Mitsubishi Lancer 2001 User Manual
General ........................
00
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This manual outlines changes in servicing
procedures related to th e chassis including vehicle
inspections, adjustments and improvements in the
newly equipped models.
Please read this manual carefully so that it will be of
assistance for your service activities.
Please note that the following service manuals are
also available and should be used in conjunction
with this manual.
TECHNICAL INFORMATION MANUAL
PYME9501
PYME9501-1
WORKSHOP MANUAL
CHASSIS GROUP PWME9511 (Basic)
PWME9511-A (Supplement)
PWME9511-B (Supplement)
ENGINE GROUP PWEE____
(Looseleaf edition)
ELECTRICAL WIRING PHME9511 (Basic)
PHME9511-A (Supplement)
PHME9511-B (Supplement)
PHME9511-C (Supplement)
BODY REPAIR MANUAL PBME9501 (Basic)
PBME9501-1 (Supplement)
PBME9501-2 (Supplement)
PARTS CATALOGUE B806F006A_
Engine .........................
Engine Lubrication .............
Fuel ...........................
Engine Cooling .................
Intake and Exhaust .............
Engine Electrical ...............
Engine and Emission Control ....
Automatic Transmission ........
11
12
13
14
15
16
17
23
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
Mitsubishi Motors Corporation Jun. 2000
E
WARNING!
(1) Improper service or maintenance of any component of the SRS and any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag or to the driver and passenger (from rendering the SRS inoperative).
(2) SRS components should not be subjected to heat, so remove the SRS-ECU, air bag module
(driver’s side and front passenger’s side), clock spring, side impact sensor and front seat
assembly (side air bag module) before drying or baking the vehicle after painting.
SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more
(3) Service or maintenance of any SRS component and SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance
of any component of the SRS and any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
GENERAL
CONTENTS
00-1
VEHICLE IDENTIFICATION 2.................
Models 2......................................
Model Code 2.................................
Chassis Number 3.............................
MAJOR SPECIFICATIONS 4...................
Hatchback 4...................................
00-2
GENERAL - Vehicle Identification
VEHICLE IDENTIFICATION
MODELS
Model code Engine model Transmission model Fuel supply system
CJ1A MNDEL6/R6 4G13 (1,298 mL) F5M41 <5M/T> MPI
(Electronically Controlled
MNJEL6/R6
CJ4A MNJEL6/R6 4G92 MPI (1,597 mL)
MRJEL6/R6 F4A41
<INVECS-II 4A/T>
Multi Point Fuel Injection)
CJ
1
MODEL CODE
A
4
2
M
NJEL
3
5
4
67
6
9
8
No. Items Contents
1 Development CJ: MITSUBISHI (2-door)
2 Engine type 1: 1,298 mL petrol engine
4: 1,597 mL petrol engine
3 Sort A: Passenger car
4 Body style M: 2-door hatchback
5 Transmission type N: 5-speed manual
transmission
R: 4-speed automatic
transmission
6 Trim level D: GL
J: GLX or GLXi
7 Specification engine
feature
8 Steering wheel
location
E: SOHC-MPI
L: Left hand
R: Right hand
9 Destination 6: For Europe
GENERAL - Vehicle Identification
CHASSIS NUMBER
The chassis number is stamped on the toeboard inside the
engine compartment.
00-3
12 3
No. Items Contents
1 Fixed figure J Asia
2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
4 Body style M 2-door hatchback
5 Transmission type N 5-speed manual transmission
6 Development order CJ COLT
7 Engine 1 4G13: 1,298 mL petrol engine
8 Sort A Passenger car
5
4
67891110
B For Europe, left hand drive
R 4-speed automatic transmission
4 4G92: 1,597 mL petrol engine
9 Model year 1 2001
10 Plant U Mizushima Motor Vehicle Works
11 Serial number - -
00-4
GENERAL - Major Specifications
MAJOR SPECIFICATIONS
HATCHBACK
9
5
2
7
3
4
1
86
Items CJ1A
MNDEL6,
MNDER6
Vehicle
dimensions
mm
mm
Overall length 1 3,900 3,900 3,900 3,900
Overall width 2 1,680 1,680 1,680 1,680
Overall height (unladen) 3 1,365,
1,380*
1,385*
1,400*
Wheelbase 4 2,415 2,415 2,415 2,415
Track-front 5 1,450 1,450 1,450 1,450
Track-rear 6 1,460 1,460 1,460 1,460
Overhang-front 7 825 825 825 825
Overhang-rear 8 660 660 660 660
Ground clearance (unladen) 9 150, 165*1,*3150, 165*1,*3150, 165*1,*3150, 165*1,*
Vehicle
weight kg
Kerb weight 950 955 975 995
Max. gross vehicle weight rating 1,445 1,445 1,470 1,480
Max. axle weight rating-front 810 810 810 810
Max. axle weight rating-rear 705 705 705 705
CJ1A
MNJEL6,
MNJER6
1
,
2
,
3
1,365,
1,380*
1,385*
1,400*
1
,
2
,
3
CJ4A
MNJEL6,
MNJER6
1,365,
1
1,380*
1,385*
1,400*
,
2
,
3
CJ4A
MNJEL6,
MNJER6
1,365,
1
1,380*
1,385*
1,400*
,
2
,
3
3
Seating capacity 5
Engine
Model No. 4G13 4G92
Total displacement mL 1,298 1,597
Transmission
Model No. F5M41 F4A41
Type 5 speed-manual 4 speed-
automatic
Fuel system Fuel supply system MPI (Electronically Controlled Multi Point Fuel Injection)
NOTE
1
: indicates vehicles with high ground suspension.
1. *
2
: indicates vehicles with rear spoiler.
2. *
3
3. *
: indicates vehicles with high ground suspension and rear spoiler.
ENGINE
CONTENTS
ENGINE <4G1> 11A......................................................
ENGINE <4G9> 11B......................................................
11A-1
11A-2
ENGINE <4G1>
CONTENTS
GENERAL 3.................................
Outline of Changes 3..........................
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
SPECIAL TOOLS 4..........................
ON-VEHICLE SERVICE 5.....................
Compression Pressure Check 5.................
Lash Adjuster Check 5.........................
CAMSHAFT AND CAMSHAFT OIL SEAL 8....
CRANKSHAFT FRONT OIL SEAL 11..........
CYLINDER HEAD GASKET 12...............
General/General Information/
ENGINE <4G1> -
Service Specifications/Sealant
GENERAL
OUTLINE OF CHANGES
The following service procedures have been
established due to the addition of the 4G13-SOHC
16 valve MPI engine. Furthermore, other items are
the same as for the 4G13-SOHC 12 valve MPI
engine.
D The basic ignition timing has been changed
as a direct-mounted crank angle sensor has
been used.
D The compression pressure has been changed.
D An auto-lash adjuster has been adopted.
D Camshaft and camshaft oil seal removal and
installation
D Crankshaft front oil seal removal and installation
D Cylinder head gasket removal and installation
GENERAL INFORMATION
Items 4G13
Compression ratio 10.0
Combustion chamber Pentroof type
Number of valve Intake 8
11A-3
Exhaust 8
V alve timing Intake Opening BTDC 17
Closing ABDC 39
Exhaust Opening BBDC 49
Closing ATDC 7
Auto-lash adjuster Equipped
_
_
_
_
SERVICE SPECIFICATIONS
Items Standard value Limit
Basic ignition timing 5_BTDC±3
Compression pressure (250 – 400 r/min) kPa 1,598 Min. 1,161
Cylinder head bolt shank length mm - 103.2
_
-
SEALANT
Items Specified sealant Remarks
Camshaft position sensor support MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
11A-4
ENGINE <4G1> -
Special Tools
SPECIAL TOOLS
Tool Number Name Use
MB990767 Front hub and
flange yoke holder
MD998719 Crankshaft pulley
holder pin
MD998443 Auto-lash adjuster
holder
MD998713 Camshaft oil seal
installer
Holding the camshaft sprocket
Supporting of lash adjuster
Press-in of the camshaft oil seal
MD998304 Crankshaft front oil
seal installer
MD998305 Crankshaft front oil
seal guide
MB991653 Cylinder head bolt
wrench
Press-fitting the crankshaft front oil seal
Cylinder head bolt removal and installation
ENGINE <4G1> -
ON-VEHICLE SERVICE
COMPRESSION PRESSURE CHECK
The disconnection of the distributor connector has been
changed to the disconnection of the crank angle sensor
connector due to the change of the crank angle sensor. Other
service procedures are the same as before.
Standard value (at engine speed of 250 - 400 r/min):
Limit (at engine speed of 250 - 4 00 r/min):
LASH ADJUSTER CHECK
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
(2) If there is a problem with the lash adjusters, the noise
On-vehicle Service
1,598 kPa
Min. 1,161 kPa
with the lash adjusters is generated after the engine
is started, an d will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
11A-5
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused by
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied.
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
11A-6
ENGINE <4G1> -
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or disappeared, oil sludge
could make the lash adjusters stick. Clean the lash
adjusters. (Refer to the Engine Workshop Manual.) If not
improved, go to step 5.
5. Bleed air from the lash adjusters.
6. If the noise has not disappeared even after the air
bleeding, clean the lash adjusters. (Refer to the Engine
Workshop Manual.)
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
(2) After parking the vehicle for long periods, the oil drains
(3) If either of the above situations occur, the abnormal
On-vehicle Service
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
out of the oil passage, and it takes time for the oil
to be supplied to th e lash adjuster, so air can get
into the high pressure chamber.
noise can be eliminated by bleeding the air from inside
the lash adjusters.
Good
Highpressure
chamber
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
ENGINE <4G1> -
On-vehicle Service
11A-7
Drive pattern for air bleeding
Gradually open the
throttle valve.
Approx.
3,000 r/min
Idle speed
15
seconds
Once
Close the throttle
valve.
15
seconds
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
11A-8
ENGINE <4G1> - Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Air Cleaner Removal and Installation
D Ignition Coil Removal and Installation
(Refer to GROUP16.)
12
Apply engine oil to all
moving parts during
installation.
3.5 Nm
4
10 - 12 Nm
13
12
5.0 Nm
14
5
3
28 - 34 Nm
10
11
6
16
15
12 - 15 Nm
22 Nm
10 - 12 Nm
10 - 12 Nm
AA""CA
"BA
8
9
88 Nm
7
Removal steps
1. Breather hose connection
2. PCV hose connection
3. Accelerator cable clamp
<LH drive vehicles>
4. Rocker cover
5. Rocker cover gasket
6. Spark plug guide
7. Timing belt front upper cover
8. Camshaft sprocket
9. Camshaft oil seal
AB""AA
AB""AA
14
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
10. Lash adjuster, intake rocker arm
and shaft assembly
11. Lash adjuster, exhaust rocker arm
and shaft assembly
12. Ignition failure sensor connector
13. Camshaft position sensor connector
14. Camshaft position sensor support
15. Camshaft
16. Camshaft position sensing cylinder
ENGINE <4G1> - Camshaft and Camshaft Oil Seal
REMOVAL SERVICE POINTS
Timing mark
Camshaft
sprocket
AA"
1. Turn the crankshaft in the forward direction (clockwise)
2. Secure the camshaft sprocket and the timing belt with
CAMSHAFT SPROCKET REMOVAL
to align the timing mark so that No.1 cylinder is at the
compression TDC.
Caution
Always turn the crankshaft in the forward direction
(clockwise).
band cables to prevent deviation from the relative positions
between the camshaft sprocket and the timing belt.
11A-9
MB990767
MD998443
MD998719
3. Use the special tool to stop the camshaft sprocket from
turning.
4. Remove the camshaft sprocket with the timing belt
attached.
Caution
Do not turn the crankshaft after the camshaft sprocket
is removed.
AB"
LASH ADJUSTER, INTAKE ROCKER ARM AND
SHAFT ASSEMBLY/LASH ADJUSTER, EXHAUST
ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
Before removing the lash adjuster, rocker arm a nd shaft
assembly, install the special tools as shown in the illustration
so that the lash adjusters will not fall out.
Notch
Notch
Front of engine
INSTALLATION SERVICE POINTS
"AA
Position the rocker arm shaft so that their notches point the
direction shown, an d install the lash adjuster, rocker arm
and shaft assembly.
LASH ADJUSTER, EXHAUST ROCKER ARM AND
SHAFT ASSEMBLY/LASH ADJUSTER, INTAKE
ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
11A-10
ENGINE <4G1> - Camshaft and Camshaft Oil Seal
MD998713
"BA
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
"CA
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
Tightening torque: 88 Nm
CAMSHAFT OIL SEAL INSTALLATION
CAMSHAFT SPROCKET INSTALLATION
ENGINE <4G1> - Crankshaft Front Oil Seal
CRANKSHAFT FRONT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Timing Belt Removal and Installation
D Crank angle sensor Removal and Installation
(Refer to GROUP16.)
5
(Lip)
Engine oil
11A-11
"BA
"BA
"BA
MD998304
5
3
1
2
Removal steps
1. Crankshaft sprocket
2. Spring pin
3. Crankshaft sensing blade
Crankshaft
4
"BA
"AA
4. Crankshaft spacer
5. Crankshaft front oil seal
INSTALLATION SERVICE POINTS
"AA
1. Apply a small amount of engine oil to the entire
2. Tap the oil seal unit it flushes with the oil seal case.
CRANKSHAFT FRONT OIL SEAL INSTALLATION
circumference of the oil seal lip.
MD998305
Oil seal
11A-12
ENGINE <4G1> - Crankshaft Front Oil Seal/Cylinder Head Gasket
Crankshaft
sensing blade
Crankshaft
sprocket
Crankshaft
spacer
Front of
engine
Spring pin
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Prevention of Fuel Discharge <before removal only>
D
Fuel Leak Check <after installation only>
D
Under Cover Removal and Installation
D
"BA
CRANKSHAFT SPACER/CRANKSHAFT SENSING
BLADE/SPRING PIN/CRANKSHAFT SPROCKET
INSTALLATION
Install t he crankshaft sprocket assembled with the spring pin,
the crankshaft sensing blade, and the crankshaft spacer to
the crankshaft.
Engine Coolant Draining and Supplying
D
Engine Oil Draining and Supplying
D
Air Cleaner Removal an d Installation
D
ENGINE <4G1> - Cylinder Head Gasket
11A-13
(Engine oil)
10 - 12 Nm
10 - 12 Nm
21
25
23
49 Nm®0Nm®20 Nm®+90°®+90°(Cold engine)
24
8
9
10
4
2
5
6
7
3
1
18
14
15
5.0 Nm
12
13
11
24 Nm
19
88 Nm
22
Removal steps
1. Crank angle sensor connector
2. Detonation sensor connector
3. Oxygen sensor (rear) connector
4. Vacuum sensor connector
5. Ignition coil connector
6. Injector connector
7. EGR solenoid valve connector
8. Throttle position sensor connector
9. Idle speed control servo connector
10. Purge control solenoid valve
connector
11. Engine coolant temperature gauge
unit connector
12. Oxygen sensor (front) connector
13. Engine coolant temperature sensor
connector
35 Nm
50 Nm
AA""CA
AB""BA
17
"AA
20
(Engine oil)
16
14. Ignition failure sensor connector
15. Camshaft position sensor connector
D
Rocker cover (Refer to P.11A-8.)
D
Intake manifold
(Refer to GROUP 15.)
D
Water inlet pipe (Refer to GROUP 14.)
16. Front exhaust pipe connection
17. Front exhaust pipe gasket
18. Exhaust manifold bracket
19. Oil level gauge assembly
20. O-ring
21. Timing belt front upper cover
22. Camshaft sprocket
23. Cylinder head bolts
24. Cylinder head assembly
25. Cylinder head gasket
11A-14
ENGINE <4G1> - Cylinder Head Gasket
REMOVAL SERVICE POINTS
Timing mark
Camshaft
sprocket
AA"
1. Turn the crankshaft in the forward direction (clockwise)
2. Secure the camshaft sprocket and the timing belt with
CAMSHAFT SPROCKET REMOVAL
to align the timing mark so that No.1 cylinder is at the
compression TDC.
Caution
Always turn the crankshaft in the forward direction
(clockwise).
band cables to prevent deviation from the relative positions
between the camshaft sprocket and the timing belt.
MB990767
MB991653
MD998719
3. Use the special tool to stop the camshaft sprocket from
turning.
4. Remove the camshaft sprocket with the timing belt
attached.
Caution
Do not turn the crankshaft after the camshaft sprocket
is removed.
AB"
CYLINDER HEAD BOLT REMOVAL
Use the special tool to loosen the bolts in 2 or 3 steps in
order of the numbers shown in the illustration, a nd remove
the cylinder head assembly.
3
1
Front of engine
5
7
10
9
8
6
2
4
ENGINE <4G1> - Cylinder Head Gasket
INSTALLATION SERVICE POINTS
"AA
1. Wipe off all oil and grease from the gasket mounting
2. Install so that the shapes of the cylinder head holes match
CYLINDER HEAD GASKET INSTALLATION
surface.
Caution
Do not allow foreign material to enter the engine
coolant or oil passages and the cylinder.
the shapes of the respective cylinder head gasket holes.
11A-15
(Engine oil)
MB991653
"BA
CYLINDER HEAD BOLT INSTALLATION
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Limit (A): 103.2 mm
2. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
A
3. Use the special tool to tighten the bolts by the following
procedure (angle-tightening procedure).
(1) Tighten the cylinder head bolts in the shown sequence
to 49 Nm.
(2) Loosen the cylinder head bolts completely in the
reverse of the shown sequence.
(3) Tighten the cylinder head bolts in the shown order
to 20 Nm.
8
10
Front of engine
6
4
1
2
3
5
9
7
11A-16
ENGINE <4G1> - Cylinder Head Gasket
Step (4)
90
Painted mark
Step (5)
_
90
_
(4) Mark the cylinder head bolts and the cylinder head with
paint, and then tighten the bolts in the shown
sequence to 90°.
(5) Tighten the bolts in the shown sequence to additional
90°, and check that the paint marks on the cylinder
head bolts are flush with the paint marks on the
cylinder head.
Caution
Painted mark
1) If the tightening angle is less than 90°, the
bolt is loose.
2) If the tightening angle is more than 90°, loosen
the bolt and repeat the procedure from step
1.
"CA
CAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
Tightening torque: 88 Nm
ENGINE <4G9>
CONTENTS
11B-1
GENERAL 2.................................
Outline of Changes 2..........................
GENERAL INFORMATION 2..................
SPECIAL TOOL 2............................
ON-VEHICLE SERVICE 2.....................
Ignition Timing Check 2........................
Lash Adjuster Check 2.........................
CAMSHAFT AND CAMSHAFT OIL SEAL 5....
TIMING BELT 6..............................
11B-2
ENGINE <4G9> -
General/General Information/
Special Tool/On-vehicle Service
GENERAL
OUTLINE OF CHANGES
The following service procedures have been
changed. Furthermore, other items are the same
as before.
D The valve timing has been changed.
D The ignition timing has been changed.
D An auto-lash adjuster has been added.
D The timing belt lower cover has been changed.
GENERAL INFORMATION
Items 4G9
V alve timing Intake Opening BTDC 12
Closing ABDC 46
Exhaust Opening BBDC 46
Closing ATDC 2
SPECIAL TOOL
Tool Number Name Use
MD998443 Auto-lash adjuster
holder
ON-VEHICLE SERVICE
_
_
_
_
Supporting of lash adjuster
IGNITION TIMING CHECK
The ignition timing has been changed. Other service
procedures are the same as before.
Standard value: Approx. 8_BTDC
LASH ADJUSTER CHECK
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, an d will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
ENGINE <4G9> -
(2) If there is a problem with the lash adjusters, the noise
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused by
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N ® D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or disappeared, oil sludge
could make the lash adjusters stick. Clean the lash
adjusters. (Refer to the Engine Workshop Manual.) If not
improved, go to step 5.
5. Bleed air from the lash adjusters.
6. If the noise has not disappeared even after the air
bleeding, clean the lash adjusters. (Refer to the Engine
Workshop Manual.)
On-vehicle Service
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
11B-3
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to th e lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.
11B-4
Good
ENGINE <4G9> -
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
(2) If the amount of oil is greater than normal, then the
(3) If the oil is degenerated, air and oil will not separate
On-vehicle Service
in through the oil screen and will get into the oil
passage.
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
easily in oil, and the amount of air mixed into the
oil will increase.
Drive pattern for air bleeding
Gradually open the
throttle valve.
Approx.
3,000 r/min
Idle speed
15
seconds
Once
Close the throttle
valve.
15
seconds
Highpressure
chamber
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
ENGINE <4G9> - Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
28 - 34 Nm
Apply engine oil to all
sliding parts during
installation.
1
11B-5
2
AA""AA
AA""AA
Notch
Notch
Front of engine
Removal steps
1. Lash adjuster, intake rocker arm
and shaft assembly
2. Lash adjuster, exhaust rocker arm
and shaft assembly
MD998443
REMOVAL SERVICE POINT
AA"
Before removing the lash adjuster, rocker arm a nd shaft
assembly, install the special tools as shown in the illustration
so that the lash adjusters will not fall out.
LASH ADJUSTER, INTAKE ROCKER ARM AND
SHAFT ASSEMBLY/LASH ADJUSTER, EXHAUST
ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
INSTALLATION SERVICE POINT
"AA
Position the rocker arm shafts so that their notches point
the direction shown, and install the lash adjuster, rocker arm
and shaft assembly.
LASH ADJUSTER, EXHAUST ROCKER ARM AND
SHAFT ASSEMBLY/LASH ADJUSTER, INTAKE
ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
11B-6
ENGINE <4G9> - Timing Belt
TIMING BELT
REMOVAL AND INSTALLATION
1
10 Nm
10 Nm
Removal steps
1. Crank angle sensor connector
"AA 2. Timing belt lower cover
2
INSTALLATION SERVICE POINT
"AA
1. Mount the bolt shown in the illustration (M6´20 mm)
2. Mount the other bolts, and tighten them to the specified
TIMING BELT LOWER COVER INSTALLATION
first.
torque.
Tightening torque: 10 Nm
ENGINE LUBRICATION -
GROUP 12
ENGINE LUBRICATION
GENERAL
OUTLINE OF CHANGE
A quality of the engine oil has been changed.
ON-VEHICLE SERVICE
Specified Engine Oil (ACEA and API classification):
General/On-vehicle Service
ACEA A1, A2, A3/API SG or higher
12-1
NOTES
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