Mitsubishi 6A1 User Manual

ENGINE

6A1 SERIES

CONTENTS

11A-0-1

GENERAL INFORMATION

1.SPECIFICATIONS
SERVICE SPECIFICATIONS
REWORK DIMENSIONS
TORQUE SPECIFICATION
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE

TIGHTENED IN PLASTIC AREA
SEALANTS
FORM-IN-PLACE GASKET (FIPG)

2.SPECIAL TOOLS

3.DRIVE BELT

4.TIMING BELT

5.FUEL AND EMISSION CONTROL PARTS

6.IGNITION SYSTEM

7.WATER PUMP AND WATER PIPE

8.INTAKE MANIFOLD AND EXHAUST MANIFOLD

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11A-0-3
11A-1-1
11A-1-1
11A-1-3
11A-1-4

11A-1-7
11A-1-7
11A-1-8
11A-2-1
11A-3-1
11A-4-1
11A-5-1
11A-6-1
11A-7-1
11A-8-1

9.ROCKER ARM AND CAMSHAFT <SOHC>

10.ROCKER COVER AND CAMSHAFT <MIVEC>

11.ROCKER ARM AND ROCKER SHAFT CAP <MIVEC>

12.CYLINDER HEAD AND VALVES

13.OIL PUMP CASE AND OIL PAN

14.PISTON AND CONNECTING ROD

15.CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL
AND DRIVE PLATE

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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11A-9-1

11A-10-1

11A-11-1
11A-12-1
11A-13-1
11A-14-1

11A-15-1

11A-0-2

NOTES

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6A1 ENGINE (E-W) -

General Information

GENERAL INFORMATION

GENERAL SPECIFICATIONS

Descriptions 6A12 6A13

11A-0-3

Type 60è V, OHV, SOHC (for each bank)
Number of cylinders 6 6
Combustion chamber Pentroof type
Total displacement dm
Cylinder bore mm
Piston stroke mm
Compression ratio or 9.0*
V alve timing (Low-speed cam)

Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration

Intake
valve

Exhaust
valve

3

Opens
(BTDC)

Closes
(ABDC)

Opens
(BBDC)

Closes 15è
(ATDC)

60è V, OHV, DOHC (for each bank)

Pentroof type
1,998 2,498

78.4 81.0

69.0 80.8

10.0 9.5*
15è

37.5è

(High-speed cam)

41è

(Low-speed cam)

82.5è

(High-speed cam)

41è

(Low-speed cam)

75è

(High-speed cam)
(Low-speed cam)

30è

(High-speed cam)

1 2

15è

53è

53è

15è

Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled forced circulation Water-cooled forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type

NOTE

1

*

: Europe and Hong Kong

2

*

: GCC and Export

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6A1 ENGINE (E -W) -

Specifications

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Items Standard value Limit

Timing belt

Auto tensioner rod projection mm 12.0 -

11A-1-1

Auto tensioner rod pushed-in amount (when pushed with a force ­of 98 - 196 N) mm

Rocker arm and camshaft <SOHC>

Camshaft cam height mm

Camshaft journal diameter mm

Rocker cover and camshaft <MIVEC>

Camshaft cam height mm (Low-speed cam)

Camshaft journal diameter mm
Valve clearance mm

Cylinder head and valve

Intake 35.20 34.70
Exhaust 34.70 34.20

Intake 34.34 33.84

(High-speed cam)

Exhaust 34.40 33.90

Intake 0.10 ­Exhaust 0.13 -

(Low-speed cam)
(High-speed cam)

1.0 or less

45 -

36.46 35.96

35.86 35.36
26 -

Flatness of cylinder head gasket surface mm - ­Cylinder head gasket surface grinding limit (including grinding of

cylinder block gasket surface) mm
Cylinder head overall height SOHC - 120.1 -

mm

MIVEC
Cylinder head bolt nominal length mm
V alve margin mm

Valve stem diameter mm
V alve stem-to-guide clearance

mm

V alve face angle
V alve stem projection mm

Intake 1.0 0.5

Exhaust 1.3 0.8

Intake 0.02 - 0.05 0.10

Exhaust

SOHC 48.45 48.95

MIVEC 48.40 48.90

Less than 0.03

119.9

119.6 119.8

- -

- 96.4

6.0 -

0.04 - 0.07 0.15
45è - 45.5è -

-

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11A-1-2

6A1 ENGINE (E-W) -

Specifications

Items Limit
Overall valve length mm 113.02 112.52

V alve spring free height mm

V alve
height N/mm

Valve spring squareness
Valve seat contact width mm
V alve guide internal diameter mm
Valve guide projection mm

spring load/installed SOHC 265/43.4 -

Intake SOHC

MIVEC

Exhaust SOHC

MIVEC
SOHC 49.9 48.9
MIVEC 51.5 50.5

MIVEC 255/44.5 -

SOHC 14.0 ­MIVEC 19.0 -

Standard value

112.37 111.87

115.32 114.82

110.74 110.74

2è 4è

0.9 - 1.3 -

6.6 -

Oil pump case and oil pan

Oil i 0.06 - 0.18 -

pump t p clearance mm

Oil 0.04 - 0.10 -

pump side clearance mm

Oil 0.10 - 0.18 0.35

pump body clearance mm

Piston and connecting rod

Piston outside diameter mm

Piston ring side clearance mm No.1 ring

Piston ring end gap mm No.1 ring

Piston pin outside diameter mm ­Piston pin press-in load (at room temperature) N -

6A12 78.4 ­6A13 81.0 -

0.02 - 0.06 -

No.2 ring

No.2 ring
Oil ring 0.20 - 0.50 1.0

0.02 - 0.06 -

0.20 - 0.35 0.8

0.35 - 0.50 0.8

19.0

4,900 - 14,700
Crankshaft pin oil clearance mm 0.02 - 0.05 0.1
Connecting rod big end side clearance mm 0.4

Crankshaft, cylinder block, flywheel and drive plate

Crankshaft end play mm 0.05 - 0.25 0.4

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0.10 - 0.25

6A1 ENGINE (E-W) -

Specifications

11A-1-3

Items Limit
Crankshaft journal diameter 6A12 53.0 -

mm

6A13

Crankshaft pin diameter mm

Crankshaft journal oil clearance mm
Cylinder block gasket surface flatness mm
Cylinder block gasket surface grinding limit (including grinding of

cylinder head gasket surface) mm
Cylinder block overall height

mm

Cylinder block cylindricity mm 0.01 or less
Cylinder block internal diame- 6A12 78.4 -

ter mm

Bearing cap bolt nominal length mm 71.1

6A12 43.0 ­6A13 51.0 -

6A12 190.0 ­6A13

6A13 81.0 -

Standard value

56.0 -

0.02 - 0.04 0.1

0.05 -

- 0.2

209.0 -

-

-

Piston-to-cylinder clearance mm 0.02 - 0.04 -

REWORK DIMENSIONS

Item Standard

Cylinder head and valves

Cylinder head oversize valve guide hole diameter mm 0.05 O.S. 11.05 11.07

0.25 O.S. 11.25 11.27

0.50 O.S. 11.50 11.52

Oversize intake valve seat 0.3 O.S.
ring hole diameter mm

Oversize exhaust valve SOHC 27.80 - 27.82
seat ring diameter mm

SOHC 29.80 - 29.82

0.6 O.S.

MIVEC 32.30 - 32.32

MIVEC 29.80 - 29.82

0.3 O.S.

0.6 O.S.

0.3 O.S.

0.6 O.S.

0.3 O.S.

-

-

-

30.10 - 30.12

32.60 - 32.62

28.10 - 28.12

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0.6 O.S.

30.10 - 30.12

11A-1-4

6A1 ENGINE (E-W) -

Specifications

TORQUE SPECIFICATION

Items Nm

Alternator and drive belt

Alternator pivot nut 44
Alternator bolt 21
Oil level gauge guide 23
Tensioner pulley 15
Engine hanger 23
Tensioner pulley bracket A 45
Crankshaft bolt 182
Engine cover 3

Timing belt

Timing belt front cover 11
Engine support bracket 49
Angle sensor 9
Angle sensor connector bracket 11
Tensioner pulley 48
Tensioner arm 24
Auto tensioner 21
Camshaft sprocket bolt 88
Idler pulley 35
Timing belt rear cover 11
Angle sensor connector bracket 11

Fuel and emission control parts

Air intake plenum stay 18
Connector bracket 11
EGR valve 22
Throttle body 12
Air intake plenum 18
Delivery pipe 12
Fuel pipe 9
Fuel pressure regulator 9
Alternator bracket 23

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6A1 ENGINE (E-W) -

Items Nm

Ignition system

Spark plug 25
Water cover (SOHC) 11
Distributor (SOHC) 13
Ignition failure sensor (MIVEC) 10
Condenser bracket assembly (MIVEC) 5
Ignition coil (MIVEC) 10

Water pump and water pipe

Engine hanger (MIVEC) 11
Engine coolant temperature gauge unit 11
Engine coolant temperature sensor 29
Heater pipe (SOHC) 23

Specifications

11A-1-5

Water inlet fitting 18
Water outlet fitting 18
Thermostat housing 23
Water pipe 13
Water pump 23

Intake manifold and exhaust manifold

Intake manifold 17
Heat protector 13
Exhaust manifold stay 44
Exhaust manifold 49

Rocker arm and camshaft <SOHC>

Rocker cover 4
Rocker arm and rocker shaft 31
Thrust case 24

Rocker arm and camshaft <MIVEC>

Rocker cover 4
Oil control valve holder 9
Cam cap 24
Bearing cap M6 11
Bearing cap M8 24

K

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11A-1-6

Items Nm

6A1 ENGINE (E-W) -

Specifications

Arm spring holder

Rocker arm and rocker shaft cap <MIVEC>

Rocker shaft cap 11

Cylinder head and valves

Cylinder head bolt 20 + 120è + 120è

Oil pan and oil pump

Oil pressure switch 10
Oil filter cover 21
Water hose 30
Bolt 68
Drain plug 39
Oil level sensor 9
Oil pan 7
Oil screen 19

11

Baffle plate 9
Relief plug 44
Oil pump case 14
Oil pump case cover 12

Piston and connecting rod

Connecting rod 18 + 90è - 100è

Crankshaft, cylinder block, flywheel and drive plate

Detonation sensor 23
Idler pulley bracket 35
Flywheel bolt 98
Drive plate bolt 98
Rear plate 11
Bell housing cover 9
Oil seal case 11
Bearing cap bolt 25 + 90è - 100è

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6A1 ENGINE (E-W) -

Specifications

11A-1-7

NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA

A new type of bolts, to be tightened in plastic area, is currently used in some parts of the engine. The
tightening method for the bolts is different from the conventional one. Be sure to observe the method
described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.

J Areas where the bolts are in use:

(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts

J Tightening Method

After tightening the bolts to the specified torque, tighten them another 90è to 100è, or 240è (twice
120è). The tightening method varies on different areas. Observe the tightening method described
in the text.

SEALANTS

Item
Water pump*
Water outlet fitting*
Engine coolant temperature sensor
Engine coolant temperature gauge unit
Camshaft bearing 3M ATD Part No. 8660 or equivalent As required
Cam cap 3M ATD Part No. 8660 or equivalent As required
Oil control valve 3M ATD Part No. 8660 or equivalent As required
Camshaft holder* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Rocker cover 3M ATD Part No. 8660 or equivalent As required
Oil pump case* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pan*
Oil pressure switch 3M ATD Part No. 8660 or equivalent As required
Oil seal case* Mitsubishi Genuine Part No. MD970389 or equivalent

Specified sealant Quantity
Mitsubishi Genuine Part No. MD970389 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent As required
3M Nut Locking Part No. 4171 or equivalent
3M ATD Part No. 8660 or equivalent As required

Mitsubishi Genuine Part No. MD970389 or equivalent As required

As required

As required

As required
Drive plate bolt 3M Nut Locking Part No. 4171 or equivalent As required
Flywheel bolt 3M Nut Locking Part No. 4171 or equivalent As required

*: parts sealed by foam-in-place gasket (FIPG)

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11A-1-8

6A1 ENGINE (E-W) -

Specifications

FORM-IN-PLACE GASKET (FIPG)

The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. 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 the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type a n d is supplied in a 100-gram
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the
atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can
be used for sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine
oil sealing.

Disassembly

The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat an d thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan.

Surface Preparation

Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.

Form-in-Place Gasket Application

When assembling parts with the FIPG, you must observe some precautions, but th e procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

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2. SPECIAL TOOLS

6A1 ENGINE (E-W) -

Special Tools

11A-2-1

Tool

Number Name Use
MB990685

MB990938 Handle

MB990767 Crankshaft pulley

MB991477

Torque wrench Adjustment of timing belt tension

Use with MD998776

Holding camshaft sprocket when loosening

holder

Valve adjusting Adjustment of valve clearance (MIVEC)
wrench

and tightening of bolt.
Use with MD998719

MB991478

MB991479

MB991614

MB991653

Valve adjusting
wrench feeler
gauge set

Rocker arm
piston checker

Angle gauge Tightening cylinder head bolt

Cylinder head bolt Tightening and loosening of cylinder head bolt
wrench

Adjustment of valve clearance (MIVEC)

Adjustment of valve clearance (MIVEC)

MB991659

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Guide D Removal of piston pin (Use with MD998780)

11A-2-2

6A1 ENGINE (E-W) -

Special Tools

Tool Use

MD998440

MD998441

MD998442 Ai Ai

MD998443

NameNumber
Leak-down tester Leak-down test of lash adjuster

Lash adjuster r bleeding of lash adjuster
retainer

r bleed wire r bleeding of lash adjuster

Lash adjuster Retainer for holding lash adjuster in rocker arm
holder

Ai

at time of removal and installation of rocker arm
and rocker shaft assembly

MD998713

MD998716

MD998717 il

MD998719 Pulley holder pin

Camshaft oil seal Installation of camshaft oil seal
installer

Crankshaft wrench Rotation of crankshaft when installing piston

Crankshaft front o
seal installer

(2)

and timing belt.

Installation of crankshaft front oil seal

Use with MB990767

MD998727

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Oil pan remover Removal of oil pan

6A1 ENGINE (E-W) -

Special Tools

11A-2-3

Tool Use

MD998735

MD998754 Pin

MD998767

MD998772

NameNumber
Valve spring Compression of valve spring

compressor

Use with MB990767

Tensioner pulley
socket wrench

Valve spring Removal and installation of valve and related
compressor parts

Adjustment of timing belt tension

MD998774 stem seal

MD998775 stem seal

MD998776 il

MD998777

V alve Installation of valve stem seal
installer

V alve Installation of valve stem seal
installer

Crankshaft rear o
seal installer

Camshaft oil seal
installer adapter

Installation of crankshaft rear oil seal
Use with MB990938

Installation of camshaft oil seal

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11A-2-4

6A1 ENGINE (E-W) -

Special Tools

Tool Use

MD998780

MD998781

MD998784

NameNumber
SETTING TOOL

Piston p

Flywheel stopper Holding flywheel and drive plate

Valve spring Compression of valve spring (MIVEC)
compressor
adapter

in

Removal and installation of piston pin

(Use with MD998772)

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6A1 ENGINE (E-W) -

3. DRIVE BELT

REMOVAL AND INSTALLATION <SOHC>

44 Nm

21 Nm

2

16

Drive Belt

3Nm

11A-3-1

1

23 Nm

6

15 Nm

3

23 Nm

5

44 Nm

8

4

10

7

11

9

44 Nm

12

182 Nm

13

15

14

Removal steps

1. Drive belt 9. T ensioner pulley bracket B

2. Alternator 10. Adjusting stud

3. Oil level gauge (dipstick) 11. Adjusting bolt

4. Oil level gauge guide G

5. O-ring 13. Special washer

6. Tensioner pulley 14. Crankshaft pulley

7. Engine hanger 15. Flange

8. Tensioner pulley bracket A 16. Engine cover

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++

A

G 12. Crankshaft bolt

A

11A-3-2

6A1 ENGINE (E-W) -

REMOVAL AND INSTALLATION <MIVEC>

21 Nm

44 Nm

2

Drive Belt

3Nm

16

23 Nm

15 Nm

1

11

44 Nm

9

3

12

13

15

14

23 Nm

7

6

10

44 Nm

8

4

182 Nm

5

Removal steps

1. Drive belt 9. T ensioner pulley bracket B

2. Alternator 10. Adjusting stud

3. Oil level gauge (dipstick) 11. Adjusting bolt

4. Oil level gauge guide G

5. O-ring 13. Special washer

6. Tensioner pulley 14. Crankshaft pulley

7. Engine hanger 15. Flange

8. Tensioner pulley bracket A 16. Engine cover

++

A

G 12. Crankshaft bolt

A

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MD998781

6A1 ENGINE (E-W) -

REMOVAL SERVICE POINTS

G

A+ CRANKSHAFT PULLEY BOLT REMOVAL

(1) Hold the flywheel or drive plate in position with the special

tool before removing the crankshaft pulley bolts.

INSTALLATION SERVICE POINTS

+

AG CRANKSHAFT PULLEY BOLT INSTALLATION

(1) Hold the flywheel or drive plate in position with the special

6AE0039

tool before installing the crankshaft pulley bolts.

Drive Belt

11A-3-3

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6A1 ENGINE (E-W) -

4. TIMING BELT

REMOVAL AND INSTALLATION <SOHC>

Timing Belt

11A-4-1

88 Nm

24 Nm

21 Nm

14

48 Nm

8

10

15

4

6

9

35 Nm

7

11 Nm

11 Nm

16

17

1

11

3

12

13

18

11 Nm

5

2

49 Nm

11 Nm

Removal steps

1. Timing belt front cover, upper right +BG 10. Auto tensioner

2. Timing belt front cover, upper left 11. Crankshaft sprocket

3. Timing belt front cover, lower 12. Sensing plate

4. Engine support bracket 13. Crankshaft spacer

5. Angle sensor G

GA++

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G 6. Timing belt 15. Camshaft sprocket

C

7. Tensioner pulley 16. Idler pulley

8. Tensioner arm 17. Timing belt rear cover, center

9. Tensioner spacer 18. Connector bracket

11 Nm

++

B

9Nm

G 14. Camshaft sprocket bolt

A

11A-4-2

6A1 ENGINE (E-W) -

REMOVAL AND INSTALLATION <MIVEC>

12 Nm

23

21

Timing Belt

48 Nm

22 Nm

12

9

44 Nm

88 Nm

16

10

13

49 Nm

11

17

35 Nm

14

11 Nm

19

15

11 Nm

11 Nm

17

1

22

18

9Nm

11 Nm

2

20

5

8

6

7

9Nm

9Nm

4

11 Nm

Removal steps

1. Timing belt front cover, upper right

2. Timing belt front cover, upper left

3. Timing belt front cover, lower

4. Engine support bracket

5. Angle sensor

6. Angle sensor

7. Spacer

GA++

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G

8. Timing belt

D

9. Tensioner pulley

10. Tensioner arm

11. Tensioner spacer

+

G 12. Auto tensioner

B

3

GB++

13. Crankshaft sprocket

14. Sensing plate

15. Washer

G 16. Camshaft sprocket bolt

A

17. Camshaft sprocket

18. Camshaft sprocket with sensing
plate

19. Idler pulley

20. Timing belt rear cover, left

21. Timing belt rear cover, right

22. Timing belt rear cover, center

23. Connector bracket

6A1 ENGINE (E-W) -

REMOVAL SERVICE POINTS

G

A+ TIMING BELT REMOVAL

(1) Mark the belt running direction for reference in

reinstallation.

(2) Loosen the bolt that secures the tensioner pulley to

remove the timing belt.

6AE0135

Timing Belt

11A-4-3

MD998719

MB990767

MD998754

MB990767

6AE0044

6AE0137

6AE0045

G

B+ CAMSHAFT SPROCKET BOLT REMOVAL

MD998719

MB990767

6AE0138

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INSTALLATION SERVICE POINTS

+

AG CAMSHAFT SPROCKET BOLT INSTALLATION

11A-4-4

MD998754

6A1 ENGINE (E-W) -

Timing Belt

MB990767

(B)

(A)

6AE0048

6AE0049

+

BG AUTO TENSIONER SETTING

(1) Set the auto tensioner in a vice, while making sure it

is not tilted.

(2) Slowly close the vice to force th e rod in until the set

hole (A) of the rod is lined up with the set hole (B) of
the cylinder.

(3) Insert a 1.4 mm wire in the set hole.
(4) Remove the auto tensioner from the vice.

6AE0050

+

CG TIMING BELT INSTALLATION

(1) Turn the crankshaft sprocket so that its timing mark will

be away from the mating timing mark by approx. three
teeth.

Caution

J

6AE0329

Timing mark

6AE0358

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(2) Bring the timing marks of the camshaft sprockets as shown

in the illustration.

If the timing marks are aligned, the piston is
brought to the TDC. When the camshaft is turned
under this condition, the valves may interfere with
the piston.

6A1 ENGINE (E-W) -

(3) Align the timing mark on the crankshaft sprocket with

that on the cylinder block side.

(4) Fit the timing belt on the sprockets in the following order:

1) Fit the timing belt on the crankshaft sprocket and
then, while giving tension to the belt, fit it on the
water pump sprocket.

2) Fit the belt on the left bank camshaft sprocket.

3) Fit the belt on the idler pulley while keeping it tight.

4) Align the timing mark on the right bank camshaft
sprocket with the mark on the cylinder block, a nd

6AE0331

then fit the belt on the camshaft sprocket.

Caution

J

The camshaft sprockets are prone to rotate. Avoid
giving excessive tension to the timing belt when
it is fitted.

Timing Belt

11A-4-5

MB990685

MD998767

5) Make sure that the left bank portion of the belt is
not slack when the belt is fitted on the tensioner pulley.
If it is slack, remove the belt and fit it again beginning
with the first step.

6AE0143

(5) Move the tensioner pulley in the direction of the arrow

and hold it in raised position by tightening the tensioner

pulley bolt.
(6) Check that all timing marks are aligned correctly.
(7) Turn the crankshaft counterclockwise a quarter turn.
(8) Turn back the crankshaft clockwise until the timing marks

align again.

6AE0057

(9) Install the special tool and a torque wrench of 0 - 5

Nm to the tensioner pulley.
(10)Torque the tensioner pulley to 3 Nm with the torque

wrench.
(11) While holding the tensioner pulley, tighten the center bolt

to specification.
(12)Turn the crankshaft clockwise 2 turns and let it stand

for about 5 minutes.

6AE0058

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-4-6

6A1 ENGINE (E-W) -

+

DG TIMING BELT INSTALLATION

(1) Turn the crankshaft sprocket so that its timing mark will

be away from the mating timing mark by approx. three

teeth.

Caution

J

MD998716

6AE0051

(2) Bring the timing marks of the camshaft sprockets as shown

in the illustration.

Caution

J

Timing Belt

If the timing marks are aligned, the piston is
brought to the TDC. When the camshaft is turned
under this condition, the valves may interfere with
the piston.

If one of the camshaft sprockets on the right bank
is turned with the timing mark on the other
sprocket aligned, there may be danger for the
intake and exhaust valves to interfere with each
other.

Paper clip

6AE0311

6AE0053

6AE0054

(3) Align the timing mark on the crankshaft sprocket with

the mating timing mark, and then turn the crankshaft

counterclockwise by one tooth.

(4) Place the timing belt over the sprockets in the following

method.

Caution

J

The camshaft sprockets on the right bank can
turn very easily because of the valve spring
tension. Use care not to allow your fingers to get
caught between the sprockets.

)

Align the timing mark of the right bank exhaust

1

camshaft sprocket with the mating timing mark and
hold the timing belt on the sprocket with a paper
clip.

)

Align the timing mark of the intake camshaft sprocket

2

and place the timing belt around that sprocket. Then,
clip the belt at th e location shown.

Caution

J

The camshaft sprockets can turn easily and
do not give excessive tension to the timing
belt.

3) Place the timing belt around the idler pulley.

6AE0055

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

4) On the left bank, make sure that the timing marks
of the camshaft sprockets are aligned and then hold
the timing belt on these sprockets with paper clips.

5) Place the timing belt around the water pump pulley.

6) Place the timing belt around the crankshaft sprocket.

7) Place the timing belt around the tensioner pulley.

6AE0056

(5) Move the tensioner pulley in the direction of the arrow

and hold it in raised position by tightening the tensioner

pulley bolt.
(6) Check that all timing marks are aligned correctly.
(7) Turn the crankshaft counterclockwise a quarter turn.
(8) Turn back the crankshaft clockwise until the timing marks

align again.

Timing Belt

11A-4-7

MB990685

MD998767

6AE0057

6AE0058

6AE0059

(9) Install the special tool and a torque wrench of 0 - 5

Nm to the tensioner pulley.
(10)Torque the tensioner pulley to 3 Nm with the torque

wrench.
(11) While holding the tensioner pulley, tighten the center bolt

to specification.
(12)Turn the crankshaft clockwise 2 turns and let it stand

for about 5 minutes.

(13)Make sure that the wire, which has been inserted when

installing the auto tensioner, can be removed easily.

Belt tension should be acceptable if the wire can be easily

removed. Remove the wrench. The belt tension can also

be verified by checking the protrusion amount of the auto

tensioner rod which should conform to the following.

Standard value: 3.8 - 4.5 mm

(14)If the wire cannot be removed easily or the rod protrusion

is not up to specification, repeat steps (9) through (12)

to obtain the correct tension.

INSPECTION

TIMING BELT

Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.

Back side is glossy without resilience and leaves no indent

when pressed with fingernail.

8EN0066

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-4-8

6A1 ENGINE (E-W) -

Timing Belt

Peeling

Cracks

Rounded edge

Abnormal wear
(Fluffy strand)

Rubber exposed

Cracks

Cracks

1EN0249

8EN0067

(2) Cracks on rubber back.
(3) Cracks or peeling of canvas.
(4) Cracks on tooth bottom.
(5) Cracks or belt sides.

(6) Abnormal wear of belt sides. The sides are normal if

they are sharp as if cut by a knife.

(7) Abnormal wear on teeth.
(8) Missing tooth.

Tooth missing
and canvas
fiber exposed

“L”

98 196 N

-

8EN0068

6AE0046

Stroke

AUTO-TENSIONER

(1) Check for oil leaks. If oil leaks are evident, replace the

auto-tensioner.
(2) Check the rod end for wear or damage and replace the

auto-tensioner if necessary.
(3) Measure the rod projection length “L”. If the reading is

outside the standard value, replace the auto tensioner.

Standard value “L”: 12 mm

(4) Press the rod by a force of 98 to 196 N and measure

the rod stroke. If the measured value exceeds the standard

value, replace the tensioner.

Standard value: 1 mm or less

6EN1033

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Fuel and Emission Control Parts

5. FUEL AND EMISSION CONTROL PARTS

REMOVAL AND INSTALLATION <SOHC>

11A-5-1

12 Nm

6

22 Nm

3

18 Nm

4

10

18 Nm

1

11

17

18 Nm

12 Nm

2

18 Nm

18 Nm

18

21

7

16

20

15

14

5

8

9

9Nm

19

13

+

23 Nm

22

Removal steps

1. Air intake plenum stay, front

2. Air intake plenum stay, rear

3. EGR valve

4. Gasket

5. Vacuum pipe

6. Throttle body

G

7. Gasket

C

8. Air intake plenum

9. Gasket

10. Control harness

11. Delivery pipe and injector

9Nm

12

12. Insulator

13. Insulator

+

G 14. Injector

B

15. Grommet

16. O-ring

17. Fuel pipe

18. O-ring

+

G 19. Fuel pressure regulator

A

20. O-ring

21. Delivery pipe

22. Alternator bracket

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-5-2

6A1 ENGINE (E-W) -

Fuel and Emission Control Parts

REMOVAL AND INSTALLATION <MIVEC>

18 Nm

1

14

18 Nm

21

2

10

14 Nm

22

8.8 Nm

11

11 Nm

6

12 Nm

25

8

20

17

18 Nm

9

24

19

18

18 Nm

11 Nm

7

13

9Nm

23

16

12 Nm

3

4

5

12

15

+

23 Nm

26

Removal steps

1. Air intake plenum stay, front

2. Air intake plenum stay, rear

3. Vacuum pipe

4. Throttle body

G

5. Gasket

C

6. Connector bracket

7. Connector bracket

8. Accelerator cable bracket

9. Ignition failure sensor

10. Air temperature sensor

11. Gasket

12. Air intake plenum

13. Gasket

9Nm

14. Control harness

15. Delivery pipe and injector

16. Insulator

17. Insulator

+

G 18. Injector

B

19. Grommet

20. O-ring

21. Fuel pipe

22. O-ring

+

G 23. Fuel pressure regulator

A

24. O-ring

25. Delivery pipe

26. Alternator bracket

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Fuel and Emission Control Parts

11A-5-3

INSTALLATION SERVICE POINTS

+

AG FUEL PRESSURE REGULATOR INSTALLATION

(1) Apply spindle oil or gasoline to the new O-ring installed

on the fuel pressure regulator.
(2) Insert the fuel pressure regulator in the delivery pipe.
(3) Make sure that the fuel pressure regulator turns smoothly;

then align the threaded holes and tighten the regulator

bolts to specification.

6AE0061

6AE0062

Caution

J

If the regulator does not turn smoothly, the O-ring
probably gets caught somewhere in the delivery
pipe. In such a case, remove the fuel pressure
regulator and reinsert it into the delivery pipe.
Check it again for smooth rotation before securing.

+

BG INJECTOR INSTALLATION

(1) Install new grommet and O-ring on the injector.
(2) Apply spindle oil or gasoline to the O-ring of the injector.
(3) While turning the injector in both directions, install it in

the delivery pipe.
(4) Make sure that the injector turns smoothly.

Caution

J

If the injector does not turn smoothly, the O-ring
probably gets caught somewhere in the delivery
pipe. In such a case, remove the injector and
reinsert it into the delivery pipe. Check it again
for smooth rotation.

(5) On the right bank, align the marks on the injector and

delivery pipe.

+

Projection

6AE0277

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

CG GASKET INSTALLATION

(1) Locate the projection on the gasket as shown.

6A1 ENGINE (E-W) -

6. IGNITION SYSTEM

REMOVAL AND INSTALLATION <SOHC>

1

Ignition System

11A-6-1

25 Nm

2

4

13 Nm

11 Nm

3

Removal steps

1. Spark plug cable

2. Spark plug

3. Water cover

+

G 4. Distributor

A

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-6-2

6A1 ENGINE (E-W) -

REMOVAL AND INSTALLATION <MIVEC>

Ignition System

1.0 Nm

25 Nm

3

1

2

Removal steps

1. Spark plug cable

2. Ignition coil

3. Spark plug

INSTALLATION SERVICE POINT

+

AG DISTRIBUTOR INSTALLATION

Alignment mark

6AE0151

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

(1) Turn the crankshaft clockwise to bring the No. 1 cylinder

piston to the compression stroke top dead center.
(2) Align the mark on the distributor housing with the mark

on the coupling.
(3) Install the distributor while aligning the coupling key with

the keyway in the camshaft end.

6A1 ENGINE (E-W) -

Water Pump and Water Pipe

7. WATER PUMP AND WATER PIPE

REMOVAL AND INSTALLATION <SOHC>

11A-7-1

18 Nm

5

4

6

14

23 Nm

13 Nm

3

13

10

29 Nm

1112

2

9

1

23 Nm

11 Nm

18 Nm

8

7

23 Nm

15

Removal steps

+

G

1. Engine coolant temperature gauge

F

+

G

E

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

unit

2. Engine coolant temperature sensor

3. Water hose

4. Water hose

5. Heater pipe

6. O-ring

7. Water inlet fitting

+

G 8. Thermostat

D

+

G 9. Water outlet fitting

C

10. Thermostat housing

11. Gasket

+

G 12. O-ring

B

+

G 13. Water pipe

B

+

G 14. O-ring

B

+

G 15. Water pump

A

11A-7-2

6A1 ENGINE (E-W) -

Water Pump and Water Pipe

REMOVAL AND INSTALLATION <MIVEC>

8

5

13

13 Nm

12

18 Nm

11

4

10

18 Nm

23 Nm

1

29 Nm

9

3

7

2

18 Nm

6

11 Nm

23 Nm

+

+

+

14

Removal steps

1. Engine hanger

G

2. Engine coolant temperature gauge

F

G

E

G

D

unit

3. Engine coolant temperature sensor

4. Water hose

5. Water hose

6. Water inlet fitting

7. Thermostat

+

G 8. Water outlet fitting

C

9. Thermostat housing

10. Gasket

+

G 11. O-ring

B

+

G 12. Water pipe

B

+

G 13. O-ring

B

+

G 14. Water pump

A

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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6A1 ENGINE (E-W) -

Water Pump and Water Pipe

11A-7-3

3mm
diameter
bead sealant

3mm
diameter
bead sealant

6AE0067

INSTALLATION SERVICE POINTS

+

AG SEALANT APPLICATION TO WATER PUMP

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

+

BG WATER PIPE / O-RING INSTALLATION

(1) Wet the O-ring (with water) to facilitate assembly.

Caution

J

Keep the O-ring free of oil or grease.

J

Secure the water pipe after the thermostat housing
has been installed.

+

CG SEALANT APPLICATION TO WATER OUTLET

FITTING

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

6AE0068

+

DG THERMOSTAT INSTALLATION

Jiggle valve

(1) Install the thermostat so that the jiggle valve will be located

in the thermostat housing as shown.

6AE0069

+

EG SEALANT APPLICATION TO ENGINE COOLANT

Specified sealant:

6AE0070

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

TEMPERATURE SENSOR

3M Nut locking Part No. 4171 or equivalent

11A-7-4

6A1 ENGINE (E-W) -

+

6AE0071

Water Pump and Water Pipe

FG SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE GAUGE UNIT

Specified sealant:

3M ATD Part No. 8660 or equivalent

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Intake Manifold and Exhaust Manifold

8. INTAKE MANIFOLD AND EXHAUST MANIFOLD

REMOVAL AND INSTALLATION <SOHC>

11A-8-1

13 Nm

49 Nm

3

5

44 Nm

6

4

17 Nm

1

2

7

9

13 Nm

Removal steps

1. Intake manifold

2. Gasket

3. Heat protector, right

4. Exhaust manifold stay

5. Exhaust manifold, right

6. Gasket

7. Heat protector, left

8. Exhaust manifold, left

9. Gasket

8

49 Nm

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-8-2

6A1 ENGINE (E-W) -

Intake Manifold and Exhaust Manifold

REMOVAL AND INSTALLATION <MIVEC>

13 Nm

49 Nm

3

5

17 Nm

1

2

6

7

9

44 Nm

4

13 Nm

Removal steps

1. Intake manifold

2. Gasket

3. Heat protector, right

4. Exhaust manifold stay

5. Exhaust manifold, right

6. Gasket

7. Heat protector, left

8. Exhaust manifold, left

9. Gasket

8

49 Nm

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Rocker Arm and Camshaft <SOHC>

9. ROCKER ARM AND CAMSHAFT <SOHC>

REMOVAL AND INSTALLATION

4Nm

1

2

11A-9-1

31 Nm

6

5

11

3

8

7

9

8

7

8

14

9

7

9

12

10

12

13

12

24 Nm

15

16

17

4

Removal steps

1. Rocker cover 10. Rocker arm shaft

2. Rocker cover gasket

3. Oil seal

+

G 4. Oil seal 13. Rocker arm shaft

GA++
GA++

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

D

G

5. Rocker arm and rocker shaft

C

G

6. Rocker arm and rocker shaft

C

+

G 7. Rocker shaft spring

C

8. Rocker arm A

9. Rocker arm B

Apply engine oil to all
moving parts before
installation.

+

G 11. Lash adjuster

B

12. Rocker arm C

+

G 14. Lash adjuster

B

15. Thrust case

16. O-ring

+

G 17. Camshaft

A

11A-9-2

For right bank

For left bank

6A1 ENGINE (E-W) -

MD998443

6AE0160

6AE0180

Rocker Arm and Camshaft <SOHC>

REMOVAL SERVICE POINT

G

A+ ROCKER ARMS AND ROCKER ARM SHAFTS

REMOVAL

(1) Before removing rocker arms and shafts assembly, install

the special tool as illustrated to prevent adjuster from

dropping.

INSTALLATION SERVICE POINTS

+

AG CAMSHAFT INSTALLATION

(1) Apply engine oil to journals and cams of the camshaft

before installation.

Be sure to install the correct camshafts on t he correct

bank.

Do not confuse the intake camshaft with the exhaust

one.

+

BG LASH ADJUSTER INSTALLATION

(1) Immerse the lash adjuster in clean diesel fuel.
(2) Using the special tool (air bleed wire), move the plunger

up and down 4 or 5 times while pushing down lightly

on the check ball in order to bleed out the air.

MD998442

Diesel
fuel

6EN0421

(3) Insert the lash adjuster to rocker arm, being careful not

to spill the diesel fuel. Then use the special tool to prevent

adjuster from falling while installing it.

MD998443

Lash adjuster

6AE0161

+

CG ROCKER SHAFT SPRING / ROCKER ARMS AND

(1) Temporarily tighten the rocker shaft with the bolt so that

all rocker arms on the inlet valve side do not push the

valves.
(2) Fit the rocker shaft spring from the above and position

it so that it is right angles to the plug guide.

NOTE

Install the rocker shaft spring before installing the exhaust

6AE0162

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

side rocker arms and rocker arm shaft.

ROCKER ARM SHAFT INSTALLATION

Right bank

6A1 ENGINE (E-W) -

6AE0163

MD998713

Rocker Arm and Camshaft <SOHC>

11A-9-3

NOTE

Install the rocker shaft spring before installing the exhaust

side rocker arms and rocker arm shaft.
(3) Remove the special tool for securing the lash adjuster.
(4) Make sure that the notch in the rocker arm shaft is in

the direction as illustrated.

+

DG CAMSHAFT OIL SEAL INSTALLATION

(1) When installing the left bank camshaft oil seal, use the

special tool to prevent interference with the knock pin.

Left bank

MD998713

6AE0164

MD998777

6AE0181

9EN0058

INSPECTION

CAMSHAFT

(1) Measure the cam height (lobe diameter) and, if the limit

is exceeded, replace the camshaft.

Standard value:

35.20 mm

34.91 mm

Limit:

34.70 mm

34.41 mm

...........................................

.......................................

...........................................

.......................................

Exhaust side

Exhaust side

Intake side

Intake side

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-9-4

6A1 ENGINE (E-W) -

Rocker Arm and Camshaft <SOHC>

LASH ADJUSTER LEAK DOWN TEST

Caution

J

The lash adjuster is a precision part. Keep it free
from dust and other foreign matters.

J

Do not disassemble lash adjuster.

J

When cleaning lash adjuster, use clean diesel fuel
only.

MD998442

MD998441

MD998440

Diesel fuel

Graduations = 1 mm

6EN0186

(1) Immerse the lash adjuster in clean diesel fuel.
(2) While lightly pushing down inner steel ball using the special

tool (Air bleed wire MD998442), move the plunger up

and down four or five times to bleed air.

Use of the special tool (Retainer MD998441) helps

facilitate the air bleeding of the rocker arm mounted type

lash adjuster.
(3) Remove the special tool (Air bleed wire MD998442) and

press the plunger. If the plunger is hard to be pushed

in, the lash adjuster is normal. If the plunger can be pushed

in all the way readily, bleed the lash adjuster again an d

test again.

If the plunger is still loose, replace the lash adjuster.

Caution

J

Upon completion of air bleeding, hold lash
adjuster upright to prevent inside diesel fuel from
spilling.

(4) After air bleeding, set lash adjuster on the special tool

(Leak down tester MD998440).
(5) After plunger has gone down somewhat [0.2 - 0.5 mm],

measure time taken for it to go down 1 mm. Replace

if measured time is out of specification.

Standard value: 4 - 20 seconds/1 mm

Lash adjuster

6EN0187

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

(Diesel fuel at 15 - 20èC)

6A1 ENGINE (E-W) -

Rocker Cover and Camshaft <MIVEC>

10. ROCKER COVER AND CAMSHAFT <MIVEC>

REMOVAL AND INSTALLATION

4Nm

1

11 Nm

2

24 Nm

24 Nm

9Nm

11A-10-1

8

3

24 Nm

Apply engine oil to all
moving parts before
installation.

11 Nm

24 Nm

10

9

11

4

11 Nm

9

12

13

6

14

5

7

Removal steps

+

G 1. Rocker cover +CG 8. Oil control valve

G

2. Rocker cover gasket

3. Oil seal

+

G

4. Circuit packing

F

+

G

5. Oil seal

E

+

G

6. Camshaft holder

D

+

G

7. Semi-circular packing

D

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

+

G 9. Cam cap

B

10. Oil control valve holder

+

G 11. Camshaft bearing cap

B

12. Arm spring holder

13. Arm spring

+

G 14. Camshaft

A

11A-10-2

6A1 ENGINE (E-W) -

Left bank
camshaft

Right bank
camshaft

6AE0229

Rocker Cover and Camshaft <MIVEC>

INSTALLATION SERVICE POINT

+

AG CAMSHAFT INSTALLATION

(1) Intake valve camshaft and exhaust valve camshaft can

be identified by their diameters at the portions indicated

in the illustration.

Intake valve camshaft: 25 mm

Exhaust valve camshaft: 30 mm

EX

Dowel p

in

IN

EXIN

Dowel p

Right
bank

Left
bank

in

6AE0230

6AE0233

(2) Before installing each camshaft, apply engine oil to its

journals and cams.
(3) The camshaft dowel pins must be positioned as shown

in the illustration.

+

G

B

CAMSHAFT BEARING CAP CAM CAP

/

INSTALLATION

(1) Apply sealant to the illustrated points of the

camshaft

holders.

Specified sealant:

3M ATD part No. 8660 or equivalent

(2) Install the bearing caps and cam caps correctly according

to the “I” (intake) and “E” (exhaust) marks as well as

the stamped cap numbers a nd front marks.
(3) Tighten the bolts in the sequence of the numbers shown

in the illustration.

Cap No.

Intake

Exhaust

Cap No.

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

Front mark

6AE0308

Protrusion

6A1 ENGINE (E-W) -

6AE0236

Screw

Rocker Cover and Camshaft <MIVEC>

+

CG OIL CONTROL VALVE INSTALLATION

11A-10-3

(1) Apply the specified sealant to the area shown.

Specified sealant:

3M ATD Part No. 8660 or equivalent

+

DG SEMI-CIRCULAR PACKING / CAMSHAFT

HOLDER INSTALLATION

(1) Make sure that the retainer of each adjusting screw is

fitted correctly.

Groove

Retainer

Pad

6AE0237

6AE0238

Caution

J

If the protrusion on the retainer is not correctly
fitted in the groove of the screw, the pad could
slip off the retainer.

(2) Apply 3 mm thick bead of foam-in-place gasket (FIPG)

to the gasket surface of the camshaft holder.

Caution

J

Since the FIPG could cause blocking of engine
oil passages, be careful not to apply FIPG to other
locations than specified.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

(3) Install the semi-circular packings.
(4) Raise the rocker arms until the rollers come into contact

with the cams, and install the camshaft holder.

(5) Tighten the bolts in the order indicated in the illustration.

106248

(6) Check the torque of the Q-marked bolts. See section +BG

for the checking order.
(7) Verify that the pad of each adjusting screw is in place.

7 3 1 5 9

6AE0239

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-10-4

Right bank

MD998713

Left bank

6A1 ENGINE (E-W) -

6AE0306

MD998777

MD998713

6AE0307

Rocker Cover and Camshaft <MIVEC>

+

EG CAMSHAFT OIL SEAL INSTALLATION

(1) When installing the left bank camshaft oil seal, use the

special tool to prevent interference with the knock pin.

10 mm

10 mm

12

MD998713

10 mm

6AE0241

Sealant application
areas

6AE0242

+

FG CIRCULAR PACKING INSTALLATION

+

GG ROCKER COVER INSTALLATION

(1) Apply the specified sealant to the area shown.

Specified sealant:

3M ATD Part No. 8660 or equivalent

INSPECTION

OIL CONTROL VALVE

(1) Connect a 12VDC power supply between terminals (1)

and (2) of the oil control valve and check if the valve

operates smoothly.

+ -

6AE0206

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

High-speed cam (H)

Valve

16 mm

6AE0227

9N0058

Rocker Cover and Camshaft <MIVEC>

11A-10-5

CAMSHAFT

(1) Measure the cam heights. If the specified limit is exceeded,

replace the camshaft.

NOTE

Each camshaft has an identification mark on its rear end

surface.

( ) Limit

: Identification mark Standard value

IN (3) 34.34 mm 33.84 mm

EX (C) 34.40 mm 33.90 mm

L
H
L
H

36.46 mm 35.96 mm

35.86 mm 35.36 mm

Identification
mark location

21 mm

Low-speed
cam (L)

6AE0228

VALVE CLEARANCE ADJUSTMENT

NOTE
Adjust the valve clearance for each cylinder and for both
intake and exhaust valves with the piston at the compression
stroke top dead center.

(1) Bring the No. 1 cylinder piston into the compression stroke

top dead center.

(2) Use th e special tool to loosen the adjusting screw.

Thickness gauge

MB991477

6AE0285

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

(3) Insert a thickness gauge of the thickness specified below

between the low-speed cam (narrow cam) and roller.

Intake

Exhaust

(4) Screw in on e of the two adjusting screws until it comes

into contact with the valve (when the turning torque

changes).

....................................................

.................................................

0.10 mm

0.13 mm

11A-10-6

MB991479

6A1 ENGINE (E-W) -

Piston

Rocker Cover and Camshaft <MIVEC>

(5) Screw in the other adjusting screw until it comes into

contact with the valve (when the turning torque changes),

and then tighten the lock nut.
(6) Loosen the adjusting screw that was screwed in first

slightly (until the turning torque becomes almost zero).

Screw in the adjusting screw until it comes into contact

with the valve again (when the turning torque changes)

and tighten the lock nut.
(7) Remove the thickness gauge.

(8) Screw the special tool into the top of piston of the rocker

arm “H”, and pull up the tool to make sure that the piston

can be lifted smoothly by hand.
(9) Perform valve clearance adjustments for other cylinders

by turning every time the crankshaft through 120è (60è

in camshaft sprocket angle) and following the above steps

(2) through (8). Perform the adjustments in the following

order of cylinder number:

No. 2 ç No. 3 ç No. 4 ç No. 5 ç No. 6

6AE0286

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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6A1 ENGINE (E-W) -

Rocker Arm and Rocker Shaft Cap <MIVEC>

11. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC>

REMOVAL AND INSTALLATION

11A-11-1

16

13

18

7

17

9

10

14

15

19

5

6

21

20

12

11

13

2

22

21

20

4

12

11

20

21

13

11

12

4

3

1

11 Nm

8

4

Removal steps

+

G 1. Rocker shaft cap

B

2. Seal cap A

3. Seal cap C

4. Intake rocker arm assembly A

5. Nut

6. Adjusting screw

7. Intake rocker arm H

8. Piston H

9. Piston spring H

10. Intake T-lever

+

G 11. Spring guide

A

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

Apply engine oil to all
moving parts before
installation.

12. Wave washer

13. Exhaust rocker arm assembly A

14. Nut

15. Adjusting screw

16. Exhaust rocker arm H

17. Piston H

18. Piston spring H

19. Exhaust T-lever L

+

G 20. Spring guide

A

21. Wave washer

22. Camshaft holder

11A-11-2

6A1 ENGINE (E-W) -

Rocker Arm and Rocker Shaft Cap <MIVEC>

T-lever

Either side may be out

6

5

Waved washer

2
1

Spring guide

4
3

Concave
side

6AE0247

10

8
7

9

6AE0249

INSTALLATION SERVICE POINTS

+

AG SPRING GUIDE INSTALLATION

(1) Install the spring guide with the concave side toward

the rocker arm. The waved washer may be installed with

either side out.

+

BG ROCKER SHAFT CAP INSTALLATION

(1) Tighten the bolts in the sequence shown.
(2) Make sure that each rocker arm moves smoothly.

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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6A1 ENGINE (E-W) -

Cylinder Head and Valves

12. CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION <SOHC>

5
12
16

19

11

4

6

13

20

17

15

1

14

10

11A-12-1

8

9

2

3

18

7

Apply engine oil to all
moving parts before
installation.

Removal steps

GA++

GB++

GB++

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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G 1. Cylinder head bolt

D

2. Cylinder head

3. Cylinder head gasket

G 4. Retainer lock

C

5. Valve spring retainer

+

G 6. Valve spring

B

7. Intake valve

G 8. Retainer lock

C

9. Valve spring retainer

+

G 10. Valve spring

B

GC++

GC++

11. Exhaust valve

G 12. Valve stem seal

A

13. Valve spring seat

G 14. Valve stem seal

A

15. Valve spring seat

16. Intake valve guide

17. Exhaust valve guide

18. Intake valve seat

19. Exhaust valve seat

20. Cylinder head

11A-12-2

6A1 ENGINE (E-W) -

REMOVAL AND INSTALLATION <MIVEC>

1

5

9

10

15

8

14

17

Cylinder Head and Valves

4

12

6

13

16

Apply engine oil to all
moving parts before
installation.

18

7

19

20

11

2

3

Removal steps

GA++

GB++

GB++

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

G 1. Cylinder head bolt

D

2. Cylinder head

3. Cylinder head gasket

G 4. Retainer lock

C

5. Valve spring retainer

+

G 6. Valve spring

B

7. Intake valve

G 8. Retainer lock

C

9. Valve spring retainer

+

G 10. Valve spring

B

G

+ 11. Exhaust valve

D

GC++

GC++

G 12. Valve stem seal

A

13. Valve spring seat

G 14. Valve stem seal

A

15. Valve spring seat

16. Intake valve guide

17. Exhaust valve guide

18. Intake valve seat

19. Exhaust valve seat

20. Cylinder head

6A1 ENGINE (E-W) -

Cylinder Head and Valves

11A-12-3

<SOHC>

MB991653

<MIVEC>

MB991653

<SOHC>

6AE0166

6AE0408

REMOVAL SERVICE POINTS

PRECAUTION FOR REMOVED PARTS

Keep removed parts in order according to the cylinder number
and intake/exhaust side.

G

A+ CYLINDER HEAD BOLT REMOVAL

(1) Using the special tool, loosen the cylinder head bolts.

Loosen evenly, little by little.

G

B+ RETAINER LOCK REMOVAL

(1) Store removed valves, springs and other parts, tagged

to indicate their cylinder Nos. and location for reassembly.

<MIVEC>

MD998772

MD998735

MD998772

6AE0167

MD998784

6AE0253

6EN1068

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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11A-12-4

6A1 ENGINE (E-W) -

G

C+ VALVE STEM SEAL REMOVAL

(1) Do n ot reuse removed valve stem seals.

6AE0082

G

D+ VALVE HANDLING PRECAUTIONS

(1) Sodium reacts violently with water or moisture generation

(2) Handling of Sodium-filled Exhaust Valves

(3) How to Neutralize Sodium

Cylinder Head and Valves

heat and liberating hydrogen. It must be handled with
utmost care because otherwise the following dangerous
conditions may result:
Loss of eyesight if sodium gets in eyes.
Burns if sodium contact skin.
Fire hazard.

Sodium-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
Never try to break the valves and expose sodium to the
air. When worn exhaust valves are to be discarded, have
them disposed of by a salvage company equipped with
special disposal system, notifying them that the valves
contain sodium.
Should the exhaust valves be broken, neutralize sodium
using the method described below, and discard the valves
in the same way as ordinary valves.

Place a container filled with more than 10 liters of water
in a well ventilated large space.
Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
Put a broken valve in the water-filled container and quickly
get away from the container at least 2 or 3 m.

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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Stem seals for intake
valves: Silver

<SOHC>

MD998774

6A1 ENGINE (E-W) -

INSTALLATION SERVICE POINTS

Stem seals
for exhaust
valves: Black

7EN0763

+

AG VALVE STEM SEAL INSTALLATION

(1) Install the valve spring seat.
(2) Use the special tool to fit a new stem seal on the valve

Cylinder Head and Valves

11A-12-5

guide.
NOTE

Valve stem seals for intake valves are different from those
for exhaust valves. They are identified by colors of their
spring sections as follows:

Stem seals for intake valves: Silver
Stem seals for exhaust valves: Black

Caution

J

Do not reuse the valve stem seal.

J

Always use the special tool to install the valve
stem seal. If the seal is improperly fitted, engine
oil may work its way down along the valve stem.

<MIVEC>

Painted
end

6AE0169

MD998775

6AE0409

Spring
retainer

Stem seal

Spring
seat

6EN0437

+

BG VALVE SPRING INSTALLATION

(1) Install the valve spring with the painted e nd on the rocker

arm side.

+

<SOHC>

CG RETAINER LOCK INSTALLATION

(1) The valve spring, if excessively compressed, causes the

bottom end of retainer to be in contact with, and damage,
the stem seal.

MD998772

6AE0167

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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11A-12-6

<MIVEC>

6A1 ENGINE (E-W) -

MD998784

Cylinder Head and Valves

MD998772

MD998735

Length of shank

6AE0253

6EN1068

9EN0251

+

DG CYLINDER HEAD BOLT INSTALLATION

(1) When installing the cylinder head bolts, check that the

shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolts.

Limit: max. 96.4 mm

(2) Install the washers as illustrated.
(3) Apply engine oil to the bolt threads and washers.

(4) Retighten the loosened bolts to a torque of 20 Nm in

the specified tightening sequence.

6AE0392

MB991614

(5) Make paint marks on the cylinder head bolts and cylinder

head.

(6) Give a 120è turn to th e bolts in the specified tightening

sequence.

Caution

120

è

J

J

6AE0339

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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If the bolts are tightened by an angle of less than
120è, they may not hold the cylinder head with
sufficient strength.
If a bolt is overtightened, completely remove all
the bolts and carry out the installation procedure
again from step (1).

6A1 ENGINE (E-W) -

INSPECTION

CYLINDER HEAD

(1) Check the cylinder head gasket surface for flatness by

(2) If the service limit is exceeded, correct to meet the

6AE0083

Cylinder Head and Valves

11A-12-7

using a straightedge and thickness gauge.

Standard value: 0.03 mm
Limit: 0.2 mm

specification.

Grinding limit: *0.2 mm

*Includes/combined with cylinder block grinding

Cylinder head height (Specification when new):

119.9 - 120.1 mm <SOHC>

119.6 - 119.8 mm <MIVEC>

Valve seat
contact

Margin

6EN0542

VALVE

(1) Check the valve face for correct contact. If incorrect, reface

using a valve refacer. Valve should make a uniform contact
with the seat at the centre of valve face.

(2) If the margin is smaller than the service limit, replace

the valve.

Standard value mm
Intake 1.0 0.5
Exhaust 1.3 0.8

Limit mm

(3) Measure the overall height of the valve. If the specified

limit is exceeded, replace the valve.

Intake SOHC

MIVEC

Exhaust SOHC

MIVEC

Standard value
mm

113.02 112.52

112.37 111.87

115.32 114.82

110.74 110.74

Limit mm

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-12-8

6A1 ENGINE (E-W) -

VALVE SPRING

Out of square

(1) Measure the valve spring’s free height. If the measurement

Cylinder Head and Valves

is less than specified, replace the spring.

Free
height

1EN0264

Valve stem end

Valve stem
projection

Standard value

mm
SOHC 49.9 48.9
MIVEC 51.5 50.5

Limit mm

(2) Measure the squareness of the spring. If the measurement

exceeds the specified limit, replace the spring.

Standard value: 2b or less
Limit: 4

b

VALVE SEAT

(1) Assemble the valve, then measure the valve stem

projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.

Valve
guide

Spring seating
surface

DEN0212

1EN0279

Standard value Limit mm

mm

48.45SOHC 48.95

MIVEC 48.40 48.90

VALVE GUIDE

(1) Measure the clearance between the valve guide and valve

stem. If the limit is exceeded, replace the valve guide
or valve, or both.

Standard value:

Intake: 0.02 - 0.05 mm
Exhaust: 0.04 - 0.07 mm

Limit:

Intake: 0.10 mm
Exhaust: 0.15 mm

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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6A1 ENGINE (E-W) -

Cylinder Head and Valves

11A-12-9

0.9 -

65

b

15

b

Cut away

1.3 mm

Valve seat
height

44

0.5 -

b

1.0 mm

44

0.9 -

b

0.5 -

1.3 mm

65

15

b

1EN0105

1.0 mm

1EN0274

VALVE SEAT RECONDITIONING PROCEDURE

(1) Before correcting the valve seat, check the clearance

between the valve guide and valve. If necessary, replace

b

the valve and/or valve guide.

(2) Using the appropriate special tool or seat grinder, correct

the valve seat to achieve the specified seat width and
angle.

(3) After correcting the valve seat, lap the valve and valve

seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION).

VALVE SEAT REPLACEMENT PROCEDURE

(1) Cut the valve seat to be replaced from the inside to thin

the wall thickness. Then, remove the valve seat.

(2) Rebore the valve seat hole in the cylinder head to a

selected oversize valve seat diameter.

Intake valve seat hole diameter

0.3 O.S. <SOHC>: 29.80 - 29.82 mm
<MIVEC>: 32.30 - 32.32 mm

0.6 O.S. <SOHC>: 30.10 - 30.12 mm
<MIVEC>: 32.60 - 32.62 mm

Exhaust valve seat hole diameter

0.3 O.S. <SOHC>: 27.80 - 27.82 mm
<MIVEC>: 29.80 - 29.82 mm

0.6 O.S. <SOHC>: 28.10 - 28.12 mm
<MIVEC>: 30.10 - 30.12 mm

Oversize valve seat
hole diameter

1EN0275

(3) Before fitting the valve seat, either heat the cylinder head

up to approximately 2 50bC or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.

(4) Correct the valve seat to the specified width and angle.

VALVE GUIDE REPLACEMENT

(1) Force the valve guide out toward the cylinder block using

a press.

(2) Machine the valve guide hole in the cylinder head to

the size of the oversize valve guide to be installed.

Caution

J

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

Valve guide hole diameters in cylinder head

0.05 O.S.: 11.05 - 11.07 mm

0.25 O.S.: 11.25 - 11.27 mm

0.50 O.S.: 11.50 - 11.52 mm

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-12-10

6A1 ENGINE (E-W) -

Cylinder Head and Valves

<SOHC>

14 mm

<DOHC>

19 mm

19 mm

1EN0106

6AE0254

(3) Press-fit the valve guide until it protrude specified value

(SOHC: 14 mm, DOHC: 19 mm) as shown in t he
illustration.

Caution

J

Press the valve guide from the cylinder head top
surface.

J

Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)

(4) After the valve guide has been installed, insert a new

valve to check for smooth sliding motion.

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Oil Pump Case and Oil Pan

13. OIL PUMP CASE AND OIL PAN

REMOVAL AND INSTALLATION <SOHC>

11A-13-1

Apply engine oil to all
moving parts before
installation.

22

14 Nm

21

1

10 Nm

25

26

18

44 Nm

12 Nm

20

19

14

24

23

17

16

19 Nm

15

9Nm

8

4

30 Nm

5

7Nm

6

2

7

21 Nm

68 Nm

3

39 Nm

10

9

9Nm

Removal steps

+

G 1. Oil pressure switch

I

+

G 2. Oil filter

H

3. Oil filter cover

4. Water hose (for Europe and GCC)

5. Water pipe (for Europe and GCC)

6. Water pipe (for Europe and GCC)

7. Bolt (for Europe and GCC)

+

G 8. Oil cooler (for Europe and GCC)

G

9. Drain plug

+

G 10. Gasket

F

11. Oil level sensor (For Europe)

12. Cover

+

G 13. Oil pan lower

D

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11

12

7Nm

13

7Nm

+

G 14. Oil pan upper

D

15. Buffle plate

16. Oil screen

17. Gasket

18. Relief plug

19. Relief spring

20. Relief plunger

+

G 21. Oil seal

C

+

G 22. Oil pump case

B

23. O-ring

24. Oil pump case cover

+

G 25. Outer rotor

A

+

G 26. Inner rotor

A

11A-13-2

6A1 ENGINE (E-W) -

REMOVAL AND INSTALLATION <MIVEC>

17

18

14

Oil Pump Case and Oil Pan

2

21 Nm

14 Nm

13

1

10 Nm

39 Nm

11

10

4

12

15

44 Nm

19 Nm

6

5

16

12 Nm

9

3

7Nm

8

7

7Nm

Apply engine oil to all
moving parts before
installation.

Removal steps

+

G

1. Oil pressure switch

I

+

G

2. Oil filter

H

3. Oil filter cover

4. Drain plug

+

G

5. Gasket

GA++

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

F

G

6. Oil pan

E

7. Oil screen

8. Gasket

9. Buffle plate +AG 18. Inner rotor

10. Relief plug

11. Relief spring

12. Relief plunger

+

G 13. Oil seal

C

+

G 14. Oil pump case

B

15. O-ring

16. Oil pump case cover

+

G 17. Outer rotor

A

6A1 ENGINE (E-W) -

REMOVAL SERVICE POINT

G

MD998727

(1) Knock the special tool deeply between the oil pan and
(2) Hitting the side of the special tool, slide th e special tool

6AE0087

INSTALLATION SERVICE POINTS

+

(1) Apply engine oil to the rotors. Then, install the rotors

Oil Pump Case and Oil Pan

11A-13-3

A+ OIL PAN REMOVAL

the cylinder block.
along the oil pan to remove it.

AG INNER ROTOR / OUTER ROTOR INSTALLATION

ensuring that the alignment dots made at disassembly
are properly aligned.

3 mm diameter
bead sealant

MD998717

6AE0091

6AE0092

6AE0093

+

BG SEALANT APPLICATION TO OIL PUMP CASE

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

+

CG OIL SEAL INSTALLATION

(1) Apply engine oil to the oil seal lip.

Using the special tool, knock the oil seal into the oil pump
case.

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-13-4

6A1 ENGINE (E-W) -

+

(1) Clean the cylinder block and oil pan gasket application
(2) Install the oil pan within 15 minutes after FIPG has been

Oil Pump Case and Oil Pan

DG OIL PAN INSTALLATION <SOHC>

surfaces.
applied to the entire flange surfaces of the oil pan.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

4

f

Bolt
hole

4 diametermm
bead sealant

Groove

+

EG OIL PAN INSTALLATION <MIVEC>

(1) Clean the cylinder block and oil pan gasket application

surfaces.

(2) Install the oil pan within 15 minutes after FIPG has been

applied to the entire flange surfaces of the oil pan.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

6AE0094

+

FG DRAIN PLUG GASKET INSTALLATION

Oil pan
side

Drain plug
gasket

7EN0307

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

(1) Install the drain plug gasket in the shown direction.

6A1 ENGINE (E-W) -

+

(1) Install the oil cooler, with the oil cooler’s positioning

6AE0172

+

(1) Clean the surfaces of the cylinder block on which the
(2) Apply engine oil to the O-ring of the oil filter.

(3) Turn down the oil filter until the O-ring contacts the cylinder

Oil Pump Case and Oil Pan

11A-13-5

GG OIL COOLER INSTALLATION

projection positioned against the rib on cylinder block.

HG OIL FILTER INSTALLATION

oil filter is to be mounted.

block surface, and then give the oil filter one more turn
(or tighten with a 16 Nm torque).

NOTE
For MD135737 oil filter, the tightening torque should be
14 Nm.

Oil passage

9EN0094

6AE0088

+

IG SEALANT APPLICATION TO SEALANT TO OIL

PRESSURE SWITCH

(1) Apply sealant to the threads of the switch.

Specified sealant:

3M ATD Part No. 8660 or equivalent

Caution

J

Use care not to allow the sealant to plug the oil
passage.

INSPECTION

OIL PUMP

(1) Check the tip clearance.

Standard value: 0.06 - 0.18 mm

(2) Check the side clearance.

Standard value: 0.04 - 0.10 mm

6AE0089

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

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11A-13-6

6A1 ENGINE (E-W) -

(3) Check the body clearance.

6AE0090

OIL LEVEL SENSOR (FOR EUROPE)

(1) Put the oil level sensor in the oil, then move the float

6AE0192

Oil Pump Case and Oil Pan

Standard value: 0.10 - 0.18 mm
Limit: 0.35 mm

up and down with the oil at a temperature either lower
than 40 èC or higher than 80èC, and check for continuity.

è

40

C
Float position
Condition when down ON (continuity)
Condition when up ON (continuity)

è

80

C
Float position
Condition when down OFF (no continuity)
Condition when up ON (continuity)

Switch ON/OFF

Switch ON/OFF

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Piston and Connecting Rod

14. PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

11A-14-1

Removal steps

+

G 1. Nut +CG 7. Piston ring No.2

GA++

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

G

G 2. Connecting rod cap +BG 8. Oil ring

F

+

G 3. Connecting rod bearing G

E

+

G 4. Piston and connecting rod 10. Piston

D

+

G 5. Connecting rod bearing 11. Connecting rod

E

+

G 6. Piston ring No.1 12. Bolt

C

++

B

Apply engine oil to all
moving parts before
installation.

G 9. Piston pin

A

6AE0095

11A-14-2

Piston pin setting tool MD998780

Push rod

Guide B

6A1 ENGINE (E-W) -

REMOVAL SERVICE POINTS

G

(1) Mark the large end of the connecting rod with the cylinder

Cylinder No.

DEN0050

G

Piston pin setting tool (MD998780) consists of the parts shown

Guide A:

17.9 mm

Guide A:

18.9 mm

in the illustration at left.
To remove the piston pin, Guide D (MB991659) is also used
in combination with the Piston pin setting tool.

Piston and Connecting Rod

A+ CONNECTING ROD CAP REMOVAL

number for use during reassembly.

B+ PISTON PIN REMOVAL

Front
mark

Base

Guide C

Guide D
MB991659

Push rod

Front mark

Guide A:

20.9 mm

Guide A:

21.9 mm

9EN0780

(1) Insert the Push Rod (special tool) into the piston from

the side on which the front mark is stamped in the piston
head, and attach the guide D to the push rod end.

(2) Place the piston and connecting rod assembly on the

Piston Pin Setting Base (special tool) with the front mark
facing upward.

(3) Using a press, remove the piston pin.

NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.

Guide D

Base

7EN0390

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Piston and Connecting Rod

11A-14-3

A

Piston pin

3mm+L

C

D

Connecting rod

Piston

B

7EN0432

INSTALLATION SERVICE POINTS

+

AG PISTON PIN INSTALLATION

(1) Measure the following dimensions of the piston, piston

pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width

(2) Calculate the following formula by substituting the

measured values.

(A - C) - (B - D)

L=

(3) Insert the Push Rod (special tool) into the piston pin an d

attach the guide A to the push rod end.

(4) Assemble the connecting rod in the piston with their front

marks facing the same direction.
(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly

having assembled in step (3) from the guide A side into

the piston pin hole on the front marked side.

(7) Screw the guide B into the guide A until the gap between

both guides amounts to the value L obtained in step

(2) plus 3 mm.

2

Guide B

Front
mark

Guide A

Push rod

Piston pin

Front mark

Guide A

Base

Guide B

7EN0433

(8) Place the piston and connecting rod assembly onto the

piston setting base with the front marks directed upward.
(9) Press-fit the piston pin using a press.

If the press-fitting force required is less than the standard

value, replace the piston and piston pin set or/and the

connecting rod.

Standard value: 5,000 - 15,000 N

7EN0391

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-14-4

6A1 ENGINE (E-W) -

+

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

(2) Install the upper side rail.

6AE0194

Piston and Connecting Rod

BG OIL RING INSTALLATION

NOTE

The side rails and spacer may be installed in either

direction.

To install the side rail, first fit one end of the rail into

the piston groove, then press the remaining portion into

position by finger. S ee illustration.

Side rail gap

Identification mark

Identification mark

1EN0269

Piston ring expander

7EN0452

Size mark

No.1

No.2

NOTE

Do not use piston ring expander when installing side

rail. Use of ring expander to expand the side rail end

gap can break the side rail, unlike other piston rings.
(3) Install the lower side rail in the same procedure as

described in step (2).
(4) Make sure that the side rails move smoothly in either

direction.

+

CG PISTON RING NO. 2 / PISTON RING NO. 1

INSTALLATION

(1) Using piston ring expander, install the piston rings with

their side having identification marks facing up.

Identification mark:

No. 1 ring: T
No. 2 ring: 2T

NOTE

The piston ring is stamped with the following size mark.

Size Size mark
Standard size None

0.50 mm O.S. 50

1.00 mm O.S. 100

Upper
side rail

in

Piston p

ring

No. 2
and spacer gap

Mitsubishi Motors Corporation Feb. 1997

K

gap

9EN0524

No. 1

Lower
side rail

6EN0549

+

DG PISTON AND CONNECTING ROD INSTALLATION

(1) Liberally coat engine oil on the circumference of the piston,

piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and

spacer) as shown in the figure.
(3) Rotate crankshaft so that the crank pin is on center of

the cylinder bore.

PWEE9622

6A1 ENGINE (E-W) -

6AE0097

No.6

in

No.2
No.4

Check
digit

6AE0341

Crankshaft p
identification mark

No.1
No.3
No.5

Piston and Connecting Rod

11A-14-5

(4) Use suitable thread protectors on connecting rod bolts

before inserting piston and connecting rod assembly into

cylinder block. Care must be taken not to nick crank pin.
(5) Using a suitable piston ring compressor tool, install piston

and connecting rod assembly into the cylinder block.

Caution

J

Insert the front mark (arrow) on the top of the
piston so it faces the engine front (timing belt
side).

+

EG CONNECTING ROD BEARINGS INSTALLATION

(1) When the bearings are to be replaced, select correct

ones and install them in the correct positions according

to the identification marks stamped on the crankshaft.

<6A12>

Crankshaft pin

Identification mark Outer diameter mm Identification mark

I

II

III

42.995 - 43.000

42.985 - 42.995

42.980 - 42.985 3

Connecting rod
bearing

1
2

Identification mark

<6A13>

Crankshaft pin

Connecting rod
bearing

Identification mark Outer diameter mm Identification mark

I

II

III

+

FG CONNECTING ROD CAP INSTALLATION

50.995 - 51.000 1

50.985 - 50.995 2

50.980 - 50.985 3

(1) Mate the correct bearing cap with th e correct connecting

rod by checking with the alignment marks marked during

disassembly. If a new connecting rod is used which has

no alignment mark, position the notches for locking the

bearing on the same side.

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-14-6

6A1 ENGINE (E-W) -

(2) Check if the thrust clearance in the connecting rod big

9EN0073

+

(1) Since the connecting rod bolts and nuts are torqued using

Piston and Connecting Rod

end is correct.

Standard value: 0.10 - 0.25 mm

Limit: 0.4 mm

GG CONNECTING ROD CAP NUT INSTALLATION

a new procedure they should be examined BEFORE

reuse. If the bolt threads are “necked down” the bolts

should be replaced.

Necking can be checked by running a nut with fingers

to the full length of the bolt’s thread. If the nut does not

run down smoothly, the bolt should be replaced.

Paint
marks

90è - 100

Bolt

Nut

Paint
marks

(2) Before installation of each nut, apply engine oil to the

threaded portion and bearing surface of the nut.

è

(3) Install each nut to the bolt and tighten it finger tight. Then

tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 18 Nm.
(5) Make a paint mark on the head of each nut.
(6) Make a paint mark on the bolt at the position 90è to

100è from the paint mark made on the nut in the direction

of tightening the nut.
(7) Give a 90è to 100è turn to the nut a nd make sure that

6EN0954

the paint mark on the nut and that on the bolt are in

alignment.

Caution

J

If the nuts are tightened by an angle of less than
90è, they may not hold the caps with sufficient
strength.

J

If a nut is tightened by an angle exceeding 100è,
completely remove all the nuts and carry out the
installation procedure again from step (1).

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

Piston ring

6A1 ENGINE (E-W) -

Push in
by the piston

Piston
ring gap

7EN0475

7EN0476

Piston and Connecting Rod

11A-14-7

INSPECTION

PISTON RING

(1) Check the side clearance between the piston ring and

ring groove. If the limit is exceeded, replace the ring or

piston, or both.

Standard value:

No. 1 0.03 - 0.07 mm
No. 2 0.02 - 0.06 mm

Limit:

No. 1 0.1 mm
No. 2 0.1 mm

Install the piston ring into the cylinder bore. Force it down

with a piston, its crown being in contact with the ring,

to correctly position it at right angles to t he cylinder wall.

Then, measure the end gap with a feeler gauge.

If the ring gap is excessive, replace piston ring.

Standard value:

No. 1
No. 2
Oil

Limit:

No. 1, No. 2 0.8 mm
Oil 1.0 mm

0.25 - 0.40 mm

0.40 - 0.55 mm

0.10 - 0.35 mm

CRANKSHAFT PIN OIL CLEARANCE (PLASTIC
GAUGE METHOD)

(1) Remove oil from crankshaft pin and connecting rod

bearing.
(2) Cut the plastic gauge to the same length as the width

of bearing and place it on crankshaft pin in parallel with

its axis.
(3) Install the connecting rod cap carefully and tighten the

bolts to specified torque.

Plastic gauge

1EN0246

(4) Carefully remove the connecting rod cap.
(5) Measure the width of the plastic gauge at its widest part

by using a scale printed on the plastic gauge package.

Standard value: 0.02 - 0.05 mm

Limit: 0.1 mm

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Crankshaft, Cylinder Block, Flywheel and
Drive Plate

11A-15-1

15. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE

REMOVAL AND INSTALLATION

5

4

35 Nm

11 Nm

6

A

20

21

19

2

23 Nm

1

13

11

3

14

98 Nm

7

8

12

98 Nm

9

11 Nm

10

9Nm

18

17

Removal steps

1. Detonation sensor

2. Idler pulley bracket <M/T>

+

G 3. Flywheel bolt <M/T>

E

4. Plate <M/T>

5. Adapter plate <M/T>

6. Flexible flywheel <M/T>

7. Adapter plate <M/T>

+

G 8. Drive plate bolt <A/T>

E

9. Adapter plate <A/T>

10. Drive plate <A/T>

11. Rear plate

12. Bell housing cover <MIVEC>

+

G 13. Oil seal case

D

+

G 14. Oil seal

C

+

G 15. Bearing cap bolt

B

15

16

Apply engine oil to all
moving parts before
installation.

+

G 16. Bearing cap

B

+

G 17. Crankshaft bearing, lower

A

18. Crankshaft

+

G 19. Thrust bearing

A

+

G 20. Crankshaft bearing, upper

A

21. Cylinder block

Caution
On the flexible wheel equipped engines, do not
remove any of the bolts “A” of the flywheel shown
in the illustration.
The balance of the flexible flywheel is adjusted in
an assembled condition. Removing the bolt,
therefore, can cause the flexible flywheel to be out
of balance, giving damage to the flywheel.

Mitsubishi Motors Corporation Feb. 1997

K

PWEE9622

11A-15-2

6A1 ENGINE (E-W) -

Crankshaft, Cylinder Block, Flywheel and
Drive Plate

Crankshaft journal
identification mark

No.2

No.1

No.3

Check
digit

Cylinder block
bearing bore
identification
mark

Timing belt side

No.4

Cylinder bore size
mark (reference)

No.2No.4

No.1No.3

6AE0343

6AE0344

INSTALLATION SERVICE POINTS

+

AG CRANKSHAFT BEARING INSTALLATION

(1) When replacing bearing, select a one of proper size

according to the identification marks stamped on both
crankshaft and cylinder block.

<6A12>

Crankshaft Journal

Identi­fication
mark

Outer diameter Inner diameter
mm

1 52.994 - 53.000

2 52.988 - 52.994

3 52.982 - 52.988

Cylinder Block Bearing
Bore

Identifi­cation
mark

0 57.000 - 57.006 1
1 57.006 - 57.012 2
2 57.012 - 57.018 3
0 57.000 - 57.006 2
1 57.006 - 57.012 3
2 57.012 - 57.018 4
0 57.000 - 57.006 3
1 57.006 - 57.012 4
2 57.012 - 57.018 5

mm

Crankshaft
Bearing

Identifica­tion mark

Oil groove

Identification
mark

Groove

<6A13>

Crankshaft Journal

Identi­fication
mark

Outer diameter Inner diameter
mm

1 55.994 - 56.000

2 55.988 - 55.994

3 55.982 - 55.988

Cylinder Block Bearing
Bore

Identifi­cation
mark

0 60.000 - 60.006 1
1 60.006 - 60.012 2
2 60.012 - 60.018 3
0 60.000 - 60.006 2
1 60.006 - 60.012 3
2 60.012 - 60.018 4
0 60.000 - 60.006 3
1 60.006 - 60.012 4
2 60.012 - 60.018 5

mm

Crankshaft
Bearing

Identifica­tion mark

(2) Install t he bearings having an oil groove to th e cylinder

block.

(3) Install the bearings having no oil groove to the bearing

caps.

(4) Install the thrust bearings at the No. 3 upper bearing

with the grooved side toward the crank web.

Identification
mark

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6AE0116

Arrow

6A1 ENGINE (E-W) -

Shank length

9EN0477

6AE0108

Crankshaft, Cylinder Block, Flywheel and
Drive Plate

+

BG BEARING CAP / BEARING CAP BOLT

11A-15-3

INSTALLATION

(1) Install the bearing caps so that their arrows are positioned

on the timing belt side.

(2) When installing the bearing cap bolts, check that the

shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.

Limit: max. 71.1 mm

(3) Apply engine oil to the threaded portion and bearing

surface of the bolt.

(4) Tighten the bearing cap bolts to 25 Nm torque in the

tightening sequence.

Paint marks

90è - 100

Paint marks

(5) Make a paint mark on the head of each nut.
(6) Make a paint mark on the area around the bolt bearing

è

surface at location 90è to 100è in the direction of tightening
the bolt.

(7) Give a 90è to 100è turn to the bolts in the tightening

sequence. Make sure that the paint mark on the bolt
and that on the area around the bolt bearing surface
are in alignment.

Caution

J

6EN0955

If the bolts are tightened by an angle of less than
90è, they may not hold the cap with sufficient
strength.

J

If a bolt is tightened by an angle exceeding 100è,
completely remove all the bolts and carry out the
installation procedure again from step (1).

(8) After installing the bearing caps, make sure that the

crankshaft turns smoothly a nd the end play is correct.
If t h e end play exceeds th e limit, replace crankshaft
bearings.

Standard value: 0.05 - 0.25 mm
Limit: 0.4 mm

6AE0109

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-15-4

6A1 ENGINE (E-W) -

MB990938

MD998776

9EN0077

Crankshaft, Cylinder Block, Flywheel and
Drive Plate

+

CG OIL SEAL INSTALLATION

(1) Apply engine oil to oil seal lip.

+

DG APPLICATION OF OIL SEAL CASE

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

6AE0110

9EN0102

6AE0101

+

EG DRIVE PLATE BOLT / FLYWHEEL BOLT

INSTALLATION

(1) Remove all the remaining sealant from bolts and thread

holes of crankshaft.
(2) Apply engine oil to the flange of bolt.
(3) Apply engine oil into the thread holes of crankshaft.
(4) Apply specified sealant to the thread of bolts.

Specified sealant:

3M Nut Locking Part No. 4171 or equivalent

(5) Tighten the bolts to specified torque.

INSPECTION

CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)

(1) Remove oil from crankshaft journal and crankshaft

bearing.
(2) Install the crankshaft.
(3) Cut the plastic gauge to the same length as the width

of bearing and place it on journal in parallel with its axis.

(4) Install the crankshaft bearing cap carefully and tighten

the bolts to specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the plastic gauge at its widest part

by using a scale printed on the plastic gauge package.

Standard value: 0.02 - 0.04 mm

Limit: 0.1 mm

6AE0102

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

6A1 ENGINE (E-W) -

Crankshaft, Cylinder Block, Flywheel and
Drive Plate

11A-15-5

C D E

A
B

12 mm

F

G

6AE0103

6AE0104

CYLINDER BLOCK

(1) Using a straightedge and feeler gauge, check the block

top surface for warpage. Make sure that the surface is

free from gasket chips and other foreign matter.

Standard value: 0.05 mm or less

Limit: 0.1 mm

(2) If the distortion is excessive, correct within the allowable

limit or replace.

Grinding limit: 0.2 mm

The total thickness of the stock allowed to be
removed from cylinder block and mating cylinder
head is 0.2 mm at maximum.

Cylinder block height (when new):

6A12 190 mm
6A13 209 mm

(3) Check cylinder walls for scratches and seizure. If defects

are evident, correct (bored to oversize) or replace.

(4) Using cylinder gauge, measure the cylinder bore and

cylindricity. If worn badly, correct cylinder to an oversize

and replace piston and piston rings. Measure at the points

shown in illustration.

Standard value:

Cylinder I.D.:

6A12 78.40 - 78.43 mm
6A13 81.00 - 81.03 mm

Out-of-roundness and taper of cylinder bore:

0.01 mm or less

BORING CYLINDER

(1) Oversize pistons to be used should be determined on

the basis of the largest bore cylinder.

Piston size identification

Size Identification mark

0.50 mm O.S. 0.50

1.00 mm O.S. 1.00

6AE0105

NOTE

Size mark is stamped on piston top.
(2) Measure outside diameter of piston to be used. Measure

it in thrust direction as shown.
(3) Based on measured piston O.D. calculate boring finish

dimension.

Boring finish dimension = Piston O.D. + (Clearance

between piston O.D. and cylinder) - 0.02 mm (honing

margin)

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

11A-15-6

6A1 ENGINE (E-W) -

Crankshaft, Cylinder Block, Flywheel and
Drive Plate

(4) Bore all cylinders to calculated boring finish dimension.

Caution

J

To prevent distortion that may result from
temperature rise during honing, bore cylinders,
working from No. 1, No. 2, No. 3, No. 4, No. 5
and No. 6

(5) Hone to final finish dimension (piston O.D. + clearance

between piston O.D. and cylinder.)
(6) Check clearance between piston and cylinder.

Clearance between piston and cylinder:

0.02 - 0.04 mm

NOTE

When boring cylinders, finish all of four cylinders to same

oversize. Do not bore only one cylinder to an oversize.

Mitsubishi Motors Corporation Feb. 1997 PWEE9622

K

NOTES

Service Bulletins

Click on the applicable bookmark to select the Service Bulletin.

SERVICE BULLETIN

QUALITY INFORMATION ANALYSIS

OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN

Subject:

Group:

INFORMATION

1. Description:

It has been found that when the 6A1 engine is installed, the water pump impeller interferes with
the cylinder block. Therefore, the procedures for positioning the water pump that are to be
followed when the water pump is installed, have been introduced.

2. Applicable Manuals:

ENGINE 6A1 (W-E)
Workshop Manual

ENGINE 6A1 (E-W)
Workshop Manual

ADDITION OF 6A1 ENGINE WATER PUMP
INSTALLATION PROCEDURES
ENGINE

INTERNATIONAL
CAR
ADMINISTRATION
OFFICE

Manual

No.: MSB-01E11-001

Date: 2001-07-25 <Model> <M/Y>

(EC)GALANT(EA0) 01-10

D

raft No.: 00EN620614

T.MASAKI-MANAGER
TECHNICAL SERVICE PLANNING

Pub. No. Language Page(s)

PWEE9202 (English) 11A-7-2
PWES9203 (Spanish)
PWEF9204 (French)
PWEG9205 (German)
PWED9206 (Dutch)
PWEW9207 (Swedish)
PWEE9622 (English) 11A-7-3
PWES9623 (Spanish)
PWEF9624 (French)
PWEG9625 (German)
PWED9626 (Dutch)
PWEW9627 (Swedish)

ENGINE 6A1 (E-W) Workshop Manual

ENGINE (E-W) –

6A1

INSTALLATION SERVICE POINTS

3 mm diameter
bead sealant

6AE0067

A

►

◄

B

►

◄

(1) Wet the O-ring (with water) to facilitate assembly.

Water Pump and Water Pipe

SEALANT APPLICATION TO WATER PUMP
Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

th

4

page added here.

WATER PIPE / O-RING INSTALLATION

Caution

•

Keep the O-ring free of oil or grease.

•

Secure the water pipe after the thermostat housing
has been installed.

11A-7-3

3 mm diameter
bead sealant

l lJigg e va ve

6AE0068

6AE0069

SEALANT APPLICATION TO WATER OUTLET FITTING

C

►

◄

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

THERMOSTAT INSTALLATION

D

►

◄

(1) Install the thermostat so that the jiggle valve will be located in

the thermostat housing as shown.

E

SEALANT APPLICATION TO ENGINE COOLANT

►

◄

TEMPERATURE SENSOR

6AE0070

Specified sealant:

3M Nut locking Part No. 4171 or equivalent

3

<Added>

Water pump

(1) Install the water pump and tighten the bolts 1 and 2 in that

order.

(2) Turn the pulley by hand and ensure that the impeller does not

interfere with the cylinder block.

(3) Tighten the bolts other than bolts 1 and 2.

6AE0415

4