11B 4G93 Engine.pdf

7/21/2019 11B 4G93 Engine.pdf

1/37

1.8L ENGINE

t

CONTENTS

CAMSHAFT AND CAMSHAFT OIL SEAL . 18

CRANKSHAFT OIL S E A L . . . . . . . . . . . . . . . . . 22

CRANKSHAFT PULLEY

..................

31

CYLINDER HEAD GASKET . . . . . . . . . . . . . . .

26

ENGINE ASSEMBLY

.....................

14

GENERAL INFORMATION

. . . . . . . . . . . . . . . . . .

I

OIL PAN

.................................

20

SEALANTS ................................

6

II

SERVICE ADJUSTMENT PROCEDURES.. .. 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 13

Compression Pressure Inspection

. . . . . . . . . . . . .

3

Curb Idle Speed Inspection

. . . . . . . . . . . . . . . . . .

1

Generator Drive Belt Tension Inspection

p and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Idle Mixture Inspection

.......................

12

Basic Idle Speed Adjustment

Ignition Timing Inspection and

Adjustment . . . . . . . . . . . . . . . .

10

110003028

Power Steering Oil Pump and Air

Conditioning Compressor Drive Belt

Tension Inspection and Adjustment

. . . . . . . . . . . . . . .

Power Steering Oil Pump Drive Belt

Tension Inspection and Adjustment

. . . . . . . . . . . .

Timing Belt Tension Adjustment . . . . . . . . . . . . . . 3

Valve Clearance Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP

00

SERVICE SPECIFICATIONS

.................

SPECIAL TOOLS .......................... 6

TIMING BELT ............................

32

TROUBLESHOOTING

...................... . 7

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

Manifold Vacuum Inspection . . . . . . . . . . . . . . . . . . 3

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11

B-2 1.8L

ENGINE -

General Information

Number of cylinders

Bore mm (in.)

GENERAL INFORMATION

4

81

O

3.19)

G ENE

R

AL SPEC FICAT10 NS

Valve timing ~ Intake valve

Exhaust valve

110003029

Opens (BTDC) 14

Closes (ABDC)

50

Opens (BBDC) 58

Closes (ATDC) 10

Items Specifications

Lubrication

Type

In-line, Over He ad Camsha ft

Pressurized feed-full filtration

Stroke mm (in.)

I

89.0 (3.50)

Piston displacement cm3 (cu.in.) I 1,834 (111.9)

Compression ratio I 9.5

~~

Firing order

I

1-3-4-2

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1.8L ENGINE - General Information

11B-3

11 3 3

ECTIONAL

VIEW

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11 B -4

1.8L ENGINE

-

General Inform ation

LUBRICATION

SYSTEM

Rocker arm shaft

11000303

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1.8L

ENGINE - Service Specif ications

11

8-5

Generator

V-ribbed type

SERVICE SPECIFICATIONS

Whe nchecked 250-500 (55-110)

-

When new belt

is

installed

I

500-700 (110-154)

-

110003032

Power steering

V-ribbed type

oil pump*'

Items

Drive belt

tension

N

(Ibs.)

When new belt is installed

650-850 (143-187)

-

When used belt is installed 400-600 (88-132)

-

Drive belt

deflection

mm (in.)

Power steering

oil

pump*2 and

Air conditioning

V-ribbed type

compressor

1 Standard value Limit

When new belt is installed 750-800 (165-176)

-

When used belt is installed 500-6 30 (110-139)

-

Generator

V-ribbed type

(Reference

value)

When used belt is installed 400 (88) l

Whencheck ed 8.5-12.0 (.34-.47) -

When new belt is installed 7.0-8.5 (.28-.34)

-

When used belt is installed

9.5

(37) -

Power steering

11

pump*'

V-ribbed type

When new belt is installed 7.5-9.0 (.30-.35) -

When used belt is installed 9.5-11.5 (.37-.45) -

Power steering

oil pump** and

Air conditioning

compressor

V-ribbed type

When new belt is installed 5.5 -6.0 (.22-.24) -

When used belt is installed

6.8- .6 (.27

-

30)

-

Actual ignition timing at curb idle

I

5 BTDC

CO concentration

%

I 0.5

or

less

Basic ignition timing at idle (except 1995 mode ls for California) 5

+

2 BTDC

1

-

-

Basic ignition timing at idle (1995 models for California)

5 3 BTDC

l

Intake manifold vacuum at curb idle k Pa (in.Hg)

- _ -

min. 60 (18)

I

100

or

less

l

C concentration ppm

Curb idle speed r/min 700 * 100 l

Compression pressure (250-400 r/min) kPa (psi)

1,400 (199) min. 1,060 (151)

max. 100 (14)

ompression pressure difference of all cylinder kPa (psi)

l

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Water outlet fitting

Oil pan

MlTSUBlSHl GEN UINE Part

No.

MD970389 or equivalent

Thermostat case

Flywhee l bolt

Drive plate bolt

Three Bond Part No. 1324 or equivalent

1.8L ENGINE - Sealants

/

Special

Tools

SEALANTS

I10003033

Items I Recomm ended sealant

SPECIAL TOOLS

110003034

Tool number and nam e

Supersession

Application

MB990938

Handle

MB990938-01

Use with M D998776

MB990767-01

Holding camshaft sprocket or

crankshaft pulley when loosening

and tightening of bolt.

Use with MD 998754. MD998719

ME990767

Cranksha ft pulley

holder

Installation of camshaft oil seal

D998713-01D998713

Cam shaft oil seal

installer

MD998717

Cranksha ft front oil

seal installer

MD998717-01

Installation of crankshaft front

oil seal

MD998754, MD 998719

MlT308239

Suppo rting the cranksha ft pulley

when crankshaft bolt and pulley

are removed or reinstalled.

Use together with M B990767

Suppo rting camshaft pulley

Cranksha ft pulley

holder

Gene ral service tool

Removal of the oil pan

D998727

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1.8L ENGINE - Special Tools

/

Troubleshoot ing 11

B-7

GENERAL

SERVICE

TOOL

MZ203827

Engine lifter

M699 1396

Oil filter wrench

Tool

General service tool Supporting engine assembly when

removing and installing transaxle

MB991396-01

Remo val and installation of engine

oil filter

Tool number and name I Supersession Application

TROUBLESHOOTING

Rpfpr tn P 1 1 A - 7

110003035

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11B-8

1.8L ENGINE - S e r v i c e A d j u s t m e n t P r o c e d u r e s

New belt

100N

(22

Ibs.) -

500-700 110-154)

7.0-8.5

.28-.34)

SERVICE ADJ USTMENT PROCEDURES

110003036

GEN

E

RAT0

R

DRIVE

BELT

TENS

I

N I N

S

PECTI N

AND ADJUSTMENT

GENERATOR DRIVE BELT TENSION INSPECTION

With belt tension gauge set

to

the belt midway between the

pulleys as shown in the illustration, check the belt tension

for standard value. Or apply a force of

98

N (22 Ibs.)

to

the

belt

to

check the deflection for standard value.

Standard value:

-

Deflection

mm

(in.)

(Reference value)

ension N (Ibs.)

250-500 55-110) 8.5-12.0 .34-.47)

Measure drive belt deflection by pulling or pushing at the mid-

point

of

the belt between two pulleys with a force of

100 N

22

Ibs.) as shown in the figure.

Standard value:

8.5-12

mm (.34-.47 in.)

. +

Belt

ension

dklx adiuster

'

GENERATOR DRIVE BELT TENSION ADJUSTMENT

(1)

Loosen the nut of the generator pivot bolt.

(2) Loosen the lock bolt.

(3)

Turn the adjusting

bolt to

adjust the belt tension or deflec-

Standard value:

I10003037

,

tion to the standard value.

Deflection

mm

(in.)

(Reference value)

tems Tension N (Ibs.)

I

I

(4) Tighten the lock bolt.

Tightening torque: 23

Nm

(17

ft.lbs.)

(5)

Tighten the nut of the generator pivot bolt.

Tightening torque: 45 Nm (33

ft.lbs.)

POWER STEERING OIL PUMP DRIVE BELT

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1.8L ENGINE -

Service Adjustment Procedures 11B-9

Standard value:

400-600

IS

readjusted

(.37-

45)

(88-1

32)

installed (.30-.35) (143- 187)

2. If the deflection is out of the standard values, adjust the

belt tension using the following procedures.

(1)

Loosen bolts A and B (for holding the oil pump).

(2)

Place a bar or similar object against the body of the

oil pump, and, while manually providing the suitable

amount of tension, adjust the amount of belt deflection .

(3) Tighten bolts

A

and

B

in that order.

Tightening torque:

A

bolt: 40

Nm

(29 ft.lbs.)

B bolt : 24 Nm (17 ft. lbs.)

(4) Check the amount of belt deflection readjust if neces-

sary.

Caut ion

Before th is check, turn the engine one t ime or m ore

in the regular direction of rotation (to the right).

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11B-10

1.8L ENGINE - Service Adjustment Procedures

Items

When

belt

tension

is readjusted

Standard value:

Deflection mm (in.) Tension

N

(Ibs.)

6.8-7.6 500-630

(.27-.30)

(110-1

39)

When new belt is

5.5-6.0

~

750-800

installed (.22-.24)

(165-176)

2. If the deflection is out of the standard values, loosen the

tension pulley nut an d adjust the belt tension with adjusting

bolt.

IGNITION TIMING INSPECTION AND

(1) Before inspection and adjustment, verify in the following

Engine coolant temperature: 80-95C

176-203F)

Lights, electric cooling fan and all accessories:

OFF

Transaxle: Neutral (P range on vehicles with A/T)

ADJUSTMENT 110003040

conditions:

(2)

Insert a paper clip into the

1

pin connector (blue) as show n

in the illustration at left.

3)

Connect a primary-voltage-detection type of tachometer

to the paper clip.

NOTE

Do not use the scan tool.

If

tested with the scan tool connected

to

the data link

connector, the ignition timing will not be the basic timing

but be ordinary timing.

(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.

Curb idle speed:

700

k

100

r lmin

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1.8L ENGINE - Serv ice Adjustment Procedures

11B-11

(10)Start the engine and run it at idle.

(11)Check that basic ignition timing is within the standard

value.

Basic ign i t ion t iming:

B B TDCk 2 Except 1996 mo delsand 1995 mo dels

for Cal i fornia)

5 BTDC 3 (1996 models and 1995 models for

Cali fornia)

(12)eExcept 1996 models and 1995 models for California>

a.

If

not within the standard value, loosen distributor hold

down nuts and adjust by rotating distributor body.

b. Tighten hold down nuts after adjusting.

Tightening torque: 12 Nm (8 ft.lbs.)

c If not within the standard value, inspect the

MFI

components by referring to GROUP 13A

-

Troubleshooting.

(13)Stop the engine, rem ove the jumper wire from the ignition

timing adjustment connector (brown), and return the con -

nector to its original condition.

(14)Start the engine and check that ignition timing is at the

standard value.

Actual ign i t ion t imin g: approx. 5 BTDC

NOTE

1. Ignition timing is variable within about k7 , even under

normal operating.

2. And it automatically advances by about

5

from 5

BTDC at higher altitudes.

CURB IDLE SPEED INSPECTION 110003041

(1) Before inspection and adjustment verify in the following

Engine coolant temperature: 80-95C (176-203F)

Lights, electric cooling fan and all accessories: OFF

Transaxle: Neutral (P range on vehicles with

A/T)

condition.

Standard value:

R;

(2)

Check the basic ignition timing.

5 BTDC

k

2

(Except 1996 models and 1995 mo dels

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11

6-12

1.8L

ENGINE

-

Service Adjustment Procedures

~

(6) Check the idle speed.

Curb id le speed:

700

100 r/min

NOTE

The idle speed is controlled automatically by the idle air

control (IAC) system.

(7)

If

there is a deviation from the standard value, refer to

GROUP 13 - Check Chart Classified by Problem Symp-

toms, and check the MFI components.

110003042

DLE MIXTURE INSPECTION

(1)

Before inspection, set the vehicle in the following condition.

Engine coolant temperature: 80-95C (176-203F )

Lights, electric cooling fan and accessories: OFF

Transaxle: Neutral (P range on vehicles with A/T)

value.

Standard value:

(2)

Make sure that the basic ignition timing is at a standard

5 BTDC?

2'

(Except 1996 m od els and 1995 mo dels

for California)

5 BTDC

k

3 (1996 models and 1995 models for

Cal i fornia)

(3)

After turning the ignition switch OFF, set a tachometer

or connect the scan tool to the data link connector.

NOTE

For tachometer setting procedure, refer to P.11B-10.

(4)

Start the engine and run at

2,500

r/min for approx. 2 min-

utes.

5 ) Set the CO tester and HC tester.

(6) Check the CO Concentration and HC concentration with

the engine at idle.

Standard value:

CO concentrat ion: 0.5% or less

HC

concent rat ion: 100 ppm or less

a

(7) If the standard value is exceeded, check the following

items.

Diagnostic output

Closed loop control

I f

closed

loop

control is performed

normally, heated oxygen sensor output signals change

within a

0-400

mV range and a 600-1,000

mV

range.)

Ignition coil, spark plug cables and spark plugs

Leaks in EGR system and EGR valve

Fuel pressure

Injectors

Evaporative emission control system

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1.8L ENGINE - S e r v i c e A d j u s t m e n t P r o c e d u r e s

11B-13

COMPRESSION PRESSURE INSPECTION

Refer to

P. l lA-12.

Standard value (at engine speed of 250-400 r/min):

L imit (at engine speed of 250-400 rlmin):

110003043

1,400 kPa

(199

psi)

min.

1,060

kPa

(151

psi)

MANIFOLD VACUUM

INSPECTION 110003044

Refer to P.11A-13.

TIMING BELT TENSION ADJUSTMENT

i i o003045

(1) Remove the timing belt upper cover.

(2) Turn the crankshaft clockwise for one turn or more to

set the No.1 cylinder to top dead compression center.

(3) Remove the access cover.

LACCeS~cover -O0IE I

4)

Loosen

the timing belt tensioner securing bolt to apply

tension to the belt by means of the force of the tensioner

spring.

Caut ion

The bolt can be lo os ened 1/4-1/2 turn .

I f

the b olt is loos ened mo re than necessary, the bolt

may

fa l l

insid e the c over.

- -

5 ) Tighten the timing belt tensioner securing bolt.

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118-12

1.8L ENGINE - Service Adjustment Procedures

-

-

(6)

Check the idle speed.

Curb id le speed:

700

? 100 r/min

NOTE

The idle speed is controlled automatically by the idle air

control (IAC) system.

(7)

If

there is a deviation from the standard value, refer

to

GROUP

13 -

Check Chart Classified by Problem Symp-

toms, and check the MFI components.

IDLE MIXTURE INSPECTION 110003042

(1)

Before inspection, set the veh icle in the following condition.

Engine coolant temperature: 80-95C (1 76-203F)

Lights, electric cooling fan and accessories: OFF

Transaxle: Neutral

(P

range on vehicles with

A/T)

value.

Standard value:

(2) Make sure that the basic ignition timing is at a standard

5 BTDCk 2 (Except 1996 models and 1995 mod els

for Cal i fornia)

5 BTDC 3 (1996 models and 1995 models for

Cali fornia)

(3)

After turning the ignition switch OFF, set a tachometer

or connect the scan tool to the data link connector.

NOTE

For tachometer setting procedure, refer to

P.11

B-10.

4)

Start the engine and run at 2,500 r/min for approx. 2 min-

utes.

5 ) Set the CO tester and HC tester.

(6) Check the CO concentration and HC concentration with

the engine at idle.

Standard value:

CO concentrat ion:

0.5

or less

HC concentrat ion: 100 ppm or less

(7) If the standard value is exceeded, check the following

items.

Diagnostic output

Closed loop control

If

closed loop control is performed

normally, heated oxygen sensor output signals change

within a 0-400 mV range and a 600-1,000 mV range.)

Ignition coil, spark plug cables and spark plugs

Leaks in EGR system and

EGR

valve

Fuel pressure

Injectors

/

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1.8L ENGINE

-

S e rv i c e A d j u s t m e n t P r o c e d u r e s

11

B-13

L A c c e s g over

E D E N W

COMPRESSION PRESSURE INSPECTION

Refer to P.11A-12.

Standard value (at engine speed

of

250-400 r lmin):

Lim it (at engine sp eed of 250-400 r /min ):

110003043

1,400 kPa (199 psi)

min. 1,060 kPa (151

psi)

MANIFOLD VACUUM INSPECTION 110003044

Refer to P.11A-13.

TIMING BELT TENSION ADJUSTMENT

110oo3045

(1) Remove the timing belt upper cover.

(2) Turn the crankshaft clockwise for one turn or more to

set the No.1 cylinder to top dead compression center.

(3) Remove the access cover.

4) Loosen the timing belt tensioner securing bolt to apply

tension to the belt by means of the force of the tensioner

spring.

Caut ion

The bolt can be loos ened 1/4-1/2 turn .

If

the bo l t is loo sened more than necessary, the bo l t

may fal l inside the cover.

11B-14

1.8L ENGINE -

Engine

Assembly

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ENGINE ASSEMBLY 110003046

REMOVAL AND INSTALLATION

I I r

Pre-removal Operation

Fuel Line Pressure Releasing (Refer to GROUP 13

- Service Adjustment Procedures.)

Hood Removal

Coolant Draining (Refer to GROUP 14 - Service

Adjustment Procedures.)

Transaxle Assembly Removal

(MTT: Refer to GROUP 22 - Transaxle Assembly.)

A R Refer to GROUP 23 - Transaxle Assembly.)

Radiator Removal (Refer to GROUP 14 - Radiator.)

Post-installation Operation

Radiator Installation Referto GROUP 14- Radiator.)

Transaxle Assembly Installation

(MTT: Refer to GROUP 22 - Transaxle Assembly.)

AT Refer to GROUP 23

-

Transaxle Assembly.)

Coolant Supplying (Refer to GROUP 14

-

Service


Hood Installation

Accelerator Cable Adjustment (Refer to GROUP

13


V-ribbed Belt Tension Adjustment of Power Steering

Oil

Pump and Air Conditioning Compressor

(Refer to P. 118-8,

9.)

I

5 Nm

Fuel rail

I

0-rina

03A0079

I Engine oi l

Removal steps

1. Vacuum hose connection

2 . Heater hose connection

20 00001079

11. Engine temperature gauge unit

connector

12. Engine coolant temperature sensor

1.8L ENGINE

-

Enaine Assemblv

11B-15

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R

58 Nm 11 Nm

100 Nm

72 f t l bs .

24 Nm

17 ft. lbs.

I

30

-_

_

45 Nm ZlOOOmJ

33 R.lbs.

11B-16

1.8L ENGINE - Engine Assembly

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REMOVAL SERVICE POINTS

+A+ POWER STEERING OIL PUMP REMOVAL

Remove the power steering oil pump from the bracket

with the hose attached.

NOTE

Place the removed power steering oil pump in a place

where it will not be a hindrance when remov ing and instal-

ling the engine assembly, and tie it with a cord.

\

\

2UlAOlCl

4 B F AIR CONDITIONING COMPRESSOR REMOVAL

4 C b ENGINE MOUNT BRACKET REMOVAL

(1)

Connect the engine assembly to an engine hoist.

(2) Place the garage jack against the engine

oil

pan w ith

a piece

of

wood in between, and after raising the

engine until there is no weight on the engine mount

brackets, remove the engine mount brackets.

4 D b

ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and harness connec-

tors, etc., are disconnected from the engine, block slowly

remove the engine assembly upward from the engine

compartment.

1.8L ENGINE

-

Engine Assembly * -

*

11B-17

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INSTA L LAT I SERV

I

C

E P NTS

.Ad ENGINE ASSEMBLY INSTALLATION

Install the engine assembly while checking

to

be sure

that the cables, hoses, and harness connectors are clear

of

the engine assembly.

.Bd ENGINE MOUNT BRA CKET 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 en-

gine.

(2)

Support the engine with a garage jack.

3)

Remove the chain block and support the engine as-

sembly with the special tool.

11B-18

1.8L ENGINE

-

Camshaft and Camshaft Oil Seal

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Distributor Removal

Timing Belt Cover Removal (Refer to P. 118-32.)

(Refer to GROUP 16 - Distributor.)

CAMSHAFT AND CAMSHAFT OIL SEAL

110003047

Post- instal lat ion Operation

Distributor Installation

(Refer to GROUP 16 - Distributor.)

Timing Belt Cover Installation (Refer to P. 118-32.)

Engine Adjustment (Refer to

P.

118-10.)


I

I

1.8L ENGINE - Camshaft and Camshaft Oil Seal

11

B-19

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MB9


(A, CA MSHAFT SPROCK ET REMOVA L

+,ROCKER ARMS AND ROCKER ARM SHA FT

ASSEMBLY (INTAK E SIDE) ROCKER ARMS AND

ROCKER ARM SHAFT ASSEMBLY (EXHAUST SIDE)

REMOVAL

Caut ion

Do not d isassemble the rocker arms and rocker arm

shaft

assembly.

INSTALLATION SERVICE POINTS

.A( CA MSHA FT OIL SEA L INSTA L LA TION

,B+

VALVE CLEARANCE ADJUSTMENT

Refer to GROUP 00

-

Maintenance Service.

11

6-20

1.8L ENGINE

-

Oil Pan

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22/37

OIL PAN

110003048


Engine

Oil

Draining and Supplying

(Refer to

GROUP 00 -

Service Adjustment

Procedures.)

Oil Dipstick Removal and Installation

40

Nm

29 f t l bs .

Removal steps

1. Front exhaust pipe

00001082

1.8L ENGINE -

Oil

Pan

11

B-21

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MD998727

REMOVAL SERVICE POINT

4 A F O I L PA N REMOVA L

After removing the oil pan mounting

bolts

and nuts, remove

the oil pan with the special

tool

and a brass bar.

Caution

Hamm er l i t t le by l i t t le, or th e oi l pan wil l be deformed.

INSTA LL A TION SERVICE POINTS

F A + OIL PAN INSTALLATION

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.

FB

RAIN PLUG GASKET INSTALLATION

Replace the drain plug gasket with the groove towards

the oil pan as shown.

11B-22

1.8L ENGINE

- Crankshaft Oil Seal

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CRANKSHAFT OIL SEAL

110003049


I

Pre-remo val and Post-instal lation Operation

Timing Belt Removal and Installation

(Refer to P. 118-32.)

Oil Pan Removal and Installation (Refer to P. 118-20.)

Transaxle Assembly Removal and Installation

( M F Refer to GROUP 22

-

Transaxle Assembly.)

A /T :

Refer to GROUP 23 - Transaxle Assembly)

Clutch Cover and Disc Removal and

Installation

I

100 Nm

72 R.lbs.

/

A01S0211-

Crankshaft front oil seal removal

steps

1.

Crankshaft sprocket

2. Key

3.

Crankshaft sensing b lade*

4. Crankshaft spacer*

b C + 5. Crankshaft front oil seal

Crankshaft rear oi l seal removal

s teps

6.

Adapter p late

p la te

F A + 8. Crankshaft rear oil seal

+ A F F B + 7. Flywheel assembly

r

drive

NOTE

*:

Vehicles for Federal and

California cFrom 1995 models>

1.8L NGIN

-

Crankshaft Oil Seal

118-23

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SEALA NT AND LUB RICATION POINTS

\

,

0150211

Lip section Y0,NM)Q3

Engine oi l

201- mis rn32

Specif ied sealant:

11

B-24

1.8L ENGINE

-

Cra n ksh a f t

Oil

Sea l

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A A F FLYWHEEL ASSEMBLY c M/T> OR DRIVE PLATE

Stop the crankshaft pulley from turning, and remove the

flywheel assembly

or drive plate

REMOVAL

INSTAL L AT I N S

E

RV C E P NTS

F A A CRANKSHAFT REAR OIL SEAL INSTALLATION

(1) Apply a small mount of engine oil to the entire circum-

(2)

Install the oil seal by tapping it as far as the chamferred

position of the oil seal case as shown in the illustration.

F B 4 FLYWHEEL ASSEMBLY cM/T> OR DRIVE PLATE

(1) Clean the sealant, oil and other particles that are adher-

ing to the mounting bolts, the thread sections of the

crankshaft, and the flywheel assembly or drive

plate

(2) Apply oil to the washer surfaces of the flywheel assem-

bly

bolts or the drive plate

bolts.

(3) Apply the specified sealant to the thread sections of

the

mounting bolts.

Specif ied sealant: Three Bond Part No. 1324

4) Tighten the mounting bolts to the specified torque.

5 )

After installation, clean

off

any sealant adhering to

the ends of the flywheel assembly mounting

bolts or the drive plate mounting

bolts

of the

ference of the oil seal lip.

c M > INSTALLATION

or equivalent

1.8L ENGINE - Crankshaf t Oil

Seal

11

B-25

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b C 4 CRANKSHAFT FRONT

OIL

SEAL INSTALLATION

(1)

Apply

a small amount of engine oil

to

the entire circum-

(2) Tap the oil seal until

it

is flush with the oil seal case.

ference

of

the oil seal lip.

11

B-26

1.8L ENGINE -

Cyl inder Head Gasket

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CYLINDER HEAD GASKET


110003050

Pre-removal O peration

Fuel Line Pressure Releasing (Refer to GROUP 13


Coolant Draining (Refer to GROUP 14 - Service


Engine Oil Draining

Air Intake Hose Removal

(Refer

to

GROUP 15 - Air Cleaner.)

Fuel rail

7

03A0079

Post-installation Operation

Air Intake Hose Installation

(Refer to GROUP

15

- Air Cleaner.)

Coolant Supplying (Refer to GROUP 14 - Service

Adiustment Procedures.)

En$ine Oil Supplying

Accelerator Cable Adjustment (Refer

to

GROUP 13


E n g in e o i l

3

00001084

8

R e m o va l s te p s

1. Breather hose connection

12. Oil pressu re switch connector

13. Engine coolant temperature gauge

1.8L ENGINE - Cyl inder Head Gasket

11

B-27

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Cold

Engine

75 Nm -+ 0 Nrn --f 20

Nrn

+90 +

+90

54 t . lbs. + 0 t.lbs.

+

14 ft.lbs.

+

+90 --f +90

\

31

3.3 Nrn

2.4 t . lbs.

/

26

Specif ied sealant:

MlTSUBlSHl GENUINE

PART

970389

or

equivalent

10

Nrn

7.2 R.lbs. 27

11B-28

1.8L ENGINE

- Cyl inder Head Gasket

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Camshaft sprocket

2OlWll6

~

Intake side

Front of engine c

\ DDIWl16

Exhaust

side Loosening order


4 A b

CAMSHAFT SPROCKET REMOVAL

(1) Rotate the crankshaft clockwise and align the timing

marks.

Caution

Always turn the crankshaft clockwise.

(2)

Tie the camsha ft sprocket and timing belt with a cord

so

that the position of the camshaft sprocket will not

move with respect to the timing belt.

(3) Use the special tool to remove the camshaft sprocket

with the timing belt attached.

Caution

After removing the camshaft sprocket, be sure

not to rotate the crankshaft.

4 B b CYLINDER HEAD ASSEMBLY REMOVAL

Loosen the bolts in

2

or

3

steps in order

of

the numbers

shown in the illustration, and remove the cylinder head

assembly.

NOTE

Use

of

commercially available cylinder head bolt wrench

is recommended.

1.8L

ENGINE

-

Cylinder Head Gasket

11

B-29

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Z01R0417

Intake side Identification ma rk

G 9 S

Fron t of

Exhaust side

01x0088

INSTALLATION SERVICE POINTS

F A 4 CYLINDER HEAD GASKET INSTALLATION

(1) Use a scraper or gasket remover to remove the gasket

adhering to the cylinder block.

Caution

Be careful not to let any foreign substances such

as gasket scraps enter the cylinder or the coolant

and oil passages.

(2) Place the cylinder head gasket on top of the cylinder

block

so

that the identification mark is facing upwards

as in the illustration.

Caution

The cylinder head gasket is easy to mls-install,

so be sure to check it. If

it

is mis-installed, malfunc-

tions such as no oil rising to the cylinder head

will occur.

-

F B 4

CYLINDERHEADASSEMBLY/WASHER/CYLlNDER

(1)

Use a scraper or gasket remover to remove the gasket

HEAD BOLT INSTALLATION

adhering to the cylinder head assembly.

Caution

Be careful not to let any foreign substances such

as gasket scraps enter the cylinder or the coolant

and oil passages.

(2) When installing the cylinder head bolts, check that

the shank length of each bolt meets the limit.

If

the

limit is exceeded, replace the bolt.

Limit (A):

96.4

mm

(3.795

in.)

and the washer of the cylinder head bolt.

(3)

Apply a small amount of engine oil

to

the thread section

11B-30 1.8L ENGINE

-

C v l i n d e r Head G a s k e t

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Frontof engine

take

side

mon1s

Exhaust side Tightening order

Step 4

Painted

mark

Step 5 .

k O

Painted mark

0 1 X 0 2 7 0

5 )

Tighten the bolts by the following procedure.

Step

1

2

3

4

5

Operation contents

Tighten

to 75

Nm

(54 ft.lbs.).

Fully loosen.

Tighten to 20 Nm

(14

f t . lbs.).

Tighten 90

of

a turn.

Tighten

90

f a turn.

Remarks

In the order shown in

the illustration.

In the reverse order to

that shown in the

illustration.


the illustration.


the illustration. Mark the

head of the cylinder

head bolt and cylinder

head by paint.


the illustration. Check

that the painted mark of

the head bolt is lined up

with that

of

the cylinder

head.

Caut ion

.-

.-

b

Be sure to observe the t ightening angle of

90, otherwise the bolt wi l l come loose.

(2)

I f the bolt is over t ightened, remove the bol t

and repeat the procedure f rom step (1).

b C 4

WATER INLE T FITTING, THERMOSTAT AND

(1) Loosen the water inlet pipe bolt shown in the illustra-

tion.

(2) Apply the specified sealant to the thermostat case

assembly as shown in the illustration.

Specif ied sealant: MlTSUBlSHl GENUINE PART

NOTE

(1)

Install the parts within 15 minutes after applying

liquid gasket.

THERMOSTAT CASE ASSEMBLY INSTALLATION

MD970389 or equivalent

1.8L ENGINE

-

Crankshaft Pul ley

11

B-31

CRANKSHAFT

PULLEY

110003051

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Pre-remov al Operation

Under Cover (L.H.) Removal

I

185 Nm

Post- instal lat ion Operation

Drive Belt Tension Adjustment

(Refer to

P.

118-8, 9.)

Under Cover (L.H.) Installation

R em ova l s t eps

1.

Drive belt (Air condit ioning)

2. Drive belt (Generator)

4 A F F A 4 3. Crankshaft pul ley bolt

201

F A + 4 . Crankshaf t pu l ley washer

5. Crankshaft pul ley

6. Dust cover

%

i

B


+A F CRANKSHAFT PULLEY BOLT REMOVAL

11

B-32

1.8L ENGINE

- Timing Belt

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TIMING BELT

11

0003052

REMOVAL AND INSTALL ATION

,

Post-installation OperationDrive Belt Tension Adjustment

(Refer

to

P. 118-8, 9.)

Under Cover Installation


Under Cover Removal

185 Nm

134

R.lbs.

21080017

1.8L ENGINE

-

Timing

Belt

11B-33

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+AF CRANKSHAFT BOLT / CRANKSHAFT PULLEY

Use the special tool to stop the crankshaft pulley from

turning, and remove the crankshaft

bolt.

Caution

Hold the special tool securely so that i t doesnt move.

REMOVAL

+BFTlMlNG BELT REMOVAL

Turn the crankshaft clockwise to align each timing

mark and to set the

No.

1 cylinder at compression

top dead center.

Caution

Always turn the crankshaft clockwise.

+

2)

Loosen the timing belt tensioner bolt.

(3)

Set a screwdriver

to

the timing belt tensioner and

press it fully back in the direction of the arrow.

4)

Temporarily tighten the timing belt tensioner bolt.

5 ) Remove the timing belt.

Caution

If the timing belt is to be re-used, use chalk to

mark the flat side of the belt wlth an arrow indicat-

ing the direction

of

rotation (clockwise).

a

11

B-34

1.8L ENGINE -

Timina Belt

(2)

Align the camshaft sprocket and the crankshaft sprock-

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Camshaft

sprocket

et timing marks.

(3) Install the timing belt in the following order, while mak-

ing sure that the tension side of the belt is not slack-

ened.

1.

Crankshaft sprocket

2.

Water pump sprocket

3.

Camshaft sprocket

4. Tensioner pulley

Caution

After installing the timing belt, apply force to turn

the camshaft sprocket counterclockwise, and re-

check that the belt is fully tensioned and that each

timing mark is in the proper position.

FBIT lM lNG BELT TENSION ADJUSTMENT

(1)

Initially loosen the fixing bolt of the tensioner pulley

fixed to the engine mount side by 1/2-1/4 turn, and

use the force of the tensioner spring to apply tension

to the belt.

(2)

Turn the crankshaft clockwise for two rotations, and

recheck that the timing marks on each sprocket are

aligned.

Caution

As the purpose of this procedure is to apply the

proper amount of tension to the tension side of

the timing belt by using the cam driving torque,

turn the crankshaft only by the amount given

above. Always turn the crankshaft clockwise.

3)

Check that all belt teeth in the section marked with

A are lifted up and that the teeth in each sprocket

are engaged. Then secure the tensioner pulley.

(4)

Lastly, lightly clamp the center of the span between

the camshaft sprocket and the water pump sprocket

on the belt tension side with your thumb and forefinger

as shown in the illustration. Then check that the clear-

ance

A

between the reverse surface of the belt and

the inside of the under cover seal line is at the standard

1.8L

ENGINE - Timing

Belt 11B-35

b C 4 FLANGE INSTALLATION

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Crankshaft

Frontof Rear of engine

Flange

2111~0114

Install the flange as shown in the illustration.

A

A

A

bD4 IMING BELT LOWER COVER /TIMING BELT UPPER

Install the bolts, being careful not to mistake the bolt sizes.

UseA bo l t : 6 x

18

(.24 x

.71)

COVER INSTALLATION

B bol t : 6

x

30 (.24 x 1.18)

[diameter

x

length mm (in.)]

b E 4 CRANKSHAFT PULLEY

/

CRANKSHAFT BOLT

(1)

Apply engine oil to the bearing surface and to the

(2)

Use the special

tool to

stop the crankshaft pulley from

INSTALLATION

thread section of the crankshaft bolt.

turning, and install the crankshaft bolt.

Caut ion

Hold the s pecia l too l securely so that i t doesn' t

move.

Documents

11B 4G93 Engine.pdf