Mitsubishi Engine 6G7 (E-W) Workshop Manual

MITSUBISHI

6G7 SERIES (E–W)

WORKSHOP MANUAL

FOREWORD

ENGINE

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. BN890001.

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 additionally in
your manual.

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11A

Revised, Deleted:

Replace the existing pages with the
corresponding pages with this sign.

Missing sheets will be supplied upon request.

E Mitsubishi Motors Corporation Apr. 2001

Pub. No. PWEE9615-A

INTRODUCTION

EXPLANATION OF MANUAL CONTENTS

Maintenance and Servicing Procedures

(1) A diagram of the component parts is

provided near the front of each section in
order to give the reader a better under­standing of the installed condition of
component parts.

(2) The numbers provided within the diagram

indicate the sequence for maintenance and
servicing procedures.

: Indicates a non-reusable part.
The tightening torque is provided where
applicable.

Classification of Major Maintenance/Service Points

When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan­dard values, information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points and explained in
detail.

AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.

D Removal steps:

The part designation number corresponds
to the number in the illustration to indicate
removal steps.

D Disassembly steps:

The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.

D Installation steps:

Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.

D Reassembly steps:

Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for
lubrication and for application of sealants
and adhesives is provided, by using sym­bols, in the diagram of component parts, or
on the page following the component parts
page, and explained.

E

Dec. 1996Mitsubishi Motors Corporation

: Grease (multipurpose grease unless

there is a brand or type specified)

: Sealant or adhesive

: Brake fluid, automatic transmission fluid

or air conditioner compressor oil

: Engine oil or gear oil

PWEE9615

INTRODUCTION

Indicates the
group title.

Indicates the
section title.

6G7 ENGINE (E-W) -

7. INTAKE MANIFOLD

REMOVAL AND INSTALLATION

21 Nm

14

9Nm

1

11

10

11 Nm

12

6

Indicates the
group number.

Indicates the
section num-

Indicates the
page number.

ber.

Intake Manifold

17

2

9Nm

4

5

21

8

9

7

3

13

14

31

22

27

13 Nm

29

30

18 Nm

19

20

18 Nm

24

18

26

18 Nm

18 Nm

28

11A-7-1

Denotes non-reusable part.

23

18 Nm

25

Denotes tightening

11 Nm

15

29 Nm

16

torque.

Removal Procedure

1. Engine harness

2. Injector and delivery pipe

3. Insulator

4. Fuel pressure regulator

"HA

5. O-ring

6. Insulator

7. Injector

"GA

8. O-ring

9. Grommet

10. Fuel pipe

11. O-ring

12. Delivery pipe

13. Intake manifold

"FA

14. Intake manifold gasket

15. Engine coolant temperature gauge

"EA

unit

Water pump

Water inlet pipe

E

Mitsubishi Motors Corporation Dec. 1996 PWEE9615

O-ring

6DN0594

7EN0874

16. Engine coolant temperature sensor

"DA

17. Water hose

18. Water hose

19. Heater inlet pipe

"CA

20. O-ring

"AA

21. Heater inlet pipe

"CA

22. O-ring

"AA

23. Water outlet fitting

24. Water outlet fitting gasket

25. Water inlet fitting

26. Thermostat

"BA

27. Thermostat housing

28. Thermostat housing gasket

29. O-ring

"AA

30. Water pipe

31. O-ring

"AA

INSTALLATION SERVICE POINTS

"AA

O-RING/WATER PIPE

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

Caution

D

Keep the O-ring of oil or grease.

This number corresponds to
the number appearing in
“Removal steps”,
“Disassembly steps”,
“Installation steps” or
“Reassembly steps”.

Operating procedures, cau­tions, etc. on removal, installa­tion, disassembly and reas­sembly are described.

Issue date

E

Dec. 1996Mitsubishi Motors Corporation

Publication number-Revision code

PWEE9615

LIST OF EFFECTIVE PAGES

Page Revision

Code

1 1A-0-1 and 11A-0-2 Dec. 1996

11A-0-3 A Apr. 2001 Revised

11A-1-1 Dec. 1996

11A-1-2 to 11A-1-5 A Apr. 2001 Revised

11A-1-6 Dec. 1996
1 1A-2-1 and 11A-2-2 Dec. 1996

11A-3-1 and 11A-3-2 A Apr. 2001 Revised
11A-4-1 A Apr. 2001 Revised

11A-4-2 Dec. 1996
11A-5-1 Dec. 1996

11A-6-1 A Apr. 2001 Revised

11A-6-2 Dec. 1996

11A-6-3 to 11A-6-6 A Apr. 2001 Revised
11A-7-1 A Apr. 2001 Revised

1 1A-7-2 and 11A-7-3 Dec. 1996
1 1A-8-1 and 11A-8-2 Dec. 1996
1 1A-9-1 to 11A-9-4 Dec. 1996

11A-10-1 A Apr. 2001 Revised

1 1A-10-2 to 11A-10-6 Dec. 1996

Date Remarks Page Revision

Code

Date Remarks

11A-10-7 A Apr. 2001 Added

1 1A-11-1 to 11A-11-4 Dec. 1996

11A-11-5 A Apr. 2001 Revised
11A-11-6 A Apr. 2001 Added
11A-12-1 A Apr. 2001 Revised
11A-12-1a and 11A-12-1b A Apr. 2001 Added

11A-12-2 Dec. 1996

11A-12-3 A Apr. 2001 Revised

11A-12-4 Dec. 1996

11A-12-5 A Apr. 2001 Revised
11A-12-5a and 11A-12-5b A Apr. 2001 Added
11A-12-6 A Apr. 2001 Revised
11A-12-7 A Apr. 2001 Added
11A-13-1 and 11A-13-2 A Apr. 2001 Revised

11A-13-3 Dec. 1996

11A-13-4 A Apr. 2001 Revised
11A-13-4a and 11A-13-4b A Apr. 2001 Added
11A-13-5 and 11A-13-6 A Apr. 2001 Revised

Missing sheets will be supplied upon request.

E

Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

E

Dec. 1996Mitsubishi Motors Corporation

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

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

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

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

PWEE9615

11A-0-2

NOTES

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E–W) – General Information

GENERAL INFORMATION

GENERAL SPECIFICATIONS

11A-0-3

Descriptions
Type 60° OHV, SOHC
Number of cylinders 6
Combustion chamber Compact type
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°

Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
Cooling system Water-cooled forced circulation

3

Closes (ABDC) 53°

Exhaust valve Opens (BBDC) 53°

Closes (ATDC) 15°

6G72

2.972

Water pump type Centrifugal impeller type

Descriptions 6G74

Type 60° OHV, SOHC
Number of cylinders 6
Combustion chamber Pentroof type
Total displacement dm
Cylinder bore mm 93.0
Piston stroke mm 85.5
Compression ratio 9.0
V alve timing Intake valve Opens (BTDC) 15°

Lubrication system Pressure feed, full-flow filtration

3

Closes (ABDC) 49°

Exhaust valve Opens (BBDC) 45°

Closes (ATDC) 19°

3.497

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

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

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 -

Valve 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

Valve stem outside diameter mm

Valve thickness to valve guide clearance mm

Valve face angle mm 45_ - 45.5_ -

Valve spring free length mm 51.0 50.0

Valve spring load/installed height N/mm 267/44.2 -

Valve 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 -

Valve guide projection from cylinder head upper surface mm 14 -

Valve stem projection mm 49.3 49.8

Oil pan and oil pump

Oil pump tip clearance mm 0.06 - 0.18 -

E

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

il

Items Standard Limit
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 No. 1 0.30 – 0.45 0.8

Piston pin outside diameter mm 22.0 –
Piston pin press-in load N (at 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 – 0.04 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. 2 0.45 – 0.60 0.8
Oil ring side

ra

6G72 0.20 – 0.60 1.0
6G74 0.10 – 0.35 1.0

Cylinder block flatness of gasket surface mm 0.05 0.1

Cylinder block grinding limit on 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 6G72 91.1 –

6G74 93.0 –

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 –

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

6G7 ENGINE (E–W) – Specifications

TORQUE SPECIFICATIONS

Items Nm

Alternator

Drive belt tensioner pulley nut 49
Crankshaft bolt 185 ± 5
Alternator pivot nut 44
Alternator bolt M8 21
Alternator bolt M10 48
Oil level gauge guide bolt 22

Air intake plenum

Air intake plenum stay bolt M8 17
Air intake plenum stay bolt M10 36
Accelerator cable bracket 9

11A-1-3

Bracket 10
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 45
Crankshaft angle sensor bolt 8
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

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-1-4

Items Nm

Intake manifold

Engine coolant temperature gauge unit 10
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 20
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
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 ± 5

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
Oil pan upper bolt 5.9

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

6G7 ENGINE (E–W) – Specifications

Items Nm
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 6G72 49

6G74 34 + 90°

Crankshaft, flywheel and drive plate

Flywheel bolt 74
Drive plate bolt 74

11A-1-5

Rear plate bolt 11
Oil seal case bolt 11
Bearing cap bolt 6G72 89

6G74 71

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

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

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 the 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 the procedure described in the

text when applying the FIPG.

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

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

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

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

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

Installation of camshaft oil seal

6G7 ENGINE (E–W) – Alternator

3. ALTERNATOR

REMOVAL AND INSTALLATION

185 ± 5 Nm

11A-3-1

7

8

9

2

AA""AA 2. Crankshaft bolt

3

"AA 3. Washer
"AA 4. Crankshaft pulley

4

Removal steps

1. Tensioner pulley

5. Alternator

49 Nm

10

22 Nm

21 Nm

48 Nm44 Nm

6

1

5

7EN1596

6. Alternator bracket

7. Dipstick

8. O-ring

9. Dipstick tube

10. O-ring

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-3-2

6G7 ENGINE (E–W) – Alternator

Crankshaft bolt

Washer

MD998781

Crankshaft pulley

Clean

Degrease

MD998781

7EN0856

Crankshaft

7EN1601

REMOVAL SERVICE POINTS

AA" CRANKSHAFT BOLT

(1) With the Special Tool fixed to the drive plate or flywheel,

remove the crankshaft bolt.

INSTALLATION SERVICE POINTS

"AA CRANKSHAFT BOLT / WASHER / CRANKSHAFT

PULLEY

(1) Clean and degrease the crankshaft sprocket fitting surface

of the crankshaft pulley, then install the crankshaft pulley
on the crankshaft.

(2) Clean the threaded hole in the crankshaft, the crankshaft

fitting surface of the crankshaft pulley, the washer fitting
surface of the crankshaft and both surfaces of the washer.

(3) Apply necessary minimum amount of engine oil on the

threads and washer fitting surface of the crankshaft bolt.

(4) With the Special Tool fixed to the drive plate or flywheel,

install the crankshaft bolt.

7EN0856

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

6G7 ENGINE (E–W) – Air Intake Plenum

4. AIR INTAKE PLENUM

REMOVAL AND INSTALLATION

11A-4-1

21 Nm

17 Nm

11 N m

11

12

17 Nm

17 Nm

9 Nm

17 Nm

4

5

2

3

10

9

13

14

36 Nm

1

10 Nm

15

17 Nm

Removal steps

1. Air intake plenum stay, front

2. Air intake plenum stay, rear

3. Throttle cable bracket

4. EGR valve

5. EGR valve gasket

6. EGR pipe

7. EGR pipe gasket

8. Connector bracket

6

56 Nm

7

8

7EN1597

9. Throttle cable clamp

10. Solenoid valve

11. Vacuum pipe

12. Throttle body

"AA 13. Throttle body gasket

14. Air intake plenum

15. Air intake plenum gasket

E

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

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

E

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

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E–W) – Timing Belt

6. TIMING BELT

REMOVAL AND INSTALLATION

11A-6-1

23 Nm

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

45 Nm

E 4. Engine support bracket

AD 6. Timing belt

C 7. Automatic tensioner



11 N m

13 Nm

Removal steps

1. Timing belt front upper cover, rear

2. Timing belt front upper cover, front

3. Timing belt front lower cover

5. Crank angle sensor

8. Tensioner pulley

9. Tensioner arm

10. Shaft

11. Idler pulley

2

8 Nm

11 N m

5

3

7EN0862

4

12. Idler pulley adjusting bracket

13. Adjusting bolt

14. Adjusting stud

B 15. Crankshaft sprocket
B 16. Sensing blade
B 17. Crankshaft spacer

18. Crankshaft key

BA 19. Camshaft sprocket bolt

20. Camshaft sprocket

21. Bracket

22. Timing belt rear cover

Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-6-2

MB990767

6G7 ENGINE (E-W) -

MD998715

7EN0145

Timing Belt

REMOVAL SERVICE POINTS

AA"

(1) When the timing belt is to be reused, in order to allow

AB"

(1) Using the Special Tool, hold the camshaft sprocket.
(2) Remove the camshaft sprocket bolt.

TIMING BELT

re-installation of the belt so that it travels in the same
direction as before it was removed, mark the direction
of travel with an arrow before removing it.

Caution

D

As water or oil on the belt can seriously reduce
itsusablelife, ensurethatthetimingbelt,sprocket,
and tensioner stay clean and dry while removed,
and never wash them. Parts that have become
too dirty should be replaced.

D

Whenany ofthepartsareoily,checktoseewhether
there are any oil leaks in any of the oil seals or
the camshaft oil seal on the front of the engine.

CAMSHAFT SPROCKET BOLT

Peeling

Cracks

7EN0005

8EN0066

Cracks

Cracks

1EN0249

INSPECTION

TIMING BELT

Check the belt in detail. If the following is evident, replace
the belt.
(1) Hardened back surface rubber.

Back surface glossy, non-elastic and so hard that even
if a finger nail is forced into it, no mark is produced.

(2) Cracked back surface rubber.
(3) Cracked or separated canvas.
(4) Cracked tooth bottom.
(5) Cracked side of belt.

(6) Side of belt badly worn.

NOTE

Rounded edge

Normal belt should have clear-cut sides as if cut with
a sharp knife.

Abnormal wear
(Fluffy strand)

8EN0067

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

Rubber exposed

Tooth missing
and canvas fiber
exposed

“L”

6G7 ENGINE (E–W) – Timing Belt

(7) Badly worn teeth.

Initial stage:
Canvas is worn (fluffy canvas fibres are visible, rubber
is gone and colour has changed to white. Canvas texture
is not clear).
Last stage:
Canvas is worn out and rubber exposed and its width
is reduced.

(8) Missing tooth.

8EN0068

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

11A-6-3

98 – 196 N

MB990767

Stroke

MD998715

6AE0046

(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 “L”: 1 mm or less

6EN1033

INSTALLATION SERVICE POINTS

A CAMSHAFT SPROCKET BOLT

(1) Using the Special Tool, hold the camshaft sprocket.
(2) Torque the camshaft sprocket bolt to the specified torque.

7EN0005

Crankshaft
sprocket

Clean



Crankshaft
sensing blade

Crankshaft
spacer

Degrease

Crankshaft

Oil pump casing

7EN1600

Apr. 2001Mitsubishi Motors Corporation

B CRANKSHAFT SPROCKET / CRANKSHAFT

SENSING BLADE / CRANKSHAFT SPACER

(1) Wipe clean the crankshaft fitting surface of the crankshaft

sprocket.

(2) Clean and degrease the crankshaft sprocket, the

crankshaft sprocket fitting surface of the crankshaft, the
sensing blade and the crankshaft spacer. Then, install
the crankshaft sprocket, crankshaft sensing blade and
crankshaft spacer on the crankshaft.

RevisedPWEE9615-A

11A-6-4

6G7 ENGINE (E–W) – Timing Belt

C AUTO-TENSIONER

(1) If the auto-tensioner rod is fully extended, set it in the

retracted position by the following procedure.

1 Set the auto-tensioner in a vice, making sure it is

not tilted.

7EN0225

A

B

Timing mark

Crankshaft sprocket

Right bank Left bank

Timing mark

2 Slowly close the vice to force the rod in until the set

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

3 Insert a metal wire (1.4 mm in diameter) into the set

holes.

4 Remove the auto-tensioner from the vice.

(2) Install the auto tensioner on the cylinder block through

the oil pump case.

7EN0227

D TIMING BELT

(1) Turn the crankshaft sprocket to position its timing mark

3 teeth away from the timing mark on the crankcase. (That
is, slightly lower the No. 1 piston from the top dead centre
on the compression stroke.)

Caution
 If the camshaft sprocket is turned with the piston

at the top dead centre on the compression stroke,
valves may interfere with the piston.

7EN0741

(2) Align the timing marks for the left bank camshaft sprocket.
(3) Align the timing marks for the right bank camshaft sprocket.

Crankshaft sprocket



Crankshaft sprocket

Timing mark

Apr. 2001Mitsubishi Motors Corporation

7EN0742

7EN0740

Caution
 The camshaft sprocket may turn unintentionally

due to the valve spring tension. Take care not
to injure your fingers.

(4) Align timing marks for the crankshaft sprocket.
(5) Install the timing belt over the sprockets in the following

sequence.

1 Place the timing belt over the crankshaft. While

applying tension to the belt, set it over the idler pulley.

2 Place the belt over the left bank camshaft sprocket.
3 While applying tension to the belt, place it over the

water pump pulley.

4 Place the belt over the right bank camshaft sprocket.
5 Place the belt over the tensioner pulley.

RevisedPWEE9615-A

6G7 ENGINE (E–W) – Timing Belt

11A-6-5

Tensioner pulley

MD998769

(6) While pressing the tensioner pulley lightly against the

timing belt, temporarily tighten its centre bolt.

(7) Check that all timing marks are in alignment.

7EN0743

(8) Using the Special Tool, turn the crankshaft

counter-clockwise a quarter turn, then turn it clockwise
and align the timing marks. Make sure that all timing marks
are in alignment.

7EN0744

Right bank Left bank

Camshaft sprocket

Auto-tensioner

Timing mark

Water pump
pulley

Camshaft sprocket

T ensioner pulley

Idler pulley

Crankshaft sprocket



Apr. 2001Mitsubishi Motors Corporation

Timing mark

7EN0745

RevisedPWEE9615-A

11A-6-6

MB998767

6G7 ENGINE (E–W) – Timing Belt

(9) Set the Special Tool and a torque wrench on the tensioner

pulley.
(10)Torque the tensioner pulley to 4.4 Nm.
(11)While holding the tensioner pulley, tighten its centre bolt

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

for approx. 5 minutes.
(13)Remove the wire, which was inserted when installing the

tensioner, from the auto tensioner. If it can be removed

easily, the timing belt tension is correct. Make sure that

7EN0746

the auto tensioner rod projection is within specification.

Standard value: 3.8 – 5.0 mm

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

is not to specification, repeat steps 9 through 12 to obtain

the correct tension.

7EN0747

E ENGINE SUPPORT BRACKET

(1) Tighten bolts to specified torque in the sequence shown.

7EN0873



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

6G7 ENGINE (E–W) – Intake Manifold

7. INTAKE MANIFOLD

REMOVAL AND INSTALLATION

11A-7-1

17

20 Nm

9 Nm

14

11

10

1

11 N m

18 Nm

2

19

20

9 Nm

12

4

5

21

18

8

18 Nm

18 Nm

24
26

23

18 Nm

25

9

7

6

3

13 Nm

13

14

31

27

29

22

28

18 Nm

15

16

10 Nm

29 Nm

Removal steps

1. Engine harness

2. Injector and delivery pipe

3. Insulator

H 4. Fuel pressure regulator

5. O-ring

6. Insulator

G 7. Injector

8. O-ring

9. Grommet

10. Fuel pipe

11. O-ring

12. Delivery pipe

F 13. Intake manifold

14. Intake manifold gasket

E 15. Engine coolant temperature gauge

unit

30

7EN0874

D 16. Engine coolant temperature sensor

17. Water hose

18. Water hose

C 19. Heater inlet pipe
A 20. O-ring
C 21. Heater inlet pipe
A 22. O-ring

23. Water outlet fitting

24. Water outlet fitting gasket

25. Water inlet fitting

B 26. Thermostat

27. Thermostat housing

28. Thermostat housing gasket

A 29. O-ring

30. Water pipe

A 31. O-ring



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-7-2

6G7 ENGINE (E-W) -

Intake Manifold

Water pump

Water inlet pipe

Jiggle valve

Outlet pipe

O-ring

6EN0594

7EN0876

INSTALLATION SERVICE POINTS

"AA

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

"BA

(1) Install the thermostat in the thermostat case with its jiggle

"CA

(1) Attach the outlet and inlet pipes in this order, one on the

O-RING / WATER PIPE

Caution

D

Keep the O-ring of oil or grease.

THERMOSTAT

valve located at the top position.

HEATER INLET AND OUTLET PIPES

top of the other.

Inlet pipe

Sealant

Surge tank stay

7EN0877

9EN0091

"DA

APPLICATION OF SEALANT TO ENGINE
COOLANT TEMPERATURE SENSOR

Specified sealant:

3M Nut Locking Part No. 4171 or equivalent

"EA

SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT

Specified sealant:

3M ATD Part No. 8660 or equivalent

1EN0338

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E-W) -

Intake Manifold

11A-7-3

Front

7IN0090

7FU0611

"FA

INTAKE MANIFOLD

(1) Tighten the nuts on the right bank to 5 - 8 Nm.
(2) Tighten the nuts on the left bank to the specified torque.

Then tighten the nuts on right bank to the specified torque.

(3) Tighten the nuts on the left bank and those on the right

bank again in that order.

"GA

INJECTOR

(1) Apply a small amount of engine oil to the O-ring.

Caution

D

Take care to prevent the engine oil from entering
the delivery pipe.

(2) Install the injector into the delivery pipe and turn it right

and left.

(3) Make sure the injector turns smoothly. If not, the O-ring

may be caught. Remove the injector and check for damage
to the O-ring, then re-insert it and confirm that it turns
smoothly.

(4) When installing the injector, set the delivery pipe setting

mark and the injector projecting portion.

Setting
mark

Projection portion

6AE0062

"HA

FUEL PRESSURE REGULATOR

(1) Apply a small amount of new engine oil to the O-ring,

then insert the fuel pressure regulator into the delivery
pipe, taking care not to damage the O-ring.

Caution

D

Take care to prevent engine oil from entering the
delivery pipe.

(2) Make sure the regulator turns smoothly. If not, the O-ring

may be caught. Remove the regulator and check for
damage to the O-ring, then re-insert it into the delivery
pipe and confirm that it turns smoothly.

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E-W) -

Exhaust Manifold & Water Pump

8. EXHAUST MANIFOLD & WATER PUMP

REMOVAL AND INSTALLATION

13 Nm

1

3

2

49 Nm

5

11A-8-1

13 Nm

35 Nm

4

41 Nm

23 Nm

Removal steps

1. Heat protector, rear

2. Exhaust manifold, rear

"BA

3. Exhaust manifold gasket, rear

4. Heat protector, front

5. Engine lift bracket

9

7

6

8

"BA
"AA

49 Nm

7EN0966

6. Exhaust manifold, front

7. Exhaust manifold gasket, front

8. Water pump

9. Water pump gasket

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

11A-8-2

6G7 ENGINE (E-W) -

Exhaust Manifold & Water Pump

Water pump

Water inlet pipe

For right bank

1 3 5

Front

Cylinder No.

O-ring

6EN0594

71N0010

INSTALLATION SERVICE POINTS

"AA

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

"BA

(1) Install gaskets with number

(2) Torque the nuts to 30 Nm.

O-RING / WATER PIPE

Caution

D

Keep the O-ring free of oil grease.

EXHAUST MANIFOLD GASKET

1, 3 and 5 embossed on their

top side to the right bank (exhaust manifold (B) side) and
install those with number
manifold (A) side).

2, 4and 6 to the left bank (exhaust

Front

For left bank

Cylinder No.

7EN0593

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E-W) -

Rocker Arms and Camshaft

9. ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION

11A-9-1

3.4 Nm

2

5

3

11

1

31 Nm

6

10

9

8

9

8

9

8

7

7

7

12

12

13

12 Nm

12

14

15

16

4

Removal steps

1. Rocker cover

2. Gasket

3. Oil seal

"EA 4. Oil seal
AA" 5. Rocker arms, Rocker arm shaft
AA" 6. Rocker arms, Rocker arm shaft

"DA 7. Rocker shaft spring

8. Rocker arm “A”

9. Rocker arm “B”

17

Apply engine oil to all
moving parts before
installation.

7EN0879

"CA 10. Rocker arm shaft
"BA 11. Lash adjuster

12. Rocker arm “C”

"CA 13. Rocker arm shaft
"BA 14. Lash adjuster

15. Thrust case (left bank)

16. O-ring (left bank)

"AA 17. Camshaft

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

11A-9-2

6G7 ENGINE (E-W) -

MD998443

6AE0160

9EN0058

Rocker Arms and Camshaft

REMOVAL SERVICE POINTS

AA"

(1) Before removing the rocker arms and rocker arm shafts,

LASH ADJUSTER

install the Special Tools to prevent the lash adjusters from
falling off.

INSPECTION

CAMSHAFT

(1) Measure the cam height.

Standard value:

IN: 37.71 mm
EX: 37.14 mm

Limit:

IN: 37.21 mm
EX: 36.64 mm

Diesel fuel

MD998440

7EN0721

Graduation
(1 mm)

LASH ADJUSTER LEAK DOWN TEST

Caution

D

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

D

Do not disassemble lash adjuster.
When cleaning lash adjuster, use clean diesel fuel
only.

(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 and
test again if the plunger is still loose, replace the lash
adjuster.

Caution

D

Uponcompletion ofair 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 between 0.20 to 0.50 mm,

measure time taken for it to go down a further 1 mm.
Replace if measured time is out of specification.

Standard value: 4 - 20 seconds/1 mm
<Diesel fuel at 15 - 20_C>

Lash adjuster

E

Dec. 1996Mitsubishi Motors Corporation

8EN0059

PWEE9615

6G7 ENGINE (E-W) -

INSTALLATION SERVICE POINTS

"AA

(1) Before attaching the camshafts, apply engine oil to the

Slot

7EN0708

Rocker Arms and Camshaft

11A-9-3

CAMSHAFT

journals and cams.
Take care not to confuse the right bank and left bank
camshafts.

NOTE
The right bank camshaft has 4-mm-wide slits in the rear
end surface.

Right bank Left bank

Approx
60

_

MD998442

Approx
71

_

MD998443

7EN0709

7EN0721

(2) Make sure the camshaft dowel pin is at the location shown.

"BA

LASH ADJUSTER

(1) Immerse the lash adjuster in clean diesel fuel No. 2.
(2) While pushing down the inside steel ball with the special

air bleeding wire tool, move the plunger up and down
four or five times to evacuate air from the lash adjuster.

(3) Taking care not to spill the diesel fuel, install the lash

adjuster into the rocker arm and attach a special tool to
prevent it from falling out.

Lash adjuster

Timing belt side

Chamfered

E

Oil hole

7EN0722

"CA

ROCKER ARM SHAFT

(1) The end with the larger chamfer is at the right on the

front bank and at the left on the rear bank.

NOTE
The side with the four bolt holes is on the intake side.

(2) The side with the oil holes is on the lower side (cylinder

head side).

9EN0511

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

11A-9-4

6G7 ENGINE (E-W) -

Rocker Arms and Camshaft

Rocker shaft
spring

MD998713

7EN0723

6AE0164

"DA

ROCKER SHAFT SPRING

(1) Insert the rocker shaft spring at a slant with respect to

the spark plug guide and install it normal to the guide.

"EA

OIL SEAL

Left bank side

MD998713

MB991559

7EN0724

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E–W) – Cylinder Head and Valves

10. CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION

Apply engine oil to all
moving parts before
installation.

11A-10-1

108 ± 5 Nm

1

2

12

21

22

13

17

6

5

7

14

11

16

3

9

10

15

18

19

20

8

Removal steps

AD 1. Cylinder head bolt

2. Washer

3. Cylinder head assembly

4. Cylinder head gasket

BC 5. Retainer lock

6. Valve spring retainer

B 7. Valve spring

8. Intake valve

BC 9. Retainer lock

10. Valve spring retainer

B 11. Valve spring



Apr. 2001Mitsubishi Motors Corporation

4

7EN0915

12. Exhaust valve

CA 13. Valve stem seal

14. Valve spring seat

CA 15. Valve stem seal

16. Valve spring seat

17. Intake valve guide

18. Snap ring

19. Exhaust valve guide

20. Intake valve seat

21. Exhaust valve seat

22. Cylinder head

RevisedPWEE9615-A

11A-10-2

MD998051

6G7 ENGINE (E-W) -

REMOVAL SERVICE POINTS

AA"

6AE0166

Cylinder Head and Valves

CYLINDER HEAD BOLT

MD998735

7EN0892

MD998772

6AE0167

AB"

RETAINER LOCK

(1) Attach a tag with the cylinder No. and mounting location

to the detached valves, springs and other parts and store
them for reassembly.

AC"

VALVE STEM SEAL

Caution

D

Do not reuse the stem seal.

7EN0444

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E-W) -

INSPECTION

CYLINDER HEAD

(1) Check the cylinder head for water leaks, gas leaks, damage

(2) Completely remove oil, fur, sealer, carbon and the like.

(3) To ensure flatness of the cylinder head bottom surface,

7EN0258

Cylinder Head and Valves

11A-10-3

or cracks before washing it.

After washing the oil passages, blow air through them
to make sure they are not clogged.

measure the distortion of the surface using a straight edge
and a thickness gauge. When the distortion exceeds the
specifications, correct by grinding the surface.

Standard values of bottom surface distortion:

Within 0.03 mm

Limit: 0.2 mm
Grinding limit: 0.2 mm
Height of the cylinder head: 12 0 mm

Caution

D

The cylinder head bottom surface may be ground
to within 0.2 mm of the mating cylinder block.

Contact to be at
the centre of the
valve face.

2

_

Margin

6EN0542

VALVES

(1) When contact between the valve and the valve seat is

improper, unbalanced or nonexistent, correct the valve
seat.

(2) Change the valve when the margin doesn’t meet the

specifications.

Standard value: Intake 1.0 mm

Exhaust 1.2 mm

Limit: Intake 0.5 mm

Exhaust 0.7 mm

(3) Measure the total length of the valve. If the measured

value is below the limit, change the valve.

Standard value: Intake 112.30 mm

Exhaust 114.11 mm

Limit: Intake 111.80 mm

Exhaust 113.61 mm

VALVE SPRING

(1) Measure the free height of the valve spring. When the

measured value exceeds the specified limit, change the
valve spring.

Standard value: 51.0 mm
Limit: 50.0 mm

(2) Measure the perpendicularity of the valve spring. When

Free height

the measured value exceeds the specified limit, change
the valve spring.

Standard value: 2_max.

1EN0264

E

Dec. 1996Mitsubishi Motors Corporation

Limit: 4

PWEE9615

_

11A-10-4

6G7 ENGINE (E-W) -

Stem outside diameter

Cylinder Head and Valves

VALVE GUIDE

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

valve stem. When the clearance exceeds the specified
limit, change the valve guide or the valve or both.

Standard value: Intake 0.02 - 0.04 mm

Exhaust 0.04 - 0.06 mm

Limit: Intake 0.10 mm

Exhaust 0.15 mm

Guide inside diameter

65

_

15

_

44

_

Valve stem
end

Valve
protrusion

Spring seat
surface

44

_

1EN0279

DEN0212

25

_

7EN0273

65

VALVE SEAT

(1) Assemble the valve, and with it pressed down on the

valve seat measure the part of the valve which protrudes
from the spring seat surface. The length measured should
be between the spring seat surface and the valve stem
end. If the measured value exceeds the limit, change the
valve.

Standard value: 49.3 mm
Limit: 49.8 mm

VALVE SEAT RECONDITIONING PROCEDURE

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

valve, and if necessary, change the valve guide before
correcting the valve seat.

_

(2) Correct so that the valve seat width and angle are as

specified in the figure at left.

(3) After making the corrections, apply lapping compound

and adjust the valve and valve seat.

E

0.5 - 1 mm

Cut off

Height of
valve seat

Oversize hole diameter

0.5 - 1 mm

Dec. 1996Mitsubishi Motors Corporation

1EN0274

1EN0275

VALVE SEAT REPLACEMENT PROCEDURE

(1) Cut off the inside of the valve seat to reduce its thickness

before pulling out the valve seat.

(2) Adjust the valve cylinder hole in the cylinder head to the

diameter of the oversize valve seat to be press fitted.

Intake valve seat hole diameter

0.30 O.S. 34.30 - 34.33 mm

0.60 O.S. 34.60 - 34.63 mm

Exhaust valve seat hole diameter

0.30 O.S. 31.80 - 31.83 mm

0.60 O.S. 32.10 - 32.13 mm

(3) When press fitting a valve seat, cool it using liquid nitrogen

so as not to gall the cylinder head inside diameter.
(4) Machine the valve seat.
(5) See “Valve seat reconditioning procedure.”

PWEE9615

14.0 mm

6G7 ENGINE (E-W) -

VALVE GUIDE REPLACEMENT PROCEDURE

(1) Remove the snap ring from the exhaust valve guide.
(2) Pull out to the cylinder block side using a press.
(3) Machine the valve guide hole in the cylinder head to match

7EN0726

(4) Press fit the valve guide until the projection is 14.0 mm,

Cylinder Head and Valves

11A-10-5

the oversize valve guide to be press fitted.

Caution

D

Do not press fit another valve guide of the same
size.

Diameter of the valve guide hole

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

as shown.

NOTE

D Press fit the valve guide from the top surface of the

cylinder head.

D Pay attention to the difference in the valve guide length

(45.5 mm for the intake side valve guide and 50.5
mm for the exhaust side valve guide).

D After press fitting the valve guide, insert a new valve

and check the contact between the valve guide and
the valve.

I.D. Colour
Silver or white

Intake side Exhaust side

MD998774

E

I.D. Colour
Black

Dec. 1996Mitsubishi Motors Corporation

7EN0763

6AE0169

INSTALLATION SERVICE POINTS

"AA

(1) Attach a valve spring seat.
(2) Attach a new stem seal to the valve guide with the Special

VALVE STEM SEAL

Tool.

NOTE

Pay attention to the difference between the intake side

and exhaust side valve stem seals.

Identifying colour at the valve stem seal portion

Intake side: Silver or white
Exhaust side: Black

Caution

D

Do not reuse valve stem seals.

D

Always use the Special Tool to install valve stem
seals. Improper installation will cause oil leaks.

PWEE9615

11A-10-6

6G7 ENGINE (E-W) -

Cylinder Head and Valves

Identification
colour

Spring
retainer

Stem seal

Spring seal

6EN0544

MD998735

7EN0892

"BA

VALVE SPRING

(1) Install the valve spring painted red side up.

"CA

VALVE RETAINER LOCK

(1) Using Special Tool install the valve retainer lock.

MD998772

6AE0167

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E–W) – Cylinder Head and Valves

11A-10-7

Washer

Cylinder head bolt

MD998051

TIMING BEL T SIDE

Round
shoulder

Cylinder
head

7EN1138

D WASHER / CYLINDER HEAD BOLT

(1) Fit the washer onto each cylinder head bolt with its round

edge toward the bolt head. Then install the cylinder head
bolts into the bolt holes.

(2) Tighten the cylinder head bolts to the specified torque

in the order shown in the illustration.
(3) Loosen all the cylinder head bolts.
(4) Retighten the cylinder head bolts to the specified torque

in the order shown in the illustration.

7EN1352



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

6G7 ENGINE (E-W) -

11. OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

Apply engine oil to all
moving parts before
installation.

22

18

21

Oil Pan and Oil Pump

20

11A-11-1

13

13 Nm

3

41 Nm

23 Nm

2

17

23 Nm

9.8 Nm

9.8 Nm

16

19

18 Nm

12

11

15

4

1

14

9.8 Nm

39 Nm

44 Nm
11 Nm

9

5

10

9.8 Nm

8

7

11 Nm

5.9 Nm

6

11 Nm

Removal steps

"GA 1. Oil pressure switch
"FA 2. Oil filter

3. Oil filter bracket

4. Oil filter bracket gasket

5. Drain plug

6. Drain plug gasket

AA""EA 7. Oil pan, lower

8. Cover

AB""DA 9. Oil pan, upper

10. Baffle plate

11. Oil screen

E

Dec. 1996Mitsubishi Motors Corporation

7EN0893

12. Oil screen gasket

13. Baffle plate

14. Plug

15. Relief spring

16. Relief plunger

"CA 17. Oil seal
"BA 18. Oil pump case

19. O-ring

20. Oil pump cover

AC""AA 21. Oil pump outer rotor
AC""AA 22. Oil pump inner rotor

PWEE9615

11A-11-2

6G7 ENGINE (E-W) -

REMOVAL SERVICE POINTS

AA"

(1) Apply wood to the oil pan side and remove the oil pan

lower with a plastic hammer.

Oil Pan and Oil Pump

OIL PAN (LOWER)

A

Alignment marks

7EN0564

7EN0565

AB"

OIL PAN (UPPER)

(1) Detach the bolt (1) shown at left.
(2) Detach all other bolts.

1

(3) Screw a bolt into bolt hole

A shown (at both ends) to

remove the oil pan.

Caution

D

Do not use a scraper or special tool to remove
the oil pan.

AC"

OIL PUMP OUTER AND INNER ROTORS

(1) Draw a setting mark on the oil pump outer and inner rotors

to facilitate reassembly.

7EN0509

INSPECTION

OIL PUMP

(1) Check for tip clearance.

Standard value: 0.06 - 0.18 mm

7EN0510

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E-W) -

(2) Check for side clearance.

Standard value: 0.04 - 0.10 mm

7EN0511

(3) Check for body clearance.

Standard value: 0.10 - 0.18 mm
Limit: 0.35 mm

Oil Pan and Oil Pump

11A-11-3

Alignment marks

7EN0512

7EN0509

7EN0767

INSTALLATION SERVICE POINTS

"AA

(1) Install the oil pump outer rotor in the proper direction using

"BA

(1) Remove the old liquid gasket from the cylinder block (oil

(2) Squeeze out about 3 mm of liquid gasket (FIPG) and

OIL PUMP INNER AND OUTER ROTORS

the setting mark drawn on it before disassembly.
Apply engine oil over the entire rotor surface.

OIL PUMP CASE

pump mounting surface) and from the oil pump.

coat the coating surface with it.

Specified sealant:

MITSUBISHI GENUINE Part No. MD970389 or
equivalent

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

11A-11-4

6G7 ENGINE (E-W) -

Oil Pan and Oil Pump

MD998717

MD998717 Crankshaft

Guide

Oil seal

Oil pump case

7EN0139

7EN0468

"CA

"DA

OIL SEAL

OIL PAN (UPPER)

(1) Clean the gasket coating surfaces of the cylinder block

and the oil pan upper.

(2) Squeeze out a 4 mm bead of liquid gasket and coat the

coating surface with it.

Top view
Flange bolt tightening sequence

41 5

8

14

18

17 13

Bottom view

7

3

26

9

10

11

15

16

12

7EN0568

A

NOTE
During attachment of the oil pan upper, the sealer must
not be expelled from the flange portion of the oil pan
for distance A as shown.

Liquid gasket:

MITSUBISHI GENUINE Part No. MD970389 or
equivalent

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E–W) – Oil Pan and Oil Pump

11A-11-5

6G72

View from above
lower oil pan

Flange bolt tightening sequence

6

2

10

8

5

View from the bottom of the lower oil pan

1

4

9

7

3

E OIL PAN (LOWER)

(1) Clean the gasket coating surfaces of the oil pan upper

and the oil pan lower.
(2) Squeeze out a 4 mm bead of liquid gasket on the coating

surfaces.

Liquid gasket:

MITSUBISHI GENUINE Part No. MD970389 or
equivalent

7EN1205

6G74

View from above
lower oil pan

Flange bolt tightening sequence

6

11

9

7

View from the bottom of the lower oil pan

51

2

4

10

8

3

7EN1598



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-11-6

6G7 ENGINE (E–W) – Oil Pan and Oil Pump

F OIL FILTER

Bracket side

Engine oil

6EN0591

(1) Clean the oil filter attaching surface on the side of the

cylinder block.
(2) Apply engine oil to the O-ring for the oil filter.
(3) Screw in the oil filter until its O-ring contacts the oil filter

attaching surface. Then tighten it further by about one

turn (at approx. 14 Nm).

G OIL PRESSURE SWITCH
Sealant: 3M ATD Part No. 8660 or equivalent

NOTE
 Sealant must not extend beyond the tip of the thread

portion.
 Do not overtighten the switch.

9EN0094



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

6G7 ENGINE (E–W) – Piston and Connecting Rod

12. PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION (6G72)

Apply engine oil to all
moving parts before
installation.

11A-12-1

8

6

4

10

7

9

11

12

5

2

Removal steps

1. Connecting rod cap nut

AG 2. Connecting rod cap

E 3. Connecting rod bearing, lower
F 4. Piston and connecting rod assem-

bly

E 5. Connecting rod bearing, upper
D 6. Piston ring No. 1

3

49 Nm

1

7EN0424

D 7. Piston ring No. 2
C 8. Oil ring

BA 9. Piston pin

10. Piston

11. Connecting rod

12. Connecting rod cap bolt



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-12-1a

6G7 ENGINE (E–W) – Piston and Connecting Rod

REMOVAL AND INSTALLATION (6G74)

6

8

4

10

9

7

11

12

13

14

5

3

2

Removal steps

H 1. Connecting rod cap nut

AG 2. Connecting rod cap

E 3. Connecting rod bearing, lower
F 4. Piston and connecting rod assem-

bly

E 5. Connecting rod bearing, upper
D 6. Piston ring No. 1
D 7. Piston ring No. 2

Apply engine oil to all
moving parts before
installation.

1

34 Nm + 90°

7EN1335

C 8. Oil ring
B 9. Snap ring

CB 10. Piston pin

B 11. Snap ring

12. Piston

13. Connecting rod

14. Bolt



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

6G7 ENGINE (E–W) – Piston and Connecting Rod

11A-12-1b

Intentionally blank



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

11A-12-2

6G7 ENGINE (E-W) -

REMOVAL SERVICE POINTS

AA"

(1) Enter the cylinder No. on the side of the large end of

Cylinder No.

7EN0448

Piston and Connecting Rod

CONNECTING ROD CAP

the connecting rod to facilitate reassembly.

Push rod

Guide B

Guide C

Base

Push rod

Front
mark

Guide A:

17.9 mm

Guide A:

18.9 mm

Guide A:

20.9 mm

Guide A:

21.9 mm

Front mark

7EN0431

AB"

PISTON PIN

The special piston pin setting tool (MD998780) consists of
the parts shown at left.

(1) Insert the special push rod tool from the front marked

(arrow) side of the piston side and attach guide C.

(2) Set the piston and connecting rod assembly to the special

tool piston pin setting base such that the front mark on
the piston faces upward.

(3) Pull out the piston pin with a press.

NOTE
After pulling out the piston pin, place the piston, the piston
pin, and the connecting rod in order for each cylinder
number.

Guide C

Base

7EN0390

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E–W) – Piston and Connecting Rod

C PISTON PIN

70°C

(1) Remove the snap rings.
(2) Heat the piston to approximately 70°C and remove the

piston pin.

Caution

 The piston pin fits tightly in the piston at normal

temperature. Be sure to heat the piston to remove
the piston pin. Be careful not to get scalded.

7EN0570

INSPECTION

PISTON RING

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

groove. If it exceeds the specified limit, change the ring

or the piston and piston ring.

Standard values:

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

11A-12-3

Push in using
the piston

Piston ring

End clearance

7EN0475

7EN0476

Limit: 0.1 mm

(2) Place the piston ring in the cylinder bore, push it in by

the piston head, and make sure it is square against the

cylinder wall.

Then measure the clearance at the ring ends with a

thickness gauge.

Change the piston ring if the clearance is excessive.

Standard values:

No. 1 0.30 – 0.45 mm
No. 2 0.45 – 0.60 mm
Oil 0.20 – 0.60 mm (6G72)

0.10 – 0.35 mm (6G74)

Limit: No. 1 0.8 mm

No. 2 0.8 mm
Oil 1.0 mm

CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAGE
METHOD)

(1) Drain oil from the crankshaft pin and the connecting rod

bearing.
(2) Place a piece of Plastigage with the length of the bearing

width on the crankshaft pin straight along the pin centre.
(3) Gently place the connecting rod cap on top and tighten

the bolt to the specified torque.
(4) Detach the bolt and gently remove the connecting rod

cap.
(5) Measure the width of the crushed Plastigage (at the widest

point) using the scale printed on the Plastigage package.

Standard value: 0.02 – 0.05 mm

1EN0246



Apr. 2001Mitsubishi Motors Corporation

Limit: 0.1 mm

RevisedPWEE9615-A

11A-12-4

Connecting rod

B

3mm+L

6G7 ENGINE (E-W) -

C

D

Piston

Piston pin

A

7EN0432

Piston and Connecting Rod

INSTALLATION SERVICE POINTS

"AA

(1) Measurethe dimensions of the following parts and portions:

(2) Calculate by substituting each measured value into the

(3) Insert the special push rod tool into the piston pin and

(4) Combine the piston and the connecting rod, matching

(5) Apply engine oil to the outer periphery of the piston pin.
(6) Insert the side of the piston pin guide A attached per

(7) Screw guide B into guide A until they are distance L

(8) Use special tools to set the piston pin to a special tool

(9) Press fit the piston pin with a press. When the load required

PISTON PIN

A: Piston pin mounting portion
B: Distance between piston bosses
C: Piston pin
D: Connecting rod

following equation:

(A - C) - (B - D)

L=

2

attach guide A to it.

their front marks.

Step (3) into the pin hole from the side of the piston
containing the front mark.

(obtained per Step (2) above) plus 3 mm apart as shown.

piston setting base with the front mark of the piston facing
up.

for press fitting the piston pin is below the standard value,
change the piston pin (piston assembly) or the connecting
rod or both.

Guide B

Guide A

Push rod

Front
mark

Standard values: 7,350 - 17,200 N

7EN0433

Piston pin

Front mark

Guide A

Base

Guide B

7EN0391

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

6G7 ENGINE (E–W) – Piston and Connecting Rod

B SNAP RING / PISTON PIN

70°C

7EN0570

Front mark “74”

Front mark

(1) Fit one snap ring with its shear droop end toward inside.
(2) Heat the piston to approximately 70°C.
(3) Align the front marks on the connecting rod and piston

on the same side. Then, fit the piston pin in through the

connecting rod and piston.
(4) After the piston pin is fitted, install the other snap ring

with its shear droop end toward inside.

Caution

 Apply a sufficient amount of engine oil to the outer

surface of the piston pin and the small end hole
of the connecting rod.

 The piston pin fits tightly in the piston at normal

temperature. Be sure to heat the piston to insert
the piston pin. Be careful not to get scalded.

11A-12-5

Upper
side rail
end gap

Spacer end gap

Side rail end

7EN0670

Lower
side rail
end gap

7EN1153

7EN0451

C OIL RING

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

upper side rail, then the lower side rail.

NOTE

 Be sure to locate the end gaps of the side rails and

spacer as shown in the illustration.

 New spacer and side rails have size identification

colors.

Size

S.T.D. None

0.50 mm O.S. Blue

1.00 mm O.S. Yellow

Identification color

(2) The side rail can be inserted easily into the piston groove

by first inserting one end and then pushing the rail into

place while turning it by hand as shown.

Caution

 The side rail may break if a ring expander is used.

(3) After installation into the piston, make sure the side rail

turns smoothly in either direction.



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-12-5a

i

d

identifi

identi ica

tion color

50.000

49.995

49.986

6G7 ENGINE (E–W) – Piston and Connecting Rod

D PISTON RING NO. 2 / PISTON RING NO. 1

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

their identification marks facing upward.

Identification mark

6G72

Piston ring expander

Identification mark

7EN0452

Size mark

No. 1
No. 2

9EN0524

Piston ring No.1
identification mark

Piston ring No.2

identification mark
6G72 T T2
6G74 1T 2T

NOTE
The piston rings have stamped size marks.

Size

S.T.D. (None)

0.50 mm O.S. 50

1.00 mm O.S. 100

Size mark

E CONNECTING ROD BEARINGS, UPPER AND

LOWER

(1) When connecting rod bearings, connecting rod or

crankshaft is to be replaced, select the proper connecting
rod bearings according to the crankshaft and connecting
rod identification marks/colors.

6G72

Identification color

6G74

Identification mark

7EN1326

7EN0603

Crankshaft

Identification mark Pin O.D.

Produc­tion part

Service

part

mm

None I 49.995 –

None II 49.985 –

None III 49.980 –

Connect-

Bearing

ng ro

identifica-

tion color

tion color

White Yellow

None Yellow

Yellow None

White Yellow

None None

Yellow Blue

White None

None Blue

Yellow Blue

ca-



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

6G7 ENGINE (E–W) – Piston and Connecting Rod

i

d

identifi

identi ica

tion color

55.000

54.994

54.988

11A-12-5b

6G72 crankshaft identification
mark positions

No. 6
No. 5

No. 4

6G74 crankshaft identification
color positions

No. 1

No. 3

No. 2

No. 5

No. 4

No. 6

No. 3
No. 2
No. 1

7EN1400

6G74

Crankshaft Connect-

Identification color Pin O.D.

Produc­tion part

None Yellow 54.994 –

None None 54.988 –

None White 54.982 –

Service

part

mm

ng ro

identifica-

tion color

0 Pink
1 Red
2 Green
0 Red
1 Green
2 Black
0 Green
1 Black
2 Brown

Bearing

ca-

tion color

Identification color

7EN0595



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

11A-12-6

Upper side rail

No. 2 ring gap
and spacer gap

6G7 ENGINE (E–W) – Piston and Connecting Rod

F PISTON AND CONNECTING ROD

No. 1

Piston pin

Lower side rail

6EN0549

(1) Liberally coat the circumference of the piston, piston ring,

and oil ring with engine oil.

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

spacer) as shown in the figure.

(3) Rotate the crankshaft so that the crank pin is positioned

at the centre line of the cylinder bore.

(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, install piston and

connecting rod assembly into cylinder block.

Caution
 Install the piston with the front mark (arrow mark)

on the top of the piston facing towards the engine
front (timing belt side).

Notches

Cylinder
number

7EN0032

G CONNECTING ROD CAP

(1) Mate the correct bearing cap with the 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.

7EN0453

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

end is correct.

Standard value: 0.10 – 0.25 mm
Limit: 0.4 mm

7EN0454



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

6G7 ENGINE (E–W) – Piston and Connecting Rod

H CONNECTING ROD CAP NUT

(1) The plastic area tightening method is used for tightening

connecting rod bolts and nuts. If a bolt is reused, check
the bolt for elongation by screwing the nut down through
the bolt. If the nut does not reach the last thread of the
bolt, replace the bolt.

(2) Before installing the nut, apply a thin coat of engine oil

to its threads and bearing surface.

(3) Install the nut on each bolt finger-tight.

11A-12-7

90° – 100°

Paint mark

Paint mark

Nut

Bolt

6AE0298

(4) To fit the bearing cap properly, tighten the nuts alternately

step by step to a torque of 34 Nm.
(5) Provide a paint mark on the head of each nut.
(6) Using the paint mark on the nut as reference point, provide

a paint mark on the bolt in the position corresponding

to a 90° turn of the nut.
(7) Turn the nut through 90° to align the paint marks on the

bolt and nut.

Caution

 If the tightening angle is shorter than 90°, sufficient

clamping force cannot be obtained.

 If the tightening angle exceeds 100°, loosen the

nut completely and repeat the above procedure
from the beginning.



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

6G7 ENGINE (E–W) – Crankshaft, Flywheel and Drive Plate

13. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE

REMOVAL AND INSTALLATION

Apply engine oil to all
moving parts before
installation.

20

6

11 N m

8

5

2

7

11A-13-1

1

74 Nm

11 N m

74 Nm

3

4

17

19

13

15

89 Nm

Removal steps

1. Adaptor plate

2. Drive plate

3. Plate

4. Adaptor plate

5. Flywheel

6. Rear plate

D 7. Oil seal case
C 8. Oil seal
B 9. Bearing cap bolt (6G72)
B 10. Bearing cap (6G72)

9

18

16

14

10

A

12

71 Nm

11

7EN1599

B 11. Bearing cap bolt (6G74)
B 12. Bearing cap (6G74)
A 13. Thrust bearing (A)
A 14. Thrust bearing (B)
A 15. Crankshaft bearing (lower)

A 17. Thrust bearing (B)

16. Crankshaft

18. Thrust bearing (A)

19. Crankshaft bearing (upper)

20. 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.



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

11A-13-2

6G7 ENGINE (E–W) – Crankshaft, Flywheel and Drive Plate

Plastigage

7EN0459

7EN0141

INSPECTION

CRANKSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)

NOTE
If the oil clearance exceeds the limit, replace the bearing,
and crankshaft if necessary.

This crankshaft oil clearance can be measured easily by using
a plastic gauge, as follows:

1 Remove oil, grease and any other foreign material from

crankshaft journal and bearing inner surface.

2 Install the crankshaft.
3 Cut the Plastigage to the same length as the width of

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

4 Gently place the crankshaft bearing cap over it and tighten

the bolts to the specified torque.

5 Remove the bolts and gently remove the crankshaft

bearing cap.

6 Measure the width of the crushed Plastigage at its widest

section by using a scale printed on the Plastigage package.

Standard values: 0.02 – 0.04 mm

Limit: 0.1 mm

12 mm

7EN0460

7EN0461

CYLINDER BLOCK

(1) Visually check for scratches, rust and corrosion. Also use

flaw detecting agents and the like to check for cracks.

If there are any defects, rectify the cylinder block.
(2) Measure the flatness of the cylinder block top surface

with a straight edge and a thickness gauge. During

measurement, the cylinder block top surface must be free

from gasket pieces and the like.

Standard values: 0.05 mm

Limit: 0.1 mm

(3) Check for scratches or seizure of the cylinder wall. If there

are any defects, correct (bore it a oversize) or change

the cylinder block.
(4) Measure the inside diameter and the ovality of the cylinder .

If the cylinder is overly worn, correct it to a larger size

and change the pistons and the piston rings.

Standard value:

Cylinder inside diameter 91.1 mm (6G72)
Ovality: 0.01 mm 93.0 mm

(6G74)



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

6G7 ENGINE (E-W) -

Crankshaft, Flywheel and Drive Plate

11A-13-3

BORING CYLINDER

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

the basis of the largest bore cylinder.

Piston size identification

Piston O.D.

Thrust
direction

6EN0554

Size

0.50 mm O.S. 0.50

1.00 mm O.S. 1.00

NOTE
Size mark is stamped on the piston top.

Identification mark

(2) Measure outside diameter of piston to be used. Measure

it in thrust direction as shown.

(3) Based on the measured piston O.D., calculate the boring

finish dimension.

Boring finish dimension = Piston O.D. + (Clearance
between piston O.D. and cylinder) - 0.02 mm (honing
margin)

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

Caution

D

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

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

between piston O.D. and cylinder.)

(6) Check the 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 the
same oversize. Do not bore only one cylinder to an
oversize.

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9615

11A-13-4

6G7 ENGINE (E–W) – Crankshaft, Flywheel and Drive Plate

The arrows indicate the identification
color positions.

No. 2 journal

No. 1 journal

No. 3 journal

Identification mark position

No. 4
No. 3
journal

No. 1
journal

journal

No. 2
journal

Cylinder bore size mark

No. 4 journal

7EN0596

7EN0991

INSTALLATION SERVICE POINTS

A CRANKSHAFT BEARING

When bearing replacement is required, select and install the
correct bearing by the following procedure.
(1) Measure the crankshaft journal diameter and confirm its

classification from the following table. In the case of a
crankshaft supplied as a service part, identification
colours/marks of its journals are painted/stamped at the
positions shown in the illustration.

(2) The cylinder block bearing bore diameter identification

marks are stamped at the position shown in the illustration
from left to right, beginning at No. 1.

No. 2

No. 1

Cylinder block bearing
bore identification mark

Timing belt side

No. 4

No. 3

7EN0992



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

6G72

identi ication

bearing bore

identification
mark

identi ication

bearing bore

part)

identi ication

6G7 ENGINE (E–W) – Crankshaft, Flywheel and Drive Plate

11A-13-4a

Combination of crankshaft journal diameter and cylinder block bearing bore diameter
Crankshaft journal Cylinder block
Classification Identification color or identification

mark
Production part Service part

1 None Yellow, 0 59.994 – 60.000 I Pink, 1

2 None None, 1 59.988 – 59.994 I Red, 2

3 None White, 2 59.982 – 59.988 I Green, 3

O.D. mm

diameter
identification

II Red, 2

III Green, 3

II Green, 3

III Black, 4

II Black, 4

III Brown, 5

Bearing

f

color or

f
mark (for service
part)

6G74

Combination of crankshaft journal diameter and cylinder block bearing bore diameter
Crankshaft journal Cylinder block
Classification Identification color O.D. mm

1 None Yellow 63.994 – 64.000 I Pink

2 None None 63.998 – 63.994 I Red

3 None White 63.982 – 63.988 I Green

Production part Service part

diameter
mark

Bearing

f
color (for service

f

II Red

III Green

II Green

III Black

II Black

III Brown



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

11A-13-4b

6G7 ENGINE (E–W) – Crankshaft, Flywheel and Drive Plate

Intentionally blank



Apr. 2001Mitsubishi Motors Corporation

AddedPWEE9615-A

6G7 ENGINE (E–W) – Crankshaft, Flywheel and Drive Plate

Identification color

Oil groove

Identification mark

Groove

7EN0600

11A-13-5

(3) Select the correct bearing from the above table on the

basis of the identification data confirmed at steps 1 and

2.
(Example of bearing selection – 6G72)

1 If the measured diameter of a crankshaft journal is

59.996 mm, Classification 1 applies.

2 Then, if the cylinder block bearing bore diameter

identification mark is I, select the bearing with
identification mark “1” or identification color “Pink”.

(4) Install the bearing halves with oil groove on the cylinder

block side.

(5) Install the bearing halves without oil groove on the bearing

cap side.

(6) Install the thrust bearings on both sides of the No. 3 bearing

with the grooves facing outward.

3

7EN0602

87

4

B BEARING CAP / BEARING BOLT

(1) Attach the bearing cap on the cylinder block as shown

in the figure.

(2) Tighten the bearing cap bolts to the specified torque in

the sequence shown in the figure.

(3) Check that the crankshaft rotates smoothly.

Crankshaft

Front mark

8

16

12

4

Bearing cap

Bearing
cap bolt

15

7

3

11

10

2

6



1

Cylinder block

5

Apr. 2001Mitsubishi Motors Corporation

2

6

14

1

9

5

13

7EN0524

RevisedPWEE9615-A

11A-13-6

MD998718

Oil seal
case

6G7 ENGINE (E–W) – Crankshaft, Flywheel and Drive Plate

(4) Check the end play. If it exceeds the limit, replace the

thrust bearing.

Standard value: 0.05 – 0.25 mm
Limit: 0.3 mm

7EN0034

C CRANKSHAFT REAR OIL SEAL

(1) Using the Special Tool, press-fit a new crankshaft rear

oil seal into the seal case.

7EN0465

MD998718

7EN0466

D OIL SEAL CASE

(1) Squeeze out a 3 mm bead of liquid gasket (FIPG) and

apply it to the coating surface.

Liquid gasket:

MITSUBISHI GENUINE Part No. MD970389

7EN0467



Apr. 2001Mitsubishi Motors Corporation

RevisedPWEE9615-A

NOTES