Mitsubishi 4G6 series Workshop Manual
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Mitsubishi 4G6 series Workshop Manual

Mitsubishi 4G6 series Workshop Manual

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See also: Service Manual , Manual
GENERAL INFORMATION
1. SPECIFICATIONS
NEW TIGHTENING METHOD -
BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA
E
Mitsubishi Motors Corporation
ENGINE
4G6 SERIES
CONTENTS
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Aug. 1998
PWEE9616-A
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11A-0-1
11A-0-3
11A-1-1
11A-1-1
11A-1-4
11A-1-9
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11A-1-9
11A-1-10
11A-2-1
11A-3-1
11A-3a-1
11A-4-1
11A-4a-1
11A-5-1
11A-5a-1
11A-6-1
11A-6a-1
11A-7-1
11A-8-1
11A-8a-1
11A-9-1
11A-11-1
11A-12-1
Revised

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  • Page 1 11A-0-1 ENGINE 4G6 SERIES CONTENTS GENERAL INFORMATION 11A-0-3 ..........
  • Page 2 11A-0-2 NOTES Mitsubishi Motors Corporation Dec. 1996 PWEE9616...

  • Page 3: General Information

    86.5 Piston stroke mm 100.0 Compression ratio Valve timing Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Lubrication system Pressure feed, full-flow filtration Oil pump type Involute gear type Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 4 Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Lubrication system Pressure feed, full-flow filtration Oil pump type Involute gear type NOTE GDI is a trademark of Mitsubishi Motors Corporation. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 5: Specifications

    Valve thickness of valve head (margin) mm SOHC Exhaust Intake Exhaust Valve overall height mm SOHC Intake 112.30 111.80 Exhaust 114.11 113.61 Intake 105.5 105.0 Exhaust 105.7 105.2 Valve stem outer diameter mm Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 6 (SOHC) mm 0.6 Oversize diameter 34.60 - 34.63 Exhaust oversize rework dimensions of 0.3 Oversize diameter 33.30 - 33.33 valve seat hole (GDI) mm 0.6 Oversize diameter 33.60 - 33.63 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 7 Cylinder block grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block Cylinder block overall height mm 4G63 4G64 Cylinder block inner diameter mm 4G63 85.0 4G64 86.5 Cylindricity mm 0.01 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...

  • Page 8: Table Of Contents

    Intake manifold stay (M6) Intake manifold stay (M8) Air intake plenum resonator (Flange bolt) Air intake plenum resonator (Bolt, washer assembly) EGR valve EGR valve support Intake manifold Timing belt Timing belt cover flange bolt Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...

  • Page 9: Table Of Contents

    Injectors and delivery pipe (Multipoint fuel injection) Fuel pressure regulator (Multipoint fuel injection) Fuel part (GDI) Fuel low pressure pipe (M6) Fuel low pressure pipe (M8) Fuel pump return nipple Clamp A Fuel pipe bracket Fuel feed pipe Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...

  • Page 10: Table Of Contents

    Water pump and water hose (GDI) Engine coolant temperature sensor Engine coolant temperature gauge unit Water inlet fitting Water outlet fitting Thermostat housing Water inlet pipe Water pump Knock sensor Exhaust manifold Exhaust manifold cover Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...

  • Page 11: Table Of Contents

    Oil pressure switch (4G63) Oil pressure switch (4G64) Relief plug Oil filter bracket Plug Flange bolt Oil pump cover bolt Oil pump cover screw Front case Transmission stay (GDI engine) Oil level gauge guide Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 12 Connecting rod cap 20 + 90_ ® 100_ Crankshaft, flywheel and drive plate Flywheel bolt Drive plate bolt Rear plate Bell housing cover Oil seal case bolt Bearing cap bolt 25 + 90_ ® 100_ Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 13 Observe the tightening method described in the text. SEALANTS Item Specified sealant Quantity Cam position sensor support Mitsubishi Genuine Part No. MD970389 or As required equivalent Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required Engine coolant temperature gauge unit 3M ATD Part No.
  • Page 14 (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 15: Special Tools

    Use with MD998375. MD998371 Silent shaft bearing Removal of counterbalance shaft front bearing puller MD998372 Silent shaft bearing Removal of counterbalance shaft rear bearing puller MD998375 Crankshaft front Installation of crankshaft front oil seal seal installer Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 16 Installation of camshaft oil seal installer MD998719 Pulley holder pin Holding camshaft sprocket Use with MB990767. MD998727 Oil pan remover Removal of oil pan MD998735 Valve spring Removal and installation of valve and related compressor parts Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 17 Installation of crankshaft rear oil seal seal installer Use with MB990938. MD998778 Crankshaft Removal of crankshaft sprocket sprocket puller MD998780 Piston setting tool Removal and installation of piston pin MD998781 Flywheel stopper Holding of flywheel and drive plate Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 18 11A-2-4 4G6 ENGINE (E - W) - Special Tools Tool Number Name MD998783 Plug wrench Removal and installation of front case cap plug retainer MD998785 Sprocket stopper Holding silent shaft sprocket Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 19: Water Pump Pulley

    Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable 7. Spark plug 8. High tension cable "BA 9. Distributor assembly 10. O-ring Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 20 2. Water pump pulley 8. Spark plug 3. Alternator brace 9. Camshaft position sensor 4. Alternator "AA 10. Camshaft position sensing support 5. Crankshaft pulley 11. Camshaft position sensing cylinder 6. Spark plug cable Mitsubishi Motors Corporation Dec. 1996 PWEE9616...

  • Page 21: Oil Level Gauge Guide

    (Vehicle for Hong Kong) 3. O-ring 9. Idler pulley 4. Drive belt (Vehicle for Hong Kong) 5. Water pump pulley 10. Crankshaft pulley 6. Alternator 11. Ignition coil 7. Alternator brace 12. Spark plug Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 22 INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent "BA DISTRIBUTOR ASSEMBLY INSTALLATION (1) Turn the crankshaft to bring No. 1 cylinder to the top dead center on compression stroke.

  • Page 23: Vacuum Pipe

    4. Solenoid valve "AA 15. EGR support (Vehicles for Europe and 2000 "AA 16. Gasket model vehicles for Hong Kong) 17. Gasket 5. Vacuum pipe 18. Intake manifold 6. Throttle body 19. Gasket Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 24 "DA 4. Throttle body gasket "AA 12. EGR support "CA 5. Intake manifold stay "AA 13. Gasket "BA 6. Air intake plenum resonator 14. Gasket 7. Gasket 15. Intake manifold 8. Water hose 16. Gasket Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 25 Intake manifold with the air intake plenum resonator and the cylinder stay block. Air intake plenum resonator "DA THROTTLE BODY GASKET INSTALLATION (1) Position the projection as shown in the illustration. Projection Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Added...

  • Page 26: Power Steering Bracket

    "CA 20. Engine support bracket 9. Idler pulley AI" "AA 21. Camshaft sprocket bolt AC" "HA 10. Oil pump sprocket 22. Camshaft sprocket AD" "GA 11. Crankshaft bolt 23. Timing belt rear cover Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 27 31. Timing belt rear right cover 15. Tensioner B 32. Timing belt rear left upper cover AF" "FA 16. Timing belt B 33. Timing belt rear left lower cover AG" "EA 17. Counterbalance shaft sprocket Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 28 (1) Remove the plug on the left side of cylinder block. (2) Insert a screwdriver (shank diameter 8 mm) to block the counterbalance shaft. (3) Remove the nut. (4) Remove the oil pump sprocket. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 29 AG" COUNTERBALANCE SHAFT SPROCKET REMOVAL (1) Set the special tool as shown to prevent the counterbalance shaft sprocket from turning together. MD998785 (2) Loosen the bolt and remove the sprocket. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 30 (2) Tighten the camshaft sprocket bolt to the specified torque. "BA CAMSHAFT SPROCKET BOLT TIGHTENING (1) Using a wrench, hold the camshaft at its hexagon and tighten the bolt to the specification. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 31 There should be no slack on the tension side. (3) Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 32 (2) Clamp the auto-tensioner in the vise with soft jaws. (3) Push in the rod little by little with the vise until the set hole A in the rod is aligned with the hole B in the cylinder. 6AE0049 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 33 (1) Check that the timing belt tensioner and spring have been installed in position. (See "JA) (2) Align timing mark on camshaft sprocket with timing mark on cylinder head. (3) Align timing mark on crankshaft sprocket with timing mark on front case. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 34 0 - 5 Nm. (12)Torque to 3.5 Nm with the torque wrench. (13)Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification. 6EN0900 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 35 (3) Place the timing mark on the crankshaft sprocket one tooth this side from the mated timing mark as in the case of the camshaft sprocket. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 36 NOTE The intake camshaft will be turned a little clockwise by the valve spring tension and stabilized in position even if the belt is clipped at one tooth offset position. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 37 There must be no slack in the timing belt between the intake and exhaust camshafts. (15)Turn the crankshaft to align the timing mark with the mark for No. 1 cylinder top dead center in the compression stroke. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 38 INSPECTION TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 39 (4) Press the rod with a force of 98 to 196 N and measure 98 to 196 N its protrusion. (5) If the measured value is 1 mm or more shorter than the Movement value obtained in step (3), replace the auto tensioner. 6EN1033 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 40: Engine Hanger

    49 Nm 13 Nm Removal steps 1. Exhaust manifold cover (Vehicle for Europe) 2. Exhaust manifold (Vehicle for Europe) 3. Exhaust manifold (Vehicle for Hong Kong) 4. Exhaust manifold gasket 5. Engine hanger Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 41: Fuel And Emission Control Parts

    17 Nm 22 Nm 23 Nm Removal steps 1. Fuel hose 2. Fuel hose 3. Fuel vapor separator 4. Water hose 5. Carburetor 6. Gasket 7. EGR valve (For GCC) 8. Gasket (For GCC) Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 42 3. EGR valve (With EGR valve) 10. Insulator 4. Cover (Without EGR valve) "AA 11. Injectors 5. EGR valve gasket 12. O-ring 6. Injectors and delivery pipe 13. Grommet 7. Insulator 14. Delivery pipe Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 43 3. EGR valve 11. Insulator 4. EGR valve gasket "AA 12. Injectors 5. Fuel hose 13. O-ring 6. Fuel return pipe 14. Grommet 7. Injectors and delivery pipe 15. Delivery pipe 8. Insulator Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 44 Remove the fuel pressure regulator and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again. "CA GASKET INSTALLATION GALANT SPACE WAGON (1) Position the projection as shown in the illustration. Projection Projection Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 45 18 Nm 8.8 Nm 11 Nm 8.8 Nm 8.8 Nm 11 Nm 11 Nm 4.9 Nm ® 17 Nm ± 2 Nm 8.8 Nm 18 Nm 11 Nm 22 Nm 23 Nm 11 Nm Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...

  • Page 46: Fuel Pipe Bracket

    "EA 15. Fuel return pipe "AA 34. Backup ring 16. Backup ring "AA 35. O-ring 17. O-ring "AA 36. Backup ring 18. Backup ring 37. Delivery pipe "EA 19. Fuel high pressure regulator 38. Engine hanger Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 47 8.8 Nm 11 Nm 8.8 Nm 8.8 Nm 11 Nm 11 Nm 4.9 Nm ® 17 Nm ± 2 Nm 8.8 Nm 18 Nm 11 Nm 18 Nm 22 Nm 23 Nm 11 Nm Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Added...
  • Page 48 "AA 39. O-ring Hong Kong) "AA 40. Backup ring 21. Backup ring (GALANT and SPACE 41. Delivery pipe WAGON for Hong Kong) 42. Engine hanger 22. O-ring (GALANT and SPACE WAGON for Hong Kong) Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Added...
  • Page 49 Caution Strictly observe the specified torque. (8) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 50 Be sure to insert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at both ends of the pipe to the specified torque. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 51 (9) Secure the fuel pipe bracket to the cam cap temporarily. (10)Tighten the bolts which are securing the pipes temporarily to the specified torque. (11)Tighten the bolts on the beam cam shaft side which have been temporarily tightened to the specified torque. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 52: Engine Coolant Temperature Gauge Unit

    4. Water inlet fitting 13. O-ring 5. Thermostat 14. Intake manifold stay "BA 6. Thermostat housing 15. Intake manifold "AA 7. Water inlet pipe 16. Intake manifold gasket "AA 8. O-ring 17. Engine hanger Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 53 5. Water inlet fitting 15. Intake manifold stay 6. Thermostat 16. Intake manifold "BA 7. Thermostat housing 17. Intake manifold gasket "AA 8. Water inlet pipe 18. Engine hanger "AA 9. O-ring 19. Detonation sensor Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 54 14. Oil level gauge guide unit 15. O-ring 6. Water inlet fitting 16. Intake manifold stay 7. Thermostat 17. Intake manifold "BA 8. Thermostat housing 18. Intake manifold gasket "AA 9. Water inlet pipe 19. Engine hanger Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 55 O-ring 6EN0594 "BA SEALANT APPLICATION TO THERMOSTAT HOUSING Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent NOTE (1) Be sure to install the housing quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from...

  • Page 56: Water Outlet Fitting

    3. Engine coolant temperature sensor "AA 9. O-ring "DA 4. Engine coolant temperature gauge "AA 10. Water inlet pipe unit 11. Water pump 5. Water inlet fitting 12. Gasket 6. Thermostat 13. Knock sensor Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 57 "BA THERMOSTAT CASE INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent "CA WATER OUTLET FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration.

  • Page 58: Heat Protector

    13 Nm 13 Nm 13 Nm Removal steps "AA 1. Water outlet fitting 2. Heat protector (Multipoint fuel injection) 3. Exhaust manifold cover (Carburetor) 4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold gasket Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 59 "AA SEALANT APPLICATION TO WATER OUTLET 3 mm diameter bead sealant FITTING Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent NOTE (1) Be sure to install the water outlet fitting quickly while the sealant is wet (within 15 minutes).

  • Page 60: Rocker Arm Shaft

    16. Rocker arm shaft (Exhaust side) 6. Oil seal "AA 17. Lash adjuster "CA 7. Oil seal 18. Camshaft AA" "BA 8. Rocker arms and rocker arm shaft AA" "BA 9. Rocker arms and rocker arm shaft Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 61 (3) Remove the special tool for securing the lash adjuster. (4) Make sure that the notch in the rocker arm shaft is in the direction as illustrated. "CA CAMSHAFT OIL SEAL INSTALLATION MD998713 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 62 Then, perform the following steps with each lash adjuster. (2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 63 (8) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. MD998442 Diesel fuel Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 64 1 mm. Standard value: 3 - 20 seconds/1 mm [with diesel fuel at 15 - Lash adjuster 20_C (59 - 68_F)] NOTE Replace the lash adjuster if the time measurement is out of specification. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 65 (20)Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 66: Camshaft Position Sensing Cylinder

    "BA 9. Intake camshaft "DA 4. Camshaft position sensing cylinder "BA 10. Exhaust camshaft "CA 5. Camshaft position sensing cylinder 11. Rocker arm support AA" "AA 12. Lash adjuster "BA 6. Oil seal Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 67 (3) Apply sealant to the illustrated position of the cylinder Timing belt side head upper surface. Specified sealant: Mitsubishi genuine Part MD970389 equivalent (4) Install the beam camshaft cap gasket. Mitsubishi Motors Corporation Mitsubishi Motors Corporation Aug. 1998 Aug. 1998 PWEE9616-A PWEE9616-A Added Added...
  • Page 68 Camshaft position sensor INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: Intake 35.79 mm Exhaust 37.14 mm Limit: Intake 35.29 mm Exhaust 36.64 mm Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 69 Diesel fuel air bleed wire is pushed in hard. MD998442 NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 70 Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel. Diesel fuel MD998442 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 71 Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel. Diesel fuel MD998442 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 72 (16)Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 73: Cylinder Head And Valves

    16. Intake valve guide 7. Intake valve 17. Exhaust valve guide AB" "CA 8. Retainer lock 18. Intake valve seat 9. Valve spring retainer 19. Exhaust valve seat "BA 10. Valve spring 20. Cylinder head Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 74 16. Intake valve guide 7. Intake valve 17. Exhaust valve guide AB" "CA 8. Retainer lock 18. Intake valve seat 9. Valve spring retainer 19. Exhaust valve seat "BA 10. Valve spring 20. Cylinder head Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 75 (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. 9EN0061 MB991654 AB" RETAINER LOCK REMOVAL MD998772 (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly. 9EN0062 MD998772 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 76 Improper installation could result in oil leaks past the valve guide. MD998774 Caution Do not reuse removed valve stem seals. 9EN0065 MD998737 "BA VALVE SPRING INSTALLATION (1) Direct the valve spring end with identification color toward the spring retainer. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 77 Tightening torque: 78 Nm (4) Loosen all bolts fully. (5) Retighten the loosened bolts to a torque of 20 Nm in the specified tightening sequence. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 78 (2) If the service limit is exceeded, correct to meet specification. Grinding limit: *0.2 mm 9EN0064 * Includes combined with cylinder block grinding. Cylinder head height (Specification when new): SOHC 119.9 - 120.1 mm 131.9 - 132.1 mm Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 79 Standard value mm Limit mm SOHC 51.0 50.0 Free height 48.3 47.3 (2) Measure the squareness of the spring and, if the limit is exceeded, replace. 1EN0264 Item Standard value mm Limit mm SOHC 1.5_ Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 80 (3) After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection (refer to VALVE SEAT in INSPECTION). 43.5_ - 44_ 6EN0491 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 81 (4) Using a valve seat cutter, correct the valve seat to the specified width and angle. See “VALVE SEAT RECONDITIONING PROCEDURE”. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 82 (45.5 mm for intake valve; 50.5 mm for exhaust valve) Protrusion (4) After the valve guide has been installed, insert a new valve to check for smooth sliding motion. 1EN0106 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 83: Oil Screen

    "IA 13. Oil pressure switch AG" "BA 32. Counterbalance shaft rear bearing, 14. Relief plug left 15. Relief plug gasket AG" "AA 33. Counterbalance shaft rear bearing, 16. Relief spring right 17. Relief plunger Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised...
  • Page 84 AF" "CA 32. Counterbalance shaft front bearing 15. Relief plug AG" "BA 33. Counterbalance shaft rear bearing, 16. Gasket left 17. Relief spring AG" "AA 34. Counterbalance shaft rear bearing, 18. Relief plunger right Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 85 AE" FLANGE BOLT REMOVAL (1) Remove the plug on the side of cylinder block. (2) Insert a Phillips screwdriver (shank diameter 8 mm) into the plug hole to lock the counterbalance shaft. Plug Screwdriver 6EN1026 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 86 (1) Apply engine oil to the outer surface of bearing. (2) Using special tools, install right rear bearing. Make sure that oil hole of bearing is aligned with oil hole of cylinder block. MD998705 6EN1034 Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 87 The left rear bearing has no oil holes. MB991603 MD998705 6EN0557 "CA COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION (1) Using special tools, install front bearing. MD998705 MD998705 Bearing Cylinder block 6EN1035 "DA COUNTERBALANCE SHAFT OIL SEAL INSTALLATION Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 88 (2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket). Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 89 (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Groove Bolt hole...
  • Page 90 (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan upper flange. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Bolt hole portion Groove...
  • Page 91 (4) Clean both mating surfaces of oil pan lower and oil pan Oil pan lower upper. (5) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan lower flange. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Bolt hole NOTE portion Groove...

  • Page 92: Driven Gear 0.06 -

    (2) Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover. (3) Check the side clearance. Standard value: Drive gear 0.08 - 0.14 mm Driven gear 0.06 - 0.12 mm Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...

  • Page 93: Piston And Connecting Rod

    "EA 3. Connecting rod bearing AB" "AA 9. Piston pin "DA 4. Piston and connecting rod assem- 10. Piston 11. Connecting rod "EA 5. Connecting rod bearing 12. Bolt "CA 6. Piston ring No. 1 Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 94 Piston Pin Setting Base, with the front mark facing upward. (3) Using a press, remove the piston pin. NOTE Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder number. Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 95 (9) Press-fit the piston pin using a press. If the press-fitting force required is less than the standard value, replace the piston and piston pin set or/and the connecting rod. Standard value: 7,350 - 17,200 N Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 96 Do not use piston ring expander when installing side rail. (3) Install the lower side rail in the same procedure as 1EN0269 described in step (2). (4) Make sure that the side rails move smoothly in either direction. Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 97 In the case of a crankshaft supplied as a service part, identification colors of its pins are painted at the positions shown in the illustration. Mitsubishi Motors Corporation Mitsubishi Motors Corporation Aug. 1998 Aug. 1998...
  • Page 98 (2) Make sure that the connecting rod big end side clearance meets the specification. Standard value: 0.10 - 0.25 mm Limit: 0.4 mm Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 99 (2) Check for the clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: 0.02 - 0.06 mm Limit: 0.1 mm Mitsubishi Motors Corporation Dec. 1996 PWEE9616...
  • Page 100 (4) Carefully remove the connecting rod cap. (5) Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package. Standard value: 0.02 - 0.05 mm Limit: 0.1 mm Mitsubishi Motors Corporation Dec. 1996 PWEE9616...

  • Page 101: Crankshaft, Flywheel And Drive Plate

    Removing bolt, "DA 14. Bearing cap bolt therefore, can cause the flexible flywheel to be out "DA 15. Bearing cap of balance, giving damage to the flywheel. "CA 16. Crankshaft bearing, lower Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 102 Groove "CA CRANKSHAFT BEARING INSTALLATION Identification color of crankshaft journal (1) From the following table, select a bearing whose size is appropriate for the crankshaft journal outside diameter. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 103 ID mark is “1” or ID color is “green” for number If there is no ID color paint on the crankshaft, measure the journal outside diameter and select a bearing Identification appropriate for the measured value. mark or color Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 104 If the bolt is overtightened (exceeding 100_), loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1). Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 105 Limit: 0.25 mm "EA OIL SEAL INSTALLATION "FA SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent NOTE (1) Be sure to install the case quickly while the sealant is wet (within 15 minutes).
  • Page 106 (3) Based on the measured piston O.D. calculate boring finish dimension. Boring finish dimension = Piston O.D. + (clearance between piston O.D. and cylinder) - 0.02 mm (honing margin) Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised...
  • Page 107 (6) Check clearance between piston and cylinder. Clearance between piston and cylinder: 0.02 - 0.04 mm NOTE When boring cylinders, finish all of four cylinders to same oversize. Do not bore only one cylinder to an oversize. Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added...
  • Page 108 NOTES...

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