Engine Mechanical (2.4L): Removal & Installation Mitsubishi Eclipse IV рестайлинг

<< A >> DRIVE BELT REMOVAL

The following operations are required due to the serpentine drive system with the drive belt auto-tensioner.

Scheme 10

Scheme 11

1. Securely insert the spindle handle or ratchet handle at a 12.7 mm (1/2-inch) angle into the jig hole of the auto-tensioner.
2. Rotate the auto-tensioner counterclockwise and align hole A with hole B. CAUTION: To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
3. Insert an L-shaped hexagon wrench, etc. into the hole to secure its position, and then remove the drive belt.

<< B >> POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL

1. With the hose installed, remove the power steering oil pump and bracket assembly from the engine assembly.
2. After removing the power steering oil pump and bracket assembly, secure it with a cord in a location where it does not interfere with engine assembly removal.

<< C >> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL

1. With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2. After removing the A/C compressor and clutch assembly, secure it with a cord in a location where it does not interfere with engine assembly removal.

<< D >> ATF WARMER (TRANSMISSION FLUID COOLER) AND BRACKET ASSEMBLY REMOVAL

With the hose installed, remove the ATF warmer (transmission fluid cooler) and bracket assembly from the transmission case front roll stopper bracket.

Scheme 12

Scheme 13

1. Remove the fuel high-pressure hose stopper.
2. Pull up the retainer and remove the fuel high-pressure hose in the direction shown. NOTE: If the retainer is released, install it after removing the fuel high-pressure hose.

Scheme 14

Scheme 15

1. Secure the A/C condenser and front end structure bar with a cord in a location where it does not interfere with engine assembly removal. CAUTION: M/T: Do not remove the flywheel bolt. If this bolt is removed, the flywheel assembly will become out of balance and damaged.
2. Remove the transaxle assembly. Refer to: (M/T: «TRANSAXLE ASSEMBLY»(ref-308282-S36144061342009020200000) ) (A/T: «TRANSAXLE ASSEMBLY»(ref-308272-S08353946212009020200000) )

<< G >> POWER STEERING OIL RESERVOIR REMOVAL

1. With the hose installed, remove the power steering oil reservoir from the vehicle (Refer to «POWER STEERING HOSES»(ref-308275-S09400885682009020200000) ).
2. After removing the power steering oil reservoir, secure it with a cord in a location where it does not interfere with engine front mounting bracket removal.

Scheme 16

Scheme 17

Scheme 18

1. Support the engine with a garage jack.
2. Remove the following special tool. < Special tool MB991895 is used > Remove special tool MB991895. < Special tool MB991928 is used > Remove special tool MB991928.
3. Hold the engine assembly with a chain block, etc.
4. Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the engine front mounting bracket.
5. Loosen the engine front mounting bracket mounting nuts and bolts, and remove the engine front mounting bracket.

<< I >> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring harness connectors, etc. are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.

<< A >> ENGINE ASSEMBLY INSTALLATION

Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.

Scheme 19

Scheme 20

Scheme 21

1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine front mounting bracket while adjusting the position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
4. Use the following special tool as during removal to support the engine. < Special tool MB991895 is used > Set special tool MB991895. Refer to: (M/T: «TRANSAXLE ASSEMBLY»(ref-308282-S36144061342009020200000) ) (A/T: «TRANSAXLE ASSEMBLY»(ref-308272-S08353946212009020200000) ) < Special tool MB991928 is used > Set special tool MB991928. Refer to: (M/T: «TRANSAXLE ASSEMBLY»(ref-308282-S36144061342009020200000) ) (A/T: «TRANSAXLE ASSEMBLY»(ref-308272-S08353946212009020200000) )

Scheme 22

1. Install the transaxle assembly. Refer to: (M/T: «TRANSAXLE ASSEMBLY»(ref-308282-S36144061342009020200000) ) (A/T: «TRANSAXLE ASSEMBLY»(ref-308272-S08353946212009020200000) )
2. Remove the cord securing the A/C condenser and the front end structure bar.

The following operations are required due to the serpentine drive system with the drive belt auto-tensioner.

Scheme 23

Scheme 24

1. Securely insert the spindle handle or ratchet handle at a 12.7 mm (1/2-inch) angle into the jig hole of the auto-tensioner.
2. Rotate the auto-tensioner counterclockwise and align hole A with hole B. CAUTION: To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
3. Insert an L-shaped hexagon wrench, etc. into the hole to secure its position, and then remove the drive belt.

REMOVAL AND INSTALLATION

Scheme 25

Scheme 26

Required Special Tools

1. MB990767: Front Hub and Flange Yoke Holder
2. MB991999: Valve Stem Seal Installer
3. MD998713: Camshaft Oil Seal Installer
4. MD998719: Pin
5. MD998772: Valve Spring Compressor

Scheme 27

1. Hold the camshaft sprocket with special tools MB990767 and MD998719.
2. Loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket.

<< B >> EXHAUST ROCKER ARM AND SHAFT ASSEMBLY/INTAKE ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

Scheme 28

1. Raise the transaxle assembly until the camshaft and transaxle mounting body side bracket do not touch it.
2. Remove the camshaft.

<< D >> VALVE SPRING RETAINER LOCKS REMOVAL

Use special tool MD998772 to compress the valve spring and then remove the valve spring retainer locks.

Scheme 29

Scheme 30

1. Apply a small amount of engine oil to the valve stem seals. CAUTION: Do not re-use the valve stem seal. The special tool MB991999 must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.
2. Use special tool MB991999 to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

>> B << EXHAUST VALVE SPRINGS/INTAKE VALVE SPRINGS INSTALLATION

Install the valve springs with the identification color painted end facing the rocker arm.

Scheme 31

>> C << VALVE SPRING RETAINER LOCKS INSTALLATION

Use special tool MD998772 to compress the valve spring and then install the valve spring retainer lock in the same manner as removal.

Scheme 32

>> D << CAMSHAFT INSTALLATION

Set the dowel pin of the camshaft in the position shown in illustration.

Scheme 33

Scheme 34

1. Place the intake rocker shaft so that its 5.5 mm (0.22 inch) hole faces toward the cylinder head.
2. Install the intake rocker arm shaft caps.
3. Tighten the intake rocker shaft mounting bolts to the specified torque. Tightening torque: 31 +/- 3 N.m (23 +/- 2 ft-lb)

Scheme 35

1. Install the exhaust rocker shaft so that its notch is positioned as shown.
2. Install the exhaust rocker arm shaft caps.
3. Tighten the exhaust rocker shaft mounting bolts to the specified torque. Tightening torque: 13 +/- 1 N.m (115 +/- 9 in-lb)

Scheme 36

1. Apply engine oil to the entire inner diameter of the oil seal lip.
2. Use special tool MD998713 to press-fit the oil seal as shown.

Scheme 37

1. Hold the camshaft sprocket with special tools MB990767 and MD998719 in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 89 +/- 9 N.m (65 +/- 7 ft-lb)

Scheme 38

1. Remove old sealant from the camshaft position sensor support and cylinder head surfaces.
2. Apply sealant to the camshaft position sensor support flange in a continuous bead as shown in the illustration. Specified sealant: 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or equivalent NOTE: Install the camshaft position sensor support within 15 minutes after applying the sealant.
3. Install the camshaft position sensor support to the cylinder head. CAUTION: Wait at least one hour for the sealant to set. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.
4. Tighten the camshaft position sensor support mounting bolts to the specified torque. Tightening torque: 14 +/- 1 N.m (120 +/- 13 in-lb)

Scheme 39

Scheme 40

1. Remove old sealant from the engine oil pressure switch and cylinder head surfaces.
2. Apply sealant to the thread of the engine oil pressure switch as shown. Specified sealant: 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or equivalent NOTE: Install the engine oil pressure switch within 15 minutes after applying the sealant. CAUTION: Wait at least one hour for the sealant to set. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.
3. Tighten the engine oil pressure switch to the specified torque as shown. Tightening torque: 10 +/- 2 N.m (89 +/- 17 in-lb)

>> K << O-RING/ENGINE OIL CONTROL VALVE INSTALLATION

Scheme 41

1. Apply a small amount of engine oil to the O-ring and then install it to the engine oil control valve.
2. Assemble the engine oil control valve to the cylinder head.
3. Tighten the engine oil control valve mounting bolt to the specified torque. Tightening torque: 11 +/- 1 N.m (98 +/- 8 in-lb)

Scheme 42

Required Special Tool

1. MD998727: Oil Pan FIPG cutter

Scheme 43

Scheme 44

1. Remove the engine oil pan mounting bolts. CAUTION: Do not use special tool MD998727 in area A of the engine oil pan. Using the special tool in area A may cause deformation of the front case because the front case is made of aluminum.
2. Tap special tool MD998727 into the range (B) between the cylinder block and the engine oil pan, and then slide the tool sideways. NOTE: If any sounding parts interfere with the removal, there is no need to use special tool MD998727.
3. Remove the engine oil pan.

Scheme 45

Scheme 46

1. Remove sealant from the engine oil pan, front case and cylinder block surfaces.
2. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown. Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™ AAD Part No.8679/8678 or equivalent NOTE: Install the engine oil pan within 15 minutes after applying sealant.
3. Assemble the engine oil pan to the cylinder block. CAUTION: Wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time.
4. Tighten the engine oil pan mounting bolts to the specified torque. Be careful when installing, as the bolts indicated in the illustration have different lengths from the other bolts. Tightening torque: 9.0 +/- 3.0 N.m (80 +/- 26 in-lb)

>> B << ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

Replace the gasket with a new gasket. Install the new gasket in the direction shown in the illustration.

Scheme 47

<< A >> TRANSAXLE ASSEMBLY REMOVAL

Refer to TRANSAXLE ASSEMBLY .

Scheme 48

Scheme 49

1. Use special tool MD998781 to secure the flywheel assembly or A/T drive plate.
2. Remove the flywheel bolts or A/T drive plate bolts.

Scheme 50

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.
2. Use special tools MB990938 and MD998776 to press-fit the oil seal.

Scheme 51

1. Use special tool MD998781 to secure the flywheel assembly or A/T drive plate in the same manner as removal.
2. Tighten the flywheel bolts or A/T drive plate bolts to the specified torque. Tightening torque: 132 +/- 5 N.m (98 +/- 3 ft-lb)

Scheme 52

1. Apply a small amount of engine oil to the outer diameter of special tool MD998285 and install it to the crankshaft.
2. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.
3. Use special tool MD998375 to press-fit the oil seal.

Scheme 53

1. Clean or degrease the front case, the crankshaft and the crankshaft balancer shaft drive sprocket as shown. NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket in the direction shown in the illustration.

Scheme 54

Scheme 55

Required Special Tools

1. MB990767: Front Hub and Flange Yoke Holder
2. MB991654: Cylinder Head Bolt Wrench (12)
3. MD998719: Pin
4. MD998738: Adjusting Bolt

<< A >> CAMSHAFT SPROCKET REMOVAL

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

1. Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to set number 1 cylinder to TDC of its compression stroke.
2. Remove the timing belt under cover rubber plug and then set special tool MD998738.
3. Screw in special tool MD998738 until it contacts the timing belt tensioner arm.
4. Secure the camshaft sprocket and valve timing belt with wire to prevent slippage between the camshaft sprocket and valve timing belt.
5. Hold the camshaft sprocket with special tools MB990767 and MD998719. CAUTION: Do not rotate the crankshaft after camshaft sprocket removal.
6. Remove the camshaft sprocket with the valve timing belt and place it on the timing belt lower cover.

<< D >> CYLINDER HEAD BOLTS REMOVAL

Use special tool MB991654 to loosen the cylinder head bolts in two or three steps in the order shown in the illustration. If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it with a magnet.

Scheme 61

>> A << CYLINDER HEAD GASKET INSTALLATION

Scheme 62

1. Degrease the cylinder head gasket mounting surface.
2. Assemble to the cylinder block so the cylinder head gasket identification mark of "381" is at the top surface and on the exhaust side.

Scheme 63

Scheme 64

Scheme 65

1. Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one. Limit (A): 99.4 mm (3.91 inches)
2. Apply a small amount of engine oil to the thread of the bolts and to the washers.
3. Use special tool MB991654 to tighten the cylinder head bolts in the following procedures. Tighten the bolts to 78 +/- 2 N.m (58 +/- 1 ft-lb) in the order shown in illustration. Loosen the bolts fully in the reverse sequence of that shown. Tighten the bolts to 20 +/- 2 N.m (15 +/- 1 ft-lb) in the order shown in illustration. Reconfirm all bolts tightened firmly. Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degrees as shown in illustration. CAUTION: The bolt is not tightening sufficiently if the tightening angle is less than 90 degrees. If the tightening angle exceeds the standard specification, remove the bolt and start over from step 1 . Tighten 90 degrees as shown in illustration, then check to see that the paint mark on the head of the cylinder head bolt and the paint mark on the cylinder head are aligned.

<< A >> VALVE TIMING BELT REMOVAL

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

1. Turn the crankshaft clockwise, align each timing mark to set number 1 cylinder to TDC of its compression stroke.
2. Remove the timing belt under cover rubber plug and then set special tool MD998738.
3. Screw in special tool MD998738 by hand until it contacts the timing belt tensioner arm. CAUTION: Special tool MD998738 must be gradually installed at a rate of 30 degrees per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and special tool MD998738 may bend.
4. Gradually screw in special tool MD998738 and then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjuster cylinder set hole B.
5. Insert a wire or pin in the set hole aligned. CAUTION: To reuse the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
6. After removal of special tool MD998738, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.

Scheme 71

1. Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MB991385.
2. Loosen the crankshaft pulley center bolt and remove the crankshaft pulley washer and crankshaft camshaft drive sprocket.

<< C >> BALANCER TIMING BELT REMOVAL

Scheme 72

Scheme 73

1. Ensure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing marks are aligned.
2. Install the balancer timing belt on the crankshaft balancer shaft drive sprocket and balancer shaft sprocket. There should be no slack on the tension side.
3. Assemble and temporarily secure the center of the pulley of the balancer timing belt tensioner so that it is at the top left from the center of the assembling bolt, and the pulley flange is at the front-side of the engine.
4. Adjust the balancer timing belt tension.

<< E >> TIMING BELT TENSIONER PULLEY INSTALLATION

Temporarily tighten the timing belt tensioner pulley as shown in illustration.

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.
2. Adjust the timing mark of the engine oil pump sprocket. Unplug the cylinder block plug. Insert a bolt (M6, section width 10 mm, nominal length 45 mm) in the plug hole. If the bolt comes in contact with the balancer shaft, turn the engine oil sprocket one rotation. Re-adjust the timing mark and then check to see that the bolt fits. Do not remove the bolt until the valve timing belt is assembled.
3. Install the valve timing belt in the following manner so that the tensile force of the belt is not lax. Place the valve timing belt on the timing belt tensioner pulley and crankshaft camshaft driver sprocket and then support it with your left hand so it does not slide. Place the valve timing belt on the engine oil pump sprocket while pulling it with the right hand. Place the valve timing belt on the timing belt idler pulley. CAUTION: Install the valve timing belt. Then apply reverse rotation (counterclockwise rotation) pressure to the cam shaft sprocket. Re-check to see that each timing mark is aligned while the tension side of the belt is right. Place the valve timing belt on the camshaft sprocket.
4. Turn the timing belt tensioner pulley in the direction shown in illustration using special tool MD998767 to apply tension to the valve timing belt. Then temporarily tighten and fix the timing belt tensioner pulley mounting bolt.
5. Check that the timing marks are aligned.
6. Remove the bolt inserted in Step 2 above, then assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified torque. Tightening torque: 30 +/- 3 N.m (23 +/- 2 ft-lb)
8. Adjust the valve timing belt tension.

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Set special tool MD998738 used when removing the valve timing belt. CAUTION: Always screw in special tool MD998738 by hand, since use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster.
2. Gradually screw in special tool MD998738 until the wire or pin inserted in the timing belt tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 turn counterclockwise.
4. Turn the crankshaft clockwise, and align each timing mark to set number 1 cylinder to TDC of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting bolt. CAUTION: When tightening the mounting bolt, ensure that the timing belt tensioner pulley does not rotate with the bolt. Allowing it to rotate with the bolt can cause deficient tension of the belt.
6. With special tool MD998767 and torque wrench, apply tension torque [3.5 N.m (31 in-lb)] to the valve timing belt, and tighten the timing belt tensioner pulley mounting bolt to the specified torque. Tightening torque: 48 +/- 5 N.m (36 +/- 3 ft-lb)
7. Remove the wire or pin inserted to timing belt tensioner adjuster.
8. Remove special tool MD998738, and install the rubber plug to the timing belt under cover.
9. Rotate crankshaft clockwise two turns, and leave it for about 15 minutes.
10. Insert the wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When the wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin. Also when the projection of timing belt tensioner adjuster rod (A) is within the standard value, appropriate tension is applied. Standard value (A): 3.8 - 4.5 mm (0.15 - 0.17 inch)
11. If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension. CAUTION: Always check the tightening torque of the crank shaft pulley center bolt when turning the crank shaft pulley center bolt counterclockwise. Retighten if it is loose.
12. Check again that the timing marks on sprockets are aligned.

Scheme 89

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