Eclipse 2008 2.4L

2008 Mitsubishi Eclipse GS
2008 ENGINE Engine Mechanical (2.4L) - Eclipse
2008 ENGINE
Engine Mechanical (2.4L) - Eclipse
GENERAL DESCRIPTION
The 4G69 (2.4L) engine is an in-line four cylinder engine. The cylinder numbers are assigned as 1 - 2 - 3 - 4
from the front of the engine (timing belt side). This engine is fired in the order of the 1, 3, 4 and 2 cylinders.
ITEM SPECIFICATION CHART

ITEM SPECIFICATION
Type In-line SOHC
Number of cylinders 4
Bore mm (in) 87 (3.43)
Stroke mm (in) 100.0 (3.94)
Total displacement cm3 (cu in) 2,378 (145.1)
Compression ratio 9.5
Firing order 1-3-4-2
Counterbalance shaft Equipped
Valve timing Intake valve Opens (BTDC) 6° < Low speed >
20° < High speed cam >
Closes (ABDC) 38° < Low speed cam >
72° < High speed cam >
Exhaust valve Opens (BBDC) 60°
Closes (ATDC) 16°
Lubrication system Pressure feed, full-flow
filtration
Oil pump type Involute gear type
ENGINE DIAGNOSIS
ENGINE DIAGNOSIS CHART
SYMPTOM 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
Drop in engine oil pressure Engine oil level is too low Check the engine oil level
Malfunction of engine oil pressure Replace the engine oil pressure
switch switch
Clogged oil filter Install a new filter
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06:28:20 a. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Worn oil pump gears or cover Replace the gears and/or the cover
Thin or diluted engine oil Change the engine oil to correct
viscosity
Stuck (opened) oil relief valve Repair the relief valve
Excessive bearing clearance Replace the bearings
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 Change the engine oil
engine oil pressure)
Worn or damaged valve stem or Replace the valve and/or the guide
valve guide
Connecting rod noise/main Insufficient oil supply Check the engine oil level
bearing noise Low engine oil pressure Refer to engine oil pressure drop
symptoms above
Thin or diluted engine oil Change the engine oil
Excessive bearing clearance Replace the bearings
SPECIAL TOOLS
SPECIAL TOOLS CHART
TOOL NUMBER AND
TOOL NAME SUPERSESSION APPLICATION
MB991958 MB991824-KIT Drive belt tension
Scan tool (MUT-III sub check
assembly) NOTE:
Ignition timing check
G: MB991826 MUT-III
A: MB991824 Trigger Harness is Curb idle speed check
Vehicle not necessary when Idle mixture check
communication pushing V.C.I. ENTER
interface (V.C.I.) key.
CAUTION:
B: MB991827 MUT- For vehicles with
III USB cable CAN
communication, use
C: MB991910 MUT- MUT-III main
III main harness A harness A to send
(Vehicles with CAN simulated vehicle
communication speed. If you
system) connect MUT-III
main harness B
D: MB991911 MUT- instead, the CAN
III main harness B communication
(Vehicles without does not function
CAN communication correctly.
system)
E: MB991914 MUT-
III main harness C
domingo, 14 de febrero de 2021 06:28:20 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
(for DaimlerChrysler
models only)
F: MB991825 MUT-
III measurement
adapter
G: MB991826 MUT-
III trigger harness
MB991668 Belt tension Tool not available Drive belt tension check
meter set [used together with scan tool
(MUT-III sub assembly)]
MB991454 Engine hanger MZ203827-01 When the engine hanger is

balancer used: Supporting the engine
assembly during removal
and installation of the
transaxle assembly
NOTE:
MB991527 Hanger Tool not available
Special tool MB991454 is a
part of engine hanger
attachment set MB991453.
MB991895 Engine hanger Tool not available
MB991928 Tool not available

Engine hanger
A: MB991929 Joint
(50) x 2
B: MB991930 Joint
(90) x 2
C: MB991931 Joint
(140) x 2
D: MB991932 Foot
(standard) x 4
E: MB991933 Foot
(short) x 2
F: MB991934 Chain
and hook assembly
MB990767 MB990767-01 Holding the camshaft
Front hub and flange yoke sprocket
holder
MD998719 Pin MIT308239
MD998772 Valve spring General service tool Compressing valve spring

compressor
MB991999 Valve stem seal - Valve stem seal installation

installer
MD998713 MD998713-01 Camshaft oil seal

Camshaft oil seal installer installation
MD998727 MD998727-01 Oil pan removal

Oil pan FIPG cutter
MD998781 General service tool Supporting the A/T drive

Flywheel stopper plate
MB990938 MB990938-01 Crankshaft rear oil seal

Installer bar installation
MD998776 Crankshaft rear MD998776-01

oil seal installer
MD998285 Crankshaft MD998285-01 Crankshaft front oil seal

front oil seal guide installation
MD998375 Crankshaft MD998375-01

front oil seal installer
MD998738 Adjusting bolt MD998738-01 Supporting the timing belt

tensioner arm and timing
belt tensioner adjuster
MB991654 Cylinder head General service tool Removal and installation of

bolt wrench (12) cylinder head bolt
MB991367 Special spanner MB991367-01 Holding the crankshaft

camshaft drive sprocket
MB991385 Pin MIT217213
MD998767 Tensioner MD998752-01 Valve timing belt tension

wrench adjustment
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
CAUTION: Check the drive belt tension after turning the crankshaft clockwise one
turn or more.
1. Make sure that the indicator mark is within the area marked with A in the illustration.
2. If the mark is out of the area, replace the DRIVE BELT.
NOTE: The drive belt tension adjustment is not necessary, as the engine is
equipped with an auto-tensioner.
Fig. 1: Drive Belt Tensioner Adjustment Indicator Mark
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
AUTO-TENSIONER CHECK
OPERATION CHECK
1. Turn OFF the engine, then check to see that the drive belt is not protruding from the pulley width of the
auto-tensioner.
2. Remove the DRIVE BELT.
3. Securely insert the spindle handle or ratchet handle at a 12.7 mm (1/2-inch) angle into the jig hole of the
auto tensioner. Turn the auto-tensioner to the left and right to check and see that there is no binding.
4. If there are any problems in the procedure 1 or 3, replace the AUTO-TENSIONER.
5. Install the DRIVE BELT.
Fig. 2: Turning Auto-Tensioner

FUNCTION CHECK
You can verify if the auto-tensioner is defective or not by checking the drive belt tension.
When using scan tool MB991958
Required Special Tools:
MB991668: Belt Tension Meter Set

MB991958: Scan Tool (MUT-III Sub Assembly)
MB991824: V.C.I.
MB991910: MUT-III Main Harness A
1. Check the DRIVE BELT TENSION.

2. Measure the drive belt tension vibration frequency by the following procedures:
CAUTION: To prevent damage to scan tool MB991824, always turn the ignition
switch to the "LOCK" (OFF) position before connecting or
disconnecting scan tool MB991824.
1. Connect special tool MB991668 to scan tool MB991824.

2. Connect scan tool MB991910 to scan tool MB991824.
3. Connect scan tool MB991910 to the data link connector.
4. Turn the ignition switch to the "ON" position and select "Belt Tension" from the scan tool menu.
CAUTION: The temperature of the surface of the belt should be as close to no

operating 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
loud sources of noise nearby, the values measured by the microph
may not correspond to actual values.
If the microphone is touching the belt while the measurement is be
made, the values measured by the microphone may not correspon
actual values.
Do not take the measurement while the vehicle's engine is running
Fig. 3: Connecting Scan Tool To Data Link Connector

5. Hold special tool MB991668 to the middle of the drive belt between the pulleys (at the place
indicated by arrow), approximately 10 - 20 mm (0.40 - 0.78 inch) away from the rear surface of the
belt so that it is perpendicular to the belt (within +/- 15 degrees).

6. 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 measure that the vibration frequency of the belt is within the
standard value.
Standard value: 120 - 154 Hz
3. If not within the standard value, replace the AUTO-TENSIONER.
When using a tension gauge
1. Check the DRIVE BELT TENSION.
Fig. 4: Checking Drive Belt Tension Using MB991668

2. Use a belt tension gauge in the middle of the belt between the pulleys (at the place indicated by the arrow)
to measure that the belt tension is within the standard value.
Standard value: 340 - 562 N
3. If not within the standard value, replace the AUTO-TENSIONER.
Fig. 5: Checking Drive Belt Tension Using Tension Gauge

VALVE CLEARANCE CHECK AND ADJUSTMENT
1. Before checks, check that the engine oil, starter and battery are normal. Also, set the vehicle in the
following condition:
Engine coolant temperature: 80 - 95°C (176 - 203°F)
Lights and all accessories: OFF
Transaxle: Neutral (P range on vehicles with A/T)
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 and adjustment.
2. Remove all of the ignition coils.

3. Remove the rocker cover.
4. Turn the crankshaft clockwise until the notch on the pulley is lined up with the "T" mark on the timing
indicator.
5. Move the rocker arms on the No.1 and No.4 cylinders up and down by hand to determine which cylinder
has its piston at the top dead center on the compression stroke.
If both intake and exhaust valve rocker arms have a valve lash, the piston in the cylinder corresponding to
these rocker arms is at the top dead center on the compression stroke.
6. Valve clearance inspection and adjustment can be performed on rocker arms indicated by white arrow
mark when the No.1 cylinder piston is at the top dead center on the compression stroke, and on rocker
arms indicated by black arrow mark when the No.4 cylinder piston is at the top dead center on the
compression stroke.
7. Measure the valve clearance.
If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance using a
thickness gauge while turning the adjusting screw.
Fig. 6: Checking Valve Clearance

Standard value (hot engine):
Intake side: 0.20 mm (0.008 inch)
Exhaust side: 0.30 mm (0.012 inch)
8. While holding the adjusting screw with a screwdriver to prevent it from turning, tighten the lock nut to
the specified torque.
Tightening torque: 9 +/- 1 N.m (80 +/- 9 in-lb)
9. Turn the crankshaft 360 degrees to line up the notch on the crankshaft pulley with the "T" mark on the
timing indicator.
10. Repeat steps (7) and (8) on other valves for clearance adjustment.
11. Install the rocker cover.
12. Install the ignition coils.
ROCKER ARM PISTON OPERATION CHECK
1. Remove all of the ignition coils.

2. Remove the rocker cover.
3. Remove the engine oil control valve.
4. Remove the engine oil pressure switch.
5. Turn the crankshaft clockwise until the notch on the crankshaft pulley is lined up with "T" mark on the
lower cover of timing belt.
6. Move the rocker arms on the No.1 and No.4 cylinders up and down by hand to determine which cylinder
has its piston at the top dead center on the compression stroke.
Fig. 7: Identifying Ignition Coils, Engine Oil Pressure Switch & Oil Control Valve
NOTE: The rocker arm piston operation check can be performed on rocker arms
indicated by white arrow mark when the No.1 cylinder piston is at the top
dead center on the compression stroke, and on rocker arms indicated by
black arrow mark when the No.4 cylinder piston is at the top dead center
on the compression stroke.
Fig. 8: Checking Rocker Arm Piston Operation

7. While shutting up the oil passage hole at the depth of the engine oil control valve's installation hole by
finger not to leak air, blow compressed air into the engine oil pressure switch's installation hole by air
blow gun. At this time, confirm that the rocker arm piston can operate.
NOTE: To fully confirm the check, prevent the compression air from leaking as
much as possible by installing the O-ring to the end of air blow gun.
8. Turn the crankshaft clockwise until the notch on the crankshaft pulley is lined up with the "T" mark on
the lower cover of timing belt.
9. Confirm the rest of the rocker arm pistons under the procedure 7.
Fig. 9: Identifying Rocker Arm Piston

10. When the rocker arm piston does not operate, replace the rocker arm assembly.
11. Install the engine oil pressure switch and the engine oil control valve (Refer to CAMSHAFT AND
VALVE STEM SEAL - REMOVAL AND INSTALLATION).
12. Install the rocker cover.
13. Install all of the ignition coils.
IGNITION TIMING CHECK
Required Special Tool:
MB991824: V.C.I.
MB991827: MUT-III USB Cable
1. Before inspection, set the vehicle in the following condition:


for checks.
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.

3. Set the timing light to the power supply line (terminal No. 1) of the ignition coil No. 2.
NOTE: The power supply line is looped and also longer than the other ones.
4. Start the engine and run it at idle.

5. Check that the idle speed is approximately 700 r/min.
6. Select scan tool MB991958 actuator test "item number 4".
7. Check that basic ignition timing is within the standard value.
Standard value: 5° BTDC +/- 3°
8. If the basic ignition timing is not within the standard value, check the following items:
Diagnostic output
Timing belt cover and crankshaft position sensor installation conditions
Crankshaft sensing blade condition

CAUTION: If the actuator test is not canceled, the forced drive will continue
for 27 minutes. Driving in this state could lead to engine failure.
9. Press the clear key on scan tool MB991958 (select forced drive stop mode), and cancel the actuator test.
10. Check that the actual ignition timing is at the standard value.
Standard value: Approximately 10° BTDC
NOTE: Ignition timing fluctuates about +/- 7° Before Top Dead Center, even under
normal operating condition.
NOTE: It is automatically further advanced by about 5° to 10° Before Top Dead

Center at higher altitudes.
CURB IDLE SPEED CHECK
MB991824: V.C.I.
1. Before inspection, set the vehicle in the following condition.

for checks.


3. Check the basic ignition timing.
4. Start the engine.

5. Run the engine at idle for 2 minutes.
6. Check the idle speed. Select item number 2 and take a reading of the idle speed.
Curb idle speed: 700 +/- 100 r/min
NOTE: The idle speed is controlled automatically by the idle air control system.
7. If the idle speed is outside the standard value, refer to, Multiport Fuel Injection (MFI) < 2.4L Engine > -
Multiport Fuel Injection (MFI) Diagnosis - SYMPTOM CHART .

IDLE MIXTURE CHECK
MB991824: V.C.I.
1. Before inspection, set the vehicle in the following condition:

for checks.


3. Check that the basic ignition timing is within the standard value.
4. Start the engine and increase the engine speed to 2,500 r/min for 2 minutes.
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value: CO contents: 0.5 % or less
HC contents: 100 ppm or less
7. If the CO and HC contents do not remain inside the standard value, check the following items:
NOTE: Replace the catalytic converter when the CO and HC contents do not
remain inside the standard value, even though the result of the inspection
is normal for all items.
Diagnostic output
Closed-loop control (When the closed-loop control is carried out normally, the output signal of the
heated oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.)
Fuel pressures
Injector
Ignition coil, spark plug
EGR system
Evaporative emission system
Compression pressure

COMPRESSION PRESSURE CHECK
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:
for checks.
2. Remove all of the ignition coils and spark plugs.

3. Disconnect the crankshaft position sensor connector.
NOTE: Doing this will prevent the engine control module from carrying out
ignition and fuel injection.
WARNING: Keep your distance from the spark plug hole when cranking. Oil,
fuel, etc., may spray out from the spark plug hole and may cause
serious injury.
4. Cover the spark plug hole with a shop towel etc., during cranking. After the engine has been cranked,
check for foreign material adhering to the shop towel.
Fig. 13: Locating Crankshaft Position Sensor

5. Set a compression gauge to one of the spark plug holes.

6. Crank the engine with the throttle valve fully open and measure the compression pressure.
Standard value (at engine speed of 200 r/min): 1,560 kPa (226 psi)
Minimum limit (at engine speed of 200 r/min): 1,130 kPa (164 psi)
Fig. 14: Measuring Compression Pressure

7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the
cylinders are below the limit.
Limit: 98 kPa (14 psi)
8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small
amount of engine oil through the spark plug hole, and repeat the operations in steps 6 to 8.
1. If the compression increases after oil is added, the cause of the malfunction is a worn or damaged
piston ring and/or cylinder inner surface.
2. If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or
pressure is leaking from the gasket.
9. Connect the crankshaft position sensor connector.
10. Install the spark plugs and ignition coils.
11. Use the scan tool MB991958 to erase the diagnostic trouble codes.
NOTE: This will erase the diagnostic trouble code resulting from the crankshaft
position sensor connector being disconnected.

MANIFOLD VACUUM CHECK
1. Start the engine and allow it to warm up until the temperature of the engine coolant reaches 80 - 95°C
(176 - 203°F).
2. Connect an engine tachometer.
3. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and connect a
vacuum gauge to the ventilation hose.
Fig. 16: Connecting Vacuum Gauge To Ventilation Hose

4. Plug the PCV valve.

5. Start the engine and check that idle speed is within specification. Then check the vacuum gauge reading.
Idle speed: 700 +/- 100 r/min
Minimum limit: 60 kPa (18 in Hg)
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
CAUTION: When the engine assembly replacement is performed, use scan tool
MB991958 to initialize the learning value (Refer to, INITIALIZATION

PROCEDURE FOR LEARNING VALUE IN MFI ENGINE ).
*: indicates parts which should be temporarily tightened, and then fully
tightened with the engine weight applied on the vehicle body.
Fig. 17: Removing/Installing Engine Assembly With Torque Specifications
Fig. 18: Removing/Installing Engine Assembly With Torque Specifications

MB991454: Engine Hanger Balancer

MB991527: Hanger
MB991895: Engine Hanger
MB991928: Engine Hanger
REMOVAL SERVICE POINTS
<< A >> DRIVE BELT REMOVAL
The following operations are required due to the serpentine drive system with the drive belt auto-tensioner.
auto-tensioner.
2. Rotate the auto-tensioner counterclockwise and align hole A with hole B.
CAUTION: To reuse the drive belt, draw an arrow indicating the rotating
direction (clockwise) on the back of the belt using chalk, etc.
Fig. 19: Rotating Auto-Tensioner Counterclockwise

3. Insert an L-shaped hexagon wrench, etc. into the hole to secure its position, and then remove the drive
belt.
Fig. 20: Securing Belt Tensioner By Inserting L-Shaped Hexagon Wrench

<> POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL
1. With the hose installed, remove the power steering oil pump and bracket assembly from the engine
assembly.
2. After removing the power steering oil pump and bracket assembly, secure it with a cord in a location
where it does not interfere with engine assembly removal.
<< C >> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
1. With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2. After removing the A/C compressor and clutch assembly, secure it with a cord in a location where it does
not interfere with engine assembly removal.
<< D >> ATF WARMER (TRANSMISSION FLUID COOLER) AND BRACKET ASSEMBLY REMOVAL
With the hose installed, remove the ATF warmer (transmission fluid cooler) and bracket assembly from the
transmission case front roll stopper bracket.
<< E >> FUEL HIGH-PRESSURE HOSE DISCONNECTION
1. Remove the fuel high-pressure hose stopper.
Fig. 21: Removing Fuel High-Pressure Hose Stopper

2. Pull up the retainer and remove the fuel high-pressure hose in the direction shown.
NOTE: If the retainer is released, install it after removing the fuel high-pressure
hose.
Fig. 22: Pulling Up Retainer And Removing Fuel High-Pressure Hose

<< F >> TRANSAXLE ASSEMBLY REMOVAL
1. Secure the A/C condenser and front end structure bar with a cord in a location where it does not interfere
with engine assembly removal.
Fig. 23: Locating Front End Structure Bar

CAUTION: M/T: Do not remove the flywheel bolt. If this bolt is removed, the
flywheel assembly will become out of balance and damaged.
2. Remove the transaxle assembly. Refer to:
(M/T: TRANSAXLE ASSEMBLY )
(A/T: TRANSAXLE ASSEMBLY )
Fig. 24: Locating Flywheel Bolt

<< G >> POWER STEERING OIL RESERVOIR REMOVAL
1. With the hose installed, remove the power steering oil reservoir from the vehicle (Refer to, POWER
STEERING HOSES ).
2. After removing the power steering oil reservoir, secure it with a cord in a location where it does not
interfere with engine front mounting bracket removal.
<< H >> ENGINE FRONT MOUNTING BRACKET REMOVAL
1. Support the engine with a garage jack.

2. Remove the following special tool.
1. < Special tool MB991895 is used >
Remove special tool MB991895.
Fig. 25: Identifying Special Tool MB991895

Remove special tool MB991928.
Fig. 26: Identifying Special Tool MB991928

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

4. Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the
engine assembly is no longer being applied to the engine front mounting bracket.
5. Loosen the engine front mounting bracket mounting nuts and bolts, and remove the engine front
mounting bracket.
Fig. 27: Holding Engine Assembly With Chain Block

<> ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and wiring harness connectors, etc. are disconnected from the engine, lift
the chain block slowly to remove the engine assembly upward from the engine compartment.
INSTALLATION SERVICE POINTS
<< A >> ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.
Fig. 28: Installing Engine Assembly

<> ENGINE FRONT MOUNTING BRACKET INSTALLATION
1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine
front mounting bracket while adjusting the position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
4. Use the following special tool as during removal to support the engine.
Set special tool MB991895. Refer to:
Fig. 29: Setting Special Tool MB991895

Set special tool MB991928. Refer to:
Fig. 30: Setting Special Tool MB991928

<< C >> TRANSAXLE ASSEMBLY INSTALLATION
1. Install the transaxle assembly, Refer to:
2. Remove the cord securing the A/C condenser and the front end structure bar.
Fig. 31: Locating Front End Structure Bar

<< D >> FUEL HIGH-PRESSURE HOSE CONNECTION
CAUTION: After connecting the fuel high-pressure hose, slightly pull it to ensure that
it is installed securely. Also confirm that there is a play of approximately 3
mm (0.12 inch). Then install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe and then install the fuel high-pressure hose.
Fig. 32: Installing Fuel High-Pressure Hose

Fig. 33: Identifying Stopper

<< E >> BRAKE BOOSTER VACUUM HOSE CONNECTION
Insert vacuum hose with its paint mark facing upward.
Fig. 34: Inserting Vacuum Hose With Paint Mark Facing Upward
CRANKSHAFT PULLEY
Fig. 35: Removing/Installing Crankshaft Pulley With Torque Specifications

REMOVAL SERVICE POINT
<< A >> DRIVE BELT REMOVAL
The following operations are required due to the serpentine drive system with the drive belt auto-tensioner.
auto-tensioner.
2. Rotate the auto-tensioner counterclockwise and align hole A with hole B.
Fig. 36: Rotating Auto-Tensioner Counterclockwise And Align Hole A With Hole B
CAUTION: To reuse the drive belt, draw an arrow indicating the rotating
3. Insert an L-shaped hexagon wrench, etc. into the hole to secure its position, and then remove the drive
belt.
Fig. 37: Securing Belt Tensioner By Inserting L-Shaped Hexagon Wrench

CAMSHAFT AND VALVE STEM SEAL

CAUTION: * Remove and assemble the marked parts in each cylinder unit.
Fig. 38: Removing/Installing Camshaft And Valve Stem Seal With Torque Specifications
Fig. 39: Removing/Installing Camshaft And Valve Stem Seal With Torque Specifications
MB990767: Front Hub and Flange Yoke Holder

MB991999: Valve Stem Seal Installer
MD998713: Camshaft Oil Seal Installer
MD998719: Pin
MD998772: Valve Spring Compressor
<< A >> CAMSHAFT SPROCKET REMOVAL
1. Hold the camshaft sprocket with special tools MB990767 and MD998719.
2. Loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket.
Fig. 40: Removing/Installing Camshaft Sprocket Mounting Bolt

<> EXHAUST ROCKER ARM AND SHAFT ASSEMBLY/INTAKE ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
CAUTION: Never disassemble the exhaust rocker arm and shaft assembly, and intake
rocker arm and shaft assembly.
<< C >> CAMSHAFT REMOVAL
1. Raise the transaxle assembly until the camshaft and transaxle mounting body side bracket do not touch it.
2. Remove the camshaft.
Fig. 41: Removing Camshaft

<< D >> VALVE SPRING RETAINER LOCKS REMOVAL
CAUTION: When removing valve spring retainer locks, leave the piston of each
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.
Use special tool MD998772 to compress the valve spring and then remove the valve spring retainer locks.
Fig. 42: Removing Valve Spring Retainer Locks

>> A << VALVE STEM SEALS INSTALLATION
1. Apply a small amount of engine oil to the valve stem seals.
CAUTION: Do not re-use the valve stem seal.

The special tool MB991999 must be used to install the valve
stem seal. Improper installation could result in oil leaking past
the valve guide.
2. Use special tool MB991999 to fill a new valve stem seal in the valve guide using the valve stem area as a
guide.
Fig. 43: Installing Valve Stem Seal

>> B << EXHAUST VALVE SPRINGS/INTAKE VALVE SPRINGS INSTALLATION
Install the valve springs with the identification color painted end facing the rocker arm.
Fig. 44: Installing Valve Springs With Identification Color Painted

>> C << VALVE SPRING RETAINER LOCKS INSTALLATION
Use special tool MD998772 to compress the valve spring and then install the valve spring retainer lock in the
same manner as removal.
Fig. 45: Installing Valve Spring Retainer Lock

>> D << CAMSHAFT INSTALLATION
Set the dowel pin of the camshaft in the position shown in illustration.
Fig. 46: Setting Dowel Pin Of Camshaft

>> E << INTAKE ROCKER ARM AND SHAFT ASSEMBLY/INTAKE ROCKER ARM SHAFT CAPS INSTALLATION
1. Place the intake rocker shaft so that its 5.5 mm (0.22 inch) hole faces toward the cylinder head.
2. Install the intake rocker arm shaft caps.
3. Tighten the intake rocker shaft mounting bolts to the specified torque.
Tightening torque: 31 +/- 3 N.m (23 +/- 2 ft-lb)
Fig. 47: Installing Intake Rocker Shaft

>> F << EXHAUST ROCKER ARM AND SHAFT ASSEMBLY/EXHAUST ROCKER ARM SHAFT CAPS INSTALLATION
1. Install the exhaust rocker shaft so that its notch is positioned as shown.
2. Install the exhaust rocker arm shaft caps.
3. Tighten the exhaust rocker shaft mounting bolts to the specified torque.
Fig. 48: Installing Exhaust Rocker Shaft

>> G << CAMSHAFT OIL SEAL INSTALLATION
1. Apply engine oil to the entire inner diameter of the oil seal lip.
2. Use special tool MD998713 to press-fit the oil seal as shown.
Fig. 49: Applying Engine Oil To Entire Inner Diameter Of Camshaft Oil Seal Lip
>> H << CAMSHAFT SPROCKET INSTALLATION
1. Hold the camshaft sprocket with special tools MB990767 and MD998719 in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolt to the specified torque.

>> I << CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION
1. Remove old sealant from the camshaft position sensor support and cylinder head surfaces.
2. Apply sealant to the camshaft position sensor support flange in a continuous bead as shown in the
illustration.
Specified sealant: 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or equivalent
NOTE: Install the camshaft position sensor support within 15 minutes after
applying the sealant.
3. Install the camshaft position sensor support to the cylinder head.
Fig. 51: Applying Sealant To Camshaft Position Sensor Support Flange

CAUTION: Wait at least one hour for the sealant to set. Never start the engine or
let engine oil or coolant touch the adhesion surface during that time.
4. Tighten the camshaft position sensor support mounting bolts to the specified torque.
>> J << ENGINE OIL PRESSURE SWITCH INSTALLATION
1. Remove old sealant from the engine oil pressure switch and cylinder head surfaces.
2. Apply sealant to the thread of the engine oil pressure switch as shown.
Specified sealant: 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or equivalent
NOTE: Install the engine oil pressure switch within 15 minutes after applying the
sealant.
Fig. 52: Applying Sealant To Thread Of Engine Oil Pressure Switch

CAUTION: Wait at least one hour for the sealant to set. Never start the engine or
let engine oil or coolant touch the adhesion surface during that time.
3. Tighten the engine oil pressure switch to the specified torque as shown.
Fig. 53: Tightening Engine Oil Pressure Switch

>> K << O-RING/ENGINE OIL CONTROL VALVE INSTALLATION
CAUTION: Never re-use the O-ring.

Before installing O-ring, wind sealing tape around the oil passages
cut-out area of engine oil control valve, to prevent damage. If the O-
ring is damaged, it can cause an oil leak.
Fig. 54: Applying Sealing Tape

1. Apply a small amount of engine oil to the O-ring and then install it to the engine oil control valve.
2. Assemble the engine oil control valve to the cylinder head.
3. Tighten the engine oil control valve mounting bolt to the specified torque.
OIL PAN
Fig. 55: Removing/Installing Oil Pan With Torque Specifications

MD998727: Oil Pan FIPG cutter
REMOVAL SERVICE POINT
<< A >> ENGINE OIL PAN REMOVAL
1. Remove the engine oil pan mounting bolts.
CAUTION: Do not use special tool MD998727 in area A of the engine oil pan.
Using the special tool in area A may cause deformation of the front
case because the front case is made of aluminum.
2. Tap special tool MD998727 into the range (B) between the cylinder block and the engine oil pan, and
then slide the tool sideways.
NOTE: If any sounding parts interfere with the removal, there is no need to use
special tool MD998727.
Fig. 56: Locating Deformation Area (Do Not Use Special Tool MD998727 In Area A Of Engine Oil
Pan)
3. Remove the engine oil pan.
Fig. 57: Removing Engine Oil Pan Using Special Tool MD998727
>> A << ENGINE OIL PAN INSTALLATION
1. Remove sealant from the engine oil pan, front case and cylinder block surfaces.
2. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown.
Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™ AAD Part No.8679/8678 or equivalent
NOTE: Install the engine oil pan within 15 minutes after applying sealant.
3. Assemble the engine oil pan to the cylinder block.
Fig. 58: Applying Sealant To Cylinder Block Mating Surface Of Engine Oil Pan
CAUTION: Wait at least one hour. Never start the engine or let engine oil or
coolant touch the sealant surface during that time.
4. Tighten the engine oil pan mounting bolts to the specified torque. Be careful when installing, as the bolts
indicated in the illustration have different lengths from the other bolts.
Tightening torque: 9.0 +/- 3.0 N.m (80 +/- 26 in-lb)
Fig. 59: Installing Oil Pan Bolts

>> B << ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION
Replace the gasket with a new gasket. Install the new gasket in the direction shown in the illustration.
Fig. 60: Engine Oil Pan Drain Plug Gasket Orientation

INSPECTION
Check the oil pan for cracks.

Check the oil pan sealant-coated surface for damage and deformation.
CRANKSHAFT OIL SEAL

< M/T >
Fig. 61: Removing/Installing Crankshaft Oil Seal With Torque Specifications (M/T)
MB990938: Installer Bar

MD998285: Crankshaft Front Oil Seal Guide
MD998375: Crankshaft Front Oil Seal Installer
MD998776: Crankshaft Rear Oil Seal Installer
MD998781: Flywheel Stopper
< A/T >
Fig. 62: Removing/Installing Crankshaft Oil Seal With Torque Specifications (A/T)
MB990938: Installer Bar

MD998285: Crankshaft Front Oil Seal Guide
MD998375: Crankshaft Front Oil Seal Installer
MD998776: Crankshaft Rear Oil Seal Installer
MD998781: Flywheel Stopper
<< A >> TRANSAXLE ASSEMBLY REMOVAL
CAUTION: Do not remove the flywheel bolt. If this bolt is removed, the flywheel
assembly will become out of balance and damaged.
Refer to, TRANSAXLE ASSEMBLY .
Fig. 63: Locating Flywheel Bolt

<> FLYWHEEL BOLTS/A/T DRIVE PLATE BOLTS REMOVAL
1. Use special tool MD998781 to secure the flywheel assembly or A/T drive plate.
2. Remove the flywheel bolts or A/T drive plate bolts.
Fig. 64: Securing Flywheel Assembly Or A/T Drive Plate

>> A << CRANKSHAFT REAR OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.
2. Use special tools MB990938 and MD998776 to press-fit the oil seal.
Fig. 65: Applying Small Amount Of Engine Oil To Entire Inner Diameter (Crankshaft Rear Oil
Seal)
>> B << FLYWHEEL BOLTS/A/T DRIVE PLATE BOLTS INSTALLATION
1. Use special tool MD998781 to secure the flywheel assembly or A/T drive plate in the same manner as
removal.
2. Tighten the flywheel bolts or A/T drive plate bolts to the specified torque.
Fig. 66: Securing Flywheel Assembly Or A/T Drive Plate

>> C << CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the outer diameter of special tool MD998285 and install it to the
crankshaft.
2. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.
3. Use special tool MD998375 to press-fit the oil seal.
Fig. 67: Installing Crankshaft Front Oil Seal

>> D << CRANKSHAFT BALANCER SHAFT DRIVE SPROCKET INSTALLATION
1. Clean or degrease the front case, the crankshaft and the crankshaft balancer shaft drive sprocket as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket in the direction shown in the illustration.
Fig. 68: Installing Crankshaft Balancer Shaft Drive Sprocket

CYLINDER HEAD GASKET

Fig. 69: Removing/Installing Cylinder Head Gasket With Torque Specifications (1 Of 2)

Fig. 70: Removing/Installing Cylinder Head Gasket With Torque Specifications (2 Of 2)

MB990767: Front Hub and Flange Yoke Holder

MB991654: Cylinder Head Bolt Wrench (12)
MD998719: Pin
MD998738: Adjusting Bolt
<< A >> CAMSHAFT SPROCKET REMOVAL
CAUTION: Never turn the crankshaft counterclockwise.
1. Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to set number 1 cylinder
to TDC of its compression stroke.
Fig. 71: Aligning Timing Marks

2. Remove the timing belt under cover rubber plug and then set special tool MD998738.
Fig. 72: Installing Special Tool

3. Screw in special tool MD998738 until it contacts the timing belt tensioner arm.
Fig. 73: Screwing Special Tool Until It Contacts Tensioner Arm

4. Secure the camshaft sprocket and valve timing belt with wire to prevent slippage between the camshaft
sprocket and valve timing belt.
Fig. 74: Securing Camshaft Sprocket And Valve Timing Belt With Wire (Tie Wraps)
5. Hold the camshaft sprocket with special tools MB990767 and MD998719.
CAUTION: Do not rotate the crankshaft after camshaft sprocket removal.
6. Remove the camshaft sprocket with the valve timing belt and place it on the timing belt lower cover.
Fig. 75: Removing/Installing Camshaft Sprocket Bolt

<> RADIATOR UPPER HOSE DISCONNECTION
Make mating marks on the radiator upper hose and the hose clamp. Disconnect the radiator upper hose.
Fig. 76: Making Mating Marks On Radiator Upper Hose & Hose Clamp
<< C >> FUEL HIGH-PRESSURE HOSE DISCONNECTION
1. Remove the fuel high-pressure hose stopper.
Fig. 77: Removing Fuel High-Pressure Hose Stopper

2. Pull up the retainer and remove the fuel high-pressure hose in the direction shown.
NOTE: If the retainer is released, install it after removing the fuel high-pressure
hose.
Fig. 78: Pulling Retainer & Remove Fuel High-Pressure Hose

<< D >> CYLINDER HEAD BOLTS REMOVAL
Use special tool MB991654 to loosen the cylinder head bolts in two or three steps in the order shown in the
illustration. If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring,
raise the bolt slightly, then remove it while holding it with a magnet.
Fig. 79: Loosening Cylinder Head Bolts In Two Or Three Steps In Sequence
>> A << CYLINDER HEAD GASKET INSTALLATION
CAUTION: Do not allow any foreign materials get into the coolant passages, oil
passages and cylinder.
1. Degrease the cylinder head gasket mounting surface.

2. Assemble to the cylinder block so the cylinder head gasket identification mark of "381" is at the top
surface and on the exhaust side.
Fig. 80: Installing Cylinder Head Gasket (Identification Mark Of "381" Facing Up)
>> B << CYLINDER HEAD BOLTS INSTALLATION
1. Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace
the bolt with a new one.
Limit (A): 99.4 mm (3.91 inches)
2. Apply a small amount of engine oil to the thread of the bolts and to the washers.
Fig. 81: Applying Engine Oil To Thread Of Head Bolts & Washers
3. Use special tool MB991654 to tighten the cylinder head bolts in the following procedures.
1. Tighten the bolts to 78 +/- 2 N.m (58 +/- 1 ft-lb) in the order shown in illustration.
2. Loosen the bolts fully in the reverse sequence of that shown.
3. Tighten the bolts to 20 +/- 2 N.m (15 +/- 1 ft-lb) in the order shown in illustration.
4. Reconfirm all bolts tightened firmly.
Fig. 82: Tightening Head Bolts Sequence

5. Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90
degrees as shown in illustration.
CAUTION: The bolt is not tightening sufficiently if the tightening

angle is less than 90 degrees.
If the tightening angle exceeds the standard specification,
remove the bolt and start over from step 1.
6. Tighten 90 degrees as shown in illustration, then check to see that the paint mark on the head of the
cylinder head bolt and the paint mark on the cylinder head are aligned.
Fig. 83: Identifying Paint Mark

>> C << FUEL HIGH-PRESSURE HOSE CONNECTION
CAUTION: After connecting the fuel high-pressure hose, slightly pull it to ensure that
it is installed securely. Also confirm that there is a play approximately 3
mm (0.12 inch). Then install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe and then install the fuel high-pressure hose.
Fig. 84: Ensuring Fuel High-Pressure Hose Is Installed Securely & Measure Its Play
Fig. 85: Identifying Stopper

>> D << RADIATOR UPPER HOSE CONNECTION
1. Insert radiator upper hose until it contacts the projection on the water outlet fitting.
2. Align the mating marks on the radiator upper hose and hose clamp, and then secure the radiator upper
hose.
Fig. 86: Aligning Mating Marks & Installing Radiator Upper Hose
>> E << CAMSHAFT SPROCKET INSTALLATION
1. Hold the camshaft sprocket with special tools MB990767 and MD998719 in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolt to the specified torque.

>> F << BRAKE BOOSTER VACUUM HOSE CONNECTION
Insert the vacuum hose with its paint mark facing upward.
Fig. 88: Inserting Vacuum Hose With Paint Mark Facing Upward
TIMING BELT
Fig. 89: Removing/Installing Timing Belt With Torque Specifications (1 Of 2)

Fig. 90: Removing/Installing Timing Belt With Torque Specifications (2 Of 2)

MB991367: Special Spanner

MB991385: Pin
MD998738: Adjusting Bolt
MD998767: Tensioner Wrench
<< A >> VALVE TIMING BELT REMOVAL
CAUTION: Never turn the crankshaft counterclockwise.
1. Turn the crankshaft clockwise, align each timing mark to set number 1 cylinder to TDC of its
compression stroke.

2. Remove the timing belt under cover rubber plug and then set special tool MD998738.
Fig. 92: Setting Special Tool MD998738

3. Screw in special tool MD998738 by hand until it contacts the timing belt tensioner arm.
Fig. 93: Screwing In Special Tool MD998738 By Hand

CAUTION: Special tool MD998738 must be gradually installed at a rate of 30

degrees per second. If it is screwed in all at once, the timing belt
tensioner adjuster rod will not easily retract and special tool
MD998738 may bend.
4. Gradually screw in special tool MD998738 and then align the timing belt tensioner adjuster rod set hole
A with the timing belt tensioner adjuster cylinder set hole B.
Fig. 94: Aligning Timing Belt Tensioner Adjuster Holes (A & B)

5. Insert a wire or pin in the set hole aligned.
CAUTION: To reuse the valve timing belt, draw an arrow indicating the rotating
Fig. 95: Securing Tensioner Plunger With Wire Or Pin

6. After removal of special tool MD998738, loosen the timing belt tensioner pulley mounting bolt and
remove the valve timing belt.
<> CRANKSHAFT PULLEY CENTER BOLT/CRANKSHAFT PULLEY WASHER/CRANKSHAFT CAMSHAFT

DRIVE SPROCKET REMOVAL
1. Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MB991385.
2. Loosen the crankshaft pulley center bolt and remove the crankshaft pulley washer and crankshaft
camshaft drive sprocket.
Fig. 96: Loosening Crankshaft Pulley Center Bolt

<< C >> BALANCER TIMING BELT REMOVAL
CAUTION: To reuse the balancer timing belt, draw an arrow indicating the rotating
direction on the back of the belt using chalk, etc.
<< A >> BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER INSTALLATION
1. Ensure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing
marks are aligned.
2. Install the balancer timing belt on the crankshaft balancer shaft drive sprocket and balancer shaft
sprocket. There should be no slack on the tension side.
Fig. 97: Aligning Balancer Sprocket Timing Marks
3. Assemble and temporarily secure the center of the pulley of the balancer timing belt tensioner so that it is
at the top left from the center of the assembling bolt, and the pulley flange is at the front-side of the
engine.
4. Adjust the balancer timing belt tension.
Fig. 98: Adjusting Balancer Timing Belt Tension

<> BALANCER TIMING BELT TENSION ADJUSTMENT
CAUTION: When tightening the mounting bolts, ensure that the tensioner does not
rotate with the bolts. Allowing it to rotate with the bolts can cause
excessive tension of the belt.
1. Lift with your fingers the balancer timing belt tensioner in the direction of the arrow. Apply a tensile
torque of [3.0 +/- 0.4 N.m (26 +/- 4 in-lb)] to the balancer timing belt so the belt is tense without any
looseness. Tighten the assembling bolt to the specified torque in this state. Then, fix the balancer timing
belt tensioner.
Fig. 99: Tightening Tensioner Pulley Bolt

2. Turn the crankshaft clockwise two turns to set number 1 cylinder to TDC of its compression stroke and
check that sprocket timing marks are aligned.
Fig. 100: Checking Sprocket Timing Marks Are Aligned
3. Apply a pressure of approximately 100 N (22 pounds) at the center (arrow area) between the sprocket as
shown in illustration, then inspect whether the belt deflection is within the standard value.
Standard value:
< When adjusting > 5 - 7 mm (0.20 - 0.27 inch)
< When replacing > 5 - 7 mm (0.20 - 0.27 inch)
4. If not within the standard value, adjust the belt tension again.
Fig. 101: Inspecting Belt Deflection

<< C >> CRANKSHAFT ANGLE SENSING BLADE/CRANKSHAFT CAMSHAFT DRIVE SPROCKET/CRANKSHAFT

PULLEY WASHER/CRANKSHAFT PULLEY CENTER BOLT INSTALLATION
1. Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft camshaft drive
sprocket and crankshaft pulley washer as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown.
3. Place the larger chamfer side of the crank shaft pulley washer in the direction shown in the Figure, and
then assemble on the crank shaft pulley center bolt.
4. Apply a small amount of engine oil to the crank shaft pulley center bolt bearing surface and screw.
Fig. 102: Installing Crankshaft Angle Sensing Blade, Crankshaft Camshaft Drive Sprocket,
Crankshaft Pulley Washer & Crankshaft Pulley Center Bolt
5. Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MB991385 in the same
manner as removal.
6. Tighten the crankshaft pulley center bolt to the specified torque.
Tightening torque: 167 N.m (123 ft-lb)
Fig. 103: Tightening Crankshaft Pulley Center Bolt

<< D >> TIMING BELT TENSIONER ADJUSTER INSTALLATION
1. Set according to the following procedures with the timing belt tensioner adjuster rod fully extended.
CAUTION: If the rod is compressed too quickly, it may be damaged.
1. Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align set hole A
of the rod with set hole B of the timing belt tensioner adjuster cylinder.
Fig. 104: Compressing Timing Belt Tensioner Adjuster Rod

2. Insert a wire or pin in the set hole aligned.
NOTE: When replacing the timing belt tensioner adjuster with new parts, the
timing belt tensioner adjuster is set with a pin.
2. Install the timing belt tensioner adjuster to the engine and then tighten the mounting bolts to the specified
torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted.
Fig. 105: Securing Tensioner Plunger With Wire Or Pin

<< E >> TIMING BELT TENSIONER PULLEY INSTALLATION
Temporarily tighten the timing belt tensioner pulley as shown in illustration.
Fig. 106: Tightening Timing Belt Tensioner Pulley In Position Shown

<< F >> VALVE TIMING BELT INSTALLATION
1. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump
sprocket.

2. Adjust the timing mark of the engine oil pump sprocket. Unplug the cylinder block plug. Insert a bolt
(M6, section width 10 mm, nominal length 45 mm) in the plug hole. If the bolt comes in contact with the
balancer shaft, turn the engine oil sprocket one rotation. Re-adjust the timing mark and then check to see
that the bolt fits. Do not remove the bolt until the valve timing belt is assembled.
Fig. 108: Adjusting Timing Mark Of Engine Oil Pump Sprocket

3. Install the valve timing belt in the following manner so that the tensile force of the belt is not lax.
1. Place the valve timing belt on the timing belt tensioner pulley and crankshaft camshaft driver
sprocket and then support it with your left hand so it does not slide.
2. Place the valve timing belt on the engine oil pump sprocket while pulling it with the right hand.
3. Place the valve timing belt on the timing belt idler pulley.
CAUTION: Install the valve timing belt. Then apply reverse rotation
(counterclockwise rotation) pressure to the cam shaft sprocket.
Re-check to see that each timing mark is aligned while the
tension side of the belt is right.
4. Place the valve timing belt on the camshaft sprocket.
Fig. 109: Installing Valve Timing Belt

4. Turn the timing belt tensioner pulley in the direction shown in illustration using special tool MD998767
to apply tension to the valve timing belt. Then temporarily tighten and fix the timing belt tensioner pulley
mounting bolt.
Fig. 110: Turning Timing Belt Tensioner Pulley To Apply Tension To Belt
5. Check that the timing marks are aligned.
Fig. 111: Checking Timing Marks Are Aligned

6. Remove the bolt inserted in Step 2 above, then assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified torque.
Fig. 112: Tightening Cylinder Block Plug

8. Adjust the valve timing belt tension.
<< G >> VALVE TIMING BELT TENSION ADJUSTMENT
1. Set special tool MD998738 used when removing the valve timing belt.
CAUTION: Always screw in special tool MD998738 by hand, since use of a

spanner or other tools may damage the wire or pin inserted in the
timing belt tensioner adjuster.
2. Gradually screw in special tool MD998738 until the wire or pin inserted in the timing belt tensioner
adjuster lightly moves.
Fig. 113: Installing Special Tool MD998738

3. Turn the crankshaft 1/4 turn counterclockwise.

4. Turn the crankshaft clockwise, and align each timing mark to set number 1 cylinder to TDC of its
compression stroke.
5. Loosen the timing belt tensioner pulley mounting bolt.
Fig. 114: Aligning Timing Mark

CAUTION: When tightening the mounting bolt, ensure that the timing belt
tensioner pulley does not rotate with the bolt. Allowing it to rotate
with the bolt can cause deficient tension of the belt.
6. With special tool MD998767 and torque wrench, apply tension torque [3.5 N.m (31 in-lb)] to the valve
timing belt, and tighten the timing belt tensioner pulley mounting bolt to the specified torque.
Fig. 115: Tightening Timing Belt Tensioner Pulley Mounting Bolt

7. Remove the wire or pin inserted to timing belt tensioner adjuster.
Fig. 116: Remove Pin Inserted From To Timing Belt Tensioner Adjuster
8. Remove special tool MD998738, and install the rubber plug to the timing belt under cover.
Fig. 117: Removing Special Tool MD998738

9. Rotate crankshaft clockwise two turns, and leave it for about 15 minutes.
10. Insert the wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When the wire
or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or
pin.
Fig. 118: Inserting Wire Or Pin

Also when the projection of timing belt tensioner adjuster rod (A) is within the standard value,
appropriate tension is applied.
Standard value (A): 3.8 - 4.5 mm (0.15 - 0.17 inch)
Fig. 119: Checking Valve Timing Belt Tension

11. If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt
tension.
CAUTION: Always check the tightening torque of the crank shaft pulley center
bolt when turning the crank shaft pulley center bolt
counterclockwise. Retighten if it is loose.
12. Check again that the timing marks on sprockets are aligned.
Fig. 120: Checking Timing Marks On Sprockets Are Aligned

INSPECTION
TIMING BELT TENSIONER ADJUSTER CHECK
1. Check for oil leak from seal, and replace it if a leak is detected.
2. Check for wear or damage at the top of the rod. Replace it, if required.
3. Hold the timing belt tensioner adjuster by hand, and press the top end of the rod onto the metal (e.g.
cylinder block) with 98 - 196 N (22 - 44 pounds) of pressure, and measure the movement of the rod.
Standard value: Within 1 mm (0.039 inch)
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
4. If the measured value is out of the standard value, replace the timing belt tensioner adjuster.
Fig. 121: Checking Timing Belt Tensioner Adjuster Condition

BALANCER TIMING BELT TENSION CHECK
Check the balancer timing belt tension in the following procedures.
1. Apply a pressure of approximately 100 N (22 pounds) at the center (arrow area) between the sprocket as
shown in illustration, then inspect whether the flexure is within the standard value.
Standard value: 5 - 10 mm (0.20 - 0.39 inch)
2. If not within the standard value, adjust the BELT TENSION.
Fig. 122: Checking Balancer Timing Belt Tension

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

ITEM SPECIFICATION
Camshaft and valve stem seal
Accumulator assembly 44 +/- 5 N.m (33 +/- 3 ft-lb)
Camshaft position sensing cylinder bolt 22 +/- 4 N.m (16 +/- 3 ft-lb)
Camshaft position sensor support bolt 14 +/- 1 N.m (120 +/- 13 in-lb)
Camshaft sprocket bolt 89 +/- 9 N.m (65 +/- 7 ft-lb)
Connector bracket bolt 11 +/- 1 N.m (98 +/- 8 in-lb)
Control wiring harness bolt 9.0 +/- 2.0 N.m (80 +/- 17 in-lb)
Control wiring harness protector bolt 5.0 +/- 1.0 N.m (44 +/- 9 in-lb)
Cylinder head plug 47 +/- 7 N.m (35 +/- 5 ft-lb)
Engine oil control valve bolt 11 +/- 1 N.m (98 +/- 8 in-lb)
Engine oil pressure switch 10 +/- 2 N.m (89 +/- 17 in-lb)
Exhaust rocker arm shaft bolt 13 +/- 1 N.m (115 +/- 9 in-lb)
Intake rocker arm shaft bolt 31 +/- 3 N.m (23 +/- 2 ft-lb)
Rocker cover assembly bolt 3.5 +/- 0.5 N.m (31 +/- 4 in-lb)
Spark plug 25 +/- 4 N.m (18 +/- 3 ft-lb)
Crankshaft oil seal
A/T drive plate bolt 132 +/- 5 N.m (98 +/- 3 ft-lb)
Flywheel bolt 132 +/- 5 N.m (98 +/- 3 ft-lb)
Crankshaft pulley
Crankshaft damper pulley bolt 25 +/- 4 N.m (18 +/- 3 ft-lb)
Cylinder head gasket
Camshaft sprocket bolt 89 +/- 9 N.m (65 +/- 7 ft-lb)
Control wiring harness bolt 9.0 +/- 2.0 N.m (80 +/- 17 in-lb)
Cylinder head bolt < Cold engine > 78 +/- 2 N.m to 0 N.m to 20 +/- 2
N.m to +90° to +90° to (58 +/- 1
ft-lb to 0 in-lb to 15 +/- 1 ft-lb to
+90° to +90°)
Engine oil dipstick guide bolt 13 +/- 1 N.m (115 +/- 9 in-lb)
Generator terminal nut 12 +/- 2 N.m (102 +/- 22 in-lb)
Intake manifold stay bolt 31 +/- 3 N.m (23 +/- 2 ft-lb)
Knock sensor connector bracket bolt 11 +/- 1 N.m (98 +/- 8 in-lb)
Pressure hose clamp bolt 12 +/- 2 N.m (102 +/- 22 in-lb)
Radiator lower hose clamp bolt 11 +/- 1 N.m (98 +/- 8 in-lb)
Water hose clamp bolt 11 +/- 1 N.m (98 +/- 8 in-lb)
Engine assembly
ATF warmer (transmission fluid cooler) bracket bolt 23 +/- 3 N.m (17 +/- 2 ft-lb)
Battery terminal nut 5.0 +/- 1.0 N.m (44 +/- 9 in-lb)
Control wiring harness bolt and nut 9.0 +/- 2.0 N.m (80 +/- 17 in-lb)
Engine front mounting bracket bolt M10 58 +/- 7 N.m (43 +/- 5 ft-lb)
Engine front mounting bracket bolt and nut M12 83 +/- 12 N.m (61 +/- 9 ft-lb)
Grounding cable bolt 9.0 +/- 2.0 N.m (80 +/- 17 in-lb)
Power steering oil pump bracket bolt 24 +/- 4 N.m (18 +/- 3 ft-lb)
Power steering oil pump bracket nut 44 +/- 10 N.m

(33 +/- 7 ft-lb)
Pressure hose clamp bolt 12 +/- 2 N.m (102 +/- 22 in-lb)
Oil pan
M6 9.0 +/- 2.0 N.m (80 +/- 17 in-lb)
Baffle plate bolt (bolt, washer assembled)
M8 22 +/- 4 N.m (16 +/- 3 ft-lb)
Engine oil pan bolt 9.0 +/- 3.0 N.m (80 +/- 26 in-lb)
Engine oil pan drain plug 39 +/- 5 N.m (29 +/- 3 ft-lb)
Engine oil pan strainer bolt 19 +/- 3 N.m (14 +/- 2 ft-lb)
Torque converter housing front lower cover bolt M10 26 +/- 5 N.m (19 +/- 4 ft-lb)
(bolt, flange)
Torque converter housing front lower cover bolt M6 9.0 +/- 1.0 N.m (80 +/- 9 in-lb)
(bolt, washer assembled)
Timing belt
M8 22 +/- 4 N.m (16 +/- 3 ft-lb)
Auto-tensioner bolt (bolt, washer assembled)
M10 44 +/- 10 N.m (33 +/- 7 ft-lb)
Balancer timing belt tensioner bolt 19 +/- 3 N.m (14 +/- 2 ft-lb)
Connector bracket bolt 11 +/- 1 N.m (98 +/- 8 in-lb)
Crankshaft pulley center bolt 167 N.m (123 ft-lb)
Cylinder block plug 30 +/- 3 N.m (23 +/- 2 ft-lb)
Generator terminal nut 12 +/- 2 N.m (102 +/- 22 in-lb)
Idler pulley bolt 79 +/- 5 N.m (59 +/- 3 ft-lb)
Timing belt idler pulley bolt 35 +/- 6 N.m (26 +/- 4 ft-lb)
Timing belt lower cover bolt (bolt, flange) M6 11 +/- 1 N.m (98 +/- 8 in-lb)
Timing belt lower cover bolt (bolt, washer M6 9.0 +/- 1.0 N.m (80 +/- 9 in-lb)
assembled)
Timing belt lower cover bracket bolt 8.5 +/- 0.5 N.m (76 +/- 4 in-lb)
Timing belt lower cover nut 11 +/- 1 N.m (98 +/- 8 in-lb)
Timing belt tensioner adjuster bolt 23 +/- 3 N.m (17 +/- 2 ft-lb)
Timing belt tensioner arm bolt 21 +/- 4 N.m (16 +/- 2 ft-lb)
Timing belt tensioner pulley bolt 48 +/- 5 N.m (36 +/- 3 ft-lb)
M6 11 +/- 1 N.m (98 +/- 8 in-lb)
Timing belt upper cover bolt (bolt, flange)
M8 14 +/- 1 N.m (120 +/- 13 in-lb)
Water pump pulley bolt 8.8 +/- 1.0 N.m (78 +/- 9 in-lb)
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS CHART

ITEM STANDARD VALUE LIMIT
Drive belt tension Vibration frequency Hz 120 - 154 -
(Reference)
Tension N (Reference) 340 - 562 -
Valve clearance (at hot) Intake valve 0.20 (0.008) -

mm (in) Exhaust valve 0.30 (0.012) -
Actual ignition timing at idle Approximately 10° -
BTDC
Basic ignition timing at idle 5°BTDC +/- 3° -
CO content % 0.5 or less -
HC contents ppm 100 or less -
Curb idle speed r/min 700 +/- 100 -
Compression pressure (250 - 400 r/min) kPa (psi) 1,560 (226) Minimum 1,130 (164)
Intake manifold vacuum at curb idle kPa (in Hg) - Minimum 60 (18)
Cylinder block heater unit internal resistance ohms 28 - 40 -
Cylinder head bolt nominal length mm (in) - 99.4 (3.91)
Balancer timing belt Deflection mm (in) 5 - 7 (0.20 - 0.27) -
tension (When adjusted)
tension (When replaced)
tension (When checked)
Timing belt tensioner adjuster rod protrusion 3.8 - 4.5 (0.15 - 0.17) -
amount mm (in)
Timing belt tensioner adjuster rod movement mm Within 1 (0.039) -
(in)
SEALANTS
SEALANTS SPECIFICATION CHART

ITEM SPECIFIED SEALANT
Camshaft position sensor support 3M™ AAD Part No.8672, 3M™ AAD Part
Engine oil pressure switch No.8679/8678 or equivalent
Engine oil pan 3M™ AAD Part No.8672, 8704, 3M™ AAD Part
No.8679/8678 or equivalent

Eclipse 2008 2.4L

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Eclipse 2008 2.4L

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2008 Mitsubishi Eclipse GS

2008 ENGINE Engine Mechanical (2.4L) - Eclipse

Engine Mechanical (2.4L) - Eclipse

ITEM SPECIFICATION CHART

domingo, 14 de febrero de 2021 06:28:26

MB991454 Engine hanger MZ203827-01 When the engine hanger is

MB991895 Engine hanger Tool not available

MB991928 Tool not available

MD998719 Pin MIT308239

MD998772 Valve spring General service tool Compressing valve spring

MB991999 Valve stem seal - Valve stem seal installation

MD998713 MD998713-01 Camshaft oil seal

MD998727 MD998727-01 Oil pan removal

MD998781 General service tool Supporting the A/T drive

MB990938 MB990938-01 Crankshaft rear oil seal

MD998776 Crankshaft rear MD998776-01

MD998285 Crankshaft MD998285-01 Crankshaft front oil seal

MD998375 Crankshaft MD998375-01

MD998738 Adjusting bolt MD998738-01 Supporting the timing belt

MB991654 Cylinder head General service tool Removal and installation of

MB991367 Special spanner MB991367-01 Holding the crankshaft

MB991385 Pin MIT217213

MD998767 Tensioner MD998752-01 Valve timing belt tension

Fig. 1: Drive Belt Tensioner Adjustment Indicator Mark

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig. 2: Turning Auto-Tensioner

When using scan tool MB991958

Required Special Tools:

MB991668: Belt Tension Meter Set

1. Check the DRIVE BELT TENSION.

1. Connect special tool MB991668 to scan tool MB991824.

CAUTION: The temperature of the surface of the belt should be as close to no

Fig. 3: Connecting Scan Tool To Data Link Connector

belt so that it is perpendicular to the belt (within +/- 15 degrees).

Standard value: 120 - 154 Hz

3. If not within the standard value, replace the AUTO-TENSIONER.

When using a tension gauge

1. Check the DRIVE BELT TENSION.

Fig. 4: Checking Drive Belt Tension Using MB991668

Standard value: 340 - 562 N

3. If not within the standard value, replace the AUTO-TENSIONER.

Fig. 5: Checking Drive Belt Tension Using Tension Gauge

VALVE CLEARANCE CHECK AND ADJUSTMENT

2. Remove all of the ignition coils.

Fig. 6: Checking Valve Clearance

Standard value (hot engine):

Intake side: 0.20 mm (0.008 inch)

Exhaust side: 0.30 mm (0.012 inch)

Tightening torque: 9 +/- 1 N.m (80 +/- 9 in-lb)

ROCKER ARM PISTON OPERATION CHECK

1. Remove all of the ignition coils.

Fig. 8: Checking Rocker Arm Piston Operation

Fig. 9: Identifying Rocker Arm Piston

IGNITION TIMING CHECK

Required Special Tool:

MB991958: Scan Tool (MUT-III Sub Assembly)

1. Before inspection, set the vehicle in the following condition:

Lights and all accessories: OFF

CAUTION: To prevent damage to scan tool MB991958, always turn the