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11D - Road Race Engineering

1. AK603576AB Clean off sealant and oil of thread of crankshaft and drive plate bolts or flywheel bolts Use special tool MB991883 to secure the drive plate or flywheel bolts Apply engine oil to thread of crankshaft and bolt seat area of drive plate or flywheel bolts Apply the sealant to the thread of drive plate bolt or flywheel bolts Specified sealant Three bond 1324 or equivalent Tighten drive plate bolts or flywheel bolts to temporary torque of 40 N m 32 ft Ib in the order shown to illustration Tighten drive plate bolts or flywheel bolts to specified tightening in the order shown in the illustration Tightening torque 130 N m 95 ft Ib TSB Revision lt lt A gt gt gt gt G lt lt gt gt F lt lt gt gt E lt lt gt gt E lt lt gt gt D lt lt gt gt C lt lt ENGINE OVERHAUL lt 2 4L ENGINE gt PISTON AND CONNECTING ROD PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION D all moving parts Apply engine oil to before installation O N gt Removal steps Connecting rod cap bolt Connecting rod cap Connecting rod bearing Connecting rod bearing Piston connecting rod assembly Piston ring Number 1 11D 63 M1113008403301 5 0 N m 20 N m 90 in Ib gt gt C lt lt 7 gt gt B lt lt 8 lt lt gt gt A 9 10 11 TSB Revision 14 ft Ib 50
2. new one i Limit 75 5 76 5 mm 2 972 3 012 inch 3 Apply engine oil to the threaded portion and seat surface of Shank length the bolt 4 Tighten crankshaft bearing cap bolts to specified torque according to the tightening order AK402401AD CAUTION When the tightening angle is smaller than the specified tightening angle the appropriate tightening capacity cannot be secured When the tightening angle is larger than the specified tightening angle remove the bolt to start from the beginning again according to the procedure 5 Use special tool Angle gauge MB991614 to tighten bolts 45 according to the tightening order TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 77 CRANKSHAFT AND CYLINDER BLOCK 6 Check end play of the crankshaft after installing the crankshaft bearing cap If the end play exceeds the limit replace the thrust bearing Standard value 0 05 0 25 mm 0 002 0 010 inch Limit 0 4 mm 0 016 inch INSPECTION M1113008802425 CRANKSHAFT OIL CLEARANCE PLASTIGAGE METHOD Oil clearance can be easily measured by using a plastigage When using a plastigage perform measurement in the follow ing procedure 1 Fully wipe oil off the outside diameter of the crankshaft and inside diameter of the bearing 2 Assemble the crankshaft 3 Place a plastigage in length equal to the bearing width on the journal shaft straight in alignment
3. CAUTION Loosing the installation bolts for the camshaft bearing cap LL at the same time causes the valve spring force which makes the installation bolts jump out resulting in the dam aged threads Always loose them four or five times First remove a mounting bolt of the front camshaft bearing cap and then a mounting bolt of each camshaft bearing cap in the order shown in the illustration 52 GW AK502389AC B VALVE TAPPET REMOVAL Pick out valve tappets with fingers and store removed valve tappets with tags describing the installed position attached for reassembly INSTALLATION SERVICE POINTS gt gt A lt lt VALVE TAPPET INSTALLATION Install valve tappets at the same position based on tags describing the installed position for reassembly gt gt B lt lt CAMSHAFT BEARING THRUST CAMSHAFT BEARING CAP CAMSHAFT BEARING CAP OIL FEEDING CAMSHAFT BEARING CAP FRONT CAMSHAFT BEARING CAP INSTALLATION 1 When replacing a camshaft bearing select a bearing with the size corresponding to the identification mark in the table below 2 Install camshaft bearings on the cylinder head Camshaft Camshaft bearing Identification Journal diameter mm Ident
4. Valve seat 1 35 1 65 0 053 0 065 YN 1 16 1 46 mm 0 046 0 058 in AK503333AE VALVE GUIDE Measure clearance between the valve guide and valve stem If the clearance exceeds the limit replace the valve guide or valve or both Standard value Intake 0 020 0 047 mm 0 0008 0 0019 inch Exhaust 0 030 0 054 mm 0 0012 0 0021 inch Limit Intake 0 10 mm 0 0039 inch Exhaust 0 11 mm 0 0043 inch VALVE SEAT Assemble the valve then measure the contact width If the measurement exceeds the specified limit replace the valve seat Standard value Intake 1 16 1 46 mm 0 046 0 058 inch Exhaust 1 35 1 65 mm 0 053 0 065 inch CAUTION If the variation in the width exceeds 0 2 mm even if the contact width is within the standard value replace or cor rect the valve sheet REPAIR PROCEDURE OF VALVE SEAT 1 Check clearance between valve guide and valve and replace the valve guide if necessary before repairing the valve seat 2 Repair the valve seat so that seat width and seat angle are to the specified shape 3 Lap valve and valve seat with lapping compound after repairing valve seat TSB Revision 11D 54 ENGINE OVERHAUL lt 2 4L ENGINE gt CYLINDER HEAD AND VALVES REPLACEMENT PROCEDURE OF VALVE SEAT 1 the valve seat to be replaced from inside to its 0 02 0 04 in wall thickn
5. 1 Completely remove liquid gasket adhering to the cylinder block and ladder frame CAUTION Sufficiently check that there is no residual oil on the place where degreasing is performed If fingerprints are left do not touch it with bare hands after the degreasing since the oils from your fingers will harm the seal ability 2 Degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and ladder frame TSB Revision 11D 58 ENGINE OVERHAUL lt 2 4L ENGINE gt 1 mm 0 04 in 0 33 in AK502868AD AK503559 BALANCER CHAIN 3 Squeeze liquid gasket of 42 5 0 5 mm 0 10 0 02 inch in thickness and apply it to the illustrated position of the ladder frame Specified sealant Three bond 1217G or exact equivalent 4 Tighten the ladder frame to the specified tightening torque in the order shown in the illustration Tightening torque 26 1 N m 19 1 ft Ib gt gt B lt lt CRANKSHAFT SPROCKET BALANCER CHAIN BALANCER SHAFT MODULE INSTALLATION 1 When the new balancer shaft module is installed supply oil to the oil pump and the balancer shaft bearing in the balancer shaft module using the following procedures 1 Clean the inside of the removed oil pan Put the balancer shaft module carefully into the oil pan so that the oil inlet can be upward 2 Pour the engine oil so that the two
6. 11D 23 ENGINE OVERHAUL lt 2 4L ENGINE gt GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Specifications 11D 2 Item M1113000202593 Engine model 4B12 Type In line OHV DOHC Number of cylinders 4 Combustion chamber Pentroof type 2 360 144 0 88 3 5 Total displacement cm cu in Cylinder bore mm in Piston stroke mm in 97 3 8 Compression ratio 10 5 Valve timing Intake valve 0 BTDC 40 BTDC 64 ABDC 24 ABDC 44 BBDC 24 BBDC 0 ATDC 20 ATDC Exhaust valve Auto lash adjuster Non equipped SERVICE SPECIFICATIONS Item Standard value M1113000302824 Timing chain Valve clearance mm in Intake 0 20 0 03 0 008 0 001 Exhaust 0 30 0 03 0 012 0 001 Camshaft Cam height of camshaft mm in Intake 44 1 1 74 43 6 1 72 Exhaust 45 0 1 77 44 5 1 75 Camshaft oil clearance mm in 0 0 032 0 013 Cylinder head and valves Distortion of cylinder head bottom mm in Within 0 05 0 002 0 2 0 008 Grinding limit of cylinder head bottom mm in z 0 2 0 008 Overall height of cylinder head mm in 128 5 5 06 Overall length of valve mm in Intake 113 18 4 456 112 68 4 436 Exhaust 105 89 4 169 105 39 4 149 Intake Valve margin mm in 1 022 0 0402 0 522 0 0206 Exhaust 1 094 0 0431 0 594 0 0234 Free hei
7. 3 300 3 540 0 1394 3 540 3 075 0 1211 3 075 3 315 0 1305 3 315 3 555 0 1400 3 555 3 090 0 1217 3 090 3 330 0 1311 3 330 3 570 0 1406 3 570 3 105 0 1222 3 105 3 345 0 1317 3 345 3 585 0 1411 3 585 3 120 0 1228 3 120 3 360 0 1323 3 360 3 600 0 1417 3 600 3 135 0 1234 3 135 3 375 0 1329 3 375 3 615 0 1423 3 615 3 150 0 1240 3 150 3 390 0 1335 3 390 3 630 0 1429 3 630 3 165 0 1246 3 165 3 405 0 1341 3 405 3 645 0 1435 3 645 3 180 0 1252 3 180 3 420 0 1346 3 420 3 660 0 1441 3 660 3 195 0 1258 3 195 3 435 0 1352 3 435 3 675 0 1447 3 675 3 210 0 1264 3 210 3 450 0 1358 3 450 3 690 0 1453 3 690 3 225 0 1270 3 225 3 465 0 1364 3 465 Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 47 CYLINDER HEAD AND VALVES CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 35 2 Num on om 26 1 ft lb 90 90 ee 55220011 90 90 M1113006903009 FINT e NO ES gt NG ine oi pply engine oil to all moving parts before installation AK703803AC Removal steps Removal steps Continued gt gt D lt lt 1 Cylinder head bolt lt lt gt gt gt gt B lt lt 11 Retainer lock gt gt D lt lt 2 Cylinder head bolt washer 12 Valve spring retainer gt gt D lt lt 3 Cylinder head bolt amp washer 13 Valve spring assembly 14 Exhaust valve gt gt C lt lt 4 Oylinder head assembly lt lt B
8. 8 in Ib 11 x 1 N m 98 8 in Ib AK802147AB Removal steps Removal steps Continued 1 Exhaust manifold bracket D gt gt B lt lt 6 O ring gt gt C lt lt 2 Exhaust manifold bracket B 7 Exhaust manifold upper cover 3 Crankshaft position sensor cover 8 Exhaust manifold gt gt C lt lt 4 Exhaust manifold bracket A gt gt A lt lt 9 Exhaust manifold gasket gt gt B lt lt 5 Crankshaft position sensor 10 Exhaust manifold lower cover TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt _ EXHAUST MANIFOLD 110 21 lt Vehicles for California gt 8 2N m 71 x 17 in Ib HH 71 17 in Ib 7m 41 10N m 30 17 ft lb 41 10N m 30 17 ft lb AK802142 AB Removal steps Removal steps Continued 1 Exhaust manifold bracket 5 Exhaust manifold upper cover 2 Crankshaft position sensor cover 6 Exhaust manifold gt gt B lt lt 3 Crankshaft position sensor gt gt A lt lt 7 Exhaust manifold gasket gt gt B lt lt 4 O ring 8 Exhaust manifold lower cover TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 22 EXHAUST MANIFOLD INSTALLATION SERVICE POINTS gt gt A lt lt EXHAUST MANIFOLD GASKET INSTALLA TION CAUTION The exhaust manifold gasket washers and nuts must not be reused gt gt B lt lt CRANKSHAFT POSITION SENSOR O RING INSTALLATION CAUTION Do not apply a force such as torsion or twist to the O ring during assembly
9. Crankshaft end play mm in 0 05 0 25 0 002 0 010 Crankshaft journal oil clearance mm in 0 012 0 030 0 0005 0 0012 0 4 0 016 0 08 0 0031 Distortion of cylinder block top surface mm in D Grinding limit of cylinder block top surface mm in Cylinder block cylinder bore mm in 88 3 46 0 05 0 0020 0 2 0 008 Cylindricity of cylinder block mm in 0 0076 0 0003 REWORK DIMENSIONS Item M1113024300930 Standard value Cylinder head and valve Cylinder head oversize valve seat bore diameter mm in Intake 0 30 Over size 36 22 36 24 1 426 1 427 Exhaust 0 30 Over size 30 22 30 24 1 190 1 191 Cylinder head oversize valve guide bore diameter mm in 0 25 Over size TSB Revision 11 23 11 25 0 442 0 443 11D 4 ENGINE OVERHAUL lt 2 4L ENGINE gt TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Item M1113023403892 Specification Generator and ignition system Idler pulley bolt Auto tensioner bolt 48 7 N m 36 4 ft lb 22 4 N m 17 22 ft lb Crankshaft pulley center bolt 210 N m 155 ft Ib Generator nut 44 10 m 32 7 ft lb Generator bolt 44 10 m 32 7 ft lb Ignition coil bolt 10 2 N m 89 17 in Ib Spark plug 25 5N 18 4 ft Ib Power steering pump bracket bolt M8 Power steering pump bracket bolt M10 m 23 22 N m 17 1 ft
10. Power steering pump bracket 9 Ignition coil 5 Auto tensioner lt lt gt gt gt gt lt lt 10 Spark plug Required Special Tool MB991883 Flywheel Stopper e MB991398 Spark plug wrench TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 11 GENERATOR AND IGNITION SYSTEM REMOVAL SERVICE POINTS lt lt A gt gt CRANKSHAFT PULLEY CENTER BOLT REMOVAL 1 Use special tool MB991883 to secure the drive plate 2 Remove the crankshaft pulley center bolt MB991883 AK502869AD lt lt B gt gt SPARK PLUG REMOVAL Using special tool MB991398 removal the spark plug MB99139 Spark plug d Y 2 x AK600875AB INSTALLATION SERVICE POINTS gt gt A lt lt SPARK PLUG INSTALLATION Use special tool MB991398 tighten the spark plug to specified tightening torque Tightening torque 25 5 N m 18 4 ft Ib a MB991398 Spark plug aD AK600875AB x TSB Revision 11D 12 ENGINE OVERHAUL lt 2 4L ENGINE gt GENERATOR AND IGNITION SYSTEM gt gt B lt lt CRANKSHAFT PULLEY CRANKSHAFT PULLEY WASHER CRANKSHAFT PULLEY CENTER BOLT INSTALLATION 1 MB991883 AK503335AD o Wipe clean with a rag Wipe clean with a rag and degrease e Wipe clean with a rag degrease and apply a small amount of engine oil Washer Crankshaft 4 sprocket 5 Sech 6 Crankshaft Crankshaft 7 pull
11. Remove the drive plate bolts or flywheel bolts lt lt B gt gt BALANCER SHAFT CHAIN TENSIONER CRANKSHAFT SPROCKET BALANCER CHAIN BALANCER SHAFT MODULE REMOVAL N CAUTION Reliably secure the plunger of the chain tensioner with hard wire to prevent it from jumping out of the main body 1 Push in the balancer shaft tensioner lever by hand and push in the plunger of the chain tensioner until it contacts the bottom Then insert hard wire piano wire etc of 1 5 or hexagonal bar wrench 1 5 mm 0 06 inch into the plunger fixing hole to secure 2 Remove the balancer shaft chain tensioner CAUTION The balancer shaft module must not be disassembled because of assembly warranty 3 Remove the crankshaft sprocket balancer chain and balancer shaft module as a unit TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 57 BALANCER CHAIN lt lt C gt gt LADDER FRAME REMOVAL 1 Pry the illustrated position with a screwdriver or tap the boss we Y Boss P with a hammer SG IER o 2 If the ladder frame does not come off insert a flatblade screwdriver into the gap between the ladder frame and bearing cap as shown in the illustration and lightly pry it to remove the ladder frame INSTALLATION SERVICE POINTS gt gt A lt lt LADDER FRAME INSTALLATION CAUTION Be sure to remove liquid gasket that has entered mounting holes
12. TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt Points of application 11D 7 SEALANTS SEALANTS Specified sealant adhesive M1113000503122 Drive plate bolt Flywheel bolt Three bond 1324 or equivalent Oil pan Ladder frame Three bond 1227D Three bond 1217G Mitsubishi Part No 1000A923 Three bond 1207F Mitsubishi Part No 1000A992 LOCTITE 5971 LOCTITE 5970 LOCTITE 5900 or equivalent Cylinder head cover matching area of the cylinder head and the timing chain case assembly Three bond 1227D Three bond 1217G Mitsubishi Part No 1000A923 or equivalent Three bond 1227D Three bond 1217G Mitsubishi Genuine Tool number and name 1000A923 or equivalent Cylinder head gasket matching area of the cylinder block and the cylinder Three bond 1217G Mitsubishi Part No 1000A923 or exact equivalent head Timing chain case Engine coolant temperature sensor Three bond 1324N LOCTITE 262 or equivalent Engine oil pressure switch NOTE The number in square brackets shows the genuine part number FORM IN PLACE GASKET FIPG The engine has several parts to which the form in place gasket FIPG is used To sufficiently achieve the aims of this gasket it is necessary to pay attention to the application amount procedure and surface status Ifthe application amount is too small a leakage will occur If the application amount is excessive the FIPG will overflow
13. is positioned facing straight upward Apply an appropriate and minimum amount of engine oil to the circumference of the tip of the intake V V T sprocket assembly and the entire circumference of the area into which the intake V V T sprocket assembly is inserted Slowly insert the intake V V T sprocket assembly into the normal position of the inlet camshaft assembly with its knock pin hole facing straight upward Install the V V T sprocket Make sure that the V V T sprocket is securely inserted into the bottom and that the V V T sprocket does not rotate with the hexagonal portion of the camshaft secured with a wrench Hold the hexagonal portion of the camshaft with a wrench and tighten the intake V V T sprocket bolt to the specified tightening torque Tightening torque 59 5 N m 44 3 ft Ib gt gt B lt lt EXHAUST V V T SPROCKET BOLT INSTALLATION 1 Assemble the exhaust V V T sprocket assembly in the following procedure Make sure that the knock pin of the exhaust camshaft assembly is positioned facing straight upward Apply an appropriate and minimum amount of engine oil to the circumference of the tip of the exhaust V V T sprocket assembly and the entire circumference of the area into which the exhaust V V T sprocket assembly is inserted Slowly insert the exhaust V V T sprocket assembly into the normal position of the exhaust camshaft assembly with its knock pin hole facing straight upwar
14. A lt lt VALVE STEM SEAL INSTALLATION CAUTION The valve stem seal must not be reused Do not damage the tappet wall during assembly Be sure to use a special tool to install the valve stem seal Poor installation causes oil loss via valve guides If oil is not applied the valve stem seal may rise to the surface after it is press fitted 1 Apply a thin coat of engine oil to a new valve stem seal AK503378AE 2 Use special tool MD998737 to press fit the valve stem seal into the valve guide with the valve stem used as a guide gt gt B lt lt RETAINER LOCK INSTALLATION Use a special tool MD998735 and MB992089 to compress the valve spring and to install the retainer lock MD998735 AK502741AD TSB Revision 11D 50 ENGINE OVERHAUL lt 2 4L ENGINE gt CYLINDER HEAD AND VALVES gt gt C lt lt CYLINDER HEAD GASKET CYLINDER HEAD ASSEMBLY INSTALLATION 1 Degrease Completely remove the liquid gasket on the upper plane of the cylinder block and the lower plane of the cylinder head CAUTION 2 Bottom face of cylinder head Degrease Top face of cylinder block AK602902AE 2 to mm 0 079 to 0 118 in AK602942 AD Sufficiently check that there is no residual oil on the place where degreasing is performed If fingerprints are
15. PISTON AND CONNECTING ROD gt gt G lt lt CONNECTING ROD CAP BOLT INSTALLATION 1 Check in the following procedure before reusing the connecting rod bolt 1 Measure the outside diameter A 2 Measure the smallest outside diameter B within the range X shown in the illustration 3 If the difference of outside diameter of thread exceeds amp the limit replace the connecting rod bolt Limit 0 1 mm 0 004 inch Apply engine oil to the threaded portion and seat surface of the bolt before installing it 3 After installing each bolt and tightening it by fingers tighten bolts alternately to properly assemble the cap 4 Tighten the bolt in several steps until the torque reaches 5 0 N m 44 in lb 5 Tighten the bolt in several steps until the torque reaches 20 N m 14 ft lb 6 Put a paint mark on the bolt head as illustrated 7 Put a paint mark on the connecting rod at 90 position in the tightening direction of the bolt with reference to the paint mark position of the bolt 20 5 mm 0 81 in x 35 mm 1 38 in 2 AK604589AD CAUTION When the tightening angle is smaller than the specified a tightening angle the appropriate tightening capacity Paint mark cannot be secured When the tightening angle is larger than the specified tightening angle remove the bolt to start from the beginning again according to the procedure 8 Tighten the bolt 90 and make sure that the
16. gasoline to the O ring of the injector Insert the injector into the delivery pipe while rotating the injector from side to side taking care not to damage the O ring Check that the injector rotates smoothly If it does not rotate smoothly the O ring may be caught Remove the injector and check the O ring for damage Then insert it again into the delivery pipe and check Make sure that the protrusion of the injector is at the center as shown in the illustration Securely assemble the injector to the injector groove and delivery pipe collar gt gt H lt lt FUEL RAIL ASSEMBLY BRACKET INJECTOR PROTECTOR REAR INSTALLATION 1 2 ab ripe 3 Install the delivery pipe assembly bracket and injector protector rear on the cylinder head Temporarily torque 3 5 1 5 N m 31 13 in Ib Tighten mounting bolts together with temporarily tightened intake manifold mounting bolts in the order shown in the illustration Tighten the delivery pipe assembly bracket injector protector rear and intake manifold in the order shown in the illustration Tightening torque 20 2 N m 15 1 ft Ib TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 20 EXHAUST MANIFOLD EXHAUST MANIFOLD REMOVAL AND INSTALLATION lt Except vehicles for California gt M1113011900738 14 1N m 124
17. install the connecting rod cap and tighten bolts to the specified tightening torque of 5 0 N m 44 in Ib 20 m 15 ft lb 90 Remove bolts and gently remove the connecting rod cap Measure the crushed plastigage width area most widely crushed using a scale printed on the plastigage bag Standard value 0 018 0 045 mm 0 0007 0 0018 inch Limit 0 1 mm 0 04 inch TSB Revision 11D 72 ENGINE OVERHAUL lt 2 4L ENGINE gt CRANKSHAFT AND CYLINDER BLOCK CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION M1113008703465 S e 26 5 2 0 N m 45 Apply engine oil to Lg 20 1 ft Ib ond D all moving parts n LISS before installation as DEG d A PH 17b Le s d AK502938AE Removal steps Removal steps Continued gt gt E lt lt 4 Crankshaft bearing cap bolt gt gt C lt lt 5 Crankshaft bearing upper gt gt E lt lt 2 Crankshaft bearing cap gt gt B lt lt 6 Thrust bearing gt gt D lt lt 3 Crankshaft bearing lower gt gt A lt lt 7 Crankshaft sensing ring lt lt A gt gt 4 Crankshaft 8 Cylinder block TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11 D 73 CRANKSHAFT AND CYLINDER BLOCK Crankshaft sensing ring AK502865AD Groove AK502394AE REMOVAL SERVICE POINT lt lt A gt gt CRANKSHAFT REMOVAL When temporarily placing the crankshaft with the crankshaft sensing ring a
18. installer 1 mm 0 004 inch 5 mm 0 020 inch AK600888AE Om Se S i LAL T o AC807670AC INSTALLATION SERVICE POINTS gt gt A lt lt ENGINE OIL PRESSURE SWITCH INSTAL LATION CAUTION Do not allow sealant to squeeze out to the screw tip Do not tighten exceeding the specified tightening torque 1 Completely remove sealant adhering to the oil pressure switch and cylinder block threaded holes 2 Apply sealant of 5 mm to the threaded portion of the oil pressure switch shown in the illustration Specified sealant Three bond 1212D Three bond 1215 or equivalent 3 Tighten the oil pressure switch to the cylinder block to the specified tightening torque Tightening torque 10 2 N m 89 17 in Ib gt gt B lt lt KNOCK SENSOR INSTALLATION Align the knock sensor connector with the position shown in the illustration and then tighten it to the specified torque Tightening torque 20 2 N m 15 1 ft Ib TSB Revision 11D 18 ENGINE OVERHAUL lt 2 4L ENGINE gt INTAKE MANIFOLD AND FUEL SYSTEM A M10 x 40 mm 1 6 in B M10 x 35 mm 1 4 in x Sts F J lt gt al AK503595AC AK502727AC MB992106 AK600790AC gt gt C lt lt GENERATOR BRACKET INSTALLATION
19. lb 44 8 N m 33 5 ft lb Throttle body and EGR system Vacuum pipe and hose bolt 11 1 N m 98 8 in Ib Throttle body bolt 9 5 2 5 N m 84 22 in lb Throttle body stay bolt 20 2N m 15 1 ft lb EGR valve support bolt EGR pipe bolt 20 2 N 15 1 ft lb 20 2 N 15 1 ft lb EGR support stay A bolt 20 2 N 15 1 ft lb EGR support stay B bolt m 20 2 N 15 1 ft lb EGR valve bolt 24 x3 N m 18 1 ft lb Manifold absolute pressure MAP sensor screw 4 0 1 0 N m 36 8 in Ib Purge solenoid valve screw Intake manifold and fuel system 4 0 1 0 N m 36 8 in Ib Oil dipstick guide bolt 10 2 N m 89 17 in Ib Injector protector rear bolt 8 5 1 5 m 31 13 in lb gt 20 2 N 15 1 ft Ib Fuel rail bolt 8 5 1 5 m 31 13 in lb gt 20 2 N 15 1 ft Ib Intake manifold bolt and nut 3 5 4 5 N m 31 13 in lb gt 20 2 N 15 1 ft Ib Intake manifold stay bolt 20 x2 N m 15 1 ft lb Injector protector front bolt 3 5 21 5 m 31 13 in lb gt 20 2 N 15 1 ft Ib Generator bracket bolt 44 8 N m 33 5 ft lb Knock sensor bolt 20 2 N m 15 1 ft lb Engine oil pressure switch 10 2 N m 89 17 in Ib Exhaust manifold Exhaust manifold upper cover bolt Except vehicles for California Exhaust manifold upper cov
20. left do not touch it with bare hands after the degreasing since the oils from your fingers will harm the seal ability Degrease the place specified in the illustration As shown the illustration apply a 2 5 0 5 mm 0 1 0 02 inch of sealant to the top face of cylinder block Specified sealant Three bond 1217G or exact equivalent Install the cylinder head gasket NOTE Check that the center of the liquid gasket is located toward the cylinder gasket in the position specified in the illustration As shown in the illustration apply a 2 5 0 5 mm 0 1 0 02 inch of sealant to the top face of cylinder head gasket Specified sealant Three bond 1217G or exact equivalent Install the cylinder head assembly TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 51 CYLINDER HEAD AND VALVES gt gt D lt lt CYLINDER HEAD BOLT INSTALLATION 1 Install new cylinder head bolts and washers in the following procedure NOTE Cylinder head bolts and washers must not be reused 2 Apply an appropriate amount of engine oil to top and bottom surfaces of washers and threaded portion of bolts 3 Install cylinder head bolts to the cylinder head NOTE Bolts and washers are different parts for bolts on the timing chain side 4 Tighten cylinder head bolts in several steps to the specified torque according to the assembly order Tightening torque 35 2 N m 26 1 ft Ib Timing chain side
21. lt 2 4L ENGINE gt 11 D 69 PISTON AND CONNECTING ROD 3 A connecting rod bearing has an identification mark at the illustrated position Identification mark AK700793AD gt gt F lt lt CONNECTING ROD CAP INSTALLATION NOTE The connecting rod resulting from the breaking process has the high insertion force The new connecting rod assembly may possibly be difficult to remove the connecting rod If difficult to remove it alternately strike the two bolt heads with a plastic hammer while the connecting rod bolt is slightly loos ened or strike the center of the cap shaft s inside diameter slightly and outward If the outside of the cap is directly struck the lateral force is added to the broken out section Thus pay attention to the bro ken out section that might be difficult to be separated or might fall Clean the broken out section before the installation to the engine using compression air 1 Assemble the bearing cap on the connecting rod by aligning it with the mark put during removal If a new connecting rod without a mating mark is used assemble so that the detent notch of the bearing is on the same side as illustrated Cylinder No Notch Front mark 2 Make sure that clearance of the thrust of the connecting rod big end is appropriate Standard value 0 10 0 25 mm 0 004 0 010 inch Limit 0 4 mm 0 016 inch TSB Revision 11D 70 ENGINE OVERHAUL lt 2 4L ENGINE gt
22. m 26 1 ft lb 90 90 Balancer chain Drive plate bolt 40 N m 30 ft lb 130 N m 96 ft lb Flywheel bolt 40 N m 30 ft lb 130 N m 96 ft lb Balancer shaft module bolt 20 15 6 244 32 ft lb 0 20 15 ft lb 135 Balancer shaft chain tensioner bolt 10 x2 N m 89 17 in Ib Lever tensioner bolt 10 x2 N m 89 17 in Ib Balancer shaft chain guide bolt 10 x2 N m 89 17 in Ib Ladder frame bolt 26 1 m 19 1 ft lb Piston and connecting rod Connecting rod cap bolt 5 0 N m 44 in Ib 20 N m 15 ft lb 90 Crankshaft and cylinder block Crankshaft sensing ring bolt 11 1 N m 98 8 in Ib Bearing cap bolt 26 5 x 2 0 N m 20 1 ft lb 45 NEW TIGHTENING METHOD BY USING 1 Cylinder head bolt PLASTIC REGION TIGHTENING BOLT 2 Bearing cap bolt TO 3 Connecting rod cap bolt Plastic region tightening bolts are used in some parts Tightening method of the engine Install these bolts according to the After tightening to the specified tightening torque method described in the relevant section because i S A gt S the tightening method of these bolts are different GO from the conventional method The service limit is determined for these bolts Be sure to strictly follow the service limit described in the body of the manual Parts to be used Follow the tightening method described in the body of the manual because the tightening method differs from part to part
23. of the sensor Assemble the sensor taking care not to give a shock to it Do not use a sensor that has fallen down Tighten the crank angle sensor to the specified torque Tightening torque 11 1 N m 98 8 in Ib gt gt C lt lt EXHAUST MANIFOLD BRACKET INSTALLATION Kg lt Exhaust manifold Make sure that exhaust manifold bracket A is in intimate con bracket A i i i Be tact with the exhaust manifold and cylinder block and then 9 tighten it to the specified tightening torque Tightening torque M10 41 10 N m 30 7 ft lb M8 20 5 m 15 3 ft Ib Exhaust manifold Exhaust manifold bracket D bracket B AK603560AH TSB Revision gt gt C lt lt gt gt B lt lt gt gt A lt lt gt gt A lt lt O O gt O N ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 23 WATER HOSE AND PIPE WATER HOSE AND PIPE REMOVAL AND INSTALLATION Removal steps Water hose Water hose Engine coolant temperature sensor Water outlet fitting Outlet fitting gasket Water inlet fitting Thermostat Thermostat housing Thermostat housing gasket Water pipe assembly M1113032900476 AK802148AB Removal steps Continued 11 Water pipe gasket 12 O ring 13 Water pump assembly 14 Water pump gasket 15 Engine hanger 16 Camshaft position sensor 17 O ring 18 Camshaft position sensor 19 O ring TSB Revision E ENGINE OVERHAUL 2 4L ENGINE 1
24. order shown in the illustration Tightening torque 3 0 1 0 N m 27 8 in Ib 5 Then tighten it to the specified tightening torque in the same order Tightening torque 5 5 0 5 N m 49 4 in Ib TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 31 OIL PAN AND TIMING CHAIN CASE gt gt E lt lt OIL FILTER INSTALLATION 1 Clean the oil filter mounting surface of the ladder frame 2 Apply engine oil to the O ring of the oil filter AK305422AD CAUTION Use special tool MB991396 to install the oil filter Tighten ing it by hand causes oil leakage due to lack of torque 3 Screw in the oil filter When the O ring contacts the mounting surface use a filter wrench to tighten it Tightening torque 3 4 turns 14 2 N m 124 17 in Ib TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 32 TIMING CHAIN TIMING CHAIN REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation M1113026600788 10 2 N m 89 17 in Ib AK502933AE Removal steps Removal steps Continued 1 Chain upper guide 6 Oil jet A gt gt D lt lt 2 Timing chain tensioner lt lt B gt gt gt gt B lt lt 7 Exhaust sprocket bolt 3 Tensioner lever 8 Exhaust V V T sprocket assembly 4 Timing chain guide lt C gt gt gt gt lt lt 9 Intake VVT sprocket bolt gt gt C lt lt 5 Timing chain 10 Intake V V T sprocket a
25. paint mark of the connecting rod is aligned with that of the bolt _ AK502749AD INSPECTION M1113008502123 PISTON RINGS 1 Check clearance between piston rings and ring grooves If the limit is exceeded replace piston rings or piston or both Standard value Number 1 ring 0 03 0 07 mm 0 001 0 003 inch Number 2 ring 0 03 0 07 mm 0 001 0 003 inch Limit 0 1 mm 0 004 inch AK502751 TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 71 PISTON AND CONNECTING ROD 2 Please down ring with piston Front mark T gt O I 2 Piston ring AK503370AF Put piston rings into the cylinder bore press them against the piston top face and push them in After achieving squareness measure the end gap with a free gauge If the end gap is excessive replace piston rings Standard value Number 1 ring 0 15 0 25 mm 0 006 0 011 inch Number 2 ring 0 25 0 40 mm 0 010 0 016 inch Oil ring 0 10 0 35 mm 0 004 0 014 inch Limit Number 1 ring 0 8 mm 0 03 inch Number 2 ring 0 8 mm 0 03 inch Oil ring 1 0 mm 0 04 inch CRANKSHAFT PIN OIL CLEARANCE PLASTIGAGE METHOD AK503374 AD Wipe oil off the crankshaft pin and connecting rod bearing Place a plastigage in length equal to the bearing width on the pin shaft straight in alignment with the shaft center Carefully
26. torque 9 5 2 5 N m 84 22 in Ib AK503290AC INTAKE MANIFOLD AND FUEL SYSTEM REMOVAL AND INSTALLATION M1113032500810 20 2N m 15 1 ft lb 3 1 gt 3 5 1 5 N m 2 N Y e 31 13 in Ib Ze _ 20 2 N m 15 x 1 ft Ib 16 aS 5 3 5 1 5 N m 20 2 Nm 89 17 in Ib 4 31 13in lb 15 1 ft lb 14 3 5 1 5 N m 20 2 N m 31 13 in lb 15 1 ft lb s 3 5 1 5 N m 20 2 N m 31 13 in Ib 15 1 13 3 5 x 1 5 N m 20 x2 N m 31 13 in Ib 15 x 1 ft Ib 20 2 N m 15 1 ft lb _10 2N m Co 20 759 gt 17 in Ib 12 homm ce zS Nin 33 5 ft Ib 15 1 ft Ib 18 AK802146AB Removal steps Removal steps Continued 1 Oil dipstick rod gt gt H lt lt 3 Injector protector rear 2 O ring gt gt H lt lt 4 Bracket gt gt H lt lt 5 Bracket TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt INTAKE MANIFOLD AND FUEL SYSTEM Removal steps Continued 11D 17 gt gt H lt lt gt gt G lt lt Fuel rail assembly Injection support O ring gt gt G lt lt Injector gt gt F lt lt 10 O ring 11 Fuel rail gt gt E lt lt 12 Intake manifold stay 13 Injector protector front gt gt D lt lt 14 Intake manifold 15 Intake manifold gasket 16 Oil dipstick guide 17 0 ring gt gt C lt lt 18 Generator bracket gt gt lt lt 19 Knock sensor gt gt lt lt 20 Engine oil pressure switch Required Special Tool MB992106 O ring
27. 11D 1 GROUP 11D ENGINE OVERHAUL lt 2 4L ENGINE gt CONTENTS GENERAL SPECIFICATIONS 11D 2 OIL PAN AND TIMING CHAIN xx AGE DNE 11D 25 SERVICE SPECIFICATIONS 11D 2 REMOVAL AND INSTALLATION 11D 25 REWORK DIMENSIONS 110 3 TIMING CHAIN 11D 32 REMOVAL AND INSTALLATION 11D 32 TORQUE SPECIFICATIONS 11D 4 INSPECTION 110 37 SEALANTS 110 7 CAMSHAFT 110 41 REMOVAL AND INSTALLATION 11D 41 SPECIAL TOOLS 11D 8 INSPECTION 11D 44 GENERATOR AND IGNITION CYLINDER HEAD AND VALVES 11D 47 SYSTEM enn eee eeeee 11D 10 REMOVAL AND INSTALLATION 11D 47 REMOVAL AND INSTALLATION 11D 10 INSPECTION 11D 51 THROTTLE BODY AND EGR BALANCER CHAIN 11D 55 5 110 14 REMOVAL AND INSTALLATION 11D 55 REMOVAL AND INSTALLATION 11D 14 PISTON AND CONNECTING ROD 11D 63 INTAKE MANIFOLD AND FUEL REMOVAL AND INSTALLATION 11D 63 SYSTEM een 6 11D 16 INSPECTION 11D 70 REMOVAL AND INSTALLATION 11D 16 CRANKSHAFT AND CYLINDER EXHAUST MANIFOLD 110 20 BLOCK 11D 72 See REMOVAL AND INSTALLATION 11D 72 INSPECTION 11D 77 WATER HOSE AND PIPE 11D 23 REMOVAL AND INSTALLATION
28. 1D 24 WATER HOSE AND PIPE INSTALLATION SERVICE POINTS gt gt A lt lt THERMOSTAT HOUSING WATER PIPE ASSEMBLY INSTALLATION Assemble the thermostat housing and water pipe and tempo rarily tighten them to the cylinder head and water pump Then tighten them to the specified tightening Tightening torque 24 3 N m 18 1 ft Ib gt gt B lt lt THERMOSTAT INSTALLATION Install the thermostat with the jiggle valve facing almost straight u upwards D Jiggle valve AK304916 AC gt gt C lt lt ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION CAUTION Be careful not to give a shock twist and the like to the resin mold with a tool during installation 1 Apply an appropriate and minimum amount of sealant to the coolant temperature sensor taking care not to allow sealant to squeeze out Specified sealant Three bond 1324N LOCTITE 262 or equivalent 2 Tighten the coolant temperature sensor to the cylinder block to the specified tightening torque Tightening torque 30 9 N m 22 6 ft lb AK502544 AD TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 25 OIL PAN AND TIMING CHAIN CASE OIL PAN AND TIMING CHAIN CASE REMOVAL AND INSTALLATION M1113026301188 oo HH 13 1 a 115 8 in Ib CS 10 2 N m K 89 17 in Ib as N m 14 2Nm 124 x 17 in Ib AK802143 AB Removal steps Removal steps Continued 1 Breather hose 8 Oil drai
29. 2937 Removal steps Continued Piston ring Number 2 Oil ring Piston pin Piston Connecting rod 11D 64 ENGINE OVERHAUL lt 2 4L ENGINE gt PISTON AND CONNECTING ROD Required Special Tool MD998780 Piston pin setting tool MB991659 Guide D MD998718 Rear oil seal installer REMOVAL SERVICE POINTS lt lt A gt gt CONNECTING ROD REMOVAL Enter cylinder Number for reassembly on the side of the con necting rod big end Cylinder No AK502531AE lt lt B gt gt PISTON PIN REMOVAL Guide A 17 9 mm Special tool MD998780 consists of parts shown in the illustra 0 70 in tion Use also special tool MB991659 to remove the piston pin Push rod Guide B Guide A 18 9 mm 0 74 in Guide C Guide A 20 9 mm 0 82 in Guide D 991659 d Guide A 21 9 mm 0 86 in CO AK305415AE TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt PISTON AND CONNECTING ROD Front mark Front mark 2 SS Push rod 3 ush ro NC Sch pin A Guide D 4 Base AK502516AD 11D 65 1 Insert the push rod into the piston pin from the front mark side of the piston top surface and attach special tool MB991659 Set the piston and connecting rod assembly on the base so that the front mark of the piston faces upward Use a press to
30. 54 3 Install the selected crankshaft bearing upper TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11 D 75 CRANKSHAFT AND CYLINDER BLOCK gt gt D lt lt CRANKSHAFT BEARING LOWER INSTALLATION PER 1 When replacing the crankshaft bearing lower select a p bearing with the size corresponding to the crankshaft journal I diameter in the table below No 1 No 2 No 3 No 4 No 5 AK502528AD 2 The crankshaft bearing lower has an identification mark at the illustrated position Crankshaft Crankshaft bearing Identification Journal diameter mm Identification 0 51 985 51 988 0 2 04665 2 04677 AK502418AH 1 51 982 51 985 1 2 04653 2 04665 2 51 979 51 982 2 2 04641 2 04653 3 51 976 51 979 3 2 04629 2 04641 4 51 973 51 976 4 2 04618 2 04629 3 Install the selected crankshaft bearing lower TSB Revision E ENGINE OVERHAUL 2 4L ENGINE 11D 76 CRANKSHAFT AND CYLINDER BLOCK gt gt E lt lt CRANKSHAFT BEARING CAP CRANKSHAFT BEARING CAP BOLT INSTALLATION 1 Install the crankshaft bearing cap with reference to the identification mark as illustrated AK502395AD 2 Make sure that the underhead length of the bolt is at or below the limit before installing the crankshaft bearing cap bolt If the length exceeds the limit replace the bolt with a
31. AC Se Shaded position AK503319AD INSTALLATION SERVICE POINTS gt gt A lt lt MANIFOLD ABSOLUTE PRESSURE MAP SENSOR INSTALLATION N CAUTION Install the manifold absolute pressure MAP sensor taking care not to give a shock to it Do not use a manifold absolute pressure MAP sensor that has fallen down gt gt B lt lt EGR INLET PIPE GASKET EGR VALVE SUPPORT GASKET EGR PIPE GASKET INSTALLATION Temporarily tighten each part so that the protrusion of each gasket is positioned as illustrated gt gt C lt lt EXHAUST GAS RECIRCULATION VALVE EXHAUST GAS RECIRCULATION VALVE GASKET INSTALLATION Install the Exhaust gas recirculation valve gasket with the diag onally shaded area used as the illustrated position so as not to confuse the front with the back TSB Revision 11D 1 6 ENGINE OVERHAUL lt 2 4L ENGINE gt INTAKE MANIFOLD AND FUEL SYSTEM gt gt D lt lt THROTTLE BODY GASKET THROTTLE BODY INSTALLATION 1 Make sure that the throttle body gasket is placed before installing the throttle body 2 Temporarily tighten throttle body and throttle body stay mounting bolts at A and B in the illustration 3 Tighten the throttle body mounting bolt at illustrated position A to the specified torque Tightening torque 20 2 N m 15 1 ft Ib 4 Tighten the throttle body mounting bolts at illustrated position B to the specified tightening torque Tightening
32. AUL lt 2 4L ENGINE gt BALANCER CHAIN 110 55 BALANCER CHAIN REMOVAL AND INSTALLATION M1113032200314 40 N m 130 N m 30 ft lb 96 ft lb 40 N m 130 N m 30 ft lb 96 ft lb Apply engine oil to 20 N m gt 44 N m 0N m 20 Nam gt 135 HD moving parts 15ft Ib 32ftlb Oftlb 15 ft lb before installation AK704645AB Removal steps Removal steps Continued lt lt A gt gt gt gt E lt lt 1 Drive plate bolt lt CVT gt 8 Balancer shaft tensioner lever 2 Adapter plate lt CVT gt 9 Balancer shaft chain guide 3 Drive plate lt CVT gt lt lt B gt gt gt gt B lt lt 10 shaft module lt lt A gt gt gt gt E lt lt 4 Flywheel bolt MT lt lt B gt gt gt gt B lt lt 11 Balancer chain 5 Flywheel lt MT gt lt lt gt gt gt gt lt lt 12 Crankshaft sprocket gt gt D lt lt 6 Rear oil seal lt lt C gt gt gt gt lt lt 13 Ladder frame lt lt B gt gt gt gt lt lt 7 Balancer shaft chain tensioner TSB Revision 11D 56 ENGINE OVERHAUL lt 2 4L ENGINE gt Required Special Tool MB991883 Flywheel stopper MB991614 Angle gauge MD998718 Rear oil seal installer MB991883 AK502869AD AK502940 BALANCER CHAIN REMOVAL SERVICE POINTS lt lt A gt gt DRIVE PLATE BOLT FLYWHEEL BOLT REMOVAL 1 Use special tool MB991883 to secure the drive plate or flywheel 2
33. Gradually push in the crankshaft sprocket and fit it into the key groove of the crankshaft Then install the balancer shaft module on the ladder frame NOTE Make sure that the balancer shaft module is com pletely intimate contact with the ladder frame NOTE Make sure that the key groove of the crankshaft is aligned with the contact surface of the cylinder block and ladder frame as shown in the illustration Crankshaft sprocket timingmark gt S AK503334AD TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 60 BALANCER CHAIN 8 Apply an appropriate and minimum amount of engine oil to the screw thread of the balancer shaft module bolt Balancer shaft module bolt Sb l AK503386AD 9 Tighten bolts to the specified tightening torque of 20 N m 14 ft Ib according to the assembly order in the illustration retighten them to 44 m 32 ft lb and then completely loosen them 10 After tightening them to the specified tightening torque of 20 m again use special tool MB991614 to tighten them up to 135 11 Pull out the hexagonal bar wrench from the balancer module sprocket AK503158AD TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 61 BALANCER CHAIN 12 Make sure that the respective timing mark is aligned with Wee each other as illustrated 13 Install the balancer chain tensioner lever an
34. ION 1 Apply a sufficient amount of engine oil to the circumference of the piston piston rings and oil ring TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 22 Side rail AK202730AG AK502730 Pin identification mark position AK502527AD PISTON AND CONNECTING ROD 2 Arrange end gap positions of piston rings and oil ring side rail and spacer as shown in the illustration 3 Insert the piston and connecting rod assembly from the top surface of the cylinder block with the front mark of the piston top face facing toward the timing belt side CAUTION Driving it in hard causes breakage of piston rings and damage to the crank pin 4 Firmly tighten the piston ring with a ring band and insert the piston and connecting rod assembly gt gt E lt lt CONNECTING ROD BEARING INSTALLATION 1 When replacing a connecting rod bearing select the bearing corresponding to the crankshaft pin outside diameter according to the crankshaft pin identification in the table below Crankshaft pin Connecting rod bearing Identification Journal diameter mm Identification mark in mark 1 47 966 47 972 1 1 8884 1 8886 2 47 960 47 966 2 1 8882 1 8884 3 47 954 47 960 3 1 8880 1 8881 2 An identification mark of a crankshaft is stamped at the illustrated position by Number TSB Revision ENGINE OVERHAUL
35. Measured valve clearance Formula Intake side A B C 0 20 mm 0 08 inch Exhaust side A B C 0 30 mm 0 012 inch Refer to Removal and installation of camshaft for removal installation and inspection procedure of valve tappets TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 41 CAMSHAFT CAMSHAFT REMOVAL AND INSTALLATION ee E pply engine oil to D al moving parts before installation gt gt C lt lt gt gt C lt lt gt gt C lt lt gt gt C lt lt lt lt gt gt gt gt B lt lt lt lt gt gt gt gt B lt lt Removal steps Engine oil control valve OCV exhaust O ring Engine oil control valve OCV intake O ring Front camshaft bearing cap Oil feeding camshaft bearing cap lt lt A gt gt lt lt A gt gt lt lt B gt gt gt gt B lt lt gt gt B lt lt gt gt B lt lt gt gt B lt lt gt gt B lt lt gt gt A lt lt M1113026900659 12 x 1 N m 107 8 in Ib AK502934 AG Removal steps Continued 7 Camshaft bearing cap 8 Thrust camshaft bearing cap 9 Bearing 10 Camshatt intake 11 Camshaft exhaust 12 Bearing 13 Valve tappet TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 42 CAMSHAFT REMOVAL SERVICE POINTS lt lt A gt gt FRONT CAMSHAFT BEARING CAP OIL FEEDING CAMSHAFT BEARING CAP CAM SHAFT BEARING CAP THRUST CAMSHAFT BEARING CAP REMOVAL
36. Tighten the Generator bracket to the specified tightening torque Tightening torque 44 8 N m 33 5 ft lb NOTE Be carelul to install mounting bolts because they are different in length gt gt D lt lt INTAKE MANIFOLD INSTALLATION CAUTION Temporarily tighten the intake manifold because there is a bolt tightening procedure for the intake manifold delivery pipe and injector protector 1 Tighten each intake manifold bolt and nut to the temporarily torque Temporarily torque 3 5 1 5 N m 31 13 in Ib 2 Then tighten the intake manifold bolt and nut to specified torque Tightening torque 20 2 N m 15 1 ft Ib gt gt E lt lt INTAKE MANIFOLD STAY INSTALLATION Make sure that the intake manifold stay is in intimate contact with the intake manifold and cylinder block boss before tighten ing it to the specified tightening torque Tightening torque 20 2 N m 15 1 ft Ib gt gt F lt lt O RING INSTALLATION 1 Apply gasoline to the O ring 2 When inserting an O ring into the injector on the injection nozzle side use special tool MB992106 to gradually expand the O ring and fit it in place TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 19 INTAKE MANIFOLD AND FUEL SYSTEM gt gt G lt lt INJECTOR AND INJECTOR SUPPORT INSTALLATION CAUTION Do not allow gasoline to enter the delivery pipe 1 2 800066 5 Apply
37. and cause a clogging or narrowing of water and oil paths Therefore to eliminate the leak from the joint it is indispensable that the FIPG be applied with a correct amount and without any gap Because the FIPG used for the engine parts becomes hardened by the reaction with the atmo spheric moisture it is normally used for the metal flange section CAUTION Reapply the FIPG with care to the followings 1 Completely remove the old FIPG including the residue in gaps of parts 2 Using Mitsubishi genuine parts cleaner MZ100387 or equivalent degrease the FIPG application surface carefully 3 According to the FIPG application proce dures apply it accurately Three bond 1212D Three bond 1215 or equivalent DISASSEMBLY The parts installed with the FIPG can be disassem bled easily without using any special method How ever in some cases it is necessary to tear the sealant in between the mating surfaces by tapping the parts with a wooden hammer or similar tools It is acceptable to lightly hit in a smooth thin gasket scraper into the mating surface but in this case a sufficient caution is required not to damage the mat ing surface The oil pan FIPG cutter Special tool MD998727 is provided Thus use this special tool GASKET SURFACE CLEANING Use a gasket scraper or wire brush to completely remove all the foreign materials adhering to the gas ket surface Check that the FIPG application surface i
38. aring cap Tighten the bolt as instructed in gt gt B lt lt Bolt Installation Point Remove the bolt and the bearing cap carefully Measure the plastigage whose width is most compressed using the scale printed on the plastigage bag When the measured value deviates from the standard one replace the bearing Standard value 0 0 032 mm 0 0013 inch CAUTION AK503391AC Under view Thickness stamp p When the bearing is used again be careful not to reverse the cylinder head side and the camshaft side at the instal lation VALVE TAPPET AK703500AF Wall thickness AK304938 AB 1 2 Check the thickness stamp If the measured value in the table value is not in agreement with the value in the table to the thickness stamp replace the valve tappet There are 47 kinds of valve tappets at intervals of 0 015 mm 0 0006 inch in the range between 3 000 0 1181 inch and 3 690 mm 0 1453 inch TSB Revision 11D 46 ENGINE A ENGINE gt Thickness mm Thickness Thickness mm Thickness Thickness mm Thickness in stamp in stamp in stamp 3 000 0 1181 3 000 3 240 0 1276 3 240 3 480 0 1370 3 480 3 015 0 1187 3 015 3 255 0 1281 3 255 3 495 0 1376 3 495 3 030 0 1193 3 030 3 270 0 1287 3 270 3 510 0 1382 3 510 3 045 0 1199 3 045 3 285 0 1293 3 285 3 525 0 1388 3 525 3 060 0 1205 3 060 3 300 0 1299
39. case is difficult to remove insert a hammer handle as shown in the illustration and lightly pry it N T d OG Ae AN Sy INSTALLATION SERVICE POINTS gt gt A lt lt TIMING CHAIN CASE INSTALLATION CAUTION Be sure to remove the liquid gasket entering the mount ing holes the O ring grooves and the cylinder gasket clearance Sufficiently check whether there is no residual oil on the place where degreasing is performed using white gasoline such as the surface where the FIPG is applied and stays or the chamfered area Do not touch the area where degreasing must be per formed since the oils from your fingers will harm the seal ability 1 Completely remove the liquid gasket adhering to the timing chain case the cylinder block and the cylinder head 2 Completely remove the sealant remaining on the 3 plane contact surface among the cylinder head the cylinder block and the gasket Carry out the degresing 5 0 5 7 5 0 5 0 10 0 02 0 30 0 02 Nep 1 WU B B view 4 5 0 5 mm 2 5 0 5 mm 0 18 0 02 in 0 10 0 02 in AK703733AH TSB Revision 11D 28 ENGINE OVERHAUL lt 2 4L ENGINE gt OIL PAN AND TIMING CHAIN CASE CAUTION Install the timing chain case within three minutes after applying the liquid gasket 3 Apply liquid gasket of 2 5 0 5 mm 0 10 0 02 inch in
40. ced angle M1113026700871 CAUTION Fix the camshaft on a vise not to damage it 3 Fixing the hexagonal area of the intake camshaft on a vise install the intake V V T sprocket N CAUTION When applying air pressure keep in mind that oil could splash 4 By applying air pressure slowly to the holed port for the advanced angle remove the stopper pin 5 Turn the intake V V T sprocket housing in the right and left directions Check it smoothly moves in the range of A approximately 20 NOTE The stopper pin is locked in the most retarded angle position 6 After the check remove the intake V V T sprocket from the intake camshaft 7 Completely remove the tape sealing the intake camshaft ports for the advanced angle and for the retarded angle TSB Revision ENGINE OVERHAUL 2 4L ENGINE 11D 38 TIMING CHAIN EXHAUST V V T SPROCKET CAUTION Never overhaul the V V T sprocket PE 1 Seal with a tape all the exhaust camshaft ports for the port Tape advanced angle and the retarded angle 2 Make a hole on the port for the retarded angle Retard Advance Make a hole port port AK800284AD A CAUTION Fix the camshaft on a vise not to damage it 3 Fixing the hexagonal area of the exhaust camshaft on a vise install the exhaust V V T sprocket The hexagonal part AK800285AD A CAUTION When applying air
41. cket by one or two teeth to align with the timing mark Align the timing mark of the crankshaft sprocket with the link plate blue to loop the timing chain Because the timing chain slacks hold it to prevent the timing mark from coming off the link plate Make sure that the timing mark of each sprocket is aligned with the link plate of the timing chain at all of three locations Install the timing chain guide and tensioner lever TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 37 Ratchet release hole i koo r AK502854 AG Retard J Advaric Retard Make a hole port port AK800281AD bX Stopper pin Xx AK800283AD Housing TIMING CHAIN gt gt D lt lt TIMING CHAIN TENSIONER INSTALLATION 1 Install the timing chain tensioner on the cylinder block and tighten it to the specified torque Tightening torque 10 2 N m 89 17 in Ib 2 Remove the hard wire piano wire or the like of 1 5 or hexagonal bar wrench 1 5 mm 0 05 inch from the timing chain tensioner This enables the plunger of the timing chain tensioner to push the tensioner lever to keep the timing chain tight INSPECTION INTAKE V V T SPROCKET CAUTION Never overhaul the V V T sprocket 1 Seal with a tape all the intake camshaft ports for the advanced angle and the retarded angle 2 Make a hole on the port for the advan
42. cutter MD998727 01 Removal of oil pan MB991448 Bushing remover and installer base MB991448 01 Press fit of front oil seal TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 9 SPECIAL TOOLS Tool number Supersession Application and name MD998735 MD998735 01 Compression of valve spring Valve spring compressor MB992089 MB992089 01 Retainer holder C MB992085 Extraction of valve stem seal Valve stem seal pliers MD998737 MD998737 01 Installation of valve stem seal Valve stem seal installer MD998780 MIT216941 Extraction and press fit of piston Piston pin pin setting tool MB991659 Guide D MB991614 General service tool Installation of crankshaft bearing Angle gauge cap bolt and installation of balancer shaft module bolt MB991614 MD998718 MD998718 01 Press fit of rear oil seal Rear oil seal installer TSB Revision 11D 1 0 ENGINE OVERHAUL lt 2 4L ENGINE gt GENERATOR AND IGNITION SYSTEM GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION M1113001002172 10 2 N m g 89 17 in Ib T 44 x 10 N m 32 7 ft Ib 155 ft Ib AK802145 AB Removal steps Removal steps Continued 1 Idler pulley lt lt A gt gt gt gt B lt lt 6 Crankshaft pulley center bolt 2 Idler pulley gt gt B lt lt 7 Crankshaft pulley washer gt gt C lt lt 3 Generator gt gt B lt lt 8 Crankshaft pulley gt gt C lt lt 4
43. d 2 Install the V V T sprocket 3 Make sure that the V V T sprocket is securely inserted into the bottom and that the V V T sprocket does not rotate with the hexagonal portion of the camshaft secured with a wrench TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 35 TIMING CHAIN 4 Hold the hexagonal portion of the camshaft with a wrench and tighten the camshaft sprocket bolt to the specified tightening torque Tightening torque 59 5 N m 44 3 ft Ib 25 25 S2 8 273 Crankshaft key Link plate orange gt gt C lt lt TIMING CHAIN INSTALLATION 1 Align the timing mark of the V V T sprocket 2 Align the crankshaft sprocket keys with illustrated positions AK502924AD 3 Align the link plate orange with the timing mark of the Timing mark exhaust V V T sprocket and loop the timing chain TSB Revision 11D 36 ENGINE OVERHAUL lt 2 4L ENGINE gt Timing mark blue 5 ink plate ST blue OG JAN Timing mark iy AK502735 AG 6 Timing mark Timing mark link plate orange link plate blue 7 VN V V T exhaust sprocket T sprocket timing mark i ming mark Crankshaft sprocket link plate blue Timing mark I TIMING CHAIN Link plate 4 Align the link plate blue with the timing mark of the intake V V T sprocket to loop the timing chain Rotate the intake V V T spro
44. d balancer chain i guide o Crank shaft sprocket E timing mark es Q lt Balancer shaft imni ket Timning mark sproc link plate timing mark AK502923 AD gt gt C lt lt BALANCER SHAFT CHAIN TENSIONER INSTALLATION 1 Attach the chain tensioner to the ladder frame CAUTION Install the chain tensioner precisely in place after installing the tensioner lever and chain guide to prevent the plunger of the chain tensioner from jumping out 2 Remove the hard wire piano wire etc of 1 5 or hexagonal bar wrench 1 5 mm 0 06 inch from the tensioner This enables the plunger of the chain tensioner to push the balancer shaft tensioner lever to keep the balancer shaft AK502940 chain tight gt gt D lt lt REAR OIL SEAL INSTALLATION CAUTION Do not apply oil to the circumference of the oil seal and oil seal pressing hole on the cylinder block side to prevent teeth from pulling out After applying a small amount of engine oil to the oil seal lip use special tool MD998718 to press fit the oil seal e EE MD998718 SSS ull AK502871AD TSB Revision 11D 62 ENGINE OVERHAUL lt 2 4L ENGINE gt BALANCER CHAIN gt gt E lt lt DRIVE PLATE BOLT FLYWHEEL BOLT INSTALLATION 1 2 MB991883 AK503335AD AK600847AE
45. e between the camshaft and valve tappet Standard value when engine is cold Intake side 0 20 0 03 mm 0 008 0 001inch Exhaust side 0 30 0 03 mm 0 012 0 001 inch If measured values are out of the standard value record measured values Rotate the crankshaft by one turn clockwise to set the Number 4 piston at top dead center on the compression stroke NOTE The timing mark of the V V T exhaust sprocket must be at the illustrated position TSB Revision 11D 40 ENGINE Exhaust valve side 6 No 2 No el A IX RH o OBOE OKO ERN a No 3 No 4 Intake valve side AK502388 AF Wall thickness 9 AK304938 AE OVERHAUL lt 2 4L ENGINE gt TIMING CHAIN Valve clearance can be measured at the illustrated location in this condition If measured values are out of the standard value record measured values If the measured value is out of the standard value replace the valve tappet NOTE There are 47 kinds of valve tappets at intervals of 0 015 mm 0 0006 inch in the range between 3 000 mm 0 1181 inch and 3 690 mm 0 145 inch Select a valve tappet in the following procedure 1 Measure thickness of a removed valve tappet 2 Calculate thickness of a valve tappet so that valve clearance meets the standard value A Thickness of valve tappet to be selected B Thickness of removed valve tappet C
46. er bolt Vehicles for California 14 x1 N m 124 8 in Ib 8 2 N m 71 17 in lb TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 5 TORQUE SPECIFICATIONS Item Specification Exhaust manifold lower cover bolt lt Except vehicles for 14 1N 124 8 in Ib California Exhaust manifold lower cover bolt Vehicles for California 8 x2 N m 71 17 in Ib Exhaust manifold nut 49 5 N m 36 3 ft lb Exhaust manifold bracket bolt M8 Except vehicles for 20 5 N m 15 3 ft lb California Exhaust manifold bracket bolt M10 Except vehicles for 41 x 10 N m 30 7 ft lb California Exhaust manifold bracket bolt Vehicles for California 41 x 10 N m 30 7 ft lb Crankshaft position sensor bolt 11 1 N m 98 8 in Ib Crankshaft position sensor cover bolt M6 11 1 N m 98 8 in Ib Water hose and pipe Water inlet fitting bolt 24 3 N Water outlet fitting bolt 24 3 N Thermostat housing bolt 24 3 N Engine hanger bolt 28 8 N Engine coolant temperature sensor 30 9 N Water pump bolt 24 3 N Water pipe nut 24 3 N Camshaft position sensor bolt 11 1 N 18 1 ft lb 18 x 1 ft lb 18 1 ft lb 21 x5 ft lb 22 x6 ft lb 18 x 1 ft lb 18 x 1 ft lb 98 8 in Ib m m m m m Oil pan and timing chain case Cylinder head cover bolt 3 0 x 1 0 N m 27 8 in Ib 5 5 0 5 N m 49 4 i
47. ess thin before pulling out Cut 4 0 5 1 mm 0 02 0 04 in AK300719AE 2 Repair the valve seat hole of the cylinder head to match it with the diameter of the oversize valve seat to be press fitted Intake valve seat bore diameter Valve seat 0 3 Over size 36 22 36 24 mm 1 426 1 427 inch ZER Exhaust valve seat bore diameter d 0 3 Over size 30 22 30 24 mm 1 190 1 191 inch Oversize hole 3 Press fit the valve seat taking care not to score the cylinder diameter EE head bore at room temperature 4 Ream the valve seat Refer to Repair procedure of valve seat REPLACEMENT PROCEDURE OF VALVE GUIDE 1 Pull out the valve guide with a press toward the cylinder block side 2 Ream the valve guide hole of the cylinder head to match it with the diameter of the oversize valve guide to be press fitted CAUTION Do not use a valve guide with the same size as that of the pulled out valve guide because it cannot be press fitted Valve guide bore diameter 0 25 Over size 11 23 11 25 mm 0 442 0 443 inch 3 Press fit the valve guide to the illustrated dimension Standard value 14 6 15 2 mm 0 57 0 60 inch NOTE Press fit the valve guide from the cylinder head top surface 4 After pressing fit the valve guide insert a new valve to check for sliding 14 6 15 2 mm 0 57 0 60 in CD KK503086AD TSB Revision ENGINE OVERH
48. ey bolt Crankshaft pulley Engine front AK602911AD Use special tool MB991883 to secure the drive plate Wipe the dirt on the crankshaft pulley washer and on the thread hole of the crankshaft using a rag Wipe the dirt on the crankshaft pulley and the crankshaft sprocket using a rag and then remove the grease from the portion shown in the illustration NOTE Remove grease to prevent the coefficient of friction of the pressing portion from declining due to adhesion of oil Install the crankshaft pulley Apply an appropriate and minimum amount of engine oil to the threaded portion of the crankshaft and lower part of the flange With the chamfered side on the inside of the crankshaft pulley washer facing the bolt top install the crankshaft pulley washer to the crankshaft pulley center bolt Tighten the crankshaft pulley center bolt to the specified tightening torque Tightening torque 210 N m 155 ft Ib TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 1 3 GENERATOR AND IGNITION SYSTEM gt gt C lt lt GENERATOR POWER STEERING PUMP BRACKET INSTALLATION 1 Temporarily tighten power steering pump bracket bolts CAUTION Always loosen the power steering pump bracket bolt and temporarily the alternator Then tighten each bolt 2 Loosen the power steering pump bracket bolt and make the power steering pump bracket unfixed 3 Temporarily tighten alternator bolts 4 T
49. ght of valve spring mm in 47 2 1 858 Squareness of valve spring 2 or less TSB Revision 4 ENGINE OVERHAUL lt 2 4L ENGINE gt REWORK DIMENSIONS Item Standard value 11D 3 Limit Clearance between valve guide Intake 0 020 0 047 0 0008 and valve stem mm in 0 0019 0 10 0 0039 Exhaust 0 030 0 054 0 0012 0 0021 0 11 0 0043 Valve seat contact width mm in Intake 1 16 1 46 0 046 0 058 Exhaust 1 35 1 65 0 053 0 065 Valve guide press in height mm in 14 6 15 2 0 57 0 60 Piston and connecting rod Piston pin press fit load N Ibf 7 500 17 500 1 686 3 934 Clearance between piston ring Number 1 0 03 0 07 0 001 0 003 0 1 0 004 and ring groove mm in Number 2 0 03 0 07 0 001 0 003 Piston ring end gap mm in Number 1 0 15 0 25 0 006 0 011 0 1 0 004 0 8 0 03 Oil 0 10 0 35 0 004 0 014 1 0 0 04 Number 2 0 25 0 40 0 010 0 016 Clearance of connecting rod big end thrust mm in 0 10 0 25 0 004 0 010 0 4 0 016 Difference of outside diameter of connecting rod bolt mm in 0 8 0 03 0 1 0 04 Connecting rod bearing oil clearance mm in 0 018 0 045 0 0007 0 0018 0 1 0 04 Crankshaft and cylinder block Underhead length of crankshaft bearing cap bolt mm 75 5 76 5 2 972 3 012 in
50. gt gt gt gt A lt lt 15 Valve stem seal gt gt C lt 5 Cylinder head gasket lt lt B gt gt gt gt lt lt 16 Valve stem seal 6 Engine oil control valve OCV filter 17 Intake valve guide lt lt A gt gt gt gt B lt lt 7 Retainer lock 18 Exhaust valve guide 8 Valve spring retainer 19 Intake valve seat 9 Valve spring 20 Exhaust valve seat 10 Intake valve 21 Cylinder head TSB Revision 11D 48 ENGINE OVERHAUL lt 2 4L ENGINE gt CYLINDER HEAD AND VALVES Required Special Tool MD998735 Valve spring compressor e MB992089 Retainer holder C MB992085 Valve stem seal pliers REMOVAL SERVICE POINTS A RETAINER LOCK REMOVAL CAUTION Be careful not to allow retainer holder C to interfere with the wall of the tappet hole and to damage it Use a special tool MD998735 and MB992089 to compress the valve spring and to remove the retainer lock NOTE Store removed parts such as valves and springs with tags describing cylinder Number and installed position attached for reassembly MD998735 AK502741AD B VALVE STEM SEAL REMOVAL Use special tool MB992085 to firmly pinch the base larger external shape of the stem seal and twist it right and left for pulling out v a ms gt 1 Valve stem seal AK502782AD TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 49 CYLINDER HEAD AND VALVES INSTALLATION SERVICE POINTS gt gt
51. ide B Guide A below the standard value replace the piston pin piston assembly or connecting rod or both Standard value 7 500 17 500 N 1 686 3 934 Ibf AK502517AE gt gt B lt lt OIL RING INSTALLATION 1 Assemble the spacer of the oil ring into the piston ring groove Then assemble the upper side rail and after this assemble the lower side rail NOTE Install the side rail and end gap of the spacer so that they are at the position as shown in the illustration AK103812 TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11 D 67 PISTON AND CONNECTING ROD CAUTION The side rail may be broken if its end gap is widened by a ring expander as in other piston rings 2 When assembling the side rail push it by fingers after fitting one end of the side rail into the piston groove for easy assembly 3 After assembling the oil ring into the piston make sure that the side rail turns smoothly to either direction AK304891 gt gt C lt lt PISTON RING NUMBER 2 PISTON RING NUMBER 1 INSTALLATION Use a piston ring expander to assemble piston rings with their identification marks facing upward Piston rings can be assem bled by hand without using the piston ring expander Piston ring expander AK304892AD Identification mark Number 1 ring 1T Number 2 ring 2T AK502529AE gt gt D lt lt PISTON CONNECTING ROD ASSEMBLY INSTALLAT
52. ification mark mark in 1 40 000 40 008 1 1 5748 1 5751 2 40 008 40 016 2 1 5751 1 5754 3 40 016 40 024 3 1 5754 1 5757 TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 43 3 Notch amp Oil hole AK702204AD dentification mark 4 Dowel pin 5 Identification mark RK AK503813AC CAMSHAFT The identification mark of the camshaft bearing is painted at the illustrated position Set the dowel pins of the camshaft at the illustrated positions Camshaft bearing caps Number 1 to Number 4 are of the same shape Install them upon checking the identification mark so as not to misidentify cap Number and to confuse the intake side with the exhaust side Identification mark stamped on front and Number 1 to Number 4 bearing caps I Intake side E Exhaust side Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps Tightening torque 12 1 N m 106 8 in Ib TSB Revision 11D 44 ENGINE OVERHAUL lt 2 4L ENGINE gt Timing chain side 1 7 2 8 AK503814AC CAMSHAFT Tighten each front camshaft bearing cap mounting bolt to the temporarily torque of 17 3 N m 14 2 ft Ib in the order of number shown 1 Tighten each front camshaft bearing cap mount
53. ighten them to the specified tightening torque according to the order as illustrated Tightening torque Power steering pump bracket M8 23 2 m 17 1 ft lb 80 mm M10 44 8 N m 33 5 ft Ib 2 3 15 in Generator 44 10 N m 32 7 ft lb 80 mm 3 15 in AK503383AG TSB Revision 11D 14 ENGINE OVERHAUL lt 2 4L ENGINE gt THROTTLE BODY AND EGR SYSTEM THROTTLE BODY AND EGR SYSTEM REMOVAL AND INSTALLATION M1113032700405 4 0 x 1 0 N m 36 8 in Ib AK900341AD Removal steps Removal steps Continued 1 Vacuum pipe and hose gt gt B lt lt 13 EGR valve support gasket 2 Purge hose 14 EGR support stay A 3 Chamber 15 EGR support stay B 4 Purge hose 16 Exhaust gas recirculation valve 5 Water hose support 6 Throttle body stay gt gt B lt lt 17 EGR inlet pipe gasket gt gt D lt lt 7 Throttle body 18 EGR inlet pipe gt gt D lt lt 8 Throttle body gasket 19 Purge solenoid valve gt gt C lt lt 9 Exhaust gas recirculation valve 20 O ring gt gt C lt lt 10 EGR valve gasket gt gt A lt lt 21 Manifold absolute pressure MAP 11 EGR pipe sensor gt gt B lt lt 12 EGR pipe gasket 22 O ring TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 15 THROTTLE BODY AND EGR SYSTEM EGR valve AK503321AC 2 N Protrusion O AS TIP AK503320
54. ing bolt to the specified torque in the order shown 2 Tightening torque 30 2 N m 22 1 ft lb gt gt C lt lt O RING ENGINE OIL CONTROL VALVE INSTALLATION CAUTION 7 1 2 3 AK303651AE AK503020AC The O ring must not be reused Wind non adhesive tape seal tape etc around the notch of the oil passage of the oil feeder control valve before installing the O ring to prevent damage Damage to the O ring causes oil leakage Apply a small amount of engine oil to the O ring of the oil feeder control valve Install the oil feeder control valve on the cylinder head Tighten the oil feeder control valve to the specified tightening torque of 10 x2 N m 89 17 in Ib M1113027000659 CAMSHAFT Measure camshaft height camshaft major axis If the height exceeds the limit replace the camshaft Standard value Intake 44 1 mm 1 74 inch Exhaust 45 0 mm 1 77 inch Limit Intake 43 6 mm 1 72 inch Exhaust 44 5 mm 1 75 inch TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 45 CAMSHAFT CAMSHAFT OIL CLEARANCE PLASTIGAGE METHOD 1 Thoroughly wipe oil on the outside diameter of the camshaft and the inside diameter of the bearing Install the bearing to the camshaft Put straightly the plastigage having the length of the bearing width on the journal axis centering the axis Carefully install the be
55. n Ib Timing chain case bolt M6 10 x2 N m 89 17 in Ib Timing chain case bolt M8 x 10 13 1 115 8 in Ib Timing chain case bolt M8 x 28 24 4 18 2 ft lb Oil pan bolt M6 10 2 89 17 in Ib Oil pan bolt M8 29 2 N 21 1 ft lb Air compressor bracket bolt 23 6N 17 4 ft lb Oil drain plug 39 5 N 29 3 ft Ib Oil filter 14 x2N m 124 17 in Ib Positive Crankcase Ventilation Valve 2 5 x0 4 N m 22 3 in Ib Engine support bracket bolt M10 45 5 N m 33 3 ft lb Engine support bracket bolt M8 23 x2N 17 x1 ft lb Timing chain Chain upper guide bolt 10 2 N Oil jet bolt 10 2 V V T intake sprocket bolt 59 5 V V T exhaust sprocket bolt 59 5 Timing chain tensioner bolt 10 2 N 89 17 in lb 89 17 in lb 44 x3 ft lb 44 3 ft lb 89 17 in lb 89 17 in Ib m m m m m m Tensioner lever bolt 10 2N TSB Revision 11D 6 ENGINE OVERHAUL lt 2 4L ENGINE gt TORQUE SPECIFICATIONS Item Specification Timing chain guide bolt 10 x2 N m 89 17 in Ib Camshaft Engine oil control valve OCV bolt 10 x2 N m 89 17 in Ib Camshaft bearing cap bolt M6 12 x 1 107 8 in Ib Front camshaft bearing cap bolt M8 17 x3 N m 14 2 ft lb 230 2 N m 22 1 ft lb Cylinder head and valves Cylinder head bolt 35 2 N
56. n plug gasket 2 PCV hose lt lt gt gt gt gt E lt lt 9 Oil filter 3 Positive Crankcase Ventilation gt gt 0 lt lt 10 Cylinder head cover Valve 11 Cylinder head cover gasket 4 Positive Crankcase Ventilation 12 Air compressor bracket Valve gasket lt lt B gt gt gt gt C lt lt 13 OU pan 5 Oil filler cap 14 Engine support bracket 6 O ring gt gt B lt lt 15 Front oil seal 7 Oil drain plug lt lt C gt gt gt gt A lt lt 16 Timing chain case TSB Revision 11D 26 ENGINE OVERHAUL lt 2 4L ENGINE gt OIL PAN AND TIMING CHAIN CASE Required Special Tool e MB991396 Oil filter wrench MD998727 Oil pan FIPG cutter MB991448 Bushing remover and installer base REMOVAL SERVICE POINTS lt lt A gt gt OIL FILTER REMOVAL Use special tool MB991396 to remove the oil filter B OIL PAN REMOVAL 1 Remove oil pan tightening bolts CAUTION Lightly tap the oil pan FIPG cutter to drive in taking care not to damage the ladder frame and oil pan sealed area 2 Lightly tap special tool oil pan FIPG cutter MD998727 to drive in the illustrated groove of the oil pan and ladder frame 3 Lightly tap and slide special tool MD998727 to remove the oil pan MD998727 FF AK502732AD TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 27 OIL PAN AND TIMING CHAIN CASE lt lt C gt gt TIMING CHAIN CASE REMOVAL If the timing chain
57. ng limit shall be within 0 2 mm 0 008 inch in combination with the cylinder block to be assembled 3 For the flatness on the cylinder head bottom measure distortion using a straight edge and free gauge If the distortion exceeds the limit grind and repair it Distortion on bottom Standard value Within 0 05 mm 0 002 inch Limit 0 2 mm 0 08 inch Grinding limit 0 2 mm 0 008 inch Cylinder head height Standard value 128 5 mm 5 06 inch VALVE 1 Repair the valve seat if contact with the valve seat is poor uneven or broken 2 Measure the margin If the limit is exceeded replace the valve Standard value Intake 1 022 mm 0 0402 inch Exhaust 1 094 mm 0 0431 inch Limit Intake 0 522 mm 0 0206 inch Exhaust 0 594 mm 0 0234 inch 3 Measure overall length of the valve If the limit is exceeded replace the valve Standard value Intake 113 18 mm 4 456 inch Exhaust 105 89 mm 4 169 inch Limit Intake 112 68 mm 4 436 inch Exhaust 105 39 mm 4 149 inch VALVE SPRING 1 Measure free height of the spring If the limit is exceeded replace the spring Standard value 47 2 mm 1 858 inch 2 Measure squareness of the spring If the inclination exceeds the limit replace the spring Standard value 2 or less Limit 4 TSB Revision Guide inside diameter Contact width ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 53 CYLINDER HEAD AND VALVES Stem diameter AK300168 AF
58. o o o 8e 5605910 53026 Seele sO 9103s o 9 43025305 sO e o o AK502392 AD e 5 Put a paint mark on all of cylinder head bolt heads and Paint mark We cylinder head d All _ Paint mark Ai CAUTION When the tightening angle is smaller than the specified tightening angle the appropriate tightening capacity cannot be secured When the tightening angle is larger than the specified Paint mark Paint mark tightening angle remove the bolt to start from the 0 AR beginning again according to the procedure 2 AK502523AD 6 Tighten the cylinder head 90 according to the tightening order Tighten it further 90 and make sure that the paint mark on the cylinder head bolt is in a straight line with that on the cylinder head INSPECTION M1113007002567 CYLINDER HEAD 1 Check the cylinder head for water leakage gas leakage damage or cracks before cleaning 2 Completely remove oil scale sealant carbon etc After cleaning oil passages blow air to make sure that they are not clogged TSB Revision 11D 52 Y kksozrab The bottom of valve seat contact facet Margin AK305408AD Length AK305409AD Squareness Free height AK305410AD ENGINE OVERHAUL 2 4L ENGINE CYLINDER HEAD AND VALVES N CAUTION The grindi
59. pressure keep in mind that oil could splash 4 By applying air pressure slowly to the holed port for the retarded angle remove the stopper pin 5 Turn the exhaust V V T sprocket housing in the right and left directions Check it smoothly moves in the range of A approximately 10 NOTE The stopper pin is locked in the most advanced angle position 6 After the check remove the exhaust V V T sprocket from the exhaust camshaft 7 Completely remove the tape sealing the exhaust camshaft ports for the advanced angle and for the retarded angle VALVE CLEARANCE ADJUSTMENT Check and adjust the valve clearance with the timing chain installed Measure valve clearance in the following procedure Stopper pin TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 39 TIMING CHAIN CAUTION Always rotate the crankshaft clockwise 1 Timing mark Exhaust valve side 2 No 1 No 3 SOE e e TA 2 2 No 1 No 2 Intake valve side AK502387AG 3 4 5 ae AK502545 AG Rotate the crankshaft clockwise to align the timing mark of the V V T sprocket with the top surface of the cylinder head as illustrated Set the Number 1 piston at top dead center on the compression stroke Valve clearance can be measured at the illustrated location in this condition Use a free gauge to measure clearanc
60. push the push rod and pull out the piston pin NOTE After pulling out the piston pin organize pistons pis ton pins and connecting rods by cylinder Number INSTALLATION SERVICE POINTS gt gt A lt lt PISTON PIN INSTALLATION AK503237AD 1 When replacing a piston check the cylinder bore size mark stamped on the illustrated position of the cylinder block and select a corresponding piston from the table below Cylinder bore size Piston size mark mark A A B None C C TSB Revision 11D 66 ENGINE OVERHAUL lt 2 4L ENGINE gt PISTON AND CONNECTING ROD Piston mark size AK503238AF NOTE The piston size mark is indicated on the piston top face 2 Insert the push rod into the piston pin and attach guide A 3 Align the front mark of the piston with that of the connecting rod to assemble 4 Apply engine oil to the circumference of the piston pin 5 Insert the guide A side of the piston pin assembled in section 1 into the pin hole from the front mark side of the piston Seen 6 Screw guide B into guide A and open clearance between 0 11 in guide A and guide B by 3 mm 0 11 inch make the base in L line with flushed surface to assemble 7 Set the piston on special tool piston setting base so that its P4 X front mark faces upward 8 Use a press to press fit the piston pin If the press fit load is Gu
61. rd value Cylinder bore 88 mm 3 46 inch Cylindricity 0 0076 mm 0 0003 inch TSB Revision
62. s smooth There must be no grease or foreign mate rial adhesion to the gasket surface Do not forget to remove the old FIPG remaining in the mounting hole and tapped hole APPLICATION PROCEDURE Apply the FIPG with a specified diameter and without any gap Completely enclose around the mounting hole When the FIPG is not hardened it can be wiped off When the FIPG is still moistened perform the installation to the specified position At the time of installation prevent the FIPG from adhering to loca tions other than it is necessary After the installation TSB Revision 11D 8 until a sufficient period of time approximately for t ENGINE OVERHAUL lt 2 4L ENGINE gt SPECIAL TOOLS one hours elapses do not contact the oil or water to the application area Also do not start the engine Because the FIPG application procedure may differ depending on the application area apply the FIPG according to the procedure described in the text SPECIAL TOOLS Tool number and name Supersession M1113000603055 Application MB991883 MB991883 Flywheel stopper Securing of drive plate or flywheel MB991398 Spark plug wrench Removal and installation of spark plug lt 7 B992106 MB992106 O ring installer Installation of O ring on injector injection nozzle side B991396 MB991396 Oil filter wrench Removal and installation of oil filter D998727 MD998727 Oil pan FIPG
63. ssembly TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 33 TIMING CHAIN REMOVAL SERVICE POINTS lt lt A gt gt TIMING CHAIN TENSIONER REMOVAL o Pen 1 Insert a flatblade screwdriver into the release hole of the timing chain tensioner to release the latch M A 2 Push the tensioner lever by hand and push in the plunger of the timing chain tensioner until it hits the bottom Then insert a hard wire piano wire or the like of 41 5 or hexagonal bar wrench 1 5 mm 0 06 inch into the fixing hole of the plunger 3 Remove the timing chain tensioner Plunger fixed O hole i r AK502854 AG B EXHAUST V V T SPROCKET BOLT REMOVAL Hold the hexagonal portion of the exhaust camshaft with a wrench and loosen the exhaust V V T sprocket bolt lt lt C gt gt INTAKE V V T SPROCKET BOLT REMOVAL Hold the hexagonal portion of the intake camshaft with a wrench and loosen the intake V V T sprocket bolt TSB Revision 11D 34 Sp V V T sprocket bolt V V T sprocket Sg ENGINE OVERHAUL lt 2 4L ENGINE gt Camshaft AK503070 AD TIMING CHAIN INSTALLATION SERVICE POINTS gt gt A lt lt INTAKE V V T SPROCKET BOLT INSTAL LATION 1 Assemble the intake V V T sprocket assembly in the following procedure Make sure that the knock pin of the inlet camshaft assembly
64. thickness to the timing chain case For illustrated A locations however apply liquid gasket of 4 5 0 5 mm 0 18 0 02 inch in diameter or liquid gasket of 2 5 0 5 mm 0 10 0 02 inch by putting one on top of another as shown in the illustration Specified sealant Three bond 1217G or exact equivalent 4 The engine oil staying at the cylinder gasket oozes to the 3 plane contact surface described in Step 2 and 3 Swiftly apply the liquid gasket to this area after degreasing Specified sealant Three bond 1217G or exact equivalent TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 29 OIL PAN AND TIMING CHAIN CASE 5 Tighten timing chain case mounting bolts to the specified Q A tightening torque Tightening torque 24 4 N m 18 2 ft lb B 10 2 N m 89 17 in Ib C 10 2 N m 89 17 in Ib D 13 1 N m 115 8 in Ib A M8 x 30 mm 1 2 in B M6 x 25 mm 1 0 in C M6 x 25 mm 1 0 in D M8 x 10 mm 0 4 in AK502378 AH gt gt B lt lt FRONT OIL SEAL INSTALLATION REES Gran Os 1 Apply engine oil to the internal circumference of the oil seal ve des 2 Use special tool MB991448 to install the front oil seal on the b Oil seal timing chain case g 1 5 2 5 mm ll e 0 06 0 09 in Si KE AH V AK800005 AC gt gt C lt lt OIL PAN INSTALLATION 1 Completely remove liquid gasket adhering to the c
65. third of the balancer module can be immersed 3 Also pour approximate 50 cm 3 1 cu in of engine oil from the oil inlet 4 By giving four clockwise rotations or more to the balancer shaft sprocket the oil is supplied to the oil pump and the balancer shaft bearing TSB Revision ENGINE OVERHAUL lt 2 4L ENGINE gt 11D 59 BALANCER CHAIN o Wipe clean with a rag 2 Wipe the dirt on the crankshaft sprocket and the crankshaft Wipe clean with a rag and degrease using a rag and then remove the grease from the portion shown in the illustration NOTE Remove grease to prevent a drop in the coefficient of friction of the pressing portion caused by adhesion of oil Crankshaft 3x EJ a Engine front Hp Crankshaft sprocket AK603521AB Balancer chain 3 Align the timing mark of the balancer shaft module sprocket link plate with that of the balancer shaft module 4 Insert a hexagonal bar wrench 3 mm 0 12 inch as illustrated to prevent the balancer shaft module sprocket from moving 5 Loop the balancer chain aligning its link plate with the timing mark 6 Install the crankshaft sprocket on the crankshaft NOTE Do not push in the crankshaft sprocket to the normal position Push it in only up to the tip of the crankshaft 7 While slanting the balancer shaft module align the link plate of another balancer chain with the timing mark of the crankshaft sprocket to loop
66. ttached temporarily place it on a V block to pre vent teeth of the sensing ring from deforming NOTE If a tooth bends be sure to replace the crankshaft sens ing ring with a new one INSTALLATION SERVICE POINTS gt gt A lt lt CRANKSHAFT SENSING RING INSTALLA TION Tighten crankshaft sensing ring bolts to specified torque in the tightening order shown in the illustration Tightening torque 11 N m 98 38 in Ib gt gt B lt lt THRUST BEARING INSTALLATION 1 Install the thrust bearing on the Number 3 bearing on the cylinder block side Application of engine oil makes the installation easy 2 Install the thrust bearing so that the grooved side is on the crankshaft weight side TSB Revision 11D 74 ENGINE OVERHAUL lt 2 4L ENGINE gt CRANKSHAFT AND CYLINDER BLOCK gt gt C lt lt CRANKSHAFT BEARING UPPER IN AK502530AD Identification mark AK502396AH STALLATION 1 When replacing the crankshaft bearing upper select a bearing with the size corresponding to the crankshaft journal diameter in the table below the illustrated position 2 The crankshaft bearing upper has an identification mark at Cylinder block Crankshaft bearing Identification Journal Identification mark diameter mm mark in 1 56 000 56 006 1 2 2047 202049 2 56 006 56 012 2 2 2050 2 2051 3 56 012 56 018 3 2 2050 2 20
67. with the shaft center 4 Carefully install the bearing cap and tighten the bolt according to the main point of installation gt gt B lt lt 5 Remove the bolt and then carefully remove the crankshaft bearing cap 6 Measure the crushed plastigage width area most widely crushed using a scale printed on the plastigage bag Standard value 0 012 0 030 mm 0 0005 0 0012 inch Limit 0 08 mm 0 0031 inch TSB Revision 11D 78 ENGINE OVERHAUL lt 2 4L ENGINE gt CRANKSHAFT AND CYLINDER BLOCK CYLINDER BLOCK 1 Visually check the cylinder block for scratch rust and corrosion Use a flaw detecting agent to check for cracks If it is found faulty repair or replace it Measure distortion on the top surface of the cylinder block using a straight edge and free gauge If distortion exceeds the limit grind and repair it A gasket or the like must not be adhered to the top surface of the cylinder block during measurement Distortion on bottom Standars value Within 0 05 mm 0 0020 inch Limit 0 2 mm 0 008 inch Grinding limit 0 2 mm 0 008 inch Check the cylinder wall for scratch or seizure If there is any defect replace the cylinder block Measure the bore and cylindricity of the cylinder using a cylinder gauge If the cylinder is excessively worn repair the cylinder and replace the piston and piston rings Measuring points are as shown in the illustration Standa
68. ylinder block and oil pan 2 Degrease the cylinder block and oil pan TSB Revision 11D 30 ENGINE OVERHAUL lt 2 4L ENGINE gt 1 mm 0 04 in 2 5 0 5 mm 0 10 0 02 in AK502377AD q 4 0 mm 0 16 in T AK502760AF OIL PAN AND TIMING CHAIN CASE CAUTION Install the oil pan within three minutes after liquid gasket is applied Apply liquid gasket of 42 5 0 5 mm 0 10 0 02 inch of thickness in diameter to the illustrated area of the oil pan Specified sealant Three bond 1217G or exact equivalent 4 Tighten the oil pan to the specified tightening torque Tightening torque M6 10 2 N m 89 17 in Ib M8 29 2 N m 21 1 ft lb gt gt D lt lt CYLINDER HEAD COVER INSTALLATION 1 Completely remove liquid gasket adhering to the cylinder head cover timing chain case and cylinder head 2 Degrease the cylinder head cover timing chain case and cylinder head CAUTION Install the cylinder head cover immediately after liquid gas ket is applied 3 Appropriately use a minimum amount of sealant Besides be careful not to allow sealant to squeeze out from the application area Apply liquid gasket of 4 mm 0 16 inch of thickness in diameter Specified sealant Three bond 1217G or exact equivalent 4 Tighten the cylinder head cover to the tightening torque in the

11D - Road Race Engineering

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