Mitsubishi 4D6, 4G6, 6A1 User Manual

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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

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

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

Oil pump pulley

98 N

Crankshaft pulley

Oil pump pulley

98 N

Crankshaft pulley

Tensioner pulley

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> -

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

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> -

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

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.

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> -

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

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

25 Nm

11200160303

Post-installation Operation

D Drive Belt Tension Adjustment (Refer to P.11A-6.) D Under Cover Installation

Removal steps

1. Drive belt (Power steering and A/C)

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

14 Nm

22 Nm

3.4 Nm

11200190418

(f 3 ± 1 mm)

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

AA""CA

28-34 Nm

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

"BA

AB""AA

Lipsection

Cam section and

88 Nm

journal section

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

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.)

"AA

MD998727

Drain plug gasket

Removal steps

1. Drain plug

2. Drain plug gasket

3. Bell housing cover

MD998727

Oil pan side

7Nm

9Nm

AA"

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

<M/T>

<A/T>

11200310135

<M/T>

Crankshaft

(Engine oil: bolt washer surface)

<A/T>

Crankshaft

(Engine oil: bolt washer surface)

Sealant: 3M Stud locking 4170 or equivalent

Crankshaft front oil seal removal steps

Timing belt (Refer to P.11A-26.)

Crank angle sensor

(Refer to GROUP 16.)

1. Crankshaft sprocket

2. Flange

3. Crankshaft sprocket B

4. Key

"CA

5. Crankshaft front oil seal

Lip section

Engine oil

Crankshaft rear oil seal removal steps

Oil pan (Refer to P.11A-19.)

AA"D

AB""BA AB""BA AB""BA AB""BA AB""BA

"AA

Transmission assembly Clutch cover and disc <M/T>

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

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.)

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

Engine oil

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)

_ ®

Cylinder Head Gasket

10 Nm

+90

11A-23

3.4 Nm

24 Nm

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

AA"

AB""BA

"AA

49 Nm

44 Nm

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.)

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

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

Painted mark

Front of engine

Step 5

Painted mark

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.)

10-12 Nm

11200430473

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

24 Nm

ENGINE <4G6> -

Timing Belt

11A-27

Timing mark (Top of cylinder head)

Timing mark

Crankshaft sprocket

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

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

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

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

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

19 Nm

108 - 127 Nm

11200460106

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

ENGINE <4G6> -

Timing Belt B

11A-31

Counterbalance shaft sprocket

Timing marks

Crankshaft sprocket B

Centre of tensioner pulley

Centre of installation bolt

Shaft

Belt tension side

Timing marks

INSTALLATION SERVICE POINTS

"AA

1. Install timing belt “B” by the following procedure.

2. Adjust the tension of timing belt “B” by the following

TIMING BELT B INSTALLATION, ADJUSTMENT

(1) Ensure that crankshaft sprocket “B” timing mark and

the counterbalance shaft sprocket timing mark are aligned.

(2) Fit timing belt “B” over crankshaft sprocket “B” and

the counterbalance shaft sprocket. Ensure that there is no slack in the belt.

procedure. (1) Temporarily fix the timing belt “B” tensioner such that

the centre of the tensioner pulley is to the left and above the centre of the installation bolt, and temporarily attach the tensioner pulley so that the flange is toward the front of the engine.

(2) Holding the timing belt “B” tensioner up with your

finger in the direction of the arrow, place pressure on the timing belt so that the tension side of the belt is taut. Now tighten the bolt to fix the tensioner.

Caution Whentighteningthebolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.

Centre of tensioner pulley

Centre of installation bolt

Crankshaft sprocket

Flange

Crankshaft

Crankshaft sprocket “B”

3. To ensure that the tension is correct, depress the belt (point A) with a finger. If not, adjust.

Standard value: 5 - 7 mm

"BA

FLANGE INSTALLATION

When installing, make sure the direction is correct. See figure.

11A-32

ENGINE <4G6> -

Timing Belt B

Crankshaft sprocket

MD998719 or MD998754

MB990767

"CA

CRANKSHAFT SPROCKET INSTALLATION

NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt.

ENGINE <4G6> -

Engine Assembly

11A-33

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

Pre-removal Operation

D Fuel Discharge Prevention (Refer to GROUP 13A

- On-vehicle Service.)

D Engine Coolant Draining D Thermostat Case Assembly Removal (Refer to

GROUP 14 - Water Hose and Water Pipe.)

D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Hood Removal (Refer to GROUP 42.) D Under Cover Removal D Radiator Assembly Removal (Refer to GROUP 14.) D Air Cleaner Removal

11200090015

Post-installation Operation

D Thermostat Case Assembly Installation (Refer to

GROUP 14 - Water Hose and Water Pipe.)

D Engine Coolant Supplying D Accelerator Cable Adjustment (Refer to GROUP

17 - On-vehicle Service.)

D Front Exhaust Pipe Installation (Refer to GROUP

15.)

D Hood Installation (Refer to GROUP 42.) D Under Cover Installation D Radiator Assembly Installation (Refer to GROUP

14.)

D Air Cleaner Installation

Delivery pipe

O-ring

Engine oil

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

"DA

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

12. PCV hose connection

11A-34

ENGINE <4G6> -

Engine Assembly

49 Nm

57 Nm*

13. Drive belt (Alternator)

14. Drive belt (Power steering and A/C)

AA" 15. Power steering oil pump and

bracket assembly

AB" 16. A/C compressor

17. Alternator connector

18. Oil pressure switch connector

19. Heater hose connection

20. Engine coolant temperature gauge unit connector

21. Engine coolant temperature sensor connector

98 Nm

22. Camshaft position sensor connector

23. Detonation sensor connector

AC"DTransmission assembly AD""CA 24. Engine mount bracket

"BA 25. Engine mount stopper

AE""AA 26. Engine assembly

Caution Mounting locations marked by * should be provisionally tightened, and thenfully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

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 engine assembly, and tie it with a cord.

Engine Assembly

11A-35

POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL

<M/T>

Flywheel

MB991453

Bolt

MZ203827

AB"

A/C COMPRESSOR REMOVAL

Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached.

NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

AC"

TRANSMISSION ASSEMBLY REMOVAL

<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.

AD"

ENGINE MOUNT BRACKET REMOVAL

1. Support the engine with a garage jack.

2. Remove the special tool which was attached when the transmission assembly was removed.

3. Hold the engine assembly with a chain block or similar tool.

4. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket.

AE"

ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.

11A-36

ENGINE <4G6> -

INSTALLATION SERVICE POINTS

"AA

Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

Engine Assembly

ENGINE ASSEMBLY INSTALLATION

Engine mount stopper

Engine mount bracket

Engine side

Dynamic damper

Arrow

"BA

ENGINE MOUNT STOPPER INSTALLATION

Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram.

"CA

ENGINE MOUNT BRACKET INSTALLATION

1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.

2. Support the engine with the garage jack.

3. Remove the chain block and support the engine assembly with the special tool.

"DA

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 it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly.

ENGINE <6A1>

11B-1

CONTENTS

GENERAL INFORMATION 2..................

SERVICE SPECIFICATIONS 2.................

SEALANTS 3................................

SPECIAL TOOLS 3...........................

ON-VEHICLE SERVICE 5.....................

Drive Belt Tension Check and Adjustment 5......

Ignition Timing Check 6.........................

Idle Speed Check 7............................

Idle Mixture Check 7...........................

Compression Pressure Check 8.................

Manifold Vacuum Check 9......................

Lash Adjuster Check 10........................

11109000610

CRANKSHAFT PULLEY 14...................

CAMSHAFT AND CAMSHAFT OIL SEAL 15...

OIL PAN 18..................................

CRANKSHAFT OIL SEAL 21..................

CYLINDER HEAD GASKET 24................

TIMING BELT 26.............................

ENGINE ASSEMBLY 30.......................

11B-2

ENGINE <6A1> -

General Information/Service Specifications

GENERAL INFORMATION

Items 6A13

Total displacement mL 2,498

Bore ´ Stroke mm 81.0 ´ 80.8

Compression ratio 9.5

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

BTDC 15_

ABDC 53_

BBDC 53_

ATDC 15_

11100010452

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 (Reference value) mm

When a used belt is installed 343 - 441 -

When checked 9.0 - 13.0 -

When a used belt is installed 10.0 - 12.0 -

When a new belt is installed 6.8 - 8.0 -

When checked 490 - 686 -

When a used belt is installed 539 - 637 -

When a new belt is installed 784 - 980 -

When checked 11.0 - 15.0 -

When a used belt is installed 12.0 - 14.0 -

When a new belt is installed 8.0 - 12.0 -

11100030496

Basic ignition timing 5_ BTDC±3_ -

Ignition timing Approx. 7° BTDC -

ENGINE <6A1> -

Items LimitStandard value

Idle speed r/min 650 ± 100 -

CO contents % 0.2 or less -

HC contents ppm 100 or less -

Compression pressure (250 - 400 r/min) kPa 1177 Min. 875

Compression pressure difference of all cylinder kPa - Max. 98

Intake manifold vacuum kPa - Min. 60

Cylinder head bolt shank length mm - 96.4

Auto-tensioner push rod movement mm Within 1 -

Timing belt tension torque Nm 3 -

Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -

Service Specifications/Sealants/Special Tools

11B-3

SEALANTS

Items Specified sealants Remarks

Oil pan MITSUBISHI GENUINE PART

MD970389 or equivalent

Flywheel bolt or drive plate bolt 3M Stud Locking 4170 or equivalent -

Semi-drying sealant

SPECIAL TOOLS

Tool Number Name Use

MB991502 MUT-II sub

assembly

MB990767 End yoke holder D Holding the camshaft sprocket

Engine idle speed check Erasing diagnosis code

D Holding the crankshaft pulley

11100050379

11100060464

MD998719 Crankshaft pulley

holder pin

MD998715 Crankshaft pulley

holder pin

11B-4

Tool UseNameNumber

ENGINE <6A1> -

Special Tools

MD998443 Auto-lash adjuster

holder

MD998713 Camshaft oil seal

installer

MD998776 Crankshaft rear oil

seal installer

MB990938 Handle Press-in of the crankshaft rear oil seal

Supporting of auto-lash adjuster

Press-in of the camshaft oil seal

Press-in of the crankshaft rear oil seal

MD998767 Tension pulley

socket wrench

MD998717 Crankshaft front

oil seal installer

MD998727 Oil pan remover Removal of oil pan

MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate

Timing belt tension adjustment

Press-in of the crankshaft front oil seal

<A/T>

GENERAL SERVICE TOOL MZ203827

Engine lifter Supporting the engine assembly during

removal and installation of the transmission

ENGINE <6A1> -

Tool UseNameNumber

Special Tools/On-vehicle Service

11B-5

Alternator pulley

Crankshaft pulley

MB991453 Engine hanger

assembly

Tension pulley

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK AND ADJUSTMENT

ALTERNATOR DRIVE BELT TENSION CHECK

Standard value:

Supporting the engine assembly during removal and installation of the transmission

11100090425

Adjusting bolt

Fixing nut

Tension N 294 - 490

Deflection (Reference value) mm 9.0 - 13.0

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT

1. Loosen the tension pulley fixing nut.

2. Use the adjusting bolt to adjust the belt tension or deflection to the standard value.

Standard value:

Items When a used

belt is installed

Tension N 343 - 441 490- 686

Deflection (Reference value) mm

10.0 - 12.0 6.8 - 8.0

When a new belt is installed

3. Tighten the fixing nut.

Tightening torque: 49 Nm Caution

Turnthecrankshaftonefull rotation or more clockwise before this check.

11B-6

ENGINE <6A1> -

On-vehicle Service

Crankshaft pulley

Power steering oil pump pulley

POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

11100130134

A/C compressor pulley

check that the amount of belt deflection is at the standard value.

Standard value:

Items When

checked

Tension N 490 - 686 539 - 637 784 - 980

Deflection (Reference value) mm

11.0 - 15.0 12.0 - 14.0 8.0 - 12.0

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: 49 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

11100170280

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: 650±100 r/min

6. Select No.17 of the MUT-II Actuator test.

7. Check that basic ignition timing is within the standard value.

Standard value: 5_BTDC±3

8. If the basic ignition timing is outside the standard value, inspect the MPI system while referring to GROUP 13A

- Troubleshooting.

ENGINE <6A1> -

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. 7_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.

11B-7

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. Adjust if necessary.

Standard value: 5_BTDC±3

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.

Curb idle speed: 650±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, check 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±3

4. Run the engine at 2,500 r/min for 2 minutes.

11100350059

1110020401

11B-8

ENGINE <6A1> -

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

CO contents: 0.2% 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.)

Crank angle sensor connector

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.

11100260482

ENGINE <6A1> -

On-vehicle Service

11B-9

Compression gauge

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):

1,177 kPa

Limit (at engine speed of 250-400 r/min):

Min. 875 kPa

8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Max. 98 kPa

(1) If the compression increases after oil is added, the

cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is added,

the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

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.

Vacuum gauge

Fuel pressure regulator

NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

MANIFOLD VACUUM CHECK

11100270393

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 the standard value. Then read off the vacuum gauge.

Limit: Min. 60 kPa

11B-10

ENGINE <6A1> -

On-vehicle Service

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

(2) If there is a problem with the lash adjusters, the noise

1. Start the engine.

11100290337

ENGINE <6A1> -

(3) Carry out lash adjuster simple check. (Refer to

5. Bleed the air from the lash adjusters. (Refer to P.11B-12.)

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.11B-12.)

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.11B-12.)

On-vehicle Service

P.11B-12.) 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.

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.

11B-11

11B-12

Timing belt side

ENGINE <6A1> -

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

(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.

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.

NOTE (1) If the vehicle is parked on a slope for a long period

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.

(2) After parking the vehicle for long periods, the oil drains

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.

(3) If either of the above situations occur, the abnormal

noise can be eliminated by bleeding the air from inside the lash adjusters.

Good

ENGINE <6A1> -

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

11B-13

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

2. Run the engine at idle for 1 - 3 minutes to let it warm up.

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.

11B-14

ENGINE <6A1> -

Crankshaft Pulley

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

Pre-removal Operation

D Under Cover Removal

(Engine oil)

11200160310

Post-installation Operation

D Drive Belt Tension Adjustment (Refer to P.11B-5.) D Under Cover Installation

MD998719

Removal steps

1. Drive belt (Power steering oil pump, or A/C compressor and power steering oil pump)

2. Drive belt (Alternator)

MB990767

177-186 Nm

AA""AA

3. Crankshaft bolt

4. Washer

5. Crankshaft pulley

REMOVAL SERVICE POINT

AA"

CRANKSHAFT BOLT REMOVAL

INSTALLATION SERVICE POINT

"AA

When installing the crankshaft bolt, apply the minimum amount of engine oil to the bearing surface and thread of the bolt.

CRANKSHAFT BOLT INSTALLATION

ENGINE <6A1> -

Camshaft and Camshaft Oil Seal

11B-15

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Engine Coolant Draining and Refilling (Refer to

GROUP 14 - On-vehicle Service.)

D Air Intake Hose Assembly Removal and Installation

D Timing Belt Removal and Installation (Refer to

P.11B-26.)

D Drive Belt Tension Adjustment (Refer to P.11B-5.)

3.4 Nm

11200220124

Apply engine oil to all sliding parts when installing.

AA""DA AA""DA

28 - 34 Nm

88 Nm

Removal steps

1. Radiator upper hose connection

2. Radiator lower hose connection

3. Blow-by hose connection

4. PCV hose connection

5. Vacuum hose connection

6. Spark plug cable

7. Rocker cover

(Engine oil)

AB""CA

"BA

AC"

"AA

22 Nm

24 Nm

8. Camshaft sprocket

9. Camshaft oil seal

10. Engine hanger

11. Thrust case

12. Rocker arm and shaft assembly

13. Camshaft

11B-16

ENGINE <6A1> -

Camshaft and Camshaft Oil Seal

Pre-removal and Post-installation Operation

D Air Intake Plenum Removal and Installation

(Refer to GROUP 15.)

D Timing Belt Removal and Installation

(Refer to P.11B-26.)

3.4 Nm

28 - 34 Nm

D Distributor Removal and Installation

(Refer to GROUP 16.)

D Drive Belt Tension Adjustment (Refer to P.11B-5.)

Apply engine oil to all sliding parts when

installing.

88 Nm

Removal steps

1. Breather hose connection

2. Blow-by hose connection

6. Spark plug cable

7. Rocker cover

AB""CA

"BA

AC"

"AA

8. Camshaft sprocket

9. Camshaft oil seal

12. Rocker arm and shaft assembly

13. Camshaft

REMOVAL SERVICE POINTS

AA"

After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION

ENGINE <6A1> -

Camshaft and Camshaft Oil Seal

11B-17

MB990767

MD998715

MD998443

AB"

AC"

CAMSHAFT SPROCKET REMOV AL

ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

1. Install the special tools as shown in the illustration so that the lash adjusters will not fall out.

2. Loosen the rocker arm and shaft assembly mounting bolt, and then remove the rocker arm and shaft assembly with the bolt still attached.

Approx. 35

Dowel pin

Approx. 35

Dowel pin

Caution Never disassemble the rocker arm and shaft assembly.

INSTALLATION SERVICE POINTS

"AA

Set the camshaft dowel pins so that they are in the position shown in the illustration.

Caution Do not mistake the camshafts for the front bank and the rear bank. The camshaft for the rear bank has a slit with a width of approximately 4 mm on its rear end.

"BA

1. Apply engine oil to the camshaft oil seal lip.

2. Use the special tool to press-fit the camshaft oil seal.

CAMSHAFT INSTALLATION

CAMSHAFT OIL SEAL INSTALLATION

MD998713

MD991559

MD998713

11B-18

ENGINE <6A1> -

Camshaft and 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.

Tightening torque: 88 Nm

"DA

1. Insert each hose as far as the projection of the water

2. Align the mating marks on the radiator hose and hose

Caution Be sure to install the clamp as far as the old clamp position.

CAMSHAFT SPROCKET INSTALLATION

RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION

inlet fitting.

clamp, and then connect the radiator hose.

ENGINE <6A1> -

Oil Pan

11B-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 D Front Exhaust Pipe Removal a n d Installation (Refer

to GROUP 15.)

Groove

Bolt hole

11200280214

D Under Cover Removal and Installation D Starter Motor Removal and Installation

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

39 Nm

7Nm

44 Nm

7Nm

44 Nm

7Nm

AA"

"AA

Removal steps

1. Drain plug

2. Drain plug gasket

3. Lower oil pan

AA"

4. Cover

5. Upper oil pan

11B-20

ENGINE <6A1> -

Oil Pan

MD998727

Drain plug gasket

MD998727

Oil pan side

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.

LOWER OIL PAN/UPPER 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

ENGINE <6A1> -

Crankshaft Oil Seal

11B-21

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

<M/T>

11200310142

<M/T>

Crankshaft

(Engine oil: bolt washer surface)

<A/T>

Crankshaft

(Engine oil: bolt washer surface)

Sealant: 3M Stud Locking 4170 or equivalent

93 - 103 Nm

"CA

<A/T>

Crankshaft front oil seal removal steps

Timing belt (Refer to P.11B-26.)

Crank angle sensor

(Refer to GROUP 16.)

1. Crankshaft sprocket

2. Crankshaft sensing blade

3. Crankshaft spacer

4. Key

5. Crankshaft front oil seal

Engine oil

Crankshaft rear oil seal removal steps

AA"D AB""BA

AB""BA AB""BA AB""BA AB""BA

"AA

Transmission assembly Clutch cover and disc <M/T>

6. Plate <M/T>

7. Adapter plate

8. Flywheel <M/T>

9. Adapter plate <M/T>

10. Drive plate <A/T>

11. Crankshaft rear oil seal

Lip section

11B-22

ENGINE <6A1> -

Crankshaft Oil Seal

<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.

ENGINE <6A1> -

Crankshaft Oil Seal

11B-23

MD998717

Crankshaft

Oil seal

"CA

CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire circumference of the oil seal lip.

2. Tap the oil seal unit it is flush with the oil seal case.

11B-24

ENGINE <6A1> -

Cylinder Head Gasket

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Engine Coolant Draining and Refilling (Refer to

GROUP 14 - On-vehicle Service.)

D Air Intake Hose Assembly Removal and Installation D Radiator Assembly Removal and Installation (Refer

to GROUP 14 - Radiator.)

D Air Intake Plenum and Intake Manifold Removal and

Installation (Refer to GROUP 15 - Air Intake Plenum.)

D Engine Cover Removal and Installation D Drive Belt Tension Adjustment (Refer to P.11B-5.) D Timing Belt Removal and Installation (Refer to

P.11B-26.)

3.4 Nm

(Engine oil)

11200400559

D Fuel Discharge Prevention (Refer to GROUP 13A

- On-vehicle Service.)

D Front Exhaust Pipe Removal and Installation (Refer

to GROUP 15.)

D Thermostat Case Assembly Removal and Installation

(Refer to GROUP 14 - Water Hoses and Pipes.)

D Water Inlet Pipe Removal and Installation (Refer to

GROUP 14 - Water Hoses and Pipes.)

3.4 Nm

20 Nm®+ 120

10 - 12 Nm

35 Nm

Removal steps

1. PCV hose connection

2. Blow-by hose connection

3. Breather hose connection

4. Vacuum hose connection

5. Spark plug cable

6. Rocker cover

_ ®

+ 120

20 Nm®+ 120

(Engine oil)

_ ®

+ 120

7. Idler pulley

8. Timing belt rear centre cover

AA""BA

"AA

9. Cylinder head bolt

10. Cylinder head assembly

11. Cylinder head gasket

ENGINE <6A1> -

Cylinder Head Gasket

11B-25

Exhaust side

Identification mark

Burred side

Head bolt

washer

Cylinder head

Exhaust side

Intake side

Front of engine

Head bolt

(Engine oil)

REMOVAL SERVICE POINT

AA"

Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly.

CYLINDER HEAD BOLT REMOVAL

INSTALLATION SERVICE POINTS

"AA

1. Wipe off all oil and grease from the gasket mounting

2. Install the gasket to the cylinder block with the identification

"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.

mark facing upwards.

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): 96.4 mm

side caused by tapping out facing upwards.

and the washer of the cylinder head bolt.

Exhaust side

Intake side

Front of engine

4. Install the bolts by the following procedure. (1) Tighten the bolts to 20 Nm in the sequence shown

in the illustration.

(2) From th e position in (1) above, turn each bolt a further

120_ in the same sequence.

(3) Turn each bolt a further 120_ in the same sequence.

Caution

1) If the tightening angle is less than 120_, that bolt will not be sufficiently tight.

2) If a bolt is tightened by morethan the specified angle, loosen the bolts and repeat the procedure from step (1).

11B-26

ENGINE <6A1> -

Timing Belt

TIMING BELT

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Under Cover Removal and Installation D Crankshaft Pulley Removal and Installation D Alternator Removal an d Installation

(Refer to GROUP 16.)

44 Nm

12 Nm

11200430480

D Drive Belt Tension Adjustment (Refer to P.11B-5.)

3Nm

10 - 12 Nm

24 Nm

35 Nm

24 Nm

10 - 12 Nm

Removal steps

1. Engine cover

2. Engine mount stay

3. Power steering hose clamp bolt

4. Crank angle sensor mounting bolt

5. Oil level gauge assembly

6. Engine hanger

7. Tension pulley bracket assembly

8. Tensioner bracket

10 - 12 Nm

22 Nm

AA""BA

9. Timing belt cover (front, upper

10. Timing belt cover (front, upper left)

11. Timing belt cover (front, lower)

"CAD

"AA

12. Flange

13. Timing belt

14. Auto tensioner

right)

Timing belt tension adjustment

Tensioner pulley

Timing belt

ENGINE <6A1> -

REMOVAL SERVICE POINT

AA"

1. Align each of the timing marks.

Timing marks

2. Loosen the centre bolt of the tension pulley and remove the timing belt.

Caution (1) If the timing belt is to be reused, use chalk to

(2) If the timing belt is to be re-used, be careful not

Timing Belt

11B-27

TIMING BELT REMOVAL

mark it with an arrow on its flat side indicating the turning direction.

to damage the teeth of the timing belt against the edges of the camshaft sprocket when removing the timing belt.

98 N - 196 N

Auto tensioner

Set pin

Movement

Push rod

INSTALLATION SERVICE POINTS

"AA

1. Apply 98 - 196 N force to the auto tensioner by pressing

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

4. Once the holes are aligned, insert the set pin.

AUTO TENSIONER INSTALLATION

it against a metal (cylinder block, etc.), a nd 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

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.

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.

11B-28

ENGINE <6A1> -

Timing Belt

Rocker cover

Camshaft sprocket

Crankshaft sprocket

Tension side A Tension side B

Rear bank side camshaft sprocket

Rocker cover

Camshaft sprocket

Timing marks

Tension side C

Tension side D

Pin holes

"BA

TIMING BELT INSTALLATION

1. Check that the timing marks of the both camshaft sprockets and the crankshaft sprocket are aligned.

NOTE In this condition, the No.1 cylinder will be in the compression top dead centre position.

2. Install the timing belt so that there is no slackness on the tension sides of the belt (A, B, C and D).

Caution Be careful not to damage the teeth of the timing belt against the edges of the camshaft sprocket when installing the timing belt.

NOTE If reusing the old timing belt, install it so that the arrow made on the belt during removal is pointing in the direction of rotation (clockwise).

3. Set the tensioner pulley so that the pin holes are at the bottom, press the tensioner pulley lightly against the timing belt, and then provisionally tighten the fixing bolt.

Fixing bolt

4. Apply force to the rear bank side camshaft sprocket in the direction of the arrow to apply tension to the tension sides (A, B, C and D), and check that all of the timing marks are aligned at this time.

ENGINE <6A1> -

Timing Belt

11B-29

MD998767

Tensioner pulley

48 Nm

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 tensioner 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 Nm <Timing belt tension torque> Caution

When tightening the fixing bolt, make sure that the tensioner pulley does not turn with the bolt.

3. Turn the crankshaft two revolutions in the clockwise direction, and after leaving it for 5 minutes or more, check if the set pin of the auto tensioner can be removed and inserted easily.

NOTE If the set pin cannot be inserted easily, the auto tensioner is good. Check if the amount of protrusion of the auto tensioner rod is within the standard value.

Standard value (A): 3.8 - 4.5 mm

If the amount of protrusion is outside the standard value, repeat the procedure in steps 1 to 3

4. Check to b e sure that the timing marks of each sprocket are aligned.

11B-30

ENGINE <6A1> -

Engine Assembly

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

Pre-removal Operation

D Fuel Discharge Prevention (Refer to GROUP 13A

- On-vehicle Service.)

D Under Cover Removal D Hood Removal (Refer to GROUP 42.) D Air Cleaner Removal D Radiator Removal (Refer to GROUP 14.) D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Engine Cover Removal D Battery Removal D Engine Coolant Draining

18 Nm

11200100558

Post-installation Operation

D Front Exhaust Pipe Installation (Refer to GROUP

15.)

D Radiator Installation (Refer to GROUP 14.) D Air Cleaner Installation D Hood Installation (Refer to GROUP 42.) D Under Cover Installation D Drive Belt Tension Adjustment (Refer to P.11B-5.) D Accelerator Cable Adjustment (Refer to GROUP

17 - On-vehicle Service.)

D Engine Cover Installation D Battery Installation D Engine Coolant Supplying

Engine oil

O-ring

Removal steps

1. Accelerator cable connection

2. Capacitor connector

3. Vacuum hose connection

4. TPS connector

5. Accelerator pedal position sensor connector <TCL>

6. ISC connector

7. Control harness connector

8. Distributor connector

9. Vacuum hose connection

10. Engine coolant temperature sensor connector

11. Engine coolant temperature gauge unit connector

12. Injector connector

"DA

13. Power steering oil pressure switch connector

14. Oil pressure harness connector

15. Thermo switch connector

16. Crank angle sensor connector

17. Brake booster vacuum hose connection

18. Fuel return hose connection

19. High-pressure fuel hose connection

20. Earth cable connection

21. Control harness connector

22. Front harness connector

23. Purge control solenoid valve connector

24. EGR solenoid valve connector

ENGINE <6A1> -

Engine Assembly

11B-31

12 Nm

35 Nm

39 Nm

67 Nm

25. Drive belt (Alternator)

26. Drive belt (Power steering and A/C)

27. Clamp bolt (Power steering hose and pipe)

AA" 28. Power steering oil pump assembly AB" 29. A/C compressor

30. Heater hose connection

AC"DTransmission assembly

31. Engine mount stay

57 Nm

98 - 118 Nm*

AD""CA 32. Engine mount bracket

"BA 33. Engine mount stopper

AE""AA 34. Engine assembly

Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

11B-32

ENGINE <6A1> -

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 engine assembly, and tie it with a cord.

Engine Assembly

POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL

<M/T>

Flywheel

MB991453

Bolt

MZ203827

AB"

A/C COMPRESSOR REMOVAL

Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached.

NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

AC"

TRANSMISSION ASSEMBLY REMOVAL

<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.

AD"

ENGINE MOUNT BRACKET REMOVAL

1. Support the engine with a garage jack.

2. Remove the special tool which was attached when the transmission assembly was removed.

3. Hold the engine assembly with a chain block or similar tool.

AE"

ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.

ENGINE <6A1> -

INSTALLATION SERVICE POINTS

"AA

Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

Engine Assembly

ENGINE ASSEMBLY INSTALLATION

11B-33

Engine mount stopper

Engine mount bracket

Engine side

Dynamic damper

Arrow

"BA

ENGINE MOUNT STOPPER INSTALLATION

Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram.

"CA

ENGINE MOUNT BRACKET INSTALLATION

1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.

2. Support the engine with the garage jack.

3. Remove the chain block and support the engine assembly with the special tool.

"DA

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.

NOTES

ENGINE <4D6>

11C-1

CONTENTS

GENERAL INFORMATION 2..................

SERVICE SPECIFICATIONS 2.................

SEALANTS 3................................

SPECIAL TOOLS 4...........................

ON-VEHICLE SERVICE 6.....................

Drive Belt Tension Check and Adjustment 6......

Valve Clearance Check and Adjustment 8........

Injection Timing Check and Adjustment 10........

Idle Speed Check 12...........................

Compression Pressure Check 12................

Timing Belt Tension Adjustment 13...............

11109000627

CRANKSHAFT PULLEY 15...................

CAMSHAFT AND CAMSHAFT OIL SEAL 16...

OIL PAN 18..................................

CRANKSHAFT OIL SEAL 20..................

CYLINDER HEAD GASKET 23................

TIMING BELT 26.............................

TIMING BELT B 30...........................

ENGINE ASSEMBLY 33.......................

11C-2

ENGINE <4D6> -

General Information/Service Specifications

GENERAL INFORMATION

Items 4D68

Total displacement mL 1,998

Bore ´ Stroke mm 82.7 ´ 93.0

Compression ratio 22.4

Combustion chamber Vortex chamber type

Camshaft arrangement SOHC

Number of valve Intake 4

Exhaust 4

Valve timing Intake Opening BTDC 20_

Closing ABDC 48_

Exhaust Opening BBDC 54_

Closing ATDC 22_

Fuel system Distribution type injection pump

11100010476

Rocker arm Roller type

Adjusting screw Elephant foot type

SERVICE SPECIFICATIONS

Items Standard value Limit

Alternator Tension N When checked 343 - 490 drive belt tension

Deflection Centre of belt When checked 8.0 - 10.0 (Reference value) mm

When a used belt is installed 392 - 490 -

When a new belt is installed 490 - 588 -

between alternator pulley and water pump pulley

Centre of belt When checked 7.9 - 9.9 between crankshaft pulley and alternator pulley

When a used belt is installed

When a new belt is installed

When a used belt is installed

8.0 - 9.4 -

7.0 - 8.0 -

7.9 - 9.2 -

11100030502

When a new belt is installed

6.8 - 7.9 -

ENGINE <4D6> -

Items LimitStandard value

Power Tension N When checked 294 - 490 steering oil pump drive belt tension

Deflection When checked 12.6 - 16.3 mm

A/C com- Tension N When checked 392 - 588 pressor drive belt tension

Deflection When checked 9.2 - 12.0 mm

When a used belt is installed 343 - 441 -

When a new belt is installed 490 - 686 -

When a used belt is installed 13.4 - 15.3 -

When a new belt is installed 10.0 - 12.6 -

When a used belt is installed 441 - 539 -

When a new belt is installed 637 - 833 -

When a used belt is installed 9.8 - 11.2 -

When a new belt is installed 7.0 - 8.6 -

Service Specifications/Sealants

11C-3

Valve clearance (at hot) Intake valve 0.35 mm

Exhaust valve 0.45 -

Injection timing (Dial gauge display value mm) 1 ± 0.03

(10_ATDC)

Idle speed r/min 800 ± 30 -

Compression pressure kPa 3,500 Min. 2,560

Compression pressure difference of all cylinder (at engine speed of 280 r/min) kPa

Cylinder head bolt shank length mm - 99.4

Timing belt deflection mm 4-5 -

Timing belt B deflection mm 5-7 -

- Max. 300

SEALANTS

Items Specified sealants Remarks

Oil pan MITSUBISHI GENUINE PART

MD970389 or equivalent

Semi-drying sealant

11100050362

Semi-circular packing and rocker cover seal, and cylinder head seal

Flywheel bolt or adapter plate bolt 3M Stud Locking 4170 or equivalent -

3M ATD Part No.8660 or equivalent

11C-4

ENGINE <4D6> -

Special Tools

SPECIAL TOOLS

Tool Number Name Use

MB991502 MUT-II sub

assembly

MB998720 Prestroke

measuring adapter

MB990767 End yoke holder Holding the camshaft sprocket

MD998719 Crankshaft pulley

holder pin

11100060471

Idle speed check

Adjustment of the injection timing

MD998754 Crankshaft pulley

holder pin

MD998364 Camshaft oil seal

installer

MD998727 Oil pan remover Removal of oil pan

MD998776 Crankshaft rear oil

seal installer

Installing the camshaft oil seal

Press-in of the crankshaft rear oil seal

MB990938 Handle

Tool UseNameNumber

ENGINE <4D6> -

Special Tools

11C-5

MD998382 Crankshaft front oil

seal installer

MD998383 Crankshaft front oil

seal guide

MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate

GENERAL SERVICE TOOL MZ203827

Engine lifter Supporting the engine assembly during

Installing the crankshaft front oil seal

<A/T>

removal and installation of the transmission

MB991453 Engine hanger as-

sembly

11C-6

ENGINE <4D6> -

On-vehicle Service

Alternator pulley

Adjusting bolt

Lock bolt

Crankshaft pulley

Water pump pulley

ON-VEHICLE SERVICE

11100090449

DRIVE BELT TENSION CHECK AND ADJUSTMENT

ALTERNATOR DRIVE BELT TENSION CHECK

Standard value:

Tension N 343 - 490

Deflection (Reference Portion A 8.0 - 10.0 value) mm

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:

Portion B 7.9 - 9.9

Pivot bolt

Items When a

used belt is installed

Tension N 392 - 490 490 - 588

Deflection Portion A 8.0 - 9.4 7.0 - 8.0 (Reference value) mm

Portion B 7.9 - 9.2 6.8 - 7.9

When a new belt is installed

4. Tighten the lock bolt.

Tightening torque: 23 Nm

5. Tighten the nut of the alternator pivot bolt.

Tightening torque: 44 Nm

6. Tighten the adjusting bolt.

Tightening torque: 10 Nm Caution

Check after turning the crankshaft once or more clockwise (right turn).

ENGINE <4D6> -

Power steering oil pump pulley

On-vehicle Service

11C-7

POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK AND ADJUSTMENT

11100110183

1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure. Measure drive belt deflection amount.

Standard value:

Water pump pulley

Oil pump

Items When

checked

Tension N 294 - 490 343 - 441 490 - 686

Deflection (Reference value) mm

12.6 - 16.3 13.4 - 15.3 10.0 - 12.6

When a used belt is installed

When a new belt is installed

2. If the tension is outside the standard value, adjust by the following procedure. (1) Loosen oil pump fixing bolts A and B. Check that

the slide bushing at the place where bolt B was installed is touching the A/C bracket and that there is no looseness in the oil pump mounting.

(2) While holding a bar or similar tool against the oil

pump body, apply a suitable amount of force to the belt with your hand to adjust the tension of the belt.

(3) Tighten oil pump fixing bolts A and B in that order.

Tightening torque: 39 Nm

(4) Check the belt tension, and readjust if necessary.

Caution Check after turning the crankshaft once or more clockwise (right turn).

11C-8

ENGINE <4D6> -

On-vehicle Service

Crankshaft pulley

A/C compressor pulley

COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

11100100203

1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure. Measure drive belt deflection amount.

Standard value:

Items When

checked

Tension N 392 - 588 441 - 539 637 - 833

Deflection (Reference value) mm

9.2 - 12.0 9.8 - 11.2 7.0 - 8.6

When a used belt is installed

When a new belt is installed

2. If the tension is outside the standard value, adjust by the following procedure. (1) Loosen tensioner pulley fixing nut A. (2) Adjust the belt tension using adjusting bolt B. (3) Tighten fixing nut A.

Tightening torque: 25 Nm

(4) Check the belt frequency, tension or deflection, and

readjust if necessary.

Caution Check after turning the crankshaft once or more clockwise (right turn).

Camshaft sprocket

Timing marks

Crankshaft pulley

VALVE CLEARANCE CHECK AND ADJUSTMENT

1. Start the engine and allow it to warm up until the engine coolant temperature reaches 80 to 95 _C.

2. Remove the timing belt upper cover.

3. Remove the rocker cover.

4. Remove the glow plug plate and all of the glow plugs.

5. Turn the crankshaft clockwise to align the crankshaft pulley timing mark and to set the No.1 cylinder or No.4 cylinder to the compression top dead centre position.

NOTE Aligning the camshaft sprocket timing mark will set the No.1 cylinder to the compression top dead centre position. If the crankshaft is turned one more full revolution from this position, the No.4 cylinder will be set to the compression top dead centre position.

11100150130

Timing belt side

ENGINE <4D6> -

On-vehicle Service

11C-9

6. Measure the valve clearance in the places indicated by arrows in the illustration. Arrow A: When the No.1 cylinder is at compression top dead centre Arrow B: When the No.4 cylinder is at compression top dead centre

Standard value:

A B

Intake 0.35 mm 0.25 mm

Exhaust 0.45 mm 0.35 mm

When warm When cold (NOTE)

Flat-tipped screwdriver

Pad

Thickness gauge

Adjusting screw

Pad

Thickness gauge

NOTE (1) When inserting the thickness gauge, press the pad

from the opposite side using a flat-tipped screwdriver or similar tool to make a gap for the thickness gauge to be inserted.

(2) If you attempt to insert the thickness gauge without

using a flat-tipped screwdriver to make a gap, the pad will become tilted as shown in the illustration, and it will not be possible to insert the thickness gauge.

7. If the clearance is outside the standard value, loosen the lock nut and turn the adjusting screw while using a thickness gauge to adjust the clearance.

11C-10

ENGINE <4D6> -

8. Tighten the lock nut while holding the adjusting screw with a screwdriver so that it doesn’t turn.

9. Turn the crankshaft one full revolution to align the crankshaft pulley timing mark.

10. Adjust the remaining valves by the same procedure as in steps 7. - 9. above.

11. Install the glow plugs and the glow plug plate.

12. Install the rocker cover.

13. Install the timing belt upper cover.

INJECTION TIMING CHECK AND ADJUSTMENT

1. Remove all of the glow plugs.

2. Remove the timing belt upper cover.

On-vehicle Service

11100180054

Camshaft sprocket

Dial gauge

Timing marks

Crankshaft pulley

Timing check plug

3. Align the timing marks of the camshaft sprocket and set the No.1 cylinder to the top dead centre position.

4. Remove the timing check plug at the rear of the injection pump.

5. Install the special tool to the timing check plug hole at the rear of the injection pump.

6. Connect the dial gauge to the special tool.

MD998720

Approx. 30

Timing mark

Set to 10 ATDC

ENGINE <4D6> -

On-vehicle Service

11C-11

7. Turn the crankshaft clockwise to move the No.1 cylinder approximately 30_ before compression top dead centre.

8. Set the needle of the dial gauge to 0.

Set to 0

9. Check that the needle doesn’t move even if the crankshaft is turned slightly (2 - 3_) in both clockwise and anti-clockwise direction.

NOTE If the needle moves, the notch is not positioned properly, so once again move the No.1 cylinder approximately 30_ before compression top dead centre.

10. Turn the crankshaft clockwise to align the No.1 cylinder to 10_ ATDC.

1±0.03 mm

11. Check that the value indicated on the dial gauge is at the standard value.

Standard value: 1±0.03 mm

Nuts

Bolts

When the value is 1±0.03 mm or more

When the value is 1±0.03 mm or less

12. If the value is outside the standard value, adjust the injection timing by the following procedure. (1) Loosen the injection pipe union nuts (4 places) on

the injection pump. (Do not remove the union nuts.)

Caution When loosening the nuts, hold the delivery valve holders with a spanner so that they don’t turn at the same time.

(2) Loosen the upper mounting nuts and the lower

mounting bolts of the injection pump. (Do not remove the nut and bolt.)

(3) Tilt the injection pump to the left or right and adjust

the needle on the dial gauge so that the display value is uniform.

(4) Provisionally tighten the mounting nuts and bolts of

the injection pump.

(5) Repeat steps 7 - 12 to check if the adjustment has

been made correctly. (6) Tighten the mounting nuts and bolts securely. (7) Tighten the injection pump union nuts securely.

Caution

When tightening the nuts, hold the delivery valve

holders with a spanner so that they don’t turn

at the same time.

13. Remove the special tool.

14. Install a new gasket to the timing check plug.

15. Tighten the timing check plug securely.

11C-12

ENGINE <4D6> -

On-vehicle Service

IDLE SPEED CHECK

11100350073

NOTE Check that the injection timing is normal, and then perform this check.

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Connect the MUT-II to the diagnosis connector.

3. Start the engine and check that the idle speed is at the standard value.

Standard value: 800±30 r/min

4. If the idle speed is not at the standard value, refer to GROUP 13E - Troubleshooting.

COMPRESSION PRESSURE CHECK

11100260505

1. Before inspection, check that the engine oil, starter motor and battery are normal. In addition, set the vehicle to the pre-inspection condition.

2. Remove the glow plug plate and all of the glow plugs.

Fuel cut solenoid valve connector

3. Disconnect the fuel cut solenoid valve connector.

NOTE Doing this will prevent carrying out fuel injection.

4. Cover the glow 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. Keepawayfromtheglowplughole when cranking.

2. If compression is measured with water, oil, fuel,

etc,.thathascomefromcracksinsidethecylinder, these materials will become heated and will gush out from glow plug hole, which is dangerous.

ENGINE <4D6> -

Compression gauge

Adapter

On-vehicle Service

11C-13

5. Set compression gauge to one of the glow plug holes.

6. Crank the engine and measure the compression pressure.

Standard value:

3,500 kPa (at engine speed of 280 r/min)

Limit: Min. 2,560 kPa (at engine speed of 280 r/min)

7. Measure the compression pressure for all cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Max. 300 kPa

8. 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 glow plug hole, and repeat the operations in steps 6 and 7. (1) If the compression increases after oil is added, the

cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is added,

the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

9. Connect the fuel cut solenoid valve connector.

10. Install the glow plugs and the glow plug plate.

Timing marks

TIMING BELT TENSION ADJUSTMENT

11100280174

There are two timing belts: one is the timing belt for the valve timing, and the other is the timing belt B for driving the right-side counterbalance shaft.

1. Remove the timing belt upper cover.

2. Remove the glow plug plate and all of the glow plugs.

3. Turn the crankshaft clockwise and check that there is nothing wrong with the timing belt. Replace the belt if necessary.

4. Turn the crankshaft clockwise to set the No.1 cylinder to the compression top dead centre position.

11C-14

Timing mark

ENGINE <4D6> -

1/2 the width of a tooth

Timing mark

On-vehicle Service

5. Turn the crankshaft anti-clockwise by 1/2 the width of a camshaft sprocket tooth in order to take up the slack in the idler pulley belt (the side where the belt is slack).

6. Loosen the timing belt tensioner mounting bolt by 1/4

- 1/3 a turn, and use the force of the tensioner spring

to apply tension to the belt.

Timing mark

Camshaft sprocket

Timing mark

Deflection

Injection pump sprocket

7. Turn the crankshaft anti-clockwise again by the width of three camshaft sprocket teeth.

Width of 2-1/2 teeth

1/2 the width of a tooth

8. Securely tighten the timing belt tensioner mounting bolt.

9. Turn the crankshaft clockwise to align the timing mark.

10. Press the belt at the point between the camshaft sprocket and the injection pump sprocket with your index finger to check the belt deflection.

Standard value: 4.0 - 5.0 mm

11. Install the timing belt upper cover.

12. Install the glow plugs and the glow plug plate.

ENGINE <4D6> -

Crankshaft Pulley

11C-15

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

Pre-removal Operation

D Under Cover Removal

11200160327

Post-installation Operation

D Drive Belt Tension Adjustment (Refer to P.11C-6.) D Under Cover Installation

Removal steps

1. Drive belt (Power steering)

2. Drive belt (A/C)

25 Nm

3. Drive belt (Alternator)

4. Crankshaft pulley

11C-16

ENGINE <4D6> -

Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Timing Belt Removal and Installation

(Refer to P.11C-26.)

D Air Pipe A Removal and Installation D Vacuum Pump Removal and Installation

(Refer to GROUP 14.)

Lip section

11200190425

6Nm

19 - 21 Nm

Engine oil

Cam section and journal section

27 - 31 Nm

19 - 21 Nm

88 Nm

27 - 31 Nm

19 - 21 Nm

AA""DA

Removal steps

1. Breather hose connection

2. Control harness

3. Rocker cover

4. Camshaft sprocket

"CA "BA "AA

5. Camshaft oil seal

6. Rocker arm and shaft assembly

7. Camshaft bearing cap

8. Camshaft

MB990767

MD998719 or MD998754

ENGINE <4D6> -

Camshaft and Camshaft Oil Seal

REMOVAL SERVICE POINT

AA"

CAMSHAFT SPROCKET REMOV AL

11C-17

Camshaft sproket side

Cap No.

Indent

Bearing cap

MD998364

5.5 mm

Oil seal

Camshaft

INSTALLATION SERVICE POINTS

"AA

The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the numbers. However, no numbers are embossed on bearing caps 1 and 5.

"BA

1. Install the rocker arm and shaft assembly to the bearing

2. Set the rocker arm springs into the bearing cap indents.

3. Check the valve clearance and adjust if necessary.

"CA

1. Apply a small amount of engine oil to the entire

2. Use the special tool to tap in the oil seal.

CAMSHAFT BEARING CAP INSTALLATION

ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION

caps.

(Refer to P.11C-8.)

CAMSHAFT OIL SEAL INSTALLATION

circumference of the oil seal lip and camshaft.

NOTE The oil seal should be tapped in until the distance from the end of the camshaft to the end of the oil seal is as shown in the illustration.

"DA

CAMSHAFT SPROCKET INST ALLATION

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.

Tightening torque: 88 Nm

11C-18

ENGINE <4D6> -

Oil Pan

OIL PAN

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Under Cover Removal and Installation D Front Exhaust Pipe Removal and Installation

(Refer to GROUP 15.)

f4±

1mm

Groove

Sealant:

MITSUBISHI GENUINE PART MD970389 or equivalent

Bolt hole

D Engine Oil Level Gauge Removal and Insertion D Engine Oil Draining and Refilling

(Refer to GROUP 12 - On-vehicle Service.)

BOLT IDENTIFICATION

A: 6´8mm B: 6´10 mm

11200280221

"AA

29 - 34 Nm

39 Nm

Removal steps

1. Drain plug

2. Drain plug gasket

3. Oil filter

4. Engine oil cooler pipe connection

9Nm

AA"

7Nm

5. Bell housing cover

6. Oil level sensor

7. Oil pan

Washer assembled bolt 9Nm Flange bolt 10 Nm

ENGINE <4D6> -

Oil Pan

11C-19

MD998727

Drain plug gasket

MD998727

Oil pan side

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

11C-20

ENGINE <4D6> -

Crankshaft Oil Seal

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

11200310159

<M/T>

127 - 137 Nm

<A/T>

127 - 137 Nm

108 - 127 Nm

Engine oil

"CA

(Engine oil)

Lip section

Crankshaft front oil seal removal steps

Timing belt (Refer to P.11C-26.)

Crank angle sensor (Refer to GROUP 16.)

1. Crankshaft sprocket

2. Flange

3. Crankshaft sprocket B

4. Key

5. Crankshaft front oil seal

Lip section

Crankshaft

(Engine oil: bolt washer surface)

Crankshaft

(Engine oil: bolt washer surface)

Sealant: 3M Stud Locking 4170 or equivalent

Crankshaft rear oil seal removal steps

AA"D

AB""BA AB""BA AB""BA AB""BA

"AA

Transmission assembly

Clutch cover and disc <M/T>

6. Adapter plate

7. Flywheel <M/T>

8. Drive plate <A/T>

9. Adapter plate <M/T>

10. Crankshaft bushing

11. Crankshaft rear oil seal

ENGINE <4D6> -

Crankshaft Oil Seal

11C-21

<M/T>

Flywheel

Crankshaft rear oil seal

MD990938

MD998781

Bolt

Crankshaft

REMOVAL SERVICE POINT

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

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 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.

11C-22

ENGINE <4D6> -

Crankshaft Oil Seal

Crankshaft

MD998382 MD998383

Oil seal

Front lower case

"CA

CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire circumference of the oil seal lip.

2. Tap the oil seal unit it is flush with the oil seal case.

ENGINE <4D6> -

Cylinder Head Gasket

11C-23

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Engine Coolant Draining and Refilling

(Refer to GROUP 14 - On-vehicle Service.)

D Air Pipe A Removal and Installation

(Refer to GROUP 15 - Intercooler.)

D Vacuum Pump Removal and Installation

(Refer to GROUP 14.)

O-ring

27 - 31 Nm

Engine oil

12 - 15 Nm

6Nm

11200400566

D Timing Belt Removal and Installation

(Refer to P.11C-26.)

D Thermostat Case Assembly Removal and Installation

(Refer to GROUP 14 - Water Hoses and Pipes.)

27 - 31 Nm

19 - 21 Nm

27 - 31 Nm

13 Nm

88 Nm®0Nm®39 Nm®+90

Removal steps

1. Breather hose connection

2. Control harness

3. Rocker cover

AA""DA

"CA

4. Fuel injection pipe

5. Camshaft bearing cap

6. Glow plug plate

7. Rocker arm and shaft assembly

8. Fuel return hose connection

9. Water temperature sensor connector

10. Vacuum air temperature sensor connector

11. Engine coolant temperature gauge unit connector

_ ®

+90

24 Nm

44 Nm

AB""BA

"AA

9Nm

29 Nm

10 - 12 Nm

12. Brake booster vacuum hose connection

13. Timing belt rear centre cover

14. Front exhaust pipe connection

15. Oil return pipe connection

16. Oil level gauge guide assembly

17. Alternator brace

18. Cylinder head bolt

19. Cylinder head assembly

20. Cylinder head gasket

11C-24

Intake side

351082

17964

Exhaust side

Front of engine

AA"

FUEL INJECTION PIPE REMOVAL

When loosening nuts at injection pipe ends, hold the nut at other side (delivery holder nut for pump side, nozzle holder nut at nozzle side) with wrench.

Caution After disconnecting the injection pipe, plug the opening so that no foreign particles get inside the pump or into the injection nozzle.

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.

Identification mark

Head bolt

washer

Cylinder head

Identification holes

Burred side

Head bolt

(Engine oil)

INSTALLATION SERVICE POINTS

"AA

1. Wipe off all oil and grease from the gasket mounting

2. Check the number of identification holes on the cylinder

3. Place the cylinder head gasket on top of the cylinder

"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.

head gasket that was removed, and select a cylinder head gasket with the same number of identification holes.

block so that the identification mark is facing upwards as shown in the illustration.

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): 119.7 mm

side caused by tapping out facing upwards.

and the washer of the cylinder head bolt.

ENGINE <4D6> -

Cylinder Head Gasket

11C-25

Intake side

86139

104257

Exhaust side

Step 4

Painted mark

Front of engine

Step 5

Painted mark

4. Tighten the bolts by the following procedure.

Step Operation Remarks

1 Tighten to 88 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 39 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.

Indent

Bearing cap

Fuel injection pipe

Nut

Nozzle holder

"CA

ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION

1. Install the rocker arm and shaft assembly to the bearing caps.

2. Set the rocker arm springs into the bearing cap indents.

3. Check the valve clearance and adjust if necessary. (Refer to P.11C-8.)

"DA

FUEL INJECTION PIPE INSTALLATION

When tightening the nuts at both ends of the fuel injection pipe, hold the delivery holder (for pump side) and the fuel injection nozzle assembly (for nozzle side) with a wrench, and tighten the nuts to the specified torque.

11C-26

ENGINE <4D6> -

Timing Belt

TIMING BELT

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Crankshaft Pulley Removal and Installation

(Refer to P.11C-15.)

D Engine Mount Bracket Removal and Installation

(Refer to GROUP 32.)

10 - 12 Nm

9Nm

10 - 12 Nm

25 Nm

11200430497

19 Nm

AA"

10 - 12 Nm

23 Nm

Removal steps

1. Water pump pulley

2. A/C tension pulley assembly

3. Timing belt front upper cover

4. Timing belt front centre cover

10 - 12 Nm

9Nm

AB""AA

10 - 12 Nm

5. Timing belt front lower cover

6. Injection pump bracket stay

"BAD

7. Timing belt

Timing belt tension adjustment

ENGINE <4D6> -

Protective tape

Timing Belt

11C-27

REMOVAL SERVICE POINTS

AA"

Attach protective tape to the engine mount bracket, and then remove the timing belt front upper cover.

TIMING BELT FRONT UPPER COVER INSTALLATION

Timing marks

AB"

TIMING BELT REMOVAL

1. Align the timing marks.

2. Loosen the installation bolt of the timing belt tensioner.

3. Move the timing belt tensioner downward a n d loosely tighten the bolt so that the tensioner doesn’t return; then remove the timing belt.

Thread diameter length´pitch (mm)

Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

Move to the bottom of the slot.

11C-28

ENGINE <4D6> -

Timing Belt

Camshaft sprocket

Timing mark

Crankshaft sprocket

Timing marks

Timing mark

Move to the bottom of the slot.

Injection pump sprocket

Oil pump sprocket

INSTALLATION SERVICE POINTS

"AA

1. Ensure that the timing marks of the camshaft sprocket,

2. Move the timing belt tensioner downward a n d loosely

3. Install the timing belt onto the crankshaft sprocket, the

"BA

1. Turn the crankshaft anti-clockwise by a distance

TIMING BELT INSTALLATION

the injection pump sprocket, the crankshaft sprocket, and the oil pump sprocket are all aligned.

tighten the bolt so that the tensioner doesn’t return.

timing belt idler, the camshaft sprocket, t h e injection pump sprocket, and the oil pump sprocket in that order.

Caution If the timing belt is reused, install so that the arrow marked on it at the time of removal is pointing in the clockwise direction.

TIMING BELT TENSION ADJUSTMENT

equivalent to 1/2 tooth of the camshaft sprocket in order to correct looseness at the timing belt idler side.

Timing mark

2-1/2 teeth

1/2 tooth

2. Loosen (by 90_ to 120_ turn) the tensioner installation bolt previously secured provisionally, taking advantage of the force of the tensioner spring to provide tension to the belt.

3. In addition, turn the crankshaft anti-clockwise by a distance equivalent to 2-1/2 teeth.

4. Tighten the timing belt tensioner to the specified torque.

Tightening torque: 48 Nm

5. Turn the crankshaft clockwise and align the timing mark.

Timing mark

Camshaft sprocket

Injection pump sprocket

ENGINE <4D6> -

6. Using the index finger, press between the camshaft sprocket and the injection pump sprocket, and check whether or not the amount of flexion is within the standard value range.

Standard value: 4 - 5 mm

Timing Belt

11C-29

11C-30

ENGINE <4D6> -

Timing Belt B

TIMING BELT B

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Crankshaft Pulley Removal and Installation

(Refer to P.11C-15.)

D Engine Mount Bracket Removal and Installation

(Refer to GROUP 32.)

48 Nm

19 Nm

108 - 127 Nm

11200460113

D Timing Belt Removal and Installation

(Refer to P.11C-26.)

AA""BA

Crankshaft sprocket

Removal steps

1. Idler pulley

2. Crankshaft sprocket

3. Flange

MB991385

(Engine oil)

REMOVAL SERVICE POINTS

AA"

4. Timing belt tensioner

AB""AA

5. Timing belt B

CRANKSHAFT SPROCKET REMOVAL

MB991367

Mitsubishi 4D6, 4G6, 6A1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION

SERVICE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

On-vehicle Service

Crankshaft Pulley

Camshaft and Camshaft Oil Seal

Oil Pan

Crankshaft Oil Seal

Cylinder Head Gasket

Timing Belt

Timing Belt B

Engine Assembly

GENERAL INFORMATION

SERVICE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

ON-VEHICLE SERVICE

Crankshaft Pulley

Camshaft and Camshaft Oil Seal

Oil Pan

Crankshaft Oil Seal

Cylinder Head Gasket

Timing Belt

Engine Assembly

GENERAL INFORMATION

SERVICE SPECIFICATIONS

SEALANTS

Special Tools

On-vehicle Service

Crankshaft Pulley

Camshaft and Camshaft Oil Seal

Oil Pan

Crankshaft Oil Seal

Cylinder Head Gasket

Timing Belt

Timing Belt B