11-1

ENGINE
CONTENTS
110003000

... . . . . . ... . . . ... .. . .. . . . .... . .. .. ... ..... . .. .. .. 1.8L ENGINE.. . . . . . . . . . . , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5L ENGINE.

1lA 11B

11A-I

1.5L ENGINE
CONTENTS
CAMSHAFT AND CAMSHAFT OIL SEAL CRANKSHAFT OIL SEAL.. CRANKSHAFT PULLEY
110003001

,.

19

............... 23 ............... 25

Ignition Timing Inspection and Adjustment ................................ 10 Manifold Vacuum Inspection .................. 13 Power Steering Oil Pump Drive Belt Tension Inspection and Adjustment . . . . . . . . . . . . 8 Timing Belt Tension Adjustment Valve Clearance Adjustment

..................29

CYLINDER HEAD GASKET ENGINE ASSEMBLY

. . . . . . . . . . . . . . 14

................... , . 16
..................2
21
.5

. . . . . . . . . . . . . . . . . . .Refer to GROUP 00

GENERAL INFORMATION OIL PAN

SERVICE SPEClFlCATlONS SPECIAL TOOLS

.................5
-6

................................. SEALANTS ...............................

SERVICE ADJUSTMENT PROCEDURES
Air Conditioning Compressor Drive Belt Tension Inspection and Adjustment . . . . . . . . Basic Idle Speed Adjustment

.....8

......................... TIMING BELT ............................ TROUBLESHOOTfNG .......................

Compression Too Low Connecting Rod Noise / Main Bearing Noise Excessive Engine Rolling and Vibration Noisy Valves Oil Pressure Drop Oil Pressure Too High Timing Belt Noise

30
7

................

...

Refer to GROUP 13

Compression Pressure Inspection . . . . . . . . . . . . .12 Curb Idle Speed Inspection

. . . . . . . . . . . . . . . . . 11
8

Generator Drive Belt Tension Inspection and Adjustment ......................... Idle Mixture Inspection.. .....................

11

11A-2

1.5L ENGINE

- General Information
110003002

GENERAL INFORMATION
GENERAL SPECIFICAT10NS

Items

1 Specifications
In-line, Over Head Camshaft 4

k b e r of cylinders

I Bore mm (in.)

1 Piston displacement cm3 (cuh.)

Compression ratio Firing order Valve timing Intake valve

1 82.0 (3.23) 1 1,468 (89.6)

9.2

75.5 (2.97)

I I

1-3-4-2

I Opens (BTDC) 1 Opens (BBDC)

I 15"
57"

Exhaust valve

I Lubrication

1 Pressurized feed-full filtration

1.5L ENGINE - General Information SECTIONAL VIEW

11A-3
110003003

I TSB Revision

11A-4
LUBRICATION SYSTEM

1.5L ENGINE - General Information

11OW3OC

'i

. Connecting rod

Crankshaft

1.5L ENGINE

- Service Specifications / Sealants

I Standard value I Limit
-

11A-5
110003005

SERVICE SPECIFICATIONS
Items Drive belt tension N (Ibs.) Generator
type

Whenchecked When new belt is installed When used belt is installed When checked When new belt is installed When used belt ISinstalled

250-500 (55-110) 500-700 (110- 154) 400 (88) 250-310 (55-68) 370-435 (82-96) 250-310 (55-68)
~

Air conditioning compressor type

,
1
When used belt is installed Drive belt deflection mm (in.) Generator ~ value) ~ Whenchecked When installed ~new belt is ~ 1 When used belt is installed ~

300-500(66-110) 500-850 (110-187) (66-110) 7.0-9.0 (.28-.35) 5.5-7.0 ~ (.22-.28) ~ 8.0 (.31) 6.0-7.0 (.24-.28) 5.0-6.0 (.20-.24) 6.0-7.0 (.24-.28) 5.5-7.5 (.22-.30) 4.0-5.5 (.16-.22) 5.5-7.5 (.22-.30) 5" k 2" BTDC 5" k 3" BTDC 10" BTDC 0.5 or less
100 or less

I 300-500

1,1

Air conditioning compressor type Power steering oil pump V-ribbed type

,
I

When checked When new belt is installed When used belt is installed When checked When new belt is installed When used belt is installed

Basic ignition timing at idle (except 1995 models for California) Basic ignition timing at idle (1995 models for California) Actual ignition timing at curb idle CO concentration % HC concentration ppm Curb idle speed r h i n Compression pressure (250-400 r/min) kPa (psi) Compression pressure difference of all cylinder kPa (psi) Intake manifold vacuum at curb idle kPa (in.Hg)

1 7 5 0 k 100 1 1,350 (192) ll-

llI min. 960 (137)

1
I

I I

max. 100 (14) min. 60 (18)

I
I
110003006

SEALANTS

I Items
Oil pan

1 Recommended sealant
MlTSUBlSHl GENUINE Part No, MD970389 or equivalent As required

11A-6

1.5L ENGINE

- Special Tools
Application Installation of camshaft oil seal

SPECIAL TOOLS
Tool
Tool number and name MD998713 Camshaft oil seal installer Supersession MD998713-01

1100030l

MD998727 Oil pan remover

General service tool

Removal of oil pan

MD998747 Crankshaft pulley holder

General service tool

Supporting crankshaft pulley

MB990767 End yoke holder

MB990767-01

Supporting camshaft pulley Supporting crankshaft pulley

MD998719 Crankshaft pulley holder pin

MIT308239

MD998011 Crankshaft rear oil seal installer

MD998011-01

Installation of crankshaft rear oil seal

MD998360 Cylinder head bolt wrench

General service tool

Removal and installation of cylinder head assembly

GENERAL SERVICE TOOL MZ203827 Engine lifter

General service tool

Supporting engine assembly when removing and installing transaxle

1.5L ENGINE

- Troubleshooting
1 Remedy

11A-7
110003008

TROUBLESHOOTING
Symptom Compression too low

I Probable cause 1 Cylinder head gasket blown 1 Piston ring worn or damage

I Replace gasket 1 Replace rings

Repair or replace piston and/or cylinder block
I

Piston or cylinder worn Valve seat worn or damage

1 Repair or replace valve and/or seat ring

Adjust valve clearance Check engine oil level Replace oil pressure switch

I Incorrect valve clearance

Oil pressure drop Engine oil level too low Oil pressure switch faulty

1 Oil filter clogged 1 oil pump gears or cover worn

I Install new filter 1 Replace gears and/or cover

~~

1 Thin or diluted engine oil

Oil relief valve stuck (open)

Change engine oil to correct viscosity Repair relief valve

1
Oil pressure too high Noisy valves

Excessive bearing clearance Oil relief valve stuck (closed) Incorrect valve clearance

1 Replace bearings
Repair relief valve Adjust valve clearance Change engine oil

1 Thin or diluted engine oil (low oil pressure) I Valve stem or valve guide worn or damaged
Connecting rod noisel main bearing noise Insufficient oil supply Low oil pressure

I Replace valve and/or guide

Check engine oil level Refer to Oil pressure drop

I Thin or diluted engine oil

Excessive bearing clearance

Timing belt noise Excessive engine rolling and vibration Incorrect belt tension Loose engine roll stopper (Front, Rear) Loose transaxle mount bracket Loose engine mount bracket Loose center member

1 Change engine oil 1 Replace bearings

Adjust belt tension Retighten

11A-8

1.5L ENGINE

- Service Adjustment -

Procedures

I"
Crankshaft
pulley
ZWMM

SERVICE ADJUSTMENT PROCEDURES

_ "

I 1 0003009

GENERATOR DRIVE BELTTENSION INSPECTION AND ADJUSTMENT

GENERATOR DRIVE BELT TENSION INSPECTION With belt tension gauge set to the belt midway between the pulleys as shown in the illustration, check the belt tension for standard value. Or apply a force of 98 N (22 Ibs.) to the belt to check the deflection for standard value. Standard value:

1 Tension N (Ibs.)
250-500 (55-110)

1 (Reference value)
I '

Deflection mm (in.)

1 7.0-9.0 (.28-.35)

GENERATOR DRIVE BELT TENSION ADJUSTMENT

110003010

(1) Loosen the nut of the generator pivot bolt. (2) Loosen the lock bolt. (3) Turn the adjusting bolt to adjust the belt tension or deflection to the standard value.

Standard value:

(4) Tighten the lock bolt.

Tightening torque: 14 Nm (10 ft.lbs.)

(5) Tighten the nut of the generator pivot bolt.

__

Tightening torque: 23 Nm (16 ft.lbs.)

Water pump

POWER STEERING OIL PUMP DRIVE BELT TENSION INSPECTION AND ADJUSTMENT
110003011

Z l J i -

POWER STEERING OIL PUMP DRIVE BELT TENSION INSPECTION Measure drive belt deflection by pulling or pushing at the midpoint of the belt between pulleys with a force of 100 N (22 Ibs.) as shown in the figure. Standard value: 5.5-7.5 mm (.22-.30 in.)

1 TSB Revision

1.5L ENGINE

- Service Adjustment

Procedures

11A-9

POWER STEER." OIL PUMP DRIVE BELT TENSION ADJUSTMENT 110003012 If the deflection is out of the standard values, adjust the belt tension using the following procedure. (1) Loosen bolts A, B and C (for holding the oil pump).

(2) Set a bar or similar tool against the oil pump body, and while applying tension to the belt, tighten the oil pump mounting bolts in the order A, B, C. (3) Tighten belt adjustment bolt.

Tightening torque: 40 Nm (29 ft.lbs.) (4) Check the belt deflection adjust if necessary. Caution Before this check, turn the engine one time or more clockwise. NOTE Verify belt is not cracked or frayed before re-using. Standard value: Used belt: 5.5-7.5 mm (.22-30 in.) New belt: 4.0-5.5 mm (.16-.22 in.)

AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT

110003013

AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION INSPECTION Measure drive belt deflection by pulling or pushing at the midpoint of the belt between pulleys with a force of 100 N (22 Ibs.). Standard value: 6.0-7.0 mm (.24-.28 in.) AIR CONDITIONING COMPRESSOR DRIVE BELT TENSION ADJUSTMENT 110003014 (1) Loosen tension pulley securing nut A. (2) Adjust belt tension with adjusting bolt B. NOTE Verify belt is not cracked or frayed before re-using. Standard value: Used belt: 6.0-7.0 mm (.24-.28 in.) New belt: 5.0-6.0 mm (.20-.24 in.) (3) Tighten securing nut A. (4) Check the belt tension after driving. Standard value: 6.0-7.0 mm (.24-.28 in.)

m -

1 TSB Revlslon

11A-10

1.5L ENGINE - Service Adjustment Procedures

'

IGNITION TIMING INSPECTION AND ADJUSTMENT

110003015

(1) Before inspection and adjustment, verify following the conditions:

0 0
0

Engine coolant temperature: 80-95C (176-203F) Lights, electric cooling fan and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T)

(2) Insert a paper clip into the 1 pin connector (blue) as shown in the illustration at left.

(3) Connect a primary-voltage-detection type of tachometer to the paper clip. NOTE Do not use the scan tool. If tested with the scan tool connected to the data link connector, the ignition timing will not be the basic timing but be ordinary timing. (4) Set up a timing light. (5) Start the engine and run at idle. (6) Check that engine idle speed is within the standard value. Curb idle speed: 750 f 100 r/min (7) Turn the ignition switch to OFF. (8) Remove the waterproof connector from the ignition timing adjustment connector (brown). (9) Connect the jumper wire to the ignition timing adjustment terminal, and to a good ground as illustrated. NOTE Grounding this terminal sets the engine to basic ignition timing.

(10)Start the engine and run it at idle. s within the standard (11)Check that basic ignition timing i value. Basic lgnltion tlmlng: 5"BTDC f 2" (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California)

I TSB Revision

1.5L ENGINE - Service Adjustment Procedures

11A-11

(12)cExcept 1996 models and 1995 models for California> a. If not within the standard value, loosen distributor hold down nuts and adjust by rotating distributor body. b. Tighten hold down nuts after adjusting. Tightening torque: 12 Nm (8 lt.lbs.) 4 9 9 6 models and 1995 models for California> If not within the standard value, inspect the MFI components by referring. to GROUP 13A Troubleshooting. (13)Stop the engine, remove the jumper wire from the ignition timing adjustment connector (brown), and return the connector to its original condition. (14)Star-l the engine and check that ignition timing is at the standard value. Actual ignition timing: approx. 10"BTDC NOTE 1. Ignition timing is variable within about f7", even under normal operation. 2. And it automatically advances by about 5" from 10" BTDC at higher altitudes.

CURB IDLE SPEED INSPECTION

110003016

(1) Before inspection and adjustment verify in the following conditions: 0 Engine coolant temperature: 80-95C (176-203F) 0 Lights, electric cooling fan and all accessories: OFF 0 Transaxle: Neutral (P range on vehicles with NT) (2) Check the basic ignition timing. Adjust if necessary. Standard value: 5"BTDCk 2' (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California) (3) After turning the ignit'on switch to OFF, install the tachometer or connect the scan tool to the data link connector (white). For the method of installing the tachometer, refer to P.11A-10. (4) Start the engine and'run it at idle. (5) Run the engine at idle for 2 minutes. (6) Check the idle speed. Curb Idle speed: 750 k 100 r/min NOTE The idle speed is controlled automatically by the idle air control (IAC) system.

(7) If there is a deviation from the standard value, refer to GROUP 13 - Check Chart Classified by Problem Symptoms, and check the MFI components.

IDLE MIXTURE INSPECTION

110003017

(1) Before inspection, set the vehicle in the following condition. 0 Engine coolant temperature: 80-95C (176-203F) 0 Lights, electric cooling fan and accessories: OFF 0 Transaxle: Neutral (P range on vehicle with AlT)

11A-12

1.5L ENGINE

- Service Adjustment Procedures

(2) Make sure that the basic ignition timing is at a standard value.

Standard value: 5"BTDC k 2" (Except 1996 models and 1995 models for California) 5"BTDC f 3" (1996 models and 1995 models for California) (3) After turning the ignition switch OFF, set a tachometer or connect the scan tool to the data link connector. NOTE For tachometer setting procedure, refer to P.1lA-10.
(4) Start the engine and run at 2,500 r/min forapprox. 2 minutes. ( 5 ) Set the CO tester and HC tester. (6) Check the CO concentration and HC concentration with the engine at idle. Standard value: CO concentration: 0.5% or less HC concentration: 100 ppm or less
(7) If the standard value is exceeded, check the following items.
#

3.

- a

Diagnostic output Closed loop control (If closed loop control is performed normally, heated oxygen sensor output signals change within a 0-400 mV range and a 600-1,000 mV range.) Fuel pressure Injectors Ignition coil, spark plug cables and spark plugs Leaks in EGR system and EGR valve Evaporative emission control system Compression pressure NOTE If CO and HC concentrations exceed the respective standard values despite the fact that the results of the inspection made on all items are normal, replace the three-way catalyst.
110003018

COMPRESSION PRESSURE INSPECTION

(1) Before inspection, check that the engine oil, starter and battery are normal. Also, verify to the following conditions: a Engine coolant temperature: 80-95C (176-203F) a Lights, electric cooling fan and all accessories: OFF a Transaxle: Neutral (P range on vehicle with A/T)
(2) Remove all of the spark plugs. (3) Disconnect the 6-pin distributor connector (except 1995 models for California) or crankshaft position sensor connector (1995 models for California).

NOTE Doing this will prevent the engine control module from carrying out ignition and fuel injection. (4) Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

1TSB Revision

. -

1.5L ENGINE - Service Adjustment Procedures

.

11A-13

- .

...,.

Caution 1. Keep away from the spark plug hole when cranking. 2. During a compression test, if water, oil, fuel, etc., . has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

(5) Set compression gauge to one of the spark plug holes. (6) Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250-400 rlmin): 1,350 kPa (192 psi) Limit (at engine speed of 250-400 r/min): min. 960 kPa (137 psi) (7) Measure the compression pressure for all the cylinders. Verify difference between maximum and minimum readings do not exceed the limit. Limit: max. 100 kPa (14 psi) (8) If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps (6) and (7). a. If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. b. If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. (9) Connect the distributor connector (except 1995 models for California) or crankshaft position sensor connector (1995 models for California). (1O)lnstall the spark plugs and spark plug cables. (11)Use the scan tool to erase the diagnostic trouble codes, or disconnect the battery ground cable for more than 10 seconds and reconnect it. NOTE This will erase the diagnostic trouble code resulting from the distributor connector being disconnected.

..--

MANIFOLD VACUUM INSPECTIONN

110003019

(1) Verify the following conditions before inspection. 0 Engine coolant temperature: 80-95C (176-203F) 0 Lights, electric cooling fan, and all accessories: OFF 0 Transaxle: Neutral (P range on vehicles with PJT)

(2) Install the tachometer or connect the scan tool to the data link connector (white). (3) Disconnect the vacuum hose from the fuel pressure regulator.

1 TSB Revision

11A-14

1.5L ENGINE

- Service Adjustment Procedures

(4) Connect a three-way vacuum tee between the removed

vacuum hose and the nipple and connect a vacuum gauge to the vacuum tee as shown. (5) Start the engine and check that idle speed is within the I standard value range. (6) Check the manifold vacuum. I Limit: 60 kPa (18 in.Hg) min.

1
TIMING BELT TENSION ADJUSTMENT
iiooo3ozo

I
The timing belt has an automatic tension adjusting mechanism. Adjustment can be made by the following procedure. (1) Remove the water pump pulley. (2) Remove the air conditioning pulley bracket.

(3) Remove the timing belt upper cover. (4) Remove the crankshaft compressor pulley and crankshaft pulley. <Vehicles for California (From 1995 models)> (Refer to P. 11A-29.) (5) Remove the timing belt lower cover. (6) Remove the spark plugs. (7) Turn the crankshaft clockwise to check for cracks or signs of wear that in the timing belt. Caution Always turn the crankshaft clockwise.
(8) Turn the crankshaft clockwise to bring the No. 1 cylinder piston to top dead center on the compression stroke.

Caution For aligning the timlng marks, never turn the crankshaft counterclockwise as it could cause inadequate belt tensioning.

1
(9) Loosen both pivot side and slot side tensioner bolts and tension the belt, making use of the tensioner spring force. (10)Turn the crankshaft clockwise by two teeth of camshaft sprocket.

ZlENC550

TSB Revision

1.5L ENGINE

- Service Adjustment Procedures

11A-15

(11) Push the timing belt tensioner inthe'direction of the arrow to check that each sprocket is kept in firm and complete engagement with the belt cogs. After this check, release hand pressure so that only the tensioner spring acts on belt and tighten the slot side bolt and then the pivot side bolt to fix the tensioner in position.

- .. . -. . .. .. __ . . (12)Check the timing belt tension. Hold the timing belt tensioner and timing belt together by hand and give the belt a slight thumb pressure at a point level with tensioner center. Make sure that the belt cog crest deflects approximately 1/4 of the tensioner attaching bolt head width.
I I

1/4 of bolt head width

muoIl

(13)lnstall the spark plugs. (14)lnstall the timing belt lower cover. (15)lnstall the crankshaft compressor pulley and crankshaft pulley. <Vehicles for California (From 1995 models)> (Refer to P. 11A-29.) (16)lnstall the timing belt upper cover. (17)lnstall the air conditioning pulley bracket. (18)lnstall the water pump pulley and adjust the drive belt deflection.

11A-16

1.5L ENGINE - Engine Assembly

ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
~~

110003021

Pie-removal Operation 0 Fuel Line Pressure Releasing (Refer to GROUP 13 - Service Adjustment Procedures.) 0 Hood Removal 0 Coolant Draining (Refer to GROUP 14 - Service Adjustment Procedures.) 0 Transaxle Assembly Removal (Refer to GROUP 22, 23 - Transaxle Assembly.) 0 Radiator Removal (Refer to GROUP 14 - Radiator.)

Post-Installation Operation Radiator Installation(Referto GROUP 14- Radiator.) Transaxle Assembly Installation (Refer to GROUP 22, 23 - Transaxle Assembly.) 0 Coolant Supplying (Refer to GROUP 14 - Service Adjustment Procedures.) 0 Hood Installation 0 Accelerator Cable Adjustment (Refer to GROUP 13 - Service Adjustment Procedures.)
0

._
5 Nm
5 Nm

3.6 R.lbs.

I
10
Removal steps

1. Ground cable connection 2. Accelerator cable connection 3. Breather hose connection 4. Vacuum hose connection 5. Heater hose connection 6. High-pressure hose connection 7. O-ring 8. Return hose connection 9. Brake booster vacuum hose connection

10. Vacuum hose connection

1.5L ENGINE - Engine Assembly

11A-17

Removal steps 11. Oxygen sensor connector 12. Ignition coil connector 13. CKP sensor and CMP sensor connector 14. Engine coolant temperature sensor connector 15. Engine coolant temperature gauge unit connector 16. Throttle position sensor connector 17. Intake air temperature sensor 18. EGR temperature sensor 19. Idle air control motor 20. Injector connector 21. Control harness

+Ab

+Bb

+Cb

,A+

22. Generator connector 23. Power steering oil pressure switch connector V-ribbed belts adjustment (Refer to P.11A-8.) 24. V-ribbed belt for air conditioning 25. Air conditioning compressor 26. V-ribbed belt for power steering 27. Power steering oil pump 28. Self-locking nuts and bolts 29. Gasket 30. Engine mount bracket (Refer to GROUP 32 - Engine Mount.) 31. Engine assembly

11A-18

1.5L ENGINE

- Engine Assembly
AIR CONDITIONING COMPRESSOR REMOVAL <VEHICLES WITH AIR CONDITIONING> Disconnect the air conditioning compressor connector and remove the compressor from the compressor bracket with the hose still attached. NOTE Place the removed air conditioning compressor in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the bracket with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

REMOVAL SERVICE POINTS

( A ,

( B ,

( C ,

ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, slowly remove the engine assembly upward from the engine compartment.

IN STA LLATlON SERVICE P0INT

F A 4 ENGINE ASSEMBLY INSTALLATION Install the engine assembly while checking to be sure that the cables, hoses, and harness connectors are clear of the engine assembly.

1.5L ENGINE - Camshaft and Camshaft Oil Seal

11A-19
__
110003022

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION
I

Pie-removal and Post-installation Operation

0 0

Timing Belt Removal and Installation (Refer to P.11A-30.) Distributor Removal and Installation (Refer to GROUP 16 - Distributor.)
1.8 Nm 1.3 ft.lbs.

32 Nm 23 ft.lbs.

I
LIP

section

H
Engine oil Removal steps 1. Rocker cover 2. Camshaft sprocket 3. Oil seal

F B I

4Ab

bC+

bA4

Valve clearance inspection and adjustment 4. Rocker arm assembly 5. Camshaft

0

REMOVAL SERVICE POINT

+ A F CAMSHAFT SPROCKET REMOVAL

)Revision

11A-20

1.5L ENGINE

- Camshaft and Camshaft Oil Seal

INSTALLATION SERVICE POINTS
. A + CAMSHAFT INSTALLATION Position the dowel pin of the camshaft as shown in the illustration.

, B A

VALVE CLEARANCE INSPECTION AND ADJUSTMENT Refer to GROUP 00 - Maintenance Service.

b C + OIL SEAL INSTALLATION

1.5L ENGINE

- Oil Pan

11A-21
110003023

OIL PAN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation Engine Oil Draining and Supplying Oil Dipstick Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to GROUP 15 - Exhaust Pipe and Muffler.)

Specified sealant: MlTSUBlSHl GENUINE PART No. MD970389 or equivalent

i i Nm 8 tt.lbs.
7 Nm 5.1 ft.lbs.

6 Nm 4.3 ft.lbs.

m 1 S w 5 1

Removal steps 1. Bell housing cover

+Ab , B + , A +
2. Drain plug 3. Gasket 4. Oil pan

MD998727 1

MD998727 -

REMOVAL SERVICE POINT

4 A F O I L PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Hammer little by little, or the oil pan will be deformed.

TCR D a t r i c i n n

11A-22

1.5L ENGINE

- Oil Pan

INSTALLATION SERVICE POINTS

, A + OIL PAN INSTALLATION Caution After cleaning the oil pan mounting bolt holes in the oil seal case, the oil pan should be installed. NOTE (1) Install the oil pan within 15 minutes after applying liquid gasket. (2) Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.

.
F B 4 DRAIN PLUG GASKET INSTALLATION Replace the gasket with a new gasket, the groove towards the oil pan as shown.

1.5L ENGINE - Crankshaft Oil Seal

11A-23
110003024

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION
Pre-removal and Post-installatlon Operation
<Crankshaft Oil Seal+ Timing Belt Removal and Installation (Refer to P.11A-30.) <Crankshaft Rear Oil Seal> 0 Oil Pan Removal and Installation (Refer to P.11A-21.)
0

Transaxle Assembly Removal and Installation (MTT: Refer to GROUP 22 - Transaxle Assembly.) (Wr: Refer to GROUP 23 - Transaxle Assembly.) Clutch Cover and DISC <MTT> Removal and Installation

Lip section

I
YOINOM:

m
Lip section
Z01NW43

<M/T>

Engine oil

4 1

<Vehicles for Federal (Up to 1995 models) and California (Up to 1994

01s0270

models)>

00001 0 7 1

Crankshaft front oil seal removal steps 1. Crankshaft sprocket 2. Crankshaft sensing blade
3. Crankshaft spacer 4. Flange

4AF

Crankshaft rear oll seal removal steps 6. Flywheel assembly <M/T> or drive plate <AK> F A 4 7. Crankshaft rear oil seal

F B I 5. Crankshaft front oil seal

11A-24

1.5L ENGINE

- Crankshaft Oil Seal

REMOVAL SERVICE POINT

A A F FLYWHEEL ASSEMBLY <Mn> OR DRIVE PLATE cA/T> REMOVAL Secure the crankshaft pulley by using the V-ribbed belt and the special tool. Caution (1) Because the V-ribbed belt installed in the vehicle may be damaged, use a new V-ribbed belt. (2) Do not use a damaged V-ribbed belt. (2) Remove the flywheel assembly or the drive plate cAiT>.

<Mn>

INSTALLATION SERVICE POINTS

F A A CRANKSHAFT REAR OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the entire circumference of the oil seal lip. (2) Tap the oil seal as shown in the illustration until it is flush with the oil seal case.

Oil seal

F B A CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the entire circurnference of the oil seal lip. ( 2 ) Tap the oil seal until it is flush with the oil seal case.

Oil seal case

1.5L ENGINE

- Cylinder Head Gasket

11A-25
110003025

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
I
~ ~~

Pre-removal Operation
0

Reduce the Inner Pressure of Fuel Line and Hose (Refer to GROUP 13 - Service Adjustment Procedures ) Draining the Engine Coolant Draining the Engine Oil Air Intake Hose Removal (Refer to GROUP 15 - Air Cleaner)

Post-installation Operation

Air Intake Hose Installation (Refer to GROUP 15 - Air Cleaner.) Refilling the Engine Oil Refilling the Engine Coolant Adjusting the Accelerator Cable (Refer to GROUP 13 - Service Adjustment Procedures)

5 Nm 3.6 ft.lbs.

15
Engine oil

- 5 Nm 3.6 ft.lbs.

0150080

00001073

Removal steps
1. Ground cable connection 2. Accelerator cable connection 3. PCV hose connection 4. Breather hose connection 5. Vacuum hose connection 6. Water hose connection (Throttle body to thermostat housing) 7. Water hose connection (Throttle body to water inlet pipe)
r .

8. Water hose connection (Heater unit to thermostat housing) 9. High-pressure fuel hose connection 10. O-ring 11. Return hose connection 12. Brake booster vacuum hose connection 13. Engine mounting stay 14. Vacuum hose 15. Radiator upper hose

11A-26

1.5L ENGINE - Cylinder Head Gasket

/ 1.3 ft.lbs.
1.8 Nm

27 9 17 ,18 /l ,20
<Cold engine> 73 Nm 53 ft.lbs.

96
h

- \ / / a

21

.24 ,
I

26 $2

23

36 ft.lbs.

01SOO62
00001074

Removal steps 16. Oxygen sensor connector 17. Ignition coil connector 18. CKP sensor and CMP sensor connector 19. Engine coolant temperature sensor connector 20. Engine coolant temperature gauge unit connector 21. Throttle position sensor connector 22. Intake air temperature sensor

23. 24. 25. 26. 27. 28. 4Ab 29. 4Bb 30. 4 C b b B 4 31. 32. F A 4 33.

EGR temperature sensor Idle air control motor Injector connector Control harness Rocker cover Timing belt upper cover Camshaft sprocket Self-lockina nuts Cylinder hzad assembly Gasket Cylinder head gasket

1.5L ENGINE - Cylinder Head Gasket REMOVAL SERVICE POINTS

11A-27

4 A b TIMING BELT UPPER COVER REMOVAL After removing the timing belt upper cover, rotate the crankshaft clockwise and align the timing marks. Caution Turn the crankshaft clockwise.

4 B b CAMSHAFT SPROCKET REMOVAL (1) Use the special tool to remove the camshaft sprocket with the timing belt attached.

(2) Tie the camshaft sprocket and timing belt with a wire so that the position of the camshaft sprocket will not move with respect to the timing belt.

4 C b CYLINDER HEAD ASSEMBLY REMOVAL Using the special tool, loosen the bolts in the order shown in the illustration (in 2 or 3 steps), remove them and then remove the cylinder head assembly. NOTE Loosening each bolt in 1 step may warp the cylinder head.

Front of engine
Intake side

Exhaust side
m(WE4

1 TSE Ravirian

11A-28

1.5L ENGINE

- Cylinder Head Gasket

INSTALLATION SERVICE POINTS

b A + CYLINDER HEAD GASKET INSTALLATION (1) Use a scraper to remove the cylinder head gasket from the cylinder block. Caution Take care that no foreign material gets into the cylinder, or into the engine coolant or oil passages.
ZOlRM17

C Camshaft sprocket side

(2) Place the cylinder head gasket on the cylinder block with the marks facing upward. Caution The cylinder head gasket is easy to mls-Install, so be sure to check it. If it is mis-installed, malfunctions such as no oil rising to the cylinder head will occur.

bB+ CYLINDER

HEAD ASSEMBLY INSTALLATION (1) Use a scraper to remove the cylinder head gasket from the cylinder head assembly. Caution Take care that no foreign material gets into the engine coolant or oil passages.

I .

(2) Using the special tool, tighten the bolts in the order shown, a minimum of 2 steps maximum of 3 steps, to specifications.

Front of engine
Intakeside

Exhaust side
yo1uo155

1.5L ENGINE

- Crankshaft Pulley

11A-29
110003026

CRANKSHAFT PULLEY
l

Pre-removal Operation
0

Under Cover Removal

Post-installation Operation a Drive Belt Tension Adjustment (Refer to P. 11A-8.)

0

Under Cover Installation

i c

AOlP0045 I

1
4 A F F A 4 4. Crankshaft compressor pulley
+AF
(Air conditioning) F A 4 5. Crankshaft pulley

Removal steps 1. Drive belt (Air conditioning) 2. Drive belt (Power steering) 3. Drive belt (Generator)

REMOVAL AND INSTALLATIONSERVICE POINTS

4AFbA4CRANKSHAFT COMPRESSOR PULLEY I CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Use the special tool and an old drive belt to secure the puI leys. Caution 1. This drive belt will get damaged. Do not use the engines drive belt. 2. Never use a damaged drive belt.

11A-30

1.5L ENGINE

- Timing Belt
I10003027

TIMING BELT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation Under Cover Removal and Installation 0 Crankshaft Pulley Removal and Installation (Refer to P.11A-29.) 0 Engine Mount Removal and Installation (Refer to GROUP 32 - Engine Mounting.)
0

\ 2
11 Nm 8 R.lbs.

8 ft.lbs.

Removal steps

FBd FB4

F A 4 3. Timing

1. Timing belt upper cover 2. Timing belt lower cover

belt

NOTE *: Vehicles for Federal <From 1996 models> and California <From 1995 models

REMOVAL SERVICE POINTS

4 A F T l M l N G BELT UPPER COVER REMOVAL After removing the timing belt upper cover, rotate the crankshaft clockwise and align the timing marks. Caution Always turn the crankshaft clockwise.

1 TSB Revision

1.5L ENGINE - Timing Belt

11A-31

4 B F T l M l N G BELT REMOVAL (1) Loosen the timing belt tensioner bolts. (2) Move the timing belt tensioner to the water pump side and temporarily tighten the bolt so that the tensioner doesnt return. (3) Remove the timing belt. Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

INSTALLATION SERVICE POINTS

Timing mark

Timing mark

4- Tension side

Timing mark Timing mark Crankshaft sorocket

F A 4 TIMING BELT INSTALLATION (1) Align the timing marks on the camshaft sprocket and crankshaft sprocket. (Now the piston in No. 1 cylinder is at the top dead center on the compression stroke.) (2) Set the timing belt first on crankshaft sprocket and then keeping the tension side of belt tight, set on the camshaft sprocket. Caution If the timing belt is re-used, install so that the arrow marked on it at time of removal is pointing in the clockwise direction. (3) Apply counterclockwise force (in the direction B) to the camshaft sprocket to give tension to the belt on tension side and make sure that all timing marks are lined up. (4) Install the crankshaft pulley temporarily. This is to prevent the belt from coming off when crankshaft is turned.

<Vehicles for Federal (Up to 1995 models) and California (Up to 1994 models)>

<Vehicles for Federal (From 1996 models) and California (From 1995 models)>

b B 4 TIMING BELT LOWER COVER /TIMING BELT UPPER COVER INSTALLATION Note that the timing belt lower and upper cover attaching bolts differ in size from one place to another. UseA bolt: 6 x 18 (.24 x .71) B bolt: 6 x 38 (.24 x 1.50) [diameter x length mm (in.)]

ZOlU0156

A
0150208

00001077

1 TSB Revision