Camshaft oil seal replacement
Before you start removing parts, do the following:
- A) Release residual pressure from the high pressure line (see chapter "fuel injection system (GDI)").
- b) Remove the engine crankcase guard.
- V) Drain coolant and engine oil.
- G) Remove the air filter.
- d) Remove the battery and battery tray.
Removal of parts is carried out in the order of the numbers indicated in the figure "Camshaft oil seal replacement".
When removing parts, pay attention to the operation to remove the camshaft pulley.
Secure the camshaft pulley against rotation using a special fork holder and special bolts.
Installation is made in an order, the return to removal.
When installing parts, pay attention to the following operations:
1. Installation of hydraulic lifters.
Attention: in case of repeated use of hydraulic lifters, it is recommended to check and clean them if necessary (see the relevant procedures in section "Rocker arms and camshafts" chapters "Engine - General Repair Procedures"), then carefully install into the cylinder head.
Camshaft oil seal replacement (4G15 engine). 1 - decorative engine cover; 2 - connector for the electromagnetic clutch of the air conditioning compressor; 3 - connector of the sensor-switch for fluid pressure in the hydraulic system of the power steering; 4 - connector of the crankshaft position sensor; 5 - ignition coil connector; 6 - throttle position sensor connector; 7 - throttle servo connector; 8 - connector for the servomotor of the exhaust gas recirculation valve; 9 - connector for the canister purge solenoid valve; 10 - connector of the wiring harness of the engine management system and injectors; 11 - connector of the noise suppression capacitor; 12 - oxygen sensor connector; 13 - camshaft position sensor connector; 14 - coolant temperature sensor connector; 15 - knock sensor connector; 16 - forced crankcase ventilation hose; 17 - ventilation hose (remove the ignition coils; intake manifold and timing belt); 18 - intermediate connector for injectors; 19 - intake valve cover of the cylinder head; 20 - gasket for the intake valve cover of the cylinder head; 21 - exhaust valve cover of the cylinder head; 22 - cylinder head exhaust valve cover gasket.
Camshaft oil seal replacement (4G93 engine). 1 - decorative engine cover; 2 - connector for the electromagnetic clutch of the air conditioning compressor; 3 - connector of the sensor-switch for fluid pressure in the hydraulic system of the power steering; 4 - connector of the crankshaft position sensor; 5 - fuel pressure sensor; 6 - connector for the servomotor of the exhaust gas recirculation valve; 7 - connector for the canister purge solenoid valve; 8 - throttle position sensor connector; 9 - throttle servo connector; 10 - ignition coil connector; 11 - connector of the wiring harness of the engine management system and injectors; 12 - oxygen sensor connector; 13 - camshaft position sensor connector; 14 - connector of the noise suppression capacitor; 15 - connector for the sensor of the coolant temperature indicator; 16 - coolant temperature sensor connector; 17 - knock sensor connector; 18 - forced crankcase ventilation hose; 19 - ventilation hose (remove the ignition coils; intake manifold and timing belt); 20 - intermediate connector for injectors; 21 - intake valve cover of the cylinder head; 22 - gasket for the intake valve cover of the cylinder head; 23 - exhaust valve cover of the cylinder head; 24 - cylinder head exhaust valve cover gasket.
Camshaft oil seal replacement (4G15 engine; continuation). 23 - camshaft pulley; 24 - rear timing belt cover (upper); 25 - camshaft seal; 26 - camshaft position sensor bracket; 27 - engine suspension bracket; 28 - round plug (remove injection pump); 29 - block of camshaft bearing caps; 30 - gasket for a block of camshaft bearing caps; 31 - intake camshaft; 32 - exhaust camshaft; 33 - camshaft position sensor rotor; 34 - rocker; 35 - hydraulic compensator.
Camshaft oil seal replacement (4G93 engine; continuation). 25 - camshaft pulley; 26 - guide roller; 27 - rear timing belt cover (upper); 28 - camshaft seal; 29 - camshaft position sensor bracket; 30 - round plug (remove injection pump); 31 - block of camshaft bearing caps; 32 - gasket for the block of camshaft bearing caps; 33 - intake camshaft; 34 - exhaust camshaft; 35 - camshaft position sensor rotor; 36 - rocker; 37 - hydraulic compensator.
2. Installation of camshafts
A) Apply a small amount of engine oil to the cams and camshaft bearing journals.
b) Install the camshafts in the cylinder head.
Attention: do not mix up camshafts. At the rear end of the exhaust camshaft there is a hole for the camshaft position sensor rotor mounting bolt.
V) Position the camshafts in the cylinder head so that their guide pins are in the position shown in the figure.
Engine 4G15.
Engine 4G93.
3. Installing the camshaft bearing caps (if filmed).
A) Apply the specified sealant in a continuous bead of approximately 3 mm diameter to the bottom of the camshaft bearing cap assembly (into a groove) in the places shown in the figure.
Sealant - Mitsubishi Genuine Part #MD970389, Three Bond 1207F or equivalent
Engine 4G15.
Engine 4G93.
b) Apply the specified sealant in a continuous bead of approximately 3 mm in diameter to the mating surface of the cylinder head at the locations shown in the figure.
Sealant - Mitsubishi Genuine Part #MD970389, Three Bond 1207F or equivalent
Engine 4G15.
Engine 4G93.
V) Install the camshaft bearing cap gasket.
G) Install the camshaft bearing cap assembly on the cylinder head until the sealant dries and hardens.
d) Install the camshaft bearing cap bolts and gradually tighten the bolts in two or three steps in the order shown in the figure. Tighten the bolts to rated torque in the final tightening sequence.
Torque:
Engine 4G15:
- A (bolt М6х32) — 10-12 Nm
- IN (bolt M6x35) — 10-12 Nm
- WITH (bolt M8x40) - 19-23 Nm
- D (bolt M8x40) - 19-23 Nm
Engine 4G93GDI:
- A (bolt М8х32) - 19-23 Nm
- IN (bolt M6x35) — 10-12 Nm
- WITH (bolt M8x40) - 19-23 Nm
- D (bolt M8x40) - 19-23 Nm
Engine 4G15.
Engine 4G93.
4. Installing the round plug.
With a special tool (mandrels) install the round plug as shown in the figure.
5. Installing the camshaft seal.
A) Apply a small amount of engine oil to the lip of the oil seal around its entire circumference.
b) Using a special mandrel, press in the oil seal as shown in the figure.
6. Installing the camshaft pulley.
Using the special tool, fix the camshaft pulley from turning in the same way as in the removal procedure, and tighten the pulley mounting bolt to the specified torque.
Tightening torque - 88 + 10 Nm
7. Installation of a decorative casing of the engine.
A) Pre-tighten the cover bolts in the sequence shown in the figure so that the cover can be moved by hand.
Engine 4G15.
Engine 4G93.
b) Finally tighten the casing mounting bolts to the specified torque in the sequence shown in the figure.
Tightening torque - 3 Nm
Installation is made in an order, the return to removal.
After completing the installation of the parts, perform the following operations:
- A) Adjust the tension of the accessory drive belts (see the relevant section of the chapter "Maintenance and general inspection and adjustment procedures").
- b) Install the battery tray and battery.
- V) Install the air filter.
- G) Fill with coolant and engine oil.
- d) Perform High Pressure Fuel Line Bleeding Procedure (refer to the appropriate procedure for installing the injection pump in chapter "fuel injection system (GDI)").
- e) Check for fuel leaks.
- and) Install the engine crankcase guard.
Replacing the front crankshaft oil seal
Before you start removing parts, do the following:
A) Remove the timing belt.
b) Remove the crankshaft position sensor.
Removal of parts is carried out in the order of the numbers indicated in the figure "Removing the crankshaft seals".
When removing parts, pay attention to the operation to remove the oil seal.
A) Cut part of the working edge of the crankshaft oil seal.
b) Wrap the tip of a screwdriver with a cloth, insert it into the slot of the stuffing box and remove the stuffing box.
Caution: Be careful not to damage the crankshaft and oil pump housing.
Parts are installed in the reverse order of removal.
When installing parts, pay attention to the following operations:
1. Installing the gland.
A) Apply a small amount of engine oil to the lip of the oil seal around its entire circumference.
b) By tapping on the mandrel, install the stuffing box so that it is flush with the stuffing box body.
2. Installing the crankshaft pulley.
A) Clean then degrease the following surfaces and parts: oil pump housing face, crankshaft surface, spacer, sensor rotor and toothed pulley.
Note: degreasing is necessary to improve the mating of parts.
Removing the crankshaft seals (4G15 engine). 1 - a gear pulley of a cranked shaft; 2 - key; 3 - rotor of the crankshaft position sensor; 4 - washer; 5 - front crankshaft oil seal; 6 - bolt for fastening the torque converter drive plate; 7 - adapter plate; 8 - torque converter drive plate; 9 - crankshaft bushing; 10 - crankshaft rear oil seal.
Removing the crankshaft seals (4G93 engine). 1 - a gear pulley of a cranked shaft; 2 - key; 3 - rotor of the crankshaft position sensor; 4 - washer; 5 - key; 6 - front crankshaft oil seal; 7- bolt for fastening the torque converter drive plate; 8 - adapter plate; 9 - torque converter drive plate; 10 - crankshaft rear oil seal.
b) Clean the surface of the crankshaft sprocket in contact with the shaft.
V) Install the washer, crankshaft position sensor rotor and crankshaft sprocket by aligning the mounting holes with the spring pin as shown.
After completing the installation of the parts, perform the following operations:
A) Install the crankshaft position sensor.
b) Install the timing belt.
Replacement of a back epiploon of a cranked shaft
Before you start removing parts, do the following:
- A) (2WD Models) Remove the gearbox.
- b) (4WD Models) Remove a transmission in gathering with a distributing box.
Removal of parts is carried out in the order of the numbers indicated in the figure "Removing the crankshaft seals".
When removing parts, pay attention to the following operations:
1. Removing the torque converter drive plate.
Using a special tool, fix the torque converter drive plate, then unscrew the mounting bolts.
Engine 4G15.
Engine 4G93.
2. Removing the gland.
A) Cut part of the working edge of the crankshaft oil seal.
b) Wrap the tip of a screwdriver with a cloth, insert it into the slot of the stuffing box and remove the stuffing box.
Caution: Be careful not to damage the crankshaft and oil pump housing.
Parts are installed in the reverse order of removal.
1. Installing a new oil seal.
A) Apply a small amount of engine oil to the lip of the oil seal around its entire circumference.
b) By tapping on the mandrel, install the stuffing box so that its end surface is located at the level of the chamfer of the stuffing box housing, as shown in the figure.
2. Installing the torque converter drive plate.
A) Before installing, clean the mounting bolts, threaded holes in the crankshaft and torque converter drive plate from oil, old sealant and other contaminants.
b) Lubricate the bearing surfaces of the washers of the torque converter drive plate mounting bolts with engine oil.
V) Apply engine oil to the threaded holes in the crankshaft.
G) Apply the specified sealant to the threads of the mounting bolt holes or to the threads of the bolts.
Sealant - 3M Stud Locking #4171, Three Bond 1324 or equivalent
d) Using the special tool, fix the torque converter drive plate in the same way as in the removal procedure, then tighten the mounting bolts to the specified torque.
Torque:
- Engine 4G15 - 127-137 Nm
- Engine 4G93 93 - 103 Nm
After completing the installation of the parts, perform the following operations.
A) (4WD Models) Establish a transmission in gathering with a distributing box.
b) (2WD Models) Install the gearbox.