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11C 1.8L Engine

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11c-I

ENGINE el .8L>
CONTENTS 111 09000733

CAMSHAFT AND CAMSHAFT OIL Curb Idle Speed Check ....................... 9


SEAL .................................... 20 Drive Belt Tension Check and Adjustment . . . . . . 6

CRANKSHAFT OIL SEAL ................. 23 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . .10


Ignition Timing Check ........................ 9
CRANKSHAFT PULLEY .................. 19 Lash Adjuster Check ........................ 13
Manifold Vacuum Check .....................
CYLINDER HEAD GASKET ............... 26
12
Timing Belt Tension Adjustment . . . . . . . . . . . . . . 12
ENGINE ASSEMBLY ..................... 15
SEALANTS ................................ 3
GENERAL INFORMATION .................. 2
SERVICE SPECIFICATIONS ................. 2
OIL PAN ................................. 22
SPECIAL TOOLS .......................... 3
ON-VEHICLE SERVICE ..................... 6
Basic Idle Speed Adjustment
............................
TIMING BELT 30
.......................... Refer to GROUP 13A
TROUBLESHOOTING ........................ 5
Compression Pressure Check . . . . . . . . . . . . . . . . 11
11c-2
~~ ~
ENGINE <I .8L> - General Information/Service Specifications
GENERAL INFORMATION i l l 00010520

GENERAL SPECIFICATIONS
Items i Specifications
Type I In-line, Overhead Camshaft
Number of cylinders I 4
Bore mm (in.) ~ 81.0 (3.19)

Stroke mm (in.) 1 89.0 (3.50)


Piston displacement cm3 (cu.in.) i 1,834 (111.9)
I 9.5
~ ~~

Compression ratio

Firing order

Valve timing Intake valve Opens BTDC 6"

Closes ABDC 54"

Exhaust valve I Opens 1 BBDC54"

i ATDC6"
Lubrication ~ Pressurized feed-full filtration

SERVICE SPECIFICATIONS 11100030632

I Items 1 Standard value 1 Limit


Generator drive belt vibration
frequency Hz
When checked I 151 - 195 -
When a used belt is installed 163 - 185 -
When a new belt is installed 195 - 230 7-
Generator drive belt tension N
(Ibs.)
When checked i 2 9 4 - 4 9 0 (66- 110) I -
When a used belt is installed 343 - 441 (77 - 99) -
When a new belt is installed 490 - 686 (110 - 154) -

Generator drive belt deflection


(Reference value) mm (in.)
When checked i 8.0 - 10.5 (-31- .41) -
When a used belt is installed 8.5 - 10.0 (.33 - .39) -

1 When a new belt is installed 1 7.0 - 8.0 (.28 - .31) -


Power steering oil pump and When checked 114 - 139 -
A/C compressor drive belt
vibration frequency Hz When a used belt is installed 121 - 133

When a new belt is installed 145 - 166 -


Power steering oil pump and When checked 392 - 588 (88 - 132) -
A/C compressor drive belt
tension N (Ibs.) When a used belt is installed 441 - 539 (99 - 121) -

When a new belt is installed 637 - 833 (143 - 187) -


ENGINE c1.8L> - Service Specifications/Sealants/Special Tools 11c-3

Items 1 Standard value 1 Limit


Power steering oil pump and When checked 10.0 - 12.0 (.39 - .47) -
A/C compressor drive belt
deflection (Reference value) When a used belt is installed 10.0 - 11.O (.39 - .43) -
rnm (in.)
When a new belt is installed 7.2 - 9.0 (.28 - .36) -

Basic ignition timing at idle 15"BTDC+3" l-


Actual ignition timing at curb idle ~ Approx. 5"BTDC ~ -

HC contents ppm 100 or less

Curb idle speed r/min 700 * 100 -

Compression pressure (at 300 r/min) kPa (psi) 1,370 (199) min. 1,040 (151)

Compression pressure difference of all cylinders kPa (psi)


1- 1 max. 100 (14)
Intake manifold vacuum at curb idle kPa (in.Hg) l- 1 min. 60 (18)
Cylinder head bolt shank length mm (in.) ~- 1 96.4 (3.80)
SEALANTS 11100050256

Oil pan MlTSUBlSHl GENUINE PART MD970389 or equivalent


Camshaft position sensor support

Flywheel bolt <M/T> or drive plate bolt <A/T> 3M Stud Locking 4170 or equivalent

SPECIAL TOOLS 11100060648

Tool ~ Tool number and name Supersession Application


MB991502 MB991496-OD 0 Checking the ignition timing
Scan tool (MUT-11) 0 Checking the idle speed

MB991668 Tool not available Drive belt tension measurement


Belt tension meter set
11C-4 ENGINE <1.8L> - Special Tools
Tool Tool number and name Supersession Application
MB990767 MB990767-01 0 Holding the camshaft
End yoke holder sprocket
0 Holding the crankshaft
pulley

MD998719 or M IT308239
MD998754
Crankshaft pulley
holder

MD998713 MD998713-01 Press-in of the camshaft oil seal


Camshaft oil seal
installer

MD998727 MD998727-01 Removal of oil pan


Oil pan remover

MD998781 General service tool Securing the flywheel <M/T> or


Flywheel stopper drive plate <A/T>

I'
MD998776 MD998776-01 Press-in of the crankshaft rear

Q Crankshaft rear oil seal


installer
oil seal

MB990938 MB990938-01
Handle

8990938

MD998717 MD998717-01 Press-in of the crankshaft front


Crankshaft front oil seal oil seal
installer

MB991653 General service tool Removal and installation of the


Cylinder head bolt cylinder head bolt
wrench
ENGINE <.8L>
I - Special Toolsnroubleshooting 11C-5

I Tool Tool number and name Supersession Application


GENERAL SERVICE MZ203827-01 Supporting the engine assembly
TOOL during removal and installation
MZ203827 of the transaxle
Engine lifter

I 2203827

MB991453 MZ203827-01
Engine hanger
assembly
11C-6 ENGINE <1.8L> - On-vehicle Service

Vibration frequency Hz 151 - 195


Tension N (Ibs.) 294 - 490 (66 - 110)
Deflection(Referencevalue) mm (in.) 8.0 - 10.5 (.31 - .41)

<When using the scan tool (MUT-IT)>


1. Connect the belt tension meter set (special tool) to the
scan tool (MUT-11).
2. Connectthe scan tool (MUT-11) to the diagnosisconnector.
3. Turn the ignition switch to “ON” and select “Belt Tension
Measurement” on the menu screen.
4. Hold the microphone to the middle of the drive belt
between the pulleys (at the place indicated by an arrow)
about 10 - 20 mm (0.39 - 0.79 in.) away from the rear
surface of the belt and so that it is perpendicular to the
9EN0656 belt (within an angle of k15”).
5. Lightly tap the middle of the belt between the pulleys
(the place indicated by the arrow) with your finger as
shown inthe illustration.Check that the vibrationfrequency
of the belt is within the standard value.
Caution
1. The temperature of the surface of the belt should
be as close as possible to normal temperature.
2. Do not allow any contaminant such as water or
oil to get onto the microphone.
3. If strong gusts of wind blow against the
microphone or if there is any source of loud noise
nearby, the values measured by the microphone
may not correspond to actual values.
4. If the microphone is touching the belt during the
measurement, the values measured by the
microphone may not correspond to actual values.
5. Do not take the measurement while the vehicle’s
engine is running.
<When using a tension gauge>
Use a belt tension gauge to check that the belt tension is
within the standard value range.
10458
ENGINE <I .8L> - On-vehicle Service 11C-7
<Belt deflection check>
Apply 98 N (22 Ibs.) of force to the middle of the drive belt
Crankshaft
between the pulleys (at the place indicated by the arrow)
pulley and check that the amount of deflection is within the standard
value range.

39EN0457

Adjusting bolt GENERATOR DRIVE BELT TENSION ADJUSTMENT


1. Loosen the nut of the generator pivot bolt.
2. Loosen the lock bolt.
3. Turn the adjusting bolt to adjust the belt tension vibration
frequency, belt tension or deflection to the standard value.
Standard value:

I Items
When a used
belt is installed
When a new belt
is installed
195 - 230

490 - 686
(77 - 99) (110 - 154)

value) mm (in.) (.33 - .39) 1 (.28- .31)

4. Tighten the nut of the generator pivot bolt.


Tightening torque: 44 Nm (33 ft.lbs.)
5. Tighten the lock bolt.
Tightening torque: 23 Nm (17 ft.lbs.)
6. Tighten the adjusting bolt.
Tightening torque: 9.8 Nm (7.2 ft.lbs.)
11C-8 ENGINE <1.8L> - On-vehicle Service
~,q
<Vehicleswithout AfC>
AfC
Oil pump pulley
POWER STEERING OIL PUMP AND AIR CONDITIONING
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT 11100130202

1. Check drive belt tension in one of the followingprocedures.


B
Standard value:
I Items When
checked
When a
used belt is
When a
new belt is
nsioner pulley

AOlU0016
IVibration fre- 114 - 139
intalled

121 - 133
installed

145 - 166
quency Hz
<Vehicleswith A/C> Tension N 392 - 588 441 - 539 637 - 833
(Ibs.) (88 - 132) (99 - 121) (143 - 187)
I

Tensioner Deflection 10.0 - 12.0 10.0 - 11.0 7.2 - 9.0


pulley (Reference val- (.39 - .47) (39 - -43) (.28 - .35)
B ue) rnrn (in.)

<When using the scan tool (MUT-II)>


Lightly tap the middle of the belt between the pulleys
(the place indicated by the arrow) with your finger as
A20R0002
shown inthe illustration.Check that the vibrationfrequency
of the belt is within the standard value.
NOTE
Check drive belt vibration frequency with the scan tool
(MUT-11) in the same procedure in WATER PUMP AND
GENERATOR. (Refer to page 11C-6.)
<When using a tension gauge>
Use a belt tension gauge to check that the belt tension
is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
<Belt deflection check>
Apply 98 N (22 Ibs.) of force to the middle of the drive
belt between the pulleys (at the place indicated by the
arrow) and check that the amount of deflection is within
the standard value range.
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
Tightening torque: 25 Nm (19 ft.lbs.)
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
ENGINE <1.8L> - On-vehicle Service 11c-9
IGNITION TIMING CHECK 11100170150

Before inspection, set the vehicle in the following


condition:
0 Engine coolant temperature:80 - 95°C (176 - 203" F)
0 Lights, electric cooling fan and all accessories: OFF
0 Transaxle: Neutral (P range on vehicles with A/T)
2. Connect the scan tool to the data link connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Check that the idle speed is at approx. 700 rlmin.
6. Select the 'item No.17' of the actuator test on the scan
tool.
7. Check that basic ignition timing is within the standard
value.
Standard value: 5" BTDC k 3"
8. If the basic ignition timing is outside the standard value,
check the MFI components by referring to GROUP 13A
- Troubleshooting.
9. Press the clear key of the scan tool (selectforce-activating
cancel mode), and cancel the actuator test.
NOTE
If it is not cancelled, force-activation continues for 27
minutes. Do not drive the vehicle in this condition, or
the engine could be damaged.
10. Check the actual ignition timing is at the standard value.
Standard value: Approx. 5" BTDC
NOTE
1. Ignitiontiming is variablewithin about +7", even under
normal operating.
2. The timing is automatically further advanced by
approx. 5" from 5"BTDC at higher altitude.

CURB IDLE SPEED CHECK 111001 90545

Before inspection, set the vehicle in the following


condition.
0 Engine coolant temperature: 80 - 95°C (176 - 203°F)
0 Lights, electric cooling fan and all accessories: OFF
0 Transaxle: Neutral (P range on vehicles with W )
Turn the ignition switch off and connect the scan tool
to the data link connector.
Check that the basic ignition timing is within the standard
value.
Standard value: 5" BTDC f 3"
4. Run the engine at idle for 2 minutes.
5. Check the curb idle speed. Select item No.22 and take
a reading of the idle speed.
Standard value: 700 k 100 r/min
NOTE
The idle speed is controlled automatically by the idle air
control system.
11c-10 ENGINE <I .8L> - On-vehicle Service
6. If the idle speed is not within the standard value, check
the MFI components by referring to GROUP 13A -
Troubleshooting.

IDLE MIXTURE CHECK 11100210258

1.Before inspection, set the vehicle in the following


condition.
0 Engine coolant temperature: 80 - 95°C (176 - 203°F)
0 Lights, electric cooling fan and all accessories: OFF
0 Transaxle: Neutral (P range on vehicles with A/T)
2. Turn the ignition switch off and connect the scan tool
to the data link connector.
3. Check that the basic ignition timing is within the standard
value.
Standard value: 5"BTDC -c 3"
4. Run the engine at 2,500 rlmin for 2 minutes.
5. Set the CO/HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value:
CO contents: 0.5% or less
HC contents: 100 ppm or less
7. If the idle speed is not within the standard value, check
the following items:
e Diagnostic output
0 Closed-loop control (When the closed-loop control
is carried out normally, the output signal of the heated
oxygen sensor repeats between 0 - 400 mV and
600 - 1,000 mV at idle.)
0 Fuel pressure
0 Injector
0 Ignition coil, spark plug cable, spark plug
0 EGR system and the EGR valve leak
0 Evaporative emission control system
0 Compression pressure
NOTE
Replace the three-way catalyst whenever the CO and
HC contents do not remain inside the standard value.
(even though the result of the inspection is normal on
all items).
ENGINE c1.8L> - On-vehicle Service 11c-11
COMPRESSION PRESSURE CHECK iiiooz606~0
1. Before inspection, set the vehicle in the following
condition.
0 Enginecoolant temperature:80 - 95°C (176 - 203°F)
0 Lights, electric cooling fan and all accessories: OFF
0 Transaxle: Neutral (P range on vehicles with A/T)
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.

Crankshaft position
4. Disconnect the crankshaft position sensor connector.
/ sensor connector NOTE
Doing this will prevent the engine module from carrying
out ignition and fuel injection.

5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the spark plug hole when crank-
ing.
2. If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.

6. Set compression gauge to one of the spark plug holes. '


7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 300 r/min):
1,370 kPa (199 psi)
Limit (at engine speed of 300 r/min):
min. 1,040 kPa (151 psi)
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: max. 100 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 7 and 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 defectivevalve seat, or pressure
is leaking from the gasket.
11c-12 ENGINE el .8L> - On-vehicle Service
10. Connect the crankshaft position sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the scan tool to erase the diagnostic trouble codes,
or disconnect the negative battery cable for more than
10 seconds and reconnect it.
NOTE
This will erase the diagnostic trouble code resulting from
the crankshaft position sensor connector being discon-
nected.

MANIFOLD VACUUM CHECK 11100270263

Engine speed detection 1. Before inspection, set the vehicle in the following
connector (blue) condition.
Engine coolant temperature:80 - 95°C (176 - 203" F)
0 Lights, electric cooling fan and all accessories: OFF
0 Transaxle: Neutral (P range on vehicles with A/T)
2. Connect the scan tool to the data link connector, or connect
a primary voltage detection type tachometer to the
connector through a paper clip.

3. Attach a three-way joint to the vacuum hose connected


between the intake manifold plenum and the fuel pressure
regulator and connect a vacuum gauge.
4. Start the engine, and check that the curb idle speed is
within the standard value range.
Standard value: 700 f 100 r/min
5. Check the manifold vacuum.
Limit: min. 60 kPa (18 in.Hg)

TIMING BELT TENSION ADJUSTMENT i11002~0129

1. Remove the timing belt upper cover.


2. Turn the crankshaft clockwise to set the No.1 cylinder
to the top dead compression center.
Caution
As the purposeof this procedureis to apply the proper
amount of tension to the timing belt by means of
the cam drive torque, be sure not to rotate the
crankshaft counterclockwise.
3. Remove the access cover.
4. Loosenthe timing belt tensionerfixingbolt to applytension
to the belt by means of the force of the tensioner spring.
Caution
-
The bolt can be loosened 90" 180". If the belt is
loosened more than necessary,the bolt may fall inside
the cover.
5. Tighten the timing belt tensioner fixing bolt.
6 . Install the access cover.
7. Install the timing belt upper cover.
ENGINE <I .8L> - On-vehicle Service * 11C-13
LASH ADJUSTER CHECK 11100290436

If an abnormal noise (clicking) assumed to caused by a fault


in the lash adjuster is heard and does not stop after the
engine is started, inspect the following items.
NOTE
(1) The abnormal noise caused by the lash adjuster occurs
just after starting and fluctuates according to the engine
speed, but is not related to the.engine load.
Thus, if the abnormal noise does not occur just after
the engine speed, if it does not fluctuate according to
the engine speed, or if it fluctuates accordingto the engine
load, the lash adjuster is not the cause of the abnormal
noise.
(2) If the lash adjuster is defective, often the abnormal noise
will not stop even if warmup operation is continued in
the idling state.
Note that the abnormal noise may stop only if the noise
is caused by fixing of oil sludge in an engine where the
oil control is poor.

1. Start the engine.


P 2. Check whether the abnormal noise starts immediately
after starting, and whether it fluctuates according to the
engine speed when the engine speed is varied.
If the abnormal noise does not occur immediately after
starting, or if it does not fluctuate according to the engine
speed, the cause is not with the lash adjuster, so
investigate for other causes of the abnormal noise. If
the abnormal noise does not fluctuate according to the
engine speed, it is assumed that the cause is not the
engine unit. (In this case, the lash adjuster is normal.)
3. Check whether the abnormal noise level does not change
when the engine load is fluctuated (ex., shift from N to
D range) in the idling state.
If the abnormal noise level fluctuates, this may be a hitting
sound caused by wear of the crankshaft bearings or
connecting rod bearings. (In this case, the lash adjuster
is normal.)
4. Check for abnormal noise in the idling state after warmup
operation is completed.
If the abnormal noise is quieter or has stopped, it is
assumed that the noise was caused by fixing of the lash
adjuster due to oil sludge, etc., so wash the lash adjuster.
(Refer to GROUP 11D - Rocker Arms and Camshaft.)
If the abnormal noise level does not fluctuate, go to step
5.
5. Bleed the air from the lash adjuster. (Refer to GROUP
11C-14.)
6. If the abnormal noise does not stop even after purging
the air, wash the lash adjuster. (Refer to GROUP 11D
- Rocker Arms and camshaft.)
11C-14 ENGINE <I .8L> - On-vehicle Service
PURGING OF THE LASH ADJUSTER
NOTE
If the vehicle is parked for a long time on a slope, the
oil in the lash adjuster will decrease, and air may enter
the high pressure chamber when starting.
When the vehicle is parked for a long time, there will
be no oil in the oil passage, and it will take time for the
oil to be supplied to the lash adjuster. Thus, air may
enter the high pressure chamber.
In the above cases, the abnormal noise can be stopped
by purging the lash adjuster.
Check the engine oil, and replenish or replace it if
necessary.
NOTE
(1) If the engine oil level is low, air will be sucked in
from the oil screen and will enter the oil passage.
(2) If the engine oil level is higher than the specified
amount, the oil will be mixed by the crankshaft and
a large amount of air may enter the oil.
(3) If the oil is deteriorated,the air and oil will not separate
easily, and the amount of air in the oil will increase.
OIL0183
(4) If due to the above types of cases, air enters the
oil and into the high pressure chamber of the lash
adjuster, the air in the high pressure chamber will
be compressed too much when the valve is opened,
so abnormal noise will occur when the valve is shut.
This is the same phenomenon as when the valve
High- clearance is excessive. In this case, the lash adjuster
pressure functions will return to normal if the air in the lash
chamber adjuster is bled out.

w 7EN0392

Air bleeding operation pattern Carry out warmup operation for one to three minutes
in the idling state.
Gradually open the throttle valve
Repeat the operation patternshown on the left in a no-load
Approx. Close the throttle valve
state, and check for abnormal noise. (Normally, the
abnormal noise will stop after the pattern is repeated
for 10 to 30 times, but if the abnormal noise level does
not change even when the pattern is repeated for 30
or more times, the cause may be other than the entry
of air.
After the abnormal noise stops, repeat the operation
7FU2059 pattern shown on the left for another five times.
For one to three minutes in the idling state, check that
the abnormal noise has stopped.
ENGINE <1.8L> - Engine Assembly 11C-15
ENGINE ASSEMBLY 11200100794

REMOVAL AND INSTALLATION


Pre-removal Operation Post-installation Operation
(1) Fuel Discharge Prevention (Refer to GROUP 13A (1) Auto-cruise Vacuum Pump and Bracket Assembly
- On-vehicle Service.) Installation (Refer to GROUP 17.)
(2) Under Cover Removal (2) Front Exhaust Pipe Installation (Refer to GROUP
(3) Hood Removal (Refer to GROUP 42.) 15.)
(4) Air Cleaner Removal (3) Radiator Installation (Refer to GROUP 14.)
(5) Radiator Removal (Refer to GROUP 14.) (4) Air Cleaner Installation .
(6) Front Exhaust Pipe Removal (Refer to GROUP 15.) (5) Hood Installation (Refer to GROUP 42.)
(7) Auto-cruise Vacuum Pump and Bracket Assembly (6) Under Cover Installation
Removal (Refer to GROUP 17.) (7) Drive Belt Tension Adjustment
(8) Accelerator Cable Adjustment (Refer to GROUP
17 - On-vehicle Service.)

1 5 Nm
I 4 ft.lbs.

Removal steps
1. Accelerator cable connection 14. Manifold differential pressure sen-
2. Vacuum hose connection sor connector
3. Brake booster vacuum hose con- 15. Heated oxygen sensor connector
nection <Vehicle for California>
4. Heater hose connection 16. Ignition failure sensor connector
5. Throttle position sensor connector 17. Engine coolant temperature gauge
6. Idle speed control connector unit connector
7. Ground cable connection 18. Engine coolant temperature sensor
8. Crank angle sensor connector connector
9. Heated oxygen sensor connector 19. Camshaft position sensor connector
10. Ignition coil connector 20. Noise condensor connector
11. Injector connector 21. Control wiring harness
12. Evaporative emission purge sole- F C d 22. High-pressure fuel hose connection
noid 23. Fuel return hose connection
13. EGR solenoid connector
11C-16 ENGINE <1.8L> - Engine Assembly
22 Nm
16 ft.lbs.
ENGINE c1.8L> - Engine Assembly 11C-17
REMOVAL SERVICE POINTS
+AbPOWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when remwing and installing the
engine assembly, and tie it with a cord.

+ B b A/C COMPRESSOR REMOVAL


Disconnect the q/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrancewhen removingand installingthe engine assembly,
and tie it with a cord.

<M/T>
+ C b TRANSAXLE ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22A.
Caution
Flywheel Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt is removed, the flywheel will become
out of balance and damaged.
<An>:
Refer to GROUP 23A.
I A 0 1 M0153

+ D b ENGINE MOUNT BRACKET REMOVAL


MZ203827
\
I I. i
, rn I1
1. Support the engine with a garage jack.
2. Remove the special tool which was attached when the
transaxle assembly was removed.
3. Hold the engine assembly with a chain block or similar
tool.
4. Place a garage jack against the engine oil pan with a
piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
I\ A01M0002
the engine mount bracket, and then remove the engine
mount bracket.

+ E b ENGINE ASSEMBLY REMOVAL


After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
slowly to removethe engineassembly upward from the engine
compartment.
11C-18 ENGINE c1.8L> - Engine Assembly

INSTALLATION SERVICE POINTS


.A+ ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not pinched.

,B+ ENGINE MOUNT BRACKET INSTALLATION


1. Place a garage jack against the engine oil pan with a
piece of wood in between, and install the engine mount
bracket while adjusting the position of the engine.
2. Support the engine with the garage jack.
3. Remove the chain block and support the engine assembly
with the special tool.

I
b C + HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the fuel rail.
2. While turning the high-pressurefuel hose clockwise and
counterclockwise, install it to the fuel rail, while being
careful not to damage the O-ring. After installing, check
I O-ring that the hose turns smoothly.
High-pressure fuel hose 3. If the hose does not turn smoothly, the O-ring is probably
B03N0012
being pinched. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert
the fuel rail and check that the hose turns smoothly.
ENGINE <1.8L> - Crankshaft Pulley 11c-19
CRANKSHAFT PULLEY 11200160211

Pre-removal Operation Post-installation Operation


0 Under Cover Removal (1) Drive Belt Tension Adjustment
(2) Under Cover Installation

177
130 -- 186
137

801R0023

Removal steps
1. Drive belt (Power steering and 2. Drive belt (Generator)
r AIC) +AF F A 4 3. Crankshaft pulley

REMOVAL SERVICE POINT


+ A F CRANKSHAFT PULLEY REMOVAL

INSTALLATION SERVICE POINT


F A + CRANKSHAFT PULLEY INSTALLATION
When installing the crankshaft bolt, apply a mininal amount
of engine oil to the bearing surface and thread of the bolt.
11c-20 ENGINE c1.8L> - Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL 11200190234

REMOVAL AND INSTALLATION

1Pre-removal and Post-installation Operation


(1) Air Cleaner Removal and Installation
(2) Timing Belt Removal and Installation (Refer to
P.11C-30.)

10 Nrn
7 ft.lbs.
/

Sealant:
MlTSUBlSHl GENUINE PART
MD970389 or equivalent

8
Lip section

01z0022

Cam section and .


journal section

01M0036

7 01M0051 Engine oil


0000451 1

Removal steps
1. Control harness connection 4 A b b B 4 7. Camshaft sprocket
2. Spark plug cable .A4 8. Camshaft oil seal
3. PCV hose connection 9. Spark plug guide oil seal
4. Rocker cover 10. Rocker arm and shaft assembly
0 Valve clearance adjustment (Refer to (intake side)
GROUP 00 - Maintenance Service.) 11. Rocker arm and shaft assembly
5. Camshaft position sensor support (exhaust side)
6. Camshaft position sensing cylinder 12. Camshaft
ENGINE c1.8L> - Camshaft and Camshaft Oil Seal 11c-21
REMOVAL SERVICE POINT
+ A F CAMSHAFT SPROCKET REMOVAL

MD998719 or

I ' Bolzoool

INSTALLATION SERVICE POINTS


I I F A + CAMSHAFT OIL SEAL INSTALLATION
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.

I MD998713
AOlX0075

b B + CAMSHAFT SPROCKET INSTALLATION


Use the special tool to stop the camshaftsprocketfrom turning
in the same way as was done during removal,and then tighten
the bolts to the specified torque.
11c-22 ENGINE <1.8L> - Oil Pan
OIL PAN 11200280313

REMOVAL AND INSTALLATION \

Pre-removal and Post-installation Operation


(1) Engine Oil Draining and Supplying (Refer to GROUP (3) Front Exhaust Pipe Removal and Installation (Refer
00 - Maintenance Service.) to GROUP 15.)
(2) Oil Dipstick Removal and Installation

2
mm (in.) 01 S 01 2 7

Sealant:
MlTSUBlSHl GENUINE PART
MD970389 or equivalent

-
10 12 Nm 22 - 25 Nm 48 Nm 39 Nm 01~0025
7 -9 ft.lbS. 16 - 18 ft-lbs. 35 ft.lbS. 29 ft-lbs. oooo4512

Removal steps
1. Transaxle stay FA+ 4. Drain plug gasket
2. Bell housing cover +A, 5. Oil pan
3. Drain plug

REMOVAL SERVICE POINT


4 A b O I L PAN REMOVAL
After removing the oil pan mounting bolts, remove the oil
pan with the special tool and a brass bar.
Caution
Perform this slowly to avoid deformation of the oil pan
flange.

INSTALLATION SERVICE POINT


.A+ DRAIN PLUG GASKET INSTALLATION
Oil pan side
Install the drain plug gasket so it faces in the direction shown
in the illustration.
Drain u
pg
l.
gasket

I 7EN0307 I
ENGINE c1.8L> - Crankshaft Oil Seal 11C-23
CRANKSHAFT OIL SEAL 11200310234

REMOVAL AND INSTALLATION

05 4’ 01M0027
00005255

\ Crankshaft

(Engi \
bolt (Engine oil:
er su bolt washer 11 5
surface)

section section
0120022

01M0153 0120020

Sealant: 3M Stud Locking 4170 or equivalent Engine oil

Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
0 Timing belt (Refer to P.11C-30.) 0 Oil pan (Refer to P.11C-22.)
0 Crankshaft position sensor 4Ab 0 Transaxle assembly
(Refer to GROUP 16.) 0 Clutch cover and disc < M F >
1. Crankshaft sprocket +B. .B+ 6. Plate <M/T>
2. Key 4BF F B I 7. Adapter plate
3. Crankshaft sensing blade +Bb bB+ 8. Flywheel <M/T>
4. crankshaft spacer +Bb bB+ 9. Drive plate <An>
bC+ 5. Crankshaft front oil seal +Bb .B+ 10. Adapter plate <M/T>
FA+ 11. Crankshaft rear oil seal

Caution
Do not disassemble the flywheel, as its runout is
adjusted as an assembly. If it is disassembled, the
flywheel may lose the balance and get damage.
I1 C-24 ENGINE <1.8L> - Crankshaft Oil Seal
<MiT> I
REMOVAL SERVICE POINT
+ A F TRANSAXLE ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22A.
Flywheel Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt is removed, the flywheel will become
out of balance and damaged.
P01M0154 <An>:
I I Refer to GROUP 23A.
+ B F PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE CAP> REMOVAL
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.

INSTALLATION SERVICE POINTS


F A + CRANKSHAFT REAR OIL SEAL INSTALLATION
rankshaft
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.

A01R0046

F B + DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER


PLATE/PLATE <MP> INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the flywheel or drive plate.
2. Apply oil to the bearing surface of the flywheel or drive
plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant:
3M Stud locking 4170 or equivalent
5. Use the special tool to hold the flywheel or drive plate
in the same manner as removal, and install the bolt.
ENGINE <1.8L> - Crankshaft Oil Seal 11C-25
-
F C d CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Tap the oil seal until it is flush with the oil seal case.

Oil seal
A7EN276
-
11C-26 ENGINE c1.8L> - Cylinder Head Gasket
CYLINDER HEAD GASKET 11200400788

REMOVAL AND INSTALLATION


I I
Pre-removal Operation Post-installation Operation
(1) Fuel Discharge Prevention (Refer to GROUP 13A (1) Thermostat Case Assembly Installation (Refer to
- On-vehicle Service.) GROUP 14 - Water Hose and Water Pipe.)
(2) Engine Oil Draining (Refer to GROUP 00 - (2) Engine Oil Supplying (Refer to GROUP 00 -
Maintenance Service.) Maintenance Service.)
(3) Thermostat Case Assembly Removal (Refer to (3) Accelerator Cable Adjustment (Refer to GROUP
GROUP 14 - Water Hose and Water Pipe.) 17 - On-vehicle Service.)

10 Nm
7 ft.1b.s. O-ring
Fuel rail

\h /, / if///?

Engine oil

22 Nm
716 ft.lbs.

44 Nm
33 ft.1b.s.

7
01M0138
00008768

Removal steps
1. Accelerator cable connection 15. Manifold differential pressure sen-
2. Vacuum hose connection sor connector
3. Brake booster vacuum hose con- 16. Heated oxygen sensor connector
nection <Vehicles for California>
4. Water hose connection 17. Ignition failure sensor connector
5. Throttle position sensor connector 18. Engine coolant temperature gauge
6. Idle speed control connector unit connector
7. Ground cable connection 19. Engine coolant temperature sensor
8. Crankshaft position sensor connec- connector
tor 20. Camshaft position sensor connector
9. Heated oxygen sensor connector 21. Noise condensor connector
10. Ignition coil connector 22. Control wiring harness
11. Ignition coil assembly b D 4 23. High-pressure fuel hose connection
12. Injector connector 24. Fuel return hose connection
13. Evaporative emission purge sole- 4Ab 25. Power steering oil pump and
noid connector bracket assembly
14. EGR solenoid valve connector
ENGINE c1.8L> - Cylinder Head Gasket * 11(2-27
<Cold engine>
74 Nm -+0 Nm -+

(54 ft.lbs. + 0 ft.lbs. -


20 Nm + + 90"
14 ft.lbs. -+ + + 90"
90" + + 90') ?* R A Nm

34

35

-
-
12 15 Nrn
9 11 ft.lbS.

34 Nm
25 ft.lbs.

AQIMOQ52

(B, bC( 26. Radiator upper hose connection 31. Intake manifold stay
27. PCV hose ( Cb bB( 32. Cylinder head bolt
28. Rocker cover 33. Spark plug guide oil seal
0 Timing belt (Refer to P.11C-30.) 34. Cylinder head assembly
29. Timing belt rear cover F A + 35. Cylinder head gasket
30. Front exhaust pipe connection

REMOVAL SERVICE POINTS


4AFPOWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
cvlinder head assembly, and tie it with a cord.
11C-28 ENGINE <1.8L> - Cylinder Head Gasket
+ B F RADIATOR UPPER HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

A04AO082

+ C b CYLINDER HEAD BOLT REMOVAL


Using the special tool, loosen the bolts in 2 or 3 steps in
the order of the numbers shown in the illustration, and remove
the cylinder head assembly.
Caution
Because the plug guides cannot be replaced by
themselves, be careful not to damage or deform them
when removing the cylinder head bolts.

[FTq
Intake side c;I1'Front of engine

O A
4
0

0120005
Exhaust side
00004766

INSTALLATION SERVICE POINTS


F A + CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Installso that the cylinder head holes matchthe respective
cylinder head gasket holes.

F B + CYLINDER HEAD BOLT INSTALLATION


Head bolt
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Limit (A): 96.4 mm (3.80 in.)
2. The head bolt washer should be installed with the burred
side, caused by tapping out, facing upwards.
3. Apply a small amount of engine oil to the thread section
0150034 01co111 and the washer of the cylinder head bolt.
00003399
ENGINE <1.8L> - Cylinder Head Gasket 11C-29
4. Using the special tool, tighten the bolts by the following
procedure.
Step Operation Remarks
1 Tighten to 74 Nm (54 In the order shown in the
ft.lbs.). illustration.
2 Fully loosen. In the reverse order of that
shown in the illustration.
Tighten to 20 Nm (14 In the order shown in the
ft. Ibs.). illustration.
Tighten 90" of a turn. In the order shown in the
illustration. Mark the head
Intake side
+ Front of engine of the cylinder head bolt
and cylinder head by paint.
Tighten 90" of a turn. In the order shown in the

k;;;;
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
10 0120005
6

Exhaust side
00004 767

~~

Step 4 Step 5
Caution
1. Always make a tightening angle just 90". If it is less
0" than 90°, the head bolt will be loosened.
2. If it is more than 90°,remove the head bolt and repeat
the procedure from step 1.

Painted mark Paint'ed mark

01x0270

b C ( RADIATOR UPPER HOSE CONNECTION


Projection 1. Insert each hose as far as the projection of the water
inlet fitting.
2. Align the mating marks on the radiator hose and hose
calmp, and then connect the radiator hose.
Water outlet fitting

04w00..
0450033
00000367

bD( HIGH-PRESSURE FUEL HOSE INSTALLATION


1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the fuel rail.
2. While turning the high-pressure fuel hose clockwise and
counterclockwise, install the fuel rail, be careful not to
damage the O-ring. After installing, check that the hose
O-ring
High-pressure fuel hose I turns smoothly.
11C-30 ENGINE <1.8L> - Cylinder Head Gasketfliming Belt

3. If the hose does not turn smoothly, the O-ring is probably


being pinched. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert
the fuel rail and check that the hose turns smoothly.

TIMING BELT 11200430299

REMOVAL AND INSTALLATION

(1) Crankshaft Pulley Removal and Installation


(Refer to P.ll C-19 )
(2) Engine Mount Bracket Removal and Installation
(Refer to GROUP 32 - Engine Mounting.)

A01M0139

Removal steps
1. Generator brace 6. Engine support bracket
2. Timing belt upper cover ,B+ 0 Timing belt tension adjustment
3. Timing belt lower cover (A, ,A+ 7. Timing belt
bC+ 4. Flange 8 . Tensioner spring
5. Power steering pump bracket stay 9. Timing belt tensioner
ENGINE <1.8L> - Timing Belt 11C-31
REMOVAL SERVICE POINT
Timing mark
+ A b TIMING BELT REMOVAL
1. Turn the crankshaft clockwise (right turn) to align each
timing mark and to set the No. 1 cylinder at compression
top dead center.
Caution
The crankshaft should always be turned only
clockwise.

- A 0 1U 0 0 2 2

2. Loosen the adjusting bolt.


3. Set a screwdriver to the timing belt tensioner and press
it fully back in the direction of the arrow.
4. Provisionally tighten the adjusting bolt.
5. Remove the timing belt.
Caution
If the timing belt is to be re-used, use chalk to mark
the flat side of the belt with an arrow indicating the
direction of rotation (right turn).

INSTALLATION SERVICE POINTS


.Ad TIMING BELT INSTALLATION
1. Set a screwdriver to the timing belt tensioner and press
it fully back in the direction of the arrow.
2. Provisionally tighten the adjusting bolt.
11C-32 ENGINE c1.8L> - Timing Belt

3. Align each of the camshaft sprocket and the crankshaft


sprocket timing marks.
4. Install the timing belt in the following order, while making
sure that the tension side of the belt is not slackened.
(1) Crankshaft sprocket
(2) Water pump sprocket
(3) Camshaft sprocket
(4) Tensioner pulley
Caution
After installing the timing belt, apply force to turn
the camshaftsprocket counterclockwise,and recheck
to be sure that the belt is fully tensioned and that
each timing mark is in the proper position.

Crankshaft
sprocket c01u0022

b B + TIMING BELT TENSION ADJUSTMENT


Loosenthe adjusting bolt of the temporarily securedtiming
-
belt tensioner by 1/4 1/2 turn, and use the force of
the tensioner spring to apply tension to the belt.
Turn the crankshaft clockwise for two rotations, and
recheckto be sure that the timing marks on each sprocket
are aligned.
Caution
As the purpose of this procedureis to apply the proper
amount of tension to the tension side of the timing
belt by using the cam driving torque, turn the
crankshaft only by the amount given above. Be sure
not to turn the crankshaft counterclockwise.
After checking to be sure that no belt teeth in the section
marked with A are lifted up and that the teeth in each
sprocket are engaged, secure the tensioner pulley.

Cranks haft F C d FLANGE INSTALLATION


sprocket Install the flange as shown in the illustration.
0 Front of engine /

Flange ’ haft
A 01C 0114

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