Details of installation of balance shafts on 2.0 l and 2.4 l engines
1 - Oil filter; 2 - Oil cooler bolt *3; 3 - Oil cooler *3; 4 - Drain plug; 5 - Sealing washer; 6 - Oil pan; 7 - Oil intake; 8 - Sealing gasket; 9 - Flange nut; 10 - Oil pump gear *2; 11 - Cork; 12 - Sealing ring; 13 - Flange bolt; 14 - Oil filter support bracket; 15 - Support bracket sealing gasket; 16 - Front cover; 17 - Sealing gasket; 18 - Left balance shaft *2; 19 - Right balance shaft *; 20 - Front balance shaft bearing *2; 21 - Left balance shaft rear bearing; 22 - Right balance shaft rear bearing *2
Notes:
*1 DOHC
*2 Engines with balance shafts
*3 Dali turbocharged
*4 Engines without balance shafts
*5 Engines with air-type oil cooler
Engines 2.0 l and 2.4 l
To perform this procedure, you will need a special seal mandrel MD998285, as well as a device MD998162 for removing the plug from the front engine cover.
Removal
1. The installation details of the balance shafts on 2.0L and 2.4L engines are shown in the illustration.
2. Disconnect the negative cable from the battery.
If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
3. Jack up the car and place it on supports.
4. Drain the engine oil.
5. Remove the oil filter, oil pressure switch, oil gauge sensor, support bracket and oil filter gasket.
6. Remove the oil pan, oil pickup and sealing gasket.
7. Unscrew the plug and remove the components of the oil pump pressure relief valve (do not forget to remove the sealing washer).
8. Lower the car to the ground.
9. Suspend the engine on a winch.
10. Remove the front powertrain suspension support bracket and the accessory drive belt.
11. Remove the timing belts and timing/balance shaft drive wheels.
12. Using special tool MD998162, remove the plug from the front engine cover.
13. Remove the plug from the side wall of the block and, inserting a Phillips screwdriver with an 8 mm diameter blade into the opened hole, lock the balancing shaft with it.
14. Unscrew the bolt securing the driven gear of the oil pump to the balance shaft.
15. Unscrew and mark the front cover mounting bolts - the bolts are of different lengths and must be screwed in strictly in their original places during installation.
16. Remove the front cover of the oil pump housing.
If necessary, the balancing shaft can be removed together with the cover.
17. Remove the balance shaft and crankshaft oil seals and the front cover gasket.
18. Remove the balance shafts and assess their wear. Check the oil flow of the shaft, check the condition of the bearing journals. Measure the values of the working clearances in the bearings and compare the measurement results with the requirements of the Specifications (front bearing of the right shaft: 0.03÷0.06 mm, rear bearing of the right shaft: 0.02÷0.05 mm); front bearing of the left shaft: 0.05÷0.09 mm, rear bearing of the left shaft: 0.04÷0.08 mm). If necessary, replace the corresponding bearings, shaft or front cover.
Installation
1. Lubricate the bearing surfaces and bearing journals of the shafts with clean engine oil. Carefully insert the balance shafts into the engine block.
2. Thoroughly clean the mating surfaces of the block and the front engine cover, finally wiping them with a rag soaked in acetone. Install a new sealing gasket.
3. After ensuring that the alignment marks are correctly aligned, install the drive and driven gears into the oil pump front casing assembly.
4. Lubricate the gears with engine oil. After replacing the sealing gasket, install the oil pump cover. Screw in the mounting bolts and tighten them to the required torque (18 N·m).
5. Using a socket head of the appropriate size or a piece of pipe of the appropriate diameter as a mandrel, seat the front crankshaft oil seal into its socket in the front engine casing.
6. Using a suitable mandrel again, press the balance shaft seal into the front housing.
7. Attach tool MD998285 to the crankshaft journal. Lubricate the outer edge of the guide tool with clean engine oil.
8. Install the front cover onto the engine. Install and temporarily tighten the flange bolts.
9. After replacing the gasket, install the oil filter support bracket. Screw in the four mounting bolts and tighten them to the required torque (22 N·m).
10. Insert the 8mm Phillips screwdriver tip into the side hole in the block.
11. Secure the oil pump driven gear to the left balance shaft - tighten the flange bolt to 40 Nm.
12. Place a new sealing ring into the groove in the front casing. Using a special drive head, install the plug and tighten it to 27 N·m.
13. Insert the pressure relief valve components (plunger and spring) into their socket in the oil filter support bracket and tighten the plug to the required torque (50 Nm).
Don't forget to replace the sealing gasket.
14. Carefully clean the mating surfaces of the oil pan and engine block.
15. Place a bead of sealant about 4 mm wide into the groove on the pan flange (the sealant is applied from the inside of the bolt holes).
16. No later than 15 minutes after applying the sealant, press the tray to the block and install the holders. Screw in the fastening bolts and tighten them to the required torque (8 Nm).
17. Install the measuring assembly and engine oil pressure sensor. Restore the original wiring connections.
18. Install a new oil filter and fill the engine with fresh engine oil of the appropriate grade (see Chapter Settings and ongoing maintenance).
19. Install the timing belts and other components of the timing drive and balance shafts. Make sure that the timing marks are correctly aligned (see Section Removal and installation the timing belt cover and timing belt).
20. Install other components removed for access purposes.
[The article is based on data from the website: MitsubishiMan]
21. Connect the negative cable to the battery. Start the engine and check for signs of developing leaks.
22. Check that the ignition timing angle is set correctly. If necessary, make the appropriate adjustments.