Mitsubishi Space Wagon 2000 User Manual
General ........................
00
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
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 ........................
11
13
14
15
16
17
21
23
26
31
33
35
37
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 th e trade mark which Mitsubishi Motors
Corporation holds.
E
Mitsubishi Motors Corporation May 1999
GENERAL
CONTENTS
00-1
HOW TO USE THIS MANUAL 2..............
Model Indications 2............................
VEHICLE IDENTIFICATION 3.................
Models 3......................................
Model Code 3.................................
Chassis Number 4.............................
Engine Model Number 5........................
New Vehicles 5................................
MAJOR SPECIFICATIONS 6..................
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)
123456
SRGCL6
SRHGL6
7
89
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
5 Transmission type N: 5-speed manual
transmission
R: 4-speed automatic
transmission
6 Trim level U,F,H,G: GLX
7 Specification engine
feature
8 Steering wheel location L: Left hand
9 Destination 6: For Europe
E,J: MPI-SOHC
C,G: GDI-DOHC
R: Right hand
00-4
GENERAL -
CHASSIS NUMBER
Vehicle Identification
23 4
1
No. Items Contents
1 Fixed figure J Asia
2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
4 Body style S 3-door station wagon
5 Transmission type N 5-speed manual transmission
6 Development order N6 SP ACE RUNNER (2WD)
7 Engine 3 4G63: 1,997 mL petrol engine
67891110
5
B For Europe, left hand drive
R 4-speed automatic transmission
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
4G64
1,997
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*
Items
5
2
9
7
N63W
SNUEL6,
SNUER6,
SNFEL6,
SNUJL6
4
1
N63W
SRUEL6,
SRUER6,
SRFEL6,
SRUJL6
8
N64W
SNHCL6,
SNGCL6,
SNHGL6
6
N64W
SRHCL6,
SRGCL6,
SRHGL6
Vehicle Overall length 1 4,290
dimensions
mm
Overall width 2 1,695
Overall height
(unladen)
3 1,650
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 displacementmL1,997 2,351
Transmis- Model No. F5M42 F4A42 F5M42 F4A42
sion
Fuel system Fuel supply system Electronically controlled multipoint
Type 5-speed manual 4-speed
automatic
5-speed manual 4-speed
automatic
Gasoline Direct Injection
injection
*: Vehicles with roof rails
ENGINE
<4G6-MPI>
CONTENTS
11C-1
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/
Service Specifications
11C-3
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
V alve 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
When adjusting the alternator
drive belt
Vibration frequency Hz 177 - 232 -
Tension N 343 - 588 -
Deflection (Reference value) mm 6.7 - 9.8 -
Vibration frequency Hz 201 - 222 -
Tension N 441 - 539 -
When replacing the alternator
drive belt
Power steering oil pump and A/C
compressor drive belt tension
(When checked)
Deflection (Reference value) mm 7.2 - 8.4 -
Vibration frequency Hz 241 - 276 -
Tension N 637 - 833 -
Deflection (Reference value) mm 5.0 - 6.4 -
Vibration frequency Hz 108 - 132 -
Tension N 392 - 588 -
Deflection (Reference value) mm 11.7 - 15.3 -
11C-4
Items LimitStandard value
ENGINE <4G6-MPI> -
Service Specifications/Sealants
Power steering oil pump and A/C
compressor drive belt tension
(When adjusted)
Power steering oil pump and A/C
compressor drive belt tension
(When replaced)
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
Vibration frequency Hz 1 14 - 126 -
Tension N 441 - 539 -
Deflection (Reference value) mm 12.5 - 14.3 -
Vibration frequency Hz 137 - 157 -
Tension N 637 - 834 -
Deflection (Reference value) mm 8.8 - 11.0 -
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
Semi-circular packing
Oil pan
Thermostat case
Flywheel or drive plate bolt 3M Stud Locking 4170 or equivalent -
3M ATD Part No.8660 or equivalent -
MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
ENGINE <4G6-MPI> -
Special Tools
SPECIAL TOOLS
Tool Number Name Use
11C-5
MB991502 MUT-II sub assem-
bly
MB991668 Belt tension meter
set
MD998299 MAS screwdriver Adjustment of the mixture adjusting screw
MB990767 End yoke holder D Holding the camshaft sprocket
D Checking the ignition timing
D Checking the idle speed
D Erasing diagnosis code
D Measuring the drive belt tension
Measuring the drive belt tension
(used together with the MUT-II)
<Vehicles without catalytic converter>
D Holding the crankshaft sprocket
MD998719 or
MD998754
MD998713 Camshaft oil seal
MD998443 Auto-lash adjuster
MD998727 Oil pan remover Removal of oil pan
Crankshaft pulley
holder pin
installer
holder
D Holding the camshaft sprocket
D Holding the crankshaft sprocket
Press-in of the camshaft oil seal
Supporting of auto-lash adjuster
MD998781 Flywheel stopper Securing the flywheel or drive plate
11C-6
Tool UseNameNumber
ENGINE <4G6-MPI> -
Special Tools/On-vehicle Service
MD998776 Crankshaft rear oil
seal installer
MB990938 Handle Press-in of the crankshaft rear oil seal
MD998767 Tension pulley
socket wrench
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter Supporting the engine assembly during
Press-in of the crankshaft rear oil seal
Timing belt tension adjustment
removal and installation of the transmission
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
MB991668
(Microphone)
Alternator
pulley
15
15
_
_
10 - 20 mm
Water pump
pulley
Crankshaft
pulley
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 a n d select “Belt Tension
Measurement” from th e 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 the MUT-II>
Alternator
pulley
Alternator
pulley
Belt tension gauge
98 N
Water pump
pulley
Crankshaft
pulley
Water pump
pulley
Crankshaft
pulley
<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
Adjusting bolt
Lock bolt
ENGINE <4G6-MPI> -
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
(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
On-vehicle Service
7.2 - 8.4 5.0 - 6.4
<Vehicles without A/C>
Oil pump pulley
98 N
Crankshaft
pulley
<Vehicles with A/C>
Oil pump pulley
98 N
Crankshaft
pulley
A
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT
A
B
1. Check if the belt tension is within the standard value
using one of the methods below.
Standard value:
Tensioner pulley
Tensioner
pulley
B
A/C
compressor
pulley
Items When
checked
Vibration
frequency
Hz
Tension N 392 - 588 441 - 539 637 - 834
Deflection
(Reference
value) mm
108 - 132 114 - 126 137 - 157
11.7 - 15.3 12.5 - 14.3 8.8 - 11.0
When a
used belt is
installed
When a new
belt is
installed
<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 t he
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> -
<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
(3) Tighten fixing nut A.
(4) Check the belt deflection amount and tension, and
On-vehicle Service
bolt B.
Tightening torque: 25 Nm
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
11C-9
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 th e 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> -
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.
On-vehicle Service
_
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.)
D Fuel pressure
D Injector
D Ignition coil, spark plug cable, spark plug
D Leak in the EGR system and in the EGR valve
D Evaporative emission control system
D Compression pressure
_
ENGINE <4G6-MPI> -
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.
On-vehicle Service
11C-11
Compression gauge
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 th e 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
Vacuum gauge
ENGINE <4G6-MPI> -
(2) If the compression does not rise after oil is added,
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
On-vehicle Service
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
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> -
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
(2) After parking the vehicle for long periods, the oil drains
(3) If either of the above situations occur, the abnormal
On-vehicle Service
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.
out of the oil passage, an d it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
noise can be eliminated by bleeding the air from inside
the lash adjusters.
11C-13
Good
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
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> -
(4) If the air which has been mixed in with the oil due
Highpressure
chamber
On-vehicle Service
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.
Drive pattern for air bleeding
Gradually open the
throttle valve.
Approx.
3,000 r/min
Idle speed
15
seconds
Once
Close the throttle
valve.
15
seconds
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
REMOVAL AND INSTALLATION
Crankshaft Pulley
11C-15
Pre-removal Operation
D Under Cover Removal
2
Post-installation Operation
D Drive Belt Tension Adjustment (Refer to P.11C-6.)
D Under Cover Installation
3
25 Nm
1
Removal steps
1. Drive belt (Power steering and
A/C)
2. Drive belt (Alternator)
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
D Air Cleaner Removal and Installation
D Timing Belt Removal and Installation (Refer to
P.11C-27.)
10 Nm
(f 3 ± 1 mm)
14 Nm
6
1
2
6
5
3.4 Nm
4
22 Nm
10
3
7
12
11
28 - 34 Nm
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
Lip section
9
13
8
Cam section
and journal
section
13
9
AA""CA
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
8. Camshaft sprocket
"BA
AB""AA
AB""AA
88 Nm
9. Camshaft oil seal
10. Spark plug guide oil seal
11. Rocker arm and shaft assembly
12. Rocker arm and shaft assembly
13. Camshaft
Engine oil
(intake side)
(exhaust side)
MB990767
ENGINE <4G6-MPI> -
MD998719 or
MD998754
Camshaft and Camshaft Oil Seal
REMOVAL SERVICE POINTS
AA"
CAMSHAFT SPROCKET REMOVAL
11C-17
MD998443
AB"
Before removing the rocker arm an d shaft assembly, install
the special tools as shown in the illustration so that the lash
adjusters will not fall out.
ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
INSTALLATION SERVICE POINTS
"AA
1. Temporarily tighten the rocker shaft with the bolt so that
2. Fit the rocker shaft spring from the above and position
3. Remove the special tool for fixing the lash adjuster.
ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
all rocker arms on the inlet valve side do not push the
valves.
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.
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
MD998713
"BA
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
"CA
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.
CAMSHAFT OIL SEAL INSTALLATION
CAMSHAFT SPROCKET INSTALLATION
ENGINE <4G6-MPI> -
OIL PAN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation
D Engine Oil Draining and Supplying
5
Oil Pan
D Oil Level Gauge Removal and Installation
D Front Exhaust Pipe Removal and Installation
11C-19
f 4 ± 1mm
Groove
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
Removal steps
"AA
1. Drain plug
2. Drain plug gasket
3. Harness connector
Bolt
hole
9Nm
39 Nm
1
3
6
2
AA"
9Nm
44 Nm
4. Bell housing cover
5. Oil pan
6. Oil level sensor
5
4
9Nm
MD998727
MD998727
REMOVAL SERVICE POINT
AA"
After removing the oil pa n 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.
OIL PAN REMOVAL
11C-20
Drain plug
gasket
ENGINE <4G6-MPI> -
INSTALLATION SERVICE POINT
"AA
Oil pan side
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Oil Pan
DRAIN PLUG GASKET INSTALLATION
ENGINE <4G6-MPI> -
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Crankshaft Oil Seal
11C-21
127 - 137 Nm
<M/T>
<M/T>
7
8
9
11
12
127 - 137 Nm
<A/T>
6
2
8
4
10
1
<A/T>
Crankshaft
Crankshaft
5
3
(Engine oil:
(Engine oil:
bolt washer surface)
bolt washer
surface)
9
10
Sealant: 3M Stud locking 4170 or equivalent
Crankshaft front oil seal removal
steps
D
Timing belt (Refer to P.11C-27.)
D
Timing belt B (Refer to P.11C-31.)
D
Crank angle sensor
(Refer to GROUP 16.)
1. Crankshaft sprocket
2. Flange
3. Crankshaft sprocket B
"CA
4. Key
5. Crankshaft front oil seal
12
Lip section
Engine oil
Crankshaft rear oil seal removal
steps
D
AA"D
AB""BA
AB""BA
AB""BA
AB""BA
AB""BA
"AA
Oil pan (Refer to P.11C-19.)
Transmission assembly
D
Clutch cover and disc <M/T>
6. Crankshaft bushing <A/T>
7. Plate <M/T>
8. Adapter plate
9. Flywheel <M/T>
10. Drive plate <A/T>
11. Adapter plate <M/T>
12. Crankshaft rear oil seal
5
Lip section
11C-22
ENGINE <4G6-MPI> -
Crankshaft Oil Seal
<M/T>
Flywheel
Bolt
REMOVAL SERVICE POINTS
AA"
<M/T>:
Refer to ’99 SPACE RUNNER/SPACE WAGON Workshop
Manual (Pub. No. PWDE9803) GROUP 22.
Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
<A/T>:
Refer to ’99 SPACE RUNNER/SPACE WAGON Workshop
Manual (Pub. No. PWDE9803) GROUP 23.
AB"
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.
TRANSMISSION ASSEMBLY REMOVAL
PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE <A/T> REMOVAL
Crankshaft
rear oil seal
MD990938
MD998776
MD998781
Crankshaft
INSTALLATION SERVICE POINTS
"AA
1. Apply a small mount of engine oil to the entire
2. Install the oil seal by tapping it as far as the chamfered
"BA
1. Clean off all sealant, oil and other substances which are
CRANKSHAFT REAR OIL SEAL INSTALLATION
circumference of the oil seal lip.
position of the oil seal case as shown in the illustration.
DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER
PLATE/PLATE <M/T> INSTALLATION
adhering to the threaded bolts, crankshaft thread holes
and the flywheel or drive plate.
ENGINE <4G6-MPI> -
2. Apply oil to the bearing surface of the flywheel or drive
plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to hold the flywheel or drive plate
in the same manner as removal, and install the bolt.
Crankshaft Oil Seal
11C-23
"CA
1. Apply a small amount of engine oil to the entire
2. Press-fit the oil seal unit it is flush with the oil seal case.
CRANKSHAFT FRONT OIL SEAL INSTALLATION
circumference of the oil seal lip.
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