent adjuster from falling while installing it.
pB+ ROCKER SHAFT’ SPRING/ROCKER ARMS AND ROCKER ARM SHAFT li’@ALLATION .(1) Temporarily tighten the rocker st-@with the bolt so that all rocker arms on the inlet valve side do not push the valves. (2) Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide; NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and ‘rocker arm shaft.
(3) Remove the special tool for securing the lash adjuster. (4) Make sure that the notch in the rockerz “: arm shaft is in the direction as illustrated.
ENGINE OVERHAUL - Rocker Arms and Camshaft INSPECTION
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113oo55o1ea
CAMSHAFT (1) Measure the cam height. Standard valuei Intake 37.39 mm (1.4720 .in.) Exhaust 37.47 mm (1.4752 ‘in;) ;’
9ENOO58
Limit: Intake 36.69 mm (1.4524 in.) * Exhaust 36.97 mm (1.4655 in.) NOTE The camshaft identification mark is stamped on the opposite end of the camshaft sprocket side.
ROCKER ARM (1) Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm. (2) Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm. (3) Check the inside diameter. If damage or seizure is evident, replace the rocker arm.
27ENOO64
LASH ADJUSTER LEAK-DOWN TEST Caution 1. The lash adjuster is a precision part. Keep it free from dust and other foreign matter. 2. Do not disassemble lash adjuster. 3. When cleaning lash adjuster, use clean diesel fuel only.
MD998442
(1) Immerse the lash adjuster in clean diesel fuel.. (2) While lightly pushing down inner steel ball using the special tool, move the plunger up and down four or five times to bleed air. Use of the special tool helps facilitate the air bleeding. of the rocker arm mounted type lash adjuster. (3) Remove the special tool and press the plunger. If the I plunger is hard to be pushed in, the lash adjuster is normal. If the plunger can be pushed in all the way readily, bleed the lash adjuster again and test again. If the plunger is still loose, replace the lash adjuster. 7EN0721 1 TSB Revision I
ENGINE OVERHAUL - Rocker Arms and Camshaft Caution
)I -
Upon completion of air bleeding’ kold &&juster upright to prevent inside’ diesel ‘fti%l frotk &Nib&.
(4) After air bleeding, set lash adjuster on the special tool (Leak down tester). (5) After plunger has gone down somewhat (.2-S mm), measure time taken for it to go down 1. mm: Replace if measured time is out of s’pecification. Standard value: 4-20 seconds / 1 mm (.04 in.) [Diesel fuel at 15-20°C (59-6yF)]
TEN0438
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11 F-34
ENGINE OVERHAUL - Cylinder Head zind Valves
CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION
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~8
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10
R’4--!Z-,1;
2 -
Removal steps 4Ab bE+ 1. Cylinder head bolt 2. Cylinder head assembly bD+ 3. Cylinder head gasket +B, bC+ 4. Retainer lock 5. Valve spring retainer bB+ 6. Valve spring 7. Intake valve +B, bC+ 8. Retainer lock 9. Valve spring retainer
bB+ 10. Valve spring
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ii. Exhaust valve 4C, .A4 12. Valve stem seal 13. Valve spring seat (C, .A4 14. Valve stem Seal 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide 18. Intake valve seat 19. Exhaust valve seat 20. Cylinder head
ENGINE OVERHAUL - Cylinder Head and Valves
REMOVAL SERVICE POINTS PRECAUTION FOR REMOVE6 PARTS Keep removed parts in order according to the cylinder nurjlber and intake/exhaust. +A, CYLINDER HEAD BOLTS REMOilAL Using the special tool, loosen the.cylinder head bolts. Loosen evenly, little by little.
+B,RETAlNER LOCK REMOVAL Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly.
+C,VALVE STEM SEAL REMOVAL Do not reuse valve stem seal. ‘21
INSTALLATION SERVICE POINTS ,A+ VALVE STEM SEAL INSTALLATION (1) Install’ the valve spring seat. SC; ‘. (2) The special tool must be’used to, install the’vafve s8tem. seal. Improper installation could,.result in oil leaking ,past the valve guide. .’ ,,, _I. ‘, Caution ‘,’ Do not reuse the valve stem seal.
.B+ VALVE SPRINGS INSTALLATION Direct the valve spring end with identification color end toward the spring retainer.
Swim ldentifica color
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6ENO437
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11 F-36
ENGINE OVERHAUL - Cylinder Head andLValv&s . .
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1
.C+ RETAINER LOCK INSTALLATION The, valve spring, if excessively compressed, causes the bottom end of retainer to be, in contact, ,with, and damage: , the stem seal.
Identification mark
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.D+ CYLINDER HEAD GASKET IDENTlFlCATtON .-Identification mark: 4G64N ” I j ,: ,,
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.E+CYLINDER HEAD BOLT INSTALLATION ; (1) When installing the cylinder head bolts, check that the’ shank length of each bolt meets the limit. If the limit is’ exceeded, replace the bolt. Limit: Max. 99.4 mm (3.91 in.) (,,_ (2) Apply engine oil to the threaded /portions of bolts ind, i, .f; to the washers. 29EN0251
I 10
4
5 BEN0695
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(3) According to the tightening sequence, tighten the bolts to the specified torque 78 Nm (58 ft.fbs.J using the special tool (MB991 654). (4) Loosen bolts completely. ! (5) Retighten the loosened bolts to 20 Nm (14:F ft.lbs~) in’ the specified tightening sequence. (6) Make a paint mark across each bolt head and cylinder’ J head. (7) *Give a 90” turn to the bolts in the specified tightening, :,; sequence. (8) Give another 90” turn to the bolts and make sure that the paint mark on the, head of each bolt. and that on the cylinder head are on th:e same straight line. ‘,I Caution 1. If the bolt is turned less than 9,~,“,.prg~r,fastening When performance may not be expected. tightening the bolt, therefore!,,,ba..:careful to give a sufficient turn to it. 2. If the bolt is overtightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from. step (1).
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ENGINE OVERHAUL c2.4L> - Cylinder Head and Valbes
INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.05 mm (.0020 in.) Limit: 0.2 mm (.008 in.) (2) If the service limit is exceeded, correct to meet specification. Grinding limit: l 0.2 mm (.008 in.) * Includes combined with cylinder block grinding. Cylinder head height (Specification when, new): 119.9-120.1 m m (4.720-4.73 i n . )
Valve seat contact M;lrgin A%+ I 6EN0542
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VALVE (1) Check the valve face for correct contact. If incorrect, reface using valve refacer. Valve seat contact stiould be maintained uniform at the center of valve face. (2) If the margin exceeds the service limit, replace,-the valve. : ” Standard value: .’ Intake 1.0 mm (0.39 in.) Exhaust 1.2 mm (.047 tn.) Limit: Intake 0.5 mm (.020. in.) Exhaust 0.7 mm (.028 in.) (3) Measure the valve’s total length. If the measurement is less than specified, replace the valve. / item
Standard value mm (in.)
Limit mm (in.) .’ ;,
Intake
112.30 (4.4213)
‘:“;jjl’.t30
Exhaust
114.11 (4.4925)
).
(4.4016).
113.61 (4.4728)
VALVE SPRING (1) Measure the free height of spring and, if it is smaller than the limit, replace. Standard value: 51.0 mm (2.008 in.) .’ , .,I Limit: 50.0 mm (1.969 in.) ‘.I
Free height
“
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11 F-38
ENGINE OVERHAUL c2.4L> - Cylinder Head and V&Iv&s (2) Measure the squareness of the spring and, if the limit is exceeded, replace. Standard value: 2” or less Limit: Max. 4”
._ ,.
Stem O.D.
Zl EN0279
Valve stem end
Valve stem projection Spring seating surface
.,
VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Standard value: Intake 0.02-9.05 mm (.0008-.OO%O in.) Exhaust 0.03-0.07 mm (.0012-.0028 in.) Limit: Intake 0.10 mm (.0039 in.) Exhaust 0.15 mm (.0059 in.) VALVE SEAT (1) Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat. Standard value: 49.30 mm (1.9409 in.) ’ Limit: 49.80 mm (1.9606 in.)
DEN0212
VALVE SEAT RECONDITIONING PROCEDURE (1) Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide. (2) Using the seat grinder, correct to obtain the specified seat width and angle. (3) After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection (refer to VALVE SEAT in INSPECTION). 26EN0491
VALVE SEAT REPLACEMENT PROCEDURE
0.5 1 mm (.020-.039 in.)
(1) Cut the valve seat to be replaced form the inside to thin the wall thickness. Then, remove the valve seat.
0.5-I mm (.020-.039 in.)
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ENGINE OVERHAUL c2.4Ls - Cylinder Head and Valves
II F&l
(2) Rebore the valve seat hole in the cylinder h&d to a selected oversize valve seat diameter. ‘. * Intake seat ring hole diameters’ 0.3 O.S. 34.30-34.33 mm (1.3504-1.3516 in.) 0.6 O.S. 34.60-34.63 mm (1.3622-1.3634 in.) Exhaust seat ring hole diamete’ri 0.3 O.S. 31.60-31.63 mm (1.2520-l .2531 in.) 0.6 O.S. 32.10-32.13 mm (1.2638-1.2650 in.) 1275
(3) Before fitting the valve seat, either heat the cylinder head up to approximately 250°C (482’F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling.
(4) Using a valve seat cutter, correct the valve seat to the specified width and angle. See “VALVE SEAT RECONDITIONING PROCEDURE”.
Removal
VALVE GUIDE REPLACEMENT PROCEDURE
installation
Press
Press
A
A Push rod
Push rod
Valve guide
Valve guide
(1) Using the push rod and a press, remove the valve guide toward cylinder head gasket surface. (2) Rebore valve guide hole to the new oversize valve guide outside diameter. Valve guide hole diameters 0.05 OS. 11.05-11.07 mm (435b.4358 in:) 11.25-11.27 mm (.4429-.4437 in.) 0.25 O.S. 11.50-11.52 mm (.4528-.4535 in.) 0.50 O.S.
26ENo54:
NOTE Do not install a valve guide of the same size .againl (3) Using the special tool, press-fit the valve guide, working from the cylinder head top surface. “’ (4) After installing valve guides, insert new valves in them to check for sliding condition. (5) When valve guides have been, replaced, check for valve contact and correct valve seats as neoesssity.
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Front Case, Counterbgkqnce
ENGINE OVERHAUL - Shaft and oil Pan
FRONT CASE, COUNTERBALANCE SHAFT AND OIL PbN ;momo~s. _..,
17. Oil pump cover .H+ 18. Oil pump driven gear : bH( 19. Oil pump’ drive gear .G+ 20. Crankshaft front oil seal ,F+ 21. Oil pump oil seal bE+ 22. Counterbalance shaft oil seal bD+ 23. Front case 24. Front case gasket 25. Counterbalance shaft, left 26. Counterbalance shaft, right dD, .C+ 27. Counterbalance shaft, front bearing dE, .B+ 28. p$rnterbalance shaft, rear bearing, 4E, ,A4 29. C$nterbalance shaft, rear bearing,
Front Case, Counterb+lanqe
ENGINE 0VER);iAUL - Shaft yI ,. ‘Q ’ oil pan. ,‘.J NOTE Never use a screwdriver or chisel, instead of’the. service ’ tool, as a deformed oil pan ftange will result in oil leakage. “.2 ,- 1 .-. -+B, PLUG REMOVAL If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.
+C, FLANGE BOLT REMOVAL (1) Remove the plug on the side of cylincfer block. (2) Insert a Phillips screwdriver [shank diameter 8 mm (.32 in.)] into the plug hole, to lock the counterbalance shaft. , i
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(3) Loosen the flange bolt.
,.‘,
-.,y
+D, COUNTERBALANCE SHAFT FRONT BEARING REMOVAL Using the special tool, remove the counterbalan”ce shaft j front bearing from the cylinder block. NOTE ’ Be sure to remove the front bearing fiist. If it has not been removed, the Rear Bearing Puller cannot be used. MD998371
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Front Case, Counterbalanqe
ENGINE OVERHAUL - Shaft and Oil Pan
+E, COUNTERBALANCE SHAFT REAR BEARING REMOVAL Using the special tool, remove the left counterbalance shaft rear bearing from the cylinder block. NOTE When removing the left counterbalance shaft rear bearing, install the special tool (MB991603) in front of the cylinder block. ., ,’ G\.” ; .‘, h’! .:,. ; Y.’ ,, .,’ ‘, 7 I. i , ;I’ :* z, ‘_ -. : . .I ,ll
Drain pi gasket
TENOJO?
Bracke; side -fB* \ m
.Nq OIL FILTER INSTALLATION (1) Clean the installation surfade of ‘the filt& bracket. ’ ! : (2) Apply engine oil to the O-ring of, the oil filter. (3) Screw the oil filter in until the 0-ritig co&acts the bracket. Then tighten 3/4 turn [tightenin‘b torque: ,i 7 Nm (12, f#s)Ji NOTE For MD1 35737, tighten dne ,tuin [iSghtening ton&e: 14 Nm (10 ft.lbs.1 after the O-ring &ntads the bis);cket. .~ ,
A6EN0591
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Front Gasp, Coynterlylaqqe , w
ENGINE OVERHAUL - Shaft and Oii’Pan,
jf& I
INSPECTION j-. 1 i,,l :1 .,* * “,~ FRONT CASE (1) Check oil holes for clogging and -clean if necessary. (2) Check left counterbalance shaft front bearing seotion$or wear, damage and seizure. If there is anything ‘wrong with the section, replace the front case. (3) Check the front case for cracks and other ‘damage. Replace cracked or damaged front case. OIL SEAL (1) Check the oil seal lip for wear and damage. Replace oil seal if necessary. (2) Check the oil seal lip for deterioration. Replace oil seal if necessary.
COUNTERBALANCE SHAFT (1) Check oil holes for clogging. (2) Check journal for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace counterbalance shaft, bearing or front case assembly.
ZDEN0711
OIL PUMP (1) Assemble the-oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness. (2) Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover, (3) Check the side clearance Standard value: Drive gear Driven gear
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0.08-0.14 mm (.0031-.0055 in.) 0.06-0.12 mm (.0024-.0047 in.)
11 F-48
ENGINE OVERHAUL - Piston and Connecting Rod
PISTON AND CONNECTING ROD
113ooMo187
REMOVAL AND INSTALLATION &, Lubricate all
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h
Removal steps .G+
bC+
1. Nut
+A, bF4 2. Connecting rod cap FE4 3. Connecting rod bearing bD4 4. Piston and connecting rod assembly bE4 5. Connecting rod bearing bC4
6. Piston ring No. 1
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7. Piston ring No. 2
bB4 8. Oil ring 4B, .A4 9. Piston pin
10. Piston 11. Connecting rod 12. Bolt
ENGINE OVERHAUL - Piston and ConnecMirg’~‘Rbd REMOVAL SERVICE POINTS
number
(A,CONNECTlNG ROD CAP REMOVAL la (i) Mark the cylinder number on the side of th6-cohnecti?g . rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder nUmb@r: ., 6r
Z7ENO448
+B, PISTON PIN REMOVAL
Piston Din settina tool Ml?216941 -
1
1 MIT310134
2
MIT310136 1 MIT310137
11
@
i:.-“‘ ‘.’ PistoqSupport ! :* .z
I
I 1 Connecting Ro@uide Pin 1 *
.~br%cting Rod&!ide FJin
4
MIT310138
5
MIT31 0139
16
1 MIT310140
7
MIT310141
Connecting Rod-Gitide Pin
8
MIT310142 -
Piston Support
9
MIT481 43
10
216943
11
10396
Connecting Rod Gtiide’Pin I Piston Support
Press Pin Stop Screw Nut
(1) Remove the stop screw from the base. (2) Select the correct piston support for your application (See’ z7Ebm425
above). Fit the piston support ,onto the base. Place the’ Y , ,~ 1 base qn press support blocks.
/
1 TSB Revision
:.
llF-50
ENGINE OVERHAUL - Piston and Conhectincl Rod ~ (3) Insert the press pin through the piston! pin .hote.’ Select the correct connecting rod guide pin (See,above). Thread the guide pin onto the threaded portion of the press pin. (4) Position the piston assembly on the piston., support in the press. With the press pin up asshown,rn Figure 4, insert the guide pin through the hole, in the piston and through the hole in the piston support. : (5) Press the piston pin out of the assembly. IMPORTANT: To avoid piston damage, The piston support must seat Squarely against the piston. ’ l Verify that the piston pin will slide throu,?! Jhe hole in the piston support. (6) Remove the piston pin from the press pin. ? , ,., l
7EN0979
INSTALLATION SERVICE POINTS .A+ PISTON PIN INSTALLATION (1) Thread the stop screw and lock nut assembly into the base. Fit the correct piston support on top of the base. Insert the press pin, thregded end up, into the hole in the piston support until the. press pin touches:the stop screw. (2) Using the markings on the press pin, &just the stop screw to the depth as shown below:““’ Depth: Refer to the operating instructions on the special tool.
TSB Revision
ENGINE OVERHAUL - Piston and CohnWina Rdd
Piston pin -8 Piston pin Front mark
Place the base on press suppOrt blocks. Slide the piston pin over the threaded end of the press pin, and thread the correct guide.pin tip against it. Coat the piston pin with oil, aiid with the @nnecting rod held in position, slide the guide pin through the piston , and connecting rod. (6) Press the piston pin througti the connecting ro;d until the guide pin contacts the stop screw. (7) Remove the piston assembly from the base. Remove the guide pin and press pin from the assembly.
Connecting rod guide pin
IMPORTANT: Due to production tolerance variations, it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.
Stop screw-r - Lock nut
‘7EN0980
(8) Check that the piston moves. smoothly. .
26EN0298
.B+ OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston rihg .groove. NOTE 1. The side rails and spacer may be installed -in either direction. 2. New spacers and side rails are colored for identification of their sizes. Size
Identification color
5
I,
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11 F-52
ENGINE OVERHAUL - Piston and Connecting Rod (2) fnstall the upper side rail. To install the side rail, first fit one en&of the rail into the piston groove, then press the remaining portion into position by finger. See illustration. Use of ring expander to ,expand the side rail end gap i can break the side rail, unlike other ,piston rings. 3 , I J Caution .$. Do not use piston ring expander .whQn~installi;(l$ side rail. :, , (3) Install the lower side rail in the same,qrocedure as ., “’ :, described in step (2). (4) Make sure that the side rails move smoothly in either / ’ direction. , ‘. !
Side rail gap
IEN 9
.C+ PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION Using piston ring expander, fit No. 2 and ‘then f$. 1 piston 1 *d-p ring into position. NOTE 1. The ring end is provided with identific@on,, mark.
\
’
Identification mark: No.1 ring 1R No.2 ring 2R 7EN0452
2. Install piston rings with identification mark facing up, to’ the piston crown side. 3. Size marks on piston rings are as follows.. 4, i ,r
Identification mark “1 R” Identification mark “2R” Size mark
Size
Size mark
c- No.1
Standard
NONE
c- No.2
0.50
PEN0524
Upper side
No.2 ring gap and spa&% gap
mm oversize
1 .OO mm oversize I
50
,’
100 I
.D+ PISTON AND CONNECTING ROD INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure. (3) Rotate crankshaft so that crank pin is on center of cylinder bore.