Mitsubishi Space Star 1999 User Manual

WORKSHOP MANUAL

SUPPLEMENT

FOREWORD

This manual outlines changes in servicing procedures related to the chassis including vehicle inspections, adjustments, and improvements in the newly equipped models. Use the following manuals in combination with this manual required.

TECHNICAL INFORMATION MANUAL PYDE9802

WORKSHOP MANUAL
CHASSIS GROUP	PWDE9803
ENGINE GROUP	PWEEjjjj
	(Looseleaf edition)
ELECTRICAL WIRING	PHDE9802
	PHDE9802- A
BODY REPAIR MANUAL	PBDE9802
PARTS CATALOGUE
SPACE RUNNER	B608V500Aj
SPACE WAGON	B608W500Aj

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

“GDI” is the trade mark which Mitsubishi Motors Corporation holds.

E Mitsubishi Motors Corporation

May 1999

General . . . . . . . . . . . . . . . . . . . . . . . .

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

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . .

Engine and Emission Control . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Transmission . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tyre . . . . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . . .

00

11

13

14

15

16

17

21

23

26

31

33

35

37

WORKSHOP MANUAL

FOREWORD

This Workshop Manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required.

TECHNICAL INFORMATION MANUAL

	IMXE99E1
WORKSHOP MANUAL
ENGINE GROUP	PWEE
	(Looseleaf edition)
ELECTRICAL WIRING	EMXE99E1
BODY REPAIR MANUAL	BMXE99E1
PARTS	N606H509D

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

General . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine Lubrication . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . . .

Engine and Emission Control . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . . .

Rear Axle . . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tyre . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

Restrain System (SRS) . . . . . . . . .

Chassis Electrical . . . . . . . . . . . . . . .

Heater, Air Conditioner and

Ventilation . . . . . . . . . . . . . . . . . . . . .

ªGDI is the trade mark which Mitsubishi Motors Corporation holds.

E Mitsubishi Motors Corporation

September 1998

00

11

12

13

14

15

16

17

21

22

26

27

31

32

33

34

35

36

37

42

51

52

54

55

WARNING!

(1)Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative).

(2)SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module, clock spring and seat belt with pre-tensioner before drying or baking the vehicle after painting.

SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more Seat belt with pre-tensioner: 90_C or more

(3)Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related component must be performed only at an authorized MITSUBISHI dealer.

(4)MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and seat belt with pre-tensioner or any SRS-related component.

NOTE

Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

00-1

GENERAL

CONTENTS

HOW TO USE THIS MANUAL . . . . . . . . . . . . . .	2	Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2	Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . .	5
VEHICLE IDENTIFICATION	3	New Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3	MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . . .	6
Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3

00-2	GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL

MODEL INDICATIONS

The following abbreviations are used in this manual for classification of model types.

2000: Indicates models equipped with the 2,000 mL <4G63> petrol engine. 2400: Indicates models equipped with the 2,400 mL <4G64> petrol engine.

MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection.

GDI: Indicates the gasoline direct injection, or engine equipped with the gasoline direct injection. SOHC: Indicates an engine with the single overhead camshaft, or models equipped with such an

engine.

DOHC: Indicates an engine with the double overhead camshaft, or models equipped with such an engine.

M/T: Indicates the manual transmission, or models equipped with the manual transmission. A/T: Indicates the automatic transmission, or models equipped with the automatic transmission. A/C: Indicates the air conditioner.

	GENERAL - Vehicle Identification			00-3
VEHICLE IDENTIFICATION
MODELS
Model code		Engine model	Transmission model	Fuel supply system
N63W	SNUEL6/R6	4G63-SOHC (1,997 mL)	F5M42 (2WD-5M/T)	MPI
	SNFEL6
	SNUJL6
	SRUEL6/R6		F4A42 (2WD-4A/T)
	SRFEL6
	SRUJL6
N64W	SNHCL6	4G64-DOHC-GDI	F5M42 (2WD-5M/T)	GDI
		(2,351 mL)
	SNGCL6
	SNHGL6
	SRHCL6		F4A42 (2WD-4A/T)
	SRGCL6
	SRHGL6

MODEL CODE

No.

Items

Contents

1

Development

N6: SPACE RUNNER

(2WD)

2

Engine type

3: 2,000 mL petrol engine

4: 2,400 mL petrol engine

3

Body type

W: Wagon

4

Body style

S: 3-door station wagon

1

2

3

4

5

6

7

8

9

5

Transmission type

N: 5-speed manual

transmission

R: 4-speed automatic

transmission

6

Trim level

U,F,H,G: GLX

7

Specification engine

E,J: MPI-SOHC

feature

C,G: GDI-DOHC

8

Steering wheel location

L: Left hand

R: Right hand

9

Destination

6: For Europe

00-4	GENERAL - Vehicle Identification

CHASSIS NUMBER

1

2

3

4

5

6

7

8

9

10

11

No.	Items		Contents
1	Fixed figure	J	Asia
2	Distribution channel	M	Japan channel
3	Destination	A	For Europe, right hand drive
		B	For Europe, left hand drive
4	Body style	S	3-door station wagon
5	Transmission type	N	5-speed manual transmission
		R	4-speed automatic transmission
6	Development order	N6	SPACE RUNNER (2WD)
7	Engine	3	4G63: 1,997 mL petrol engine
		4	4G64: 2,351 mL petrol engine
8	Sort	W	Station wagon
9	Model year	Y	2000
10	Plant	Z	Okazaki Motor Vehicle Works
11	Serial number	-	-

GENERAL - Vehicle Identification	00-5

ENGINE MODEL NUMBER

1.	The engine model number is stamped at the cylinder
		block as shown in the following.
		Engine model	Engine displacement mL
		4G63	1,997
		4G64	2,351
2.	The engine serial number is stamped near the engine
		model number.
		Engine serial number	AA0201 to YY9999

NEW VEHICLES

New vehicles has been added as shown below.

New vehicle has been developed from the respective basic vehicle. Specification show only a particular part of the new vehicle. For the remaining par, refer to specifications for basic vehicle.

New vehicle	Basic vehicle
N63W SNUEL6	N61W SNUCL6
N63W SNUER6	N61W SNUCR6
N63W SNFEL6	N61W SNFCL6
N63W SNUJL6	N61W SNUGL6
N63W SRUEL6	N61W SRUCL6
N63W SRUER6	N61W SRUCR6
N63W SRFEL6	N61W SRFCL6
N63W SRUJL6	N61W SRUGL6
N64W SNHCL6	N61W SNUCL6
N64W SNGCL6	N61W SNFCL6
N64W SNHGL6	N61W SNUGL6
N64W SRHCL6	N61W SRUCL6
N64W SRGCL6	N61W SRFCL6
N64W SRHGL6	N61W SRUGL6

00-6	GENERAL - Major Specifications

MAJOR SPECIFICATIONS

									3	3*
	5				9	4		8			6
					7
	2					1
Items					N63W		N63W		N64W		N64W
					SNUEL6,		SRUEL6,		SNHCL6,		SRHCL6,
					SNUER6,		SRUER6,		SNGCL6,		SRGCL6,
					SNFEL6,		SRFEL6,		SNHGL6		SRHGL6
					SNUJL6		SRUJL6
Vehicle		Overall length		1	4,290
dimensions
		Overall width		2	1,695
mm
		Overall height		3	1,650
		(unladen)			1,680*
		Wheelbase		4	2,550
		Track-front		5	1,460
		Track-rear		6	1,465
		Overhang-front		7	890
		Overhang-rear		8	850
		Ground clear-		9	155
		ance (unladen)
Vehicle		Kerb weight			1,360		1,380		1,400		1,420
weight kg
		Max. gross vehicle			1,880				1,920
		weight
		Max. axle weight			1,000				1,050
		rating-front
		Max. axle weight			900
		rating-rear
Seating capacity					5
Engine		Model No.			4G63				4G64
		Total displacement			1,997				2,351
		mL
Transmis-		Model No.			F5M42		F4A42		F5M42		F4A42
sion
		Type			5-speed manual		4-speed		5-speed manual		4-speed
							automatic				automatic
Fuel system		Fuel supply system			Electronically controlled multipoint				Gasoline Direct Injection
					injection

*: Vehicles with roof rails

11C-1

ENGINE

<4G6-MPI>

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . 3

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6

Drive Belt Tension Check and Adjustment . . . . . . 6

Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . 9

Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Compression Pressure Check . . . . . . . . . . . . . . . . 11

Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 12

Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 12

CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . 15 CAMSHAFT AND CAMSHAFT OIL SEAL . . 16 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . 21 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . 24 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 34

11C-2

NOTES

ENGINE <4G6-MPI> -	General/General Information/	11C-3
	Service Specifications

GENERAL

OUTLINE OF CHANGES

The following service procedures have been established in line with the addition of vehicles with 4G63-MPI engine.

GENERAL INFORMATION

Items			4G63
Total displacement mL			1,997
Bore ´ Stroke mm			85.0 ´ 88.0
Compression ratio			10.0
Combustion chamber			Pentroof type
Camshaft arrangement			SOHC
Number of valve	Intake		8
	Exhaust		8
Valve timing	Intake	Opening	BTDC 11_
		Closing	ABDC 53_
	Exhaust	Opening	BBDC 63_
		Closing	ATDC 21_
Fuel system			Electronically controlled multipoint fuel injection
Rocker arm			Roller type
Auto-lash adjuster			Equipped

SERVICE SPECIFICATIONS

	Items				Standard value		Limit
	Alternator drive belt checked			Vibration frequency Hz	177	- 232	-
				Tension N	343	- 588	-
				Deflection (Reference value) mm	6.7 - 9.8		-
	When adjusting	the	alternator	Vibration frequency Hz	201	- 222	-
	drive belt
				Tension N	441	- 539	-
				Deflection (Reference value) mm	7.2 - 8.4		-
	When replacing	the	alternator	Vibration frequency Hz	241	- 276	-
	drive belt
				Tension N	637	- 833	-
				Deflection (Reference value) mm	5.0 - 6.4		-
	Power steering oil pump and A/C			Vibration frequency Hz	108	- 132	-
	compressor drive belt tension
				Tension N	392	- 588	-
	(When checked)
				Deflection (Reference value) mm	11.7 - 15.3		-

	11C-4	ENGINE <4G6-MPI> - Service Specifications/Sealants
	Items				Standard value		Limit
	Power steering oil pump and A/C		Vibration frequency Hz		114 - 126		-
	compressor drive	belt tension
			Tension N		441 - 539		-
	(When adjusted)
			Deflection (Reference value) mm		12.5 - 14.3		-
	Power steering oil pump and A/C		Vibration frequency Hz		137 - 157		-
	compressor drive	belt tension
			Tension N		637 - 834		-
	(When replaced)
			Deflection (Reference value) mm		8.8 - 11.0		-
	Basic ignition timing				5_ BTDC ± 3_		-
	Ignition timing				Approx.10_ BTDC		-
	Idle speed r/min				750 ± 100		-
	CO contents %				0.5 or less		-
	HC contents ppm				100 or less		-
	Compression pressure kPa-r/min				1,400		Min. 1,060
	Compression pressure difference of all cylinder kPa				-		Max. 100
	Intake manifold vacuum kPa				-		Min. 69
	Cylinder head bolt shank length mm				-		99.4
	Auto-tensioner push rod movement mm				Within 1		-
	Timing belt tension torque Nm (Reference value)				3.5		-
	Auto-tensioner rod protrusion amount mm				3.8 - 4.5		-
	Timing belt B tension mm				5 - 7		-
	SEALANTS
	Items			Specified sealants		Remarks
	Rocker cover and cylinder head			3M ATD Part No.8660 or equivalent		-
	Semi-circular packing
	Oil pan			MITSUBISHI GENUINE	PART	Semi-drying sealant
	Thermostat case			MD970389 or equivalent
	Flywheel or drive plate bolt			3M Stud Locking 4170 or equivalent		-

		ENGINE <4G6-MPI> - Special Tools				11C-5
SPECIAL TOOLS
Tool		Number	Name	Use
		MB991502	MUT-II sub assem-	D	Checking the ignition timing
			bly	D	Checking the idle speed
				D	Erasing diagnosis code
				D Measuring the drive belt tension
		MB991668	Belt tension meter	Measuring the drive belt tension
			set	(used together with the MUT-II)

MD998299	MAS screwdriver	Adjustment of the mixture adjusting screw
		<Vehicles without catalytic converter>

MB990767	End yoke holder	D	Holding	the	camshaft sprocket
		D	Holding	the	crankshaft sprocket

MD998719	or	Crankshaft pulley	D	Holding	the	camshaft sprocket
MD998754		holder pin	D	Holding	the	crankshaft sprocket

MD998713	Camshaft oil seal	Press-in of the camshaft oil seal
	installer

MD998443	Auto-lash adjuster	Supporting of auto-lash adjuster
	holder

MD998727	Oil pan remover	Removal of oil pan

	MD998781	Flywheel stopper	Securing the flywheel or drive plate

11C-6 ENGINE <4G6-MPI> - Special Tools/On-vehicle Service

Tool	Number	Name	Use
	MD998776	Crankshaft rear oil	Press-in of the crankshaft rear oil seal
		seal installer

MB990938	Handle	Press-in of the crankshaft rear oil seal

MD998767	Tension	pulley	Timing belt tension adjustment
	socket wrench

	GENERAL	Engine lifter	Supporting the engine assembly during
	SERVICE		removal and installation of the transmission
	TOOL
	MZ203827
	MB991453	Engine hanger
		assembly

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK AND

ADJUSTMENT

ALTERNATOR DRIVE BELT TENSION CHECK

Check the drive belt tension in the following procedure.

Standard value:

Vibration frequency Hz	177 - 232
Tension N	343 - 588
Deflection (Reference value) mm	6.7 - 9.8

ENGINE <4G6-MPI> - On-vehicle Service	11C-7

	15_	15_	10 - 20 mm
			Water pump
			pulley
MB991668			Crankshaft
(Micro-
phone)			pulley

Alternator pulley

Belt tension gauge

Water pump pulley

Crankshaft pulley

Alternator pulley

98 N

Water pump pulley

Crankshaft pulley

Alternator pulley

<When using the MUT-II>

1.Connect the special tool (belt tension meter set) to the MUT-II.

2.Connect the MUT-II to the diagnosis connector.

3.Turn the ignition switch to ON and select “Belt Tension Measurement” from the menu screen.

4.Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15_).

5.Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

Caution

(1)The temperature of the surface of the belt should be as close as possible to normal temperature.

(2)Do not let any contaminants such as water or oil get onto the microphone.

(3)If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

(4)If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values.

(5)Do not take the measurement while the vehicle’s engine is running.

<When using a tension gauge>

Use a belt tension gauge to check that the belt tension is within the standard value.

<Belt deflection check>

Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

11C-8	ENGINE <4G6-MPI> - On-vehicle Service

Adjusting bolt

Lock bolt

<Vehicles without A/C>

Oil pump pulley

98 N

AB

Crankshaft pulley

Tensioner pulley

<Vehicles with A/C>

Oil pump pulley
98 N		Tensioner
		pulley
Crankshaft	A	B
pulley

A/C compressor pulley

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT

1.	Loosen the nut of the alternator pivot bolt.
2.	Loosen the lock bolt.
3.	Use the adjusting bolt to adjust the belt tension and belt
		deflection to the standard values.
		Standard value:
		Items	When adjusting	When replacing
		Vibration frequency Hz	201 - 222	241 - 276
		Tension N	441 - 539	637 - 833
		Deflection	7.2 - 8.4	5.0 - 6.4
		(Reference value) mm
4.	Tighten the nut of the alternator pivot bolt.
		Tightening torque: 49 Nm
5.	Tighten the lock bolt.
		Tightening torque: 22 Nm
6.	Tighten the adjusting bolt.
		Tightening torque: 5 Nm

POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

1.Check if the belt tension is within the standard value using one of the methods below.

Standard value:

Items	When	When a	When a new
	checked	used belt is	belt is
		installed	installed
Vibration	108 - 132	114 - 126	137 - 157
frequency
Hz
Tension N	392 - 588	441 - 539	637 - 834
Deflection	11.7 - 15.3	12.5 - 14.3	8.8 - 11.0
(Reference
value) mm

<When measuring the vibration frequency>

With your finger tip lightly tap the centre of the belt between the pulleys in the location shown by the arrow in the illustration and then measure the belt vibration frequency.

NOTE

Refer to P.11C-7 for information regarding the vibration frequency measurement method using MUT-II.

<When measuring the tension>

Use a belt tension gauge to measure the belt tension.

ENGINE <4G6-MPI> - On-vehicle Service	11C-9

<When measuring the deflection>

Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection.

2.If the tension or deflection is outside the standard value, adjust by the following procedure.

(1)Loosen tensioner pulley fixing nut A.

(2)Adjust the amount of belt deflection using adjusting bolt B.

(3)Tighten fixing nut A.

Tightening torque: 25 Nm

(4)Check the belt deflection amount and tension, and readjust if necessary.

Caution

Check after turning the crankshaft once or more clockwise (right turn).

IGNITION TIMING CHECK

1.Before inspection, set the vehicle to the pre-inspection condition.

2.Connect the MUT-II to the diagnosis connector.

3.Set up a timing light.

4.Start the engine and run at idle.

5.Check that engine idle speed is within the standard value.

Standard value: 750 ± 100 r/min

6.Select No.17 of the MUT-II Actuator test.

7.Check that basic ignition timing is within the standard value.

Standard value: 5_ BTDC±3_

8.If the basic ignition timing is outside the standard value, inspect the MPI system while referring to GROUP 13A

-Troubleshooting.

9.Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test.

Caution

If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.

10.Check that ignition timing is at the standard value.

Standard value: approx. 10_BTDC

NOTE

1.Ignition timing is variable within about ± 7_, even under normal operating.

2.And it is automatically further advanced by about 5_ from standard value at higher altitudes.

11C-10	ENGINE <4G6-MPI> - On-vehicle Service

IDLE SPEED CHECK

1.Before inspection, set the vehicle to the pre-inspection condition.

2.Turn the ignition switch to “LOCK” (OFF) position and connect the MUT-II to the diagnosis connector.

3.Check the basic ignition timing.

Standard value: 5_ BTDC±3_

4.Run the engine at idle for 2 minutes.

5.Check the idle speed. Select item No. 22 and take a reading of the idle speed.

Standard value: 750 ± 100 r/min

NOTE

The idle speed is controlled automatically by the idle speed control (ISC) system.

6.If the idle speed is outside the standard value, inspect the MPI components by referring to GROUP 13A - Troubleshooting.

IDLE MIXTURE CHECK

1.Before inspection, set the vehicle to the pre-inspection condition.

2.Turn the ignition switch to “LOCK” (OFF) position and connect the MUT-II to the diagnosis connector.

3.Check that the basic ignition timing is within the standard value.

Standard value: 5_ BTDC±3_

4.Run the engine at 2,500 r/min for 2 minutes.

5.Set the CO, HC tester.

6.Check the CO contents and the HC contents at idle.

Standard value

CO contents: 0.5% or less

HC contents: 100 ppm or less

7.If there is a deviation from the standard value, check the following items:

D Diagnosis output

D Closed-loop control (When the closed-loop control is normal, the output signal of the oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV

at idle.)

DFuel pressure

DInjector

DIgnition coil, spark plug cable, spark plug

DLeak in the EGR system and in the EGR valve

DEvaporative emission control system

DCompression pressure

ENGINE <4G6-MPI> - On-vehicle Service	11C-11

Compression gauge

NOTE

Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

COMPRESSION PRESSURE CHECK

1.Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition.

2.Disconnect the spark plug cables.

3.Remove all of the spark plugs.

4.Disconnect the crank angle sensor connector.

NOTE

Doing this will prevent the engine-ECU <M/T> or engine-A/T-ECU <A/T> from carrying out ignition and fuel injection.

5.Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

Caution

1.Keep away from the spark plug hole when cranking.

2.If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

6.Set compression gauge to one of the spark plug holes.

7.Crank the engine with the throttle valve fully open and measure the compression pressure.

Standard value (at engine speed of 250 - 400 r/min): 1,400 kPa

Limit (at engine speed of 250 - 400 r/min): Min. 1,060 kPa

8.Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Max. 100 kPa

9.If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 7 and 8.

(1)If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

11C-12	ENGINE <4G6-MPI> - On-vehicle Service

Vacuum gauge

(2)If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

10.Connect the crank angle sensor connector.

11.Install the spark plugs and spark plug cables.

12.Use the MUT-II to erase the diagnosis codes.

NOTE

This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

MANIFOLD VACUUM CHECK

1.Before inspection, set the vehicle to the pre-inspection condition.

2.Attach a three-way union to the vacuum hose between the fuel pressure regulator and the air intake plenum, and connect a vacuum gauge.

3.Start the engine and check that idle speed is within standard value. Then read off the vacuum gauge.

Limit: Min. 69 kPa

LASH ADJUSTER CHECK

If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check.

NOTE

(1)The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load.

Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters.

(2)If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up.

The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick.

1.Start the engine.

2.Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed.

If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused by the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.)

ENGINE <4G6-MPI> - On-vehicle Service	11C-13

3.While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N ® D).

If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.)

4.After the engine has warmed up, run it at idle and check if any noise can be heard.

If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters. (Refer to the Engine Workshop Manual.) If not improved, go to step 5.

5.Bleed air from the lash adjusters.

6.If the noise has not disappeared even after the air bleeding, clean the lash adjusters. (Refer to the Engine Workshop Manual.)

<LASH ADJUSTER AIR BLEEDING>

NOTE

(1)If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine.

(2)After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber.

(3)If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.

	1. Check the engine oil and replenish or replace the oil
	if necessary.
	NOTE
	(1)	If there is a only small amount of oil, air will be drawn
		in through the oil screen and will get into the oil
		passage.
	(2)	If the amount of oil is greater than normal, then the
Good		oil will being mixed by the crankshaft and a large
		amount of air may get mixed into the oil.
	(3)	If the oil is degenerated, air and oil will not separate
		easily in oil, and the amount of air mixed into the
		oil will increase.

11C-14	ENGINE <4G6-MPI> - On-vehicle Service

Highpressure chamber

Drive pattern for air bleeding

	Gradually open the			Close the throttle
	throttle valve.			valve.
	Approx.
3,000 r/min
Idle speed
15		15
	seconds	seconds

Once

(4)If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal.

2.Run the engine at idle for 1 - 3 minutes to let it warm up.

3.With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters.)

4.After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times.

5.Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.

	ENGINE <4G6-MPI> - Crankshaft Pulley			11C-15
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
	Pre-removal Operation		Post-installation Operation
	D Under Cover Removal		D Drive Belt Tension Adjustment (Refer to P.11C-6.)
			D Under Cover Installation

2

3

25 Nm

1

Removal steps
1. Drive belt (Power steering and	2.	Drive belt (Alternator)
A/C)	3.	Crankshaft pulley

11C-16 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

DAir Cleaner Removal and Installation

DTiming Belt Removal and Installation (Refer to P.11C-27.)

10 Nm

1

14 Nm

4

22 Nm

3 10 12

6

7

13

Removal steps

1.Control harness connection

2.Spark plug cable and ignition coil

3.PCV hose connection

4.Breather hose

5.Rocker cover

6.Camshaft position sensor support

7.Camshaft position sensing cylinder AA" "CA 8. Camshaft sprocket

(f 3 ± 1 mm)

2				6
5
	3.4 Nm
			Sealant:
			MITSUBISHI GENUINE PART
			MD970389 or equivalent
11
							Lip section
	28 - 34 Nm				9
8						Cam section
						and journal
						section
9					13
	88 Nm
					Engine oil

"BA 9.	Camshaft oil seal
10.	Spark plug guide oil seal
AB" "AA 11.	Rocker arm and shaft assembly
AB" "AA 12.	(intake side)
	Rocker arm and shaft assembly
	(exhaust side)
13.	Camshaft

ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal	11C-17

MB990767

MD998719 or

MD998754

MD998443

REMOVAL SERVICE POINTS

AA" CAMSHAFT SPROCKET REMOVAL

AB" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

Before removing the rocker arm and shaft assembly, install the special tools as shown in the illustration so that the lash adjusters will not fall out.

INSTALLATION SERVICE POINTS

"AA ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION

1.Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve side do not push the valves.

2.Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide.

NOTE

Install the rocker shaft spring before installing the rocker arm and rocker arm shaft on the exhaust side.

3.Remove the special tool for fixing the lash adjuster.

4.Confirm that the rocker shaft notch is in the direction shown in the diagram.

11C-18 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal

"BA CAMSHAFT OIL SEAL INSTALLATION

1.Apply engine oil to the camshaft oil seal lip.

2.Use the special tool to press-fit the camshaft oil seal.

MD998713

"CA CAMSHAFT SPROCKET INSTALLATION

Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque.

	ENGINE <4G6-MPI> - Oil Pan		11C-19
OIL PAN
REMOVAL AND INSTALLATION
	Pre-removal and Post-installation Operation
	D Under Cover Removal and Installation	D Oil Level Gauge Removal and Installation
	D Engine Oil Draining and Supplying	D Front Exhaust Pipe Removal and Installation

	5
f 4 ± 1 mm			39 Nm			5
Groove	Bolt		2
	hole
			1
Sealant:
MITSUBISHI GENUINE PART							4
MD970389 or equivalent
		9 Nm	6
			3
					9 Nm		9 Nm
						44 Nm
Removal steps
1. Drain plug						4. Bell housing cover
"AA 2. Drain plug gasket			AA"			5. Oil pan
3. Harness connector						6. Oil level sensor

		REMOVAL SERVICE POINT
MD998727	MD998727
		AA" OIL PAN REMOVAL
		After removing the oil pan mounting bolts, remove the oil
		pan with the special tool and a brass bar.
		Caution
		Perform this slowly to avoid deformation of the oil pan
		flange.

11C-20	ENGINE <4G6-MPI> - Oil Pan
		INSTALLATION SERVICE POINT
		"AA DRAIN PLUG GASKET INSTALLATION
	Oil pan side	Install the drain plug gasket in the direction so that it faces
		as shown in the illustration.
Drain plug
gasket

ENGINE <4G6-MPI> - Crankshaft Oil Seal

11C-21

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

127 - 137 Nm

7

<M/T>

8

9

11

127 - 137 Nm

12

<A/T>

6

2

8

4

10

1

<M/T>

<A/T>

5

3

Crankshaft

Crankshaft

(Engine oil:

12

5

bolt washer

(Engine oil:

surface)

bolt wash-

er surface)

9

Lip section

Lip section

10

Sealant: 3M Stud locking 4170 or equivalent

Engine oil

Crankshaft front oil seal removal

Crankshaft rear oil seal removal

steps

steps

D

Timing belt (Refer to P.11C-27.)

AA"

D

Oil pan (Refer to P.11C-19.)

D Timing belt B (Refer to P.11C-31.)

D Transmission assembly

D

Crank angle sensor

D

Clutch cover and disc <M/T>

(Refer to GROUP 16.)

6. Crankshaft bushing <A/T>

1. Crankshaft sprocket

AB" "BA 7. Plate <M/T>

2. Flange

AB" "BA 8. Adapter plate

3. Crankshaft sprocket B

AB" "BA 9. Flywheel <M/T>

4. Key

AB" "BA 10. Drive plate <A/T>

"CA 5. Crankshaft front oil seal

AB" "BA 11. Adapter plate <M/T>

"AA 12. Crankshaft rear oil seal