11E-1

GROUP 11E

ENGINE
MECHANICAL
<4G69>
CONTENTS

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

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11E-18
SEALANTS . . . . . . . . . . . . . . . . . . . . 11E-2 REMOVAL AND INSTALLATION . . . . . . . . 11E-18

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11E-3 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11E-23

REMOVAL AND INSTALLATION . . . . . . . . 11E-23
ON-VEHICLE SERVICE. . . . . . . . . . . 11E-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11E-25
DRIVE BELT TENSION CHECK. . . . . . . . . 11E-7
AUTO-TENSIONER CHECK . . . . . . . . . . . 11E-7 CRANKSHAFT OIL SEAL . . . . . . . . . 11E-26
VALVE CLEARANCE CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 11E-26
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11E-10
ROCKER ARM PISTON OPERATION CYLINDER HEAD GASKET . . . . . . . . 11E-30
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11E-11
REMOVAL AND INSTALLATION . . . . . . . . 11E-30
IGNITION TIMING CHECK . . . . . . . . . . . . . 11E-12
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11E-13 TIMING BELT . . . . . . . . . . . . . . . . . . . 11E-36
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11E-14 REMOVAL AND INSTALLATION . . . . . . . . 11E-36
COMPRESSION PRESSURE CHECK. . . . 11E-15 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11E-45
MANIFOLD VACUUM CHECK . . . . . . . . . . 11E-15
ENGINE ASSEMBLY . . . . . . . . . . . . . 11E-46
CRANKSHAFT PULLEY . . . . . . . . . . 11E-17 REMOVAL AND INSTALLATION . . . . . . . . 11E-46
REMOVAL AND INSTALLATION . . . . . . . . 11E-17
11E-2 ENGINE MECHANICAL <4G69>
SERVICE SPECIFICATIONS

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
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
 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
11E-3
SPECIAL TOOLS
M1112000601313

Tool Number Name Use

A
MB992080 Belt tension meter set Drive belt tension check
A: MB992081 A: Belt tension meter
B: MB992082 B: Microphone assembly
B
B992080

MB991502 M.U.T.-II sub assembly • Drive belt tension check

• Checking the ignition timing
• Checking the idle speed

B991502

MB991955 M.U.T.-III sub assembly CAUTION

A A: MB991824 A: Vehicle communication If you connect M.U.T.-III main
B: MB991827 interface (V.C.I.) harness A to a vehicle without
C: MB991910 B: M.U.T.-III USB cable CAN communication system
D: MB991911 C: M.U.T.-III main harness A to use the M.U.T.-III, a pulse
MB991824
E: MB991825 (Vehicles with CAN signal may interfere with the
B F: MB991826 communication system) simulated vehicle speed lines,
D: M.U.T.-III main harness B thus causing the M.U.T.-III
(Vehicles without CAN inoperative. Therefore, use
communication system) the M.U.T.-III main harness B
MB991827 E: M.U.T.-III adapter harness (MB991911) instead.
C
F: M.U.T.-III trigger harness • Drive belt tension check
• Checking the ignition timing
DO NOT USE
• Checking the idle speed

MB991910

MB991911

MB991825

MB991826

MB991955
11E-4 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS

Tool Number Name Use

MB991668 Belt tension meter set Drive belt tension check (used
together with M.U.T.-II or
M.U.T.-III)

B991668

MB990767 Front hub and flange yoke Holding the camshaft sprocket
holder

B990767

MD998719 Pin

D998719

MD998772 Valve spring compressor Compressing valve spring

MD998772

MB991999 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
 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
11E-5
Tool Number Name Use
MB990938 Installer bar Crankshaft rear oil seal
installation

MD998776 Crankshaft rear oil seal

installer

D998776

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
11E-6 ENGINE MECHANICAL <4G69>
SPECIAL TOOLS

Tool Number Name Use

MD998767 Tensioner wrench Valve timing belt tension
adjustment

D998767

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
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11E-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK FUNCTION CHECK
M1111003100548
The auto-tensioner can be checked whether it is in
CAUTION good condition by checking its tension.
Check the drive belt tension after turning the
When the vibration frequency is
crankshaft clockwise one turn or more.
measured (Belt tension meter set is
used): Recommendation
Indicator mark 1. Check the drive belt tension (Refer to P.11E-7).
2. Measure the drive belt tension vibration frequency
by the following procedures:
A Belt tension meter set (MB992080)

MB992081

AC301702AB

1. Make sure that the indicator mark is within the

area marked with A in the illustration.
2. If the mark is out of the area, replace the drive MB992082
belt. (Refer to P.11E-17).
AC507219AB
NOTE: The drive belt tension check is not neces-
sary as auto-tensioner is adopted. (1) Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
AUTO-TENSIONER CHECK (MB992081) of special tool belt tension meter
M1111003000905 set (MB992080).
OPERATION CHECK (2) Press the "POWER" button to turn on the
1. Turn OFF the engine from the idle state then power supply.
check to see that the drive belt is not protruding (3) Press the numeral key of "1" and check that
from the pulley width of the auto-tensioner. "No. 1" appears on the upper left of the
2. Remove the drive belt.(Refer to P.11E-17). display.
NOTE: This operation is to temporarily set the
preset data such as the belt specifications,
because if the measurement is taken without
input of the belt specifications, conversion to
tension value (N) cannot be made, resulting in
judgement of error.
(4) Press "Hz" button twice to change the display
to the frequency display (Hz).

AC301703

3. Securely insert the spindle handle or ratchet

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.
4. If there are any problems in the procedure 1 or 3,
replace the auto-tensioner.(Refer to P.11E-36).
5. Install the drive belt.(Refer to P.11E-17).
11E-8 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

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
• Do not allow any contaminants such as water Hz
or oil to get onto the microphone. NOTE: To take the measurement repeatedly,
• If strong gusts of wind blow against the fillip the belt again.
microphone or if there are any loud sources (8) Press and hold the "POWER" button to turn off
of noise nearby, the values measured by the the power supply.
microphone may not correspond to actual 3. If not within the standard value, replace the
values. auto-tensioner (Refer to P.11E-36).
• If the microphone is touching the belt while
the measurement is being made, the values When the vibration frequency is
measured by the microphone may not corre- measured (M.U.T.-II is used):
spond to actual values. Recommendation
• Do not take the measurement while the vehi- 1. Check the drive belt tension. (Refer to P.11E-7).
cle's engine is running.
2. Measure the drive belt tension vibration frequency
by the following procedures:
CAUTION
Water MB992080
pump
pulley
15 10 15 mm
15 16-pin

Gently tap
with your
finger

MUT-II

Alternator
pulley

AC301266AE MB991668

(5) Hold special tool MB992080 to the middle of AC211862 AB

the belt between the pulleys (at the place
To prevent damage to M.U.T.-II, always turn the
indicated by arrow) where it does not contact
ignition switch to the "LOCK" (OFF) position
the belt (approximately 10 − 15 mm away from
before connecting or disconnecting M.U.T.-II.
the rear surface of the belt) so that it is
(1) Connect special tool belt tension meter set
perpendicular to the belt (within an angle of ±
(MB991668) to the M.U.T.-II.
15°).
(2) Connect the M.U.T.-II to the diagnosis
(6) Press the "MEASURE" button.
connector.
(7) Gently tap the middle of the belt between the
(3) Turn the ignition switch to "ON" position, and
pulleys (the place indicated by the arrow) with
select "BELT TENSION" on the menu screen.
your finger as shown in the illustration, and
check that the vibration frequency of the belt is
within the standard value.
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11E-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
• Do not allow any contaminants such as water Hz
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.11E-36).
microphone or if there are any loud sources
of noise nearby, the values measured by the When the vibration frequency is
microphone may not correspond to actual measured (V.C.I. is used):
values. Recommendation
• If the microphone is touching the belt while 1. Check the drive belt tension. (Refer to P.11E-7).
the measurement is being made, the values
2. Measure the drive belt tension vibration frequency
measured by the microphone may not corre-
by the following procedures:
spond to actual values.
• Do not take the measurement while the vehi- CAUTION
cle's engine is running.

16-pin
Water MB991668
pump
pulley
15˚ 10 – 20 mm
15˚

Gentry tap MB991824

with your
finger
MB991668

Alternator MB991911
pulley
AC211863AB

To prevent damage to special tool V.C.I.

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

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
• Do not allow any contaminants such as water Hz
or oil to get onto the microphone. 3. If not within the standard value, replace the
• If strong gusts of wind blow against the alternator drive belt auto tensioner. (Refer to
microphone or if there are any loud sources P.11E-36).
of noise nearby, the values measured by the
microphone may not correspond to actual When the tension is measured
values. 1. Check the drive belt tension. (Refer to P.11E-7).
• If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not corre-
Belt tension
spond to actual values. Water pump
gauge
• Do not take the measurement while the vehi- pulley
cle's engine is running.

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

Alternator
pulley
Gentry tap
with your
finger

AC301267AB

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

Ignition coils

Rocker cover AK304505AB

No. 1 No. 2 No. 3 No. 4 1. Remove all of the ignition coils.

Exhaust valve side
AK303689 AB 2. Remove the rocker cover.
3. Remove the oil control valve.
8. Valve clearance inspection and adjustment can be
4. Remove the taper plug.
performed on rocker arms indicated by white
arrow mark when the No.1 cylinder piston is at the 5. Turn the crankshaft clockwise until the notch on
top dead centre on the compression stroke, and the crankshaft pulley is lined up with "T" mark on
on rocker arms indicated by black arrow mark the lower cover of timing belt.
when the No.4 cylinder piston is at the top dead 6. Move the rocker arms on the No.1 and No.4
centre on the compression stroke. cylinders up and down by hand to determine
9. Measure the valve clearance. which cylinder has its piston at the top dead
centre on the compression stroke.
If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance NOTE:
Intake valve side
using a thickness gauge while turning the
adjusting screw.
Standard value (hot engine):
Intake valve: 0.20 mm
Exhaust valve: 0.30 mm
10.While holding the adjusting screw with a
screwdriver to prevent it from turning, tighten the No. 1 No. 2 No. 3 No. 4
lock nut to the specified torque. Exhaust valve side
Tightening torque: 9 ± 1 N⋅m AK303689 AC

11.Turn the crankshaft through 360° to line up the The rocker arm piston operation check can be per-
notch on the crankshaft pulley with the "T" mark formed on rocker arms indicated by white arrow mark
on the timing indicator. when the No.1 cylinder piston is at the top dead cen-
tre on the compression stroke, and on rocker arms
12.Repeat steps (9) and (10) on other valves for
indicated by black arrow mark when the No.4 cylin-
clearance adjustment.
der piston is at the top dead centre on the compres-
13.Install the rocker cover. sion stroke.
11E-12 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

IGNITION TIMING CHECK

Rocker arm M1111001700997
Rocker arm
piston

Oil passage
Blow
compression
air AK302684AC 16 PIN
MB991502
7. While shutting up the oil passage hole at the AK303691AF
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.
16-PIN
NOTE: To fully confirm the check, prevent the com-
pression air from leaking as much as possible by
installing the O-ring to the end of air blowgun.
8. Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt. MB991911
9. Confirm the rest of the rocker arm pistons under
the procedure 7. MB991824
10.When the rocker arm piston does not operate,
replace the rocker arm assy.
11.Apply sealant to threaded portion.
Specified sealant: LOCTITE203MP
CAUTION
Do not start the engine within one hour after the MB991827 AK303690AB
engine taper plug has been installed.
12.Install the taper plug and tighten to the specified 1. Before inspection, set the vehicle to the
torque. pre-inspection condition.
Tightening torque: 10 ± 2 N⋅m 2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the M.U.T.-II/III to the
13.Install the oil control valve. (Refer to Camshaft diagnosis connector.
and Valve Stem Seal − Removal and Installation
3. Connect a timing light.
P.11E-18.)
4. Start the engine and let it run at idle.
14.Install all of the ignition coils.
5. Use the M.U.T.-II/III to measure engine idle speed
15.Install the rocker cover. and check that it is within the standard value.
Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
6. Select No. 17 of the M.U.T.-II/III Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5° BTDC ± 3°
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11E-13
8. If the basic ignition timing is outside the standard IDLE SPEED CHECK
value, inspect the MPI system (Refer to P.13C-21, M1111003500911

GROUP 13C − Troubleshooting − Inspection chart

for diagnosis code).
CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this con-
dition may damage the engine.
9. Press the M.U.T.-II/III clear key (Select a forced
driving cancel mode) to release the Actuator test. 16 PIN
MB991502
10.Check that ignition timing is at the standard value. AK303691AF
Standard value: approximately 10° BTDC
NOTE: .
• The ignition timing may fluctuate within ± 7°
BTDC. This is normal.
• In higher altitude, the ignition timing is more 16-PIN
advanced than the standard value by approxi-
mately 5°.
11.Remove the timing light.
12.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III.
MB991911

MB991824

MB991827 AK303690AB

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 M.U.T.-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Check that ignition timing is at the standard value.
Standard value: approximately 10° BTDC
6. Check the idle speed.
Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
NOTE: .
• The idle speed is controlled automatically by
the idle speed control system.
• When using the M.U.T.-II/III, select item No. 22
and take a reading of the idle speed.
11E-14 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

7. If the idle speed is outside the standard value, 3. Connect a timing light.
inspect the MPI system (Refer to P.13C-21, 4. Start the engine and let it run at idle.
GROUP 13C − Troubleshooting − Inspection chart 5. Check that ignition timing is at the standard value.
for diagnosis code).
Standard value: approximately 10° BTDC
8. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III. 6. Run the engine at 2,500 r/min for 2 minutes.
7. Set the CO, HC tester.
IDLE MIXTURE CHECK 8. Check the CO contents and the HC contents at
M1111002100426
idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
9. If there is a deviation from the standard value,
check the following items:
• Diagnosis output
• Fuel pressure
16 PIN
MB991502 • Injector
AK303691AF • Ignition coil, spark plug
• EGR control system
• Evaporative emission control system
• Compression pressure
NOTE: Replace the three way catalyst when the
16-PIN CO and HC contents are not within the standard
value, even though the result of the inspection is
normal on all items.
10.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III.

MB991911

MB991824

MB991827 AK303690AB

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 M.U.T.-II/III to the
diagnosis connector.
 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE
11E-15
COMPRESSION PRESSURE CHECK (1) If the compression increases after oil is added,
M1111002600636 the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
surface.
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
Crank angle
sensor seat, or pressure is leaking from the gasket.
connector 9. Connect the crank angle sensor connector.
10.Install the spark plugs and tighten to the specified
torque.
AK303421AB Tightening torque: 25 ± 4 N⋅m
11.Install the ignition coils.
1. Before inspection, set the vehicle to the
pre-inspection condition. 12.Use the M.U.T.-II/III to erase the diagnosis codes.
2. Remove all of the ignition coils and spark plugs. NOTE: This will erase the diagnosis code result-
ing from the crank angle sensor connector being
3. Disconnect the crank angle sensor connector.
disconnected.
NOTE: Doing this will prevent the
engine-ECU<M/T> or engine-A/T-ECU<A/T> from MANIFOLD VACUUM CHECK
carrying out ignition and fuel injection. M1111002700569

CAUTION
• Keep away from the spark plug hole when
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 the spark plug
hole, which is dangerous. 16 PIN
MB991502
4. Cover the spark plug hole with a shop towel etc.,
AK303691AF
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
5. Set compression gauge to one of the spark plug
holes.
6. Crank the engine with the throttle valve fully open
16-PIN
and measure the compression pressure.
Standard value (at engine speed of 200
r/min):
1,560 kPa
Limit (at engine speed of 200 r/min):
Minimum 1130 kPa MB991911
7. Measure the compression pressure for all the
cylinders, and check that the pressure differences MB991824
of the cylinders are below the limit.
Limit: Maximum 98 kPa
8. If there is a cylinder with compression or a
compression difference that is outside the limit,
pour a small amount of engine oil through the
spark plug hole, and repeat the operations in MB991827 AK303690AB
steps from (5) to (7).
1. Before inspection, set the vehicle to the
pre-inspection condition.
11E-16 ENGINE MECHANICAL <4G69>
ON-VEHICLE SERVICE

2. Turn the ignition switch to the "LOCK" (OFF) 4. Plug the PCV valve.
position and then connect the M.U.T.-II/III to the 5. Start the engine and check that idle speed is
diagnosis connector. within the standard valve.
Ventilation hose Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
6. Check the intake manifold vacuum.
Plug Limit: Minimum 60 kPa
PCV valve
7. Turn off the ignition switch.
Vacuum gauge
8. Remove the vacuum gauge and then connect the
ventilation hose.
AK303422 AB 9. Turn the ignition switch to the "LOCK" (OFF)
3. Disconnect the ventilation hose from the PCV position and then remove the M.U.T.-II/III.
valve, and connect a vacuum gauge to the
ventilation hose.
 ENGINE MECHANICAL <4G69>
CRANKSHAFT PULLEY
11E-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.11E-7).
P.51-31). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).

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
CAUTION
The following operations will be needed due to the To reuse the drive belt, draw an arrow indicating
introduction of the serpentine drive system with the the rotating direction (clockwise) on the back of
drive belt auto-tensioner. 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.
11E-18 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL

CAMSHAFT AND VALVE STEM SEAL

REMOVAL AND INSTALLATION
M1112006600501

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.11E-36).
P.15-8). • Ignition Coils Installation (Refer to GROUP 16, Ignition
• Ignition Coils Removal (Refer to GROUP 16, Ignition Sys- System − Ignition Coil P.16-47).
tem − Ignition Coil P.16-47). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Timing Belt Upper Cover Removal (Refer to P.11E-36). P.15-8).
• Drive Belt Tension Check (Refer to P.11E-7).
• Valve Clearance Check and Adjustment (Refer to
P.11E-10).

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.11E-36).
>>J<< 6. O-ring
 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
11E-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.14-32). <<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
11E-20 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> CAMSHAFT SPROCKET >>A<< VALVE STEM SEALS INSTALLA-
REMOVAL TION
1. Apply a small amount of engine oil to the valve
stem seals.
MB990767
CAUTION
• Do not re-use the valve stem seal.
• Special tool valve stem seal installer
(MB991999) must be used to install the valve
MD998719
stem seal. Improper installation could result
in oil leaking past the valve guide.

AC102532AB
MB991999
1. Use the following special tools to hold the
Valve
camshaft sprocket.
• Front hub and flange yoke holder (MB990767) Valve stem
• Pin (MD998719) seal
2. Loosen the camshaft sprocket mounting bolt and
remove the camshaft sprocket. Valve guide

<<B>> EXHAUST ROCKER ARM AND

AC308654AC

SHAFT ASSEMBLY/INLET ROCKER ARM 2. Use the special tool to fill a new valve stem seal in
AND SHAFT ASSEMBLY REMOVAL the valve guide using the valve stem area as a
guide.
CAUTION
Never disassemble the exhaust rocker arm and
shaft assembly, and inlet rocker arm and shaft
>>B<< EXHAUST VALVE SPRINGS/INLET
assembly. VALVE SPRINGS INSTALLATION
Rocker arm side
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL
CAUTION
When removing valve spring retainer locks, leave Identification
colour
the piston of each cylinder in the TDC (Top Dead
Inlet side:
Centre) position. The valve may fall into the cylin- Light blue
der if the piston is not properly in the TDC posi- Exhaust side:
tion. Orange AC107415AC

Install the valve springs with its identification colour

painted end facing the locker arm.
MD998772

AC301867AB

Use special tool valve spring compressor

(MD998772) to compress the valve spring and then
remove the valve spring retainer lock.
 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL
11E-21
>>C<< VALVE SPRING RETAINER LOCKS >>F<< EXHAUST ROCKER ARM AND
INSTALLATION SHAFT ASSEMBLY/EXHAUST ROCKER
ARM SHAFT CAPS INSTALLATION
Engine front
MD998772

AC301867AB Notch
Use special tool valve spring compressor AC301870AB
(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same man- 1. Install the exhaust rocker shaft so that its notch is
ner as removal. positioned as shown.
2. Install the exhaust rocker arm shaft caps.
>>D<< CAMSHAFT INSTALLATION 3. Tighten the exhaust rocker shaft mounting bolts to
the specified torque.
Dowel pin Tightening torque: 13 ± 1 N⋅m

>>G<< CAMSHAFT OIL SEAL

INSTALLATION
Camshaft oil seal

AC301868AB

Set the dowel pin of the camshaft in the position

shown in the figure. (Engine oil)

>>E<< INLET ROCKER ARM AND SHAFT

ASSEMBLY/INLET ROCKER ARM SHAFT MD998713 AC102323AC

CAPS INSTALLATION 1. Apply engine oil to the entire inner diameter of the
Engine front oil seal lip.
φ 5.5 mm
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seal as shown.

AC301869AB

1. Place the inlet rocker shaft so that its 5.5 mm hole

faces toward the cylinder head.
2. Install the inlet rocker arm shaft caps.
3. Tighten the inlet rocker shaft mounting bolts to the
specified torque.
Tightening torque: 31 ± 3 N⋅m
11E-22 ENGINE MECHANICAL <4G69>
CAMSHAFT AND VALVE STEM SEAL

>>H<< CAMSHAFT SPROCKET NOTE: Install the camshaft position sensor sup-
INSTALLATION port within 15 minutes after applying the sealant.
3. Install the camshaft position sensor support to the
cylinder head.
MB990767 CAUTION
Wait at least one hour. Never start the engine or
let engine oil or coolant touch the adhesion sur-
face during that time.
MD998719 4. Tighten the camshaft position sensor support
mounting bolts to the specified torque.
Tightening torque: 14 ± 1 N⋅m
AC102532AB

1. Use the following special tool as during removal to >>J<< O-RING/OIL CONTROL VALVE
hold the camshaft sprocket. INSTALLATION
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719) CAUTION
2. Tighten the camshaft sprocket mounting bolt to • Never re-use the O-ring.
•

the specified torque.

Tightening torque: 89 ± 9 N⋅m
Tape
>>I<< CAMSHAFT POSITION SENSOR
SUPPORT INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.

AK303651AD

φ 3 mm 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.
1. Apply a small amount of engine oil to the O-ring
and then install it to the oil control valve.
AC301268AB
2. Assemble the oil control valve to the cylinder
2. Apply the sealant to the camshaft position sensor head.
support flange in a continuous bead as shown in 3. Tighten the oil control valve mounting bolt to the
the illustration. specified torque.
Specified sealant: MITSUBISHI GENUINE Tightening torque: 11 ± 1 N⋅m
PART MD970389 or equivalent
 ENGINE MECHANICAL <4G69>
OIL PAN
11E-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.51-31). Roll Stopper and Centre Member P.32-13).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Front Exhaust Pipe Installation (Refer to GROUP 15,
Service − Engine Oil Replacement P.12-4). Exhaust Pipe and Main Muffler P.15-25).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Exhaust Pipe and Main Muffler P.15-25). Service − Engine Oil Replacement P.12-4).
• Centre Member Removal (Refer to GROUP 32, Engine • Under Cover Installation (Refer to GROUP 51, Under
Roll Stopper and Centre Member P.32-13). Cover P.51-31).

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
11E-24 ENGINE MECHANICAL <4G69>
OIL PAN

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> ENGINE LOWER OIL PAN >>A<< ENGINE UPPER OIL PAN INSTAL-
REMOVAL LATION
1. Remove the engine lower oil pan mounting bolts. 1. Remove sealant from the engine upper oil pan
CAUTION and cylinder block surfaces.
Do not use special tool oil pan FIPG cutter
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.

φ 4 mm
Groove Bolt hole
portion portion AC102242AB

2. Apply a bead of the sealant to the mating surface

Engine lower oil pan of the engine upper oil pan as shown.
AC102931AB
Specified sealant: MITSUBISHI GENUINE
2. Apply a piece of wood to the lower oil pan and PART MD970389 or equivalent
strike it with a hammer to remove the engine NOTE: Install the engine upper oil pan within 15
lower oil pan. minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
<<B>> ENGINE UPPER OIL PAN block.
REMOVAL CAUTION
1. Remove the engine upper oil pan mounting bolts. Then wait at least one hour. Never start the
CAUTION engine or let engine oil or coolant touch the seal-
Do not use special tool oil pan FIPG cutter ant surface during that time.
(MD998727). The engine upper oil pan is made of B B
aluminium and this tool will damage it. B B

B
A
A B B

B B

AC102946AB
B B

2. Screw in the bolt into bolt hole A in the location B

shown. Then lift the upper oil pan and remove it. B

B
A A

AC102929AB

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

shown, and tighten them to the specified torque.
 ENGINE MECHANICAL <4G69>
OIL PAN
11E-25
Name Symbol Quantity Size mm 4. Insert the bolts to the engine lower oil pan as
(D × L) shown, and tighten them to the specified torque in
the order shown.
Flange bolt A 2 M6 × 16
Name Symbol Quantity Size mm
B 16 M6 × 18
(D × L)
NOTE: D: Nominal diameter, L: Nominal length Flange bolt A 1 M6 × 75
Tightening torque: 9.0 ± 3.0 N⋅m
B 11 M6 × 10
NOTE: D: Nominal diameter, L: Nominal length
>>B<< ENGINE LOWER OIL PAN
Tightening torque: 9.0 ± 3.0 N⋅m
INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan. >>C<< ENGINE OIL PAN DRAIN PLUG
GASKET INSTALLATION

Engine lower
oil pan side

φ 4 mm
Groove Bolt hole
portion portion AC102243AB
AC102325 AF
2. Apply a bead of the sealant to the mating surface
of the engine lower oil pan as shown. Replace the gasket with a new one. Install the new
gasket in the direction shown in the illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
>>D<< TRANSMISSION HOUSING FRONT
NOTE: Install the engine lower oil pan within 15
minutes after applying sealant. LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
3. Assemble the engine lower oil pan to the engine
stay in the following order.
upper oil pan.
1. Tighten the engine side four mounting bolts to the
CAUTION specified torque.
Then wait at least one hour. Never start the
Tightening torque: 22 ± 4 N⋅m
engine or let engine oil or coolant touch the seal-
ant surface during that time. 2. Tighten the transmission side two mounting bolts
to the specified torque.
B-1 B-11
B-10 Tightening torque: 44 ± 10 N⋅m

B-4 INSPECTION
B-7 M1112002900254
• Check the oil pan for cracks.
B-5
B-6 • Check the oil pan sealant-coated surface for
B-8 A-3 damage and deformation.

B-9 B-12 B-2

AC102930AB
11E-26 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION
M1112003101061

<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.11E-36). • Clutch cover and clutch disc (Refer
>>D<< 1. Crankshaft balancer shaft drive to GROUP 21B, Clutch P.21B-3).
sprocket <<B>> >>B<< 4. Flywheel bolts
2. Crankshaft key 5. Flywheel adapter plate
>>C<< 3. Crankshaft front oil seal 6. Flywheel assembly
7. Flywheel adapter plate
8. Crankshaft bush
>>A<< 9. Crankshaft rear oil seal
 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
11E-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.11E-36). GROUP 23A, Transmission
>>D<< 1. Crankshaft balancer shaft drive Assembly P.23A-147).
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
11E-28 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> TRANSMISSION ASSEMBLY >>A<< CRANKSHAFT REAR OIL SEAL
REMOVAL INSTALLATION
CAUTION
Oil seal
AC300897

MB990938

Engine front (Engine oil)

Flywheel
assembly
Flywheel
bolt MD998776 Crankshaft
AC102328 AB

AC308604 AB
1. Apply a small amount of engine oil to the entire
Do not remove the flywheel bolt. If this bolt is inner diameter of the oil seal lip.
removed, the flywheel assembly will become out 2. Use the following special tools to press-fit the oil
of balance and damaged. seal.
Refer to GROUP 22A, Transmission Assembly • Installer bar (MB990938)
P.22A-14. • Crankshaft rear oil seal installer (MD998776)

<<B>> FLYWHEEL BOLTS/A/T DRIVE >>B<< FLYWHEEL BOLTS/A/T DRIVE

PLATE BOLTS REMOVAL PLATE BOLTS INSTALLATION

MD998781
MD998781

AC301854AB AC301855AB

1. Use special tool flywheel stopper (MD998781) to 1. Use special tool flywheel stopper (MD998781) to
secure the flywheel assembly or A/T drive plate. secure the flywheel assembly or A/T drive plate in
2. Remove the flywheel bolts or A/T drive plate bolts. 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
 ENGINE MECHANICAL <4G69>
CRANKSHAFT OIL SEAL
11E-29
>>C<< CRANKSHAFT FRONT OIL SEAL >>D<< CRANKSHAFT BALANCER SHAFT
INSTALLATION DRIVE SPROCKET INSTALLATION
Crankshaft MD998375 : Clean
: Clean and degrease

Crankshaft
(Engine oil) balancershaft
drive sprocket

MD998285 Oil seal

(Oil applied to the
circumference) AC102329AC

1. Apply a small amount of engine oil to the outer

diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
2. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip. Crankshaft
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal. Front case

Engine front
AC301346AB

1. Clean or degrease the front case, the crankshaft

and the crankshaft balancer shaft drive sprocket
as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
in the direction shown in the illustration.
11E-30 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
M1112004001272

Pre-removal Operation Post-installation Operation

• Fuel Line Pressure Reduction [Refer to GROUP 13C, • Accelerator Cable Installation (Refer to GROUP 17,
On-vehicle Service − Fuel Pump Connector Disconnec- Accelerator Cable and Pedal P.17-7).
tion (How to Reduce Pressurized Fuel Lines) P.13C-428]. • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.15-8).
Service − Engine Coolant Replacement P.14-17). • 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.15-8). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Accelerator Cable Removal (Refer to GROUP 17, Accel- On-vehicle Service − Accelerator Cable Check and
erator Cable and Pedal P.17-7). Adjustment P.17-6).
• 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
11E-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.14-32).
15, Exhaust Manifold P.15-20). <<C>> >>C<< 14. Fuel high-pressure hose
• Timing belt upper cover (Refer to connection
P.11E-36). • Rocker cover assembly (Refer to
<<A>> >>E<< 11. Camshaft sprocket P.11E-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
11E-32 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET

REMOVAL SERVICE POINTS AC107621

<<A>> CAMSHAFT SPROCKET Wiring band

REMOVAL
CAUTION
Never turn the crankshaft anti-clockwise.

AC301451AC

Timing mark 4. Secure the camshaft sprocket and valve timing

belt with wiring bands and so on to prevent
slippage between the camshaft sprocket and
valve timing belt.
AC301450AB

1. Turn the crankshaft clockwise, align the timing

MB990767
marks on the camshaft sprocket to set No.1
cylinder to TDC of its compression stroke.
MD998719
MD998738

AC100302 AB

5. Use the following special tools to hold the

camshaft sprocket.
Timing belt
• Front hub and flange yoke holder (MB990767)
under cover
• Pin (MD998719)
AC301452AB
CAUTION
2. Remove the timing belt under cover rubber plug Do not rotate the crankshaft after camshaft
and then set special tool adjusting bolt sprocket removal.
(MD998738).
6. Remove the camshaft sprocket with the valve
timing belt and place it on the timing belt lower
Timing belt cover.
tensioner arm
<<B>> RADIATOR UPPER HOSE
MD998738
DISCONNECTION

AC301373AB

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

with the timing belt tensioner arm.
Mating marks

AC200641AB

Make mating marks on the radiator upper hose and

the hose clamp. Disconnect the radiator upper hose.
 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
11E-33
<<C>> FUEL HIGH-PRESSURE HOSE <<D>> CYLINDER HEAD BOLTS
DISCONNECTION REMOVAL

MB991654
Stopper

AC304581AB

1. Remove the fuel high-pressure hose stopper. Engine front

3 5 10 8 2

1 7 9 6 4

AC301454AB
Retainer
AC304582AB Use special tool cylinder head bolt wrench
(MB991654) to loosen the cylinder head bolts in two
2. Remove the fuel high-pressure hose in the or three steps in the order of the numbers shown in
direction shown in the figure while the retainer is the illustration. If the cylinder head bolts cannot be
pulled up. pulled out due to the washer being trapped in the
NOTE: If the retainer is released, install it after valve spring, raise the bolt slightly, then remove it
removing the fuel high-pressure hose. while holding it by using a magnet.

INSTALLATION SERVICE POINTS

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

Identification
mark "381"

Exhaust side

AC302180AB
11E-34 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET

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

90˚ 90˚

AC102537AC

Paint marking Paint marking

1. Check that the nominal length of each cylinder
head bolt meets the limit. If it exceeds the limit, AC102331AB
replace the bolts with a new one.
(4) Apply a paint mark to the heads of the cylinder
Limit (A): 99.4 mm head bolts and cylinder head, then tighten 90
2. Apply a small amount of engine oil to the thread of degree angle as shown.
the bolts and to the washers. CAUTION
• The bolt is not tightening sufficiently if the
tightening angle is less than a 90 degree
angle.
• If the tightening angle exceeds the standard
specification, remove the bolt and start over
MB991654 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
head bolts and the paint mark on the cylinder
head is on a linear line.
Engine front

8 6 1 3 9

10 4 2 5 7

AC301456AB
 ENGINE MECHANICAL <4G69>
CYLINDER HEAD GASKET
11E-35
>>C<< FUEL HIGH-PRESSURE HOSE >>D<< RADIATOR UPPER HOSE
CONNECTION CONNECTION
CAUTION
Fuel Projection
high-pressure
3 mm
hose

Water outlet fitting

Mating marks
Fuel line pipe
(Engine oil applied) AC200642 AB

AC301864AB
1. Insert radiator upper hose until it contacts the
projection on the water outlet fitting.
2. Align the mating marks on the radiator upper hose
and hose clamp, and then secure the radiator
upper hose.

>>E<< CAMSHAFT SPROCKET

INSTALLATION

Stopper
AC304583AB
MB990767
After connecting the fuel high-pressure hose,
slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
MD998719
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.
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
the specified torque.
Tightening torque: 89 ± 9 N⋅m
11E-36 ENGINE MECHANICAL <4G69>
TIMING BELT

TIMING BELT
REMOVAL AND INSTALLATION
M1112004301024

Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Under Cover • Crankshaft Shaft Damper Pulley Installation (Refer to
P.51-31). P.11E-17).
• Crankshaft Shaft Damper Pulley Removal (Refer to • Drive Belt Tension Check (Refer to P.11E-7).
P.11E-17). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).

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

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
11E-38 ENGINE MECHANICAL <4G69>
TIMING BELT

REMOVAL SERVICE POINTS

<<A>> VALVE TIMING BELT REMOVAL Timing belt
tensioner arm
CAUTION
Never turn the crankshaft anti-clockwise. MD998738

Timing mark

AC301373AB

3. Screw in the special tool with hands until it

contacts the timing belt tensioner arm.
Camshaft CAUTION
sprocket
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
Timing mark screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.

Timing mark A
Engine oil pump B
Crankshaft sprocket
camshaft
drive sprocket AC301866AB

1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke. AC301856 AB

4. Gradually screw in the special tool and then align

MD998738 the timing belt tensioner adjuster rod set hole A
with the timing belt tensioner adjuster cylinder set
hole B.
Timing belt tensioner
pulley mounting bolt
Wire or pin
Timing belt
under cover
AC301452AB

2. Remove the timing belt under cover rubber plug

and then set special tool adjusting bolt
(MD998738).
AC302414AB

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

CAUTION
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
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.
 ENGINE MECHANICAL <4G69>
TIMING BELT
11E-39
<<B>> CRANKSHAFT PULLEY CENTRE INSTALLATION SERVICE POINTS
BOLT/CRANKSHAFT PULLEY >>A<< BALANCER TIMING BELT/BAL-
WASHER/CRANKSHAFT CAMSHAFT ANCER TIMING BELT TENSIONER
DRIVE SPROCKET REMOVAL INSTALLATION
Crankshaft
camshaft MB991385
drive Balancershaft
sprocket sprocket

Belt tension
side
MB991367

Timing
AC102332AB mark
Timing
1. Use the following special tools to hold the mark
crankshaft camshaft drive sprocket.
• Special spanner (MB991367)
• Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft pulley washer and
crankshaft camshaft drive sprocket. Crankshaft
balancershaft
<<C>> BALANCER TIMING BELT drive sprocket

REMOVAL AC301402AB

CAUTION 1. Ensure that the crankshaft balancer shaft drive

To reuse the balancer timing belt, draw an arrow sprocket timing marks and balancer shaft
indicating the rotating direction on the back of sprocket timing marks are aligned.
the belt using chalk, etc. 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
side.

Centre of the
mounting bolt

Centre of
the pulley
AC301403AB

3. Assemble and temporarily fix the centre of the

pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the
assembling bolt, and the pulley flange is at the
front-side of the engine.
4. Adjust the balancer timing belt tension.
11E-40 ENGINE MECHANICAL <4G69>
TIMING BELT

>>B<< BALANCER TIMING BELT

TENSION ADJUSTMENT
Approximately 100 N
CAUTION
When tightening the mounting bolts, ensure that
the tensioner does not rotate with the bolts.
Allowing it to rotate with the bolts can cause Deflection
excessive tension of the belt.

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
AC301404 <When replacing> 5 − 7 mm
1. Lift with your fingers the balancer timing belt 4. If not within the standard value, adjust the belt
tensioner in the direction of the arrow. Apply a tension again.
tensile torque of 3.0 ± 0.4 N⋅m to the balancer
timing belt so the belt is tense without any >>C<< CRANKSHAFT ANGLE SENSING
looseness. Tighten the assembling bolt to the BLADE/CRANKSHAFT CAMSHAFT
specified torque in this state. Then, fix the DRIVE SPROCKET/CRANKSHAFT
balancer timing belt tensioner. PULLEY WASHER/CRANKSHAFT
Tightening torque: 19 ± 3 N⋅m PULLEY CENTRE BOLT INSTALLATION
: Clean
: Clean and degrease
Balancershaft : Apply engine oil
sprocket

Crankshaft pulley
centre bolt
Crankshaft angle
sensing blade
Timing Crankshaft
mark pulley washer
Timing
mark

Crankshaft
balancershaft Crankshaft camshaft Crankshaft
drive sprocket drive sprocket
Engine front
AC301402AC AC301347AB

2. Turn the crankshaft clockwise two turns to set 1. Clean or degrease the crankshaft, the crankshaft
No.1 cylinder to TDC of its compression stroke angle sensing blade, the crankshaft camshaft
and check that sprocket timing marks are aligned. drive sprocket and crankshaft pulley washer as
shown.
NOTE: Also clean the degreased surfaces.
 ENGINE MECHANICAL <4G69>
TIMING BELT
11E-41
2. Install the crankshaft angle sensing blade and (1) Slowly compress the timing belt tensioner
crankshaft camshaft drive sprocket in the direction adjuster rod using a press or vice, then align
shown. the set hole A of the rod with set hole B of the
3. Place the larger chamfer side of the crankshaft timing belt tensioner adjuster cylinder.
pulley washer in the direction shown in the Figure
and then assemble on the crankshaft pulley Wire or pin
centre bolt.
4. Apply a small of engine oil to the crankshaft pulley
centre bolt bearing surface and screw.

Crankshaft
camshaft MB991385
drive
sprocket
AC302025AB

(2) Insert a wire or pin in the set hole aligned.

MB991367 NOTE: When replacing the timing belt ten-
sioner adjuster with new parts, the timing belt
tensioner adjuster is set with a pin.
AC102332AB
2. Install the timing belt tensioner adjuster to the
5. Use the following special tool as during removal to engine and then tighten the mounting bolt to the
hold the crankshaft camshaft drive sprocket. specified torque. Do not remove the wire or pin
• Special spanner (MB991367) until the tension of the valve timing belt is
• Pin (MB991385) adjusted.
6. Tighten the crankshaft pulley centre bolt to the Tightening torque: 23 ± 3 N⋅m
specified torque.
>>E<< TIMING BELT TENSIONER
Tightening torque: 167 N⋅m
PULLEY INSTALLATION
>>D<< TIMING BELT TENSIONER
ADJUSTER INSTALLATION
1. Set according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
CAUTION
If the compression is too fast the procedure may Timing belt tensioner
damage the rod. Make a point to slowly and thor- pulley hole
oughly compress. AC102336AB

Temporarily tighten the timing belt tensioner pulley

A B
as shown.

AC302024 AB
11E-42 ENGINE MECHANICAL <4G69>
TIMING BELT

>>F<< VALVE TIMING BELT

INSTALLATION Camshaft
sprocket

Timing mark

Timing belt
tensioner Belt tension
pulley side

Camshaft
sprocket
Timing belt
Idler pulley
Timing mark

Engine oil pump

Timing mark Crankshaft sprocket
camshaft
Engine oil pump drive sprocket AC301372AC
Crankshaft sprocket
camshaft
3. Incorporate the valve timing belt in the following
drive sprocket AC301374AB manner so that the tensile force of the belt is not
lax.
1. Align the timing marks on the camshaft sprocket,
crankshaft camshaft drive sprocket and engine oil (1) Place the valve timing belt on the timing belt
pump sprocket. tensioner pulley and crankshaft camshaft
driver sprocket and then support it with your
Bolt left hand so it does not slide.
Balancershaft
(2) Place the valve timing belt on the engine oil
pump sprocket while pulling it with the right
hand.
(3) Place the valve timing belt on the timing belt
idler pulley.
CAUTION
Plug Incorporate the valve timing belt. Then apply
Cylinder block
AC301871AB
reverse rotation (anti-clockwise rotation) pres-
sure to the camshaft sprocket. Re-check to see
2. Adjust the timing mark of the engine oil pump that each timing mark is aligned while the ten-
sprocket. Unplug the cylinder block plug. Insert a sion side of the belt is right.
bolt (M6, section width 10 mm, nominal length 45 (4) Place the valve timing belt on the camshaft
mm) from the plug hole. If the bolt comes in sprocket.
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 MD998767
remove the bolt until the valve timing belt is
assembled.

AC301858 AB
 ENGINE MECHANICAL <4G69>
TIMING BELT
11E-43
4. Turn the timing belt tensioner pulley in the >>G<< VALVE TIMING BELT TENSION
direction shown in the figure using special tool ADJUSTMENT
tensioner wrench (MD998767) to apply tension to
the valve timing belt. Then temporarily tighten and
fix the timing belt tensioner pulley mounting bolt. MD998738

Timing mark

Timing belt
under cover
AC301452AB

Camshaft 1. Set special tool adjusting bolt (MD998738) used

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

Camshaft
sprocket
Plug
Cylinder block
AC301871AB
Timing mark
6. Remove the bolt inserted in Step 2 above, then
assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque. Timing mark
Tightening torque: 30 ± 3 N⋅m Engine oil pump
8. Adjust the valve timing belt tension. Crankshaft sprocket
camshaft
drive sprocket AC301372AB

4. Turn the crankshaft in the clockwise direction,

align each timing mark to set No.1 cylinder to TDC
of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.
11E-44 ENGINE MECHANICAL <4G69>
TIMING BELT

CAUTION 9. Rotate crankshaft clockwise two turns, and leave

When tightening the mounting bolt, ensure that it for about 15 minutes.
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt. Wire or pin

MD998767

AC301857AB

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

ensure that it can be pulled out with a light load.
AC301859 AB
When wire or pin can be lightly removed,
6. With special tool tensioner wrench (MD998767) appropriate tension is applied on timing belt. In
and torque wrench, apply tension torque 3.5 N⋅m this case, remove wire or pin.
to the valve timing belt, and tighten the timing belt
tensioner pulley mounting bolt to the specified
torque.
Tightening torque: 48 ± 5 N⋅m A

Rod
Wire or pin

AC301375AB

Also the projection of timing belt tensioner

adjuster rod (A) is within the standard value,
appropriate tension is applied.
AC301857AB
Standard value (A): 3.8 − 4.5 mm
7. Remove wire or pin inserted to timing belt 11.If wire or pin cannot be easily pulled out, repeat
tensioner adjuster. Step 1 through Step 9 to reach proper valve timing
belt tension.

MD998738

Timing belt
under cover
AC301452AB

8. Remove special tool adjusting bolt (MD998738),

and install the rubber plug to the timing belt under
cover.
 ENGINE MECHANICAL <4G69>
TIMING BELT
11E-45
CAUTION 98 – 196 N
Always check the tightening torque of the crank-
shaft pulley centre bolt when turning the crank- Movement
A B
shaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose.
Rod

Timing mark

AC301376AB

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
Camshaft
sprocket measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
Timing mark
B: Length when it is pressed
A − B: Movement
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.
Timing mark

Engine oil pump BALANCER TIMING BELT TENSION

Crankshaft sprocket
camshaft
CHECK
drive sprocket Check the balancer timing belt tension in the follow-
AC301866AB
ing procedures.
12.Check again that the timing marks on sprockets
are aligned.
Approximately 100 N
INSPECTION
M1112004400460

TIMING BELT TENSIONER ADJUSTER

CHECK Deflection

1. Check for oil leak from seal, and replace it if leak

is detected.
2. Check for wear or damage at the top of the rod. AC301405AB

Replace it, if required.

1. Apply a pressure of approximately 100 N at the
centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the
flexure is within the standard value.
Standard value: 5 − 10 mm
2. If not within the standard value, adjust the belt
tension. (Refer to P.11E-36).
11E-46 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001002191

<M/T>
CAUTION
• When the engine assembly replacement is performed, use the M.U.T.-II/III to initialise the learning
value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for Learning
Value in MPI Engine P.00-21).
• *: 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.51-31). Exhaust Pipe and Main Muffler P.15-25).
• Fuel Line Pressure Reduction [Refer to GROUP 13C, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Disconnec- Radiator P.14-35).
tion (How to Reduce Pressurized Fuel Lines) P.13C-428]. • Accelerator Cable Installation (Refer to GROUP 17,
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Accelerator Cable and Pedal P.17-7).
Service − Engine Oil Replacement P.12-4). • Battery and Battery Tray Installation
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
Service − Engine Coolant Replacement P.14-17). P.15-8).
• Transmission Oil Draining (Refer to GROUP 22A, • Hood Installation (Refer to GROUP 42, Hood P.42-4).
On-vehicle Service − Transmission Oil Replacement • Transfer Oil Refilling (Refer to GROUP 22A, On-vehicle
P.22A-8). Service − Transfer Oil Replacement P.22A-8).
• Transfer Oil Draining (Refer to GROUP 22A, On-vehicle • Transmission Oil Refilling (Refer to GROUP 22A,
Service − Transfer Oil Replacement P.22A-8). On-vehicle Service − Transmission Oil Replacement
• Hood Removal (Refer to GROUP 42, Hood P.42-4). P.22A-8).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
P.15-8). Service − Engine Coolant Replacement P.14-17).
• Battery and Battery Tray Removal • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Accelerator Cable Removal (Refer to GROUP 17, Accel- Service − Engine Oil Replacement P.12-4).
erator Cable and Pedal P.17-7). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Radiator Assembly Removal (Refer to GROUP 14, Radia- On-vehicle Service − Accelerator Cable Check and
tor P.14-35). Adjustment P.17-6).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Fuel Leak Check
Exhaust Pipe and Main Muffler P.15-25). • Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-5).
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11E-47

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
11E-48 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

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 mounting insulator
10. Heater water hoses connection <<G>> >>A<< 15. Engine assembly
<<D>> >>E<< 11. Fuel high-pressure hose
connection
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11E-49
<A/T>
CAUTION
• When the engine assembly replacement is performed, use the M.U.T.-II/III to initialise the learning
value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for Learning
Value in MPI Engine P.00-21).
• *: 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.51-31). Exhaust Pipe and Main Muffler P.15-25).
• Fuel Line Pressure Reduction [Refer to GROUP 13C, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Disconnec- Radiator P.14-35).
tion (How to Reduce Pressurized Fuel Lines) P.13C-428]. • Accelerator Cable Installation (Refer to GROUP 17,
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Accelerator Cable and Pedal P.17-7).
Service − Engine Oil Replacement P.12-4). • Battery and Battery Tray Installation
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
Service − Engine Coolant Replacement P.14-17). P.15-8).
• Transmission Fluid Draining (Refer to GROUP 23A, • Hood Installation (Refer to GROUP 42, Hood P.42-4).
On-vehicle Service − Automatic Transmission Fluid • Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle
Change P.23A-124). Service − Transfer Oil Replacement P.23A-128).
• Transfer Oil Draining (Refer to GROUP 23A, On-vehicle • Transmission Fluid Refilling (Refer to GROUP 23A,
Service − Transfer Oil Replacement P.23A-128). On-vehicle Service − Automatic Transmission Fluid
• Hood Removal (Refer to GROUP 42, Hood P.42-4). Change P.23A-124).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
P.15-8). Service − Engine Coolant Replacement P.14-17).
• Battery and Battery Tray Removal • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Accelerator Cable Removal (Refer to GROUP 17, Accel- Service − Engine Oil Replacement P.12-4).
erator Cable and Pedal P.17-7). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Radiator Assembly Removal (Refer to GROUP 14, Radia- On-vehicle Service − Accelerator Cable Check and
tor P.14-35). Adjustment P.17-6).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Fuel Leak Check
Exhaust Pipe and Main Muffler P.15-25). • Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-5).
11E-50 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

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
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11E-51

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 mounting insulator
8. Heater water hoses connection <<G>> >>A<< 13. Engine assembly
<<D>> >>E<< 9. Fuel high-pressure hose
connection
11E-52 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

REMOVAL SERVICE POINTS <<C>> A/C COMPRESSOR AND CLUTCH

<<A>> DRIVE BELT REMOVAL ASSEMBLY REMOVAL
The following operations will be needed due to the With the hose installed, remove the A/C compressor
introduction of the serpentine drive system with the and clutch assembly from the bracket.
drive belt auto-tensioner. NOTE: After removing the A/C compressor and
AC301703 clutch assembly, secure it with a cord in the location
Auto-tensioner
where the removal and installation of the engine
assembly cannot be hindered.

<<D>> FUEL HIGH-PRESSURE HOSE

Hole B REMOVAL

Hole A
AC301704AB

1. Securely insert the spindle handle or ratchet

handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner. Stopper
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
AC304581AB
CAUTION
To reuse the drive belt, draw an arrow indicating 1. Remove the fuel high-pressure hose stopper.
the rotating direction (clockwise) on the back of
the belt using chalk, etc.

Auto-tensioner

L-shaped Retainer
hexagon AC304582AB
wrench AC301705AB
2. Remove the fuel high-pressure hose in the
3. Insert an L-shaped hexagon wrench, etc. into the direction shown in the figure while the retainer is
hole to fix and then remove the drive belt. pulled up.
NOTE: If the retainer is released, install it after
<<B>> POWER STEERING OIL PUMP removing the fuel high-pressure hose.
AND BRACKET ASSEMBLY REMOVAL
With the hose installed, remove the power steering
oil pump and bracket assembly from the engine
assembly.
NOTE: After removing the power steering oil pump
and bracket assembly, secure it with a cord in the
location where the removal and installation of the
engine assembly cannot be hindered.
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11E-53
<<E>> TRANSMISSION ASSEMBLY (1) <Special tool engine hanger (MB991895) is
REMOVAL used>
Remove special tool MB991895.
MB991928

MB991527

AC300950AB MB991454
AC211405AB
1. Pre-tighten the 2 bolts on the car to assemble the
(2) <Special tool engine hanger (MB991928) is
radiator support upper insulator to set special tool
used>
engine hanger MB991895 or engine hanger
MB991928. Remove special tool MB991928.

CAUTION
MB991454
AC300897
MB991527

Engine front
Flywheel
assembly
Flywheel
bolt AC107632 AB

AC308604 AB 3. Hold the engine assembly with a chain block, etc.

M/T: Do not remove the flywheel bolt. If this bolt 4. Place a garage jack against the engine oil pan
is removed, the flywheel assembly will become with a piece of wood in between so that the weight
out of balance and damaged. of the engine assembly is no longer being applied
to the engine mounting insulator.
2. Remove the transmission assembly (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-14, 5. Loosen the engine mounting insulator mounting
A/T: Refer to GROUP 23A, Transmission nuts and bolts, and remove the engine mounting
Assembly P.23A-147). insulator.

<<F>> ENGINE MOUNTING INSULATOR <<G>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring har-
REMOVAL
ness connectors and so on are disconnected from
1. Support the engine with a garage jack. the engine, lift the chain block slowly to remove the
2. Remove the following special tool. engine assembly upward from the engine compart-
MB991895 ment.

MB991527

MB991454
AC107631AB
11E-54 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY

INSTALLATION SERVICE POINTS

MB991928
>>A<< ENGINE ASSEMBLY INSTALLA-
TION

MB991454
MB991527
MB991527

MB991454
AC211405AB

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

used>
AC107632 AB
Set special tool MB991928. (M/T: Refer to
GROUP 22A, Transmission Assembly
Install the engine assembly, being careful not to
P.22A-14, A/T: Refer to GROUP 23A,
pinch the cables, hoses or wiring harness connec-
Transmission Assembly P.23A-147).
tors.

>>C<< SELF-LOCKING NUTS

>>B<< ENGINE MOUNTING INSULATOR
INSTALLATION
INSTALLATION
1. Place a garage jack against the engine oil pan CAUTION
with a piece of wood in between, and install the Do not tighten the self-locking nuts while the
engine mounting insulator while adjusting the engine is hot.
position of the engine. Tighten the self-locking nuts to the specified torque
while the engine is cold.
2. Support the engine assembly with a garage jack.
Tightening torque: 45 ± 5 N⋅m
3. Remove the chain block.
4. Use the following special tool as during removal to
support the engine. >>D<< TRANSMISSION ASSEMBLY
MB991895 INSTALLATION
1. Install the transmission assembly. (M/T: Refer to
MB991527 GROUP 22A, Transmission Assembly P.22A-14,
A/T: Refer to GROUP 23A, Transmission
Assembly P.23A-147).

MB991454
AC107631AB

(1) <Special tool engine hanger (MB991895) is

used>
Set special tool MB991895. (M/T: Refer to
GROUP 22A, Transmission Assembly
P.22A-14, A/T: Refer to GROUP 23A, AC300950AB

Transmission Assembly P.23A-147). 2. Remove from the car the two bolts, to assemble
the radiator support upper insulator.
 ENGINE MECHANICAL <4G69>
ENGINE ASSEMBLY
11E-55
>>E<< FUEL HIGH-PRESSURE HOSE
INSTALLATION
CAUTION
Fuel
high-pressure
3 mm
hose

Fuel line pipe

(Engine oil applied)
AC301864AB

Stopper
AC304583AB

After connecting the fuel high-pressure hose,

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.
NOTES