2.4L SOHC - Engine Code 4G64 - VIN [G]: Removal & Installation Mitsubishi Eclipse II

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

Removal

1. Release fuel pressure from fuel system. See «FUEL PRESSURE RELEASE»(ref-49422-S31937809352001011500000) . Remove hood and engine undercover assembly. Drain cooling system. Remove radiator.
2. Remove all necessary electrical connectors, vacuum hoses, fuel hoses, coolant hoses and cables. Using approved refrigerant recovery/recycling equipment, discharge A/C system. Remove A/C and power steering hoses. Remove generator. Drain engine oil and transaxle oil. Remove transaxle. See the TRANSMISSION REMOVAL & INSTALLATION - M/T article or see the TRANSMISSION REMOVAL & INSTALLATION - A/T article in the appropriate TRANS SERVICE section.
3. Remove air cleaner and intake hose assembly. Remove condenser tank. Remove all drive belts. Remove exhaust manifold heat shield. Disconnect exhaust pipe from exhaust manifold. Disconnect front and rear lower engine mounts.
4. Support engine using hoist. Remove engine mount brackets. Raise engine slightly. Ensure all cables, hoses and electrical harnesses are disconnected from engine. Lift engine assembly upward from vehicle to remove from engine compartment.

Installation

To install, reverse removal procedure. Ensure all wiring and hoses are cleared when lowering engine into engine compartment. With weight of engine on insulators, tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Replace all fluids, adjust all cables and linkages and charge A/C system.

1. Release fuel pressure from fuel system. See «FUEL PRESSURE RELEASE»(ref-49422-S31937809352001011500000). Disconnect negative battery cable. Disconnect air intake hose from air intake pipe.
2. Drain cooling system. Disconnect all necessary electrical connectors, vacuum hoses, coolant hoses, fuel hoses and cables from intake manifold, injectors and throttle body. (Scheme 49)
3. Remove air intake pipe and throttle body. Remove air intake plenum from intake manifold. Remove fuel delivery pipe with fuel injectors and pressure regulator attached. DO NOT allow fuel injectors to fall from delivery pipe during removal.
4. Remove distributor. Remove intake manifold-to-cylinder block support brace. Remove intake manifold-to-cylinder head bolts. Remove intake manifold and gasket. If necessary, remove remaining components from intake manifold.

To install, reverse removal procedure. Use NEW gaskets, fuel injector insulators and "O" rings. Adjust all control cables. Fill cooling system.

Scheme 49

Remove exhaust manifold heat shield. Disconnect exhaust pipe and gasket from manifold. Remove oxygen sensor. Remove exhaust manifold.

To install, reverse removal procedure. Use NEW gaskets and exhaust pipe-to-manifold nuts.

1. Release fuel pressure from fuel system. See «FUEL PRESSURE RELEASE»(ref-49422-S31937809352001011500000).
2. Drain cooling system. Remove air intake hose and pipe from top of rocker cover. Disconnect all necessary electrical connectors, vacuum hoses, coolant hoses, fuel hoses, spark plugs and cables.
3. Remove power steering pump (with hoses connected if possible) and support aside. Disconnect exhaust pipe from exhaust manifold. Remove upper front timing belt cover.
4. Turn crankshaft to TDC of compression stroke on cylinder No. 1 by aligning mark on cylinder head with mark on camshaft sprocket. (Scheme 55) Remove rocker cover. Remove distributor cap.
5. Mark rotor-to-distributor position. Mark distributor-to-cylinder head position. Remove distributor. Mark timing belt in alignment with timing mark on camshaft sprocket. Using plastic tie-wraps, secure timing belt to camshaft sprocket to maintain correct position. Remove camshaft sprocket bolt.
6. Slide camshaft sprocket (with belt attached) off camshaft. DO NOT turn crankshaft. Using Cylinder Head Bolt Wrench (MD998051 or MB991654), loosen cylinder head bolts (in 2-3 steps) in proper sequence. (Scheme 50) Remove cylinder head and gasket.

Scheme 50

1. Install cylinder head using NEW gasket. Ensure identification mark at timing belt end of gasket faces upward. (Scheme 51) DO NOT apply sealant to head gasket. Install and tighten cylinder head bolts (in 5 steps) to specification in proper sequence. (Scheme 50) See «TORQUE SPECIFICATIONS»(ref-49422-S29453208162001011500000).
2. To complete installation, reverse removal procedure. Apply sealant to contact surfaces of semi-circular packing. Adjust all control cables. Fill cooling system.

Scheme 51

1. Remove engine under cover. Remove A/C and power steering hose mounting bracket, and oxygen sensor connector bracket from upper engine mount. Remove all drive belts, remove drive belt tensioner and drive pulleys from crankshaft and water pump. (Scheme 52)and (Scheme 53). Support engine and remove upper engine mount.
2. Remove crankshaft sprocket bolt access cover. Using End Yoke Holder (MB990767-01) and Crankshaft Pulley Holder (MD998719), remove crankshaft pulley bolt and pulley. Remove upper and lower timing belt covers. Note bolt lengths and locations. (Scheme 54)
3. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with timing mark on cylinder head and timing mark on crankshaft sprocket align with timing mark on engine. (Scheme 55) Loosen timing belt tensioner pulley center bolt, and move pulley toward water pump. Finger tighten bolt to secure tensioner pulley in this position. Remove front timing belt. Remove hydraulic timing belt tensioner bolts, and remove tensioner from engine.
4. Remove oil pump sprocket nut and sprocket (for seal replacement). Remove oil pump sprocket access plug from cylinder block. (Scheme 56) Insert a.31" (8.0 mm) diameter Phillips screwdriver to block left silent shaft.
5. Remove front crankshaft sprocket and crankshaft flange (sensing blade). (Scheme 57) Remove rear timing belt tensioner pulley assembly. Remove rear timing belt. Remove right silent shaft sprocket with spacer (for seal replacement). Remove rear crankshaft sprocket with key (for seal replacement).

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

1. Install rear crankshaft sprocket, keyway and flange (sensing blade) onto crankshaft. (Scheme 57) Lubricate and install right counterbalance shaft spacer and sprocket. Ensure chamfered side of spacer is installed into counterbalance shaft seal. If reused, install rear timing belt in original direction of rotation. Ensure timing marks are aligned. (Scheme 58)
2. Install rear timing belt tensioner. Hold tensioner tightly against belt while tightening bolt. Depress belt between sprockets to ensure deflection is.20-28" (5-7 mm). (Scheme 59). Adjust as necessary.
3. Install crankshaft front sprocket. Install oil pump sprocket. Hold left counterbalance shaft using a.31" (8.0 mm) diameter Phillips screwdriver through access hole. (Scheme 56) Ensure screwdriver can be inserted at least 2.4" (61.0 mm).
4. Remove screwdriver if it cannot be inserted at least 2.4" (61.0 mm), and rotate oil pump sprocket one revolution. Align timing mark. Insert screwdriver, and ensure it can be inserted at least 2.4" (61.0 mm).
5. DO NOT remove screwdriver until timing belt is installed. Install camshaft sprocket (if it has been removed for oil seal replacement). Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-49422-S29453208162001011500000).
6. Align timing marks on camshaft sprocket, crankshaft sprocket and oil pump sprocket. Install timing belt onto crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order, ensure there is no slack in belt tension. If belt is reused, ensure original direction of rotation is maintained.
7. Position tensioner pulley with pin holes at bottom. (Scheme 55) Press tension pulley lightly against timing belt and lightly tighten center (fixing) bolt. Install a long set screw into left engine support bracket until screw end makes contact with tensioner arm. At that point, turn set screw in more, and then remove set pin locking auto tensioner. Remove set screw from engine support. Tighten center bolt to specification. (Scheme 60) See «TORQUE SPECIFICATIONS»(ref-49422-S29453208162001011500000).
8. After turning crankshaft 1/4 revolution in counterclockwise direction, turn crankshaft in clockwise direction until timing marks are aligned. Loosen tension pulley bolt. Using tensioner wrench (MD998767) and a torque wrench, apply 31 INCH lbs. (3.5 N.m) of tension to belt in a counterclockwise direction. Tighten pulley bolt to 32-40 ft. lbs. (43-54 N.m) while applying tension to timing belt. (Scheme 61) CAUTION: When tightening pulley bolt, ensure tension pulley does not turn with bolt.
9. Turn crankshaft in clockwise direction 2 revolutions until timing marks are aligned. Let engine stand 15 minutes and then measure protrusion of auto-tensioner rod. If protrusion is not.150-.177" (3.8-4.5 mm), repeat steps 8) and 9). Ensure timing marks of all sprockets are aligned properly. To complete installation, reverse removal procedure.

Scheme 58

Scheme 59

Scheme 60

Scheme 61

1. Remove valve cover. Remove upper front timing belt cover. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke and timing mark on camshaft sprocket aligns with timing mark on cylinder head. (Scheme 55)
2. Mark timing belt in alignment with timing mark on camshaft sprocket. Secure belt to sprocket with plastic tie-wraps. Remove camshaft sprocket bolt. Slide camshaft sprocket and belt off camshaft. NOTE: Check lash adjuster free play before rocker arm removal. See INSPECTION procedure.
3. Install Lash Adjuster Retainer (MD998443) on rocker arm to prevent adjuster from falling out of rocker arm. (Scheme 62) Uniformly loosen rocker shaft mounting bolts, and remove rocker shaft assembly. Remove camshaft and oil seal. If removing lash adjusters from rocker arms, mark for installation reference.

Scheme 62

1. Lubricate camshaft lobes and camshaft bearing journals, and install camshaft into cylinder head. Install lash adjusters in rocker arms (if removed). Install lash adjuster retainers.
2. Ensure rocker arm components are installed in original location. Ensure notch in each rocker shaft is positioned outboard. (Scheme 63)and (Scheme 64). Fit intake rocker shaft springs at right angles to spark plug guides before installing exhaust rocker shaft. (Scheme 65)To complete installation, reverse removal procedure.

Scheme 63

Scheme 64

Scheme 65

1. Remove accelerator cable, connection for breather hose and connection for PCV hose. Remove spark plug loom and rocker cover. Remove distributor. Remove timing belt. See «TIMING BELT»(ref-49422-S22149098072001011500000) .
2. Remove camshaft sprocket. Remove camshaft oil seal. Remove intake and exhaust rocker arm and shaft assemblies. See «ROCKER ARM & VALVE LASH ADJUSTER»(ref-49422-S31044571582004022600000) . Remove camshaft from head. To install, reverse removal procedure.

Remove front cover and oil pump. See OIL PUMP & FRONT COVER . Remove silent shafts from cylinder block.

Note. Rear bearing(s) cannot be removed unless front bearings have been removed from block.

1. Coat bearing outer area with engine oil before installing. Mount rear silent shaft bearing on indicated installer. See «SILENT SHAFT BEARING REMOVAL & INSTALLATION»(ref-49422-S34046529512001011500000) .
2. Ensure oil hole in bearing aligns with oil hole in cylinder block. Note left rear bearing does not have oil hole. Install rear bearings in cylinder block. Repeat procedure for front bearings
3. Install front bearing on bearing installer. Ensure ratchet ball on bearing installer engages in oil hole of bearing. Coat outer area of bearing with engine oil.
4. Place bearing installer over guide pins, and drive bearing into cylinder block. On all models, install balance shafts in original location. To complete installation, reverse removal procedure.

SILENT SHAFT SPECIFICATIONS

SILENT SHAFT BEARING REMOVAL & INSTALLATION

1. Remove transaxle/transmission. See the TRANSMISSION REMOVAL & INSTALLATION - M/T article or see the TRANSMISSION REMOVAL & INSTALLATION - A/T article in the appropriate TRANS SERVICE section.
2. Remove flywheel or drive plate. Remove rear main oil seal case and gasket from rear of cylinder block. Remove oil separator and oil seal from seal case.

1. Coat seal lip with oil. Using Seal Installer MD998776-A or MD998376-01, install seal in seal case until it bottoms.
2. Install oil separator in seal case with hole of separator at bottom of seal case (toward oil pan). Install seal case and gasket. Install flywheel or drive plate. To complete installation, reverse removal procedure.

Scheme 66

Removal steps

1. Radiator lower hose connection
2. Water inlet fitting
3. Thermostat

Removal Service Point

RADIATOR LOWER HOSE DISCONNECTION

Scheme 67

Place a mating mark on the radiator hose and the hose clamp.

Then, disconnect the radiator hose.

Installation Service Points

THERMOSTAT INSTALLATION

Scheme 68

Install the thermostat so that the jiggle valve is facing straight up and is aligned with the mark on the thermostat case as shown in the illustration.

RADIATOR LOWER HOSE CONNECTION

Scheme 69

1. Insert each hose as far as the projection of the water outlet fitting or water inlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

Drain cooling system. Remove necessary coolant hoses. Remove timing belt. See TIMING BELT . Remove water pump mounting bolts. Note bolt length and location. Remove water pump.

To install, reverse removal procedure. Use NEW gasket and "O" ring. Install "O" ring on coolant pipe, and apply water to "O" ring. DO NOT apply grease or oil to "O" ring. Ensure bolts are installed in original location.

Drain engine oil. Remove oil pan bolts. Using Gasket Cutter (MD998727), cut gasket along sealing surface of cylinder block. Remove oil pan and gasket.

To install, apply sealant to oil pan flange at timing chain case and rear seal case areas. Install oil pan and gaskets. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Disassembly

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-49422-S22149098072001011500000) . Remove oil filter, oil pressure switch, oil pan and oil screen.
2. Remove oil filter bracket, front cover and oil pump assembly. Remove plug cap located on front of front cover using Plug Cap Wrench (MD998162-01). Remove rear cover. Mark direction of gear installation for reassembly reference.

Reassembly & Installation

1. Lubricate oil pump gears with engine oil, and install. Ensure timing marks are aligned. Install oil pump cover, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49422-S29453208162001011500000) .
2. If crankshaft oil seal was removed, use Seal Installer (MD998375 or C-3095-A) to install seal in front cover. Use a socket of proper diameter to install silent shaft oil seals.
3. Position Oil Seal Guide (MD998285) over front of crankshaft. Lubricate crankshaft oil seal and oil seal guide with engine oil. Install front cover with NEW gasket, and temporarily tighten bolts. Install oil filter bracket. Ensure correct length bolts are installed.
4. To complete installation, reverse removal procedure. Install plug cap using NEW "O" ring, and tighten to specification. Apply thread sealant to oil pressure switch threads before installing. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49422-S29453208162001011500000) .

OIL PUMP SPECIFICATIONS