14-6. TSB Revision ENGINE COOLING ON-VEHICLE SERVICE

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1 14-6 RADIATOR CAP DRAIN PLUG ENGINE COOLING ON-VEHICLE SERVICE When removing the radiator cap, use care to avoid contact with hot coolant or steam Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube After relieving the steam pressure, remove the cap by slowly turning it counterclockwise 2 Remove the radiator cap, radiator drain plug and cylinder block drain plug to drain the coolant 3 Remove the reserve tank and drain the coolant 4 After completely draining the coolant, reinstall the drain plugs and flush the engine and radiator using a radiator cleaning fluid 5 After the flushing is completed, completely drain the cleaning fluid LOOSEN ACX00896AC LEFT BANK RIGHT BANK DRAIN PLUG AC AB CYLINDER BLOCK DRAIN PLUG 6 Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten at the standard torque Specified sealant: 3M Nut Locking Part number 4171 or equivalent Tightening torque: 39 N m (29 ft-lb) AC200625AB 7 Loosen the air bleed bolt LABEL AIR BLEED BOLT AC AD

2 MB AIR HOSE LABEL AC203208AB AIR BLEED BOLT AC AD ENGINE COOLING 14-7 ON-VEHICLE SERVICE Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze The use of an improper anti-freeze can cause the corrosion of the aluminum components 8 By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60% Use special tool MB to refill the coolant A convenient mixture is a 50% water and 50% antifreeze solution [freezing point: 31 C ( 328 F)] Recommended antifreeze: MITSUBISHI GENUINE Part number MD or equivalent Quantity: Without rear heater 90 cm 3 (95 quart) With rear heater 100 cm 3 (106 quart) NOTE: For the usage of special tool MB991870, refer to the instructions enclosed with the special tool 9 Pour in coolant until it overflows from the air bleed bolt hole, and then tighten the air bleed bolt Tightening torque: <30L> 17 20N m (12 14 ft-lb) <35L> 12 15N m ( in-lb) 10Reinstall the radiator cap 11Start the engine and let it warm up until the thermostat opens 12After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine 13Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim Rein stall the cap Do not overfill the tank 14Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary ENGINE COOLANT CONCENTRATION TEST M Refer to GROUP 00, RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE P00-36 DRIVE BELT TENSION CHECK AND ADJUSTMENT M Refer to GROUP 00, Maintenance Service P00-43

3 14-10 REMOVAL AND INSTALLATION ENGINE COOLING COOLING FAN COOLING FAN M N m 43 in-lb N m in-lb N m in-lb 2 1 REMOVAL STEPS 1 SHROUD ASSEMBLY 2 DRIVE BELTS 3 COOLING FAN AND FAN CLUTCH ASSEMBLY REMOVAL STEPS (Continued) 4 PULLEY 5 FAN CLUTCH 6 COOLING FAN AC AB INSPECTION Cooling Fan Check M Check the blades for damage and cracks Check for cracks and damage around bolt holes in the fan hub If any portion of the fan is damaged or cracked, replace the cooling fan Fan Clutch Check Check to ensure that fluid in the fan clutch is not leaking at the case joint and seals If fluid quantity decreases due to leakage, the fan speed will decrease and engine overheating might result When the fan attached to the engine is turned by hand, it should have some resistance If the fan turns lightly or freely with no resistance, it is faulty Check the bimetal strip for damage

4 ENGINE ELECTRICAL CHARGING SYSTEM Example 4 PROBABLE CAUSE: Short-circuit in stator coil AKX00194 Example 5 PROBABLE CAUSE: Open circuit in supplementary diode AKX00195 GENERATOR ASSEMBLY REMOVAL AND INSTALLATION M N m 124 in-lb 52 N m 38 ft-lb N m 16 ft-lb 3 AC AB REMOVAL STEPS 1 DRIVE BELT (FOR A/C) 2 DRIVE BELT (FOR POWER STEERING) REMOVAL STEPS (Continued) 3 DRIVE BELT (FOR GENERATOR) 4 GENERATOR

5 11A-30 REMOVAL AND INSTALLATION ENGINE MECHANICAL <30L ENGINE> TIMING BELT TIMING BELT M Pre-removal Operation Engine Coolant Draining and Refilling (Refer to GROUP 14, On-vehicle Service P14-5) Cooling Fan Removal (Refer to GROUP 14, Cooling Fan P14-10) Generator Removal and Installation (Refer to GROUP 16, Generator P16-13) 1 24 N m 17 ft-lb N m 43 in-lb 74 N m 54 ft-lb 24 N m 17 ft-lb 11 N m 97 in-lb 14 N m 124 in-lb 7 11 N m 97 in-lb 5 44 N m 33 ft-lb N m 97 in-lb 24 N m 17 ft-lb 44 N m 33 ft-lb N m 134 ft-lb 9 48 N m 35 ft-lb 11 N m 97 in-lb REMOVAL STEPS 1 POWER STEERING DRIVE BELT COVER <<A>> 2 POWER STEERING OIL PUMP ASSEMBLY (ENGINE OIL) ACX00343 AB REMOVAL STEPS (Continued) <<A>> 3 A/C COMPRESSOR ASSEMBLY 4 COMPRESSOR BRACKET 5 TIMING INDICATOR BRACKET 6 ACCESSORY MOUNT ASSEMBLY

6 ENGINE MECHANICAL <30L ENGINE> 11A-31 TIMING BELT REMOVAL STEPS (Continued) 7 TIMING BELT UPPER COVER ASSEMBLY <<B>> >>C<< 8 CRANKSHAFT PULLEY 9 TIMING BELT LOWER COVER ASSEMBLY <<C>> >>B<< 10 TIMING BELT >>A<< 11 AUTO-TENSIONER REMOVAL STEPS (Continued) 12 TENSION PULLEY 13 TENSIONER ARM ASSEMBLY Required Special Tools: MD990767: End Yoke Holder MD998715: Crankshaft Pulley Holder Pin MD998767: Tension Pulley Socket Wrench MD998769: Crankshaft Pulley Spacer REMOVAL SERVICE POINTS <<A>> POWER STEERING OIL PUMP ASSEMBLY / A/C COMPRESSOR ASSEMBLY REMOVAL 1 Do not disconnect the hoses to remove the pump and compressor 2 Support the removed pump and compressor with a wire, etc so that they will not get in the way while working <<B>> CRANKSHAFT PULLEY REMOVAL Use special tools MD and MB to remove the crankshaft pulley from the crankshaft MD MB ACX00323AB

7 11A-32 ENGINE MECHANICAL <30L ENGINE> TIMING BELT CAMSHAFT SPROCKET (RIGHT BANK) TIMING MARK CAMSHAFT SPROCKET (LEFT BANK) TIMING MARK <<C>> TIMING BELT REMOVAL Never turn the crankshaft counterclockwise 1 Turn the crankshaft clockwise to align each timing mark and to set the number 1 cylinder to compression top dead center 2 If the timing belt is to be reused, chalk mark the flat side of the belt with an arrow indicating the clockwise direction 3 Loosen the center bolt of the tension pulley, and then remove the timing belt CENTER BOLT TENSION PULLEY CRANKSHAFT SPROCKET TIMING MARK ACX00332 AB A B AUTO-TENSIONER AMOUNT PUSHED IN PUSHROD ACX00306AB INSTALLATION SERVICE POINTS >>A<< AUTO-TENSIONER INSTALLATION 1 While holding the auto-tensioner by hand, press the end of the pushrod against a metal surface (such as the cylinder block) with a force of N m ( ft-lb) and measure how far the pushrod is pushed in Standard value: Within 1 mm (004 inch) A: Length when no force is applied B: Length when force is applied A B: Amount pushed in 2 If it is not within the standard value, replace the autotensioner

8 ENGINE MECHANICAL <30L ENGINE> 11A-33 TIMING BELT PLUG Place the auto-tensioner perpendicular to the jaws of the vice If there is a plug at the base of the auto-tensioner, insert a plain washer onto the end of the auto-tensioner to protect the plug 3 Place two dolly blocks in a vice as shown in the illustration, and then place the auto-tensioner in the vice PLAIN WASHER DOLLY BLOCKS ACX00333AB PIN HOLE A PIN HOLE B ACX00334AB Never compress the pushrod too fast, or the pushrod may be damaged 4 Slowly compress the pushrod of the auto-tensioner until pin hole A in the pushrod is aligned with pin hole B in the cylinder 5 Insert the setting pin into the pin holes once they are aligned NOTE: If replacing the auto-tensioner, the pin will already be inserted into the pin holes of the new part Do not remove the setting pin from the auto-tensioner 6 Install the auto-tensioner to the engine >>B<< TIMING BELT INSTALLATION The camshaft sprocket (right side) can turn easily due to the spring force applied, so be careful not to get your fingers caught 1 Align the timing marks of the camshaft sprocket with those of crankshaft sprocket 2 Install the timing belt by the following procedure so that there is no deflection in the timing belt between each sprocket and pulley (1) Crankshaft sprocket (2) Idler pulley (3) Camshaft sprocket (Left side) (4) Water pump pulley (5) Camshaft sprocket (Right side) (6) Tension pulley

9 11A-34 ENGINE MECHANICAL <30L ENGINE> TIMING BELT CAMSHAFT SPROCKET (RIGHT BANK) CAMSHAFT SPROCKET (LEFT BANK) 3 Turn the camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched Check all timing marks again TIMING MARK WATER PUMP PULLEY TIMING MARK CENTER BOLT IDLER PULLEY TENSION PULLEY CRANKSHAFT SPROCKET : BELT TENSION SIDE TIMING MARK ACX00332AC 4 Use special tool MD to push the tensioner pulley into the timing belt, and then temporarily tighten the center bolt MD ACX00335AB 5 Use special tool MD to turn the crankshaft 1/4 turn counterclockwise and then turn it again clockwise until the timing marks are aligned TIMING MARK MD ACX00336AB

10 ENGINE MECHANICAL <30L ENGINE> 11A-35 TIMING BELT 48 N m (35 ft-lb) MD CENTER BOLT PIN HOLES TENSION PULLEY TENSION TORQUE 44 N m (39 in-lb) ACX00337AB When tightening the center bolt, be careful that the tensioner pulley does not turn with the bolt 6 Loosen the center bolt of the tensioner pulley Use special tool MD and a torque wrench to apply the standard torque to the timing belt as shown in the illustration Then tighten the center bolt to the specified torque Standard value: 44 N m (39 in-lb) <Timing belt tension torque> Tightening torque: 48 N m (35 ft-lb) 7 Remove the setting pin that has been inserted into the autotensioner 8 Turn the crankshaft two turns clockwise to align the timing marks SETTING PIN ACX00339AB A 9 Wait for at least five minutes, and then check that the autotensioner pushrod extends within the standard value Standard value (A): mm ( inch) 10If no, repeat the operation in steps (5) to (9) above 11Check again that the timing marks of each sprocket are aligned ACX00339AB >>C<< CRANKSHAFT PULLEY INSTALLATION Use special tools MD and MB to install the crankshaft pulley MD MB ACX00323AB

11 11A-36 ENGINE MECHANICAL <30L ENGINE> SPECIFICATIONS PUSHROD INSPECTION AUTO-TENSIONER Check the auto-tensioner for possible leaks Check the pushrod for cracks M SPRING AUTO-TENSIONER ACX00340AB SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS ITEM Accessory mount assembly mounting bolt Accessory mount assembly mounting bolt (12 100) Baffle plate attaching bolt Camshaft position sensor Camshaft sprocket attaching bolt Camshaft thrust case attaching bolt Crankshaft position sensor attaching bolt Crankshaft pulley attaching bolt Crossmember assembly mounting nut Cylinder head bolt <cold engine> Drive plate bolt Engine mount insulator attaching bolt Engine mount insulator attaching nut Generator drive belt tension pulley fixing nut High-pressure fuel hose Oil dipstick assembly attaching bolt Oil pan attaching bolt Oil pan drain plug Oil screen attaching bolt (8 20) Oil screen attaching bolt Power steering oil pump drive belt cover attaching bolt Power steering oil pump mounting bolt Rocker arm and shaft assembly mounting bolt Rocker cover attaching bolt Timing belt auto-tensioner M SPECIFICATION 44 N m (33 ft-lb) 74 N m (54 ft-lb) N m ( in-lb) 88 N m (78 in-lb) 88 N m (65 ft-lb) 13 N m (115 in-lb) 88 N m (78 in-lb) 181 N m (134 ft-lb) 108 N m (80 ft-lb) 108 N m (80 ft-lb) 74 N m (54 ft-lb) 44 N m (33 ft-lb) 25 N m (18 ft-lb) 49 N m (36 ft-lb) 49 N m (43 in-lb) 48 N m (35 ft-lb) 88 N m (78 ft-lb) 39 N m (29 ft-lb) 19 N m (14 ft-lb) N m ( in-lb) 49 N m (43 in-lb) 24 N m (17 ft-lb) 32 N m (23 ft-lb) 34 N m (30 in-lb) 24 N m (17 ft-lb)

12 11C-24 ENGINE MECHANICAL <35L ENGINE> CRANKSHAFT FRONT OIL SEAL CRANKSHAFT FRONT OIL SEAL REMOVAL AND INSTALLATION M Pre-removal and Post-installation Operation Timing Belt Removal and Installation (Refer to P11C-30) 6 ENGINE OIL 2 88 N m 78 in-lb N REMOVAL STEPS >>B<< 1 CRANKSHAFT SPROCKET 2 CRANKSHAFT POSITION SENSOR >>B<< 3 CRANKSHAFT SENSING BLADE >>B<< 4 CRANKSHAFT SPACER ACX00362AB REMOVAL STEPS (Continued) 5 KEY >>A<< 6 CRANKSHAFT FRONT OIL SEAL Required Special Tool: MD998717: Crankshaft Front Oil Seal Installer INSTALLATION SERVICE POINTS CRANKSHAFT MD >>A<< CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the oil seal lip and then insert 2 Using special tool MD998717, tap the oil seal into the front case MD OIL SEAL ACX00363AB

13 ITEM Timing belt lower cover attaching bolt Timing belt lower cover attaching nut Timing belt tension arm assembly attaching bolt Timing belt tension pulley attaching bolt Timing belt upper cover attaching bolt (6 18) Timing belt upper cover attaching bolt Timing indicator bracket attaching bolt Transmission mounting bolt Water outlet pipe attaching bolt Water passage assembly attaching bolt Water pipe and hose assembly attaching bolt SERVICE SPECIFICATIONS ENGINE MECHANICAL <30L ENGINE> 11A-37 SPECIFICATIONS SPECIFICATION 11 N m (97 in-lb) 49 N m (43 in-lb) 44 N m (33 ft-lb) 48 N m (35 ft-lb) 11 N m (97 in-lb) 14 N m (124 in-lb) 11 N m (97 in-lb) 35 N m (26 ft-lb) 14 N m (124 in-lb) 19 N m (14 ft-lb) 14 N m (124 in-lb) M ITEM STANDARD VALUE LIMIT Basic ignition timing at idle 5 BTDC ± 3 Actual ignition timing at curb idle Approximately 10 BTDC CO contents % 05 or less HC contents ppm 100 or less Curb idle speed r/min 700 ± 100 Compression pressure ( r/min) kpa (psi) 1200 (171) Minimum 890 (127) Compression pressure difference of all cylinder kpa (psi) 98 (14) Intake manifold vacuum at curb idle kpa (in Hg) Minimum 60 (18) Timing belt tensioner torque N m (in-lb) 44 (39) Timing belt tensioner adjuster rod protrusion amount mm ( ) (in) Timing belt tensioner adjuster rod movement mm (in) Within 1 (0040) SEALANT ITEM Oil pan SPECIFIED SEALANT MITSUBISHI GENUINE Part No MD or equivalent M

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