Transcription
11D-1GROUP 11DENGINE OVERHAUL 2.4L ENGINE CONTENTSGENERAL SPECIFICATIONS . . . . . .11D-2SERVICE SPECIFICATIONS. . . . . . .11D-2REWORK DIMENSIONS . . . . . . . . . .11D-3TORQUE SPECIFICATIONS . . . . . . .11D-4SEALANTS . . . . . . . . . . . . . . . . . . . .11D-7SPECIAL TOOLS. . . . . . . . . . . . . . . .11D-8GENERATOR AND IGNITIONSYSTEM . . . . . . . . . . . . . . . . . . . . . . .11D-10REMOVAL AND INSTALLATION . . . . . . . .THROTTLE BODY AND EGRSYSTEM . . . . . . . . . . . . . . . . . . . . . . .REMOVAL AND INSTALLATION . . . . . . . .INTAKE MANIFOLD AND FUELSYSTEM . . . . . . . . . . . . . . . . . . . . . . .REMOVAL AND INSTALLATION . . . . . . . .EXHAUST MANIFOLD. . . . . . . . . . . .REMOVAL AND INSTALLATION . . . . . . . .WATER HOSE AND PIPE . . . . . . . . .REMOVAL AND INSTALLATION . . . . . . . .11D-1011D-1411D-14OIL PAN AND TIMING CHAINCASE. . . . . . . . . . . . . . . . . . . . . . . . . . 11D-25REMOVAL AND INSTALLATION . . . . . . . .11D-25TIMING CHAIN . . . . . . . . . . . . . . . . . . 11D-32REMOVAL AND INSTALLATION . . . . . . . .11D-32INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11D-37CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11D-41REMOVAL AND INSTALLATION . . . . . . . .11D-41INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11D-44CYLINDER HEAD AND VALVES. . . . 11D-47REMOVAL AND INSTALLATION . . . . . . . .11D-47INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11D-51BALANCER CHAIN . . . . . . . . . . . . . . 11D-55REMOVAL AND INSTALLATION . . . . . . . .11D-55PISTON AND CONNECTING ROD . . 11D-6311D-1611D-1611D-2011D-2011D-2311D-23REMOVAL AND INSTALLATION . . . . . . . .11D-63INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11D-70CRANKSHAFT AND CYLINDERBLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11D-72REMOVAL AND INSTALLATION . . . . . . . .11D-72INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11D-77
11D-2ENGINE OVERHAUL 2.4L ENGINE GENERAL SPECIFICATIONSGENERAL SPECIFICATIONSItemSpecificationsEngine model4B12TypeIn-line OHV, DOHCNumber of cylinders4Combustion chamberPentroof typeTotal displacement cm3 (cu in)2,360 (144.0)Cylinder bore mm (in)88 (3.5)Piston stroke mm (in)97 (3.8)Compression ratio10.5Valve timingIntake valveExhaust valveOpen0 BTDC 40 BTDCClose64 ABDC 24 ABDCOpen44 BBDC 24 BBDCClose0 ATDC 20 ATDCAuto lash adjusterM1113000202593Non-equippedSERVICE SPECIFICATIONSItemM1113000302824Standard valueLimitIntake0.20 0.03 (0.008 0.001) Exhaust0.30 0.03 (0.012 0.001) 44.1 (1.74)43.6 (1.72)45.0 (1.77)44.5 (1.75)0 0.032 (0.013) Distortion of cylinder head bottom mm (in)Within 0.05 (0.002)0.2 (0.008)Grinding limit of cylinder head bottom mm (in) 0.2 (0.008)Overall height of cylinder head mm (in)128.5 (5.06) Overall length of valve mm (in)Intake113.18 (4.456)112.68 (4.436)Exhaust105.89 (4.169)105.39 (4.149)Intake1.022 (0.0402)0.522 (0.0206)Exhaust1.094 (0.0431)0.594 (0.0234)Free height of valve spring mm (in)47.2 (1.858) Squareness of valve spring2 or less4 Timing chainValve clearance mm (in)CamshaftCam height of camshaft mm (in) IntakeExhaustCamshaft oil clearance mm (in)Cylinder head and valvesValve margin mm (in)TSB Revision
11D-3ENGINE OVERHAUL 2.4L ENGINE REWORK DIMENSIONSItemClearance between valve guideand valve stem mm (in)Standard valueLimitIntake0.020 0.047 (0.0008 0.0019)0.10 (0.0039)Exhaust0.030 0.054 (0.0012 0.0021)0.11 (0.0043)1.16 1.46 (0.046 0.058) 1.35 1.65 (0.053 0.065) 14.6 15.2 (0.57 0.60) 7,500 17,500 (1.686 3.934) Valve seat contact width mm (in) IntakeExhaustValve guide press-in height mm (in)Piston and connecting rodPiston pin press-fit load N (lbf)Clearance between piston ringand ring groove mm (in)Number 10.03 0.07 (0.001 0.003)0.1 (0.004)Number 20.03 0.07 (0.001 0.003)0.1 (0.004)Piston ring end gap mm (in)Number 10.15 0.25 (0.006 0.011)0.8 (0.03)Number 20.25 0.40 (0.010 0.016)0.8 (0.03)Oil0.10 0.35 (0.004 0.014)1.0 (0.04)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 boltmm (in) 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 blockUnderhead length of crankshaft bearing cap bolt mm 75.5 76.5 (2.972 3.012)(in) Crankshaft end play mm (in)0.05 0.25 (0.002 0.010)0.4 (0.016)Crankshaft journal oil clearance mm (in)0.012 0.030 (0.0005 0.0012)0.08 (0.0031)Distortion of cylinder block top surface mm (in) 0.05 (0.0020)Grinding limit of cylinder block top surface mm (in) 0.2 (0.008)Cylinder block cylinder bore mm (in)88 (3.46) Cylindricity of cylinder block mm (in)0.0076 (0.0003) REWORK DIMENSIONSItemM1113024300930Standard valueCylinder head and valveCylinder head oversize valve seat bore diameter mm (in)Cylinder head oversize valve guide bore diameter mm (in)TSB RevisionIntake0.30 Oversize36.22 36.24(1.426 1.427)Exhaust0.30 Oversize30.22 30.24(1.190 1.191)0.25 Oversize11.23 11.25(0.442 0.443)
11D-4ENGINE OVERHAUL 2.4L ENGINE TORQUE SPECIFICATIONSTORQUE ator and ignition systemIdler pulley bolt48 7 N m (36 4 ft-lb)Auto tensioner bolt22 4 N m (17 2 ft-lb)Crankshaft pulley center bolt210 N m (155 ft-lb)Generator nut44 10 N m (32 7 ft-lb)Generator bolt44 10 N m (32 7 ft-lb)Ignition coil bolt10 2 N m (89 17 in-lb)Spark plug25 5 N m (18 4 ft-lb)Power steering pump bracket bolt (M8)23 2 N m (17 1 ft-lb)Power steering pump bracket bolt (M10)44 8 N m (33 5 ft-lb)Throttle body and EGR systemVacuum pipe and hose bolt11 1 N m (98 8 in-lb)Throttle body bolt9.5 2.5 N m (84 22 in-lb)Throttle body stay bolt20 2 N m (15 1 ft-lb)EGR valve support bolt20 2 N m (15 1 ft-lb)EGR pipe bolt20 2 N m (15 1 ft-lb)EGR support stay A bolt20 2 N m (15 1 ft-lb)EGR support stay B bolt20 2 N m (15 1 ft-lb)EGR valve bolt24 3 N m (18 1 ft-lb)Manifold absolute pressure (MAP) sensor screw4.0 1.0 N m (36 8 in-lb)Purge solenoid valve screw4.0 1.0 N m (36 8 in-lb)Intake manifold and fuel systemOil dipstick guide bolt10 2 N m (89 17 in-lb)Injector protector rear bolt3.5 1.5 N m (31 13 in-lb) 20 2 N m(15 1 ft-lb)Fuel rail bolt3.5 1.5 N m (31 13 in-lb) 20 2 N m(15 1 ft-lb)Intake manifold bolt and nut3.5 1.5 N m (31 13 in-lb) 20 2 N m(15 1 ft-lb)Intake manifold stay bolt20 2 N m (15 1 ft-lb)Injector protector front bolt3.5 1.5 N m (31 13 in-lb) 20 2 N m(15 1 ft-lb)Generator bracket bolt44 8 N m (33 5 ft-lb)Knock sensor bolt20 2 N m (15 1 ft-lb)Engine oil pressure switch10 2 N m (89 17 in-lb)Exhaust manifoldExhaust manifold upper cover bolt Except vehicles forCalifornia 14 1 N m (124 8 in-lb)Exhaust manifold upper cover bolt Vehicles for California 8 2 N m (71 17 in-lb)TSB Revision
ENGINE OVERHAUL 2.4L ENGINE TORQUE SPECIFICATIONSItemSpecificationExhaust manifold lower cover bolt Except vehicles forCalifornia 14 1 N m (124 8 in-lb)Exhaust manifold lower cover bolt Vehicles for California 8 2 N m (71 17 in-lb)Exhaust manifold nut49 5 N m (36 3 ft-lb)Exhaust manifold bracket bolt (M8) Except vehicles forCalifornia 20 5 N m (15 3 ft-lb)Exhaust manifold bracket bolt (M10) Except vehicles forCalifornia 41 10 N m (30 7 ft-lb)Exhaust manifold bracket bolt Vehicles for California 41 10 N m (30 7 ft-lb)Crankshaft position sensor bolt11 1 N m (98 8 in-lb)Crankshaft position sensor cover bolt (M6)11 1 N m (98 8 in-lb)11D-5Water hose and pipeWater inlet fitting bolt24 3 N m (18 1 ft-lb)Water outlet fitting bolt24 3 N m (18 1 ft-lb)Thermostat housing bolt24 3 N m (18 1 ft-lb)Engine hanger bolt28 8 N m (21 5 ft-lb)Engine coolant temperature sensor30 9 N m (22 6 ft-lb)Water pump bolt24 3 N m (18 1 ft-lb)Water pipe nut24 3 N m (18 1 ft-lb)Camshaft position sensor bolt11 1 N m (98 8 in-lb)Oil pan and timing chain caseCylinder head cover bolt3.0 1.0 N m (27 8 in-lb) 5.5 0.5N m (49 4 in-lb)Timing chain case bolt (M6)10 2 N m (89 17 in-lb)Timing chain case bolt (M8 10)13 1 N m (115 8 in-lb)Timing chain case bolt (M8 28)24 4 N m (18 2 ft-lb)Oil pan bolt (M6)10 2 N m (89 17 in-lb)Oil pan bolt (M8)29 2 N m (21 1 ft-lb)Air compressor bracket bolt23 6 N m (17 4 ft-lb)Oil drain plug39 5 N m (29 3 ft-lb)Oil filter14 2 N m (124 17 in-lb)Positive Crankcase Ventilation Valve2.5 0.4 N m (22 3 in-lb)Engine support bracket bolt (M10)45 5 N m (33 3 ft-lb)Engine support bracket bolt (M8)23 2 N m (17 1 ft-lb)Timing chainChain upper guide bolt10 2 N m (89 17 in-lb)Oil jet bolt10 2 N m (89 17 in-lb)V.V.T. intake sprocket bolt59 5 N m (44 3 ft-lb)V.V.T. exhaust sprocket bolt59 5 N m (44 3 ft-lb)Timing chain tensioner bolt10 2 N m (89 17 in-lb)Tensioner lever bolt10 2 N m (89 17 in-lb)TSB Revision
11D-6ENGINE OVERHAUL 2.4L ENGINE TORQUE SPECIFICATIONSItemSpecificationTiming chain guide bolt10 2 N m (89 17 in-lb)CamshaftEngine oil control valve (OCV) bolt10 2 N m (89 17 in-lb)Camshaft bearing cap bolt (M6)12 1 N m (107 8 in-lb)Front camshaft bearing cap bolt (M8)17 3 N m (14 2 ft-lb) 30 2 N m (22 1 ft-lb)Cylinder head and valvesCylinder head bolt35 2 N m (26 1 ft-lb) 90 90 Balancer chainDrive plate bolt40 N m (30 ft-lb) 130 N m (96 ft-lb)Flywheel bolt40 N m (30 ft-lb) 130 N m (96 ft-lb)Balancer shaft module bolt20 (15 ft-lb) 44 (32 ft-lb) 0 20 (15 ft-lb) 135 Balancer shaft chain tensioner bolt10 2 N m (89 17 in-lb)Lever tensioner bolt10 2 N m (89 17 in-lb)Balancer shaft chain guide bolt10 2 N m (89 17 in-lb)Ladder frame bolt26 1 N m (19 1 ft-lb)Piston and connecting rodConnecting rod cap bolt5.0 N m (44 in-lb) 20 N m (15 ft-lb) 90 Crankshaft and cylinder blockCrankshaft sensing ring bolt11 1 N m (98 8 in-lb)Bearing cap bolt26.5 2.0 N m (20 1 ft-lb) 45 NEW TIGHTENING METHOD BY USINGPLASTIC REGION TIGHTENING BOLT.Plastic region tightening bolts are used in some partsof the engine. Install these bolts according to themethod described in the relevant section becausethe tightening method of these bolts are differentfrom the conventional method. The service limit isdetermined for these bolts. Be sure to strictly followthe service limit described in the body of the manual. Parts to be usedTSB Revision1. Cylinder head bolt2. Bearing cap bolt3. Connecting rod cap bolt Tightening methodAfter tightening to the specified tightening torque,further tighten 90 and 90 , or 180 (90 90 ).Follow the tightening method described in thebody of the manual because the tighteningmethod differs from part to part.
11D-7ENGINE OVERHAUL 2.4L ENGINE SEALANTSSEALANTSPoints of applicationSpecified sealant / adhesiveDrive plate boltThree bond 1324 or equivalentM1113000503122Flywheel boltOil panThree bond 1227D, Three bond 1217G (Mitsubishi PartNo.1000A923), Three bond 1207F (Mitsubishi Part No.1000A992),LOCTITE 5971, LOCTITE 5970, LOCTITE 5900 or equivalentLadder frameCylinder head cover (matching area of Three bond 1227D, Three bond 1217G(Mitsubishi Partthe cylinder head and the timing chain No.1000A923) or equivalentcase assembly)Three bond 1227D, Three bond 1217G(Mitsubishi Genuine Tool number and name 1000A923) orequivalentCylinder head gasket (matching areaof the cylinder block and the cylinderhead)Three bond 1217G(Mitsubishi Part No.1000A923) or exactequivalentTiming chain caseEngine coolant temperature sensorThree bond 1324N, LOCTITE 262 or equivalentEngine oil pressure switchThree bond 1212D, Three bond 1215 or equivalentNOTE: The number in square brackets shows thegenuine part number.FORM-IN-PLACE GASKET (FIPG)The engine has several parts to which theform-in-place gasket (FIPG) is used. To sufficientlyachieve the aims of this gasket, it is necessary to payattention to the application amount, procedure, andsurface status.If the application amount is too small, a leakage willoccur. If the application amount is excessive, theFIPG will overflow and cause a clogging or narrowingof water and oil paths. Therefore, to eliminate theleak from the joint, it is indispensable that the FIPGbe applied with a correct amount and without anygap.Because the FIPG used for the engine partsbecomes hardened by the reaction with the atmospheric moisture, it is normally used for the metalflange section.CAUTIONReapply the FIPG with care to the followings.1. Completely remove the old FIPG including theresidue in gaps of parts.2. Using Mitsubishi genuine parts cleaner(MZ100387) or equivalent, degrease the FIPGapplication surface carefully.3. According to the FIPG application procedures, apply it accurately.TSB Revision.DISASSEMBLYThe parts installed with the FIPG can be disassembled easily without using any special method. However, in some cases, it is necessary to tear thesealant in between the mating surfaces by tappingthe parts with a wooden hammer or similar tools. It isacceptable to lightly hit in a smooth, thin gasketscraper into the mating surface, but, in this case, asufficient caution is required not to damage the mating surface. The oil pan FIPG cutter (Special tool:MD998727) is provided. Thus, use this special tool.GASKET SURFACE CLEANINGUse a gasket scraper or wire brush to completelyremove all the foreign materials adhering to the gasket surface. Check that the FIPG application surfaceis smooth. There must be no grease or foreign material adhesion to the gasket surface. Do not forget toremove the old FIPG remaining in the mounting holeand tapped hole.APPLICATION PROCEDUREApply the FIPG with a specified diameter and withoutany gap. Completely enclose around the mountinghole. When the FIPG is not hardened, it can bewiped off. When the FIPG is still moistened, performthe installation to the specified position. At the time ofinstallation, prevent the FIPG from adhering to locations other than it is necessary. After the installation,
11D-8ENGINE OVERHAUL 2.4L ENGINE SPECIAL TOOLSuntil a sufficient period of time (approximately for tone hours) elapses, do not contact the oil or water tothe application area. Also, do not start the engine.Because the FIPG application procedure may differdepending on the application area, apply the FIPGaccording to the procedure described in the text.SPECIAL TOOLSToolM1113000603055Tool numberand nameSupersessionApplicationMB991883Flywheelstopper Securing of drive plate or flywheelMB991398Spark plugwrench Removal and installation of sparkplugMB992106O-ring installer Installation of O-ring on injectorinjection nozzle sideMB991883B992106MB991396 Oil filter wrenchRemoval and installation of oilfilterMD998727Oil pan FIPGcutterMD998727-01Removal of oil panMB991448Bushingremover andinstaller baseMB991448-01Press fit of front oil sealB991396D998727TSB Revision
ENGINE OVERHAUL 2.4L ENGINE SPECIAL TOOLSTool11D-9Tool numberand nameSupersessionApplicationMD998735Valve springcompressorMD998735-01Compression of valve springMB992089MB992089-01Retainer holderCMB992085 Valve stem sealpliersExtraction of valve stem sealMD998737MD998737-01Valve stem sealinstallerInstallation of valve stem sealMD998780Piston pinsetting toolMIT216941Extraction and press fit of pistonpinMB991659Guide D MB991614Angle gaugeGeneral service toolInstallation of crankshaft bearingcap bolt and installation ofbalancer shaft module boltMD998718Rear oil sealinstallerMD998718-01Press fit of rear oil sealMB991614TSB Revision
11D-10ENGINE OVERHAUL 2.4L ENGINE GENERATOR AND IGNITION SYSTEMGENERATOR AND IGNITION SYSTEMREMOVAL AND INSTALLATIONM111300100217210 2 N·m89 17 in-lb925 5 N·m18 4 ft-lb1023 2 N·m17 1 ft-lb44 8 N·m33 5 ft-lb54848 7 N·m36 4 ft-lb22 4 N·m17 2 ft-lb17648 7 N·m36 4 ft-lb244 10 N·m32 7 ft-lb44 10 N·m32 7 ft-lb210 N·m155 ft-lb3AK802145 AB C C 1.2.3.4.5.Removal stepsIdler pulleyIdler pulleyGeneratorPower steering pump bracketAuto tensionerRequired Special Tool: MB991883: Flywheel Stopper MB991398: Spark plug wrenchTSB Revision A B B B B A 6.7.8.9.10.Removal steps (Continued)Crankshaft pulley center boltCrankshaft pulley washerCrankshaft pulleyIgnition coilSpark plug
ENGINE OVERHAUL 2.4L ENGINE GENERATOR AND IGNITION SYSTEM11D-11REMOVAL SERVICE POINTS. A CRANKSHAFT PULLEY CENTER BOLTREMOVAL1. Use special tool MB991883, to secure the drive plate.2. Remove the crankshaft pulley center bolt.MB991883AK502869 AD. B SPARK PLUG REMOVALUsing special tool MB991398, removal the spark plug.MB991398Spark plugAK600875ABINSTALLATION SERVICE POINTS. A SPARK PLUG INSTALLATIONUse special tool MB991398, tighten the spark plug to specifiedtightening torque.Tightening torque: 25 5 N m (18 4 ft-lb)MB991398Spark plugAK600875AB.TSB Revision
11D-12ENGINE OVERHAUL 2.4L ENGINE GENERATOR AND IGNITION SYSTEM B CRANKSHAFT PULLEY / CRANKSHAFTPULLEY WASHER / CRANKSHAFT PULLEYCENTER BOLT INSTALLATION1. Use special tool MB991883, to secure the drive plate.MB991883AK503335 AD: Wipe clean with a rag.: Wipe clean with a rag and degrease.: Wipe clean with a rag, degrease andapply a small amount of engine oil.WasherCrankshaftpulley boltCrankshaftsprocketCrankshaftCrankshaft pulleyEngine front2. Wipe the dirt on the crankshaft pulley washer and on thethread hole of the crankshaft using a rag.3. Wipe the dirt on the crankshaft pulley and the crankshaftsprocket using a rag, and then remove the grease from theportion shown in the illustration.NOTE: Remove grease to prevent the coefficient of frictionof the pressing portion from declining due to adhesion of oil.4. Install the crankshaft pulley.5. Apply an appropriate and minimum amount of engine oil tothe threaded portion of the crankshaft and lower part of theflange.6. With the chamfered side on the inside of the crankshaftpulley washer facing the bolt top, install the crankshaft pulleywasher to the crankshaft pulley center bolt.7. Tighten the crankshaft pulley center bolt to the specifiedtightening torque.Tightening torque: 210 N m (155 ft-lb)AK602911AD.TSB Revision
ENGINE OVERHAUL 2.4L ENGINE GENERATOR AND IGNITION SYSTEM11D-13 C GENERATOR / POWER STEERING PUMPBRACKET INSTALLATIONPower steeringpump bracket1Generator54280 mm(3.15 in)380 mm(3.15 in)1. Temporarily tighten power steering pump bracket bolts.CAUTIONAlways loosen the power steering pump bracket bolt, andtemporarily the alternator. Then tighten each bolt.2. Loosen the power steering pump bracket bolt and make thepower steering pump bracket unfixed.3. Temporarily tighten alternator bolts.4. Tighten them to the specified tightening torque according tothe order as illustrated.Tightening torquePower steering pump bracket:M8: 23 2 N m (17 1 ft-lb)M10: 44 8 N m (33 5 ft-lb)Generator: 44 10 N m (32 7 ft-lb)AK503383AGTSB Revision
11D-14ENGINE OVERHAUL 2.4L ENGINE THROTTLE BODY AND EGR SYSTEMTHROTTLE BODY AND EGR SYSTEMREMOVAL AND INSTALLATIONM111303270040511 1 N·m98 8 in-lb111 1 N·m98 8 in-lb439.5 2.5 N·m84 22 in-lb6220 2 N·m15 1 ft-lb71220 2 N·m15 1 ft-lb81316141120 2 N·m15 1 ft-lb24 3 N·m18 1 ft-lb189101720 2 N·m15 1 ft-lb20191520 2 N·m15 1 ft-lb54.0 1.0 N·m36 8 in-lb22 214.0 1.0 N·m36 8 in-lbAK900341AD D D C C B 1.2.3.4.5.6.7.8.9.10.11.12.Removal stepsVacuum pipe and hosePurge hoseChamberPurge hoseWater hoseThrottle body stayThrottle bodyThrottle body gasketExhaust gas recirculation valveEGR valve gasketEGR pipeEGR pipe gasketTSB Revision B 13.14.15.16. B 17.18.19.20. A 21.22.Removal steps (Continued)EGR valve support gasketEGR support stay AEGR support stay BExhaust gas recirculation valvesupportEGR inlet pipe gasketEGR inlet pipePurge solenoid valveO-ringManifold absolute pressure (MAP)sensorO-ring
ENGINE OVERHAUL 2.4L ENGINE THROTTLE BODY AND EGR SYSTEM11D-15INSTALLATION SERVICE POINTS. A MANIFOLD ABSOLUTE PRESSURE (MAP)SENSOR INSTALLATIONCAUTION Install the manifold absolute pressure (MAP) sensor,taking care not to give a shock to it. Do not use a manifold absolute pressure (MAP) sensorthat has fallen down. B EGR INLET PIPE GASKET / EGR VALVESUPPORT GASKET / EGR PIPE GASKETINSTALLATIONTemporarily tighten each part so that the protrusion of eachgasket is positioned as illustrated.ProtrusionEGR valveEGR inlet pipeEGR valve pipeProtrusionAK503321ACProtrusionAK503320AC. C EXHAUST GAS RECIRCULATION VALVE /EXHAUST GAS RECIRCULATION VALVE GASKETINSTALLATIONInstall the Exhaust gas recirculation valve gasket with the diagonally shaded area used as the illustrated position so as not toconfuse the front with the back.EGR valveShaded positionAK503319AD.TSB Revision
11D-16ENGINE OVERHAUL 2.4L ENGINE INTAKE MANIFOLD AND FUEL SYSTEM D THROTTLE BODY GASKET / THROTTLEBODY INSTALLATIONB1. Make sure that the throttle body gasket is placed beforeinstalling the throttle body.2. Temporarily tighten throttle body and throttle body staymounting bolts at A and B in the illustration.3. Tighten the throttle body mounting bolt at illustrated positionA to the specified torque.Tightening torque: 20 2 N m (15 1 ft-lb)BBBAAK503290AC4. Tighten the throttle body mounting bolts at illustratedposition B to the specified tightening torque.Tightening torque: 9.5 2.5 N m (84 22 in-lb)INTAKE MANIFOLD AND FUEL SYSTEMREMOVAL AND INSTALLATIONM11130325008103.5 1.5 N·m 20 2 N·m31 13 in-lb15 1 ft-lb6111892716173510 2 N·m89 17 in-lb1043.5 1.5 N·m31 13 in-lb20 2 N·m 15 1 ft-lb3.5 1.5 N·m 20 2 N·m31 13 in-lb15 1 ft-lb15143.5 1.5 N·m 20 2 N·m31 13 in-lb15 1 ft-lb3.5 1.5 N·m 20 2 N·m31 13 in-lb15 1 ft-lb133.5 1.5 N·m 20 2 N·m31 13 in-lb15 1 ft-lb20 2 N·m15 1 ft-lb10 2 N·m2089 17 in-lb191244 8 N·m33 5 ft-lb20 2 N·m15 1 ft-lb18AK802146ABRemoval steps1. Oil dipstick rod2. O-ring H H H TSB RevisionRemoval steps (Continued)3. Injector protector rear4. Bracket5. Bracket
ENGINE OVERHAUL 2.4L ENGINE INTAKE MANIFOLD AND FUEL SYSTEM11D-17Removal steps (Continued) H 6. Fuel rail assembly G 7. Injection support8. O-ring G 9. Injector F 10.O-ring E D C B A 11. Fuel rail12.Intake manifold stay13.Injector protector front14.Intake manifold15.Intake manifold gasket16.Oil dipstick guide17.O-ring18.Generator bracket19.Knock sensor20.Engine oil pressure switchRequired Special Tool: MB992106: O-ring installerINSTALLATION SERVICE POINTS. A ENGINE OIL PRESSURE SWITCH INSTALLATION 1 mm (0.004 inch)5 mm (0.020 inch)1.2.AK600888AECAUTIONDo not allow sealant to squeeze out to the screw tip.Do not tighten, exceeding the specified tighteningtorque.Completely remove sealant adhering to the oil pressureswitch and cylinder block threaded holes.Apply sealant of 5 mm to the threaded portion of the oilpressure switch shown in the illustration.Specified sealant:Three bond 1212D, Three bond 1215 or equivalent3. Tighten the oil pressure switch to the cylinder block to thespecified tightening torque.Tightening torque: 10 2 N m (89 17 in-lb). B KNOCK SENSOR INSTALLATIONAlign the knock sensor connector with the position shown in theillustration, and then tighten it to the specified torque.Tightening torque: 20 2 N m (15 1 ft-lb)Knock sensor45 AC807670 AC.TSB Revision
11D-18ENGINE OVERHAUL 2.4L ENGINE INTAKE MANIFOLD AND FUEL SYSTEM C GENERATOR BRACKET INSTALLATIONBAABTighten the Generator bracket to the specified tighteningtorque.Tightening torque: 44 8 N m (33 5 ft-lb)NOTE: Be careful to install mounting bolts because they aredifferent in length.A:M10 40 mm (1.6 in)B:M10 35 mm (1.4 in)BAAAK503595AC. D INTAKE MANIFOLD INSTALLATIONCAUTIONTemporarily tighten the intake manifold because there is abolt tightening procedure for the intake manifold, deliverypipe and injector protector.1. Tighten each intake manifold bolt and nut to the temporarilytorque.Temporarily torque: 3.5 1.5 N m (31 13 in-lb)2. Then tighten the intake manifold bolt and nut to specifiedtorque.Tightening torque: 20 2 N m (15 1 ft-lb). E INTAKE MANIFOLD STAY INSTALLATIONMake sure that the intake manifold stay is in intimate contactwith the intake manifold and cylinder block boss before tightening it to the specified tightening torque.Tightening torque: 20 2 N m (15 1 ft-lb)AK502727AC. F O-RING INSTALLATION1. Apply gasoline to the O-ring.2. When inserting an O-ring into the injector on the injectionnozzle side, use special tool MB992106 to gradually expandthe O-ring, and fit it in place.O-ringMB992106AK600790 AC.TSB Revision
ENGINE OVERHAUL 2.4L ENGINE INTAKE MANIFOLD AND FUEL SYSTEM11D-19 G INJECTOR AND INJECTOR SUPPORTINSTALLATIONCAUTIONDo not allow gasoline to enter the delivery pipe.1. Apply gasoline to the O-ring of the injector.2. Insert the injector into the delivery pipe while rotating theinjector from side to side, taking care not to damage theO-ring.3. Check that the injector rotates smoothly. If it does not rotatesmoothly, the O-ring may be caught. Remove the injectorand check the O-ring for damage. Then, insert it again intothe delivery pipe and check.4. Make sure that the protrusion of the injector is at the centeras shown in the illustration.AK5027445. Securely assemble the injector to the injector groove anddelivery pipe collar.AK800066. H FUEL RAIL ASSEMBLY / BRACKET /INJECTOR PROTECTOR REAR INSTALLATION1. Install the delivery pipe assembly, bracket and injectorprotector rear on the cylinder head.Temporarily torque: 3.5 1.5 N m (31 13 in-lb)6874952311110AK700818AC2. Tighten mounting bolts together with temporarily tightenedintake manifold mounting bolts in the order shown in theillustration.3. Tighten the delivery pipe assembly, bracket, injectorprotector rear and intake manifold in the order shown in theillustration.Tightening torque: 20 2 N m (15 1 ft-lb)TSB Revision
11D-20ENGINE OVERHAUL 2.4L ENGINE EXHAUST MANIFOLDEXHAUST MANIFOLDREMOVAL AND INSTALLATIONM1113011900738 Except vehicles for California 14 1 N·m124 8 in-lb7811 1 N·m98 8 in-lb5649 5 N·m36 3 ft-lb1041 10 N·m30 17 ft-lb20 5 N·m15 3 ft-lb1914 1 N·m124 8 in-lb211 1 N·m98 8 in-lb441 10 N·m30 17 ft-lb341 10 N·m30 17 ft-lbAK802147AB C C B 1.2.3.4.5.Removal stepsExhaust manifold bracket DExhaust manifold bracket BCrankshaft position sensor coverExhaust manifold bracket ACrankshaft position sensorTSB Revision B A Removal steps (Continued)6. O-ring7. Exhaust manifold upper cover8. Exhaust manifold9. Exhaust manifold gasket10.Exhaust manifold lower cover
11D-21ENGINE OVERHAUL 2.4L ENGINE EXHAUST MANIFOLD Vehicles for California 8 2 N·m71 17 in-lb5611 1 N·m98 8 in-lb3449 5 N·m36 3 ft-lb8 2 N·m71 17 in-lb788 2 N·m71 17 in-lb8 2 N·m71 17 in-lb11 1 N·m98 8 in-lb1241 10 N·m30 17 ft-lb41 10 N·m30 17 ft-lbAK802142 AB B B 1.2.3.4.Removal stepsExhaust manifold bracketCrankshaft position sensor coverCrankshaft position sensorO-ringTSB Revision A 5.6.7.8.Removal steps (Continued)Exhaust manifold upper coverExhaust manifoldExhaust manifold gasketExhaust manifold lower cover
11D-22ENGINE OVERHAUL 2.4L ENGINE EXHAUST MANIFOLDINSTALLATION SERVICE POINTS. A EXHAUST MANIFOLD GASKET INSTALLATIONCAUTIONThe exhaust manifold gasket, washers and nuts must notbe reused. B CRANKSHAFT POSITION SENSOR /O-RING INSTALLATIONCAUTION Do not apply a force such as torsion or twist to theO-ring during assembly of the sensor. Assemble the sensor, taking care not to give a shock toit. 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-lb). C EXHAUST MANIFOLD BRACKETINSTALLATIONCrank angle sensorcoverExhaust manifoldbracket BExhaust manifoldbracket AMake sure that exhaust manifold bracket A is in intimate contact with the exhaust manifold and cylinder block, and thentighten it to the specified tightening torque.Tightening torque:M10: 41 10 N m (30 7 ft-lb)M8: 20 5 N m (15 3 ft-lb)Exhaust manifoldbracket DAK603560AHTSB Revision
11D-23ENGINE OVERHAUL 2.4L ENGINE WATER HOSE AND PIPEWATER HOSE AND PIPEREMOVAL AND INSTALLATIONM111303290047624 3 N·m18 1 ft-lb10111230 9 N·m22 6 ft-lb424 3 N·m18 1 ft-lb5328 8 N·m21 5 ft-lb1516124 3 N·m18 1 ft-lb71724 3 N·m18 1 ft-lb624 3 N·m18 1 ft-lb11 1 N·m98 8 in-lb919821811 1 N·m98 8 in-lb1314AK802148 AB C B A A Removal steps1. Water hose2. Water hose3. Engine coolant temperature sensor4. Water outlet fitting5. Outlet fitting gasket6. Water inlet fitting7. Thermostat8. Thermostat housing9. Thermostat housing gasket10.Water pipe assemblyTSB RevisionRemoval steps (Continued)11. Water pipe gasket12.O-ring13.Water pump assembly14.Water pump gasket15.Engine hanger16.Camshaft position sensor17.O-ring18.Camshaft position sensor19.O-ring
11D-24ENGINE OVERHAUL 2.4L ENGINE WATER HOSE AND PIPEINSTALLATION SERVICE POINTS. A THERMOSTAT HOUSING / WATER PIPEASSEMBLY INSTALLATIONAssemble the thermostat housing and water pipe, and temporarily tighten them to the cylinder head and water pump. Thentighten them to the specified tightening.Tightening torque: 24 3 N m (18 1 ft-lb). B THERMOSTAT INSTALLATIONInstall the thermostat with the jiggle-valve facing almost straightupwards.Jiggle valveAK304916 AC. C ENGINE COOLANT TEMPERATURESENSOR INSTALLATIONCAUTIONBe careful not to give a shock, twist and the like to theresin mold with a tool during installation.1. Apply an appropriate and minimum amount of sealant to thecoolant temperature sensor, taking care not to allow sealantto squeeze out.Specified sealant:Three bond 1324N, LOCTITE 262 or equivalent2. Tighten the coolant temperature sensor to the cylinder blockto the spe
size 11.23 11.25 (0.442 0.443) TORQUE SPECIFICATIONS TSB Revision 11D-4 ENGINE OVERHAUL 2.4L ENGINE TORQUE SPECIFICATIONS M1113023403892 Item Specification Generator and ignition system Idler pulley bolt 48 7 N m (36
