Engine Mechanical (3.8L): Removal & Installation Mitsubishi Eclipse IV рестайлинг

REMOVAL AND INSTALLATION

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Required Special Tools

1. MB991454: Engine Hanger Balancer
2. MB991895: Engine Hanger
3. MB991928: Engine Hanger
4. MB992012: Engine Hanger Plate A
5. MB992013: Engine Hanger Plate B

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

<< B >> EXHAUST MANIFOLD (RIGHT BANK) REMOVAL

Do not remove the center exhaust pipe, and pull out the exhaust manifold (right bank) between the crossmember and cylinder block.

<< C >> RADIATOR REMOVAL

Secure the A/C condenser and front end structure bar with a cord in a location where it does not interfere engine assembly removal.

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<< D >> POWER STEERING OIL PUMP REMOVAL

Remove the power steering oil pump from the engine with the hose attached.

Note. Place the removed power steering oil pump in a place where it will not interfere when removing and installing the engine assembly, and secure it with a cord or wire.

<< E >> ENGINE HANGER/ENGINE OIL DIPSTICK ASSEMBLY/THROTTLE BODY STAY/INTAKE MANIFOLD PLENUM STAY (REAR) REMOVAL

After removing the intake manifold plenum stay (rear), throttle body stay, engine oil dipstick assembly and engine hanger, set special tools MB992012 and MB992013 to each cylinder head.

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<< F >> TRANSAXLE ASSEMBLY REMOVAL

Remove the transaxle assembly

For M/T: Refer to, REMOVAL AND INSTALLATION < 6M/T > .

For A/T: Refer to, < 5A/T > .

<< G >> A/C COMPRESSOR ASSEMBLY REMOVAL

Remove the compressor from the compressor bracket with the hose still attached.

Note. Place the removed A/C compressor where it will not interfere when removing and installing the engine assembly, and secure it with a cord or wire.

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1. Support the engine with a garage jack.
2. < Engine hanger MB991895 is used > Remove special tool MB991895.
3. < Engine hanger MB991928 is used > Remove special tool MB991928.
4. Remove special tool MB991454 and hook it again see scheme 33, then, hold the engine assembly with the chain block, etc.
5. Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine is no longer being applied to the engine mount.
6. Loosen the engine mount mounting nuts and bolts, and remove the engine mount.

<< I >> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring harness connectors and so on 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.

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1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount while adjusting the position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
4. < Engine hanger MB991895 is used > Set special tool MB991895 to the strut mounting nuts (A and B) and front end structure bar assembling bolts (C and D) as shown in illustration. Remove special tool MB991454 and hook it again as shown in illustration. Then, set special tool MB991454 to hold the engine assembly.
5. < Engine hanger MB991928 is used > Assemble special tool MB991928. (Set following parts to the base hanger) SLIDE BRACKET (HI) FOOT (STANDARD) (MB991932) JOINT (140) (MB991931) Set special tool MB991928 to the strut mounting nuts (A and B) and front end structure bar assembling bolts (A and B) and (C and D) as shown in illustration. Remove special tool MB991454 and hook it again as shown in illustration. Then, set special tool MB991454 to hold the engine assembly. NOTE: Adjust the engine hanger balance by sliding the slide bracket (HI).

<< A >> CAMSHAFT SPROCKET REMOVAL

Use special tools MD998715 and MB990767 to remove the camshaft sprocket.

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1. Make a notch in the oil seal lip section with a knife, etc. CAUTION: Be careful not to damage the camshaft and the cylinder head.
2. Cover the end of a flat-tipped screwdriver with a shop towel and insert into the notched section of the oil seal, and pry out the oil seal to remove it.

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1. Apply engine oil to the camshaft oil seal lip.
2. Use special tool MD998713 to press-fit the camshaft oil seal.

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1. Use special tools MD998715 and MB990767 in the same way as during removal to install the camshaft sprocket.
2. Tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 88 +/- 10 N.m (65 +/- 7 ft-lb)

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Required Special Tools

1. MB990767: Front Hub and Flange End Yoke Holder
2. MD998443: Auto-lash Adjuster Holder
3. MD998713: Camshaft Oil Seal Installer
4. MD998715: Crankshaft Pulley Holder Pin
5. MD998772: Valve Spring Compressor
6. MB991999: Valve Stem Seal Installer

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Required Special Tools

1. MB990767: Front Hub and Flange End Yoke Holder
2. MD998443: Auto-lash Adjuster Holder
3. MD998713: Camshaft Oil Seal Installer
4. MD998715: Crankshaft Pulley Holder Pin
5. MD998772: Valve Spring Compressor
6. MB991999: Valve Stem Seal Installer

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1. Install special tool MD998443 as shown in the illustration so that the lash adjusters will not fall out. CAUTION: Never disassemble the rocker arm and shaft assembly.
2. Loosen the rocker arm and shaft assembly mounting bolt, and then remove the rocker arm and shaft assembly with the bolt still attached.

<< B >> CAMSHAFT SPROCKET REMOVAL

Use special tools MD998715 and MB990767 to remove the camshaft sprocket.

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1. Make a notch in the oil seal lip section with a knife, etc. CAUTION: Be careful not to damage the camshaft and the cylinder head.
2. Cover the end of a flat-tipped screwdriver with a shop towel and insert into the notched section of the oil seal, and pry out the oil seal to remove it.

<< D >> VALVE SPRING RETAINER LOCK REMOVAL

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

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Note. Installation position of valve spring compressor special tool (MD998772) is different between exhaust side and intake side.

>> A << CAMSHAFT OIL SEAL CASE GASKET/CAMSHAFT OIL SEAL CASE/OIL FEEDER CONTROL VALVE HOUSING GASKET/OIL FEEDER CONTROL VALVE HOUSING INSTALLATION

1. Install the camshaft oil seal case gasket and oil feeder control valve housing gasket with protrusions aligned facing upward.
2. Install the camshaft oil seal case and oil feeder control valve housing to the cylinder head.
3. Tighten the engine oil control valve mounting bolt to the specified torque. Tightening torque: 24 ± 3 N.m (18 ± 2 ft-lb)

>> B << GASKET/OIL FEEDER CONTROL VALVE PIPE/EYE BOLT INSTALLATION

1. Install a gasket to one of oil feeder control valve pipes and tighten the eye bolt by hand.
2. Install a gasket to the other oil feeder control valve pipe and tighten the eye bolt to 30 ± 3 N.m (22 ± 2 ft-lb).
3. Tighten the eye bolt which is temporarily tightened by step 1 to 30 ± 3 N.m (22 ± 2 ft-lb).
4. Tighten the oil feeder control valve pipe mounting bolt to the specified torque. Tightening torque: 11 ± 1 N.m (98 ± 8 in-lb)

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1. Apply a small amount of engine oil to the O-ring and then install it to the 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 191

1. Remove 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 in illustration. 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. 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. Tightening torque: 10 +/- 2 N.m (89 +/- 17 in-lb)

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1. Apply a small amount of engine oil to the valve stem seal. CAUTION: Valve stem seals cannot be reused. 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.

>> F << VALVE SPRING INSTALLATION

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

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>> G << VALVE SPRING RETAINER LOCK INSTALLATION

Use special tool MD998772 to compress the valve spring in the same manner as removal.

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1. Install the intake side rocker arm and shaft assembly so that the 6 mm (0.24inch) and 5.5 mm (0.22 inch) holes of rocker arm shaft face the cylinder head side.
2. Tighten the intake side rocker arm shaft mounting bolts to 31 ± 3 N.m (23 ± 2 ft-lb).
3. Install the exhaust side rocker arm and shaft assembly so that the notch of rocker arm shaft is located as shown in the figure.
4. Check that the identification mark of exhaust side rocker shaft cap is located as shown in the figure.
5. Tighten the exhaust side rocker arm shaft mounting bolts to 13 ± 1 N.m (115 ± 9 in-lb).
6. Remove special tool MD998443.

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1. Apply engine oil to the camshaft oil seal lip.
2. Use special tool MD998713 to press-fit the camshaft oil seal.

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1. Use special tools MD998715 and MB990767 in the same way as during removal to install the camshaft sprocket.
2. Tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 88 +/- 10 N.m (65 +/- 7 ft-lb)

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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 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. 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)

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1. Remove the engine lower oil pan mounting bolts. CAUTION: Do not use oil pan remover special tool (MD998727). The engine upper oil pan is made of aluminum and this tool will damage it.
2. Apply a piece of wood to the lower oil pan and strike it with a hammer to remove the engine lower oil pan.

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1. Align the recessed area in the flywheel with the location shown in illustration. Mark the flywheel.
2. Turn the crankshaft so that the mark is positioned as shown in illustration.
3. Remove the engine upper oil pan mounting bolts. CAUTION: Do not use oil pan remover special tool (MD998727). The engine upper oil pan is made of aluminum and this tool will damage it.
4. Screw in the bolt (M10) into bolt hole A in the location shown in illustration. Then lift the upper oil pan and remove it.

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1. Remove old sealant from the oil pan and cylinder block mating surfaces.
2. Degrease the sealant-coated surface and the engine mating surface.
3. Check that the recessed area in the flywheel and the mark is positioned as shown in illustration.
4. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown in illustration. Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™ AAD Part No.8679/8678 or equivalent NOTE: The sealant should be applied in a continuous bead approximately 4.0 mm (0.16 inch) in diameter.
5. Assemble the oil pan to the cylinder block within 15 minutes after applying the sealant. CAUTION: The bolt holes for bolts 13 and 14 in the illustration are cut away on the transaxle side. Be careful not to insert these bolts at an angle.
6. Tighten the bolts in the order shown in the illustration.

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1. Remove sealant from the engine lower oil pan and engine upper oil pan.
2. Apply a bead of the sealant to the mating surface of the engine lower oil pan as shown in illustration. Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™ AAD Part No.8679/8678 or equivalent NOTE: Install the engine lower oil pan within 15 minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine upper oil pan. CAUTION: Then 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 bolts in the order shown in the illustration.

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1. Remove the engine lower oil pan mounting bolts. CAUTION: Do not use oil pan remover special tool (MD998727). The engine upper oil pan is made of aluminum and this tool will damage it.
2. Apply a piece of wood to the lower oil pan and strike it with a hammer to remove the engine lower oil pan.

>> B << CRANKSHAFT SPACER/CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION

To prevent the crankshaft pulley mounting bolt from loosening, degrease or clean the crankshaft, the crankshaft spacer, the crankshaft sensing blade and the crankshaft at the shown positions.

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Required Special Tools

1. MD998718: Crankshaft Rear Oil Seal Installer
2. MD998781: Flywheel Stopper

<< A >> FLYWHEEL BOLTS/DRIVE PLATE BOLTS REMOVAL

Use special tool MD998781 to secure the drive plate and remove the flywheel bolts or drive plate bolts.

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1. Apply a small amount of engine oil to the entire circumference of the oil seal lip.
2. Use special tool MD998718 to tap in the oil seal as shown in illustration.

>> B << DRIVE PLATE BOLTS/FLYWHEEL BOLTS INSTALLATION

Use special tool MD998781 in the same way as during removal to install the flywheel bolts or drive plate bolts.

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Required Special Tools

1. MB990767: Front Hub and Flange End Yoke Holder
2. MD998051: Cylinder Head Bolt Wrench
3. MD998715: Crankshaft Pulley Holder Pin

Use special tools MD998715 and MB990767 to remove the camshaft sprocket.

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<< B >> CYLINDER HEAD ASSEMBLY REMOVAL

Use special tool MD998051 to loosen each bolt in two or three steps in the order shown in the illustration.

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1. Degrease the cylinder head and cylinder block gasket mounting surfaces.
2. Make sure that the gasket has the proper identification mark for the engine.
3. Lay the cylinder head gasket on the cylinder block with the identification mark at the front top.

>> B << CYLINDER HEAD ASSEMBLY INSTALLATION

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1. Use a scraper to clean the gasket surface of the cylinder head assembly. CAUTION: Install the head bolt washers with the beveled side facing upwards as shown in illustration.
2. Using special tool MD998051 and a torque wrench, tighten the bolts to the specified torque in the order shown in the illustration. (in two or three cycles) Tightening torque: 108 +/- 5 N.m (80 +/- 3 ft-lb) to 0 N.m (0 in-lb) to 108 +/- 5 N.m (80 +/- 3 ft-lb)

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1. Use special tools MD998715 and MB990767 in the same way as during removal to install the camshaft sprocket.
2. Tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 88 +/- 10 N.m (65 +/- 7 ft-lb)

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Required Special Tools

1. MB991800: Pulley Holder
2. MB991802: Pin B
3. MD998767: Tension Pulley Socket Wrench
4. MD998769: Crankshaft Pulley Spacer

<< A >> CRANKSHAFT PULLEY REMOVAL

Use special tools MB991800 and MB991802 to remove the crankshaft pulley from the crankshaft.

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<< B >> TIMING BELT REMOVAL

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1. Turn the crankshaft clockwise to align each timing mark and to set the number 1 cylinder to compression top dead center.
2. If the timing belt is to be reused, chalk an arrow on the flat side of the belt, indicating the clockwise direction.
3. Loosen the center bolt of the tensioner pulley, then remove the timing belt.

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1. If the auto-tensioner rod remains fully extended, set according to the following procedure. CAUTION: Place the auto-tensioner perpendicular to the jaws of the vice. Place two dolly blocks in a vice as shown in the illustration, and then place the auto-tensioner in the vice. CAUTION: Never compress the pushrod too fast, or it may be damaged. Slowly compress the pushrod of the auto-tensioner until pin hole A in the pushrod is aligned with pin hole B in the cylinder. Insert the setting pin into the pin holes once they are aligned. NOTE: If replacing the auto-tensioner, the pin will already be inserted into the pin holes of the new part. CAUTION: Do not remove the setting pin from the auto-tensioner. Install the auto-tensioner to the engine.

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1. Align the timing marks on the camshaft sprockets with those on the rocker cover and the timing mark on the crankshaft sprocket with that on the engine block as shown in illustration. CAUTION: The camshaft sprocket (right bank) can turn easily due to the spring force applied, so be careful not to get your fingers caught.
2. Install the timing belt by the following procedure so that there is no deflection in the timing belt between each sprocket and pulley. Crankshaft sprocket Idler pulley Camshaft sprocket (Left bank) Water pump pulley Camshaft sprocket (Right bank) Tensioner pulley
3. Turn the camshaft sprocket (Right bank) counterclockwise until the tension side of the timing belt is firmly stretched. Check all the timing marks again.
4. Use special tool MD998767 to push the tensioner pulley into the timing belt, then temporarily tighten the center bolt.
5. Use special tool MD998769 to turn the crankshaft 1/4 turn counterclockwise, then turn it again clockwise until the timing marks are aligned. CAUTION: When tightening the center bolt, be careful that the tensioner pulley does not turn with the bolt.
6. Loosen the center bolt of the tensioner pulley. Use special tool MD998767 and a torque wrench to apply the tension torque to the timing belt as shown in illustration. Then tighten the center bolt to the specified torque. Standard value: 4.4 N.m (39 in-lb) < Timing belt tension torque > Tightening torque: 48 +/- 6 N.m (36 +/- 4 ft-lb)
7. Remove the setting pin that has been inserted into the auto-tensioner.
8. Turn the crankshaft clockwise twice to align the timing marks.
9. Wait for at least five minutes, then check that the auto-tensioner pushrod extends within the standard value range. Standard value (A): 4.8-6.0 mm (0.19-0.24 inch)
10. If not, repeat steps 1 through 8 above.
11. Check again that the timing marks of the sprockets are aligned.

>> C << CRANKSHAFT PULLEY INSTALLATION

Use special tools MB991800 and MB991802 to install the crankshaft pulley.

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1. Check for oil leak from seal, and replace it if leak is detected.
2. Check for wear or damage at the top of the rod. Replace it, if required.
3. While holding the auto-tensioner with your hand, press the end of the pushrod against a metal surface (such as the cylinder block) with a force of 98-196 N (22-44 pound) and measure how far the pushrod is pushed in. Standard value: Within 1 mm (0.04 inch) A: Length when no force is applied B: Length when force is applied A - B: Movement in
4. If the measured value is out of the standard value, replace the auto-tensioner adjuster.