1.8l engine - Mirage Performance Online

Transcription

1.8L ENGINE
t
CONTENTS
CAMSHAFT AND CAMSHAFT OIL SEAL
..
18
............... 22
.................. 31
CRANKSHAFT OIL SEAL..
CRANKSHAFT PULLEY
CYLINDER HEAD GASKET
I
II
’
............... 26
..................... 14
GENERAL INFORMATION ..................2
OIL PAN .................................
20
SEALANTS ................................
6
ENGINE ASSEMBLY
SERVICE ADJUSTMENT PROCEDURES..
... 8
Basic Idle Speed Adjustment
...........................
Refer to GROUP 13
Compression Pressure Inspection . . . . . . . . . . . . .13
Curb Idle Speed Inspection . . . . . . . . . . . . . . . . . .11
p
Generator Drive Belt Tension Inspection
and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Idle Mixture Inspection .......................
12
Ignition Timing Inspection and
Adjustment . . . . . . . . . . . . . . . .
10
Manifold Vacuum Inspection . . . . . . . . . . . . . . . . . .13
110003028
Power Steering Oil Pump and Air
Conditioning Compressor Drive Belt
Tension Inspection and Adjustment
<Vehicles with Air Conditioning> . . . . . . . . . . . . . . .9
Power Steering Oil Pump Drive Belt
Tension Inspection and Adjustment
<Vehicles without Air Conditioning> . . . . . . . . . . . . 8
Timing Belt Tension Adjustment
. . . . . . . . . . . . . .13
Valve Clearance Adjustment
...........................
SERVICE SPECIFICATIONS
Refer to GROUP 00
.................5
..........................
TIMING BELT ............................
TROUBLESHOOTING ......................
SPECIAL TOOLS
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
6
32
.7
11B-2
1.8L ENGINE
- General Information
GENERAL INFORMATION
110003029
GENERAL SPECIFICAT10NS
1 Specifications
Items
1 In-line, Over Head Camshaft
Type
Number of cylinders
4
Bore mm (in.)
81 .O (3.19)
I 89.0 (3.50)
Stroke mm (in.)
Piston displacement cm3 (cu.in.)
Compression ratio
~~
Firing order
Valve timing
~
Intake valve
Exhaust valve
Lubrication
I 1,834 (111.9)
I 9.5
I 1-3-4-2
Opens (BTDC)
14"
Closes (ABDC)
50"
Opens (BBDC)
58"
Closes (ATDC)
10"
Pressurized feed-full filtration
1.8L ENGINE
SECTIONAL VIEW
- General
Information
11B-3
110003030
I TSB Revision
11B-4
1.8L ENGINE
- General Information
LUBRICATION SYSTEM
11000303
Rocker arm shaft
1.8L ENGINE
b
- Service Specifications
118-5
SERVICE SPECIFICATIONS
Whenchecked
1 Standard value
' 250-500 (55-110)
When new belt is installed
I 500-700 (110-154)
Items
Drive belt
tension
N (Ibs.)
Generator
V-ribbed type
110003032
1 When used belt is installed
1 400 (88)
1 Limit
-
-
l-
Power steering
oil pump*'
V-ribbed type
650-850 (143-187)
-
When used belt is installed
400-600 (88-132)
-
Power steering
750-800 (165-176)
-
500-630 (110-139)
-
Whenchecked
8.5-12.0 (.34-.47)
-
7.0-8.5 (.28-.34)
-
9.5 (37)
7.5-9.0 (.30-.35)
-
V-ribbed type
9.5-11.5 (.37-.45)
-
Power steering
oil pump** and
Air conditioning
compressor
V-ribbed type
5.5-6.0 (.22-.24)
-
6.8 -7.6 (.27- .30)
-
oil pump*2 and
Air conditioning
compressor
V-ribbed type
Drive belt
deflection
mm (in.)
Generator
V-ribbed type
(Reference
value)
Power steering
011 pump*'
+ 2" BTDC
1-
l-
Actual ignition timing at curb idle
1 5" k 3" BTDC
I 5"BTDC
CO concentration %
I
Basic ignition timing at idle (except 1995 models for California)
Basic ignition timing at idle (1995 models for California)
HC concentration ppm
Curb idle speed r/min
Compression pressure (250-400 r/min) kPa (psi)
Compression pressure difference of all cylinder kPa (psi)
Intake manifold vacuum at curb idle kPa (in.Hg)
NOTE
* l : Vehicles without air conditioning
*? Vehicles with air conditioning
1
5"
0.5 or less
-
-
I 100 or less
l-
l-
1 max. 100 (14)
1 700 * 100
1 1,400 (199)
-_-
l1 min. 1,060 (151)
min. 60 (18)
1.8L ENGINE
- Sealants / Special Tools
SEALANTS
1
I10003033
I Recommended sealant
Items
MlTSUBlSHl GENUINE Part No. MD970389 or equivalent
Water outlet fitting
Oil pan
Thermostat case
Three Bond Part No. 1324 or equivalent
Flywheel bolt
Drive plate bolt
SPECIAL TOOLS
110003034
Tool number and name
Supersession
Application
MB990938
Handle
MB990938-01
Use with MD998776
ME990767
MB990767-01
Holding camshaft sprocket or
crankshaft pulley when loosening
and tightening of bolt.
Crankshaft pulley
holder
Use with MD998754. MD998719
MD998713
MD998713-01
Installation of camshaft oil seal
MD998717-01
Installation of crankshaft front
oil seal
Camshaft oil seal
installer
MD998717
Crankshaft front oil
seal installer
MD998754, MD998719 MlT308239
Crankshaft pulley
holder
Supporting the crankshaft pulley
when crankshaft bolt and pulley
are removed or reinstalled.
Use together with MB990767
Supporting camshaft pulley
MD998727
1
Removal of the oil pan
General service tool
Oil pan remover
I
1 MD998776
I
I MD998776-01
~~~
Installation of crankshaft rear
oil seal
Use with ME990938
TSB Revision
1.8L ENGINE - Special Tools / Troubleshooting
Tool
Tool number and name
GENERAL SERVICE
TOOL
MZ203827
I Supersession
11B-7
I Application
General service tool
Supporting engine assembly when
removing and installing transaxle
MB991396-01
Removal and installation of engine
oil filter
Engine lifter
M699 1396
Oil filter wrench
TROUBLESHOOTING
Rpfpr tn P 1 1 A - 7
110003035
11B-8
1.8L ENGINE
I
,-,
100 N (22 Ibs.)
- Service Adjustment
1
Procedures
SERVICE ADJUSTMENT PROCEDURES
110003036
GENERAT0R DRIVE BELT TENSI0N INS PECTI0N
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)
Tension N (Ibs.)
250-500 (55-110)
1
8.5-12.0 (.34-.47)
Measure drive belt deflection by pulling or pushing at the midpoint 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.)
. .+
(
d
k
'
l
x
GENERATOR DRIVE BELT TENSION ADJUSTMENT
Belt tension
adiuster
I10003037
.'
(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, tion to the standard value.
Standard value:
Items
1
Tension N (Ibs.)
I
New belt
500-700 (110-154)
Deflection mm (in.)
, (Reference value)
I
I
7.0-8.5 (.28-.34)
(4) Tighten the lock bolt.
Tightening torque: 23 Nm (17 ft.lbs.)
(5) Tighten the nut of the generator pivot bolt.
POWER STEERING OIL PUMP DRIVE BELT
TENSION INSPECTION AND ADJUSTMENT
<Vehicles without Air Conditioning>
110003038
I
Crankshaft pulley
Z
l
m
1. Press in the V-ribbed belt at the illustrated position with
about 100 N (22 Ibs.) and measure deflection.
Use a belt tension gauge to check that the belt tension
is at the standard value.
NOTE
Verify belt is not cracked or frayed before re-using.
1 TSB Revision
1.8L ENGINE - Service Adjustment Procedures
11B-9
Standard value:
IS readjusted
(.37-.45)
400-600
(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 necessary.
Caution
Before this check, turn the engine one time or more
in the regular direction of rotation (to the right).
POWER STEERING OIL PUMP AND AIR
CONDITIONING COMPRESSOR DRIVE BELT
TENSION INSPECTION AND ADJUSTMENT
eve hicles with Air Conditio ning>
110003039
1.
TSB Revision
Press in the V-ribbed belt at the illustrated position with
about 100 N (22 Ibs.) and measure deflection.
Use a belt tension gauge to check that the belt tension
is at the standard value.
NOTE
Verify belt is not cracked or frayed before re-using.
t
11B-10
1.8L ENGINE
- Service Adjustment Procedures
Standard value:
Items
Deflection mm (in.) Tension N (Ibs.)
When belt tension
is readjusted
6.8-7.6
(.27-.30)
When new belt is
installed
1 5.5-6.0
(.22-.24)
500-630
(110-1 39)
~
,
750-800
(165-176)
2. If the deflection is out of the standard values, loosen the
tension pulley nut and adjust the belt tension with adjusting
bolt.
IGNITION TIMING INSPECTION AND
ADJUSTMENT
110003040
(1) Before inspection and adjustment, verify in the following
conditions:
0
0
0
Engine coolant temperature: 80-95°C (176-203°F)
Lights, electric cooling fan and all accessories: OFF
Transaxle: Neutral (P range on vehicles with A/T)
(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.
Curb idle speed: 700 k 100 rlmin
(7) Turn the ignition switch to OFF.
(8) Remove the waterproof connector from the ignition timing
adjustment connector (brown).
(9) Connect the jumper wire to the ignition timing adjustment
terminal, and a good ground as illustrated.
NOTE
Grounding this terminal sets the engine to basic ignition
timing.
1 TSB Revhon
I
11B-11
(10)Start the engine and run it at idle.
(11)Check that basic ignition timing is within the standard
value.
Basic ignition timing:
B"BTDCk2"(Except 1996 modelsand 1995 models
for California)
5"BTDC k 3" (1996 models and 1995 models for
California)
(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.
c
<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 connector to its original condition.
(14)Start the engine and check that ignition timing is at the
standard value.
Actual ignition timing: 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
R;
110003041
(1) Before inspection and adjustment verify in the following
condition.
Lights, electric cooling fan and all accessories: OFF
0
(2) Check the basic ignition timing.
Standard value:
5"BTDCk 2" (Except 1996 models and 1995 models
for California)
California)
(3) After turning the ignition switch to OFF, install the tachometer or connect the scan tool to the data link connector
(white). For the method of installing the tachometer, refer
to P.11B-10.
(4) Start the engine and run it at idle.
(5) Run the engine at idle for 2 minutes.
1 TSB Revision
116-12
~
(6) Check the idle speed.
Curb idle speed: 700 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 Symptoms, and check the MFI components.
IDLE MIXTURE INSPECTION
110003042
(1) Before inspection, set the vehicle in the following condition.
0
0
Lights, electric cooling fan and accessories: OFF
0
(2) Make sure that the basic ignition timing is at a standard
value.
Standard value:
5"BTDC? 2' (Except 1996 models and 1995 models
for California)
California)
(3) After turning the ignition switch OFF, set a tachometer
or connect the scan tool to the data link connector.
- a
NOTE
For tachometer setting procedure, refer to P.11B-10.
(4) Start the engine and run at 2,500 r/min for approx. 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.
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.)
0
Fuel pressure
0
Injectors
0
Ignition coil, spark plug cables and spark plugs
0
Leaks in EGR system and EGR valve
0
Evaporative emission control system
0
Compression pressure
r
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.
0
0
i
1 TSB Revision
I
i
11B-13
COMPRESSION PRESSURE INSPECTION
110003043
Refer to P.llA-12.
Standard value (at engine speed of 250-400 r/min):
1,400 kPa (199 psi)
Limit (at engine speed of 250-400 rlmin):
min. 1,060 kPa (151 psi)
MANIFOLD VACUUM INSPECTION
110003044
Refer to P.11A-13.
TIMING BELT TENSION ADJUSTMENT
"
iio003045
(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.
I
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.
Caution
The bolt can be loosened 1/4-1/2 turn.
If the bolt is loosened more than necessary, the bolt
may fall inside the cover.
(5) Tighten the timing belt tensioner securing bolt.
(6) Check that the clearance between the timing belt and
the under cover is at the standard value as shown in
the illustration.
Standard value: approx. 30 mm (1.18 in.)
(7) Install the access cover.
(8) Install the timing belt upper cover.
t
I TSB Revision
I
118-12
1.8L ENGINE
- Service Adjustment Procedures
(6) Check the idle speed.
Curb idle 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 Symptoms, and check the MFI components.
IDLE MIXTURE INSPECTION
110003042
(1) Before inspection, set the vehicle in the following condition.
0
0
Lights, electric cooling fan and accessories: OFF
0
(2) Make sure that the basic ignition timing is at a standard
value.
Standard value:
5"BTDCk 2" (Except 1996 models and 1995 models
for California)
5"BTDC 5 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.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 concentration: 0.5% or less
HC concentration: 100 ppm or less
I
(7) If the standard value is exceeded, check the following
items.
0
Diagnostic output
0
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.)
0
Fuel pressure
0
Injectors
0
Ignition coil, spark plug cables and spark plugs
0
Leaks in EGR system and EGR valve
0
Evaporative emission control system
0
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.
/
11B-13
COMPRESSION PRESSURE INSPECTION
110003043
Refer to P.11A-12.
Standard value (at engine speed of 250-400 rlmin):
1,400 kPa (199 psi)
Limit (at engine speed of 250-400 r/min):
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.
L A c c e s g cover
EDENW
(4) Loosen the timing belt tensioner securing bolt to apply
tension to the belt by means of the force of the tensioner
spring.
Caution
The bolt can be loosened 1/4-1/2 turn.
If the bolt is loosened more than necessary, the bolt
may fall inside the cover.
(5) Tighten the timing belt tensioner securing bolt.
(6) Check that the clearance between the timing belt and
the under cover is at the standard value as shown in
the illustration.
Standard value: approx. 30 mm (1.18 in.)
(7) Install the access cover.
(8) Install the timing belt upper cover.
1.8L ENGINE - Engine Assembly
11B-14
ENGINE ASSEMBLY
110003046
REMOVAL AND INSTALLATION
I
I
r
Post-installation Operation
Radiator Installation(Referto GROUP 14- Radiator.)
0 Transaxle Assembly Installation
(MTT: Refer to GROUP 22 - Transaxle Assembly.)
(AT Refer to GROUP 23 - Transaxle Assembly.)
0 Coolant Supplying (Refer to GROUP 14 - Service
Adjustment Procedures.)
0 Hood Installation
Accelerator Cable Adjustment (Refer to GROUP 13
- Service Adjustment Procedures.)
0 V-ribbed Belt Tension Adjustment of Power Steering
Oil Pump and Air Conditioning Compressor
(Refer to P. 118-8, 9.)
Pre-removal Operation
0 Fuel Line Pressure Releasing (Refer to GROUP 13
0 Hood Removal
0 Coolant Draining (Refer to GROUP 14 - Service
0 Transaxle Assembly Removal
(MTT: Refer to GROUP 22 - Transaxle Assembly.)
( A R Refer to GROUP 23 - Transaxle Assembly.)
0 Radiator Removal (Refer to GROUP 14 - Radiator.)
0
I
5 Nm
I
I
I
Fuel rail
0-rina
Engine oil
03A0079
I
I
I
20
Removal steps
1. Vacuum hose connection
2. Heater hose connection
(Thermostat housing to heater unit)
3. Heater hose connection
(Heater unit to water inlet pipe)
4. High-pressure fuel hose connection
5. O-ring
6. Fuel return hose connection
7. Accelerator cable connection
8. Brake booster vacuum hose
connection
9. Oxygen sensor connector
10. Oil pressure switch connector
00001079
11. Engine temperature gauge unit
connector
12. Engine coolant temperature sensor
connector
13. Distributor connector
14. Idle air control motor connector
15. Heated oxygen sensor connector
(front) <Vehicles for California>
16. EGR temperature sensor connector
<Vehicles for California>
17. Throttle position sensor connector
18. Injector connector
19. Control harness assembly
20. Generator harness connection
1.8L ENGINE - Enaine Assemblv
58 Nm
11B-15
11 Nm
100 Nm
72 ftlbs.
24 Nm
17 ft.lbs.
I
30
R
k
4AF
- _-_
45 Nm
33 R.lbs.
Removal steps
ZlOOOmJ
4BF
21. Power steering oil pressure switch
connector
22. Air conditioning compressor connector
23. V-ribbed belt
24. Power steering oil pump connection
25. Air conditioning compressor connection
26. Front exhaust pipe connection
27. Gasket
28. Starter and generator harness clamp
qCFFB429. Engine mount bracket
+DF
F A 4 30. Engine assembly
11B-16
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 removing and installing the engine assembly, and tie it with a cord.
4 B F AIR CONDITIONING COMPRESSOR <VEHICLES
WITH AIR CONDITIONING> REMOVAL
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 installing the engine assembly, and tie it with a cord.
\
\
2UlAOlCl
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 with
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 connectors, etc., are disconnected from the engine, block slowly
remove the engine assembly upward from the engine
compartment.
*
*-
11B-17
INSTA LLAT I0N S ERV ICE P0I NTS
.Ad
.Bd
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.
ENGINE MOUNT BRACKET 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 engine.
(2) Support the engine with a garage jack.
(3) Remove the chain block and support the engine assembly with the special tool.
11B-18
1.8L ENGINE
- Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
110003047
I
I
Distributor Removal
(Refer to GROUP 16 - Distributor.)
Timing Belt Cover Removal (Refer to P. 118-32.)
Removal steps
2. Breather hose connection
3. PCV hose connection
4. Rocker cover
FB4
Valve clearance adjustment
5. Timing belt (Refer to P. 11B-32.)
I
Distributor Installation
(Refer to GROUP 16 - Distributor.)
Timing Belt Cover Installation (Refer to P. 118-32.)
Engine Adjustment (Refer to P. 118-10.)
4Ab
4Bb
4Bb
.A4
6 . Camshaft sprocket
7. Camshaft oil seal
8. Rocker arms and rocker arm shaft
assembly (Intake side)
9. Rocker arms and rocker arm shaft
assembly (Exhaust side)
10. Camshaft
1.8L ENGINE - Camshaft and Camshaft Oil Seal
11B-19
(A,
CAMSHAFT SPROCKET REMOVAL
MB9
+,ROCKER
ARMS AND ROCKER ARM SHAFT
ASSEMBLY (INTAKE SIDE) I ROCKER ARMS AND
ROCKER ARM SHAFT ASSEMBLY (EXHAUST SIDE)
REMOVAL
Caution
Do not disassemble the rocker arms and rocker arm
shaft assembly.
INSTALLATION SERVICE POINTS
A
.(
CAMSHAFT OIL SEAL INSTALLATION
,B+
VALVE CLEARANCE ADJUSTMENT
Refer to GROUP 00 - Maintenance Service.
116-20
1.8L ENGINE
OIL PAN
- Oil Pan
110003048
Engine Oil Draining and Supplying
(Refer to GROUP 00 - Service Adjustment
Procedures.)
Oil Dipstick Removal and Installation
40 Nm
29 ftlbs.
+AF
FB+
FA+
Removal steps
1. Front exhaust pipe
2. Gasket
3. Bell housing cover
4. Drain plug
5. Drain plug gasket
6. Oil pan
7. Oil screen assembly
8. Gasket
00001082
1.8L ENGINE
MD998727
- Oil Pan
11B-21
REMOVAL SERVICE POINT
4 A F O I L PAN REMOVAL
After removing the oil pan mounting bolts and nuts, remove
the oil pan with the special tool and a brass bar.
Caution
Hammer little by little, or the oil pan will be deformed.
F A + OIL PAN INSTALLATION
NOTE
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.
(1) Install the oil
FB+ DRAIN 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
CRANKSHAFT OIL SEAL
110003049
I
Pre-removal and Post-installation Operation
<Crankshaft Front Oil Seal>
0 Timing Belt Removal and Installation
(Refer to P. 118-32.)
<Crankshaft Rear Oil Seal>
0 Oil Pan Removal and Installation (Refer to P. 118-20.)
0
0
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 <MTT> Removal and
Installation
I
100 Nm
72 R.lbs.
/
A01S0211-
Crankshaft front oil seal removal
steps
1. Crankshaft sprocket
2. Key
3. Crankshaft sensing blade*
bC+
4. Crankshaft spacer*
5. Crankshaft front oil seal
+AF
FB+
FA+
Crankshaft rear oil seal removal
steps
6. Adapter plate
7. Flywheel assembly <M/T> or drive
plate <AiT>
8. Crankshaft rear oil seal
NOTE
*: Vehicles for Federal <From 1996 Sedan> and
California cFrom 1995 models>
1.8L ENGINE - Crankshaft Oil Seal
118-23
SEALANT AND LUBRICATION POINTS
<MK>
\
,
0150211
Lip section
Y0,NM)Q3
Engine oil
b
201-
1
misrn32
Specified sealant:
Three Bond Part No. 1324 or equivalent
00001083
I
11B-24
1.8L ENGINE
- Crankshaft
Oil Seal
A A F FLYWHEEL ASSEMBLY cM/T> OR DRIVE PLATE
c M > REMOVAL
Stop the crankshaft pulley from turning, and remove the
flywheel assembly <M/T> or drive plate <A/Tr.
Caution
(1) Use only the specified special tools, otherwise
the damper section of the crankshaft pulley could
be damaged.
(2) In order not to damage the timing belt lower cover
and front flange, hold the special tool securely
so that it doesn’t move.
INSTALLAT I0 N S ERVIC E P0INTS
F A A CRANKSHAFT REAR OIL SEAL INSTALLATION
(1) Apply a small mount of engine oil to the entire circum4
ference of the oil seal lip.
(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
c M > INSTALLATION
(1) Clean the sealant, oil and other particles that are adhering to the mounting bolts, the thread sections of the
crankshaft, and the flywheel assembly <M/T> or drive
plate <AlT>.
(2) Apply oil to the washer surfaces of the flywheel assembly <M/T> bolts or the drive plate <A/T> bolts.
(3) Apply the specified sealant to the thread sections of
the mounting bolts.
Specified sealant: Three Bond Part No. 1324
or equivalent
(4) Tighten the mounting bolts to the specified torque.
( 5 ) After installation, clean off any sealant adhering to
the ends of the flywheel assembly <M/T> mounting
bolts or the drive plate <A/T> mounting bolts of the
crankshaft,
1.8L ENGINE
- Crankshaft Oil Seal
11B-25
b C 4 CRANKSHAFT FRONT OIL SEAL INSTALLATION
(1) Apply a small amount of engine oil to the entire circumference of the oil seal lip.
(2) Tap the oil seal until it is flush with the oil seal case.
1.8L ENGINE - Cylinder Head Gasket
11B-26
CYLINDER HEAD GASKET
110003050
Fuel Line Pressure Releasing (Refer to GROUP 13
0 Coolant Draining (Refer to GROUP 14 - Service
0 Engine Oil Draining
0 Air Intake Hose Removal
(Refer to GROUP 15 - Air Cleaner.)
Air Intake Hose Installation
(Refer to GROUP 15 - Air Cleaner.)
0 Coolant Supplying (Refer to GROUP 14 - Service
Adiustment Procedures.)
0 En$ine Oil Supplying
0 Accelerator Cable Adjustment (Refer to GROUP 13
0
0
’
Fuel rail
7
03A0079
Engine oil
8’
3
00001084
Removal steps
1. Breather hose connection
2. PCV hose
3. Vacuum hose connection
4. Water hose connection (Thermostat
case to throttle body)
5. Water hose connection (Throttle body
to water inlet fitting)
6. High-pressure fuel hose connection
7. O-ring
8. Fuel return hose connection
10. Brake booster vacuum hose connection
11. Oxygen sensor connector
12. Oil pressure switch connector
13. Engine coolant temperature gauge
unit connector
14. Engine coolant temperature sensor
connector
15. Distributor connector
16. Idle air control motor connector
17. Heated oxygen sensor connector
(front) <Vehicles for California>
18. EGR temperature sensor connector
<Vehicles for California>
19. Throttle position sensor
20. Injector connector
21. Control harness assembly
22. Spark plug cable
1.8L ENGINE - Cylinder Head Gasket
Cold Engine
75 Nm -+ 0 Nrn
54 ft.lbs.
--f
20 Nrn
+ 0 ft.lbs. + 14
+90° + +90"
ft.lbs. + +90" --f +90'
3
\
3.3 Nrn
2.4 ft.lbs.
11B-27
31
26
/
Specified sealant:
MlTSUBlSHl GENUINE PART
970389 or equivalent
10 Nrn
7.2 R.lbs.
27
Removal steps
23. Radiator upper hose connection
b C 4 24. Water inlet fitting, thermostat and
thermostat case assembly
25. O-ring
26. Rocker cover
27. Timing belt upper cover
4Ab
28. Camshaft sprocket
29.
30.
b B 4 31.
b B 4 32.
4 B b b B 4 33.
F A 4 34.
Self-locking nuts
Gasket
Cylinder head bolt
Washer
Cylinder head assembly
Cylinder head gasket
11B-28
1.8L ENGINE
- Cylinder Head Gasket
4 A b CAMSHAFT SPROCKET REMOVAL
(1) Rotate the crankshaft clockwise and align the timing
marks.
Caution
Always turn the crankshaft clockwise.
Camshaft sprocket
2OlWll6
(2) Tie the camshaft 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.
~
Intake side
Exhaust side
Front of engine c3
\
Loosening order
DDIWl16
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
11B-29
Head Gasket
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.
Z01R0417
Intake side
Identification mark
“G9S
(2) Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
as in the illustration.
Front of
Caution
The cylinder head gasket is easy to mls-install,
so be sure to check it. If it is mis-installed, malfunctions such as no oil rising to the cylinder head
will occur.
Exhaust side
-
F B 4 CYLINDER HEADASSEMBLY/WASHER/CYLlNDER
HEAD BOLT INSTALLATION
(1) Use a scraper or gasket remover to remove the gasket
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.)
(3) Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
01x0088
@
Washer
Installso that the sagging
side made by tapping out
the washer IS facing
upward.
(4) Install so that the sagging side made by tapping out
the washer is facing upward.
Cylinder head
man11
I TSB Revision
I
11B-30
ntake side
1.8L ENGINE
- Cvlinder Head Gasket
( 5 ) Tighten the bolts by the following procedure.
Front of engine
Operation contents
Remarks
1
Tighten to 75 Nm
(54 ft.lbs.).
In the order shown in
the illustration.
2
Fully loosen.
In the reverse order to
that shown in the
illustration.
3
Tighten to 20 Nm
the illustration.
Step
Exhaust side
Step 4
mon1s
Tightening order
Step 5
Tighten 90" of a turn.
the illustration.Mark the
head of the cylinder
head bolt and cylinder
head by paint.
Tighten 90"of a turn.
the illustration. Check
that the painted mark of
the head bolt is lined up
with that of the cylinder
head.
.
4
k
O
0
5
Painted mark
(14 ft.lbs.).
Painted mark
01X0270
.-
.-
Caution
Be sure to observe the tightening angle of
90°, otherwise the bolt will come loose.
(2) If the bolt is overtightened, remove the bolt
and repeat the procedure from step (1).
b)
b C 4 WATER INLET FITTING, THERMOSTAT AND
THERMOSTAT CASE ASSEMBLY INSTALLATION
(1) Loosen the water inlet pipe bolt shown in the illustration.
(2) Apply the specified sealant to the thermostat case
assembly as shown in the illustration.
Specified sealant: MlTSUBlSHl GENUINE PART
MD970389 or equivalent
NOTE
(1) Install the parts 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.
(3) Apply a small amount of water to the O-ring of the
water inlet pipe, and press the thermostat case assembly onto the water inlet pipe.
(4) Install the thermostat case assembly mounting bolt.
(5) Tighten the water inlet pipe bolt.
mm (in.)
ma17
1 TSB Revision
1.8L ENGINE
- Crankshaft Pulley
11B-31
CRANKSHAFT PULLEY
110003051
Drive Belt Tension Adjustment
(Refer to P. 118-8, 9.)
Under Cover (L.H.) Installation
Under Cover (L.H.) Removal
I
185 Nm
201m
Removal steps
1. Drive belt (Air conditioning)
2. Drive belt (Generator)
4 A F F A 4 3. Crankshaft pulley bolt
FA+
4. Crankshaft pulley washer
5. Crankshaft pulley
6. Dust cover
%
“i
B
+ A F CRANKSHAFT PULLEY BOLT REMOVAL
INSTALLATION SERVICE POINT
F A + CRANKSHAFT PULLEY WASHER / CRANKSHAFT
PULLEY BOLT INSTALLATION
When installing the crankshaft pulley bolt, install so that
the sharp side of the crankshaft pulley washer is at the
pulley side.
1.8L ENGINE - Timing Belt
11B-32
TIMING BELT
110003052
,
I
Drive Belt Tension Adjustment
(Refer to P. 118-8, 9.)
Under Cover Installation
0 Under Cover Removal
185 Nm
134 R.lbs.
21080017
00001086
Removal steps
1. Clamp section of air conditioning
2. Drive belt (Power steering,
Air conditioning)
3. Drive belt (Generator)
d A F ,Ed
4. Crankshaft bolt
d A F .Ed
5. Crankshaft pulley
F D d 6. Timing belt upper cover
1 TSB Revision
F D d 7. Timing belt lower cover
F C + 8. Flange
F B d 0 Timing belt tension adjustment
dBF FAA 9. Timing belt
10. Timing belt tensioner
11. Tensioner spacer
12. Tensioner spring
1.8L ENGINE
- Timing Belt
11B-33
+ A F CRANKSHAFT BOLT / CRANKSHAFT PULLEY
REMOVAL
Use the special tool to stop the crankshaft pulley from
turning, and remove the crankshaft bolt.
Caution
Hold the special tool securely so that it doesn’t move.
+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.
+
e
(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.
a
Caution
If the timing belt is to be re-used, use chalk to
mark the flat side of the belt wlth an arrow indicating the direction of rotation (clockwise).
IN STA LLAT I0N SERVI CE
A
.+
driver
TSB Revision
P0INTS
TIMING BELT INSTALLATION
(1) With the timing belt tensioner bolt loosened, use a
screwdriver to fully turn the timing belt tensioner as
close to the engine mount as possible, and then temporarily tighten the tensioner bolt.
1
11B-34
1.8L ENGINE
- Timina Belt
(2) Align the camshaft sprocket and the crankshaft sprocket timing marks.
(3) Install the timing belt in the following order, while making sure that the tension side of the belt is not slackened.
1. Crankshaft sprocket
2. Water pump sprocket
3. Camshaft sprocket
4. Tensioner pulley
I
Caution
After installing the timing belt, apply force to turn
the camshaft sprocket counterclockwise, and recheck that the belt is fully tensioned and that each
timing mark is in the proper position.
Camshaft sprocket
'
F B I T l M l N G 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 clearance A between the reverse surface of the belt and
the inside of the under cover seal line is at the standard
value.
Standard value: Approx. 30 mm (1.18 In.)
cover
rmcmto
TSB Revision
1.8L ENGINE - Timing Belt
Crankshaft
C Frontof
'
Rear of engine
11B-35
b C 4 FLANGE INSTALLATION
Install the flange as shown in the illustration.
Flange
2111~0114
bD4 TIMING BELT LOWER COVER/TIMING BELT UPPER
COVER INSTALLATION
Install the bolts, being careful not to mistake the bolt sizes.
UseA bolt: 6 x 18 (.24 x .71)
B bolt: 6 x 30 (.24 x 1.18)
[diameter x length mm (in.)]
A
A
A
b E 4 CRANKSHAFT PULLEY / CRANKSHAFT BOLT
INSTALLATION
(1) Apply engine oil to the bearing surface and to the
thread section of the crankshaft bolt.
(2) Use the special tool to stop the crankshaft pulley from
turning, and install the crankshaft bolt.
Caution
Hold the special tool securely so that it doesn't
move.

1.8l engine - Mirage Performance Online

Transcription

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