Mitsubishi Sigma 1995 User Manual

Page 1
MlTSUBlSHl
MOTORS
Workshop
Manual
Page 2
Page 3
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
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
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
--
.
Page 4
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 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
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
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
1
or
1
1
,
0
Mitsubishi Motors Australia Ltd. Sept. 1994 AW342051 -A REVISED
Page 5
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"
Page 6
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
Page 7
00-2-1
SECTION 2 - VEHICLE SPECIFICATIONS
<
R
Series
Magna Sedan
>
-
Magna Wagon
Verada Sedan
Page 8
00-2-2
SECTION
2
-
VEHICLE SPECIFICATIONS <S Series>
Verada
Wagon
Page 9
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
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 Carby
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL ECI Multi
3.OL ECI-Multi
3.OL ECI-Multi
2.6L Carby
2.6L Carby
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
Engine Type
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL 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
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
2.6L 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
Page 10
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 Carby
2.6L ECT-Multi
2.6L ECT-Multi
2.6L ECI-Multi
2.6L ECT-Mu!ti
3.0L ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
3.0L ECI-Multi
3.OL ECI-Multi
2.6L Carby
2.6L Carby
2.6L ECI-Mul ti
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
3.0L ECI-Multi
3.0L ECI-Mult~
Engine 'ry pe
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
2.6L ECI-Multi
2.6L ECI-Multi
3.0L ECI-Multi
3.0L 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
2.6L ECI-Multi
2.6L ECI-Multi
3.OL ECI-Multi
3.OL ECI-Multi
2.6L ECT-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 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
Page 11
,
..
...
......
.
.
.....
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
Page 12
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
Page 13
'
'
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
Page 14
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
Page 15
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
.
Page 16
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
1
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
Page 17
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
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
Page 18
..
-.
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
Page 19
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.
Page 20
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
MI0
MI2
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.
-.
.
Page 21
Page 22
Page 23
TOWING POINTS
00-3-6
Front Rear Sedan
Rear Wagon
Page 24
Page 25
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
Page 26
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
Page 27
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.
Page 28
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
Page 29
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
Page 30
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
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
X
XI
X
I
I
Page 31
*
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
....................................................................
........................................................
.........................................
..............................
...........
Page 32
SERVICE BULLETIN REFERENCE
DATE
NUMBER SUBJECT
CHANGES
I
Page 33
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
.....................
.....................
.....................
...................
........................
Page 34
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
Page 35
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
Page 36
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.
Page 37
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
Page 38
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
Page 39
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
Page 40
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
.....................................
........................................
...............................
..............................
Page 41
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
Page 42
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
Page 43
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
.
Page 44
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.
Page 45
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
Page 46
(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
Page 47
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.
Page 48
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
Page 49
,
.
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
Page 50
(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
Page 51
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
Page 52
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.
Page 53
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.
-
Page 54
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
Oil
pump
pump
to block
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.
Page 55
-
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;
Page 56
(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.
Page 57
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
Page 58
(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
Page 59
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
Page 60
(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
Page 61
,/"
.'.
,
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:
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.
Page 62
(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
Page 63
(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
Page 64
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.
Page 65
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.
Page 66
@
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
Page 67
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
Page 68
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
Page 69
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
Page 70
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
.........................
.......................
...........................
...........................
......................
.........................
.................
.....................
.....................
.........................
Page 71
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
...................
....................
........................
............................
..........................
...........
Page 72
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
Page 73
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
Page 74
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
I
I
Page 75
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
100
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
Page 76
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
Page 77
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
Page 78
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
Page 79
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.
Page 80
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
Page 81
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.
Page 82
(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
Page 83
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
Page 84
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
Page 85
(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
(
\
.
.'
Page 86
(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
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
Page 87
.
.
.
...
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.
,
Page 88
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
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
Page 89
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.
Page 90
(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.
Page 91
-
-
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
Page 92
.
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.
Page 93
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
Page 94
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
Page 95
(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
Page 96
SERVICE BULLETIN REFERENCE
DATE
NUMBER SUBJECT
CHANGES
I
Page 97
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
Page 98
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.
Page 99
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 to
0.150
0.12
0.046
0.066
kPa
mm
mm
mm
mm mm
EllMlO
SPECIAL TOOLS
.........................................
s
Holder/tensioner timing chain
Page 100
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
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
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