Mitsubishi 6G7 User Manual
ENGINE
6G7 SERIES
CONTENTS
11A-0-1
GENERAL INFORMATION 11A-0-3
1. SPECIFICATIONS 11A-1-1
SERVICE SPECIFICATIONS 11A-1-1
REWORK DIMENSIONS 11A-1-2
TORQUE SPECIFICATIONS 11A-1-3
SEALANTS 11A-1-5
FORM-IN-PLACE GASKET 11A-1-6
2. SPECIAL TOOLS 11A-2-1
3. ALTERNATOR 11A-3-1
4. AIR INTAKE PLENUM 11A-4-1
5. IGNITION SYSTEM 11A-5-1
6. TIMING BELT 11A-6-1
7. INTAKE MANIFOLD 11A-7-1
8. EXHAUST MANIFOLD & WATER PUMP 11A-8-1
9. ROCKER ARMS AND CAMSHAFT 11A-9-1
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10. CYLINDER HEAD AND VALVES 11A-10-1
11. OIL PAN AND OIL PUMP 11A-11-1
12. PISTON AND CONNECTING ROD 11A-12-1
13. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-13-1
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Dec. 1996Mitsubishi Motors Corporation
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PWEE9615
11A-0-2
NOTES
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Dec. 1996Mitsubishi Motors Corporation
PWEE9615
6G7 ENGINE (E-W) -
General Information
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Descriptions 6G72-SOHC
Type 60_ OHV, SOHC
Number of cylinders 6
Combustion chamber Compact type
11A-0-3
Total displacement dm
Cylinder bore mm 91.1
Piston stroke mm 76.0
Compression ratio 8.9
V alve timing Intake valve Opens (BTDC) 15°
(Camshaft identification mark: 1)
Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
Cooling system Water-cooled forced circulation
Water pump type Centrifugal impeller type
3
Closes (ABDC) 53°
Exhaust valve Opens (BBDC) 53°
Closes (ATDC) 15°
2.972
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Dec. 1996Mitsubishi Motors Corporation
PWEE9615
6G7 ENGINE (E-W) -
Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard Limit
Timing belt
Auto-tensioner rod length mm 3.8 - 5.0 -
Auto-tensioner rod projection length mm 12 -
11A-1-1
Auto-tensioner rod pushed-in amount (when pushed with a force of 98
- 196 N) mm
Rocker arms and camshaft
Camshaft cam height mm (Identification
mark: 1)
Camshaft journal outside diameter mm 45 -
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.03 0.2
Cylinder head grinding limit of gasket surface mm
(Total resurfacing depth of both cylinder head and cylinder block)
Cylinder head overall height mm 120 -
V alve thickness of valve head (margin) mm
Valve overall height mm
Intake 37.71 37.21
Exhaust 37.14 36.64
Intake 1.0 0.5
Exhaust 1.2 0.7
Intake 112.30 111.80
Exhaust 114.11 113.61
1.0 or less -
4 - 20/1.0 -
- 0.2
V alve stem outside diameter mm
V alve thickness to valve guide clearance mm
V alve face angle mm 45_ - 45.5_ -
V alve spring free length mm 51.0 50.0
V alve spring load/installed height N/mm 267/44.2 -
V alve spring out-of-squareness 2_ or less Maximum 4_
Valve seat valve contact width mm 0.9 - 1.3 -
Valve guide inside diameter mm 6.0 -
V alve guide projection from cylinder head upper surface mm 14 -
V alve stem projection mm 49.3 49.8
Oil pan and oil pump
Oil pump tip clearance mm 0.06 - 0.18 -
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Dec. 1996Mitsubishi Motors Corporation
Intake 6.0 -
Exhaust 6.0 -
Intake 0.02 - 0.04 0.10
Exhaust 0.04 - 0.06 0.15
PWEE9615
11A-1-2
Items LimitStandard
Oil pump side clearance mm 0.04 - 0.10 -
Oil pump body clearance mm 0.10 - 0.18 0.35
Piston and connecting rod
Piston outside diameter mm 91.1 -
6G7 ENGINE (E-W) -
Specifications
Piston ring to ring groove clearance mm
Piston ring end gap mm
Piston pin outside diameter mm 22.0 -
Piston pin press-in load N (Room temperature) 7,350 - 17,200 -
Crankshaft pin oil clearance mm 0.02 - 0.05 0.1
Connecting rod big end side clearance mm 0.10 - 0.25 0.4
Crankshaft, flywheel and drive plate
Crankshaft end play mm 0.05 - 0.25 0.3
Crankshaft journal outside diameter mm 60 -
Crankshaft pin outside diameter mm 50 -
Crankshaft journal oil clearance mm 0.02 - 0.05 0.1
Piston to cylinder clearance mm 0.02 - 0.04 -
No. 1 0.03 - 0.07 0.1
No. 2 0.02 - 0.06 0.1
No. 1 0.30 - 0.45 0.8
No. 2 0.45 - 0.60 0.8
Oil ring side rail 0.20 - 0.60 1.0
Cylinder block flatness of gasket surface mm 0.05 0.1
Cylinder block grinding limit of gasket surface mm
(Total resurfacing depth of both cylinder head and cylinder block)
Cylinder block overall height mm 210.5 -
Cylinder bore inside diameter mm 91.1 -
Cylindricity mm 0.01 -
- 0.2
REWORK DIMENSIONS
Items Standard value Limit
Oversize rework dimensions of valve
guide hole mm
Oversize rework dimensions of intake
valve seat hole mm
Oversize rework dimensions of
exhaust valve seat hole mm
0.05 Oversize diameter 11.05 - 11.07 -
0.25 Oversize diameter 11.25 - 11.27 -
0.50 Oversize diameter 11.50 - 11.52 -
0.3 Oversize diameter 34.30 - 34.33 -
0.6 Oversize diameter 34.60 - 34.63 -
0.3 Oversize diameter 31.80 - 31.83 -
0.6 Oversize diameter 32.10 - 32.13 -
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Dec. 1996Mitsubishi Motors Corporation
PWEE9615
6G7 ENGINE (E-W) -
Specifications
TORQUE SPECIFICATIONS
Items Nm
Alternator
Drive belt tensioner pulley nut 49
Crankshaft bolt 181
Alternator pivot nut 44
Alternator bolt M8 21
Alternator bolt M10 48
Dipstick tube 13
Air intake plenum
Air intake plenum stay bolt M8 17
Air intake plenum stay bolt M10 35
Accelerator cable bracket 4
11A-1-3
Bracket 11
Throttle body bolt 11
Air intake plenum bolt and nut 17
Exhaust gas recirculation valve bolt 21
Exhaust gas recirculation pipe bolt 17
Exhaust gas recirculation pipe flare nut 56
Ignition system
Spark plugs 25
Distributor 23
Timing belt
Timing belt cover bolt M6 11
Timing belt cover bolt M8 13
Engine support bracket 44
Crankshaft angle sensor bolt 9
Auto tensioner bolt 23
Tensioner pulley bolt 48
Tensioner arm bolt 44
Idler pulley bolt 44
Camshaft sprocket bolt 88
Bracket 23
Timing belt rear cover bolt 13
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Dec. 1996Mitsubishi Motors Corporation
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11A-1-4
Items Nm
Intake manifold
Engine coolant temperature gauge unit 11
Engine coolant temperature sensor 29
Heater pipe bolt 18
Water outlet fitting bolt 18
Water inlet fitting bolt 18
Thermostat housing bolt 18
Water pipe bolt 13
Delivery pipe 11
Intake manifold bolt 21
Fuel pipe bolt 8.8
Fuel pressure regulator bolt 8.8
6G7 ENGINE (E-W) -
Specifications
Exhaust manifold
Heat protector bolt 13
Exhaust manifold bolt 49
Engine hanger 35
Oil level gauge guide bolt 13
Water pump bolt M8 23
Water pump bolt M10 41
Rocker arms and camshaft
Rocker cover bolt 3.4
Rocker shaft bolt 31
Thrust case bolt 12
Cylinder head and valve
Cylinder head bolt 108
Oil pan and oil pump
Oil pressure switch 9.8
Oil filter bracket bolt M8 23
Oil filter bracket bolt M10 41
Drain plug 39
Oil pan, lower bolt 11
Cover bolt 11
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Dec. 1996Mitsubishi Motors Corporation
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6G7 ENGINE (E-W) -
Items Nm
Oil pan, upper bolt 5.9
Baffle plate bolt (oil pan side) 11
Baffle plate bolt (cylinder block side) 9.8
Oil screen bolt 18
Relief plug 44
Oil pump case bolt 13
Oil pump cover bolt 9.8
Piston and connecting rod
Connecting rod cap 51
Crankshaft, flywheel and drive plate
Flywheel bolt 74
Drive plate bolt 74
Specifications
11A-1-5
Rear plate bolt 11
Oil seal case bolt 11
Bearing cap bolt 93
SEALANTS
Description Specified sealant Quantity
Engine coolant temperature gauge unit 3M ATD Part No. 8660 As required
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 As required
Oil pressure switch 3M ATD Part No. 8660 As required
Oil pan MITSUBISHI GENUINE Part No. MD970389 As required
Oil pump case MITSUBISHI GENUINE Part No. MD970389 As required
Oil seal case MITSUBISHI GENUINE Part No. MD970389 As required
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Dec. 1996Mitsubishi Motors Corporation
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11A-1-6
6G7 ENGINE (E-W) -
Specifications
FORM-IN-PLACE GASKET
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 and 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 and 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.
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 t h e old sealant remaining in the bolt holes.
Form-in-Place Gasket Application (FIPG)
When assembling parts with the FIPG, you must observe some precautions, but the procedure is very
simple as in the case of a conventional pre-cut 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.
The FIPG application procedure may vary on different areas. Observe th e procedure described in the
text when applying the FIPG.
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Dec. 1996Mitsubishi Motors Corporation
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6G7 ENGINE (E-W) -
Special Tools
2. SPECIAL TOOLS
Tool Number Name Use
11A-2-1
MB991559 Camshaft oil seal
installer adaptor
MD998051 Cylinder head bolt
wrench
MD998440 Leak-down tester Leak-down test of lash adjuster
MD998441 Lash adjuster Air bleeding of lash adjuster retainer
Installation of camshaft oil seal (on left bank)
(Used in combination with MD998713)
Loosening and tightening of cylinder head bolt
MD998442 Air bleed wire Air bleeding of lash adjuster
MD998443 Auto-lash adjuster
holder
MD998717 Crankshaft front oil
seal
MD998718 Crankshaft rear oil
seal installer
Holding of the lash adjuster to prevent it from
falling when rocker shaft assembly is removed
or installed
Installation of crankshaft front oil seal installer
Press fitting crankshaft rear oil
MD998772 Valve spring
compressor
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Dec. 1996Mitsubishi Motors Corporation
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Compressing of the valve springs
11A-2-2
Tool UseNameNumber
6G7 ENGINE (E-W) -
Special Tools
MD998774 Valve stem seal
installer
MD998780 Piston pin setting
tool
MD998781 Flywheel stopper Holding flywheel or drive plate
MD998767 Tensioner pulley Adjustment of timing belt tension
Installation of valve stem seal
Removal and installation of piston pin
MB990767 End yoke holder Holding camshaft sprocket
(Used in combination with MD998715)
MD998715 Pulley holder pin Holding camshaft sprocket
(Used in combination with MB990767)
MD998735 Valve spring
compressor
adaptor
MD998769 Crank pulley
spacer
Compressing the valve springs
Cranking the crankshaft to install timing belt
MD998713 Camshaft oil seal
installer
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Dec. 1996Mitsubishi Motors Corporation
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Installation of camshaft oil seal
6G7 ENGINE (E-W) -
3. ALTERNATOR
REMOVAL AND INSTALLATION
181 Nm
Alternator
11A-3-1
7
8
9
13 Nm
10
AA""AA
2
3
4
Removal steps
1. Tensioner pulley
2. Crankshaft bolt
3. Washer
4. Crankshaft pulley
5. Alternator
49 Nm
21 Nm
44 Nm
48 Nm
6
1
5
7EN1030
6. Alternator bracket
7. Dip stick
8. O-ring
9. Dip stick tube
10. O-ring
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Dec. 1996Mitsubishi Motors Corporation
PWEE9615
11A-3-2
6G7 ENGINE (E-W) -
Alternator
MD998781
7EN0856
REMOVAL SERVICE POINTS
AA"
(1) With the Special Tool fixed to the drive plate or flywheel
CRANKSHAFT BOLT
remove the crankshaft bolt.
INSTALLATION SERVICE POINTS
"AA
(1) With the Special Tool fixed to the drive plate or flywheel
CRANKSHAFT BOLT
install the crankshaft bolt.
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Dec. 1996Mitsubishi Motors Corporation
PWEE9615
6G7 ENGINE (E-W) -
4. AIR INTAKE PLENUM
REMOVAL AND INSTALLATION
17 Nm
Air Intake Plenum
10
11
11A-4-1
11 Nm
9
21 Nm
17 Nm
17 Nm
4Nm
2
3
17 Nm
4
1
5
12
35 Nm
11 Nm
13
7
6
56 Nm
8
7EN1031
Removal steps
1. Air intake plenum stay, front
2. Air intake plenum stay, rear
3. Accelerator cable bracket
4. EGR valve
5. EGR valve gasket
6. EGR pipe
7. EGR pipe gasket
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Dec. 1996Mitsubishi Motors Corporation
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"AA
8. Connector bracket
9. Vacuum pipe
10. Throttle body
11. Throttle body gasket
12. Air intake plenum
13. Air intake plenum gasket
11A-4-2
Protrusion
6G7 ENGINE (E-W) -
INSTALLATION SERVICE POINTS
"AA
(1) Install gasket with protrusion as illustrated.
6AE0277
THROTTLE BODY GASKET
Air Intake Plenum
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Dec. 1996Mitsubishi Motors Corporation
PWEE9615
6G7 ENGINE (E-W) -
5. IGNITION SYSTEM
REMOVAL AND INSTALLATION
Ignition System
23 Nm
11A-5-1
1
3
25 Nm
2
4
1
7EN0965
Removal steps
1. Spark plug cable
2. Spark plug
3. Distributor
4. O-ring
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Dec. 1996Mitsubishi Motors Corporation
PWEE9615
6G7 ENGINE (E-W) -
6. TIMING BELT
REMOVAL AND INSTALLATION
Timing Belt
11A-6-1
23Nm
44 Nm
48 Nm
23 Nm
21
22
20
19
88 Nm
7
13 Nm
6
10
9
14
12
16
17
44 Nm
11
13
18
8
15
1
44 Nm
"DA
AA""CA
"BA
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11 Nm
13 Nm
11 Nm
4
Removal steps
1. Timing belt front upper cover, rear
2. Timing belt front upper cover, front
3. Timing belt front lower cover
4. Engine support bracket
5. Crank angle sensor
6. Timing belt
7. Automatic tensioner
8. Tensioner pulley
9. Tensioner arm
10. Shaft
11. Idler pulley
Dec. 1996Mitsubishi Motors Corporation
2
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3
AB""AA
5
9Nm
7EN0862
12. Idler pulley adjusting bracket
13. Adjusting bolt
14. Adjusting stud
15. Crankshaft sprocket
16. Sensing blade
17. Crankshaft spacer
18. Crankshaft key
19. Camshaft sprocket bolt
20. Camshaft sprocket
21. Bracket
22. Timing belt rear cover
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