11C-1

GROUP 11C

ENGINE
MECHANICAL
<4G69>
CONTENTS

GENERAL INFORMATION . . . . . . . . 11C-2 REMOVAL AND INSTALLATION . . . . . . . . 11C-17

SERVICE SPECIFICATIONS. . . . . . . 11C-2 CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11C-18
SEALANTS . . . . . . . . . . . . . . . . . . . . 11C-3 REMOVAL AND INSTALLATION . . . . . . . . 11C-18

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11C-4 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11C-23

REMOVAL AND INSTALLATION . . . . . . . . 11C-23
ON-VEHICLE SERVICE. . . . . . . . . . . 11C-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11C-26
DRIVE BELT TENSION CHECK. . . . . . . . . 11C-8
AUTO-TENSIONER CHECK . . . . . . . . . . . 11C-8 CRANKSHAFT OIL SEAL . . . . . . . . . 11C-26
VALVE CLEARANCE CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 11C-26
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11C-11
ROCKER ARM PISTON OPERATION CYLINDER HEAD GASKET . . . . . . . . 11C-30
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C-11 REMOVAL AND INSTALLATION . . . . . . . . 11C-30
IGNITION TIMING CHECK . . . . . . . . . . . . . 11C-13
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11C-14 TIMING BELT . . . . . . . . . . . . . . . . . . . 11C-36
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11C-14 REMOVAL AND INSTALLATION . . . . . . . . 11C-36
COMPRESSION PRESSURE CHECK. . . . 11C-15 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11C-45
MANIFOLD VACUUM CHECK . . . . . . . . . . 11C-16
ENGINE ASSEMBLY . . . . . . . . . . . . . 11C-47
CRANKSHAFT PULLEY . . . . . . . . . . 11C-17 REMOVAL AND INSTALLATION . . . . . . . . 11C-47
11C-2 ENGINE MECHANICAL <4G69>
GENERAL INFORMATION

GENERAL INFORMATION
M1111000100505

Item 4G69
Total displacement mL 2,378
Bore × Stroke mm 87 × 100
Compression ratio 9.5
Compression chamber Pentroof
Camshaft arrangement SOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake valve Open (BTDC) 10° <low speed cam A>
12° <low speed cam B>
24° <High speed cam>
Closes (ABDC) 42° <low speed cam A>
44° <low speed cam B>
68° <High speed cam>
Exhaust valve Open (BTDC) 58°
Closes (ABDC) 18°
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type

SERVICE SPECIFICATIONS
M1112000300278

Item Standard value Limit

Drive belt tension Vibration frequency Hz A/C compressor type: 113 − 145 −
(Reference) MSC90CA
A/C compressor type: 120 − 154 −
MSC105CA
Tension N (Reference) 340 − 555 −
Valve clearance (at hot) mm Intake valve 0.20 −
Exhaust valve 0.30 −
Basic ignition timing 5° BTDC ± 3° −
Ignition timing Approximately −
10° BTDC
Idle speed r/min M/T 680 ± 100 −
A/T 750 ± 100 −
CO contents % 0.5 or less −
HC contents ppm 100 or less −
Compression pressure kPa-r/min 1,560 − 200 1,130 − 200
Compression pressure difference of all cylinders kPa − Maximum 98
 ENGINE MECHANICAL <4G69>
SEALANTS
11C-3
Item Standard value Limit
Intake manifold vacuum kPa − Minimum 60
Cylinder head bolt nominal length mm − 99.4
Balancer timing belt tension (When adjusted) Deflection mm 5−7 −
Balancer timing belt tension (When replaced) Deflection mm 5−7 −
Balancer timing belt tension (When checked) Deflection mm 5 − 10 −
Timing belt tensioner adjuster rod protrusion amount mm 3.8 − 4.5 −
Timing belt tensioner adjuster rod movement mm Within 1 −

SEALANTS
M1112000500294

Item Specified sealant Remark

Camshaft position sensor support MITSUBISHI GENUINE PART MD970389 or Semi-drying
Engine upper oil pan equivalent sealant
Engine lower oil pan
Taper plug LOCTITE203MP Anaerobic
sealant
11C-4 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS

SPECIAL TOOLS
M1112000600332

Tool Number Name Use

MB991502 MUT-II sub assembly • Drive belt tension check
• Checking the ignition timing
• Checking the idle speed

B991502

MB991955 MUT-III sub assembly • Drive belt tension check

A A: MB991824 A: Vehicle communication • Checking the ignition timing
B: MB991827 interface (V.C.I.) • Checking the idle speed
C: MB991910 B: MUT-III USB cable
D: MB991911 C: MUT-III main harness A
MB991824
E: MB991825 (Vehicles with CAN
B F: MB991826 communication system)
D: MUT-III main harness B
(Vehicles without CAN
communication system)
MB991827 E: MUT-III measurement
C
adapter
F: MUT-III trigger harness
DO NOT USED

MB991910

MB991911

MB991825

MB991826

MB991955

MB991668 Belt tension meter set Drive belt tension check (used
together with MUT-II or MUT-III)

B991668
 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
11C-5
Tool Number Name Use
MB990767 Front hub and flange yoke Holding the camshaft sprocket
holder

B990767

MD998719 Pin

D998719

MD998772 Valve spring compressor Compressing valve spring

MD998772

MD998774 Valve stem seal installer Valve stem seal installation

MD998713 Camshaft oil seal installer Camshaft oil seal installation

D998713

MD998781 Flywheel stopper • Supporting the flywheel

assembly <M/T>
• Supporting the A/T drive plate
<A/T>
D998781

MB990938 Installer bar Crankshaft rear oil seal

installation

B990938

MD998776 Crankshaft rear oil seal

installer

D998776
11C-6 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS

Tool Number Name Use

MD998285 Crankshaft front oil seal Crankshaft front oil seal
guide installation

D998285

MD998375 Crankshaft front oil seal

installer

MD998738 Adjusting bolt Supporting the timing belt

tensioner arm and timing belt
tensioner adjuster

D998738

MB991654 Cylinder head bolt wrench Removal and installation of

(12) cylinder head bolt

B991654

MB991367 Special spanner Holding the crankshaft camshaft

drive sprocket

B991367

MB991385 Pin

B991385

MD998767 Tensioner wrench Valve timing belt tension

adjustment

D998767
 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
11C-7
Tool Number Name Use
MB991454 Engine hanger balancer When the engine hanger is
used: Supporting the engine
assembly during removal and
installation of the transmission
B991454
assembly
NOTE: Special tool MB991454
MB991527 Hanger is a part of engine hanger
attachment set MB991453.

B991527

MB991895 Engine hanger

Z203830

MB991928 Engine hanger

Slide bracket (HI) A: MB991929 A: Joint (50) × 2
B: MB991930 B: Joint (90) × 2
E C: MB991931 C: Joint (140) × 2
D: MB991932 D: Foot (standard) × 4
F E: MB991933 E: Foot (short) × 2
A F: MB991934 F: Chain and hook assembly
D
B
C
B991928
11C-8 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK 4. If there are any problems in the procedure 1 or 3,
M1111003100548 replace the auto-tensioner.(Refer to P.11C-36).
CAUTION 5. Install the drive belt.(Refer to P.11C-17).
Check the drive belt tension after turning the
crankshaft clockwise one turn or more. FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
Indicator mark
When using MUT-II
1. Check the drive belt tension. (Refer to P.11C-8).
2. Measure the drive belt tension vibration frequency
A by the following procedures:
CAUTION

AC301702AB

1. Make sure that the indicator mark is within the

area marked with A in the illustration. 16-pin
2. If the mark is out of the area, replace the drive
belt. (Refer to P.11C-17).
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.

AUTO-TENSIONER CHECK
M1111003000251 MUT-II
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.11C-17).
MB991668

AC211862 AB

To prevent damage to MUT-II, always turn the

ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
AC301703 connector.
(3) Turn the ignition switch to "ON" position, and
3. Securely insert the spindle handle or ratchet select "BELT TENSION" on the menu screen.
handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11C-9
CAUTION Standard value:
• The temperature of the surface of the belt <A/C compressor type: MSC90CA> 113 − 145
should be as close to normal temperature as Hz
possible. <A/C compressor type: MSC105CA> 120 − 154
Hz
• Do not allow any contaminants such as water
or oil to get onto the microphone. 3. If not within the standard value, replace the
• If strong gusts of wind blow against the auto-tensioner. (Refer to P.11C-36).
microphone or if there are any loud sources
When using V.C.I.
of noise nearby, the values measured by the
microphone may not correspond to actual 1. Check the drive belt tension. (Refer to P.11C-8).
values. 2. Measure the drive belt tension vibration frequency
• If the microphone is touching the belt while by the following procedures:
the measurement is being made, the values CAUTION
measured by the microphone may not
correspond to actual values.
• Do not take the measurement while the
vehicle's engine is running.
16-pin

Water MB991668
pump
pulley
15˚ 10 – 20 mm
15˚

MB991824

Gentry tap MB991668

with your
finger
MB991911

AC211863AB
Alternator
pulley To prevent damage to special tool V.C.I.
(MB991824), always turn the ignition switch to
the "LOCK" (OFF) position before connecting or
disconnecting special tool V.C.I. (MB991824).
AC301266AB (1) Connect special tool belt tension meter set
(4) Hold special tool belt tension meter set (MB991668) to special tool V.C.I. (MB991824).
(MB991668) to the middle of the drive belt (2) Connect special tool MUT-III main harness B
between the pulleys (at the place indicated by (MB991911) to special tool V.C.I. (MB991824).
arrow), approximately 10 − 20 mm away from (3) Connect special tool MUT-III main harness B
the rear surface of the belt so that it is (MB991911) to the diagnosis connector.
perpendicular to the belt (within an angle of ± (4) Turn the ignition switch to "ON" position, and
15 degree). select "Belt Tension" on the menu screen.
(5) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and
measure that the vibration frequency of the
belt is within the standard value.
11C-10 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

CAUTION (6) Gently tap the middle of the belt between the
• The temperature of the surface of the belt pulleys (the place indicated by the arrow) with
should be as close to normal temperature as your finger as shown in the illustration, and
possible. measure that the vibration frequency of the
• Do not allow any contaminants such as water belt is within the standard value.
or oil to get onto the microphone. Standard value:
• If strong gusts of wind blow against the <A/C compressor type: MSC90CA> 113 − 145
microphone or if there are any loud sources Hz
of noise nearby, the values measured by the <A/C compressor type: MSC105CA> 120 − 154
microphone may not correspond to actual Hz
values. 3. If not within the standard value, replace the
• If the microphone is touching the belt while alternator drive belt auto tensioner. (Refer to
the measurement is being made, the values P.11C-36).
measured by the microphone may not
correspond to actual values. When using a tension gauge
• Do not take the measurement while the 1. Check the drive belt tension. (Refer to P.11C-8).
vehicle's engine is running.

Belt tension
Water pump
gauge
Water MB991668 pulley
pump
pulley
15˚ 10 – 20 mm
15˚

Gentry tap
with your
finger

Alternator
pulley
Alternator
pulley

AC301267AB
AC301266AB
2. Use a belt tension gauge in the middle of the belt
(5) Hold special tool belt tension meter set between the pulleys (at the place indicated by the
(MB991668) to the middle of the drive belt arrow) to measure that the belt tension is within
between the pulleys (at the place indicated by the standard value.
arrow), approximately 10 − 20 mm away from
Standard value: 340 − 555 N
the rear surface of the belt so that it is
perpendicular to the belt (within an angle of ± 3. If not within the standard value, replace the
15 degree). auto-tensioner. (Refer to P.11C-36).
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11C-11
VALVE CLEARANCE CHECK AND Standard value (hot engine):
Intake valve: 0.20 mm
ADJUSTMENT
M1111001500131 Exhaust valve: 0.30 mm
1. Start the engine and allow it to warm up until the 10.While holding the adjusting screw with a
engine coolant temperature reaches 80 − 95°C. screwdriver to prevent it from turning, tighten the
2. Turn the ignition switch to the "LOCK" (OFF) lock nut to the specified torque.
position. Tightening torque: 9 ± 1 N⋅m
3. Remove all ignition coils.
11.Turn the crankshaft through 360° to line up the
4. Remove all spark plugs from the cylinder head for notch on the crankshaft pulley with the "T" mark
easy inspection. on the timing indicator.
5. Remove the rocker cover. 12.Repeat steps (9) and (10) on other valves for
6. Turn the crankshaft clockwise until the notch on clearance adjustment.
the pulley is lined up with the "T" mark on the 13.Install the rocker cover.
timing indicator.
14.Install the spark plugs and tighten to the specified
7. Move the rocker arms on the No.1 and No.4 torque.
cylinders up and down by hand to determine
Tightening torque: 25 ± 4 N⋅m
which cylinder has its piston at the top dead
center on the compression stroke. If both intake 15.Install the ignition coils.
and exhaust valve rocker arms have a valve lash,
the piston in the cylinder corresponding to these ROCKER ARM PISTON OPERATION
rocker arms is at the top dead center on the CHECK
compression stroke. M1111051000023

Intake valve side Taper plug

Oil control valve

Ignition coils
No. 1 No. 2 No. 3 No. 4
Exhaust valve side Rocker cover AK304505AB
AK303689 AB

1. Remove all of the ignition coils.

8. Valve clearance inspection and adjustment can be
performed on rocker arms indicated by white 2. Remove the rocker cover.
arrow mark when the No.1 cylinder piston is at the 3. Remove the oil control valve.
top dead centre on the compression stroke, and 4. Remove the taper plug.
on rocker arms indicated by black arrow mark 5. Turn the crankshaft clockwise until the notch on
when the No.4 cylinder piston is at the top dead the crankshaft pulley is lined up with "T" mark on
centre on the compression stroke. the lower cover of timing belt.
9. Measure the valve clearance. 6. Move the rocker arms on the No.1 and No.4
If the valve clearance is not as specified, loosen cylinders up and down by hand to determine
the rocker arm lock nut and adjust the clearance which cylinder has its piston at the top dead
using a thickness gauge while turning the centre on the compression stroke.
adjusting screw.
11C-12 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

NOTE: 7. While shutting up the oil passage hole at the

Intake valve side depth of the oil control valve's installation hole by
finger not to leak air, blow compression air into the
taper plug's installation hole by air blowgun. At
this time, confirm that the rocker arm piston can
operate.
NOTE: To fully confirm the check, prevent the
compression air from leaking as much as possible by
No. 1 No. 2 No. 3 No. 4 installing the O-ring to the end of air blowgun.
Exhaust valve side
AK303689 AC
8. Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
The rocker arm piston operation check can be the lower cover of timing belt.
performed on rocker arms indicated by white arrow
9. Confirm the rest of the rocker arm pistons under
mark when the No.1 cylinder piston is at the top dead
the procedure 7.
centre on the compression stroke, and on rocker
arms indicated by black arrow mark when the No.4 10.When the rocker arm piston does not operate,
cylinder piston is at the top dead centre on the replace the rocker arm assy.
compression stroke. 11.Apply sealant to threaded portion.
Specified sealant: LOCTITE203MP
Rocker arm Rocker arm
piston CAUTION
Do not start the engine within one hour after the
engine taper plug has been installed.
12.Install the taper plug and tighten to the specified
torque.
Oil passage Tightening torque: 10 ± 2 N⋅m
Blow
compression 13.Install the oil control valve. (Refer to Camshaft
air AK302684AC and Valve Stem Seal − Removal and Installation
P.11C-18.)
14.Install all of the ignition coils.
15.Install the rocker cover.
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11C-13
IGNITION TIMING CHECK 2. Turn the ignition switch to the "LOCK" (OFF)
M1111001700607 position and then connect the MUT-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Use the MUT-II/III to measure engine idle speed
and check that it is within the standard value.
Standard value
: 680 ± 100 r/min <M/T>
16 PIN
MB991502 : 750 ± 100 r/min <A/T>
AK303691AF 6. Select No. 17 of the MUT-II/III Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5° BTDC ± 3°
8. If the basic ignition timing is outside the standard
16-PIN
value, inspect the MPI system (Refer to P.13B-20,
GROUP 13B − Troubleshooting − Inspection chart
for diagnosis code).
CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
MB991911
condition may damage the engine.
MB991824 9. Press the MUT-II/III clear key (Select a forced
driving cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
Standard value: approximately 10° BTDC
NOTE: .
• The ignition timing may fluctuate within ± 7°
BTDC. This is normal.
MB991827 AK303690AB • In higher altitude, the ignition timing is more
advanced than the standard value by
1. Before inspection, set the vehicle to the
approximately 5°.
pre-inspection condition.
11.Remove the timing light.
12.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.
11C-14 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

IDLE SPEED CHECK 7. If the idle speed is outside the standard value,
M1111003500654 inspect the MPI system (Refer to P.13B-20,
GROUP 13B − Troubleshooting − Inspection chart
for diagnosis code).
8. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.

IDLE MIXTURE CHECK

M1111002100426

16 PIN
MB991502
AK303691AF

16-PIN 16 PIN
MB991502
AK303691AF

MB991911
16-PIN
MB991824

MB991911

MB991827 AK303690AB MB991824

1. Before inspection, set the vehicle to the
pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the MUT-II/III to the
diagnosis connector.
3. Connect a timing light. MB991827 AK303690AB
4. Start the engine and let it run at idle.
1. Before inspection, set the vehicle to the
5. Check that ignition timing is at the standard value. pre-inspection condition.
Standard value: approximately 10° BTDC 2. Turn the ignition switch to the "LOCK" (OFF)
6. Check the idle speed. position and then connect the MUT-II/III to the
Standard value diagnosis connector.
: 680 ± 100 r/min <M/T> 3. Connect a timing light.
: 750 ± 100 r/min <A/T> 4. Start the engine and let it run at idle.
NOTE: . 5. Check that ignition timing is at the standard value.
• The idle speed is controlled automatically by Standard value: approximately 10° BTDC
the idle speed control system.
6. Run the engine at 2,500 r/min for 2 minutes.
• When using the MUT-II/III, select item No. 22
and take a reading of the idle speed. 7. Set the CO, HC tester.
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11C-15
8. Check the CO contents and the HC contents at CAUTION
idle. • Keep away from the spark plug hole when
Standard value cranking.
CO contents: 0.5 % or less • If compression is measured with water, oil,
HC contents: 100 ppm or less fuel, etc., that has come from cracks inside
9. If there is a deviation from the standard value, the cylinder, these materials will become
check the following items: heated and will gush out from the spark plug
• Diagnosis output hole, which is dangerous.
• Fuel pressure 4. Cover the spark plug hole with a shop towel etc.,
• Injector and after the engine has been cranked, check that
• Ignition coil, spark plug no foreign material is adhering to the shop towel.
• EGR control system 5. Set compression gauge to one of the spark plug
• Evaporative emission control system holes.
• Compression pressure 6. Crank the engine with the throttle valve fully open
NOTE: Replace the three way catalyst when the and measure the compression pressure.
CO and HC contents are not within the standard Standard value (at engine speed of 200
value, even though the result of the inspection is r/min):
normal on all items. 1,560 kPa
10.Turn the ignition switch to the "LOCK" (OFF)
Limit (at engine speed of 200 r/min):
position and then remove the MUT-II/III.
Minimum 1130 kPa
COMPRESSION PRESSURE CHECK 7. Measure the compression pressure for all the
M1111002600636 cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
8. If there is a cylinder with compression or a
Crank angle compression difference that is outside the limit,
sensor pour a small amount of engine oil through the
connector
spark plug hole, and repeat the operations in
steps from (5) to (7).
(1) If the compression increases after oil is added,
AK303421AB
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
1. Before inspection, set the vehicle to the surface.
pre-inspection condition. (2) If the compression dose not rise after oil is
2. Remove all of the ignition coils and spark plugs. added, the cause is a burnt or defective valve
3. Disconnect the crank angle sensor connector. seat, or pressure is leaking from the gasket.
NOTE: Doing this will prevent the 9. Connect the crank angle sensor connector.
engine-ECU<M/T> or engine-A/T-ECU<A/T> from 10.Install the spark plugs and tighten to the specified
carrying out ignition and fuel injection. torque.
Tightening torque: 25 ± 4 N⋅m
11.Install the ignition coils.
12.Use the MUT-II/III to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.
11C-16 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

MANIFOLD VACUUM CHECK 1. Before inspection, set the vehicle to the

M1111002700569 pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the MUT-II/III to the
diagnosis connector.

Ventilation hose

16 PIN
MB991502 Plug
PCV valve
AK303691AF
Vacuum gauge

AK303422 AB

16-PIN 3. Disconnect the ventilation hose from the PCV

valve, and connect a vacuum gauge to the
ventilation hose.
4. Plug the PCV valve.
5. Start the engine and check that idle speed is
within the standard valve.
MB991911 Standard value
: 680 ± 100 r/min <M/T>
MB991824 : 750 ± 100 r/min <A/T>
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
7. Turn off the ignition switch.
8. Remove the vacuum gauge and then connect the
ventilation hose.
MB991827 AK303690AB
9. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.
 ENGINE MECHANICAL <4G69>
CRANKSHAFT PULLEY
11C-17
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600539

Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Tension Check (Refer to P.11C-8).
P.51-19). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).

1
2

25 ± 4 N·m

AC308973AB

Removal steps 1. Securely insert the spindle handle or ratchet

<<A>> 1. Drive belt handle with a 12.7 mm insertion angle into the jig
2. Crank shaft damper pulley hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
REMOVAL SERVICE POINT
hole A with hole B.
<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the CAUTION
introduction of the serpentine drive system with the To reuse the drive belt, draw an arrow indicating
drive belt auto-tensioner. the rotating direction (clockwise) on the back of
the belt using chalk, etc.
AC301703
Auto-tensioner
Auto-tensioner

Hole B

Hole A L-shaped
hexagon
AC301704AB
wrench AC301705AB

3. Insert an L-shaped hexagon wrench, etc. into the

hole to fix and then remove the drive belt.
11C-18 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL

CAMSHAFT AND VALVE STEM SEAL

REMOVAL AND INSTALLATION
M1112006600330

CAUTION
* Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation Post-installation Operation
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Timing Belt Upper Cover Installation (Refer to P.11C-36).
P.15-4). • Ignition Coils Installation (Refer to GROUP 16, Ignition
• Ignition Coils Removal (Refer to GROUP 16, Ignition System − Ignition Coil P.16-41).
System − Ignition Coil P.16-41). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Timing Belt Upper Cover Removal (Refer to P.11C-36). P.15-4).
• Drive Belt Tension Check (Refer to P.11C-8).
• Valve Clearance Check and Adjustment (Refer to
P.11C-11).

3.5 ± 0.5 N·m

1
7

N8

4 11 ± 1 N·m

9.0 ± 2.0 N·m 24 ± 3 N·m

N 9

5
6N (Engine oil)

44 ± 5 N·m
10

AC308974 AB

Camshaft removal steps Camshaft removal steps

1. Rocker cover PCV hose connection 7. Rocker cover assembly
2. Rocker cover breather hose 8. Rocker cover gasket
connection 9. Spark plug guide oil seals
3. Control wiring harness connection 10. Accumulator assembly
4. Engine hanger • Valve timing belt (Refer to
>>J<< 5. Oil control valve P.11C-36).
>>J<< 6. O-ring
 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
11C-19

Apply engine oil to all 31 ± 3 N·m

moving parts before 11 11 ± 1 N·m
installation. 13 ± 1 N·m
18
12
19
47 ± 7 N·m 21
22
16 14 ± 1 N·m

25 ± 4 N·m
22 ± 4 N·m
23 13
24* 17
25* 20
26*
N 28*
29* 24*
25*
27*
28* N
89 ± 9 N·m
29*

15 N
14 AC308975AB

Camshaft removal steps Valve stem seal removal steps

11. Connector bracket 1. Rocker cover PCV hose connection
>>I<< 12. Camshaft position sensor support 2. Rocker cover breather hose
13. Camshaft position sensing cylinder connection
<<A>> >>H<< 14. Camshaft sprocket 3. Control wiring harness connection
>>G<< 15. Camshaft oil seal 4. Engine hanger
>>F<< 16. Exhaust rocker arm shaft caps 7. Rocker cover assembly
<<B>> >>F<< 17. Exhaust rocker arm and shaft 8. Rocker cover gasket
assembly 9. Spark plug guide oil seals
>>E<< 18. Inlet rocker arm shaft caps >>F<< 16. Exhaust rocker arm shaft caps
<<B>> >>E<< 19. Inlet rocker arm and shaft assembly <<B>> >>F<< 17. Exhaust rocker arm and shaft
>>D<< 20. Camshaft assembly
• Water inlet fitting and thermostat >>E<< 18. Inlet rocker arm shaft caps
case assembly (Refer to GROUP <<B>> >>E<< 19. Inlet rocker arm and shaft assembly
14, Water Hose and Water Pipe 23. Spark plugs
P.14-27). <<C>> >>C<< 24. Valve spring retainer locks
21. Cylinder head plug 25. Valve spring retainers
22. Oil control valve filter >>B<< 26. Inlet valve springs
>>B<< 27. Exhaust valve springs
>>A<< 28. Valve stem seals
29. Valve spring seats
11C-20 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL

REMOVAL SERVICE POINTS Use special tool valve spring compressor

<<A>> CAMSHAFT SPROCKET REMOVAL (MD998772) to compress the valve spring and then
remove the valve spring retainer lock.

MB990767
INSTALLATION SERVICE POINTS
>>A<< VALVE STEM SEALS INSTALLATION
1. Apply a small amount of engine oil to the valve
stem seals.
MD998719 CAUTION
• Do not re-use the valve stem seal.
• Special tool valve stem seal installer
AC102532AB (MD998774) must be used to install the valve
stem seal. Improper installation could result
1. Use the following special tools to hold the
in oil leaking past the valve guide.
camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719) MD998774
2. Loosen the camshaft sprocket mounting bolt and Valve
remove the camshaft sprocket.
Valve stem
<<B>> EXHAUST ROCKER ARM AND SHAFT seal
ASSEMBLY/INLET ROCKER ARM AND SHAFT
Valve guide
ASSEMBLY REMOVAL
CAUTION AC308654AB
Never disassemble the exhaust rocker arm and
shaft assembly, and inlet rocker arm and shaft 2. Use the special tool to fill a new valve stem seal in
assembly. the valve guide using the valve stem area as a
guide.
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL >>B<< EXHAUST VALVE SPRINGS/INLET VALVE
SPRINGS INSTALLATION
CAUTION
When removing valve spring retainer locks, leave Rocker arm side
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.
Identification
colour
Inlet side:
Light blue
MD998772
Exhaust side:
Orange AC107415AC

Install the valve springs with its identification colour

painted end facing the locker arm.

AC301867AB
 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
11C-21
>>C<< VALVE SPRING RETAINER LOCKS 1. Place the inlet rocker shaft so that its 5.5 mm hole
INSTALLATION faces toward the cylinder head.
2. Install the inlet rocker arm shaft caps.
3. Tighten the inlet rocker shaft mounting bolts to the
MD998772 specified torque.
Tightening torque: 31 ± 3 N⋅m

>>F<< EXHAUST ROCKER ARM AND SHAFT

ASSEMBLY/EXHAUST ROCKER ARM SHAFT
CAPS INSTALLATION
AC301867AB Engine front
Use special tool valve spring compressor
(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same
manner as removal.

>>D<< CAMSHAFT INSTALLATION

Notch
Dowel pin AC301870AB

1. Install the exhaust rocker shaft so that its notch is

positioned as shown.
2. Install the exhaust rocker arm shaft caps.
3. Tighten the exhaust rocker shaft mounting bolts to
the specified torque.
Tightening torque: 13 ± 1 N⋅m
AC301868AB

Set the dowel pin of the camshaft in the position

>>G<< CAMSHAFT OIL SEAL INSTALLATION
shown in the figure.
Camshaft oil seal
>>E<< INLET ROCKER ARM AND SHAFT
ASSEMBLY/INLET ROCKER ARM SHAFT CAPS
INSTALLATION
Engine front
(Engine oil)
φ 5.5 mm

MD998713 AC102323AC

1. Apply engine oil to the entire inner diameter of the

oil seal lip.
2. Use special tool camshaft oil seal installer
AC301869AB (MD998713) to press-fit the oil seal as shown.
11C-22 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL

>>H<< CAMSHAFT SPROCKET INSTALLATION NOTE: Install the camshaft position sensor
support within 15 minutes after applying the
sealant.
MB990767 3. Install the camshaft position sensor support to the
cylinder head.
CAUTION
Wait at least one hour. Never start the engine or
MD998719
let engine oil or coolant touch the adhesion
surface during that time.
4. Tighten the camshaft position sensor support
AC102532AB
mounting bolts to the specified torque.
1. Use the following special tool as during removal to Tightening torque: 14 ± 1 N⋅m
hold the camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
>>J<< O-RING/OIL CONTROL VALVE
• Pin (MD998719)
INSTALLATION
2. Tighten the camshaft sprocket mounting bolt to
the specified torque. CAUTION
• Never re-use the O-ring.
Tightening torque: 89 ± 9 N⋅m •

>>I<< CAMSHAFT POSITION SENSOR SUPPORT

INSTALLATION Tape
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.

φ 3 mm
AK303651AD

Before installing O-ring, wind the tape with the

soft adhesion (sealing tape) around the oil
passages cut-out area of engine oil control
valve to prevent the damage. If the O-ring is
damaged, it can be the cause of oil leak.
AC301268AB
1. Apply a small amount of engine oil to the O-ring
2. Apply the sealant to the camshaft position sensor and then install it to the oil control valve.
support flange in a continuous bead as shown in 2. Assemble the oil control valve to the cylinder
the illustration. head.
Specified sealant: MITSUBISHI GENUINE 3. Tighten the oil control valve mounting bolt to the
PART MD970389 or equivalent specified torque.
Tightening torque: 11 ± 1 N⋅m
 ENGINE MECHANICAL <4G69>
OIL PAN
11C-23
OIL PAN
REMOVAL AND INSTALLATION
M1112002800763

Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Under Cover • Centre Member Installation (Refer to GROUP 32, Engine
P.51-19). Roll Stopper and Centre Member P.32-12).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Front Exhaust Pipe Installation (Refer to GROUP 15,
Service − Engine Oil Replacement P.12-3). Exhaust Pipe and Main Muffler P.15-13).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Exhaust Pipe and Main Muffler P.15-13). Service − Engine Oil Replacement P.12-3).
• Centre Member Removal (Refer to GROUP 32, Engine • Under Cover Installation (Refer to GROUP 51, Under
Roll Stopper and Centre Member P.32-12). Cover P.51-19).

N 1

48 ± 7 N·m

2
8

N 1
12 ± 2 N·m
48 ± 7 N·m

9.0 ± 3.0 N·m

4
N 6
9.0 ± 3.0 N·m
9.0 ± 1.0 N·m
3
44 ± 10 N·m

39 ± 5 N·m 5
7 22 ± 4 N·m

9.0 ± 3.0 N·m 9.0 ± 3.0 N·m AC308976 AB

Removal steps Removal steps (Continued)

1. Engine oil cooler tube gaskets 4. Flywheel housing front lower cover
<M/T> <M/T> or torque converter housing
2. Engine oil cooler hose and bracket front lower cover <A/T>
assembly <M/T> 5. Engine oil pan drain plug
>>D<< 3. Transmission housing front lower >>C<< 6. Engine oil pan drain plug gasket
cover stay <<A>> >>B<< 7. Engine lower oil pan
<<B>> >>A<< 8. Engine upper oil pan
11C-24 ENGINE MECHANICAL <4G69>
OIL PAN

REMOVAL SERVICE POINTS 2. Screw in the bolt into bolt hole A in the location
<<A>> ENGINE LOWER OIL PAN REMOVAL shown. Then lift the upper oil pan and remove it.
1. Remove the engine lower oil pan mounting bolts.
INSTALLATION SERVICE POINTS
CAUTION
>>A<< ENGINE UPPER OIL PAN INSTALLATION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of 1. Remove sealant from the engine upper oil pan
aluminium and this tool will damage it. and cylinder block surfaces.

φ 4 mm
Engine lower oil pan Groove Bolt hole
AC102931AB
portion portion AC102242AB

2. Apply a piece of wood to the lower oil pan and 2. Apply a bead of the sealant to the mating surface
strike it with a hammer to remove the engine of the engine upper oil pan as shown.
lower oil pan. Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
<<B>> ENGINE UPPER OIL PAN REMOVAL NOTE: Install the engine upper oil pan within 15
1. Remove the engine upper oil pan mounting bolts. minutes after applying sealant.
CAUTION 3. Assemble the engine upper oil pan to the cylinder
Do not use special tool oil pan remover block.
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.

A
A

AC102946AB
 ENGINE MECHANICAL <4G69>
OIL PAN
11C-25
CAUTION 2. Apply a bead of the sealant to the mating surface
Then wait at least one hour. Never start the of the engine lower oil pan as shown.
engine or let engine oil or coolant touch the Specified sealant: MITSUBISHI GENUINE
sealant surface during that time. PART MD970389 or equivalent
NOTE: Install the engine lower oil pan within 15
B B
B B
minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine
B upper oil pan.
B CAUTION
Then wait at least one hour. Never start the
B B engine or let engine oil or coolant touch the
sealant surface during that time.
B B B-1 B-11
B-10

B B B-4
B-7
B B-5
B B-6
B B-8 A-3

B
B-9 B-12 B-2
A A AC102930AB

4. Insert the bolts to the engine lower oil pan as

AC102929AB shown, and tighten them to the specified torque in
4. Insert the bolts to the engine upper oil pan as the order shown.
shown, and tighten them to the specified torque. Name Symbol Quantity Size mm
Name Symbol Quantity Size mm (D × L)
(D × L) Flange bolt A 1 M6 × 75
Flange bolt A 2 M6 × 16 B 11 M6 × 10
B 16 M6 × 18 NOTE: D: Nominal diameter, L: Nominal length
NOTE: D: Nominal diameter, L: Nominal length Tightening torque: 9.0 ± 3.0 N⋅m
Tightening torque: 9.0 ± 3.0 N⋅m
>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
>>B<< ENGINE LOWER OIL PAN INSTALLATION INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.
Engine lower
oil pan side

AC102325 AF
φ 4 mm
Replace the gasket with a new one. Install the new
Groove Bolt hole
portion portion AC102243AB
gasket in the direction shown in the illustration.
11C-26 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL

>>D<< TRANSMISSION HOUSING FRONT 2. Tighten the transmission side two mounting bolts
LOWER COVER STAY INSTALLATION to the specified torque.
Install the transmission housing front lower cover Tightening torque: 44 ± 10 N⋅m
stay in the following order.
1. Tighten the engine side four mounting bolts to the INSPECTION
specified torque. M1112002900254
• Check the oil pan for cracks.
Tightening torque: 22 ± 4 N⋅m
• Check the oil pan sealant-coated surface for
damage and deformation.

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION
M1112003100411

<M/T>

6 4 132 ± 5 N·m

7
9N

3 9

(Lip section) (Lip section)

3N Engine oil

1
AC308977 AB

Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
• Valve timing belt, balancer timing <<A>> • Transmission assembly
belt (Refer to P.11C-36). <<B>> >>B<< 4. Flywheel bolts
>>D<< 1. Crankshaft balancer shaft drive 5. Flywheel adapter plate
sprocket 6. Flywheel assembly
2. Crankshaft key 7. Flywheel adapter plate
>>C<< 3. Crankshaft front oil seal 8. Crankshaft bush
>>A<< 9. Crankshaft rear oil seal
 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
11C-27
<A/T>

4 132 ± 5 N·m
6

N 8

5
7

3 8

(Lip section) (Lip section)

3N Engine oil

1
AC308978AB

Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
• Valve timing belt, balancer timing • Transmission assembly (Refer to
belt (Refer to P.11C-36). GROUP 23A, Transmission
>>D<< 1. Crankshaft balancer shaft drive Assembly P.23A-172).
sprocket <<B>> >>B<< 4. A/T drive plate bolts
2. Crankshaft key 5. A/T drive plate adapter plate
>>C<< 3. Crankshaft front oil seal 6. A/T drive plate
7. Crankshaft bush
>>A<< 8. Crankshaft rear oil seal
11C-28 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINTS 1. Apply a small amount of engine oil to the entire
<<A>> TRANSMISSION ASSEMBLY REMOVAL inner diameter of the oil seal lip.
CAUTION 2. Use the following special tools to press-fit the oil
seal.
AC300897
• Installer bar (MB990938)
• Crankshaft rear oil seal installer (MD998776)

Engine front >>B<< FLYWHEEL BOLTS/A/T DRIVE PLATE

Flywheel BOLTS INSTALLATION
assembly
Flywheel
bolt

AC308604 AB MD998781
Do not remove the flywheel bolt shown by the
arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly AC301855AB
P.22A-15.
1. Use special tool flywheel stopper (MD998781) to
<<B>> FLYWHEEL BOLTS/A/T DRIVE PLATE secure the flywheel assembly or A/T drive plate in
BOLTS REMOVAL the same manner as removal.
2. Tighten the flywheel bolts or A/T drive plate bolts
to the specified torque.
Tightening torque: 132 ± 5 N⋅m

MD998781 >>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
Crankshaft MD998375

AC301854AB

1. Use special tool flywheel stopper (MD998781) to (Engine oil)

secure the flywheel assembly or A/T drive plate.
2. Remove the flywheel bolts or A/T drive plate bolts.
MD998285 Oil seal
INSTALLATION SERVICE POINTS (Oil applied to the
circumference) AC102329AC
>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION 1. Apply a small amount of engine oil to the outer
diameter of special tool crankshaft front oil seal
Oil seal guide (MD998285) and install it to the crankshaft.
2. Apply a small amount of engine oil to the entire
MB990938 inner diameter of the oil seal lip.
3. Use special tool crankshaft front oil seal installer
(Engine oil) (MD998375) to press-fit the oil seal.

MD998776 Crankshaft
AC102328 AB
 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
11C-29
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE 1. Clean or degrease the front case, the crankshaft
SPROCKET INSTALLATION and the crankshaft balancer shaft drive sprocket
as shown.
: Clean
: Clean and degrease NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
Crankshaft in the direction shown in the illustration.
balancershaft
drive sprocket

Crankshaft

Front case

Engine front
AC301346AB
11C-30 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
M1112004000848

Pre-removal Operation Post-installation Operation

• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Accelerator Cable Installation (Refer to GROUP 17,
On-vehicle Service − Fuel Pump Connector Accelerator Cable and Pedal P.17-7).
Disconnection (How to Reduce Pressurized Fuel Lines) • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.13B-428]. P.15-4).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17). Service − Engine Coolant Replacement P.14-17).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Accelerator Cable Adjustment (Refer to GROUP 17,
P.15-4). On-vehicle Service − Accelerator Cable Check and
• Accelerator Cable Removal (Refer to GROUP 17, Adjustment P.17-5).
Accelerator Cable and Pedal P.17-7). • Fuel Leak Check

5
4

5.0 ± 1.0 N·m

6 2

9.0 ± 2.0 N·m

13 ± 1 N·m
1
14 ± 3 N·m

(Engine oil) N 7

AC308979AB

Removal steps Removal steps (Continued)

1. Control wiring harness connection 5. Brake booster vacuum hose
2. Battery wiring harness connection connection
3. Radiator lower hose clamp 6. Engine oil level gauge and guide
4. Canister vacuum hose connection assembly
7. O-ring
 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
11C-31

13
14 (Engine oil)

<Cold engine>
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚

15 12

(Engine oil)

9 16

8
11 ± 1 N·m

11 17 N

31 ± 3 N·m
10

31 ± 3 N·m

89 ± 9 N·m AC308980AB

Removal steps Removal steps (Continued)

8. Detonation sensor connection • Water inlet fitting and thermostat
9. Battery wiring harness connection case assembly (Refer to GROUP
10. Inlet manifold stay 14, Water Hose and Water Pipe
• Exhaust manifold (Refer to GROUP P.14-27).
15, Exhaust Manifold P.15-11). <<C>> >>C<< 14. Fuel high-pressure hose
• Timing belt upper cover (Refer to connection
P.11C-36). • Rocker cover assembly (Refer to
<<A>> >>E<< 11. Camshaft sprocket P.11C-18).
<<B>> >>D<< 12. Radiator upper hose connection <<D>> >>B<< 15. Cylinder head bolts
13. Water hose connection 16. Cylinder head assembly
>>A<< 17. Cylinder head gasket
11C-32 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET

REMOVAL SERVICE POINTS 3. Screw in the special tool until it comes in contact
<<A>> CAMSHAFT SPROCKET REMOVAL with the timing belt tensioner arm.
AC107621
CAUTION
Never turn the crankshaft anti-clockwise. Wiring band

Timing mark

AC301451AC

4. Secure the camshaft sprocket and valve timing

AC301450AB belt with wiring bands and so on to prevent
slippage between the camshaft sprocket and
1. Turn the crankshaft clockwise, align the timing
valve timing belt.
marks on the camshaft sprocket to set No.1
cylinder to TDC of its compression stroke.

MB990767
MD998738

MD998719

Timing belt AC100302 AB

under cover
AC301452AB 5. Use the following special tools to hold the
camshaft sprocket.
2. Remove the timing belt under cover rubber plug
• Front hub and flange yoke holder (MB990767)
and then set special tool adjusting bolt
• Pin (MD998719)
(MD998738).
CAUTION
Do not rotate the crankshaft after camshaft
Timing belt sprocket removal.
tensioner arm
6. Remove the camshaft sprocket with the valve
MD998738 timing belt and place it on the timing belt lower
cover.

AC301373AB
 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
11C-33
<<B>> RADIATOR UPPER HOSE 2. Remove the fuel high-pressure hose in the
DISCONNECTION direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.

<<D>> CYLINDER HEAD BOLTS REMOVAL

Mating marks

AC200641AB

Make mating marks on the radiator upper hose and MB991654

the hose clamp. Disconnect the radiator upper hose.

<<C>> FUEL HIGH-PRESSURE HOSE REMOVAL

Engine front

3 5 10 8 2

Stopper
1 7 9 6 4

AC304581AB

1. Remove the fuel high-pressure hose stopper. AC301454AB

Use special tool cylinder head bolt wrench

(MB991654) to loosen the cylinder head bolts in two
or three steps in the order of the numbers shown in
the illustration. If the cylinder head bolts cannot be
pulled out due to the washer being trapped in the
valve spring, raise the bolt slightly, then remove it
while holding it by using a magnet.

Retainer
AC304582AB
11C-34 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET
INSTALLATION
CAUTION
Do not allow any foreign materials get into the MB991654
coolant passages, oil passages and cylinder.
1. Degrease the cylinder head gasket mounting
surface.

Engine front

Identification
mark "381" 8 6 1 3 9

Exhaust side
10 4 2 5 7

AC302180AB

2. Assemble to the cylinder block so the cylinder AC301456AB

head gasket identification mark of "381" is at the
top surface and on the exhaust side. 3. Use special tool cylinder head bolt wrench
(MB991654) to tighten the cylinder head bolts in
the following procedures.
>>B<< CYLINDER HEAD BOLTS INSTALLATION
(1) Tighten the bolts to 78 ± 2 N⋅m in the order
shown.
(Engine oil)
(2) Loosen the bolts fully in the reverse sequence
to that shown.
(3) Tighten the bolts to 20 ± 2 N⋅m in the order
shown.
Step (4) Step (5)
A
90˚ 90˚

AC102537AC

1. Check that the nominal length of each cylinder

head bolt meets the limit. If it exceeds the limit,
replace the bolts with a new one.
Paint marking Paint marking
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of AC102331AB

the bolts and to the washers. (4) Apply a paint mark to the heads of the cylinder
head bolts and cylinder head, then tighten 90
degree angle as shown.
 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
11C-35
CAUTION
• The bolt is not tightening sufficiently if the >>D<< RADIATOR UPPER HOSE CONNECTION
tightening angle is less than a 90 degree
angle.
Projection
• If the tightening angle exceeds the standard
specification, remove the bolt and start over
from step 1.
(5) Tighten in a 90 degree angle as shown in the
instructions of the figure, then check to see
that the paint mark on the head of the cylinder Water outlet fitting
Mating marks
head bolts and the paint mark on the cylinder
head is on a linear line. AC200642 AB

1. Insert radiator upper hose until it contacts the

>>C<< FUEL HIGH-PRESSURE HOSE
projection on the water outlet fitting.
INSTALLATION
2. Align the mating marks on the radiator upper hose
CAUTION and hose clamp, and then secure the radiator
Fuel upper hose.
high-pressure
3 mm
hose
>>E<< CAMSHAFT SPROCKET INSTALLATION

MB990767
Fuel line pipe
(Engine oil applied)
AC301864AB MD998719

AC100302 AB

1. Use the following special tool as during removal to

hold the camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
Stopper
AC304583AB the specified torque.
After connecting the fuel high-pressure hose, Tightening torque: 89 ± 9 N⋅m
slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.
11C-36 ENGINE MECHANICAL <4G69>
TIMING BELT

TIMING BELT
REMOVAL AND INSTALLATION
M1112004300827

Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Under Cover • Crankshaft Shaft Damper Pulley Installation (Refer to
P.51-19). P.11C-17).
• Crankshaft Shaft Damper Pulley Removal (Refer to • Drive Belt Tension Check (Refer to P.11C-8).
P.11C-17). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).

2
14 ± 3 N·m

11 ± 1 N·m

1 3
5
4

14 ± 1 N·m 12
11
48 ± 5 N·m

14 ± 1 N·m

6
9
8.8 ± 1.0 N·m 11 ± 1 N·m
21 ± 4 N·m
8
13
44 ± 10 N·m
23 ± 3 N·m

22 ± 4 N·m
10

7
79 ± 5 N·m
11 ± 1 N·m
9.0 ± 1.0 N·m
AC308981AB

Removal steps Removal steps (Continued)

1. Control wiring harness connection 7. Idler pulley
2. Battery wiring harness connection 8. Auto-tensioner
3. Connector bracket 9. Timing belt lower cover
• Engine front mounting bracket >>G<< • Valve timing belt tension
(Refer to GROUP 32, Engine adjustment (Installation only)
Mount P.32-5). <<A>> >>F<< 10. Valve timing belt
4. Harness bracket >>E<< 11. Timing belt tensioner pulley
5. Timing belt upper cover 12. Timing belt tensioner arm
6. Water pump pulley >>D<< 13. Timing belt tensioner adjuster
 ENGINE MECHANICAL <4G69>
TIMING BELT
11C-37

14
35 ± 6 N·m

22

21
19 ± 3 N·m

18
(Engine oil)

20 16
15
19
167 N·m 17 8.5 ± 0.5 N·m
AC308982 AB

Removal steps Removal steps (Continued)

14. Timing belt Idler pulley >>C<< 20. Crankshaft angle sensing blade
15. Timing belt lower cover bracket >>B<< • Balancer timing belt tension
16. Crank angle sensor adjustment (Installation only)
<<B>> >>C<< 17. Crankshaft pulley centre bolt >>A<< 21. Balancer timing belt tensioner
<<B>> >>C<< 18. Crankshaft pulley washer <<C>> >>A<< 22. Balancer timing belt
<<B>> >>C<< 19. Crankshaft camshaft drive sprocket
11C-38 ENGINE MECHANICAL <4G69>
TIMING BELT

REMOVAL SERVICE POINTS 2. Remove the timing belt under cover rubber plug
<<A>> VALVE TIMING BELT REMOVAL and then set special tool adjusting bolt
(MD998738).
CAUTION
Never turn the crankshaft anti-clockwise.
Timing belt
tensioner arm
Timing mark
MD998738

AC301373AB
Camshaft
sprocket
3. Screw in the special tool with hands until it
contacts the timing belt tensioner arm.
Timing mark CAUTION
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
Timing mark adjuster rod will not easily retract and the special
Engine oil pump
tool may bend.
Crankshaft sprocket
camshaft
A
drive sprocket AC301866AB B

1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke.

MD998738
AC301856 AB

4. Gradually screw in the special tool and then align

the timing belt tensioner adjuster rod set hole A
with the timing belt tensioner adjuster cylinder set
hole B.
Timing belt
under cover
AC301452AB
 ENGINE MECHANICAL <4G69>
TIMING BELT
11C-39
Timing belt tensioner INSTALLATION SERVICE POINTS
pulley mounting bolt >>A<< BALANCER TIMING BELT/BALANCER
Wire or pin TIMING BELT TENSIONER INSTALLATION

Balancershaft
sprocket

Belt tension
AC302414AB side

5. Insert a wire or pin in the set hole aligned.

Timing
CAUTION mark
To reuse the valve timing belt, draw an arrow Timing
indicating the rotating direction (clockwise) on mark
the back of the belt using chalk, etc.
6. After removal of the special tool, loosen the timing
belt tensioner pulley mounting bolts and remove
the valve timing belt.

<<B>> CRANKSHAFT PULLEY CENTRE Crankshaft

balancershaft
BOLT/CRANKSHAFT PULLEY drive sprocket
WASHER/CRANKSHAFT CAMSHAFT DRIVE
SPROCKET REMOVAL AC301402AB

Crankshaft 1. Ensure that the crankshaft balancer shaft drive

camshaft MB991385 sprocket timing marks and balancer shaft
drive sprocket timing marks are aligned.
sprocket
2. Install the balancer timing belt on the crankshaft
balancer shaft drive sprocket and balancer shaft
sprocket. There should be no slack on the tension
MB991367 side.

Centre of the
AC102332AB mounting bolt

1. Use the following special tools to hold the

crankshaft camshaft drive sprocket.
• Special spanner (MB991367)
• Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
Centre of
remove the crankshaft pulley washer and the pulley
crankshaft camshaft drive sprocket. AC301403AB

<<C>> BALANCER TIMING BELT REMOVAL 3. Assemble and temporarily fix the centre of the
pulley of the balancer timing belt tensioner so that
CAUTION it is at the top left from the centre of the
To reuse the balancer timing belt, draw an arrow assembling bolt, and the pulley flange is at the
indicating the rotating direction on the back of front-side of the engine.
the belt using chalk, etc.
4. Adjust the balancer timing belt tension.
11C-40 ENGINE MECHANICAL <4G69>
TIMING BELT

>>B<< BALANCER TIMING BELT TENSION

ADJUSTMENT
CAUTION Balancershaft
When tightening the mounting bolts, ensure that sprocket
the tensioner does not rotate with the bolts.
Allowing it to rotate with the bolts can cause
excessive tension of the belt.

Timing
mark
Timing
mark

AC301404
Crankshaft
1. Lift with your fingers the balancer timing belt balancershaft
drive sprocket
tensioner in the direction of the arrow. Apply a
tensile torque of 3.0 ± 0.4 N⋅m to the balancer AC301402AC
timing belt so the belt is tense without any
looseness. Tighten the assembling bolt to the 2. Turn the crankshaft clockwise two turns to set
specified torque in this state. Then, fix the No.1 cylinder to TDC of its compression stroke
balancer timing belt tensioner. and check that sprocket timing marks are aligned.
Tightening torque: 19 ± 3 N⋅m
Approximately 100 N

Deflection

AC301405AB

3. Apply a pressure of approximately 100 N at the

centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the belt
deflection is within the standard value.
Standard value:
<When adjusting> 5 − 7 mm
<When replacing> 5 − 7 mm
4. If not within the standard value, adjust the belt
tension again.
 ENGINE MECHANICAL <4G69>
TIMING BELT
11C-41
>>C<< CRANKSHAFT ANGLE SENSING 5. Use the following special tool as during removal to
BLADE/CRANKSHAFT CAMSHAFT DRIVE hold the crankshaft camshaft drive sprocket.
SPROCKET/CRANKSHAFT PULLEY • Special spanner (MB991367)
WASHER/CRANKSHAFT PULLEY CENTRE BOLT • Pin (MB991385)
INSTALLATION 6. Tighten the crankshaft pulley centre bolt to the
specified torque.
: Clean
: Clean and degrease Tightening torque: 167 N⋅m
: Apply engine oil

>>D<< TIMING BELT TENSIONER ADJUSTER

Crankshaft pulley INSTALLATION
centre bolt 1. Set according to the following procedures when
Crankshaft angle the timing belt tensioner adjuster rod is fully
sensing blade extended.
Crankshaft CAUTION
pulley washer
If the compression is too fast the procedure may
damage the rod. Make a point to slowly and
thoroughly compress.

A B

Crankshaft camshaft Crankshaft

drive sprocket
Engine front
AC301347AB

1. Clean or degrease the crankshaft, the crankshaft AC302024 AB

angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as (1) Slowly compress the timing belt tensioner
shown. adjuster rod using a press or vice, then align
NOTE: Also clean the degreased surfaces. the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the Wire or pin
direction shown.
3. Place the larger chamfer side of the crankshaft
pulley washer in the direction shown in the Figure
and then assemble on the crankshaft pulley
centre bolt.
4. Apply a small of engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
AC302025AB
Crankshaft
camshaft MB991385 (2) Insert a wire or pin in the set hole aligned.
drive
sprocket
NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Install the timing belt tensioner adjuster to the
MB991367 engine and then tighten the mounting bolt to the
specified torque. Do not remove the wire or pin
AC102332AB
until the tension of the valve timing belt is
adjusted.
11C-42 ENGINE MECHANICAL <4G69>
TIMING BELT

Tightening torque: 23 ± 3 N⋅m 2. Adjust the timing mark of the engine oil pump
sprocket. Unplug the cylinder block plug. Insert a
>>E<< TIMING BELT TENSIONER PULLEY bolt (M6, section width 10 mm, nominal length 45
INSTALLATION mm) from the plug hole. If the bolt comes in
contact with the balancer shaft, turn the engine oil
sprocket one rotation. Re-adjust the timing mark
and then check to see that the bolt fits. Do not
remove the bolt until the valve timing belt is
assembled.

Camshaft
Timing belt tensioner sprocket
pulley hole
AC102336AB

Temporarily tighten the timing belt tensioner pulley

as shown. Timing belt
tensioner Belt tension
pulley side
>>F<< VALVE TIMING BELT INSTALLATION

Timing mark
Timing belt
Idler pulley

Engine oil pump

Camshaft
Crankshaft sprocket
sprocket
camshaft
drive sprocket AC301372AC
Timing mark
3. Incorporate the valve timing belt in the following
manner so that the tensile force of the belt is not
lax.
Timing mark (1) Place the valve timing belt on the timing belt
tensioner pulley and crankshaft camshaft
Engine oil pump driver sprocket and then support it with your
Crankshaft sprocket
left hand so it does not slide.
camshaft
drive sprocket (2) Place the valve timing belt on the engine oil
AC301374AB
pump sprocket while pulling it with the right
1. Align the timing marks on the camshaft sprocket, hand.
crankshaft camshaft drive sprocket and engine oil (3) Place the valve timing belt on the timing belt
pump sprocket. idler pulley.

Bolt
CAUTION
Balancershaft Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation)
pressure to the camshaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is right.
(4) Place the valve timing belt on the camshaft
sprocket.
Plug
Cylinder block
AC301871AB
 ENGINE MECHANICAL <4G69>
TIMING BELT
11C-43

Bolt
Balancershaft
MD998767

Plug
Cylinder block
AC301858 AB AC301871AB

4. Turn the timing belt tensioner pulley in the 6. Remove the bolt inserted in Step 2 above, then
direction shown in the figure using special tool assemble the cylinder block plug.
tensioner wrench (MD998767) to apply tension to 7. Tighten the cylinder block plug to the specified
the valve timing belt. Then temporarily tighten and torque.
fix the timing belt tensioner pulley mounting bolt.
Tightening torque: 30 ± 3 N⋅m
8. Adjust the valve timing belt tension.
Timing mark
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT

MD998738

Camshaft
sprocket

Timing mark
Timing belt
under cover
AC301452AB

Timing mark 1. Set special tool adjusting bolt (MD998738) used

Engine oil pump when removing the valve timing belt.
Crankshaft sprocket CAUTION
camshaft Always screw in the special tool in with your
drive sprocket AC301372AB hands, since use of a spanner or other tools may
damage the wire or pin inserted in the timing belt
5. Check that the timing marks are aligned.
tensioner adjuster.
2. Gradually screw in the special tool to a position in
which the wire or pin inserted in the timing belt
tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 of a revolution in the
anti-clockwise direction.
11C-44 ENGINE MECHANICAL <4G69>
TIMING BELT

Tightening torque: 48 ± 5 N⋅m

Timing mark

Wire or pin

Camshaft
sprocket

AC301857AB
Timing mark
7. Remove wire or pin inserted to timing belt
tensioner adjuster.

Timing mark MD998738

Engine oil pump
Crankshaft sprocket
camshaft
drive sprocket AC301372AB

4. Turn the crankshaft in the clockwise direction, Timing belt

align each timing mark to set No.1 cylinder to TDC under cover
of its compression stroke. AC301452AB

5. Loosen the timing belt tensioner pulley mounting

8. Remove special tool adjusting bolt (MD998738),
bolt.
and install the rubber plug to the timing belt under
CAUTION cover.
When tightening the mounting bolt, ensure that 9. Rotate crankshaft clockwise two turns, and leave
the timing belt tensioner pulley does not rotate it for about 15 minutes.
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
Wire or pin
MD998767

AC301857AB

AC301859 AB 10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out with a light load.
6. With special tool tensioner wrench (MD998767) When wire or pin can be lightly removed,
and torque wrench, apply tension torque 3.5 N⋅m appropriate tension is applied on timing belt. In
to the valve timing belt, and tighten the timing belt this case, remove wire or pin.
tensioner pulley mounting bolt to the specified
torque.
 ENGINE MECHANICAL <4G69>
TIMING BELT
11C-45
12.Check again that the timing marks on sprockets
are aligned.

A
INSPECTION
M1112004400460

TIMING BELT TENSIONER ADJUSTER

Rod CHECK
1. Check for oil leak from seal, and replace it if leak
is detected.
AC301375AB 2. Check for wear or damage at the top of the rod.
Replace it, if required.
Also the projection of timing belt tensioner
adjuster rod (A) is within the standard value, 98 – 196 N
appropriate tension is applied.
Standard value (A): 3.8 − 4.5 mm A B
Movement

11.If wire or pin cannot be easily pulled out, repeat

Step 1 through Step 9 to reach proper valve timing Rod
belt tension.
CAUTION
Always check the tightening torque of the
crankshaft pulley centre bolt when turning the AC301376AB
crankshaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose. 3. Hold the timing belt tensioner adjuster by hand,
and press top end of the rod onto the metal (e.g.
cylinder block) under a pressure of 98 − 196 N to
Timing mark measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A − B: Movement
4. If the measured value is out of the standard value,
Camshaft replace the timing belt tensioner adjuster.
sprocket

Timing mark

Timing mark

Engine oil pump

Crankshaft sprocket
camshaft
drive sprocket AC301866AB
11C-46 ENGINE MECHANICAL <4G69>
TIMING BELT

BALANCER TIMING BELT TENSION 1. Apply a pressure of approximately 100 N at the

CHECK centre (arrow area) between the sprocket as
Check the balancer timing belt tension in the shown in the figure, then inspect whether the
following procedures. flexure is within the standard value.
Standard value: 5 − 10 mm
2. If not within the standard value, adjust the belt
Approximately 100 N
tension. (Refer to P.11C-36).

Deflection

AC301405AB
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11C-47
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001000946

<M/T>
CAUTION
*: 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
• Under Cover Removal (Refer to GROUP 51, Under Cover • Front Exhaust Pipe Installation (Refer to GROUP 15,
P.51-19). Exhaust Pipe and Main Muffler P.15-13).
• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Radiator P.14-29).
Disconnection (How to Reduce Pressurized Fuel Lines) • Accelerator Cable Installation (Refer to GROUP 17,
P.13B-428]. Accelerator Cable and Pedal P.17-7).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Battery and Battery Tray Installation
Service − Engine Oil Replacement P.12-3). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.15-4).
Service − Engine Coolant Replacement P.14-17). • Hood Installation (Refer to GROUP 42, Hood P.42-4).
• Transmission Oil Draining (Refer to GROUP 22A, • Transfer Oil Refilling (Refer to GROUP 22A, On-vehicle
On-vehicle Service − Transmission Oil Replacement Service − Transfer Oil Replacement P.22A-8).
P.22A-8). • Transmission Oil Refilling (Refer to GROUP 22A,
• Transfer Oil Draining (Refer to GROUP 22A, On-vehicle On-vehicle Service − Transmission Oil Replacement
Service − Transfer Oil Replacement P.22A-8). P.22A-8).
• Hood Removal (Refer to GROUP 42, Hood P.42-4). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner Service − Engine Coolant Replacement P.14-17).
P.15-4). • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Battery and Battery Tray Removal Service − Engine Oil Replacement P.12-3).
• Accelerator Cable Removal (Refer to GROUP 17, • Accelerator Cable Adjustment (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7). On-vehicle Service − Accelerator Cable Check and
• Radiator Assembly Removal (Refer to GROUP 14, Adjustment P.17-5).
Radiator P.14-29). • Fuel Leak Check
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11C-8).
Exhaust Pipe and Main Muffler P.15-13). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-6).
11C-48 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

9.0 ± 2.0 N·m

4 1
3

9.0 ± 2.0 N·m

5.0 ± 1.0 N·m

N 6 6N
48 ± 7 N·m 9.0 ± 2.0 N·m
7
5.0 ± 1.0 N·m

N 6 12 ± 2 N·m
48 ± 7 N·m
AC308983 AB

Removal steps Removal steps (Continued)

1. Control wiring harness connection <<A>> 5. Drive belt
2. Battery wiring harness connection 6. Engine oil cooler tube gaskets
3. Canister vacuum hose connection 7. Engine oil cooler hose and bracket
4. Brake booster vacuum hose assembly
connection
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11C-49

10 11
(Engine oil)

15

24 ± 4 N·m
8 44 ± 10 N·m

N 13 70 ± 4 N·m*

44 ± 10 N·m*
22 ± 4 N·m

44 ± 10 N·m*

12 9

14
AC308984 AB

Removal steps Removal steps (Continued)

<<B>> 8. Power steering oil pump and <<E>> >>D<< • Transmission assembly
bracket assembly 12. Earth cable connection
<<C>> 9. A/C compressor and clutch 13. Self-locking nuts
assembly <<F>> >>B<< 14. Engine front mounting bracket
10. Heater water hoses connection <<G>> >>A<< 15. Engine assembly
<<D>> >>E<< 11. Fuel high-pressure hose
connection
11C-50 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

<A/T>
CAUTION
*: 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
• Under Cover Removal (Refer to GROUP 51, Under Cover • Front Exhaust Pipe Installation (Refer to GROUP 15,
P.51-19). Exhaust Pipe and Main Muffler P.15-13).
• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Radiator P.14-29).
Disconnection (How to Reduce Pressurized Fuel Lines) • Accelerator Cable Installation (Refer to GROUP 17,
P.13B-428]. Accelerator Cable and Pedal P.17-7).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Battery and Battery Tray Installation
Service − Engine Oil Replacement P.12-3). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.15-4).
Service − Engine Coolant Replacement P.14-17). • Hood Installation (Refer to GROUP 42, Hood P.42-4).
• Transmission Fluid Draining (Refer to GROUP 23A, • Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle
On-vehicle Service − Automatic Transmission Fluid Service − Transfer Oil Replacement P.23A-147).
Change P.23A-144). • Transmission Fluid Refilling (Refer to GROUP 23A,
• Transfer Oil Draining (Refer to GROUP 23A, On-vehicle On-vehicle Service − Automatic Transmission Fluid
Service − Transfer Oil Replacement P.23A-147). Change P.23A-144).
• Hood Removal (Refer to GROUP 42, Hood P.42-4). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner Service − Engine Coolant Replacement P.14-17).
P.15-4). • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Battery and Battery Tray Removal Service − Engine Oil Replacement P.12-3).
• Accelerator Cable Removal (Refer to GROUP 17, • Accelerator Cable Adjustment (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7). On-vehicle Service − Accelerator Cable Check and
• Radiator Assembly Removal (Refer to GROUP 14, Adjustment P.17-5).
Radiator P.14-29). • Fuel Leak Check
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11C-8).
Exhaust Pipe and Main Muffler P.15-13). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-6).
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11C-51

9.0 ± 2.0 N·m

4 1
3

9.0 ± 2.0 N·m

5.0 ± 1.0 N·m

9.0 ± 2.0 N·m

5.0 ± 1.0 N·m

AC308985AB

Removal steps Removal steps (Continued)

1. Control wiring harness connection 4. Brake booster vacuum hose
2. Battery wiring harness connection connection
3. Canister vacuum hose connection <<A>> 5. Drive belt
11C-52 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

8 9
(Engine oil)

13

24 ± 4 N·m
6 44 ± 10 N·m

44 ± 10 N·m*
N 11 45 ± 5 N·m*

22 ± 4 N·m
44 ± 10 N·m*

10
12
7 AC308986AB

Removal steps Removal steps (Continued)

<<B>> 6. Power steering oil pump and <<E>> >>D<< • Transmission assembly
bracket assembly 10. Earth cable connection
<<C>> 7. A/C compressor and clutch >>C<< 11. Self-locking nuts
assembly <<F>> >>B<< 12. Engine front mounting bracket
8. Heater water hoses connection <<G>> >>A<< 13. Engine assembly
<<D>> >>E<< 9. Fuel high-pressure hose
connection
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11C-53
REMOVAL SERVICE POINTS NOTE: After removing the power steering oil pump
<<A>> DRIVE BELT REMOVAL and bracket assembly, secure it with a cord in the
The following operations will be needed due to the location where the removal and installation of the
introduction of the serpentine drive system with the engine assembly cannot be hindered.
drive belt auto-tensioner.
AC301703
<<C>> A/C COMPRESSOR AND CLUTCH
Auto-tensioner ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly from the bracket.
NOTE: After removing the A/C compressor and
clutch assembly, secure it with a cord in the location
Hole B where the removal and installation of the engine
assembly cannot be hindered.
Hole A
AC301704AB
<<D>> FUEL HIGH-PRESSURE HOSE REMOVAL

1. Securely insert the spindle handle or ratchet

handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
CAUTION Stopper
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc. AC304581AB

1. Remove the fuel high-pressure hose stopper.

Auto-tensioner

L-shaped
hexagon
wrench AC301705AB

3. Insert an L-shaped hexagon wrench, etc. into the Retainer

hole to fix and then remove the drive belt. AC304582AB

2. Remove the fuel high-pressure hose in the

<<B>> POWER STEERING OIL PUMP AND
direction shown in the figure while the retainer is
BRACKET ASSEMBLY REMOVAL
pulled up.
With the hose installed, remove the power steering
oil pump and bracket assembly from the engine NOTE: If the retainer is released, install it after
assembly. removing the fuel high-pressure hose.
11C-54 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

<<E>> TRANSMISSION ASSEMBLY REMOVAL (2) <Special tool engine hanger (MB991928) is
used>
Remove special tool MB991928.

MB991454
MB991527

AC300950AB

1. Pre-tighten the 2 bolts on the car to assemble the

radiator support upper insulator to set special tool AC107632 AB

engine hanger MB991895 or engine hanger 3. Hold the engine assembly with a chain block, etc.
MB991928.
4. Place a garage jack against the engine oil pan
2. Remove the transmission assembly (M/T: Refer to with a piece of wood in between so that the weight
GROUP 22A, Transmission Assembly P.22A-15, of the engine assembly is no longer being applied
A/T: Refer to GROUP 23A, Transmission to the engine front mounting bracket.
Assembly P.23A-172).
5. Loosen the engine front mounting bracket
mounting nuts and bolts, and remove the engine
<<F>> ENGINE FRONT MOUNTING BRACKET front mounting bracket.
REMOVAL
1. Support the engine with a garage jack. <<G>> ENGINE ASSEMBLY REMOVAL
2. Remove the following special tool. After checking that all cables, hoses and wiring
MB991895 harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
MB991527 the engine assembly upward from the engine
compartment.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY INSTALLATION

MB991454 MB991454
AC107631AB
MB991527
(1) <Special tool engine hanger (MB991895) is
used>
Remove special tool MB991895.
MB991928

AC107632 AB

Install the engine assembly, being careful not to

pinch the cables, hoses or wiring harness
MB991527 connectors.

MB991454
AC211405AB
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11C-55
>>B<< ENGINE FRONT MOUNTING BRACKET
INSTALLATION >>D<< TRANSMISSION ASSEMBLY
1. Place a garage jack against the engine oil pan INSTALLATION
with a piece of wood in between, and install the 1. Install the transmission assembly. (M/T: Refer to
engine front mounting bracket while adjusting the GROUP 22A, Transmission Assembly P.22A-15,
position of the engine. A/T: Refer to GROUP 23A, Transmission
2. Support the engine assembly with a garage jack. Assembly P.23A-172).
3. Remove the chain block.
4. Use the following special tool as during removal to
support the engine.
MB991895

MB991527

AC300950AB

2. Remove from the car the two bolts, to assemble

MB991454 the radiator support upper insulator.
AC107631AB

(1) <Special tool engine hanger (MB991895) is >>E<< FUEL HIGH-PRESSURE HOSE
used> INSTALLATION
Set special tool MB991895. (M/T: Refer to CAUTION
GROUP 22A, Transmission Assembly
Fuel
P.22A-15, A/T: Refer to GROUP 23A, high-pressure
Transmission Assembly P.23A-172). hose
3 mm

MB991928

Fuel line pipe

(Engine oil applied)
MB991527 AC301864AB

MB991454
AC211405AB

(2) <Special tool engine hanger (MB991928) is

used>
Set special tool MB991928. (M/T: Refer to
GROUP 22A, Transmission Assembly
P.22A-15, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-172).
Stopper
AC304583AB
>>C<< SELF-LOCKING NUTS INSTALLATION After connecting the fuel high-pressure hose,
CAUTION slightly pull it to ensure that it is installed
Do not tighten the self-locking nuts while the securely. Also confirm that there is a play
engine is hot. approximately 3 mm. Then install the stopper
Tighten the self-locking nuts to the specified torque securely.
while the engine is cold. Apply a small amount of engine oil to the fuel line
Tightening torque: 45 ± 5 N⋅m pipe and then install the fuel high-pressure hose.
NOTES