Mitsubishi 4G63 Turbo Workshop Manual

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Page 1

GROUP 11D

ENGINE OVERHAUL

<4G63-Turbo>

CONTENTS

11D-1

HOW TO USE THIS MANUAL. . . . . . 11D-2

GENERAL INFORMATION . . . . . . . . 11D-4

GENERAL SPECIFICATIONS . . . . . . 11D-4

SERVICE SPECIFICATIONS. . . . . . . 11D-5

REWOK DIMENSIONS . . . . . . . . . . . 11D-6

TORQUE SPECIFICATIONS . . . . . . . 11D-7

SEALANTS . . . . . . . . . . . . . . . . . . . . 11D-10

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11D-11

ALTERNATOR AND IGNITION

SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 11D-14

REMOVAL AND INSTALLATION . . . . . . . . 11D-14

SOLENOID AND VACUUM HOSE . . 11D-15

REMOVAL AND INSTALLATION . . . . . . . . 11D-15

INLET MANIFOLD . . . . . . . . . . . . . . . 11D-30

REMOVAL AND INSTALLATION . . . . . . . . 11D-30

EXHAUST MANIFOLD . . . . . . . . . . . . 11D-31

REMOVAL AND INSTALLATION . . . . . . . . 11D-31

WATER PUMP AND WATER

HOSE . . . . . . . . . . . . . . . . . . . . . . . . . 11D-33

REMOVAL AND INSTALLATION . . . . . . . . 11D-33

ROCKER ARMS AND CAMSHAFT . . 11D-35

REMOVAL AND INSTALLATION . . . . . . . . 11D-35

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-37

CYLINDER HEAD AND VALVES. . . . 11D-40

REMOVAL AND INSTALLATION . . . . . . . . 11D-40

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-43

OIL PAN AND OIL PUMP. . . . . . . . . . 11D-46

REMOVAL AND INSTALLATION . . . . . . . . 11D-46

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-53

TIMING BELT. . . . . . . . . . . . . . . . . . . 11D-16

REMOVAL AND INSTALLATION . . . . . . . . 11D-16

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11D-26

FUEL AND EMISSION PARTS . . . . . 11D-28

REMOVAL AND INSTALLATION . . . . . . . . 11D-28

PISTON AND CONNECTING ROD . . 11D-55

REMOVAL AND INSTALLATION . . . . . . . . 11D-55

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-60

CRANKSHAFT AND CYLINDER

BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11D-62

REMOVAL AND INSTALLATION . . . . . . . . 11D-62

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-66

Page 2

11D-2

ENGINE OVERHAUL <4G63-Turbo>

HOW TO USE THIS MANUAL

Scope of Service Explanations

This manual describes service procedures performed after removal of the engine from the vehicle. For removal of the engine from the vehicle, installation of the engine in the vehicle, and on-vehicle inspection and service of the engine, please use the separate Workshop Manuals prepared for the vehicle.

How to Read Explanations

Service steps

(1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed con dition of the component parts. (2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such, and tightening torques are shown.

·Removal steps The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence.

·Installation steps Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse.

·Disassembly steps The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence.

·Reassembly steps Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.

M1113025100296

Classification of Service Points

Key service points, service standards, and instructions for using special tools are collated as service points and explained in detail.

<<A>>: Outward-pointing brackets denote removal service points or disassembly service points. >>A<<: Inward-pointing brackets denote installation service points or reassembly service points.

Lubricant and Sealant Symbols

Every location where a lubricant or sealant must be applied or added is indicated using a relevant symbol in the component part drawing and/or on the page after the component part drawing.

. . . . . . . . . . Grease

. . . . . . . . . . Sealant or form-in-place gasket (FIPG)

. . . . . . . . . . Brake fluid

. . . . . . . . . . Engine oil or gear oil

Inspection

Only those inspection procedures which use special tools or measuring appliances are described. You must perform general visual inspection and part cleaning whenever necessary although their procedures are not described in this manual.

AK202851

Page 3

ENGINE OVERHAUL <4G63-Turbo>

HOW TO USE THIS MANUAL

11D-3

11-54

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION

ENGINE OVERHAUL

Apply engine oil to all moving parts before installation.

Denotes non-reusable part.

Group title

11 ± 1 N·m

Section titlePage number

11 ± 1 N·m

9.0 ± 1.0 N·m

Tightening torque

132 ± 5 N·m

Removal steps

1. Drive plate bolt

2. Adapter plate

3. Drive plate

4. Crankshaft bushing

5. Rear plate

6. Bellhousing cover >>E<< 7. Oil seal case >>D<< 8. Oil seal >>C<< 9. Bearing cap bolt

10. Bearing cap >>B<< 11. Crankshaft bearing, lower >>A<< 12. Crankshaft

The alphabetical character in this category of heading matches that of the relevant removal steps, installation steps, disassembly steps, or reassembly steps.

25 ± 2 N·m + 90º to 100º

INSTALLATION SERVICE POINTS

>>A<< THRUST BEARING INSTALLATION

Grooves

AK204351

Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.

AK100786

AK300250

Page 4

11D-4

ENGINE OVERHAUL <4G63-Turbo>

GENERAL INFORMATION

VEHICLE AND ENGINE MODELS

GENERAL INFORMATION

M1113000100523

Vehicle name Vehicle

model

OUTLANDER CU2W 4G63-7 1,997 Double overhead camshaft, 16-valve

Engine model Displacement mLSpecification

GENERAL SPECIFICATIONS

M1113000200779

Item Specification

Bore × stroke mm 85 × 88

Displacement mL 1,997

Combustion chamber Pentroof type

Number of cylinders 4

Valve mechanism Type Double overhead camshaft

Number of intake valves 2

Number of exhaust valves

Lash adjusters Hydraulic

Rocker arms Roller cam followers

Compresssion ratio 9.0

Fuel injection system Electronically controlled multi-point injection (MPI)

system

Ignition system Electronically controlled two-coil system

Generator Alternator (with built-in IC regulator)

Starter motor Gear reduction drive type

Page 5

ENGINE OVERHAUL <4G63-Turbo>

SERVICE SPECIFICATIONS

Item Standard value Limit

TIMING BELT

11D-5

M1113000300776

Auto-tensioner rod extension length (with timing belt installed) mm

Auto-tensioner rod extension length (when free) mm 12.0

Auto-tensioner rod retraction length (when pressed with force of 98 to 196 N) mm

ROCKER ARMS AND CAMSHAFTS

Cam height mm 34.91 34.41

CYLINDER HEAD AND VALVES

Cylinder head gasket surface warp mm Less than 0.05 0.2

Cylinder head gasket surface grinding limit (including cylinder block grinding amount) mm

Cylinder head overall height mm 131.9 − 132.1

Cylinder head bolt nominal length mm

Valve margin mm Intake valves 1.0 0.5

Exhaust valves 1.5 1.0

Valve stem diameter mm 6.6

Valve face angle 43.5° − 44°

Valve stem-to-guide clearance mm Intake valves 0.02 − 0.05 0.10

Exhaust valves 0.05 − 0.09 0.15

3.8 − 4.5

Less than 1

−

0.2

−

99.4

−

Valve height mm Intake valves 109.5 109.0

Exhaust valves 109.7 109.2

Valve stem projection mm Intake valves 49.2 49.7

Exhaust valves 48.4 48.9

Valve spring free height mm 47.0 46.0

Valve spring load/height N/mm 240/40

Valve spring squareness 1.5° or smaller 4°

Valve face-to-seat contact width mm 0.9 − 1.3

Valve guide inside diameter mm 6.6

Valve guide press-in height mm 19.2 − 19.8

OIL PAN AND OIL PUMP

Oil pump gear side clearance mm Drive gear 0.08 − 0.14

Driven gear 0.06 − 0.12

Oil cooler by-pass valve mm Dimension (Normal

temperature)

By-pass hole closing temperature 97 to 103°C

34.5

40.0

−

Page 6

11D-6

Item Standard value Limit

ENGINE OVERHAUL <4G63-Turbo>

REWOK DIMENSIONS

Oil pressure at curb idle speed kPa [oil temperature is 75 to 90°]

PISTONS AND CONNECTING RODS

Piston outside diameter mm 85.0

Piston ring side clearance in ring groove mm

Piston ring end gap mm No. 1 0.20 − 0.30 0.8

Piston pin outside diameter mm 22.0

Piston pin press-in load (at ambient temperature) N 7,350 − 17,100

Oil clearance at crankshaft pins mm 0.03 − 0.05 0.1

Connecting rod big end thrust clearance mm 0.10 − 0.25 0.4

CRANKSHAFT AND CYLINDER BLOCK

Crankshaft end play mm 0.05 − 0.25 0.4

Crankshaft journal diameter mm 57.0

Crankshaft pin diameter mm 45.0

Oil clearance at crankshaft journals mm 0.03 − 0.04 0.1

No. 1 0.03 − 0.07 0.1

No. 2 0.02 − 0.06 0.1

No. 2 0.30 − 0.45 0.8

Oil ring 0.10 − 0.40 1.0

78 or more

−

Cylinder block gasket surface warp mm 0.05 0.1

Cylinder block gasket surface grinding limit (including cylinder head grinding amount) mm

Cylinder block overall height mm 284

Cylinder bore diameter mm 85

Taper of cylinder mm 0.01 or less

Cylinder-to-piston clearance mm 0.02 − 0.04

Crankshaft bearing cap bolt nominal length mm

−

0.2

−

71.1

REWOK DIMENSIONS

M1113024300394

Item Standard value

CYLINDER HEAD AND VALVES

Diameter of oversize valve seat ring hole in cylinder head mmIntake 0.3 oversize 35.30 − 35.33

0.6 oversize 35.60 − 35.63

Exhaust 0.3 oversize 33.30 − 33.33

0.6 oversize 33.60 − 33.63

Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 12.05 − 12.07

0.25 oversize 12.25 − 12.27

0.50 oversize 12.50 − 12.52

Page 7

ENGINE OVERHAUL <4G63-Turbo>

TORQUE SPECIFICATIONS

Item N⋅m

ALTERNATOR AND IGNITION COIL

Oil level gauge guide bolt 13 ± 1

Idler pulley bolt 79 ± 5

Auto-tensioner assembly bolt (M8) 24 ± 4

Auto-tensioner assembly bolt (M10) 44 ± 10

Water pump pulley bolts 8.8 ± 1.0

Alternator brace bolt (flange bolt) 23 ± 3

Alternator brace bolts (washer assembled bolt) 22 ± 4

Alternator nuts 44 ± 10

Crankshaft pulley bolts 25 ± 4

Center cover bolts 3.0 ± 0.5

Ignition coil bolts 10 ± 2

11D-7

M1113023400989

Spark plugs 25 ± 5

SOLENOID AND VACUUM HOSE

Vacuum pipe and hose assembly bolts 11 ± 1

EGR valve bolts 20 ± 2

Engine hanger bolt 19 ± 3

Solenoid valve assembly nut 36 ± 6

Solenoid valve assembly bolts(M6) 9.0 ± 1.0

Solenoid valve assembly bolts(M8) 23 ± 4

TIMING BELT

Timing belt cover bolts (flange bolt) 11 ± 1

Timing belt cover bolt (washer-assembled bolt) 9.0 ± 1.0

Power steering pump bracket bolts 49 ± 9

Tensioner pulley bolt 48 ± 5

Tensioner arm bolt 21 ± 4

Auto-tensioner bolts 23 ± 3

Idler pulley bolt 35 ± 6

Crankshaft angle sensor bolts 8.8 ± 1.0

Oil pump sprocket nut 54 ± 4

Crankshaft bolt 167

Tensioner "B" bolt 19 ± 3

Counterbalance shaft sprocket bolt 45 ± 3

Rocker cover bolts 3.5 ± 0.5

Engine support bracket bolts 49 ± 5

Camshaft sprocket bolts 88 ± 10

Page 8

11D-8

Item N⋅m

FUEL SYSTEM

Throttle body bolts 19 ± 3

Fuel pressure regulator bolts 9.0 ± 2.0

Delivery pipe and injector assembly bolts 11 ± 1

INLET MANIFOLD

Inlet manifold stay bolts 31 ± 3

Inlet manifold bolts (M8) 20 ± 2

Inlet manifold bolts and nuts (M10) 36 ± 6

Detonation sensor 23 ± 2

EXHAUST MANIFOLD

Engine hanger bolt 19 ± 3

Turbocharger heat protector bolts 23 ± 3

Oxygen sensor 44 ± 5

Exhaust fitting bracket bolts 36 ± 5

ENGINE OVERHAUL <4G63-Turbo>

TORQUE SPECIFICATIONS

Exhaust fitting bolts 59 ± 5

Air outlet fitting bolts 19 ± 1

Oil return pipe bolts 14 ± 1

Exhaust manifold heat protector bolts 23 ± 3

Turbocharger assembly and pipe assembly bolts, nuts 59 ± 5

Oil pipe bolt (flange bolt) 11 ± 1

Oil pipe bolt (eye bolt M10) 17 ± 2

Water pipe bolt (eye bolt M12) 28 ± 5

Water pipe bolt (flange bolt) 10 ± 1

Exhaust manifold nuts (M8) 33 ± 6

Exhaust manifold nuts (M10) 55 ± 10

WATER PUMP AND WATER HOSE

Engine coolant temperature sensor 29 ± 10

Engine coolant temperature gauge unit 10.8 ± 1.0

Water outlet fitting bolts 13 ± 2

Water inlet fitting bolts 13 ± 2

Thermostat housing bolts 23 ± 4

Water inlet pipe bolt (M8) 13 ± 2

Water pump bolts 14 ± 1

ROCKER ARMS AND CAMSHAFTS

Camshaft position sensor bolt 10 ± 1

Cover bolts 10 ± 2

Camshaft position sensing cylinder bolt 22 ± 4

Camshaft position sensor support bolts 14 ± 1

Bearing cap bolts 20 ± 1

Oil delivery body bolts 11 ± 1

Page 9

ENGINE OVERHAUL <4G63-Turbo>

TORQUE SPECIFICATIONS

Item N⋅m

CYLINDER HEAD AND VALVES

Cylinder head bolts 78 ± 2 → 0 → 20 ± 2 → + 90° + 90°

OIL PUMP CASE AND OIL PAN

Drain plug 39 ± 5

Oil filter 14 ± 2

Oil pan bolts 9.0 ± 3.0

Oil screen bolts 19 ± 3

Oil pressure switch 19 ± 3

Oil cooler by-pass valve 54 ± 5

Relief plug 44 ± 5

Oil filter bracket bolts 19 ± 3

Plug cap 23 ± 3

Flange bolt 36 ± 3

Oil pump case bolts 23 ± 3

11D-9

Oil pump cover bolts 17 ± 1

Oil pump cover screw 10 ± 2

PISTONS AND CONNECTING RODS

Connecting rod cap nuts 20 ± 2 → 90° to 94°

CRANKSHAFT AND CYLINDER BLOCK

Flywheel bolts 132 ± 5

Rear plate bolt 11 ± 1

Bell housing cover bolts 9.0 ± 1.0

Rear oil seal case bolts 11 ± 1

Beam bearing cap bolts 25 ± 2 → 90° to 100°

Page 10

11D-10

ENGINE OVERHAUL <4G63-Turbo>

SEALANTS

M1113000500703

Item Specified sealant

Engine support bracket bolts Mitsubishi Genuine Part No.MD970389

or equivalent

Semicircular packing 3M ATD No.8660 or equivalent

Rocker cover Mitsubishi Genuine Part No. MD970389

or equivalent

Engine coolant temperature e gauge unit 3M Nut Locking Part No.4171 or

equivalent

Engine coolant temperature sensor 3M ATD No.8660 or equivalent

Water outlet fitting* Mitsubishi Genuine Part No. MD970389

Thermostat housing*

Cylinder head (camshaft bearing cap fitting section) 3M ATD No.8660 or equivalent

Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389

Oil pressure switch 3M ATD No.8660 or equivalent

or equivalent

Oil pan* Mitsubishi Genuine Part No. MD970389

Rear oil seal case*

NOTE: *: Part to be sealed with a form-in-place gasket (FIPG)

or equivalent

FORM-IN-PLACE GASKET (FIPG)

This engine has several areas where the form-in-place gasket (FIPG) is used for sealing. To ensure that the FIPG fully serves its purpose, it is necessary to observe some precautions when applying it. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of fluid passages. To prevent leaks or blocking of passages, therefore, it is absolutely necessary to apply the FIPG evenly without a break, while observing the correct bead size. FIPG hardens as it reacts with the moisture in the atmospheric air, and it is usually used for sealing metallic flange areas.

REMOVAL OF FIPG SEALED PARTS

Parts sealed with a FIPG can be easily removed without need for the use of a special method. In some cases, however, the FIPG in joints may have to be broken by tapping parts with a mallet or similar tool. You can also tap a flat, thin gasket scraper into the joint to break the FIPG, taking extreme care not to damage the mating surfaces.The oil pan cutter (MD998727) is available as a special tool for removing the oil pan. The tool, however, must not be.

CLEANING FIPG APPLICATION SURFACE

Thoroughly remove all substances deposited on the FIPG application surface, using a gasket scraper or wire brush. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free from oils, greases and foreign substances. Do not fail to remove old FIPG that may remain in the fastener fitting holes.

APPLICATION OF FIPG

Applied FIPG bead should be of the specified size and free of any break. FIPG can be wiped away unless it has completely hardened. Install the mating parts in position while the FIPG is still wet (in less than 15 minutes after application). Do not allow FIPG to spread beyond the sealing areas during installation. Avoid operating the engine or letting oils or water come in contact with the sealed area before a time sufficient for FIPG to harden (approximately one hour) has passed. FIPG application method may vary from location to location. Follow the instruction for each particular case described later in this manual.

Page 11

ENGINE OVERHAUL <4G63-Turbo>

SPECIAL TOOLS

Tool Number Name Use

MD998781 Flywheel stopper Retention of flywheel

D998781

11D-11

M1113000600788

D998767

MD998778 Crankshaft sprocket

puller

Removal of crankshaft sprocket and crankshaft sprocket B

MD998785 Sprocket stopper Retention of counterbalancer

shaft sprocket

MD998767 Tension pulley socket

wrench

Manipulation of tensioner pulley during adjustment of timing belt tension

MD998738 Set screw Retention of tensioner arm and

auto-tensioner during timing belt installation

D998738

D998713

MD998713 Camshaft oil seal

Installation of camshaft oil seal

installer

MD998442 Air bleed wire Air bleeding of lash adjuster

Page 12

11D-12

Tool Number Name Use

ENGINE OVERHAUL <4G63-Turbo>

SPECIAL TOOLS

B991654

MB991654 Cylinder head bolt

wrench

MD998772 Valve spring

compressor

MD998735 Valve spring

compressor

MD998737 Valve stem seal

installer

Removal and installation of cylinder head bolts

Compression of valve spring

Installation of valve stem seal

MD998162 Plug wrench Removal and installation of front

case plug cap (Use with MD998783.)

MD998783 Plug wrench retainer Removal and installation of front

case plug cap (Use with MD998162.)

MD998371 Silent shaft bearing

puller

MD998372 Silent shaft bearing

puller

Removal of counterbalancer shaft front bearing

Removal of counterbalancer shaft front and rear bearings

Page 13

ENGINE OVERHAUL <4G63-Turbo>

SPECIAL TOOLS

Tool Number Name Use

11D-13

MB991603 Silent shaft bearing

installer stopper

MD998705 Silent shaft bearing

installer

MD998375 Crankshaft front oil

seal installer

MD998285 Crankshaft front oil

seal guide

Guide and stopper for removal and press-fitting of counterbalancer shaft rear bearing

Press-fitting of counterbalancer shaft front and rear bearings

Installation of crankshaft front oil seal

Guide for installation of crankshaft front oil seal

D998285

D998776

MD998780 Piston pin setting tool Removal and press-fitting of

piston pin

MD998776 Crankshaft rear oil

seal installer

Installation of crankshaft rear oil seal

MB990938 Handle Installation of crankshaft rear oil

seal (Use with MD998776.)

Page 14

11D-14

ENGINE OVERHAUL <4G63-Turbo>

ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION

13 ± 1 N·m

M1113001000701

44 ± 10 N·m

3.0 ± 0.5 N·m

10 ± 2 N·m

25 ± 5 N·m

44 ± 10 N·m

22 ± 4 N·m

23 ± 3 N·m

79 ± 5 N·m

24 ± 4 N·m

Removal steps

1. Oil level gauge

2. O-ring

3. Oil level gauge guide

4. O-ring

5. Idler pulley

6. Cap

7. Auto-tensioner assembly

8. Water pump pulley

8.8 ± 1.0 N·m

25 ± 4 N·m

Removal steps (Continued)

9. Alternator brace

10. Alternator

11. Crankshaft pulley

12. Center cover

13. Spark plug cable

14. Ignition coil

15. Spark plug

AK305988

Page 15

ENGINE OVERHAUL <4G63-Turbo>

SOLENOID AND VACUUM HOSE

11D-15

REMOVAL AND INSTALLATION

20 ± 2 N·m

11 ± 1 N·m

9.0 ± 1.0 N·m

19 ± 3 N·m

36 ± 6 N·m

M1113025300074

23 ± 4 N·m

11 ± 1 N·m

Removal steps

1. Vacuum pipe and hose assembly

2. Vacuum pipe and hose assembly

3. Vacuum pipe and hose assembly

4. EGR valve

AK400296

Removal steps (Continued)

5. EGR valve gasket

6. Solenoid valve

7. Solenoid valve

8. Engine hanger

Page 16

11D-16

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

REMOVAL AND INSTALLATION

11 ± 1 N·m

48 ± 5 N·m

9.0 ± 1.0 N·m

23 ± 3 N·m

167 N·m

49 ± 5 N·m

M1113001900867

21 ± 4 N·m

11 ± 1 N·m

3.5 ± 0.5 N·m

88 ± 10 N·m

35 ± 6 N·m

<<A>> >>M<<

>>L<<

>>K<<

<> >>J<< <<C>> >>I<<

45 ± 3 N·m

19 ± 3 N·m

Removal steps

1. Timing belt front upper cover

2. Timing belt front lower cover

3. Power steering pump bracket

4. Timing belt

5. Tensioner pulley

6. Tensioner arm

7. Auto-tensioner

8. Idler pulley

9. Crankshaft angle sensor

10. Oil pump sprocket

11. Crankshaft bolt

54 ± 5 N·m

8.8 ± 1.0 N·m

<<D>> >>I<<

<<E>> >>H<< <<F>> >>G<<

<<G>> >>E<<

>>I<<

>>F<<

49 ± 9 N·m

AK305989

Removal steps (Continued)

12. Crankshaft sprocket

13. Crankshaft sensing blade

14. Tensioner "B"

15. Timing belt "B"

16. Counterbalancer shaft sprocket

17. Spacer

18. Crankshaft sprocket "B"

19. Crankshaft key

20. Breather hose

21. PCV hose

22. PCV valve

Page 17

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

11D-17

Removal steps (Continued)

23. PCV valve gasket

24. Oil filler cap

>>D<< >>D<<

>>C<< >>B<<

<<H>> >>A<<

25. Rocker cover

26. Rocker cover gasket "A"

27. Rocker cover gasket "B"

28. Semicircular packing

29. Engine support bracket

30. Camshaft sprocket bolt

31. Camshaft sprocket

32. Timing belt rear cover, right

33. Timing belt rear upper cover, left 34 Timing belt rear lower cover, left

REMOVAL SERVICE POINTS <<A>> TIMING BELT REMOVAL

CAUTION

Never remove the timing belt with any piston at the top dead center (TDC). If a piston is at TDC, the exhaust valves of the cylinder are pushed by the exhaust cams, compressing the valve springs. If the belt is removed under this condition, the sprocket will be turned in the reverse direction by the force of the springs, incurring risk of injury.

2. Set the timing mark of the exhaust camshaft sprocket to a point about one tooth before the TDC of the No.1 cylinder piston on compression stroke.

3. Loosen the lock nut of the tensioner pulley, then remove the timing belt.

<> OIL PUMP SPROCKET REMOVAL

1. Remove the plug on the left side of cylinder block.

AK202756AB

1. If the timing belt is to be reused, make an arrow mark with something like chalk on the back of the belt indicating the direction of rotation so it may be reinstalled in the same direction.

Timing marks

AK304440

Crosspoint screwdriver

AK202825

2. Insert a crosspoint screwdriver (shank diameter 8 mm) to prevent the counterbalancer shaft from rotating.

3. Remove the flange bolt.

4. Remove the oil pump sprocket.

<<C>> CRANKSHAFT BOLT REMOVAL

MD998781

AK202738

1. Hold the drive plate with the special tool Fly wheel stopper (MD998781).

2. Remove the crankshaft bolt.

Page 18

11D-18

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

<<D>> CRANKSHAFT SPROCKET REMOVAL

MD998778

AK304176

Use the special tool Crankshaft sprocket puller (MD998778) if the sprocket is stuck and hard to remove.

<<E>> TIMING BELT "B" REMOVAL

<<F>> COUNTERBALANCER SHAFT SPROCKET REMOVAL

MD998785

AK300138

1. Use the special tool Sprocket stopper (MD998785) to prevent the counterbalancer shaft sprocket from rotating.

2. Remove the counterbalancer shaft mounting bolt.

<<G>> CRANKSHAFT SPROCKET "B" REMOVAL

AK300137

CAUTION

Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed or immersed in solvent. Replace parts if contaminated. If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water pump for leaks.

1. Mark the belt running direction for reinstallation.

2. Loosen the tensioner "B" bolt, and then remove the timing belt "B."

MD998778

AK300139

Use the special tool Crankshaft sprocket puller (MD998778) if the sprocket is stuck and hard to remove.

<<H>> CAMSHAFT SPROCKET BOLT REMOVAL

AK305990AC

Remove the camshaft sprocket bolt while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.

Page 19

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

11D-19

INSTALLATION SERVICE POINTS >>A<< CAMSHAFT SPROCKET BOLT

INSTALLATION

AK305990AC

>>C<< SEMICIRCULAR PACKING INSTALLATION

1. Remove thoroughly the old sealant and FIPG remaining on the semicircular packing, cylinder head, and rocker cover.

AK202860AB

2. Apply sealant to the surface indicated in the drawing of the semicircular packing.

Specified sealant:

3M ATD No.8660 or equivalent

3. Install the semicircular packing on the cylinder head.

AK304435

Tighten the camshaft sprocket bolt to 88 ± 10 N⋅m while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.

>>B<< ENGINE SUPPORT BRACKET INSTALLATION

AK202743AB

1. Remove thoroughly the old sealant remaining on the indicated bolt and in its hole.

2. Coat the bolt with sealant, then install and tighten it.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

10 mm

Semicircular packing

Cylinder head

AK304411

4. Apply sealant to the area indicated in the drawing of the semicircular packing and cylinder head.

Specified sealant:

3M ATD No.8660 or equivalent

Page 20

11D-20

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

>>D<< ROCKER COVER/ROCKER COVER GASKET "A" INSTALLATION

Timing belt side

AK304203

1. Apply beads of FIPG on the surfaces of the rocker cover indicated in the drawing.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

2. Install the rocker cover gasket "A" on the rocker cover before the FIPG hardens.

Timing belt side

>>E<< CRANKSHAFT SPROCKET "B" INSTALLATION

Sprocket "B"

Degrease

Front case

Clean and then degrease the crankshaft sprocket "B" and the sprocket fitting surface of the crankshaft.

NOTE: Degreasing is necessary to prevent lack of frictional coefficient between the mating surfaces.

Crankshaft

AK301828

>>F<< SPACER INSTALLATION

Counter

Oil seal

Spacer

balance shaft

AK304204

3. Apply beads of FIPG to the surfaces of the rocker cover indicated in the drawing.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

4. Install the rocker cover on the cylinder head before the FIPG hardens.

Chamfered

AK301298

CAUTION

If the spacer is opposite in direction to that shown in the drawing when installed, it will damage the oil seal lip.

1. Smear slightly oil on the outer surface of the spacer that comes into contact with the oil seal.

2. Install the spacer with the chamfered end toward the oil seal.

Page 21

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

11D-21

>>G<< COUNTERBALANCER SHAFT SPROCKET INSTALLATION

MD998785

AK300138

1. Use the special tool Sprocket stopper (MD998785) as shown in the drawing to prevent the counterbalancer shaft sprocket from rotating.

2. Tighten the sprocket mounting bolt to 45 ± 3 N⋅m.

>>H<< TIMING BELT "B" INSTALLATION

Tensioner "B"

Tensioner "B" centre

Tension section of belt

Mounting bolt centre

Timing belt "B"

AK305992

3. Make sure that the tensioner "B" center is positioned as shown in the drawing relative to the mounting bolt center.

Timing marks

AK305991

1. Align the timing marks on the crankshaft sprocket "B" and counterbalancer shaft sprocket with the corresponding timing marks on the oil pump case.

2. Install the timing belt "B" on the crankshaft sprocket "B" and counterbalancer shaft sprocket. There should be no slack in the tension section of the belt.

AK304436

4. Lift the tensioner "B" with fingers to move it in the direction of the arrow until the tension section of the timing belt becomes taut. While keeping the tensioner "B" in this position, tighten its bolt.

NOTE: When the bolt is tightened, prevent the tensioner "B" shaft from turning. If the shaft turns, the belt will be overtightened.

5. Make sure that the timing marks on the oil pump case and those of the sprockets are all aligned with each other.

5 – 7 mm

AK305993

6. Push a central point of the timing belt "B" tension section lightly with an index to see if it deflects 5 − 7 mm.

Page 22

11D-22

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

>>I<< CRANKSHAFT BOLT/CRANKSHAFT SPROCKET/CRANKSHAFT SENSING BLADE INSTALLATION

Crankshaft bolt

Big chamfered side

Sprocket

Washer

1. Clean and then degrease the crankshaft sprocket, sprocket fitting surface of the crankshaft, and crankshaft sensing blade. Install the crankshaft sprocket and crankshaft sensing blade on the crankshaft.

2. Clean the bolt hole in the crankshaft, and then washer.

3. Apply a necessary minimum amount of oil to the threads and seating surface of the crankshaft bolt.

Sensing blade

Clean

Degrease

Crankshaft

AK301075

>>J<< OIL PUMP SPROCKET INSTALLATION

AK300172

1. Prevent the counterbalancer shaft from rotating in the same method as in the removal procedure.

2. Install the oil pump sprocket.

3. Apply a thin coat of engine oil to the seating surface of the nut.

4. Tighten the flange nut to 54 ± 5 N⋅m.

>>K<< AUTO-TENSIONER INSTALLATION

MD998781

AK202738

4. Hold the drive plate using the special tool Fly wheel stopper (MD998781).

5. Tighten the crankshaft bolt to a torque of 167 N⋅m.

AK301074

1. If the auto-tensioner rod remains in its fully extended position, reset it to the retracted position as follows:

(1) Clamp the auto-tensioner in a vise at right

angles to the jaws.

(2) Push in the rod little by little with the vise until

the set hole A in the rod is aligned with the set hole "B" in the cylinder.

(3) Insert a piece of wire (1.4 mm diameter) into

the set holes.

(4) Remove the auto-tensioner from the vise.

Page 23

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

AK300154

2. Install the auto-tensioner in position. Leave the wire installed until the auto-tensioner is completely installed.

11D-23

NOTE: If the timing marks were aligned, the exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the force of the valve springs.

Timing marks

AK304441

>>L<< TENSIONER PULLEY INSTALLATION

Tensioner pulley hole

AK300147

Install the tensioner pulley with its holes aligned as shown in the drawing.

>>M<< TIMING BELT INSTALLATION

Timing marks

2. Align the timing mark on the intake camshaft sprocket with that on the rocker cover.

NOTE: The intake camshaft will be turned slightly clockwise from where the timing marks are aligned by the force of the valve springs and stay there.

Timing marks

AK304563

3. Bring the timing mark on the crankshaft sprocket to a point one sprocket tooth away from the mating timing mark in the counterclockwise direction like in the operation with the exhaust camshaft sprocket.

AK304440

1. Bring the timing mark on the exhaust camshaft sprocket to a point one sprocket tooth away from the timing mark on the rocker cover in the counterclockwise direction.

60 mm or more

Counter balance shaft

AK301077

4. Align the timing mark on the oil pump sprocket with that on the cylinder block.

(1) Remove the plug from the cylinder block.

Page 24

11D-24

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

(2) Insert a crosspoint screwdriver with a shank

diameter of 8 mm through the plug hole. If it can be inserted 60 mm or more, the sprocket is in the correct phase. If the insertion depth is up to 20 − 25 mm, the screwdriver is blocked by the counterbalancer shaft. Then turn the oil pump sprocket one turn and realign the timing marks. Then check that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished.

Timing marks

AK202761

(3) Turn the oil pump sprocket counterclockwise

by one sprocket tooth.

6. Turn the intake camshaft sprocket counterclockwise to bring the timing mark on it one sprocket tooth away from the mating timing mark in the counterclockwise direction. Then install the timing belt on the sprocket and hold it in place with a paper clip.

NOTE: The timing marks will be aligned when the belt is installed since the intake camshaft is turned slightly clockwise by the force of the valve springs.

Timing marks

AK305994

7. Turn the exhaust camshaft sprocket clockwise to align the timing marks, and make sure that the intake camshaft sprocket timing marks are also aligned.

AK202771

5. Install the timing belt on the exhaust camshaft sprocket, and hold it in place with a paper clip at the point indicated in the drawing.

AK202772

Crankshaft sprocket

Oil pump sprocket

AK202762AE

8. Install the timing belt on the idler pulley, oil pump sprocket, and crankshaft sprocket, in this order.

NOTE: There should be no slack in the installed portion of the belt.

Camshaft sprocket

Tensioner pulley

AK202773

9. Install the timing belt on the tensioner pulley.

Page 25

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

NOTE: Turning slightly the intake camshaft sprocket counterclockwise will facilitate installation of the belt on the tensioner pulley.

Crankshaft sprocket

11D-25

MD998738

AK202763AB

10.Turn slightly the crankshaft sprocket clockwise to take up the slack in the idler pulley portion of the timing belt.

11.Check that each of the timing marks on the crankshaft, oil pump, and exhaust camshaft sprockets is one sprocket tooth away from its mating timing mark in the counterclockwise direction.

MD998767

AK202764

12.Turn the tensioner pulley counterclockwise using the special tool Tension pulley socket wrench (MD998767) to give tension to the belt and hold the tensioner in position by temporarily tightening the tensioner lock bolt.

NOTE: Take up the slack in the belt portion between the intake and exhaust camshaft sprockets.

13.Turn the crankshaft clockwise to make the timing mark align with the No.1 cylinder top dead center mark.

AK202774

14.Install the special tool Set screw (MD998738) and turn down the tool until the wire (inserted in the auto-tensioner when it was installed) can be moved freely.

15.Loosen the tensioner pulley lock bolt.

MD998767

AK202775

CAUTION

Prevent the timing belt from slipping as it becomes loose following rotation of the intake and exhaust camshafts.

16.Turn the torque wrench attached to the special tool Tension pulley socket wrench (MD998767) counterclockwise until the slack in the timing belt is taken up.

17.Turn the torque wrench clockwise from the position of step 16 until the torque wrench reading becomes 3.5 N⋅m, then tighten the tensioner pulley lock bolt.

18.Remove the special tool Set screw (MD998738) that was installed in step 14.

19.Turn the crankshaft clockwise two turns, then let it alone for approx. 15 minutes.

Page 26

11D-26

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

Extension amount

AK202829

20.Check that the wire (inserted in the auto-tensioner when it was installed) can be moved freely. If the wire can be pulled freely, the belt tensioner is adjusted properly. Remove the wire. At that time, check that the auto-tensioner rod extends by the specified amount.

Standard value: 3.8 − 4.5 mm

CAUTION

Be sure to check the tightening torque of the crankshaft bolt anytime the crankshaft has been turned counterclockwise. If the torque lower than specification, tighten the bolt to the specified torque.

21.If the wire cannot be pulled out freely, perform the steps 14 through 18 again to make the belt tension proper.

INSPECTION

M1113002000685

TIMING BELT

Check closely the entire timing belt. Replace it if any of the following conditions is found.

Cracks

Peeling of canvas

Cracks in tooth roots

Cracks in sides

AK202793

2. Cracks in back rubber surface.

3. Cracks in canvas.

4. Cracks in tooth roots.

5. Cracks in belt sides.

Rounded edge

Abnormal wear (Fluffy strand)

AK202795

6. Abnormally worn belt sides;

NOTE: belt sides are normal if they have “knife-cut” surfaces.

Canvas lost and rubber exposed

Cracks

AK202794

1. Hardened back side rubber.

Back side surface is glossy, lacking in elasticity, and so hard that no impression is left when pressed with fingernail.

Missing Tooth

AK202796

7. Badly worn teeth. Initial stage: Canvas is worn (canvas fiber is fluffy; teeth look whitish due to worn-out rubber; canvas texture is unclear) Second stage: Canvas is lost and rubber is exposed (tooth width narrows down)

8. Missing tooth.

Page 27

ENGINE OVERHAUL <4G63-Turbo>

TIMING BELT

11D-27

AUTO-TENSIONER

12 mm

AK301307

1. Check the auto-tensioner for leaks from the sealed sections.

Replace it if leaky.

2. Check the rod end for wear and other damage.

Replace the auto-tensioner if the rod is badly worn or damaged.

3. Measure the extension length of the rod.

If it is not within the standard value range, replace the auto-tensioner.

Standard value: 12 mm

98 to 196 N

Movement

AK301308

4. Press the rod with a force of 98 to 196 N and measure the amount of retraction. If the measurement exceeds the standard value, replace the auto-tensioner.

Standard value: 1 mm maximum

Page 28

11D-28

ENGINE OVERHAUL <4G63-Turbo>

FUEL AND EMISSION PARTS

REMOVAL AND INSTALLATION

9.0 ± 2.0 N·m

11 ± 1 N·m

M1113002200708

19 ± 3 N·m

>>C<< >>B<<

Removal steps

1. Throttle body

2. Throttle body gasket

3. Fuel pressure regulator

4. O-ring

5. Injector and delivery pipe

6. Insulator

>>A<<

AK400297

Removal steps (Continued)

7. O-ring

8. Injector

9. O-ring

10. Grommet

11. Delivery pipe

Page 29

ENGINE OVERHAUL <4G63-Turbo>

FUEL AND EMISSION PARTS

11D-29

INSTALLATION SERVICE POINTS >>A<< INJECTOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring.

CAUTION

Prevent engine oil from getting into the delivery pipe.

2. Insert the injector into the delivery pipe while turning it in both directions carefully not to damage the O-ring.

3. Check that the injector turns smoothly. If it does not, the O-ring may be jamming, so remove the injector and check the O-ring for damage. If the O-ring is intact, insert the injector into the delivery pipe and check it for smooth rotation again.

>>B<< FUEL PRESSURE REGULATOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring.

CAUTION

Prevent engine oil from getting into the delivery pipe.

3. Check that the fuel pressure regulator turns smoothly. If it does not, the O-ring may be jamming, so remove the fuel pressure regulator and check the O-ring for damage. If the O-ring is intact, insert it into the delivery pipe and check it for smooth rotation again.

>>C<< THROTTLE BODY GASKET INSTALLATION

Ta b

AK305995

Install the throttle body gasket with its tab located as shown in the drawing.

2. Insert the fuel pressure regulator into the delivery pipe while turning it in both directions carefully not to damage the O-ring.

Page 30

11D-30

ENGINE OVERHAUL <4G63-Turbo>

INLET MANIFOLD

REMOVAL AND INSTALLATION

36 ± 6 N·m

20 ± 2 N·m

M1113026100062

36 ± 6 N·m

23 ± 2 N·m

>>A<<

31 ± 3 N·m

Removal steps

1. Inlet manifold stay

2. Alternator brace stay

3. Inlet manifold

4. Inlet manifold gasket

5. Detonatoin sensor

INSTALLATION SERVICE POINTS >>A<< INLET MANIFOLD STAY

INSTALLATION

Intake manifold stay

AK400302

AK400845

Tighten the bolts to the specified torque 31 ± 3 N⋅m on both ends after making sure that the stay is in close contact with the bosses on the inlet manifold and cylinder block.

Page 31

ENGINE OVERHAUL <4G63-Turbo>

EXHAUST MANIFOLD

11D-31

REMOVAL AND INSTALLATION

19 ± 3 N·m

55 ± 10 N·m

M1113004900725

23 ± 3 N·m

59 ± 5 N·m

33 ± 6 N·m

11 ± 1 N·m

17 ± 2 N·m

19 ± 1 N·m

59 ± 5 N·m

44 ± 5 N·m

>>C<<

>>B<<

28 ± 5 N·m

10 ± 1 N·m

36 ± 5 N·m

Removal steps

1. Engine hanger

2. Oxygen sensor

3. Turbocharge heat protector

4. Exhaust fitting bracket

5. Exhaust fitting

6. Exhaust fitting gasket

7. Air outlet fitting

8. Air outlet fitting gasket

9. Oil return pipe

10. Oil return pipe gasket

11. Oil return pipe gasket

10 ± 1 N·m

28 ± 5 N·m

23 ± 3 N·m

14 ± 1 N·m

>>A<<

AK400396

Removal steps (Continued)

12. Exhaust manifold heat protector

13. Turbocharge assembly and pipe assembly

14. Turbocharge gasket

15. Ring

16. Oil pipe

17. Water pipe "B"

18. Water pipe "A"

19. Turbocharge assembly

20. Exhaust manifold

21. Exhaust manifold gasket

Page 32

11D-32

ENGINE OVERHAUL <4G63-Turbo>

EXHAUST MANIFOLD

INSTALLATION SERVICE POINT >>A<< EXHAUST MANIFOLD

INSTALLATION

1. Hand tighten all the exhaust manifold mounting nuts.

2. Tighten the M8 nuts to 29 ± 3 N⋅m in the indicated sequence.

3. Tighten the M10 nuts to 49 ± 5 N⋅m in the indicated sequence.

4. Tighten the M8 nuts again to 29 ± 3 N⋅m in the indicated sequence.

543

5. Finally tighten the M10 nuts and the M8 nuts to the specified torque, both in the indicated sequence.

Tightening torque: 33 ± 6 N⋅m <M8> 55 ± 10 N⋅m <M10>

AK305997

>>B<< OIL RETURN PIPE GASKET INSTALLATION

Ta b

AK305998

Install the oil return pipe gasket with its tab located as shown in the drawing.

NOTE: The gasket on the turbocharger end of the pipe does not require special alignment for installation.

>>C<< OUTLET FITTING GASKET INSTALLATION

Ta b

AK400303

Install the air outlet fitting gasket with its tab located as shown in the drawing.

Page 33

ENGINE OVERHAUL <4G63-Turbo>

WATER PUMP AND WATER HOSE

11D-33

REMOVAL AND INSTALLATION

13 ± 2 N·m

M1113017900372

13 ± 2 N·m

23 ± 4 N·m

10.8 ± 1.0 N·m

29 ± 10 N·m

14 ± 1 N·m

>>E<< >>D<<

>>C<< >>B<< >>A<< >>A<< >>A<<

Removal sequence

1. Water hose

2. Water hose

3. Water hose

4. Water hose

5. Engine coolant temperature sensor

6. Engine coolant temperature gauge unit

7. Water inlet fitting

8. Thermostat

9. Water outlet fitting

10. Thermostat housing

11. O-ring

12. Water inlet pipe

13. O-ring

14. Water pump

15. Water pump gasket

AK304981

INSTALLATION SERVICE POINTS >>A<< O-RING/WATER INLET PIPE

INSTALLATION

CAUTION

• Never allow any oil or grease to touch the O-rings.

• Clamp the water inlet pipe only after installation of the thermostat case.

Replace the O-rings at both ends of the water inlet pipe with new ones. Insert the O-rings into the water pump and thermostat housing after wetting their peripheries with water.

Page 34

11D-34

ENGINE OVERHAUL <4G63-Turbo>

WATER PUMP AND WATER HOSE

>>B<< THERMOSTAT HOUSING INSTALLATION

AK305999

1. Remove all old FIPG remaining on the thermostat housing and cylinder head.

2. Apply a 2.7 ± 0.3 mm diameter bead of FIPG on the indicated surface of the thermostat housing.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

>>C<< WATER OUTLET FITTING INSTALLATION

>>D<< ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION

AK300711

1. Remove all old sealant remaining on the threaded hole in the engine coolant temperature gauge unit and the thermostat housing.

NOTE: A new engine coolant temperature gauge unit is coated with sealant. It does not require coating with sealant before installation.

2. Apply sealant to the indicated threads of the engine coolant temperature gauge unit.

Specified sealant:

3M Nut Locking Part No.4171 or equivalent

AK202755AB

1. Remove all old FIPG remaining on the water outlet fitting and thermostat housing.

2. Apply a 2.7 ± 0.3 mm diameter bead of FIPG to the indicated surface of the water outlet fitting.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

>>E<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

AK300712

CAUTION

When using a tool, avoid letting it touch the connector portion which is made of plastic.

1. Remove all old sealant remaining on the threads of the engine coolant temperature sensor and in the threaded hole in the thermostat housing.

2. Apply sealant to the engine coolant temperature sensor's threads indicated in the drawing.

Specified sealant:

3M ATD Part No.8660 or equivalent

Page 35

ENGINE OVERHAUL <4G63-Turbo>

ROCKER ARMS AND CAMSHAFT

11D-35

REMOVAL AND INSTALLATION

20 ± 1 N·m

M1113005400853

11 ± 1 N·m

22 ± 4 N·m

10 ± 2 N·m

14 ± 1 N·m

10.8 ± 1.0 N·m

>>F<< >>E<< >>D<< >>C<< >>C<< >>C<< >>C<< >>C<< >>C<< >>C<< >>B<<

Removal steps

1. Camshaft position sensor

2. O-ring

3. Cover

4. Gasket

5. Camshaft position sensing cylinder

6. Camshaft position sensor support

7. Camshaft oil seal

8. Bearing cap, rear right

9. Bearing cap, rear left

10. Bearing cap, front

11. Bearing cap No.5

12. Bearing cap No.2

13. Bearing cap No.3

14. Bearing cap No.4

15. Camshaft

Apply engine oil to all moving parts before installation.

<<A>> >>A<<

AK306000

Removal steps (Continued)

16. Rocker arm

17. Lash adjuster

18. Oil delivery body

SERVICE POINTS FOR REMOVAL <<A>> LASH ADJUSTER REMOVAL

CAUTION

When reusing a lash adjuster, it must be washed and inspected before installation. (Refer to

P.11D-37, the instruction under LASH ADJUSTER

in the INSPECTION section.)

Page 36

11D-36

ENGINE OVERHAUL <4G63-Turbo>

ROCKER ARMS AND CAMSHAFT

INSTALLATION SERVICE POINTS >>A<< LASH ADJUSTER INSTALLATION

CAUTION

When reusing a lash adjuster, it must be washed and inspected before installation. (Refer to

P.11D-37, the instruction under LASH ADJUSTER

in the INSPECTION section.)

Install the lash adjuster into the rocker arm, being careful not to spill the diesel fuel it contains.

>>B<< CAMSHAFT INSTALLATION

Timing belt side

Slit

Exhaust camshaft

AK202869

CAUTION

• Do not confuse the intake camshaft with the exhaust camshaft.

• The exhaust camshaft has a 4 mm wide slit at the rear end.

>>C<< BEARING CAP INSTALLATION

Dowel pin

2. The bearing caps No. 2 to 5 are identical in shape for both intake and exhaust camshafts. Check the identification mark on each cap before installation.

Identification mark (stamped on front and

Nos. 2 − 5 bearing caps) I: intake camshaft E: exhaust camshaft

3. Remove completely sealant remaining on the bearing caps and cylinder head.

AK202871AB

4. Apply sealant to the surfaces indicated in the drawing.

Specified sealant:

3M ATD No.8660 or equivalent

5. Install each bearing cap and tighten its bolts in two or three passes.

6. Finally tighten the bolts to 20 ± 1 N⋅m.

7. Check that the rocker arms are correctly installed.

NOTE: Wipe off any squeezed out sealant completely.

AK203979

1. Set each camshaft with its dowel pin at the top.

Cap number Intake/exhaust

identification letter

AK202870

>>D<< CAMSHAFT OIL SEAL INSTALLATION

MD998713

AK304515

Use the special tool Camshaft oil seal installer (MD998713) to drive each oil seal into position in the cylinder head.

Page 37

ENGINE OVERHAUL <4G63-Turbo>

ROCKER ARMS AND CAMSHAFT

11D-37

>>E<< CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION

AK202754AB

1. Remove completely the FIPG remaining on the camshaft position sensor support and cylinder head.

2. Apply a 3 ± 1 mm diameter bead of FIPG to the indicated surface of the camshaft position sensor support.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

INSPECTION

M1113005500708

CAMSHAFT

AK202797AB

Measure the cam height (nose-to-heel diameter). If any cam is worn beyond the limit, replace the camshaft.

Standard value: Intake: 35.79 mm Exhaust: 35.49 mm

Limit: Intake: 35.29 mm Exhaust: 34.99 mm

>>F<< CAMSHAFT POSITION SENSING CYLINDER INSTALLATION

Smaller vane

Camshaft posittion sensor

AK306001

1. Turn the exhaust camshaft to the No.1 cylinder top dead center position.

NOTE: The camshaft will slightly turn counterclockwise by the force of the exhaust valve spring.

2. Install the camshaft position sensing cylinder with the smaller vane located as shown in the drawing.

LASH ADJUSTERS

CAUTION

• The lash adjuster is a precision-engineered component. Do not allow dust or other foreign matter to enter it.

• Do not disassemble lash adjusters.

• Use only non-contaminated diesel fuel to

clean the lash adjuster.

For rough cleaning

ABC

1. Prepare three containers and approximately five liters of diesel fuel. Pour into each container the diesel fuel in an amount enough for a lash adjuster placed in the container in its upright position to completely submerge.

For finish cleaning

For diesel fuel filling

AK202836

Page 38

11D-38

ENGINE OVERHAUL <4G63-Turbo>

ROCKER ARMS AND CAMSHAFT

CAUTION

The hole in the side of the lash adjuster must be directed toward the inside of container A. Never direct it against any person.

4. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure

Diesel fuel

chamber.

AK300587

2. Place the lash adjuster in container A and wash its outside surface.

NOTE: Use a nylon brush if there are hard-to-remove deposits.

Diesel fuel

MD998442

AK202839

CAUTION

The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.

Diesel fuel

MD998442

AK202839

CAUTION

The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.

5. Soak the lash adjuster in the diesel fuel in container B. Move the plunger in and out 5 − 10 times by gently pushing the internal steel ball using the special tool Air bleed wire (MD998442) until the plunger moves smoothly to wash the lash adjuster’s pressure chamber.

3. While gently pushing the internal steel ball using the special tool Air bleed wire (MD998442), move the plunger in and out 5 − 10 times to eliminate stiffness in the plunger and expel contaminated oil.

NOTE: The plunger must be free from jamming and any other abnormalities. If a defect is found in plunger operation, replace the lash adjuster.

MD998442

Diesel fuel

AK202840

MD998442

Diesel fuel

AK202840

CAUTION

The hole in the side of the lash adjuster must be directed toward the inside of container B. Never direct it against any person.

6. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber.

Page 39

ENGINE OVERHAUL <4G63-Turbo>

ROCKER ARMS AND CAMSHAFT

8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.

11D-39

MD998442

Diesel fuel

AK202841

CAUTION

Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel.

7. Soak the lash adjuster in the diesel fuel in container C. Gently push the internal steel ball using the special tool Air bleed wire (MD998442).

MD998442

Diesel fuel

AK202842

AK202843

9. Take the lash adjuster out of the container, place it upright with the plunger at the top, and push the plunger firmly. The plunger must not move at all.

NOTE: If the lash adjuster contracts, perform the operations 7 through 9 again. Replace the lash adjuster if it still contracts even after the pressure chamber has completely been filled with diesel fuel (air has been bled).

10.Keep the serviced lash adjusters in their upright positions to prevent diesel fuel from spilling out. Protect them from dust or other foreign matter. Install the lash adjusters onto the engine as soon as possible.

Page 40

11D-40

ENGINE OVERHAUL <4G63-Turbo>

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION

M1113006900787

78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚

Apply engine oil to all moving parts before installation.

AK306002

<<A>> >>D<<

<> >>C<<

>>B<<

Removal steps

1. Cylinder head bolt

2. Cylinder head assembly

3. Cylinder head gasket

4. Retainer lock

5. Valve spring retainer

6. Valve spring

<> >>C<<

>>B<<

<<C>> >>A<<

Removal steps (Continued)

7. Intake valve

8. Retainer lock

9. Valve spring retainer

10. Valve spring

11. Exhaust valve

12. Valve stem seal

13. Valve spring seat

Page 41

ENGINE OVERHAUL <4G63-Turbo>

CYLINDER HEAD AND VALVES

11D-41

Removal steps (Continued)

<<C>> >>A<<

14. Valve stem seal

15. Valve spring seat

16. Intake valve guide

17. Exhaust valve guide

18. Intake valve seat

19. Exhaust valve seat

20. Cylinder head

REMOVAL SERVICE POINTS <<A>> CYLINDER HEAD BOLT REMOVAL

MB991654

AK202723

Use the special tool Cylinder head bolt wrench (MB991654) to loosen the cylinder head bolts.

<> RETAINER LOCK REMOVAL

MD998735

NOTE: Store removed valves, springs and other parts, after putting to each of them a tag that identifies its cylinder No. or installation location.

<<C>> VALVE STEM SEAL REMOVAL

AK304633

Do not reuse removed valve stem seal.

INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL

INSTALLATION

CAUTION

The special tool must always be used when installing the valve stem seal. Improper installation could result in oil leaks past the valve guide.

AK306003

MD998772

AK202742

Compress the valve spring using the special tool Valve spring compressor (MD998735 or MD998772), then remove the retainer lock.

1. Install the valve spring seat.

2. Install the valve.

3. Apply a thin coat of engine oil to a new valve stem seal.

MD998737

AK304485

4. Use the special tool Valve stem seal installer (MD998737) to install the stem seal on the valve guide. Use the stem of the valve to guide the stem seal.

Page 42

11D-42

Intake valve stem seal Colour: Gray

ENGINE OVERHAUL <4G63-Turbo>

CYLINDER HEAD AND VALVES

Exhaust valve stem seal Colour: Grayish green

Compress the valve spring using the special tool Valve spring compressor (MD998735 or MD998772), then install the retainer lock.

>>D<< CYLINDER HEAD BOLT INSTALLATION

AK304538

NOTE: Do not confuse the stem seals for intake valves with those for exhaust valves.

>>B<< VALVE SPRING INSTALLATION

Painted end

AK300717

Install the valve spring whose small diameter is shown from the rocker arm side.

>>C<< RETAINER LOCK INSTALLATION

MD998735

Shank length

AK300591AB

1. When reusing a cylinder head bolt, check that its nominal length (shank length) is not greater than the limit. If the limit is exceeded, replace the bolt.

Limit: 99.4 mm

2. Apply engine oil to the threads and washer of the bolt.

MB991654

AK306003

MD998772

AK202742

Timing belt side

410

AK202723

13968

AK306004AC

3. Tighten the bolts to 78 ± 2 N⋅m in the indicated sequence.

NOTE: Use the special tool Cylinder head bolt wrench (MB991654) to tighten the bolts.

4. Loosen all the bolts completely.

5. Tighten the bolts again to a torque of 20 ± 2 N⋅m in the indicated sequence.

Page 43

ENGINE OVERHAUL <4G63-Turbo>

CYLINDER HEAD AND VALVES

90˚

Paint marks

AK202720

CAUTION

• If the tightening angle is smaller than 90°, proper fastening performance could not be assured. Be sure to respect that angle.

• If the bolt is tightened to an angle greater than the specified angle, loosen the bolt completely and then retighten it beginning with the first step.

6. Make paint marks on each bolt’s head and on the cylinder head.

7. Turn the bolts 90° in the tightening direction and in the indicated sequence.

8. Give another 90° turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the cylinder head are on the same line.

11D-43

CAUTION

The thickness of the metal that can be removed by grinding from both the cylinder head and the mating cylinder block is limited to 0.2 mm in total.

3. Check the cylinder head gasket surface for warp using a straightedge and thickness gauge.

If the surface is warped beyond the limit, grind the surface for rectification.

Gasket surface warp Standard value: Less than 0.05 mm Limit: 0.2 mm Grinding limit: 0.2 mm

Cylinder head height (standard value for new

part): 131.9 − 132.1 mm

VALVES

1. Check the valve face for correct contact with the seat. Reface the valve if the contact is partial or one sided.

Contact (Should be at centre of face)

Margin

INSPECTION

M1113007000680

CYLINDER HEAD

1. Before cleaning the cylinder head, check it for traces of water and gas leakage and for cracks and any other damage.

2. Thoroughly remove oils, scale, sealants, carbon and other contamination. Clean the oil passages, then check using compressed air that they are not blocked.

AK202724

AK300593

2. Measure the margin.

Replace the valve if its margin is smaller than the limit.

Standard values: Intake 1.0 mm Exhaust 1.5 mm

Limits: Intake 0.5 mm Exhaust 1.0 mm

Page 44

11D-44

ENGINE OVERHAUL <4G63-Turbo>

CYLINDER HEAD AND VALVES

VALVE GUIDE

Valve guide

Total length

AK202876

3. Measure the total length of the valve.

Replace the valve if the length is less than the limit.

Standard values: Intake 109.5 mm Exhaust 109.7 mm

Limits: Intake 109.0 mm Exhaust 109.2 mm

VALVE SPRINGS

Out of square

Free height

Stem diameter

Guide inside diameter

AK300168

Measure the valve guide inside diameter and valve stem diameter to calculate the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.

Standard values: Intake 0.02 − 0.05 mm Exhaust 0.05 − 0.09 mm

Limits: Intake 0.10 mm Exhaust 0.15 mm

VALVE SEATS

Valve stem end

Valve stem projection

AK300594

1. Measure the free height of the spring.

Replace the spring if its height is smaller than the limit.

Standard value: 47.0 mm Limit: 46.0 mm

2. Measure the squareness of the spring.

Replace the spring if it is out of square beyond the limit.

Standard value: 1.5° or smaller Limit: 4°

Spring seating surface

AK202814

With the valve installed in position and its face pressed against the valve seat, measure the valve stem projection (distance between the valve stem end and spring seating surface). If the measurement exceeds the limit, replace the valve seat.

Standard values: Intake 49.2 mm Exhaust 48.4 mm

Limits: Intake 49.7 mm

Exhaust 48.9 mm

Page 45

ENGINE OVERHAUL <4G63-Turbo>

CYLINDER HEAD AND VALVES

11D-45

VALVE SEAT RECONDITIONING

1. Before reconditioning the valve seat, check the clearance between the valve guide and valve stem and, if necessary, replace the valve guide.

0.9 ‘1.3 mm 44˚

10˚

AK304983

65˚

0.9 ‘1.3 mm 44˚

10˚

2. Resurface the valve seat to the indicated width and angles.

3. After resurfacing, lap the valve and valve seat using lapping compound.

VALVE SEAT REPLACEMENT

0.5 - 1 mm

Intake valve seat hole diameters:

0.3 oversize: 35.30 − 35.33 mm

0.6 oversize: 35.60 − 35.63 mm

Exhaust valve seat hole diameters:

0.3 oversize: 33.30 − 33.33 mm

0.6 oversize: 33.60 − 33.63 mm

3. Before fitting the valve seat, cool it in liquid nitrogen to prevent damage to its hole in the cylinder head due to interference.

4. Resurface the valve seat. See the VALVE SEAT RECONDITIONING section.

VALVE GUIDE REPLACEMENT

1. Force out the valve guide toward the cylinder block using a press.

CAUTION

Do not use a replacement valve guide of the same size as the removed one.

2. Machine the valve guide hole in the cylinder head to the size matched to the selected oversize valve guide.

Valve guide hole diameters

0.05 oversize: 12.05 − 12.07 mm

0.25 oversize: 12.25 − 12.27 mm

0.50 oversize: 12.50 − 12.52 mm

Cut

0.5 - 1 mm

AK300719

1. Cut inside of the valve seat to be replaced until its wall becomes thin enough for removal, then remove the valve seat.

Valve seat height

Oversize hole diameter

AK300720

2. Rebore the valve seat hole in the cylinder head to a diameter matched to the diameter of the selected oversize valve seat.

19.2 – 19.8 mm

AK400848

3. Press-fit the valve guide until it remains protruded above the cylinder head by the amount indicated in the drawing.

Standard value: 19.2 − 19.8 mm

NOTE: Press the valve guide from above the cylinder head.

NOTE: The valve guides for the intake valves are different in length from those for the exhaust valves (45.5 mm for intake valves; 50.5 mm for exhaust valves)

4. After installing the valve guide, insert a new valve in it to check for smooth movement.

Page 46

11D-46

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

Apply engine oil to all moving parts before installation.

23 ± 3 N·m

54 ± 5 N·m

19 ± 3 N·m

23 ± 3 N·m

M1113008100657

10 ± 2 N·m

17 ± 1 N·m

19 ± 3 N·m

>>N<< >>M<<

<<A>> >>L<< <> >>L<<

>>K<<

<<C>> >>J<<

36 ± 3 N·m

23 ± 3 N·m

44 ± 5 N·m

Removal steps

1. Drain plug

2. Drain plug gasket

3. Oil filter

4. Transmission stay

5. Oil pan lower

6. Oil pan upper

7. Oil screen

8. Gasket

9. Oil cooler by-pass valve

10.Oil pressure switch

11. Relief plug

12.Gasket

13.Relief spring

14.Relief plunger

15.Oil filter bracket

16.Gasket

17.Plug

23 ± 3 N·m

39 ± 5 N·m

9.0 ± 3.0 N·m

<<D>> >>I<<

>>H<<

>>G<< >>G<< >>F<< >>E<< >>D<<

<<E>> >>C<< <<F>> >>B<<

<<F>> >>A<<

9.0 ± 3.0 N·m

Removal steps (Continued)

18.O-ring

19.Flange bolt

20.Front case

21.Gasket

22.Oil pump cover

23.Oil pump driven gear

24.Oil pump drive gear

25.Crankshaft front oil seal

26.Counterbalancer shaft oil seal

27.Oil pump oil seal

28.Counterbalancer shaft, right

29.Counterbalancer shaft, left

30.Counterbalancer shaft front bearing

31.Counterbalancer shaft rear bearing, right

32.Counterbalancer shaft rear bearing, left

22 ± 4 N·m

AK400304

Page 47

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

11D-47

REMOVAL SERVICE POINTS

<<A>> OIL PAN LOWER REMOVAL

Remove the oil pan by tapping it through a piece of wood applied to a side with a plastic hammer.

CAUTION

Do not use a scraper or the special tool to remove the oil pan.

<> OIL PAN UPPER REMOVAL

Screw bolts into the bolt holes A shown in the drawing (holes at both ends) to remove the oil pan.

CAUTION

Do not use a scraper or the special tool to remove the oil pan.

AK304400

<<D>> FLANGE BOLT REMOVAL

Plug

1. Remove the plug on the left side of the cylinder block. Insert a cross point screwdriver (shank diameter 8 mm) into the plug hole more than 60 mm to prevent the left counterbalancer shaft from rotating.

Crosspoint screwdriver

AK202752

AK300173

<<C>> PLUG REMOVAL

MD998162

MD998783

Fit the teeth of the special tools in notches of the plug as shown in the drawing and support the tool with the special tool to loosen the plug.

• Plug wrench (MD998162)

• Plug wrench retainer (MD998783)

AK300171

2. Loosen and remove the flange bolt.

<<E>> COUNTERBALANCER SHAFT FRONT BEARING REMOVAL

CAUTION

MD998371

AK300174

Remove the front bearing first. Otherwise, the special tool cannot be used.

Use the special tool Silent shaft bearing puller (MD998371) to remove the counterbalancer shaft front bearing from the cylinder block.

Page 48

11D-48

ENGINE OVERHAUL <4G63-Turbo>

<<F>> COUNTERBALANCER SHAFT REAR BEARING REMOVAL

OIL PAN AND OIL PUMP

MB991603

MD998705

Rear bearing

MD998372

AK300175

1. Use the special tool Silent shaft bearing puller (MD998372) to remove the counterbalancer shaft rear bearings from the cylinder block.

MB991603

MD998372

AK300176

2. When removing the rear bearing of the left counterbalancer shaft, install the special tool Silent shaft bearing installer stopper (MB991603) on the front of the cylinder block and use a special tool Silent shaft bearing puller (MD998372) to pull out the bearing.

INSTALLATION SERVICE POINTS >>A<< LEFT COUNTERBALANCER

SHAFT REAR BEARING INSTALLATION

MB991603

AK300619

1. Install special tool Silent shaft bearing installer stopper (MB991603) to the cylinder block.

2. Apply engine oil to the rear bearing outer surface and bearing hole in the cylinder block.

3. Using special tool Silent shaft bearing installer (MD998705), install the rear bearing.

NOTE: The left rear bearing has no oil holes.

>>B<< RIGHT COUNTERBALANCER SHAFT REAR BEARING INSTALLATION

MD998705(Guide pin)

1. Install the guide pin of the Silent shaft bearing installer (MD998705) in the threaded hole of the cylinder block as shown.

Ratchet ball

AK300178

Oil hole

MD998705

AK300177

Rear bearing right

AK300621

2. Align the ratchet ball of the special tool with the oil hole in the rear bearing to install the bearing of the special tool.

3. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.

Page 49

MD998705

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

11D-49

MD998705(Guide pin)

AK300179

MD998705

AK300622

4. Using special tool Silent shaft bearing installer (MD998705), install the rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole of the cylinder block.

>>C<< COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION

MD998705

MD998705(Guide pin)

AK300178

2. Install the guide pin of the Silent shaft bearing installer (MD998705) in the threaded hole of the cylinder block as shown.

Ratchet ball

Front bearing right

Oil hole

AK304592

3. Align the ratchet ball of the special tool with the oil hole in the rear bearing to install the bearing of the special tool.

4. Apply engine oil to the front bearing outer surface and bearing hole in the cylinder.

Rear bearing installing portion

AK300623

1. Remove the rear bearing installing portion from the special tool Silent shaft bearing installer (MD998705).

MD998705

MD998705(Guide pin)

AK300179

AK300624

Page 50

11D-50

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

5. Using special tool Silent shaft bearing installer (MD998705), install the rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole of the cylinder block.

>>D<< OIL PUMP OIL SEAL INSTALLATION

Socket wrench

Oil seal

Front case

AK304594

Use an appropriate socket wrench to install the oil pump oil seal.

>>E<< COUNTERBALANCER SHAFT OIL SEAL INSTALLATION

>>G<< OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR INSTALLATION

Alignment mark

AK300180

Apply engine oil generously to the gears and line up the alignment marks.

>>H<< FRONT CASE INSTALLATION

Socket wrench

Oil seal

Front case

AK304593

Use an appropriate socket wrench to install the counterbalancer shaft oil seal.

>>F<< CRANKSHAFT OIL SEAL INSTALLATION

MD998375

Oil seal

Front case

MD998285

AK300181AD

1. Install the special tool crankshaft front oil seal guide (MD998258) on the front end of crankshaft and apply a thin coat of engine oil to the outer surface of the special tool. Be sure to use the special tool when the front case is fitted with an oil seal.

2. Install the front case on the cylinder block with a new front case gasket in between and temporarily tighten all the flange bolts except those that are used for tightening the filter bracket.

3. Install the oil filter bracket on the front case with the oil filter bracket gasket in between and temporarily tighten the washer-assembled bolts.

AK304595

Use the special tool Crankshaft front oil seal installer (MD998375) to install the crankshaft oil seal.

MD998285

AK300182

4. Tighten all the bolts to the specified torques.

Page 51

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

11D-51

>>I<< FLANGE BOLT INSTALLATION

AK300172

1. Insert a correspond screwdriver (shank diameter 8 mm) into the hole in the left side of the cylinder block to prevent the counterbalancer shaft from rotating.

>>K<< OIL PRESSURE SWITCH INSTALLATION

CAUTION

AK300715

Be careful not to block the oil passage with sealant.

1. Apply sealant to the threaded portion.

Specified Sealant:

3M ATD Part No.8660 or equivalent

MD998054

AK300183

2. Tighten the flange bolts.

>>J<< PLUG INSTALLATION

1. Install a new O-ring on the front case.

MD998162

MD998783

AK300184

2. Use the special tools to tighten the plug to the specified torque.

• Plug wrench (MD998162)

• Plug wrench retainer (MD998783)

AK204037

2. Tighten the oil pressure switch together with the cylinder block by the specified torque using of the special tool Oil pressure switch wrench MD998054.

Tightening torque: 19 ± 3 N⋅m

Page 52

11D-52

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

>>L<< OIL PAN UPPER/OIL PAN LOWER INSTALLATION

CAUTION

Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage.

1. Clean the gasket surfaces of the cylinder block and oil pan.

CAUTION

Timing belt side

Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage.

2. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

Bolt hole area

Grooved area

AK304401

CAUTION

Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage.

4. Thoroughly remove old FIPG from the gasket surfaces of the oil pan upper and lower sections.

CAUTION

Timing belt side

Bolt hole area

Grooved area

AK304403

Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage.

5. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or

equivalent

NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

Timing belt side

M6 × 16

AK304402

3. Install the shorter bolts in the locations indicated in the drawing.

AK304404

6. Install the oil pan lower section by tightening the bolts in the indicated sequence.

Page 53

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

11D-53

>>M<< OIL FILTER INSTALLATION

AK301069

1. Clean the installation surface of the filter bracket.

2. Apply engine oil to the o-ring of the oil filter.

3. Install the oil filter to the bracket and tighten it to the specified torque.

Tightening torque: 14 ± 2 N⋅m

4. If no torque wrench can be used for tightening, use the following procedure:

(1) Screw in the oil filter until its o-ring contacts

the oil filter bracket.

(2) Tighten the oil filter 3/4 turn.

>>N<< DRAIN PLUG GASKET INSTALLATION

Drain plug

CAUTION

Installing the gasket with the wrong side facing the oil pan will result in oil leakage.

Replace the drain plug gasket with a new one. Install it with the side indicated in the drawing toward the oil pan.

INSPECTION

M1113008200386

COUNTERBALANCE SHAFTS

1. Check that the oil holes are not blocked.

Clean if necessary.

AK202835AB

2. Check the journals for seizure, damage and defective contact with bearings.

If any of these faults is found, replace the counterbalance shaft, bearings and/or oil pump case assembly.

Gasket

Oil pan

Oil pan side

AK300601AB

OIL PUMP

AK202831

1. Install the drive and driven gears in the oil pump case.

2. Measure the gear side clearance using a straight edge and thickness gauge.

Standard values: Drive gear 0.08 − 0.14 mm Driven gear 0.06 − 0.12 mm

Page 54

11D-54

ENGINE OVERHAUL <4G63-Turbo>

OIL PAN AND OIL PUMP

OIL COOLER BY-PASS VALVE

Valve

1. Make sure that valve moves smoothly.

AK000032

2. Ensure that the dimension L measures the standard value under normal temperature and humidity.

Standard value: 34.5 mm

3. The dimension must be the standard value when measured after the valve has been dipped in 97 to 103°C oil.

Standard value: 40.0 mm

Page 55

ENGINE OVERHAUL <4G63-Turbo>

PISTON AND CONNECTING ROD

11D-55

REMOVAL AND INSTALLATION

M1113008400863

7 8

>>G<<

<<A>> >>F<<

>>E<< >>D<<

>>C<<

Apply engine oil to all moving parts before installation.

Removal steps

1. Connecting rod cap nut

2. Connecting rod cap

3. Connecting rod bearing

4. Piston and connecting rod assembly

5. Connecting rod bearing

6. Piston ring No. 1

>>C<< >>B<<

<> >>A<<

20 ± 2 N·m + 90º to 94º

Removal steps (Continued)

7. Piston ring No. 2

8. Oil ring

9. Piston pin

10. Piston

11. Connecting rod

12. Bolt

AK306012

Page 56

11D-56

REMOVAL SERVICE POINTS <<A>> CONNECTING ROD CAP

REMOVAL

ENGINE OVERHAUL <4G63-Turbo>

PISTON AND CONNECTING ROD

Push rod

Cylinder number

AK300189

Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly.

<> PISTON PIN REMOVAL

Guide A: 18.9 mm

Push rod

Guide B

Guide A: 17.9 mm

Guide C

Guide A: 20.9 mm

Front mark

Guide C

Base

AK301478

1. Insert the tool element, Push rod, into the piston from the front mark side, then attach the element, Guide C, to the push rod.

2. Place the piston and connecting rod assembly on the element, Base, with the front mark facing up.

3. Use a press to remove the piston pin.

NOTE: Keep the disassembled pistons, piston pins and connecting rods cylinder by cylinder.

Base

Guide A: 21.9 mm

AK301431

The special tool Piston pin setting tool (MD998780), consists of the elements shown in the drawing.

INSTALLATION SERVICE POINTS >>A<< PISTON PIN INSTALLATION

Timing belt side

1. When replacing a piston, check the cylinder bore size mark stamped at the indicated location on the cylinder block and select an appropriate replacement piston using the following table.

Crankshaft bore size mark

No.4 No.3 No.2 No.1

AK305985

Page 57

ENGINE OVERHAUL <4G63-Turbo>

PISTON AND CONNECTING ROD

11D-57

Cylinder bore size mark Piston size mark

7. Insert the assembly of piston pin, Push rod, and

II No mark

III C

NOTE: The piston size mark is located on the piston top surface.

8. Screw the tool element, Guide B, into the tool

Connecting rod

Piston

Piston pin

Guide A (put together in step 4.) into the piston holes from the front mark side.

3 mm + L

Guide B

Guide A

AK301480

element, Guide A until the gap between both the elements is equal to the dimension L (obtained in step 3.) plus 3 mm.

Push rod

AK202784

2. Measure the following dimensions:

A: Piston pin insertion hole length

B: Distance between piston bosses

C: Piston pin length

D: Connecting rod small end width

3. Obtain dimension L from the measurements using the following formula.

L = [(A-C) − (B-D)] ÷ 2

4. Insert the tool element, Push rod, into the piston pin and attach the element, Guide A, to the push rod end.

5. Assemble the connecting rod with the piston with their front marks facing in the same direction.

6. Apply engine oil to the outside surface of the piston pin.

Front mark

Guide A

Base

Guide B

AK305971

9. Place the piston and connecting rod assembly onto the element, Piston setting base, with the front marks facing up.

10.Install the piston pin using a press. If the required press force is less than the standard value, replace the piston and piston pin assembly or the connecting rod, or both.

Standard value: 7,350 − 17,100 N

Page 58

11D-58

ENGINE OVERHAUL <4G63-Turbo>

PISTON AND CONNECTING ROD

>>B<< OIL RING INSTALLATION

Upper side rail end gap

Spacer end gap

1. Fit the oil ring spacer into the piston ring groove.

Install the upper side rail, then the lower side rail.

NOTE: Locate the side rail and spacer end gaps as shown in the drawing.

NOTE: New spacers and side rails are an identified by color marks as follows:

Size Color mark

Standard No mark

0.50 mm oversize Red

1.00 mm oversize Yellow

CAUTION

Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings.

Side rail end

Lower side rail end gap

AK202879

>>C<< PISTON RING NO. 2/PISTON RING NO. 1 INSTALLATION

Piston ring expander

AK202786

Identification mark

Size marks

AK202807

Using a piston ring expander, install the piston rings with their identification marks facing up (toward the piston crown).

Identification marks: No.1 ring: 1R No.2 ring: 2R

NOTE: Each of the available piston rings has a size mark as follows:

No. 1

No. 2

AK202785

2. To install each side rail, first fit one end of the rail into the piston groove, then press the remaining portion progressively into position by finger as shown in the drawing.

3. Make sure that the installed side rails move smoothly in either direction.

Size Size mark

Standard No. 1 ring No mark (white paint on

periphery)

No. 2 ring No mark

0.50 mm oversize 50

1.00 mm oversize 100

Page 59

ENGINE OVERHAUL <4G63-Turbo>

PISTON AND CONNECTING ROD

11D-59

>>D<< PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION

1. Apply engine oil generously to the piston's outside surface, piston rings, and oil ring.

Side rail

No. 1

No. 2

2. Align the end gaps of the piston rings and oil ring (side rails and spacer) as shown in the drawing.

3. Insert the piston and connecting rod assembly from the top of cylinder with the front mark on the crown toward the camshaft sprocket.

Side rail

AK202730

Locations of crankshaft pin diameter marks

No. 2

No. 1

No. 4

No. 3

AK304412

2. Crankshaft pin diameter marks are stamped in the indicated locations.

Connecting bearing

Identification mark position

AK304598

AK202798

CAUTION

• Do not strike the assembly with a large force. Doing so could break the piston rings.

• When striking the assembly into cylinder, do not allow it to interfere with the oil jet.

4. Use a piston ring band to hold the piston rings compressed when inserting the piston and connecting rod assembly into the cylinder.

>>E<< CONNECTING ROD BEARING INSTALLATION

1. When replacing the connecting rod bearing, select a bearing of the size appropriate for the crankshaft pin diameter in accordance with the crankshaft pin and connecting rod bearing matching table shown below.

3. Connecting rod bearing identification mark is stamped in the indicated location on each bearing.

Crankshaft pin Connecting rod

bearing

Identification mark

Diameter mm Identification

mark

I 44.995 − 45.000 0

II 44.985 − 44.995 1

III 44.980 − 44.985 2

If the crankshaft pin diameter mark is “I,” select a bearing marked “1.”

If the crankshaft pin diameter mark is illegible, measure the pin diameter and select a bearing with the mark corresponding to the measurement.

4. Install the upper and lower halves of the selected bearing on the connecting rod big end and cap, respectively.

Page 60

11D-60

ENGINE OVERHAUL <4G63-Turbo>

PISTON AND CONNECTING ROD

>>F<< CONNECTING ROD CAP INSTALLATION

Cylinder number

Notches

1. Install the bearing cap on the connecting rod while aligning the marks made during disassembly. If the connecting rod is new and has no alignment mark, assemble it with the cap such that the both bearing locating notches are on the same side as shown in the drawing.

AK300193

3. Finger-tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the cap properly.

4. Tighten the nuts to a torque of 20 ± 2 N⋅m.

90˚ to 94˚

Paint marks

Nut

Bolt

AK300612

5. Make a paint mark on the head of each nut.

CAUTION

• If the tightening angle is less than 90°, adequate tightness could not be assured.

• If the tightening angle exceeds 94°, loosen the nut completely and then perform the tightening procedure again beginning with the first step.

AK202821

2. Make sure that the thrust clearance of the connecting rod big end is proper.

Standard value: 0.10 − 0.25 mm

Limit: 0.4 mm

>>G<< CONNECTING ROD CAP NUT INSTALLATION

1. The connecting rod cap bolts and nuts are tightened using the torque-to-yield method. For this reason, each bolt to be reused must be checked for elongation before installation.

Whether or not the bolt has been elongated can be determined by running a nut with fingers through all the threads of the bolt. If the nut does not turn smoothly over all the threads, the bolt has been elongated and must be replaced.

2. Apply engine oil to the threads and bearing surface of each nut before installation.

6. Make a paint mark on the bolt at a point 90° to 94° away from the paint mark made on the nut in the tightening direction.

7. Turn the nut 90° to 94° to bring the mark on the nut into alignment with that on the bolt.

INSPECTION

M1113008500688

PISTON RING

AK202787

1. Measure the clearance between each piston ring and its groove. If the limit is exceeded, replace the ring or piston, or both.

Standard values: No. 1 ring: 0.03 − 0.07 mm No. 2 ring: 0.02 − 0.06 mm

Limits: 0.1 mm

Page 61

ENGINE OVERHAUL <4G63-Turbo>

PISTON AND CONNECTING ROD

Push in by piston

Piston ring

Piston ring gap

AK301481

2. Install a piston ring or oil ring side rail into the cylinder bore and force it down with the head of a piston until the ring is at right angles to the cylinder wall. Measure the end gap with a thickness gauge.

NOTE: If the end gap is excessive, replace the piston ring.

Standard values: No. 1 ring: 0.20 − 0.30 mm No. 2 ring: 0.30 − 0.45 mm Oil ring: 0.10 − 0.40 mm

Limits: No. 1 ring: 0.8 mm No. 2 ring: 0.8 mm Oil ring: 1.0 mm

11D-61

CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD)

1. Wipe off oil from the crankshaft pin and connecting rod bearing.

2. Cut a piece of plastic gauge whose length is equivalent to the width of the bearing and place it on the crankshaft pin in parallel with its axis.

3. Install the connecting rod cap carefully and tighten the nuts to the specified torque 20 ± 2 N⋅m + 90° to 94°.

4. Remove the nuts, then remove the connecting rod cap carefully.

AK202848

5. Measure the largest width of the crushed plastic gauge using the ruler printed on the bag of the plastic gauge.

Standard value: 0.03 − 0.05 mm

Limit: 0.1 mm

Page 62

11D-62

ENGINE OVERHAUL <4G63-Turbo>

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION

M1113008700875

11 ± 1 N·m

132 ± 5 N·m

9.0 ± 1.0 N·m

11 ± 1 N·m

>>F<< >>E<< >>D<<

Removal steps

1. Flywheel bolt

2. Flywheel

3. Rear plate

4. Bell housing cover

5. Oil seal case

6. Oil seal

7. Bearing cap bolt

25 ± 2 N·m +

Apply engine oil to all moving parts before installation.

>>D<< >>C<<

>>C<< >>B<<

<<A>> >>A<<

AK400305

Removal steps (Continued)

8. Beam bearing cap

9. Crankshaft bearing, lower

10. Crankshaft

11. Crankshaft bearing, upper

12. Thrust bearing

13. Oil jet

14. Cylinder block

Page 63

ENGINE OVERHAUL <4G63-Turbo>

CRANKSHAFT AND CYLINDER BLOCK

11D-63

REMOVAL SERVICE POINTS <<A>> OIL JET REMOVAL

AK304984

CAUTION

Be extremely careful not to give damage to the cylinder wall.

Use a suitably long metal rod to drive out the oil jet.

INSTALLATION SERVICE POINTS >>A<< OIL JET INSTALLATION

NOTE: Applying engine oil to the bearings will help facilitate holding them in position.

>>C<< CRANKSHAFT BEARING INSTALLATION

Location of crankshaft journal diameter marks

No. 2

No. 1

No. 4

1. Location of crankshaft journal diameter marks

If the crankshaft journal diameter mark is “0” and the cylinder block bearing bore mark is “1,” then select a bearing with a “2” mark as the No. 1, 2, 4 or 5 bearing and a bearing with a “1” mark as the No. 3 bearing.

No. 3

No. 5

AK304413

AK304985

Using a 4.5 mm diameter pin punch, drive the oil jet from the crankshaft journal bearing bore side of the cylinder block until it bottoms.

>>B<< THRUST BEARING INSTALLATION

Groove

If the crankshaft journal diameter mark is illegible, measure the journal diameter and select a bearing with the mark corresponding to the measurement.

Timing belt side

Diameter identification marks of bearing bores in cylinder block

No. 4

No. 5

Cylinder bore size mark

No. 1

No. 3

No. 2

AK304599

Install the two thrust bearings in the No. 3 bearing bore in the cylinder block. Each thrust bearing must be installed with the grooved end toward the crankshaft web.

AK304518

2. The diameter identification marks of the bearing bores in the cylinder block are stamped in the location shown in the drawing.

Page 64

11D-64

ENGINE OVERHAUL <4G63-Turbo>

CRANKSHAFT AND CYLINDER BLOCK

Crankshaft journal diameter

Cylinder block bearing bore

Identificati on mark

Journal diameter

Identificati

on mark measurem ent mm

0 56.994 −

57.000

1 56.988 −

56.994

2 56.982 −

56.988

Crankshaft bearing identification mark location

Crankshaft bearing

Identificati on mark

>>D<< BEAM BEARING CAP/BEARING CAP BOLT INSTALLATION

1. Install the beam bearing cap on the cylinder block with the arrow pointing to the timing belt.

Shank length

AK301471

2. Measure the shank length of each bearing cap bolt before installation. If the measurement exceeds the limit, replace the bolt.

Limit: 71.1 mm

3. Apply engine oil to the threads and bearing surface of the bolt.

Identification mark

AK304464

3. The size mark of each crankshaft bearing is indicated by ink in the location shown in the drawing.

Groove

For upper

For lower

AK301466

4. Install bearing halves with oil grooves in the cylinder block bearing bores.

5. Install bearing halves with no oil grooves in the beam bearing cap.

AK400306

Arrow

3 2

4. Tighten the bolts to 25 ± 2 N⋅m in the indicated sequence.

5. Make a paint mark on the head of the bolt.

6. Make a paint mark on the bearing cap at a point 90 to 100° away from the paint mark made on the bolt head in the tightening direction.

Paint mark

90˚

Paint mark

AK300200

Page 65

ENGINE OVERHAUL <4G63-Turbo>

CRANKSHAFT AND CYLINDER BLOCK

11D-65

CAUTION

• If the tightening angle is less than 90°, adequate tightness could not be assured.

• If the tightening angle exceeds 100°, loosen the bolt completely and then perform the tightening again beginning with the first step.

7. Turn clockwise the bolts 90° to 100° in the indicated tightening sequence to bring the mark on each bolt head into alignment with that on the bearing cap.

AK300201

8. After installing the beam bearing cap, measure the end play of the crankshaft. If the end play exceeds the limit, replace the crankshaft bearings.

Standard value: 0.05 − 0.25 mm

Limit: 0.4 mm

>>E<< REAR OIL SEAL INSTALLATION

MB990938

MD998776

AK300202

Use the special tools to press-fit the rear oil seal in the rear oil seal case.

• Handle (MB990938)

• Crankshaft rear oil seal installer (MD998776)

>>F<< REAR OIL SEAL CASE INSTALLATION

1. Remove completely old FIPG remaining on the rear oil seal case and cylinder block.

AK300576

2. Apply a bead of FIPG to the surface of the rear oil seal case as shown in the drawing.

Specified sealant:

Page 66

11D-66

ENGINE OVERHAUL <4G63-Turbo>

CRANKSHAFT AND CYLINDER BLOCK

INSPECTION

M1113008800645

CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD)

This plastic gauge method is recommended as a simplest way of measuring the crankshaft oil clearance. Measure the crankshaft oil clearance using a plastic gauge as follows:

1. Wipe off oil from the crankshaft journal surface and the crankshaft bearing inner surface.

2. Install the crankshaft.

Plastic gauging material

AK300203

3. Cut a piece of plastic gauge whose length is equivalent to the width of the bearing and place it on the crankshaft journal in parallel with its axis.

4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque of 25 ± 2 N⋅m + 90° to 100°.

5. Remove the bolts, then remove the crankshaft bearing cap carefully.

Plastic gauging material

CYLINDER BLOCK

1. Visually check the cylinder block for scratches, rust, and any other corrosion. Also check it for cracks using a flaw detecting penetrant.

If any defect is evident, replace the cylinder block.

C D E

A B

AK300205

2. Use a straightedge and thickness gauge to check the cylinder block top surface for warp.

Make sure that the surface is free from remaining gasket material and other foreign matter.

Standard value: 0.05 mm

Limit: 0.1 mm

3. If the distortion is excessive, correct within the allowable limit or replace.

Grinding limit: 0.2 mm *Includes/combined with cylinder head grinding Cylinder block height (when new): 284 mm

4. Check cylinder walls for scratches and seizure.

If defects are evident, rebore to oversize or replace the cylinder block.

AK300204

6. Measure the largest width of the crushed plastic gauge using the ruler printed on the bag of the plastic gauge.

Standard value: 0.02 − 0.04 mm

Limit: 0.1 mm

12mm

Center

Bottom

AK300206

5. Use a cylinder gauge to measure the cylinder bore diameter and taper.

If the cylinder is worn badly, rebore it to an oversize and replace the piston and piston rings with ones matched with the new bore size.

Standard value: 85.0 mm

Taper: 0.01 mm

Page 67

ENGINE OVERHAUL <4G63-Turbo>

CRANKSHAFT AND CYLINDER BLOCK

11D-67

BORING CYLINDERS

1. Select an oversize of the pistons to be used based on the largest of the cylinder bores.

Piston outside diameter

2. Oversize pistons are available in two oversizes:

0.50 mm and 1.00 mm. Bore each cylinder to a size that provides the standard clearance when combined with the selected piston. The reference position for piston diameter measurement is as shown in the drawing.

Thrust direction

AK300577

3. Based on the piston diameter measurement, calculate the boring finish dimension.

• Boring finish dimension = [Piston diameter] + [0.02 − 0.04 mm (clearance between piston and cylinder)] − [0.02 mm (honing margin)]

CAUTION

To prevent deformation of cylinder block that would result from the heat generated by boring, bore the cylinders in the following sequence: No. 2 → No. 4 → No. 1 → No. 3.

4. Bore all the cylinders to the calculated boring finish dimension.

5. Hone the bored cylinders to the final finish dimension (piston diameter + clearance between piston and cylinder).

6. Check the clearance between the piston and cylinder.

Standard value: 0.02 − 0.04 mm

Page 68

NOTES

Mitsubishi 4G63 Turbo Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

HOW TO USE THIS MANUAL

GENERAL INFORMATION

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

REWOK DIMENSIONS

TORQUE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION

SOLENOID AND VACUUM HOSE

REMOVAL AND INSTALLATION

TIMING BELT

REMOVAL AND INSTALLATION

INSPECTION

FUEL AND EMISSION PARTS

REMOVAL AND INSTALLATION

INLET MANIFOLD

REMOVAL AND INSTALLATION

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

WATER PUMP AND WATER HOSE

REMOVAL AND INSTALLATION

ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION

INSPECTION

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION

INSPECTION

VALVE SEAT RECONDITIONING

VALVE SEAT REPLACEMENT

VALVE GUIDE REPLACEMENT

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS

INSPECTION

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

INSPECTION

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION

INSPECTION