Mitsubishi Outlander (2003),Outlander (2004),Outlander (2005),Outlander (2006) Workshop Manual
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Page 3
GROUP 00
GENERAL
CONTENTS
00-1
HOW TO USE THIS MANUAL. . . . . . 00-2
HOW TO USE
TROUBLESHOOTING/INSPECTION
SERVICE POINTS . . . . . . . . . . . . . . . 00-6
VEHICLE IDENTIFICATION . . . . . . . 00-16
GENERAL DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . . 00-20
PRECAUTIONS BEFORE SERVICE. 00-22
SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). . . . . . . . . . . . . . . . . . 00-27
SRS SERVICE PRECAUTIONS . . . . . 00-28
SUPPORT LOCATIONS FOR LIFTING
AND JACKING . . . . . . . . . . . . . . . . . . 00-31
STANDARD PART/TIGHTENING-
TORQUE TABLE . . . . . . . . . . . . . . . . 00-33
Page 4
00-2
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
SCOPE OF MAINTENANCE, REPAIR AND
SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components. For
detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
"On-vehicle Service" is procedures for performing
inspections and adjustments of particularly important
locations with regard to the construction and for
maintenance and servicing, but other inspection (for
looseness, play, cracking, damage, etc.) must also
be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.
GENERAL
M1001000100660
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
• If a DANGER is not followed, the result is severe
bodily harm or even death.
• If a WARNING is not followed, the result could be
bodily injury.
• If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.
INDICATION OF TIGHTENING TORQUE
Tightening torques (units: N⋅m) are set to take into
account the central value and the allowable
tolerance. The central value is the target value, and
the allowable tolerance provides the checking range
for tightening torques. If bolts and nuts are not
provided with tightening torques, refer to P.00-33.
MODEL INDICATIONS
The following abbreviations are used in this manual
for identification of model types.
MPI::Indicates the multipoint injection.
SOHC::Indicates an engine with the single overhead
camshaft.
DOHC::Indicates an engine with the double
overhead camshaft.
2000:: Indicates models equipped with the 2,000 mL
<4G63> petrol engine.
2400::Indicates models equipped with the 2,400 mL
<4G69> petrol engine.
M/T:: Indicates the manual transmission.
A/T:: Indicates the automatic transmission.
A/C:: Indicates the air conditioner.
Page 5
NOTES
GENERAL
HOW TO USE THIS MANUAL
00-3
Page 6
00-4
GENERAL
HOW TO USE THIS MANUAL
<<A>>
>>A<<
Symbols are used to show the locations for lubrication
These symbols are included in the diagram of compo-
nent parts or on the page following the component
parts page. The symbols do not always have accompanying text to support that symbol.
.
(s
.
disassembly.
or reassembly.
Multi-purpose grease unless there is a
AC301960
Page 7
GENERAL
HOW TO USE THIS MANUAL
00-5
For bolts and nuts which do
not have a tightening torque
listed, refer to the "Standard
Parts tightening-torque Table"
parts sets are
On removal,
reassembly are described
AC300860
Page 8
00-6
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
M1001000200582
CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the MUT-II/III can be used follows the basic outline
described below. Even in systems for which the MUT-II/III cannot be used, some of these systems still follow
this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is required, the details of such differences or additions will also
be listed.
Diagnosis method
Gathering information
from the customer.
Check trouble symptom.
Reoccurs
Read the diagnosis code. Read the diagnosis code.
No diagnosis code
or communication
with MUT-II/III not
possible
Refer to the INSPECTION CHART
FOR TROUBLE SYMPTOMS
(Refer to applicable group.)
Diagnosis code
displayed.
After taking note of the
malfunction code, erase the
diagnosis code memory.
Recheck trouble symptom.
Read the diagnosis codes.
Diagnosis code
displayed.
Refer to the INSPECTION CHART
FOR DIAGNOSIS CODES
(Refer to applicable group.)
Diagnosis code
displayed.
Does not reoccur
No diagnosis
code.
No diagnosis
code.
INTERMITTENT MALFUNCTIONS
AC300864
AC
2. SYSTEM OPERATION AND SYMPTOM
VERIFICATION TESTS
If verification of the symptom(s) is difficult,
procedures for checking operation and verifying
symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the
"Diagnosis function " section are described.
4. DIAGNOSIS CODE CHART
Diagnostic trouble codes and diagnostic items are
shown.
5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to
each diagnosis code (Refer to How to read
inspection procedure ).
Page 9
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-7
6. TROUBLE SYMPTOM CHART
If there are trouble symptoms even though the
MUT-II/III does not find any diagnosis codes,
Inspection procedures for each trouble symptom will
be found by means of this chart.
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptoms classified in the Symptom Chart
(Refer to How to read inspection procedure P.00-9).
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgment values have
been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors,
inspection items, and judgment values have been
provided in this chart as reference information.
10. INSPECTION PROCEDURE BY USING AN
OSCILLOSCOPE
When there are inspection procedures using an
oscilloscope, these are described here.
DIAGNOSIS FUNCTION
HOW TO READ DIAGNOSIS CODE
CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>
<Using the MUT-II>
Steering shaft
MUT-II
AC300830
Connect the MUT-II to the diagnosis connector, and
read the diagnosis code.
AC
<Using the MUT-III>
<Using the MUT-III>
16-PIN
MB991911
MB991824
MB991827
AC308915
AC
Connect the MUT-III to the 16-pin diagnosis
connector, and read the diagnosis code.
NOTE: For details on how to use the MUT-III, refer to
the "MUT-III operation manual."
1. Ensure that the ignition switch is at the
"LOCK" (OFF).
2. Start up the personal computer.
3. Connect MUT-III USB cable MB991827 to
special tool Vehicle Communication Interface
(V.C.I.) MB991824 and the personal
computer.
4. Connect MUT-III main harness B MB991911
to the V.C.I.
5. Connect MUT-III main harness B to the
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON"
position.
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green
colour.
7. Start the MUT-III system on the PC and turn
the ignition switch to the "ON" position.
8. Read the diagnosis code.
9. Disconnecting the MUT-III is the reverse of
the connecting sequence, making sure that
the ignition switch is at the "LOCK" (OFF).
Page 10
00-8
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
NOTE: The ABS warning lamp may flash when the
ignition switch is turned ON with the MUT-II/III
connected. This is because the diagnosis display
function of the ABS warning lamp is activated by
grounding the diagnosis connector terminal No.1,
and is not detrimental in any way.
ERASING DIAGNOSIS CODE (BY USING THE
MUT-II/III)
CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>
Steering shaft
MUT-II
ERASING DIAGNOSIS CODE (BY USING NO
MUT-II/III)
CAUTION
Some diagnosis codes can not be erased
according to the procedure below. If you attempt
to erase a diagnosis code, refer to an applicable
GROUP.
1. Turn the ignition switch to the "LOCK" (OFF)
position.
2. Disconnect the negative battery cable, wait for at
least 10 minutes, and then reconnect it.
3. Start the engine and let it run at idle for 10
minutes.
INPUT SIGNAL CHECK (WHEN USING THE
MUT-II/III) <SWS>
CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>
AC308915
AC
AC
AC300830
<Using the MUT-III>
16-PIN
MB991911
MB991824
MB991827
Connect the MUT-II/III to the diagnosis connector,
and erase the diagnosis code. The procedure is the
same as "HOW TO READ DIAGNOSIS CODE ".
Steering shaft
<Using the MUT-III>
16-PIN
MB991824
MUT-II
AC300830
MB991911
AC
MB991827
AC308915
AC
Page 11
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-9
1. Connect the MUT-II/III to the diagnosis connector,
and erase the diagnosis code.
2. If the MUT-II/III buzzer sounds once when each
switch is operated (ON/OFF), the input signal for
that switch circuit system is normal.
INPUT SIGNAL CHECK (WHEN USING A
VOLTMETER) <SWS>
Steering shaft
MB991529
12345678
9101112
13 14
15 16
AC300831
AB
1. Use the special tool diagnosis code check
harness (MB991529) to connect the ETACS
terminal (terminal 9) and the earth terminals
(terminals 4 and 5) of the diagnosis connector to
the voltmeter.
2. If the needle of the voltmeter flickers once when
each switch is operated (ON/OFF), the input
signal for that switch circuit system is normal.
HOW TO USE THE INSPECTION
PROCEDURES
The causes of many of the problems occurring in
electric circuitry are generally the connectors,
components, the ECU, the wiring harnesses
between connectors, in that order. These inspection
procedures follow this order. They first try to discover
a problem with a connector or a defective
component.
Page 12
00-10
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
Relevant circuit(s) of the component which
the Code No. indicates are described.
AC301964
AB
Page 13
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-11
Explains about the basic
operation of the components.
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Start of diagnosis
procedure
Describes
inspection
procedure.
Describes possible
causes(s) for that
diagnosis code.
HARNESS CHECK
Check for an open or short circuit in the harness
between the terminals which were faulty according to
the connector measurements. Carry out this
inspection while referring to the Electrical Wiring
Manual. Here, "Check the wiring harness between
the power supply and terminal xx" also includes
checking for blown fuse. For inspection service
points when there is a blown fuse, refer to
"Inspection Service Points for a Blown Fuse ."
MEASURES TO TAKE AFTER REPLACING THE
ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection
procedure from the beginning.
CONNECTOR MEASUREMENT SERVICE
POINTS
Turn the ignition switch to the "LOCK" (OFF) position
when connecting and disconnecting the connectors.
Turn the ignition switch to "ON" when measuring,
unless there are instructions to the contrary.
AC301965
IF INSPECTING WITH THE CONNECTOR
CONNECTED
<Waterproof Connectors>
MD998459
AC300881
AB
Be sure to use special tool harness connector
(MD998459). Never insert a test probe from the
harness side, as this will reduce the waterproof
performance and result in corrosion.
AB
Page 14
00-12
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
<Ordinary (non-waterproof) Connectors>
Connector
AC300882
AB
Check by inserting the multi-meter test probe from
the harness side. Note that if the connector (control
unit, etc.) is too small to permit insertion of the test
probe, it should not be forced; use the backprobing
tool for this purpose.
IF INSPECTING WITH THE CONNECTOR
DISCONNECTED
<When Inspecting a Female Pin>
Use the special tool inspection harness (MB991219)
(inspection harness for connector pin contact
pressure in the harness set for inspection). The
inspection harness for connector pin contact
pressure should be used. the test bar should never
be forcibly inserted, as it may cause a defective
contact.
<When Inspecting a Male Pin>
CAUTION
AC300890
At this time, be careful not to short the connector
pins with the test bars. To do so may damage the
circuits inside the ECU.Touch the pin directly
with the test bar.
MB991219
ACX00865
AB
Page 15
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-13
CONNECTOR INSPECTION SERVICE
POINTS
VISUAL INSPECTION
Connector disconnected or
improperly connected
Stretched or broken wires
•
• Low connection pressure due to rusted terminals
or foreign matter lodged in terminals
CONNECTOR PIN INSPECTION
AC300898
If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be
perfect even if the connector body is connected, and
the pins may pull out of the reverse side of the
connector. Therefore, gently pull the harnesses one
by one to make sure that no pins pull out of the
connector.
Harness wire breakage
at terminal section
Low contact
pressure
Good
Bad
AC300896
AB
Connector is disconnected or improperly connected
• Connector pins are pulled out
• Due to harness tension at terminal section
• Low contact pressure between male and female
terminals
CONNECTOR ENGAGEMENT INSPECTION
MB991219
AC300899
AB
Use the special tool inspection harness (MB991219)
(connector pin connection pressure inspection
harness of the inspection harness set) to inspect the
engagement of the male pins and females pins. (Pin
drawing force: 1 N or more)
Page 16
00-14
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
INSPECTION SERVICE POINTS FOR A
BLOWN FUSE
Battery
Fuse
Short-circuit
Load
switch
Load
occurrence
section
Remove the blown fuse and measure the resistance
between the load side of the blown fuse and the
earth. Close the switches of all circuits which are
connected to this fuse. If the resistance is almost 0 Ω
at this time, there is a short somewhere between
these switches and the load. If the resistance is not 0
Ω, there is no short at the present time, but a
momentary short has probably caused the fuse to
blow.
The main causes of a short circuit are the following.
• Harness being clamped by the vehicle body
• Damage to the outer casing of the harness due to
wear or heat
• Water getting into the connector or circuitry
• Human error (mistakenly shorting a circuit, etc.)
AC300900
AB
Page 17
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-15
HOW TO COPE WITH INTERMITTENT
MALFUNCTIONS
NOTE: If determining the cause is difficult, the flight
recorder function of the MUT-II/III can also be used.
Intermittent malfunctions often occur under certain
conditions, and if these conditions can be
ascertained, determining the cause becomes simple.
In order to ascertain the conditions under which an
intermittent malfunction occurs, first ask the
customer for details about the driving conditions,
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the
trouble symptoms. Next, ascertain whether the
reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or
some other factor. If vibration is thought to be the
cause, carry out the following checks with the
connectors and components to confirm whether the
trouble symptom occurs. The objects to be checked
are connectors and components which are indicated
by inspection procedures or given as probable
causes (which generates diagnosis codes or trouble
symptoms).
• Gently shake the connector up, down and to the
left and right.
• Gently shake the wiring harness up, down and to
the left and right.
• Gently rock each sensor and relay, etc. by hand.
• Gently shake the wiring harness at suspensions
and other moving parts.
AC300901
Page 18
00-16
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION CODE PLATE
1
2
4567
3
GENERAL
M1001000400713
The plate shows model code, engine model,
transmission model and body colour code.
No. Item Content
1 MODEL CU2WXNMML6CU2W:
Vehicle model
XNMML6:
Model series
2 ENGINE 4G63 Engine model
3 EXT W83A Exterior code
4 TRANS AXLE F5M42 F5M42:Trans
mission
model
5 COLOUR W83 W83: Body
colour code
6 INT 62A 62A: Interior
code
7OPT ZP3 ZP3:
AC301477
The vehicle information code plate is riveted to the
AB
For monotone colour vehicles, the body colour code
shall be indicated.
back of the hood.
MODELS
Model code Engine model Price class Transmission
model
CU2W XNMML6 4G63-DOHC (1,997
mL)
XNMMZL6 W5M42
XNHMZL6 Sport
CU5W XNMYZL6 4G69-SOHC MIVEC
(2,378 mL)
XRMYZL6 W4A42
XRMYZR6
XNHYZL6 Sport W5M42
Comfort F5M42
<2WD, 5M/T>
<4WD, 5M/T>
Comfort W5M42
<4WD, 5M/T>
<4WD, 4A/T with
sport mode>
<4WD,5M/T>
Equipment
code
Fuel supply
system
MPI
XRHYZL6 W4A42
XRHYZR6
<4WD, 4A/T with
sport mode>
Page 19
GENERAL
VEHICLE IDENTIFICATION
00-17
MODEL CODE
CU 2 W LZ
123
XNMM 6
45678910
AC301363
AB
No. Item Content
1 Development CU: MITSUBISHI
OUTLANDER
2 Engine type 2: 1,997 mL petrol engine
5: 2,378 mL petrol engine
3 Sort W: Wagon
4 Body style X: 5-door hatchback
5 Transmission
type
N: 5-speed manual
transmission
R: 4-speed automatic
transmission
6Trim level M: COMFORT
H: SPORT
7 Specification
engine feature
M: MPI-DOHC
Y: MPI-SOHC MIVEC
8 Special feature None: 2WD
Z: 4WD
9 Steering wheel
location
L: Left hand
R: Right hand
10 Destination 6: For Europe
Page 20
00-18
GENERAL
VEHICLE IDENTIFICATION
CHASSIS NUMBER
The chassis number is stamped on the toeboard
inside the engine compartment.
M B X CU 2 W 4 U 000001N
J
23
1
AC300903
AB
6
5
4
78910 11
No. Item Content
AC309285
AB
1 Fixed figure J Asia
2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
B For Europe, left hand drive
4 Body style X 5-door hatchback
5 Transmission type N 5-speed manual transmission
R 4-speed automatic transmission
6 Development order CU OUTLANDER
7 Engine 2 1,997 mL petrol engine
5 2,378 mL petrol engine
8 Soft W Station wagon
9 Model year 4 2004
10 Plant U Mizushima
11 Serial number
−−
Page 21
GENERAL
VEHICLE IDENTIFICATION
00-19
ENGINE MODEL STAMPING
<4G63>
<4G69>
Front of the vehicle
Front of the
vehicle
AC300905
AC309481
The engine model is stamped on the cylinder block.
This engine model numbers are shown as follows.
Engine model Engine displacement
4G63 1,997 mL
4G69 2,378 mL
The engine serial number is stamped near the
engine model number.
AD
AB
Page 22
00-20
GENERAL DATA AND SPECIFICATIONS
GENERAL
GENERAL DATA AND SPECIFICATIONS
7
1
2
Items CU2W
3465
XNMML6 XNMMZL6 XNHMZL6
M1001000900558
8
9
AC300072
AB
Vehicle
dimensions mm
Front track 1 1,495
Overall width 2 1,750
Front overhang 3 945
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,545
Ground clearance (unladen) 7 195
Overall height (unladen) 8 1,620/1,670*
Rear track 9 1,505
Vehicle weight kg Kerb weight 1,435 1,540
Max. gross vehicle weight 1,970 2,070
Max. axle weight rating-front 1,050
Max. axle weight rating-rear 1,065
Max. trailer weight With brake 1,500
Without brake 570
Max. trailer-nose weight 75
Seating capacity 5
Engine Model code 4G63
Total displacement mL 1,997
Transmission Model code F5M42 W5M42
Type 5-speed manual
Fuel system Fuel supply system MPI
NOTE: *: Vehicles with roof rails
Page 23
GENERAL
GENERAL DATA AND SPECIFICATIONS
Items CU5W
XNMYZL6 XRMYZL6/R6XNHYZL6 XRHYZL6/R
00-21
6
Vehicle
dimensions
mm
Vehicle
weight kg
Front track 1 1,495
Overall width 2 1,750
Front overhang 3 945
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,545
Ground clearance (unladen) 7 195
Overall height (unladen) 8 1,620/1,670*
Rear track 9 1,505
Kerb weight 1,540 LHD: 1,560,
RHD: 1,565
Max. gross vehicle weight 2,070
Max. axle weight rating-front 1,050
Max. axle weight rating-rear 1,065
Max. trailer weight With brake 1,500
Without
brake
Max. trailer-nose weight 75
570
1,540 LHD: 1,560,
RHD: 1,565
Seating capacity 5
Engine Model code 4G69
Total displacement mL 2,378
Transmission Model code W5M42 W4A42 W5M42 W4A42
Type 5-speed
manual
Fuel system Fuel supply system MPI
NOTE: *: Vehicles with roof rails
4-speed
automatic
5-speed
manual
4-speed
automatic
Page 24
00-22
PRECAUTIONS BEFORE SERVICE
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)
CAUTION
Items to review when servicing SRS:
1. Be sure to read GROUP 52B − Supplemental
Restraint System (SRS). For safe operation,
please follow the directions and heed all
warnings.
2. Wait at least 60 seconds after disconnecting
the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.
3. Warning labels must be heeded when
servicing or handling SRS components.
Warning labels can be found in the following
locations.
• Front impact sensor
• Hood
• Sun visor
• Glove box
• SRS-ECU
• Steering wheel
• Clock spring
• Steering joint cover
• Air bag module (Driver's or front
passenger's)
• Side air bag module (Driver's side or front
passenger's side)
• Side impact sensor
• Seat belt pre-tensioner
• Instrument panel
4. Always use the designated special tools and
test equipment.
5. Store components removed from the SRS in a
clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward. Do
not place anything on top of it.
6. Never attempt to disassemble or repair the
SRS components (SRS-ECU, air bag module
and clock spring).
7. Whenever you finish servicing the SRS, check
the SRS warning lamp operation to make sure
that the system functions properly.
GENERAL
M1001000500538
8. Be sure to deploy the air bag before
disposing of the air bag module or disposing
of a vehicle equipped with an air bag (Refer to
GROUP 52B − Air Bag Module Disposal
Procedures).
Observe the following when carrying out
operations on places where SRS components are
installed, including operations not directly
related to the SRS air bag.
1. When removing or installing parts, do not
allow any impact or shock to the SRS
components.
2. If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt
pre-tensioner.
• SRS-ECU, air bag module, clock spring,
front impact sensor, the side impact
sensor: 93 °C or more
• Seat belt pre-tensioner: 90 °C or more
Page 25
GENERAL
PRECAUTIONS BEFORE SERVICE
00-23
INITIALIZATION PROCEDURE FOR
LEARNING VALUE IN MPI ENGINE
Initialization Procedure
1. After the ignition switch is in "LOCK" (OFF)
position, connect MUT-II/III with the diagnosis
connector.
2. Select the item on the screen of the initialization
for learning, and perform the initialization.
Service Item
At replacing engine
assembly *
3
− *
1,*2
At replacing injector and
at cleaning *
2
At replacing throttle body
and at cleaning *
2
At replacing detonation
sensor
1
NOTE: *
NOTE: *
: Initialize A/T-related learning value.
2
: After initializing the learning value, the
idling learning in MPI engine is required (Refer to
LEARNING PROCEDURE FOR IDLING IN MPI
ENGINE).
NOTE: *
3
: The datum items on MUT-II/III display are
shown, but do not use them.
All ranges
Misfire-related
Learning value for
air/fuel ratio
Idle speed
control-related
Learning value for
knocking
LEARNING PROCEDURE FOR IDLING IN
MPI ENGINE
Purpose
When the engine-ECU <M/T> or the
engine-A/T-ECU <A/T> is replaced, or when the
learning value is initialized, the idling is not stabilized
because the learning value in MPI engine is not
completed. In this case, carry out the learning
method for the idling through the following
procedures.
Learning Procedure
1. Start the engine and carry out the warm-up for the
engine coolant temperature to reach 80°C or
more.
2. When the engine coolant temperature is 80°C or
more, the warm-up is not needed if the ignition
switch is in "ON" position once.
3. Place the ignition switch in "LOCK" (OFF) position
and stop the engine.
4. After 10 seconds or more, start the engine again.
5. For 10 minutes, carry out the idling under the
condition shown below and then confirm the
engine has the normal idling.
• Transmission: Neutral (A/T: "P" range)
• Operation in ignition-related, fan and
attachments: Not to be operated
• Engine coolant temperature: 80°C or more
NOTE: When the engine stalls during the idling,
check the dirtiness (on the throttle valve) of the
throttle body and then perform the service from
Procedure 1 again.
Page 26
00-24
GENERAL
PRECAUTIONS BEFORE SERVICE
SERVICING ELECTRICAL SYSTEM
CAUTION
Before connecting or disconnecting the negative
(−) cable, be sure to turn off the ignition switch
and the lighting switch (If this is not done, there
is the possibility of semiconductor parts being
damaged).
AC300693
Before replacing a component related to the
electrical system and before undertaking any repair
procedures involving the electrical system, be sure to
first disconnect the negative (−) cable from the
battery in order to avoid damage caused by
short-circuiting.
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine
inspection can be carried out. If you see the words
"Set the vehicle to the pre-inspection condition". In
this manual, it means to set the vehicle to the
following condition.
• Engine coolant temperature 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
• A/T: P range
VEHICLE WASHING
Approximately 40 cm
AC300832
If high-pressure car-washing equipment or steam
car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
avoid damage to plastic components, etc.
• Spray nozzle distance: Approx. 40 cm or more
• Spray pressure: 3,900 kPa or less
• Spray temperature: 82°C or less
• Time of concentrated spray to one point: within
30 sec.
AB
Page 27
GENERAL
PRECAUTIONS BEFORE SERVICE
00-25
MUT-II/III
MUT-II Sub-assembly
Rom pack
AC300834
MUT-III sub assembly
Vehicle communication interface (V.C.I.)
MB991824
MUT-III USB cable
AB
MB991827
MUT-III main harness A
Do not used
MB991910
MUT-III main harness B
MB991911
MUT-III measurement adapter
MB991825
MUT-III trigger harness
MB991826
AC305090
AB
Refer to the "MUT-II REFERENCE MANUAL",
"MUT-II OPERATING INSTRUCTIONS" or "MUT-III
OPERATION MANUAL" for instructions on handling
the MUT-II/III.
Page 28
00-26
GENERAL
PRECAUTIONS BEFORE SERVICE
CAUTION
<Using the MUT-II>
Steering shaft
MUT-II
AC308915
AC
AC
AC300830
<Using the MUT-III>
16-PIN
MB991911
MB991824
MB991827
Turn the ignition switch to the "LOCK" (OFF)
position before connecting or disconnecting the
MUT-II/III.
Connect the MUT-II/III to the diagnosis connector as
shown in the illustration.
IN ORDER TO PREVENT VEHICLES
FROM FIRE
"Improper installation of electrical or fuel related parts
could cause a fire. In order to retain the high quality
and safety of the vehicle, it is important that any
accessories that may be fitted or
modifications/repairs that may be carried out which
involve the electrical or fuel systems, MUST be
carried out in accordance with MMC's
information/Instructions".
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
• Wear protective clothing, including impervious
gloves where practicable.
• Avoid contaminating clothes, particularly
underpants, with oil.
• Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
• Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from
personal clothing.
• Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
• Obtain First Aid treatment immediately for open
cuts and wounds.
• Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
• Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
• Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
• If skin disorders develop, obtain medical advice
without delay.
Page 29
GENERAL
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
The Supplemental Restraint System (SRS) and seat
belt with pre-tensioner is designed to supplement the
driver's and front passenger's seat belts to help
reduce the risk or severity of injury to the driver and
front passenger by activating and deploying both
front air bags in certain frontal collisions.
The SRS consist of four air bag modules, SRS air
bag control unit (SRS-ECU), two front impact
sensors, two side impact sensors, SRS warning
lamp, clock spring and seat belt pre-tensioner. Front
air bags are located in the centre of the steering
wheel and above the glove box. Side air bag are
located inside the front seatback assemblies. Each
air bag is made up of a folded air bag and an inflator
unit. The SRS-ECU under the front floor console
monitors the system and has a front air bag safing
SRS warning lamp
00-27
M1001009800020
G-sensor, front air bag analog G-sensor and a side
air bag safing G-sensor. The front impact sensor is
assembled outside the headlamp support panel to
monitor impact in case of front impact. The side
impact sensors inside the centre pillars monitor the
shock incurred by the sides of the vehicle. The
warning lamp on the instrument panel indicates the
operational status of the SRS. The clock spring is
installed in the steering column. The seat belt
pre-tensioner is built into the driver's and
passenger's front seat belt retractor.
Only authorized service personnel should do work on
or around the SRS components. Those service
personnel should read this manual carefully before
starting any such work.
Driver's air bag
module
Clock spring
SRS-ECU
Seat belt with pre-tensioner
Passenger's (front)
air bag module
Side air bag module
Side impact sensor
Side impact sensor
Side air bag module
Front impact sensor
AC301343
AB
Page 30
00-28
SRS SERVICE PRECAUTIONS
GENERAL
SRS SERVICE PRECAUTIONS
DANGER
In order to avoid injury to yourself or others
from accidental deployment of the air bag
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-9.
CAUTION
Never Attempt to Repair the Following
Components:
1. SRS air bag control unit (SRS-ECU)
2. Front impact sensor
3. Clock spring
4. Driver's and front passenger's air bag
modules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE
procedures in this manual, starting at page
P.52B-174.
SRS-ECU terminal No. Destination of harness Remedy
CAUTION
SRS-ECU connector
Do not attempt to repair the wiring harness
connectors of the SRS. If a defective wiring
harness is found, repair or replace it by referring
to the table below.
M1001006000047
AC300634
AB
1, 2 Instrument panel wiring harness →
Front wiring harness (RH) → Front
impact sensor (RH)
3, 4 Instrument panel wiring harness →
Front wiring harness (LH) → Front
impact sensor (LH)
7 Instrument panel wiring harness→
Earth
8 Instrument panel wiring harness →
SRS warning lamp
9, 10 Instrument panel wiring harness →
Air bag module (Front passenger's
side)
11, 12 Instrument panel wiring harness →
Clock spring → Air bag module
(Driver's side)
13 Instrument panel wiring harness →
Junction block (fuse No.3)
Correct or replace each wiring
harness.
Correct or replace each wiring
harness.
Correct or replace the instrument
panel wiring harness.
Correct or replace the instrument
panel wiring harness.
Correct or replace the instrument
panel wiring harness.
Correct or replace instrument panel
wiring harness. Replace the clock
spring.
Correct or replace the instrument
panel wiring harness.
Page 31
GENERAL
SRS SERVICE PRECAUTIONS
SRS-ECU terminal No. Destination of harness Remedy
00-29
16 Instrument panel wiring harness →
Junction block (fuse No.2)
20 Instrument panel wiring harness →
Diagnosis connector
21, 22 Floor wiring harness (RH) → Side air
bag module (LH)
23, 24 Floor wiring harness (RH) → Side air
bag module (RH)
27, 28 Floor wiring harness (RH) → Seat
belt pre-tensioner (Front
passenger's side)
29, 30 Floor wiring harness (LH) → Seat
belt pre-tensioner (driver's side)
34, 36 Floor wiring harness (LH) → Side
impact sensor (LH)
40, 42 Floor wiring harness (RH) → Side
impact sensor (RH)
DANGER
Correct or replace the instrument
panel wiring harness.
Correct or replace the instrument
panel wiring harness.
Correct or replace the floor wiring
harness.
Correct or replace the floor wiring
harness.
Connect or replace the floor wiring
harness.
Connect or replace the floor wiring
harness.
Connect or replace the floor wiring
harness.
Connect or replace the floor wiring
harness.
Insulating tape
Battery
Battery cable
AC300580
AB
After disconnecting the battery cable, wait 60
seconds or more before proceeding with the
following work. In addition, insulate the
negative battery terminal with a tape. The
condenser inside the SRS-ECU is designed
to retain enough voltage to deploy the air
bag for a short time even after the battery
has been disconnected, so serious injury
may result from unintended air bag
deployment if work is done on the SRS
system immediately after the battery cables
are disconnected.
Page 32
00-30
SRS SERVICE PRECAUTIONS
CAUTION
The SRS components and seat belt with
pre-tensioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and front
passenger’s air bag modules, clock spring, side
air bag modules, and seat belt pre-tensioner
before drying or baking the vehicle after painting.
• SRS-ECU, air bag modules, clock spring,
impact sensors: 93°C or more
• Seat belt with pre-tensioner 90°C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
CAUTION
SRS-Harness connector
GENERAL
SRS-ECU harness connector
(rear side)
AC300673
AB
If checks are carried out by using the SRS-ECU
harness connector, observe the following
procedures: Insert the special tool (probe in the
harness set) MB991222 into connector from
harness side (rear side), and connect the tester
to this probe. If any tool than special tool is used,
damage to the harness and other components
will result. Never insert the probe directly to the
terminals from the front of the connector. The
terminals are plated to increase their
conductivity, so that if they are touched directly
by the probe, the plating may break, which will
cause drops in reliability.
Page 33
GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING
00-31
SUPPORT LOCATIONS FOR LIFTING AND JACKING
M1001000700093
SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR
DOUBLE-POST LIFT AND PLATE TYPE LIFT
CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
GARAGE JACK
CAUTION
Never support any point other than the specified one, or that point will be deformed.
<2WD>
Rear suspension crossmember
<4WD>
Rear differential
AC300835
Page 34
00-32
SUPPORT LOCATIONS FOR LIFTING AND JACKING
GENERAL
AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT
CAUTION
• If rubber attachments with grooves that are too thick are used at the front support positions, the
front fender may become bent, so be sure to use rubber attachments with groove thicknesses of
18 mm or less.
• If attachments which are not high enough are used, they may damage areas such as the side step.
Be sure to use attachments which are high enough, or remove the side step if not using
attachments.
AXLE STANDS
Bolts
Rubber
Bolts
Rubber
SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Bolts
Bolts
AC300836
AB
Page 35
GENERAL
STANDARD PART/TIGHTENING-TORQUE TABLE
PLATE TYPE LIFT
CAUTION
To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
Support the side sill flange with a lift.
STANDARD PART/TIGHTENING-TORQUE TABLE
Each torque value in the table is a standard value for
tightening under the following conditions.
1. Bolts, nuts and washers are all made of steel and
plated with zinc.
2. The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
1. If toothed washers are inserted.
Thread size Torque N⋅m
Bolt nominal
diameter (mm)
M5 0.8 2.5 ± 0.5 5.0 ± 1.0 6.0 ± 1.0
Pitch
(mm)
Head mark "4" Head mark "7" Head mark "8"
2. If plastic parts are fastened.
3. If bolts are tightened to plastic or die-cast
inserted nuts.
4. If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
00-33
M1001001100362
M6 1.0 5.0 ± 1.0 9.0 ± 2.0 10 ± 2
M8 1.25 12 ± 2 22 ± 4 25 ± 4
M10 1.25 24 ± 4 44 ± 10 53 ± 7
M12 1.25 41 ± 8 83 ± 12 98 ± 12
M14 1.5 73 ± 12 140 ± 20 155 ± 25
M16 1.5 110 ± 20 210 ± 30 235 ± 35
M18 1.5 165 ± 25 300 ± 40 340 ± 50
M20 1.5 225 ± 35 410 ± 60 480 ± 70
M22 1.5 300 ± 40 555 ± 85 645 ± 95
M24 1.5 395 ± 55 735 ± 105 855 ± 125
Flange bolt and nut tightening torque
Thread size Torque N⋅m
Bolt nominal
diameter (mm)
M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2
M8 1.25 13 ± 2 24 ± 4 27 ± 5
M10 1.25 26 ± 4 49 ± 9 58 ± 7
M10 1.5 24 ± 4 45 ± 8 55 ± 10
Pitch
(mm)
Head mark "4" Head mark "7" Head mark "8"
M12 1.25 46 ± 8 95 ± 15 105 ± 15
M12 1.75 43 ± 8 83 ± 12 98 ± 12
NOTE: .
•
Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
•
Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the
bolt strength.
Page 36
NOTES
Page 37
GROUP 11A
11A-1
00
11
ENGINE
MECHANICAL
CONTENTS
GENERAL INFORMATION . . . . . . . . 11A
SERVICE SPECIFICATIONS. . . . . . . 11A
SEALANTS . . . . . . . . . . . . . . . . . . . . 11A
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A
ON-VEHICLE SERVICE. . . . . . . . . . . 11A
DRIVE BELT TENSION CHECK. . . . . . . . . 11A
AUTO-TENSIONER CHECK . . . . . . . . . . . 11A
IGNITION TIMING CHECK . . . . . . . . . . . . . 11A
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A
COMPRESSION PRESSURE CHECK. . . . 11A
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A
CRANKSHAFT PULLEY . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . . 11A
CAMSHAFT AND VALVE STEM
SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . . 11A
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION <2WD>. . 11A
REMOVAL AND INSTALLATION <4WD>. . 11A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A
CRANKSHAFT OIL SEAL . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . . 11A
CYLINDER HEAD GASKET. . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . . 11A
TIMING BELT . . . . . . . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . . 11A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . . 11A
12
13
14
15
16
17
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
Page 38
11A-2
ENGINE MECHANICAL
GENERAL INFORMATION
GENERAL INFORMATION
M1111 000 10 035 6
Item 4G63
Total displacement mL 1,997
Bore
Stroke mm 85 88
Compression ratio 10.0
Compression chamber Pentroof
Camshaft arrangement DOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake opening BTDC 17
Intake closing ABDC 51
Exhaust opening BBDC 57
Exhaust closing ATDC 13
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS
M1112000300234
Item Standard value Limit
Drive belt tension Vibration frequency Hz
(Reference)
Tension N (Reference) 245 - 412 Basic ignition timing 5 BTDC 2Ignition timing Approximately
Idle speed r/min 750 100 CO contents % 0.5 or less HC contents ppm 100 or less Compression pressure kPa-r/min 1,370 - 250 930 - 250
Compression pressure difference of all cylinders kPa
110
- 144 -
-
BTDC
10
- Maximum 98
Intake manifold vacuum kPa
Cylinder head bolt nominal length mm
Balancer timing belt tension (When
adjusted)
Balancer timing belt tension (When
replaced)
- Minimum 60
- 99.4
Deflection mm 5
Deflection mm 5 - 7 -
- 7 -
Page 39
ENGINE MECHANICAL
SEALANTS
Item Standard value Limit
11A-3
Balancer timing belt tension (When
Deflection mm 5 - 10 -
checked)
Timing belt tensioner adjuster rod protrusion amount mm 3.8 - 4.5 Timing belt tensioner adjuster rod movement mm Within 1 -
SEALANTS
Item Specified Sealant Remark
Cylinder head MITSUBISHI GENUINE PART MD970389 or
Camshaft position sensor support
equivalent
Rocker cover
Camshaft end seal 3M ATD Part No.8660 or equivalent
Rocker cover gasket MITSUBISHI GENUINE PART MD970389 or
Engine oil pan <2WD>
equivalent
Engine upper oil pan <4WD>
Engine lower oil pan <4WD>
Semi-drying
sealant
M1112000500238
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub assembly
B991502
MB991668 Belt tension meter set Drive belt tension check (used
B991668
MD998772 Valve spring compressor Compressing valve spring
MD998772
MD998737 Valve stem seal installer Valve stem seal installation
Drive belt tension check
Checking the ignition timing
Checking the idle speed
together with MUT-II)
M1112000600279
Page 40
11A-4
ENGINE MECHANICAL
SPECIAL TOOLS
Tool Number Name Use
MD998713 Camshaft oil seal installer Camshaft oil seal installation
D998713
MD998727 Oil pan remover Oil pan removal <2WD>
D998727
MD998781 Flywheel stopper Supporting the flywheel
D998781
B990938
D998776
D998285
MB990938 Installer bar Crankshaft rear oil seal
installation
MD998776 Crankshaft rear oil seal
installer
MD998285 Crankshaft front oil seal
guide
Crankshaft front oil seal
installation
MD998375 Crankshaft front oil seal
installer
B991654
MB991654 Cylinder head bolt wrench
(12)
Removal and installation of
cylinder head bolt
Page 41
ENGINE MECHANICAL
SPECIAL TOOLS
Tool Number Name Use
MD998738 Adjusting bolt Supporting the timing belt
tensioner arm and timing belt
tensioner adjuster
D998738
MB991367 Special spanner Holding the crankshaft camshaft
drive sprocket
B991367
MB991385 Pin
B991385
MD998767 Tensioner wrench Valve timing belt tension
adjustment
11A-5
D998767
Page 42
11A-6
CAUTION
ENGINE MECHANICAL
ON-VEHICLE SERVICE
Tool Number Name Use
MB991454 Engine hanger balancer When the engine hanger is used:
Supporting the engine assembly
during removal and installation of
the transmission assembly
B991454
NOTE: Special tool MB991454 is
a part of engine hanger
MB991527 Hanger
B991527
attachment set MB991453.
MB991895 Engine hanger
Z203830
Slide bracket (HI)
F
D
B
C
MB991928
A: MB991929
B: MB991930
C: MB991931
E
D: MB991932
E: MB991933
A
B991928
F: MB991934
Engine hanger
A: Joint (50)
B: Joint (90)
C: Joint (140)
D: Foot (standard)
E: Foot (short)
F: Chain and hook
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111 003 10 039 9
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.
assembly
2
2
2
4
2
2. If the mark is out of the area, replace the drive
belt. (Refer to
311A.)
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.
Indicator mark
A
AC107639
AB
1. Make sure that the indicator mark is within the
area marked with A in the illustration.
Page 43
ENGINE MECHANICAL
AC107640
AB
ON-VEHICLE SERVICE
11A-7
AUTO-TENSIONER CHECK
M1111 003000 154
OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to
311A.)
3. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
4. If there are any problems in the procedure 1 or 3,
replace the auto-tensioner.(Refer to
5. Install the drive belt.(Refer to
311A.)
311A.)
FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
When using MUT-II
1. Check the drive belt tension. (Refer to
2. Measure the drive belt tension vibration frequency
by the following procedures:
311A.)
CAUTION
16-pin
MUT-II
MB991668
AC211862
To prevent damage to MUT-II, always turn the
ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
connector.
(3) Turn the ignition switch to ON position, and
select "BELT TENSION" on the menu screen.
AB
Page 44
11A-8
CAUTION
ENGINE MECHANICAL
ON-VEHICLE SERVICE
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.
Do not take the measurement while the
vehicle’s engine is running.
MB991668
Water pump
pulley
Power steering
oil pump pulley
15˚
15˚
10 – 20 mm
Belt tension gauge
Water pump
pulley
Power steering
oil pump pulley
AC102807
AB
2. Use a belt tension gauge in the middle of the belt
between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
the standard value.
Standard value: 245
- 412 N
3. If not within the standard value, replace the autotensioner.(Refer to
311A.)
IGNITION TIMING CHECK
M1111 001 70 042 5
AC102022
Y0195AU
Gentry tap with
your finger
AC102806
AB
(4) Hold special tool belt tension meter set
(MB991668) to the middle of the drive belt
between the pulleys (at the place indicated by
arrow), approximately 10
- 20 mm away from
the rear surface of the belt so that it is
perpendicular to the belt (within an angle of
15 degree).
(5) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and
measure that the vibration frequency of the
belt is within the standard value.
Standard value: 110
- 144 Hz
3. If not within the standard value, replace the autotensioner. (Refer to
311A.)
When using a tension gauge
1. Check the drive belt tension. (Refer to
311A.)
MUT-II
AK000871
1. Before inspection, set the vehicle to the pre-
inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the MUT-II to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Use the MUT-II to measure engine idle speed and
check that it is within the standard value.
Standard value: 750
100 r/min
6. Select No. 17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5
BTDC 2
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to
GROUP 13A
- Troubleshooting - Inspection chart
for diagnosis code).
AC
313A,
Page 45
ENGINE MECHANICAL
CAUTION
AC102022
Y0195AU
AK000871
MUT-II
AC
AK000899
Engine speed
ditection connector
AC
ON-VEHICLE SERVICE
11A-9
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
condition may damage the engine.
9. Press the MUT-II clear key (Select a forced driving
cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
Standard value: approximately 10
BTDC
NOTE: .
The ignition timing may fluctuate within 7
BTDC. This is normal.
In higher altitude, the ignition timing is more
advanced than the standard value by
approximately 5
.
11.Remove the timing light.
12.Turn off the ignition switch and then remove the
MUT-II.
IDLE SPEED CHECK
M1111 003500 472
Standard value: 750
100 r/min
NOTE: .
The idle speed is controlled automatically by
the idle speed control system.
When using the MUT-II, select item No. 22 and
take a reading of the idle speed.
8. If the idle speed is outside the standard value,
inspect the MPI system (Refer to
GROUP 13A
- Troubleshooting - Inspection chart
313A,
for diagnosis code).
IDLE MIXTURE CHECK
M1111 002100 255
AC102022
Y0195AU
MUT-II
AK000871
AC
1. Before inspection, set the vehicle to the preinspection condition.
2. Turn the ignition switch to "LOCK" (OFF) position.
3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.
4. Connect a timing light.
5. Start the engine and let it run at idle.
6. Check that ignition timing is at the standard value.
Standard value: approximately 10
7. Check the idle speed.
BTDC
1. Before inspection, set the vehicle to the preinspection condition.
2. Turn the ignition switch to "LOCK" (OFF) position.
3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.
4. Connect a timing light.
Engine speed
ditection connector
AK000899
AC
5. Start the engine and let it run at idle.
6. Check that ignition timing is at the standard value.
Standard value: approximately 10
BTDC
7. Run the engine at 2,500 r/min for 2 minutes.
8. Set the CO, HC tester.
9. Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
10.If there is a deviation from the standard value,
check the following items:
Page 46
11A-10
CAUTION
ENGINE MECHANICAL
ON-VEHICLE SERVICE
Diagnosis output
Fuel pressure
Injector
Ignition coil, spark plug cable, spark plug
EGR control system
Evaporative emission control system
Compression pressure
NOTE: Replace the three way catalyst when the
CO and HC contents are not within the standard
value, even though the result of the inspection is
normal on all items.
COMPRESSION PRESSURE CHECK
M1111 002 60 046 5
Crank angle
sensor
connector
AK201364
1. Before inspection, set the vehicle to the preinspection condition.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE: Doing this will prevent the engine-ECU<M/
T> or engine-A/T-ECU<A/T> from carrying out
ignition and fuel injection.
AC
8. Measure the compression pressure for all the
cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
9. If there is a cylinder with compression or a
compression difference that is outside the limit,
pour a small amount of engine oil through the
spark plug hole, and repeat the operations in
steps from (6) to (8).
(1) If the compression increases after oil is added,
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
surface.
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
10.Connect the crank angle sensor connector.
11.Install the spark plugs and spark plug cables.
12.Use the MUT-II to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.
MANIFOLD VACUUM CHECK
M1111 002 70 041 7
AC102022
Y0195AU
MUT-II
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.
5. Cover the spark plug hole with a shop towel etc.,
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
6. Set compression gauge to one of the spark plug
holes.
7. Crank the engine with the throttle valve fully open
and measure the compression pressure.
Standard value (at engine speed of 250 r/
min):
1,370 kPa
Limit (at engine speed of 250 r/min):
Minimum 930 kPa
AK000871
AC
1. Before inspection, set the vehicle to the preinspection condition.
2. Turn the ignition switch to "LOCK" (OFF) position.
3. Connect a tachometer or connect the MUT-II to
the diagnosis connector.
Vacuum
gauge
Fuel pressure
regulator
AK201369AB
Page 47
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-11
4. Attach a three-way joint to the vacuum hose
between the fuel pressure regurator and the air
intake plenum, and connect a vacuum gauge.
5. Start the engine and check that idle speed is
within the standard valve.
Standard value: 750
100 r/min
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
7. Turn off the ignition switch.
8. Remove the vacuum gauge and the three-way
joint, and then connect the vacuum hose.
9. Remove the engine tachometer or the MUT-II.
LASH ADJUSTER CHECK
M1111 002900 336
If an abnormal noise (knocking) that seems to be
coming from the lash adjuster is heard after starting
the engine and dose not stop, carry out the following
check.
NOTE: .
The abnormal noise which is caused by a
problem with the lash adjusters is generated after
the engine is started, and will vary according to
the engine speed. However, this noise is not
related to the actual engine load.
Because of this, if the noise dose not occur
immediately after the engine is started, if it dose
not change in accordance with the engine speed,
or if it changes in accordance with the engine
load, the source of the noise is not the lash
adjusters.
If there is a problem with the lash adjusters, the
noise will almost never disappear, even if the
engine has been run at idle to let it warm up.
The only case where the noise might disappear is if
the oil in the engine has not been looked after
properly and oil sludge has caused the lash
adjusters to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the
engine is started, and that the noise changes in
accordance with changes in the engine speed.
If the noise dose not occur immediately after the
engine is started, or if it dose not change in
accordance with the engine speed, the problem is
not being caused by the lash adjusters, so check
for some other cause of the problem. Moreover, if
the noise dose not change in accordance with the
engine speed, the cause of the problem is
probably not with the engine (In these cases, the
lash adjusters are normal).
3. While the engine is idling, check that the noise
level does not change when the engine load is
varied (for example, by shifting from N to D).
If the noise level changes, the cause of the noise
is probably parts striking because of worn
crankshaft bearings or connecting rod bearings
(In such cases, the lash adjusters are normal).
4. After the engine has warmed up, run it at idle and
check if any noise can be heard.
If the noise has become smaller or disappeared,
oil sludge could make the lash adjusters stick.
Clean the lash adjusters (Refer to GROUP 11D
Rocker Arms and Camshaft
Camshaft Inspection
311B). If not improved,
- Rocker Arms and
-
go to step 5.
5. Bleed air from the lash adjusters (Refer to
).
311A
6. If the noise has not disappeared even after the air
bleeding, clean the lash adjusters (Refer to
GROUP 11D
Rocker Arms and Camshaft Inspection
- Rocker Arms and Camshaft -
311B).
<LASH ADJUSTER AIR BLEEDING>
NOTE: .
If the vehicle is parked on a slope fir a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high
pressure chamber when starting the engine.
After parking the vehicle for long periods, the oil
drains out of the oil passage, and it takes time for
the oil to be supplied to the lash adjuster, so air
can get into the high-pressure chamber.
If either of the above situations occur, the
abnormal noise can be eliminated by bleeding
the air from inside the lash adjusters.
Good
Max
Min.
AKX00328
1. Check the engine oil and replenish or replace the
oil if necessary.
AE
Page 48
11A-12
ENGINE MECHANICAL
ON-VEHICLE SERVICE
NOTE: .
If there is an only small amount of oil, air will
be drawn in through the oil screen and will get
into the oil passage.
If the amount of oil is greater than normal, then
the oil will being mixed by the crankshaft and a
large amount of air may get mixed into the oil.
If the oil is degenerated, air and oil will not
separate easily in oil, and the amount of air
mixed into the oil will increase.
High-pressure chamber
AK100001
AC
If the air which has been mixed in with the oil
due to any of the above reasons gets into the
high pressure chamber of the lash adjuster,
the air inside the high pressure chamber will
be compressed when the valve is open and
the lash adjuster will over-compress, resulting
in abnormal noise when the valve close. This
is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air
inside the lash adjusters is then released, the
operation of the lash adjusters will return to
normal.
Drive pattern for air breeding
Gradually open
the throttle valve
Approximately
3,000 r/min
Idle speed
15 s 15 s
2. Run the engine at idle for 1
Close the throttle valve
Once
- 3 minutes to let it
AKX00330
AE
warm up.
3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
if the abnormal noise disappears (The noise
should normally disappear after 10
- 30
repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is
probably not due to air inside the lash adjusters).
4. After the noise has disappeared, repeat the drive
pattern shown in the illustration above a further 5
times.
5. Run the engine at idle for 1
- 3 minutes and check
that the noise has disappeared.
Page 49
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
ENGINE MECHANICAL
CRANKSHAFT PULLEY
M1112001600409
11A-13
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
2
1
Post-installation Operation
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
<<A>>
25 ± 4 N·m
Removal steps
1. Drive belt
2. Crank shaft damper pulley
AC300537
AB
Page 50
11A-14
ENGINE MECHANICAL
CRANKSHAFT PULLEY
REMOVAL SERVICE POINT
<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the
serpentine drive system with the drive belt autotensioner.
Auto-tensioner
Hole B
Hole A
1. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.
AC107640
AC
CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk.
Auto-tensioner
L-shaped
hexagon
wrench
2. Align hole A with hole B, insert an L-shaped
hexagon wrench, etc. to fix and then remove the
drive belt.
AC107641
AB
Page 51
ENGINE MECHANICAL
CAUTION
CAMSHAFT AND VALVE STEM SEAL
CAMSHAFT AND VALVE STEM SEAL
REMOVAL AND INSTALLATION
M1112006600211
*Remove and assemble the marked parts in each cylinder unit.
11A-15
Pre-removal Operation
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
Battery and Battery Tray Removal
Valve Timing Belt Removal (Refer to 311A).
11 ± 1 N·m
3.0 ± 0.5 N·m
2
11 ± 1 N·m
4
5
8
8.8 ± 1.0 N·m
Post-installation Operation
Valve Timing Belt Installation (Refer to 311A).
Battery and Battery Tray Installation
Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner 315).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Drive Belt Tension Check (Refer to 311A).
6
3.5 ± 0.5 N·m
9.0 ± 2.0 N·m
1
9
11 ± 1 N·m
N
11
N
3
Removal steps
1. Accelerator cable connection
2. Rocker cover centre cover
3. Crank angle sensor connector
4. Control wiring harness connection
Spark plug cables and ignition coils
(Refer to GROUP 16, Ignition Coil
316).
10
>>N<<
>>M<<
12
11 ± 1 N·m
7
AC300538
Removal steps
5. Rocker cover PCV hose
6. Rocker cover breather hose
7. Control wiring harness connection
8. Rocker cover
9. Camshaft end seal
10. Spark plug hole gaskets
&RQWLQXHG
AB
Page 52
11A-16
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
>>L<<
<<A>> >>K<<
89 ± 9 N·m
Removal steps
11. Rocker cover gasket
12. Radiator upper hose connection
&RQWLQXHG
24
20 ± 1 N·m
23
21
19
N
17
18
31*
32*
33*
N
34*
20
22
25 ± 4 N·m
27
28
25
30
11 ± 1 N·m
29
16
26
22 ± 4 N·m
15
Apply engine oil to all
moving parts before
installation.
13
10 ± 2 N·m
N
14
>>J<<
>>I<<
<<B>> >>H<<
>>G<<
>>F<<
>>F<<
>>F<<
>>F<<
>>F<<
Removal steps
13. Camshaft position sensor support
cover
14. Camshaft position sensor support
cover gasket
15. Camshaft position sensing cylinder
16. Camshaft position sensor support
17. Camshaft sprockets
18. Camshaft oil seals
19. Camshaft bearing caps, front
20. Camshaft bearing caps, rear
21. Camshaft bearing caps, No.2
22. Camshaft bearing caps, No.5
23. Camshaft bearing caps, No.3
>>F<<
>>E<<
>>E<<
>>D<<
<<C>> >>C<<
>>B<<
>>A<<
>>A<<
14 ± 1 N·m
31*
32*
33*
N
35*
AC300539
Removal steps
24. Camshaft bearing caps, No.4
25. Inlet camshaft
26. Exhaust camshaft
27. Rocker arms
28. Rocker arm lash adjusters
29. Oil delivery body
30. Spark plugs
31. Valve spring retainer locks
32. Valve spring retainers
33. Valve springs
34. Inlet valve stem seals
35. Exhaust valve stem seals
&RQWLQXHG
AB
Page 53
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
LUBRICATION AND SEALING POINTS
<The bottom view of the rocker cover>
11A-17
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
<View A>
10 mm
Sealant:
10 mm
10 mm
A
A
A
MITSUBISHI GENUINE
PART MD970389 or
equivalent
(Lip section)
Engine oil
AC300541
10 mm
10 mm
Rocker
cover
Cylinder
head
Sealant: 3M ATD Part No.8660
or equivalent
φ 3 mm
Sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
<Top view of cylinder head>
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
Page 54
11A-18
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
REMOVAL SERVICE POINTS
<<A>> RADIATOR UPPER HOSE
DISCONNECTION
Mating marks
AC200641
Make mating marks on the radiator hose and the
hose clamp. Disconnect the radiator hose.
<<B>> CAMSHAFT SPROCKETS REMOVAL
AC
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL
CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.
MD998772
AC201799
Use special tool valve spring compressor
(MD998772) to compress the valve spring, remove
the valve spring retainer locks.
AB
AC201457
AB
1. Hold the hexagon part of the camshaft with a
wrench.
2. Loosen the camshaft sprocket mounting bolts and
remove the camshaft sprocket.
INSTALLATION SERVICE POINTS
>>A<< EXHAUST VALVE STEM SEALS/INLET
VALVE STEM SEALS INSTALLATION
Gray Gray green
Inlet side
1. Check the valve stem seal colour to identify the
inlet side or exhaust side.
2. Apply a small amount of engine oil to the valve
stem seals.
Exhaust side
AC201542
AB
Page 55
ENGINE MECHANICAL
CAUTION
AC107414
AC
MD998737
Valve
Valve stem
seal
Valve guide
AC201453
AB
Rocker arm side
Identification
colour
AC201799
MD998772
AB
CAMSHAFT AND VALVE STEM SEAL
11A-19
Valve stem seals cannot be reused.
The special tool valve stem seal installer
(MD998737) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
3. Use special tool to fill a new valve stem seal in the
valve guide using the valve stem area as a guide.
>>B<< VALVE SPRINGS INSTALLATION
>>D<< ROCKER ARM LASH ADJUSTERS
INSTALLATION
CAUTION
If the rocker arm lash adjuster is reused, always
clean and check it before installation. (Refer to
GROUP 11B, Rocker Arms and Camshaft
-
Inspection).
>>E<< EXHAUST CAMSHAFT/INLET CAMSHAFT
INSTALLATION
1. Remove sealant remained on the cylinder head.
2. Apply engine oil to the cam and the journal of the
camshaft.
CAUTION
Engine front
Slit
Install the valve springs with its identification colour
painted end facing the locker arm.
>>C<< VALVE SPRING RETAINER LOCKS
INSTALLATION
Exhaust camshaft
AC201458
AB
Do not install wrong camshaft at the side of inlet
or exhaust. The exhaust camshaft has a slit at the
rear surface.
3. Install the camshaft to the cylinder head.
>>F<< CAMSHAFT BEARING CAPS, NO. 4/
CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT
BEARING CAPS, NO. 5/CAMSHAFT BEARING
CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/
CAMSHAFT BEARING CAPS, FRONT
INSTALLATION
Approximately 3˚
Dowel pin
Use special tool valve spring compressor
(MD998772) to compress the valve spring in the
same manner as removal.
Inlet side
Exhaust side
AC201459
AB
1. Set the dowel pin of the camshaft to the position
as shown in the illustration.
Page 56
11A-20
Engine front
E 4
Bearing
cap No.
Identification of
inlet side and
exhaust side
AC201460
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
AB
2. Since the shape of camshaft bearing caps No.2 5 is identical, check the identification marks so
that the bearing cap No., inlet side, or exhaust
side cannot be mistaken to install to the direction
as shown in the illustration.
Identification mark (engraved on the front
and bearing caps No.2
- 5)
I: Inlet side
E: Exhaust side
5. Check the identification marks on the camshaft
bearing caps, front so that inlet side and exhaust
side cannot be mistaken in the same way as that
of bearing caps No.2
- 5.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
the pressure in 2 to 3 times and finally tighten to
the specified torque.
Tightening torque: 20
7. Ensure that the rocker arms are installed properly.
NOTE: Remove an excess of sealant completely.
>>G<< CAMSHAFT OIL SEALS INSTALLATION
1 N¼m
Engine front
AC201461
AB
3. Apply sealant to the positions (6 areas) of the
upper side of the cylinder head as shown in the
illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the camshaft bearing caps, rear
and camshaft bearing caps, front within 15
minutes after applying liquid gasket.
Engine front
Front
marking
MD998713
AC102323
AB
1. Apply engine oil to the entire inner diameter of the
oil seal lip.
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seals.
>>H<< CAMSHAFT SPROCKETS INSTALLATION
AC201457
AB
AC201462
AB
4. Position the camshaft bearing caps, rear in the
direction as shown in the illustration for
installation.
1. Hold the hexagon part of the camshaft with a
wrench in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolts to
the specified torque.
Tightening torque: 89
9 N¼m
Page 57
ENGINE MECHANICAL
CAUTION
AC201463
φ 3 mm
AB
AC201464
AB
Dowel pin
Vane (large)
Vane (small)
Approximately 45˚
CAMSHAFT AND VALVE STEM SEAL
11A-21
>>I<< CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.
2. Apply the sealant to the camshaft position sensor
support flange in a continuous bead as shown in
the illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the camshaft position sensor
support within 15 minutes after applying liquid
gasket.
3. Install the camshaft position sensor support to the
cylinder head.
2. Install the vane (small) of the camshaft position
sensing cylinder at an angle of approximately 45
degrees to the position of the dowel pin of the
exhaust camshaft.
3. Tighten the camshaft position sensing cylinder
mounting bolts to the specified torque.
Tightening torque: 22
4 N¼m
>>K<< RADIATOR UPPER HOSE CONNECTION
Projection
Water outlet fitting
Mating marks
AC200642
AE
1. Insert each hose as far as the projection of the
water outlet fitting.
2. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
4. Tighten the camshaft position sensor support
mounting bolts to the specified torque.
>>J<< CAMSHAFT POSITION SENSING
CYLINDER INSTALLATION
1. Set the dowel pin of the exhaust camshaft to the
position (No.1 cylinder at compression TDC) as
shown in the illustration.
NOTE: Use the force of the exhaust valve spring
to rotate anti-clockwise.
Tightening torque: 14
1 N¼m
>>L<< ROCKER COVER GASKET INSTALLATION
1. Remove sealant remained on the rocker cover.
AC201465
AB
2. Apply sealant to the positions (4 areas) of the
lower side of the rocker cover as shown in the
illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the rocker cover gasket within 15
minutes after applying liquid gasket.
3. Install the rocker cover gasket to the rocker cover.
Page 58
11A-22
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
>>M<< CAMSHAFT END SEAL INSTALLATION
>>N<< ROCKER COVER INSTALLATION
Engine front
10 mm
10 mm
Cylinder head
AC201468
AB
Apply sealant to the positions of the camshaft end
seal as shown in the illustration and install to the
cylinder head.
Specified sealant: 3M ATD Part No.8660 or
equivalent
NOTE: Install the camshaft end seal within 15
minutes after applying liquid gasket.
AC201469
AB
1. Apply sealant to the positions of the rocker cover
gasket (6 areas) as shown in the illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the rocker cover within 15 minutes
after applying liquid gasket.
2. Install the rocker cover to the cylinder head.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
3. Tighten the rocker cover mounting bolts to the
specified torque.
Tightening torque: 3.5
0.5 N¼m
Page 59
ENGINE MECHANICAL
OIL PAN
REMOVAL AND INSTALLATION <2WD>
M1112002800592
OIL PAN
11A-23
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
5
N
4
Post-installation Operation
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
1
35 ± 6 N·m
39 ± 5 N·m
3
9.0 ± 3.0 N·m
Removal steps
1. Exhaust manifold bracket
2. Flywheel housing front lower cover
3. Engine oil pan drain plug
9.0 ± 3.0 N·m
>>B<<
<<A>> >>A<<
2
26 ± 5 N·m
9.0 ± 1.0 N·m
AC300542
Removal steps
4. Engine oil pan drain plug gasket
5. Engine oil pan
&RQWLQXHG
AB
Page 60
11A-24
CAUTION
ENGINE MECHANICAL
OIL PAN
REMOVAL SERVICE POINT
<<A>> ENGINE OIL PAN REMOVAL
1. Remove the engine oil pan mounting bolts.
Perform this slowly to avoid deformation of the
engine oil pan flange.
MD998727
MD998727
AC102324
AB
2. Remove the engine oil pan using special tool oil
pan remover (MD998727).
INSTALLATION SERVICE POINTS
>>A<< ENGINE OIL PAN INSTALLATION
1. Remove sealant from the engine oil pan and
cylinder block surfaces.
3. Assemble the engine oil pan to the cylinder block.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.
M6 × 8 mm
AC102698
4. Tighten the engine oil pan mounting bolts to the
specified torque. Be careful when installing, as the
oil pan mounting bolts (indicated in the illustration)
have different lengths from the other bolts.
Tightening torque: 9.0
3.0 N¼m
>>B<< ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION
AB
φ 4 mm
Groove portion
Bolt hole portion
AC102133
AB
2. Apply a bead of the sealant to the cylinder block
mating surface of the engine oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine oil pan within 15 minutes
after applying sealant.
Engine
oil pan
side
AC102325
AE
Replace the gasket with a new gasket. Install the
new gasket in the direction shown in the illustration.
Page 61
ENGINE MECHANICAL
OIL PAN
11A-25
REMOVAL AND INSTALLATION <4WD>
M1112002800600
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).
6
Post-installation Operation
Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
9.0 ± 3.0 N·m
39 ± 5 N·m
>>D<<
>>C<<
N
4
3
9.0 ± 3.0 N·m
9.0 ± 3.0 N·m
Removal steps
1. Transmission housing front lower
cover stay
2. Flywheel housing front lower cover
3. Engine oil pan drain plug
4. Engine oil pan drain plug gasket
5
9.0 ± 3.0 N·m
<<A>> >>B<<
<<B>> >>A<<
44 ± 10 N·m
5. Engine lower oil pan
6. Engine upper oil pan
1
22 ± 4 N·m
Removal steps
2
9.0 ± 1.0 N·m
AC300543
&RQWLQXHG
AB
Page 62
11A-26
CAUTION
CAUTION
ENGINE MECHANICAL
OIL PAN
REMOVAL SERVICE POINTS
<<A>> ENGINE LOWER OIL PAN REMOVAL
1. Remove the engine lower oil pan mounting bolts.
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
Engine lower oil pan
2. Apply a piece of wood to the lower oil pan and
strike it with a hammer to remove the engine lower
oil pan.
<<B>> ENGINE UPPER OIL PAN REMOVAL
1. Remove the engine upper oil pan mounting bolts.
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
AC102931
AB
INSTALLATION SERVICE POINTS
>>A<< ENGINE UPPER OIL PAN INSTALLATION
1. Remove sealant from the engine upper oil pan
and cylinder block surfaces.
φ 4 mm
Groove
portion
2. Apply a bead of the sealant to the mating surface
of the engine upper oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine upper oil pan within 15
minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
block.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.
B
B
Bolt hole
portion
B
AC102242
B
AB
A
A
AC102946
AB
2. Screw in the bolt into bolt hole A in the location
shown. Then lift the upper oil pan and remove it.
B
B
B
B
B
B
B
A
A
B
B
B
B
B
AC102929
AB
4. Insert the bolts to the engine upper oil pan as
shown, and tighten them to the specified torque.
Page 63
ENGINE MECHANICAL
CAUTION
AC102243
AB
Groove
φ 4 mm
portion
Bolt hole
portion
AC102930
AB
A-3
B-6
B-7
B-10
B-11
B-1
B-4
B-5
B-12
B-2
B-8
B-9
OIL PAN
11A-27
Name Symbol Quantity Size mm
L)
(D
Flange bolt A 2 M6
B16M6
16
18
NOTE: D: Nominal diameter, L: Nominal length
Tightening torque: 9.0
3.0 N¼m
>>B<< ENGINE LOWER OIL PAN INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.
2. Apply a bead of the sealant to the mating surface
of the engine lower oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine lower oil pan within 15
minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine
upper oil pan.
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.
Name Symbol Quantity Size mm
L)
(D
Flange bolt A 1 M6
B11M6
75
10
NOTE: D: Nominal diameter, L: Nominal length
Tightening torque: 9.0
3.0 N¼m
>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION
Engine lower
oil pan side
AC102325
AF
Replace the gasket with a new one. Install the new
gasket in the direction shown in the illustration.
>>D<< TRANSMISSION HOUSING FRONT
LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
stay in the following order.
1. Tighten the engine side four mounting bolts to the
specified torque.
Tightening torque: 22
4 N¼m
2. Tighten the transmission side two mounting bolts
to the specified torque.
Tightening torque: 44
10 N¼m
4. Insert the bolts to the engine lower oil pan as
shown, and tighten them to the specified torque in
the order shown.
INSPECTION
M1112002900210
Check the oil pan for cracks.
Check the oil pan sealant-coated surface for
damage and deformation.
Page 64
11A-28
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
M1112003100273
132 ± 5 N·m
4
5
N
3
1
>>D<<
>>C<<
2
Crankshaft front oil seal removal
steps
Valve timing belt, balancer timing
belt (Refer to
1. Crankshaft balancer shaft drive
sprocket
2. Crankshaft key
3. Crankshaft front oil seal
311A).
N
9
3
Lip section
Engine oil
<<A>>
<<B>> >>B<<
>>A<<
7
8
6
9
Lip section
Crankshaft rear oil seal removal
steps
Transmission assembly
4. Flywheel bolts
5. Flywheel adapter plate
6. Flywheel assembly
7. Flywheel adapter plate
8. Crankshaft bush
9. Crankshaft rear oil seal
AC300544
AB
Page 65
ENGINE MECHANICAL
CAUTION
AC300897
Flywheel bolt
Engine front
AB
Flywheel
assembly
AC211914
AC
MD998781
AC102328
AB
Oil seal
MB990938
MD998776
Crankshaft
(Engine oil)
CRANKSHAFT OIL SEAL
11A-29
REMOVAL SERVICE POINTS
<<A>> TRANSMISSION ASSEMBLY REMOVAL
Do not remove the flywheel bolt shown by the
arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly
322A.
<<B>> FLYWHEEL BOLTS REMOVAL
2. Use the following special tools to press-fit the oil
seal.
Installer bar (MB990938)
Crankshaft rear oil seal installer (MD998776)
>>B<< FLYWHEEL BOLTS INSTALLATION
MD998781
AC211914
AC
1. Use special tool flywheel stopper (MD998781) to
secure the flywheel in the same manner as
removal.
2. Tighten the flywheel bolts to the specified torque.
Tightening torque: 132
5 N¼m
1. Use special tool flywheel stopper (MD998781) to
secure the flywheel.
2. Remove the flywheel bolts.
INSTALLATION SERVICE POINTS
>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION
>>C<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION
Crankshaft
MD998285
(Oil applied to the
circumference)
MD998375
(Engine oil)
Oil seal
AC102329
AC
1. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
2. Apply a small amount of engine oil to the outer
diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.
1. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
Page 66
11A-30
ENGINE MECHANICAL
CYLINDER HEAD GASKET
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE
SPROCKET INSTALLATION
: Clean
: Clean and degrease
Crankshaft
Front case
Crankshaft
balancershaft
drive sprocket
Engine front
AC211222
AB
1. Clean or degrease the front case, the crankshaft
and the crankshaft balancer shaft drive sprocket
as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
in the direction shown in the illustration.
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal Operation
Fuel Line Pressure Reduction [Refer to GROUP 13A, On-
vehicle Service - Fuel Pump Connector Disconnection
(How to Reduce Pressurized Fuel Lines) 313A.]
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
Battery Removal
Rocker Cover Centre Cover Removal (Refer to 311A
).
Valve Timing Belt Removal (Refer to 311A).
M1112004000655
Post-installation Operation
Valve Timing Belt Installation (Refer to 311A).
Rocker Cover Centre Cover Installation (Refer to 311A
).
Battery Installation
Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner 315).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Accelerator Cable Adjustment (Refer to GROUP 17, On-
vehicle Service - Accelerator Cable Check and
Adjustment 317).
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
Fuel Leak Check
Page 67
ENGINE MECHANICAL
CYLINDER HEAD GASKET
5.0 ± 1.0 N·m
11A-31
9
10
13 ± 1 N·m
(Engine oil)
18
16
5.0 ± 1.0 N·m
N
19
17
7
5
6
12
14
8
15
4
9.0 ± 2.0 N·m
13
11
3
20
2
1
Removal steps
1. A/C compressor connector
2. Power steering fluid pressure
switch connector
3. Crank angle sensor connector
4. Ignition coil connectors
5. Detonation sensor connector
6. Purge control solenoid valve
connector
7. EGR control solenoid valve
connector
8. Injector connectors
9. Throttle position sensor connector
10. Idle speed control servo connector
11. Camshaft position sensor
connector
AC300545
Removal steps
12. Oxygen sensor connector
13. Engine coolant temperature sensor
connector
14. Engine coolant temperature gauge
unit connector
15. Capacitor connector
16. Accelerator cable connection
17. Brake booster vacuum hose
connection
18. Engine oil level gauge and guide
assembly
19. O-ring
20. Canister vacuum hose connection
&RQWLQXHG
AB
Page 68
11A-32
<Cold engine>
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
ENGINE MECHANICAL
CYLINDER HEAD GASKET
24
25
26
5.0 ± 1.0 N·m
11 ± 1 N·m
21
(Engine oil)
22
28
31 ± 3 N·m
23
27
30
N
(Engine oil)
29
N
Removal steps
21. Detonation sensor connection
22. Battery wiring harness connection
23. Inlet manifold stay
Exhaust manifold (Refer to GROUP
15, Exhaust Manifold
Water outlet fitting and thermostat
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
314).
Rocker cover (Refer to 311A).
24. Heater water hose connection
315).
>>C<<
>>C<<
<<A>> >>B<<
>>A<<
AC300546
Removal steps
25. Fuel return line hose connection
26. Fuel high-pressure hose
connection
27. O-ring
28. Cylinder head bolts
29. Cylinder head assembly
30. Cylinder head gasket
&RQWLQXHG
AB
Page 69
ENGINE MECHANICAL
CAUTION
AC201623
MB991654
Engine front
1
2
4
6
9
7
3
510
8
AB
CYLINDER HEAD GASKET
REMOVAL SERVICE POINT
<<A>> CYLINDER HEAD BOLTS REMOVAL
11A-33
Identification
mark "63"
Exhaust side
Using special tool cylinder head bolt wrench
(MB991654), loosen the cylinder head bolts in two or
three steps in the order of the numbers shown in the
illustration.
NOTE: If the cylinder head bolts cannot be pulled out
due to the washer being trapped in the valve spring,
raise the bolt slightly, then remove it while holding it
by using a magnet.
INSTALLATION SERVICE POINTS
>>A<< CYLINDER HEAD GASKET INSTALLATION
AC107217
AC
2. Assemble to the cylinder block so the cylinder
head gasket identification mark "63" is at the top
surface and on the exhaust side.
>>B<< CYLINDER HEAD BOLTS INSTALLATION
(Engine oil)
A
AC102537
AB
1. Check that the nominal length of each cylinder
head bolt meets the limit. If it exceeds the limit,
replace the bolt with a new one.
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
Do not allow any foreign materials to get into the
coolant passages, oil passages and cylinder.
1. Remove the gasket from the cylinder head and
cylinder block.
Page 70
11A-34
MB991654
Engine front
ENGINE MECHANICAL
CYLINDER HEAD GASKET
CAUTION
The bolt is not tightened sufficiently if the bolt is
tightened less than 90 degree angle.
(5) Tighten the bolt an additional 90 degree angle
as shown. Then check to see that the paint
mark on the head of the cylinder head bolts
and the paint mark on the cylinder head are
aligned.
(6) If tightening the bolt 90 degree angle results in
moving the paint mark on the bolt past the
paint mark on the cylinder head, remove the
bolt and start over from step 1.
8
10
61
4
2
3
5
9
7
AC201625
AB
3. Use special tool cylinder head bolt wrench
(MB991654) to tighten the cylinder head bolts as
follows:
(1) Tighten the cylinder head bolts to 78
2 N¼m
in the order shown.
(2) Loosen the bolts fully in the reverse order of
that shown.
(3) Tighten the cylinder head bolts to 20
2 N¼m
in the order shown.
Step (4) Step (5)
90˚ 90˚
>>C<< O-RING/FUEL HIGH-PRESSURE HOSE
INSTALLATION
CAUTION
Do not let any engine oil get into the delivery
pipe.
1. Apply a small amount of new engine oil to the Oring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
Tightening torque: 5.0
1.0 N¼m
Paint marking
Paint marking
AC102331
AB
(4) Apply a paint mark to the heads of the cylinder
head bolts and cylinder head, then tighten 90
degree angle as shown.
Page 71
REMOVAL AND INSTALLATION
ENGINE MECHANICAL
TIMING BELT
TIMING BELT
M1112004300656
11A-35
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Crankshaft Shaft Damper Pulley Removal (Refer to
311A).
2
11 ± 1 N·m
8
48 ± 5 N·m
Post-installation Operation
Crankshaft Shaft Damper Pulley Installation (Refer to
311A).
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
10
9
21 ± 4 N·m
8.8 ± 1.0 N·m
44 ± 10 N·m
N
5
>>H<<
3
6
22 ± 4 N·m
Removal steps
1. Control wiring harness connection
2. Timing belt upper cover
3. Water pump pulley
4. Idler pulley
5. End cap
6. Auto-tensioner
7. Timing belt lower cover
11 ± 1 N·m
9.0 ± 1.0 N·m
1
79 ± 5 N·m
7
<<A>> >>F<<
23 ± 3 N·m
4
>>G<<
>>E<<
>>D<<
11
AC300547
Removal steps
Engine front mounting bracket
(Refer to GROUP 32, Engine
Mount
Valve timing belt tension
adjustment
8. Valve timing belt
9. Timing belt tensioner pulley
10. Timing belt tensioner arm
11. Timing belt tensioner adjuster
332).
&RQWLQXHG
AB
Page 72
11A-36
CAUTION
ENGINE MECHANICAL
TIMING BELT
<<B>>
19 ± 3 N·m
(Engine oil)
16
35 ± 6 N·m
21
20
17
19
18
167 N·m
Removal steps
12. Power steering fluid pressure
switch connector
13. Power steering oil pump assembly
14. A/C compressor connector
15. Power steering oil pump bracket
16. Timing belt idler pulley
17. Crank angle sensor
8.8 ± 1.0 N·m
12
22 ± 4 N·m
49 ± 9 N·m
<<C>> >>C<<
>>C<<
>>B<<
>>A<<
<<D>> >>A<<
22 ± 4 N·m
13
14
15
Removal steps
18. Crankshaft camshaft drive sprocket
19. Crankshaft angle sensing blade
Balancer timing belt tension
adjustment
20. Balancer timing belt tensioner
21. Balancer timing belt
49 ± 9 N·m
&RQWLQXHG
AC300548
AB
REMOVAL SERVICE POINTS
<<A>> VALVE TIMING BELT REMOVAL
Never turn the crankshaft anti-clockwise.
Timing mark
AC102487
1. Turn the crankshaft clockwise, align each timing
mark to set No.1 cylinder to TDC of its
compression stroke.
MD998738
Timing belt
under cover
AC102492AB
2. Remove the timing belt under cover rubber plug
and then set the special tool adjusting bolt
(MD998738).
Page 73
ENGINE MECHANICAL
CAUTION
CAUTION
AC107289
MD998738
Timing belt
tensioner arm
AB
AC102775
AB
A
B
AC107185
AB
Wire
Timing belt
tensioner pulley
mounting bolt
TIMING BELT
11A-37
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.
3. Screw in the special tool until it comes in contact
with the timing belt tensioner arm.
<<B>> POWER STEERING OIL PUMP ASSEMBLY
REMOVAL
With the hose installed, remove the power steering
oil pump assembly from the bracket.
NOTE: Secure the removed power steering oil pump
assembly with cord or rope at a position where they
will not interfere with the removal of the balancer
timing belt.
<<C>> CRANKSHAFT CAMSHAFT DRIVE
SPROCKET REMOVAL
Crankshaft
camshaft
drive
sprocket
MB991385
MB991367
AC102332
AB
4. Gradually screw in the special tool. Then align the
timing belt tensioner adjuster rod set hole A with
the timing belt tensioner adjustor cylinder set hole
B.
5. Insert a wire, etc.in the set hole.
1. Use the following special tools to support the
crankshaft camshaft drive sprocket.
Special spanner (MB991367)
Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft camshaft drive sprocket.
<<D>> BALANCER TIMING BELT REMOVAL
CAUTION
To reuse the balancer timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.
INSTALLATION SERVICE POINTS
>>A<< BALANCER TIMING BELT/BALANCER
TIMING BELT TENSIONER INSTALLATION
Balancershaft sprocket
Belt tension side
Timing mark
Timing mark
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.
6. After removal of adjusting bolt special tool, loosen
the timing belt tensioner pulley mounting bolt and
remove the valve timing belt.
Crankshaft
balancershaft
drive sprocket
AC102689
AB
1. Ensure that the crankshaft balancershaft drive
sprocket timing marks and balancershaft sprocket
timing marks are aligned.
Page 74
11A-38
CAUTION
ENGINE MECHANICAL
TIMING BELT
2. Install the balancer timing belt on the crankshaft
balancershaft drive sprocket and balancershaft
sprocket. There should be no slack on the tension
side.
Centre of the
mounting bolt
Centre of
the pulley
AC102690
AB
3. Assemble and temporarily fix the centre of the
pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the mounting
bolt, and the pulley flange is at the front-side of
the engine.
4. Adjust the balancer timing belt tension.
>>B<< BALANCER TIMING BELT TENSION
ADJUSTMENT
1. With your fingers, lift the balancer timing belt
tensioner in the direction of the arrow. Apply
pressure of 3.0
0.4 N¼m to the balancer timing
belt. Tighten the assembling bolt to the specified
torque. Then, fix the balancer timing belt
tensioner.
Tightening torque: 19
Balancershaft sprocket
Timing mark
Crankshaft
balancershaft
drive sprocket
3 N¼m
Timing mark
AC102689
AC
2. Turn the crankshaft clockwise two turns to set
No.1 cylinder to TDC of its compression stroke
and check that the sprocket timing marks are
aligned.
When tightening the mounting bolt, ensure that
the tensioner does not rotate with the bolt.
Allowing it to rotate with the bolt can cause
excessive tension of the belt.
AC102691
Page 75
ENGINE MECHANICAL
AC102693
AB
Deflection
Approximately 100 N
AC211535
AB
: Clean
: Clean and degrease
: Apply engine oil
Crankshaft camshaft
drive sprocket
Crankshaft pulley
center bolt
Crankshaft
Crankshaft angle
sensing blade
Crankshaft
pulley washer
Engine front
TIMING BELT
3. Apply a pressure of approximately 100N at the
centre (arrow area) between the sprocket as
shown, then inspect whether the belt deflection is
within the standard value.
Standard value:
At adjustment: 5
At replacement: 5
- 7 mm
- 7 mm
4. If not within the standard value, adjust the belt
tension again.
>>C<< CRANKSHAFT ANGLE SENSING BLADE/
CRANKSHAFT CAMSHAFT DRIVE SPROCKET
INSTALLATION
11A-39
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the direction
shown.
3. Place the larger chamfer side of the crank shaft
pulley washer in the direction shown and then
assemble on the crankshaft pulley centre bolt.
4. Apply some engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
Crankshaft
camshaft
drive
sprocket
5. Use the following special tool as during removal to
support the crankshaft camshaft drive sprocket.
Special spanner (MB991367)
Pin (MB991385)
6. Tighten the crankshaft pulley centre bolts to the
specified torque.
Tightening torque: 167 N
MB991385
MB991367
AC102332
¼m
AB
1. Clean or degrease the crankshaft, the crankshaft
angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as
shown.
NOTE: Also clean the degreased surfaces.
>>D<< TIMING BELT TENSIONER ADJUSTER
INSTALLATION
1. Install according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
CAUTION
If the compression is too fast, the procedure may
damage the rod.
A
(1) Slowly compress the timing belt tensioner
adjuster rod using a press or vice, then align
the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
B
AC102334
AB
Page 76
11A-40
ENGINE MECHANICAL
TIMING BELT
Wire
AC102335
AB
(2) Insert a wire or pin into the aligned set hole.
NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Assemble the timing belt tensioner adjuster to the
engine, then tighten the assembling bolt to the
specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.
Tightening torque: 23
3 N¼m
>>E<< TIMING BELT TENSIONER PULLEY
INSTALLATION
>>F<< VALVE TIMING BELT INSTALLATION
Timing mark
Camshaft sprocket
Crankshaft
camshaft
drive sprocket
Timing mark
Timing mark
Engine oil
pump sprocket
AC102486
AC
1. Align the timing marks on the camshaft sprocket,
crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Timing belt tensioner
pulley hole
AC102336
AB
Temporarily tighten the timing belt tensioner pulley as
shown.
Bolt
Balancershaft
Plug
Cylinder
block
AC102337
AE
2. Adjust the timing mark of the engine oil pump
sprocket. Unplug the cylinder block plug. Insert a
bolt (M6 sectional width 10 mm, minor diameter
45 mm) from the plug hole and then check. If the
bolt comes in contact with the balancer shaft turn
the sprocket one rotation. Re-adjust the timing
mark and then check to see that the bolt fits. Do
not remove the bolt until the valve timing belt is
assembled.
Page 77
ENGINE MECHANICAL
AC102488
Inlet side
camshaft sprocket
Exhaust side
camshaft sprocket
Timing belt
tensioner
pulley
Timing belt
idler pulley
Crankshaft
camshaft
drive
sprocket
Engine
oil pump
sprocket
AC
AC201801
Paper clip
AB
TIMING BELT
11A-41
3. Install the valve timing belt as follows:
Timing mark
Timing mark
AC201802
AB
(3) Use two wrenches to align the timing mark on
the rocker cover with that on the camshaft
sprocket. Pass the valve timing belt around the
inlet-side camshaft sprocket.
Paper clip
(1) Pass the valve timing belt around the
crankshaft camshaft drive sprocket, the engine
oil pump sprocket and the timing belt idler
pulley in that order.
(2) Pass the valve timing belt around the exhaust-
side camshaft sprocket, and hold the valve
timing belt with paper clip.
AC201803
AB
(4) Hold the valve timing belt with paper clips.
(5) Pass the valve timing belt around the timing
belt tensioner pulley.
CAUTION
Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation)
pressure to the cam shaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is tight.
(6) Remove the two paper clips.
MD998767
AC102694
AB
4. Turn the timing belt tensioner in the direction
shown using special tool tensioner wrench
(MD998767) to apply tension to the valve timing
belt. Then pre-tighten the timing belt tensioner
pulley.
5. Check that the timing marks are aligned.
Page 78
11A-42
CAUTION
ENGINE MECHANICAL
TIMING BELT
Bolt
Balancershaft
Plug
Cylinder
block
AC102337
AE
6. Remove the bolt inserted in Step 2 above, then
assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque.
Tightening torque: 30
3 N¼m
8. Adjust the valve timing belt tension.
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT
MD998738
CAUTION
When tightening the mounting bolt, ensure that
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
MD998767
AC102695
6. With special tool tensioner wrench (MD998767)
and torque wrench, apply tension torque 3.5 N
and tighten the timing belt tensioner pulley
mounting bolt to the specified torque.
Tightening torque: 48
5 N¼m
AB
¼m,
Timing belt
under cover
AC102492AB
1. Set special tool adjusting bolt (MD998738) when
removing the valve timing belt.
Always screw in special tool by hand, since use
of a spanner or other tools may damage the wire
or pin inserted in the timing belt tensioner
adjuster.
2. Gradually screw in special tool until the wire or pin
inserted in the timing belt tensioner adjuster lightly
moves.
3. Turn the crankshaft 1/4 turn anti-clockwise.
4. Turn the crankshaft in the clockwise direction until
you align each timing mark to set No.1 cylinder to
TDC of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.
Wire
AC102776
AB
7. Remove wire or pin inserted to timing belt
tensioner.
MD998738
Timing belt
under cover
AC102492AB
8. Remove the special tool adjusting bolt
(MD998738), and install the rubber plug to the
timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and
leave it for about 15 minutes.
Page 79
ENGINE MECHANICAL
AC102776
AB
Wire
AC102338
AB
Timing belt
tensioner
adjuster
A
TIMING BELT
10.Insert wire or pin removed in Step 7 again, and
ensure that it can be pulled out easily. When wire
or pin can be easily removed, appropriate tension
is applied on timing belt. In this case, remove wire
or pin.
11A-43
CAUTION
Always check the tightening torque of the crank
shaft pulley centre bolt when turning the crack
shaft pulley centre bolt anti-clockwise. Retighten if it is loose.
Timing mark
Camshaft
sprocket
If the projection of timing belt tensioner adjuster
rod is within the standard value, appropriate
tension is applied.
Standard value (A): 3.8
- 4.5 mm
11.If wire or pin cannot be easily pulled out, repeat
Step 1 through Step 9 to reach proper valve timing
belt tension.
Crankshaft
camshaft
drive sprocket
Timing mark
Timing mark
Engine
oil pump
sprocket
AC201411
AB
12.Check again that the timing marks on sprockets
are aligned.
>>H<< END CAP INSTALLATION
CAUTION
Always replace the end cap with new parts since
there may be fall-off or sealing defect if the end
cap is re-used.
INSPECTION
M1112004400352
TIMING BELT TENSIONER ADJUSTER
CHECK
1. Check for oil leak from seal, and replace it if leak
is detected.
2. Check for wear or damage at the top of the rod.
Replace it, if required.
Page 80
11A-44
A
B
Rod
98 – 196 N
Movement
Timing belt
tensioner
adjuster
AC102339
ENGINE MECHANICAL
AB
3. Hold the timing belt tensioner adjuster by hand,
and press the top end of the rod onto the metal
(e.g. cylinder block) under a pressure of 98
- 196
N to measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
- B: Movement
A
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.
TIMING BELT
BALANCER TIMING BELT TENSION
CHECK
Check the balancer timing belt tension as follows:
Approximately 100 N
Deflection
AC102693
1. Apply a pressure of approximately 100 N at the
centre (arrow area) between the sprocket as
shown then inspect whether the deflection is
within the standard value.
Standard value: 5
2. If not within the standard value, adjust the belt
tension. (Refer to
- 10 mm
311A).
AB
Page 81
ENGINE MECHANICAL
CAUTION
ENGINE ASSEMBLY
11A-45
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001000720
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation
Fuel Line Pressure Reduction [Refer to GROUP 13A, On-
vehicle Service - Fuel Pump Connector Disconnection
(How to Reduce Pressurized Fuel Lines) 313A.]
Hood Removal (Refer to GROUP 42, Hood 342).
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
Battery and Battery Tray Removal
Rocker Cover Centre Cover Removal (Refer to 311A
).
Radiator Assembly Removal (Refer to GROUP 14,
Radiator 314).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Starter Assembly Removal (Refer to GROUP 16, Starter
Motor Assembly 316).
Post-installation Operation
Starter Assembly Installation (Refer to GROUP 16,
Starter Motor Assembly 316).
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Radiator Assembly Installation (Refer to GROUP 14,
Radiator 314).
Battery and Battery Tray Installation
Rocker Cover Centre Cover Installation (Refer to 311A
).
Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner 315).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Accelerator Cable Adjustment (Refer to GROUP 17, On-
vehicle Service - Accelerator Cable Check and
Adjustment 317).
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
Hood Installation (Refer to GROUP 42, Hood 342).
Fuel Leak Check
Page 82
11A-46
5.0 ± 1.0 N·m
ENGINE MECHANICAL
ENGINE ASSEMBLY
9
10
17
5.0 ± 1.0 N·m
18
7
5
6
12
14
8
4
3
15
9.0 ± 2.0 N·m
11
13
2
1
9.0 ± 2.0 N·m
Removal steps
1. A/C compressor connector
2. Power steering fluid pressure
switch connector
3. Crank angle sensor connector
4. Ignition coil connectors
5. Detonation sensor connector
6. Purge control solenoid valve
connector
7. EGR control solenoid valve
connector
8. Injector connectors
9. Throttle position sensor connector
<<A>>
5.0 ± 1.0 N·m
16
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m
Removal steps
10. Idle speed control servo connector
11. Camshaft position sensor
connector
12. Oxygen sensor connector
13. Engine coolant temperature sensor
connector
14. Engine coolant temperature gauge
unit connector
15. Capacitor connector
16. Battery wiring harness connection
17. Accelerator cable connection
18. Drive belt
AC300549
&RQWLQXHG
AB
Page 83
19
ENGINE MECHANICAL
ENGINE ASSEMBLY
23
11A-47
24
25
5.0 ± 1.0 N·m
44 ± 10 N·m*
28
N
27
45 ± 5 N·m*
12 ± 2 N·m
29
26
22 ± 4 N·m
N
(Engine oil)
20
22 ± 4 N·m
22
<<B>>
<<B>>
Removal steps
19. Brake booster vacuum hose
connection
20. Canister vacuum hose connection
21. A/C compressor and clutch
assembly
22. Power steering oil pump assembly
23. Heater water hoses connection
24. Fuel return line hose connection
>>E<<
>>E<<
<<C>> >>D<<
>>C<<
<<D>> >>B<<
<<E>> >>A<<
21
AC300550
Removal steps
25. Fuel high-pressure hose
connection
26. O-ring
Transmission assembly
27. Self-locking nuts
28. Engine front mounting bracket
29. Engine assembly
&RQWLQXHG
AB
Page 84
11A-48
CAUTION
ENGINE MECHANICAL
ENGINE ASSEMBLY
REMOVAL SERVICE POINTS
<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the
serpentine drive system with the drive belt autotensioner.
Auto-tensioner
Hole B
Hole A
1. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk.
AC107640
AC
<<C>> TRANSMISSION ASSEMBLY REMOVAL
AC300950
AB
1. Pre-tighten the 2 bolts on the car to assemble the
radiator support upper insulator to set the special
tools engine hanger MB991895 or engine hanger
MB991928.
2. Remove the transmission assembly (Refer to
GROUP 22A, Transmission Assembly
322A).
<<D>> ENGINE FRONT MOUNTING BRACKET
REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
MB991895
Auto-tensioner
L-shaped
hexagon
wrench
AC107641
AB
2. Align hole A with hole B, insert an L-shaped
hexagon wrench, etc. to fix and then remove the
drive belt.
<<B>> A/C COMPRESSOR AND CLUTCH
ASSEMBLY/POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly, and power steering oil pump
assembly from the bracket.
NOTE: Secure the removed A/C compressor and
clutch assembly, and power steering oil pump
assembly with cord or rope at a position where they
will not interfere with the removal of the engine
assembly.
MB991527
MB991454
AC107631
AB
(1) <Special tool engine hanger (MB991895) is
used>
Remove special tool MB991895.
MB991928
MB991527
MB991454
AC211405
AB
(2) <Special tool engine hanger (MB991928) is
used>
Remove special tool MB991928.
Page 85
ENGINE MECHANICAL
AC107632
AB
MB991527
MB991454
AC107632
AB
MB991527
MB991454
ENGINE ASSEMBLY
3. Hold the engine assembly with a chain block, etc.
4. Place a garage jack against the engine oil pan
with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
to the engine front mounting bracket.
5. Loosen the engine front mounting bracket
mounting nuts and bolt, and remove the engine
front mounting bracket.
11A-49
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
4. Use the following special tool as during removal to
support the engine.
MB991895
MB991527
MB991454
AC107631
(1) <Special tool engine hanger (MB991895) is
used>
Set special tool MB991895. (Refer to
GROUP 22A, Transmission Assembly
322A).
AB
<<E>> ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and wiring
harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
the engine assembly upward from the engine
compartment.
INSTALLATION SERVICE POINTS
>>A<< ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, being careful not to
pinch the cables, hoses or wiring harness
connectors.
>>B<< ENGINE FRONT MOUNTING BRACKET
INSTALLATION
1. Place a garage jack against the engine oil pan
with a piece of wood in between, and install the
engine front mounting bracket while adjusting the
position of the engine.
MB991928
MB991527
MB991454
AC211405
AB
(2) <Special tool engine hanger (MB991928) is
used>
Set special tool MB991928 (Refer to
GROUP 22A, Transmission Assembly
322A).
>>C<< SELF-LOCKING NUTS INSTALLATION
CAUTION
Do not tighten the self-locking nuts while the
engine is hot.
Tighten the self-locking nuts to the specified torque
while the engine is cold.
Tightening torque: 45
>>D<< TRANSMISSION ASSEMBLY
INSTALLATION
1. Install the transmission assembly (Refer to
GROUP 22A, Transmission Assembly
5 N¼m
322A).
Page 86
11A-50
AC300950
ENGINE MECHANICAL
ENGINE ASSEMBLY
AB
2. Remove from the car the 2 bolts, to assemble the
radiator support upper insulator.
>>E<< O-RING/FUEL HIGH-PRESSURE HOSE
INSTALLATION
CAUTION
Do not let any engine oil get into the delivery
pipe.
1. Apply a small amount of new engine oil to the Oring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
Tightening torque: 5.0
1.0 N¼m
Page 87
11B-32
CAUTION
CAUTION
CAUTION
ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
SERVICE POINTS FOR REMOVAL
<<A>> LASH ADJUSTER REMOVAL
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
311B, the instruction under LASH ADJUSTER
in the INSPECTION section.)
INSTALLATION SERVICE POINTS
>>A<< LASH ADJUSTER INSTALLATION
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
311B, the instruction under LASH ADJUSTER
in the INSPECTION section.)
Install the lash adjuster into the rocker arm, being
careful not to spill the diesel fuel it contains.
>>B<< CAMSHAFT INSTALLATION
Timing belt side
1. Set each camshaft with its dowel pin at the top.
Cap number
Intake/exhaust
identification
letter
AK202870
AB
2. The bearing caps No. 2 to 5 are identical in shape
for both intake and exhaust camshafts. Check the
identification mark on each cap before installation.
Identification mark (stamped on front and
Nos. 2
- 5 bearing caps)
I: intake camshaft
E: exhaust camshaft
3. Remove completely sealant remaining on the
bearing caps and cylinder head.
Slit
Exhaust camshaft
AK202869
AB
Do not confuse the intake camshaft with the
exhaust camshaft.
The exhaust camshaft has a 4 mm wide slit at
the rear end.
>>C<< BEARING CAP INSTALLATION
Dowel pin
AK202871AB
4. Apply sealant to the surfaces indicated in the
drawing.
Specified sealant:
3M ATD No.8660 or equivalent
5. Install each bearing cap and tighten its bolts in
two or three passes.
6. Finally tighten the bolts to 20
1 N¼m.
7. Check that the rocker arms are correctly installed.
NOTE: Wipe off any squeezed out sealant completely.
AK203979
AC
Page 88
ENGINE OVERHAUL
AK202872
MD998713
AB
AK202754AB
AK202844
Cam position
sensor
Smaller vane
AB
ROCKER ARMS AND CAMSHAFT
11B-33
>>D<< CAMSHAFT OIL SEAL INSTALLATION
Use the special tool Camshaft oil seal installer
(MD998713) to drive each oil seal into position in the
cylinder head.
>>E<< CAMSHAFT POSITION SENSOR
SUPPORT INSTALLATION
1. Turn the exhaust camshaft to the No.1 cylinder top
dead center position.
NOTE: The camshaft will slightly turn counterclockwise by the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with
the smaller vane located as shown in the drawing.
INSPECTION
M1113005500388
CAMSHAFT
AK202797AB
Measure the cam height (nose-to-heel diameter).
If any cam is worn beyond the limit, replace the camshaft.
Standard value: 34.91 mm
Limit: 34.41 mm
1. Remove completely the FIPG remaining on the
2. Apply a 3
>>F<< CAMSHAFT POSITION SENSING
CYLINDER INSTALLATION
camshaft position sensor support and cylinder
head.
1 mm diameter bead of FIPG to the
indicated surface of the camshaft position sensor
support.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
LASH ADJUSTERS
CAUTION
The lash adjuster is a precision-engineered
component. Do not allow dust or other foreign
matter to enter it.
Do not disassemble lash adjusters.
Use only non-contaminated diesel fuel to
clean the lash adjuster.
For rough
cleaning
ABC
1. Prepare three containers and approximately five
liters of diesel fuel. Pour into each container the
diesel fuel in an amount enough for a lash
adjuster placed in the container in its upright
position to completely submerge.
For finish
cleaning
For diesel
fuel filling
AK202836
AB
Page 89
11B-34
CAUTION
AK202837
ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
2. Place the lash adjuster in container A and wash
its outside surface.
NOTE: Use a nylon brush if there are hard-toremove deposits.
Diesel fuel
MD998442
AK202839
AB
The steel ball spring of the lash adjuster is
extremely weak. The lash adjuster’s functionality
may be badly affected if the special tool is
inserted too strongly.
3. While gently pushing the internal steel ball using
the special tool Air bleed wire (MD998442), move
the plunger in and out 5
- 10 times to eliminate
stiffness in the plunger and expel contaminated
oil.
NOTE: The plunger must be free from jamming
and any other abnormalities. If a defect is found in
plunger operation, replace the lash adjuster.
CAUTION
The hole in the side of the lash adjuster must be
directed toward the inside of container A. Never
direct it against any person.
4. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.
Diesel fuel
MD998442
AK202839
AB
CAUTION
The steel ball spring of the lash adjuster is
extremely weak. The lash adjuster’s functionality
may be badly affected if the special tool is
inserted too strongly.
5. Soak the lash adjuster in the diesel fuel in
container B. Move the plunger in and out 5
times by gently pushing the internal steel ball
using the special tool Air bleed wire (MD998442)
until the plunger moves smoothly to wash the lash
adjuster’s pressure chamber.
MD998442
Diesel fuel
AK202840
- 10
AB
MD998442
Diesel fuel
AK202840
AB
CAUTION
The hole in the side of the lash adjuster must be
directed toward the inside of container B. Never
direct it against any person.
6. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.
Page 90
ENGINE OVERHAUL
CAUTION
AK202841
Diesel fuel
MD998442
AB
AK202842
Diesel fuel
MD998442
AB
ROCKER ARMS AND CAMSHAFT
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could
enter the pressure chamber when the chamber is
filled with diesel fuel.
7. Soak the lash adjuster in the diesel fuel in
container C. Gently push the internal steel ball
using the special tool Air bleed wire (MD998442).
11B-35
8. Place the lash adjuster upright with the plunger at
the top. Push the plunger firmly until it makes a full
stroke, then return the plunger slowly and release
the hold of the steel ball to allow the pressure
chamber to be filled with diesel fuel.
AK202843
9. Take the lash adjuster out of the container, place it
upright with the plunger at the top, and push the
plunger firmly. The plunger must not move at all.
NOTE: If the lash adjuster contracts, perform the
operations 7. through 9. again. Replace the lash
adjuster if it still contracts even after the pressure
chamber has completely been filled with diesel
fuel (air has been bled).
10.Keep the serviced lash adjusters in their upright
positions to prevent diesel fuel from spilling out.
Protect them from dust or other foreign matter.
Install the lash adjusters onto the engine as soon
as possible.
Page 91
11B-36
CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION
2
4
5
6
N
12
13
N
16
ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
M1113006900389
78 ± 2 N·m → loosen completely
→
20 ± 2 N·m → 90˚ + 90˚
1
20
17
15
N
14
8
9
10
N
18
19
N
N
11
7
3
N
Apply engine oil
to all moving
parts before
installation.
<<A>> >>D<<
<<B>> >>C<<
>>B<<
Removal steps
1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
4. Retainer lock
5. Valve spring retainer
6. Valve spring
<<B>> >>C<<
>>B<<
>>A<<
AK202895
Removal steps
7. Intake valve
8. Retainer lock
9. Valve spring retainer
10. Valve spring
11. Exhaust valve
12. Valve stem seal
13. Valve spring seat
&RQWLQXHG
AB
Page 92
ENGINE OVERHAUL
AK202723
MB991654
AB
AK202742
MD998772
AB
AK202873
MD998735
AB
CYLINDER HEAD AND VALVES
11B-37
&RQWLQXHG
>>A<<
Removal steps
14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head
REMOVAL SERVICE POINTS
<<A>> CYLINDER HEAD BOLT REMOVAL
Use the special tool Cylinder head bolt wrench
(MB991654) to loosen the cylinder head bolts.
<<B>> RETAINER LOCK REMOVAL
INSTALLATION SERVICE POINTS
>>A<< VALVE STEM SEAL INSTALLATION
MD998737
AK202874
CAUTION
The special tool must always be used when
installing the valve stem seal. Improper installation could result in oil leaks past the valve guide.
1. Install the valve spring seat.
2. Install the valve.
3. Apply a thin coat of engine oil to a new valve stem
seal.
4. Use the special tool Valve stem seal installer
(MD998737) to install the stem seal on the valve
guide. Use the stem of the valve to guide the stem
seal.
AB
Compress the valve spring using the special tool
Valve spring compressor (MD998772), then remove
the retainer lock.
NOTE: Store removed valves, springs and other
parts, after putting to each of them a tag that identifies its cylinder No. or installation location.
Intake valve stem seal
Colour: Gray
Exhaust valve stem seal
Colour: Grayish green
AK202875
AB
NOTE: Do not confuse the stem seals for intake
valves with those for exhaust valves.
>>B<< VALVE SPRING INSTALLATION
Spring
Painted
end
retainer
Stem
seal
Spring
seat
AK202551AB
Install each valve spring with the painted end toward
the rocker arm.
Page 93
11B-38
ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
>>C<< RETAINER LOCK INSTALLATION
MD998772
AK202742
MD998735
AK202873
AB
AB
2. Apply engine oil to the threads and washer of the
bolt.
NOTE: Use the special tool Cylinder head bolt
wrench (MB991654) to tighten the bolts.
Timing belt side
13968
410
3. Tighten the bolts to 78
25
2 N¼m in the indicated
7
AK202806
AB
sequence.
4. Loosen all the bolts completely.
5. Tighten the bolts again to a torque of 20
2 N¼m
in the indicated sequence.
Compress the valve spring using the special tool
Valve spring compressor (MD998772), then install
the retainer lock.
>>D<< CYLINDER HEAD BOLT INSTALLATION
Nominal length
AK202750
MB991654
AK202723
AB
AB
1. When reusing a cylinder head bolt, check that its
nominal length (shank length) is not greater than
the limit. If the limit is exceeded, replace the bolt.
Limit: 99.4 mm
90˚
90˚
Paint marks
AK202720
AB
CAUTION
If the tightening angle is smaller than 90,
proper fastening performance could not be
assured. Be sure to respect that angle.
If the bolt is tightened to an angle greater than
the specified angle, loosen the bolt completely and then retighten it beginning with
the first step.
6. Make paint marks on each bolt’s head and on the
cylinder head.
7. Turn the bolts 90
in the tightening direction and in
the indicated sequence.
8. Give another 90
turn in the tightening direction to
each bolt, making sure that the paint mark on the
bolt head and that on the cylinder head are on the
same line.
INSPECTION
M1113007000378
CYLINDER HEAD
1. Before cleaning the cylinder head, check it for
traces of water and gas leakage and for cracks
and any other damage.
Page 94
ENGINE OVERHAUL
CAUTION
AK202724
AK202729
Contact
(Should be at
center of face)
Margin
AB
CYLINDER HEAD AND VALVES
11B-39
2. Thoroughly remove oils, scale, sealants, carbon
and other contamination. Clean the oil passages,
then check using compressed air that they are not
blocked.
The thickness of the metal that can be removed
by grinding from both the cylinder head and the
mating cylinder block is limited to 0.2 mm in
total.
3. Check the cylinder head gasket surface for warp
using a straightedge and thickness gauge.
If the surface is warped beyond the limit, grind the
surface for rectification.
Gasket surface warp
Standard value: Less than 0.05 mm
Limit: 0.2 mm
Grinding limit: 0.2 mm
Cylinder head height (standard value for new
part):
131.9
- 132.1 mm
Standard values:
Intake 1.0 mm
Exhaust 1.5 mm
Limits:
Intake 0.5 mm
Exhaust 1.0 mm
Total length
AK202876
3. Measure the total length of the valve.
Replace the valve if the length is less than the
limit.
Standard values:
Intake 109.50 mm
Exhaust 109.70 mm
Limits:
Intake 109.00 mm
Exhaust 109.20 mm
VALVE SPRINGS
Out of square
AB
VALVES
1. Check the valve face for correct contact with the
seat. Reface the valve if the contact is partial or
one sided.
2. Measure the margin.
Replace the valve if its margin is smaller than the
limit.
Free height
AK202706
AB
1. Measure the free height of the spring.
Replace the spring if its height is smaller than the
limit.
Standard value: 47.0 mm
Limit: 46.0 mm
2. Measure the squareness of the spring.
Replace the spring if it is out of square beyond the
limit.
Standard value: 1.5
Limit: 4
or smaller
Page 95
11B-40
ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
VALVE GUIDE
valve
guide
Stem diameter
Guide inside diameter
AK202709
AB
Measure the valve guide inside diameter and valve
stem diameter to calculate the clearance between
the valve guide and valve stem.
If the limit is exceeded, replace the valve guide or
valve, or both.
Standard values:
Intake 0.02
Exhaust 0.05
- 0.05 mm
- 0.09 mm
Limits:
Intake 0.10 mm
Exhaust 0.15 mm
With the valve installed in position and its face
pressed against the valve seat, measure the valve
stem projection (distance between the the valve stem
end and spring seating surface). If the measurement
exceeds the limit, replace the valve seat.
Standard values:
Intake 49.20 mm
Exhaust 48.40 mm
Limits:
Intake 49.70 mm
Exhaust 48.90 mm
VALVE SEAT RECONDITIONING
1. Before reconditioning the valve seat, check the
clearance between the valve guide and valve
stem and, if necessary, replace the valve guide.
0.9 – 1.3mm
65˚
15˚
0.9 – 1.3 mm
65˚
25˚
VALVE SEATS
Valve stem
end
Valve stem
projection
Spring
seating
surface
AK202814
AB
44˚
AK202850
AB
2. Resurface the valve seat to the indicated width
and angles.
3. After resurfacing, lap the valve and valve seat
using lapping compound.
Page 96
ENGINE OVERHAUL
AK202707
0.5 – 1 mm
0.5 – 1 mm
Cut
AB
AK202708
Valve seat
height
Oversize hole diameter
AB
CYLINDER HEAD AND VALVES
11B-41
VALVE SEAT REPLACEMENT
1. Cut inside of the valve seat to be replaced until its
wall becomes thin enough for removal, then
remove the valve seat.
4. Resurface the valve seat. See the VALVE SEAT
RECONDITIONING section.
VALVE GUIDE REPLACEMENT
1. Force out the valve guide toward the cylinder
block using a press.
CAUTION
Do not use a replacement valve guide of the
same size as the removed one.
2. Machine the valve guide hole in the cylinder head
to the size matched to the selected oversize valve
guide.
Valve guide hole diameters
0.05 oversize: 12.05
0.25 oversize: 12.25
0.50 oversize: 12.50
- 12.07 mm
- 12.27 mm
- 12.52 mm
2. Rebore the valve seat hole in the cylinder head to
a diameter matched to the diameter of the
selected oversize valve seat.
Intake valve seat hole diameters:
0.3 oversize: 35.30
0.6 oversize: 35.60
- 35.33 mm
- 35.63 mm
Exhaust valve seat hole diameters:
0.3 oversize: 33.30
0.6 oversize: 33.60
- 33.33 mm
- 33.63 mm
3. Before fitting the valve seat, cool it in liquid
nitrogen to prevent damage to its hole in the
cylinder head due to interference.
19.2 – 19.8 mm
AK202877
AB
3. Press-fit the valve guide until it remains protruded
above the cylinder head by the amount indicated
in the drawing.
NOTE: .
1. Press the valve guide from above the cylinder
head.
2. The valve guides for the intake valves are different in length from those for the exhaust
valves (45.5 mm for intake valves; 50.5 mm for
exhaust valves)
4. After installing the valve guide, insert a new valve
in it to check for smooth movement.
Page 97
11B-42
OIL PAN AND OIL PUMP
REMOVAL AND INSTALLATION
ENGINE OVERHAUL
OIL PAN AND OIL PUMP
M1113008100301
Apply engine oil
to all moving
parts before
installtion.
19 ± 3 N·m
23 ± 3 N·m
16
15
14
13
23 ± 3 N·m
26
25
19
17
18
20
27
36 ± 3 N·m
10 ± 2 N·m
23
22
24
17 ± 1 N·m
23 ± 3 N·m
19 ± 3 N·m
21
19 ± 3 N·m
9.0 ± 3.0 N·m
10
28
32
31
30
29
8
9
7
4
>>O<<
>>N<<
<<A>> >>M<<
<<B>> >>L<<
<<C>> >>L<<
11
23 ± 3 N·m
12
3
44 ± 5 N·m
39 ± 5 N·m
2
1
9.0 ± 3.0 N·m
Removal steps
1. Drain plug
2. Drain plug gasket
3. Oil filter
4. Transmission stay <4WD>
5. Oil pan <2WD>
6. Oil pan lower section <4WD>
7. Oil pan upper section <4WD>
8. Oil screen
9. Gasket
10.Oil pressure switch
39 ± 5 N·m
9.0 ± 3.0 N·m
1
2
5
9.0 ± 3.0 N·m
>>K<<
<<D>> >>J<<
<<E>> >>I<<
>>H<<
6
9.0 ± 3.0 N·m
Removal steps
11.Relief plug
12.Gasket
13.Relief spring
14.Relief plunger
15.Oil filter bracket
16.Gasket
17.Plug
18.O-ring
19.Flange bolt
20.Front case
22 ± 4 N·m
&RQWLQXHG
AK202676
AB
Page 98
ENGINE OVERHAUL
CAUTION
AK202574
MD998727
AB
OIL PAN AND OIL PUMP
11B-43
&RQWLQXHG
>>G<<
>>G<<
>>F<<
>>E<<
>>D<<
<<F>> >>C<<
<<G>> >>B<<
<<G>> >>A<<
Removal steps
21.Gasket
22.Oil pump cover
23.Oil pump driven gear
24.Oil pump drive gear
25.Crankshaft front oil seal
26.Counterbalancer shaft oil seal
27.Oil pump oil seal
28.Counterbalancer shaft, right
29.Counterbalancer shaft, left
30.Counterbalancer shaft front bearing
31.Counterbalancer shaft rear bearing,
right
32.Counterbalancer shaft rear bearing,
left
REMOVAL SERVICE POINTS
<<A>> OIL PAN REMOVAL <2WD>
<<C>> OIL PAN UPPER SECTION REMOVAL
<4WD>
A
A
AK202692
AB
Screw bolts into the bolt holes A shown in the drawing (holes at both ends) to remove the oil pan.
CAUTION
Do not use a scraper or the special tool to
remove the oil pan.
<<D>> PLUG REMOVAL
MD998162
1. Remove the oil pan bolts.
2. Insert the special tool Oil pen remover
(MD998727) into the joint between the cylinder
block and oil pan by tapping the tool with a
hammer.
3. Remove the oil pan by tapping an edge of the
special tool Oil pen remover (MD998727) with a
hammer to move it sideways.
<<B>> OIL PAN LOWER SECTION REMOVAL
<4WD>
Remove the oil pan by tapping it through a piece of
wood applied to a side with a plastic hammer.
Do not use a scraper or the special tool to
remove the oil pan.
MD998783
AK202585
AB
Fit the teeth of the special tool in notches of the plug
as shown in the drawing and support the tool with the
special tool to loosen the plug.
Plug wrench (MD998162)
Plug wrench retainer (MD998783)
<<E>> FLANGE BOLT REMOVAL
Plug
Crosspoint
screwdriver
AK202586
AB
1. Remove the plug on the left side of the cylinder
block. Insert a cross point screwdriver (shank
diameter 8 mm) into the plug hole more than 60
mm to prevent the left counterbalancer shaft from
rotating.
Page 99
11B-44
CAUTION
AK202642
ENGINE OVERHAUL
OIL PAN AND OIL PUMP
2. When removing the rear bearing of the left
counterbalancer shaft, install the special tool
Silent shaft bearing installer stopper (MB991603)
on the front of the cylinder block and use a special
tool Silent shaft bearing puller (MD998372) to pull
out the bearing.
INSTALLATION SERVICE POINTS
>>A<< LEFT COUNTERBALANCER SHAFT REAR
BEARING INSTALLATION
2. Loosen and remove the flange bolt.
<<F>> COUNTERBALANCER SHAFT FRONT
BEARING REMOVAL
Front
bearing
MD998371
AK202633
AB
Remove the front bearing first. Otherwise, the
special tool cannot be used.
Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
front bearing from the cylinder block.
<<G>> COUNTERBALANCER SHAFT REAR
BEARING REMOVAL
1. Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
rear bearings from the cylinder block.
MB991603
MB991603
MD998705
AK202548
AB
1. Install the special tool Silent shaft bearing installer
stopper (MB991603) on the cylinder block.
MB991603
MD998705
Rear bearing
AK202635
AB
2. Set the rear bearing on the special tool Silent
shaft bearing installer (MD998705).
NOTE: The left counterbalancer shaft rear bearing has no oil hole.
3. Force the rear bearing into the cylinder block by
sticking the special tool.
MD998372
AK202634
AB
Page 100
ENGINE OVERHAUL
AK202579
Guide pin
AB
AK202549
Ratchet ball
Oil
hole
AB
Rear bearing (Right)
AK202580
Guide pin
MD998705
AB
OIL PAN AND OIL PUMP
>>B<< RIGHT COUNTERBALANCER SHAFT
REAR BEARING INSTALLATION
11B-45
MD998705
1. Install the guide pin on the cylinder block.
2. Set the bearing on the special tool Silent shaft
bearing installer (MD998705) with its oil hole on
the ratchet ball.
AK202581
AB
>>C<< COUNTERBALANCER SHAFT FRONT
BEARING INSTALLATION
Tool element for
rear bearing
installation
AK202582
AB
1. Detach from the special tool Silent shaft bearing
installer (MD998705) its element for rear bearing
installation.
3. Insert the special tool Silent shaft bearing installer
(MD998705) while passing the guide pin through
its hole and force the bearing into position by
striking the tool.
Guide pin
AK202579
AB
2. Install the guide pin on the cylinder block.
Front bearing
Ratchet ball
Oil
hole
AK202549
AC
3. Set the bearing on the special tool Silent shaft
bearing installer (MD998705) with its oil hole on
the ratchet ball.
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