11-1ENGINE CONTENTS 110003000 ... . . . . . ... . . . ... .. . .. . . . .... . .. .. ... ..... . .. .. .. 1.8L ENGINE.. . . . . . . . . . . , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5L ENGINE. 1lA 11B 11A-I 1.5L ENGINE CONTENTS CAMSHAFT AND CAMSHAFT OIL SEAL CRANKSHAFT OIL SEAL.. CRANKSHAFT PULLEY 110003001 ,. 19 ............... 23 ............... 25 Ignition Timing Inspection and Adjustment ................................ 10 Manifold Vacuum Inspection .................. 13 Power Steering Oil Pump Drive Belt Tension Inspection and Adjustment . . . . . . . . . . . . 8 Timing Belt Tension Adjustment Valve Clearance Adjustment ..................29 CYLINDER HEAD GASKET ENGINE ASSEMBLY . . . . . . . . . . . . . . 14 ................... , . 16 ..................2 21 .5 . . . . . . . . . . . . . . . . . . .Refer to GROUP 00 GENERAL INFORMATION OIL PAN SERVICE SPEClFlCATlONS SPECIAL TOOLS .................5 -6 ................................. SEALANTS ............................... SERVICE ADJUSTMENT PROCEDURES Air Conditioning Compressor Drive Belt Tension Inspection and Adjustment . . . . . . . . Basic Idle Speed Adjustment .....8 ......................... TIMING BELT ............................ TROUBLESHOOTfNG ....................... Compression Too Low Connecting Rod Noise / Main Bearing Noise Excessive Engine Rolling and Vibration Noisy Valves Oil Pressure Drop Oil Pressure Too High Timing Belt Noise 30 7 ................ ... Refer to GROUP 13 Compression Pressure Inspection . . . . . . . . . . . . .12 Curb Idle Speed Inspection . . . . . . . . . . . . . . . . . 11 8 Generator Drive Belt Tension Inspection and Adjustment ......................... Idle Mixture Inspection.. ..................... 11 11A-2 1.5L ENGINE - General Information 110003002 GENERAL INFORMATION GENERAL SPECIFICAT10NS 1 Items 1 Specifications In-line, Over Head Camshaft 4 I k b e r of cylinders I Bore mm (in.) 1 1 Piston displacement cm3 (cuh.) Compression ratio Firing order Valve timing Intake valve 1 82.0 (3.23) 1 1,468 (89.6) 9.2 75.5 (2.97) I I I 1-3-4-2 I Opens (BTDC) 1 Opens (BBDC) I 15" 57" Exhaust valve I Lubrication 1 Pressurized feed-full filtration I General Information SECTIONAL VIEW 11A-3 110003003 I TSB Revision I .1.5L ENGINE . Connecting rod Crankshaft .General Information 11OW3OC n i 'i .11A-4 LUBRICATION SYSTEM 1.5L ENGINE . Service Specifications / Sealants I Standard value I Limit - 11A-5 110003005 SERVICE SPECIFICATIONS Items Drive belt tension N (Ibs.5 (.5-7.22-.5L ENGINE .0-5.5 or less 100 or less I 300-500 1.5-7. MD970389 or equivalent As required .0 ~ (.24-.1 p e - Air conditioning compressor type Power steering oil pump V-ribbed type .24) 6.0-7.1.20-.0-7.28) ~ 8.22-.Hg) 1 7 5 0 k 100 1 1. 100 (14) min.22) 5.350 (192) ll- - llI min.5 (.28) 5. 960 (137) 1 I I I max.35) 5.28) 5.30) 4.28-.) Generator type 1 Whenchecked When new belt is installed When used belt is installed When checked When new belt is installed When used belt ISinstalled 250-500 (55-110) 500-700 (110.0 (.0 (.31) 6.22-.5-7.24-.) Generator ~ value) ~ Whenchecked When installed ~new belt is ~ 1 When used belt is installed ~ 300-500(66-110) 500-850 (110-187) (66-110) 7.0-6. I When checked When new belt is installed When used belt is installed When checked When new belt is installed When used belt is installed 1 - - Basic ignition timing at idle (except 1995 models for California) Basic ignition timing at idle (1995 models for California) Actual ignition timing at curb idle CO concentration % HC concentration ppm Curb idle speed r h i n Compression pressure (250-400 r/min) kPa (psi) Compression pressure difference of all cylinder kPa (psi) Intake manifold vacuum at curb idle kPa (in.154) 400 (88) 250-310 (55-68) 370-435 (82-96) 250-310 (55-68) ~ Air conditioning compressor type . 1 When used belt is installed Drive belt deflection mm (in.0-9.0 (. .0 (. 60 (18) I I 110003006 SEALANTS I Items Oil pan 1 Recommended sealant MlTSUBlSHl GENUINE Part No.30) 5" k 2" BTDC 5" k 3" BTDC 10" BTDC 0.16-.5 (.0 (. 5L ENGINE .11A-6 1.Special Tools Application Installation of camshaft oil seal SPECIAL TOOLS Tool Tool number and name MD998713 Camshaft oil seal installer Supersession MD998713-01 1100030l MD998727 Oil pan remover General service tool Removal of oil pan MD998747 Crankshaft pulley holder General service tool Supporting crankshaft pulley MB990767 End yoke holder MB990767-01 Supporting camshaft pulley Supporting crankshaft pulley MD998719 Crankshaft pulley holder pin MIT308239 Q MD998011 Crankshaft rear oil seal installer MD998011-01 Installation of crankshaft rear oil seal MD998360 Cylinder head bolt wrench General service tool Removal and installation of cylinder head assembly GENERAL SERVICE TOOL MZ203827 Engine lifter General service tool Supporting engine assembly when removing and installing transaxle . Rear) Loose transaxle mount bracket Loose engine mount bracket Loose center member 1 Change engine oil 1 Replace bearings Adjust belt tension Retighten .1.5L ENGINE .Troubleshooting 1 Remedy 11A-7 110003008 TROUBLESHOOTING Symptom Compression too low I Probable cause 1 Cylinder head gasket blown 1 Piston ring worn or damage 1 I Replace gasket 1 Replace rings Repair or replace piston and/or cylinder block I Piston or cylinder worn Valve seat worn or damage 1 Repair or replace valve and/or seat ring Adjust valve clearance Check engine oil level Replace oil pressure switch I Incorrect valve clearance Oil pressure drop Engine oil level too low Oil pressure switch faulty 1 Oil filter clogged 1 oil pump gears or cover worn I Install new filter 1 Replace gears and/or cover ~~ 1 Thin or diluted engine oil Oil relief valve stuck (open) Change engine oil to correct viscosity Repair relief valve 1 Oil pressure too high Noisy valves Excessive bearing clearance Oil relief valve stuck (closed) Incorrect valve clearance 1 Replace bearings Repair relief valve Adjust valve clearance Change engine oil 1 Thin or diluted engine oil (low oil pressure) I Valve stem or valve guide worn or damaged Connecting rod noisel main bearing noise Insufficient oil supply Low oil pressure I Replace valve and/or guide Check engine oil level Refer to “Oil pressure drop” I Thin or diluted engine oil ’ Excessive bearing clearance Timing belt noise Excessive engine rolling and vibration Incorrect belt tension Loose engine roll stopper (Front. check the belt tension for standard value.) Water pump POWER STEERING OIL PUMP DRIVE BELT TENSION INSPECTION AND ADJUSTMENT 110003011 I Z l J i - I POWER STEERING OIL PUMP DRIVE BELT TENSION INSPECTION Measure drive belt deflection by pulling or pushing at the midpoint of the belt between pulleys with a force of 100 N (22 Ibs.Service Adjustment - Procedures I" Crankshaft pulley ZWMM SERVICE ADJUSTMENT PROCEDURES _ " I 1 0003009 GENERATOR DRIVE BELTTENSION INSPECTION AND ADJUSTMENT GENERATOR DRIVE BELT TENSION INSPECTION With belt tension gauge set to the belt midway between the pulleys as shown in the illustration.35) GENERATOR DRIVE BELT TENSION ADJUSTMENT 110003010 (1) Loosen the nut of the generator pivot bolt. Tightening torque: 23 Nm (16 ft.5L ENGINE .lbs. Standard value: (4) Tighten the lock bolt.) 1 7. (2) Loosen the lock bolt.0-9.5 mm (.5-7.28-.) 250-500 (55-110) I 1 (Reference value) I ' Deflection mm (in.11A-8 1. Tightening torque: 14 Nm (10 ft.) (5) Tighten the nut of the generator pivot bolt. Standard value: 5.22-. __ .lbs.30 in. Or apply a force of 98 N (22 Ibs. Standard value: 1 Tension N (Ibs.) to the belt to check the deflection for standard value. (3) Turn the adjusting bolt to adjust the belt tension or deflection to the standard value.0 (.) 1 1 TSB Revision I .) as shown in the figure. 0 mm (. Tightening torque: 40 Nm (29 ft.) (4) Check the belt deflection adjust if necessary. adjust the belt tension using the following procedure.0 mm (.24-.) New belt: 5.24-.0 mm (. turn the engine one time or more clockwise.5-7.) I m - I 1 TSB Revlslon ." OIL PUMP DRIVE BELT TENSION ADJUSTMENT 110003012 If the deflection is out of the standard values.) AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT 110003013 AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION INSPECTION Measure drive belt deflection by pulling or pushing at the midpoint of the belt between pulleys with a force of 100 N (22 Ibs.28 in. C. NOTE Verify belt is not cracked or frayed before re-using. Standard value: 6.0 mm (.Service Adjustment Procedures 11A-9 POWER STEER.) AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION ADJUSTMENT 110003014 (1) Loosen tension pulley securing nut A.0-7.lbs.28 in. NOTE Verify belt is not cracked or frayed before re-using. (3) Tighten belt adjustment bolt.5L ENGINE .0-7.24 in. B. Standard value: 6.22 in.) New belt: 4. (2) Set a bar or similar tool against the oil pump body. tighten the oil pump mounting bolts in the order A.1. Standard value: Used belt: 5.24-.28 in.20-. Standard value: Used belt: 6.0-7.0-6. B and C (for holding the oil pump). and while applying tension to the belt. Caution Before this check.0-5. (4) Check the belt tension after driving.) (3) Tighten securing nut A.).5 mm (. (2) Adjust belt tension with adjusting bolt B. (1) Loosen bolts A.22-30 in.16-.5 mm (. and to a good ground as illustrated. verify following the conditions: 0 0 0 Engine coolant temperature: 80-95°C (176-203°F) Lights. NOTE Grounding this terminal sets the engine to basic ignition timing. If tested with the scan tool connected to the data link connector. (10)Start the engine and run it at idle.Service Adjustment Procedures ' IGNITION TIMING INSPECTION AND ADJUSTMENT 110003015 (1) Before inspection and adjustment. electric cooling fan and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T) (2) Insert a paper clip into the 1 pin connector (blue) as shown in the illustration at left.5L ENGINE . Curb idle speed: 750 f 100 r/min (7) Turn the ignition switch to OFF. s within the standard (11)Check that basic ignition timing i value. the ignition timing will not be the basic timing but be ordinary timing. (9) Connect the jumper wire to the ignition timing adjustment terminal. Basic lgnltion tlmlng: 5"BTDC f 2" (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California) I TSB Revision . (3) Connect a primary-voltage-detection type of tachometer to the paper clip. (8) Remove the waterproof connector from the ignition timing adjustment connector (brown).11A-10 1. (4) Set up a timing light. (5) Start the engine and run at idle. (6) Check that engine idle speed is within the standard value. NOTE Do not use the scan tool. (13)Stop the engine. and check the MFI components. And it automatically advances by about 5" from 10" BTDC at higher altitudes. Curb Idle speed: 750 k 100 r/min NOTE The idle speed is controlled automatically by the idle air control (IAC) system. Adjust if necessary. refer to GROUP 13 . Actual ignition timing: approx. install the tachometer or connect the scan tool to the data link connector (white). b. loosen distributor hold down nuts and adjust by rotating distributor body. 2. remove the jumper wire from the ignition timing adjustment connector (brown). 10"BTDC NOTE 1. even under normal operation.lbs. inspect the MFI components by referring. Tighten hold down nuts after adjusting. IDLE MIXTURE INSPECTION 110003017 (1) Before inspection. set the vehicle in the following condition. to GROUP 13A Troubleshooting. and return the connector to its original condition. Standard value: 5"BTDCk 2' (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California) (3) After turning the ignit'on switch to OFF. For the method of installing the tachometer. Ignition timing is variable within about f7". electric cooling fan and all accessories: OFF 0 Transaxle: Neutral (P range on vehicles with NT) (2) Check the basic ignition timing. 0 Engine coolant temperature: 80-95°C (176-203°F) 0 Lights.1. refer to P. (14)Star-l the engine and check that ignition timing is at the standard value. (7) If there is a deviation from the standard value. electric cooling fan and accessories: OFF 0 Transaxle: Neutral (P range on vehicle with AlT) .Check Chart Classified by Problem Symptoms. Tightening torque: 12 Nm (8 lt. If not within the standard value. CURB IDLE SPEED INSPECTION 110003016 J (1) Before inspection and adjustment verify in the following conditions: 0 Engine coolant temperature: 80-95°C (176-203°F) 0 Lights. (4) Start the engine and'run it at idle.11A-10. (6) Check the idle speed.5L ENGINE .) 4 9 9 6 models and 1995 models for California> If not within the standard value. (5) Run the engine at idle for 2 minutes.Service Adjustment Procedures 11A-11 (12)cExcept 1996 models and 1995 models for California> a. .5% or less HC concentration: 100 ppm or less (7) If the standard value is exceeded. NOTE Doing this will prevent the engine control module from carrying out ignition and fuel injection. heated oxygen sensor output signals change within a 0-400 mV range and a 600-1. NOTE For tachometer setting procedure. check that no foreign material is adhering to the shop towel. check that the engine oil. verify to the following conditions: a Engine coolant temperature: 80-95°C (176-203°F) a Lights. 110003018 COMPRESSION PRESSURE INSPECTION (1) Before inspection. ( 5 ) Set the CO tester and HC tester.500 r/min forapprox. starter and battery are normal. set a tachometer or connect the scan tool to the data link connector. check the following items.5L ENGINE . # 3. (4) Start the engine and run at 2. replace the three-way catalyst. Also. Standard value: CO concentration: 0.1lA-10.Service Adjustment Procedures (2) Make sure that the basic ignition timing is at a standard value.11A-12 1. and after the engine has been cranked.) Fuel pressure Injectors Ignition coil. electric cooling fan and all accessories: OFF a Transaxle: Neutral (P range on vehicle with A/T) (2) Remove all of the spark plugs. spark plug cables and spark plugs Leaks in EGR system and EGR valve Evaporative emission control system Compression pressure NOTE If CO and HC concentrations exceed the respective standard values despite the fact that the results of the inspection made on all items are normal. 2 minutes.000 mV range.a Diagnostic output Closed loop control (If closed loop control is performed normally. 1TSB Revision . Standard value: 5"BTDC k 2" (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California) (3) After turning the ignition switch OFF. (4) Cover the spark plug hole with a shop towel etc. refer to P. (6) Check the CO concentration and HC concentration with the engine at idle. (3) Disconnect the 6-pin distributor connector (except 1995 models for California) or crankshaft position sensor connector (1995 models for California). . 960 kPa (137 psi) (7) Measure the compression pressure for all the cylinders. Limit: max. 2.5L ENGINE . if water.. .-- MANIFOLD VACUUM INSPECTIONN 110003019 (1) Verify the following conditions before inspection. the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. pour a small amount of engine oil through the spark plug hole. 1 TSB Revision I . and all accessories: OFF 0 Transaxle: Neutral (P range on vehicles with PJT) (2) Install the tachometer or connect the scan tool to the data link connector (white). Caution 1.. 0 Engine coolant temperature: 80-95°C (176-203°F) 0 Lights. and repeat the operations in steps (6) and (7). oil. which is dangerous. b. (5) Set compression gauge to one of the spark plug holes. (1O)lnstall the spark plugs and spark plug cables. or pressure is leaking from the gasket. Verify difference between maximum and minimum readings do not exceed the limit. or disconnect the battery ground cable for more than 10 seconds and reconnect it. .. these materials will become heated and will gush out from the spark plug hole. 100 kPa (14 psi) (8) If there is a cylinder with compression or a compression difference that is outside the limit.. (11)Use the scan tool to erase the diagnostic trouble codes.. (3) Disconnect the vacuum hose from the fuel pressure regulator.. (6) Crank the engine with the throttle valve fully open and measure the compression pressure. electric cooling fan._ . NOTE This will erase the diagnostic trouble code resulting from the distributor connector being disconnected. 11A-13 .350 kPa (192 psi) Limit (at engine speed of 250-400 r/min): min. fuel. (9) Connect the distributor connector (except 1995 models for California) or crankshaft position sensor connector (1995 models for California). . Standard value (at engine speed of 250-400 rlmin): 1. has come from cracks inside the cylinder. - - 1. If the compression increases after oil is added.Service Adjustment Procedures . a. During a compression test.. . Keep away from the spark plug hole when cranking. the cause is a burnt or defective valve seat. etc. If the compression does not rise after oil is added. Service Adjustment Procedures ’ I (4) Connect a three-way vacuum tee between the removed 1 vacuum hose and the nipple and connect a vacuum gauge to the vacuum tee as shown. (7) Turn the crankshaft clockwise to check for cracks or signs of wear that in the timing belt. Caution Always turn the crankshaft clockwise. (6) Remove the spark plugs. (10)Turn the crankshaft clockwise by two teeth of camshaft sprocket. 1 (9) Loosen both pivot side and slot side tensioner bolts and tension the belt. <Vehicles for California (From 1995 models)> (Refer to P. 1 TIMING BELT TENSION ADJUSTMENT iiooo3ozo 1 I The timing belt has an automatic tension adjusting mechanism. I 1 i (3) Remove the timing belt upper cover. never turn the crankshaft counterclockwise as it could cause inadequate belt tensioning. 11A-29. (4) Remove the crankshaft compressor pulley and crankshaft pulley. Caution For aligning the timlng marks. making use of the tensioner spring force. (1) Remove the water pump pulley. (6) Check the manifold vacuum.11A-14 1. 1 cylinder piston to top dead center on the compression stroke.) (5) Remove the timing belt lower cover. (5) Start the engine and check that idle speed is within the I standard value range. (2) Remove the air conditioning pulley bracket.5L ENGINE .Hg) min. I Limit: 60 kPa (18 in. (8) Turn the crankshaft clockwise to bring the No. Adjustment can be made by the following procedure. ZlENC550 1 TSB Revision I . 5L ENGINE .. release hand pressure so that only the tensioner spring acts on belt and tighten the slot side bolt and then the pivot side bolt to fix the tensioner in position..Service Adjustment Procedures 11A-15 (11) Push the timing belt tensioner inthe'direction of the arrow to check that each sprocket is kept in firm and complete engagement with the belt cogs. Hold the timing belt tensioner and timing belt together by hand and give the belt a slight thumb pressure at a point level with tensioner center. . (12)Check the timing belt tension. Make sure that the belt cog crest deflects approximately 1/4 of the tensioner attaching bolt head width. . I I 1/4 of bolt head width muoIl (13)lnstall the spark plugs. <Vehicles for California (From 1995 models)> (Refer to P.. (14)lnstall the timing belt lower cover.) (16)lnstall the timing belt upper cover.1. 11A-29. __ . . After this check. (18)lnstall the water pump pulley and adjust the drive belt deflection.. . (15)lnstall the crankshaft compressor pulley and crankshaft pulley. . . (17)lnstall the air conditioning pulley bracket. . -. Breather hose connection 4.) 0 Transaxle Assembly Removal (Refer to GROUP 22. Vacuum hose connection 5. O-ring 8.) 0 Hood Installation 0 Accelerator Cable Adjustment (Refer to GROUP 13 .Transaxle Assembly._ 5 Nm 5 Nm 3.6 R. 23 .Service Adjustment Procedures.Service Adjustment Procedures.Service Adjustment Procedures.) 0 Hood Removal 0 Coolant Draining (Refer to GROUP 14 .lbs.Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION ~~ 110003021 Pie-removal Operation 0 Fuel Line Pressure Releasing (Refer to GROUP 13 . Heater hose connection 6. Vacuum hose connection .Radiator.5L ENGINE . I 10 Removal steps ‘8 1.Service Adjustment Procedures. High-pressure hose connection 7.) Post-Installation Operation Radiator Installation(Referto GROUP 14.) 0 Radiator Removal (Refer to GROUP 14 . 23 . Return hose connection 9.) Transaxle Assembly Installation (Refer to GROUP 22. Brake booster vacuum hose connection 10.11A-16 1.Radiator.) 0 0 . Accelerator cable connection 3.) 0 Coolant Supplying (Refer to GROUP 14 . Ground cable connection 2.Transaxle Assembly. 5L ENGINE .1. Engine coolant temperature gauge unit connector 16. Gasket 30.) 24.Engine Mount.A+ 22.) 31. Throttle position sensor connector 17. Self-locking nuts and bolts 29.Engine Assembly 11A-17 Removal steps 11. Engine assembly . Ignition coil connector 13. Power steering oil pressure switch connector V-ribbed belts adjustment (Refer to P. Generator connector 23. CKP sensor and CMP sensor connector 14. Engine coolant temperature sensor connector 15. Intake air temperature sensor 18. Oxygen sensor connector 12. V-ribbed belt for air conditioning 25. Engine mount bracket (Refer to GROUP 32 . Air conditioning compressor 26. Idle air control motor 20. Power steering oil pump 28. V-ribbed belt for power steering 27. Control harness +Ab +Bb +Cb . Injector connector 21.11A-8. EGR temperature sensor 19. POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the bracket with the hose attached. IN STA LLATlON SERVICE P0INT F A 4 ENGINE ASSEMBLY INSTALLATION Install the engine assembly while checking to be sure that the cables. NOTE Place the removed air conditioning compressor in a place where it will not be a hindrance when removing and installing the engine assembly. etc.5L ENGINE . hoses and harness connectors. hoses.Engine Assembly AIR CONDITIONING COMPRESSOR REMOVAL <VEHICLES WITH AIR CONDITIONING> Disconnect the air conditioning compressor connector and remove the compressor from the compressor bracket with the hose still attached.. and tie it with a cord. are disconnected from the engine. and harness connectors are clear of the engine assembly. . ENGINE ASSEMBLY REMOVAL After checking that all cables. REMOVAL SERVICE POINTS ( A . 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. ( B . ( C . slowly remove the engine assembly upward from the engine compartment. and tie it with a cord.11A-18 1. Camshaft and Camshaft Oil Seal 11A-19 __ 110003022 CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION I Pie-removal and Post-installation Operation 0 0 Timing Belt Removal and Installation (Refer to P.Distributor.8 Nm 1. 3 5 I LIP section H Engine oil Removal steps 1. Camshaft 0 REMOVAL SERVICE POINT + A F CAMSHAFT SPROCKET REMOVAL I )Revision . Rocker cover 2.11A-30.lbs.lbs. Rocker arm assembly 5.) Distributor Removal and Installation (Refer to GROUP 16 . / 32 Nm 23 ft.5L ENGINE . Camshaft sprocket 3. Oil seal F B I 4Ab bC+ bA4 Valve clearance inspection and adjustment 4.) 1.1.3 ft. B A VALVE CLEARANCE INSPECTION AND ADJUSTMENT Refer to GROUP 00 .Maintenance Service.11A-20 1. b C + OIL SEAL INSTALLATION .Camshaft and Camshaft Oil Seal INSTALLATION SERVICE POINTS . A + CAMSHAFT INSTALLATION Position the dowel pin of the camshaft as shown in the illustration.5L ENGINE . . Exhaust Pipe and Muffler. / 2 m 1 S w 5 1 Removal steps 1.3 ft. or the oil pan will be deformed.1 ft. MD970389 or equivalent i i Nm 8 tt. B + . Drain plug 3. remove the oil pan with the special tool and a brass bar. Bell housing cover +Ab . Caution Hammer little by little. Gasket 4.Oil Pan 11A-21 110003023 OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Oil Draining and Supplying Oil Dipstick Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to GROUP 15 . A + 2. I TCR D a t r i c i n n I . 6 Nm 4. Oil pan MD998727 1 MD998727 - REMOVAL SERVICE POINT 4 A F O I L PAN REMOVAL After removing the oil pan mounting bolts.lbs.5L ENGINE .lbs.1. 7 Nm 5.) Specified sealant: MlTSUBlSHl GENUINE PART No.lbs. the oil pan should be installed. A + OIL PAN INSTALLATION Caution After cleaning the oil pan mounting bolt holes in the oil seal case.11A-22 1. .5L ENGINE . the groove towards the oil pan as shown. NOTE (1) Install the oil pan within 15 minutes after applying liquid gasket. (2) Then wait at least one hour. . Never start the engine or let engine oil or coolant touch the adhesion surface during that time. F B 4 DRAIN PLUG GASKET INSTALLATION Replace the gasket with a new gasket.Oil Pan INSTALLATION SERVICE POINTS . Crankshaft rear oil seal F B I 5.) <Crankshaft Rear Oil Seal> 0 Oil Pan Removal and Installation (Refer to P.Crankshaft Oil Seal 11A-23 110003024 CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installatlon Operation <Crankshaft Oil Seal+ Timing Belt Removal and Installation (Refer to P.Transaxle Assembly. Flywheel assembly <M/T> or drive plate <AK> F A 4 7.Transaxle Assembly.) (Wr: Refer to GROUP 23 . Crankshaft front oil seal .5L ENGINE .11A-30.) Clutch Cover and DISC <MTT> Removal and Installation 5 7 Lip section I YOINOM: I m Lip section Z01NW43 <M/T> Engine oil 4 1 / <Vehicles for Federal (Up to 1995 models) and California (Up to 1994 01s0270 models)> 00001 0 7 1 Crankshaft front oil seal removal steps 1. Crankshaft sprocket 2.1.) 0 0 Transaxle Assembly Removal and Installation (MTT: Refer to GROUP 22 . Crankshaft spacer 4.11A-21. Flange 4AF Crankshaft rear oll seal removal steps 6. Crankshaft sensing blade 3. ( 2 ) Tap the oil seal until it is flush with the oil seal case. (2) Tap the oil seal as shown in the illustration until it is flush with the oil seal case. (2) Remove the flywheel assembly or the drive plate cAiT>.Crankshaft Oil Seal REMOVAL SERVICE POINT A A F FLYWHEEL ASSEMBLY <Mn> OR DRIVE PLATE cA/T> REMOVAL Secure the crankshaft pulley by using the V-ribbed belt and the special tool. Oil seal F B A CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the entire circurnference of the oil seal lip. Oil seal case 1 . (2) Do not use a damaged V-ribbed belt. <Mn> INSTALLATION SERVICE POINTS F A A CRANKSHAFT REAR OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the entire circumference of the oil seal lip.5L ENGINE .11A-24 1. use a new V-ribbed belt. Caution (1) Because the V-ribbed belt installed in the vehicle may be damaged. Service Adjustment Procedures) 5 Nm 3. Ground cable connection 2. Engine mounting stay 14. Water hose connection (Throttle body to water inlet pipe) r . Return hose connection 12.1. Vacuum hose connection 6. Accelerator cable connection 3.lbs.Cylinder Head Gasket 11A-25 110003025 CYLINDER HEAD GASKET REMOVAL AND INSTALLATION I ~ ~~ Pre-removal Operation 0 0 Reduce the Inner Pressure of Fuel Line and Hose (Refer to GROUP 13 .) Refilling the Engine Oil Refilling the Engine Coolant Adjusting the Accelerator Cable (Refer to GROUP 13 . O-ring 11. 0150080 00001073 Removal steps 1. PCV hose connection 4.5L ENGINE .Air Cleaner) Post-installation Operation Air Intake Hose Installation (Refer to GROUP 15 .6 ft. Water hose connection (Throttle body to thermostat housing) 7.5 Nm 3.Service Adjustment Procedures ) Draining the Engine Coolant Draining the Engine Oil Air Intake Hose Removal (Refer to GROUP 15 . 8. 15 Engine oil I .Air Cleaner. Water hose connection (Heater unit to thermostat housing) 9. Radiator upper hose .lbs. Brake booster vacuum hose connection 13. Vacuum hose 15.6 ft. High-pressure fuel hose connection 10. Breather hose connection 5. 96 h . EGR temperature sensor Idle air control motor Injector connector Control harness Rocker cover Timing belt upper cover Camshaft sprocket Self-lockina nuts Cylinder hzad assembly Gasket Cylinder head gasket .lbs. 4 C b b B 4 31.8 Nm 27 9 ’17 .3 ft.20 <Cold engine> 73 Nm 53 ft. 26. CKP sensor and CMP sensor connector 19. Engine coolant temperature sensor connector 20. 24.5L ENGINE . 25. F A 4 33. 01SOO62 00001074 Removal steps 16.Cylinder Head Gasket / 1. 4Ab 29. Oxygen sensor connector 17.24 . 4Bb 30.\ / / a 21 I . Ignition coil connector 18.11A-26 1. Engine coolant temperature gauge unit connector 21. 27. I 26 $2 23 36 ft.lbs. 28. Intake air temperature sensor 23.18 /l . 1.lbs. 32. Throttle position sensor connector 22. 5L ENGINE . loosen the bolts in the order shown in the illustration (in 2 or 3 steps). Front of engine Intake side e I Exhaust side m(WE4 1 TSE Ravirian .Cylinder Head Gasket REMOVAL SERVICE POINTS 11A-27 4 A b TIMING BELT UPPER COVER REMOVAL After removing the timing belt upper cover.1. 4 B b CAMSHAFT SPROCKET REMOVAL (1) Use the special tool to remove the camshaft sprocket with the timing belt attached. NOTE Loosening each bolt in 1 step may warp the cylinder head. (2) Tie the camshaft sprocket and timing belt with a wire so that the position of the camshaft sprocket will not move with respect to the timing belt. Caution Turn the crankshaft clockwise. remove them and then remove the cylinder head assembly. 4 C b CYLINDER HEAD ASSEMBLY REMOVAL Using the special tool. rotate the crankshaft clockwise and align the timing marks. or into the engine coolant or oil passages.11A-28 1. to specifications.Cylinder Head Gasket INSTALLATION SERVICE POINTS b A + CYLINDER HEAD GASKET INSTALLATION (1) Use a scraper to remove the cylinder head gasket from the cylinder block. malfunctions such as no oil rising to the cylinder head will occur. (2) Using the special tool. - . a minimum of 2 steps maximum of 3 steps. ZOlRM17 C Camshaft sprocket side I (2) Place the cylinder head gasket on the cylinder block with the marks facing upward. Caution Take care that no foreign material gets into the engine coolant or oil passages. so be sure to check it.5L ENGINE . bB+ CYLINDER HEAD ASSEMBLY INSTALLATION (1) Use a scraper to remove the cylinder head gasket from the cylinder head assembly. Front of engine Intakeside Exhaust side yo1uo155 . If it is mis-installed. tighten the bolts in the order shown. Caution Take care that no foreign material gets into the cylinder. Caution The cylinder head gasket is easy to mls-Install. I . Never use a damaged drive belt. 1 4 A F F A 4 4. This drive belt will get damaged. Drive belt (Generator) REMOVAL AND INSTALLATIONSERVICE POINTS 4AFbA4CRANKSHAFT COMPRESSOR PULLEY I CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Use the special tool and an old drive belt to secure the puI leys. Drive belt (Air conditioning) 2. Crankshaft pulley Removal steps 1.Crankshaft Pulley 11A-29 110003026 CRANKSHAFT PULLEY l Pre-removal Operation 0 Under Cover Removal Post-installation Operation a Drive Belt Tension Adjustment (Refer to P. 11A-8. Drive belt (Power steering) 3.5L ENGINE . Crankshaft compressor pulley +AF (Air conditioning) F A 4 5. 2. Do not use the engine’s drive belt.1. Caution 1. . i c AOlP0045 I .) 0 Under Cover Installation /’ / ’ . ) 0 Engine Mount Removal and Installation (Refer to GROUP 32 .lbs. 1 TSB Revision .5L ENGINE . Removal steps FBd FB4 F A 4 3. rotate the crankshaft clockwise and align the timing marks.11A-30 1.) 0 1 \ 2 11 Nm 8 R.11A-29. Timing 1. Timing belt lower cover belt NOTE *: Vehicles for Federal <From 1996 models> and California <From 1995 models REMOVAL SERVICE POINTS 4 A F T l M l N G BELT UPPER COVER REMOVAL After removing the timing belt upper cover. Caution Always turn the crankshaft clockwise.Engine Mounting. Timing belt upper cover 2.Timing Belt I10003027 TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation 0 Crankshaft Pulley Removal and Installation (Refer to P.lbs. ‘3 8 ft. 24 x 1. (4) Install the crankshaft pulley temporarily. set on the camshaft sprocket. Caution If the timing belt is to be re-used.) (2) Set the timing belt first on crankshaft sprocket and then keeping the tension side of belt tight. (3) Remove the timing belt. install so that the arrow marked on it at time of removal is pointing in the clockwise direction. <Vehicles for Federal (Up to 1995 models) and California (Up to 1994 models)> <Vehicles for Federal (From 1996 models) and California (From 1995 models)> b B 4 TIMING BELT LOWER COVER /TIMING BELT UPPER COVER INSTALLATION Note that the timing belt lower and upper cover attaching bolts differ in size from one place to another.Timing Belt 11A-31 4 B F T l M l N G BELT REMOVAL (1) Loosen the timing belt tensioner bolts.50) [diameter x length mm (in. INSTALLATION SERVICE POINTS Timing mark Timing mark 4. use chalk to mark (on its flat side) an arrow indicating the clockwise direction. This is to prevent the belt from coming off when crankshaft is turned. UseA bolt: 6 x 18 (. Caution If the timing belt is re-used.1.Tension side Timing mark Timing mark Crankshaft sorocket F A 4 TIMING BELT INSTALLATION (1) Align the timing marks on the camshaft sprocket and crankshaft sprocket.71) B bolt: 6 x 38 (. (Now the piston in No.5L ENGINE .24 x . 1 cylinder is at the top dead center on the compression stroke. (3) Apply counterclockwise force (in the direction B) to the camshaft sprocket to give tension to the belt on tension side and make sure that all timing marks are lined up. (2) Move the timing belt tensioner to the water pump side and temporarily tighten the bolt so that the tensioner doesn’t return.)] ZOlU0156 A A 0150208 00001077 1 TSB Revision J .