Mitsubishi 4G63 Turbo Workshop Manual
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
11D-2
ENGINE OVERHAUL <4G63-Turbo>
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
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
ENGINE OVERHAUL <4G63-Turbo>
HOW TO USE THIS MANUAL
11D-3
11-54
CRANKSHAFT AND CYLINDER BLOCK
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION
ENGINE OVERHAUL
Apply engine oil
to all moving
parts before
installation.
Denotes non-reusable part.
16
15
Group title
9
8
11 ± 1 N·m
14
Section titlePage number
3
11 ± 1 N·m
6
4
5
9.0 ± 1.0 N·m
7
Tightening torque
2
1
132 ± 5 N·m
A
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.
13
12
11
10
25 ± 2 N·m + 90º to 100º
INSTALLATION SERVICE POINTS
>>A<< THRUST BEARING INSTALLATION
Grooves
AK204351
AB
Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.
AK100786
AB
AK300250
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
2
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
ENGINE OVERHAUL <4G63-Turbo>
SERVICE SPECIFICATIONS
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
−
−
−
−
−
−
−
−
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
ENGINE OVERHAUL <4G63-Turbo>
TORQUE SPECIFICATIONS
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
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
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°
11D-10
ENGINE OVERHAUL <4G63-Turbo>
SEALANTS
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
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.
ENGINE OVERHAUL <4G63-Turbo>
SPECIAL TOOLS
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
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
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
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.)
11D-14
ENGINE OVERHAUL <4G63-Turbo>
ALTERNATOR AND IGNITION SYSTEM
ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION
2
13 ± 1 N·m
3
M1113001000701
1
10
44 ± 10 N·m
13
12
3.0 ± 0.5 N·m
10 ± 2 N·m
14
15
25 ± 5 N·m
44 ± 10 N·m
6
4
9
22 ± 4 N·m
7
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
8
11
5
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
AC
ENGINE OVERHAUL <4G63-Turbo>
SOLENOID AND VACUUM HOSE
SOLENOID AND VACUUM HOSE
11D-15
REMOVAL AND INSTALLATION
20 ± 2 N·m
11 ± 1 N·m
3
4
5
9.0 ± 1.0 N·m
7
19 ± 3 N·m
36 ± 6 N·m
M1113025300074
6
23 ± 4 N·m
11 ± 1 N·m
11 ± 1 N·m
8
2
Removal steps
1. Vacuum pipe and hose assembly
2. Vacuum pipe and hose assembly
3. Vacuum pipe and hose assembly
4. EGR valve
1
AK400296
Removal steps (Continued)
5. EGR valve gasket
6. Solenoid valve
7. Solenoid valve
8. Engine hanger
AB
11D-16
ENGINE OVERHAUL <4G63-Turbo>
TIMING BELT
TIMING BELT
REMOVAL AND INSTALLATION
11 ± 1 N·m
11 ± 1 N·m
2
1
48 ± 5 N·m
12
11
9.0 ± 1.0 N·m
5
23 ± 3 N·m
167 N·m
49 ± 5 N·m
M1113001900867
6
21 ± 4 N·m
7
11 ± 1 N·m
29
21
32
11 ± 1 N·m
23
33
22
24
3.5 ± 0.5 N·m
28
25
20
26
27
31
30
88 ± 10 N·m
35 ± 6 N·m
<<A>> >>M<<
>>L<<
>>K<<
<<B>> >>J<<
<<C>> >>I<<
4
45 ± 3 N·m
19 ± 3 N·m
16
17
14
13
8
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
10
54 ± 5 N·m
15
34
19
18
8.8 ± 1.0 N·m
<<D>> >>I<<
<<E>> >>H<<
<<F>> >>G<<
<<G>> >>E<<
>>I<<
>>F<<
9
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
3
AB
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.
<<B>> 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
AB
Crosspoint
screwdriver
AK202825
AD
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
AC
1. Hold the drive plate with the special tool Fly wheel
stopper (MD998781).
2. Remove the crankshaft bolt.
11D-18
ENGINE OVERHAUL <4G63-Turbo>
TIMING BELT
<<D>> CRANKSHAFT SPROCKET
REMOVAL
MD998778
AK304176
AB
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
AD
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
AD
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.
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
10 mm
Semicircular
packing
Cylinder head
AK304411
AB
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
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
AB
>>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
AD
>>F<< SPACER INSTALLATION
Counter
Oil seal
Spacer
balance
shaft
AK304204
AB
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
AD
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.
ENGINE OVERHAUL <4G63-Turbo>
TIMING BELT
11D-21
>>G<< COUNTERBALANCER SHAFT
SPROCKET INSTALLATION
MD998785
AK300138
AD
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
AC
3. Make sure that the tensioner "B" center is
positioned as shown in the drawing relative to the
mounting bolt center.
Timing
marks
Timing
marks
AK305991
AC
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
AB
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
AC
6. Push a central point of the timing belt "B" tension
section lightly with an index to see if it deflects 5 −
7 mm.
Loading...