Mitsubishi Engine, Oil pan, Crankshaft oil seal, Cylinder head gasket, Timing chain, 4B12 Balancer shaft Balancer timing chain, 4B12 Oil pump module Balancer shaft, Crankshaft pulley, Camshaft, Valve stem seal, Engine assembly Service Manual

11A-1

GROUP 11A

ENGINE

MECHANICAL

CONTENTS

SERVICE SPECIFICATIONS. . . . . . .

11A-2

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

11A-2

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

11A-3

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

11A-8

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

DRIVE BELT AUTO-TENSIONER CHECK

11A-8

11A-8

IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-10

IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-11

IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-12

VALVE CLEARANCE CHECK AND ADJUSTMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11A-12

COMPRESSION PRESSURE CHECK. . . . 11A-14

MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-15

CRANKSHAFT PULLEY . . . . . . . . . .

11A-16

REMOVAL AND INSTALLATION . . . . . . . . 11A-16

CAMSHAFT . . . . . . . . . . . . . . . . . . . .

11A-19


VALVE STEM SEAL . . . . . . . . . . . . .

11A-30


OIL PAN . . . . . . . . . . . . . . . . . . . . . . .

11A-36


INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-38

CRANKSHAFT OIL SEAL . . . . . . . . .

11A-39


CYLINDER HEAD GASKET . . . . . . . .

11A-41


TIMING CHAIN . . . . . . . . . . . . . . . . . .

11A-50


BALANCER TIMING CHAIN, BALANCER

SHAFT AND OIL PUMP MODULE <4B12>

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11A-56


BALANCER SHAFT AND OIL PUMP MODULE

<4B12> . . . . . . . . . . . . . . . . . . . . . . . .

11A-59


ENGINE ASSEMBLY . . . . . . . . . . . . .

11A-63


11A-2

Item

Drive belt tension

Valve clearance (at cold) mm

Basic ignition timing

Ignition timing

ENGINE MECHANICAL

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

Standard value Limit

115

− 156

−

M1112000302906

Vibration frequency Hz

(Reference)

Tension N (Reference)

Intake valve

Exhaust valve

Idle speed r/min 4B11

4B12

CO contents %

HC contents ppm

Compression pressure (at engine speed of 200 r/min) kPa

4B11

4B12

Compression pressure difference of all cylinders kPa

Intake manifold vacuum kPa

234

− 421

0.20

± 0.03

0.30

± 0.03

5

° BTDC ± 3°

Approximately

10

° BTDC

650

± 100

750

± 100

0.3 or less

200 or less

1,470

1,440

−

−

−

−

−

−

−

−

−

−

−

Minimum 1,000

Minimum 1,000

Maximum 98

Minimum 60

SEALANTS

Item

Rocker cover assembly (matching area of the cylinder head assembly and the timing chain case assembly)

Engine oil pan

Drive plate mounting bolt

Cylinder block (matching area of the cylinder head assembly, cylinder head gasket and the timing chain case assembly)

Timing chain case assembly

M1112000502751

Specified sealant

ThreeBond 1217G (MITSUBISHI

MOTORS GENUINE Part

No.1000A923), ThreeBond 1227D,

LOCTITE 5900 or equivalent


MOTORS GENUINE Part

No.1000A923), ThreeBond 1227D,

ThreeBond 1207F (MITSUBISHI

MOTORS GENUINE Part

No.1000A992), LOCTITE 5970,

LOCTITE 5900 or equivalent

ThreeBond 1324 or equivalent


MOTORS GENUINE Part

No.1000A923), LOCTITE 5900 or equivalent

Tool a a b c b

B992080


SPECIAL TOOLS

SPECIAL TOOLS

Number

MB992080 a: MB992081 b: MB992082

11A-3

Name

Belt tension meter set a: Belt tension meter b: Microphone assembly

M1112000603212

Use

Alternator and others belt tension check

MB992744

MB992745

a. MB992744 b. MB992745 c. MB992746 d. MB992747 e. MB992748 a. Vehicle communication interface-Lite

(V.C.I.-Lite) b. V.C.I.-Lite main harness A (for vehicles with CAN communication) c. V.C.I.-Lite main harness B (for vehicles without CAN communication) d. V.C.I.-Lite USB cable short e. V.C.I.-Lite USB cable long

• Checking the ignition timing

• Checking the idle speed

DO NOT USE

MB992746 d

MB992747 e

MB992748

ACB05421 AB

11A-4

Tool a b c

MB991824

MB991827

Number

MB991955 a: MB991824 b: MB991827 c: MB991910 d: MB991911 e: MB991825 f: MB991826


SPECIAL TOOLS

Name Use

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

CAUTION

For vehicles with CAN communication, use

M.U.T.-III main harness A to send simulated vehicle speed. If you connect

M.U.T.-III main harness B instead, the CAN communication does not function correctly.

• Checking the ignition timing

• Checking the idle speed

MB991910 d

DO NOT USE

MB991911 e

MB991825 f

MB991826

MB991955

MB990767 Front hub and flange yoke holder

Holding the crankshaft pulley

B990767

MD998719 Pin

D998719

Tool Number

MB992103


SPECIAL TOOLS

11A-5

Name Use

Chain tension release bar Camshaft and camshaft sprocket assembly (exhaust side) removal

B992103

MD998772 Valve spring compressor Valve spring compression

MD998772

MB992090 Retainer holder attachment

B992090

MB992089 Retainer holder C

MB992085 Valve stem seal pliers Valve stem seal removal

MD998737 Valve stem seal installer Valve stem seal press-fitting

MD998727 Oil pan FIPG cutter Engine oil pan removal

D998727

MB991883 Flywheel stopper

MB991883

Supporting the drive plate

11A-6

Tool

MB991614

Number

MD998718


SPECIAL TOOLS

Name

Crankshaft rear oil seal installer

Use

Press-fitting the crankshaft rear oil seal

MB991448 Bush remover and installer base

Press-fitting the crankshaft front oil seal

MB991614 Angle gauge Balancer shaft and oil pump module bolt installation

Tool

B991454

Number

MB991454

MB991527


SPECIAL TOOLS

11A-7

Name Use

Engine hanger balancer Support of engine assembly

Hanger

NOTE: .

•

For the engine hanger balancer (MB991454), use a chain only.

•

Engine hanger balancer

(MB991454) is a part of the engine hanger assembly

(MB991453).

Slide bracket (HI)

f d a

B991527 e

MB991928 a: MB991929 b: MB991930 c: MB991931 d: MB991932 e: MB991933 f: MB991934

b c

B991928 AI

MB991895

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 hanger

Z203830

MB991956 Engine hanger plate

B991956

MB992853 Engine hanger plate

B992853

11A-8


ON-VEHICLE SERVICE


DRIVE BELT TENSION CHECK

M1111003103752

CAUTION

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

Indicator mark

4. Securely set the tool to the hexagonal part of the auto-tensioner.

5. Check that no binding is present by turning the auto-tensioner in the left and right directions.

6. If there are any problems in the procedure 2 or 5, replace the drive belt auto-tensioner (Refer to

P.11A-50 ).

7. Install the drive belt (Refer to P.11A-16 ).

A

ACC00374 AB

1. Make sure that the indicator mark on the drive belt auto-tensioner is within the area marked with A in the illustration.

2. If the mark is out of the area A, replace the drive belt (Refer to

P.11A-16 ).

NOTE: The drive belt tension adjustment is not necessary as the drive belt auto-tensioner is adopted.

FUNCTION CHECK

The drive belt auto-tensioner can be checked whether it is in good condition by checking its tension.

<When the vibration frequency is measured: Recommendation>

1. Check the tension of the drive belt (Refer to

P.11A-8 ).

Belt tension meter set (MB992080)

MB992081

DRIVE BELT AUTO-TENSIONER CHECK

M1111003003476

OPERATION CHECK

1. Stop the engine from the idle state.

2. Check that the drive belt are not protruding from the pulley width of drive belt auto-tensioner.

3. Remove the drive belt (Refer to

P.11A-16

).

WARNING

Be sure to set the tool to the hexagonal part securely to prevent the tool from falling off because the tension of the auto-tensioner is high.

ACC00375

MB992082

AC507219AB

2. Connect special tool microphone assembly

(MB992082) to special tool belt tension meter

(MB992081) of special tool belt tension meter set

(MB992080).

3. Press the "POWER" button to turn on the power supply.

4. Press number key "1". Check to ensure that "No.

01" appears on the upper left of the display and that the following numeric values are displayed for individual items ("M", "W", and "S"):

M 000.9 g/m

W 010.0 mm/R

S 0100 mm

NOTE: If numeric values have not been entered

(new tool), set them according to the belt specifications as shown below. Once you set them, you do not have to set them again. The settings remain undeleted even after battery replacement.



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.

<Setting procedure>

(1) Press down the "MASS" button till the belt mass select display appears.

(2) Press the "UP" or "DOWN" button to select "01

1.5GT 0.9" and press the "MEASURE" button to decide it.

Check to ensure that "M 000.9 g/m" is displayed.

(3) Press the "WIDTH" button to change to the belt width input display.

(4) Press number keys "0", "1", "0", and "0" sequentially, and press the "SELECT" button to apply them. Check to ensure that "W 010.0 mm/R" appears on the display.

(5) Press the "SPAN" button to change to the span length input display.

(6) Press number keys "0", "1", "0", and "0" sequentially, and press the "SELECT" button to apply them. Check to ensure that "S 0100 mm" appears on the display.

5. Press "Hz" button twice to change the display to the frequency display (Hz).

10 – 15 mm

11A-9

CAUTION

• When measuring, make sure that the engine

is cold.

• Measure after turning the crankshaft clock-

wise one turn or more.

• Do not let any contaminants such as water or

oil get onto the microphone.

• If strong gusts of wind blow against the

microphone or if there is 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 vehi-

cle's engine is running.

Gentry tap with your finger

Crankshaft pulley

15˚

15˚

A/C compressor pulley

MB992080

ACB00850 AB

6. Hold special tool MB992080 to the middle of the drive belt between the pulleys (at the place indicated by arrow) where it does not contact the drive belt (approximately 10

− 15 mm away from the rear surface of the belt) so that it is perpendicular to the drive belt (within an angle of

± 15°).

7. Press the "MEASURE" button.

8. Gently tap the middle of the drive belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration.

9. Check that the vibration frequency of the drive belt is within the standard value.

11A-10



Standard value (Reference): 115

− 156 Hz

NOTE: To take the measurement repeatedly, fillip the drive belt again.

10.After the completion of the measurement, press and hold the "POWER" button to turn off the power supply.

11.If not within the standard value, replace the drive belt auto-tensioner (Refer to

P.11A-50 ).

IGNITION TIMING CHECK

M1111001703242

Diagnosis connector

<When tension is measured>

1. Check the tension of the drive belt (Refer to

P.11A-8 ).

CAUTION

• When measuring, make sure that the engine

is cold.

• Measure after turning the crankshaft clock-

wise one turn or more.

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017 AB

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.-III to the diagnosis connector.

Equipment side connector

No.1 Ignition coil

Power supply line

(terminal No. 3)

Crankshaft pulley

Belt tension gauge


ACB00851 AB

2. Use a belt tension gauge in the middle of the drive belt between the pulleys shown in the figure (at the place indicated by the arrow) to check that the drive belt tension is within the standard value.

Standard value (Reference): 234

− 421 N

3. If not within the standard value, replace the drive belt auto-tensioner (Refer to

P.11A-50 ).

AK604618 AC

3. Set the timing light to the power supply line

(terminal No. 3) of the ignition coil No. 1.

4. Start the engine and let it run at idle.

5. Select item No. 2 on the M.U.T.-III to measure engine idle speed and check that it is approximately 650 r/min<4B11> or 750 r/min<4B12>.

6. Select item No. 11 (actuator test function) on the

M.U.T.-III, and set the ignition timing to the basic ignition timing.

7. Check that basic ignition timing is within the standard value.

Standard value: 5

° BTDC ± 3°

MB992745, MB991910

MB992744, MB991824



8. If the basic ignition timing is outside the standard value, inspect the MPI system (Refer to GROUP

13A

− Troubleshooting − Inspection chart for trouble symptom ).

CAUTION

If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.

9. Cancel the actuator test function item No. 11,

Basic ignition timing set mode, on the M.U.T-III.

10.Check that ignition timing is at the standard value.

Standard value: approximately 10

° BTDC

NOTE: .

•

The ignition timing may fluctuate within

±

7

°

.

This is normal.

•

In higher altitude, the ignition timing is more advanced than the standard value by approximately 5

°

.

•

Wait till approximately 1 minute passes after the engine started, and check the ignition timing when the engine stabilized.

11.Remove the timing light.

12.Turn the ignition switch to the "LOCK" (OFF) position and then disconnect the M.U.T.-III.

IDLE SPEED CHECK

M1111003503329

Diagnosis connector

MB992747, MB992748, MB991827

ACB05017 AB

11A-11


2. Turn the ignition switch to "LOCK" (OFF) position.

3. Connect the M.U.T.-III to the diagnosis connector.


No.1 Ignition coil

Power supply line

(terminal No. 3)

AK604618 AC




6. Check that ignition timing is at the standard value.


° BTDC

NOTE: .

•


±

7

°

.

This is normal.

•


°

.

•


7. Check the idle speed.

Standard value:

650

± 100 r/min <4B11>

750

± 100 r/min <4B12>

NOTE: .

•

The idle speed is controlled automatically by the idle speed control system.

•

When using the M.U.T.-III, select item No. 2 and take a reading of the idle speed.

8. If the idle speed is outside the standard value, inspect the MPI system (Refer to GROUP 13A

−

Troubleshooting

− Inspection chart for trouble symptom ).

9. Remove the timing light.

10.Turn the ignition switch to the "LOCK" (OFF) position and then disconnect the M.U.T.-III.

11A-12

IDLE MIXTURE CHECK

M1111002102295

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017 AB

Power supply line

(terminal No. 3)







No.1 Ignition coil

NOTE: .

•


±

7

°

.

This is normal.

•


°

.

•


7. Run the engine at 2,000

− 3,000 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: 0.3 % or less

HC contents: 200 ppm or less

10.If there is a deviation from the standard value, inspect the MPI system (Refer to GROUP 13D

−

Troubleshooting

− Inspection chart trouble symptom ).

11.Remove the HC, CO tester and timing light.

12.Turn the ignition switch to the "LOCK" (OFF) position and then disconnect the M.U.T-III.

VALVE CLEARANCE CHECK AND

ADJUSTMENT

M1111001502182

NOTE: Perform the valve clearance check and adjustment at the engine cold state.

1. Remove all ignition coils.

2. Remove the cylinder head cover.

CAUTION

Turn the crankshaft always clockwise.

AK604618 AC




6. Check that ignition timing is at the standard value.


° BTDC

Timing mark

AK604565 AD

3. Turn the crankshaft clockwise, and align the timing mark on the exhaust camshaft sprocket against the upper face of the cylinder head as shown in Figure. Therefore, No.1 cylinder goes to the compression top dead centre.

Exhaust valve side

No.1

No.3



Wall thickness

11A-13

No.1

No.2

Intake valve side

AK502387AH

4. Using a thickness gauge, measure the valve clearance with the arrow shown in Figure. If deviated from the standard value, make note for the valve clearance.

Standard value:

Intake valve 0.20

± 0.03 mm

Exhaust valve 0.30

± 0.03 mm

Timing mark

AK304938 AB

8. Using a micrometer, measure the thickness of the removed valve tappet.

9. Calculate the thickness of the newly installed valve tappet through the following equation.

A: thickness of newly installed valve tappet

B: thickness of removed valve tappet

C: measured valve clearance

Equation

Intake valve: A = B + (C

− 0.20 mm)

Exhaust valve: A = B + (C

− 0.30 mm)

NOTE:

Thickness stamp

Under view

3

.

0 0

0

AK604566AD

5. Turn the crankshaft clockwise 360 degrees, and put the timing mark on the exhaust camshaft sprocket in position shown in Figure. Therefore,

No.4 cylinder goes to the compression top dead centre.

Exhaust valve side

No.2

No.4

No.3

No.4

Intake valve side

AK502388 AE

6. Check the valve clearance with the arrow shown in Figure. In the same procedure as 4.

7. If the valve clearance is deviated from the standard value, remove the camshaft and the valve tappet. For the camshaft removal, refer to

Camshaft Removal and Installation

P.11A-19

.

AK703500AC

The valve tappet ranges 3,000

−

3,690 mm and has 47 types per 0.015 mm. The thickness below a decimal point is stamped on the reverse side of the valve tappet.

10.Install the valve tappet selected through the procedure 9, and put the camshaft in position. For the camshaft installation, refer to Camshaft

Removal and Installation

P.11A-19 .

11.After installing the timing chain, measure the valve clearance using the procedure 3 to 6.

Confirm the clearance is within the standard value.

CAUTION

Completely remove all the old liquid gasket, which might be remaining among the components.

12.Remove any liquid gasket remaining on the cylinder head cover, the timing chain case and the cylinder head.

11A-14



13.Using white gasoline and so on, degrease the cylinder head cover, timing chain case and cylinder head.

CAUTION

The cylinder head cover should be installed within 3 minutes of applying liquid gasket.

2. Disconnect the ignition coil connectors and then remove all of the ignition coils and spark plugs.

Injector connectors

4 mm

2 mm

2 mm

Cylinder head

4 mm


AK 701438 AB

14.Apply a 4 mm bead of liquid gasket as illustrated.

Specified sealant:

ThreeBond 1217G or equivalent

11

1 5

6

12

AK502603AD

3. Disconnect the all of the injector connectors.

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.

Compression gauge

16

10

4

2

7 13

15

9

Engine front

3

8

14

AC506743 AG

15. Install the cylinder head cover and tighten the tightening bolts using the following procedures.

(1) Temporarily tighten to the following torque in order shown in the illustration.

Tightening torque: 3.0

± 1.0 N⋅m

(2) Tighten to the specified torque in order shown in the illustration.

Specified torque: 5.5

± 0.5 N⋅m

16.Install the ignition coils.

COMPRESSION PRESSURE CHECK

M1111002604155


AK502604AD

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):

1,470 kPa <4B11>

1,440 kPa <4B12>

Limit (at engine speed of 200 r/min):

Minimum 1,000 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.

(1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

9. Connect the injector connector.

10.Install the spark plugs and spark plug cables.

11A-15

MANIFOLD VACUUM CHECK

M1111002702587

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017 AB




Vacuum gauge

PCV valve

MB992747, MB992748, MB991827

ACB05017 AB

11.Use the M.U.T.-III to erase the diagnosis codes.

NOTE: This will erase the diagnosis code resulting from the injector connectors being disconnected.

Plug

AK502601AD

4. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose.

Plug the PCV valve.

5. Start the engine and check that idle speed is approximately 650 r/min<4B11> or 750 r/min<4B12>.

6. Check the intake manifold vacuum.

Limit: Minimum 60 kPa

7. Turn off the ignition switch.

8. Remove the vacuum gauge and then connect the ventilation hose to the PCV valve.

9. Disconnect the M.U.T.-III.

11A-16


CRANKSHAFT PULLEY


REMOVAL AND INSTALLATION

M1112001604821

Pre-removal Operation

• Engine Room Under Cover Front A, B and Engine Room

Side Cover (RH) Removal (Refer to GROUP 51

− Under

Cover ).

Post-installation Operation

• Drive Belt Tension Check (Refer to

P.11A-8 ).


Side Cover (RH) Installation (Refer to GROUP 51

− Under

Cover ).

4

1

210 N·m 0 N·m 210 N·m

2

3

(Engine oil)

Removal steps

<<

A

>> >>

B

<< 1.

Drive belt

<> >>

A

<< 2.

Crankshaft pulley centre bolt

<> >>

A

<< 3.

Crankshaft pulley washer

<> >>

A

<< 4.

Crankshaft pulley

REMOVAL SERVICE POINTS

<<A>> DRIVE BELT REMOVAL

To introduce the serpentine drive system with the auto-tensioner, the following operations will be required.

ACB00863AB

WARNING


L-shaped hexagon wrench

ACC00376AB


2. Rotate the auto-tensioner anti-clockwise.

3. Insert the L-shaped hexagon wrench into the auto-tensioner hole to fix the auto-tensioner.



CAUTION

To reuse the drive belt, draw an arrow indicating the rotating direction on the back of the belt using chalk to install the same direction.

4. Remove the drive belt.

11A-17

INSTALLATION SERVICE POINTS

>>A<< CRANKSHAFT PULLEY/CRANK-

SHAFT PULLEY WASHER/CRANKSHAFT

PULLEY CENTRE BOLT INSTALLATION

<> CRANKSHAFT PULLEY CENTRE

BOLT/CRANKSHAFT PULLEY

WASHER/CRANKSHAFT PULLEY

REMOVAL

: Wipe clean with a rag.

: Wipe clean with a rag and degrease.

: Apply a small amount of engine oil.

MD998719

Crankshaft pulley washer

Crankshaft sprocket

MB990767

ACB01872AB

1. Use the following special tools to support the crankshaft pulley:

• Front hub and flange yoke holder (MB990767)

• Pin (MD998719)

2. Loosen the crankshaft pulley centre bolt and remove the crankshaft pulley washer and crankshaft pulley.

Crankshaft

Crankshaft pulley centre bolt

Crankshaft pulley

Engine front

AC606441 AD

1. Wipe off the dirt on the crankshaft sprocket, crankshaft and crankshaft pulley as shown in the figure using a rag, and then degrease the areas.

NOTE: Degrease them to prevent drop in the friction coefficient of the pressed area which is caused by oil adhesion.

2. Install the crankshaft pulley.

3. Wipe off the dirt on the crankshaft pulley washer and the crankshaft pulley centre bolt as shown in the figure using a rag.

4. Apply an adequate and minimum amount of engine oil to the thread of the crankshaft pulley centre bolt and the lower area of the flange.

MD998719

MB990767

ACB01872AB

5. Use the following special tools as during removal to support the crankshaft pulley:

11A-18



• Front hub and flange yoke holder (MB990767)

• Pin (MD998719)

6. Tighten the crankshaft pulley centre bolt to the specified torque.

Tightening torque: 210 N

⋅m

7. Loosen the crankshaft pulley centre bolt fully.

8. Tighten the crankshaft pulley centre bolt to the specified torque again.

Tightening torque: 210 N

⋅m

1. Install the drive belt to each pulley as shown in the figure.

WARNING


>>B<< DRIVE BELT INSTALLATION

CAUTION

• To reuse the drive belt, install it by aligning

the arrow mark on the backside of belt marked at the removal with the rotating direction.

•

Drive belt


ACC00376AB


3. Rotate the auto-tensioner anti-clockwise and remove the L-shaped hexagon wrench fixing the auto-tensioner.

4. Apply tension to the drive belt while slowly turning the auto-tensioner clockwise.

Notched pulley Flat pulley

AC704717AG

Check that the notches of the notched pulley and the notches of the drive belt are fit correctly.

•

Check that the drive belt is installed in the centre of the flat surface of the flat pulley.

Drive belt auto-tensioner pulley

Drive belt

Idler pulley

Alternator pulley

Water pump pulley

Crankshaft pulley

Idler pulley


ACB00849 AB


CAMSHAFT

11A-19

CAMSHAFT


M1112023100866




− Under

Cover ).

• Air Cleaner Assembly Removal (Refer to GROUP 15 − Air

Cleaner ).


• Air Cleaner Assembly Installation (Refer to GROUP 15 −

Air Cleaner ).



− Under

Cover ).

2

4

3.0 ± 1.0 N·m 5.5 ± 0.5 N·m

Apply engine oil to all moving parts before installation.

N

5

12 ± 1 N·m

17 ± 3 N·m 30 ± 2 N·m

7

12 ± 1 N·m

9

11

12

10

3

17

19

20

18

8

13

14

15

16

3.0 ± 0.5 N·m

59 ± 5 N·m

22

23

21

1

(Engine oil)

25

N

24

10 ± 2 N·m

22

13 ± 1 N·m

6

V.V.T. sprocket bolt

Engine oil

23

AC607720

ACB01329 AB

11A-20


CAMSHAFT

Camshaft removal steps

1.

Engine upper cover

•

Ignition coil (Refer to GROUP 16

−

Ignition System, Ignition Coil )

2.

Breather hose

3.

PCV hose connection

•

Control wiring harness connection

<<

A

>> >>

G

<<

4.

Rocker cover assembly

<<

<>

C

>>

5.

Rocker cover gasket

•

No.1 cylinder compression top dead centre setting <only at removal>.

•

Valve clearance adjustment (Refer to

P.11A-12

) <only at installation>.

6.

Service hole bolt

•

Camshaft and camshaft sprocket assembly (exhaust side) removal preparatory operation <only at removal>.

<<

D

>> >>

F

<<

7.

Camshaft bearing front cap assembly

>>

E

<<

8.

Camshaft bearing

<<

E

>>

>>

D

<<

9.

Camshaft bearing oil feeding cap

(exhaust side)

<<

E

>>

>>

D

<<

10. Camshaft bearing cap (exhaust side)

<<

E

>>

>>

D

<<

11. Camshaft bearing cap (exhaust side)

<<

E

>>

>>

D

<<

12. Camshaft bearing thrust cap

(exhaust side)

<<

F

>>

>>

E

<<

13. Camshaft and camshaft sprocket assembly (exhaust side)

<<

G

>> >>

B

<<

14. Exhaust camshaft sprocket

<<

G

>> >>

B

<<

15. Camshaft (exhaust side)

>>

E

<<

16. Camshaft bearing

<<

E

>>

>>

D

<<

17. Camshaft bearing oil feeding cap

(inlet side)

<<

E

>>

>>

D

<<

18. Camshaft bearing cap (inlet side)

<<

E

>>

>>

D

<<


<<

E

>>

>>

D

<<

20. Camshaft bearing thrust cap (inlet side)

>>

C

<<

21. Camshaft and camshaft sprocket assembly (inlet side)

<<

G

>> >>

B

<<

22. Inlet V.V.T. sprocket assembly

<<

G

>> >>

B

<<

23. Camshaft (inlet side)

Oil feeder control valve removal steps

1.

Engine upper cover

<<

H

>> >>

A

<<

24. Oil feeder control valve (OCV) inlet

>>

A

<<

25. O-ring


<<A>> ROCKER COVER ASSEMBLY

REMOVAL

16

1

2

6

7

12

13

14

15

11

5

<> NO.1 CYLINDER COMPRESSION

TOP DEAD CENTRE SETTING

CAUTION

Never turn the crankshaft anti-clockwise.

Cylinder head upper surface

Timing chain mating mark

Paint markings

9

3

8

Engine front

AC506743 AF

Loosen the rocker cover assembly mounting bolts in the order of number shown in the figure, and remove the rocker cover assembly.

Camshaft sprocket timing marks

10

4

Timing chain mating mark

AC506744 AB

1. Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the No.1 cylinder to the top dead centre of compression. At this time, check that the crankshaft pulley timing mark is in the "T" mark position of the ignition timing indicator of the timing chain case assembly.

2. Put paint marks on both the camshaft sprocket and valve timing chain at the position of camshaft sprocket timing chain mating mark (circular hole).

<<C>> CAMSHAFT AND CAMSHAFT

SPROCKET ASSEMBLY (EXHAUST SIDE)

REMOVAL PREPARATORY OPERATION

Precision flat-tipped screwdriver


CAMSHAFT

Crankshaft pulley

11A-21

1. Insert a precision flat-tipped screwdriver through the service hole of the timing chain case, press up the timing chain tensioner ratchet to unlock, and keep the timing chain tensioner with that state.

NOTE: Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.

Service hole

A

SectionA-A


Ratchet

Service hole

A

Timing chain tensioner

Timing chain tensioner construction diagram

Ratchet release hole

Ratchet


AC509155 AB

11A-22


CAMSHAFT

CAUTION

• When inserting special tool chain tension

release bar (MB992103) into the timing chain case assembly inside, pay attention to the position of the valve timing chain to avoid damage to the valve timing chain and timing chain tension side guide. Do not insert the special tool MB992103 beyond its insertion guideline.

• If unlocking the timing chain tensioner is

insufficient, the special tool MB992103 cannot be inserted to the insertion guideline. Do not insert the special tool MB992103 forcibly, follow Step 1 again to unlock the timing chain tensioner and insert the special tool

MB992103.

MB992103

MB992103

Valve timing chain

Insertion standard line

AC507118 AB

B

A

Camshaft sprocket

(inlet side)

Valve timing chain

(tension side)


Timing chain tension side guide

AC508123

MB992103

C


AC509159AB

2. With the timing chain tensioner unlocked, insert special tool chain tension release bar

(MB992103) from the timing chain case assembly inside along the tension side of the valve timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly

(A in the figure).


CAMSHAFT

NOTE: With the timing chain tensioner unlocked, insert the special tool MB992103 along the tension side of the valve timing chain, according to the special tool MB992103 top shape. The special tool MB992103 can be inserted smoothly to the position where the special tool MB992103 insertion guideline aligns with the timing chain case assembly top surface (B in the figure), and the spread timing chain tension side guide can be hold (C in the figure).

3. With the special tool MB992103 inserted up to the insertion guide line, press the special tool

MB992103 against the inlet side camshaft sprocket and spread and hold the timing chain tension side guide.

4. Remove the precision flat-tipped screwdriver unlocking the timing chain tensioner.

CAUTION

The valve timing chain may be bitten by other parts. After sagging the valve timing chain, never rotate the crankshaft.

MB992103

Hexagon part of exhaust camshaft

11A-23

<<D>> CAMSHAFT BEARING FRONT

CAP ASSEMBLY REMOVAL

CAUTION

Be careful not to drop the camshaft bearing.


4

2

1

3

Engine front

AC506745 AB

Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

<<E>> CAMSHAFT BEARING OIL

FEEDING CAP/CAMSHAFT BEARING

CAP/CAMSHAFT BEARING THRUST CAP

REMOVAL

CAUTION

When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring force and the threads are damaged. Always loosen the mounting bolts in four or five steps.

Valve timing chain

AC506748AB

5. With the timing chain tension side guide spread, hook the special tool MB992103 over the hexagon part of the camshaft on the exhaust side, and turn the camshaft clockwise to apply slack to the valve timing chain between the camshaft sprockets.

Engine front

Camshaft bearing cap

2 6 8

4

1

1

2

5

5

6

7

7

8

3

3

4


AC506746 AB

11A-24


CAMSHAFT

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

3. Remove special tool chain tension release bar

(MB992103) inserted into the timing chain case assembly inside.

<<F>> CAMSHAFT AND CAMSHAFT

SPROCKET ASSEMBLY (EXHAUST SIDE)

REMOVAL

CAUTION

The valve timing chain may be bitten by other parts. After removing the camshaft and camshaft sprocket assembly, never rotate the crankshaft.

Rope

Valve timing chain

Camshaft and camshaft sprocket assembly

AC508124AC

1. Raise slightly the transmission side of the camshaft and camshaft sprocket assembly

(exhaust side) by using the slack of the valve timing chain, and remove from the cam bearing.

Camshaft and camshaft sprocket assembly

AC509403 AB

4. After removing the camshaft and camshaft sprocket assembly (exhaust side), hang up the valve timing chain with a rope to prevent the valve timing chain from falling into the timing chain case assembly.

<<G>> SPROCKET/CAMSHAFT

REMOVAL

Hexagon part of camshaft

MB992103

AC700424AB

Hold the hexagon part of the camshaft with a monkey wrench. Loosen the sprocket mounting bolt and remove the sprocket from the camshaft.

Valve timing chain

AC506749

AB

2. Remove the valve timing chain from the camshaft and camshaft sprocket assembly (exhaust side) toward the timing chain case assembly, and remove the camshaft and camshaft sprocket assembly (exhaust side) toward the transmission.

<<H>> OIL FEEDER CONTROL VALVE

REMOVAL

CAUTION

After removal of the oil feeder control valve, be careful to prevent dust from getting into the oil passage in the cylinder head.


VALVE INSTALLATION


CAMSHAFT

>>A<< O-RING/OIL FEEDER CONTROL

CAUTION

When installing the oil feeder control valve, be careful to avoid damage to the O-ring.

Apply engine oil to the O-ring of the oil feeder control valve and install the oil feeder control valve to the cylinder head.

11A-25

>>C<< CAMSHAFT AND CAMSHAFT

SPROCKET ASSEMBLY (INLET SIDE)

INSTALLATION

Paint markings

(inlet side)

>>B<< CAMSHAFT/SPROCKET

INSTALLATION

Hexagon part of camshaft

AC509403 AC

1. Align the inlet side paint mark of the valve timing chain which was put at removal with the paint mark of the inlet side camshaft sprocket, and install the camshaft sprocket to the valve timing chain.

2. Install the camshaft and camshaft sprocket assembly (inlet side) to the cylinder head.

AC611532 AD

1. Use a monkey wrench to secure the hexagon part of the camshaft in the same manner as removal.

V.V.T.

sprocket

Camshaft

>>D<< CAMSHAFT BEARING THRUST

CAP/CAMSHAFT BEARING

CAP/CAMSHAFT BEARING OIL FEEDING

CAP INSTALLATION

Engine front

Identification of inlet side and exhaust side

Bearing cap No.

V.V.T. sprocket bolt

AC607720AE

2. Apply an adequate and minimum amount of engine oil to the positions shown of the camshaft and inlet V.V.T. sprocket assembly.

3. Install the sprocket to the camshaft.

4. Apply an adequate and minimum amount of engine oil to the inlet V.V.T. sprocket bolt.

5. Tighten the sprocket bolt to the specified torque.

Tightening torque: 59

± 5 N⋅m

7

8

8


3

4

4

1

2

2

6

6

5

3

1

7 5


AC506778 AB

1. Install the camshaft bearing caps to the cylinder head.

11A-26


CAMSHAFT

NOTE: Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the inlet and exhaust sides for correct installation.

2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps.


± 1 N⋅m

Camshaft bearing front cap assembly

Identification mark

1

2

3

Journal diameter mm

40.000

− 40.008 1

40.008

− 40.016 2

40.016

− 40.024 3

Camshaft bearing identification mark


Crankshaft pulley

>>E<< CAMSHAFT BEARING/CAMSHAFT

AND CAMSHAFT SPROCKET ASSEMBLY

(EXHAUST SIDE) INSTALLATION

CAUTION

• Be careful not to drop the camshaft bearing.

•

When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.

Service hole

A

SectionA-A


Service hole

Ratchet


Identification mark

A


Timing chain tensioner construction diagram


Ratchet

AC611697 AC

Notch

Identification mark

Oil hole

AC708893 AE

1. When replacing the camshaft bearing, select a camshaft bearing in relevant size according to the camshaft bearing front cap assembly identification mark in the table below. The camshaft bearing identification mark is stamped at the position shown in the figure.


AC509155

AB

2. In the same manner as removal, insert the precision flat-tipped screwdriver through the service hole of the timing chain case, press up the ratchet of timing chain tensioner to unlock, and hold the unlocked timing chain tensioner.

NOTE: Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.


CAMSHAFT

CAUTION

• When inserting special tool chain tension

release bar (MB992103) into the timing chain case assembly inside, pay attention to the position of the valve timing chain to avoid damage to the valve timing chain and timing chain tension side guide. Do not insert the special tool MB992103 beyond its insertion guideline.

• If unlocking the timing chain tensioner is

insufficient, the special tool MB992103 cannot be inserted to the insertion guideline. Do not insert the special tool MB992103 forcibly, follow Step 2 again to unlock the timing chain tensioner and insert the special tool

MB992103.

MB992103

Valve timing chain

(exhaust camshaft and camshaft sprocket assembly side)

11A-27

Valve timing chain

Insertion standard line

AC507118 AB

Camshaft sprocket

(inlet side)

D

A

B

Valve timing chain

(tension side)


MB992103


AC508125

MB992103

C


AC509177 AB

3. With the timing chain tensioner unlocked, insert special tool chain tension release bar

(MB992103) from the timing chain case assembly inside along the tension side of the valve timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly

(A in the figure).

11A-28

NOTE: With the timing chain tensioner unlocked, insert the special tool MB992103 along the tension side of the valve timing chain, according to the special tool MB992103 top shape. The special too MB992103 can be inserted smoothly to the position where the special tool MB992103 insertion guideline aligns with the timing chain case assembly top surface, and the spread timing chain tension side guide can be hold.

4. With the special tool MB992103 inserted up to the insertion guide line, press the special tool

MB992103 against the inlet side camshaft sprocket (B in the figure) and spread and hold the timing chain tension side guide (C in the figure).

5. Remove the precision flat-tipped screwdriver unlocking the timing chain tensioner.

6. Pull up the camshaft and camshaft sprocket assembly (exhaust side) mounting area of the valve timing chain (D in the figure) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the valve timing chain.

CAUTION


Paint markings

(exhaust side)

AC506752

AB


CAMSHAFT

7. Align the exhaust side paint mark of the valve timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the valve timing chain to the camshaft sprocket.

8. Install the camshaft and camshaft sprocket assembly (exhaust side) to the cylinder head.

9. Remove the special tool MB992103 inserted into the timing chain case assembly inside.

>>F<< CAMSHAFT BEARING FRONT CAP

ASSEMBLY INSTALLATION

CAUTION

When the mounting bolts are tightened with the camshaft bearing front cap tilted, the camshaft bearing front cap is damaged. Install the camshaft bearing front cap properly to the cylinder head and camshaft.

(1)

Engine front

4

3

2

1

(2)


1

3

4

2

AC511062 AB

1. Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap to the specified torque in the order shown in the figure (1).


± 3 N⋅m

2. Tighten the camshaft bearing front cap to the specified torque again in the order shown in the figure (2).


± 2 N⋅m

3. After the camshaft bearing font cap installation, check that the paint markings of the camshaft sprocket and the timing chain and the timing mark of the crankshaft pulley and the "T" mark position of ignition timing indicator are aligned respectively.

>>G<< ROCKER COVER ASSEMBLY

INSTALLATION

1. Remove the sealant from the joints between the rocker cover assembly and cylinder head and timing chain case assembly, and degrease the surface where the sealant is applied by white gasoline or the like.

CAUTION


CAMSHAFT

After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

11A-29

NOTE: Install the rocker cover assembly immediately after the application of sealant.

11

1 5

6

12

Cylinder head

4 mm

16

10

4

2

7

13

4 mm


AC506753 AE

2. Apply sealant to the joint between the cylinder head and timing chain case assembly as shown in the figure and install the rocker cover assembly to the cylinder head.

Specified sealant: ThreeBond 1217G or equivalent

15

9

Engine front

3

8

14

AC506743 AG

3. Tighten the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.


± 1.0 N⋅m

4. Tighten again the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.


± 0.5 N⋅m

11A-30


VALVE STEM SEAL

VALVE STEM SEAL


M1112008101787

CAUTION

* Remove and assemble the marked parts in each cylinder unit.




− Under

Cover ).

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle

Service, Engine Oil Replacement ).

• Rocker Cover Assembly Removal (Refer to

P.11A-19

).

• Engine Oil Pan Removal (Refer to

P.11A-36 ).

• Valve Timing Chain Removal (Refer to

P.11A-50 ).


• Valve Timing Chain Installation (Refer to

P.11A-50

).

• Engine Oil Pan Installation (Refer to

P.11A-36 ).

• Valve Clearance Check (Refer to

P.11A-12 ).

• Rocker Cover Assembly Installation (Refer to

P.11A-19

).

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle




− Under

Cover ).

17 ± 3 N·m 30 ± 2 N·m

12 ± 1 N·m

5

3

1

6

4

9

12 ± 1 N·m

10

11

12

7

2

8 14*

15*

16*

17*

N

18*

13

14*

15*

16*

17*

18*

N


AC904692 AC


VALVE STEM SEAL

11A-31

Removal steps

<<

A

>> >>

F

<<

1.


>>

E

<<

2.

Camshaft bearing

<> >>

D

<<

3.


(exhaust side)

<> >>

D

<<

4.

Camshaft bearing cap (exhaust side)

<> >>

D

<<

5.

Camshaft bearing cap (exhaust side)

<> >>

D

<<

6.

Camshaft bearing thrust cap

(exhaust side)

>>

E

<<

7.

Camshaft and camshaft sprocket assembly (exhaust side)

>>

E

<<

8.

Camshaft bearing

<> >>

D

<<

9.


(inlet side)

<> >>

D

<<


<> >>

D

<<


<> >>

D

<<

12. Camshaft bearing thrust cap (inlet side)

13. Camshaft and camshaft sprocket assembly (inlet side)

•

Spark plug (Refer to GROUP 16

−

Ignition System, Ignition Coil ).

<<

C

>> >>

C

<<

14. Valve tappet

<<

D

>> >>

B

<<

15. Valve spring retainer lock

16. Valve spring retainer

17. Valve spring

<<

E

>>

>>

A

<<

18. Valve stem seal


<<A>> CAMSHAFT BEARING FRONT


1. Temporarily install the engine oil pan which was removed at the valve timing chain removal (Refer

to P.11A-36

).

CAUTION

When supporting the engine and transmission assembly with a garage jack, be careful not to deform the engine oil pan.

2. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transmission assembly.

MB991454

MB991956

MB991527

MB991928

AC506487 AD

MB991527

MB991454

MB991956

MB991895

AC506484 AD

3. Remove special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed.

CAUTION



4

2

1

3

Engine front

AC506745 AB

4. Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

11A-32

<> CAMSHAFT BEARING OIL



REMOVAL

CAUTION



VALVE STEM SEAL

<<C>> VALVE TAPPET REMOVAL

CAUTION

• Do not use pliers or other tools to remove the

valve tappets. Always remove them by hands.

• When reusing the removed valve tappet, it

has to be installed in the same position as before. Be sure to put a tab that shows the original installation position on the valve tappet when storing it.

Valve tappet

Engine front


2

1

1

2

6

5

5

6

8

7

7

8

4

3

3

4

AC509270 AB

Remove all of the valve tappets by hands.

<<D>> VALVE SPRING RETAINER LOCK

REMOVAL

MD998772


AC506746 AB

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

MB992090

MB992089

AC509271

AB

1. Screw in special tool retainer holder attachment

(MB992090) to special tool valve spring compressor (MD998772), and assemble special tool retainer holder C (MB992089).

CAUTION position.


VALVE STEM SEAL

When removing the valve spring retainer lock, leave the piston of the cylinder in the TDC (Top

Dead Centre) position. The valve may fall into the cylinder if the piston is not properly in the TDC

2. Install special tool MD998772 (with special tools

MB992090 and MB992089 attached) to the cylinder head and compress the valve spring.

Then, remove the valve spring retainer lock.

11A-33

CAUTION

• Valve stem seals cannot be reused.

• Do not damage the wall of the tappet hole

when installing the valve stem seal.

•

Special tool valve stem seal installer

(MD998737) must be used to install the valve stem seal. Improper installation of the valve stem seal could result in oil leaking past the valve guide.

MD998737

<<E>> VALVE STEM SEAL REMOVAL

Valve

Valve stem seal

MB992085

Valve guide

Valve stem seal

AK502782AB

Use special tool valve stem seal pliers (MB992085) to nip the base of the stem seal (where the outside diameter is larger) securely, and remove it by twisting it to the left and right.

AC308654AE

2. Use special tool valve stem seal installer

(MD998737) to press-fit a new valve stem seal in the valve guide using the valve stem area as a guide.

>>B<< VALVE SPRING RETAINER LOCK

INSTALLATION


>>A<< VALVE STEM SEAL INSTALLA-

TION

1. Apply a small amount of engine oil to the valve stem seals.

MD998772

MB992090

MB992089

AC509271

AB

11A-34


VALVE STEM SEAL

In the same manner as removal, use special tool valve spring compressor (MD998772) with special tool retainer holder attachment (MB992090) and special tool retainer holder C (MB992089) attached to compress the valve spring, and install the valve spring retainer lock.





Engine front

>>C<< VALVE TAPPET INSTALLATION

1. Apply a small amount of engine oil to the valve tappets.

CAUTION

• Do not use pliers or other tools to install the

valve tappets. Always install them by hand.

•

Be sure to install the valve tappets in the same position as before.


Bearing cap No.


7 3 1 5

Valve tappet

8 4

2 6

AC509270

AB

2. Install the valve tappet to the cylinder head by hand.

8

4 2 6

3

1

7 5


AC506778 AB


NOTE: Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the cap number and additionally its symbol to identify the inlet and exhaust sides for correct installation.



± 1 N⋅m

>>E<< CAMSHAFT BEARING/CAMSHAFT


(EXHAUST SIDE) INSTALLATION

CAUTION


•




VALVE STEM SEAL

3


3

11A-35

>>F<< CAMSHAFT BEARING FRONT CAP


CAUTION


(1)

Engine front

4

(2)

1

2 4

Identification mark

1

2

AC511062 AB

Notch

AC611697 AC

Identification mark

1. Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap mounting bolts to the specified torque in the order shown in the figure

(1).


± 3 N⋅m

2. Tighten again the camshaft bearing front cap mounting bolts to the specified torque again in the order shown in the figure (2).


± 2 N⋅m

Oil hole

AC708893 AE

When replacing the camshaft bearing, select a camshaft bearing in relevant size according to the camshaft bearing front cap identification mark in the table below. Identification mark of the camshaft bearing is painted in the position shown in the figure.

Camshaft


1

2

3


40.000

− 40.008

1

40.008

− 40.016

2

40.016

− 40.024

3


MB991454

MB991956

MB991527

MB991928

AC506487 AD

MB991527

MB991454

MB991956

MB991895

AC506484 AD

11A-36


OIL PAN

3. Install special tool engine hanger (MB991928 or

MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed (Refer to

P.11A-50 ).

4. Remove the garage jack which supports the engine and transmission assembly.

5. Remove the engine oil pan installed temporarily.

OIL PAN


M1112002803416




− Under

Cover ).



• Alternator and Others Belt Removal (Refer to

P.11A-16

).


• Alternator and Others Belt Installation (Refer to

P.11A-16 ).





− Under

Cover ).

7

N

6

31 ± 2 N·m

23 ± 6 N·m

1

39 ± 5 N·m

5

10 ± 2 N·m

23 ± 6 N·m

4

3

23 ± 6 N·m

2

23 ± 6 N·m

ACC00061 AB


OIL PAN

Removal steps

1.

A/C compressor and clutch connector connection

<<

A

>> >>

B

<<

2.

A/C compressor and clutch assembly

3.

A/C compressor bracket A

4.

A/C compressor bracket B

5.

Engine oil pan drain plug

6.

Engine oil pan drain plug gasket

<> >>

A

<<

7.

Engine oil pan


<<A>> A/C COMPRESSOR AND CLUTCH

ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly together with the hose from the bracket.

2. Tie the removed A/C compressor and clutch assembly with a string at a position where they will not interfere with the removal and installation of engine oil pan.

11A-37

CAUTION

Do not forcibly drive in special tool oil pan FIPG cutter (MD998727) to avoid damage to the engine oil pan seal surface of cylinder block assembly.

<Engine front>

Engine oil pan

<Engine rear>

Crankshaft pulley

AC506757 AB

Engine oil pan

<> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.

Engine oil filter

AC506758 AB

MD998727

MD998727

AC102324 AB

2. Insert special tool oil pan FIPG cutter (MD998727) from the engine oil pan removal groove of the cylinder block assembly.

3. Lightly tap the special tool (MD998727) with a hammer to slide the engine oil pan seal surface, cut off the liquid gasket, and remove the engine oil pan.


>>A<< ENGINE OIL PAN INSTALLATION

1. Remove all the traces of sealant adhering to the engine oil pan and cylinder block assembly using a remover or others. Then, degrease them.

11A-38

1mm


OIL PAN

Tightening torque:

M6: 10

± 2 N⋅m

M8: 29

± 2 N⋅m

>>B<< A/C COMPRESSOR AND CLUTCH


2 mm or

3 mm

AC506756AB

2. Apply the sealant without any gap to the mating surface of engine oil pan as shown in the figure, and install the engine oil pan to the cylinder block assembly.

Specified sealant: ThreeBond 1217G or equivalent

NOTE: Install the engine oil pan immediately after applying sealant.

CAUTION

After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

3. Tighten the engine oil pan mounting bolts to the specified torque.

1

3

2


AC506759 AK

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.


± 6 N⋅m

INSPECTION

M1112002900920

• Check the engine oil pan for cracks.

• Check the engine oil pan sealant-coated surface for damage and deformation.


CRANKSHAFT OIL SEAL



M1112003104286

11A-39

40 N·m 130 N·m

3

2

5

N

4

N

1

Crankshaft front oil seal removal steps

•

Crankshaft pulley (Refer to

P.11A-16 .)

>>

C

<< 1.

Crankshaft front oil seal

Crankshaft rear oil seal removal steps

•

Transmission assembly (Refer to

GROUP 23A - Transmission

Assembly .)

<<

A

>> >>

B

<< 2.

Drive plate bolt

>>

B

<< 3.

Drive plate adapter plate

>>

B

<< 4.

Drive plate

>>

A

<< 5.

Crankshaft rear oil seal


AC506760AF

<<A>> DRIVE PLATE BOLT REMOVAL

Cylinder block

MB991883

Drive plate

AC506761 AC

Fix the drive plate using the flywheel stopper (Special Tool: MB991883), and loosen the drive plate bolts.


>>A<< CRANKSHAFT REAR OIL SEAL

INSTALLATION

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

11A-40

Oil seal

MD998718



4. Apply a small amount of engine oil to the drive plate bolt bearing surface, and apply the sealant to the drive plate bolt threads.

Specified sealant: ThreeBond 1324 or equivalent

(Engine oil)

4

7

Crankshaft

AC506762AB

2. Using the crankshaft rear oil seal installer (Special tool: MD998718), press in the crankshaft rear oil seal up to the cylinder block assembly end surface.

>>B<< DRIVER PLATE/DRIVE PLATE

ADAPTER PLATE/DRIVE PLATE BOLT

INSTALLATION

1. Remove the engine oil and deposits from the drive plate bolt threads, crankshaft tapped hole, and drive plate.

2. Install the drive plate and drive plate adapter plate to the crankshaft.

1

6

2

5

3

AC609796 AC

5. Tighten the drive plate bolt to the specified torque

40 N

⋅m in the order of the number shown in the figure.

6. After tightening to the specified torque, tighten the drive plate bolt again to the specified torque 130

N

⋅m in the order of the number shown in the figure.

Cylinder block

MB991883

Drive plate

>>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION

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

CAUTION

When installing the crankshaft oil seal, be careful to avoid damage to the crankshaft front oil seal.

Timing chain case

MB991448

AC506761 AC

3. In the same way as with removal, fix the drive plate using a flywheel stopper (Special tool:

MB991883).

AC506763AB

2. Using a bush remover and installer base (Special tool: MB991448), press in the crankshaft front oil seal up to the chamfered surface of timing chain case.

AC609795AC


CYLINDER HEAD GASKET



M1112004005218

11A-41


• Fuel Line Pressure Reduction (Refer to GROUP 13A −

On-vehicle Service, How to Reduce Pressurized Fuel

Lines ).

• Engine Room Under Cover Front A, B, D and Engine

Room Side Cover (RH) Removal (Refer to GROUP 51

−

Under Cover ).

• Engine Coolant Draining (Refer to GROUP 14 − On-vehicle Service, Engine Coolant Replacement ).

• Air Cleaner Intake Hose and Air Cleaner Assembly

Removal (Refer to GROUP 15

− Air Cleaner ).

• Ignition Coil Removal (Refer to GROUP 16 − Ignition System, Ignition Coil ).

• Exhaust Manifold Removal (Refer to GROUP 15 −

Exhaust Manifold ).

• Throttle Body Assembly Removal (Refer to GROUP 13A

− Throttle Body Assembly ).

• Thermostat Case Removal (Refer to GROUP 14 − Water

Hose and Water Pipe ).


• Thermostat Case Installation (Refer to GROUP 14 −

Water Hose and Water Pipe ).

• Throttle Body Assembly Installation (Refer to GROUP

13D

− Throttle Body Assembly ).

• Exhaust Manifold Installation (Refer to GROUP 15 −

Exhaust Manifold ).

• Ignition Coil Installation (Refer to GROUP 16 − Ignition

System, Ignition Coil ).

• Air Cleaner Intake Hose and Air Cleaner Assembly Installation (Refer to GROUP 15

− Air Cleaner ).

• Engine Coolant Refilling (Refer to GROUP 14 − On-vehicle Service, Engine Coolant Replacement ).


Room Side Cover (RH) Installation (Refer to GROUP 51

−

Under Cover ).

• Fuel Leak Check.

11A-42



1

24 ± 3 N·m

7

N

8

N 9

6

11

10

15

2

N

3

4

N

5

12

13

Removal steps

1.


<<

A

>> >>

G

<< 2.

Hose clip

<<

A

>> >>

G

<< 3.

Radiator upper hose connection

<<

A

>> >>

G

<< 4.

Hose clip

<<

A

>> >>

G

<< 5.

Radiator lower hose connection

6.

Heater hose connection

7.

Water pump line pipe

8.

Cooling water line gasket

9.

O-ring

14

20 ± 2 N·m

ACC00062 AB

Removal steps (Continued)

10. Canister vacuum hose connection

11. Brake booster vacuum hose connection

12. Engine oil level gauge

13. Inlet manifold stay

14. Rocker cover PCV hose connection

<> >>

F

<< 15. Fuel high-pressure hose connection



17 ± 3 N·m 30 ± 2 N·m

12 ± 1 N·m

20

18

21

19

16

17

11A-43

12 ± 1 N·m


<Cold engine>

35 ± 2 N·m +90˚ +90˚

25

N

(Engine oil)

<Cold engine>

35 ± 2 N·m +90˚ +90˚

22

23

(Engine oil)

N

24

N

26

N

27

Removal steps

•

Valve timing chain (Refer to

P.11A-50 )

<<

C

>> >>

E

<<

16. Camshaft bearing front cap assembly

>>

C

<< 17. Camshaft bearing

<<

D

>> >>

D

<< 18. Camshaft bearing oil feeding cap

<<

D

>> >>

D

<< 19. Camshaft bearing cap

<<

D

>> >>

D

<< 20. Camshaft bearing cap

AC704318AK


<<

D

>> >>

D

<<

21. Camshaft bearing thrust cap

>>

C

<<

22. Camshaft and camshaft sprocket assembly

>>

C

<<

23. Camshaft bearing

<<

E

>>

>>

B

<<

24. Cylinder head bolt

<<

E

>>

>>

B

<<

25. Cylinder head bolt assembly

>>

A

<<

26. Cylinder head assembly

>>

A

<<

27. Cylinder head gasket

11A-44




<<A>> HOSE CLIP/RADIATOR HOSE DIS-

CONNECTION

Retainer

Mating marks

AC606081 AE

1. Make mating marks on the radiator hose and the hose clip as shown to install them in the original position.

AC301861AB

2. Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.

NOTE: If the retainer is released, install it securely after removing the fuel high-pressure hose.

Claw (Tip)

Hose clip

AC302615 AE

2. Break off the tip of hose clip claw and spread out the hose clip, then disconnect the radiator lower hose.

NOTE: If there is a hose clip claw, the hose clip cannot spread to capacity because the claw contacts the hose clip.

<<C>> CAMSHAFT BEARING FRONT


1. Temporarily install the engine oil pan which was removed at the valve timing chain removal (Refer

to P.11A-36

).

CAUTION


2. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transmission assembly.

MB991527

<> FUEL HIGH-PRESSURE HOSE

REMOVAL

Stopper

MB991454

MB991956

MB991928

AC506487 AD

MB991527

AC301860AB

1. Remove the stopper of the fuel high-pressure hose.

MB991454

MB991956

MB991895

AC506484 AD



3. Remove special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed.

CAUTION



4

2

11A-45

<<D>> CAMSHAFT BEARING OIL



REMOVAL

CAUTION


Engine front


1

3

Engine front

AC506745 AB

Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

2 6 8

4

1

1

5

5

7

7

3

3

2 6 8 4


AC506746 AB

Loosen the camshaft bearing caps mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<<E>> CYLINDER HEAD BOLT/CYLINDER

HEAD BOLT ASSEMBLY REMOVAL

Engine front

3 5

10

8 2

1 7

9

6 4

AC506767 AB

Loosen and remove the bolts in two or three steps in the order of number shown in the figure.

11A-46




>>A<< CYLINDER HEAD GASKET/CYLIN-

DER HEAD ASSEMBLY INSTALLATION

CAUTION

Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.

Degrease

2 mm or 3 mm

Cylinder head gasket

Cylinder head gasket

Bottom view of cylinder head

Degrease

2 mm or 3 mm

Top view of cylinder block

AC607682AB

1. Wipe off the sealant and grease on the top surface of the cylinder block and the bottom surface of the cylinder head, and degrease the surface where the sealant is applied.

Cylinder block

AC511063 AC

2. Apply the sealant to the top surface of the cylinder block as shown.

Specified sealant: Three bond 1217G or equivalent

3. Install the cylinder head gasket to the cylinder block.

NOTE: .

•

Install the cylinder head gasket immediately after the application of sealant.

•

When the cylinder head gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.

4. Apply the sealant to the top surface of the cylinder head gasket as shown.


CAUTION

After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.

5. Install the cylinder head assembly.

>>B<< CYLINDER HEAD BOLT

ASSEMBLY/CYLINDER HEAD BOLT

INSTALLATION

1. Replace a cylinder head bolts with a new one.

2. For two bolts of the timing chain side, the washer can be removed from the bolt. Install the washer, with its sag facing upward, to the bolts.

3. Apply a small amount of engine oil to the cylinder head bolt threads and the washers.

Engine front

8

6 1 3 9



11A-47

>>C<< CAMSHAFT BEARING/CAMSHAFT


INSTALLATION

CAUTION


•


10

4 2 5 7

AC506767 AC


4. Tighten the cylinder head bolts by the following procedure (plastic region angular tightening method).

(1) Tighten the cylinder head bolts to the specified torque in the order shown in the figure in two or three steps.


± 2 N⋅m

CAUTION

• The cylinder head bolt is not tightened suffi-

ciently if the tightening angle is less than a

180 degrees angle.

•

If the tightening angle exceeds the standard specification, remove the cylinder head bolt and repeat the installation steps from Step 1.

Identification mark

Notch

AC611697 AC

Identification mark

Paint marks

Paint marks

180˚

AC506768AB

(2) Put a paint mark on the cylinder head bolt head and cylinder head, tighten to 180

± 2 degrees in the order shown in the figure, and check that the paint mark on the cylinder head bolt head aligns with the paint mark on the cylinder head.

Oil hole

AC708893 AE

When replacing the camshaft bearing, select a camshaft bearing in relevant size according to the camshaft bearing front cap identification mark in the table below. Identification mark of the camshaft bearing is painted in the position shown in the figure.

Camshaft


1

2

3


40.000

− 40.008

1

40.008

− 40.016

2

40.016

− 40.024

3


11A-48

Engine front


Bearing cap No.








>>E<< CAMSHAFT BEARING FRONT

CAP ASSEMBLY INSTALLATION

CAUTION


(1)

Engine front

4

3

(2)


1

3

7

8

8

3

4

4

1

2

2

6

6

5

3

1

7 5


AC506778 AB


NOTE: Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the inlet and exhaust sides for correct installation.



± 1 N⋅m

2

1

4

2

AC511062 AB

1. Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap mounting bolts to the specified torque in the order shown in the figure

(1).


± 3 N⋅m

2. Tighten the camshaft bearing front cap mounting bolts to the specified torque again in the order shown in the figure (2).


± 2 N⋅m

MB991527

MB991454

MB991956

MB991928

AC506487 AD

MB991527

MB991454

MB991956

MB991895

AC506484 AD

P.11A-50 ).




MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed (Refer to

4. Remove the garage jack which supports the engine and transmission assembly.

5. Remove the engine oil pan installed temporarily.

>>F<< FUEL HIGH-PRESSURE HOSE

INSTALLATION

CAUTION

After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 3-mm play. After the check, install the stopper securely.

Protrusion

11A-49

Apply a small amount of engine oil to the fuel line pipe, and install the fuel high-pressure hose.

>>G<< RADIATOR HOSE/HOSE CLIP

CONNECTION

CAUTION

Never reuse the hose clip whose claw is broken off to prevent the rusting.

1. Make mating mark on a new hose clip in the same position as the remove one.

Mating marks

Fuel high-pressure hose

3 mm

Pipe, fitting, or etc.

AC606082 AU

Fuel line pipe

(Engine oil applied)

AC301864AB

2. Insert the radiator hose until the protrusion of the pipe.

3. Align the mating marks on the radiator hose and hose clip.

4. Remove the hose clip claw and shorten the hose clip, then install the radiator hose.

Stopper

AC301863AB

11A-50


TIMING CHAIN

TIMING CHAIN


M1112007202041




−

Under Cover ).



• Rocker Cover Assembly Removal (Refer to

P.11A-19

).

• Engine Oil Pan Removal (Refer to

P.11A-36 ).


• Engine Oil Pan Installation (Refer to

P.11A-36 ).

• Rocker Cover Assembly Installation (Refer to

P.11A-19

).





−

Under Cover ).


10 ± 2 N·m

9

10

24 ± 4 N·m

48 ± 6 N·m

10 ± 2 N·m

26 ± 3 N·m

1

44 ± 8 N·m

8

10 ± 2 N·m

10 ± 2 N·m

11

4

7

N

6

5

N

10 ± 2 N·m

48 ± 7 N·m

22 ± 4 N·m

3

2

<<

A

>>

<>

Removal steps

•

Crankshaft pulley (Refer to

P.11A-16 )

>>

E

<<

1.

Water pump pulley

2.

Idler pulley

3.

Alternator drive belt auto-tensioner

•

Engine and transmission assembly holding

•

Engine mounting bracket (Refer to

GROUP 32

− Engine Mounting )

AC904716 AC


4.

Cylinder block engine front mounting bracket

5.

Gasket

<<

C

>> >>

D

<<

6.


>>

C

<<

7.

Crankshaft front oil seal

<<

D

>> >>

B

<<

8.


9.


>>

A

<<

10. Valve timing chain

11. Timing chain loose side guide


TIMING CHAIN


<<A>> CRANKSHAFT PULLEY REMOVAL

When removing the crankshaft pulley, slightly loosen the water pump pulley mounting bolts before removal of the alternator and others belt.

Oil control valve

(inlet side)

<> ENGINE AND TRANSMISSION

ASSEMBLY HOLDING

Install a special tool for holding the engine and transmission assembly.

1. <When special tool engine hanger (MB991928) is used>

(1) Assemble special tool engine hanger

(MB991928) (Set the following parts on the base hanger).

• Slide bracket (HI)

• Foot x 2 (standard) (MB991932)

• Foot x 2 (short) (MB991933)

•

Joint x 2 (90) (MB991930)

MB991933

MB991930

MB991956

MB991527

11A-51

AC600152AB

MB991454 MB991928

MB991956

AC506487 AD

(3) Install special tool engine hanger plate

(MB991956) to the cylinder head, and set special tool hanger (MB991527) and the chains of special tool engine hanger balancer

(MB991454) to the engine assembly to hold the engine and transmission assembly.

MB991932

2. <When special tool engine hanger (MB991895) is used>

AC506488 AB

(2) Set the foot of the special tools (MB991930,

MB991932 and MB991933) as shown in the figure.

NOTE: Slide the slide bracket (HI) to adjust the engine hanger balance.

CAUTION

Place a rag between special tool engine hanger

(MB991895) and the windshield to prevent the special tool (MB991895) from interfering with the windshield.

11A-52

MB991895

AC506485 AB


TIMING CHAIN

<<C>> TIMING CHAIN CASE ASSEMBLY

REMOVAL

CAUTION

If the adhesive strength of sealant on the timing chain case assembly is so strong that the boss may be damaged by peeling off, do not peel it off forcibly.

Rag

AC506486 AB

(1) Set the foot of special tool engine hanger

(MB991895) as shown in the figure.

NOTE: Slide the foot to adjust the engine hanger balance.

MB991956

Boss


AC700719 AC

1. After removing the timing chain case assembly mounting bolts, slightly pry the boss of the timing chain case assembly shown in the figure using a flat-tipped screwdriver, and remove the timing chain case assembly from the cylinder head and cylinder block.

Hammer

Oil control valve

(inlet side)

MB991527

AC600152AB

AK901126AC

2. If the sealant cannot be peeled off easily, insert a wooden hammer shank into the timing chain case assembly inside as shown in the figure, pry slightly, and remove the timing chain case assembly from the cylinder head and cylinder block.

MB991454

MB991895

MB991956

AC506484 AD

(2) Install special tool engine hanger plate

(MB991956) to the cylinder head, and set special tool hanger (MB991527) and the chains of special tool engine hanger balancer

(MB991454) to the engine assembly to hold the engine and transmission assembly.

<<D>> TIMING CHAIN TENSIONER

REMOVAL

1. Temporarily install the crankshaft pulley to the crankshaft.

CAUTION

Turn the crankshaft clockwise.



TIMING CHAIN

11A-53


>>A<< VALVE TIMING CHAIN INSTALLA-

TION


Crankshaft sprocket timing mark

AC506772 AB

2. Turn the crankshaft clockwise to align the sprocket timing marks as shown in the figure and set the cylinder No. 1 to the top dead centre of compression.

NOTE: At this time, it is not necessary that the link plate (orange or blue) of the valve timing chain always aligns with each sprocket timing mark.

3. Remove the crankshaft pulley installed temporarily.


Hard wire or



AC506774 AB

1. Set the timing marks of the camshaft sprockets and the crankshaft sprocket as shown in the figure.

Link plates (orange) Link plate (blue)

Mating mark

Mating mark

Tension side


AC506773 AB

4. Using a precision flat-tipped screwdriver, release the ratchet of timing chain tensioner.

5. Compress the plunger of timing chain tensioner and insert hard wire (such as the piano wire) or the L-shaped hexagon wrench (1.5 mm) to fix the plunger of the timing chain tensioner.

6. Remove the timing chain tensioner.

Mating mark

Link plate (blue)

AC506772

AN

11A-54

>>B<< TIMING CHAIN TENSIONER

INSTALLATION

Link plates (orange)

Link plate (blue)


TIMING CHAIN

2. Align each sprocket timing chain mating mark with the link plate (orange or blue) of valve timing chain to avoid slack of the valve timing chain tension side, and install the valve timing chain to the sprockets.

>>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION

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

CAUTION

When installing the crankshaft front oil seal, be careful to avoid damage to the crankshaft front oil seal.

Timing chain case

MB991448

Mating mark

Mating mark

AC506763AB

2. Using special tool bush remover and installer base (MB991448), press in the crankshaft front oil seal up to the chamfered surface of timing chain case.

Mating mark

Link plate (blue)

AC506772 AO

1. Check that the sprocket timing chain mating marks align with the link plates (orange or blue) of the valve timing chain, and install the timing chain tensioner to the cylinder block.

Hard wire or



AC506773 AC

2. Remove the hard wire or L-shaped hexagon wrench fixing the plunger of the timing chain tensioner to apply tension to the valve timing chain.

>>D<< TIMING CHAIN CASE ASSEMBLY

INSTALLATION

CAUTION

• Be sure to remove the sealant inside the

mounting holes and the O-ring grooves.

• After degreasing with degreasing agent,

check that there is no oil on the surface where the sealant is applied.

• After degreasing with degreasing agent,

never touch the degreased area with fingers.

1. Remove sealant from the timing chain case assembly and the timing chain case assembly mounting surface of the cylinder block and the cylinder head, and degrease the surface where the sealant is applied.

2. Remove all the sealant adhering to the gasket between the cylinder head and cylinder block

(three-surface aligned part.) Then, degrease the surfaces.

3. As for the three-surface aligned part that is indicated in step 2 above, the engine oil oozes from the cylinder head gasket. Thus, quickly apply the sealant to it after degreasing.


TIMING CHAIN

11A-55

7.5 ± 0.5 mm

Ø2.5 ± 0.5 mm

Ø2.5 ± 0.5 mm

1 ± 0.5 mm

A-A view

A A

D

C-C view

C

B

A

A

Ø2.5 ± 0.5 mm

3 ± 0.5 mm

4.5 ± 0.5 mm

3 ± 0.5 mm

2.5 mm

B-B view

Ø4.5 ± 0.5 mm Ø2.5 ± 0.5 mm

AK703733 AE

4. Apply a bead of the sealant to the timing chain case assembly mounting surface. The bead diameter should be 2.5

± 0.5 mm. Overlap the part "A" with the diameter of 4.5

± 0.5 mm or 2.5 ±

0.5 mm as shown in the figure, and apply the sealant.


CAUTION

• If the sealant contacts any other part during

installation of the timing chain case assembly, apply sealant again before installing the timing chain case assembly.

• After the installation, until a sufficient period

of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

5. Install the timing chain case assembly to the cylinder block and cylinder head so that the sealant does not contact other parts.

NOTE: Install the timing chain case assembly immediately after applying sealant.

B

A

B

A

A

C

A

A

A

B

B

B

B

AC506776 AB

6. Insert the bolts to the timing chain case assembly as shown, and tighten them to the specified torque.

Name Symbol Quantity Size mm (D

× L)

Flange bolt

Bolt

A

B

C

6

6

1

M6

× 25

M8

× 30

M6

× 25

NOTE: D: Nominal diameter, L: Nominal length

11A-56


BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL PUMP MODULE <4B12>

Tightening torque:

A, C: 10

± 2 N⋅m

B: 24

± 4 N⋅m

>>E<< WATER PUMP PULLEY

INSTALLATION

Temporarily tighten the water pump pulley mounting bolts. Then, tighten them to the specified torque after the installation of alternator and others belt.


± 1.0 N⋅m

BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL

PUMP MODULE <4B12>


M1112008500306

Pre-removal and Post-installation Operation

• Valve Timing Chain Removal and Installation (Refer to

P.11A-50 ).


5

6

10 ± 2 N·m

3

10 ± 2 N·m

2

10 ± 2 N·m

1

4

Removal steps

<<

A

>> >>

B

<<

1.


2.

Balancer timing chain guide

3.


(Engine oil)

20 N·m 44 N·m 0 N·m

20 N·m +135˚

AC506779AI


>>

A

<<

4.

Balancer shaft and oil pump module

>>

A

<<

5.

Balancer timing chain

>>

A

<<

6.

Crankshaft sprocket



REMOVAL SERVICE POINT

<<A>> TIMING CHAIN TENSIONER

REMOVAL

CAUTION

Securely install the plunger of the timing chain tensioner. Otherwise, it may pop out.

Hard wire or L-shaped hexagon wrench

11A-57

(1) Clean the inside of the removed engine oil pan, and put the balancer shaft and oil pump module into the engine oil pan with its oil inlet port facing up.

(2) Pour new engine oil until two-thirds of the balancer shaft and oil pump module is soaked.

(3) Fill the engine oil (approximately 50 mL) into the balancer shaft and oil pump module from the oil inlet port.



AC506781 AB

1. Press the balancer timing chain against the timing chain tensioner, compress the plunger of the timing chain tensioner and insert hard wire (piano wire, etc.) or L-shaped hexagon wrench (1.5 mm) to fix the plunger of the timing chain tensioner.

2. Remove the timing chain tensioner.


>>A<< CRANKSHAFT SPROCKET/BAL-

ANCER TIMING CHAIN/BALANCER

SHAFT AND OIL PUMP MODULE INSTAL-

LATION

1. When installing the new balancer shaft and oil pump module, apply oil to the oil pump in the balancer shaft and oil pump module and the balancer shaft bearing as follows.


Oil inlet port

Balancer shaft sprocket

AC509273 AB

(4) Turn the balancer shaft sprocket of the balancer shaft and oil pump module clockwise four rotations or more to apply the engine oil to the entire area of the oil pump and the balancer shaft bearing.

: Wipe clean with a rag.

: Wipe clean with a rag and degrease.

Crankshaft

Engine front

Crankshaft sprocket

AC807896 AD

2. Wipe the dirt on the crankshaft sprocket and the crankshaft using a rag, and then remove the grease from the portion shown in the illustration.

NOTE: Remove grease to prevent a drop in the coefficient of friction of the pressing portion caused by adhesion of oil.

Engine oil

Engine oil pan

AC509272 AB

11A-58




Link plate (orange)

7. Loosen each balancer shaft and oil pump module bolt fully in the reverse sequence to that shown.

8. Tighten the balancer shaft and oil pump module bolts to the specified torque of 20 N

⋅m in the order of number shown in the figure.


1

3


(key slot)

Balancer shaft sprocket timing mark

4

2

AC506784 AB

Balancer shaft housing timing mark

Link plate (blue)

AC506780 AF

3. With the link marks (orange and blue) of balancer timing chain aligned with the timing marks of balancer sprocket and crankshaft sprocket, install the balancer shaft and oil pump module together with the balancer timing chain and crankshaft sprocket as one unit to the cylinder block. At this time, securely bring the balancer shaft and oil pump module into contact with the rudder frame mounting area.

4. Apply an adequate and minimum amount of engine oil to the threads and bearing surfaces of the balancer shaft and oil pump module bolts.


1

3


MB991614

AC506777 AB

9. After tightening to the specified torque, tighten the balancer shaft and oil pump module bolts to 135 degrees, using special tool angle gauge

(MB991614), in the order of number shown in the figure.

>>B<< TIMING CHAIN TENSIONER

INSTALLATION

Hard wire or L-shaped hexagon wrench

4

2

AC506784 AB

5. Tighten the balancer shaft and oil pump module bolts to the specified torque of 20 N


6. Retighten the balancer shaft and oil pump module bolts to the specified torque of 44 N



AC506781 AB

1. Install the timing chain tensioner to the cylinder block.

2. Remove the hard wire or L-shaped hexagon wrench fixing the plunger of the timing chain tensioner to apply tension to the balancer timing chain.


BALANCER SHAFT AND OIL PUMP MODULE <4B12>

11A-59



M1112008900274

Pre-removal and Post-installation Operation

• Engine Oil Pan Removal and Installation (Refer to

P.11A-36 ).

10 ± 2 N·m

1

(Engine oil)

Removal step

<<

A

>> >>

A

<< 1.


20 N·m 44 N·m 0 N·m

20 N·m +135˚

AC509274 AF

REMOVAL SERVICE POINT

<<A>> BALANCER SHAFT AND OIL

PUMP MODULE REMOVAL

CAUTION

• Turn the crankshaft clockwise.

•

Never turn the crankshaft after the cylinder

No. 1 or No. 4 is set to the top dead centre of compression.

Balancer shaft sprocket timing mark

Balancer shaft and oil pump module timing mark

Paint markings

AC509275AB

11A-60



1. Turn the crankshaft clockwise to align the timing mark of the balancer shaft sprocket with the timing mark of the balancer shaft and oil pump module, and set the cylinder No. 1 or No. 4 to the top dead centre of compression.

2. Put paint marks on the balancer shaft sprocket timing mark and balancer timing chain.

CAUTION

Securely install the plunger of the timing chain tensioner. Otherwise, it may pop out.

L-shaped hard wire or


4. Use a wrench to remove the mounting bolt at the lower side of the balancer timing chain guide shown in the figure so that the balancer timing chain guide is unrestricted.

5. Support the balancer shaft and oil pump module with a hand, and remove the balancer shaft and oil pump module mounting bolt.



AC509276AB

<Timing chain case internal diagram>

L-shaped hard wire or



AC509279AB

6. Remove the balancer shaft and oil pump module from the rudder frame with the balancer timing chain attached, and move it to the centre of the engine.

7. Remove the balancer timing chain from the balancer shaft and oil pump module, and remove the balancer shaft and oil pump module.



AC509277AB

3. Press the balancer timing chain against the timing chain tensioner, compress the plunger of the timing chain tensioner and insert L-shaped hard wire (piano wire of

φ1.5 mm) or L-shaped hexagon wrench (1.5 mm) to the plunger fixing hole of the timing chain tensioner from under the timing chain case, and fix the plunger of the timing chain tensioner.

CAUTION

When the tooth jump of the balancer timing chain from the crankshaft sprocket occurs, the timing between the balancer shaft and the oil pump module becomes off, resulting in the abnormal engine vibration. Be sure that the tooth jump will not occur.

Protrusion

Cable band


AC509280 AB

8. After the balancer shaft and oil pump module is removed, using a cable band, tie the balancer timing chain at the protrusion of the rudder frame to prevent the tooth jump of balancer timing chain from the crankshaft sprocket.


AC509278 AB



INSTALLATION SERVICE POINT

>>A<< BALANCER SHAFT AND OIL

PUMP MODULE INSTALLATION

1. When installing the new balancer shaft and oil pump module, apply oil to the oil pump in the balancer shaft and oil pump module and the balancer shaft bearing as follows.




Paint marking or timing mark

11A-61

Paint markings

AC509279 AC

Oil inlet port

Engine oil

Engine oil pan

AC509272

AB

(1) Clean the inside of the removed engine oil pan, and put the balancer shaft and oil pump module into the engine oil pan with its oil inlet port facing up.

(2) Pour new engine oil until two-thirds of the balancer shaft and oil pump module is soaked.

(3) Fill the engine oil (approximately 50 mL) into the balancer shaft and oil pump module from the oil inlet port.


3. Regarding the prevention of the tooth jump of the balancer timing chain, install the balancer shaft sprocket to the balancer timing chain with aligning the paint marking of the balancer shaft sprocket

(the timing mark of the new balancer shaft and oil pump module) with that of the balancer timing chain.

4. With the paint marking of the balancer timing chain aligned with that of the balancer sprocket

(the timing mark of the new balancer shaft and oil pump module), install the balancer shaft and oil pump module to the rudder frame. Securely bring the balancer shaft and oil pump module into contact with the rudder frame mounting area.

5. Apply an adequate and minimum amount of engine oil to the threads and bearing surfaces of the balancer shaft and oil pump module bolts.


1

3

4

2


AC509273 AB

(4) Turn the balancer shaft sprocket of the balancer shaft and oil pump module clockwise four rotations or more to apply the engine oil to the entire area of the oil pump and the balancer shaft bearing.

2. Remove the cable band installed to prevent the tooth jump of the balancer timing chain from the crankshaft sprocket from the balancer timing chain.

AC506784 AB

6. Tighten the balancer shaft and oil pump module bolts to the specified torque 20 N


7. Tighten the balancer shaft and oil pump module bolts again to the specified torque 44 N


8. Loosen the balancer shaft and oil pump module bolts fully in the reverse sequence to that shown.

9. Tighten the balancer shaft and oil pump module bolts to the specified torque 20 N


11A-62

1

4





3

2

AC506784 AB

10.After tightening to the specified torque, tighten the balancer shaft and oil pump module bolts to 135 degrees, using special tool angle gauge

(MB991614), in the order of number shown in the figure.

11.Tighten the mounting bolt of the balancer timing chain lower with the standard torque.


± 2 N⋅m

12.Remove the plunger of the timing chain tensioner using the L-shaped hard wire (

φ1.5 mm piano wire, etc.) or L-shaped hexagon wrench (1.5 mm).

MB991614

AC506777 AB


ENGINE ASSEMBLY

11A-63

ENGINE ASSEMBLY


M1112001007000

CAUTION

When the engine assembly is replaced, initialise the learned value using M.U.T.-III (Refer to GROUP 00

− Precautions before Service, and Initialisation Procedure of MPI Engine Learned Value ).


• Hood Removal (Refer to GROUP 42A − Hood ) <LH drive vehicles>.

• Hood Removal (Refer to GROUP 42A − Hood ) <RH drive vehicles>.

• Fuel Line Pressure Reduction (Refer to GROUP 13A −

On-vehicle Service, How to Reduce Pressurized Fuel

Lines ).



−

Under Cover ).

• Engine Coolant Draining (Refer to GROUP 14 − On-vehicle Service, Engine Coolant Replacement ).



• Transmission Fluid Draining (Refer to GROUP 23A −

On-vehicle Service, CVT Fluid Replacement ).

• Transfer Oil Draining (Refer to GROUP 23A − On-vehicle

Service, Transfer Oil Replacement ).

• Engine Cover Removal (Refer to

P.11A-19

).

• Air Cleaner Intake Hose and Air Cleaner Assembly

Removal (Refer to GROUP 15

− Air Cleaner ).

• Battery and Battery Tray Removal (Refer to GROUP 54A

− Battery ).

• Engine-ECU Removal (Refer to GROUP 13A −

Engine-ECU ).

• Exhaust Manifold Removal (Refer to GROUP 15 −

Exhaust Manifold ).

• Alternator and Others Belt Removal (Refer to

P.11A-16

).


• Alternator and Others Belt Installation (Refer to

P.11A-16 ).

• Exhaust Manifold Installation (Refer to GROUP 15 −

Exhaust Manifold ).

• Engine-ECU Installation (Refer to GROUP 13A −

Engine-ECU ).

• Battery and Battery Tray Installation (Refer to GROUP

54A

− Battery ).

• Air Cleaner Intake Hose and Air Cleaner Assembly Installation (Refer to GROUP 15

− Air Cleaner ).

• Engine Cover Installation (Refer to

P.11A-19

).

• Transfer Oil Refilling (Refer to GROUP 23A − On-vehicle

Service, Transfer Oil Replacement ).

• Transmission Fluid Refilling (Refer to GROUP 23A −

On-vehicle Service, CVT Fluid Replacement ).



• Engine Coolant Refilling (Refer to GROUP 14 − On-vehicle Service, Engine Coolant Replacement ).

• Alternator and Others Belt Tension Check (Refer to

P.11A-8

).



−

Under Cover ).

• Fuel Leak Check.

• Hood Installation (Refer to GROUP 42A − Hood ) <LH drive vehicles>.

• Hood Installation (Refer to GROUP 42A − Hood ) <RH drive vehicles>.

11A-64


ENGINE ASSEMBLY

7

9

8

10

9.0 ± 1.0 N·m

12 ± 2 N·m

N

3

4

6

2

N

5

1

Removal steps

1.


2.

Battery cable connection

<<

A

>> >>

F

<<

3.

Hose clip

<<

A

>> >>

F

<<

4.

Radiator upper hose connection

<<

A

>> >>

F

<<

5.

Hose clip

<<

A

>> >>

F

<<

6.

Radiator lower hose connection

7.

Heater hose connection

ACC00063 AB


8.

Canister vacuum hose connection

9.

Brake booster vacuum hose connection

<> >>

E

<<

10. Fuel high-pressure hose connection

•

Alternator and others belt (Refer to

P.11A-16 )

15


ENGINE ASSEMBLY

11A-65

12

50 ± 5 N·m

66 ± 7 N·m

14

11

13

44 ± 10 N·m

Removal steps

<<

C

>> >>

D

<< 11. A/C compressor and clutch assembly

12. Inlet manifold assembly (Refer to

GROUP 15

− Inlet Manifold )

•

Transmission assembly (Refer to

GROUP 23A

− Transmission

Assembly ).

>>

C

<< 13. Earth cable connection

<<

D

>> >>

B

<< 14. Engine mounting bracket

<<

E

>>

>>

A

<< 15. Engine assembly

23 ± 6 N·m

ACC00064 AB


<<A>> HOSE CLIP/RADIATOR HOSE DIS-

CONNECTION

Mating marks

AC606081 AE

1. Make mating marks on the radiator hose and the hose clip as shown to install them in the original position.

11A-66

<> FUEL HIGH-PRESSURE HOSE

REMOVAL

Claw (Tip)

Hose clip


ENGINE ASSEMBLY

<<C>> A/C COMPRESSOR AND CLUTCH

ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly together with the hose from the bracket.

2. Tie the removed A/C compressor and clutch assembly with a string at a position where it will not interfere with the removal and installation of engine assembly.

AC302615 AE

2. Break off the tip of hose clip claw and spread out the hose clip, then disconnect the radiator lower hose.

NOTE: If there is a hose clip claw, the hose clip cannot spread to capacity because the claw contacts the hose clip.

<<D>> ENGINE MOUNTING BRACKET

REMOVAL

CAUTION


1. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine assembly.

Stopper

MB991527

AC301860AB

1. Remove the stopper of the fuel high-pressure hose.

Retainer

MB991454

MB991956

MB991928

AC506487 AD

MB991527

MB991454

MB991956

B

MB991895

AC506484 AD

AC301861AB

2. Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.

NOTE: If the retainer is released, install it securely after removing the fuel high-pressure hose.

A

MB992853

ACB01874AB


ENGINE ASSEMBLY

2. Remove special tools engine hanger (MB991928 or MB991895) and engine hanger plate

(MB992853) which was installed for supporting the engine assembly when the transmission assembly was removed (Refer to GROUP 23A

−

Transmission Assembly ).

3. Operate a garage jack so that the engine weight is not applied to the engine mounting bracket, and remove the engine mounting bracket.

11A-67

1. Install special tool engine hanger plate

(MB991956) to the cylinder head, and set special tool hanger (MB991527) and the chains of special tool engine hanger balancer (MB991454) to the engine assembly to hold the engine assembly.

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

<<E>> ENGINE ASSEMBLY REMOVAL

MB991454

MB991527

>>B<< ENGINE MOUNTING BRACKET

INSTALLATION

CAUTION


1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mounting bracket while adjusting the position of the engine.

MB991956

AC506787 AB

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

MB991527

MB991454


>>A<< ENGINE ASSEMBLY INSTALLA-

TION

MB991956

MB991956

MB991928

AC506487 AD

MB991527

Oil control valve

(inlet side)

MB991454

AC600152AB

MB991527

MB991454

MB991956

MB991895

AC506484 AD


MB991895) which is used during installation of transmission assembly to hold the engine assembly (Refer to GROUP 23A

− Transmission

Assembly ).

3. Remove the garage jack which supports the engine assembly.

MB991956

AC506787 AB

11A-68

>>C<< EARTH CABLE CONNECTION

15˚ 15˚

AC606264 AB


ENGINE ASSEMBLY

>>E<< FUEL HIGH-PRESSURE HOSE

INSTALLATION

CAUTION

After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 3-mm play. After the check, install the stopper securely.

Fuel high-pressure hose

3 mm

1. Install the earth cable in the direction shown in the illustration.

2. Tighten the alternator mounting bolt to the specified torque.


± 10 N⋅m Fuel line pipe

(Engine oil applied)

AC301864AB

>>D<< A/C COMPRESSOR AND CLUTCH


Stopper

1

3

2


AC506759

AK

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.


± 6 N⋅m

AC301863AB

Apply a small amount of engine oil to the fuel line pipe, and install the fuel high-pressure hose.

>>F<< RADIATOR HOSE/HOSE CLIP

CONNECTION

CAUTION

Never reuse the hose clip whose claw is broken off to prevent the rusting.

1. Make mating mark on a new hose clip in the same position as the remove one.

Protrusion

Pipe, fitting, or etc.

Mating marks

AC606082 AU


ENGINE ASSEMBLY

2. Insert the radiator hose until the protrusion of the pipe.

3. Align the mating marks on the radiator hose and hose clip.

11A-69

4. Remove the hose clip claw and shorten the hose clip, then install the radiator hose.

Mitsubishi Engine, Oil pan, Crankshaft oil seal, Cylinder head gasket, Timing chain, 4B12 Balancer shaft Balancer timing chain, 4B12 Oil pump module Balancer shaft, Crankshaft pulley, Camshaft, Valve stem seal, Engine assembly Service Manual

Assistant Bot

GROUP 11A

ENGINE

MECHANICAL

CONTENTS

SERVICE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

ON-VEHICLE SERVICE

CRANKSHAFT PULLEY

CAMSHAFT

VALVE STEM SEAL

OIL PAN

CRANKSHAFT OIL SEAL

CYLINDER HEAD GASKET

TIMING CHAIN

BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL

PUMP MODULE <4B12>

BALANCER SHAFT AND OIL PUMP MODULE <4B12>

ENGINE ASSEMBLY

Key Features

Frequently Answers and Questions

How do I check the drive belt tension?

How do I adjust the ignition timing?

How do I check the idle speed?

What is the standard valve clearance?

How do I check the compression pressure?

Related manuals

Mitsubishi Engine, Oil pan, Crankshaft oil seal, Cylinder head gasket, Timing chain, 4B12 Balancer shaft Balancer timing chain, 4B12 Oil pump module Balancer shaft, Crankshaft pulley, Camshaft, Valve stem seal, Engine assembly Service Manual

Assistant Bot

GROUP 11A

ENGINE

MECHANICAL

CONTENTS

SERVICE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

ON-VEHICLE SERVICE

CRANKSHAFT PULLEY

CAMSHAFT

VALVE STEM SEAL

OIL PAN

CRANKSHAFT OIL SEAL

CYLINDER HEAD GASKET

TIMING CHAIN

BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL

PUMP MODULE <4B12>

BALANCER SHAFT AND OIL PUMP MODULE <4B12>

ENGINE ASSEMBLY

Key Features

Frequently Answers and Questions

How do I check the drive belt tension?

How do I adjust the ignition timing?

How do I check the idle speed?

What is the standard valve clearance?

How do I check the compression pressure?

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