Mitsubishi Mirage 2015 User Manual

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Page 1

GROUP 11

ENGINE

CONTENTS

ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

11-1

Page 2

NOTES

Page 3

GROUP 11A

ENGINE

MECHANICAL

CONTENTS

11A-1

GENERAL INFORMATION . . . . . . . . 11A-2

ENGINE DIAGNOSIS. . . . . . . . . . . . . 11A-2

SERVICE SPECIFICATIONS. . . . . . . 11A-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-4

ON-VEHICLE SERVICE. . . . . . . . . . . 11A-8

DRIVE BELT TENSION CHECK 

AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 11A-8

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

IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-12

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

VALVE CLEARANCE CHECK 

AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 11A-13

COMPRESSION PRESSURE CHECK. . . . 11A-16

MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-17

CRANKSHAFT PULLEY . . . . . . . . . . 11A-18

REMOVAL AND INSTALLATION . . . . . . . . 11A-18

ROCKER COVER ASSEMBLY . . . . . 11A-22

REMOVAL AND INSTALLATION . . . . . . . . 11A-22

CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11A-23

REMOVAL AND INSTALLATION . . . . . . . . 11A-23

OIL FEEDER CONTROL VALVE . . . . 11A-29

REMOVAL AND INSTALLATION . . . . . . . . 11A-29

VALVE STEM SEAL . . . . . . . . . . . . . . 11A-30

REMOVAL AND INSTALLATION . . . . . . . . 11A-30

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-37

REMOVAL AND INSTALLATION . . . . . . . . 11A-37

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

CRANKSHAFT OIL SEAL . . . . . . . . . 11A-39

REMOVAL AND INSTALLATION . . . . . . . . 11A-39

CYLINDER HEAD GASKET . . . . . . . . 11A-42

REMOVAL AND INSTALLATION . . . . . . . . 11A-42

TIMING CHAIN CASE 

ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 11A-44

REMOVAL AND INSTALLATION . . . . . . . . 11A-44

TIMING CHAIN . . . . . . . . . . . . . . . . . . 11A-45

REMOVAL AND INSTALLATION . . . . . . . . 11A-45

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-46

REMOVAL AND INSTALLATION . . . . . . . . 11A-46

Page 4

11A-2

ENGINE MECHANICAL

GENERAL INFORMATION

M1111000102426

Item 3A92

Total displacement cm3 (cu in)

Bore  stroke mm (in) 75.0 (2.95)  90.0 (3.54)

Compression ratio 10.5

Combustion chamber Pentroof type

Camshaft arrangement DOHC

Valve timing Intake opening BTDC 41  ATDC 9 

Intake closing ABDC 19  ABDC 69

Exhaust opening BBDC 35

Exhaust closing ATDC 5

Fuel system Electronically controlled multiport fuel injection

Ignition system Electronic-controlled 3-coil

1,193 (72.8)

ENGINE DIAGNOSIS

M1111000700466

Symptom Probable cause Remedy

Compression is too low

Drop in engine oil pressure

Blown cylinder head gasket Replace the gasket.

Worn or damaged piston rings Replace the rings.

Worn piston or cylinder Repair or replace the piston and/or the

cylinder block.

Worn or damaged valve seat Repair or replace the valve and/or the

seat ring

Engine oil level is too low Check the engine oil level.

Malfunction of engine oil pressure switch Replace the engine oil pressure switch.

Clogged oil filter Install a new filter.

Worn oil pump gears or cover Replace the gears and/or the cover.

Thin or diluted engine oil Change the engine oil to the correct

viscosity.

Stuck (opened) oil relief valve Repair the relief valve.

Excessive bearing clearance Replace the bearings.

Engine oil pressure too high

Noisy valves Incorrect valve clearance Adjust valve clearance

Connecting rod noise/main bearing noise

Stuck (closed) oil relief valve Repair the relief valve.

Thin or diluted engine oil (low engine oil pressure)

Worn or damaged valve stem or valve guide

Insufficient oil supply Check the engine oil level.

Thin or diluted engine oil Change the engine oil.

Excessive bearing clearance Replace the bearings.

Change the engine oil.

Replace the valve and/or the guide.

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Page 5

ENGINE MECHANICAL

SERVICE SPECIFICATIONS

11A-3

SERVICE SPECIFICATIONS

Item Standard value Limit

Drive belt tension (When checked)

Drive belt tension (When adjusted)

Drive belt tension (When replaced)

Vibration frequency Hz

Tension N (lb) 490  686 (110.2  154.2)

Deflection mm (in) [Reference]

Vibration frequency Hz

Tension N (lb) 539  637 (121.2  143.2)

Deflection mm (in) [Reference]

Vibration frequency Hz

Tension N (lb) 882  980 (198.3  220.3)

Deflection mm (in) [Reference]

Vehicle s without A/C 144  169

Vehicles with A/C 143  169

Vehicle s without A/C 8.3  10.5 (0.33  0.41)

Vehicles with A/C 8.5  10.9 (0.34  0.42)

Vehicle s without A/C 151  163

Vehicles with A/C 150  163

Vehicle s without A/C 8.8  9.9 (0.35  0.38)

Vehicles with A/C 9.1  10.2 (0.36  0.40)

Vehicle s without A/C 192  202

Vehicles with A/C 192  202

Vehicle s without A/C 6.2  6.8 (0.25  0.26)

Vehicles with A/C 6.3  6.9 (0.25  0.27)



M1112000303051

Basic ignition timing 5 BTDC  3

Ignition timing Approximately 8 BTDC

Idle speed r/min 700  50

CO contents % 0.5 or less

HC contents ppm 100 or less

Valve clearance mm (in)

Compression pressure kPa (psi)

Compression pressure difference of all cylinders kPa (psi)

Intake manifold vacuum kPa (in Hg)

cold engine Intake 0.22  0.04 (0.009  0.001)

Exhaust 0.30  0.04 (0.012  0.001)

at engine speed of 250 r/min 1,410 (205) Minimum 950



(138)

Maximum 98 (14)

Minimum 60 (17)

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Page 6

11A-4

B992080

ACB05421

MB992745

MB992746

MB992744

MB992747

MB992748

DO NOT USE

ENGINE MECHANICAL

SPECIAL TOOLS

M1112000603193

Tool Tool nu mbe r and n ame Supersession Application

MB992080

a: MB992081 b: MB992082

Belt tension meter set

a: Belt tension meter b: Microphone assembly

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

Tool not available Drive belt tension check



 Checking the ignition timing  Checking the idle speed  Erasing the diagnostic trouble

code

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Page 7

ENGINE MECHANICAL

CAUTION

MB991910

MB991826

MB991958

MB991911

MB991914

MB991824

MB991827

MB991825

DO NOT USE

B990767

D998719

SPECIAL TOOLS

11A-5

Tool Tool numb er and name Sup ersession Applicat ion

MB991958

a. MB991824 b. MB991827 c. MB991910 d. MB991911 e. MB991914 f. MB991825 g. MB991826

M.U.T.-III sub-assembly

a. Vehicle

MB991824-KIT

NOTE: G: MB991826 M.U.T.-III Trigger Harness is not necessary when pushing V.C.I. ENTER key.

M.U.T.-III main harness A (MB991910) should be used. M.U.T.-III main harness B and C should not be used for this vehicle.

 Checking the ignition timing  Checking the idle speed  Erasing the diagnostic trouble

code

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 main

harness C (for

Chrysler models only) f. M.U.T.-III

measurement adapter g. M.U.T.-III trigger

harness

MB990767 Front hub and flange yoke holder

MD998719 Pin

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MB990767-01 Holding the crankshaft pulley

MIT308239

Page 8

11A-6

B991992

MD998772

B992090

B992922

D998727

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Tool numb er and name Sup ersession Applicat ion

MB991992 Torque wrench adaptor



V.V.T. sp ro ck et b olt r em ov al a nd installation

MD998772 Valve spr ing co mpressor

MB992090 Retainer holder attachment

MB992089 Retainer holder C

MB992085 Valve ste m s eal pliers

General service tool



Valv e s pring c ompress ion

Valv e stem sea l remov al

MB992922 Valve stem s eal in staller adjustable

MD998727 Oil pan FIPG cutter



Valv e s tem sea l press -fittin g

MD998727-01 Oil pan removal

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Page 9

ENGINE MECHANICAL

B991993

B991928

Slide bracket (HI)

Z203830

MB992906

MB992336

SPECIAL TOOLS

Tool Tool numb er and name Sup ersession Applicat ion

MB991993



Front oil seal installation Crankshaft front oil seal guide

11A-7

MB990699 Differential oil seal installer

MB991928

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

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

MB991895 Engine hanger



Tool not available Supporting the engine assembly

Tool not available

MB992906



Engine hanger attachment

MB992336

a: MB992353  2



Engine assembly removal and

installation

b: MB992354  2

EV battery cart

a: Rigid caster b: Swivel caster

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Page 10

11A-8

CAUTION

AC507219

MB992082

MB992081

Belt tension meter set (MB992080)

ENGINE MECHANICAL

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK AND ADJUSTMENT

DRIVE BELT TENSION CHECK

 When checking the drive belt tension, make sure that

the engine is cold.

 Check the drive belt tension after turning the crank-

shaft clockwise one turn or more.

Check the drive belt tension in the following procedure.

NOTE: For the vehicles without A/C, the check procedure is also same.

Standard value:

Item When

checked

When adjusted

M1111003103945

When replaced

Vibration frequency Hz

Te ns ion N (lb)

Deflection mm (in) [Reference]

144  169* 143  169*

490  686 (110.2



154.2)

8.3  10.5 

(0.33

0.41)*

8.5  10.9 

(0.34

0.42)*

151  163*

150  163*

539  637 (121.2

143.2)

8.8  9.9 (0.35

0.38)*

9.1  10.2 (0.36

0.40)*



192  202*

882  980



(198.3



220.3)

6.2  6.8 

(0.25

0.26)*

6.3  6.9 

(0.25

0.27)*

NOTE: .



*1: Vehicles without A/C



*2: Vehicles with A/C

1. Connect special tool microphone assembly (MB992082) to special tool belt tension meter (MB992081) of special tool belt tension meter set (MB992080).

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

3. Press 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

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Page 11

ENGINE MECHANICAL

CAUTION

AK603849

15˚

10 – 15 mm (0.4 – 0.5 in)

Crankshaft pulley

Generator pulley

Water pump pulley

A/C compressor pulley

MB992080 (Microphone)

ON-VEHICLE SERVICE

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 judgment of error.

(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.

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

11A-9

 Do not let any contaminants such as water or oil get

 If strong gusts of wind blow against the microphone or

 If the microphone is touching the belt while the mea-

 Do not take the measurement while the vehicle's engine

5. Hold special tool MB992080 to the middle of the drive belt

6. Press the "MEASURE" button.

7. Gently tap the middle of the drive belt between the pulleys

8. Check that the vibration frequency of the drive belt is within

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onto the microphone.

if there is loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

surement is being made, the values measured by the microphone may not correspond to actual values.

is running.

between the pulleys (at the place indicated by arrow) where it does not contact the drive belt [approximately 10

 0.5 inch) away from the rear surface of the belt] so

(0.4

 15 mm

that it is perpendicular to the drive belt (within an angle of 

).

(the place indicated by the arrow) with your finger as shown in the illustration.

the standard value.

Page 12

11A-10

CAUTION

AK305688

Generator pulley

Water pump pulley

A/C compressor pulley

Crankshaft pulley

Tension gauge

AKB00833

Generator pulley

Water pump pulley

A/C compressor pulley

Approximately 100 N (22 lb)

Crankshaft pulley

Deflection

AK800521

Generator pivot bolt

Adjusting bolt

Generator fixing nut

ENGINE MECHANICAL

ON-VEHICLE SERVICE

NOTE: To ta ke t he m ea su re me nt r ep ea te dly, fi ll ip t he d ri ve belt again.

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

Use a belt tension gauge in the middle of the drive belt between the pulleys shown in the figure to check that the drive belt ten

sion is within the standard value.

NOTE: Before inspection, remove the oil dipstick guide assembly (Refer to P.11A-44).

Apply approximately 100 N (22 pounds) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

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DRIVE BELT TENSION ADJUSTMENT

If not within the standard value, adjust the belt tension by the following procedure.

1. Loosen the nut for generator pivot bolt.

2. Loosen the generator fixing nut.

3. Temporarily tighten the generator fixing nut.

Tightening torque: 10  3 Nm (89  26 in-lb)

4. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values.

5. Tighten the nut for generator pivot bolt.

Tightening torque: 47  5 Nm (35  3 ft-lb)

6. Tighten the generator fixing nut.

Tightening torque: 23  2 Nm (17  1 ft-lb)

7. Tighten the adjusting bolt.

Tightening torque: 5.0  1.0 Nm (44  8 in-lb)

When checking the belt tension, turn the crankshaft clockwise one turn or more.

8. Check the belt tension, and readjust if necessary.

Page 13

ENGINE MECHANICAL

CAUTION

AKB00552

2 31

No.1 Ignition coil

Power supply line (terminal No. 3)

Equipment side connector

ON-VEHICLE SERVICE

9. When the belt tension is adjusted by measuring the deflection, adjust it with a tool for vibration frequency measurement or tension measurement afterward.

11A-11

IGNITION TIMING CHECK

M1111001703305

1. Before inspection, set the vehicle to the pre-inspection condition.

To prevent d amage to scan tool ( M.U .T.-III ), always turn th e ignition switch to the "LOCK" (OFF) position before con

necting or disconnecting scan tool (M.U.T.-III).

2. Turn the ignition switch to the "LOCK" (OFF) position and then connect scan tool (M.U.T.-III) to the data link connector [Refer to GROUP 13A Connect the Scan Tool (M.U.T.-III)

 Diagnostic Function, How to

P.13A-10].

3. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

NOTE: The power supply line is looped and also longer than the other ones.

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

5. Select the item No. 2 on scan tool (M.U.T.-III) and measure engine idle speed and check that it is approximately 700 r/min.

6. Select No. 11 (actuator test function) of the scan tool (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

8. If the basic ignition timing is outside the standard value, inspect the MFI system (Refer to GROUP 13A Symptom Chart

P.13A-52).

 Diagnosis,

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 scan tool (M.U.T.-III)

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

Standard value: Approximately 8 BTDC

11.R emo ve the tim ing light.

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

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Page 14

11A-12

CAUTION

AKB00552

2 31

No.1 Ignition coil

Power supply line (terminal No. 3)

Equipment side connector

ENGINE MECHANICAL

ON-VEHICLE SERVICE

IDLE SPEED CHECK

M1111003503363

1. Before inspection, set the vehicle to the pre-inspection condition.

To prevent d amage to scan tool ( M.U .T.-III ), always turn th e ignition switch to the "LOCK" (OFF) position before con

necting or disconnecting scan tool (M.U.T.-III).

2. Turn the ignition switch to the "LOCK" (OFF) position and then connect scan tool (M.U.T.-III) to the data link connector [Refer to GROUP 13A Connect the Scan Tool (M.U.T.-III)

 Diagnostic Function, How to

P.13A-10].

3. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

NOTE: The power supply line is looped and also longer than the other ones.

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

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

Standard value: Approximately 8 BTDC

6. Check the idle speed.

Standard value: 700  50 r/min

NOTE: .



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



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

7. If the idle speed is outside the standard value, inspect the MFI system (Refer to GROUP 13A Chart

P.13A-52).

 Diagnosis, Symptom

8. Remove the timing light.

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

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IDLE MIXTURE CHECK

M1111002102314

1. Before inspection, set the vehicle to the pre-inspection condition.

To prevent d amage to scan tool ( M.U .T.-III ), always turn th e ignition switch to the "LOCK" (OFF) position before con

necting or disconnecting scan tool (M.U.T.-III).

2. Turn the ignition switch to the "LOCK" (OFF) position and then connect scan tool (M.U.T.-III) to the data link connector [Refer to GROUP 13A Connect the Scan Tool (M.U.T.-III)

 Diagnostic Function, How to

P.13A-10].

Page 15

ENGINE MECHANICAL

CAUTION

AKB00552

2 31

No.1 Ignition coil

Power supply line (terminal No. 3)

Equipment side connector

AKB00553

Timing mark

AKB00554

Paint mark

6.5 teeth (65 degrees)

Timing mark

ON-VEHICLE SERVICE

11A-13

3. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

NOTE: The power supply line is looped and also longer than the other ones.

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

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

Standard value: Approximately 8 BTDC

6. Run the engine at 2,000  3,000 r/min for 2 minutes.

7. Set the CO, HC tester.

8. Check the CO contents and the HC contents at idle.

Standard value

CO contents: 0.5 % or less HC contents: 100 ppm or less

9. If there is a deviation from the standard value, inspect the MFI system (Refer to GROUP 13A

P.13A-52).

Chart

 Diagnosis, Symptom

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

11.Tur n t he ignitio n s witch to the "LOCK" (OFF) position and then disconnect the scan tool (M.U.T.-III).

VALVE CLEAR ANCE CHECK AND ADJUSTMENT

M1111001502267

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

1. Remove the cylinder head cover assembly (Refer to

P.11A-22).

Turn th e c rankshaft al ways clock wis e.

2. 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 center.

3. Apply the paint mark to the 6.5th tooth (65 degrees) counterclockwise from the timing mark on the exhaust camshaft sprocket.

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Page 16

11A-14

AKB00555AB

Timing mark

Paint mark

65 degrees

AKA00384

Exhaust side

No.3

Intake side

No. 1

AKB00556

Paint mark

12 teeth (120 degrees)

AKB00557

Paint mark

120 degrees

Timing mark

ENGINE MECHANICAL

ON-VEHICLE SERVICE

4. Turn the crankshaft clockwise 130 degrees, and align the paint mark against the upper face of the cylinder head as shown in figure.

5. 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 [cold engine]:

Intake valve 0.22  0.04 mm (0.009  0.001 inch) Exhaust valve 0.30  0.04 mm (0.012  0.001 inch)

6. Apply the paint mark to the 12th tooth (120 degrees) counterclockwise from the paint mark.

7. Turn the crankshaft clockwise 240 degrees, and align the paint mark against the upper face of the cylinder head as shown in figure.

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Page 17

ENGINE MECHANICAL

AKA00384

Exhaust side

No. 3

Intake side

No.2

AKB00558

Paint mark

5.5 teeth (55 degrees)

Timing mark

AKB00559

Timing mark

Paint mark

120 degrees

AKA00384

Exhaust side

No. 2

Intake side

No.1

AK304938

Wall thickness

ON-VEHICLE SERVICE

11A-15

8. Check the valve clearance with the arrow shown in figure. In the same procedure as 5.

9. Apply the paint mark to the 5.5th tooth (55 degrees) clockwise from the timing mark on the exhaust camshaft sprocket.

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10.Turn the crankshaft clockwise 240 degrees, and align the paint mark against the upper face of the cylinder head as shown in figure.

11.C hec k the va lve clearanc e with the ar row sh own in figu re. In the same procedure as 5.

12.If the valve clearance is deviated from the standard value, remove the camshaft and the valve tappet (Refer to

P.11A-23).

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

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

A: Thickness of new valve tappet B: Thickness of old valve tappet C: Measured valve clearance

Equation

Intake valve: A = B + [C  0.22 mm (0.009 in)] Exhaust valve: A = B + C  0.30 mm (0.012 in)]

Page 18

11A-16

CAUTION

AK305693

Identification mark

AKB00560 AB

Injector connectors

AKB00561

Compression gauge

ENGINE MECHANICAL

ON-VEHICLE SERVICE

NOTE: The valve tappet ranges 5.10  5.70 mm (0.2008 

0.2244 inch) and has 31 types per 0.02 mm (0.0008 inch). The thickness below a decimal point is stamped on the reverse side of the valve tappet. Example: In case of 5.40 mm (0.2126 inch), "40" is stamped.

15.Install the valve tappet selected through the procedure 14.

16.Install the camshaft (Refer to P.11A-23).

17.Install the cylinder head cover assembly (Refer to

P.11A-22).

COMPRESSION PRESSURE CHECK

M1111002604230

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Disconnect the connector of the ignition coil, and then remove all of the ignition coils and spark plugs (Refer to GROUP 11B

 Generator and Ignition System P.11B-10).

3. Disconnect the all of the injector connectors.

 Keep away from the spark plug hole when cranking.  If compression is measured with water, oil, fuel, etc.,

that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

4. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

5. Set compression gauge to one of the spark plug holes.

6. Cranking the engine with the accelerator pedal fully depressed, measure the compression pressure.

Standard value [at engine speed of 250 r/min]: 1,410

kPa (205 psi)

Limit [at engine speed of 250 r/min]: Minimum 950

kPa (138 psi)

TSB Revision

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 (14 psi)

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 all of the injector connectors.

Page 19

ENGINE MECHANICAL

CAUTION

AKB00562

PCV valve

Plug

Vacuum gauge

ON-VEHICLE SERVICE

11A-17

10.Install all of the spark plugs and ignition coils (Refer to GROUP 11B

 Generator and Ignition System P.11B-10).

To prevent d amage to scan tool ( M.U .T.-III ), always turn th e ignition switch to the "LOCK" (OFF) position before con necting or disconnecting scan tool (M.U.T.-III).

11.Tur n t he ignitio n s witch to the "LOCK" (OFF) position and then connect scan tool (M.U.T.-III) to the data link connector [Refer to GROUP 13A Connect the Scan Tool (M.U.T.-III)

 Diagnostic Function, How to

P.13A-10].

12.Use the scan tool (M.U.T.-III) to erase the diagnostic trouble codes (Refer to GROUP 13A

 Diagnostic Function, How to

Read and Erase Diagnostic Trouble Codes P.13A-10).

NOTE: This will erase the diagnostic trouble codes resulting from the injector connectors being disconnected.

MANIFOLD VACUUM CHECK

M1111002702640

1. Before inspection, set the vehicle to the pre-inspection condition.

To prevent d amage to scan tool ( M.U .T.-III ), always turn th e ignition switch to the "LOCK" (OFF) position before con

necting or disconnecting scan tool (M.U.T.-III).

2. Turn the ignition switch to the "LOCK" (OFF) position and then connect scan tool (M.U.T.-III) to the data link connector [Refer to GROUP 13A Connect the Scan Tool (M.U.T.-III)

 Diagnostic Function, How to

P.13A-10].

3. 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.

4. Start the engine and check that idle speed is approximately 700 r/min.

5. Check the inlet manifold vacuum.

Limit: Minimum 60 kPa (17 in Hg)

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

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

8. Disconnect the scan tool (M.U.T.-III).

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Page 20

11A-18

CAUTION

ACB03468

(Engine oil)

50 N·m, +60˚, 0 N·m, 50 N·m then +60˚ 37 ft-lb

, +60˚, 0

ft-lb, 37 ft-lb

then +60˚

AC310987

Nut for generator pivot bolt

Adjusting bolt

Generator fixing nut

ENGINE MECHANICAL

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

Pre-removal Operation

 Engine Room Under Cover Front Removal (Refer to

GROUP 51

 Under Cover P.51-15).

M1112001604939

Post-installation Operation

 Drive Belt Tension Check and Adjustment (Refer to

P.11A-8).

 Engine Room Under Cover Front Installation (Refer to

GROUP 51

 Under Cover P.51-15).

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

Removal steps

1. Drive belt Front wheelhouse splash shield



(Refer to GROUP 42A Shield

P.42A-10).

Removal steps (Continued)

<<C>>

A/C compressor suction hose



clamp (Refer to GROUP 55A

 Splash

Refrigerant Line

P.55A-49)

<Vehicles with A/C>. <<D>> >>A<< <<D>> >>A<< <<D>> >>A<<

REMOVAL SERVICE POINTS

2. Crankshaft pulley center bolt

3. Crankshaft pulley washer

4. Crankshaft pulley

<<A>> DRIVE BELT REMOVAL

1. Loosen the nut for generator pivot bolt and generator fixing nut.

To r eus e t he driv e b elt , draw an arrow indi cat ing the ro ta ting direction (clockwise) on the back of the belt using chalk, etc.

2. Turn the adjusting bolt in the counterclockwise direction (to the left) to remove the drive belt.



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Page 21

ENGINE MECHANICAL

ACB04319

ACC04376

MD998719

MB990767

CRANKSHAFT PULLEY

11A-19

<> FRONT WHEELHOUSE SPLASH SHIELD REMOVAL

Remove the securing clips on the vehicle front side to create sufficient clearance for the removal and installation of the crankshaft pulley.

<<C>> A/C COMPRESSOR SUCTION HOSE CLAMP REMOVAL

Disconnect the clamp of the A/C compressor suction hose from the side member to create sufficient clearance for the removal and installation of the crankshaft pulley center bolt.

<<D>> CRANKSHAFT PULLEY CENTER BOLT/CRANKSHAFT PULLEY WASHER/CRANKSHAFT PULLEY REMOVAL

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 center bolt and remove the crankshaft pulley washer and crankshaft pulley.

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Page 22

11A-20

CAUTION

AK901203

Crankshaft

Crankshaft pulley

Crankshaft pulley center bolt

Crankshaft pulley washer

: Wipe clean with a rag. : Wipe clean with a rag and degrease. : Wipe clean with a rag, degrease and apply a small amount of engine oil.

Engine front

ACC04376

MD998719

MB990767

AK901204

Figure A Figure B

Paint markings

Crankshaft pulley center bolt

60˚

ENGINE MECHANICAL

CRANKSHAFT PULLEY

INSTALLATION SERVICE POINT

>>A<< CRANKSHAFT PULLEY/CRANKSHAFT PULLEY WASHER/CRANKSHAFT PULLEY CEN

TER BOLT INSTALLATION

1. Using a rag, wipe dirt on the crankshaft thread hole and the crankshaft pulley washer.

2. Using a rag, wipe dirt on the crankshaft pulley and then degrease the place specified in the illustration.

NOTE: Perform degreasing to prevent the friction resistance from decreasing in the compressed area due to the residual oil.

3. Install the crankshaft pulley.

4. Apply the minimum amount of engine oil to the crankshaft bolt threads and the seating surface.

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

 Front hub and flange yoke holder (MB990767)  Pin (MD998719)

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

Tightening torque: 50 Nm (37 ft-lb)

7. As shown in figure A, put a paint mark on one angle of the crankshaft pulley center bolt. Then, put a paint mark on the crankshaft pulley on the extended line of the angle next to the marked angle.

 When the tightening angle is smaller than the specified

tightening angle, the appropriate tightening capacity cannot be secured.

 When the tightening angle is larger than the specified

tightening angle, remove the bolt to start from the beginning again according to the procedure.

8. Tighten the crankshaft pulley center bolt in a 60, and check that the paint mark on the crankshaft pulley center bolt aligns with the paint mark on the crankshaft pulley as shown in figure B.

Page 23

ENGINE MECHANICAL

CAUTION

AC704717

Drive belt

Notched pulley

Flat pulley

ACA00740

Water pump pulley

Crankshaft pulley

Generator pulley

AC706892

Water pump pulley

Crankshaft pulley

Generator pulley

A/C compressor pulley

CRANKSHAFT PULLEY

11A-21

9. Loosen the crankshaft pulley center bolt completely after steps 6 to 8, and then repeat steps 6 to 8.

>>B<< DRIVE BELT INSTALLATION

 To reu se the dri ve belt, instal l it by al ign ing the ar row

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

 Check that the notches of notched pulley and notches

of drive belt are fit correctly.

 Check that the drive belt is installed in the center of flat

surface of flat pulley.

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

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Page 24

11A-22

ACC02731

2.0 ± 0.5 N·m then 7.0 ± 0.5 N·m 18 ± 4 in-lb

then

62 ± 4 in-lb

ENGINE MECHANICAL

ROCKER COVER ASSEMBLY

REMOVAL AND INSTALLATION

Pre-removal Operation

 Air Cleaner Assembly Removal (Refer to GROUP 15  Air

Cleaner

 Ignition Coil Removal (Refer to GROUP 11B  Generator

and Ignition System

P.15-5).

P.11B-10).

M1112010000137

Post-installation Operation

 Ignition Coil Installation (Refer to GROUP 11B  Genera-

tor and Ignition System P.11B-10).

 Air Cleaner Assembly Installation (Refer to GROUP 15 

Air Cleaner

P.15-5).

Removal steps

1. Breather hose

2. PCV hose

Removal steps (Continued)

>>A<<

INSTALLATION SERVICE POINT

3. Cylinder head cover assembly

4. Cylinder head cover gasket

>>A<< CYLINDER HEAD COVER ASSEMBLY INSTALLATION

For the installation procedure, refer to GROUP 11B  Oil Pan and Timing Chain Case

P.11B-23.

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Page 25

ENGINE MECHANICAL

ACD01187

(Engine oil)

Apply engine oil to all moving parts before installation.

<Cold engine> 11 ± 1 N·m 97 ± 8 in-lb

<Cold engine> 20 ± 1 N·m

14.8 ± 0.7 ft-lb

92 ± 13 N·m

68 ± 9 ft-lb

9.5 ± 2.5 N·m

84 ± 22 in-lb

65 ± 5 N·m

48 ± 3 ft-lb

CAMSHAFT

11A-23

REMOVAL AND INSTALLATION

Pre-removal operation

 Cylinder Head Cover Assembly Removal (Refer to

P.11A-22).

M1112007801686

Post-installation operation

 Val ve Clear an ce Adjustm en t (Refer t o P.11A-13).  Cylinder Head Cover Assembly Installation (Refer to

P.11A-22).

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

Removal steps

1. Service hole bolt

2. Gasket

3. Camshaft sprocket bolt

4. V.V.T. sprocket bolt

5. Front camshaft bearing cap

Removal steps (Continued)

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

6. Camshaft bearing cap

7. Exhaust camshaft

8. Intake camshaft

9. Va lve tap pet

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Page 26

11A-24

CAUTION

ACB04329

Timing mark

Timing mark (Groove)

AC311262

ACD01286

Plate

Service hole

ENGINE MECHANICAL

CAMSHAFT

REMOVAL SERVICE POINTS

<<A>> SERVICE HOLE BOLT/GASKET/SPROCKET BOLT/CAMSHAFT BEARING CAP/CAMSHAFT REMOVAL

Never turn the crankshaft counterclockwise.

1. Turn the crankshaft clockwise, and align the timing mark of the camshaft sprocket and that of the V.V.T. sprocket assembly (the groove of V.V.T. sprocket assembly side face). Then set No.1 cylinder to the TDC.

2. Remove the service hole bolt and gasket from the timing chain case.

3. While holding the intake camshaft hexagonal area with a wrench or a similar tool, slightly turn the exhaust camshaft clockwise to tighten the timing chain at the timing chain tensioner side and shorten the plunger of the timing chain tensioner.

NOTE:

This allows the plate on the timing chain tensioner to

move to the lower end position.

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Page 27

ENGINE MECHANICAL

CAUTION

ACD01188

Service hole

ACD01287

Plate

Service hole

Pin or similar tool

AC312249

Cable band or similar tool

Paint mark

AC311264

CAMSHAFT

11A-25

After a pin or a similar tool is inserted, never rotate the crankshaft. Otherwise, the timing chain will be out of align ment.

4. Insert a pin [3 mm (0.1 inch) in diameter] or a similar tool to the timing chain tensioner through the service hole as shown with the timing chain tensioner plunger compressed.

If the inserted pin or a similar tool slides laterally, it may be disengaged from the plate hole. Repeat from step 3.

NOTE: Pull out the pin or a similar tool after installing the camshaft sprocket bolt.

5. Put a paint mark on the V.V.T sprocket and the timing chain.

6. Fix the camshaft sprocket and the timing chain using a cable band or a similar tool.

7. While holding the exhaust camshaft hexagonal area with a wrench or a similar tool, loosen the camshaft sprocket bolt.

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Page 28

11A-26

CAUTION

AC311265

MB991992

AC404316

Engine front

AC312250

ENGINE MECHANICAL

CAMSHAFT

8. While holding the intake camshaft hexagonal area using a wrench or a similar tool, use special tool torque wrench adapter (MB991992) to loosen the V.V.T. sprocket bolt.

9. Loosen the camshaft sprocket bolt and V.V.T. sprocket bolt immediately before they touch the inside of the timing chain case.

This action slackens the timing chain. If you attempt to remove the camshaft without doing this, the journal at the cylinder head side will be damaged.

10.Slide the camshaft sprocket towards the front of the engine to disengage the exhaust camshaft dowel pin.

Slide the V.V.T. sprocket assembly towards the front of the engine to disengage the intake camshaft dowel pin. This action slackens the timing chain.

NOTE: If the dowel pin is difficult to disengage, slide the sprocket towards the front of the engine by twisting the hex agonal portion to the right and left slightly with a wrench.

11.Loos en the front cam shaft bearing ca p mounting bo lts , a nd then loosen each camshaft bearing cap mounting bolts in the order shown. Remove the front camshaft bearing cap and each camshaft bearing cap.

When you lift the camshaft forcibly, the journal may be damaged. Never use any tools, but lift it with your hands.

12.Lift the exhaust camshaft horizontally while rotating it slightly clockwise with your hands. Then remove it from the groove on the cylinder head.

NOTE: Holding the rear end of the exhaust camshaft facilitates lifting it.

Do not turn the crankshaft after removing the camshaft sprocket with the timing chain.

13.Remove the camshaft sprocket bolt, and then remove the exhaust camshaft.

Do not turn the crankshaft after removing the V.V.T. sprocket assembly with the timing chain.

14.Lift the intake camshaft vertically to remove the V.V.T. sprocket bolt. Then remove the intake camshaft.

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Page 29

ENGINE MECHANICAL

CAUTION

AK901163AD

V.V.T.sprocket bolt

: Wipe clean with a rag, degrease and apply a small amount of engine oil.

V.V.T. sprocket assembly

Intake camshaft

AC205417

Bearing cap No.

Identification of intake side and exhaust side

Engine front

Front mark

E 2

CAMSHAFT

11A-27

After disconnecting the camshaft sprocket and the V.V.T. sprocket assembly (with the timing chain for each) from the camshaft, do not dislocate the camshaft sprocket, the V.V.T. sp ro ck et a ss emb ly, an d th e ti min g ch ai n.

15.After removal, place the camshaft sprocket and timing chain assembly, and the V.V.T. sprocket and timing chain assembly on the timing chain case assembly

<> VALVE TAPPET REMOVAL

To facilitate re a ssembly, attach a ta g to each valv e t ap p et removed that shows where it has been assembled.

INSTALLATION SERVICE POINTS

>>A<< VALVE TAPPET INSTALLATION

Reassemble each valve tappet to the correct location shown on the tag.

>>B<< CAMSHAFT/CAMSHAFT BEARING CAP/SPROCKET BOLT INSTALLATION

1. Apply a proper minimum quantity of engine oil to the following points.

 Intake camshaft end  Insertion hole in V.V.T. sprocket assembly (all over inside

and outside surfaces)

 Threads and head of V.V.T. sprocket bolt  Bearing surface of V.V.T. sprocket bolt

2. Temporarily assemble the intake camshaft to the V.V.T. sprocket assembly (but do not engage the sprocket with the dowel pin).

3. Install the camshaft bearing cap at the intake side to secure the intake camshaft.

Camshaft bearing caps (No.2 to 4) are identical. To avoid confusion (bearing cap No. and intake/exhaust side), confirm each identification mark and face the front mark towards the direction shown before installing them.

Identification mark (engraved on the front and bearing caps No.2  4)

I: Intake side E: Exhaust side

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Page 30

11A-28

CAUTION

AC312251

V.V.T. sprocket assembly

Camshaft sprocket

Intake camshaft

Exhaust camshaft

Dowel pin

Hole

Groove

AC404316

Engine front

AC311267

MB991992

ENGINE MECHANICAL

CAMSHAFT

4. Engage the V.V.T. sprocket with the dowel pin by twisting the hexagonal portion on the intake camshaft with a wrench slightly.

5. Rotate the exhaust camshaft counterclockwise with your hand slightly to engage it with the groove on the cylinder head journal (but do not engage the sprocket with the dowel pin).

6. Install the camshaft bearing cap and the front camshaft bearing cap at the exhaust side to secure the exhaust camshaft.

7. Engage the dowel pin with the hole on the camshaft sprocket by twisting the hexagonal portion on the exhaust camshaft with a wrench slightly.

NOTE: If it is difficult to insert the exhaust camshaft into the camshaft sprocket, check that the hole on the sprocket is aligned with the dowel pin. Then press in the sprocket again by twisting the camshaft to the right and left slightly.

8. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order shown, and then tighten the front camshaft bearing cap mounting bolts as well.

Tightening torque:

Camshaft bearing cap mounting bolts: 11  1 Nm (97

 8 in-lb)

Front camshaft bearing cap mounting bolts: 20  1

m (14.8  0.7 ft-lb)

Check that the sprocket has been engaged with the dowel pin securely, and then tighten the bolt.

9. While holding the intake camshaft hexagonal area using a wrench or a similar tool, use special tool torque wrench adapter (MB991992) to tighten the V.V.T. sprocket bolt to the specified torque. Since the V.V.T. sprocket bolt is tightened by special tool, calculate the tightening torque by the following formula.

Tightening torque:

 (65  5)  {L (L + 150)} Nm

 65  5: Tightening torque of the V.V.T. sprocket

bolt (unit: N

m)

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Page 31

ENGINE MECHANICAL

CAUTION

AC311268

ACB04720

Oil filler cap

OIL FEEDER CONTROL VALVE

 L: Distance between the center of a torque

wrench drive and of its handle (unit: mm)

 150: Length of special tool (unit: mm)

 (48  3)  {L (L + 5.9)} ft-lb

 48  3 ft-lb: Tightening torque of the V.V.T.

sprocket bolt (unit: ft-lb)

 L: Distance between the center of a torque

wrench drive and of its handle (unit: inch)

 5.9: Length of special tool (unit: inch)

 Check that the sprocket has been engaged with the

dowel pin securely, and then tighten the bolt.

 After all of the sprocket bolts have been tightened,

check that the sprockets are directly in line without any slant. If the engine is started while the sprockets are installed improperly, the engine will be damaged.

10.While holding the exhaust camshaft hexagonal area using a wrench or similar tool, tighten the camshaft sprocket bolt to the specified torque.

Tightening torque: 92  13 Nm (68  9 ft-lb)

11A-29

OIL FEEDER CONTROL VALVE

REMOVAL AND INSTALLATION

For the removal and installation procedures, refer to GROUP 11B  Camshaft P.11B-40.

M1112010600021

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Page 32

11A-30

CAUTION

ACB03505

Apply engine oil to all moving parts before installation.

10*

<Cold engine> 11 ± 1 N·m 97 ± 8 in-lb

<Cold engine> 20 ± 1 N·m

14.8 ± 0.7 ft-lb

ENGINE MECHANICAL

VALVE S TEM SEA L

VALVE STEM SEAL

REMOVAL AND INSTALLATION

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

Pre-removal operation

 Timing Chain Removal (Refer to P.11A-45).  Spark Plug Removal (Refer to GROUP 11B  Generator

and Ignition System

P.11B-10).

Post-installation operation

 Spark Plug Installation (R efer to GROUP 11B  Generator

and Ignition System

 Timing Chain Installation (Refer to P.11A-45).

M1112008101884

P.11B-10).

<<A>> >>D<< <<A>> >>D<<

<> >>C<<

Removal steps

1. Front camshaft bearing cap

2. Camshaft bearing cap

3. Intake camshaft and V.V.T. sprocket assembly

4. Exhaust camshaft and camshaft sprocket assembly

5. Va lve t appet

<<C>> >>B<<

<<D>> >>A<<

>>A<<

Removal steps (Continued)

6. Va lve s pring retain er lo ck

7. Va lve s pring retain er

8. Va lve s pring

9. Valve stem seal

10. Valve s pring seat

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Page 33

ENGINE MECHANICAL

CAUTION

AC404316

Engine front

VALVE S TEM SEA L

11A-31

REMOVAL SERVICE POINTS

<<A>> CAMSHAFT BEARING CAP REMOVAL

Loosen the front camshaft bearing cap mounting bolts in the order shown, and then loosen each camshaft bearing cap mounting bolts as well. Remove the front camshaft bearing cap and each camshaft bearing cap.

<> VALVE TAPPET REMOVAL

To facilitate re a ssembly, attach a ta g to each valv e t ap p et removed that shows where it has been assembled.

<<C>> VALVE SPRING RETAINER LOCK REMOVAL

1. Temporarily install the oil pan which was removed at the timing chain case removal.

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

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

3. Remove special tool engine hanger (MB991928 or MB991895) for holding the engine assembly, which have been attached when the timing chain case was removed.

4. Remove the brake booster vacuum pipe (Refer to GROUP 35A

 Master Cylinder Assembly and Brake Booster

Assembly

P.35A-28).

5. Remove the engine hanger (Refer to GROUP 11B  Fuel and Emission Parts

P.11B-13).

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Page 34

11A-32

CAUTION

ACB04330

MD998772

MB992090

MB992089

AKB00107

MB992085

Valve stem seal

ENGINE MECHANICAL

VALVE S TEM SEA L

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

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

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

7. 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.

<<D>> VALVE STEM SEAL REMOVAL

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.

INSTALLATION SERVICE POINTS

>>A<< VALVE SPRING SEAT / VALVE STEM SEAL INSTALLATION

 The valve stem seal must not be reused.  Do not damage the tappet wall during assembly.  Be sure to use a special tool to install the valve stem

seal. Poor installation causes oil loss via valve guides.

 If oil is not applied, the valve stem seal may rise to the

surface after it is press fitted.

1. Apply a small amount of engine oil to the press-fit part and

lip part of the new valve stem seal.

2. Use a special tool to install the valve stem seal, obeying the

following procedures.

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Page 35

ENGINE MECHANICAL

AKB00106

Valve stem seal installer adjustable

(MB992922)

AKA00417

Outer circumference line of chuck

Rock nut (small)Shoulder of valve

stem seal

Sleeve

Chuck

VALVE S TEM SEA L

11A-33

3. Special tool valve stem seal installer adjustable (MB992922)

is composed of the components shown in the illustration. 1: Chuck 2: Sleeve 3: Rock nut (small) 4: Outer pipe 5: Rock nut (large) 6: Guide pin (5.9) 7: Guide pin (4.9) 8: Cap 9:Guide pin (5.4)

4. Adjust the inside chuck diameter, obeying the following

procedures.

(1) Install the sleeve to the chuck as shown in the illustration. (2) Install the shoulder of the valve stem seal to the chuck,

aligning with the outer circumference line of the chuck as

shown in the illustration. (3) Turn the sleeve to wring the chuck. (4) Stop the sleeve at the position where you can easily

remove the valve stem seal by hand. (5) Use the (small) rock nut to fix the sleeve.

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Page 36

11A-34

AKB00167

AKA00541AF

L L1

Reference: Insertion length (L) of valve stem seal is the same as that of checkpoint (L1).

Same length

AKA00420

Outer circumference line of chuck

Outer pipe

Chuck

Mark

AKA00418

Checkpoint (L1) of insertion length

End face

End face of chuck threads

Chuck

Outer pipe

Rock nut (large)

Vernier caliper

ENGINE MECHANICAL

VALVE S TEM SEA L

5. Adjust the stem seal insertion length, obeying the following procedures.

(1) The position, in which the end face of the outer pipe is

aligned with the outer circumference line of the chuck, is 0 mm of the insertion length. Insert the chuck and the sleeve into the outer pipe to fit the nut as shown in the illustration.

(2) Turn the chuck to adjust the valve stem seal insertion

length.

NOTE: The insertion length can change by 1 mm (0.04 inch) per the chuck turn. To ea si ly k no w ho w ma ny t im es the chuck is turned, put the mark at the position shown in the illustration.

(3) Use a vernier caliper to measure the checkpoint (L1) of

the insertion length shown in the illustration. Check the insertion length.

 14.4 mm (0.57 inch)

(4) Use the (large) rock nut to fix the sleeve.

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Page 37

ENGINE MECHANICAL

AKA00419

Cap

Chuck

AKB00043

AC205417

Bearing cap No.

Identification of intake side and exhaust side

Engine front

Front mark

E 2

VALVE S TEM SEA L

11A-35

6. Install the cap to the chuck.

7. Apply the engine oil to the valve stem seal to set the chuck.

8. Install the valve spring seat.

9. Use the plastic hammer to insert the valve stem seal.

>>B<< VALVE SPRING RETAINER LOCK INSTALLATION

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

>>C<< VALVE TAPPET INSTALLATION

Reassemble each valve tappet to the correct location shown on the tag.

>>D<< CAMSHAFT BEARING CAP INSTALLATION

1. Camshaft bearing caps (No.2 to 4) are identical. To avoid confusion (bearing cap No. and intake/exhaust side), confirm each identification mark and face the front mark towards the direction shown before installing them.

Identification mark (engraved on the front and bearing caps No.2

I: Intake side E: Exhaust side

 4)

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Page 38

11A-36

AC404316

Engine front

ENGINE MECHANICAL

VALVE S TEM SEA L

2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order shown, and then tighten the front camshaft bearing cap mounting bolts as well.

Tightening torque:

Camshaft bearing cap mounting bolts: 11  1 Nm (97

 8 in-lb)

Front camshaft bearing cap mounting bolts: 20  1

m (14.8  0.7 ft-lb)

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Page 39

ENGINE MECHANICAL

ACB03574

11 ± 3 N·m 97 ± 26 in-lb

10 ± 2 N·m 89 ± 17 in-lb

39 ± 5 N·m 29 ± 3 ft-lb

<CVT> 26 ± 6 N·m 19 ± 4 ft-lb

26 ± 6 N·m 19 ± 4 ft-lb

OIL PAN

11A-37

REMOVAL AND INSTALLATION

Pre-removal Operation

 Engine Oil Draining (Refer to GROUP 12  On-vehicle

Service, Engine Oil Replacement

 Drive Belt Removal (Refer to P.11A-18) <Vehicles with

A/C>.

 Starter Assembly Remo val (Refer to GROUP 16  Start-

ing System, Starter Assembly P.16-21).

 Oil Dipstick Removal (Refer to GROUP 11B  Generator

and Ignition System

P.11B-10).

P.12-4).

M1112002803494

Post-installation Operation

 Oil Dipstick Installation (Refer to GROUP 11B  Generator

and Ignition System

 Starter Assembly Installation (Refer to GROUP 16  Start-

ing System, Starter Assembly P.16-21).

 Drive Belt Installation (Refer to P.11A-18) <Vehicles with

A/C>.

 Engine Oil Refilling (Refer to GROUP 12  On-vehicle

Service, Engine Oil Replacement

P.11B-10).

P.12-4).

<<A>>



1. Transaxle stay

2. Bell housing cover

3. Oil drain plug

Removal steps

A/C compressor and clutch assembly, A/C compressor bracket (Refer to GROUP 55A Compressor Assembly



P.55A-44)

<Vehicles with A/C>.

REMOVAL SERVICE POINTS

<<A>> A/C COMPRESSOR AND CLUTCH ASSEMBLY/A/C COMPRESSOR BRACKET 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

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removal and installation of oil pan.

<> >>A<<

Removal steps (Continued)

4. Oil drain plug gasket

5. Oil pan

6. Oil strainer

7. Oil strainer gasket Stiffener plate (Refer to GROUP



11B

 Crankshaft and Cylinder

Block

P.11B-63).

Page 40

11A-38

AC102324

MD998727

ENGINE MECHANICAL

OIL PAN

3. Remove the A/C compressor bracket.

<> OIL PAN REMOVAL

1. Remove the oil pan mounting bolts.

2. Use special tool oil pan FIPG cutter (MD998727) to remove the oil pan.

INSTALLATION SERVICE POINT

>>A<< OIL PAN INSTALLATION

For the installation procedure, refer to GROUP 11B  Oil Pan and Timing Chain Case

P.11B-23.

INSPECTION

M1112002900919

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

deformation.

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Page 41

ENGINE MECHANICAL

ACB03577

11 ± 3 N·m 97 ± 26 in-lb

(Engine oil)

100 ± 5 N·m 74 ± 3 ft-lb

(Engine oil)

CRANKSHAFT OIL SEAL

11A-39

REMOVAL AND INSTALLATION

<M/T>

M1112003104275

>>C<<

Crankshaft front oil seal removal steps

Crankshaft pulley (Refer to



P.11A-18).

1. Front oil seal

<<A>> >>B<<

>>A<<

Crankshaft rear oil seal removal steps

Transaxle assembly (Refer to



GROUP 22A

P.22A-12).

Clutch cover and disc (Refer to



GROUP 21B Oil pan (Refer to P.11A-37).



2. Flywheel bolt

3. Flywheel

4. Oil seal case

 Transaxle Assembly

 Clutch P.21B-3).

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Page 42

11A-40

ACB03579

(Engine oil)

11 ± 3 N·m 97 ± 26 in-lb

100 ± 5 N·m 74 ± 3 ft-lb

<CVT>

ENGINE MECHANICAL

CRANKSHAFT OIL SEAL

>>C<<

Crankshaft front oil seal removal steps

Crankshaft pulley (Refer to



P.11A-18).

1. Front oil seal

TSB Revision

 Transaxle Assembly

Crankshaft rear oil seal removal steps

Transaxle assembly (Refer to

<<A>> >>B<<

>>A<<



GROUP 23A

P.23A-138).

Oil pan (Refer to P.11A-37).



2. Drive plate bolt

3. Adapter plate

4. Drive plate

5. Oil seal case

REMOVAL SERVICE POINT

<<A>> FLYWHEEL BOLT/DRIVE PLATE BOLT REMOVAL

For the removal procedure, refer to GROUP 11B  Crankshaft and Cylinder Block

P.11B-63.

INSTALLATION SERVICE POINTS

>>A<< OIL SEAL CASE INSTALLATION

For the installation procedure, refer to GROUP 11B  Crankshaft and Cylinder Block P.11B-63.

Page 43

ENGINE MECHANICAL

CAUTION

AC311773

MB990699

(Engine oil)

Oil seal

MB991993

Crankshaft

CRANKSHAFT OIL SEAL

11A-41

>>B<< FLYWHEEL BOLT/DRIVE PLATE BOLT INSTALLATION

For the installation procedure, refer to GROUP 11B  Crankshaft and Cylinder Block P.11B-63.

>>C<< FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the outer circumference of special tool crankshaft front oil seal guide (MB991993) and install it to the crankshaft.

2. Apply a small amount of engine oil to the entire inner circumference of the oil seal lip.

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

3. Using special tool differential oil seal installer (MB990699), drive the oil seal so that it is flush with the timing chain case.

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Page 44

11A-42

ACB03506

(Engine oil)

24.5 ± 2.0 N·m then +180˚ to 184˚

18.4 ± 0.7 ft-lb then +180˚ to 184˚

ENGINE MECHANICAL

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

Pre-removal Operation

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

 Battery P.54A-7).

 Intake Manifold Removal (Refer to GROUP 15  Intake

Manifold

 Exhaust Manifold Removal (Refer to GROUP 15 

Exhaust Manifold

 Intake Camshaft and V.V.T. Sprocket Assembly, Exhaust

Camshaft and Camshaft Sprocket Assembly Removal (Refer to

P.15-6).

P.15-8).

P.11A-30).

M1112004005263

Post-installation Operation

 Intake Camshaft and V.V.T. Sprocket Assembly, Exhaust

Camshaft and Camshaft Sprocket Assembly Installation (Refer to

 Exhaust Manifold Installation (Refer to GROUP 15 

Exhaust Manifold

 Intake Manifold Installation (Refer to GROUP 15  Intake

Manifold

 Battery and Battery Tray Installation (Refer to GROUP

54A

P.11A-30).

P.15-8).

P.15-6).

 Battery P.54A-7).

Removal steps

Radiator upper hose connection



(Refer to GROUP 14

P.14-16).

1. Heater water hose A connection

 Radiator

Removal steps (Continued)

<<A>> >>B<<

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

2. Cylinder head bolt

3. Cylinder head bolt washer

4. Cylinder head assembly

5. Cylinder head gasket

REMOVAL SERVICE POINT

<<A>> CYLINDER HEAD BOLT REMOVAL

1. Temporarily install the timing chain case assembly, engine mounting insulator and oil pan which was removed at the timing chain case removal.

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Page 45

ENGINE MECHANICAL

CAUTION

CYLINDER HEAD GASKET

11A-43

2. Remove special tool engine hanger (MB991928 or MB991895) for holding the engine assembly, which have been attached when the timing chain case was removed.

3. Remove the brake booster vacuum pipe (Refer to GROUP

 Master Cylinder Assembly and Brake Booster

35A Assembly

P.35A-28).

4. Remove the engine hanger (Refer to GROUP 11B  Fuel and Emission Parts P.11B-13).

5. Loosen the cylinder head bolts in two or three steps.

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

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

7. Remove the engine mounting insulator and timing chain case assembly.

8. Remove the cylinder head bolts.

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION

For the installation procedure, refer to GROUP 11B  Cylinder Head and Valves

P.11B-45.

>>B<< CYLINDER HEAD BOLT WASHER/CYLINDER HEAD BOLT INSTALLATION

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

2. Temporarily install the cylinder head bolt and washer assembly onto the cylinder head.

3. Temporarily install the timing chain case assembly and engine mounting insulator.

4. Tighten the cylinder head bolts (Refer to GROUP 11B  Cylinder Head and Valves

5. Install the engine hanger (Refer to GROUP 11B  Fuel and Emission Parts

P.11B-13).

6. Install the brake booster vacuum pipe (Refer to GROUP 35A  Master Cylinder Assembly and Brake Booster Assembly

P.35A-28).

7. Install special tool engine hanger (MB991928 or MB991895) for holding the engine assembly.

8. Remove the oil pan, engine mounting insulator and timing chain case assembly.

P.11B-45).

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Page 46

11A-44

ACD01189

(Engine oil)

42 ± 16 N·m 31 ± 11 ft-lb

11 ± 3 N·m 97 ± 26 in-lb

9.5 ± 2.5 N·m 84 ± 22 in-lb

42 ± 16 N·m 31 ± 11 ft-lb

9.5 ± 2.5 N·m 84 ± 22 in-lb

ENGINE MECHANICAL

TIMING CHAIN CASE ASSEMBLY

REMOVAL AND INSTALLATION

Pre-removal Operation

 Crankshaft Pulley Removal (Refer to P.11A-18).  Generator Assembly Removal (Refer to GROUP 16 

Charging System, Generator Assembly

 Water Pump Removal (Refer to GROUP 14  Water

 Cylinder Head Cover Assembly Removal (Refer to

P.14-13).

Pump

P.11A-22).

P.16-16).

M1112010200153

Post-installation Operation

 Cylinder Head Cover Assembly Installation (Refer to

P.11A-22).

 Water Pump Installation (Refer to GROUP 14  Water

Pump

P.14-13).

 Generator Assembly Installation (Refer to GROUP 16 

Charging System, Generator Assembly

 Crankshaft Pulley Installation (Refer to P.11A-18).

P.16-16).

Removal steps

1. Oil dipstick assembly

2. O-ring Oil pan (Refer to P.11A-37).



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<<A>> >>B<<

<> >>A<<

Removal steps (Continued)

Engine mounting insulator (Refer to



GROUP 32

 Engine Mounting

P.32-2).

3. Timing chain case assembly

4. O-ring

Page 47

ENGINE MECHANICAL

CAUTION

TIMING CHAIN

11A-45

REMOVAL SERVICE POINTS

<<A>> ENGINE MOUNTING INSULATOR REMOVAL

1. Secure special tool engine hanger (MB991928 or MB991895) for holding the engine assembly (Refer to GROUP 22A

 Transaxle Assembly P.22A-12) <M/T> or (Refer to GROUP 23A  Transaxle Assembly P.23A-138) <CVT>.

2. Adjust the special tool not to allow the weight of the engine assembly to rest on the engine mounting insulator. Then remove the engine mounting insulator.

<> TIMING CHAIN CASE ASSEMBLY REMOVAL

Remove the timing chain case assembly from above the vehicle.

INSTALLATION SERVICE POINTS

>>A<< TIMING CHAIN CASE ASSEMBLY INSTALLATION

For the installation procedure, refer to GROUP 11B  Oil Pan and Timing Chain Case

P.11B-23.

>>B<< ENGINE MOUNTING INSULATOR INSTALLATION

Use special tool engine hanger (MB991928 or MB991895) as during removal to install the engine mounting insulator.

TIMING CHAIN

REMOVAL AND INSTALLATION

Never overhaul the V.V.T. sprocket assembly.

Pre-removal Operation

 Timing chain case assembly Removal (Refer to

P.11A-44).

For the removal and installation procedures, refer to GROUP 11B  Timing Chain P.11B-30.

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Post-installation Operation

 Timing chain case assembly Installation (Refer to

P.11A-44).

M1112007202030

Page 48

11A-46

CAUTION

ENGINE MECHANICAL

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

M1112001007044

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

 Precautions before Service, Initialization Procedure for Learning Value in MFI Engine

P.00-41).

Pre-removal Operation

 Fuel Line Pressure Reduction (Refer to GROUP 13A 

On-vehicle Service, Reduce Pressurized Fuel Lines

P.13A-641).

 Engine Room Under Cover Removal (Refer to GROUP 51

 Under Cover P.51-15).

 Engine Coolant Draining (Refer to GROUP 14  On-vehi-

cle Service, Engine Coolant Replacement P.14-6).

 Engine Oil Draining (Refer to GROUP 12  On-vehicle

Service, Engine Oil Replacement

 Transmission Oil Draining (Refer to GROUP 22A 

On-vehicle Service, Transmission Oil Replacement

P.22A-7) <M/T>.

 CVT Fluid Draining (Refer to GROUP 23A  On-vehicle

Service, CVT Fluid Replacement

 Starter Assembly Remo val (Refer to GROUP 16  Start-

ing System, Starter Assembly P.16-21).

 Bell Housing Cover Removal (Refer to P.11A-37).  Drive Shaft Assembly Removal (Refer to GROUP 26 

Drive Shaft Assembly

 Exhaust Manifold Removal (Refer to GROUP 15 

Exhaust Manifold

 Air Cleaner Assembly Removal (Refer to GROUP 15  Air

Cleaner

 Radiator Assembly Removal (Refer to GROUP 14  Radi-

ator P.14-16).

P.15-5).

P.26-20).

P.15-8).

P.12-4).

P.23A-121) <CVT>.

Post-installation Operation

 Radiator Assembly Installation (Refer to GROUP 14 

Radiator

 Air Cleaner Assembly Installation (Refer to GROUP 15 

Air Cleaner

 Exhaust Manifold Installation (Refer to GROUP 15 

Exhaust Manifold

 Drive Shaft Assembly Installation (Refer to GROUP 26 

Drive Shaft Assembly

 Bell Housing Cover Installation (Refer to P.11A-37).  Starter Assembly Installation (Refer to GROUP 16  Start-

ing System, Starter Assembly P.16-21).

 Transmission Oil Refilling (Refer to GROUP 22A 

On-vehicle Service, Transmission Oil Replacement

P.22A-7). <M/T>.

 CVT Fluid Refilling (Refer to GROUP 23A  On-vehicle

Service, CVT Fluid Replacement

 Engine Oil Refilling (Refer to GROUP 12  On-vehicle

Service, Engine Oil Replacement

 Engine Coolant Refilling (Refer to GROUP 14  On-vehi-

cle Service, Engine Coolant Replacement P.14-6).

 Fuel Leak Check  Engine Room Under Cover Installation (Refer to GROUP

P.14-16).

P.15-5).

P.15-8).

P.26-20).

P.23A-121) <CVT>.

P.12-4).

 Under Cover P.51-15).

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Page 49

ENGINE MECHANICAL

ACB03674

ENGINE ASSEMBLY

11A-47

>>C<<

Removal steps

Control wiring harness connection



Brake booster vacuum hose



connection (Refer to GROUP 35A Master Cylinder Assembly and Brake Booster Assembly

P.35A-28).

Purge hose connection (Refer to



GROUP 11B Parts

P.11B-13).

Clutch cable connection (Refer to



GROUP 21A

P.21A-5) <M/T>.

Gearshift cable and select cable



connection (Refer to GROUP 22A Transaxle Assembly <M/T>. Transaxle control cable connection



(Refer to GROUP 23A Assembly To rq u e c on v ert e r a nd dri v e p la t e



coupling bolt (Refer to GROUP 23A  Transaxle Assembly P.23A-138)

<CVT>.

 Fuel and Emission

 Clutch Control

P.22A-12)

 Transaxle

P.23A-138) <CVT>.

<<A>>



<> >>B<<



<> >>B<<

<<C>> >>A<<

Removal steps (Continued)

A/C compressor and clutch



assembly (Refer to GROUP 55A Compressor Assembly <Vehicles with A/C>. Heater water hose A connection



(Refer to Heater water hose B connection



(Refer to GROUP 14 and Water Pipe Fuel main pipe connection (Refer to



GROUP 13A Engine mounting insulator (Refer to



GROUP 32

P.32-2).

Transaxle mounting insulator



(Refer to GROUP 32 Mounting

1. Engine and transaxle assembly Transaxle assembly coupling bolt



(Refer to GROUP 22A Assembly Transaxle assembly coupling bolt



(Refer to GROUP 23A Assembly

2. Transaxle assembly

3. Engine assembly

P.11A-42).

 Water Hose

P.14-15).

 Injector P.13A-651).

 Engine Mounting

 Transaxle

P.32-3).

P.22A-12) <M/T>.

P.23A-138) <CVT>.

P.55A-44)

 Transaxle



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Page 50

11A-48

CAUTION

ACB04381

MB992336

ENGINE MECHANICAL

ENGINE ASSEMBLY

REMOVAL SERVICE POINTS

<<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 and transaxle assembly.

<> ENGINE MOUNTING INSULATOR/TRANSAXLE MOUNTING INSULATOR REMOVAL

1. Secure special tool engine hanger (MB991928 or MB991895) for holding the engine and transaxle assembly (Refer to GROUP 22A

 Transaxle Assembly P.22A-12)

<M/T> or (Refer to GROUP 23A  Transaxle Assembly

P.23A-138) <CVT>.

2. Adjust the special tool not to allow the weight of the engine and transaxle assembly to rest on the engine mounting insulator and transaxle mounting insulator. Then remove the engine mounting insulator and transaxle mounting insulator.

<<C>> ENGINE AND TRANSAXLE ASSEMBLY REMOVAL

1. Place special tool EV battery cart (MB992336) below the engine and transaxle assembly.

When supporting the engine and transaxle assembly with special tool, be careful not to deform the oil pan.

2. Place special tool (MB992336) against the oil pan with a piece of wood in between to support the engine and transaxle assembly.

3. Remove special tool engine hanger (MB991928 or MB991895).

4. Confirm that the cable, the hose and the harness connector are all disconnected.

Do not bend the fuel main pipe.

5. Raise the body slowly with a lift, and remove the engine and transaxle assembly.

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Page 51

ENGINE MECHANICAL

ACB04381

MB992336

ACB03675

45˚

ENGINE ASSEMBLY

11A-49

INSTALLATION SERVICE POINTS

>>A<< ENGINE AND TRANSAXLE ASSEMBLY INSTALLATION

Use special tool EV battery cart (MB992336) as during removal to install the engine and transaxle assembly.

>>B<< TRANSAXLE MOUNTING INSULATOR/ENGINE MOUNTING INSULATOR INSTALLATION

Use special tool engine hanger (MB991928 or MB991895) as during removal to install the transaxle mounting insulator and engine mounting insulator.

>>C<< CONTROL WIRING HARNESS CONNECTION

1. Install the ground terminal to the timing chain case as shown.

2. Tighten the ground terminal mounting bolt to the specified torque.

Tightening torque: 9.0  2.0 Nm (80  17 in-lb)

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Page 52

NOTES

Page 53

GROUP 80A

CONFIGURATION

DIAGRAMS

CONTENTS

80A-1

OVERALL CONFIGURATION 

DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 80A-2

HOW TO READ CONFIGURATION 

DIAGRAMS . . . . . . . . . . . . . . . . . . . . 80A-3

ENGINE COMPARTMENT. . . . . . . . . 80A-4

ENGINE AND TRANSAXLE . . . . . . . 80A-8

INSTRUMENT PANEL . . . . . . . . . . . . 80A-12

FLOOR . . . . . . . . . . . . . . . . . . . . . . . . 80A-20

ROOF . . . . . . . . . . . . . . . . . . . . . . . . . 80A-22

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 80A-24

LIFTGATE . . . . . . . . . . . . . . . . . . . . . . 80A-26

Page 54

80A-2

ACC0 4191

Instrument panel wiring harness

Control wiring harness

Roof wiring harness

Liftgate wiring harness

Front door wiring harness

Rear door wiring harness

Floor wiring harness

Front wiring harness

Battery (-) wiring harness

CONFIGURATION DIAGRAMS

OVERALL CONFIGURATION DIAGRAM

M1801000104293

NOTE: .

1. This illustration shows only major wiring harnesses.

2. *: also equipped at the right side.

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Page 55

CONFIGURATION DIAGRAMS

AC208446

Denotes connector No. The same connector No. is used throughout the circuit diagrams to facilitate connector location searches. The first alphabetical symbol indicates the location site of the connector and a number that follows is the unique number. Numbers are usually assigned to parts in clockwise order on the diagram.

Example: A-19

Number specific to connector (serial number)

Connector location site symbol A: ENGINE COMPARTMENT E: ROOF B: ENGINE AND TRANSAXLE F: DOOR C: INSTRUMENT PANEL G: LIFTGATE

D: FLOOR

Denotes ground point. Same ground number is used throughout circuit diagrams to facilitate search of ground point. Refer to GROUP 70 COMPONENT LOCATIONS

-GROUND MOUNTING LOCATIONS for details of ground points.

Denotes the color of the tube (If not specified, it is black). R: Red Y: Yellow

The number of connector pins and the connector color (except milk white)* are shown for ease of retrieval.

Example: (2-B)

Connector color (milk white if no color is indicated)

Number of connector pins

*: Typical connector colors B: Black BR: Brown Y: Yellow V: Violet L: Blue O: Orange G: Green GR: Gray R: Red None: Milk white

A-15 (2) FOG LIGHT (RH) A-16 (2-GR) HORN (LOW) A-17 (2-B) HEADLIGHT (RH) A-18 (2-B) WINDSHIELD WASHER MOTOR A-19 (2-GR) DUAL PRESSURE SWITCH

Indicates the device to which the connector is connected.

The mark shows the standard mounting position of wiring harness.

A-17

A-16

A-15

A-18

A-19

Denotes a section covered by a corrugated tube.

FRONT WIRING HARNESS (RH)

Denotes harness name.

HOW TO READ CONFIGURATION DIAGRAMS

80A-3

HOW TO READ CONFIGURATION DIAGRAMS

M1801000200748

The wiring harness diagrams clearly show the connector locations and harness configurations on actual vehicles. Some variations are included in one configuration diagram. Accordingly, some diagrams may not be applicable for individual vehicles.

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Page 56

80A-4

ACC06681

Connector color code B : Black BR : Brown G : Green GR : Gray L : Blue None : Milk white O : Orange R : Red V : Violet Y : Yellow

A-01

A-25

A-26

A-28

A-27

A-29

Connector symbol

-01 thru

-38

A-38

CONFIGURATION DIAGRAMS

ENGINE COMPARTMENT

M1801000309474

A-01 (2-B) Side turn-signal light (RH) A-02 (2-B) Side turn-signal light (LH) A-04X (4) Horn relay A-06X (4) Cooling fan control relay (Low) A-07X (4) Cooling fan control relay (High) A-08X (4) Fog light relay A-10X (4) Headlight relay (High)

A-11X (4) Headlight relay (Low) A-12X (4) MFI relay A-13X (4) Power window relay A-14X (4) Starter relay A-17X (4) A/C compressor relay A-18X (4) Throttle actuator control motor relay A-21 (3-B) Headlight (LH)

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Page 57

CONFIGURATION DIAGRAMS

ACC06682

A-02

A-04X A-06X A-07X A-08X A-10X A-11X A-12X A-13X A-14X A-17X A-18X

A-24

A-22

A-21

Front wiring harness

A-23

A-32X A-33X A-34X

A-37

ENGINE COMPARTMENT

80A-5

A-22 (2-B) Position light (LH) A-23 (2-B) Front turn-signal light (LH) A-24 (2-B) Fog light (LH) A-25 (1-B) Horn A-26 (2-B) Fog light (RH) A-27 (2-B) Front turn-signal light (RH) A-28 (2-B) Position light (RH)

A-29 (3-B) Headlight (RH) A-32X (4) PTC heater relay 1 A-33X (4) PTC heater relay 2 A-34X (4) PTC heater relay 3 A-37 (2-B) Front side marker light (LH) A-38 (2-B) Front side marker light (RH)

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Page 58

80A-6

ACC06681

Connector color code B : Black BR : Brown G : Green GR : Gray L : Blue None : Milk white O : Orange R : Red V : Violet Y : Yellow

A-113

A-115

A-122

A-114

A-116

Front wiring harness

Connector symbol

-101 thru

-122

A-119

ENGINE COMPARTMENT (CONTINUED)

CONFIGURATION DIAGRAMS

ENGINE COMPARTMENT

A-101 (2-GR) Brake fluid level switch A-102 (5-GR) Windshield wiper motor A-103 (3-B) Brake vacuum sensor A-104 (13) Front wiring harness and control

wiring harness combination (integrated in relay box)

A-105 (1) Relay box (integrated in relay box)

A-106 (12) Joint connector (1) (integrated in relay

box) A-107 (2-B) Front wheel speed sensor (LH) A-108 (4-B) Spare connector

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Page 59

CONFIGURATION DIAGRAMS

ACC06682

A-101

A-104

A-105

A-106

A-102

A-103

A-107

A-108

A-121

A-111

A-110

ENGINE COMPARTMENT

80A-7

A-110 (4-GR) Cooling fan motor A-111 (2-B) Ambient temperature sensor

<Vehicles with automatic air

conditioning system> A-113 (2-B) Spare connector <Vehicles with KOS> A-114 (2-B) Washer motor

A-115 (3-B) A/C pressure sensor A-116 (2-B) Front wheel speed sensor (RH) A-119 (38-B) ASC-ECU A-121 (2-Y) Front impact sensor (LH) A-122 (2-Y) Front impact sensor (RH)

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Page 60

80A-8

ACC06684

B-01

B-02

B-03

B-13

B-12

Grounding cable

Connector symbol

-01 thru

-16

Connector color code B : Black BR : Brown G : Green GR : Gray L : Blue None : Milk white O : Orange R : Red V : Violet Y : Yellow

CONFIGURATION DIAGRAMS

ENGINE AND TRANSAXLE

M1801000405242

B-01 (2-B) Oil feeder control valve B-02 (3-GR) No.1 ignition coil B-03 (3-GR) No.2 ignition coil B-04 (3-GR) No.3 ignition coil

B-06 (2-B) Evaporative emission purge solenoid B-07 (2-B) Engine coolant temperature sensor B-08 (4-B) Heated oxygen sensor (rear)

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Page 61

CONFIGURATION DIAGRAMS

ACC06685

B-04

B-10 <M/T>

B-09

B-06

B-07

B-08 <CVT>

B-11

B-08 <M/T>

Battery (-) wiring harness

Control wiring harness

B-15

B-10 <CVT>

B-16

ENGINE AND TRANSAXLE

80A-9

B-09 (3-B) Camshaft position sensor B-10 (6-B) Throttle body assembly B-11 (4-B) Manifold absolute pressure sensor B-12 (1-L) Engine oil pressure switch

B-13 (2-B) Knock sensor B-15 (5-B) Mass airflow sensor B-16 (6-B) Linear air-fuel ratio sensor

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Page 62

80A-10

ACC06684

B-101 B-102

B-103

Grounding cable

Connector symbol

-101 thru

-116

Connector color code B : Black BR : Brown G : Green GR : Gray L : Blue None : Milk white O : Orange R : Red V : Violet Y : Yellow

B-111

B-112

B-113

B-114

B-115

B-116

CONFIGURATION DIAGRAMS

ENGINE AND TRANSAXLE (CONTINUED)

ENGINE AND TRANSAXLE

B-101 (2-GR) No.1 injector B-102 (2-GR) No.2 injector B-103 (2-GR) No.3 injector B-105 (3-B) Secondary speed sensor <CVT>

B-106 (10-B) Transmission range switch <CVT> B-107 (3-B) Output speed sensor <CVT> B-108 (3-B) Primary speed sensor <CVT>

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Page 63

CONFIGURATION DIAGRAMS

ACC06685

B-109

B-108

B-105

B-106

B-110

B-107

Battery (-) wiring harness

Control wiring harness

ENGINE AND TRANSAXLE

80A-11

B-109 (22-B) CVT assembly B-110 (2-B) Backup light switch <M/T> B-111 (1-B) Starter B-112 (1) Starter

B-113 (1-B) A/C compressor and clutch assembly B-114 (3-B) Crankshaft position sensor B-115 (1) Generator B-116 (4-GR) Generator

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Page 64

80A-12

ACD03456

Connector symbol

-01 thru

-37

C-05

Junction block

Instrument panel wiring harness

C-13

C-22

C-36

Connector color code B: Black BR: Brown G: Green GR: Gray L: Blue None: Milk white O: Orange R: Red V: Violet Y: Yellow

Front wiring harness

C-04 C-10

C-23

Control wiring harness

C-32

C-03

CONFIGURATION DIAGRAMS

INSTRUMENT PANEL

M1801000703548

C-01 (22-GR) Joint connector (CAN1) C-02 (2-B) Passenger's (front) air bag module

C-03 (4) IG2 relay <Vehicles with KOS> C-04 (4) IG1 relay <Vehicles with KOS> C-05 (4) ACC relay <Vehicles with KOS> C-06 (20) Instrument panel wiring harness and

C-07 (18) Multivision display C-08 (5) Multivision display C-09 (20) Radio and CD player

(squib)

multivision display wiring harness

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C-10 (4) Joint connector (10) C-11 (13) Instrument panel wiring harness and

front door wiring harness (RH) combination

C-12 (22) Instrument panel wiring harness and

front door wiring harness (RH)

combination C-13 (16-B) Data link connector C-14 (8) Blower switch <Vehicles without

automatic air conditioning system> C-17 (10) Selector lever assembly <CVT>

Page 65

CONFIGURATION DIAGRAMS

ACD03457

C-25 C-35

C-30

C-02

Floor wiring harness

C-11

C-12

C-18

C-27

C-28

C-29

C-14

C-21

C-31

C-26

C-24

C-07

C-09

C-34 C-06

C-08

C-37

C-01

C-17

INSTRUMENT PANEL

80A-13

C-18 (2) Key slot <Vehicles with KOS> C-21 (2) Accessory socket C-22 (22) Instrument panel wiring harness and

front door wiring harness (LH) combination

C-23 (13) Instrument panel wiring harness and

front door wiring harness (LH)

combination C-24 (1) PTC heater C-25 (3) PTC heater C-26 (1) PTC heater C-27 (15-Y) SRS-ECU

C-28 (15-Y) SRS-ECU C-29 (30-Y) SRS-ECU C-30 (14) PTC heater control unit C-31 (9) Heated seat switch C-32 (10) Instrument panel wiring harness and

roof wiring harness combination C-34 (18) Radio and CD player C-35 (2-O) Passenger’s (front) air bag module

(squib) C-36 (2-B) Driver’s knee air bag module (squib) C-37 (1) Radio antenna

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Page 66

80A-14

ACD03456

Connector symbol

-102 thru

-132

C-129

C-110 C-114

C-108

Junction block

C-126

Connector color code B: Black BR: Brown G: Green GR: Gray L: Blue None: Milk white O: Orange R: Red V: Violet Y: Yellow

Front wiring harness

C-124

Control wiring harness

C-111

C-125

C-107

C-119

INSTRUMENT PANEL (CONTINUED)

CONFIGURATION DIAGRAMS

INSTRUMENT PANEL

C-102 (4) Outside/inside air selection damper

C-105 (22-GR) Joint connector (7) C-106 (5) Hazard warning light switch C-107 (4) Joint connector (8) C-108 (24) Combination meter C-109 (22-GR) Joint connector (9) C-110 (10) Engine switch C-111 (11) Remote controlled mirror switch C-112 (24) Auto A/C controller assembly

control motor

(A/C-ECU)

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C-113 (10-G) Heater control panel <Vehicles without

automatic air conditioning system> C-114 (5) Mode selection damper control motor

and potentiometer C-115 (1-B) Parking brake switch C-116 (5) Inside transmission antenna assembly

(front) <Vehicles with KOS> C-117 (18) Instrument panel wiring harness and

floor wiring harness combination C-118 (10) Instrument panel wiring harness and

floor wiring harness combination

Page 67

CONFIGURATION DIAGRAMS

ACD03457

C-106

C-109

C-131C-102

Instrument panel wiring harness

Floor wiring harness

C-123

C-121 C-122

C-105

C-115

C-117

C-116

C-132

C-118

C-120

C-112 C-113

INSTRUMENT PANEL

80A-15

C-119 (5-G) Air mixing damper control motor and

potentiometer

C-120 (2) Fin thermo sensor <Vehicles with air

conditioning system>

C-121 (4) Heater resister <Vehicles without

automatic air conditioning system>

C-122 (4) Power transistor <Vehicles with

automatic air conditioning system>

C-123 (2) Blower motor

C-124 (22) Instrument panel wiring harness and

floor wiring harness combination C-125 (12-GR) Joint connector (6) and floor wiring

harness combination C-126 (12-GR) Joint connector (6) and instrument

panel wiring harness combination C-129 (5) ASC off switch C-131 (32) KOS and OSS-ECU C-132 (16) KOS and OSS-ECU

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Page 68

80A-16

ACD03456

Connector symbol

-201 thru

-230

Connector color code B: Black BR: Brown G: Green GR: Gray L: Blue None: Milk white O: Orange R: Red V: Violet Y: Yellow

C-203

C-208

C-204

Junction block

C-210

C-215

Front wiring harness

C-206

C-214

C-220

C-211

C-212

C-213

C-227

C-205

C-222

C-223

C-209

C-207

C-201

C-221

C-226

C-202

C-225

C-219

C-228

INSTRUMENT PANEL (CONTINUED)

CONFIGURATION DIAGRAMS

INSTRUMENT PANEL

C-201 (4) Joint connector (3) C-202 (12-L) Joint connector (5) C-203 (22-GR) Joint connector (CAN2) C-204 (13-GR) Joint connector (2) C-205 (4) Stoplight switch C-206 (6-B) Accelerator pedal position sensor C-207 (8) Electric power steering-ECU C-208 (2-B) Electric power steering-ECU

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C-209 (26) Transaxle control module <CVT> C-210 (22) Transaxle control module <CVT> C-211 (13) Front wiring harness and floor wiring

harness combination C-212 (18) Front wiring harness and instrument

panel wiring harness combination C-213 (22-GR) Front wiring harness and instrument

panel wiring harness combination

Page 69

CONFIGURATION DIAGRAMS

ACD03457

Instrument panel wiring harness

Floor wiring harness

C-230

INSTRUMENT PANEL

80A-17

C-214 (10) Front wiring harness and instrument

panel wiring harness combination

C-215 (18) Front wiring harness and control

wiring harness combination C-219 (22-L) Joint connector (4) C-220 (22-L) Joint connector (4) C-221 (4) Spare connector C-222 (2) Clutch interlock switch (for cruise

control system and OSS) <M/T>

C-223 (2) Clutch interlock switch (for starter

relay) <M/T> C-225 (35-GR) Engine control module C-226 (26-GR) Engine control module C-227 (28-GR) Engine control module C-228 (30-GR) Engine control module C-230 (28) Hands free module

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Page 70

80A-18

ACC06690

C-301

C-302

Connector symbol

-301 thru

-314

Steering column

C-303

C-304

C-306

C-307

C-308

C-309

Instrument panel wiring harness

Connector color code B: Black BR: Brown G: Green GR: Gray L: Blue None: Milk white O: Orange R: Red V: Violet Y: Yellow

Steering sub wiring harness

Clock spring

C-310

C-311

Steering switch grounding

C-313

C-314

C-312

INSTRUMENT PANEL (CONTINUED)

CONFIGURATION DIAGRAMS

INSTRUMENT PANEL

C-301 (10) Clock spring and steering sub wiring

C-302 (1) Horn switch C-303 (6) Ignition switch <Vehicles without

C-304 (7) Key reminder switch <Vehicles without

C-306 (10) Clock spring C-307 (4-Y) Clock spring

harness combination

KOS>

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C-308 (10) Column switch C-309 (2-O) Driver's air bag module (squib) C-310 (2) Steering lock solenoid <Vehicles

without KOS> C-311 (5) Steering wheel sensor C-312 (4) Steering wheel multi-function switch C-313 (6) Cruise control switch C-314 (2-B) Driver’s air bag module (squib)

Page 71

INSTRUMENT PANEL (CONTINUED)

ACC06691

C-401 C-402

Connector symbol

-401 thru

-420

ETACS-ECU

C-405

C-410

C-406

C-408

C-407

C-412

C-414

C-416

C-417

C-418

C-419

Junction block

C-403 C-404

C-409

C-413

C-415

C-420

C-411

CONFIGURATION DIAGRAMS

INSTRUMENT PANEL

80A-19

C-401 (4) Roof wiring harness and junction block

C-402 (6) Instrument panel wiring harness and

C-403 (14) Instrument panel wiring harness and

C-404 (8) Instrument panel wiring harness and

C-405 (13) Front wiring harness and junction

C-406 (10) Front wiring harness and junction

C-407 (20) ETACS-ECU C-408 (1) Front wiring harness and junction

combination

junction block combination

block combination

C-409 (4) No connection C-410 (4) Fuel pump relay C-411 (4) No connection C-412 (4) Rear window defogger relay C-413 (4) No connection C-414 (4) Blower relay C-415 (4) Heated seat relay C-416 (24-GR) ETACS-ECU C-417 (24) ETACS-ECU C-418 (10) Floor wiring harness and junction

block combination C-419 (4) Floor wiring harness and junction

block combination C-420 (4) No connection

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Page 72

80A-20

ACD03458

Connector symbol

D-18

D-02

Floor wiring harness

D-01

Connector color code B: Black BR: Brown G: Green GR: Gray L: Blue NONE: Milk white O: Orange R: Red V: Violet Y: Yellow

D-20

D-29

D-37

D-31

D-35

D-27

CONFIGURATION DIAGRAMS

FLOOR

M1801003500931

D-01 (3) Front door switch (RH) D-02 (8) Floor wiring harness and rear door

D-03 (2-GR) Rear wheel speed sensor (RH) D-04 (3) Rear door switch (RH) D-05 (6) Rear combination light (RH) D-06 (5-GR) Fuel pump module D-07 (13) Floor wiring harness and liftgate wiring

D-08 (8) Floor wiring harness and liftgate wiring

D-09 (6) Rear combination light (LH)

wiring harness (RH) combination

harness combination

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D-10 (3) Rear door switch (LH) D-11 (4) Joint connector (13) D-12 (2-GR) Rear wheel speed sensor (LH) D-13 (5) Inside transmission antenna assembly

(rear) <Vehicles with KOS> D-14 (8) Floor wiring harness and rear door

wiring harness (LH) combination D-15 (3) Front door switch (LH) D-16 (2-B) Seat belt pre-tensioner (LH) D-17 (4) Joint connector (12)

Page 73

CONFIGURATION DIAGRAMS

ACD03459

D-03

D-04

D-05

D-06

D-07

D-08

D-09

D-13

D-12

D-25

D-19

D-10

D-11

D-14

D-17

D-16

D-32

D-15

D-24

D-23

D-22

D-26

D-30

D-36

D-21

FLOOR

80A-21

D-18 (5) Outside transmission antenna

assembly (passenger’s side)

<Vehicles with KOS> D-19 (12-GR) Joint connector (11) D-20 (2-B) Seat belt pre-tensioner (RH) D-21 (5) Outside transmission antenna

assembly (driver’s side) <Vehicles

with KOS> D-22 (2-B) Curtain air bag module (squib) (RH) D-23 (2-B) Curtain air bag module (squib) (LH) D-24 (2-Y) Side impact sensor (LH)

D-25 (2-Y) Side-airbag module (squib) (LH) D-26 (2) Front seat belt switch (driver’s side) D-27 (2-Y) Side-airbag module (squib) (RH) D-29 (2-Y) Side impact sensor (RH) D-30 (4) Heated seat (LH) D-31 (4) Heated seat (RH) D-32 (3) Luggage compartment light D-35 (2) Front seat belt switch (passenger’s

side) D-36 (3-B) Fuel tank differential pressure sensor D-37 (4-B) Occupant classification-ECU

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Page 74

80A-22

ACC06695

E-04

Connector symbol

E-01

Roof wiring harness

E-05

CONFIGURATION DIAGRAMS

ROOF

M1801003400042

E-01 (3) Front dome light E-04 (3) Microphone unit <Vehicles with

hands-free interface system>

E-05 (5) Passenger's air bag OFF indicator

light assembly

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Page 75

CONFIGURATION DIAGRAMS

ACC06696

FRONT DOOR

(Passenger's side) (Driver's side)

F-01 F-02 F-14 F-08

F-12 F-11F-10

Front door wiring harness (RH)

Front door wiring harness (LH)

Connector symbol

-01 thru

-15

F-05 F-06 F-07 F-15

F-04 F-13

F-09

DOOR

80A-23

DOOR

M1801001403896

F-01 (10) Door mirror assembly (RH) F-02 (6-GR) Front power window motor (RH) F-04 (16) Power window main switch <Vehicles

F-05 (10) Front door lock actuator (RH) F-06 (10) Door mirror assembly (LH) F-07 (6-GR) Front power window motor (LH) F-08 (8) Front power window sub switch F-09 (10) Front door lock actuator (LH) F-10 (2) Front door speaker (RH)

h safety system>

wit

F-11 (2-GR) Lock/unlock switch (driver’s side)

ehicles with KOS>

<V F-12 (2) Front door speaker (LH) F-13 (16) Power window main switch <Vehicles

hout safety system>

wit F-14 (4) Front power window sub switch

ehicles with safety system>

<V F-15 (4) Power window main switch <Vehicles

h safety system>

wit

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Page 76

80A-24

ACB04364

REAR DOOR

(LH)(RH)

F-101 F-102

F-108F-107

Rear door wiring harness (RH)

Rear door wiring harness (LH)

Connector symbol

-101 thru

-108

F-103 F-104 F-105 F-106

DOOR (CONTINUED)

CONFIGURATION DIAGRAMS

DOOR

F-101 (8) Rear power window sub switch (RH) F-102 (2-B) Rear power window motor (RH) F-103 (10) Rear door lock actuator (RH) F-104 (8) Rear power window sub switch (LH)

F-105 (2-B) Rear power window motor (LH) F-106 (10) Rear door lock actuator (LH) F-107 (2) Rear door speaker (RH) F-108 (2) Rear door speaker (LH)

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Page 77

CONFIGURATION DIAGRAMS

ACC06697

Connector symbol

G-01

G-02

G-03

G-04

G-06G-07G-12

G-13

G-09

G-10

G-11

Liftgate wiring harness

Floor wiring harness

LIFTGATE

80A-25

LIFTGATE

M1801001901765

G-01 (2-B) High-mounted stoplight G-02 (1-B) Rear window defogger () G-03 (4) Rear wiper motor G-04 (2) Lock/unlock switch (liftgate) <Vehicles

with KOS> G-06 (4) Liftgate latch switch assembly G-07 (2-B) Outside transmission antenna

assembly

KOS>

(liftgate) <Vehicles with

G-09 (2-GR) Outer tone alarm <Vehicles with KOS> G-10 (5) Rear view camera G-11 (1-B) Rear window defogger (+) G-12 (2) License plate light G-13 (2-B) Evaporative emission ventilation

solenoid

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Page 78

80A-26

NOTES

CONFIGURATION DIAGRAMS

ROOF

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Page 79

GROUP 11B

ENGINE OVERHAUL

CONTENTS

11B-1

GENERAL SPECIFICATIONS . . . . . . 11B-2

SERVICE SPECIFICATIONS. . . . . . . 11B-2

REWORK DIMENSIONS . . . . . . . . . . 11B-3

TORQUE SPECIFICATIONS . . . . . . . 11B-4

SEALANTS AND ADHESIVES . . . . . 11B-6

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-8

GENERATOR AND IGNITION 

SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 11B-10

REMOVAL AND INSTALLATION . . . . . . . . 11B-10

FUEL AND EMISSION PARTS . . . . . 11B-13

REMOVAL AND INSTALLATION . . . . . . . . 11B-13

INTAKE MANIFOLD . . . . . . . . . . . . . 11B-16

REMOVAL AND INSTALLATION . . . . . . . . 11B-16

EXHAUST MANIFOLD. . . . . . . . . . . . 11B-17

REMOVAL AND INSTALLATION . . . . . . . . 11B-17

OIL PAN AND TIMING CHAIN 

CASE. . . . . . . . . . . . . . . . . . . . . . . . . . 11B-23

REMOVAL AND INSTALLATION . . . . . . . . 11B-23

TIMING CHAIN . . . . . . . . . . . . . . . . . . 11B-30

REMOVAL AND INSTALLATION . . . . . . . . 11B-30

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-36

CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11B-40

REMOVAL AND INSTALLATION . . . . . . . . 11B-40

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-43

CYLINDER HEAD AND VALVES. . . . 11B-45

REMOVAL AND INSTALLATION . . . . . . . . 11B-45

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-51

PISTON AND CONNECTING ROD . . 11B-55

REMOVAL AND INSTALLATION . . . . . . . . 11B-55

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-61

CRANKSHAFT AND 

CYLINDER BLOCK . . . . . . . . . . . . . . 11B-63

REMOVAL AND INSTALLATION . . . . . . . . 11B-63

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-69

WATER HOSE AND PIPE . . . . . . . . . 11B-19

REMOVAL AND INSTALLATION . . . . . . . . 11B-19

Page 80

11B-2

ENGINE OVERHAUL

GENERAL SPECIFICATIONS

M1113000203240

Item 3A92

To ta l displacement cm

Bore  stroke mm (in) 75.0 (2.95)  90.0 (3.54)

Compression ratio 10.5

Combustion chamber Pentroof type

Camshaft arrangement DOHC

Valve timing Intake opening BTDC 41  ATDC 9 

Fuel system Electronically controlled multiport fuel injection

Ignition system Electronic-controlled 3-coil

(cu in)

Intake closing ABDC 19  ABDC 69

Exhaust opening BBDC 35

Exhaust closing ATDC 5

1,193 (72.8)

SERVICE SPECIFICATIONS

M1113000303742

Item Standard value Limit

Timing chain

Valve clearance [c old en gin e] mm (in) Intake 0.22  0.04 (0.009  0.001)

Exhaust 0.30  0.04 (0.012  0.001)

Camshaft

Cam height mm (in) Intake 44.81 (1.764) 44.31 (1.744)

Exhaust 43.98 (1.731) 43.48 (1.712)

Cylinder head and valves

Cylinder head bottom face distortion mm (in) 0.03 (0.001) or less

Cylinder head overall height mm (in) 112.9  113.1 (4.445  4.452)

Valve margin mm (i n) Intake 0.85 (0.033)

Exhaust 1.50 (0.059)

Valve length mm (i n) Intake 87.21 (3.433) 86.71 (3.414)

Exhaust 88.54 (3.486) 88.04 (3.466)

Valve spring fr ee len gth mm (in) 49.6 (1.95) 48.6 (1.91)

Valve spring ou t-o f-s qua reness 2 or less 4

Valve stem-to-g uid e c lea rance mm (in) Intake 0.020  0.047 (0.0008  0.0018) 0.10 (0.004)

Exhaust 0.030  0.057 (0.0012  0.0022) 0.15 (0.006)

Valve seat contact width m m ( in) 1.1  1.5 (0.044  0.059)

Valve guide pre ss- fit height mm (in) 12.7  13.3 (0.50  0.52)



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ENGINE OVERHAUL

REWORK DIMENSIONS

Item Standard value Limit

Piston and connecting rod

Piston pin press-fit load N (lb) 2,000  8,000 (449.7  1798.5)

Connecting rod big end thrust clearance mm (in) 0.10  0.35 (0.004  0.013) 0.4 (0.02)

Outside diameter difference of connecting rod bolt mm (in) 0  0.1 (0  0.003)

Piston ring to ring groove clearance mm (in) No. 1 0.03  0.07 (0.0012  0.0027) 0.1 (0.004)

No. 2 0.02  0.06 (0.0008  0.0023) 0.1 (0.004)

Piston ring end gap mm (in) No. 1 0.15  0.30 (0.006  0.011) 0.8 (0.03)

No. 2 0.20  0.40 (0.008  0.015) 0.8 (0.03)

Oil ring 0.10  0.35 (0.004  0.013) 1.0 (0.04)

Crankshaft pin oil clearance mm (in) 0.026  0.062 (0.0011  0.0024) 0.1 (0.004)

Crankshaft and cylinder block

Crankshaft bearing cap bolt shank leng

Crankshaft end play mm (in) 0.09  0.27 (0.004  0.010) 0.30 (0.012)

Crankshaft journal oil clearance mm (in) 0.023  0.043 (0.0010  0.0016) 0.1 (0.004)

Cylinder block top surface distortion mm (in) 0.05 (0.002) 0.1 (0.004)

Cylinder bore mm (in) 75.0 (2.95)

Cylindrically mm (in) 0.01 (0.0004) or less

th mm (in) 74.15  74.85 (2.920  2.946)

11B-3



REWORK DIMENSIONS

Item Dimension

Cylinder head and valve

Cylinder head oversize valve seat bore diameter mm

Cylinder head oversize valve guide bore diameter mm

Intake 0.30 O.S. 31.83  31.85 (1.2532  1.2539)

Exhaust 0.30 O.S. 28.32  28.34 (1.1150  1.1157)

Intake 0.05 O.S. 10.56  10.58 (0.4158  0.4165)

Exhaust 0.05 O.S. 10.55  10.57 (0.4154  0.4161)

M1113024301814

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11B-4

ENGINE OVERHAUL

TORQUE SPECIFICATIONS

Item Specification

Generator and ignition system

Crankshaft pulley center bolt 50 Nm (37 ft-lb), +60, 0 Nm (0 ft-lb), 

50 Nm (37 ft-lb) then +60

Generator brace bolt (M8) 5.0  1.0 Nm (44  8 in-lb)

Generator brace bolt (M10) 38  5 Nm (28  3 ft-lb)

Generator nut (M8) 23  2 Nm (17  1 ft-lb)

Generator nut (M10) 47  5 Nm (35  3 ft-lb)

Ignition coil bolt 9.5  2.5 Nm (84  22 in-lb)

Oil dipstick guide bolt 11  3 Nm (97  26 in-lb)

Spark plug 25  5 Nm (18  3 ft-lb)

Water pump pulley bolt 11  3 Nm (97  26 in-lb)

Fuel and emission parts

Engine hanger bolt 25  5 Nm (18  3 ft-lb)

Evaporative emission purge solenoid nut 5.5  1.5 Nm (49  13 in-lb)

Fuel rail and fuel injector assembly bolt 14  3 Nm (124  26 in-lb)

Throttle body bolt 9.5  2.5 Nm (84  22 in-lb)

M1113023406062

Intake manifold

Intake manifold bolt 28  2 Nm (21  1 ft-lb)

Intake manifold stay bolt 19  1 Nm (14.0  0.7 ft-lb)

Manifold absolute pressure sensor bolt 5.5

Exhaust manifold

Exhaust manifold bolt and nut 34  3 Nm (25  2 ft-lb)

Exhaust manifold cover bolt 9.5  2.5 Nm (84  22 in-lb)

Linear air-fuel ratio sensor 44  5 Nm (32  3 ft-lb)

Water hose and pipe

Engine coolant temperature sensor 30  9 Nm (22  6 ft-lb)

Engine oil pressure switch 10  2 Nm (89  17 in-lb)

Camshaft position sensor bolt 9.5  2.5 Nm (84  22 in-lb)

Crankshaft position sensor bolt 9.5  2.5 Nm (84  22 in-lb)

Knock sensor bolt 20  2 Nm (15  1 ft-lb)

Water inlet fitting bolt 11  3 Nm (97  26 in-lb)

Water pipe bolt 11  3 Nm (97  26 in-lb)

 1.5 Nm (49  13 in-lb)

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ENGINE OVERHAUL

TORQUE SPECIFICATIONS

Item Specification

Oil pan and timing chain case

Cylinder head cover bolt 2.0  0.5 Nm then 7.0  0.5 Nm (18  4 in-lb then 62  4 in-lb)

Oil drain plug 39  5 Nm (29  3 ft-lb)

Oil filter cover bolt 23  6 Nm (17  4 ft-lb)

Oil filter stud 27  2 Nm (20  1 ft-lb)

Oil pan bolt 11  3 Nm (97  26 in-lb)

Oil strainer bolt 10  2 Nm (89  17 in-lb)

PCV valve 2.5  0.4 Nm (22  3 in-lb)

Service hole bolt 9.5  2.5 Nm (84  22 in-lb)

Stud (M10  80.5) 11  2 (97  17 in-lb)

Stud (M10  90.8) 10  1 (89  8 in-lb)

Timing chain case bolt (M6) 9.5  2.5 Nm (84  22 in-lb)

Timing chain case bolt (M10) 42  16 Nm (31  11 ft-lb)

Transaxle stay 26  6 Nm (19  4 ft-lb)

Water pump bolt 11  3 Nm (97  26 in-lb)

11B-5

Timing chain

Camshaft sprocket bolt 92  13 Nm (68  9 ft-lb)

Chain guide bolt 9.5  2.5 Nm (84

Tensioner lever bolt 23  6 Nm (17  4 ft-lb)

Timing chain tensioner bolt 9.5  2.5 Nm (84  22 in-lb)

V.V.T. spro cket b ol t 65  5 Nm (48  3 ft-lb)

Camshaft

Camshaft bearing cap bolt 11  1 Nm (97  8 in-lb)

Front camshaft bearing cap bolt 20  1 Nm (14.8  0.7 ft-lb)

Oil feeder control valve bolt 10  2 Nm (89  17 in-lb)

Oil feeder control valve filter bolt 44  5 Nm (32  3 ft-lb)

Cylinder head and valves

Cylinder head bolt 24.5  2.0 Nm (18.4  0.7 ft-lb) then +180 to 184

Piston and connecting rod

Connecting rod cap bolt 14.7  2.0 Nm (11.1  0.7 ft-lb) then +90 to 94

Crankshaft and cylinder block

Bell housing cover bolt (M6) 11  3 Nm (97  26 in-lb)

Bell housing cover bolt (M8) 26  6 Nm (19  4 ft-lb)

 22 in-lb)

Crankshaft bearing cap bolt 35  2 Nm (26  1 ft-lb) then +60 to 64

Crankshaft sensing ring bolt 10  2 Nm (89  17 in-lb)

Drive plate bolt 100  5 Nm (74  3 ft-lb)

Flywheel bolt 100  5 Nm (74 

Oil seal case bolt 11  3 Nm (97  26 in-lb)

Stiffener plate bolt 26  6 Nm (19  4 ft-lb)

3 ft-lb)

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11B-6

ENGINE OVERHAUL

SEALANTS AND ADHESIVES

M1113000503940

Item Specified sealant and adhesive Remark

Engine coolant temperature sensor LOCTITE 262, ThreeBond 1324N or equivalent Anaerobic

hesive

Cylinder block crank angle se face

Engine oil pressure switch ThreeBond 1215, ThreeBond 1141J, ThreeBond

Timing chain case (matching area of the cylind

er block, the cylinder head gasket and

the cylinder head)

Cylinder head cover (matching area of the cylind

er head and timing chain case)

Cylinder head gasket (matching area of the cylind

er block, the cylinder head gasket and

the cylinder head)

Timing chain case (Area of the water pump) ThreeBond 1227D, ThreeBond 1207F

Oil pan ThreeBond 1217G (MITSUBISHI MOTORS

Oil seal case

nsor mounting

ThreeBond 1207F (MITSUBISHI MOTORS GENUINE Part No.1000A992) or equivalent

12D or equivalent

ThreeBond 1217G (MITSUBISHI MOTORS GENUINE Part No.1000A923), LOCTITE 5900, LOCTITE 5970 or equivalent

(MITSUB

ISHI MOTORS GENUINE Part

No.1000A992) or equivalent

GENUINE Part No.1

000A923), ThreeBond 1227D, LOCTITE 5900, LOCTITE 5970 or equivalent

Semi-drying sealant

Flywheel bolt <M/T> LOCTITE 2701 or equivalent Anaerobic

hesive

Drive plate bolt <CVT> LOCTITE 2701, ThreeBond 1324 or equivalent

NOTE: The number in brackets shows the genuine part number.

LIQUID GASKET (FIPG)

FIPG is used for some parts in the engine. It is necessary to pay attention to an application amount, application procedure and applied surface condition for this gasket to fully achieve its purpose. To o small ap p lication am o unt of F IP G or the d i rty surfa ce

ere the FIPG is applied might cause the water or oil leakage.

wh To o l a rg e a p plication amount of FIPG overfl ow s a n d m i gh t c l og or narrow the passage of water or oil. It is absolutely essential that the surface where the FIPG is applied must be cleaned and the appropriate amount of FIPG must be evenly applied to prevent the leakage from the connected area. FIPG used for engine parts hardens reacting with moisture in

e air, and is usually used for metal flanges.

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ENGINE OVERHAUL

CAUTION

SEALANTS AND ADHESIVES

Reapply the FIPG with care to the followings.

 Completely remove the old FIPG including the residue

in gaps of parts.

 Using MITSUBISHI MOTORS GENUINE parts cleaner

00387) or equivalent, degrease the FIPG applica-

(MZ1 tion surface carefully.

 According to the FIPG application procedures, apply it

accu

rately.

DISASSEMBLY

Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.

Parts assembled with FIPG can be easily disassembled without using a special method. In some cases, however, it is necessary to lightly tap parts with a wooden hammer or similar tool to

reak sealant between mating surfaces. Or lightly driving a

b smooth and thin gasket scraper in mating surfaces is useful, but full care must be exercised not to damage mating surfaces. As special tool oil pan FIPG cutter (MD998727) is set, use this tool.

11B-7

CLEANING OF GASKET SURFACE

Completely remove all deposits from the gasket surface with a gasket scraper or wire brush. Make sure that the surface to which FIPG is applied is smooth. Completely remove all the old FIPG, which might be remaining

installation hole, the thread hole or among the compo-

in the nents.

APPLICATION PROCEDURE

Apply FIPG in a determined diameter and continuously without break. Completely enclose the periphery of mounting holes. FIPG can be wiped off if it is not hardened. Install parts in place while FIPG is still wet. Take care not to allow FIPG to adhere to other locations than necessary locations during installation. Do not pour oil or water on applied locations or do not start the engine until sufficient time (approximately one hour) passes. The application procedure of FIPG may differ depending on areas. Follow the procedure in the body of the manual to apply FIPG.

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11B-8

MB991883

B992106

B991953

B991396

MB991828

D998727

B991993

ENGINE OVERHAUL

SPECIAL TOOLS

Tool Tool nu mbe r and n ame Supersession Application

MB991883 Flywheel stopper

MB992106 O-ring installer

MB991953 Oxygen sensor wrench

MB991396 Oil filter wrench

General service tool



Supporting the flywheel <M/T> or drive p

late <CVT>

Installation of O-ring on fuel in

jector injection nozzle side

MB991953-01 Removal and installation of linear

air-fuel ratio

General service tool or MB991

396-01

Removal and installation of oil filter

M1113000603538

sensor

MB991828 Oil filter wrench

MD998727 Oil pan FIPG cutter

MB990699 Differential oil seal

staller

MB991993 Crankshaft front oil seal guide

General service tool

MD998727-01 Removal of oil pan



Installation of front oil seal

Installation of timing chain case

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ENGINE OVERHAUL

MB992676

B992000

D999597

B992922

SPECIAL TOOLS

Tool Tool nu mbe r and n ame Supersess ion Applica tio n

MB992676



Installation of oil filter stud

Oil filter stud setter

11B-9

MB992000 Crankshaft adapter

MD999597 Valve spr ing co mpressor

MB992085 Valve ste m s eal pliers

MB992922 Valve stem s eal in staller adjustable



Turn the crankshaft

Compression of valve spring

Valv e stem sea l remov al

Valv e s tem sea l press -fittin g

MD998780 Piston pin setting tool

MB991659 Guide D

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MIT216941 Removal and press-fitting of

piston



Page 88

11B-10

MB991614

AKC00219AB

9.5 ± 2.5 N·m 84 ± 22 in-lb

11 ± 3 N·m 97 ± 26 in-lb

38 ± 5 N·m 28 ± 3 ft-lb

23 ± 2 N·m 17 ± 1 ft-lb

5.0 ± 1.0 N·m 44 ± 8 in-lb

47 ± 5 N·m 35 ± 3 ft-lb

25 ± 5 N·m 18 ± 3 ft-lb

11 ± 3 N·m 97 ± 26 in-lb

50 N·m, +60˚, 0 N·m, 50 N·m then +60˚ 37 ft-lb

, +60˚, 0

ft-lb

37 ft-lb

then +60˚

GENERATOR AND IGNITION SYSTEM

ENGINE OVERHAUL

Tool Tool nu mbe r and n ame Supersess ion Applica tio n

MB991614 Angle gauge

General service tool

Tightening crankshaft bearing cap bolt

GENERATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION

M1113001002837

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ENGINE OVERHAUL

AK600409

MB991883

AK600409

MB991883

GENERATOR AND IGNITION SYSTEM

11B-11

Removal steps

1. Oil dipstick guide

2. Oil dipstick

3. O-ring

4. Generator

5. Generator brace

6. Water pump pulley

Removal steps (Continued)

>> >>A<<

>> >>

7. Crankshaft pulley center bolt

8. Crankshaft pulley washer

9. Crankshaft pulley

10.Ignition coil

11. Spark plug

REMOVAL SERVICE POINT

<<A>> CRANKSHAFT PULLEY CENTER BOLT REMOVAL

1. Lock the flywheel or drive plate with special tool flywheel stopper (MB991883).

2. Remove the crankshaft pulley center bolt.

INSTALLATION SERVICE POINTS

>>A<< CRANKSHAFT PULLEY / CRANKSHAFT PULLEY WASHER / CRANKSHAFT PULLEY CENTER BOLT INSTALLATION

1. Lock the flywheel or drive plate with special tool flywheel stopper (MB991883).

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Page 90

11B-12

CAUTION

AK901203

Crankshaft

Crankshaft pulley

Crankshaft pulley center bolt

Crankshaft pulley washer

: Wipe clean with a rag. : Wipe clean with a rag and degrease. : Wipe clean with a rag, degrease and apply a small amount of engine oil.

Engine front

AK901204

Figure A Figure B

Paint markings

Crankshaft pulley center bolt

60˚

ENGINE OVERHAUL

GENERATOR AND IGNITION SYSTEM

2. Using a rag, wipe dirt on the crankshaft thread hole and the crankshaft pulley washer.

3. Using a rag, wipe dirt on the crankshaft pulley and then deg

rease the place specified in the illustration.

NOTE: Perform degreasing to prevent the friction resistance from decreasing in the comp

ressed area due to the residual

oil.

4. Install the crankshaft pulley.

5. Apply the minimum amount of engine oil to the crankshaft pulley ce

nter bolt threads and the seating surface.

6. Tighten the crankshaft pulley center bolt to the specified

ue of 50 Nm (37 ft-lb).

torq

7. As shown in figure A, put a paint mark on one angle of the crankshaf

t pulley center bolt. Then, put a paint mark on the crankshaft pulley on the extended line of the angle next to the marked angle.

 When the tightening angle is smaller than the specified

tightening angle, the appropriate tightening capacity cannot be secured.

 When the tightening angle is larger than the specified

tighten

ing angle, remove the bolt to start from the

beginning again according to the procedure.

8. Tighten the crankshaft pulley center bolt in a 60, and check tha

t the paint mark on the crankshaft pulley center bolt aligns with the paint mark on the crankshaft pulley as shown in figure B.

9. Loosen the crankshaft pulley center bolt completely after s 6 to 8, and then repeat steps 6 to 8.

step

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ENGINE OVERHAUL

ACC06804

9.5 ± 2.5 N·m 84 ± 22 in-lb

25 ± 5 N·m 18 ± 3 ft-lb

14 ± 3 N·m 124 ± 26 in-lb

5.5 ± 1.5 N·m 49 ± 13 in-lb

FUEL AND EMISSION PARTS

11B-13

REMOVAL AND INSTALLATION

M1113002201615

>> >>E<<

Removal steps

1. Purge hose

2. Purge hose

3. Evaporative emission purge solenoid

4. Engine hanger

5. Throttle body

6. Throttle body gasket

7. Fuel rail and fuel injector assembly

Removal steps (Continued)

>> >> >> >>

8. Insulator

9. Injector support

10.Fuel injector assembly

11. O-ring

12.O-ring

13.Fuel injector

14.Fuel rail

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Page 92

11B-14

CAUTION

AC904227

MB992106

O-ring

AC506793

Projection part

ENGINE OVERHAUL

FUEL AND EMISSION PARTS

REMOVAL SERVICE POINT

<<A>> FUEL RAIL AND FUEL INJECTOR ASSEMBLY REMOVAL

Do not drop the fuel injector.

Remove the fuel rail with the fuel injectors attached to it.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION

1. Apply a small amount of new engine oil to the O-ring.

2. While turning the fuel injector to the right and left, install the

O-ring

to the fuel injector with care not to damage the

O-ring.

>>B<< O-RING INSTALLATION

1. Apply a small amount of new engine oil to the O-ring.

2. Using special tool O-ring installer (MB992106), install the

fue

l injector paying attention to avoid damage to the O-ring.

>>C<< FUEL INJECTOR ASSEMBLY INSTALLATION

1. Apply a small amount of new engine oil to the O-ring.

2. Turning the fuel injector assembly to right and left, install it to

fuel rail with care not to damage the O-ring. After the

the installation, check for its smooth rotation. At this time, check that the projection part of the fuel injector assembly is in the center.

3. If the rotation is not smooth, the O-ring may be caught.

Remove t damage. After this, re-insert it to the fuel rail and check for its smooth rotation.

he fuel injector assembly and check the O-ring for

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ENGINE OVERHAUL

CAUTION

ACA00290

Fuel rail brim

Injector support

Fuel injector groove

FUEL AND EMISSION PARTS

>>D<< INJECTOR SUPPORT INSTALLATION

Install the injector support to the fuel injector groove and fuel rail brim, and fix the fuel injector assembly and fuel rail.

>>E<< FUEL RAIL AND FUEL INJECTOR ASSEMBLY INSTALLATION

1. Apply a small amount of new engine oil to the O-ring at the

end of the fuel injector assembly.

When installing the fuel rail and fuel injector assembly to the cylinder head, take care not to damage the O-ring at the tip of the fuel injector assembly.

2. Install the fuel rail and fuel injector assembly to the cylinder

head. Be careful not to damage the O-ring.

3. Tighten the fuel rail mounting bolts to the specified torque.

Tightening torque: 14  3 Nm (124  26 in-lb)

>>F<< THROTTLE BODY GASKET INSTALLATION

Securely insert the gasket in the groove of the inlet manifold without causing any torsion or damage to the gasket.

11B-15

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Page 94

11B-16

CAUTION

ACB03397

19 ± 1 N·m

14.0 ± 0.7 ft-lb

28 ± 2 N·m 21 ± 1 ft-lb

19 ± 1 N·m

14.0 ± 0.7 ft-lb

5.5 ± 1.5 N·m 49 ± 13 in-lb

ENGINE OVERHAUL

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

M1113026101281

 When removing or installing the manifold absolute pressure sensor, be careful not to apply impact

to the sensor.

 Do not reuse the manifold absolute pressure sensor that has been dropped.

Removal steps

1. Manifold absolute pressure nsor

2. O-ring

>> >> >>

Removal steps (Continued)

3. Intake manifold stay

4. Intake manifold

5. Intake manifold gasket

INSTALLATION SERVICE POINTS

>>A<< INTAKE MANIFOLD GASKET INSTALLATION

Securely insert the gasket in the groove of the intake manifold without causing any torsion or damage to the gasket.

>>B<<INTAKE MANIFOLD/INTAKE MANIFOLD STAY INSTALLATION

1. Install the intake manifold and intake manifold stay temporarily tighten the mounting bolts.

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ENGINE OVERHAUL

CAUTION

ACC06805

9.5 ± 2.5 N·m 84 ± 22 in-lb

34 ± 3 N·m 25 ± 2 ft-lb

44 ± 5 N·m 32 ± 3 ft-lb

9.5 ± 2.5 N·m 84 ± 22 in-lb

34 ± 3 N·m 25 ± 2 ft-lb

EXHAUST MANIFOLD

Check that the sealing surfaces of the intake manifold and intake manifold stay contact securely after temporary tightening.

2. Tighten the intake manifold and intake manifold stay bolts to the specified torque.

Tightening torque:

Intake manifold: 28  2 Nm (21  1 ft-lb) Intake manifold stay: 19  1 Nm (14.0  0.7 ft-lb)

EXHAUST MANIFOLD

11B-17

REMOVAL AND INSTALLATION

M1113004902152

>> >>A<<

Removal steps

1. Linear air-fuel ratio sensor

2. Exhaust manifold cover

3. Nut

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Removal steps (Continued)

4. Washer

5. Exhaust manifold

6. Exhaust manifold gasket

Page 96

11B-18

AC606118

MB991953

AC606118

MB991953

ENGINE OVERHAUL

EXHAUST MANIFOLD

REMOVAL SERVICE POINT

<<A>> LINEAR AIR-FUEL RATIO SENSOR REMOVAL

1. Remove the linear air-fuel ratio sensor connector connection and harness clip.

2. Use special tool heated oxygen sensor wrench (MB991953) to r

emove the linear air-fuel ratio sensor.

INSTALLATION SERVICE POINT

>>A<< LINEAR AIR-FUEL RATIO SENSOR INSTALLATION

1. In the same manner as removal, use special tool heated oxygen sensor wrench (MB991953) to tighten the linear air-fuel ratio sensor to the specified torque.

Tightening torque: 44  5 Nm (32  3 ft-lb)

2. Install the linear air-fuel ratio sen and harness clip.

sor connector connection

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ENGINE OVERHAUL

CAUTION

ACC06785

11 ± 3 N·m 97 ± 26 in-lb

20 ± 2 N·m 15 ± 1 ft-lb

10 ± 2 N·m 89 ± 17 in-lb

9.5 ± 2.5 N·m 84 ± 22 in-lb

30 ± 9 N·m 22 ± 6 ft-lb

11 ± 3 N·m 97 ± 26 in-lb

9.5 ± 2.5 N·m 84 ± 22 in-lb

WATER HOSE AND PIPE

11B-19

REMOVAL AND INSTALLATION

M1113010201018

 When removing or installing the camshaft position sensor or crankshaft position sensor, be care-

ful not to apply impact to the sensor.

 Do not reuse the camshaft position sensor or crankshaft position sensor that has been dropped.

>> >>

1. Engine oil pressure switch

2. Knock sensor

3. Camshaft position sensor

4. O-ring

5. Crankshaft position sensor

6. O-ring

7. Engine coolant temperature sensor

Removal steps

>> >>

Removal steps (Continued)

8. Water inlet fitting

9. Thermostat

10.Water hose A

11. Water hose B

12.Water pipe

13.Water pipe gasket

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Page 98

11B-20

AK901146

ACB05737

Marking

AK304916

Jiggle valve

ENGINE OVERHAUL

WATER HOSE AND PIPE

INSTALLATION SERVICE POINTS

>>A<< WATER PIPE GASKET INSTALLATION

Install the water pipe gasket as its protrusion is in the direction shown.

>>B<< WATER HOSE A INSTALLATION

Make sure that the marking on the hose should face towards the transaxle.

>>C<< THERMOSTAT INSTALLATION

Install the thermostat onto the cylinder block such that the jiggle valve is positioned on top of the thermostat housing.

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Page 99

ENGINE OVERHAUL

CAUTION

AK400587AD

AK901147

A-A

1 mm (0.04 in)

AKB00479AB

Knock sensor

30˚

10˚

Marking on cylinder block

WATER HOSE AND PIPE

11B-21

>>D<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

Be careful not to damage the connector portion (made of resin) of the sensor with the tool.

1. Remove any sealant that may be remaining on the engine coolant temperature sensor or the threaded hole in the cylinder head.

2. Apply sealant onto the threaded portion (illustrated) of the

senso

Specified sealant:

LOCTITE 262 or equivalent

3. Install the engine coolant temperature sensor onto the cylinder b

lock by tightening it to 30  9 Nm (22  6 ft-lb).

>>E<< CRANKSHAFT POSITION SENSOR INSTALLATION

Apply sealant correctly so that it will not be squeezed out onto the end of the threaded portion upon assembly.

1. Remove any sealant that may be remaining on the angle sensor or the mounting face on the cylinder block.

2. Apply a bead of sealant with a diameter of 1.7  0.5 mm (0.07  0.01 inch) on the cylinder block as illustrated.

Specified sealant:

ThreeBond 1207F or equivalent

3. Install the crankshaft position sensor onto the cylinder block by tigh

tening it to 9.5  2.5 Nm (84  22 in-lb).

>>F<< KNOCK SENSOR INSTALLATION

Align the knock sensor connector with the position shown in the illustration, and then tighten it to the specified torque of 20  2 Nm (15  1 ft-lb).

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Page 100

11B-22

CAUTION

AK402699

1 mm (0.04 in)

5 mm (0.2 in)

ENGINE OVERHAUL

WATER HOSE AND PIPE

>>G<< ENGINE OIL PRESSURE SWITCH INSTALLATION

Apply sealant correctly so that it will not be squeezed out onto the end of the threaded portion upon assembly.

1. Remove any sealant that may be remaining on the engine oil pressure switch or the threaded hole in the cylinder block.

2. Apply sealant to the threaded portion of the engine oil pre

ssure switch as illustrated.

Specified sealant:

ThreeBond 1215 or equivalent

3. Install the engine oil pressure switch onto the cylinder block by tigh

tening it to 10  2 Nm (89  17 in-lb).

TSB Revision

Mitsubishi Mirage 2015 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual