Mitsubishi 4G63 Turbo Workshop Manual

11D-1

GROUP 11D

ENGINE OVERHAUL <4G63-Turbo>

CONTENTS

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

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

REMOVAL AND INSTALLATION . . . . . . . . 11D-16 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11D-26

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

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

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

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

M1113025100296

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 condition 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.

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>	11D-3
HOW TO USE THIS MANUAL

Page number			Group title			Section title

11-54	ENGINE OVERHAUL
	CRANKSHAFT AND CYLINDER BLOCK
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION
		3	2
Apply engine oil	Denotes non-reusable part.
to all moving		11 ± 1 N·m		1
parts before
installation.		6		132 ± 5 N·m
	9	4		A
16	8
		5
		9.0 ± 1.0 N·m
	11 ± 1 N·m	7

Tightening torque

15

14

13

12

11

25 ± 2 N·m + 90º to 100º

10

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.

AK204351AB

INSTALLATION SERVICE POINTS

>>A<< THRUST BEARING INSTALLATION

		Grooves
		AK100786AB
Procedures and cautions for removal, instal-
lation, disassembly, and reassembly are ex-
plained under this category of heading.				AK300250

11D-4	ENGINE OVERHAUL <4G63-Turbo>
	GENERAL INFORMATION

GENERAL INFORMATION

VEHICLE AND ENGINE MODELS				M1113000100523
Vehicle name	Vehicle	Engine model	Displacement	Specification
	model		mL
OUTLANDER	CU2W	4G63-7	1,997	Double overhead camshaft, 16-valve

	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	2
	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

ENGINE OVERHAUL <4G63-Turbo>	11D-5
SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

M1113000300776

Item			Standard value	Limit
TIMING BELT
Auto-tensioner rod extension length			3.8 − 4.5	−
(with timing belt installed) mm
Auto-tensioner rod extension length (when free) mm			12.0	−
Auto-tensioner rod retraction length			Less than 1	−
(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			−	0.2
(including cylinder block grinding amount) mm
Cylinder head overall height mm			131.9 − 132.1	−
Cylinder head bolt nominal length mm			−	99.4
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
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	34.5	−
		temperature)
		By-pass hole closing	40.0	−
		temperature 97 to
		103°C

11D-6	ENGINE OVERHAUL <4G63-Turbo>
	REWOK DIMENSIONS
Item		Standard value	Limit
Oil pressure at curb idle speed kPa		78 or more	−
[oil temperature is 75 to 90°]
PISTONS AND CONNECTING RODS
Piston outside diameter mm		85.0	−
Piston ring side clearance in ring	No. 1	0.03 − 0.07	0.1
groove mm
	No. 2	0.02 − 0.06	0.1
Piston ring end gap mm	No. 1	0.20 − 0.30	0.8
	No. 2	0.30 − 0.45	0.8
	Oil ring	0.10 − 0.40	1.0
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
Cylinder block gasket surface warp mm		0.05	0.1
Cylinder block gasket surface grinding limit		−	0.2
(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		−	71.1

REWOK DIMENSIONS

			M1113024300394
Item			Standard value
CYLINDER HEAD AND VALVES
Diameter of oversize valve seat ring hole in cylinder head	Intake	0.3 oversize	35.30 − 35.33
mm
		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>				11D-7
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
				M1113023400989
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
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	ENGINE OVERHAUL <4G63-Turbo>
		TORQUE SPECIFICATIONS
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
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>				11D-9
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
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
	or equivalent
Thermostat housing*
Cylinder head (camshaft bearing cap fitting section)	3M ATD No.8660 or equivalent
Camshaft position sensor support*	Mitsubishi Genuine Part No. MD970389
	or equivalent
Oil pressure switch	3M ATD No.8660 or equivalent
Oil pan*	Mitsubishi Genuine Part No. MD970389
	or equivalent
Rear oil seal case*

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

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>	11D-11
SPECIAL TOOLS

SPECIAL TOOLS

M1113000600788

Tool	Number	Name	Use
	MD998781	Flywheel stopper	Retention of flywheel

D998781

MD998778	Crankshaft sprocket	Removal of crankshaft sprocket
	puller	and crankshaft sprocket B

MD998785	Sprocket stopper	Retention of counterbalancer
		shaft sprocket

MD998767	Tension pulley socket	Manipulation of tensioner pulley
	wrench	during adjustment of timing belt
		tension
D998767
MD998738	Set screw	Retention of tensioner arm and
		auto-tensioner during timing belt
		installation
D998738

MD998713	Camshaft oil seal	Installation of camshaft oil seal
	installer

D998713

MD998442

Air bleed wire

Air bleeding of lash adjuster

11D-12	ENGINE OVERHAUL <4G63-Turbo>
		SPECIAL TOOLS
Tool	Number	Name	Use
	MB991654	Cylinder head bolt	Removal and installation of
		wrench	cylinder head bolts
	B991654
	MD998772	Valve spring	Compression of valve spring
		compressor

MD998735	Valve spring	Compression of valve spring
	compressor

MD998737	Valve stem seal	Installation of valve stem seal
	installer

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	Removal of counterbalancer shaft
	puller	front bearing

MD998372	Silent shaft bearing	Removal of counterbalancer shaft
	puller	front and rear bearings

	ENGINE OVERHAUL <4G63-Turbo>		11D-13
		SPECIAL TOOLS
Tool	Number	Name	Use
	MB991603	Silent shaft bearing	Guide and stopper for removal
		installer stopper	and press-fitting of
			counterbalancer shaft rear
			bearing
	MD998705	Silent shaft bearing	Press-fitting of counterbalancer
		installer	shaft front and rear bearings

MD998375	Crankshaft front oil	Installation of crankshaft front oil
	seal installer	seal

MD998285	Crankshaft front oil	Guide for installation of
	seal guide	crankshaft front oil seal

D998285

MD998780	Piston pin setting tool Removal and press-fitting of
	piston pin

MD998776	Crankshaft rear oil	Installation of crankshaft rear oil
	seal installer	seal

D998776

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

M1113001000701

				12	3.0 ± 0.5 N·m
	2	1
					10 ± 2 N·m
				13
					14
13 ± 1 N·m				15
				25 ± 5 N·m
	3	10
			44 ± 10 N·m
	4
	9
	22 ± 4 N·m
			8
	7
44 ± 10 N·m	23 ± 3 N·m
		8.8 ± 1.0 N·m
	25 ± 4 N·m
	79 ± 5 N·m		11
6
	24 ± 4 N·m		5
				AK305988AC
	Removal steps			Removal steps (Continued)
1.	Oil level gauge			9. Alternator brace
2.	O-ring			10. Alternator
3.	Oil level gauge guide			11. Crankshaft pulley
4.	O-ring			12. Center cover
5.	Idler pulley			13. Spark plug cable
6.	Cap			14. Ignition coil
7.	Auto-tensioner assembly			15. Spark plug
8.	Water pump pulley

ENGINE OVERHAUL <4G63-Turbo>	11D-15
SOLENOID AND VACUUM HOSE

SOLENOID AND VACUUM HOSE

REMOVAL AND INSTALLATION

M1113025300074

20 ± 2 N·m

4

5	19 ± 3 N·m
	8	23 ± 4 N·m

9.0 ± 1.0 N·m

36 ± 6 N·m

11 ± 1 N·m

7

3	6 11 ± 1 N·m

11 ± 1 N·m

2

1

			AK400296AB
	Removal steps		Removal steps (Continued)
1.	Vacuum pipe and hose assembly	5.	EGR valve gasket
2.	Vacuum pipe and hose assembly	6.	Solenoid valve
3.	Vacuum pipe and hose assembly	7.	Solenoid valve
4.	EGR valve	8.	Engine hanger

11D-16	ENGINE OVERHAUL <4G63-Turbo>
	TIMING BELT

TIMING BELT

REMOVAL AND INSTALLATION

		M1113001900867
			24	3.5 ± 0.5 N·m
		21		28
	1
11 ± 1 N·m		22		25
				20

5 6

48 ± 5 N·m

23

					21 ± 4 N·m				26
11 ± 1 N·m				12	7
				23 ± 3 N·m					27
						32	11 ± 1 N·m
				11	11 ± 1 N·m		33
				167 N·m	29
	2			49 ± 5 N·m
		9.0 ± 1.0 N·m
	31		4	45 ± 3 N·m	16 17
				19 ± 3 N·m					3
				14
	30						34	9
	88 ± 10 N·m						19
									49 ± 9 N·m
						15	18 8.8 ± 1.0 N·m
					13
		8			10				AK305989AB
	35 ± 6 N·m				54 ± 5 N·m
			Removal steps				<<D>>	>>I<<	Removal steps (Continued)
		1. Timing belt front upper cover							12. Crankshaft sprocket
		2. Timing belt front lower cover						>>I<<	13. Crankshaft sensing blade
<<A>>	>>M<<	3. Power steering pump bracket					<<E>>	>>H<<	14. Tensioner "B"
		4.	Timing belt						15. Timing belt "B"
	>>L<<	5.	Tensioner pulley				<<F>>	>>G<<	16. Counterbalancer shaft sprocket
		6.	Tensioner arm					>>F<<	17. Spacer
	>>K<<	7. Auto-tensioner					<<G>>	>>E<<	18. Crankshaft sprocket "B"
		8.	Idler pulley						19. Crankshaft key
<<B>>	>>J<<	9.	Crankshaft angle sensor						20. Breather hose
		10. Oil pump sprocket							21. PCV hose
<<C>>	>>I<<	11. Crankshaft bolt							22. PCV valve

ENGINE OVERHAUL <4G63-Turbo>	11D-17
TIMING BELT

Removal steps (Continued)

23.PCV valve gasket

24.Oil filler cap >>D<< 25. Rocker cover

>>D<< 26. Rocker cover gasket "A"

>>C<<	27. Rocker cover gasket "B"
	28. Semicircular packing
>>B<< 29. Engine support bracket
<<H>> >>A<<	30. Camshaft sprocket bolt

31.Camshaft sprocket

32.Timing belt rear cover, right

33.Timing belt rear upper cover, left

34Timing belt rear lower cover, left

REMOVAL SERVICE POINTS <<A>> TIMING BELT REMOVAL

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

AK304440AB

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.

Crosspoint

screwdriver

AK202825AD

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

AK202738AC

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

AK304176AB

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

<<E>> TIMING BELT "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."

<<F>> COUNTERBALANCER SHAFT SPROCKET REMOVAL

MD998785

AK300138AD

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

MD998778	AK300139AD

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>	11D-19
TIMING BELT

INSTALLATION SERVICE POINTS >>A<< CAMSHAFT SPROCKET BOLT INSTALLATION

AK305990AC

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

>>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.

10 mm
		10 mm
Semicircular
packing	Cylinder head	AK304411AB

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

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

11D-20	ENGINE OVERHAUL <4G63-Turbo>
	TIMING BELT

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

Timing belt side

AK304203AB

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

AK304204AB

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.

>>E<< CRANKSHAFT SPROCKET "B" INSTALLATION

Sprocket "B"

Crankshaft

Degrease
Front case	AK301828AD

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.

>>F<< SPACER INSTALLATION

Counter

Oil seal balance shaft

Spacer

Chamfered

AK301298AD

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>		11D-21
	TIMING BELT
>>G<< COUNTERBALANCER SHAFT		Tension section of belt
SPROCKET INSTALLATION	Tensioner "B"
			Timing
			belt "B"
	MD998785
	Tensioner "B"
	centre	Mounting bolt centre
			AK305992AC

		3. Make sure that the tensioner "B" center is
	AK300138AD	positioned as shown in the drawing relative to the
	1. Use the special tool Sprocket stopper	mounting bolt center.
	(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
	Timing
	marks	AK304436AB
		4. Lift the tensioner "B" with fingers to move it in the
	Timing	direction of the arrow until the tension section of
	marks	the timing belt becomes taut. While keeping the
		tensioner "B" in this position, tighten its bolt.
	AK305991AC	NOTE: When the bolt is tightened, prevent the
	1. Align the timing marks on the crankshaft sprocket	tensioner "B" shaft from turning. If the shaft turns,
		the belt will be overtightened.
	"B" and counterbalancer shaft sprocket with the	5. Make sure that the timing marks on the oil pump
	corresponding timing marks on the oil pump case.
		case and those of the sprockets are all aligned
	2. Install the timing belt "B" on the crankshaft
		with each other.
	sprocket "B" and counterbalancer shaft sprocket.
	There should be no slack in the tension section of	5 – 7 mm
	the belt.
		AK305993AC

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