Mitsubishi 4b12 Service Manual Engine

11C-1
GROUP 11C
ENGINE
MECHANICAL
<2.4L ENGINE>
CONTENTS
GENERAL INFORMATION . . . . . . . .
11C-2
ENGINE DIAGNOSIS. . . . . . . . . . . . .
11C-2
SERVICE SPECIFICATIONS. . . . . . .
11C-3
VALVE STEM SEAL . . . . . . . . . . . . . . 11C-38

REMOVAL AND INSTALLATION . . . . . . . .
11C-38
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11C-46

SEALANTS . . . . . . . . . . . . . . . . . . . .
11C-4
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11C-5
ON-VEHICLE SERVICE. . . . . . . . . . .
11C-8
DRIVE BELT TENSION CHECK. . . . . . . . .
11C-8
AUTO-TENSIONER CHECK . . . . . . . . . . .
11C-9
VALVE CLEARANCE CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
11C-11
IGNITION TIMING CHECK . . . . . . . . . . . . .
11C-11
CURB IDLE SPEED CHECK . . . . . . . . . . .
11C-13
IDLE MIXTURE CHECK . . . . . . . . . . . . . . .
11C-14
COMPRESSION PRESSURE CHECK. . . .
11C-16
MANIFOLD VACUUM CHECK . . . . . . . . . .
11C-17
CRANKSHAFT PULLEY . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . .
11C-46
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11C-48
CRANKSHAFT OIL SEAL . . . . . . . . . 11C-49

11C-49
CYLINDER HEAD GASKET . . . . . . . . 11C-52

11C-52
TIMING CHAIN . . . . . . . . . . . . . . . . . . 11C-64
11C-19
11C-19
11C-24
11C-24
11C-64
BALANCER TIMING CHAIN, BALANCER

SHAFT AND OIL PUMP MODULE. . . 11C-72
11C-72
BALANCER SHAFT AND OIL PUMP

MODULE . . . . . . . . . . . . . . . . . . . . . . . 11C-76
11C-76
ENGINE ASSEMBLY . . . . . . . . . . . . . 11C-81

11C-81
11C-2
ENGINE MECHANICAL <2.4L ENGINE>

GENERAL INFORMATION
GENERAL INFORMATION
The 4B12 (2.4 L) 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 chain
side). The firing order is 1-3-4-2.
ITEMS
SPECIFICATIONS
Type
In-line DOHC
Number of cylinders
Bore mm (in)
88 (3.5)
Stroke mm (in)
97 (3.8)
Total displacement cm3 (cu. in)
2,360 (144.0)
Compression ratio
10.5
Firing order
1-3-4-2
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
40 0
Closes (ABDC)
64 24
Opens (BBDC)
24 44
Closes (ATDC)
0 20
ENGINE DIAGNOSIS
M1111000101605
M1111000700433
SYMPTOMS
PROBABLE CAUSE
REMEDY
Compression is too
low
Blown cylinder head gasket
Replace the gasket.
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
Engine oil level is too low
Check the engine oil level.
Malfunction of engine oil pressure switch
Replace the engine 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 the correct

viscosity.
Stuck (opened) oil relief valve
Repair the relief valve.
Excessive bearing clearance
Replace the bearings.
Engine oil pressure

too high
Stuck (closed) oil relief valve
Repair the relief valve.
Noisy valves
Incorrect valve clearance
Adjust valve clearance
Thin or diluted engine oil (low engine oil

pressure)
Change the engine oil.
Worn or damaged valve stem or valve

guide
Replace the valve and/or the guide.
Drop in engine oil

pressure
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11C-3

SERVICE SPECIFICATIONS
SYMPTOMS
PROBABLE CAUSE
REMEDY
Connecting rod
noise/main bearing
noise
Insufficient oil supply
Check the engine oil level.
Thin or diluted engine oil
Change the engine oil.
Excessive bearing clearance
Replace the bearings.
SERVICE SPECIFICATIONS
Item
Drive belt tension
Vibration frequency Hz
(Reference)
M1111000301836
Standard value
Limit
102 129
Tension N (lb) (Reference) 248 400 (56

90)
Intake valve
0.20 0.03
(0.008 0.001)
Exhaust valve
0.30 0.03
(0.012 0.001)
Basic ignition timing at idle
5 BTDC 3
Actual ignition timing at curb idle
Approximately
10 BTDC
CO contents %
0.5 or less
HC contents ppm
100 or less
Curb idle speed r/min
650 100
Compression pressure (200 r/min) kPa (psi)
1,440 (208.8)
Minimum 1,000
(145.0)
Compression pressure difference of all cylinder kPa (psi)
100 (14.5)
Intake manifold vacuum at curb idle kPa (in Hg)
Minimum 60
(17.8)
Valve clearance (at cold) mm (in)
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11C-4

SEALANTS
SEALANTS
M1111000500763
Item
Specified sealant
Rocker cover assembly (matching area of the cylinder head and

the timing chain case assembly)
Three bond 1217G (Mitsubishi Genuine

Part No.1000A923), Three bond 1227D,
LOCTITE 5900 or equivalent
Engine oil pan

Part No.1000A923), Three bond 1227D,
Three bond 1207F (Mitsubishi Genuine
Part No.1000A992), LOCTITE 5971,
LOCTITE 5970, LOCTITE 5900 or
equivalent
Flywheel bolt <M/T> or drive plate bolt <CVT>
Three bond 1324 or exact equivalent
Cylinder head gasket (matching area of the cylinder block and

the cylinder head)

Part No.1000A923), LOCTITE 5900 or
equivalent
Timing chain case assembly
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11C-5

SPECIAL TOOLS
SPECIAL TOOLS
Tool
a
b
B992080
MB991824
MB991827
MB991910
DO NOT USE
MB991911
M1111000602272
Tool number and name
Supersession
Application
MB992080
Belt tension meter set
a: MB9912081
Belt tension meter
b: MB992082
Mic assembly
Tool not available
Drive belt tension

(frequency) measurement
MB991958
Scan tool (M.U.T.-III sub
assembly)
a: MB991824
Vehicle communication
interface (V.C.I.)
b: MB991827
M.U.T.-III USB cable
c: MB991910
M.U.T.-III main harness A
(Vehicles with CAN
communication system)
d: MB991911
M.U.T.-III main harness B
(Vehicles without CAN
communication system)
e: MB991914
M.U.T.-III main harness C
(for Chrysler models only)
f: MB991825
M.U.T.-III adapter harness
g: MB991826
M.U.T.-III trigger harness
MB991824-KIT
NOTE: MB991826
M.U.T.-III Trigger
Harness is not
necessary when
pushing V.C.I.
ENTER key.
DO NOT USE
MB991914
MB991825
MB991826
MB991958
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CAUTION
For vehicles with CAN
communication, use
M.U.T.-III main harness A
to send simulated vehicle
speed. If you connect
M.U.T.-III main harness B
instead, the CAN
communication does not
function correctly.
Ignition timing check
Curb idle speed check
Idle mixture check
Erasing the diagnostic
trouble code
11C-6

SPECIAL TOOLS
Tool
Supersession
MB992278
Belt tension release wrench
Application
Auto-tensioner tension
release
MB992278
MB990767
Front hub and flange yoke
holder
MB990767-01
Holding the crankshaft

pulley
MD998719
Pin
MIT308239
MB992103
Chain tension release bar
Camshaft and camshaft

sprocket assembly
(exhaust side) removal
MD998772
Valve spring compressor
General service
tool
Valve spring compression
MB992090
Retainer holder attachment
MB992089
Retainer holder C
MB992085
Valve stem seal pliers
B990767
D998719
B992103
MD998772
B992090
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Valve stem seal removal
11C-7

SPECIAL TOOLS
Tool
Supersession
Application
MD998737
Valve stem seal installer
MD998737-01
Valve stem seal

press-fitting
MD998727
Oil pan FIPG cutter
MD998727-01
Engine oil pan removal
MB991883
Flywheel stopper
General service
tool
Supporting the flywheel

<M/T> or drive plate <CVT>
MD998718
Crankshaft rear oil seal
installer
MD998718-01
Press-fitting the crankshaft

rear oil seal
MB991448
Bush remover and installer
base
MB991448-01
Press-fitting the crankshaft

front oil seal
MB991614
Angle gauge
Balancer shaft and oil pump

module installation
D998727
MB991883
MB991614
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11C-8

ON-VEHICLE SERVICE
Tool
Supersession
Application
MB991454
Engine hanger balancer
MZ203827-01
MB991895
Engine hanger
Tool not available
Supporting the engine

and transaxle assembly
during removal and
installation of the timing
chain
Supporting the engine
assembly during
removal and installation
of the transaxle
assembly
NOTE: Special tool
MB991454 is a part of
engine hanger attachment
set MB991453.
B991454
MB991895
MB991928
Engine hanger
Slide bracket (HI)
a: MB991929
Joint (50) 2
e
b: MB991930
Joint (90) 2
f
a
c: MB991931
d
Joint (140) 2
b
d: MB991932
c
Foot (standard) 4
B991928
e: MB991933
Foot (short) 2
f: MB991934
Chain and hook assembly
MB992201
Engine hanger plate
Tool not available
Transaxle assembly
removal
B992201
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003102997
1. Remove the radiator condenser tank mounting bolts.

2. Move the radiator condenser tank to a place where it will not
be a hindrance when checking the drive belt tension.
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ON-VEHICLE SERVICE
Auto-tensioner
Indicator mark
AC506730 AC
11C-9
CAUTION
Check the drive belt tension after turning the crankshaft
clockwise one turn or more.
3. Make sure that the indicator mark on the auto-tensioner is
within the area marked with A in the illustration.
4. If the mark is out of the area A, replace the drive belt (Refer
to P.11C-19.)
NOTE: The drive belt tension check is not necessary as the
auto-tensioner is adopted.
5. Tighten the radiator condenser tank mounting bolts to the
specified torque.
Tightening torque: 12 2 N m (102 22 in-lb)
AUTO-TENSIONER CHECK
M1111003001942
OPERATION CHECK
Required Special Tool:
MB992278: Belt tension release wrench
1. Turn off the engine from the idle state then check to see that
the drive belt is not protruding from the pulley width of the
auto-tensioner.
2. Remove the drive belt (Refer to P.11C-19.)
3. Using the special tool MB992278 and a straight offset
wrench as shown, check that no binding is present by
turning the auto-tensioner in the left and right directions.
4. If there are any problems in the procedure 1 or 3, replace
the auto-tensioner (Refer to P.11C-64.)
5. Install the drive belt (Refer to P.11C-19.)
Auto-tensioner
MB992278
AC804028AE
FUNCTION CHECK
The auto-tensioner can be checked whether it is in good condition by checking its tension.
.
<When the vibration frequency is measured:

Recommendation>
Required Special Tools:
MB992080: Belt Tension Meter Set
MB992081: Belt Tension Meter
MB992082: Mic Assembly
1. Check the tension of the drive belt (Refer to P.11C-8.)
2. Check the tension of the drive belt in the following
procedures.
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11C-10

ON-VEHICLE SERVICE
(1) Connect special tool MB992082 to special tool

MB992081 of special tool MB992080.
(2) Press the "POWER" button to turn on the power supply.
(3) Press the numeral key of "1" and check that "No. 1"
appears on the upper left of the display.
NOTE: This operation is to temporarily set the preset
data such as the belt specifications, because if the measurement is taken without input of the belt specifications,
conversion to tension value (N) cannot be made, resulting in judgement of error.
(4) Press "Hz" button twice to change the display to the
frequency display (Hz.)
Belt tension meter set (MB992080)

MB992081
MB992082
AC507219AD
Power steering
oil pump pulley
10 15 mm
(0.4 0.59 inch)
Idler pulley
Gently tap with your finger

15
15
MB992080
Idler pulley
Crankshaft
pulley
Generator
pulley
CAUTION
The temperature of the surface of the belt should be as
close to normal temperature as possible.
Do not allow any contaminants such as water or oil to
get onto the microphone.
If strong gusts of wind blow against the microphone or
if there are any loud sources of noise nearby, the values measured by the microphone may not correspond
to actual values.
If the microphone is touching the belt while the measurement is being made, the values measured by the
microphone may not correspond to actual values.
Do not take the measurement while the vehicle's engine
is running.
(5) Hold special tool MB992080 to the middle of the belt
between the pulleys (at the place indicated by arrow)
where it does not contact the belt [approximately 10 15
mm (0.4 0.59 inch) away from the rear surface of the
belt] so that it is perpendicular to the belt (within an angle
of 15 degree angle.)
(6) Press the "MEASURE" button.
(7) Gently tap the middle of the belt between the pulleys (the
place indicated by the arrow) with your finger as shown in
the illustration, and check that the vibration frequency of
the belt is within the standard value.
Standard value: 102 129 Hz
NOTE: To take the measurement repeatedly, tap the belt
again.
(8) Press and hold the "POWER" button to turn off the power
supply.
3. If not within the standard value, replace the auto-tensioner
(Refer to P.11C-64.)
AC607321AD
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ON-VEHICLE SERVICE
11C-11
<When using a tension gauge>

1. Check the tension of the drive belt (Refer to P.11C-8.)
2. Use a belt tension gauge in the middle of the belt between
the pulleys shown in the figure (at the place indicated by the
arrow) to check that the belt tension is within the standard
value.
Standard value: 248 400 N (56 90 lb)
Power steering
oil pump pulley
Idler pulley
3. If not within the standard value, replace the auto-tensioner

(Refer to P.11C-64.)
Belt
tension
gauge
Idler pulley
Crankshaft
pulley
Generator
pulley
AC506733 AD
VALVE CLEARANCE CHECK AND ADJUSTMENT
M1111001501509
Refer to GROUP00, Maintenance service <2.4L ENGINE>

Intake And Exhaust Valve Clearance (Inspect And Adjust)
P.00-85.
IGNITION TIMING CHECK
M1111001702755

MB991958: Scan Tool (M.U.T.-III Sub Assembly)
MB991824: V.C.I.
MB991827: M.U.T.-III USB Cable
MB991910: M.U.T.-III Main Harness A
1. Before inspection, 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 CVT)
NOTE: On vehicles for Canada, the headlight, taillight, etc.
remain lit even when the lighting switch is in "OFF" position
but this is no problem for checks.
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11C-12

ON-VEHICLE SERVICE
CAUTION
To prevent damage to scan tool MB991958, always turn the
ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
Data link connector
MB991910
MB991824
MB991827
AC608435 AB
Equipment side connector

No. 1 ignition coil
1 2 3
Power supply line
(terminal No. 3)
AK604618 AB
3. Set the timing light to the terminal No. 3 power supply line
(white-red) of the ignition coil No. 1.
4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 650 r/min.
6. Select scan tool MB991958 actuator test "item number 11".
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
(Refer to GROUP 13B, Multiport Fuel Injection (MFI)
Diagnosis Symptom Chart P.13B-56).
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. Cancel the setting mode of the scan tool MB991958.
10.Check that the actual ignition timing is at the standard value.
Standard value: Approximately 10 BTDC
NOTE: The ignition timing fluctuates about 7 , even under
normal operating condition.
NOTE: It is automatically further advanced by about 5
from 10 Before Top Dead Center at higher altitudes.
NOTE: Wait till approximately 1 minute passes after the
engine started, and check the ignition timing when the
engine stabilized.
11.Remove the timing light.
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ON-VEHICLE SERVICE
11C-13
CAUTION
12.Disconnect scan tool MB991958 from the data link
connector.
CURB IDLE SPEED CHECK
M1111003502757

MB991824: V.C.I.
CAUTION
Data link connector
MB991910
MB991824
MB991827
AC608435 AB
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11C-14

ON-VEHICLE SERVICE
No. 1 ignition coil
1 2 3
Power supply line
(terminal No. 3)
AK604618 AB
4. Start the engine.
5. Run the engine at idle for 2 minutes.
6. Check the actual ignition timing is at the standard value.
NOTE: It is automatically further advanced by about 5 from
10 Before Top Dead Center at higher altitudes.
engine stabilized.
7. Check the idle speed. Select item number 2 and take a
reading of the idle speed.
Curb idle speed: 650 100 r/min
NOTE: The idle speed is controlled automatically by the idle
air control system.
8. If the idle speed is outside the standard value (Refer to
GROUP 13B, Multiport Fuel Injection (MFI) Diagnosis
Symptom Chart P.13B-56).
9. Remove the timing light.
CAUTION
connector.
IDLE MIXTURE CHECK
M1111002102013

MB991824: V.C.I.
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ON-VEHICLE SERVICE
11C-15
CAUTION
Data link connector
MB991910
MB991824
MB991827
AC608435 AB

No. 1 ignition coil
1 2 3
Power supply line
(terminal No. 3)
AK604618 AB
4. Start the engine and let it run at idle.
5. Check that the actual ignition timing is at the standard value.
NOTE: It is automatically further advanced by about 5 from
10 Before Top Dead Center at higher altitudes.
engine stabilized.
6. Run the engine and increase the engine speed to 2,000
3,000 r/min for 2 minutes.
7. Set the CO, HC tester.
8. Check the CO contents and the HC contents at idle.
Standard value:
CO contents: 0.5% or less
HC contents: 100 ppm or less
9. If there is a deviation from the standard value, inspect the
MFI system (Refer to GROUP 13B, Multiport Fuel Injection
(MFI) Diagnosis Symptom Chart P.13B-56).
10.Remove the CO, HC tester and timing light.
CAUTION
connector.
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11C-16

ON-VEHICLE SERVICE
COMPRESSION PRESSURE CHECK
M1111002603334

MB991824: V.C.I.
1. Before inspection, check that the engine oil, starter and
battery are normal. Also, set the vehicle in the following
condition:
2. Turn the ignition switch to the "LOCK" (OFF) position.
3. Disconnect the connector of the ignition coil, and then
remove all the ignition coils and the spark plugs.
4. Disconnect the all of the injector connectors.
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.
Injector
connectors
5. Cover the spark plug hole with a shop towel etc., after the
engine has been cranked, check that no foreign material is
adhering to the shop towel.
AK502603AE
6. Set compression gauge to one of the spark plug holes.

7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 200 r/min): 1,440
kPa (208.8 psi)
Limit (at engine speed of 200 r/min): Minimum 1,000
kPa (145.0 psi)
Compression gauge
AK502604AE
8. Measure the compression pressure for all the cylinders, and

check that the pressure differences of the cylinders are
below the limit.
Limit: Maximum 100 kPa (14.5 psi)
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 from 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 all of the injector connector.
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ON-VEHICLE SERVICE
11C-17
11.Install the spark plugs and ignition coils.

12.Use the scan tool MB991958 to erase the diagnosis codes.
NOTE: This will erase the diagnosis code resulting from the
injector connectors being disconnected.
13.Select "Mode $0A" from "Special Function" of Scan tool
MB991958. Check whether the permanent-DTC (PDTC) is
stored or not. If stored, clear the PDTC. (Refer to GROUP
13B Multiport Fuel Injection (MFI) <2.4 L Engine>
Multiport Fuel Injection (MFI) Diagnosis Diagnostic
Function P.13B-12)
Data link connector
MB991910
MB991824
MB991827
AC608435 AB
MANIFOLD VACUUM CHECK
M1111002702167

MB991824: V.C.I.
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11C-18

ON-VEHICLE SERVICE
CAUTION
Data link connector
MB991910
MB991824
MB991827
AC608435 AB
Vacuum gauge
PCV valve
Plug
AK502601AE
3. Disconnect the ventilation hose from the positive crankcase

ventilation (PCV) valve, and then connect a vacuum gauge
to the ventilation hose. Plug the PCV valve.
4. Start the engine and check that idle speed is approximately
650 r/min.
5. Check the intake manifold vacuum.
Limit: Minimum 60 kPa (17.8 in Hg)
6. Turn off the ignition switch.
7. Remove the vacuum gauge and then connect the ventilation
hose to the PCV valve.
CAUTION
8. Disconnect scan tool MB991958 from the data link
connector.
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CRANKSHAFT PULLEY
11C-19
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001602955
Pre-removal Operation
Engine Room Under Cover Front B and Engine Room
Side Cover (RH) Removal (Refer to GROUP 51, Under
Cover P.51-20.)
Post-installation Operation
Drive Belt Tension Check (Refer to P.11C-8.)
Engine Room Under Cover Front B and Engine Room
Side Cover (RH) Installation (Refer to GROUP 51, Under
Cover P.51-20.)
12 2 Nm
102 22 in-lb
5
210 Nm
155 ft-lb
4
(Engine oil)
2
AC611683AC
<<A>>
<>
<<C>>
>>B<<
>>A<<
1.
2.
3.
Removal steps
Radiator condenser tank assembly
Drive belt
Crankshaft pulley center bolt

MB992278: Belt Tension Release Wrench
MB990767: Front Hub and Flange Yoke Holder
MD998719: Pin
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<<C>>
<<C>>
>>A<<
>>A<<
4.
5.
Removal steps (Continued)

Crankshaft pulley washer
Crankshaft pulley
11C-20

CRANKSHAFT PULLEY
REMOVAL SERVICE POINTS

.
<<A>> RADIATOR CONDENSER TANK ASSEMBLY REMOVAL

Remove the radiator condenser tank assembly mounting bolt,
and move the radiator condenser tank assembly to a place
where it does not interfere with the drive belt removal and
installation.
.
<> DRIVE BELT REMOVAL

Since the serpentine drive system with the auto-tensioner is
used, the following operations will be required.
CAUTION
To reuse the drive belt, draw an arrow indicating the rotating direction on the back of the belt using chalk to install
the same direction.
1. Rotate the pulley bolt of the auto-tensioner counterclockwise
with an special tool MB992278 and insert the L-shaped
hexagon wrench into the auto-tensioner hole to fix the
auto-tensioner.
2. Remove the drive belt.
Auto-tensioner
MB992278
AC804028AF
Auto-tensioner
L-shaped
hexagon
wrench
Pulley bolt
AC511067AC
<<C>> CRANKSHAFT PULLEY CENTER

BOLT/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT PULLEY REMOVAL
MD998719
1. Hold the crankshaft pulley with special tools MB990767 and

MD998719.
2. Loosen the crankshaft pulley center bolt and remove the
crankshaft pulley center bolt, crankshaft pulley washer and
crankshaft pulley.
Crankshaft pulley
MB990767
AC506738 AC
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CRANKSHAFT PULLEY
11C-21
INSTALLATION SERVICE POINTS

.
>>A<< CRANKSHAFT PULLEY/CRANKSHAFT

PULLEY WASHER/CRANKSHAFT PULLEY CENTER BOLT INSTALLATION
: Wipe clean with a rag.
: Wipe clean with a rag and degrease.
: Apply a small amount of engine oil.
Crankshaft
pulley washer
Crankshaft
sprocket
1. Wipe off the dirt on the crankshaft and crankshaft pulley as

shown in the figure using a rag.
2. Wipe off the dirt on the crankshaft sprocket, crankshaft and
crankshaft pulley as shown in the figure using a rag, and
then degrease them.
NOTE: Degrease them to prevent drop in the friction coefficient of the pressed area, which is caused by oil adhesion.
3. Install the crankshaft pulley.
4. Wipe off the dirt on the crankshaft pulley washer and
crankshaft pulley center bolt as shown in the figure using a
rag.
5. Apply an adequate and minimum amount of engine oil to the
threads of the crankshaft pulley center bolt and lower area of
the flange.
Crankshaft
Crankshaft
pulley center bolt
Crankshaft
pulley
Engine front
AC606441AB
MD998719
6. Hold the crankshaft pulley with special tools MB990767 and

MD998719 in the same manner as removal.
7. Tighten the crankshaft pulley center bolt to the specified
torque.
Tightening torque: 210 N m (155 ft-lb)
Crankshaft pulley
MB990767
AC506738 AC
TSB Revision
11C-22

CRANKSHAFT PULLEY
>>B<< DRIVE BELT INSTALLATION

CAUTION
To reuse the drive belt, install it by aligning the arrow
mark on the backside of belt marked at the removal
with the rotating direction.
Check that the notches of the notched pulley and the
notches of the drive belt are fit correctly.
Check that the drive belt is installed in the center of the
flat surface of the flat pulley.
Drive belt
Notched pulley
Flat pulley
AC704717AG
1. Install the drive belt to each pulleys as shown in the figure.

Auto-tensioner
Water pump
pulley
Power steering
oil pump pulley
Idler pulley
Generator
pulley
Idler
pulley
Crankshaft
pulley
Drive belt
A/C compressor
pulley
AC706598AC
TSB Revision

CRANKSHAFT PULLEY
2. Set an special tool MB992278 to the pulley bolt of the

auto-tensioner. Then, rotate the auto-tensioner
counterclockwise and remove the L-shaped hexagon
wrench fixing the auto-tensioner.
3. Apply tension to the drive belt while slowly turning the
auto-tensioner clockwise.
Auto-tensioner
MB992278
AC804028AF
Auto-tensioner
L-shaped
hexagon
wrench
Pulley bolt
11C-23
AC511067AC
TSB Revision
11C-24

CAMSHAFT
CAMSHAFT
M1112007800906
Engine Room Under Cover Front A, B and Engine Room
Cover P.51-20.)
Air Cleaner Assembly Removal (Refer to GROUP 15, Air
Cleaner P.15-10.)
Strut Tower Bar Removal (Refer to GROUP 42A, Strut
Tower Bar P.42A-15.)
Ignition Coil Removal (Refer to GROUP 16, Ignition System Ignition Coil P.16-51.)
3.0 1.0 Nm
5.5 0.5 Nm
to
27 8 in-lb
49 4 in-lb
Ignition Coil Installation (Refer to GROUP 16, Ignition
System Ignition Coil P.16-51.)
Strut Tower Bar Installation (Refer to GROUP 42A, Strut
Tower Bar P.42A-15.)
Air Cleaner Assembly Installation (Refer to GROUP 15,
Air Cleaner P.15-10.)
Cover P.51-20.)
Apply engine oil to all

moving parts before
installation.
3.0 0.5 Nm
27 4 in-lb
6
3
12 1 Nm
107 8 in-lb
17 3 Nm
30 2 Nm
to
13 2 ft-lb
22 1 ft-lb
13
11
10 2 Nm
89 17 in-lb
22
20
4
21
9
10
17
15
16
18
27
30
59 5 Nm
44 3 ft-lb
28
24
25
23
10 2 Nm
89 17 in-lb
10 2 Nm
89 17 in-lb
31
(Engine oil)
12
14
19
12 1 Nm
107 8 in-lb
29 N
N
(Engine oil)
32
8
13 1 Nm
115 8 in-lb
25 4 Nm
18 3 ft-lb
26
AC708410 AF
TSB Revision

CAMSHAFT
1.
2.
3.
4.
<<A>>
>>G<<
<>
5.
6.
7.
8.
<<C>>
<<D>>
<<E>>
>>F<<
>>E<<
>>D<<
9.
10.
11.
<<E>>
>>D<<
12.
<<E>>
>>D<<
13.
<<E>>
>>D<<
14.
Camshaft removal steps

Engine upper cover
Breather hose connection
PCV hose connection
Control wiring harness
connection
Rocker cover assembly
Rocker cover gasket
Number 1 cylinder compression
top dead center setting (only at
removal.)
Valve clearance adjustment
(Refer to P.11C-11) (only at
installation.)
Timing chain upper guide
Service hole bolt
Camshaft and camshaft sprocket
assembly (exhaust side) removal
preparatory operation (only at
removal.)
Front camshaft bearing cap
Camshaft bearing
Oil feed camshaft bearing cap
(exhaust side)
Camshaft bearing cap (exhaust
side)
side)
Thrust camshaft bearing cap
(exhaust side)
<<F>>
>>E<<
<<G>>
<<G>>
<<E>>
>>B<<
>>B<<
>>E<<
>>D<<
<<E>>
>>D<<
<<E>>
>>D<<
<<E>>
>>D<<
>>C<<
<<G>>
<<G>>
>>B<<
>>B<<
<<H>>
<>
>>A<<
>>A<<
<>
>>A<<
>>A<<
11C-25
Camshaft removal steps

15. Camshaft and camshaft sprocket
assembly (exhaust side)
16. Camshaft sprocket (exhaust side)
17. Camshaft (exhaust side)
18. Camshaft bearing
19. Oil feed camshaft bearing cap
(intake side)
20. Camshaft bearing cap (intake
side)
21. Camshaft bearing cap (intake
side)
22. Thrust camshaft bearing cap
(intake side)
assembly (intake side)
24. Camshaft sprocket (intake side)
25. Camshaft (intake side)
Oil feed control valve removal
steps
Drive belt (Refer to P.11C-19)
26. Power steering oil pump

assembly
27. Intake oil feeder control valve
connector connection
28. Intake oil feeder control valve
29. O-ring
30. Exhaust oil feeder control valve
31. Exhaust oil feeder control valve
32. O-ring

MB992103: Chain Tension Release Bar

.
<<A>> ROCKER COVER ASSEMBLY REMOVAL

6
13
18
8
Engine front
12
11
14
17
10
15
16
Loosen the rocker cover assembly mounting bolts in the order

of number shown in the figure, and remove the rocker cover
assembly.
AC506743 AD
.
TSB Revision
11C-26

CAMSHAFT
<> NUMBER 1 CYLINDER COMPRESSION

TOP DEAD CENTER SETTING
Cylinder head upper surface

Paint
markings
Timing chain
mating mark
Timing chain
mating mark
Camshaft sprocket
timing marks
AC506744 AC
CAUTION
Never turn the crankshaft counterclockwise.
1. Turn the crankshaft clockwise so that the camshaft sprocket
timing marks become horizontal to the cylinder head upper
surface, and set the number 1 cylinder to the top dead
center of compression. At this time, check that the
crankshaft pulley timing mark is in the 0-degree angle
position of the ignition timing indicator of the timing chain
case assembly.
2. Put paint marks on both the camshaft sprocket and timing
chain at the position of camshaft sprocket timing chain
mating mark (circular hole.)
.
<<C>> CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (EXHAUST SIDE) REMOVAL
PREPARATORY OPERATION
Precision flat-tipped
screwdriver
Crankshaft pulley
Service hole
1. Insert a precision flat-tipped screwdriver through the service

hole of the timing chain case assembly, press up the timing
chain tensioner ratchet to unlock, and keep the timing chain
tensioner with that state.
NOTE: Lightly press down the tail end of the precision
flat-tipped screwdriver to press up the tip of the precision
flat-tipped screwdriver inserted to the timing chain tensioner
to unlock.
Section A-A
Precision flat-tipped screwdriver
Ratchet
Service hole
Timing chain
tensioner
Ratchet
release hole
Timing chain tensioner

construction diagram
Ratchet
Ratchet
release hole
AC509155AC
TSB Revision

CAMSHAFT
11C-27
CAUTION
When inserting special tool MB992103 into the timing
chain case assembly inside, pay attention to the position of the timing chain to avoid damage to the timing
chain and timing chain tension side guide. Do not
insert the special tool MB992103 beyond its insertion
guideline.
If unlocking the timing chain tensioner is insufficient,
the special tool MB992103 cannot be inserted to the
insertion guideline. Do not insert the special tool
MB992103 forcibly, follow Step 1 again to unlock the
timing chain tensioner and insert the special tool
MB992103.
MB992103
Timing chain
Insertion standard line
AC507118AC
TSB Revision
11C-28

CAMSHAFT
MB992103
A
Camshaft
sprocket
(intake side)
Valve timing chain
(tension side)
Timing chain
tension
side guide
AC508123
MB992103
2. With the timing chain tensioner unlocked, insert special tool

MB992103 inside the timing chain case assembly along the
tension side of the timing chain until the insertion guide line
aligns with the upper surface of the timing chain case
assembly (Figure A.)
NOTE: With the timing chain tensioner unlocked, insert the
special tool MB992103 along the tension side of the timing
chain, according to the special tool MB992103 top shape.
The special tool MB992103 can be inserted smoothly to the
position where the special tool MB992103 insertion guide
line aligns with the timing chain case assembly top surface
(Figure B), and the spread timing chain tension side guide
can be held (Figure C.)
3. With the special tool MB992103 inserted up to the insertion
guide line, press the special tool MB992103 against the
intake side camshaft sprocket and spread and hold the
timing chain tension side guide.
4. Remove the flat-tipped precision screwdriver unlocking the
timing chain tensioner.
CAUTION
The timing chain may snag on by other parts. After sagging the timing chain, never rotate the crankshaft.
Timing chain tension

side guide
AC509159AB
MB992103
Timing chain
Hexagon
part of
exhaust
camshaft
5. With the timing chain tension side guide spread, hook the
special tool MB992103 over the hexagon part of the
camshaft on the exhaust side, and turn the camshaft
clockwise to apply slack to the timing chain between the
camshaft sprockets.
AC506748 AC
.
TSB Revision

CAMSHAFT
11C-29
<<D>> FRONT CAMSHAFT BEARING CAP

REMOVAL
Front camshaft
bearing cap
Loosen the front camshaft bearing cap mounting bolts in the

order of number shown in the figure, and remove the front camshaft bearing cap.
4
2
1
Engine front
3
AC506745AG
<<E>> OIL FEEDING CAMSHAFT BEARING

CAP/CAMSHAFT BEARING CAP/THRUST
CAMSHAFT BEARING CAP REMOVAL
CAUTION
When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring
force and the threads are damaged. Always loosen the
mounting bolts in four or five steps.
Loosen the camshaft bearing cap mounting bolts in the order of
number shown in the figure in four or five steps, and remove
the camshaft bearing caps.
Engine front
Camshaft bearing cap
AC506746 AC
TSB Revision
11C-30

CAMSHAFT
<<F>> CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (EXHAUST SIDE) REMOVAL
1. Raise slightly the transaxle side of the camshaft and
camshaft sprocket assembly (exhaust side) by using the
slack of the timing chain, and remove from the cam bearing.
Camshaft and camshaft

sprocket assembly
AC508124AD
Camshaft and
camshaft sprocket
assembly
2. Remove the timing chain from the camshaft and camshaft

sprocket assembly (exhaust side) toward the timing chain
case assembly, and remove the camshaft and camshaft
sprocket assembly (exhaust side) toward the transaxle.
3. Remove special tool MB992103 inserted into the timing
chain case assembly.
MB992103
Timing chain
Rope
AC506749 AC
CAUTION
The timing chain may snag on other parts. After removing
the camshaft and camshaft sprocket assembly, never
rotate the crankshaft.
4. After removing the camshaft and camshaft sprocket
assembly (exhaust side), hang up the timing chain with a
rope to prevent the timing chain from falling into the timing
chain case assembly.
Timing chain
AC509403AD
.
TSB Revision

CAMSHAFT
11C-31
<<G>> CAMSHAFT SPROCKET/CAMSHAFT

REMOVAL
Hexagon part
of camshaft
Hold the hexagon part of the camshaft with a monkey wrench.

Loosen the camshaft sprocket mounting bolt and remove the
camshaft sprocket from the camshaft.
AC700424AD
.
<<H>> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
1. With the hose installed, remove the power steering oil pump
assembly from the bracket.
2. Tie the removed power steering oil pump assembly with a
string at a position where it will not interfere with the removal
and installation of oil feed control valve.
.
<> OIL FEEDER CONTROL VALVE REMOVAL

CAUTION
After removal of the oil feeder control valve, be careful to
prevent dust from getting into the oil passage in the cylinder head.

.
>>A<< O-RING/OIL FEEDER CONTROL VALVE

INSTALLATION
CAUTION
When installing the oil feeder control valve, be careful to
avoid damage to the O-ring.
Apply engine oil to the O-ring of the oil feeder control valve and
install the oil feeder control valve to the cylinder head.
.
>>B<< CAMSHAFT/CAMSHAFT SPROCKET

INSTALLATION
Hexagon part
of camshaft
1. Use a monkey wrench to secure the hexagon part of the

camshaft in the same manner as removal.
AC611532AB
TSB Revision
11C-32

CAMSHAFT
Camshaft
sprocket
Camshaft
Camshaft
sprocket bolt

camshaft and camshaft sprocket as shown in the figure.
3. Install the camshaft sprocket to the camshaft.
camshaft sprocket mounting bolt.
5. Tighten the camshaft sprocket mounting bolt to the specified
torque.
Tightening torque: 59 5 N m (44 3 ft-lb)
AC607720AB
>>C<< CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (INTAKE SIDE) INSTALLATION
1. Align the intake side paint mark of the timing chain which
was put at removal with the paint mark of the intake side
camshaft sprocket, and install the camshaft sprocket to the
timing chain.
2. Install the camshaft and camshaft sprocket assembly (intake
side) to the cylinder head.
Paint markings
(intake side)
AC509403AE
.
>>D<< THRUST CAMSHAFT BEARING

CAP/CAMSHAFT BEARING CAP/OIL FEEDING
CAMSHAFT BEARING CAP/CAMSHAFT
BEARING INSTALLATION
1. Install the camshaft bearing caps to the cylinder head.
NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing
cap number and additionally its symbol to identify the intake
and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolts to the
specified torque in the order of number shown in the figure
in two or three steps.
Engine front
E 5
Identification of intake side

and exhaust side
Bearing cap No.

7
5
AC506778AC
TSB Revision
11C-33

CAMSHAFT
>>E<< CAMSHAFT BEARING/CAMSHAFT AND

CAMSHAFT SPROCKET ASSEMBLY (EXHAUST
SIDE) INSTALLATION
CAUTION
Be careful not to drop the camshaft bearing.
When installing the camshaft and camshaft sprocket
assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing
cap deviate from its position.
1. When replacing the camshaft bearing, according to the
identification mark of front camshaft bearing cap in the table
below, select a camshaft bearing with the corresponding
size. Note that the identification mark of camshaft bearing is
stamped on the place shown in the figure.
Front camshaft
bearing cap
Identification
mark
Identification Journal diameter

mark
mm (in)
AC611697AD
Notch
40.000 - 40.008
(1.5748 - 1.5751)
40.008 - 40.016
(1.5751 - 1.5754)
40.016 - 40.024
(1.5754 - 1.5757)
Identification mark
Oil hole
Camshaft bearing
identification mark
AC708893 AD
TSB Revision
11C-34

CAMSHAFT
Precision flat-tipped
screwdriver
Crankshaft pulley
Service hole
2. In the same manner as removal, insert the precision

flat-tipped screwdriver through the service hole of the timing
chain case assembly, press up the ratchet of timing chain
tensioner to unlock, and hold the unlocked timing chain
tensioner.
NOTE: Lightly press down the tail end of the precision
flat-tipped screwdriver to press up the tip of the precision
flat-tipped screwdriver inserted to the timing chain tensioner
to unlock.
Section A-A
Precision flat-tipped screwdriver
Ratchet
Service hole
Timing chain
tensioner
Ratchet
release hole

construction diagram
Ratchet
Ratchet
release hole
AC509155AC
TSB Revision

CAMSHAFT
11C-35
CAUTION
When inserting special tool MB992103 into the timing
chain case assembly, pay attention to the position of
the timing chain to avoid damage to the timing chain
and timing chain tension side guide. Do not insert the
special tool MB992103 beyond its insertion guideline.
If unlocking the timing chain tensioner is insufficient,
the special tool MB992103 cannot be inserted to the
insertion guideline. Do not insert the special tool
MB992103 forcibly, follow Step 2 again to unlock the
timing chain tensioner and insert the special tool
MB992103.
MB992103
Timing chain
Insertion standard line
AC507118AC
TSB Revision
11C-36

CAMSHAFT
Timing chain
(exhaust camshaft and
camshaft sprocket
assembly side)
Camshaft
sprocket
(intake side)
MB992103
Timing chain
(tension side)
Timing chain
tension
side guide
AC508125
Timing chain
tensioner
MB992103
3. With the timing chain tensioner unlocked, insert special tool

MB992103 inside the timing chain case assembly along the
tension side of the timing chain until the insertion guide line
aligns with the upper surface of the timing chain case
assembly (Figure A.)
NOTE: With the timing chain tensioner unlocked, insert the
special tool MB992103 along the tension side of the timing
chain, according to the special tool MB992103 top shape.
The special tool MB992103 can be inserted smoothly to the
position where the special tool MB992103 insertion guideline aligns with the timing chain case assembly top surface,
and the spread timing chain tension side guide can be hold.
4. With the special tool inserted up to the insertion guide line,
press the special tool MB992103 against the intake side
camshaft sprocket (Figure B) and spread and hold the
timing chain tension side guide (Figure C.)
5. Remove the flat-tipped precision screwdriver unlocking the
timing chain tensioner.
6. Pull up the camshaft and camshaft sprocket assembly
(exhaust side) mounting area of the timing chain (Figure D)
to provide allowance for easy installation of the camshaft
and camshaft sprocket assembly (exhaust side) to the
timing chain.
CAUTION
assembly (exhaust side), be careful not to let the camshaft
bearing which is installed to the front cam bearing deviate
from its position.
Timing chain
tension side guide
AC509177 AD
7. Align the exhaust side paint mark of the timing chain which
was put at removal with the paint mark of the exhaust side
camshaft sprocket, and install the timing chain to the
camshaft sprocket.
8. Install the camshaft and camshaft sprocket assembly
(exhaust side) to the cylinder head.
9. Remove the special tool MB992103 inserted into the timing
chain case assembly inside.
Paint markings
(exhaust side)
AC506752 AB
TSB Revision

CAMSHAFT
11C-37
>>F<< FRONT CAMSHAFT BEARING CAP

INSTALLATION
Engine front
CAUTION
When the mounting bolts are tightened with the front camshaft bearing cap tilted, the front camshaft bearing cap is
damaged. Install the front camshaft bearing cap properly
to the cylinder head and camshaft.
1. Install the front camshaft bearing cap to the cylinder head,
and temporarily tighten the front camshaft bearing cap
mounting bolts to the specified torque in the order of the
figure (1.)
(2)
(1)
Front
camshaft
bearing
cap
4
3
1
3
2. Tighten the front camshaft bearing cap mounting bolts again

to the specified torque in the order of the figure (2.)
AC511062AF
3. After the front camshaft bearing cap installation, check that

the paint markings of the camshaft sprocket and the timing
chain and the timing mark of the crankshaft pulley and the
0-degree angle position of ignition timing indicator are
aligned respectively.
.
>>G<< ROCKER COVER ASSEMBLY

INSTALLATION
1. Wipe off the sealant on the mating surface of the rocker
cover assembly and cylinder head and timing chain case
assembly, and degrease the surface where the sealant is
applied.
Cylinder head
4 mm
( 0.14 in)
4 mm
( 0.14 in)

13
1
6
7
12
18
17
11
Engine front
CAUTION
After the installation, until a sufficient period of time (one
hour or more) elapses, do not apply the oil or water to the
sealant application area or start the engine.
2. Apply sealant to the joint between the cylinder head and
timing chain case assembly as shown in the figure and
install the rocker cover assembly to the cylinder head.
Specified sealant: Three bond 1217G or equivalent
NOTE: Install the rocker cover assembly immediately after
applying sealant.
AC506753AF
14
15
10
16
3. Tighten the rocker cover assembly mounting bolts to the

specified torque in the order of number shown in the figure.
Tightening torque: 3.0 1.0 N m (27 8 in-lb)
4. Tighten again the rocker cover assembly mounting bolts to
the specified torque in the order of number shown in the
figure.
AC506743AE
TSB Revision
11C-38

VALVE STEM SEAL
VALVE STEM SEAL

M1112008100966
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
Cover P.51-20.)
Engine Oil Draining (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-5.)
Rocker Cover Assembly Removal (Refer to P.11C-24.)
Engine Oil Pan Removal (Refer to P.11C-46.)
Timing Chain Removal (Refer to P.11C-64.)
12 1 Nm
107 8 in-lb
4
5
17 3 Nm
30 2 Nm
to
13 2 ft-lb
22 1 ft-lb
Timing Chain Installation (Refer to P.11C-64.)
Engine Oil Pan Installation (Refer to P.11C-46.)
Valve Clearance Check (Refer to P.11C-11.)
Rocker Cover Assembly Installation (Refer to P.11C-24.)
Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-5.)
Cover P.51-20.)
12
3
9
12 1 Nm
107 8 in-lb
11
10
1
2
13
15*
7
16*
8
15*
16*
17*
18*
19* N
17*
18*
N 19*
14
25 5 Nm
18 3 ft-ib

moving parts before
installation.
AC709946AD
<<A>>
<>
>>F<<
>>E<<
>>D<<
1.
2.
3.
<>
>>D<<
4.
<>
>>D<<
5.
<>
>>D<<
6.
Removal steps
Camshaft bearing
Oil feeding camshaft bearing cap
(exhaust side)
side)
side)
Thrust camshaft bearing cap
(exhaust side)
TSB Revision
>>E<<
<>
>>E<<
>>D<<
<>
<>
<>
>>D<<
>>D<<
>>D<<

Camshaft and camshaft sprocket
assembly (exhaust side)
8. Camshaft bearing
9. Oil feeding camshaft bearing cap
(intake side)
10. Camshaft bearing cap (intake side)
11. Camshaft bearing cap (intake side)
(intake side)
7.

VALVE STEM SEAL
<<C>>
<<D>>
>>C<<
>>B<<
<<E>>
>>A<<
11C-39

assembly (intake side)
14. Spark plug
15. Valve tappet
16. Valve spring retainer lock
17. Valve spring retainer
18. Valve spring
19. Valve stem seal

MD998772: Valve Spring Compressor
MB992089: Retainer Holder C
MB992090: Retainer Holder Attachment
MB992085: Valve Stem Seal Pliers

MD998737: Valve Stem Seal Installer

.
<<A>> FRONT CAMSHAFT BEARING CAP

REMOVAL
Front camshaft
bearing cap
CAUTION
Loosen the front camshaft bearing cap mounting bolts in the
order of number shown in the figure, and remove the front camshaft bearing cap.
4
2
1
Engine front
3
AC506745AG
TSB Revision
11C-40

VALVE STEM SEAL
<> OIL FEEDING CAMSHAFT BEARING

CAUTION
Loosen the camshaft bearing caps mounting bolts in the order
of number shown in the figure in four or five steps, and remove
Engine front
AC506746 AC
<<C>> VALVE TAPPET REMOVAL

CAUTION
Do not use pliers or other tools to remove the valve tappets. Always remove them by hand.
When reusing the removed valve tappet, it has to be
installed in the same position as before. Be sure to put
a tab that shows the original installation position on the
valve tappet when storing it.
Remove all of the valve tappets by hand.
Valve tappet
AC509270 AC
TSB Revision

VALVE STEM SEAL
11C-41
<<D>> VALVE SPRING RETAINER LOCK

REMOVAL
1. Screw in special tool MB992090 to special tool MD998772
and assemble special tool MB992089.
MD998772
CAUTION
When removing the valve spring retainer lock, leave the
piston of the cylinder in the TDC (Top Dead Center) position. The valve may fall into the cylinder if the piston is not
properly in the TDC position.
2. Install special tool MD998772 (with special tools MB992090
and MB992089 attached) to the cylinder head and compress
the valve spring. Then, remove the valve spring retainer
lock.
MB992090
MB992089
AC509271 AC
.
<<E>> VALVE STEM SEAL REMOVAL

Use special tool MB992085 to grip the base of the stem seal
(where the outside diameter is larger) securely, and remove it
by twisting it to the left and right.
MB992085
Valve stem seal
AC608112 AB
TSB Revision
11C-42

VALVE STEM SEAL

.
>>A<< VALVE STEM SEAL INSTALLATION

CAUTION
Valve stem seals cannot be reused.
Do not damage the wall of the tappet hole when installing the valve stem seal.
Special tool MD998737 must be used to install the valve
stem seal. Improper installation of the valve stem seal
could result in oil leaking past the valve guide.
1. Apply a small amount of engine oil to the press-fit part and
lip part of the new valve stem seal.
AC708679AC
MD998737
2. Use special tool MD998737 to press-fit a new valve stem

seal in the valve guide using the valve stem area as a guide.
Valve
Valve stem
seal
Valve guide
AC308654AG
TSB Revision

VALVE STEM SEAL
11C-43
>>B<< VALVE SPRING RETAINER LOCK

INSTALLATION
MD998772
In the same manner as removal, use special tool MD998772

(with special tools MB992090 and MB992089 attached) to
compress the valve spring, and install the valve spring retainer
lock.
MB992090
MB992089
AC509271 AC
.
>>C<< VALVE TAPPET INSTALLATION

1. Apply a small amount of engine oil to the valve tappets.
CAUTION
Do not use pliers or other tools to install the valve tappets. Always install them by hand.
Be sure to install the valve tappets in the same position
as before.
2. Install the valve tappet to the cylinder head.
Valve tappet
AC509270 AC
TSB Revision
11C-44

VALVE STEM SEAL

CAMSHAFT BEARING CAP INSTALLATION
1. Install the camshaft bearing caps to the cylinder head.
NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the cap
number and additionally its symbol to identify the intake and
exhaust sides for correct installation.
Engine front
E 5

and exhaust side
Bearing cap No.

7
5
AC506778AC
TSB Revision
11C-45

VALVE STEM SEAL
>>E<< CAMSHAFT BEARING/CAMSHAFT AND

CAMSHAFT SPROCKET ASSEMBLY (EXHAUST
SIDE) INSTALLATION
CAUTION
deviate from its position.
When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below,
select a camshaft bearing with the corresponding size. Note
that the identification mark of camshaft bearing is stamped on
the place shown in the figure.
Front camshaft
bearing cap
Identification
mark

mark
mm (in)
AC611697AD
Notch
Camshaft bearing
identification mark
40.000 - 40.008
(1.5748 - 1.5751)
40.008 - 40.016
(1.5751 - 1.5754)
40.016 - 40.024
(1.5754 - 1.5757)
Identification mark
Oil hole
AC708893 AD
>>F<< FRONT CAMSHAFT BEARING CAP

INSTALLATION
Engine front
(2)
(1)
4
3
2
1
Front
camshaft
bearing
cap
1
3
4
2
CAUTION
figure (1.)
AC511062AF
TSB Revision
11C-46

OIL PAN
OIL PAN
M1112002802769
Cover P.51-20.)
Drive Belt Removal (Refer to P.11C-19.)
Drive Belt Installation (Refer to P.11C-19.)
Cover P.51-20.)
23 6 Nm
17 4 ft-lb
29 2 Nm
22 1 ft-lb
39 5 Nm
29 3 ft-lb
10 2 Nm
89 17 in-lb
23 6 Nm
17 4 ft-lb
23 6 Nm
17 4 ft-lb
3
23 6 Nm
17 4 ft-lb
2
AC803678AB
1.
<<A>>
>>C<<
2.
3.
Removal steps
A/C compressor and clutch
A/C compressor and clutch
assembly
A/C compressor bracket A

MD998727: Oil Pan FIPG Cutter
TSB Revision
<>
>>B<<
>>A<<
4.
5.
6.
7.

A/C compressor bracket B
Engine oil pan drain plug
Engine oil pan drain plug gasket
Engine oil pan

OIL PAN
11C-47

.
<<A>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly together
with the hose from the bracket.
2. Tie the removed A/C compressor and clutch assembly with
a string at a position where they will not interfere with the
removal and installation of engine oil pan.
.
<> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.
<Engine front>
Engine oil pan
Crankshaft pulley
CAUTION
Do not forcibly drive in special tool MD998727 to avoid
damage to the engine oil pan seal surface of cylinder block
assembly.
2. Insert special tool MD998727 from the engine oil pan
removal groove of the cylinder block assembly.
3. Lightly tap the special tool MD998727 with a hammer to
slide the engine oil pan seal surface, cut off the liquid
gasket, and remove the engine oil pan.
AC506757AC
<Engine rear>
Engine oil pan
Engine oil filter

AC506758AC
MD998727
MD998727
AC102324 AB
TSB Revision
11C-48

OIL PAN

.
>>A<< ENGINE OIL PAN INSTALLATION
2.5 mm
( 0.1in)
AC506756AD
1. Remove all the traces of sealant adhering to the engine oil

pan and cylinder block assembly using a remover or others.
Then, degrease them.
2. Apply the sealant without any gap to the mating surface of
engine oil pan as shown in the figure, and install the engine
oil pan to the cylinder block assembly.
NOTE: Install the engine oil pan immediately after applying
sealant.
CAUTION
3. Tighten the engine oil pan mounting bolts to the specified
torque.
Tightening torque:
M6: 10 2 N m (89 17 in-lb)
M8: 29 2 N m (21 1 ft-lb)
.
>>B<< ENGINE OIL PAN DRAIN PLUG GASKET

INSTALLATION
Replace the engine oil pan drain plug gasket with a new one.
Install the new engine oil pan drain plug gasket in the direction
shown in the illustration.
Engine oil
pan side
Engine oil pan

drain plug gasket
AC102325AJ
.
>>C<< A/C COMPRESSOR AND CLUTCH

ASSEMBLY INSTALLATION
Tighten A/C compressor and clutch assembly mounting bolts to

the specified torque in the order of number shown in the illustration.
1
3
A/C compressor
and clutch assembly
AC506759 AE
INSPECTION
M1112002900834
Check the engine oil pan for cracks.

Check the engine oil pan sealant-coated surface for damage and deformation.
TSB Revision
11C-49

CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL

M1112003103380
<M/T>
130 Nm
40 Nm
to
96 ft-lb
30 ft-lb
2
N
7
3
<CVT>
40 Nm
130 Nm
to
30 ft-lb
96 ft-lb
6
N1
2, 4
Seating surface: Engine oil

Thread: Three bond 1324
or exact equivalent
Engine oil
AC807650AE
>>C<<
1.
<<A>>
>>B<<
2.
Crankshaft front oil seal removal

steps
Crankshaft pulley (Refer to
P.11C-19)
Crankshaft front oil seal
Crankshaft rear oil seal removal
steps <M/T>
Manual transaxle assembly (Refer
to GROUP 22A, Transaxle
Assembly P.22A-12)
Clutch cover and clutch disk (Refer
to GROUP 21B, Clutch P.21B-3)
Flywheel bolt

MB991883: Flywheel Stopper
MD998718: Crankshaft Rear Oil Seal Installer
MB991448: Bush Remover And Installer Base
TSB Revision
>>B<<
>>A<<
3.
7.
<<A>>
>>B<<
>>B<<
>>B<<
>>A<<
4.
5.
6.
7.

steps <M/T> (Continued)
Flywheel assembly
steps <CVT>
CVT assembly (Refer to GROUP
23A, Transaxle Assembly
P.23A-152)
Drive plate bolt
Adapter plate
Drive plate
11C-50

CRANKSHAFT OIL SEAL
REMOVAL SERVICE POINT

.
<<A>> FLYWHEEL BOLT <M/T>/DRIVE PLATE

BOLT <CVT> REMOVAL
Fix the flywheel assembly using special tool MB991883, and
loosen the flywheel bolts <M/T.>
Fix the drive plate using special tool MB991883, and loosen the
drive plate bolts <CVT.>
Cylinder block
MB991883
Flywheel
assembly
<M/T>
or
drive plate
<CVT>
AC506761 AI

.
>>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION

MD998718
1. Apply a small amount of engine oil to the entire inner

diameter of the crankshaft rear oil seal lip.
2. Using special tool MD998718, press in the crankshaft rear
oil seal up to the cylinder block end surface.
(Engine oil)
Crankshaft
Cylinder block
AC506762 AE
.
>>B<< DRIVE PLATE <CVT>/ADAPTER PLATE

<CVT>/DRIVE PLATE BOLT <CVT>/FLYWHEEL
ASSEMBLY <M/T>/FLYWHEEL BOLT <M/T>
INSTALLATION
1. Remove the sealant, engine oil, and other adhering
materials from the drive plate installation face, the
crankshaft screw hole and drive plate bolts <CVT.>
Remove the sealant, engine oil, and other adhering
materials from the flywheel assembly installation face, the
crankshaft screw hole and flywheel bolts <M/T.>
2. Install the drive plate and drive plate adapter plate to the
crankshaft <CVT.>
Install the flywheel assembly to the crankshaft <M/T.>
TSB Revision

CRANKSHAFT OIL SEAL
Cylinder block
MB991883
Flywheel
assembly
<M/T>
or
drive plate
<CVT>
AC506761 AI
11C-51
3. Use special tool MB991883 to secure the drive plate in the

same manner as removal <CVT.>
Use special tool MB991883 to secure the flywheel assembly
in the same manner as removal <M/T.>
4. Apply a small amount of engine oil to the screw holes of the
crankshaft and the bearing surface of the drive plate bolts
<CVT.>
Apply a small amount of engine oil to the screw holes of the
crankshaft and the bearing surface of the flywheel bolts
<M/T.>
5. Apply specified sealant to the drive plate bolts <CVT> or
flywheel bolts <M/T> threads.
Specified sealant: Three bond 1324 or exact equivalent
AC609795AE
6. Tighten the drive plate bolts <CVT> or flywheel bolts <M/T>

to the specified torque in the order shown in the illustration.
5
3
7. Tighten the drive plate bolts <CVT> or flywheel bolts <M/T>

to the specified torque again in the order shown in the
illustration.
AC609796 AB
>>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
diameter of the crankshaft front oil seal lip.
Timing chain case
CAUTION
When installing the crankshaft front oil seal, be careful to
avoid damage to the crankshaft front oil seal.
2. Using special tool MB991448, press in the crankshaft front
oil seal up to the chamfered surface of timing chain case.
MB991448
AC506763 AC
TSB Revision
11C-52

CYLINDER HEAD GASKET

Fuel Line Pressure Reduction (Refer to GROUP 13B,
On-vehicle Service How to Reduce Pressurized Fuel
Lines P.13B-1000.)
Cover P.51-20.)
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-26.)
Cleaner P.15-10.)
Ignition Coil Removal (Refer to GROUP 16, Ignition System Ignition Coil P.16-51.)
Exhaust Manifold Removal (Refer to GROUP 15, Exhaust
Manifold P.15-26.)
Throttle Body Assembly Removal (Refer to GROUP 13B,
Throttle Body Assembly P.13B-1020.)
EGR Valve and EGR Valve Stay Removal (Refer to
GROUP 17, EGR Valve P.17-106.)
Water Pump Removal (Refer to GROUP 14, Water Pump
P.14-40.)
TSB Revision
M1112004004130
Water Pump Installation (Refer to GROUP 14, Water
Pump P.14-40.)
EGR Valve and EGR Valve Stay Installation (Refer to
GROUP 17, EGR Valve P.17-106.)
Throttle Body Assembly Installation (Refer to GROUP
13B, Throttle Body Assembly P.13B-1020.)
Exhaust Manifold Installation (Refer to GROUP 15,
Exhaust Manifold P.15-26.)
Ignition Coil Installation (Refer to GROUP 16, Ignition
System Ignition Coil P.16-51.)
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Fuel Leak Check
Cover P.51-20.)
11C-53

10
5
N
14
24 3 Nm
18 2 ft-lb
6
N
7
3
11
12
13
<<A>>
<<A>>
>>H<<
>>H<<
>>G<<
1.
2.
3.
4.
5.
6.
7.
8.
Removal steps
Control wiring harness connection
Radiator upper hose connection
Radiator lower hose connection
Heater hose connection
Cooling water line hose <M/T> or
CVT fluid cooler water return hose
B <CVT> connection
Water pump inlet pipe
Cooling water line gasket
O-ring
TSB Revision
<>
>>F<<
20 2 Nm
15 1 ft-lb
AC702470 AC

9. Emission vacuum hose connection
10. Brake booster vacuum hose
connection
11. Engine oil level gauge
12. Intake manifold stay
13. Cylinder head cover PCV hose
connection
14. Fuel high-pressure hose
connection
11C-54

12 1 Nm
107 8 in-lb
30 2 Nm
17 3 Nm
to
13 2 ft-lb
22 1ft-lb
19
20
18
12 1 Nm
107 8 in-lb

moving parts before
installation.
17
15
<Cold engine>
35 2 Nm
to +90 to +90
26 1 ft-lb
16
24 N
(Engine oil)
<Cold engine>
35 2 Nm
to +90 to +90
26 1 ft-lb
21
22
23
(Engine oil)
25
26
AC704318AF
<<C>>
<<D>>
<<D>>
<<D>>
>>E<<
>>C<<
>>D<<
>>D<<
>>D<<
15.
16.
17.
18.
19.
Removal steps
Valve timing chain (Refer to
P.11C-64)
Camshaft bearing
Oil feeding camshaft bearing cap

MB991454: Engine Hanger Balancer
MB991895: Engine Hanger
TSB Revision
<<D>>
<<E>>
<<E>>
>>D<<
>>C<<
>>C<<
>>B<<
>>B<<
>>A<<
>>A<<

assembly
22. Camshaft bearing
23. Cylinder head bolt
24. Cylinder head bolt assembly
25. Cylinder head assembly
26. Cylinder head gasket

11C-55

.
<<A>> RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp
as shown to install them in the original position. Then, remove
them.
Mating marks
AC606081AH
.
<> FUEL HIGH-PRESSURE HOSE

DISCONNECTION
1. Remove the stopper of the fuel high-pressure hose.
Stopper
AC301860 AC
2. Raise the retainer of the fuel high-pressure hose and pull out
the fuel high-pressure hose in the direction shown in the
figure.
NOTE: If the retainer is released, install it securely after
removing the fuel high-pressure hose.
Retainer
AC301861AC
.
<<C>> FRONT CAMSHAFT BEARING CAP

REMOVAL
1. Temporarily install the engine oil pan which was removed at
the timing chain removal (Refer to P.11C-46.)
CAUTION
When supporting the engine and transaxle assembly with
a garage jack, be careful not to deform the engine oil pan.
2. Place a garage jack against the engine oil pan with a piece
of wood in between to support the engine and transaxle
assembly.
TSB Revision
11C-56

3. Remove special tool MB991454, MB991928 or MB991895

which was installed for supporting the engine and transaxle
assembly when the timing chain was removed.
MB991928
MB991454
AC611558AB
MB991895
MB991454
AC611557AB
Front camshaft
bearing cap
CAUTION
4. Loosen the front camshaft bearing cap mounting bolts in the
order of number shown in the figure, and remove the front
camshaft bearing cap.
4
2
1
Engine front
3
AC506745AG
TSB Revision

11C-57
<<D>> OIL FEEDING CAMSHAFT BEARING

CAUTION
Loosen the camshaft bearing cap mounting bolts in the order of
number shown in the figure in four or five steps, and remove
Engine front
AC506746 AC
<<E>> CYLINDER HEAD BOLT/CYLINDER HEAD

BOLT ASSEMBLY REMOVAL
Loosen and remove the cylinder head bolts in two or three
steps in the order of number shown in the figure.
Engine front
10
4
AC506767AD
TSB Revision
11C-58


.
>>A<< CYLINDER HEAD GASKET/CYLINDER

HEAD ASSEMBLY INSTALLATION
CAUTION
Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.
1. Remove the sealant and grease on the top surface of
cylinder block and on the bottom surface of the cylinder
head. Then, degrease the sealant application surface.
Degrease
Bottom view of cylinder head
Degrease
Top view of cylinder block

AC607682AB
2 mm or 3 mm ( 0.08 in or 0.12 in)
3. Within three minutes after the sealant application, install the

cylinder head gasket to the cylinder block.
NOTE: When the cylinder gasket is installed to the cylinder
block, check that the sealant is securely applied to the bead
line of the cylinder head gasket.
4. Apply the sealant to the top surface of cylinder head gasket
as shown in the figure.
Cylinder head
gasket
Cylinder head
gasket
CAUTION
5. Within three minutes after the sealant application, install the
cylinder head assembly.
2 mm or 3 mm
( 0.08 in or 0.12 in)
Cylinder
block
2. Apply the sealant to the top surface of cylinder block as

shown in the figure.
AC511063 AD
TSB Revision

11C-59
>>B<< CYLINDER HEAD BOLT

ASSEMBLY/CYLINDER HEAD BOLT
INSTALLATION
Engine front
10
1. Replace cylinder head bolts with a new ones.

2. For two cylinder head bolts of the timing chain side, the
washer can be removed from the bolt. Install the washer,
with its sag facing upward, to the cylinder head bolts.
3. Apply a small amount of engine oil to the cylinder head bolt
threads and the washers.
4. Tighten the cylinder head bolts by the following procedure
(plastic region angular tightening method.)
(1) Tighten the cylinder head bolts to the specified torque in
the order of number shown in the figure.
CAUTION
When the tightening angle is smaller than the specified
tightening angle, the appropriate tightening capacity
cannot be secured.
When the tightening angle is larger than the specified
tightening angle, remove the cylinder head bolt to start
from the beginning again according to the procedure.
(2) Apply paint marks to the head of cylinder head bolt and
the cylinder head.
(3) Tighten the cylinder head bolt to 90 degrees angle in the
tightening order. Additionally tighten to 90 degrees angle,
and check that the paint mark on the cylinder head bolt is
aligned with the paint mark on the cylinder head.
AC506767AE
Paint mark
Paint mark
90
Paint marks
90
Paint marks
AC708680AC
.
TSB Revision
11C-60

>>C<< CAMSHAFT BEARING/CAMSHAFT AND

CAMSHAFT SPROCKET ASSEMBLY
INSTALLATION
CAUTION
deviate from its position.
When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below,
select a camshaft bearing with the corresponding size. Note
that the identification mark of camshaft bearing is stamped on
the place shown in the figure.
Front camshaft
bearing cap
Identification
mark

mark
mm (in)
AC611697AD
Notch
40.000 - 40.008
(1.5748 - 1.5751)
40.008 - 40.016
(1.5751 - 1.5754)
40.016 - 40.024
(1.5754 - 1.5757)
Identification mark
Oil hole
Camshaft bearing
identification mark
AC708893 AD
TSB Revision

11C-61

CAMSHAFT BEARING CAP INSTALLATION
1. Install the camshaft bearing caps to the cylinder heads.
NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing
cap number and additionally its symbol to identify the intake
and exhaust sides for correct installation.
Engine front
E 5

and exhaust side
Bearing cap No.

7
6
1
AC506778AC
>>E<< FRONT CAMSHAFT BEARING CAP

INSTALLATION
Engine front
(2)
(1)
4
3
2
1
Front
camshaft
bearing
cap
1
3
4
2
CAUTION
figure (1.)
AC511062AF
TSB Revision
11C-62

3. Install special tool MB991454, MB991928 or MB991895

which was installed for supporting the engine and transaxle
assembly when the timing chain was removed (Refer to
P.11C-64.)
4. Remove the garage jack which supports the engine and
transaxle assembly.
5. Remove the engine oil pan installed temporarily.
MB991928
MB991454
AC611558AB
MB991895
MB991454
AC611557AB
>>F<< FUEL HIGH-PRESSURE HOSE

CONNECTION
Fuel
high-pressure
hose
3 mm
(0.12 in)
CAUTION
After connecting the fuel high-pressure hose, slightly pull
it in the pull-out direction to check that it is installed firmly.
In addition, check that there is approximately 3mm (0.12
inch) play. After the check, install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe, and
install the fuel high-pressure hose.
Fuel line pipe

(Engine oil applied)
AC301864 AD
Stopper
AC301863AC
TSB Revision

11C-63
>>G<< O-RING INSTALLATION

Thermostat case
CAUTION
Avoid adhesion of engine oil or grease to the O-ring.
Fit the O-ring in the water pump inlet pipe groove, wet the
O-ring circumference or the pipe mounting area inner wall, and
then insert the O-ring.
O-ring
Water pump
inlet pipe
AC103007AF
>>H<< RADIATOR LOWER HOSE/RADIATOR

UPPER HOSE CONNECTION
1. Insert radiator hose as far as the projection of the water inlet
fitting or water outlet fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
Protrusion
Pipe, fitting, or etc.
Mating marks
AC606082 BD
TSB Revision
11C-64

TIMING CHAIN
TIMING CHAIN
M1112007201286
Cover P.51-20.)
Rocker Cover Assembly Removal (Refer to P.11C-24.)
Engine Oil Pan Removal (Refer to P.11C-46.)
Engine Oil Pan Installation (Refer to P.11C-46.)
Rocker Cover Assembly Installation (Refer to P.11C-24.)
Cover P.51-20.)
10 2 Nm
89 17 in-lb

moving parts before
installation.
9
12
10 2 Nm
89 17 in-lb
11
24 4 Nm
18 3 ft-lb
45 5 Nm
34 3 ft-lb
23 2 Nm
17 1 ft-lb
10
10 2 Nm
89 17 in-lb
13
10 2 Nm
89 17 in-lb
9.0 1.0 Nm
80 9 in-lb
8N
2
48 7 Nm
36 5 ft-lb
<>
<<C>>
10 2 Nm
89 17 in-lb
25 4 Nm
18 3 ft-lb
3
22 4 Nm
16 3 ft-lb
>>E<<
13 2 Nm
111 2 in-lb
6N
48 7 Nm
36 5 ft-lb
<<A>>
10 2 Nm
89 17 in-lb
1.
2.
3.
4.
Removal steps
Crankshaft pulley (Refer to
P.11C-19)
Water pump pulley
Idler pulley
Auto-tensioner
Power steering oil pump assembly
Engine and transaxle assembly
holding
Engine mounting insulator (Refer to
GROUP 32, Engine Mounting
P.32-5)
TSB Revision
AC700425 AD
5.
<<D>>
>>D<<
>>C<<
<<E>>
>>B<<
>>A<<
6.
7.
8.
9.
10.
11.
12.
13.

Cylinder block engine front
mounting bracket
Gasket
Crankshaft front oil seal
Timing chain upper guide
Timing chain tension side guide
Timing chain
Timing chain loose side guide

TIMING CHAIN

11C-65

MB991448: Bush Remover and Installer Base

.
<<A>> CRANKSHAFT PULLEY REMOVAL

When removing the crankshaft pulley, slightly loosen the water
pump pulley mounting bolts before removal of the drive belt.
.
<> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
1. With the hose installed, remove the power steering oil pump
assembly from the bracket.
and installation of timing chain.
.
<<C>> ENGINE AND TRANSAXLE ASSEMBLY

HOLDING
Install a special tool for holding the engine and transaxle
assembly.
1. <Special tool MB991928 is used>
(1) Assemble the special tool MB991928. Set the following
parts on the base hanger.
Slide bracket (HI)
Foot x 4 (standard) (MB991932)
Joint x 2 (90) (MB991930)
(2) Set the foot of the special tool as shown in the figure.
NOTE: Slide the slide bracket (HI) to adjust the engine
hanger balance.
MB991930
MB991932
MB991932
AC611565AB
(3) Mount special tool MB991454 to the power steering oil

pump bracket and engine hanger, and set it to special
tool MB991928 to support the engine and transaxle
assembly.
MB991928
MB991454
AC611558AB
TSB Revision
11C-66

TIMING CHAIN
2. <Special tool MB991895 is used>

(1) Set the foot of special tool MB991895 as shown in the
figure.
NOTE: Slide the foot to adjust the engine hanger balance.
MB991895
AC611564AB
(2) Mount special tool MB991454 to the power steering oil

pump bracket and the engine hanger, and set it to special
tool MB991895 to support the engine and transaxle
assembly.
MB991895
MB991454
AC611557AB
.
<<D>> TIMING CHAIN CASE ASSEMBLY

REMOVAL
CAUTION
If the adhesive strength of sealant on the timing chain case
assembly is so strong that the boss may be damaged by
peeling off, do not peel it off forcibly.
1. After removing the timing chain case assembly mounting
bolts, slightly pry the boss of the timing chain case assembly
shown in the figure using a flat-tipped screwdriver, and
remove the timing chain case assembly from the cylinder
head and cylinder block.
Boss
Timing chain
case assembly
AC700719AC
2. If the sealant cannot be peeled off easily, insert a wooden

hammer shank into the timing chain case assembly inside
as shown in the figure, pry slightly, and remove the timing
chain case assembly from the cylinder head and cylinder
block.
Hammer
Timing chain
case assembly
AC506771AC
TSB Revision

TIMING CHAIN
11C-67
<<E>> TIMING CHAIN TENSIONER REMOVAL

1. Temporarily install the crankshaft pulley to the crankshaft.
CAUTION
2. Turn the crankshaft clockwise to align the sprocket timing
marks as shown in the figure and set the number 1 cylinder
to the top dead center of compression stroke.
NOTE: At this time, it is not necessary that the link plate
(orange or blue) of the timing chain always aligns with each
sprocket timing mark.
3. Remove the crankshaft pulley installed temporarily.
Camshaft sprocket
timing marks
Crankshaft sprocket
timing mark
AC506772AG
Hard wire or
L-shaped
hexagon
wrench
Timing chain
tensioner
Ratchet release hole
4. Using a flat-tipped precision screwdriver, release the ratchet

of timing chain tensioner.
5. Compress the plunger of timing chain tensioner and insert
hard wire (such as piano wire) or the L-shaped hexagon
wrench [1.5 mm(0.05 inch)] to fix the plunger of the timing
chain tensioner.
6. Remove the timing chain tensioner.
AC506773 AD
TSB Revision
11C-68

TIMING CHAIN

.
>>A<< TIMING CHAIN INSTALLATION

1. Set the timing marks of the camshaft sprockets and the
crankshaft sprocket as shown in the figure.
Camshaft sprocket
timing marks
Crankshaft sprocket
timing mark
Link plates (orange)
Mating
mark
AC506774AC
Link plate (blue)
2. Align each sprocket timing chain mating marks with the link
plate (orange or blue) of timing chain to avoid slack of the
timing chain tension side, and install the timing chain to the
sprockets.
Mating
mark
Tension side
Mating mark
Link plate (blue)

AC506772AR
TSB Revision

TIMING CHAIN
11C-69
>>B<< TIMING CHAIN TENSIONER

INSTALLATION
Link plates (orange)
Mating
mark
Mating mark
Link plate (blue)
1. Check that the sprocket timing chain mating marks align

with the link plates (orange or blue) of the timing chain, and
install the timing chain tensioner to the cylinder block.
Mating
mark
Link plate (blue)

AC506772 AS
2. Remove the hard wire or L-shaped hexagon wrench fixing

the plunger of the timing chain tensioner to apply tension to
the timing chain.
Hard wire or
L-shaped
hexagon
wrench
Timing chain
tensioner
AC506773 AE
>>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
diameter of the crankshaft front oil seal lip.
Timing chain case
CAUTION
When installing the crankshaft front oil seal, be careful to
avoid damage to the crankshaft front oil seal.
2. Using special tool MB991448, press in the crankshaft front
oil seal up to the chamfered surface of timing chain case.
MB991448
AC506763 AC
TSB Revision
11C-70

TIMING CHAIN
.
>>D<< TIMING CHAIN CASE ASSEMBLY

INSTALLATION
1.
2.
3.
4.5 0.5 mm
(0.18 0.02 in)
A
A
BA
C
4.5 0.5 mm
( 0.18 0.02 in)
3 0.5 mm
(0.12 0.02 in)
2.5 mm
(0.1 in)
2.5 0.5 mm
( 0.1 0.02 in)
1 0.5 mm
(0.04 0.02 in)
3 0.5 mm
2.5 0.5 mm
(0.12 0.02 in)
( 0.1 0.02 in)
2.5 0.5 mm
( 0.1 0.02 in)
Section B B
4.
CAUTION
Be sure to remove the sealant remaining in the mounting hole, O-ring groove, and gap between parts.
After degreasing with degreasing agent, check that
there is no oil on the surface where the sealant is
applied.
After degreasing with degreasing agent, never touch
the degreased area with fingers.
Remove sealant from the timing chain case assembly and
the timing chain case assembly mounting surface of the
cylinder block and the cylinder head, and degrease the
surface where the sealant is applied.
Remove all the sealant adhering to the gasket between the
cylinder head and cylinder block (three-surface aligned
part.) Then, degrease the surfaces.
As for the three-surface aligned part that is indicated in Step
2 above, the engine oil oozes from the cylinder head gasket.
Thus, quickly apply the sealant to it after degreasing.
Apply a bead of the sealant to the timing chain case
assembly mounting surface. The bead diameter should be
2.5 0.5 mm (0.1 0.02 inch.) Overlap the part "A" with the
diameter of 4.5 0.5 mm (0.18 0.02 inch) or 2.5 0.5 mm
(0.1 0.02 inch) as shown in the figure, and apply the
sealant.
CAUTION
If the sealant contacts any other part during installation
of the timing chain case assembly, apply sealant again
before installing the timing chain case assembly.
After the installation, until a sufficient period of time
(one hour or more) elapses, do not apply the oil or
water to the sealant application area or start the engine.
5. Install the timing chain case assembly to the cylinder block
and cylinder head so that the sealant does not contact other
parts.
NOTE: Install the timing chain case assembly immediately
after applying sealant.
Section A A
7.5 0.5 mm
(0.30 0.02 in)
2.5 0.5 mm
( 0.1 0.02 in)
Section C C
AC709691AC
TSB Revision

TIMING CHAIN
6. Insert the bolts to the timing chain case assembly as shown,

and tighten them to the specified torque.
Bolt (symbol)
Thread
diameter x
Length mm
Tightening torque
Flange bolt (A) M6 25
10 2 N m (89
17 in-lb)
Flange bolt (B) M8 28
24 4 N m (18 2
ft-lb)
Bolt (C)
10 2 N m (89
17 in-lb)
A
C
11C-71
M6 25
B
B
AC506776 AC
>>E<< WATER PUMP PULLEY INSTALLATION

Temporarily tighten the water pump pulley mounting bolts.
Then, tighten them to the specified torque after the installation
of drive belt.
TSB Revision
11C-72

BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL PUMP MODULE
BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL

PUMP MODULE
M1112008500254
Pre-removal and Post-installation Operation

Timing Chain Removal and Installation (Refer to
P.11C-64.)

moving parts before
installation.
6
5
3
10 2 Nm
89 17 in-lb
1
10 2 Nm
89 17 in-lb
10 2 Nm
89 17 in-lb
2
(Engine oil)
20 Nm
44 Nm
20 Nm
to
to 0 Nm to
to +135
15 ft-lb
32 ft-lb
15 ft-lb
<<A>>
>>B<<
1.
2.
3.
Removal steps
Balancer timing chain guide
Balancer timing chain guide

MB991614: Angle Gauge
TSB Revision
AC506779 AG
>>A<<
4.
>>A<<
>>A<<
5.
6.

module
Balancer timing chain
Crankshaft sprocket

11C-73

.
<<A>> TIMING CHAIN TENSIONER REMOVAL
Hard wire or L-shaped

hexagon wrench
Timing chain
tensioner
CAUTION
Securely install the plunger of the timing chain tensioner.
Otherwise, it may pop out.
1. Press the balancer timing chain against the timing chain
tensioner, compress the plunger of the timing chain
tensioner and insert hard wire (piano wire, etc.) or L-shaped
hexagon wrench [1.5 mm (0.05 inch)] to fix the plunger of
the timing chain tensioner.
2. Remove the timing chain tensioner.
AC506781AB

.
>>A<< CRANKSHAFT SPROCKET/BALANCER

TIMING CHAIN/BALANCER SHAFT AND OIL
PUMP MODULE INSTALLATION
Balancer shaft and oil pump module
Oil inlet
port
Engine
oil
Engine
oil pan
AC509272 AB
Balancer
shaft
sprocket
1. When installing the new balancer shaft and oil pump

module, apply oil to the oil pump in the balancer shaft and oil
pump module and the balancer shaft bearing as follows.
(1) Clean the inside of the removed engine oil pan, and put
the balancer shaft and oil pump module into the engine
oil pan with its oil inlet port facing up.
(2) Pour new engine oil until two-thirds of the balancer shaft
and oil pump module is soaked.
(3) Fill the new engine oil [approximately 50 cm3 (3.05
cu.in.)] into the balancer shaft and oil pump module from
the oil inlet port.
(4) Turn the balancer shaft sprocket of the balancer shaft

and oil pump module clockwise four rotations or more to
apply the engine oil to the entire area of the oil pump and
the balancer shaft bearing.
AC509273 AB
TSB Revision
11C-74

: Wipe clean with a rag.

: Wipe clean with a rag and degrease.
Crankshaft
2. Wipe the dirt on the crankshaft sprocket and the crankshaft

using a rag, and then remove the grease from the portion
shown in the illustration.
NOTE: Remove grease to prevent a drop in the coefficient
of friction of the pressing portion caused by adhesion of oil.
Engine
front
Crankshaft sprocket
AC807896AB
Link plate (orange)

Crankshaft
sprocket
timing mark
Crankshaft
sprocket
timing mark
(key slot)
Balancer shaft
housing
timing mark
Balancer shaft
sprocket
timing mark
Link plate (blue)
AC506780AE
Balancer shaft and

oil pump module
1
3. With the link marks (orange or blue) of balancer timing chain

aligned with the timing marks of balancer sprocket and
crankshaft sprocket, install the balancer shaft and oil pump
module together with the balancer timing chain and
crankshaft sprocket as one unit to the cylinder block. At this
time, securely bring the balancer shaft and oil pump module
into contact with the rudder frame mounting area.
threads and bearing surfaces of the balancer shaft and oil
pump module mounting bolts.
5. Tighten the balancer shaft and oil pump module mounting

bolts to the specified torque in the order of number shown in
the figure.
6. Retighten the balancer shaft and oil pump module mounting
the figure.
AC506784 AB
7. Loosen each balancer shaft and oil pump module mounting

bolts fully in the reverse sequence to that shown.
bolts again to the specified torque in the order of number
TSB Revision

Balancer shaft and
oil pump module
1
11C-75
9. After tightening to the specified torque, tighten the balancer

shaft and oil pump module mounting bolts to 135 degrees
angle, using special tool MB991614, in the order of number
AC506784 AB
Balancer shaft and

oil pump module
MB991614
AC506777AB
>>B<< TIMING CHAIN TENSIONER

INSTALLATION
Hard wire or L-shaped
hexagon wrench
Timing chain
tensioner
1. Install the timing chain tensioner to the cylinder block.

2. Remove the hard wire or L-shaped hexagon wrench fixing
the plunger of the timing chain tensioner to apply tension to
the balancer timing chain.
AC506781AB
TSB Revision
11C-76

BALANCER SHAFT AND OIL PUMP MODULE

M1112008900230
Pre-removal and Post-installation Operation

Engine Oil Pan Removal and Installation (Refer to
P.11C-46.)
10 2 Nm
89 17 in-lb
1
(Engine oil)
20 Nm
44 Nm
20 Nm
to
to 0 Nm to
to +135
15 ft-lb
32 ft-lb
15 ft-lb
<<A>>
>>A<<
1.
Removal steps
module

MB991614: Angle Gauge
TSB Revision
AC509274 AE

11C-77

.
<<A>> BALANCER SHAFT AND OIL PUMP MODULE REMOVAL

CAUTION
Never turn the crankshaft after the number 1 cylinder or
number 4 cylinder is set to the top dead center of compression.
1. Turn the crankshaft clockwise to align the timing mark of the
balancer shaft sprocket with the timing mark of the balancer
shaft and oil pump module, and set the number 1 cylinder or
number 4 cylinder to the top dead center of compression.
2. Put paint mark on the balancer shaft sprocket timing mark
and balancer timing chain.
Balancer shaft
sprocket
timing mark
Balancer
shaft and
oil pump
module
timing mark
Paint
markings
AC509275 AB
L-shaped hard wire or

L-shaped hexagon wrench
CAUTION
Securely install the plunger of the timing chain tensioner.
Otherwise, it may pop out.
3. Press the balancer timing chain against the timing chain
tensioner, compress the plunger of the timing chain
tensioner and insert L-shaped hard wire (piano wire, etc.) or
L-shaped hexagon wrench [1.5 mm (0.05 inch)] to the
plunger fixing hole of the timing chain tensioner from under
the timing chain case, and fix the plunger of the timing chain
tensioner.

AC509276 AB
<Timing chain case L-shaped hard wire or

internal diagram>
L-shaped hexagon wrench
Balancer
timing chain
Timing chain
tensioner
AC509277AB
TSB Revision
11C-78

4. Use a wrench to remove the mounting bolt at the lower side

of the balancer timing chain guide shown in the figure so
that the balancer timing chain guide is unrestricted.
5. Support the balancer shaft and oil pump module with a
hand, and remove the balancer shaft and oil pump module
mounting bolts.
Balancer timing
chain guide
AC509278 AB
Balancer shaft and

oil pump module
Balancer
timing
chain
Protrusion
Balancer
timing
chain
6. Remove the balancer shaft and oil pump module from the
rudder frame with the balancer timing chain attached, and
move it to the center of the engine.
7. Remove the balancer timing chain from the balancer shaft
and oil pump module, and remove the balancer shaft and oil
pump module.
AC509279 AB
Cable band
CAUTION
When the tooth jump of the balancer timing chain from the
crankshaft sprocket occurs, the timing between the balancer shaft and the oil pump module becomes off, resulting in the abnormal engine vibration. Be sure that the tooth
jump will not occur.
8. After the balancer shaft and oil pump module is removed,
using a cable band, tie the balancer timing chain at the
protrusion of the rudder frame to prevent the tooth jump of
balancer timing chain from the crankshaft sprocket.
AC509280 AD
INSTALLATION SERVICE POINT

.
>>A<< BALANCER SHAFT AND OIL PUMP MODULE INSTALLATION

1. When installing the new balancer shaft and oil pump
module, apply engine oil to the oil pump in the balancer
shaft and oil pump module and the balancer shaft bearing as
follows.
TSB Revision

Oil inlet
port
Engine
oil pan
Engine
oil
11C-79
(1) Clean the inside of the removed engine oil pan, and put
the balancer shaft and oil pump module into the engine
oil pan with its oil inlet port facing up.
(2) Pour new engine oil until two-thirds of the balancer shaft
and oil pump module is soaked.
(3) Fill the new engine oil [approximately 50 cm3 (3.05
cu.in.)] into the balancer shaft and oil pump module from
the oil inlet port.
AC509272 AB
Balancer
shaft
sprocket
Balancer
timing
chain
AC509273 AB
Balancer shaft
sprocket
Paint marking
or timing mark
Paint markings
AC509279 AC
Balancer shaft and

oil pump module
1
(4) Turn the balancer shaft sprocket of the balancer shaft

and oil pump module clockwise four rotations or more to
apply the engine oil to the entire area of the oil pump and
the balancer shaft bearing.
2. Remove the cable band installed to prevent the tooth jump
of the balancer timing chain from the crankshaft sprocket
from the balancer timing chain.
3. Regarding the prevention of the tooth jump of the balancer

timing chain, install the balancer shaft sprocket to the
balancer timing chain with aligning the paint mark of the
balancer shaft sprocket (the timing mark of the new balancer
shaft and oil pump module) with that of the balancer timing
chain.
4. With the paint mark of the balancer timing chain aligned with
that of the balancer sprocket (the timing mark of the new
balancer shaft and oil pump module), install the balancer
shaft and oil pump module to the rudder frame. Securely
bring the balancer shaft and oil pump module into contact
with the rudder frame mounting area.
threads and bearing surfaces of the balancer shaft and oil
pump module mounting bolts.
the figure.
7. Retighten the balancer shaft and oil pump module mounting
the figure.
AC506784 AB
8. Loosen each balancer shaft and oil pump module mounting

bolts fully in the reverse sequence to that shown.
bolts again to the specified torque in the order of number
TSB Revision
11C-80

Balancer shaft and
oil pump module
AC506784 AB
10.After tightening to the specified torque, tighten the balancer

shaft and oil pump module mounting bolts to 135 degrees
angle, using special tool MB991614, in the order of number
11.Tighten the mounting bolt of the lower side of the balancer
timing chain guide with the standard torque.
12.Remove the plunger of the timing chain tensioner using the
L-shaped hard wire (piano wire, etc.) or L-shaped hexagon
wrench [1.5 mm (0.05 inch).]
Balancer shaft and

oil pump module
MB991614
AC506777AB
TSB Revision

ENGINE ASSEMBLY
11C-81
ENGINE ASSEMBLY
M1112001005695
CAUTION
When the engine assembly replacement is performed, use scan tool MB991958 to initialize the learning value (Refer to GROUP 00, Initialization Procedure for Learning Value in MFI Engine P.00-38.)
Hood Removal (Refer to GROUP 42A, Hood P.42A-7.)
Fuel Line Pressure Reduction (Refer to GROUP 13B,
On-vehicle Service How to Reduce Pressurized Fuel
Lines P.13B-1000.)
Side Cover Removal (Refer to GROUP 51, Under Cover
P.51-20.)
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Transmission Oil Draining (Refer to GROUP 22A,
On-vehicle Service Transmission Oil Replacement
P.22A-8) <M/T.>
Transmission Fluid Draining (Refer to GROUP 23A,
On-vehicle Service Transmission Fluid Replacement
P.23A-136) <CVT.>
Engine Upper Cover Removal (Refer to P.11C-24.)
Exhaust Manifold Removal (Refer to GROUP 15, Exhaust
Manifold P.15-26.)
Cleaner P.15-10.)
Battery and Battery Tray Removal (Refer to GROUP 54A,
Battery P.54A-10.)
Engine control module Removal (Refer to GROUP 13B,
Engine Control Module P.13B-1022.)
Radiator Removal (Refer to GROUP 14, Radiator
P.14-53.)
Drive Belt Removal (Refer to P.11C-19.)
TSB Revision
Drive Belt Installation (Refer to P.11C-19.)
Radiator Installation (Refer to GROUP 14, Radiator
P.14-53.)
Engine control module Installation (Refer to GROUP 13B,
Engine Control Module P.13B-1022.)
Battery and Battery Tray Installation (Refer to GROUP
54A, Battery P.54A-10.)
Exhaust Manifold Installation (Refer to GROUP 15,
Exhaust Manifold P.15-26.)
Transmission Oil Draining (Refer to GROUP 22A,
On-vehicle Service Transmission Oil Replacement
P.22A-8) <M/T.>
Transmission Fluid Draining (Refer to GROUP 23A,
On-vehicle Service Transmission Fluid Replacement
P.23A-136) <CVT.>
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Drive Belt Tension Check (Refer to P.11C-8.)
Fuel Leak Check.
Engine Room Under Cover Front and Engine Room Side
Cover Installation (Refer to GROUP 51, Under Cover
P.51-20.)
Engine Upper Cover Installation (Refer to P.11C-24.)
Hood Installation (Refer to GROUP 42A, Hood P.42A-7.)
11C-82

ENGINE ASSEMBLY
6
7
8.5 1.5 Nm
76 13 in-lb 12 2 Nm
102 22 in-lb
5
3
8
AC506785AC
<<A>>
<<A>>
>>E<<
>>E<<
1.
2.
3.
4.
5.
6.
Removal steps
Control wiring harness connection
Battery cable connection
Radiator upper hose connection
Radiator lower hose connection
Heater hose connection
Emission vacuum hose connection
TSB Revision
7.
<>
>>D<<
8.
9.

Brake booster vacuum hose
connection
Cooling water line hose connection
Fuel high-pressure hose
connection
11C-83

ENGINE ASSEMBLY
14
66 7 Nm
49 5 ft-lb
13 2 Nm
111 22 in-lb
50 5 Nm
37 3 ft-lb
10
9.0 2.0 Nm
80 17 in-lb
13
11
12
25 4 Nm
18 3 ft-lb
23 6 Nm
17 4 ft-lb
AC609240AC
<<C>>
<<D>>
<<E>>
>>C<<
Removal steps
10. Power steering oil pump assembly
11. A/C compressor and clutch
assembly
Manual transaxle assembly <M/T>

TSB Revision
<<E>>
<<F>>
<<G>>
>>B<<
>>A<<
12.
13.
14.

CVT assembly <CVT>
Grounding cable connection
Engine mounting insulator
Engine assembly

MB992201: Engine Hanger Plate
11C-84

ENGINE ASSEMBLY

.
<<A>> RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp
as shown to install them in the original position. Then, remove
them.
Mating marks
AC606081AH
.
<> FUEL HIGH-PRESSURE HOSE

DISCONNECTION
1. Remove the stopper of the fuel high-pressure hose.
Stopper
AC301860 AC
2. Raise the retainer of the fuel high-pressure hose and pull out
the fuel high-pressure hose in the direction shown in the
figure.
NOTE: If the retainer is released, install it securely after
removing the fuel high-pressure hose.
Retainer
AC301861AC
.
<<C>> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
1. Remove the power steering oil pump assembly together with
the hose from the bracket.
and installation of engine assembly.
.
TSB Revision

ENGINE ASSEMBLY
11C-85
<<D>> A/C COMPRESSOR AND CLUTCH

ASSEMBLY REMOVAL
1. Remove the A/C compressor and clutch assembly together
with the hose from the bracket.
2. Tie the removed A/C compressor and clutch assembly with
a string at a position where it will not interfere with the
removal and installation of engine assembly.
.
<<E>> MANUAL TRANSAXLE ASSEMBLY

<M/T>/CVT ASSEMBLY <CVT> REMOVAL
1. Install the front end upper bar bolts to the position as shown
in the figure.
2. Remove the transaxle assembly (Refer to GROUP 22A,
Transaxle Assembly P.22A-12) <M/T> or (Refer to GROUP
23A, Transaxle Assembly P.23A-152) <CVT.>
AC609445AB
.
<<F>> ENGINE MOUNTING INSULATOR

REMOVAL
CAUTION
When supporting the engine assembly with a garage jack,
be careful not to deform the engine oil pan.
of wood in between to support the engine assembly.
TSB Revision
11C-86

ENGINE ASSEMBLY
MB991928
2. Remove special tool MB991928 or MB991895 and

MB992201 which was installed for supporting the engine
assembly when the transaxle assembly was removed (Refer
to GROUP 22A, Transaxle Assembly P.22A-12) <M/T> or
(Refer to GROUP 23A, Transaxle Assembly P.23A-152)
<CVT.>
3. Operate a garage jack so that the engine weight is not
applied to the engine mounting insulator, and remove the
engine mounting insulator.
AC611566AB
MB991895
AC611563AE
MB992201
AC611567AB
<<G>> ENGINE ASSEMBLY REMOVAL

AC609297
1. Mount the special tool MB991454 to the power steering oil

pump bracket and the engine hanger, and set the chain
block.
2. After checking that all cables, hoses and wiring harness
connectors and so on are disconnected from the engine, lift
the engine assembly slowly with the chain block to remove
the engine assembly upward from the engine compartment.
MB991454
AC611556AB
TSB Revision

ENGINE ASSEMBLY
11C-87

.
>>A<< ENGINE ASSEMBLY INSTALLATION

AC609297
Install the engine assembly, being careful not to pinch the

cables, hoses, or wiring harness connectors.
MB991454
AC611556AB
>>B<< ENGINE MOUNTING INSULATOR

INSTALLATION
CAUTION
When supporting the engine assembly with a garage jack,
be careful not to deform the engine oil pan.
of wood in between, and install the engine mounting
insulator while adjusting the position of the engine assembly.
2. Remove special tool MB991454.
TSB Revision
11C-88

ENGINE ASSEMBLY
3. Install special tool MB992201 and MB991928 or MB991895

which is used during installation of transaxle assembly to
hold the engine assembly (Refer to GROUP 22A, Transaxle
Assembly P.22A-12) <M/T> or (Refer to GROUP 23A,
Transaxle Assembly P.23A-152) <CVT.>
MB992201
AC611567AB
MB991928
AC611566AB
MB991895
AC611563AE
>>C<< A/C COMPRESSOR AND CLUTCH

ASSEMBLY INSTALLATION
Tighten A/C compressor and clutch assembly mounting bolts to
the specified torque in the order of number shown in the illustration.
1
3
A/C compressor
and clutch assembly
AC506759 AE
TSB Revision

ENGINE ASSEMBLY
11C-89
>>D<< FUEL HIGH-PRESSURE HOSE

CONNECTION
Fuel
high-pressure
hose
3 mm
(0.12 in)
CAUTION
After connecting the fuel high-pressure hose, slightly pull
it in the pull-out direction to check that it is installed firmly.
In addition, check that there is approximately 3 mm (0.12
inch) play. After the check, install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe, and
install the fuel high-pressure hose.
Fuel line pipe

(Engine oil applied)
AC301864 AD
Stopper
AC301863AC
>>E<< RADIATOR LOWER HOSE/RADIATOR

UPPER HOSE CONNECTION
1. Insert radiator hose as far as the projection of the water inlet
fitting or water outlet fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
Protrusion
Pipe, fitting, or etc.
Mating marks
AC606082 BD
TSB Revision
NOTES

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11C-1

VALVE STEM SEAL . . . . . . . . . . . . . . 11C-38

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11C-46

DRIVE BELT TENSION CHECK. . . . . . . . .

VALVE CLEARANCE CHECK AND

IGNITION TIMING CHECK . . . . . . . . . . . . .

CURB IDLE SPEED CHECK . . . . . . . . . . .

IDLE MIXTURE CHECK . . . . . . . . . . . . . . .

COMPRESSION PRESSURE CHECK. . . .

MANIFOLD VACUUM CHECK . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . .

CRANKSHAFT OIL SEAL . . . . . . . . . 11C-49

CYLINDER HEAD GASKET . . . . . . . . 11C-52

TIMING CHAIN . . . . . . . . . . . . . . . . . . 11C-64

REMOVAL AND INSTALLATION . . . . . . . .

BALANCER TIMING CHAIN, BALANCER

BALANCER SHAFT AND OIL PUMP

ENGINE ASSEMBLY . . . . . . . . . . . . . 11C-81

ENGINE MECHANICAL <2.4L ENGINE>

Total displacement cm3 (cu. in)

Blown cylinder head gasket

Replace the gasket.

Worn or damaged piston rings

Replace the rings.

Worn piston or cylinder

Repair or replace the piston and/or the

Worn or damaged valve seat

Repair or replace the valve and/or the

Engine oil level is too low

Check the engine oil level.

Malfunction of engine oil pressure switch

Replace the engine 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 the correct

Stuck (opened) oil relief valve

Repair the relief valve.

Excessive bearing clearance

Replace the bearings.

Engine oil pressure

Stuck (closed) oil relief valve

Repair the relief valve.

Incorrect valve clearance

Adjust valve clearance

Thin or diluted engine oil (low engine oil

Change the engine oil.

Worn or damaged valve stem or valve

Replace the valve and/or the guide.

Drop in engine oil

ENGINE MECHANICAL <2.4L ENGINE>

Insufficient oil supply

Check the engine oil level.

Thin or diluted engine oil

Change the engine oil.

Excessive bearing clearance

Replace the bearings.