11A-1

GROUP 11A

CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 11A-2 REMOVAL AND INSTALLATION . . . . . . . . 11A-22

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-24
ENGINE DIAGNOSIS. . . . . . . . . . . . . 11A-2
CRANKSHAFT FRONT OIL SEAL. . . 11A-24
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-3 REMOVAL AND INSTALLATION . . . . . . . . 11A-24

ON VEHICLE SERVICE . . . . . . . . . . . 11A-6 CRANKSHAFT REAR OIL SEAL. . . . 11A-26

DRIVE BELT TENSION CHECK REMOVAL AND INSTALLATION . . . . . . . . 11A-26
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 11A-6
IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-6 CYLINDER HEAD GASKET . . . . . . . . 11A-28
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-7 REMOVAL AND INSTALLATION . . . . . . . . 11A-28
CURB IDLE SPEED CHECK . . . . . . . . . . . 11A-7
COMPRESSION PRESSURE CHECK. . . . 11A-8 TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-32
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-9 REMOVAL AND INSTALLATION . . . . . . . . 11A-32
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A-10
TIMING BELT B . . . . . . . . . . . . . . . . . 11A-36
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-12 REMOVAL AND INSTALLATION . . . . . . . . 11A-36
REMOVAL AND INSTALLATION . . . . . . . . 11A-12
SPECIFICATIONS . . . . . . . . . . . . . . . 11A-40
CAMSHAFT AND CAMSHAFT FASTENER TIGHTENING
OIL SEAL . . . . . . . . . . . . . . . . . . . . . . 11A-19 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 11A-40
REMOVAL AND INSTALLATION . . . . . . . 11A-19 SERVICE SPECIFICATIONS . . . . . . . . . . . 11A-41
SEALANT AND ADHESIVE . . . . . . . . . . . . 11A-41
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-22
11A-2 ENGINE MECHANICAL <2.4L>
GENERAL DESCRIPTION

GENERAL DESCRIPTION
M1111000100099
The 4G64 (2.4L) engine is an in-line four cylinder engine. The cylinder numbers are assigned as 1 − 2 − 3 − 4
from the front of the engine (timing belt side). This engine is fired in the order of the 1, 3, 4 and 2 cylinders.

ITEMS SPECIFICATIONS
Type In-line SOHC
Number of cylinders 4
Bore mm (in) 86.5 (3.41)
Stroke mm (in) 100.0 (3.94)
Piston displacement cm3 (cu in) 2,351 (143.4)
Compression ratio 9.0
Firing order 1−3−4−2
Counterbalance shaft Equipped
Valve timing Intake valve Opens (BTDC) 16°
Closes (ABDC) 60° <M/T>
53° <A/T>
Exhaust valve Opens (BBDC) 60° <M/T>
50° <A/T>
Closes (ATDC) 16°
Lubrication Pressure feed-full flow filtration
Oil pump type Involute gear type

ENGINE DIAGNOSIS
M1111000700109

SYMPTOMS PROBABLE CAUSE REMEDY

Compression is too Blown cylinder head gasket Replace the gasket
low Worn or damaged piston rings Replace the rings
Worn piston or cylinder Repair or replace the piston and/or the
cylinder block
Worn or damaged valve seat Repair or replace the valve and/or the
seat ring
Drop in oil pressure Engine oil level is too low Check the engine oil level
Malfunction of oil pressure switch Replace the oil pressure switch
Clogged oil filter Install a new filter
Worn oil pump gears or cover Replace the gears and/or the cover
Thin or diluted engine oil Change the engine oil to correct viscosity
Stuck (opened) oil relief valve Repair the relief valve
Excessive bearing clearance Replace the bearings
Oil pressure too high stuck (closed) oil relief valve Repair the relief valve

TSB Revision
 ENGINE MECHANICAL <2.4L>
SPECIAL TOOLS
11A-3
SYMPTOMS PROBABLE CAUSE REMEDY
Noisy valves Malfunction of lash adjuster (including Check the lash adjuster
entry of air into high pressure chamber)
Thin or diluted engine oil (low oil Change the engine oil
pressure)
Worn or damaged valve stem or valve Replace the valve and/or the guide
guide
Connecting rod noise/ Insufficient oil supply Check the engine oil level
main bearing noise Low oil pressure Refer to oil pressure drop symptoms
above
Thin or diluted engine oil Change the engine oil
Excessive bearing clearance Replace the bearings

SPECIAL TOOLS
M1111000600317

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991502 MB991496-OD • Ignition timing check
Scan tool (MUT-II) • Idle speed check

B991502

MB991453 MZ203827-01 When an engine lifer is

Engine hanger used: Supporting the
attachment set engine assembly during
removal and installation of
B991453
the transaxle

GENERAL SERVICE MZ203827-01

TOOL
MZ203827
Engine lifter
MZ203827

MB991454 MZ203827-01 When the engine hanger is

Engine hanger balancer used: Supporting the
engine assembly during
removal and installation of
B991454
the transaxle
NOTE: Special tool
MB991895 − MB991454 is a part of
Engine hanger engine hanger attachment
set MB991453.

MB991895

TSB Revision
11A-4 ENGINE MECHANICAL <2.4L>
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB990767 MB990767-01 Holding the camshaft
End yoke holder sprocket when loosening
and tightening bolt

B990767

MD998719 MT308239
Crankshaft pulley holder
pin

D998719

MD998443 MD998443-01 Supporting of the auto-lash

Lash adjuster holder (8) adjuster to prevent it from
falling when rocker shaft
assembly is removed or
installed
D998443

MD998713 MD998713-01 Camshaft oil seal

Camshaft oil seal installer installation

D998713

MD998727 MD998727-01 Oil pan removal

Oil pan remover

D998727

MB991367 MB991367-01 Holding the crankshaft

Special spanner sprocket

B991367

MD998375 MD998375-01 Crankshaft front oil seal

Crankshaft oil seal installation
installer

MD998781 General service tool Flywheel <M/T> or drive

Flywheel stopper plate <A/T> supporting

D998781

TSB Revision
 ENGINE MECHANICAL <2.4L>
SPECIAL TOOLS
11A-5
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MD998776 MD998776-01 Crankshaft rear oil seal
Crankshaft rear oil seal installation
installer

D998776

MB990938 MB990938-01
Handle

B990938

MB991654 General service tool Removal and installation of

Cylinder head bolt cylinder head bolt
wrench (12)

B991654

MD998738 General service tool • Holding the auto-

Adjusting screw tensioner
• Timing belt tension
adjustment
D998738

MD998767 MD998752-01 Timing belt tension

Tensioner pulley socket adjustment
wrench

D998767

TSB Revision
11A-6 ENGINE MECHANICAL <2.4L>
ON VEHICLE SERVICE

ON VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
M1111003100106
Refer to GROUP 00, Maintenance Service − Drive Belts
(Check Condition) P.00-44.

IGNITION TIMING CHECK

M1111001700061

Required Special Tool:

MB991502: Scan Tool (MUT-II)
1. Before inspection, set vehicles in the following condition:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights and all accessories: OFF
• Transaxle: Neutral (P range on vehicles with A/T)
CAUTION
To prevent damage to scan tool MB991502, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991502.
2. Connect scan tool MB991502 to the data link connector.
3. Set up a timing light.
4. Start the engine and run it at idle.
16 PIN 5. Check that the idle speed is approximately 700 r/min.
6. Select scan tool MB991502 actuator test "item number 17."
MB991502
AKX01177AB 7. Check that basic ignition timing is within the standard value.
Standard value: 5° BTDC ± 3°
8. If the basic ignition timing is not within the standard value,
check the following items:
• Diagnosis output
• Timing belt cover and crankshaft position sensor installation
conditions
• Crankshaft sensing blade condition
CAUTION
If the actuator test is not canceled, the forced drive will
continue for 27 minutes. Driving in this state could lead to
engine failure.
9. Press the clear key on scan tool MB991502 (select forced
drive stop mode), and cancel the actuator test.
10.Check that the actual ignition timing is at the standard value.
Standard value: Approximately 10° BTDC
NOTE: Ignition timing fluctuates about ± 7° Before Top Dead
Center, even under normal operating condition.
NOTE: It is automatically further advanced by about 5° to
10° Before Top Dead Center at higher altitudes.

TSB Revision
 ENGINE MECHANICAL <2.4L>
ON VEHICLE SERVICE
11A-7
IDLE MIXTURE CHECK
M1111002100062

Required Special Tool:

MB991502: Scan Tool (MUT-II)
1. Before inspection, set vehicles in the following condition:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights and all accessories: OFF
• Transaxle: Neutral (P range on vehicles with A/T)
CAUTION
To prevent damage to scan tool MB991502, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991502.
2. Connect scan tool MB991502 to the data link connector.
3. Check that the basic ignition timing is within the standard
value.
16 PIN
Standard value: 5° BTDC ± 3°
4. Start the engine and increase the engine speed to 2,500 r/
MB991502
AKX01177AB
min for 2 minutes.
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value:
CO contents: 0.5 % or less
HC contents: 100 ppm or less
7. If the CO and HC contents do not remain inside the standard
value, check the following items:
NOTE: Replace the catalytic converter when the CO and HC
contents do not remain inside the standard value, even
though the result of the inspection is normal for all items.
• Diagnosis output
• Closed-loop control (When the closed-loop control is carried
out normally, the output signal of the heated oxygen sensor
changes between 0 − 400 mV and 600 − 1,000 mV at idle.)
• Fuel pressures
• Injector
• Ignition coil, spark plug cable, spark plug
• EGR system and EGR valve leak
• Evaporative emission control system
• Compression pressure

CURB IDLE SPEED CHECK

M1111003500245

Required Special Tool:

• MB991502: Scan Tool (MUT-II)
1. Before inspection and adjustment set vehicles in the
following condition.
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights and all accessories: OFF
• Transaxle: Neutral (P range on vehicles with A/T)

TSB Revision
11A-8 ENGINE MECHANICAL <2.4L>
ON VEHICLE SERVICE

CAUTION
To prevent damage to scan tool MB991502, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991502.
2. Connect scan tool MB991502 to the data link connector.
3. Check the basic ignition timing.
Standard value: 5° BTDC ± 3°
16 PIN 4. Start the engine.
MB991502
5. Run the engine at idle for 2 minutes.
AKX01177AB 6. Check the idle speed. Select item number 22 and take a
reading of the idle speed.
Curb idle speed: 700 ± 100 r/min
NOTE: The idle speed is controlled automatically by the idle
air control system.
7. If the idle speed is outside the standard value, refer to
GROUP 13A, Diagnosis − Symptom Chart P.13A-25.

COMPRESSION PRESSURE CHECK

M1111002600238
1. Before inspection, check that the engine oil, starter and
battery are normal. Also, set the vehicle in the following
condition:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Lights, and all accessories: OFF
• Transaxle: Neutral (P range on vehicles with A/T)
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crankshaft position sensor connector.
NOTE: Doing this will prevent the engine control module
from carrying out ignition and fuel injection.
WARNING
Keep your distance from the spark plug hole when
cranking. Oil, fuel, etc., may spray out from the spark
plug hole and may cause serious injury.
5. Cover the spark plug hole with a shop towel etc., during
cranking. After the engine has been cranked, check for
foreign material adhering to the shop towel.
6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
COMPRESSION
measure the compression pressure.
GAUGE Standard value (at engine speed of 250 − 400 r/min):
1,275 kPa (185 psi)
Minimum limit (at engine speed of 250 − 400 r/min):
959 kPa (139 psi)
8. Measure the compression pressure for all the cylinders, and
AKX01178 AB check that the pressure differences of the cylinders are
below the limit.
Limit: 98 kPa (14 psi)

TSB Revision
 ENGINE MECHANICAL <2.4L>
ON VEHICLE SERVICE
11A-9
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount of
engine oil through the spark plug hole, and repeat the
operations in steps 6 to 8.
(1) If the compression increases after oil is added, the cause
of the malfunction is a worn or damaged piston ring and/
or cylinder inner surface.
(2) If the compression does not rise after oil is added, the
cause is a burnt or defective valve seat, or pressure is
leaking from the gasket.
10.Connect the crankshaft position sensor connector.
11.Install the spark plugs and spark plug cables.
12.Use the scan tool to erase the diagnostic trouble codes.
NOTE: This will erase the diagnostic trouble code resulting
from the crankshaft position sensor connector being discon-
nected.

MANIFOLD VACUUM CHECK

M1111002700235
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 − 95°C (176 −
VACUUM GAUGE
203°F).
2. Connect a tachometer.
3. Attach a tee-fitting union to the vacuum hose between the
fuel pressure regulator and the intake manifold plenum, and
connect a vacuum gauge.
4. Start the engine and check that idle speed is within
specification. Then check the vacuum gauge reading.
AKX01179AB
Idle speed: 700 ± 100 r/min
Minimum limit: 60 kPa (18 in Hg)

TSB Revision
11A-10 ENGINE MECHANICAL <2.4L>
ON VEHICLE SERVICE

LASH ADJUSTER CHECK

M1111002900121
If an abnormal noise (chattering noise) suspected to be caused
by malfunction of the lash adjuster is produced immediately
after starting the engine and does not disappear, perform the
following check.
NOTE: An abnormal noise due to malfunction of the lash
adjuster is produced immediately after starting the engine and
changes with the engine speed, irrespective of the engine load.
If, the abnormal noise is not produced immediately after start-
ing the engine or does not change with the engine speed, or it
changes with the engine load, the lash adjuster is not the cause
for the abnormal noise.
NOTE: When the lash adjuster is malfunctioning, the abnormal
noise is rarely eliminated by continuing the warming-up of the
engine at idle speed.
However, the abnormal noise may disappear only when seizure
is caused by oil sludge in the engine whose oil is not main-
tained properly.
1. Start the engine.
2. Check if the abnormal noise produced immediately after
starting the engine, changes with the change in the engine
speed.
If the abnormal noise is not produced immediately after
starting the engine or it does not change with the engine
speed, the lash adjuster is not the cause for the noise.
Therefore, investigate other causes. The abnormal noise is
probably caused by some other parts than the engine proper
if it does not change with the engine speed. (In this case, the
lash adjuster is in good condition.)
3. With the engine idling, change the engine load (shift from N
to D range, for example) to make sure that there is no
change in the level of abnormal noise.
If there is a change in the level of abnormal noise, suspect a
tapping noise due to worn crankshaft bearing or connecting
rod bearing. (In this case, the lash adjuster is in good
condition.)
4. After completion of warm-up, run the engine at idle to check
for abnormal noise.
If the noise is reduced or disappears, clean the lash adjuster
(Refer to GROUP 11B-Engine overhaul − Rocker Arms and
Camshaft − Inspection P.11B-27.) As it is suspected that the
noise is due to seizure of the lash adjuster. If there is no
change in the level of the abnormal noise, proceed to step 5.
5. Run the engine to bleed the lash adjuster system. (Refer to.)
6. If the abnormal noise does not disappear after air bleeding
operation, clean the lash adjuster (Refer to GROUP 11B-
Engine overhaul − Rocker Arms and Camshaft − Inspection
P.11B-27.)
.

TSB Revision
 ENGINE MECHANICAL <2.4L>
ON VEHICLE SERVICE
11A-11
Bleeding lash adjuster system
NOTE: Parking the vehicle on a grade for a long time may
decrease oil in the lash adjuster, causing air to enter the high
pressure chamber when starting the engine.
NOTE: After parking for many hours, oil may run out from the
oil passage and take time before oil is supplied to the lash
adjuster, causing air to enter the high pressure chamber.
NOTE: In the above cases, abnormal noise can be eliminated
by bleeding the lash adjuster system.
1. Check engine oil and add or change oil if required.
NOTE: If the engine oil level is low, air is sucked from the oil
screen, causing air to enter the oil passage.
NOTE: If the engine oil level is higher than specification, oil
GOOD
may be stirred by the crankshaft, causing oil to be mixed
with a large quantity of air.
MAXIMUM
NOTE: If oil is deteriorated, air is not easily separated from
oil, increasing the quantity of air contained in oil.
MINIMUM
AKX00328AB

NOTE: If air mixed with oil enters the high pressure chamber
inside the lash adjuster from the above causes, air in the
high pressure chamber is compressed excessively while the
HIGH- valve is opened, resulting in an abnormal noise when the
PRESSURE valve closes.
CHAMBER
This is the same phenomenon as that observed when the
valve clearance has become excessive. The lash adjuster
can resume normal function when air entered the lash
adjuster is removed.
AKX00329AB 2. Idle the engine for one to three minutes to warm it up.

AIR BLEEDING OPERATION PATTERN 3. Repeat the operation pattern, shown in left figure, at no load
OPEN THROTTLE CLOSE to check for abnormal noise. (Usually the abnormal noise is
THROTTLE VALVE
VALVE GRADUALLY eliminated after repetition of the operation 10 to 30 times. If,
APPROXI- however, no change is observed in the level of abnormal
MATELY noise after repeating the operation more than 30 times,
3,000 r/min
suspect that the abnormal noise is due to some other
IDLING 15 s 15 s factors.)
OPERATION
4. After elimination of abnormal noise, repeat the operation
ONCE shown in left figure five more times.
AKX00330 AB 5. Run the engine at idle for one to three minutes to make sure
that the abnormal noise has been eliminated.

TSB Revision
11A-12 ENGINE MECHANICAL <2.4L>
ENGINE ASSEMBLY

ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001000407

CAUTION
*: Indicates parts which should be temporarily tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal Operation Post-installation Operation
• Hood Removal (Refer to GROUP 42, Hood P.42-7.) • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Fuel Line Pressure Reduction [Refer to GROUP 13A, On- Exhaust Pipe and Main Muffler P.15-21.)
vehicle Service − Fuel Pump Relay Disconnection (How • Reserve Tank and Radiator Installation (Refer to GROUP
to Reduce Pressurized Fuel Lines) P.13A-580.] 14, Radiator P.14-21.)
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser- • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
vice − Engine Oil Replacement P.12-3.) P.15-6.)
• Engine Coolant Draining [Refer to GROUP 00, Mainte- • Strut Tower Bar Installation (Refer to GROUP 42, Strut
nance Service − Engine Coolant (Change) P.00-56.] Tower Bar P.42-11.)
• Strut Tower Bar Removal (Refer to GROUP42, Strut • Drive Belt Tension Adjustment [Refer to GROUP 00,
Tower Bar P.42-11.) Maintenance Service − Drive Belts (Check Condition)
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.00-44.]
P.15-6.) • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-
• Reserve Tank and Radiator Removal (Refer to GROUP vice − Engine Oil Replacement P.12-3.)
14, Radiator P.14-21.) • Engine Coolant Refilling [Refer to GROUP 00, Mainte-
• Front Exhaust Pipe Removal (Refer to GROUP 15, nance Service − Engine Coolant (Change) P.00-56.]
Exhaust Pipe and Main Muffler P.15-21.) • Accelerator Cable Adjustment (Refer to GROUP 17, On-
vehicle Service − Accelerator Cable Check and Adjust-
ment P.17-5.)
• Hood Installation (Refer to GROUP42, Hood P.42-7.)

13
11
1 18

12 10
4.8 ± 1.0 N·m
44 ± 8 in-lb
5 9 FUEL RAIL
14 O-RING
ENGINE OIL
6
5
18 N 8
12 ± 2 N·m
100 ± 22 in-lb
15 7
19 20

16
2

3
17 4 AC106493 AB
REMOVAL STEPS REMOVAL STEPS (Continued)
1. ACCELERATOR CABLE 3. BRAKE BOOSTER VACUUM
CONNECTION HOSE CONNECTION
2. PURGE HOSE CONNECTION 4. VACUUM HOSE CONNECTION

TSB Revision
 ENGINE MECHANICAL <2.4L>
ENGINE ASSEMBLY
11A-13
REMOVAL STEPS (Continued) REMOVAL STEPS (Continued)
5. IGNITION COIL CONNECTOR 14. ENGINE COOLANT
6. INJECTOR CONNECTOR TEMPERATURE GAUGE UNIT
7. MANIFOLD DIFFERENTIAL CONNECTOR
PRESSURE SENSOR 15. IDLE AIR CONTROL MOTOR
CONNECTOR CONNECTOR
8. THROTTLE POSITION SENSOR 16. EVAPORATIVE EMISSION
CONNECTOR PURGE SOLENOID VALVE
9. HEATED OXYGEN SENSOR CONNECTOR
CONNECTOR 17. EGR SOLENOID VALVE
10. CAPACITOR CONNECTOR CONNECTOR
11. ENGINE COOLANT >>D<< 18. HIGH-PRESSURE FUEL HOSE
TEMPERATURE SENSOR CONNECTION
CONNECTOR 19. FUEL RETURN HOSE
12. CAMSHAFT POSITION CONNECTION
SENSOR CONNECTOR 20. PRESSURE HOSE
13. KNOCK SENSOR CONNECTOR CONNECTION

29 49 ± 10 N·m
29 ± 3 N·m 36 ± 7 ft-lb
21 ± 3 ft-lb
35 28
29 ± 3 N·m
21 ± 3 ft-lb

11 ± 1 N·m
96 ± 8 in-lb
23
30 31 49 ± 10 N·m
36 ± 7 ft-lb

25 32
14 ± 1 N·m
117 ± 13 in-lb 22
12 ± 2 N·m 24
100 ± 22 in-lb
86 ± 12 N·m
21 64 ± 8 ft-lb

34 34
27
(ENGINE OIL) 26

33

81 ± 12 N·m*
60 ± 9 ft-lb* AC001694 AD

21. OIL DIPSTICK AND DIPSTICK 23. HEATER HOSE CONNECTION

GUIDE 24. GENERATOR CONNECTOR
22. PRESSURE HOSE CONNECTION

TSB Revision
11A-14 ENGINE MECHANICAL <2.4L>
ENGINE ASSEMBLY

25. OIL PRESSURE SWITCH <<A>> 30. POWER STEERING OIL PUMP
CONNECTOR AND BRACKET ASSEMBLY
26. DRIVE BELT (POWER STEERING 31. A/C COMPRESSOR ASSEMBLY
OIL PUMP AND A/C CONNECTOR
COMPRESSOR) <<B>> 32. A/C COMPRESSOR
27. DRIVE BELT (GENERATOR) <<C>> • TRANSAXLE ASSEMBLY
28. CRANKSHAFT POSITION SENSOR <<D>> >>C<< 33. ENGINE MOUNT BRACKET
CONNECTOR >>B<< 34. ENGINE MOUNT STOPPER
29. POWER STEERING PRESSURE <<E>> >>A<< 35. ENGINE ASSEMBLY
SWITCH CONNECTOR

Required Special Tools:

• MB991453: Engine Hanger Assembly
• MZ203827: Engine Lifter
• MB991454: Engine hanger balancer (MB991453, part of the engine hanger attachment set)
• MB991895: Engine Hanger

REMOVAL SERVICE POINTS

.

<<A>> POWER STEERING OIL PUMP AND BRACKET

ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE: Place the removed power steering oil pump in a place
where it will not be a hindrance when removing and installing
the engine assembly, and secure it with a cord or wire.
.

<<B>> A/C COMPRESSOR REMOVAL

Remove the compressor from the compressor bracket with the
hose still attached.
NOTE: Place the removed A/C compressor where it will not be
a hindrance when removing and installing the engine assem-
bly, and secure it with a cord or wire.
.

<<C>> TRANSAXLE ASSEMBLY REMOVAL

CAUTION
<M/T> Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become out
of balance and damaged.
1. <Engine lifter MZ20783827 is used>
Remove the transaxle assembly.
FLYWHEEL
<M/T>: Refer to GROUP 22A, Transaxle Assembly P.22A-
16.
BOLT <A/T>: Refer to GROUP 23A, Transaxle Assembly P.23A-
366.
AC000126 AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
ENGINE ASSEMBLY
11A-15
2. <Engine hanger MB991895 is used>
(1) Loosely fit the two radiator support upper insulator
mounting bolts to the vehicle body.
(2) Remove the transaxle assembly.
<M/T>: Refer to GROUP 22A, Transaxle Assembly
P.22A-16.
<A/T>: Refer to GROUP 23A, Transaxle Assembly
P.23A-366.

AC106166 AB

<<D>> ENGINE MOUNT BRACKET REMOVAL

1. Support the engine with a garage jack.

GARAGE JACK
AC106167AB

2. <Engine lifter MZ2073827 is used>

MZ203827 Remove special tools MB991453 and MZ203827 which was
attached when the transaxle assembly was removed.

MB991453
AC000127 AB

3. <Engine hanger MB991895 is used>

Remove special tools MB991895 which was attached when
the transaxle assembly was removed.

MB991454 MB991895

AC106164 AB

TSB Revision
11A-16 ENGINE MECHANICAL <2.4L>
ENGINE ASSEMBLY

4. Hold the engine assembly with a chain block or similar tool.

MB991454 5. Place a garage jack against the engine oil pan with a piece
of wood in between, jack up the engine so that the weight of
the engine is no longer being applied to the engine mount
bracket, and then remove the engine mount bracket.

AC102341AC

<<E>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
MB991454
slowly to remove the engine assembly upward from the engine
compartment.

AC102341AC

INSTALLATION SERVICE POINTS

.

>>A<< ENGINE ASSEMBLY INSTALLATION

Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
.

>>B<< ENGINE MOUNT STOPPER INSTALLATION

Clamp the engine mount stopper so that the arrow points in the
ENGINE SIDE
ENGINE MOUNT direction as shown in the diagram.
ENGINE MOUNT STOPPER
BRACKET

ARROW AC000128 AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
ENGINE ASSEMBLY
11A-17
>>C<< ENGINE MOUNT BRACKET INSTALLATION
1. Place a garage jack against the engine oil pan with a piece
of wood in between, and install the engine mount bracket
while adjusting the position of the engine.
2. Support the engine with the garage jack.

GARAGE JACK
AC106167AB

3. <Engine lifter MZ2073827 is used>

MB991454
Remove the chain block and support the engine assembly
with special tools MB991453 and MZ203827.

AC102341AC

MZ203827

MB991453
AC000127 AB

TSB Revision
11A-18 ENGINE MECHANICAL <2.4L>
ENGINE ASSEMBLY

4. <Engine hanger MB991895 is used>

MB991454
Remove the chain block and support the engine assembly
with special tools MB991895.

AC102341AC

MB991454 MB991895

AC106164 AB

>>D<< HIGH-PRESSURE FUEL HOSE INSTALLATION

CAUTION
Do not allow any engine oil to enter the fuel rail.
1. Apply a small amount of new engine oil to the O-ring.
2. While turning the high-pressure fuel hose to the right and
FUEL RAIL left, install it to the fuel rail, while being careful not to
damage the O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose and
O-RING check the O-ring for damage. Replace if necessary.
HIGH-PRESSURE 4. Re-insert the fuel rail and confirm the hose turns smoothly.
AC000129 AB
FUEL HOSE

TSB Revision
 ENGINE MECHANICAL <2.4L>
CAMSHAFT AND CAMSHAFT OIL SEAL
11A-19
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
M1112001900314

Pre-removal and Post-installation Operation

• Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner P.15-6.)
• Timing Belt Removal and Installation (Refer to P.11A-32.)

9.8 ± 2.0 N·m

1 Ø 3 mm
87 ± 17 in-lb
(0.1 in)
6 1
3
2 8

7 3.4 ± 0.5 N·m

14 ± 1 N·m 31 ± 4 in-lb
117 ± 13 in-lb SEALANT:
21 ± 4 N·m MITUBISHI GENUINE PART
16 ± 3 ft-lb NO.MD970389 OR EQUIVALENT

5 4 12 N 14 LIP
SECTION
8 13
9 31 ± 3 N·m
23 ± 2 ft-lb 11
15 CAM SECTION
AND JOURNAL
SECTION
10

15
N 11 88 ± 10 N·m ENGINE OIL
65 ± 7 ft-lb
AC000130 AD

CAMSHAFT REMOVAL STEPS CAMSHAFT REMOVAL STEPS

1. IGNITION COIL CONNECTOR <<A>> >>C<< 10. CAMSHAFT SPROCKET
2. SPARK PLUG CABLE 12. SPARK PLUG GUIDE OIL SEAL
3. IGNITION COIL <<B>> >>A<< 13. ROCKER ARM AND SHAFT
4. PCV HOSE ASSEMBLY (INTAKE SIDE)
5. BREATHER HOSE <<B>> >>A<< 14. ROCKER ARM AND SHAFT
6. CONTROL HARNESS ASSEMBLY (EXHAUST SIDE)
CONNECTION 15. CAMSHAFT
7. ROCKER COVER CAMSHAFT OIL SEAL
8. CAMSHAFT POSITION SENSOR REMOVAL STEPS
SUPPORT <<A>> >>C<< 10. CAMSHAFT SPROCKET
9. CAMSHAFT POSITION >>B<< 11. CAMSHAFT OIL SEAL
SENSING CYLINDER

Required Special Tools:

• MB990767: End Yoke Holder
• MB998713: Crankshaft Oil Seal Installer
• MD998443: Auto-lash Adjuster Holder
• MD998719: Crankshaft Pulley Holder Pin

TSB Revision
11A-20 ENGINE MECHANICAL <2.4L>
CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL SERVICE POINTS

.

<<A>> CAMSHAFT SPROCKET REMOVAL

1. Use special tools MB990767 and MD998719 to loosen the
camshaft sprocket securing bolt.
MB990767
2. Remove the camshaft sprocket.

MD998715
ACX00301AB

<<B>> ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

1. Install special tool MD998443 as shown in the illustration so
MB998443 that the lash adjusters will not fall out.
CAUTION
Never disassemble the rocker arm and shaft assembly.
2. Loosen the rocker arm and shaft assembly mounting bolt,
and then remove the rocker arm and shaft assembly with the
bolt still attached.

ACX00331AB

INSTALLATION SERVICE POINTS

.

>>A<< ROCKER ARM AND SHAFT ASSEMBLY INSTALLA-

TION
1. Temporarily tighten the rocker shaft with the bolt so that all
rocker arms do not push the valves.
2. Fit the rocker shaft spring from the above and position it so
that it is right angles to the plug guide.
PLUG GUIDE
NOTE: Install the rocker shaft spring before installing the
rocker arm and rocker arm shaft on the exhaust side.
3. Tighten the rocker arm and shaft assembly mounting bolt to
the specified torque.
Tightening torque: 31 ± 3 N⋅m (23 ± 2 ft-lb)
ROCKER SHAFT SPRING
4. Remove special tool MD998443.

ROCKER SHAFT
SPRING PLUG GUIDE

ACX00378AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
CAMSHAFT AND CAMSHAFT OIL SEAL
11A-21
5. Make sure that the notch in the end of the rocker arm shaft
NOTCH is facing the direction shown.

AC000131AB

>>B<< CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the camshaft oil seal lip.
<RIGHT BANK>
2. Use special tool MD998713 to press-fit the camshaft oil
seal.

MD998713
ACX00372 AB

>>C<< CAMSHAFT SPROCKET INSTALLATION

1. Install the camshaft sprocket.
2. Use special tools MB990767 and MD998719 to tighten the
camshaft sprocket securing bolt to the specified torque.
MB990767
Tightening torque: 88 ± 10 N⋅m (65 ± 7 ft-lb)

MD998715
ACX00301AB

TSB Revision
11A-22 ENGINE MECHANICAL <2.4L>
OIL PAN

OIL PAN
REMOVAL AND INSTALLATION
M1112002800280

Pre-removal and Post-installation Operation

• Engine Oil Draining and Refilling (Refer to GROUP 12,
On-vehicle Service − Engine Oil Replacement P.12-3.)
• Oil Dipstick Removal and Installation
• Front Exhaust Pipe Removal and Installation (Refer to
GROUP 15, Exhaust Pipe and Main Muffler P.15-21.)

Ø 4 mm
(0.2 in)

GROOVE
N 2

4 3
39 ± 5 N·m 1
29 ± 4 ft-lb
26 ± 4 N·m
BOLT HOLE 19 ± 3 ft-lb
8.8 ± 1.0 N·m
78 ± 9 in-lb
SEALANT: 6.9 ± 0.9 N·m
MITUBISHI GENUINE PART 61 ± 8 in-lb
NO.MD970389 OR EQUIVALENT
AC000132 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. DRAIN PLUG 3. BELL HOUSING COVER
>>B<< 2. DRAIN PLUG GASKET <<A>> >>A<< 4. OIL PAN

Required Special Tool:

• MD998727: Oil Pan Remover

TSB Revision
 ENGINE MECHANICAL <2.4L>
OIL PAN
11A-23
REMOVAL SERVICE POINT
.

<<A>> OIL PAN REMOVAL

CAUTION
MD998727 MD998727
Perform this slowly to avoid deformation of the oil pan
flange.
After removing the oil pan mounting bolts, remove the oil pan
with special tool MD998727 and a brass bar.

ACX00366 AB

INSTALLATION SERVICE POINTS

.

>>A<< OIL PAN INSTALLATION

CAUTION
After installing the oil pan, wait at least one hour before
starting the engine.
1. Remove sealant from the oil pan and cylinder block mating
surfaces.
2. Degrease the sealant-coated surface and the engine mating
surface.
3. Apply MITSUBISHI GENUINE PART number MD970389 or
equivalent around the gasket surface of the oil pan.
NOTE: The sealant should be applied in a continuous bead
approximately 4 mm (0.2 inch) in diameter.
4. Assemble the oil pan to the cylinder block within 15 minutes
FRONT OF ENGINE
after applying the sealant.
Be careful when installing the oil pan. The bolts indicated in
M6 × 8mm the illustration have different lengths from the other bolts.

AC000133 AB

>>B<< DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction shown in the illus-
tration.

OIL PAN
SIDE

DRAIN PLUG
GASKET
ACX00364 AB

TSB Revision
11A-24 ENGINE MECHANICAL <2.4L>
CRANKSHAFT FRONT OIL SEAL

INSPECTION
M1112002900124
• Check the oil pan for cracks.
• Check the oil pan sealant-coated surface for damage and
deformation.

CRANKSHAFT FRONT OIL SEAL

REMOVAL AND INSTALLATION
M1112003400274

Pre-removal and Post-installation Operation

• Timing Belt Removal and Installation (Refer to P.11A-32.)
• Crankshaft Position Sensor Removal and Installation
(Refer to GROUP 16, Ignition System − Crankshaft Posi-
tion Sensor <2.4L Engine>P.16-55 .)

CRANKSHAFT

N5
3
4 2

1
5 118 – 9 N•m
87 – 7 ft-lb

ENGINE OIL
AC000134 AB
(ENGINE OIL)
REMOVAL STEPS REMOVAL STEPS (Continued)
<<A>> >>B<< 1. CRANKSHAFT SPROCKET >>B<< 3. CRANKSHAFT SPROCKET B
>>B<< 2. CRANKSHAFT SENSING 4. KEY
BLADE >>A<< 5. CRANKSHAFT FRONT OIL
• TIMING BELT B (REFER TO SEAL
P.11A-36.)

Required Special Tools:

• MB991367: Special Spanner
• MB998375: Crankshaft Front Oil Seal Installer

TSB Revision
 ENGINE MECHANICAL <2.4L>
CRANKSHAFT FRONT OIL SEAL
11A-25
REMOVAL SERVICE POINT
.

<<A>> CRANKSHAFT SPROCKET REMOVAL

1. Use the crankshaft pulley mounting bolt to secure special
CRANKSHAFT tool MB991367.
PULLEY
MOUNTING
2. Loosen the crankshaft sprocket mounting bolt, and remove
BOLT the sprocket.
CRANKSHAFT
SPROCKET

MB991367

AC000135AB

INSTALLATION SERVICE POINTS

.

>>A<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply engine oil to the entire inside diameter of the oil seal
FRONT CASE lip.
MB998375 2. Use special tool MD998375 to press-fit the oil seal until it is
flush with the front case.

OIL SEAL
AC000136 AB

>>B<< CRANKSHAFT SPROCKET B/CRANKSHAFT

SENSING BLADE/CRANKSHAFT SPROCKET
INSTALLATION
1. To prevent the crankshaft bolt from loosening, degrease or
CRANKSHAFT
CRANKSHAFT SPROCKET B CRANKSHAFT clean the seating surfaces of the crankshaft, crankshaft
SPROCKET sprocket B, crankshaft sensing blade and crankshaft at the
shown positions.
2. Install the crankshaft sensing blade so that they face as
shown in the illustration.
3. Apply the minimum amount of engine oil to the seat surface
CRANKSHAFT PART: and thread of the crankshaft bolt.
SENSING BLADE CLEANING
SHADED PART: DEGREASE AC004794AB

4. Use the crankshaft pulley mounting bolt to secure special

CRANKSHAFT tool MB991367.
PULLEY
MOUNTING
5. Tighten the crankshaft sprocket bolt to the specified torque.
CRANKSHAFT
BOLT Tightening torque: 118 ± 9 N⋅m (87 ± 7 ft-lb)
SPROCKET

MB991367

AC000135AB

TSB Revision
11A-26 ENGINE MECHANICAL <2.4L>
CRANKSHAFT REAR OIL SEAL

CRANKSHAFT REAR OIL SEAL

REMOVAL AND INSTALLATION
M1112003700275

<M/T>
2 1

132 ± 5 N·m
5 98 ± 3 ft-lb
6 N 6

4
<A/T>
3 1
132 ± 5 N·m
CRANKSHAFT
98 ± 3 ft-lb

ENGINE OIL
5

AC000138 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

• OIL PAN (REFER TO P.11A-22.) <<B>> >>B<< 2. FLYWHEEL <M/T>
<<A>> • TRANSAXLE ASSEMBLY <<B>> >>B<< 3. DRIVE PLATE <A/T>
CLUTCH COVER AND CLUTCH
<<B>> >>B<< 4. ADAPTER PLATE <M/T>
•
DISC <M/T> (REFER TO 5. CRANKSHAFT BUSHING
GROUP 21B, CLUTCH P.21B-2.)
>>A<< 6. CRANKSHAFT REAR OIL SEAL
<<B>> >>B<< 1. ADAPTER PLATE

Required Special Tools:

• MB990938: Handle
• MD998776: Crankshaft Rear Oil Seal Installer
• MD998781: Flywheel Stopper

REMOVAL SERVICE POINTS

.

<<A>> TRANSAXLE ASSEMBLY REMOVAL

CAUTION
<M/T> Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt is removed, the flywheel will become out
of balance and damaged.
<M/T>: Refer to GROUP 22A, Transaxle Assembly P.22A-16.
<A/T>: Refer to GROUP 23A, Transaxle Assembly P.23A-366.
FLYWHEEL

BOLT

AC000126 AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
CRANKSHAFT REAR OIL SEAL
11A-27
<<B>> ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE PLATE
<A/T>/ADAPTER PLATE <M/T> REMOVAL
Use special tool MD998781 to secure the flywheel or drive
MD998781 plate, and remove the bolt.

ACX00296AB

INSTALLATION SERVICE POINTS

.

>>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION

CRANKSHAFT
1. Apply a small amount of engine oil to the entire inside
REAR OIL SEAL diameter of the oil seal lip.
CRANKSHAFT 2. Use special tools MB990938 and MD998776 to tap in the oil
MB990938 seal as shown in the illustration.

MB998776
AC000140 AB

>>B<< ADAPTER PLATE <M/T>/DRIVE PLATE <A/T>/

FLYWHEEL <M/T>/ADAPTER PLATE INSTALLATION
Use special tool MD998781 to hold the flywheel or drive plate
MD998781 in the same manner as removal, and install the bolt.

ACX00296AB

TSB Revision
11A-28 ENGINE MECHANICAL <2.4L>
CYLINDER HEAD GASKET

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
M1112004000354

Pre-removal Operation Post-installation Operation

• Fuel Line Pressure Reduction [Refer to GROUP 13A, On- • Front Exhaust Pipe Installation (Refer to GROUP 15,
vehicle Service − Fuel Pump Relay Disconnection (How Exhaust Pipe and Main Muffler P.15-21.)
to Reduce Pressurized Fuel Lines) P.13A-580.] • Thermostat Case Assembly Installation (Refer to GROUP
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser- 14, Water Hose and Water Pipe P.14-28.)
vice − Engine Oil Replacement P.12-3.) • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining [Refer to GROUP 00, Mainte- P.15-6.)
nance Service − Engine Coolant (Change) P.00-56.] • Strut Tower Bar Installation (Refer to GROUP42, Strut
• Strut Tower Bar Removal (Refer to GROUP42, Strut Tower Bar P.42-11.)
Tower Bar P.42-11.) • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner vice − Engine Oil Replacement P.12-3.)
P.15-6.) • Engine Coolant Refilling [Refer to GROUP 00, Mainte-
• Thermostat Case Assembly Removal (Refer to GROUP nance Service − Engine Coolant (Change) P.00-56.]
14, Water Hose and Water Pipe P.14-28.) • Accelerator Cable Adjustment (Refer to GROUP 17, On-
• Front Exhaust Pipe Removal (Refer to GROUP 15, vehicle Service − Accelerator Cable Check and Adjust-
Exhaust Pipe and Main Muffler P.15-21.) ment P.17-5.)

13
11
1 18

12 10
4.8 ± 1.0 N·m
44 ± 8 in-lb
5 9 FUEL RAIL
14 O-RING
ENGINE OIL
6
5
18 N 8
12 ± 2 N·m
100 ± 22 in-lb
15 7
19 20

16
2

3
17 4 AC106493 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. ACCELERATOR CABLE 7. MANIFOLD DIFFERENTIAL
CONNECTION PRESSURE SENSOR
2. PURGE HOSE CONNECTION CONNECTOR
3. BRAKE BOOSTER VACUUM 8. THROTTLE POSITION SENSOR
HOSE CONNECTION CONNECTOR
4. VACUUM HOSE CONNECTION 9. HEATED OXYGEN SENSOR
5. IGNITION COIL CONNECTOR (FRONT) CONNECTOR
6. INJECTOR CONNECTOR 10. CAPACITOR CONNECTOR

TSB Revision
 ENGINE MECHANICAL <2.4L>
CYLINDER HEAD GASKET
11A-29
REMOVAL STEPS (Continued) REMOVAL STEPS (Continued)
11. ENGINE COOLANT 16. EVAPORATIVE EMISSION
TEMPERATURE SENSOR PURGE SOLENOID VALVE
CONNECTOR CONNECTOR
12. CAMSHAFT POSITION 17. EGR SOLENOID VALVE
SENSOR CONNECTOR CONNECTOR
13. KNOCK SENSOR CONNECTOR >>C<< 18. HIGH-PRESSURE FUEL HOSE
14. ENGINE COOLANT CONNECTION
TEMPERATURE GAUGE UNIT 19. FUEL RETURN HOSE
CONNECTOR CONNECTION
15. IDLE AIR CONTROL MOTOR 20. PRESSURE HOSE
CONNECTOR CONNECTION

9.8 ± 2.0 N·m

87 ± 17 in-lb

24
<COLD ENGINE>
79 ± 4 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
58 ± 3 ft-lb → 0 in-lb → 15 ± 1 ft-lb → +90˚ → +90˚ 23
27 28
(ENGINE OIL) 25
3.4 ± 0.5 N·m
31 ± 4 in-lb
N 29 26

34

12 ± 2 N·m
29 ± 3 N·m
100 ± 22 in-lb
21 ± 3 ft-lb
31
14 ± 1 N·m
49 ± 10 N·m
117± 13 in-lb 22 36 ± 7 ft-lb
35 N

29 ± 3 N·m
21 ± 3 ft-lb
21
N 32 49 ± 10 N·m
36 ± 7 ft-lb

(ENGINE OIL) 35 ± 6 N·m

26 ± 4 ft-lb
33

30 35 ± 6 N·m
26 ± 4 ft-lb
30 ± 2 N·m
23 ± 2 ft-lb
AC001695 AG

TSB Revision
11A-30 ENGINE MECHANICAL <2.4L>
CYLINDER HEAD GASKET

REMOVAL STEPS REMOVAL STEPS (Continued)

21. OIL DIPSTICK AND DIPSTICK 29. SPARK PLUG GUIDE OIL SEAL
GUIDE 30. WATER HOSE CONNECTION
22. PRESSURE HOSE • TIMING BELT (REFER TO
CONNECTION P.11A-32.)
23. SPARK PLUG CABLE 31. POWER STEERING PRESSURE
24. IGNITION COIL SWITCH
25. RADIATOR UPPER HOSE <<A>> 32. POWER STEERING OIL PUMP
CONNECTION AND BRACKET ASSEMBLY
26. PCV HOSE CONNECTION 33. EXHAUST MANIFOLD
27. BREATHER HOSE BRACKET
CONNECTION <<B>> >>B<< 34. CYLINDER HEAD ASSEMBLY
28. ROCKER COVER >>A<< 35. CYLINDER HEAD GASKET

Required Special Tool:

• MB991654: Cylinder Head Bolt Wrench (12)

REMOVAL SERVICE POINTS

.

<<A>> POWER STEERING OIL PUMP AND BRACKET

ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE: Place the removed power steering oil pump in a place
where it will not be a hindrance when removing and installing
the cylinder head assembly, and secure it with a cord or wire.
.

<<B>> CYLINDER HEAD ASSEMBLY REMOVAL

CAUTION
Be careful not to damage or deform the plug guides when
removing the cylinder head bolts. Plug guides cannot be
replaced separately.
Using special tool MB991654, loosen the bolts in two or three
steps in the order of the numbers shown in the illustration, then
remove the cylinder head assembly.

MB991654

INTAKE SIDE FRONT OF

ENGINE

3 5 10 8 2

1 7 9 6 4

EXHAUST SIDE AC000142 AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
CYLINDER HEAD GASKET
11A-31
INSTALLATION SERVICE POINTS
.

>>A<< CYLINDER HEAD GASKET INSTALLATION

1. Wipe off all oil and grease from the gasket mounting
surface.
2. Match the shapes of the cylinder head holes with their
respective cylinder head gasket holes.
.

>>B<< CYLINDER HEAD ASSEMBLY INSTALLATION

1. When installing the cylinder head bolts, the length below the
head of the bolts should be within the limit.
(ENGINE OIL) If it is outside the limit, replace the bolts.
Limit (A): 99.4 mm (3.91 inches)
2. Apply a small amount of engine oil to the thread section and
the washer of the cylinder head bolt.
A

AC000143 AB
CAUTION
• Always tighten cylinder head bolts at a 90 degree angle.
If it is less than 90 degree angle, the bolt will loosen.
• If it is more than 90 degree angle, remove the head bolt
and repeat the procedure from step 1.
3. Using special tool MB991654, tighten the bolts by the
following procedure.

MB991654 STEP OPERATION REMARKS

(1) Tighten to 79 ± 4 Tighten in the order shown in
N⋅m (58 ± 3 ft-lb) the illustration.

FRONT OF
(2) Fully loosen. Tighten in the reverse order of
INTAKE SIDE that shown in the illustration.
ENGINE
(3) Tighten to 20 ± 2 Tighten in the order shown in
8 6 1 3 9 N⋅m (15 ± 1 ft-lb) the illustration.
(4) Tighten 90° of a Tighten in the order shown in
10 4 2 5 7 turn. the illustration. Mark the head
of the cylinder head bolt and
EXHAUST SIDE AC000142AC cylinder head with a paint mark.
(5) Tighten 90° of a Tighten in the order shown in
STEP (4) STEP (5)
turn. the illustration. Check that the
painted mark of the head bolt is
90˚ 90˚
aligned with that of the cylinder
head.

PAINTED MARKS PAINTED MARKS

AC000144 AB

TSB Revision
11A-32 ENGINE MECHANICAL <2.4L>
TIMING BELT

>>C<< HIGH-PRESSURE FUEL HOSE INSTALLATION

CAUTION
Do not allow engine oil to enter the fuel rail.
1. Apply a small amount of new engine oil to the O-ring.
FUEL RAIL 2. While turning the high-pressure fuel hose to the right and
left, install the fuel rail, while being careful not to damage the
O-ring. After installing, check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose and
O-RING check the O-ring for damage.
HIGH-PRESSURE
AC000129 AB 4. Re-insert the fuel rail and confirm the hose turns smoothly.
FUEL HOSE

TIMING BELT
REMOVAL AND INSTALLATION
M1112004300355

Pre-removal Operation Post-installation Operation

• Engine Mount Bracket Removal (Refer to GROUP 32, • Engine Mount Bracket Installation (Refer to GROUP 32,
Engine Mounting P.32-4.) Engine Mounting P.32-4.)
• Drive Belt Tension Adjustment [Refer to GROUP 00,
Maintenance Service − Drive Belts (Check Condition)
P.00-44.]

23 ± 3 N·m 7
17 ± 3 ft-lb
9
5

14 ± 1 N·m
117 ± 13 in-lb 8
3
8.8 ± 1.0 N·m 6 48 ± 6 N·m
78 ± 9 in-lb 36 ± 4 ft-lb
2
11 ± 1 N·m
96 ± 8 in-lb
11 ± 1 N·m 8.8 ± 1.0 N·m
96 ± 8 in-lb 78 ± 9 in-lb
4

25 ± 4 N·m
18 ± 4 ft-lb
AC000145 AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
TIMING BELT
11A-33
REMOVAL STEPS REMOVAL STEPS (Continued)
1. DRIVE BELT (POWER 6. TIMING BELT LOWER COVER
STEERING OIL PUMP AND A/C ASSEMBLY
COMPRESSOR) >>C<< • TIMING BELT TENSION
2. DRIVE BELT (GENERATOR) ADJUSTMENT
3. WATER PUMP PULLEY <<A>> >>B<< 7. TIMING BELT
4. CRANKSHAFT PULLEY 8. TENSIONER PULLEY
5. TIMING BELT UPPER COVER >>A<< 9. AUTO-TENSIONER
ASSEMBLY

Required Special Tools:

• MD998738: Adjusting Screw
• MD998767: Tensioner Wrench

REMOVAL SERVICE POINT

.

<<A>> TIMING BELT REMOVAL

CAUTION
The crankshaft should always be turned in the forward
TIMING MARKS direction only.
1. Turn the crankshaft in the forward direction (to the right) to
align the camshaft sprocket timing marks.

CAMSHAFT
SPROKET
AC000146AB
CAUTION
If the timing belt is to be re-used, use chalk to mark (on its
flat side) an arrow indicating the clockwise direction.
2. Loosen the tension pulley fixing bolt.
3. Move the tension pulley to the water pump side, and then
FIXING BOLT remove the timing belt.

AC000147AB

TSB Revision
11A-34 ENGINE MECHANICAL <2.4L>
TIMING BELT

INSTALLATION SERVICE POINTS

.

>>A<< AUTO-TENSIONER INSTALLATION

98 – 196 N 1. Apply 98 − 196 N (22 − 44 pound) force to the pushrod of the
(22 – 44 lb) auto-tensioner by pressing it against a metal object (such as
the engine block) and measure the movement of the
A B pushrod.
Standard value: Within 1 mm (0.04 inch)
AMOUNT
PUSHED IN A: Length when it is free (not pressed)
B: Length when it is pressed
PUSHROD A − B: Movement
AUTO-TENSIONER
2. If it is outside the standard value, replace the auto-tensioner.
ACX00306AC
CAUTION
Never compress the pushrod too fast, or it may be dam-
A B aged.
3. Use a press or vise to gently compress the auto-tensioner
pushrod until pin hole A of the pushrod and pin hole B of the
tensioner cylinder are aligned.

AC000148AB

4. When the holes are aligned, insert the set pin.

SET PIN
NOTE: When replacing the auto-tensioner with a new part,
the pin will be in the auto-tensioner.
5. Install the auto-tensioner to the engine.

AC000149AB

>>B<< TIMING BELT INSTALLATION

TIMING MARK TIMING MARK
1. Align the timing marks on the camshaft sprocket, crankshaft
(TOP OF CAMSHAFT sprocket and oil pump sprocket.
CYLINDER SPROCKET
HEAD)

TIMING MARK TIMING MARK

TIMING MARK
OIL PUMP
CRANKSHAFT SPROCKET
SPROCKET AC001788AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
TIMING BELT
11A-35
60 mm 2. After aligning the timing mark on the oil pump sprocket,
(2.4 in) 8 mm remove the cylinder block plug and insert a Phillips) head 8
(0.3 in)
OR MORE mm (0.3 inch) screwdriver. Check to be sure that the
PLUG
screwdriver goes in 60 mm (2.4 inches) or more. If the
screwdriver will only go in 20 − 25 mm (0.8 − 1.0 inch)
SCREW- before striking the counterbalance shaft, turn the sprocket
DRIVER
COUNTER
once, realign the timing marks and check that the
BALANCE screwdriver goes in 60 mm (2.4 inches) or more.
SHAFT CYLINDER The screwdriver should not be taken out until the timing belt
BLOCK
AC000151AB is installed.
CAUTION
If the timing belt is re-used, install so that the arrow
marked on it at time of removal is pointing in the clockwise
direction.
3. Install the belt to the crankshaft sprocket, oil pump sprocket
and camshaft sprocket in that order, so that there is no
slackness in the belt tension.
4. Set the tension pulley so that the pin holes are at the bottom,
press the tension pulley lightly against the timing belt, and
then provisionally tighten the fixing bolt.
FIXING
BOLT
5. Adjust the timing belt tension.
BELT TENSION
PIN SIDE
HOLES

BELT TENSION SIDE AC000150 AB

>>C<< TIMING BELT TENSION ADJUSTMENT

CAUTION
Do not use a spanner or the similar tool to turn special tool
MD998738
MD998738. Otherwise, the auto-tensioner set pin may be
TENSIONER broken. Turn special tool MD998738 by hand only.
ARM 1. Remove the rubber plug from the rear of the timing belt
PUSHROD cover assembly. Then screw in special tool MD998738 by
hand until the tensioner arm is touching the auto-tensioner
pushrod.
2. After turning the crankshaft 1/4 of a revolution in the
AUTO-TENSIONER
counterclockwise direction, turn it in the clockwise direction
AC000152AB until the timing marks are aligned.
CAUTION
When tightening the fixing bolt, make sure that the tension
48 ± 6 N·m(36 ± 4 ft-lb) pulley does not turn with the bolt.
3. Loosen the tension pulley fixing bolt, and then use special
TENSION
tool MD998767 and a torque wrench to tighten the fixing bolt
DIRECTION to the specified torque while applying tension to the timing
MD998767
belt.
Timing belt tension torque: 3.5 N⋅m (31 in-lb)
Tightening torque:48 ± 6 N⋅m (36 ± 4 ft-lb)
4. Remove the set pin that has been inserted into the auto-
AC000153 AB
tensioner, and then remove special tool MD998767.

TSB Revision
11A-36 ENGINE MECHANICAL <2.4L>
TIMING BELT B

5. Turn the crankshaft two revolutions clockwise so that the

timing marks are aligned. After leaving it for 15 minutes,
measure the amount of protrusion of the auto-tensioner.
A
Standard value (A): 3.8 − 4.5 mm (0.15 − 0.18 inch)
6. If the amount of protrusion is outside the standard value,
repeat steps (1) through (5).
AUTO- 7. Check again to be sure that the timing marks of each
TENSIONER sprocket are aligned.
AC000154 AB

TIMING BELT B
REMOVAL AND INSTALLATION
M1112004600107

5
19 ± 3 N·m
14 ± 2 ft-lb
4

1
2 3

(ENGINE OIL)

118 ± 9 N·m AC000155 AB

87 ± 7 ft-lb
REMOVAL STEPS REMOVAL STEPS (Continued)
1. TIMING BELT (REFER TO <<A>> >>B<< 2. CRANKSHAFT SPROCKET
P.11A-32.) >>B<< 3. CRANKSHAFT SENSING
>>C<< • TIMING BELT B TENSION BLADE
ADJUSTMENT 4. TIMING BELT B TENSIONER
<<B>> >>A<< 5. TIMING BELT B

Required Special Tool:

• MB991367: Special Spanner

TSB Revision
 ENGINE MECHANICAL <2.4L>
TIMING BELT B
11A-37
REMOVAL SERVICE POINTS
.

<<A>> CRANKSHAFT SPROCKET REMOVAL

1. Use the crankshaft pulley mounting bolt to hold special tool
CRANKSHAFT MB991367.
PULLEY
MOUNTING
2. Loosen the crankshaft sprocket mounting bolt, and remove
BOLT the sprocket.
CRANKSHAFT
SPROCKET

MB991367

AC000135AB

<<B>> TIMING BELT B REMOVAL

CAUTION
If the belt is to be re-used, mark an arrow on the belt with
chalk indicating the clockwise direction of rotation.

AC000156 AB

INSTALLATION SERVICE POINTS

.

>>A<< TIMING BELT B INSTALLATION

1. Ensure that crankshaft sprocket B timing marks and the
COUNTERBALANCE SHAFT SPROCKET
counterbalance shaft sprocket timing marks are aligned.
BELT TENSION SIDE
2. Fit timing belt B over crankshaft sprocket B and the
counterbalance shaft sprocket. Ensure that there is no slack
in the belt.
TIMING TIMING
MARKS MARKS

CRANKSHAFT
SPROCKET B AC000157AB

TSB Revision
11A-38 ENGINE MECHANICAL <2.4L>
TIMING BELT B

>>B<< CRANKSHAFT SENSING BLADE/CRANKSHAFT

SPROCKET INSTALLATION
1. To prevent the crankshaft bolt from loosening, degrease or
CRANKSHAFT
CRANKSHAFT SPROCKET B CRANKSHAFT clean the seating surfaces of the crankshaft, crankshaft
SPROCKET sprocket B, crankshaft sensing blade and crankshaft at the
shown positions.
2. Install the crankshaft sensing blade so that they face as
shown in the illustration.
3. Apply the minimum amount of engine oil to the seat surface
CRANKSHAFT PART: and thread of the crankshaft bolt.
SENSING BLADE CLEANING
SHADED PART: DEGREASE AC004794AB

4. Use the crankshaft pulley mounting bolt to secure special

CRANKSHAFT tool MB991367.
PULLEY
MOUNTING
5. Tighten the crankshaft sprocket bolt to the specified torque.
CRANKSHAFT
BOLT Tightening torque: 118 ± 9 N⋅m (87 ± 7 ft-lb)
SPROCKET

MB991367

AC000135AB

>>C<< TIMING BELT B TENSION ADJUSTMENT

1. Temporarily fix the timing belt B tensioner so the center of
the tensioner pulley is to the left and above the center of the
mounting bolt. Temporarily attach the tensioner pulley so the
CENTER OF
flange is toward the front of the engine.
TENSIONER
PULLEY

CENTER OF
MOUNTING BOLT
AC000158 AB
CAUTION
When tightening the bolt, ensure that the tensioner pulley
shaft does not rotate with the bolt. Allowing it to rotate
with the bolt can cause excessive tension of the bolt.
SHAFT
2. Holding the timing belt B tensioner up with your finger in the
direction of the arrow, apply pressure on the timing belt so
the tension side of the belt is taut. Now tighten the bolt to fix
the tensioner.
19 ± 3 N·m Tightening torque: 19 ± 3 N⋅m (14 ± 2 ft-lb)
14 ± 2 ft-lb
AC000159 AB

TSB Revision
 ENGINE MECHANICAL <2.4L>
TIMING BELT B
11A-39
3. To ensure that the tension is correct, depress the belt (point
A A) with a finger. Adjust the belt tension if it is incorrect.
CENTER OF
Standard value: 5 − 7 mm (0.2 − 0.3 inch)
TENSIONER
PULLEY

CENTER OF
INSTALLATION
BOLT
AC000160 AB

TSB Revision
11A-40 ENGINE MECHANICAL <2.4L>
SPECIFICATIONS

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1111003800183

ITEMS SPECIFICATIONS
Auto-tensioner attaching bolt 23 ± 3 N⋅m (17 ± 3 ft-lb)
Bell housing cover attaching bolt (bolt, flange) 26 ± 4 N⋅m (19 ± 3 ft-lb)
Bell housing cover attaching bolt (bolt, washer assembled) 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)
Camshaft position sensor sensing cylinder attaching bolt 21 ± 4 N⋅m (16 ± 3 ft-lb)
Camshaft position sensor support attaching bolt 14 ± 1 N⋅m (117 ± 13 in-lb)
Camshaft sprocket attaching bolt 88 ± 10 N⋅m (65 ± 7 ft-lb)
Crankshaft pulley attaching bolt 25 ± 4 N⋅m (18 ± 4 ft-lb)
Crankshaft sprocket attaching bolt 118 ± 9 N⋅m (87 ± 7 ft-lb)
Cylinder head attaching bolt 79 ± 4 N⋅m → 0 N⋅m → 20 ± 2 N⋅m →
+90° → +90°
(58 ± 3 ft-lb → 0 in-lb → 15 ± 1 ft-lb →
+90° → +90°)
Drive plate attaching bolt <A/T> 132 ± 5 N⋅m (98 ± 3 ft-lb)
Engine mount bracket attaching bolt M12 × 74 86 ± 12 N⋅m (64 ± 8 ft-lb)
M12 × 108 81 ± 12 N⋅m (60 ± 9 ft-lb)
Engine mount bracket attaching nut 86 ± 12 N⋅m (64 ± 8 ft-lb)
Exhaust manifold bracket attaching bolt 35 ± 6 N⋅m (26 ± 4 ft-lb)
Flywheel attaching bolt <M/T> 132 ± 5 N⋅m (98 ± 3 ft-lb)
High-pressure fuel hose attaching bolt 4.8 ± 1.0 N⋅m (44 ± 8 in-lb)
Ignition coil attaching bolt 9.8 ± 2.0 N⋅m (87 ± 17 in-lb)
Intake manifold stay attaching bolt 30 ± 2 N⋅m (23 ± 2 ft-lb)
Oil dipstick guide attaching bolt 14 ± 1 N⋅m (117 ± 13 in-lb)
Oil pan attaching bolt 6.9 ± 0.9 N⋅m (61 ± 8 in-lb)
Oil pan drain plug 39 ± 5 N⋅m (29 ± 4 ft-lb)
Power steering oil pump attaching bolt 29 ± 3 N⋅m (21 ± 3 ft-lb)
Power steering oil pump bracket attaching bolt 49 ± 10 N⋅m (36 ± 7 ft-lb)
Pressure hose attaching bolt 12 ± 2 N⋅m (100 ± 22 in-lb)
Pressure tube attaching bolt 12 ± 2 N⋅m (100 ± 22 in-lb)
Rocker arm and shaft assembly attaching bolt 31 ± 3 N⋅m (23 ± 2 ft-lb)
Rocker cover attaching bolt 3.4 ± 0.5 N⋅m (31 ± 4 in-lb)
Tensioner pulley attaching bolt 48 ± 6 N⋅m (36 ± 4 ft-lb)
Timing belt B tensioner attaching bolt 19 ± 3 N⋅m (14 ± 2 ft-lb)
Timing belt lower cover attaching bolt (bolt, flange) 11 ± 1 N⋅m (96 ± 8 in-lb)
Timing belt lower cover attaching bolt (bolt, washer assembled) 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)
Timing belt upper cover attaching bolt M6 11 ± 1 N⋅m (96 ± 8 in-lb)
M8 14 ± 1 N⋅m (117 ± 13 in-lb)
Water pump pulley attaching bolt 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)

TSB Revision
 ENGINE MECHANICAL <2.4L>
SPECIFICATIONS
11A-41
SERVICE SPECIFICATIONS
M1111000300338

ITEMS STANDARD VALUE LIMIT

Actual ignition timing at idle Approximately 10° BTDC −
Auto-tensioner pushrod movement mm (in) Within 1 (0.04) −
Auto-tensioner rod protrusion mm (in) 3.8 − 4.5 (0.15 − 0.18) −
Basic ignition timing at idle 5°BTDC ± 3° −
CO content % 0.5 or less −
Compression pressure (250 − 400 r/min) kPa (psi) 1,275 (185) Minimum 959 (139)
Compression pressure difference of all cylinder kPa (psi) − 98 (14)
Curb idle speed r/min 700 ± 100 −
Cylinder head bolt shank length mm (in) − 99.4 (3.91)
HC contents ppm 100 or less −
Intake manifold vacuum at curb idle kPa (in Hg) − Minimum 60 (18)
Timing belt B tension mm (in) 5 − 7 (0.2 − 0.3) −

SEALANT AND ADHESIVE

M1111000500235

ITEM SPECIFIED SEALANT

Camshaft position sensor support and oil pan MITSUBISHI GENUINE Sealant Part No.
MD970389 or equivalent

TSB Revision
NOTES