11-1

GROUP 11

ENGINE
CONTENTS

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

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

NOTES
 11A-1

GROUP 11A

ENGINE
MECHANICAL
CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 11A-2 CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-28
ENGINE DIAGNOSIS. . . . . . . . . . . . . 11A-2 REMOVAL AND INSTALLATION . . . . . . . . 11A-28

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-3 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-38

REMOVAL AND INSTALLATION . . . . . . . . 11A-38
ON VEHICLE SERVICE . . . . . . . . . . . 11A-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-40
DRIVE BELT TENSION CHECK. . . . . . . . . 11A-7
AUTO-TENSIONER CHECK . . . . . . . . . . . 11A-8 CRANKSHAFT OIL SEAL . . . . . . . . . 11A-41
IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-11 REMOVAL AND INSTALLATION . . . . . . . . 11A-41
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-12
CURB IDLE SPEED CHECK . . . . . . . . . . . 11A-13 CYLINDER HEAD GASKET . . . . . . . . 11A-44
COMPRESSION PRESSURE CHECK. . . . 11A-14 REMOVAL AND INSTALLATION . . . . . . . . 11A-44
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-15
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A-15 TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-50
REMOVAL AND INSTALLATION . . . . . . . . 11A-50
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-18 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-61
REMOVAL AND INSTALLATION . . . . . . . . 11A-18
SPECIFICATIONS . . . . . . . . . . . . . . . 11A-63
CRANKSHAFT PULLEY . . . . . . . . . . 11A-26 FASTENER TIGHTENING
REMOVAL AND INSTALLATION . . . . . . . . 11A-26 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 11A-63
SERVICE SPECIFICATIONS . . . . . . . . . . . 11A-65
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 11A-65
11A-2 ENGINE MECHANICAL
GENERAL DESCRIPTION

GENERAL DESCRIPTION
M1111000100334
The 4G63 (2.0L) engine is an in-line four-cylinder
engine. The cylinder numbers are assigned as 1-2-3-
4 from the front of the engine (timing belt side). This
engine’s firing order is 1, 3, 4, 2.
ITEMS SPECIFICATIONS
Type In-line DOHC
Number of cylinders 4
Bore mm (in) 85 (3.35)
Stroke mm (in) 88 (3.46)
Engine displacement cm3 (cu. in) 1,997 (121.9)
Compression ratio 8.8
Firing order 1-3-4-2
Valve timing Intake valve Opens (BTDC) 17°
Closes (ABDC) 59°
Exhaust valve Opens (BBDC) 57°
Closes (ATDC) 15°

ENGINE DIAGNOSIS
M1111000700154

SYMPTOM PROBABLE CAUSE REMEDY

Compression is too low Blown cylinder head gasket Replace the gasket.
Worn or damaged piston rings Replace the rings.
Worn piston or cylinder Repair or replace the piston and/or
the cylinder block.
Worn or damaged valve seat Repair or replace the valve and/or the
seat ring.
Worn or damaged valve guide Replace the valve guide.
Drop in oil pressure Engine oil level is too low Check the engine oil level.
Malfunction of oil pressure switch Replace the oil pressure switch.
Clogged oil filter Install a new filter.
Worn oil pump gears or cover Replace the gears and/or the cover.
Thin or diluted engine oil Change the engine oil. Be sure to use
the correct viscosity.
Stuck (open) oil relief valve Repair the relief valve.
Excessive bearing clearance Replace the bearings.
Oil pressure too high Stuck (closed) oil relief valve Repair the relief valve.

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 ENGINE MECHANICAL
SPECIAL TOOLS
11A-3
SYMPTOM PROBABLE CAUSE REMEDY
Noisy valves Malfunction of lash adjuster Check the lash adjuster.
(including entry of air into high
pressure chamber)
Thin or diluted engine oil (low oil Change the engine oil. Be sure to use
pressure) the correct viscosity.
Worn or damaged valve stem or Replace the valve and/or the guide.
valve guide
Connecting rod noise/main Insufficient oil supply Check the engine oil level.
bearing noise Low oil pressure Refer to oil pressure drop symptoms
above.
Thin or diluted engine oil Change the engine oil. Be sure to use
the correct viscosity.
Excessive bearing clearance Replace the bearings.
Noisy timing belt Incorrect belt tension Adjust the belt tension and/or replace
the timing belt.
Excessive engine rolling and Loose engine roll stopper (Front, Retighten.
vibration Rear)
Loose transaxle mount bracket
Loose engine mount bracket
Loose center member
Broken transaxle mount insulator Replace.
Broken engine mount insulator
Broken engine roll stopper insulator

SPECIAL TOOLS
M1111000600492

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991502 MB991496-OD • Drive belt tension
Scan tool (MUT-II) check
• Ignition timing check
• Idle speed check
B991502

MB991668 Tool not available Drive belt tension check

Belt tension meter set (used together with scan
tool)

B991668

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11A-4 ENGINE MECHANICAL
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991958 − • Drive belt tension
A Scan tool (MUT-III sub check
assembly) • Ignition timing check
A: MB991824 • Idle speed check
Vehicle communication
MB991824
interface (V.C.I.)
B: MB991827
B MUT-III USB cable
C: MB991910
MUT-III main harness A
(Vehicles with CAN
MB991827
communication system)
C D: MB991911
MUT-III main harness B
(Vehicles without CAN
communication system)
MB991910 E: MB991914
D
MUT-III main harness C
(for Chrysler models
only)
F: MB991825
MUT-III adapter
MB991911
Harness
E G: MB991826
MUT-III trigger harness

MB991914

MB991825

MB991826
MB991958

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 ENGINE MECHANICAL
SPECIAL TOOLS
11A-5
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MB991453 MZ203827-01 When the engine hanger
Engine hanger assembly is used: Supporting the
engine assembly during
removal and installation
B991453
of the transaxle assembly
NOTE: Special tool
GENERAL SERVICE MZ203827-01 MB991454 is a part of
TOOL MZ203827 engine hanger
Engine lifter attachment set
MB991453.
MZ203827

MB991454 MZ203827-01
Engine hanger balancer

B991454

MB991895 −
Engine hanger

MB991895

MB991928 −
SLIDE BRACKET (HI) Engine hanger
A: MB991929
E Joint (50) × 2
B: MB991930
Joint (90) × 2
F A C: MB991931
D Joint (140) × 2
B D: MB991932
C Foot (standard) × 4
B991928
E: MB991933
Foot (short) × 2
F: MB991934
Chain and hook
assembly
MD998772 General service tool Compressing valve
Valve spring compressor spring

MD998772

MD998737 MD998737-01 Valve stem seal

Valve stem seal installer installation

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11A-6 ENGINE MECHANICAL
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MD998713 MD998713-01 Camshaft oil seal
Camshaft oil seal installer installation

D998713

MD998727 MD998727-01 Oil pan removal

Oil pan remover

D998727

MD998781 General service tool Supporting the flywheel

Flywheel stopper

D998781

MB990938 MB990938-01 Crankshaft rear oil seal

Installer bar installation

B990938

MD998776 MD998776-01
Crankshaft rear oil seal
installer

D998776

MD998285 MD998285-01 Crankshaft front oil seal

Crankshaft front oil seal installation
guide

D998285

MD998375 MD998375-01
Crankshaft front oil seal
installer

MB991654 General service tool Removal and installation

Cylinder head bolt wrench of cylinder head bolt
(12)

B991654

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 ENGINE MECHANICAL
ON VEHICLE SERVICE
11A-7
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MD998738 General service tool Supporting the timing belt
Adjusting bolt tensioner arm and timing
belt tensioner adjuster

D998738

MB991367 MB991367-01 Holding the crankshaft

Special spanner sprocket

B991367

MB991385 MIT217213
Pin

B991385

MD998767 MD998752-01 Valve timing belt tension

Tensioner wrench adjustment

D998767

ON VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100344

CAUTION
Check the drive belt tension after turning the crankshaft
clockwise one turn or more.
1. Make sure that the indicator mark is within the area marked
with A in the illustration.
2. If the mark is out of the area, replace the drive belt (Refer to
P.11A-26.)
NOTE: The drive belt tension check is not necessary as
A
auto-tensioner is adopted.

INDICATOR
MARK
AC211616AB

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11A-8 ENGINE MECHANICAL
ON VEHICLE SERVICE

AUTO-TENSIONER CHECK
M1111003000121

OPERATION CHECK
1. Turn OFF the engine from the idle state then check to see
that the drive belt is not protruding from the pulley width of
the auto-tensioner.
2. Remove the drive belt.(Refer to P.11A-26.)
Y1848AU 3. Securely insert the spindle handle or ratchet handle with a
12.7mm (1/2-inch) insertion angle into the jig hole of the
auto tensioner. Turn the auto-tensioner to the left and right
to check and see that there is no threading.
4. If there are any problems in the procedure 1 or 3, replace
the auto-tensioner.(Refer to P.11A-50.)
5. Install the drive belt.(Refer to P.11A-26.)

AC211619

FUNCTION CHECK
You can verify if the auto-tensioner is defective or not by check-
ing the drive belt tension.
.

When using scan tool MB991502

Required Special Tools:
• MB991502: Scan Tool (MUT-II)
• MB991668: Belt Tension Meter Set
1. Check the drive belt tension. (Refer to P.11A-26.)
2. Measure the drive belt tension vibration frequency by the
following procedures:
CAUTION
To prevent damage to scan tool MB991502, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991502.
(1) Connect special tool MB991668 to scan tool MB991502.
16-PIN (2) Connect the scan tool MB991502 to the data link
connector.
(3) Turn the ignition switch to ON position, and select "BELT
TENSION" on the menu screen.

MB991502

MB991668

AC211432 AB

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 ENGINE MECHANICAL
ON VEHICLE SERVICE
11A-9
CAUTION
• The temperature of the surface of the belt should be as
close to normal temperature as possible.
• Do not allow any contaminants such as water or oil to
get onto the microphone.
• If strong gusts of wind blow against the microphone or
if there are any loud sources of noise nearby, the val-
ues measured by the microphone may not correspond
to actual values.
• If the microphone is touching the belt while the mea-
surement 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.
POWER STEERING 10 – 20 mm (4) Hold special tool MB991668 to the middle of the drive
OIL PUMP PULLEY (0.40 – 0.78 in)
belt between the pulleys (at the place indicated by arrow),
MB991668 15˚ approximately 10 − 20 mm (0.40 − 0.78 inch) away from
WATER 15˚ the rear surface of the belt so that it is perpendicular to
PUMP the belt (within an angle of ± 15 degree).
PULLEY
(5) Gently tap the middle of the belt between the pulleys (the
place indicated by the arrow) with your finger as shown in
GENTLY TAP WITH
YOUR FINGER the illustration, and measure that the vibration frequency
of the belt is within the standard value.
AC102806AB Standard value: 110 − 144 Hz
3. If not within the standard value, replace the auto-tensioner.
(Refer to P.11A-26.)
.

When using scan tool MB991958

Required Special Tools:
• MB991668: Belt Tension Meter Set
• MB991958: Scan Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991911: Main Harness B
1. Check the drive belt tension. (Refer to P.11A-7.)
2. Measure the drive belt tension vibration frequency by the
following procedures:

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11A-10 ENGINE MECHANICAL
ON VEHICLE SERVICE

CAUTION
To prevent damage to scan tool MB991824, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991824.
(1) Connect special tool MB991668 to scan tool MB991824.
16-PIN (2) Connect scan tool MB991911 to scan tool MB991824.
(3) Connect scan tool MB991911 to the data link connector.
(4) Turn the ignition switch to the "ON" position and select
"Belt Tension Measurement" from the menu scan tool
MB991824 screen.
CAUTION
• The temperature of the surface of the belt should be as
MB991911 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 val-
ues measured by the microphone may not correspond
to actual values.
MB991668 • If the microphone is touching the belt while the mea-
MB991824 AC211433 AB surement 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.
POWER STEERING 10 – 20 mm (5) Hold special tool MB991668 to the middle of the drive
OIL PUMP PULLEY (0.40 – 0.78 in)
belt between the pulleys (at the place indicated by arrow),
MB991668 15˚ approximately 10 − 20 mm (0.40 − 0.78 inch) away from
WATER 15˚ the rear surface of the belt so that it is perpendicular to
PUMP the belt (within an angle of ± 15 degree).
PULLEY
(6) Gently tap the middle of the belt between the pulleys (the
place indicated by the arrow) with your finger as shown in
GENTLY TAP WITH
YOUR FINGER the illustration, and measure that the vibration frequency
of the belt is within the standard value.
AC102806AB Standard value: 110 − 144 Hz
3. If not within the standard value, replace the auto-tensioner.
(Refer to P.11A-50.)
.

When using a tension gauge

1. Check the drive belt tension. (Refer to P.11A-7.)
POWER STEERING 2. Use a belt tension gauge in the middle of the belt between
BELT TENSION
GAUGE OIL PUMP PULLEY the pulleys (at the place indicated by the arrow) to measure
that the belt tension is within the standard value.
WATER PUMP
PULLEY
Standard value: 245 − 412 N
3. If not within the standard value, replace the auto-
tensioner.(Refer to P.11A-50.)

AC102807AB

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 ENGINE MECHANICAL
ON VEHICLE SERVICE
11A-11
IGNITION TIMING CHECK
M1111001700384

Required Special Tools:

• MB991502: Scan Tool (MUT-II)
• MB991958: Scan Tool (MUT-III Sub Assembly)
• MB991824: V.I.C.
• MB991827: USB Cable
• MB991911: Main Harness B
1. Before inspection, set vehicle to the following conditions:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights and all accessories: OFF
• Transaxle: Neutral
CAUTION
To prevent damage to scan tool MB991502 or MB991958,
always turn the ignition switch to the "LOCK" (OFF) posi-
tion before connecting or disconnecting scan tool
MB991502 or MB991958.
16-PIN 2. Connect scan tool MB991502 or MB991958 to the data link
connector.
3. Set up a timing light.
MB991502 4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 850 r/min.
AK204070AB
6. Select scan tool MB991502 or MB991958 MFI actuator test
"item number 17."
7. Check that basic ignition timing is within the standard value.
Standard value: 5° BTDC ± 3°
8. If the basic ignition timing is not within the standard value,
16-PIN
check the following items:
• Is the MFI system diagnostic trouble code is output
• Timing belt cover and crankshaft position sensor installation
conditions
• Crankshaft sensing blade condition
MB991911 CAUTION
If the actuator test is not canceled, the forced drive will
MB991824 continue for 27 minutes. Driving in this state could lead to
engine failure.
9. Press the clear key on scan tool MB991502 or MB991958
(select forced- drive stop mode), and cancel the actuator
test.
[Link] that the actual ignition timing is at the standard value.
Standard value: Approximately 5° BTDC
MB991827 AK204071AB NOTE: Ignition timing fluctuates about ± 7° Before Top Dead
Center, even under normal operating condition.
NOTE: It is automatically further advanced by about 5° to
10° Before Top Dead Center at higher altitudes.

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11A-12 ENGINE MECHANICAL
ON VEHICLE SERVICE

IDLE MIXTURE CHECK

M1111002100233

Required Special Tools:

• MB991502: Scan Tool (MUT-II)
• MB991958: Scan Tool (MUT-III Sub Assembly)
• MB991824: V.I.C.
• MB991827: USB Cable
• MB991911: Main Harness B
1. Before inspection, set vehicle to the following conditions:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights and all accessories: OFF
• Transaxle: Neutral
CAUTION
To prevent damage to scan tool MB991502 or MB991958,
always turn the ignition switch to the "LOCK" (OFF) posi-
tion before connecting or disconnecting scan tool
MB991502 or MB991958.
16-PIN 2. Connect scan tool MB991502 or MB991958 to the data link
connector.
3. Confirm basic ignition timing is within the standard value.
MB991502 (Refer to Ignition Timing Check P.11A-11.)
Standard value: 5° BTDC ± 3°
AK204070AB
4. Increase engine speed to 2,500 r/min for 2 minutes.
5. Set the CO/HC tester.
6. Check the CO and HC contents at idle.
Standard value:
CO contents: 0.5% or less
16-PIN
HC contents: 100 ppm or less
7. If the CO and HC contents do not remain inside the standard
value, check the following items:
• If the MFI system diagnostic trouble code is output
• Closed-loop control (When the closed-loop control is carried
MB991911
out normally, the output signal of the heated oxygen sensor
changes between 0 − 400 mV and 600 − 1,000 mV at idle.)
• Fuel pressure
MB991824
• Injector(s)
• Ignition coil, spark plug cable, spark plug
• EGR system and EGR valve leak
• Evaporative emission control system
• Compression pressure
NOTE: Replace the catalytic converter when the CO and HC
contents do not remain inside the standard value, even
MB991827 AK204071AB though the result of the inspection is normal for all items.

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 ENGINE MECHANICAL
ON VEHICLE SERVICE
11A-13
CURB IDLE SPEED CHECK
M1111003500450

Required Special Tools:

• MB991502: Scan Tool (MUT-II)
• MB991958: Scan Tool (MUT-III Sub Assembly)
• MB991824: V.I.C.
• MB991827: USB Cable
• MB991911: Main Harness B
1. Before inspection, set vehicle to the following conditions:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights and all accessories: OFF
• Transaxle: Neutral
CAUTION
To prevent damage to scan tool MB991502 or MB991958,
always turn the ignition switch to the "LOCK" (OFF) posi-
tion before connecting or disconnecting scan tool
MB991502 or MB991958.
16-PIN 2. Connect scan tool MB991502 or MB991958 to the data link
connector.
3. Confirm basic ignition timing is within the standard value.
MB991502 (Refer to Ignition Timing Check P.11A-11.)
Standard value: 5° BTDC ± 3°
AK204070AB
4. Start the engine.
5. Run the engine at idle for 2 minutes.
6. Check the idle speed. Select MFI service data item number
22 and take a reading of the idle speed.
Curb idle speed: 850 ± 100 r/min
16-PIN
NOTE: The idle speed is controlled automatically by the idle
air control system.
7. If the idle speed is outside the standard value, refer to
GROUP 13A, Diagnosis − Symptom Chart P.13A-27.

MB991911

MB991824

MB991827 AK204071AB

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11A-14 ENGINE MECHANICAL
ON VEHICLE SERVICE

COMPRESSION PRESSURE CHECK

M1111002600421
1. Before inspection, check that the engine oil, starter and
battery are normal. Also, set the vehicle to the following
conditions:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights, and all accessories: OFF
• Transaxle: Neutral
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crankshaft position sensor connector.
CRANKSHAFT
POSITION NOTE: Doing this will prevent the engine control module
SENSOR from carrying out ignition and fuel injection.
CONNECTOR
WARNING
Keep your distance from the spark plug hole when
cranking. Oil, fuel, etc., may spray out from the spark
plug hole and may cause serious injury.
5. Cover the spark plug holes with a shop towel etc. Crank the
engine for a few seconds to clear debris from a round the
AK204072 AB
spark plug holes. After the engine has been cranked, check
for foreign material adhering to the shop towel.
6. Install the 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): 1,128
COMPRESSION GAUGE kPa (163 psi)
Minimum limit (at engine speed of 250 r/min): 951 kPa
(138 psi)
AK100050AB
AK100050 8. Measure the compression pressure for all the cylinders, and
check that the pressure differences of the cylinders are
below the limit.
Limit: 98 kPa (14 psi)
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 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 does not rise after oil is added, the
cause is a burnt or defective valve seat, or pressure is
leaking from the gasket.
[Link] the crankshaft position sensor connector.
[Link] the spark plugs and spark plug cables.
[Link] the scan tool to erase the diagnostic trouble codes.
NOTE: This will erase the diagnostic trouble code resulting
from the crankshaft position sensor connector being discon-
nected.

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 ENGINE MECHANICAL
ON VEHICLE SERVICE
11A-15
NOTE: If the negative (−) cable has been disconnected from
the battery terminal in order to erase the diagnostic trouble
code, operate the engine at idle for approximately 10 min-
utes after restarting.

MANIFOLD VACUUM CHECK

M1111002700387
1. Before inspection, check that the engine oil, starter and
battery are normal. Also, set the vehicle to the following
conditions:
VACUUM GAUGE
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights, and all accessories: OFF
• Transaxle: Neutral
2. Connect an engine tachometer.
3. Attach a tee-fitting joint to the vacuum hose between the fuel
pressure solenoid and the intake manifold plenum, and
AK203946AB connect a vacuum gauge.
4. Start the engine and check that idle speed is within
specification. Then check the vacuum gauge reading.
Idle speed: 850 ± 100 r/min
Minimum limit: 51 kPa (15 in Hg)

LASH ADJUSTER CHECK

M1111002900347
If an abnormal noise (chattering noise) is heard by malfunction
of the lash adjuster immediately after starting the engine and
does not disappear, it might be the lash adjusters. Perform the
following check.
NOTE: An abnormal noise due to malfunction of the lash
adjuster is produced immediately after starting the engine and
changes with the engine speed, irrespective of the engine load.
If, the abnormal noise is not produced immediately after start-
ing the engine or does not change with the engine speed, or it
changes with the engine load, the lash adjuster is not the cause
for the abnormal noise.
NOTE: When the lash adjuster is malfunctioning, the abnormal
noise is rarely eliminated by running the engine at idle speed.
However, the abnormal noise may disappear only when seizure
is caused by oil sludge in the engine whose oil is not main-
tained properly.
1. Start the engine.
2. Check if the abnormal noise produced immediately after
starting the engine changes with the change in the engine
speed.
If the abnormal noise is not produced immediately after
starting the engine or it does not change with the engine
speed, the lash adjuster is not the cause for the noise.
Therefore, investigate other causes. The abnormal noise is
probably caused by some other parts than the engine proper
if it does not change with the engine speed. (In this case, the
lash adjuster is in good condition.)
3. With the engine idling, change the engine load to make sure
that there is no change in the level of abnormal noise.
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11A-16 ENGINE MECHANICAL
ON VEHICLE SERVICE

If there is a change in the level of abnormal noise, suspect a

tapping noise due to worn crankshaft bearing or connecting
rod bearing. (In this case, the lash adjuster is in good
condition.)
4. After completion of warm-up, run the engine at idle to check
for abnormal noise.
If the noise is reduced or disappears, clean the lash adjuster
(Refer to GROUP 11B − Engine overhaul − Rocker Arms
and Camshaft − Inspection P.11B-32.) It is suspected that
the noise is due to collapse of the lash adjuster. If there is no
change in the level of the abnormal noise, proceed to step 5.
5. Run the engine to bleed the lash adjuster system. (Refer to.)
6. If the abnormal noise does not disappear after air bleeding
operation, clean the lash adjuster (Refer to GROUP 11B −
Engine overhaul − Rocker Arms and Camshaft − Inspection
P.11B-32.)
.

Bleeding lash adjuster system

NOTE: Parking the vehicle on a grade for a long time may drain
oil from the lash adjuster, causing air to enter the high pressure
chamber when starting the engine.
NOTE: After parking for many hours, oil may drain from the oil
passage and take time before oil is supplied to the lash
adjuster, causing air to enter the high pressure chamber.
NOTE: In the above cases, abnormal noise can be eliminated
by bleeding the lash adjuster system.
1. Check engine oil. Add or change oil as required.
NOTE: If the engine oil level is low, air is sucked from the oil
screen, causing air to enter the oil passage.
NOTE: If the engine oil level is higher than specification, oil
GOOD
may be stirred by the crankshaft, causing oil to be mixed
with air creating aerated (foaming) oil.
MAXIMUM
NOTE: If oil is deteriorated, air is not easily separated from
oil, increasing the quantity of air contained in oil.
MINIMUM
AKX00328AB

HIGH-PRESSURE
CHAMBER AK100001AD

NOTE: If air mixed with oil enters the high pressure chamber
inside the lash adjuster from the above causes, air in the
high pressure chamber is compressed excessively while the
valve is being opened, resulting in an abnormal noise when
the valve closes.

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 ENGINE MECHANICAL
ON VEHICLE SERVICE
11A-17
This is the same phenomenon as that observed when the
valve clearance has become excessive. The lash adjuster
can resume normal function when air entered the lash
adjuster is removed.
2. Idle the engine for one to three minutes to warm it up.
AIR BLEEDING OPERATION PATTERN 3. Repeat the operation pattern, shown in left figure, at no load
OPEN THROTTLE CLOSE to check for abnormal noise. (Usually the abnormal noise is
THROTTLE VALVE
VALVE GRADUALLY eliminated after repetition of the operation 10 to 30 times. If,
APPROXI- however, no change is observed in the level of abnormal
MATELY noise after repeating the operation more than 30 times,
3,000 r/min
suspect that the abnormal noise is due to some other
IDLING 15 s 15 s factors.)
OPERATION
4. After elimination of abnormal noise, repeat the operation
ONE CYCLE shown in left figure five more times.
AKX00330 AD 5. Run the engine at idle for one to three minutes to make sure
that the abnormal noise has been eliminated.

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11A-18 ENGINE MECHANICAL
ENGINE ASSEMBLY

ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001000667

CAUTION
• If the vehicle is equipped with the Bremboä disc brake, during maintenance, take care not to con-
tact the parts or tools to the caliper because the paint of caliper will be scratched.
• *: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation Post-installation Operation
• Fuel Line Pressure Reduction [Refer to GROUP 13A, On- • Air Outlet Fitting Installation (Refer to GROUP 15,
vehicle Service − Fuel Pump Connector Disconnection Exhaust Manifold and Turbocharger P.15-16.)
(How to Reduce Pressurized Fuel Lines) P.13A-765.] • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Hood Removal (Refer to GROUP 42, Hood P.42-7.) Exhaust Pipe and Main Muffler P.15-23.)
• Under Cover Removal (Refer to GROUP 51, Front • Front Axle Crossmember Bar Installation (Refer to
Bumper P.51-2.) GROUP 32, Engine Roll Stopper and Centermember
• Side Cover Removal P.32-6.)
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser- • Radiator Assembly Installation (Refer to GROUP 14,
vice − Engine Oil Replacement P.12-3.) Radiator P.14-22.)
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Rocker Cover Center Cover Installation (Refer to P.11A-
Service − Engine Coolant Replacement P.14-18.) 28.)
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Accelerator Cable Installation (Refer to GROUP 17,
Tower Bar.) Accelerator Cable and Pedal P.17-5.)
• Air Cleaner Assembly Removal (Refer to GROUP 15, Air • Battery and Battery Tray Installation
Cleaner P.15-7.) • Air Pipe C, Air Pipe B and Air Hose A Installation (Refer to
• Air Pipe C, Air Pipe B and Air Hose A Removal (Refer to GROUP 15, Charge Air Cooler P.15-8.)
GROUP 15, Charge Air Cooler P.15-8.) • Air Cleaner Assembly Installation (Refer to GROUP 15,
• Battery and Battery Tray Removal Air Cleaner P.15-7.)
• Accelerator Cable Removal (Refer to GROUP 17, Accel- • Strut Tower Bar Installation (Refer to GROUP 42, Strut
erator Cable and Pedal P.17-5.) Tower Bar.)
• Rocker Cover Center Cover Removal (Refer to P.11A- • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
28.) Service − Engine Coolant Replacement P.14-18.)
• Radiator Assembly Removal (Refer to GROUP 14, Radia- • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-
tor P.14-22.) vice − Engine Oil Replacement P.12-3.)
• Front Axle Crossmember Bar Removal (Refer to GROUP • Drive Belt Tension Check (Refer to P.11A-7.)
32, Engine Roll Stopper and Centermember P.32-6.) • Side Cover Installation
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Under Cover Installation (Refer to GROUP 51, Front
Exhaust Pipe and Main Muffler P.15-23.) Bumper P.51-2.)
• Air Outlet Fitting Removal (Refer to GROUP 15, Exhaust • Accelerator Cable Adjustment (Refer to GROUP 17, On-
Manifold and Turbocharger P.15-16.) vehicle Service − Accelerator Cable Check and Adjust-
ment P.17-4.)
• Hood Installation (Refer to GROUP 42, Hood P.42-7.)
• Fuel Leak Check

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 ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-19
8

5 4
10 1
6 1
5.0 ± 1.0 N·m
44 ± 9 in-lb
11
15

7 2 13
3 14
14 ± 3 N·m 26 ± 5 N·m 12
124 ± 26 in-lb 19 ± 4 ft-lb 5.0 ± 1.0 N·m
44 ± 9 in-lb

17
16

19

18

21 20
11 ± 1 N·m
98 ± 8 in-lb

AC211077AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. IGNITION COIL CONNECTORS 8. THROTTLE POSITION SENSOR
2. HEATER OXYGEN SENSOR CONNECTOR
(FRONT) CONNECTOR 9. IDLE AIR CONTROL MOTOR
3. CRANKSHAFT POSITION CONNECTOR
SENSOR CONNECTOR 10. INJECTOR CONNECTORS
4. MANIFOLD DIFFERENTIAL 11. CAMSHAFT POSITION SENSOR
PRESSURE SENSOR CONNECTOR
CONNECTOR 12. ENGINE COOLANT
5. FUEL PRESSURE SOLENOID TEMPERATURE GAUGE UNIT
CONNECTOR CONNECTOR
6. KNOCK SENSOR CONNECTOR 13. ENGINE COOLANT
7. EVAPORATIVE EMISSION TEMPERATURE SENSOR
PURGE SOLENOID CONNECTOR CONNECTOR

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11A-20 ENGINE MECHANICAL
ENGINE ASSEMBLY

REMOVAL STEPS (Continued)

14. CONTROL WIRING HARNESS
AND TRANSAXLE WIRING
HARNESS COMBINATION
15. GROUND CABLE CONNECTION
16. GENERATOR CONNECTOR
17. GENERATOR TERMINAL
18. EGR VACUUM REGULATOR
SOLENOID VALVE CONNECTOR
19. ENGINE OIL PRESSURE SWITCH
CONNECTOR
20. TURBOCHARGER WASTEGATE
ACTUATOR BOLTS
<<A>> 21. DRIVE BELT

33
35
34
22

5.0 ± 1.0 N·m

44 ± 9 in-lb

36 N (ENGINE OIL)

67 ± 7 N·m*
50 ± 5 ft-lb*

12 ± 2 N·m
102 ± 22 in-lb 23
22 ± 4 N·m
16 ± 3 ft-lb

37

98 ± 10 N·m* 30 N 24 22 ± 4 N·m
73 ± 7 ft-lb* 25 16 ± 3 ft-lb

40 ± 5 N·m
N 32 26 30 ± 3 ft-lb

38
42 ± 2 N·m
31 ± 1 ft-lb
29 31
42 ± 2 N·m
31 ± 1 ft-lb
27
28 AC211078AB

REMOVAL STEPS REMOVAL STEPS (Continued)

22. BRAKE BOOSTER VACUUM 24. POWER STEERING PRESSURE
HOSE CONNECTION SWITCH CONNECTOR
23. PURGE HOSE CONNECTION 25. POWER STEERING OIL PUMP
HEAT PROTECTOR

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 ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-21
REMOVAL STEPS (Continued)
<<B>> 26. POWER STEERING OIL PUMP,
BRACKET AND RESERVOIR
ASSEMBLY
27. A/C COMPRESSOR
CONNECTOR
<<B>> 28. A/C COMPRESSOR AND
CLUTCH ASSEMBLY
29. ENGINE OIL COOLER FEED
HOSE CONNECTION
30. ENGINE OIL COOLER TUBE
GASKETS
31. ENGINE OIL COOLER RETURN
HOSE CONNECTION
32. ENGINE OIL COOLER TUBE
GASKETS
33. HEATER WATER HOSES
CONNECTION
34. FUEL RETURN LINE HOSE
CONNECTION
>>D<< 35. FUEL HIGH-PRESSURE HOSE
CONNECTION
>>D<< 36. O-RING
• TRANSFER ASSEMBLY (REFER
TO GROUP 22A, TRANSFER
ASSEMBLY P.22A-15.)
<<C>> >>C<< • TRANSAXLE ASSEMBLY
<<D>> >>B<< 37. ENGINE FRONT MOUNTING
BRACKET AND CUSHION
STOPPERS ASSEMBLY
<<E>> >>A<< 38. ENGINE ASSEMBLY
Required Special Tools:
• MB991453: Engine Hanger Assembly • MB991928: Engine Hanger
• MB991454: Engine Hanger Balancer • MZ203827: Engine Lifter
• MB991895: Engine Hanger

REMOVAL SERVICE POINTS

.

<<A>> DRIVE BELT REMOVAL

The following operations will be needed due to the serpentine
drive system with the drive belt auto-tensioner.
AUTO-
1. Securely insert the spindle handle or ratchet handle with a
TENSIONER 12.7mm (1/2-inch) insertion angle into the jig hole of the
auto-tensioner, and turn the auto-tensioner
counterclockwise until it hits the stopper.

HOLE B
HOLE A
AC210996 AB

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11A-22 ENGINE MECHANICAL
ENGINE ASSEMBLY

CAUTION
To reuse the drive belt, draw an arrow indicating the rotat-
ing direction (to the right) on the back of the belt using
chalk, etc.
2. Align hole A with hole B, insert an L-shaped hexagon
wrench, etc. to fix and then remove the drive belt.

AUTO-
TENSIONER

L-SHAPED
HEXAGON
WRENCH
AC210998AB

<<B>> POWER STEERING OIL PUMP, BRACKET AND

RESERVOIR ASSEMBLY/ A/C COMPRESSOR AND
CLUTCH ASSEMBLY REMOVAL
With the hose installed, remove the power steering oil pump
assembly, and A/C compressor and clutch assembly from the
bracket.
NOTE: Secure the removed power steering oil pump assembly,
and A/C compressor and clutch assembly with cord or rope at a
position where they will not interfere with the removal of the
engine assembly.
.

<<C>> TRANSAXLE ASSEMBLY REMOVAL

1. Pre-tighten the 2 bolts on the car to assemble the radiator
support upper insulator to set the special tools MZ203827,
MB991895 or MB991928.
2. Remove the transaxle assembly. (Refer to GROUP 22A −
Transaxle Assembly P.22A-21.)

AC107630AB

<<D>> ENGINE FRONT MOUNTING BRACKET AND

CUSHION STOPPERS ASSEMBLY REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.

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 ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-23
MZ203827 (1) <Engine lifter (special tool MZ203827) is used>
Remove special tool MZ203827.

MB991453
AC207721AB

MB991895 (2) <Engine hanger (special tool MB991895) is used>

Remove special tool MB991895.

MB991454
AC209097AB

(3) <Engine hanger (special tool MB991928) is used>

MB991928
Remove the base hanger and the following tool.
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)

SLIDE BRACKET (HI)

MB991454
MB991930
MB991932
AC209108AB

3. Hold the engine assembly with a chain block, etc.

MB991453 OR 4. Place a garage jack against the engine oil pan with a piece
MB991454 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 and
cushion stoppers assembly.

AC100954AE
AC100954

<<E>> ENGINE ASSEMBLY REMOVAL

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

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11A-24 ENGINE MECHANICAL
ENGINE ASSEMBLY

INSTALLATION SERVICE POINTS

.

>>A<< ENGINE ASSEMBLY INSTALLATION

Install the engine assembly, being careful not to pinch the
MB991453 OR cables, hoses or wiring harness connectors.
MB991454

AC100954AE
AC100954

>>B<< ENGINE FRONT MOUNTING BRACKET AND

CUSHION STOPPERS ASSEMBLY INSTALLATION
ENGINE SIDE ENGINE SIDE
1. Arrow marks on the engine front mounting cushion stopper
should face the shown direction.
NOTE: Disregard F and R stamped as a shared part.
2. Place a garage jack against the engine oil pan with a piece
R F
of wood in between, and install the engine front mounting
R
F

bracket and cushion stoppers while adjusting the position of

ENGINE FRONT MOUNTING the engine.
CUSHION STOPPER
<VEHICLE <VEHICLE 3. Support the engine assembly with a garage jack.
REAR VIEW> FRONT VIEW> 4. Remove the chain block.
AC210426 AB
5. Use the following special tool as during removal to support
the engine.
MZ203827 (1) <Engine lifter (special tool MZ203827) is used>
Set special tool MZ203827.

MB991453
AC207721AB

MB991895 (2) <Engine hanger (special tool MB991895) is used>

Set special tool MB991895.

MB991454
AC209097AB

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 ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-25
SLIDE BRACKET (HI)
(3) <Engine hanger (special tool MB991928) is used>
a. Set following parts to the base hanger.
FRONT SIDE
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)

JOINT (90)
(MB991930)

FOOT (STADARD)
(MB991932) AC209516AB

b. Set special tool MB991928.

MB991928

SLIDE BRACKET (HI)

MB991454
MB991930
MB991932
AC209108AB

>>C<< TRANSAXLE ASSEMBLY INSTALLATION

1. Install the transaxle assembly. (Refer to GROUP 22A −
Transaxle Assembly P.22A-21.)
2. Remove from the car the 2 bolts, to assemble the radiator
support upper insulator.

AC107630AB

>>D<< O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
Do not let any engine oil get into the fuel rail.
1. Apply a small amount of new engine oil to the O-ring.
2. Turning the fuel high-pressure hose to the right and left,
install it to the fuel rail, 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 high-pressure hose and
check the O-ring for damage. After this, re-insert it to the fuel
rail 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 N⋅m (44 ± 9 in-lb)

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11A-26 ENGINE MECHANICAL
CRANKSHAFT PULLEY

CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600335

CAUTION
If the vehicle is equipped with the Bremboä disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operation Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Front • Drive Belt Tension Check (Refer to P.11A-7.)
Bumper P.51-2.) • Side Cover Installation
• Side Cover Removal • Under Cover Installation (Refer to GROUP 51, Front
Bumper P.51-2.)

25 ± 4 N·m
18 ± 3 ft-lb

AC210941AB

REMOVAL STEPS
<<A>> 1. DRIVE BELT
2. CRANK SHAFT DAMPER PULLEY
REMOVAL SERVICE POINT
.

<<A>> DRIVE BELT REMOVAL

The following operations will be needed due to the serpentine
drive system with the drive belt auto-tensioner.

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 ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-27
AUTO-
1. Securely insert the spindle handle or ratchet handle with a
TENSIONER 12.7mm (1/2-inch) insertion angle into the jig hole of the
auto-tensioner, and turn the auto-tensioner
counterclockwise until it hits the stopper.
CAUTION
To reuse the drive belt, draw an arrow indicating the rotat-
ing direction (to the right) on the back of the belt using
chalk, etc.
HOLE B
HOLE A
AC210996 AB

2. Align hole A with hole B, insert an L-shaped hexagon

wrench, etc. to fix and then remove the drive belt.

AUTO-
TENSIONER

L-SHAPED
HEXAGON
WRENCH
AC210998AB

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11A-28 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL

CAMSHAFT AND VALVE STEM SEAL

REMOVAL AND INSTALLATION
M1112006600147

CAUTION
• If the vehicle is equipped with the Bremboä disc brake, during maintenance, take care not to con-
tact the parts or tools to the caliper because the paint of caliper will be scratched.
• *Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Front • Valve Timing Belt Installation (Refer to P.11A-50.)
Bumper P.51-2.) • Accelerator Cable Installation (Refer to GROUP 17,
• Side Cover Removal Accelerator Cable and Pedal P.17-5.)
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Air Pipe C Installation (Refer to GROUP 15, Charge Air
Service − Engine Coolant Replacement P.14-18.) Cooler P.15-8.)
• Air Duct Removal (Refer to GROUP 15, Air Cleaner P.15- • Air Duct Installation (Refer to GROUP 15, Air Cleaner
7.) P.15-7.)
• Air Pipe C Removal (Refer to GROUP 15, Charge Air • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Cooler P.15-8.) Service − Engine Coolant Replacement P.14-18.)
• Accelerator Cable Removal (Refer to GROUP 17, Accel- • Drive Belt Tension Check (Refer to P.11A-7.)
erator Cable and Pedal P.17-5.) • Side Cover Installation
• Valve Timing Belt Removal (Refer to P.11A-50.) • Under Cover Installation (Refer to GROUP 51, Front
Bumper P.51-2.)
• Accelerator Cable Adjustment (Refer to GROUP 17, On-
vehicle Service − Accelerator Cable Check and Adjust-
ment P.17-4.)

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 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-29

3.0 ± 0.5 N·m 1 11 ± 1 N·m

27 ± 4 in-lb 98 ± 8 in-lb

10
11
3.5 ± 0.5 N·m
11 ± 1 N·m 31 ± 4 in-lb
11 ± 1 N·m
98 ± 8 in-lb 98 ± 8 in-lb

11 ± 1 N·m
5 98 ± 8 in-lb

12

7
10.5 ± 0.5 N·m 13
93 ± 4 in-lb

N 16
3 14
15 N 6
5.0 ± 1.0 N·m
44 ± 9 in-lb
9
2
8

AC211071AP

REMOVAL STEPS REMOVAL STEPS (Continued)

1. ROCKER COVER CENTER 7. ROCKER COVER BREATHER
COVER HOSE
• SPARK PLUG CABLES AND 8. CAMSHAFT POSITION SENSOR
IGNITION COILS (REFER TO CONNECTOR
GROUP 16, IGNITION COIL P.16- 9. GROUND TERMINAL
39.) 10. CONTROL WIRING HARNESS
2. HEATED OXYGEN SENSOR CONNECTION
(FRONT) CONNECTOR 11. VACUUM HOSE AND PIPE
3. CRANKSHAFT POSITION ASSEMBLY
SENSOR CONNECTOR 12. VACUUM PIPE BRACKET
4. CONTROL WIRING HARNESS >>M<< 13. ROCKER COVER
CONNECTION >>L<< 14. CAMSHAFT END SEAL
5. ROCKER COVER PCV HOSE 15. SPARK PLUG HOLE GASKETS
<<A>> >>N<< 6. RADIATOR UPPER HOSE >>K<< 16. ROCKER COVER GASKET
CONNECTION

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11A-30 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL

24
26
20 ± 1 N·m
14 ± 0.5 ft-lb
28 APPLY ENGINE OIL
27 29 TO ALL MOVING
25 PARTS BEFORE
30 INSTALLATION.
23

N 22
21

89 ± 9 N·m 11 ± 1 N·m
65 ± 7 ft-lb 98 ± 8 in-lb
34 17
22 ± 4 N·m
25 ± 4 N·m 33 16 ± 3 ft-lb
18 ± 3 ft-lb
20 19
35* 31
10 ± 2 N·m
36* 32 89 ± 17 in-lb
37*
N 38* 18 N

14 ± 1 N·m
120 ± 13 in-lb

35*
36*
37*
39* N
AZ
AC211072AZ

REMOVAL STEPS REMOVAL STEPS (Continued)

17. CAMSHAFT POSITION SENSOR >>F<< 27. CAMSHAFT BEARING CAPS,
SUPPORT COVER NUMBER 3
18. CAMSHAFT POSITION SENSOR >>F<< 28. CAMSHAFT BEARING CAPS,
SUPPORT COVER GASKET NUMBER 4
>>J<< 19. CAMSHAFT POSITION SENSING >>E<< 29. INLET CAMSHAFT
CYLINDER >>E<< 30. EXHAUST CAMSHAFT
>>I<< 20. CAMSHAFT POSITION SENSOR 31. ROCKER ARMS
SUPPORT >>D<< 32. ROCKER ARM LASH
<<B>> >>H<< 21. CAMSHAFT SPROCKETS ADJUSTERS
>>G<< 22. CAMSHAFT OIL SEALS 33. OIL DELIVERY BODY
>>F<< 23. CAMSHAFT BEARING CAPS, 34. SPARK PLUGS
FRONT <<C>> >>C<< 35. VALVE SPRING RETAINER
>>F<< 24. CAMSHAFT BEARING CAPS, LOCKS
REAR 36. VALVE SPRING RETAINERS
>>F<< 25. CAMSHAFT BEARING CAPS, >>B<< 37. VALVE SPRINGS
NUMBER 2 >>A<< 38. INLET VALVE STEM SEALS
>>F<< 26. CAMSHAFT BEARING CAPS, >>A<< 39. EXHAUST VALVE STEM SEALS
NUMBER 5

Required Special Tools:

• MD998713: Camshaft Oil Seal Installer • MD998772: Valve Spring Compressor
• MD998737: Valve Stem Seal Installer

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 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-31
REMOVAL SERVICE POINTS
.

<<A>> RADIATOR UPPER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.

MATING MARKS

AC200641AB

<<B>> CAMSHAFT SPROCKETS REMOVAL

1. Hold the hexagon part of the camshaft with a wrench.
2. Loosen the camshaft sprocket mounting bolts and remove
the camshaft sprocket.

AC201457AB

<<C>> VALVE SPRING RETAINER LOCKS REMOVAL

CAUTION
When removing valve spring retainer locks, leave the pis-
ton of each cylinder in the TDC (Top Dead Center) position.
The valve may fall into the cylinder if the piston is not
properly in the TDC position.
Use special tool MD998772 to compress the valve spring,
remove the valve spring retainer locks.
MD998772

AC201799 AB

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11A-32 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL

INSTALLATION SERVICE POINTS

.

>>A<< EXHAUST VALVE STEM SEALS/INLET VALVE STEM

SEALS INSTALLATION
1. Apply a small amount of engine oil to the valve stem seals.
CAUTION
• Valve stem seals cannot be reused.
• The special tool MD998737 must be used to install the
valve stem seal. Improper installation could result in oil
leaking past the valve guide.
2. Use special tool MD998737 to fill a new valve stem seal in
MD998737 the valve guide using the valve stem area as a guide.

VALVE
VALVE
STEM
SEAL
VALVE
GUIDE

AC107414 AC

GRAY GRAY GREEN

INLET SIDE EXHAUST SIDE

AC201542AB

NOTE: Check the valve stem seal color to identify the inlet
side or exhaust side.
.

>>B<< VALVE SPRINGS INSTALLATION

ROCKER ARM SIDE
The small end of the valve spring should face the rocker arm.

SMALL END

AC211159AB

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 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-33
>>C<< VALVE SPRING RETAINER LOCKS INSTALLATION
Use special tool MD998772 to compress the valve spring in the
same manner as removal.
MD998772

AC201799 AB

>>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 P.11B-32.)
.

>>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
Do not install wrong camshaft at the side of inlet or
exhaust. The exhaust camshaft has a slit at the rear sur-
face.
3. Install the camshaft to the cylinder head.
ENGINE FRONT

SLIT

EXHAUST
CAMSHAFT
AC201458AB

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11A-34 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL

>>F<< CAMSHAFT BEARING CAPS, NUMBER

4/CAMSHAFT BEARING CAPS, NUMBER 3/CAMSHAFT
BEARING CAPS, NUMBER 5/CAMSHAFT BEARING CAPS,
NUMBER 2/CAMSHAFT BEARING CAPS,
REAR/CAMSHAFT BEARING CAPS, FRONT
INSTALLATION
1. Set the dowel pin of the camshaft to the position as shown in
APPROXIMATELY 3˚ the illustration.
DOWEL PIN

INLET SIDE EXHAUST SIDE

AC201459AB

2. Since the shape of camshaft bearing caps number 2 − 5 is

identical, check the identification marks so that the bearing
BEARING CAP cap No., inlet side, or exhaust side cannot be mistaken to
NUMBER install to the direction as shown in the illustration.
ENGINE FRONT
Identification mark (engraved on the front and bearing
E4

caps number 2 − 5)
I: Inlet side
IDENTIFICATION
OF INLET SIDE E: Exhaust side
AND EXHAUST
SIDE AC201460 AB

3. Apply sealant to the positions (6 areas) of the upper side of

ENGINE FRONT
the cylinder head as shown in the illustration.
Specified sealant: 3Mä AAD Part No. 8672, 3Mä AAD
Part No. 8679/8678 or equivalent

AC201461AB

4. Position the camshaft bearing caps, rear in the direction as

shown in the illustration for installation.
5. Check the identification marks on the camshaft bearing
FRONT caps, front so that inlet side and exhaust side cannot be
ENGINE FRONT MARKING
mistaken in the same way as that of bearing caps number 2
− 5.
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 ± 1 N⋅m (14 ± 0.5 ft-lb)
AC201462AB

7. Ensure that the rocker arms are installed properly.

NOTE: Remove an excess of sealant completely.
.

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 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-35
>>G<< CAMSHAFT OIL SEALS INSTALLATION
1. Apply engine oil to the entire inner diameter of the oil seal
lip.
2. Use special tool MD998713 to press-fit the oil seals.

MD998713 AC102323AB

>>H<< CAMSHAFT SPROCKETS 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 N⋅m (65 ± 7 ft-lb)

AC201457AB

>>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: 3Mä AAD Part No. 8672, 3Mä AAD
Part No. 8679/8678 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.
φ 3 mm (0.12 in) AC201463AB
CAUTION
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.
Tightening torque: 14 ± 1 N⋅m (120 ± 13 in-lb)
.

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11A-36 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL

>>J<< CAMSHAFT POSITION SENSING CYLINDER

INSTALLATION
APPROXIMATELY 45˚ 1. Set the dowel pin of the exhaust camshaft to the position
DOWEL PIN (number 1 cylinder at compression TDC) as shown in the
VANE (SMALL) illustration.
NOTE: Use the force of the exhaust valve spring to rotate
counterclockwise.
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.
VANE (LARGE) 3. Tighten the camshaft position sensing cylinder mounting
AC201464AB
bolts to the specified torque.
Tightening torque: 22 ± 4 N⋅m (16 ± 3 ft-lb)
.

>>K<< ROCKER COVER GASKET INSTALLATION

1. Remove sealant remained on the rocker cover.
2. Apply sealant to the positions (4 areas) of the lower side of
the rocker cover as shown in the illustration.
Specified sealant: 3Mä AAD Part No. 8672, 3Mä AAD
Part No. 8679/8678 or equivalent
3. Install the rocker cover gasket to the rocker cover.

AC201465AB

>>L<< CAMSHAFT END SEAL INSTALLATION

Apply sealant to the positions of the camshaft end seal as
shown in the illustration and install to the cylinder head.
Specified sealant: 3Mä AAD Part No. 8672, 3Mä AAD
Part No. 8679/8678 or equivalent

10 mm
(0.39 in)

10 mm
(0.39 in)

CYLINDER HEAD
AC201468 AB

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 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-37
>>M<< ROCKER COVER INSTALLATION
1. Apply sealant to the positions of the rocker cover gasket (6
ENGINE FRONT
areas) as shown in the illustration.
Specified sealant: 3Mä AAD Part No. 8672, 3Mä AAD
Part No. 8679/8678 or equivalent
2. Install the rocker cover to the cylinder head.
3. Tighten the rocker cover mounting bolts to the specified
torque.
Tightening torque: 3.5 ± 0.5 N⋅m (31 ± 4 in-lb)
AC201469AB

>>N<< RADIATOR UPPER HOSE CONNECTION

1. Insert each hose as far as the projection of the water outlet
fitting.
PROJECTION
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

WATER OUTLET MATING

FITTING MARKS
AC200642 AB

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11A-38 ENGINE MECHANICAL
OIL PAN

OIL PAN
REMOVAL AND INSTALLATION
M1112002800495

Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Front • Starter Assembly Installation (Refer to GROUP 16, Starter
Bumper P.51-2.) Motor Assembly P.16-24.)
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser- • Front Exhaust Pipe Installation (Refer to GROUP 15,
vice − Engine Oil Replacement P.12-3.) Exhaust Pipe and Main Muffler P.15-23.)
• Front Axle Crossmember Bar Removal (Refer to GROUP • Front Axle Crossmember Bar Installation (Refer to
32, Engine Roll Stopper and Centermember P.32-6.) GROUP 32, Engine Roll Stopper and Centermember
• Front Exhaust Pipe Removal (Refer to GROUP 15, P.32-6.)
Exhaust Pipe and Main Muffler P.15-23.) • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-
• Starter Assembly Removal (Refer to GROUP 16, Starter vice − Engine Oil Replacement P.12-3.)
Motor Assembly P.16-24.) • Under Cover Installation (Refer to GROUP 51, Front
Bumper P.51-2.)

3
4 N

9.0 ± 1.0 N·m

80 ± 9 in-lb

2 N
11
22 ± 4 N·m N 5
16 ± 3 ft-lb
14 ± 1 N·m
N 7 120 ± 13 in-lb

6
42 ± 2 N·m N 9
31 ± 1 ft-lb
1
<BOLT, WASHER
9.0 ± 3.0 N·m 26 ± 5 N·m ASSEMBLED>
80 ± 26 in-lb 19 ± 4 ft-lb 9.0 ± 1.0 N·m
80 ± 9 in-lb
39 ± 5 N·m 8 10 <BOLT, FLANGE>
29 ± 3 ft-lb 10 ± 2 N·m
9.0 ± 3.0 N·m 89 ± 17 in-lb
80 ± 26 in-lb AC210942 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. FLYWHEEL HOUSING FRONT 7. ENGINE OIL COOLER TUBE
LOWER COVER GASKETS
2. GASKET 8. ENGINE OIL PAN DRAIN PLUG
3. OIL RETURN TUBE >>B<< 9. ENGINE OIL PAN DRAIN PLUG
4. OIL RETURN TUBE GASKET GASKET
>>C<< 5. OIL RETURN TUBE GASKET <<A>> >>A<< 10. ENGINE OIL PAN
6. ENGINE OIL COOLER RETURN 11. CYLINDER BLOCK BAFFLE
HOSE PLATE

Required Special Tool:

• MD998727: Oil Pan Remover

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 ENGINE MECHANICAL
OIL PAN
11A-39
REMOVAL SERVICE POINT
.

<<A>> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.
CAUTION
Perform this slowly to avoid deformation of the engine oil
pan flange.
MD998727 MD998727 2. Remove the engine oil pan using special tool MD998727.

AC102324 AB

INSTALLATION SERVICE POINTS

.

>>A<< ENGINE OIL PAN INSTALLATION

1. Remove sealant from the engine oil pan and cylinder block
surfaces.
2. Apply a bead of the sealant to the cylinder block mating
surface of the engine oil pan as shown.
Specified sealant: 3Mä AAD Part No. 8672, 8704, 3Mä
AAD Part No. 8679/8678 or equivalent
NOTE: Install the engine oil pan within 15 minutes after
applying sealant.
φ 4 mm 3. Assemble the engine oil pan to the cylinder block.
(0.16 in)
GROOVE BOLT HOLE CAUTION
PORTION PORTION AC211002 AB Then wait at least one hour. Never start the engine or let
engine oil or coolant touch the sealant surface during that
time.
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 N⋅m (80 ± 26 in-lb)

M6 × 8 mm

AC211004 AB

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11A-40 ENGINE MECHANICAL
OIL PAN

>>B<< ENGINE OIL PAN DRAIN PLUG GASKET

INSTALLATION
Replace the gasket with a new gasket. Install the new gasket in
the direction shown in the illustration.
ENGINE
OIL PAN
SIDE

AC102325 AE

>>C<< OIL RETURN TUBE GASKET INSTALLATION

Oil return tube gasket should be replaced with a new one, and
set the convex part to the position as shown in the illustration
for installation.
NOTE: There is no specific direction indicated for installing the
CONVEX PART
turbocharger side of the oil return tube gasket.

AC211005 AB

INSPECTION
M1112002900180
• Check the engine oil pan for cracks.
• Check the engine oil pan sealant-coated surface for dam-
age and deformation.

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 ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-41
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
M1112003100217

CAUTION
If the vehicle is equipped with the Bremboä disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.

132 ± 5 N·m
98 ± 3 ft-lb

6 N 5

N 3

3 6

1
(LIP SECTION) (LIP SECTION)
ENGINE OIL

AC210943AB

CRANKSHAFT FRONT OIL SEAL CRANKSHAFT REAR OIL SEAL

REMOVAL STEPS REMOVAL STEPS
• VALVE TIMING BELT, BALANCER • TRANSFER ASSEMBLY (REFER
TIMING BELT (REFER TO P.11A- TO GROUP 22A, TRANSFER
50.) ASSEMBLY P.22A-15.)
>>D<< 1. CRANKSHAFT BALANCER • TRANSAXLE ASSEMBLY (REFER
SHAFT DRIVE SPROCKET TO GROUP 22A, TRANSAXLE
2. CRANKSHAFT KEY ASSEMBLY P.22A-21.)
>>C<< 3. CRANKSHAFT FRONT OIL SEAL <<A>> >>B<< 4. FLYWHEEL BOLTS
5. FLYWHEEL ASSEMBLY
>>A<< 6. CRANKSHAFT REAR OIL SEAL
Required Special Tools:
• MB990938: Installer Bar • MD998776: Crankshaft Rear Oil Seal Installer
• MD998285: Crankshaft Front Oil Seal Guide • MD998781: Flywheel Stopper
• MD998375: Crankshaft Front Oil Seal Installer

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11A-42 ENGINE MECHANICAL
CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINT

.

<<A>> FLYWHEEL BOLTS REMOVAL

1. Use special tool MD998781 to secure the flywheel.
2. Remove the flywheel mounting bolts.

MD998781
AC211171AB

INSTALLATION SERVICE POINTS

.

>>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire inner
OIL SEAL
diameter of the oil seal lip.
2. Use special tools MB990938 and MD998776 to press-fit the
MB990938 oil seal.

(ENGINE OIL)

MD998776 CRANKSHAFT
AC102328 AB

>>B<< FLYWHEEL BOLTS INSTALLATION

1. Use special tool MD998781 to secure the flywheel in the
same manner as removal.
2. Tighten the flywheel mounting bolts to the specified torque.
Tightening torque: 132 ± 5 N⋅m (98 ± 3 ft-lb)

MD998781
AC211171AB

>>C<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire inner
CRANKSHAFT MD998375
diameter of the oil seal lip.
2. Apply a small amount of engine oil to the outer diameter of
special tool MD998285 and install it to the crankshaft.
(ENGINE OIL)
3. Use special tool MD998375 to press-fit the oil seal.

MD998285 OIL SEAL

(OIL APPLIED TO THE
CIRCUMFERENCE) AC102329AC

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 ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-43
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE
SPROCKET INSTALLATION
1. Clean or degrease the front case, the crankshaft and the
: CLEAN
crankshaft balancer shaft drive sprocket as shown.
: CLEAN AND DEGREASE NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket in the
direction shown in the illustration.
CRANKSHAFT

FRONT CASE
CRANKSHAFT
BALANCERSHAFT
DRIVE SPROCKET

ENGINE FRONT
AC211222 AB

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11A-44 ENGINE MECHANICAL
CYLINDER HEAD GASKET

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
M1112004000592

CAUTION
If the vehicle is equipped with the Bremboä disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operation Post-installation Operation
• Fuel Line Pressure Reduction [Refer to GROUP 13A, On- • Valve Timing Belt Installation (Refer to P.11A-50.)
vehicle Service − Fuel Pump Connector Disconnection • Starter Assembly Installation (Refer to GROUP 16, Starter
(How to Reduce Pressurized Fuel Lines) P.13A-765.] Motor Assembly P.16-24.)
• Under Cover Removal (Refer to GROUP 51, Front • Front Exhaust Pipe Installation (Refer to GROUP 15,
Bumper P.51-2.) Exhaust Pipe and Main Muffler P.15-23.)
• Side Cover Removal • Front Axle Crossmember Bar Installation (Refer to
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle GROUP 32, Engine Roll Stopper and Centermember
Service − Engine Coolant Replacement P.14-18.) P.32-6.)
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser- • Radiator Assembly Installation (Refer to GROUP 14,
vice − Engine Oil Replacement P.12-3.) Radiator P.14-22.)
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Rocker Cover Center Cover Installation (Refer to P.11A-
Tower Bar.) 28.)
• Air Cleaner Assembly Removal (Refer to GROUP 15, Air • Accelerator Cable Installation (Refer to GROUP 17,
Cleaner P.15-7.) Accelerator Cable and Pedal P.17-5.)
• Air Hose E, Air Pipe C and Air Hose D Removal (Refer to • Battery Installation
GROUP 15, Charge Air Cooler P.15-8.) • Air Hose E, Air Pipe C and Air Hose D Installation (Refer
• Battery Removal to GROUP 15, Charge Air Cooler P.15-8.)
• Accelerator Cable Removal (Refer to GROUP 17, Accel- • Air Cleaner Assembly Installation (Refer to GROUP 15,
erator Cable and Pedal P.17-5.) Air Cleaner P.15-7.)
• Rocker Cover Center Cover Removal (Refer to P.11A- • Strut Tower Bar Installation (Refer to GROUP 42, Strut
28.) Tower Bar.)
• Radiator Assembly Removal (Refer to GROUP 14, Radia- • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-
tor P.14-22.) vice − Engine Oil Replacement P.12-3.)
• Front Axle Crossmember Bar Removal (Refer to GROUP • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
32, Engine Roll Stopper and Centermember P.32-6.) Service − Engine Coolant Replacement P.14-18.)
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11A-7.)
Exhaust Pipe and Main Muffler P.15-23.) • Side Cover Installation
• Starter Assembly Removal (Refer to GROUP 16, Starter • Under Cover Installation (Refer to GROUP 51, Front
Motor Assembly P.16-24.) Bumper P.51-2.)
• Valve Timing Belt Removal (Refer to P.11A-50.) • Accelerator Cable Adjustment (Refer to GROUP 17, On-
vehicle Service − Accelerator Cable Check and Adjust-
ment P.17-4.)
• Fuel Leak Check

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 ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-45

5 4
10 1
1
17 6 5.0 ± 1.0 N·m
16 44 ± 9 in-lb
11
15

7 13
3 2 14
12
5.0 ± 1.0 N·m
19 18 44 ± 9 in-lb
9.0 ± 1.0 N·m
80 ± 9 in-lb

21
13 ± 1 N·m
115 ± 9 in-lb

(ENGINE OIL) N 20
AC211073 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. IGNITION COIL CONNECTORS 11. CAMSHAFT POSITION SENSOR
2. HEATED OXYGEN SENSOR CONNECTOR
(FRONT) CONNECTOR 12. ENGINE COOLANT
3. CRANKSHAFT POSITION TEMPERATURE GAUGE UNIT
SENSOR CONNECTOR CONNECTOR
4. MANIFOLD DIFFERENTIAL 13. ENGINE COOLANT
PRESSURE SENSOR TEMPERATURE SENSOR
CONNECTOR CONNECTOR
5. FUEL PRESSURE SOLENOID 14. CONTROL WIRING HARNESS
CONNECTOR AND TRANSAXLE WIRING
6. KNOCK SENSOR CONNECTOR HARNESS COMBINATION
7. EVAPORATIVE EMISSION 15. GROUND CABLE CONNECTION
PURGE SOLENOID CONNECTOR 16. EGR VACUUM REGULATOR
8. THROTTLE POSITION SENSOR SOLENOID VALVE CONNECTOR
CONNECTOR 17. EGR VACUUM REGULATOR
9. IDLE AIR CONTROL MOTOR SOLENOID VALVE AND
CONNECTOR BRACKET ASSEMBLY
10. INJECTOR CONNECTORS 18. BRAKE BOOSTER VACUUM
HOSE CONNECTION

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11A-46 ENGINE MECHANICAL
CYLINDER HEAD GASKET

REMOVAL STEPS (Continued)

19. ENGINE OIL DIPSTICK AND
DIPSTICK GUIDE
20. O-RING
21. PURGE HOSE CONNECTION

32
31
30
<COLD ENGINE>
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
58 ± 1 ft-lb → 0 in-lb → 15 ± 1 ft-lb → +90˚ → +90˚
5.0 ± 1.0 N·m
44 ± 9 in-lb

33 N (ENGINE OIL)
34

(ENGINE OIL)

35
24

23 N 36

29
31 ± 3 N·m
23 ± 2 ft-lb 35 ± 6 N·m
26 ± 4 ft-lb

22
22 ± 4 N·m 27 N
16 ± 3 ft-lb

26 9.0 ± 1.0 N·m

80 ±9 in-lb

25 N

28 N 14 ± 1 N·m
120 ± 13 in-lb

AC211074AB

REMOVAL STEPS REMOVAL STEPS (Continued)

22. GENERATOR BRACE BOLT • WATER OUTLET FITTING AND
23. BATTERY WIRING HARNESS THERMOSTAT CASE ASSEMBLY
CONNECTION (REFER TO GROUP 14, WATER
24. INLET MANIFOLD STAY HOSE AND PIPE P.14-29.)
25. GASKET • ROCKER COVER (REFER TO
26. OIL RETURN TUBE P.11A-28.)
27. OIL RETURN TUBE GASKET 30. WATER RETURN HOSE
>>D<< 28. OIL RETURN TUBE GASKET CONNECTION
29. TURBOCHARGER BRACKET

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 ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-47
REMOVAL STEPS (Continued)
31. FUEL RETURN LINE HOSE
CONNECTION
>>C<< 32. FUEL HIGH-PRESSURE HOSE
CONNECTION
>>C<< 33. O-RING
<<A>> >>B<< 34. CYLINDER HEAD BOLTS
35. CYLINDER HEAD ASSEMBLY
>>A<< 36. CYLINDER HEAD GASKET
Required Special Tool:
• MB991654: Cylinder Head Bolt Wrench (12)

REMOVAL SERVICE POINT

.

<<A>> CYLINDER HEAD BOLTS REMOVAL

Using special tool 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,
MB991654 then remove it while holding it by using a magnet.

ENGINE FRONT

3 5 10 8 2

1 7 9 6 4

AC201623AB

INSTALLATION SERVICE POINTS

.

>>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION
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.

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11A-48 ENGINE MECHANICAL
CYLINDER HEAD GASKET

2. Assemble to the cylinder block so the cylinder head gasket

identification mark "63" is at the top surface and on the
exhaust side.

IDENTIFICATION
MARK "63"

EXHAUST SIDE

AC107217AC

>>B<< CYLINDER HEAD BOLTS INSTALLATION

1. Check that the nominal length of each cylinder head bolt
(ENGINE OIL) meets the limit. If it exceeds the limit, replace the bolt with a
new one.
Limit (A): 99.4 mm (3.91 inches)
2. Apply a small amount of engine oil to the thread of the bolts
and to the washers.
A

AC102537AB

3. Use special tool MB991654 to tighten the cylinder head

bolts as follows:
(1) Tighten the cylinder head bolts to 78 ± 2 N⋅m (58 ± 1 ft-lb)
in the order shown.
(2) Loosen the bolts fully in the reverse order of that shown.
MB991654 (3) Tighten the cylinder head bolts to 20 ± 2 N⋅m (15 ± 1 ft-lb)
in the order shown.

ENGINE FRONT

8 6 1 3 9

10 4 2 5 7

AC201625AB

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 ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-49
STEP (4) STEP (5)
(4) Apply a paint mark to the heads of the cylinder head bolts
and cylinder head, then tighten 90 degree angle as
90˚ 90˚ shown.
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.
PAINT MARKING PAINT MARKING Then check to see that the paint mark on the head of the
cylinder head bolts and the paint mark on the cylinder
AC102331AB 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.
.

>>C<< O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
Do not let any engine oil get into the fuel rail.
1. Apply a small amount of new engine oil to the O-ring.
2. Turning the fuel high-pressure hose to the right and left,
install it to the fuel rail, 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 high-pressure hose and
check the O-ring for damage. After this, re-insert it to the fuel
rail 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 N⋅m (44 ± 9 in-lb)
.

>>D<< OIL RETURN TUBE GASKET INSTALLATION

Oil return tube gasket should be replaced with a new one, and
set the convex part to the position as shown in the illustration
for installation.
NOTE: There is no specific direction indicated for installing the
CONVEX PART
turbocharger side of the oil return tube gasket.

AC211005 AB

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11A-50 ENGINE MECHANICAL
TIMING BELT

TIMING BELT
REMOVAL AND INSTALLATION
M1112004300593

CAUTION
If the vehicle is equipped with the Bremboä disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operation Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Front • Front Exhaust Pipe Installation (Refer to GROUP 15,
Bumper P.51-2.) Exhaust Pipe and Main Muffler P.15-23.)
• Side Cover Removal • Front Axle Crossmember Bar Installation (Refer to
• Crankshaft Shaft Damper Pulley Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember
P.11A-26.) P.32-6.)
• Front Axle Crossmember Bar Removal (Refer to GROUP • Crankshaft Shaft Damper Pulley Installation (Refer to
32, Engine Roll Stopper and Centermember P.32-6.) P.11A-26.)
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11A-7.)
Exhaust Pipe and Main Muffler P.15-23.) • Side Cover Installation
• Under Cover Installation (Refer to GROUP 51, Front
Bumper P.51-2.)

21 ± 4 N·m
16 ± 2 ft-lb
8
7
1 48 ± 5 N·m
11 ± 1 N·m 36 ± 3 ft-lb
98 ± 8 in-lb

8.8 ± 1.0 N·m

78 ± 9 in-lb
23 ± 3 N·m
17 ± 2 ft-lb 9
4
44 ± 10 N·m
33 ± 7 ft-lb

5 6

79 ± 5 N·m
3
24 ± 4 N·m
18 ± 3 ft-lb 59 ± 3 ft-lb

11 ± 1 N·m 9.0 ± 1.0 N·m

98 ± 8 in-lb 80 ± 9 in-lb
AC211075 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. TIMING BELT UPPER COVER 4. AUTO-TENSIONER
2. WATER PUMP PULLEY 5. TIMING BELT LOWER COVER
3. IDLER PULLEY

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 ENGINE MECHANICAL
TIMING BELT
11A-51
REMOVAL STEPS (Continued)
• ENGINE FRONT MOUNTING
BRACKET (REFER TO GROUP
32, ENGINE MOUNT P.32-3.)
>>G<< • VALVE TIMING BELT TENSION
ADJUSTMENT
<<A>> >>F<< 6. VALVE TIMING BELT
>>E<< 7. TIMING BELT TENSIONER
PULLEY
8. TIMING BELT TENSIONER ARM
>>D<< 9. TIMING BELT TENSIONER
ADJUSTER

12 ± 2 N·m
102 ± 22 in-lb
22 ± 4 N·m 11
16 ± 3 ft-lb

14
35 ± 6 N·m
26 ± 4 ft-lb

10 22 ± 4 N·m
19 16 ± 3 ft-lb
18
19 ± 3 N·m
14 ± 2 ft-lb 40 ± 5 N·m
12 30 ± 3 ft-lb

(ENGINE OIL)
49 ± 9 N·m
36 ± 7 ft-lb 13 49 ± 9 N·m
36 ± 7 ft-lb
15
17
16 8.8 ± 1.0 N·m
167 N·m 78 ± 9 in-lb
123 ft-lb
AC211076 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

10. POWER STEERING PRESSURE 15. CRANKSHAFT POSITION
SWITCH CONNECTOR SENSOR
11. POWER STEERING OIL PUMP <<C>> >>C<< 16. CRANKSHAFT CAMSHAFT
HEAT PROTECTOR DRIVE SPROCKET
<<B>> 12. POWER STEERING OIL PUMP, >>C<< 17. CRANKSHAFT ANGLE SENSING
BRACKET AND RESERVOIR BLADE
ASSEMBLY >>B<< • BALANCER TIMING BELT
13. POWER STEERING OIL PUMP TENSION ADJUSTMENT
BRACKET >>A<< 18. BALANCER TIMING BELT
14. TIMING BELT IDLER PULLEY TENSIONER
<<D>> >>A<< 19. BALANCER TIMING BELT

Required Special Tools:

• MB991367: Special Spanner • MD998738: Adjusting Bolt
• MB991385: Pin • MD998767: Tensioner Wrench

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11A-52 ENGINE MECHANICAL
TIMING BELT

REMOVAL SERVICE POINTS

.

<<A>> VALVE TIMING BELT REMOVAL

CAUTION
Never turn the crankshaft counterclockwise.
TIMING MARK 1. Turn the crankshaft clockwise, align each timing mark to set
number 1 cylinder to TDC of its compression stroke.

AC102487AC

2. Remove the timing belt under cover rubber plug and then
set the special tool MD998738.
MD998738
CAUTION
The special tool MD998738 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 MD998738 may bend.
TIMING BELT
UNDER COVER
AC211534AB

3. Screw in the special tool MD998738 until it comes in contact

TIMING BELT with the timing belt tensioner arm.
TENSIONER ARM

MD998738

AC107289 AB

4. Gradually screw in the special tool MD998738. Then align

the timing belt tensioner adjuster rod set hole A with the
A timing belt tensioner adjustor cylinder set hole B.
B

AC102775AB

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 ENGINE MECHANICAL
TIMING BELT
11A-53
TIMING BELT 5. Insert a wire, [Link] the set hole.
TENSIONER PULLEY CAUTION
MOUNTING BOLT
To reuse the valve timing belt, draw an arrow indicating the
rotating direction (clockwise) on the back of the belt using
WIRE chalk.
6. After removal of adjusting bolt special tool MD998738,
loosen the timing belt tensioner pulley mounting bolt and
remove the valve timing belt.

AC107185AB

<<B>> POWER STEERING OIL PUMP, BRACKET AND

RESERVOIR 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
1. Hold the crankshaft camshaft drive sprocket with special
CRANKSHAFT tools MB991367 and MB991385.
CAMSHAFT MB991385
DRIVE 2. Loosen the crankshaft pulley center bolt and remove the
SPROCKET crankshaft camshaft drive sprocket.

MB991367

AC102332AB

<<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 1. Ensure that the crankshaft balancer shaft drive sprocket
timing marks and balancer shaft sprocket timing marks are
BELT TENSION SIDE
aligned.
TIMING 2. Install the balancer timing belt on the crankshaft balancer
TIMING MARK shaft drive sprocket and balancer shaft sprocket. There
MARK should be no slack on the tension side.

CRANKSHAFT
BALANCERSHAFT
DRIVE SPROCKET AC102689AB

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11A-54 ENGINE MECHANICAL
TIMING BELT

3. Assemble and temporarily fix the center of the pulley of the

CENTER OF THE balancer timing belt tensioner so that it is at the top left from
MOUNTING BOLT the center of the assembling bolt, and the pulley flange is at
the front-side of the engine.
4. Adjust the balancer timing belt tension.

CENTER OF
THE PULLEY
AC102690 AB

>>B<< BALANCER TIMING BELT TENSION ADJUSTMENT

CAUTION
When tightening the mounting bolts, ensure that the ten-
sioner does not rotate with the bolts. Allowing it to rotate
with the bolts can cause excessive tension of the belt.
1. With your fingers, lift the balancer timing belt tensioner in the
BELT TENSION SIDE direction of the arrow. Apply pressure of [3.0 ± 0.4 N⋅m (26 ±
4 in-lb)] to the balancer timing belt. Tighten the assembling
bolt to the standard torque. Then, fix the balancer timing belt
tensioner.
Tightening torque: 19 ± 3 N⋅m (14 ± 2 ft-lb)

AC102691AB

BALANCERSHAFT SPROCKET 2. Turn the crankshaft clockwise two turns to set number 1
cylinder to TDC of its compression stroke and check that the
sprocket timing marks are aligned.
TIMING
TIMING MARK
MARK

CRANKSHAFT
BALANCERSHAFT
DRIVE SPROCKET AC102689AB

3. Apply a pressure of approximately 100N (22 pounds) at the

APPROXIMATELY center (arrow area) between the sprocket as shown, then
100 N (22 lb) inspect whether the belt deflection is within the standard
value.
Standard value:
At adjustment: 5 − 7 mm (0.20 − 0.27 inch)
DEFLECTION At replacement: 5 − 7 mm (0.20 − 0.27 inch)
4. If not within the standard value, adjust the belt tension again.
AC102693AB

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 ENGINE MECHANICAL
TIMING BELT
11A-55
>>C<< CRANKSHAFT ANGLE SENSING
BLADE/CRANKSHAFT CAMSHAFT DRIVE SPROCKET
INSTALLATION
1. Clean or degrease the crankshaft, the crankshaft angle
: CLEAN sensing blade, the crankshaft camshaft drive sprocket and
: CLEAN AND DEGREASE crankshaft pulley washer as shown.
: APPLY ENGINE OIL NOTE: Also clean the degreased surfaces.
2. Install the crankshaft angle sensing blade and crankshaft
CRANKSHAFT PULLEY camshaft drive sprocket in the direction shown.
CENTER BOLT
3. Place the larger chamfer side of the crank shaft pulley
CRANKSHAFT CAMSHAFT washer in the direction shown and then assemble on the
DRIVE SPROCKET crankshaft pulley center bolt.
CRANKSHAFT 4. Apply some engine oil to the crankshaft pulley center bolt
bearing surface and screw.

CRANKSHAFT
PULLEY WASHER CRANKSHAFT
ANGLE SENSING
BLADE
ENGINE FRONT
AC211535 AB

5. Hold the crankshaft camshaft drive sprocket with special

CRANKSHAFT tools MB991367 and MB991385 in the same manner as
CAMSHAFT MB991385
removal.
DRIVE
SPROCKET 6. Tighten the crankshaft pulley center bolts to the specified
torque.
Tightening torque: 167 N⋅m (123 ft-lb)
MB991367

AC102332AB

>>D<< TIMING BELT TENSIONER ADJUSTER

INSTALLATION
1. Install according to the following procedures when the timing
belt tensioner adjuster rod is fully extended.

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11A-56 ENGINE MECHANICAL
TIMING BELT

CAUTION
If the compression is too fast, the procedure may damage
the rod.
B
(1) Slowly compress the timing belt tensioner adjuster rod
A 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.

AC102334AB

(2) Insert a wire. into the aligned set hole.

WIRE
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 standard torque.
Do not remove the wire or pin until the tension of the valve
timing belt is adjusted.
Tightening torque: 23 ± 3 N⋅m (17 ± 2 ft-lb)
AC102335AB
.

>>E<< TIMING BELT TENSIONER PULLEY INSTALLATION

Temporarily tighten the timing belt tensioner pulley as shown.

TIMING BELT TENSIONER

PULLEY HOLE
AC102336AB

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 ENGINE MECHANICAL
TIMING BELT
11A-57
>>F<< VALVE TIMING BELT INSTALLATION
1. Align the timing marks on the camshaft sprocket, crankshaft
TIMING MARK camshaft drive sprocket and engine oil pump sprocket.

CAMSHAFT
SPROCKET

CRANKSHAFT
CAMSHAFT
DRIVE SPROCKET ENGINE OIL
PUMP SPROCKET

TIMING MARK
TIMING MARK AC102486AD

2. After aligning the timing marks of the engine oil pump

PLUG
sprocket, remove the cylinder block plug and insert a Phillips
screw driver with a shaft diameter of 8 mm (0.31 inch)
through the plug hole to check that the shaft of the screw
driver can be inserted for 60 mm (2.36 inches) or more. If
the screw driver makes contact with the balancer shaft and
60 mm (2.36 in)
OR MORE
can be inserted for only 20 − 25 mm (0.79 − 0.98 inch), turn
the engine oil pump sprocket for one round and align timing
marks again to check that screw driver can be inserted for
60 mm or more. Do not take the screw driver out before
STARTER completing installation of the valve timing belt.
8 mm
3. Install the valve timing belt as follows:
(0.31 in)
BALANCER
SHAFT

AC211545 AB

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11A-58 ENGINE MECHANICAL
TIMING BELT

INLET SIDE EXHAUST SIDE

(1) Pass the valve timing belt around the crankshaft
CAMSHAFT CAMSHAFT camshaft drive sprocket, the engine oil pump sprocket
SPROCKET SPROCKET and the timing belt idler pulley in that order.

TIMING
BELT
IDLER
TIMING BELT
PULLEY
TENSIONER
PULLEY

CRANKSHAFT ENGINE
CAMSHAFT OILPUMP
DRIVE SPROCKET
SPROCKET

AC102488AD

(2) Pass the valve timing belt around the exhaust-side

camshaft sprocket, and hold the valve timing belt with
PAPER paper clips.
CLIP

AC211558AB

(3) Use two wrenches to align the timing mark on the rocker
TIMING MARK cover with that on the camshaft sprocket. Pass the valve
timing belt around the inlet-side camshaft sprocket.

AC211559AB

(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 rota-
tion (counterclockwise rotation) pressure to the cam shaft
PAPER
CLIP 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.
AC211560 AB

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 ENGINE MECHANICAL
TIMING BELT
11A-59
4. Turn the timing belt tensioner in the direction shown using
special tool 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.

MD998767

AC102694 AB

6. Remove the Phillips screw driver inserted in Step 2 above,

then assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified torque.
Tightening torque: 30 ± 3 N⋅m (23 ± 2 ft-lb)
8. Adjust the valve timing belt tension.

SCREW
DRIVER
PLUG

AC211564AB

>>G<< VALVE TIMING BELT TENSION ADJUSTMENT

1. Set special tool MD998738 when removing the valve timing
belt.
MD998738
CAUTION
Always screw in special tool MD998738 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 MD998738 until the wire or
TIMING BELT
UNDER COVER
pin inserted in the timing belt tensioner adjuster lightly
moves.
AC211534AB
3. Turn the crankshaft 1/4 turn counterclockwise.
4. Turn the crankshaft in the clockwise direction until you align
each timing mark to set number 1 cylinder to TDC of its
compression stroke.
5. Loosen the timing belt tensioner pulley mounting bolt.

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11A-60 ENGINE MECHANICAL
TIMING BELT

CAUTION
When tightening the mounting bolts, ensure that the timing
belt tensioner pulley does not rotate with the bolts. Allow-
ing it to rotate with the bolts can cause deficient tension of
the belt.
6. With special tool MD998767 and torque wrench, apply
tension torque [3.5 N⋅m(31 in-lb)], and tighten the timing belt
tensioner pulley mounting bolt to the specified torque.
Tightening torque: 48 ± 5 N⋅m (36 ± 3 ft-lb)

MD998767

AC102695AB

7. Remove wire or pin inserted to timing belt tensioner.

WIRE

AC102776AB

8. Remove the special tool MD998738, and install the rubber

plug to the timing belt under cover.
MD998738
9. Rotate the crankshaft clockwise two turns, and leave it for
about 15 minutes.

TIMING BELT
UNDER COVER
AC211534AB

[Link] 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.
WIRE

AC102776AB

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 ENGINE MECHANICAL
TIMING BELT
11A-61
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 (0.15 − 0.17 inch)
A
[Link] wire or pin cannot be easily pulled out, repeat Step 1
through Step 9 to reach proper valve timing belt tension.
CAUTION
TIMING BELT
TENSIONER
Always check the tightening torque of the crank shaft pul-
ADJUSTER ley center bolt when turning the crack shaft pulley center
AC102338AB bolt counterclockwise. Re-tighten if it is loose.

TIMING MARK [Link] again that the timing marks on sprockets are aligned.

CAMSHAFT
SPROCKET

CRANKSHAFT
CAMSHAFT
DRIVE SPROCKET ENGINE OIL
PUMP SPROCKET

TIMING MARK
TIMING MARK
AC201411AB

INSPECTION
M1112004400299

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.
98 – 196 N 3. Hold the timing belt tensioner adjuster by hand, and press
(22 – 44 lb) MOVEMENT the top end of the rod onto the metal (e.g. cylinder block)
under a pressure of 98 − 196 N (22 − 44 pounds) to
A B measure the movement of the rod.
Standard value: Within 1 mm (0.039 inch)
A: Length when it is free (not pressed)
TIMING BELT B: Length when it is pressed
ROD
TENSIONER A − B: Movement
ADJUSTER
4. If the measured value is out of the standard value, replace
AC102339AB the timing belt tensioner adjuster.

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11A-62 ENGINE MECHANICAL
TIMING BELT

BALANCER TIMING BELT TENSION CHECK

Check the balancer timing belt tension as follows:
1. Apply a pressure of approximately 100N (22 pounds) at the
APPROXIMATELY center (arrow area) between the sprocket as shown then
100 N (22 lb) inspect whether the deflection is within the standard value.
Standard value: 5 − 10 mm (0.20 − 0.39 inch)
2. If not within the standard value, adjust the belt tension.
DEFLECTION (Refer to P.11A-50.)

AC102693AB

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 ENGINE MECHANICAL
SPECIFICATIONS
11A-63
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1111003800280

ITEM SPECIFICATION
Camshaft and valve stem seal
Camshaft bearing cap bolt 20 ± 1 N⋅m (14 ± 0.5 ft-lb)
Camshaft position sensing cylinder bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Camshaft position sensor support bolt 14 ± 1 N⋅m (120 ± 13 in-lb)
Camshaft position sensor support cover bolt 10 ± 2 N⋅m (89 ± 17 in-lb)
Camshaft sprocket bolt 89 ± 9 N⋅m (65 ± 7 ft-lb)
Control wiring harness bracket bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Ground terminal bolt (control wiring harness) 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Heated oxygen sensor (front) bolt 10.5 ± 0.5 N⋅m (93 ± 4 in-lb)
Oil delivery body bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Rocker cover bolt 3.5 ± 0.5 N⋅m (31 ± 4 in-lb)
Rocker cover center cover bolt 3.0 ± 0.5 N⋅m (27 ± 4 in-lb)
Spark plug 25 ± 4 N⋅m (18 ± 3 ft-lb)
Vacuum pipe bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Vacuum pipe bracket bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Crankshaft oil seal
Flywheel bolt 132 ± 5 N⋅m (98 ± 3 ft-lb)
Crankshaft pulley
Crankshaft damper pulley bolt 25 ± 4 N⋅m (18 ± 3 ft-lb)
Cylinder head gasket
Cylinder head bolt <Cold engine> 78 ± 2 N⋅m → 0 N⋅m → 20 ± 2
N⋅m → +90° → +90°
(58 ± 1 ft-lb → 0 in-lb → 15 ± 1
ft-lb → +90° → +90°)
EGR solenoid valve and bracket assembly bolt 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Engine oil dipstick guide bolt 13 ± 1 N⋅m (115 ± 9 in-lb)
Fuel high-pressure hose bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Generator brace bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Ground cable bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Ground terminal bolt (control wiring harness) 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Inlet manifold stay bolt 31 ± 3 N⋅m (23 ± 2 ft-lb)
Oil return tube bolt (bolt, flange) M6 14 ± 1 N⋅m (120 ± 13 in-lb)
Oil return tube bolt (bolt, washer assembled) M6 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Turbocharger bracket bolt 35 ± 6 N⋅m (26 ± 4 ft-lb)
Engine assembly
Engine front mounting bracket and cushion stopper nut (flange M10 67 ± 7 N⋅m (50 ± 5 ft-lb)
nut, self locking)

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11A-64 ENGINE MECHANICAL
SPECIFICATIONS

ITEM SPECIFICATION
Engine front mounting bracket and cushion stopper nut (nut, M12 98 ± 10 N⋅m (73 ± 7 ft-lb)
assembled)
Engine oil cooler line eye bolt 42 ± 2 N⋅m (31 ± 1 ft-lb)
Fuel high-pressure hose bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Generator terminal nut 14 ± 3 N⋅m (124 ± 26 in-lb)
Ground cable bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Ground terminal bolt (battery wiring harness) 26 ± 5 N⋅m (19 ± 4 ft-lb)
Ground terminal bolt (control wiring harness) 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Power steering oil pressure hose bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Power steering oil pump and bracket assembly bolt M8 22 ± 4 N⋅m (16 ± 3 ft-lb)
M10 40 ± 5 N⋅m (30 ± 3 ft-lb)
Power steering oil pump heat protector bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Power steering oil reservoir bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Turbocharger wastegate actuator bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Oil pan
Cylinder block baffle bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Engine oil cooler line eye bolt 42 ± 2 N⋅m (31 ± 1 ft-lb)
Engine oil pan bolt 9.0 ± 3.0 N⋅m (80 ± 26 in-lb)
Engine oil pan drain plug 39 ± 5 N⋅m (29 ± 3 ft-lb)
Flywheel housing front lower cover bolt (bolt, flange) M6 10 ± 2 N⋅m (89 ± 17 in-lb)
Flywheel housing front lower cover bolt (bolt, flange) M10 26 ± 5 N⋅m (19 ± 4 ft-lb)
Flywheel housing front lower cover bolt (bolt, washer M6 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
assembled)
Oil return tube bolt (bolt, flange) M6 14 ± 1 N⋅m (120 ± 13 in-lb)
Oil return tube bolt (bolt, washer assembled) M6 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Timing belt
Auto-tensioner bolt (bolt, flange) M8 24 ± 4 N⋅m (18 ± 3 ft-lb)
Auto-tensioner bolt (bolt, washer assembled) M10 44 ± 10 N⋅m (33 ± 7 ft-lb)
Balancer timing belt tensioner bolt 19 ± 3 N⋅m (14 ± 2 ft-lb)
Crankshaft position sensor bolt 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)
Crankshaft pulley center bolt 167 N⋅m (123 ft-lb)
Cylinder block plug 30 ± 3 N⋅m (23 ± 2 ft-lb)
Idler pulley bolt 79 ± 5 N⋅m (59 ± 3 ft-lb)
Power steering oil pressure hose bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Power steering oil pump and bracket assembly bolt M8 22 ± 4 N⋅m (16 ± 3 ft-lb)
M10 40 ± 5 N⋅m (30 ± 3 ft-lb)
Power steering oil pump bracket bolt 49 ± 9 N⋅m (36 ± 7 ft-lb)
Power steering oil pump heat protector bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Power steering oil reservoir bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Timing belt idler pulley bolt 35 ± 6 N⋅m (26 ± 4 ft-lb)

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 ENGINE MECHANICAL
SPECIFICATIONS
11A-65
ITEM SPECIFICATION
Timing belt lower cover bolt (bolt, flange) M6 11 ± 1 N⋅m (98 ± 8 in-lb)
Timing belt lower cover bolt (bolt, washer assembled) M6 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Timing belt tensioner adjuster bolt 23 ± 3 N⋅m (17 ± 2 ft-lb)
Timing belt tensioner arm bolt 21 ± 4 N⋅m (16 ± 2 ft-lb)
Timing belt tensioner pulley bolt 48 ± 5 N⋅m (36 ± 3 ft-lb)
Timing belt upper cover bolt (bolt, flange) M6 11 ± 1 N⋅m (98 ± 8 in-lb)
Water pump pulley bolt 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)

SERVICE SPECIFICATIONS
M1111000300510

ITEM STANDARD LIMIT

VALUE
Drive belt tension Vibration frequency Hz 110 − 144 −
(Reference)
Tension N (Reference) 245 − 412 −
Actual ignition timing at idle Approximately −
5° BTDC
Basic ignition timing at idle 5°BTDC ± 3° −
CO content% 0.5 or less −
HC contents ppm 100 or less −
Curb idle speed r/min 850 ± 100 −
Compression pressure (250 r/min) kPa (psi) 1,128 (163) Minimum 951
(138)
Intake manifold vacuum at curb idle kPa (in Hg) − Minimum 51
(15)
Cylinder head bolt nominal length mm (in) − 99.4 (3.91)
Balancer timing belt tension (When Deflection mm (in) 5 − 7 (0.20 − −
adjusted) 0.27)
Balancer timing belt tension (When Deflection mm (in) 5 − 7 (0.20 − −
replaced) 0.27)
Balancer timing belt tension (When Deflection mm (in) 5 − 10 (0.20 − −
checked) 0.39)
Timing belt tensioner adjuster rod protrusion amount mm (in) 3.8 − 4.5 (0.15 − −
0.17)
Timing belt tensioner adjuster rod movement mm (in) Within 1 (0.039) −

SEALANTS
M1111000500332

ITEM SPECIFIED SEALANT

Camshaft end seal Specified sealant: 3Mä AAD Part No. 8672, 3Mä
Camshaft position sensor support AAD Part No. 8679/8678 or equivalent
Cylinder head

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11A-66 ENGINE MECHANICAL
SPECIFICATIONS

ITEM SPECIFIED SEALANT

Engine oil pan Specified sealant: 3Mä AAD Part No. 8672, 8704,
3Mä AAD Part No. 8679/8678 or equivalent
Rocker cover Specified sealant: 3Mä AAD Part No. 8672, 3Mä
Rocker cover gasket AAD Part No. 8679/8678 or equivalent

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 11B-1

GROUP 11B

ENGINE OVERHAUL
CONTENTS

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-2 ROCKER ARMS AND CAMSHAFT . . 11B-29

REMOVAL AND INSTALLATION . . . . . . . . 11B-29
GENERATOR AND IGNITION INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-32
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-5
REMOVAL AND INSTALLATION . . . . . . . . 11B-5 CYLINDER HEAD AND VALVES. . . . 11B-35
REMOVAL AND INSTALLATION . . . . . . . . 11B-35
SOLENOID AND VACUUM HOSE . . 11B-6 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-40
REMOVAL AND INSTALLATION . . . . . . . . 11B-6
OIL PAN AND OIL PUMP. . . . . . . . . . 11B-44
TIMING BELT. . . . . . . . . . . . . . . . . . . 11B-7 REMOVAL AND INSTALLATION . . . . . . . . 11B-44
REMOVAL AND INSTALLATION . . . . . . . . 11B-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-52
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11B-19
PISTON AND CONNECTING ROD . . 11B-54
FUEL AND EMISSION PARTS . . . . . 11B-21 REMOVAL AND INSTALLATION . . . . . . . . 11B-54
REMOVAL AND INSTALLATION . . . . . . . . 11B-21 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-61

INTAKE MANIFOLD . . . . . . . . . . . . . 11B-23 CRANKSHAFT AND CYLINDER

REMOVAL AND INSTALLATION . . . . . . . . 11B-23 BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11B-63
REMOVAL AND INSTALLATION . . . . . . . . 11B-63
EXHAUST MANIFOLD. . . . . . . . . . . . 11B-25 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-67
REMOVAL AND INSTALLATION . . . . . . . . 11B-25
SPECIFICATIONS . . . . . . . . . . . . . . . 11B-69
WATER PUMP & WATER HOSE . . . 11B-27 FASTENER TIGHTENING
REMOVAL AND INSTALLATION . . . . . . . . 11B-27 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 11B-69
GENERAL SPECIFICATIONS . . . . . . . . . . 11B-71
SERVICE SPECIFICATIONS . . . . . . . . . . . 11B-72
SEALANTS AND ADHESIVES . . . . . . . . . . 11B-74
11B-2 ENGINE OVERHAUL
SPECIAL TOOLS

SPECIAL TOOLS
M1113000600443

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MD998781 General service tool Supporting flywheel and drive
Flywheel stopper plate

D998781

MD998778 General service tool Removal of crankshaft sprocket

Crankshaft sprocket
puller

MD998785 MD998785 Supporting counterbalance

Sprocket stopper shaft sprocket

MD998767 MD998752-01 Adjustment of timing belt

Tension pulley wrench tension

D998767

MD998738 General service tool • Holding the auto-tensioner

Adjusting screw • Timing belt tension
adjustment

D998738

Md998713 MD998713-01 Installation of camshaft oil seal

Camshaft Oil Seal
Installer

D998713

MD998442 General service tool Air bleed of lash adjuster

Air bleed wire

MB991654 General service tool Removal and installation of

Cylinder head bolt cylinder head bolt
wrench (12)

B991654

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 ENGINE OVERHAUL
SPECIAL TOOLS
11B-3
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MD998735 MD998735-01 Compression of valve spring
Valve spring compressor

MD998772 General service tool Compression of valve spring

Valve spring compressor

MD998737 MD998737-01 Installation of valve steam seal

Valve steam seal
installer

MD998727 MD998727-01 Removal of oil pan

Oil pan remover

D998727

MD998162 MD998162-01 Removal and installation of

Plug wrench Use with front case cap plug
MD998783

MD998783 General service tool

Plug wrench retainer

MD998371 MD998371-01 Removal of counterbalance

Silent shaft bearing shaft front bearing
puller

MD998372 MD998372-01 Removal of counterbalance

Silent shaft bearing shaft rear bearing
puller

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11B-4 ENGINE OVERHAUL
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991603 − Removal and installation of rear
Bearing installer stopper bearing

MD998705 MD998373-01 Use Installation of counterbalance

Silent shaft bearing with MB990938-01 shaft bearing
installer

MD998285 MD998285-01 Installation of crankshaft front

Crankshaft front oil seal oil seal
guide

D998285

MD998375 MD998375-01
Crankshaft front oil seal
installer

MD998780 MIT216941 Removal and installation of

Piston pin setting tool piston pin

MB990938 MB990938-01 Installation of crankshaft rear oil

Handle seal

B990938

MD998776 MD998376-01
Crankshaft rear oil seal
installer

D998776

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 ENGINE OVERHAUL
GENERATOR AND IGNITION SYSTEM
11B-5
GENERATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION
M1113001000370

11 3.0 ± 0.5 N·m

27 ± 3 in-lb
1

10 ± 2 N·m
2 89 ± 17 in-lb
12

13

13 ± 1 N·m
14
115 ± 8 in-lb 25 ± 5 N·m
19 ± 3 ft-lb

3
44 ± 10 N·m
9 33 ± 6 ft-lb

22 ± 4 N·m
8
17 ± 2 ft-lb

7
6

44 ± 10 N·m
33 ± 6 ft-lb 23 ± 3 N·m
17 ± 2 ft-lb 8.8 ± 1.0 N·m
78 ± 8 in-lb

5
79 ± 5 N·m
58 ± 3 ft-lb 10
24 ± 4 N·m 25 ± 4 N·m AK203805 AB
18 ± 2 ft-lb 19 ± 2 ft-lb

REMOVAL STEPS REMOVAL STEPS (Continued)

1. OIL DIPSTICK 8. GENERATOR BRACE
2. O-RING 9. GENERATOR
3. OIL DIPSTICK GUIDE 10. CRANKSHAFT PULLEY
4. O-RING 11. CENTER COVER
5. IDLER PULLEY 12. SPARK PLUG CABLE
6. AUTO-TENSIONER 13. IGNITION COIL
7. WATER PUMP PULLEY 14. SPARK PLUG

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11B-6 ENGINE OVERHAUL
SOLENOID AND VACUUM HOSE

SOLENOID AND VACUUM HOSE

REMOVAL AND INSTALLATION
M1113025300029

11 ± 1 N·m
98 ± 8 in-lb
11 ± 1 N·m 7
98 ± 8 in-lb
11 ± 1 N·m
98 ± 8 in-lb

8
9.0 ± 1.0 N·m 4
80 ± 8 in-lb
6

2
9.0 ± 1.0 N·m
80 ± 8 in-lb
5

3
9
9.0 ± 1.0 N·m
80 ± 8 in-lb

AK203806AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. VACUUM PIPE AND HOSE ASSEMBLY 6. SOLENOID VALVE
2. SOLENOID VALVE 7. VACUUM PIPE AND HOSE ASSEMBLY
3. SOLENOID VALVE 8. VACUUM PIPE AND HOSE ASSEMBLY
4. VACUUM HOSE 9. VACUUM HOSE ASSEMBLY
5. VACUUM HOSE

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 ENGINE OVERHAUL
TIMING BELT
11B-7
TIMING BELT
REMOVAL AND INSTALLATION
M1113001900481

3.5 ± 0.5 N·m

10 ± 2 N·m 31 ± 4 in-lb
89 ± 17 in-lb 28
24
11 ± 1 N·m 25
95 ± 9 in-lb
23
1 5 22
48 ± 6 N·m 6
35 ± 4 ft-lb 7 21

21 ± 4 N·m 26
16 ± 2 ft-lb
8
24 ± 3 N·m 27
18 ± 1 ft-lb
32 11 ± 1 N·m
11 ± 1 N·m 95 ± 9 in-lb
95 ± 9 in-lb
33
13
12
167 N·m 29
123 ft-lb
49 ± 5 N·m
2 36 ± 3 ft-lb
11 ± 1 N·m 9.0 ± 1.0 N·m
95 ± 9 in-lb 80 ± 8 in-lb
45 ± 3 N·m
31 4 33 ± 2 ft-lb 17 18
19 ± 3 N·m
14 ± 2 ft-lb
3
15

30 34
20 10
49 ± 9 N·m
88 ± 10 N·m 36 ± 6 ft-lb
65 ± 7 ft-lb 19
16
14
9 11
8.8 ± 1.0 N·m AK203807AB
35 ± 6 N·m 54 ± 5 N·m
26 ± 4 ft-lb 40 ± 3 ft-lb 78 ± 8 in-lb

REMOVAL STEPS REMOVAL STEPS (Continued)

1. TIMING BELT FRONT UPPER COVER <<C>> >>I<< 12. CRANKSHAFT BOLT
2. TIMING BELT FRONT LOWER COVER <<D>> >>I<< 13. CRANKSHAFT SPROCKET
3. POWER STEERING PUMP BRACKET >>I<< 14. CRANKSHAFT SENSING BLADE
<<A>> >>M<< 4. TIMING BELT 15. TENSIONER B
>>L<< 5. TENSIONER PULLEY <<E>> >>H<< 16. TIMING BELT B
6. TENSIONER ARM <<F>> >>G<< 17. COUNTERBALANCE SHAFT
7. SHAFT SPROCKET
>>K<< 8. AUTO-TENSIONER >>F<< 18. SPACER
9. IDLER PULLEY <<G>> >>E<< 19. CRANKSHAFT SPROCKET B
10. CRANKSHAFT ANGLE SENSOR 20. CRANKSHAFT KEY
<<B>> >>J<< 11. OIL PUMP SPROCKET 21. BREATHER HOSE

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11B-8 ENGINE OVERHAUL
TIMING BELT

REMOVAL STEPS (Continued)

[Link] HOSE
[Link] VALVE
[Link] FILLER CAP
>>D<< [Link] COVER
>>D<< [Link] COVER GASKET A
[Link] COVER GASKET B
>>C<< [Link] PACKING
>>B<< [Link] SUPPORT BRACKET
<<H>> >>A<< [Link] SPROCKET BOLT
[Link] SPROCKET
[Link] BELT REAR COVER, RIGHT
[Link] BELT REAR UPPER COVER,
LEFT
34 TIMING BELT REAR LOWER COVER,
LEFT
Required Special Tools:
• MD998738: Adjusting Screw • MD998781: Flywheel Stopper
• MD998767: Tensioner Pulley Wrench • MD998785: Sprocket Stopper
• MD998778: Crankshaft Sprocket Puller

REMOVAL SERVICE POINTS

.

<<A>> TIMING BELT REMOVAL

1. If the timing belt is to be reused, make an arrow mark with
something like chalk on the back of the belt indicating the
direction of rotation so it may be reinstalled in the same
direction.

AK202756AC
CAUTION
Never remove the timing belt with any piston at the top
TIMING MARKS dead center (TDC). If a piston is at TDC, the exhaust valves
of the cylinder are pushed by the exhaust cams, com-
pressing the valve springs. If the belt is removed under
this condition, the sprocket will be turned in the reverse
direction by the force of the springs, incurring risk of
injury.
2. Set the timing mark of the exhaust camshaft sprocket to a
point about one tooth before the TDC of the No.1 cylinder
AK202903 AC piston on compression stroke.
3. Loosen the lock nut of the tensioner pulley, then remove the
timing belt.
.

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 ENGINE OVERHAUL
TIMING BELT
11B-9
<<B>> OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips crosspoint screwdriver [shank diameter 8
mm (0.3 inch)] through the plug hole to block the left
counterbalance shaft.
3. Loosen the nut, and then remove the oil pump sprocket.

PLUG
CROSSPOINT
SCREWDRIVER
AKX00469AC

CROSSPOINT
SCREWDRIVER

AK202825 AC

<<C>> CRANKSHAFT BOLT LOOSENING

1. Install special tool MD998781 to hold the flywheel or drive
plate.
2. Loosen and remove the crankshaft bolt and washer.

MD998781

AKX00460AB

<<D>> CRANKSHAFT SPROCKET REMOVAL

1. Set special tool MD998778 as shown in the illustration.
2. Screw in the center bolt of the special tool to remove the
crankshaft sprocket.
MD998778

AKX00463AB

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11B-10 ENGINE OVERHAUL
TIMING BELT

<<E>> TIMING BELT "B" REMOVAL

CAUTION
Water or oil on the belt shortens its life drastically, so the
removed timing belt, sprocket, and tensioner must be free
from oil and water. These parts should not be washed or
immersed in solvent. Replace parts if [Link] there
is oil or water on each part, check the front case oil seals,
camshaft oil seal and water pump for leaks.
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner "B" bolt, and then remove the timing
belt "B."
AKX00474

<<F>> COUNTERBALANCE SHAFT SPROCKET REMOVAL

1. Set special tool MD998785 as shown to prevent the
counterbalance shaft sprocket from turning together.
2. Loosen the bolt and remove the sprocket.

MD998785

AKX00461AB

<<G>> CRANKSHAFT SPROCKET "B" REMOVAL

1. Set special tool MD998778 as shown in the illustration.
2. Screw in the center bolt of the special tool to remove
MD998778 crankshaft sprocket "B."

AKX00462AB

<<H>> CAMSHAFT SPROCKET REMOVAL

Remove the camshaft sprocket bolt while preventing the cam-
shaft from rotation using a wrench fitted on the hexagonal por-
tion of the camshaft.

AK202858AC

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 ENGINE OVERHAUL
TIMING BELT
11B-11
INSTALLATION SERVICE POINTS
.

>>A<< CAMSHAFT SPROCKET INSTALLATION

Tighten the camshaft sprocket bolt while preventing the cam-
shaft from rotation using a wrench fitted on the hexagonal por-
tion of the camshaft.
Tightening torque: 88 ± 10 N⋅m (65 ± 7 ft-lb)

AK202858AC

AK202859

>>B<< ENGINE SUPPORT BRACKET INSTALLATION

Coat the threads of the seal bolt A in the illustration with 3Mä
AAD Part number 8672 or equivalent before tightening.
Tightening torque: 49 ± 5 N⋅m (36 ± 3 ft-lb)

AK202743 AC

>>C<< SEMICIRCULAR PACKING INSTALLATION

1. Remove thoroughly the old sealant remaining on the
semicircular packing, cylinder head, and rocker cover.
2. Apply sealant 3Mä AAD Part number 8660 or equivalent to
the surface indicated in the drawing of the semicircular
packing.
3. Install the semicircular packing on the cylinder head.

AK202860AC

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11B-12 ENGINE OVERHAUL
TIMING BELT

4. Apply sealant 3Mä AAD Part number 8660 or equivalent to

10 mm
(0.4 in) the area indicated in the drawing of the semicircular packing
and cylinder head.

10 mm
(0.4 in)
SEMICIRCULAR
PACKING
CYLINDER HEAD AK202861 AC

>>D<< ROCKER COVER/ROCKER COVER GASKET A

INSTALLATION
TIMING BELT SIDE 1. Apply beads of sealant MITSUBISHI Genuine Part number
MD970389 or equivalent on the surfaces of the rocker cover
indicated in the drawing.
2. Install the rocker cover gasket A on the rocker cover before
the FIPG hardens.

AK202862 AC

TIMING BELT SIDE

3. Apply beads of sealant MITSUBISHI Genuine Part number
MD970389 or equivalent to the surfaces of the rocker cover
indicated in the drawing.
4. Install the rocker cover on the cylinder head before the FIPG
hardens.

AK202863 AC

>>E<< CRANKSHAFT SPROCKET "B" INSTALLATION

Clean and then degrease the front case of the front case,
SPROCKET "B" crankshaft sprocket "B" and crankshaft surface on which
CRANKSHAFT
sprocket "B" is attached.
NOTE: Degreasing is necessary to prevent decrease in the fric-
tion between contacting surfaces.

DEGREASE
FRONT CASE AK101651AB

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 ENGINE OVERHAUL
TIMING BELT
11B-13
>>F<< SPACER INSTALLATION
1. Apply a thin coat of clean engine oil to the lip area of the oil
SPACER seal.
OIL SEAL
2. Install the spacer with the chamfered end facing toward the
oil seal.

SHARP COUNTER
EDGE CHAMFER BALANCE
SHAFT AKX00577AB

>>G<< COUNTERBALANCE SHAFT SPROCKET

INSTALLATION
1. Install the counterbalance shaft sprocket and screw the bolt.
2. Install special tool MD998785 as shown in the illustration to
lock the counterbalance shaft.
3. Tighten the bolt, and then remove the special tool.
MD998785 Tightening torque: 45 ± 3 N⋅m (33 ± 2 ft-lb)

AKX00461AB

>>H<< TIMING BELT "B" INSTALLATION

1. Align timing marks on the crankshaft sprocket "B" and
TIMING counterbalance shaft sprocket with the marks on the front
MARK case.
2. Install the timing belt "B" on the crankshaft sprocket "B" and
TIMING counterbalance shaft sprocket. There should be no slack on
MARKS
(ON FRONT the tension side.
CASE)

AKX00487AB

3. Make sure that the relationship between the tensioner pulley

center and the bolt center is as shown in the illustration.
TENSIONER "B"

CENTER OF
TENSIONER
PULLEY CENTER OF BOLT
AKX00488AB

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11B-14 ENGINE OVERHAUL
TIMING BELT

4. Move tensioner "B" in the direction of the arrow while lifting

with your finger to give sufficient tension to the tension side
of timing belt. In this condition, tighten the bolt to secure
tensioner "B." When the bolt is tightened, use care to
prevent the tensioner pulley shaft from turning with the bolt.
If the shaft is turned with the bolt, the belt will be over
tensioned.
Tightening torque: 19 ± 3 N⋅m (14 ± 2 ft-lb)
TENSIONER "B"
BOLT
AKX00489AB

5. Check that timing marks on the sprockets are aligned with

BELT DEFLECTION the timing marks on the front case.
6. With your index finger, press the midway of span on the
tension side of timing belt "B." The bolt must deflect 5 to 7
mm (0.20 to 0.28 inch).

TIMING
MARKS

TIMING
MARKS AKX00490AB

>>I<< CRANKSHAFT SENSING BLADE/CRANKSHAFT

SPROCKET/CRANKSHAFT BOLT INSTALLATION
SPROCKET
1. Clean and then degrease the contacting surfaces of the
CRANKSHAFT SENSING BLADE crankshaft sprocket, sensing blade and crankshaft.
BOLT CRANKSHAFT NOTE: Degreasing is necessary to prevent decrease in the
friction between contacting surfaces.
CLEAN
2. Clean the bolt hole in the crankshaft, the crankshaft
contacting surface of the crankshaft sprocket, and the
washer.
WASHER
3. Install the sensing blade and the crankshaft sprocket to the
BIG CHAMFERED SIDE DEGREASE crankshaft.
AK101650AB
4. Apply an appropriately small amount of oil to the threads
and seating surface of the crankshaft bolt.
5. Install the washer to the crankshaft bolt with its largely
chamfered side toward the bolt head.
6. Lock the flywheel using the special tool MD998781.
7. Tighten the crankshaft bolt to the specified torque.
Tightening torque: 167 N⋅m (123 ft-lb)

MD998781

AKX00460AB

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 ENGINE OVERHAUL
TIMING BELT
11B-15
>>J<< OIL PUMP SPROCKET INSTALLATION
1. Insert a Phillips head screwdriver [shank diameter 8 mm
(0.3 inch)] through the plug hole on the left side of the
cylinder block to block the left counterbalance shaft.
2. Install the oil pump sprocket.
3. Apply a thin coat of engine oil to the seating surface of the
SCREW- nut.
DRIVER 4. Tighten the nut to the specified torque.
Tightening torque: 54 ± 5 N⋅m (40 ± 3 ft-lb)
AKX00530AB

>>K<< AUTO-TENSIONER INSTALLATION

1. If the auto-tensioner rod remains in its fully extended
A position, reset it to the retracted position as follows:
B (1) Clamp the auto-tensioner in a vise at right angles to the
jaws.
(2) Push in the rod little by little with the vise until the set hole
A in the rod is aligned with the set hole B in the cylinder.
(3) Insert a piece of wire [1.4 mm (0.055 inch) diameter] into
the set holes.
(4) Remove the auto-tensioner from the vise.
AKX00480AB

2. Install the auto-tensioner in position. Leave the wire installed

until the auto-tensioner is completely installed.

AKX00479

>>L<< TENSIONER PULLEY INSTALLATION

Install the tensioner pulley with its holes aligned as shown in
the drawing.

SMALL HOLE

AKX00475AB

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11B-16 ENGINE OVERHAUL
TIMING BELT

>>M<< TIMING BELT INSTALLATION

1. Bring the timing mark on the exhaust camshaft sprocket to a
TIMING MARKS point one sprocket tooth away from the timing mark on the
rocker cover in the counterclockwise direction.
NOTE: If the timing marks were aligned, the exhaust cam-
shaft would be turned counterclockwise by one sprocket
tooth and stay there by the force of the valve springs.

AK202903 AC

2. Align the timing mark on the intake camshaft sprocket with

that on the rocker cover.
TIMING MARKS
NOTE: The intake camshaft will be turned slightly clockwise
from where the timing marks are aligned by the force of the
valve springs and stay there.

AK202904 AC

3. Bring the timing mark on the crankshaft sprocket to a point

one sprocket tooth away from the mating timing mark in the
counterclockwise direction like in the operation with the
exhaust camshaft sprocket.

AK202760AC

4. Align the timing mark on the oil pump sprocket with that on
the cylinder block.
(1) Remove the plug from the cylinder block.
(2) Insert a crosspoint screwdriver with a shank diameter of 8
mm through the plug hole. If it can be inserted 60 mm
(2.36 inches) or more, the sprocket is in the correct
phase. If the insertion depth is up to 20 − 25 mm (0.78 to
PLUG 0.98 inch), the screwdriver is blocked by the
CROSSPOINT
SCREWDRIVER counterbalancer shaft. Then turn the oil pump sprocket
AK202752 AC one turn and realign the timing marks. Then check that
the screwdriver can be inserted 60 mm (2.36 inches) or
more. Keep the screwdriver inserted until installation of
timing belt is finished.

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 ENGINE OVERHAUL
TIMING BELT
11B-17
(3) Turn the oil pump sprocket counterclockwise by one
sprocket tooth.
TIMING MARKS

AK202761 AC

5. Install the timing belt on the exhaust camshaft sprocket, and

hold it in place with a paper clip at the point indicated in the
drawing.

AK202771

6. Turn the intake camshaft sprocket counterclockwise to bring

the timing mark on it one sprocket tooth away from the
mating timing mark in the counterclockwise direction. Then
install the timing belt on the sprocket and hold it in place with
a paper clip.
NOTE: The timing marks will be aligned when the belt is
installed since the intake camshaft is turned slightly clock-
wise by the force of the valve springs.

AK202772

TIMING MARKS
7. Turn the exhaust camshaft sprocket clockwise to align the
timing marks, and make sure that the intake camshaft
sprocket timing marks are also aligned.

AK202847 AC

8. Install the timing belt on the idler pulley, oil pump sprocket,
and crankshaft sprocket, in this order.
NOTE: There should be no slack in the installed portion of
the belt.

OIL PUMP
CRANKSHAFT SPROCKET
SPROCKET AK202762AC

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11B-18 ENGINE OVERHAUL
TIMING BELT

9. Install the timing belt on the tensioner pulley.

NOTE: Turning slightly the intake camshaft sprocket coun-
terclockwise will facilitate installation of the belt on the ten-
sioner pulley.

CAMSHAFT
SPROCKET

TENSIONER
PULLEY
AK202773 AC

[Link] slightly the crankshaft sprocket clockwise to take up

CRANKSHAFT
SPROCKET the slack in the idler pulley portion of the timing belt.
[Link] that each of the timing marks on the crankshaft, oil
pump, and exhaust camshaft sprockets is one sprocket
tooth away from its mating timing mark in the
counterclockwise direction.

AK202763AC

[Link] the tensioner pulley counterclockwise using the special

tool MD998767 to give tension to the belt and hold the
tensioner in position by temporarily tightening the tensioner
MD998767
lock bolt.
NOTE: Take up the slack in the belt portion between the
intake and exhaust camshaft sprockets.
[Link] the crankshaft clockwise to make the timing mark align
with the No.1 cylinder top dead center mark.

AK202764 AC

[Link] the special tool MD998738 and turn down the tool
until the wire (inserted in the auto-tensioner when it was
MD998738 installed) can be moved freely.

AK202774 AC
CAUTION
Prevent the timing belt from slipping as it becomes loose
following rotation of the intake and exhaust camshafts.
[Link] the tensioner pulley lock bolt.
[Link] the torque wrench attached to the special tool
MD998767 counterclockwise until the slack in the timing belt
is taken up.
[Link] the torque wrench clockwise from the position of step
16. until the torque wrench reading becomes 3.5 N⋅m (31 in-
lb), then tighten the tensioner pulley lock bolt.
MD998767 AK202775 AC

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 ENGINE OVERHAUL
TIMING BELT
11B-19
[Link] the special tool that was installed in step 14.
[Link] the crankshaft clockwise two turns, then let it alone for
approx. 15 minutes.
[Link] that the wire (inserted in the auto-tensioner when it
EXTENSION
AMOUNT was installed) can be moved freely. If the wire can be pulled
freely, the belt tensioner is adjusted properly. Remove the
wire. At that time, check that the auto-tensioner rod extends
by the specified amount.
Standard value: 3.8 − 4.5 mm (0.15 - 0.18 inch)
AK202829 AC
CAUTION
Be sure to check the tightening torque of the crankshaft
bolt anytime the crankshaft has been turned counterclock-
wise. If the torque lower than specification, tighten the bolt
to the specified torque.
[Link] the wire cannot be pulled out freely, perform the steps 14.
through 18. again to make the belt tension proper.

INSPECTION
M1113002000340
.

TIMING BELT
Check the timing belt closely. Replace the belt with a new one if
any of the following defects are evident:
1. Hardening of rubber backing.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.

AK100218

2. Surface cracks on the backing rubber.

CRACKS 3. Cracks or peeling of the canvas.
4. Cracks on the tooth bottom.
5. Cracks on the belt sides.
PEELING

CRACKS

CRACKS AK100209AB

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11B-20 ENGINE OVERHAUL
TIMING BELT

6. Abnormal wear on the belt sides.

NOTE: The sides of the belt are normal if they are sharp as
ROUNDED EDGE if cut by a knife.

ABNORMAL WEAR
(EXPOSED CORE WIRE)
AK100219AB

7. Abnormal wear on teeth.

CANVAS WORN Initial stage: Canvas worn (fluffy canvas fibers,
EXPOSING RUBBER
rubbery texture gone, white discoloration, canvas
texture indistinct)
Final stage: Canvas worn, exposing rubber (tooth
MISSING TEETH width reduced)
8. Missing teeth.

AK100220AB

AUTO-TENSIONER
1. Check the auto-tensioner for leaks from the sealed sections.
12 mm Replace it if leaky.
(0.5 in) 2. Check the rod end for wear and other damage.
Replace the auto-tensioner if the rod is badly worn or
damaged.
3. Measure the extension length of the rod.
If it is not within the standard value range, replace the auto-
tensioner.
AKX00477AB Standard value: 12 mm (0.5 inch)

4. Press the rod with a force of 98 to 196 N (22 to 44) and

98 TO 196 N (22 TO 44 lb)
measure the amount of retraction. If the measurement
exceeds the standard value, replace the auto-tensioner.
Standard value: 1.0 mm (0.04 inch) or less
MOVEMENT

AKX00478AB

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 ENGINE OVERHAUL
FUEL AND EMISSION PARTS
11B-21
FUEL AND EMISSION PARTS
REMOVAL AND INSTALLATION
M1113002200333

12 ± 1 N·m
107 ± 8 in-lb 8

15 19 ± 3 N·m
14 ± 2 ft-lb
5 10 1
13
14 2
12 3
11
7
8.8 ± 2.0 N·m 9
79 ± 16 in-lb 6 20 ± 2 N·m
15 ± 1 ft-lb
4

AK203808 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. THROTTLE BODY 9. INSULATOR
>>C<< 2. THROTTLE BODY GASKET 10. FUEL RETURN PIPE
3. EGR VALVE 11. INSULATOR
4. EGR VALVE GASKET >>A<< 12. INJECTOR
5. FUEL HOSE 13. O-RING
>>B<< 6. FUEL PRESSURE REGULATOR 14. GROMMET
7. O-RING 15. FUEL RAIL
8. INJECTOR AND FUEL RAIL

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11B-22 ENGINE OVERHAUL
FUEL AND EMISSION PARTS

INSTALLATION SERVICE POINTS

.

>>A<< INJECTOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring.
CAUTION
Prevent engine oil from getting into the delivery pipe.
2. Insert the injector into the delivery pipe while turning it in
both directions carefully not to damage the O-ring.
3. Check that the injector turns smoothly. If it does not, the O-
ring may be jamming, so remove the injector and check the
O-ring for damage. If the O-ring is intact, insert the injector
into the delivery pipe and check it for smooth rotation again.
.

>>B<< FUEL PRESSURE REGULATOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring.
CAUTION
Prevent engine oil from getting into the delivery pipe.
2. Insert the fuel pressure regulator into the delivery pipe while
turning it in both directions carefully not to damage the O-
ring.
3. Check that the fuel pressure regulator turns smoothly. If it
does not, the O-ring may be jamming, so remove the fuel
pressure regulator and check the O-ring for damage. If the
O-ring is intact, insert it into the delivery pipe and check it for
smooth rotation again.
.

>>C<< THROTTLE BODY GASKET INSTALLATION

Install the throttle body gasket with its tab located as shown in
TAB the drawing.

AK203932AB

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 ENGINE OVERHAUL
INTAKE MANIFOLD
11B-23
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
M1113002700275

5.0 ± 1.0 N·m 22 ± 4 N·m 2 1 11 ± 1 N·m

45 ± 8 in-lb 17 ± 2 ft-lb 98 ± 8 in-lb

4 36 ± 6 N·m 3
26 ± 4 ft-lb
5

36 ± 6 N·m
26 ± 4 ft-lb 23 ± 4 N·m
17 ± 2 ft-lb
20 ± 2 N·m
15 ± 1 ft-lb 8
9

36 ± 6 N·m
26 ± 4 ft-lb

31 ± 3 N·m
23 ± 2 ft-lb

AK203809 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. BRACKET >>A<< 6. INTAKE MANIFOLD STAY
2. ENGINE HANGER 7. GENERATOR BRACE STAY
>>C<< 3. AIR CONTROL VALVE BRACKET 8. INTAKE MANIFOLD
>>B<< 4. MDP SENSOR 9. INTAKE MANIFOLD GASKET
5. O-RING

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11B-24 ENGINE OVERHAUL
INTAKE MANIFOLD

INSTALLATION SERVICE POINTS

.

>>A<< INTAKE MANIFOLD STAY INSTALLATION

Tighten the bolts to the specified torque on both ends after
making sure that the stay is in close contact with the bosses on
the intake manifold and cylinder block.
Tightening torque: 31 ± 3 N⋅m (23 ± 2 ft-lb)

INTAKE MANIFOLD
STAY

AK202865 AC

>>B<< MDP SENSOR INSTALLATION

CAUTION
• Install the MDP sensor carefully not to give it a shock.
• Do not use the sensor that has fallen to floor or any
other surface.
.

>>C<< AIR CONTROL VALVE BRACKET INSTALLATION

1. Temporarily tighten the air control valve bracket and engine
hanger together with the intake manifold using a jointly
fastened bolt.
2. Tighten the bolt shown in Fig.1 to the specified torque.
Tightening torque: 23 ± 4 N⋅m (17 ± 2 ft-lb)
3
3. Tighten the bolt shown in Fig.2 to the specified torque.
1
Tightening torque: 36 ± 6 N⋅m (26 ± 4 ft-lb)
2
4. Tighten the bolt shown in Fig.3 together with the engine
AK203868 AB hanger to the specified torque.
Tightening torque: 22 ± 4 N⋅m (17 ± 2 ft-lb)

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 ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-25
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113004900372

14 ± 1 N·m
124 ± 8 in-lb 12

17 ± 2 N·m
13 ± 1 ft-lb

1 20
64 ± 5 N·m
47 ± 3 ft-lb
19 ± 3 N·m
14 ± 2 ft-lb 19
11 ± 1 N·m 15
98 ± 8 in-lb

33 ± 6 N·m
24 ± 4 ft-lb
31 ± 2 N·m
23 ± 1 ft-lb
14
16 10 ± 1 N·m
3 55 ± 5 N·m 89 ± 8 in-lb
41 ± 6 ft-lb 42 ± 7 N·m
31 ± 5 ft-lb 18
44 ± 5 N·m 13 10 ± 1 N·m
33 ± 3 ft-lb 89 ± 8 in-lb 17
5
6

2
14 ± 1 N·m
124 ± 8 in-lb 10 42 ± 7 N·m
31 ± 5 ft-lb

8
59 ± 5 N·m 9
44 ± 3 ft-lb 9.0 ± 1.0 N·m 19 ± 1 N·m
11 80 ± 8 in-lb 14 ± 1 ft-lb
4 36 ± 5 N·m
27 ± 3 ft-lb 14 ± 1 N·m 7 AK203810 AB
124 ± 8 in-lb
REMOVAL STEPS REMOVAL STEPS (Continued)
1. ENGINE HANGER 12. EXHAUST MANIFOLD HEAT
2. TURBOCHARGER HEAT PROTECTOR PROTECTOR
3. OXYGEN SENSOR 13. TURBOCHARGER ASSEMBLY AND
4. EXHAUST FITTING BRACKET PIPE ASSEMBLY
5. EXHAUST FITTING 14. TURBOCHARGER GASKET
6. EXHAUST FITTING GASKET 15. OIL PIPE
7. AIR OUTLET FITTING 16. WATER PIPE B
>>C<< 8. AIR OUTLET FITTING GASKET 17. WATER PIPE A
9. OIL RETURN PIPE 18. TURBOCHARGER ASSEMBLY
10. OIL RETURN PIPE GASKET >>A<< 19. EXHAUST MANIFOLD
>>B<< 11. OIL RETURN PIPE GASKET 20. EXHAUST MANIFOLD GASKET

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11B-26 ENGINE OVERHAUL
EXHAUST MANIFOLD

INSTALLATION SERVICE POINT

.

>>A<< EXHAUST MANIFOLD INSTALLATION

1. Hand tighten all the exhaust manifold mounting nuts.
2. Tighten the M8 nuts to 29 ± 3 N⋅m (21 ± 2 ft-lb) in the
indicated sequence.
3. Tighten the M10 nuts to 49 ± 3 N⋅m (36 ± 3 ft-lb) in the
indicated sequence.
4. Tighten the M8 nuts again to 29 ± 3 N⋅m (21 ± 2 ft-lb) in the
indicated sequence.
5. Finally tighten the M10 nuts and the M8 nuts to the specified
torque, both in the indicated sequence.
Tightening torque:
3 4 5 6 33 ± 6 N⋅m (24 ± 4 ft-lb) M8
55 ± 10 N⋅m (41 ± 6 ft-lb) M10

1 7 9 8 2

AK202866 AC

>>B<< OIL RETURN PIPE GASKET INSTALLATION

Install the oil return pipe gasket with its lug located as shown in
the drawing.
NOTE: The gasket on the turbocharger end of the pipe does
not require special alignment for installation.
TAB

AK202867 AC

>>C<< OUTLET FITTING GASKET INSTALLATION

Install the air outlet fitting gasket with its lug located as shown
in the drawing.
TAB

A
A AK202868 AC

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 ENGINE OVERHAUL
WATER PUMP & WATER HOSE
11B-27
WATER PUMP & WATER HOSE
REMOVAL AND INSTALLATION
M1113017900208

5.0 ± 1.0 N·m 10 ± 1 N·m

13 ± 2 N·m 45 ± 8 in-lb
115 ± 17 in-lb 89 ± 8 in-lb
7
23 ± 4 N·m
17 ± 2 ft-lb

11 29 ± 10 N·m
22 ± 6 ft-lb
8 23 ± 4 N·m
17 ± 2 ft-lb
N 12 5
2 10.8 ± 1.0 N·m
96 ± 8 in-lb
6

4 3
9
10 N

15
23 ± 2 N·m
17 ± 2 ft-lb

14 N
13
14 ± 1 N·m AK203811 AB
124 ± 8 in-lb

REMOVAL STEPS REMOVAL STEPS (Continued)

1. WATER HOSE 8. THERMOSTAT
2. WATER HOSE >>B<< 9. THERMOSTAT HOUSING
3. WATER HOSE 10. THERMOSTAT HOUSING GASKET
4. WATER HOSE >>A<< 11. WATER INLET PIPE
>>E<< 5. ENGINE COOLANT TEMPERATURE >>A<< 12. O-RING
SENSOR 13. WATER PUMP
>>D<< 6. ENGINE COOLANT TEMPERATURE 14. WATER PUMP GASKET
GAUGE UNIT 15. KNOCK SENSOR
>>C<< 7. WATER OUTLET FITTING

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11B-28 ENGINE OVERHAUL
WATER PUMP & WATER HOSE

INSTALLATION SERVICE POINTS

.

>>A<< WATER INLET PIPE/O-RING INSTALLATION

CAUTION
• Never apply any oil or grease to the O-ring.
• Secure the water inlet pipe after the thermostat housing
has been installed.
Replace the water inlet pipe O-ring with new one, then apply
water to the O-ring so that they can be inserted easily into the
water pump.
.

>>B<< THERMOSTAT HOUSING INSTALLATION

ø 3 mm (0.12 in) 1. Clean the sealant application surfaces of the thermostat
housing and cylinder head.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant
Mitsubishi Genuine Parts number MD970389, or equivalent
to the outlet fitting.
3. After installation, wait at least one hour. Never start the
engine or let coolant touch the adhesion surface during that
time.

AK203834 AB

>>C<< OUTLET FITTING INSTALLATION

1. Clean the sealant application surfaces of the outlet fittings
ø 3 mm (0.12 in) and thermostat housing.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant
Mitsubishi Genuine Parts number MD970389, or equivalent
to the outlet fitting.
3. After installation, wait at least one hour. Never start the
engine or let coolant touch the adhesion surface during that
time.

AK203833AB

>>D<< ENGINE COOLANT TEMPERATURE GAUGE UNIT

INSTALLATION
1. When reusing the gauge unit, clean its thread.
2. Apply 3Mä AAD Part number 8672 or equivalent to the
engine coolant temperature gauge unit.

AK100245

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 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-29
>>E<< ENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION
1. When reusing the sensor, clean its thread.
2. Apply 3Mä AAD Part number 8731 or equivalent to the
engine coolant temperature sensor.

AK100244

ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION
M1113005400433

10 ± 2 N·m
89 ± 17 in-lb
8 3
11 4
5
20 ± 1 N·m 14 9
15 ± 1 ft-lb 13 14 ± 1 N·m
12 124 ± 9 in-lb

2
1
10
22 ± 4 N·m
98 ± 8 ft-lb
15 6
8.8 ± 1.0 N·m
11 ± 1 N·m 79 ± 9 in-lb
98 ± 8 in-lb

7 18

16
17

APPLY ENGINE OIL

TO ALL MOVING
PARTS BEFORE
INSTALLTION.

AK203812 AB

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11B-30 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

REMOVAL STEPS REMOVAL STEPS (Continued)

1. CAM POSITION SENSOR >>C<< 9. BEARING CAP, REAR LEFT
2. O-RING >>C<< 10. BEARING CAP, FRONT
3. COVER >>C<< 11. BEARING CAP NO.5
4. GASKET >>C<< 12. BEARING CAP NO.2
>>F<< 6. CAMSHAFT POSITION SENSOR >>C<< 13. BEARING CAP NO.3
SUPPORT >>C<< 14. BEARING CAP NO.4
>>E<< 5. CAMSHAFT POSITION SENSING >>B<< 15. CAMSHAFT
CYLINDER 16. ROCKER ARM
>>D<< 7. CAMSHAFT OIL SEAL <<A>> >>A<< 17. LASH ADJUSTER
>>C<< 8. BEARING CAP, REAR RIGHT 18. OIL DELIVERY BODY

Required Special Tools:

• MD998442: Air Bleed Wire • MD998713: Camshaft Oil Seal Installer

REMOVAL SERVICE POINT

.

<<A>> LASH ADJUSTER REMOVAL

CAUTION
When reusing a lash adjuster, it must be washed and
inspected before installation. (Refer to P.11B-32)

INSTALLATION SERVICE POINTS

.

>>A<< LASH ADJUSTER INSTALLATION

CAUTION
When reusing a lash adjuster, it must be washed and
inspected before installation. (Refer to P.11B-32)
Install the lash adjuster into the rocker arm, being careful not to
spill the diesel fuel it contains.
.

>>B<< CAMSHAFT INSTALLATION

CAUTION
• Do not confuse the intake camshaft with the exhaust
TIMING BELT SIDE
camshaft.
• The exhaust camshaft has a 4 mm (0.16 inch) wide slit
SLIT
at the rear end.

EXHAUST CAMSHAFT
AK202869 AC

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 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-31
>>C<< BEARING CAP INSTALLATION
DOWEL PIN
1. Set each camshaft with its dowel pin at the top.

AK203979 AB

2. The bearing caps Nos. 2 − 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
CAP NUMBER bearing caps)
INTAKE/EXHAUST I: intake side
IDENTIFICATION
LETTER E: exhaust side
3. Remove completely sealant remaining on the bearing caps
and cylinder head.
AK202870 AC

4. Apply sealant MITSUBISHI Genuine Part number

MD970389 or equivalent to the surfaces indicated in the
drawing.
5. Install each bearing cap and tighten its bolts in two or three
passes.
6. Finally tighten the bolts to the specified torque.
Tightening torque: 20 ± 1 N⋅m (15 ± 1 ft-lb)
7. Check that the rocker arms are correctly installed.
AK103803 NOTE: Wipe off any squeezed out sealant completely.
.

>>D<< CAMSHAFT OIL SEAL INSTALLATION

Use the special tool MD998713 to drive each oil seal into posi-
MD998713 tion in the cylinder head.

AK202872 AC

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11B-32 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

>>E<< CAMSHAFT POSITION SENSING CYLINDER

INSTALLATION
1. Turn the exhaust camshaft to the No.1 cylinder top dead
SMALLER VANE
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.

CAMSHAFT
POSITION
SENSOR AK202844 AC

>>F<< CAMSHAFT POSITION SENSOR SUPPORT

INSTALLATION
Apply a 3 mm (0.12 inch) bead of sealant MITSUBISHI Genu-
ine Part number MD970389 or equivalent to the area shown.

AK100756

INSPECTION
M1113005500366
.

CAMSHAFT
Measure the cam height and replace the camshaft if any height
exceeds the specified limit.
Standard value:
Intake: 35.79 mm (1.41 inches)
Exhaust: 35.49 mm (1.40 inches)
Limit:
Intake: 35.29 mm (1.39 inches)
Exhaust: 34.99 mm (1.38 inches)
AK100584

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 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-33
LASH ADJUSTERS
CAUTION
• The lash adjuster is a precision-engineered compo-
nent. 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.
1. Prepare three containers and approximately five liters of
FOR ROUGH FOR FINISH FOR DIESEL
diesel fuel. Pour into each container the diesel fuel in an
CLEANING CLEANING FUEL FILLING amount enough for a lash adjuster placed in the container in
its upright position to completely submerge.

A B C
AK202665 AC

2. Place the lash adjuster in container A and wash its outside

surface.
NOTE: Use a nylon brush if there are hard-to-remove
deposits.

DIESEL FUEL

AK202666 AC
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.
3. While gently pushing the internal steel ball using the special
tool 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
DIESEL FUEL
MD998442 other abnormalities. If a defect is found in plunger operation,
replace the lash adjuster.
AK202680 AD
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.
MD998442

DIESEL FUEL
AK202681 AC

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11B-34 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

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 − 10 times by gently pushing the
internal steel ball using the special tool MD998442 until the
plunger moves smoothly to wash the lash adjuster’s
DIESEL FUEL pressure chamber.
MD998442

AK202680 AD
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.
MD998442

DIESEL FUEL
AK202681 AC
CAUTION
Do not use container C for cleaning. If cleaning is per-
formed in container C, foreign matter could enter the pres-
sure 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
MD998442.

DIESEL FUEL
MD998442

AK202682 AC

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.

MD998442 DIESEL FUEL

AK202683 AC

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 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-35
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 con-
tracts even after the pressure chamber has completely been
filled with diesel fuel (air has been bled).
[Link] the serviced lash adjusters in their upright positions to
prevent diesel fuel from spilling out. Protect them from dust
AK202684 or other foreign matter. Install the lash adjusters onto the
engine as soon as possible.

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION
M1113006900367

78 N·m → BACK OFF → 20 N·m → 90˚ + 90˚

58 ft-lb 15 ft-lb
1
2
8
9
4
5 10
20 14
6
15
12
17
13
16

19
18 11

APPLY ENGINE OIL

TO ALL MOVING
PARTS BEFORE
INSTALLTION.

AK203813 AB

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11B-36 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

REMOVAL STEPS REMOVAL STEPS (Continued)

<<A>> >>D<< 1. CYLINDER HEAD BOLT <<D>> 11. EXHAUST VALVE
2. CYLINDER HEAD ASSEMBLY <<C>> >>A<< 12. VALVE STEM SEAL
3. CYLINDER HEAD GASKET 13. VALVE SPRING SEAT
<<B>> >>C<< 4. RETAINER LOCK <<C>> >>A<< 14. VALVE STEM SEAL
5. VALVE SPRING RETAINER 15. VALVE SPRING SEAT
>>B<< 6. VALVE SPRING 16. INTAKE VALVE GUIDE
7. INTAKE VALVE 17. EXHAUST VALVE GUIDE
<<B>> >>C<< 8. RETAINER LOCK 18. INTAKE VALVE SEAT
9. VALVE SPRING RETAINER 19. EXHAUST VALVE SEAT
>>B<< 10. VALVE SPRING 20. CYLINDER HEAD

Required Special Tools:

• MB991654: Cylinder Head Bolt Wrench (12) • MD998737: Valve Stem Seal Installer
• MD998735: Valve Spring Compressor • MD998772: Valve Spring Compressor

REMOVAL SERVICE POINTS

.

<<A>> CYLINDER HEAD BOLT REMOVAL

Using the special tool MB991653 to loosen the cylinder head
bolts.

MB991654

AK202723 AC

<<B>> RETAINER LOCK REMOVAL

1. Using special tool MD998735 or MD998772, compress the
MD998735 retainer locks.
2. Remove the retainer locks.
NOTE: Tag removed valves, springs and other components,
noting their cylinder numbers and locations to facilitate reas-
sembly. Store these components safely.

AK202873 AC

MD998772

AK202742 AC

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 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-37
<<C>> VALVE STEM SEAL REMOVAL
Do not reuse removed valve stem seal.

AK203194

<<D>> VALVE HANDLING PRECAUTIONS

Sodium reacts violently with water or moisture generation heat
and liberating hydrogen. It must be handled with utmost care
because otherwise the following dangerous conditions may
result:
• Loss of eyesight if sodium gets in eyes.
• Burns if sodium contact skin.
• Fire hazard.
1. Handling of Sodium-filled Exhaust Valves
(1) Sodium-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
(2) Never try to break the valves and expose sodium to the
air.
(3) When worn exhaust valves are to be discarded, have
them disposed of by a salvage company equipped with
special disposal system, notifying them that the valves
contain sodium.
(4) Should the exhaust valves be broken, neutralize sodium
using the method described below, and discard the
valves in the same way as ordinary valves.
CAUTION
• Do not let the solution contact the eyes or the skin.
• Should it get in the eyes, immediately flush them with
clean water thoroughly, and receive medical attention.
When it contacts he skin, wash with ample amounts of
clean water.
2. How to Neutralize Sodium
(1) Place a container filled with more than 10 liters (10.6 qt)
of water in a well ventilated large space.
(2) Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
CAUTION
• Valves must be neutralize one at a time.
• Put a valve in the container only after sodium in the pre-
ceding one has completely reacted with water.
(3) Put a broken valves in the water-filled container and
quickly get away from the container at least 2 or 3 m (6.6
or 9.8 ft)

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11B-38 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

(4) Keep fire away from the container during the

neutralization. The resulting hydrogen gas is highly
explosive.
NOTE: The reaction occurs when water enters the cavity
in he valve. Hydrogen gas may be trapped inside the
valve, temporarily blocking the water passage. In such a
case, wait until hydrogen gas in released and remaining
sodium reacts with water.
(5) After the neutralization of sodium, water in the container
contains sodium hydroxide and is highly alkaline. The
water solution should be disposed of according to local
regulations.

INSTALLATION SERVICE POINTS

.

>>A<< VALVE STEM SEAL INSTALLATION

RUBBER COLOUR: RUBBER COLOUR:

GRAY GRAY GREEN

AK202875 AC

NOTE: Do not confuse the stem seals for intake valves with
those for exhaust valves.
CAUTION
• Do not reuse removed valve stem seals.
• The valve stem seal must be installed using the correct
special tool. Incorrect installation could result in oil
leaking past the valve guide.
MD998737 1. Install the valve spring seat.
2. Using special tool MD998737, install a new stem seal to the
valve guide.

AK202874 AC

>>B<< VALVE SPRING INSTALLATION

Install the valve spring so that the painted end is on the rocker
SPRING
RETAINER
arm side.
PAINTED
END

STEM SEAL

SPRING SEAT

AK100160AB

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 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-39
>>C<< RETAINER LOCK INSTALLATION
Using special tool MD998735 or MD998772, compress the
MD998735 valve spring and insert the retainer lock into position.
NOTE: The valve spring, if excessively compressed, causes
the bottom end of retainer to be in contact with the stem seal,
and damage it.

AK202873 AC

MD998772

AK202742 AC

>>D<< CYLINDER HEAD BOLT INSTALLATION

1. When the removed cylinder head bolts are to be reused,
check that the shank length of each bolt meets the limit. If it
exceeds the limit, replace the bolts.
Limit: 99.4 mm (3.91 inches)
2. Apply engine oil to the thread of the bolts and to the
washers.
SHANK LENGTH

AKX00467AB

3. Using special tool MB991654 tighten the bolts to the

TIMING BELT SIDE specified torque 78 N⋅m (58 ft-lb), using the tightening
sequence shown.
4. Loosen all bolts fully in the reverse order of tightening.
5. Retighten the loosened bolts to 20 N⋅m (15 ft-lb) in the
8 6 1 3 9 tightening sequence shown.

10 4 2 5 7

AKX00526AB

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11B-40 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

CAUTION
• If the bolt is turned less than 90 degree angle, proper
90˚
fastening performance may not be achieved. Be careful
to turn each bolt exactly 90 degree angle.
• If the bolt is overtightened, loosen the bolt completely
and then retighten it by repeating the tightening proce-
dure from step 1.
6. Make a paint mark across each bolt head and cylinder head.
90˚ PAINT MARK
7. Tighten the cylinder head bolts 90 degree angle in the
specified order.
AKX00449AB
8. Tighten the bolts another 90 degree angle in the same order
as in step 7, and check that the paint marks on the cylinder
head bolt are aligned with the paint marks on the cylinder
head.

INSPECTION
M1113007000356
.

CYLINDER HEAD
1. Before cleaning the cylinder head, check it for water leaks,
gas leaks, cracks, and other damage.
2. Remove all oil, water scale, sealant, and carbon. After
cleaning the oil passages, blow air through them to verify
that they are not blocked.
3. Check the cylinder head gasket surface for flatness by using
a straight edge and feeler gauge.
Standard value: 0.05 mm (0.0020 inch)
Limit: 0.2 mm (0.008 inch)
AK202724
4. If flatness exceeds the specified limit, grind the gasket
surface to specification.
Grinding limit: *0.2 mm (0.008 inch)
*Includes/combined with cylinder block grinding
Cylinder head height (Specification when new):
131.9 − 132.1 mm (5.193 − 5.201 inches)
.

VALVE
1. Check the valve face for correct contact. If contact is uneven
or incomplete, reface the valve seat.
2. If the margin is less than specified, replace the valve.
VALVE SEAT Standard value:
CONTACT Intake: 1.0 mm (0.039 inch)
MARGIN
Exhaust: 1.5 mm (0.059 inch)
Limit:
Intake: 0.5 mm (0.020 inch)
Exhaust: 1.0 mm (0.039 inch)
AK100161AB
3. Measure the valve length. If the measurement is less than
specified, replace the valve.
Standard value:
Intake: 109.50 mm (4.311 inches)
Exhaust: 109.70 mm (4.319 inches)

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 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-41
Limit:
Intake: 109.00 mm (4.291 inches)
Exhaust: 109.20 mm (4.299 inches)
.

VALVE SPRING
1. Measure the valve spring free height. If the measurement is
OUT OF SQUARE less than specified, replace spring.
Standard value: 50.4 mm (1.98 inches)
Limit: 49.4 mm (1.94 inches)
2. Measure the squareness of the spring. If the measurement
FREE HEIGHT is less than specified, replace the spring.
Standard value: 2° or less
Limit: 4°
AK100152 AB

VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the clearance exceeds the specified limit, replace the
valve guide or valve, or both.
Standard value:
VALVE
Intake: 0.02 − 0.05 mm (0.0008 − 0.0020 inch)
GUIDE
Exhaust: 0.05 − 0.09 mm (0.0020 − 0.0035 inch)
Limit:
STEM O.D.
Intake: 0.10 mm (0.0039 inch)
GUIDE I.D. Exhaust: 0.15 mm (0.0059 inch)
AK100210 AB

VALVE SEAT
Assemble the valve, then measure the valve stem projection
VALVE STEM END
between the end of the valve stem and the spring seating
surface. If the measurement exceeds the specified limit,
VALVE STEM replace the valve seat.
PROJECTION
Standard value:
SPRING SEATING Intake: 49.20 mm (1.9370 inches)
SURFACE Exhaust: 48.40 mm (1.9055 inches)
Limit
Intake: 49.70 mm (1.9567 inches)
AK100206 AB
Exhaust: 48.90 mm (1.9252 inches)
.

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11B-42 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

VALVE SEAT RECONDITIONING PROCEDURE

1. Before correcting the valve seat, check the clearance
0.9 – 1.3 mm
(0.04 – 0.05 in) between the valve guide and valve. If necessary, replace the
65˚ valve guide.
2. Using the appropriate special tool or seat grinder, correct the
valve seat to achieve the specified seat width and angle.
3. After correcting the valve seat, lap the valve and valve seat
using lapping compound. Then, check the valve stem
projection (refer to VALVE SEAT in INSPECTION).
43.5˚ – 44˚ 10˚
AK100818 AC

VALVE SEAT REPLACEMENT PROCEDURE

1. Cut the valve seat to be replaced from the inside to reduce
0.5 – 1.0 mm (0.020 – 0.039 in) the wall thickness. Then, remove the valve seat.

CUT AWAY

0.5 – 1.0 mm
(0.020 – 0.039 in)

AK100153AB

2. Rebore the valve seat hole in the cylinder head to match the
selected oversize valve seat diameter.
Intake valve seat hole diameter
0.3 oversize: 35.30 − 35.33 mm (1.3898 − 1.3909
VALVE SEAT
inches)
HEIGHT
0.6 oversize: 35.60 − 35.63 mm (1.4016 − 1.4028
inches)

OVERSIZE VALVE
Exhaust valve seat hole diameter
SEAT HOLE DIAMETER 0.3 oversize: 33.30 − 33.33 mm (1.3110 − 1.3122
AK100154AB
inches)
0.6 oversize: 33.60 − 33.63 mm (1.3228 − 1.3240
inches)
3. Prevent galling of the cylinder head bore by cooling the
valve seat with liquid nitrogen before press-fitting it.
4. Correct the valve seat to achieve the specified width and
angle (refer to VALVE SEAT RECONDITIONING
PROCEDURE).
.

VALVE GUIDE REPLACEMENT PROCEDURE

1. Using a press, push the valve guide out toward the cylinder
block side.
2. Rebore the valve guide hole in the cylinder head to match
the oversize valve guide that is to be fitted.

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 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-43
CAUTION
Do not install a valve guide of the same size again.
Valve guide hole diameters in cylinder head
0.05 oversize: 12.05 − 12.07 mm (0.4744 − 0.4751
inch)
0.25 oversize: 12.25 − 12.27 mm (0.4823 − 0.4831
inch)
0.50 oversize: 12.50 − 12.52 mm (0.4921 − 0.4929
inch)
3. Press-fit the valve guide until it projects by the specified
amount.
Standard value: 19.5 mm (0.768 inch)
CAUTION
• The valve guide must be installed from the upper side
of the cylinder head.
• The valve guides differ in length on the intake and
PROTRUSION exhaust sides.
AK100151AB Valve guide length
Intake: 45.5 mm (1.791 inches)
Exhaust: 50.5 mm (1.988 inches)
4. After press-fitting the valve guide, insert a new valve and
check that it slides smoothly.

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11B-44 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION
M1113008100271

19 ± 3 N·m
14 ± 2 ft-lb
29 30
APPLY ENGINE OIL 8
TO ALL MOVING
PARTS BEFORE 27
INSTALLTION.

31
20
23 ± 3 N·m
17 ± 2 ft-lb

54 ± 5 N·m 21
40 ± 5 ft-lb 25 19 28
22 7
15 23
9 10 ± 2 N·m
89 ± 17 in-lb
24 17 ± 1 N·m 6
13 ± 1 ft-lb
14
5 22 ± 4 N·m
17 ± 2 ft-lb

18 4
26 19 ± 3 N·m
13 17 23 ± 3 N·m 14 ± 2 ft-lb
16 36 ± 3 N·m 18 ± 2 ft-lb
12 27 ± 1 ft-lb
19 ± 3 N·m 11 23 ± 3 N·m
14 ± 2 ft-lb 17 ± 2 ft-lb
10 2 9.0 ± 3.0 N·m
80 ± 26 in-lb
44 ± 5 N·m
3 33 ± 3 ft-lb 39 ± 5 N·m 1
14 ± 2 N·m 29 ± 4 ft-lb
124 ± 17 in-lb AK203814AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. DRAIN PLUG <<C>> >>I<< 18. FLANGE BOLT
>>N<< 2. DRAIN PLUG GASKET >>H<< 19. OIL PUMP CASE
>>M<< 3. OIL FILTER 20. OIL PUMP CASE GASKET
<<A>> >>L<< 4. OIL PAN 21. OIL PUMP CASE COVER
5. OIL SCREEN >>G<< 22. OIL PUMP DRIVEN GEAR
6. OIL SCREEN GASKET >>G<< 23. OIL PUMP DRIVE GEAR
7. BAFFLE PLATER >>F<< 24. CRANKSHAFT OIL SEAL
>>K<< 8. OIL PRESSURE SWITCH >>E<< 25. COUNTERBALANCE SHAFT OIL SEAL
9. OIL COOLER BY-PASS VALVE >>D<< 26. OIL PUMP OIL SEAL
10. RELIEF PLUG 27. COUNTERBALANCE SHAFT, RIGHT
11. GASKET 28. COUNTERBALANCE SHAFT, LEFT
12. RELIEF SPRING <<D>> >>C<< 29. COUNTERBALANCE SHAFT FRONT
13. RELIEF PLUNGER BEARING
14. OIL FILTER BRACKET <<E>> >>B<< 30. COUNTERBALANCE SHAFT REAR
15. OIL FILTER BRACKET GASKET BEARING, RIGHT
<<B>> >>J<< 16. RLUG CAP <<E>> >>A<< 31. COUNTERBALANCE SHAFT REAR
17. O-RING BEARING, LEFT

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 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-45
Required Special Tools:
• MB991603: Bearing Installer Stopper • MD998375: Crankshaft Front Oil Seal Installer
• MD998162: Plug Wrench • MD998705: Silent Shaft Bearing Installer
• MD998285: Crankshaft Front Oil Seal Guide • MD998727: Oil Pan Remover
• MD998371: Silent Shaft Bearing Puller • MD998783: Plug Wrench Retainer
• MD998372: Silent Shaft Bearing Puller

REMOVAL SERVICE POINTS

.

<<A>> OIL PAN REMOVAL

1. Remove all oil pan bolts.
MD998727 2. Drive in special tool MD998727 between the cylinder block
and oil pan.
NOTE: Never use a screwdriver or chisel to remove the oil
pan. It will deform the oil pan flange and result in oil leakage.
3. Gently hit the special tool on its corner (shoulder), then slide
it along the oil pan to remove it.

AKX00466AB

<<B>> PLUG CAP REMOVAL

1. Fit special tool MD998162 on the plug cap, and then hold it
MD998162 in position with special tool MD998783.
2. Loosen the plug.
3. Remove special tools MD998783 and MD998162 and then
the plug cap.

MD998783
AKX00468AB

<<C>> FLANGE BOLT REMOVAL

1. Remove the plug on the side of the cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (0.3
inch)] into the plug hole to lock the counterbalance shaft.

PLUG
SCREWDRIVER

AKX00469AB

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11B-46 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

3. Loosen the flange bolt.

AKX00574

<<D>> COUNTERBALANCE SHAFT FRONT BEARING

REMOVAL
Using special tool MD998371, remove the counterbalance
shaft front bearing from the cylinder block.
NOTE: Be sure to remove the front bearing first.
If it has not been removed, special tool MD998372 cannot be
used for rear balance shaft bearing removal.

FRONT
BEARING
MD998371
AKX00447AB

<<E>> COUNTERBALANCE SHAFT REAR BEARING

REMOVAL
1. Install special tools MB991603 and MD998372 in front of the
cylinder block when removing the left counterbalance shaft
MB991603 rear bearing.
2. Using special tool MD998372, remove the right
counterbalance shaft rear bearing from the cylinder block.
MD998372

AKX00452AB

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 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-47
INSTALLATION SERVICE POINTS
.

>>A<< COUNTERBALANCE SHAFT REAR BEARING, LEFT

INSTALLATION
1. Install special tool MB991603 to the cylinder block.
MB991603
2. Apply engine oil to the rear bearing outer surface and
bearing hole in the cylinder block.
3. Using special tool MD998705, install the rear bearing.
NOTE: The left rear bearing has no oil holes.

MD998705

AKX00453AB

REAR
BEARING
MB991603

MD998705

AKX00528AB

>>B<< COUNTERBALANCE SHAFT REAR BEARING,

RIGHT INSTALLATION
1. Apply engine oil to the bearing outer surface and bearing
hole in the cylinder block.
2. Using special tool MD998705, install the rear bearing. Make
sure that the oil hole of the bearing is aligned with that of the
cylinder block.

MD998705

BEARING
OIL HOLE

AKX00533AB

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11B-48 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

>>C<< COUNTERBALANCE SHAFT FRONT BEARING

INSTALLATION
1. Apply engine oil to the front bearing outer surface and
bearing hole in the cylinder.
2. Using special tool MD998705, install the front bearing. Make
sure that the oil hole of the bearing is aligned with that of the
cylinder block.

MD998705

MD998705

BEARING

CYLINDER
BLOCK
OIL HOLE
AKX00534AB

>>D<< COUNTERBALANCE SHAFT OIL SEAL

INSTALLATION
Using a suitable socket wrench, install the counterbalance shaft
oil seal into the front case.
SOCKET WRENCH

OIL SEAL FRONT CASE

AKX00576AB

>>E<< OIL PUMP OIL SEAL INSTALLATION

Using a suitable socket wrench, install the oil pump oil seal into
the front case.
SOCKET
OIL SEAL WRENCH

FRONT CASE

AKX00570AB

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 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-49
>>F<< CRANKSHAFT FRONT OIL SEAL INSTALLATION
Using special tool MD998375, install the crankshaft front oil
seal into the front case.
MD998375

FRONT CASE

OIL SEAL AKX00575AB

>>G<< OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR

INSTALLATION
Install the oil pump gears into the front case and line up the
alignment marks.

ALIGNMENT
MARK

AKX00594AB

>>H<< OIL PUMP CASE ASSEMBLY/OIL FILTER BRACKET

INSTALLATION
1. Set special tool MD998285 on the front end of crankshaft
and apply a thin coat of engine oil to the outer surface of
special tool MD998285.
2. Apply engine oil to the lip of the crankshaft front oil seal.

MD998285

AKX00589AB

3. Install the oil pump case assembly together with the new
front case gasket.
4. Install the oil filter bracket together with the new gasket.
5. Tighten the all flange bolts to the specified torque.
Tightening torque: 23 ± 3 N⋅m (17 ± 2 ft-lb)

MD998285

AKX00590AB

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11B-50 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

>>I<< FLANGE BOLT INSTALLATION

1. Insert a Phillips head screwdriver [shank diameter 8 mm
(0.3 inch)] into the hole in the left side of the cylinder block to
lock the counterbalance shaft.

SCREWDRIVER AKX00573AB

2. Secure the oil pump driven gear onto the left counterbalance
shaft by tightening the flange bolt to the specified torque.
Tightening torque: 36 ± 3 N⋅m (27 ± 1 ft-lb)
3. Pull out the screwdriver and screw in the plug.

AKX00574

>>J<< PLUG CAP INSTALLATION

1. Install a new O-ring to the groove of the front case.
MD998162 2. Install the plug cap to the front case.
3. Fit special tool MD998162 on the plug cap, and then hold it
in position with special tool MD998783.
4. Tighten the plug cap to the specified torque.
Tightening torque: 23 ± 3 N⋅m (17 ± 2 ft-lb)
5. Remove special tools MD998783 and MD998162.
MD998783
AKX00468AB

>>K<< OIL PRESSURE SWITCH INSTALLATION

CAUTION
Be careful not to block the oil passage with sealant.
1. Apply 3Mä AAD Part number 8672 or equivalent to the
thread of oil pressure switch.

AKX00688

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 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-51
2. Tighten the oil pressure switch together with the oil filter
MD998054 bracket by the specified torque using of the special tool
MD998054.
Tightening torque: 19 ± 3 N⋅m (14 ± 2 ft-lb)

AK204037AB

>>L<< OIL PAN INSTALLATION

1. Clean both gasket surfaces of oil pan and cylinder block.
2. Apply a 4 mm (0.15 inch) diameter bead of sealant
(MITSUBISHI Genuine Part number MD970389 or
equivalent) to the flange of the oil pan.
Apply sealant as indicated by the broken line in the
illustration; the grooves must be traced and the bolt holes
must be surrounded with a bead of sealant.
3. Install the oil pump case assembly to the front side of the
cylinder block.
NOTE: Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
GROOVE

SEALANT
BOLT HOLE

AKX00532AB

4. Fit an 8 mm (0.30 inch) long bolt in each of the two holes

TIMING BELT SIDE identified by the letter "S" in the illustration and a 10 mm
(0.39 inch) long bolt in each of the remaining 17 holes.
Tighten all bolts to the specified torque.
S
Tightening torque: 9.0 ± 3.0 N⋅m (80 ± 26 in-lb)
NOTE: After installation, keep the sealed area away from
the oil for approximately one hour.

AKX00496AB

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11B-52 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

>>N<< DRAIN PLUG GASKET INSTALLATION

CAUTION
If the gasket is installed in the wrong direction, oil leaks
will occur.
Install the drain plug gasket in the direction shown.
DRAIN PLUG

OIL PAN
GASKET

OIL PAN
SIDE

AKX00596AB

>>M<< OIL FILTER INSTALLATION

1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the o-ring of the oil filter.
BRACKET SIDE 3. Install the oil filter to the bracket and tighten it to the
specified torque.
Tightening torque: 14 ± 2 N⋅m (124 ± 17 in-lb)
4. If no torque wrench can be used for tightening, use the
following procedure:
(1) Screw in the oil filter until its o-ring contacts the oil filter
AKX00529AB bracket.
(2) Tighten the oil filter 3/4 turn.

INSPECTION
M1113008200182
.

COUNTERBALANCER SHAFTS
1. Check that the oil holes are not blocked.
Clean if necessary.

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 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-53
2. Check the journals for seizure, damage and defective
contact with bearings.
If any of these faults is found, replace the counterbalancer
shaft, bearings and/or oil pump case assembly.

AK202835AC

OIL PUMP
1. Install the drive and driven gears in the oil pump case.
2. Measure the gear side clearance using a straight edge and
thickness gauge.
Standard values:
Drive gear 0.08 − 0.14 mm (0.0031 − 0.0055 inch)
Driven gear 0.06 − 0.12 mm (0.0023 − 0.0047 inch)

AK202831

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11B-54 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION
M1113008400506

6
APPLY ENGINE OIL 7
TO ALL MOVING
PARTS BEFORE 8
INSTALLTION.
10
9 4

12

11

2 20 ± 2 N·m
15 ± 1 ft-lb
1 +
AK203815AB
90˚ to 94˚

REMOVAL STEPS REMOVAL STEPS (Continued)

>>G<< 1. NUT >>C<< 7. PISTON RING NO.2
<<A>> >>F<< 2. CONNECTING ROD CAP >>B<< 8. OIL RING
>>E<< 3 CONNECTING ROD BEARING <<B>> >>A<< 9. PISTON PIN
>>D<< 4. PISTON AND CONNECTING ROD 10. PISTON
>>E<< 5. CONNECTING ROD BEARING 11. CONNECTING ROD
>>C<< 6. PISTON RING NO.1 12. BOLT

Required special tool:

• MIT216941: Piston Pin Setting Tool

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 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-55
REMOVAL SERVICE POINTS
.

<<A>> CONNECTING ROD CAP REMOVAL

1. Mark the cylinder number on the side of the connecting rod
big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in
CYLINDER NUMBER
that order according to the cylinder number.

AKX00600AB

<<B>> PISTON PIN REMOVAL

PISTON PIN SETTING
TOOL MIT216941 ITEM NO. PART NO. DESCRIPTION
1 1. MIT310134 Base
2
2. MIT310136 Piston support
3. MIT310137 Connecting rod guide pin
4. MIT310138 Connecting rod guide pin
3 4 5
5. MIT310139 Connecting rod guide pin
6. MIT310140 Piston support
6 7 8 7. MIT310141 Connecting rod guide pin
8. MIT310142 Piston support
11 9. MIT48143 Press pin
10
10. 216943 Stop screw
9 11. 10396 Nut

1. Remove the stop screw from the base.

AKX00598AB 2. Select the correct piston support for your application (See
above). Fit the piston support onto the base. Place the base
on press support blocks.

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11B-56 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

3. Insert the press pin through the piston pin hole. Select the
correct connecting rod guide pin (See above). Thread the
guide pin onto the threaded portion of the press pin.
PRESS 4. Position the piston assembly on the piston support in the
PIN
press. With the press pin up as shown, insert the guide pin
PISTON PIN
through the hole in the piston and through the hole in the
piston support.
FRONT MARK
FRONT CAUTION
MARK
To avoid piston damage, the piston support must seat
squarely against the piston. Verify that the piston pin will
slide through the hole in the piston support.
CONNECTING 5. Press the piston pin out of the assembly.
ROD GUIDE PIN
6. Remove the piston pin from the press pin.
BASE

AKX00516AB

INSTALLATION SERVICE POINTS

.

>>A<< PISTON PIN INSTALLATION

TIMIMG BELT SIDE
1. When replacing the piston, read off the cylinder bore size
CRANKSHAFT
BORE SIZE
mark on the cylinder block as illustrated, and select a piston
MARK according to the flowing table.
CYLINDER BORE PISTON SIZE MARK
No.4 SIZE MARK
No.3 I A
No.2
No.1 II None

AK200852 AC
III C

NOTE: The piston size mark shows on the top of the piston.

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 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-57
2. Thread the stop screw and lock nut assembly into the base.
Fit the correct piston support on top of the base. Insert the
press pin, threaded end up, into the hole in the piston
support until the press pin touches the stop screw.
3. Using the markings on the press pin, adjust the stop screw
PRESS
PIN to the depth shown on the instruction for special tool
BASE MIT216941.
PISTON
SUPPORT
LOCKNUT

STOP SCREW

PIN DEPTH SET FLAT PISTON

LOCATION SUPPORT

AKX00599AB

4. Place the base on press support blocks.

5. Slide the piston pin over the threaded end of the press pin,
PRESS PIN and thread the correct guide pin up against it.
6. Coat the piston pin with engine oil. With the connecting rod
PISTON PIN held in position, slide the guide pin through the piston and
FRONT connecting rod.
FRONT MARK
MARK 7. Press the piston pin through the connecting rod until the
guide pin contacts the stop screw.

CONNECTING
CAUTION
ROD GUIDE PIN Due to production tolerance variations, it is necessary to
visually inspect the piston pin depth after installation to
verify that the piston pin is centered. Adjust if necessary.
BASE
8. Remove the piston assembly from the base. Remove the
guide pin and press pin from the assembly.

STOP JAM NUT

SCREW

AKX00517AB

9. Check that the piston moves smoothly.

AKX00568

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11B-58 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
.

>>B<< OIL RING INSTALLATION

1. Fit the oil ring spacer into the piston ring groove.
UPPER SIDE RAIL
NOTE: The side rails and spacer may be installed in either
direction.
NOTE: New spacers and side rails are colored for identifica-
tion of their sizes.
SPACER
SIZE IDENTIFICATION COLOR
Standard None
LOWER SIDE RAIL
AKX00473AB
0.50 mm (0.020 in) oversize Red
diameter
1.00 mm (0.040 in) oversize Yellow
diameter

CAUTION
Do not use a piston ring expander when installing side rail.
SIDE RAIL END
2. Install the upper side rail.
To install the side rail, first fit one end of the rail into the
piston groove, then press the remaining portion into position
by finger. See illustration.
3. Install the lower side rail in the same procedure as described
in step 2.
4. Make sure that the side rails move smoothly in both
directions.
AKX00442AB

>>C<< PISTON RING NUMBER 2/PISTON RING NUMBER 1

INSTALLATION
1. To prevent wrong installation, check the identification mark
IDENTIFICATION MARK "1R" of each piston ring. The identification mark is stamped near
IDENTIFICATION SIZE MARK the ring gap:
MARK "2R"
Identification mark:
Number 1 ring: 1R
NO.1 Number 2 ring: 2R
NO.2 NOTE: Size marks on piston rings are as follows.
SIZE SIZE MARK
AKX00527AB Standard No.1 ring (None) White paint to the ring periphery
No.2 ring (None) Black paint to the ring periphery
0.50 mm (0.020 in) 50
oversize diameter
1.00 mm (0.040 in) 100
oversize diameter

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 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-59
2. Using the piston ring expander, fit number 2 into the number
2 groove of piston.
NOTE: Install piston rings with identification mark facing up,
to the piston crown side.
3. Install the number 1 piston ring in the same manner as step
2.

AKX00515

>>D<< CONNECTING ROD BEARING INSTALLATION

IDENTIFICATION MARK OF CRANKSHAFT 1. Measure the crankshaft pin diameter and confirm its
PIN DIAMETER classification from the following table. In the case of a
crankshaft supplied as a service part, identification marks of
its pins are stamped at the positions shown in the
illustration.
CRANKSHAFT PIN OUTSIDE CONNECTING
NO.2
DIAMETER ROD BEARING
NO.1 NO.3
IDENTIFICATION SIZE mm (in) IDENTIFICATION
NO.4 MARK MARK
AK102988AB
I 44.995 − 45.000 0
IDENTIFICATION MARK OF CONNECTING (1.7715 − 1.7717)
ROD BEARING SIZE
II 44.985 − 44.995 1
(1.7711 − 1.7715)
III 44.980 − 44.985 2
(1.7709 − 1.7711)

2. If the crankshaft pin outside diameter identification mark is

IDENTIFICATION
MARK "I", for example, select a bearing whose identification mark
AK203964AB
is "0."
If there is no identification mark or no identification color
paint on the crankshaft, measure the pin outside diameter
and select a bearing appropriate for the measured value.
3. Install the selected bearing in the big end and in the cap of
the connecting rod.
.

>>E<< PISTON AND CONNECTING ROD INSTALLATION

1. Apply engine oil on the circumference of the piston, piston
UPPER SIDE NO.1 rings, and oil ring.
RAIL
2. Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the illustration.
TIMING BELT
SIDE PISTON PIN 3. Rotate the crankshaft so that crank pin is on the center of
the cylinder bore.

LOWER
NO.2 RING GAP SIDE RAIL
AND SPACER GAP
AKX00456AB

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11B-60 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

4. Use suitable thread protectors on the connecting rod bolts

TIMING BELT SIDE
before inserting the piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.
5. Insert the piston and connecting rod assembly into the
cylinder with front mark on the piston crown pointing to the
FRONT MARK timing belt side.
CAUTION
Must be careful the piston and connecting rod shall not
AK102993 AB
touch to the oil jet at the installation.
6. Using a suitable piston ring compressor tool,0 install the
piston and connecting rod assembly into the cylinder block.
.

>>F<< CONNECTING ROD CAP INSTALLATION

1. Verifying the mark made during disassembly, install the
bearing cap to the connecting rod. If the connecting rod is
new with no index mark, make sure that the bearing locking
notches are on the same side as shown.
CYLINDER NO.

NOTCHES

AKX00535AB

2. Make sure that the connecting rod big end side clearance
meets the specification.
Standard value: 0.10 − 0.25 mm (0.004 − 0.009 inch)
Limit: 0.4 mm (0.015 inch)

AKX00578

>>G<< CONNECTING ROD CAP NUT TIGHTENING

1. The connecting rod bolts should be examined before reuse.
If the bolt threads are damaged, the bolt should be replaced.
Hand-thread the nut to the full length of the bolt threads. If
the nut does not run down smoothly, the bolt should be
replaced.
2. Before installation of each nut, apply engine oil to the
threaded portion and bearing surface of the nut.
3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to a torque of 20 ± 2 N⋅m
(15 ± 1 ft-lb) to install the cap properly.

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 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-61
5. Make a paint mark on the head of each nut.
PAINT MARK
90˚ to 94̊ CAUTION
PAINT
MARK • If the nut is turned less than 90 degree angle, proper
fastening performance may not be achieved. Be careful
to tighten the nut exactly 90 degree angle.
• If the nut is overtightened (exceeding 94 degree angle),
NUT loosen the nut completely and then retighten it by
BOLT
repeating the tightening procedure from step 3.
6. Make a paint mark on the bolt end at the position 90 degree
AKX00450AB
angle to 94 degree angle from the paint mark made on the
nut in the direction of tightening the nut.
7. Turn the nut further 90 degree angle to 94 degree angle and
make sure that the paint marks on the nut and bolt are
aligned.

INSPECTION
M1113008500343
.

PISTON RING
1. Check for side clearance.
If the limit is exceeded, replace the ring or piston, or both.
Standard value:
No.1: 0.03 − 0.07 mm (0.0012 − 0.0028 inch)
No.2: 0.02 − 0.06 mm (0.0008 − 0.0024 inch)
Limit:
No.1: 0.1 mm (0.0039 inch)
No.2: 0.1 mm (0.0039 inch)
AK202787

2. Install the piston ring into the cylinder bore. Force the ring
FORCE RING DOWN down with a piston, the piston crown being in contact with
WITH PISTON
the ring, to correctly position it at right angles to the cylinder
wall. Then, measure the end gap with a feeler gauge.
If the end gap is excessive, replace the piston ring.
Standard value:
No.1 ring: 0.20 − 0.30 mm (0.0079 − 0.0118 inch)
No.2 ring: 0.35 − 0.50 mm (0.0128 − 0.0197 inch)
Oil ring: 0.10 − 0.40 mm (0.0039 − 0.0157 inch)
PISTON RING END GAP AK202788 AC
Limit:
No.1, No.2 ring: 0.8 mm (0.031 inch)
Oil ring: 1.0 mm (0.039 inch)
.

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11B-62 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

CRANKSHAFT PIN OIL CLEARANCE

(PLASTIC GAUGING MATERIAL METHOD)
1. Remove oil from the crankshaft pin and connecting rod
bearing.
2. Cut the plastic gauging material to the same length as the
width of bearing and place it on crankshaft pin in parallel
with its axis.v
3. Install the connecting rod cap carefully and tighten the nuts
to the specified torque. (See "Connecting rod cap nut
tightening" procedure.)
PLASTIC GAUGING 4. Carefully remove the connecting rod cap.
MATERIAL AK100208AB
5. Measure the width of the plastic gauging material at its
widest part by using a scale printed on its package.
Standard value: 0.03 − 0.05 mm (0.0012 − 0.0020 inch)
Limit: 0.1 mm (0.004 inch)

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 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-63
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION
M1113008700488

11 ± 1 N·m
98 ± 8 in-lb
3

1
15 6
132 ± 5 N·m
98 ± 3 ft-lb

4
5 9.0 ± 1.0 N·m
80 ± 8 in-lb
11 ± 1 N·m
12 98 ± 8 in-lb
14 11

13
32 ± 2 N·m
24 ± 1 ft-lb 10

8 APPLY ENGINE OIL

TO ALL MOVING
PARTS BEFORE
25 ± 2 N·m INSTALLTION.
18 ± 1 ft-lb + 90˚
7

AK203816 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. FLY WHEEL BOLT >>B<< 9. CRANKSHAFT BEARING, LOWER
2. FLY WHEEL 10. CRANKSHAFT
3. REAR PLATE >>B<< 11. CRANKSHAFT BEARING, UPPER
4. BELL HOUSING COVER >>A<< 12. THRUST BEARING
>>E<< 5. OIL SEAL CASE 13. CHECK VALVE
>>D<< 6. OIL SEAL 14. OIL JET
>>C<< 7. BEARING CAP BOLT 15. CYLINDER BLOCK
>>C<< 8. BEAM BEARING CAP

Required Special Tools:

• MD998776: Crankshaft Rear Oil Seal Installer • MB990938: Handle
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11B-64 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

INSTALLATION SERVICE POINTS

.

>>A<< CRANKSHAFT THRUST BEARING INSTALLATION

1. Install the two thrust bearings in the number 3 bearing bore
in the cylinder block. For easier installation, apply engine oil
to the bearings; this will help hold them in position.
2. The thrust bearings must be installed with their groove side
toward the crankshaft web.

GROOVE
AKX00497AB

>>B<< CRANKSHAFT BEARING INSTALLATION

When bearing replacement is required, select and install the
correct bearing by the following procedure.
IDENTIFICATION MARK OF CRANKSHAFT 1. Measure the crankshaft journal diameter and confirm its
JOURNAL DIAMETER classification from the following table. In the case of a
crankshaft supplied as a service part, identification marks of
its journals are stamped at the positions shown in the
illustration.

NO.2
NO.1 NO.3

NO.4 NO.5 AK102989AB

2. The cylinder block bearing bore diameter identification

IDENTIFICATION MARK OF BEARING marks are stamped at the position shown in the illustration
BORE SIZE
from left to right, beginning at No.1.

NO.1 NO.2 NO.3 NO.4 NO.5

BEARING BORE
IDENTIFICATION
MARK

CYLINDER
INNER
DIAMETER
SIZE MARK

BOTTOM OF REAR FACE OF

CYLINDER BLOCK CYLINDER
BLOCK

AKX00499AC

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 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-65

CRANKSHAFT JOURNAL OUTSIDE CYLINDER BLOCK CRANKSHAFT BEARING

DIAMETER BEARING BORE
IDENTIFICATION SIZE mm (in) IDENTIFICATION MARK IDENTIFICATION MARK
MARK
0 56.994 − 57.000 0 0
(2.2439 − 2.2441)
1 1
2 2
1 56.988 − 56.994 0 1
(2.2436 − 2.2439)
1 2
2 3
2 56.982 − 56.988 0 2
(2.2434 − 2.2436)
1 3
2 4

IDENTIFICATION MARK OF For example, if the crankshaft journal outside diameter identifi-
CRANKSHAFT BEARING SIZE cation mark is "0" and cylinder block bearing bore identification
mark is "1," select a bearing whose identification mark is "1".
If there is no identification mark stamp on the crankshaft, mea-
sure the journal outside diameter and select a bearing appropri-
ate for the measured value.

IDENTIFICATION
MARK
AK203965 AB

3. Install the bearings having an oil groove to the cylinder

block.
GROOVE
4. Install the bearings having no oil groove to the bearing cap.

FOR UPPER

FOR LOWER
AKX00498AB

>>C<< BEARING CAP/BEARING CAP BOLT INSTALLATION

1. Install the bearing caps so that the arrow points to the timing
belt side.
2. Before installing the bearing cap bolts, check that the shank
length of each bolt meets the limit. If it exceeds the limit,
replace the bolt.
Limit (A): 71.1 mm (2.79 inches)
A
3. Apply engine oil to the threaded portion and bearing surface
SHANK LENGTH
of the bolt.
AKX00525AB

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11B-66 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

4. Tighten the bolts to 25 ± 2 N⋅m (18 ± 1 ft-lb) in the tightening

sequence shown.

8 4 1 5 9

7 3 2 6 10

ARROW AK202737 AC

5. Make a paint mark on the head of each bolt.

6. Make a paint mark on the bearing cap at the position 90
PAINT MARK PAINT MARK
degree angle from the paint mark made on the bolt in the
direction of tightening the bolt.
CAUTION
• If the bolt is overtightened, loosen the bolt completely
and then retighten it by repeating the tightening proce-
90˚ dure from step 4.
• If the bolt is turned less than 90 degree angle, proper
AKX00451AB
fastening performance may not be achieved. Be sure to
turn the bolt exactly 90 degree angle.
7. Turn each bolt 90 degree angle in the tightening sequence
specified in step 4, and make sure that the paint marks on
the bolt and cap are aligned.
8. Make sure that the crankshaft turns smoothly and the end
play is correct. If the end play exceeds the limit, replace the
number 3 crankshaft bearings.
Standard value: 0.05 − 0.25 mm (0.002 − 0.009 inch)
Limit: 0.40 mm (0.0015 inch)

AKX00580

>>D<< OIL SEAL INSTALLATION

Using special tools MD998776 and MB990938, press-fit the oil
seal in the case.
MB990938

MD998776

AKX00588AB

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 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-67
>>E<< SEALANT APPLICATION TO OIL SEAL CASE
1. Apply sealant MITSUBISHI Genuine Part number
MD970389 or equivalent to the gasket surface of oil seal
case.
NOTE: Be sure to install the case quickly while the sealant is
wet (within 15 minutes).
2. Apply engine oil to the oil seal lip, and then install the oil seal
case onto the cylinder block.
NOTE: After installation, keep the sealed area away from
the oil for approximately one hour.
AKX00581

INSPECTION
M1113008800344
.

CRANKSHAFT JOURNAL OIL CLEARANCE

<PLASTIC GAUGING MATERIAL METHOD>
1. Remove oil from the crankshaft journal and crankshaft
PLASTIC GAUGING MATERIAL bearing.
2. Install the crankshaft.
3. Cut the plastic gauging material to the same length as the
width of bearing and place it on journal in parallel with its
axis.

AKX00586AB

4. Install the crankshaft bearing cap carefully and tighten the

bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the plastic gauging material at its
widest part by using a scale printed on the plastic gauging
material package.
Standard value: 0.02 − 0.04 mm (0.0008 − 0.0015 inch)
PLASTIC GAUGING Limit: 0.1 mm (0.003 inch)
MATERIAL
AKX00579AB

CYLINDER BLOCK
C D E 1. Visually check for scratches, rust, and corrosion.
A F Use also a flaw detecting agent for the check. If defects are
B G evident, correct or replace.
2. Using a straightedge and feeler gauge, check the block top
surface for war page. Make sure that the surface is free from
gasket chips and other foreign matter.
Standard value: 0.05 mm (0.0020 inch)
Limit: 0.1 mm (0.003 inch)

AKX00605AB
3. If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm (0.007 inch)
*Includes/combined with cylinder head grinding

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11B-68 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

Cylinder block height (when new):

290 mm (11.4 inches)
4. Check cylinder walls for scratches and seizure. If defects
are evident, replace or bore to oversize and replace pistons
and piston rings.
5. Using a cylinder gauge, measure the cylinder bore and
cylindrically. If worn badly, correct the cylinder to an oversize
A and replace the piston and piston rings. Measure at the
B points shown in the illustration.
Standard value:
12 mm
(0.5 in) Cylinder inner diameter 85.0 mm (3.35 inches)
Cylindrically 0.01 mm (0.0003 inch) or less
CENTER
BOTTOM
AKX00457AB

BORING CYLINDER
1. Oversize pistons to be used should be determined on the
basis of the largest bore cylinder.
Piston size identification
SIZE IDENTIFICATION MARK
0.50 mm (0.020 in) oversize 50
diameter

12.5 mm 1.00 mm (0.040 in) oversize 100

PISTON DIAMETER diameter
AK203804 AB

NOTE: Size mark is stamped on the piston top.

2. Measure the outside diameter (OD) of the piston to be used.
Measure it in thrust direction as shown.
3. Based on the measured piston OD, calculate the boring
finish dimension.
Boring finish dimension = Piston OD +
(clearance between piston OD and cylinder) −
0.02 mm (0.0008 inch) (honing margin)
CAUTION
To prevent distortion that may result from temperature rise
during honing, bore cylinders, working from number 2 to
number 4 to number 1 to number 3.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance
between piston OD and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.02 − 0.04 mm (0.0008 − 0.0015 inch)
NOTE: When boring cylinders, finish all of four cylinders to
the same oversize. Do not bore only one cylinder to an over-
size.

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 ENGINE OVERHAUL
SPECIFICATIONS
11B-69
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1113023400484

Items Specifications
Generator and ignition coil
Auto-tensioner assembly bolt M8 24 ± 4 (18 ± 2 ft-lb)
Auto-tensioner assembly bolt M10 44 ± 10 (33 ± 6 ft-lb)
Center cover bolt 3.0 ± 0.5 (27 ± 3 in-lb)
Crankshaft pulley bolt 25 ± 4 (19 ± 2 ft-lb)
Generator brace bolt (flange bolt) 23 ± 3 (17 ± 2 ft-lb)
Generator brace bolt (bolt, washer assembly) 22 ± 4 (17 ± 2 ft-lb)
Generator pivot nut 44 ± 10 (33 ± 6 ft-lb)
Idler pulley bolt 79 ± 5 (58 ± 3 ft-lb)
Ignition coil bolt 10 ± 2 (89 ± 17 in-lb)
Oil dipstick guide bolt 13 ± 1 (115 ± 8 in-lb)
Spark plugs 25 ± 5 (19 ± 3 ft-lb)
Water pump pulley bolt 8.8 ± 1.0 (78 ± 8 in-lb)
Vacuum pipe and hose
Solenoid valve assembly bolt 9.0 ± 1.0 (80 ± 8 in-lb)
Vacuum pipe and hose assembly bolt 11 ± 1 (98 ± 8 in-lb)
Timing belt
Auto-tensioner bolt 24 ± 3 (18 ± 1 ft-lb)
Camshaft sprocket bolt 88 ± 10 (65 ± 7 ft-lb)
Counterbalance shaft sprocket bolt 45 ± 3 (33 ± 2 ft-lb)
Crankshaft angle sensors bolt 8.8 ± 1.0 (78 ± 8 in-lb)
Crankshaft bolt 167 (123 ft-lb)
Engine support bracket bolt 49 ± 5 (36 ± 3 ft-lb)
Idler pulley 35 ± 6 (26 ± 4 ft-lb)
Oil pump sprocket nut 54 ± 4 (40 ± 2 ft-lb)
PCV valve 10 ± 2 (89 ± 17 in-lb)
Power steering pump bracket bolt 49 ± 9 (36 ± 6 ft-lb)
Rocker cover bolt 3.5 ± 0.5 (31 ± 4 in-lb)
Tensioner arm bolt 21 ± 4 (16 ± 2 ft-lb)
Tensioner B bolt 19 ± 3 (14 ± 2 ft-lb)
Tensioner pulley bolt 48 ± 6 (35 ± 4 ft-lb)
Timing belt cover bolt (flange bolt) 11 ± 1 (98 ± 8 in-lb)
Timing belt cover bolt (bolt, washer assembly) 9.0 ± 1.0 (80 ± 8 in-lb)
Fuel system
EGR valve bolt 20 ± 2 (15 ± 1 ft-lb)
Fuel pressure regulator bolt 8.8 ± 2.0 (79 ± 16 in-lb)
Fuel rail bolt 12 ± 1 (107 ± 8 in-lb)

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11B-70 ENGINE OVERHAUL
SPECIFICATIONS

Items Specifications
Throttle body bolt 19 ± 3 (14 ± 2 ft-lb)
Intake manifold
Air control valve bracket bolt 23 ± 4 (17 ± 2 ft-lb)
Bracket bolt 11 ± 1 (98 ± 8 in-lb)
Engine hanger bolt 22 ± 4 (17 ± 2 ft-lb)
Intake manifold bolt M8 20 ± 2 (15 ± 1 ft-lb)
Intake manifold bolt, nut M10 36 ± 6 (26 ± 4 ft-lb)
Intake manifold stay bolt 31 ± 3 (23 ± 2 ft-lb)
MDP sensor bolt 5.0 ± 1.0 (45 ± 8 in-lb)
Exhaust manifold
Air outlet fitting bolt 19 ± 1 (14 ± 1 ft-lb)
Engine hanger bolt 19 ± 3 (14 ± 2 ft-lb)
Exhaust fitting bolt 59 ± 5 (44 ± 3 ft-lb)
Exhaust fitting bracket bolt 36 ± 5 (27 ± 3 ft-lb)
Exhaust manifold heat protector bolt 14 ± 1 (124 ± 8 in-lb)
Exhaust manifold nut M8 29 ± 3 (21 ± 2 ft-lb)
Exhaust manifold nut M10 49 ± 5 (36 ± 3 ft-lb)
Oil pipe bolt (eye bolt M10) 17 ± 2 (13 ± 1 ft-lb)
Oil pipe bolt (eye bolt M12) 31 ± 2 (23 ± 1 ft-lb)
Oil pipe bolt (flange bolt) 11 ± 1 (98 ± 8 in-lb)
Oil return pipe bolt (oil pan side) 14 ± 1 (124 ± 8 in-lb)
Oil return pipe bolt (turbocharger side) 9.0 ± 1.0 (80 ± 8 in-lb)
Oxygen sensor 44 ± 5 (33 ± 3 ft-lb)
Turbocharger assembly and pipe assembly bolt, nut 64 ± 5 (47 ± 3 ft-lb)
Turbocharger heat protector bolt 14 ± 1 (124 ± 8 in-lb)
Water pipe bolt (eye bolt M12) 42 ± 7 (31 ± 5 ft-lb)
Water pipe bolt (flange bolt) 10 ± 1 (89 ± 8 in-lb)
Water pump and water hose
Engine coolant temperature gauge unit 10.8 ± 1.0 (96 ± 8 in-lb)
Engine coolant temperature sensor 29 ± 10 (22 ± 6 ft-lb)
Knock sensor bolt 23 ± 2 (17 ± 2 ft-lb)
Thermostat housing bolt 23 ± 4 (17 ± 2 ft-lb)
Water inlet pipe bolt M6 5.0 ± 1.0 (45 ± 8 in-lb)
Water inlet pipe bolt M8 13 ± 2 (115 ± 17 in-lb)
Water outlet fitting bolt 10 ± 1 (89 ± 8 in-lb)
Water pump bolt 14 ± 1 (124 ± 8 in-lb)
Rocker arms and camshafts
Bearing cap bolt 20 ± 1 (15 ± 1 ft-lb)
Camshaft position sensing cylinder bolt 22 ± 4 (17 ± 2 ft-lb)
Camshaft position sensor bolt 8.8 ± 1.0 (78 ± 8 in-lb)

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 ENGINE OVERHAUL
SPECIFICATIONS
11B-71
Items Specifications
Camshaft position sensor support bolt 14 ± 1 (124 ± 8 in-lb)
Cover bolt 10 ± 2 (89 ± 17 in-lb)
Oil delivery body bolt 11 ± 1 (98 ± 8 in-lb)
Cylinder head and valves
Cylinder head bolt 78 ± 2 (58 ± 1 ft-lb) → back off
→ 20 ± 2 (15 ± 1 ft-lb) → 90° + 90°
Oil pump case and oil pan
Baffle plate bolt 22 ± 4 (17 ± 2 ft-lb)
Drain plug 39 ± 5 (29 ± 3 ft-lb)
Flange bolt 36 ± 3 (27 ± 1 ft-lb)
Oil cooler by-pass valve 54 ± 5 (40 ± 3 ft-lb)
Oil filter 14 ± 2 (124 ± 17 in-lb)
Oil filter bracket bolt 19 ± 3 (14 ± 2 ft-lb)
Oil pan bolt 9.0 ± 3.0 (80 ± 26 in-lb)
Oil pressure switch 19 ± 3 (14 ± 2 ft-lb)
Oil pump case bolt 23 ± 3 (17 ± 2 ft-lb)
Oil pump cover bolt 17 ± 1 (13 ± 1 ft-lb)
Oil pump cover screw 10 ± 2 (89 ± 17 in-lb)
Oil screen bolt 19 ± 3 (14 ± 2 ft-lb)
Plug cap 23 ± 3 (17 ± 2 ft-lb)
Relief plug 44 ± 5 (33 ± 3 ft-lb)
Pistons and connecting rods
Connecting rod cap nut 20 ± 2 (15 ± 1 ft-lb) + 90° to 94°
Crankshaft and cylinder block
Beam bearing cap bolt 25 ± 2 (18 ± 1 ft-lb) + 90°
Bell housing cover bolt 9.0 ± 1.0 (80 ± 8 in-lb)
Check valve 32 ± 2 (24 ± 1 ft-lb)
Flywheel bolt 132 ± 5 (98 ± 3 ft-lb)
Oil seal case bolt 11 ± 1 (98 ± 8 in-lb)
Rear plate bolt 11 ± 1 (98 ± 8 in-lb)

GENERAL SPECIFICATIONS
M1113000200456

Descriptions Specifications
Type In-line OHV, DOHC
Number of cylinders 4
Combustion chamber Pentroof type
Total displacement dm3 (cubic inches) 1,997 (122)
Cylinder bore mm (in) 85.0 (3.35)
Piston stroke mm (in) 88.0 (3.46)
Compression ratio 8.8

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11B-72 ENGINE OVERHAUL
SPECIFICATIONS

Descriptions Specifications
Number of valve Intake 2
Exhaust 2
Valve timing Intake valve Opens (BTDC) 21°
Closes (ABDC) 59°
Exhaust valve Opens (BBDC) 58°
Closes (ATDC) 18°
Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
Cooling system Water-cooled forced circulation
Water pump type Centrifugal impeller type

SERVICE SPECIFICATIONS
M1113000300390

Items Standard value Limit

Timing belt
Auto tensioner rod length mm (in) 4.8 − 6.0 (0.19 − 0.21) −
Auto tensioner rod production length mm (in) 12 (0.5) −
Auto tensioner rod pushed-in amount 1.0 (0.03) or less −
[when pushed with a force of 98 to 196 N (22 to 44 lb)] mm
(in)
Rocker arms and camshaft
Camshaft cam height mm (in) Intake 35.79 (1.41) 35.29 (1.39)
Exhaust 35.49 (1.40) 34.99 (1.38)
Cylinder head and valve
Cylinder head flatness of gasket surface mm (in) Less than 0.03 (0.0012) 0.2 (0.008)
Cylinder head grinding limit of gasket surface mm (in) − 0.2* (0.008)
*Total resurfacing depth of both cylinder head and cylinder
block
Cylinder head overall height mm (in) 119.9 − 120.1 −
(4.720 − 4.728)
Cylinder head bolt shank length mm (in) − 99.4 (3.913)
Valve stem outside diameter mm (in) 6.0 (0.236) −
Valve stem-to-guide clearance mm (in) Intake 0.02 − 0.05 0.10 (0.0039)
(0.0008 − 0.0020)
Exhaust 0.05 − 0.09 0.15 (0.0059)
(0.0020 − 0.0035)
Valve face angle 45° − 45.5° −
Valve margin mm (in) Intake 1.0 (0.039) 0.5 (0.020)
Exhaust 1.5 (0.059) 1.0 (0.039)
Valve stem projection mm (in) Intake 49.20 (1.9370) 49.70 (1.9567)
Exhaust 48.40 (1.9055) 48.90 (1.9252)

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 ENGINE OVERHAUL
SPECIFICATIONS
11B-73
Items Standard value Limit
Overall valve length mm (in) Intake 109.50 (4.311) 109.00 (4.291)
Exhaust 109.70 (4.319) 109.20 (4.299)
Valve spring free height mm (in) 50.4 (1.98) 49.4 (1.94)
Valve spring load/installed height N (lb) /mm (in) 279/40 (63/1.57) −
Valve spring squareness Max. 2° 4°
Valve seat contact width mm (in) 0.9 − 1.3 (0.035 − 0.051) −
Valve guide inside diameter mm (in) 6.0 (0.236) −
Valve guide projection mm (in) 19.5 (0.768) −
Oversize valve guide hole diameter mm (in) 0.05 oversize 12.05 − 12.07 −
diameter (0.4744 − 0.4751)
0.25 oversize 12.25 − 12.27 −
diameter (0.4921 − 0.4929)
0.50 oversize 12.50 − 12.52 −
diameter (0.4528 − 0.4535)
Oversize intake valve seat hole diameter 0.30 oversize 35.30 − 35.33 −
mm (in) diameter (1.3898 − 1.3909)
0.60 oversize 35.60 − 35.63 −
diameter (1.4016 − 1.4028)
Oversize exhaust valve seat hole diameter 0.30 oversize 33.30 −33.33 −
mm (in) diameter (1.3110 − 1.3122)
0.60 oversize 33.60 − 33.63 −
diameter (1.3228 − 1.3240)
Oil pump and oil pan
Oil pump side clearance mm (in) Drive gear 0.08 − 0.14 −
(0.0031 − 0.0055)
Driven gear 0.06 − 0.12 −
(0.0023 − 0.0047)
Piston and connecting rod
Piston outside diameter mm (in) 85.0 (3.35) −
Piston ring side clearance mm (in) No.1 0.03 − 0.07 0.1 (0.0039)
(0.0012 − 0.0028)
No.2 0.02 − 0.06 0.1 (0.0039)
(0.0008 − 0.0024)
Piston ring end gap mm (in) No.1 0.20 − 0.30 0.8 (0.031)
(0.0079 − 0.0118)
No.2 0.35 − 0.50 0.8 (0.031)
(0.0128 − 0.0197)
Oil ring 0.10 − 0.40 1.0 (0.039)
(0.0039 − 0.0157)
Piston pin outside diameter mm (in) 22.0 (0.87) −
Piston pin press-in load [at room temperature] N (lb) 7,350 − 17,200 −
(1.653 − 3.866)

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11B-74 ENGINE OVERHAUL
SPECIFICATIONS

Items Standard value Limit

Crankshaft pin oil clearance mm (in) 0.03 − 0.05 0.1 (0.004)
(0.0012 − 0.0020)
Connecting rod big end side clearance mm (in) 0.10 − 0.25 0.4 (0.016)
(0.0039 − 0.0098)
Crankshaft and cylinder block
Crankshaft end play mm (in) 0.05 − 0.25 0.4 (0.016)
(0.0020 − 0.0098)
Crankshaft journal outside diameter mm (in) 57 (2.24) −
Crankshaft pin outside diameter mm (in) 45 (1.77) −
Crankshaft journal oil clearance mm (in) 0.02 − 0.04 0.1 (0.004)
(0.0008 − 0.0016)
Cylinder block gasket surface flatness mm (in) 0.05 (0.0020) 0.1 (0.004)
Cylinder block gasket surface grinding limit mm (in) − 0.2 (0.008)
Cylinder block overall height mm (in) 290(11.4) −
Cylinder bore inside diameter mm (in) 85.0 (3.35) −
Cylinder bore cylindricity mm (in) 0.01 (0.0004) or less −
Piston-to-cylinder clearance mm (in) 0.02 − 0.04 −
(0.0008 − 0.0016)
Bearing cap bolt shank length mm (in) − 71.1 (2.799)

SEALANTS AND ADHESIVES

M1113000500383

Items Specified sealant Quantity

Rocker cover Mitsubishi Genuine Part No.MD970389 or equivalent As required
Semicircular packing 3Mä AAD Part No.8660 or equivalent As required
Engine support bracket 3Mä AAD Part No.8672 or equivalent As required
Engine coolant temperature 3Mä AAD Part No.8731 or equivalent As required
sensor
Engine coolant temperature 3Mä AAD Part No.8672 or equivalent As required
gauge unit
Water outlet fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required
Thermostat housing Mitsubishi Genuine Part No.MD970389 or equivalent As required
Camshaft position sensor Mitsubishi Genuine Part No.MD970389 or equivalent As required
support
Oil pan Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pressure switch 3Mä AAD Part No.8672 or equivalent As required
Oil seal case Mitsubishi Genuine Part No.MD970389 or equivalent As required

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