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
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
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
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
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.
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..
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
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.
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.
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
.......... 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.
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
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
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
(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.
(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
(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
.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.
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.
(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.
(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
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
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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