Mitsubishi Engine 6G7 Workshop Manual

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MITSUBISHI

ENGINE

6G7 SERIES

WORKSHOP MANUAL

FOREWORD

This Workshop Manual contains procedures for removal, disassembly, inspection, adjustment, reassembly and installation, etc. for service mechanics.

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

FILING INSTRUCTION

Please keep these manual pages in the binder No. BN940001. File these pages according to the signs “Added”, “Revised” and “Deleted” on the “List of effective pages” which are interpreted below. Added: File the pages with this sign addition-

ally in your manual.

Revised. Deleted: Replace the existing pages

with the corresponding pages with this sign.

Missing sheets will be supplied upon request.

Engine <Up to 2001>

Engine <From 2002>

11A

11B

Mitsubishi Motors Corporation

Aug. 2001

Pub. No. PWEE9061-I

Page 2

Denotes tightening torque NOTE:

11A: Torque may also be shown

in rectangles in the order of units (Nm, kgm and ft-lbs. from left) as follows.

11B: Torque values are given

only in SI unit.

33 3.3 23

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Denotes service point for removal or disassembly.

NOTE: cAd is used in 11A.

AA" is used in 11B.

Denotes service point for installation or disassembly.

NOTE: DAC is used in 11A. "AA is used in 11B.

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PWEE9061-I

Missing sheets will be supplied upon request.

11A-0-1 I Aug. 2001 Revised

11A-0-3 D Aug. 1994 11A-0-4 Oct. 1990 11A-0-5 D Aug. 1994 11A-0-6 Oct. 1990 11A-0-6a and 11A-0-6b D Aug. 1994 11A-0-7 and 11A-0-8 C Dec. 1993 11A-0-9 and 11A-0-10 A Sept. 1992 11A-0-11 C Dec. 1993 11A-0-12 A Sept. 1992 11A-0-13 to 11A-0-16 C Dec. 1993 11A-1-1 to 11A-1-4 F Aug. 1997 11A-1-5 H Mar. 2000 11A-1-6 E Nov. 1995 11A-1-7 and 11A-1-8 H Mar. 2000 11A-1-9 E Nov. 1995 11A-1-10 H Mar. 2000 11A-1-11 D Aug. 1994 11A-1-12 G May 1999 11A-1-13 to 11A-1-20 H Mar. 2000 11A-2-1 E Nov. 1995 11A-2-2 to 11A-2-4 D Aug. 1994 11A-3-1 to 11A-3-6 D Aug. 1994 11A-3a-1 to 11A-3a-3 H Mar. 2000 11A-3b-1 H Mar. 2000 11A-3c-1 H Mar. 2000 11A-4-1 and 11A-4-2 Oct. 1990 11A-4-3 D Aug. 1994 11A-4-4 Oct. 1990 11A-4-5 D Aug. 1994 11A-4a-1 D Aug. 1994 11A-4a-2 G May 1999 11A-4a-3 H Mar. 2000 11A-4a-4 F Aug. 1997 11A-4b-1 and 11A-4b-2 H Mar. 2000 11A-5-1 and 11A-5-2 D Aug. 1994 11A-5-3 to 11A-5-13 H Mar. 2000 11A-6-1 H Mar. 2000 11A-6-2 C Dec. 1993 11A-6-3 to 11A-6-13 H Mar. 2000 11A-6a-1 and 11A-6a-2 D Aug. 1994 11A-6a-3 and 11A-6a-4 H Mar. 2000 11A-6a-4a and 11A-6a-4b H Mar. 2000 11A-6a-5 and 11A-6a-6 D Aug. 1994

11A-6b-1 and 11A-6b-2 H Mar. 2000 11A-6c-1 to 11A-6c-4 H Mar. 2000 11A-7-1 and 11A-7-2 D Aug. 1994 11A-7-3 to 11A-7-6 C Dec. 1993 11A-7-7 D Aug. 1994 11A-7-8 H Mar. 2000 11A-7-8a and 11A-7-8b H Mar. 2000 11A-7-9 and 11A-7-10 D Aug. 1994 11A-7a-1 and 11A-7a-2 A Sept. 1992 11A-8-1 and 11A-8-2 D Aug. 1994 11A-8-3 to 11A-8-5 H Mar. 2000 11A-8-6 to 11A-8-8 D Aug. 1994 11A-8-9 E Nov. 1995 11A-9-1 to 11A-9-4 C Dec. 1993 11A-9a-1 to 11A-9a-5 H Mar. 2000 11A-10-1 D Aug. 1994 11A-10-2 A Sept. 1992 11A-10-3 Oct. 1990 11A-11-1 A Sept. 1992 11A-11-2 D Aug. 1994 11A-11-3 to 11A-11-8 E Nov. 1995 11A-12-1 to 11A-12-9 H Mar. 2000 11A-13-1 to 11A-13-3 E Nov. 1995 11A-13-4 D Aug. 1994 11A-13-4a and 11A-13-4b D Aug. 1994 11A-13-4c G May 1999 11A-13-4d H Mar. 2000 11A-13-5 D Aug. 1994 11A-13-6 H Mar. 2000 11A-13-6a and 11A-13-6b H Mar. 2000 11A-13-7 G May 1999 11A-13-8 to 11A-13-12 D Aug. 1994 11A-13-13 and 11A-13-14 H Mar. 2000 11A-14-1 C Dec. 1993 11A-14-1a C Dec. 1993 11A-14-1b H Mar. 2000 11A-14-2 A Sept. 1992 11A-14-3 H Mar. 2000 11A-14-4 C Dec. 1993 11A-14-5 B Dec. 1992 11A-14-6 to 11A-14-10 H Mar. 2000 11A-15-1 to 11A-15-9 H Mar. 2000 11A-16-1 H Mar. 2000 11A-16-2 C Dec. 1993

Page Revision Date Remarks Page Revision Date Remarks

code code

List of Effective Pages

Page 5

PWEE9061-I

Missing sheets will be supplied upon request.

11A-16-3 E Nov. 1995

11B-0-1 to 11B-0-4 I Aug. 2001 Added 11B-1-1 to 11B-1-10 I Aug. 2001 Added 11B-2-1 to 11B-2-3 I Aug. 2001 Added 11B-3-1 to 11B-3-4 I Aug. 2001 Added 11B-4-1 to 11B-4-4 I Aug. 2001 Added 11B-5-1 to 11B-5-5 I Aug. 2001 Added 11B-6-1 to 11B-6-17 I Aug. 2001 Added 11B-7-1 to 11B-7-6 I Aug. 2001 Added 11B-8-1 to 11B-8-6 I Aug. 2001 Added 11B-9-1 to 11B-9-4 I Aug. 2001 Added 11B-10-1 to 11B-10-9 I Aug. 2001 Added 11B-11-1 to 11B-11-5 I Aug. 2001 Added 11B-12-1 to 11B-12-13 I Aug. 2001 Added 11B-13-1 to 11B-13-10 I Aug. 2001 Added 11B-14-1 to 11B-14-14 I Aug. 2001 Added 11B-15-1 to 11B-15-10 I Aug. 2001 Added

Page Revision Date Remarks Page Revision Date Remarks

code code

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11A-0-1

ENGINE

6G7 SERIES

CONTENTS

GENERAL INFORMATION 11A- 0- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. SPECIFICATIONS 11A- 1- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS 11A- 1- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATIONS 11A- 1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 11A- 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEALANT 11A- 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. SPECIAL TOOLS 11A- 2- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. COOLING FAN AND DRIVE BELT 11A- 3- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3a. COOLING FAN AND ALTERNATOR (2001 MODEL PAJERO) 11A-3a- 1. . . . . . . . . . . . . . .

3b. VACCUM TANK AND HOSE (GDI) 11A-3b- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3c. EGR SYSTEM (GDI) 11A-3c- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. INTAKE MANIFOLD 11A- 4- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4a. AIR INTAKE PLENUM (6G74) 11A-4a- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4b. INTAKE SYSTEM, IGNITION SYSTEM (GDI) 11A-4b- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. TIMING BELT (TWO-CAMSHAFT ENGINE) 11A- 5- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. TIMING BELT (FOUR-CAMSHAFT ENGINE) 11A- 6- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6a. INTAKE MANIFOLD (6G74) 11A-6a- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6b. WATER HOSE, WATER PIPE (GDI) 11A-6b- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6c. FUEL SYSTEM (GDI) 11A-6c- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. EXHAUST MANIFOLD 11A- 7- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7a. TURBOCHARGER 11A-7a- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. ROCKER ARMS AND CAMSHAFTS (TWO-CAMSHAFT ENGINE) 11A- 8- 1. . . . . . .

9. CAMSHAFTS, ROCKER ARMS AND BEARING CAPS

(FOUR-CAMSHAFT ENGINE) 11A- 9- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9a. ROCKER ARMS, CAMSHAFTS (GDI) 11A-9a- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. ROCKER ARMS AND ROCKER SHAFTS

(TWO-CAMSHAFT ENGINE) 11A-10- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. CYLINDER HEAD AND VALVE (TWO-CAMSHAFT ENGINE) 11A-11- 1. . . . . . . . . . . . . . . .

12. CYLINDER HEAD AND VALVE (FOUR-CAMSHAFT ENGINE) 11A-12- 1. . . . . . . . . . . . . .

13. OIL PAN AND OIL PUMP 11A-13- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. PISTON AND CONNECTING ROD 11A-14- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-15- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16. CYLINDER BLOCK 11A-16- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RevisedPWEE9061-I Mitsubishi Motors Corporation

Aug. 2001

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