Mitsubishi 4D6, 4G6, 6A1 User Manual
ENGINE
11A-1
CONTENTS
ENGINE <4G6> 11A............................................
ENGINE <6A1> 11B............................................
ENGINE <4D6> 11C............................................
11109000276
11A-2
ENGINE <4G6>
CONTENTS
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 3.................
SEALANTS 4................................
SPECIAL TOOLS 4...........................
ON-VEHICLE SERVICE 6.....................
Drive Belt Tension Check and Adjustment 6......
Ignition Timing Check 7.........................
Idle Speed Check 8............................
Idle Mixture Check 8...........................
Compression Pressure Check 9.................
Manifold Vacuum Check 10.....................
11109000603
Lash Adjuster Check 11........................
CRANKSHAFT PULLEY 15...................
CAMSHAFT AND CAMSHAFT OIL SEAL 16...
OIL PAN 19..................................
CRANKSHAFT OIL SEAL 20..................
CYLINDER HEAD GASKET 22................
TIMING BELT 26.............................
TIMING BELT B 30...........................
ENGINE ASSEMBLY 33.......................
ENGINE <4G6> -
General Information/Service Specifications
11A-3
GENERAL INFORMATION
Items 4G63
Total displacement mL 1,997
Bore ´ Stroke mm 85.0 ´88.0
Compression ratio 10.0
Combustion chamber Pentroof type
Camshaft arrangement SOHC
Intake
Number of valve
Exhaust
Opening
Intake
Closing
Valve timing
Opening
Exhaust
Closing
Fuel system Electronically controlled multipoint fuel injection
8
8
BTDC 11_
ABDC 53_
BBDC 63_
ATDC 21_
11100010469
Rocker arm Roller type
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS
Items Standard value Limit
When checked 294 - 490 -
Tension N
Alternator drive When a new belt is installed 490 - 686 belt
tension
Power steering
oil pump and
A/C compressor
drive belt
tension
Deflection
(Reference
value) mm
Tension N
Deflection
mm
mm
When a used belt is installed 343 - 441 -
When checked 7.7 - 12.3 -
When a used belt is installed 8.4 - 10.6 -
When a new belt is installed 5.9 - 7.7 -
When checked 392 - 588 -
When a used belt is installed 441 - 539 -
When a new belt is installed 637 - 833 -
When checked 11.7 - 15.3 -
When a used belt is installed 12.5 - 14.3 -
When a new belt is installed 8.8 - 11.0 -
11100030489
Basic ignition timing 5_ BTDC±2_ -
Ignition timing Approx. 10_BTDC -
11A-4
Items LimitStandard value
Idle speed r/min 750 ± 100 -
CO contents % 0.5 or less -
HC contents ppm 100 or less -
Compression pressure (250 - 400 r/min) kPa 1,400 Min. 1,060
Compression pressure difference of all cylinder kPa - Max. 100
Intake manifold vacuum kPa - Min. 69
Cylinder head bolt shank length mm - 99.4
Auto-tensioner push rod movement mm Within 1 -
Timing belt tension torque Nm (Reference value) 3.5 -
Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -
Timing belt B tension mm 5-7 -
ENGINE <4G6> -
Service Specifications/Sealants/Special Tools
SEALANTS
Items Specified sealants Remarks
Rocker cover and cylinder head
Semi-circular packing
Oil pan
Thermostat case
Flywheel bolt 3M Stud Locking 4170 or equivalent -
3M ATD Part No.8660 or equivalent -
MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub assem-
bly
MB990767 End yoke holder D Holding the camshaft sprocket
D Checking the idle speed
D Erasing diagnosis code
D Holding the crankshaft sprocket
11100050201
11100060457
MD998719 or
MD998754
Crankshaft pulley
holder pin
D Holding the camshaft sprocket
D Holding the crankshaft sprocket
Tool UseNameNumber
ENGINE <4G6> -
Special Tools
11A-5
MD998713 Camshaft oil seal
installer
MD998443 Auto-lash adjuster
holder
MD998727 Oil pan remover Removal of oil pan
MD998781 Flywheel stopper Securing the flywheel
Press-in of the camshaft oil seal
Supporting of auto-lash adjuster
MD998776 Crankshaft rear oil
seal installer
MB990938 Handle Press-in of the crankshaft rear oil seal
MD998767 Tension pulley
socket wrench
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter Supporting the engine assembly during
Press-in of the crankshaft rear oil seal
Timing belt tension adjustment
removal and installation of the transmission
MB991453 Engine hanger
assembly
11A-6
ENGINE <4G6> -
On-vehicle Service
Alternator pulley
Crankshaft pulley
Adjusting bolt
Lock bolt
Water pump
pulley
ON-VEHICLE SERVICE
11100090432
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the two
pulleys as shown in the illustration. In addition, press this
section with a force of 98 N and check that the amount of
belt deflection is at the standard value.
Standard value:
Tension N 294 - 490
Deflection (Reference value) mm 7.7 - 12.3
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Standard value:
Items When a used
belt is installed
Tension N 343 - 441 490- 686
Deflection (Reference
value) mm
8.4 - 10.6 5.9- 7.7
When a new
belt is installed
4. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
5. Tighten the lock bolt.
Tightening torque: 22 Nm
6. Tighten the adjusting bolt.
Tightening torque: 10 Nm
ENGINE <4G6> -
On-vehicle Service
11A-7
<VehicleswithoutA/C>
Oil pump pulley
98 N
A
Crankshaft
pulley
<VehicleswithA/C>
Oil pump pulley
98 N
Crankshaft
pulley
A
B
Tensioner pulley
Tensioner
pulley
B
A/C
compressor
pulley
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT
11100130127
1. Use a belt tension gauge to check that the belt tension
is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
Standard value:
Items When
checked
Tension N 392 - 588 441 - 539 637-833
Deflection
(Reference
value) mm
11.7 - 15.3 12.5 - 14.3 8.8 - 11.0
When a
used belt is
installed
When a new
belt is
installed
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
Tightening torque: 25 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
IGNITION TIMING CHECK
11100170297
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Check that engine idle speed is within the standard value.
Standard value: 750±100 r/min
6. Select No.17 of the MUT-II Actuator test.
11A-8
ENGINE <4G6> -
7. Check that basic ignition timing is within the standard
value.
Standard value: 5_BTDC±2
8. If the basic ignition timing is outside the standard value,
inspect the MPI system while referring to GROUP 13A
- Troubleshooting.
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this condition
may damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 10_BTDC
NOTE
1. Ignition timing is variable within about ± 7_, even
2. And it is automatically further advanced by about
On-vehicle Service
_
under normal operating.
5_ from standard value at higher altitudes.
IDLE SPEED CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
3. Check the basic ignition timing.
Standard value: 5_BTDC±2
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a
reading of the idle speed.
Standard value: 750±100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
6. If the idle speed is outside the standard value, inspect
the MPI components by referring to GROUP 13A Troubleshooting.
_
IDLE MIXTURE CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
3. Check that the basic ignition timing is within the standard
value.
Standard value: 5_BTDC±2
4. Run the engine at 2,500 r/min for 2 minutes.
_
11100350066
11100210418
ENGINE <4G6> -
ENGINE <4G6> -
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value
7. If there is a deviation from the standard value, check
the following items:
D Diagnosis output
D Closed-loop control (When the closed-loop control
D Fuel pressure
D Injector
D Ignition coil, spark plug cable, spark plug
D Leak in the EGR system and in the EGR valve
D Evaporative emission control system
D Compression pressure
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
On-vehicle Service
On-vehicle Service
CO contents: 0.5% or less
HC contents: 100 ppm or less
is normal, the output signal of the oxygen sensor
changes between 0 - 400 mV and 600 - 1,000 mV
at idle.)
11A-9
COMPRESSION PRESSURE CHECK
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the spark plug hole when
cranking.
2. If compression is measured with water, oil, fuel,
etc.,thathascomefromcracksinsidethecylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
11100260499
11A-10
Compression gauge
ENGINE <4G6> -
6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 250-400 r/min):
Limit (at engine speed of 250-400 r/min):
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 100 kPa
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
(1) If the compression increases after oil is added, the
(2) If the compression does not rise after oil is added,
10. Connect the crank angle sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
On-vehicle Service
1,400 kPa
Min. 1,060 kPa
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
Vacuum gage
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 to 95_C.
2. Connect a tachometer.
3. Attach a three-way union to the vacuum hose between
the fuel pressure regulator and the air intake plenum,
and connect a vacuum gauge.
4. Start the engine and check that idle speed is within
standard value. Then read off the vacuum gauge.
Limit: Min. 69 kPa
11100270409
ENGINE <4G6> -
On-vehicle Service
11A-11
LASH ADJUSTER CHECK
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused y
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N ® D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or has disappeared,
the cause of the noise was probably that oil sludge had
caused the lash adjusters to become stuck. If this
happens, carry out the following check. If the noise level
does not change, go to step 5.
(1) Let the engine cool down sufficiently.
(2) Turn the crankshaft two full revolutions.
11100290344
11A-12
ENGINE <4G6> -
(3) Carry out lash adjuster simple check. (Refer to
5. Bleed the air from the lash adjusters. (Refer to P.11A-13.)
6. If the noise does not disappear even after the air has
been bled from the lash adjusters, carry out the following
check.
Carry out lash adjuster simple check. (Refer to P.11A-13.)
D If one of the rocker arms can be pushed down easily
D If two or more of the rocker arms can be pushed
D If the lash adjuster simple check has been carried
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to the
Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the Engine
Workshop Manual.)
7. Start the engine and check that the abnormal noise has
disappeared. If necessary, bleed the air from the lash
adjusters. (Refer to P.11A-13.)
On-vehicle Service
P.11A-13.)
D If any of the rocker arms can be pushed down
easily during the lash adjuster simple check,
replace the corresponding lash adjusters.
D If the lash adjuster simple check has been carried
out but all lash adjusters are normal (if none of
the rocker arms could be pushed down easily),
check for some other cause of the problem.
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to
the Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the
Engine Workshop Manual.)
during the lash adjuster simple check, replace the
corresponding lash adjuster.
down easily during the lash adjuster simple check,
the cause may be that the oil passage to the cylinder
head is blocked.
Check for blockages in the oil passage, and clear
the blockages if any are found. If there are no
blockages, replace the lash adjusters.
out but all lash adjusters are normal (if none of the
rocker arms could be pushed down easily), check
for some other cause of the problem.
ENGINE <4G6> -
<LASH ADJUSTER SIMPLE CHECK>
1. Stop the engine.
2. Remove the rocker cover.
3. Set the No.1 cylinder to the compression top dead centre
position.
4. Check the rocker arms indicated by white arrows in the
illustration by the procedures given below.
<Checking an intake-side rocker arm>
Check whether the rocker arm moves downwards when
the part of the rocker arm which touches the top of the
lash adjuster is pushed.
D If the rocker arm moves down easily when it is pushed,
D If the rocker arm feels extremely stiff when it is pushed
<Checking an exhaust-side rocker arm>
NOTE
It will not be possible to depress the Y-shaped rocker
arm at the exhaust valve side if one lash adjuster is
defective but the other one is normal. In such cases,
carry out the following procedure using a thickness gauge.
(1) Check that a thickness gauge with a thickness of
(2) If the thickness gauge can be inserted easily, make
(3) If the thickness gauge cannot be inserted easily, the
5. Slowly turn the crankshaft 360_ in the clockwise direction.
6. Check the rocker arms indicated by black arrows in the
illustration in the same way as explained in step 4.
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
(2) After parking the vehicle for long periods, the oil drains
(3) If either of the above situations occur, the abnormal
On-vehicle Service
make a note of which is the corresponding lash
adjuster.
and does not move down, the lash adjuster is normal,
so check for some other cause of the problem.
0.1 - 0.2 mm can be inserted easily between the
valve and the lash adjuster.
a note of which is the corresponding lash adjuster.
lash adjuster is normal, so check for some other cause
of the problem.
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
noise can be eliminated by bleeding the air from inside
the lash adjusters.
11A-13
11A-14
Good
ENGINE <4G6> -
ENGINE <4G6> -
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
(2) If the amount of oil is greater than normal, then the
(3) If the oil is degenerated, air and oil will not separate
On-vehicle Service
On-vehicle Service
in through the oil screen and will get into the oil
passage.
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
easily in oil, and the amount of air mixed into the
oil will increase.
Drive pattern for air bleeding
Gradually open the
throttle valve.
Approx.
3,000 r/min.
Idle speed
15
seconds
Once
Close the throttle
valve.
15
seconds
High
pressure
chamber
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
ENGINE <4G6> -
Crankshaft Pulley
11A-15
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation
D Under Cover Removal
2
25 Nm
11200160303
Post-installation Operation
D Drive Belt Tension Adjustment (Refer to P.11A-6.)
D Under Cover Installation
3
Removal steps
1. Drive belt (Power steering and
A/C)
1
2. Drive belt (Alternator)
3. Crankshaft pulley
11A-16
ENGINE <4G6> -
Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Air Cleaner Removal and Installation
D Timing Belt Removal and Installation (Refer to
P.11A-26.)
D Relay Box Removal and Installation
10 Nm
1
2
4
14 Nm
3
22 Nm
3.4 Nm
11200190418
5
(f 3 ± 1 mm)
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
5
AA""CA
5
28-34 Nm
9
6
12
Removal steps
1. Control harness connection
2. Spark plug cable
3. PCV hose connection
4. Rocker cover
5. Camshaft position sensor support
6. Camshaft position sensing cylinder
7. Camshaft sprocket
8
7
"BA
AB""AA
AB""AA
8
Lipsection
11
10
Cam section and
88 Nm
journal section
12
Engine oil
8. Camshaft oil seal
9. Spark plug guide oil seal
10. Rocker arm and shaft assembly
(intake side)
11. Rocker arm and shaft assembly
(exhaust side)
12. Camshaft
MB990767
ENGINE <4G6> -
MD998719 or
MD998754
Camshaft and Camshaft Oil Seal
REMOVAL SERVICE POINTS
AA"
CAMSHAFT SPROCKET REMOVAL
11A-17
MD998443
AB"
Before removing the rocker arm and shaft assembly, install
the special tools as shown in the illustration so that the lash
adjusters will not fall out.
ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
INSTALLATION SERVICE POINTS
"AA
1. Temporarily tighten the rocker shaft with the bolt so that
2. Fit the rocker shaft spring from the above and position
3. Remove the special tool for fixing the lash adjuster.
ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
all rocker arms on the inlet valve side do not push the
valves.
it so that it is right angles to the plug guide.
NOTE
Install the rocker shaft spring before installing the rocker
arm and rocker arm shaft on the exhaust side.
4. Confirm that the rocker shaft notch is in the direction
shown in the diagram.
11A-18
ENGINE <4G6> -
Camshaft and Camshaft Oil Seal
MD998713
"BA
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
"CA
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
CAMSHAFT OIL SEAL INSTALLATION
CAMSHAFT SPROCKET INSTALLATION
ENGINE <4G6> -
Oil Pan
11A-19
OIL PAN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Oil Draining and Supplying (Refer to GROUP
12 - On-vehicle Service.)
D Oil Level Gauge Removal and Installation
5
f 4 ± 1mm
Groove
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
Bolt
hole
11200280207
D Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
5
3
4
"AA
MD998727
Drain plug
gasket
Removal steps
1. Drain plug
2. Drain plug gasket
3. Bell housing cover
MD998727
Oil pan side
7Nm
2
9Nm
AA"
1
4. Oil level sensor
5. Oil pan
9Nm
REMOVAL SERVICE POINT
AA"
After removing the oil pan mounting bolts, remove the oil
pan with the special tool and a brass bar.
Caution
Perform this slowly to avoid deformation of the oil pan
flange.
OIL PAN REMOVAL
INSTALLATION SERVICE POINT
"AA
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
DRAIN PLUG GASKET INSTALLATION
11A-20
ENGINE <4G6> -
Crankshaft Oil Seal
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
127-137 Nm
127-137 Nm
6
8
<M/T>
7
8
<A/T>
10
11200310135
9
11
12
2
4
1
<M/T>
Crankshaft
(Engine oil:
bolt washer surface)
<A/T>
Crankshaft
(Engine oil:
bolt washer
surface)
9
10
Sealant: 3M Stud locking 4170 or equivalent
Crankshaft front oil seal removal
steps
Timing belt (Refer to P.11A-26.)
D
Crank angle sensor
D
(Refer to GROUP 16.)
1. Crankshaft sprocket
2. Flange
3. Crankshaft sprocket B
4. Key
"CA
5. Crankshaft front oil seal
5
3
12
Lip section
Engine oil
Crankshaft rear oil seal removal
steps
Oil pan (Refer to P.11A-19.)
D
AA"D
AB""BA
AB""BA
AB""BA
AB""BA
AB""BA
"AA
Transmission assembly
Clutch cover and disc <M/T>
D
6. Crankshaft bushing
7. Plate <M/T>
8. Adapter plate
9. Flywheel <M/T>
10. Drive plate <A/T>
11. Adapter plate <M/T>
12. Crankshaft rear oil seal
5
Lip section
ENGINE <4G6> -
Crankshaft Oil Seal
11A-21
<M/T>
Flywheel
Crankshaft
rear oil seal
MD990938
MD998781
Bolt
Crankshaft
REMOVAL SERVICE POINTS
AA"
<M/T>:
Refer to GROUP 22.
Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
<A/T>:
Refer to GROUP 23.
AB"
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.
TRANSMISSION ASSEMBLY REMOVAL
PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE <A/T> REMOVAL
INSTALLATION SERVICE POINTS
"AA
1. Apply a small mount of engine oil to the entire
2. Install the oil seal by tapping it as far as the chamfered
CRANKSHAFT REAR OIL SEAL INSTALLATION
circumference of the oil seal lip.
position of the oil seal case as shown in the illustration.
MD998776
"BA
DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER
PLATE/PLATE <M/T> INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the flywheel or drive plate.
2. Apply oil to the bearing surface of the flywheel or drive
plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to hold the flywheel or drive plate
in the same manner as removal, and install the bolt.
"CA
CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Press-fit the oil seal unit it is flush with the oil seal case.
11A-22
ENGINE <4G6> -
Cylinder Head Gasket
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal Operation
D Fuel Discharge Prevention (Refer to GROUP 13A
- On-vehicle Service.)
D Engine Oil Draining (Refer to GROUP 12 -
On-vehicle Service.)
D Thermostat Case Assembly Removal (Refer to
GROUP 14 - Water Hose and Water Pipe.)
1
10
5
11200400542
Post-installation Operation
D Thermostat Case Assembly Installation (Refer to
GROUP 14 - Water Hose and Water Pipe.)
D Engine Oil Supplying (Refer to GROUP 12 -
On-vehicle Service.)
D Accelerator Cable Adjustment (Refer to GROUP
17 - On-vehicle Service.)
Delivery pipe
O-ring
9
10
Engine oil
7
2
8
6
4
3
11
Removal steps
1. Accelerator cable connection
2. Vacuum hose connection
3. Brake booster vacuum hose
connection
4. Vacuum hose connection
5. Throttle position sensor connector
6. Idle speed control connector
"CA
7. Injector connector
8. Purge control solenoid valve
connector
9. EGR solenoid valve connector
10. High-pressure fuel hose connection
11. Fuel return hose connection
ENGINE <4G6> -
<Cold engine>
78 Nm®0Nm®20 Nm®+90
(Engine oil)
17
19
_ ®
Cylinder Head Gasket
10 Nm
+90
_
16
27
12
28
11A-23
15
14
3.4 Nm
26
13
22
18
20
21
24 Nm
23
31 Nm
12. Radiator upper hose connection
13. PCV hose
14. Ignition coil connector
15. Ignition coil assembly
16. Breather hose
17. Engine coolant temperature sensor
connector
18. Engine coolant temperature gauge
unit connector
19. Camshaft position sensor
20. Water hose connection
29
24
AA"
AB""BA
"AA
49 Nm
44 Nm
25
34 Nm
21. Heater hose connection
22. Thermostat case assembly
23. Water hose connection
24. Power steering oil pump and
bracket assembly
25. Front exhaust pipe connection
26. Rocker cover
Timing belt (Refer to P.11A-26.)
D
27. Cylinder head bolt
28. Cylinder head assembly
29. Cylinder head gasket
11A-24
ENGINE <4G6> -
REMOVAL SERVICE POINTS
AA"
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
cylinder head assembly, and tie it with a cord.
Cylinder Head Gasket
POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Intake side
351082
17964
Exhaust side
Head bolt
A
washer
Front of engine
Burred side
Cylinder
head
Head bolt
(Engine
oil)
AB"
CYLINDER HEAD BOLT REMOVAL
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
Caution
Because the plug guides cannot be replaced by
themselves, be careful not to damage or deform the plug
guides when removing the cylinder head bolts.
INSTALLATION SERVICE POINTS
"AA
1. Wipe off all oil and grease from the gasket mounting
2. Install so that the shapes of the cylinder head holes match
"BA
1. When installing the cylinder head bolts, the length below
2. The head bolt washer should be installed with the burred
3. Apply a small amount of engine oil to the thread section
CYLINDER HEAD GASKET INSTALLATION
surface.
the shapes of the respective cylinder head gasket holes.
CYLINDER HEAD BOLT INSTALLATION
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Limit (A): 99.4 mm
side caused by tapping out facing upwards.
and the washer of the cylinder head bolt.
ENGINE <4G6> -
Cylinder Head Gasket
11A-25
Intake side
86139
104257
Exhaust side
Step 4
_
90
Painted mark
Front of engine
Step 5
Painted mark
90
4. Tighten the bolts by the following procedure.
Step Operation Remarks
1 Tighten to 78 Nm. Carry out in the order
shown in the illustration.
2 Fully loosen. Carry out in the reverse
order of that shown in the
illustration.
3 Tighten to 20 Nm. Carry out in the order
shown in the illustration.
4 Tighten 90_of a turn. In the order shown in the
illustration. Mark the head
of the cylinder head bolt
_
5 Tighten 90_of a turn. In the order shown in the
and cylinder head by paint.
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Caution
1. Always make a tightening angle just 90_. If it is less
than 90_, the head bolt will be loosened.
2. If it is more than 90_, remove the head bolt and repeat
the procedure from step 1.
"CA
HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the high-pressure fuel hose to the right
and left, install the delivery pipe, while being careful not
to damage the O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert
the delivery pipe and check that the hose turns smoothly.
11A-26
ENGINE <4G6> -
Timing Belt
TIMING BELT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Crankshaft Pulley Removal and Installation (Refer
to P.11A-15.)
D Engine Mount Bracket Removal and Installation
(Refer to GROUP 32 - Engine Mounting.)
1
10-12 Nm
5
11200430473
3
48 Nm
AA""BA
"CAD
"AA
9Nm
Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
Timing belt tension adjustment
3. Timing belt
4. Tension pulley
5. Auto tensioner
4
24 Nm
2
ENGINE <4G6> -
Timing Belt
11A-27
Timing mark (Top
of cylinder head)
Timing mark
Timing mark
Crankshaft
sprocket
B
A
Auto tensioner
Timing mark
98N - 196N
Camshaft sprocket
Timing mark
Oil pump
sprocket
Centre bolt
Movement
Push rod
REMOVAL SERVICE POINT
AA"
1. Turn the crankshaft clockwise (right turn) to align each
2. Loosen the tension pulley centre bolt.
3. Move the tension pulley to the water pump side, and
TIMING BELT REMOVAL
timing mark and to set the No. 1 cylinder at compression
top dead centre.
Caution
The crankshaft should always be turned only
clockwise.
then remove the timing belt.
Caution
If the timing belt is to be re-used, use chalk to mark
(on its flat side) an arrow indicating the clockwise
direction.
INSTALLATION SERVICE POINTS
"AA
1. Apply 98 - 196 N force to the auto tensioner by pressing
AUTO TENSIONER INSTALLATION
it against a metal (cylinder block, etc.), and measure the
movement of the push rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
AB
2. If it is out of the standard value, replace the auto tensioner.
3. Use a press or vice to gently compress the auto tensioner
push rod until pin hole A of the push rod and pin hole
B of the tensioner cylinder are aligned.
Caution
If the compression speed is too fast, the rod may
become damaged, so be sure to carry out this
operation slowly.
11A-28
ENGINE <4G6> -
Timing Belt
Timing mark (Top
of cylinder head)
Timing mark
Timing mark
Crankshaft
sprocket
Plug
Set pin
Timing mark
Camshaft sprocket
Timing mark
60 mm or
more
Counterbalance
shaft
Oil pump
sprocket
Screwdriver
Cylinder
block
8mm
4. Once the holes are aligned, insert the set pin.
NOTE
When replacing the auto tensioner with a new part, the
pin will be in the auto tensioner.
5. Install the auto tensioner to the engine.
"BA
TIMING BELT INSTALLATION
1. Align the timing marks on the camshaft sprocket,
crankshaft sprocket and oil pump sprocket.
2. After aligning the timing mark on the oil pump sprocket,
remove the cylinder block plug and insert a Phillips
screwdriver with a diameter of 8 mm, and check to be
sure that the screwdriver goes in 60 mm or more. If
the screwdriver will only go in 20 - 25 mm before striking
the counterbalance shaft, turn the sprocket once, realign
the timing mark and check that the screwdriver goes in
60 mm or more. The screwdriver should not be taken
out until the timing belt is installed.
Fixing bolt
Pin hole
Belt tension side
Belt tension side
3. Install the belt to the crankshaft sprocket, oil pump
sprocket and camshaft sprocket in that order, so that
there is no slackness in the belt tension.
Caution
If the timing belt is re-used, install so that the arrow
marked on it at time of removal is pointing in the
clockwise direction.
4. Set the tension pulley so that the pin holes are at the
top, press the tension pulley lightly against the timing
belt, and then provisionally tighten the fixing bolt.
5. Adjust the timing belt tension.
ENGINE <4G6> -
Timing Belt
11A-29
50 Nm
MD998767
A
Auto tensioner
Tension
direction
"CA
TIMING BELT TENSION ADJUSTMENT
1. After turning the crankshaft 1/4 of a revolution in the
anticlockwise direction, turn it in the clockwise direction
until the timing marks are aligned.
2. Loosen the tension pulley fixing bolt, and then use the
special tool and a torque wrench to tighten the fixing
bolt to the specified torque while applying tension to the
timing belt.
Standard value: 3.5 Nm <Timing belt tension torque>
Caution
When tightening the fixing bolt, make sure that the
tension pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise
direction so that the timing marks are aligned. After leaving
it for 15 minutes, measure the amount of protrusion of
the auto tensioner.
Standard value (A): 3.8 - 4.5 mm
4. If the amount of protrusion is outside the standard value,
repeat the operation in steps (1) to (3).
5. Check again to be sure that the timing marks of each
sprocket are aligned.
11A-30
ENGINE <4G6> -
Timing Belt B
TIMING BELT B
REMOVAL AND INSTALLATION
1
19 Nm
4
108 - 127 Nm
11200460106
5
3
2
Removal steps
1. Timing belt (Refer to P.11A-26.)
AA""CA 2. Crankshaft sprocket
"BA 3. Flange
Crankshaft
sprocket
MD998719 or MD998754
MB990767
4. Timing belt B tensioner
AB""AA 5. Timing belt B
REMOVAL SERVICE POINTS
AA"
AB"
Caution
If timing belt “B” is to be re-used, use chalk to mark
it with an arrow on its flat side indicating the turning
direction (to the right).
CRANKSHAFT SPROCKET REMOVAL
TIMING BELT B REMOVAL
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