Mitsubishi 3000 GT, Diamante, Galant, Mirage User Manual

BACKUP

Service Manual

ENGINE

1992

-

1993

FOREWORD

The information contained in this service manual

has been prepared for the professional automotive
technician involved in daily repair operations. In­formation in this manual is divided into groups by
engine models. Each group is further divided to
address individual components within the group.
These groups contain general information, specifica­tion, removal and installation, disassembly and
reassembly procedures for the components. The

first page of each group contains an alphabetical
index to assist in finding the location of the
component. The information, descriptions and spe­cifications were in effect at the time this manual
was released.

GROUP INDEX

Introduction

Engine

4Gl

463

466 <1992>

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

. . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . .

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

mm

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

mm

This

BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE
WHOLE SECTIONS.
a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original
manual was lost or destroyed.)

Please See

Mitsubishi Motors Co[poration reserves the right to make changes

dew?

or to make addltlons to or improvements in its products

impoang

previously manufactured.

This

BACKUP was sold to you under the fact that you do

README.N

any obligations upon itself to install them on its products

or

READMEHTML

Thank you. G~mm~emymanual@hotma~l.com

VOLUNTARY TECHNICIAN

CERTIFICATION THROUGH

for

additional Information.

WE SUPPORT

National

lnstit~te

AUTOMOTIVE

SERVICE

EXCELLENCE

for

indeed

OWN

WIthout

469

6G7

4G6 <1993>

in

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*..

m

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

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

CCT

@ qgg2

M&ubi&i Motors Corporation

Printed in Japan

INTRODUCTION

CONTENTS

:,

ENGINE MODEL TABLE
EXPLANATION OF MANUAL CONTENTS

FORM-IN-PLACE GASKET

Disassembly
Form-In-Place Gasket Application

Surface

Preparation

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

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

. . . . . . . . . . . . . . . . . ..I................

._......................

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

4

. . . . . . . .

2
6

6

6

6

SPECIAL TOOL NOTE
TORQUE REFERENCES

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.....

1.

:

._

.

5
5

,

‘-:

:

2

INTRODUCTION

EXPLANATION OF MANUAL CONTENTS

0

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 under-

standing of the installed condition of

component parts.

(2) The numbers provided within the diagram

indicate the sequence for maintenance

and servicing procedures; the symbol

indicates a non-reusable part; the tighten-

ing torque is provided where applicable.

m

Removal steps:

l Disassembly steps:

0

Installation steps:

l Reassembly steps:

I

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

The part designation number corresponds

to the number in the illustration to indicate
disassembly steps.

Specified in case installation is impossible

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

Specified in case reassembly is

ble

in reverse order of disassembly
Omitted if reassembly is possible
verse order of disassembly steps.

ia

im$ossi-

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.

GAO:

Indicates that there are essential points for

removal or disassembly.

I)A4:

Indicates that there are essential points for

installation or reassembly.

Symbols for Lubrication, Sealants and
Adhesives

Information concerning the locations for
tion 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.

lubrica-

&

. . Grease

(multrpurpose grease unless there is

a brand or type specified)

. . . . .

Sealant or adhesive

. . . . .

i

:m

Brake fluid, automatic transmission

fllid

or air conditioning compressor

. . . . . Engine oil or gear oil

I

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INTRODUCTION

Indicates the
section title.

3

Denotes non-reusable

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

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

“ln-

I

I

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4

ENGINE MODEL TABLE - 1992

Engine

Series,

4Gl
4G3

4G6

INTRODUCTION

4G9

6G7

4693

6672

6G72 3.0 (183)

6G72

Turbo

1.8

(1

IO)

3.0(I83)

3.0 (183)

ENGINE MODEL TABLE - 1993

In-line,

6O”V.

SOHC

6O”V.

DOHC

6O“V.

DOHC

SOHC

(per bank)

(per bank)

(per bank)

E$po

LRV

bgmante,
h&ntero,

Diamante, 3000GT

4 3000GT

.K

c:

Truck

4G9

6G7

4664
4G93
6672

6672

6G72

Turbo

.

2.4(146)

1.8 (1

IO)

3.0 (I 83)

3.0 (183)

3.0 (183)

1

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In-line, SOHC

In-line, SOHC

6O”V.

SOHC

(per bank)

6O”V,

DOHC 4

(per bank)

6O”V.

DOHC

(per bank)

4
4
2

4

E$po-LRV.
@age,

Diamante,

Mhtero,
C$mante,

3600GT

Expo LRV

Expo

Truck

3000GT

SPECIAL TOOL NOTE

INTRODUCTION

.

1

6

Please refer to the special tool cross reference chart which is located in the service manual at the beginning of
each group, for a cross reference from the MMC special tool number to the special tool number that is
available in your market.

iiS *‘l
*.j,

l”

“...!: ‘/’

TORQUE REFERENCES

General tightening torque is as shown in the following table.

The specific part tightening torque is shown at the beginning of each group.

Flange bolt

Heaid.

i-MC 7

ft.lbS.

Size mm
(dia. x pitch)

5 x 0.8

6x

1.0
8 x 1.25

10x1.25
12x

1.25

14x1.5

Bolt with spring washer

Head mark 4 Head mark 7 Head mark 10 Head mark 4

Nm

ft.lbs. Nm ft.lbs. Nm ft.lbs. Nm ft.lbs. Nm

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

A new type of bolts, to be tightened in plastic area, is currently used in
tightening method for the bolts is different from the conventional one. Be sure to observe the

so’me

parts of the engine. The

method

described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.

l Areas where the bolts are in use:

(1) Cylinder head bolts

(2)

Main bearing cap bolts

(3) Connecting rod cap bolts

Remarks:
The bolts in
The bolts in (3) apply to the

l Tightening Method

After tightening the bolts to the specified torque, tighten them another

(1)

and (2) apply to the

4G15, 4G6 <1993>

4G6 <I 993>

and

and

4G93

4693

engines.

engines.

90”

or 180” (twice 90”). The

tightening method varies on different areas. Observe the tightening method described in the text.

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INTRODUCTION

FORM-IN-PLACE GASKET

The engine has several areas where the form-in-place gasket
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 vulcanization (Rn/) type and is supplied in a loo-gram
tube (Part No. MD970389 or
atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No.
for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine oil sealing.

Disassembly

The parts assembled with the
cases, however, the sealant between the joined surfaces may have to be broken

mallet or similar tool. A flat 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.

MD9971 10).

FIPG

can be easily disassembled without use of a special method. In some

Since the

RTV

(FIPG)

is in use. To ensure that the gasket fully

hardens as it reacts with the moisture in the

MD970389,

bylightly

can be used

striking with a

Surface

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
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

When assembling parts with the FIPG, you must observe some precautions, but the procedure is very simple
as in the case of a conventional precut gasket.

Applied
circumference with a completely continuous bead. The
the
make sure that the gasket is applied to the required area only.
The
when applying the FIPG.

Preparation

FIPG

is to be applied is flat.‘ Make sure that there

5

FIPG

bead should be of the specified size and without breaks. Also be sure

FIPG

can be wiped away unless it is hardened. While

FIPG

is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted,

FIPG

application procedure may vary on different areas. Observe the procedure described in the text

toencircle

the bolt hole

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4G15

CONTENTS

BRACKET
CRANKSHAFT, FLYWHEEL AND

DRIVE PLATE
CYLINDER HEAD AND VALVES
EXHAUST MANIFOLD AND

WATER PUMP
FRONT CASE AND OIL PUMP
FUEL AND EMISSION PARTS
GENERAL INFORMATION
GENERAL SPECIFICATIONS
GENERATOR AND IGNITION SYSTEM

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

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

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

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

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

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

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

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

........

53

51
33

28
39

22

14

INTAKE
PISTON AND CONNECTING ROD

ROCKER ARMS AND CAMSHAFT
SEALANT
SERVICE SPECIFICATIONS
SPECIAL TOOLS

THROlTLE

TIMING

2

TORQUE SPECIFICATIONS

5

MANIFOLD

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

BODY

BELT

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

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

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

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

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

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

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

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

26
43
30
11

6
12
24
17
10

IlA-2

4Gl

ENGINE - General Information

GENERAL INFQRMATION

ENGINE SECTIONAL VIEW

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3

1

EN0086

4Gl

ENGINE

-

General Information

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1

VA-4

4Gl

ENGINE - General Information

UBRICATION

SYSTEM

0’

t7;

ii

I

P

‘Z

:
ii

OTJ

09

1

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4Gl

ENGINE - General Specifications

GENERAL SPECIFICATIONS

Items
We

Number of cylinders

Combustion chamber
Total displacement
Cylinder bore
Piston stroke
Compression ratio
Valve timing

(): Camshaft identification mark

Intake valve

Opens
Closes

Exhaust valve

Opens

Closes
Lubrication system
Oil pump type
Cooling system
Water pump type
EGR valve
Injector type and number
Injector identification No.
Fuel regulated pressure kpa (psi)
Throttle bore mm (in.)
Throttle position sensor
Closed throttle position switch

Y’

1: up to 1992 models

“2:

From 1993 models

.---

cm3 (cu.in.)

mm (in.)
mm (in.)

BTDC

ABDC

BBDC

ATDC

Specifications
In-line OHV, SOHC

4

Pentroof

1,468 (89.58)

75.5 (2.972)
82 (3.228)

9.2

(1 I*’

14”

51” 53”

51” 57”
14”
Pressure feed, full-flow filtration
Trochoid type
Water-cooled forced circulation
Centrifugal impeller type

Single type
Electromagnetic, 4

BDH182

335 (47.6)

46(1.811)
dariable

Contact type, within idle speed control
Movable contact type within throttle position sensor*’

type

(6)**

15”

15”

resistor type

motor”

1

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I

1

IA-6

4Gl

ENGINE - Service Specifications

SERVICE SPECIFICATIONS

Items

Cylinder head

Flatness of gasket surface

Grinding limit of gasket surface

t

Total resurfacing depth of both cylinder

head and cylinder block
Overall height
Oversize rework dimensions of valve guide hole

(both intake and exhaust)

0.05

(.002)

0.25(.010)

0.50

(.020)

Oversize rework dimensions of intake valve
seat ring hole (primary)

0.3

(.012)

0.6(.024)

Oversize rework dimensions of intake valve
seat ring hole (secondary)

0.3

(.012)

0.6

(.024)

Oversize rework dimensions of exhaust valve

seat ring hole

0.3

(.012)

0.6

(.024)

Camshaft

Cam height

Intake

Exhaust 39.10 (1.5394)
Journal diameter

3il

clearance

Standard value

d.05 (.0020)

106.9-107.1 (4.209-4.217)

12.05-12.07 (.4744-.4752)

12.25-

12.27

12.50-12.52 (.4921 -.4929)

27.42-27.44(1.0795-1.0803)

27.72-27.74(1.0913-1.0922)

32.43-32.45

32.73-32.75

35.43-35.45(1.3949-1.3957)

35.73-35.75(1.4067-1.4075)

38.78 (1.5268)

45.93-45.94(1.8083-1.8087)

0.06-0.10(.0024-.0039)

(.4823-.4831)

(1.2768-1.2776)
(1.2886-1.2894)

“”

Limit

0.2(.008)

"0.2

3

1

“1

'$

1,

I)

1

1:

!

(.008)

38.28

38.60(1.5197)

mm (in.)

(1.5071)

qockerarm

.D.

3ocker

arm-to-shaft clearance

qockerarmshaft
I.D.

3verall

length
Intake
Exhaust

TSB Revision

18.91

-18.93(.7445-.7453)

0.01

-0.04(.0004-.0016)

18.89-18.90(.7437-.7441)

365(14.37)

346(13.62)

0.1

(.004)

Items
Valve

Overall length

Intake
Exhaust

Stem diameter

Intake

Exhaust

Face angle

Thickness of valve head (margin)

Intake
Exhaust

Stem-to-guide clearance

Intake

Exhaust

Valve clearance

Intake
Exhaust

4Gl

ENGINE - Service Specifications

Standard value

100.75 (3.9665)

101.05 (3.9783)

6.57 - 6.58

6.53 - 6.55

(2587 - .2591)

(2571 - .2579)

45” - 45”30’

1 .o

(.039)

1.5

l.059)

0.02 - 0.05

0.05 - 0.09

0.07

0.09

(0008 - .0020)
(.0020 - .0035)

(.0028)

Up to 1992 models

(.0035)

From 1993 models

0.17 (0067)

Limit

0.5

(020)

1 .o (.039)

0.10

(.0039)

0.15

(.OOSS)

mm (in.)

.,_ ..“.. ..“_

.

.

1 t..

,-i

,

-7, ,i ,,- <

i

7/

Valve spring
Free height

Intake
Exhaust

-oad/installed

height

Intake

Exhaust

3ut-of-squareness
halve

guide

3verall

length
Intake
Exhaust

.D.

I.D.
;ervice size
‘Tess-in

lalve
;eat
lalve

temperature

seat

angle

contact width

Gnkage
iervice size

N/mm

(Ibs./in.)

46.1 (1.815)

46.8 (1.843)

230/40

(51/I

.57)

290140

(64/l

.57)

Max. 2”

44 ( 1.732)

49.5 (1.949)

6.60 - 6.62

12.055 - 12.065

0.05

(.002),

(.2598 - .2606)

(4746 - .4750)

0.25

(.Ol).

Room temperature

43”30’ - 44”

0.9 - 1.3

0.3

LO1 2),

(035 - .051)

0.6

(024)

0.50 (02) oversize

oversize

45.1 (1.776)

45.8 (1.803)

4”

0.2

(.008)

. .

\-TSR

Revision

I

IIA-8

4Gl

ENGINE - Service Specifications

mm (in.)

Items

Piston

O.D.

Piston-to-cylinder clearance
Service size

Piston ring

End gap

No. 1 ring
No. 2 ring

Oil ring

Ring-to-ring groove clearance

No. 1 ring
No. 2 ring

Service size

Piston pin

O.D.

Press-in load N (psi)
Press-in temperature

Standard value

75.48 - 75.50 (2.9716 - 2.9724)

0.02 - 0.04

0.25
oversize

0.20 - 0.40 l.0079 -

0.20 - 0.35

0.20 - 0.70

0.03 - 0.07

0.02 - 0.06 f.0008 -

0.25

(.Ol),

oversize

18.003 -

5,000 - 15,000 (1 ,102 - 3,307)

Room temperature

(0008 - .0016)

t.01).

0.50

(.02),

(.0079 - .0138)

LOO79 - .0276)

(.0012 - .0028)

0.50

(.02),

18.005 l.7088 -

0.75

.0157)

.0024)

0.75

(.03),

(.03),

.7089)

1

1

.OO

.OO

(.04)

(04)

Limit

0.8

(.031)

0.8

f.031)

1 .o i.039)

0.1

(.004)

0.1 i.004)

Connecting rod

Big end center-to small end center length
Bend
Twist
Big end side clearance

Crankshaft

End play
Journal O.D.
Pin O.D.

Dut-of-roundness and taper of journal and pin
3il

clearance of journal

3il

clearance of pin

Cylinder

Ilatness
Grinding

3verall

block

.D.

of gasket surface
limit of gasket surface

Total resurfacing depth of both cylinder
block and cylinder head

height

130.95-

0.05

0.1

0.10 - 0.25

0.05-0.18 (.0020- .0071)

48 (1.89)
42 (1.65)

0.005 (.0002)

0.02 - 0.05

0.02 - 0.05

75.50 - 75.53 (2.9724 - 2.9736)

0.05 i.002)

255.9 - 256.1

131.05 (5.1555-5.1594)

(.0020)

(.004)

(.0039 - .0098)

(.0008 - .0020)

(.0008 - .0020)

(10.075 - 10.083)

0.4

f.016)

0.3

(.012)

0.1 i.004)

0.1

(.004)

0.1 i.004)

*0.2

(.008)

TSB

Revision

Items

Oil

pump

Tip clearance
Side clearance

Body clearance

Drive belt deflection

New belt
Used belt

Injector

Coil resistance

Throttle position sensor

Resistance

Idle speed control motor

Coil resistance

Idle air control motor

Coil resistance

fI?

kR

rc1

0

4Gl

ENGINE - Service Specifications

Standard value

0.03 - 0.08

0.04-0.10(.0016-.0039)
O.lO-0.18(.0039-.0071)

5.5 -7.0

8.0

(.32)

13 - 16

3.5-6.5

5 - 35 at

28 - 33 at

LOOI

(.22 - .28)

at

20°C (68°F)

20°C (68°F)

20°C (68°F)

2 -

.0031)

Limit

0.35

rn:fq,

(in,

i ,I :, i /

.’

(.Orl38)

Idle speed control motor position sensor

Resistance

kfi

4-6

1

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1

IA-IO

4Gl

ENGINE - Torque Specifications

TORQUE SPECIFICATIONS

Generator and ignition system

Oil level gauge guide mounting bolt
Water pulley bolt

pump

Generator brace bolt
Generator brace mounting bolt
Generator pivot nut
Crankshaft bolt
Crankshaft pulley bolt
Spark plug
Distributor

Timing belt

Engine support bracket, left
Tensioner bolt
Camshaft sprocket bolt

Fuel and emission parts

Throttle body mounting bolts
Fuel rail mounting bolts
Fuel regulator bolts

pressure

EGR valve (California) mounting bolts

Nm

11
9

14
24
23
85

14
25
12

36
24
70

19
12

9

13

ftlbs.

-

8
7

10

17
17

61

10

18

9

i

ii 26

17

51

14

‘7

9

7
9

Throttle body

Throttle position sensor attaching bolts

Intake manifold

Cable bracket bolt
Engine coolant temperature gauge unit
Engine coolant temperature sensor

Therm0
flater

Thermostat housing bolt and nut
Intake manifold stay bolt
Engine support bracket stay
Intake manifold bolt and nut

Exhaust manifold and water pump

Exhaust manifold cover “A” bolt
Exhaust manifold cover “A” and

Exhaust manifold cover “B” bolt
Exhaust manifold nut

Vater inlet pipe bolt
Vater
Ixygen

switch

outlet fitting bolt

bolt

pump

sensor

“B”

mounting bolt

2.0

14
11
30

8

19
18

22

36

18

30
9
24

18
14
14
45

1.5

11
8
22
6
14
13
16
26
13

22
7

18
13

11
11
33

jocker

arms and camshaft

jocker cover bolt
locker arm shaft bolt
iocker arm lock nut

TSB Revision

1.8
32
15

1.3
24
11

461

ENGINE - Torque Specifications / Sealant

Cylinder head and valves

Cylinder head bolt

Front case and oil pump

pan

Oil drain plug

pan

Oil bolt
Oil screen bolt

Oil relief valve plug

Front case bolt

Oil pump cover screw

Piston and connecting rod

Connecting rod cap nut

Crankshaft, flywheel and drive plate

Flywheel and drive plate
Rear plate bolt
Bell housing cover bolt
Oil seal case bolt
Bearing cap bolt

3il switch

pressure

Nm

73

40
7

19

45

I4

IO

20 +

135

11

9

11

53

19

I/4

turns

ft.lbs.‘, I. ‘-,.‘.,;

53

29

5
14

33

11

8

14.5 +

98
8
7
8

38

14

l/4

turns

$8;

_.”.c

Bracket
Exhaust pipe support bracket
Engine support bracket, front

7011

stopper bracket, front

3011

stopper bracket, rear

SEALANT

Items

Therm0

Engine coolant temperature sensor
Engine coolant temperature gauge unit
Oil pan
Oil pressure switch threads

switch

36
60
65

120

Specified sealant

3M

Nut Locking part No. 4171 or equivalent

3M

Nut Locking part No. 4171 or equivalent

3M

ATD Part No. 8660 or equivalent

Mitsubishi Genuine Part No. MD970389 or equivalent

3M ATD Part No. 8660 or equivalent

26
43
47
87

Quantity

As required
As required

As required
As required
As required

TSB Revision

1

IA-12

SPECIAL TOOLS

Tool

4Gl

ENGINE - Special Tools

MD99801 1

Crankshaft rear
oil seal installer

Crankshaft front

oil seal installer

MD99871

Camshaft oil seal

3

MD99801 I-01

MD998713-01

Installation of crankshaft rear oil seal

Installation of camshaft oil seal

TSB Revision

Removal of oil pan

ompresslon 0

,.

i

.

.

4Gl

ENGINE - Special Tools

Valve stem seal

compressor

Flywheel stopper

1

TSB Revision

4Gl

1 IA-14

ENGINE - Generator and Ignition System

GENERATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION

*

_,

12 Nm
9

ftJp3.

14 Nm

10 ft.lbs.

Ji

I

24Nr;l

17

ft.lbs.

9Nm

7

23 Nm

” Rm/b=-

I

n

\!

I

85 Nm
81

ft.lbs.

1

TSB Revision

1

Removal steps

1,

Oil level gauge

2. Oil level gauge guide

3. O-ring

+C4

4. Drive belt

5. Water pump pulley

6. Generator brace

7. Generator

(IA!) +B4

8. Crankshaft bolt

9. Special washer

IO. Crankshaft pulley

11. Damper pulley

12. Spark plug cable

13.

Spark

*A4 ‘ll.

;.s;;$butor

.

-

plug

1

EN0325

461

ENGINE

-

Generator and Ignition System

REMOVAL SERVICE POINT

OAo

CRANKSHAFT BOLT REMOVAL

(I) Using the special tool, hold the drive plate or flywheel.
(2) Remove the crankshaft bolt.

INSTALLATION SERVICE POINTS

r)A4

DISTRIBUTOR ASSEMBLY INSTALLATlOy

(1) Turn the crankshaft to bring the No. I cylinder piston to the

top dead center on compression stroke.

(2) Align the mating mark on

thedistributor

housing with that

on the coupling key.

/

1

EL004

(3) Install the distributor with the coupling key fitted in the

keyway at the end of the camshaft.

r)64

CRANKSHAFT BOLT INSTALLATION

(I) Using the special tool, hold the drive plate or flywheel.

(2) Install the crankshaft bolt.

1 EN0326

F

#c4

(I) Adjust the belt deflection with the adjusting bolt to the

1

EN029'

1

TSB Revision

DRIVE BELT TENSION ADJUSTMENT

standard value.

Standard value:

New belt
Used belt

5.5 - 7.0 mm

8.0 mm

(.32

in.)

(.22 - .28

in.)

4Gl

ENGINE - Generator and Ignition System

6EN059E

(2)

Or using a tension gauge, adjust the tension to the standard
value.

Standard value:

New belt 500

Used belt 400 N (88 Ibs.)

(3) Tighten the lock bolt to the specified torque.
(4) Tighten the nut for pivot bolt to th$ specified torque.

6EN0591

-

700

N (116 -

154

Ibs.)

1

TSB Revision

I

I

461

TIMING BELT

REMOVAL AND INSTALLATION

ENGINE - Timing Belt

2bnhll

17

ft.lbs.

d

7

8

I

Removal steps

1. Timing belt upper cover

2. Timing belt lower cover

@I$ eC4

OBO
$I$

3. Timing belt

4. Engine support bracket, left

5. Tensioner spring

+B4

6. Tensioner

7. Crankshaft sprocket

8. Flange

*A4

9. Camshaft sprocket bolt

10. Camshaft sprocket

TSB Revision

1

EN0327

I

461

ENGINE

-

Timing Belt

REMOVAL SERVICE POINTS

OAo

TIMING BELT REMOVAL

(1) Mark belt running direction for reference in reinstallation.

(2) Loosen the tensioner bolts and move the tensioner toward

the water pump.

(3) Remove the timing belt.

NOTE

(1)

Water or oil on the belt shortens its life drastically, so

the removed timing belt, sprocket, and tensioner must
be kept free from oil and water. Do not immerse parts in
cleaning solvent.

(2) If there is oil or water on any part, check the front case

oil seal, camshaft oil seal and

4Bo

CRANKSHAFT SPROCKET

~

wfter

pump for leaks.

,

REldOVAL

r-

@o

CAMSHAFT SPROCKET BOLT LOOSENING

INSPECTION

TIMING BELT

Replace belt if any of the following conditions exist.
(1) Hardening of back rubber side is glossy without resilience

and leaves no indent when pressed with fingernail.

461

ENGINE - Timing Belt

Peeling

Cracks

Roundededge

Abnormal wear

(Fluffy strand)

Rubber exposed

1

EN024E

8EN006;

Cracks on

(2)

Cracks or

(3)

Cracks on

(4)

(5) Cracks on

(6)

Abnormal wear of belt sides. The sides are normal if they

rubber back

peeling of canvas

rib root

belt sides

are sharp as if cut by a knife.

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

Water

pump

Tooth missing
and canvas fiber

MIT308239

/

8EN006

I

01

PO281

INSTALLATION SERVICE

I)A4

CAMSHAFT SPROCKET BOLT TIGHTENING

I)B4

TENSIONER INSTALLATION

(I)

Move the tensioner pulley toward the water pump and

POIFTS

tighten the tensioner mounting bolts.

1 EN0003

TSB Revision

11

A-20

4Gl

ENGINE - Timing Belt

I)cg

TIMING BELT INSTALLATION

(1) Align the timing marks on the camshaft sprocket and the

crankshaft sprocket with their timing marks.

-

1

EN033

(2) Set the timing belt first on crankshaft sprocket and then

keeping the tension side belt tight, set on the camshaft
sprocket.

(3) Loosen the tensioner mounting bolts @ and
(4) Check that the belt completely meshes with the sprocket.

Also check the timing marks on the sprockets for align-

4

0.

4Gl

ENGINE - Timina Belt

\

Tensioner slot side

il

1

ENOOOE

(5) Turn the crankshaft clockwise by 3 crankshaft

teeth.

(6) Tighten bolt @ first and then bolt 0. If bolt @ is tightened

first, the tensioner will turn together with the bolt, resulting
in an overtensioned belt.

(7) Check the belt tension. Hold the tensioner and ‘timing belt

together by hand and give the belt a slight thumb pressure
at a point level with tensioner center. Make sure that belt
cog crest comes as deep as about
slot side tensioner bolt head.

l/4

of the width of the

s@Cxket

I

ll4of

bolt head

1

EN025

TSB

Revision

461

IIA-22

ENGINE - Fuel and Emission Parts

FUEL AND EMISSION PARTS

REMOVAL AND INSTALLATION

19 Nm

;;

14

ft.lbs.

TSB Revision

Removal steps

1.

Throttle body

2.

Gasket

3. Injectors and fuel rail

4.

eB4 ;.

*A4
*A4

Insulator

Fuw&ressure regulator

7:

Insulator

8. Injector clip

9.

Injector

10.

O-ring

11.

Grommet

12.

Fuel rail

13. EGR valve (For California)

14.

Gasket

1 EN0238

461

ENGJNE - Fuel and Emission Parts

INSPECTION

INJECTORS

(1) Using an ohmmeter (circuit tester), test for,

between terminals of injector; the circuit should be closed.
If failure is detected, replace the injector.

Standard value: 13 - 16 Cn [at

6FU192C

EGR VALVE

(1) Check the EGR valve for sticking or carbon deposits.

If such conditions exist, clean or replace the EGR valve.

(2) Connect a hand vacuum pump to the nipple of the EGR

valve and plug the other nipple.

(3) Apply a vacuum of 500 mmHg (19.7

that vacuum is maintained. If there is a leak, replace the

EGR valve.
In addition, check the valve for its opening and closing

6EM038~

motion by applying and removing vacuum.

20°C (68”F)l

in.Hg)

to make sure

‘,.$

::.

:.

‘I’ ,L

cont$u~ty,

1

EN025C

INSTALLATION SERVICE POINTS

#A4

(1) Before installing an injector, the rubber O-ring must be

(2) Install injector top end into the fuel rail. Be
(3) Install injector clip by sliding open ends onto both injector

I)64

(1) Before installing the pressure regulator, the O-ring must be

INJECTORS / INJECTOR

lubricated with a

*drop

of clean engine oil to aid in

CLIP INSTALLATICjbi

installation.

careful

not

damage O-ring during installation.
and fuel rail.

FUEL PRESSURE REGULATOR INSTALLATION

lubricated

a drop of clean engine oil to aid in

yjth

installation.

to

6FUO71,

TSB Revision

4Gl

1

M-24

ENGINE - Throttle Body

THROTTLE BODY

DISASSEMBLY AND REASSEMBLY

Up to 1992 models

1

2Nm

1.4 ftlbs.

Disassembly steps

4ArJ bA4 1.

From 1993 models

Throttle position sensor

2.

Idle

speed control motor

3. Throttle valve set screw

4. Throttle body

“p

2Nm

1.4

ft.lbs.

6FU1292

Disassembly steps

8:;

I)A4

I.

Throttle position sensor

2.

Idle arr

control motor

4BO

3. O-ring

4. Throttle body

5. Fixed speed adjusting screw

]

TSB Revision

1 EN0336

461

ENGINE - Throttle Bodv

Closed throttle position switch*

Throttle

Throttle position
sensor output

*

From 1993 models

Dosition

Throttle position
sensor connector

DISASSEMBLY

6Ab

THROTTLE POSITION SENSOR AND

CONTROL MOTOR

SERVJCE

POINTS

/ IDLE

IDLE

SPEED

AIR CONTROL IMOTOR

REMOVAL

(1)

DO not disassemble the sensor and motor.

(2)

DO

not immerse in solvent the sensor and motor to clean.

Clean them with shop towel.

aB0

THROlTLE

BODY REMOVAL

(1) Do not remove the throttle valve.
(2) Check if the vacuum port or passage is clogged. Use

compressed air to clean the vacuum passage.

REASSEMBLY SERVICE POINT

/

round

View

P

7FUO535

P

+A4 THROTTLE

POSITION SENSOR INSTALLATION

(1) Check correct installation of the throttle position sensor.

While moving the throttle lever in both open and close

directions, check to see that resistance between terminals

@ and @ or @ and @ changes. If the resistance changes

smoothly, the throttle position sensor has been installed

correctly.

1 EN024S

TSB Revision

llA-26

4Gl

ENGINE - Intake Manifold

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

8Nm
Gft.!bs.

14

Nm

IO ft.lbs.

A*

Removal steps

I.

Water hose

eC4

2. Engine coolant temperature gauge unit

eB4

3. Engine coolant temperature sensor

*AiJ

4. Thermoswitch

5. Water outlet fitting

6. Water outlet fitting gasket

7. Thermostat

8. Outer cable bracket

9. Inner cable bracket

10.

Engine hanger

11. Thermostat housing

12. Intake manifold stay

13. Engine support bracket stay (From 1993
models)

14. Intake manifold

15. Intake manifold gasket

18Nm

13

ftlbs.

For

k:E

AIT

-18Nm

13

ft.lbs.

/

. .

[

TSB Revision

I

Sealant

Sealant

4Gl

ENGINE

lEN033E

-

Intake Manifold

INSTALLATION SERVICE POINTS

#A4

SEALANT APPLICATION TO

Specified sealant:

3M

Nut Locking Part No. 4171 or equivalent

I)B4

SEALANT APPLICATION TO ENGINE COOLANT

-

TEMPERATURE GAUGE UNIT
Specified sealant:

3M ATD Part No. 8660 or equivalent

THERM0 SWIT&

,-

(” *f ‘; : i’<, ‘* ; *

. .

,,

Sealant

9EN009;

9EN0091

I)c4

SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE SENSOR
Specified sealant:

3M

Nut Locking Part No. 4171 or equivalent

1

TSB Revision

1

IA-28

461

ENGINE

Exhaust Manifold and Water

-

EXHAUST MANIFOLD AND WATER PUMP

REMOVAL AND INSTALLATION

14
10

Nm
ft.lbs.

Pump*

7

30 Nm
22

ft.lbs.

9Nm’

7 klbs.

1

-

14 Nm

10

ftlbs.

Removal steps

1.

Exhaust manifold cover “A”

2. Oxygen sensor - [1992,1993 (FED)

3. Engine hanger

4. Exhaust manifold

5. Exhaust manifold cover “B”

6. Exhaust manifold gasket

7. Water hose

+A4

8. Water inlet pipe

*AC

9. O-ring

10.

Water pump

11. Water pump gasket

models1

1 EN0339

TSB Revision

4Gl

ENGINE - Exhaust Manifold and Water Pump

O-ring

I

Water inlet pipe

Water

pump

6EN0594

INSTALLATION SERVICE POINT

I)A4

WATER PIPE / O-RING INSTALLATION.

(1)

Wet the O-ring (with water) to

Caution

Keep the O-ring free of oil or grease

facilitateFas-6embly.

‘.‘ ) & p

:.

TSB

Revision

1 IA-30

461

ENGINE

Rocker Arms and Camshaft

-

ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION

1.8Nm

1.3ft.lbs.

‘_

1

I

32

Nm

23

ft.lbs.

TSB Revision

Removal steps

1.

Breather hose

2. PCV hose

3. Rocker cover

4. Rocker cover gasket

)C4

5. Oil seal

6. Rocker arm and rocker arm shaft

eB4

7. Rocker arm and rocker arm shaft

#Bd

8. Rocker arm “D”

9. Wave washer

10. Spacer

11. Rocker arm “C”

12. Rocker arm shaft (exhaust side)

13. Rocker arm “B”

14. Rocker arm spring

15. Rocker arm “A”

16. Rocker arm shaft (intake side)

17. Adjusting screw

18. Nut

+A4

19. Camshaft

1

EN0340

461

ENGINE - Rocker Arms and Camshaft

INSPECTION

CAMSHAFT

(1) Measure the cam height.

Standard value:

38.78

39.10 mm

38.28 mm (1.5071 in.)

38.60 mm (1.5197 in.)

1

EN009s

Intake

Exhaust

Limit:

Intake
Exhaust

ROCKER ARM

l

Check the roller surface. If any dents, damage or seizure is
evident, replace the rocker arm.

l

Check rotation of the roller. If it does not rotate smoothty or
if looseness is evident, replace the rocker arm.

l

Check the inside diameter. If damage or seizure is
replace the rocker arm.

l Check the screw end for wear. If considerable wear is

evident, replace the adjusting screw.

mti

(1.5268 ‘in.)

(1.53& Sii.)

qfq/&&l

.:-

_j

*

”

,

evident,

C

Timing belt side

Wave washer

Bolt hole

center

1

EN005:

1 EN0342

INSTALLATION SERVICE POINTS

I)A4

CAMSHAFT INSTALLATION

(1)

Position the dowel pin of the camshaft as shown in the

illustration.

I)B4

(1)

ROCKER ARM AND ROCKER ARM SHAFT
INSTALLATION

install

the rocker arm shaft assembly wnlle

respecuny LIW

illustrated positions.

NOTE
Make sure that the bolt hole center is offset toward the
indicated side with respect to the rocker arm shaft
centerline.

. .

+c4

TSB Revision

OIL SEAL INSTALLATION

1

IA-32

4Gl

ENGINE

-

Rocker Arms and Camshaft

Intake 1 Intake 2

/

Exhaust 1

’ /

Exhaust 2

Exhaust 3

Exhaust 4

lEN015t

lEN0122

VALVE CLEARANCE ADJUSTMENT

~

(1) Position the No. 1 cylinder at the top dead center on

compression stroke.

(2) Adjust the valve clearance at the points shown in the

illustration.

(3) Loosen the adjusting screw locknut’.
(4) Using a feeler gauge, adjust the valve clearance by turning

the adjusting screw.

Standard value: on cold engine

Intake
Exhaust

0.07 mm

0.09 mm

0.17 mm

(.0028

(.0035

(.0067

in.) Up to 1992 models

in.) From 1993 models

in.)

(5) While holding the adjusting screw with a screwdriver,

tighten the lock nut.

(6) Rotate clockwise the crankshaft one complete turn (360”

1

degrees).

(7) Adjust the valve clearance at the points shown in the

illustration.

(8) Repeat steps (3) to (5) to adjust the valve clearance of

remaining valves.

Intake 3 Intake 4

-.----

lEN0156

TSB Revision

4Gl

ENGINE - Cylinder Head and Valves

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION

2-

73 Nm
53

ft.lbs.

Removal steps

(JAI) #E4

(IBI) #Q

(IBM) bC4

$I$ #A4
@I$ #A4

1. Cylinder head bolt

2. Cylinder head, valve assembly

I)D4

3. Cylinder head gasket

4. Retainer lock

5. Valve spring retainer

#B4

6. Valvespring

7. Intake valve (primary)

8. intake valve (secondary)

9. Retainer lock

10.

Valve spring retainer

+B4

11. Valve spring

12. Exhaust valve

13. Valve stem seal

14. Valve spring seat

15. Valve stem seal

16. Valve spring seat

17. Intake valve guide

18. Exhaust valve guide

19. Intake valve seat (primary)

20.

Intake valve seat (secondary)

21. Exhaust valve seat

22. Cylinder head

1ENOlOl

TSB Revision

1 IA-34

461

ENGINE - Cvlinder Head and Valves

REMOVAL SERVICE POINTS

(IAN

CYLINDER HEAD BOLT REMOVAL

OBo

RETAINER LOCK REMOVAL

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

to indicate their cylinder No. and location to aid reassembly.

j

$0

(1) Do not reuse removed valve stem seals.

INSPECTION

CYLINDER HEAD

(1) Check the cylinder head gasket

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

TSB Revision

VALVE STEM SEAL REMOVAL

&$-face

using a straightedge and

Standard value: 0.05 mm
Limit: 0.2 mm

tion.

Grinding limit:

* Total resurfacing depth of

cylinder block

Cylinder head height

106.9

-

(.008

*0.2 mm

107.1 mm (4.209 - 4.217 in.)

thicknessygauge.

(.0020 jn.)

in.)

(.008 ind

bo$

(Specifieatidn

i:
;-

".

.,

for flatness by

>:

cylinder head and

when new):

4Gl

ENGINE - Cylinder Head and Valves

VALVE

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

using valve

refacer.

Valve

should“ma,ke

a uniform contact

with the seat at the center of valve ‘face.

(2) If the margin is smaller than the

ser@cefimit,

replace the

valve.

Standard value:

1.0

6EN054:

Intake
Exhaust

1.5

Limit:

Intake 0.5 mm
Exhaust

1.0

mm
mm

mm

(.039
(.059

(.020
(.039

in.)
in.)

in.)

in.)

VALVE SPRING

(1) Measure the free height of the spring and, if it is smaller

than the limit, replace.

Free
height

Standard value:

Intake
Exhaust

46.1 mm

(1.815

in.)

48.8 mm (1.643 in.)

Limit:

Intake

1

I

EN0264

Exhaust

45.1 mm

45.8 mm

(1.776
(1.803

in.)

in.)

(2) Measure the squareness of the spring and, if the limit is

exceeded, replace.

Standard value: 2” or less
Limit: 4”

Valve
guide

0.9 -1.3 mm 0.9 -1.3 mm

(.035-

,051

in.)

Exhaust

44” 44”

(.035-

Intake

1

EN027!

,051

in.)

T

1

EN01 71

TSB Revision

VALVE GUIDE

(1)

Measure the clearance between the valve guide and the

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

Standard value:

Intake

Exhaust

0.02 - 0.05 mm

0.05 - 0.09 mm

(.OOOS -

JO20 in.)

(.0020 - .0035 in.1

Limit:

Intake
Exhaust

0.10 mm

0.15 mm I.0059 in.)

(.0039

in.)

VALVE SEAT RECONDlTlONlNG PROCEDURE

(1)

Before attempting reconditioning of the valve seat, check

the valve guide-to-valve stem clearance and replace the

valve guide if necessary.
(2) Recondition to the specified seat width and seat angle.
(3) After reconditioning, fit up the valve and valve seat using

lapping compound.

1

IA-36

4Gl

ENGINE - Cylinder Head and Valves

0.5 - 1 mm

Oversize I.D.

f.02 - .04

in.)

0.5-

1 mm

(.02 - .04

I

in.)

1

EN0275

VALVE SEAT REPLACEMENT PROCEDURE

(1)

Cut the

valve

seat to be replaced from the inside to thin the

wall thickness. Then, remove the valve seat.

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

oversize valve seat diameter.

Seat ring hole diameter: See “Service Specifications”
in page

(3) Before fitting the valve seat, either

up to approximately
using cooling spray, to prevent the

llA-6

250°C (482°F)

&at

the cylinder head
or cool the valve seat

cy%nder

head bore from

galling.

(4) Using valve seat cutter, correct

tie

valve seat to the
specified width and angle. See “VALVE SEAT RECON­DITIONING PROCEDURE.”

VALVE GUIDE REPLACEMENT PROCEDURE

(1) Push out the valve guide toward the combustion chamber

side using a press.

(2) Rebore the valve guide hole in the cylinder head to the size

corresponding to the oversize valve guide to be installed.

Caution
Do not install a valve guide of the same size again.

Valve guide hole diameter: See “Service Specifica-

tions” in page

IIA-6

(3) Install the valve guide until it projects 17 mm

1ENOlOf

REASSEMBLY SERVICE POINTS

+A4

(1) Install the valve spring seat.
(2) The special tool must be used to install the valve stem seal.

TSB Revision

(67

in.) from

the cylinder head as illustrated.

NOTE

(1)

The valve guide must be installed from the upper side of

the cylinder head.

(2) Note that the intake and exhaust valve guides differ in

length: 44 mm (1.732 in.) on intake side, 49.5 mm
(1.949 in.) on exhaust side.

(3) After installation of the valve guide, install a new valve

and check that it slides

smoothly.

VALVE STEM SEAL INSTALLATION

Improper installation could result in oil leaking past the valve

guide.

Caution
Do not reuse removed valve stem seal.

;
c

Painted end

4Gl

ENGINE - Cylinder Head and Valves

+B4

I

Spring retainer

VALVE SPRING INSTALLATION

(1)

~.s$~~;~

valve spring with the painted end on the rocker

_

Stem seal

Spring seat

6EN043i

I)c4

RETAINER LOCK INSTALLATION

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

bottom end of retainer to be in contact with, and damage,

the stem seal.

+

+-

Timing belt side

I

Timing belt side

Identification mark

1

FNOlill

lEN0109

TSB

I)D4

(1) Clean both gasket surfaces of cylinder block and cylinder

(2) Do not apply sealant.
(3) Confirm the identification mark on cylinder head gasket.

I)E4

(1)

(2) Repeat the tightening sequence several times, and torque

Revision

CYLINDER HEAD GASKET

INSTALLATlON

head.

The identification mark is stamped on the top surface of the
gasket at its front end.

Identification mark

3Vll: Up to 1992 models

1CG:

From 1993 models

CYLINDER HEAD BOLT INSTALLATION

Using the special tool and a torque wrench, tighten the

bolts in the shown sequence.

the bolts to specification in the final sequence.

1 IA-38

461

ENGINE - Cvlinder Head and Valves

TSB Revision

4Gl

ENGINE - Front Case and Oil Pump

FRONT CASE AND OIL PUMP

REMOVAL AND INSTALLATION

45 Nm
33

ft.lbs.

I

7

Removal steps

eD4

1. Oil filter

2.

Drain plug

QAI$~C~

@I) +A4
@I) +A4

3. Drain plug gasket

4. Oil pan

5.

Oil screen

6. Oil screen gasket

7.

Relief plug

8.

Gasket

9.

Relief spring

10.

+B4

Relief plunger

11. Oil seal

12.

Front case

13. Front case gasket

14. Oil pump cover

15. Outer rotor

16. Inner rotor

TSB

lEN0165

Revision

1

IA-40

4Gl

ENGINE - Front Case and Oil

Puma,

lEN008t

REMOVAL SERVICE POINTS

OAo

OIL PAN REMOVAL

1

(1) Knock the special tool deeply between the oil pan and the

cylinder block.

(2) Hitting the side of the special tool, slide the special tool

along the oil pan to remove it.

OBo

(I)

OUTER ROTOR / INNER ROTOR REMOVAL

Make alignment marks on the outer and inner rotors for

reference in reassembly.

INSPECTION

OIL PUMP

(1)

Check the tip clearance.

Standard value: 0.03 - 0.08 mm

.?

(.00?2 - .0031 in.)

TSB

(2) Check the side clearance.

(3) Check the body clearance.

Revision

Standard value: 0.04 - 0.10 mm

(.0016 - .0039

!
fI

?

?’

Standard value: 0.10 - 0.18 mm I.0039
Limit: 0.35

(.138

in.)

“,
i
:s

P

E

I

-

.0071

in.)

in.)

4Gl

ENGINE - Front Case and Oil Pump

INSTALLATION SERVICE POINTS

I)A4

(1) Install the outer rotor in the same direction as before noting

INNER ROTOR / OUTER ROTOR INSTALLATION

the mark put at the time of removal. Apply engine oil to the
entire rotor surface.

I

MD998305 n’

lEN00801

eB4

\

(1) Set the special tool on the crankshaft front end and apply

CRANKSHAFT FRONT OIL SEAL INSTALLATION

engine oil to its outer circumference.

(2) Apply a light coat of engine oil to the oil seal lip and then

slide the oil seal down along the special tool by hand until it
touches the front case. Install the oil seal in the front case
using the other special tool.

TSB Revision

4Gl

ENGINE

-

Front Case and Oil

I)c4

OIL PAN INSTALLATION

(1) Scrape clean or wire brush all

Puma

gask{t

surfaces removing all

loose material.

(2) Apply a 4 mm

pan flange.

Specified sealant:

Mitsubishi Genuine Part No.
lent

(16

in.) diameter

beid

of sealant to the oil

.F

1

‘%lD970389

or equiva-

i.

(3) The oil pan should be installed within 15 minutes after the

application of sealant.

4 mm

(.I

based sealant

6 in.) diameter

Groove
portion

Bog,hole

po

+on

t

;

J

I)04

OIL FILTER INSTALLATION

(1) Clean the filter installation surface of the filter bracket.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Screw the oil filter on the bracket until the O-ring contacts

the base. Then tighten one additional turn.

TSB Revision

4Gl

ENGINE- Piston and Connecting Rod

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

yl&g

. .

Removal steps

OAo $1 k khecting

3. Connecting rod bearing

*iI4

4. Piston and connecting rod

5. Connecting rod bearing

eC4

6. Piston ring No. 1

eC4

7. Piston ring No. 2

I)B4

8. Oil ring

oBoeA 9. Piston pin

10.

Piston

11. Connecting rod

12. Bolt

rod cap

TSB Revision

-

‘.

1

EN0245

IlA-44

4Gl

ENGINE

-

Piston and Connecting Rod

Piston pin setting tool

ylinder No.

MIT21

6941

DENOOM

DISASSEMBLY

OAo

CONNECTING ROD CAP REMOVAL

(1)

Mark the cylinder number on the side of the connecting rod

big end for correct reassembly.

(IBM

PISTON PIN REMOVAL

Item

No.

1

2
3
4

5
6
7
8
9

10

11

,SERVlCE

Part No.

MIT310134
MIT310136
MIT310137
MIT310138
MIT310139

MIT310140
MIT310141
MIT310142
M IT48

143

2 16943

10396

POINT6

Description
Base

Piston Support
Connecting Rod Guide Pin
Connecting Rod Guide Pin
Connecting Rod Guide Pin

Piston Support
Connecting Rod Guide Pin
Piston Support
Press Pin
Stop Screw
Nut

Press pin

$Mgg

h

, Piston pin

Front mark

Connecting rod

de

pin

7EN042E

(2) Select the correct piston support for your

above.) Fit the piston support onto the base. Place the base
on the press support blocks.

(3)

Insert

the press pin through the piston pin hole. Select the
correct connecting rod guide pin. (See above.) Thread the
guide pin onto the threaded portion of the press pin.

(4) Position the piston assembly on the piston support in the

press. With the press pin up as shown in the illustration,
insert the guide pin through the hole in the piston and

through the hole in the piston support.

(5)

Press the piston pin out of the assembly.

IMPORTANT: To avoid piston damage,

l

The piston support must seat squarely against the
piston.

l

Verify that the piston pin will
in the piston support.

(6)

Remove the piston pin from the

qide

f$ess

applrcatron.

9

through the hole

pin.

1

(See

7EN042E

ivision

Piston

kg

End gap

5EN0066

6EN0548

INSPECTION

PISTON RING

(1)

Check for side clearance.

If the limit is exceeded, replace the ring or piston, or both.

Standard value:

No. 1
No. 2

Limit: 0.1 mm

0.03 - 0.07 mm (A012 -

0.02 - 0.08 mm

(.004

in.)

(&IO8 - .0024.‘in.)

(2) insert the piston ring into the cylinder bore. Force the ring

down with a piston, the piston crown being in contact with
the ring, to correctly position it at right angles to the cylinder

wall. Then, measure the end gap with a

If the end gap is excessive, replace the piston ring.

Standard value:

No. 1
No. 2

Oil

0.20 - 0.40 mm

0.20 - 0.35 mm

0.20 - 0.70 mm

(.0079 - .0157
(-0079 - .0138
(.0079 - .0276

Limit:

No. 1, No. 2 0.8 mm
Oil

1.0 mm

(.031
(.038

in.)

in.)

.0028 h.)

thickne$s

in.)
in.)
in.)

gauge.

&llT;E;yFT

(1)

Remove oil from crankshaft pin and connecting rod bearing.

PlN

OIL CLEARANCE (PLASTIC GAUGE

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

bearing and place it on a crankshaft pin in parallel with its
axis.

(3)

Install the connecting rod cap carefully and tighten the bolts

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

using a scale printed on the plastic gauge package.

Standard value: 0.02 - 0.05 mm

Limit: 0.1 mm

(.004

in.)

(.OOOS - AI020

in.)

1

TSB Revision

I

11 A-46

4Gl

ENGINE

-

Piston and Connecting Rod

7EN0421

REASSEMBLY SERVICE

I)A4

PISTON PIN INSTALLATION

(I)

Thread the stop screw and lock nut

Fit the correct piston support on the top of the base.

the press pin, threaded end up, into
support until the press pin touches

(2) Using the graduations on the press

POINTS-

asiembly

,’

into the base.

t?re

hole in the piston

e

stop screw.

n,

adjust the stop

Insert

screw to the correct depth of 49 mm (1.93 in.)

(3) Place the base on the press support blocks.
(4) Slide the piston pin over the threaded end of the press pin,

and thread the correct guide pin up against it.

(5) Coat the piston pin with oil, and with the connecting rod

held in position, slide the guide pin through the piston and
the connecting rod.

(6) Press the piston pin through the connecting rod until the

guide pin contacts the stop screw.

(7) Remove the piston assembly from the base. Remove the

guide pin and the press pin from the assembly.

IMPORTANT: Due to production tolerance variations, it

is necessary to visually inspect t@ piston pin depth
after installation to verify that the piston pin is
centered. Adjust if necessary.

‘*

7EN042:

TSB Revision

3

4Gl

ENGINE - Piston and Connecting Rod

*6+

OIL RING INSTALLATION

(1)

Fit the oil ring spacer into the piston ring groove.

NOTE

The side rails and spacer may be installed in either direction.

I

1

EN027;

Side rail gap

1

EN026E

7EN045:

(2) Install the upper side rail.

To install the side rail, first fit one end of the rail into the
piston groove, then press the remaining portion into
position by finger. See illustration.

Caution
Do not use piston ring expander when installing the

side rail.

(3) Install the lower side rail in the same procedure as

described in step (2).

(4) Make sure that the side rails move smoothly in either

direction.

I)c4

PISTON RING No. 2 / PISTON RING

iuo.

1 IN-

STALLATION

(1)

Using piston ring expander, fit No. 2 and then No. 1 piston

ring into position.
NOTE

(1) Note the difference in shape between

No.‘l,

and No. 2

piston rings.

(2) Install piston rings No. 1 and No. 2 with their side having

marks facing up (on the piston crown side).

-l

No. 2
and

spa&gap

,

No. 1

I

rinq qap

Identification mark
stamped

1’

Barrel

type

Identification mark stamped

1

L

No. 2

Taper type

1

No.

6EN054!

TSB Revision

EN027t

1

side

I)D4

PISTON AND CONNECTING ROD ASSEMBLY IN-

STALLATION

(1)

Apply engine oil to the piston surface, piston rings, and oil

ring.

(2) Align the gaps of piston rings and oil ring (side rails and

spacer) as shown in the illustration.

IlA-48

461

ENGINE

-

Piston and Connecting Rod

Timing belt

c3

side

ront mark

1

EN0247

(3) Rotate crankshaft so that the crank

pi^n

is on the center of

the cylinder bore.

(4) Use suitable thread protectors on

theconnecting

rod bolts

before inserting piston and connecting rod assembly into

the cylinder block.

Care must be taken not to nick the crank pin.

(5) Using a suitable piston ring compressor. tool, install the

piston and connecting rod assembly

I)E4

CONNECTING ROD CAP

(1) Verifying the mark made during

ir#o

the cylinder block.

INST&LLATION

dis$ssembly,

install the
bearing cap to the connecting rod. If the connecting rod is
new with no index mark, make sure
notches come on the same side

th@

the bearing locking

as-,

shown.

e

(2) Make sure that connecting rod big end side clearance

meets the specification.

Standard value: 0.10 - 0.25 mm
Limit: 0.4 mm

(.018

in.)

f.0039 - .00!38

3

in.)

I)F4

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

(2) Install the connecting rod cap on the big end of connecting

(3) Before installing the nuts the threads-should be oiled with
(4) Install both nuts on each bolt finger tight, then alternately
(5) Tighten the nuts to 20 Nm (14.5

TSB Revision

CONNECTING ROD CAP NUT

[NSTALLATION

new procedure, they should be examined BEFORE reuse. If

the bolt threads are “necked down” the bolts should be

replaced.
Necking can be checked by running a

I”
&rt

with fingers to the
full length of the bolt’s thread. If the nut does not run down
smoothly the bolt should be replaced.

rod.
engine oil.
torque each nut to assemble the cap properly.

ft.lbs.)

and plus

l/4

(90”)

turn.

t

461

ENGINE

-

Crankshaft, Flywheel and Drive Plate

CRANKSHAFT, FLYWHEEL AND DRIVE PLATE

REMOVAL AND INSTALLATION

., 135.Nm

19 Nm

l4 fi*‘bfm

184%

11 Nm
8

ft.lbs.

8

I fL

.Y fths-

Al,

3

\

135Nm

- 6 ft.lbk.

53 Nm
38

1

TSB Revision

I

ft.lbs.

Removal steps

1.

Flywheel bolt

2.

Flywheel

3. Drive plate bolt

4.

Adaptor plate

5.

Drive plate

6.

Adaptor plate

7.

Crankshaft bushing

8. Rear plate

9. Bell housing cover

10. Oil seal case

11.

Oil seal case gasket

*Cl4

12.

Rear oil seal

13. Bearing cap bolt

*C4

14. Bearing cap

#B+

15. Crankshaft bearing, lower

16. Crankshaft

@B4

17. Crankshaft bearing, upper

#A4

18. Oil pressure switch

19. Cylinder block

I

For MIT

1

EN343

1

IA-50

461

ENGINE

-

Crankshaft, Flywheel and Drive Plate

INSPECTION

CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIC
GAUGE METHOD)

(1) Remove oil from the crankshaft journal and the crankshaft

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

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

6EN055C

(4) Install the crankshaft bearing cap carefully and tighten the

bolts to the specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6)

Measure the width of the plastic gauge at its widest part by

using a scale printed on the plastic gauge package.

Standard value: 0.02 - 0.05 mm

Limit: 0.1 mm

(.004

in.)

rr,

(.OOOS - .0020

in.)

;
i;

CYLINDER BLOCK

(1)

Using a straightedge and feeler

surface for

warpage.

Make sure

gaugzcheck

thagthe

the block top

surface is free

from gasket chips and other foreignimatters.

Standard value: 0.05 mm
Limit: 0.1 mm

(004

in.)

(.002

in.)

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

limit or replace.

Grinding limit: 0.2 mm

(.008

in.)

The total resurfacing depth of both cylinder block

and mating cylinder head is 0.2 mm
maximum.

$

(008

in.) at

Cylinder block height (When new)?

Al

B

0

(3) Check cylinder walls for scratches

255.9 - 256.1 mm

(10.075 - lO~iO88

and

seizure. If defects

in.)

are evident, correct (rebore to an oversize) or replace.

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

cylindricity. If worn badly, correct the cylinder to an oversize
and replace the piston and piston rings. Measure at the
points shown in illustration.

i

Standard value:

Cylinder I.D.

75.50

75.53 mm

-

(2.9724 - 2.9736 in.)

Cylindricity: 0.01 mm

(0004

in.) or less

TSB Revisipn

4Gl

ENGINE - Crankshaft, Flywheel and Drive Plate

BORING CYLINDER

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

basis of the largest bore cylinder.

Piston size identification

Thrust
direction

6EN055

Size

0.50

0.75

1

.OO

mm

(.02 in.) O.S.

mm

(.03

mm

(.04

in.)

in.)

OS.

OS.

Identification

0.25

0.50

0.75

1 .oo

I-

NOTE

Size mark is stamped on the piston top.
(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.

I,:“.

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

(.OOOS

in.)

(honing margin)

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

Caution

To prevent distortion that may result from temperature

rise during honing, bore cylinders, in this order: No. 2

to No. 4 to No. 1 to No. 3.

(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

(.OOOS - .0016

in.)

NOTE
When boring cylinders, finish all of four cylinders to the
same oversize, Do not bore only one cylinder to an

oversize.

lwer

Grooveless

bearing

Upper and lower bearings
(for No.

3)

Upper bearing
(for No.

1.2.4.5)

9EN0094

1

EN027

TSB

INSTALLATION SERVICE POINTS

*A+

(1)

+B4

(1)

(2) No. 1, 2, 4 and 5 lower bearings (cap side) are not provided
(3) No. 3 bearings are flanged and provided with no groove.

Revision

SEALANT APPLICATION TO OIL PRESSURE

SWITCH

Coat the threads of switch with sealant before

installirlg

the

switch.

Specified sealant: 3M ATD Part No. 8660 or equivalent
Caution

1. Keep the end of threaded portion clear of sealant.

2. Avoid an overtightening.
CRANKSHAFT BEARING INSTALLATION

No. 1, 2, 4 and 5 upper bearings (cylinder block side) are

provided with oil groove.
with oil groove.
Common bearings are used on the cap side and cylinder

block side.

11

A-52

Timing
belt side

401

ENGINE - Crankshaft, Flywheel and Drive

I)c4

INSTALLATION OF BEARING

(1) Install according to the front mark end cap No.

NO174

Cap No.

1

EN017E

Pla$

CAP

Oil seal

Oil seal case

1

EN028C

1

EN027:

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

crankshaft turns smoothly and the end play is correct. If the

end play exceeds the limit, replace crankshaft bearings.

Standard value: 0.05 - 0.18 mm
Limit: 0.3 mm

eD4

OIL SEAL INSTALLATION

(.012

in.)

(.0020 - .0071

in.)

TSB Revision

4Gl

BRACKET

REMOVAL AND INSTALLATION

65

Nm

47

ft.lbs.

2

60

Nm

44

36
26

ft.1bs.h

Nm

ft.lbs.

1

/--+GFL

yy

ENGINE - Bracket

l.lA-53

Removal steps

1.

Exhaust pipe support bracket

2. Engine support bracket, front

3. Roll stopper bracket, front

4. Roll stopper bracket, rear

120

Nm

67

ftlbs.

‘\

TSB Revision

1

EN0347

I

NOTES

ENGINE

4637

CONTENTS

BRACKET

CRANKSHAFT, FLYWHEEL AND
DRIVE PLATE

CYLINDER HEAD AND VALVES
EXHAUST MANIFOLD AND

WATER PUMP

FRONT CASE, OIL PUMP AND OIL PAN

FUEL AND EMISSION
GENERAL INFORMATION
GENERAL SPECIFICATIONS

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

. .

.._..............._...._..............................

f.......................

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

PARTS

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

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

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

62

58

39

32

. . . . . . . .

45
26

‘2

5

GENERATOR AND IGNITION SYSTEM
INTAKE

PISTON AND CONNECTING ROD
ROCKER ARMS AND CAMSHAFT
SEALANT
SERVICE SPECIFICATIONS
SPECIAL TOOLS

THROTTLE BODY
TIMING
TORQUE SPEClklCATlONS

MANIFOLD

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

BELT

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

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

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

..........:.........

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

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

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

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

........

..........

/.

16
30
52
34

12

6

13

28

18

10

IIB-2

4G3

ENGINE - General Information

GENERAL INFORMATION

ENGINE SECTIONAL VIEW

1

TSB Revision

3ENOO86

I

4G3

ENGINE - General Information

pqJp3

I

\

TSB Revision

3EN0087

IIB-4

JBRICATION SYSTEM

4G3

ENGINE - General Information

TSB Revision

3LUOO20

4G3

ENGINE

GENERAL SPECIFICATIONS

-

General Specifications

ptgpg

Description

Type

Number of cylinders

Combustion chamber
Total displacement
Cylinder bore

Piston stroke
Compression ratio
Valve timing:

( 1:

camshaft identification mark

Intake valve

Opens
Closes

Exhaust valve

Opens
Closes

Lubrication system

Oil pump type
Cooling system
Water pump type
EGR type
Injector type and number
Injector identification mark
Fuel regulated pressure
Throttle bore
Throttle position sensor
Closed throttle position switch

cm3

mm (in.)

mm (in.)

mm (in.)

(cu. in.)

kPa

(psi)

Specifications

In-line OHV, SOHC
4
Compact type

1.755 (107.10)

80.6 (3.17)

86 (3.39)

9.0

(AR)

20” BTDC
52” ATDC

55” BBDC

17” ATDC
Pressure feed, full-flow filtration

Involute gear type
Water-cooled forced circulation
Centrifugal impeller type
Single type
Electromagnetic 4

N210H

335 (47.6)
50 (1.969)

Variable resistor type
Contact type, within idle speed control motor

““:’:

:

: .///,.’

.

-_

.I-.: :_

I .,

.-

IIB-6

4G3

ENGINE - Service Specifications

SERVICE SPECIFICATIONS

Standard

Cylinder head

Flatness of gasket surface
Grinding limit of gasket surface

*

Total resurfacing depth of both cylinder head

and cylinder block
Overall height
Oversize rework dimensions of valve

guide hole
(both intake and exhaust)

0.05

(002)

0.25

(.OlO)

0.50 (020)

Oversize rework dimensions of intake valve

seat ring hole

0.30 (012) 43.30 - 43.33

0.60

(024)

Oversize rework dimensions of exhaust
valve seat ring hole

0.30

(012)

0.60

(.024)

0.05

(.0020)

88.4 - 88.6 (3.480 -

13.05-

13.25 - 12.27

13.50-

43.60-43.63(1.7165-1.7177)

37.30 -37.33 (1.4685 - 1.4697)

37.60 - 37.63 (1.4803 -

13.07

13.52

3.4881

(.5138-.5146)

(5217 - 95224)

(.5315-.5323)

(1.7047 -

1.7059)

1.4815)

i

7

t

mm (in.)

Limit

0.2

(.008)

“0.2 (008)

Camshaft

Cam height 35.91 (1.4138)
Fuel pump driving cam diameter
Journal diameter
Oil clearance

Rocker arm

I.D.
Rocker arm-to-shaft clearance 0.01 - 0.04

Rocker shaft

O.D.
Overall length

Intake

Exhaust

40

(1.57)

33.94 - 33.95 (1.3362 -

0.05 - 0.09

18.91 - 18.93

18.89-

365.5

350.0

(0020 - .0035)

(.0004 - .0016)

18.90

(14.035)
(13.780)

1.3366)

(.7444 - .7453)

(7437 - .7440)

.I

c

_

<

i

35.41 (1.3941)

39.5 (1.555)

0.1

(.004)

1

TSB Revision

1

463

ENGINE - Service Specifications

mm (in.)

Standard

Valve

Overall length

Intake
Exhaust

Stem diameter

Intake
Exhaust

Face angle

Thickness of valve

head (margin)

Intake
Exhaust

Stem-to-guide
clearance

Intake 0.03 - 0.06
Exhaust

Valve spring

Free height
Load/installed height

Out-of-squareness

N/mm

(Ibs./in.)

98.2 (3.866)

95.5 (3.760)

7.96-7.98(.313-.314)

7.93 - 7.95

45” - 45”30’

1.2

(.047)

1.5

(.059)

0.05 - 0.09

49.2 (1.937)
31

O/37.3

Max. 2”

(.312 - ,313)

(0012 - .0024)

(.0020 - .0035)

(68/l

.469)

Limit

I

c’:,;

*‘:’ ;, :,i :;

0.7
1 .o

0.10

0.15

48.2 (1.896)

4”

.-y >,-;

(.028)

i.039)

(.0039)

c.qaq$l)

. .

,.

,.

,

Valve guide

Overall length

Intake

Exhaust
I.D.

O.D.

Service size

Press-in temperature

Valve seat

Seat angle
Valve contact width

Sinkage

service

size

44 (1.73)
48 (1.89)

7.2 -7.25

13.06-13.07(.5142-.5146)

0.05
Room temperature

43”30’ - 44”

0.9 - 1.3

0.3

(.2835 - .2854)

(.002),

0.25

(.035 - .051)

(.OlZ),

0.6 (024) oversize

(.Ol),

0.50

(.02)

oversize

0.2

,!

4

(.008)

1

TSB Revision

463

ENGINE - Service

SDecifications

mm (in.)

Silent shaft
Journal diameter

Right(front)

(rear)

Left (front)

(rear)

Oil clearance

Right(front)

(rear)

Left

Ifrar$)

r

Piston

O.D.

Piston-to-cylinder clearance
Service size

Piston ring

End gap

No. 1 ring
No. 2 ring
Oil ring

Ring-to-ring groove clearance

No. 1 ring
No. 2 ring

Service size

Standard

38.96 - 38.98 (1.5339 - 1.5346)

35.95 - 35.97 (1.4154 -

18.47 - 18.48

35.95 - 35.97 (I

0.02 - 0.06

0.05 - 0.09

0.02 - 0.05

0.05 - 0.09

80.57 - 80.60 (3.1720 - 3.1732)

0.02 - 0.04

0.25

(.Ol),

0.30-0.45(.0118-.0177)

0.20-

0.35 (.0079 -

0.20 - 0.70

0.05 - 0.09

0.02 - 0.06

0.25

(.Ol),

(.7272 - .7276)

.4154- 1.4161)

(.0008 - .0024)
(.0020 - .0035)

(.0008 - .0020)

(.0020 - .0035)

(.0008 - .0016)

0.50

(.02),

LOO79 - .0276)

(.0020 - .0035)
(.0008 - .0024)

0.50

(.02),

0.75

.0138)

0.75

1.4161)

(.03), 1.OO

(.03), 1.OO

(.04)

(.04)

oversize

oversize

Limit

0.8

(.031)

0.8

(.031)

1 .o(.039)

Piston

pin

O.D.
Press-in load N
Press-in temperature

Connecting rod

Big end center-to small end center length
Bend
Twist
Big end side clearance

(Ibs.)

19.00 - 19.01

5,000 - 15,000 (I, 102 - 3,307)

Room temperature

153.6 - 153.7 (6.047 -

0.05

(.0020)

0.1

(.004)

0.10 - 0.25

(.7480 - .7484)

6.051)

(.0039 - .0098)

0.4

(.OI 6)

TSB Revision

463

ENGINE - Service Specifications

Crankshaft

End play

Journal O.D.

Pin O.D.
Out-of-roundness and taper of journal

and pin

Oil clearance of journal
Oil clearance of pin

Journal undersize

0.25

(.OlO)

U.S.

0.50

(.020)

U.S.

0.75

(.030)

U.S.

Pin undersize

0.25

(.OlO)

U.S.

0.50 (020) U.S.

0.75

(.030)

U.S.

Cylinder block

I.D.
Flatness of gasket surface
Grinding limit of gasket surface

*

Total resurfacing depth of both cylinder block

and cylinder

Dverall

height

head

Standard

0.05-0.18(.0020-.0071)

57 (2.24)
45 (1.77)
Within 0.01 (0004)

0.02-0.05 (.0008- .0020)

0.02 - 0.05

56.74 - 56.75 (2.2339 - 2.2342)

56.49 - 56.50 (2.2240 - 2.2244)

56.24-56.25 (2.2142-2.2146)

44.74-44.75(1.7614-1.7618)

44.49 -44.50 (1.7516 - 1.7520)

44.24-44.25 (1.7417 - 1.7421)

80.60 - 80.63 (3.1732 - 3.1744)

0.05

(.002)

285.1

(.0008 - .0020)

-285.3(11.224-11.232)

Limit

0.3

(;012~

:, .’ ,/

* ,‘/~

0.10

(.0039)

0.10

(.0039)

0.

i

(IboT$

*0.2 (068)

.

-.

3il

pump

side

clearance
Drive gear
Driven gear

Irive

belt deflection

Jew belt

Jsed belt

njector

:oil resistance

‘hrottle

position sensor

3esistance kfi

dle

speed control motor

:oil

resistance

dle

speed control motor position sensor

jesistance

CR

IR

kfi

0.08-0.14 (0031 - .0055)

0.06 - 0.12

6.5-8(.26-.31)

8 - 11

I3 -

16 at

3.5-6.5

5 - 35 at

4-6

(0024 - .0047)

(31 - .43)

20°C (68°F)

20°C (68°F)

TSB Revision

IIB-10

4G3

ENGINE - Torque Specifications

TORQUE SPECIFICATIONS

Generator and ignition system

pump

Water pulley bolt

Generator brace bolt

Generator brace mounting bolt

Generator pivot nut
Damper pulley bolt
Crankshaft pulley bolt

Spark plug
Distributor mounting nut

Timing belt

Tensioner bolt and nut

pump

Oil sprocket nut
Crankshaft sprocket bolt
Tensioner

Engine support bracket, left
Camshaft sprocket bolt

Fuel and emission parts

Throttle body mounting bolts

Fuel rail mounting bolts
Fuel regulator bolts

EGR valve mounting bolts

“B”

pressure

bolt

Nm

9

I4

19

23

17
17

25

12

26
37
120

19
36
90

19

12
9
22

,

.,:

i

ft.lbs.

7

IO

14

I7

12

12
18

9

19

27

87

I4

26
65

14

9
7
16

Throttle body

Throttle position sensor attaching bolts

Intake manifold

Engine coolant temperature gauge unit
Engine coolant temperature sensor

Water outlet fitting bolt

Intake manifold plenum stay bolt
Intake manifold plenum bolt and nut

Thermostat housing bolt and nut

Intake manifold stay bolt

Intake manifold bolt and nut

Exhaust manifold and water pump

Oil level guide bolt

Exhaust manifold cover “A” bolt

Exhaust manifold cover “A” and “B” mounting bolt

Exhaust manifold cover “B” bolt
Exhaust manifold nut

Water inlet pipe bolt

Water pump bolt

gauge

2.0

11

30

19
18
18

I8

22

18

14
30
9
24

18

14

14

1.4

8
22

14
13
13

I3

16

I3

10

9

22

7

t

17

I3

10

IO

1

TSB Revision

Rocker cover bolt
Camshaft bearing cap bolt
Camshaft

Oil pressure gauge unit

Oil filter bracket
Oil pan drain plug
Oil pan bolt
Oil screen nut
Oil pump cover bolt
Oil pump driven gear bolt
Oil relief valve plug

bearin

(M8)

4G3

ENGINE - Torque Specifications

3ear

plate bolt

3ell

housing cover bolt

3il

seal case bolt

3earing
3racket

Exhaust pipe support bracket

3011
3011

Ingine support bracket, right

cap bolt

stopper bracket, front
stopper bracket, rear

53

36
65

120

65

38

26
47
87
47

[

TSB Revision

I

IIB-12

SEALANT

4G3

ENGINE - Sealant

Engine coolant temperature sensor
Engine coolant temperature gauge unit
Semi-circular packing

Oil pan
Oil pressure gauge unit

Oil pressure switch

Specified sealant

3M Nut Locking Part No. 4171 or equivalent
3M ATD Part No. 8660 or equivalent
3M ATD Part No. 8660 or equivalent

MITSUBISHI GENUINE Part

MD970389
3M

ATD Part No. 8660 or equivalent

3M

ATD Part No. 8660 or equivalent

or equivalent

~‘Ouantity

ps

required

ps

required

As required

ks

required

As required
%s

required

T

1

TSB Revision

SPECIAL TOOLS

463

ENGINE - Special Tools

r00i

ff!f

Number and
tool name

MB990767
Lns”, yo!;

MD9987

MD99801 1

Crankshaft rear

oil seal installer

MD9981

Piston pin setting

tool

MD998280

Silent shaft
bearing installer

@

0

holder

19

28

Supersession

MB990767-01

Use with

MD99801 l-01 Installation of crankshaft rear oil seal

Use with

M B990938-01

MD9981

MD998280-01

Use with

MIT308239

84-01

MIT21

5869

Application

Holdingcamshaft

or

torquing

Removal and Installation of piston pin

Installation of silent shaft bearing front

bolt.

sprocket when loosening

.

MD998282

Silent shaft
bearing puller

MD998283

Silent shaft
bearing puller

MD998285

Crankshaft front

oil seal guide

M

0998286 MD998286-01
Silent shaft
bearing installer

/

MD998304

Crankshaft front
oil seal installer

M D998282-01

Use with MIT304204

M D998283-01

Use with

MD998285-01 Installation of crankshaft front oil seal

M D998304-0

MIT304204

I

Removal of silent shaft bearing front

Removal of silent shaft bearing rear

Installation of silent shaft bearing rear

Installation of crankshaft front oil seal

]

TSB Revision

IIB-14

463

ENGINE - Special Tools

Leak-down tester

Air bleed wire

MD998713

Camshaft oil seal

installer

MD998719

Pulley holding

pins (2)

M D998727

Oil pan remover

M D998728

Valve stem seal

installer

M D9987 13-O

M

IT308239

MD998728-01 Installation of valve stem seal

1

Installation of camshaft oil seal

Holding camshaft sprocket when loosening
or torquing bolt

Removal of oil pan

_

1

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I

463

ENGINE - Special Tools

Removal of crankshaft sprocket

1

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IIB-16

4G3

ENGINE - Generator and Ignition System

GENERATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION

-

18

25 Nm

ft.lbs.

14 ilm

10 ft.lbs.

19
14

I

Nm
ft.lbs.

9Nm

7

ftlbs.

@-

17 Nm
12

ft.lbs.

23 Nm

17

ft.lbs.

17’Nm

12

ft.lbs.

7

12 Nm
9

ft.lbs.

Removal steps

+B4 1.

Drive belt

2. Water pump

3.

Generator brace

4.

Generator

5.6.Damper pulley
Adapter

7.

Crankshaft pulley

8. Spark plug cable

9.

Spark plug

10.

Distributor

11.

O-ring

pulley

3EN0212

4G3

ENGINE

3EN022~

-

Generator and Ignition System

INSTALLATION SERVICE POINTS

I)Ag

DISTRIBUTOR INSTALLATION

(1)

Turn the crankshaft so that the

center.

(2) Align the distributor housing and gear mating marks.

(3) Install the distributor to the engine while aligning the fine

cut (groove or projection) of the distributor’s installation

flange with the center of the distributor installation stud.

I&.

1 cylinder is at

to;

dead

Crankshaft pulley

Generato

Crankshaft pulley

$F&j

pump

3EN0226

Water pump pulley

6EN059f

I)B4

DRIVE BELT TENSION ADJUSTMENT

(1) Move the generator to give greater tension to the belt so

that the specified deflection is obtained.

Standard value:

New belt: 6.5 - 8 mm
Used belt: 8 -11

i

mm

(.26- .31

(.31- .43

in.)

in.)

Or using a tension gauge, adjust the tension to the standard

value.

Standard value:

New belt: 500 - 700 N (110 - 154
Used belt: 400 N (88

Ibs.)

Ibs.)

(3) Tighten the generator brace bolt.
(4) Tighten the nut for the generator pivot bolt.

L

5

IIB-18

4G3

TIMING BELT

REMOVAL AND INSTALLATION

ENGINE - Timing Belt

36Nm l5

26

ft.lbs.

I

13

37
27

Nm
ft.lbs.

12

I I

Removal steps

1. Timing belt front upper cover

(IAO eH4

461) +F4
(I$$ +E4

OEo *II4 11.
(IFI) eC4

SO
(IHO #A4

2. Timing belt front lower cover

3. Timing belt

#G4

4. Tensioner

#G4

5. Tensioner spring

6. Oil pump sprocket

7. Crankshaft bolt

8. Crankshaft sprocket

9. Flange

10.

Tensioner “B”
Timing belt

12. Silent shaft sprocket

*B4

13. Spacer

14. Crankshaft sprocket

15. Engine support bracket, left

16. Camshaft sprocket bolt

17. Camshaft sprocket

18. Timing belt under upper cover

19. Timing belt under lower cover

“6”

“B”

3EN0213

_.

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463

ENGINE - Timing Belt

REMOVAL SERVICE POINTS

qA0

TIMING BELT REMOVAL

(1) Mark the belt running direction for reference

tion.

aB0

OIL PUMP SPROCKET REMOVAL

(1) Remove the plug on the left side of the cylinder block.
(2) Insert a Phillips screwdriver [shank diameter 8 mm

to block the left silent shaft.
(3) Remove the nuts.
(4) Remove the oil pump sprocket.

-in reihstalla-

(31

in.)]

@r)

CRANKSHAFT BOLT LOOSENING

(1)

Using the special tool, hold the drive plate or flywheel.

(2) Remove the crankshaft bolt.

I

\t lEN03261

3EN021

(IDO

CRANKSHAFT SPROCKET REMOVAL

(IEI)

TIMING BELT “B” REMOVAL

(1) Mark the belt running direction for reference in reinstalla-

tion.

TSB Revision

1

IIB-20

4G3

ENGINE

-

Timing Belt

OF0

OGo

QHo

SILENT SHAFT SPROCKET REMOVAL

CRANKSHAFT SPROCKET

CAMSHAFT SPROCKET BOLT LOOSENING

i

* -,

“B’

REMOVAL

Cracks

&

-

\

000

B

00

INSPECTION

TIMING BELT / TIMING BELT “B”

Replace belt if any of the following
(1) Hardening of back rubber - the ba

8EN006E

(2) Cracks on rubber back
(3) Cracks or peeling of canvas
(4) Cracks on rib root
(5) Cracks on belt sides

1

EN024E

TSB Revision

B

ditions

ide is glossy without

resilience and leaves no indent whe pressed with
nail.

k

4

\

exist.

finger-

Rounded edge

/

Abnormal wear

(Fluffy strand)

Rubber exposed

Tooth missing

and canvas

463

8EN0067

ENGINE - Timing Belt

(6)

Abnormal wear of belt

are sharp as if cut by a knife.

(7) Abnormal wear in teeth
(8) Missing tooth

sides.

The sides are normal if they

)’

8EN006E

INSTALLATION SERVICE POINTS

I)A4

CAMSHAFT SPROCKET BOLT

#B4

SPACER INSTALLATION

(1)

Install the spacer with the chamfered end toward the oil

seal.

INSTALLATION,

I)c4 SILENT SHAFT SPROCKET INSTALLATION

1

TSB Revision

11

B-22

4G3

ENGINE - Timing Belt

I)04

TIMING BELT “B” INSTALLABON

(1)

Align the timing marks on the crankshaft sprocket “B” and

silent shaft sprocket with the marks on the front case
respectively.

(2) Install the timing belt “B” on the crankshaft sprocket “B”

and silent shaft sprocket. There should be no slack on the
tension side.

(3) Make sure that the relationship between the tensioner

pulley center and the bolt center’ is as shown in the
illustration.

(4) Move the tensioner “B” in the direction of arrow while

lifting with a finger to give a sufficient tension to the tension
side of timing belt. In this condition, tighten the bolt to

secure tensioner “B”. When the bolt is tightened, use care
to prevent the shaft from turning together. If the shaft is
turned together, the belt will be

(5) Check to ensure that the timing marks on the sprockets and

front case are in alignment.

(6) Press with index finger the center of span on the tension

side of timing belt “B”. The belt must deflect 5 to 7 mm

(20

to 28 in.).

I)E4

CRANKSHAFT BOLT TIGHTEifING

(1)

Using the special tool, hold the drive plate or flywheel.

(2) Install the crankshaft bolt.

overtensioned.

c

I

$

TSB Revision

Y--l

Screwdriver

463

ENGINE

- Timinn

I)F4

OIL PUMP SPROCKET INSTALLATION

(1)

Insert a Phillips screwdriver [shank diameter 8 mm

Belt

IT&23

through the plug hole on the left side of the cylinder block to

block the left silent shaft.
(2) Install the oil pump sprocket.
(3) Tighten the nuts to the specified torque.

(31

in.)]

6R?”’ ”

3EN0231

3EN017

I)Gg

(1)

TENSIONER / TENSIONER SPRING INSTALLATION

Hook the tensioner spring ends to the water pump body

and tensioner bracket.

(2) Move the tensioner fully toward the water pump and

tighten the nut and bolt.

I)H4

3EN017t

TSB Revision

TIMING BELT INSTALLATION

(I)

Align the timing marks on the camshaft sprocket and

crankshaft sprocket with their timing marks.

11

B-24

4G3

ENGINE - Timing Belt

(2) Align the timing mark on the oil pump sprocket with its

mating mark.

(3) Remove the plug on the cylinder block and insert a Phillips

screwdriver [shank diameter 8 mm
hole. If it can be inserted as deep
more, the timing marks are correctly *lioned. If the inserted
depth is only 20 to 25 mm (8 to 1
sprocket one turn and realign the timing marks. Then check
to ensure that the screwdriver can be inserted 60 mm (2.4
in.) or more. Keep the screwdriver inserted until installation
of the timing belt is finished.

(4) Install the timing belt on the crankshaft sprocket, oil pump

sprocket and camshaft sprocket in
be no slack on the tension side.

(.31

in.)] through the

‘8s

60 mm (2.4 in.) or

.Odn.),

turn the oil pump

t&t

order. There should

(5) Loosen the tensioner mounting

(6) Turn the crankshaft clockwise by

sprocket (or crankshaft sprocket).

‘)

Apply force to the tensioner in the direction shown by arrow

(7

@ to make the belt engage completely with each sprocket.

bol)

and nut.

z

!!
:i

45

t\;ivo

teeth of camshaft

TSB Revision

4G3

ENGINE - Timing Belt

(8) Tighten the tensioner attaching nut, then tighten ‘the

tensioner attaching bolt.

Caution
If the bolt is tightened first, tensioner turns as the bolt
is tightened, resulting in an excessive belt tension.

(9) Hold the center of the tension side span of the timing belt

(between the camshaft and oil pump sprockets) between
your thumb and index finger as shown. Then, make sure
that the clearance between the belt back surface and cover
is standard value.

Standard value: 12 mm

(.47

in.)

1

TSB Revision

I

11

B-26

4G3

ENGINE

FUEL AND EMISSION PARTS

REMOVAL AND INSTALLATION

Fuel and Emission Parts

-

-3

12 Nm

9

ft.lbs.

L

.

‘2

4
I

;

.:

19 Nm

14ftJbs.

22

Nm

16

ft.lbs.

Removal steps

1.

Throttle body assembly

2.

Gasket

3. Injector and fuel rail

#B4

4. Fuel pressure regulator

5.

O-ring

6.

Fuel rail

7.

Insulator

8.

*A4

Insulator

9.

Injector

10.

G-ring

11. Wornmet

3EN0150

TSB Revision

4G3

ENGINE

-

Fuel and Emission Parts

Yrm7

6FU192C

6EM038

INSPECTION

INJECTORS

(1) Using an ohmmeter (circuit tester), test for

. .

,. x,r,

con&uity

-’

between terminals of injector; the circuit should be closed.
If failure is detected, replace the injector.

Standard value: 13 - 16 n at

20°C (68°F)

EGR VALVE

(1) Check EGR valve for sticking or carbon deposits.

If such conditions exist clean or replace EGR valve.

(2) Connect a hand vacuum pump to the nipple of EGR valve

and plug the other nipple.

(3) Apply a vacuum of 500 mm Hg (19.7

in.Hg)

to make sure

that vacuum is maintained. If there is a leak, replace the

EGR valve.
In addition, check the valve for its opening and closing
motion by applying and removing vacuum.

INSTALLATION SERVICE POINTS

3EN015;

I)A4

INJECTOR INSTALLATION

(1) Before installing an injector, the rubber O-ring must be

lubricated with. a drop of clean engine oil to aid in
installation.

(2) Install injector top end into the fuel pipe. Be careful not to

damage O-ring during installation.

r)64 FUEL PRESSURE REGULATOR INSTALLATION

(1)

Before installing the pressure regulator, the O-ring must be

lubricated with a drop of clean engine oil to aid in
installation.

0-rinb

6FUO714

TSB Revision

11 B-28

THROTTLE BODY

4G3

ENGINE - Throttle Body

DISASSEMBLY AND

REASSEMBLY

Disassembly steps

(I$!

#A4

1. Throttle position sensor

2.

Idle

speed control motor

3. Throttle valve set screw

OBO

4. Throttle body

DISASSEMBLY SERVICE POINTS

(IAI)

(1) Do not disassemble the sensor an8 motor.
(2) Do not immerse in solvent the sensor and motor.

1

TSB Revision

THRO-ITLE

POSITION SENSOR AND IDLE SPEED

CONTROL MOTOR REMOVAL-

Clean them with shop towel.

6FU1292

a:

r

Throttle position

sensor

power supply

\

Throttle
sensor output

poskion

Throttle position

sensor connector

P

Ground

/

View

4G3

P

7FU053E

ENGINE - Throttle Bodv

QBo

THROlTLE BODY REMOVAL

(1)

Do not remove the throttle valve

(2) Check if the vacuum port or

compressed air to clean the vacuum passage.

REASSEMBLY SERVICE POINT

I)A4

THROlTLE POSITION SENSOR INSTALLATION

(1)

Check correct installation of the throttle position sensor.

While moving the throttle lever in both open and close
directions, check to see that resistance between terminals

(ij

and @ or @ and @ changes. If resistance changes
smoothly, the throttle position sensor has been installed
correctly.

b&sage

is

clog&~& ‘&e

1

EN024E

TSB Revision

11 B-30

463

ENGINE - Intake Manifold

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

18

Nm

13 ftlbs.

1

5

19

Nm

14ft.lbs.

I

18N‘m

13

ft.lbs.

Removal steps

1.

Water hose “A”

2. Water hose “B”

eB4

3. Engine coolant temperature gauge unit

#A4

4. Engine coolant temperature sensor

5. Water outlet fitting

6. Water outlet fitting gasket

7. Thermostat

8. Intake manifold plenum stay

9. Intake manifold plenum

IO.

Intake manifold plenum gasket

11. Intake manifold stay

12. Engine hanger

13. Thermostat housing

14. Intake manifold

15. Intake manifold gasket

22’Nm

16 ftlbs.

3EN0154

TSB Revision

463

ENGINE - Intake Manifold

Sealant

ZEN0219

9EN009

INSTALLATION SERVICE

I)A4

SEALANT APPLICATION TO EyGlNE

POlNTS

Coo&ANT

TEMPERATURE SENSOR

Specified sealant:

3M

Nut Locking Part No. 4171 or equivalent

r)64

SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE GAUGE UNIT

Specified sealant:

3M

ATD Part No. 8660 or equivalent

TS8

Revision

11

B-32

463

ENGINE

-

Exhaust Manifold and Water Pump

EXHAUST MANIFOLD AND WATER PUMP

REMOVAL AND INSTALLATION

30 Nm

14 Nm

10

ft.lbs.

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3.

O-ring

4. Exhaust manifold cover “A”

5.

Engine hanger

6.

Exhaust manifold

7. Exhaust manifold gasket

8. Exhaust manifold cover “B”

#A4

9. Water inlet pipe

10.

O-ring

11.

Water

12. Water pump gasket

14 Nm

10 ft.lbs.

pump

3EN0222

TSB Revision

JE

Water!

O-ring

\

inlet pipe

4G3

ENGINE

Water pump

6EN059

-

Exhaust Manifold and Water Pump

1

INSTALLATION SERVICE POINT

I)A4

WATER INLET PIPE INSTALLATION

ring

(1) Wet the

Caution
Keep the O-ring free of oil or grease

(with water) to facilitate assembly.”

0- .

-’

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I

IIB-34

4G3

ENGINE - Rocker Arms and Camshaft

ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION

20 Nm

14

ft.lbs.

11 Nm

8

ft.lbs. +

/

6

Removal steps

1.

Breather hose

2.

P.C.V. hose

3.

Oil seal

4.

Rocker cover

5.

Gasket

6. Rocker arm and rocker shaft

7. Rear camshaft bearing cap

8.

+E4
*DC 10.

eD4
+D4

#C4

eC4

6Ab MI

’ ’

iA4

Rocker arm

9. Wave washer
Camshaft bearing

11. Rocker shaft spring

12.

Camshaft bearing

13.

Camshaft bearing

14. Right rocker shaft

15. Left rocker shaft

16. Front bearing cap

17. Lash adiuster

il. ~S+;~;tular

cap No.
cap No.

cap No.

packing

4

3

2

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eF4 20:

Camshaft oil seal

3EN0156

4G3

ENGINE

-

Rocker Arms and Camshaft:

REMOVAL SERVICE POINT

QAQ

(1)

(2) Remove the lash adjuster holders and the lash adjusters.

ROCKER ARM AND

Mark lash adjusters for installation in the same position.

ROCKkR

’

SHAFT REMOVAL

INSPECTION

CAMSHAFT

(1)

Measure the cam height.

Standard value: 35.91 mm
Limit: 35.41 mm (1.3941 in.)

ROCKER ARM

(1) Visually check the roller and replace if dent, damage,

seizure is evident.

(2) Check roller for smooth rotation. Replace if it is binding or

there is an excessive play.

(3) Check the inside diameter and replace the rocker arm if

damage or seizure is observed.

(j.4138

in.)

or

7ENO06

LASH ADJUSTER LEAK DOWN TEST

Caution

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

2. Do not disassemble lash adjuster.

3.

When cleaning lash adjuster: use clean diesel fuel only.

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11 B-36

463

ENGINE

-

Rocker Arms and Camshaft

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

wire, move the plunger up and

bleed air.
Use of the Retainer facilitates the aitbleeding of the rocker

arm mounted type lash adjuster.

(3) Remove the small wire and press

is hard to be pushed in, the lash ad&ster is normal. If the
plunger can be pushed in all the

adjuster again and test again.

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

Caution

Upon completion of air bleeding, hold the lash adjuster

upright to prevent inside diesel fuel from spilling.

do9

four or five times to

i

thdplunger.

wayreadily,

”

If the plunger

bleed the lash

6EN057C

Division = 1 mm

‘:.

.:::

.....

..::i:i:i:::.:.:.:

.....

. .

.:.:.:.

....

..........

.....

.

..

.

.

t.04 in.)

7EN043

Apply sealant

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

(Leak down tester

(5) After the plunger has gone down somewhat 0.2 - 0.5 mm

(.008 ­(.04

tion.

Standard value: 4
[Diesel fuel at 15 -

INSTALLATION SERVICE POINTS

I)A4

SEMI-CIRCULAR PACKING INSTALLATION

(1) Apply specified sealant to the portions indicated in the

illustration.

Specified sealant:

020 in.), measure time taken

in.). Replace if the measured time is out of specifica-

3M ATD Part No. 8660 or equivalent

MD998440).

20 seconds

­20°C

&iii

DEN005:

(59 -

“for

it to go down 1 mm

/

1 mm

68“F)]

(.04

in.)

IOmm

Semi-circular

Cylinder’head ’

-

’

3EN004L

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Lash

adjister

4G3

ENGINE - Rocker Arms and Camshaft

#B4

LASH ADJUSTER

(1)

Dip the lash adjuster in clean diesel fuel.

(2) While using a small wire to lightly press the check ball

downward, move the plunger up and down four or five
times to bleed out the air.

6EN0421

(3)

Insert

MD99?443-01

7EN017,

the lash adjuster to the rocker arm, being careful not
to spill the diesel fuel. Then use the special tool to prevent
the lash adjuster from falling while installing the rocker arm

and shaft assembly to the cylinder head.

IiUSTALLATlON

Rocker shaft

for exhaust

Camshaft

for intake

Front mark

/

0

0

i!if

No. 2

No. 3

Cap No.

/

1

6

0

No. 4

3EN019’

Rocker cover
attaching
bolt hole

0

3EN0093

I)c4

ROCKER SHAFT INSTALLATION

(1) Install the rocker shafts with notches up and toward the

front bearing cap.

(2) The overall length of the left (intake) rocker shaft is 356.5

mm (14.04 in.); that of right (exhaust) rocker shaft is 350
mm (13.78 in.).

I)D4 CAMSHAFT BEARING CAP IDENTIFICATION

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11

B-38

Wave washer

4G3

ENGINE

Wave washer

-

Rocker Arms and Camshaft

+E4

WAVE WASHER INSTALLATIdN

Install the wave washer in correct ‘direction as shown.

I

3EN0081

eF+

CAMSHAFT OIL SEAL INSTALLATION

1

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