Ⅰ Engine Ⅰ-1

ENGINE MAINTENANCE

General ············································································· I-2

4G64 S4 MPI Engine ························································ I-5

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 Ⅰ-2 Ⅰ Engine

GENERAL

Operation Instructions ····················································I -3

Engine Type ···································································I -4
Tightening Torques ························································I -4
Sealant （FIPG） ·························································I -4

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 Ⅰ Engine Ⅰ-3
Ⅰ-3

Operation Instructions
Assembly Name Subassembly Name
。
Maintenance Steps Removal steps: The part numbers correspond
(1) The front figure shows the sectional diagram to the numbers in the composition diagram Engine - Front cover,
from which we can know the installation status and express the removal steps Oil Pump

of all the parts. Disassembly steps: The part numbers Front cover, oil pump
correspond to the numbers in the Removal and installation
The part numbers are used for the working composition diagram and express the
steps, at the same time non-reusable parts disassembly steps Non-reusable part
(denoted by mark ) and the tightening
Installation steps: The installation steps which
torque are marked with symbols.
are not allowed to be reversed to the
removal are clarified. The installation steps
which are allowed to be reversed to the
removal may be omitted.

Assembly steps: The assembly steps which

are not allowed to be reversed to 1.4kg.m 1.0kg.m
disassembly are clarified. The
installation steps which are allowed to be
reversed to the removal may be omitted.

1.9kg.m

4.5kg.m
Classification of Maintenance Notices
All movable parts are
： Denoting notice for removal and applied with engine oil in
0.7kg.m
When the maintenance notice, standard value disassembly installation.
and application method of special tools are ：Denoting notice for installation and
available, the maintenance notice provides the assembly
detailed descriptions concentratedly.
Removal steps: Tightening torque
1. Engine oil filter
2. Drain plug
3. Oil plug washer 4.0kgm
4. Oil pan
Markings for filling oil, sealant and adhesive 5. Oil filter screen
Grease (unless otherwise specified, this 6. Oil filter washer
is multi-purpose grease) 7. Overflow valve plug
The portions for oil filling, sealant and adhesive 8. Overflow valve plug
application or replenishing are shown in the 9. Overflow valve spring
composition diagram. 10. Seal
11. Oil pump casing These number correspond the that of removal,
Sealant or adhesive 12. O ring
disassembly installation and assembly
13. Oil pump casing cover
14. Outer rotator
15. Inner rotator
Engine oil or gear oil 9EN0040

Notice for removal

Removal of
Oil pan
(1) Remove the bolt, and then use a special
tool to remove the Oil pan. Describing maintenance
essentials and notices for
removal, installation,
These English letters correspond with that of
disassembly and assembly.
removal, installation, disassembly and
assembly.

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 Ⅰ-4 Ⅰ Engine

Engine Type
Engine
Type Displacement Configuration
4G64 S4 MPI 2,351 mL 4-cylinder, in-line, SOHC

Tightening Torque
The tightening torques for the general parts are listed in the table.
The tightening torques for the special parts are shown at the beginning of each
group.

Tightening Torques of Bolts and Nut

Torque (kg.m)
Bolt
Pitch Bolt (spring washer) Flange Bolt
Diameter
Head Marking 4 Head Marking 7 Head Marking 10 Head Marking 4 Head Marking 7
M6 1.0 － 0.9 1.3 － 1.1
M8 1.25 1.1 1.8 3.0 1.4 2.4
M10 1.25 2.0 3.4 6.0 3.0 5.0
M12 1.25 3.6 6.2 10.8 5.5 9.0

Tightening Torques of Conical Thread

Thread Dimension Torque (kg.m)
Light Alloy Cast Iron and Steel
NPTF 1/16 0.5 － 0.8 0.8 － 1.2
PT 1/8 0.8 － 1.2 1.5 － 2.2
PT 1/4 2.0 － 3.0 3.5 － 4.5
NPTF 1/4 2.0 － 3.0 3.5 － 4.5
PT 3/8 4.0 － 5.5 5.5 － 7.5
PT 1/2 7.0 － 10.0 12.0 － 16.0

Sealant (FIPG)
Many portions on the engine and transmission are applied with sealant. When the sealant is applied,
special attentions must be paid to the amount, positions and surface status of sealant application to
reach the seal goal. Insufficient application may cause leakage, and excessive application may result in
blockage or narrowing of water or oil passage due to sealant overflow. Therefore, to prevent the
bonding faces from leakage, application of correct amount of sealant is absolutely necessary.
The FIPG used in the engine is room temperature vulcanized (RTV), and is supplied in the form of 100
gram tube (Part No. MD970389 is for engine, and Part No. MD997740 for transmission). RTV is
vulcanized when it is reacted with the water in the atmosphere. So it is usually used on the metal end
face.
It is easy to disassemble the units which are assembled with sealant without adopting any special
method. But in some cases, wooden hammer or its like is required to lightly tap the units to destroy the
sealant on the bonding faces, or flat, smooth and thin sealant scraper is lightly tapped into the bonding
faces. But care must be taken not to damage the bonding faces. When engine oil pan is removed, the
special tool (MD998728) for the oil pan should be used

Cleaning of Seal Faces

Remove the impure objects from the seal faces by using sealant scraper or wire brush. Make sure that
the seal surfaces are flat, smooth and free from any dirt and foreign object. Do not forget to remove the
sealant from the installation holes and the threaded holes.
Essentials of Application
When FIPG is used to assemble the parts, the following caution must be paid attention to: Evenly
apply the sealant on the stipulated diameter, and surround the circumference of the installation hole.
Apply the sealant which is not vulcanized. Install the parts to their positions when the sealant is in wet
status (with 15min). During installation, take care not apply the sealant to the place where the sealant
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 Ⅰ Engine Ⅰ-5
is not needed. After installation, wait for full vulcanization of the sealant (about 1h is required).During
this time, do not oil or water this portion or start the engine.

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 Ⅰ-6 Ⅰ Engine

4G64 S4 MPI Engine

General ············································································ I -6
General Specification ······················································· I -7
Special Service Tools ······················································I -11
AC Generator and Ignition System··································I -14
Timing Belt ·····································································I -16
Fuel System ····································································I -26
Intake Manifold·······························································I -27
Exhaust Manifold and Water Pump ·································I -28
Rocker Arm and Camshaft ··············································I -29
Cylinder Head and Valve·················································I -35
Front Cover, Oil Pump, Balancing Shaft and Oil Pan ····I -41
Piston and Connecting Rod Assembly ·····························I -49
Crankshaft, Cylinder Block and Flywheel ·······················I -56
AC Generator··································································I -62
Starter ·············································································I -67
Throttle Body··································································I -72

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 Ⅰ Engine Ⅰ-6

General

Specification
Items
4G64 S4 MPI
Configuration In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pent-roof combustion chamber
Total Displacement mL 2,351
Cylinder diameter mm 86.5
Piston Stroke mm 100.0
Compression ratio 9.5
Open 18 ° before Top dead center
Intake valve
Close 53 ° after Bottom dead center
Valve timing
Open 50 ° before Bottom dead center
Exhaust valve
Close 18 ° after Top dead center
Lubricating system Pressure supplied and full flow filtered
Pump configuration Gear-type
Cooling system Water-cooled and forced cycling
Pump configuration Outflow wheel

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 Ⅰ-7 Ⅰ Engine

General Specification
1 Maintenance Standard: (Unit：mm)

Using Limit
Items Standard Value
Value
Tensioner arm protrusion 12 ——
Generator Belt
Tensioner arm compression (98～196N) ≤1 ——
Intake 37.39 36.89
Cam height
Cam shaft Exhaust 36.83 36.33
Shaft diameter 45.0
Lower surface flatness 0.03 0.2
Sum of surface grinding limit * grinding
—— * 0.2
Cylinder head amount of cylinder block and cylinder head
Total height 119.9－120.1
Cylinder head bolt length 97.4 ≤99.4
Intake 1.0 0.5
Edge thickness
Exhaust 1.2 0.7
Valve stem diameter 6.0 ——
Radial gap between valve Intake 0.02－0.05 0.10
Valve
stem and pipe Exhaust 0.03－0.07 0.15
Banking angle 45°－45.5° ——
Intake 112.30 111.80
Height
Exhaust 114.11 113.61
Free height 51.0 50.0
Operation pretensioning force/Operation
Valve spring 27.2/44.2 ——
height kg/mm
Verticality ≤2° ≤4°
Contact belt width 0.9－1.3 ——
Inner diameter 6.0 ——
Valve pipe Outer diameter 11.0 ——
Compressed height 14.0 ——
Valve stem protrusion 49.3 49.8
Side gap Driving gear 0.08－0.14 ——
Oil Pump
Driven gear 0.06－0.12 ——
Piston Piston gap 0.02－0.04 ——
No.1 ring 0.02－0.06 0.1
Side gap
No.2 ring 0.02－0.06 0.1
Piston ring End gap No.1 ring 0.25－0.35 0.8
No.2 ring 0.40－0.55 0.8
Oil ring 0.10－0.40 1.0
Outer diameter Φ22.0 ——
Piston pin Compression force kg 755－1750 ——
Compression temperature Room temperature ——
Crankshaft Crankshaft pin play 0.02－0.05 0.1
Connecting rod Big end side gap 0.10－0.25 0.4
Axial gap 0.05－0.18 0.25
Crankshaft Main shaft diameter Φ57 ——
Connecting rod shaft diameter Φ45 ——
Main shaft axial gap 0.02－0.04 0.1

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 Ⅰ Engine Ⅰ-8

Using Limit
Items Standard Value
Value
Upper surface flatness 0.05 0.1
Sum of surface grinding limit * grinding amount of
—— * 0.2
Cylinder block cylinder block and cylinder head
Total height 290±0.1 ——
Inner diameter of cylinder hole Φ86.50～Φ86.53 ——
Cylinder block Cylinder hole cylindricality 0．01 ——
Generator Rotator coil resistance 3－5 ——
Dimensions of valve pipe installation 0.05 O.S. 11.05－11.07
holes (Intake valve and exhaust valve) 0.25 O.S. 11.25－11.27
after being enlarged twice 0.50 O.S. 11.50－11.52
Cylinder head Dimensions of Intake valve retainer hole 0.30 O.S. 34.435－34.455
after being enlarged twice 0.60 O.S. 34.735－34.755
Dimensions of exhaust valve retainer 0.30 O.S. 31.935－31.955
hole after being enlarged twice 0.60 O.S. 32.235－32.255

Note:
O.S.： enlarged diameter

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 Ⅰ-9 Ⅰ Engine
2. Tightening Torque

Tightened Unit Torque (kg.m)

AC Generator and Ignition System
AC generator fixing bolt 2.4
Support arm bolt 2.4
Pivot nut 2.3
Camshaft belt pulley bolt 2.5
Spark plug 2.5
Ignition coil bol 1.1
Timing Belt
Timing belt front lower cover 1.1
Tensioner belt pulley bolt 4.9
Tensioner wheel arm bolt 2.2
Automatic tensioner wheel bolt 2.4
Intermediate belt pulley bolt 3.6
Tensioner belt pulley rack 4.9
Timing belt rear cover 1.1
Timing belt indicator 0.9
Oil pump belt pulley 5.5
Crankshaft belt pulley bolt 12.0
Tensioner “B” 1.9
Balance shaft belt pulley 4.6
Camshaft belt pulley bolt 9.0
Balance shaft belt pulley 4.6
Fuel System
Throttle 1.9
Fuel distribution pipe assembly 1.2
Intake Manifold
Engine eyebolt 1.9
Engine cooling water temperature sensor 3.0
Water outlet pipe joint bolt 2.0
Intake manifold bolt 2.0
Water temperature sensor 3.0
Exhaust Manifold
Exhaust manifold cover bolt 1.4
Water Intake pipe joint bolt 2.4
Exhaust manifold nut (M8) 3.0
Exhaust manifold nut (M10) 5.0
Cooling water bypass pipe joint bolt 2.4
Cooling water pipe assembly bolt 1.3
Thermostat casing bolt 2.4
Water pump bolt 1.4
Rocker Arm and Camshaft
Rocking rod cover bolt 0.4
Rocker arm and Camshaft assembly bolt 3.2
Thrust cover screw 1.9

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 Ⅰ Engine Ⅰ-10

Tightened Unit Torque (kg.m)

Cylinder Head and Valve
Cylinder head bolt 2.0＋90°＋90°
Front cover and oil pump
Drain plug 4.5
Oil pan 0.7
Suction strainer bolt and nut 1.9
Oil pressure cock 1.0
Pressure release plug 4.5
Oil filter rack bolt 1.9
Front cover bolt 2.4
Plug 2.4
Flange bolt 3.7
Oil pump cover bolt 1.6
Oil pump cover screw 1.0
Piston and connecting rod assembly
Connecting rod nut 2.0＋90°～100°
Crankshaft, cylinder block, Flywheel and drive plate
Flywheel bolt 13.5
Rear cover plate installation bolt 1.1
Seal cover installation bolt 1.1
Main bearing cover bolt 2.5＋90°～100°

New Tightening Method - Tightening Method of Bolt in Plastic Range

A new tightening method, the tightening method in plastic range, is used for some parts in the engine. This bolt tightening method
is different from the traditional one.
To tighten these bolts, strictly follow the used limits stipulated in this text.
Tightening method in plastic range is used for the following bolts:
(1) Cylinder head bolt
(2) Main bearing cover bolt
(3) Connecting rod bolt
· Tightening Method:
After all the bolts are tightened to the stipulated torque, retighten them further for 90 ~ 100 ° (two 90 ° for Cylinder head
bolt).The tightening methods are different in the difference ranges. The method described in the text must be followed.

3 Sealant
Application Position Brand Used
Water outlet pipe joint MD970389 or equivalent
Cooling water bypass pipe joint MD970389 or equivalent
Water thermometer unit 3M ATD No.8660 or equivalent
Oil pressure cock 3M ATD No.8660 or equivalent
Oil pan MD970389 or equivalent
Oil Seal cover MD970389 or equivalent
Water temperature sensor 3M NUT LOCKING No.4171 or equivalent

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 Ⅰ-11 Ⅰ Engine

Special Service Tools

Tool No. Description Purpose

MD998719 used for fixing cam

MB990767 Crankshaft pulley spanner
shaft belt

MB990938 Handle Used together with MD998776

MD998783 used for tensioning

MD990685 Torque spanner
timing belt

Used for removal of front cover

MD998162 Thread plug spanner
plug

MD998375 used for installation of

MD998285 Crankshaft front oil seal guide
crankshaft front oil seal

MD998375 Crankshaft front seal installer Installation of crankshaft front seal

MD998713 Camshaft oil seal installer Installation of camshaft oil seal

MB990767 used for fixing cam

MD998719 Pulley fixing pin
shaft belt pulley

MD998727 Oil pan remover Removal of Oil pan

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 Ⅰ Engine Ⅰ-12

Tool No. Description Purpose

Removal of front bearing of

MD998371 Balancing shaft bearing puller
reverse Balancing shaft

Removal of rear bearing of reverse

MD998372 Balancing shaft bearing puller
Balancing shaft

MD998772 Valve spring compressor Removal of valve and related parts

MD998774 Valve seal installer Installation of valve seal

MB990938 used for installation of

MD998776 Crankshaft rear seal installer
crankshaft rear seal

MD998778 Crankshaft belt pulley puller Removal of crankshaft belt pulley

Removal and installation of piston

MD998780 Piston installer
pin

Fixation of Flywheel and drive

MD998781 Flywheel Pawl
disk

Used for removal and installation

MD998783 Thread plug spanner retainer
of front cover thread plug

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 Ⅰ-13 Ⅰ Engine

Tool No. Description Purpose

Direction limiting for removal

Balancing shaft bearing puller and installation of rear bearing of
MB991603
plate reverse Balancing shaft, and used
together with MD998372

Removal and installation of

MB991654 Cylinder head bolt spanner (12)
cylinder head bolt

Tappet Leakage-Check
MD998440 Hydraulic tappet leakage test
Tester

MD998441 Hydraulic tappet bleeder Hydraulic tappet air bleeding

MD998442 Hydraulic tappet lever Hydraulic tappet air bleeding

Hydraulic tappet retainer used for

MD998443 Hydraulic tappet retainer Removal and installation of
rocker arm shaft assembly

Installation of front and rear

MD998705 Balancing shaft bearing installer bearings of reverse Balancing
shaft

Retaining of Balancing shaft

MD998785 Timing belt pulley Pawl
belt pulley

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 Ⅰ Engine Ⅰ-14

AC Generator and Ignition System

8 25N.m
5 23N.m

10
4
11N.m

24N.m

23N.m

11N.m

11
3
9
2
1

6
25N.m

Removal steps
1. Drive belt
2. Water pump belt pulley
3. Power steering pump belt pulley
4. AC generator support
5. AC Generator
6. Crankshaft belt pulley
7. Spark plug cable
8. Spark plug
9. Ignition coil
10. Front upper cover of timing belt
11. Ignition coil holder

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 Ⅰ Engine Ⅰ-15

Notice for Removal

Removal of Crankshaft Bolt

(1) Hold the Flywheel with the special tool.

(2) Remove the crankshaft bolt.

Notice for Installation

Installation of Crankshaft Bolt

(1) Hold the Flywheel with the special tool.

(2) Install the crankshaft bolt.

Adjust the drive belt tension to its standard value with help of
flexibility indicator or tensimeter.

Standard Value

New belt·········································· 5.5－7.5mm

Used Belt ······································· 7.5－8.5mm

Standard Value

New belt ············································ 50－70N

Used Belt ············································ 35－45N

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 Ⅰ-16 Ⅰ Engine

Timing Belt

11N.
17
16
2
15 20
45N.
8
19N. 88N.
19
18
12
14 162N.m
48N. 11
13 3
48N.
24N.
10
1 54N. 9
8.8N.m
7
5
11N. 6
4 35N.
22N.

Removal steps
1. Timing belt front lower cover
2. Timing belt
3. Tensioner belt pulley
4. Tensioner arm
5. Automatic tensioner
6. Intermediate belt pulley bolt
7. Tensioner belt pulley rack
8. Timing belt rear cover
9. Timing belt indicator
10. Oil pump belt pulley
11. Crankshaft bolt
12. Crankshaft belt pulley
13. Flange
14. Tensioner B
15. Timing belt
[Link] shaft belt pulley
17. Bush
[Link] belt pulley
19. Cam shaft belt pulley bolt
20. Crankshaft belt pulley

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 Ⅰ Engine Ⅰ-17

Notice for Removal

Removal of Timing Belt

(1) Note down the rotary direction of the belt for correct
installation.

Note: • Water or grease attached to the belt may

dramatically shorten the service life of the belt.
Therefore, after removal, pay special attention to
prevent water or grease from attaching and
polluting the belt, pulley, tensioner, and etc. Do
not clean these parts. Replace with new ones if
seriously polluted.

• If any water or oil or grease is found on these parts, check

the front cover seal, cam shaft seal and water pump for
leakage.

Removal of oil pump belt pulley

(1) Remove the thread plug on the side of cylinder block.

(2) Insert a cross-head screwdriver in a diameter of 8mm to fix

the left Balancing shaft.

(3) Remove the nut from the oil pump belt pulley.

(4) Remove the oil pump belt pulley.

Removal of Crankshaft Bolt

(1) Fix the Flywheel with the special tool.

(2) Remove the crankshaft bolt. Support the Flywheel with the
special tool.

Removal of Crankshaft Belt Pulley

(1) If removal is not easy due to adhesion, use special tool.

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 Ⅰ-18 Ⅰ Engine

Removal of Timing Belt B

(1) Note down the rotary direction of the belt for correct
installation.

Note：

• Water or oil or grease attached to the belt may dramatically

shorten the service life of the belt. Therefore, after removal,
pay special attention to prevent water or oil or grease from
attaching and polluting the belt, pulley, tensioner, and etc. Do
not clean these parts. Replace with new ones if seriously
polluted.

• If any water or oil or grease is found on these parts, check the

front cover seal, cam shaft seal and water pump for leakage.

Removal of Balancing shaft Belt Pulley

(1) Fix the Balancing shaft belt pulley by using the tool as
shown in the Fig.

(2) Remove Balancing shaft belt pulley.

Removal of Crankshaft Belt Pulley B

(1) If removal is not easy due to adhesion, use special tool.

Removal of Crankshaft Belt Pulley Bolt

(1) Fix the cam shaft Timing Belt pulley by using the
special tool.

(2) Remove the crankshaft belt pulley bolt

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 Ⅰ Engine Ⅰ-19

INSPECTION
1 Timing Belt

Carefully check all the parts of the belt, and replace with
new one if any of the following damages is found:

(1) The back rubber is aged and reflective, and has no signs
after being scratched by finger nail and no elasticity.

(2) Back rubber is cracked.

(3) Canvas is cracked and stripped.

(4) Belt cog bottom is cracked.

(5) Belt side is cracked.

(6) Belt side is abnormally worn. It means that the belt

side is normal if it is so tidy and uniform as cut with
sharp knife.

(7) Belt cog is abnormally worn.

(8) Cog is lost.

Belt cog lost

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 Ⅰ-20 Ⅰ Engine

2 Automatic Tensioner

(1) Check the automatic tensioner for leakage, and replace

Plug
with new one if necessary.

(2) Check the rod end for wear or damage, and replace with
new one if necessary.

(3) Measure the protrusion of the rod. Replace the automatic

tensioner with new one if not satisfactory.

Standard value： 12mm

6EN0161

(4) Press down the rod with a force of 98～196N, and

measure the displacement of the rod at the same time.
98～196N
(5) Replace the automatic tensioner if the displacement of
Rod displacement
the rod is more than 1mm less than the value measured
in Step (3).

Standard value： ≤ 1mm

(6) Firmly fix the automatic tensioner by using a vice with

soft mouth.

Caution:
Plug
Brass or aluminium Vice Lip • Since there is a protrusion of the thread plug at the
bottom end of the automatic tensioner, insert a flat
padding plate between the vice and the thread plug to
prevent the two from direct contact.

(7) Rotate the vice handle to push the rod of automatic

Flat pad
tensioner inward. Replace the automatic tensioner with
Brass or aluminium Vice Lip
new one if the pushing is very easy. Some resistance
should be felt when the rod is pushed inward.

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 Ⅰ Engine Ⅰ-21

Notice for Installation

Tightening of Crankshaft Belt Pulley Bolt

(1) Fix the cam shaft Timing Belt pulley by using the special
tool.

(2) Tighten the crankshaft belt pulley bolt to the stipulated

torque.

Bush Installation of Bush

Seal
(1) When installing the bush, place the side with chamfer to face
the seal.

Chamfer Balance
shaft

Installation of Balancing shaft Belt Pulley

(1) Fix the Balancing shaft belt pulley by using the tool as
shown in the Fig.

(2) Tighten the bolt to the stipulated torque.

Installation of Timing Belt B

Timing
marking (1) Align the markings on the crankshaft belt pulley and the
(Front
cover) Timing Balancing shaft belt pulley to the markings on the front
Marking
cover.

(2) Install the Timing Belt on the crankshaft belt pulley and
the Balancing shaft belt pulley. It is not allowed that there is
no looseness on the side of tension.

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 Ⅰ-22 Ⅰ Engine

(3) Make sure that the centers of the tensioner pulley and the
bolt are positioned as shown in the Fig.
Tensioner“B”

Tensioner
wheel
center Bolt center

(4) Apply a finger force to the side of Timing Belt tensioner, and
at the same time move tensioner B in the direction of the
arrow. At this time, tighten the bolt to fix tensioner B. Pay
attention not to rotate the shaft together with the belt
pulley to overtension the belt during tightening the bolt.

(5) Make sure that the markings on the belt and front cover are
aligning each other.
Cogged belt drop
(6) Press the central portion of the Timing Belt B on the side of
Timing the tensioner with index finger, and check that the
marking
depression of the belt is 5～7mm.
Timing
marking

Installation of Crankshaft Bolt

(1) Hold the Flywheel with the special tool.

(2) Install the crankshaft bolt.

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 Ⅰ Engine Ⅰ-23

Installation of Oil Pump Belt Pulley.

(1) Insert a cross-head screwdriver into the plug hole on the left
side of the cylinder block to resist the rotation of the
Balancing shaft.

(2) Install the oil pump belt pulley.

(3) Apply oil on the mating faces of the nut and the bearing.

(4) Tighten the nut to the stipulated torque.

Installation of Automatic Tensioner

(1) If the automatic tensioner rod is at extended position, retract

it in the following steps:

(2) Firmly fix the automatic tensioner by using a vice with soft
mouth.

Caution:

• Since there is a protrusion of the thread plug at the bottom

end of the automatic tensioner, insert a flat padding plate
between the vice and the thread plug to prevent the two
from direct contact.

(3) Slowly push the rod inward by using the vice until hole A in
the rod is aligned with hole R in the oil cylinder.

(4) Insert a steel wire (in diameter of 1.4mm) into the aligned
holes.

(5) Remove the automatic tensioner by using a vice.

(6) Install the automatic tensioner on the front cover, and tighten
the bolt to the stipulated torque

Caution:

• Leave the steel wire in the automatic tensioner.

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 Ⅰ-24 Ⅰ Engine

Installation of Timing Belt

(1) Make sure that the Timing Belt tensioner is well installed.

(2) Align the marking on cam shaft belt pulley to the marking
on the cylinder head.

(3) Align the marking on the crankshaft belt pulley to the

marking on the front cover.

(4) Align the marking on the oil pump belt pulley to its
corresponding marking.

(5) Remove the plug from the cylinder block, and then insert a
cross-head screwdriver (in diameter of 8mm）into the hole.
Insertion of above 60mm means the alignment of the timing
markings. If the insertion is not over 20～25mm, rotate the
oil pump belt pulley one turn, and then align the timing
markings. Recheck that the screwdriver is inserted by over
[Link] the screwdriver in the inserted position until the
installation of the belt is completed.

(6) Connect the Timing Belt in turn onto the crankshaft belt
pulley, intermediate wheel, cam shaft belt pulley and
Tensioner pulley tensioner belt pulley.

(7) Lift the tensioner belt pulley in the direction of arrow, and
then tighten the central bolt.

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 Ⅰ Engine Ⅰ-25

(8) Check that all the timing markings are in a straight line.

(9) Remove the screwdriver inserted in Step (5), and install the
plug.

(10) Counterclockwise rotate the crankshaft a quarter turn. Then

clockwise rotate until all the timing markings are realigned.

(11) Install the sleeve spanner and torque spanner of the special
tools onto the tensioner belt pulley, and then loosen the
central bolt of the tensioner belt pulley.

Note：

If special tools are not used, general spanners, which

can be used to measure the torque of 0~0.3 kg.m.

(12) Tighten to the torque of 0.26～0.27kg.m by using torque

spanner.

(13) On the one hand, retain the tensioner belt pulley by using
special tools and torque spanners, and on the other hand,
tighten the central bolt to its standard value.

(14) Clockwise rotate the crankshaft two turns, and leave it for
about [Link] check the automatic tensioner fixing
steel wire for free slide.

Note：

Fixing steel wire If the steel wire does not slide freely, repeat above Step
(10) until the steel wire slides freely.

(15) Remove the automatic tensioner fixing steel wire.

(16) Measure distance "A" (between the tensioner arm and the
automatic tensioner body).

Standard value： 3.8－4.5mm

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 Ⅰ-26 Ⅰ Engine

Fuel System

19N.m 19N.m

2
3

4
1
20N.m

8
6 12N.m

7
5

Removal Steps

1. Water pipe
2. Water pipe
3. Throttle body
4. Pad
5. Cover
6. Pad
7. Fuel distribution pipe assembly

Notice for Installation

Installation of Fuel Distribution Pipe Assembly

Before installation of fuel distribution pipe assembly, carefully

lubricate the mating surface or O ring on the manifold with mineral
oil, and align the central line of the injector to that of the
installation hole, and insert it into the Intake manifold. Finally
tighten the bolt to the stipulated torque.

(1) Mineral oil ：ISO Grade 10 (10cs (centistokes) at 40 °)

(2) Avoid the oil, when used, from entering the inside of injector.

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 Ⅰ Engine Ⅰ-27

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 Ⅰ-28 Ⅰ Engine

Intake Manifold
1
Removal Steps

1. Engine lift ring

2. Engine water temperature sensor
19N.m
3. Water outlet joint
4. Inlet manifold rack
5. Inlet manifold
6. Inlet manifold pad
6

20N.m

5
20N.m

3
4
7 19N.m
13N.m
13N.m
30N.m 2

Notice for Installation

Application of Sealant of Engine Water Temperature Sensor

Sealant specification: 3 M nut lock part NO.4171 or equivalent

Application of Sealant of Water Outlet Joint

Sealant OD 3mm
Sealant specification: Mitsubishi Brand part NO.MD970389 or
equivalent

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 Ⅰ Engine Ⅰ-29

Exhaust Manifold and Water

Pump

Removal Steps
11. Water temperature induction plug
1. Oil dip stick
12. Water bypass pipe joint
2. Oil dip stick pipe
3. Ring 13. Water pipe assembly

4. Thermal baffle 14. Water pipe O ring

15. Thermostat casing
5. Engine lift ring
16. Water inlet pipe
6. Oxygen sensor
17. O ring
7. Exhaust manifold
18. Water pump
8. Exhaust manifold pad
19. Water pump pad
9. Water outlet joint
10. Thermostat

O ring
Notice for Installation

Installation of O Ring

(1) Moist the O ring with water for convenience of assembly.

Caution: O ring should be free from oil or grease.

6EN0594

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 Ⅰ-30 Ⅰ Engine

Installation of Water Bypass Pipe Joint

Sealant 3mm in
OD squeezed out
Sealant specification：

Sealant specification: Mitsubishi Brand part NO.MD970389

or equivalent

Note：

(1) Quickly install the water bypass pipe joint when the sealant is
6EN0996 still wet (within 15min).

(2) Do not add any oil to the sealing portion within about 1h after
installation.

Rocker Arm and Cam Shaft

Apply engine oil to all

moving portions during
installation

Removal Steps
1. Vent hose
2. PCV hose 6. Rocker arm cover

3. PCV valve 7. Rocker arm cover pad

4. PCV valve pad 8. Oil seal

5. Oil filler cap 9. Rocker arm and rocker arm shaft

10. Rocker arm and rocker arm shaft

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 Ⅰ Engine Ⅰ-31

11. Rocker arm shaft spring 17. Rocker arm shaft (exhaust side)
12. Rocker arm A 18. Hydraulic tappet
13. Rocker arm B 19. Oil Seal
14. Rocker arm shaft (Intake side) 20. Thrust cover
15. Hydraulic tappet 21. O ring
16. Rocker arm C 22. Cam shaft

Notice for Removal

(1) Before removal of the Rocker arm and rocker arm shaft
assembly, use the special tool for installation as shown in the
Fig. to prevent Hydraulic tappet from falling.

6AE0160

INSPECTION

Cam shaft

(1) Measure cam height.

For standard value and used limit value, see the following table:

Standard Value Used Limit Value

Intake 37.39 36.89
Exhaust 36.83 36.33

Rocker Arm

(1) Check the roller surface for any signs of damage or seize and
replace the rocker arm, if any.

(2) Check the roller for smooth rotation. Replace the rocker arm if
the rotation is not smooth or loose.

(3) Check the inner diameter. Replace the rocker arm if there is any
damage or seize.
Roller end
7EN0064
Hydraulic Tappet
Caution:
(1) Hydraulic tappet is a precision part. Its surface should be free
from any dust, foreign objects, etc.

(2) Do not remove the hydraulic tappet.

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 Ⅰ-32 Ⅰ Engine
(3) Clean the hydraulic tappet with clean
diesel oil.

(1) Prepare 3 containers and about 5L of diesel oil. Pour adequate

diesel oil to each container to immerse the vertically positioned
Outside cleaning Inside cleaning Add diesel
hydraulic tappet, and then proceed the following steps:

A B C
6EN1698

(2) Put the hydraulic tappet into container A, and clean its surface.

Caution： Remove the hard cohesive with nylon brush.

Diesel

6EN1699

(3) Install special tool MD998441 on the hydraulic tappet.

MD99844 (4) Gently push the internal steel ball by using special tool
MD998442, and move the plunger for 5 to 10 strokes until it
slides smoothly. Moreover, eliminate the plunger slide
resistance and remove the dirty oil.

Caution:
Diesel
MD998442
• The steel ball spring is very soft, so do not us too much force in
6EN1700
order to prevent the hydraulic tappet from damage when air
leakage wire is used to push the steel ball.

• If the plunger slides with resistance or blocking or mechanical

device is abnormal, replace the hydraulic tappet.

MD99844 (5) Take out the hydraulic tappet from the container. Then gently
push the steel ball and move the plunger to remove the diesel
oil from the pressure cavity.

MD998442

Diesel 6EN1701

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 Ⅰ Engine Ⅰ-33

(6) Install special tool MD998441 on the hydraulic tappet.

(7) Put the hydraulic tappet into container B. Gently push the
internal steel ball by using special tool MD998442, and move
the plunger for 5 to 10 strokes until it slides smoothly. This
operation may clean the pressure cavity of the hydraulic tappet.

Diesel Caution:

The steel ball spring is very soft, so do not us too much force
in order to prevent the hydraulic tappet from damage when air
leakage wire is used to push the steel ball.

(8) Take out the hydraulic tappet from the container. Then gently
push the steel ball and move the plunger to remove the diesel
oil from the pressure cavity.

Diesel

(9) Put the hydraulic tappet into container C. Then gently push the
internal steel ball by using special tools MD998442.

Caution:

Do not clean the hydraulic tappet in container C. If the

Diesel hydraulic tappet is cleaned in container C, foreign objects may
enter the pressure cavity with diesel oil.

(10) Place the hydraulic tappet vertically with its plunger at the top
end, and stably move the plunger downward until it reaches its
max. travel. Then slowly return the plunger, and release the
steel ball to fill the pressure cavity

(11) Remove special tool MD998441.

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 Ⅰ-34 Ⅰ Engine

(12) Take out the hydraulic tappet from the container. Place the
hydraulic tappet vertically with its plunger at top end. Stably
push the plunger, and check for no movement. Check it and
the new hydraulic tappet for their height comparison.

Caution:

It the hydraulic tappet becomes smaller, repeat Steps (9) to (12)

to fill the hydraulic tappet with diesel oil. If it becomes even
smaller when these steps are conducted, replace the hydraulic
tappet.

Graduation
(13) Install the hydraulic tappet onto the special tool.

(14) After the plunger drops by 0.2~0.5mm, measure the time

required by the plunger to drop by 1mm.
Hydraulic tappet
Standard value ： 3~20sec/1mm (with diesel oil at
15~20℃ )

Caution: Replace the hydraulic tappet if the measured value is not

satisfactory.

(15) Install special tool MD998441 on the hydraulic tappet.

(16) Replace the hydraulic tappet into container C, and then gently
push the internal steel ball by using special tools MD998442.

(17) Place the hydraulic tappet vertically with its plunger at the top
end, and stably move the plunger downward until it reaches its
max. travel. Then slowly return the plunger, and release the
steel ball to fill the pressure cavity with diesel oil.

(18) Remove special tool MD998441.

(19) Take out the hydraulic tappet from the container. Place the
hydraulic tappet vertically with its plunger at top end. Stably
push the plunger, and check for no movement. Check it and
the new hydraulic tappet for their height comparison.

Caution：If the hydraulic tappet becomes smaller, repeat Steps

(15) to (19) to fill the hydraulic tappet with diesel oil.
If it becomes even smaller when these steps are
conducted, replace the hydraulic tappet.

(20) Hold the hydraulic tappet vertically to prevent the diesel oil
from flowing out. Avoid hydraulic tappet from being polluted
by dust or foreign object. Install the hydraulic tappet onto the
engine as soon as possible.

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 Ⅰ Engine Ⅰ-35

Notice for Installation

Installation of Seal

Installation of Hydraulic Tappet

(1) Insert the hydraulic tappet into the rocker arm, and pay attention
not cause the diesel oil to overflow. Then use special tool to
Hydraulic tappet prevent it from falling during installation.

Caution:

• The hydraulic tappet must be cleaned if reused.

Installation of Rocker Arm Shaft Spring, Rocker Arm and Rocker

Arm Shaft

(1) Temporarily tighten the Intake rocker arm shaft until all the
rocker arms do not push the valve.

(2) Install the rocker arm shaft spring with it vertical to the spark
plug pipe.

Note：First install rocker arm shaft spring, and then install the
6AE0162
exhaust rocker arm and rocker arm shaft.

(3) Remove the special tool used for holding the hydraulic tappet.

(4) Make sure that the notch on rocker arm shaft is positioned as
shown in the Fig.

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