Mitsubishi 4D6, Manual

Page 1: ...ENGINE 4G6 11A ENGINE 6A1 11B ENGINE 4D6 11C 11A 1 ENGINE CONTENTS 11109000276 ...

Page 2: ...Belt Tension Check and Adjustment 6 Ignition Timing Check 7 Idle Speed Check 8 Idle Mixture Check 8 Compression Pressure Check 9 Manifold Vacuum Check 10 Lash Adjuster Check 11 CRANKSHAFT PULLEY 15 CAMSHAFT AND CAMSHAFT OIL SEAL 16 OIL PAN 19 CRANKSHAFT OIL SEAL 20 CYLINDER HEAD GASKET 22 TIMING BELT 26 TIMING BELT B 30 ENGINE ASSEMBLY 33 ...

Page 3: ...pped SERVICE SPECIFICATIONS 11100030489 Items Standard value Limit When checked 294 490 Tension N When a used belt is installed 343 441 Alternator drive When a new belt is installed 490 686 belt tension When checked 7 7 12 3 Deflection Reference When a used belt is installed 8 4 10 6 value mm When a new belt is installed 5 9 7 7 When checked 392 588 Tension N When a used belt is installed 441 539 ...

Page 4: ...rotrusion amount mm 3 8 4 5 Timing belt B tension mm 5 7 SEALANTS 11100050201 Items Specified sealants Remarks Rocker cover and cylinder head Semi circular packing 3M ATD Part No 8660 or equivalent Oil pan Thermostat case MITSUBISHI GENUINE PART MD970389 or equivalent Semi drying sealant Flywheel bolt 3M Stud Locking 4170 or equivalent SPECIAL TOOLS 11100060457 Tool Number Name Use MB991502 MUT II...

Page 5: ...f oil pan MD998781 Flywheel stopper Securing the flywheel MD998776 Crankshaft rear oil seal installer Press in of the crankshaft rear oil seal MB990938 Handle Press in of the crankshaft rear oil seal MD998767 Tension pulley socket wrench Timing belt tension adjustment GENERAL SERVICE TOOL MZ203827 Engine lifter Supporting the engine assembly during removal and installation of the transmission MB99...

Page 6: ...90 Deflection Reference value mm 7 7 12 3 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 a used belt is installed When a new belt is installed Tension N 343 441 490 686 Deflection Reference value mm 8 4 10 6 5 9 7 7 ...

Page 7: ...he 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 11100170297 1 Before inspect...

Page 8: ...gher altitudes IDLE SPEED CHECK 11100350066 1 Before inspection set the vehicle to the pre inspection condition 2 Turn the ignition switch to OFF and connect the MUT II to the diagnosis connector 3 Check the basic ignition timing Standard value 5_ BTDC 2_ 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 mi...

Page 9: ...ontents are not within the standard value even though the result of the inspection is normal on all items COMPRESSION PRESSURE CHECK 11100260499 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 ...

Page 10: ... the malfunction is a worn or damaged piston ring and or cylinder inner surface 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 re...

Page 11: ...urs 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 y the lash adjusters so check for some other cause of the problem Moreover if the noise does not change in accordance wit...

Page 12: ...lash adjuster simple check Refer to P 11A 13 D If one of the rocker arms can be pushed down easily during the lash adjuster simple check replace the corresponding lash adjuster D If two or more of the rocker arms can be pushed down easily during the lash adjuster simple check the cause may be that the oil passage to the cylinder head is blocked Check for blockages in the oil passage and clear the ...

Page 13: ... the following procedure using a thickness gauge 1 Check that a thickness gauge with a thickness of 0 1 0 2 mm can be inserted easily between the valve and the lash adjuster 2 If the thickness gauge can be inserted easily make a note of which is the corresponding lash adjuster 3 If the thickness gauge cannot be inserted easily the lash adjuster is normal so check for some other cause of the proble...

Page 14: ...lting 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 ch...

Page 15: ...AL AND INSTALLATION Pre removal Operation D Under Cover Removal Post installation Operation D Drive Belt Tension Adjustment Refer to P 11A 6 D Under Cover Installation 1 2 3 25 Nm Removal steps 1 Drive belt Power steering and A C 2 Drive belt Alternator 3 Crankshaft pulley ...

Page 16: ... 4 9 7 6 f 3 1 mm Sealant MITSUBISHI GENUINE PART MD970389 or equivalent 5 3 4 Nm Lipsection Cam section and journal section Engine oil 12 12 8 5 14 Nm 11 10 22 Nm Removal steps 1 Control harness connection 2 Spark plug cable 3 PCV hose connection 4 Rocker cover 5 Camshaft position sensor support 6 Camshaft position sensing cylinder AA CA 7 Camshaft sprocket BA 8 Camshaft oil seal 9 Spark plug gui...

Page 17: ...HAFT 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 fi...

Page 18: ...ine oil to the camshaft oil seal lip 2 Use the special tool to press fit the camshaft oil seal 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 MD998713 ...

Page 19: ... GENUINE PART MD970389 or equivalent 4 7 Nm Removal steps 1 Drain plug AA 2 Drain plug gasket 3 Bell housing cover 4 Oil level sensor AA 5 Oil pan REMOVAL SERVICE POINT 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 INSTALLATION SERVICE POINT AA DRAIN PLUG G...

Page 20: ...ine oil 127 137 Nm 6 8 Crankshaft front oil seal removal steps D Timing belt Refer to P 11A 26 D Crank angle sensor Refer to GROUP 16 1 Crankshaft sprocket 2 Flange 3 Crankshaft sprocket B 4 Key CA 5 Crankshaft front oil seal Crankshaft rear oil seal removal steps D Oil pan Refer to P 11A 19 AA D Transmission assembly D Clutch cover and disc M T 6 Crankshaft bushing AB BA 7 Plate M T AB BA 8 Adapt...

Page 21: ... oil seal case as shown in the illustration BA DRIVE PLATE A T FLYWHEEL M T ADAPTER PLATE PLATE M T INSTALLATION 1 Clean off all sealant oil and other substances which are adhering to the threaded bolts crankshaft thread holes and the flywheel or drive plate 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 thr...

Page 22: ...fer to GROUP 14 Water Hose and Water Pipe D Engine Oil Supplying Refer to GROUP 12 On vehicle Service D Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service 1 8 2 3 4 5 6 7 9 11 Delivery pipe O ring Engine oil 10 10 Removal steps 1 Accelerator cable connection 2 Vacuum hose connection 3 Brake booster vacuum hose connection 4 Vacuum hose connection 5 Throttle position sensor connector ...

Page 23: ...oil assembly 16 Breather hose 17 Engine coolant temperature sensor connector 18 Engine coolant temperature gauge unit connector 19 Camshaft position sensor 20 Water hose connection 21 Heater hose connection 22 Thermostat case assembly 23 Water hose connection AA 24 Power steering oil pump and bracket assembly 25 Front exhaust pipe connection 26 Rocker cover D Timing belt Refer to P 11A 26 AB BA 27...

Page 24: ...m the plug guides when removing the cylinder head bolts INSTALLATION SERVICE POINTS AA CYLINDER HEAD GASKET INSTALLATION 1 Wipe off all oil and grease from the gasket mounting surface 2 Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes BA CYLINDER HEAD BOLT INSTALLATION 1 When installing the cylinder head bolts the length below the ...

Page 25: ...tening angle just 90_ If it is less than 90_ the head bolt will be loosened 2 If it is more than 90_ remove the head bolt and repeat the procedure from step 1 CA HIGH PRESSURE FUEL HOSE INSTALLATION 1 Apply a small amount of new engine oil to the O ring Caution Do not let any engine oil get into the delivery pipe 2 While turning the high pressure fuel hose to the right and left install the deliver...

Page 26: ...shaft Pulley Removal and Installation Refer to P 11A 15 D Engine Mount Bracket Removal and Installation Refer to GROUP 32 Engine Mounting 10 12 Nm 48 Nm 1 2 5 24 Nm 4 3 9 Nm Removal steps 1 Timing belt upper cover 2 Timing belt lower cover CA D Timing belt tension adjustment AA BA 3 Timing belt 4 Tension pulley AA 5 Auto tensioner ...

Page 27: ...pply 98 196 N force to the auto tensioner by pressing it against a metal cylinder block etc and measure the movement of the push rod Standard value Within 1 mm A Length when it is free not pressed B Length when it is pressed A B Movement 2 If it is out of the standard value replace the auto tensioner 3 Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push ...

Page 28: ...check that the screwdriver goes in 60 mm or more The screwdriver should not be taken out until the timing belt is installed 3 Install the belt to the crankshaft sprocket oil pump sprocket and camshaft sprocket in that order so that there is no slackness in the belt tension Caution If the timing belt is re used install so that the arrow marked on it at time of removal is pointing in the clockwise d...

Page 29: ...belt Standard value 3 5 Nm Timing belt tension torque Caution When tightening the fixing bolt make sure that the tension pulley does not turn with the bolt 3 Turn the crankshaft two revolutions in the clockwise direction so that the timing marks are aligned After leaving it for 15 minutes measure the amount of protrusion of the auto tensioner Standard value A 3 8 4 5 mm 4 If the amount of protrusi...

Page 30: ... AA CA 2 Crankshaft sprocket BA 3 Flange 4 Timing belt B tensioner AB AA 5 Timing belt B REMOVAL SERVICE POINTS AA CRANKSHAFT SPROCKET REMOVAL AB TIMING BELT B REMOVAL Caution If timing belt B is to be re used use chalk to mark it with an arrow on its flat side indicating the turning direction to the right MD998719 or MD998754 MB990767 Crankshaft sprocket ...

Page 31: ...e front of the engine 2 Holding the timing belt B tensioner up with your finger in the direction of the arrow place pressure on the timing belt so that the tension side of the belt is taut Now tighten the bolt to fix the tensioner Caution When tightening the bolt ensure that the tensioner pulley shaft does not rotate with the bolt Allowing it to rotate with the bolt can cause excessive tension on ...

Page 32: ...G6 Timing Belt B 11A 32 CA CRANKSHAFT SPROCKET INSTALLATION NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt MD998719 or MD998754 MB990767 Crankshaft sprocket ...

Page 33: ...ater Pipe D Engine Coolant Supplying D Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service D Front Exhaust Pipe Installation Refer to GROUP 15 D Hood Installation Refer to GROUP 42 D Under Cover Installation D Radiator Assembly Installation Refer to GROUP 14 D Air Cleaner Installation O ring Delivery pipe Engine oil 1 2 3 4 5 6 7 8 9 10 11 10 12 Removal steps 1 Accelerator cable conn...

Page 34: ...eater hose connection 20 Engine coolant temperature gauge unit connector 21 Engine coolant temperature sensor connector 22 Camshaft position sensor connector 23 Detonation sensor connector AC D Transmission assembly AD CA 24 Engine mount bracket BA 25 Engine mount stopper AE AA 26 Engine assembly Caution Mounting locations marked by should be provisionally tightened and then fully tightened after ...

Page 35: ...AL M T Refer to 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 GROUP 23 AD ENGINE MOUNT BRACKET REMOVAL 1 Support the engine with a garage jack 2 Remove the special tool which was attached when the transmission assembly was removed 3 Hold the engine assembly with a chain block or ...

Page 36: ...ith the garage jack 3 Remove the chain block and support the engine assembly with the special tool DA HIGH PRESSURE FUEL HOSE INSTALLATION 1 Apply a small amount of new engine oil to the O ring Caution Do not let any engine oil get into the delivery pipe 2 While turning the high pressure fuel hose to the right and left install it to the delivery pipe while being careful not to damage the O ring Af...

Page 37: ... 5 Drive Belt Tension Check and Adjustment 5 Ignition Timing Check 6 Idle Speed Check 7 Idle Mixture Check 7 Compression Pressure Check 8 Manifold Vacuum Check 9 Lash Adjuster Check 10 CRANKSHAFT PULLEY 14 CAMSHAFT AND CAMSHAFT OIL SEAL 15 OIL PAN 18 CRANKSHAFT OIL SEAL 21 CYLINDER HEAD GASKET 24 TIMING BELT 26 ENGINE ASSEMBLY 30 ...

Page 38: ...ERVICE SPECIFICATIONS 11100030496 Items Standard value Limit When checked 294 490 Tension N When a used belt is installed 343 441 Alternator drive When a new belt is installed 490 686 belt tension When checked 9 0 13 0 Deflection Reference When a used belt is installed 10 0 12 0 value mm When a new belt is installed 6 8 8 0 When checked 490 686 Tension N When a used belt is installed 539 637 Power...

Page 39: ...ment mm Within 1 Timing belt tension torque Nm 3 Auto tensioner rod protrusion amount mm 3 8 4 5 SEALANTS 11100050379 Items Specified sealants Remarks Oil pan MITSUBISHI GENUINE PART MD970389 or equivalent Semi drying sealant Flywheel bolt or drive plate bolt 3M Stud Locking 4170 or equivalent SPECIAL TOOLS 11100060464 Tool Number Name Use MB991502 MUT II sub assembly Engine idle speed check Erasi...

Page 40: ...ar oil seal MB990938 Handle Press in of the crankshaft rear oil seal MD998767 Tension pulley socket wrench Timing belt tension adjustment MD998717 Crankshaft front oil seal installer Press in of the crankshaft front oil seal MD998727 Oil pan remover Removal of oil pan MD998781 Flywheel stopper Securing the flywheel M T or drive plate A T GENERAL SERVICE TOOL MZ203827 Engine lifter Supporting the e...

Page 41: ... force of 98 N and check that the amount of belt deflection is at the standard value Standard value Tension N 294 490 Deflection Reference value mm 9 0 13 0 ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1 Loosen the tension pulley fixing nut 2 Use the adjusting bolt to adjust the belt tension or deflection to the standard value Standard value Items When a used belt is installed When a new belt is insta...

Page 42: ... tensioner pulley fixing nut A 2 Adjust the amount of belt deflection using adjusting bolt B 3 Tighten fixing nut A Tightening torque 49 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 11100170280 1 Before inspection set the vehicle to the pre inspection condition 2 Connec...

Page 43: ...the ignition switch to OFF and connect the MUT II to the diagnosis connector 3 Check the basic ignition timing Adjust if necessary 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 Curb idle speed 650 100 r min NOTE The idle speed is controlled automatically by the idle speed control ISC system 6 If the id...

Page 44: ...andard value even though the result of the inspection is normal on all items COMPRESSION PRESSURE CHECK 11100260482 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 e...

Page 45: ... is a worn or damaged piston ring and or cylinder inner surface 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...

Page 46: ...urs 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 y the lash adjusters so check for some other cause of the problem Moreover if the noise does not change in accordance wit...

Page 47: ...lash adjuster simple check Refer to P 11B 12 D If one of the rocker arms can be pushed down easily during the lash adjuster simple check replace the corresponding lash adjuster D If two or more of the rocker arms can be pushed down easily during the lash adjuster simple check the cause may be that the oil passage to the cylinder head is blocked Check for blockages in the oil passage and clear the ...

Page 48: ...lowing procedure using a thickness gauge 1 Check that a thickness gauge with a thickness of 0 1 0 2 mm can be inserted easily between the valve and the lash adjuster 2 If the thickness gauge can be inserted easily make a note of which is the corresponding lash adjuster 3 If the thickness gauge cannot be inserted easily the lash adjuster is normal so check for some other cause of the problem 5 Slow...

Page 49: ...lting 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 ch...

Page 50: ...6 Nm 1 2 3 Engine oil 4 5 Removal steps 1 Drive belt Power steering oil pump or A C compressor and power steering oil pump 2 Drive belt Alternator AA AA 3 Crankshaft bolt 4 Washer 5 Crankshaft pulley REMOVAL SERVICE POINT AA CRANKSHAFT BOLT REMOVAL INSTALLATION SERVICE POINT AA CRANKSHAFT BOLT INSTALLATION When installing the crankshaft bolt apply the minimum amount of engine oil to the bearing su...

Page 51: ...lation Refer to P 11B 26 D Drive Belt Tension Adjustment Refer to P 11B 5 1 2 3 4 5 6 7 8 9 10 11 12 13 Apply engine oil to all sliding parts when installing 28 34 Nm 88 Nm 22 Nm 24 Nm 3 4 Nm Engine oil 5 Removal steps AA DA 1 Radiator upper hose connection AA DA 2 Radiator lower hose connection 3 Blow by hose connection 4 PCV hose connection 5 Vacuum hose connection 6 Spark plug cable 7 Rocker co...

Page 52: ...on Adjustment Refer to P 11B 5 Apply engine oil to all sliding parts when installing 3 4 Nm 1 2 6 7 9 12 13 8 28 34 Nm 88 Nm Removal steps 1 Breather hose connection 2 Blow by hose connection 6 Spark plug cable 7 Rocker cover AB CA 8 Camshaft sprocket BA 9 Camshaft oil seal AC 12 Rocker arm and shaft assembly AA 13 Camshaft REMOVAL SERVICE POINTS AA RADIATOR UPPER HOSE RADIATOR LOWER HOSE DISCONNE...

Page 53: ...sembly INSTALLATION SERVICE POINTS AA CAMSHAFT INSTALLATION Set the camshaft dowel pins so that they are in the position shown in the illustration Caution Do not mistake the camshafts for the front bank and the rear bank The camshaft for the rear bank has a slit with a width of approximately 4 mm on its rear end BA CAMSHAFT OIL SEAL INSTALLATION 1 Apply engine oil to the camshaft oil seal lip 2 Us...

Page 54: ...ring removal and then tighten the bolts to the specified torque Tightening torque 88 Nm DA RADIATOR LOWER HOSE RADIATOR UPPER HOSE CONNECTION 1 Insert each hose as far as the projection of the water inlet fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose Caution Be sure to install the clamp as far as the old clamp position ...

Page 55: ...vel Gauge Removal and Installation D Front Exhaust Pipe Removal and Installation Refer to GROUP 15 D Under Cover Removal and Installation D Starter Motor Removal and Installation 7 Nm 7 Nm 1 2 3 4 5 39 Nm 44 Nm 44 Nm 7 Nm Groove Bolt hole Sealant MITSUBISHI GENUINE PART MD970389 or equivalent 7 Nm 5 3 Removal steps 1 Drain plug AA 2 Drain plug gasket AA 3 Lower oil pan 4 Cover AA 5 Upper oil pan ...

Page 56: ...remove the oil pan with the special tool and a brass bar Caution Perform this slowly to avoid deformation of the oil pan flange INSTALLATION SERVICE POINT AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration MD998727 MD998727 Drain plug gasket Oil pan side ...

Page 57: ... 7 8 10 5 11 Engine oil 93 103 Nm Crankshaft front oil seal removal steps D Timing belt Refer to P 11B 26 D Crank angle sensor Refer to GROUP 16 1 Crankshaft sprocket 2 Crankshaft sensing blade 3 Crankshaft spacer 4 Key CA 5 Crankshaft front oil seal Crankshaft rear oil seal removal steps AA D Transmission assembly D Clutch cover and disc M T AB BA 6 Plate M T AB BA 7 Adapter plate AB BA 8 Flywhee...

Page 58: ...of the oil seal lip 2 Install the oil seal by tapping it as far as the chamfered position of the oil seal case as shown in the illustration BA DRIVE PLATE A T FLYWHEEL M T ADAPTER PLATE PLATE M T INSTALLATION 1 Clean off all sealant oil and other substances which are adhering to the threaded bolts crankshaft thread holes and the flywheel or drive plate 2 Apply oil to the bearing surface of the fly...

Page 59: ... 11B 23 CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the entire circumference of the oil seal lip 2 Tap the oil seal unit it is flush with the oil seal case Crankshaft MD998717 MD998717 Oil seal ...

Page 60: ...lt Removal and Installation Refer to P 11B 26 D Fuel Discharge Prevention Refer to GROUP 13A On vehicle Service D Front Exhaust Pipe Removal and Installation Refer to GROUP 15 D Thermostat Case Assembly Removal and Installation Refer to GROUP 14 Water Hoses and Pipes D Water Inlet Pipe Removal and Installation Refer to GROUP 14 Water Hoses and Pipes 1 2 3 4 5 6 7 8 9 10 11 3 4 Nm 3 4 Nm Engine oil...

Page 61: ...d with the burred side caused by tapping out facing upwards 3 Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt 4 Install the bolts by the following procedure 1 Tighten the bolts to 20 Nm in the sequence shown in the illustration 2 From the position in 1 above turn each bolt a further 120_ in the same sequence 3 Turn each bolt a further 120_ in the s...

Page 62: ... 10 12 Nm 10 12 Nm 10 12 Nm 24 Nm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 44 Nm 12 Nm 3 Nm 22 Nm 35 Nm 24 Nm Removal steps 1 Engine cover 2 Engine mount stay 3 Power steering hose clamp bolt 4 Crank angle sensor mounting bolt 5 Oil level gauge assembly 6 Engine hanger 7 Tension pulley bracket assembly 8 Tensioner bracket 9 Timing belt cover front upper right 10 Timing belt cover front upper left 11 Timin...

Page 63: ...inst a metal cylinder block etc and measure the movement of the push rod Standard value Within 1 mm A Length when it is free not pressed B Length when it is pressed A B Movement 2 If it is out of the standard value replace the auto tensioner 3 Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned Cau...

Page 64: ... old timing belt install it so that the arrow made on the belt during removal is pointing in the direction of rotation clockwise 3 Set the tensioner pulley so that the pin holes are at the bottom press the tensioner pulley lightly against the timing belt and then provisionally tighten the fixing bolt 4 Apply force to the rear bank side camshaft sprocket in the direction of the arrow to apply tensi...

Page 65: ... the fixing bolt make sure that the tensioner pulley does not turn with the bolt 3 Turn the crankshaft two revolutions in the clockwise direction and after leaving it for 5 minutes or more check if the set pin of the auto tensioner can be removed and inserted easily NOTE If the set pin cannot be inserted easily the auto tensioner is good Check if the amount of protrusion of the auto tensioner rod ...

Page 66: ...e Cover Installation D Battery Installation D Engine Coolant Supplying 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 O ring Engine oil 9 19 18 Nm 23 24 Removal steps 1 Accelerator cable connection 2 Capacitor connector 3 Vacuum hose connection 4 TPS connector 5 Accelerator pedal position sensor connector TCL 6 ISC connector 7 Control harness connector 8 Distributor connector 9 Vacuum ho...

Page 67: ...d pipe AA 28 Power steering oil pump assembly AB 29 A C compressor 30 Heater hose connection AC D Transmission assembly 31 Engine mount stay AD CA 32 Engine mount bracket BA 33 Engine mount stopper AE AA 34 Engine assembly Caution Mounting locations marked by should be provisionally tightened and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine ...

Page 68: ...AL M T Refer to 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 GROUP 23 AD ENGINE MOUNT BRACKET REMOVAL 1 Support the engine with a garage jack 2 Remove the special tool which was attached when the transmission assembly was removed 3 Hold the engine assembly with a chain block or ...

Page 69: ...ith the garage jack 3 Remove the chain block and support the engine assembly with the special tool DA HIGH PRESSURE FUEL HOSE INSTALLATION 1 Apply a small amount of new engine oil to the O ring Caution Do not let any engine oil get into the delivery pipe 2 While turning the high pressure fuel hose to the right and left install it to the delivery pipe while being careful not to damage the O ring Af...

Page 70: ...NOTES ...

Page 71: ...n Check and Adjustment 6 Valve Clearance Check and Adjustment 8 Injection Timing Check and Adjustment 10 Idle Speed Check 12 Compression Pressure Check 12 Timing Belt Tension Adjustment 13 CRANKSHAFT PULLEY 15 CAMSHAFT AND CAMSHAFT OIL SEAL 16 OIL PAN 18 CRANKSHAFT OIL SEAL 20 CYLINDER HEAD GASKET 23 TIMING BELT 26 TIMING BELT B 30 ENGINE ASSEMBLY 33 ...

Page 72: ...ion pump Rocker arm Roller type Adjusting screw Elephant foot type SERVICE SPECIFICATIONS 11100030502 Items Standard value Limit Alternator Tension N When checked 343 490 drive belt tension When a used belt is installed 392 490 When a new belt is installed 490 588 Deflection Centre of belt When checked 8 0 10 0 Reference value mm between alternator pulley and water pump pulley When a used belt is ...

Page 73: ...s installed 9 8 11 2 When a new belt is installed 7 0 8 6 Valve clearance at hot Intake valve 0 35 mm Exhaust valve 0 45 Injection timing Dial gauge display value mm 1 0 03 10_ATDC Idle speed r min 800 30 Compression pressure kPa 3 500 Min 2 560 Compression pressure difference of all cylinder at engine speed of 280 r min kPa Max 300 Cylinder head bolt shank length mm 99 4 Timing belt deflection mm...

Page 74: ...t of the injection timing MB990767 End yoke holder Holding the camshaft sprocket MD998719 Crankshaft pulley holder pin MD998754 Crankshaft pulley holder pin MD998364 Camshaft oil seal installer Installing the camshaft oil seal MD998727 Oil pan remover Removal of oil pan MD998776 Crankshaft rear oil seal installer Press in of the crankshaft rear oil seal MB990938 Handle ...

Page 75: ...ing the crankshaft front oil seal MD998383 Crankshaft front oil seal guide MD998781 Flywheel stopper Securing the flywheel M T or drive plate A T GENERAL SERVICE TOOL MZ203827 Engine lifter Supporting the engine assembly during removal and installation of the transmission MB991453 Engine hanger as sembly ...

Page 76: ...7 9 9 9 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 a used belt is installed When a new belt is installed Tension N 392 490 490 588 Deflection Portion A 8 0 9 4 7 0 8 0 Reference value mm Portion B 7 9 9 2 6 8 7 9...

Page 77: ... is outside the standard value adjust by the following procedure 1 Loosen oil pump fixing bolts A and B Check that the slide bushing at the place where bolt B was installed is touching the A C bracket and that there is no looseness in the oil pump mounting 2 While holding a bar or similar tool against the oil pump body apply a suitable amount of force to the belt with your hand to adjust the tensi...

Page 78: ...ion and readjust if necessary Caution Check after turning the crankshaft once or more clockwise right turn VALVE CLEARANCE CHECK AND ADJUSTMENT 11100150130 1 Start the engine and allow it to warm up until the engine coolant temperature reaches 80 to 95 _C 2 Remove the timing belt upper cover 3 Remove the rocker cover 4 Remove the glow plug plate and all of the glow plugs 5 Turn the crankshaft cloc...

Page 79: ...he opposite side using a flat tipped screwdriver or similar tool to make a gap for the thickness gauge to be inserted 2 If you attempt to insert the thickness gauge without using a flat tipped screwdriver to make a gap the pad will become tilted as shown in the illustration and it will not be possible to insert the thickness gauge 7 If the clearance is outside the standard value loosen the lock nu...

Page 80: ...cover 13 Install the timing belt upper cover INJECTION TIMING CHECK AND ADJUSTMENT 11100180054 1 Remove all of the glow plugs 2 Remove the timing belt upper cover 3 Align the timing marks of the camshaft sprocket and set the No 1 cylinder to the top dead centre position 4 Remove the timing check plug at the rear of the injection pump 5 Install the special tool to the timing check plug hole at the ...

Page 81: ...pump Do not remove the union nuts Caution When loosening the nuts hold the delivery valve holders with a spanner so that they don t turn at the same time 2 Loosen the upper mounting nuts and the lower mounting bolts of the injection pump Do not remove the nut and bolt 3 Tilt the injection pump to the left or right and adjust the needle on the dial gauge so that the display value is uniform 4 Provi...

Page 82: ...that the engine oil starter motor and battery are normal In addition set the vehicle to the pre inspection condition 2 Remove the glow plug plate and all of the glow plugs 3 Disconnect the fuel cut solenoid valve connector NOTE Doing this will prevent carrying out fuel injection 4 Cover the glow plug hole with a shop towel etc and after the engine has been cranked check that no foreign material is...

Page 83: ...he malfunction is a worn or damaged piston ring and or cylinder inner surface 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 9 Connect the fuel cut solenoid valve connector 10 Install the glow plugs and the glow plug plate TIMING BELT TENSION ADJUSTMENT 11100280174 There are two timing belts one is the timin...

Page 84: ...y the width of three camshaft sprocket teeth 8 Securely tighten the timing belt tensioner mounting bolt 9 Turn the crankshaft clockwise to align the timing mark 10 Press the belt at the point between the camshaft sprocket and the injection pump sprocket with your index finger to check the belt deflection Standard value 4 0 5 0 mm 11 Install the timing belt upper cover 12 Install the glow plugs and...

Page 85: ... INSTALLATION Pre removal Operation D Under Cover Removal Post installation Operation D Drive Belt Tension Adjustment Refer to P 11C 6 D Under Cover Installation 25 Nm 1 2 3 4 Removal steps 1 Drive belt Power steering 2 Drive belt A C 3 Drive belt Alternator 4 Crankshaft pulley ...

Page 86: ...Air Pipe A Removal and Installation D Vacuum Pump Removal and Installation Refer to GROUP 14 Cam section and journal section Lip section Engine oil 1 2 3 4 5 6 7 8 6 Nm 27 31 Nm 19 21 Nm 88 Nm 19 21 Nm 27 31 Nm 19 21 Nm 5 8 7 7 Removal steps 1 Breather hose connection 2 Control harness 3 Rocker cover AA DA 4 Camshaft sprocket CA 5 Camshaft oil seal BA 6 Rocker arm and shaft assembly AA 7 Camshaft ...

Page 87: ... valve clearance and adjust if necessary Refer to P 11C 8 CA CAMSHAFT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the entire circumference of the oil seal lip and camshaft 2 Use the special tool to tap in the oil seal NOTE The oil seal should be tapped in until the distance from the end of the camshaft to the end of the oil seal is as shown in the illustration DA CAMSHAFT SPROCKE...

Page 88: ...d Insertion D Engine Oil Draining and Refilling Refer to GROUP 12 On vehicle Service f4 1 mm Bolt hole Groove B Sealant MITSUBISHI GENUINE PART MD970389 or equivalent BOLT IDENTIFICATION A 6 8 mm B 6 10 mm 1 2 3 4 5 6 7 29 34 Nm 9 Nm 39 Nm 7 Nm Washer assembled bolt 9 Nm Flange bolt 10 Nm A B B B B 7 7 Removal steps 1 Drain plug AA 2 Drain plug gasket 3 Oil filter 4 Engine oil cooler pipe connecti...

Page 89: ... oil pan with the special tool and a brass bar Caution Perform this slowly to avoid deformation of the oil pan flange INSTALLATION SERVICE POINT AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration MD998727 MD998727 Drain plug gasket Oil pan side ...

Page 90: ... 10 11 127 137 Nm 108 127 Nm 127 137 Nm 10 6 11 5 9 Crankshaft front oil seal removal steps D Timing belt Refer to P 11C 26 D Crank angle sensor Refer to GROUP 16 1 Crankshaft sprocket 2 Flange 3 Crankshaft sprocket B 4 Key CA 5 Crankshaft front oil seal Crankshaft rear oil seal removal steps AA D Transmission assembly D Clutch cover and disc M T AB BA 6 Adapter plate AB BA 7 Flywheel M T AB BA 8 ...

Page 91: ...of the oil seal lip 2 Install the oil seal by tapping it as far as the chamfered position of the oil seal case as shown in the illustration BA DRIVE PLATE A T FLYWHEEL M T ADAPTER PLATE INSTALLATION 1 Clean off all sealant oil and other substances which are adhering to the threaded bolts crankshaft thread holes and the flywheel or drive plate 2 Apply oil to the bearing surface of the flywheel or d...

Page 92: ...CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the entire circumference of the oil seal lip 2 Tap the oil seal unit it is flush with the oil seal case Crankshaft Oil seal MD998382 MD998383 Front lower case ...

Page 93: ..._ 90_ O ring Engine oil 6 Nm 27 31 Nm 12 15 Nm 44 Nm 24 Nm 10 12 Nm 29 Nm 9 Nm 27 31 Nm 27 31 Nm 1 2 3 4 5 6 8 9 10 11 12 13 14 15 17 18 19 16 16 20 7 Removal steps 1 Breather hose connection 2 Control harness 3 Rocker cover AA DA 4 Fuel injection pipe 5 Camshaft bearing cap 6 Glow plug plate CA 7 Rocker arm and shaft assembly 8 Fuel return hose connection 9 Water temperature sensor connector 10 V...

Page 94: ... holes on the cylinder head gasket that was removed and select a cylinder head gasket with the same number of identification holes 3 Place the cylinder head gasket on top of the cylinder block so that the identification mark is facing upwards as shown in the illustration BA CYLINDER HEAD BOLT INSTALLATION 1 When installing the cylinder head bolts the length below the head of the bolts should be wi...

Page 95: ...ake a tightening angle just 90_ If it is less than 90_ the head bolt will be loosened 2 If it is more than 90_ remove the head bolt and repeat the procedure from step 1 CA ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION 1 Install the rocker arm and shaft assembly to the bearing caps 2 Set the rocker arm springs into the bearing cap indents 3 Check the valve clearance and adjust if necessary Refer to P ...

Page 96: ...e Mount Bracket Removal and Installation Refer to GROUP 32 10 12 Nm 9 Nm 25 Nm 23 Nm 19 Nm 10 12 Nm 10 12 Nm 10 12 Nm 9 Nm 10 12 Nm 1 2 3 4 5 6 7 Removal steps 1 Water pump pulley 2 A C tension pulley assembly AA 3 Timing belt front upper cover 4 Timing belt front centre cover 5 Timing belt front lower cover 6 Injection pump bracket stay BA D Timing belt tension adjustment AB AA 7 Timing belt ...

Page 97: ...gn the timing marks 2 Loosen the installation bolt of the timing belt tensioner 3 Move the timing belt tensioner downward and loosely tighten the bolt so that the tensioner doesn t return then remove the timing belt Caution If the timing belt is to be re used use chalk to mark on its flat side an arrow indicating the clockwise direction Protective tape Timing marks Thread diameter length pitch mm ...

Page 98: ...wise direction BA TIMING BELT TENSION ADJUSTMENT 1 Turn the crankshaft anti clockwise by a distance equivalent to 1 2 tooth of the camshaft sprocket in order to correct looseness at the timing belt idler side 2 Loosen by 90_ to 120_ turn the tensioner installation bolt previously secured provisionally taking advantage of the force of the tensioner spring to provide tension to the belt 3 In additio...

Page 99: ...sing the index finger press between the camshaft sprocket and the injection pump sprocket and check whether or not the amount of flexion is within the standard value range Standard value 4 5 mm Injection pump sprocket Camshaft sprocket ...

Page 100: ...o P 11C 15 D Engine Mount Bracket Removal and Installation Refer to GROUP 32 D Timing Belt Removal and Installation Refer to P 11C 26 Engine oil 48 Nm 19 Nm 108 127 Nm 1 2 3 4 5 Removal steps 1 Idler pulley AA BA 2 Crankshaft sprocket 3 Flange 4 Timing belt tensioner AB AA 5 Timing belt B REMOVAL SERVICE POINTS AA CRANKSHAFT SPROCKET REMOVAL Crankshaft sprocket MB991385 MB991367 ...

Page 101: ...nd above the centre of the installation bolt and temporarily attach the tensioner pulley so that the flange is toward the front of the engine 2 Holding the timing belt B tensioner up with your finger in the direction of the arrow place pressure on the timing belt so that the tension side of the belt is taut Now tighten the bolt to fix the tensioner Caution When tightening the bolt ensure that the ...

Page 102: ...KET INSTALLATION 1 Apply as little engine oil as possible to the seat and the thread of the crankshaft bolt 2 Secure the crankshaft sprocket in the same way as during removal and then tighten the bolt to the specified torque Tightening torque 108 127 Nm ...

Page 103: ...ice D Air Cleaner Assembly Installation D Hood Installation Refer to GROUP 42 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Removal steps 1 Vacuum hose connection 2 Vacuum air temperature sensor con nector 3 Brake booster vacuum hose connec tion 4 Alternator connector 5 Oil pressure switch connector 6 Engine oil level sensor connector 7 Glow plug connector 8 Engine coolant temperature sensor connector...

Page 104: ...ket assembly AB 23 A C compressor 24 Engine oil cooler pipe connection 25 Fuel hose connection 26 Clamp bolt Power steering hose and pipe AC D Transmission assembly AD CA 27 Engine mount bracket BA 28 Engine mount stopper AE AA 29 Engine assembly Caution Mounting locations marked by should be provisionally tightened and then fully tightened after placing the vehicle horizontally and loading the fu...

Page 105: ...AL M T Refer to 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 GROUP 23 AD ENGINE MOUNT BRACKET REMOVAL 1 Support the engine with a garage jack 2 Remove the special tool which was attached when the transmission assembly was removed 3 Hold the engine assembly with a chain block or ...

Page 106: ... so that the arrow points in the direction as shown in the diagram CA ENGINE MOUNT BRACKET INSTALLATION 1 Place a garage jack against the engine oil pan with a piece of wood in between and install the engine mount bracket while adjusting the position of the engine 2 Support the engine with the garage jack 3 Remove the chain block and support the engine assembly with the special tool Engine mount s...