11A 4G15 Engine

32
11-1 ENGINE CONTENTS 110003000 1.5L ENGINE. ... . . . . .... . . . ... .. . .. . . . .. . . . .. . . ........ . . . .... 1lA 1.8L ENGINE.. . . . . . ... .. , . , . .. . . . .. . . . . . . . .. . . . .. . . . . . . . . .. . . 11B

Transcript of 11A 4G15 Engine

Page 1: 11A 4G15 Engine

11-1

ENGINE CONTENTS 110003000

1.5L ENGINE. ... . . . . . ... . . . ... .. . .. . . . .. . . . .. . . ... .. ... . . . .. .. 1lA

1.8L ENGINE.. . . . . . . . . . . , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

Page 2: 11A 4G15 Engine

11 A-I

1.5L ENGINE CONTENTS 110003001

CAMSHAFT AND CAMSHAFT OIL SEAL ,. 19 Ignition Timing Inspection and Adjustment ................................ 10

CRANKSHAFT OIL SEAL.. ............... 23 Manifold Vacuum Inspection . . . . . . . . . . . . . . . . . . 13

Power Steering Oil Pump Drive Belt Tension Inspection and Adjustment 8 .................. CRANKSHAFT PULLEY 29 . . . . . . . . . . . . Timing Belt Tension Adjustment . . . . . . . . . . . . . . 14 CYLINDER HEAD GASKET ............... 25 Valve Clearance Adjustment

ENGINE ASSEMBLY ................... , . 16 . . . . . . . . . . . . . . . . . . . Refer to GROUP 00

GENERAL INFORMATION .................. 2 SERVICE SPEClFlCATlONS ................. 5

OIL PAN ................................. 21 SPECIAL TOOLS ......................... - 6

SEALANTS ............................... . 5 TIMING BELT ............................ 30

SERVICE ADJUSTMENT PROCEDURES ..... 8 TROUBLESHOOTfNG ....................... 7 Air Conditioning Compressor Drive Belt Compression Too Low Tension Inspection and Adjustment . . . . . . . . Basic Idle Speed Adjustment Excessive Engine Rolling and Vibration . . . . . . . . . . . . . . . . . . . Refer to GROUP 13

Noisy Valves Compression Pressure Inspection . . . . . . . . . . . . . 12

Oil Pressure Drop Curb Idle Speed Inspection . . . . . . . . . . . . . . . . . 11

Oil Pressure Too High Generator Drive Belt Tension Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 8 Timing Belt Noise

Idle Mixture Inspection.. . . . . . . . . . . . . . . . . . . . . . 11

Connecting Rod Noise / Main Bearing Noise

Page 3: 11A 4G15 Engine

11 A-2 1.5L ENGINE - General Information

GENERAL INFORMATION 11 0003002

GENERAL S P ECI FIC AT1 0 N S

k b e r of cylinders

1 Items 1 Specifications I In-line, Over Head Camshaft

4

Compression ratio

Firing order

I Bore mm (in.) 1 75.5 (2.97) I

9.2

1-3-4-2

1 82.0 (3.23) I

Exhaust valve 1 Opens (BBDC)

1 Piston displacement cm3 (cuh.) 1 1,468 (89.6) I

57"

Valve timing Intake valve I Opens (BTDC) I 15"

I Lubrication 1 Pressurized feed-full filtration I

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1.5L ENGINE - General Information 11 A-3

SECTIONAL VIEW 110003003

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11 A-4 1.5L ENGINE - General Information

LUBRICATION SYSTEM

n 11OW3OC

i 'i

Crankshaft

. Connecting rod

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1.5L ENGINE - Service Specifications / Sealants 1 1 A-5

Drive belt tension N (Ibs.)

SERVICE SPECIFICATIONS

Generator Whenchecked 250-500 (55-110) - type When new belt is installed 500-700 (1 10- 154) -

When used belt is installed 400 (88) -

11 0003005

Air conditioning compressor type

Items I Standard value I Limit 1

When checked 250-310 (55-68) . - When new belt is installed 370-435 (82-96) - When used belt IS installed 250-310 (55-68) -

Drive belt deflection mm (in.)

, 300-500(66-110)

1 500-850 (110-187)

When used belt is installed I 300-500 (66-110)

~ - -

-

Generator

~ ~ ~ ~ ~ ~ ~ p e

Whenchecked 7.0-9.0 (.28-.35) 1 - When new belt is installed 5.5-7.0 (.22-.28) , -

value) 1 When used belt is installed 8.0 (.31) - 1

Curb idle speed r h i n 1 750k 100 l - I

Air conditioning , When checked compressor I

type When new belt is installed

When used belt is installed

Compression pressure (250-400 r/min) kPa (psi) 1 1,350 (192) - I min. 960 (137) I

6.0-7.0 (.24-.28) - 5.0-6.0 (.20-.24) 1 - 6.0-7.0 (.24-.28) -

Compression pressure difference of all cylinder kPa (psi) l - 1 max. 100 (14) I

Power steering When checked oil pump V-ribbed type When new belt is installed

When used belt is installed

Intake manifold vacuum at curb idle kPa (in.Hg) l - I min. 60 (18) I

5.5-7.5 (.22-.30) - 4.0-5.5 (.16-.22)

5.5-7.5 (.22-.30) - -

SEALANTS

Basic ignition timing at idle (except 1995 models for California)

Basic ignition timing at idle (1995 models for California)

Actual ignition timing at curb idle

CO concentration %

HC concentration ppm

110003006

5" k 2" BTDC - 5" k 3" BTDC - 10" BTDC - 0.5 or less -

100 or less l -

I Items 1 Recommended sealant

Oil pan MlTSUBlSHl GENUINE Part No, MD970389 or equivalent

As required

Page 7: 11A 4G15 Engine

11 A-6 1.5L ENGINE - Special Tools

SPECIAL TOOLS 1100030l

Tool number and name Supersession Tool Application

Installation of camshaft oil seal

MD998713

Camshaft oil seal installer

MD998713-01

Removal of oil pan General service tool MD998727

Oil pan remover

MD998747

Crankshaft pulley holder

General service tool Supporting crankshaft pulley

MB990767

End yoke holder

MB990767-01 Supporting camshaft pulley Supporting crankshaft pulley

MD998719

Crankshaft pulley holder pin

MIT308239

Q Installation of crankshaft rear oil seal

MD998011-01 MD998011

Crankshaft rear oil seal installer

MD998360

Cylinder head bolt wrench

General service tool Removal and installation of cylinder head assembly

GENERAL SERVICE TOOL MZ203827

Engine lifter

General service tool Supporting engine assembly when removing and installing transaxle

Page 8: 11A 4G15 Engine

1.5L ENGINE - Troubleshooting 11 A-7

I Incorrect valve clearance

Engine oil level too low

Oil pressure switch faulty

Oil pressure drop

TROUBLESHOOTING 110003008

Symptom I Probable cause 1 Remedy

Adjust valve clearance

Check engine oil level

Replace oil pressure switch

Compression too low 1 Cylinder head gasket blown I Replace gasket

1 Thin or diluted engine oil

Oil relief valve stuck (open)

1 Piston ring worn or damage 1 Replace rings

~~

Change engine oil to correct viscosity

Repair relief valve

1 Piston or cylinder worn

Oil pressure too high

Noisy valves

Repair or replace piston and/or cylinder block I

Oil relief valve stuck (closed)

Incorrect valve clearance

Repair relief valve

Adjust valve clearance

Valve seat worn or damage 1 Repair or replace valve and/or seat ring

Connecting rod noisel main bearing noise

Insufficient oil supply

Low oil pressure

Check engine oil level

Refer to “Oil pressure drop”

1 Oil filter clogged I Install new filter

Incorrect belt tension

Loose engine roll stopper (Front, Rear) Loose transaxle mount bracket Loose engine mount bracket Loose center member

1 oil pump gears or cover worn 1 Replace gears and/or cover

Adjust belt tension

Retighten

1 Excessive bearing clearance 1 Replace bearings

1 Thin or diluted engine oil (low oil pressure) Change engine oil

I Valve stem or valve guide worn or damaged I Replace valve and/or guide

I Thin or diluted engine oil 1 Change engine oil

’ Excessive bearing clearance 1 Replace bearings

Timing belt noise

Excessive engine rolling and vibration

Page 9: 11A 4G15 Engine

11 A-8 1.5L ENGINE - Service Adjustment Procedures

Crankshaft pulley

ZWMM

SERVICE ADJUSTMENT PROCEDURES I 1 0003009

_ " I " - GENERATOR DRIVE BELTTENSION INSPECTION AND ADJUSTMENT GENERATOR DRIVE BELT TENSION INSPECTION With belt tension gauge set to the belt midway between the pulleys as shown in the illustration, check the belt tension for standard value. Or apply a force of 98 N (22 Ibs.) to the belt to check the deflection for standard value. Standard value:

1 Tension N (Ibs.) I Deflection mm (in.) 1 (Reference value) I '

250-500 (55-110) 1 7.0-9.0 (.28-.35)

GENERATOR DRIVE BELT TENSION ADJUSTMENT

(1) Loosen the nut of the generator pivot bolt. (2) Loosen the lock bolt. (3) Turn the adjusting bolt to adjust the belt tension or deflec-

Standard value:

110003010

tion to the standard value.

(4) Tighten the lock bolt. Tightening torque: 14 Nm (10 ft.lbs.)

(5) Tighten the nut of the generator pivot bolt. Tightening torque: 23 Nm (16 ft.lbs.) __ .

Water pump

I ZlJi- I

POWER STEERING OIL PUMP DRIVE BELT TENSION INSPECTION AND ADJUSTMENT

POWER STEERING OIL PUMP DRIVE BELT TENSION INSPECTION Measure drive belt deflection by pulling or pushing at the mid- point of the belt between pulleys with a force of 100 N (22 Ibs.) as shown in the figure. Standard value: 5.5-7.5 mm (.22-.30 in.)

110003011

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1.5L ENGINE - Service Adjustment Procedures 11 A-9

POWER STEER." OIL PUMP DRIVE BELT TENSION

If the deflection is out of the standard values, adjust the belt tension using the following procedure. (1) Loosen bolts A, B and C (for holding the oil pump).

ADJUSTMENT 110003012

I m- I

(2) Set a bar or similar tool against the oil pump body, and while applying tension to the belt, tighten the oil pump mounting bolts in the order A, B, C.

(3) Tighten belt adjustment bolt. Tightening torque: 40 Nm (29 ft.lbs.)

(4) Check the belt deflection adjust if necessary. Caution Before this check, turn the engine one time or more clockwise. NOTE Verify belt is not cracked or frayed before re-using. Standard value:

Used belt: 5.5-7.5 mm (.22-30 in.) New belt: 4.0-5.5 mm (.16-.22 in.)

AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT

AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION INSPECTION Measure drive belt deflection by pulling or pushing at the mid- point of the belt between pulleys with a force of 100 N (22 Ibs.). Standard value: 6.0-7.0 mm (.24-.28 in.)

11000301 3

AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION

(1) Loosen tension pulley securing nut A. (2) Adjust belt tension with adjusting bolt B.

ADJUSTMENT 110003014

NOTE Verify belt is not cracked or frayed before re-using. Standard value:

Used belt: 6.0-7.0 mm (.24-.28 in.) New belt: 5.0-6.0 mm (.20-.24 in.)

(3) Tighten securing nut A. (4) Check the belt tension after driving.

Standard value: 6.0-7.0 mm (.24-.28 in.)

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Page 11: 11A 4G15 Engine

11A-10 1.5L ENGINE - Service Adjustment Procedures '

IGNITION TIMING INSPECTION AND

(1) Before inspection and adjustment, verify following the

Engine coolant temperature: 80-95°C (1 76-203°F) Lights, electric cooling fan and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T)

ADJUSTMENT 11 0003015

conditions: 0 0 0

(2) Insert a paper clip into the 1 pin connector (blue) as shown in the illustration at left.

(3) Connect a primary-voltage-detection type of tachometer to the paper clip. NOTE Do not use the scan tool. If tested with the scan tool connected to the data link connector, the ignition timing will not be the basic timing but be ordinary timing.

(4) Set up a timing light. (5) Start the engine and run at idle. (6) Check that engine idle speed is within the standard value.

(7) Turn the ignition switch to OFF. (8) Remove the waterproof connector from the ignition timing

(9) Connect the jumper wire to the ignition timing adjustment

Curb idle speed: 750 f 100 r/min

adjustment connector (brown).

terminal, and to a good ground as illustrated. NOTE Grounding this terminal sets the engine to basic ignition timing.

(10)Start the engine and run it at idle. (11)Check that basic ignition timing is within the standard

value. Basic lgnltion tlmlng:

5"BTDC f 2" (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California)

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1.5L ENGINE - Service Adjustment Procedures 11A-11

J

(12)cExcept 1996 models and 1995 models for California> a. If not within the standard value, loosen distributor hold

down nuts and adjust by rotating distributor body. b. Tighten hold down nuts after adjusting.

Tightening torque: 12 Nm (8 lt.lbs.) 4 9 9 6 models and 1995 models for California> If not within the standard value, inspect the MFI components by referring. to GROUP 13A - Troubleshooting.

(13)Stop the engine, remove the jumper wire from the ignition timing adjustment connector (brown), and return the con- nector to its original condition.

(14)Star-l the engine and check that ignition timing is at the standard value. Actual ignition timing: approx. 10"BTDC NOTE 1. Ignition timing is variable within about f7", even under

normal operation. 2. And it automatically advances by about 5" from 10"

BTDC at higher altitudes.

CURB IDLE SPEED INSPECTION 110003016

(1) Before inspection and adjustment verify in the following

Engine coolant temperature: 80-95°C (1 76-203°F) Lights, electric cooling fan and all accessories: OFF Transaxle: Neutral (P range on vehicles with NT)

conditions: 0 0

0

Standard value: (2) Check the basic ignition timing. Adjust if necessary.

5"BTDC k 2' (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California)

(3) After turning the ignit'on switch to OFF, install the tachome- ter or connect the scan tool to the data link connector (white). For the method of installing the tachometer, refer

(4) Start the engine and'run it at idle. (5) Run the engine at idle for 2 minutes. (6) Check the idle speed.

Curb Idle speed: 750 k 100 r/min NOTE The idle speed is controlled automatically by the idle air control (IAC) system.

(7) If there is a deviation from the standard value, refer to GROUP 13 - Check Chart Classified by Problem Symp- toms, and check the MFI components.

to P.11A-10.

IDLE MIXTURE INSPECTION 11 000301 7

(1) Before inspection, set the vehicle in the following condition. Engine coolant temperature: 80-95°C (1 76-203°F) Lights, electric cooling fan and accessories: OFF Transaxle: Neutral (P range on vehicle with AlT)

0 0

0

Page 13: 11A 4G15 Engine

11A-12 1.5L ENGINE - Service Adjustment Procedures

(2) Make sure that the basic ignition timing is at a standard value. Standard value:

5"BTDC k 2" (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California)

(3) After turning the ignition switch OFF, set a tachometer or connect the scan tool to the data link connector. NOTE For tachometer setting procedure, refer to P.1lA-10.

(4) Start the engine and run at 2,500 r/min forapprox. 2 minutes. (5 ) Set the CO tester and HC tester. (6) Check the CO concentration and HC concentration with

the engine at idle. Standard value:

CO concentration: 0.5% or less HC concentration: 100 ppm or less

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

# 3. - a

Diagnostic output Closed loop control (If closed loop control is performed normally, heated oxygen sensor output signals change within a 0-400 mV range and a 600-1,000 mV range.) Fuel pressure Injectors Ignition coil, spark plug cables and spark plugs Leaks in EGR system and EGR valve Evaporative emission control system Compression pressure

NOTE If CO and HC concentrations exceed the respective standard values despite the fact that the results of the inspection made on all items are normal, replace the three-way catalyst.

COMPRESSION PRESSURE INSPECTION

(1) Before inspection, check that the engine oil, starter and battery are normal. Also, verify to the following conditions:

11 000301 8

a Engine coolant temperature: 80-95°C (1 76-203°F) a Lights, electric cooling fan and all accessories: OFF a Transaxle: Neutral (P range on vehicle with A/T)

(2) Remove all of the spark plugs. (3) Disconnect the 6-pin distributor connector (except 1995

models for California) or crankshaft position sensor con- nector (1995 models for California). NOTE Doing this will prevent the engine control module from carrying out ignition and fuel injection.

(4) Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

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Page 14: 11A 4G15 Engine

1.5L ENGINE - Service Adjustment Procedures 11A-13 _ . - -

- . . ... , . .

..--

Caution 1. Keep away from the spark plug hole when cranking. 2. During a compression test, if water, oil, fuel, etc.,

has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

.

(5) Set 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 250-400 rlmin):

Limit (at engine speed of 250-400 r/min): 1,350 kPa (192 psi)

min. 960 kPa (137 psi) (7) Measure the compression pressure for all the cylinders.

Verify difference between maximum and minimum read- ings do not exceed the limit. Limit: max. 100 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) and (7). a. 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.

b. 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 distributor connector (except 1995 models for California) or crankshaft position sensor connector (1995 models for California).

(1O)lnstall the spark plugs and spark plug cables. (11)Use the scan tool to erase the diagnostic trouble codes,

or disconnect the battery ground cable for more than 10 seconds and reconnect it. NOTE This will erase the diagnostic trouble code resulting from the distributor connector being disconnected.

MANIFOLD VACUUM INSPECTIONN 11 000301 9

(1) Verify the following conditions before inspection. 0 Engine coolant temperature: 80-95°C (1 76-203°F) 0 Lights, electric cooling fan, and all accessories: OFF 0 Transaxle: Neutral (P range on vehicles with PJT)

(2) Install the tachometer or connect the scan tool to the data link connector (white).

(3) Disconnect the vacuum hose from the fuel pressure regula- tor.

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11A-14 1.5L ENGINE - Service Adjustment Procedures ’ I

(4) Connect a three-way vacuum tee between the removed 1 vacuum hose and the nipple and connect a vacuum gauge to the vacuum tee as shown.

(5) Start the engine and check that idle speed is within the standard value range. I

(6) Check the manifold vacuum. Limit: 60 kPa (18 in.Hg) min. I

1 1

ZlENC550

I TIMING BELT TENSION ADJUSTMENT iiooo3ozo I

The timing belt has an automatic tension adjusting mechanism. 1 Adjustment can be made by the following procedure. (1) Remove the water pump pulley. (2) Remove the air conditioning pulley bracket.

i

(3) Remove the timing belt upper cover. (4) Remove the crankshaft compressor pulley and crankshaft

pulley. <Vehicles for California (From 1995 models)> (Refer to P. 11A-29.)

(5) Remove the timing belt lower cover. (6) Remove the spark plugs. (7) Turn the crankshaft clockwise to check for cracks or signs

of wear that in the timing belt. Caution Always turn the crankshaft clockwise.

(8) Turn the crankshaft clockwise to bring the No. 1 cylinder piston to top dead center on the compression stroke. Caution For aligning the timlng marks, never turn the crank- shaft counterclockwise as it could cause inadequate belt tensioning.

1 (9) Loosen both pivot side and slot side tensioner bolts and

tension the belt, making use of the tensioner spring force. (10)Turn the crankshaft clockwise by two teeth of camshaft

sprocket.

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Page 16: 11A 4G15 Engine

1.5L ENGINE - Service Adjustment Procedures 11A-15

1/4 of bolt head width

muoIl

(11) Push the timing belt tensioner inthe'direction of the arrow to check that each sprocket is kept in firm and complete engagement with the belt cogs. After this check, release hand pressure so that only the tensioner spring acts on belt and tighten the slot side bolt and then the pivot side bolt to fix the tensioner in position.

I - .. . -. . .. . . __ . . I

(12)Check the timing belt tension. Hold the timing belt tensioner and timing belt together by hand and give the belt a slight thumb pressure at a point level with tensioner center. Make sure that the belt cog crest deflects approximately 1/4 of the tensioner at- taching bolt head width.

(13)lnstall the spark plugs. (14)lnstall the timing belt lower cover. (1 5)lnstall the crankshaft compressor pulley and crankshaft

pulley. <Vehicles for California (From 1995 models)> (Refer

(16)lnstall the timing belt upper cover. (1 7)lnstall the air conditioning pulley bracket. (18)lnstall the water pump pulley and adjust the drive belt

to P. 11A-29.)

deflection.

Page 17: 11A 4G15 Engine

11A-16 1.5L ENGINE - Engine Assembly

ENGINE ASSEMBLY REMOVAL AND INSTALLATION

110003021

~~

Pie-removal Operation 0 Fuel Line Pressure Releasing (Refer to GROUP 13

- Service Adjustment Procedures.) 0 Hood Removal 0 Coolant Draining (Refer to GROUP 14 - Service

Adjustment Procedures.) 0 Transaxle Assembly Removal (Refer to GROUP 22,

23 - Transaxle Assembly.) 0 Radiator Removal (Refer to GROUP 14 - Radiator.)

Post-Installation Operation 0 Radiator Installation (Referto GROUP 14- Radiator.) 0 Transaxle Assembly Installation

(Refer to GROUP 22, 23 - Transaxle Assembly.) 0 Coolant Supplying (Refer to GROUP 14 - Service

Adjustment Procedures.) 0 Hood Installation 0 Accelerator Cable Adjustment (Refer to GROUP 13

- Service Adjustment Procedures.)

. _

5 Nm 5 Nm 3.6 R.lbs.

I ‘8 10

Removal steps 1. Ground cable connection 2. Accelerator cable connection 3. Breather hose connection 4. Vacuum hose connection 5. Heater hose connection 6. High-pressure hose connection 7. O-ring 8. Return hose connection 9. Brake booster vacuum hose connec-

tion 10. Vacuum hose connection

Page 18: 11A 4G15 Engine

1.5L ENGINE - Engine Assembly 11A-17

Removal steps 11. Oxygen sensor connector 12. Ignition coil connector 13. CKP sensor and CMP sensor

14. Engine coolant temperature sensor

15. Engine coolant temperature gauge

16. Throttle position sensor connector 17. Intake air temperature sensor 18. EGR temperature sensor 19. Idle air control motor 20. Injector connector 21. Control harness

connector

connector

unit connector

22. Generator connector 23. Power steering oil pressure switch

connector

(Refer to P.11A-8.) V-ribbed belts adjustment

24. V-ribbed belt for air conditioning 25. Air conditioning compressor 26. V-ribbed belt for power steering 27. Power steering oil pump 28. Self-locking nuts and bolts 29. Gasket 30. Engine mount bracket (Refer to

GROUP 32 - Engine Mount.)

+ A b

+ B b

+Cb ,A+ 31. Engine assembly

Page 19: 11A 4G15 Engine

11A-18 1.5L ENGINE - Engine Assembly

REMOVAL SERVICE POINTS (A, AIR CONDITIONING COMPRESSOR REMOVAL

<VEHICLES WITH AIR CONDITIONING> Disconnect the air conditioning compressor connector and remove the compressor from the compressor bracket with the hose still attached. NOTE Place the removed air conditioning compressor in a place where it will not be a hindrance when removing and instal- ling the engine assembly, and tie it with a cord.

(B, POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the bracket with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and instal- ling the engine assembly, and tie it with a cord.

(C, ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connec- tors, etc., are disconnected from the engine, slowly remove the engine assembly upward from the engine compart- ment.

I N STA L LATlO N SERVICE P 0 I NT F A 4 ENGINE ASSEMBLY INSTALLATION

Install the engine assembly while checking to be sure that the cables, hoses, and harness connectors are clear of the engine assembly.

Page 20: 11A 4G15 Engine

1.5L ENGINE - Camshaft and Camshaft Oil Seal 11A-19

CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION

I Pie-removal and Post-installation Operation 0 Timing Belt Removal and Installation

(Refer to P.11A-30.) 0 Distributor Removal and Installation

(Refer to GROUP 16 - Distributor.)

3

LIP section

H Engine oil

Removal steps 1. Rocker cover 2. Camshaft sprocket

b C + 3. Oil seal 4 A b

__ 110003022

1.8 Nm 1.3 ft.lbs.

/

32 Nm 23 ft.lbs.

5 I

F B I

b A 4 5. Camshaft

0 Valve clearance inspection and

4. Rocker arm assembly adjustment

REMOVAL SERVICE POINT + A F CAMSHAFT SPROCKET REMOVAL

I

)Revision

Page 21: 11A 4G15 Engine

11 A-20 1.5L ENGINE - Camshaft and Camshaft Oil Seal

INSTALLATION SERVICE POINTS .A+ CAMSHAFT INSTALLATION

Position the dowel pin of the camshaft as shown in the illustration.

,BA VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Refer to GROUP 00 - Maintenance Service.

b C + OIL SEAL INSTALLATION

Page 22: 11A 4G15 Engine

1.5L ENGINE - Oil Pan 11 A-21

OIL PAN REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation Engine Oil Draining and Supplying Oil Dipstick Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to GROUP 15 - Exhaust Pipe and Muffler.)

Specified sealant: MlTSUBlSHl GENUINE PART No. MD970389 or equivalent

Removal steps 1. Bell housing cover 2. Drain plug

,B+ 3. Gasket + A b ,A+ 4. Oil pan

MD998727 1 MD998727 -

110003023

ii Nm 8 tt.lbs.

7 Nm 5.1 ft.lbs.

/ 6 Nm 2 4.3 ft.lbs.

m1Sw51

REMOVAL SERVICE POINT 4 A F O I L PAN REMOVAL

After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Hammer little by little, or the oil pan will be deformed.

I TCR D a t r i c i n n I

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11 A-22 1.5L ENGINE - Oil Pan

INSTALLATION SERVICE POINTS ,A+ OIL PAN INSTALLATION

Caution After cleaning the oil pan mounting bolt holes in the oil seal case, the oil pan should be installed. NOTE (1) Install the oil pan within 15 minutes after applying

liquid gasket. (2) Then wait at least one hour. Never start the engine

or let engine oil or coolant touch the adhesion surface during that time.

.

F B 4 DRAIN PLUG GASKET INSTALLATION Replace the gasket with a new gasket, the groove towards the oil pan as shown.

Page 24: 11A 4G15 Engine

1.5L ENGINE - Crankshaft Oil Seal 11 A-23

CRANKSHAFT OIL SEAL 11 0003024

REMOVAL AND INSTALLATION

Pre-removal and Post-installatlon Operation <Crankshaft Oil Seal+

Timing Belt Removal and Installation (Refer to P.11A-30.)

<Crankshaft Rear Oil Seal> 0 Oil Pan Removal and Installation (Refer to P.11A-21.)

0 Transaxle Assembly Removal and Installation (MTT: Refer to GROUP 22 - Transaxle Assembly.) (Wr: Refer to GROUP 23 - Transaxle Assembly.)

0 Clutch Cover and DISC <MTT> Removal and Installation

5

Lip section I YOINOM:

Engine oil

4

/ 1

<Vehicles for Federal (Up to 1995 models) and California (Up to 1994 models)>

7

m I Lip section

Z01NW43 <M/T>

Crankshaft front oil seal removal steps 1. Crankshaft sprocket 2. Crankshaft sensing blade 3. Crankshaft spacer 4. Flange

F B I 5. Crankshaft front oil seal

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Crankshaft rear oll seal removal steps 6. Flywheel assembly <M/T> or drive

F A 4 7. Crankshaft rear oil seal plate <AK>

4 A F

Page 25: 11A 4G15 Engine

11 A-24 1.5L ENGINE - Crankshaft Oil Seal

Oil seal

Oil seal case

REMOVAL SERVICE POINT A A F FLYWHEEL ASSEMBLY <Mn> OR DRIVE PLATE

Secure the crankshaft pulley by using the V-ribbed belt and the special tool. Caution (1) Because the V-ribbed belt installed in the ve-

hicle may be damaged, use a new V-ribbed belt.

(2) Do not use a damaged V-ribbed belt.

plate cAiT>.

cA/T> REMOVAL

(2) Remove the flywheel assembly <Mn> or the drive

INSTALLATION SERVICE POINTS F A A CRANKSHAFT REAR OIL SEAL INSTALLATION

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

(2) Tap the oil seal as shown in the illustration until it ference of the oil seal lip.

is flush with the oil seal case.

F B A CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the entire circurn-

( 2 ) Tap the oil seal until it is flush with the oil seal case. ference of the oil seal lip.

1

Page 26: 11A 4G15 Engine

1.5L ENGINE - Cylinder Head Gasket 11 A-25

CYLINDER HEAD GASKET REMOVAL AND INSTALLATION

I

Pre-removal Operation 0 Reduce the Inner Pressure of Fuel Line and Hose

(Refer to GROUP 13 - Service Adjustment Proce- dures ) Draining the Engine Coolant Draining the Engine Oil

0 Air Intake Hose Removal (Refer to GROUP 15 - Air Cleaner)

110003025

~ ~~

Post-installation Operation Air Intake Hose Installation

Refilling the Engine Oil Refilling the Engine Coolant Adjusting the Accelerator Cable (Refer to GROUP

(Refer to GROUP 15 - Air Cleaner.)

13 - Service Adjustment Procedures)

5 Nm 3.6 ft.lbs.

15 I

Engine oil

0150080

- 5 Nm 3.6 ft.lbs.

00001073

Removal steps 1. Ground cable connection 2. Accelerator cable connection 3. PCV hose connection 4. Breather hose connection 5. Vacuum hose connection 6. Water hose connection

7. Water hose connection

(Throttle body to thermostat housing)

(Throttle body to water inlet pipe)

8. Water hose connection (Heater unit to thermostat housing)

9. High-pressure fuel hose connection .r 10. O-ring

11. Return hose connection 12. Brake booster vacuum hose

connection 13. Engine mounting stay 14. Vacuum hose 15. Radiator upper hose

Page 27: 11A 4G15 Engine

11 A-26 1.5L ENGINE - Cylinder Head Gasket

1.8 Nm / 1.3 ft.lbs.

96 21 17 ’ ,18

h - \ / / a /l I

9 ,20

.24

26 $2 23

,

27

<Cold engine> 73 Nm 53 ft.lbs.

I

36 ft.lbs. 01SOO62

00001074

Removal steps 16. Oxygen sensor connector 17. Ignition coil connector 18. CKP sensor and CMP sensor

19. Engine coolant temperature sensor

20. Engine coolant temperature gauge

21. Throttle position sensor connector 22. Intake air temperature sensor

connector

connector

unit connector

23. EGR temperature sensor 24. Idle air control motor 25. Injector connector 26. Control harness 27. Rocker cover 28. Timing belt upper cover 29. Camshaft sprocket 30. Self-lockina nuts

4 A b 4 B b

4 C b b B 4 31. Cylinder hzad assembly 32. Gasket

F A 4 33. Cylinder head gasket

Page 28: 11A 4G15 Engine

11 A-27 1.5L ENGINE - Cylinder Head Gasket

REMOVAL SERVICE POINTS 4 A b TIMING BELT UPPER COVER REMOVAL

After removing the timing belt upper cover, rotate the crank- shaft clockwise and align the timing marks. Caution Turn the crankshaft clockwise.

4 B b CAMSHAFT SPROCKET REMOVAL

with the timing belt attached. (1) Use the special tool to remove the camshaft sprocket

(2) Tie the camshaft sprocket and timing belt with a wire so that the position of the camshaft sprocket will not move with respect to the timing belt.

4 C b CYLINDER HEAD ASSEMBLY REMOVAL Using the special tool, loosen the bolts in the order shown in the illustration (in 2 or 3 steps), remove them and then remove the cylinder head assembly. NOTE Loosening each bolt in 1 step may warp the cylinder head.

Front of engine Intake side e

Exhaust side

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1 TSE Ravirian

I

Page 29: 11A 4G15 Engine

11 A-28 1.5L ENGINE - Cylinder Head Gasket

ZOlRM17

C Camshaft sprocket side I

Front of engine Intakeside

Exhaust side yo1uo155

INSTALLATION SERVICE POINTS b A + CYLINDER HEAD GASKET INSTALLATION

(1) Use a scraper to remove the cylinder head gasket from the cylinder block. Caution Take care that no foreign material gets into the cylinder, or into the engine coolant or oil passages.

(2) Place the cylinder head gasket on the cylinder block with the marks facing upward. Caution The cylinder head gasket is easy to mls-Install, so be sure to check it. If it is mis-installed, malfunc- tions such as no oil rising to the cylinder head will occur.

bB+ CYLINDER HEAD ASSEMBLY INSTALLATION (1) Use a scraper to remove the cylinder head gasket

from the cylinder head assembly. Caution Take care that no foreign material gets into the engine coolant or oil passages.

I. - . (2) Using the special tool, tighten the bolts in the order

shown, a minimum of 2 steps maximum of 3 steps, to specifications.

Page 30: 11A 4G15 Engine

1.5L ENGINE - Crankshaft Pulley 11 A-29

l Pre-removal Operation 0 Under Cover Removal

CRANKSHAFT PULLEY 110003026

Post-installation Operation a Drive Belt Tension Adjustment

0 Under Cover Installation (Refer to P. 11A-8.)

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AOlP0045 I

1 .

Removal steps 1. Drive belt (Air conditioning) 2. Drive belt (Power steering) 3. Drive belt (Generator)

4 A F F A 4 4. Crankshaft compressor pulley (Air conditioning)

+ A F F A 4 5. Crankshaft pulley

REMOVAL AND INSTALLATION SERVICE POINTS 4AFbA4CRANKSHAFT COMPRESSOR PULLEY I

CRANKSHAFT PULLEY REMOVAL AND INSTALLATION

Use the special tool and an old drive belt to secure the pu I leys . Caution 1. This drive belt will get damaged. Do not use the

engine’s drive belt. 2. Never use a damaged drive belt.

Page 31: 11A 4G15 Engine

11 A-30 1.5L ENGINE - Timing Belt

TIMING BELT I10003027

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation 0 Under Cover Removal and Installation 0 Crankshaft Pulley Removal and Installation

(Refer to P.11A-29.) 0 Engine Mount Removal and Installation

(Refer to GROUP 32 - Engine Mounting.)

1

11 Nm 8 R.lbs.

8 ft.lbs.

Removal steps FBd 1. Timing belt upper cover FB4 2. Timing belt lower cover F A 4 3. Timing belt

\ - ‘3 2

NOTE *: Vehicles for Federal <From 1996 models> and California <From 1995 models

REMOVAL SERVICE POINTS 4AFTlMlNG BELT UPPER COVER REMOVAL

After removing the timing belt upper cover, rotate the crank- shaft clockwise and align the timing marks. Caution Always turn the crankshaft clockwise.

1 TSB Revision

Page 32: 11A 4G15 Engine

1.5L ENGINE - Timing Belt 11 A-31

4BFTlMlNG BELT REMOVAL (1) Loosen the timing belt tensioner bolts. (2) Move the timing belt tensioner to the water pump side

and temporarily tighten the bolt so that the tensioner doesn’t return.

(3) Remove the timing belt. Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clock- wise direction.

Timing mark

Timing mark

4- Tension side

Timing mark

Timing mark

Crankshaft sorocket

<Vehicles for <Vehicles for Federal (Up to Federal (From 1995 models) 1996 models) and California and California (Up to 1994 (From 1995 models)> models)>

ZOlU0156

A A 0150208

00001077

INSTALLATION SERVICE POINTS F A 4 TIMING BELT INSTALLATION

(1) Align the timing marks on the camshaft sprocket and crankshaft sprocket. (Now the piston in No. 1 cylinder is at the top dead center on the compression stroke.)

(2) Set the timing belt first on crankshaft sprocket and then keeping the tension side of belt tight, set on the camshaft sprocket. Caution If the timing belt is re-used, install so that the arrow marked on it at time of removal is pointing in the clockwise direction.

(3) Apply counterclockwise force (in the direction B) to the camshaft sprocket to give tension to the belt on tension side and make sure that all timing marks are lined up.

(4) Install the crankshaft pulley temporarily. This is to pre- vent the belt from coming off when crankshaft is turned.

b B 4 TIMING BELT LOWER COVER /TIMING BELT UPPER

Note that the timing belt lower and upper cover attaching bolts differ in size from one place to another. UseA bolt: 6 x 18 (.24 x .71)

COVER INSTALLATION

B bolt: 6 x 38 (.24 x 1.50) [diameter x length mm (in.)]

1 TSB Revision J