Mitsubishi Sigma 1995 User Manual

MlTSUBlSHl

MOTORS

Workshop

Manual

7

1

QUICK

i

nlarhen

I

on

this page, locate the corresponding black marker on the bage of the group

1

VOII

desire to find.

I.

---

REFERENCE

on

pages of the various groups. Then,

R

INDEX:

and

To use, bend nlar~ual hack

S

SERIES

~ ~

to

hy

means of, the index.marks

expose black

'

1

i

1

m~eneral Information

1

11 Engine

1

12

/

13 Fuel

1

14 Cooling p5 Intake and Exhaust k6 Engine Electrical

GROUP

Lubrication

-

---

INDEX

---

--

>

-

WORKSHOP

INCLUDING

SEDAN AND WAGON

Part

No. AW342051

MITSUBISHI

MOTORS

COPYRIGHT

MANUAL

1995

MODEL

7----

I

22 Manual Transmission

L_

[

26 Front Axle

@7

Rear

[Far s~s~ensionm

-

35 service

1

36 Parking Brakes

--

3

A-

ACTIVE-Electronic Control Suspension

.

--

Brakes

.

--

-

11111

SERVICE DIVISION

TONSLEY PARK

SOUTH AUSTRALIA

Body

Repair Manual

MITSUBISHI AUSTRALIA

AUST

CO.

No.

O

Mitsubishi Motors Australia Ltd. March 1995

W7

870

-

395

MOTORS

LTD.

1

42A Body

1

428 Body Repa

1

51 Exterior

528

. .

p5

supplemental Restraint System

--

Heater, Air conditioner and Ventilation

--

I

x

(SRS)

REVISED

--

.

List of effective pages

Filling instructions

File these pages in your

AW34205 1.

All

revised pages carry a revision date, part number and that the page has been modified. Alterations to the text single vertical marker adjacent to the revision.

Major revisions or new page layouts carry the revision date, part number and

ADDED

replace. Destroy the old pages to avoid confusion at

Group

Group Group

Group

Group Group

Group Group Group

Group

only, no vertical line.

Fit the new pages to your manual as soon as possible, removing the current pages they

00

13 16

23

33A 33B

34 37

42B 5

1

52

52B

53

pages

page pages

pages

page page

page pages

page pages pages

pages

00-2-5 00-2- 10

13-3-1 16-3A-3 & 16-3B-2 16-3C-7

1

16-623-2- 14 23-4A33A-233B-5-3 33B-5-8 34-2-

1

37-4-

1

37-2B42B- 1-5 5 1-3-8 52-2-8 52-2-

1 52B-052B-3-3 52B-3-5 52B-3-7 52B-3- 10 52B-3- 13 52B-3- 15 53B-3- 18 52B-552B-6-5

54-3C-4 54-3D-

TRJKR-TSJKS

to

00-2-7

to

00-2-

11

&

16-5-1

to

23-2- 15

1

to

23-4A-3

1

to

33A-2-2

to

33B-5-4

1

to

5 1-3-9

to

52-2-9

1

to

53B-3- 1 1

to

52B-3- 16

to

52B-3- 19

1

to

54-3C-5

1

to

54-3D-3

Loose Leaf Workshop Manual part number

REVISED

and/or illustrations are indicated by a

or

ADDED

REVISED

a

later date.

Group

~

Group

54

55

pages

page

54-3D- 12 54-3D-20 54-3D-24 54-3D-36 54-3D-60 54-3D-70 54-3D-74 54-3D-80 54-3D-82 54-3D- 104 54-3D- 108 54-3D54-3D- 1 18 54-3D- 124 54-3D- 134 54-3D- 146 54-3D- 152 54-3D- 156 54-3D- 162 54-3D- 168 54-3D- 178 54-3D- 190 54-3D- 196 54-3D-208 54-3D-2 16 54-9-6 54-12-8 55-2-4

1

12.

to

54-9-8

&

to to to to to to to

to

to to to to to to to to to

to to to to to

54-12-11

to signify

54-3D- 18 54-3D-2 54-3D-28 54-3D-40 54-3D-64 54-3D-7 54-3D-78

54-3D-86

54-3D- 105 54-3D- 1 10 54-3D- 1 13 54-3D- 12 54-3D- 125 54-3D- 139 54-3D- 150 54-3D- 154 54-3D- 159

54-3D- 176 54-3D- 183 54-3D- 195 54-3D-203 54-3D-2 14

1

or

1

,

0

Mitsubishi Motors Australia Ltd. Sept. 1994 AW342051 -A REVISED

SECTION

1

-

INTRODUCTION

USING THE MANUAL

The pages of this service manual are numbered using a three segment numbering system, these number groups

located in the centre of each page, are divided by a dash, and serve the following functions.

The first figure indicates the service manual The second figure indicates the The last figure is the

page sequence number

section number

group;

within a

within the

EXAMPLE

group;

section.

Each section commences with page

1.

!'?

Group

illustrations

When reference is made to a side of the vehicle, or a handed component, the side is defined as viewed from the driver's seat unless otherwise specified.

Where possible the component parts described in this manual have been identified by a part number or serial number. Where this is the case, the component part or serial number should be established and then reconciled with the service

are numbered in sequence within each section.

specifications/descriptions in this manual.

-1

11 - Engine

Section

4

-

~h~ine Overhaul

Page number within section

METRIC CONVERSION

In this manual all measurements and capacities are quoted in Metric Units. To carry out conversions from Metric to imperial or vice versa, multiply the unit to be converted by the appropriate factor, or in the case of Temperature, Fuel and Oil consumption apply the required formula. These may be found in the Conversion Values column of the Conversion Chart.

Examples:

Converting millimetres to inches

1.2 mm x 0.03937 (from table)

Converting 860F:

OF

to

OC

5

OC =-(OF-32) (from table)

9

5.

-

-(86-32)

-

9

=

0.050"

Quantity

LENGTH

MASS

AREA

VOLUME

VOLUMEFLUIDS

FORCE TORQUE

PRESSURE VACUUM VELOCITY TEMPERATURE

1

POWER

CONVERSION CHART - METRIC AND IMPERIAL MEASURES

I

Metric units

Name Symbol

millimetre metre kilometre

gram kilogram tonne

square millirnetre square centimetre

square metre cubic centimetre

cubic metre

newton newton metre

kilopascal kilopascal kilometre per hour degree Celsius

I

kilowatt

I

kW

I

metric to imperial

=

1 mm 1 m 1 km

1 g = 0.0353 02s. 1 kg = 2.2 lbs. 1

t = 0.984 ton

1

mm" 0.00155 in.' cm2 = 0.155 in.2

1 1 m2 = 1.20 yd'

1 cm3 1 m3 = 35.3 ft.3

1 litre = 1.76 pts.

litre = 0.2199 gallon

1 1 N = 0.225 lb. force 1

Nrn = 0.74 lb. ft.

1 Nrn

1

kPa = 0.145 p.s.i. 1 kPa = 0.295 in. 1

km/h = 0.621 m.p.h.

OF

1

k kW = 1.34 h.p.

0.03937 inches

=

1.09 yard

=

0.621 miles

=

0.0610 in.'

=

8.94 1b. ins.

=-

5

Conversion Values

Oc

+

32

Hg.

imperial to metric

1

inch = 25.4 mm 1 yard 1 mile = 1.61 km

1 oz. 1 lb. 1 ton

1 in.2 = 645.16 mm2 1

in.' = 6.45 crn' 1

yd2 = 0.836 1

in.' = 16.4 cm3

ft.3 = 0.0283 m'

1 1 pt.

1 gallon = 4.546 litre

1

lb. force = 4.45 N 1 Ib. ft. = 1.36 Nm

1 Ib. in.

1

p.s.i. = 6.89 kPa

1

in. Hg. = 3.386 kPa 1 m.p.h. = 1.61 km/h

OC = -(OF-32)

1

1 h.p. = 0.746 kW

=

0.914 m

=

28.3 g

=

0.454 kg

=

1.02 t

=

0.568 litre

=

5 9

I

m2

0.113 Nrn

I

litre per 100 krn

litre per 1000 km

00-2-1

SECTION 2 - VEHICLE SPECIFICATIONS

<

R

Series

Magna Sedan

>

-

Magna Wagon

Verada Sedan

00-2-2

SECTION

2

-

VEHICLE SPECIFICATIONS <S Series>

Verada

Wagon

00-2-3

MODEL IDENTIFICATION < R

Australia

Model Name

Magna GLX Magna GLX Magna Executive Magna Executive

Magna SE Magna SE Magna Elite Magna Executive

Magna Executive

Verada

Verada V6Xi Magna GLX

Magna GLX

Magna Executive

Magna Executive Magna SE

Magna SE

Magna Executive Magna Executive

Verada

New Zealand

Model Model

Name Code

Magna GLX TR7-D-41

Magna GLX

Magna Super Saloon TR7-P-41

Magna Super Saloon

V3000 Executive KR5-D-41

V3000 Executive KR6-D-41

V3000 Super Saloon KR6-P-41

V3000 SEi KR6-X-41

Magna GLX TR7-H-45

Magna GLX

V3000 Executive KR5-D-45

V3000 Executive KR6-D-45

V3000 Elite KR6-P-45

V6Ei

Model Code

TR1-H-41 TR2-H-41 TR3-D-41 TR4-D-41 TR3-P-41 TR4-P-41 TR4-X-41 TR5-D-41 TR6-D-41 KR8-P-41 KR8-X-41 TR1-H-45 TR2-H-45 TR3-D-45 TR4-D-45 TR3-P-45 TR4-P-45 TR5-D-45 TR6-D-45 KR8-P-45

TR8-D-41 TR8-P-41

TR8-H-45

Body TY pe

Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Wagon Wagon Wagon Wagon Wagon Wagon Wagon Wagon Wagon

Body Type

Sedan Sedan Sedan Sedan Sedan Sedan Sedan Sedan Wagon Wagon Wagon Wagon Wagon

Series

>

Engine TY pe

2.6L Carby

2.6L ECI-Multi

3.OL ECI-Multi

3.OL ECI Multi

3.OL ECI-Multi

2.6L Carby

2.6L ECI-Multi

3.OL ECI-Multi

Engine Type

2.6L ECI-Multi

3.OL ECI-Multi

2.6L ECI-Multi

3.OL ECI-Multi

Transaxle

5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 4 speed automatic 5 speed manual

4

speed automatic

5

speed manual

4

speed automatic 5 speed manual 4 speed automatic

5

speed manual 4 speed automatic 4 speed automatic

5 speed manual 4 speed automatic 5 speed manual 4 speed automatic

5

speed manual 4 speed automatic 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic

Price Line

GLX GLX Executive Executive S E S E Elite Executive Executive V6Ei V6Xi GLX GLX Executive Executive S E SE Executive Executive V6 Ei

Price Line

GLX GLX Super Saloon Super Saloon Executive Executive Super Saloon SEi GLX GLX Executive Executive Elite

Papua New Guinea, Brunei & Fiji

Model Name

Magna Executive Magna Executive Magna SE Magna SE Magna Elite Verada Ei Verada Xi Magna Executive Magna Executive Magna SE Magna SE Verada Ei KR6-P-45

Model Body Code

TR7-D-41 Sedan TR8-D-41 Sedan TR7-P-41 Sedan TR8-P-41 Sedan TR8-X-41 Sedan KR6-P-41 Sedan KR6-X-41 Sedan TR7-D-45 Wagon TR8-D-45 Wagon TR7-P-45 Wagon TR8-P-45

Type

Wagon Wagon

Engine TY pe

2.6L ECI-Multi

3.OL ECI-Multi

2.6L ECI-Multi

2.6L ECI Multi

2.6L ECI-Multi

3.OL ECI-Multi

Transaxle

5 speed manual 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 4 speed automatic 4 speed automatic 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic

4

speed automatic

Price Line

Executive Executive SE SE Elite Ei Xi Executive Executive S E

S

E

V6 Ei

MODEL IDENTIFICATION cS Series>

Australia

klodel Model Body Name

Magno GLX TS I -H-4 Magn;~ GLX Magna Executive TS3-D-4 Magna Executi\.e M;L~I~;L SE Magna SE TS4-P-4 Magna SE TS6-P-4 Magno Executite TS5-D-41 Sedan Mt~g~ia Executi\ c TS6-D-41 Sedan Vcr;~cl;~ V6Ei KSX-P-4 Vcr;~di~ V6Xi KSX-X-41 Sedan Magna CiLX TS I -H-45 Wagon Mag~i;~ GLX Magn;~ Exccurivc TS3-D-45 Wagon hl;~g~i;~

Executive

Magnu SE TS3-P-45 hlugna SE TS4-P-45 Wagon Mi~grli~ SE TS6-P-45 Wagon Magna Executi\.e TS5-D-45 Wagon

hlugnu

Exccuti\,e TS6-D-45 Wag011

Vel-ada V6t:1 KSX-P-45 Wagon

New Zealand

Model Name

MiLgll;' G LX Magna (ILX Magni~

Super

Saloon Magnu Super St~loon V3000 Executive V.7')OO Excc~~tive

V.ir/Oo

Super Si~loon V3000 SEi Mag~ia GLX M

;Lg"iL G LX

V3000

Executi\,e V3OOO Exccutivc V3OOO Elite

Code

TS2-H-4

TS4-D-4 TS3-P-4

TS2-H-45 Wagon

TS4-D-45 Wagon

Model Code

TS7-D-41 TSX-D-4 TS7-P-4 TSX-P-4

KSS-D-4 KS6-D-4

KS6-P-4 KS6-X-4 TS7-H-45 TSX-H-45

KS5-D-45

KS6-D-45

KS6-P-45

Type

1

Sedan

1

Sedan

1

Sedan

I

Sedan

1

Sedan

1

Sedan

1

Scdan

I

Scdan

Wagon

Hody 'Iy pe

Sedan

1

Sedan

1

Sedan

1

SetIan

I

Scdan

I

Sedan Sedan

I

1

Sedan Wag 0 n Wagon Wag

0

Wagon Wagon

n

Engine 5pe

2.6L Carby

2.6L ECT-Multi

2.6L ECI-Multi

2.6L ECT-Mu!ti

3.0L ECI-Multi

3.OL ECI-Multi

3.0L ECI-Multi

3.OL ECI-Multi

2.6L Carby

2.6L ECI-Mul ti

2.6L ECI-Multi

3.OL ECI-Multi

3.0L ECI-Multi

3.0L ECI-Mult~

Engine 'ry pe

2.6L ECI-Multi

3.OL ECI-Multi

2.6L ECI-Multi

3.0L ECI-Multi

Transaxle

5 speed manual 4 specd automatic 5 spccd manual 4 speed automatic 5 speed manual 4 spced automatic 4 speed automatic 5 speed manual 4 speed automatic 4 speed automatic 4 speed automatic 5 spccd manual 4 speed automatic 5 speed manual 4 spced automatic 5 speed manual 4 speed automatic 4 speed automatic 5 speed manual 4 spced automatic 4 speed automatic

Transaxle

5 speed manual 4 speed automatic 5 speed 4 specd automatic 5 4 specd automatic 4 spccd automatic 4 speed automatic 5 speed 4 speed automatic 5 spced manual 4 speed 4 speed automatic

manual

\peed manual

manual

automatic

Price Line

GLX GLX

Executivc Executivc

SE SE SE

Executive

Executive V6Ei V6Xi GLX GLX Executive Executive S E SE S E Excculi\ e Exccutitc V6Ei

Price 1,iiie

GLX GLX Super Saloon Super

S;~loon

Executi\ c

Executi\ e Super

Saloon SEi GLX GLX Executive Executive

Elite

Papua New Guinea, Brunei & Fiji

Model Model Name Code

Mi~g~ia Executi\ c TS7-D-4 Magna Executi\ Magna SE TS7-P-4 Magn;~ SE Magna Elite TSX-X-4 Veracla Ei KS6-P-4

Vcl-ads

Xi KS6-X-4 Magnil Exccuti\~e TS7-D-45 Magna Executive Magna SE TS7-P-45 Mngna SF: Verada Ei KS6-P-45

e

TSX-D-4

TSX-P-4

TS8-D-45

TS8-P-45

I I

1

I

I I

Hody TY pe

Sedan Sedan Sedan Scdan Sedan Scdan

I

Scclan Wagon Wagon Wagon Wagon Wagon

-

Engine TY pe

2.6L ECI-Multi

2.6L ECI-Mulli

2.6L ECI-Multi

3.OL ECI-Multi

2.6L ECT-Multi

2.6L ECI Multi

2.6L ECI-Multi

3.OL ECI-Multi

Transaxle

5 speed manual 4 speed automatic 5

speed manual 4 spced automatic 4 speed automatic 4 spced automatic 4 speed

5

4 specd automatic 5 speed 4 speed automatic 4 spced automatic

auto~natic

speed manual

manual

Price Line

Executive

Executive SF: S

E

Elite Ei Xi Exccuti\c Executive SE SE

E

i

South East Asia

Model Model Name

Sigma Sigma KS2-X-45 Wagon

O

Mitsubishi Motors Australia Ltd. March 1995 AW342051 -B REVISED

Code

KS2-X-4

Hody TY pe

1

Sedan

Engine Type

3.OL ECI-Mulli

3.OL ECI-Multi

Transaxle

4 speed automatic 4

\peed automatic

Price Line

,

..

...

......

.

.....

00-2-5

OPTIONAL EQUIPMENT CODES

Code

No.

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

A03 A13

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

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

A15

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

A26 B14

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

C34

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

D66

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

D67

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

D68

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

D69

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

D78

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

E02 E24 (Export). E25 (Export).

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

E55

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

E48

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

E49 G39

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

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

H5O H57

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

514 .Roof Rack

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

530 .Cruise Control

*K20

*YO6 *Y14 *Y19

*Y26 *Y27

*Y29 .Radiator Insect Screen *Y31 .Fire Extinguisher

*Y34 Mudflaps - rear *Y44 .Cargo Barrier

*Y51 *Y52 *Y54 .Air Conditioner - Vendor Fitment *Y57 *Y58

*Y63 *Y64 *Y69 *Y71 *Y86 *Y90

*Y91 *Y92

*Y93 Rear Window Venetian (Internal)

*Y94 Side Window Venetian (Internal)

*Z46

*Government and Fleet Orders only.

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

R17

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

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

V03

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

V20

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

V21

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

V98 W37

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

W44

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

X27

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

X30

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

X62

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

X66

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

X67

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

X71

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

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

Y25

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

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

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

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

Y50

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

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

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

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

245

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

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

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

Equipment Description

.Supplementary Restraint System (SRS) .Luxury Pack

Luxury Pack

Luxury Pack .ABS Brakes .Seat Height Adjuster .5 speed Manual Transaxle - F5M31 (4 Cylinder Models)

.4 speed Automatic Transaxle - F4A23 (Carburettor Models) .4 speed Automatic Transaxle - F4A33 (ECI-Multi 4 Cylinder Models) .4 speed Automatic Transaxle - F4A33 (V6 ECI-Multi Models) .5 speed Manual Transaxle - F5M33 (V6 ECI-Multi Models)

.3.0 litre V6 Engine (ECI-Multi Version) .2.6 litre Engine (ECI-Multi Leaded Fuel) .3.0 litre V6 Engine (ECI-Multi Leaded Fuel) .2.6 litre Engine (Carburettor Version) .2.6 litre Engine (ECI-Multi Version) .3.0 litre V6 Engine (ECI-Multi Version)

Sunroof

.Air Conditioning - M.M.A.L. Fitment

.Auto Air Conditioning

.Police Vehicle

CD Player

.Monotone Paint .Metallic Paint

Pearlescent Paint

.Cargo Compartment Blind (Wagon) .Cast Alloy Wheels

.Cast Alloy Wheels and Tyres .Export Vehicle Leaded Fuel Magna .Export Vehicle Brunei .Export Vehicle New Zealand .Export Vehicle New Zealand Police

.Export Vehicle New Zealand Police .Export Vehicle Fiji

.Rear Bumper Protector .Sun Visor Rear - Exterior

Sun Visor(B1ade) .Fuel Cap (locking) .Sun Visor (Mesh) .Door Weathershield

Weathershield (LH Door) .Air Conditioning - M.M.A.L. Fitment

Air Conditioning - Dealer Fitment

Rubber Floor Mats (Front and Rear) Rubber Floor Mats (Front Only) Additional Set of Keys

Roof Rack

Headlamp Protectors

Rear Window Louvre Towbar Package - 1200 kg (Manual) Towbar package - 1200 kg (Automatic)

Rear Window Blind - Internal

Bonnet Protector

.Cargo Barrier - Wagon

Roof Ladder Rack

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

This number is stamped on the plenum chamber above the Data Plate and also on the compliance plate. It supplies information for vehicle identification purposes and should be quoted when ordering parts or in any correspondence related to the vehicle.

6MMTR2H41MA000000

Geographic Area

T

MODEL ASSEMBLY BODY

1

LINE CLASS No. T-Magna R-Series K-Verada S-Series

pacific Regions

and

~a'gna ~erada?~3000 ENGINE/TRANS. COMBINATION

1-2.6

litre Carb (Man) Unleaded

2-2.6

litre Carb (Man) Unleaded

3-2.6

litre ECI-Multi (Man) Unleaded litre ECI-Multi (Auto) Unleaded

4-2.6

litre ECI-Multi (Man) Unleaded

5-3.0

litre ECI-Multi (Auto) Unleaded

6-3.0

litre ECI-Multi (Man) Leaded export

7-2.6 8-2.6

litre ECI-Multi (Auto) Leaded export

H-High 41-Sedan M-1991 A-Adelaide P-Premium 45-Wagon N-1992

X-Luxury P-1993

ENGINE/TRANS. COMBINATION

1

-

2

-

3

-

4

-

5-3.0 litre ECI-Multi (Man) Leaded export

litre ECI-Multi (Auto) Leaded export

6-3.0

-

7 8-3.0 litre ECI-Multi (Auto) Unleaded

ENGINE NUMBER LOCATION

Location

The engine number is stamped on the right hand front, top edge of the cylinder block. Always quote the engine

number when ordering engine replacement parts.

TYPE YEAR PLANT

T-Tonsley Park

R-1994

Engine number locations

'

ENGINE NUMBER IDENTIFICATION

ENGINE CAPACITY TYPE TRANS AXLE YEAR SERIAL

SERIES BUILT No. W-4G54 5-2555cm3 3-Balance shaft 1-Automatic

Y-6G72 7-2972cm3 West East 2-Manual

Z-

1990 Commencing from

A-1991 No. 1 each engine

ECI-Multi version B-1992 and transaxle type

9-Balance shaft C- 1993

West East D-1994 Carburettor version E- 1995

2-V6

6672

West East

ECI-Multi version

*Where special engines (for export models) are built, the engine option code will be stamped in this position.

TRANSAXLE SERIAL NUMBER LOCATION

.

DATA PLATE

The Data Plate is compartment and

*Body sequential

In

all correspondence related to a vehicle or when purchasing spare parts, the following information should be quoted: The engine number The VIN code.

I'

The trim code.

The paint code. The option codels.

O

Mitsubishi Motors Australia Ltd. Sept.

Manual transaxle serial number

SOA No.: PAINT

TRIM LWR OPTIONS

BUILT

BODY

Automatic transaxle serial number (typical)

*

USE GENUINE MlTSUBlSHl PARTS

ALL CORRESPONDENCE MUST QUOTE

~~~~~~~~~~~~~ns

m

co

-

m7

.m

,*

attached to the right hand side of the plenum chamber (adjacent to the compliance plate) in the engine

is stamped with vehicle option codes, trim codes and a daily body sequential build number. build number

1994

V.I.N.SHOWNONCOMPLlANCEPLATE

AS WELL AS INFORMATION ABOVE

REVISED

00-2-8

COMPLIANCE PLATE

APPROVAL No. CATEGORY MA

MlTSUBlSHl MOTORS AUST. LTD.

MAGNA TR

0

GVM

SEATS

0

VIN

THIS VEHICLE WAS MANUFAC1-URED TO COMPLY

WITH THE MOTOR VEHICLE STANDARDS ACT

All vehicles are manufactured to conform to specific safety environmental or consumer protective requirements as defined by the Australian Design Rules (ADR).

1989

NOTE:

The Compliance Plate is attached to the right hand side of the plenum chamber in the engine compartment and must never be removed from the vehicle.

AUSTRALIAN DESIGN RULES

Australian Design Rules require the manufacturer of components and/or a complete vehicle to conform to specific

safety, environmental or consumer protective requirements as defined by that particular rule.

There is legislation that requires, amongst other things, that no modifications be made to a vehicle that would cause that vehicle not to comply with the Design Rules of that vehicle (parts replacement using approved M.M.A.L. components is permissible). Before interchanging or adding optional equipment it is recommended that advice be sought from an Authorised M.M.A.L. Dealer or from a M.M.A.L. Regional Office, because it is possible to inadvertently cause a vehicle not to comply with a Design Rule.

VEHICLE DIMENSIONS

Wheelbase Overall length < R series Overall length < S series Overall width. Overall height Front track..

Rear track

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

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

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

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

>

.........

>

.........

Magna

Sedan Wagon

.2722mm 2722mm .4746mm 4790mm .4746mm 4790mm .1775mm 1775mm .1450mm 1470mm .1535mm 1535mm .1525mm 1505mm

Verada

Sedan Wagon

2722mm 2722mm 483 1mm 4888mm 4786mm 4843mm

1775mm 1775mm 1449mm 1446mm 1535mm 1535mm 1525mm 1505mm

V3000

Sedan

2722mm 2722mm 4746mm 4790mm 4746mm 4843mm

1775mm 1775mm 1449mm 1446mm 1535mm 1535mm 1525mm 1505mm

(NZ)

,

Wagon

Ground clearance 112mm 122mm

-

minimum @ GVM

Turning circle

-

kerb to kerb - RHS 11.0 m 11.0 m

-

LHS 11.4 m 11.4 m

KERB MASS (Estimated)

Australian Models

R

Sedan Model Code

TR/TSl-H-41 TR/TS2-H-4 TR/TS3-D-41 TR/TS4-D-4 1 TR/TS3-P-41 TR/TS4-P-41 TR4-X-41 TR/TS5-D-41 TR/TS6-D-4 1 KR/KS8-P-41 KR/KS8-X-41

New Zealand Models Sedan

Model Mass Code

TR/TS7-D-41 TR/TS8-D-41 1386 TR/TS8-P-41 KR/KS5-D-4

KR/KS6-D-41 KR/KS6-P-4 1 KR/KS6-X-41 1529

........

1

........

...........

........

I

........

Series

Mass Kg

1335 1357 1347 1384 1380 1420 1427 1370 1407 1472 1521

R

Series

Kg

1349 1419

1379

1416 1452

S Series Mass

Kg

1360 1382 1375 1406 1389 1428

.

1430 1466 1446 1480

S Series Mass

Kg

1345 1376 1423 1368

1404 1443

1530

R

Wagon

Model Code

TR/TS 1 -H-45 TR/TS2-H-45 TR/TS3-D-45 TR/TS4-D-45 TR/TS3-P-45 TR/TS4-P-45 TR/TS5-D-45 TR/TS6-D-45 KR/KS8-P-45

Wagon Model Mass Code

TR/TS7-H-45 1438 TR/TS8-H-45 KR/KS5-D-45 KR/KS6-D-45 1522

KR/KS6-P-45

........

Series

Mass

Kg

1428 1442 1443 1476 1482 1516 1459 1495 1563

R

Series

Kg

1471 1488

1555

S Series Mass

Kg

1454 1468 1469 1502 1496 1530 1520 1556 1595

S Series

Mass Kg

1440

1473 1456 1492

1537

Papua New Guinea. Brunei Sedan

Model Mass Mass Code

TR/TS7-D-4 1 1374 1373 TR/TS8-D-41 141 1 1404 TR/TS8-P-41 1427 1428

KR/KS6-P-41

KR/KS6-X-4

NOTE:

Kerb mass as specified is with no load. full fuel tank. oil. water etc . Tolerance is

........

1

&

Fiji

Models

R

Series S Series

Kg Kg

1479 1490 152

1

1535

OPTIONAL EQUIPMENT MASS (Estimated)

A03

--

-

A13

-

H50

W37

-

B14

NOTE:

Supplemental Restraint System

Luxury Pack

Air conditioning

Cast alloy wheels

ABS brakes

The mass quoted for factory approved options is not the actual mass of the option. but the difference in mass between the standard vehicle and one fitted with the option

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

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

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

.........

Kg

+

+ +

+

9.3

7.0

23.0

11.0

25.0

Wagon Model Mass Code

TR/TS7-D-45 1469 TR/TS8-D-45 1502

TR/TS7-P-45

TR/TS8-P-45 KR/KS6-P-45 1571

........

R

Series

Kg

1490 1524

f

.

2%

S Series Mass

Kg

1469 1498 1561 1525

1561

.

Some items listed as options on page 00-2-5 may be fitted as standard equipment . When this is the case the mass of that equipment is included in the kerb mass quoted above

.

GENERAL SPECIFICATIONS

Front Suspension

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

Brakes

Type- front - 14".

-

front - 15".

-rear (All). Master cylinder

Vacuum booster Park brake.

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

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

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

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

Clutch

Type

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

Clutch disc diameter

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

Engine

Typc

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

Model..

Displacement

Rorc Strohc. Compression ratio - ECI-Multi

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

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

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

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

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

-

Carburettor.

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

Independent McPherson strut type with A-arms and stabiliser bar

.256 mm x 24 mm ventilated disc with BCI single piston,

sliding caliper

.276 mm x 24

mm

ventilated disc with BCI single piston,

sliding caliper

.258 mm x 10.4

mm

solid disc with BCI single piston, sliding caliper BCI tandem master cylinder with integral proportioning valves and "fast fill" system BCI 20511 80 mm dual diaphragm "Master Vac". Ratio 5:

1

Cable operated on rear wheels, drum in disc

Hydraulically actuated single dry disc with diaphragm type pressure plate

,225 mm

OHC 4 cylinder in line, OHCIOHVNIV

-

V6

with counter-balance shafts

,4654 6G72 V6 .2555cc 2972 cc .9 1.10 mrn 91.1 mm .98.00 mm 76.0 mirl

10:

.9.2:

8.8:

1

Fuel System

Type - carbureltor models

fuel injection models

Rear Suspension (Sedan).

(Wagon)

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

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

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

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

Steering

Type

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

Ratio Turns lock

to

lock

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

Manual Transaxle

Model-- 4 ~ylinder models

--

Vh

modcls

-

New Zealand V6 model>

Type

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

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

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

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

Automatic 'I'ransaxle

Model - carburcttor 4 cylinder models

-

fuel injection 1 cylindcr models

-

fue! injection 4 cylinder models

-

fuel in,jection 4 cylinder models

-

t'ue! injection 4 cylinder models

-

fucl in.jection V6 models

-

fuel injection V6 models

-

fuel injection V6 models

-

fuel injection V6 models

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

..........

........

Mikuni resin body carburettor with low

pressure.

in-tank electric fuel pump Electroniaally controlled "multi point" injection system with high pressure, in-tank electric fuel pump

.3 link torsion axle with coil springs .5 link tubular axle with coil springs and lateral rod

Rack and pinion power assisted with collapsible steering column

17:

1

3.09

F5M3!-2-RPKJ 25 tooth splined drive shafts

F5M33-2-SNQJ 17 tooth splined drive shafts F5M33-2-SNZJ 25 tooth spiined drive shafts Cable operated 5 speed, with synchrornesh on all gears

-

15

F3A23-2-LPN

tooth spiined drive shafri F4A.13-I-MPNI - 25 tooth splincd drive shafts F4.433-I -MPP! F4A3.1-I-MPP2

--

27 tooth splined drive shafts

--

27 tooth splined drive shafts F4A37-1-MPQ1 - 27 tooth splined drive shafts F4A33-I-MNN6 25 tooth splined drive shafts F4A33- 1 -MNP6 - 27 tooth splined drive shafts F4A33-1-MNP9 - 27 tooth splined drive shafts F4A33- 1 -MNQ3 - 27 tooth splined drive shafts

O

Mitsubishi Motors Australia

Ltd.

Sept. 1994 AW342051 -A

REVISED

r

',

Gear

Ratios

Manual Transaxle

(4 Cylinder) (V6 ECI-Multi) (Carburettor)

F5M31-2-RPKJ 5M33-2-SNZ J

1st ..................... .3.166:1

2nd

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

3rd

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

4th

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

5th

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

Reverse

Transfer gear.

Differential ratio

Final gear ratios

Type

*NOTE:

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

............. 1.192:

..........

.........

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

Transaxle models marked * require 27 tooth splined drive shafts.

1.833:l

1.240:l

,0396: 1 .0.666: .3.166: 1

3.41 I:

.4.068:

1

I

1

Vehicle standing height

As

measured from the wheel centre to wheel arch.

Sedan and Wagon KR

Sedan (with ECSj

(All

models) ....... .406 c 10

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

*F5M33-2-SNQJ

4.153: 1

2

pinion, helical cut spur gear set

Front

mm

,396

-+

5 mrn

Automatic Transaxle

(ECI-Multi) (V6 ECI-Multi)

*F4A33-1-MNPQ1 *F4A33-1-MNQ3

F4A33-1-MPP2 *F4A33-1-MNP9

*F4A33-1-MPP1 *F4A33-1-MNP6

F4A23-2-LPN F4A33-1-MPN 1 F4A33-1-MNN6

1

3.900:

1

3.958:

1

Rear

382

*

10 rnm

367

-+

5 rnm

0

Mitsubishi Motors Australia Ltd. Sept. 1994

REVISED

..

-.

SECTION

PROTECTING THE VEHICLE Wiring Connectors

3

-

SERVICE INFORMATION

When performing maintenance or repair When uncoupling a connector, pull on the

operations use suitable covers to prevent damage

to

connector

NOT

the harness.

paint and interior trim.

If high pressure or steam cleaning equipment is being used to wash the vehicle, the spray nozzle should be positioned a

MINIMUM

of

300

mm from any

plastic components and all opening parts,

e.g. doors,

Correct

deck lid etc.

Although the paint surface will resist damage, any oil, brake fluid or petrol spills should be cleaned up as soon as possible to prevent discolouration.

SPECIAL TOOLS

Special tools are developed to prevent component

damage during

assembly/disassembly procedures and

to reduce the possibility of operator injury.

It

is therefore recommended that spicial tools are used whenever they are available for a particular operation.

Fig. 1-Disconnecting wiring harness

To uncouple a connector with a catch, press in the

NON RE-USABLE PARTS

direction of the arrows shown in Fig. 2.

If any of the parts listed below are removed, they

must be replaced with new parts:

Oil seals

Gaskets (except rocker cover)

O-rings

D-rings

Lock washers

SpIit pins

Self-locking nuts

RUBBERIPLASTIC COMPONENTS

Avoid spilling petrol, oiI, solvents, brake fluid etc.

on plastic and rubber components, as this may lead

to deterioration of the component.

METRIC FASTENERS

The vehicles covered in this Service Manual are in most instances, fitted with metric fasteners. The only exceptions are seat belt and child restraint anchorages, in these applications Imperial fasteners, conforming to Australian Design Rules and International Standards, are used.

ELECTRICAL SYSTEM SERVICE PRECAUTIONS

When performing any repair work on the

electricaI system always disconnect the negative cable from the battery.

CAUTION:

the negative cable, ensure that the ignition and

lighting switches are turned this may result in damage to electronic components incorporated in same equipment.

Before connecting or disconnecting

OFF.

Failure to do

I

Fig. 2-Uncoupling connectors

When coupling a connector with a catch insert the

connectors until they "snap".

Wiring Harness Routing

Wiring harnesses, with the exception of those connected to the engine and transaxle, should be routed and clamped so that there is no slack in the harness.

If a harness mounting identification mark is visible on a harness, the harness should be clamped at that point.

I

Fig. 3-Harness identification mark

When routing harnesses to the engine or transaxle allow sufficient slack to prevent harness breakage or uncoupling but not enough to allow the harness to contact surrounding parts.

NOTE:

If anv section of a harness does contact a componen; or body panel, ensure that sufficient protection, in the form of insulation tape etc.

is

provided.

When installing and tightening components ensure

that wiring harnesses are not pinched or damaged.

Continuity and Voltage Testing

When performing continuity or voltage checks it is

recommended that harness connectors remain coupled.

Following this practice will facilitate identification of

faults and reduce the possibility of terminal damage.

To check wiring and connectors insert a suitable test

probe into the back of the connector.

NOTE:

If the connector

type insert the probe through the wire hole in the seal taking care not to damage the wiring

insulation.

is

a sealed (or waterproof)

If it is necessary to uncouple connectors to perform checks, DO NOT force probes into female terminals. This will open the terminal and result in poor contact. Always use the finest probe available.

Fig. 4-Inserting test probe

Electrical Component Protection

Sensors, relays, control units etc. are sensitive to shock, impact and, in the case of electronic components, excessive temperatures.

Handle all electrical components with care and

avoid dropping them.

When body repair or paint operations involving

temperatures higher than

80°C

are being performed, remove electronic components which may be affected prior to commencing work.

When performing electrical welding operations,

ensure that

BOTH

battery cables are disconnected from the battery to prevent damage to electronic components.

CAUTION:

ensuring that all lights and the ignition are switched off.

Fuses and Fusible Links

Disconnect the negative cable first,

If a blown fuse is to be replaced, use only a fuse of

the specified rating.

If a higher rating fuse is fitted, the system may not be adequately protected and component or harness damage may result.

~ccessor~ Fitment

When fitting accessories, always follow the manufacturers instructions and ensure that the wiring used is adequate for the current draw of the equipment.

INSTALLATION OF RADIO EQUIPMENT

Although the various electronic control systems used have been designed to minimize any possibility of radio wave interference, if the antenna or antenna cable of a radio transceiver is positioned too close to a control unit, unit operation may be affected.

To prevent radio wave interference, the following points should be observed:-

(I)

Install the antenna on the roof or rear bumper

bar.

(2)

Route the antenna cable at least

200

mm away from control units and wiring harnesses. If a cable must cross a harness, it should cross at right angles.

(3)

Ensure that the impedance of the antenna and cable are closely matched and that the standing wave ratio is kept low to reduce the number of radio waves emitted from the antenna cable.

(4)

Do not install a high output unit.

(5)

After installing the unit; road test the vehicle and ensure that vehicle operation is not affected when the transmitter is used.

STANDARD PARTS TORQUE CHART

Standard bolt and nut tightening toque

Pitch Bolt nominal

Flange bolt andf nut tightening toque

Bolt nom~nal dlameter (mm) (mm) Head mark

M6 1.0 4-6 (0.4-0.6. 2.9-4.3) 8-12 (0.8-1.2. 5.8-8.7) 9-14 (0.9-1.4. 6.5-10)

MI0

MI2

Pi,ch

1.25

1.5

1.25

1.75

@

21-31 (2.1-3.1, 15-22) 19-29 (1.9-2.9, 14-21) 38-55

(3.8-5.5. 2740)

34-52 (3.4-5.2, 25-38)

Torque Nm (kgm. lt.lbs.)

Head mark

19-28 (1.9-2.8, 14-20) 39-60 36-54 (3.6-5.4, 26-39) 80-1 10 (8.0-11. 58-80) 70-95 (70-9.5, 51-69)

@

(3.9-6.0. 28-43)

Head mark

50-65 45-65 90-120 85-110 (8.5-11, 61-80)

@

(5.0-6.5. 36-47) (4.5-6.5. 33-47)

(9.0-12. 65-81)

Taper thread tightening toque

Thread size

NPTF

116

PT

118

PT

114.

NPTF

114

PT

318

NOTE: NPTF is dry seat pipe thread, wh~le PT is pipe thread.

Female thread material: Light alloy

5-8 (0.5-0.8. 3.6-5.8) 8-12 (0.8-1.2, 5.8-8.7) 20-30 (2.0-3.0, 14-22)

(4.0-5.5. 29-40)

40-55

Female thread mater~al: Steel

8-12 (0.8-1.2, 5.8-8.7)

16-20 (1.6-2.0, 12-14) 35-45 (3.5. 25-33) 60-75 (6.0-7.5, 43-54)

Each torque value in the table is a standard value for As a standard practice in the following instances,

tightening under the following conditions. reduce the values shown in the table to the

(1)

Bolts, nuts and washers are all made of steel and plated with zinc.

(2)

The threads and bearing surface of bolts and nuts are all in dry condition.

percentages indicated below: a. If spring washers are used

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

b. If threads and bearing surfaces are stained

with oil..

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

85% 85%

The values in the table are not applicable:

(1)

If toothed washers are inserted.

(2)

If plastic parts are fastened.

(3)

If bolts are tightened to plastic or die-cast inserted nuts.

(4)

If self-tapping screws or self-locking nuts are used.

-.

.

TOWING POINTS

00-3-6

Front Rear Sedan

Rear Wagon

00-4-1

SECTION

GENERAL INFORMATION

Lubricant recommendations have been determined to maintain maximum performance and provide optimum vehicle protection under various operating conditions. The information contained in this section should, therefore, be used as a guide to ensure that the

correct lubricant is selected.

While, in most cases, no particular brand of lubricant is recommended, lubricants manufactured by a reputable oil company should always be used.

It is important that the material used meets the classification requirements stated in this manual.

NOTE: The M.M.A.L. lubricant specifications

stated in this manual are the result of considerable development work, and have been established to ensure that materials used meet all the requirements of a specific application.

Lubricants and coolants which meet these specifications are formulated with the optimum quantities of a carefully balanced combination of selected additives, and are suitable for use in vehicles marketed by M.M.A.L. Any arbitrary addition of proprietary materials may disrupt the balance of these additives and destroy the essential properties of the lubricant or coolant, resulting in failure of the mechanical assembly.

Furthermore the addition of proprietary materials is an unnecessary and expensive penalty to vehicle operating costs.

of

Classification Engine Oils

Lubricants

4

-

LUBRICANTS

Grease

Semi-solid lubricants specified for chassis and similar applications should meet NLGI Multi-purpose, non-melt type No. otherwise stated.

Points NOT Requiring Lubrication

The bearings listed below are permanently lubricated and require only inspection and/or replacement when a complete component overhaul is performed.

(i) Starter motor bushes

(ii) Clutch release bearing (man. trans.)

(iii) Alternator bearings

The rubber bushings used at the points listed below are designed to grip the contacting metal parts firmly and act as a flexible medium between metal parts.

The use of any lubricant on these bushes will reduce the friction required for correct operation and result in premature failure of the bushing.

(i) Rear axle arm bushings

(ii) Front suspension bushings

(iii) Engine drive belts

The application of any lubricant to the air cleaner

element will destroy the effectiveness of the element.

2

specifications except where

Two designations, SAE and API, are used to match engine oils to service requirements. Generally, designations will be found on the oil container.

The SAE grade number indicates engine oil viscosity or fluidity. For example SAE 30 is a single viscosity oil. Most engine oils have multiple viscosity grades such as SAE multigrade oils have a more constant viscosity than single grade oils for the same temperature rise.

quality and ranges from service requirements.

Gear Oils

its API classification. The classification range for gear oils is from application.

Automatic Transaxle Fluid

Transmission Fluid. Use of MMAL specified fluid is mandatory to ensure correct operation of the transmission.

10W 30, with a low viscosity when cold. These

API

The

Gear oil performance level, or quality, is shown by

Mitsubishi Magna ELC-4-SP Automatic

classification indicates oil performance or

'%A" to "SG" depending on

"GG1" to "GG5 (plus)" depending on

Engine Oil Change Frequency

Regular oil changing is essential for efficient running

and long engine life.

Under normal operating conditions, in temperate climates, engine oil change intervals should be 10,000 km or six months (whichever occurs first).

Changing the oil every six months regardless of distance travelled, will minimize the harmful effects of any condensation or sludge that may form in the engine when most trips are of short duration at slow speeds, such as city traffic type driving.

If a vehicle is operated under unusual or severe conditions, such as those listed below, the protective life of the oil can be significantly reduced, necessitating oil changes at 5,000 km intervals.

Frequent towing of trailers, boats, etc., Continuous operation at higher than normal

loadings,

Operating in dusty or sandy terrain, Extremely short run operation,

i.e. good roads

LUBRICANT CHART

00-4-2

COMPONENT

Engine

Power steering

Automatic Transaxle

M.M.A.L.

SPEC. No.

ES-X64022

Type 3

ES-X64022

LUBRICANT

Conformiilg to the requirements of the A.P.I. classification "For Service SG, with a phosphorus content not exceeding 0.1% by weight, suitable for use

in vehicles equipped with a catalytic converter",

having the correct S.A.E. Viscosity grade number for

the expected temperature range.

Atmospheric lemperalure

30 20 10 0 10

C

sr~x

i---~-

D

8

<<-

:-

<y

E

zD

L

82

?,

-

G

*

cw

?S

W-

-- -

0

y

>

1

--

101

101~

-p~~

20

30

40

!XW:40.t,! 50

101 40 201-

30

-~-pL

40

50"

--,>

-

-~ ~-

~~,

-,>

-~-/

Mitsubishi Power Steering Fluid

Mitsubishi Magna

ELC-4-SP

Automatic Transmission

Fluid.

Manual transaxle

Radiator

Brakes Clutch

Front and rear wheel bearings

Seat slides Door check straps

Engine hood lock Door lock and striker

Body

-

Door

Hood

Front seat

Deck lid

hinges

-

lock cylinders

-

hinges

-

recliner

-

lock

-

lock cylinder

-

hinges

ESX-64021

Type 4

ES-X64216

MS41/46

MS42/5

MS42/2

42/MS

1481-X

Hypoid gear oil: API classification GL-4

SAE Viscosity No.

75W-85W

Rain or demineralized water plus Mitsubishi Longlife

coolant in the required concentration.

DOT 4 fluid conforming to AS1960-1983 Grade 3

Multi-purpose, non-melt type No. 2 Grease

Lithium base, multi-purpose EP No. 2 Grease

Mitsubishi "Easi-Lube" stick lubricant

Engine oil

Battery terminals

Speedometer cable

42MS/272

42MS 4599

Petroleum jelly

Shell Alvania RVI speedometer cable lubricant

SECTION 5 - LUBRICATION AND MAINTENANCE

SPECIFICATIONS

Engine tune-up

Carburettor models

Idle speed (r.p.m.) - manual..

-

automatic..

A/C idle up speed (r.p.m.) - manual .850 k 50

-

Ignition timing

basic (hose to outer can dis-

connected and plugged).

-

idle advance (hose connected to

outer can).

Spark plugs

-

type

-gap

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

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

Fuel injection 4 cylinder models

Idle speed (r.p.m.). Ignition timing

Spark plugs

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

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

-

type

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

-gap

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

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

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

.........

-

auto

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

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

,750 .BOO k 50

,900 k 50

...

.5O

.Champion N9YC

.800 + 50 .So

.N9YC

+_

50

+_

2' B.T.D.C. @ idle speed

13O + 4O B.T.D.C. @ idle speed

0.7 to 0.8 mm

k

YzO

B.T.D.C. (electronic spark timing cut)

13O k 2O B.T.D.C. (with electronic spark timing)

0.7 to 0.8 mm

Fuel injection V6 models (incl.

Idle speed (r.p.m.) Ignition timing

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

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

V3000)

.700

+_

100

.So k 2O B.T.D.C. (electronic spark liming cut)

lSO + 2O B.T.D.C. (with electronic spark timing)

Spark

plugs - type

-

Idle CO% (V3000).

NOTE:: The above specifications were correct at time of publication. If these specifications differ from those

on the Vehicle Emission Control Decal (located on the underside of the engine hood) use the specifications listed on the decal.

Drive belt tension

Alternator and power steering - New belt Air-conditioning

Drive belt tension

Alternator and power steering - New belt

Air-conditioning

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

gap

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

(4

cylinder models)

-

Used belt

-

New belt

-

Used belt

(6

cylinder models)

-

Used belt

-

New belt

-

Used belt .390-490

.......

......

.......

......

.......

......

.......

......

.N9YC4 .1.0 mm pre-gapped

.1.5% k 0.5%

,650

N

,530 N ,440-540 N .340-440

N

,690-880 N ,490 N ,590-690 N

N

Water pump belt deflection (4 cylinder models only)5-7 mm with 70 N force

NOTE: A new belt becomes classified as a used belt after 5 minutes running time.

00-5-2

SPECIFICATIONS CONT.

Clutch pedal

Pedal play (at clev~c p~n) Pedal free travel (includtng pedal play)

Front wheel alignment

Toe-in - measured at centre of tyre trend

on

Toe-our

turns - measured

inner tvheel on 20" .22"

Stccring wheel freepluy

At btcering wheel circumference

Hrahc pad wear limit

Minimum pad material thickness - Front and rear

hrahe adjujt~llent

Park

LCLCS \trohe

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

Br~~hc pedal adjustment

Ped;ll t'reeplay

Pedal height

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

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

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

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

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

on

outer wheel with

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

..........

I

1

to

3

mm

.6 to 13 mm

.O

2

3.0 mm

I

.0 mm

lo

5 notchej @ 196

.3 lo

8

mm

176

to

18 1 mm

N

SPECIAL TOOLS

MBOO 1502 Multi-Use-Tester (MUT) MKP-A ROM Pack

EX

MI5

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

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

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

---

LED, Test lamp Adjustable power riming light

CO meter Spark plug gapping gauge Tilchometer

TORQUE SPECIFICATIONS

Nni

Alternator- pivot bolt

-

adjusting bolt clamp

Balance shaft chain adjusting bolt

Balance shaft chain cover Battery terminal clamp

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

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

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

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

H~ake caliper guide pin bolt

front

-rear

Engine oil drain plug

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

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

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

Exha~~st m;rnifold to cylinder head nut Front strut lo knuckle bolt Rear shock absorber to axle bolt Road whccls (in sequence) Spark plug

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

Steering rack to cl.ossmember bolt Tic rod end to knuckle nut..

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

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

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

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

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

Trailing arm (rear axle) to body bolt

Transaxlc drain plug Transaxle filler plug Transaxle oil pan bolts Water pulnp lnounting bolt.;

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

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

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

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

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

20 to 25

15

12 to 15 to

20

4

to

5

2.5

I

O

Mitsubishi Motors Australia Ltd. March 1995 AW342051

-B

I

REVISED

FLUID

CAPACITIES.

Engine oil pan - 4654 without filter

-

4654 with filter

-

6672 without filter

-

6672 with filter Manual transaxle .2.0 litres Automatic transaxle - F4A23 (incl. T/C)

Cooling system - 4654 ECI-Multi models.

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

-

F4A33 (incl. T/C)

-

4654 Carby models

-

6672 models .9.5 litres

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

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

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

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

..........

........

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

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

.4.1 litres .4.6 litres .4.0 litres

.4.3

litres

.6.1 litres .7.5 litres .9.6 litres .8.4 litres

LUBRICATION

Check fluid level and condition

-

engine

-

brake master cylinder

-clutch master cylinder.

-p owersteering transaxlemanuul

-

transaxle automatic Change automatic transaxle fluid Change manual transaxle fluid (normal usage). Change manual transaxle fluid (severe usage) Change engine oil every 6 months or. Change engine oil filter every

UNDER HOOD OPERATIONS

Check engine coolant level and concentration Drain, flush and refill cooling system using rain or demineralised water and

Valve clearance adjustment Check battery electrolyte specific gravity. Check all fluid lines and hoses for routing, tightness and leaks Check ignition cables: distributor cap and rotor for damage Lubricate distributor (carby models). Check adjustment and condition of external drive belts Replace fuel filter (carby models). Replace fuel filter (MPI models). Replace spark plugs (conventional type) Replace spark Clean and check air cleaner element.. Replace air cleaner element (noimal usage) Replace air cleaner element (severe usage). Test oxygen sensor (Magna MPl 4 cyl) Replace timing belt Checkignitiontiming Check idle speed and CO concentration Check air conditioning refrigerant level at receiver drier sight glass

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

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

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

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

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

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

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

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

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

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

6

months or.

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

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

24

months or.

(if

applicable).

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

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

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

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

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

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

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

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

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

plug5 (platinum type).

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

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

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

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

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

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

*

(carby models).

~p

--

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

-

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

~-

Kilometre Intervals

i:

X X~X

XI

X X XI X

X

I

X X X X XXX

X

.......... Specified Coolant in the recommended concentration every

x;

I

x

X X X

X

I

X

"":

X

XXX X X

I

X!

X

X X

I

X

x

i

X X X

xX

I

x

X~

X X X XXX

XI

X

XI

X

I

*

Adjustment is not re uired during regular maintenance.

catalytic converter

UNDER VEHICLE OPERATIONS

Check exhaust system for alignment, security and leaks.. Check fuel, oil, brake and vapour lines for damage, deterioration and leaks Check front and rear suspension components for alignment, and security Check condition of ball joint seals and all bushes Check steering components for alignment, wear and security Check driveshaft dust boots for damage and deterioration Check rear wheel bearings for play

SUSPENSION, STEERING, TYRES AND BRAKES

Check tyres for wear, damage and pressure. Brakes - check and adjust handbrake as necessary

-

check padllining wear.

-drain, flush and refill brake hydraulic system using the specified brake fluid (every

an! the secondary air supply system, If a fault is evident I-efer to Group 13 -Fuel Systems for diagnosis and adjustment procedures.

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

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

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

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

24

months)

This

item is included as a check only, to indicate correct operation of emission control systems including the

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

damage, wear

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

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

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

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

or.

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

--

1

Kilometre Intervals

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

ROAD TEST

Check operation and/or performance of the following: Steering and suspension (including shock absorbers) Brakes and clutch (including handbrake) Engine and driveability Vehicle lighting (including instrument panel, interior ant1 warning lights). Seat belts

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

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

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

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

...........

SERVICE BULLETIN REFERENCE

DATE

NUMBER SUBJECT

CHANGES

I

11

-0-

1

GROUP

SEC'TION

Subject Number Number

LNDEX SERVICE DIAGNOSIS

SPECIFICATIONS AND GENERAL INFORMATION

IN-VEHICLE SERVICE PROCEDURES 4654

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

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

specifications General Information

Engine Maintenance Compression Test Cylinder Head Cylinder Head Disassembly Valve Guides Valve Seat Insert Valves Valve Springs Camshaft and Camshaft Bearing Cap Rocker Arms and Rocker Arm Shafts Cylinder Head Reassembly Water Pump Pulley Seal Replacement Camshaft and Counter Balance Shaft, Drive Chains and Oil Pump

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

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

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

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

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

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

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

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

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

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

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

11

.

ENGINE

0

.

INDEX

4654

...........

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

Section Page

0

1

2

ENGINE OVERHAUL

General Engine Cylinder Block Pistons. Piston Pins and Piston Rings Connecting Rods Crankshaft Main and Connecting Rod Bearings

Counter-Balance Shaft and Bearings

Sprocket. Chain. Tensioner and Guide

Flywheel and Ring Gear

Ring Gear Replacement

Oil Seals. Oil Pan and Oil Screen Cylinder Block Reassembly

Information

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

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

4654

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

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

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

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

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

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

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

4

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

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

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

Subject

Section Page

Number Number

SPECIFICATIONS AND GENERAL INFORMATION 6672

Specifications Special Tools Torque Specifications General Information

SERVICE DIAGNOSIS

IN-VEHICLE SERVICE PROCEDURE

Compression Test Timing Belt Adjustment Timing Belt Cylinder Head Cylinder Head Disassembly Valve Guides Valveseats Valves

Valve Springs Camshafts and Camshaft Bearing Caps Rocker Arms and Rocker Arm Shafts Cylinder Head Reassembly

ENGINE OVERHAUL 6672

Engine CylinderBlock Pistons. Piston Pins and Piston Rings Connecting Rods Crankshaft Main and Connecting Rod Bearings Oil Seals. Oil Pan and Oil screen Flywheel and Ring Gear Ring Gear Replacement Cylinder Block Reassembly

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

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

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

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

6672

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

5

6

7

11-1-1

Condition

LOW COMPRESSION (DRY TEST)

LOW COMPRESSION (WET TEST)

NOISY VALVES

CONNECTING ROD NOISE

SECTION

Possible Cause

Valves sticking or seating poorly. Blown cylinder head gasket (if

pressure low in adjacent cylinders or coolant is contaminated with

engine oil).

Worn or sticking rings.

Worn rocker arms.

Worn valve guides.

Worn or damaged camshaft lobes. Excessive valve seat or valve face

run-out.

Malfunctioning hydraulic tappet adjusters.

Insufficient oil supply. Low oil pressure.

1

-

SERVICE DIAGNOSIS

Corrective Action

Overhaul valve system. Install new head gasket.

Replace or free-up rings.

Replace arms and check oil supply holes.

Replace guides and install new valves.

Replace camshaft. Re-cut valves and seats.

Replace defective tappet adjusters.

Check engine oil level. Check oil pump output.

if

necessary

MAIN BEARING NOISE

OIL PUMPING AT

RINGS

Thin or diluted oil. Excessive bearing clearance.

Connecting rod journal out-of-round.

Misaligned connecting rods.

Insufficient oil supply.

Low oil pressure. Thin or diluted oil. Excessive bearing clearance.

Excessive end play.

Crankshaft journals out-of-round or worn.

Loose flywheel. Worn, scuffed or broken rings.

Carbon in oil ring slots. Rings fitted too tight in grooves.

Change oil to correct viscosity.

Measure bearings for correct clearances. Replace if necessary.

Remove crankshaft and regrind

journals.

Replace the bent connecting rods. Check engine oil level. Check oil pump output. Change oil to correct viscosity. Measure bearings for correct

clearances. Replace if necessary. Check respective end thrust bearing

for wear on flanges. Remove the crankshaft and regrind

Tighten to correct torque. Hone cylinder bores and install new

rings. Install new rings. Remove the rings. Check the

grooves. If groove is not correct width, replace the pistons.

J

Condition

Possible Cause

Corrective Action

OIL PUMPING AT

RINGS (CONT.)

LOW

OIL PRESSURE

INDICATED

ENGINE DIAGNOSIS

A vacuum gauge can be beneficial as an aid in

diagnosing engine problems.

Obtain a reliable, calibrated vacuum guage and "tee" it into the inlet manifold at the brake booster vacuum connection.

fluctuation will be noticed on the gauge when the engine is running. This can be removed by fitting a small petrol tap between the gauge and manifold. With

the engine running, close the tap slowly until the

fluctuation disappears.

Use the readings as outlined opposite, to carry out

your diagnosis.

As for all 4-cylinder engines, a slight

WITH

Compression rings installed upside

down.

Low oil level.

Faulty oil pressure sending

Thin or diluted oil.

Oil pump relief valve stuck. Oil pump suction tube loose, bent

or cracked. Clogged oil filter. Excessive bearing clearance. Excessive oil pump gear clearance.

VACUUM GAUGE

nit.

Remove and refit rings correctly.

Check and top up oil level if required.

Install a new sending unit. Change the oil to correct viscosity.

Remove the valve and inspect. Remove the oil pan and install a

new tube if required.

Install a new oil filter.

Check the bearing clearance.

Remove oil pump and check gears for wear and clearance.

25 25

100 I00 100 0

80 20

lo

in..

Hg

kP.

1 2 3 4

NORMAL ENGINE NORMAL ENGINE VALVE SPRINGS VALVE GUIDES

WEAK WORN

on..

Hg

kP.

100

5

VALVE LEAKING

6 7

VALVE BURNT

VALVE STICKING VALVE TIMING

8

LATE

100

9

WORN RINGS WORN

m

10 11 12

RINGS OR IGNITION DEFECTIVE IGNITION RETARDED

80 20 80 20

n

kH9

kP. O kP.

100

25

30

in..

100

INFERIOR LUBRICANT

80 20

a"..

Hg

kP.

1w

13 14 15 16

CARBURETTOR LEAKING INTAKE LEAKING HEAD BLOCKED EXHAUST

ADJUSTMENT SYSTEM GASKET SYSTEM

(between cylinders)

Readings

1.

2. With a rapid opening and closing of the throttle, the

3. With fast running engine, the hand reads between 10

4. With engine idling, hand vibrates rapidly between 14

5. When valve should close, hand drops two or three

6. At idle, the hand drops consistantly a few points.

7. At idle, the hand sometimes drops around four points.

8. At fast idle, the hand reads steady from 8 to

-

ins.Hg (kPa)

With the engine idling, the hand is steady between 17 and 21 (57 to 71).

hand will fall to 2 (6.5) and swing back to 24 or 25 (81

84), settling on normal idle reading. Rings and

to

valves indicated

and 22 (34 to 74). Increase speed increases hand fluctuations.

OK.

and 19 (47 to 64).

points.

15

to 50).

(27

9. At idle the hand reads steady but lower than normal. Inferior lubricant may also be indicated.

10. With rapid opening and closing of the throttle, the hand falls to

0 and rises to 23 (78) or less.

11. With a slowly fluctuating hand between 14 and 16 (47 to 54), check ignition system for faults.

12. At fast idle, a steady reading between 14 and 17 (47 to 58) is registered.

13. Check idle mixture if hand moves slowly between

(44

and 17

to 57).

14. At idle or fast idle, hand reads between 3 and 5 (10 and 17). Check gaskets.

15. Hand moves consistantly between 5 and 19 (17 and

64).

16. High reading at start reducing to 1 (3) or increases to

'15 to 16 (51 to 54).

~g

0 and

O

n

13

SECTION

2

ENGINE GENERAL

-

SPECIFICATIONS AND GENERAL INFORMATION

SPECIFICATIONS

4654

Type.. Number of cylinders

Engine number-carburettor models. Bore

Stroke

Compression ratio (ECI-Multi models). Compression ratio (carby models) Compression pressure @ 250 rpm.. Compression pressure @ 250 rpm.. Maximum variation between cylinders Spark plug type Firing order

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

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

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

-ECI-Multi models

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

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

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

Displacement ,2555 cm3 RAC power rating.

Direction of rotation

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

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

..........

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

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

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

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

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

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

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

.In line OHC with Counter Balance Shafts and

Roller Rockers

.Four

W591, W592 W531, W532

9. mm

.98.0 mm .20.5

.9.2:1

.8.5:1 ,1250 kPa (approx.) carby models

1300 kPa (approx.) ECI-blulti models 10%

N9YC

.I, 3, 4, .Clockwise observed from front of engine

2

CYLINDER HEAD

Material .Aluminium alloy Type.

Maximum allowable distortion. Cylinder head height (between block and rocker

cover gasket surface) .90.0 mm

Maximum allowable re-machining of surface

Inler valve seat insert hole diameter

-0.05 mm Oversize

-0.3 mm Oversize

-0.6 mm Oversize

Exhaust valve seat insert hole diameter

-0.05 mm Oversize

-0.3 mm Oversize

-0.6 mm Oversize

Inlet and exhaust valve seat insert height

-0.3 mm Oversize

-0.6 mm Oversize

Valve guide hole diameter

-0.05 mm Oversize

-0.25 mm Oversize

-0.50 mm Oversize

Camshaft/camshaft bearing clearance.

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

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

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

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

.....

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

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

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

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

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

...........

.Hemispherical combustion chambers, cross flow

design

.0.2 mm

.0.2 mm or less, combined with cylinder block

grinding

.44.050 to 31.075 mm .44.300 to 44.325 mm

.44.600 to 44.625 mm

.38.050 to 38.075 mm .38.300 to 38.325 mm .35.600 to 38.625 mm

.7.90 to 8.10 mm .8.20 to 8.40 mm

.l3.05 to 13.07 mm .13.25 to 13.27 mm .13.50 to 13.52 mm .0.05 to 0.09 mm

VA I,V

ES

Macerial- Inlet.

-

Vul\je Icnglh- Inlet 107.96 mm

Head diameter - Inlet

Stem diameter 8.0 mm Stem diameter wear limit - Inlet.

Valve face angle. .4S0

head thickness - Inlet

Valve

Val\,e seat contact width Valve s~em to guide clearance

In\talled height between spring seat and retainer Val\,e stem seal inslulled dimension

Hydra~~lic lash adjuster dry clearance

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

Exhaust.

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

-

Exhaust. 105.86 mm

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

-

Exhaust. 38.0 mm

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

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

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

-

Exhaust. .0.15 mm

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

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

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

-

Exhaust 2.50 mm

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

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

--

-

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

Inlet Exhaust

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

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

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

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

Heat Resisting Steel of Heat Resisting Austenitic Steel

.46.0 mm

0.10

mm

1.70 mm

0.90 to 1.30

0.025 to 0.055 mm

0

')SO

10

0.085 nlni

40.40 mm

14.70 to 15.10

0.5 to 1.3 nim

VALVE: GUIDES

Outside diameter Inside diameter Length - [nlet. .47.0 mm

-Exhaust

Installed dimension

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

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

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

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

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

13.06 to 13.07 mm

8.000 to 8.01 8 nlm

.52.Omm

14.70 to 15.30

Cylinder head hole size for oversize guides

0.05

-0.95

-0.5Umm.. 13.50to 13.52mm

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

mm..

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

mm..

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

13.05 to 13.07mm

13.25 to 13.27 mm

+_

mm

I

.0 mm

mln

mm

JIS STD (SUH3B)

VALVE SPRINGS

Numbel. Free length. Load/compsessed height 28 kg140.40 mm

Out of Square. .4"max.

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

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

.47.5 to 46.3 mni

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

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

8

VALVE TIMING

Inletopens 2 SOBTDC Inlet closes. Du~~tion Exhaustopens Exhaust closes. 20" ATDC Duration Overlap

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

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

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

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

6

1 " ABDC

266"

66"BBDC

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

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

266"

.............................................. 45"

CAMSHAFT

Material Grey cast iron Carnshaftbearings Bearing clearance

Jo~~nial diameter 34.0 mm

End that Camshaft bend. Height of cam lobe- Inlet.

Nominal cam lift 10.5 mm Rocker arm to rocker shaft clearance

O

Mitsubishi Motors Australia Ltd. March 1995

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

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

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

.0.05 to 0.09 mm

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

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

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

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

-

Exhaust .42.56 m~n

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

.0.10 .0.02 mm or less .42.50 mm

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

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

AW342051-B

.0.013 to 0.043 mm

5

to

0.20 mm

I

REVISED

11-2-3

SPROCKET CAMSHAFT

Material .Cast iron Number of teeth .38

SPROCKET-CAMSHAFT DRIVE

Material .Grey cast iron Number of teeth.. .19

SPROCKET-COUNTER BALANCE SHAFTS

Material .Carbon steel Number of teeth.. .17

SPROCKET-COUNTER BALANCE SHAFT DRIVE

Material .Grey cast iron Number of teeth .34

TIMING CHAIN

Type. .Duplex roller Number of links .lo2 Pitch .9.525 mm Chain tensioner spring length

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

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

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

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

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

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

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

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

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

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

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

-Unloaded .65.71 mm

-Loaded at 2.0 kg.

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

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

.36.91 mm

COUNTER BALANCE SHAFTS DRIVE CHAIN

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

Type. .Single row bush type Number of links .90

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

Pitch .8.0 mm Chain adjuster. .Hydraulic

COUNTER BALANCE SHAFTS

Front journal diameter .23.0 mm Rear journal diameter .43.0 mm

Journal to bearing clearance-Front

CYLINDER BLOCK

Material .Alloy cast iron Maximum allowable distortion upper face Height of block (between cylinder head and oil

pan gasket surface). .316.0 mm

Cylinder bore diameter .91.1 mm Maximum bore oversize. .1.20 mm Maximum diameter difference between cylinders

Maximum bore wear (before reconditioning).

Maximum ovality and taper (before

reconditioning) .0.12 mm Reconditioning work limits for ovality and taper ~ain-bearing tunnel bore diameter

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

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

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

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

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

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

-Rear. .0.043 to 0.086 mm

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

........

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

..... Maximum allowable re-machining of surface

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

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

.. .0.02 mm

.....

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

.. .0.01 mm

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

.0.02 to 0.06 mm

.0.l mm

.0.20 mm or less, with cylinder head machining

combined

.0.2 mm

.64.0 mm

PISTONS

Material .Aluminium alloy Type. .Closed slipper (elliptically turned) Piston pin hole .22.0 mm Mass of pistons. .440 4 grams

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

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

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

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

PISTONS (Continued)

Piston diameter

Measuring position. Grade

Piston to bore clearance Piston oversizes .0.25 mm

PISTON PIN

Type.. Material Diameter. .22.0 mm Length 79.0 mm Offset in piston. .1.0 mm Clearance in piston..

PISTON RINGS

Number ...................................... 3

Ring gap-New-Compression..

Side clearance-New-Compression

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

A

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

B .91.08 to 91.09 mm

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

C .91.09 to 91.10 mm

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

D .91.11 to 91.12 mm

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

E

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

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

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

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

-Scraper and oil ring

-Service limit (All) .1.00 mm

-Service limit-Compression

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

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

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

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

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

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

...........

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

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

-Scraper

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

-Scraper .0.12 mm

...........

.2.0 mm up from bottom of skirt .91.07 to 91.08 mm

.91.12 to 91.13 mm .0.02 to 0.04 mm

0.50 mm

0.75 mm

1.00 mm

.Press fit in connecting rod .Cold forged chrome molybdenum steel

.0.005 to 0.009 mm

.0.249 to 0.399 mm .0.249 to 0.449 mm

.0.061 to 0.100 mm .0.020 to 0.061 mm

......

.0.15 mm

CONNECTING RODS

Material .Drop forged steel Length between centres .166.0 mm Conrod mass .831 grams

Small end bore diameter Big end bore diameter

Conrod bearing clearance

Conrod bearing undersizes

Conrod bend or distortion (within).

Conrod side clearance on journal Bearing material Aluminium-Tin

CRANKSHAFT

Material .Drop forged steel Number of main bearings. Main bearing journals

-Standard diameter .60.0 mm

-Maximum allowable taper. .0.01 mm

Main bearing clearance-All except centre journal.

Bearing material Aluminium-Tin

Main bearing undersizes-Rework diameter

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

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

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

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

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

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

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

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

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

.21.974 to 21.985 mm .56.00 mm .0.015 to 0.056 mm .0.25 mm

0.50 mm

0.75 mm .0.025 mm .0.10 to 0.25 mm

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

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

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

.5

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

-Maximum allowable ovality .0.01 mm

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

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

.0.016 to 0.045 mm

-Centre journal

.........

.0.028 to 0.057 mm

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

-0.25 mm

-0.50 mm

-0.7.5 mm

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

.59.735 to 59.750 mm .59.485 to 59.500 mm .59.235 to 59.250 mm

CRANKSHAFT (Continued)

Main bearing journal length-All except No. 3

-No. 3..

Connecting rod bearing journal

-Standard diameter .53.00 mm

-Maximum allowable ovality

-Maximum allowable taper. Conrod journal length. Conrod bearing undersizes-Rework diameter

-0.25 mm

-0.50 mm

-0.75 mm Crankshaft end float End float controlled by Dynamic balance in relation to centre line Flywheel out of round. Flywheel run out @ 115 mm

OIL

PUMP

Pump type Gear Drive. .Chain drive from crankshaft Oil pressure-Idle pressure

Oil pressure relief valve

Location .Oil pump Spring free length. .47.0 mm Load .4.3 kg/40.0 mm

Low pressure warning switch operating pressure. Oil filter Crankcase oil capacity-with filter

Pump body to gear clearance. Gear end play Gear to bearing clearance

Driven gear rear end bearing clearance

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

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

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

-Relief valve

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

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

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

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

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

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

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

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

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

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

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

-without filter .4.1 litres

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

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

...........

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

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

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

...........

..........

...

.......

..

.31.00 to 31.05 mm .30.90 to 31.10 mm

.0.01 mm .0.01 mm

.28.35 to 28.40 mm

.52.735 to 52.750 mm .52.484 to 52.500 mm

.52.235 to 52.250 mm .0.050 to 0.178 mm

3

.No. .34 g/cm .0.127 mm .0.13 mm max.

.I47 kPa (min.) .550 k 50 kPa

.29 kPa or less .Full flow sealed 'can'

.4.6 litres .0.105 to 0.150 mm

.0.06 to 0.12 mm .0.044 to 0.066 mm

bearing

.0.020 to 0.046 mm

SPECIAL TOOLS

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

El92 Compressor-Piston ring E0102 Compressor-Valve Spring

E9A5 Counter-balance shaft bearing installer

E9ASA E9A6. Counter-balance shaft bearing puller E9M30D.. .Installer valve stem seal E9M30

E11M12S. Remover/Installer kit-Piston pin E9M40 .Hydraulic tappet adjuster kit E1150.. .Hydraulic tappet leakdown tester E9M58 .Chain setting tool EllMlO "C" tensioner setting tool

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

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

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

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

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

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

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

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

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

Counter-balance shaft bearing installer sleeve

Kit-Remover/Installer valve guide and oil seal installer

11-2-6

I

APPLICATION

Balance chain

Guide

A attaching bolts ......................

Guide B special bolt

special bolt B

Tensioner C attaching bolts ...................

Balance shaft bearing retainer bolts Camshaft bearing caps

*Connecting rod cap

Counter-balance shaft sprocket bolts Crankshaft pulley

Cylinder head attaching bolts-(new gasket) Cylinder head to timing chain cover

Engine damper insulator bolts ...................

Engine mount bracket to chain case cover bolts Engine mount insulator nut (large)

Engine mount insulator nut (small) ..............

Flywheel or drive plate Front engine mount bolts to chain case bracket Front roll stopper bracket to centre member bolts

Front roll stopper bracket to engine ..............

Front roll stopper insulator bolt Inlet/exhaust manifold Knock sensor

Main bearing cap

Mount bracket to manual transaxle nut Oil filter Oil

Oil pan drain plug .............................

Oil pick up pipe to block

Oil pressure switch

Oil pump cover to body screw

Oil pump to block .............................

Oil pump relief valve plug ......................

Rear roll insulator bolt

Rear roll stopper bracket to centre member bolts

Rear roll stopper bracket to engine Rocker cover Spark plug

Sump drain plug ................................

Thermostat housing bolts

Thrust plate to cylinder block

Timing chain guide attaching bolts Timing chain cam sprocket retainer ~ransaxle insulator bracket to side frame bolts Water pump pulley

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

an

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

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

balance shaft)

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

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

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

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

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

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

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

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

TORQUE SPECIFICATIONS

A

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

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

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

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

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

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

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

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

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

...........

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

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

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

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

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

(L.H.

counter

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

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

.......

....

......... Mount bracket to automatic transaxle nut

...

.

...

4G54

1

*NCYIE: Torque figures quoted are for clean. dry threads in good condition. with the exception of connecting

rod nuts which should be oiled with clean gear oil or automatic transmission fluid prior to installation

.

Fig. I-Mitsubishi 2600 engine longitudinal section

GENERAL INFORMATION

The Mitsubishi 2600 engine is a four cylinder,

overhead cam, cross flow design with hemispherical

combustion chambers. Two counter balance shafts are

incorporated in the cylinder block to reduce engine noise and vibration.

The cylinder head is made of aluminium alloy, being

light in weight and ensuring maximum cooling effect.

Hemispherical combustion chambers permit the use of

large diameter valves helping improve fuel combustion

efficiency and minimising differences in combustion chamber volume, thus ensuring smooth engine operation. The cross flow design permits the intake gases to be drawn into the cylinder and exhaust gases

to be driven out from the cylinder in one direction, thus

improving the effect of combustion chamber scavenging and spark plug cooling.

The camshaft is chain driven by the crankshaft and

is supported in the cylinder head by five journals and

by caps. Valve clearance is maintained

auto-

by roller rocker arms incorporating hydraulic tappet units. Inlet valves are on the left, exhaust valves are on the right.

The cylinder block is made of alloy cast iron, with good

wear resistance characteristics. The crankshaft is supported by five main journals, thrust being taken by the centre bearing.

Two counter balance shafts are incorporated in the

cylinder block to cancel vertical and secondary

vibrating forces of the engine. The shafts are chain driven from the crankshaft at twice crankshaft speed and in opposite direction to each other. The left hand

shaft is mounted in the upper section of the block and rotates in the same direction as the crankshaft. The

right hand shaft mounted in the lower section of the

block, rotates in the opposite direction to the crankshaft. The right hand shaft rotational direction is reversed by means of a gear drive which in turn is used as the engine oil lubrication pump.

11-3-1

SECTION

3

-

IN-VEHICLE SERVICE PROCEDURES

ENGINE MAINTENANCE

Engine maintenance is most important in determining whether or not the vehicle will perform with maximum economy and efficiency.

With this in mind, it is important that engine and other component servicing is carried out at the intervals specified in the Lubrication and Maintenance section, or more often if required.

The service details outlined in this section may be carried out with the engine still in the vehicle.

CAUTION: On fuel injection models, the residual

fuel pressure and amount of fuel remaining in the fuel lines, make it essential that care is taken when disconnecting fuel lines. Use suitable containers and/or rags to contain fuel spillage.

COMPRESSION TEST

An engine without reasonably high and uniform compression cannot be effectively tuned. The compression of each cylinder should be tested before any other tuning operations are performed. The engine must be at operating temperature when performing the compression test.

Compression pressure with engine warm, spark plugs removed, wide open throttle at minimum cranking speed of 250

r.p.m. should be within the

specified limits.

(1) Remove any foreign matter from around spark plugs by blowing out plug area with compressed air, then loosen all plugs one turn.

(2) Start the engine and accelerate to

1000 r.p.m. to blow out loosened carbon. Stop engine and remove plugs, note cylinder from which each plug was removed for future reference.

NOTE: Clearing out carbon in this manner is

important in preventing false compression readings due to particles of carbon becoming

lodged under the valves.

-

(3)

Disconnect coil

(4) Remove air cleaner and block throttle and choke

(carburettor models) in wide open position.

(5) Disconnect the control relay (ECI-Multi models)

to prevent fuel injection.

(6)

Connect remote control starter switch to the

starter solenoid.

(7)

Insert the compression gauge firmly in spark plug opening, and crank engine through at least four compression strokes to obtain highest possible reading.

(8)

Test and record compression of each cylinder. Compression should read within the limits indicated in the specifications.

(9)

If one or more cylinders read low or uneven, inject about a tablespoon of engine oil on top of pistons in low reading cylinders. Crank engine several times and re-check compression. If compression comes up but does not reach normal, rings are worn. compression does not improve, valves are sticking or seating poorly. If two adjacent cylinders show low compression, and injecting oil does not improve condition, the cause may be a head gasket leak between the cylinders.

CYLINDER HEAD Removal

NOTE: Prior to removing cylinder head

engine to cool otherwise cylinder head

may occur.

(1)

Disconnect the battery negative (ground) terminal.

(2)

Drain the water from the radiator and cylinder block by removing the lower hose.

(3) Remove the water pump drive belt and water

pump, refer Group 14. If the cylinder head disassembled, remove the water pump pulley.

(4) Disconnect the exhaust pipe from the manifold. (5) Remove the air cleaner (carburettor models).

primary

lead.

allow the

warpage

is

to be

If

Fig. 1-Section view cylinder head

1. Rocker cover

2. Roller rocker arm

3.

Hydraulic tappet unit

4.

Camshaft bearing cap

5.

Camshaft

6.

Cylinder head

7.

Intake valve

8.

Valve seat insert

9.

Exhaust valve

10. Valve guide

11. Valve stem seal

12. Valve spring

13.

Valve spring retainer

14.

Rocker arm shaft

(6) Remove the air cleaner duct from the throttle

body (ECI-Multi models).

(7)

Disconnect the throttle cable, fuel supply and return lines, vacuum hoses, electrical leads, radiator and heater hoses, etc.

(8)

Manually rotate the engine until No. 1 piston is at top dead centre on the compression stroke. Aligning the crankshaft pulley timing mark on the

T'

mark of

the timing plate will ensure this position, refer Fig. 2.

(9)

Remove the distributor.

Fig. 2-Top dead centre position for No. 1 piston

(10)

If

the cylinder head is to be disassembled, the inlet and exhaust manifolds can now be removed for easier handling of the head.

(11) Remove the rocker cover. Check the location of

the camshaft dowel pin which should be in the

upper-

most position.

(12) With a suitable marking pencil, mark the timing

chain in line with the camshaft dowel pin.

(13) Remove the camshaft sprocket bolt and distributor drive gear and remove the sprocket from the camshaft and rest on the sprocket holder, refer Fig. 3.

(14) Loosen the cylinder head bolts in two stages to prevent cylinder head warpage-use order shown in Fig. 4.

@

Front of englne

Fig. 4-Cylinder head bolt removing sequence

(15) Remove the cylinder head from the cylinder block by raising it vertically over the timing chain and sprocket.

NOTE:

The cylinder head is positioned on the

block by two dowel pins. When removing the

head, do not twist or slide it or the camshaft

sprocket may be dislodged from the chain.

(16) Clean head thoroughly and inspect for damaged surfaces, components, cracks, water leaks, etc.

Installation

(1) Ensure that the joint surface between the top of

the chain cover and cylinder block is flat.

(2) Apply sealant to the two joint surfaces as shown

in Fig.

5.

NOTE:

Do not remove the sprocket from the

timing chain, as this will necessitate timing

chain cover removal to realign the timing gears.

t

holder

(3)

Fit the cylinder head gasket to the cylinder block

locating it correctly on the dowel pins.

(4) Install the cylinder head locating it on the dowel

pins. Do not slide the head across the dowel pins as damage to the head surface may occur. Care must also be taken to avoid dislocation of the camshaft sprocket

Fig. 3-Timing chain sprocket holder from the timing chain.

Fig. 5-Sealing points

f

(5) Tighten the cylinder head bolts in three stages (13) Install the air cleaner or- air cleaner duct

to the specified torque and in the sequence shown in (ECI-Multi models).

Fig. 6.

(14) Install the distributor.

(15) Reconnect the throttle cable, fuel supply and

return lines, vacuum hoses, electrical leads, radiator

Guide

hole

and heater hoses etc.

(16) Reconnect exhaust pipe.

(17) Fill the radiator using rain water or demineralised

water and

Mitsubishi Long Life Coolant in the required

concentration, refer Group 14.

(18) Connect battery cable and start engine. If it is

suspected that oil has leaked from the hydraulic tappet

adjusters, slow race the engine a minute at a time from idle to 3000

r.p.m. to bleed off the air.

Fig. 6-Cylinder head bolt tightening sequence

NOTE: Using Special Tool E11M10, release oil

pump timing chain ratchet to allow timing chain and sprocket to be relocated on to the camshaft. Refer Section

3

this Group.

3000

r.p.rn.

(6) Install the camshaft sprocket and distributor

,

.

drive onto the camshaft, rotating the camshaft to align the dowel pin to the sprocket. Ensure that the sprocket mating mark is aligned with the timing chain

plated

0

link. Temporarily tighten the sprocket bolt.

(7) Turn the crankshaft back

sprocket bolt to the specified torque.

(8) Install semi-circular (front) rubber packing to the

cylinder head and apply sealant as outlined in Fig.

90° and tighten the

4

7

Fig. 8-Bleeding air from hydraulic tappet adjusters

Approx. 1 min.

C

and to the rear of the rocker cover.

Apply sealant to the rocker cover contact area camshaft rear bearing cap.

Apply sealant

o

rn5C$o rnm

Cylinder Semi-circular head packing

of

the

-

,

15

mm

..

-

15

mm

Fig. 7-Sealing of cylinder head and rocker cover packing

(9) Install the rocker shaft cover and tighten the

retaining bolts to specification.

..L'

NOTE: It has been'btablished that over tight-

ening of the rocker cover bolts can result in

4

distortion of No.

camshaft journal with sub-

sequent danger of camshaft seizure.

(10) Install the intake and -exhaust manifolds using new gaskets. Apply sealer to the inlet manifold gasket as outlined in Group 15. Tighten all nuts to the specified torque.

(11) Install the water pump pulley, tightening the bolt to the specified torque.

(12) Install the water pump and drive belt, tightening to the specified torque ensuring the drive belt has the correct tension, refer Group 14.

(19) Run the engine until normal operating temper-

ature is reached and check for water and oil leaks.

(20) Set engine idle speed and ignition timing to specifications and check that idle CO concentration is within the specified range.

CYLINDER HEAD DISASSEMBLY

NOTE: If valve grinding or seat

refacing is considered necessary, note the following prior to disassembly:-

(a) If the valves or seats are badly worn, it may be necessary to replace the parts rather than recut or regrind them. This decision depends on the amount of dry clearance available at that rocker.

the valve, rocker

the assembled

the cam.

.

(c) Insert a ;ui?ab~e~.5

mm

wire probe through the hole in the rocker the ball in the hydraulic unit relieving the Measure the clearance

between the gauges.

yalve stem and hydraulic unit with feeler

-

*-5-

.,,

(d) The specified dry clearance is 0.5 to 1.3 mm; therefore,&e amount valve

and/& seat, must

clearance

is maintained.

of

material removed from the

be

such that the specified dry

The valve'stem tip must not be ground to obtain the required clearance.

With head removed from engine, and intake and

exhaust manifolds removed, proceed as follows:

(1)

Remove spark plugs.

(2) Fit tappet adjuster clips (part of Kit

each rocker arm, refer Fig. 9.

NOTE:

If the clips are not installed on the rocker arms, on removal of the rocker shaft assemblies the tappet adjusters will fall from the rocker arms.

E9M40) to

Cleaning and Inspection

Check the cylinder head for water leakage and

damage before cleaning.

Clean each part carefully removing all pieces of dirt,

oil, grease and carbon deposits. Clean oil holes and

passages using compressed air ensuring they are not clogged.

Care should be taken not to damage valve seats,

cylinder head surface and camshaft journals.

Using a straight edge and feeler gauge, check the

cylinder head for distortion as shown in Fig. 11.

Fig. 9-Rocker arm clip installation

(3) Remove camshaft bearing cap bolts.

(4) Holding the front and rear caps, remove the

rocker arm shaft assemblies.

(5)

Remove the caps, rocker arms, springs, and wave

washers from the shafts keeping them in the order of

removal. Care should be taken not to lose the camshaft

cap locating dowel pins.

(6)

Remove clips from rocker arms, remove tappet

adjusters and store in order of removal.

(7)

Remove the camshaft.

(8)

Remove the water pump pulley oil seal from the

end of the camshaft.

(9) Using a valve spring compressor, remove the

collets, spring retainers, springs, spring seats and valves,

keeping them in order of removal.

(10) Remove valve stem seals, refer Fig. 10.

NOTE:

Valve stem seals should not be re-used.

Fig. 11-Checking for cylinder head distortion

If cylinder head distortion exceeds the specified limit

it must be resurfaced.

Check the cylinder head manifold mounting surfaces

for flatness or damage.

Check condition of camshaft oil seal, replace if

necessary.

VALVE

clearance exceeds the specified limit replace the guide with the next oversize guide. Valve guides are shrunk into position, therefore when replacement is necessary the following procedure must be adopted.

No. cylinder block surface, refer Fig. 12.

GlJlDES

Check the valve stem to guide clearance. If the

(1) Heat the cylinder head (see note) and using Tool

E9M30, remove the defective guide towards

Fig. 10-Removing valve stem seals

Fig. 12-Removing valve guides

,

.

NOTE: This operation should be conducted with

the cylinder head temperature raised to a maximum of 250°C The cylinder head should

be kept at this temperature for a minimum

amount of time.

CAUTION: Exceeding 250°C could cause per-

manent damage to cylinder head.

(2) With the cylinder head at normal temperature,

ream the head as specified for the oversize guide.

(3) Heat the cylinder head to the correct temperature (see note), No. E9M30, install guides to the specified dimension.

Refer Fig.

(4) After guide is installed check the inside diameter and ream to specification if necessary.

13.

and

the guides quickly Using Too1

(1) Check valve guide for wear, if faulty replace

guide as previously described.

(2)

Re-condition the seat using either a seat grinder

or seat cutter.

(3)

he

valve seat contact width should be as specified, at the centre of the valve face and as shown in Fig. 14.

(4) After cutting, lap the valve and valve seat lightly

with a fine lapping compound.

Replacing Valve Seat Insert

Check the valve seat insert "sinkage" by measuring

the installed height

spring

specified limit, replace the seat insert as follows:

retainer

and

of

the valve spring between the

seat

If

the

sinkage exceeds the

r

Valve guide ~nstaller

I

VALVE SEAT INSERT

The valve seat should be checked for overheating and a suitable improper contact with the valve face. If faulty it must be re-cut or replaced.

".

Re-Cutting Valve Seat

Valve guide

Fig. 13-Installing valve guides

Contact width

Exhaust Intake

I

)\5-checking valve spring installed height

Fig.

(1) Thin dhwn the valve seat insert by cutting, with

cutteqto within 0.5 to 1.0 mm of the cylinder

head, refer to

(2) Remove the

insert bore diameter in the specifications, r

{F3

\

Fig, 16

(A).

'halve

seat insert and cut the seat

aq height to the dimension shown

\

TDO

mm;LJ--,H

Remove

New hole

44"

30'

Fig. 14-Valve seat angles

44"

60"

25"

30'

I

Old hole

A

Fig. 16-Replacing valve seat insert

B

(3) Heat the cylinder head to correct temperature (see note previous page) and press in the new valve seat insert.

(4)

Cut the insert to form a new seat as described

in Re-cutting Valve Seat.

VALVES

Check each valve for wear, damage and deformation of the head, stem and stem tip.

If

the stem tip is pitted or the thickness of the valve head is less than the specified limit, the valve must be replaced.

(1) Check the camshaft for bend by supporting

at the ends and mounting a dial indicator at the No.

it

2

or No. 3 journal. Rotate the camshaft once. Half of the total indicator reading is the amount of camshaft bend, if this exceeds the specified limit the camshaft should be repaired or replaced.

(2) Check the cam lobes and profile for damage. If the lobe or profiles are damaged, or worn excessively (see specifications), replace the camshaft.

Fig. 17-Valve check points

VALVE SPRINGS

Check the free length and tension of each valve

If

spring.

they are not within specifications replace the

spring.

Using a square, check the squareness of each spring. If the spring is excessively out of square, replace the spring.

CAMSHAFT AND CAMSHAFT BEARING CAP

Fig. 19-Checking cam lobe height

(3) Check the camshaft caps for damage on the

inner surface. If the caps are excessively damaged the

cylinder head must be replaced.

Check the camshaft journal to cap clearance by installing the caps to the cylinder head and measuring the cap inside diameter and the camshaft journal outside diameter as shown in Figs. 20 and 21. If the

clearance exceeds the specified limit and the journals

are worn, replace the camshaft. If the caps are worn replace the cylinder head.

NCKE:

The cap retaining nuts must be tightened to the specified torque prior to measuring internal diameter.

Fig. 18-Checking camshaft for bend Fig. 20-Measuring camshaft cap diameter

Fig. 21-Measuring camshaft journal diameter

(4) Check the camshaft end float, if it exceeds the

specified limit check the camshaft and cylinder head

for wear and replace the faulty component, refer fig. 22.

NOTE:

The hydraulic tappet urrit component, once cleaned ensure the units are protected to prevent the ingress of dirt or foreign material. Do not attempt to dismantle the unit.

is

a precision

Fig. 22 -Checking camshaft end float

ROCKERARMS ANDROCKER ARMSHAFTS

(1) Clean the rocker arms and shafts in a suitable solvent ensuring all oil holes and galleries are clear. A length of hard 0.5 mm wire can be used to clear the tappet bleed off hole in the rocker arm.

(2)

Check if rocker arm to cam lobe contact face is worn or damaged. If only slight wear is evident, it can be corrected with an oil stone. If severely worn or damaged the arm must be replaced.

(3) Using diesel fuel thoroughly clean the hydraulic

tappet units.

I

Fig. 23-Rocker arm and hydraulic tappet unit

(4) When cleaned, bleed the hydraulic units using

the following procedure:

(a) fit the hydraulic unit into the rocker arm and support on a block, in a bath of clean diesel fuel, refer Fig. 24.

(b) Using a suitable 0.5 mm wire probe, lightly push down the steel ball and move the rocker arm

up and down

(c) Allow the ball to seat by removing the probe

and push down hard on the rocker arm. If the rocker arm moves slightly, repeat step (b) several times.

(d) If the rocker arm still moves when tested as

in step (c), replace the unit.

(5) The hydraulic units can be tested using leak-

down tester, Special Tool E1150.

(a) Place a fully bled unit containing diesel fluid

into a 13 mm socket and place the assembly into the tester cup.

(b) Adjust the ram so the pointer is on the "Set"

mark as it touches the unit.

(c) Lower the weight and after the plunger has fallen slightly (0.2 to 0.5 mm), measure the leakdown rate with the aid of a stop watch.

Leak down rate: temperature at 15 to

4

or 5 times, refer Fig. 24.

4

to

20

secs/mm

25OC).

(diesel fuel

Fig. 24-Bleeding hydraulic tappet unit

(6) The fully bled units should be stored in an upright position ready for re-assembly to ensure the diesel fuel in the units is not spilt.

(7) Check the clearance between the rocker arms and rocker arm shafts, if they exceed the specified limit replace the arms or shafts.

(8) Check the rocker arm shafts for damage and bend, if faulty they must be replaced.

(4) Ensure the valve moves smoothly in the guide. (5) Install valve springs and spring retainers.

NOTE: Install valve springs with the enamel

identification marks facing the rocker arms.

(6) Using a valve spring compressor install the valve

collets.

NOTE: When compressing the spring, take care

that the spring retainer is not forced against the valve stem seal.

(7) Position the camshaft onto the cylinder head and

check end float.

(8) Remove the camshaft and install the oil seal on

the end of the shaft.

(9) Reposition the camshaft onto the cylinder head.

(10) Install the caps, rocker arms, springs and wave washers onto both rocker arm shafts. The caps must be installed with the indicating arrow to the front of the engine and in the order they were removed. The right hand shaft has 16 lubrication holes, the left hand shaft has 8 lubrication holes.

NOTE: When assembling the rocker arm shafts

to the caps align the mating marks on the shafts and cap.

CYLINDER HEAD REASSEMBLY

When assembling cylinder head ensure all parts are thoroughly cleaned and that all moving parts are lubricated with engine oil prior to assembly.

(1)

Install the valve spring seats.

(2) Install the valve

using Tool No.

sterr. seals over the valve guides

E9M30C. The seal is installed to the

specified position by the tool. Incorrect fitment will

result in damage to the seal and subsequent oil leakage.

NOTE: Old stem seals must not be reused.

Bearing Bearing cap, front cap, No.

Wave arm washer

Bearing Bearing

2

cap, No.

Mating marks

3

Mating

cap. No. 4 cap, rear

Bearing

Fig. 25-Installing valve stem seals

Fig. 26-Assembly of rocker arm shafts

Install the wave washers with the convex side facing

(3) Apply engine oil to the valve stem and install the the front of the engine.

valves into the guides. Do not use excessive force to

(11)

Position the camshaft with the sprocket locating

press the valve stem past the valve stem seal. dowel in the uppermost position, refer Fig. 29.

I,

i

:

(12) Install the hydraulic tappet units to the rocker

arms

with the hole in the unit to the top of the rocker

and in the order they were removed, and fit tappet

arm

adjuster retaining clips (part of Kit

E9M40) to each rocker arm. Keep the hydraulic units vertical to prevent spillage of the diesel fuel.

Tappet unit retaining clip

Fig. 29-Installing rocker shaft assemblies

Hydraulic tappet unit

Fig. 27-Installing hydraulic tappet unit

NOTE:

Prior to fitting rocker shaft assembly to cylinder head, place silastic bead as shown in Fig.

28

to the cylinder head where the

camshaft cap is fitted.

No.

WATER PUMP PULLEY SEAL REPLACEMENT

(1) Loosen water pump drive belt adjusting bolts,

refer Group 14.

(2) Remove the drive belt from the water pump.

(3)

Remove the camshaft pulley cover and remove

the drive belt.

(4) Remove the bolt and remove the water pump

5

drive pulley from the camshaft.

(5) Insert a suitable hook between the camshaft and

seal lip and withdraw the seal from the camshaft.

(6) Wrap a cleaning rag around a screwdriver and

wipe out the

(7)

Lubricate the seal (lip and outer edge), seal

camshaftheal housing area.

housing and camshaft with engine oil. Install the seal onto the camshaft.

(8)

Position a suitable socket over the camshaft against the seal and tap gently with a hammer until the seal is in place.

(9) Install the drive pulley, cover and belt and adjust

the belt as outlined in Group 14.

Fig. 28-Sealing bearing cap

(13) Install the cap dowel bushings and position the

rocker shaft assembly onto the cylinder head.

NOTE:

The oil seal on the rear of the camshaft must be positioned to ensure adequate sealing prior to fitting the rear bearing cap.

(14) Install cap retaining bolts and tighten in two stages, to the specified torque. Tightening order No. 3, 2, 4, front and rear.

(15) Remove hydraulic tappet retaining clips.

(16) Install spark plugs.

-

11 - 3 - 10

CAMSHAFT AND COUNTER-BALANCE SHAFT

DRIVE CHAINS AND OIL PUMP

Both the camshaft and the counter-balance drive chains are fitted with a hydraulic tensioner supplied by engine oil pressure.

The timing chain tensioner is equipped with a ratchet mechanism which does not allow the tensioner to return unless the ratchet release lever is released. This ratchet mechanism ensures that the chain tension is

maintained when oil pressure is low or not available,

i.e. engine start up.

Both tensioners are also equipped with a spring

which supplements hydraulic pressure, spring force and

hydraulic pressure are used to maintain chain tension.

NOTE: WITH THIS CHAIN TENSIONING

MECHANISM, REGULAR SERVICE ADJUSTMENT IS NOT REQUIRED ON EITHER CHAIN.

CAUTION: THE COUNTER-BALANCE

SHAFT CHAIN STILL FEATURES AN ACCESS POINT FOR GUIDE

"B"

ON THE TIMING CASE COVER, SHOULD IT BE NECESSARY TO ADJUST AFTER HIGH MILEAGE OR REPAIR SITUATION. THIS POINT IS USED FOR EXTERNAL CHAIN ADJUSTMENT AFTER A REPAIR OR AFTER MILEAGE.

Tensioner C Crankshaft

sprocket

B

Fig. 30-Counter balance shafts chain drive

Oil

pump

to block

16

mm

011

pump

to block

45

block

mm

Removal

(1)

Disconnect negative battery lead.

(2) Drain the cooling system.

(3) Rotate the engine to T.D.C. with No.

1

piston on

compression.

(4) Remove the stone guard (where fitted), drain the engine oil and remove the oil pan bolts. Remove the oil pan and oil pump pick up pipe.

(5) Support the engine under block and remove the

front engine mount.

(6) Lower engine and remove crankshaft pulley. (7) Remove the alternator and air conditioning

compressor (if fitted).

(8)

Remove rocker cover, distributor and remove the two bolts attaching the cylinder head to the timing chain cover.

(9)

Remove the timing chain cover being careful not to damage the head gasket.

(10) Loosen counter-balance shaft sprocket bolts.

(11) Remove the balance shaft chain guides-A, B and

tensioner C-Refer Fig. 30.

(12) Remove the bolts retaining the counter-balance

shaft sprockets

(13) Remove the crankshaft sprocket

balance4haft sprockets

'%".

'%"

and drive chain

'%",

counter-

'%".

(14) Remove the camshaft sprocket retaining bolt and

remove the sprocket holder.

(15) Move the timing chain ratchet release lever downwards and depress the chain tensioner and remove the camshafts sprocket and the timing chain, refer

Fig. 31.

to cover 40

mm

Oil

pump

to block

Fig. 31-Timing chain release lever

(16) Remove crankshaft sprocket and chain guides.

(17) Remove the oil pump retaining bolts and remove

the oil pump.

Installation

(1) Install the oil pump, timing chain guides and the

camshaft sprocket holder.

NOTE:

Fill the

oil

pump with engine oil prior

to

installation.

(2) Install the camshaft and crankshaft sprockets onto the timing chain with the sprocket mating marks aligned with the plated links on the chain.

(3)

With the sprocket and chain mating marks aligned, install the crankshaft sprocket onto the crankshaft.

-

Crankshaft sprocket

-

Camshaft sprocket

Sprocket holder

(8)

Install the counter-balance shaft sprockets onto

the shaft and oil pump driven gear at the same time.

(9)

Temporarily install chain guides "A",

'73"

and tensioner "C" to prevent the chain from jumping over teeth of sprocket.

(10)

Apply Loctite 242 to the bolt threads, install the sprocket retaining bolts and tighten to the specified torque.

NOTE: Ensure the sprocket mating marks align

with the plated chain link.

Fig. 32-Timing chain drive

NOTE: Move the timing chain ratchet release lever

in direction shown in Fig. 31 to aid installation by allowing the tensioner sleeve to retract into

the oil pump body.

(4) Align camshaft dowel pin with the camshaft sprocket and install sprocket onto camshaft. Tighten bolt to the specified torque.

(5) Install the counter-balance shaft crankshaft s~rocket

'73"

"B".

(6)

Install the two counter-balance shaft sprockets

onto chain

"T3"

aligning the mating marks on the sprockets with the plated links on the chain, refer Fig. 33.

Tensloner and

'

Rubber

washer

Fig. 34-Tensioner "C" assembly

NOTE: Special bolt

"A"

of guide

"B"

(Fig. 33) has Loctite 242 on the bolt thread with a flat washer. On re-assembling an engine, fit the bolt and flat

242

washer with Loctite

on the thread and

tighten to 30-35 Nm.

(11) Tighten the chain guide "A" mounting bolts. (12) Tighten the chain tensioner "C" mounting bolts

while pushing down on balance chain, see Fig. 35, so as to- put the "C" tensioner body in its lowest position.

Fig. 33-Counter-balance shaft chain alignment

NOTE: Ensure the right hand sprocket (oil pump)

is installed with the chamfer side facing inward and the left hand sprocket with the chamfer facing outward.

(7) While holding the chain and sprockets assembled

as above, install the chain onto the crankshaft sprocket with the plated chain link aligned with the mating mark

on the crankshaft sprocket.

~i~;~35--~hain guide installation

,;.

r;

(13) Remove the slackness from the chain by pushing

'73"

down on

guide, refer Fig. 35, and observing the

gap at the "C" tensioner, refer Fig. 34, lock the

adjusting bolt

'73"

of guide

'73"

when a gap of 3 mm

is achieved.

NWE: Ensure there is a 3 mm gap, refer

Fig. 34, between the tensioner sleeve assembly and the body of chain guide

"C".

(14) Install the timing chain cover.

(15) Install the bolts attaching the cylinder head to the timing cover and torque to specification, install distributor and rocker shaft cover.

(16) Install the crankshaft pulley and tighten the

retaining bolt to the specified torque.

(17) Install front engine mounting.

(18) Install the oil pump pick up and engine oil pan,

tighten retaining bolts to the specified torque. Install the stone guard (where fitted).

(19) Install the alternator and air conditioning com-

pressor (where fitted), readjust drive belt.

(20) Fill the engine with the correct grade and

quantity of first grade engine oil.

(21) Fill the cooling system with rain or demineralized

water and Mitsubishi

Longlife Coolant in the required

concentration, refer Group 14.

(22) Start the engine and set ignition timing to

specifications.

Counter-Balance Shaft Chain Resetting Procedure

If the counter-balance shaft chain has to be set up because the chain drive mechanism has been disturbed or the chain guide

'73"

has been released, proceed as

follows:

Chain

guide

"B"

Fig. 36-Adjusting counter balance shaft chain

Remove the chain guide

'73"

adjuster access cover

on the timing cover.

Loosen the adjuster bolt and adjust the guide by pushing the guide firmly (approx. 5-6 kg) to take up chain clearance. Special Tool EllMlO will facilitate this

procedure. Tighten the adjuster bolt to the specified torque and install the cover plate.

Camshaft Drive Chain Tensioner Setting Procedure

NWE: The timing chain ratchet release lever must

be pushed down to allow the tensioner to be pushed back to the bottom of its travel,

i.e.

minimum tension position.

This is necessary when installing the timing chain

and sprocket on to the camshaft.

Fig. 37-Positioning chain setting tool

The ratchet release lever can be released by positioning the Special Tool EllMlO down the inside timing cover from the top after the rocker cover has been removed.

A guide channel is cast on the inside of the timing cover to direct the tool onto the camshaft chain ratchet release lever.

(1) Install the tool down the inside of the timing cover, position the blade of Special Tool EllMlO 90 degrees to the camshaft, to assist in passing chain guides etc.

NOTE: The blade direction of the tool is identified

on the top of the handle.

(2) Insert the tool so that the mark on the shaft is level with the top of the cylinder head.

(3) Rotate the tool 90 degrees, so that the blade of the tool is aligned with the camshaft.

(4) Position the tool all the way down to hold the ratchet lever in the released position. The weight of the tool is sufficient to hold the ratchet disengaged.

CAUTION: DO NOT OVERLOAD THE

RATCHET RELEASE LEVER OR DAMAGE TO THE LEVER MAY OCCUR.

NOTE: When the tool is removed and the ratchet

lever is released the ratchet is re-applied and tension is applied automatically.

I

. .

SECTION

GENERAL INFORMATION

The procedures outlined in this section cover the major overhaul of the engine. The engine may be either (15) Remove the torque converter to drive plate in or out of the vehicle depending on the reconditioning required. the transaxle.

CAUTION: On fuel injection models, the residual

fuel pressure and amount of fuel remaining in the fuel lines, make it essential that care is taken when disconnecting fuel lines. Use suitable containers and/or rags to contain fuel spillage.

NOTE: Chloro-Fluro-Carbons.

Legislation in various states, prohibits the release of CF.C recovery unit will be required to contain spent gases if the air conditioning hoses are disconnected. Check your relevant state government authority in regards to the relevant legislation.

ENGINE Engine (Automatic Models) or Engine and

Transaxle (Manual Models) Removal

(1) Drain engine coolant.

(2) Remove engine hood.

(3) Disconnect battery. (4) Remove coolant recovery bottle.

(5) Remove air cleaner assembly.

(6) Disconnect wiring from the alternator, starter motor, carburettor, distributor, oil pressure switch and the injection control loom (ECI-Multi models).

(7) Disconnect the earth strap at the intake manifold (carburettor models) or the surge tank (ECI-Multi models).

(8) Disconnect accelerator cable. (9) Disconnect radiator and heater hoses from

engine.

(10) Disconnect all vacuum hoses and label for easy

installation.

(11) Disconnect the fuel bowl vapour hose of the

intake manifold (carburettor models).

(12) Disconnect the fuel supply and return hoses. (13) Remove the starter motor.

CF.C's to atmosphere. Therefore a

4

-

amount of

ENGINE OVERHAUL

For automatic models proceed as follows:

(14) Remove the torque converter lower cover plate.

attaching bolts and push the torque converter towards

(16) Remove the drive shaft centre bearing to cylinder

block bolts and support the drive shaft.

(17) Disconnect the front exhaust pipe from the

manifold and remove the exhaust pipe stay strap.

(18) Position a suitable support under the transaxle

to support the weight of the transaxle.

(19) Attach a suitable lifting bracket to the engine

and, using a hoist, support the weight of the engine.

(20) Remove the transaxle to engine attaching bolts. (21) Remove the front roll stopper through bolt and

damper to engine bracket bolt.

(22) Remove the rear roll stopper through bolt and

remove the roll stopper from the cross-member.

(23) Remove the engine mount through bolt and remove the engine mount from the engine mount bracket.

(24) Seperate the engine from the transaxle and lift the engine out of the vehicle.

For manual models proceed as follows:

(14) Disconnect wiring from the reverse light switch.

(15) Disconnect the clutch hydraulic line.

(16) Disconnect gear shift control cables.

(17) Disconnect the engine earth cable at the

transaxle.

(18) Disconnect the speedometer from the transaxle.

(19) Drain transaxle oil.

(20) Raise the front of the vehicle and support on jack

stands.

(21) Disconnect the drive shafts from the transaxle,

refer Group 26, and support to avoid damaging the

joints.

(22) Disconnect the exhaust pipe from the manifold

and remove the exhaust pipe stay strap.

(23) Attach a suitable lifting bracket to the engine

and, using a hoist, support the weight of the engine.

(24) Remove the front and rear roll stopper through

Fig. 1-Disconnecting radiator hoses bolts.

Fig. 2-Front engine mount

(25) Remove the rear roll stopper from the

cross-member.

(26) Remove the nuts from the engine and transaxle

mounting through bolts.

(27) Slightly raise the hoist so that all load is off of

the mounting bolts.

(28) Remove the mounting through bolts then, while pushing the transaxle downwards, lift the engine and transaxle assembly from the vehicle.

Installation

Install by reversing the removal procedure, noting the

following:

(I) Ensure that no cables, connectors or hoses are

caught or damaged on installation.

(2) New retainer rings must be fitted when installing

the drive shafts.

(3) All engine mounts must be aligned before being tightened to the specified torque (ensure front and rear roll stopper bolts are positioned in the correct hole in the engine brackets).

(4) Fill and ensure all fluid levels are at the correct level.

(5)

Run the engine and check for oil, fuel and

exhaust leaks. Rectify where necessary.

(6) Adjust all linkages and settings to specifications.

(7) Ensure vacuum hose connections are correct, refer Group 17 for hose connection graphics.

(8) Set engine idle speed and ignition timing to specifications and check that idle CO concentration is within the specified range.

(4) Remove the flywheel and clutch assembly or

torque convertor drive plate.

(5) Remove the bolt retaining the oil pump driven gear to the counter-balance shaft and then remove the oil pump retaining bolts and remove the pump.

(3) Remove the counter-balance shaft and camshaft drive chains as previously described.

NOTE: If the bolt retaining the oil pump gear to

the counter-balance shaft is difficult to remove, remove the oil pump and counter-balance shaft

as an assembly and then remove the bolt.

(6) Remove the bolts securing the left hand counter-

balance shaft thrust plate.

(7) Remove the thrust plate.

(8) Withdraw the counter-balance shaft.

(9)

Remove the crankshaft rear oil seal assembly.

(10) With the cylinder block on its side, remove the

connecting rod caps.

(11) With the aid of a soft piece of wood push the piston and rod assembly out through the top of the cylinder block, keeping the piston assemblies and caps in the order removed.

CYLINDER BLOCK Disassembly

The following description details the disassembly with the engine removed from the vehicle and axle removed from the engine.

(1)

Remove the cylinder head assembly as described

under Cylinder Head Removal, refer Section 3.

(2) Remove the oil pan and oil screen.

trans-

Fig. 4-Removing piston from connecting rod

CALITION: When removing pistons, ensure the

front mark of the piston is facing upwards or DAMAGE to the piston WILL RESULT.

Fig. 3-Cylinder block

i,

NOTE: Prior to removing the piston and rod

assemblies, remove all carbon deposits and/or cylinder ridge from the cylinder bore.

(12) Remove the piston rings from the piston keeping

them in order of removal.

(13) Remove the pistons from the rods using special

tools required from kit

EllM12, refer Fig.

4.

CAUTION: When removing pistons, ensure the

front mark of the piston is facing upwards or damage to the piston will result.

(14)

Remove the crankshaft bearing caps and lower

bearings keeping them in the order removed.

(15) Remove the crankshaft and the upper bearing

halves.

NOTE: The main bearings (except the centre one)

to

are interchangeable, however, if they are

be reused they should be installed in the original position.

(4) If the cylinder does not require re-boring, remobe the ridge at the top of the cylinder and hone the bores if necessary.

Cleaning and Inspection

Before cleaning, check the cylinder block for water

leakage, cracks or damage.

When cleaning, remove all traces of oil, grease, dirt,

carbon, and scale from all components. Clean out all

oil passages by blowing with compressed air.

Checking Cylinder Block

(1) Check the cylinder bores for scratches, rust,

corrosion, cracks or any defects or damage, if faulty

the block must be

(2) Check the upper surface of the cylinder block for distortion using a straight edge and feeler gauges. If it is not within specifications the surface must be re faced.

rebored or replaced.

NOTE: If refacing is necessary, an equivalent

amount must be removed from the timing chain case to maintain a flat gasket surface.

Fig. 6-Measuring cylinder bores

Cylinder Boring

(1) The piston size to be used should be determined

by the cylinder which has the largest bore size.

(2) Check the outside diameter of each oversize piston at the skirt and across the thrust faces. The measurement should be taken at a point 2.0 mm from the bottom of the piston.

(3) To determine the cylinder re-boring size as follows:

(a) Measure the diameter of the piston.

(b) Allow piston to bore clearance.

(c) Honing margin

(d) Size after boring to 0.02 mm.

(4)

The cylinder should be re-bored to the size

obtained by the calculation.

(5) The final cut should not be greater than

mm.

0.05

NmE:

Do not attempt

=

0.02 mnl or less.

=

(a) + (b) - (c) = (a) + 0

to

cut too much from

procecd

the bore at one time.

(6)

To prevent heat distortion of the bores when reboring, the cylinders should be bored in the following sequence: 2-4-1-3 or 3-1-4-2.

Fig. 5-Checking cylinder block for distortion

(3) Measure the cylinder bore size at three levels. If

the wear exceeds the specified limit the cylinders must

be re-bored to the next piston size.

NOTE: If only one cylinder requires re-boring,

all the cylinders

MUST

be re-bored.

Fig. 7-Measuring piston diameter

(7)

Thc cylinder bore size will vary immediately after re-boring, due to the heat generated by the cutting operation, therefore care should be taken when

measuring the bore size.

(8) After cutting, the bore should be honed accur-

ately to the finished size. The bores should be honed

until all traces of the cutting operation are removed.

The honing angle should be between

(9)

Check the piston to cylinder wall clearance.

PISTONS. PISTON PINS AND PISTON RINGS

(1)

Check the pistons for seizure, nicks, wear, cracks

30° and 454

and any other defect. Replace any faulty pistons.

(2)

Check the piston pin to pin hole fit. The pin must be a smooth hand press fit into the piston hole. Replace any piston and pin assembly that is defective.

(3) Check the piston rings for breakage, damage and

abnormal wear. Replace any defective rings.

NOTE:

If a piston

also be fitted.

is

replaced, new rings should

(4) Measure the piston ring side clearance by placing

the ring in its respective piston groove and checking

it

the clearance with a feeler gauge. If

exceeds the

specified limit, recheck the clearance with a new piston

If

ring.

the clearance is still excessive replace the piston

and rings, if it is within specification, replace the rings

only.

(5) Measure the piston ring end gap by inserting the

ring into the

cyIinder and positioning it at right angles

to the cylinder wall by pressing it down with a piston.

Remove the piston and measure the ring gap using a feeler gauge. If the gap exceeds the specified limit, replace the piston rings.

NWE:

If the cylinders are not being re-bored, the ring gap measurement should be made at the lower part of the cylinder, the area having the least wear. When replacing the piston rings, be sure to use rings of the same size.

Fig. 9-Measuring piston ring gap

CONNECTING RODS

(I)

Check the connecting rod for damage at the thrust faces at either side and for step wear or severely rough surface of the inside diameter of the small end.

Replace faulty rods.

NCWE:

(2)

When using a new connecting rod, the cylinder number should be stamped or marked on the big end.

Measure the connecting rod small end diameter,

if not within specifications, replace the rod.

(3) Using a connecting rod aligner, check the rod for

bend and twist. If a rod falls just outside the specified

A

limit it can be straightened by using a press.

rod that

is severely bent or distorted must be replaced.

(4)

Measure the connecting rod side clearance by assembling the rod and bearing onto the crankshaft and tightening the bolts to the specified torque. Measure the clearance between the connecting rod and crankshaft using feeler gauges. If this exceeds the specified

limit, replace the rod.

Fig. 8-Measuring piston ring side clearance

Fig. 10-Measuring connecting rod side clearance

,/"

.'.

,

CRANKSHAFT

1

(1) Check the crankshaft journals for damage,

Fillet

uneven wear and cracks. Check all oil holes for clog-

R

ging.

(2) Check the crankshaft for bending by support-

it

between centres and positioning a dial indicator

ing

F~llet

R

on the centre journal. Rotate the shaft once noting the total indicator reading. Half of the reading is the amount of bend, if this exceeds the specified limit, repair or replace the crankshaft.

Fig. 13-Crankshaft journal fillet radii

(5) Check the crankshaft end float by assembling

the crankshaft, bearings and caps to the cylinder block.

Insert a feeler gauge between the centre bearing and crankshaft, if the end float exceeds the specified limit, replace the centre bearing.

I

Fig. 11-Measuring crankshaft bend

(3)

Measure the crankshaft journal diameters as shown in Fig. 12. If they are excessively out of round, tapered or worn they must be re-ground to the next undersize.

NOTE:

(4) When grinding the crankshaft, care must be

taken to ensure the crankshaft journal fillet radii are

2.5

Grinding of crankshaft journals must only be done shaft bend.

ground, the correct undersize bearings must be

fitted.

AFTER

Whenever crankshaft journals are re-

checking/repairing crank-

mm.

Fig. 14-Measuring crankshaft end float

MAIN AND CONNECTING ROD BEARINGS

(I)

Check all bearings for peeling, melting, seizure

and improper contact. Replace any faulty bearings.

(2) Checking the journal to bearing clearance can

be done using either of two methods:

(a) measure journal and bearing diameters; (b) using the plastigauge method.

Measuring Diameters

(1) Measure the outside diameter of the main and

connecting rod journals, refer Fig. 12.

(2) Assemble the bearings and caps and measure the bearing inside diameter, refer Fig. 15. The clearance is the difference between the respective bearing and

Fig. 12-Measuring crankshaft journal diameter journal diameter.

(3) If the clearance is not within specification and

the journal diameter is within specification the bearings

must be replaced.

Fig. 15-Measuring bearing diameter

Plastigauge Method

(1)

Remove all oil, grease and dirt from the bear-

ings and journals.

(2) Cut a piece of Plastigauge the length of the

bearing width and place it across the bearing, away

from the oil hole.

(3) Install the

crankshaft/connecting rod, bearing

and caps and torque them to specifications.

NOTE:

Do not rotate the crankshaft or connecting

rod during this operation.

COUNTER-BALANCE SHAFT AND BEARINGS

(1) Check bearings for scratches, seizing and

excessive clearance. Replace bearings as necessary.

(2) Check bearing clearance by measuring the outside diameter of the journal and the inside diameter of the bearing.

If clearance exceeds specification and the journal diameter is within specification the bearing must be replaced.

NOTE:

The left hand front bearing is serviced as an assembly with the thrust plate. The right hand front bearing is serviced as part of the oil pump cover.

(3) Check oil passages for clogging.

Rear Bearing Replacement

(1) Using Tool No. E9A6 insert the tool through the shaft hole at the front of the cylinder block until its rotatable claw portion passes beyond the bearing.

(2) Pull the tool forward to fit the claws into the

bearing.

(3)

Hold the shaft of the tool with a spanner and

turn the nut of the tool, this will pull out the bearing.

Cylinder block front surface

Bearing puller Bearing

(4) Remove the caps and measure the width of the Plastigauge using the scale printed on the Plastigauge packet.

(5) If the clearance is not within specification and

the journal diameter is within specification the bearings

must be replaced.

Fig. 16-Checking bearing clearance using

Plastigauge

cylinder block

Fig. 17-Removing counter-balance shaft bearing

Cylinder block Bearing front surface installer

Cylinder block

Fig. 18-Installing counter-balance shaft bearing

(4) Using Tool No.

E9A5,

the bearing can be press

fitted to the specified position. Since the tool has no guide, extra care must be taken to align the bearing outside diameter and cylinder hole.

NOTE: Use sleeve tool No. E9A5A in conjunc-

tion with tool right hand shaft bearing.

SPROCKET, CHAIN,

NO.

E9A5 when installing the

TENSIONER AND GUIDE

(1) Check all sprockets for teeth damage and wear. Check counter-balance shaft sprockets for damaged cushion ring and ring guide. Ensure cushion ring rotates smoothly.

(2)

Check the chain for roller play, wear, damage,

disconnected links, etc.

(3) Check the chain tensioner rubber shoe for wear and the tensioner spring length specification.

(4) Check the chain guides for wear and damage.

If the guides are severely worn or damaged they should

be replaced.

FLYWHEEL AND RlNG GEAR

(1) Check the flywheel surface for wear or damage, if excessively worn or damaged, replace the flywheel.

(2) Check the flywheel surface run-out, if it exceeds the specified limit replace the flywheel.

(3) Check the ring gear for damage, cracking and wear, replace if necessary.

OIL SEALS, OIL PAN AND OIL SCREEN

(1)

Check the front and rear crankshaft seals for

damaged or worn lips. Replace the seal if defective.

(2) Check the oil pan for damage and cracks, repair

or replace the oil pan as necessary.

(3) Check the oil screen for failure, damage and cracks. Check the O-ring for defects. Replace any faulty parts.

CYLINDER BLOCK REASSEMBLY

When assembling the cylinder block the following

procedures should be observed:

Thoroughly clean all components especially oil

holes, bearings, housings, bores and cylinder

walls. Apply engine oil to sliding and rotating parts

such as cylinder walls, pistons, bearings and gears

prior to installation.

Gaskets and oil seals should be replaced with new

parts.

Apply sealant to gasket as required. Torque all bolts to specification and in the specified sequence where necessary.

Check all oil clearances, thrust clearances and backlash where necessary.

(1) Install main bearings, upper, to the cylinder block. If reusing the main bearings, install them in their original position.

(2)

Position crankshaft onto cylinder block and

apply oil to journals.

(3) Install the bearing caps and bearings, tightening the cap bolts to specification and in the sequence of: centre, No. 2, No.

NOTE: The caps must be installed with the arrow

mark facing the front of the engine and in the correct order.

4,

front and rear.

Fig. 19-Checking flywheel surface run-out

RlNG GEAR REPLACEMENT

(1) Remove the ring gear by cutting through the

valley of the ring gear teeth to within 1 mm of the

flywheel circumference and then split with a hammer

and chisel.

NOTE: Do not attempt to remove the ring gear by

heating.

(2) Install the ring gear by heating it on a gas ring

to 260 to

280°C and shrinkage-fit it on the flywheel. between the push rod and guide bar.

Engine

front

Fig. 20-Installing main bearing caps

(4) Ensure that the crankshaft rotates lightly and smoothly and that the end float is within specifications.

(5)

Using Tool No.

E9A7

set the piston pin positively

Identification

fitNO355

Fig. 21-Fitting piston pin onto tool

(6)

Lubricate the outer surface of the piston pin and

small end bore of the connecting rod.

(7) With the connecting rod and piston front marks aligned (arrow on piston, numerals on connecting rod), insert the piston pin, guide bar (EllM12-4) and push rod (EllM12-3) into the piston.

-

.

Front mark

'1

Fig. 23-Installing piston pin

(11) Install the piston rings in the following order:

(a) Install the oil ring expander. (b) Fit one end of the oil ring top side rail into

the groove and "peel" the ring into the groove. (Refer Fig. 24). Fit the lower side rail in a similar manner.

NOTE: Ensure that both upper and lower side mils

can be turned freely in the piston.

Side

rail gap

Fig. 22-Piston and connecting rod assembled into

tool

(8)

"

Insert guide bar (E11M12-4) in the slot provided in the tool base (E9M70), with the piston top surface positioned on the side indicated by the arrow stamped on the base and the front mark on the piston facing upward, refer Fig. 23.

CAUTION: When installing piston pin ensure the

front mark of the piston is facing upwards or damage to the piston will result.

(9) With the aid of a press, install the piston pin until the top end of the guide bar bottoms in the tool base. The force required to install the pin must be between

7360 to 17165 N.

NOTE: If the force required to fit the pin is not as

specified, the piston pin must be removed and the pin and connecting rod diameters checked.

(10) With the piston assembled to the connecting rod

ensure that the piston moves freely and lightly.

Fig. 24-Fitting oil ring side rail

(c) Install the No. 2 piston ring and then No. 1

piston ring.

NOTE: No. 2 piston ring is identified by a mark

on the ring face. The ring must be fitted with the mark facing the top of the piston.

(12) Position the piston rings so that the ring gaps are as far from each other as possible and that they do not align with the piston pin and thrust side of the piston, refer Fig. 26.

(13) Apply a liberal amount of engine oil to the piston and rings.

(14) Compress the rings using a piston ring compressor. Install the piston and connecting rod assembly into the cylinder ensuring the piston front mark is facing the front of the engine and the assemblies are fitted into the correct cylinder.

N(JTE: It is advisable to fit plastic covers or mask-

ing tape around the connecting rod bolts to protect the cylinder walls and crankshaft

journals from damage.

Front

of

engine

side rail

NOTE: The crankshaft oil seal lip should be

lubricated with engine oil prior to installation.

(18) Install the flywheel (or torque convertor drive

plate) tightening the bolts to the specified torque.

Fig. 28-Rear crankshaft seal assembly

(19)

Lubricate the right hand counter-balance shaft bearing journal, and install the shaft into the cylinder block being careful not to damage the rear bearing.

upper side rail

Fig. 26-Piston ring gap position

(15) Install the connecting rod caps in the correct order, with the cylinder number marks on the cap, aligned with the numbers on the connecting rod. Tighten the cap bolts to the specified torque.

(16) Check the connecting rod big-end side clearance.

(17) Install the crankshaft rear oil seal case. If the oil seal has been removed from the case, install a new oil seal to the case, ensuring it is properly seated into the case and that the oil hole in the separator faces the bottom of the case, refer Fig. 28.

I

NOTE: The counter-balance shafts are not inter-

changeable. The left hand shaft is identified the key way at the forward end of the shaft, the key way on the right hand shaft is further back.

(20) Install the oil pump assembly, making sure that the key way of the oil pump driven gear fits the woodruff key in the counter-balance shaft. Firmly tighten the oil pump mounting bolts.

NOTE: Fill the oil pump with engine oil prior to

installation.

(21) Tighten the bolt securing the counter-balance shaft to the oil pump driven gear.

NOTE: If the fit of the counter-balance shaft to

the oil pump gear is tight, install the shaft to

I

the gear first and then install the shaft and oil pump onto the cylinder block, as an assembly.

(22) Lubricate the left hand counter-balance shaft bearing journal and install the shaft into the cylinder block being careful not to damage the rear bearing.

(23) Install a new O-ring in the thrust plate taking care not to twist the O-ring.

(24) Lubricate the O-ring prior to installation of the thrust plate.

(25) Install the thrust plate, using two 6 mm diameter

threaded bolts, with the heads removed, as guide pins,

refer Fig. 30.

by

-

Fig. 27-Tighten connecting rod bearing caps

NOTE: FaiIure to use the guide pins will neces-

sitate rotation of the thrust plate to align the bolt holes, which may cause damage or twisting of the thrust plate O-ring.

@

HrbaIance

shaft,

right

Cham tensloner

Gu~de

(6

mm d~a

bolt with

head removed

Thrust plate

30-installing

Fig.

(26) Install the drive chains, sprockets and timing cover as previously described under Camshaft and Counter-Balance Shaft Drive Chains and Oil Pump, refer Section 3.

(27) Install the oil screen.

(28) Install the oil pan with a new gasket, coating both sides of the entire gasket with sealant. The oil pan bolts should be tightened in a criss-cross pattern.

(29) Install the oil pressure switch.

(30)

Set the engine upright and install the cylinder head assembly as previously described under Cylinder Head.

(31) Install the engine mounting brackets and install

engine into vehicle as previously described.

counter-balance shaft thrust plate

C

Fig. 29-Counter-balance

nter balance t, left

der block

shaft system

11-5-1

SECTION

5

-

SPECIFICATIONS AND GENERAL INFORMATION 6672

SPECIFICATIONS

I

ENGINE GENERAL

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

Type.

Number of cylinders .Six Bore

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

Stroke Displacement ,2972 cc Max. power -95 RON fuel

Compression ratio .10:1 Compression pressure @ 250 rprn.. Pressure difference between cylinders Spark plug type Firing order .l-2-3-4-5-6 Direction of rotation

I

CYLINDER HEAD

Material .Aluminium alloy Type. .Compact hemi-spherical Maximum allowable distortion. .0.2 mm Grinding limit .0.2 mrn

N(TTE:

stock should be included in the grinding limit.

........................................7

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

-91 RON fuel.. .I12

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

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

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

If the cylinder block gasket surface has already been ground, then the thickness of the removed

lnlet valve seat insert hole diameter

-0.3 mrn Oversize

-0.6 mrn Oversize

Exhaust valve seat insert hole diameter

-0.3 mrn Oversize

-0.6 mrn Oversize

Inlet and exhaust valve seat insert height

-0.3 rnm Oversize

-0.6 mm Oversize

Valve guide hole diameter

-0.05 rnrn Oversize

-0.25 mrn Oversize

-0.50 rnrn Oversize

Carnshaft/carnshaft bearing clearance.

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

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

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

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

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

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

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

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

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

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

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

...........

V6

91.1

6.0 rnrn

,123 kW (DIN) @ 5500 rpm

,1300 kPa

100

N9YC4

.Clockwise observed from front of engine

.44.300 to 44.325 rnrn .44.600 to 44.625 mm

.38.300 to 38.325 rnrn .38.600 to 38.625 rnm

.7.90 to 8.10 rnm

.8.20 to 8.40 rnm

.13.050 to 13.068 mrn .13.250 to 13.268 rnrn .13.500 to 13.518 rnm .0.05 to 0.09 mm

I

OHC/OHV

rnrn

kW

(DIN) @ 5000 rpm

kPa

Pre-gapped

I

VALVES

Head diameter - Inlet

-

Valve length - Inlet

-

Exhaust .102.7 rnm

Stem diameter - Inlet

-

Stem diameter wear limit - Inlet Valve face angle

Valve head thickness - Inlet

Valve seat contact width

Valve stem to guide clearance

Installed height between spring 'seat and retainer Hydraulic lash adjuster dry clearance..

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

Exhaust .35 rnrn

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

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

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

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

Exhaust

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

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

-

Exhaust .0.15 mrn

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

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

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

-

Exhaust .3.5 rnm

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

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

-

...........

Inlet Exhaust

..........

........

..

.43

mrn

.103.0 rnrn

.7.960 to 7.975 rnm .7.930 to 7.950 mrn .0.10 rnm

.45O to 45.s0 .1.2 rnrn

.0.90 to 1.30 mm

.0.03 to 0.06 rnm

.0.05 to 0.09 mm .40.4 to 41.4 rnm .0.5 to 1.3 rnrn

II

-5-2

SPECIFICATIONS CONT.

VA1,VE

GUIDES

13.06 to 13.07

8.000 to 8.02

44.0

mrn

48.0 mrn

14.60 + 0.30 lnrn

13.050 to 13.068 mrii

13.250 to 13.268

13.500 to 13.5 18

V:i I ,V E SPRINGS

N~~nihcr

LC

I.o;icl I~lst;lllcd Iicigtir 40.4 Inn1

Out

VAI,VE

llilct opcli\. 16" BTDC Inlet clo\c\ Iluration I:ulia~!\t opcli\. 56" ABDC t.:kliau\t clo\c\. 26" A'I'DC Il~~ration 262O O\crlalj 42"

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

.

Ic'11gtll .40.8

01

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

Cc'

i~i\t:~llctl height

.

S~LI;II.C .4"1nax.

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

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

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

'TIR.IIN(;

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

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

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

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

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

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

12

323

.66"

262"

I

111111

N

(0'

AHIlC

40.4

mrn

mnl

liirii

mrn

mm

CAMSHAF'I'

Matcri:~l. Cast ~ron C'a~ii\lii~l't hearing5 Aluminiuln alloy Hca~.i~ig clcar~uicc

Jourri;il diameter 34.0

tieight ol'~.om lobe - Inlct

Nomin:~l cam Kochcr arm to rocker \hal.t cleari~nce

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

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

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

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

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

-

.

1111

Exh;rust .4 1.25 mrn

.

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

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

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

7.

0.0

1

to 0.04 mm

4 1.25 mrn

.6.25 mni

0.0

I

to

0.03

mrn

ni111

CY1,INDER BLOCK

M:rtcri~~l. Alloy cast iron Flatness Grinding Ilmlt.. .0.2

NOTE:

should he included in the grinding limit

Cylinder bore dialnctcr Maxi~iii~ni bore oversize. 1.00 Maximi~ln di;r~iictcr dilli.rcncc hetween cylinders Maxilni~m horc wear (before reconditioning). Maximu~n rcconditioriilig) 0.02

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

of

gasket surt'acc

. .

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

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

Less than 0.05 lnln

rnrn

If the cylinder hcad gasket surface has already been ground, the thickness of the removed stock

of

0.2

mm

91

.I

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

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

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

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

o~

ality and taper (before

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

mm

mrn

0.02

rnm

0.02 rnln

mm

O

Mitsubishi Motors Australia Ltd. March 1995 AW342051-B REVISED

SPECIFICATIONS CONT.

PISTONS

Material .Aluminium alloy Type. Auto thermic type

Piston pin hole diameter. Piston diameter.

Piston to bore clearance

Piston oversizes

PISTON PIN

Type. Material .Alloy steel

Diameter. .22.001 to 22.007 mm Offset in piston. .0.3 mm

PISTON RINGS

Number Ring gap - New - Compression

Service limit - Compression

Side clearance - Compression

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

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

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

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

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

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

-

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

-

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

-

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

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

.22.0 mm .91.05 to 91.07 mm .0.03 to 0.05 mm .0.25 mm

0.50 mm

0.75 mm

1.00 mm

Press fit in connecting rod

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

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

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

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

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

-

Scraper Oil ring

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

-

Scraper .0.8 mm

-

Oil ring .1.0 mm

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

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

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

-

Scraper .0.02-0.06 mm

-

Service limit .0.1 mm

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

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

3

.0.30 to 0.45 mm

.0.45 to 0.60 mm .0.20 to 0.60 mm .0.8 mm

.0.03-0.09 mm

CONNECTING RODS

Material .Forged carbon steel Length between centres Small end bore diameter Big end bore diameter

Conrod bearing clearance

Conrod bearing undersizes

Conrod - bend .0.05 mm Conrod side clearance on journal Bearing material .Aluminium alloy

CRANKSHAFT

Material .Cast iron Number of main bearings.. .4 Main bearing journals diameter.

End float controlled by

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

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

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

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

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

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

-

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

-

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

.140.9 to 141.0 mm .22 mm .53 .0.016 to 0.046 mm .0.25 mm

.0.50 mm

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

-

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

twist .0.1 mm

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

service limit .0.4

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

.0.10 to 0.25 mm

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

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

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

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

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

.60.0 mm .No. 3 bearing

mm

0.75 mm

mm

SPECIFICATIONS CONT.

I

CRANKSHAFT (Continued)

End play.

-

Big end journal diameter

-

Main bearing clearance Big end bearing clearance

-

El92 Compressor-Piston ring E0102 Compressor-Valve Spring

MB990767 Remover/Installer - Camshaft sprocket E9M30FA .Installer valve stem seat MD998115 Remover/Installer - valve guide E9M40 .Hydraulic tappet adjuster kit E1150. .Hydraulic tappet leakdown tester MD998713 E9M20A. MD998722 Remover/Installer - piston pin MD998718 MD998747 .Crankshaft pulley holder MD998719 .Pins - To be used with MB990767 EllM12..

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

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

Limit .0.3 mm

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

maximum allowable ovality maximum allowable taper

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

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

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

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

Service limit (maidbig end)

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

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

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

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

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

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

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

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

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

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

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

.0.05 to 0.25 mm .50.0 mm

.0.03 mm .0.005 mm .0.02 to 0.048 mm .0.016 to 0.048 mm .0.1 mm

.Installer - camshaft oil seal

Remover/Installer - cylinder head bolts

.Installer - Crankshaft oil seal rear

.Piston pin removing tool

I

APPLICATION

Alternator bracket bolt Alternator mounting bolt Alternator pivot nut. Alternator stay bolt Alternator stay nut.. Camshaft bearing cap bolt Camshaft sprocket bolt Connecting rod cap

Coolant temperature gauge unit.

Coolant temperature sensor

Crankshaft bolt.. Cylinder head bolt - Cold Dipstick mounting bolt

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

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

Nm

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

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

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

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

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

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

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

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

TORQUE SPECIFICATIONS CONT .

APPLICATION

Distributor adaptor bolt

Drive belt tension bolt Drive belt tension nut Drive plate bolt Engine mount front

-

Through bolt nut large

Engine mount front to mounting bracket Engine mounting bracket front to block

10 x

45

35

10 x 10 x 97 mm bolt 10 x 68 mm bolt

12x

71

Exhaust manifold nut Flywheel mounting bolt Heat protector bolt Heater pipe bolt Intake manifold nut Knock sensor Main bering cap bolt Oil filter Oil pan Oil pan drain plug Oil pressure switch Oil pump cover bolt Oil relief valve plug Oil screen bolt Rocker cover bolt Roll stopper front

Roll stopper rear

Sump drain plug Timing belt cover bolt Timing belt rear upper cover. left Tensioner bolt Tensioner bracket bolt

Tensioner bracket stay bolt

Thermo switch Water inlet fitting bolt Water outlet fitting bolt

Water pipe bolt

Water pump bolt

--

Support bracket to block

10 x 25 mm bolts 12 x 30 mm bolt

Through bolt nut

Mounting bolt Support bracket to block

10

x x

12

Through bolt nut

Mounting bolt

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

mm bolts mm bolts

mm

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

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

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

--

bracket bolt

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

bolt

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

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

25

mm bolts

30 mm bolts

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

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

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

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

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

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

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

-

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

small

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

--

10 rnm

8 mm

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

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

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

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

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

...........

Fig.

1-6672

engine longitudinal section

GENERAL INFORMATION

The

6672

engine is a overhead cam crossflow design, with a compact spherical combusion chamber, petrol engine. arrangement which contributes to better

The cylinder head is made of an aluminium alloy efficiency. casting, into which the valve guides and valve seat rings of heat resisting steel, have been press-fitted.

The cylinder block is an alloyed casting. The block is a short skirt type. The walls are made as thin as possible to minimise the overall weight of the cylinder block. The exterior walls are shaped and ribbed to

provide sufficient strength.

The water jacket is of the full-jacket type, which

ensures that each cylinder is cooled properly.

60° V6,

overhead valve, serviceability of the auxiliaries.

hemi- The inlet and exhaust ports are in a cross-flow

The right and left banks are angled

the engine easy to install in the vehicle and enhances

60'

which makes

intake/exhaust

11-6-1

Condition

LOW COMPRESSION

(DRY TEST)

LOW COMPRESSION

(WET TEST)

NOISY VALVES

CONNECTING ROD NOISE

SECTION

Possible Cause

Valves sticking or seating poorly. Blown cylinder head gasket (if

pressure low in adjacent cylinders or coolant is contaminated with engine oil).

Worn or sticking rings.

Worn rocker arms.

Worn valve guides.

Worn or damaged camshaft lobes. Excessive valve seat or valve face

run-out. Malfunctioning hydraulic tappet

adjusters.

Insufficient oil supply.

Low oil pressure.

6

-

SERVICE DIAGNOSIS

Corrective Action

Overhaul valve system. Install new head gasket.

Replace or free-up rings.

Replace arms and check oil supply holes.

Replace guides and if necessary install new valves.

Replace camshaft. Re-cut valves and seats.

Replace defective tappet adjusters.

Check engine oil level. Check oil pump output.

MAIN BEARING NOISE

OIL PUMPING AT RINGS

Thin or diluted oil. Excessive bearing clearance.

Connecting rod journal out-of-round.

Misaligned connecting rods. Insufficient oil supply. Low oil pressure.

Thin or diluted oil.

Excessive bearing clearance.

Excessive end play.

Crankshaft journals out-of-round

or worn. Loose flywheel. Worn, scuffed or broken rings.

Carbon in oil ring slots.

Change oil to correct viscosity. Measure bearings for correct

clearances. Replace if necessary.

Remove crankshaft and regrind

journals.

Replace the bent connecting rods. Check engine oil level. Check oil pump output. Change oil to correct viscosity. Measure bearings for correct

clearances. Replace if necessary. Check respective end thrust bearing

for wear on flanges.

Remove the crankshaft and regrind

journals. Tighten to correct torque.

Hone cylinder bores and install new

rings.

Install new rings.

Rings fitted too tight in grooves.

Remove the rings. Check the

grooves. If groove is not

width, replace the pistons.

correz

Condition

OIL PUMPING AT

KINGS (CONT.)

Possible Cause

Compression rings installed upside down.

Corrective Action

Remove and refit rings correctly.

I

LOW OIL PRESSURE

1

INDICATED

ENGINE DIAGNOSIS WITH VACUUM GAUGE

A vacuum gauge can be beneficial as an aid in

diagnosing engine problems.

Obtain a reliable, calibrated vacuum guage and "tee"

it into the inlet manifold at the brake booster vacuum connection.

Use the readings as outlined opposite, to carry out

your diagnosis.

Low oil level.

Faulty oil pressure sending unit.

I

Thin or diluted oil. Oil pump relief valve stuck. Oil pump suction tube loose, bent

or cracked. Clogged oil filter. Excessive bearing clearance. Excessive oil pump gear clearance.

Change the oil to correct viscosity. Remove the valve and inspect. Remove the oil pan and install a

new tube if required. Install a new oil filter.

I

Check the bearing clearance.

Remove oil pump and check gears for wear and clearance.

I

NORMAL ENGINE

1 2

8".

Hs

hP.

NORMAL ENGINE VALVE SPRINGS

3 4

WEAK WORN

0".

Hg

kP.

I00

O

VALVE GUIDES

5

6

VALVE LEAKING VALVE BURNT

VALVE STICKING VALVE TIMING

7

LATE

I0

I00

9

25

0".

)O

IM

0

kP. kP. hP.

Hg

10 11 12

I00

WORN RINGS WORN RINGS OR IGNITION DEFECTIVE IGNITION RETARDED

INFERIOR LUBRICANT

80

100

13 14 15 16

CARBURETTOR LEAKING INTAKE LEAKING HEAD BLOCKED EXHAUST

ADJUSTMENT SYSTEM GASKET SYSTEM

(between cylinders)

Readlngs - Ins Hg (kPa) 1 Wlth the engine Idling, the hand

and 21 (57 to 71)

2 With a rapld openlng and closing of the throttle, the

hand will fall to 2 (65) and

84), settllng on normal Idle read~ng Rlngs and

to valves

~nd~cated

3

Wlth fast running engine, the hand reads between 10

OK

and 22 (34 to 74) Increase speed fluctuat~ons

Wlth englne

4

idling,

hand v~brates rap~dly between 14

and 19 (47 to 64)

5 When valve should close, hand drops two or three

polnts

6 At

Idle, the hand drops conslstantly a few polnts 7 At ~dle, the hand sometimes drops around four po~nts 8 At fast

~dle, the hand reads steady from 8 to 15 (27

IS

steady between

17

swlng back to 24 or 25 (81

increases

hand

9 At ~dle the hand reads steady but lower than normal

Inferlor lubr~cant may also be ~nd~cated Wlth rapld openlny and closlng of the throttle the

10

hand falls to Wlth a slowly

11

0 and rises to 23 (78) or less

fluctuating

hand between 14 arid 16 (47

to 54), check lgnltlon system for faults

12 At fast

13 Check Idle mlxture

Idle, a steady readlng between 14 and 17 (47

IS

to 58)

registered

~f

hand moves slowly between 13

and 17 (44 to 57)

14 At

Idle or fast Idle hand reads between 3 and 5 (10

and 17) Check gaskets

15 Hand moves cons~stanlly between 5 and 19

64)

16 Hlgh readlng at slat reduc~ng to 1 (3) or 0 and

increases

to 15 to 16 (51 to 54)

to 50)

8

(17

and

SECTION

7

-

IN-VEHICLE SERVICE PROCEDURE

COMPRESSION TEST TIMING BELT ADJUSTMENT

An engine without reasonably high and uniform

compression cannot be effectively tuned. The com-

pression of each cylinder should be tested before any other tuning operations are performed. The engine must be at operating temperature when performing the

compression test.

Compression pressure with engine warm, spark plugs removed, wide open throttle at minimum cranking speed of 250

r.p.m. should be within the specified

(1)

Ensure engine is at No. I TDC and remove the

access cover, refer Fig. 2.

(2) Using Special Tool No.

MD998160 loosen timing

bolt 1-2 turns.

(3)

Rotate crankshaft

TWO TURNS

direction.

(4) Tighten tension bolt to specified torque. (5) Replace the access cover.

limits.

(1) Remove any foreign matter from around spark plugs by blowing out plug area with compressed air, then loosen all plugs one turn.

(2)

Start the engine and accelerate to 1000 r.p.m. to blow out loosened carbon. Stop engine and remove plugs, note cylinder from which each plug was removed

, ,

I

,

!

I

,

.

,

for future reference.

NOTE:

Clearing out carbon in this manner important in preventing false compression readings due to particles of carbon becoming lodged under the valves.

is

I

i

,

"

.

';-,

'

I-

,

~~

\

,,A',

:<

>'

\.

'

\,

\

,\

-

-7'

Access

->

,

i.

'<

,.-'

9;

in a clockwise

cover

\

,.\~

.

01L0144

Fig. I - Checking compression

(3)

Disconnect coil

(4) Disconnect the

primary

lead.

ECI-klulti control relay to prewnt

fuel injection.

(5) Connect remote control starter switch to the

starter solenoid.

(6) Insert the compression gauge in spark plug opening, and crank engine through at least four compression strokes to obtain highest possible reading.

(7) Test and record compression of each cylinder. Conlpression should read within the limits indicated in the specifications.

(8)

If one or more cylinders read low or uneven, inject about a tablespoon of engine oil on top of pistons in low reading cylinders. Crank engine several

times and re-check compression. If compression comes

up but does not reach normal, rings are worn. If

compression does not improve, valves are seating poorly. conlpression, and

If

two adjacent cylinders show low

injecting

oil does not improve

stick~ng or

condition, the cause may be a head gasket leak between

the cylinders.

\'\,\

\,

-,

M

'\

-,

,,<\<

,

.

D998 1 60

,

j

;

,/'

.

$,&.

~

\

"

..\

-

I

i

OIL0143

I

'

,

.

y\

..\.,,

,,-:

j'/p,

Fig. 2 - Timing belt adjustment

TIMING BELT Inspection

Removal

(I)

Remove alternator, power steering and air

conditioning belts.

(2) Remove power steering pump and air conditioner

compressor.

(3) Remove crankshaft pulley, bolt and washer using

Special Tool Nos.

MB990767 and MD998715, refer

Fig. 3.

Crack

Inspect timing belt for cracking, brittleness, damage

or worn and broken teeth. Refer Figs. 5 and 6.

Fig.

3

-

Crankshaft pulley removal

rack

Fig. 5 - Timing belt cracked

Rubber exposed

(4)

Remove right and left upper timing belt covers. (5) Remove front crankshaft flange. (6) Remove lower timing belt cover.

1

(7) Manually rotate engine to No.

using Special Tool-No.

3.

Ensure that all timing marks are aligned, refer

10.

Fig.

NOTE:

When the timing belt is to be reused, the

MD998716, as shown in Fig.

Top Dead Centre

direction of rotation should be marked on the belt, so that on assembly it is installed in the same direction.

Tooth missing end canvas

f~ber exposed

7EN209

Fig. 6 - Timing belt teeth damage

Inspect timing belt tensioner by rotating the pulley.

If

it does not rotate smoothly or irregular noise or

backlash is observed, replace timing belt tensioner.

Refer Fig. 7.

Fig.

4

-

Marking direction of timing belt

(8) Remove lockbolt, tensioner and spring and

remove the timing belt.

Fig. 7

-

Timing belt tensioner

Installation

(1)

Install timing belt tensioner and tighten bolt Fig.

finger tight.

(2) Install tensioner spring to the pin above the water

pump case and the tensioner.

NOTE: Ensure the direction of the tensioner

spring hook is as shown in Fig.

8

-

Fig.

Tensioner spring fitment

8.

(3)

Force the tensioner in direction of arrow, refer

and

tighten

Fig.

(4)

Align timing marks on camshaft sprockets and

the

lock

9

-

Belt tensioner positioning

'

crankshaft sprocket, refer Fig. 10.

(5)

Install timing belt as follows:-

Route the timing belt onto the crankshaft sprocket and then onto the camshaft sprocket of the left hand bank, maintaining tension in the tension side, refer Fig. 10.

Camshaft sprocket

Timing

belt tensioner

Water pump pulley

Timing

(on belt cover)

mark

Crankshaft sprocket

Fig. 10 - Timing mark identification

Continue the belt around the water pump pulley and the camshaft sprocket of the right hand bank and the belt tensioner.

(6)

Loosen belt tensioner bolt 1 or 2 turns.

(7)

Install flange onto front crankshaft sprocket.

(8)

Using tool No. MD998716 smoothly rotate the crankshaft clockwise tighten tensioner lock bolt to specified torque.

two turns,

refer Fig. 11, and

CYLINDER HEAD

Removal

NOTE:

(11) Disconnect the battery negative (ground)

terminal.

(2) Drain the water from the radiator and cylinder

block by removing lower hose.

(3)

body.

(4)

return lines, vacuum hoses, electrical leads, radiator and heater hoses etc.

(5) Manually rotate the engine to No. 1 top dead centre on the compression stroke, aligning the crankshaft pulley timing mark on the timing plate.

(6)

Group 15.

(7) Remove timing cover and belt.

(8) (9)

MD998051, in the sequence shown, refer Fig. 13.

Prior to removing cylinder head, allow

engine to cool otherwise head

occur.

Remove the air cleaner duct from the throttle

Disconnect the throttle cable, fuel supply and

Remove inlet and exhaust manifolds, refer

Remove rocker covers.

Remove cylinder head bolts, using tool NO.

warpage may

"T"

mark of the

11

-

Fig.

(9) Remove front flange and install timing belt lower

cover and refit front flange.

(10) Install timing belt left and right upper covers.

(11) Install crankshaft pulley, washer and using special tool Nos. bolt to specified torque.

Fig. 12

(12)

lnstall air conditioning compressor and power

steering pump.

(13) Install alternator, power steering and air

conditioner belts.

Crankshaft tool location

MB990767 and MD998719, tighten

-

Holding crankshaft pulley

a

T~m~ng

belt s~de

7EN231

Fig. 13 - Removal sequence of cylinder head bolts

(10) Before cleaning, check the cylinder head for

water and gas leaks.

After cleaning, check for damage and cracks.

Installation

(1) Ensure that the joint surface between the cylinder

head and block are clean.

(2) Fit the cylinder head gasket to the cylinder block.

06 02 03

05

01

04

-h

08

0

T~m~ng belt

s~de

07 03 02 06

Fig. 14 - Tightening sequence of cylinder head bolts

(3) Tighten cylinder head bolts in three stages to the

specified torque and in the sequence shown in Fig. 14.

(4) Install timing belt and covers. (5) Install the rocker cover and silastic as shown on

Fig. 15. Tighten bolts to specified torque.

-

4

7EN238

3000

r.p

m.

LL

-

Fig. 16- Bleeding air from hydraulic tappet adjusters

(11) Run the engine until normal operating temper-

ature is reached and check for water and oil leaks.

(12) Set engine idle speed and ignition timing to

specifications.

Approx

1

mln

c

-

Fig. 15

(6) Install exhaust and inlet manifolds with new

gaskets, refer Group

(7) Reconnect the throttIe cable, fuel supply and

return lines, vacuum hoses, electrical leads, radiator

and heater hoses.

(8) Install the air cleaner duct to the throttle body.

(9) Fill the radiator with rainwater or demineralised water and Mitsubishi concentration, refer Group

(10) Connect the battery and start engine. If it is suspected that oil has leaked from the hydraulic tappet adjusters, slow race the engine a minute at a time from idle to 3000

Sealing rocker cover to cylinder head

15.

Longlife Coolant in the required

14.

r.p.m. to bleed

off

the air.

CYLINDER HEAD DISASSEMBLY

NOTE:

(a) If the balves or seats are badly worn, it may be

necessary to replace the parts rather than recut or

regrind them. This decision depends on the amount

of dry clearance available at that rocker.

(b) To measure the dry clearance, the valve, rocker and shaft, and camshaft must be in the assembled condition with the cam follower on the base circle of the cam.

(c) Insert a suitable 0.5 mm wire probe through the hole in the rocker arm to unseat the ball in the hydraulic unit relieving the oil behind it. Measure the clearance between the valve stem and hydraulic unit with feeler gauges.

(d) The specified dry clearance is 0.5 to 1.3 mm; therefore, the amount of material removed from the valve and/or seat, must be such that the specified dry clearance is maintained.

The valve stem tip must not be ground to obtain the required clearance.

(1) Remove spark plugs.

(2) Fit tappet adjuster clips (part of kit each rocker arm, refer Fig. 17.

(3) Remove camshaft sprockets using tool Nos. MB990767 and MD998715, refer Fig. 18.

(4) Remove camshaft sprocket inner cover, and on left hand bank, removedistributor and distributor adaptor.

(5) Loosen camshaft bearing cap bolts, do not remove bolts from the cap.

If valve grinding or seat refacing is considered necessary, note the following prior to disassembly:-

E9M40) to

17 - Rocker arm clip installation

Pig.

Fig. 19 - Removing valve stem seals

Care should be taken not to damage valve seats,

cylinder head surface and camshaft journals.

Using a straight edge and feeler gauge, check the

cylinder head for distortion as

thown in Fig. 20.

18 - Removing camshaft sprocket

Fig.

(6)

Remove rocker arm, shaft and bearing cap as an

assembly.

After

removal mark the left and right bank for

identification.

(7) Remove clips from rocker arms, remove the tappet

adjusters and store in order of removal.

(8)

Remove the camshafts. (9) Remove the camshaft front oil seal. (10) Using a valve spring compressor, remove the

collets, spring retainers, springs, spring seats and valves, keeping them in order of removal.

(11) Remove valve stem seals, refer Fig. 19.

NUTE: Valve stem oil seals should not be re-used.

Cleaning and Inspection

Check the cylinder head for water leakage and

damage before cleaning.

Clean each part carefully removing all pieces of

dirt, oil,

greage and carbon deposits. Clean oil holes

and passages using compressed air, ensuring they are

not clogged.

Fig. 20

-

Checking for cylinder head distortion

If cylinder head distortion exceeds the specified limit,

it

must be resurfaced. Check the cylinder head manifold mounting surfaces

for flatness or damage.

Check condition of camshaft oil seal, replace if

necessary.

VALVE GUIDES

Check the valve stem to guide clearance. If the clearance exceeds the specified limit, replace the guide with the next oversize guide. Valve guides are shrunk into position, therefore when replacement is necessary the following procedure must be adopted.

(1) Heat the cylinder head (see note) and using Tool No.

MD998115, remove the defective guide towards

cylinder block surface, refer Fig. 21.

NOTE: This operation should be conducted with

the cylinder head temperature raised to a

maximum of

250°C

The cylinder head should

be kept at this temperature for a minimum

amount of time.

CAUTION: Exceeding

250°C,

could cause per-

manent damage to cylinder head.

(2)

U'itll ~t~e cylinder head at normal tcmpcrature,

ream the head as specified for the oversize guide.

(3)

Heat the cylinder head to the correct temperature (sce note), and insert the guides quick]!.. Using Tool No. MD998115, install guides to the specified

dimension, refer Fig. 21.

(4)

After guide is installed, check the insidc diameter

ancl rcaln to specification if necessary.

Removal lnstallat~on

Press Press

I

-~

1

MD998115

17

LJ

push rod

Valve

guide

(2)

Keconclition tl~e scat by 11si11g either a scat grinclcr

or seat cutter.

(3)

The valve seat contact wicllh should he as

specifit.d, at thc centre of the valve hcc and as sho\vn

in

fig.

23.

Exhaust

-

/

45'

35'

\

-

li~t~jki.

i.iiv3h

A,

i

'Fig. 71 - Removing and installing valve guides

\OTE:

The inlet and exhaust valve guides are

dift'crent length. refer Fig.

Inlet

22.

of

6EN319

Fig.

23

-

Valvc \eat an~lcj

(4)

..iftcr cutting, lap the

\;al\c

and

\al\c

cat

ligl~rl!

\\.irh a fine lapping compound.

Hcploce Calve Seat Inserts

Check the

wive

seat insert

"sinkage"

by r-ncas~~ring

the installed height of the valve sprins bet\vecri the

If

spring retainer and seat.

the sinkage exceeds thc

spccit'ietl limit, replace the scat inscrt as i'oilo\vs:

1

Fig. 22 - Inlet and exhaust valve guides

VALVE SEATS

The valve seat should be checked for over-heating

and incorrect contact

with the valve face. If faulty,

must be re-cut or replaced.

Re-Cutting Valve Seat

(I) Check valve guide for wear, if not to specification,

replace guide as previously described.

-

Fig. 24 - Checking valve spring installed heighr

it

(1)

Thin clown the valve seat insert by cutting, with

a suitable cutter, to within 0.5 to 1.0

head, reftr to Fig. 25

(2)

Remove the valvc seat insert and cut the seat

(PI).

rnm

inscrt bore diameter and height to the dimension sho\j.n in the specifications, refer Fig. 25

iB).

of the c!jlincler

Out

of

squareness

0'

4"

max

Free

length

D~ameter

of

oversize

l-'ig.

25 - Replacing valve seat In\ert\

hole

VALVES

('heck each val\.c for wear. damage and

dclbrmatio~i of the head, stem and stem tip.

II'thc stem tip is pitted or the thickness of the valvc

hcild

i\

Icss

~IILIII

the specified limit, ~hc valve

rcplaccd.

I

Stem

tip

I3

I~LIS~

be

I

1

Fig. 27 - Checking valvc spring

I

CAMSWAFT AND CAMSHAFT BEARING CAP

(

I)

Check camshail journals for wear or rlarnagc, replacc if necessary. If journals are damaged. check camshaft bcuring for wear or damage. If camshaft bearing

If the lobe or profiles are damaged or worn excessi\cl~..

(see specifications) replace the c:rmshaft.

is badly worn, replace cylinder head.

(2) Check the cam lobes and profiles I'or d;ull;~gc.

1

Valve head

Fig. 26 - Valve check points

VALVE SPRINGS

Check thc free length and tension of each valve spring. If spring.

spring. If the spring is more than replacc the spring. refer Fig. 27.

O

they arc

Using

Mitsubishi Motors Australia Ltd. March 1995

a

not

within specifications replace the

square, check the scluareness of each

4"

OLI~

of square,

I

Fig.

18

--

Camshaft inspection

ROCKER ARMS AND ROCKER SHAFTS

(1) Remove all bearing cap bolls and separate the

rocker

excessive play, check damage or seizure and replace as necessary.

hydraulic

and s~lpport on a block,

AW342051

arnls, springs and bearing caps from the rocker

shafts, refer Fig. 29.

(2)

Check the roller for smooth rotation and

iT

replace the rocker arm

U\ing diesel fuel thoroughly clean the

(3)

tamet units.

.

(4)

When cleaned, bleed the hydraulic units using

the following procedure:

refer Fig. 3

-B

-

(a) Fit

I.

~

[he hydraulic unit into the rocker arm

the roller binds or [heir is

the valve contact s~~rfacc for

in

a bath of clean diesel fuel,

I

REVISED

Fig.

29 - Rocker shaft assembly

@

Rocker arm shaft "8"

@

Rocker arm shaft

@

Bearing cap No. 1

@

Rocker arm

@

Spring

@

Bearing cap No.

@

Bearing cap No.

@

Bear~ng cap No.

"A"

2

3

4

NOTE:

The hydraulic tappet unit is a precision component, once cleaned ensure the units are protected to prevent the ingress of dirt or

foreign material. Do not attempt to dismantle

the unit.

(b) Using a suitable 0.5 rnm wire probe, lightly push down the steel ball and move the rocker arm up and down 4 or 5 times, refer Fig. 31.

(c) Allow the ball to seat by removing the probe and push down hard on the rocker arm. If the rocker arm moves slightly, repeat step

(b)

several times.

(d) If the rocker arm still moves when tested as in step (c), replace the unit.

(5) The hydraulic units can be tested using leak-down

tester, Special Tool

E1150.

(a) Place a fully bled unit containing diesel fluid into a 13 mm socket and place the assembly into

ttc

cup.

(b) Adjust the ram so the pointer is on the "Set" mark as it touches the unit.

(c) Lower the weight and after the plunger has fallen slightly (0.2 to

0.5 mm), measure the leak-

down rate with the aid of a stop watch.

4

Leak down rate:

temperature at 15 to

to 20 secs/mm (diesel fuel

25OC).

%

tester

Fig. 30 - Rocker arm and hydraulic tappet unit

Fig. 31

-

Bleeding hydraulic tappet unit

(6)

The fully bled units should be stored in an upright position ready for re-assembly to ensure the diesel fuel in the units is not

(7)

Check the clearance between the rocker arms and rocker arm shafts, replace the arms or shafts.

(8) Check the rocker arm shafts for damage and

bend, if faulty they must be replaced.

CYLINDER HEAD REASSEMBLY

When assembling cylinder head ensure all parts are thoroughly cleaned and that all moving parts are lubricated with engine oil prior to assembly.

(1) Install the valve spring seats.

(2) Install the valve stem seals over the valve guides using Tool No. specified position by the tool. Incorrect fitment will result in damage to the seal and subsequent oil leakage.

NOTE: Old stem seals must not be reused.

spilt.

if

they exceed the specified limit

E9M30D. The seal is installed to the

I

1

View

Notch Rocker arm sha'ft

Cap. No.

P

L

P

011

hole

\

OII

groove

/

...

------

-

Rocker arm shaft

-----

0

-----

"B"

Rocker arm

shaft

(A)

I

-

I

(B)

"a

I

.,.

Fig. 32 - Installing valve stem seals (typical)

(3) Apply engine oil to the valve stem and install the valves into the guides. Do not use excessive force to press the valve stem past the valve stem seal.

(4) Ensure the valve moves smoothly in the guide.

(5)

Install valve springs and spring retainers.

NOTE: Install valve springs with the enamel

identification marks facing the rocker arms.

(6)

Using a valve spring compressor install the valve

collets.

NOTE: When compressing the spring, take care

that the spring retainer is not forced against the valve stem seal.

(7)

Lubricate and install the camshaft onto the

cylinder head.

A

(8) Install notched end of rocker arm shafts

B

to No. 1 camshaft bearing cap as shown in Fig. 33. The shaft with the small oil hole is rocker shaft

Insert the bolts through the hole of the bearing cap and rocker shaft, refer Fig. 33.

and

A.

Fig. 33 - Installation of rocker arm shafts

(9) Install the rocker arms, springs, camshaft bearing

caps and bolts as shown in Fig. 34.

@

Cap No.

@

Front mark

@

Bearing cap No.

@

Rocker shaft spring

@

Front mark

@

Bearing cap No.

@

Bearing cap No.

@

Bearing cap No.

Fig. 34 - Installation of rocker arm, springs and

bearing caps

1

2

3

4

(

\

.

.'

(10) Install the hydraulic tappet units to the rocker

arms

with the hole in the unit to the top of the rocker

and in the order they were removed, and fit tappet

arm

adjuster retaining clips (part of Kit rocker arm. Keep the hydraulic units vertical to prevent spillage of the diesel fuel.

I

Fig. 35 - Installing hydraulic tappet unit

E9M40) to each

Tappet

unit

retaining

clip

Hydraulic tappet

unit

(11) Install the rocker arm assembly such that the arrows on the bearing caps are in as the arrow on the cylinder head.

(12) Tighten cap retaining bolts in two stages to the

specified torque, in the sequence; cap No. 2, 3,

(13) Remove the hydraulic tappet retaining clips.

(14) Install the distributor adaptor with a new

ring, to the left hand bank cylinder head.

(15) Apply a slight amount of oil around the inner circumference of the camshaft oil seal lip and install using Special Tool NO.

I

MD998713 refer Fig. 37.

Ihe same direction

I

1 and 4.

'0'

NOTE:

Prior to fitting rocker shaft assembly to

cylinder head, place silastic as shown in Fig.

between No. 1 and No. 4 bearing cap surface

and cylinder head.

Rocker arm shaft assembly

(B)

Arrow marks (bearing cap)

Arrow mark Sealing agent

36

Camshaft

Fig. 37 - Installing camshaft oil seal

(16) Install the circular packing using Special Tool

MD998714 in conjunction with transmission spacer

No. No.

MD724328, refer Fig. 38.

NOTE: If the spacer is not used with the Special

Tool, the circular packing will be driven in too far.

1.3-1.5

mm

7EN221

Circular packing

Fig. 36

Rocker arm shaft

assembly (A)

-

Sealing and installation of rocker arm

assembly.

Fig. 38 - Installing circular packer

.

...

SECTION

8

-

ENGINE OVERHAUL

ENGINE

or

Engine (Automatic Models) Transaxle (Manual Models) Removal

(1) Drain engine coolant. (2) Remove engine hood. (3) Disconnect battery. (4) Remove coolant recovery bottle. (5) Remove air cleaner assembly.

(6) Disconnect wiring from the alternator, starter motor, distributor, oil pressure switch and the injection control loom.

(7) Disconnect the earth strap at the intake

manifold.

(8) Disconnect accelerator cable. (9) Disconnect radiator and heater hoses from

engine.

(10) Disconnect all vacuum hoses and label for easy

installation.

(11) Disconnect the fuel supply and return hoses. (12) Remove ECS compressor assembly (where fitted). (13) Remove the starter motor. (14) Remove air conditioner low pressure hose and

high pressure hose and electrical connector.

NOTE: Chloro-Fluoro-Carbons.

Legislation in various states, prohibits the release of CFC recovery unit will be required to contain

spent gases if the air conditioning hoses are disconnected. Check your state government authority in regards to their relevant legislation.

(15) Remove power steering feed hose and return

hose.

(16) Remove underbody dust shields.

CFC's to atmosphere. Therefore a

Engine and

(26) Remove the engine mount through bolt and remove the engine mount from the engine mount bracket.

(27) Separate the engine from the transaxle and lift the engine out of the vehicle.

NOTE: Ensure that all cables, hoses, harness con-

nectors etc. are disconnected prior to removing engine.

For manual models proceed

(17) Disconnect wiring from the reverse light switch. (18) Disconnect the clutch hydraulic line. (19) Disconnect gear shift control cables. (20) Disconnect the engine earth cable at the

transaxle.

(21) Disconnect the speedometer from the transaxle. (22) Drain transaxle oil. (23) Raise the front of the vehicle and support on jack

stands.

(24) Disconnect the drive shafts from the transaxle, refer Group 26, and support to avoid damaging the joints.

(25) Disconnect the exhaust pipe from the manifold and remove the exhaust pipe stay strap.

(26) Attach a suitable lifting bracket to the engine and, using a hoist, support the weight of the engine.

(27) Remove the front and rear roll stopper through

bolts.

(28) Remove the rear roll stopper from the cross-member.

(29) Remove the nuts from the engine

mounting through bolts.

(30) Slightly raise the hoist so that all load is off of the mounting bolts.

(31) Remove the mounting through bolts then, while

pushing the transaxle downwards, lift the engine and

transaxle assembly from the vehicle.

Installation

as

follows:

and transaxle

For automatic models proceed

(17) Remove the torque converter lower cover plate.

(18) Remove the torque converter to drive plate attaching bolts and push the torque converter towards the transaxle.

(19) Remove the drive shaft centre bearing to cylinder block bolts and support the drive shaft.

(20) Disconnect the exhaust pipes from the manifolds,

(21) Position a suitable support under the transaxle

to support the weight of the transaxle.

(22) Attach a suitable lifting bracket to the engine

and, using a hoist, support the weight of the engine.

(23) Remove the transaxle to engine attaching bolts.

(24) Remove the rear roll stopper through bolt and damper to engine bracket bolt.

(25) Remove the front roll stopper through bolt and

remove the roll stopper from the cross-member.

as

follows:

Install by reversing the removal procedure, noting the

following:

(1) Ensure that no cables, connectors or hoses are

caught or damaged on installation.

(2)

New

retainer rings must be fitted when installing

the drive shafts.

(3) All engine mounts must be aligned before being

tightened to the specified torque (ensure front and rear

roll stopper bolts are positioned in the correct hole in

the engine brackets).

(4) Fill and ensure all fluid levels are at the correct

level.

(5) Run the engine and check for oil, fuel and

exhaust leaks. Rectify where necessary.

(6) Adjust all linkages and settings to specifications. (7) Ensure vacuum hose connections are correct,

refer Group 17 for hose connection graphics.

(8) Set engine idle speed and ignition timing to

specifications.

,

CYLINDER BLOCK Disassembly

The following description details the disassembly

with the engine removed from the vehicle and

trans-

axle removed from the engine.

(1) Remove the cylinder head assembly as described

under Cylinder Head Removal, refer Section

7.

(2) Remove torque converter drive plate or flywheel

and clutch assembly.

(3)

Remove the oil pan, oil screen and the rear oil

seal case assembly.

(4)

With the aid of a soft piece of wood, push the piston and rod assembly out through the top of the cylinder block.

Mark the connecting rods as shown in Fig. 1, keep

piston assemblies in order.

Fig.

Push

rod

Removing piston from connecting rod

2

-

1EN0114

NOTE:

Prior to removing the piston and rod assemblies, remove all carbon deposits and/or cylinder ridge from the cylinder bore.

der

number

1

-

Fig.

(5)

Remove piston rings No. 1 and No. 2.

(6)

Remove the oil rings.

(7)

Remove the pistons from the connecting rods

Marking connecting rod

by using Special Tool Nos. EllM12-1 push rod and E9M70 base, refer Fig. 2.

I

NmE:

Ensure when placing piston on special

tool,

the frontmark

64272

is facing up.

(8) Remove the crankshaft bearing cap and lower

bearings, keeping them in the order removed.

(9)

Remove the crankshaft and the upper bearing

halves, refer Fig.

3.

Cleaning and Inspection

Before cleaning, check the cylinder block for water

leakage, cracks or damage.

When cleaning, remove all traces of oil, grease, dirt,

carbon, and scale from all components. Clean out all

oil passages by blowing with compressed air.

@

Cylinder block

@

Bearing cap

@)

Bearing cap bolt

@

Thrust bearing A lower

@

Thrust bearing B lower

@

Crankshaft bear~ng lower

Fig.

@

Crankshaft

@)

Thrust bearing A upper

@

Thrust bearing B upper

@

Crankshaft bearing upper

@

Oil seal case

@

Crankshaft rear oil seal

3 - Crankshaft removal

Checking Cylinder Block

(1)

Check the cylinder bores for scratches, rust, corrosion, cracks or any defects or damage, if faulty the block must be

rebored or replaced.

(2) Check the upper surface of the cylinder block

for distortion, using a straight edge and feeler gauges.

If it is not within specifications the surface must be

refaced, refer Fig. 4.

NOTE: The main bearings are interchangeable,

however, if they are to be reused they should be installed in the original position.

Cylinder Boring

(1)

The piston size to be used should bc detclmined

by the cylinder which has the largest bore size.

(2) Check the outside diameter of each oversize

piston at the skirt and across the thrust

Faces. The measurement should be taken at the datum point from the bottom of the piston, refer Fig. 6.

(3) To determine the cylinder re-boring size proceed

as follows:

(a) Measure the diameter of the piston. (b) Allow piston to bore clearance. (c) Honing margin (d) Size after boring

=

0.02 mm or less.

=

(a) + (b) - (c)

=

(a) + 0 to 0.02 mm.

(4) The cylinder should be re-bored to the size

obtained bv the calculation.

(5)

The *final cut should not be greater than

0.05 mm.

--

-

Fig. 4 - Checking cylinder block for distortion

(3) Measure the cylinder bore size at three levels.

If

the wear exceeds the specified limit the cylinders must

be re-bored to the next piston size, refer Fig. 5.

NOTE: If only one cylinder required re-boring,

all the cylinders

If

the cylinder does not require re-boring, remove

(4)

the ridge at

MUST

t

he top of the cylinder and hone the bores

be re-bored.

if necessary.

NOTE: Do not attempt

to

cut too much from

the bore at one time.

(6) To prevent heat distortion of the bores when re-

boring, the cylinders should be bored in their numerical

sequence.

1

1-

I

measurement

Fig.

6

-

Measuring piston diameter

(7)

The cylinder bore size will vary immediately after

re-boring, due to the heat generated by the cutting

operation, therefore care should be taken when

measuring the bore size.

(8) After cutting, the bore should be honed accurately to the finished size. The bores should be honed until all traces of the cutting operation are removed.

The honing angle should be between 30° and 459

(9)

Check the piston to cylinder wall clearance.

I

Thrust

-

d~rection

7EN268

Fig. 5

-

Measuring cylinder bores

PISTONS, PISTON PINS AND PISTON RINGS

(I) Check the pistons for seizure, nicks, wear, cracks and any other defect. Replace any faulty pistons.

(2)

Check the piston pin to pin hole fit. The pin must be a smooth hand press fit into the piston hole. Replace any piston and pin assembly that is defective.

(3)

Check the piston rings for breakage, damage and

abnormal wear. Replace any defective rings.

NOTE: If a piston is replaced, new rings should

also be fitted.

(4)

Measure the piston ring side clearance by placing the ring in its respective piston groove and checking the clearance with a feeler gauge. If it exceeds the specified limit, recheck the clearance with a new piston ring. If the clearance is still excessive replace the piston and rings, if it is within specification, replace the rings only.

(5)

Measure the piston ring end gap by inserting the ring into the cylinder and positioning it at right angles to the cylinder wall by pressing it down with a piston.

Remove the piston and measure the ring gap using a feeler gauge. If the gap exceeds the specified limit, replace the piston rings.

NOTE:

If

the cylinders are not being re-bored, the ring gap measurement should be made at the lower part of the cylinder, the area having the least wear. When replacing the piston rings, be

sure to use rings of the same size.

CONNECTING RODS

(1)

Check the connecting rod for damage at the thrust faces at either side and for step wear or severely rough surface of the inside diameter of the small end. Replace faulty rods.

NOTE: When using a new connecting rod, the

cylinder number should be stamped or marked on the big end.

(2)

Measure the connecting rod small end diameter,

if not within specifications, replace the rod.

(3)

Using a connecting rod aligner, check the rod for

If

bend and twist.

a rod falls just outside the specified limit it can be straightened by using a press. A rod that is severely bent or distorted must be replaced.

(4)

Measure the connecting rod side clearance by assembling the rod and bearing onto the crankshaft and tightening the bolts to the specified torque. Measure the clearance between the connecting rod and crankshaft using feeler gauges. If this exceeds the specified limit, replace the rod.

h

I.

..

Fig.

7

-

Measuring piston ring side clearance

-

Fig.

9

-

Measuring connecting rod side clearance

CRANKSHAFT

(1)

Check crankshaft journals for damage, uneven

wear and cracks. Check all oil holes for clogging.

(2)

Measure the crankshaft journal diameters as

10.

shown in Fig.

If they are excessively out of round,

tapered or worn the crankshaft must be replaced.

/

4b

Piston

ring

Piston ring

I

Fig.

8

-

Measuring piston ring gap

gap

6EN037

J

NOTE: The crankshaft

REGROUND.

(3)

When checking the crankshaft ensure the

crankshaft journal fillet radii are

MUST

NOT BE

1.5

mm, refer Fig.

11.

-

Fig. 10 - Measuring crankshaft journal diameter

8-5

MAIN AND CONNECTING ROD-BEARINGS

(1) Check all bearings for peeling, melting, seizure

and improper contact. Replace any faulty bearings.

(2) Checking the journal to bearing clearance can

be done using either

of

two methods:

(a) measure journal and bearing diameters.

(b) using the plastigauge method.

Measuring Diameters

(1) Measure the outside diameter

connecting rod journals, refer Fig.

of

the main and

10.

(2) Assemble the bearings and caps and measure the bearing inside diameter, refer Fig. 13. The clearance is the difference between the respective bearing and

journal diameter.

(3) If the clearance is not

within specification and the journal diameter is within specification the bearings must be replaced.

7EN263

Fig.

11

-

Crankshaft journal fillet radii

(4)

Check the crankshaft end float by assembling

the crankshaft, bearings and caps to the cylinder block.

Insert a feeler gauge between the centre bearing and

crankshaft,

if

the end float exceeds the specified limit,

replace the thrust bearings, refer Fig. 12.

Fig. 12 - Measuring crankshaft end float

-

Fig. 13

Measuring bearing diameter

Plastigauge Method

(1) Remove all oil, grease and dirt from the bear-

ings and journals.

(2) Cut a piece of Plastigauge the length of the

bearing width and place it across the bearing, away

from the oil hole, refer Fig. 14.

(3) Install the

crankshaft/connecting rod, bearing

and caps and torque them to specifications.

NOTE:

Do not rotate the crankshaft or connecting

rod during this operation.

(4)

Remove the caps and measure the width

of

the Plastigauge using the scale printed on the Plastigauge packet.

(5) If the clearance is not within specification and

the journal diameter is within specification the bearings

must be replaced.

.1

.

I

.

Fig. 14 - Checking bearing clearance using

Plastigauge

OIL SEALS, OIL PAN AND OIL SCREEN

(1)

Check the front and rear crankshaft seals for

damaged or worn lips. Replace the seal if defective.

(2) Check the oil pan for damage and cracks, repair

or replace the oil pan as necessary.

(3) Check the oil screen for failure, damage and

cracks. Replace any faulty parts.

FLYWHEEL AND RING GEAR

(1) Check the flywheel surface for wear or damage,

if excessively worn or damaged, replace the flywheel.

(2) Check the flywheel surface run-out, if it exceeds

the specified limit replace the flywheel.

(3) Check the ring gear for damage, cracking and

wear, replace if necessary.

Fig. 15

I

-

Checking flywheel surface run-out

RING GEAR REPLACEMENT

(1) Remove the ring gear by cutting through the

1

valley of the ring gear teeth to within

mm of the flywheel circumference and then split with a hammer and chisel.

NOTE:

Do not attempt to remove the ring gear

by

heating.

(2) Install the ring gear by heating it on a gas ring

to 260 to

280°C and shrinkage-fit it on the flywheel.

I

Fig. 16 - Cylinder block, bearing and bearing cap assembly

CYLINDER BLOCK REASSEMBLY

When assembling the cylinder block the following

procedures should be observed:

Thoroughly clean all components especially oil

holes, bearings, housings, bores and cylinder walls. Apply engine oil to sliding and rotating parts such as cylinder walls, pistons, bearings and gears prior to installation.

. Gaskets and oil seals should be replaced with new

parts.

. Apply sealant to gasket as required.

Torque all bolts to specification and in the specified sequence where necessary. Check all oil clearances, thrust clearances and

backlash where necessary.

(1) Install main bearings, upper, to the cylinder block. If reusing the main bearings, install them in their original position.

(2)

Assemble the thrust bearings A and B onto the

cylinder block, refer Fig. 16.

NmE:

Install the thrust bearings with the grooves

facing outward.

(3)

Position crankshaft onto the cylinder block and

apply oil to journals.

(4)

Install bearings, lower thrust bearings A and and bearing cap onto cylinder block. Tighten bolts to specification and in the sequence as shown in Fig. 17.

Fig.

17 - Tightening sequence of bearing cap

B

NOTE: The bearing cap must be installed with

the arrow mark facing the front of the engine.

(5)

Ensure the crankshaft rotates lightly and

smoothly and that the end float is within specifications.

(6)

Install the piston pin between the pushrod Special Tool NO. EllM12-1 and the guide Special Tool EllM12-5 and apply engine oil to the piston pin.

NOTE: There are 4 front marks for the pistons.

The front mark faces forward.

Push rod

P~ston pln

Front

mark

lEN0117

Side

rail

edge

Fig. 19 - Installing oil ring side rail

Fig. 18 - Piston pin installation

(8) Insert the guide bar in the slot provided in tool support, with the flat side of the guide bar aligned with the inner wall of the slot. Sit the connecting rod small end, to rest positively on the tool support. Turn the piston pin assembly half a turn.

(9) With the aid of a press, install the piston pin until the top end of the guide bar bottoms in the tool base. The force required to install the pin must be between 7500 to 17500 N.

NOTE: If the force required to fit the pin is not as

specified, the piston pin must be removed and

the pin and connecting rod diameters checked.

(10) With the piston assembled to the connecting rod

ensure that the piston moves freely and lightly.

(11) Install the piston rings in the following order:

(a) Install the oil ring expander.

(b) Fit one end of the oil ring top side rail into the groove and "peel" the ring into the groove. (Refer Fig. 19). Fit the lower side rail in a similar manner.

NOTE: Ensure that both upper and lower side rails

can be turned freely in the piston.

No.

2

and

I

spacer

Fig. 20 - Piston ring identification and position

slot

(c) Install the No. 2 piston ring and then No.

piston ring.

NOTE: No. 2 piston ring is identified by a mark

on the ring face. The ring must be fitted with

the mark facing the top of the piston.

1

(12) Position the piston rings so that the ring gaps are as far from each other as possible and that they do not align with the piston pin and thrust side of the piston, refer Fig. 20.

(13) Apply a liberal amount of engine oil to the piston and rings.

(14) Compress the rings using a piston ring compressor. Install the piston and connecting rod assembly into the cylinder ensuring the piston front mark is facing the front of the engine and the assemblies are fitted into the correct cylinder.

NOTE: Ensure that the front marks on the pistons

are facing towards the front of the engine. Also the connecting rods front marks are facing towards the front of the engine.

(15) Install the connecting rod caps in the correct order, with the cylinder number marks on the cap, aligned with the numbers on the connecting rod. Tighten the cap bolts to the specified torque.

(16) Check the connecting rod big-end side clearance.

(17) Install the crankshaft rear oil seal case. If the oil seal has been removed from the case, install a new oil seal to the case, ensuring it is properly seated into the case using Special Tool No.

MD998718, refer Fig. 21.

(18) Apply silastic to area as shown in Fig. 21. Apply a small amount of oil around the circumference of the oil seal lip and install the oil seal assembly onto the cylinder block.

(19) Install oil screen, and tighten attaching bolts to specified torque.

(20) Install oil pan noting the following; ensure that

the cylinder block and the oil pan surfaces are clean.

Apply approved liquid silastic all around oil pan

flange, refer Fig. 22.

Install the oil pan within 15 minutes of applying the

liquid gasket.

Tighten flange bolts in the sequence shown in Fig.

22 to the specified torque.

NOTE: Recommended sealants for oil pan are

listed below:

Loctite 857 Superflex Ultra Blue Permatex 77BR Ultra Blue

Three Band

Mitsubishi Dealers)

1207D (available through

diameter

4z%

Groove Hole of bolt

Fig. 22 - Sealing oil pan

(21) Install torque converter drive plate or flywheel

and clutch assembly.

k

Fig. 21

-

Rear oil seal

SERVICE BULLETIN REFERENCE

DATE

NUMBER SUBJECT

CHANGES

I

GROUP 12 . LUBRICATION

SECTION

Subject

INDEX

SERVICE DIAGNOSIS

ENGINE LUBRICATION SYSTEM 4654 ENGINE

ENGINE LUBRICATION SYSTEM 6672 ENGINE

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

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

Specifications

General Information ...................................

Oil Pump Oil Filter Oil pressure switch

Specifications General Information Oil Pump and Oil Pan Oil Filter

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

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

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

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

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

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

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

0 . INDEX

.......

Section Page

Number Number

12-1-1

SECTION

Condition Possible Cause Corrective Action

OIL PRESSURE DROP

Low oil level. Faulty oil pressure sender unit.

Thin or diluted oil. Oil pump relief valve stuck.

Oil pump suction tube loose, bent or cracked.

Clogged oil filter. Excessive bearing clearance. Excessive oil pump gear clearance.

1

-

SERVICE DIAGNOSIS

Check the engine oil level. Install a new sender unit. Change the oil to correct viscosity. Remove the valve and inspect. Remove the oil pan and install a new

tube if required. Install a new oil filter. Check the bearing clearance. Remove oil pump and check gears for

wear and clearance.

SECTION

2

-

ENGINE LUBRICATION SYSTEM 4G54 ENGINE

SPECIFICATIONS

OIL

PUMP

Pump type Drive Oil pressure

Oil pressure relief valve

Location Spring free length

Load Low pressure warning switch operating pressure Oil filter Crankcase oil capacity

Pump body to gear clearance Gear end play Gear to bearing clearance Driven gear rear end bearing clearance..

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

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

-

Idle pressure

-

Relief valve

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

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

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

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

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

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

-

with filter

-

without filter

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

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

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

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

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

TORQUE SPECIFICATIONS

Counter balance shaft sprocket bolt Crankshaft pulley Oil filter Oil pan Oil pan drain plug.. Oil pressure switch Oil pump cover to body screw Oil pump to block

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

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

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

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

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

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

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

.....

...........

I

Gear Chain drive from crankshaft

147

kPa (min.)

550 + 50

Oil pump

47.0

4.3 kg/40.0 29

kPa or less

Full flow sealed 'can'

4.6

litres

4.1

litres

0.105

0.06

0.020

0.044

mm

to

to to

0.150

0.12

0.046

0.066

kPa

mm

mm mm

EllMlO

SPECIAL TOOLS

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

s

Holder/tensioner timing chain

GENERAL INFORMATION Disassembly

The oil pump is a Gear type and is chain driven by

the crankshaft via a sprocket on the oil pump drive

gear. The oil pump driven gear is attached to the right

hand counterbalance shaft thus rotating it in the

opposite direction to the crankshaft.

Engine oil is picked up from the oil pan through the oil screen and fed from the oil pump to the full flow oil filter. The filtered oil flows throughout the

lubrication system of the engine and returns to the oil

pan.

If

during operation the oil pump delivery pressure exceeds the maximum specified, the relief valve will open allowing the excess oil to escape out of the pump.

OIL PUMP Removal and Installation

Refer to Group

I

-

Camshaft and Counter Balance

Shaft Drive Chains and Oil Pump for removal and

installation procedures of the oil pump.

(1) Remove the pump cover plate and remove the

gears.

(2)

Remove the tensioner from the pump body by

holding the ratchet lever in the retracted position

(i.e.

hold ratchet lever down).

(3)

Gently rotate the tensioning sleeve to push out

the locking roll pin and remove the sleeve and spring.

(4)

Remove the relief valve plug and withdraw the

spring and relief valve from the body.

Inspection

Clean all disassembled parts with a suitable cleaning solvent and replace any defective parts after performing the following checks:-

Oil Pump Body and Cover

Check the entire body for cracks and abnormal wear, check the gear contacting portions for ridge wear.

Check the oil holes and orifices in the body for clogging, blow out deposits with compressed air.

/

@

6

1. Oil filter

2.

Oil pump gasket

3.

Oil pump cover

4. Dowel 13. Plug

5.

Oil pump driven gear 14. Relief spring

6. Oil pump drive gear 15. Relief valve

7. Oil pump body

8.

Flange bolt balance shaft

9.

-

10. Tensioner spring

11.

-

12.

Tensioner

16. Right hand counter-

17. Balance shaft to oil Pump key

Fig. I-Lubrication system components