7/21/2019 11B 4G93 Engine.pdf
1/37
1.8L ENGINE
t
CONTENTS
CAMSHAFT AND CAMSHAFT OIL SEAL . 18
CRANKSHAFT OIL S E A L . . . . . . . . . . . . . . . . . 22
CRANKSHAFT PULLEY
..................
31
CYLINDER HEAD GASKET . . . . . . . . . . . . . . .
26
ENGINE ASSEMBLY
.....................
14
GENERAL INFORMATION
. . . . . . . . . . . . . . . . . .
I
OIL PAN
.................................
20
SEALANTS ................................
6
II
SERVICE ADJUSTMENT PROCEDURES.. .. 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 13
Compression Pressure Inspection
. . . . . . . . . . . . .
3
Curb Idle Speed Inspection
. . . . . . . . . . . . . . . . . .
1
Generator Drive Belt Tension Inspection
p and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Idle Mixture Inspection
.......................
12
Basic Idle Speed Adjustment
Ignition Timing Inspection and
Adjustment . . . . . . . . . . . . . . . .
10
110003028
Power Steering Oil Pump and Air
Conditioning Compressor Drive Belt
Tension Inspection and Adjustment
. . . . . . . . . . . . . . .
Power Steering Oil Pump Drive Belt
Tension Inspection and Adjustment
. . . . . . . . . . . .
Timing Belt Tension Adjustment . . . . . . . . . . . . . . 3
Valve Clearance Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP
00
SERVICE SPECIFICATIONS
.................
SPECIAL TOOLS .......................... 6
TIMING BELT ............................
32
TROUBLESHOOTING
...................... . 7
Compression Too Low
Connecting Rod Noise
/
Main Bearing Noise
Excessive Engine Rolling and Vibration
Noisy Valves
Oil Pressure Drop
Oil Pressure Too High
Timing Belt Noise
Manifold Vacuum Inspection . . . . . . . . . . . . . . . . . . 3
7/21/2019 11B 4G93 Engine.pdf
2/37
11
B-2 1.8L
ENGINE -
General Information
Number of cylinders
Bore mm (in.)
GENERAL INFORMATION
4
81
O
3.19)
G ENE
R
AL SPEC FICAT10 NS
Valve timing ~ Intake valve
Exhaust valve
110003029
Opens (BTDC) 14
Closes (ABDC)
50
Opens (BBDC) 58
Closes (ATDC) 10
Items Specifications
Lubrication
Type
In-line, Over He ad Camsha ft
Pressurized feed-full filtration
Stroke mm (in.)
I
89.0 (3.50)
Piston displacement cm3 (cu.in.) I 1,834 (111.9)
Compression ratio I 9.5
~~
Firing order
I
1-3-4-2
7/21/2019 11B 4G93 Engine.pdf
3/37
1.8L ENGINE - General Information
11B-3
11 3 3
ECTIONAL
VIEW
7/21/2019 11B 4G93 Engine.pdf
4/37
11 B -4
1.8L ENGINE
-
General Inform ation
LUBRICATION
SYSTEM
Rocker arm shaft
11000303
7/21/2019 11B 4G93 Engine.pdf
5/37
1.8L
ENGINE - Service Specif ications
11
8-5
Generator
V-ribbed type
SERVICE SPECIFICATIONS
Whe nchecked 250-500 (55-110)
-
When new belt
is
installed
I
500-700 (110-154)
-
110003032
Power steering
V-ribbed type
oil pump*'
Items
Drive belt
tension
N
(Ibs.)
When new belt is installed
650-850 (143-187)
-
When used belt is installed 400-600 (88-132)
-
Drive belt
deflection
mm (in.)
Power steering
oil
pump*2 and
Air conditioning
V-ribbed type
compressor
1 Standard value Limit
When new belt is installed 750-800 (165-176)
-
When used belt is installed 500-6 30 (110-139)
-
Generator
V-ribbed type
(Reference
value)
When used belt is installed 400 (88) l
Whencheck ed 8.5-12.0 (.34-.47) -
When new belt is installed 7.0-8.5 (.28-.34)
-
When used belt is installed
9.5
(37) -
Power steering
11
pump*'
V-ribbed type
When new belt is installed 7.5-9.0 (.30-.35) -
When used belt is installed 9.5-11.5 (.37-.45) -
Power steering
oil pump** and
Air conditioning
compressor
V-ribbed type
When new belt is installed 5.5 -6.0 (.22-.24) -
When used belt is installed
6.8- .6 (.27
-
30)
-
Actual ignition timing at curb idle
I
5 BTDC
CO concentration
%
I 0.5
or
less
Basic ignition timing at idle (except 1995 mode ls for California) 5
+
2 BTDC
1
-
-
Basic ignition timing at idle (1995 models for California)
5 3 BTDC
l
Intake manifold vacuum at curb idle k Pa (in.Hg)
- _ -
min. 60 (18)
I
100
or
less
l
C concentration ppm
Curb idle speed r/min 700 * 100 l
Compression pressure (250-400 r/min) kPa (psi)
1,400 (199) min. 1,060 (151)
max. 100 (14)
ompression pressure difference of all cylinder kPa (psi)
l
7/21/2019 11B 4G93 Engine.pdf
6/37
Water outlet fitting
Oil pan
MlTSUBlSHl GEN UINE Part
No.
MD970389 or equivalent
Thermostat case
Flywhee l bolt
Drive plate bolt
Three Bond Part No. 1324 or equivalent
1.8L ENGINE - Sealants
/
Special
Tools
SEALANTS
I10003033
Items I Recomm ended sealant
SPECIAL TOOLS
110003034
Tool number and nam e
Supersession
Application
MB990938
Handle
MB990938-01
Use with M D998776
MB990767-01
Holding camshaft sprocket or
crankshaft pulley when loosening
and tightening of bolt.
Use with MD 998754. MD998719
ME990767
Cranksha ft pulley
holder
Installation of camshaft oil seal
D998713-01D998713
Cam shaft oil seal
installer
MD998717
Cranksha ft front oil
seal installer
MD998717-01
Installation of crankshaft front
oil seal
MD998754, MD 998719
MlT308239
Suppo rting the cranksha ft pulley
when crankshaft bolt and pulley
are removed or reinstalled.
Use together with M B990767
Suppo rting camshaft pulley
Cranksha ft pulley
holder
Gene ral service tool
Removal of the oil pan
D998727
7/21/2019 11B 4G93 Engine.pdf
7/37
1.8L ENGINE - Special Tools
/
Troubleshoot ing 11
B-7
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter
M699 1396
Oil filter wrench
Tool
General service tool Supporting engine assembly when
removing and installing transaxle
MB991396-01
Remo val and installation of engine
oil filter
Tool number and name I Supersession Application
TROUBLESHOOTING
Rpfpr tn P 1 1 A - 7
110003035
7/21/2019 11B 4G93 Engine.pdf
8/37
11B-8
1.8L ENGINE - S e r v i c e A d j u s t m e n t P r o c e d u r e s
New belt
100N
(22
Ibs.) -
500-700 110-154)
7.0-8.5
.28-.34)
SERVICE ADJ USTMENT PROCEDURES
110003036
GEN
E
RAT0
R
DRIVE
BELT
TENS
I
N I N
S
PECTI N
AND ADJUSTMENT
GENERATOR DRIVE BELT TENSION INSPECTION
With belt tension gauge set
to
the belt midway between the
pulleys as shown in the illustration, check the belt tension
for standard value. Or apply a force of
98
N (22 Ibs.)
to
the
belt
to
check the deflection for standard value.
Standard value:
-
Deflection
mm
(in.)
(Reference value)
ension N (Ibs.)
250-500 55-110) 8.5-12.0 .34-.47)
Measure drive belt deflection by pulling or pushing at the mid-
point
of
the belt between two pulleys with a force of
100 N
22
Ibs.) as shown in the figure.
Standard value:
8.5-12
mm (.34-.47 in.)
. +
Belt
ension
dklx adiuster
'
GENERATOR DRIVE BELT TENSION ADJUSTMENT
(1)
Loosen the nut of the generator pivot bolt.
(2) Loosen the lock bolt.
(3)
Turn the adjusting
bolt to
adjust the belt tension or deflec-
Standard value:
I10003037
,
tion to the standard value.
Deflection
mm
(in.)
(Reference value)
tems Tension N (Ibs.)
I
I
(4) Tighten the lock bolt.
Tightening torque: 23
Nm
(17
ft.lbs.)
(5)
Tighten the nut of the generator pivot bolt.
Tightening torque: 45 Nm (33
ft.lbs.)
POWER STEERING OIL PUMP DRIVE BELT
7/21/2019 11B 4G93 Engine.pdf
9/37
1.8L ENGINE -
Service Adjustment Procedures 11B-9
Standard value:
400-600
IS
readjusted
(.37-
45)
(88-1
32)
installed (.30-.35) (143- 187)
2. If the deflection is out of the standard values, adjust the
belt tension using the following procedures.
(1)
Loosen bolts A and B (for holding the oil pump).
(2)
Place a bar or similar object against the body of the
oil pump, and, while manually providing the suitable
amount of tension, adjust the amount of belt deflection .
(3) Tighten bolts
A
and
B
in that order.
Tightening torque:
A
bolt: 40
Nm
(29 ft.lbs.)
B bolt : 24 Nm (17 ft. lbs.)
(4) Check the amount of belt deflection readjust if neces-
sary.
Caut ion
Before th is check, turn the engine one t ime or m ore
in the regular direction of rotation (to the right).
7/21/2019 11B 4G93 Engine.pdf
10/37
11B-10
1.8L ENGINE - Service Adjustment Procedures
Items
When
belt
tension
is readjusted
Standard value:
Deflection mm (in.) Tension
N
(Ibs.)
6.8-7.6 500-630
(.27-.30)
(110-1
39)
When new belt is
5.5-6.0
~
750-800
installed (.22-.24)
(165-176)
2. If the deflection is out of the standard values, loosen the
tension pulley nut an d adjust the belt tension with adjusting
bolt.
IGNITION TIMING INSPECTION AND
(1) Before inspection and adjustment, verify in the following
Engine coolant temperature: 80-95C
176-203F)
Lights, electric cooling fan and all accessories:
OFF
Transaxle: Neutral (P range on vehicles with A/T)
ADJUSTMENT 110003040
conditions:
(2)
Insert a paper clip into the
1
pin connector (blue) as show n
in the illustration at left.
3)
Connect a primary-voltage-detection type of tachometer
to the paper clip.
NOTE
Do not use the scan tool.
If
tested with the scan tool connected
to
the data link
connector, the ignition timing will not be the basic timing
but be ordinary timing.
(4) Set up a timing light.
5 ) Start the engine and run at idle.
6)
Check that engine idle speed is within the standard value.
Curb idle speed:
700
k
100
r lmin
7/21/2019 11B 4G93 Engine.pdf
11/37
1.8L ENGINE - Serv ice Adjustment Procedures
11B-11
(10)Start the engine and run it at idle.
(11)Check that basic ignition timing is within the standard
value.
Basic ign i t ion t iming:
B B TDCk 2 Except 1996 mo delsand 1995 mo dels
for Cal i fornia)
5 BTDC 3 (1996 models and 1995 models for
Cali fornia)
(12)eExcept 1996 models and 1995 models for California>
a.
If
not within the standard value, loosen distributor hold
down nuts and adjust by rotating distributor body.
b. Tighten hold down nuts after adjusting.
Tightening torque: 12 Nm (8 ft.lbs.)
c If not within the standard value, inspect the
MFI
components by referring to GROUP 13A
-
Troubleshooting.
(13)Stop the engine, rem ove the jumper wire from the ignition
timing adjustment connector (brown), and return the con -
nector to its original condition.
(14)Start the engine and check that ignition timing is at the
standard value.
Actual ign i t ion t imin g: approx. 5 BTDC
NOTE
1. Ignition timing is variable within about k7 , even under
normal operating.
2. And it automatically advances by about
5
from 5
BTDC at higher altitudes.
CURB IDLE SPEED INSPECTION 110003041
(1) Before inspection and adjustment verify in the following
Engine coolant temperature: 80-95C (176-203F)
Lights, electric cooling fan and all accessories: OFF
Transaxle: Neutral (P range on vehicles with
A/T)
condition.
Standard value:
R;
(2)
Check the basic ignition timing.
5 BTDC
k
2
(Except 1996 models and 1995 mo dels
7/21/2019 11B 4G93 Engine.pdf
12/37
11
6-12
1.8L
ENGINE
-
Service Adjustment Procedures
~
(6) Check the idle speed.
Curb id le speed:
700
100 r/min
NOTE
The idle speed is controlled automatically by the idle air
control (IAC) system.
(7)
If
there is a deviation from the standard value, refer to
GROUP 13 - Check Chart Classified by Problem Symp-
toms, and check the MFI components.
110003042
DLE MIXTURE INSPECTION
(1)
Before inspection, set the vehicle in the following condition.
Engine coolant temperature: 80-95C (176-203F )
Lights, electric cooling fan and accessories: OFF
Transaxle: Neutral (P range on vehicles with A/T)
value.
Standard value:
(2)
Make sure that the basic ignition timing is at a standard
5 BTDC?
2'
(Except 1996 m od els and 1995 mo dels
for California)
5 BTDC
k
3 (1996 models and 1995 models for
Cal i fornia)
(3)
After turning the ignition switch OFF, set a tachometer
or connect the scan tool to the data link connector.
NOTE
For tachometer setting procedure, refer to P.11B-10.
(4)
Start the engine and run at
2,500
r/min for approx. 2 min-
utes.
5 ) Set the CO tester and HC tester.
(6) Check the CO Concentration and HC concentration with
the engine at idle.
Standard value:
CO concentrat ion: 0.5% or less
HC
concent rat ion: 100 ppm or less
a
(7) If the standard value is exceeded, check the following
items.
Diagnostic output
Closed loop control
I f
closed
loop
control is performed
normally, heated oxygen sensor output signals change
within a
0-400
mV range and a 600-1,000
mV
range.)
Ignition coil, spark plug cables and spark plugs
Leaks in EGR system and EGR valve
Fuel pressure
Injectors
Evaporative emission control system
7/21/2019 11B 4G93 Engine.pdf
13/37
1.8L ENGINE - S e r v i c e A d j u s t m e n t P r o c e d u r e s
11B-13
COMPRESSION PRESSURE INSPECTION
Refer to
P. l lA-12.
Standard value (at engine speed of 250-400 r/min):
L imit (at engine speed of 250-400 rlmin):
110003043
1,400 kPa
(199
psi)
min.
1,060
kPa
(151
psi)
MANIFOLD VACUUM
INSPECTION 110003044
Refer to P.11A-13.
TIMING BELT TENSION ADJUSTMENT
i i o003045
(1) Remove the timing belt upper cover.
(2) Turn the crankshaft clockwise for one turn or more to
set the No.1 cylinder to top dead compression center.
(3) Remove the access cover.
LACCeS~cover -O0IE I
4)
Loosen
the timing belt tensioner securing bolt to apply
tension to the belt by means of the force of the tensioner
spring.
Caut ion
The bolt can be lo os ened 1/4-1/2 turn .
I f
the b olt is loos ened mo re than necessary, the bolt
may
fa l l
insid e the c over.
- -
5 ) Tighten the timing belt tensioner securing bolt.
7/21/2019 11B 4G93 Engine.pdf
14/37
118-12
1.8L ENGINE - Service Adjustment Procedures
-
-
(6)
Check the idle speed.
Curb id le speed:
700
? 100 r/min
NOTE
The idle speed is controlled automatically by the idle air
control (IAC) system.
(7)
If
there is a deviation from the standard value, refer
to
GROUP
13 -
Check Chart Classified by Problem Symp-
toms, and check the MFI components.
IDLE MIXTURE INSPECTION 110003042
(1)
Before inspection, set the veh icle in the following condition.
Engine coolant temperature: 80-95C (1 76-203F)
Lights, electric cooling fan and accessories: OFF
Transaxle: Neutral
(P
range on vehicles with
A/T)
value.
Standard value:
(2) Make sure that the basic ignition timing is at a standard
5 BTDCk 2 (Except 1996 models and 1995 mod els
for Cal i fornia)
5 BTDC 3 (1996 models and 1995 models for
Cali fornia)
(3)
After turning the ignition switch OFF, set a tachometer
or connect the scan tool to the data link connector.
NOTE
For tachometer setting procedure, refer to
P.11
B-10.
4)
Start the engine and run at 2,500 r/min for approx. 2 min-
utes.
5 ) Set the CO tester and HC tester.
(6) Check the CO concentration and HC concentration with
the engine at idle.
Standard value:
CO concentrat ion:
0.5
or less
HC concentrat ion: 100 ppm or less
(7) If the standard value is exceeded, check the following
items.
Diagnostic output
Closed loop control
If
closed loop control is performed
normally, heated oxygen sensor output signals change
within a 0-400 mV range and a 600-1,000 mV range.)
Ignition coil, spark plug cables and spark plugs
Leaks in EGR system and
EGR
valve
Fuel pressure
Injectors
/
7/21/2019 11B 4G93 Engine.pdf
15/37
1.8L ENGINE
-
S e rv i c e A d j u s t m e n t P r o c e d u r e s
11
B-13
L A c c e s g over
E D E N W
COMPRESSION PRESSURE INSPECTION
Refer to P.11A-12.
Standard value (at engine speed
of
250-400 r lmin):
Lim it (at engine sp eed of 250-400 r /min ):
110003043
1,400 kPa (199 psi)
min. 1,060 kPa (151
psi)
MANIFOLD VACUUM INSPECTION 110003044
Refer to P.11A-13.
TIMING BELT TENSION ADJUSTMENT
110oo3045
(1) Remove the timing belt upper cover.
(2) Turn the crankshaft clockwise for one turn or more to
set the No.1 cylinder to top dead compression center.
(3) Remove the access cover.
4) Loosen the timing belt tensioner securing bolt to apply
tension to the belt by means of the force of the tensioner
spring.
Caut ion
The bolt can be loos ened 1/4-1/2 turn .
If
the bo l t is loo sened more than necessary, the bo l t
may fal l inside the cover.
11B-14
1.8L ENGINE -
Engine
Assembly
7/21/2019 11B 4G93 Engine.pdf
16/37
ENGINE ASSEMBLY 110003046
REMOVAL AND INSTALLATION
I I r
Pre-removal Operation
Fuel Line Pressure Releasing (Refer to GROUP 13
- Service Adjustment Procedures.)
Hood Removal
Coolant Draining (Refer to GROUP 14 - Service
Adjustment Procedures.)
Transaxle Assembly Removal
(MTT: Refer to GROUP 22 - Transaxle Assembly.)
A R Refer to GROUP 23 - Transaxle Assembly.)
Radiator Removal (Refer to GROUP 14 - Radiator.)
Post-installation Operation
Radiator Installation Referto GROUP 14- Radiator.)
Transaxle Assembly Installation
(MTT: Refer to GROUP 22 - Transaxle Assembly.)
AT Refer to GROUP 23
-
Transaxle Assembly.)
Coolant Supplying (Refer to GROUP 14
-
Service
Adjustment Procedures.)
Hood Installation
Accelerator Cable Adjustment (Refer to GROUP
13
- Service Adjustment Procedures.)
V-ribbed Belt Tension Adjustment of Power Steering
Oil
Pump and Air Conditioning Compressor
(Refer to P. 118-8,
9.)
I
5 Nm
Fuel rail
I
0-rina
03A0079
I Engine oi l
Removal steps
1. Vacuum hose connection
2 . Heater hose connection
20 00001079
11. Engine temperature gauge unit
connector
12. Engine coolant temperature sensor
1.8L ENGINE
-
Enaine Assemblv
11B-15
7/21/2019 11B 4G93 Engine.pdf
17/37
R
58 Nm 11 Nm
100 Nm
72 f t l bs .
24 Nm
17 ft. lbs.
I
30
-_
_
45 Nm ZlOOOmJ
33 R.lbs.
11B-16
1.8L ENGINE - Engine Assembly
7/21/2019 11B 4G93 Engine.pdf
18/37
REMOVAL SERVICE POINTS
+A+ POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump from the bracket
with the hose attached.
NOTE
Place the removed power steering oil pump in a place
where it will not be a hindrance when remov ing and instal-
ling the engine assembly, and tie it with a cord.
\
\
2UlAOlCl
4 B F AIR CONDITIONING COMPRESSOR REMOVAL
4 C b ENGINE MOUNT BRACKET REMOVAL
(1)
Connect the engine assembly to an engine hoist.
(2) Place the garage jack against the engine
oil
pan w ith
a piece
of
wood in between, and after raising the
engine until there is no weight on the engine mount
brackets, remove the engine mount brackets.
4 D b
ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connec-
tors, etc., are disconnected from the engine, block slowly
remove the engine assembly upward from the engine
compartment.
1.8L ENGINE
-
Engine Assembly * -
*
11B-17
7/21/2019 11B 4G93 Engine.pdf
19/37
INSTA L LAT I SERV
I
C
E P NTS
.Ad ENGINE ASSEMBLY INSTALLATION
Install the engine assembly while checking
to
be sure
that the cables, hoses, and harness connectors are clear
of
the engine assembly.
.Bd ENGINE MOUNT BRA CKET INSTALLATION
(1)
Place a garage jack against the engine oil pan with
a piece of wood in between, and install the engine
mount bracket while adjusting the position of the en-
gine.
(2)
Support the engine with a garage jack.
3)
Remove the chain block and support the engine as-
sembly with the special tool.
11B-18
1.8L ENGINE
-
Camshaft and Camshaft Oil Seal
7/21/2019 11B 4G93 Engine.pdf
20/37
Pre-removal Operation
Distributor Removal
Timing Belt Cover Removal (Refer to P. 118-32.)
(Refer to GROUP 16 - Distributor.)
CAMSHAFT AND CAMSHAFT OIL SEAL
110003047
Post- instal lat ion Operation
Distributor Installation
(Refer to GROUP 16 - Distributor.)
Timing Belt Cover Installation (Refer to P. 118-32.)
Engine Adjustment (Refer to
P.
118-10.)
REMOVAL AND INSTALLATION
I
I
1.8L ENGINE - Camshaft and Camshaft Oil Seal
11
B-19
7/21/2019 11B 4G93 Engine.pdf
21/37
MB9
REMOVAL SERVICE POINTS
(A, CA MSHAFT SPROCK ET REMOVA L
+,ROCKER ARMS AND ROCKER ARM SHA FT
ASSEMBLY (INTAK E SIDE) ROCKER ARMS AND
ROCKER ARM SHAFT ASSEMBLY (EXHAUST SIDE)
REMOVAL
Caut ion
Do not d isassemble the rocker arms and rocker arm
shaft
assembly.
INSTALLATION SERVICE POINTS
.A( CA MSHA FT OIL SEA L INSTA L LA TION
,B+
VALVE CLEARANCE ADJUSTMENT
Refer to GROUP 00
-
Maintenance Service.
11
6-20
1.8L ENGINE
-
Oil Pan
7/21/2019 11B 4G93 Engine.pdf
22/37
OIL PAN
110003048
REMOVAL AND INSTALLATION
Engine
Oil
Draining and Supplying
(Refer to
GROUP 00 -
Service Adjustment
Procedures.)
Oil Dipstick Removal and Installation
40
Nm
29 f t l bs .
Removal steps
1. Front exhaust pipe
00001082
1.8L ENGINE -
Oil
Pan
11
B-21
7/21/2019 11B 4G93 Engine.pdf
23/37
MD998727
REMOVAL SERVICE POINT
4 A F O I L PA N REMOVA L
After removing the oil pan mounting
bolts
and nuts, remove
the oil pan with the special
tool
and a brass bar.
Caution
Hamm er l i t t le by l i t t le, or th e oi l pan wil l be deformed.
INSTA LL A TION SERVICE POINTS
F A + OIL PAN INSTALLATION
NOTE
(1)
Install the oil pan within 15 minutes after applying
liquid gasket.
(2)
Then wait at least one hour. Never start the engine
or
let engine
oil
or coolant touch the adhesion surface
during that time.
FB
RAIN PLUG GASKET INSTALLATION
Replace the drain plug gasket with the groove towards
the oil pan as shown.
11B-22
1.8L ENGINE
- Crankshaft Oil Seal
7/21/2019 11B 4G93 Engine.pdf
24/37
CRANKSHAFT OIL SEAL
110003049
REMOVAL AND INSTALLATION
I
Pre-remo val and Post-instal lation Operation
Timing Belt Removal and Installation
(Refer to P. 118-32.)
Oil Pan Removal and Installation (Refer to P. 118-20.)
Transaxle Assembly Removal and Installation
( M F Refer to GROUP 22
-
Transaxle Assembly.)
A /T :
Refer to GROUP 23 - Transaxle Assembly)
Clutch Cover and Disc Removal and
Installation
I
100 Nm
72 R.lbs.
/
A01S0211-
Crankshaft front oil seal removal
steps
1.
Crankshaft sprocket
2. Key
3.
Crankshaft sensing b lade*
4. Crankshaft spacer*
b C + 5. Crankshaft front oil seal
Crankshaft rear oi l seal removal
s teps
6.
Adapter p late
p la te
F A + 8. Crankshaft rear oil seal
+ A F F B + 7. Flywheel assembly
r
drive
NOTE
*:
Vehicles for Federal and
California cFrom 1995 models>
1.8L NGIN
-
Crankshaft Oil Seal
118-23
7/21/2019 11B 4G93 Engine.pdf
25/37
SEALA NT AND LUB RICATION POINTS
\
,
0150211
Lip section Y0,NM)Q3
Engine oi l
201- mis rn32
Specif ied sealant:
11
B-24
1.8L ENGINE
-
Cra n ksh a f t
Oil
Sea l
7/21/2019 11B 4G93 Engine.pdf
26/37
REMOVAL SERVICE POINT
A A F FLYWHEEL ASSEMBLY c M/T> OR DRIVE PLATE
Stop the crankshaft pulley from turning, and remove the
flywheel assembly
or drive plate
REMOVAL
INSTAL L AT I N S
E
RV C E P NTS
F A A CRANKSHAFT REAR OIL SEAL INSTALLATION
(1) Apply a small mount of engine oil to the entire circum-
(2)
Install the oil seal by tapping it as far as the chamferred
position of the oil seal case as shown in the illustration.
F B 4 FLYWHEEL ASSEMBLY cM/T> OR DRIVE PLATE
(1) Clean the sealant, oil and other particles that are adher-
ing to the mounting bolts, the thread sections of the
crankshaft, and the flywheel assembly or drive
plate
(2) Apply oil to the washer surfaces of the flywheel assem-
bly
bolts or the drive plate
bolts.
(3) Apply the specified sealant to the thread sections of
the
mounting bolts.
Specif ied sealant: Three Bond Part No. 1324
4) Tighten the mounting bolts to the specified torque.
5 )
After installation, clean
off
any sealant adhering to
the ends of the flywheel assembly mounting
bolts or the drive plate mounting
bolts
of the
ference of the oil seal lip.
c M > INSTALLATION
or equivalent
1.8L ENGINE - Crankshaf t Oil
Seal
11
B-25
7/21/2019 11B 4G93 Engine.pdf
27/37
b C 4 CRANKSHAFT FRONT
OIL
SEAL INSTALLATION
(1)
Apply
a small amount of engine oil
to
the entire circum-
(2) Tap the oil seal until
it
is flush with the oil seal case.
ference
of
the oil seal lip.
11
B-26
1.8L ENGINE -
Cyl inder Head Gasket
7/21/2019 11B 4G93 Engine.pdf
28/37
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
110003050
Pre-removal O peration
Fuel Line Pressure Releasing (Refer to GROUP 13
- Service Adjustment Procedures.)
Coolant Draining (Refer to GROUP 14 - Service
Adjustment Procedures.)
Engine Oil Draining
Air Intake Hose Removal
(Refer
to
GROUP 15 - Air Cleaner.)
Fuel rail
7
03A0079
Post-installation Operation
Air Intake Hose Installation
(Refer to GROUP
15
- Air Cleaner.)
Coolant Supplying (Refer to GROUP 14 - Service
Adiustment Procedures.)
En$ine Oil Supplying
Accelerator Cable Adjustment (Refer
to
GROUP 13
- Service Adjustment Procedures.)
E n g in e o i l
3
00001084
8
R e m o va l s te p s
1. Breather hose connection
12. Oil pressu re switch connector
13. Engine coolant temperature gauge
1.8L ENGINE - Cyl inder Head Gasket
11
B-27
7/21/2019 11B 4G93 Engine.pdf
29/37
Cold
Engine
75 Nm -+ 0 Nrn --f 20
Nrn
+90 +
+90
54 t . lbs. + 0 t.lbs.
+
14 ft.lbs.
+
+90 --f +90
\
31
3.3 Nrn
2.4 t . lbs.
/
26
Specif ied sealant:
MlTSUBlSHl GENUINE
PART
970389
or
equivalent
10
Nrn
7.2 R.lbs. 27
11B-28
1.8L ENGINE
- Cyl inder Head Gasket
7/21/2019 11B 4G93 Engine.pdf
30/37
Camshaft sprocket
2OlWll6
~
Intake side
Front of engine c
\ DDIWl16
Exhaust
side Loosening order
REMOVAL SERVICE POINTS
4 A b
CAMSHAFT SPROCKET REMOVAL
(1) Rotate the crankshaft clockwise and align the timing
marks.
Caution
Always turn the crankshaft clockwise.
(2)
Tie the camsha ft sprocket and timing belt with a cord
so
that the position of the camshaft sprocket will not
move with respect to the timing belt.
(3) Use the special tool to remove the camshaft sprocket
with the timing belt attached.
Caution
After removing the camshaft sprocket, be sure
not to rotate the crankshaft.
4 B b CYLINDER HEAD ASSEMBLY REMOVAL
Loosen the bolts in
2
or
3
steps in order
of
the numbers
shown in the illustration, and remove the cylinder head
assembly.
NOTE
Use
of
commercially available cylinder head bolt wrench
is recommended.
1.8L
ENGINE
-
Cylinder Head Gasket
11
B-29
7/21/2019 11B 4G93 Engine.pdf
31/37
Z01R0417
Intake side Identification ma rk
G 9 S
Fron t of
Exhaust side
01x0088
INSTALLATION SERVICE POINTS
F A 4 CYLINDER HEAD GASKET INSTALLATION
(1) Use a scraper or gasket remover to remove the gasket
adhering to the cylinder block.
Caution
Be careful not to let any foreign substances such
as gasket scraps enter the cylinder or the coolant
and oil passages.
(2) Place the cylinder head gasket on top of the cylinder
block
so
that the identification mark is facing upwards
as in the illustration.
Caution
The cylinder head gasket is easy to mls-install,
so be sure to check it. If
it
is mis-installed, malfunc-
tions such as no oil rising to the cylinder head
will occur.
-
F B 4
CYLINDERHEADASSEMBLY/WASHER/CYLlNDER
(1)
Use a scraper or gasket remover to remove the gasket
HEAD BOLT INSTALLATION
adhering to the cylinder head assembly.
Caution
Be careful not to let any foreign substances such
as gasket scraps enter the cylinder or the coolant
and oil passages.
(2) When installing the cylinder head bolts, check that
the shank length of each bolt meets the limit.
If
the
limit is exceeded, replace the bolt.
Limit (A):
96.4
mm
(3.795
in.)
and the washer of the cylinder head bolt.
(3)
Apply a small amount of engine oil
to
the thread section
11B-30 1.8L ENGINE
-
C v l i n d e r Head G a s k e t
7/21/2019 11B 4G93 Engine.pdf
32/37
Frontof engine
take
side
mon1s
Exhaust side Tightening order
Step 4
Painted
mark
Step 5 .
k O
Painted mark
0 1 X 0 2 7 0
5 )
Tighten the bolts by the following procedure.
Step
1
2
3
4
5
Operation contents
Tighten
to 75
Nm
(54 ft.lbs.).
Fully loosen.
Tighten to 20 Nm
(14
f t . lbs.).
Tighten 90
of
a turn.
Tighten
90
f a turn.
Remarks
In the order shown in
the illustration.
In the reverse order to
that shown in the
illustration.
In the order shown in
the illustration.
In the order shown in
the illustration. Mark the
head of the cylinder
head bolt and cylinder
head by paint.
In the order shown in
the illustration. Check
that the painted mark of
the head bolt is lined up
with that
of
the cylinder
head.
Caut ion
.-
.-
b
Be sure to observe the t ightening angle of
90, otherwise the bolt wi l l come loose.
(2)
I f the bolt is over t ightened, remove the bol t
and repeat the procedure f rom step (1).
b C 4
WATER INLE T FITTING, THERMOSTAT AND
(1) Loosen the water inlet pipe bolt shown in the illustra-
tion.
(2) Apply the specified sealant to the thermostat case
assembly as shown in the illustration.
Specif ied sealant: MlTSUBlSHl GENUINE PART
NOTE
(1)
Install the parts within 15 minutes after applying
liquid gasket.
THERMOSTAT CASE ASSEMBLY INSTALLATION
MD970389 or equivalent
1.8L ENGINE
-
Crankshaft Pul ley
11
B-31
CRANKSHAFT
PULLEY
110003051
7/21/2019 11B 4G93 Engine.pdf
33/37
REMOVAL AND INSTALLATION
Pre-remov al Operation
Under Cover (L.H.) Removal
I
185 Nm
Post- instal lat ion Operation
Drive Belt Tension Adjustment
(Refer to
P.
118-8, 9.)
Under Cover (L.H.) Installation
R em ova l s t eps
1.
Drive belt (Air condit ioning)
2. Drive belt (Generator)
4 A F F A 4 3. Crankshaft pul ley bolt
201
F A + 4 . Crankshaf t pu l ley washer
5. Crankshaft pul ley
6. Dust cover
%
i
B
REMOVAL SERVICE POINT
+A F CRANKSHAFT PULLEY BOLT REMOVAL
11
B-32
1.8L ENGINE
- Timing Belt
7/21/2019 11B 4G93 Engine.pdf
34/37
TIMING BELT
11
0003052
REMOVAL AND INSTALL ATION
,
Post-installation OperationDrive Belt Tension Adjustment
(Refer
to
P. 118-8, 9.)
Under Cover Installation
Pre-removal Operation
Under Cover Removal
185 Nm
134
R.lbs.
21080017
1.8L ENGINE
-
Timing
Belt
11B-33
7/21/2019 11B 4G93 Engine.pdf
35/37
REMOVAL SERVICE POINTS
+AF CRANKSHAFT BOLT / CRANKSHAFT PULLEY
Use the special tool to stop the crankshaft pulley from
turning, and remove the crankshaft
bolt.
Caution
Hold the special tool securely so that i t doesnt move.
REMOVAL
+BFTlMlNG BELT REMOVAL
Turn the crankshaft clockwise to align each timing
mark and to set the
No.
1 cylinder at compression
top dead center.
Caution
Always turn the crankshaft clockwise.
+
2)
Loosen the timing belt tensioner bolt.
(3)
Set a screwdriver
to
the timing belt tensioner and
press it fully back in the direction of the arrow.
4)
Temporarily tighten the timing belt tensioner bolt.
5 ) Remove the timing belt.
Caution
If the timing belt is to be re-used, use chalk to
mark the flat side of the belt wlth an arrow indicat-
ing the direction
of
rotation (clockwise).
a
11
B-34
1.8L ENGINE -
Timina Belt
(2)
Align the camshaft sprocket and the crankshaft sprock-
7/21/2019 11B 4G93 Engine.pdf
36/37
Camshaft
sprocket
et timing marks.
(3) Install the timing belt in the following order, while mak-
ing sure that the tension side of the belt is not slack-
ened.
1.
Crankshaft sprocket
2.
Water pump sprocket
3.
Camshaft sprocket
4. Tensioner pulley
Caution
After installing the timing belt, apply force to turn
the camshaft sprocket counterclockwise, and re-
check that the belt is fully tensioned and that each
timing mark is in the proper position.
FBIT lM lNG BELT TENSION ADJUSTMENT
(1)
Initially loosen the fixing bolt of the tensioner pulley
fixed to the engine mount side by 1/2-1/4 turn, and
use the force of the tensioner spring to apply tension
to the belt.
(2)
Turn the crankshaft clockwise for two rotations, and
recheck that the timing marks on each sprocket are
aligned.
Caution
As the purpose of this procedure is to apply the
proper amount of tension to the tension side of
the timing belt by using the cam driving torque,
turn the crankshaft only by the amount given
above. Always turn the crankshaft clockwise.
3)
Check that all belt teeth in the section marked with
A are lifted up and that the teeth in each sprocket
are engaged. Then secure the tensioner pulley.
(4)
Lastly, lightly clamp the center of the span between
the camshaft sprocket and the water pump sprocket
on the belt tension side with your thumb and forefinger
as shown in the illustration. Then check that the clear-
ance
A
between the reverse surface of the belt and
the inside of the under cover seal line is at the standard
1.8L
ENGINE - Timing
Belt 11B-35
b C 4 FLANGE INSTALLATION
7/21/2019 11B 4G93 Engine.pdf
37/37
Crankshaft
Frontof Rear of engine
Flange
2111~0114
Install the flange as shown in the illustration.
A
A
A
bD4 IMING BELT LOWER COVER /TIMING BELT UPPER
Install the bolts, being careful not to mistake the bolt sizes.
UseA bo l t : 6 x
18
(.24 x
.71)
COVER INSTALLATION
B bol t : 6
x
30 (.24 x 1.18)
[diameter
x
length mm (in.)]
b E 4 CRANKSHAFT PULLEY
/
CRANKSHAFT BOLT
(1)
Apply engine oil to the bearing surface and to the
(2)
Use the special
tool to
stop the crankshaft pulley from
INSTALLATION
thread section of the crankshaft bolt.
turning, and install the crankshaft bolt.
Caut ion
Hold the s pecia l too l securely so that i t doesn' t
move.
Top Related