Engine Mechanical : Group 11A

11A-1
GROUP 11A
ENGINE
MECHANICAL
<4D5-SOHC>
CONTENTS
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GENERAL INFORMATION . . . . . . . . 11A-2 CAMSHAFT AND VALVE STEM
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-18
SERVICE SPECIFICATIONS. . . . . . . 11A-2 REMOVAL AND INSTALLATION . . . . . . . . 11A-18
SEALANTS . . . . . . . . . . . . . . . . . . . . 11A-3 OIL PAN AND OIL SCREEN . . . . . . . 11A-22

REMOVAL AND INSTALLATION . . . . . . . . 11A-22
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-4
CRANKSHAFT OIL SEAL . . . . . . . . . 11A-25
ON-VEHICLE SERVICE. . . . . . . . . . . 11A-6 REMOVAL AND INSTALLATION . . . . . . . . 11A-25
DRIVE BELT TENSION CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-6 CYLINDER HEAD GASKET . . . . . . . . 11A-27
VALVE CLEARANCE CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 11A-27
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-8
INJECTION TIMING CHECK AND TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-31
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-10
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-12
COMPRESSION PRESSURE CHECK. . . . 11A-12
TIMING BELT B . . . . . . . . . . . . . . . . . 11A-34
TIMING BELT TENSION ADJUSTMENT . . 11A-13
TIMING BELT B TENSION ADJUSTMENT 11A-14
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-36

CRANKSHAFT PULLEY . . . . . . . . . . 11A-15
11A-2 ENGINE MECHANICAL <4D5-SOHC>
GENERAL INFORMATION
GENERAL INFORMATION
M1111000100839
Item 4D56
Total displacement mL 2,477
Bore × Stroke mm 91.1 × 95.0
Compression ratio 21
Combustion chamber Vortex chamber type
Camshaft arrangement SOHC
Number of valve Intake 4
Exhaust 4
Valve timing Intake Opening BTDC 20°
Closing ABDC 49°
Exhaust Opening BBDC 55°
Closing ATDC 22°
Fuel system Distribution type injection pump
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Rocker arm Double roller type
Adjusting screw Elephant foot type
SERVICE SPECIFICATIONS
M1111000300899
Items Standard value Limit

Alternator drive belt Tension N 245 −441 −
(When checked) Deflection mm (Reference) 12.0 −17.0 −
(When adjusted) Deflection mm (Reference) 13.0 −16.0 −
(When replaced) Deflection mm (Reference) 10.0 −13.0 −
Power steering oil pump drive belt Tension N 294 −490 −
tension (When checked) Deflection mm (Reference) 8.0 −12.0 −
tension (When adjusted)
Deflection mm (Reference) 9.0 −11.5 −
tension (When replaced) Deflection mm (Reference) 6.0 −8.0 −
A/C compressor drive belt tension Tension N 338 −430 −
(When checked) Deflection mm (Reference) 7.2 −8.4 −
(When adjusted) Deflection mm (Reference) 7.2 −8.4 −
(When replaced) Deflection mm (Reference) 5.5 −6.9 −
ENGINE MECHANICAL <4D5-SOHC>
SEALANTS
11A-3
Items Standard value Limit
Valve clearance (at hot) mm 0.25 −
Injection timing (Value indicated on dial gauge mm) 9° ATDC (1 ± 0.03) −
Idle speed r/min 750 ± 30 −
Compression pressure kPa (at engine speed of 280 r/min) 3,100 Min. 2,800
Compression pressure difference of all cylinder (at engine speed − Max. 294
of 280 r/min) kPa
Timing belt tension mm 4 −5 −
Timing belt B tension mm 4 −5 −
SEALANTS
M1111000500440
Item Specified Sealant Remark
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Semi-circular packing 3M ATD Part No. 8660 or equivalent Semi-drying sealant
Engine oil pan MITSUBISHI GENUINE PART MD970389 Semi-drying sealant
or equivalent
SPECIAL TOOLS
SPECIAL TOOLS
M1111000601150
Tool Number Name Use

MB991955 M.U.T.-III sub assembly • Checking the ignition timing
A A: MB991824 A: Vehicle communication • Checking the idle speed
B: MB991827 interface (V.C.I.) CAUTION
C: MB991910 B: M.U.T.-III USB cable For vehicles with CAN
D: MB991911 C: M.U.T.-III main harness A communication, use M.U.T.-III
MB991824
E: MB991825 (Vehicles with CAN main harness A to send
B F: MB991826 communication system) simulated vehicle speed. If
D: M.U.T.-III main harness B you connect M.U.T.-III main
(Vehicles without CAN harness B instead, the CAN
communication system) communication does not
MB991827 E: M.U.T.-III measurement function correctly.
C
adapter
F: M.U.T.-III trigger harness
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MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
MD998384 Prestroke measuring adapter Adjustment of the injection

timing
D998384
MB992040 Crank pulley holder Holding the crankshaft sprocket
B992040
SPECIAL TOOLS
11A-5
MB990767 Front hub and flange yoke Holding the camshaft sprocket
holder
B990767
MD998719 Crankshaft pulley holder pin
D998719
MD998381 Camshaft oil seal installer Camshaft oil seal installation
D998381
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MD998772 Valve spring compressor Compressing valve spring
MD998772
MD998729 Valve stem seal installer Valve stem seal installation
MD998729
MD998727 Oil pan FIPG cutter Oil pan removal
D998727
MD998781 Flywheel stopper Supporting the flywheel

assembly
D998781
MD998376 Crankshaft rear oil seal Crankshaft rear oil seal

installer installation
ON-VEHICLE SERVICE

MD998383 Crankshaft front oil seal Crankshaft front oil seal
guide installation
D998383
MD998382 Crankshaft front oil seal

installer
D998382
MD998051 Cylinder head bolt wrench Removal and installation of

cylinder head bolt
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MB991614 Angle gauge Tightening cylinder head bolt
MB991614
MB991683 Sling chain set Removal and installation of

engine assembly
B991683
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND <When using the tension gauge>
ADJUSTMENT Water pump
M1111003100991 Tension gauge
pulley
ALTERNATOR DRIVE BELT TENSION
CHECK AND ADJUSTMENT
Check the drive belt tension in the following proce- Crankshaft
dure. pulley
Standard value:
Item When When When
checked adjusted replaced Alternator pulley AK403465 AB
Tension N 245 −441 294 −392 392 −588
Use a belt tension gauge to check that the belt ten-
Deflection mm 12.0 − 13.0 − 10.0 − sion is within the standard value.
(Reference) 17.0 16.0 13.0
ON-VEHICLE SERVICE
11A-7
<Belt deflection check> POWER STEERING OIL PUMP DRIVE
Water pump BELT TENSION CHECK
pulley
Approximately
100 N
Crankshaft Water pump

pulley pulley
Power steering
pump pulley
Crankshaft
Deflection pulley
Alternator pulley AK403466 AB
Apply approximately 100 N of force to the middle of AC501167AB

the drive belt between the pulleys (at the place indi-
Check the drive belt tension in the following proce-
cated by the arrow) and check that the amount of
dure.
deflection is within the standard value.
Standard value:
Item When When When
checked adjusted replaced
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Adjusting Tension N 294 −490 343 −441 490 −686
bolt Deflection mm 8.0 −12.0 9.0 −11.5 6.0 −8.0
Alternator (Reference)
fixing nut
<When using the tension gauge>
Place a belt tension gauge at the centre of the belt
Nut for alternator between the pulleys (arrow), and check that the belt
pivot bolt AK403467 AB
tension is within the standard value.
If not within the standard value, adjust the belt ten-
sion by the following procedure. <Belt deflection check>
1. Loosen the nut of the nut for alternator pivot bolt. Apply approximately 100 N of pressure against the
2. Loosen the alternator fixing nut. location between the pulleys shown by the arrow in
3. Use the adjusting bolt to adjust the belt tension the illustration and then measure the deflection.
and belt deflection to the standard values. If not within the standard value, adjust the belt ten-
4. Tighten the nut of the nut for alternator pivot bolt. sion by the following procedure.
Tightening torque: 44 ± 10 N⋅ m
5. Tighten the alternator fixing nut.
Tightening torque: 23 ± 2 N⋅ m A
6. Tighten the adjusting bolt.
Tightening torque: 5.0 ± 1.0 N⋅ m
CAUTION
B C
Always replace the two V-belts together as a
set, and do not apply any oil to the belts.
AC503534 AB
1. Loosen the power steering oil pump fixing bolts A,

B, and C.
2. Adjust the belt tension by placing a bar or others
to the body of the power steering oil pump, giving
an appropriate tension to the belt by hands.
ON-VEHICLE SERVICE
3. Tighten the fixing bolts in the order of A, B, and C If not within the standard value, adjust the belt ten-
to the specified torque. sion by the following procedure.
Tension pulley Adjusting bolt
CAUTION
When checking the belt tension, turn the crank-
shaft clockwise one turn or more.
4. Check the belt tension, and readjust if necessary.
A/C COMPRESSOR DRIVE BELT TEN-

SION CHECK AND ADJUSTMENT
AC501168 AC
Tension pulley
1. Use the adjusting bolt to adjust the belt tension.
The tension will increase when turning the
adjusting bolt clockwise, and decrease when
turning anti-clockwise.
CAUTION
When checking the belt tension, turn the crank-
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shaft clockwise one turn or more.
Crankshaft pulley A/C compressor pulley 2. Check the belt tension, and readjust if necessary.
AC501168AB
Check the drive belt tension by the following proce- VALVE CLEARANCE CHECK AND
dures. ADJUSTMENT
Standard value: M1111001500380
Item When When When 1. Start the engine and allow it to warm up until the
checked adjusted replaced engine coolant temperature reaches 80 to 90° C
Tension N 338 −430 338 −430 461 −614 2. Remove the timing belt upper cover.
3. Remove the rocker cover.
Deflection mm 7.2 −8.4 7.2 −8.4 5.5 −6.9
(Reference) Timing marks Timing marks
<When using the tension gauge>

Place a belt tension gauge at the centre of the belt
between the pulleys (arrow), and check that the belt
tension is within the standard value.
<Belt deflection check>

Apply approximately 100 N of pressure against the Camshaft Crankshaft pulley
location between the pulleys shown by the arrow in sprocket AK403468 AB
the illustration and then measure the deflection.

4. Align the camshaft sprocket timing marks and set
the No. 1 cylinder at top dead centre.
ON-VEHICLE SERVICE
11A-9
CAUTION 6. If the clearance is outside the standard value,
The crankshaft should always be turned in a loosen the lock nut of the rocker arm and adjust
clockwise direction. by turning the adjusting screw while using a
thickness gauge to measure the clearance.
7. Tighten the lock nut while holding the adjusting
screw with a screwdriver so that it doesn't turn.
8. Turn the crankshaft 360° clockwise to bring No. 4
cylinder to the top dead centre position.
AK403469 AB
5. Measure the valve clearance at the places

indicated by arrows in the illustration according to
the methods shown below.
Standard value: 0.25 mm AK403469 AC
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Adjusting
9. Measure the valve clearances at the places
screw indicated by arrows in the illustration. If the
clearance is not within the standard value, repeat
pad
steps 7 and 8 above.
Thickness
Flat-tipped screwdriver gauge
AK403470 AB
a. Give a clearance, pushing the pad by a

flat-tipped screwdriver in the opposite
direction of the thickness gauge insertion
as shown in the illustration.
AK202860AB
NOTE: Do not damage the pad retainer and
so on when pushing the pad by a
10 mm
flat-tipped screwdriver.
b. Insert the thickness gauge into the clear-
ance.
10 mm
Semicircular
packing Cylinder head AK304411AB
10.Apply specified sealant to the section of the

semi-circular packing shown in the illustration.
Specified sealant: 3M ATD Part No. 8660 or
AK402925
equivalent
11.Install the rocker cover.
12.Install the timing belt upper cover.
ON-VEHICLE SERVICE
INJECTION TIMING CHECK AND

ADJUSTMENT
M1111001800024
1. Remove all of the glow plugs.
2. Remove the timing belt upper cover.
Timing marks Timing marks
MD998384
AK403476 AB
7. Install the special tool prestroke measuring

adapter (MD998384) to the check plug at the rear
of the injection pump.
Camshaft Crankshaft pulley
sprocket AK403468 AB
Approximately 30˚
3. Align the timing marks of the camshaft sprocket
and set the No. 1 cylinder to the top dead centre
position.
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AK403477 AB
8. Turn the crankshaft clockwise to move the No. 1

Timing cylinder approximately 30° before compression
check plug top dead centre.
AK403474 AB 9. Set the needle of the dial gauge to 0.
10.Check that the needle doesn't move even if the
4. Remove the timing check plug at the rear of the crankshaft is turned slightly (2 −3° ) in both
injection pump. clockwise and counterclockwise direction.
NOTE: If the needle moves, the notch is not posi-
tioned properly, so once again move the No. 1 cyl-
Nut MD998384
Push rod
inder approximately 30° before compression top
dead centre.
1±0.003mm
10mm
AK403475 AB
5. Before installation of special tool prestroke

measuring adapter (MD998384), make sure that
push rod is protruding by 10 mm. Protrusion of Set to 9˚ ATDC
push rod can be adjusted with an inner nut. AK403478 AB
6. Connect the dial gauge to the special tool.
11.Turn the crankshaft clockwise to align the No. 1
cylinder to 9° ATDC.
12.Check that the value indicated on the dial gauge
is at the standard value.
Standard value: 1 ± 0.03 mm
ON-VEHICLE SERVICE
11A-11
Injection pipe Injection pipe

union nuts union nuts
Nuts Nuts
Bolts Bolts
AK408479 AB AK408479 AB
13.If the needle is outside the standard value, adjust (6) Tighten the mounting nuts to the specified
the injection timing by the following procedure. torque.
(1) Loosen the injection pipe union nuts (4 places) Tightening torque: 19 ± 3 N⋅ m
on the injection pump. (Do not remove the (7) Tighten the mounting bolts to the specified
union nuts.) torque.
CAUTION Tightening torque: 24 ± 3 N⋅ m
When loosening the nuts, hold the delivery valve
(8) Tighten the injection pump union nuts to the
holders with a spanner so that they don't turn at
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specified torque.
the same time.
(2) Loosen the upper mounting nuts and the lower Tightening torque: 30 ± 7 N⋅ m
mounting bolts of the injection pump. (Do not CAUTION
remove the nut and bolt.) When tightening the nuts, hold the delivery valve
1±0.03mm or more holders with a spanner so that they don't turn at
the same time.
14.Remove the special tool prestroke measuring
adapter (MD998384).
1±0.03mm or less
Front
View Gasket
AK403480 AB
Timing
(3) Tilt the injection pump to the left and right and check plug
adjust the needle on the dial gauge so that the
display value is uniform.
(4) Provisionally tighten the mounting nut and bolt AK403482 AB
of the injection pump.

15.Install a new gasket to the timing check plug.
(5) Repeat steps 8 −12 to check if the adjustment
has been made correctly. 16.Tighten the timing check plug to the specified
torque.
17.Install the timing belt upper cover.
18.Install all of the glow plugs
ON-VEHICLE SERVICE
IDLE SPEED CHECK 2. Remove all of the glow plugs.

M1111003501141
1. Set the vehicle to the pre-inspection condition.
Diagnosis
connector Injection pump assembly
connector (12 pin)
MB991910 AK403485AB
3. Disconnect the injection pump assembly

connector (12 pin).
MB991824
NOTE: Doing this will prevent carrying out fuel
injection.
4. Cover the glow 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.
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CAUTION
• Keep away from the glow plug hole when
MB991827 AC501413AB
cranking.
• If compression is measured with water, oil,
fuel, etc., that has come from cracks inside
the cylinder, these materials will become
heated and will gush out from glow plug hole,
which is dangerous.
Tachometer
Compression
gauge
Injection
nozzle AK403483 AB
2. Turn the ignition switch to "LOOK" (OFF) position,

and connect the diagnosis connector to the
M.U.T.-III.
If the M.U.T.-III is not used, connect a tachometer AK403486AB
to the injection nozzle or the pipe. 5. Set compression gauge to one of the glow plug
3. Start the engine, and let it run at idle. holes.
4. Check the idle speed. 6. Crank the engine and measure the compression
Standard value: 750 ± 30 r/min pressure.
5. If the idle speed is not within the standard value, Standard value (at engine speed of 280
inspect the diesel system (Refer to GROUP 13A − r/min): 3,100 kPa
Troubleshooting −Inspection Chart for Diagnosis Limit (at engine speed of 280 r/min): min.
Code ). 2,800 kPa
7. Measure the compression pressure for all the
COMPRESSION PRESSURE CHECK cylinders, and check that the pressure differences
M1111002601327
of the cylinders are below the limit.
1. Before inspection, check that the engine oil,
starter and battery are normal. In addition, set the Limit: max 294 kPa
vehicle to the pre-inspection condition.
ON-VEHICLE SERVICE
11A-13
8. If there is a cylinder with compression or a 4. Loosen the two tensioner mounting bolts 1 or 2
compression difference that is outside the limit, turns.
pour a small amount of engine oil through the NOTE: This will allow the tensioner spring to ten-
glow plug hole, and repeat the operations in steps sion the timing belt automatically.
(6) and (7).
(1) If the compression increases after oil is added, Camshaft spocket
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
surface.
(2) If the compression does not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
9. Connect the injection pump assembly connector
(12 pin). AK403489 AB
10.Install the glow plugs.
5. Turn the crankshaft clockwise and stop at the
second teeth of the camshaft sprocket.
TIMING BELT TENSION ADJUSTMENT CAUTION
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M1111002800094 • This will allow the timing belt to be tensioned
1. Remove the timing belt upper cover. by a specified amount, so never overturn the
2. Turn the crankshaft in the clockwise direction and crankshaft.
check the timing belt around its entire • Never turn the crankshaft counterclockwise.
circumference for abnormalities.
Timing marks Bolt A
(slot side)
Bolt B
Timing marks AK403488 AC

AK403487 AB
6. To prevent the tensioner bracket from be turned
3. Align the timing marks on the sprockets with the together with the crankshaft, first tighten slot-side
timing mark on the front upper case. bolt A to the specified torque, and then tighten bolt
CAUTION B to the specified torque.
When aligning the timing mark, be sure not to Tightening torque: 26 ± 3 N⋅ m
turn the crankshaft in the counterclockwise
direction as this can cause improper belt ten-
sion.
Tension side
Bolt A
(slot side)
Bolt B
AK403488 AB
ON-VEHICLE SERVICE
CAUTION
When aligning the timing mark, be sure not to
Deflection turn the crankshaft in the counterclockwise
direction as this can cause improper belt ten-
sion.
AK403491 AB
7. Turn the crankshaft counterclockwise to align the

timing marks. Push down belt at a point halfway
with a forefinger to check that defection of belt is
Access cover
up to standard value.
AK403492 AB
Standard value: 4.0 −5.0 mm
8. Mount the timing belt upper cover. 4. Remove the access cover.
TIMING BELT B TENSION ADJUSTMENT
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M1111004900019
1. Remove timing belt upper cover.
2. Turn the crankshaft in the clockwise direction and
check the timing belt around its entire
Pivot side bolt
circumference for abnormalities.
Timing marks Slot side nut
AK403493 AB
5. Loosen the tensioner pivot side bolt 1 turn and

slot side nut 1 or 2 turns.
NOTE: These works will allow the tensioner
spring to tension timing belt B automatically.
Timing marks 6. First tighten tensioner slot side nut, and then
AK403487 AB tighten pivot side bolt to the specified torque.
3. Align the timing marks on the sprockets with the Tightening torque:
timing mark on the front upper case. Pivot side bolt 23 ± 3 N⋅ m
Slot side nut 26 ± 3 N⋅ m
Access cover
Guide
AK403494 AB
7. Install the access cover while sliding the front

lower cover down along the two guides.
8. Install the timing belt upper cover.
CRANKSHAFT PULLEY
11A-15
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600959
Pre-removal Operation Post-installation Operation

• Engine Room Under Cover Removal (Refer to GROUP 51 • Drive Belt Tension Check and Adjustment (Refer to
−Under Cover ). P.11A-6).
• Engine Room Under Cover Installation (Refer to GROUP
51 −Under Cover ).
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25 ± 4 N·m 7
185 ± 5 N·m 4
2 6
(Engine oil)
1
AC501887 AB
Removal steps Removal steps (Continued)

<<A>> 1. A/C compressor drive belt <<D>> >>A<< 5. Crankshaft pulley centre bolt
<> 2. Power steering oil pump drive belt >>A<< 6. Special washer
<<C>> 3. Alternator drive belts >>A<< 7. Crankshaft pulley
4. Crankshaft pulley (for A/C)
CRANKSHAFT PULLEY
REMOVAL SERVICE POINTS

<<A>> A/C COMPRESSOR DRIVE BELT <<C>> ALTERNATOR DRIVE BELTS
REMOVAL REMOVAL
CAUTION
To reuse the drive belt, draw an arrow indicating Adjusting
bolt
the rotating direction (to the right) on the back of
the belt using chalk, etc.
Alternator
Adjusting bolt fixing nut
Nut for alternator

pivot bolt
AC503982AB
1. Loosen the nut for alternator pivot bolt and locking

bolt.
Crankshaft pulley A/C compressor CAUTION
AC503581AB
To reuse the drive belt, draw an arrow indicating
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Turn the adjusting bolt anti-clockwise (in the left the rotating direction (to the right) on the back of
turn), and remove the drive belt. the belt using chalk, etc.
2. Turn the adjusting bolt anti-clockwise (in left turn),
<> POWER STEERING OIL PUMP and remove the drive belt.
DRIVE BELT REMOVAL
CAUTION <<D>> CRANKSHAFT PULLEY CENTRE
To reuse the drive belt, draw an arrow indicating BOLT REMOVAL
the rotating direction (to the right) on the back of
the belt using chalk, etc.
MB992040
B C AC502472AB
AC503534 AB 1. Use special tool crank pulley holder (MB992040),

hold the crankshaft pulley.
Loosen the mounting bolts shown in the figure to
remove the drive belt. 2. Remove the crankshaft pulley centre bolt.
CRANKSHAFT PULLEY
11A-17
INSTALLATION SERVICE POINT 2. Clean the bolt hole in the crankshaft, the
>>A<< CRANKSHAFT PULLEY/SPECIAL crankshaft contacting surface and special washer
contacting surface of the crankshaft pulley, and
WASHER/CRANKSHAFT PULLEY CEN- the special washer.
TRE BOLT INSTALLATION 3. Apply an appropriately small amount of oil to the
Crankshaft threads and seating surface of the crankshaft
Crankshaft pulley Crankshaft pulley centre bolt.
pulley centre
bolt Clean
Special washer
Degrease
AC503579AB
1. Clean and then degrease the crankshaft sprocket MB992040

contacting surface of the crankshaft pulley. AC502472AB
NOTE: Degreasing is necessary to prevent 4. Use special tool crank pulley holder (MB992040)
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decrease in the friction between contacting sur- as in the removal procedure to retain crankshaft
faces. pulley, and tighten crankshaft pulley centre bolt to
the specified torque.
CAMSHAFT AND VALVE STEM SEAL

M1112006600987
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
Apply engine oil to all

moving parts before 5.9 ± 1.0 N·m
installation. 8 11 ± 1 N·m
6 10 N
10 mm 10 mm 1
7
N 9
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10 AC503599
37 ± 2 N·m
Sealant: 3M ATD Part No. 8660 or 37 ± 2 N·m
equivalent
20 ± 1 N·m
13
2 14
N 12
11
16*
15
17*
18*
69 ± 5 N·m
5 19* N
11 ± 1 N·m 20*
11 ± 1 N·m
11 ± 1 N·m
4 3 AC502018AB
Camshaft removal steps Camshaft removal steps

1. Control wiring harness connector 9. Rocker cover gasket
2. Battery wiring harness connector 10. Semi-circular packing
3. Crank angle position sensor • Valve clearance adjustment
connector (Refer to P.11A-8).
4. Crank angle position sensor <<A>> >>H<< 11. Camshaft sprocket
connector clamp >>G<< 12. Camshaft oil seal
>>E<< 5. Timing belt front upper cover <> >>D<< 13. Rocker arm and shaft assembly
6. Breather hose connection >>F<< 14. Camshaft bearing caps
7. Rocker cover 15. Camshaft
8. Oil filler cap
11A-19
Valve stem seal removal steps
1. Control wiring harness connector
Cable tie wrap
2. Battery wiring harness connector
3. Crank angle position sensor
connector
4. Crank angle position sensor
connector clamp
>>E<< 5. Timing belt front upper cover
6. Breather hose connection
7. Rocker cover
Camshaft sprocket
9. Rocker cover gasket AC502476 AB
<> >>D<< 13. Rocker arm and shaft assembly
• Windshield wiper (Refer to 2. Secure the camshaft sprocket and the valve
GROUP 51 −Windshield wiper ). timing belt with cable bands to prevent deviation
• Cowl top panel from the relative positions between the camshaft
<<C>> >>C<< 16. Valve spring retainer locks sprocket and the valve timing belt.
17. Valve spring retainers
>>B<< 18. Valve springs
>>A<< 19. Valve stem seals
20. Valve spring seats
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MB990767
<<A>> CAMSHAFT SPROCKET
REMOVAL
MD998719
CAUTION
Always turn the crankshaft in the forward direc- AC503762 AB
tion (clockwise).
3. Use the following special tools to stop the
Timing marks camshaft sprocket from turning.
• Front hub and flange yoke holder (MB990767)
• Crankshaft pulley holder pin (MD998719)
CAUTION
Do not turn the crankshaft after the camshaft
sprocket is removed.
4. Remove the camshaft sprocket with the valve
timing belt attached.
AC503587AB
<> ROCKER ARM AND SHAFT
1. Turn the crankshaft in the forward direction
(clockwise) to align the timing mark so that No.1 ASSEMBLY REMOVAL
cylinder is at the compression TDC (Top Dead CAUTION
Centre) position. Never disassemble the rocker arm and shaft
assembly.
Loosen the rocker arm and shaft assembly mounting
bolt, and then remove the rocker arm and shaft
assembly with the bolt still attached.
<<C>> VALVE SPRING RETAINER LOCKS >>B<< VALVE SPRINGS INSTALLATION

REMOVAL
Rocker arm side
CAUTION
When removing valve spring retainer lock, leave
the piston of each cylinder in the TDC position.
The valve may fall into the cylinder if the piston is
not properly in the TDC position.
Identification
colour
AC201453AD
Install the valve spring with its identification colour

painted end facing the rocker arm.
MD998772 >>C<< VALVE SPRING RETAINER LOCKS

INSTALLATION
AC502475AB
Use special tool valve spring compressor
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(MD998772) to compress the valve spring, remove
the valve spring retainer lock.
INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEALS INSTALLA-
TION MD998772
1. Apply a small amount of engine oil to the valve
stem seal. AC502475AB
CAUTION Use special tool valve spring compressor

(MD998772) to compress the valve spring in the
same manner as removal, and install the valve
MD998729
Valve spring retainer lock.
Valve stem >>D<< ROCKER ARM AND SHAFT

seal
Valve spring
ASSEMBLY INSTALLATION
seat 1. Install the rocker arm and shaft assembly to the
bearing caps.
Valve guide
AC308920AC
• Valve stem seal cannot be reused.

• Special tool valve stem seal installer
(MD998729) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
Chamfer
2. Use special tool to fill a new valve stem seal in the
valve guide using the valve stem area as a guide.
AC503766 AB
2. Set the washer so that it faces in the direction

shown in the illustration, and then install the bolt.
11A-21
>>E<< TIMING BELT FRONT UPPER >>G<< CAMSHAFT OIL SEAL
COVER INSTALLATION INSTALLATION
1 Camshaft
MD998381
1
2
1
Oil seal
AC503597AB AC502587AB
Install the bolts to the timing belt front upper cover at 1. Apply new engine oil to the camshaft oil seal lip.
the shown position.
2. Use special tool camshaft oil seal installer
No. Bolt diameter × length mm (MD998381) to press-fit the camshaft oil seal.
1 6 × 22
2 6 × 50 >>H<< CAMSHAFT SPROCKET
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3 6 × 60 INSTALLATION
>>F<< CAMSHAFT BEARING CAPS

INSTALLATION
MB990767
Cap numbers
MD998719
2
AC503762 AB
1. Use the following special tools to stop the

camshaft sprocket from turning in the same way
Front of engine
AC503779AB as was done during removal.
• Front hub and flange yoke holder (MB990767)
The cap numbers are embossed on the top surface • Crankshaft pulley holder pin (MD998719)
of the bearing caps, so install in the order of the num-
bers. However, no numbers are embossed on bear- 2. Tighten the timing belt train bolt to the specified
ing caps 1 and 5. torque.
OIL PAN AND OIL SCREEN

M1112002500319

• Engine Room Under Cover Removal (Refer to GROUP 51 • Engine Oil Refilling (Refer to GROUP 12 −On-vehicle
−Under Cover ). Service, Engine Oil Replacement ).
• Engine Oil Draining (Refer to GROUP 12 −On-vehicle • Engine Room Under Cover Installation (Refer to GROUP
Service, Engine Oil Replacement ). 51 −Under Cover ).
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5
N9 19 ± 3 N·m
39 ± 5 N·m 19 ± 3 N·m
1 8
N 2 6
7
3 4
9.0 ± 3.0 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m

AC501853AB

1. Engine oil pan drain plug <<A>> • Steering column shaft assembly
>B<< 2. Engine oil pan drain plug gasket and shaft assembly connecting
3. Alternator vacuum pump oil return bolt
hose connection <> • Power steering gear box
4. Flywheel housing front lower connecting bolts
cover <> • Return tube clamp
5. Engine oil level gauge <> • Pressure tube clamp
<<C>> >>A<< 6. Engine oil pan and engine oil pan
strainer assembly
11A-23
Removal steps (Continued) CAUTION
7. Engine oil pan
8. Engine oil pan strainer
9. Engine oil pan strainer gasket
B

<<A>> STEERING COLUMN SHAFT A
ASSEMBLY AND SHAFT ASSEMBLY
CONNECTING BOLT DISCONNECTION
<R.H. fender side>
AC504256AB
Shaft assembly
connecting bolt MD998727 MD998727
18 ± 2 N·m
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Upper arm (R.H.)
AC502232AB
Disconnect the steering column shaft and the shaft

assembly. AC104547AC
Do not use special tool oil pan FIPG cutter

<> POWER STEERING GEAR BOX (MD998727) in area A of the oil pan. Using the
CONNECTING BOLTS/RETURN TUBE special tool in area A may cause deformation of
CLAMP/PRESSURE TUBE CLAMP the front case because the front case is made of
aluminium.
REMOVAL
2. Tap special tool MD998727 into the range (B)
between the cylinder block and the oil pan, and
then slide the tool sideways.
NOTE: If any sounding parts interfere with the
removal, there is no need to use special tool
MD998727.
3. With the oil pan separated from the cylinder block,
remove the oil screen assembly mounting bolts,
and then remove the oil pan together with the oil
screen assembly.
AC502231AB
Remove the mounting bolts of the power steering INSTALLATION SERVICE POINTS
gear box and of the tube clamp, and hung the power
steering gear box using a wire or other similar mate- >>A<< ENGINE OIL PAN AND ENGINE
rial. OIL PAN STRAINER ASSEMBLY INSTAL-
LATION
<<C>> ENGINE OIL PAN AND ENGINE 1. Remove sealant from the engine oil pan and
OIL PAN STRAINER ASSEMBLY cylinder block surfaces.
REMOVAL
1. Remove the engine oil pan mounting bolts.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the seal-
ant surface during that time.
4. Tighten the engine oil pan bolts to the specified
torque.
Ø4 mm Tightening torque: 9.0 ± 3.0 N⋅ m
Groove Bolt hole

AC503481AB >>B<< ENGINE OIL PAN DRAIN PLUG
GASKET INSTALLATION
2. Apply a bead of the sealant to the cylinder block
mating surface of the engine oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent Engine oil pan side
NOTE: Install the engine oil pan within 15 minutes
after applying sealant.
3. Assemble the engine oil pan to the cylinder block.
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AC102325 AI
Replace the gasket with a new gasket. Install the

new gasket in the direction shown in the illustration.
CRANKSHAFT OIL SEAL
11A-25
CRANKSHAFT OIL SEAL
M1112003101094
132 ± 5 N·m
11 ± 1 N·m
5
N6
4
3
8N
7
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2 8
1
N2
(Lip section) (Lip section)
Engine oil
AC502585 AB
Crankshaft front oil removal Crankshaft rear oil seal

steps removal steps (Continued)
• Timing belt B (Refer to P.11A-34). <<A>> >>C<< 3. Flywheel assembly
1. Crankshaft sprocket B 4. Ball bearing
>>D<< 2. Crankshaft front oil seal 5. Oil seal case
Crankshaft rear oil seal 6. Gasket
removal steps >>B<< 7. Oil separator
• Transmission assembly (Refer to >>A<< 8. Crankshaft rear oil seal
GROUP 22A −Transmission
assembly ).
CRANKSHAFT OIL SEAL
REMOVAL SERVICE POINT Push the oil separator into the oil seal case, with its
oil hole at the case bottom (indicated by an arrow in
<<A>> FRYWHEEL ASSEMBLY
illustration).
REMOVAL
>>C<< FLYWHEEL ASSEMBLY
INSTALLATION
MD998781
AC503817 AB
1. Use the special tool flywheel stopper MD998781

(MD998781), hold the flywheel. AC503817 AB
2. Remove the flywheel assembly.

1. Use special tool flywheel stopper (MD998781) to
secure the flywheel assembly in the same manner
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as removal.
>>A<< CRANKSHAFT REAR OIL SEAL 2. Tighten the flywheel bolts to the specified torque.
INSTALLATION Tightening torque: 132 ± 5 N⋅ m
>>D<< CRANKSHAFT FRONT OIL SEAL

MD998376
INSTALLATION
Oil seal Front lower
Crankshaft
case
Oil pump
drive shaft
AC503776AB
Use the special tool crankshaft rear oil seal installer

(MD998376), press-fit the rear oil seal in the oil seal MD998382 MD998383
case. (Apply oil to outer surface)
AC503778AB
>>B<< OIL SEPARATOR INSTALLATION 1. Attach special tool crankshaft front oil seal guide
(MD998383) to the crankshaft and apply engine
Oil seal case Oil separator oil to the outer surface of the tool.
2. Using special tool crankshaft front oil seal installer
(MD998382), press-fit the front oil seal into the
front lower case.
Oil hole
Oil pan mounting surface
AC503777 AB
CYLINDER HEAD GASKET
11A-27
M1112004001692
5.0 ± 1.0 N·m

5.0 ± 1.0 N·m
6
29 ± 2 N·m to 122˚ - +124˚ 5 7
(During cold engine)
5.0 ± 1.0 N·m
4
(Engine oil)
10
23 ± 3 N·m
23 ± 3 N·m
30 ± 7 N·m
3
8
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12 9
23 ± 3 N·m
11
23 ± 3 N·m 12 ± 1 N·m
N 13
2N (Engine oil)
AC502586AB

1. Oil level gauge and guide <> >>C<< 7. Fuel injection pipes
assembly 8. By-pass hose connection
2. O-ring 9. Fuel hose
<<A>> >>D<< 3. Radiator upper hose • Water pipe C (Refer to GROUP
• Rocker cover (Refer to 14 −Water hose and water pipe ).
P.11A-18). <<C>> 10. Power steering oil pump
4. Engine coolant temperature assembly
gauge unit connector 11. Power steering oil pump bracket
5. Engine coolant temperature <<D>> >>B<< 12. Cylinder head assembly
sensor connector >>A<< 13. Cylinder head gasket
6. Glow plug terminal
REMOVAL SERVICE POINTS <<C>> POWER STEERING OIL PUMP

<<A>> RADIATOR UPPER HOSE DISCON- ASSEMBLY REMOVAL
NECTION 1. Remove the power steering oil pump assembly
After making mating marks on the radiator upper from the bracket with the hose attached.
hose and the hose clamp, disconnect the radiator 2. Place the removed power steering oil pump
upper hose. assembly in a place where it will not be a
hindrance when removing and installing the
<> FUEL INJECTION PIPES engine assembly, and tie it with cord.
REMOVAL
<<D>> CYLINDER HEAD ASSEMBLY
CAUTION
REMOVAL
After disconnecting the injection pipe, plug the
opening so that no foreign particles get inside
the pump or into the injection nozzle. MD998051
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Nut AC502540
Delivery holder
AC503283 AB
When loosening nuts at both ends of injection pipe,

hold the delivery holder (for pump side) and the
6 14 16 8 4
injection nozzle assembly (for nozzle side) with
wrench and loosen nut. 2 10 18 12
1 9 17 11 3
5 13 15 7
Front of engine AC503868

AC503912AB
Using special tool cylinder head bolt wrench

(MD998051), loosen the cylinder head bolts in two or
three steps in the order of the numbers shown in the
illustration.
11A-29
>>A<< CYLINDER HEAD GASKET CAUTION
INSTALLATION Do not allow foreign material to enter the engine
coolant or oil passages and the cylinder.
CAUTION
The thickness of the original cylinder head gas- 2. Clean the cylinder head assembly and the
ket is selected according to the protrusion cylinder block mating surfaces with a scraper or a
amount of the piston. Therefore, if the piston or wire brush.
the connecting rod is replaced, the protrusion
amount may be changed. Always select a correct
gasket by measuring the protrusion amount.
(Refer to GROUP 11B> −Cylinder Head and
Valves ).
Identification mark
Cylinder head
Chamfered
bolt washer
side
AC503931AB
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3. Install the cylinder head bolt washer to the
cylinder head bolt so that the washer chamfered
side faces as shown.
4. Apply a small amount of engine oil to the cylinder
A head bolt thread and the washer.
MD998051
B
AC503769AB
AC502540
When replacing the cylinder head gasket only, con-
firm the gasket identification mark, and then select a
replacement part according to the following table.
Spec Identification mark (size) Part number
13 5 3 11 15
A D5-774 (fitted thickness 1.45 ± MD377774
17 9 1 7
0.04)
B D5-774 (fitted thickness 1.50 ± MD377775 18 10 2 8 16
0.04) 14 6 4 12
C D5-774 (fitted thickness 1.55 ± MD377776 Front of engine AC503868

0.04) AC503912AC
5. Tighten the cylinder head bolts according to the

>>B<< CYLINDER HEAD ASSEMBLY following procedure (angle-tightening procedure).
INSTALLATION (1) Use special tool cylinder head bolt wrench
(MD998051) to tighten the cylinder head bolts
1. Select a cylinder head gasket of correct
in the order of illustrated numbers to 29 ± 2
specification.
N⋅ m.
CAUTION
• If the cylinder head bolt is tightened less than >>C<< FUEL INJECTION PIPES
the specified lower limit of 120 degree angle, INSTALLATION
the bolt may become loose. Be sure to tighten When tightening the nuts at both ends of the fuel
correctly. injection pipe, hold the delivery holder (for pump
• If the cylinder head bolt is tightened in excess side) and the injection nozzle assembly (for nozzle
of the specified upper limit of 124 degree side) with a wrench, and tighten the nuts to the spec-
angle, loosen the bolt completely and repeat ified torque.
the entire procedures.
MB991614 >>D<< RADIATOR UPPER HOSE

CONNECTION
To reuse the radiator upper hose, align the mating
marks that were made during removal, and then
install the hose clamp.
MD998051
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AC502541
13 5 3 11 15
17 9 1 7
18 10 2 8 16
14 6 4 12
Front of engine AC503868

AC503913AB
(2) Using special tool angle gauge (MB991614),

tighten the cylinder head bolts in the illustrated
sequence by a further 120 to 124 degree
angle.
TIMING BELT
11A-31
TIMING BELT
M1112004301358

• Cooling Fan Removal (Refer to GROUP 14 −Radiator Fan • Cooling Fan Installation (Refer to GROUP 14 −Radiator
). Fan ).
• Drive Belt Tension Check and Adjustment (Refer to
P.11A-6).
11
3 9 10
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26 ± 3 N·m
11 ±1 N·m
26 ± 3 N·m
7
11 ±1 N·m
6
1 9.0 ± 1.0 N·m
11 ±1 N·m
8
4
5
22 ± 4 N·m
11 ±1 N·m 11 ±1 N·m
AC502129AB

1. Crank angle sensor connector 6. Crank angle sensor
2. Battery wiring harness connector 7. Crankshaft sensing blade
>>B<< 3. Timing belt front upper cover <<A>> >>A<< 8. Timing belt
4. Tension pulley and tension pulley 9. Tensioner spacer
bracket assembly 10. Tensioner spring
>>B<< 5. Timing belt front lower cover 11. Timing belt tensioner
TIMING BELT
REMOVAL SERVICE POINT 1. Align the timing marks of the 3 sprocket.

<<A>> TIMING BELT REMOVAL 2. When reusing timing belt, make sure the arrow
mark is pointing in the same direction as when the
1. When reinstalling timing belt, mark an arrow at the
belt was removed.
belt to show rotation direction.
CAUTION
Tilt to water pump side
1. Engage the belt on the various sprockets
A while maintaining tension on the belt of ten-
sion side.
2. Align the injection pump sprocket with the
timing mark, hold the sprocket so that is does
not turn and engage the belt.
B Timing
marks
Tension
AC503588AB Timing
side
marks
2. Loosen the timing belt tensioner mounting bolt A
and B.
3. Push timing belt tensioner to water pump side and
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tighten the timing belt tensioner mounting bolt A
and B. Secure so that timing tensioner will not Camshaft
move back. sprocket

>>A<< TIMING BELT INSTALLATION
Timing Fuel injection
marks pump sprocket
Timing
marks Timing
marks Crankshaft
sprocket
AC501169AB
3. Install the timing belt to the crankshaft sprocket, to

Camshaft injection pump sprocket, to tensioner and to
sprocket camshaft sprocket in that order. Being careful not
to allow deflection on the tension side of the
timing belt.
4. Loosen the tensioner mounting bolts and apply
tension with the spring.
Fuel injection
pump sprocket
Timing
marks Crankshaft
sprocket
AC504264AB
TIMING BELT
11A-33
CAUTION Amount of belt
1. When turning the crankshaft in step 5, strictly deflection
observe the specified amount of rotation (2
teeth on the camshaft sprocket) in order to
apply a constant force to the tension side of
the belt.
2. Do not turn the crankshaft anti-clockwise.
3. Do not touch the belt buring adjustment.
Camshaft sprocket AC503595AB
9. Press on the centre of the bolt with an index finger

to check the amount of deflection.
2 teeth Standard value: 4 −5 mm
>>B<< TIMING BELT FRONT LOWER

COVER/TIMING BELT FRONT UPPER
AC503593AB
COVER INSTALLATION
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5. Turn the crankshaft clockwise and stop at the 1
second lobe of the camshaft sprocket.
A Tensioner 1
2
mounting bolt
1
Tensioner 3
Tensioner
mounting bolt 1
1 2
AC503594AB
6. Make sure that the part indicated by arrow A does

not float upward.
7. Tighten the tensioner mounting bolts, starting with 1
the bolt in the elongated hole. If the lower bolt is
1
tightened first, belt tension will become too tight. AC503596AB
8. Turn the crankshaft anti-clockwise and align the Install the bolts to the timing belt front lower cover
timing mark. Next, make sure that the timing and timing belt front upper cover at the shown posi-
marks of all sprockets are aligned. tion.
No. Bolt diameter × length mm
1 6 × 22
2 6 × 50
3 6 × 60
TIMING BELT B
TIMING BELT B
M1112004600185
7
6
N4 5
3
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2
26 ± 3 N·m
1
AC502130 AB

• Timing belt (Refer to P.11A-31). 4. Gasket
1. Crankshaft sprocket 5. Tensioner spacer B
2. Flange 6. Tensioner spring B
<<A>> >>A<< 3. Timing belt B 7. Timing belt tensioner B
REMOVAL SERVICE POINT

<<A>> TIMING BELT B REMOVAL 3. Push timing belt tensioner to water pump side and
1. When reinstalling timing belt B, mark an arrow at tighten the timing belt tensioner mounting bolt A
the belt to show rotation direction. and nut B. Secure so that timing belt tensioner will
not move back.
Water pump
AC503589AB
2. Loosen the timing belt tensioner mounting bolt A

and nut B.
TIMING BELT B
11A-35
INSTALLATION SERVICE POINT 3. Install timing belt B and make sure there is no
>>A<< TIMING BELT B INSTALLATION deflection on the tension side.
4. Press the deflection side of timing belt B with the
hand and fully stretch the tensioner side.
5. Make sure that the timing marks are aligned.
Timing marks 6. Loosen the tensioner mounting bolt and nut so
that only the pressure of the spring is applied to
A
timing belt B.
Timing belt
tensioner B 7. Tighten the tensioner mounting bolt A and nut B,
tightening the nut first. If the bolt is tightened first,
the tensioner will move and tension the belt.
Timing
marks Tightening torque: 26 ± 3 N⋅ m
B
Countrebalance
shaft sprocket
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Timing Belt deflection
marks
AC504265AB
Crankshaft
sprocket B AC503591AB
1. Align the timing marks of the 3 sprocket.
8. Press in the direction of the arrow in the figure
2. When reusing timing belt B, make sure the arrow
with the index finger to check the amount of
mark is pointing in the same direction as when the
deflection.
belt was removed.
Standard value: 4 −5 mm
Timing marks
A
Deflection
side
Timing
marks B
Tension
side
Timing
marks
AC503590AB
ENGINE ASSEMBLY
ENGINE ASSEMBLY
M1112001002221

• Engine Oil Draining (Refer to GROUP 12 −On-vehicle Service, • Front Exhaust Pipe Installation (Refer to GROUP 15 −Exhaust
Engine Oil Replacement ). Pipe, Main Muffler and Catalytic Converter ).
• Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Serv- • Cowl Top Panel Front Installation
ice, Engine Coolant Replacement ). • Windshield Wiper assembly Installation (Refer to GROUP 51 −
• Engine Room Under Cover Removal (Refer to GROUP 51 − Windshield Wiper ).
Under Cover ). • Radiator Installation (Refer to GROUP 14 −Radiator ).
• Hood Removal (Refer to GROUP 42 −Hood ). • Battery and Battery Tray Installation
• Air Cleaner Removal (Refer to GROUP 15 −Air Cleaner ). • Air Cleaner Installation (Refer to GROUP 15 −Air Cleaner ).
• Battery and Battery Tray Removal • Hood Installation (Refer to GROUP 42 −Hood ).
• Radiator Removal (Refer to GROUP 14 −Radiator ). • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Serv-
• Windshield Wiper assembly Removal (Refer to GROUP 51 − ice, Engine Coolant Replacement ).
Windshield Wiper ). • Engine Oil Refilling (Refer to GROUP 12 −On-vehicle Service,
• Cowl Top Panel Front Removal Engine Oil Replacement ).
• Front Exhaust Pipe Removal (Refer to GROUP 15 −Exhaust • Engine Room Under Cover Installation (Refer to GROUP 51 −
Pipe, Main Muffler and Catalytic Converter ). Under Cover ).
• Fuel Line Air-bleeding (Refer to GROUP 13A −On-vehicle Serv-
ice, Evacuation of Water from Fuel Filter ).
• Drive Belt Tension Check and Adjustment (Refer to P.11A-6).
1
20 ± 2 N·m
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5.0 ± 1.0 N·m
3
12 ± 2 N·m
12 ± 2 N·m
22 ± 4 N·m
AC501848AB

1. Control wiring harness 2. Battery wiring harness connection
connection 3. Earth cable connection
ENGINE ASSEMBLY
11A-37
23 ± 3 N·m
4
23 ± 3 N·m
5
7
10
6 47 ± 7 N·m
45 ± 5 N·m
5.0 ± 1.0 N·m
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11 22 ± 4 N·m
9
AC502602AB
• Cooling fan (Refer to GROUP 14 − 8. Brake booster vacuum hose

Radiator fan ). connection
<<A>> 4. Power steering oil pump <> 9. A/C compressor assembly
assembly • Transmission assembly (Refer to
5. Engine oil cooler feed hose GROUP 22A −Transmission
connection assembly ).
6. Engine oil cooler return hose • Starter motor (Refer to GROUP
connection 16 −Starter motor ).
7. Fuel hoses connection 10. Engine mounting bolts
<<C>> >>A<< 11. Engine assembly
ENGINE ASSEMBLY

<<A>> POWER STEERING OIL PUMP 2. Lift special tool sling chain set (MB991683) and
ASSEMBLY REMOVAL chain block slowly to remove the engine assembly
upwards from the engine compartment.
1. With the hose installed, remove the power
steering oil pump assembly from the engine
assembly.
INSTALLATION SERVICE POINT
2. After removing the power steering oil pump >>A<< ENGINE ASSEMBLY INSTALLA-
assembly, secure it with a cord in the location TION
where the removal and installation of the engine
assembly cannot be hindered.
MB991683
<> A/C COMPRESSOR ASSEMBLY
REMOVAL
1. With the hose installed, remove the A/C
compressor assembly from the bracket.
2. After removing the A/C compressor assembly,
secure it with a cord in the location where the
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removal and installation of the engine assembly AC502542AB
cannot be hindered. 1. Use special tool sling chain set (MB991683) and
chain block to lift the engine assembly in the same
<<C>> ENGINE ASSEMBLY REMOVAL manner as removal.
1. Check that all cables, hoses and wiring harness 2. Install the engine assembly, being careful not to
connectors are disconnected from the engine pinch the cables, hoses or wiring harness
connectors.
MB991683
AC502542AB

Engine Mechanical : Group 11A

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Engine Mechanical : Group 11A

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11A-1

SEALANTS . . . . . . . . . . . . . . . . . . . . 11A-3 OIL PAN AND OIL SCREEN . . . . . . . 11A-22

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-36

Items Standard value Limit

Item Specified Sealant Remark

Tool Number Name Use

MD998384 Prestroke measuring adapter Adjustment of the injection

MB992040 Crank pulley holder Holding the crankshaft sprocket

MD998719 Crankshaft pulley holder pin

MD998381 Camshaft oil seal installer Camshaft oil seal installation

MD998729 Valve stem seal installer Valve stem seal installation

MD998727 Oil pan FIPG cutter Oil pan removal

MD998781 Flywheel stopper Supporting the flywheel

MD998376 Crankshaft rear oil seal Crankshaft rear oil seal

Tool Number Name Use

MD998382 Crankshaft front oil seal

MD998051 Cylinder head bolt wrench Removal and installation of

MB991683 Sling chain set Removal and installation of

Crankshaft Water pump

Apply approximately 100 N of force to the middle of AC501167AB

1. Loosen the power steering oil pump fixing bolts A,

A/C COMPRESSOR DRIVE BELT TEN-

<When using the tension gauge>

<Belt deflection check>

the illustration and then measure the deflection.

5. Measure the valve clearance at the places

a. Give a clearance, pushing the pad by a

10.Apply specified sealant to the section of the

INJECTION TIMING CHECK AND

Timing marks Timing marks

7. Install the special tool prestroke measuring

8. Turn the crankshaft clockwise to move the No. 1

5. Before installation of special tool prestroke

Injection pipe Injection pipe

of the injection pump.

IDLE SPEED CHECK 2. Remove all of the glow plugs.

3. Disconnect the injection pump assembly

2. Turn the ignition switch to "LOOK" (OFF) position,

Timing marks AK403488 AC

7. Turn the crankshaft counterclockwise to align the

TIMING BELT B TENSION ADJUSTMENT

5. Loosen the tensioner pivot side bolt 1 turn and

7. Install the access cover while sliding the front

Pre-removal Operation Post-installation Operation

Removal steps Removal steps (Continued)

REMOVAL SERVICE POINTS

Nut for alternator

1. Loosen the nut for alternator pivot bolt and locking

AC503534 AB 1. Use special tool crank pulley holder (MB992040),

1. Clean and then degrease the crankshaft sprocket MB992040

CAMSHAFT AND VALVE STEM SEAL

Apply engine oil to all

Camshaft removal steps Camshaft removal steps

<<C>> VALVE SPRING RETAINER LOCKS >>B<< VALVE SPRINGS INSTALLATION

Install the valve spring with its identification colour

MD998772 >>C<< VALVE SPRING RETAINER LOCKS

Use special tool valve spring compressor

INSTALLATION SERVICE POINTS

CAUTION Use special tool valve spring compressor