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00-1

GROUP 00

GENERAL CONTENTS HOW TO USE THIS MANUAL. . . . . .

00-2

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . .

00-27

SRS SERVICE PRECAUTIONS . . . . .

00-28

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS . . . . . . . . . . . . . . .

00-6

VEHICLE IDENTIFICATION . . . . . . .

00-16

SUPPORT LOCATIONS FOR LIFTING AND JACKING . . . . . . . . . . . . . . . . . . 00-31

GENERAL DATA AND SPECIFICATIONS . . . . . . . . . . . . . . .

00-20

STANDARD PART/TIGHTENINGTORQUE TABLE . . . . . . . . . . . . . . . .

PRECAUTIONS BEFORE SERVICE.

00-22

00-33


00-2

GENERAL HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission. ON-VEHICLE SERVICE "On-vehicle Service" is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed. INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.

DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance. LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value.

M1001000100660

REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time). DANGER, WARNING, AND CAUTION DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows: • If a DANGER is not followed, the result is severe bodily harm or even death. • If a WARNING is not followed, the result could be bodily injury. • If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

INDICATION OF TIGHTENING TORQUE Tightening torques (units: N⋅m) are set to take into account the central value and the allowable tolerance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques, refer to P.00-33.

MODEL INDICATIONS The following abbreviations are used in this manual for identification of model types. MPI::Indicates the multipoint injection. SOHC::Indicates an engine with the single overhead camshaft. DOHC::Indicates an engine with the double overhead camshaft. 2000:: Indicates models equipped with the 2,000 mL <4G63> petrol engine. 2400::Indicates models equipped with the 2,400 mL <4G69> petrol engine. M/T:: Indicates the manual transmission. A/T:: Indicates the automatic transmission. A/C:: Indicates the air conditioner.


GENERAL HOW TO USE THIS MANUAL

NOTES

00-3


00-4

GENERAL HOW TO USE THIS MANUAL

(s . <<A>> >>A<<

Symbols are used to show the locations for lubrication . These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.

disassembly. or reassembly.

Multi-purpose grease unless there is a

AC301960


00-5

GENERAL HOW TO USE THIS MANUAL

For bolts and nuts which do not have a tightening torque listed, refer to the "Standard Parts tightening-torque Table"

parts sets are

On removal, reassembly are described

AC300860


00-6

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS M1001000200582

CONTENTS OF TROUBLESHOOTING Troubleshooting of electronic control systems for which the MUT-II/III can be used follows the basic outline described below. Even in systems for which the MUT-II/III cannot be used, some of these systems still follow this outline. 1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed.

Diagnosis method Gathering information from the customer. Check trouble symptom. Reoccurs Read the diagnosis code.

No diagnosis code or communication with MUT-II/III not possible

Does not reoccur

Diagnosis code displayed.

Diagnosis code displayed.

After taking note of the malfunction code, erase the diagnosis code memory.

No diagnosis code.

Recheck trouble symptom. Read the diagnosis codes. Diagnosis code displayed.

Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group.)

Read the diagnosis code.

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group.)

No diagnosis code.

INTERMITTENT MALFUNCTIONS

AC300864AC

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown. 3. DIAGNOSIS FUNCTION Details which are different from those in the "Diagnosis function " section are described.

4. DIAGNOSIS CODE CHART Diagnostic trouble codes and diagnostic items are shown. 5. DIAGNOSIS CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnosis code (Refer to How to read inspection procedure ).


00-7

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

6. TROUBLE SYMPTOM CHART If there are trouble symptoms even though the MUT-II/III does not find any diagnosis codes, Inspection procedures for each trouble symptom will be found by means of this chart. 7. SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart (Refer to How to read inspection procedure P.00-9).

<Using the MUT-III> <Using the MUT-III>

16-PIN

8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this chart as reference information.

MB991911 MB991824

9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items, and judgment values have been provided in this chart as reference information. 10. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are described here.

DIAGNOSIS FUNCTION HOW TO READ DIAGNOSIS CODE

CAUTION Before connecting or disconnecting the MUT-II/III, turn the ignition switch to the "LOCK" (OFF) position. <Using the MUT-II> <Using the MUT-II> Steering shaft

MUT-II

AC300830 AC

Connect the MUT-II to the diagnosis connector, and read the diagnosis code.

MB991827

AC308915 AC

Connect the MUT-III to the 16-pin diagnosis connector, and read the diagnosis code. NOTE: For details on how to use the MUT-III, refer to the "MUT-III operation manual." 1. Ensure that the ignition switch is at the "LOCK" (OFF). 2. Start up the personal computer. 3. Connect MUT-III USB cable MB991827 to special tool Vehicle Communication Interface (V.C.I.) MB991824 and the personal computer. 4. Connect MUT-III main harness B MB991911 to the V.C.I. 5. Connect MUT-III main harness B to the diagnosis connector. 6. Turn the V.C.I. power switch to the "ON" position. NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green colour. 7. Start the MUT-III system on the PC and turn the ignition switch to the "ON" position. 8. Read the diagnosis code. 9. Disconnecting the MUT-III is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF).


00-8

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

NOTE: The ABS warning lamp may flash when the ignition switch is turned ON with the MUT-II/III connected. This is because the diagnosis display function of the ABS warning lamp is activated by grounding the diagnosis connector terminal No.1, and is not detrimental in any way. ERASING DIAGNOSIS CODE (BY USING THE MUT-II/III)

CAUTION Before connecting or disconnecting the MUT-II/III, turn the ignition switch to the "LOCK" (OFF) position. <Using the MUT-II>

ERASING DIAGNOSIS CODE (BY USING NO MUT-II/III)

CAUTION Some diagnosis codes can not be erased according to the procedure below. If you attempt to erase a diagnosis code, refer to an applicable GROUP. 1. Turn the ignition switch to the "LOCK" (OFF) position. 2. Disconnect the negative battery cable, wait for at least 10 minutes, and then reconnect it. 3. Start the engine and let it run at idle for 10 minutes. INPUT SIGNAL CHECK (WHEN USING THE MUT-II/III) <SWS>

Steering shaft

MUT-II

CAUTION Before connecting or disconnecting the MUT-II/III, turn the ignition switch to the "LOCK" (OFF) position. <Using the MUT-II>

AC300830 AC

Steering shaft

<Using the MUT-III>

MUT-II 16-PIN AC300830 AC

<Using the MUT-III>

MB991911 16-PIN MB991824

MB991911 MB991827

AC308915 AC

MB991824

Connect the MUT-II/III to the diagnosis connector, and erase the diagnosis code. The procedure is the same as "HOW TO READ DIAGNOSIS CODE ".

MB991827

AC308915 AC


GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

1. Connect the MUT-II/III to the diagnosis connector, and erase the diagnosis code. 2. If the MUT-II/III buzzer sounds once when each switch is operated (ON/OFF), the input signal for that switch circuit system is normal. INPUT SIGNAL CHECK (WHEN USING A VOLTMETER) <SWS>

00-9

1. Use the special tool diagnosis code check harness (MB991529) to connect the ETACS terminal (terminal 9) and the earth terminals (terminals 4 and 5) of the diagnosis connector to the voltmeter. 2. If the needle of the voltmeter flickers once when each switch is operated (ON/OFF), the input signal for that switch circuit system is normal.

HOW TO USE THE INSPECTION PROCEDURES

Steering shaft MB991529

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC300831AB

The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.


00-10

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Relevant circuit(s) of the component which the Code No. indicates are described.

AC301964AB


00-11

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Explains about the basic operation of the components.

Start of diagnosis procedure

Describes inspection procedure.

Explains about technical details.

Describes the conditions for that diagnosis code being set.

Describes possible causes(s) for that diagnosis code.

AC301965AB

HARNESS CHECK Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements. Carry out this inspection while referring to the Electrical Wiring Manual. Here, "Check the wiring harness between the power supply and terminal xx" also includes checking for blown fuse. 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.

CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR CONNECTED <Waterproof Connectors> MD998459

AC300881AB

Be sure to use special tool harness connector (MD998459). Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.


00-12

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

<Ordinary (non-waterproof) Connectors>

Use the special tool inspection harness (MB991219) (inspection harness for connector pin contact pressure in the harness set for inspection). The inspection harness for connector pin contact pressure should be used. the test bar should never be forcibly inserted, as it may cause a defective contact. <When Inspecting a Male Pin>

Connector

CAUTION AC300882AB

Check by inserting the multi-meter 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 the backprobing tool for this purpose. IF INSPECTING WITH THE CONNECTOR DISCONNECTED <When Inspecting a Female Pin>

AC300890

At this time, be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU.Touch the pin directly with the test bar. MB991219

ACX00865AB


00-13

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR INSPECTION SERVICE POINTS VISUAL INSPECTION

• Low connection pressure due to rusted terminals or foreign matter lodged in terminals CONNECTOR PIN INSPECTION

Connector disconnected or improperly connected

AC300898

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

Stretched or broken wires

CONNECTOR ENGAGEMENT INSPECTION Harness wire breakage at terminal section

MB991219

Low contact pressure Good Bad

AC300899AB AC300896AB

Connector is disconnected or improperly connected • Connector pins are pulled out • Due to harness tension at terminal section • Low contact pressure between male and female terminals

Use the special tool inspection harness (MB991219) (connector pin connection pressure inspection harness of the inspection harness set) to inspect the engagement of the male pins and females pins. (Pin drawing force: 1 N or more)


00-14

GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

Battery

Fuse

Load switch

Short-circuit occurrence section

Load

AC300900AB

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0 Ω at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 Ω, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following. • Harness being clamped by the vehicle body • Damage to the outer casing of the harness due to wear or heat • Water getting into the connector or circuitry • Human error (mistakenly shorting a circuit, etc.)


GENERAL HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS NOTE: If determining the cause is difficult, the flight recorder function of the MUT-II/III can also be used.

AC300901

00-15

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which generates diagnosis codes or trouble symptoms). • Gently shake the connector up, down and to the left and right. • Gently shake the wiring harness up, down and to the left and right. • Gently rock each sensor and relay, etc. by hand. • Gently shake the wiring harness at suspensions and other moving parts.


00-16

GENERAL VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION CODE PLATE 1

No.

Item

Content

1

MODEL

CU2WXNMM CU2W: L6 Vehicle model

3

2

5

M1001000400713

The plate shows model code, engine model, transmission model and body colour code.

XNMML6: Model series

4

6

7

AC301477AB

The vehicle information code plate is riveted to the back of the hood.

2

ENGINE

4G63

Engine model

3

EXT

W83A

Exterior code

4

TRANS AXLE F5M42

F5M42:Trans mission model

5

COLOUR

W83

W83: Body colour code

6

INT

62A

62A: Interior code

7

OPT

ZP3

ZP3: Equipment code

For monotone colour vehicles, the body colour code shall be indicated.

MODELS Model code

Engine model

Price class

Transmission model

Fuel supply system

CU2W

4G63-DOHC (1,997 mL)

Comfort

F5M42 <2WD, 5M/T>

MPI

XNMML6 XNMMZL6 XNHMZL6

CU5W

XNMYZL6

Sport 4G69-SOHC MIVEC (2,378 mL)

Comfort

XRMYZL6

XRHYZL6 XRHYZR6

W5M42 <4WD, 5M/T> W4A42 <4WD, 4A/T with sport mode>

XRMYZR6 XNHYZL6

W5M42 <4WD, 5M/T>

Sport

W5M42 <4WD,5M/T> W4A42 <4WD, 4A/T with sport mode>


00-17

GENERAL VEHICLE IDENTIFICATION

MODEL CODE

CU 2 W X N M M Z L 6

1

2 3 4 5 6 7 8 9 10

No.

Item

Content

1

Development

CU: MITSUBISHI OUTLANDER

2

Engine type

2: 1,997 mL petrol engine 5: 2,378 mL petrol engine

3

Sort

W: Wagon

4

Body style

X: 5-door hatchback

5

Transmission type

N: 5-speed manual transmission R: 4-speed automatic transmission

6

Trim level

M: COMFORT H: SPORT

7

Specification engine feature

M: MPI-DOHC Y: MPI-SOHC MIVEC

8

Special feature

None: 2WD Z: 4WD

9

Steering wheel location

L: Left hand R: Right hand

10

Destination

6: For Europe

AC301363 AB


00-18

GENERAL VEHICLE IDENTIFICATION

CHASSIS NUMBER

The chassis number is stamped on the toeboard inside the engine compartment.

AC300903AB

J

M B

X

N

CU

2

W

4

U

000001

1

2

4

5

6

7

8

9

10

11

3

AC309285AB

No.

Item

Content

1

Fixed figure

J

Asia

2

Distribution channel

M

Japan channel

3

Destination

A

For Europe, right hand drive

B

For Europe, left hand drive

4

Body style

X

5-door hatchback

5

Transmission type

N

5-speed manual transmission

R

4-speed automatic transmission

6

Development order

CU

OUTLANDER

7

Engine

2

1,997 mL petrol engine

5

2,378 mL petrol engine

8

Soft

W

Station wagon

9

Model year

4

2004

10

Plant

U

Mizushima

11

Serial number


00-19

GENERAL VEHICLE IDENTIFICATION

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block. This engine model numbers are shown as follows.

<4G63>

Engine model

Engine displacement

4G63

1,997 mL

4G69

2,378 mL

The engine serial number is stamped near the engine model number. Front of the vehicle AC300905AD

<4G69>

Front of the vehicle

AC309481AB


00-20

GENERAL GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS M1001000900558

8 7 9

1

3

4 6

2

5 AC300072AB

Items

CU2W XNMML6

Vehicle dimensions mm

Front track

1

1,495

Overall width

2

1,750

Front overhang

3

945

Wheel base

4

2,625

Rear overhang

5

975

Overall length

6

4,545

Ground clearance (unladen)

7

195

Overall height (unladen)

8

1,620/1,670*

Rear track

9

1,505

Vehicle weight kg Kerb weight

1,435

1,540

Max. gross vehicle weight

1,970

2,070

Max. axle weight rating-front

1,050

Max. axle weight rating-rear

1,065

Max. trailer weight

With brake

1,500

Without brake

570

Max. trailer-nose weight Seating capacity Engine Transmission Fuel system

XNMMZL6

75 5

Model code

4G63

Total displacement mL

1,997

Model code

F5M42

Type

5-speed manual

Fuel supply system

MPI

NOTE: *: Vehicles with roof rails

W5M42

XNHMZL6


00-21

GENERAL GENERAL DATA AND SPECIFICATIONS

Items

CU5W XNMYZL6

Vehicle dimensions mm

Vehicle weight kg

XRMYZL6/R XNHYZL6 6

XRHYZL6/R 6

LHD: 1,560, RHD: 1,565

1,540

LHD: 1,560, RHD: 1,565

W5M42

W4A42

W5M42

W4A42

Type

5-speed manual

4-speed automatic

5-speed manual

4-speed automatic

Fuel supply system

MPI

Front track

1 1,495

Overall width

2 1,750

Front overhang

3 945

Wheel base

4 2,625

Rear overhang

5 975

Overall length

6 4,545

Ground clearance (unladen)

7 195

Overall height (unladen)

8 1,620/1,670*

Rear track

9 1,505

Kerb weight

1,540

Max. gross vehicle weight

2,070

Max. axle weight rating-front

1,050

Max. axle weight rating-rear

1,065

Max. trailer weight With brake

1,500

Without brake Max. trailer-nose weight

570 75

Seating capacity

5

Engine

Model code

4G69

Total displacement mL

2,378

Transmission Model code

Fuel system

NOTE: *: Vehicles with roof rails


00-22

GENERAL PRECAUTIONS BEFORE SERVICE

PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CAUTION Items to review when servicing SRS: 1. Be sure to read GROUP 52B − Supplemental Restraint System (SRS). For safe operation, please follow the directions and heed all warnings. 2. Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. 3. Warning labels must be heeded when servicing or handling SRS components. Warning labels can be found in the following locations. • Front impact sensor • Hood • Sun visor • Glove box • SRS-ECU • Steering wheel • Clock spring • Steering joint cover • Air bag module (Driver's or front passenger's) • Side air bag module (Driver's side or front passenger's side) • Side impact sensor • Seat belt pre-tensioner • Instrument panel 4. Always use the designated special tools and test equipment. 5. Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do not place anything on top of it. 6. Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module and clock spring). 7. Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure that the system functions properly.

M1001000500538

8. Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag (Refer to GROUP 52B − Air Bag Module Disposal Procedures). Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag. 1. When removing or installing parts, do not allow any impact or shock to the SRS components. 2. If heat damage may occur during paint work, remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, the side impact sensor, and the seat belt pre-tensioner. • SRS-ECU, air bag module, clock spring, front impact sensor, the side impact sensor: 93 °C or more • Seat belt pre-tensioner: 90 °C or more


GENERAL PRECAUTIONS BEFORE SERVICE

00-23

INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MPI ENGINE

LEARNING PROCEDURE FOR IDLING IN MPI ENGINE

Initialization Procedure 1. After the ignition switch is in "LOCK" (OFF) position, connect MUT-II/III with the diagnosis connector. 2. Select the item on the screen of the initialization for learning, and perform the initialization.

Purpose When the engine-ECU <M/T> or the engine-A/T-ECU <A/T> is replaced, or when the learning value is initialized, the idling is not stabilized because the learning value in MPI engine is not completed. In this case, carry out the learning method for the idling through the following procedures.

Service

Item

At replacing engine assembly *1,*2

All ranges

− *3

Misfire-related

At replacing injector and Learning value for air/fuel ratio at cleaning *2 At replacing throttle body Idle speed control-related and at cleaning *2 At replacing detonation sensor

Learning value for knocking

NOTE: *1: Initialize A/T-related learning value. NOTE: *2: After initializing the learning value, the idling learning in MPI engine is required (Refer to LEARNING PROCEDURE FOR IDLING IN MPI ENGINE). NOTE: *3: The datum items on MUT-II/III display are shown, but do not use them.

Learning Procedure 1. Start the engine and carry out the warm-up for the engine coolant temperature to reach 80°C or more. 2. When the engine coolant temperature is 80°C or more, the warm-up is not needed if the ignition switch is in "ON" position once. 3. Place the ignition switch in "LOCK" (OFF) position and stop the engine. 4. After 10 seconds or more, start the engine again. 5. For 10 minutes, carry out the idling under the condition shown below and then confirm the engine has the normal idling. • Transmission: Neutral (A/T: "P" range) • Operation in ignition-related, fan and attachments: Not to be operated • Engine coolant temperature: 80°C or more NOTE: When the engine stalls during the idling, check the dirtiness (on the throttle valve) of the throttle body and then perform the service from Procedure 1 again.


00-24

GENERAL PRECAUTIONS BEFORE SERVICE

SERVICING ELECTRICAL SYSTEM CAUTION Before connecting or disconnecting the negative (−) cable, be sure to turn off the ignition switch and the lighting switch (If this is not done, there is the possibility of semiconductor parts being damaged).

PRE-INSPECTION CONDITION "Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words "Set the vehicle to the pre-inspection condition". In this manual, it means to set the vehicle to the following condition. • Engine coolant temperature 80 to 90°C • Lamps, electric cooling fan and all accessories: OFF • M/T: Neutral • A/T: P range

VEHICLE WASHING

AC300693

Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (−) cable from the battery in order to avoid damage caused by short-circuiting.

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

Approximately 40 cm

AC300832AB

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc. • Spray nozzle distance: Approx. 40 cm or more • Spray pressure: 3,900 kPa or less • Spray temperature: 82°C or less • Time of concentrated spray to one point: within 30 sec.


00-25

GENERAL PRECAUTIONS BEFORE SERVICE

MUT-II/III

MUT-III sub assembly

MUT-II Sub-assembly Vehicle communication interface (V.C.I.)

Rom pack MB991824

MUT-III USB cable AC300834AB

MB991827

MUT-III main harness A

Do not used

MB991910

MUT-III main harness B

MB991911

MUT-III measurement adapter

MB991825

MUT-III trigger harness

MB991826 AC305090AB

Refer to the "MUT-II REFERENCE MANUAL", "MUT-II OPERATING INSTRUCTIONS" or "MUT-III OPERATION MANUAL" for instructions on handling the MUT-II/III.


00-26

GENERAL PRECAUTIONS BEFORE SERVICE

ENGINE OILS

CAUTION <Using the MUT-II> Steering shaft

MUT-II

AC300830 AC

<Using the MUT-III>

16-PIN

MB991911 MB991824

MB991827

AC308915 AC

Turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the MUT-II/III. Connect the MUT-II/III to the diagnosis connector as shown in the illustration.

IN ORDER TO PREVENT VEHICLES FROM FIRE "Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMC's information/Instructions".

Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided. Recommended Precautions The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. Other precautions: • Avoid prolonged and repeated contact with oils, particularly used engine oils. • Wear protective clothing, including impervious gloves where practicable. • Avoid contaminating clothes, particularly underpants, with oil. • Do not put oily rags in pockets, the use of overalls without pockets will avoid this. • Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal clothing. • Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. • Obtain First Aid treatment immediately for open cuts and wounds. • Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. • Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. • Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. • If skin disorders develop, obtain medical advice without delay.


00-27

GENERAL SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The Supplemental Restraint System (SRS) and seat belt with pre-tensioner is designed to supplement the driver's and front passenger's seat belts to help reduce the risk or severity of injury to the driver and front passenger by activating and deploying both front air bags in certain frontal collisions. The SRS consist of four air bag modules, SRS air bag control unit (SRS-ECU), two front impact sensors, two side impact sensors, SRS warning lamp, clock spring and seat belt pre-tensioner. Front air bags are located in the centre of the steering wheel and above the glove box. Side air bag are located inside the front seatback assemblies. Each air bag is made up of a folded air bag and an inflator unit. The SRS-ECU under the front floor console monitors the system and has a front air bag safing

M1001009800020

G-sensor, front air bag analog G-sensor and a side air bag safing G-sensor. The front impact sensor is assembled outside the headlamp support panel to monitor impact in case of front impact. The side impact sensors inside the centre pillars monitor the shock incurred by the sides of the vehicle. The warning lamp on the instrument panel indicates the operational status of the SRS. The clock spring is installed in the steering column. The seat belt pre-tensioner is built into the driver's and passenger's front seat belt retractor. Only authorized service personnel should do work on or around the SRS components. Those service personnel should read this manual carefully before starting any such work.

SRS warning lamp

Seat belt with pre-tensioner

Driver's air bag module

Passenger's (front) air bag module Side air bag module Side impact sensor

Clock spring

SRS-ECU

Side impact sensor Side air bag module Front impact sensor AC301343 AB


00-28

GENERAL SRS SERVICE PRECAUTIONS

SRS SERVICE PRECAUTIONS M1001006000047

CAUTION

DANGER

In order to avoid injury to yourself or others from accidental deployment of the air bag during servicing, read and carefully follow all the precautions and procedures described in this manual.

SRS-ECU connector

CAUTION Do not use any electrical test equipment on or near SRS components, except those specified on P.52B-9. CAUTION Never Attempt to Repair the Following Components: 1. SRS air bag control unit (SRS-ECU) 2. Front impact sensor 3. Clock spring 4. Driver's and front passenger's air bag modules 5. Side air bag module 6. Side impact sensor 7. Seat belt with pre-tensioner NOTE: If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page P.52B-174. SRS-ECU terminal No. Destination of harness

AC300634 AB

Do not attempt to repair the wiring harness connectors of the SRS. If a defective wiring harness is found, repair or replace it by referring to the table below.

Remedy

1, 2

Instrument panel wiring harness → Front wiring harness (RH) → Front impact sensor (RH)

Correct or replace each wiring harness.

3, 4

Instrument panel wiring harness → Front wiring harness (LH) → Front impact sensor (LH)

Correct or replace each wiring harness.

7

Instrument panel wiring harness→ Earth

Correct or replace the instrument panel wiring harness.

8

Instrument panel wiring harness → SRS warning lamp

Correct or replace the instrument panel wiring harness.

9, 10

Instrument panel wiring harness → Air bag module (Front passenger's side)

Correct or replace the instrument panel wiring harness.

11, 12

Instrument panel wiring harness → Clock spring → Air bag module (Driver's side)

Correct or replace instrument panel wiring harness. Replace the clock spring.

13

Instrument panel wiring harness → Junction block (fuse No.3)

Correct or replace the instrument panel wiring harness.


GENERAL SRS SERVICE PRECAUTIONS

00-29

SRS-ECU terminal No.

Destination of harness

Remedy

16

Instrument panel wiring harness → Junction block (fuse No.2)

Correct or replace the instrument panel wiring harness.

20

Instrument panel wiring harness → Diagnosis connector

Correct or replace the instrument panel wiring harness.

21, 22

Floor wiring harness (RH) → Side air Correct or replace the floor wiring bag module (LH) harness.

23, 24

Floor wiring harness (RH) → Side air Correct or replace the floor wiring bag module (RH) harness.

27, 28

Floor wiring harness (RH) → Seat belt pre-tensioner (Front passenger's side)

Connect or replace the floor wiring harness.

29, 30

Floor wiring harness (LH) → Seat belt pre-tensioner (driver's side)

Connect or replace the floor wiring harness.

34, 36

Floor wiring harness (LH) → Side impact sensor (LH)

Connect or replace the floor wiring harness.

40, 42

Floor wiring harness (RH) → Side impact sensor (RH)

Connect or replace the floor wiring harness.

DANGER Insulating tape Battery

Battery cable AC300580AB

After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. In addition, insulate the negative battery terminal with a tape. The condenser inside the SRS-ECU is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.


00-30

GENERAL SRS SERVICE PRECAUTIONS

CAUTION The SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag modules, and seat belt pre-tensioner before drying or baking the vehicle after painting. • SRS-ECU, air bag modules, clock spring, impact sensors: 93°C or more • Seat belt with pre-tensioner 90°C or more CAUTION Whenever you finish servicing the SRS, always erase the diagnosis code and check warning lamp operation to make sure that the system functions properly. CAUTION SRS-Harness connector

SRS-ECU harness connector (rear side)

AC300673AB

If checks are carried out by using the SRS-ECU harness connector, observe the following procedures: Insert the special tool (probe in the harness set) MB991222 into connector from harness side (rear side), and connect the tester to this probe. If any tool than special tool is used, damage to the harness and other components will result. Never insert the probe directly to the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability.


GENERAL SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-31

SUPPORT LOCATIONS FOR LIFTING AND JACKING M1001000700093

SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR DOUBLE-POST LIFT AND PLATE TYPE LIFT CAUTION Do not support the vehicles at locations other than specified supporting points. Doing so will cause damage, etc. GARAGE JACK CAUTION Never support any point other than the specified one, or that point will be deformed.

<2WD>

Rear suspension crossmember

<4WD>

Rear differential

AC300835


00-32

GENERAL SUPPORT LOCATIONS FOR LIFTING AND JACKING

AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT CAUTION • If rubber attachments with grooves that are too thick are used at the front support positions, the front fender may become bent, so be sure to use rubber attachments with groove thicknesses of 18 mm or less. • If attachments which are not high enough are used, they may damage areas such as the side step. Be sure to use attachments which are high enough, or remove the side step if not using attachments. AXLE STANDS Bolts

Bolts

Rubber Rubber

SINGLE-POST LIFT OR DOUBLE-POST LIFT Bolts

Bolts

AC300836AB


00-33

GENERAL STANDARD PART/TIGHTENING-TORQUE TABLE

PLATE TYPE LIFT

CAUTION To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift. Support the side sill flange with a lift.

STANDARD PART/TIGHTENING-TORQUE TABLE Each torque value in the table is a standard value for tightening under the following conditions. 1. Bolts, nuts and washers are all made of steel and plated with zinc. 2. The threads and bearing surface of bolts and nuts are all in dry condition. The values in the table are not applicable: 1. If toothed washers are inserted. Thread size Torque N⋅m

M1001001100362

2. If plastic parts are fastened. 3. If bolts are tightened to plastic or die-cast inserted nuts. 4. If self-tapping screws or self-locking nuts are used. Standard bolt and nut tightening torque

Bolt nominal diameter (mm)

Pitch (mm)

Head mark "4"

Head mark "7"

Head mark "8"

M5

0.8

2.5 ± 0.5

5.0 ± 1.0

6.0 ± 1.0

M6

1.0

5.0 ± 1.0

9.0 ± 2.0

10 ± 2

M8

1.25

12 ± 2

22 ± 4

25 ± 4

M10

1.25

24 ± 4

44 ± 10

53 ± 7

M12

1.25

41 ± 8

83 ± 12

98 ± 12

M14

1.5

73 ± 12

140 ± 20

155 ± 25

M16

1.5

110 ± 20

210 ± 30

235 ± 35

M18

1.5

165 ± 25

300 ± 40

340 ± 50

M20

1.5

225 ± 35

410 ± 60

480 ± 70

M22

1.5

300 ± 40

555 ± 85

645 ± 95

M24

1.5

395 ± 55

735 ± 105

855 ± 125

Flange bolt and nut tightening torque Thread size Torque N⋅m Bolt nominal diameter (mm)

Pitch (mm)

Head mark "4"

Head mark "7"

Head mark "8"

M6

1.0

5.0 ± 1.0

10 ± 2

12 ± 2

M8

1.25

13 ± 2

24 ± 4

27 ± 5

M10

1.25

26 ± 4

49 ± 9

58 ± 7

M10

1.5

24 ± 4

45 ± 8

55 ± 10

M12

1.25

46 ± 8

95 ± 15

105 ± 15

M12

1.75

43 ± 8

83 ± 12

98 ± 12

NOTE: . • Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques. • Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the bolt strength.


NOTES


11A-1

GROUP 11A

00 11

ENGINE MECHANICAL

12 13 14 15 16

CONTENTS

17 GENERAL INFORMATION . . . . . . . .

11A

SERVICE SPECIFICATIONS. . . . . . .

11A

SEALANTS . . . . . . . . . . . . . . . . . . . .

11A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11A

ON-VEHICLE SERVICE. . . . . . . . . . .

CAMSHAFT AND VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

21

11A

22

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A

25

REMOVAL AND INSTALLATION . . . . . . . .

REMOVAL AND INSTALLATION <2WD>. .

11A

REMOVAL AND INSTALLATION <4WD>. .

11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

27

CRANKSHAFT OIL SEAL . . . . . . . . . 11A

31

11A

DRIVE BELT TENSION CHECK. . . . . . . . .

11A

AUTO-TENSIONER CHECK . . . . . . . . . . .

11A

IGNITION TIMING CHECK . . . . . . . . . . . . .

11A

IDLE SPEED CHECK . . . . . . . . . . . . . . . . .

11A

IDLE MIXTURE CHECK . . . . . . . . . . . . . . .

11A

COMPRESSION PRESSURE CHECK. . . .

11A

MANIFOLD VACUUM CHECK . . . . . . . . . .

11A

LASH ADJUSTER CHECK . . . . . . . . . . . . .

11A

REMOVAL AND INSTALLATION . . . . . . . .

11A

CYLINDER HEAD GASKET . . . . . . . . 11A REMOVAL AND INSTALLATION . . . . . . . .

11A

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A REMOVAL AND INSTALLATION . . . . . . . .

11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

CRANKSHAFT PULLEY . . . . . . . . . . 11A REMOVAL AND INSTALLATION . . . . . . . .

11A

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A REMOVAL AND INSTALLATION . . . . . . . .

11A

26

32 33 34 35 36 37 42 51 52 54 55


ENGINE MECHANICAL

11A-2

GENERAL INFORMATION

GENERAL INFORMATION M1111000100356

Item

4G63

Total displacement mL

1,997

Bore ™ Stroke mm

85 ™ 88

Compression ratio

10.0

Compression chamber

Pentroof

Camshaft arrangement

DOHC

Number of valve Valve timing

Intake

8

Exhaust

8

Intake opening

BTDC 17•

Intake closing

ABDC 51•

Exhaust opening

BBDC 57•

Exhaust closing

ATDC 13•

Fuel system

Electronically controlled multipoint fuel injection

Rocker arm

Roller type

Auto-lash adjuster

Equipped

SERVICE SPECIFICATIONS M1112000300234

Item

Standard value

Limit

Vibration frequency Hz (Reference)

110 - 144

-

Tension N (Reference)

245 - 412

-

Basic ignition timing

5• BTDC – 2•

-

Ignition timing

Approximately 10• BTDC

-

Idle speed r/min

750 – 100

-

CO contents %

0.5 or less

-

HC contents ppm

100 or less

-

Compression pressure kPa-r/min

1,370 - 250

930 - 250

Compression pressure difference of all cylinders kPa

-

Maximum 98

Intake manifold vacuum kPa

-

Minimum 60

Cylinder head bolt nominal length mm

-

99.4

Drive belt tension

Balancer timing belt tension (When adjusted)

Deflection mm

5-7

-

Balancer timing belt tension (When replaced)

Deflection mm

5-7

-


ENGINE MECHANICAL

11A-3

SEALANTS

Item

Standard value

Limit

5 - 10

-

Timing belt tensioner adjuster rod protrusion amount mm

3.8 - 4.5

-

Timing belt tensioner adjuster rod movement mm

Within 1

-

Balancer timing belt tension (When checked)

Deflection mm

SEALANTS M1112000500238

Item

Specified Sealant

Remark

Cylinder head

MITSUBISHI GENUINE PART MD970389 or equivalent

Semi-drying sealant

Camshaft position sensor support Rocker cover Camshaft end seal

3M ATD Part No.8660 or equivalent

Rocker cover gasket

MITSUBISHI GENUINE PART MD970389 or equivalent

Engine oil pan <2WD> Engine upper oil pan <4WD> Engine lower oil pan <4WD>

SPECIAL TOOLS M1112000600279

Tool

Number

Name

Use

MB991502

MUT-II sub assembly

œ Drive belt tension check œ Checking the ignition timing œ Checking the idle speed

MB991668

Belt tension meter set

Drive belt tension check (used together with MUT-II)

MD998772

Valve spring compressor

Compressing valve spring

MD998737

Valve stem seal installer

Valve stem seal installation

B991502

B991668

MD998772


ENGINE MECHANICAL

11A-4

SPECIAL TOOLS

Tool

Number

Name

Use

MD998713

Camshaft oil seal installer

Camshaft oil seal installation

MD998727

Oil pan remover

Oil pan removal <2WD>

MD998781

Flywheel stopper

Supporting the flywheel

MB990938

Installer bar

Crankshaft rear oil seal installation

MD998776

Crankshaft rear oil seal installer

MD998285

Crankshaft front oil seal guide

MD998375

Crankshaft front oil seal installer

MB991654

Cylinder head bolt wrench (12)

D998713

D998727

D998781

B990938

D998776

Crankshaft front oil seal installation

D998285

B991654

Removal and installation of cylinder head bolt


ENGINE MECHANICAL

11A-5

SPECIAL TOOLS

Tool

Number

Name

Use

MD998738

Adjusting bolt

Supporting the timing belt tensioner arm and timing belt tensioner adjuster

MB991367

Special spanner

Holding the crankshaft camshaft drive sprocket

MB991385

Pin

MD998767

Tensioner wrench

D998738

B991367

B991385

D998767

Valve timing belt tension adjustment


ENGINE MECHANICAL

11A-6

ON-VEHICLE SERVICE

Tool

Number

Name

Use

MB991454

Engine hanger balancer

MB991527

Hanger

When the engine hanger is used: Supporting the engine assembly during removal and installation of the transmission assembly NOTE: Special tool MB991454 is a part of engine hanger attachment set MB991453.

MB991895

Engine hanger

B991454

B991527

Z203830

MB991928 A: MB991929 B: MB991930 E C: MB991931 D: MB991932 E: MB991933 F: MB991934

Slide bracket (HI)

F A

D B

Engine hanger A: Joint (50) ™ 2 B: Joint (90) ™ 2 C: Joint (140) ™ 2 D: Foot (standard) ™ 4 E: Foot (short) ™ 2 F: Chain and hook assembly

C B991928

ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK M1111003100399

CAUTION Check the drive belt tension after turning the crankshaft clockwise one turn or more.

Indicator mark

A

AC107639AB

1. Make sure that the indicator mark is within the area marked with A in the illustration.

2. If the mark is out of the area, replace the drive belt. (Refer to 311A.) NOTE: The drive belt tension check is not necessary as auto-tensioner is adopted.


ENGINE MECHANICAL

11A-7

ON-VEHICLE SERVICE

AUTO-TENSIONER CHECK M1111003000154

CAUTION

OPERATION CHECK 1. Turn OFF the engine from the idle state then check to see that the drive belt is not protruding from the pulley width of the auto-tensioner. 2. Remove the drive belt.(Refer to 311A.)

16-pin

MUT-II

AC107640AB

3. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto tensioner. Turn the auto-tensioner to the left and right to check and see that there is no threading. 4. If there are any problems in the procedure 1 or 3, replace the auto-tensioner.(Refer to 311A.) 5. Install the drive belt.(Refer to 311A.)

FUNCTION CHECK You can verify if the auto-tensioner is defective or not by checking the drive belt tension. When using MUT-II 1. Check the drive belt tension. (Refer to 311A.) 2. Measure the drive belt tension vibration frequency by the following procedures:

MB991668 AC211862 AB

To prevent damage to MUT-II, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting MUT-II. (1) Connect special tool belt tension meter set (MB991668) to the MUT-II. (2) Connect the MUT-II to the diagnosis connector. (3) Turn the ignition switch to ON position, and select "BELT TENSION" on the menu screen.


ENGINE MECHANICAL

11A-8

ON-VEHICLE SERVICE

CAUTION

œ The temperature of the surface of the belt should be as close to normal temperature as possible. œ Do not allow any contaminants such as water or oil to get onto the microphone. œ If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. œ If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. œ Do not take the measurement while the vehicle’s engine is running. Power steering oil pump pulley

Power steering oil pump pulley

Water pump pulley

AC102807AB

2. Use a belt tension gauge in the middle of the belt between the pulleys (at the place indicated by the arrow) to measure that the belt tension is within the standard value. Standard value: 245 - 412 N 3. If not within the standard value, replace the autotensioner.(Refer to 311A.)

IGNITION TIMING CHECK

15˚

MB991668 Water pump pulley

10 – 20 mm

Belt tension gauge

M1111001700425

15˚

AC102022 Y0195AU

MUT-II Gentry tap with your finger AC102806 AB

(4) Hold special tool belt tension meter set (MB991668) to the middle of the drive belt between the pulleys (at the place indicated by arrow), approximately 10 - 20 mm away from the rear surface of the belt so that it is perpendicular to the belt (within an angle of – 15 degree). (5) Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and measure that the vibration frequency of the belt is within the standard value. Standard value: 110 - 144 Hz 3. If not within the standard value, replace the autotensioner. (Refer to 311A.) When using a tension gauge 1. Check the drive belt tension. (Refer to 311A.)

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to the "LOCK" (OFF) position and then connect the MUT-II to the diagnosis connector. 3. Connect a timing light. 4. Start the engine and let it run at idle. 5. Use the MUT-II to measure engine idle speed and check that it is within the standard value. Standard value: 750 – 100 r/min 6. Select No. 17 of the MUT-II Actuator test. 7. Check that basic ignition timing is within the standard value. Standard value: 5• BTDC – 2• 8. If the basic ignition timing is outside the standard value, inspect the MPI system (Refer to 313A, GROUP 13A - Troubleshooting - Inspection chart for diagnosis code).


ENGINE MECHANICAL

11A-9

ON-VEHICLE SERVICE

CAUTION If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. 10.Check that ignition timing is at the standard value. Standard value: approximately 10• BTDC NOTE: . œ The ignition timing may fluctuate within – 7• BTDC. This is normal. œ In higher altitude, the ignition timing is more advanced than the standard value by approximately 5•. 11.Remove the timing light. 12.Turn off the ignition switch and then remove the MUT-II.

Standard value: 750 – 100 r/min NOTE: . œ The idle speed is controlled automatically by the idle speed control system. œ When using the MUT-II, select item No. 22 and take a reading of the idle speed. 8. If the idle speed is outside the standard value, inspect the MPI system (Refer to 313A, GROUP 13A - Troubleshooting - Inspection chart for diagnosis code).

IDLE MIXTURE CHECK M1111002100255

AC102022 Y0195AU

MUT-II

IDLE SPEED CHECK M1111003500472

AC102022 Y0195AU AK000871 AC

MUT-II

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position. 3. Connect the MUT-II to the diagnosis connector or connect a tachometer to the engine speed detection connector. 4. Connect a timing light.

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position. 3. Connect the MUT-II to the diagnosis connector or connect a tachometer to the engine speed detection connector. 4. Connect a timing light.

Engine speed ditection connector

AK000899 AC

Engine speed ditection connector

AK000899 AC

5. Start the engine and let it run at idle. 6. Check that ignition timing is at the standard value. Standard value: approximately 10• BTDC 7. Check the idle speed.

5. Start the engine and let it run at idle. 6. Check that ignition timing is at the standard value. Standard value: approximately 10• BTDC 7. Run the engine at 2,500 r/min for 2 minutes. 8. Set the CO, HC tester. 9. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.5 % or less HC contents: 100 ppm or less 10.If there is a deviation from the standard value, check the following items:


ENGINE MECHANICAL

11A-10 œ œ œ œ œ œ œ

ON-VEHICLE SERVICE

Diagnosis output Fuel pressure Injector Ignition coil, spark plug cable, spark plug EGR control system Evaporative emission control system Compression pressure NOTE: Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

COMPRESSION PRESSURE CHECK M1111002600465

Crank angle sensor connector

AK201364AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crank angle sensor connector. NOTE: Doing this will prevent the engine-ECU<M/ T> or engine-A/T-ECU<A/T> from carrying out ignition and fuel injection.

8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Maximum 98 kPa 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 from (6) to (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 dose 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 crank angle sensor connector. 11.Install the spark plugs and spark plug cables. 12.Use the MUT-II to erase the diagnosis codes. NOTE: This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

MANIFOLD VACUUM CHECK M1111002700417

AC102022 Y0195AU

MUT-II

CAUTION

œ Keep away from the spark plug hole when cranking. œ 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. 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. 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 r/ min): 1,370 kPa Limit (at engine speed of 250 r/min): Minimum 930 kPa

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position. 3. Connect a tachometer or connect the MUT-II to the diagnosis connector. Vacuum gauge

Fuel pressure regulator

AK201369AB


ENGINE MECHANICAL

11A-11

ON-VEHICLE SERVICE

4. Attach a three-way joint to the vacuum hose between the fuel pressure regurator and the air intake plenum, and connect a vacuum gauge. 5. Start the engine and check that idle speed is within the standard valve. Standard value: 750 – 100 r/min 6. Check the intake manifold vacuum. Limit: Minimum 60 kPa 7. Turn off the ignition switch. 8. Remove the vacuum gauge and the three-way joint, and then connect the vacuum hose. 9. Remove the engine tachometer or the MUT-II.

LASH ADJUSTER CHECK M1111002900336

If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and dose not stop, carry out the following check. NOTE: . œ The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise dose not occur immediately after the engine is started, if it dose not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. œ If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick. 1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise dose not occur immediately after the engine is started, or if it dose not change in accordance with the engine speed, the problem is not being caused by the lash adjusters, so check for some other cause of the problem. Moreover, if the noise dose not change in accordance with the engine speed, the cause of the problem is probably not with the engine (In these cases, the lash adjusters are normal).

3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N to D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings (In such cases, the lash adjusters are normal). 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters (Refer to GROUP 11D Rocker Arms and Camshaft - Rocker Arms and Camshaft Inspection 311B). If not improved, go to step 5. 5. Bleed air from the lash adjusters (Refer to 311A ). 6. If the noise has not disappeared even after the air bleeding, clean the lash adjusters (Refer to GROUP 11D - Rocker Arms and Camshaft Rocker Arms and Camshaft Inspection 311B).

<LASH ADJUSTER AIR BLEEDING> NOTE: . œ If the vehicle is parked on a slope fir a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. œ After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high-pressure chamber. œ If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.

Good Max Min. AKX00328 AE

1. Check the engine oil and replenish or replace the oil if necessary.


ENGINE MECHANICAL

11A-12

ON-VEHICLE SERVICE

NOTE: . 혵 If there is an only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. 혵 If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. 혵 If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.

High-pressure chamber AK100001AC

혵 If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve close. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal.

Drive pattern for air breeding Gradually open Close the throttle valve the throttle valve Approximately 3,000 r/min Idle speed

15 s

15 s

Once AKX00330AE

2. Run the engine at idle for 1 - 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration above and check if the abnormal noise disappears (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters). 4. After the noise has disappeared, repeat the drive pattern shown in the illustration above a further 5 times. 5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.


ENGINE MECHANICAL CRANKSHAFT PULLEY

11A-13

CRANKSHAFT PULLEY REMOVAL AND INSTALLATION M1112001600409

Pre-removal Operation Â&#x153; Under Cover Removal (Refer to GROUP 51, Under Cover 351).

Post-installation Operation Â&#x153; Drive Belt Tension Check (Refer to 311A). Â&#x153; Under Cover Installation (Refer to GROUP 51, Under Cover 351).

2 1

25 ± 4 N·m

AC300537AB

<<A>>

1. 2.

Removal steps Drive belt Crank shaft damper pulley


ENGINE MECHANICAL

11A-14

CRANKSHAFT PULLEY

REMOVAL SERVICE POINT

CAUTION

<<A>> DRIVE BELT REMOVAL The following operations will be needed due to the serpentine drive system with the drive belt autotensioner.

To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk. Auto-tensioner

Auto-tensioner

Hole B

L-shaped hexagon wrench Hole A

AC107641AB

AC107640AC

1. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.

2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.


ENGINE MECHANICAL

11A-15

CAMSHAFT AND VALVE STEM SEAL

CAMSHAFT AND VALVE STEM SEAL REMOVAL AND INSTALLATION M1112006600211

CAUTION *Remove and assemble the marked parts in each cylinder unit. Pre-removal Operation œ Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). œ Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner 315). œ Battery and Battery Tray Removal œ Valve Timing Belt Removal (Refer to 311A).

Post-installation Operation œ Valve Timing Belt Installation (Refer to 311A). œ Battery and Battery Tray Installation œ Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner 315). œ Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). œ Drive Belt Tension Check (Refer to 311A).

11 ± 1 N·m 3.0 ± 0.5 N·m

11 ± 1 N·m

2

4 6 3.5 ± 0.5 N·m

5 8 9.0 ± 2.0 N·m

1 8.8 ± 1.0 N·m

11 ± 1 N·m

9 N

11

12 11 ± 1 N·m

3

N 10

7

AC300538 AB

1. 2. 3. 4. œ

Removal steps Accelerator cable connection Rocker cover centre cover Crank angle sensor connector Control wiring harness connection Spark plug cables and ignition coils (Refer to GROUP 16, Ignition Coil 316).

>>N<< >>M<<

Removal steps &RQWLQXHG

5. Rocker cover PCV hose 6. Rocker cover breather hose 7. Control wiring harness connection 8. Rocker cover 9. Camshaft end seal 10. Spark plug hole gaskets


ENGINE MECHANICAL

11A-16 <<A>>

CAMSHAFT AND VALVE STEM SEAL

>>L<< >>K<<

Removal steps &RQWLQXHG

11. Rocker cover gasket 12. Radiator upper hose connection

22

20

24

25

23

20 ± 1 N·m

Apply engine oil to all moving parts before installation.

21

26

19 17

N 18

11 ± 1 N·m

89 ± 9 N·m

13

30 29

25 ± 4 N·m

22 ± 4 N·m

15 31* 32* 33* N 34*

16

27 28

10 ± 2 N·m

14 N

14 ± 1 N·m

31* 32* 33* 35* N AC300539 AB

<<B>>

>>J<< >>I<< >>H<< >>G<< >>F<< >>F<< >>F<< >>F<< >>F<<

Removal steps 13. Camshaft position sensor support cover 14. Camshaft position sensor support cover gasket 15. Camshaft position sensing cylinder 16. Camshaft position sensor support 17. Camshaft sprockets 18. Camshaft oil seals 19. Camshaft bearing caps, front 20. Camshaft bearing caps, rear 21. Camshaft bearing caps, No.2 22. Camshaft bearing caps, No.5 23. Camshaft bearing caps, No.3

>>F<< >>E<< >>E<< >>D<< <<C>>

>>C<< >>B<< >>A<< >>A<<

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

Removal steps &RQWLQXHG

Camshaft bearing caps, No.4 Inlet camshaft Exhaust camshaft Rocker arms Rocker arm lash adjusters Oil delivery body Spark plugs Valve spring retainer locks Valve spring retainers Valve springs Inlet valve stem seals Exhaust valve stem seals


ENGINE MECHANICAL

11A-17

CAMSHAFT AND VALVE STEM SEAL

LUBRICATION AND SEALING POINTS <The bottom view of the rocker cover>

10 mm

10 mm

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent Rocker cover

<View A>

10 mm

10 mm

Cylinder head

A 10 mm

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Sealant: 3M ATD Part No.8660 or equivalent A A

Ï&#x2020; 3 mm

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

(Lip section)

Engine oil

AC300541

<Top view of cylinder head>

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent


ENGINE MECHANICAL

11A-18

CAMSHAFT AND VALVE STEM SEAL

REMOVAL SERVICE POINTS

<<C>> VALVE SPRING RETAINER LOCKS REMOVAL

<<A>> RADIATOR UPPER HOSE DISCONNECTION

CAUTION When removing valve spring retainer locks, leave the piston of each cylinder in the TDC (Top Dead Centre) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.

Mating marks

MD998772

AC200641AC

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose. <<B>> CAMSHAFT SPROCKETS REMOVAL

AC201799 AB

Use special tool valve spring compressor (MD998772) to compress the valve spring, remove the valve spring retainer locks.

INSTALLATION SERVICE POINTS >>A<< EXHAUST VALVE STEM SEALS/INLET VALVE STEM SEALS INSTALLATION Gray

Gray green

Inlet side

Exhaust side

AC201457AB

1. Hold the hexagon part of the camshaft with a wrench. 2. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprocket.

AC201542AB

1. Check the valve stem seal colour to identify the inlet side or exhaust side. 2. Apply a small amount of engine oil to the valve stem seals.


ENGINE MECHANICAL

11A-19

CAMSHAFT AND VALVE STEM SEAL

CAUTION

œ Valve stem seals cannot be reused. œ The special tool valve stem seal installer (MD998737) must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide. MD998737 Valve Valve stem seal Valve guide AC107414 AC

3. Use special tool to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

>>D<< ROCKER ARM LASH ADJUSTERS INSTALLATION

CAUTION If the rocker arm lash adjuster is reused, always clean and check it before installation. (Refer to GROUP 11B, Rocker Arms and Camshaft Inspection). >>E<< EXHAUST CAMSHAFT/INLET CAMSHAFT INSTALLATION 1. Remove sealant remained on the cylinder head. 2. Apply engine oil to the cam and the journal of the camshaft.

CAUTION Engine front

>>B<< VALVE SPRINGS INSTALLATION

Slit

Rocker arm side Exhaust camshaft AC201458AB

Do not install wrong camshaft at the side of inlet or exhaust. The exhaust camshaft has a slit at the rear surface. 3. Install the camshaft to the cylinder head.

Identification colour AC201453AB

Install the valve springs with its identification colour painted end facing the locker arm. >>C<< VALVE SPRING RETAINER LOCKS INSTALLATION

>>F<< CAMSHAFT BEARING CAPS, NO. 4/ CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT BEARING CAPS, NO. 5/CAMSHAFT BEARING CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/ CAMSHAFT BEARING CAPS, FRONT INSTALLATION Approximately 3˚

MD998772

Dowel pin

Inlet side

Exhaust side

AC201799 AB

Use special tool valve spring compressor (MD998772) to compress the valve spring in the same manner as removal.

AC201459AB

1. Set the dowel pin of the camshaft to the position as shown in the illustration.


ENGINE MECHANICAL

11A-20

E4

Engine front

CAMSHAFT AND VALVE STEM SEAL

Bearing cap No. Identification of inlet side and exhaust side AC201460AB

2. Since the shape of camshaft bearing caps No.2 5 is identical, check the identification marks so that the bearing cap No., inlet side, or exhaust side cannot be mistaken to install to the direction as shown in the illustration. Identification mark (engraved on the front and bearing caps No.2 - 5) I: Inlet side E: Exhaust side

5. Check the identification marks on the camshaft bearing caps, front so that inlet side and exhaust side cannot be mistaken in the same way as that of bearing caps No.2 - 5.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time. 6. Tighten the bearing cap mounting bolts increasing the pressure in 2 to 3 times and finally tighten to the specified torque. Tightening torque: 20 – 1 N¼m 7. Ensure that the rocker arms are installed properly. NOTE: Remove an excess of sealant completely. >>G<< CAMSHAFT OIL SEALS INSTALLATION

Engine front

MD998713

AC201461AB

3. Apply sealant to the positions (6 areas) of the upper side of the cylinder head as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the camshaft bearing caps, rear and camshaft bearing caps, front within 15 minutes after applying liquid gasket.

Engine front

Front marking

AC201462AB

4. Position the camshaft bearing caps, rear in the direction as shown in the illustration for installation.

AC102323 AB

1. Apply engine oil to the entire inner diameter of the oil seal lip. 2. Use special tool camshaft oil seal installer (MD998713) to press-fit the oil seals. >>H<< CAMSHAFT SPROCKETS INSTALLATION

AC201457AB

1. Hold the hexagon part of the camshaft with a wrench in the same manner as removal. 2. Tighten the camshaft sprocket mounting bolts to the specified torque. Tightening torque: 89 – 9 N¼m


ENGINE MECHANICAL CAMSHAFT AND VALVE STEM SEAL

>>I<< CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION 1. Remove sealant from the camshaft position sensor support and cylinder head surfaces.

11A-21

2. Install the vane (small) of the camshaft position sensing cylinder at an angle of approximately 45 degrees to the position of the dowel pin of the exhaust camshaft. 3. Tighten the camshaft position sensing cylinder mounting bolts to the specified torque. Tightening torque: 22 – 4 N¼m >>K<< RADIATOR UPPER HOSE CONNECTION Projection

φ 3 mm

AC201463 AB

2. Apply the sealant to the camshaft position sensor support flange in a continuous bead as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the camshaft position sensor support within 15 minutes after applying liquid gasket. 3. Install the camshaft position sensor support to the cylinder head.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time. 4. Tighten the camshaft position sensor support mounting bolts to the specified torque. Tightening torque: 14 – 1 N¼m

Water outlet fitting

Mating marks AC200642 AE

1. Insert each hose as far as the projection of the water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose. >>L<< ROCKER COVER GASKET INSTALLATION 1. Remove sealant remained on the rocker cover.

>>J<< CAMSHAFT POSITION SENSING CYLINDER INSTALLATION Approximately 45˚

Dowel pin

Vane (small)

Vane (large) AC201464AB

1. Set the dowel pin of the exhaust camshaft to the position (No.1 cylinder at compression TDC) as shown in the illustration. NOTE: Use the force of the exhaust valve spring to rotate anti-clockwise.

AC201465AB

2. Apply sealant to the positions (4 areas) of the lower side of the rocker cover as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the rocker cover gasket within 15 minutes after applying liquid gasket. 3. Install the rocker cover gasket to the rocker cover.


ENGINE MECHANICAL

11A-22

CAMSHAFT AND VALVE STEM SEAL

>>M<< CAMSHAFT END SEAL INSTALLATION >>N<< ROCKER COVER INSTALLATION Engine front

AC201469AB

1. Apply sealant to the positions of the rocker cover gasket (6 areas) as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the rocker cover within 15 minutes after applying liquid gasket. 2. Install the rocker cover to the cylinder head.

10 mm 10 mm

Cylinder head AC201468 AB

Apply sealant to the positions of the camshaft end seal as shown in the illustration and install to the cylinder head. Specified sealant: 3M ATD Part No.8660 or equivalent NOTE: Install the camshaft end seal within 15 minutes after applying liquid gasket.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time. 3. Tighten the rocker cover mounting bolts to the specified torque. Tightening torque: 3.5 – 0.5 N¼m


ENGINE MECHANICAL

11A-23

OIL PAN

OIL PAN REMOVAL AND INSTALLATION <2WD> M1112002800592

Pre-removal Operation Â&#x153; Under Cover Removal (Refer to GROUP 51, Under Cover 351). Â&#x153; Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315).

Post-installation Operation Â&#x153; Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Â&#x153; Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Under Cover Installation (Refer to GROUP 51, Under Cover 351).

1

5 N

4

35 ± 6 N·m

3

39 ± 5 N·m

9.0 ± 3.0 N·m

2 26 ± 5 N·m 9.0 ± 1.0 N·m

9.0 ± 3.0 N·m

1. 2. 3.

Removal steps Exhaust manifold bracket Flywheel housing front lower cover Engine oil pan drain plug

AC300542 AB

>>B<< 4. <<A>> >>A<< 5.

Removal steps &RQWLQXHG

Engine oil pan drain plug gasket Engine oil pan


ENGINE MECHANICAL

11A-24

OIL PAN

REMOVAL SERVICE POINT

3. Assemble the engine oil pan to the cylinder block.

<<A>> ENGINE OIL PAN REMOVAL 1. Remove the engine oil pan mounting bolts.

CAUTION Perform this slowly to avoid deformation of the engine oil pan flange.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time.

MD998727

MD998727

M6 × 8 mm AC102698 AB

INSTALLATION SERVICE POINTS

4. Tighten the engine oil pan mounting bolts to the specified torque. Be careful when installing, as the oil pan mounting bolts (indicated in the illustration) have different lengths from the other bolts. Tightening torque: 9.0 – 3.0 N¼m

>>A<< ENGINE OIL PAN INSTALLATION 1. Remove sealant from the engine oil pan and cylinder block surfaces.

>>B<< ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

AC102324 AB

2. Remove the engine oil pan using special tool oil pan remover (MD998727).

Engine oil pan side

φ 4 mm Groove portion Bolt hole portion

AC102133AB

2. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the engine oil pan within 15 minutes after applying sealant.

AC102325 AE

Replace the gasket with a new gasket. Install the new gasket in the direction shown in the illustration.


ENGINE MECHANICAL

11A-25

OIL PAN

REMOVAL AND INSTALLATION <4WD> M1112002800600

Pre-removal Operation Â&#x153; Under Cover Removal (Refer to GROUP 51, Under Cover 351). Â&#x153; Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Â&#x153; Centre Member Removal (Refer to GROUP 32, Engine Roll Stopper and Centre Member 332).

Post-installation Operation Â&#x153; Centre Member Installation (Refer to GROUP 32, Engine Roll Stopper and Centre Member 332). Â&#x153; Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Â&#x153; Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Under Cover Installation (Refer to GROUP 51, Under Cover 351).

6

9.0 ± 3.0 N·m

N

2

4

3

9.0 ± 3.0 N·m

39 ± 5 N·m

44 ± 10 N·m

9.0 ± 1.0 N·m

22 ± 4 N·m

5 9.0 ± 3.0 N·m

1

9.0 ± 3.0 N·m AC300543 AB

>>D<<

1.

>>C<<

2. 3. 4.

Removal steps Transmission housing front lower cover stay Flywheel housing front lower cover Engine oil pan drain plug Engine oil pan drain plug gasket

<<A>> <<B>>

>>B<< >>A<<

5. 6.

Removal steps &RQWLQXHG

Engine lower oil pan Engine upper oil pan


ENGINE MECHANICAL

11A-26

OIL PAN

REMOVAL SERVICE POINTS

INSTALLATION SERVICE POINTS

<<A>> ENGINE LOWER OIL PAN REMOVAL 1. Remove the engine lower oil pan mounting bolts.

>>A<< ENGINE UPPER OIL PAN INSTALLATION 1. Remove sealant from the engine upper oil pan and cylinder block surfaces.

CAUTION Do not use special tool oil pan remover (MD998727). The engine upper oil pan is made of aluminium and this tool will damage it.

Ï&#x2020; 4 mm Bolt hole portion

Groove portion

Engine lower oil pan AC102931AB

2. Apply a piece of wood to the lower oil pan and strike it with a hammer to remove the engine lower oil pan. <<B>> ENGINE UPPER OIL PAN REMOVAL 1. Remove the engine upper oil pan mounting bolts.

CAUTION Do not use special tool oil pan remover (MD998727). The engine upper oil pan is made of aluminium and this tool will damage it.

AC102242AB

2. Apply a bead of the sealant to the mating surface of the engine upper oil pan as shown. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the engine upper oil pan within 15 minutes after applying sealant. 3. Assemble the engine upper oil pan to the cylinder block.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time. B

B

B

B

B A

B

A B

B

B

B

AC102946AB

2. Screw in the bolt into bolt hole A in the location shown. Then lift the upper oil pan and remove it.

B

B

B

B

B B A

A AC102929AB

4. Insert the bolts to the engine upper oil pan as shown, and tighten them to the specified torque.


ENGINE MECHANICAL

11A-27

OIL PAN

Name

Symbol

Flange bolt A B

Quantity

Size mm (D ™ L)

Name

2

M6 ™ 16

Flange bolt A

16

M6 ™ 18

B

NOTE: D: Nominal diameter, L: Nominal length Tightening torque: 9.0 – 3.0 N¼m >>B<< ENGINE LOWER OIL PAN INSTALLATION 1. Remove sealant from the engine lower oil pan and engine upper oil pan.

Symbol

Quantity

Size mm (D ™ L)

1

M6 ™ 75

11

M6 ™ 10

NOTE: D: Nominal diameter, L: Nominal length Tightening torque: 9.0 – 3.0 N¼m >>C<< ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

Engine lower oil pan side

φ 4 mm AC102325 AF

Bolt hole portion

Groove portion

AC102243AB

2. Apply a bead of the sealant to the mating surface of the engine lower oil pan as shown. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the engine lower oil pan within 15 minutes after applying sealant. 3. Assemble the engine lower oil pan to the engine upper oil pan.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time. B-1

B-11

M1112002900210

B-7 B-6 A-3

B-8 B-9

B-12

B-2

>>D<< TRANSMISSION HOUSING FRONT LOWER COVER STAY INSTALLATION Install the transmission housing front lower cover stay in the following order. 1. Tighten the engine side four mounting bolts to the specified torque. Tightening torque: 22 – 4 N¼m 2. Tighten the transmission side two mounting bolts to the specified torque. Tightening torque: 44 – 10 N¼m

INSPECTION

B-10

B-4 B-5

Replace the gasket with a new one. Install the new gasket in the direction shown in the illustration.

AC102930AB

4. Insert the bolts to the engine lower oil pan as shown, and tighten them to the specified torque in the order shown.

œ Check the oil pan for cracks. œ Check the oil pan sealant-coated surface for damage and deformation.


ENGINE MECHANICAL

11A-28

CRANKSHAFT OIL SEAL

CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION M1112003100273

132 ± 5 N·m

4 5 7

8 9

6

N

3 N

9

3

2

Lip section

Lip section

Engine oil

1

AC300544 AB

œ

>>D<<

1.

>>C<<

2. 3.

Crankshaft front oil seal removal steps Valve timing belt, balancer timing belt (Refer to 311A). Crankshaft balancer shaft drive sprocket Crankshaft key Crankshaft front oil seal

<<A>> <<B>>

>>B<<

>>A<<

œ 4. 5. 6. 7. 8. 9.

Crankshaft rear oil seal removal steps Transmission assembly Flywheel bolts Flywheel adapter plate Flywheel assembly Flywheel adapter plate Crankshaft bush Crankshaft rear oil seal


ENGINE MECHANICAL

11A-29

CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINTS <<A>> TRANSMISSION ASSEMBLY REMOVAL

CAUTION

2. Use the following special tools to press-fit the oil seal. œ Installer bar (MB990938) œ Crankshaft rear oil seal installer (MD998776) >>B<< FLYWHEEL BOLTS INSTALLATION

Engine front

MD998781

Flywheel assembly Flywheel bolt AC300897 AB

Do not remove the flywheel bolt shown by the arrow. If this bolt is removed, the flywheel assembly will become out of balance and damaged. Refer to GROUP 22A, Transmission Assembly 322A. <<B>> FLYWHEEL BOLTS REMOVAL

AC211914AC

1. Use special tool flywheel stopper (MD998781) to secure the flywheel in the same manner as removal. 2. Tighten the flywheel bolts to the specified torque. Tightening torque: 132 – 5 N¼m >>C<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

MD998781

Crankshaft

MD998375

(Engine oil) AC211914AC

1. Use special tool flywheel stopper (MD998781) to secure the flywheel. 2. Remove the flywheel bolts.

INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION Oil seal

MB990938 (Engine oil)

MD998776

Crankshaft AC102328 AB

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.

MD998285 (Oil applied to the circumference)

Oil seal AC102329 AC

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip. 2. Apply a small amount of engine oil to the outer diameter of special tool crankshaft front oil seal guide (MD998285) and install it to the crankshaft. 3. Use special tool crankshaft front oil seal installer (MD998375) to press-fit the oil seal.


ENGINE MECHANICAL

11A-30

CYLINDER HEAD GASKET

>>D<< CRANKSHAFT BALANCER SHAFT DRIVE SPROCKET INSTALLATION : Clean : Clean and degrease

Crankshaft

Front case Crankshaft balancershaft drive sprocket

Engine front

AC211222 AB

1. Clean or degrease the front case, the crankshaft and the crankshaft balancer shaft drive sprocket as shown. NOTE: Also clean the degreased surfaces. 2. Install the crankshaft balancer shaft drive sprocket in the direction shown in the illustration.

CYLINDER HEAD GASKET REMOVAL AND INSTALLATION M1112004000655

Pre-removal Operation Â&#x153; Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) 313A.] Â&#x153; Under Cover Removal (Refer to GROUP 51, Under Cover 351). Â&#x153; Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Â&#x153; Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner 315). Â&#x153; Battery Removal Â&#x153; Rocker Cover Centre Cover Removal (Refer to 311A ). Â&#x153; Valve Timing Belt Removal (Refer to 311A).

Post-installation Operation Â&#x153; Valve Timing Belt Installation (Refer to 311A). Â&#x153; Rocker Cover Centre Cover Installation (Refer to 311A ). Â&#x153; Battery Installation Â&#x153; Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner 315). Â&#x153; Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Â&#x153; Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and Adjustment 317). Â&#x153; Drive Belt Tension Check (Refer to 311A). Â&#x153; Under Cover Installation (Refer to GROUP 51, Under Cover 351). Â&#x153; Fuel Leak Check


ENGINE MECHANICAL

11A-31

CYLINDER HEAD GASKET

9 5.0 ± 1.0 N·m

10

16

12

7 17

5

6 14

8

5.0 ± 1.0 N·m

4 18

15 9.0 ± 2.0 N·m

13 11

3

20 2

13 ± 1 N·m

1

(Engine oil)

N

19

AC300545 AB

Removal steps A/C compressor connector Power steering fluid pressure switch connector 3. Crank angle sensor connector 4. Ignition coil connectors 5. Detonation sensor connector 6. Purge control solenoid valve connector 7. EGR control solenoid valve connector 8. Injector connectors 9. Throttle position sensor connector 10. Idle speed control servo connector 11. Camshaft position sensor connector 1. 2.

Removal steps &RQWLQXHG

12. Oxygen sensor connector 13. Engine coolant temperature sensor connector 14. Engine coolant temperature gauge unit connector 15. Capacitor connector 16. Accelerator cable connection 17. Brake booster vacuum hose connection 18. Engine oil level gauge and guide assembly 19. O-ring 20. Canister vacuum hose connection


ENGINE MECHANICAL

11A-32

CYLINDER HEAD GASKET

24 25

26

<Cold engine> 78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚

5.0 ± 1.0 N·m

27 N

(Engine oil)

28

(Engine oil)

29

22 11 ± 1 N·m

21 30 N 31 ± 3 N·m

23

AC300546 AB

21. 22. 23. œ

œ

œ 24.

Removal steps Detonation sensor connection Battery wiring harness connection Inlet manifold stay Exhaust manifold (Refer to GROUP 15, Exhaust Manifold 315). Water outlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe 314). Rocker cover (Refer to 311A). Heater water hose connection

>>C<< <<A>>

>>C<< >>B<< >>A<<

25. 26. 27. 28. 29. 30.

Removal steps &RQWLQXHG

Fuel return line hose connection Fuel high-pressure hose connection O-ring Cylinder head bolts Cylinder head assembly Cylinder head gasket


ENGINE MECHANICAL

11A-33

CYLINDER HEAD GASKET

REMOVAL SERVICE POINT <<A>> CYLINDER HEAD BOLTS REMOVAL

Identification mark "63" MB991654

Exhaust side AC107217AC

2. Assemble to the cylinder block so the cylinder head gasket identification mark "63" is at the top surface and on the exhaust side.

Engine front

>>B<< CYLINDER HEAD BOLTS INSTALLATION 3

5

10

8

2 (Engine oil)

1

7

9

6

4

AC201623 AB

Using special tool cylinder head bolt wrench (MB991654), loosen the cylinder head bolts in two or three steps in the order of the numbers shown in the illustration. NOTE: If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it by using a magnet.

INSTALLATION SERVICE POINTS >>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION Do not allow any foreign materials to get into the coolant passages, oil passages and cylinder. 1. Remove the gasket from the cylinder head and cylinder block.

A

AC102537AB

1. Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one. Limit (A): 99.4 mm 2. Apply a small amount of engine oil to the thread of the bolts and to the washers.


ENGINE MECHANICAL

11A-34

CYLINDER HEAD GASKET

CAUTION The bolt is not tightened sufficiently if the bolt is tightened less than 90 degree angle. (5) Tighten the bolt an additional 90 degree angle as shown. Then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head are aligned. (6) If tightening the bolt 90 degree angle results in moving the paint mark on the bolt past the paint mark on the cylinder head, remove the bolt and start over from step 1.

MB991654

Engine front

8

6

1

3

9

>>C<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

10

4

2

5

7

Do not let any engine oil get into the delivery pipe. 1. Apply a small amount of new engine oil to the Oring. 2. Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly. 4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 – 1.0 N¼m

AC201625 AB

3. Use special tool cylinder head bolt wrench (MB991654) to tighten the cylinder head bolts as follows: (1) Tighten the cylinder head bolts to 78 – 2 N¼m in the order shown. (2) Loosen the bolts fully in the reverse order of that shown. (3) Tighten the cylinder head bolts to 20 – 2 N¼m in the order shown. Step (4) 90˚

Paint marking

Step (5) 90˚

Paint marking AC102331AB

(4) Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown.

CAUTION


ENGINE MECHANICAL

11A-35

TIMING BELT

TIMING BELT REMOVAL AND INSTALLATION M1112004300656

Pre-removal Operation Â&#x153; Under Cover Removal (Refer to GROUP 51, Under Cover 351). Â&#x153; Crankshaft Shaft Damper Pulley Removal (Refer to 311A).

Post-installation Operation Â&#x153; Crankshaft Shaft Damper Pulley Installation (Refer to 311A). Â&#x153; Drive Belt Tension Check (Refer to 311A). Â&#x153; Under Cover Installation (Refer to GROUP 51, Under Cover 351).

10 9 2

8

48 ± 5 N·m

11 ± 1 N·m 21 ± 4 N·m

3 8.8 ± 1.0 N·m

23 ± 3 N·m

11

1 6 44 ± 10 N·m

N

5 4 22 ± 4 N·m

7

79 ± 5 N·m

11 ± 1 N·m 9.0 ± 1.0 N·m

>>H<<

1. 2. 3. 4. 5. 6. 7.

Removal steps Control wiring harness connection Timing belt upper cover Water pump pulley Idler pulley End cap Auto-tensioner Timing belt lower cover

AC300547 AB

Removal steps &RQWLQXHG

Engine front mounting bracket (Refer to GROUP 32, Engine Mount 332). Â&#x153; Valve timing belt tension adjustment 8. Valve timing belt 9. Timing belt tensioner pulley 10. Timing belt tensioner arm 11. Timing belt tensioner adjuster

Â&#x153;

>>G<< <<A>>

>>F<< >>E<< >>D<<


ENGINE MECHANICAL

11A-36

TIMING BELT

12

22 ± 4 N·m

16 35 ± 6 N·m

21 20

22 ± 4 N·m

13

19 ± 3 N·m

14 (Engine oil) 49 ± 9 N·m

15 18

49 ± 9 N·m

17

19

8.8 ± 1.0 N·m

167 N·m AC300548 AB

<<B>>

Removal steps 12. Power steering fluid pressure switch connector 13. Power steering oil pump assembly 14. A/C compressor connector 15. Power steering oil pump bracket 16. Timing belt idler pulley 17. Crank angle sensor

<<C>>

<<D>>

>>C<< >>C<< >>B<<

18. 19. œ

>>A<< >>A<<

20. 21.

Removal steps &RQWLQXHG

Crankshaft camshaft drive sprocket Crankshaft angle sensing blade Balancer timing belt tension adjustment Balancer timing belt tensioner Balancer timing belt

REMOVAL SERVICE POINTS <<A>> VALVE TIMING BELT REMOVAL

CAUTION Never turn the crankshaft anti-clockwise.

MD998738

Timing mark

Timing belt under cover AC102492 AB

AC102487

1. Turn the crankshaft clockwise, align each timing mark to set No.1 cylinder to TDC of its compression stroke.

2. Remove the timing belt under cover rubber plug and then set the special tool adjusting bolt (MD998738).


ENGINE MECHANICAL

11A-37

TIMING BELT

CAUTION The special tool can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool may bend. Timing belt tensioner arm

MD998738

AC107289 AB

<<B>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL With the hose installed, remove the power steering oil pump assembly from the bracket. NOTE: Secure the removed power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the balancer timing belt. <<C>> CRANKSHAFT CAMSHAFT DRIVE SPROCKET REMOVAL Crankshaft camshaft drive sprocket

MB991385

3. Screw in the special tool until it comes in contact with the timing belt tensioner arm. MB991367

B

A

AC102332 AB

AC102775AB

4. Gradually screw in the special tool. Then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjustor cylinder set hole B. Timing belt tensioner pulley mounting bolt

1. Use the following special tools to support the crankshaft camshaft drive sprocket. œ Special spanner (MB991367) œ Pin (MB991385) 2. Loosen the crankshaft pulley centre bolt and remove the crankshaft camshaft drive sprocket. <<D>> BALANCER TIMING BELT REMOVAL

CAUTION To reuse the balancer timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.

INSTALLATION SERVICE POINTS >>A<< BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER INSTALLATION

Wire

Balancershaft sprocket Belt tension side AC107185 AB

Timing mark

Timing mark

5. Insert a wire, etc.in the set hole.

CAUTION To reuse the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk. 6. After removal of adjusting bolt special tool, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.

Crankshaft balancershaft drive sprocket

AC102689 AB

1. Ensure that the crankshaft balancershaft drive sprocket timing marks and balancershaft sprocket timing marks are aligned.


ENGINE MECHANICAL

11A-38

TIMING BELT

2. Install the balancer timing belt on the crankshaft balancershaft drive sprocket and balancershaft sprocket. There should be no slack on the tension side. Centre of the mounting bolt

1. With your fingers, lift the balancer timing belt tensioner in the direction of the arrow. Apply pressure of 3.0 – 0.4 N¼m to the balancer timing belt. Tighten the assembling bolt to the specified torque. Then, fix the balancer timing belt tensioner. Tightening torque: 19 – 3 N¼m Balancershaft sprocket

Timing mark

Centre of the pulley

Timing mark

AC102690 AB

3. Assemble and temporarily fix the centre of the pulley of the balancer timing belt tensioner so that it is at the top left from the centre of the mounting bolt, and the pulley flange is at the front-side of the engine. 4. Adjust the balancer timing belt tension. >>B<< BALANCER TIMING BELT TENSION ADJUSTMENT

CAUTION When tightening the mounting bolt, ensure that the tensioner does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension of the belt.

AC102691

Crankshaft balancershaft drive sprocket

AC102689AC

2. Turn the crankshaft clockwise two turns to set No.1 cylinder to TDC of its compression stroke and check that the sprocket timing marks are aligned.


ENGINE MECHANICAL

11A-39

TIMING BELT

Approximately 100 N

Deflection

AC102693 AB

3. Apply a pressure of approximately 100N at the centre (arrow area) between the sprocket as shown, then inspect whether the belt deflection is within the standard value. Standard value: At adjustment: 5 - 7 mm At replacement: 5 - 7 mm 4. If not within the standard value, adjust the belt tension again. >>C<< CRANKSHAFT ANGLE SENSING BLADE/ CRANKSHAFT CAMSHAFT DRIVE SPROCKET INSTALLATION : Clean : Clean and degrease : Apply engine oil

2. Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown. 3. Place the larger chamfer side of the crank shaft pulley washer in the direction shown and then assemble on the crankshaft pulley centre bolt. 4. Apply some engine oil to the crankshaft pulley centre bolt bearing surface and screw. Crankshaft camshaft drive sprocket

MB991367

AC102332 AB

5. Use the following special tool as during removal to support the crankshaft camshaft drive sprocket. œ Special spanner (MB991367) œ Pin (MB991385) 6. Tighten the crankshaft pulley centre bolts to the specified torque. Tightening torque: 167 N¼m >>D<< TIMING BELT TENSIONER ADJUSTER INSTALLATION 1. Install according to the following procedures when the timing belt tensioner adjuster rod is fully extended.

Crankshaft pulley center bolt Crankshaft camshaft drive sprocket

CAUTION Crankshaft

If the compression is too fast, the procedure may damage the rod. A

Crankshaft pulley washer Engine front

MB991385

B

Crankshaft angle sensing blade AC211535AB

1. Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft camshaft drive sprocket and crankshaft pulley washer as shown. NOTE: Also clean the degreased surfaces.

AC102334 AB

(1) Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt tensioner adjuster cylinder.


ENGINE MECHANICAL

11A-40

TIMING BELT

>>F<< VALVE TIMING BELT INSTALLATION Wire Timing mark

AC102335 AB

(2) Insert a wire or pin into the aligned set hole. NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin. 2. Assemble the timing belt tensioner adjuster to the engine, then tighten the assembling bolt to the specified torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted. Tightening torque: 23 Â&#x2013; 3 NÂźm

Camshaft sprocket

Crankshaft camshaft drive sprocket

Timing mark Timing mark

>>E<< TIMING BELT TENSIONER PULLEY INSTALLATION

Engine oil pump sprocket

AC102486 AC

1. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket. Bolt Balancershaft

Timing belt tensioner pulley hole

Plug AC102336AB

Temporarily tighten the timing belt tensioner pulley as shown.

Cylinder block AC102337 AE

2. Adjust the timing mark of the engine oil pump sprocket. Unplug the cylinder block plug. Insert a bolt (M6 sectional width 10 mm, minor diameter 45 mm) from the plug hole and then check. If the bolt comes in contact with the balancer shaft turn the sprocket one rotation. Re-adjust the timing mark and then check to see that the bolt fits. Do not remove the bolt until the valve timing belt is assembled.


ENGINE MECHANICAL TIMING BELT

3. Install the valve timing belt as follows: Inlet side camshaft sprocket

11A-41

Timing mark Timing mark

Exhaust side camshaft sprocket

AC201802 AB

Timing belt tensioner pulley

Crankshaft camshaft drive sprocket

Timing belt idler pulley

(3) Use two wrenches to align the timing mark on the rocker cover with that on the camshaft sprocket. Pass the valve timing belt around the inlet-side camshaft sprocket.

Engine oil pump sprocket

AC102488 AC

(1) Pass the valve timing belt around the crankshaft camshaft drive sprocket, the engine oil pump sprocket and the timing belt idler pulley in that order.

Paper clip

AC201803AB

(4) Hold the valve timing belt with paper clips. (5) Pass the valve timing belt around the timing belt tensioner pulley.

CAUTION Paper clip

Incorporate the valve timing belt. Then apply reverse rotation (anti-clockwise rotation) pressure to the cam shaft sprocket. Re-check to see that each timing mark is aligned while the tension side of the belt is tight. (6) Remove the two paper clips.

AC201801AB

(2) Pass the valve timing belt around the exhaustside camshaft sprocket, and hold the valve timing belt with paper clip. MD998767

AC102694 AB

4. Turn the timing belt tensioner in the direction shown using special tool tensioner wrench (MD998767) to apply tension to the valve timing belt. Then pre-tighten the timing belt tensioner pulley. 5. Check that the timing marks are aligned.


ENGINE MECHANICAL

11A-42

TIMING BELT Bolt

CAUTION When tightening the mounting bolt, ensure that the timing belt tensioner pulley does not rotate with the bolt. Allowing it to rotate with the bolt can cause deficient tension of the belt.

Balancershaft

Plug Cylinder block AC102337 AE

6. Remove the bolt inserted in Step 2 above, then assemble the cylinder block plug. 7. Tighten the cylinder block plug to the specified torque. Tightening torque: 30 – 3 N¼m 8. Adjust the valve timing belt tension. >>G<< VALVE TIMING BELT TENSION ADJUSTMENT

MD998767

AC102695AB

6. With special tool tensioner wrench (MD998767) and torque wrench, apply tension torque 3.5 N¼m, and tighten the timing belt tensioner pulley mounting bolt to the specified torque. Tightening torque: 48 – 5 N¼m

MD998738

Wire

Timing belt under cover AC102492 AB

1. Set special tool adjusting bolt (MD998738) when removing the valve timing belt.

CAUTION Always screw in special tool by hand, since use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster. 2. Gradually screw in special tool until the wire or pin inserted in the timing belt tensioner adjuster lightly moves. 3. Turn the crankshaft 1/4 turn anti-clockwise. 4. Turn the crankshaft in the clockwise direction until you align each timing mark to set No.1 cylinder to TDC of its compression stroke. 5. Loosen the timing belt tensioner pulley mounting bolt.

AC102776 AB

7. Remove wire or pin inserted to timing belt tensioner.

MD998738

Timing belt under cover AC102492 AB

8. Remove the special tool adjusting bolt (MD998738), and install the rubber plug to the timing belt under cover. 9. Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.


ENGINE MECHANICAL

11A-43

TIMING BELT

CAUTION Always check the tightening torque of the crank shaft pulley centre bolt when turning the crack shaft pulley centre bolt anti-clockwise. Retighten if it is loose.

Wire

Timing mark

AC102776 AB

10.Insert wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin.

Camshaft sprocket

Crankshaft camshaft drive sprocket

A

Timing belt tensioner adjuster

Timing mark Timing mark

AC102338AB

If the projection of timing belt tensioner adjuster rod is within the standard value, appropriate tension is applied. Standard value (A): 3.8 - 4.5 mm 11.If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension.

Engine oil pump sprocket

AC201411AB

12.Check again that the timing marks on sprockets are aligned. >>H<< END CAP INSTALLATION

CAUTION Always replace the end cap with new parts since there may be fall-off or sealing defect if the end cap is re-used.

INSPECTION M1112004400352

TIMING BELT TENSIONER ADJUSTER CHECK 1. Check for oil leak from seal, and replace it if leak is detected. 2. Check for wear or damage at the top of the rod. Replace it, if required.


ENGINE MECHANICAL

11A-44

TIMING BELT

98 â&#x20AC;&#x201C; 196 N

Movement

BALANCER TIMING BELT TENSION CHECK Check the balancer timing belt tension as follows:

A

B Approximately 100 N

Rod

Timing belt tensioner adjuster AC102339 AB

3. Hold the timing belt tensioner adjuster by hand, and press the top end of the rod onto the metal (e.g. cylinder block) under a pressure of 98 - 196 N to measure the movement of the rod. Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 4. If the measured value is out of the standard value, replace the timing belt tensioner adjuster.

Deflection

AC102693 AB

1. Apply a pressure of approximately 100 N at the centre (arrow area) between the sprocket as shown then inspect whether the deflection is within the standard value. Standard value: 5 - 10 mm 2. If not within the standard value, adjust the belt tension. (Refer to 311A).


ENGINE MECHANICAL ENGINE ASSEMBLY

11A-45

ENGINE ASSEMBLY REMOVAL AND INSTALLATION M1112001000720

CAUTION *: indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body. Pre-removal Operation Â&#x153; Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) 313A.] Â&#x153; Hood Removal (Refer to GROUP 42, Hood 342). Â&#x153; Under Cover Removal (Refer to GROUP 51, Under Cover 351). Â&#x153; Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Â&#x153; Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner 315). Â&#x153; Battery and Battery Tray Removal Â&#x153; Rocker Cover Centre Cover Removal (Refer to 311A ). Â&#x153; Radiator Assembly Removal (Refer to GROUP 14, Radiator 314). Â&#x153; Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Â&#x153; Starter Assembly Removal (Refer to GROUP 16, Starter Motor Assembly 316).

Post-installation Operation Â&#x153; Starter Assembly Installation (Refer to GROUP 16, Starter Motor Assembly 316). Â&#x153; Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Â&#x153; Radiator Assembly Installation (Refer to GROUP 14, Radiator 314). Â&#x153; Battery and Battery Tray Installation Â&#x153; Rocker Cover Centre Cover Installation (Refer to 311A ). Â&#x153; Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner 315). Â&#x153; Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Â&#x153; Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Â&#x153; Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and Adjustment 317). Â&#x153; Drive Belt Tension Check (Refer to 311A). Â&#x153; Under Cover Installation (Refer to GROUP 51, Under Cover 351). Â&#x153; Hood Installation (Refer to GROUP 42, Hood 342). Â&#x153; Fuel Leak Check


ENGINE MECHANICAL

11A-46

ENGINE ASSEMBLY

9 5.0 ± 1.0 N·m

10

17

12

7 5

6 14

8

5.0 ± 1.0 N·m

4

15 11

9.0 ± 2.0 N·m

13

3

2 1

9.0 ± 2.0 N·m

18 5.0 ± 1.0 N·m

16

9.0 ± 2.0 N·m 5.0 ± 1.0 N·m

1. 2. 3. 4. 5. 6. 7. 8. 9.

Removal steps A/C compressor connector Power steering fluid pressure switch connector Crank angle sensor connector Ignition coil connectors Detonation sensor connector Purge control solenoid valve connector EGR control solenoid valve connector Injector connectors Throttle position sensor connector

10. 11. 12. 13. 14.

<<A>>

15. 16. 17. 18.

AC300549 AB

Removal steps &RQWLQXHG

Idle speed control servo connector Camshaft position sensor connector Oxygen sensor connector Engine coolant temperature sensor connector Engine coolant temperature gauge unit connector Capacitor connector Battery wiring harness connection Accelerator cable connection Drive belt


ENGINE MECHANICAL

11A-47

ENGINE ASSEMBLY

23 24 19

25 5.0 ± 1.0 N·m

26 N

(Engine oil)

12 ± 2 N·m

20 44 ± 10 N·m*

22 ± 4 N·m

27

N

22 22 ± 4 N·m

45 ± 5 N·m*

29 28 21 AC300550 AB

<<B>> <<B>>

Removal steps 19. Brake booster vacuum hose connection 20. Canister vacuum hose connection 21. A/C compressor and clutch assembly 22. Power steering oil pump assembly 23. Heater water hoses connection 24. Fuel return line hose connection

>>E<< <<C>> <<D>> <<E>>

>>E<< >>D<< >>C<< >>B<< >>A<<

Removal steps &RQWLQXHG

25. Fuel high-pressure hose connection 26. O-ring œ Transmission assembly 27. Self-locking nuts 28. Engine front mounting bracket 29. Engine assembly


ENGINE MECHANICAL

11A-48

ENGINE ASSEMBLY

REMOVAL SERVICE POINTS

<<C>> TRANSMISSION ASSEMBLY REMOVAL

<<A>> DRIVE BELT REMOVAL The following operations will be needed due to the serpentine drive system with the drive belt autotensioner. Auto-tensioner

AC300950AB

Hole B

Hole A

AC107640AC

1. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.

CAUTION To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.

1. Pre-tighten the 2 bolts on the car to assemble the radiator support upper insulator to set the special tools engine hanger MB991895 or engine hanger MB991928. 2. Remove the transmission assembly (Refer to GROUP 22A, Transmission Assembly 322A). <<D>> ENGINE FRONT MOUNTING BRACKET REMOVAL 1. Support the engine with a garage jack. 2. Remove the following special tool. MB991895 MB991527

Auto-tensioner

L-shaped hexagon wrench

MB991454 AC107631AB AC107641AB

2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt. <<B>> A/C COMPRESSOR AND CLUTCH ASSEMBLY/POWER STEERING OIL PUMP ASSEMBLY REMOVAL With the hose installed, remove the A/C compressor and clutch assembly, and power steering oil pump assembly from the bracket. NOTE: Secure the removed A/C compressor and clutch assembly, and power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the engine assembly.

(1) <Special tool engine hanger (MB991895) is used> Remove special tool MB991895. MB991928

MB991527 MB991454 AC211405 AB

(2) <Special tool engine hanger (MB991928) is used> Remove special tool MB991928.


ENGINE MECHANICAL

11A-49

ENGINE ASSEMBLY

2. Support the engine assembly with a garage jack. 3. Remove the chain block. 4. Use the following special tool as during removal to support the engine.

MB991454 MB991527

MB991895 MB991527

AC107632 AB

3. Hold the engine assembly with a chain block, etc. 4. Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the engine front mounting bracket. 5. Loosen the engine front mounting bracket mounting nuts and bolt, and remove the engine front mounting bracket.

MB991454 AC107631AB

(1) <Special tool engine hanger (MB991895) is used> Set special tool MB991895. (Refer to GROUP 22A, Transmission Assembly 322A).

<<E>> ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.

MB991928

MB991527

INSTALLATION SERVICE POINTS >>A<< ENGINE ASSEMBLY INSTALLATION

MB991454 AC211405 AB

(2) <Special tool engine hanger (MB991928) is used> Set special tool MB991928 (Refer to GROUP 22A, Transmission Assembly 322A).

MB991454 MB991527

>>C<< SELF-LOCKING NUTS INSTALLATION

CAUTION Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.

Do not tighten the self-locking nuts while the engine is hot. Tighten the self-locking nuts to the specified torque while the engine is cold. Tightening torque: 45 – 5 N¼m

>>B<< ENGINE FRONT MOUNTING BRACKET INSTALLATION 1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine front mounting bracket while adjusting the position of the engine.

>>D<< TRANSMISSION ASSEMBLY INSTALLATION 1. Install the transmission assembly (Refer to GROUP 22A, Transmission Assembly 322A).

AC107632 AB


ENGINE MECHANICAL

11A-50

ENGINE ASSEMBLY

>>E<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

AC300950AB

2. Remove from the car the 2 bolts, to assemble the radiator support upper insulator.

Do not let any engine oil get into the delivery pipe. 1. Apply a small amount of new engine oil to the Oring. 2. Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly. 4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 Â&#x2013; 1.0 NÂźm


ENGINE OVERHAUL

11B-27

INTAKE MANIFOLD

INTAKE MANIFOLD REMOVAL AND INSTALLATION M1113002700286

36 ± 6 N·m

19 ± 3 N·m

2

4 3

36 ± 6 N·m 20 ± 2 N·m

31 ± 3 N·m

1

AK204438 AB

Removal steps

>>A<< 1. Intake manifold stay 2. Intake manifold 3. Intake manifold gasket 4. Engine hanger

INSTALLATION SERVICE POINTS >>A<< INTAKE MANIFOLD STAY INSTALLATION

Intake manifold stay AK202865 AB

Tighten the bolts to the specified torque 31 – 3 N¼m on both ends after making sure that the stay is in close contact with the bosses on the intake manifold and cylinder block.


ENGINE OVERHAUL

11B-28

EXHAUST MANIFOLD

EXHAUST MANIFOLD REMOVAL AND INSTALLATION M1113004900383

14 ± 1 N·m 44 ± 5 N·m 29 ± 3 N·m

1

14 ± 1 N·m

2

6 4

5

49 ± 5 N·m

3

35 ± 6 N·m

44 ± 5 N·m AK204437 AB

Removal steps 1. Oxygen sensor 2. Exhaust manifold cover 3. Exhaust manifold bracket

Removal steps &RQWLQXHG

4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold gasket


ENGINE OVERHAUL

11B-29

WATER PUMP AND WATER HOSE

WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION M1113017900220

13 ± 2 N·m

7

9 13 ± 2 N·m

13 ± 2 N·m

6 1 23 ± 4 N·m

2

11

5 10

4

8

10.8 ± 1.0 N·m

3 29 ± 10 N·m

14 23 ± 2 N·m

13 12 14 ± 1 N·m AK204436AB

>>E<< >>D<< >>C<< >>B<< >>A<< >>A<< >>A<<

Removal sequence 1. Water hose 2. Water hose 3. Coolant temperature sensor 4. Coolant temperature gauge unit 5. Water inlet fitting 6. Thermostat 7. Water outlet fitting 8. Thermostat housing 9. O-ring 10. Water inlet pipe 11. O-ring 12. Water pump 13. Water pump gasket 14. Knock sensor

INSTALLATION SERVICE POINTS >>A<< O-RING/WATER INLET PIPE INSTALLATION

CAUTION

œ Never allow any oil or grease to touch the Orings. œ Clamp the water inlet pipe only after installation of the thermostat case. Replace the O-rings at both ends of the water inlet pipe with new ones. Insert the O-rings into the water pump and thermostat housing after wetting their peripheries with water.


11B-30

ENGINE OVERHAUL WATER PUMP AND WATER HOSE

>>B<< THERMOSTAT HOUSING INSTALLATION

>>D<< COOLANT TEMPERATURE GAUGE UNIT INSTALLATION

AK202918AB

1. Remove all old FIPG remaining on the thermostat housing and cylinder head. 2. Apply a 2.7 – 0.3 mm diameter bead of FIPG on the indicated surface of the thermostat housing. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent >>C<< WATER OUTLET FITTING INSTALLATION

AK202800AB

1. Remove all old sealant remaining on the threaded hole in the coolant temperature gauge unit and the thermostat housing. NOTE: A new coolant temperature gauge unit is coated with sealant. It does not require coating with sealant before installation. 2. Apply sealant to the indicated threads of the coolant temperature gauge unit. Specified sealant: 3M Nut Locking Part No.4171 or equivalent >>E<< COOLANT TEMPERATURE SENSOR INSTALLATION

AK202755AB

1. Remove all old FIPG remaining on the water outlet fitting and thermostat housing. 2. Apply a 2.7 – 0.3 mm diameter bead of FIPG to the indicated surface of the water outlet fitting. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent

AK202799AB

CAUTION When using a tool, avoid letting it touch the connector portion which is made of plastic. 1. Remove all old sealant remaining on the threads of the coolant temperature sensor and in the threaded hole in the thermostat housing. 2. Apply sealant to the coolant temperature sensor’s threads indicated in the drawing. Specified sealant: 3M ATD Part No.8660 or equivalent


ENGINE OVERHAUL

11B-31

ROCKER ARMS AND CAMSHAFT

ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION M1113005400455

10 ± 2 N·m

3

8

N4

11 14 13 20 ± 1 N·m

6 9

12

14 ± 1 N·m

2N 1

10 22 ± 4 N·m

5

15

8.8 ± 1.0 N·m 11 ± 1 N·m

18

N7

16 17

Apply engine oil to all moving parts before installation.

AK202894 AB

>>F<< >>E<< >>D<< >>C<< >>C<<

1. 2. 3. 4. 5. 6. 7. 8. 9.

Removal steps Camshaft position sensor O-ring Cover Gasket Camshaft position sensing cylinder Camshaft position sensor support Camshaft oil seal Bearing cap, rear right Bearing cap, rear left

>>C<< >>C<< >>C<< >>C<< >>C<< >>B<< <<A>> >>A<<

Removal steps &RQWLQXHG

10. Bearing cap, front 11. Bearing cap No.5 12. Bearing cap No.2 13. Bearing cap No.3 14. Bearing cap No.4 15. Camshaft 16. Rocker arm 17. Lash adjuster 18. Oil delivery body


ENGINE OVERHAUL

11B-32

ROCKER ARMS AND CAMSHAFT

SERVICE POINTS FOR REMOVAL

1. Set each camshaft with its dowel pin at the top.

<<A>> LASH ADJUSTER REMOVAL

CAUTION When reusing a lash adjuster, it must be washed and inspected before installation. (Refer to 311B, the instruction under LASH ADJUSTER in the INSPECTION section.)

INSTALLATION SERVICE POINTS >>A<< LASH ADJUSTER INSTALLATION

Cap number Intake/exhaust identification letter

AK202870 AB

CAUTION When reusing a lash adjuster, it must be washed and inspected before installation. (Refer to 311B, the instruction under LASH ADJUSTER in the INSPECTION section.) Install the lash adjuster into the rocker arm, being careful not to spill the diesel fuel it contains. >>B<< CAMSHAFT INSTALLATION Timing belt side

2. The bearing caps No. 2 to 5 are identical in shape for both intake and exhaust camshafts. Check the identification mark on each cap before installation. Identification mark (stamped on front and Nos. 2 - 5 bearing caps) I: intake camshaft E: exhaust camshaft 3. Remove completely sealant remaining on the bearing caps and cylinder head.

Slit

Exhaust camshaft AK202869 AB AK202871AB

CAUTION

œ Do not confuse the intake camshaft with the exhaust camshaft. œ The exhaust camshaft has a 4 mm wide slit at the rear end. >>C<< BEARING CAP INSTALLATION Dowel pin

AK203979 AC

4. Apply sealant to the surfaces indicated in the drawing. Specified sealant: 3M ATD No.8660 or equivalent 5. Install each bearing cap and tighten its bolts in two or three passes. 6. Finally tighten the bolts to 20 – 1 N¼m. 7. Check that the rocker arms are correctly installed. NOTE: Wipe off any squeezed out sealant completely.


ENGINE OVERHAUL

11B-33

ROCKER ARMS AND CAMSHAFT

>>D<< CAMSHAFT OIL SEAL INSTALLATION MD998713

1. Turn the exhaust camshaft to the No.1 cylinder top dead center position. NOTE: The camshaft will slightly turn counterclockwise by the force of the exhaust valve spring. 2. Install the camshaft position sensing cylinder with the smaller vane located as shown in the drawing.

INSPECTION M1113005500388

CAMSHAFT AK202872 AB

Use the special tool Camshaft oil seal installer (MD998713) to drive each oil seal into position in the cylinder head. >>E<< CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION AK202797AB

Measure the cam height (nose-to-heel diameter). If any cam is worn beyond the limit, replace the camshaft. Standard value: 34.91 mm Limit: 34.41 mm AK202754AB

1. Remove completely the FIPG remaining on the camshaft position sensor support and cylinder head. 2. Apply a 3 – 1 mm diameter bead of FIPG to the indicated surface of the camshaft position sensor support. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent

LASH ADJUSTERS

CAUTION

œ The lash adjuster is a precision-engineered component. Do not allow dust or other foreign matter to enter it. œ Do not disassemble lash adjusters. œ Use only non-contaminated diesel fuel to clean the lash adjuster. For rough cleaning

For finish cleaning

For diesel fuel filling

B

C

>>F<< CAMSHAFT POSITION SENSING CYLINDER INSTALLATION Smaller vane A

AK202836 AB

Cam position sensor AK202844 AB

1. Prepare three containers and approximately five liters of diesel fuel. Pour into each container the diesel fuel in an amount enough for a lash adjuster placed in the container in its upright position to completely submerge.


ENGINE OVERHAUL

11B-34

ROCKER ARMS AND CAMSHAFT

CAUTION The hole in the side of the lash adjuster must be directed toward the inside of container A. Never direct it against any person. 4. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber. AK202837

2. Place the lash adjuster in container A and wash its outside surface. NOTE: Use a nylon brush if there are hard-toremove deposits. Diesel fuel MD998442 AK202839 AB

CAUTION

Diesel fuel MD998442 AK202839 AB

CAUTION The steel ball spring of the lash adjuster is extremely weak. The lash adjuster’s functionality may be badly affected if the special tool is inserted too strongly. 3. While gently pushing the internal steel ball using the special tool Air bleed wire (MD998442), move the plunger in and out 5 - 10 times to eliminate stiffness in the plunger and expel contaminated oil. NOTE: The plunger must be free from jamming and any other abnormalities. If a defect is found in plunger operation, replace the lash adjuster.

The steel ball spring of the lash adjuster is extremely weak. The lash adjuster’s functionality may be badly affected if the special tool is inserted too strongly. 5. Soak the lash adjuster in the diesel fuel in container B. Move the plunger in and out 5 - 10 times by gently pushing the internal steel ball using the special tool Air bleed wire (MD998442) until the plunger moves smoothly to wash the lash adjuster’s pressure chamber.

MD998442 Diesel fuel AK202840 AB

CAUTION

MD998442 Diesel fuel AK202840 AB

The hole in the side of the lash adjuster must be directed toward the inside of container B. Never direct it against any person. 6. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber.


ENGINE OVERHAUL ROCKER ARMS AND CAMSHAFT

11B-35

8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.

MD998442

Diesel fuel AK202841 AB

CAUTION Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel. 7. Soak the lash adjuster in the diesel fuel in container C. Gently push the internal steel ball using the special tool Air bleed wire (MD998442).

MD998442

Diesel fuel AK202842 AB

AK202843

9. Take the lash adjuster out of the container, place it upright with the plunger at the top, and push the plunger firmly. The plunger must not move at all. NOTE: If the lash adjuster contracts, perform the operations 7. through 9. again. Replace the lash adjuster if it still contracts even after the pressure chamber has completely been filled with diesel fuel (air has been bled). 10.Keep the serviced lash adjusters in their upright positions to prevent diesel fuel from spilling out. Protect them from dust or other foreign matter. Install the lash adjusters onto the engine as soon as possible.


ENGINE OVERHAUL

11B-36

CYLINDER HEAD AND VALVES

CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION M1113006900389

78 ± 2 N·m → loosen completely → 20 ± 2 N·m → 90˚ + 90˚

1 2

4 5 6 12 N 13 16 N

8 9 10 14 N 15 17 N

20

19 N 11

18 N 7

3N

Apply engine oil to all moving parts before installation.

AK202895 AB

Removal steps

<<A>> >>D<< 1. Cylinder head bolt <<B>> >>C<< >>B<<

2. 3. 4. 5. 6.

Cylinder head assembly Cylinder head gasket Retainer lock Valve spring retainer Valve spring

<<B>> >>C<< >>B<< >>A<<

Removal steps &RQWLQXHG

7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring 11. Exhaust valve 12. Valve stem seal 13. Valve spring seat


ENGINE OVERHAUL

11B-37

CYLINDER HEAD AND VALVES Removal steps &RQWLQXHG

>>A<< 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

INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL INSTALLATION

MD998737

REMOVAL SERVICE POINTS <<A>> CYLINDER HEAD BOLT REMOVAL AK202874 AB

CAUTION MB991654

AK202723 AB

Use the special tool Cylinder head bolt wrench (MB991654) to loosen the cylinder head bolts. <<B>> RETAINER LOCK REMOVAL MD998772

The special tool must always be used when installing the valve stem seal. Improper installation could result in oil leaks past the valve guide. 1. Install the valve spring seat. 2. Install the valve. 3. Apply a thin coat of engine oil to a new valve stem seal. 4. Use the special tool Valve stem seal installer (MD998737) to install the stem seal on the valve guide. Use the stem of the valve to guide the stem seal. Intake valve stem seal Colour: Gray

AK202742 AB

Exhaust valve stem seal Colour: Grayish green

AK202875 AB

NOTE: Do not confuse the stem seals for intake valves with those for exhaust valves.

MD998735

>>B<< VALVE SPRING INSTALLATION

Painted end AK202873 AB

Compress the valve spring using the special tool Valve spring compressor (MD998772), then remove the retainer lock. NOTE: Store removed valves, springs and other parts, after putting to each of them a tag that identifies its cylinder No. or installation location.

Spring retainer

Stem seal Spring seat AK202551AB

Install each valve spring with the painted end toward the rocker arm.


ENGINE OVERHAUL

11B-38

CYLINDER HEAD AND VALVES

>>C<< RETAINER LOCK INSTALLATION MD998772

2. Apply engine oil to the threads and washer of the bolt. NOTE: Use the special tool Cylinder head bolt wrench (MB991654) to tighten the bolts. Timing belt side

8

6

1

3

10

4

2

5

9

AK202742 AB

MD998735

7 AK202806 AB

3. Tighten the bolts to 78 – 2 N¼m in the indicated sequence. 4. Loosen all the bolts completely. 5. Tighten the bolts again to a torque of 20 – 2 N¼m in the indicated sequence. AK202873 AB

Compress the valve spring using the special tool Valve spring compressor (MD998772), then install the retainer lock.

90˚

>>D<< CYLINDER HEAD BOLT INSTALLATION 90˚

Paint marks AK202720 AB

CAUTION

Nominal length

AK202750 AB

MB991654

œ If the tightening angle is smaller than 90•, proper fastening performance could not be assured. Be sure to respect that angle. œ If the bolt is tightened to an angle greater than the specified angle, loosen the bolt completely and then retighten it beginning with the first step. 6. Make paint marks on each bolt’s head and on the cylinder head. 7. Turn the bolts 90• in the tightening direction and in the indicated sequence. 8. Give another 90• turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the cylinder head are on the same line.

AK202723 AB

1. When reusing a cylinder head bolt, check that its nominal length (shank length) is not greater than the limit. If the limit is exceeded, replace the bolt. Limit: 99.4 mm

INSPECTION M1113007000378

CYLINDER HEAD 1. Before cleaning the cylinder head, check it for traces of water and gas leakage and for cracks and any other damage.


ENGINE OVERHAUL

11B-39

CYLINDER HEAD AND VALVES

2. Thoroughly remove oils, scale, sealants, carbon and other contamination. Clean the oil passages, then check using compressed air that they are not blocked.

Standard values: Intake 1.0 mm Exhaust 1.5 mm Limits: Intake 0.5 mm Exhaust 1.0 mm

AK202724

Total length

CAUTION The thickness of the metal that can be removed by grinding from both the cylinder head and the mating cylinder block is limited to 0.2 mm in total. 3. Check the cylinder head gasket surface for warp using a straightedge and thickness gauge. If the surface is warped beyond the limit, grind the surface for rectification. Gasket surface warp Standard value: Less than 0.05 mm Limit: 0.2 mm Grinding limit: 0.2 mm Cylinder head height (standard value for new part): 131.9 - 132.1 mm VALVES 1. Check the valve face for correct contact with the seat. Reface the valve if the contact is partial or one sided.

AK202876 AB

3. Measure the total length of the valve. Replace the valve if the length is less than the limit. Standard values: Intake 109.50 mm Exhaust 109.70 mm Limits: Intake 109.00 mm Exhaust 109.20 mm VALVE SPRINGS Out of square

Free height

AK202706 AB

Contact (Should be at center of face) Margin

AK202729 AB

2. Measure the margin. Replace the valve if its margin is smaller than the limit.

1. Measure the free height of the spring. Replace the spring if its height is smaller than the limit. Standard value: 47.0 mm Limit: 46.0 mm 2. Measure the squareness of the spring. Replace the spring if it is out of square beyond the limit. Standard value: 1.5Â&#x2022; or smaller Limit: 4Â&#x2022;


ENGINE OVERHAUL

11B-40

CYLINDER HEAD AND VALVES

VALVE GUIDE

With the valve installed in position and its face pressed against the valve seat, measure the valve stem projection (distance between the the valve stem end and spring seating surface). If the measurement exceeds the limit, replace the valve seat. Standard values: Intake 49.20 mm Exhaust 48.40 mm

valve guide

Stem diameter Guide inside diameter

AK202709 AB

Measure the valve guide inside diameter and valve stem diameter to calculate the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Standard values: Intake 0.02 - 0.05 mm Exhaust 0.05 - 0.09 mm

Limits: Intake 49.70 mm Exhaust 48.90 mm

VALVE SEAT RECONDITIONING 1. Before reconditioning the valve seat, check the clearance between the valve guide and valve stem and, if necessary, replace the valve guide. 0.9 – 1.3 mm

0.9 – 1.3mm

65˚

65˚

Limits: Intake 0.10 mm Exhaust 0.15 mm

25˚

15˚

VALVE SEATS

44˚ Valve stem end Valve stem projection Spring seating surface

AK202814 AB

AK202850 AB

2. Resurface the valve seat to the indicated width and angles. 3. After resurfacing, lap the valve and valve seat using lapping compound.


ENGINE OVERHAUL

11B-41

CYLINDER HEAD AND VALVES

VALVE SEAT REPLACEMENT

4. Resurface the valve seat. See the VALVE SEAT RECONDITIONING section.

0.5 – 1 mm

VALVE GUIDE REPLACEMENT 1. Force out the valve guide toward the cylinder block using a press. Cut

CAUTION 0.5 – 1 mm

AK202707 AB

1. Cut inside of the valve seat to be replaced until its wall becomes thin enough for removal, then remove the valve seat.

Do not use a replacement valve guide of the same size as the removed one. 2. Machine the valve guide hole in the cylinder head to the size matched to the selected oversize valve guide. Valve guide hole diameters 0.05 oversize: 12.05 - 12.07 mm 0.25 oversize: 12.25 - 12.27 mm 0.50 oversize: 12.50 - 12.52 mm

Valve seat height

Oversize hole diameter AK202708 AB

2. Rebore the valve seat hole in the cylinder head to a diameter matched to the diameter of the selected oversize valve seat. Intake valve seat hole diameters: 0.3 oversize: 35.30 - 35.33 mm 0.6 oversize: 35.60 - 35.63 mm Exhaust valve seat hole diameters: 0.3 oversize: 33.30 - 33.33 mm 0.6 oversize: 33.60 - 33.63 mm 3. Before fitting the valve seat, cool it in liquid nitrogen to prevent damage to its hole in the cylinder head due to interference.

19.2 – 19.8 mm AK202877 AB

3. Press-fit the valve guide until it remains protruded above the cylinder head by the amount indicated in the drawing. NOTE: . 1. Press the valve guide from above the cylinder head. 2. The valve guides for the intake valves are different in length from those for the exhaust valves (45.5 mm for intake valves; 50.5 mm for exhaust valves) 4. After installing the valve guide, insert a new valve in it to check for smooth movement.


ENGINE OVERHAUL

11B-42

OIL PAN AND OIL PUMP

OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION M1113008100301

19 ± 3 N·m

10

Apply engine oil to all moving parts before installtion.

32 31

28

30

21 23 ± 3 N·m 10 ± 2 N·m

23 ± 3 N·m

29

22

20

23 24

8

16

19 ± 3 N·m

9

7

19 ± 3 N·m

26

15

17 ± 1 N·m

25 19

14 13

27

17 18

9.0 ± 3.0 N·m

36 ± 3 N·m

11 3

4

23 ± 3 N·m

23 ± 3 N·m

1

39 ± 5 N·m

12

2 44 ± 5 N·m

5

6

9.0 ± 3.0 N·m 39 ± 5 N·m

9.0 ± 3.0 N·m

22 ± 4 N·m

2

1 9.0 ± 3.0 N·m

AK202676 AB

9.0 ± 3.0 N·m

>>O<< >>N<< <<A>> <<B>> <<C>>

>>M<< >>L<< >>L<<

Removal steps 1. Drain plug 2. Drain plug gasket 3. Oil filter 4. Transmission stay <4WD> 5. Oil pan <2WD> 6. Oil pan lower section <4WD> 7. Oil pan upper section <4WD> 8. Oil screen 9. Gasket 10.Oil pressure switch

>>K<<

<<D>>

>>J<<

<<E>>

>>I<< >>H<<

Removal steps &RQWLQXHG

11.Relief plug 12.Gasket 13.Relief spring 14.Relief plunger 15.Oil filter bracket 16.Gasket 17.Plug 18.O-ring 19.Flange bolt 20.Front case


ENGINE OVERHAUL

11B-43

OIL PAN AND OIL PUMP

>>G<< >>G<< >>F<< >>E<< >>D<< <<F>> >>C<< <<G>> >>B<< <<G>> >>A<<

Removal steps &RQWLQXHG

21.Gasket 22.Oil pump cover 23.Oil pump driven gear 24.Oil pump drive gear 25.Crankshaft front oil seal 26.Counterbalancer shaft oil seal 27.Oil pump oil seal 28.Counterbalancer shaft, right 29.Counterbalancer shaft, left 30.Counterbalancer shaft front bearing 31.Counterbalancer shaft rear bearing, right 32.Counterbalancer shaft rear bearing, left

REMOVAL SERVICE POINTS <<A>> OIL PAN REMOVAL <2WD>

<<C>> OIL PAN UPPER SECTION REMOVAL <4WD> A

A

AK202692 AB

Screw bolts into the bolt holes A shown in the drawing (holes at both ends) to remove the oil pan.

CAUTION Do not use a scraper or the special tool to remove the oil pan.

MD998727

<<D>> PLUG REMOVAL MD998162

AK202574 AB

1. Remove the oil pan bolts. 2. Insert the special tool Oil pen remover (MD998727) into the joint between the cylinder block and oil pan by tapping the tool with a hammer. 3. Remove the oil pan by tapping an edge of the special tool Oil pen remover (MD998727) with a hammer to move it sideways. <<B>> OIL PAN LOWER SECTION REMOVAL <4WD> Remove the oil pan by tapping it through a piece of wood applied to a side with a plastic hammer.

MD998783 AK202585 AB

Fit the teeth of the special tool in notches of the plug as shown in the drawing and support the tool with the special tool to loosen the plug. œ Plug wrench (MD998162) œ Plug wrench retainer (MD998783) <<E>> FLANGE BOLT REMOVAL

CAUTION Do not use a scraper or the special tool to remove the oil pan. Plug

Crosspoint screwdriver AK202586 AB

1. Remove the plug on the left side of the cylinder block. Insert a cross point screwdriver (shank diameter 8 mm) into the plug hole more than 60 mm to prevent the left counterbalancer shaft from rotating.


ENGINE OVERHAUL

11B-44

OIL PAN AND OIL PUMP

2. When removing the rear bearing of the left counterbalancer shaft, install the special tool Silent shaft bearing installer stopper (MB991603) on the front of the cylinder block and use a special tool Silent shaft bearing puller (MD998372) to pull out the bearing.

INSTALLATION SERVICE POINTS AK202642

2. Loosen and remove the flange bolt.

>>A<< LEFT COUNTERBALANCER SHAFT REAR BEARING INSTALLATION MB991603

<<F>> COUNTERBALANCER SHAFT FRONT BEARING REMOVAL

MD998705 AK202548 AB

Front bearing

1. Install the special tool Silent shaft bearing installer stopper (MB991603) on the cylinder block.

MD998371 AK202633 AB

MB991603

CAUTION Remove the front bearing first. Otherwise, the special tool cannot be used. Use the special tool Silent shaft bearing puller (MD998371) to remove the counterbalancer shaft front bearing from the cylinder block. <<G>> COUNTERBALANCER SHAFT REAR BEARING REMOVAL 1. Use the special tool Silent shaft bearing puller (MD998371) to remove the counterbalancer shaft rear bearings from the cylinder block. MB991603

MD998372

AK202634 AB

MD998705

Rear bearing AK202635 AB

2. Set the rear bearing on the special tool Silent shaft bearing installer (MD998705). NOTE: The left counterbalancer shaft rear bearing has no oil hole. 3. Force the rear bearing into the cylinder block by sticking the special tool.


ENGINE OVERHAUL

11B-45

OIL PAN AND OIL PUMP

>>B<< RIGHT COUNTERBALANCER SHAFT REAR BEARING INSTALLATION

MD998705

Guide pin AK202581 AB

AK202579 AB

1. Install the guide pin on the cylinder block.

>>C<< COUNTERBALANCER SHAFT FRONT BEARING INSTALLATION

Rear bearing (Right) Ratchet ball

Oil hole

Tool element for rear bearing installation AK202582 AB

AK202549 AB

2. Set the bearing on the special tool Silent shaft bearing installer (MD998705) with its oil hole on the ratchet ball.

1. Detach from the special tool Silent shaft bearing installer (MD998705) its element for rear bearing installation.

MD998705

Guide pin Guide pin AK202579 AB

AK202580 AB

3. Insert the special tool Silent shaft bearing installer (MD998705) while passing the guide pin through its hole and force the bearing into position by striking the tool.

2. Install the guide pin on the cylinder block. Front bearing Ratchet ball

Oil hole

AK202549 AC

3. Set the bearing on the special tool Silent shaft bearing installer (MD998705) with its oil hole on the ratchet ball.


ENGINE OVERHAUL

11B-46

OIL PAN AND OIL PUMP

>>E<< COUNTERBALANCER SHAFT OIL SEAL INSTALLATION MD998705 Socket wrench

Oil seal

Front case

Guide pin AK202580 AB

4. Insert the special tool Silent shaft bearing installer (MD998705) into the cylinder block while passing the guide pin through its hole and force the bearing into position by striking the tool.

AK202646 AB

Use an appropriate socket wrench to install the counterbalancer shaft oil seal. >>F<< CRANKSHAFT OIL SEAL INSTALLATION

MD998375 Oil seal Front case AK202583AB

>>D<< OIL PUMP OIL SEAL INSTALLATION

Oil seal

Socket wrench

AK202645 AB

Use the special tool Crankshaft front oil seal installer (MD998375) to install the crankshaft oil seal. >>G<< OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR INSTALLATION

Front case Alignment marks AK202639 AB

Use an appropriate socket wrench to install the oil pump oil seal. AK202660 AB

Apply engine oil generously to the gears and line up the alignment marks.


ENGINE OVERHAUL

11B-47

OIL PAN AND OIL PUMP

>>H<< FRONT CASE INSTALLATION Counterbalancer shaft, left

MD998285

1. Insert a correspond screwdriver (shank diameter 8 mm) into the hole in the left side of the cylinder block to prevent the counterbalancer shaft from rotating.

Counterbalancer shaft, right

AK202577 AB

1. Install the special tool crankshaft front oil seal guide (MD998258) on the front end of crankshaft and apply a thin coat of engine oil to the outer surface of the special tool. Be sure to use the special tool when the front case is fitted with an oil seal. 2. Install the front case on the cylinder block with a new front case gasket in between and temporarily tighten all the flange bolts except those that are used for tightening the filter bracket. 3. Install the oil filter bracket on the front case with the oil filter bracket gasket in between and temporarily tighten the washer-assembled bolts.

AK202642

2. Tighten the flange bolts. >>J<< PLUG INSTALLATION 1. Install a new O-ring on the front case. MD998162

MD998783 AK202585 AB

2. Use the special tool to tighten the plug to the specified torque. œ Plug wrench (MD998162) œ Plug wrench retainer (MD998783)

MD998285

AK202656 AB

4. Tighten all the bolts to the specified torques.

>>K<< OIL PRESSURE SWITCH INSTALLATION

>>I<< FLANGE BOLT INSTALLATION

AK202625AB

Crosspoint screwdriver

CAUTION AK202641 AB

Be careful not to block the oil passage with sealant. 1. Apply sealant to the threaded portion. Specified Sealant: 3M ATD Part No.8660 or equivalent


ENGINE OVERHAUL

11B-48

OIL PAN AND OIL PUMP

Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

MD998054

M6 × 16 AK204037AD

2. Tighten the oil pressure switch together with the cylinder block by the specified torque using of the special tool Oil pressure switch wrench MD998054. Tightening torque: 19 – 3 N¼m >>L<< OIL PAN UPPER SECTION/OIL PAN LOWER SECTION INSTALLATION <4WD>

CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. 1. Clean the gasket surfaces of the cylinder block and oil pan. Timing belt side

AK202685 AB

3. Install the shorter bolts in the locations indicated in the drawing.

CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. 4. Thoroughly remove old FIPG from the gasket surfaces of the oil pan upper and lower sections. Timing belt side

Bolt hole area

Grooved area

Bolt hole area

Grooved area AK202688 AB

CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage. 2. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan.

AK202686 AB

CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage.


ENGINE OVERHAUL

11B-49

OIL PAN AND OIL PUMP

5. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

Timing belt side M6 × 8

Timing belt side 9

Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

8 5

4

12

1 11

3 2

6

7

AK202693 AB

10 AK202687 AB

6. Install the oil pan lower section by tightening the bolts in the indicated sequence. >>M<< OIL PAN INSTALLATION <2WD>

3. Install the shorter bolts in the locations indicated in the drawing. >>N<< OIL FILTER INSTALLATION Bracket side

CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. 1. Thoroughly remove old FIPG from the gasket surfaces of the cylinder block and oil pan.

Engine oil

Timing belt side AK202556 AB

Bolt hole area

Grooved area AK202694 AB

CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage. 2. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan.

1. Clean the installation surface of the filter bracket. 2. Apply engine oil to the o-ring of the oil filter. 3. Install the oil filter to the bracket and tighten it to the specified torque. Tightening torque: 14 – 2 N¼m 4. If no torque wrench can be used for tightening, use the following procedure: (1) Screw in the oil filter until its o-ring contacts the oil filter bracket. (2) Tighten the oil filter 3/4 turn.


ENGINE OVERHAUL

11B-50

OIL PAN AND OIL PUMP

>>O<< DRAIN PLUG GASKET INSTALLATION Drain plug

AK202835AB

Oil pan Gasket

Oil pan side

2. Check the journals for seizure, damage and defective contact with bearings. If any of these faults is found, replace the counterbalance shaft, bearings and/or oil pump case assembly. OIL PUMP

AK202603AB

CAUTION Installing the gasket with the wrong side facing the oil pan will result in oil leakage. Replace the drain plug gasket with a new one. Install it with the side indicated in the drawing toward the oil pan.

INSPECTION M1113008200212

COUNTERBALANCE SHAFTS 1. Check that the oil holes are not blocked. Clean if necessary.

AK202831

1. Install the drive and driven gears in the oil pump case. 2. Measure the gear side clearance using a straight edge and thickness gauge. Standard values: Drive gear 0.08 - 0.14 mm Driven gear 0.06 - 0.12 mm


ENGINE OVERHAUL

11B-51

PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION M1113008400528

6 7 8

Apply engine oil to all moving parts before installation.

10 4

9 12 11

5

3 2 1

20 ± 2 N·m + 90˚ to 94˚

AK202896 AB

>>G<< <<A>> >>F<< >>E<< >>D<< >>C<<

1. 2. 3. 4. 5. 6.

Removal steps Connecting rod cap nut Connecting rod cap Connecting rod bearing Piston and connecting rod assembly Connecting rod bearing Piston ring No. 1

Removal steps &RQWLQXHG

>>C<< 7. Piston ring No. 2 >>B<< 8. Oil ring <<B>> >>A<< 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt


ENGINE OVERHAUL

11B-52

PISTON AND CONNECTING ROD

REMOVAL SERVICE POINTS <<A>> CONNECTING ROD CAP REMOVAL Push rod

Cylinder number

Front mark Front mark

Guide C

AK202812 AB

Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly.

Base

<<B>> PISTON PIN REMOVAL Guide A: 17.9 mm Push rod

Guide B AK202781 AB

Guide A: 18.9 mm

GuidE C Guide A: 20.9 mm Base

1. Insert the tool element, Push rod, into the piston from the front mark side, then attach the element, Guide C, to the push rod. 2. Place the piston and connecting rod assembly on the element, Base, with the front mark facing up. 3. Use a press to remove the piston pin. NOTE: Keep the disassembled pistons, piston pins and connecting rods cylinder by cylinder.

INSTALLATION SERVICE POINTS Guide A: 21.9 mm

>>A<< PISTON PIN INSTALLATION Timing belt side

Crankshaft bore size mark

AK202783 AB

No.4 No.3 No.2 No.1

The special tool Piston pin setting tool (MD998780), consists of the elements shown in the drawing.

AK202923 AB

1. When replacing a piston, check the cylinder bore size mark stamped at the indicated location on the cylinder block and select an appropriate replacement piston using the following table. Cylinder bore size mark

Piston size mark

I

A

II

No mark

III

C


ENGINE OVERHAUL

11B-53

PISTON AND CONNECTING ROD

NOTE: The piston size mark is located on the piston top surface.

D

C

3 mm + L

Guide B

Guide A AK202789 AB

Connecting rod Piston

B

8. Screw the tool element, Guide B, into the tool element, Guide A until the gap between both the elements is equal to the dimension L (obtained in step 3.) plus 3 mm.

Piston pin

A

Push rod Piston pin Front mark

AK202784 AB

2. Measure the following dimensions: A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width 3. Obtain dimension L from the measurements using the following formula. L = [(A-C) - (B-D)] Â? 2 4. Insert the tool element, Push rod, into the piston pin and attach the element, Guide A, to the push rod end. 5. Assemble the connecting rod with the piston with their front marks facing in the same direction. 6. Apply engine oil to the outside surface of the piston pin. 7. Insert the assembly of piston pin, Push rod, and Guide A (put together in step 4.) into the piston holes from the front mark side.

Front mark

Guide A Base

Guide B

AK202782 AB

9. Place the piston and connecting rod assembly onto the element, Piston setting base, with the front marks facing up. 10.Install the piston pin using a press. If the required press force is less than the standard value, replace the piston and piston pin assembly or the connecting rod, or both. Standard value: 7,350 - 17,100 N


ENGINE OVERHAUL

11B-54

PISTON AND CONNECTING ROD

>>B<< OIL RING INSTALLATION

>>C<< PISTON RING NO. 2/PISTON RING NO. 1 INSTALLATION

Lower side rail end gap

Upper side rail end gap

Piston ring expander Spacer end gap

AK202879 AB AK202786 AB

1. Fit the oil ring spacer into the piston ring groove. Install the upper side rail, then the lower side rail. NOTE: . 1. Locate the side rail and spacer end gaps as shown in the drawing. 2. New spacers and side rails are an identified by color marks as follows: Size

Color mark

Standard

Non mark

0.50 mm oversize

Blue

1.00 mm oversize

Yellow

Identification mark Size marks

No. 1 No. 2

AK202807 AB

CAUTION Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings. Side rail end

Using a piston ring expander, install the piston rings with their identification marks facing up (toward the piston crown). Identification marks: No. 1 ring 1R No. 2 ring 2R NOTE: Each of the available piston rings has a size mark as follows: Size

Size mark

Standard No. 1 ring No mark (blue paint on periphery) No. 2 ring No mark (green paint on periphery) AK202785 AB

2. To install each side rail, first fit one end of the rail into the piston groove, then press the remaining portion progressively into position by finger as shown in the drawing. 3. Make sure that the installed side rails move smoothly in either direction.

0.50 mm oversize

50

1.00 mm oversize

100

>>D<< PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION 1. Apply engine oil generously to the pistonâ&#x20AC;&#x2122;s outside surface, piston rings, and oil ring.


ENGINE OVERHAUL

11B-55

PISTON AND CONNECTING ROD Side rail No. 1

No. 2

2. Crankshaft pin diameter marks are stamped in the indicated locations.

Side rail AK202730 AB

2. Align the end gaps of the piston rings and oil ring (side rails and spacer) as shown in the drawing. 3. Insert the piston and connecting rod assembly from the top of cylinder with the front mark on the crown toward the camshaft sprocket.

AK202719AB

3. Connecting rod bearing identification mark is stamped in the indicated location on each bearing. Crankshaft pin

Connecting rod bearing

Identification Diameter mm mark

Identification mark

I

44.995 - 45.000 1

II

44.985 - 44.995 2

44.980 - 44.985 3 <Bearing selection example> If the crankshaft pin diameter mark is “I”, select a bearing marked “1”. If the crankshaft pin diameter mark is illegible, measure the pin diameter and select a bearing with the mark corresponding to the measurement. 4. Install the upper and lower halves of the selected bearing on the connecting rod big end and cap, respectively. III

AK202798

CAUTION

œ Do not strike the assembly with a large force. Doing so could break the piston rings. œ When striking the assembly into cylinder, do not allow it to interfere with the oil jet. 4. Use a piston ring band to hold the piston rings compressed when inserting the piston and connecting rod assembly into the cylinder.

>>F<< CONNECTING ROD CAP INSTALLATION >>E<< CONNECTING ROD BEARING INSTALLATION 1. When replacing the connecting rod bearing, select a bearing of the size appropriate for the crankshaft pin diameter in accordance with the crankshaft pin and connecting rod bearing matching table shown below. Locations of crankshaft pin diameter marks

Cylinder number

Bearing locating notches AK202813 AB

No. 1

No. 4

No. 2 No. 3

AK202909 AB

1. Install the bearing cap on the connecting rod while aligning the marks made during disassembly. If the connecting rod is new and has no alignment mark, assemble it with the cap such that the both bearing locating notches are on the same side as shown in the drawing.


ENGINE OVERHAUL

11B-56

PISTON AND CONNECTING ROD

CAUTION

œ If the tightening angle is less than 90•, adequate tightness could not be assured. œ If the tightening angle exceeds 94•, loosen the nut completely and then perform the tightening procedure again beginning with the first step. 7. Turn the nut 90• to 94• to bring the mark on the nut into alignment with that on the bolt. AK202821

2. Make sure that the thrust clearance of the connecting rod big end is proper. Standard value: 0.10 - 0.25 mm Limit: 0.4 mm >>G<< CONNECTING ROD CAP NUT INSTALLATION 1. The connecting rod cap bolts and nuts are tightened using the torque-to-yield method. For this reason, each bolt to be reused must be checked for elongation before installation. Whether or not the bolt has been elongated can be determined by running a nut with fingers through all the threads of the bolt. If the nut does not turn smoothly over all the threads, the bolt has been elongated and must be replaced. 2. Apply engine oil to the threads and bearing surface of each nut before installation. 3. Finger-tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the cap properly. 4. Tighten the nuts to a torque of 20 – 2 N¼m. 90˚ to 94˚

INSPECTION M1113008500365

PISTON RING

AK202787

1. Measure the clearance between each piston ring and its groove. If the limit is exceeded, replace the ring or piston, or both. Standard values: No. 1 ring: 0.03 - 0.07 mm No. 2 ring: 0.02 - 0.06 mm Limits: 0.1 mm Force ring down with piston

Paint marks

Paint marks

Piston ring Nut

Bolt

AK202721 AB

5. Make a paint mark on the head of each nut. 6. Make a paint mark on the bolt at a point 90•to 94• away from the paint mark made on the nut in the tightening direction.

End gap

AK202788 AB

2. Install a piston ring or oil ring side rail into the cylinder bore and force it down with the head of a piston until the ring is at right angles to the cylinder wall. Measure the end gap with a thickness gauge. NOTE: If the end gap is excessive, replace the piston ring. Standard values: No. 1 ring: 0.25 - 0.35 mm No. 2 ring: 0.40 - 0.55 mm Oil ring: 0.10 - 0.40 mm


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2001 mitsubishi airtrek service repair manual  
2001 mitsubishi airtrek service repair manual  
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