11E-1
GROUP 11E
ENGINE
MECHANICAL
<4G69>
CONTENTS
SERVICE SPECIFICATIONS. . . . . . .
11E-2
SEALANTS . . . . . . . . . . . . . . . . . . . .
11E-2
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11E-3
ON-VEHICLE SERVICE. . . . . . . . . . .
11E-7
DRIVE BELT TENSION CHECK. . . . . . . . .
11E-7
AUTO-TENSIONER CHECK . . . . . . . . . . .
11E-7
VALVE CLEARANCE CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
11E-10
ROCKER ARM PISTON OPERATION
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11E-11
IGNITION TIMING CHECK . . . . . . . . . . . . .
11E-12
IDLE SPEED CHECK . . . . . . . . . . . . . . . . .
11E-13
IDLE MIXTURE CHECK . . . . . . . . . . . . . . .
11E-14
COMPRESSION PRESSURE CHECK. . . .
11E-15
MANIFOLD VACUUM CHECK . . . . . . . . . .
11E-15
CRANKSHAFT PULLEY . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
CAMSHAFT AND VALVE STEM
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11E-18
REMOVAL AND INSTALLATION . . . . . . . .
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11E-23
REMOVAL AND INSTALLATION . . . . . . . .
11E-23
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11E-25
CRANKSHAFT OIL SEAL . . . . . . . . . 11E-26
REMOVAL AND INSTALLATION . . . . . . . .
11E-17
11E-17
11E-18
11E-26
CYLINDER HEAD GASKET . . . . . . . . 11E-30
REMOVAL AND INSTALLATION . . . . . . . .
11E-30
TIMING BELT . . . . . . . . . . . . . . . . . . . 11E-36
REMOVAL AND INSTALLATION . . . . . . . .
11E-36
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11E-45
ENGINE ASSEMBLY . . . . . . . . . . . . . 11E-46
REMOVAL AND INSTALLATION . . . . . . . .
11E-46
11E-2
ENGINE MECHANICAL <4G69>
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
M1112000300278
Item
Standard value
Limit
A/C compressor type:
MSC90CA
113 − 145
−
A/C compressor type:
MSC105CA
120 − 154
−
340 − 555
−
Intake valve
0.20
−
Exhaust valve
0.30
−
Basic ignition timing
5° BTDC ± 3°
−
Ignition timing
Approximately
10° BTDC
−
M/T
680 ± 100
−
A/T
750 ± 100
−
CO contents %
0.5 or less
−
HC contents ppm
100 or less
−
Compression pressure kPa-r/min
1,560 − 200
1,130 − 200
Compression pressure difference of all cylinders kPa
−
Maximum 98
Intake manifold vacuum kPa
−
Minimum 60
Cylinder head bolt nominal length mm
−
99.4
Balancer timing belt tension (When adjusted) Deflection mm
5−7
−
Balancer timing belt tension (When replaced) Deflection mm
5−7
−
Balancer timing belt tension (When checked)
5 − 10
−
Timing belt tensioner adjuster rod protrusion amount mm
3.8 − 4.5
−
Timing belt tensioner adjuster rod movement mm
Within 1
−
Drive belt tension
Vibration frequency Hz
(Reference)
Tension N (Reference)
Valve clearance (at hot) mm
Idle speed r/min
Deflection mm
SEALANTS
M1112000500294
Item
Specified sealant
Remark
Camshaft position sensor support
MITSUBISHI GENUINE PART MD970389 or
equivalent
Semi-drying
sealant
LOCTITE203MP
Anaerobic
sealant
Engine upper oil pan
Engine lower oil pan
Taper plug
11E-3
ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
SPECIAL TOOLS
M1112000601313
Tool
A
Number
Name
Use
MB992080
A: MB992081
B: MB992082
Belt tension meter set
A: Belt tension meter
B: Microphone assembly
Drive belt tension check
MB991502
M.U.T.-II sub assembly
• Drive belt tension check
• Checking the ignition timing
• Checking the idle speed
MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826
M.U.T.-III sub assembly
A: Vehicle communication
interface (V.C.I.)
B: M.U.T.-III USB cable
C: M.U.T.-III main harness A
(Vehicles with CAN
communication system)
D: M.U.T.-III main harness B
(Vehicles without CAN
communication system)
E: M.U.T.-III adapter harness
F: M.U.T.-III trigger harness
B
B992080
B991502
A
MB991824
B
MB991827
C
DO NOT USE
MB991910
D
MB991911
E
MB991825
F
MB991826
MB991955
CAUTION
If you connect M.U.T.-III main
harness A to a vehicle without
CAN communication system
to use the M.U.T.-III, a pulse
signal may interfere with the
simulated vehicle speed lines,
thus causing the M.U.T.-III
inoperative. Therefore, use
the M.U.T.-III main harness B
(MB991911) instead.
• Drive belt tension check
• Checking the ignition timing
• Checking the idle speed
11E-4
ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
Tool
Number
Name
Use
MB991668
Belt tension meter set
Drive belt tension check (used
together with M.U.T.-II or
M.U.T.-III)
MB990767
Front hub and flange yoke
holder
Holding the camshaft sprocket
MD998719
Pin
MD998772
Valve spring compressor
Compressing valve spring
MB991999
Valve stem seal installer
Valve stem seal installation
MD998713
Camshaft oil seal installer
Camshaft oil seal installation
MD998781
Flywheel stopper
• Supporting the flywheel
assembly <M/T>
• Supporting the A/T drive plate
<A/T>
B991668
B990767
D998719
MD998772
D998713
D998781
11E-5
ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
Tool
Number
Name
Use
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
MD998738
Adjusting bolt
Supporting the timing belt
tensioner arm and timing belt
tensioner adjuster
MB991654
Cylinder head bolt wrench
(12)
Removal and installation of
cylinder head bolt
MB991367
Special spanner
Holding the crankshaft camshaft
drive sprocket
MB991385
Pin
D998776
Crankshaft front oil seal
installation
D998285
D998738
B991654
B991367
B991385
11E-6
ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
Tool
Number
Name
Use
MD998767
Tensioner wrench
Valve timing belt tension
adjustment
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
D998767
B991454
B991527
Z203830
MB991928
A: MB991929
B: MB991930
E C: MB991931
D: MB991932
E: MB991933
F: MB991934
Slide bracket (HI)
F
A
D
B
C
B991928
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
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11E-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
FUNCTION CHECK
M1111003100548
CAUTION
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.
The auto-tensioner can be checked whether it is in
good condition by checking its tension.
When the vibration frequency is
measured (Belt tension meter set is
used): Recommendation
1. Check the drive belt tension (Refer to P.11E-7).
2. Measure the drive belt tension vibration frequency
by the following procedures:
Indicator mark
A
Belt tension meter set (MB992080)
MB992081
AC301702AB
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 P.11E-17).
NOTE: The drive belt tension check is not necessary as auto-tensioner is adopted.
AUTO-TENSIONER CHECK
M1111003000905
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 P.11E-17).
AC301703
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 P.11E-36).
5. Install the drive belt.(Refer to P.11E-17).
MB992082
AC507219AB
(1) Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
(MB992081) of special tool belt tension meter
set (MB992080).
(2) Press the "POWER" button to turn on the
power supply.
(3) Press the numeral key of "1" and check that
"No. 1" appears on the upper left of the
display.
NOTE: This operation is to temporarily set the
preset data such as the belt specifications,
because if the measurement is taken without
input of the belt specifications, conversion to
tension value (N) cannot be made, resulting in
judgement of error.
(4) Press "Hz" button twice to change the display
to the frequency display (Hz).
11E-8
•
•
•
•
•
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
CAUTION
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
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.
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.
Do not take the measurement while the vehicle's engine is running.
Standard value:
<A/C compressor type: MSC90CA> 113 − 145
Hz
<A/C compressor type: MSC105CA> 120 − 154
Hz
NOTE: To take the measurement repeatedly,
fillip the belt again.
(8) Press and hold the "POWER" button to turn off
the power supply.
3. If not within the standard value, replace the
auto-tensioner (Refer to P.11E-36).
When the vibration frequency is
measured (M.U.T.-II is used):
Recommendation
1. Check the drive belt tension. (Refer to P.11E-7).
2. Measure the drive belt tension vibration frequency
by the following procedures:
CAUTION
Water
pump
pulley
MB992080
15
10
15 mm
15
16-pin
Gently tap
with your
finger
MUT-II
Alternator
pulley
AC301266AE
(5) Hold special tool MB992080 to the middle of
the belt between the pulleys (at the place
indicated by arrow) where it does not contact
the belt (approximately 10 − 15 mm away from
the rear surface of the belt) so that it is
perpendicular to the belt (within an angle of ±
15°).
(6) Press the "MEASURE" button.
(7) 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
check that the vibration frequency of the belt is
within the standard value.
MB991668
AC211862 AB
To prevent damage to M.U.T.-II, always turn the
ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting M.U.T.-II.
(1) Connect special tool belt tension meter set
(MB991668) to the M.U.T.-II.
(2) Connect the M.U.T.-II to the diagnosis
connector.
(3) Turn the ignition switch to "ON" position, and
select "BELT TENSION" on the menu screen.
11E-9
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
•
•
•
•
•
CAUTION
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
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.
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.
Do not take the measurement while the vehicle's engine is running.
Standard value:
<A/C compressor type: MSC90CA> 113 − 145
Hz
<A/C compressor type: MSC105CA> 120 − 154
Hz
3. If not within the standard value, replace the
auto-tensioner. (Refer to P.11E-36).
When the vibration frequency is
measured (V.C.I. is used):
Recommendation
1. Check the drive belt tension. (Refer to P.11E-7).
2. Measure the drive belt tension vibration frequency
by the following procedures:
CAUTION
16-pin
Water
pump
pulley
MB991668
15˚
10 – 20 mm
15˚
MB991824
Gentry tap
with your
finger
MB991668
Alternator
pulley
MB991911
AC211863AB
AC301266AB
(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.
To prevent damage to special tool V.C.I.
(MB991824), always turn the ignition switch to
the "LOCK" (OFF) position before connecting or
disconnecting special tool V.C.I. (MB991824).
(1) Connect special tool belt tension meter set
(MB991668) to special tool V.C.I. (MB991824).
(2) Connect special tool M.U.T.-III main harness B
(MB991911) to special tool V.C.I. (MB991824).
(3) Connect special tool M.U.T.-III main harness B
(MB991911) to the diagnosis connector.
(4) Turn the ignition switch to "ON" position, and
select "Belt Tension" on the menu screen.
11E-10
•
•
•
•
•
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
CAUTION
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
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.
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.
Do not take the measurement while the vehicle's engine is running.
Water
pump
pulley
Standard value:
<A/C compressor type: MSC90CA> 113 − 145
Hz
<A/C compressor type: MSC105CA> 120 − 154
Hz
3. If not within the standard value, replace the
alternator drive belt auto tensioner. (Refer to
P.11E-36).
When the tension is measured
1. Check the drive belt tension. (Refer to P.11E-7).
Water pump
pulley
Belt tension
gauge
MB991668
15˚
10 – 20 mm
15˚
Alternator
pulley
Gentry tap
with your
finger
AC301267AB
Alternator
pulley
AC301266AB
(5) 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).
(6) 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.
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: 340 − 555 N
3. If not within the standard value, replace the
auto-tensioner. (Refer to P.11E-36).
VALVE CLEARANCE CHECK AND
ADJUSTMENT
M1111001500131
1. Start the engine and allow it to warm up until the
engine coolant temperature reaches 80 − 95°C.
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Remove all ignition coils.
4. Remove all spark plugs from the cylinder head for
easy inspection.
5. Remove the rocker cover.
11E-11
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
6. Turn the crankshaft clockwise until the notch on
the pulley is lined up with the "T" mark on the
timing indicator.
7. Move the rocker arms on the No.1 and No.4
cylinders up and down by hand to determine
which cylinder has its piston at the top dead
center on the compression stroke. If both intake
and exhaust valve rocker arms have a valve lash,
the piston in the cylinder corresponding to these
rocker arms is at the top dead center on the
compression stroke.
14.Install the spark plugs and tighten to the specified
torque.
Tightening torque: 25 ± 4 N⋅m
15.Install the ignition coils.
ROCKER ARM PISTON OPERATION
CHECK
M1111051000023
Taper plug
Oil control valve
Intake valve side
Ignition coils
Rocker cover
No. 2 No. 3
No. 1
Exhaust valve side
No. 4
AK303689 AB
8. Valve clearance inspection and adjustment can be
performed on rocker arms indicated by white
arrow mark when the No.1 cylinder piston is at the
top dead centre on the compression stroke, and
on rocker arms indicated by black arrow mark
when the No.4 cylinder piston is at the top dead
centre on the compression stroke.
9. Measure the valve clearance.
If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance
using a thickness gauge while turning the
adjusting screw.
Standard value (hot engine):
Intake valve: 0.20 mm
Exhaust valve: 0.30 mm
10.While holding the adjusting screw with a
screwdriver to prevent it from turning, tighten the
lock nut to the specified torque.
Tightening torque: 9 ± 1 N⋅m
11.Turn the crankshaft through 360° to line up the
notch on the crankshaft pulley with the "T" mark
on the timing indicator.
12.Repeat steps (9) and (10) on other valves for
clearance adjustment.
13.Install the rocker cover.
AK304505AB
1.
2.
3.
4.
5.
Remove all of the ignition coils.
Remove the rocker cover.
Remove the oil control valve.
Remove the taper plug.
Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt.
6. Move the rocker arms on the No.1 and No.4
cylinders up and down by hand to determine
which cylinder has its piston at the top dead
centre on the compression stroke.
NOTE:
Intake valve side
No. 1
No. 2
No. 3
No. 4
Exhaust valve side
AK303689 AC
The rocker arm piston operation check can be performed on rocker arms indicated by white arrow mark
when the No.1 cylinder piston is at the top dead centre on the compression stroke, and on rocker arms
indicated by black arrow mark when the No.4 cylinder piston is at the top dead centre on the compression stroke.
11E-12
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
IGNITION TIMING CHECK
Rocker arm
M1111001700997
Rocker arm
piston
Oil passage
Blow
compression
air
AK302684AC
7. While shutting up the oil passage hole at the
depth of the oil control valve's installation hole by
finger not to leak air, blow compression air into the
taper plug's installation hole by air blowgun. At
this time, confirm that the rocker arm piston can
operate.
NOTE: To fully confirm the check, prevent the compression air from leaking as much as possible by
installing the O-ring to the end of air blowgun.
8. Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt.
9. Confirm the rest of the rocker arm pistons under
the procedure 7.
10.When the rocker arm piston does not operate,
replace the rocker arm assy.
11.Apply sealant to threaded portion.
Specified sealant: LOCTITE203MP
CAUTION
Do not start the engine within one hour after the
engine taper plug has been installed.
12.Install the taper plug and tighten to the specified
torque.
Tightening torque: 10 ± 2 N⋅m
13.Install the oil control valve. (Refer to Camshaft
and Valve Stem Seal − Removal and Installation
P.11E-18.)
14.Install all of the ignition coils.
15.Install the rocker cover.
16 PIN
MB991502
AK303691AF
16-PIN
MB991911
MB991824
MB991827
AK303690AB
1. Before inspection, set the vehicle to the
pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the M.U.T.-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Use the M.U.T.-II/III to measure engine idle speed
and check that it is within the standard value.
Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
6. Select No. 17 of the M.U.T.-II/III Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5° BTDC ± 3°
11E-13
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to P.13C-21,
GROUP 13C − Troubleshooting − Inspection chart
for diagnosis code).
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 M.U.T.-II/III 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: .
• The ignition timing may fluctuate within ± 7°
BTDC. This is normal.
• In higher altitude, the ignition timing is more
advanced than the standard value by approximately 5°.
11.Remove the timing light.
12.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III.
IDLE SPEED CHECK
M1111003500911
16 PIN
MB991502
AK303691AF
16-PIN
MB991911
MB991824
MB991827
AK303690AB
1. Before inspection, set the vehicle to the
pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the M.U.T.-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Check that ignition timing is at the standard value.
Standard value: approximately 10° BTDC
6. Check the idle speed.
Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
NOTE: .
• The idle speed is controlled automatically by
the idle speed control system.
• When using the M.U.T.-II/III, select item No. 22
and take a reading of the idle speed.
11E-14
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
7. If the idle speed is outside the standard value,
inspect the MPI system (Refer to P.13C-21,
GROUP 13C − Troubleshooting − Inspection chart
for diagnosis code).
8. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III.
IDLE MIXTURE CHECK
M1111002100426
16 PIN
MB991502
AK303691AF
16-PIN
MB991911
MB991824
MB991827
AK303690AB
1. Before inspection, set the vehicle to the
pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the M.U.T.-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Check that ignition timing is at the standard value.
Standard value: approximately 10° BTDC
6. Run the engine at 2,500 r/min for 2 minutes.
7. Set the CO, HC tester.
8. Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
9. If there is a deviation from the standard value,
check the following items:
• Diagnosis output
• Fuel pressure
• Injector
• Ignition coil, 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.
10.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III.
11E-15
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
COMPRESSION PRESSURE CHECK
M1111002600636
Crank angle
sensor
connector
AK303421AB
1. Before inspection, set the vehicle to the
pre-inspection condition.
2. Remove all of the ignition coils and spark plugs.
3. 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.
CAUTION
• Keep away from the spark plug hole when
cranking.
• 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.
4. 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.
5. Set compression gauge to one of the spark plug
holes.
6. Crank the engine with the throttle valve fully open
and measure the compression pressure.
Standard value (at engine speed of 200
r/min):
1,560 kPa
(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.
9. Connect the crank angle sensor connector.
10.Install the spark plugs and tighten to the specified
torque.
Tightening torque: 25 ± 4 N⋅m
11.Install the ignition coils.
12.Use the M.U.T.-II/III to erase the diagnosis codes.
NOTE: This will erase the diagnosis code resulting from the crank angle sensor connector being
disconnected.
MANIFOLD VACUUM CHECK
M1111002700569
16 PIN
MB991502
AK303691AF
16-PIN
Limit (at engine speed of 200 r/min):
Minimum 1130 kPa
7. 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
8. 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 (5) to (7).
MB991911
MB991824
MB991827
AK303690AB
1. Before inspection, set the vehicle to the
pre-inspection condition.
11E-16
ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the M.U.T.-II/III to the
diagnosis connector.
Ventilation hose
PCV valve
4. Plug the PCV valve.
5. Start the engine and check that idle speed is
within the standard valve.
Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
Plug
Vacuum gauge
AK303422 AB
3. Disconnect the ventilation hose from the PCV
valve, and connect a vacuum gauge to the
ventilation hose.
7. Turn off the ignition switch.
8. Remove the vacuum gauge and then connect the
ventilation hose.
9. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III.
ENGINE MECHANICAL <4G69>
CRANKSHAFT PULLEY
11E-17
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600539
Pre-removal Operation
• Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-31).
1
Post-installation Operation
• Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
2
25 ± 4 N·m
AC308973AB
<<A>>
1.
2.
Removal steps
Drive belt
Crank shaft damper pulley
REMOVAL SERVICE POINT
<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the
introduction of the serpentine drive system with the
drive belt auto-tensioner.
Auto-tensioner
1. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc.
AC301703
Auto-tensioner
Hole B
Hole A
AC301704AB
L-shaped
hexagon
wrench
AC301705AB
3. Insert an L-shaped hexagon wrench, etc. into the
hole to fix and then remove the drive belt.
11E-18
ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
CAMSHAFT AND VALVE STEM SEAL
REMOVAL AND INSTALLATION
M1112006600501
CAUTION
* Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-8).
• Ignition Coils Removal (Refer to GROUP 16, Ignition System − Ignition Coil P.16-47).
• Timing Belt Upper Cover Removal (Refer to P.11E-36).
Post-installation Operation
• Timing Belt Upper Cover Installation (Refer to P.11E-36).
• Ignition Coils Installation (Refer to GROUP 16, Ignition
System − Ignition Coil P.16-47).
• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-8).
• Drive Belt Tension Check (Refer to P.11E-7).
• Valve Clearance Check and Adjustment (Refer to
P.11E-10).
2
3.5 ± 0.5 N·m
1
7
N8
4
9.0 ± 2.0 N·m
N
9
11 ± 1 N·m
24 ± 3 N·m
3
5
6N
(Engine oil)
44 ± 5 N·m
10
AC308974 AB
1.
2.
>>J<<
>>J<<
3.
4.
5.
6.
Camshaft removal steps
Rocker cover PCV hose connection
Rocker cover breather hose
connection
Control wiring harness connection
Engine hanger
Oil control valve
O-ring
7.
8.
9.
10.
•
Camshaft removal steps
Rocker cover assembly
Rocker cover gasket
Spark plug guide oil seals
Accumulator assembly
Valve timing belt (Refer to
P.11E-36).
11E-19
ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
Apply engine oil to all
moving parts before
installation.
31 ± 3 N·m
11
13 ± 1 N·m
11 ± 1 N·m
18
12
19
47 ± 7 N·m
21
22
16
14 ± 1 N·m
25 ± 4 N·m
22 ± 4 N·m
23
13
24*
25*
26*
N 28*
29*
17
20
24*
25*
27*
28* N
29*
89 ± 9 N·m
15 N
14
>>I<<
<<A>>
<<B>>
<<B>>
>>H<<
>>G<<
>>F<<
>>F<<
>>E<<
>>E<<
>>D<<
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
•
21.
22.
Camshaft removal steps
Connector bracket
Camshaft position sensor support
Camshaft position sensing cylinder
Camshaft sprocket
Camshaft oil seal
Exhaust rocker arm shaft caps
Exhaust rocker arm and shaft
assembly
Inlet rocker arm shaft caps
Inlet rocker arm and shaft assembly <<B>>
Camshaft
Water inlet fitting and thermostat
<<B>>
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
<<C>>
P.14-32).
Cylinder head plug
Oil control valve filter
AC308975AB
1.
2.
>>F<<
>>F<<
>>E<<
>>E<<
>>C<<
>>B<<
>>B<<
>>A<<
3.
4.
7.
8.
9.
16.
17.
18.
19.
23.
24.
25.
26.
27.
28.
29.
Valve stem seal removal steps
Rocker cover PCV hose connection
Rocker cover breather hose
connection
Control wiring harness connection
Engine hanger
Rocker cover assembly
Rocker cover gasket
Spark plug guide oil seals
Exhaust rocker arm shaft caps
Exhaust rocker arm and shaft
assembly
Inlet rocker arm shaft caps
Inlet rocker arm and shaft assembly
Spark plugs
Valve spring retainer locks
Valve spring retainers
Inlet valve springs
Exhaust valve springs
Valve stem seals
Valve spring seats
11E-20
ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
REMOVAL SERVICE POINTS
<<A>> CAMSHAFT SPROCKET
REMOVAL
INSTALLATION SERVICE POINTS
>>A<< VALVE STEM SEALS INSTALLATION
1. Apply a small amount of engine oil to the valve
stem seals.
MB990767
CAUTION
• Do not re-use the valve stem seal.
• Special tool valve stem seal installer
(MB991999) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
MD998719
AC102532AB
1. Use the following special tools to hold the
camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719)
2. Loosen the camshaft sprocket mounting bolt and
remove the camshaft sprocket.
<<B>> EXHAUST ROCKER ARM AND
SHAFT ASSEMBLY/INLET ROCKER ARM
AND SHAFT ASSEMBLY REMOVAL
CAUTION
Never disassemble the exhaust rocker arm and
shaft assembly, and inlet rocker arm and shaft
assembly.
MB991999
Valve
Valve stem
seal
Valve guide
AC308654AC
2. Use the special tool to fill a new valve stem seal in
the valve guide using the valve stem area as a
guide.
>>B<< EXHAUST VALVE SPRINGS/INLET
VALVE SPRINGS INSTALLATION
Rocker arm side
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL
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.
Identification
colour
Inlet side:
Light blue
Exhaust side:
Orange
AC107415AC
Install the valve springs with its identification colour
painted end facing the locker arm.
MD998772
AC301867AB
Use special tool valve spring compressor
(MD998772) to compress the valve spring and then
remove the valve spring retainer lock.
11E-21
ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
>>C<< VALVE SPRING RETAINER LOCKS
INSTALLATION
>>F<< EXHAUST ROCKER ARM AND
SHAFT ASSEMBLY/EXHAUST ROCKER
ARM SHAFT CAPS INSTALLATION
Engine front
MD998772
AC301867AB
Use special tool valve spring compressor
(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same manner as removal.
>>D<< CAMSHAFT INSTALLATION
Dowel pin
Notch
AC301870AB
1. Install the exhaust rocker shaft so that its notch is
positioned as shown.
2. Install the exhaust rocker arm shaft caps.
3. Tighten the exhaust rocker shaft mounting bolts to
the specified torque.
Tightening torque: 13 ± 1 N⋅m
>>G<< CAMSHAFT OIL SEAL
INSTALLATION
Camshaft oil seal
AC301868AB
Set the dowel pin of the camshaft in the position
shown in the figure.
>>E<< INLET ROCKER ARM AND SHAFT
ASSEMBLY/INLET ROCKER ARM SHAFT
CAPS INSTALLATION
Engine front
φ 5.5 mm
AC301869AB
1. Place the inlet rocker shaft so that its 5.5 mm hole
faces toward the cylinder head.
2. Install the inlet rocker arm shaft caps.
3. Tighten the inlet rocker shaft mounting bolts to the
specified torque.
Tightening torque: 31 ± 3 N⋅m
(Engine oil)
MD998713
AC102323AC
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 seal as shown.
11E-22
ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
>>H<< CAMSHAFT SPROCKET
INSTALLATION
NOTE: Install the camshaft position sensor support within 15 minutes after applying the sealant.
3. Install the camshaft position sensor support to the
cylinder head.
CAUTION
Wait at least one hour. Never start the engine or
let engine oil or coolant touch the adhesion surface during that time.
MB990767
4. Tighten the camshaft position sensor support
mounting bolts to the specified torque.
Tightening torque: 14 ± 1 N⋅m
MD998719
AC102532AB
1. Use the following special tool as during removal to
hold the camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
the specified torque.
Tightening torque: 89 ± 9 N⋅m
>>J<< O-RING/OIL CONTROL VALVE
INSTALLATION
CAUTION
• Never re-use the O-ring.
•
Tape
>>I<< CAMSHAFT POSITION SENSOR
SUPPORT INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.
AK303651AD
Before installing O-ring, wind the tape with the
soft adhesion (sealing tape) around the oil
passages cut-out area of engine oil control
valve to prevent the damage. If the O-ring is
damaged, it can be the cause of oil leak.
φ 3 mm
AC301268AB
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
1. Apply a small amount of engine oil to the O-ring
and then install it to the oil control valve.
2. Assemble the oil control valve to the cylinder
head.
3. Tighten the oil control valve mounting bolt to the
specified torque.
Tightening torque: 11 ± 1 N⋅m
11E-23
ENGINE MECHANICAL <4G69>
OIL PAN
OIL PAN
REMOVAL AND INSTALLATION
M1112002800763
Pre-removal Operation
• Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-31).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-25).
• Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper and Centre Member P.32-13).
N
Post-installation Operation
• Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper and Centre Member P.32-13).
• Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-25).
• Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
1
48 ± 7 N·m
2
8
N
1
12 ± 2 N·m
48 ± 7 N·m
9.0 ± 3.0 N·m
4
N
6
9.0 ± 3.0 N·m
44 ± 10 N·m
39 ± 5 N·m
9.0 ± 3.0 N·m
2.
>>D<<
3.
9.0 ± 1.0 N·m
5
22 ± 4 N·m
7
1.
3
Removal steps
Engine oil cooler tube gaskets
<M/T>
Engine oil cooler hose and bracket
assembly <M/T>
Transmission housing front lower
cover stay
9.0 ± 3.0 N·m
AC308976 AB
4.
<<A>>
<<B>>
>>C<<
>>B<<
>>A<<
5.
6.
7.
8.
Removal steps (Continued)
Flywheel housing front lower cover
<M/T> or torque converter housing
front lower cover <A/T>
Engine oil pan drain plug
Engine oil pan drain plug gasket
Engine lower oil pan
Engine upper oil pan
11E-24
ENGINE MECHANICAL <4G69>
OIL PAN
REMOVAL SERVICE POINTS
<<A>> ENGINE LOWER OIL PAN
REMOVAL
INSTALLATION SERVICE POINTS
>>A<< ENGINE UPPER OIL PAN INSTALLATION
1. Remove the engine lower oil pan mounting bolts.
1. Remove sealant from the engine upper oil pan
and cylinder block surfaces.
CAUTION
Do not use special tool oil pan FIPG cutter
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
φ 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 FIPG cutter
(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
B
A
A
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
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.
11E-25
ENGINE MECHANICAL <4G69>
OIL PAN
Name
Symbol
Flange bolt A
B
Quantity
Size mm
(D × L)
2
M6 × 16
16
M6 × 18
NOTE: D: Nominal diameter, L: Nominal length
Tightening torque: 9.0 ± 3.0 N⋅m
>>B<< ENGINE LOWER OIL PAN
INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.
4. Insert the bolts to the engine lower oil pan as
shown, and tighten them to the specified torque in
the order shown.
Name
Symbol
Flange bolt A
B
Quantity
Size mm
(D × L)
1
M6 × 75
11
M6 × 10
NOTE: D: Nominal diameter, L: Nominal length
Tightening torque: 9.0 ± 3.0 N⋅m
>>C<< ENGINE OIL PAN DRAIN PLUG
GASKET INSTALLATION
Engine lower
oil pan side
φ 4 mm
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
B-10
AC102325 AF
Replace the gasket with a new one. Install the new
gasket in the direction shown in the illustration.
>>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 N⋅m
2. Tighten the transmission side two mounting bolts
to the specified torque.
Tightening torque: 44 ± 10 N⋅m
INSPECTION
B-4
B-7
B-5
B-6
A-3
B-8
B-9
B-12
B-2
AC102930AB
M1112002900254
• Check the oil pan for cracks.
• Check the oil pan sealant-coated surface for
damage and deformation.
11E-26
ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
M1112003101061
<M/T>
6
4
132 ± 5 N·m
8
5
7
9N
3
9
2
(Lip section)
(Lip section)
Engine oil
3N
1
AC308977 AB
•
>>D<<
1.
>>C<<
2.
3.
Crankshaft front oil seal removal
steps
Valve timing belt, balancer timing
belt (Refer to P.11E-36).
Crankshaft balancer shaft drive
sprocket
Crankshaft key
Crankshaft front oil seal
<<A>>
<<B>>
•
•
>>B<<
>>A<<
4.
5.
6.
7.
8.
9.
Crankshaft rear oil seal removal
steps
Transmission assembly
Clutch cover and clutch disc (Refer
to GROUP 21B, Clutch P.21B-3).
Flywheel bolts
Flywheel adapter plate
Flywheel assembly
Flywheel adapter plate
Crankshaft bush
Crankshaft rear oil seal
11E-27
ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
<A/T>
4
6
N
132 ± 5 N·m
8
5
7
3
8
2
(Lip section)
(Lip section)
Engine oil
3N
1
AC308978AB
•
>>D<<
1.
>>C<<
2.
3.
Crankshaft front oil seal removal
steps
Valve timing belt, balancer timing
belt (Refer to P.11E-36).
Crankshaft balancer shaft drive
sprocket
Crankshaft key
Crankshaft front oil seal
•
<<B>>
>>B<<
>>A<<
4.
5.
6.
7.
8.
Crankshaft rear oil seal removal
steps
Transmission assembly (Refer to
GROUP 23A, Transmission
Assembly P.23A-147).
A/T drive plate bolts
A/T drive plate adapter plate
A/T drive plate
Crankshaft bush
Crankshaft rear oil seal
11E-28
ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
REMOVAL SERVICE POINTS
<<A>> TRANSMISSION ASSEMBLY
REMOVAL
INSTALLATION SERVICE POINTS
>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION
CAUTION
Oil seal
AC300897
MB990938
Engine front
(Engine oil)
Flywheel
assembly
Flywheel
bolt
MD998776
Crankshaft
AC102328 AB
Do not remove the flywheel bolt. If this bolt is
removed, the flywheel assembly will become out
of balance and damaged.
Refer to GROUP 22A, Transmission Assembly
P.22A-14.
1. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
2. Use the following special tools to press-fit the oil
seal.
• Installer bar (MB990938)
• Crankshaft rear oil seal installer (MD998776)
<<B>> FLYWHEEL BOLTS/A/T DRIVE
PLATE BOLTS REMOVAL
>>B<< FLYWHEEL BOLTS/A/T DRIVE
PLATE BOLTS INSTALLATION
AC308604 AB
MD998781
AC301854AB
1. Use special tool flywheel stopper (MD998781) to
secure the flywheel assembly or A/T drive plate.
2. Remove the flywheel bolts or A/T drive plate bolts.
MD998781
AC301855AB
1. Use special tool flywheel stopper (MD998781) to
secure the flywheel assembly or A/T drive plate in
the same manner as removal.
2. Tighten the flywheel bolts or A/T drive plate bolts
to the specified torque.
Tightening torque: 132 ± 5 N⋅m
11E-29
ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
>>C<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION
Crankshaft
MD998375
: Clean
: Clean and degrease
(Engine oil)
MD998285
(Oil applied to the
circumference)
>>D<< CRANKSHAFT BALANCER SHAFT
DRIVE SPROCKET INSTALLATION
Crankshaft
balancershaft
drive sprocket
Oil seal
AC102329AC
1. 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.
2. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.
Crankshaft
Front case
Engine front
AC301346AB
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.
11E-30
ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
M1112004001272
Pre-removal Operation
• Fuel Line Pressure Reduction [Refer to GROUP 13C,
On-vehicle Service − Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) P.13C-428].
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-8).
• Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal P.17-7).
5
Post-installation Operation
• Accelerator Cable Installation (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-8).
• Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17).
• Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service − Accelerator Cable Check and
Adjustment P.17-6).
• Fuel Leak Check
4
5.0 ± 1.0 N·m
3
2
6
9.0 ± 2.0 N·m
1
13 ± 1 N·m
14 ± 3 N·m
(Engine oil)
N
7
AC308979AB
1.
2.
3.
4.
Removal steps
Control wiring harness connection
Battery wiring harness connection
Radiator lower hose clamp
Canister vacuum hose connection
5.
6.
7.
Removal steps (Continued)
Brake booster vacuum hose
connection
Engine oil level gauge and guide
assembly
O-ring
11E-31
ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
13
14
(Engine oil)
<Cold engine>
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
15
12
(Engine oil)
9
16
8
11 ± 1 N·m
17 N
11
31 ± 3 N·m
10
31 ± 3 N·m
89 ± 9 N·m
Removal steps
Detonation sensor connection
Battery wiring harness connection
Inlet manifold stay
Exhaust manifold (Refer to GROUP
15, Exhaust Manifold P.15-20).
Timing belt upper cover (Refer to
•
P.11E-36).
11. Camshaft sprocket
12. Radiator upper hose connection
13. Water hose connection
8.
9.
10.
•
<<A>>
<<B>>
>>E<<
>>D<<
AC308980AB
•
<<C>>
>>C<<
14.
•
<<D>>
>>B<<
>>A<<
15.
16.
17.
Removal steps (Continued)
Water inlet fitting and thermostat
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
P.14-32).
Fuel high-pressure hose
connection
Rocker cover assembly (Refer to
P.11E-18).
Cylinder head bolts
Cylinder head assembly
Cylinder head gasket
11E-32
ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
REMOVAL SERVICE POINTS
<<A>> CAMSHAFT SPROCKET
REMOVAL
AC107621
Wiring band
CAUTION
Never turn the crankshaft anti-clockwise.
AC301451AC
Timing mark
4. Secure the camshaft sprocket and valve timing
belt with wiring bands and so on to prevent
slippage between the camshaft sprocket and
valve timing belt.
AC301450AB
1. Turn the crankshaft clockwise, align the timing
marks on the camshaft sprocket to set No.1
cylinder to TDC of its compression stroke.
MB990767
MD998719
MD998738
AC100302 AB
Timing belt
under cover
AC301452AB
2. Remove the timing belt under cover rubber plug
and then set special tool adjusting bolt
(MD998738).
Timing belt
tensioner arm
MD998738
5. Use the following special tools to hold the
camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719)
CAUTION
Do not rotate the crankshaft after camshaft
sprocket removal.
6. Remove the camshaft sprocket with the valve
timing belt and place it on the timing belt lower
cover.
<<B>> RADIATOR UPPER HOSE
DISCONNECTION
AC301373AB
3. Screw in the special tool until it comes in contact
with the timing belt tensioner arm.
Mating marks
AC200641AB
Make mating marks on the radiator upper hose and
the hose clamp. Disconnect the radiator upper hose.
11E-33
ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
<<C>> FUEL HIGH-PRESSURE HOSE
DISCONNECTION
<<D>> CYLINDER HEAD BOLTS
REMOVAL
MB991654
Stopper
AC304581AB
1. Remove the fuel high-pressure hose stopper.
Engine front
3
5
10
8
2
1
7
9
6
4
AC301454AB
Retainer
AC304582AB
2. Remove the fuel high-pressure hose in the
direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.
Use special tool cylinder head bolt wrench
(MB991654) to loosen the cylinder head bolts in two
or three steps in the order of the numbers shown in
the illustration. 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 get into the
coolant passages, oil passages and cylinder.
1. Degrease the cylinder head gasket mounting
surface.
Identification
mark "381"
Exhaust side
AC302180AB
11E-34
ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
2. Assemble to the cylinder block so the cylinder
head gasket identification mark of "381" is at the
top surface and on the exhaust side.
>>B<< CYLINDER HEAD BOLTS
INSTALLATION
(Engine oil)
3. Use special tool cylinder head bolt wrench
(MB991654) to tighten the cylinder head bolts in
the following procedures.
(1) Tighten the bolts to 78 ± 2 N⋅m in the order
shown.
(2) Loosen the bolts fully in the reverse sequence
to that shown.
(3) Tighten the bolts to 20 ± 2 N⋅m in the order
shown.
Step (4)
90˚
Step (5)
90˚
A
AC102537AC
1. Check that the nominal length of each cylinder
head bolt meets the limit. If it exceeds the limit,
replace the bolts 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.
MB991654
Engine front
8
6
1
3
9
10
4
2
5
7
AC301456AB
Paint marking
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
• The bolt is not tightening sufficiently if the
tightening angle is less than a 90 degree
angle.
• If the tightening angle exceeds the standard
specification, remove the bolt and start over
from step 1.
(5) Tighten in a 90 degree angle as shown in the
instructions of the figure, then check to see
that the paint mark on the head of the cylinder
head bolts and the paint mark on the cylinder
head is on a linear line.
11E-35
ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
>>C<< FUEL HIGH-PRESSURE HOSE
CONNECTION
>>D<< RADIATOR UPPER HOSE
CONNECTION
CAUTION
Fuel
high-pressure
hose
Projection
3 mm
Water outlet fitting
Fuel line pipe
(Engine oil applied)
Mating marks
AC200642 AB
AC301864AB
1. Insert radiator upper hose until it contacts the
projection on the water outlet fitting.
2. Align the mating marks on the radiator upper hose
and hose clamp, and then secure the radiator
upper hose.
>>E<< CAMSHAFT SPROCKET
INSTALLATION
Stopper
AC304583AB
After connecting the fuel high-pressure hose,
slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.
MB990767
MD998719
AC100302 AB
1. Use the following special tool as during removal to
hold the camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
the specified torque.
Tightening torque: 89 ± 9 N⋅m
11E-36
ENGINE MECHANICAL <4G69>
TIMING BELT
TIMING BELT
REMOVAL AND INSTALLATION
M1112004301024
Pre-removal Operation
• Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-31).
• Crankshaft Shaft Damper Pulley Removal (Refer to
P.11E-17).
Post-installation Operation
• Crankshaft Shaft Damper Pulley Installation (Refer to
P.11E-17).
• Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
2
14 ± 3 N·m
11 ± 1 N·m
1
3
5
4
12
14 ± 1 N·m
11
48 ± 5 N·m
14 ± 1 N·m
6
9
8.8 ± 1.0 N·m
11 ± 1 N·m
21 ± 4 N·m
8
13
44 ± 10 N·m
23 ± 3 N·m
10
22 ± 4 N·m
79 ± 5 N·m
11 ± 1 N·m
7
9.0 ± 1.0 N·m
AC308981AB
1.
2.
3.
•
•
4.
Removal steps
Control wiring harness connection
Battery wiring harness connection
Connector bracket
Engine mounting insulator (Refer to
GROUP 32, Engine Mount P.32-7)
<M/T>.
Engine mounting insulator (Refer to
GROUP 32, Engine Mount P.32-6)
<A/T>.
Harness bracket
>>G<<
<<A>>
>>F<<
>>E<<
Removal steps (Continued)
Timing belt upper cover
Water pump pulley
Idler pulley
Auto-tensioner
Timing belt lower cover
Valve timing belt tension
adjustment (Installation only)
10. Valve timing belt
11. Timing belt tensioner pulley
5.
6.
7.
8.
9.
•
ENGINE MECHANICAL <4G69>
TIMING BELT
>>D<<
11E-37
Removal steps (Continued)
12. Timing belt tensioner arm
13. Timing belt tensioner adjuster
14
35 ± 6 N·m
22
21
19 ± 3 N·m
18
(Engine oil)
20
19
167 N·m
17
16
15
8.5 ± 0.5 N·m
AC308982 AB
<<B>>
<<B>>
<<B>>
>>C<<
>>C<<
>>C<<
14.
15.
16.
17.
18.
19.
Removal steps
Timing belt Idler pulley
Timing belt lower cover bracket
Crank angle sensor
Crankshaft pulley centre bolt
<<C>>
Crankshaft pulley washer
Crankshaft camshaft drive sprocket
>>C<<
>>B<<
>>A<<
>>A<<
Removal steps (Continued)
20. Crankshaft angle sensing blade
Balancer timing belt tension
•
adjustment (Installation only)
21. Balancer timing belt tensioner
22. Balancer timing belt
11E-38
ENGINE MECHANICAL <4G69>
TIMING BELT
REMOVAL SERVICE POINTS
<<A>> VALVE TIMING BELT REMOVAL
CAUTION
Never turn the crankshaft anti-clockwise.
Timing belt
tensioner arm
MD998738
Timing mark
AC301373AB
3. Screw in the special tool with hands until it
contacts the timing belt tensioner arm.
Camshaft
sprocket
Timing mark
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 mark
Crankshaft
camshaft
drive sprocket
A
Engine oil pump
sprocket
B
AC301866AB
1. Turn the crankshaft clockwise, align each timing
mark to set No.1 cylinder to TDC of its
compression stroke.
AC301856 AB
4. Gradually screw in the special tool and then align
the timing belt tensioner adjuster rod set hole A
with the timing belt tensioner adjuster cylinder set
hole B.
MD998738
Timing belt tensioner
pulley mounting bolt
Timing belt
under cover
Wire or pin
AC301452AB
2. Remove the timing belt under cover rubber plug
and then set special tool adjusting bolt
(MD998738).
AC302414AB
5. Insert a wire or pin in the set hole aligned.
CAUTION
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk, etc.
6. After removal of the special tool, loosen the timing
belt tensioner pulley mounting bolts and remove
the valve timing belt.
11E-39
ENGINE MECHANICAL <4G69>
TIMING BELT
<<B>> CRANKSHAFT PULLEY CENTRE
BOLT/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT CAMSHAFT
DRIVE SPROCKET REMOVAL
Crankshaft
camshaft
drive
sprocket
INSTALLATION SERVICE POINTS
>>A<< BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER
INSTALLATION
MB991385
Balancershaft
sprocket
Belt tension
side
MB991367
Timing
mark
AC102332AB
1. Use the following special tools to hold the
crankshaft camshaft drive sprocket.
• Special spanner (MB991367)
• Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft pulley washer and
crankshaft camshaft drive sprocket.
Timing
mark
Crankshaft
balancershaft
drive sprocket
<<C>> BALANCER TIMING BELT
REMOVAL
CAUTION
To reuse the balancer timing belt, draw an arrow
indicating the rotating direction on the back of
the belt using chalk, etc.
AC301402AB
1. Ensure that the crankshaft balancer shaft drive
sprocket timing marks and balancer shaft
sprocket timing marks are aligned.
2. Install the balancer timing belt on the crankshaft
balancer shaft drive sprocket and balancer shaft
sprocket. There should be no slack on the tension
side.
Centre of the
mounting bolt
Centre of
the pulley
AC301403AB
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
assembling bolt, and the pulley flange is at the
front-side of the engine.
4. Adjust the balancer timing belt tension.
11E-40
ENGINE MECHANICAL <4G69>
TIMING BELT
>>B<< BALANCER TIMING BELT
TENSION ADJUSTMENT
Approximately 100 N
CAUTION
When tightening the mounting bolts, ensure that
the tensioner does not rotate with the bolts.
Allowing it to rotate with the bolts can cause
excessive tension of the belt.
Deflection
AC301405AB
AC301404
1. Lift with your fingers the balancer timing belt
tensioner in the direction of the arrow. Apply a
tensile torque of 3.0 ± 0.4 N⋅m to the balancer
timing belt so the belt is tense without any
looseness. Tighten the assembling bolt to the
specified torque in this state. Then, fix the
balancer timing belt tensioner.
Tightening torque: 19 ± 3 N⋅m
3. Apply a pressure of approximately 100 N at the
centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the belt
deflection is within the standard value.
Standard value:
<When adjusting> 5 − 7 mm
<When replacing> 5 − 7 mm
4. If not within the standard value, adjust the belt
tension again.
>>C<< CRANKSHAFT ANGLE SENSING
BLADE/CRANKSHAFT CAMSHAFT
DRIVE SPROCKET/CRANKSHAFT
PULLEY WASHER/CRANKSHAFT
PULLEY CENTRE BOLT INSTALLATION
: Clean
: Clean and degrease
: Apply engine oil
Balancershaft
sprocket
Crankshaft pulley
centre bolt
Crankshaft angle
sensing blade
Timing
mark
Crankshaft
pulley washer
Timing
mark
Crankshaft
balancershaft
drive sprocket
Crankshaft camshaft
drive sprocket
AC301402AC
2. Turn the crankshaft clockwise two turns to set
No.1 cylinder to TDC of its compression stroke
and check that sprocket timing marks are aligned.
Engine front
Crankshaft
AC301347AB
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.
11E-41
ENGINE MECHANICAL <4G69>
TIMING BELT
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the direction
shown.
3. Place the larger chamfer side of the crankshaft
pulley washer in the direction shown in the Figure
and then assemble on the crankshaft pulley
centre bolt.
4. Apply a small of engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
Crankshaft
camshaft
drive
sprocket
(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.
Wire or pin
MB991385
AC302025AB
MB991367
AC102332AB
5. Use the following special tool as during removal to
hold the crankshaft camshaft drive sprocket.
• Special spanner (MB991367)
• Pin (MB991385)
6. Tighten the crankshaft pulley centre bolt to the
specified torque.
Tightening torque: 167 N⋅m
(2) Insert a wire or pin in the set hole aligned.
NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt
tensioner adjuster is set with a pin.
2. Install the timing belt tensioner adjuster to the
engine and then tighten the mounting 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 ± 3 N⋅m
>>E<< TIMING BELT TENSIONER
PULLEY INSTALLATION
>>D<< TIMING BELT TENSIONER
ADJUSTER INSTALLATION
1. Set according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
CAUTION
If the compression is too fast the procedure may
damage the rod. Make a point to slowly and thoroughly compress.
A
Timing belt tensioner
pulley hole
AC102336AB
Temporarily tighten the timing belt tensioner pulley
as shown.
B
AC302024 AB
11E-42
ENGINE MECHANICAL <4G69>
TIMING BELT
>>F<< VALVE TIMING BELT
INSTALLATION
Camshaft
sprocket
Timing mark
Timing belt
tensioner
pulley
Camshaft
sprocket
Belt tension
side
Timing belt
Idler pulley
Timing mark
Timing mark
Engine oil pump
sprocket
Crankshaft
camshaft
drive sprocket
AC301374AB
1. Align the timing marks on the camshaft sprocket,
crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
Balancershaft
Plug
Cylinder block
AC301871AB
2. Adjust the timing mark of the engine oil pump
sprocket. Unplug the cylinder block plug. Insert a
bolt (M6, section width 10 mm, nominal length 45
mm) from the plug hole. If the bolt comes in
contact with the balancer shaft, turn the engine oil
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.
Crankshaft
camshaft
drive sprocket
Engine oil pump
sprocket
AC301372AC
3. Incorporate the valve timing belt in the following
manner so that the tensile force of the belt is not
lax.
(1) Place the valve timing belt on the timing belt
tensioner pulley and crankshaft camshaft
driver sprocket and then support it with your
left hand so it does not slide.
(2) Place the valve timing belt on the engine oil
pump sprocket while pulling it with the right
hand.
(3) Place the valve timing belt on the timing belt
idler pulley.
CAUTION
Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation) pressure to the camshaft sprocket. Re-check to see
that each timing mark is aligned while the tension side of the belt is right.
(4) Place the valve timing belt on the camshaft
sprocket.
MD998767
AC301858 AB
ENGINE MECHANICAL <4G69>
TIMING BELT
4. Turn the timing belt tensioner pulley in the
direction shown in the figure using special tool
tensioner wrench (MD998767) to apply tension to
the valve timing belt. Then temporarily tighten and
fix the timing belt tensioner pulley mounting bolt.
11E-43
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT
MD998738
Timing mark
Timing belt
under cover
AC301452AB
1. Set special tool adjusting bolt (MD998738) used
when removing the valve timing belt.
Camshaft
sprocket
Timing mark
Timing mark
Engine oil pump
sprocket
Crankshaft
camshaft
drive sprocket
AC301372AB
CAUTION
Always screw in the special tool in with your
hands, 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 the special tool to a position in
which the wire or pin inserted in the timing belt
tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 of a revolution in the
anti-clockwise direction.
5. Check that the timing marks are aligned.
Bolt
Timing mark
Balancershaft
Camshaft
sprocket
Plug
Cylinder block
AC301871AB
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 N⋅m
8. Adjust the valve timing belt tension.
Timing mark
Timing mark
Crankshaft
camshaft
drive sprocket
Engine oil pump
sprocket
AC301372AB
4. Turn the crankshaft in the clockwise direction,
align each timing mark to set No.1 cylinder to TDC
of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.
11E-44
ENGINE MECHANICAL <4G69>
TIMING BELT
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.
9. Rotate crankshaft clockwise two turns, and leave
it for about 15 minutes.
Wire or pin
MD998767
AC301857AB
AC301859 AB
6. With special tool tensioner wrench (MD998767)
and torque wrench, apply tension torque 3.5 N⋅m
to the valve timing belt, and tighten the timing belt
tensioner pulley mounting bolt to the specified
torque.
Tightening torque: 48 ± 5 N⋅m
10.Insert wire or pin removed in Step 7 again, and
ensure that it can be pulled out with a light load.
When wire or pin can be lightly removed,
appropriate tension is applied on timing belt. In
this case, remove wire or pin.
A
Rod
Wire or pin
AC301375AB
AC301857AB
7. Remove wire or pin inserted to timing belt
tensioner adjuster.
MD998738
Timing belt
under cover
AC301452AB
8. Remove special tool adjusting bolt (MD998738),
and install the rubber plug to the timing belt under
cover.
Also the projection of timing belt tensioner
adjuster rod (A) 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.
11E-45
ENGINE MECHANICAL <4G69>
TIMING BELT
CAUTION
Always check the tightening torque of the crankshaft pulley centre bolt when turning the crankshaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose.
98 – 196 N
A
B
Movement
Rod
Timing mark
AC301376AB
Camshaft
sprocket
Timing mark
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.
Timing mark
Crankshaft
camshaft
drive sprocket
3. Hold the timing belt tensioner adjuster by hand,
and press 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
Engine oil pump
sprocket
AC301866AB
BALANCER TIMING BELT TENSION
CHECK
Check the balancer timing belt tension in the following procedures.
12.Check again that the timing marks on sprockets
are aligned.
Approximately 100 N
INSPECTION
M1112004400460
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.
Deflection
AC301405AB
1. Apply a pressure of approximately 100 N at the
centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the
flexure is within the standard value.
Standard value: 5 − 10 mm
2. If not within the standard value, adjust the belt
tension. (Refer to P.11E-36).
11E-46
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001002191
<M/T>
CAUTION
• When the engine assembly replacement is performed, use the M.U.T.-II/III to initialise the learning
value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for Learning
Value in MPI Engine P.00-21).
• *: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation
• Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-31).
• Fuel Line Pressure Reduction [Refer to GROUP 13C,
On-vehicle Service − Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) P.13C-428].
• Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17).
• Transmission Oil Draining (Refer to GROUP 22A,
On-vehicle Service − Transmission Oil Replacement
P.22A-8).
• Transfer Oil Draining (Refer to GROUP 22A, On-vehicle
Service − Transfer Oil Replacement P.22A-8).
• Hood Removal (Refer to GROUP 42, Hood P.42-4).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-8).
• Battery and Battery Tray Removal
• Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal P.17-7).
• Radiator Assembly Removal (Refer to GROUP 14, Radiator P.14-35).
• Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-25).
Post-installation Operation
• Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-25).
• Radiator Assembly Installation (Refer to GROUP 14,
Radiator P.14-35).
• Accelerator Cable Installation (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
• Battery and Battery Tray Installation
• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-8).
• Hood Installation (Refer to GROUP 42, Hood P.42-4).
• Transfer Oil Refilling (Refer to GROUP 22A, On-vehicle
Service − Transfer Oil Replacement P.22A-8).
• Transmission Oil Refilling (Refer to GROUP 22A,
On-vehicle Service − Transmission Oil Replacement
P.22A-8).
• Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17).
• Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service − Accelerator Cable Check and
Adjustment P.17-6).
• Fuel Leak Check
• Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-5).
11E-47
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
9.0 ± 2.0 N·m
1
4
3
9.0 ± 2.0 N·m
5
5.0 ± 1.0 N·m
2
N
6N
6
48 ± 7 N·m
9.0 ± 2.0 N·m
7
5.0 ± 1.0 N·m
N
6
12 ± 2 N·m
48 ± 7 N·m
AC308983 AB
1.
2.
3.
4.
Removal steps
Control wiring harness connection
Battery wiring harness connection
Canister vacuum hose connection
Brake booster vacuum hose
connection
<<A>>
5.
6.
7.
Removal steps (Continued)
Drive belt
Engine oil cooler tube gaskets
Engine oil cooler hose and bracket
assembly
11E-48
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11
10
(Engine oil)
15
24 ± 4 N·m
8
N
13
44 ± 10 N·m
70 ± 4 N·m*
44 ± 10 N·m*
22 ± 4 N·m
44 ± 10 N·m*
9
12
14
AC308984 AB
<<B>>
<<C>>
<<D>>
Removal steps
Power steering oil pump and
bracket assembly
9. A/C compressor and clutch
assembly
10. Heater water hoses connection
11. Fuel high-pressure hose
connection
8.
>>E<<
<<E>>
>>D<<
<<F>>
<<G>>
>>B<<
>>A<<
•
12.
13.
14.
15.
Removal steps (Continued)
Transmission assembly
Earth cable connection
Self-locking nuts
Engine mounting insulator
Engine assembly
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11E-49
<A/T>
CAUTION
• When the engine assembly replacement is performed, use the M.U.T.-II/III to initialise the learning
value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for Learning
Value in MPI Engine P.00-21).
• *: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation
• Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-31).
• Fuel Line Pressure Reduction [Refer to GROUP 13C,
On-vehicle Service − Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) P.13C-428].
• Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17).
• Transmission Fluid Draining (Refer to GROUP 23A,
On-vehicle Service − Automatic Transmission Fluid
Change P.23A-124).
• Transfer Oil Draining (Refer to GROUP 23A, On-vehicle
Service − Transfer Oil Replacement P.23A-128).
• Hood Removal (Refer to GROUP 42, Hood P.42-4).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-8).
• Battery and Battery Tray Removal
• Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal P.17-7).
• Radiator Assembly Removal (Refer to GROUP 14, Radiator P.14-35).
• Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-25).
Post-installation Operation
• Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-25).
• Radiator Assembly Installation (Refer to GROUP 14,
Radiator P.14-35).
• Accelerator Cable Installation (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
• Battery and Battery Tray Installation
• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-8).
• Hood Installation (Refer to GROUP 42, Hood P.42-4).
• Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle
Service − Transfer Oil Replacement P.23A-128).
• Transmission Fluid Refilling (Refer to GROUP 23A,
On-vehicle Service − Automatic Transmission Fluid
Change P.23A-124).
• Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17).
• Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service − Accelerator Cable Check and
Adjustment P.17-6).
• Fuel Leak Check
• Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-5).
11E-50
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
9.0 ± 2.0 N·m
4
1
3
9.0 ± 2.0 N·m
5
5.0 ± 1.0 N·m
2
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m
AC308985AB
1.
2.
3.
Removal steps
Control wiring harness connection
Battery wiring harness connection
Canister vacuum hose connection
4.
<<A>>
5.
Removal steps (Continued)
Brake booster vacuum hose
connection
Drive belt
11E-51
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
8
9
(Engine oil)
13
24 ± 4 N·m
6
44 ± 10 N·m
44 ± 10 N·m*
N
11
45 ± 5 N·m*
22 ± 4 N·m
44 ± 10 N·m*
10
12
<<B>>
6.
<<C>>
7.
<<D>>
>>E<<
8.
9.
Removal steps
Power steering oil pump and
bracket assembly
A/C compressor and clutch
assembly
Heater water hoses connection
Fuel high-pressure hose
connection
7
<<E>>
>>D<<
<<F>>
<<G>>
>>C<<
>>B<<
>>A<<
•
10.
11.
12.
13.
AC308986AB
Removal steps (Continued)
Transmission assembly
Earth cable connection
Self-locking nuts
Engine mounting insulator
Engine assembly
11E-52
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
REMOVAL SERVICE POINTS
<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the
introduction of the serpentine drive system with the
drive belt auto-tensioner.
Auto-tensioner
AC301703
Hole B
<<C>> A/C COMPRESSOR AND CLUTCH
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly from the bracket.
NOTE: After removing the A/C compressor and
clutch assembly, secure it with a cord in the location
where the removal and installation of the engine
assembly cannot be hindered.
<<D>> FUEL HIGH-PRESSURE HOSE
REMOVAL
Hole A
AC301704AB
1. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc.
Stopper
AC304581AB
1. Remove the fuel high-pressure hose stopper.
Auto-tensioner
L-shaped
hexagon
wrench
Retainer
AC304582AB
AC301705AB
3. Insert an L-shaped hexagon wrench, etc. into the
hole to fix and then remove the drive belt.
<<B>> POWER STEERING OIL PUMP
AND BRACKET ASSEMBLY REMOVAL
With the hose installed, remove the power steering
oil pump and bracket assembly from the engine
assembly.
NOTE: After removing the power steering oil pump
and bracket assembly, secure it with a cord in the
location where the removal and installation of the
engine assembly cannot be hindered.
2. Remove the fuel high-pressure hose in the
direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.
11E-53
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
<<E>> TRANSMISSION ASSEMBLY
REMOVAL
(1) <Special tool engine hanger (MB991895) is
used>
Remove special tool MB991895.
MB991928
MB991527
MB991454
AC300950AB
1. Pre-tighten the 2 bolts on the car to assemble the
radiator support upper insulator to set special tool
engine hanger MB991895 or engine hanger
MB991928.
CAUTION
AC211405AB
(2) <Special tool engine hanger (MB991928) is
used>
Remove special tool MB991928.
MB991454
AC300897
MB991527
Engine front
Flywheel
assembly
Flywheel
bolt
AC107632 AB
AC308604 AB
M/T: Do not remove the flywheel bolt. If this bolt
is removed, the flywheel assembly will become
out of balance and damaged.
2. Remove the transmission assembly (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-14,
A/T: Refer to GROUP 23A, Transmission
Assembly P.23A-147).
<<F>> ENGINE MOUNTING INSULATOR
REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
MB991895
MB991527
MB991454
AC107631AB
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 mounting insulator.
5. Loosen the engine mounting insulator mounting
nuts and bolts, and remove the engine mounting
insulator.
<<G>> 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.
11E-54
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
INSTALLATION SERVICE POINTS
>>A<< ENGINE ASSEMBLY INSTALLATION
MB991928
MB991454
MB991527
MB991527
MB991454
AC211405AB
AC107632 AB
Install the engine assembly, being careful not to
pinch the cables, hoses or wiring harness connectors.
>>B<< ENGINE MOUNTING INSULATOR
INSTALLATION
1. Place a garage jack against the engine oil pan
with a piece of wood in between, and install the
engine mounting insulator while adjusting the
position of the engine.
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.
MB991895
MB991527
(2) <Special tool engine hanger (MB991928) is
used>
Set special tool MB991928. (M/T: Refer to
GROUP 22A, Transmission Assembly
P.22A-14, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-147).
>>C<< SELF-LOCKING NUTS
INSTALLATION
CAUTION
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 N⋅m
>>D<< TRANSMISSION ASSEMBLY
INSTALLATION
1. Install the transmission assembly. (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-14,
A/T: Refer to GROUP 23A, Transmission
Assembly P.23A-147).
MB991454
AC107631AB
(1) <Special tool engine hanger (MB991895) is
used>
Set special tool MB991895. (M/T: Refer to
GROUP 22A, Transmission Assembly
P.22A-14, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-147).
AC300950AB
2. Remove from the car the two bolts, to assemble
the radiator support upper insulator.
ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
>>E<< FUEL HIGH-PRESSURE HOSE
INSTALLATION
CAUTION
Fuel
high-pressure
hose
3 mm
Fuel line pipe
(Engine oil applied)
AC301864AB
Stopper
AC304583AB
After connecting the fuel high-pressure hose,
slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.
11E-55
NOTES
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